Product Overview

Summary: This Electric Vehicle Maintenance and Repair SOP sets out clear, step-by-step procedures for safely inspecting, servicing and repairing EVs in Australian workplaces. It helps your team manage high-voltage and battery-related risks while maintaining consistency, compliance and efficiency across your workshop or fleet operations.

Electric vehicles introduce a new set of risks that traditional workshop practices were never designed to manage. High-voltage systems, large-format lithium-ion batteries and complex electronic controls present serious hazards if they are not isolated, tested and handled in a controlled way. This Electric Vehicle Maintenance and Repair Safe Operating Procedure provides a structured, practical framework for completing routine servicing, diagnostics and repairs on EVs while keeping technicians, other workers and visitors safe.

Developed for the Australian regulatory environment, this SOP supports your WHS obligations by clearly outlining how to identify EV-specific hazards, implement isolation and lock-out procedures, select appropriate PPE and manage work areas to prevent inadvertent contact with live components. It also addresses fire and thermal runaway risks, safe lifting and towing of EVs, and the interface between EV systems and workshop infrastructure such as hoists and charging equipment. By standardising how EV work is planned, authorised and carried out, this document helps you reduce the likelihood of electric shock, arc flash, burns and battery-related incidents, while also improving service quality and customer confidence.

Whether you are transitioning an existing workshop to include EVs, managing a mixed ICE/EV fleet, or operating a specialist EV service centre, this SOP gives you a ready-to-use, defensible procedure that can be tailored to your specific site, brands and equipment. It supports onboarding of new technicians, underpins toolbox talks and training, and provides clear evidence of systematic risk management in the event of an audit or incident investigation.

Key Benefits

• Ensure safe, consistent handling of high-voltage EV systems across all technicians and shifts.
• Reduce the risk of electric shock, arc flash, battery fire and other serious incidents during maintenance and repair.
• Demonstrate compliance with Australian WHS legislation and relevant electrical safety requirements for EV work.
• Streamline training and induction for technicians moving from internal combustion engine vehicles to EVs.
• Improve customer and stakeholder confidence by showing that EV servicing is managed under a formal, documented safety procedure.

Who is this for?

• Automotive Workshop Managers
• Fleet Managers
• Electric Vehicle Technicians
• Automotive Electricians
• WHS Managers and Advisors
• Service Centre Supervisors
• Dealership Service Managers
• Local Government Fleet Coordinators
• Mining and Construction Fleet Supervisors
• Training and Compliance Coordinators

Hazards Addressed

• Electric shock from high-voltage traction batteries and power electronics
• Arc flash and burns from incorrect disconnection or testing of live components
• Thermal runaway and fire involving lithium-ion traction batteries
• Exposure to hazardous fumes and gases released from damaged batteries
• Unintended vehicle movement during diagnostics, software updates or charging
• Crush and impact injuries from improper jacking, hoisting or lifting of EVs with heavy battery packs
• Manual handling injuries when removing or installing heavy battery modules and components
• Slips, trips and falls due to trailing EV charging leads and diagnostic cables
• Short circuits and equipment damage caused by incorrect use of tools or test equipment on EV systems
• Psychosocial stress and fatigue related to working with unfamiliar high-risk technology without clear procedures

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and EV System Overview
• 3.0 Roles, Responsibilities and Authorisations
• 4.0 Competency, Licensing and Training Requirements
• 5.0 Required Tools, Test Equipment and PPE
• 6.0 Pre-Work Planning and Risk Assessment for EV Tasks
• 7.0 Vehicle Reception, Identification and Initial Safety Checks
• 8.0 High-Voltage System Isolation, Lock-Out and Tag-Out Procedure
• 9.0 Verification of De-energised State and Testing for Absence of Voltage
• 10.0 Safe Work Practices for Routine EV Maintenance
• 11.0 Safe Work Practices for Diagnostics, Software Updates and Fault-Finding
• 12.0 Procedures for Battery Removal, Handling and Reinstallation
• 13.0 Hoisting, Jacking and Supporting EVs with Underfloor Batteries
• 14.0 Management of Damaged, Swollen or Suspect Batteries
• 15.0 Fire, Thermal Runaway and Emergency Response Procedures
• 16.0 Safe Use of EV Charging Equipment in the Workshop
• 17.0 Housekeeping, Workshop Layout and Segregation of EV Work Areas
• 18.0 Environmental Management and Disposal of EV Components
• 19.0 Incident Reporting, Investigation and Corrective Actions
• 20.0 Documentation, Records and Review of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing Electrical Risks in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS/NZS 4836:2011 Safe working on or near low-voltage electrical installations and equipment
• AS 5732:2022 Electric vehicle (EV) operations – Maintenance and repair (where applicable)
• AS 5733:2022 Electric vehicle (EV) operations – Safe operation (where applicable)
• AS/NZS 4761.1:2018 Competencies for working with electrical equipment for hazardous voltages
• Manufacturer-specific EV service and repair guidelines and safety bulletins