CLARK MOTOR CONTROLLER MODEL FZ5035A 8064706 ZAPI DUALAC2 POWER 36/48V FSIP #11 12:11

The CLARK MODEL FZ5035A (ZAPI DUALAC2) is a programmable, solid-state DC motor controller designed specifically for the traction motor (the drive wheel) of electric industrial vehicles like forklifts, pallet trucks, and walkie stackers.

Its core function is to act as a sophisticated electronic throttle. It takes a signal from the operator’s accelerator pedal and precisely regulates the power delivered from the battery to the motor, enabling smooth, controlled acceleration, deceleration, and direction changes.

Key Specifications from the Label

• OEM Brand: CLARK

• Clark Controller Model: FZ5035A

• Clark Part Number: 8064706

• Actual Manufacturer/Model: ZAPI DUALAC2 (This is the true model of the controller)

• Operating Voltage: 36V or 48V DC (Compatible with both common battery systems; must be configured correctly in software).

• Current Rating: The “#11” is a Clark-specific amperage code. For the DUALAC2 series, #11 typically indicates a 250 Amp controller. This is a medium-to-high-duty rating, offering more power than a #10 (200A).

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

Key Features and Functions

• Dedicated Traction Control: This controller is designed only for the drive motor. A separate controller (often also a ZAPI model) would be used to control the hydraulic pump motor for lifting.

• Advanced Programmability: Requires a ZAPI programmer (or a compatible Clark programmer with ZAPI software) to configure its operating parameters. Settings include:

  • Maximum speed (forward and reverse)

  • Acceleration and deceleration rates (ramp times)

  • Current limit (set by the #11 / 250A hardware)

  • Regenerative braking strength

  • Throttle type calibration (e.g., for potentiometer or Hall effect pedals)

• Integrated Diagnostics: Features comprehensive self-diagnostics. It stores error codes for faults such as:

  • Over-current

  • Over-temperature

  • Throttle input error

  • “Field Loss” (a fault in the motor’s field winding circuit)

  • Under-voltage (low battery)

• Protection Circuits: Built-in protection against electrical faults that could damage the controller, motor, or battery, including short circuits and voltage spikes.

• Regenerative Braking: Converts the vehicle’s kinetic energy back into electrical energy during braking or deceleration, returning it to the battery to improve efficiency and extend run time.

Common Applications

This controller is found on a wide range of 36V/48V Clark electric material handling equipment that uses separate controllers for drive and hydraulic functions. Its higher 250A rating makes it suitable for vehicles that require more power and torque. Examples include:

• Clark Electric Rider Pallet Trucks

• Clark Electric Walkie/Rider Reach Trucks

• Clark Electric Counterbalance Forklifts (smaller models)

Important Notes for Replacement/Repair

1. ZAPI-Centric Service: For troubleshooting, programming, and replacement, you must treat this as a ZAPI DUALAC2 controller. It requires ZAPI-specific diagnostic tools and software.

2. Critical Compatibility: The part number (8064706) and amperage code (#11 = ~250A) are vital for a correct replacement. The amperage code must be matched exactly. Installing a controller with a different amperage (e.g., a #10/200A or a #13/350A) is not compatible and will cause operational issues or damage.

3. Programming is Mandatory: A new or replacement controller will be blank and must be programmed with the correct parameters for the specific vehicle it is installed in. This is not a plug-and-play component.

4. Voltage Setting: While the hardware is compatible with 36V and 48V systems, the software must be configured for the correct system voltage of the truck.

5. Core Value: This faulty unit has a “core value” and should be returned to the rebuilder/supplier (like FSIP) for a significant credit when exchanging for a rebuilt unit.