Safe Towing and Recovery Operations for Electric Vehicles

What are Towing Operations?

Vehicle towing and recovery operations are the process of safely relocating vehicles that are broken down or immobilized due to a collision to technical services or secure areas. It is critically important that these operations, a fundamental part of traffic and field safety, are conducted in accordance with standards to protect the vital safety of response teams and the environment.

Why is it Different for Electric Vehicles? 

In classic vehicles with internal combustion engines, shifting into neutral disconnects the mechanical link between the wheels and the engine, allowing the vehicle to roll freely. However, in electric vehicles, the powertrain is directly connected to the wheels. Electric motors are designed to generate electricity through the rotation of the wheels while the vehicle is in motion, known as regenerative braking. Even if the vehicle is turned off, wheels continuing to rotate on the ground will cause the system to generate electricity on its own. This creates a unique dynamic within the mechanical and electronic architecture of electric vehicles not encountered in traditional vehicles.

What are the Dangers? 

Towing electric vehicles using traditional methods (with a rope or dragging on two wheels) presents highly serious operational hazards: 

Overheating and Thermal Runaway: Uncontrolled electrical energy generated by the rotation of the wheels rapidly damages the motor and inverter components of the vehicle. This unplanned energy generation can lead to overheating in high voltage Lithium Ion batteries and thermal runaway reactions that are extremely difficult to stop with external intervention, ultimately causing severe fires. 

High Voltage Risk: Unseen damage may have occurred within the battery pack or high voltage cables, especially if the towing operation is performed following a severe collision. An incorrect transportation method or towing angle strains these components further, creating a direct risk of electrocution for recovery teams working in the field. 

Mechanical Damage: Attaching hooks or ropes to incorrect locations without adhering to manufacturer instructions causes permanent damage to the chassis, cooling lines, or aerodynamic underbody covers of the vehicle. 

How Should It Be Done?

To eliminate risks during the operation, the following steps must be followed:

Use of Flatbed Tow Trucks: The safest and universally accepted standard in the industry is the use of flatbed type tow trucks where all four wheels of the vehicle are lifted off the ground.

Activation of Towing or Transport Mode: Prior to the loading process, Towing Mode or Transport Mode must be activated from the infotainment screen of the vehicle. This mode disables the electronic parking brake and allows for short distance free rolling so the vehicle can be pulled onto the platform.

Use of Wheel Dollies: In scenarios where the low voltage system of the vehicle has completely failed or the screen is not working, wheel dollies must be placed under the wheels to completely cut off the contact of the tires with the ground.

Some Manufacturer Warnings

NEVER TRANSPORT YOUR VEHICLE IN A POSITION WHERE THE WHEELS CAN ROTATE. THIS CAN LEAD TO SIGNIFICANT DAMAGE AND OVERHEATING. ALTHOUGH RARE, OVERHEATING CAN CAUSE SURROUNDING COMPONENTS TO IGNITE.

The vehicle can be damaged if towed with one axle lifted. Transport the vehicle only on a tow vehicle. Do not pull or secure the vehicle by the towing hook, body parts, or chassis parts.

The recovery of electric vehicles following a breakdown or collision is a technical operation that requires high engineering awareness and safety consciousness rather than a standard logistics activity. As a requirement of a strong road and occupational safety culture, strictly adhering to vehicle specific manufacturer guidelines by all responding teams in the field is the only absolute way to eliminate both mechanical losses and life threatening thermal hazards.