Fleet Electrification Safety: Essential Guidelines for Maintenance and Operations Teams (Part 1 of 2)
S Curve Strategies works with fleets across the nation to transition to electric vehicles (EVs). Along this journey, we find that maintenance and operations teams face new safety considerations that differ significantly from those for traditional internal combustion engine (ICE) vehicles. While EVs offer numerous operational benefits—including lower maintenance costs and reduced emissions—they also introduce unique safety protocols that every team member must understand.
This two-part series provides essential safety information for fleet maintenance and operations teams transitioning to electric vehicles. In Part 1, we'll cover the fundamentals of EV safety, high-voltage systems, battery considerations, and charging infrastructure. Part 2 will address maintenance procedures, training requirements, operational safety, and emergency response protocols.
Understanding the Fundamentals: What Makes EVs Different?
EVs operate on high-voltage electrical systems, typically 400-800 volts or higher. This is dramatically different from the 12-volt systems found in conventional vehicles. Additionally, EVs contain large lithium-ion battery packs that require specific handling procedures.
Key differences include:
High-voltage electrical systems can cause serious injury or death if mishandled
Lithium-ion battery packs with unique fire and thermal management considerations
Regenerative braking systems that function differently from traditional brakes
Reduced noise levels create new situational awareness challenges
Different fluid systems (no oil changes, but coolant for battery thermal management)
High-Voltage Safety Protocols
De-energizing Procedures
Before any maintenance work on high-voltage components, technicians must follow proper de-energizing procedures:
Disconnect the service disconnect - Every EV has a manual service disconnect, typically located near the battery pack
Wait for capacitor discharge - Allow time for high-voltage capacitors to discharge (typically 5-10 minutes, but verify with manufacturer specifications)
Verify zero voltage - Use appropriate testing equipment to confirm no voltage is present
Lock out/tag out - Follow LOTO procedures to prevent accidental re-energization
Identification of High-Voltage Components
All technicians must be trained to identify high-voltage components, which are typically marked with orange coloring or warning labels. High-voltage components include:
Battery pack assemblies
High-voltage cables (orange-colored)
Inverters and converters
Electric drive motors
Charging ports and onboard chargers
Critical Rule: Never touch, cut, or remove any orange-colored components or cables without proper training and following de-energizing procedures.
Battery Safety Considerations
Thermal Management
EV batteries operate within specific temperature ranges. Maintenance teams should:
Monitor battery temperature warnings and management systems
Ensure cooling systems are functioning properly
Never operate vehicles with damaged or malfunctioning thermal management systems
Understand that battery performance degrades outside optimal temperature ranges
Physical Damage Assessment
Battery damage can compromise safety. Inspect regularly for:
Physical impacts to the undercarriage (especially important for fleet vehicles)
Leaking fluids from battery compartments
Swelling or deformation of battery pack housing
Unusual odors (sweet or chemical smells)
Warning lights or error codes related to battery systems
If damage is suspected: Isolate the vehicle in a well-ventilated area away from other vehicles and structures, and contact the manufacturer or a certified EV technician immediately.
Fire Safety
While EV fires are statistically rare, lithium-ion battery fires require different suppression methods than traditional vehicle fires:
Water is actually recommended for EV battery fires, but in large quantities (thousands of gallons may be required)
Fires can reignite hours or even days after initial suppression
Toxic gases may be released during battery fires
Never attempt to fight an EV battery fire without proper training and equipment
Emergency Response Plan: Ensure your facility has an emergency response plan specific to EVs, and that local fire departments are aware of EVs in your fleet.
Charging Infrastructure Safety
Daily Operations
Safe charging practices include:
Inspecting cables and connectors for damage before each use
Ensuring charging areas are free from water, debris, and trip hazards
Never forcing connectors that don't fit properly
Disconnecting chargers by gripping the connector, not pulling the cable
Reporting any damaged equipment immediately and removing it from service
Electrical Safety
Charging infrastructure operates at both high voltage and high current:
Only qualified electricians should install, modify, or repair charging equipment
Ensure proper grounding and overcurrent protection
Maintain clearances required by electrical code
Post appropriate warning signage
Install Ground Fault Circuit Interrupter (GFCI) protection where required
Weather Considerations
Modern charging equipment is designed for outdoor use, but teams should:
Exercise extra caution during wet conditions
Never use damaged charging equipment in rain or snow
Keep charging ports clean and free from moisture accumulation
Follow manufacturer guidance for extreme temperature operations
Conclusion: Building a Foundation for Safe Fleet Electrification
Understanding the fundamentals of EV safety—from high-voltage systems and battery considerations to charging infrastructure protocols—is the essential first step in successfully transitioning your fleet to electric vehicles. These safety protocols protect your team members while ensuring the reliable operation of your electric fleet.
In Part 2 of this series, we'll dive deeper into maintenance procedures and best practices, training certification requirements, operational safety for drivers and fleet managers, comprehensive emergency response procedures, and strategies for creating a lasting culture of safety within your organization.
Fleet electrification offers tremendous benefits, but safety must remain the top priority throughout the transition. By investing in proper knowledge, equipment, and procedures from the start, your maintenance and operations teams can work safely and confidently with electric vehicles.
About S Curve Strategies
S Curve Strategies develops transportation electrification strategies for states, counties, and electric utilities across the U.S. We create electric vehicle charging infrastructure, fleet electrification, and stakeholder engagement strategies that increase EV adoption and reduce greenhouse gas emissions.
Our hands-on experience spans various roles—from utility program experts and grant writers to project managers and technical advisors—ensuring holistic, sustainable outcomes for our clients. Our project portfolio includes comprehensive fleet electrification plans for entities like Clark County Nevada, the New York Power Authority, Viejas Indian Reservation, and the San Diego Unified School District's $9.7 million clean mobility initiative.
For assistance with your fleet electrification project, including safety planning and workforce development, contact S Curve Strategies at (619) 851-3928 or abolduc@scurvestrategies.com. Visit us at www.scurvestrategies.com.
This blog post is for informational purposes only and does not replace manufacturer-specific training or official safety standards. Always follow OSHA regulations, NFPA guidelines, and manufacturer recommendations for your specific vehicles and equipment.
Continue to Part 2: [Fleet Electrification Safety: Maintenance, Training, and Emergency Response (Part 2 of 2)]