panasonic SA-AK240EE Service Manual

CD Stereo System

SA-AK240EE

Colour

(S)... Silver Type

ORDER NO. MD0601009C3

Notes: This model’s CD mechanism changer unit is CRS1. Please refer to the original Service Manual (Order No. MD0509368C0) for this mechanism.

Specifications

n AMPLIFIER SECTION

RMS Output power

THD 10%, both channels driven

1 kHz 115 W per channel (3 Ω )

Total output power 230 W

n FM/AM TUNER, TERMINALS SECTION

Preset station FM 15 stations

AM 15 stations

Frequency Modulation (FM)

Frequency range 87.50 to 108.00 MHz (50 kHz

steps)

Sensitivity 4.0 µV (IHF)

S/N 26dB 2.2 µV

ntenna terminals 75 Ω (unbalanced)

mplitude Modulation (AM)

Frequency range 522 to 1629 kHz (9 kHz step)

Sensitivity

S/N 20dB (at 999 kHz) 560 µV/m

Music Port input jack

Terminal Stereo, 3.5 mm jack

Sensitivity 100 mV, 4.7 kΩ

Phone jack

Terminal Stereo, 3.5 mm jack

n CASSETTE DECK SECTION

Track system 4 track, 2 channel

Heads

Record/playback Solid permalloy head

Erasure Double gap ferrite head

Motor DC servo motor

Recording system AC bias 100 kHz

Erasing system AC erase 100 kHz

Tape speed 4.8 cm/s

Overall frequency response (+3, -6 dB) at DECK OUT

NORMAL 35 Hz to 14 kHz

S/N ratio 50 dB (A weighted)

Wow and flutter 0.18 % (WRMS)

Fast forward and rewind time Approx. 120 seconds with

C-60 cassette tape

n DISC SECTION

Disc played [8 cm or 12 cm]

(1) CD-Audio (CD-DA)

(2) CD-R/RW (CD-DA, MP3, WMA formatted disc)

(3) MP3/WMA

Bit rate

MP3, WMA 32 kbps to 320 kbps

Sampling frequency

MP3/WMA 32 kHz, 44.1 kHz, 48 kHz

SA-AK240EE

CD-DA 44.1 kHz

Decoding 16 bit linear

Digital filter 8fs

D/A converter MASH (1 bit DAC)

Pick up

Wavelength 780 nm

Beam Source Semiconductor laser

udio output (Disc)

Number of channels 2 (Stereo) (FL,FR)

n GENERAL

Power supply AC 230 V, 50Hz

Power consumption 95 W

Power consumption in standby mode

0.5 W

Dimensions (W x H x D) 250 x 330 x 343 mm

Mass 6.9 kg

Operating temperature range +5 to +35°C

Operating humidity range 5 to 90% RH (no condensation)

n SYSTEM

SC-AK240 (EE-S) Music center: SA-AK240 (EE-S)

Speaker: SB-AK240 (GC-S)

For information on speaker, please refer to the original Service Manual (Order No. MD0512446A3)

Notes:

1. Specifications are subject to change without notice. Mass and dimensions are approximate.

2. Total harmonic distortion is measured by the digital spectrum analyzer.

CONTENTS

Page Page

1 Safety Precautions

1.1. General Guidelines

1.2. Before repair and adjustment

1.3. Protection Circuitry

2 Prevention of Electro Static Discharge (ESD) to

Electrostatically Sensitive (ES) Devices

3 Handling Precautions For Traverse Deck

4 Precaution of Laser Diode

5 Handling the Lead-free Solder

5.1. About lead free solder (PbF)

6 New Features

6.1. CRS1 Mechanism Overview

6.2. Music Port

7 Accessories

8 Operating Instructions Procedures

9 Self diagnosis and special mode setting

9.1. Special Mode Table

9.2. Error code Table

10 Assembling and Disassembling

10.1. Caution

10.2. Disassembly flow chart

10.3. Main Parts Location

10.4. Disassembly of Top Cabinet

10.5. Disassembly of Rear Panel

10.6. Disassembly of CD Changer Unit (CRS1)

10.7. Disassembly of Main P.C.B.

10.8. Disassembly of Transformer P.C.B.

10.9. Disassembly of Power P.C.B.

10.10. Disassembly of Front Panel Unit

10.11. Disassembly for Panel P.C.B.

10.12. Disassembly of Deck mechanism unit

10.13. Disassembly of Deck P.C.B.

10.14. Disassembly of Traverse Unit

10.15. Disassembly of optical pickup unit (CD mechanism )

10.16. Disassembly of Deck Mechanism

10.17. Replacement for cassette lid

10.18. Rectification for tape jam problem

11 Service Fixture and Tools

12 Service Positions

12.1. Checking and Repairing of Main P.C.B.

12.2. Checking and Repairing of Transformer P.C.B.

12.3. Checking and Repairing of Panel, Deck & Deck

Mechanism P.C.B.

12.4. Checking and Repairing of Power P.C.B.

13 Adjustment Procedures

13.1. Cassette Deck Section

13.2. Tuner Section

14 Voltage and Waveform Chart

14.1. CD Servo P.C.B. & Main P.C.B.

14.2. Power P.C.B. & Transformer P.C.B.

14.3. Waveform Chart

15 Wiring Connection Diagram

16 Block Diagram

17 Schematic Diagram

17.1. Notes of Schematic Diagrams

17.2. (A) CD Servo Circuit

17.3. (B) Main (Tuner) Circuit

17.4. (B) Main Circuit

17.5. (C) Panel Circuit

17.6. (D) Transformer Circuit

17.7. (H) Power Circuit

17.8. (F) Deck Circuit & (G) Deck Mechanism Circuit

SA-AK240EE

18 Printed Circuit Board 75

18.1. (A) CD Servo P.C.B.

18.2. (B) Main P.C.B.

18.3. (C) Panel P.C.B.

18.4. (D) Transformer P.C.B.

18.5. (E) Power P.C.B.

18.6. (F) Deck P.C.B. & (G) Deck Mechanism P.C.B.

19 Illustration of ICs, Transistors and Diodes

20 Terminal Function of IC's

20.1. IC7001 (MN6627954MA) Servo Processor,Digital Signal

Processor/Digital filter and D/A Converter

20.2. IC7002 (BA5948FPE2) IC 4CH Drive

20.3. IC2801 (C2CBYY000053) System Microprocessor

21 Exploded Views

21.1. Cabinet Parts Location

21.2. Deck Mechanism Parts Location (RAA4502-S)

21.3. Packaging

22 Replacement Parts List

SA-AK240EE

1 Safety Precautions

1.1. General Guidelines

1. When servicing, observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.

2. After servicing, ensure that all the protective devices such as insulation barriers and insulation papers shields are properly installed.

3. After servicing, check for leakage current checks to prevent from being exposed to shock hazards.

1.1.1. Leakage Current Cold Check

1. Unplug the AC cord and connect a jumper between the two prongs on the plug.

2. Using an ohmmeter measure the resistance value, between the jumpered AC plug and each exposed metallic cabine t part on the equipment such as screwheads, connectors, control shafts, etc. When the expose d metallic part has a return path to the chassis, the reading should be between 1MΩ and 5.2MΩ . When the exposed metal does not have a return path to the chassis, the reading must be

Fig. 1

1.1.2. Leakage Current Hot Check (See Figure 1)

1. Plug the AC cord directly into the AC outlet. Do not use an isolation transformer for this check.

2. Connect a 1.5kΩ, 10 watts resistor, in parallel with a 0.15µF capacitor, between each exposed metallic part on the set and a good earth ground such as a water pipe, as shown in Figure 1.

3. Use an AC voltmeter, with 1000 ohms/volt or more sensitivity, to measure the potential across the resistor.

4. Check each exposed metallic part, and measure the voltage at each point.

5. Reverse the AC plug in the AC outlet and repeat each of the above measurements.

6. The potential at any point should not exceed 0.75 volts RMS. A leakage current tester (Simpson Model 229 or equivalent) may be used to make the hot checks, leakage current must not exceed 1/2 milliamp. Should the measurement is out of the limits specified, there is a possibility of a shock hazard, and the equipment should be repaired and rechecked before it is returned to the customer.

1.2. Before repair and adjustment

Disconnect AC power, discharge Power Capacitors C5101 , C5104, C5171 , C5172 , C5920 , C5940 and C5950 through a 10Ω,5W resistor to ground.

DO NOT SHORT-CIRCUIT DIRECTLY (with a screwdriver blade, for instance), as this may destroy solid state devices.

After repairs are completed, restore power gradually using a variac, to avoid overcurrent.

Current consum ption at AC 230V, 50 Hz in NO SIGNAL mode (volume min at CD mode) should be ~ 350mA .

1.3. Protection Circuitry

The protection circuitry may have operated if either of the following conditions are noticed:

· No sound is heard when the power is turned on.

· Sound stops during a performance.

The function of this circuitry is to prevent circuitry damage if, for example, the positive and negative speaker connection wires are

“shorted”, or if speaker systems with an impedance less than the indicated rated impedance of the amplifier are used.

If this occurs, follow the procedure outlines below:

1. Turn off the power.

2. Determine the cause of the problem and correct it.

SA-AK240EE

3. Turn on the power once again after one minute.

Note :

When the protection circuitry functions, the unit will not operate unless the power is first turned off and then on again.

2 Prevention of Electro Static Discharge (ESD) to

Electrostatically Sensitive (ES) Devices

Some semiconductor (solid state) devices can be damaged easily by electricity. Such components commonly are called Electrostatically Sensitive (ES) Devices. Examples of typical ES devices are integrated circuits and some field-effect transistors and semiconductor “chip” components. The following techniques should be used to help reduce the inciden ce of component damage caused by electro static discharge (ESD).

1. Immediately before handling any semiconductor component or semiconductor-equiped assembly, drain off any ESD on your body by touching a known earth ground. Alternatively, obtain and wear a commercially available discharging ESD wrist strap, which should be removed for potential shock reasons prior to applying power to the unit under test.

2. After removing an electrical assembly equiped with ES devices, place the assembly on a conductive surface such as aluminium foil, to prevent electrostatic charge build up or exposure of the assembly.

3. Use only a grounded-tip soldering iron to solder or unsold er ES devices.

4. Use only an anti-static solder remover device. Some solder removal devices not classified as “anti-static (ESD protected)” can generate electrical charge to damage ES devices.

5. Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage ES devices.

6. Do not remove a replacement ES device from its protective package until immediately before you are ready to install it. (Most replacement ES devices are packaged with leads electrically shorted together by conductive foam, aluminium foil or comparable conductive material).

7. Immediately before removing the protective material from the leads of a replacement ES device, touch the protective material to the chassis or circuit assembly into which the device will be installed.

Caution

Be sure no power is applied to the chassis or circuit, and observe all other safety precautions.

8. Minimize body motions when handling unpackaged replacement ES devices. (Otherwise harmless motion such as the brushing together of your clothes fabric or the lifting of your foot from a carpeted floor can generate static electricity (ESD) sufficient to damage an ES device).

SA-AK240EE

3 Handling Precautions For Traverse Deck

The laser diode in the traverse deck (optical pickup) may break down due to potential difference caused by the static electricity of clothes or our human body.

So, be careful of electrostatic breakdown during repair of the traverse deck (optical pickup).

· Way of handling the traverse deck (optical pickup)

1. Do not subject the traverse deck (optical pickup) to static electricity as it is extremely sensitive to electrical shock.

2. To prevent the breakdown of the laser diode, an antistatic shorting pin is inserted into the flexible board (FFC board).

3. Do not to apply excessive stress to the flexible board (FFC board). When removing or connecting the short pin, finish the job in as short time as possible.

4. Do not turn the variable resistor for laser power adjustment. (It is pre-adjusted during production time)

Grounding for electrostatic breakdown prevention

1. Human body grounding

Use the anti-static wrist strap to discharge the static electricity from your body.

2. Work table grounding

Put a conductive material (sheet) or steel sheet on the area where the traverse deck (optical pickup) is place, and ground the sheet.

Caution :

The static electricity of your clothes will not be grounded through the wrist strap. So, take care not to let your clothes touch the traverse deck (optical pickup).

Caution when replacing the Traverse Deck

The traverse deck has a short point shorted with solder to protect the laser diode against electrostatics breakdown. Be sure to remove the solder from the short point before making connections.

SA-AK240EE

4 Precaution of Laser Diode

Caution :

This product utilizes a laser diode with the unit turned "ON", invisible laser radiation is emitted from the pick up lens. Wavelength : 780 nm Maximum output radiation power from pick up : 100 µW/VDE Laser radiation from pick up unit is safety level, but be sure the followings:

1. Do not disassemble the optical pick up unit, since radiation from exposed laser diode is dangerous.

2. Do not adjust the variable resistor on the pick up unit. It was already adjusted.

3. Do not look at the focus lens using optical instruments.

4. Recommend not to look at pick up lens for a long time.

CAUTION!

THIS PRODUCT UTILIZES A LASER.

USE OF CONTROLS OR ADJUSTMENTS OR PERFORMANCE OF PROCEDURES OTHER THAN THOSE SPECIFIED HEREIN MAY RESULT IN HAZARDOUS RADIATION EXPOSURE.

n Use of caution label

SA-AK240EE

5 Handling the Lead-free Solder

5.1. About lead free solder (PbF)

Distinction of PbF P.C.B.:

P.C.B.s (manufactured) using lead free solder will have a PbF stamp on the P.C.B.

Caution:

· Pb free solder has a higher melting point than standard solder; Typically the melting point is 50 - 70°F (30 - 40°C) higher. Please use a high temperature soldering iron. In case of soldering iron with temperature control, please set it to 700 ± 20°F (370 ± 10°C).

· Pb free solder will tend to splash when heated too high (about 1100°F/600°C).

· W hen soldering or unsoldering, please completely remove all of the solder on the pins or solder area, and be sure to heat the

soldering points with the Pb free solder until it melts enough.

6 New Features

6.1. CRS1 Mechanism Overview

SA-AK240EE

6.1.1. General Feature

· This is a five disc changer mechanism for CD/DVD. The outline figure is shown below.

SA-AK240EE

· The mechanism has "CHANGE WHILE PLAY" function. It open other trays for disc exchanging while one tray is at PLAY position performing recording or reproducing.

· The mechanism can quickly change all trays with "CHANGE ALL" function. All trays can be move to OPEN position with one operation.

· There is no sensor to indicate presence of disc on any tray.

6.1.2. Hardware composition

· Below is the hardware components of the mechanism

Name Function

Open Switch (OPEN-SW) The switch is used to detect normal tray opening

The switch is used for detect tray being manually push/trigger when full open Home Switch (HOME-SW) Is used to detect cam gear home position Close Sensor (CLOSE-SENSOR) Used for normal single tray closing

Used to detect cam gear rotate to Play Driving position Play Switch (PLAY-SW) Detect TRV clamping complete position Stocking Switch (STOCK-SW) Detect tray completely transfer for play position to stocking position UD Sensor (UD-SENSOR) Detect TRV vertical movement position Top Switch (TOP-SW) Detect a default position of TRV vertical movement position Driver IC To drive Motor Motor Main driving source for changer Plunger Switching the driving source from motor to:

1. Tray open/close

2. Drive tray to play/stock position and TRV vertical movement

6.1.3. Mechanism Operation

· This mechanism has the following state:

1. Driving of a tray to open/close

2. Up/down operation of a traverse performs a state changes of tray.

By using the plunger to lift/release of a switching gear, and the cam gear to lift/release the function gear the motor can be link to several gear trains to perform various operations.

· The functions that can be perform in this mechanism are described as below:

Condition Explanation

Open current playing tray The state to change current playing disc. All tray will be open at once and current tray at PLAY position

Open All The state where all trays being driven to OPEN position. The disc can be taken in or out from tray to tray

Stock The state where the trays are stored in STOCK position Play The state where one of the tray 5 trays is being driven to PLAY position and clamped by traverse unit Play & Open Tray-* The state where one of the tray is in playing position performing recording or reproducing, other trays can

Change The state when one of the opened tray being driven from OPEN position to STOCK position and other

Close All The state where all open trays will being driven from OPEN position to STOCK position, one by one from

will be expose.

by close tray one by one from top to bottom.

be used (OPEN position) for disc exchanging without stopping the recording or reproducing process.

opened trays remain still at OPEN position.

top to bottom

Note: * represent tray number (from 1 ~ 5)

6.1.4. New CD Mechanism (CRS1)

Note:

This service manual does not contain the following information for the mention CD Mechanism drive:

· Schematic Diagram, Block Diagram and P.C.B. layout of CD Loading P.C.B.

· Part List for individual parts of the mechanism.

· Explode d View and Parts List for individual parts of the CD Mechanism drive.

Please refer to the original service manual (Order No. MD0509368C0) for the CD Mechanism Drive CRS1.

6.2. Music Port

SA-AK240EE

With reference to page 16 of the operating instruction manual.

SA-AK240EE

7 Accessories

Remote Control

FM Antenna Wire

AC Cord

AM Loop Antenna

8 Operating Instructions Procedures

SA-AK240EE

9 Self diagnosis and special mode setting

This unit is equipped with functions for checking and inspecting namely: Self-Diagnostic and Test Mode.

9.1. Special Mode Table

Item FL Display Key Operation

Mode Name Description Front Key

Self -Diagnostic

Mode

CD Test Mode To enter into checking the

CD Auto

Adjustment

To enter into self diagnostic checking for main unit.

reliability of changer unit.

To check the CD auto adjustment result for FLOCK, TLOCK and CLVS.

1. Select [

] for TAPE mode (Ensure no tape is inserted).

2. Press and hold [ seconds follow by [

To exit, press main unit or remote control.

1. Select [ ] for CD mode.

2. Press and hold [ seconds follow by [

To exit, press main unit or remote control.

In CD Test Mode:

1. Press [0] button on the remote control.

To exit, press main unit or remote control.

SA-AK240EE

]button for 3

button on

] button for 3

button on

CD Changer

Reliability Test

(CRS1)

Doctor Mode To enter into Doctor

Cold Start To activate cold start

Changer

Reliability Test

To determine the reliability of CD Changer Unit. (For more information, refer to section 9.1.1)

Mode for checking of various items and displaying EEPROM and firmware version.

upon next AC power up.

To check the function operation of changer unit. (For more information, refer to 9.1.1)

1. All segments will light up for 1 second.

2. The Check Sum of EEPROM and firmware version will be display.

* ROM correction ** Firmware version No:

In Self-Diagnostic Mode:

1. Select [

2. Press [

To exit, press main unit or remote control. (The tray will return to PLAY position and then power off)

In any mode:

1. Press [ follow by [4] and [7] on remote control.

To exit, press [ENTER] button on remote control or unit or remote control.

In doctor mode:

1. Press [4] button on remote control.

To exit, press [ENTER] button on remote control or unit or remote control.

In doctor mode:

1. Press [DISC] on remote control.

To exit, press [ENTER] button on remote control or unit or remote control.

] for CD mode.

] button.

button on

] button on main unit

button on main

SA-AK240EE

Item FL Display Key Operation

Mode Name Description Front Key

FL Display Test To check the FL

segments display (All segments will light up and LED will blink at 0.5 second interval)

Tape Eject Test To check on the tape

eject function (For deck 1/2)

9.1.1. CD changer unit ageing test mode

Below is the process flow chart of ageing for the CD changer unit. (CRS1)

In doctor mode:

1. Press [DIMMER] button on remote control.

In doctor mode:

1. Press [PROGRAM] button on remote control.

SA-AK240EE

9.2. Error code Table

Self-Diagnosis Function (refer Section 9.1) provides information on any problems occuring for the unit and its respective components by display ing the error codes. These error code such as U**, H** and F** are stored in memory and held unless it is cleared.

SA-AK240EE

The error code is automatically display after entering into self-diagnostic mode.

Error Code Diagnosis Contents Description of error Automatic FL Display Remarks

H01 Mode SW, plunger

and capstan motor abnormal

For deck mechanism unit (For deck 1/2). Press [

] on main unit for

next error.

H02 Rec INH SW

abnormal

For deck mechanism unit (For deck 2). Press [

] on main unit for

next error.

H03 HALF SW abnormal For deck mechanism unit (For deck 1/2).

Press [

] on main unit for

next error.

F01

Reel pulse abnormal

For deck mechanism unit (For deck 1/2). Press [

] on main unit for

next error.

F02

F15 RESET SW

F26 Transmission error

TPS error

abnormal

between CD Servo LSI IC and microprocessor IC

REST SW: ON is not detected within the specified time.

When set to CD mode, the sense signal does not turn “Low”, a fail safe time after system command

For CD unit (For Traverse). Press [

] on main unit for

next error.

For CD unit (For Traverse). Press [

] on main unit for

next error.

transmission is sent.

F61 Power Amp IC output

abnormal

IHMS Cam gear

abnormality

Upon power on, PCONT=HIGH, DCDET=L after checking LSI.

Cam gear does not rotate to “HOME” position.

For power. Press [

] on main unit for

next error.

For CD changer unit (CRS1). Press [SINGLE CHANGE] on main unit for next error.

ICSL Cam gear/gear units

abnormal

ISTK Drive rack/gear

assembly abnormal

IPLY Drive rack/gear

assembly abnormal

Cam gear does not rotate to “PLAY” driving position and hence does not drive playing tray to “STOCK” position.

The tray drive rack does not move to “STOCK” position. (Tray does not move to “STOCK” position)

The tray drive rack does not move to “PLAY” position. (Tray does not move to “PLAY” position)

For CD changer unit (CRS1). Press [SINGLE CHANGE] on main unit for next error.

Error Code Diagnosis Contents Description of error Automatic FL Display Remarks

ITOP UD assembly UD Rack does not move to

front direction. This lead to UD base not raise to top

For CD changer unit (CRS1). Press [SINGLE CHANGE] on main unit for next error.

position.

SA-AK240EE

IUDS UD assembly After TOP SW is detected,

UD rack does not move into tray 1 position.

HOME Cam gear/gear

assembly abnormal

Cam gear does not move to “HOME” position under following conditions

1. After tray is load to “PLAY” position.

2. After tray is unload to “STOCK” position.

LOAD Tray drive assembly

abnormal

Tray unit does not move from “STOCK” to “PLAY” position

PDRV Cam gear/gear

assembly abnormal

Cam gear does not move from “HOME” to “PLAY” drive position.

For CD changer unit (CRS1). Press [SINGLE CHANGE] on main unit for next error.

UDU UD base asssembly

abnormal

UDD UD base asssembly

abnormal

UD1 UD base asssembly

abnormal

F1NG Fail - safe mode. (For

open/close tray unit(s))

UD Base assembly does not move upwards from tray 5 to tray 2

UD Base assembly does not move downwards from tray 1 to tray 5.

UD Base assembly does not move to tray 1.

When the tray open operation is performed, it fails to open. It will automatically close all trays after the time-out by the microprocessor. During this time when it fails, the error code will appear.

For CD changer unit (CRS1). Press [SINGLE CHANGE] on main unit for next error.

SA-AK240EE

Error Code Diagnosis Contents Description of error Automatic FL Display Remarks

F2NG Fail - safe mode. (For

open/close tray unit(s))

When the tray close operation is performed, it fails to close. It will automatically open all trays after the time-out by the microprocessor. During this time when it fails, the error code will appear.

For CD changer unit (CRS1). Press [SINGLE CHANGE] on main unit for next error.

SRVC_TRV To unlock the

traverse unit for service

RSET Cam gear jam/close

sensor faulty

1. All trays set to “STOCK” position

2. Mechanism set to tray 5

3. Cam gear set to “HOME” position

During tray re-open, the cam gear will rotate in the opposite direction to reset the cam gearposition. When it fails, the error code will appear.

For CD changer unit (CRS1). Press [SINGLE CHANGE] on main unit.

For CD changer unit (CRS1). Press [SINGLE CHANGE] on main unit for next error.

CRS1 Error Code display

1. The errors that occured in CRS1 Mechanism can be recalled and displayed, in the order of the occurence under self-diagnostic (Refer to Section 9.1 for procedures to enter this mode.

· Only the first 5 errors will be memorized (in backup memory). The subsequence error shall be ignored and not memorize.

For system with EEPROM as memory backup,memory space in EEPROM is neccesary.

2. To display all error code memorized

In CRS1 Self-Diagnostic mode, press [SINGLE CHANGE] to display subsequence error code.

It shall repeat after reaching error no. 5.

e.g.:

[1____IHMS]→ [SINGLE CHANGE]

[2____ITOP]→ [SINGLE CHANGE]

[3____HOME]→ [SINGLE CHANGE]

[4____LOAD]→ [SINGLE CHANGE]

[5_____UDD]→ [SINGLE CHANGE]

3. To clear the error code memory

In CRS1 Self-Diagnostic mode, long press [SINGLE CHANGE] key (2s or more)

SA-AK240EE

10 Assembling and Disassembling

10.1. Caution

Special Note:

This model uses a new CD changer unit CRS1. In this following section does not contain the necessary disassembly & assembly information for the CD changer unit (CRS1) except the disasembly & assembly of traverse unit. Kindly refer to the original service manual for the CD changer unit. (Order No. MD0509368C0).

“ATTENTION SERVICER”

Some chassis components may have sharp edges. Be careful when disassembling and servicing.

1. This section describes procedures for checking the operation of the major printed circuit boards and replacing the main components.

2. For reassembly after operation checks or replacement, reverse the respective procedures. Special reassembly procedures are described only when required.

3. Select items from the following index when checks or replacement are required.

4. Refer to the Parts No. on the page of “Parts Location and Replacement Parts List” (Section 22), if necessary.

Warning :-

This product uses a laser diode. Refer to caution statement Precaution of Laser Diode.

Caution:

After replacing of CD Changer Unit, ageing test is necessary. Please confirm operation for CD Changer Unit.

Below is the list of disassembly sections

· Disasse mbly of Top Cabinet

· Disasse mbly of Rear Panel

· Disasse mbly of CD Changer Unit

· Disasse mbly of Main P.C.B.

· Disasse mbly of Transformer P.C.B.

· Disasse mbly of Power P.C.B.

· Disasse mbly of Front Panel Unit

· Disasse mbly of Panel P.C.B.

· Disasse mbly of Deck Mechanism Unit

· Disasse mbly for Deck P.C.B.

· Disasse mbly of Traverse Unit

· Disasse mbly of Optical Pickup Unit (CD Mechanism)

· Disasse mbly of Deck Mechanism

· Replacement for cassette lid

· Rectification for tape jam problem

SA-AK240EE

10.2. Disassembly flow chart

The following chart is the procedure for disassembling the casing and inside parts for internal inspection when carrying out the servicing.

To assemble the unit, reverse the steps shown in the chart as below.

10.3. Main Parts Location

SA-AK240EE

10.4. Disassembly of Top Cabinet

Step 1 Remove 3 screws at each side and 5 screws at rear

panel.

Step 2 Lift up both sides of the top cabinet, push the top cabinet towards the rear to remove the top cabinet.

10.5. Disassembly of Rear Panel

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

Step 1 Remove 5 screws.

Step 2 Disconnect cable CN2810 (Fan) at Main P.C.B..

Step 3 Remove rear panel.

10.6. Disassembly of CD Changer Unit (CRS1)

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

Step 1 Remove 1 screw at rear panel.

Step 2 Detach the FFC cables (CN2801 & CN2805).

SA-AK240EE

Step 3 Release the claws on both ends.

Note:

For disassembly & assembly of traverse unit, please refer to section 10.14 of this service manual.Please refer to original Service Manual for the Disassembly and Assembly of the CD Changer Unit (CRS1).

Step 4 Lift the CD changer unit upwards to remove it.

· Disasse mbly of Mecha Chassis

Step 5 Remove 2 screws.

Step 6 Remove the Mecha Chassis.

SA-AK240EE

10.7. Disassembly of Main P.C.B.

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

· Follow the (Step 1) - (Step 4) of Item 10.6 - Disassembly of CD Changer Unit

· Follow the (Step 1) - (Step 3) of Item 10.5 - Disassembly of Rear Panel

Step 1 Disconnect FFC cables (CN2803, CN280 6 and CN2951).

Step 2 Detach connectors (CN2808 & CN2809).

Step 3 Remove Main P.C.B..

10.8. Disassembly of Transformer P.C.B.

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

· Follow the (Step 1) - (Step 3) of Item 10.5 - Disassembly of Rear Panel

· Follow the (Step 1) - (Step 4) of Item 10.6 - Disassembly of CD Changer Unit

Step 1 Disconnect connectors (CN5950 & CN5951).

Step 2 Remove 3 screws (Mounting screws for transformer to

bottom chassis).

Step 3 Push the Transformer P.C.B. sidewards to remove it.

10.9. Disassembly of Power P.C.B.

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

· Follow the (Step 1) - (Step 4) of Item 10.6 - Disassembly of CD Changer Unit

· Follow the (Step 1) - (Step 3) of Item 10.5 - Disassembly of Rear Panel

· Follow the (Step 1) - (Step 3) of Item 10.7 - Disassembly of Main P.C.B.

Step 1 Remove the 5 screws on Power P.C.B..

SA-AK240EE

Step 2 Detach cable (CN5950) remove the 5 screws on Power

P.C.B..

Step 3 Remove Power P.C.B..

Note:

Insulate the Power P.C.B. with insulation material to avoid short circuit.

· Replacement of the Power Amp IC or Voltage Regulator

Step 4 Remove 2 screws at the Power Amp IC and/or 3

screws to Voltage Regulator.

Step 5 Cut the joints with a metal cutter as shown below.

Step 6 Desolder the terminals to replace the components.

Step 7 Fix back the cut portion with a screw as shown.

SA-AK240EE

10.10. Disassembly of Front Panel Unit

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

· Follow the (Step 1) - (Step 4) of Item 10.6 - Disassembly of CD Changer Unit

Step 1 Disconnect connectors (CN2803, CN2806, CN2951, CN5950 & CN5951).

Step 2 Bent the front panel unit slightly forward as arrow shown.

Step 3 Release 2 claws outwards.

SA-AK240EE

Step 4 Remove the front panel unit.

Note: Ensure 2 claws located at the bottom chassis is seated

into the 2 slots at bottom of front panel at 2 catches (one on

each side) of bottom chassis to be aligned to front panel’s slot. Assembly is secured upon hearing clicking sound.

10.11. Disassembly for Panel P.C.B.

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

· Follow the (Step 1) - (Step 4) of Item 10.6 - Disassembly of CD Changer Unit

· Follow the (Step 1) - (Step 4) of Item 10.10 - Disassembly of Front Panel Unit

Step 1 Remove the volume knob.

Step 2 Remove Lid.

Note: Do not misplace the spring.

Step 2 Remove 12 screws.

Step 3 Release 2 catches.

Step 4 Remove Panel P.C.B..

10.11.1. Disassembly of Lid

Step 1 Lift the spring sideward.

SA-AK240EE

10.12. Disassembly of Deck mechanism unit

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

· Follow the (Step 1) - (Step 4) of Item 10.6 - Disassembly of CD Changer Unit

· Follow the (Step 1) - (Step 4) of Item 10.10 - Disassembly of Front Panel Unit

Step 1 Detach FFC cable (CN971).

Step 2 Disconnect FFC cable (CN1001).

Step 3 Remove the 5 screws.

Step 4 Push the lever upward, and then open the cassette lid

ass’y (For DECK1 and DECK2).

Step 5 Tilt the cassette mechanism unit in the direction of arrow (1), and then remove it in the direction of arrow (2).

Note: For disassembly of parts for deck mechanism unit, refer to Section 10.15.

10.13. Disassembly of Deck P.C.B.

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

· Follow the (Step 1) - (Step 4) of Item 10.6 - Disassembly of CD Changer Unit

· Follow the (Step 1) - (Step 4) of Item 10.10 - Disassembly of Front Panel Unit

Step 1 Remove 2 screws.

Step 2 Desolder wire at deck motor terminals (W1002).

Step 3 Remove Deck P.C.B.

10.14. Disassembly of Traverse Unit

· Follow the (Step 1) - (Step 2) of Item 10.4 - Disassembly of Top Cabinet

· Follow the (Step 1) - (Step 4) of Item 10.6 - Disassembly of CD Changer Unit

Important notes: Ensure all the trays are in the “STOCK” position before proceeding to the disassemble of traverse unit. For procedures to set the trays in “STOCK” position, please refer to original Service Manual for CRS1, Section 7. Disassembling Procedure When Tray In Play Position, Order No. MD0509368C0.

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panasonic SA-AK240EE Service Manual

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