Electric vehicles are increasingly present on the streets and in repair shops, but repairing them requires specific knowledge, appropriate tools, and proper certifications.
Working on an electric vehicle without training or the right tools can pose serious safety risks and legal liabilities. Therefore, it is crucial to be familiar with all the necessary procedures to avoid problems.
In this article, learn about the legislation that regulates work on electric vehicles in Portugal, the certification requirements for technicians, and the necessary tools.
What Types Of Certification Are Required For Technicians Working With Electric Vehicles?
To work with high voltage in electric and hybrid vehicles, technicians must have specific training and certification.
These courses, recognized by technical entities or manufacturers, cover topics such as:
- High voltage electrical hazards;
- Safe isolation procedures;
- Diagnosis and repair of electrical systems;
- Correct use of insulated tools.
Without this accredited training, working on high voltage systems is neither recommended nor safe.
Do Repair Shops Need Their Own Certification To Work With Electric Vehicles?
Auto repair shops that want to repair these types of vehicles need to demonstrate that they comply with safety standards and that their technicians are competent to work on high-voltage systems. This may involve:
- Specific risk assessment for electric vehicles;
- Documented work and electrical isolation procedures;
- Certified training records for technicians;
- Appropriate insulated tools and protective equipment.
Compliance with these requirements ensures that the repair shop follows best practices and reduces exposure to legal and accident risks.
What Are The Risks Of Working On An Electric Vehicle Without Certification?
The consequences stem from the fact that electric vehicles contain high-voltage systems that require specific training to avoid the risk of electric shock and other serious hazards. Working on high-voltage systems without accredited qualifications can result in:
- Civil and criminal liability in the event of an accident or injury;
- Administrative penalties for non-compliance with occupational safety standards;
- Failure of technical inspections or internal audits;
- Potential invalidation of manufacturer warranties.
What Checks Should Be Performed Before Starting To Repair An Electric Vehicle?
Before any repair, it is necessary to:
- Isolate and disconnect the high-voltage system;
- Prevent inadvertent reactivation (lockout/tagout);
- Verify the absence of voltage with certified tools;
- Document the safe condition before working;
- Use Personal Protective Equipment (PPE) and compatible insulated tools.
What Are Electric Vehicle Tools?
Electric vehicle tools are instruments designed and tested for safe work on high-voltage electrical systems.
These tools feature reinforced insulation and are manufactured to prevent electrical conduction, even with accidental contact.
They include wrenches, pliers, and electrical testing equipment that comply with specific insulation standards such as IEC 60900, ensuring protection up to certain voltage levels.
Why Are Electric Vehicle Tools Not Common Tools?
Common tools do not provide adequate electrical insulation, so in high-voltage systems (above 60V, typical in electric vehicles), they can allow a discharge or short circuit.
As a result, damage to electric vehicles can occur or, in more serious cases, the safety of technicians can be jeopardized, causing workplace accidents.
Are Insulated Tools Mandatory?
Yes. Even if the system is turned off, there may still be stored energy, so these tools are indispensable for inspections, diagnostics, and repairs.
Therefore, whenever it is necessary to work with or near high-voltage systems, insulated tools are essential for technical safety and mandatory for:
- Minimizing the risk of electric shock;
- Avoiding labor or safety violations;
- Ensuring compliance with technical and training standards.
What Types Of Tools Comply With Standards And Certification?
The most common insulated tools for electric vehicles include:
- Insulated wrenches in various sizes;
- Insulated pliers and cutters;
- Insulated torque wrenches;
- Voltage and continuity testers suitable for high voltage.
Each must have insulation certification in accordance with standards such as IEC 60900 and recognized safety tests.
What Is IEC 60900?
IEC 60900 is the international standard that defines the safety requirements for insulated hand tools used in work under voltage up to 1,000V in alternating current and 1,500V in direct current.
This standard is essential for work on electric and hybrid vehicles, where high-voltage systems are present.
In this regard, tools certified according to IEC 60900 undergo rigorous testing, such as electrical insulation, mechanical strength, impact, flame, and moisture tests. The goal is to ensure that, even under adverse conditions, the tool protects the user from electric shock.
How To Identify Certified Insulated Tools?
To identify certified insulated tools, you should check that:
- They have the IEC 60900 marking engraved or printed on the tool;
- They clearly indicate the maximum voltage supported (usually 1,000V);
- They have double insulation, usually with two visible colors (e.g., red and yellow), which allow wear to be detected;
- They are accompanied by documentation or certification from the manufacturer.
What PPE Is Essential For High Voltage Automotive Work?
Mandatory PPE for working on electric vehicles includes:
- Certified insulating gloves;
- Safety glasses to protect against sparks or electric arcs;
- Insulating footwear and antistatic clothing;
- Insulating mats for work areas;
- Safety signage for the work area;
- Rescue pole.
What Tools Are Available In The Kroftools Catalog For Working Safely With Electric Vehicles?
To repair electric vehicles safely and in compliance with legal standards, you will find the following tools in the KROFtools catalog:
20 Pieces 1/2″ VDE Insulated Tool Set
This set includes 20 VDE/IEC 60900 certified insulated sockets, suitable for work up to 1,000V and ideal for safe work on electrical and electronic systems, including electric vehicles.
The insulation ensures protection against electric shock, while maintaining mechanical strength and precision in tightening.
Click on the image for more information about the 20 Pieces 1/2″ VDE Insulated Tool Set (ref. 3020).
20 Pieces VDE Insulated Tool Set
Professional set of insulated open-end and adjustable wrenches, certified according to IEC 60900.
Allows you to work safely on live components and is suitable for automotive electrical maintenance, electrical panels, and hybrid or electric vehicles. The two-color insulation makes it easy to identify wear.
Click on the image for more information about the 20 Pieces VDE Insulated Tool Set (ref. 3021).
111 Pieces VDE Insulated Tool Set
This case is the complete solution for professionals who work on high-voltage systems, as it includes 111 VDE insulated tools, certified for up to 1,000V, organized for quick access in a workshop environment.
It is suitable for electric vehicle technicians, industrial maintenance, and specialized electrical work.
Click on the image for more information about the 111 Pieces VDE Insulated Tool Set (ref. 3022).
VDE Insulated Box Spanner 1/2″
These insulated box wrenches, certified to VDE/IEC 60900, have been developed for safe operation on live components.
The insulation ensures electrical protection without compromising torque resistance, making them suitable for professional automotive and electrical maintenance.
Includes the following sizes, all certified for work up to 1,000V:
- 10 mm (Ref. 150610)
- 11 mm (Ref. 150611)
- 12 mm (Ref. 150612)
- 13 mm (Ref. 150613)
- 14 mm (Ref. 150614)
- 16 mm (Ref. 150616)
- 17 mm (Ref. 150617)
- 18 mm (Ref. 150618)
- 19 mm (Ref. 150619)
- 22 mm (Ref. 150622)
- 24 mm (Ref. 150624)
- 27 mm (Ref. 150627)
Click on the image for more information about the VDE Insulated Box Spanner 1/2″ (ref. 281).
Our catalog also includes tool trolleys equipped with insulated tool modules (Ref: 8498PRE | 8498VER), and the modules can also be purchased individually.
If you want to equip your workshop to work with electric vehicles, invest in insulated and certified tools and make sure your team has the proper training to work on high-voltage systems.
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