Product Overview

Summary: This Electric Vehicle Diagnostic Procedures Safe Operating Procedure provides a clear, step-by-step framework for safely diagnosing faults in hybrid and battery electric vehicles. It helps technicians manage high-voltage and stored-energy risks while delivering consistent, high-quality diagnostic outcomes in line with Australian WHS obligations.

Electric vehicles introduce high-voltage systems, complex electronics and energy storage hazards that traditional workshop practices were never designed to manage. This Safe Operating Procedure sets out a structured, repeatable approach for performing EV diagnostics that keeps technicians safe while protecting valuable assets and maintaining manufacturer warranties. It covers the full workflow from vehicle intake and job scoping through to safe isolation, fault-finding, validation and return to service, with a strong focus on high-voltage risk control and WHS compliance in an Australian context.

By implementing this SOP, workshops and fleet operators can significantly reduce the risk of electric shock, arc flash, thermal events and unintended vehicle movement during diagnostic work. The document standardises how scan tools, OEM software, test equipment and personal protective equipment (PPE) are used around high-voltage components and battery systems. It also helps businesses demonstrate due diligence under WHS legislation, improve technician confidence when working on EV platforms, and deliver consistent, professional service outcomes to customers as the Australian vehicle fleet rapidly transitions to electric.

Key Benefits

• Ensure safe, consistent diagnostic practices around high-voltage EV systems in line with Australian WHS requirements.
• Reduce the risk of electric shock, arc flash, battery thermal events and unintended vehicle movement during diagnostic work.
• Standardise the use of diagnostic tools, OEM software and test equipment across technicians and sites.
• Streamline fault-finding workflows to minimise rework, downtime and customer callbacks.
• Demonstrate due diligence to regulators, OEMs and clients through a documented, defensible diagnostic procedure.

Who is this for?

• Automotive Technicians
• EV and Hybrid Vehicle Technicians
• Workshop Managers
• Service Advisors
• Fleet Maintenance Coordinators
• WHS Managers
• Auto-Electrical Specialists
• Technical Trainers in Automotive Workshops

Hazards Addressed

• Electric shock from exposed or damaged high-voltage components and cabling
• Arc flash and electrical burns during testing or probing of live circuits
• Thermal runaway and fire risk associated with lithium-ion traction batteries
• Unintended vehicle movement due to drive systems being energised during diagnostics
• Exposure to hazardous substances from damaged batteries (electrolyte leaks, off-gassing)
• Musculoskeletal injuries from handling heavy EV components or battery modules
• Slips, trips and falls created by diagnostic leads, charging cables and tooling around the vehicle
• Eye and skin injuries from flying debris during component access or battery enclosure opening

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and EV System Overview
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and OEM Requirements
• 5.0 Required Tools, Test Equipment and Diagnostic Software
• 6.0 Personal Protective Equipment (PPE) and Safety Devices
• 7.0 Pre-Work Checks and Vehicle Intake Process
• 8.0 High-Voltage Isolation and Verification of De-energised State
• 9.0 Safe Work Area Setup and Access Control
• 10.0 Step-by-Step EV Diagnostic Procedure
• 11.0 Specific Procedures for Battery, Inverter, Motor and Charging System Diagnostics
• 12.0 Managing Live Testing on Energised Circuits (When Unavoidable)
• 13.0 Hazard Identification, Risk Assessment and Control Measures
• 14.0 Handling Damaged or Suspect Batteries and Thermal Event Precursors
• 15.0 Re-energisation, Functional Testing and Return-to-Service Checks
• 16.0 Documentation, Reporting and Recordkeeping Requirements
• 17.0 Training, Competency Assessment and Refresher Requirements
• 18.0 Emergency Procedures for Electric Shock, Fire and Battery Incidents
• 19.0 Inspection, Maintenance and Calibration of Diagnostic Equipment
• 20.0 Review, Audit and Continuous Improvement of the Procedure

Legislation & References

• WHS Act and WHS Regulations in applicable Australian state or territory
• Safe Work Australia – Model Code of Practice: Managing electrical risks in the workplace
• Safe Work Australia – Model Code of Practice: Managing risks of plant in the workplace
• AS/NZS 3000:2018 Electrical installations (Australian/New Zealand Wiring Rules) – general electrical safety principles
• AS/NZS 4836:2011 Safe working on or near low-voltage electrical installations and equipment
• AS/NZS 4761:2018 Competencies for working with electrical equipment for hazardous voltages
• AS ISO 45001:2018 Occupational health and safety management systems
• Manufacturer and OEM EV service and safety bulletins (as applicable)