Kenwood D40-1132-05 User manual

D40-1132-05
CASSETTE MECHANISM ASSY
SERVICE MANUAL
C1999-5 PRINTED IN KOREA
B51-7505-00 (K) 482
Top View
Bottom View
]CASE LIFTER
MOTOR PULLY
(MAIN MOTOR ASS'Y)
A GEAR
(SUB MOTOR ASS'Y)
FFC CABLE
7C GEAR
5B GEAR
6D GEAR
MODE SW
REEL PWB
CM1 MAIN MOTOR ASS'Y
CM2 SUB MOTOR ASS'Y
|PS ACTUATOR PLATE
*EJECT LEVER
‚FLY WHEEL
—MAIN BELT
\CASSETTE CASE

D40-1132-05
2
CONTENTS / DISASSEMBLY FOR REPAIR
CONTENTS / DISASSEMBLY FOR REPAIR.............2
MECHANISM DESCRIPTION ..................................13
ADJUSTMENT..........................................................19
EXPLODED VIEW....................................................20
PARTS LIST .............................................................21
CONTENTS
DISASSEMBLY FOR REPAIR
1.1. GUIDE BRACKET
CAUTION:
This part is damageable during disassembling, and it cannot
be reused.
Disassembling
(a) Note that 0GUIDE BRACKET is locked at three places
shown in figure.
(b) Set the mechanism in "R.PLAY" mode (see 2.1 Manual
Operation).
(c) Push "B" portion strongly upward with a proper tool, and
the Bracket will be unlocked at once.
If the above unlocking failed, break the lock with nippers
(In such a case, take care not to allow debris to enter the
deck.)
Reassembling
(a) From the side of PINCH ROLLER ARM Ass'y, first insert
"D" portion into a hole in 1CHASSIS Ass'y.
(b) Adjusting three locks and "E" portion, push the Bracket
down until it clicks.
(c) Make sure that the Bracket is locked at three places.
(hooks are engaged with the Chassis.)

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3
DISASSEMBLY FOR REPAIR
Disassembling
(a) Rotate 7D GEAR by hand until the position shown in fig-
ure where ‘PACK SLIDER gets stuck to the stopper.
-Position traveling over the PULL.E a little.-
(b) Raising the part shown in figure with a thin edge screw-
driver, push the ‘PACK SLIDER in arrow direction,
avoiding interference with the stopper.
(c) Disengage the boss from the PS ACTUATOR PLATE,
and the PACK SLIDER will be removed.
(d) Further turning CCW the |PS ACTUATOR PLATE,
raise the Guide shown with an arrow while meeting with
the hole in ]CASE LIFTER, and the PS ACTUATOR
PLATE can be removed.
(e) At the same time, remove “PS SPRING from the
]CASE LEFTER (if necessary), and from the |PS
ACTUATOR PLATE.
Reassembling
(a) Rotating 7D GEAR in the deck until the position where a
marker on OP PLATE Ass'y travels over the pulley a lit-
tle.
(b) Hook “PS SPRING to the |PS ACTUATOR PLATE
from the bottom. Meeting the hole with the boss of
]CASE LIFTER, insert a bent portion into a sector hole
in the ]CASE LIFTER (step (b) in previous item).
(c) Under this condition, insert the ‘PACK SLIDER so that
its "A" and "B" portions come out under and above the
]CASE LIFTER respectively.
(d) Insert the boss into |PS ACTUATOR PLATE, and slide
toward the front.
(e) Rotate the D GEAR clockwise to set up the EJECT sta-
tus.
(f) Hook another end “PS SPRING to the ]CASE LIFTER.
(a)
(b)
(d)
(b)
(c)
(d)
‘PACK SLIDER
‘PACK SLIDER
‘PACK SLIDER
|PS ACTUATOR PLATE
|PS ACTUATOR PLATE
|PS ACTUATOR PLATE
]CASE LIFTER
]CASE LIFTER
“PS SPRING
B
A
C
1.2. ‘PACK SLIDER/|PS ACTUATOR PLATE
CAUTION:
The PACK SLIDER is damageable during disassembling, and it cannot be reused. and it cannot be reused.

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DISASSEMBLY FOR REPAIR
1.3. \CASSETTE CASE/]CASE LIFTER
Disassembling
(a) Set the mechanism in EJECT POSITION.
(b) Remove D2x3 CAMERA SCREW.
(c) Push ]CASE LIFTER in arrow direction so that "E" and
"F" portions are disengaged.
Reassembling
(a) Confirm that the mechanism is at EJECT position.
(b) Meeting the holes in ]CASE LIFTER with the holes in
\CASSETTE CASE as shown in figure, assemble these
parts.
(c) Meeting A, B, C with A', B', C' respectively, insert the
Cassette Case obliquely. (Note that "D" portion may get
stuck.)
(d) When the Cassette Case becomes horizontal, confirm that A, B, C are engaged, then adjust fitting at E and F portions in
Fig.(c) in previous item, and insert the Case completely. (Step (c) in previous item) (Fitting is over when no gap is found.)
(e) Tighten 2x3 SCREW.

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5
DISASSEMBLY FOR REPAIR
Disassembling
(a) Open and remove the Washer at the lead edge of
…REEL Ass'y as shown in figure. (The washer is dam-
ageable, and it cannot be reused.)
(b) Raise and remove :REEL CAP/REEL Ass'y.
(c) For ‚FL CAPSTAN Ass'y, open and remove the Washer
in the same manner.
(d) Remove the FL CAPSTAN Ass'y from the bottom (In
such a case, HJP WASHERS may stay on the Chassis,
and take care not to allow them to enter the deck.) (See
Fig.(d) in next item)
(e) Insert a flat-head screwdriver into ∞§PINCH ROLLER
Ass'y as shown in figure, and raise the Ass'y until it
clicks. Thus, it will be unlocked.
(f) Then, remove the Pinch Roller Ass'y by hand.
Reassembling
(a) Insert the …REEL Ass'y into the REEL SHAFT.
(b) Insert "REEL WING SPRING, then a :REEL CAP on
it, and push them until they pass through the REEL
SHAFT.
(c) Under this condition, insert BP WASHER CUT.
(d) Insert the ‚FL CAPSTAN Ass'y into the CHASSIS Ass'y
and lock with GP WASHER (At this time, don't forget to
insert HJP WASHERS.)
(e) The PINCH ROLLER Ass'y is designed so as to be fit by
a force, and therefore insert it into the SHAFT of
1CHASSIS Ass'y at portions F and R.
(f) The PINCH ROLLER Ass'y is designed so as to be fit by
a force, and therefore insert it into the SHAFT of
1CHASSIS Ass'y at portions F and R. Next, press to fit
the Springs attaching to @HEAD PANEL Ass'y at both F
and R in the same manner.
1.4. –REEL Ass'y/‚FL CAPSTAN Ass'y/∞§PINCH ROLLER Ass'y
CAUTION:
As :REEL CAP/∞§PINCH ROLLER Ass'y are damageable during disassembling, they cannot be reused.

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6
DISASSEMBLY FOR REPAIR
1.5. ’REEL PWB Ass'y/ CR DETECTIVE PLATE
Disassembling
(a) Remove four screws as shown in figure.
Remove the REEL PWB Ass'y, can be removed.
Reassembling
(a) Align the marking of the MODE SW on he REEL PWB
Ass'y with a square hole, as shown in fig(a).
(b) IN reassembling, adjust the REEL PWB Ass'y so that the
first tooth of &OP PLATE gear enters between two pro-
trusions that can be seen through a window, then adjust
four screw positions.
(c) Tighten four 200 2 X 2.2CAMERA SCREW. (previous
Fig.(a))
1.6. 5B GEAR/6C GEAR/7D GEAR
Disassembling
(a) As these Gears are fit forcibly, to remove the Gears.
raise them from the bottom with a flathead screw driver
while taking care not to damage other parts.
(b) As for the disassembling order, first remove 6C GEAR,
then 5B GEAR or 7D GEAR. (Removed parts cannot
be reused.)
Reassembling
(a) Fit the B GEAR forcibly with a small gear side facing up
while meshing with A GEAR ( CM2 SUB MOTOR Ass'y).
(b) Fit the D GEAR forcibly with a small gear side facing
down while meshing a small gear with the gear of &OP
PLATE Ass'y.
(c) Fit the C GEAR forcibly with a small gear side facing
down while meshing a small gear with D GEAR and also
a large gear with B GEAR.
In any case after fitting, confirm that the Gears rotate
smoothly.

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DISASSEMBLY FOR REPAIR
1.7. CM2 SUB MOTOR Ass'y
Disassembling
(a) Break the solders of two wires (violet and gray) of M
CONNECTOR WIRE.
(b) Remove two screws. (Assume that the GEARS were
already removed.)
Reassembling
(a) Insert CM2 SUB MOTOR while taking care not to allow
A GEAR to interfere with the edge of 1CHASSIS Ass'y.
(b) In such a case, meet screw holes with holes in the
CHASSIS as shown in figure.
(c) Tighten E42 X 3 TAMS SCREW.
(d) Solder lead wires of M CONNECTOR Ass'y.
1.8. —MAIN BELT/ CM1 MAIN MOTOR
Disassembling
(a) Disengage —MAIN BELT while :taking care not to dam-
age the back of Belt.
(b) Break the solders of two wires (red and brown) of M
CONNECTOR WIRE connected to CM1 MAIN MOTOR.
(c) Remove two screws. (Assume that the GEARS were
already removed.)

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8
DISASSEMBLY FOR REPAIR
Reassembling
(a) Insert CM1 MAIN MOTOR into a hole in 1CHASSIS
while taking care not to damage the surface.
(b) In such a case, the direction of terminals should be as
shown in figure.
(c) Tighten two pieces of E42 X 3TAMS SCREWS.
(d) Insert lead wires from under the terminals, and solder
them.
(e) Engage the MAIN BELT in the order given in the figure.
(For 12only pass the belt under them.)
(f) After engagement, check if the Belt is twisted. If it is twist-
ed, straighten the Belt with plastic tweezers, etc. Do not
use a metallic tool, which could damage the belt.
In engaging the Main Belt, do not bring the Main Belt in
contact with the edge of metallic parts to prevent a nick
or scratch.
1.9. &OP PLATE/(S.B PLATE
Disassembling
(a) Move &OP PLATE to the front end position.
(b) Remove KPK COLOR SCREW.
(c) Dismount (S.B PLATE.
Reassembling
(a) Insert bent portion A of S.B PLATE into a rectangular
hole A' in 4MAIN PLATE.
(b) Insert portion B with a pin into a slot B' of OP PLATE
Ass'y.
(c) Insert portion C into a hole C' in 1CHASSIS.
(d) Tighten KPK COLOR SCREW.
(e) Moving the &OP PLATE Ass'y to the front and rear,
check for smooth movement.

9
D40-1132-05
DISASSEMBLY FOR REPAIR
1.10. &OP PLATE Ass'y
Disassembling
(a) Remove DCAMERA TAPPING SCREW.
(b) Remove &O.P PLATE HOLDER.
(c) Slide the O.P PLATE HOLDER in arrow direction todis-
engage from the pin A and take it out.
Reassembling
(a) Align studs B, C, and D on 1CHASSIS Ass'y Ass'y with
pin E of @HEAD PANEL Ass'y.
(b) Adjust _EJECT LEVER position to the corner of hole in
the Chassis as shown in figure.
(c) Mount &O.P PLATE Ass'y so that the boss F of ™FR
PLATE enters a slot of O.P PLATE Ass'y. (At this time,
the O.P PLATE Ass'y will be oblique because it rides on
the EJECT LEVER.)
(d) Under this condition move the part of OP PLATE Ass'y in
arrow direction, and the OP PLATE Ass'y will be locked
by the EJECT LEVER. (If not locked, with this part held
in arrow direction, move the OP PLATE to the front and
rear.)
(e) Moving the OP PLATE to the front and rear, confirm that
the EJECT LEVER is engaged and disengaged.

10
D40-1132-05
DISASSEMBLY FOR REPAIR
1.11. ™7FR PLATE/¡FR GEAR
Disassembling
(a) These parts will be removed when &OP PLATE Ass'y is
removed.
Disassembling
(a) Mount ¡FR GEAR on the boss of ™FR PLATE.
(b) Insert this boss into portion B between 1CHASSIS Ass'y
and 4MAIN PLATE, and insert pin C of CHASSIS Ass'y
into a hole in the FR PLATE. Under this condition, shift
the FR PLATE so that the boss D meets a hole in the
CHASSIS Ass'y.
(c) From the back side, check the assembling condition with
the CHASSIS Ass'y.
1.12. =P GEAR/9P.G PLATE
CAUTION:
These parts cannot be reused, and they should be scrapped
after removed.
Disassembling
(a) Insert a flat-head screwdriver under the Gear and raise it
to remove the Gear from 9P.G PLATE.
(b) Slide 4MAIN PLATE up to the position shown in figure.
(c) Turn and remove 9PG PLATE downward (upward of
CHASSIS).
Reassembling
(a) Adjust the MAIN PLATE to the position in previous step
(b).
(b) Insert a hex. portion of 9PG PLATE into a hole, and
meet a hole in the Plate with a hole in the CHASSIS
Ass'y. (In such a case, insert the PG PLATE in the direc-
tion as shown, and turn it to adjust both holes.)
(c) Fit forcibly the p GEAR into a hole in PG PLATE.
(d) Moving the MAIN PLATE, make sure that the PG PLATE
moves smoothly.

11
DISASSEMBLY FOR REPAIR
D40-1132-05
1.13. _EJECT LEVER
Disassembling
(a) Slide _EJECT LEVER until it gets stuck at the rear.
(b) Move it to the left, and it will be removed.
Reassembling
(a) Mount the Eject Lever Ass'y so that its portion A comes
under the 1CHASSIS Ass'y as shown in figure.
(b) Push the Ass'y so that C, D, E, F portions enter C', D', E',
F' portions respectively.
1.14. @HEAD PANEL Ass'y
Disassembling
(a) Pull @HEAD PANEL Ass'y in arrow direction to disen-
gage hooks at three positions of CHASSIS, then raise it
upward.
Reassembling
(a) Adjust 4MAIN PLATE so that its hole positions in the
center of Chassis as shown in figure.
(b) Mount the Head Panel Ass'y on the CHASSIS Ass'y
while taking care of four points shown in figure. (Leave
parts under the Ass'y positioned in the center, where
they may be in unstable state.)
(c) Slide the Ass'y in arrow direction. (If it does not slide
smoothly, unstable parts mentioned in step (b) may be
shifted to either side. In such a case, raise the Ass'y and
correct parts with tweezers, etc.)
(c) When all portions enter properly, the EJECT LEVER will contact the side surface of CHASSIS then slide it to the front as it is.
(d) Check if the EJECT LEVER falls by gravity. (If it cannot slide or does not fall by gravity, it will be stuck or de formed Check the
EJECT LEVER.)

12
DISASSEMBLY FOR REPAIR
D40-1132-05
1.15. HD1 P HEAD/$HEAD SP PLATE
Disassembling
(a) Remove two CADJUST SCREWS.
(b) Thus, HD1 P HEAD and $HEAD SP PLATE will be
removed.
Reassembling
(a) Insert ADJUST SCREWS into p HEAD/HEAD SP PLATE
in this order.
(b) Insert a flexible cable into a hole A of @HEAD PANEL
Ass'y as shown in figure.
(c) Under this condition, insert ADJUST SCREWS as
shown, then tighten the screws.
1.16. 4MAIN PLATE
Reassembling
(a) Following the disassembling flowchart, if there are parts
to be removed, shift 4MAIN PLATE in arrow direction,
so that they can be removed.
Disassembling
(a) Insert portions A and B into 1CHASSIS Ass'y and
mount the Main Plate on the CHASSIS, avoiding sticking
at both ends, as shown in figure.
(b) Under this condition, slide the Main Plate while pushing
the portion C (so that it slides under the CHASSIS).
(c) Confirm that the Main Plate moves smoothly.

13
D40-1132-05
MECHANISM DESCRIPTION
2.1. DESCRIPTION OF MANUAL OPERATION
Naturally, this mechanism operates under microprocessor control, and manual operation may cause a trouble.
However, manual operation will be necessary for repair, etc. and in such a case, perform as follows.
2.1.1 Position in Each Mode
The mode can be oonfirmed from the fact that which marking written on the REEL PWB Ass'y the tab attaching to the
OP PLATE Ass'y points out.
2.1.2 Manual Operation in Each Mode
To move a mechanism manually in each mode, rotate the D GEAR by hand. (In such a case, wear gloves for easier
operation and for protection of GEARS.)
In a manual operation, take extreme care not to damage GEARS, and to prevent later malfunction of mechanism.
To change mode from EJECT to other mode, rotate
the D Gear in CCW direction as shown in figure.

14
D40-1132-05
MECHANISM DESCRIPTION
Fig.1
Fig.2
2.2. OPERATIONAL DESCRIPTION
2.2.1 PACK IN PLAY
Pulling in a cassette tape
(a) lnsert a cassette tape in the arrow direction as shown in Fig.1.
(b) The Pack Slider is pushed, and the *EJECT LEVER Ass'y is
moved via the PS |ACTUATOR PLATE as shown in Fig.2.
(f) At this time, the OP PLATE Ass'y has been locked by the
EJECT LEVER Ass'y and therefore the EJECT LEVER rmoves,
too. (Fig.3)
(h)At the same time, a bent part of \CASSETTE CASE inserted in
a slot of EJECT LEVER Ass'y shown in Fig.4 slides along the
slot, so that the CASSEITE CASE lowers.
(c) The *EJECT LEVER is pushed and the EJECT SW is turned OFF.
(d) The microprocessor detects this and drives the CM2 SUB-MOTOR Ass'y.
(e) The SUB-MOTOR Ass'y rotates CW, and a driving force is transmitted via 567B/C/D GEAR to move the &OP PLATE Ass'y.
(g)The EJECT LEVER Ass'y moves the |PS ACTUATOR and ‘PACK SLIDER (reverse motion of (b) to pull in a cassette tape.

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15
MECHANISM DESCRIPTION
(i) On the other hand, the OP PLATE rotates the MODE SW because it meshes with the GEAR. Thus, the micro-
processor detects the MODE SW and it stops the Sub Motor at the F PLAY (or R PLAY) position.
(j) The cassette tape is placed in PLAY mode.
Reel Rotation
(k) As the OP PLATE moves, along its slot the (SB PLATE
performs a seesaw motion in the center of A. Thus, the
SB PLATE reciprocates the 4MAIN PLATE in arrow
directions.
(l) As the MAIN PLATE moves, the 9PG PLATE moves like a seesaw along the Z-shaped slot and the slot in
the Chassis.
(m)The =P GEAR on PG PLATE meshes with …REEL Ass'y and ‚FL CAPSTAN Ass'y. (In the order of 123)

MECHANISM DESCRIPTION
(n) The MAIN MOTOR Ass'y drives the FL CAPSTAN Ass'y
via the belt, and consequently the FL CAPSTAN Ass'y
rotates the REEL Ass'y.
Head UP and Pinch Roller
(o) The @HEAD PANEL Ass'y is moved by the OP PLATE while the HP GUIDE PIN Shown in figure slides along the slot in OP
PLATE, then the HEAD moves UP.
(p) When the HEAD PANEL is placed at the PLAY position, the boss of PR ACTUATOR is locked by the MAIN PLATE and the
PR Actuator is swung to the F side (or R side).
(q) At the same time, the PR SPRING is also swung, so that the PINCH ROLLER is pushed against the CAPSTAN.
(r) The CAPSTAN is driven as shown in step(n), and therefore the PINCH ROLLER pushed against the Capstan pulls the tape to
feed it out by means of this pinching force.
D40-1132-05
16

D40-1132-05
17
MECHANISM DESCRIPTION
2.2.2 EJECT (in PLAY/FF/REW/PAUSE mode)
(a) Rotate the CM2 SUB MOTOR in CCW direction to drive the &OP PLATE Ass'y via 567B/C/D GEAR.
(b) At the position shown in figure, the *EJECT LEVER Ass'y is locked so that it moves together with the OP PLATE Ass'y.
(c) The \CASSETTE CASE is moved up along a slot of
EJECT LEVER in reverse motion of EJECT PLAY.
(d) The |PS ACTUATOR PLATE is pushed by the EJECT
LEVER Ass'y, then it rotates to push out the PACK
SLIDER.
(e) Thus, a cassette tape is pushed out by the ‘PACK
SLIDER.
2.2.3 Direction Change
(a) Which direction FWD or REW should be changed to is
determined by the microprocessor that has saved current
mode according to the MODE SW position, then the CM2
SUB MOTOR is rotated CW (REW FWD) or CCW
(FWD REV).
(b) The &OP PLATE is moved via 567B/C/D GEAR.
(c) Two modes FWD and REV are attained by the OP PLATE
that reciprocates as shown in figure, and accordingly, the
(SB PLATE moves like a seesaw along this slot to recip-
rocate the 4MAIN PLATE.
(d) Hence, FWD (or REV) motion is executed by the operation
after step m) in 2.2.1(l).

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18
MECHANISM DESCRIPTION
2.2.4 FF/REW (FF from PLAY; REW in parentheses)
(a) The CM2 SUB MOTOR rotates CCW to drive the &OP PLATE via A GEAR and then 567B/C/D GEAR.
(b) A boss of ™FR PLATE enters a slot in OP PLATE and it is positioned, then the =F GEAR meshes with the …REEL Ass'y
and ‚FL CAPSTAN Ass'y. ( FF/REW are attained through reciprocating motions in these two modes.)
(c)A driving force of FL CAPSTAN Ass'y is transmitted to the REEL Ass'y via F GEAR.

D40-1132-05
19
ADJUSTMENT
(b)Adjustment
Assemble the tape deck into the radio set. (As the tape
speed will vary a little depending on the radio set, the
speed should be adjusted with the radio set in which the
deck is actually used.)
Connect the output to the frequency counter, and play the
test tape mentioned above with the deck set in FOR-
WARD mode.
Insert a screwdriver into a speed adjusting hole of the
motor, and rotate a little so that its tip enters VR for
adjustment.
Rotating slowly the screwdriver CW or CCW, adjust the
frequency to 3 kHz.
3.1.2 Azimuth Adjustment
(this adjustment is necessary if head was replaced.)
(a) Tools required
Test tape
1ABEX TCC-153(10 kHz)
2Mirror tape such as TEAC MTT-902
Screw locking bond
(b) Adjustment
Playing the mirror tape in FWD mode, rotate screw A
and Bso as to eliminate a curl at the guides on both
ends of head while looking into the mirror.
Play the tape in REV mode. and make adjustment in the
same manner.
Connect the head output to electronic voltmeter, and
insert the TCC-153 tape. Play the tape in FWD mode,
and search the point where the output becomes maxi-
mum while rotating the screwA. Then, play the tape in
REV mode, make adjustment in the same manner while
rotating the screwB.
Further, reverse the tape, and in FWD and REV modes
respectively, search the point where the output of L and
R channels becomes maximum.
To lock the screws, apply the bond to periphery of both
screws.
3.1 Adjustment
3.1.1 Tape Speed Adjustment
(this adjustment is necessary if main motor was replaced.)
(a) Tools required
Test tape ABEX TCC-112 (frequency 3 kHz)
Ceramic screwdriver (tip 1.2mm)
Frequency counter
Radio set

D40-1132-05
DPX-5000
58
56
57
52
53
54
44
CM1
CM2
25 21 24
45
23
65
65
66
66
67
67
33
32
10
11
1
31
30
9
9
HD1
17
15
4
22
12
12
20
5
6
7
26
48
48
49
27
893
94
61
94
92
75
D
N
GH
CC
F
B
E
E
E
B
G
H
N
D
Ax2
Ax2
K
J
J
1
2
3
AB
Parts with exploded numbers larger than 700 are not supplied.
D40-1132-05
20
EXPLODED VIEW