Moving Beyond the ICE Age
EV & PHEV Fundamentals Training Manual
The automotive industry is rapidly transitioning from Internal Combustion Engine (ICE) vehicles to electrified platforms. Workshops that are not prepared risk being left behind.
Moving Beyond the ICE Age is designed to give technicians, workshop owners, and apprentices a structured and practical introduction to Hybrid, Plug-In Hybrid (PHEV), and Battery Electric Vehicle (EV) systems — without unnecessary complexity.
This manual focuses on understanding system architecture, safety, servicing requirements, and workshop readiness.
What’s Included
Hybrid II – Understanding PHEVs
Plug-In Hybrid Electric Vehicles Explained
- How PHEVs differ from conventional hybrids
- High-voltage battery integration
- Internal combustion engine interaction
- Drive motor operation
- Energy management strategies
Feature Vehicle: Mitsubishi Outlander PHEV
- System layout overview
- Component identification
- Operational modes
- Common service considerations
Introduction to Electric Vehicles (EVs)
EV Fundamentals
- EV architecture explained
- High-voltage system layout
- Power distribution principles
- Drive motor operation basics
Key EV Components
- High-voltage battery packs
- Inverters and converters
- On-board chargers
- DC-DC converters
- Electric drive motors
- Thermal management systems
Feature Vehicle: Tesla Model 3
- Platform overview
- High-voltage system architecture
- Component placement
- Service considerations
The New Australian Standard
Understanding compliance and safety requirements is critical before working on EVs.
This section covers:
- Workshop safety expectations
- Technician responsibilities
- High-voltage risk awareness
- General compliance considerations
How to Be EV Ready
Electrification requires changes in workshop setup, tooling, and procedures.
Preparing the Workshop
- Dedicated EV work areas
- Safety signage
- Isolation procedures
- Emergency response planning
Tools & PPE
- Insulated tools
- High-voltage rated gloves
- Safety equipment requirements
- Testing equipment basics
Servicing an EV
Everything You Need to Get Started
- Safe vehicle shut-down procedures
- Isolation fundamentals
- Routine maintenance differences vs ICE
- Inspection procedures
- Cooling system considerations
- Software and system checks
EV & PHEV Charging Systems
Charger Types & Operation
- AC charging fundamentals
- DC fast charging overview
- On-board vs off-board charging
- Charging safety considerations
- Workshop charging setup basics
Who This Manual Is For
- Automotive technicians
- Workshop owners
- Apprentices
- Fleet maintenance teams
- Workshops preparing for EV integration
Why This Training Matters
The shift to electrification is accelerating. Workshops must:
✅ Understand high-voltage system fundamentals
✅ Prepare facilities safely
✅ Invest in correct tools and PPE
✅ Service EVs and PHEVs confidently
✅ Comply with Australian standards
Without proper training, high-voltage systems present safety risks and liability exposure.
The Moving Beyond the ICE Age – EV & PHEV Fundamentals Training Manual provides a clear, practical starting point for workshops entering the electric vehicle era — helping technicians transition from traditional ICE servicing to modern electrified vehicle systems safely and professionally.
