prt40c Repair PDF

WATCH BASIC
REPAIR MANUAL
(RANKS A AND B)
JULY 1997
PRT-40C ABX-68B MWA-800G

(QW-1470) (QW-1359) (QW-1325)
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BASIC REPAIR MANUAL
(Ranks A and B)
Definition of Ranks B:
<Digital>
Ranks B refers to the level at which technical skills and tools are possessed that enable
evaluation of the quality of all parts at the individual part level, replace or adjust those parts
and perform waterproof inspections, excluding watches equipped with a sensor and the
Professional Diver’s Watches.
<Analog>
Ranks B refers to the level at which technical skills and tools are possessed that enable
evaluation of the quality of all parts at the individual part level, replace or adjust those parts
and perform waterproof inspections, excluding the train wheel unit.
Definition of Ranks A:
Ranks A refers to the level at which technical skills and tools are possessed that enable
evaluation of the quality of all parts of all watches at the individual part level, replace or adjust
those parts and perform waterproof inspections, excluding the Professional Diver’s Watches.
CONTENTS
FLOW CHART FOR REPAIR OF MODULE WITHOUT MOVEMENT ............................ 1

FLOW CHART FOR REPAIR OF MODULE WITH MOVEMENT ................................... 2
FLOW CHART FOR REPAIR OF CASING PARTS ........................................................ 3
1. Circuit Explanation of Quartz Watches ............................................................... 4
1-1 Circuit Diagram .............................................................................................................. 4
1-2 Digital Quartz Watches .................................................................................................. 5
1-3 Analog Watches ............................................................................................................. 5
2. Measurement of Current Consumption (Oscillation Check) ............................. 6
3. Quality Evaluation and Replacement of Electronic Parts .................................. 8
3-1 Capacitors/Chip ............................................................................................................. 8
3-2 Transistors ..................................................................................................................... 9
3-3 Coils ............................................................................................................................... 9
3-4 Oscillators/Quartz .......................................................................................................... 9
4. Accuracy Setting Method for Casio Watches ................................................... 10
4-1 Accuracy Setting by Capacitor/Trimmer ...................................................................... 10
4-2 Accuracy Setting by Pad Selection .............................................................................. 11
4-3 Digital Tuning (Pattern Cutting) Method ...................................................................... 11
5. LCD Replacement ................................................................................................ 12

6. Quality Evaluation and Replacement of EL ....................................................... 12
7. Names of Casing Parts ....................................................................................... 14
7-1 G-Shock ....................................................................................................................... 14
7-2 Baby-G ......................................................................................................................... 15
7-3 Twincept ....................................................................................................................... 16
7-4 Data Bank .................................................................................................................... 17
7-5 Diver's Watch ............................................................................................................... 18
7-6 Watches Equipped with a Sensor/Pressure (Side Sensor) ......................................... 19
7-7 Watches Equipped with a Sensor/Pressure (Front Sensor) ........................................ 20
8. Replacement of Casing Parts ............................................................................. 21
8-1 Glass Replacement ..................................................................................................... 21
8-2 Button Replacement .................................................................................................... 22
8-3 Register Ring Replacement ......................................................................................... 23
8-4 Piezo Replacement ..................................................................................................... 23
9. Analog Block Replacement ................................................................................ 24
10. Waterproof Inspection ......................................................................................... 26
10-1 Water Resistant Tester .............................................................................................. 27
10-2 Air Leak Checker ....................................................................................................... 28
10-3 Water Pressure Tester and Hot Plate ........................................................................ 30
11. Quality Evaluation and Replacement of Sensor/Pressure .............................. 32
11-1 Trouble Shooting with Sensor/Pressure Trimming Jig Set ......................................... 33
11-2 Trouble Shooting without Sensor/Pressure Trimming Jig Set .................................... 34
11-3 Sensor/Pressure Quality Evaluation .......................................................................... 35
11-4 Removal and Attachment of Sensor/Pressure ........................................................... 35
11-4-1 Sensor/Pressure Equipped on Side of the Watch .................................................. 35
11-4-2 Sensor/Pressure Equipped on Front of the Watch ................................................. 36
12. Altimeter of Watches Equipped with a Sensor/Pressure ................................. 36
13. Quality Evaluation and Replacement of Sensor/Magnetic .............................. 37
13-1 When a Watch Does Not Indicate Directions Correctly ............................................. 37
13-2 Quality Evaluation of Sensors/Magnetic .................................................................... 37
13-3 Quality Evaluation of Sensors/Magnetic .................................................................... 38
14. Quality Evaluation and Replacement of Coil Ass'y .......................................... 38
15. Repair of Module/with movement ...................................................................... 39
15-1 Precautions when Repairing Modules/with movement .............................................. 39
15-2 The Structure and Names of Parts of Module/with movement .................................. 40
15-3 Explanation of Each Part of Module/with movement ................................................. 42
15-3-1 Train Wheel Part ..................................................................................................... 42
15-3-2 Correction Part ....................................................................................................... 42
15-3-3 Calendar Part ......................................................................................................... 43
15-4 Disassembly, Cleaning, Lubrication and Reassembly of Module/with movement ..... 44
15-4-1 Disassembling ........................................................................................................ 44

15-4-2 Cleaning ................................................................................................................. 44
15-4-3 Lubrication and Reassembly .................................................................................. 45
15-4-4 Confirmation ........................................................................................................... 46
16. Clock Repair (Heat Seal Replacement) .............................................................. 46

FLOW CHART FOR REPAIR OF MODULE WITHOUT MOVEMENT
(RANKS A AND B)
Module without
Movement is broken
What is wrong ?
Yes
EL doesn’t light Display trouble Sensor trouble
Refer to 6. Quality Sensor/magnetic

evaluation and Sensor/pressure ?
replacement of EL Sensor/magnetic ?
Sensor/pressure
Yes Refer to 11. Quality Refer to 13. Quality

LCD is broken ? evaluation and evaluation and
replacement of replacement of
sensor/pressure sensor/magnetic
No
Refer to 5. LCD Yes

replacement Battery have
much power
No
No good Current Good

consumption is
OK ?
Replacement of PCB ass’y Refer to
or replacement of Refer to Watch
2. Measurement of Basic Repair
each components. (Refer to current consumption
3. Quality evaluation and Manual (Ranks
(Oscillation check) C and D)
replacement of electronic parts.)
Water resistant inspection

(In case the watch is water resistant)
Refer to 10. Waterproof inspection.
Repair is finished
—1—

FLOW CHART FOR REPAIR OF MODULE WITH MOVEMENT
(RANKS A AND B)
Module with
Movement is broken
What is wrong ?
Yes
EL doesn’t light Hands are not Sensor trouble

moving
Refer to 6. Quality Sensor/magnetic

No Battery have Sensor/pressure ?
evaluation and
replacement of EL much power Sensor/magnetic ?
Sensor/pressure
Yes
Refer to Watch
Basic Repair Refer to 11. Quality Refer to 13. Quality
Manual (Ranks evaluation and evaluation and
C and D) replacement of replacement of
sensor/pressure sensor/magnetic
No good Current Good

consumption is
OK ?
Refer to
2. Measurement of
current consumption
(Oscillation check)
Replacement of PCB ass’y Repair of mechanical portion.

or replacement of Refer to 9. Analog blcok
each components. (Refer to replacement, 14. Quality evaluation
3. Quality evaluation and and replacement of coil ass'y and
replacement of electronic parts.) 15. Repair of module/with movement.

Repair is finished
—2—

FLOW CHART FOR REPAIR OF CASING PARTS
(RANKS A AND B)
The casing parts of watch

is broken
What is wrong ?
Yes
Band or Dial are Case/Center ass'y is Alarm doesn't

broken broken sound
Refer to Watch
Basic Repair Manual Which part is
Refer to 8-4. Piezo
(Ranks C and D) broken
replacement
Register ring is
Glass is broken Button is broken Case is broken
broken
Refer to Watch Basic

Refer to 8-1. Glass Refer to 8-2. Button Refer to 8-3. Register Repair Manual
replacement replacement ring replacement (Ranks C and D)

Repair is finished
—3—

1. Circuit Explanation of Quartz Watches
The basic circuits employed in quartz watches are as described below. Nearly all portions of these
circuits are contained in the LSI, and therefore cannot be repaired. (Fig. 1-1) However, they are
important in terms of understanding the operating principle of the quartz watches.
1-1 Circuit Diagram
Fig. 1-1
—4—

1-2 Digital Quartz Watches
Power Unit (Battery):
There are two types of batteries: a battery/lithium (3.0 V, mainly used in digital watches), and a battery/
silver oxide (1,55V, mainly used in analog watches). In addition, since the driving voltage of the LCD
driver is 3 V and that of the oscillator is 1.5 V, a voltage halver (for the oscillator) is provided in the LSI
of the modules using a battery/lithium, while a voltage doubler (for driving the LCD) is provided in the
LSI of the modules using a battery/silver oxide.
Oscillator:
This circuit generates a 32,768 Hz signal with the oscillator/quartz and capacitor/trimmer.
Frequency divider:
This circuit converts the 32,768 Hz signals produced with the oscillation circuit to 1 Hz signals with
Count Down Flip Flop.
Counter (memory):
This circuit controls the counting of time, calendar and stopwatch functions, etc. based on the 1 Hz
signals produced by the dividing circuit.
Driver:
This circuit drives the LCD, alarm, EL and so forth.
DIGITAL QUARTZ WATCH
Fig. 1-2
1-3 Analog Watches

Oscillator and Frequency divider:
These circuits function in the same manner as in digital watches.
Coil driver:
This circuit provides a 1 Hz alternating current (signal) to the coil of the analog block.
—5—

Stepping Motor:
This is composed of a coil, stator and rotor. This motor turns the rotor 180 degrees per second when
the 1 Hz alternating current signal is received from the coil driver, resulting in rotation of the gears of
the train wheel unit. Operation beyond this point is performed by the mechanical portion.
Mechanical block:
This unit moves the hands and calendar wheel as a result of its gears being turned by the motive force
from the rotor.
ANALOG QUARTZ WATCH
Fig. 1-3
2. Measurement of Current Consumption (Oscillation Check)

Tool used
NO. Code No. Tool name
1 1904 5153 HP-fingerstall
2 1902 0974 Battry checker
3 1904 5277 Multimeter
4 1901 9523 Precision tweezers
5 Lead wire
6 Alligator clip
7 IC clip
In cases when the battery life of a watch appears to be extremely short, it is possible that current
consumption has increased abnormally due to circuit shorts, defective parts or other problems.
When this happens, the quality of the module can be evaluated by measuring current consumption.
In addition, in the case of analog watches, it is possible to determine whether the location of the
malfunction is in the electronic portion or mechanical portion of the watch by measuring current con-
sumption (oscillation check).
—6—

The measurement procedure is described below.
1) Remove the cover/back and take out the battery. (Use a plastic tweezers or finger stall.)
2) After checking that the battery still has sufficient charge with a battery checker, place the battery
on the plate/main of the module with the plus side facing down.
3) After setting the measurement range of the analog multimeter to an alternating current range of 30
or 50 µA, place the plus end of the probe (colored red) on the battery (minus side) and place
the minus end (colored black) on the battery contact (–) of the module/with movement. (Fig.
2-1)
4) Although the procedure up to step 3) is satisfactory for analog watches, in the case of digital and
combination watches, the AC operation is performed with the watch left in the state in step 3).
(Fig. 2-2)
In the case of performing this procedure alone, since it is difficult to perform the AC operation with
one hand while holding the two tester probes with the other hand, this can be done easier by using
that which has an alligator clip and IC clip attached to the lead wires. (Fig. 2-3)
5) In the case of digital and combination watches, current consumption can be considered to
be normal if the needle on the multimeter points to between roughly 3 and 10 µA. In the
case of analog watches, current consumption can be considered to be normal if the needle
on the multimeter deflects between roughly 0 and 10 µA every second.
Current consumption differs according to the module. Refer to the List of Current Consumption for
each module in the Watch Index Book for the proper current consumption value of each model.
6) In the case of analog watches, if the needle deflects normally as described in 5) above, it can be
assumed that 1 Hz signal is reaching the coil ass'y of the stepping motor. Thus, when repairing
an analog watch that has malfunctioned with the hands stopped, first try measuring current
consumption. If current consumption is found to be normal, it means that the cause of the mal-
function lies in the mechanical portion (past the rotor). Conversely, if current consumption is found
to be abnormal, this means that the cause of the malfunction lies in the electronic circuits and coil
ass'y.
Black probe Red probe
Red
Black
Fig. 2-1
d
Re
Fig. 2-3
Black
Fig. 2-2 Lead wire IC clip Alligator clip
—7—

3. Quality Evaluation and Replacement of Electronic Parts
Tool used
1 1904 5153 HP-fingerstall (two set)
Terminals
4-1 1904 1667 Soldering iron (110 V/117 V)
4-2 1904 1668 Soldering iron (220 V) for solder
Ceramic
5 1901 9868 Solder wick
6 1901 9401 Solder
7 Lead wire
8 Alligator clip
9 IC clip
3-1 Capacitors/Chip Fig. 3-1
Capacitors/chip consist of two extremely thin metal plates

(electrodes), combined as shown in the drawing, sur-
rounded by a ceramic covering. The function of the ca-
pacitor/chip is to store electrical charge. (Fig. 3-1) It has
the characteristic of allowing the flow of alternating cur-
rent but not direct current. Short circuit Crack
Fig. 3-2
The capacitors/chip may be damaged by an internal short
circuit to crack. (Fig. 3-2)
In quartz watches, capacitors/chip are typically used in
the voltage doubling circuits (VSS1, VSS2, VSS3) that
produce the driving voltage for the LCD display, and in
the pulse generators (VC, VCC/VC1, VC2) for driving the
LSI or in the power supply (VCH) for the LSI block. In
addition, as one method of adjusting the accuracy of the
watch, a capacitor/chip is selected corresponding to the
variation in accuracy of the oscillator/quartz instead of a
Fig. 3-3
capacitor/trimmer. Quality evaluation of capacitors/chip
is performed using a multi-meter according to the follow-
ing procedure. Capacitor/Chip
1) Remove the capacitor/chip to be inspected from the P.C.B.
2) Set the multimeter to the 1 KΩ or 10 KΩ range.
3) Place the probe of the multimeter against two electrodes of the capacitor/chip to observe the state
of charging and discharging. If the capacitor/chip is acceptable, the multimeter will display a cer-
tain constant resistance value since electricity initially is charged within the capacitor/chip (the
resistance value varies according to the type of capacitor/chip). When charging is completed, the
resistance value reaches infinity, and the needle returns to its original position. (Fig. 3-3) If the
capacitor/chip is defective, the needle will point to 0 Ω (indicating a short) or remain at ∞ (indicating
an open circuit).
—8—

3-2 Transistors
In watches, transistors are mainly used to perform signal
amplification in the alarm (BD) and EL (LD) drive circuits. E
Evaluation of their quality is performed as described below. C
1) Remove the transistor to be inspected from the P.C.B. B
3) Measure the resistance between the base (B) and emit- NPN
ter (E), and between the base (B) and collector (C). If E C E
the transistor is acceptable, the respective resistance val- C
B
ues will be in the range of 50-200 Ω. (Fig. 3-4) B
3-3 Coils
Coils are used to increase voltage and so forth for generat- Fig. 3-4
ing the driving voltages for the alarm and EL. Evaluation of
their quality is performed as described below.
1) Remove the coil to be inspected from the P.C.B.
3) Measure the resistance value. If the coil is acceptable, the resistance value will be in the range of
80-150 Ω .
3-4 Oscillators/Quartz
Oscillators/quartz produce a stable 32,768 Hz signal with
the oscillation circuit in the LSI. The most effective way
Clip
to evaluate the quality of a oscillator/quartz is to use a
dummy watch for checking oscillators/quartz. The proce-
dure for making a dummy watch is described below.
1) Have available a digital watch (preferably of the solar
battery type that does not require AC operation).
2) Disassemble the module and remove the oscillator/
quartz from the PCB ass’y.
Dummy module
3) Solder lead wires to the terminals to which the oscilla-
tor/quartz was soldered (XT, XTB), and reassemble Fig. 3-5
the watch with the wires extending outside the watch.
4) Attach IC clips, etc. to the terminals of the lead wires. (This completes the dummy watch.)
5) When desiring to check a oscillator/quartz, first remove that oscillator/quartz from the PCB ass’y,
and attach the IC clips of the dummy watch to its legs. If the dummy watch starts to run normally,
it means that the oscillator/quartz being checked is not defective.
—9—

4. Accuracy Setting Method for Casio Watches
Although the oscillation frequency of the oscillator/quartz used in watches is said to be 32,768 Hz, in
actuality there is a slight degree of variation between individual oscillators/quartz. Accuracy setting is
required in order to maintain the accuracy claimed in the specifications of watches using these oscil-
lators/quartz.
This accuracy setting procedure is naturally also required when a oscillator/quartz has been replaced
during repairs.
The following provides a description of the accuracy setting method for Casio watches.
4-1 Accuracy Setting by Capacitor/Trimmer

Tool used
1 Quartz timer
3-2 1904 1668 Soldering iron (220 V) Quartz timer
5 1901 9401 Solder
6 1901 9975 Ceramic screw driver (small)
The capacitor/trimmer is a capacitor equipped with a
volume that enables the capacitance to be varied.
When the accuracy of a watch is measured with a
quartz timer and the accuracy is found to be incor-
rect, accuracy can be adjusted by turning the volume
Fig. 4-1
of the capacitor/trimmer.
This procedure must always be performed when the watch no longer keeps the correct time or after
the oscillator/quartz has been replaced. Furthermore, the accuracy (monthly) and setting range (daily)
of each watch (module) is indicated in the Specifications of the Service Manual or the List of Current
Consumption in Watch Index Book.
In the case of a watch accurate to a monthly error of ±15 seconds, the daily error is normally set to a
range of +0.25 to +0.35 seconds.
This is done in consideration of the temperature characteristics of the oscillator/quartz. Even if the
watch were set to be accurate to a daily error of ±0 seconds, the watch would end up running slow at
atmospheric temperatures outside the vicinity of 25 °C. Watches are therefore set to a range of +0.25
to +0.35 seconds at the outset to enable them to maintain a constant accuracy (±15 seconds) within
an atmospheric temperature range of 0-40 °C. (Fig. 4-2)
25 °C
°C
32,768=0
Fig. 4-2
— 10 —

4-2 Accuracy Setting by Pad Selection
The capacitance of the capacitor in the LSI can be
changed to nine different levels by combining the Oscillator/Quartz
open and shorted states of pads G1-G3 of the PCB
ass’y. (Fig. 4-3)
These changes in capacitance can be used to ad-
just the accuracy.
The combinations of these pads are as shown in
the following chart.
Although they can be adjusted during repairs, since
it is necessary to disassemble and reassemble the
module each time the rate is adjusted, this proce-
dure is actually quite difficult.
Thus, in the case a watch no longer runs accurately Fig. 4-3
or a oscillator/quartz has been damaged in modules for which accuracy setting is performed in this
manner, it is preferable that repairs are performed by replacement of the PCB ass’y or module.
(+) Side, Gain <----- ACCURACY (Sec./ Day) -----> (–) Side, Lose
G1 Open (Close) (Open) (Close) Open (Close) Open Close
G2 Open (Open) (Close) (Close) Open (Open) Close Close
G3 Open (Open) (Open) (Open) Close (Close) Close Close
Notes: "Close" means the lead wire is connected (or soldered).

"Open" means the lead wire is cut (or not soldered).
4-3 Digital Tuning (Pattern Cutting) Method

This method is used for analog watches
(and mainly those of the two hand type).
Even if the oscillation frequency is not
32,768 Hz, a constant accuracy is main-
tained by adjusting the alternating current Oscillator/Quartz
signals that forcibly enter the coil. That
adjustment procedure is performed by
cutting lead wires (3-5) on the P.C.B. (Fig.
4-4)
The combination of cuts are also varies
according to the oscillator/quartz.
Thus, in the case the oscillator/quartz has
been damaged in a module in which this Fig. 4-4
rate setting method is employed, replace-
ment must be performed from the PCB ass’y or module.
Furthermore, when checking the accuracy with a quartz timer, checking should be performed at
a gate time of 10 seconds.
— 11 —

5. LCD Replacement
Tool used
2 1901 9672 Precision screwdriver set
4 1901 9519 Blower brush
When the LCD is missing characters, there are many

cases in which this is repaired by replacing the LCD.
In addition, the LCD is also replaced when it is
cracked. The LCD is replaced according to the
procedure described below.
1) Remove the module from the case.
2) Remove the hooks of the plate/main, and sepa-
rate housing-1 and housing-2.
3) Remove the PCB ass’y from housing-1.
4) Turn the housing-1. And insert the end of a twee-
zers into the hooks that hold down the LCD of
housing-1, remove the hooks and remove the LCD Fig. 5-1
from housing-1. (Fig. 5-1)
5) When installing the new LCD, install the LCD while spreading apart the hooks of housing-1 with the
end of a tweezers and then secure the LCD in position by catching the hooks on the LCD.
6) Reassemble the module.
6. Quality Evaluation and Replacement of EL

Since the EL has an impedance of ∞ and capacitance of 1,500 PF, quality cannot be evaluated by
measuring using a multimeter.
Therefore a module equipped with an EL is modified according to the following procedure to prepare
an EL checker that is used in quality evaluations.
Tool used
4-2 1904 1668 Soldering iron (220 V)
6 1901 9401 Solder
7 Lead wire
8 Alligator clip
— 12 —

1) Materials Used
a) One module equipped with an EL (transformer
up-conversion type)
QW-1199/1219/1298/1188/1289/1431/1433/
1299/1441/1557 or equivalent modules
b) Two alligator clips (with lead wires)
2) Disassemble the module and remove the PCB
ass’y.
3) Solder one of the lead wires of the alligator clips
to the SE terminals of the four terminals to which
the transformer is soldered on the PCB ass’y. (Fig.
6-1/Fig. 6-2)
4) Reassemble the module with the lead wires still
soldered to the PCB ass’y. The lead wires should
extend outside the module from the side of hous-
ing-2. (When it is difficult to pull the lead wire
Fig. 6-1
through the gap in housing-2, either grind hous- SE Terminal
ing-2 slightly or melt it with a soldering iron to
create a larger gap.)
5) Twist the other lead wire around one of the four screws on the main plate and fasten it to the plate/
main. (This completes the EL checker.)
6) When checking the EL, connect alligator clips to the two terminals of the EL being checked and try
illuminating the EL by pressing the light button of the checker (module) to make the circuit. (Fig. 6-
3) At this time, the EL connected with the alligator clips is not defective if it lights simultaneous to
pressing of the light button on the EL checker.
Alligator clip P.C.B. Ass’y EL
Fig. 6-2 Fig. 6-3

Lead wire Alligator clip EL Checker
— 13 —

7. Names of Casing Parts
7-1 G-Shock
Bezel Screw/Decorative
Button ass'y (10H)
Button ass'y (6H)
Screw/Decorative Protector/
Case back
Glass & packing
Packing/Glass
Case/Center ass'y
Button ass'y (2H)

Protector/Case back
Button ass'y (4H)
Button ass'y (8H)
Dial (Inner)
E-ring
Dial (Outer)
Cover/Inner
Cushion/Rubber (Inner)
Module/without movement
Cushion/Rubber (Back)
Packing/O-ring (Back)
Cover/Back ass'y
Screw/Decorative
Cover/Bottom
Screw/Decorative
Screw (Back)
— 14 —

7-2 Baby-G
Protector
Bezel
Screw/Decorative Screw/Decorative
Case/Center ass'y
Glass & packing
Button ass'y (10H) Packing/Glass
Button ass'y (8H)

Cover/End piece
E-ring
Spring rod
Spring rod Button ass'y (2H)
Button ass'y (4H)
Cover/End piece
Dial
Cover/Inner
Tape/Adhesive Cushion/Rubber (Inner)
Module/without Movement
Cushion/Rubber (Back)
Cover/Back ass'y
Screw (Back)
— 15 —

7-3 Twincept
Screw/Decorative
Button ass'y (10H)
Button ass'y (Light)

Bezel
Cushion
Button ass'y (8H)
Case/Center ass'y
Button ass'y (2H)
E-ring
Button ass'y (4H)
LCD
Interconnector
Dial supporter
Rubber/Conductive
Hand/Minute
Hand/Hour
Dial/EL
Module/with Movement
Screw/Tapping
Spring/Coil Spring/Coil
Cover/Back ass'y
Screw (Back)
— 16 —

7-4 Data Bank
Panel
Button ass'y (light)
Button ass'y (10H)

E-ring
Button ass'y (9H) Case/Center ass'y
Button ass'y (2H)
Button ass'y (3H)
E-ring
Module/without Movement
Plate
Tape/Adhesive
Casing frame
Seal
Tape/Conductive
Piezo
Tape/Adhesive
Cover/Back
Screw (Back)
— 17 —

7-5 Diver's Watch
Screw/Decorative
Bezel
Panel
Tape/Adhesive
Register ring
Spring/Leaf Glass & packing
Packing/Glass
Packing/O-ring
Bezel ring
Button ass'y (10H)
Case/Center ass'y
Button ass'y (8H)
Button ass'y (2H)
E-ring
Button ass'y (4H)
Dial supporter
Hand/Minute
Hand/Hour
Module/with Movement
Casing frame
Cover/Back
Screw (Back)
— 18 —

7-6 Watches Equipped with a Sensor/Pressure (Side Sensor)
Case/Center ass'y
Register ring E-ring
Screw (Dorative piece)
Button ass'y (2H)
Packing/O-ring
Packing/O-ring (Sensor)
Piece/Decorative (9H)
Plate (sensor)
Screw (Decorative piece)
Piece/Decorative (3H)
Screw
Button a'ssy (10H)
Plate/Protection
Button a'ssy (8H)
Cover/Sensor
Button a'ssy (Light)
E-ring
Button a'ssy (4H)
Spring /Coil (Back)
Dial
Screw
Screw
Screw
Module/without Movement (sensor)
Spring/Coil (Sensor)
Sensor/Pressure
Holder
Screw/Flat
Casing frame
Tape/Conductive
Sheet/Insulation
Piezo
Tape/Adhesive
Cover/Back
Screw (Back)
— 19 —

7-7 Watches Equipped with a Sensor/Pressure (Front Sensor)
Screw/Decorative
Panel
Button ass'y (10H)
Button ass'y (8H) E-ring
E-ring Button ass'y (2H)
Packing/O-ring (Sensor)
Button ass'y (4H)
Sensor/Pressure
Case/Center ass'y
Casing frame
Holder
Screw
Module/
without Movement (Sensor)
Cover/Back ass'y
Screw (Back)
— 20 —

8. Replacement of Casing Parts
8-1 Glass Replacement
Tool used
2 1901 9439 Buckskin
3 1901 9522 Hand press
Mineral glass is used in models having water resistance up to

200 meters, and the glass can be replaced. Parts information
for the glass is contained in parts lists (P/L, P.P.L.). Glass is
indicated as “Glass & packing”.
The procedure for replacing the glass is as described below.
Fig. 8-1
1) Have a new glass & packing available. (Fig. 8-1)
2) Remove the band, cover/back and module from the watch
leaving only the case/center ass'y.
3) Remove the old glass and packing/glass from the case.
Wipe the glass fit part of the case with cloth.
4) Place the case in the hand press. The lower pressing piece
of the hand press should be large enough to hold the pe-
riphery of the case, and large enough to that the case sits
level without tipping.
The upper pressing piece should be the same size or slightly
Fig. 8-2
smaller than the periphery of the glass (so that it allows
press fitting to be performed around the outside edge of the
glass).
5) Install the new packing/glass in the case. The old packing/glass should not be reused since it
can cause defective water resistance and separation of the glass from the case.
6) Place the glass on the press fit portion of the case. When it is difficult to position the glass at this
time, temporarily fasten the glass to the case with cellophane tape to prevent it from moving.
7) Turn the handle of the hand press with the case and glass positioned as described above to press
fit the glass into the case. (Fig. 8-2)
When the upper pressing piece begins to make contact with the glass, turn the handle a little at a
time. Temporarily stop turning the handle and take the watch out of the hand press to check
that the glass is sitting level in the case. (If press fitting is continued until the glass is completely
press fit in the case, it will be impossible to correct the position of the glass if it is not sitting level in
the case. Always make sure to discontinue press fitting to check that the glass is level.)
8) If the glass is being press fit on an angle, place a piece of cloth or buckskin on the part of
the glass that is higher (the part that has been pressed in the least) and continue press fitting.
(Tilting of the glass is corrected since pressure is increased correspondingly by the presence of the
cloth or buckskin.)
9) When appears that the glass is being pressed in on an angle, press the glass in a little at a time
while interrupting press fitting to make sure that tilting has been corrected.
10)When the glass has been completely pressed in, check the quality of the fit visually and if there is
no problem, install the module and cover/back.
11)In the case of water-resistant watches, always make sure to perform the waterproof inspec-
tion after repair is completed.
— 21 —

8-2 Button Replacement
If a watch has been dropped or bumped on hard object, a button may be damaged or a button shaft
may become bent by the impact.
If this happens, it is necessary to replace the button since it may no longer operate or water may enter
through the space around the button resulting in defective water resistance.
In addition, since buttons will no longer be able to be depressed if dust or other dirt becomes trapped
in the button holes of the case, it is necessary to remove the buttons from case and remove the dust
or dirt.
The buttons are fastened to the case with E-rings.
The procedure for removing and installing buttons is indicated below. Precision screw driver (–)
Tool used
3 1904 1659 Silicone grease
1) Remove the cover/back of the watch and take

out the module.
2) Insert a precision screw driver (minus) into the
gap between the E-ring and the button shaft
in the case, and push the E-ring off the button
shaft. Be careful not to apply excessive force
with the screwdriver or the E-ring may pop out
of the case and become lost. (Fig. 8-3) Fig. 8-3
3) Remove the button from the case and replace E-ring
it with a new one.
Apply silicon grease to the packing/O-ring attached to the button shaft at this time to ensure proper
water resistance and smooth button operation.
4) Attach the button to the case.
5) Install the E-ring on the button shaft and fasten the button to the case.
Align the groove of the button shaft for the E-ring at the same position on the side of the inside of
the case, and place the E-ring at that location.
Then, using a minus screwdriver, push gently on the E-ring from above so that it catches on the
shaft.
If the E-ring has been spread apart so that it does not catch on the button shaft, either replace it
with a new one or press it together so that it catches on the shaft.
6) Attach the module and cover/back.
7) In the case of water-resistant watches, always make sure to perform the waterproof inspec-
tion after repair is completed.
— 22 —

8-3 Register Ring Replacement
Tool used
2 1901 9524 Case opener A
3 1901 9521 Silicone grease coating case
The bezel provided on the upper surface of the watch case that rotates is referred to as a register ring.
A packing/O-ring is installed between the case and register ring so that the register ring rotates smoothly.
In addition, a spring/leaf is used on some models to prevent the register ring from rotating in the
opposite direction.
When the register ring suddenly is no longer able to be rotated or the rotary torque becomes extremely
heavy, this is frequently caused by a broken packing/O-ring.
When this happens, remove the register ring and replace the packing/O-ring.
When removing the register ring from the case, open the case by inserting a case opener A between
the case and register ring.
There are some models in which the gap between the case and register ring is slightly wider for
inserting the case opener.
When attaching the register ring, it is usually pressed onto the case from above until it catches on the
case. Use the hand press for the attachment.
Furthermore, there are many cases in which the register ring, panel and tape/adhesive (for securing
the plate) supplied from Casio are only available as separate parts for those register rings of the MD,
LD and AD series. In this case, order all three parts from Casio and assemble them into a single unit
before installing on the watch.
8-4 Piezo Replacement

In nearly all watches equipped with an alarm, a piezoelectric device on the inside of the watch cover/
back sounds an alarm as a result of a spring/coil and so forth contacting a P.C.board.
If this piezoelectric device is cracked, the alarm will no longer be sounded and the piezoelectric device
must be replaced.
Some piezoelectric devices are supplied in the form of a cover/back ass'y in which the piezoelectric
device is already installed in the cover/back, while other are supplied as individual parts referred to as
piezo.
In the case of the latter, a piezo must be available when replacing the cover/back.
The procedure for attaching the piezo to the cover/back is as described below.
Tool used
1 1901 9524 Case opener A
2 1901 9522 Hand press
3 Hair drier
— 23 —

1) Remove the old piezo from the cover/back (first Cover/Back Hand press
take out the piezo from the cover/back using a case
opener A and then clean by wiping with alcohol).
2) Have available the new piezo and the tape/adhe-
sive (thermal compression bonding type).
3) Apply a piece of tape/adhesive to the cover/back
and affix the piezo on the tape. (The piezo should
be positioned so that it contacts the spring/
coil.)
4) With the piezo attached to the tape as in 3) above
and facing up, place the cover/back on a hand
press and apply pressure. Apply pressure by turn-
ing the handle about 180 degree more after the Fig. 8-4
upper pressing piece of the hand press makes Hair drier
contact with the piezo.
5) With the piezo and cover/back still in the press, heat the cover/back for about 30 seconds with a
hair-dryer. (Fig. 8-4)
6) When tape/conductive, sheet/insulation and so forth are required following thermal compression
bonding, affix the tape over the piezo.
7) Once the cover/back has cooled, attach it to the watch and check the sound pressure.
8) In the case of water-resistant watches, always make sure to perform the waterproof inspection
after repair is completed.
9. Analog Block Replacement

In the case of modules/with movement in combination watches that use plastic gears, only the analog
portion of the block can be replaced.
Although the replacement procedure in this case differs slightly depending on the model, it generally
consists of the steps described below.
Tool used
4 1904 1647 Anti-mafnetic screw driver set
1) Remove the module from the case.

2) Remove the hands, dial, wheel/hour, washer, battery and so forth from the module/with movement.
3) Remove the hooks of the plate/main, and separate the module from the plate/main, housing-1 and
housing-2.
4) Remove the two or three screws to remove the P.C.B. from housing-1.
5) Remove the one or two screws and remove the analog block from housing-1.
6) Replace the analog block with a new one. (Before attaching the new analog block to housing-1,
blow off any dirt or dust with the blow brush.)
7) Reassemble the watch in the reverse order of steps 1) to 5).
Furthermore, the following precautions should be observed when replacing the analog block.
a) Avoid touching the coil ass'y and be careful not break the coil wire.
— 24 —

b) When putting the analog block down, place it with the shaft side facing up (to prevent the shaft
of the wheel/second from breaking).
c) Since small particles of dust trapped between the gears can cause modules/with movement,
and particularly plastic movements, to stop, in addition to keeping the location where repair
work is performed as clean as possible, an effort should also be made to blow the analog block
with the blow brush several times during the course of repair work.
Wheel/Hour
Analog block
LCD
Interconnector
Housing
Terminal/Battery –
Battery/Silver oxide
PCB ass'y
Coil
Sheet/Insulaion
Plate/Main
Screw
Sheet/Insulation
— 25 —

10. Waterproof Inspection
Waterproof inspections are performed on all Casio water resistant watches at the factory correspond-
ing to the level of water resistance, and are confirmed to satisfy the inherent water resistance specifi-
cations of each model prior to shipment.
Once the cover/back is opened during repairs, however, it goes without saying that the water resis-
tance confirmed at the factory is no longer applicable. The majority of Casio water resistant watches
are of the sports and outdoor use. Since there are many occasions during which these models are
used in contact with or in water, it is necessary to perform a waterproof inspection corresponding to
the level of water resistance of each model following all repair procedures that involve opening the
cover/back of the watch to confirm that a level of water resistance is ensured.
In addition, since plastic cases are used in many Casio watches, even when these cases appear to be
free of any damage, water may enter the watch which is through the micro-cracks result of the watch
being subjected to excessive shock during use.
Thus, with respect to water resistant watches, it is preferable to perform a waterproof inspection
whenever the watch is returned to the owner, even after repairs have been performed, such as replac-
ing the band, that do not involve opening the cover/back.
There are primarily three types of instruments used for performing the waterproof inspection.
These consist of a water resistant tester, air leak checker and water pressure tester and hot plate.
Although the water resistant tester is used most commonly, the majority of these testers are only
able to apply 10 bar of pressure at most. In the case of models having water resistance of 50 M (5 bar)
and 100 M (10 bar), this inspection is sufficient.
Even when this inspection is performed on watches having water resistance of 200 M (20 bar) and 300
M (30 bar), there is very little chance that problems with water resistance will occur when used in
ordinary environments.
However, since some users use these models for scuba diving, inspections using this water resistant
tester are not sufficient.
In such cases, it is preferable to perform the waterproof inspection using an water pressure tester
and hot plate.
Although the air leak checker is used in the same manner as the water resistant tester, since the
inspection can be performed faster and water is not required, this instrument is considered to be
suitable for service centers repairing a large volume of watches.
Indication Necessary pressure Water pressure Tester

Water Resistant Tester Air Leak Checker
on the watch for the inspection and Hot Plate
No indication Not necessary Not necessary Not necessary

Recommended
Water resistant 2.5bar Indispensable Not necessary
(usefull)
50 meter Recommended
5bar Indispensable Not necessary
water resistant (usefull)
10bar Indispensable Recommended
22bar Indispensable Indispensable
25bar Indispensable Indispensable
Note: Professional diver’s watches (DEP series) are not included in the chart above.
For the repair of the professional diver’s watches, please send to the nearest Diver ASC.
— 26 —

10-1 Water Resistant Tester
This tester is used to determine the locations of water penetra-
tion in watches that have been judged to have defective water
resistance.
Thus, this instrument is also useful since it is able to determine
what part should be replaced in the case of defective water re-
sistance.
Tool used
1 1904 5225 Water resistant tester
1) Place water in the cylinder and cover the cylinder with the
watch suspended inside. (At this time, the watch should be
suspended in the space above the water.) The air pres-
sure and water pressure in the cylinder at this time are 1 bar,
and the air pressure inside the watch is also 1 bar. Water resistant tester
2) Pressurize the inside of the cylinder to the pre-
scribed pressure. (The cylinder should be pres- Many bubbles (leaking point)
surized by 1 bar for every 10 meters of water resis-
tance.)
3) Once the cylinder has been pressurized, leave
the instrument for 3 minutes. Although the in-
side of the cylinder is pressurized at this time, if the
water resistance of the watch is satisfactory, the
pressure inside the watch will remain at 1 bar even
after 3 minutes. What is more, if the water resis-
tance of the watch is defective, the inside of the
watch will also be pressurized with the air pressure
and water pressure inside the cylinder. Fig. 10-1
4) Lower the watch into the water after 3 minutes
have passed, and secure it in that position. Small quantity of bubbles
5) Gradually reduce the air pressure in the cylinder.
If the water resistance of the watch is satisfactory, there
will be no change in the watch even though the water
pressure has lowered.
If water resistance is defective and the inside of the
watch is pressurized, the air pressure inside the watch
will decrease accompanying the decrease in water
pressure causing air to be released from the watch.
As a result, many bubbles will appear from the lo-
cation of defective water resistance. (Fig. 10-1)
This makes it possible to determine the location of the Fig. 10-2
leaking.
In this case, although small quantity of bubbles may appear from the gaps between the case and
buttons, case and bezel and so forth, this is the result of air trapped in the gaps being released as
bubbles, and does not indicate defective water resistance. (Fig. 10-2)
— 27 —

The difference between these two situations in the amount of bubbles produced.
In the case of defective water resistance, bubbles are released continuously, while in the case of
air trapped in the gaps as described above, the number of bubbles is less and bubbles no longer
appear after a short time.
In the case of watches in which the entire case is covered by a bezel as in the G-Shock and Baby-
G models, the amount of air trapped in the gap between the case and bezel is quite large.
It is therefore recommended to perform the waterproof inspection after first removing the bezel on
these models.
6) Furthermore, when a watch has been found to have defective water resistance, the watch
should be taken out of the water as soon as the defective location can be determined.
If the watch is left in the water until the scale reaches 0, water will begin to penetrate inside the
watch resulting in the risk of damage to the module.
10-2 Air Leak Checker

This instrument is also used to perform waterproof inspections, but there is no risk of damage to the
watch caused by entrance of water even for watches with defective water resistance.
In addition, since the waterproof inspection can be performed in a relatively short time (about 1 minute),
this is useful when performing waterproof inspections on a large volume of watches.
However, this instrument is more expensive than water resistant testers.
And the location of the defective water resistance cannot be determined with this instrument alone.
In order to determine the location of a leaking in, it is necessary to perform a waterproof inspection
using a water resistant tester.
The following is the instruction of one of the air leak checker WPC-8002 which is delivered by CASIO.
WPC-8002 measure the air leakage of the watch by using the sensor which detects the glass defor-
mation.
Tool used

2 1901 9710 Waterproof checker
3-1 1901 9712 Air compressor (100 V)
3-2 1901 9711 Air compressor (220 V)
1) Turn the power switch on.

After the power on, wait for 3 minutes for warming up of the circuit to keep the sensor accuracy.
2) Place the watch on the support.
3) Press down the head onto the center of the watch glass.
4) Turn the clamping screw to clockwise to fix the head.
On this time never turn the Clamping screw with too much force.
5) Close the capsule.
6) Turn the clamp to the end to fix the capsule.
7) Set the hand of the indicator at zero position by turning ZERO ADJ.dial.
Then READY lamp will be lit.
8) Turn START switch on.
Continuously press down the START switch until the air pressure is increased to 5 bar.
Note: In case the START switch is released before the air is increased to 5 bar, press down RESET
switch and start again from zero bar. Never press the START switch on the halfway.
9) Release the START switch when the hand of the pressure gauge reaches at 5 bar.
— 28 —

10)Wait about one minute for the judgment of the air tightness.
In case the watch has no air leakage
The hand of the indicator will moves to left side at first, and it will be back to center (zero point)
approx. 15 seconds later. Then it will moves to left side again and it will be back to center again
before the hand will pass over red zone of the indicator. And then OK lamp will be lit.
In case the watch has air leakage
The hand of the scale indicator will moves to left side at first, and it will be back to center (zero
point) within 15 seconds. Then it will moves to right side, and NG lamp will be lit.
In case the watch has big air leakage
The NG lamp will be lit 15 seconds later without any moving of the hand.
11)In case the OK lamp is lit, the water resistant of the watch is satisfactory.
In case the NG lamp is lit, check the watch by using of water resistant tester to clarify the leaking
point. And replace the necessary parts with new one.
Capsule
Head
Clamping screw
Support
Clamp
Indicator
NG lamp
Pressure gauge
OK lamp
ZERO ADJ.
dial
POWER lamp
POWER switch START switch
READY lamp RESET switch
— 29 —

10-3 Water Pressure Tester and Hot Plate
Waterproof inspections are inherently performed using this method.
In addition, differing from the water resistant tester and air leak checker, since this instrument allows
pressurization up to 20 bar, this instrument is used to perform inspections in the case of inspecting the
inherent level of water resistance of the G-Shock and Diver's Watch models. (Professional diver's
watches must always be inspected with this instrument.)
However this instrument is also expensive and the inspection itself requires a relatively long time (at
least 15 minutes).
And determination of locations of defective water resistance in watches must be performed with a
water resistant tester.
Furthermore, since this is a destructive inspection, the modules of watches having defective water
resistance are destroyed as a result of performing inspections with this instrument.
It is therefore recommended to inspect waterproof using an air leak checker or water resistant tester to
confirm the absence of serious water resistance defects before using this instrument.
Tool used
2 Water pressure tester
3 1904 5345 Hot plate (100 V)
4-1 1901 9725 Power transformer (100 V to 120 V)
1) Open the valve screw and the cap.

2) Turn the press giving handle to anti-clockwise to the end.
3) Pour the water up to top of the water pressure tank.
4) Place the watch on the watch setting table which is a accessory of the water pressure tester. And
set them in the water pressure tank. If some bubbles are remained in the tank, remove them.
5) Close the cap without the valve screw. On this time water will be overflowed from the small holes of
the cap. (Even a small amount of the air should not be remained in the tank.)
Use the closing rod for the final tightening of the cap.
6) Close the valve screw.
7) Turn the pressure giving handle to clockwise. Then the water pressure value will begin to rise.
Note: In case the water pressure value do not rise, open the cap and valve screw, and turn the
pressure giving handle to clockwise and anti-clockwise for several times, and lean the water
pressure tester with pressure gauge side down.
Then small bubbles will be appeared from the small hole in the tank. After that close the cap
and valve screw again to give the water pressure by turning the pressure giving handle.
8) Stop to turn the pressure giving handle at inherent water resistant point of each watches. (The
tank should be pressurized by 1 bar for every 10 meters of water resistance.)
9) Leave the water pressure tester for 10 minutes without any operation.
10)After 10 minutes has passed, turn the pressure giving handle to anti-clockwise to release the water
pressure.
11)Open the valve screw, and then open the cap.
12)Take out the watch setting table from the water pressure tank.
13)Take the watch from the watch setting table and wipe the water on the watch with dry cloth.
— 30 —

14)Place the watch with cover/back side down on heated hot plate for 10 minutes.
Note1: Set the temperature of the hot plate approx. 60 °C.
Note2: In case the hot plate HM-11 which is delivered by CASIO is used, place the silicone rubber
with thermo tape for the prevention of excessive heating to the watch.
15)After 10 minutes have passed, take the watch from the hot plate, and place the watch with glass
side down on the wet cloth for one minute.
16)One minute later, take the watch and wipe the water on the watch glass, and check whether the
condensed water is under the glass or not.
In case the condensed water is not appeared
The watch is watertight, and water resistant checking is finished.
In case the condensed water is appeared
Replace the case/center ass’y with new one. And make the water resistant checking from the first
step.
Pressure gauge
Watch pressure
Pressure giving
Valve screw
Cap
Closing rod Watch setting
Silicone rubber
Hot plate
— 31 —

11. Quality Evaluation and Replacement of Sensor/Pressure
The sensor/pressure is used in watches equipped with altimeters, barometers and depth meters, and
is a device that measures air pressure.
Since the sensor itself has a certain degree of variation in accuracy, trimming is required with the
sensor/pressure connected to the module in order to ensure that the accuracy of the watch remains
constant.
Malfunctions involving the sensor/pressure include inaccuracy of sensor measured values, FULL dis-
play and Sensor Errors.
When any of these malfunctions occur, however, replacement is usually performed with a module with
sensor (on which trimming has been performed at the Casio factory).
However, when a Sensor/pressure trimming jig set is available, repairs can be performed by replacing
the individual sensor or adjusting the sensor. (Fig. 11-1)
Fig. 11-1 (SENSOR/PRESSURE TRIMMING JIG SET)
— 32 —

11-1 Trouble Shooting with Sensor/Pressure Trimming Jig Set
Change the
display to
barometer mode
OK
Check the
Finish
display
No good
The value is Display shows Display shows

inaccurate "FULL" "SENSOR ERROR"
Check the
Read and write connection of FPC or
down the value springs/coil of the
sensor
Perform AC Check the Yes Is it good

resistance vakue
condition ?
of the sensor
No
Read and write

down the value Fix the
Yes conection
again Is the value
correct?
Compare the value of Relace the

the watch and correct sensor with new
barometer one
No
More than
How is the 10 hPa (mb)
difference ?
Less than 10 hPa (mb)
Set the value Sensor trimming Replace the

according to the with Sensor/ module with
correct Pressure Trimming sensor with new
barometer Jig Set one
— 33 —

11-2 Trouble Shooting without Sensor/Pressure Trimming Jig Set
Change the
display to
barometer mode
OK
Check the
Finish
display
No good
The value is Display shows Display shows

inaccurate "FULL" "SENSOR ERROR"
Check the
Read and write connection of FPC or
down the value springs/coil of the
sensor
Perform AC
Yes Is it good
condition ?
Read and write No

down the value
again
Compare the value of

the watch and correct
barometer Fix the
conection
More than
How is the 10 hPa (mb)
difference ?
Less than 10 hPa (mb)
Set the value Replace the

according to the module with
correct sensor with new
barometer one
— 34 —

11-3 Sensor/Pressure Quality Evaluation Sensor
Tool used
1 1901 9708 Aneroid barometer (3-1050-05)
3 1901 9523 Precision tweezers F. P. C.
4 1904 5277 Multimeter Joiner
5 1901 9924 Pressure sensor trimming jig set
6 1901 9949 Holder (for ALT-6000)
7 Holder (Universal) A B
Evaluation of the quality of the sensor/pressure is performed by

C D
measuring the resistance values detected from the four terminals
on the sensor. The resistance values between each terminal are
as shown right. (Fig. 11-2)
If any one of the measured values is found to be outside the A ← 3.75 ± 0.75 KΩ → B
standard value, the sensor or module with sensor have to be re-
placed. C ← 3.75 ± 0.75 KΩ → D
11-4 Removal and Attachment of Sensor/Pressure

In case the module with sensor is removed from the case for the replacement of sensor/pressure,
module with sensor or case/center ass’y and so forth, the module and the sensor/pressure should be
separated and they should be removed one by one.
The procedure of removal and attachment of sensor/pressure is as shown below.
11-4-1 Sensor/Pressure Equipped on Side of the Watch

For the names of each parts and construction, please refer to page 19 the exploded view of the
Watches Equipped with a Sensor/Pressure (Side Sensor).
1) Open the cover/back.
2) Remove the screw holding the flexible cable over the module along with the holder, and separate
the flexible cable from the module.
3) Remove all parts including the cap/sensor, cover/sensor and packing/o-ring (sensor)
4) While holding onto the flexible cable with a tweezers, remove the sensor/pressure by pushing it to
the outside from the sensor box of the case/center.
5) Install a new sensor/pressure by first inserting the cable into the case.
Be careful so that the sensor is positioned correctly.
In addition, do not break the cable by pinching with the tweezers or bending excessively.
6) Install the cable in the module, attach the holder, tighten the screw and connect the module and
sensor.
7) Perform the AC (All Clear) procedure when the module and sensor have been connected.
Air pressure will not be measured and "SENSOR ERROR" will continue to be displayed if this AC
procedure is not performed.
8) Perform sensor trimming with the Sensor/pressure trimming jig set in case only the sensor/pres-
sure is replaced with new one.
9) In the case of water-resistant watches, always make sure to perform the waterproof inspection
after the repair is completed.
— 35 —

11-4-2 Sensor/Pressure Equipped on Front of the Watch
For the names of each parts and construction. Please refer to page 20 the exploded view of the
Watches Equipped with a Sensor/pressure (Front Sensor).
1) Open the cover/back.
2) Take out the module from the case. The module is hooked in 6 and 12 o’clock side of the case. So
unhook two hooks with precision screw driver or tweezers at first, then lift up the module from the
case.
3) Unscrew and remove two screws under the module.
4) Remove the holder and casing frame of the sensor from the case.
5) Take out the sensor/pressure from the case.
6) When the sensor/pressure is installed again, apply the silicone grease to the packing/O-ring(sensor).
7) Install the sensor/pressure.
8) Set the holder and casing frame of the sensor. And screw up two screws for the holder.
9) Set the module in the case. Be careful to hook the two hooks in the case.
10)Perform AC operation.
11)Perform sensor trimming with the Sensor/pressure trimming jig set in case only the sensor/pres-
sure is replaced with new one.
12)In the case of water-resistant watches, always make sure to perform the waterproof inspection
after the repair is completed.
12. Altimeter of Watches Equipped with a Sensor/Pressure

Altimeters consist of actual altimeters and relative altimeters.
Actual altimeters express the altitude of a certain location from sea level in the form of a direct mea-
surement using light (laser, etc.), radio waves or sound waves.
Relative altimeters express the difference in elevation between one location and another by using the
phenomenon in which air pressure decreases by 12 hPa (mb) for 100 meter increase in altitude (up to
1,000 meters above sea level).
All altimeters used in Casio
watches are relative altimeters.
They display the value that results by
converting the difference in air pres-
sure between certain locations mea-
sured with the sensor/pressure and a
reference altitude, and then adding
that difference to the reference alti-
tude.
What is important here is that since
air pressure changes by the day and
hour, even when air pressure is mea-
sured at the same location, relative al-
titude changes proportional to
changes in air pressure.
Consequently, when using the altim-
eter (relative altimeter) of a Casio
watch, it is necessary to set the refer-
ence altitude (0 meters or the altitude
value for that location) according to the
instruction manual for each use.
— 36 —

13. Quality Evaluation and Replacement of Sensor/Magnetic
Tool used
4-2 1904 1668 Soldering iron (220 V)
6 1901 9401 Solder
The sensors/magnetic used in Casio watches equipped with an electronic compass consist of mag-
netic resistance (MR) devices in which the resistance value changes in response to the effects of the
earth's magnetism.
These devices combine a total of four magnetic resistors, with two in the direction of the X axis and
two in the direction of the Y axis.
In addition, a bias magnetic field is generated within the device as well in order to detect the direction
of weak magnetic fields such as those produced by the earth's magnetism.
The effects of the earth's magnetism and this bias magnetic field produce a change in the resistance
values of the four magnetic resistors.
That change is then detected as a potential difference (voltage) at the output terminal to determine
direction.
13-1 When a Watch Does Not Indicate Directions Correctly

Since a device is used in which resistance values change according to the effects of the earth's
magnetism as described above, when the watch does not indicate the correct direction, the following
three types of causes should be considered other than a malfunction in the sensor/magnetic itself.
1) Measurements are made nearby or inside objects that block the earth's magnetism such as iron
desks or lockers, inside a vehicle or indoors (especially reinforced concrete buildings).
2) Measurements are made in close proximity to objects that generate their own powerful magnetic
field causing distortion of the earth's magnetism, such as magnetic necklaces, high-voltage power
lines, aerial lines and electrical appliances (including televisions, personal computers and speak-
ers).
3) The watch itself has become magnetized for reasons such as placing the watch near any of the
objects described in 2) above.
In the case of 1) or 2), direction will be determined correctly if measurement is performed in a
different location. In the case of 3) however, “bidirectional calibration” and “northerly calibra-
tion” should be performed to demagnetize the watch.
Correction is performed as described in each instruction manual or operation chart in the service
manual.
13-2 Quality Evaluation of Sensors/Magnetic
When the watch still does not measure direction correctly even when the above corrections have been
made or when sensor error is displayed or direction is not displayed, the sensor/magnetic may have a
malfunction. Evaluation of the quality of sensor/magnetic is performed by measuring the resistance
value between the terminals of the sensor.
The resistance values between each terminal are as shown in next page.
— 37 —

If any of the resistance values are found to be abnormal, the sensor/magnetic, PCB ass’y or module is
replaced with a new one.
No. of pin Resistance value
No.3 and No.6 800 Ω ± 200 Ω
No.2 and No.7 800 Ω ± 200 Ω
No.1 and No.5 70 Ω ± 14 Ω
No.1 and No.4 85 Ω ± 17 Ω
13-3 Quality Evaluation of Sensors/Magnetic Fig. 13-1

In case the sensor/magnetic is replaced, be sure to keep the followings for the handling of the sensor.
1) Be sure to gasp the sensor/magnetic with fingers of wearing the fingerstall, and don’t gasp the
sensor with tweezers to prevent the wire from breaking.
2) Be careful direction of the sensor when the
new sensor is installed.
The direction of the sensor must be as
shown right. Be careful for four marks on
each corner of the sensor. Also be careful
for top and bottom of the sensor.
3) Be sure to install the new sensor flatly on
the PCB.
4) In the case of models using a triple sensor
(ATC-1000/ATC-1100/ATC-1200/PRT-40,
etc.), as the sensor/pressure is used, the
sensor/magnetic or module with sensor
must be replaced unless a sensor/pres-
sure trimming jig set is available. (The sen-
sor/magnetic cannot be replaced by the
PCB ass’y.) Fig. 13-2
14. Quality Evaluation and Replacement of Coil Ass'y

Tool used
When an analog or combination watch has stopped running, a defective PCB ass’y or coil ass'y should
be considered when oscillation is unable to be confirmed by performing an oscillation check (see 2.
Measurement of Current Consumption (Oscillation Check)).
In this case, determining whether the defect lies in the PCB ass’y or the coil ass'y is performed by
measuring the resistance value of the coil ass'y.
— 38 —

Remove the coil ass'y from the module/with movement
and measure the resistance value at the two terminals
with a multimeter. If the resistance value at this time is
roughly 3 KΩ, the coil ass'y is not defective. (Fig. 14-1)
Furthermore, some models of analog watches use a
battery/lithium (3 V).
The resistance value of the coil ass'y in these models
is roughly 6 KΩ.
When grabbing the coil ass'y with a tweezers, al-
ways make sure to grab onto the metal portion (side
opposite that with the terminals).
Never grab the coil ass'y on the terminal side or coil
(wire) (since this can break the coil wire).
Fig. 14-1
15. Repair of Module/with movement
Regular maintenance must be performed on modules/with movement to eliminate friction between
mechanical components and maintain smooth operation.
In the case of metal movements in particular, the watch may stop running as a result of being out of oil
even when there are no malfunctions.
There are many cases in which this is repaired by cleaning and lubricating of the movement.
There are two types of modules/with movement used in Casio watches, namely plastic movements
and metal movements.
Although plastic movements require little maintenance such as regular lubrication, they are more
susceptible to shock than metal movements, thus requiring that caution be used when handling parts.
Although metal movements are more resistant to shock than plastic movements, they require mainte-
nance in the form of regular cleaning and lubrication.
15-1 Precautions when Repairing Modules/with movement

1) Since several extremely small gears and screws are used in analog movements, caution must be
taken during repair work to ensure that they are not lost.
2) Since modules/with movement are susceptible to fine particles of dust and hair, in addition to
keeping the location where repair work is performed clean, an effort should be made to remove
any dust and hairs by blowing the movement with an blow brush several times during the course of
repair work.
Particular caution should be taken with respect to plastic movements since they easily pick up
electrostatic charge making it easy for dust and hair to become adhered to the movement.
3) When repairing an module/with movement, anti-magnetic tweezers should be prepared exclu-
sively and distinguished from tweezers used in other repairs (see below).
4) When grabbing the coil ass'y with a tweezers, always hold onto the metal portion to prevent break-
ing of the wire.
5) When picking up plastic gears with tweezers, grab the shaft or body from above or below.
— 39 —

15-2 The Structure and Names of Parts of Module/with movement
(Train wheel side)
Screw
Bridge/Train wheel
Wheel/Third
Wheel/Fifth
Wheel/Second
Rotor
Bridge/Cannon pinion
Screw
Jumper/Setting lever
Lever/Setting
Wheel/Minute
Wheel/Cannon pinion
Wheel/Setting
Yoke
Coil ass'y
: Moebius 8031
: Moebius D-5 Stator
Wheel/Sliding pinion
Pin/Setting lever
Plate/Main
Crown with stem
— 40 —

(Minute train side)
Holder/Movement
EL
Spring/Coil
Holder/Hour wheel
C-ring
Indicator/Day
Screw
Jumper/Date indicator
Wheel/Driving calender
Lever/Date stop
Lever/Day setting
Indicator/Date
Plate/Date indicator guide
Wheel/Hour
— 41 —

15-3 Explanation of Each Part of Module/with movement
Modules/with movement can be broadly divided into the train wheel unit, correcting unit and calendar
unit according to their respective functions.
15-3-1 Train Wheel Part

The train wheel unit is composed of the stepping motor (coil ass'y, stator and rotor), wheel/fifth (wheel/
intermediate), wheel/second, wheel/third, wheel/cannon pinion (ass'y), wheel/minute and wheel/hour.
To begin with, the stator connected to the coil ass'y becomes a magnet as a result of a 1 Hz signal
from the coil ass'y.
Since the 1 Hz signal flowing to the coil ass'y at this time is an alternating current, the N and S poles
of the stator rotate in reverse in every second.
A part of the rotor is made of a magnet that is repulsed each time the N and S poles of the stator rotate
in reverse, rotating 180 degree each time in one second.
This rotation is transferred via the wheel/fifth (wheel/intermediate), wheel/second, wheel/third and so
forth, with deceleration occurring after each round of transmission.
This transmission of rotation results in movement of the hands at- Shaft
tached to the gear shaft. (Fig. 15-1, Fig. 15-2)
Pinion
In the train wheel unit, the wheel/minute and wheel/hour on the
dial side sandwiched around the plate/main are referred to as the
Wheel
minute train side, while the portion on the battery side is referred to
as the train wheel side. Fig. 15-1
Battery Hand/Minute Hand/Hour

Hand/Second Wheel/Minute
Stator
Coil ass’y
LSI
Wheel/Hour
Rotor
Wheel/Second Wheel/Cannon pinion
Oscillator/Quartz
Wheel/Third
Fig. 15-2
15-3-2 Correction Part

The correction part refers to the part that performs correction of time and date.
It is composed of the lever/setting, jumper/setting lever, lever/stop, lever/reset, wheel/sliding pinion
and wheel/setting. First, when the crown is pulled out, the lever/setting rotates simultaneous to the
crown being pulled out. This causes the end of the lever/stop to make contact with the rotor or wheel/
fifth (wheel/intermediate) causing the hands to stop. At the same time, since the jumper/setting lever
causes the wheel/sliding pinion to slide toward the center of the movement, the wheel/sliding pinion
engages with the wheel/setting making it possible to set the time.
— 42 —

When the crown is turned in this state, rotation is transferred in the order of the crown, wheel/sliding
pinion, wheel/setting and wheel/minute.
The wheel/minute causes the wheel/hour and wheel/cannon pinion to rotate resulting in movement of
the hand/minute and hand/hour. (Fig. 15-3)
Since only a portion of the wheel/cannon pinion rotates at this time, rotation is not transferred to the
wheels/second and third.
Wheel/Cannon pinion
Crown with stem Hand/Minute
Wheel/Minute
Pinion/Sliding Hand/Hour
Wheel/Setting
Wheel/Hour
Fig. 15-3
15-3-3 Calendar Part Wheel/Intermediate

The calendar unit provided in analog watches displays the Indicator/Date Wheel/Hour
date using rotating disks referred to as the indicator/date and
indicator/day.
It is composed of the wheel/intermediate, wheel/driving cal-
ender, indicator/date, jumper/date and jumper/day. To begin
with, rotation is transferred from the wheel/hour that drives
Wheel/Driving
the hand/hour to the wheel/intermediate and then the wheel/ Finger/Date
calender
driving calender.
The wheel/driving calender is designed to make one revolu- Fig. 15-4
tion in 24 hours.
Finger/Day
The finger/date attached to the indicator/date engages once
Wheel/Intermediate
a day with the gear on the inside of the indicator/date to ad-
vance the date. Indicator/Day
In the case of advancing the day, the finger/date attached to
the wheel/driving calender similarly engages once a day with
the star/day attached to the indicator/day.
Furthermore, the timing by which the day advances is usually
after the timing by which the day advances to prevent the
Lever/Day setting
load of calendar operation from being applied simultaneously. Wheel/Driving
In the case of correcting the date, the wheel/setting turns the calender
indicator/date and star/day directly. However, since the day
Fig. 15-5
and date are normally advanced from about 12:00 midnight
until about 4:00 AM, calendar correction should not be per-
formed during this time.
— 43 —

15-4 Disassembly, Cleaning, Lubrication and Reassembly of Module/with movement
Tool used
5 1904 1648 Rodico
6 1904 1646 Anti-magnetic tweezers
7 1904 1671 Movement holder
8 1904 5155 Movement placing block
9-1 1904 1654 Eye lens (2.0 magnification)
9-2 1904 5150 Eye kens with holder (2.5 magnification)
9-3 1901 9911 Eye kens with glass holder (2.5 magnification)
10 1904 5154 Cleaning brush
11 1904 1652 Oil injector set
12 1904 1651 Oil pot
13 1904 1650 Oil (Moebius No.9010)
14 1904 1673 Grease (Moebius No.8200/20cc)
16 1901 9756 Hand fixing tool
17 Isopropyl alcohol
18 Benzene
19 Petri dish
15-4-1 Disassembling
Although disassembly is basically performed in the order of PCB ass’y, coil ass'y, minute train side,
correction part and train wheel part, with respect to the details of the disassembly procedure, each
part should be disassembled one at a time according to the disassembly procedure described in the
exploded view of the service manual for each module/with movement.
For those persons who are unfamiliar with the disassembly procedure, make the repair work as fol-
lows.
a) Lay the parts out in the order they are disassembled in order to makes assembly work
easier.
b) Make the sketches of the movement while the movement is disassembled in order to make
clear the position of each components on reassembling.
When disassembling, perform work while checking each part for damaged locations and the
presence of dust and dirt.
Isoprophyl alcohol or benzene
15-4-2 Cleaning
Once disassembly work is completed, clean each
Wheels Petri dish
component part.
1) Pour some cleaning fluid into a container such
as a Petri dish. Use benzene or isoprophyl
alcohol when cleaning metal movements, and
isoprophyl alcohol when cleaning plastic move-
ments. (Never use benzene to clean plas-
tic movements.) (Fig. 15-6)
Fig. 15-6
— 44 —

2) Place all the component parts, except for the rotor, in
Rotor
the cleaning fluid and clean each part with a cleaning
brush. Clean the areas around lubrication points par-
ticularly carefully.
3) Component parts may also be cleaned by pouring
Tweezers
cleaning fluid into an ultrasonic cleaner instead of per-
forming steps 1) and 2) above.
4) Never clean the rotor with cleaning fluid. Remove
any dust and metal particles using a Rodico. (Fig. 15-
7) Fig. 15-7
Rodico
15-4-3 Lubrication and Reassembly

Once cleaning has been completed, reassemble each part.
Although the order of assembly is basically opposite that of disassembly, with respect to the details of
the assembly procedure, assembly should be performed according to the assembly procedure de-
scribed in the exploded view of the service manual for each module/with movement.
When assembling the train wheel side in particular, installing all of the gears and so forth and
covering with the bridge/train wheel check that each gear and rotor is securely installed in the proper
hole while viewing the module/with movement from the side with the screws still loose.
If the shaft has shifted out of position from the hole, adjust the position of the shaft with a pointed rod
such as an oil injector so that all gears are aligned at the proper positions.
In addition, lubricate the plate/main, bridge/train wheel, cannon pinion with driving wheel ass'y and
lever/setting. Both oil and grease are used for lubrication.
When using oil, place a suitable amount of oil to an oil pot, transfer that oil to the oil injector and drop
onto the movement.
The following indicates important points to be remembered regarding lubrication.
Fig.No. Parts name Oil/ Grease

Fig.15-8 Plate/Main Grease/Oil
Fig.15-9 Lever/Setting Grease
Fig.15-10 Wheel/Cannon pinion Grease/Oil
Fig.15-11 Wheel/Second Oil
Fig.15-12 Bridge/Train wheel Oil
Fig.15-13 Pinion/Sliding Grease
: Grease
Fig.15-14 Crown with stem Grease
: Oil
Fig. 15-8
Fig. 15-10
Fig. 15-13
Fig. 15-9 Fig. 15-11 Fig. 15-12 Fig. 15-14
— 45 —

15-4-4 Confirmation
When all parts have been assembled, install the battery and with the crown pulled out, set temporarily
the hand/second and push in the crown to see if the watch runs.
If the hand/second moves normally, remove the hand/second and install the wheel/hour, washer, dial
and hands (hour, minute and second) to the movement.
If the hand/second does not move normally, repeat the disassembly and reassembly procedures.
(Refer to Hand Attachment and Removal in WATCH BASIC REPAIR MANUAL (RANKS C AND D).)
In the case of a waterproof watch, always make sure to perform the waterproof inspection after
repair is completed.
16. Clock Repair (Heat Seal Replacement)

In some digital clocks, the LCD and P.C.B. ass’y are joined with a heat seal. (Fig. 16-1)
Thus, thermal compression bonding of the heat seal must be performed when replacing the LCD,
replacing the P.C.B. ass’y or the display is defective due to a cracked heat seal.
Furthermore, since thermal compression bonding cannot be repeated on a seal once it has cracked, a
new heat seal must be always be used.
Tool used LCD Heat seal
NO. Code No. Tool name P.C.B. ass’y

1 Aceton
2-1 1901 9525 Soldering iron UNI MAX (220 V)
3 1901 9516 Heat seal tip (J34674-1)
4 1901 9515 Tip B (J34622-2)
5 5041 2091 Screw (3mm X 5)
6 5021 1134 Screw (1.7mm X 7) X 2pcs.
7 1901 9514 LCD fixing plate
8 6311 9609 Nut (A41984-1) X 2pcs. Fig. 16-1
1) Peel off the old heat seal from the LCD and P.C.B. ass’y.
2) Carefully wipe the bonding surfaces of the LCD and P.C.B. ass’y with a solvent such as acetone
(also referred to as dimethylketone/CH3- CO-CH3) to completely remove all paste of the old heat
seal.
Although isopropyl alcohol ((CH3)2CHO) or other solvents may also be used to wipe the bonding
surfaces, since they do not effectively remove the paste, acetone yields the best results.
Dampen a cloth with acetone and wipe off any paste remaining on the terminal surfaces by wiping
in the perpendicular direction (in the direction of the wiring leading from the components).
3) Attach the heat seal to the LCD by thermal compression bonding.
(This work is generally performed easier by joining the heat seal to the LCD first.)
There are two ways of performing thermal compression bonding: a method that uses a soldering
iron and silicon rubber, and a method that uses a soldering iron and heat seal chips.
Use a soldering iron of at least 60 W when using with silicon rubber, and at least 30 W when using
with heat seal chips.
4) Put one side of the heat seal on the terminal of the LCD.
Be sure the black carbon lines of the heat seal and terminals of the LCD are overlapped exactly.
— 46 —

5) On using both silicone rubber and heat seal tip, perform the thermal compression bonding by
touching the soldering iron vertically to heat seal and LCD from upper side as shown in drawing
with following conditions.
Pressure: 10kg/ cm2
Pressing time: approx. 10 seconds.
Firstly make the bonding at both end to fix the position of the heat seal on LCD, and then make the
bonding to the rest.
6) When the thermal compression bonding is completed, turn the LCD with heat seal and check the
condition of the bonding.
On this time, you can judge the bonding was performed correctly if the bonding part is turned
translucent.
In case the bonding part is not translucent partially, perform the thermal compression bonding
again to such part.
7) Perform the thermal compression bonding of heat seal (with LCD) and P.C.B. ass’y. Though the
bonding way is as same as the one of the heat seal and LCD, perform the thermal compression
bonding until the terminals of the P.C.B. ass’y are float up on the heat seal.
8) When the thermal compression bonding is completed, reassemble them and install the battery to
the clock to check the display.
Fig. 16-2
— 47 —

MA0700271A

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WATCH BASIC

PRT-40C ABX-68B MWA-800G

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FLOW CHART FOR REPAIR OF MODULE WITHOUT MOVEMENT ............................ 1

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EL doesn’t light Display trouble Sensor trouble

Refer to 6. Quality Sensor/magnetic

Yes Refer to 11. Quality Refer to 13. Quality

Refer to 5. LCD Yes

No good Current Good

Water resistant inspection

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EL doesn’t light Hands are not Sensor trouble

Refer to 6. Quality Sensor/magnetic

No good Current Good

Replacement of PCB ass’y Repair of mechanical portion.

Water resistant inspection

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The casing parts of watch

Band or Dial are Case/Center ass'y is Alarm doesn't

Refer to Watch Basic

Water resistant inspection

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1-1 Circuit Diagram

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DIGITAL QUARTZ WATCH

1-3 Analog Watches

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ANALOG QUARTZ WATCH

2. Measurement of Current Consumption (Oscillation Check)

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Black probe Red probe

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3-1 Capacitors/Chip Fig. 3-1

Capacitors/chip consist of two extremely thin metal plates

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4-1 Accuracy Setting by Capacitor/Trimmer

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Notes: "Close" means the lead wire is connected (or soldered).

4-3 Digital Tuning (Pattern Cutting) Method

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When the LCD is missing characters, there are many

6. Quality Evaluation and Replacement of EL

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Alligator clip P.C.B. Ass’y EL

Fig. 6-2 Fig. 6-3

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Glass & packing

Button ass'y (2H)

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Glass & packing

Button ass'y (10H) Packing/Glass

Button ass'y (8H)

Tape/Adhesive Cushion/Rubber (Inner)

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Button ass'y (10H)

Button ass'y (Light)

Button ass'y (2H)

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Button ass'y (light)