Product Overview

Summary: This SOP sets out a safe, consistent method for carrying out oil changes on diesel engines in Australian workplaces. It helps businesses protect workers from burns, chemical exposure, environmental contamination and equipment failure, while keeping plant and vehicles compliant, reliable and ready for work.

Oil changes on diesel engines are a routine task, but when they are done without a clear procedure they can quickly lead to serious safety incidents, costly breakdowns, and environmental harm. This Safe Operating Procedure provides a clear, step‑by‑step method for planning and performing oil changes on diesel engines used in vehicles, plant, and fixed equipment across Australian industries. It addresses everything from isolating the engine and allowing it to cool, through to correct selection of oil and filters, spill control, and waste oil disposal.

The document is designed to help businesses meet their WHS duties by embedding hazard identification and control into a task that is often treated as “low risk”. It standardises how technicians work across shifts and sites, reduces the likelihood of engine damage from incorrect servicing, and ensures waste oil and filters are managed in line with environmental and regulatory expectations. Whether you maintain a small fleet of utes and generators or a large operation with heavy diesel plant, this SOP supports safer workshops, better equipment reliability, and a defensible maintenance regime aligned with Australian best practice.

Key Benefits

• Reduce the risk of burns, slips, and chemical exposure during diesel engine oil changes.
• Ensure consistent, manufacturer‑aligned servicing that extends engine life and reduces unplanned downtime.
• Demonstrate due diligence with a documented process that supports WHS and environmental compliance.
• Standardise training for new and existing maintenance staff, improving quality and reducing rework.
• Minimise environmental impact and regulatory risk through clear waste oil and filter disposal controls.

Who is this for?

• Diesel Mechanics
• Fleet Maintenance Managers
• Workshop Supervisors
• Plant and Equipment Operators
• Agricultural Machinery Technicians
• Mining and Civil Maintenance Teams
• WHS Managers
• Facilities and Asset Managers

Hazards Addressed

• Burns from hot engine components and hot oil
• Exposure to used engine oil, solvents and cleaning chemicals
• Slips, trips and falls from oil spills and contaminated workshop floors
• Crush and pinch injuries from moving plant or unsecured vehicles
• Fire risk from flammable liquids and ignition sources in workshops
• Musculoskeletal injuries from awkward postures and manual handling of components and oil drums
• Environmental contamination from spills, leaks or incorrect disposal of waste oil and filters

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and References
• 3.0 Roles and Responsibilities
• 4.0 Required Qualifications and Training
• 5.0 Tools, Equipment and Materials
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre‑Service Safety Checks and Engine Isolation
• 8.0 Preparation of Work Area and Environmental Controls
• 9.0 Step‑by‑Step Oil Change Procedure
• 10.0 Spill Prevention, Control and Clean‑up
• 11.0 Waste Oil and Filter Handling, Storage and Disposal
• 12.0 Post‑Service Checks, Run‑Up and Leak Inspection
• 13.0 Documentation, Service Records and Tagging
• 14.0 Hazard Identification and Risk Controls
• 15.0 Emergency Procedures and First Aid Considerations
• 16.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS regulations
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Managing risks of hazardous chemicals in the workplace
• AS/NZS 4024.1: Safety of machinery – Series
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• Relevant state and territory environmental protection regulations for waste oil disposal