Skip to content
As a company, Autotech Training are advocates for ensuring that anyone working on or around electric/hybrid vehicles can not only do so skilfully, but safely. We frequently talk about the fact electric and hybrid vehicles are effectively giant batteries and while training isn’t regulated, it is vital that at the very least, people have an educated level of awareness.
It’s a topic we speak often about through numerous channels, including speaking at key events, and we are not the only ones raising the profile of electric and hybrid vehicles - from the dangers they can yield to the benefits of training.
We believe the following excerpt from Fleet Maintenance magazine, which was written by Peter Zaidel, a product manager with KPA, clearly depicts the issues at hand, the real risks, and the importance of training and safety wear……..
There are new dangers that hybrid vehicles can bring to the service technician. Fortunately, manufacturers designed hybrid vehicles not only with an eye on fuel efficiency, but also with strong consideration for the safety of service technicians.
Here are key safety basics to share with service technicians:
Almost all hybrids share these common identifiers. One is hybrid badging on the body of the vehicle, typically the rear right section and under-hood identifiers, including the extra motor and the inverter. Another is the "Ready" indicator inside the vehicle in the ignition area. There is also orange high-voltage power cables.
This may be the single most important safety factor for service technicians working in a shop where there are hybrid vehicles because the hybrid system is silent when running on battery. Hybrid systems can automatically turn themselves off and on, switching between the high-voltage battery and the gasoline engine, so it is easy for the technician to be unpleasantly surprised that a vehicle thought to be 'off' is in fact 'on.'
Zaidel recommends observing these service protocols:
- A hybrid is not necessarily powered off until it is verified that the vehicle is powered down.
- Keep vehicle keys a safe distance from the hybrid - more than 20' - as many hybrids have a keyless ignition, with on/off sensitivity up to 20' away from the vehicle.
- Always check the vehicle dashboard hybrid indicator to ensure the vehicle is truly "off" before any kind of work is performed on the vehicle.
While the amount of voltage and amperage in hybrid vehicles is enough to be fatal if a technician comes in contact with the high-voltage circuits, the high-voltage system does not ground to the body or the chassis, but rather is isolated from the vehicle body completely. A technician would have to touch pole-to-pole or become part of the circuit for an injury to occur.
As a highly visible safety warning, all high-voltage circuits are encased and heavily insulated, and normally identified by the SAE standard color-coding of bright orange.
Never cut into, touch, mangle or otherwise disturb the big orange cables that carry the high voltage from the batteries (in the back) to the controller (in the front). Always wear class "O" heavy-duty gloves (lineman's gloves) rated to withstand 1,000 volts when disconnecting high-voltage components, such as the battery.
These gloves should be maintained in excellent condition and checked prior to each use to ensure there are no leaks. Even a small opening can draw current that is seeking a ground.
Always disconnect the high-voltage hybrid battery before doing any major repair work or electrical work and most manufacturers also recommend waiting at least 10 minutes before working on the vehicle after the battery has been isolated or disconnected. The high-voltage capacitors need time to discharge so there is no residual voltage to pose a shock hazard.
Hybrid vehicles may seem similar to gasoline-powered engines, and indeed there is much in common. But the differences are important ones from a safety perspective, bringing risks of injury and even death to the untrained or careless service technician.
Proper training, adherence to a company's service operations protocols and constant vigilance around these 'silent while on' vehicles will ensure a safe environment.
We credit Fleet Maintenance magazine and Peter Zaidel for the above.
Autotech Training offers IMI Levels 1-4 electric/hybrid vehicle training courses and IMI Levels 1-3 electric HGV courses. These can be delivered at the company’s dedicated EV Training Suite or on the premises of any company or garage across the country.
Autotech Training also offers a Workshop and Electric Vehicle Safety Package worth £630 which includes:
- Transparent Insulating Shroud 1000V
- Insulated Rescue Pole
- High Voltage Floor Matting – 1 Metre
- High Voltage / No Admittance Sign
- Set of 4 Posts & Bases with Chain (Black / Yellow)
- High Voltage Sign (Double Sided)
- Electric Shock First Aid Poster
- Safety Lockout Padlock
- Steering Wheel Lockout Cover 500mm
- Terminal/Cable End Insulated Covers – 10pc
- Lockout Tags – 10pc
For further information contact 01234 240 503 or visit www.autotechtraining.co.uk
