SOP: AC Clutch

Title
Replacement

• By Anil K. Verma

c Copyright, Confidential, Tata Motors Limited

 Safety Guidelines

1. PPEs are must while working on AC

System of the bus to protect from hit
injuries, burns & ingress of particles in
the eyes

2. Proper Care to be taken as the AC

system components get extremely
heated up in operation.

3. Ignition switch must be off & LOTO to

be used to get protection from accidental
cranking and injuries from rotating parts.
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 AC Clutch Drive Set Assy

AC Alt Belt Tensioner AC Alternator

Drive Belt
AC Alternator
AC Clutch
M16 Nut

Tensioner
spring

Alt Mounting
Adjustable
Bracket
AC Alt Mounting AC Alt & Comp
Hinge Bolt Base Plate
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 AC Clutch Physical Location in the Bus

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 AC Clutch Replacement Procedure

Step 1 : Park the bus inside the Shed

on level surface & place the Wheel
chokes

Step 2 : Switch off the Engine Ignition

Key, Manual Cut-off switch & Use the
LOTO

Step 3 : Remove all the Electrical

connections of the AC Alternator

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 AC Clutch Replacement Procedure

Step 4 : Loose Alternator Belt tensioner

using 24/27 no wrench

Step 5 : Loose the Adjuster & remove

the Alternator drive belt.

Step 6 : Remove the AC Alt adjuster

and It’s mounting on the Alternator
using Spanner 16/17 & 20/22

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 AC Clutch Replacement Procedure

Step 7 : Remove the AC Alternator’s

mounting Bolt from hinge bracket

Step 8 :Loosen main M16 Tensioner nut

using 24 no spanner to remove the belts

Step 9 :Remove main fan from engine

pulley to Alternator

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 Step 10 : Open the center bolt of clutch
assembly using the spanner 18/19 and
16 no socket.

Step 11 : Remove the center nut &

retighten the same nut in clutch
assembly

Step 12 :Hold the assembly with

spanner of 36/41 No & tight the long
bolt using another spanner and
remove the clutch assembly carefully.
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 Step 13 :Refit the clutch assembly
using spanner of 36/41 No & tight the
long bolt using another spanner

Step 14 : Tighten the center nut &

Step 15 : Tighten the center bolt of clutch

assembly using the spanner 18/19 and
16 no socket.

c Copyright, Confidential, Tata Motors Limited

 AC Clutch Replacement Procedure

Step 16 :Fit main fan from engine pulley

to Alternator

Step 17 :Tighten main M16 Tensioner

nut using 24 no spanner to remove the
belts

Step 18 : Tighten the AC

Alternator’s mounting Bolt from
hinge bracket
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 AC Clutch Replacement Procedure

Step 19 : Tighten the Adjuster & remove

the Alternator drive belt.

Step 20 : Tighten the AC Alt adjuster

and It’s mounting on the Alternator
using Spanner 16/17 & 20/22

Step 21 : Tighten Alternator Belt

tensioner using 24/27 no wrench

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 Thanks

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