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AFVi
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EV 101: Electric Vehicle High-Voltage Safety Awareness

This course prepares non-high-voltage personnel to safely recognize, identify, and work in proximity to electric vehicles (EVs) operating in medium-duty and heavy-duty commercial environments — including hybrid, plug-in hybrid, battery electric, and fuel cell electric trucks, buses, and fleet vehicles. Learners will gain awareness of the unique hazards posed by high-voltage DC and AC systems in heavy-duty platforms.

The course aligns with the ASE Electric Vehicle High-Voltage Electrical Safety Standards, Level ONE — Electrically Aware Person, and references applicable OSHA, NFPA 70E, FMVSS, and SAE requirements. It establishes the boundaries of what a Level ONE individual may and may not do around an electric vehicle and prepares them to respond appropriately when high-voltage hazards are encountered in commercial fleet and transit environments.

Prerequisites

Basic electrical training

First Aid Training, including CPR

Who Should Attend?

This course is designed for anyone who works on or around electric vehicles, but does not perform work on high-voltage systems or components. This includes technicians and other workers who:

  • Perform basic preventive maintenance and repairs not related to the high-voltage systems or components (tire rotations, etc.)
  • Handle non-high-voltage components of EVs
  • Are involved in non-maintenance areas of EV fleet operations
  • Fleet or dealer service managers and supervisors
  • Corporate/agency safety managers
  • Risk management staff

Course Objectives

  • Identify an electric vehicle in a commercial fleet environment.
  • Recognize the twelve distinct high-voltage components found on electric vehicles.
  • Describe the electrical hazard thresholds defined by FMVSS 305 and OSHA and compare them to the operating voltages of commercial electric vehicles.
  • Explain the risks associated with damaged high-voltage lithium-ion battery packs in commercial vehicles.
  • Identify orange high-voltage cabling, internationally recognized warning labels, and OEM-specific markings that indicate high-voltage components.
  • Apply the three-step procedure for aiding a person subjected to high-voltage shock.
  • Recognize appropriate physical barriers and signage that establish a safety zone around an electric vehicle in a commercial fleet service bay.
  • Understand the role and responsibilities of a Level ONE – Electrically Aware Person.

Course Outline

Module 1 Introduction to Electric Vehicles and the Level ONE Role
Module 2 Identifying EVs and High-Voltage Components
Module 3 Understanding High-Voltage Hazards: Shock, Arc Flash, and Arc Blast
Module 4 Lithium-Ion Battery Risks: Stranded Energy, Thermal Runaway, and Fire Behavior
Module 5 Warning Labels, Orange Cabling, and OEM Identification
Module 6 Shop Safety Zones: Barriers, Signage, Cones, and the EV Service Safety Kit
Module 7 Emergency Response: Aiding a Shock Victim and Responding to Battery Fires
Module 8 Regulatory Framework: OSHA, NFPA 70E, FMVSS, and SAE Standards Overview
Module 9 Lockout/Tagout Awareness and Level ONE Boundaries

Educators/Trainers/Field Service Representatives

Instructional staff members of colleges, universities, private training organizations, fleets, dealers or manufacturers are not candidates for this course, but have numerous options for bringing AFVi’s training classes to their campuses or facilities. For more information, contact us at 800-510-6484.

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