INSULATION 4853133 - Caterpillar

Place the machine on a firm level surface free of obstacles.
Connect the analyzer tool.
Start the engine.
Using analyzer, navigate to Diagnostics >> System >> Brk Pedal Prs.
Release the park brake.
Pump the service brake several times slowly.
Wait for 10 seconds approximately (analyzer should read less than 103 kPa (15 psi).
Apply the service brakes with a single pedal press to full travel.Note: This is the point where maximum boost pressure is reached inside the boost section.There will be a defined force change and the analyzer should read 5378 to 5861 kPa (780 to 850 psi) for the TL943D, TL1055D, and the TL1255D. Or 6205 to 6550 kPa (900 to 950 psi) for the TL642D.
Illustration 6 g06072683
(A) Measure the distance from the pedal to fire-wall
(B) Free play with engine running is 0.0 to 3.0 mm (0.00 to 0.12 inch)Note: Remove the floor mat before measuring the distance from the pedal to fire-wall.
Illustration 7 g06072684
Have an assistant measure the distance from the back of the pedal arm to the cab fire wall. This distance should be greater than or equal to 38.1 mm (1.50 inch) for the TL943D, TL1055D, and the TL1255D. Or greater than or equal to 50.8 mm (2.00 inch) for the TL642D. Refer to Illustration 7.
If the pedal distance is less than 38.1 mm (1.50 inch) for the TL943D, TL1055D, and the TL1255D or less than 50.8 mm (2.00 inch) for the TL642D, check the pedal free play. If the free play is correct, then purge the brake system. If free play exists, it may be adjusted to zero free play in the following steps :
Illustration 8 g06072702
(C) Locknut
(D) Push rod
(E) Push rod gap
(F) Stop ring
(G) PistonNote: Push rod gap can be measured only with booster fed pressure.
Piston (G) must be in the full back position, making contact with stop ring (F).
Piston (G) is moved against the stop ring (F) by the booster pressure. When the booster is not fed, piston (G) cannot return completely against the stop ring (F). This occurrence could cause an incorrect gap measurement.Free Play Adjustment
Note: Do not adjust when the engine is off. Over adjustment of the free play may result in brake drag.
Slide boot up to reveal locknut (C) and push rod (D).
Start the engine to supply boost pressure and ensure that the push rod is fully returned to the stop ring (F).
Loosen locknut (C) to 17.0 mm (0.67 inch). Swivel the push rod first clockwise to shorten it (to be sure it was not previously over-adjusted), and then counter-clockwise to lengthen it until it contains the piston (G). Use only the finger effort to adjust. To achieve the free play as shown in Illustration 6, the push rod gap (E) must be 0.0 to 0.5 mm (0.00 to 0.02 inch).
Hold the push rod (D) with a suitable tool and tighten the locknut (C). Reinstall the boot.
Ensure the proper service brake operation.Brake Bleeding Procedure
Air in the system will not allow the brakes to apply properly. There is one brake bleeder on the brake valve and two service