What this checklist covers
The EV Battery Handling Checklist is a 15-point scorecard for battery inspection, storage, lifting procedures, isolation, damage assessment, temperature control, and emergency response. Each criterion is scored from 1 to 5 on what the auditor sees on the day, and every gap goes into an action plan with an owner and a close date.
AutoSmart tip: EV battery handling is the highest-risk activity in an automotive dealership environment. A damaged or thermally compromised lithium battery cannot be safely stored indoors — if in doubt, treat it as a thermal runaway risk and place it outdoors on a non-combustible surface, with a clear exclusion zone and the fire service contacted for guidance before any further handling.
The checks
Tap Yes, No or Maybe to try it: your answers stay in this page and clear when you refresh. For a detailed walkthrough, download our PDF or book a demo.
Battery inspection and damage assessment
- Is a visual inspection of the HV battery pack completed before any handling — checking for physical damage, deformation, leakage, unusual odour, or discolouration that may indicate a compromised cell?
- Is the battery damage assessment conducted by an HV-certified technician using the OEM inspection criteria, not a general visual check by untrained staff?
- Is a battery found with visible damage, swelling, electrolyte leakage, or thermal signs quarantined immediately in a safe external location, with no further handling until specialist assessment is complete?
- Is a damaged battery stored outdoors or in a designated ventilated, fire-safe area — not in the workshop, parts store, or any enclosed space where a thermal event could spread?
Storage and temperature control
- Are batteries removed from vehicles for storage placed in a designated, clearly marked battery storage area with appropriate ventilation and fire suppression provision?
- Is battery storage temperature monitored where required by the OEM specification, with batteries not exposed to extreme heat or cold that could accelerate degradation or risk thermal event?
- Are stored batteries maintained at the OEM- recommended state of charge for storage — not left fully charged or fully depleted for extended periods?
- Is a register maintained for batteries in storage, recording the battery ID, vehicle VIN, condition at removal, state of charge, and storage start date?
Lifting procedure and isolation
- Is the battery fully isolated before removal — with voltage verified as zero — and the isolation confirmed documented on the job card before any lifting or mechanical disconnection begins?
- Is the battery lifted using OEM-specified equipment (battery lifting cradle, jig, or equivalent) that supports the battery evenly without applying pressure to the cell structure?
- Are manual handling risks assessed for each battery removal — with team lifts or mechanical assistance required for batteries above the safe single-person lift weight?
Emergency response and governance
- Is an emergency response plan specific to battery thermal events posted in the EV bay and at the battery storage area, covering immediate actions, evacuation, fire service notification, and safe perimeter establishment?
- Are all workshop staff aware of the thermal runaway risk and the initial signs — heat, gas evolution, unusual sound, smoke — and trained to immediately evacuate and call emergency services without attempting to handle the battery?
- Is the fire service pre-informed of the dealership's EV battery storage location (if applicable), so first responders have relevant information before arriving on site?
- Are battery handling incidents and near-misses reported and reviewed in the safety management process, with learnings shared with all relevant staff?
How to run it
How the scoring works
Before the visit, fill in the dealer or centre, the auditor, the date and the audit cycle. Then score each of the 15 checks from 1 to 5 on what you see on the day, not on what the site aims for, and add them up out of 75.
- 1Not in place
- 2Attempted
- 3Defined
- 4Managed
- 5Fully sustained
- Green60–75 · 80–100%Compliant. Keep the standard.
- Amber38–59 · 50–79%Improvement needed: a structured action plan within 30 days.
- Red0–37 · Below 50%Priority intervention, escalated to regional management.
Then close every gap
Each gap goes into the action plan tracker and moves through four stages until the auditor closes it.
- 1PendingOwner and close date set
- 2In progressWork under way, evidence gathered
- 3CompletedEvidence submitted for review
- 4ApprovedVerified and closed by the auditor
