Training, investment vital for servicing EVs

LAS VEGAS — Electric vehicles (EVs) are coming — and automotive service shops can either be early adopters or stay on the sidelines.

It is only a matter of time before an EV pulls into an aftermarket shop bay for maintenance work, so there are some safety precautions shops need to take with these high-voltage machines.

EV service was the topic of several seminars at the recent AAPEX 2024 in Las Vegas during which speakers urged shop owners to train employees and invest in equipment.

Fortunately, EVs require many of the same maintenance services as internal combustion engine (ICE) vehicles, such as tires, brakes and steering and suspension.

Many shops have already been servicing hybrid vehicles, so they are on track to transition to also working on EVs, seminar speakers said.

"We have had hybrids now for over 20 years and we've had battery electric vehicles for going on 15. They are not impossible to figure out," said Brittany Kearns, project manager for EV service concept at Bosch Mobility.

"Training programs are really going to be the key to helping technicians and shop owners and workshops feel more approachable, feel more confident working on these vehicles," she said.

Kearns said Bosch's internal projections predict battery electric vehicles will achieve a 9% market share in North America by 2030, up from the current 2%, with hybrids making up 4%. She noted that many OEMs are rethinking their EV strategies and moving more towards the production of hybrids and plug-in hybrid models for the near future as EV sales have plateaued this year.

"First take and invest your time and your effort into quality training programs. And the training programs are going to be what helps bridge that gap and make these vehicles and these systems more approachable, more transparent, and give you that clear next steps that you can work on these and future-proof your shop," she said.

Shops need to learn about PPE (personal protection equipment) for working on or near the high-voltage batteries, what employers are going to be responsible for providing their techs, and lockout/tagout procedures for securing the EV service area.

Justin Allen, regional field trainer for Hunter Engineering Co., said shops need to overcome the misconception that the small percentage of EVs on the road won't impact their businesses.

"It turns out they (EVs) are heavy and there is very torquey output on these things. Both of those mean you are shredding the rubber like crazy. Tires are wearing out faster than anybody anticipates on these cars, and because they are driving them with all that acceleration, having fun with it, they are shredding the tires.

"So the tire business is expected to go up 36% by 2030 as opposed to 2021 numbers," he said.

"And what does tire sales mean for your business? Well, hopefully it means that you're going to have some opportunity to do alignment work, too."

He noted that EV drivers are sensitive to road noise, so alignments will be an important remedy. And with alignments may be the need for ADAS camera calibration.

"So ADAS calibrations, alignments, tires, electrical issues. There's plenty of business to be captured there, but it is evolving — fewer of those transmission services, fewer of those oil changes.

"But the consumer is probably misled a little bit with the idea that the maintenance isn't going to be a thing. I think consumers, on average, believe that an EV is a lot like a remote-controlled car that you just put in batteries and you go, and you charge it, you go. There's more to that."

According to the "2024 Joint EV Trends and Outlook Forecast," sponsored by the Auto Care Association and MEMA Aftermarket Suppliers, small- to medium-sized shops will need to investment $80,000 to $270,000 in equipment and training over the next few years to service EVs.

The report estimated investments for a shop with three to five service bays and one to three technicians will include:

• Technician training and certification: $2,500 – $10,000;

• Safety equipment: $5,000 – $15,000;

• Level 3 charging capabilities (50-150 kw): $40,000 – $100,000;

• Battery testing equipment: $10,000 – $20,000;

• Diagnostic tools: $7,500 – $15,000; and

• Lift modifications and battery handling equipment: $15,000 – $40,000.

Bill Weaver, senior instructor with NAPA Autotech, said shops don't need to run out and buy a complete set of insulated tools and equipment to service EVs all at once, but rather build up to a full set by first purchasing a core amount of tools, such as basic meters.

But he urged shop owners to arm their technicians with safety equipment and training before servicing EVs.

"Has your technician been instructed on how to work on an EV safely? Are you just expecting the 12-volt guy to go work on 400 volts and hope everything works out okay? That doesn't seem like it's a very proactive way to treat our technicians. And let's face it, we have a technician shortage out there. We don't need to be getting rid of anymore of them in the industry," he quipped.

"So we are looking to make sure that your technician walks into a training facility with the ability to learn and walks out with the knowledge that they have to keep your business, your customers, themselves and their counterparts, their co-workers, all safe."

The shop should have a designated EV bay that is cordoned off with cones and safety tape/rope. The car keys should be secured so no one other than the technician has access to the vehicle. There is also protective gear techs should be wearing when working with the battery.

Weaver said that techs won't always have to wear protective clothing, but they need to know how to assess the situation to determine if protective gear is necessary.

Weaver also advised shops to keep EV service tools in a dedicated box so they aren't subjected to the abuse other shop tools receive.

In 2023 the National Institute for Automotive Service Excellence (ASE) developed the Electric Vehicle Technician/Shop Personnel Electrical Safety Standards to establish electrical safety requirements, standards, procedures and safe work practices.

ASE also offers two certifications for EV/hybrid vehicle service based on involvement in the shop:

• Level One — xEV Electrical Safety Awareness Certification is designed for anyone who may encounter an EV in the shop, including sales, service and related employees, to know how to identify hazards and reduce risks.

"We felt it was very important to have something that was for everybody that was coming in contact with EVs," said Matt Shepanek, vice president of credential testing programs for ASE.

"So at ASE, we focus on technicians for the most part, and we also have things for parts and service consultants. But in this instance, we thought it was really important that anybody who comes in contact with EVs to know the safety aspects."

• Level Two — xEV Technician Electrical Safety Certification is designed for service professionals or specialists who have received high-voltage electrical training and work with and around EVs.

In the future, Shepanek said ASE plans to develop a Level Three certification for technicians who actually open up and service the internal battery packs.

Some of the risks in dealing with EVs is electric shock, so protective masks, insulated gloves and clothing, and grounding boots protect the technician from an arc flash.

The shop should institute a buddy system in the bay so a tech has someone else around who can provide help and use a rescue stick to pull the tech away from danger.

"You want to maintain personal proficiency and electrical safety, understand the safety concepts around the electric vehicles, the PPE, obviously the safety training for operational efficiency, first aid, emergency response training. All of these things are important and factor in," Shepanek said.

The ASE standards and certification information is available for free to download at www.ase.com/ev.