Handling EV repairs requires extreme caution—one wrong move with a metal tool touching the wrong component can result in fatal electrocution. That’s why having the proper tools and training is absolutely essential. Unlike traditional ICE vehicles with 12V batteries, EV batteries operate at much higher voltages, ranging from 200 to 800 volts.

Let’s dive into the tools that will enable you to safely perform EV repairs. This is a critical consideration for your shop, especially as EVs—first hitting the market more than 10 years ago—are starting to come out of warranty. With projections showing that over a third of vehicles sold in California will be electric by 2026, there’s no better time to get prepared than right now.

Personal Protective Equipment (PPE)

With PPE, redundancy is key. Safety isn't about having one line of defense—it's about creating multiple, overlapping layers of protection. Think of PPE as a comprehensive safety net, where each piece of equipment serves as a critical backup to the others. For example, insulated gloves alone aren't enough, you also need insulated hand tools. You should wear Electrical safety shoes as well as use a rubber floor mat.

Insulated Gloves: High-voltage gloves rated for the voltage you’re working with (e.g., Class 0 for up to 1,000V AC). Must be tested every 6 months. Inspect for any tears or damage that may cause danger, or use a specialized tool that inflates the gloves to test for any leaks.

Overgloves: Designed to wear over Class 0 insulated gloves. Overgloves are abrasion-resistant, cut-resistant, puncture-resistant and have the strongest tear-resistance, all while maintaining dexterity.

Face Shield: For protection against arc flashes and splashes.

Insulated Footwear: Made with special non-conductive materials. Provides a high-resistance barrier between the wearer and electrical ground.

Electrical Insulation Suit: Protects against burns from arc flashes or electrical discharges. Made from flame-resistant materials that won't ignite or melt when exposed to high temperatures.

Safety Tools

Insulated Repair Tools: Very important as they prevent electrical current from passing through the tool to the user's hand. You should have a set of insulated sockets, spanners, pliers, screwdrivers, cable cutters, etc.

Check out this set here

Multimeter: In EV repair, a multimeter is used to measure voltage, current, resistance, and continuity in both high-voltage and low-voltage systems, helping to diagnose faults in components like batteries, inverters, sensors, and wiring. It can also be used to perform a live dead live check on the high-voltage battery. Multimeters are not suitable for high-voltage insulation testing. 

Megger (aka megohmmeter or insulation tester): Unlike a multimeter, a megger applies a high voltage across the insulation and measures the resulting resistance in megohms to ensure that there is no significant leakage current that could cause hazards, malfunctions, or inefficiency. 

Check out the Launch Resistance Tester here

Insulating Mats: Prevents electrical current from passing through the body to the ground.

Rescue Hook: Shock-resistant rescue hook for safely removing an injured person from electrical contact in the event of an emergency.

Caution Stanchions: Cordon off the area when performing high-voltage, dangerous repairs.

Class C Fire extinguisher: Class C extinguishers are suited for fires originating from an energized component. They typically use CO2 gas or a dry powder to extinguish the fire.

Vehicle Fire Blanket: Allows you to contain flames, smoke, and toxic fumes, especially in enclosed areas that may endanger other people.

Conclusion

The high-voltage systems in EVs pose unique risks, but with proper training and the equipment outlined above—like insulated tools, PPE, and diagnostic devices—you can safely and effectively service these advanced vehicles. As the EV market continues to expand rapidly, investing in these measures now ensures not only compliance with safety standards but also positions your shop to meet the demands of a growing industry.

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