SAFARI

BRAKES 5 Bypass Valve The Bypass valve is provided in the rear brake circuit between Tandem master cylinder and LCRV. The Bypass valve bypass the LCRV (Load conscious pressure reducing valve) in rear only braking (i.e. front brake failed) condition. The feedback of front brake line pressure is provided to the Bypass valve. In case of front brake failure, the low front line pressure being sensed by the Bypass valve and the 100% brake line pressure from TMC is applied on to the rear brakes with out reduction in pressure. The Bypass valve is located at RH long member of the chassis (between pillar “B” and “C”) on vehicles with ABS system as well as with non-ABS system. The location of Bypass valve is changed to firewall area only for vehicles with ABS system for improving brake pipe layout. Removal of Bypass valve Unscrew the coupling nuts of front and rear brake lines (Fig. 1). During replacement unscrew and remove the Hexagonal bolts holding Bypass valve on mounting. Remove Bypass valve assembly. Installation of Bypass valve Position the Bypass valve on the mounting bracket (Ensure that the bleed screw is at top), screw in the Hexagonal bolts. Tighten the Hexagonal bolts. Connect the front and rear brake lines with the help of coupling nuts, the tightening torque should be 1.4-1.8 kgm. BLEEDING OF BRAKE ACTUATION SYSTEM WITH BYPASS (ABS & NON ABS): Bleeding has to be started first from the point farthest from the master cylinder as per following order. 1 Bleeding of Rear Left Brake 2 Bleeding of Rear Right Brake 3 Bleeding of Front Left Brake 4 Bleeding of Front Right Brake 5 Bleeding of Bypass valve Please note that 1 & 2 can be bled simultaneously if possible. Similarly 3 & 4 can also be bled simultaneously if possible. BLEEDING OF BRAKE WITH ABS For bleeding vehicles with ABS use TATA MOTORS supplied ABS diagnostic software. Follow screen instructions for bleeding and bleed bypass valve at the end manually after all on screen instructions are over. PLEASE NOTE THATWHENEVER FRONT CIRCUIT IS BLED, BLEEDING AT BYPASS VALVE IS MANDATORY. 1. Bleed Screw 2. FromTandemmaster cylinder 3. ToLCRV Fig. 1 1 2 3 4 5 6 4. To Rear Brake Line 5. FromFront Brake Line 6. FromLCRV