Zapi Smart Handset Training EN Printout

CLARK EUROPE GMBH
COMPANY PRESENTATION
Zapi Handset Basic-Training
- Different Versions
- Console equipment
- Clark handset cable
- Connectors
- Adaptors
- Location of diagnostic connectors
- Handset buttons
- Handset settings
- How to connect to a CAN-Bus system/ List of nodes
- How to connect to serial bus
- The menus
- Zapi Ultra Console Part 2
XY Confidential, proprietary and trade secret information.

2
Version/Document Do not copy or disclose to anyone!
Two Smart-Handset Versions:
Old and new

Zapi-Smart-Handset.
Both looking the same.
Use 4x AA battery
Only a little difference.
AFG: old version

4AFG: new version
Clark PN 4579313

3
Two Smart-Handset Versions:
AFG 4AFG
- Supply voltage 24-80 Volt - Supply voltage 24-60 Volt
- Old and new
Batteries only necessary - On 80 Volt trucks use
if 2 pole CAN connector batteries and 2 pole CAN
is used Zapi-Smart-Handset. connector (Adaptor),
- Use of eight pole Serial- otherwise you get an error
Connector without message
Both looking the same.
batteries possible - Use batteries when
- Set Serial-Baudrate to connecting with eight pole
9600 bps Serial-Connector
- Set serial Baud-Rate to
1200 bps
Only a little difference.
AFG: old version

4AFG: new version
Clark PN 4579313

4
Zapi-Ultra-Handset:
The very old Zapi Ultra The Ultra Handset connects

Handset, the predecessor only with serial port.
of the Smart Console. No batteries are needed, the
We don‘t want to talk handset is supplied with
about that too long. We power by the controller.
will give a short This handset is available from
summarize at the end of various forklift manufacturers
the training. with their own software
If you have questions versions.
concerning this handset,
please contact the Attention: A Clark Ultra
service department! handset will not connect to a
Jungheinrich or Linde truck
and counter wise a Linde or
Jungheinrich handset will not
connect to a Clark truck!

5
Console equipment DA15 connector for console cable
3.2-inch TFT LCD display
Keypad with function keys
USB port

6
Clark handset cable
The Clark adapter cable PN#8119548 is included with the

Smart console.
The cable is equipped with an eight-pin MOLEX SPOX, as

well as a two-pin and a four-pin AMP ECONOSEAL
connector each.
Additionally included with the Smart Console are:
EPX/ECX adapter cable PN#8041365

Four to two pole CAN-BUS adapter PN#4580460

7
The Connectors of the Smart-Handset
8 (6) pole Serial-Connector,

four data wires and 12V 4 pole CAN-Connector, CAN
supply voltage. High, Low and truck battery
voltage.
Connects directly to the
controller, on some
controllers an adaptor is Connects to the truck‘s
necessary. Old handset CAN-Bus, handset is
AFG is powered by 12V powered by truck battery.
supply voltage, new 2 pole CAN-
handset 4AFG needs Attention: The new handset
Connector, CAN High
four AA batteries. 4AFG can‘t handle an 80 V
and Low wire.
truck battery. Use 4 -> 2
Connects to the truck‘s pole adaptor on 80 V
CAN-Bus, handset must be trucks.
powered by batteries.

8
The Adaptors
Zapi AC3 serial Adaptor,
needed for Clark EPX trucks.
Plug the adaptor directly to the

traction or pump controller, on
traction controller you need to
remove the display connector.
PN#8041365
Special handset cable only for Clark
Order-Picker COP1.
4 -> 2 pole CAN-Bus adaptor,
PN#2631252
needed for 80V trucks with 4
pole CAN-connector and new
4AFG handset.
Connect the handset to the
CAN-Bus with this adaptor.
PN#4580460

9
Location of diagnostic connectors
GTX/GEX20-50:
SRX14-16: CAN Bus

connector next to
CAN Bus the pump 80V
connector behind AC3 controller,
the cover under two or four pole.
the steering If four pole, use
wheel, 2 or 4 pole. adaptor -> 2pole
for new 4AFG
handset.
GTX/GEX16-20s:
CAN Bus
connector next to
the pump
controller, two or
four pole.

10
Location of diagnostic connectors
4 pole CAN-connector
at WSX pallet truck.
Handset connector at COP1,

located under the front bottom
plate near the horn. Use the
special COP adaptor.
EPX20-32i:
Connect directly
to the traction or
pump controller
using the 8-pole
-> 6-pole serial
adapter.
To be continued

11
Handset buttons
Arrow up and down button to Power-On button. Press this
scroll through menus. button about two seconds to
switch the handset on.
Arrow left and right to If power voltage is supplied by
increase/decrease values. truck battery the handset will
start up with key and you don‘t
need to press this button.
OK button to confirm
actions and to enter
menus.
F1, F2 and F3:
Contextual use, for example F1 ESC button to cancel
clears the alarm history in the actions or leave menus.
„Alarm“ menu, the display will tell
you what the keys are used for.

12
Handset Settings
At first usage of the
handset the right battery
type and Serial-Baud-Rate
must be set. Set SBR to
1200 bps on new 4AFG
handset and to 9600 bps
on old AFG handset.
To change the handset‘s

parameters move to „Menu
Console“ press „OK“, then
move to „Console Parameter“
and press „OK“ again.
Apply changes by
pressing „ESC“ and
then „OK“

13
How to connect to a CAN-Bus system
You now have to choose „Node“
number and Baud rate of the CAN-Bus.
The node number is the number of the
First you have to plug the
controller you want to connect to, on
handset either in a two or
the following page you will find a list of
four pole CAN-connector.
node numbers and Baud rate settings.
With a four-pole connector
the handset starts up with
the key switch, with a two-
pole connector you have to
switch it on with the „Power-
On“ button.
Then we choose „CAN CONSOLE“

and press „OK“
We get this

14
List of nodes and baudrate settings
Truck Traction Traction Pump Steering Valve CAN- Height- Baudrate

(Master) Slave controller controller Tiller encoder
GTX 3 4 5 - 9 8 - 125/
GEX 1200 serial
EPX Only - Only - - - - 1200/9600
serial serial serial
SRX 2 - 5 6 9 8 10 125
SX/PX 2 - - - - 8 - 250
Pallet 2 - - 6 - - - 125
truck
COP 2 - - 6 - - - 125

15
Connecting to the serial bus
Plug the 8 pole connector or the serial Once connected, you get the status
adaptor cable directly in the controller. screen, no matter if connected to
serial or CAN bus:
Choose „RS232 CONSOLE“ and Controller type: T for traction (P for pump)
press „OK“ If you get this message, check ACE2 Software revision
the Baudrate setting and make
sure the truck‘s key switch is
on. Set Baudrate to 1200 and
try connecting again.
Controller Voltage Motor current Working hours

16
Connecting to the serial bus
Plug the 8 pole connector or the serial Once connected, you get the status
adaptor cable directly in the controller. screen, no matter if connected to
serial or CAN bus:
Choose „RS232 CONSOLE“ and

press „OK“ If you get this message, check M for „Master“ (S for „Slave“)
the Baudrate setting and make
sure the truck‘s key switch is
on. Set Baudrate to 1200 and
try connecting again.
Error or status messages may appear here.

17
Main Menu
After pressing „OK“ you get to the „Main Menu“, scroll with the arrow up and down buttons.
Page 1 Page 2 Page 3
Press „OK“ to enter a menu.

Press „ESC“ to leave a menu.

18
Menu „Parameter Change“
Move to the parameter you want to change with the up and down buttons, change the value with
left and right button. All changes are in real time, you can try your settings immediately.
When leaving the menu with the „ESC“ button you will be asked to save the changed parameters.
Apply with „OK“ or discard your changes with „ESC“.

19
Menu „Parameter Change“
Some parameters are separately stored for each driving mode (Power/Eco/Standard/Turtle), you
first have to choose the driving mode in which you want to change the settings!
These parameters are stored To change settings in different driving modes:

separately for each driving mode:
- A) Choose driving mode on the display
Traction controller: - B) Enter „Parameter Change“ menu
- Acceleration delay - C) Modify parameter(s)
- Release Braking - D) Leave menu with „ESC“ and store with „OK“
- Inverse Braking - E) Choose another driving mode on the display
- Max speed for-and backward - Continue with step B) to E)
- Cutback speed
Pump controller:
- Max speed up

20
Tester
In the tester you can check the status of the controller, it‘s inputs and outputs. By
pressing F2 you log the selected four values to an .csv Exel file on USB stick.

21
Alarms
In the „Alarms“ menu you can see which alarms occurred since the logbook was cleared.
Error message Working hour
For further information about the

error message, please consult
the Service Manual of the truck.
Still questions? Contact the

Service Department of CMHEU!
It‘s useful to clear the error logbook after repair or inspection of a truck.

22
Program VACC
Enter the „Program VACC“ menu,

Press „OK“
Select direction and enable switch (Enable switch: SRX146
– Footswitch, pallet trucks handle switch, GEX/GTX
integrated to ACC pedal)
Now press the pedal, do the same with the other direction.
Store with „ESC“ and „OK“

23
Save and Restore parameters
You can save all

parameters of the
connected controller The stored
to the handset. parameters can be
Choose a storage written back to the
Empty battery symbol, please
exchange batteries of handset! box for your controller. You will
controller, if it is not only see storage box
empty you will be numbers that match
asked to overwrite your controller type!
the existing data.

24
Set Options
In the „Options“ menu you can set the function of different in-and
outputs, switch functions on and off and configure them.
What exactly you can do in this menu depends on the controller, please
refer to the truck‘s Service-Manual and the controller‘s Installatio-
Manual.
Options of a SRX14 Traction controller.

25
Adjustments
In the „Adjustments“ menu the battery can be set,

levers and pedals can be teached and different
adjustments can be done, depending on the kind of
controller and truck. Please refer to the Service-
Manual.
For difficult adjustments we will release special
training documents in the future.
For further questions please contact the Service-
Department.

26
Special Adjustments
The “Special Adjustments” menu should not be touched, and values not changed. Only very sometimes
it’s necessary to “Set Temperature”. Please measure the temperature of the controller and adjust it to
the right value if it doesn’t match.
On the older Ultra version of the Zapi

Handset, the menus “Special Adjustment”
and “Hardware Settings” could only be
accessed by a special key combination that
was not documented. For this reason, the
parameters of these menus are often not
listed in the Service-Manuals, controller
documentation and parameter lists.

27
Hardware Settings
The “Hardware Settings” menu should not be touched, and values not changed. Just check that the parameters
“Compensation”, “Slip Control” and “DC-Link Comps.” are set to “ON” on all AC-controllers.
On the older Ultra version of the Zapi Handset, the menus “Special Adjustment” and “Hardware Settings” could only be accessed
by a special key combination that was not documented. For this reason, the parameters of these menus are often not listed in the
Service-Manuals, controller documentation and parameter lists.

28
Clear EEPROM
“Clear EEProm” will delete all settings stored in the connected

controller.
Don’t do it if you don’t know what you are doing!!!
Before clearing the EEProm save all settings to the handset!
After clearing all settings will be set to factory settings of the

Controller, not to factory settings of the truck!

29
Save Parameters USB
Save all parameters/settings of

the connected controller to an
USB stick. You will get an
Excel file with information
about software revision, node
number, working hours and
settings.
If you are not sure the settings

on your controller are okay, you
can compare to the factory
settings or send us the file for
analysis.
To store the parameters your

handset should be equipped
with fresh batteries. Your
handset will create a folder for
each controller type, you don’t
have to choose a folder.

30
Zapi-Ultra-Handset 2
Usage of the old Ultra handset is similar Some special settings are in a hidden
to the Smart handset. menu which is not documented in the
Zapi documentation.
Use „Roll“ and buttons to move To enter this menu go in the “Alarms”
through the menus. With „Param. Set“ menu and press “Param.Set” up and
buttons you can change values and down at the same time.
options. Be careful in this menu, you can erase all
With the „Enter“ button you enter into settings!!
menus, with the „OUT“ button you leave.
If you changed parameters or options and

you leave a menu, you will be asked to
store your settings. Confirm with “Enter”,
otherwise your settings will be lost when
switching the key off.
To enter the configuration menu of the

controller press “Roll” up and “Param.Set”
up at the same time.

31
???
Still Questions?
Contact the CMHEU Service Department
Email: truck-technics@clarkmheu.com
Phone: +49 2065 49913-335

32

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CLARK EUROPE GMBH

XY Confidential, proprietary and trade secret information.

Old and new

Both looking the same.

Only a little difference.

AFG: old version

XY Confidential, proprietary and trade secret information.

Only a little difference.

AFG: old version

XY Confidential, proprietary and trade secret information.

The very old Zapi Ultra The Ultra Handset connects

XY Confidential, proprietary and trade secret information.

3.2-inch TFT LCD display

Keypad with function keys

XY Confidential, proprietary and trade secret information.

The Clark adapter cable PN#8119548 is included with the

The cable is equipped with an eight-pin MOLEX SPOX, as

Additionally included with the Smart Console are:

EPX/ECX adapter cable PN#8041365

XY Confidential, proprietary and trade secret information.

8 (6) pole Serial-Connector,

XY Confidential, proprietary and trade secret information.

Plug the adaptor directly to the

XY Confidential, proprietary and trade secret information.

SRX14-16: CAN Bus

XY Confidential, proprietary and trade secret information.

Handset connector at COP1,

XY Confidential, proprietary and trade secret information.

XY Confidential, proprietary and trade secret information.

To change the handset‘s

XY Confidential, proprietary and trade secret information.

Then we choose „CAN CONSOLE“

XY Confidential, proprietary and trade secret information.

Truck Traction Traction Pump Steering Valve CAN- Height- Baudrate

XY Confidential, proprietary and trade secret information.

Controller Voltage Motor current Working hours

XY Confidential, proprietary and trade secret information.

Choose „RS232 CONSOLE“ and

Error or status messages may appear here.

XY Confidential, proprietary and trade secret information.

Page 1 Page 2 Page 3

Press „OK“ to enter a menu.

XY Confidential, proprietary and trade secret information.

XY Confidential, proprietary and trade secret information.

These parameters are stored To change settings in different driving modes:

XY Confidential, proprietary and trade secret information.

XY Confidential, proprietary and trade secret information.

Error message Working hour

For further information about the

Still questions? Contact the

XY Confidential, proprietary and trade secret information.

Enter the „Program VACC“ menu,

Store with „ESC“ and „OK“

XY Confidential, proprietary and trade secret information.

You can save all

XY Confidential, proprietary and trade secret information.

Options of a SRX14 Traction controller.

XY Confidential, proprietary and trade secret information.

In the „Adjustments“ menu the battery can be set,

XY Confidential, proprietary and trade secret information.

On the older Ultra version of the Zapi

XY Confidential, proprietary and trade secret information.

XY Confidential, proprietary and trade secret information.

“Clear EEProm” will delete all settings stored in the connected