What energy sources need to be isolated?

All forms of hazardous energy associated with the equipment must be identified and isolated. This includes electrical (mains power, batteries, capacitors), hydraulic (pressurised fluid lines, rams, accumulators), pneumatic (compressed air, gas lines), mechanical (moving parts, springs, flywheels, conveyor belts), thermal (steam, heated surfaces, ovens), chemical (process chemicals, pipelines), gravity (raised loads, counterweights, suspended platforms) and stored or residual energy (capacitors, pressurised vessels, spring-loaded mechanisms). Each energy source must have a documented isolation point and method.

What does AS/NZS 4024.1603 require for LOTO procedures?

AS/NZS 4024.1603 (Control of hazardous energy) sets out requirements for documented isolation procedures, the use of personal locks and danger tags, try-out verification of zero energy, group lockout arrangements for multi-person work, and training for all affected personnel. It applies to all plant where uncontrolled release of energy could cause injury. The standard complements the WHS Regulations requirement for the PCBU to manage risks associated with plant.

Is this LOTO isolation checklist free to use?

Yes. Download and use this LOTO isolation checklist for free. Open the file in your browser and use Print then Save as PDF. No MapTrack account is required. If you want digital isolation permits with electronic lock registers, QR code scanning at isolation points and automated audit trails, MapTrack can help. Book a demo to see how.

How often should LOTO isolation checklists be reviewed and updated?

The LOTO isolation checklist itself should be reviewed at least annually as part of the organisation's safety management system review. Beyond that scheduled review, an immediate update is required after any incident or near miss involving an isolation failure, when new plant or energy sources are introduced, or when changes to legislation or standards affect isolation requirements. AS 4024.1603 requires that procedures for controlling hazardous energy are documented, maintained and reviewed. Keeping checklists current ensures they reflect the actual equipment and energy sources present on site.

Free loto / isolation checklist

Q: What is a LOTO isolation checklist?

A LOTO (lockout/tagout) isolation checklist is a structured form used to ensure that equipment or plant is properly de-energised, locked out and tagged before maintenance, repair or inspection work begins. It documents every energy source (electrical, hydraulic, pneumatic, mechanical, thermal, chemical, gravity and stored energy), the isolation points, lock and tag numbers, and the results of zero-energy verification testing. In Australia, isolation procedures are a requirement under WHS regulations, and a well-completed LOTO checklist demonstrates that the correct process has been followed to protect workers from the uncontrolled release of hazardous energy.

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Free LOTO / isolation checklist (PDF-ready). Covers lock points, energy sources, tags, verification and re-energisation procedure. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a loto / isolation checklist?

A lockout/tagout (LOTO) isolation checklist is a systematic form used to ensure that all hazardous energy sources on a piece of equipment or plant are identified, isolated, locked, tagged and verified as zero energy before any maintenance, repair, cleaning or inspection work begins. It is a critical safety control under Australian WHS legislation, designed to prevent the uncontrolled release of stored energy, which can result in electrocution, crushing, burns, amputations and fatalities. The checklist also documents the re-energisation procedure to ensure equipment is safely returned to service when the work is complete.

Failure to properly isolate equipment is a leading cause of serious workplace injuries and fatalities in Australian industry. The LOTO isolation checklist provides a step-by-step verification process that ensures no energy source is overlooked, every worker applies their own personal lock, and zero energy is confirmed before hands-on work begins. The completed checklist creates a defensible audit trail that demonstrates compliance with AS 4024.1603 and WHS Regulations. AS 4024.1603 (Safety of machinery, Lockout/tagout) and the WHS Regulations 2011, Part 4.6 (Electrical safety), define the minimum requirements for isolation procedures. A completed LOTO checklist with lock and tag serial numbers, isolation point identification and personal verification signatures provides the documented proof regulators and insurers expect during audits and incident investigations.

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Benefits of using this loto / isolation checklist

Worker safety: prevents the uncontrolled release of hazardous energy during maintenance, protecting workers from serious injury or death.
Regulatory compliance: meets WHS isolation requirements and demonstrates due diligence to regulators and auditors.
Complete energy identification: the structured energy source table ensures no energy type is overlooked, reducing the risk of residual energy incidents.
Clear accountability: documents who applied each lock and tag, who verified zero energy and who authorised re-energisation.
Audit trail: signed checklists create a defensible record for safety audits, investigations and insurance claims.
Safe re-energisation: the re-energisation checklist ensures equipment is returned to service only after all personnel are clear and guards are replaced.

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When you move your checklists from paper to MapTrack, you get:

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Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
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Build conditional logic (show or hide questions based on answers).
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Electronic signatures.
Edit forms later without reprinting.
Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).
Escalate critical hazards instantly to safety managers via push notification.
Maintain an auditable safety register that satisfies WHS regulator requests.
Correlate incident trends across sites with built-in safety analytics.

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What to include in a loto / isolation checklist

This loto / isolation checklist covers 8 key areas:

Isolation details: permit/reference number, date, site/location, equipment/plant being isolated and reason for isolation.
Personnel: isolation officer and authorised person.
Energy source identification table: energy type (electrical, hydraulic, pneumatic, mechanical, thermal, chemical, gravity, stored energy), isolation point, isolation method, lock number and tag number.
Pre-isolation checklist (P/F/N/A): all energy sources identified, affected personnel notified, equipment shut down in normal sequence, all isolation points locked and tagged, stored/residual energy dissipated or blocked, zero energy verification completed (try test), isolation register updated, LOTO signage in place.
Overall result: pass, fail or action required.
Isolation verification: verified by, date and time.
Re-energisation checklist: all tools and materials removed, guards and covers replaced, all personnel clear, locks and tags removed by authorised person only, affected personnel notified, equipment restarted and tested.
Sign-off: isolation officer and supervisor signatures.

How to use this loto / isolation checklist

Fill in the isolation details - permit number, date, site, equipment being isolated and the reason for isolation.: Assign a unique permit or reference number for traceability. Record the equipment name, asset ID, location and the specific reason for isolation (maintenance, repair, cleaning, inspection). This information identifies the scope of the isolation event.
Record the isolation officer and authorised person names.: The isolation officer is the competent person who performs the physical isolation. The authorised person approves the isolation and ensures the procedure is followed. Record both names with their roles and contact details.
Identify all energy sources associated with the equipment using the energy source table - document each energy type, isolation point, method, lock number and tag number.: Review the equipment isolation diagram or register. List every energy source: electrical, hydraulic, pneumatic, mechanical, thermal, chemical, gravitational and stored energy. For each source, record the specific isolation point, the method of isolation and the lock and tag numbers applied.
Notify all affected personnel that the equipment is being isolated.: Inform all workers, operators and contractors who may be affected by the equipment being taken out of service. Use a verbal briefing, written notice or toolbox talk and obtain acknowledgement that they understand the isolation is in effect.
Shut down the equipment following the normal shutdown sequence.: Follow the manufacturer or site procedure for normal shutdown. Do not simply switch off at the isolator as this may leave stored energy in the system. Allow the equipment to come to a complete stop before proceeding to isolation.
Apply locks and tags to all isolation points. Each person working on the equipment should apply their own lock.: Use a personal danger lock and tag for each isolation point. Each worker applies their own lock so that the equipment cannot be re-energised until every worker has removed their lock. Use a multi-lock hasp where more than one person needs to lock the same point.
Dissipate or block any stored or residual energy (e.g. bleed hydraulic lines, discharge capacitors, block raised loads).: After isolation, stored energy may remain in the system. Bleed hydraulic and pneumatic lines to zero pressure. Discharge capacitors. Block or pin raised loads, spring-loaded mechanisms or counterweights. Verify that all stored energy has been safely dissipated or restrained.
Perform zero energy verification - attempt to start the equipment (try test) to confirm isolation is effective.: Press the start button or operate the controls to verify the equipment does not start. This try test confirms that all energy sources have been effectively isolated. Return controls to the off position after the try test. If the equipment starts, stop immediately and re-check all isolation points.
Complete the pre-isolation checklist, marking each item as Pass, Fail or N/A.: Work through each checklist item systematically: all energy sources identified, affected personnel notified, equipment shut down, all points locked and tagged, stored energy dissipated, zero energy verified, isolation register updated and signage in place. Mark each as Pass, Fail or N/A.
When work is complete, follow the re-energisation checklist before removing locks and returning equipment to service.: Confirm all tools and materials have been removed, guards and covers are replaced, all personnel are clear of the equipment and accounted for. Each worker removes their own lock only. Notify affected personnel that the equipment is being re-energised. Start the equipment and verify normal operation.

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How often should you complete this checklist?

A LOTO isolation checklist must be completed every time equipment or plant is isolated for maintenance, repair, cleaning, inspection or any other work that could expose workers to hazardous energy. This includes planned maintenance, breakdown repairs, cleaning inside machinery, changing tooling or dies, and clearing jams or blockages. A new checklist is required for each isolation event - even if the same equipment was isolated previously. If additional workers need to work on the equipment, each person must apply their own lock using a group isolation or multi-lock hasp arrangement. Check your organisation's isolation management procedure and your state or territory WHS regulations for specific requirements.

Frequently asked questions

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 4024.1603 - Safety of machinery: Lockout/tagout procedures
OSHA 29 CFR 1910.147 - The Control of Hazardous Energy (Lockout/Tagout)
WHS Regulations 2011, Chapter 5 - Plant and Structures
ANSI/ASSE Z244.1 - Control of Hazardous Energy

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