Fleet Electrification Safety: Maintenance, Training, and Emergency Response (Part 2 of 2)
Welcome to Part 2 of our comprehensive guide on fleet electrification safety for maintenance and operations teams. In Part 1, we covered the fundamentals of EV safety, high-voltage system protocols, battery safety considerations, and best practices for charging infrastructure. If you haven't read Part 1 yet, we recommend starting there to build a strong foundation in EV safety basics.
S Curve Strategies knows fleet safety. In this second installment, we'll explore the practical aspects of safely maintaining electric vehicles, establishing effective training programs, ensuring operational safety for your drivers and fleet managers, developing emergency response protocols, and fostering a lasting culture of safety within your organization.
Maintenance Procedures and Best Practices
Personal Protective Equipment (PPE)
Appropriate PPE for working on EVs includes:
Class 0 or higher voltage-rated gloves with leather protectors (for high-voltage work)
Safety glasses or face shields (for any work near batteries or high-voltage components)
Non-conductive footwear (for high-voltage work)
Arc-rated clothing (for energized work, though energized work should be avoided when possible)
Routine Maintenance Tasks
Many EV maintenance tasks are similar to ICE vehicles, but with key differences:
Safe tasks with proper training:
Tire rotation and replacement
Brake system inspection (though brakes last much longer due to regenerative braking)
Cabin air filter replacement
Wiper blade replacement
12-volt battery maintenance
Coolant system checks (following manufacturer procedures)
Tasks requiring specialized training:
High-voltage component repair or replacement
Battery pack service
Charging system diagnostics
Powertrain component service
Software updates affecting safety systems
Facility Considerations
Shops working on EVs should address:
Ventilation: Ensure adequate ventilation in service bays
Spill containment: Have procedures for battery coolant or electrolyte spills
Fire suppression: Upgrade systems if necessary for EV-specific needs
Tool requirements: Invest in insulated tools and high-voltage testing equipment
Storage protocols: Establish procedures for storing damaged EVs safely
Training Requirements
Certification Levels
EV technician training typically includes multiple levels:
Level 1 - Awareness Training
All fleet personnel who work around EVs
Recognition of high-voltage hazards
Emergency response procedures
Basic EV operation
Level 2 - Non-Energized Maintenance
Technicians performing routine maintenance
De-energizing procedures
Working on de-energized high-voltage systems
Battery system awareness
Level 3 - Energized Systems
Advanced technicians only
Diagnostics on energized systems
High-voltage component replacement
Battery system repair
Ongoing Education
Technology evolves rapidly in the EV space. Establish:
Regular refresher training (annually recommended)
Manufacturer-specific training for each vehicle model
Updates on new safety protocols and procedures
Incident review and lessons learned sessions
Operational Safety for Drivers and Fleet Managers
Driver Training
Operators should understand:
Regenerative braking feel and response
Limited range in extreme temperatures
Proper charging procedures
Warning light meanings specific to EVs
Silent operation and pedestrian awareness
Range Management
Operational safety includes avoiding stranded vehicles:
Implement range buffer policies (never below 20% charge)
Plan routes accounting for charging infrastructure
Monitor real-time range impacts (weather, payload, terrain)
Have protocols for emergency charging situations
Situational Awareness
The near-silent operation of EVs creates new hazards:
Pedestrians and cyclists may not hear approaching vehicles
Remind drivers to remain vigilant in parking areas and around pedestrians
Consider additional safety measures (backup alarms, warning systems) for fleet vehicles
Emergency Response Procedures
Vehicle Accidents
In the event of an accident involving an EV:
Ensure scene safety - Assume high-voltage hazards exist
Identify the vehicle as an EV - Look for badging, charging ports, lack of exhaust
Contact emergency services - Inform them it's an electric vehicle
Evacuate if necessary - If smoke, fire, or unusual smells are present
Keep unauthorized personnel away - Establish a safety perimeter
Provide emergency response guides - Keep manufacturer emergency response guides accessible
First Aid for Electrical Shock
If someone receives an electrical shock:
Do not touch the victim if they are still in contact with the voltage source
Cut power immediately if safe to do so
Call emergency services immediately
Begin CPR if trained and if the victim is no longer in contact with an electrical source
Treat for shock (keep warm, elevate legs if no spinal injury suspected)
Creating a Culture of Safety
Successful fleet electrification requires organizational commitment to safety:
Leadership Responsibilities:
Allocate budget for training and equipment
Establish clear safety policies and procedures
Support maintenance teams with adequate time and resources
Foster a reporting culture for safety concerns
Team Responsibilities:
Complete all required training
Follow established procedures without shortcuts
Report safety hazards immediately
Stay current on manufacturer updates and recalls
Continuous Improvement:
Conduct regular safety audits
Review and update procedures as technology evolves
Learn from incidents and near-misses
Share best practices across the organization
Resources and Next Steps
As you transition your fleet to electric vehicles, consider these action items:
Assess current capabilities - Identify gaps in training, equipment, and facilities
Develop a training plan - Ensure all team members receive appropriate certification
Invest in proper equipment - PPE, tools, and testing equipment for EV service
Update procedures - Revise maintenance and emergency protocols for EVs
Partner with experts - Work with manufacturers, trainers, and consultants as needed
Conclusion: Ensuring Long-Term Safety Success
Combined with the foundational knowledge from Part 1—covering high-voltage systems, battery safety, and charging infrastructure—the maintenance procedures, training programs, operational protocols, and emergency response strategies outlined in this Part 2 provide a comprehensive framework for safe fleet electrification.
The technology may be new, but the fundamental principle remains unchanged: a well-trained, well-equipped team following established safety protocols is the foundation of a successful and safe fleet operation. By implementing proper training programs, maintaining adequate PPE and equipment, establishing clear procedures, and fostering a culture that prioritizes safety, your organization can confidently embrace the transition to electric vehicles.
Fleet electrification offers tremendous environmental and economic benefits, but these advantages can only be fully realized when safety remains the unwavering top priority. The investment you make today in safety training, equipment, and culture will pay dividends in protecting your most valuable asset—your people—while positioning your fleet for success in the electric future.
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 includes developing fleet electrification plans for diverse clients such as Clark County Nevada's 2,400-vehicle fleet, the New York Power Authority Transit Bus Electrification Master Plan, Viejas Indian Reservation's comprehensive fleet assessment, and the San Diego Unified School District's $9.7 million clean mobility initiative. We are also partnering with Los Angeles County and Black & Veatch to create a first-of-its-kind regional EVSE workforce training program that will support certification for community colleges across California and be made public later this year.
From fleet assessments and charging infrastructure design to workforce development and training programs, S Curve Strategies provides the expertise to ensure safe, successful fleet electrification.
For assistance with your fleet electrification project, including safety planning, workforce development, and implementation support, 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.
Read Part 1: [Fleet Electrification Safety: Essential Guidelines for Maintenance and Operations Teams (Part 1 of 2)]