Product Overview

Summary: This SOP sets out a structured, WHS-aligned framework for training, assessing and certifying electric vehicle (EV) technicians in Australia. It ensures workers who service, repair or modify EVs are competent to manage high-voltage systems safely, protecting your people, customers and business from serious electrical and fire risks.

Electric vehicles introduce high-voltage, high-energy systems into workshops that have traditionally dealt primarily with low-voltage automotive electrics. Without a clear, consistent and documented approach to training and certification, businesses face elevated risks of electric shock, arc flash, battery thermal runaway, and non-compliance with Australian WHS requirements. This Safe Operating Procedure provides a comprehensive, end-to-end framework for how your organisation selects, trains, assesses and authorises EV technicians to work safely on hybrid and battery electric vehicles.

The SOP defines competency pathways aligned with Australian automotive qualifications, OEM requirements and WHS legislation, covering induction, theory and practical training, supervised work, formal assessment and ongoing competency maintenance. It clearly sets out the minimum training content required for different levels of work (e.g. basic inspection, de-energised work, live testing, battery pack work), as well as record-keeping, licence and certification management, and refresher training intervals. By implementing this procedure, organisations can demonstrate due diligence, reduce reliance on informal “on-the-job” learning, and build a defensible training framework that stands up to regulator and client scrutiny.

This document is particularly valuable for workshops transitioning into EV servicing or expanding their EV capabilities. It helps standardise expectations across sites, integrate OEM and RTO training with internal WHS systems, and create a clear authorisation matrix so only appropriately trained technicians perform high-risk EV tasks. The result is a safer workplace, greater confidence for technicians, and a stronger reputation for professionalism in a rapidly evolving industry.

Key Benefits

• Ensure only properly trained and certified technicians work on high-voltage EV systems, significantly reducing the risk of electric shock and serious injury.
• Demonstrate compliance with Australian WHS legislation and duty of care obligations through documented competency and authorisation processes.
• Standardise EV training requirements across multiple sites or workshops, improving consistency, quality and safety performance.
• Streamline onboarding and upskilling of technicians as your EV service offering grows, reducing downtime and training confusion.
• Reduce business exposure to regulatory enforcement, workers compensation claims and reputational damage arising from poorly managed EV work.

Who is this for?

• Workshop Managers
• Service Centre Managers
• Fleet Maintenance Managers
• Automotive Business Owners
• WHS Managers and Advisors
• Training and Development Managers
• Human Resources Managers
• Electric Vehicle Technicians
• Automotive Electricians
• Dealership Service Managers
• RTO Training Managers (Automotive)
• EV Conversion Specialists

Hazards Addressed

• Electric shock from high-voltage EV components and cabling
• Arc flash and arc blast during testing or fault conditions
• Thermal runaway and fire from lithium-ion traction batteries
• Exposure to hazardous battery chemicals and off-gassing during damage or failure
• Unintended vehicle movement due to improper isolation of drive systems
• Burns from hot components and electrical faults
• Psychological stress for workers asked to perform tasks they are not trained for
• Manual handling injuries related to heavy battery packs and EV components when handled by untrained staff

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (EV and High-Voltage Systems)
• 3.0 Roles, Responsibilities and Authorisation Levels
• 4.0 Competency Framework and Technician Categories (e.g. Awareness, Restricted, Full High-Voltage)
• 5.0 Entry Requirements and Prerequisites for EV Training
• 6.0 Training Program Structure (Induction, Theory, Practical and On-the-Job Components)
• 7.0 Mandatory Training Content for EV Technicians
• 8.0 Supervision Requirements for Trainees and Partially Competent Staff
• 9.0 Assessment, Verification of Competency (VoC) and Certification Processes
• 10.0 Recognition of Prior Learning (RPL) and OEM Training Integration
• 11.0 Authorisation to Work on EV Systems (Permits, Cards and Registers)
• 12.0 Refresher Training, Reassessment and Ongoing Competency Management
• 13.0 Record-Keeping, Training Registers and Document Control
• 14.0 WHS and Regulatory Compliance Considerations for EV Training
• 15.0 Interface with Electrical Safety Procedures and Lockout/Tagout Requirements
• 16.0 Contractor and Third-Party Technician Management
• 17.0 Incident, Near-Miss and Competency Gap Review Process
• 18.0 Continuous Improvement of the EV Training and Certification Program
• 19.0 References, Supporting Documents and Related Procedures

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 and state/territory equivalents
• Safe Work Australia – Model Code of Practice: Managing Electrical Risks in the Workplace
• Safe Work Australia – Model Code of Practice: How to Manage Work Health and Safety Risks
• AS/NZS 4836: Safe working on or near low-voltage and extra-low-voltage electrical installations and equipment (as guidance for safe electrical work practices)
• AS/NZS 3000: Electrical installations (Australian/New Zealand Wiring Rules) – for general electrical safety principles
• AS 5732: Electric vehicle operations – Maintenance and repair (where applicable to EV service environments)
• AS/NZS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use
• AUR Automotive Retail, Service and Repair Training Package (including EV-specific units of competency)
• OEM (manufacturer) EV training and certification requirements applicable to specific vehicle brands