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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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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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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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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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.