CLARK MOTOR CONTROLLER MODEL FZ5035A 8064706 ZAPI DUALAC2 POWER 36/48V FSIP #8 11:32

The CLARK MODEL FZ5035A (ZAPI DUALAC2) is a programmable, solid-state DC motor controller designed for the traction circuit of electric industrial vehicles like forklifts and pallet trucks. Its primary function is to regulate power from the battery to the drive motor based on the operator’s commands from the accelerator pedal.

This controller is responsible for smooth acceleration, precise speed control, directional movement (forward/reverse), and regenerative braking.

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)

• Current Rating: The “#8” is a Clark-specific code that corresponds to the amperage rating. For this series, #8 typically indicates a 170 Amp controller. This is a mid-range amperage suitable for smaller to medium-duty forklifts.

• 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

• Traction Control: Dedicated controller for the drive wheel motor only. (A separate controller would handle the hydraulic pump motor).

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

  • Maximum speed (separate for forward and reverse)

  • Acceleration and deceleration rates (ramp times)

  • Current limit (#8 = ~170A)

  • Regenerative braking level

  • Choice of throttle type (e.g., potentiometer, Hall effect)

• Integrated Diagnostics: Features comprehensive self-diagnostics. It can store error codes (e.g., for over-current, over-temperature, throttle input error, “field loss” on certain motors) to greatly simplify troubleshooting.

• Protection Circuits: Built-in protection against:

  • Over-current and short circuits

  • Low battery voltage (cut-off)

  • Controller over-temperature

  • Faulty throttle signal

• Regenerative Braking: Helps slow the vehicle by converting momentum back into electrical energy to recharge the battery, improving efficiency and reducing brake wear.

Common Applications

This controller is found on a wide range of 36V/48V Clark electric material handling equipment that uses a separate controller for the hydraulic functions. Examples include:

• Clark Electric Pallet Trucks

• Clark Electric Walkie Stackers

• Smaller Clark Electric Forklifts (Cushion and Pneumatic tire 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 (#8 = ~170A) are vital for a correct replacement. Installing a controller with a different amperage (e.g., a #13/350A) could lead to immediate damage or unreliable operation.

3. Programming is Mandatory: A new or replacement controller will not function out of the box. It must be programmed with the correct parameters for the specific vehicle.

4. Voltage Setting: While the hardware is compatible with 36V and 48V, 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.