Thermo King Electric Pallet Jack (EPJ) Installation guide

Brand: Thermo King

Model: Electric Pallet Jack (EPJ)

Type: Installation guide

Kit 401586

Figure 1. EPJ Installation Kit Components

RCS1641

ABC

D E

EPJ Installation Kit 401586 Optional Installation Kits

A = Cable Kit New Trailer Installation Kit* 401363

B = Fuse Kit Retrofit Trailer Installation Kit* 401364

C = Cable Hardware Kit Optional Stretch Cable 401365

D = EPJ Mounting Kit *EPJ installation also requires one of these kits.

E = EPJ Hardware Kit

Installation Instructions

Electric Pallet Jack (EPJ) for Trailers Equipped

with Liftgate Battery Box

Best Installation Practices and Procedures

IImmppoorrttaanntt:: EPJ Charger Box must be mounted securely to OEM stringers with supplied angle

brackets and mounting hardware.

• A motorcycle/ATV lift is recommend for installing the charger box.

• Charger box should be located close to the liftgate battery box to help shorten the DC cable

run and reduce voltage loss.

• Ideally the back of charger box should face the back of liftgate battery box.

• Charger box should be perpendicular to OEM stringers to allow the mounting brackets to be

mounted firmly to them.

• Battery cables at charger box require a drip loop to prevent water from migrating down the

cables causing corrosion of terminals.

Figure 2. Typical EPJ Charger Box Installation Shown

RCS1479

Item Description

1. EPJ Charger Box

2. Liftgate Battery Box

3. OEM Stringers

STEP 1 – EPJ Charger Box Installation Procedures

KIT D and KIT E components required for these procedures

1. Raise charger box into position and loosely attach two angle brackets onto slotted holes of

mounting channels with supplied 1/2” hardware.

2. Use angle brackets as a guide and drill mounting holes into OEM stringers.

a. Bolt angle brackets together with supplied 3/8” hardware.

b. Follow same procedure for all remaining angle brackets.

3. Tighten all hardware to specifications shown.

Figure 3. EPJ Charger Box Installation

RCS639-1

OEM Stringers

3/8”

1/2”

3/8”

Torque Speciﬁcations

3/8-16 Hardware 31 ft-lbs. (42 N·m)

60-65 ft-lbs. (81-88 N·m)

1/2-13 Hardware

STEP 2 - DC Cable Installation Procedures

KIT A and KIT C components required for these procedures

IImmppoorrttaanntt:: Turn DC power disconnect switch to OFF position before connecting battery cables.

Figure 4. DC Power Disconnect Switch Shown

RCS1480-1

IImmppoorrttaanntt:: Battery cables at charger box require a drip loop to prevent water from migrating

down the cables causing corrosion of terminals ((SSeeee FFiigguurree 55)).

1. Slide RREEDD protective cap over terminal ring end of red cable and attach to positive (+) stud on

back of EPJ Charger Box.

2. Slide BBLLAACCKK black protective cap over terminal ring of black cable and attach to negative (-)

stud on back of EPJ Charger Box.

3. Use two wrenches and tighten nuts to 25 ft-lbs. (34 N•m).

IImmppoorrttaanntt:: You must hold the nuts on the inside of the box with a wrench when tightening

bulkhead stud nuts on the outside.

4. Apply dielectric grease to nuts and terminals and position protective caps over studs.

Figure 5. Correct DC Cable Installation with Drip Loop Shown

INCORRECT CORRECT

RCS1642

STEP 3 - Fuse Block Mounting Procedures

KIT B components required for these procedures

1. Route both DC cables into liftgate battery box.

• Access holes may need to be drilled to run cables into liftgate battery box.

• Use supplied grommets to protect cables when routed through access holes.

2. Secure 150 Amp fuse block inside battery box with supplied 1/4” hardware.

IImmppoorrttaanntt:: Do not reverse the polarity on the DC input to the inverter. Permanent damage to

the inverter will result!

3. Install fuse onto studs and tighten securely

4. Cut RREEDD (+) cable to length, slide supplied heat shrink onto cable and attach terminal ring

securely.

a. Position heat shrink partway onto terminal ring and apply heat.

b. Attach to one of the studs of the fuse block.

5. Attach the supplied 12” RREEDD (+) cable with terminal ring onto the other fuse block stud.

a. Cut cable to length, slide supplied heat shrink onto cable and attach terminal ring

securely.

b. Position heat shrink partway onto terminal ring and apply heat.

c. Attach cable to the positive (+) battery post securely.

6. Cut BBLLAACCKK (-) cable to length, slide supplied heat shrink onto cable and attach terminal ring

securely.

a. Position heat shrink partway onto terminal ring and apply heat.

b. Attach cable to the negative (-) battery post securely.

7. Secure all cables with supplied band wraps or clamps.

Figure 6. Typical Fuse Block Installation Shown

STEP 4 - AC Cable Installation Procedures

NNoottee:: The provided AC cable is designed to not need protection or shielding under the trailer.

However, it should be firmly secured with band ties or clamps and additional protection

added where needed.

Retrofit Trailer Installations - Kit 401364

KIT 401364 components required for these procedures

1. Route AC cable down the length of the trailer to the rear corner (road or curbside).

2. Route cable through an access hole in floor and up along the roller door track.

NNoottee:: Ensure cable does not interfere with door operation or by product moving in and out of

the trailer.

3. Mark position of AC Outlet protection bracket holes. It should be mounted as high and close

to below the door track as possible.

4. Route AC cable into outlet box and connect to GFCI outlet. See “GFCI Wiring Diagram,” p. 11.

5. Install bracket and GFCI to trailer wall with installer supplied fasteners.

6. Install protective covers over power cable as needed.

7. Attach supplied nameplate near the GFCI box.

Figure 7. Protective Cover Shown Installed Over Power Cable

RCS1476-1

New Trailer Installations - Kit 401363

KIT 401363 components required for these procedures

New Trailer Build Recommendations for EPJ Integration:

• In-wall conduit 3/4” or larger should be provided from underneath the trailer to a pre-determined height inside the trailer less than 6 ft.

off the floor of the trailer.

• A recessed AC outlet compartment should be integrated into the trailer wall to reduce the chance of cargo impact. This recessed box

should not allow the GFI outlet to protrude past the wall. See “EPJ Recessed AC Outlet Box Dimensions,” p. 12.

• It is also advised to install the GFI outlet on the same side of the trailer as the EPJ box to create the simplest and shortest AC cable run.

1. Route AC cable down length of trailer to where the in-wall conduit is located.

2. Route AC cable up through conduit and into trailer.

3. Install water tight connector, route AC cable into box and wire to GFCI outlet. See “GFCI

Wiring Diagram,” p. 11.

4. Secure box into recessed wall compartment with installer supplied fasteners and reinstall

cover.

5. Attach supplied nameplate near the GFCI box.

Figure 8. Example OEM recessed wall compartment with GFCI box inside

RCS1475-1

STEP 5 - Unit Activation and Operation Verification

1. After completing the installation, turn the EPJ DC disconnect switch to the ON position.

2. Open the EPJ box and press the inverter’s ON button as shown to turn on.

a. Battery voltage must be above 12.2 for the system to first initiate.

b. The inverter’s ON button will need to be pressed whenever the DC power switch was

turned to the OFF position and back on.

3. Set desired mode setting based on information on next page.

a. The system will shut off after 1 or 3 minutes below 12.5V or 12.2V depending on Mode

Setting on next page.

b. Once the system has shut off due to low voltage, apply a battery charger and bring the

system voltage back above 13.1V.

4. If the system recovers and again starts to power the EPJ or simulated load, then the

operation has been verified and the installation is complete.

a. The system will shutdown based on the prescribed operating time and voltage shutdown

setting based on mode selected as shown on the next page.

5. Close the EPJ box and ensure everything is secure before releasing the unit.

Figure 9. Inverter Front Panel

1. Serial Number 4. Digital Display

2. Power Cable 5. Power/Select Button

3. Status Indicator 6. Remote Port

Inverter Codes

E05 Normal operation, DC volts less than 12.6

E01 Normal operation, DC volts less than 12.2

Inverter will beep once, then count down for 4 minutes.

It will then beep every 5 seconds for 1 minute and then shut down.

E03 Output fault, try to cycle input power.

If not cleared, inverter is damaged.

Mode Settings

Built-in low voltage and under voltage protection preserves lift gate battery power to keep the

EPJ from depleting the LG batteries. Four different mode settings are available to customize

how to utilize the available power from the liftgate battery based on fleet's operations.

TToo cchhaannggee MMooddee sseettttiinngg::

1. Turn unit ON or when unit is already in operation.

2. Press and hold ‘Power/Select’ button for 5 seconds.

3. Display shows existing unit program mode.

4. Press ‘Power/Select’ button to toggle between different program modes to the desired new

setting.

5. Wait for 5 seconds and the new desired setting will be set to the unit.

Table 1. Unit Settings

Mode Under

Voltage

Shutdown

Setting

Operating

Time*

Power Save

Mode

Low Voltage Shutdown

PO1 —Warm climates

EPJ not compatible with Power Saver Mode

12.2V 1 minute OFF

If LG batteries are <10.2V for

three seconds, the inverter will

automatically shut off to

protect the batteries. The

inverter will power back up

when input battery voltage is

raised to normal operating

ranges.

P02 —Warm climates

EPJ compatible with Power Saver Mode

12.2V 1 minute ON

P03 — Northern/colder climates

Liftgate battery prioritized

EPJ not compatible with Power Saver Mode

12.5V 3 minutes OFF

P04 — Northern/colder climates

Liftgate battery prioritized

EPJ compatible with Power Saver Mode

Note: P04 is the factory default setting.

12.5V 3 minutes ON

*Operating Time after Under Voltage Setting is reached.

MMooddee sseettttiinngg wwiitthh PPoowweerr SSaavvee MMooddee SSeelleecctteedd

If mode is set to P02 or P04 where the power save mode is active, when no AC load is connected

to the unit, the inverter will pulse two sinewave AC Output cycles every 4 seconds to detect if AC

load is present. If it senses AC load connected is >10W, it will continuously provide AC Output

power. Unit will switch back to pulsing two AC Output cycles if it senses the AC Output load

drops to ~ 6W or below.

TToo rreesseett tthhee GGFFCCII wwhheenn PP0022 aanndd PP0044 mmooddee iiss sseelleecctteedd::

Press and hold the “RESET” button on GFCI for more than 4 seconds.

IImmppoorrttaanntt:: The GFCI is specific to this application. If a replacement GFCI is necessary, only

Thermo King P/N 424456 can be used so the inverter’s power save modes work

properly.

GFCI Wiring Diagram

Figure 10. GFCI Wiring Connections Shown

RCS1484

Electrical

Box

WHITE WIRE

BLANC

HOT WIRE

FIL ACTIF

Black

White

WHITE WIRE

FIL BLANC

HOT WIRE

FIL ACTIF

Grounding

connection to

box (if box has a

grounding terminal)

Wire

Connector

LINE cable brings power to the GFCI

Yellow

sticker

remains

in place

to cover

terminals

About Wire Connections:

Side Wire:

For Back wire -

Insert bare wire fully

and tighten terminal

clamp on conductor

ONLY

Wire 3/4" (1.9 cm)

Back Wire:

Wire 5/8" (1.6 cm)

For Side wire -

Loop clockwise 2/3 of the

way around screw

Connect the LINE cable wires to the LINE terminals:

• The white wire connects to the WHITE terminal (Silver)

• The black wire connects to the HOT terminal (Brass or Black)

• Connect the ground wire

Complete the installation:

• Fold the wires into the box, keeping the grounding wire away from the

WHITE and HOT terminals. Screw the receptacle to the box and attach

EPJ Recessed AC Outlet Box Dimensions

Figure 11. EPJ Recessed AC Outlet Box Dimensions shown

3.38 in.

1.73 in.

2.85 in. 3.94 in. 4X .189 in.

10X .281 in. 13.00 in.

4X 4.25 in.

2X 4.25 in.

4X .75 in.

3X .75 in.

3.83 in.

3.84 in.

3.83 in.

2X 4X R .500 in.

10.00 in.

FRONT REAR

9.63 in.

2X 1.79 in.

TOP

2.82 in.

0.90 in.

1.300 in.

2X 1.69 in.

3.42 in.

6.83 in.

SIDE

RCS1168

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Thermo King Electric Pallet Jack (EPJ) Installation guide

Thermo King Electric Pallet Jack (EPJ) Installation guide

Thermo King Electric Pallet Jack (EPJ) Installation guide

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