Trane Thermo King EPJ Charger User manual

Revision A
July 2022 TTKK 5566991177--1111--MMMM--EENN
Electric Pallet Jack (EPJ) Charger
(For 401586 models only)
Maintenance Manual

©2022 Trane Te hnologies TK 56917-11-MM-EN
Introduction
This manual is published for informational purposes only. Thermo King®makes no representations warranties express
or implied, with respe t to the information re ommendations and des riptions ontained herein. Information provided
should not be regarded as all-in lusive or overing all ontingen ies. If further information is required, Thermo King
Corporation Servi e Department should be onsulted.
TThheerrmmoo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqquuiippmmeenntt wwhhii hh hhaass bbeeeenn ““ssoo iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd
oorr aalltteerreedd aass,, iinn tthhee mmaannuuffaa ttuurreerr’’ss jjuuddggmmeenntt,, ttoo aaffffee tt iittss iinntteeggrriittyy..””
MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy
ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorr
aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd
oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee
ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..
Revision History
Revision A (07/22) Released new manual.
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TK 56917-11-MM-EN 3
eneral Information
The maintenance information in this manual covers unit models:
Electric Pallet Jack (EPJ) Charger 401586 (*For 401586 models only)
Note: *401586 inverters are identified as being black in color, not white.
For further information, refer to:
Electronic Parts Catalog (EPC)
The information in this manual is provided to assist owners, operators and service people in understanding the operation as well as the proper
upkeep and maintenance of the Thermo King EPJ charger.
IInnttrroodduu ttiioonn

4TK 56917-11-MM-EN
About This Manual
Purpose
The purpose of this manual is to provide general pro edural and maintenan e information ne essary to understand the
operation and maintenan e of your Thermo King Ele tri Pallet Ja k (EPJ) Charger for peak operating standards. This
in ludes safety information, operational information, unit information su h as bills of material and kit numbers, general
unit information, maintenan e pro edures and related information, and diagnosti and troubleshooting information.
Contents
This manual is organized into the following hapters:
Chapter Purpose
Safety Precautions Provides detailed safety information. You should be familiar with the safety
precautions before working on the EPJ Charger.
Model Systems (Systems Designations) Table This table lists the bill of material (BOM) and kit options that make up your
EPJ Charger. Use them for the following purposes:
1. To communicate with TK Service Department: If you need to call TK
Service, you must know your model number(s) in order for the service
representative to help you.
Specifications Lists EPJ Charger specifications.
General Description Gives an overview description of your EPJ Charger including standard and
optional features, illustrations, and general information.
System Components Explains each EPJ Charger component location and function.
Operating Instructions Provides EPJ Charger operating instructions.
Power Inverter Overview Provides an overview of power inverter operation and features.
Diagnostic Procedures Provides diagnostic procedures for the EPJ Charger along with removal and
replacement of the power inverter.
Maintenance Inspection Schedule Table of routine maintenance procedures.
Power Inverter Dimensions Overall dimensions of inverter.
Schematic Diagram Schematic diagram of EPJ Charger system.
Before you Call Thermo King Service!
Who to all: Your Thermo King Servi e Representative.
Before you all Thermo King Servi e, have the following information on hand:
• Power Inverter Model Number - found on front panel of the inverter.
Blank Pages
This manual may ontain blank pages at the end of hapters. This is normal. There is no information missing from the
manual.
Using the Model Systems Table in “Model Systems (System Designations)”
The Model Systems Table in this se tion list important unit information that you will need to ommuni ate with the
Thermo King Servi e Department.
IInnttrroodduu ttiioonn

TK 56917-11-MM-EN 5
SSaaffeettyy PPrree aauuttiioonnss ............................................................................................................................................................ 77
Danger, Warning, Caution, and Noti e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ele tri al Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Danger..................................................................................... 7
Warning.................................................................................... 8
Caution ................................................................................... 8
Noti e .................................................................................... 9
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MMooddeell SSyysstteemmss ((SSyysstteemm DDeessiiggnnaattiioonnss)) ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... .. 1111
Serial Number Lo ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SSppee iiffii aattiioonnss .. .. .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... .... 1122
Power Inverter Spe ifi ations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
EPJ Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GGeenneerraall DDeess rriippttiioonn.. .. .... .. .......... ...... ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... 1144
EPJ Charger Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Features................................................................................... 14
SSyysstteemm CCoommppoonneennttss .... .. .......... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... .. 1155
Charger En losure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DC Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DC Power Dis onne t Swit h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AC Output Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GFCIOutlet.................................................................................... 16
OOppeerraattiinngg IInnssttrruu ttiioonnss .. ...... ...... ...... ...... ...... .......... ...... ...... ...... .... .. ...... .. .... .. ...... .... .. ...... ...... .... .. ...... ...... ...... ...... .... .. ...... 1177
Charging a EPJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PPoowweerr IInnvveerrtteerr OOvveerrvviieeww ............................................................................................................................................ 1188
Inverter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Status Indi ator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ModeSettings................................................................................. 21
DDiiaaggnnoossttii PPrroo eedduurreess .. .......... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... .. 2222
Qui k Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Advan ed Diagnosti Pro edures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GFCI Outlet Output Diagnosti s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power Inverter Diagnosti s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GFCI Repla ement Pro edures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of Contents

6TK 56917-11-MM-EN
Power Inverter Diagnosti s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Basi Diagnosti Pro edures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Diagnosti Pro edures using Power Inverter Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power Inverter Repla ement Pro edures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inverter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inverter Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inverter Mode Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
MMaaiinntteennaann ee aanndd IInnssppee ttiioonn SS hheedduullee...... .. .... .. .......... ...... ...... ...... .......... .. .... .. ...... .... .. ...... ...... .... .. ...... ...... ...... .... 3322
Routine Servi e and Maintenan e Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PPoowweerr IInnvveerrtteerr DDiimmeennssiioonnss........................................................................................................................................ 3333
SS hheemmaattii DDiiaaggrraamm ...... ...... ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... ...... .... .. ...... ...... ...... .. 3344
TTaabbllee ooff CCoonntteennttss

TK 56917-11-MM-EN 7
Safety Precautions
Danger, Warning, Caution, and Notice
Thermo King®re ommends that all servi e be performed by a Thermo King dealer and to be aware of several general
safety pra ti es.
Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit
depend upon the stri t observan e of these pre autions. The four types of advisories are defined as follows:
DDAANNGGEERR
HHaazzaarrdd!!
IInnddii aatteess aann iimmmmiinneennttllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhii hh,, iiff nnoott aavvooiiddeedd,, wwiillll rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..
WWAARRNNIINNGG
HHaazzaarrdd!!
IInnddii aatteess aa ppootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhii hh,, iiff nnoott aavvooiiddeedd,, oouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..
CCAAUUTTIIOONN
HHaazzaarrdd!!
IInnddii aatteess aa ppootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhii hh,, iiff nnoott aavvooiiddeedd,, oouulldd rreessuulltt iinn mmiinnoorr oorr mmooddeerraattee iinnjjuurryy aanndd
uunnssaaffee pprraa ttii eess..
NN TTIICCEE
HHaazzaarrdd!!
IInnddii aatteess aa ssiittuuaattiioonn tthhaatt oouulldd rreessuulltt iinn eeqquuiippmmeenntt oorr pprrooppeerrttyy--ddaammaaggee oonnllyy aa iiddeennttss..
Electrical Hazards
Danger
DDAANNGGEERR
HHaazzaarrddoouuss VVoollttaaggee!!
WWiillll sshhoo kk,, bbuurrnn oorr aauussee ddeeaatthh.. DDiiss oonnnnee tt ppoowweerr bbeeffoorree sseerrvvii iinngg uunniitt..
DDAANNGGEERR
HHaazzaarrddoouuss VVoollttaaggee!!
PPootteennttiiaallllyy lleetthhaall vvoollttaaggeess eexxiisstt wwiitthhiinn tthhee ppoowweerr iinnvveerrtteerr aass lloonngg aass tthhee bbaatttteerryy ssuuppppllyy iiss oonnnnee tteedd.. DDuurriinngg
aannyy sseerrvvii ee wwoorrkk,, tthhee bbaatttteerryy ssuuppppllyy sshhoouulldd bbee ddiiss oonnnnee tteedd..
DDAANNGGEERR
RRiisskk ooff IInnjjuurryy!!
DDoo nnoott oonnnnee tt oorr ddiiss oonnnnee tt bbaatttteerriieess wwhhiillee tthhee ppoowweerr iinnvveerrtteerr iiss ooppeerraattiinngg ffrroomm tthhee bbaatttteerryy ssuuppppllyy..
DDaannggeerroouuss aarr iinngg mmaayy rreessuulltt..

8TK 56917-11-MM-EN
Warning
WWAARRNNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
IImmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy aabblleess oouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. BBaatttteerryy aabblleess mmuusstt bbee iinnssttaalllleedd,,
rroouutteedd,, aanndd ssee uurreedd pprrooppeerrllyy ttoo pprreevveenntt tthheemm ffrroomm rruubbbbiinngg,, hhaaffffiinngg,, oorr mmaakkiinngg oonnttaa tt wwiitthh hhoott,, sshhaarrpp,, oorr
rroottaattiinngg oommppoonneennttss..
WWAARRNNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
AAllwwaayyss oovveerr bbaatttteerryy tteerrmmiinnaallss ttoo pprreevveenntt tthheemm ffrroomm mmaakkiinngg oonnttaa tt wwiitthh mmeettaall oommppoonneennttss dduurriinngg bbaatttteerryy
iinnssttaallllaattiioonn.. BBaatttteerryy tteerrmmiinnaallss ggrroouunnddiinngg aaggaaiinnsstt mmeettaall oouulldd aauussee tthhee bbaatttteerryy ttoo eexxppllooddee..
WWAARRNNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
WWhheenn rreemmoovviinngg bbaatttteerryy aabblleess,, AALLWWAAYYSS ddiiss oonnnnee tt tthhee nneeggaattiivvee bbaatttteerryy tteerrmmiinnaall ffiirrsstt.. TThheenn rreemmoovvee tthhee
ppoossiittiivvee tteerrmmiinnaall.. WWhheenn rree oonnnnee ttiinngg tthhee bbaatttteerryy tteerrmmiinnaallss,, oonnnnee tt tthhee ppoossiittiivvee tteerrmmiinnaall ((++)) ffiirrsstt,, aanndd
oonnnnee tt tthhee nneeggaattiivvee ((--)) tteerrmmiinnaall llaasstt..
WWAARRNNIINNGG
HHaazzaarrddoouuss VVoollttaaggee!!
TTrreeaatt aallll wwiirreess aanndd oonnnnee ttiioonnss aass iiff tthheeyy wweerree hhiigghh vvoollttaaggee uunnttiill aa mmeetteerr aanndd wwiirriinngg ddiiaaggrraamm iinnddii aattee
ootthheerrwwiissee.. OOnnllyy uussee ttoooollss wwiitthh iinnssuullaatteedd hhaannddlleess.. NNeevveerr hhoolldd uunniinnssuullaatteedd mmeettaall ttoooollss nneeaarr eexxppoosseedd,, eenneerrggiizzeedd
oonndduu ttoorrss.. IIff tthheerree iiss aa rriisskk ooff eenneerrggiizzeedd eellee ttrrii aall oonnttaa tt,, aarr ,, oorr ffllaasshh,, ttee hhnnii iiaannss MMUUSSTT ppuutt oonn aallll PPPPEE iinn
aa oorrddaann ee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr lloo aall,, ssttaattee,, oorr oouunnttrryy--ssppee iiffii rreeqquuiirreemmeennttss ffoorr aarr ffllaasshh
pprroottee ttiioonn PPRRIIOORR ttoo sseerrvvii iinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,, DDIISSCCOONNNNEECCTTIINNGG,, OORR VVOOLLTTAAGGEE
TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHHIINNGG CCLLOOTTHHIINNGG.. EELLEECCTTRRIICCAALL MMEETTEERRSS AANNDD
EEQQUUIIPPMMEENNTT MMUUSSTT BBEE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..
WWAARRNNIINNGG
PPeerrssoonnaall PPrroottee ttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
AA bbaatttteerryy aann bbee ddaannggeerroouuss.. AA bbaatttteerryy oonnttaaiinnss aa ffllaammmmaabbllee ggaass tthhaatt aann iiggnniittee oorr eexxppllooddee.. AA bbaatttteerryy ssttoorreess
eennoouugghh eellee ttrrii iittyy ttoo bbuurrnn yyoouu iiff iitt ddiiss hhaarrggeess qquuii kkllyy.. AA bbaatttteerryy oonnttaaiinnss bbaatttteerryy aa iidd tthhaatt aann bbuurrnn yyoouu..
AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess aanndd ppeerrssoonnaall pprroottee ttiivvee eeqquuiippmmeenntt wwhheenn wwoorrkkiinngg wwiitthh aa bbaatttteerryy.. IIff yyoouu
ggeett bbaatttteerryy aa iidd oonn yyoouu,, iimmmmeeddiiaatteellyy fflluusshh iitt wwiitthh wwaatteerr aanndd ggeett mmeeddii aall aatttteennttiioonn..
WWAARRNNIINNGG
EEllee ttrrii aall SShhoo kk aanndd BBuurrnn HHaazzaarrdd!!
DDoo nnoott ddiissmmaannttllee tthhee TThheerrmmoo KKiinngg PPoowweerr IInnvveerrtteerr.. IItt ddooeess nnoott oonnttaaiinn aannyy uusseerr--sseerrvvii eeaabbllee ppaarrttss.. AAtttteemmppttiinngg
ttoo sseerrvvii ee tthhee uunniitt yyoouurrsseellff oouulldd rreessuulltt iinn aann eellee ttrrii aall sshhoo kk oorr bbuurrnnss..
Caution
CCAAUUTTIIOONN
RRiisskk ooff IInnjjuurryy!!
AAllwwaayyss ddiiss oonnnnee tt ppoowweerr aatt tthhee bbaatttteerryy bbeeffoorree rreemmoovviinngg oorr rreeppaaiirriinngg eellee ttrrii aall oommppoonneennttss.. FFaaiilluurree ttoo ddoo ssoo
mmaayy rreessuulltt iinn ppeerrssoonnaall iinnjjuurryy oorr ddaammaaggee ttoo tthhee eeqquuiippmmeenntt..
CCAAUUTTIIOONN
HHaazzaarrddoouuss SSeerrvvii ee PPrroo eedduurreess!!
TTrroouubblleesshhoooottiinngg ooff TTaaiill LLiifftt CChhaarrggeerr sshhoouulldd bbee ddoonnee bbyy qquuaalliiffiieedd ppeerrssoonnnneell..
SSaaffeettyy PPrree aauuttiioonnss

TK 56917-11-MM-EN 9
Notice
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DDoo nnoott ooppeerraattee tthhee uunniitt iiff iitt iiss vviissiibbllyy ddaammaaggeedd..
Battery Installation and Cable Routing
WWAARRNNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
AAnn iimmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy oouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. AA TThheerrmmoo KKiinngg aapppprroovveedd bbaatttteerryy
mmuusstt bbee iinnssttaalllleedd aanndd pprrooppeerrllyy ssee uurreedd ttoo tthhee bbaatttteerryy ttrraayy..
WWAARRNNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
IImmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy aabblleess oouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. BBaatttteerryy aabblleess mmuusstt bbee iinnssttaalllleedd,,
rroouutteedd,, aanndd ssee uurreedd pprrooppeerrllyy ttoo pprreevveenntt tthheemm ffrroomm rruubbbbiinngg,, hhaaffffiinngg,, oorr mmaakkiinngg oonnttaa tt wwiitthh hhoott,, sshhaarrpp,, oorr
rroottaattiinngg oommppoonneennttss..
WWAARRNNIINNGG
FFiirree HHaazzaarrdd!!
DDoo nnoott aattttaa hh ffuueell lliinneess ttoo bbaatttteerryy aabblleess oorr eellee ttrrii aall hhaarrnneesssseess.. TThhiiss hhaass tthhee ppootteennttiiaall ttoo aauussee aa ffiirree aanndd
oouulldd aauussee sseerriioouuss iinnjjuurryy oorr ddeeaatthh..
WWAARRNNIINNGG
PPeerrssoonnaall PPrroottee ttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
AA bbaatttteerryy aann bbee ddaannggeerroouuss.. AA bbaatttteerryy oonnttaaiinnss aa ffllaammmmaabbllee ggaass tthhaatt aann iiggnniittee oorr eexxppllooddee.. AA bbaatttteerryy ssttoorreess
eennoouugghh eellee ttrrii iittyy ttoo bbuurrnn yyoouu iiff iitt ddiiss hhaarrggeess qquuii kkllyy.. AA bbaatttteerryy oonnttaaiinnss bbaatttteerryy aa iidd tthhaatt aann bbuurrnn yyoouu..
AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess aanndd ppeerrssoonnaall pprroottee ttiivvee eeqquuiippmmeenntt wwhheenn wwoorrkkiinngg wwiitthh aa bbaatttteerryy.. IIff yyoouu
ggeett bbaatttteerryy aa iidd oonn yyoouu,, iimmmmeeddiiaatteellyy fflluusshh iitt wwiitthh wwaatteerr aanndd ggeett mmeeddii aall aatttteennttiioonn..
WWAARRNNIINNGG
PPeerrssoonnaall PPrroottee ttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
AA bbaatttteerryy aann bbee ddaannggeerroouuss.. AA bbaatttteerryy oonnttaaiinnss aa ffllaammmmaabbllee ggaass tthhaatt aann iiggnniittee oorr eexxppllooddee.. AA bbaatttteerryy ssttoorreess
eennoouugghh eellee ttrrii iittyy ttoo bbuurrnn yyoouu iiff iitt ddiiss hhaarrggeess qquuii kkllyy.. AA bbaatttteerryy oonnttaaiinnss bbaatttteerryy aa iidd tthhaatt aann bbuurrnn yyoouu..
AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess aanndd ppeerrssoonnaall pprroottee ttiivvee eeqquuiippmmeenntt wwhheenn wwoorrkkiinngg wwiitthh aa bbaatttteerryy.. IIff yyoouu
ggeett bbaatttteerryy aa iidd oonn yyoouu,, iimmmmeeddiiaatteellyy fflluusshh iitt wwiitthh wwaatteerr aanndd ggeett mmeeddii aall aatttteennttiioonn..
WWAARRNNIINNGG
PPeerrssoonnaall PPrroottee ttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
OOvveerr hhaarrggiinngg oorr oovveerr--ddiiss hhaarrggiinngg ooff aann AAGGMM BBaatttteerryy.. TThheerree iiss aa vveerryy rreeaall ppoossssiibbiilliittyy ooff iinndduu iinngg eennoouugghh hheeaatt
iinnttoo aann AAGGMM bbaatttteerryy ttoo iinniittiiaattee tthheerrmmaall rruunnaawwaayy iiff tthhee bbaatttteerryy iiss hhaarrggeedd aatt ttoooo hhiigghh aa vvoollttaaggee.. TThhiiss oouulldd
aauussee yyoouurr AAGGMM bbaatttteerryy ttoo ggeett vveerryy hhoott.. AAllwwaayyss wweeaarr ppeerrssoonnaall pprroottee ttiivvee eeqquuiippmmeenntt wwhheenn wwoorrkkiinngg wwiitthh aa
bbaatttteerryy..
WWAARRNNIINNGG
PPeerrssoonnaall PPrroottee ttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
AA bbaatttteerryy aann bbee ddaannggeerroouuss.. LLiitthhiiuumm IIoonn bbaatttteerriieess aarree ppootteennttiiaallllyy hhaazzaarrddoouuss.. TThhee oommbbuussttiioonn ggaass ffrroomm tthheessee
bbaatttteerriieess iiss ttooxxii aanndd aann pprreesseenntt aa sseerriioouuss FFIIRREE HHAAZZAARRDD iiff ddaammaaggeedd,, ddeeffee ttiivvee oorr iimmpprrooppeerrllyy uusseedd.. AA bbaatttteerryy
ssttoorreess eennoouugghh eellee ttrrii iittyy ttoo bbuurrnn yyoouu iiff iitt ddiiss hhaarrggeess qquuii kkllyy.. AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess aanndd
ppeerrssoonnaall pprroottee ttiivvee eeqquuiippmmeenntt wwhheenn wwoorrkkiinngg wwiitthh aa bbaatttteerryy.. DDoo nnoott rreeppllaa ee tthhee bbaatttteerryy wwiitthh aannyy ttyyppee ootthheerr
tthhaann tthhee oonnee aapppprroovveedd bbyy TThheerrmmoo KKiinngg ffoorr tthhiiss uunniitt..
SSaaffeettyy PPrree aauuttiioonnss

10 TK 56917-11-MM-EN
WWAARRNNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
AAllwwaayyss oovveerr bbaatttteerryy tteerrmmiinnaallss ttoo pprreevveenntt tthheemm ffrroomm mmaakkiinngg oonnttaa tt wwiitthh mmeettaall oommppoonneennttss dduurriinngg bbaatttteerryy
iinnssttaallllaattiioonn.. BBaatttteerryy tteerrmmiinnaallss ggrroouunnddiinngg aaggaaiinnsstt mmeettaall oouulldd aauussee tthhee bbaatttteerryy ttoo eexxppllooddee..
CCAAUUTTIIOONN
HHaazzaarrddoouuss SSeerrvvii ee PPrroo eedduurreess!!
SSeett aallll uunniitt eellee ttrrii aall oonnttrroollss ttoo tthhee OOFFFF ppoossiittiioonn bbeeffoorree oonnnnee ttiinngg bbaatttteerryy aabblleess ttoo tthhee bbaatttteerryy ttoo pprreevveenntt
uunniitt ffrroomm ssttaarrttiinngg uunneexxppee tteeddllyy aanndd aauussiinngg ppeerrssoonnaall iinnjjuurryy..
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DDoo nnoott oonnnnee tt ootthheerr mmaannuuffaa ttuurreerr’’ss eeqquuiippmmeenntt oorr aa eessssoorriieess ttoo tthhee uunniitt oorr ttoo tthhee TTKK BBaatttteerriieess uunnlleessss
aapppprroovveedd bbyy TThheerrmmoo KKiinngg.. FFaaiilluurree ttoo ddoo ssoo aann rreessuulltt iinn sseevveerree ddaammaaggee ttoo eeqquuiippmmeenntt aanndd vvooiidd tthhee wwaarrrraannttyy..
SSaaffeettyy PPrree aauuttiioonnss

TK 56917-11-MM-EN 11
Model Systems (System Designations)
Thermo King Electric Pallet Jack (EPJ) Charger
System Designation System Number BOM Install Kit Wiring Diagram Schematic Diagram
EPJ Charger N/A 401586 See below N/A See “Schematic
Diagram,” p. 34
New Trailer Installation Kit N/A 401363 N/A
Retro-Fit Trailer
Installation Kit N/A 401364 N/A
NNoottee:: When calling the dealer or factory for information or parts please have the Bill of Material (B M) number for your
particular unit handy.
Serial Number Location
IMPORTANT NOTE
This manual is for 401586 Inverters only — These Inverters are identified as being BLACK
This manual does not pertain to earlier Inverter’s —These Inverters are identified as being WHITE
Figure 1. Power Inverter Serial Number Location Shown
AC Output
Pure Sine Wave Output : 120VAC 60Hz, 2000W / 16.6A
1
RCS1852
1. Serial Number Location

12 TK 56917-11-MM-EN
Specifications
Power Inverter Specifications
Electrical Specifications
Continuous Power* 2000 W
Surge Power (Peak)** 4000 W
AC Output Voltage (12.5V) 120 VAC RMS ± 5%
AC Output Current 16.6 AAC
AC Output Voltage Range 104-127 VAC
AC Output Frequency 60 Hz ± 0.5 Hz
AC Output Waveform Pure sine wave (<3% THD)
Optimum Efficiency >85%
DC Input Voltage (Nominal) 12.5 VDC
DC Operation Voltage Range *** 10.2 - 15.75 VDC
DC Input Current (Full Load) 187 DCA
DC Input Current (No Load) Mode use (P01, P03) Nominal 0.2ADC
Mode use (P02, P04) Nominal 1.30ADC
Protection
Low Voltage Alarm 12.2-12.5 VDC
Low Voltage Shutdown 10.2 VDC
Low Voltage Recovery 13.1 VDC
High Voltage Shutdown *** 15.75 VDC
Output Power Warning Yes, with warning code
Output Power Shutdown Yes, with shutdown code
Temperature Warning Yes, with warning code
Temperature Shutdown Yes, with shutdown code
Display Specifications
LED Status Indicator
Green – inverter is operating normally.
Amber – An amber warning light will happen often under normal
operation and should not be a cause for major concern. See “Power
Inverter Diagnostics,” p. 28 for various warning conditions.
Red – an error has been detected and the inverter has shut down. Check
the error code on the digital display.
Digital display Volts in, power out, error codes
General Specifications
Operating Temperature –40F to 104F (–40C to 40C)
Inverter Weight 11.5 lb. (5.2 kg)
Inverter Size (L x W x H) 5 x 9.1 x 4.3 " (38.1 x 23.1 x 10.9 cm)
Regulatory Approval
Conforms to UL STD 458, Certified to CSA STD C22.2 No. 107.1
Complies with FCC PART 15 CLASS B
*Specifications met when DC voltage at nominal (12.5V) and temp at 25C.
**Surge ratings are based on resistive load (output voltage may drop).
***Damage can occur if input voltage exceeds 16 VDC.

TK 56917-11-MM-EN 13
EPJ Safety Features
The EPJ Charger system is equipped with numerous features to help guarantee safe and trouble-free operation.
Electrical Protection
20A Fuse – Located inside the EPJ enclosure.
150A Fuse – Located inside the EPJ enclosure.
150A Fuse – Located near the lift gate (LG) battery.
DC Disconnect Switch – Red knob located on outside of enclosure disconnects all 12 Vdc battery power to the inverter.
Ground Fault Circuit Interrupter (GFCI) Outlet – Located inside the truck box or trailer. A power indicator light on GFCI alerts that 120 Vac
power is present. The GFCI outlet monitors the amount of power going to the EPJ. If the GFCI detects the interruption in current it will cut power
to the outlet.
SSppee iiffii aattiioonnss

14 TK 56917-11-MM-EN
eneral Description
EPJ Charger Overview
The Thermo King Ele tri Pallet Ja k (EPJ) Charger is an on-board harging system to help ensure your EPJ stays
harged while in transit and between delivery stops. It has been designed to provide safe, simple and reliable harging
for your EPJ batteries. Please take the time to read this manual to familiarize yourself with the features of your EPJ
harger.
Features
• Ensures your EPJ stays harged
• Generates 120 volt power dire tly from lift gate battery pa k
• Built-in low voltage prote tion to preserve liftgate operation
• Hermeti ally-sealed IP69K waterproof plasti en losure
• Easy to operate and maintain
Figure 2. EPJ Charger Enclosure Shown
RCS1685-1

TK 56917-11-MM-EN 15
System Components
Charger Enclosure
A waterproof sealed automotive–rated en losure ontains the EPJ harging omponents. The en losure is lo ated
under the tru k or trailer typi ally near the lift gate (LG) batteries and is se ured to the OEM stringers with aluminum
mounting hannels. A power dis onne t swit h is lo ated on the side of the en losure to dis onne t (LG) DC battery
power to the power inverter inside. Lifting and turning the lat h opens the door to a ess the harging omponents
inside the en losure.
Figure 3. Components Inside Enclosure Shown
RCS1212-3
11 10
9
8
7
6
5
4
3
2
1
1. Enclosure Door 7. 150 AMP Fuse
2. 20 Amp Fuse 8. DC Power Disconnect Switch
3. Negative Battery Cable and Stud 9. Enclosure
4. EPJ Power Cord (to GFCI) 10. 2000W Pure Sine Wave Power Inverter
5. Positive Battery Cable and Stud 11. AC Output Power Cable
6. Inverter Chassis Ground Wire
Power Inverter
The Thermo King 2000 watt pure sine wave power inverter is mounted inside the en losure. Cables are atta hed from
the inverter’s DC terminals to the power studs on the en losure. Cables from the LG batteries are onne ted to these
power studs. The inverter hanges the 12 volt dire t urrent (DC) from the (LG) batteries into 2000 watts of ontinuous,
pure sine wave alternating urrent (AC), similar to the 120 VAC, 60 Hz voltage provided by your utility.
DC Power Cables
Cables from the LG batteries are onne ted to the DC power and ground studs lo ated on the rear of the en losure.
Inside the en losure, ables from the studs are onne ted to the DC terminals on the inverter.
IImmppoorrttaanntt:: D N T reverse the polarity on the DC input to the power inverter. Permanent damage to the inverter will
result and will void the warranty.

16 TK 56917-11-MM-EN
DC Power Disconnect Switch
A DC power dis onne t swit h is lo ated on the side of the en losure. The swit h is used to dis onne t all DC battery
voltage to the power inverter. Prote tion to the inverter is provided by the 150 Amp fuse inside the en losure onne ted
to the swit h.
AC Output Power Cable
The power inverter is equipped with a AC output power able and a 20 Amp in line fuse. This output able is onne ted
to the EPJ power able and routed to the ground fault ir uit interrupter (GFCI) outlet lo ated inside the tru k box or
trailer. When the EPJ is onne ted to this GFCI outlet, and the EPJ harging system is asking for power, the EPJ
batteries will be re harged, assuming inverter operating parameters are met. It is normal operation for no power to be
available at the GFCI outlet when operating parameters are not met, whi h typi ally is when sour e batteries are at a
low voltage.
IImmppoorrttaanntt:: The inverter’s AC power cable must be connected only to a single GFCI outlet. No other electrical
connections should be made to this cable.
FCI Outlet
A GFCI outlet is typi ally lo ated inside the argo box on a side wall near the door opening. This allows easy a ess for
EPJ for harging. A yellow nameplate identifies the GFCI outlet. A weatherproof over prote ts the GFCI outlet when
not in use.
IImmppoorrttaanntt:: The GFCI is specific to this application. If a replacement GFCI is necessary, only Thermo King P/N 424456
can be used for proper inverter operation.
Figure 4. Typical Recessed FCI with Weatherproof Cover Shown
RCS1475-1
Figure 5. Thermo King FCI P/N 424456 Shown
RCS1198-3
SSyysstteemm CCoommppoonneennttss

TK 56917-11-MM-EN 17
Operating Instructions
Charging a EPJ
1. Verify pilot light is illuminated on GFCI outlet.
NNoottee:: If the GFCI pilot light is not illuminated, see “Quick Troubleshooting Guide,” p. 22.
2. Conne t pallet ja k to the GFCI outlet lo ated inside the tru k or trailer.
3. LLeeaavvee EEPPJJ pplluuggggeedd iinn wwhhiillee iinn ttrraannssiitt — unplug EPJ when in use.
NNoottee:: Ensure power cable does not interfere with door operation or by product moving in and out of the truck or trailer.
Figure 6. EPJ Shown Connected to FCI Outlet
RCS1476
IMPORTANT NOTE
Depleting the EPJ battery and then trying to rapidly recharge it is not recommended.
The EPJ should be connected to GFCI while in route and between each stop to maintain the battery charge. This allows the majority of the
charging to occur when the truck is in route.

18 TK 56917-11-MM-EN
Power Inverter Overview
Please take a few minutes reviewing the front and rear panels of the power inverter. This will help you understand how
to operate and servi e the power inverter.
FFrroonntt PPaanneell::
1. SSeerriiaall NNuummbbeerr – a unique identifi ation number assigned to ea h inverter. This number must be re orded for
warranty registration.
2. AACC OOuuttppuutt – a 15” long 12AWG AC output pigtail is hardwired dire tly to a remote ground fault ir uit interrupter
(GFCI) outlet.
3. SSttaattuuss IInnddii aattoorr – a green, red, or amber LED provides the inverter’s status.
4. DDiiggiittaall DDiissppllaayy – a three- hara ter alphanumeri display shows the inverter’s measured battery voltage, total AC
output power, and any error or warning odes.
5. PPoowweerr//SSeellee tt BBuuttttoonn – this momentary button allows the inverter to be turned on or off and swit h between P01
and P04 inverter settings.
6. RReemmoottee PPoorrtt – not used.
Figure 7. Front Panel
AC Output
Pure Sine Wave Output : 120VAC 60Hz, 2000W / 16.6A
3
4
5
6
2
1
RCS1673
RReeaarr PPaanneell::
7. CCoooolliinngg FFaannss – intake ooling fans automati ally turn on when the inverter’s internal temperature rises above a
safe level, and turn off when the inverter’s internal temperature falls to a safe level.
8. MMoouunnttiinngg FFllaannggeess – (front and rear) used to mount and se ure the inverter.
9. DDCC NNeeggaattiivvee TTeerrmmiinnaall ((bbllaa kk)) – inverter’s onne tion to the negative terminal on the 12 VDC battery bank. M8 x
1.25 Torque 22–28 Nm (6–21 lb. ft).
10. DDCC PPoossiittiivvee TTeerrmmiinnaall ((rreedd)) – inverter’s onne tion to the positive terminal on the 12 VDC battery bank. M8 x 1.25
Torque 22–28 Nm (6–21 lb. ft).
11. MMooddeell NNuummbbeerr – the model number of the inverter.
12. CChhaassssiiss GGrroouunndd CCoonnnnee ttiioonn – (not shown) lo ated on side of inverter with a 2–14 AWG ground wire.
Figure 8. Rear Panel
Black
12 Volt
Battery only
11
8
7
10
9
RCS1674
Red
Made in
China

TK 56917-11-MM-EN 19
Inverter Operation
1. To a ess inverter, lift and turn lat h on en losure’s door.
2. To turn inverter on, press and hold power/sele t button for 1 se ond until you hear a “beep”.
• The status indi ator light will illuminate.
• The digital display will show inverter’s ode revision level and sele ted mode setting. See “Mode Settings,” p. 21,
fa tory default setting is P04.
• The digital display will alternately show inverter’s measured battery voltage and AC output power.
• Under normal operation, if the battery voltage is not within operating range of the urrent mode setting, the GFCI
will not have power. See “Mode Settings,” p. 21.
3. To turn inverter off, press power/sele t button.
• Inverter’s display and indi ator light will no longer be illuminated.
• GFCI outlet will no longer have power.
IImmppoorrttaanntt:: The power/select button is not a power disconnect switch and will not remove the DC power from the
inverter. You must turn the DC disconnect switch to the FF position to disconnect all power to the inverter.
Figure 9. Power/Select Button and Digital Display Shown
AC Output
Pure Sine Wave Output : 120VAC 60Hz, 2000W / 16.6A
2
1
RCS1682
1. Power/Select Button 2. Digital Display
Status Indicator
When the inverter is on, the indi ator light may illuminate green, amber, or red to display the inverter’s status:
•GGrreeeenn – inverter is operating normally.
•AAmmbbeerr – a warning has been dete ted. Inverter will shut down at any time. Che k error ode on digital display.
• An amber warning light will happen often under normal operation and should not be a ause for major on ern.
See“Power Inverter Diagnosti s,” p. 28 for various warning onditions.
•RReedd – an error has been dete ted and inverter may shut down at any time. Che k error ode on digital display.
NNoottee:: When status indicator light is amber or red, use digital display and troubleshooting tables to resolve issue.
Figure 10. Status Indicator Light Shown
AC Output
Pure Sine Wave Output : 120VAC 60Hz, 2000W / 16.6A
1
RCS1683
1. Status Indicator Light
PPoowweerr IInnvveerrtteerr OOvveerrvviieeww

20 TK 56917-11-MM-EN
Digital Display
The alphanumeri display shows the inverter’s battery voltage, total AC output power, along with additional operation
odes. The display has one line of three alphanumeri hara ters that alternately shows the inverter’s measured battery
voltage (in volts) and AC output power (in kilowatts) under normal operating onditions. It also displays error/warning
odes that alert you to problems with the inverter, and are used in onjun tion with the troubleshooting tables to
resolve any operating issues.
Table 1. Examples of Digital Display Readings
Display Meaning
12.5 Measured battery voltage.
0.80 Total AC output power in kW (800W as shown).
E01 Error or warning code. See “Diagnostic Procedures using Power Inverter Error Codes,” p. 29 for details.
P01–P04 Unit’s setting. See table on page 21.
U x.x, R x.x Unit’s revision level.
Figure 11. Digital Display Shown
AC Output
Pure Sine Wave Output : 120VAC 60Hz, 2000W / 16.6A
1
RCS1684
1. Digital Display
PPoowweerr IInnvveerrtteerr OOvveerrvviieeww