Product Overview

Summary: This Safe Operating Procedure provides a step-by-step framework for safely retrofitting conventional internal combustion engine vehicles to electric power in Australian workplaces. It helps workshops, fleet operators and conversion specialists manage high-voltage, fire, lifting and environmental risks while ensuring WHS compliance and consistent technical quality across every conversion.

Retrofitting conventional vehicles to electric power is rapidly emerging as a practical pathway to decarbonise fleets and extend the life of existing assets in Australia. However, working with high-voltage systems, lithium-based batteries and modified drivetrains introduces significant safety, compliance and quality risks that are very different from traditional mechanical vehicle work. This SOP provides a structured, WHS-focused method for planning and executing retrofit projects, from initial vehicle assessment and de-energisation through to installation, testing, verification and handover.

The procedure is designed to support workshops and businesses that may be transitioning from conventional automotive servicing into the EV retrofit space. It sets out clear roles and responsibilities, mandatory competencies, PPE requirements and isolation controls for high-voltage work, as well as practical guidance on safe lifting, manual handling, fire risk management and environmental controls. By implementing this SOP, organisations can demonstrate due diligence under Australian WHS legislation, reduce the likelihood of electrical incidents, fires and rework, and provide clients with confidence that their converted vehicles are built and commissioned to a repeatable, defensible standard.

Key Benefits

• Ensure safe management of high-voltage and battery-related risks during all stages of the retrofit process.
• Reduce the likelihood of electrical shocks, arc flash, fire incidents and vehicle damage in the workshop.
• Standardise retrofit workflows to improve quality, traceability and consistency across multiple vehicles and teams.
• Streamline compliance with Australian WHS requirements, roadworthiness and vehicle modification regulations.
• Support upskilling of automotive staff transitioning from conventional vehicle servicing to electric vehicle work.

Who is this for?

• Automotive Workshop Managers
• Fleet Managers
• Automotive Electricians
• Mechanical Technicians
• WHS Managers and Advisors
• EV Conversion Specialists
• Automotive Engineers
• RTO Trainers in Automotive and EV Technology
• Project Managers – Fleet Electrification
• Compliance and Risk Managers in Transport Businesses

Hazards Addressed

• Electric shock and arc flash from high-voltage components and cabling
• Thermal runaway and fire involving lithium-based traction batteries
• Uncontrolled movement of vehicles during retrofit activities
• Crush and impact injuries from lifting, hoisting and handling heavy components (engines, battery packs, motors)
• Exposure to hazardous substances such as battery electrolytes and coolants
• Ergonomic and manual handling injuries from awkward loads and repetitive tasks
• Slips, trips and falls in congested workshop areas with tools, cables and components
• Noise and vibration from power tools and cutting equipment used during removal and modification
• Inadequate isolation and lockout/tagout of electrical and mechanical energy sources
• Environmental contamination from spills of fuels, oils and coolants removed during conversion

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (EV, HV, LV, BMS, isolation zones)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 6.0 Pre-Retrofit Planning and Risk Assessment
• 7.0 Vehicle Selection, Inspection and Suitability Assessment
• 8.0 Workshop Preparation, Zoning and Housekeeping Requirements
• 9.0 High-Voltage Safety, Isolation and Lockout/Tagout Procedures
• 10.0 Decommissioning of Conventional Powertrain (Engine, Fuel System, Exhaust)
• 11.0 Handling and Disposal of Fuels, Oils, Coolants and Other Fluids
• 12.0 Battery Pack Handling, Storage and Fire Risk Controls
• 13.0 Installation of Electric Drivetrain, Battery Systems and Power Electronics
• 14.0 Electrical Cabling, Earthing/Bonding and Protection Requirements
• 15.0 Integration with Vehicle Control Systems and Instrumentation
• 16.0 Mechanical Modifications, Mounting Systems and Structural Considerations
• 17.0 Testing, Commissioning and Verification Procedures
• 18.0 Roadworthiness, Compliance and Certification Checks
• 19.0 Emergency Procedures for Electrical Shock, Fire and Chemical Exposure
• 20.0 Incident Reporting, Investigation and Corrective Actions
• 21.0 Training, Induction and Competency Management
• 22.0 Documentation, Labelling and Record Keeping
• 23.0 Review, Audit and Continuous Improvement of Retrofit Practices

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) and state/territory equivalents
• Safe Work Australia – Model Code of Practice: Managing Electrical Risks in the Workplace
• Safe Work Australia – Model Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Model Code of Practice: Managing Risks of Plant in the Workplace
• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS/NZS 5732:2022 Electric vehicle (EV) operations – Maintenance and repair
• AS 5732.2 (if applicable): Electric vehicle workshop safety and procedures (or latest related EV service standard)
• AS/NZS 4836:2011 Safe working on or near low-voltage electrical installations and equipment
• AS 5732.x / related guidance on high-voltage systems in electric vehicles (where adopted in Australia)
• AS 1940:2017 The storage and handling of flammable and combustible liquids (for removal and handling of fuels)
• National Heavy Vehicle Regulator (NHVR) – Vehicle Standards Bulletin and modification codes (where applicable)
• State and territory road authority requirements for vehicle modifications and certification (e.g. VSB 14)
• AS/NZS 4501 series: Occupational protective clothing and PPE (as relevant to electrical and workshop work)