This EV & Hybrid High Voltage Isolation SOP (Safe Operating Procedure) covers isolating the high voltage traction battery of an electric or hybrid vehicle before service, repair or diagnostic work. It covers following the manufacturer's sequence for the exact model, removing the service disconnect, waiting out capacitor discharge, proving the meter and testing for zero energy, and locking out and handing over safely. It's written by WHS specialists, aligned to Australian WHS legislation, and fully editable in Microsoft Word.
Who it's for
Automotive workshops and mechanics
Dealership service departments
Fleet maintenance workshops
Auto electricians
Collision repair and panel shops
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
Electric shock or electrocution from energised high voltage parts
Arc flash from a short circuit near high voltage conductors
Stored energy in inverter capacitors after the disconnect is removed
Burns from hot high voltage cables, connectors or battery parts
Battery fire or thermal runaway
Vehicle movement or rolling during isolation
Cooling fans and other moving parts
Another worker starting before isolation is verified
What's included
7 pre-operational checks, from high voltage competency and the manufacturer's isolation procedure to insulated gloves, meter ratings and barricading
A 13-step isolation procedure covering immobilising the vehicle, service disconnect removal, capacitor discharge, prove-test-prove and lockout
Isolation and energy control throughout, including securing the removed disconnect, personal locks and re-verifying at handover
7 shutdown, housekeeping and post-operation steps
Emergency actions for smoke, arcing, battery swelling or leaks, battery fires and electric shock to a co-worker
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 set out who is competent to do this work?
No. Competency and authorisation for high voltage vehicle work sit in a separate high voltage vehicle work procedure. This SOP covers the isolation task itself.
Can the dashboard be used to confirm the system is dead?
No. Technicians verify zero energy with a meter rated for the vehicle's high voltage class, proving the meter before and after the test.
Does it cover installing home EV chargers?
No. Fixed charger installation is electrical work for a licensed electrician and is covered by our separate EV Charger 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.
