While the options for technicians looking to train on electric vehicles (EVs) are plentiful enough, comparatively few currently focus exclusively on forklift trucks. For this reason, some technicians in this segment opt for automotive EV qualifications, as the principle of learning to work safely on high-voltage systems is very similar.
The most prominent provider of qualifications in this area is the IMI (Institute of the Motor Industry), a respected sector skills council and awarding organisation. To facilitate its qualifications, the IMI uses over 600 quality-monitored centres, largely comprising of colleges and training centres.
“In terms of EV qualifications there are four levels,” explains Tom Denton, a fellow and technical consultant at the IMI. “Level 1 is simply about awareness: EVs are quiet in operation; they are very high voltage; here is the location of the charging port; and so on. This level takes no more than one day to complete and is suitable for anyone involved in EVs, including sales, admin and management staff.”
Levels 2, 3 and 4 are for technicians and will likely take two days each for those already familiar with maintaining and servicing conventional (fossil fuel) vehicles. Technicians attending a Level 2 course will learn how to de-energise the high-voltage system and work safely on the low-voltage aspects of the vehicle.
“A Level 3 course explains how to diagnose and work on the high-voltage systems with the power off, while Level 4 addresses the same but with the power on,” says Denton. “A good example of a Level 4 task is removing the battery, finding and replacing faulty cells, and returning the battery pack to its position. You can’t actually switch a battery off; it’s fundamentally live all the time.”
Another interesting offer is IMI TechSafe, a recognition within the IMI professional register that identifies a member’s professionalism and safe working practice in the EV field.
“There’s no legislation that says you must be qualified to work on EVs, even though some are incredibly complex,” states Denton. “The vast majority of technicians are obviously qualified, but there are no actual regulations, even though the IMI is working constantly to change that stance.”
In essence, IMI TechSafe means that after completing at least a Level 2 EV qualification, technicians can go on the IMI’s professional register with an extra tick in the box. To maintain registration, technicians must complete mandatory CPD (continuing professional development) over a three-year period.
The need for more EV technicians across the light, heavy and industrial vehicle sectors, is apparent and increasing; see table.
“There’s currently huge demand for IMI qualifications,” reveals Denton. “And while at this precise moment we have enough EV technicians for the number of EVs in use, it will be different in a few years’ time. The IMI is of course trying to mitigate against this outcome, but it’s not easy. My advice to existing vehicle technicians is get on an EV course as soon as possible. It only requires a few days, not weeks, out of the workshop or factory, so disruption to the business is minimal. And you’ll learn a lot in that time.”
Technicians will discover how to isolate or de-energise the EV, and check the correct completion of this task so that diagnosis, maintenance or repair activities can proceed safely. The EV then needs ‘locking’ in that state to avoid someone inadvertently turning it back on. “Technicians will learn what’s dangerous, what they can and can’t touch, and how to mitigate risks, partly through PPE such as high-voltage gloves,” says Denton. “Furthermore, many are not aware that when an EV is in a live and potentially dangerous state it requires fencing off within the workshop or factory. Some workshops deploy useful systems where they place a cone on top of the EV: red, not sure if it’s safe, stay away. The red cone must stay in place until a technician de-energises the EV, after which a green cone can take its place.”
GUIDING LIGHT
Although there is no legislation that mandates qualification to work on EVs, industrial guidance on safety states that technicians must be qualified to at least Level 2.
“The industrial guidance comes from the IMI working closely with the HSE [Health and Safety Executive],” explains Denton. “Moreover, while there are no specific regulations to say you must be qualified to work on EVs, the HSE’s Electricity at Work Regulations 1989 state that anyone working on high-voltage systems should be either fully supervised or fully competent and qualified.”
BOX: EV TRAINING PROFILE
The Forklift Training Engineering Centre (F-TEC), part of Karl Baum Associates, is a dedicated training facility offering a range of forklift engineering programmes. Among the courses now available from F-TEC is a Level 3 in high-voltage EV rectification. Designed to complement current industry qualifications, technicians will gain an Ofqual-accredited qualification. The course consists of two separate units: high-voltage EV maintenance and high-voltage EV rectification.
The maintenance course involves understanding high-voltage EV components and operating systems and knowing how to identify the hazards. Technicians will also learn how to reduce the risks for themselves and others, while understanding how to prepare high-voltage EVs prior to carrying out routine maintenance.
Offering the same or similar safety guidelines, the rectification course helps trainees to understand the appropriate information required to undertake the task, while also knowing how to use the correct equipment and tools. It is suitable for service/repair technicians, diagnostic technicians and auto electricians. A further aspect of this course ensures participants know how to record information correctly.
BOX: BATTERY BASICS
When it comes to operating electric vehicles, Moorgate Forklifts, an established forklift supplier to businesses in West Yorkshire, puts forward an important recommendation: stabilise charging (optimise the charging rate) after several charges, as this helps to increase the battery’s lifespan.
It is also important to note the heat of the forklift. Just like a car, electric forklifts can overheat, which is damaging to the battery.
Its further advice is to keep charging the battery until it has reached 100%, as disconnecting beforehand can reduce operating life. And, do not run the electric forklift battery until flat; connect it to charge with around 25% life remaining.
Every few weeks, technicians should clean the forklift battery to remove dirt before it has chance to corrode the battery, suggests the company.
It adds that topping up the battery fluid levels is another essential part of electric forklift maintenance, as low fluid levels are a common cause of breakdowns. It is usually necessary to top up the battery fluid level around every 10 charges. A forklift running on low battery fluid will operate inefficiently and could run into difficulty. Top up the fluid when the battery is fully charged.