This Automotive Refrigerant Service SOP (Safe Operating Procedure) covers the safe recovery, evacuation and recharge of vehicle air conditioning refrigerant using a recovery, recycling and recharging unit. It covers identifying R134a or R1234yf, checking the unit and hoses, full recovery before opening the circuit, vacuum and leak checks, recharging to specification, logging quantities and responding to refrigerant releases. It's written by WHS specialists, aligned to Australian WHS legislation, and fully editable in Microsoft Word.
Who it's for
Automotive air conditioning specialists
Mechanical repair workshops
Auto electricians
Fleet and transport maintenance workshops
Dealership service departments
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
Frostbite and cold burns from liquid refrigerant
Eye injury from refrigerant spray when hoses or fittings are disconnected
Asphyxiation from refrigerant vapour in a poorly ventilated bay or pit
Fire risk from mildly flammable refrigerants such as R1234yf
Toxic decomposition gases from vapour contacting flames or hot surfaces
Hose whip or ejected fittings from opening a circuit before recovery
Cross-contamination from connecting the wrong refrigerant type
Manual handling of refrigerant cylinders and recovery equipment
Crush injury from incorrect use of a hoist, jack or stand
What's included
8 pre-operational checks, from a current refrigerant handling licence and refrigerant type to unit calibration, ventilation and PPE
A 10-step operating procedure covering hose connection, recovery, evacuation, leak checks, oil and dye, recharge and system testing
Isolation and energy control for the pressurised refrigerant circuit, ignition, hoists and stands, and hybrid or EV high voltage compressors
6 shutdown, housekeeping and post-operation steps, including the refrigerant log
Emergency actions for unexpected releases, skin or eye contact, inhalation and refrigerant fires
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 include licence requirements?
Yes. Technicians must hold a current refrigerant handling licence covering automotive air conditioning work before recovering, evacuating or recharging refrigerant.
Does it cover hybrid and electric vehicles?
Partly. The air conditioning service steps apply, but work on high voltage compressors needs the manufacturer's high voltage isolation procedure first, which this SOP doesn't replace.
Is a P2 mask enough?
No. The SOP notes a P2 mask gives no protection against refrigerant vapour, decomposition gases or low oxygen, and that work in a poorly ventilated area should stop until it is ventilated and assessed.
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.
