32 | Plant & Works Engineering www.pwemag.co.uk June/July 2025 Handling & Safety Matters Focus on: Handling & Storage who are certified in electrical safety. This could include components such as: Parts of the operator compartment Mast Some hydraulic components Parts of the cooling system Carriage Wheels and tyres Operations and their technicians should carefully review the service manual for the particular forklift or container handler they plan to conduct service or maintenance on to understand whether certified individuals are required for specific work. USED FOR MAINTENANCE AND REPAIRS Master Service Disconnect (MSD) Also referred to as a manual service disconnect, the truck MSD breaks the series connections within the battery, making the contactor connections to the motor inactive. Using the MSD is typically the first step for shutting down and securing a high-voltage circuit in the truck. Rubber gloves and other prescribed PPE must be worn when pulling the MSD, which is usually located behind an unlocked door on the truck and marked with a triangle decal with a flash or lightning bolt symbol. High-Voltage Interlock Loop (HVIL) This continuous low-voltage wire runs through all of the high-voltage connections in the system to monitor the integrity of the circuit and the security of all high-voltage covers. If the loop is broken because the MSD has been pulled or a cover is open, this system disables the contactors so they cannot engage and the highvoltage system is not activated RUNNING CONTINUOUSLY FROM TRUCK KEY-ON Ground Fault Detection (GFD) High-voltage wire has a metal shield that is connected to the truck. When there is an abrasion on the wire, the ground fault detection senses it and disconnects the truck, triggering a fault code so that operation of the truck is halted until the issue has been resolved. Power Enable Loop (PEL) This software monitors the temperature and voltage in a battery module. When a battery module goes out of its rated temperature or voltage range, the power enable loop opens and that battery is disabled to allow it to return to an appropriate temperature or to allow the voltage imbalance to be corrected. Why go electric? Pressure is mounting to significantly reduce greenhouse gas (GHG) emissions and accelerate the transition from fossil fuels to renewable energy sources, and regulatory requirements are growing. There is also a variety of benefits that can make electric-powered materials handling equipment an attractive solution. Battery electric forklifts produce zero tailpipe emissions. Compared to ICE models, electric alternatives produce less noise and vibration, offering a more comfortable experience for the operator. Electric equipment can also be less expensive to maintain. For example, diesel engines require regular oil changes, usually every 500 or 1,000 hours of use, with each typically requiring multiple gallons or litres of costly oil. Not only are oil changes eliminated, but electric equipment reduces or eliminates many of the other extensive service requirements associated with ICE equipment for the engine, fuel and air filters, transmission and brakes. And as emission standards for ICE equipment get more stringent, there is more emissionsrelated equipment on ICE trucks to maintain, such as the diesel particulate filter (DPF), diesel exhaust fluid (DEF) system and exhaust gas recirculation components. Because of the reduced components of electric equipment, servicing a high-voltage truck can be less expensive in some cases than ICE alternatives. High-voltage battery systems are used on heavy-duty equipment like high-capacity forklifts because of physical equipment design considerations, and because they offer productivity benefits that can be advantageous for some operations. From a design perspective, to achieve the necessary power using lower voltage wires, the wires would be thick and heavy enough that their bend radius would not allow them to fit within the frame of the truck. In terms of productivity, higher voltages allow for faster charging compared to lower voltage systems and provide very responsive performance. For further information please visit: www.hyster.com
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