CLARK MOTOR CONTROLLER MODEL FZ5120 8043780 ZAPI COMBIAC2 POWER 48V FSIP #9 11:42

The CLARK MODEL FZ5120 (ZAPI COMBIAC2) is an advanced, programmable, dual-function DC motor controller. It is engineered to control both the traction motor (for driving) and the hydraulic pump motor (for lifting and tilting) in a single, integrated unit. This “combi” design is a hallmark of ZAPI’s technology, simplifying the vehicle’s electrical system by combining two vital functions into one robust controller.

It serves as the central command module for the forklift, interpreting the operator’s inputs and delivering precise power to the respective motors.

Key Specifications from the Label

• OEM Brand: CLARK

• Clark Controller Model: FZ5120

• Clark Part Number: 8043780

• Actual Manufacturer/Model: ZAPI COMBIAC2 (This is the true model of the controller)

• Power Supply: 48V DC (Designed specifically for a 48-volt battery system)

• Current Rating: The “#9” is a Clark-specific code. For the COMBIAC2 series, #9 typically indicates a specific amperage combination, often in the range of 225-250 Amps for the traction circuit and a separate rating (e.g., 180A) for the pump circuit. This is a medium-duty rating.

• Rebuilder/Supplier Marking: “FSIP” (Flight Systems Industrial Products) indicates this specific unit was likely rebuilt by or sourced from this major rebuilder.

Key Features and Functions

• Dual Integrated Control: The defining feature. Manages both drive and hydraulic functions, allowing for coordinated control (e.g., allowing “inching” or slight movement while lifting).

• Extensive Programmability: Requires a ZAPI programmer (or a compatible Clark programmer with ZAPI software) to configure hundreds of parameters for both motor circuits independently. This includes:

  • Traction Settings: Max speed, acceleration/deceleration rates, current limit, regenerative braking strength.

  • Pump Settings: Lift and lower speeds, current limits (to control lifting power and protect the hydraulic system).

• Comprehensive Diagnostics: Features advanced self-diagnostics and stores detailed error codes for faults in either circuit (e.g., pump over-current, traction motor field loss, accelerator errors, overheating). This is invaluable for troubleshooting.

• Protection Circuits: Built-in protection for:

  • Over-current and short circuits on both outputs

  • Low battery voltage cut-off

  • Controller over-temperature

  • Faulty throttle or command signals

• Regenerative Braking: Standard feature that recovers energy during braking to improve efficiency and increase battery run time.

Common Applications

This controller is typically found on 48V Clark electric forklifts that require integrated control. Examples include:

• Clark Electric Cushion Tire Forklifts

• Clark Electric Pneumatic Tire Forklifts

• Some electric reach trucks

Important Notes for Replacement/Repair

1. Treat it as a ZAPI Unit: For all purposes of diagnosis, programming, and replacement, this is a ZAPI COMBIAC2 controller. It requires ZAPI-specific tools and knowledge.

2. Precise Match is Critical: The part number (8043780) and amperage code (#9) are essential. The #9 code must be matched exactly, as it defines the current capabilities for both the drive and pump functions. Using an incorrect amperage code (e.g., a #14/400A) could cause severe damage to the motors or the controller itself.

3. Mandatory Programming: A new or replacement controller is blank and must be programmed with the specific software parameters for the make and model of the forklift. It is not plug-and-play.

4. Core Value: This faulty unit has a core value and should be returned to the supplier (like FSIP) for a credit when exchanging for a rebuilt unit.