Heavy-duty forklifts are increasingly powered by electric sources like batteries, rather than internal combustion engines (ICE). To achieve the charging speed and power delivery required by applications with demanding duty cycles and heavy loads, this high-capacity electric material handling equipment relies on high-voltage battery systems. Not all electric materials handling equipment uses high-voltage batteries. For example, a 4,000-pound, or 2,000-kilogram, capacity counterbalanced forklift with an integrated lithium-ion battery might use a dual voltage battery that can operate at 48 or 96 volts (V). However, for equipment that does use highvoltage battery systems, there are important safety considerations. Electrical safety responsibilities The European Committee for Electrotechnical Standardisation (CENELEC) defines the EN 50110 standard. It defines a shared responsibility for electrical safety. The owner of the premises where equipment is being maintained or serviced, their equipment dealer 30 | Plant & Works Engineering www.pwemag.co.uk June/July 2025 Handling & Safety Matters Focus on: Handling & Storage As more heavy-duty forklifts adopt high-voltage electric power, operations must understand the servicing and safety requirements. From certification levels to shared responsibilities under EN 50110, proper training, procedures, and precautions are critical to maintaining safety and compliance when working with high-voltage material handling equipment. Ricky Hirani, Global Commercial Product Leader, Big Trucks & Port Equipment, for Hyster explains further. What operations need to know about servicing high-voltage equipment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and the manufacturer all need to work together with a shared interest in the safety of work being performed. Training and certification requirements While it’s very common for operations with materials handling equipment like forklifts to service their own equipment, maintenance or repair work on high-voltage circuits, often identified by orange cables, requires individuals who are certified to work with these kinds of systems. EN 50110 identifies three levels of certification, identifying the technical knowledge required by individuals in order to work with high-voltage equipment and requiring individuals to be recertified every three years. Electrical instructed person (EIP, also known as VOP/EUP) One who is allowed to pull the master service disconnect (MSD) but not to measure 0-volt in the system. They assist the high-voltage technician (HVT) in working on high-voltage components and are able to assess the risks of the task at hand and deny work if in doubt about the situation. High-voltage technician (HVT, also known as VP/EFK) One who is allowed to pull the MSD and allowed to measure 0-volt in the system. They are able to work on high-voltage equipment independently or with the help of an EIP. They must understand when procedures are not clear and are able to consult with the high-voltage work supervisor (HVWS). High-voltage work supervisor (HVWS, also known as WV/VEFK) One who is responsible for defining procedures and seeing to it that procedures are followed. In addition to electrical certification, individuals must also have training and certification specific to the materials handling equipment they will be working directly with. What does this mean for operations? Businesses need to be aware of these requirements so that they only allow individuals with proper certification to participate in maintenance or repair work that requires specialised training. They should also confirm that their authorised dealer’s technicians are current on the certifications required. Two technicians are required when disconnecting and reconnecting high-voltage systems: one technician working on the truck and another in a support role to immediately intervene if necessary. While it is essential that only certified individuals are engaged in work that requires such certification, not all work on this equipment, like changing windshield wipers or light bulbs, requires certification. Maintenance or repairs on systems that are not powered by high-voltage circuits may not require technicians
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