CLARK FZ5024A 36/48V PUMP AC2 INVERTER CONTROL 8051761 #3 17:44

The CLARK FZ5024A (ZAPI PUMP AC2) is a programmable, high-performance DC motor controller designed exclusively to operate the hydraulic pump motor on an electric forklift or other material handling equipment.

Its sole purpose is to power the pump that creates hydraulic pressure for lifting and lowering loads, tilting the mast, and operating attachments. It interprets signals from the operator’s hydraulic controls and delivers precise, powerful current to the pump motor to perform these functions efficiently, especially under heavy loads.

Key Specifications from the Label

• OEM Brand: CLARK

• Clark Controller Model: FZ5024A

• Clark Part Number: 8051761

• Actual Manufacturer/Technology: ZAPI (The “AC2” is a ZAPI series identifier for pump controls).

• Function: PUMP INVERTER CONTROL (Dedicated hydraulic pump controller).

• Operating Voltage: 36V or 48V DC (Compatible with both battery systems; must be configured for the correct voltage in software).

• Current Rating: The “#3” is a Clark-specific amperage code. For pump controllers, #3 indicates a high amperage rating, typically in the range of 170-200 Amps. This high rating is designed for demanding hydraulic applications that require significant power and torque.

Key Features and Functions

• High-Power Pump Control: Designed specifically for high-demand hydraulic systems, providing the necessary current for lifting heavy loads, faster cycle times, or operating powerful attachments.

• Smooth & Precise Control: Manages current flow to ensure smooth operation of the hydraulic pump, reducing mechanical shock and allowing for precise load handling even at high power.

• Programmability: Requires a ZAPI programmer to configure operational parameters, including:

  • Maximum pump speed (lift and lower)

  • Acceleration and deceleration rates

  • Current (torque) limit (set by the #3 / ~170-200A hardware)

  • Diagnostic and protection settings

• Integrated Diagnostics: Features self-diagnostics and stores error codes for faults such as:

  • Pump motor over-current

  • Controller over-temperature

  • Short circuit protection

  • Low battery voltage detection

• Protection Circuits: Includes built-in protection for the pump motor and controller, including thermal overload and under-voltage shutdown.

Common Applications

This high-capacity pump controller is used in 36V/48V Clark electric material handling equipment where robust hydraulic performance is required. It is typically used in systems where the pump is controlled separately from the drive. Applications include:

• Large Clark Electric Forklifts (with high lifting capacities)

• Clark Electric Forklifts with heavy-duty attachments

• Clark Electric Reach Trucks designed for heavy loads

• Any application requiring more hydraulic power than a #1 or #2 pump controller can provide

Important Notes for Replacement/Repair

1. Specialized Function: This is exclusively a pump controller and cannot be used to replace traction controllers (DUALAC2) or combined controllers (COMBIAC2).

2. ZAPI Technology: The “AC2” nomenclature is proprietary to ZAPI. It requires ZAPI-specific tools and knowledge for programming and diagnostics.

3. Critical Amperage Match: The amperage code (#3) must be matched exactly when replacing. Using a controller with a different rating (#1, #2, or #4) would result in improper performance and could damage the hydraulic system.

4. Programming Required: A new or replacement unit will need to be programmed with the correct parameters for the specific vehicle application.

5. Core Value: This unit has core value and should be returned for credit when exchanging for a rebuilt unit.