Operating and Charging
2. Repair and Maintenance
There are differences in servicing and maintenance management to be aware of when switching to BEVs. In general, BEVs require less maintenance than internal combustion engine vehicles as there are fewer components and moving parts.
Key Points
BEVs generally need slightly less maintenance than diesel vehicles as there are fewer moving parts. The BETT project will add to the evidence base showing the maintenance savings from BEV HGVs.
Specific BEV safety training should be provided for personnel that will work on electric vehicles, with the level of training depending on the degree of interaction with the high voltage system.
Detailed Guidance
Vehicle Maintenance
There are differences in servicing and maintenance management to be aware of when switching to BEVs. In general, BEVs require less maintenance than internal combustion engine vehicles as there are fewer components and moving parts.
The table below shows information on the maintenance requirements of electric and diesel HGVs.
| ICE | EV |
|---|---|---|
Engine/motor | High: Regular oil and oil filter changes | Low: Motor sealed for life |
Power electronics | Low: Minimum power electronics in ICE | Low: Power electronics are sealed for life |
Brakes | High: Regular brake pad and brake disc replacement | Med: Reduced brake wear due to electrical regeneration breaking |
Fuel storage | Low: Fuel filter changes | Low: Battery sealed for life, but may require replacement for very high mileage vehicles. |
The evidence base on maintenance requirements for large electric HGVs is limited as few such vehicles are in operation. We will monitor maintenance schedules and operations as part of BETT and update this information in due course.
Manufacturers will have additional workshop guidance for BEV servicing which typically include a dedicated bay with appropriate markings for BEV maintenance, two trained technicians to be on-site during BEV maintenance work, and hazard signage.
Maintenance Training
The legal requirement for training on high voltage (HV) vehicles is covered by health and safety law which ensures employees are competent to undertake the work. This is reflected in industry standards such as BS 10125 which provides guidance for body-shops and accident repair centres. It recommends BEV hazard management and awareness training is provided for technicians working on HV vehicles.
BEV safety training is available at different levels depending on the level of interaction the technicians would have with the vehicle. Below is an example of BEV training levels offered by Central College Nottingham.
Level 1 Awareness aimed at employees working around, but not on high voltage systems (e.g., workshop office staff). This is provided as an online course.
Level 2 Hazard Management aimed at personnel interacting with a high voltage vehicle (e.g., valets, fleet drivers, breakdown personnel etc.). This is a half day course.
Level 3 Electrically Propelled Vehicle and Replacements Training aimed to give qualified motor technicians add-on knowledge for HV vehicles with modules in Safety Around HV systems, Awareness, Hazard Management, Service Repair and Replacement. Does not cover live working (e.g., battery cell replacement). This is a two-day course.
Level 4 Live Working – Aimed at technicians looking to undertake live working on batteries and HV systems.
In addition, manufacturers often require technicians to have bespoke training on their vehicles, to the same competency level as their dealer network. Training covers HV automotive safety and vehicle-specific maintenance procedures. Top-up training would then be available to cover minor changes and new model releases.