Becoming a ZF high voltage Expert

#futuremobility

June 23, 2021
3 minutes read

The ZF high voltage experts

Qualifying as a ZF high voltage expert

Qualifying as a ZF high voltage expert is not a difficult path – as long as you have the motivation, willpower and desire to establish your workshop as an expert for hybrid and electric vehicles.

Your qualification pathway depends on your existing training. The flowchart from the DGUV Information 209-093 of the professional association shows you your recommended learning needs. For example, a person with previous knowledge of electrical engineering in the automotive sector must complete 48 teaching units in order to achieve the level 2 qualification.

What needs to be considered? The important documents and levels

DGUV Info 209-093

The DGUV Info 209-093 is a great document for employers and supervisors, because you can see exactly which qualification requirements are necessary for specific work on high voltage vehicles. However, you must bear in mind that this is not a regulation or law – rather, it is designed to help you as an employer make the risk assessment of high voltage vehicles easier and to ensure the safest possible working environment for your employees.

Now let's take a closer look at the different qualification levels – there are three altogether:

Level 1: Electrotechnical/expertly instructed person
Level 2: Qualified for work in research and development and on non high voltage intrinsically safe production vehicles and prototypes
Level 3: Qualified for work on live high voltage components

What the levels mean and what concrete activities you can do with them can best be seen in the following table:

Level 1	Level 2	Level 3
Non-electrotechnical tasks	Eletrotechnical tasks on stress-free high voltage systems	Work on live high voltage components
General maintenance and repair work	Certified unlocking	Repair work on the live high voltage system
Working on the low voltage vehicle electrical system	Repair work on the stress-free high voltage system	Troubleshooting the live high voltage system
Specified work on high voltage systems	Troubleshooting the voltage-free high voltage system
Test drives	Removal and installation of (high voltage) components
	Certified commissioning

By the way:

Here at ZF were are defining Level 2, a person "qualified for work in research and development and on non high voltage intrinsically safe production vehicles and prototypes" as ZF high voltage expert. The final step would then be ZF high voltage expert Level 3.

My tip for employers or mechanics – if you intend to maintain, service or provide hybrid, electric or fuel cell vehicles as rental cars, you definitely need training!

A practical example

High voltage vers. oil change

It's no secret that high voltage vehicles pose electrical hazards. Let's take one of my favourite subjects as an example: changing transmission oil.

At first glance, this has nothing directly to do with the high voltage system. However, it is in direct proximity to the high voltage system. For example, the connections for the electric motor in our 8P are located directly next to the oil pan. Also, for other activities such as changing the clutch or working on the chassis, there are special features to consider, so training is necessary… in fact, it is vital.

Because when working with high voltage vehicles the number one rule is: SAFETY FIRST!

Learn more about this topic here:

Transmission oil change guide