prEN 1459-7

SLOVENSKI STANDARD
01-julij-2025
Vozila za talni transport - Terenska vozila - Varnostne zahteve in preverjanje - 7.
del: Elektrifikacija
Rough-terrain trucks - Safety requirements and verification - Part 7: Electrification
Geländegängige Stapler - Sicherheitstechnische Anforderungen und Verifizierung - Teil
7: Elektrifizierung
Chariots tout-terrain - Exigences de sécurité et vérification - Partie 7 : Électrification
Ta slovenski standard je istoveten z: prEN 1459-7
ICS:
43.120 Električna cestna vozila Electric road vehicles
53.060 Industrijski tovornjaki Industrial trucks
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

DRAFT
EUROPEAN STANDARD
NORME EUROPÉENNE
EUROPÄISCHE NORM
April 2025
ICS 53.060
English Version
Rough-terrain trucks - Safety requirements and
verification - Part 7: Electrification
Chariots tout-terrain - Exigences de sécurité et Geländegängige Stapler - Sicherheitstechnische
vérification - Partie 7 : Électrification Anforderungen und Verifizierung - Teil 7:
Elektrifizierung
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee
CEN/TC 150.
If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations
which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC
Management Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and
United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2025 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 1459-7:2025 E
worldwide for CEN national Members.

Contents Page
European foreword . 4
Introduction . 5
1 Scope . 6
2 Normative references . 7
3 Terms and definitions . 7
4 Safety requirements and/or protective measures . 10
4.1 General. 10
4.1.1 Context . 10
4.1.2 Specific relation with EN 1459-1 and EN 1459-2 . 10
4.1.3 Voltage range . 10
4.2 Protection against direct contact with live parts . 10
4.2.1 Protections . 10
4.2.2 Protection degree . 11
4.2.3 Specific requirements for connectors . 11
4.2.4 Protection from residual voltages . 12
4.3 Protection against indirect contact . 13
4.3.1 Equipotential bonding . 13
4.3.2 Connection to the truck frame . 13
4.3.3 On-board chargers and other connections to a grounded external power supply . 13
4.4 Insulation resistance . 14
4.4.1 General. 14
4.4.2 Insulation resistance of the truck . 14
4.4.3 Insulation resistance of the REESS . 14
4.4.4 Insulation resistance of the coupling system for charging the REESS . 14
4.4.5 Detection of frame faults (on-board insulation monitoring device) . 14
4.5 Rechargeable electric energy storage system (REESS) . 14
4.5.1 Protection in case of excessive current . 14
4.5.2 Prevention of accumulation of gas for open type lead acid REESS . 15
4.5.3 Protection against electrolyte spills . 15
4.5.4 Protection against accidental or unintentional detachment . 15
4.5.5 REESS compliance . 15
4.6 In-use safety requirements . 15
4.6.1 Active operating mode . 15
4.6.2 REESS charging . 16
4.6.3 Direction control . 16
4.6.4 Limited mode. 16
4.7 Emergency operations . 17
4.7.1 Emergency stop . 17
4.7.2 Emergency switching off . 17
5 Verification . 18
5.1 Measurements of insulation resistance . 18
5.2 Continuity test for equipotential bonding . 18
6 Information for use . 19
6.1 General. 19
6.2 Contents . 19
6.2.1 Operator’s manual,. 19
6.2.2 Maintenance manual . 19
6.3 Signals and warning devices . 20
6.3.1 Safety signs . 20
6.3.2 Cables colour . 20
6.3.3 Warning devices . 20
Annex A (informative) List of significant hazards . 21
Annex B (normative) Isolation resistance measurement method . 30
B.1 General . 30
B.2 Measurement method . 30
Annex ZA (informative) Relationship between this European Standard and the essential
requirements of Directive 2006/42/EC aimed to be covered . 35
Annex ZB (informative) Relationship between this European Standard and the essential
requirements of Regulation (EU) 2023/1230 aimed to be covered . 38
Bibliography . 41
European foreword
This document (prEN 1459-7:2025) has been prepared by Technical Committee CEN/TC 150 “Industrial
Trucks - Safety”, the secretariat of which is held by BSI.
This document is currently submitted to the CEN Enquiry.
This document has been prepared under a standardization request addressed to CEN by the European
Commission. The Standing Committee of the EFTA States subsequently approves these requests for its
Member States.
For the relationship with EU Legislation, see informative Annex ZA and Annex ZB, which are an integral
part of this document.
EN 1459 consists of the following parts, under the general title Rough-terrain trucks — Safety
requirements and verification:
— Part 1: Variable-reach trucks;
— Part 2: Slewing variable-reach trucks;
— Part 3: Interface between the variable-reach truck and the work platform;
— Part 4: Additional requirements for variable-reach trucks handling freely suspended loads;
— Part 5: Attachment interface;
— Part 6: Application of EN ISO 13849-1 to slewing and non-slewing variable-reach rough-terrain trucks;
— Part 7: Electrification;
— Part 9: Variable-reach trucks equipped with work platforms having a front guard that can be opened.
Introduction
This document is a type-C standard as stated in EN ISO 12100.
This document is of relevance, in particular, for the following stakeholder groups representing the market
players with regard to machinery safety:
— machine manufacturers (small, medium and large enterprises);
— health and safety bodies (regulators, accident prevention organizations, market surveillance, etc.).
Others can be affected by the level of machinery safety achieved with the means of the document by the
above-mentioned stakeholder groups:
— machine users/employers (small, medium and large enterprises);
— machine users/employees (e.g. trade unions, organizations for people with special needs);
— service providers, e.g. for maintenance (small, medium and large enterprises);
— consumers (in case of machinery intended for use by consumers).
The above-mentioned stakeholder groups have been given the possibility to participate at the drafting
process of this document.
The machinery concerned and the extent to which hazards, hazardous situations or hazardous events are
covered are indicated in the Scope of this document.
When requirements of this type-C standard are different from those which are stated in type-A or type-B
standards, the requirements of this type-C standard take precedence over the requirements of the other
standards for machines that have been designed and built according to the requirements of this type-C
standard.
1 Scope
This document specifies electrical safety requirements for electrical systems of rough-terrain variable-
reach trucks and slewing rough-terrain variable-reach trucks powered by one or more electric motors
(hereafter referred to as trucks), namely pure electric and hybrid electric trucks, including when
hydraulic systems are electrically powered. This document applies to electrical systems with maximum
voltage greater than 32 up to 1500 V DC or greater than 21 up to 1000 V AC r.m.s.
This document deals with all significant hazards, hazardous situations and events relevant to the trucks
when they are used as intended and under conditions of misuse which are reasonably foreseeable by the
manufacturer.
The significant hazards (see EN ISO 12100:2010, Annex B) dealt with in this document are listed in
Annex A.
This document does not deal with hazards which could occur:
— during construction;
— when operating trucks in potentially explosive atmospheres.
This document does not cover:
— electrical systems of trucks with maximum working voltage up to 32 V DC or 21 V AC r.m.s (see
relevant requirements in EN 1459-1 or EN 1459-2, as applicable);
— electric regenerative braking systems;
— electrical systems of externally-powered trucks designed for operation only when mains-connected.
NOTE Electrical systems of trucks designed to be both externally-powered and self-propelled are covered in
this document when not mains-connected.
This document does not deal with sales literature.
This document does not address hazards specifically related to:
— trucks designed to operate with varying levels of autonomy (autonomous trucks), including trucks
which move autonomously to the charging station, or when truck has embedded safety-systems with
fully or partially self-evolving behaviour or logic using machine learning approaches;
— trucks with communication network connection.
This document is not applicable to trucks manufactured before the date of its publication.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
EN 60529:1991, Degrees of protection provided by enclosures (IP Code)
EN ISO 6682:2008, Earth-moving machinery — Zones of comfort and reach for controls (ISO 6682:1986,
including Amd 1:1989)
ISO 7000:2019, Graphical symbols for use on equipment — Registered symbols
EN 60204-1:2018, Safety of machinery — Electrical equipment of machines — Part 1: General
requirements
EN ISO 17409:2020, Electrically propelled road vehicles — Conductive power transfer — Safety
requirements (ISO 17409:2020)
EN ISO 13850:2015, Safety of machinery — Emergency stop function — Principles for design
(ISO 13850:2015)
EN 60947-5-5:1997, Low-voltage switchgear and controlgear — Part 5-5: Control circuit devices and
switching elements — Electrical emergency stop device with mechanical latching function
EN ISO 12100:2010, Safety of machinery — General principles for design — Risk assessment and risk
reduction (ISO 12100:2010)
EN 1459-1:2025, Rough-terrain trucks — Safety requirements and verification — Part 1: Variable-reach
trucks
EN 1459-2:2015+A1:2018, Rough-terrain trucks — Safety requirements and verification — Part 2: Slewing
variable-reach trucks
3 Terms and definitions
For the purposes of this document, the terms and definitions given in EN 1459-1:2025,
EN 1459-2:2015+A1:2018 and the following apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https://www.iso.org/obp/
— IEC Electropedia: available at https://www.electropedia.org/
3.1
voltage class
classification of an electric component or circuit according to its maximum working voltage (3.2)
[SOURCE: ISO 6469-3:2021, definition 3.36]

As impacted by EN 60529:1991/corrigendum May 1993, EN 60529:1991/A1:2000. EN 60529:1991/A2:2013 and
EN 60529:1991/AC:2016-12.
As impacted by EN 60947-5-5:1997/A1:2005, EN 60947-5-5:1997/A2:2017 and EN 60947-5-5:1997/A11:2013.
Table 1 — Voltage classes
Maximum working voltage
Voltage class
V DC V AC r.m.s.
VC-A 0 < U ≤ 60 0 < U ≤ 30
VC-A1 0 < U ≤ 32 0 < U ≤ 21
VC-A2 32 < U ≤ 60 21 < U ≤ 30
VC-B 60 < U ≤ 1500 30 < U ≤ 1000
VC-B1 60 < U ≤ 75 30 < U ≤ 50
VC-B2 75 < U ≤ 1500 50 < U ≤ 1000
VC-C 1500 < U ≤ 36000 1000 < U ≤ 36000
U = maximum working voltage
NOTE The classification of voltage classes VC-A, VC-B and VC-C is according to
ISO 6469-3:2021.
3.2
maximum working voltage
highest value of AC voltage (r.m.s) or of DC voltage that can occur under any normal operating conditions
according to the manufacturer's specifications, disregarding transients and ripple
[SOURCE: ISO 6469-3:2021, definition 3.26]
3.3
direct contact
electric contact of human beings or livestock with live parts
[IEV ref 195-06-03]
3.4
live part
conductor or conductive part intended to be energized in normal use
Note 1 to entry: This concept does not necessarily imply a risk of electric shock.
[SOURCE: IEC 60050-826:2004, definition 826-12-08, modified – Reference to PEN, PEL and PEM
conductors removed, reference to running rails added. IEC 62128-1:2013, definition 3.1.13]
3.5
indirect contact
electric contact of human beings or livestock with exposed-conductive-parts that have become live under
fault conditions
[IEV ref 195-06-04]
3.7
connector
device designed for providing connection and disconnection to a suitable mating component
[IEV ref 482-05-55]
Note 1 to entry: A connector has one or more contact members.
3.8
end-of-charge voltage
voltage attained at the end of a charging step, at a specified constant current
[IEV ref 151-12-19, MOD]
3.9
exposed conductive part
conductive part of equipment that can be touched under the provisions of the protection degree IPXXB and
that is not live under normal conditions, but that can become live when basic insulation fails
[IEV ref 195-06-10, MOD]
3.10
hybrid truck
truck powered by at least two different on-board energy storage systems and two different energy
converters, where at least one converter converts electrical energy
3.11
rechargeable electrical energy storage system
REESS
rechargeable system with maximum voltage greater than 32 up to 1500 V DC that provides electrical
energy
Note 1 to entry: REESS includes the necessary systems for physical support, the battery management system and
the casing.
3.12
conductive part
part which can carry electric current
[IEV ref 195-01-06]
3.13
basic insulation
insulation applied to live parts for protection against direct contact under fault-free conditions
Note 1 to entry: Where insulation is not provided by solid insulation only, it is complemented with protective
barriers or protective enclosures to prevent access to live parts in order to achieve basic protection.
3.14
REESS nominal voltage
value of the voltage used by the manufacturer or supplier to designate or identify a REESS
[IEV ref 482-03-31, MOD]
3.15
battery management system
BMS
electronic system associated with a battery which has functions to control current in case of overcharge,
overcurrent, overdischarge, and overheating, and which monitors and/or manages the state of the
battery, calculates secondary data, reports that data and/or controls its environment to influence the
battery's safety, performance and/or service life
Note 1 to entry: Overdischarge cut off is not mandatory if there is an agreement on this between the cell
manufacturer and the customer.
Note 2 to entry: The function of the battery management system (BMS) can be assigned to the battery pack or to
equipment that uses the battery.
Note 3 to entry: The BMS can be divided and it can be found partially in the battery pack and partially on the
equipment that uses the battery.
Note 4 to entry: The BMS is sometimes also referred to as a BMU (battery management unit).
3.16
truck inlet
part of a truck equipped with an on-board charger enabling the connection of a flexible cable for charging
the REESS
3.17
regenerative braking
braking with conversion of kinetic energy into electric energy for charging the rechargeable electrical
energy storage system (REESS)
4 Safety requirements and/or protective measures
4.1 General
4.1.1 Context
Trucks shall comply with the safety requirements and/or protective/risk reduction measures of this
clause. In addition, trucks shall be designed according to the principles of EN ISO 12100:2010 for relevant
but not significant hazards which are not dealt with by this document.
4.1.2 Specific relation with EN 1459-1 and EN 1459-2
Trucks shall comply with EN 1459-1:2025 or EN 1459-2:2015+A1:2018, as applicable, for the significant
hazards not covered by this document (see Annex A).
4.1.3 Voltage range
Electrical systems of trucks powered by REESS of the lead-acid type shall be designed to operate in the
voltage range from 70 % up to 120 % of the REESS nominal voltage or as indicated by the REESS
instructions.
Electrical systems of trucks powered by REESS other than lead-acid type shall be designed to operate in
the voltage range as indicated by the REESS instructions.
Verification by design check.
4.2 Protection against direct contact with live parts
4.2.1 Protections
The protections against direct contact with live parts (e.g. solid insulator, barrier, enclosure) shall not be
able of being opened, disassembled or removed without the use of tools or keys.
Verification by design check.
4.2.2 Protection degree
The minimum protection degree in accordance with EN 60529:1991 shall be as given in Table 2:
Table 2 — Protection degree
Cab type Zone VC-A2 VC-B
a
IPXXB IPXXD
zone of reach
Non-enclosed cab
elsewhere on the truck IPXXB IPXXB
inside the cab IPXXB IPXXD
Enclosed cab
outside the cab IPXXB IPXXB
a
Zone of reach according to EN ISO 6682:2008.
Verification by type-test in accordance with EN 60529:1991 , Clause 15.
4.2.3 Specific requirements for connectors
4.2.3.1 Truck inlet
The truck inlet shall comply with the applicable standard (for example EN 60309, EN 62196).
Verification by design check.
For REESS with an end-of-charge voltage exceeding 60 V, switching of external power shall be controlled
via the connector auxiliary contacts or via other devices connected to the Batteries Management System
to prevent arcing at the connector and to ensure that the charger is not energised until it is connected to
the REESS.
Verification by design check.
4.2.3.2 Other connectors
Connectors shall be protected against accidental contacts with live parts. Connectors are deemed to meet
this requirement if:
— they comply with the protection degree IPXXB when separated without the use of tools or keys; or
— they are provided with a locking mechanism and other components shall first be removed with the
use of tools or keys in order to separate the connector; or
— the voltage of the live parts becomes ≤ DC 60 V or ≤ AC 30 V r.m.s within one second after the
connector is separated.
Verification by design check or measurement.
4.2.3.3 Service disconnection
It shall be possible to electrically disconnect the REESS for maintenance and replacement operations.
Verification by design check.
Where a service disconnection can be opened, disassembled or removed without the use of tools or keys,
the protection degree IPXXB shall be met.
Verification by design check.
4.2.4 Protection from residual voltages
After disconnecting the REESS, either of the following requirements shall apply:
— the voltage of the capacitors (except REESS) shall be less than 60 V DC after 10 s, or
— a permanent and indelible warning label shall be affixed on, or in close proximity to, the enclosure
containing the capacitors. Safety signs in Figure 1 and Figure 3 shall be used. The background shall
be yellow, the bordering and the symbol shall be black.

a) Symbol ISO 7000- 0434A
b) symbol ISO 7000- 0434B
Figure 1 — Symbol ISO 7000- 0434A and ISO 7000- 0434B
Exempted from this requirement are components having a stored charge of 60 µC or less (see
EN 60204-1:2018, 6.2.4).
Verification by measurement or visual examination.
4.3 Protection against indirect contact
4.3.1 Equipotential bonding
For trucks with VC-B systems the exposed conductive parts, such as the metallic barrier and enclosure or
motor frames, shall be securely galvanically connected to the truck frame for instance by connections
with electrical wire, ground cable, welds or by connections using bolts so that no dangerous electric
potential can exist.
Verification by design check.
The resistance between all exposed conductive parts and the electrical chassis shall be lower than 0,1 Ω
when there is current flow of at least 0,2 A. This requirement is deemed as satisfied if the galvanic
connection has been established by welding.
For exclusions see EN 60204-1:2018, 8.2.5.
Verification by type-test in 5.2.
4.3.2 Connection to the truck frame
For trucks with VC-B systems there shall be no electrical connection between live parts and the truck
frame, except for:
— insulation monitoring device;
— VC-A circuits which are galvanically separated from the REESS;
— earthing terminal of on-board chargers (see also 4.2.3).
This requirement may also be applied to VC-A2 systems.
Verification by design check.
4.3.3 On-board chargers and other connections to a grounded external power supply
When trucks are fitted with on-board chargers or other devices intended to be connected to a grounded
external electric power supply through a conductive connection, a device enabling the galvanic
connection of the truck frame to the earth ground shall be provided.
The device shall enable connection to the earth ground before external voltage is supplied to the truck
and shall retain this connection until after the exterior voltage is removed from the truck.
Alternatively, class II protection may be provided (see EN 60204-1:2018, 6.3.2.2). In such case, access
openings intended for inspection and maintenance of class II protection shall be provided on the truck in
accordance with EN ISO 2860:2008 (see also 6.2).
The requirements of EN 60204-1:2018, 6.3 (Fault protection), 7.2.1 (Overcurrent protection) and
Clause 8 (Equipotential bonding) up to and including 8.2 shall apply.
EN ISO 17409:2020 shall be applied for charging modes 2, 3 or 4.
A galvanic connection to the earth ground does not need to be provided if the truck cannot be charged
without completely removing the REESS from the truck.
NOTE This document provides requirements on connection to the earth ground only in case the truck is
involved. In case the REESS that has to be removed from the truck for charging purposes, the REESS is considered
as a separate item.
Verification by design check.
4.4 Insulation resistance
4.4.1 General
Insulation resistance of VC-B trucks shall comply with the requirements set out below. The requirements
may also be applied to VC-A2 trucks.
The measurements of insulation resistance shall be conducted in accordance with requirements in 5.1.
4.4.2 Insulation resistance of the truck
If AC buses and DC buses are galvanically isolated from each other, insulation resistance between all high
voltage buses and the electrical chassis shall have a minimum value of 100 Ω/V of the maximum working
voltage for DC buses, and a minimum value of 500 Ω/V of the maximum working voltage for AC buses.
4.4.3 Insulation resistance of the REESS
The insulation resistance between the truck frame and the live parts of the disconnected, filled and
charged REESS mounted on the truck shall be at least 500 Ω/V multiplied by the maximum working
voltage of the REESS.
A REESS having a nominal voltage not higher than 60 V DC, shall have an insulation resistance of at least
50 Ω multiplied by the nominal REESS voltage when measured between a REESS terminal and metallic
container, vehicle frame or other conductive supporting structure.
4.4.4 Insulation resistance of the coupling system for charging the REESS
The truck inlet and the circuit that is galvanically connected to the truck inlet during charging of the
REESS shall have an insulation resistance between the circuit and the truck frame of at least 1,0 MΩ when
the charger coupler is disconnected. During the measurement the REESS may be disconnected.
4.4.5 Detection of frame faults (on-board insulation monitoring device)
VC-B trucks shall be provided with an on-board insulation monitoring device.
Verification by design check.
The on-board insulation monitoring device shall give a visual, and optionally also audible, warning to the
operator when the truck is switched on if the insulation resistance of circuits directly connected to the
REESS drops below the minimum values required in 4.4.
Verification by design check.
4.5 Rechargeable electric energy storage system (REESS)
4.5.1 Protection in case of excessive current
The truck shall be equipped with one or more protective devices such as fuses, circuit breakers and/or
main contactors to prevent from overheating in case of excessive current.
For other than lead acid type REESS, the BMS, when fitted, or the machine control system shall be
designed such that corrective measures are initiated to prevent overtemperature exposure, for example
deactivation of the REESS.
The limit of the overtemperature in the BMS shall be in accordance with the specification of the REESS.
NOTE The Battery Management System requirements are given in separate standards, see for example
EN 62619, EN IEC 62485-6, EN 1175:2020, Clauses C.2.3.2 to C.2.6.
Verification by design check.
4.5.2 Prevention of accumulation of gas for open type lead acid REESS
4.5.2.1 During usage
Suitable ventilation openings shall be provided in the open type lead acid REESS container, compartment
or cover so that dangerous accumulation of gases does not occur when the equipment is used in
accordance with information for use.
NOTE For open type lead acid batteries the experience has indicated, when openings are positioned such that
gases can escape freely, ventilation openings are usually satisfactory if they provide a cross section in square
millimetres equal to half the number of cells, multiplied by the 5 h rated capacity in amperes hour. This level of
ventilation is however not intended to cover the charging condition.
Verification by design check.
4.5.2.2 During charging
Hydrogen emissions shall be limited to an extent so that dangerous accumulation of gases does not occur
when open type lead acid REESS charging is carried out in accordance with information for use.
Information on hydrogen emissions shall be provided according to one of the test method described in
the applicable standards (see 4.5.5), for example EN 62485-3:2014, Clause 6.
Verification by design check.
4.5.3 Protection against electrolyte spills
The operator shall be protected in case electrolyte is spilled from the REESS or its components when it is
tilted in any direction, leaned left or right against the ground or even when the REESS is put upside-down.
Verification by design check.
4.5.4 Protection against accidental or unintentional detachment
The REESS and its components shall be installed in the truck in such a way so as to preclude the possibility
of inadvertent or unintentional detachment or ejection of the REESS.
Verification by design check.
The REESS and its components shall not be ejected when the truck is tilted in any direction, leaned left or
right against the ground or even when the REESS is put upside-down.
Verification by design check.
4.5.5 REESS compliance
The REESS shall fulfil the applicable standards, for example EN 62485-3:2014, EN IEC 62485-6:2021,
EN IEC 62619:2022.
Verification by design check.
4.6 In-use safety requirements
4.6.1 Active operating mode
The travel control system shall be so arranged that on level ground the truck will start from standstill
only when the control(s) for speed and direction are activated.
Verification by design check.
Any initial activation of the drive system shall only be possible from the neutral position of the speed and
directional controls.
Verification by design check.
Means shall be provided to avoid any truck movement when switching on the travel control system.
EN 1459-1:2025, 4.2.3 and 4.2.4, and EN 1459-2:2015+A1:2018, 4.2.2 and 4.2.3, shall not apply to trucks
other than hybrid trucks where an internal combustion engine provides directly the travelling propulsion
power.
Verification by design check.
An indication shall be given to the operator when the truck is switched in active operating possible mode.
This may be momentary and it is not required for a hybrid truck where an internal combustion engine
provides directly the travelling propulsion power.
Verification by design check.
4.6.2 REESS charging
When external charging supply cables are connected to the truck, powered travelling movements shall
be prevented.
Verification by design check.
4.6.3 Direction control
If a truck is equipped with a direction control the state of this control shall be identified to the operator.
Verification by design check.
It shall not be possible to activate the truck reverse control function in an uncontrolled manner whilst
the truck is in forward motion, and vice versa, insofar as such activation could cause a sudden and strong
deceleration or wheel lock. However, it may be possible for the control function to be activated only if the
system is able to slow down the truck gradually before reversing.
Verification by design check.
4.6.4 Limited mode
4.6.4.1 Indication of reduced power
If the electric propulsion system is equipped with a means to automatically reduce the truck power,
significant reductions shall be indicated to the operator.
Verification by design check.
4.6.4.2 Automatic restoration of drive system
The automatic release of the drive system from a limited mode shall not cause an unintended movement.
A release of the speed limitation shall be possible only after return to neutral position of the speed control
or if the system is able to carry it out gradually.
Verification by design check.
4.6.4.3 Indication of energy content of REESS
The REESS state of charge shall be indicated to the operator by a visual signal. The indication used for
point 4.6.4.1 shall not be used for this purpose.
Verification by design check.
4.7 Emergency operations
4.7.1 Emergency stop
An emergency stop control complying with EN ISO 13850:2015 category 0 or category 1 shall be
provided at the operating position on the truck.
NOTE For a remote control position, if fitted, EN 1459-1 and EN 1459-2 makes reference to ISO 15817:2012
(see Clause 4.5).
Verification by design check.
4.7.2 Emergency switching off
4.7.2.1 Access and identification
An emergency switching off control or controls shall be provided which shall always be accessible to the
operator:
— in case of 4.7.2.3 c) or d) whilst at the operating position on the truck;
— in case of 4.7.2.3 a) or b) within the closest proximity to the REESS.
Verification by design check.
Enclosures containing emergency switching off controls in 4.7.2.3 a) or b) shall be identified using the
symbol in Figure 2.
Figure 2 — Symbol ISO 7000-5638
Verification by visual examination.
4.7.2.2 Function
Actuation of the switching off control shall initiate the interruption of the electrical power supplies to all
power circuits:
— within 0,2 s for emergency stop category 0;
— within 5 s for emergency stop category 1.
Verification by design check and measurement.
In accordance with EN 60204-1:2018, 9.2.3.4.3 actuation of the emergency switching off control shall
initiate within 0,2 s the stop of all movements that are electrically/electronically powered or controlled.
Verification by design check and measurement.
4.7.2.3 Emergency switching off devices
The emergency switching off device shall be capable of interrupting the normal maximum current by one
of the following:
a) for VC-A2 trucks, a connector comprising two main contacts each one disconnecting one line of the
power supply;
b) a manually actuated power switch directly disconnecting one line of the power supply;
c) a manually actuated control switch disconnecting the power supply to the coil of one contactor in
one line of the power supply and disconnecting or disabling the electronic power switching circuit,
e.g. inverter or controller for AC motors. In trucks driven by series-wound DC motors with
mechanical commutator, two independent contactors are required to switch off the power supply;
d) manually actuated control switch disconnecting one line of the power supply by a solid-state switch.
When methods b), c) or d) are used, switching off devices shall be of positive opening action type
complying with EN 60947-5-5:1997 and coloured red.
Verification by design check.
It shall be possible to re-establish the power supply to the truck systems only by manual resetting of the
switching off control followed by the normal operation of the controls.
Verification by design check.
Reset shall not initiate a restart of movements.
Verification by design check.
For hybrid trucks where an internal combustion engine provides directly the travelling propulsion
power, the device that activates/deactivates the main electrical system, e.g. the ignition switch, may be
used as the switching off device if it deactivates truck movements.
Verification by design check.
5 Verification
5.1 Measurements of insulation resistance
The measurements of insulation resistance shall be conducted in accordance with the provisions laid
down in Annex B.
5.2 Continuity test for equipotential bonding
The equipotential bonding resistances shall be tested with a test current of at minimum 0,2 A and a
voltage ≤ 60 V DC, which shall be passed through the equipotential bonding path between any two
exposed conductive parts of voltage class B equipment for at least 5 s. This path shall be isolated from
other unintended potential paths for measurement. These equipotential bonding paths shall include
voltage class B component housings, connections to electric chassis and the vehicle electric chassis or
protective barriers and protective enclosures.
A lower test current and/or a shorter test time may be used, provided the accuracy of the equipotential
bonding resistance test results remain on a sufficient accuracy level.
The voltage drop between any two exposed conductive parts in a distance of 2,5 m which can be
simultaneously touched by a person shall be measured. The resistance shall be calculated based on the
applied current and this voltage drop.
This is a type-test.
6 Information for use
6.1 General
Information for use shall be drawn up according to EN ISO 12100:2010, 6.4.
6.2 Contents
6.2.1 Operator’s manual
Information for use shall contain as a minimum:
a) information about the charging areas and their ventilation;
b) information concerning the charging procedure;
c) location and operation of switching off control(s);
d) location and need to keep clear the battery blow off vents;
e) information on inspection and maintenance procedures of class II protection and frequency.
6.2.2 Maintenance manual
Information for maintenance shall contain as a minimum:
a) instructions for washing;
b) procedure to verify and discharge of residual voltages, when necessary;
c) information on marking and identification of higher voltage wires and harnesses;
d) location and operation of switching off control(s);
e) instructions to fix a frame fault;
f) instructions to verify that the on-board insulation monitoring device is functioning correctly.
6.3 Signals and warning devices
6.3.1 Safety signs
The symbol ISO 7000-6042 shown in Figure 3 shall be placed on, or in close proximity to, the REESS. The
background shall be yellow, the bordering and the symbol shall be black.

Figure 3 — Symbol ISO 7000-6042
The symbol shall in addition be placed on all enclosures and barriers, which when removed expose
unprotected live parts.
6.3.2 Cables colour
VC-B cables shall
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