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DP2 ZAPI HANDSET GUIDE [ZAPI PRESENTATION 12-2-14]

Gain insights on how to effectively utilize the DP2 Zapi handset to enhance your productivity and efficiency in your daily operations on 12-2-14.

Written by Nash Bernardo

Updated at February 20th, 2025

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                                              Zapi
                                          Handset
                                            Guide


    1.Turn the Key Switch off, remove
    cover (s) as needed

    2. Remove the Rubber Dust Cover 
    from the Zapi Controller

    The Zapi AC-0 means that it is an A/C (Altering Current) Inverter & the Amperage is a 150 Amp Maximum Capacity


    1.Turn the Key Switch off

    2. Remove the Rubber Dust Cover 


    from the Zapi Controller

    3. Connect the Zapi Handset to the Exposed Pins


    1.Turn the Key Switch off

    2. Remove the Rubber Dust Cover
    from the Zapi Controller

    3. Connect the Zapi Handset to the Exposed Pins

     

    **Note the Connector Shape and
    position**


    4. Turn The Key Switch On

    5. This will power up the Zapi Handset

     

     

     

     

    AC0T2SE4: The controller you are connected to
    EP2.33:       Firmware version
    24V:            The Voltage of the Controller
    150A:          The Maximum Amperage
    00001:        The Hours on the unit

     

     

     

     

     

     

     

     

     

     

     


    1.Press the Roll Up & Enter Button Simultaneously

    2. This will allow You to get to the
    Tester & Parameter Change Menus,
    then by using the Roll up or Down
    Buttons on the left you can go to the 
    desired functions.


    1.The Tester menu will allow you to

    see a variety of live inputs

      
     

     

     
     
     
     
     
     

     

     
     
     
     
     

    Tester to see live inputs 

     
     
     
     
     

    Description 

     
     
     
     
     

    Off Or Neutral 

     
     
     
     
     

    On or Actuated 

     
     
     
     
     

    1 

     
     
     
     

    Battery Voltage 

     
     
     
     

    Display Battery Voltage at the Controller 

     
     
     
     

    #N/A 

     
     
     
     

    #N/A 

     

     
     
     
     
     

    2 

     
     
     
     

    Cut Back Switch 2 

     
     
     
     

    Brake Switch 

     
     
     
     

    Off GND 

     
     
     
     

    +VB 

     
     
     
     
     

    3 

     
     
     
     

    Lift Stop Switch 

     
     
     
     

    Lift Limit Switch 

     
     
     
     

    Off GND 

     
     
     
     

    +VB 

     
     
     
     
     

    4 

     
     
     
     

    Quck Inverse 

     
     
     
     

    Is the Belly Button Safety Reversing 

     
     
     
     

    Off GND 

     
     
     
     

    +VB 

     
     
     
     
     

    5 

     
     
     
     

    HS 

     
     
     
     

    Hard & Soft leave at Factory Setting 

     
     
     
     

    #N/A 

     

     
     
     
     

    #N/A 

     

     
     
     
     
     

    6 

     
     
     
     

    Handle Seat Switch 

     
     
     
     

    2 Brake Switch 

     
     
     
     

    Off GND 

     
     
     
     

    +VB 

     
     
     
     
     

    7 

     
     
     
     

    Backward Switch 

     
     
     
     

    Travel in Fork Direction 

     
     
     
     

    Off GND 

     
     
     
     

    +VB 

     
     
     
     
     

    8 

     
     
     
     

    Forward Switch 

     
     
     
     

    Travel in Power Head Direction 

     
     
     
     

    Off GND 

     
     
     
     

    +VB 

     
     
     
     
     

    9 

     
     
     
     

    Decent Switch 

     
     
     
     

    Lowering Switch 

     
     
     
     

    Off GND 

     
     
     
     

    +VB 

     
     
     
     
     

    10 

     
     
     
     

    Lifting Switch 

     
     
     
     

    Raise Lift Switch 

     
     
     
     

    Off GND 

     
     
     
     

    +VB 

     
     
     
     
     

    11 

     
     
     
     

    Brake Pedal Pot 

     
     
     
     

    Not Used 

     
     
     
     

    #N/A 

     
     
     
     

    #N/A 

     
     
     
     
     

    12 

     
     
     
     

    Accelerator 

     
     
     
     

    Speed Controller in Handle 

     
     
     
     

    0.0 

     
     
     
     

    2.5 

     
     
     
     
     

    13 

     
     
     
     

    Motor Temp 

     
     
     
     

    Temperature of the Drive Motor 

     
     
     
     

    32C 

     
     
     
     

    32C+ 

     
     
     
     
     

    14 

     
     
     
     

    Temperature 

     
     
     
     

    Temperature of the Controller 

     
     
     
     

    28C 

     
     
     
     

    28C+ 

     
     
     
     
     

    15 

     
     
     
     

    Battery Charge 

     
     
     
     

    State of Charge in Percent 

     
     
     
     

    80%=25.4? 

     
     
     
     

     

     
     
     
     
     

    16 

     
     
     
     

    Current RMS 

     
     
     
     

    Motor Current 

     
     
     
     

    0 

     
     
     
     

    Increase with Travel 

     
     
     
     
     

    17 

     
     
     
     

    Encoder 

     
     
     
     

    Encoder in the Drive Motor 

     
     
     
     

    0.0 Hz 

     
     
     
     

    .49 down to 0 

     
     
     
     
     

    18 

     
     
     
     

    Frequency 

     
     
     
     

    Frequency of Hz to the drive motor 

     
     
     
     

    0.0 Hz 

     
     
     
     

    Reverse- Forward + up to 23? 

     
     
     
     
     

    19 

     
     
     
     

    Motor Power 

     
     
     
     

    Watts Used 

     
     
     
     

    0.0 

     
     
     
     

    Up to 148 

     
     
     
     
     

    20 

     
     
     
     

    Flux Miliwb 

     
     
     
     

    #N/A 

     
     
     
     

    #N/A 

     
     
     
     

    #N/A 


    1.The Tester menu will allow you to
    see a variety of live inputs

     

     

    The Item listed are a few of the
    Item you will see in the Tester Mode


    1.The Tester menu will allow you to see variety of live inputs

    2. The Alarm menu will show you
    the stored Controller Faults and
    can be cleared from the menu

     

     

    The items shown are few example
    of what a Alarm will look like

     

     

     

     

     


    3. The Parameter Change menu will
    Allow adjustments to the unit
     

     

     

     
     
     
     
     
     

     

     
     
     
     
     

    Parmeter Changes 

     
     
     
     
     

    Value 

     
     
     
     
     

    1 

     
     
     
     

    Accelerator Delay 

     
     
     
     

    Level 9 

     
     
     
     
     

    2 

     
     
     
     

    Anti Roll Back 

     
     
     
     

    Leave set at 80% (the factory setting 

     
     
     
     
     

    3 

     
     
     
     

    Aux Time 

     
     
     
     

    #N/A 

     
     
     
     
     

    4 

     
     
     
     

    Inching Level 

     
     
     
     

    #N/A 

     
     
     
     
     

    5 

     
     
     
     

    Max Current (Leave at Factory Setting) (Increase as a last effort for heavier loads, consumes more battery power) 

     
     
     
     

    70% 

     
     
     
     
     

    6 

     
     
     
     

    RPM Creep 

     
     
     
     

    100% 

     
     
     
     
     

    7 

     
     
     
     

    Frequency Creep 

     
     
     
     

    5 Hz 

     
     
     
     
     

    8 

     
     
     
     

    HS Cut Back 

     
     
     
     

    100% 

     
     
     
     
     

    9 

     
     
     
     

    Cut Back Speed 2 ( Pin Wheeling Speed) 

     
     
     
     

    37% 

     
     
     
     
     

    10 

     
     
     
     

    Cut Back Speed (for trucks with masts 

     
     
     
     

    100% 

     
     
     
     
     

    11 

     
     
     
     

    Max Speed FWD & REV 

     
     
     
     

    80% 

     
     
     
     
     

    12 

     
     
     
     

    Brake Level Cut Back 

     
     
     
     

    5 

     
     
     
     
     

    13 

     
     
     
     

    Speed Limit Brake 

     
     
     
     

    Level 1 

     
     
     
     
     

    14 

     
     
     
     

    Pedal Brake 

     
     
     
     

    Level 9 

     
     
     
     
     

    15 

     
     
     
     

    Quick Inversion 

     
     
     
     

    Level 6 

     
     
     
     
     

    16 

     
     
     
     

    Inverse Brake (Plugging) 

     
     
     
     

    Level 4 

     
     
     
     
     

    17 

     
     
     
     

    Release Brake (Time for Brake to Release) 

     
     
     
     

    Level 5 


     

    1.The Tester menu will Allow you to see a variety
    of live inputs

     

     

     

    2. The Alarms menu will show you the Stored
    Controller Fault and can be cleared from the
    menu

    3. The Parameter Change menu
    allow adjustments to the unit

     

     

     

     

    The items shown are a few of the
    Parameter you can Adjust

     

     

     

     

     

     

     

     

     


    4. The Program VACC will allow you
    to program the speed controller

     

     

     

     
     
     
     
     
     

     

     
     
     
     
     

    Program VACC (VARIABLE ACCELLERATOR CONTROL CARD 

     
     
     
     
     

    Off Or Neutral 

     
     
     
     
     

    Full FWD or RVS 

     
     
     
     
     

    1 

     
     
     
     

    Select Program VACC 

     
     
     
     

    0.0 

     
     
     
     

    2.5 

     
     
     
     
     

    2 

     
     
     
     

    Press the Enter Button 

     
     
     
     

    0.0 

     
     
     
     

    0.0 

     
     
     
     
     

    3 

     
     
     
     

    Press & Hold the Enter Button for 2 seconds 

     
     
     
     

    0.0 

     
     
     
     

    0.0 

     
     
     
     
     

    4 

     
     
     
     

    Zapi Hand Set should Zero out 

     
     
     
     

    0.0 

     
     
     
     

    0.0 

     
     
     
     
     

    5 

     
     
     
     

    Twist the accelerator Full Forward then back to Neutral and then Full Reverse 

     
     
     
     

    0.0 

     
     
     
     

    2.5 


    1.The Tester menu will allow you to see a variety
    of live inputs

     

     

     

    2. The Alarms menu will show you the stored 
    Controller Faults and can be cleared from the
    menu

     

    3. The Parameter Change menu will allow
    adjustment to the unit

    4. The Program VACC will allow you
    to program the speed controller
     

     

     

    This is what the programing screen
    will look like

    **NOTE:
    When a Zapi Controller or a
    Accelerator has been replaced it is
    necessary to RE-Program the 
    Vacc with the Zapi Handset

     

     

     


    Replacement Zapi Control Programming Procedure

    When a Zapi AC-0 Controller is replaced, the following programming procedure must be performed after the controller is installed in the truck.

    TO PROGRAM VACC:
    1. Turn on the ZAPI handset.

    2. Press enter and press roll up or roll down to find the program VACC.

    3. Press enter to go into the program VACC function.

    4. Press enter to clear the value, then display will show 0.0 for both VACC and settings.

    5. Push the accelerator forward to the max. then push the accelerator backward to the max. 
    Setting value should go from 0.0 in neutral to 2.4 or 2.5 at max. each way.

    6. Press out (display will ask you “are you sure”)

    7. Press enter for yes.

    **NOTE:
    When a Zapi Controller or a
    Accelerator has been replaced it is
    necessary to RE-Program the 
    Vacc with the Zapi Handset

     

     

     


    For further instructions go to:
    http://www.bigjoesupport.com/

    Site Overview

    This website was established to provide support to end users and Dealers of Big Joe equipment. Some features of the website include:

    • Online Parts Catalog

    A comprehensive library of parts illustrations, service manuals and documentation for almost every Big Joe made! The list keeps growing as we continue to add and update both new and legacy equipment information.

    • Quick Search

    A search utility to help you find what you're looking for in the Online Parts Catalog.

    • Dealer Locator

    Find a Big Joe Dealer - search by state/country or proximity to zip code.

    In addition to the parts illustrations and service documentation that  are available to everyone. Dealers have access to the following resources:

    • Parts Pricing and Availability

    Listed next to each part number when viewing a parts drawing in the Online Parts Catalog.

    • Quick Quote

    Do you have a list of Parts and need list price, cost and availability? Use the Quick Quote tool in the left window panel of the Online Parts Catalog.

    • Dealer Tools

    Downloads that include the Parts Order Form, Warranty Registration From, Warranty Card, Dealer Promotional Merchandise, MSDS sheets and a website tutorial.

    • Order Parts

    Submit a parts order from a list or add items while browsing the Online Parts Catalog.

    If you're a Dealer and don't have your login and password, call us today! it takes less than a minute to set you up.

    Thanks for Stopping by, keep checking back for more news and updates.
    - The Big Joe Support team


    News
    July 18, 2014

    We have received some information from a couple of customers that they have had some issues with intermittent stop and start in refrigerated trailer delivery applications and therefore we have updated our Service Bulletins with a possible solution for this problem should it occur.

    June 12, 2014

    We have received some information from our charger supplier in regards to the charging procedures for the following truck models J1, WPT-45, PDS & Cb-22. Because of this we have updated the Service Bulletin that can find under the Service Tab once you logged in. Once you have downloaded the PDF file click on the informative Bulletins link and then chose the link for IF-006 to read more about this important information.

    May 14, 2014

    We are pleased to announce that we have now updated the website so that you can get your freight charges and tracking number for your order (it currently only works for UPS orders). Once you are logged in you can either go to “View Orders”.  and find your order by looking for your PO # and when you find that click on the corresponding “Order ID” in the left column this will give you a new window where you can see freight charges and also have a link to track the package. The other way you can do is to click on the “Order Tracking” and enter either your PO # or the “Sales Order #” (Not Order ID), if you chose to use your PO # then check mark the “PO #” box on the right side. When you have entered this information click on the “Search UPS” button and that will open up a new window where you can see freight charges and also have a link to track the package.

    November 27,2013

    When you are logged in the website you can now go to the Dealer Tools tab and download an instructional PDF for how to order parts on the www.bigjoesupport.com website.

    November 8, 2013

    We have now posted D40 manual under the Online Parts Catalog tab.

    September 4, 2013

    We have now posted both the EZ-30 and EZ-40 manuals under the Online Parts Catalog tab.


    *Click on link to see original document:

     

     

    https://static.helpjuice.com/helpjuice_production/uploads/upload/image/14012/3893129/1710193636960-8.%2BZapi%2BPresentation%2B12-2-14.pdf

     

     

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