Risks When Working With Electric and Hybrid Vehicles - EINTAC

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Servicing, repair, maintenance and rescue of Electric & Hybrid vehicles can put unwary workers at risk of electric shock resulting in serious injury or death. Voltages present in electric and hybrid vehicles (EHVs) are significantly higher (currently up to 800 Volts direct current (dc)) than those used in other vehicles (12/24 Volts dc). In dry conditions, accidental contact with parts that are live at voltages above 70-90 volts dc can be fatal. For EHVs, dc voltages between 60 and 1500 Volts are referred to as ‘high voltage’.

Battery systems may contain chemicals that can be harmful if released. They also store significant amounts of energy that can give rise to explosion if not dealt with correctly.

EHVs introduce hazards into the workplace in addition to those normally associated with the repair and maintenance of vehicles. For example, roadside recovery, first responders and other vehicle related activities including seemingly non-hazardous activities, such as valeting. These risks include:

  • The presence of high voltage components and cabling capable of delivering a fatal electric shock.
  • The storage of electrical energy with the potential to cause explosion or fire.
  • Components that may retain a dangerous voltage even when a vehicle is switched off and/or ‘discharged.’
  • Electric motors or the vehicle itself that may move unexpectedly due to magnetic forces within the motors.
  • Manual handling risks associated with heavy battery pack replacement or disposal.
  • The potential for the release of explosive gases and harmful liquids if batteries are damaged or incorrectly handled.
  • The possibility of people being unaware of vehicles moving as when electrically driven they are silent in operation.
  • The potential for the electrical systems on the vehicle to affect medical devices such as pacemakers.


Here at EINTAC Ltd, we are pleased to offer a wide range of products which include the basic PPE and safety equipment required to work safely on EHVs. It is important that the correct equipment is used and to never work on EHVs using modified or improvised equipment. To reduce risks, we recommend the following:

  • Warn others about the current state of the vehicle being worked on.
  • Only use insulated tools when carrying out repair or maintenance work on the vehicles
  • Be over protective when it comes to safety clothing
  • Attend one of our safety training courses to develop skills and knowledge
  • Use safety signs to assist in ensuring that correct procedures are being adhered to
  • Lock off and isolate before working on electric and hybrid vehicles.

Additional skills and training will be necessary to allow people to work safely with EHVs. The levels of competency required will vary greatly and are dependent on the type of work that people are expected to do. Please see our list of training courses.

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