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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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If you still have questions or prefer to get help directly from an agent, please submit a request.
We’ll get back to you as soon as possible.

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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

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

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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.

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Thanks for Stopping by, keep checking back for more news and updates.
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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

 

 

user manual zapi

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