CLARK FZ5024A 36/48V PUMP AC2 INVERTER CONTROL 8051761 #4 17:54

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.

This particular unit, with its #4 amperage code, is the highest-rated pump controller in this series. Its purpose is to power the hydraulic pump that creates pressure for lifting and lowering very heavy loads, tilting the mast, and operating demanding attachments. It is engineered for applications where maximum hydraulic power and torque are required.

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 “#4” is a Clark-specific amperage code. For pump controllers, #4 indicates the highest amperage rating in this series, typically in the range of 225-250 Amps. This is designed for the most demanding hydraulic applications.

Key Features and Functions

• Maximum Power Pump Control: Designed for high-demand hydraulic systems that require extreme power, such as lifting very heavy loads to full height quickly or operating high-pressure attachments.

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

• 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 #4 / ~225-250A hardware)

  • Diagnostic and protection settings

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

  • Pump motor over-current

  • Controller over-temperature

  • Short circuit protection

  • Low battery voltage detection

• Robust Protection Circuits: Includes heavy-duty built-in protection for the pump motor and controller, including thermal overload and under-voltage shutdown, crucial for handling the high electrical demands.

Common Applications

This maximum-capacity pump controller is used in the largest 36V/48V Clark electric material handling equipment where superior hydraulic performance is non-negotiable. Applications include:

• Large Capacity Clark Electric Forklifts (e.g., 6,000 – 8,000+ lb capacity)

• Clark Electric Forklifts with high-pressure attachments (e.g, carton clamps, rotators)

• Container Handlers and other specialized high-force equipment

• Any application requiring the absolute maximum hydraulic power available from a 36/48V system

Important Notes for Replacement/Repair

1. Specialized High-Power Function: This is exclusively a high-capacity pump controller. It is not interchangeable with lower-rated pump controllers (#1, #2, #3) or any traction controllers.

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

3. Critical Amperage Match: The amperage code (#4) is absolutely essential and must be matched exactly. Using a lower-rated controller will result in failure to perform, while using a higher-rated one could cause catastrophic damage to the hydraulic system.

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

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