Operation and Installation Instructions 691 LOCK SYSTEM
Contents
1. 5 MOUNTING 6 AGUADO see he ee oo D us A a ee oe ee e aa d 6 P w r Unit 24 o se ga 2 oR aa des Eee ERR E CR RADARS OO 6 Control Module 6 Ser MEG Sic a aa ue douane dre Cd PRE ed rave ose da 6 PLUMBING 3 lt 4 5 US Us EME Y HAGEL MEd OE e a 7 Single 691 Brake Lock System 7 Dual 691 Brake Lock System 7 3 Channel Anti Lock 691 Brake Lock System 8 4 Channel Anti Lock 691 Brake Lock System 8 WIRING 9 Wining WS UGGS 5 e Le eu dns Re con e re em 9 Connecting External Inputs de 9 Connecting the Vehicle HOM 9 Connecting Power for the Control Module 9 BLEEDING lt lt se male md ame 4064 2 RAR IAE 6 Se 10 Tips on Bleeding Brake Systems 10 Bleeding Procedures 10 11 HORN WARNING CIRCUIT TEST2. 11 691 OPERATING INSTRUCTIONS 11 Using 691 as a LOCK System 11 Using 691 as an Interlock 2 e EN se ENS ARR ee a 12 691 System Installation Checklist Insert BRAKE LOCK APPLICATIONS Wiring Diagram 14 INTERLOCK APPLICATIONS Wiring Diagram 15 TROUBLESHOOTING 16 18 691 MODEL NUMBERS 19 20 691 ACCESSORIES SELF ADHESIVE LABELS NOTE All 691 models include the self adhesive labels shown below Determine which labels are used in your application THIS NOTICE MUST BE AFFIXED ON DASH IN VIEW OF OPERATOR A WARNING Serious inja Operator must read and or death can understand Warnings and occur if these Operating Instructions before instructions are PREVENT using vehicle not followed Form no 81 690 032 This vehicle is equipped with 691 Brake Lock System Operator must read and understand warnings and operating instructions before using vehicle Form no 691 B ra ke Lock 81 690 032 THIS NOTICE MUST BE AFFIXED ON DASH IN VIEW OF OPERATOR Do not use 691 Brake Lock in place of original equip ment parking brake TO LOCK Always apply parking
3. The horn warning circuit must be tested on a regular basis After the system has been activated and is locked momentarily unplug the 2 wire black amp white connector leading to pressure switch 2 stamped 1 800 While unplugged the horn will activate If the horn does not activate during this test determine the cause of the problem and correct before using the 691 Brake Lock System 691 OPERATING INSTRUCTIONS A CAUTION Do not operate power unit without first filling with proper fluid Using 691 as a Lock System Only units with 691 User Interface To Activate Lock System 1 Bring vehicle to a complete stop 2 Set mechanical parking brake 3 Move the user interface lock release switch to the lock position 4 User Interface alarm will sound and then deactivate after reaching locking pressure 5 The locked indicator lamp will come on after locking pressure is reached 6 Apply other provided holding devices NOTE If pressure drops below required system pressure the locked indicator lamp will go off and user interface alarm will activate This process may take only a frac tion of a second A CAUTION If user interface alarm does not sound or fails to deacti vate or if the locked indicator lamp does not remain on discontinue use of the 691 Brake Lock System Determine the cause of the problem and correct before using 11 To Deactivate Lock Device 1 Disengage other provided holding de
4. insulate and seal any of the unused wires Using the Brown Wire as an External Output When activating the 691 System with the user interface the brown wire can be used to signal other circuits It will provide a positive signal up to 1 amp of power to lights relays etc If this current limit is exceeded the output or control module may operate erratically or not at all NOTE The brown wire will not provide an output when the 691 System is activated by the external input of the gray wire This is an inherent design to provide protection from improper wiring A CAUTION If the gray wire is allowed to short to ground the vehi cle brakes will apply Connecting the Vehicle Horn The yellow 691 harness wire must be connected to a horn or other suitable warning device for your application The yellow wire sends a ground signal to sound the horn when necessary 1 On most vehicles the best way to connect this wire without adding a relay is to find the horn wire from the horn switch in the steering wheel This switch typically grounds this wire to sound the horn splic ing in the yellow wire at this point is all that is necessary 2 If splicing into the horn switch wire is not convenient add a relay that is switched by the ground signal from the yellow wire and that connects the appropriate signal directly to the horn itself The yellow wire will provide a ground of up to 1 amp to drive a warning device If this current li
5. use a system pressure of 1 72 2 07 bar 25 30 psi Tips on Bleeding Brake Systems 1 Patience is often necessary Brake fluids can be easily aerated by being forced through tubes too fast or agitating them Once brake fluid has been aerated the best way to get the air back out is to let it sit Several hours or overnight may be necessary While bleeding make every effort to move the fluid slowly This is especially important when applying the brake pedal and when opening bleeder screws Avoid rapid pumping of the brake pedal as it can cause the fluid to become aerated Always wear safety glasses and be cautious when opening bleeder screws with any pressure applied Air pockets will shoot the fluid out at a rapid rate Connect a length of poly style air line from the bleeder screw into a container to recapture the fluid during the bleeding process In some cases gravity bleeding is the best form of bleeding Start bleeding process at the actuators and work toward the foundation brakes Even when the brake system seems to be well bled it may still contain small amounts of air We recommend re bleeding the brake system after the vehicle has been parked overnight 10 Bleeding Procedures NOTE To assure successful brake system bleeding complete all bleeding procedure steps in the order that they are listed Brake System Bleed Point Brake System Bleed Point FIGURE 22 h Disconnect
6. brake and other provided hold 1 Set parking brake ing devices when using 691 System 2 Move lock switch to LOCK position Do not use 691 Brake Lock for overnight or prolonged parking TO RELEASE Release 691 Brake Lock before moving vehicle 1 Move lock switch to RELEASE position 691 Brake Lock and warning circuit are disabled if 2 Release parking brake battery power is lost or disconnected Use in all applications Use in all applications using a user interface THIS NOTICE MUST BE AFFIXED ON DASH IN VIEW OF OPERATOR Serious injury or death can occur if these instructions are not followed Operator must read and understand warnings and operating instructions before using vehicle Form no 81 690 032 This vehicle is equipped with a 691 Brake Lock System that is activated by a remote input Unintended operation of the remote input will cause the brakes to apply or release without warning The operator must understand the function of the remote inputs Be aware of all conditions that will cause the 691 Brake Lock System to activate or deacti vate without user intervention Use in all applications where the 691 System is remotely activated INTRODUCTION Vehicles today have two separate brake systems One is the service brake system and the other is the parking brake system The service brake system is used to slow or stop a vehicle during normal operation The parking brake system is usually cable oper
7. frame must be made to absorb shock and vibration Common methods used to absorb this shock are coiling the brake tubing or using a short length of purchased brake hose Follow procedures outlined by the vehicle manufacturer or SAE specifications 3 Connect the upstream line coming from the vehicle master cylinder to the fluid inlet port on the end of the single actuator Connect the downstream line going to either the front or rear brakes from the side outlet port on the same end of the single actuator See Figure 16 From Master Cylinder port not shown 4 Determine the shape and length of a new piece of tubing to connect the power unit and single actuator See Figure 17 FIGURE 17 Power Unit 5 6 Connect one end of the new tubing to the single actuator Connect the other end of the new tubing to the power unit This connection can be made to either the side or top port Remove the plastic shipping plug from the top port To install line in the side port use 3 16 hex key wrench to move the steel plug from side port to top port Install the remaining brass adapter from the fitting package in the selected port prior to connecting the line See Figure 18 Plug One of These Ports FIGURE 18 LINE FROM MASTER CYLINDER ACTUATOR FRONT WHEELS REAR WHEELS OUTLET Single Brake System with 691 System Dual 691 Brake Lock System FRONT WHEELS LINES FROM DUAL LINES FROM DUA
8. on brown harness wire and or green user interface wire PS1 lock On when system is locked at full pressure Receives ground signal from pressure switch 1 on white wire On when power unit is pressurizing the system Controls user interface audible alarm On whenever any pressure is present in the system Receives ground signal from pressure switch 2 on violet wire On when negative signal is present on gray harness wire Delay Alarm Comes on 9 seconds after activating the system if full system pressure has not been attained horn output Also comes on anytime the power unit runs to repressurize the system The input LED s should be on when receiving their respective signal and off when not Replace the 691 Control Module when this is not observed 16 Cause Solution Test in order indicated When the 691 System is activated the brakes will not lock up and the power unit does not run When the 691 System is activated the brakes will not lock up and the power unit continues to run The 691 System will activate and lock up the brakes but the power unit 48805 running The power unit does not operate to release the brakes when the 691 System is deactivated The brakes release but the 691 Power Unit does not stop run ning 1 No electric power Check the battery fuse and wiring connections 2 High Pressure Switch is inoperative Activate the 691 System If PS1 lock LED is on unplug pressure swit
9. stray signals are not being introduced into the external inputs If the being activated gray wire is not connected to an external input ensure that it is capped off and not shorting to ground inadvertently NOTE While deactivated occa sional operation of power unit and Motor Down LED is normal to relieve pressure caused by thermal expansion of fluid in the power unit While the 691 System is activated 1 Change in temperature has caused the system to contract and reduce the power unit and horn activate brake system pressure intermittently The power unit runs briefly to restore brake system pressure to the original lock up pressure This is considered normal operation as fluid temperature changes 2 The service brake system or 691 System has air in it Bleed service brakes and 691 System 3 Hydraulic leak in either the 691 System or service brake system Inspect all tubing and connectors for leaks and tighten or replace as necessary 4 The power unit is not functioning properly Replace the power unit No test to troubleshoot this condition NOTES 18 691 MODELS AND REPLACEMENT PARTS TABLE 1 System 1 High 2 Low Vehicle Model Description Fluid Pressure Pressure Number Switch Kit Switch Kit E 02 691 223 Dual 1 1 4 SF or BF 20 410 014 02 600 051 02 600 050 02 691 303 3 Channel SF or BF 20 410 014 02 600 051 02 600 050 F 099 691 305 3 Channel SF or BF 20 410 014 02 600 0
10. 0 amp fuse and not a circuit breaker If you have checked no in any of the above boxes that apply to your application determine the reason and correct Complete this section after Installing the 691 System O Yes O No 1 Have the warning labels been installed in the vehicle cab in view of the operator O Yes O No 2 Activate the 691 System Does the power unit run for approximately 4 seconds O Yes O No 3 Deactivate the 691 system Does the power unit run for approximately 6 seconds O Yes O No 4 Remove the cover from the vehicle master cylinder reservoir and activate the 691 system There may be an initial swirl but the fluid level will remain the same unless the system has been improperly plumbed Is the fluid level remaining the same O Yes O No 5 Is the 691 Operation and Installation Manual stored in the cab of the vehicle If you have checked no in any of the above boxes determine the reason and correct MICO is a registered trademark of MICO Incorporated MICO is registered in the U S Patent and Trademark Office as well as in Australia Canada Great Britain Indonesia Japan Peoples Republic of China and South Korea MICO Incorporated MICO West Division 1911 Lee Boulevard Zip Code 56003 2507 701 East Francis Street Zip Code 91761 5514 P O Box 8118 North Mankato MN U S A 56002 8118 P O Box 9058 Ontario CA U S A 91762 9058 507 625 6426 Facsimile 507 625 3212 909
11. 1 User Interface is not installed with this system another visual identifier must be used to inform the operator that the 691 System is locked See sche matic on page 14 PLUMBING Determine the type of brake system on your vehicle refer to pages 3 amp 4 All brake systems in use today require the MICO 691 Actuator s be installed after the anti lock brake valve and combination warning valve if so equipped Contact MICO Incorporated if you have questions Single 691 Brake Lock System LINE FROM MASTER CYLINDER REAR WHEELS FRONT WHEELS Single Brake System 1 Disconnect the existing brake line necessary to install the single actuator Reduce fluid loss by plugging the ports Do not loosen or remove hydraulic lines that are not effected by the installation of the single actuator 2 Determine the length and shape of new or modified brake lines needed to install the actuator The installer must be qualified to modify existing brake tubing or new factory double flared SAE approved brake line must be used When adding or replacing brake lines do not use smaller diameter than existing lines The MICO 691 Actuator is supplied with brass adapters designed to mate with 1 4 inverted flare tube nuts Contact MICO Incorporated or a local brake fitting supplier to obtain proper fittings to install different size lines All new connections or modifications between flexing vehicle sections such as vehicle body and
12. 51 02 600 050 o 02 691 209 Dual 1 1 4 SF or BF 20 410 014 02 600 051 02 600 050 02 691 403 4 Channel SF or BF 20 410 014 02 600 051 02 600 050 BF Brake Fluid HO Mineral Base Hydraulic Oil SF Silicone Fluid Inch diameter of actuator bore Consists of two 1 1 4 inch diameter single actuator Consists of one 1 3 4 inch diameter single actuator and one 1 1 4 inch diameter dual actuator e Consists of one 1 1 4 inch diameter single actuator and one 1 1 4 inch diameter dual actuator e Consists of two 1 1 4 inch diameter dual actuators xx 691 ACCESSORIES Part Description 02 600 038 Remote Reservoir Kit for Silicone Fluid Models 32 820 022 11 Extension Harness from Power Unit to Control 19 User Control Actuator Interface Module Repair Kit 32 585 007 29 585 001 20 460 013 one 02 600 035 32 820 021 20 460 017 one 02 600 041 32 585 007 29 585 001 20 460 018 one 02 600 042 32 820 021 20 460 017 one 02 600 041 32 585 007 29 585 001 20 460 017 two 02 600 041 two 32 820 021 32 585 007 29 585 001 20 460 018 two 02 600 042 two 32 820 021 32 585 007 29 585 001 20 460 017 02 600 041 32 820 021 20 Reservoir Breather Plug 34 001 089 34 001 089 34 001 089 34 001 089 34 001 089 34 001 089 34 001 089 34 001 089 34 001 089
13. 691 System is com Follow procedures outlined in Vehicle Manufac plete 691 System and brake system must be turer s Service Manual or SAE Standards when bled of air Bleed MICO 691 System according to making new connections or adding to existing procedures outlined in this manual Bleed brake brake systems Use only steel brake tubing con system according to vehicle manufacturer s forming to SAE specifications recommendations Vehicle Brake System Always use clean fluid The self adhesive warning labels page 1 ac conforming to vehicle manufacturer s recommen companying each MICO locking device must be dations 691 Power Unit See BEFORE affixed in the vehicle cab in view of operator PROCEEDING page 3 for proper fluid type Keep this manual in the cab of the vehicle after Improper or contaminated fluid may cause gummy installing the 691 System deposits softening and swelling of rubber seals and may render the 691 System inoperative Such a condition must be corrected immediately MICO could not possibly know of and give advice with respect to all conceivable applications in which this product may be used and the possible hazards and or results of each application MICO has not undertaken any such wide evaluation Therefore anyone who uses an application which is not recommended by the manufacturer first must completely satisfy himself that a danger will not be created by the application selected or by the particular model of ou
14. 91 Actuator Position 1 Front axle 2 Rear axle 3 4 wheel Typical Dual System Vertical Split Two independent braking systems One system leads to the front brakes and the other system to the rear brakes Identifying Feature 1 Two lines from master cylinder 2 Combination valve used on some models Position 1 Position 2 Single Actuator Single Actuator FIGURE 6 691 Actuator Position 1 Front axle 2 Rear axle 3 4 wheel Some imported vehicles use two separate air boosted master cylinders Front Wheels Front Wheels 2 A o E E 2 E Front Wheels Front Wheels To Combinotion Worning Valve and Master Cylinder Position 3 Dual Actuator Position 1 Single Actuator Position 2 Dual Actuator FIGURE 7 To Combination Warning Valve and Moster Cylinder Anti Lock Valve Position 3 Dual Actuator Position Position 1 2 Single Actuator Single Actuator FIGURE 8 To Air Hydraulic Boosters Position 1 Single Actuator FIGURE 9 To Combinotion Worning Valve ond or Moster Cylinder 3 Chonnel Anti Lock Valve Position 1 Dual Actuator Position 2 Single Actuator FIGURE 10 To Moster Cylinder 4 Channel Anti Lock Valve Position 1 Position Single Actuator Dual Actuator FIGURE 11 Position 2 Dual Actuator Rear Wheels Rear Wheels Rear Wheels Rear Wheels Rear Wheels Typical Split System 1 1 2 x 1 2 Two i
15. 947 4077 Facsimile 909 947 6054 Web Site www mico com Form No 80 690 039 Revised 3 31 03 Printed in U S A A G e Conson BRAKE LOCK APPLICATIONS 86 87 87a 85 Horn Relay 14 12 VDC EXTERNAL INPUT DIRECT ALARM OUTPUT LOCKED OUTPUT User Interface Schematic Z 2 E 9 _ oa oa lt x O l a E 86 87 30 87 89 Horn Relay YELLOW Wipe 15 12 VDC EXTERNAL INPUT DIRECT ALARM OUTPUT LOCKED OUTPUT User Interface Schematic Before Troubleshooting Unplug wire harness connectors Check to be sure contacts are clean and making good contact and re connect Check the integrity of all wiring at the connectors Also check to be sure all unused wires are properly capped TROUBLESHOOTING Motor Downl LED Display Motor Up Ext PSI lock Alarm PS2 Ext Delay Alarm fniieo 691 Br LED Display Explanation Motor Down On when system is releasing pressure Remains on for three seconds after PS2 goes off On when system has been activated proper signal on Ext or Ext until PS1 comes on Ext On when positive signal is present
16. HEEL ANTI LOCK VALVE Dual Brake Systems with 691 System DUAL DUAL ACTUATOR ACTUATOR z POWER OUTLET POWER INLET OUTLET OUTLET ese REAR WHEELS FRONT WHEELS zg 38 4 Channel Anti lock Brake System with 691 System WARNING Power is supplied to the 691 Control Module at all times To prevent unintended actuation of the 691 System be sure the lock release switch if applicable is in the release position CAUTION Do not operate the 691 Power Unit without first filling the power unit reservoir with proper fluid 691 Wiring Instructions Refer to diagrams on pages 14 amp 15 The 691 System is designed for use on vehicles with a 12 volt DC negative ground system References to ground in this literature refer to vehicle chassis ground which is connected to the negative battery terminal References to hot or positive refer to connection to the positive terminal of the 12 volt DC battery NOTE All positive connections to the battery must be made through a high quality properly rated fuse Do not use a slow blow fuse or circuit breaker Optional extension harness 32 820 022 page 19 is avail able from MICO Incorporated when the control module is not mounted directly to the power unit The supplied wire harness has been designed with sufficient wire length to complete most installations If additional wire is necessary be s
17. L MASTER CYLINDER MASTER CYLINDER WARNING PROPORT I ONING VALVE ANTI LOCK CONTROL VALVE REAR WHEELS REAR WHEELS FRONT WHEELS COMBINATION WARNING VALVE Dual Brake Systems 1 Disconnect the existing rear brake lines necessary to install the dual actuator Reduce fluid loss by plugging the ports Note which master cylinder port supplies fluid to the front brakes and rear brakes Do not reverse the front and rear fluid paths during the installation of new brake lines 2 Determine the length and shape of new or modified brake lines needed to install the dual actuator The installer must be qualified to modify existing brake tubing or new factory double flared SAE approved brake line must be used When adding or replacing brake lines do not use smaller diameter than existing lines The MICO 691 Actuator is supplied with brass adapters designed to mate with 1 4 inverted flare tube nuts Contact MICO Incorporated or a local brake fitting supplier to obtain proper fittings to install different size lines All new connections or modifica tions between flexing vehicle sections such as vehicle body and frame must be made to absorb shock and vibration Common methods used to absorb this shock 3 Channel Anti Lock 691 Brake Lock are coiling the brake tubing or using a short length of System purchased brake hose Follow procedures outlined by the vehicle manufacturer or SAE specifi
18. NG PORT 7 16 20UNF Control Module AE DIA 4 PLACES 00000000 6 9 27 TYP PART NUMBER SERIAL NUMBER 3 8 16UNC 2 PLACES 1 1 4 Diameter Bore Single Actuator 4 SAE PORT FROM MASTER CYLINDER 4 SAE PORT TO BRAKE LINE 4 SAE PORT FROM POWER 8 1 249 DIA TYP 234 5 9 23 1 3 4 Diameter Bore Single Actuator 4 SAE PORT FROM MASTER CYLINDER 4 SAE PORT TO BRAKE LINE 4 SAE PORT FROM POWER UNIT Bloia TYP 7 9 16 User Interface 46 g1 DIA 2 PLACES Remote Reservoir optional See 691 Accessories on page 19 BOSS WITH 3 2 713 DIA WIRE HOLE 5 2 21R 4 PLACES 6 4 25 2 PLACES power unit reservoir Check the CAUTION label around the power unit reservoir breather filler plug to verify fluid type refer to Figure 13 MOUNTING Several self adhesive labels are supplied with each 691 Brake Lock Determine which labels are used in your application and affix in the vehicle cab in view of the operator See page 1 Control Module 1 A mounting bracket is provided with the 691 Control Module to mount the control module directly to the 691 Power Unit See power unit dimensional drawing on page 5 The control module can be mounted on top of the power unit as shown as well as mounted to either side The control mod
19. Operation and Installation Instructions ame MTC READ GENERAL INSTALLATION GUIDELINES SHEET FORM NO 81 600 001 BEFORE PROCEEDING WARNING The MICO 691 System is a supplemental safety 6 Do not use sealants tapes teflon or cement device which provides additional brake holding compounds on any connections or fittings These action when used with existing vehicle parking sealants or compounds can contaminate the brake It is not for dynamic service braking hydraulic brake system and interfere with the The 691 System must be used in combination with operation of brake components or MICO 691 an audible and or visual alarm as a warning to System signal the user of any loss of brake system pres All fittings and connections must be in good sure Do not disconnect warning devices condition and properly torqued All lines fittings and surrounding areas must be Brake hoses brake lines MICO 691 System cleaned of dirt or road residue before any lines or brake components cylinders and all fittings must fittings are disconnected Special care must be be routinely inspected for leaks damage or wear taken so dirt and road residue are not allowed to Proper fluid levels must be maintained In the enter the hydraulic brake system This can con event of any loss of fluid brake system must be taminate the system and interfere with proper carefully inspected for leaks operation of brakes and MICO 691 System When installation of MICO
20. ated and used to hold the vehicle stationary while parked Experience has shown that some vehicle applications re quire more brake holding capacity than provided by prop erly maintained parking brakes The MICO 691 Brake Lock System uses the vehicle service brakes to supple ment the parking brake The 691 System provides pres sure to the service brake system in the same manner as when the vehicle operator presses on the brake pedal The 691 also provides external inputs which can activate the system without direct operator interjection The 691 Brake Lock System consists of The Control Module and User Interface Figure 1 The control module controls operation of the system through the user interface or remote activation The user interface incorporates a manually activated switch audible alarm and locked lamp FIGURE 1 The Power Unit Figure 2 The power unit uses a 12 volt DC pump to produce pressure in the vehicle service brake system to lock the brakes The pump reverses flow to release locking pressure Two pressure switches are located on the power unit The pressure switches sense the pressure that the power unit is producing The high pressure switch starts and stops the pump while pressurizing the sys tem The low pressure switch starts and stops the pump while releasing pressure from the system Although the power unit contains a built in fluid reservoir a remote reservoir is available as an option for sp
21. cations 3 Connect the upstream line coming from the master cylinder to the fluid inlet port on one end of the actua tor Note that the actuator is not directional and does not have a front and rear Connect the downstream line going to the rear brakes from the side outlet port on the same end of the dual actuator See Figure 19 LINES FROM DUAL MASTER CYLINDER ALL WHEEL ANTI LOCK VALVE FRONT WHEELS REAR WHEELS From a 3 Channel Anti lock Brake System The 3 channel anti lock brake system uses both a single and a dual actuator Follow the plumbing instructions for both the Single 691 Brake Lock System and the Dual 691 Brake Lock System to connect the appropriate lines To connect the hydraulic line from the power unit to both actuators either a tee can be added to this line or the plug Master Cynder To in the unused port on the pressure switch manifold can be Brakes removed to accommodate the connection 4 Repeat steps 1 2 amp 3 to install the front brake lines 5 Determine the shape and length of a new piece of tubing to connect the power unit and dual actuator 6 Connect one end of the new tubing to the dual actuator See Figure 20 FIGURE 19 Brakes LINES FROM DUAL MASTER CYLINDER ALL WHEEL FRONT WHEELS REAR WHEELS INLET INLET GLE purket OUTLET ACTUATOR Plug One of These Ports 3 Channel Anti lock Brake System with 691 System 4 Channel Anti Lock 691 Brake Power U
22. ch 1 If pump runs replace pressure switch 1 high pressure switch or check for a short to ground in the wiring The Power Unit or Control Module is inoperative Activate the 691 System If Motor Up LED is on check for 12 VDC at the power unit connector Unplug the power unit and attach a voltmeter to blue to green to the connector leading to the control module If 12 VDC is present replace the power unit If 12 VDC is not present replace the control module The Control Module is not receiving an input signal Activate the 691 System Check Ext and Ext LED s If neither are on check that a ground signal is present at the gray lead in the main wiring har ness or the green lead from the user interface or that a positive signal is present on the brown wire in the main wiring harness If not determine the reason and correct The fluid level in the reservoir is low Deactivate the 691 System Verify that the power unit is mounted level Remove the reservoir breather filler plug and fill the reservoir with proper fluid to within 1 4 of top Reinstall breather filler plug Hydraulic leak in either the 691 System or service brake system Inspect all tubing and connections for leaks and tighten or replace as necessary The actuator is not functioning properly Activate the 691 System Check the vehicle master cylinder reservoir for excessive fluid level This condition indicates that the seals in the actuator a
23. ecial applications Refer to 691 Accessories chart on page 19 FIGURE 2 The Actuator Figure 3 The actuator is a mechanical device that links the hydraulics of the 691 System to the vehicle service brake system The actuator separates the 691 System fluid from the vehicle service brake system Various actuators are available for use in different types of service brake systems FIGURE 3 PRINCIPLE OF OPERATION 1 When the 691 System is activated the control module starts the power unit pumping fluid into the actuator s As the actuator s become pressurized they isolate the vehicle master cylinder and pressurize the service brakes When lock pressure is reached the high pressure switch signals the control module to stop the pump While the pump is stopped locking pressure is held in the brake system If locking pressure drops the high pressure switch signals for the power unit to turn on and restore locking pressure 2 When the 691 System is deactivated the pump reverses and releases pressure The actuator releases pressure from the brakes and opens the ports to the vehicle master cylinder When locked pressure returns to zero psi a signal from the low pressure switch stops the pump NOTE Brake System fluid and 691 Sys tem fluid always remain isolated from one another INSTALLING A 691 SYSTEM BEFORE PROCEEDING There are four steps to installing the 691 System 1 Mounting 2 Plumbing 3 Wirin
24. from the fitting package in the actuator ports and torque 7 9 10 2 N m 70 90 Ib in Power Unit 1 The power unit can be mounted in the engine com partment on the frame rail or in the cab However it must be protected from dirt moisture and possible impact Easy access to the reservoir breather filler plug must be maintained to allow for filling and check ing fluid level The reservoir breather plug must be kept in an upright position If this is not possible a remote reservoir can be installed refer to 691 acces sories on page 19 Mark and drill two 7 16 diameter holes 2 5 16 apart Fabricated mounting brackets can be used Mount the power unit using two 3 8 16UNC bolts and lock washers 691 models designated HO must use mineral base hydraulic oil in the power unit reservoir 691 models designated SF must use DOT 5 silicone fluid in the FIGURE 13 AWS DS Pressure J Switches x X D CAUTION Label lamp Find a mounting location in the cab of the vehicle where A The operator has easy access to the lock release rocker switch B The lock lamp is visible to the operator C It is protected from having something spilled on it D There is easy routing of wires from the 691 Control Module to the user interface 2 The user interface is not necessary for applications where the 691 System is activated by other manual switches or electrical interlocks NOTE When the 69
25. g 4 Bleeding The 691 System must only be installed by someone with good working knowledge of automotive brake and electri cal systems It is important that the installer of the 691 System under stands fluid types used in various 691 Systems Read and understand this instruction manual before installing the 691 Brake Lock System Brake System Fluid For all 691 installations the vehicle s brake system fluid does not change Vehicles currently using brake fluid in the brake system will continue to use brake fluid Vehicles currently using mineral base hydraulic oil in the brake system will continue to use mineral base hydraulic oil 691 System Fluid The two 691 Power Unit designs DOT 5 silicone fluid SF and mineral base hydraulic oil HO assure seal compatibility with your existing brake system NOTE Power unit and brake system fluids do not become intermixed when a 691 System is installed The 691 Actuator s isolate the 691 System fluid from the brake system IDENTIFY YOUR BRAKE SYSTEM Typical hydraulic braking systems in use today vary depending on manufacturer and size of vehicle For in stance a vehicle equipped with a single system may have a firewall mounted booster or possibly a frame mounted remote booster The same holds true for the dual and split systems The rear wheel anti lock system is a dual brake system with an anti lock valve installed All wheel anti lock systems are defined as 3 channel or 4 channel
26. ill absorb shock O Yes O No 5 Is there a proper fluid level of clean appropriate fluid in the power unit reservoir or remote reservoir O Yes O No O N A 6 If an optional remote reservoir is used was the power unit reservoir topped off first O Yes O No 7 Is the vehicle master cylinder reservoir at the full level with proper fluid If you have checked no in any of the above boxes determine the reason and correct Complete this section after Wiring the 691 System O Yes O No 1 Are the wires protected from being hit or kicked and not hanging loose or pulled too tight O Yes O No O NA 2 If additional wire was added is it the correct gauge and color as indicated in the 691 Operation and Installation Manual O Yes O No 3 Trace each wire are all wires either connected to something or properly capped off O Yes O No Did the horn sound during the HORN WARNING CIRCUIT TEST as indicated in the 691 Operation and Installation Manual S O Yes O No O N A O Yes O No O N A O Yes O No O N A O Yes O No O N A O Yes O No If the gray wire is connected to an input does it work properly If the brown wire is connected to an input does it work properly If the brown wire is connected to an output does it work properly If the brown wire is connected to both an input and output do they work properly MN a Is the red wire connected directly to positive battery through a 3
27. k valve s 2 One line from anti lock valve to rear brakes 3 Separate lines from anti lock valve to each front wheel 691 Actuator Position 1 Front axle 2 Rear axle 1 amp 2 4 wheel NOTE Some 3 channel anti lock brake systems use two separate anti lock valves Typical 4 Channel All Wheel Anti Lock System Provides braking control by way of an independent channel for each front wheel and each rear wheel Identifying Feature 1 Two lines from master cylinder to anti lock valve 2 Separate lines from anti lock valve to each of the front and rear wheels 691 Actuator Position 1 Front axle 2 Rear axle 1 amp 2 4 wheel NOTE Some 4 channel anti lock brake systems use two separate anti lock valves DIMENSIONAL DATA 1 1 4 Diameter Bore Dual Actuator 4 SAE PORT BOTH ENDS FROM MASTER CYLINDER 1 4 SAE PORT TO BRAKE LINE 4 SAE PORT pa 2 PLACES FROM POWER UNIT 1 1 1 1 15 0 41 B32 DIA TYP so Li 57 2 2 25 361 2 TYP 14 22 1 3 4 Diameter Bore Dual Actuator 276 1 FROM MAS 4 SAE PORT FRON POWER UNIT 4 SAE PORT BOTH ENDS TER CYLINDER Es 4 SAE PORT TO BRAKE LINE ADIA TYP 2 PLACES 15 0 358 6 14 12 Power Unit 94 7 3 73 _ 49 5 1 95 REF E 4 SAE O RING PORT 7 16 20UNF 2B BRASS BREATHER millimeters inches 112 5 4 43 REF OPTIONAL MOUNTING 691 CONTROL MODULE 4 SAE O RI
28. lease the pedal C Repeat this process multiple times at each bleed point without pumping the pedal in between al 6 Pressure Bleed There are two options for pressure bleeding the brake system either using a commercial pressurized bladder type bleeder or by activating the 691 Power Unit Using commercial bleeder Follow manufacturer s instructions Using 691 Power Unit A Activate the 691 System A CAUTION Be careful when opening the bleeder screw it will be un der high pressure Wear safety glasses B Starting at the actuators and moving outward to foundation brakes open bleeder screw 1 2 turn The 691 Power Unit will run with the re lease of pressure and will stop automatically when the actuator reaches the end of its stroke Most air will come out at end of the actuator stroke C After power unit stops running close the bleeder screw D Deactivate the 691 System After 691 Power Unit stops running slowly depress and release brake pedal 3 to 5 times or until a firm pedal is achieved This step is to replenish the actua tors NOTE The 691 Power Unit will run during first brake application E Be sure the 691 Power Unit reservoir and vehicle master cylinder reservoir remain filled with proper fluid F Repeat steps A thru E at each bleed point until all air is purged before switching to the next bleed point G After the above steps are completed check to see if brake pedal height and feel are the sa
29. me as before the 691 System was installed If the pedal does not feel as firm as before let the vehicle sit for several hours or overnight and repeat pressure bleeding 7 Activate the 691 System Open bleeder screw 1 4 turn See Figure 23 Close bleeder screw when a steady stream of fluid is present Power Unit Power unit Bleed Point Bleed Point WARNING Before moving the vehicle a firm pedal must be achieved when the 691 System is deactivated If a firm pedal is not achieved repeat bleeding procedure for the 691 System and the service brake system until a firm pedal is achieved Make several brake applica tions with vehicle stationary and check fittings for leaks 8 Reconnect horn or other warning devices HORN WARNING CIRCUIT TEST The 691 Control Module provides two alarm wires direct alarm and delayed alarm The direct alarm wire is the white wire in the User Interface cable It provides a ground signal whenever the system is pressurizing It activates the User Interface audible alarm The delayed alarm wire the yellow wire in the main 691 wire harness is also referred to as the horn wire It provides a ground signal if the system takes longer than nine seconds to initially pres surize or anytime the system is re pressurizing The yellow wire must be connected to the vehicle s horn or to a form of warning device that will guarantee that the operator is aware that the system is re pressurizing
30. mit is exceeded or if the yellow wire is connected improper ly the warning device or control module may operate erratically or not at all Be sure to check for proper operation of the horn circuit on a regular basis See page 11 HORN WARNING CIRCUIT TEST Connecting Power for the Control Module 1 Connect the black wire directly to battery negative or equivalent ground This wire carries the full current of the 691 System and must have a good ground If additional wire is necessary for this connection it must be a minimum of 14 gauge wire 2 Connect the red wire to a 30 amp fuse which is connected directly to battery positive This wire also carries full 691 System current Do not connect this through any auxiliary wiring Do not use a slow blow fuse or circuit breaker BLEEDING A CAUTION Vehicle Brake System Always use clean fluid con forming to vehicle manufacturer s recommendations 691 Power Unit Check the CAUTION label on the 691 Power Unit reservoir for proper fluid type Refer to Figure 13 All electrical connections must be completed and the power unit reservoir filled with proper fluid before bleeding The hydraulic brake system must be bled whenever any line has been disconnected Although we recommend the use of pressure bleeding equipment when bleeding the system some vehicle manufacturers do not advise certain bleeding methods Refer to Vehicle Manufacturers bleed ing recommendations When pressure bleeding
31. ndependent braking systems One system leads to the front and the rear brakes and the other system leads only to the rear brakes Identifying Feature 1 Two lines from master cylinder 2 Single hose to each front wheel 3 Two hoses to rear axle 691 Actuator Position 1 Front axle 2 Rear axle 3 4 wheel CAUTION Whether position 2 or 3 is used both halves of system must be locked Typical Rear Wheel Anti Lock System Dual Vertical Split Two independent braking systems One system leads to the front brakes and the other system to the rear brakes Identifying Feature 1 Two lines from master cylinder 2 Anti lock control valve between master cylinder and rear wheels 691 Actuator Position 1 Front axle 2 Rear axle 3 4 wheel Imported Truck 3 Channel All Wheel Anti Lock System Provides braking control by way of independent anti lock channels for each rear wheel and a third channel for the front wheels Identifying Feature 1 Three separate air hydraulic brake boosters 2 One line to front brakes 3 Separate lines to each rear wheel 691 Actuator Position 1 Front axle 2 Rear axle 1 amp 2 4 wheel NOTE The anti lock functions on air booster system not the hydraulic side Typical 3 Channel All Wheel Anti Lock System Provides braking control by way of independent anti lock channels for each front wheel and a third channel for both rear wheels Identifying Feature 1 Two lines from master cylinder to anti loc
32. ng Vehicle make Model Year Vehicle 1 D number Model number of 691 System installed Complete this section after Mounting the 691 System O Yes O No 1 Is the 691 Power Unit mounted upright and level O Yes O No 2 Is the power unit breather plug clean and away from contaminants O Yes O No 3 Can the fluid in the power unit reservoir be easily checked O Yes O No 4 Is the actuator s mounted at a lower level than the vehicle master cylinder O Yes O No 5 Is the actuator mounted horizontally level with bleeder screws facing up O Yes O No 6 Is the user interface if used mounted where it can be easily seen and away from where it will get O N A spilled on If you have checked no in any of the above boxes determine the reason and correct Complete this section after Plumbing the 691 System O Yes O No 1 Are all fluid lines properly connected as shown From a Master Cylinder geo not shown 3 4 port not shown gt To Brakes To Brakes From From Power Unit Power Unit Master Cylinder To Brakes O Yes No 2 Is the unused port on the power unit pump manifold properly plugged Plug One of These Ports O Yes No 3 Have all upward U shapes in the fluid lines where air can be trapped been eliminated Yes No 4 Have fluid line connections between flexing vehicle sections been made using coiled tube or brake hose that w
33. nit Lock System FIGURE 20 FIGURE 21 LINES FROM DUAL MASTER CYLINDER ALL WHEEL ANTI LOCK VALVE 7 Connect the other end of the new tubing to the power unit This connection can be made to either the side or top port Remove the plastic shipping plug from the top port of the power unit To install line in the side port use 3 16 hex key wrench to move the steel plug from side port to top port Install the remaining brass adapter from the fitting package in the selected port prior to connecting the line See Figure 21 FRONT WHEELS REAR WHEELS 4 Channel Anti lock Brake System The 4 channel anti lock brake system uses two dual actuators Follow the plumbing instructions for the Dual 691 Brake Lock System to connect the appropriate lines To connect the hydraulic line from the power unit to both actuators either a tee can be added to this line or the plug in the unused port on the pressure switch manifold can be removed to accommodate the connection LINES FROM DUAL MASTER CYLINDER LINES FROM DUAL MASTER CYLINDER ANTI LOCK COMBINATION WARNING VALVE CONTROL VALVE COMB NAT ON WARNING VALVE POWER UNIT POWER UNIT INLET FRONT WHEELS REAR WHEELS FRONT WHEELS REAR WHEELS INLET INLET INLET INLET ACTUATOR OUTLET OUTLET ACTUATOR LINES FROM DUAL MASTER CYLINDER OUTLET OUTLET ALL W
34. r product that is selected for the application MICO has made every attempt to present accurate information in catalogs brochures and other printed material MICO can accept no responsibility for errors from unintentional oversights that may exist Due to a continuous program of product improvement materials specifications and product documentation are sub ject to change without notice or obligation MICO is a registered trademark of MICO Incorporated MICO is registered in the U S Patent and Trademark Office as well as in Australia Canada Great Britain Indonesia Japan Peoples Republic of China and South Korea MICO Incorporated MICO West Division 1911 Lee Boulevard Zip Code 56003 2507 701 East Francis Street Zip Code 91761 5514 P O Box 8118 North Mankato MN U S A 56002 8118 P O Box 9058 Ontario CA U S A 91762 9058 507 625 6426 Facsimile 507 625 3212 909 947 4077 Facsimile 909 947 6054 Form No 81 690 032 Revised 3 25 04 Printed in U S A A P Const Table of Contents Page SELF ADHESIVE LABELS 1 INTRODUCTION 2 PRINCIPLE OF OPERATION 2 INSTALLING A 691 SYSTEM 3 IDENTIFY YOUR BRAKE SYSTEM 3 4 DIMENSIONAL DATA
35. re allowing 691 System fluid to leak into the vehicle service brake system Refer to TABLE 7 pages 19 amp 20 for the proper actuator repair kit Replace the seals in the actuator NOTE The vehicle brake system may need to be flushed and refilled The power unit is not properly building pressure Replace the power unit no test to troubleshoot this condition High pressure switch is inoperative Active the 691 System If PS2 LED is off replace pressure switch 1 high pressure switch 1 No electric power Check the battery fuse and wiring connections 2 Low pressure switch is inoperative Deactivate the 691 system If PS2 LED is off replace pressure switch 2 low pressure switch 3 The power unit or control module is inoperative Deactivate the 691 System If the Motor Down LED is on check for 12 VDC at power unit connector Unplug power unit and attach a voltmeter to blue to green to the connector leading to control module If 12 VDC is present replace the power unit If 12 VDC is not present replace control module 1 Low pressure switch is inoperative Deactivate the 691 System If the PS2 LED is on replace pressure switch 2 low pressure switch 2 The control module is inoperative Deactivate the 691 System If Motor Down LED is off replace the control module 17 The 691 System and Motor Up 1 The control module is receiving false signals LED come on unexpectedly without Be sure
36. systems To Master Cylinder tion 3 Single Actuator Front Wheels Rear Wheels Position 1 Position 2 Single Actuator Single Actuator FIGURE 5 To Combination Warning Valve and Master Cylinder 1 Identify your vehicle brake system See pages 3 amp 4 2 Be sure you have the correct 691 model number and it contains all the parts Refer to Table 1 pages 19 amp 20 All vehicles currently using automotive brake fluid DOT 3 4 5 or 5 1 in the brake system must use the 691 model numbers designated SF All vehicles currently using mineral base hydraulic oil in the brake system must use the 691 model numbers designated HO 3 Check brake pedal height and feel With the vehicle running push on the brake pedal until there is no more forward movement Measure and record the distance from pedal to floor Brake pedal height and feel will be the same after the 691 System is in stalled refer to Figure 4 FIGURE 4 Check the number of outlet lines from the anti lock control valve To be absolutely sure which braking system your vehicle is equipped with check it Look for identifying fea tures such as dual flex lines at rear axle or front wheels number of master cylinder lines anti lock valve s etc Then compare with the circuits shown in Figures 5 thru 11 Typical Single System One single hydraulic system serving both front and rear brakes Identifying Feature 1 One line from master cylinder 6
37. the vehicle horn and other warning devices Be sure the 691 Power Unit reservoir remains filled with the proper fluid during entire bleeding process Check the CAUTION label on the 691 Power Unit reservoir for proper fluid type Make sure the vehicle master cylinder reservoir is full of fluid specified by the vehicle manufacturer Gravity Bleed After the initial installation DO NOT apply the brake pedal Remove the cap from the master cylinder reservoir One at a time open each bleeder screw in the vehicle brake system beginning with bleeder screws on the actuators and moving outward to the foundation brakes NOTE In some situations to save time all bleeder screws may be opened simultaneously Do not deplete reservoir fluid level When a steady stream of fluid is present close the bleeder and proceed to the next If gravity flow is not obtained within 5 minutes proceed to next step Also check for blocked or crimped lines or loops in tubing where air may be trapped Manual Bleed Manually bleed the brakes depress ing and releasing brake pedal slowly and to disperse fluid through the brake system without agitating it Do not depress pedal when bleeder screw is closed Do not release pedal when bleeder screw is open Bleed 691 Actuators first After actuators are bled continue by bleeding foundation brakes A Open bleeder screw then slowly apply the pedal to the limit of its stroke B Close the bleeder and slowly re
38. ule can also be mounted to position the harness connection in the opposite direction shown 2 When the 691 Control Module is not mounted to the 691 Power Unit an optional 11 wire harness 32 820 022 is available from MICO Inc See page 19 for 691 Accessories Actuator 1 Repeat the mounting procedures for each actuator used in your system 2 Find a location preferably on the frame rail away from heat where the actuator s will mount allowing easy access to brake lines refer to Figure 12 The actua tor s must be mounted horizontally below the level of the vehicle master cylinder The bleeder screws must be in an upright position Relocate the bleeder screws as necessary to maintain upright position Torque bleeder screws 17 6 20 3 N m 13 15 lb ft FIGURE 14 RECOMMENDED ACTUATOR MOUNTING LOCATION INSIDE OR OUTSIDE FRAME RAIL 3 Using the actuator mounting brackets as a template mark and drill four 11 32 diameter holes Fabricated mounting brackets can be used to mount the actua tor s The strength of fabricated brackets must be User Interface 1 A dash mounted user interface is provided for use by the operator in the cab The user interface includes a manually activated switch audible alarm and locked adequate to prevent flexing of brake lines Install the actuator using four 5 16 18UNC grade 5 bolts lock washers and nuts Torque 27 1 33 9 N m 20 25 lb ft Install the brass adapters
39. ure to use the proper gauge When making wire connections soldering and sealing with adhesive lined heat shrink is the recommended method All wires that are not used must be sealed and insulated to keep from shorting to each other or ground Connecting External Inputs Activating the 691 System by use of the user interface rocker switch is not always convenient External inputs can activate the 691 System through the use of external switches dash mounted switches or relays This provides flexibility for manual operation by the user or allows other circuits to activate the brakes External Inputs There are three external inputs available The 691 is activated upon receiving a signal at any of the inputs and does not deactivate until all input signals have been removed Two of the external inputs are activated by a positive sig nal 12 VDC and the third is activated by a negative ground signal The negative input is accessed from the gray wire in the main 691 Wire Harness The two positive inputs are 1 The green wire in the user interface cable 2 The brown wire in the main 691 Wire Harness NOTE These inputs are connected together internally so if one is receiving a positive sig nal the other will also have a positive signal present This is commonly used to provide an external signal to the brown wire when the switch on the 691 User Interface is activated To prevent unintentional activation of the 691 System
40. vices 2 Switch the user interface to release position The locked indicator lamp will deactivate and the power unit will return brake system to static system pressure 3 Release mechanical parking brake Using 691 as an Interlock NOTE The 691 Interlock can be activated by the rocker switch if applicable whether the vehicle s ignition is on or off as long as the battery connection exists To Activate 1 Bring vehicle to a complete stop 2 Set mechanical parking brake 3 Satisfy the conditions that activate remote input To Deactivate 1 Disengage other provided holding devices 2 Deactivate remote input 3 Release mechanical holding devices NOTE To release the brakes in case of an electrical failure complete the following steps A Remove 691 System fuse B Apply other provided holding devices and mechanical parking brake to keep the vehicle from rolling Release residual pressure from 691 System by carefully loosening bleeder screw nearest the power unit inlet port of 691 Actuator Be careful when opening the bleeder screw it may be under high pressure D Disengage other provided holding devices E Release mechanical parking brake 12 691 System Installation Checklist NOTE As you install the 691 System complete this check list Upon completion of the 691 installation retain this checklist with the 691 Operation and Installation Manual Date installed Name of person s installi
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