The electric vehicle maintenance conversation has typically focused disproportionally on just that — the vehicles. So, let’s shift the discourse toward the infrastructure that keeps these trucks charged. Especially if you’re considering having on-site charging stations, there are a number of key factors that all-diesel delivery fleets hadn’t really had to consider.
 Of course, the first question on most people’s minds is “what’s it going to cost?”

The biggest costs for operating an electric charging station are electricity (obviously) and maintenance.

The electricity part of it can be quite variable, affected by a number of factors. Electricity costs, according to the U.S. Department of Energy (DOE), depend not only on the type of equipment installed, but also the time of day and length of time that the chargers are used. Some local utilities might offer time-of-use rates to incentivize operators to charge outside of peak times.

As for maintenance costs, those too can vary, but the DOE estimates that operators can expect to spend around $400 for a charger annually. Many charging networks also offer maintenance plans for an additional fee. The California Energy Commission, in its Electric Vehicle Charger Selection Guide, notes that extended warranties for DC fast chargers can cost upwards of $800 a year.

There’s a wide range of best practices fleet operators should be regularly performing in their charging station maintenance schedules, but some of the basic, most common procedures include proper, secure storage of cables to minimize damage, making sure the equipment’s always kept clean, and checking and testing specific parts of the chargers at regular intervals.

You’ll have to make sure enclosures are free of corrosion, dents and any damage to their seals. Moisture also can be a charging device’s worst enemy, so make sure you’re always keeping it dry. This especially can be a challenge in higher-humidity regions, so daily moisture attention and control may be necessary. The same goes for any biological pests — insects, rodents and other vermin — as those can compromise the integrity of the charging equipment. Charging equipment should be visually inspected weekly or at least bi-weekly, to ensure that it remains in tip-top shape.  

Another part of the standard EV charging station maintenance checklist, according to charging technology and services company EVConnect, is to test all connection points and emergency stop functionality. Not unlike a typical vehicle inspection, routine checks will need to be carried out by a licensed professional and signed by a local or state government official. And, as is the case with your fleet equipment itself, preventive maintenance will always ultimately cost less than unplanned repairs, not only in parts and labor, but in downtime. Local and state governments usually will incentive such preventive members with uptime thresholds. Many municipal and statewide entities require a minimum amount of uptime (approximately 95 to 97%) for fleet operators to qualify for government grants.

And, because this is rapidly evolving technology, be sure to always stay on top of software and cybersecurity updates. The last thing you’ll want is to get hacked. That could bring your operation to a standstill and result in a wildly unpredictable amount of downtime. You know what they say, “an ounce of prevention is worth a pound of cure.”