Panasonic AJD440 - DVCPRO PLAYER User manual

Sec. 1 Maintenance
Sec. 2 Mechanical Adjustment
Sec. 3 Major Mechanism Parts Replacement
and Adjustment Procedures
This material is mentioned about procedures of Mechanical Adjustment and Replacement for DVCPRO
product. Please refer to below indicated table, which models apply to this material.
TYPE Category Models
A25M Studio VTR AJ-D440, AJ-D450, AJ-D640, AJ-D650, AJ-D750, AJ-D850
B25M Camera Recorder AJ-D200, AJ-D210, AJ-D215, AJ-D400, AJ-D610, AJ-D700,
AJ-D700A, AJ-D800, AJ-D800A, AJ-D810, AJ-D810A
C25M Lap-top & Portable AJ-D220, AJ-D230, AJ-D230H, AJ-D250, AJ-LT75, AJ-LT85
D25M 4X Transmitter AJ-DE77, AJ-D780
E50M Studio VTR AJ-D940, AJ-D950, AJ-D950A
F50M Camera Recorder AJ-D90, AJ-D900W, AJ-D900WA, AJ-D910WA, AJ-PD900W,
AJ-PD900WA
G50M Portable AJ-D92, AJ-D94, AJ-D95DC
ORDER NO. VSD9912M914
D20/D25
© 2000 Matsushita Electric Industrial Co., Ltd. All rights reserved.
Unauthorized copying and distribution is a violation of law.
DVCPRO MECHANISM
2nd Issue

WARNING
This service information is designed for experienced repair technicians only and is not designed for use by the general public. It does not
contain warnings or cautions to advise non-technical individuals of potential dangers in attempting to service a product.
Products powered by electricity should be serviced or repaired only by experienced professional technicians. Any attempt to service or
repair the product or products dealt with in this service information by anyone else could result in serious injury or death.
CONTENTS
Section 1
1. Maintenance Parts Schedule Charts..........................................................................1-1
2. Parts and Sensor Location.........................................................................................1-3
3. DVCPRO Test Fixture & Tool Kit List..........................................................................1-5
4. Alignment Tapes........................................................................................................1-9
5. Cleaning Procedures............................................................................................... 1-11
Section 2
1. Name of Tape Transportation.....................................................................................2-1
2. Table of Test Point .....................................................................................................2-2
3. Mechanical Adjustment Procedures......................................................................... 2-11
4. No Tape Loading Procedures ..................................................................................2-52
5. Test Point and VR Location for CAMERA RECORDER ...........................................2-53
Section 3
1. Major Mechanical Parts Replacement and Adjustment Procedures...........................3-1
2. Connector Location..................................................................................................3-26

MAINTENANCE
CONTENTS
1. Maintenance Parts Schedule Chart.............................................................................................. 1-1
1-1. Type of VTR (except Camera Recorder)................................................................................... 1-1
1-2. Type of Camera Recorder ........................................................................................................ 1-2
2. Parts and Sensor Location........................................................................................................... 1-3
2-1. Type of VTR (except Camera Recorder)................................................................................... 1-3
2-2. Type of Camera Recorder ........................................................................................................ 1-4
3. DVCPRO Test Fixture & Tool Kit List............................................................................................ 1-5
4. Alignment Tapes............................................................................................................................ 1-9
4-1. DVCPRO Alignment Tape......................................................................................................... 1-9
4-1-1. VFM3580KM (NTSC) .................................................................................................. 1-9
4-1-2. VFM3581KM (NTSC) .................................................................................................. 1-9
4-1-3. VFM3582KM (NTSC) .................................................................................................. 1-9
4-1-4. VFM3380KM (NTSC) .................................................................................................. 1-9
4-1-5. VFM3583KM (NTSC) .................................................................................................. 1-9
4-1-6. VFM3680KM (PAL) ................................................................................................... 1-10
4-1-7. VFM3681KM (PAL) ................................................................................................... 1-10
4-1-8. VFM3682KM (PAL) ................................................................................................... 1-10
4-1-9. VFM3480KM (PAL) ................................................................................................... 1-10
4-1-10. VFM3683KM (PAL) ................................................................................................... 1-10
5. Cleaning Procedures....................................................................................................................1-11
5-1. Cleaning of Head Chips : (Daily)..............................................................................................1-11
5-2. Cleaning of Drum Lead : (Weekly)...........................................................................................1-11
5-3. Cleaning of A/C Head : (Weekly).............................................................................................1-11
5-4. Cleaning of Pinch Roller and Capstan : (Weekly).....................................................................1-11
5-5. Cleaning of Post : (Weekly) .....................................................................................................1-11

1-1
1. Maintenance Parts Schedule Charts
1-1. Type of VTR ( except Camera Recorder ) Hours of Use (unit hours)
Name Apply 2,000H4,000H6,000H8,000H10,000H12,000H
Tape Path Cleaning 25M, 50M "C" Clean the Tape Path at each 500 hours
1Cylinder Ass’y25M, 50M RRRR RIM
2Pinch Arm Unit 25M, 50M R, G R, G R, G R, G R, G IM
3Cleaning Arm Unit 25M, 50M RRRR RIM
4S,T Reel Rotor Unit 25M, 50M R (50M) R (25M) R (50M) R (25M) IM
5Thrust Screw Unit 25M, 50M R, L (50M) R, L R, L (50M) R, L (25M) IM
6S1 Loading Arm Unit 50M RIM
7T1 Boat Unit 50M RIM
8S5 Post Base A Unit 50M RIM
9Tension Arm Unit 50M RIM
10 Mechanism Unit 25M, 50M R
11 Front Loading Unit 25M, 50M R
12 Fan Motor 25M, 50M Replace the Fan Motor at each 10,000 hours Operation Hours
The following parts are included in the mechanism chassis. Therefore usual replacement is not necessary if the
mechanism unit is replaced. Hours of Use (unit hours)
Name 12,000H
13 A/C Head IM
14 Loading Motor (1) AU IM
15 Reel Drive Motor Unit IM
16 Mode Switch Unit IM
17 Pinch Solenoid IM
18 S,T Brake Solenoid IM
19 Distinction SW Unit IM
20 Cleaner Solenoid IM
21 Main Cam Gear IM
22 Front Loading Motor F
"R":These parts are replacement parts.
"IM":These parts are included in Mech. Chassis Unit. Replacing Mech. Chassis Unit is recommended.
"F":These parts are included in Mech. Chassis.
"G":Wipe the old grease and apply new grease. (Use Molytone Grease)
"L":The lubrication is necessary.
"C" :This mark means cleaning is necessary.
<Note>
Hours of Use are based on the head rotation
hours.
Hours of Use are recommendation. It may
depend on temperature, humidity or dust.
Hours of Use are listed as the reference of
maintenance. They do not mean guaranteed
hours.

1-2
1-2. Type of Camera Recorder
Hours of Use (unit hours)
Name Apply 2,000H4,000H6,000H8,000H10,000H12,000H
Tape Path Cleaning 25M, 50M "C" Clean the Tape Path at each 500 hours
1Cylinder Assy’y25M, 50M RR R R IM
2Pinch Arm Unit 25M, 50M R, G R, G R, G R, G R, G IM
3Cleaning Arm Unit 25M, 50M RRRR RIM
4S,T Reel Motor Unit 25M, 50M R (50M) R (25M) R (50M) R (25M) IM
5Thrust Screw Unit 25M, 50M R, L (50M) R, L R, L (50M) R, L (25M) IM
6S1 Loading Arm Unit 50M RIM
7T1 Boat Unit 50M RIM
8S5 Post Base A Unit 50M RIM
9Tension Arm Unit 50M RIM
10 M cassette Brake (S,T) AU 25M, 50M RIM
11 Mechanism Unit 25M, 50M IM
The following parts are included in the mechanism chassis. Therefore usual replacement is not necessary if the
mechanism unit is replaced.
Hours of Use (unit hours)
Name 12,000H
12 A/C Head IM
13 Loading Motor (1) AU IM
14 Mode Switch Unit IM
15 Pinch Solenoid IM
16 S,T Brake Solenoid IM
17 Cleaner Solenoid IM
18 Main Cam Gear IM
"R":These parts are replacement parts.
"IM":These parts are included in Mechanism Unit. Replacing Mech. Chassis Unit is recommended.
"F":These parts are included in Mechanism Unit.
"G":Wipe the old grease and apply new grease. (Use Molytone Grease)
"L":The lubrication is necessary.
"C" :This mark means cleaning is necessary.
<Note>
Hours of Use are based on the head rotation
hours.
Hours of Use are recommendation. It may
depend on temperature, humidity or dust.
Hours of Use are listed as the reference of
maintenance. They do not mean guaranteed
hours.

1-3
2. Parts and Sensor Location
2-1. Type of VTR (except Camera Recorder)
Tape Detect
LED
Tape Beginning
Detect Sensor
T-Reel FG
Sensor
S-Reel
FG Sensor
Dew
Sensor
Tension
Sensor
Tape End
Detect Sensor
Reel Position Sensor
1. Cylinder Ass’y
20. Cleaner Solenoid 13. A/C Head
14. Loading Motor (1) AU
16. Mode SW Unit
17. Pinch Solenoid
5. Trust Screw Unit
18. T-Brake Solenoid
18. S-Brake Solenoid
4. S-Reel Rotor
4. T-Reel Rotor Unit
15. Reel Drive Motor Unit
9. Tension Arm Unit
8. S5 Post Base A Unit
7. T1 Boat Unit 3. Cleaning Arm
21. Main Cam Gear
6. S1 Loading Arm
Unit 2. Pinch Arm Unit
19. Distinction SW Unit

1-4
2-2. Type of Camera Recorder
15. Pinch Solenoid
5. Trust Screw Unit
4. T-Reel Motor Unit
2. Pinch Arm Unit
18. Main Cam Gear
Tape Detect
LED
Tape Beginning
Detect Sensor
T-Reel FG
Sensor
S-Reel
FG Sensor
Dew
Sensor
Tension
Sensor
Tape End
Sensor
17. Cleaner Solenoid
1. Cylinder Unit
12. A/C Head
13. Loading Motor (1) AU
MIC Connector
16. T Brake
Solenoid
16. S Brake
Solenoid
4. S-Reel Motor Unit
3. Cleaning Arm Unit
8. S5 Post Base A Unit
6. S1 Loading Arm Unit
7. T1 Boat Unit
9. Tension Arm Unit
14. Mode SW Unit
10. M Cassette Brake (S) AU
10. M Cassette Brake (T) AU

No.
P/N(NTSC) P/N(PAL) JIG & EQUIPMENT
AJ-D750 AJ-D700 AJ-D650 AJ-D640
AJ-
AJ-D220 AJ-D200 AJ-LT75
AJ-
AJ-
AJ-
AJ-D950 AJ-D780 AJ-LT85 AJ-DE77 AJ-D210
PURPOSE
General Jigs
1
VFK71A
---->
Dial Torque Gauge 1.5cN-m (150g)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Reel Break Force Confirmation
2
VFK0357
---->
Eccentric Screwdriver (1.5)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Mechanical Adjustment
3
VFK1145
---->
Back Tension Meter (T2-M30-P)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Tension Adjustment
4
VFK1146
---->
Philips Driver
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
General
5
VFK1147
---->
Philips Driver
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
General
6
VFK1148
---->
Hex Driver (1.5)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Mechanical Adjustment
7
VFK1149
---->
Post Driver
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Post height Adjustment
8
VFK1150
---->
Nut Driver (5.5mm)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Mechanical Adjustment
9
VFK1151
---->
Nut Driver (2.5mm)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Mechanical Adjustment
10
VFK1178
---->
Hex Driver (0.89)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Mechanical Adjustment
11
VFK1179
---->
Hex Driver (0.71)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Mechanical Adjustment
12
VFK1188A
---->
Dial Tension Gauge 30mN (30g)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Tension Adjustment
13
VFK1190
---->
HEX. Wrench
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Mechanical Adjustment
14
VFK1191A
---->
Dial Torque Gauge 0.45cN-m (45g)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Reel Torque Adjustment
15
VFK1209A
---->
Torque Driver 4-30cN-m (0.4-3Kg)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
A/C Head Adjustment
16
VFK1341
---->
CC Filter (3600K)
Y
Camera Adjustment
17
VFK1342
---------
CC Filter (4500K)
Y
Camera Adjustment
18
------------
VFK1343
CC Filter (3600K)
Y
Camera Adjustment
19
VFK1345
---->
CC Filter Holder
Y
Camera Adjustment
20
VFK1346
---->
CC Filter Step Down Ring
Y
Camera Adjustment
21
VFK1347
---->
CC Filter (5100K)
Y
Camera Adjustment
22
VFK1375
---->
1.5mm Hex Bit
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
A/C Head Adjustment
23
VFKW1000AA
---->
EVR I/F BOX
Y
Y
Y
Y
Y
Electrical Adjustments
24
VFKW1000C
---->
EVR RS-232 Cable
Y
Y
Y
Y
Y
Cable between PC and I/F Box
25
VFK1300
---->
AD Board (DAQ-12)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Interchangeability Adjustment
26
VFK1542
---->
T Arm Height Adj. Tool A
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
T1 Loading Arm Height Adj.
27
VFK1543
---->
T Arm Height Adj. Tool B
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
T1 Loading Arm Height Adj.
28
VFK1152
---->
Dial Torque Gauge Adapter
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Adapter for Reel Torque Gauge
29
VFK1153
---->
Mech. Neutral Plate (Post / M)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Post Height Coarse Adjustment
30
VFK1154
---->
Post Height Fixture
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Post Height Coarse Adjustment
31
VFK1155
---->
Neutral Position Tool (White)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Tension Adjustment
32
VFK1156
---->
Neutral Position Tool (Black)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Tension Adjustment
33
VFK1158A
---->
Auto B.E.R. Counter
Y
Y
Y
Y
Y
Y
EQ Adjustment (Bit Error Count)
34
VFK1481
---->
LISTA Software
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Interchangeability Adjustment
35
VFK1160C
---->
RF Auto Adj. Software
Y
Y
Y
Y
Y
RF Adjustment
36
VFK1162B
---->
EVR Software
Y
Y
Y
Software for EVR
37
VFK1163
---->
EQ. Adjustment Tool
Y
Y
Y
Y
EQ Adjustment
38
VFK1180
---->
EVR Sub I/F Board
Y
Y
Y
Y
Electrical Adjustment w/EVR
39
VFK1185
---->
B.E.R. Counter Cable
Y
Y
Y
Y
Y
Y
Cable for B.E.R. Counter
40
VFK1186
---->
LISTA Cable
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Interchangeability Adjustment
41
VFK1187
---->
EVR Cable
Y
Y
Y
Y
Cable for EVR
42
VFK1192
---->
F Extension Board
Y
Y
Y
Y
Y
Y
Circuit Board Extension
43
VFK1193
---->
H Extension Board
Y
Y
Y
Y
Y
Y
Circuit Board Extension
44
VFK1194
---->
Extension Board
Y
Y
Y
Y
Circuit Board Extension
45
VFK1208
---->
Neutral Position Tool (W/Hole)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Tension Adjustment
46
VFK1210
---->
Multi-Canon Cable
Y
Y
Y
Y
Cable for EVR
47
VFM3000EDS
---->
DV Alignment Tape (LISTA)
Y
Y
Y
Y
Y
Y
Y
DV Playback Confirmation
48
VFM3010EDS
VFM3110EDS
DV Alignment Tape (Colour Bar)
Y
Y
Y
Y
Y
Y
Y
DV Playback Adjustment
49
VFM3580KM
VFM3680KM
M Alignment Tape (No.1)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Electrical Adjustment
50
VFM3581KM
VFM3681KM
M Alignment Tape (No.2)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tape Interchangeability Adjustment
51
VFM3582KM
VFM3682KM
M Alignment Tape (No.3)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
A/C Head Adjustment
52
VFK1248A
---->
F Memory Version Up Software
Y
Y
Y
Y
Software Version Up
53
VFK1304
---->
F Memory Version Up Tool
Y
Y
Y
Y
Software Version Up
54
VFK1305
---->
Extender Cable (120P)
Y
Y
Cable for Extension
55
VFK1306
---->
Extender Cable (52P)
Y
Y
Cable for Extension
56
VFK1307
---->
Extender Cable (70P)
Y
Y
Cable for Extension
57
VFK1348
---->
Mech. Neutral Plate (Post / L)
Y
Y
Tape Post Height Coarse Adjustment
58
VFK1369
---->
Tape Beg./End Det Cassette (L)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Detector Sensitivity Adjustment
59
VFK1339
VFK1340
EVR Software
Y
Y
Electrical Adjustment
60
VFK1228
---->
B.E.R. Counter Cable
Y
Y
Cable for B.E.R. Counter
61
VFK1357
---->
Extension Board
Y
Y
Circuit Board Extension
62
VFK1358
---->
Extension Cable (A/C HEAD)
Y
Y
Circuit Board Extension
63
VFM3580KL
VFM3680KL
L Alignment Tape (No.1)
P
P
P
P
P
Y
P
P
P
Y
Electrical Adjustment
64
VFM3581KL
VFM3681KL
L Alignment Tape (No.2)
P
P
P
P
P
Y
P
P
P
Y
Tape Interchangeability Adjustment
65
VFM3582KL
VFM3682KL
L Alignment Tape (No.3)
P
P
P
P
P
Y
P
P
P
Y
A/C Head Adjustment
66
VFK1383
---->
Extender Board
Y
67
VFK1487
---->
RF Tool Modif. Kit
Y
Y
68
VFK1468
---->
F Memory Version Up Software
Y
69
VFK1481
---->
LISTA Software
Y
Y
Y
Y
Y : Available
P : Possible to use
3. DVCPRO Test Fixture & Tool Kit List
D Kit (VFK104-KIT)
C Kit (VFK103P-KIT : NTSC / VFK103E-KIT : PAL)
B Kit (VFK102-KIT)
A Kit (VFK101P-KIT : NTSC / VFK101E-KIT : PAL)

1-6
3
VFK1145
(T2-M30-P)
Back Tension Meter
7
VFK1149 (2.5mm)
Post Driver
8
VFK1150 (5.5mm)
Nut Driver
12
VFK1188 :30mN
(30g)
Dial Tension Gauge
1
14
VFK71 :1.5cN-m
(150g)
Dial Torque Gauge
VFK1191 :0.45cN-m
(45g)
15
VFK1209 :4-30cN-m
(0.4-3Kg)
Torque Driver
19
VFK1345
CC Filter Folder
20
CC Filter Step
Down Ring
VFK1346
22
VFK1375 (1.5mm)
Hex Bit
23
VFKW1000AA
EVR I/F Box
24
VFKW1000C
EVR RS-232 Cable
25
VFK1300
A/D Board (DAQ-12)
2
Eccentric Screwdriver
VFK0357 (1.5mm)
10
6
VFK1148 (1.5mm)
Hex Driver
VFK1178 (0.89mm)
11
VFK1179 (0.71mm)
28
Dial Torque Gauge Adapter
VFK1152
13
VFK1190
Hex Wrench
4
Phillips Driver
VFK1146
5VFK1147
9
VFK1151 (2.5mm)
Nut Driver
18
VFK1343 (3600K)
16
VFK1341 (3600K)
CC Filter
17 VFK1342 (4500K)
21
VFK1346 (5100K)
26
T Arm Height Adj. Tool A
VFK1542
27
T Arm Height Adj. Tool B
VFK1543

1-7
33
VFK1158A
Auto B.E.R Counter
34
VFK1481
LISTA Software
35
VFK1160C
RF Auto Adj. Software
37
VFK1163
E.Q. Adjustment Tool
38
VFK1180
EVR Sub I/F Board
VFK1153
Mech. Neutral Plate
(Post / M)
29
30
VFK1154
Post Height Fixture
36
VFK1162B
EVR Software
41
VFK1187
EVR Cable
VFK1208
45
Neutral Position Tool
42
VFK1192 (F)
Extension Board
46
Multi-Canon Cable
VFK1210
39
VFK1185
BER Counter Cable
40
VFK1186
LISTA Cable
48
VFM3010EDS
DV Alignment Tape
49
50
51
VFM3580KM
VFM3581KM
VFM3582KM
M Alignment Tape
47
VFM3000EDS
DV Alignment Tape
31
VFK1155 (Silver)
PLAY Position Tool
32
VFK1156 (Black)
REV Position Tool
43
VFK1193 (H)
Extension Board
44
VFK1194
Extension Board