KENWORTH T680 - MIRRORS SERVICE MANUAL
Contents
1. Na ede E Na aaa 27 Copyrighi Lang Mekra North America 2014 Page 3 of 28 Revised 03 2014 Mele KENWORTH T680 if MIRRORS SERVICE MANUAL 1 MIRROR SYSTEM Precautions When removing and installing the mirror system from to the truck s door make sure the mirror is properly supported to avoid damage to the mirror system truck and personal injury Removal 1 With the mirror system in its nominal position remove the four bolts that secure the mirror system to the truck 2 Carefully disconnect the truck s connector from the old damaged mirror system Pull on Plug Assembly Installation 1 Before inserting the truck s connector into the replacement mirror connector inspect the truck s connector for any damage defects corrosion etc If truck connector appears to be okay then insert the truck s connector into the mirror system s connector if not then refer to the truck service manual for replacement 2 Place the new mirror system against the truck s and secure it to the panel by fastening the four bolts to the specified torque value as specified in the truck service manual Copyright Lang Mekra North America 2014 Page 4 of 28 Revised 03 2014 Mele KENWORTH T680 i MIRRORS SERVICE MANUAL 2 CARRIER GLASS ASSEMBLY Warning Wear protective gloves and safety glasses especially when replacing broken glass 2 1 CONVEX MIRROR GLASS j2. saang a Da A Were PN a UE aa a aa NB 6 3 Housing removal and FEPIACE MOI aksa sasaka aaa d E Emu cana S xu a A CES nux cep aaa a na ap a aja sa a eani EY a aaa NAK 8 eroe ai 9 5 BAN a SIRA E NGA aa a aja aa aa 10 6 Electrical comporient replacement cepere eere ga NDE aaa daa ga aaa E cob ag a aaa aaa a a a ag aa aa 10 anaa kanaka A aaa kaa AN 11 622 TAI SENSOFTEDIACSINS MM ara TI 12 NICS OU ce agak ala ang nah Kabag aab ada na aa ahaaa ti naa a a a a angah 14 6 3 1 NNR nag ana M 14 6 3 2 Heaters WITE aaa ee tt Sa ga a BAN I Tm 15 6 3 3 WIL E Siaga a KUA E A EN ng aa NB IA EE CEU 16 Ba kaa agan Bag Ka a na A wikis Ska aan A 17 6 4 1 Wire pmlayoul aaa anaa aa E aa a a a a BAR aa a a agak 17 6 4 2 Removalof wire Termlhials soe tcd eaa
3. a on aima ama goma aos aima on aon a gos TTET 100011 Copyright Lang Mekra North America 2014 Page 25 of 28 Revised 03 2014 Mele KENWORTH T680 MIRRORS SERVICE MANUAL 9 2 RIGHT HAND PDC mama v 1111 Copyright Lang Mekra North America 2014 Page 26 of 28 Revised 03 2014 KENWORTH 680 i MIRRORS SERVICE MANUAL 10 WARRANTY COVERAGE Lang Mekra provides a warranty for all production and service parts per Paccar Supplier Warranty Agreement Warranty claims must be submitted through Paccar The warranty will cover Functional quality of components Lang Mekra workmanship Confirmed field failures Labor costs for replacement Approved administrative costs The warranty will not cover Glass breakage and other impact which have been abused or mistreated Minor reassembly Unnecessary service Unauthorized product alterations and or additions Unreasonable costs Please do not submit warranty claims for items that have suffered impact Copyright Lang Mekra North America 2014 Page 27 of 28 Revised 03 2014 Mele KENWORTH T680 MIRRORS SERVICE MANUAL Copyright Lang Mekra North America 2014 Page 28 of 28 Revised 03 2014
4. uj Removal 1 Push the main mirror glass inward at the bottom The actuator clutch will allow this manual adjustment of a motorized mirror This will provide enough clearance in order to lift up on the convex mirror to disengage the tabs from the manual socket plate 2 With the flat mirror pushed inward push up on the convex mirror approximately 72 to disengage the tabs on the convex carrier plate from the manual socket plate The convex mirror can now be removed from the mirror housing Disconnect the heating element wires from the heater foil terminals by pulling firmly on the wire connectors to completely free the convex mirror from the mirror assembly Installation Install the replacement convex carrier assembly in the reverse operation of it being removed 5 Inspect the condition of the heating element wires corrosion exposed wire etc before inserting the connectors onto the heater foil terminals If they are in good condition then insert the connectors Note The manual socket plate is fixed to the bezel The illustrations shown below demonstrate how to carefully remove the glass carrier from the manual socket plate 1 SIR Fixed to bezel Copyright Lang Mekra North America 2014 Page 5 of 28 Revised 03 2014 Mele KENWORTH T680 i MIRRORS SERVICE MANUAL 2 2 MAIN MIRROR GLASS The flat mirror glass has the option of being removed with or without having the convex mirror removed H
5. a higher torque is applied then the holes could fracture causing the actuator to become nonoperational HE x n SS 2 LU Ha M RS I P x 2 E N 2 Removal LY 0 Optional Remove the mirror system from the truck see 1 1 Remove the glass and the housing see 2 3 2 Unplug the actuator see 4 and the OAT sensor see 6 3 1 from the bezel 3 Remove the 6 Screws Torx T25 from the back of the mirror and remove the bezel ensure that the wires are not entangled in the bezel when removing the bezel Installation Position the bezel on the arm so that the holes are aligned and install the 2 lowest screws first Position the actuator and install the 4 screws Torque screws to values as shown in the figure above Plug the actuator connector Make sure it is secured with the lever Rout the heater wires and OAT sensor see 6 3 1 VN Re install the glass and housing see 3 2 Copyright Lang Mekra North America 2014 Page 10 of 28 Revised 03 2014 KENWORTH 680 MIRRORS SERVICE MANUAL 6 ELECTRICAL COMPONENT REPLACEMENT 6 1 CONTROL CABLE REPLACEMENT lf your mirror system s electrical components and or heating elements fail then follow the troubleshooting section to determine the problem If the problem can be determined then take the necessary steps to resolve the issue NOTE Do NOT remove the existing control cable at t
6. see 3 amp 2 Plug the mirror and truck connectors together fit the mirror onto the truck and secure it with the four bolts as specified Copyright Lang Mekra North America 2014 Page 11 of 28 Revised 03 2014 Mele KENWORTH T680 MIRRORS SERVICE MANUAL 6 2 SENSOR REPLACEMENT The OAT sensor is located on the Left Hand Mirror driver side Before replacing the sensor check if it is faulty Remove the mirror and test the resistance with an ohmmeter between terminals 5 amp 6 on the connector See the table below to compare the reading against actual temperatures Temp deg C deg F Min Resistance kOhms Nom Resistance kOhms Max Resistance kOhms 5 22 Replacement OAT Sensor Butt Splice Procedure 1 Remove the mirror system from the truck see 1 carrier glass assemblies see 2 and the housing see 3 from the mirror 2 Remove the faulty OAT sensor by cutting the green and blue wires approximately 1 4 before the sensor and appropriately dispose the faulty OAT sensor otrip the ends of the wires on the remaining cable approximately 3 8 from the cut Use butt splice supplied and slide over one of the wires Separate the wire strands in a way that the wires fray as shown in the figure below Push the two wires new OAT sensor amp remaining cable together to intertwine the two wire strands QU VEN ws S9 olide the butt splice over the combined wires and c
7. C R59 6089 102 594120002 PDC 614810003 614810003 PDC 614810004 614810004 PDC R22 6123 100 134810003 PDC 10 R22 6124 100 134810004 PDC HOUSING RH PRIMED WITH CLIPS 154810011 PDC CARRIER ASSY MAIN NH HTD 12 13 14 15 16 17 18 19 154810011 154810012 084803997 094800013 094800014 614800003 614800004 614810008 614810005 204810008 204810015 204810016 204810023 204810024 114810002 21 1 R59 6092 220000 594810001 PDC 2 R59 6093 220000 594810002 PDC 3 R59 6092 221000 594810003 PDC _ 4 R59 6093 221000 594810004 PDC 5 859 6089 02 594120002 0 6 61481000 614810003 PDC 7 614810004 614810004 PDC 8 R226123100 134810003 0 _ nip 10 R22 6124 100 134810004 PDC Se 12 154810011 PDC _ 13 1546402 154810012 PDC 14 084803997 084803997 0 15 094800013 094800013 PDC 16 094800014 094800014 PDC 17 61480000 614800003 PDC 18 614800004 614800004 PDC _ 19 614810008 614810008 PDC 20 614810005 6148100050 _ 21 208008 204810008 PDC 22 204810015 204810015 PDC 23 zo4s10016 204810016 PDC 24 204810023 204810023 PDC _ 25 204810020 204810024 PDC 26 114810000 1148100020 Copyright Lang Mekra North America 2014 Page 24 of 28 Revised 03 2014 Mele KENWORTH T680 i MIRRORS SERVICE MANUAL 9 1 LEFT HAND PDC Ue T a ncm KG R
8. KENWORTH T680 MIRRORS SERVICE MANUAL Copyright Lang Mekra North America 2014 Revised 03 2014 Mieke KENWORTH T680 MIRRORS SERVICE MANUAL FOREWORD Read this manual carefully before operating For the most recent version of this manual visit www lang mekra com If you have any questions contact technical support at Telephone 1 888 MEKRA 40 Fax 803 337 5265 E mail quality lang mekra com NOTE If you have trouble with any portion of this service manual please call our service line at 803 337 5264 and ask for customer service Our hours of operation are 9 00 am 4 00 pm EST Monday Friday These Products may be the subject of Pending U S Patent Applications or may be covered by but not limited to one or more of the following U S Patents or patent applications 8544151 B2 US 20130043362 A1 US 20130092812 A1 61 769 838 Kenworth T680 MIRRORS SERVICE MANUAL 2014 By Lang Mekra North America LLC 2nd Edition January 2014 All rights reserved Any reprinting or unauthorized use without the written permission of Lang Mekra North America LLC is expressly prohibited Copyright Lang Mekra North America 2014 Page 2 of 28 Revised 03 2014 Mele KENWORTH T680 MIRRORS SERVICE MANUAL TABLE OF CONTENTS MEN SYS sk aaa A GG 4 22 Carrier GlaSS aS eM D Y Ae 5 Dila SCOP CCIM Ol Ol lS Sse a aaa MAD aaa A 5 2 2
9. a Lek o Fere a eo 18 6 4 3 Connector t tot 19 7 Heaters troubleshooting aeter m 20 ANY GIG 20 52 a Vii aa hel E Rois 21 Vox Heater CHECKING M A aan a Dan aaa a EN a SE a 21 74 Truck connector CNECKING A A it a 21 8 as saa aas nak a ba Dika iod eee ocu Eae sos devo Vou bsec eee 22 Balt Analys inaa aaa ng eag aa ee 22 aaa a aa divido Era aa DN Baga a aa aga 23 9 35 aaa a Na aa aaa a BAN agan a a Uii Lis 23 8 4 Truck connector 23 9 IG ccc 24 SX MEM Edo e I ajana a a aan aas Ma 25 925 RONCHANO ab dine E 26 10
10. d green wire in between the tab and bezel shown above This will help keep the OAT sensor in place during operation Copyright Lang Mekra North America 2014 Page 14 of 28 Revised 03 2014 Mele KENWORTH T680 if MIRRORS SERVICE MANUAL Right hand bezel opening 6 3 2 Heaters wires Socket Plate Slot Routing 1 Guide both sets of heater wires through the opening located on the right side of the bezel shown above 2 Guide the convex heater wires through the slot located on the adjustable socket plate Insert all four connectors onto the heater foil terminals Note The convex heater wires contain two sets of wires leading into the connector The main heater wires branch off of the convex heater wires Copyright Lang Mekra North America 2014 Page 15 of 28 Revised 03 2014 Mele KENWORTH T680 i MIRRORS SERVICE MANUAL 6 3 3 Actuator wires um i p 1 CES Routing 1 Route the actuator wires between the bezel and the arm 2 Guide the wires along the right side of the arm and insert the connector into the actuator shown above 3 Inserta tie wrap in the location shown above to avoid loose connection during operation Copyright Lang Mekra North America 2014 Page 16 of 28 Revised 03 2014 Mele KENWORTH T680 if MIRRORS SERVICE MANUAL 6 4 ELECTRICAL CONNECTOR 6 4 1 Wire pin layout The wire pin layout does not change for Left Hand Right Hand Manual nor Remot
11. de it out of the slot See below 2 connector sits quite tight and one needs to pull and wiggle the connector in a downward direction until it slides out of the slot Warning Using a lever between the holder and the top of the connector to slide it down can damage the wires connector and connector housing Installation 1 Attach the electrical connector onto the connector housing 2 Slide the connector into the slot provided on the connector housing while pushing the extra cable into the arm 3 Slide the connector until it is locked into place Copyright Lang Mekra North America 2014 Page 19 of 28 Revised 03 2014 Mele KENWORTH T680 MIRRORS SERVICE MANUAL 7 HEATERS TROUBLESHOOTING 7 1 ANALYSIS Mirror will not Heat Remove glass See2 Replace Carrier Glass Assembly POS SMI RF Kit 8 9 10 or 11 see 2 and 9 Is Voltage present at Heater connectors when switch is operated See 7 2 Is the resistance of the heater foil too specification See 7 3 Check connection at terminals Make sure connection is secure Is Voltage present at truck connector when switch is operated See 7 4 Cab internal problem See truck fault finding Work instructions Wire Harness continuity ok See 6 4 1 Replace control cable Kit 2 3 4 or 5 See 9 and 6 1 Check connection at terminals Make sure connection is secure Copyright Lang Mekra North America 2014 Page 20
12. e Mirrors Pin layout is the same for all mirrors See the table below for the wire pin layout tet Hand RightHand Color Function Remote Manual Remote Manual M Bak Heter X X X 2 Wwt AtGrd X X 3 VelomActUR X X _ 4 GreyActUD X X 5 Green X X 6 Bue OAT X X 7 Sealing Plug 8 Black Heater X X X X Add plug e Plug all unused cavities with a sealing plug sealing Plug e The 2 black heater wires have no polarity and can be inserted vice versa at either 1 or 8 e The electrical wire diagram of the left hand mirror system is shown below Except for the OAT sensor green and blue wires the diagram is the same for the right hand mirror 16 AWG BLACK 16 AWG WHITE 18 AWG YELLOW 18 AWG GRAY 18 AWG GREEN 16 AWG BLACK 18 AWG BLUE 16 AWG BLACK 16 AWG BLACK CONVEX MIRROR OAT SENSOR Copyright Lang Mekra North America 2014 Revised 03 2014 1 HEAT MOTOR COMMON 3 MOTOR LEFT RIGHT 4 MOTOR UP DOWN 5 OAT OAT 7 OPEN HEAT Page 17 of 28 Melo KENWORTH T680 MIRRORS SERVICE MANUAL 6 4 2 Removal of wire terminals Note A special tool is required to remove wires from the connector Ref Contact TPA Removal Tool 776441 1 It can be substituted with a modified screwdriver or other 1 Insert the removal tool into
13. ee 6 4 1 bis eference source not found and 6 1 Check connection at terminals Make sure connection is secure Copyright Lang Mekra North America 2014 Page 22 of 28 Revised 03 2014 Mele KENWORTH T680 i MIRRORS SERVICE MANUAL 8 2 ACTUATOR VOLTAGE CHECKING With a voltmeter check if there is 12V when operating the mirror from the truck cab When operating up and down check between and When operating Left and Right check between mE Left Hand Right Hand 1 White Grey 2 crey White 4 White Left Right 8 3 ACTUATOR CHECKING Apply 12V between and the actuator should work up or down Uere 7 LIIN Apply 12V between 3 and the actuator should work left or right 18556 AU AX N ae Down 8 4 TRUCK CONNECTOR CHECKING With a voltmeter check if there is 12V while operating the mirror from the truck cab down check between cavity 2 and 4 Left and Right check between cavity 2 and 3 If no voltage is recorded then problem is inside the cab Copyright Lang Mekra North America 2014 Page 23 of 28 Revised 03 2014 Mele KENWORTH T680 MIRRORS SERVICE MANUAL 9 PDC LIST ITEM 1 KENWORTH P LMNA DESCRIPTION R59 6092 220000 594810001 PDC R59 6093 220000 594810002 PDC R59 6092 221000 594810003 PDC R59 6093 221000 594810004 PD
14. enter it Copyright Lang Mekra North America 2014 Page 12 of 28 Revised 03 2014 Melo KENWORTH T680 i MIRRORS SERVICE MANUAL 8 Apply heat evenly around the length of the tubing from the center and out to the ends until the tubing recovers and the adhesive flows Continue distributing the heat over the butt splice until the solder flows into the wire strands Remove the heat and allow it to cool for a perfect connection 9 Repeat step 4 8 above for the other wire 10 Install OAT sensor as shown in 6 3 1 OOO For Best Results Use a heat device capable of producing a temperature of 500 F When using an open flame do not isolate the flame on one area of the tubing Make sure to distribute the heat evenly Failure to heat the connector until the solder is melted will result in an inferior connection Overheating the connector may cause damage to the tubing The use of a liquid flux is recommended especially with used wire For more information see the following website video available http www calcentron com Pages elektralink elektralink sealed solder connectors html Copyright Lang Mekra North America 2014 Page 13 of 28 Revised 03 2014 Mele KENWORTH T680 i MIRRORS SERVICE MANUAL 6 3 WIRES ROUTING 6 3 1 wires Routing 1 Route the OAT wires between the bezel and arm 2 Insert the OAT sensor into the slot located at the bottom of the bezel as shown above 3 Place the blue an
15. he beginning This cable will be used to guide the new control cable through the mirror s arm into the correct position Procedure 1 2 3 4 5 Control cable Remove the mirror system from the truck See 1 and disconnect the connectors carefully Remove carrier glass assemblies see 2 and the housing see 3 Disconnect all connecters i e actuator heater foils and remove the OAT left hand only from its location Cut the faulty cable wire just before the first heater foil connecters Insert this wire into the flex guard supplied with the replacement kit and tape them tight with electrical tape Insert the terminals of the new wire control cable at the other side of the flex guard and tape them tight Terminals Old Control cable cut Flex guard Pull the old control cable through the arm until all wires of the new cable are outside of the mirror arm Remove the flex guard and tape from the new control cable Insert the terminals ends of the cable into the correct holes on the connector see 6 4 1 and ensure that the holes without wires are plugged with the yellow seal plug Attach the electrical connector back onto the connector housing while pushing the extra cable into the arm see 6 4 3 Rout the wire to the different components Actuator Heater foil OAT sensor left hand only and reconnect the connectors into position see 6 3 Re install the housing and carrier glass assemblies
16. i MIRRORS SERVICE MANUAL 3 HOUSING REMOVAL AND REPLACEMENT Removal 1 Remove the main mirror glass see 2 2 2 The bezel is equipped with an opening and two molded in thumb tabs located at the top of the mirror housing as shown in the figure The opening will give your hand the needed space to push on the thumb tabs which will disengage the housing clips from the bezel tabs 3 Pushonthe top two tabs until the housing clips are completely disengaged from the bezel tabs 4 Once the top two tabs are disengaged the lower clips will disengage from the bezel tabs by pulling the housing away from the arm Installation 1 Position the housing at the back of the mirror 2 Engage the bottom of the housing making sure that the side walls of the housing is inside the lip of the bezel Also ensure the OAT sensor is positioned correctly on the Left Hand Mirror Apply force onto the back cover until all the clips have engaged and the housing is seated correctly Make sure that the side walls of the housing are inside the lip of the bezel MC Copyright Lang Mekra North America 2014 Page 8 of 28 Revised 03 2014 Melo KENWORTH T680 i MIRRORS SERVICE MANUAL 4 ACTUATOR Precautions f you don t have the proper tools for applying the torque shown below then the actuator may become dysfunctional by applying the wrong torque The actuat
17. of 28 Revised 03 2014 Mele KENWORTH T680 if MIRRORS SERVICE MANUAL 7 2 VOLTAGE AT HEATER TERMINALS Check for voltage between the connectors on both sets of connectors when the heater is switched on Measure the resistance of the heater foil in question Compare your measurements with the table below i 4mm ool m uU 7 LL A 7 4 TRUCK CONNECTOR CHECKING When the heater is switched on gt measure voltage between cavities 1 and 8 If no voltage is recorded then problem is inside the cab Copyright Lang Mekra North America 2014 Page 21 of 28 Revised 03 2014 Mele KENWORTH T680 MIRRORS SERVICE MANUAL 8 REMOTE TROUBLESHOOTING 8 1 ANALYSIS Remote Mirror will not move Replace mirror with remote control mirror if remote power mirrors are desired Is the Actuator present To identify it see 8 2 Replace Actuator Kit 1 See 4 Is Voltage present at actuator connector when switch is operated See 8 3 Is Actuator working when voltage is applied directly to the terminals See 8 3 Check connection at terminals Make sure connection is secure Is Voltage present at truck connector when switch is operated See 8 4 Cab internal problem See truck fault finding Work instructions Replace control cable Kit 4 or 5 See Error Wire Harness continuity ok o
18. ors holes are a critical area and if a higher torque is applied then the holes could fracture causing the actuator to become non operational SS GERD 8 d Removal Ng y 0 Optional Remove the mirror system from the truck see 1 4 screws Torx T25 y ll gg LL P nu y 1 Remove the main glass convex optional see 2 2 Remove the Housing see 3 3 To remove the actuator connector from the actuator push the lever on the actuator as shown and pull the wire harness 4 Remove the 4 Screws Torx 25 from the back of the mirror SY NTH fh TAG x Ht a mt Installation Position the actuator correctly See figures below Install the 4 screws Torx T25 torque 2 0 2 8 Nm Plug the actuator connector Make sure it is secured with the lever ow I Re install the glass housing and the mirror system on the truck see 3 2 1 8 3 Torque Actuator Orientation 20 28Nm The Actuator flat side should match the Bezel feature Facing the truck Copyright Lang Mekra North America 2014 Page 9 of 28 Revised 03 2014 Mele KENWORTH T680 if MIRRORS SERVICE MANUAL 5 BEZEL Precautions If you don t have the proper tools for applying the torque shown below then the actuator may become dysfunctional by applying the wrong torque The actuators holes are a critical area and if
19. owever removal of the convex first will provide additional hand clearance to lift up on the flat glass during removal Tab Back view of main mirror glass carrier Removal 1 Push the main mirror glass inward at the top 2 Insert hand from the bottom of glass and press tab down with fingers while pushing glass upwards to disengage tab Push the main mirror glass inward at the bottom Push the main mirror glass up approximately gt to disengage the tabs on the carrier plate from the actuator See note below The main mirror glass can now be removed from the actuator Disconnect the heating element wires from the heater foil terminals by pulling firmly on the wire connectors to completely free the main glass from the mirror assembly Copyright Lang Mekra North America 2014 Page 6 of 28 Revised 03 2014 Mele KENWORTH T680 MIRRORS SERVICE MANUAL Installation 1 Install the replacement main carrier assembly in the reverse operation of it being removed 2 Inspect the condition of the heating element wires corrosion exposed wire etc before inserting the connectors onto the heater foil terminals If they are in good condition then insert the connectors Note The actuator is fixed to the bezel The illustration below demonstrates how to carefully remove the glass carrier plate from the actuator Actuator Copyright Lang Mekra North America 2014 Page 7 of 28 Revised 03 2014 Melo KENWORTH T680
20. the extraction slot in the cap assembly Terminal Position Assurance TPA 2 Hook the removal tool firmly against the edge of the slot and pull on the TPA until it is completely removed from the housing assembly Retain the red cap for use with the connector assembly after the contacts are replaced Modified or Substitute 3 18 mm 125 In Screwdriver TENG LL LLL ML LLL Ld SS Slot in Removal Tool Z Engages TPA Through 7 Removal Tool Slot LLLL LLL 254 Assembly TPA Wi m II I Engagement Notch TPA Locked Position 3 Insert the tip of the contact TPA removal tool into the contact cavity and deflect the contact retention finger Gently pull the wire until the contact is free from the housing Repeat this procedure for the remaining contacts to be removed Retention Finger Contact TPA Removal Tool Rotating the contacts to remove them from the housing without using the extraction tool may damage the housing resulting in reduced contact retention upon subsequent use of the housing More information on the Connector instruction datasheet to download Ctrl Click on the button J With courtesy of DOWNLOAD Copyright Lang Mekra North America 2014 Page 18 of 28 Revised 03 2014 Mele KENWORTH T680 i MIRRORS SERVICE MANUAL 6 4 3 Connector installation Removal 1 Toremove the connector pull down on the connector to sli
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