Electromobility in the commercial vehicle workshop

The electrification of the commercial vehicle sector is no longer a vision of the future - it is the present. Mercedes-Benz, MAN, Volvo, DAF and Scania are already supplying electric trucks as standard. For independent workshops, this means that fleet operators increasingly expect their service partners to service electric vehicles competently and safely. Those who plan for electric trucks in the commercial vehicle workshop in a structured way will position themselves as a sought-after service partner at an early stage.

If you want to service an e-truck professionally, you need five modules - and you need them all before the first vehicle enters the workshop:

• Qualified personnel as a qualified person for electrical work in accordance with EU Directive 2009/104 (transposed into national regulations) at the levels of sensitised person, expert instructed person, expert person (FHV) for work on high-voltage systems in a de-energised state, and extended authorisation
• VDE-certified HV tool to IEC 60900, insulated up to 1,000 V
• Personal protective equipmentInsulating gloves class 0/00, face protection, flame-retardant clothing
• HV safety area with floor markings, signage, rescue equipment
• Charging infrastructureat least one 22 kW AC wallbox for the workshop stop

The traction battery is the most valuable component of an electric truck. It also offers workshops a completely new field of business: condition testing (state of health), cooling system maintenance, module replacement and insulation testing. The hourly rate for HV work is usually significantly higher than the rate for conventional mechanical work. Those who build up expertise early on therefore position themselves as the preferred partner for fleet operators who are switching to electromobility.

Practical Insight: When planning investments for the e-truck workshop, most companies underestimate one point: fire protection. Lithium-ion battery fires in electric trucks are extremely high-energy (fire temperatures over 1,000 °C, spontaneous combustion possible) and cannot be controlled with standard workshop extinguishing systems. In terms of standardisation, the requirements from IEC 60900 (insulated hand tools up to 1,000 V AC), supplemented by DIN VDE 0683 for live working. In addition, the national occupational health and safety regulations (in implementation of EU Directive 2009/104) require a separate fire area with F90 walls for HV workplaces as well as an outdoor quarantine area for damaged vehicles (at least 10 metres away from other buildings). Requirements for the provision of extinguishing water, on the other hand, are regulated by the relevant property insurer guidelines for lithium-ion batteries; they must therefore be agreed with the local property insurer. This fire protection component is a key infrastructure investment for each workshop. Grants and low-interest loans can also be obtained via national funding programmes for SMEs and the skilled trades. Those who skimp here, on the other hand, risk not only insurance exclusions, but also liability claims that threaten their existence in the event of a fire. It is therefore essential to consult the relevant national health and safety authority and the local fire brigade at an early stage.

For alternative drive technology, Alltrucks is bundling three partner programmes that workshops can use as points of contact: firstly, cooperation with SANY and SuperPanther for battery electric commercial vehicles and - since 01.04.2026 - also REFIRE for hydrogen-powered fuel cell lorries. We will be happy to clarify the specific conditions and access to the specialist training programme together. So please get in touch with us.

High-voltage systems in commercial vehicles operate with voltages of up to 800 volts. Contact with live parts can therefore be fatal. There is a danger to life from 50 volts AC or 120 volts DC. For this reason, national health and safety regulations implementing EU Directive 2009/104 define who is authorised to do what. Compromises are ruled out.

• Level S - Sensitised person: Allows conventional work on HV vehicles without intervention in the HV system (tyres, brakes, bodywork). Training duration: 1 day.
• Level 1S - Qualified instructed person for HV systems in commercial vehicles: Minimum qualification for every mechanic who works on HV components. Safe disconnection, voltage-free test, PPE handling. Training duration: 3-5 days per employee, with annual refresher training.
• Level 2S: Qualified person (FHV) for work on high-voltage systems in a de-energised state: All work on de-energised HV systems and components or in their danger zone, e.g. measuring insulation resistances, repairing, replacing, modifying and testing, is considered to be work on high-voltage systems in a de-energised state.
• Level 3S - Extended authorisations: Authorised to work under voltage and as a system supervisor. Recommended for workshop managers and diagnostic specialists. Building on 2S, +2-3 days additional training.

The five safety rules apply without exception and in exactly the same order. No rule may be skipped, abbreviated or ignored „from experience“:

• 1. unlocking: Pull the service disconnect and keep it in a safe place. In the case of software-based activation, the absence of voltage must be verified by measurement.
• 2. secure against being switched on again: Personal lock on the disconnect (lockout/tagout), attach warning sign „Do not switch on - work is in progress“.
• 3. check that there is no voltage: With a two-pole voltage tester in accordance with national electrician test regulations (EU 2009/104) in the live/dead/live sequence. Observe manufacturer-specific waiting time (5-10 minutes) for capacitor discharge.
• 4. earthing and short-circuiting: Limited application in the commercial vehicle context - carry out insulation measurement instead, fit insulating covers.
• 5 Cover or cordon off neighbouring parts: Treat orange-coloured HV cables that have not been disconnected as live and protect them.

For a commercial vehicle workshop with four to six mechanics, Alltrucks recommends: all mechanics at least level 1S, two mechanics level 2S, one workshop manager or specialist level 3S. This means that qualified staff are always available to cover the HV work - even in the event of illness or holidays.

Practical Insight: The HV qualification is not just a safety issue - it is also a funding opportunity. National funding programmes for charging infrastructure and SME financing often subsidise HV training for workshop employees. The complete qualification cascade (sensitised person, expert person, extended authorisation) is therefore a clearly calculable training module, the net cost of which is noticeably reduced after funding. Refinancing via the above-average HV hourly rates (significantly above the regular rate) is typically achieved within the first financial year. Accredited training centres also hold regional appointments; however, waiting times can be several weeks depending on the region. Recommendation: Secure training dates in good time, as demand in the industry is rising sharply and bottlenecks are foreseeable.

The HV qualification levels according to EU 2009/104 are initially the legal foundation. In the Alltrucks network, they are also embedded in the Alltrucks training and the Certification as a multi-brand system technician. This dovetails the HV stages with the multi-brand diagnostic expertise at Bosch, Knorr-Bremse and OEM interfaces, which is already required in the e-truck service. The specific training programme and partner conditions will be agreed jointly.

The good news is that the necessary investments are manageable, plannable and - with the right approach - typically amortised in the medium term. Contrary to what is often feared, this is not about a big bang, but a gradual build-up based on your actual e-truck volume. The following planning for the e-truck in the commercial vehicle workshop is also based on experience from the Alltrucks network.

The aim: to be able to act before the first fleet customer asks. Budget class: Entry package.

• Training courses: 2 mechanics at level 2S, all other employees at level 1, check Alltrucks training together with us.
• Tools & PPE: VDE HV tool set in accordance with IEC 60900, PPE for 2 employees, measuring equipment with insulation measuring device and two-pole voltage tester.
• Infrastructure: HV safety area in accordance with national health and safety regulations (EU 2009/104) with floor markings, signage, rescue equipment and a 22 kW AC wallbox including installation.

Expansion of the range of services and capacity. Scalable according to actual volume. Budget class: Expansion package.

• Training courses: 1 workshop manager at level 3S, refresher training for existing level 2S employees, manufacturer-specific training.
• Infrastructure: Battery quarantine area in the outdoor area, battery table for removing the traction batteries.
• Lifting technology: Check lifts for HV suitability and retrofit (insulated mounts, ESD protection), lowering device for battery removal.

Optional, for workshops with strategic requirements as an e-truck competence centre. Budget class: Future package.

• DC fast charging station 50-150 kW - Typically eligible for funding via national funding programmes for charging infrastructure; check current conditions with the responsible national body.
• Dedicated e-truck workstation with full HV equipment and battery lift.
• Specialisation in battery diagnostics and module repair as an independent business segment.

• Alltrucks partner benefits: Favourable conditions on HV training courses and cooperation with e-truck manufacturers.
• National funding programmes for charging infrastructure: Programme conditions for DC and AC charging points depend on the cut-off date - check current quotas with the responsible national authority.
• Regional funding programmes: available in many regions for small and medium-sized enterprises - vary in amount and conditions.
• National credit programmes: Low-interest loans for investments in environmental protection and energy efficiency - check the current programme portfolio with the relevant national development bank.
• Special tax depreciation: Investments in e-mobility infrastructure are eligible for special depreciation in many EU countries - coordinate the specific amount with your tax advisor according to the national legal situation.

Conservative scenario: 3 e-truck orders per week, 2 hours of HV work at the HV hourly rate over 48 weeks therefore result in a noticeable additional annual output. The phase 1 investment also pays for itself with a steady volume of e-trucks. typically within the first financial year.

Realistic scenario: 5 orders per week of 3 hours each - the additional contribution margin is noticeably higher than in the conservative approach. Phases 1 and 2 of the investment are therefore typically amortised within the first financial year.

Practical Insight: The biggest challenge with the introduction of phasing is not the investment in tools, but the procurement of qualified personnel. In the Alltrucks network, a large proportion of workshops report that they simply cannot find HV Stage 2S mechanics - not even with above-standard offers. The most effective approach is therefore to train your own mechanics internally. Recommendation: Build up a talent pool by placing interested mechanics per workshop on a development path to become level 2S specialists over a period of several months. Experience has shown that this significantly increases staff loyalty, as the investment in personal qualifications is perceived by the employees as appreciation. An accompanying salary adjustment through a noticeable monthly bonus for the HV specialists also pays for itself quickly with regular HV orders. The phase introduction must therefore have two pillars: Investment plan and personnel development plan, in parallel and with equal priority.

The transformation of the commercial vehicle workshop is not taking place in one big leap, but in four parallel lines of development - powertrain, assistance systems, diagnostics and data interfaces. However, if you think along all four lines, you will not be building an electrified diesel workshop, but a genuine workshop of the future.

The manufacturers are already delivering in series. Mercedes eActros 600, Volvo FH Electric, MAN eTGX, DAF XD Electric, Scania 45 R BEV - the model range is growing by the month. Industry analyses expect between 25 and 40 percent of all newly registered heavy commercial vehicles in Europe to be electric by 2030. In contrast, the stock is changing more slowly but inexorably: by 2027, the proportion of electrified trucks will be in double figures in most workshop catchment areas. Anyone starting out by then will have lost two years of the learning curve.

The topics in this guide are not separate from each other - they grow together. A modern e-truck has high-voltage components, intelligent battery management and continuous data communication with the manufacturer's backend. Anyone planning a battery change on an eActros therefore has three tasks in parallel before the activation: firstly HV safety testing and insulation measurement, then coolant handling of the thermally coupled traction battery and finally a software handshake via the manufacturer's diagnostics.

Garages that invest today will not be one of many tomorrow, but one of few. In most regions, the density of independent garages with e-truck capability is less than 10 per cent. Those who make the Phase 1 investment therefore not only gain service expertise, but also a unique selling point. Fleet operators are also increasingly pooling their requirements with a small number of service partners - and selecting those that cover their entire fleet (diesel and electric).

• Market analysis: How many e-trucks are registered in your catchment area - and how many do you expect in 2027?
• Customer dialogue: Talk to every fleet customer about their electrification roadmap. Nothing is more convincing than the prospect of a concrete order.
• Conversation with Alltrucks: Work out an individual investment plan for the entry into e-trucks in a joint discussion with Alltrucks.
• Book your first training course: Level 2S for two mechanics. This makes entry irreversible.
• Start funding applications: Check national funding programmes, regional programmes and national loan programmes in parallel - the waiting times are often several months.

Practical Insight: The decisive strategic effect over the next three years will be the positioning as an e-truck first port of call for fleet customers. According to industry forecasts, the number of e-trucks in the central logistics, industrial and port clusters is growing significantly. Workshops in these clusters therefore have the opportunity to establish themselves as a regional competence centre at an early stage. In concrete terms, this means: initially direct contact with local logistics providers, then pilot projects for service flat rates and availability contracts, as well as a clear multi-brand strategy as a strategic addition to OEMs for mixed fleets. On the diagnostics side, the Alltrucks multi-brand diagnostics with the KTS Truck V3 (Bosch + Knorr-Bremse integration) the cross-brand service expertise that a mixed fleet of e-trucks requires. Top workshops also go one step further and offer „Total Care“ contracts: flat-rate maintenance, unscheduled repairs, HV service and availability guarantee for a fixed monthly fee. These business models thus shift the value of the workshop from hourly rates to predictable availability.