SHARP 27DVS100 Service Manual

27DV-S100 27DV-CS10

SERVICE MANUAL

S81Z627DV-S10

TV/VCR/DVD COMBINATION

Chassis No. B00A

27DV-S100

MODELS

In the interests of user-safety (Required by safety regulations in some countries) the set should be restored to its original condition and only parts identical to those specified should be used.

CONTENTS

» IMPORTANT SERVICE SAFETY PRECATION ....................................................................................... 2

» SAFETY PRECAUTIONS ........................................................................................................................ 6

» ELECTRICAL SPECIFICATIONS ............................................................................................................ 7

» LOCATION OF USER'S CONTROL ........................................................................................................ 8

» DISASSEMBLY AND REASSEMBLY..................................................................................................... 12

» INSTALLATION AND SERVICE INSTRUCTIONS ................................................................................. 16

» PRECAUTIONS IN REASSEMBLING ................................................................................................... 22

» FUNCTION OF MAJOR MECHANICAL PARTS.................................................................................... 23

» ADJUSTMENT, REPLACEMENT AND ASSEMBLY OF MECHANICAL UNITS.................................... 25

» ADJUSTMENT OF THE VCR ELECTRICAL CIRCUITRY..................................................................... 45

» TEST MODE OF DVD SECTION........................................................................................................... 47

» TROUBLESHOOTING........................................................................................................................... 50

» CHASSIS LAYOUT................................................................................................................................. 72

» IC FUNCTION LIST OF DVD SECTION ................................................................................................ 74

» BLOCK DIAGRAM OF TV SECTION.....................................................................................................94

» BLOCK DIAGRAM OF VCR SECTION .................................................................................................. 96

» BLOCK DIAGRAM OF DVD SECTION................................................................................................ 106

» OVERALL SCHEMATIC DIAGRAM ..................................................................................................... 108

» DESCRIPTION OF SCHEMATIC DIAGRAM....................................................................................... 110

» PRINTED WIRING BOARD ASSEMBLIES.......................................................................................... 143

» REPLACEMENT PARTS LIST ............................................................................................................. 155

» PACKING OF THE SET ....................................................................................................................... 185

27DV-CS10

Page

SHARP CORPORATION

This document has been published to be used for after sales service only. The contents are subject to change without notice.

27DV-S100 27DV-CS10

IMPORTANT SERVICE SAFETY PRECAUTION

Ë Service work should be performed only by qualified service technicians who are thoroughly

familiar with all safety checks and servicing guidelines which follow:

WARNING

1. For continued safety, no modification of any circuit should be attempted.

2. Disconnect AC power before servicing.

3. Semiconductor heat sinks are potential shock hazards when the chassis is operating.

4. The chassis in this receiver has two ground systems which are separated by insulation material. The nonisolated (hot) ground system is for the +B voltage regulator circuit and the horizontal output circuit.The isolated ground system is for the low +B DC v oltages and the secondary circuit of the high voltage transformer . To prevent electrical shock use an isolation transformer between the line cord and power receptacle, when servicing this chassis.

CAUTION: FOR CONTINUED PROTECTION AGAINST A RISK OF FIRE, REPLACE

6.3A 125V

ONLY WITH SAME TYPE 6.3A125V FUSE.

SERVICING OF HIGH VOLTAGE SYSTEM AND PICTURE TUBE

When servicing the high voltage system, remove the static charge by connecting a 10k ohm resistor in series with an insulated wire (such as a test probe) between the picture tube ground and the anode lead. (A C line cord should be disconnected from AC outlet.)

1. Note that the picture tube in this receiver employs integral implosion protection.

2. Replace with tube of the same type number for continued safety.

3. Do not lift picture tube by the neck.

4. Handle the picture tube only when wearing shatterproof goggles and after discharging the high voltage anode completely.

X-RADIATION AND HIGH VOLTAGE LIMITS

1. Be sure all service personnel are aware of the procedures and instructions covering X-radiation. The only potential source of X-ray in current solid state TV receivers is the picture tube. Howev er, the picture tube does not emit measurable X-Ray r adiation if the high voltage is as specified in the “High V oltage Check” instructions. It is only when high voltage is excessive that Xradiation is capable of penetrating the shell of the picture tube including the lead in glass material. The important precaution is to keep the high voltage below the maximum level specified.

2. It is essential that servicepersonel have available at all times an accurate high voltage meter. The calibration of this meter should be checked periodically.

3. High voltage should always be kept at the rated v alue

-no higher. Operation at higher voltages may cause a failure of the picture tube or high voltage circuitry and;also,under certain conditions, may produce radiation that exceeds specifications.

4. When the high voltage regulator is operating properly there is no possibility of an X-radiation problem. Every time a color chassis is serviced, thebrightness should be tested while monitoring the high voltage with a meter to be certain that the high voltage does not exceed the specified value and that it is regulating correctly.

5. Do not use a picture tube other than that specified or make unrecommended circuit modifications to the high voltage circuitry.

6. When trouble shooting and taking test measurements on a receiver with excessiv e high voltage , av oid being unnecessarily close to the receiver. Do not operate the receiver longer than is necessary to locate the cause of excessive voltage.

IMPORTANT SERVICE SAFETY PRECAUTION

2 2

(Continued)

27DV-S100 27DV-CS10

BEFORE RETURNING THE RECEIVER (Fire & Shock Hazard)

Before returning the receiver to the user, perform the following safety checks.

1. Inspect all lead dress to make certain that leads are not pinched or that hardware is not lodged between the chassis and other metal parts in the receiver.

2. Inspect all protective devices such as non-metallic control knobs, insulating materials, cabinet backs, adjustment and compartment covers or shields, isolation resistor-capacity networks, mechanical insulators, etc.

3. To be sure that no shock hazard exists, check for leakage current in the following manner.

» Plug the AC cord directly into a 120 volt AC outlet,

(Do not use an isolation transformer for this test).

» Using to clip leads, connect a 1.5k ohm, 10 watt

resistor paralleled by a 0.15µF capacitor in series with all exposed metal cabinet parts and a known earth ground, such as electrical conduit or electrical ground connected to earth ground.

» Use an AC voltmeter having with 5000 ohm per volt,

or higher, sensitivity to measure the A C v oltage drop across the resistor.

» Connect the resistor connection to all exposed metal

parts having a return to the chassis (antenna, metal cabinet, screw heads, knobs and control shafts, escutcheon, etc.) and measure the AC voltage drop across the resistor. AII check must be repeated with the AC line cord plug connection reversed. (If necessary, a nonpolarized adapter plug must be used only for the purpose of completing these check.) Any current measured must not exceed 0.5 milliamp. Any measurements not within the limits outlined above are indicative of a potential shock hazard and corrective action must be taken before returning the instrument to the customer.

VOLTMETER

1.5k ohm 10W

0.15µF

TEST PROBE

TO EXPOSED METAL PARTS

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CONNECT TO KNOWN EARTH GROUND

SAFETY NOTICE

Many electrical and mechanical parts in television receivers have special safety-related characteristics. These characteristics are often not evident from visual inspection, nor can protection afforded by them be necessarily increased by using replacement components rated for higher voltage, wattage, etc. Replacement parts which have special safety characteristics are identified in this manual; electrical components having such features are identified by “ å” and shaded areas in the Replacement Parts Lists and Schematic Diagrams.

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For continued protection, replacement parts must be identical to those used in the original circuit. The use of a substitute replacement parts which do not have the same safety characteristics as the factory recommended replacement parts shown in this service manual, may create shock, fire, X-radiation or other hazards.

27DV-S100 27DV-CS10

PRECAUTIONS A PRENDRE LORS DE LA REPARATION

Ne peut effectuer la réparation qu’ un technicien spécialisé qui s’est parfaitement accoutumé à toute vérification de sécurité et aux conseils suivants.

AVERTISSEMENT

1. N’entreprendre aucune modification de tout circuit. C’est dangereux.

2. Débrancher le récepteur avant toute réparation.

3. Les déversoirs thermiques à semi-conducteurs peuvent présenter un danger de choc électrique lorsque le réceqteur est en marche.

4. Le châssis de ce récepteur a deux systèmes de mise à la terre qui sont séparés par un matériau isolant. Le système de mise à la terre non-isolée (chaud) est pour le circuit du régulateur de tension +B et le circuit de sortie horizontale. Le système de mise à la terre isolé est pour les basses tensions C. C . +B et le circuit secondaire du transformateur de haute tension.

PRECAUTION: POUR LA PROTECTION CONTINUE CONTRE LES RISQUES

6.3A 125V

D'INCENDIE, REMPLACERLE FUSIBLEPAR UN FUSIBLE DE MEME TYPE 6.3-125V .

REPARATION DU SYSTEME A HAUTE TENSION ET DU TUBE-IMAGE

Lors de la réparation de ce systéme, supprimer la charge statique en branchant une résistance de 10 k en série a vec un fil isolé (comme une sonde d’essai) entre la mise à la terre du tube-image et le fil d’anodel. (Le corden d’alimentation doit être retiré de la prise murale.)

1. Il est à noter que le tube-image de ce récepteur est intégralement protégé contre l’implosion.

2. Par mesure de sécurité, changer le tube-image pour un tube du même numéro de type.

3. Ne pas lever le tube-image par son col.

4. Ne manipuler le tube-image qu’en porant des lunettes incassables et qu’après avoir déchargé totalement la haute tension.

LIMITES DES RADIATIONS X ET DE LA HAUTE TENSION

1. Tout le personnel réparateur doit être instruit des instructions et procédés relatifs aux radiations X. Le tube-image, seule source de rayons X dons les téleviseurs transistorisés, n’émet pour tant pas de rayons mesur ables si la haute tension est mainten ue à un niveau préconisé dans la section “Vérification de la haute tension”. C’est seulement quand la haute tension est excessiv e que les rayons X peuv ent entrer dans l’enveloppe du tube-image y compris le conducteur de verre. Il est important de maintenir la haute tension en-dessous du niveau spécifié.

2. Il est essentiel que le réparateur ait sous la main un voltmètre à haute tension qui doit être périodiquement étalonné.

3. La haute tension doit toujours être maintenue à la valeur de régime-et pas plus haute. L’opér ation à des tensions plus élevées peut entraîner une panne du tube-image ou du circuit à haute tension et, dans certaines conditions, peut entraîner une radiation dépassant les niveaux préscrits.

4. Quand le régulateur à haute tension fonctionne correctement, il n’y a aucun problème de radiation X. Chaque fois qu’un châssis couleurs est réparé, la luminosité doit être examinée bout en contrôlant la haute tension à l’aide d’un voltmètre pour s’assurer que la haute tension ne dépasse pas la valeur spécifiée et qu’elle soit correctement réglée.

5. Ne pas utiliser un tube-image autre que celui spécifié et ne pas effectuer de modifications déconseillées du circuit à haute tension.

6. Lors de la recherche des pannes et des mesures d’essai sur un récepteur qui présente une haute tension excessive, éviter de s’approcher inutilement du récepteur. Ne pas faire fonctionner le récepteur plus longtemps que nécessaire pour localiser la cause de la tension excessive.

27DV-S100

27DV-CS10

PRECAUTIONS A PRENDRE LORS DE LA REPARATION

(Suite)

VERIFICATIONS CONTRE L’INCEN-DIE ET LE CHOC ELECTRIQUE

Avant de rendre le récepteur à l’utilisateur, effectuer les vérifications suivantes.

1. Inspecter tous les faisceaux de câbles pour s’assurer que les fils ne soient pas pincés ou qu’un outil ne soit pas placé entre le châssis et les autres pièces métalliques du récepteur.

2. Inspecter tous les dispositifs de protection comme les boutons de commande non-métalliques, les isolants, le dos du coffret, les couvercles ou blindages de réglage et de compar timent, les réseaux de résistance-capacité, les isolateurs mécaniques, etc.

3. S’assurer qu’il n’y ait pas de danger d’électrocution en vérifiant la fuite de courant, de la facon suivante:

» Brancher le cordon d’alimentation directem-ent à une

prise de courant de 120V. (Ne pas utiliser de transformateur d’isolation pour cet essai).

» A l’aide de deux fils à pinces, brancher une résistance

de 1,5 k 10 w atts en parallèle avec un condensateur de 0,15µF en série avec toutes les pièces métalliques exposées du coffret et une terre connue comme une conduite électrique ou une prise de terre branchée à la terre.

» Utiliser un voltmètre CA d’une sensibilité d’au moins

5000 /V pour mesurer la chute de tension en tr avers de la résistance.

» Toucher avec la sonde d’essai les pièces métalliques

exposées qui présentent une voie de retour au châssis (antenne, coffret métallique, tête des vis, arbres de commande et des boutons, écusson, etc.) et mesurer la chute de tension CA en-travers de la résistance. Toutes les vérifications doivent être refaites après avoir inversé la fiche du cordon d’alimentation. (Si nécessaire, une prise d’adpatation non polarisée peut être utilisée dans le but de terminer ces vérifications.) Tous les courants mesurés ne doivent pas dépasser 0,5 mA. Dans le cas contraire, il y a une possibilité de choc électrique qui doit être supprimée avant de rendre le récepteur au client.

Voltmètre CA

1.5k ohm 10W

0.15µF

SONDE D'ESSAI

AUX PIECES METALLIQUES EXPOSEES

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BRANCHER A UNE TERRE CONNUE

AVIS POUR LA SECURITE

De nombreuses pièces, électriques et mécaniques, dans les téléviseurs présentent des caractéristiques spéciales relatives à la sécurité, qui ne sont souvent pas évidentes à vue. Le degré de protection ne peut pas être nécessairement augmentée en utilisant des pièces de remplacement étalonnées pour haute tension, puissance, etc. Les pièces de remplacement qui présentent ces caractéristiques sont identifiées dans ce manuel; les pièces électriques qui présentent ces particularités sont

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identifiées par la marque “ å “ et hachurées dans la liste des pièces de remplacement et les diagrammes schématiques. Pour assurer la protection, ces pièces doivent être identiques à celles utilisées dans le circuit d’origine. L’utilisation de pièces qui n’ont pas les mêmes caractéristiques que les pièces recommandées par l’usine, indiquées dans ce manuel, peut provoquer des électrocutions, incendies, radiations X ou autres accidents.

27DV-S100 27DV-CS10

SAFETY PRECAUTIONS

Precaution to be taken when replacing and servicing the Laser Pickup.

The product is a Class 1 Laser Product. However Laser component is capable of emitting radiation exceeding the limit for Class 1. It is important that following precautions are observed during servicing to protect your eyes against e xposure to the laser beam.

1. When the cabinet is removed, interlock is defeated (if equipped), the power is turned on without a disk in position, Do not look into the pickup lens.

2. The laser power output of the pickup unit and replacement service par ts are all factory pre-set before shipment. Do not attempt to re-adjust the laser pickup unit during replacement or servicing.

PRODUIT LASER

DE CLASSE 1

CLASS 1 LASER PRODUCT

3. Under no circumstances stare into the pickup lens at any time.

4. Caution-Use of controls or adjustment or performance of procedures other than those specified herein may result in hazardous radiation exposure.

» LASER SPECIFICATIONS

Laser Diode Properties Material : AIGalnP Wave length

D VD: 645~660nm

CD : 770~810nm Emission Duration : Continuous Laser output : Max. 0.6 mW

(Top View)

CAUTION-WHEN OPEN. DO NOT STARE INTO BEAM OR VIEW DIRECTLY WITH OPTICAL INSTRUMENTS.

VARNONG-NÄR DENNA DEL ÄR ÖPPNAD. STIRRA EJ IN I STRÅLEN OCH BETRAKTA EJ STRÅLEN MED OPTISKA INSTRUMENT.

ADVARSEL-VED ÅBNING. SE IKKE IND I STRÅLEN-HELLER IKKE MED OPTISKE INSTRUMENTER.

VARO! AVATTAESSA OLET ALTTIINA. ÄLÄ TUIJOTA SÄTEESEEN ÄLÄKÄ KATSO SITÄ OPTISEN LAITTEEN LÄPI.

VARNING-NÄR DENNA DEL ÄR ÖPPNAD. STIRRA EJ IN I STRÅLEN OCH BETRAKTA EJ STRÅLEN GENOM OPTISKT INSTRUMENT.

ADVARSE-NÅR DEKSEL ÅPNES. STIRR IKKE INN I STRÅLEN ELLER SE DIREKTE MED OPTISKE INSTRUMENTER.

(Back of product)

DVD Unit

NOTE:

Laser beam is emitted when this is open. Do not stare into the beam. Do not view the beam through any optical instrument, either.

ELECTRICAL SPECIFICATIONS

TV SECTION

POWER INPUT: 120 V AC 60 Hz

POWER RATING: 165 W

PICTURE SIZE

Width: 37.8 cm

Height: 38.7 cm

Depth: 37.5 cm

CONVERGENCE: Magnetic

SWEEP DEFLECTION: Magnetic

FOCUS: Hi-Bi-Potential Electrostatic

INTERMEDIATE FREQUENCIES

Picture IF Carrier Frequency: 45.75 MHz

Sound IF Carrier Frequency: 41.25 MHz

Color Sub-Carrier Frequency: 42.17 MHz (Nominal)

AUDIO POWER OUTPUT RATING: 3 W + 3 W (at 10% Distortion)

SPEAKER

Size: 8 cm (3-1")

Voice Coil Impedance: 16 ohm at 400 Hz

VHF/UHF ANTENNA INPUT IMPEDANCE: 75 ohm unbalanced

TUNING RANGES

VHF-Channels: 2 thru 13

UHF -Channels: 14 thru 69

CATV Channels: 1,14 thru 125 (EIA, Channel Plan)

27DV-S100 27DV-CS10

VCR SECTION

Video Recording System: Rotary Two-Head Helical Scanning

Number of Video Heads: 4 pcs.

Video Signal Standard: NTSC Color System

Maximum Recording Time: (SP)120 min (with T-120)

DVD SECTION

Playback-compatible discs: DVD (regional code "1"/"ALL"), Video CD (NTSC),

Operating Temperature: 5°C to 40°C (41°F to 104°F)

Storage Temperature: -20°C to 60°C (-4°F to 140°F)

Format: VHS Standard

Tape Width: 12.7mm (1/2inch)

Tape Speed: (SP)33.35mm/sec (1.31 i.p.s)

(LP)16.68mm/sec (0.66 i.p.s) Play back only (EP)11.12 mm/sec (0.44 i.p.s)

(EP)360 min (with T-120) Video Input: 0.5 to 2.0 Vp-p, 75 ohm unbalanced Audio Input: -8 dB, 47k ohm unbalanced (0 dB-0.775 Vrms)

CD, DA, MP3, Music CD

Signal system: NTSC

Specifications are subject to change without prior notice.

27DV-S100 27DV-CS10

LOCATION OF USER'S CONTROL

Front (TV/VCR controls)

Cassette compartment

POWER button

REC button

ÈREW (rewind) button

VOL + / – (UP/DOWN) buttons

' / " (UP/DOWN) buttons

Front (DVD controls)

VCR mode indicator

|PLAY button

STOP/ EJECT button

TAMPER PROOF indicator

PROGRAM TIMER indicator

REC indicator

POWER/WAKE-UP TIMER indicator

FF (fast forward) button

Sensor area for Remote Control

DVD mode indicator

OPEN-CLOSE button

|È

SKIP/REV (reverse) button

|PLAY button

SKIP/FWD (forward) è

VIDEO / L-AUDIO-R terminals

Ë Insert the headphones (not supplied) into the headphone jack to listen to audio.

button

(Inside the cover)

PHONES (Headphone jack)

STOP button

Disc tray

Rear

27DV-S100 27DV-CS10

LOCATION OF USER'S CONTROL (Continued)

Video output terminal

Video input terminal

DVD OPTICAL DIGITAL output terminal

DVD COAXIAL DIGITAL output terminal

Audio input terminals

Audio output terminals

ANT/CABLE terminal (75Ω)

27DV-S100 27DV-CS10

Remote Control Unit (Cover closed)

LOCATION OF USER'S CONTROL (Continued)

POWER

DVD

SLOW

F.ADV

SKIP (REV)

STILL/PAUSE

REV (reverse)

STOP

REPEAT

MUTE

MTS

CATV

INPUT

DVD

SUBTITLE

ANGLE

SKIP (FWD)

PLAY

FWD (forward)

ZOOM

DVD/TV

DISPLAY

CH '/", TR /

FLASHBACK

Ë Using Your Remote Control With Your unit

After installing the batteries, press TV to switch to the TV mode. (If you can change the channel of the TV by pressing CH '/" or CHANNEL SELECT buttons,you are in TV mode.)

VOL

CHANNEL SELECT buttons

–

Loading the Batteries

Ë Before using the unit, prepare the Remote Control.

To use the Remote Control, insert batteries first.

Insert the batteries

Battery

Pull up

• With your thumbnail, pull up the slit as indicated by the arrow to remove the back cover. Insert two batteries (size “AA”). Be sure to match the battery

Cover

–

±/— terminals with the ±/— marks inside the compartment.

–

LOCATION OF USER'S CONTROL (Continued)

Remote Control Unit (Cover open)

27DV-S100 27DV-CS10

DVD

RETURN

CURSOR

DVD

NUMBER buttons

MEMORY

VCR

CONFIRM

PAUSE/STILL

T.PROOF

REW (rewind)

AUDIO

SET UP

SET

TITLE

CLEAR

PROG.

ON/OFF

PLAY

STOP

DVD

SUBTITLE ANGLE

DVD

DISC MENU

VIRTUAL PROGRAM DIRECT

GAMMA

S.PICTURE

VCR

COUNTER RESET SLOW REC (record) TAPE SPEED FF (fast forward)

DPSS

27DV-S100 27DV-CS10

DISASSEMBLY AND REASSEMBLY

1. Remove the 16 rear cover fixing screws and detach the rear cover.

2. Take out the anode cap, CRT PWB, connectors OO, K and M, coating earth, speaker connectors SE, connector DC and others.

3. Remove the 2 main chassis fixing screws and take out the main chassis.

4. Remove the 5 fixing screws from the sub-chassis f or the VCR power/deflection PWB and detach this sub-chassis.

5. Remove the 5 VCR shielding case fixing screws and detach the shielding case.

6. Remove the 4 cassette housing fixing screws and detach the cassette housing.

27DV-S100 27DV-CS10

7. Remove the 2 mechanism chassis bracket fixing screws and the head amplifier shielding case fixing screw.

8. Remove the 3 mechanism chassis fixing screws and detach the mechanism chassis from the main PWB.

9. Remove the 2 DVD mechanism unit reinforcement fixing screws and detach this reinforcement.

10.Remove the 4 DVD mechanism unit fixing screws and detach the DVD mechanism unit.

11.Remove the 1 main PWB fixing screws and detach the main PWB.

12.Remove the 1 TV signal PWB fixing screw and detach the TV signal PWB.

13.Remove the 2 TV power PWB fixing screws and detach the TV power PWB.

» DVD section

14.Remove the 5 DVD shielding case fixing screws and detach the DVD shielding case.

15.Undo the 4 hooks from the chassis for the DVD main and sub PWBs, and detach this chassis.

16.Remove the 4 DVD main PWB fixing screws and detach the DVD main PWB.

17.Remove the DVD sub PWB fixing scre w , undo the hook and detach the DVD sub PWB.

18.Finally remove the 4 DVD mechanism fixing screws and detach the DVD mechanism.

14 14

27DV-S100 27DV-CS10

REPLACEMENT OF MAIN PARTS <Take out disk>

1. Remove the mechanism with angle from the set (refer to 17 on PARTS LIST (See page 183)).

2. It is in such cases as the thin driver, and it is pushed in slowly, and a tra y is dra wn in the arrow direction the slide rack on the left of the base chassis.

3. Take out disk.

Front Side

1. After setting the mechanism chassis to the angle state, ground it to prevent the electrostatic discharge damage of the pickup.

2. Remove the DVD shield (lower) 5 (refer to the illustration on PARTS LIST (See page 183)).

3. Remove the DVD main PWB unit 35 , and loosen the 4 screws 56 to remove the DVD main PWB unit 35 . (Pickup relay FFC isn’t removed.) (refer to the illustration on PARTS LIST (See page 183))

4. Remove screws fixing the base chassis (located at the back right and at front left when facing the set).

5. With the pickup FFC connected, turn over the base chassis and short (solder) two short lands on the pickup interface PWB in order to prevent the electrostatic discharge damage of the pickup.

6. Remove the pickup FFC from the main PWB.

7. Remove the pickup FFC from the pickup interface PWB.

8. Remove the traverse mounting screws to remove the traverse chassis ass’y.

Note: After assembly and wiring, remove the solder joint of the short land. If short-circuited, a disk is not played

back.

Pickup FFC

Sled Motor Lead Wire

Loading Motor Lead Wire

Since the pickup optical axis and turntable inclination of DVD are adjusted with higher accuracy than of CD/MD, make a replacement as a mechanism service chassis ass’y (refer to Parts List).

Traverse Fixing Screw

Pickup FFC

Pickup interface PWB

Short Land

27DV-S100

27DV-CS10

For servicing the TV’s component units, undo the lead dressing holders and place the main chassis upright as shown below. Connect necessary leads for quick servicing.

FRONT

DE ZA

GBN

N(H)

Remove the four screws from the cathode ray tube, and detach the cathode ray tube (weighing 35 kg or so). » The cathode ray tube has a high-tension static charge and a

high vacuum. Handle it with enough care on the following occasions.

For disposal of the cathode ray tube

1) The high-voltage electrode, which is covered with the anode cap atop the cathode ray tube, may have a high-tension static charge. Before detaching the anode cap, be sure to get this electrode fully discharged.

2) The cathode ray tube has a high vacuum inside. Crack the tip of the air vent on the neck socket of the cathode ray tube in order to get the tube out of vacuum.

Get the air vent tip cracked to let in air.

27DV-S100 27DV-CS10

INSTALLATION AND SERVICE INSTRUCTIONS

Note: (1) When performing any adjustments to resistor controls and transformers use non-metallic scre wdriver

or TV alignment tools.

(2) Before performing adjustment, TV set must be on at least 15 minutes.

CIRCUIT PROTECTION

The receiver is protected by a 6.3A fuse (F701), mounted on PWB-A, wired into one side of the AC line input.

X-RADIATION PROTECTOR CIRCUIT TEST

After service has been performed on the horizontal deflection system, high voltage system, or +B system, test the X-Radiation protector circuit to ascertain proper operation as follows:

1. Apply 120V AC using a variac transformer for accurate input voltage.

2. Allow for warm up and using the remote controller, set the brightness level and contrast level to maximum.

3. Check the voltage of test point TP653. (It’s voltage should be about 11.1V DC.)

4. Apply external 14.5V DC at TP653 by using an external DC supply . The increased v oltage will cause the horizontal oscillator to stop and the TV to shut off.

5. To re-star t the oscillator, remove the external DC power supply and short together TP651 and TP652. Once the TV set operates normally again, remove the short between TP651 and TP652.

HIGH V OL T AGE CHECK

High voltage is not adjustable b ut must be checked to verify that the receiver is operating within safe and efficient design limitations as specified checks should be as follows:

1. Connect an accurate high voltage meter between ground and anode of Picture tube.

2. Operate receiver for at least 15 minutes at 120V AC line voltage, with strong air signal or properly tuned in test signal.

3. Set to Ser vice mode on, “Mute” and bus data 1(Ymute on).

4. The voltage should be approximately 29.2kV (at zero beam). If a correct reading cannot be obtained, chec k circuitry for malfunctioning components. After the voltage test, “Mute” and b us data “0” (Y-mute off).

27DV-S100 27DV-CS10

The R-series SHARP TV/VCR COMBINATION have most of the analog setup adjustments eliminated. Coil and variable resistor adjustments are now performed digitally by using the remote controller or set’s volume and channel change function buttons. Note: There are still a few analog adjustments in the R-series such as 120V adjust, focus, master screen

voltage and coils in the picture I/F detector circuit. Follow the steps below , whenever service adjustment is required. See “T ab le-B” to determine, if service adjustments are required.

1. Service mode

Before putting unit into the service mode, check that customer adjustments are in the normal mode, use the reset function in the video adjust menu to ensure customer controls are in their proper (reset) position.

To enter the service mode

Plug in a television set, during push S2507 (CH-up). When successfuly entered, the service mode will be displayed as shown in Figure A.

To exit service mode

Turn off the power or unplug the set.

2. Adjustment Item selection

Once in the service mode, press the channel up or channel down button on the remote controller or at the set (Table-A). Select the item y ou wish to adjust.

3. Data number selection

Press the volume up or down button to adjust the data number in the upper right hand side of the screen.

Figure A.

27DV-S100 27DV-CS10

ITEM

SUB COTRAST(*1) PICTURE 20 00 - 31 Adjustment is required of each set. TINT (*1) TINT 30 00 - 47 Adjustment is required of each set. SUB COLOR (*1) COLOR 18 00 - 31 Adjustment is required of each set. BRIGHTNESS (*1) BRIGHT 55 00 - 95 Adjustment is required of each set. SHARPNESS SHARP 15 00 - 47 Fix at "8" V-POSITION (*1) V POSITION 95 00-127 Adjustment is required of each set. H-POSITION (*1) H POSITION 17 00 - 31 Adjustment is required of each set. R CUT-OFF (*1) R CUT-OFF 64 00-255 Adjustment is required of each set. G CUT-OFF (*1) G CUT-OFF 64 00-255 Adjustment is required of each set. B CUT-OFF (*1) B CUT-OFF 64 00-255 Adjustment is required of each set. G GAIN (*1) G GAIN 64 00-127 Adjustment is required of each set. B GAIN (*1) B GAIN 64 00-127 Adjustment is required of each set. Y-γ CURVE Y-γ CURVE 00 00 - 03 Fix at "03" VSM PHASE VSM PHASE 01 00 - 03 Fix at "02" APACON PEAK f0 APA PEAK f0 01 00 - 07 Fix at "01" DC RESTRATION RATE DC REST 21 00 - 63 Fix at "07" DC RESTRATION LIMIT DC REST LMT 00 00 - 03 Fix at "02" BLACK STRETCH POINT BLK STRETCH 03 00 - 07 Fix at "00" APL VS BPS APL VS BPS 01 00 - 03 Fix at "01" B.L.C B.L.C 01 00 - 01 Fix at "00" DYNAMIC ABL POINT DY ABL POINT 04 00 - 07 Fix at "06" DYNAMIC ABL GAIN DY ABL GAIN 04 00 - 07 Fix at "03" ABL POINT ABL POINT 03 00 - 07 Fix at "07" ABL GAIN ABL GAIN 03 00 - 07 Fix at "04" Y-DL Y-DL 01 00 - 01 Fix at "01" TOF-Q TOF-Q 04 00 - 07 Fix at "04" VSM GAIN VSM GAIN 01 00 - 03 Fix at "02" OSD SL OSD SL 00 00 - 01 Fix at "00" C-DECODE C-DECODE 161 00-255 Fix at "153" DVD BR-OFF DVD BR-OFF 30 30 - 70 Fix at "50" PICTURE HEIGHT V AMP 22 00-127 Adjustment is required of each set. V-LINEARITY V-LINEARITY 22 00 - 31 Adjustment is required of each set. V-S CORRECTION V-S CORRECT 40 00 - 63 Fix at "47" PICTURE WIDTH H AMP 30 00 - 63 Adjustment is required of each set. E-W PARABOLA E-W PARABOLA 19 00 - 63 Adjustment is required of each set. E-W CORNER E-W CORNER 18 00 - 31 Adjustment is required of each set. TRAPEZIUM TRAPEZIUM 55 00-127 Adjustment is required of each set. AGC AGC 01 00 - 01 Fix at "01" Y-MUTE MUTE 00 00 - 02 00=NORMAL, 01=NO-Y, 02=NO-VERTICAL ENERGY SAVE ENERGY SAVE 21 00 - 63 Fix at "21" TEXT BOX TEXT BOX 8 00 - 31 Adjustment is required of each set. TEXT PICTURE TEXT PICTURE 20 00 - 80 Fix at "20" CCD LEVEL CCD LEVEL 04 00 - 20 Fix at "10" OPTION (VCR) OPTION (VCR) 39 00-255 Fix at "39" OPTION (TV) OPTION (TV) 31 00-127 Fix at "127" MTS INPUT LEVEL INPUT LEVEL 07 00 - 15 Adjustment is required of each set. MTS VCO MTS VCO 37 00 - 63 Adjustment is required of each set. MTS FILTER FILTER 30 00 - 63 Adjustment is required of each set. WIDE BAND DETECT WIDE BAND 35 00 - 63 Adjustment is required of each set. SPECTRAL DETECT SPECTRAL 22 00 - 63 Adjustment is required of each set. H COMP H COMP 03 00 - 07 Fix at "03" V COMP V COMP 03 00 - 07 Fix at "03" CCD POSITION CCD POSITION 38 00 - 63 Fix at "38"

OSD DISPLAY INITIAL

RANGE SETTING DATA

(*1) Set the adjustment value to tuner input instead of the adjustment at DVD input (play).

Table-A

PART ADJUSTMENT REPLACED NECESSARY UNNECESSARY IC2001 X Data is stored in IC2003.

IC401 X

IC2003 X CRT X Adjust items related to picture tube only.

The adjustment is needed to compensate for characteristics of parts including IC401. Initial setting values are written from IC2001. Adjust for best results.

NOTE

Table-B

SERVICE ADJUSTMENT

Screen Adjustment

1. Select a good local channel.

2. Enter the service mode and select the service adjustment item "COLOR" and set the data value to "0" to set the color level to minimum. You may skip this step, if you selected a B/W picture or monoscope pattern.

3. Select service adjustment item "MUTE" and adjust the data value to "1", this turns off the luminance signal (Y-mute).

4. Adjust the master screen control until raster darkens to the point where raster is barely seen.

5. Adjust service adjustments item "R-CUT OFF" red "G-CUT OFF" green and "B-CUT OFF" blue to obtain a good grey scale with normal whites at low brightness level.

6. Select the service adjustment item "MUTE" and reset data to "0". Select service adjustment item "COLOR" and reset data to obtain normal color level.

White Balance Adjustment

1. Select a good local channel.

2. Enter the service mode and select the service adjustment item "COLOR" and set to "0" (minimum color). "COLOR" does not have to be adjusted if you selected a B/W picture or monoscope pattern.

3. Alternately adjust the service adjustment data of "G GAIN" and "B GAIN" until a good grey scale with normal whites is obtained.

4. Select the ser vice adjustment item "COLOR" and adjust data to obtain normal color level.

Picture Adjustment

1. Select a good local channel.

2. Make sure the customer picture control is maximum.

3. Enter the service mode and select the service adjustment item "PICTURE".

4. Adjust the data value to achieve normal contrast range.

Tint Adjustment

1. Select a good local channel.

2. Set customer tint control to center of it’s range.

3. Enter the service mode and select the service adjustment item "TINT".

4. Adjust "TINT" data value to obtain normal flesh tones.

Color Adjustment

1. Select a good local channel.

2. Make sure the customer color control is set to center position .

3. Enter the service mode and select the service adjustment item "COLOR".

4. Adjust "COLOR" data value to obtain normal color level.

27DV-S100 27DV-CS10

Brightness Adjustment

1. Select a good local channel.

2. Make sure the customer brightness control is set to center position.

3. Enter the service mode and select the service adjustment item "BRIGHT".

4. Adjust "BRIGHT" data value to obtain normal brightness level.

Vertical Phase Adjustment

1. Receive a good local channel.

2. Enter the service mode and select "V-POSITION".

3. Adjust data value so that picture is approximate center.

Vertical-Size Adjustment

1. Receive a good local channel.

2. Enter the service mode and select "V-AMP".

3. While observing the top and bottom of the screen, adjust the data value to proper vertical size.

Side Pincushion Adjustment

1. Receive a good local channel or crosshatch pattern signal.

2. Set to standard setting mode.

3. Enter the service mode and select "E-W P ARABOLA".

4. Adjust the data so that the outer most line on the screen be straight.

Corner Distortion Adjustment

1. Receive a good local channel or crosshatch pattern signal.

2. Set to standard setting mode.

3. Enter the service mode and select "E-W CORNER".

4. Adjust the data so that the vertical lines should be straight.

Trapezoidal Distortion Adjustment

1. Receive a good local channel or crosshatch pattern signal.

2. Set to standard setting mode.

3. Enter the service mode and select "TRAPEZIUM".

4. Adjust the data so that the leftmost and rightmost vertical lines are parallel to each other.

Horizontal Position Adjustment

1. Receive a good local channel or crosshatch pattern signal.

2. Set to standard setting mode.

3. Enter the service mode and select "H-POSITION".

4. Adjust so that the left and right overscans are equal to each other.

27DV-S100 27DV-CS10

Horizontal Size Adjustment

1. Receive a good local channel or crosshatch pattern signal.

2. Set to standard setting mode.

3. Enter the service mode and select "H-AMP".

4. Adjust the data to obtain the best horizontal size.

Caption Position Adjustment (Horizontal)

1. Receive a good local channel.

2. Enter the service mode and select "TEXT BOX".

3. A black text box appears on the screen. (see Figure B below)

4. Adjust the data value so that text box is positioned in the center of the screen.

White Balance Adjustment of Component Signal Input

1. Feed the B/W pattern signal via the component signal input from signal generator.

2. Set "Y-MUTE" bus data to "01" to get the Y signal mute.

3. Select a luminance-short gun, and adjust the bus data of "R CUT-OFF", "G CUT-OFF" and "B CUT-OFF" to have the luminance at the white level.

4. Adjust the "G GAIN" and "B GAIN" setting to obtain the specified white level.

Sub-brightness Adjustment of Component Signal Input

1. Feed the B/W pattern signal via the component signal input from signal generator.

2. Make sure the customer brightness control is set to center position.

3. Enter the service mode and select "BRIGHT".

4. Adjust the data value to obtain normal br ightness level.

MTS ADJUSTMENT

MTS Level Adjustment (for TV tuner)

1. Receive the following monaural signal. Monaural signal: 300Hz, 245mVrms.

2. Connect the rms voltmeter to pin (39) of IC3001.

3. Enter the service mode and select "INPUT LEVEL".

4. Adjust the data so that the rms voltmeter reads 490 +10/-10mVrms.

MTS VCO Adjustment (for TV tuner)

1. Keep the unit in no-signal state.

2. Connect the frequency counter to pin (39) of IC3001.

3. Connect a capacitor (100uF, 50V) between positive (+) side of C3005 and ground.

4. Enter the service mode and select "MTS VCO".

5. Adjust the data so that the frequency counter reads

62.94 +0.72/-0.75kHz.

Filter Adjustment (for TV tuner)

1. Feed the following stereo pilot signal to pin (14) of IC3001. Stereo pilot signal: 9.4kHz, 600mVrms.

2. Enter the service mode and select "FILTER".

3. Adjust the data until "OK" appears in position on the screen. Make sure the "OK" is displayed almost at the center of the data range.

27DV-S100 27DV-CS10

Separation Adjustment (for VCR tuner)

1. Connect the rms voltmeter to pin (22) of IC3601 (or negative (-) side of C1321).

2. Receive the following composite stereo signal 1. Composite stereo signal: 30% modulation, left channel only, noise reduction on, 300Hz.

3. Adjust R3601 to become the output level as the minimum.

4. Receive the following composite stereo signal 2. Stereo signal: 30% modulation, left channel only , noise reduction on, 3kHz.

5. Adjust R3612 to become the output level as the minimum.

6. Take the above steps 1 thru 5 again for fine adjustment.

Separation Adjustment (for TV tuner)

1. Connect the rms voltmeter to pin (39) of IC3001.

2. Receive the following composite stereo signal 1. Composite stereo signal: 30% modulation, left channel only, noise reduction on, 300Hz.

3. Enter the service mode and select "WIDE BAND".

4. Adjust the data until the AC voltage reading of the rms voltmeter is minimum.

5. Receive the following composite stereo signal 2. Stereo signal: 30% modulation, left channel ony, noise reduction on, 3kHz.

6. Enter the service mode and select "SPECTRAL".

7. Adjust the data until the AC voltage reading of the rms voltmeter is minimum.

8. Take the above steps 1 thru 7 again for fine adjustment.

MTS Level Adjustment (for VCR tuner)

1. Receive the following monaural signal. Monaural signal: 300Hz, 245mVrms.

2. Connect the rms voltmeter to pin (22) of IC3601 (or negative (-) side of C1321).

3. Adjust R3614 to become the output level as 490 +10/-10mVrms.

27DV-S100 27DV-CS10

PRECAUTIONS IN REASSEMBLING

INSTALLING THE CASSETTE HOUSING

When the cassette housing is installed on the mechanism, the initial setting is essential condition. There are two initial setting methods, namely electrical and mechanical.

1. Electrical initial setting

So as to perform initial setting of mechanism execute the Step 1 of Installation of cassette housing. After ascertaining the retur n to the initial setting position (*1) install the cassette housing. (Conditions: When mechanism and PWB have been installed)

Pulley feed gear

Screwdriver

Tint mark (*1)

Installing the mechanism on PWB

Lower vertically the mechanism, paying attention to the mechanism edge, and install the mechanism with due care so that the parts are not damaged. So as to fix the mechanism to the main PWB install two housings. (Fit the antenna cover to one of them. For other, fix the vicinity of loading motor and solder joint side of main PWB.) Connect again the FFC cable (AA-MH, AD-ME, AH-MZ) between the mechanism and the main PWB.

2. Mechanical initial setting

Feed the pulley f eed gear of loading motor with screw driver. After ascertaining the return to the initial set position (*1) install the cassette housing in the specified position. (This method is applied only for the mechanism.)

Casecon drive gear

Drive angle of cassette housing

Parts which need particular care

When installing the mechanism chassis on the PWB unit, take care so as to prevent deformation due to contact of mechanism chassis with REC TIP SW.

END SENSOR

REC TIP SW

AE CONNECTOR

AD CONNECTOR

START SENSOR

AL CONNECTOR

FUNCTION OF MAJOR MECHANICAL PARTS (TOP VIEW)

1815

27DV-S100 27DV-CS10

No. Function

1 Full erase head 2 Supply pole base ass’y 3 Tension arm ass’y 4 Idler wheel ass’y 5 Pinch drive lever ass’y 6 Supply reel disk 7 Supply main brake ass’y 8 Take-up main brake ass’y

No. Function

11 Reverse guide lever ass’y 12 Casecon drive gear 13 Take-up reel disk 14 Pinch roller lever ass’y 15 Drum ass’y 16 Loading motor 17 Drum motor 18 Take-up pole base ass’y

9 Pinch drive cam

10 A/C Head ass’y

19 Impedance roller ass’y

27DV-S100 27DV-CS10

FUNCTION OF MAJOR MECHANICAL PARTS (BOTTOM VIEW)

19 20

No. Function

12 Casecon drive gear 19 Slow brake 20 Master cam 21 Capstan D.D. motor

22 Reel belt 23 Clutch lever 24 Limiter pulley ass'y 26 Shifter

27DV-S100 27DV-CS10

ADJUSTMENT, REPLACEMENT AND ASSEMBLY OF MECHANICAL UNITS

The explanation given below relates to the on-site general service (field service) but it does not relates to the adjustment and replacement which need high-grade equipment, jigs and skill. For example, the drum assembling, replacement and adjustment service must be performed by the person who have finished the technical courses.

MECHANISM CONFIRMATION ADJUSTMENT JIG

So as to perform completely the mechanism adjustment prepare the following special jigs. So as to maintain the initial performance of the machine the maintenance and check are necessary. Utmost care must be tak en so that the tape is not damaged. If adjustment needs any jig, be sure to sue the required jig.

This cassette torque meter is used

1. Torque Cassette Meter JiGVHT-063 CZ

JiGTG0090 CM

2. Torque Gauge JiGTG1200 CN

3. Torque Gauge Head JiGTH0006 AW

for checking and adjusting the torque of take-up for measuring tape back tension.

These Jigs are used for checking and adjusting the torque of takeup and supply reel disks.

4. Torque Driver JiGTD1200 CB

Master Plane Jig and JiGRH0002 BR

5. Reel Disk Height

Adjusting Jig JiGMP0001 BY

JiGSG2000 BS

6. Tension Gauge

JiGSG0300 BF

Pinch pressing force

measuring jig

Hex Wrench (1.2mm) JiGHW0012 AE

Hex Wrench (1.5mm) JiGHW015 AE

Reverse guide height

adjusting box driver

JiGTDP003 BK

JiGDRiVER11055

When fixing an y part to the threaded hole using resin with screw , use the jig. (Specified torque 5 kg)

These Jigs are used for checking and adjusting the reel disk height.

There are two gauges used for the tension measurements, 300 g and

2.o kg.

This Jig is used with the tension gauge. Rotary transformer clearance adjusting jig.

This Jigs are used for loosening or tightening special hexagon type screws.

This Jig is used for height adjustment of the reverse guide (for reverse guide height adjustment).

27DV-S100 27DV-CS10

No. Jig Item Part No. Code Configuration Remarks

These tapes are especially used for electrical fine adjustment.

10. Alignment T ape

Guide roller height

11. adjustment drive

X value adjustment

12. gear type screw driver

Reverse Guide Height

13. Adjusting

VROATSV CD

VROEBZCS

JiGDRiVERH-4 AP

JiGDRiVER-6

JiGRVGH-F18

Video Audio Hi-Fi Audio Track 525 Monoscope 7k — 58µm NTSC Color Bar 1k — 58µm

525 Monoscope 1k — 19µm

This screwdriver is used for adjusting the guide roller height.

For X value adjustment.

This Jig is used for height adjustment of the reverse guide.

MAINTENANCE CHECK ITEMS AND EXECUTION TIME

NOTE : Part replacement. : Cleaning : Apply grease <Specified> Cleaning liquid Industrial ethyl alcohol

Maintained

Parts

Remarks

Ref.No.

500 hrs.

1000 hrs.

1500 hrs.

2000 hrs.

Possible symptom

encountered

Guide roller ass’y Sup guide shaft Reverse guide Slant pole on pole base Full erase head A/C head

Upper and lower drum ass’y

Capstan D.D. motor Pinch roller

Reel belt

Tension band ass’y Loading motor

Idler ass’y Limiter pulley Supply/take-up main brake levers

AHC

(Automatic Head Cleaner)

—

7,8

58 59

61 12

60 46 48

24,25

Colour and beating Small sound or sound

distortion

No tape running, uneven colour

No tape running, tape slack

No tape running, tape slack, no fast forward/ rewind motion

Lateral noises Head occasionally blocked

Abnormal rotation or significant vibration requires replacement.

Clean tape contact part with the specified cleaning liquid.

Clean tape contact area with the specified cleaning liquid.

Replace the roller of the cleaner when it wears down. Just change the AHC roller assembly for new one.

Screen swaying Cassette not loaded or

unloaded No tape running, tape

slack

Tape slack

Clean rubber and rubber contact area with the specified cleaning liquid.

Poor S/N ratio, no colour Poor flatness of the envelope with alignment tape

* This mechanism does not need electric adjustment with variable resistor. Check parts. If any deviation is found,

clean or replace parts.

Perform the maintenance with the regular intervals as follows so as to maintain the quality of machine.

27DV-S100 27DV-CS10

Video head cleaning procedure

1. Apply one drop of cleaning liquid to the cleaning paper with the baby oiler.

2. Gently press the cleaning paper against the video head to fix your finger, and move the upper drum so that each head is passed to and for 5 times (do not move the cleaning paper).

3. Wipe with the dry cleaning paper.

Notes :

• Use the commercially available ethanol of Class 1 as

cleaning liquid.

• Since the video head may be damaged, do not move

up and down the cleaning paper.

• Whenever the video head is cleaned, replace the

cleaning paper.

• Do not apply this procedure for the parts other than

the video head.

Gently press the cleaning paper to fix with your finger, and rotate the upper drum to clean. Move to and for 5 times for each head. (Do not move the cleaning paper.)

ZPAPRA56-001E Cleaning Paper ZOiLR-02-24TE Babe Oiler (Spoit)

Rotate the upper drum with one hand.

Parts Code Description

27DV-S100

500g

Mechanism chassis

Weight to prevent float (500g)

27DV-CS10

REMOVING AND INSTALLING THE CASSETTE HOUSING

• Removal

1. In the cassette removing mode, remove the cassette.

2. Unplug the power cord.

3. Remove in the following numerical order. a) Remove two screws 1. b) Slide and pull up the cassette housing control.

Figure 1-1.

Notes:

1. When fitting the S/E sensor holder to the cassette controller frame L/R, take care.

2. Misengagement of teeth of casecon drive gear and drive angle gear causes malfunction. (The cassette cannot be set, load and ejection are repeated).

3. In the case when you use the magnet screw driver, never approach the magnet driver to the A/C head, FE head, and drum.

4. When installing or removing, take care so that the cassette housing control and tool do not contact the guide pin or drum.

5. After installing the cassette housing control once perform cassette loading operation.

TO RUN A TAPE WITHOUT THE CASSETTE HOUSING CONTROL ASSEMBLY

1. Remove the full-surface panel.

2. Short-circuit R7057 and JUMPER:420.

3. Plug in the power cord.

4. Turn off the power switch.

(The mechanism moves to the cassette mounting position.)

5. Open the lid of a cassette tape by hand.

6. Hold the lid with two pieces of vinyl tape.

7. Set the cassette tape in the mechanism chassis.

8. Stabilize the cassette tape with a weight (500g) to

prevent floating.

9. Turn on the power switch.

10. Perform running test.

11. After running test, once turn off the power to let the

mechanism move to the cassette mounting position, then remove the cassette.

• Reassembly

1. Before installing the cassette housing control, shortcircuit R7057 and JUMPER:420 provided on the main PWB, prug in the power cord, and then press the STOP/EJECT button. The casecon drive gear turns and stops when the positioning mark appears. Engage two teeth of casecon drive gear with the three teeth of casecon drive angle gear, and set on the mechanism chassis as shown below.

Casecon drive gear

Casecon drive angle gear

Figure 1-2.

2. Install in the reverse order of removal.

Figure 1-3.

Note:

The weight should not be more than 500g. To take out the cassette tape.

1. Turn off the power switch.

2. Take out the cassette tape.

27DV-S100 27DV-CS10

REEL DISK REPLACEMENT AND HEIGHT CHECK

• Removal

1. Remove the cassette housing control assembly.

2. Pull the tension band out of the tension arm ass'y.

3. Remove the Supply/Take-up main brake ass'y.

4. Open the hook at the top of the reel disk, and remove the reel disk.

Note:

Take care so that the tension band ass'y and main brake ass'y (especially soft brake) are not deformed.

Tension arm ass'y

Supply main brake ass'y

Tension band ass'y

Supply reel disk

Take-up main brake ass'y

Take-up reel disk

3. After checking the reel disk height, wind the tension band ass'y around the reel disk, and insert into the hole of tension arm ass'y.

4. Assemble the Supply main brake ass'y.

Notes:

1. When installing the reel disk, take due care so that the tension band ass'y is not deformed and grease does no adhere.

2. Do not damage the Supply main brake ass'y. Be careful so that grease does not adhere to the brake surface.

• Reassembly (Take-up reel disk)

1. Clean the reel disk shaft and apply grease (SC-141) to it.

2. Align the phase of the reel disk to that of the reel relay gear and to install a new take-up reel disk onto the shaft.

3. Check the reel disk height and reassemble the take-up main brake ass'y.

Note:

1. Take care so that the Take-up main brake ass'y is not damaged. Take care so that grease does not adhere the brake surface.

2. After reassembly, check the video search rewind back tension (see page 32), and check the brake torque (see page 34).

Figure 1-4.

Note:

When the tension band ass'y is pressed in the direction of the arrow for removal, the catch is hard to be deformed.

Figure 1-5.

• Height checking and adjustment Note:

1. Set the master plane with due care so that it does not contact the drum.

2. When putting the master plane, shift the reverse guide a little in the loading direction. Care must be taken since excessive shift results in damage.

Master plane

Reverse guide

Supply reel disk

Cassette lock release shaft

Take-up reel disk

Position pin

Figure 1-6.

• Reassembly (Supply reel disk)

1. Clean the reel disk shaft and apply grease (SC-141) to it.

2. Match the phases of reel disk and reel relay gear, and set the new reel disk.

Note:

Check that the reel disk is lower than part A but higher than part B. If the height is not correct, readjust the reel disk height by changing the poly-slider washer under the reel disk.

• Problems caused by maladjustments

1. Tapes may get scratched.

27DV-S100 27DV-CS10

Note:

Whenever replacing the reel disk, perform the height checking and adjustment.

Master plane

10 ± 0.2mm

Reel disk

Reel disk height adjusting jig

Mechanism chassis

Figure 1-7.

CHECKING AND ADJUSTMENT OF TAKEUP TORQUE IN FAST FORWARD MODE

• Remove the cassette housing control assembly.

• After short-circuiting R7057 and JUMPER:420 provided on the main PWB, plug in the power cord, then turn on the power.

• Setting

1. Set a torque gauge to zero on the scale. Place it on the take-up reel disk.

2. Press the FF button.

3. To calculate the remaining capacity of the play back mode, slowly rotate the supply reel disk, and then shift it into the forward mode.

• Checking

1. Turn the torque gauge slowly (one rotation every 2 to 3 seconds) by hand in the CW direction.

2. Make sure that the indication of torque gauge is not less than 30mN·m (306gf·cm).

Torque gauge

Notes:

1. Hold the torque gauge by hand so that it is not moved.

2. Do not keep the reel disk in lock state. Do not allow long-time measurement.

5. CHECKING AND ADJUSTMENT OF

TAKE-UP TORQUE IN REWIND MODE

• Remove the cassette housing control assembly.

• After short-circuiting R7057 and JUMPER:420 provided on the main PWB, plug in the power cord, then turn on the power.

• Setting

1. Set a torque gauge to zero on the scale. Place it on the supply reel disk.

2. Press the rewind button.

3. To calculate the remaining capacity, slowly rotate the take-up reel disk, and then shift it into the rewind mode.

• Checking

1. Turn the torque gauge slowly (one rotation every 2 to 3 seconds) by hand in the CCW direction.

2. Make sure that the indication of torque gauge is not less than 30mN·m (306gf·cm).

Torque gauge

30mN·m (306gf·cm) or more

CCW

The gauge is held at its maximum value. (Red mark)

30mN·m (306gf·cm) or more

Idler ass'y

Figure 1-8.

The gauge is held at its maximum value. (Red mark)

• Adjustment

1. If the FF winding-up torque is less than the specified value, clean the capstan D.D. motor pulley, drive belt, and limiter pulley with cleaning liquid, and check again.

2. If the torque is less than the set value, replace the reel belt.

• Problems caused by maladjustments

1. Tapes may fail to be wound up near the FF end.

Supply reel disk

Idler ass'y

Figure 1-9.

• Adjustment

1. If the rewind winding-up torque is less than the specified value, clean the capstan D.D. motor pulley, drive belt, and limiter pulley with cleaning liquid, rewind again, and check the winding-up torque.

2. If the winding-up torque is still out of range, replace the drive belt.

• Problems caused by maladjustments

1. Tapes may fail to be wound up near the REW end.

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