IT’S ALL ABOUT SAFETY

You’ve probably heard about the safety concerns when working with EVs.

Here’s a deeper dive into why and how to maintain safety in your shop //

By Mike Bailey

Automotive aftermarket shops fall into two categories.

The first are the proactive. They are those who embrace change enthusiastically and invest in their facility, equipment, business and talent. Equipment and software are purchased, services are advertised and staff are trained. When vehicles equipped with the ‘new’ technology require service and repair, the shop and staff are ready.

Then there are the shops which embrace change slowly — the reactive. These are the shops that wait until vehicles sporting the said ‘new’ technology are in their bays. These shops then realize they are ill-equipped to repair these vehicles. There are stark reasons why the vehicle with this technology is not serviceable at this shop, such as inadequate service information, a lack of proper equipment on the premises or staff who do not have the proper training. Those falling under this category require the most time to rectify the deficiency. Training takes time.

These examples have been the norm for decades. I could not begin to count the number of Friday afternoon phone calls I’ve taken from technicians and shop owners asking for diagnostic help on a vehicle.

Many times, the technician has taken a training class on the topic and may want to double-check their data or needs to clarify a key point we discussed during class.

Then there are the others, like those who wait until they are neck-deep in a problem vehicle and don’t have the training or skills to get through the diagnosis. In either case, I am happy to help as best I can, usually with positive results. Often, on a Friday afternoon.

Now add hybrid and battery electric vehicles into the mix. Unless the technician calling has taken training, they get a flat-out “No, sorry, you should not be working on this vehicle.”

To quote the words of a friend: “Some may say the waves are far from the shore.” Those days have passed. According to

Statistics Canada, in 2021, there were more than 303,00 hybrids and more than 152,00 EVs on our roads.

Since then, numbers have increased dramatically. Older hybrids that were sitting idle may be back on the road. Stats also show that hybrids and battery electric vehicles are also increasing in popularity in rural and northern communities.

The service and repair of hybrids and BEVs requires preparation. Businesses need to be ready. Gone are the glory days of ‘muddling through’ modern technology. These vehicles are different. These are entirely different propulsion systems.

When it comes to hybrids and EVs, learning by making mistakes can be fatal. Period.

Safety must be policy if you plan to service BEVs. Business owners and technicians have heard about it for years now. Technicians might have taken classes — a long time ago — where safety was discussed. It’s time to consider all the pieces to the safety puzzle for an automotive repair business.

Towing and recovery

If your business model includes operating a towing/recovery service, consider the daily activities of your operators.

There is the obvious possibility of damage to the vehicle during recovery or while securing one to the towing vehicle. Components in these vehicles reduce weight by design and are easily damaged. Lockout service or boosting may require special procedures.

What are the limits to roadside service and what is safe to touch on a hybrid or BEV?

Chargers and parking

Shop owners might want to install Level 2 chargers in their parking lot to help promote their electric services. Have you carefully considered the location of your charger(s)? This may also be the time to decide on a safe area to locate EV-specific parking spots. Does your insurance company have anything to say about this? Should you designate “EV tow-in” spaces?

Counter staff

Counter staff require training to do their jobs around EVs. This goes beyond the obvious requirement to understand EV components and their operation for quoting and explanation of work to customers. All staff must require training to safely interact with technicians who are performing work on exposed high-voltage systems. A safe distance should exist from the dangerous area.

Signage

We all know customers should not be on the shop floor. They may try to enter the shop through the reception area or open bay doors. Supervision is necessary.

While ordering promotional signage to advertise your shop’s hybrid/EV repair expertise, it may be time to upgrade or install signage to help keep customers out of the service bays. “Danger –High Voltage” signage applies here.

Work area

The EV service area should be strategically located. High-traffic areas are not appropriate. The bay next to the front counter is not the best choice. Traction batteries and interior panels, when removed, require space. Not all battery packs are serviceable but for those that are, the work area must be suitably spacious. Consider the storage of a removed battery pack after the workday is over.

Identify EVs undergoing high voltage system service in the shop as “dangerous” using a buffer zone. Warning cones and boundary tape work for this. Emergency equipment for electrocution and fire should be readily available in this area. In the unlikely event that an EV must move outside in an emergency, it should have a straight path leading outside and away from the building.

Tools and equipment

Your shop may already have equipment that is useful and safe to use on EVs. CAT III 1000v is the standard for digital multimeters. Lab scopes will require differential probes. High voltage glove certification expires every six months. Battery packs are heavy and may be located inside or underneath a vehicle. Inspect tools and equipment before every use. An assortment of insulated tools rated at 1000v should be on-hand.

Technician upskilling

The last piece of the safety puzzle is the technician. They require hybrid/EV training. This instructor is a firm believer in hands-on training. Safe work habits develop and become routine through this training model.

Testing and wearing proper PPE should become automatic. A vehicle safe-down and confirmation should become automatic. Proper work methods and procedures should become automatic. Eliminating the possibility of becoming part of a live high-voltage circuit should be automatic. Using equipment safely should become automatic.

This is too much to implement on a Friday afternoon.

Mike Bailey is chief technical and developmental officer and cofounder of Environmental Motorworks. He is a licensed 310S and 310T Technician in Ontario and is certified to deliver HRAI’s Ozone Depletion Certification Program, as well as the EPA Section 609 Automotive Refrigerant Training Program in the U.S.

Baywatch Fuel Cell Coolant

Liqui Moly has released the Fuel Cell Coolant FCF 20. Based on ethylene glycol, combined with non-ionic additives, it provides low electrical conductivity. The product also combines optimum thermal dissipation with material compatibility and aging stability. There is significant heat development in batteries and fuel cells. Optimal thermal release is essential with fuel cells, as the heat generated can be higher than with classic, comparatively powerful combustion engines The coolant is designed to meet the demands of fuel cell vehicles and ensure the maximum service life of components.

www.liqui-moly.com

Ev Chargers

Autel has released the MaxiCharger Home and Commercial Level 2 AC chargers. These are available in 40 amp and 50 amp flexible charging configurations and are compatible with all plug-in electric vehicles. The 40 amp chargers are available as either an in-body holster or a separate holster, with either a NEMA 6-50 or a NEMA 14-50 plug. The MaxiCharger Home 50 amp is an in-Body Holster style and is ready for hard-wire installation. The Commercial Level 2 AC charger offers 50 amp flexible charging. It features a J1772 standard charging port compatible with all EVs, 25-foot charging cable with a specially designed, ergonomic charging connector, LED lights to show charge status at a glance, is Wi-Fi-enabled for remote access and over-the-air firmware upgrades and more.

www.autelenergy.us

Leveling Suspension

KW V3 Leveling suspension for Tesla Model Y and Tesla Model 3 provides better driving dynamics, handling and roll comfort combined with minimal lowering or optional ride height adjustment. This stainless steel suspension comes with individually adjustable compression and rebound damping. Users can choose between ‘comfort’ or ‘plus’ sporty ride setting. The standard ground clearance of the Teslas can be increased by five millimeters. Alternatively, a discreet, continuously variable lowering of zero to 20 millimeters is possible on both axles. The KW V3 Leveling suspensions are available for all Tesla Model 3 and Tesla Model Y with all-wheel drive. www.kwsuspensions.net

Battery Cooling Fan For Hybrids

Continental has expanded its line of hybrid battery cooling fans. The company now provides direct replacement fans for the Buick LaCrosse, Chevrolet Impala and Volt, Ford C-Max and Fusion, Honda Civic, www.continentalaftermarket.com

Hyundai Sonata, Kia Optima, Toyota Camry and Prius hybrid models and more from 2003-2021. The fans are designed as an exact replacement for the original fan to restore the original battery cooling performance to the vehicle. A properly functioning is critical to maintaining the health of the battery and the vehicle’s overall fuel economy. The fans feature an OE design, including identical mounting locations and plug-and-play electrical connections, to help ensure an easy installation.

Ev Chargers

Bosch’s EV300 Level 2 EV Charging Station and EV3000 DC Fast Charger for electric vehicles are fully UL and cUL compliant. The EV300 charges up to four times faster than a standard plug outlet while the EV3000 charges up to four times faster than a standard Level 2 charging station. The EV300 is a compact indoor/outdoor charger. It has a 16-foot cable for areas with limited space. It is designed to provide a lowmaintenance alternative. No app is required to charge. Owners can pre-set times and length of charging in the vehicle and the EV300 informs battery status through a blinking light. The EV3000 was developed for EVs parked for a few hours and is ideal for workplaces, public parking lots, dealerships and fleets. It’s compatible with most BEVs in North America and exceeds IP 55 standards allowing safe charging indoors or outdoors in many types of weather, including rain, snow and sleet.

www.boschevsolutions.com

Ev Transmission Fluid

The Top Tec Gear EV 510 gear oil has been released by Liqui Moly solely for electric vehicles. These vehicles do require oils, notably transmission lubricant. Given the torque of EVs, the right fluid is needed. This product has been developed exclusively for electric vehicles and meets the strict manufacturer requirements of Tesla.

www.liqui-moly.com