Mastering EV Repairs: Essential Equipment, PPE, and Training

Tools, Equipment, and Training

The increasing adoption of electric vehicles (EVs) is reshaping the automotive industry, presenting new challenges and opportunities for repair shops. EVs operate at high voltages, contain advanced electrical components, and require specialized handling. Preparing your shop or school for EV work demands an investment in the right tools, safety equipment, and training. In this comprehensive guide, we’ll cover the essential equipment and training resources, including offerings from Legacy EV, to help your shop thrive in the electrified automotive landscape.

Understanding the Unique Challenges of EV Work

Electric vehicles differ significantly from internal combustion engine (ICE) vehicles. Their high-voltage systems, which can exceed 800 volts, pose unique safety risks and demand specialized knowledge. EV batteries are heavy, sensitive to temperature, and potentially hazardous if mishandled. Effective preparation includes adopting a rigorous safety culture, equipping your shop with the proper tools and equipment, and continually educating your team to stay ahead of industry standards.

Essential PPE for EV Work

Personal protective equipment (PPE) is the first layer of defense for technicians working on high-voltage systems. While many items may only be required for specific tasks, having them readily available ensures technicians are prepared for any situation.

High-Voltage Gloves and Leather Protectors

Purpose: Protects against electrical shock when working on energized systems.

Details: High-voltage gloves, typically Class 0 (rated for up to 1,000 volts), are essential for safe handling of live components. These rubber gloves must be paired with leather protectors to prevent wear and punctures. Technicians should inspect the gloves for damage before each use, as even small imperfections can compromise their safety.

Arc-Rated Face Shields and Safety Goggles

Purpose: Protects against arc flashes, chemical splashes, and flying debris.

Details: Arc-rated face shields are essential when working near battery packs or high-voltage components. Pair them with safety goggles to shield your eyes from debris and chemicals. Proper face protection ensures technician safety during high-risk tasks.

Insulated Mats and Blankets

Purpose: Prevents grounding risks and reduces electrical exposure.

Details: Insulated mats provide a non-conductive surface for technicians working on energized components, while blankets can cover live parts to create a safer environment. These tools are essential for minimizing the risk of accidental grounding.

Rescue Hooks

Purpose: Safely removes individuals from high-voltage contact.

Details: In the event of an electrical accident, a rescue hook provides a safe way to pull someone away from the hazard without endangering others.

Automated External Defibrillator (AED)

Purpose: Provides life-saving assistance in the event of cardiac arrest.

Details: High-voltage electrical work carries inherent risks, including the possibility of severe electrical shocks that could lead to cardiac arrest. Having an AED on-site is a critical safety measure. Modern AEDs are user-friendly, providing voice instructions to guide users through the process. This device can be the difference between life and death in an emergency, offering technicians and shop owners peace of mind.

Tools and Equipment for EV Work

Proper tools are essential for diagnosing, servicing, and repairing EVs safely and efficiently. Each piece of equipment serves a specific purpose, ensuring technicians can address the unique demands of EV systems.

Digital Multimeter (DMM) Rated for High Voltage

Purpose: Measures voltage, current, resistance, and other electrical parameters.

Details: A digital multimeter (DMM) is a cornerstone of any EV technician’s toolkit. While many shops already use multimeters for traditional 12-volt systems, those working with high-voltage systems must use a model rated for CAT III or CAT IV. These ratings indicate that the multimeter can safely handle higher voltages, typically up to 1,000 volts. DMMs are used for tasks like verifying voltage levels, diagnosing circuit issues, and testing continuity. Investing in a reliable DMM not only enhances safety but also ensures accurate measurements for troubleshooting and repairs.

Insulation Resistance Tester or Megohmmeter

Purpose: Verifies the integrity of high-voltage cables and components.

Details: Insulation testers – also referred to as Megohmmeters or “Meggers” –  measure the resistance of high-voltage cables as well as isolation, ensuring they can safely handle the electrical load without leaking current. They can measure large amounts of electrical resistance with great accuracy. This tool is crucial for diagnosing potential issues in cables and components, such as degradation or insulation failure, which could lead to dangerous short circuits.

Thermal Camera or Infrared Thermometer

Purpose: Detects overheating or hotspots in EV components.

Details: A thermal camera is an invaluable tool for monitoring the thermal performance of battery packs, inverters, and high-voltage wiring. It allows technicians to identify overheating issues before they lead to failure, protecting both the vehicle and its occupants. By providing a visual representation of heat distribution, thermal cameras make it easier to pinpoint problem areas.

OBD-II Scanner with EV Capabilities

Purpose: Diagnosis of EV-specific issues.

Details: An advanced OBD-II scanner is essential for reading trouble codes specific to EV systems, including battery health, charging systems, and electric drivetrains. Unlike standard scanners, EV-capable models provide insights into system integration and software-related issues, making them a critical diagnostic tool.

Battery Lift Table

Purpose: Safely removes and installs heavy EV battery packs.

Details: EV batteries can weigh hundreds of pounds, making manual handling impractical and unsafe. A battery lift table provides a stable platform for removing and installing these heavy components, reducing the risk of injury and ensuring precise positioning during service.

Insulated Torque Wrench

Purpose: Secures high-voltage connections with precision.

Details: Properly torqued connections are essential for maintaining the safety and reliability of high-voltage systems. An insulated torque wrench provides the precision needed for securing battery terminals and other components accurately without risking electrical shock.

Insulated Tool Set

Purpose: Work on live high voltage equipment safely.

Details: In most cases high voltage can be disconnected from the system before work begins. However, there are times, such as when working on

Lockout/Tagout (LOTO) Kits

Purpose: Prevents accidental and dangerous energization during maintenance.

Details: A LOTO kit ensures that high-voltage systems are securely isolated while technicians work on them, reducing the risk of accidental activation.

Personal protective equipment (PPE) is the first layer of defense for technicians working on high-voltage systems.

Setting Up an EV-Friendly Workspace

Preparing your shop for EV work goes beyond acquiring tools and PPE. An organized, safety-oriented workspace is essential for efficient and effective operations.

High-Voltage Work Zone: Designate a specific area for high-voltage tasks, equipped with insulated mats, barriers, and clear signage. This minimizes risks and reinforces safety protocols.

Battery Storage Area: Store EV batteries in a temperature-controlled, fireproof room with spill containment measures to ensure safety and longevity.

EV Charging Station: Install a charging station to facilitate safe charging practices and provide technicians with hands-on training opportunities.

Training Your Team for EV Work

Investing in comprehensive training is crucial to equip your team with the necessary skills and knowledge for EV servicing. Legacy EV offers specialized training programs designed to meet these needs.

Legacy EV Training Offerings

Level 2 High Voltage Safety Training: This certification is designed for service professionals, technicians, or specialists who have undergone high-voltage electrical training. It focuses on the service, operations, and repair of electrically powered high-voltage vehicles, ensuring that individuals can safely and effectively work with these systems.

EV Fundamentals Certification Bootcamp: A comprehensive program where learners wire, program, commission, tune, and practice fault-finding in various EV systems using fully functional EV training benches. High Voltage Personal Protective Equipment (PPE) is demonstrated and used during hands-on exercises, providing practical experience in a controlled environment.

While Legacy EV offers robust training programs, other reputable organizations provide EV training and certification:

National Institute for Automotive Service Excellence (ASE): Offers certifications that include EV and hybrid vehicle components, ensuring technicians are up-to-date with current technologies.

Society of Automotive Engineers (SAE): Provides training programs focusing on EV technology, standards, and safety protocols.

Automotive Career Development Center (ACDC): Specializes in hybrid and electric vehicle training for automotive professionals.

Conclusion

The shift toward EVs offers automotive shops an opportunity to grow and innovate. By investing in the right tools, PPE, and training—such as Legacy EV’s programs—your shop can safely and effectively meet the demands of electric vehicle service. With the right preparation, your business can position itself as a leader in this exciting and transformative market.