International 405 Standard Service Manual Version 4
Contents
1. 4 2589150C2 584005010 PDC BRACKET ASSY BLK STD HTD RH lt 4 2505275C3 584004002 PDC BRACKET ASSY BLK STD RH o 5 2589153C2 584005012 PDC_ BRACKET ASSY BLK STD HTD RH W LKD 5 2505278C3 584004004 PDC BRACKET ASSY BLK STD RH W LKD 5 2505291C4 584004008 PDC BRACKET ASSY BLK STD CB RH W LKD_ 5 2589154C2 584005016 PDC BRACKET ASSY BLK STD HTD CB RH W LKD _ 614051210 PDC 6 2589243C3 614052220 PDC STD MIRR HEAD MANUAL HTD 8 2505813C2 404055700 PDC STD FLAT GLASS PLATE ASSY_ o 8 2505814C2 404055800 PDC STD FLAT GLASS PLATE ASSY HTD 9 2505815C2 404065204 PDC STD CONVEX GLASS PLATEASSY 9 2505816C2 404065304 PDC STD CONVEX GLASS PLATE ASSY HTD CLAMP KIT BLACK S 2507274C1 624059999 PDC CLAMP KIT BLACK 2506235C91 204001611 PDC FASTENER KIT 2509065C91 614000001 PDC Upper Holder Kit LH 2509068C91 614000004 PDC Upper Holder Kit LH No CB Ground 2509066C91 614000002 PDC Upper Holder Kit RH 2509069C91 614000005 PDC Upper Holder Kit RH No CB Ground 2509067C91 614000003 PDC Upper Holder Kit RH with Lookdown Attachment Version 4 0 For the most recent version of this manual visit www lang mekra com GO O1 01 O1 C1 P IAIA P Fax 803 337 5265 Page 18 If you have any guestions please contact Lang Mekra Technical Suppo2. Changing Upper Fastener Kit Removing or Adjusting Look Down Mirror Removing Attaching or Adjusting Mirror Head Mirror Plate Exchange Removing Mirror Plate Mirror Plate Exchange Installing Mirror Plate General Maintenance amp Cleaning Tips Troubleshooting amp Repair Bracket Does Not Fold Back Bracket Folds Back Too Easily Mirror Movement Analysis Wiring amp Connections Control Cable Replacement CB Cable Replacement Mirror Heat Analysis Flowchart Mirror Heat Analysis Surface Finishes Warranty Coverage Available Service Parts Illustrations Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 Flip Out Arm Mirror A Bracket E r Look Down Mirror Main Mirror Convex Mirror For the most recent version of this manual visit www lang mekra com Page 3 If you have any guestions please contact Lang Mekra Technical Support LANG www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 G 1 Removal of Complete Bracket Assembly 1 Remove antenna from antenna base in J Holder CB Antenna 2 Disconnect control cable and CB cable inside the cab Mount 3 Remove 3 screws from upper holder using a T 40 driver Be sure to hold the mirror steady to prevent damage or personal injury Important DO NOT use the flip out arm as a handle to Look Down Mirror hold or carry th
3. should be torqued to 10 N m using a T 30 driver If you still encounter difficulties contact the Lang Mekra Technical Support center at 1 888 MEKRA 4 U EN C Jl J Center Pivot Screw Ly 0009 Clamp Screws 9000 I Center Pivot Screw Version 4 0 For the most recent version of this manual visit www lang mekra com Page 12 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 T 3 1 Wiring amp Connections Mirror Head Internal Wiring Oe oe o Control Cable Schematic Heater Ground peter oo Version 4 0 For the most recent version of this manual visit www lang mekra com Page 13 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 T 4 1 Mirror Heat Analysis Flowchart Lang Mekra strongly suggests the use of a test unit to simplify troubleshooting available through the International Service Parts group Are all cables connected and No Connect Cables amp Route Properly See section W 2 for details routed properly Yes Remove Mirror Plate See Manual G 4 1 Yes Yes Are heater wires attached No Attach Heater Wires Are heater termi
4. If you have any guestions please contact Lang Mekra Technical Support LANG www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 International Standard Series Mirror System Manual Version 4 0 For the most recent version of this manual visit www lang mekra com Page 1 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 Product Features Customer Support a Replaceable Components Toll Free Support Hotline 1 888 MEKRA 4 U a Minimal Diagnosis amp Repair Time Web Accessible Service Manuals a Spring Loaded Fold Away amp Product Updates www lang mekra com a Independent Main and Convex Mirror Adjustment E Mail a Self Regulating Heaters quality lang mekra com Fax 803 337 5265 These Products May Be The Subject of Pending U S Patent Applications or May Be Covered By One or More of the Following U S Patents 4 991 950 5 110 196 5 137 247 5 196 965 385 243 5 687 035 387 317 Version 4 0 For the most recent version of this manual visit www lang mekra com Page 2 G 1 G 2 1 G 2 2 G 3 G 4 1 G 4 2 G 5 Vdd T 1 2 T 2 T 3 1 T 3 2 T 3 3 T 4 1 T 4 2 T 5 Warranty W 1 W 2 W 3 Version 4 0 If you have any questions please contact Lang Mekra Technical Support LANG www lang mekra com Contents General Procedures Removal of Complete Bracket Assembly
5. and lookdown mirror plates Version 4 0 For the most recent version of this manual visit www lang mekra com Page 8 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 G 4 2 Mirror Plate Exchange Installing Mirror Plate To Install the Mirror Plate 1 Attach wire terminals to back of new mirror plate 2 Place glass between mirror housing and bezel Align locking clips on bezel with mirror housing Make sure all the clips are inside the housing 3 Press mirror plate into housing firmly ensuring that all clips lock into place i Note The procedure is the same for main convex and lookdown mirror plates Version 4 0 For the most recent version of this manual visit www lang mekra com Page 9 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 G 5 General Maintenance and Cleaning Tips There are two main types of mirror glass 1 surface and 2 surface Each type has different properties 15 surface glass has an exposed reflective surface 2 surface glass has a shielded reflective surface When cleaning 1 surface mirror glass abrasive cleaners or brushes should be avoided Excessive abrasion may damage the reflective surface 2 surface glass can be scra
6. are periodically updated Be sure to check the after market part listings available through International for the latest revisions to this list LM Aftermarket Int l Part Part Part Description E _584052003 PD _ MIRROR SYS STD LHBLK 1 assaensoss saeosazs P00 hao Ssom Sanda strc LH Manual Heated CB 3561590C97 994052008 PDC MIRROR SYS STD RH CB BLK 2 voaesress 904058012 POG_ MIRROR SYS STO HTL 594052004 PDC MIRROR SYS STD RH BLK_ caceees Gee SST LI 2 3602840C3 _504053014 PDC MIRROR SYS STD RH HTD BLK wW LKD 2 3602841693 _504053018 PDC _ MIRROR SYS STD RH HTD CB BLK W LKO 2 2588604C93 594052024 PDC_ Mirror System Standard 960Bracket RH Manual Heated CB Version 4 0 For the most recent version of this manual visit www lang mekra com Page 17 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com oo 250630004 584004029 PDC BRACKET ASSY BLK HTD RMT LTD CB PREMIUM LH 3 2505276C4 584004005 PDC__ BRACKETASSY BLK STD CBLH lt 3 2589149C2 584005009 PDC BRACKET ASSY BLK STD HTD LH lt 3 2505274C3 584004001 PDC_ BRACKET ASSY BLK STD LH lt 4 2589152C2 584005014 PDC BRACKET ASSY BLK STD HTD CB RH _ lt 4 2505277C4 584004006 PDC BRACKET ASSY BLK STD CB RH _ o lt
7. ary replace the control cable as indicated in the flowchart Always perform a continuity check see T 3 1 on the control cable and confirm the fault before attempting to replace the control cable If the control cable functions properly the mirror head assembly flat or convex must be replaced See G 3 for details T 5 Surface Finishes For the black version the paint on the bracket and other metal parts is a flexible weather resistant powder coating This coating CCE Heater Wires Heater Wires requires no topcoat If the paint is chipped or otherwise damaged a matching wet paint may be used if the surface is properly prepared Version 4 0 For the most recent version of this manual visit www lang mekra com Page 15 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email guality lang mekra com Fax 803 337 5265 W 1 Warranty Coverage Lang Mekra provides a warranty for production parts covering materials and workmanship Warranty reimbursement includes part replacement repair time at accepted labor rates and reasonable administrative costs The time period of the warranty coverage and specific terms are determined by International The warranty will cover The warranty will not cover a Functional Quality of Components a Glass Breakage and Other Impact Abuse Mistreatment a Lan
8. e mirror 4 Remove the 3 screws from the lower holder using a T 40 driver Lower P Holder Flip Out Arm Version 4 0 For the most recent version of this manual visit www lang mekra com Page 4 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 G 2 1 Changing the Upper Fastener Kit Important hold the mirror and bracket system in place firmly throughout this process to avoid damaging the door or the mirror 1 Remove fastener kit using a 13 mm socket and a 6 mm allen wrench Hold the mirror in place to prevent it from falling 2 Assemble upper fastener kit as shown 3 Hand tighten nut on bolt Torque nut to 10 N m 7 3 ft lbs Important DO NOT use the flip out arm as a handle to hold Upper Holder or carry the mirror MENNE E DAN om N CB Antenna Mount Flip Out Arm Version 4 0 For the most recent version of this manual visit www lang mekra com Page 5 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 G 2 2 Removing or Adjusting Look Down Mirror To remove or adjust the look down mirror use a 6 mm allen driver and 13 mm socket at the Importa
9. g Mekra Workmanship a Minor Re assembly a Confirmed Field Failures a Unnecessary and or Improper Service a Labor Costs for Replacement a Unauthorized Product Alterations and or Additions u Reasonable Administrative Costs u Unreasonable Costs Please Do Not Submit Warranty Claims for Items That Have Suffered Impact Parts Returned Exhibiting Impact Damage Will Be Denied Coverage and May Be Returned Freight Collect Lang Mekra reserves the right to inspect submitted warranty claims Upon satisfactory performance and history dealers fleets and other end users may be granted coverage based on description alone Evaluation points will include a Complete and Accurate Claim Descriptions a Use of Appropriate Replacement Parts a Absence of Rejected Claims Version 4 0 For the most recent version of this manual visit www lang mekra com Page 16 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 W 2 Available Service Parts All warranty replacements should utilize the appropriate service part or parts Unnecessary replacements are not covered by warranty The list below represents all parts currently available for service and after market use relating to the International Standard Series mirror system The reference number given corresponds to the illustrations following in W 3 Please note that the illustrations and parts information
10. nals secured No See Manual T 4 2 Yes Yes Cab Internal Problem Is function through bracket control cable ok See Manual T 4 2 See Manual T 3 1 Replace Glass Plate Assembly No Replace Control Cable See Manual G 5 2 Yes Is continuity of bracket Is function from mirror head ok See Manual T 4 3 Yes Replace Flat or Convex Mirror Head Assembly control cable ok See Manual T 3 1 No See Manual G 3 Version 4 0 For the most recent version of this manual visit www lang mekra com Page 14 If you have any guestions please contact Lang Mekra Technical Support LANG www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 A T 4 2 Mirror Heat Analysis 1 2 Follow the flowchart in T 4 1 to diagnose mirror heat problems Remove the mirror glass according to G 5 1 Check to ensure the mirror is heated Heater terminals are present on the back of the glass Make sure all cables and connections are tight Check to see if the heater terminals are secure See Illustration If not replace the glass plate assembly Using a tester unit or supplying power to the bracket cable according to T 3 1 test the function of the heat by applying power to connector inside the cab If the mirror functions properly the fault is cab internal If the mirror does not function properly the problem is located within the mirror system Check the connections and if necess
11. nt DO NOT use the flip out arm as a handle to hold or carry the mirror look down mirror nut and bolt Nominal setting for the look down mirror nut and bolt is 14 N m 10 ft lbs The flip out arm is attached by a bolt with a 4 mm allen head torqued to 3 N m 2 ft lbs Flip Out Arm Nut amp Bolt Upper Holder i N VINA l LEY Look Down Mirror Nut amp Bolt ee NN AOA Version 4 0 For the most recent version of this manual visit www lang mekra com Page 6 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 G 3 Removing Attaching or Adjusting the Mirror Heads From the Bracket To Adjust Mirror Head Angle On the Tube 1 Loosen the two clamp screws using a T 30 driver To prevent the mirror from sliding down hold it in place while removing the screws 2 Adjust mirror head to desired position Tighten clamp screws to 10 N m Main Mirror j Head U i in Clamp a _ Clamp MAKE SURE THE OPTIMUM VIEWING ANGLE Convex Mirror IS ASSURED FOR THE DRIVER OF THE VEHICLE Head AT ALL TIMES To Remove Mirror Head Loosen the two clamp bolts using a T 30 driver To prevent the mirror from sliding down hold it in place To Attach Mirror Head 1 Place the mirror head on the bracke
12. ntire system foldaway force should be between 190 amp 320 N When the detent is in the nominal position the detent spring should be almost fully compressed T 1 2 Bracket Folds Back Too Easily If the bracket folds back too easily check the following 1 Upper fastener kit G 2 should be torqued to 10 N m 7 3 ft lbs If the upper fastener kit is too loose tighten it to the specified torque 2 Ensure the lower pivot is in the correct detent position The arrow on the front outer surface of the holder should align with the arrow on the tube connector Version 4 0 For the most recent version of this manual visit www lang mekra com Page 11 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U T 2 Mirror Movement Analysis Email quality lang mekra com Fax 803 337 5265 Currently International Standard Series mirrors are not offered with a remote control option The mirrors are manually adjusted If any difficulty is found when attempting to adjust the mirror or if the mirror will not hold its position check the following 1 Remove the mirror plate according to G 4 1 2 Ensure there are no obstructions or foreign objects blocking movement of the mirror head 3 Ensure all components are present and in proper working order see illustration 4 Check the torque setting of the fasteners The center pivot screw should be set at 9 N m The clamp screws
13. rt LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 2509070091 614000006 PDC Upper Holder Kit with Lookdown Attachment No CB Ground 614003501 PDC 19 2507656C91 614003502 PDC_ FLIPOUTARMKITRIGHT Version 4 0 For the most recent version of this manual visit www lang mekra com Page 19 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 W 3 Illustrations 1 2 3 4 5 Version 4 0 For the most recent version of this manual visit www lang mekra com Page 20 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 12 ae SS sm x KO l 3 o Am cre For the most recent version of this manual visit www lang mekra com Page 21 If you have any guestions please contact Lang Mekra Technical Support LANG www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 Version 4 0 For the most recent version of this manual visit www lang mekra com Page 22
14. t and hand tighten the bolts at the mounting clamp 2 Adjust the mirror to the optimum position for the driver 3 Tighten the two bolts at the mounting clamp to 10 N m from the bottom Version 4 0 For the most recent version of this manual visit www lang mekra com Page 7 If you have any guestions please contact Lang Mekra Technical Support a www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 G 4 1 Mirror Plate Exchange Removing Mirror Plate Your Lang Mekra mirror system is equipped with a durable To Remove the Mirror Plate mirror plate The mirror glass is reinforced with anti shatter 1 Use a small flat head screwdriver to push in the adhesive to minimize splintering in the event of breakage We locking tabs thru the access slots along the mirror strongly recommend the prompt replacement of damaged housing Do not use the screwdriver to pry the mirror plates mirror plate 2 Start pushing in the tabs near the corner of the If you have a heated mirror be careful not to damage the mirror then continue around the mirror while pulling wiring or the heater connections when changing the mirror lightly on the mirror bezel plate especially when detaching heater wires from the mirror 3 Pull the mirror bezel away from the housing If the plate Kate e lot tor mirror is heated detach the heater wires Do not cut the wires locking tabs Note The procedure is the same for main convex
15. tched but the reflective surface will not be damaged A standard glass cleaner and a soft clean cloth should be used to clean the mirror surface To verify whether you have 1 or 2 surface glass place an object such as a pen on the glass surface Angle the pen to one side so that you can see the tip If there is a gap between the tip of the object and the tip of the image your glass is 2 surface If there is no gap between the tip of the object and the tip of the image your glass is 1 surface 1 Surface Glass 2 d Surface Glass Reflective Object Reflective Object Surface Surface N Image Image Version 4 0 For the most recent version of this manual visit www lang mekra com Page 10 If you have any guestions please contact Lang Mekra Technical Support LANG A www lang mekra com Tel 1 888 MEKRA 4 U Email quality lang mekra com Fax 803 337 5265 T 1 1 Bracket Does Not Fold Back or is Difficult to Fold Back The mirror brackets are equipped with a fold away feature sometimes referred to as a break away system The mirrors will fold forward or backward manually or upon impact This feature minimizes damage to the mirror system and the door The upper holder is designed to give the bracket stability However the upper fastener kit may sometimes require adjustment See G 2 to service the upper fastener If the break away force is too high difficult to fold back you may loosen the nut in the lower holder The e
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