This Battery Charging & Jump Starting SOP (Safe Operating Procedure) covers charging 12V and 24V vehicle lead-acid batteries with a workshop charger, and jump starting vehicles with jumper leads or a portable jump starter. It covers battery inspection, ventilation and ignition control, the correct lead connection and disconnection sequence, monitoring while charging, storing damaged batteries and responding to acid spills or venting. It's written by WHS specialists, aligned to Australian WHS legislation, and fully editable in Microsoft Word.
Who it's for
Mechanical repair workshops
Auto electricians
Roadside assistance providers
Fleet and transport maintenance teams
Farms and businesses with vehicle fleets
Use it to
Train and induct workers in exactly how you expect the task to be done
Keep a clear reference at the machine, in the vehicle or on site
Record competency with the built-in sign-off
Show clients, insurers and auditors your safe work methods are written down
What this SOP covers
Explosion from hydrogen gas released during charging
Acid burns to skin and eyes from electrolyte or a cracked battery case
Short circuits when tools or jewellery bridge the terminals
Arc flash and sparking from reversed polarity or the wrong connection order
Battery rupture from sparks near the battery while hydrogen is present
Damage to vehicle electronics from reverse polarity or voltage spikes
Crush injury if the vehicle moves during jump starting
Manual handling of batteries and burns from hot engine parts
Fire from smoking, welding or grinding near a charging battery
What's included
8 pre-operational checks, from inspecting the battery for damage or swelling to charger voltage, ventilation and hybrid or EV identification
An 11-step operating procedure covering vehicle set-up, charger connection, jump starting, cranking and monitoring for heat or gassing
Isolation and energy control setting out the jumper lead connection and disconnection sequence, earth points and charger switching
6 shutdown, housekeeping and post-operation steps
Emergency actions for leaking, swelling or venting batteries, acid contact, spills and fire
PPE checklist and a list of related documents
Competency acknowledgement and worker sign-off
Space for your logo, SOP number, version and review dates
Why use this template
Saves hours compared with writing an SOP from a blank page
Written as clear, numbered steps that workers can follow on the job
Fully editable, so you can match it to your equipment, site and how your team works
The competency sign-off gives you a training record from day one
How it works
Buy online and download straight away. You'll also get an email with your link.
Add your logo, company name, SOP number and dates.
Check it suits your equipment and site, and edit anything you need to.
Train your workers and have them sign the competency acknowledgement.
Need more than one SOP?
This SOP is also included in the Ultimate Automotive & Mechanical SOP Bundle. At $197 for the whole bundle, it works out much cheaper than buying SOPs one at a time.
Common questions
Does it cover hybrid and electric vehicles?
No. High voltage traction batteries need the manufacturer's high voltage isolation procedure. The SOP tells workers not to proceed if the vehicle has one.
Does it set out the jumper lead sequence?
Yes. It sets out the order for connecting and disconnecting each clamp, with the final negative going to an unpainted earth point away from the battery.
Can it be used for home or business battery systems?
No. Fixed battery energy storage systems are covered by the separate Battery Storage System Installation SOP.
Can I change it?
Yes. It's a Microsoft Word file, so you can add, remove or change any step, check or hazard, and add your own logo and details.
Does it suit my state?
Yes. It's written to the model WHS laws and suits all states and territories, including Victoria under the OHS Act and Regulations.
What if it doesn't suit my work?
You're covered by our 30-day money-back guarantee if it isn't fit for purpose.
