A Guide to EV/HEV Repair & Safety | Kent Automotive

A Guide to EV/HEV Repair & Safety in Automotive Shops: Protecting Your Team and Your Business

As electric and hybrid vehicles (EVs and HEVs) continue to gain traction on the road, dealerships and collision centers are seeing an increasing number of EVs requiring service. But these vehicles come with unique risks, especially high-voltage components that demand specialized knowledge and equipment to ensure safety.

Understanding the risks, using the right tools, and following EV safety protocols are essential to protecting your team and your business.

Understanding High-Voltage Components in EVs

EV/HEV repair starts with recognizing what sets these vehicles apart: their high-voltage systems. EV battery packs, motors, and inverters can carry voltages up to 800 volts, presenting serious hazards like electrical shock, arc flash, or even fire.

The number one rule when working on EVs? Always treat the vehicle as if it is live until you can confirm otherwise with diagnostic tools. This means taking extra precautions and being equipped with the right safety measures before starting any work.

Personal Protective Equipment (PPE): Your First Line of Defense

When working on high-voltage EV and HEV systems, wearing the appropriate personal protective equipment (PPE) is essential. Technicians should always wear rubber insulating gloves, protective clothing, and eye protection to safeguard against electrical shock.

● Kent Automotive Solution: Novax® Rubber Insulating Gloves Kit 

This kit includes high-dielectric rubber gloves, leather protectors, and a convenient carry bag. Designed to meet NFPA 70E standards, it supports extended wear without fatigue—a key factor in EV maintenance efficiency.

Dedicated Workspace for EV Repairs

To prevent accidents, it’s important to designate a specific area in your shop for EV repairs. This space should be equipped with proper safety signage and tools to minimize risks, ensuring that both technicians and other employees stay clear of high-voltage areas. Establishing a dedicated workspace helps contain potential hazards and keeps your shop running efficiently, whether you're servicing EVs or HEVs.

● Kent Automotive Solution: Dielectric Corrugated Switchboard Mat 

Our extra-thick vinyl mat adds a vital layer of protection in EV repair shops. It also improves traction, helping prevent slips in critical areas.

Proper Labeling of High-Voltage Components

Working with high-voltage components requires clear identification to avoid confusion and ensure that all employees are aware of the potential dangers. Color-coded and clearly marked components help prevent accidental contact and reinforce EV safety standards in your shop.

● Kent Automotive Solution: Fuse Carrier Isolation Port/Socket Lockout 

This lockout device isolates fuse holders and signals that high-voltage work is in progress. It prevents unauthorized reactivation and adapts to various EV systems, making it ideal for consistent EV safety compliance.

Creating a Safe Working Environment for Electric Vehicle Repairs

Beyond PPE and a dedicated workspace, shops should invest in comprehensive safety kits that include signage, lockout devices, and barriers to clearly mark high-voltage areas and prevent unauthorized access. The goal is to create an environment where safety protocols are visible and easy to follow, ensuring that both technicians and non-technicians are aware of the risks.

● Kent Automotive Solution: EV Advance Bundle 

This all-in-one EV safety kit includes arc flash protection gear, rescue hooks, signage, and more. With dielectric mats and stanchions included, it empowers EV repair shops to protect employees and meet EV guidelines with confidence.

Why EV/HEV Safety Matters

The shift toward electric and hybrid mobility is already here. According to investment bank UBS, 20% of all new vehicles will be electric by 2025, with that number expected to rise to 50% by 2030. As EVs become more common, dealerships and collision centers must adapt quickly, not only to maintain vehicles but to do so safely.

EV systems operate at high voltages, often above 400 volts and sometimes up to 800 volts. This introduces serious risks, including electric shock, arc flash, and thermal burns. That’s why a safety-first mindset isn’t just smart—it’s essential for every EV repair shop.

Committing to safety means:

● Minimizing liability exposure

● Reducing the risk of technician injury

● Enhancing shop reputation and customer trust

● Staying compliant with evolving industry standards

To help shops navigate these challenges, GMG EnviroSafe’s EV Repair Resource Center offers free safety training modules, technician checklists, and over 35 EV Emergency Response

Guides maintained by the National Fire Protection Association (NFPA). It’s a one-stop resource for shops looking to build a strong foundation in electric vehicle safety.

For additional training tools and regulatory support, KPA’s EV Safety Resource Hub provides expert-backed insights and compliance solutions tailored to the unique risks of EV maintenance.

Whether you're just starting to service EVs or expanding your capabilities, leveraging trusted EV safety resources helps ensure your team stays protected and your shop stays ahead.

Make Safety Your Priority with the Right Tools and Procedures

As the automotive industry shifts toward electric and hybrid vehicles, shops must adapt their safety procedures and ensure they are fully equipped to handle the unique challenges that EV repairs present. From wearing proper PPE to setting up dedicated workspaces and implementing labeling systems, every step counts toward creating a safer environment for your team.

At Kent Automotive, we’re committed to supporting your shop with high-quality products and expert guidance. Whether you need insulated gloves, safety mats, or a comprehensive EV safety kit, we have the tools to help you meet your safety goals. Explore our full range of EV safety products and let us help you prepare for the future of automotive repairs.

For more information on our EV/HEV safety products, visit our EV safety page or contact a Kent Representative to get personalized guidance for your shop.