Setting up a workshop for the servicing and maintenance of electric heavy-duty trucks requires a specialized approach. Electric trucks come with distinct technologies, components, and safety requirements that differ significantly from conventional internal combustion engine (ICE) vehicles. Below are the key considerations for both the workshop setup and staff retraining:

Workshop Infrastructure
To accommodate electric heavy-duty trucks, several adaptations to the physical environment are necessary:

Electrical supply and charging infrastructure forms the backbone of these new-generation workshops. The installation of high-capacity charging stations compatible with heavy-duty electric trucks is a must. This ensure sufficient electrical capacity in the workshop to handle the power requirements for charging trucks, which might require upgrading the existing electrical grid or creating dedicated lines for high-voltage systems. In addition to other specialised tools, it may be required to implement energy management systems to efficiently distribute and monitor electricity use.

Safety Measures for High Voltage
Designate specific areas for handling high-voltage components, as electric trucks use voltages as high as 600-800V or more. Here, install insulated flooring in high-voltage areas to reduce electrical risks. Proper ventilation is crucial, therefore proper ventilation systems to prevent the buildup of hazardous gases from battery systems or charging processes are required. Equip the workshop with special tools rated for high-voltage use (e.g., insulated gloves, tools, and mats).

Battery Storage and Management
Design a dedicated space for storing, diagnosing, and maintaining high-voltage batteries. In line with this, implement safety protocols for battery storage, including fire suppression systems and temperature control to manage thermal risks associated with lithium-ion batteries. As the components are different from ICE powertrains, install lifts or other equipment to handle the heavy and bulky electric battery packs.

Space for Diagnostic Equipment
Allocate space for diagnostic stations with advanced software to analyze electric drivetrains, battery health, and electric powertrain components. Ensure that charging bays are spacious enough to accommodate larger electric trucks.

Specialized Tools and Equipment
Maintaining electric trucks requires specialized tools:

High-voltage diagnostic tools for inspecting and repairing electric drivetrains and battery systems are needed for this new technology. Additionally, insulated tools, designed to work safely around high-voltage systems are a must.

Today, much of the work done in a workshop requires computers. Nowadays, a technician has to be familiar with various diagnostic tools, rather than having physical strength. Software tools for monitoring and diagnosing the performance of electric powertrains and battery systems are required to perform work on electric trucks. 

Staff Retraining
The transition to servicing electric trucks necessitates comprehensive retraining for workshop staff. This training should cover the following areas:

Understanding Electric Powertrains:
Mechanics and technicians need to learn how electric motors, inverters, and power electronics function. Furthermore, staff must understand the key differences between electric and traditional ICE systems, such as the absence of a transmission in some electric trucks.

Extensive safety training is critical to ensure technicians know how to safely work around high-voltage systems. Staff should be trained on how to de-energize and isolate high-voltage components before starting any work. Certification programs on high-voltage safety should be mandatory, as mishandling these systems can result in severe injury or death.

Training on how to safely remove, inspect, and service large battery packs is necessary. Technicians should understand how to assess battery health, manage thermal issues, and safely dispose of damaged or spent batteries. Emergency procedures for battery-related fires or leaks should be included and drills conducted on a regular basis to re-assess the need for training on these issues.

Diagnostic software proficiency is a topic that should be included in the training schedule of workshop staff. Electric vehicles rely heavily on software-based systems for monitoring and troubleshooting. Therefore, mechanics will need training in using specialized diagnostic software to interpret fault codes, check battery health, and optimize electric powertrains.

First-Aid and Emergency Protocols
First-aid training specific to electrical injuries and high-voltage shock should be provided. Workshops should establish clear emergency procedures, including the correct handling of electrical fires or battery ruptures. Damaged batteries can self-ignite, starting difficult to extinguish fires. Burning lithium-ion batteries release harmful fumes and gasses, leading to respiratory issues, skin irritation, and environmental damage. Battery fires are challenging to extinguish: these batteries generate their own heat, making them difficult to put out without special equipment.

Certification and Compliance
Technicians will need updated certifications to work on electric heavy-duty trucks, which typically include:

OEM training programs specific to electric truck models.

High-voltage system certification** to meet regulatory and safety standards.

Workshops must also adhere to local and national regulatory standards for working with high-voltage systems, fire safety, and hazardous waste disposal (e.g., for batteries).

Environmental Considerations
Set up proper systems for recycling or safely disposing of high-voltage batteries and other hazardous materials related to electric trucks. Supporting this, workshops can incorporate energy-efficient practices to minimize the environmental footprint, such as using renewable energy sources to power charging stations.

Continuous Learning and Adaptation
The electric truck market is rapidly evolving, and workshops need to keep pace with advances in technology. Implementing continuous learning programs to regularly update staff on new developments in electric truck servicing is essential for long-term success.

Converting a workshop to accommodate electric heavy-duty trucks is a multifaceted process, requiring upgrades to infrastructure, tools, safety protocols, and a thorough retraining of staff. By focusing on high-voltage safety, battery management, and diagnostic software skills, workshops can ensure they are prepared to maintain the next generation of electric trucks safely and efficiently.

Electrifying Malaysia’s Transportation
Asian Trucker is organising the Asian Trucker Forum, an upcoming conference dedicated to the evolving landscape of electric trucks and buses. As a leader in the industry, your company plays a pivotal role in shaping the future of sustainable transportation. We would like to invite you to become a sponsor for this significant event.

Event Overview:

• Date: 16 May 2025
• Venue: Setia City Convention Centre
• Theme: Pioneering the Future of Transportation

This conference will bring together industry experts, policymakers, and key stakeholders to address the challenges and opportunities presented by the adoption of electric vehicles in the commercial sector. It will be an excellent platform for companies like yours to showcase innovations, share insights, and explore real-world use cases that can serve as valuable learning experiences for others in the industry.