Pioneer DLS-6 Service manual

DLS6

ORDER NO. MD0801003CE

A6

Mechanism Unit

CONTENTS

Page Page

1 Mechanism Overview (DLS6) 2

2 Prevention of Electrostatic Discharge (ESD) to

Electrostatically Sensitive (ES) Devices

3 Precaution of Laser Diode

4 About Lead Free Solder (PbF)

5 Handling Precautions for Traverse Unit

6 Mechanism Drive Unit

7 Mechanism Operation Description 11

8 Assembling & Disassembling

3

9 Disassembly Flow

10 DLS6 Mechanism Reliability

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5

11 Exploded Views

6

12 Replacement Parts List

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39

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© 2008 Matsushita Electric Industrial Co. Ltd.. All
rights reserved. Unauthorized copying and
distribution is a violation of law.

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1 Mechanism Overview (DLS6)

DLS6 mechanism is a single tray mechanism used for CD/DVD models. DVD system control is through the DVD/HDMI module
except for traverse control.

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2 Prevention of Electrostatic Discharge (ESD) to

Electrostatically Sensitive (ES) Devices

Some semiconductor (solid state) devices can be damaged easily by static 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 incidence of component damage
caused by electrostatic discharge (ESD).

1. Immediately before handling any semiconductor component or semiconductor-equipped 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 equipped with ES devices, place the assembly on a conductive surface such as
aluminum foil, to prevent electrostatic charge buildup or exposure of the assembly.

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

4. Use only an anti-static solder removal device. Some solder removal devices not classified as "anti-static (ESD protected)" can
generate electrical charge sufficient 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, aluminum 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 bodily 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).

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3 Precaution of Laser Diode

CAUTION :

This product utilizes a laser diode with the unit turned "on", invisible laser radiation is emitted from the pickup lens.
Wavelength: 655 nm (DVD)/785 nm (CD)
Maximum output radiation power from pickup: 100 µW/VDE

Laser radiation from the pickup unit is safety level, but be sure the followings:

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

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

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

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

ACHTUNG :

Dieses Produkt enthält eine Laserdiode. Im eingeschalteten Zustand wird unsichtbare Laserstrahlung von der
Lasereinheitadgestrahit.

Wellenlänge: 655 nm (DVD)/785 nm (CD)
Maximale Strahlungsleistung der Lasereinhelt: 100 µW/VDE

Die strahlungan der Lasereinheit ist ungefährlich, wenn folgende Punkte beachtet werden:

1. Die Lasereinheit nicht zerlegen, da die Strahlung an der freigelegten Laserdiode gefährlich ist.

2. Den werksseitig justierten Einstellregler der Lasereinheit nicht verstellen.

3. Nicht mit optischen Instrumenten in die Fokussierlinse blicken.

4. Nicht über längere Zeit in die Fokussierlinse blicken.

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4 About Lead Free Solder (PbF)

4.1. Service caution based on legal restrictions

4.1.1. General description about Lead Free Solder (PbF)

The lead free solder has been used in the mounting process of all electrical components on the printed circuit boards used for this
equipment in considering the globally environmental conservation.

The normal solder is the alloy of tin (Sn) and lead (Pb). On the other hand, the lead free solder is the alloy mainly consists of tin
(Sn), silver (Ag) and Copper (Cu), and the melting point of the lead free solder is higher approx.30 degrees C (86°F) more than that
of the normal solder.

Definition of PCB Lead Free Solder being used

The letter of “PbF” is printed either foil side or components side on the PCB using the lead free solder.
(See right figure)

Service caution for repair work using Lead Free Solder (PbF)

" The lead free solder has to be used when repairing the equipment for which the lead free solder is used.

(Definition: The letter of “PbF” is printed on the PCB using the lead free solder.)

" To put lead free solder, it should be well molten and mixed with the original lead free solder.

" Remove the remaining lead free solder on the PCB cleanly for soldering of the new IC.

" Since the melting point of the lead free solder is higher than that of the normal lead solder, it takes the longer time to melt

the lead free solder.

" Use the soldering iron (more than 70W) equipped with the temperature control after setting the temperature at 350±30

degrees C (662±86°F).

Recommended Lead Free Solder (Service Parts Route.)

" The following 3 types of lead free solder are available through the service parts route.

RFKZ03D01K-----------(0.3mm 100g Reel)

RFKZ06D01K-----------(0.6mm 100g Reel)

RFKZ10D01K-----------(1.0mm 100g Reel)

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Note

* Ingredient: tin (Sn), 96.5%, silver (Ag) 3.0%, Copper (Cu) 0.5%, Cobalt (Co) / Germanium (Ge) 0.1 to 0.3%

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5 Handling Precautions for Traverse Unit

The laser diode in the optical pickup unit may break down due to static electricity of clothes or human body. Special care must be
taken avoid caution to electrostatic breakdown when servicing and handling the laser diode in the traverse unit.

5.1. Cautions to Be Taken in Handling the Optical Pickup Unit

The laser diode in the optical pickup unit may be damaged due to electrostatic discharge generating from clothes or human body.
Special care must be taken avoid caution to electrostatic discharge damage when servicing the laser diode.

1. Do not give a considerable shock to the optical pickup unit as it has an extremely high-precise structure.

2. To prevent the laser diode from the electrostatic discharge damage, the flexible cable of the optical pickup unit removed should
be short-circuited with a short pin or a clip (Figure 1).

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5.2. Grounding for electrostatic breakdown prevention

Some devices such as the CD/DVD player use the optical pickup (laser diode) and the optical pickup will be damaged by static
electricity in the working environment. Proceed servicing works under the working environment where grounding works is
completed.

5.2.1. Worktable grounding

1. Put a conductive material (sheet) or iron sheet on the area where the optical pickup is placed, and ground the sheet (Figure 2).

5.2.2. Human body grounding

1. Use the anti-static wrist strap to discharge the static electricity form your body (Figure 2).

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6 Mechanism Drive Unit

6.1. Gears’ operations (Playability)

The arrows indicate the movement of the gears during play operation.

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6.2. Traverse slide plate/Sub rack/OPU assembly

The arrows indicate the movement of the parts during play operation.

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6.3. Switch / Motors

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7 Mechanism Operation Description

7.1. Open/Close Operation

Below shows the inter relation of parts during the open & close operations.

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7.2. Play Operation

Below shows the inter relation of parts during the play operation.

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7.3. Initialization

During the power-up of main unit (using DLS6 mechanism), the state of switches is sensored by the micro-p IC and the traverse
motor is adjusted accordingly. (This is the initialization process).

Note: Refer to Table 1 for the initialization process. Figures 6 & 7 show the flow of the initialization.

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7.4. Fail safe

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7.5. Switches and motors

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8 Assembling & Disassembling

8.1. Flow Chart

8.1.1. Disassembly flow chart

Below describes the disassembly flow for the mechanism.

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8.1.2. Assembly flow chart

Below describes the assembly flow for the mechanism.

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8.2. Preparation of Service jig

Step 1: Cut the gear out from the clamp plate unit.

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8.3. Checking of Mechanism unit

8.3.1. Before disassembling

Step 1: Check if the sub rack is disengaged from the traverse
slide plate before disassembly.

Step 2: Insert the gear into the hexagonal wrench.

Caution:

If it is engaged, the following steps are necessary.

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Step 1: Release the FFC from the slot.

Step 2: Use service jig to turn the gear counter clockwise.

Step 3: Check that the screw is in this postion then stop turning
the service jig.

Step 4: Insert the FFC behind the slot.

8.3.2. Before assembling

Step 1: Check if the sub rack is below the guide line before
assembly, otherwise the following steps are necessary.

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Step 2: Turn over the traverse unit, use service jig to turn the
gear counter clockwise.

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8.4. Disassembling Procedures

8.4.1. Disassembly of traverse unit

Caution:

Do ensure that the traverse unit is in the conditiion to be
disassembled, please refer to section 8.3.1.

Note:

Mechanism unit (DLS6) reliability test must be carry out in
complete unit or using the Reliability P.C.B. (Refer to section

10).

Step 3: Once the sub rack is below the guide line, it is ready for
the assembly.

Step 1: Release the guide.

Step 2: Push the traverse slide plate (rib), ensure both grooves
are opened.

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Step 3: Release the FFC as arrows shown.

Step 4: Lift the traverse unit up by approximately 45° as shown.

Caution:

Ensure the OPU is face upwards, avoid touching the
surface of the traverse unit.

Step 5: Slide out the traverse unit as arrow shown.

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8.4.2. Disassembly of clamp plate unit

" Follow the (Step 1) to (Step 5) of item 8.4.1.

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Caution:

Avoid touching the drysurf areas. Below diagram shows the
areas for the drysurf to be applied.

Step 1: Releas e the catches at both sides of the clamp plate
unit.

Step 2: Slide the clamp plate unit as arrows shown.

Step 3: Lift up and remove the clamp plate unit as arrow
shown.

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8.4.3. Disassembly of tray

" Follow the (Step 1) to (Step 5) of item 8.4.1.

" Follow the (Step 1) to (Step 3) of item 8.4.2.

Step 4: Release the catches respectively as arrows shown to
remove the tray.

Step 1: Release the guide.

Step 2: Push the traverse slide plate (rib) until it stop.

Caution:

Avoid touching the drysurf and grease areas. Below
diagram shows the areas of greasing points.

Step 3: Slide the tray out fully.

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8.4.4. Disassembly of tray drive gear 3

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8.4.5. Disassembly of traverse slide plate

" Follow the (Step 1) to (Step 5) of item 8.4.1.

" Follow the (Step 1) to (Step 3) of item 8.4.2.

" Follow the (Step 1) to (Step 4) of item 8.4.3.

Step 1: Use a screw driver to release the catch and push down
the tray drive gear 3 in order of sequences (1) to (2).

" Follow the (Step 1) to (Step 5) of item 8.4.1.

" Follow the (Step 1) to (Step 3) of item 8.4.2.

" Follow the (Step 1) to (Step 4) of item 8.4.3.

" Follow the (Step 1) of item 8.4.4.

Step 1: Slide the traverse slide plate till it come to a stop as
arrow shown.

Step 2: Release the guide.

Step 3: Slide the traverse slide plate until it stop.

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Step 4: Hold both points (A) and (B) of the traverse slide plate
to remove it.

Caution:

Avoid touching the grease areas. Below diagram shows the
areas of greasing points.

8.4.6. Disassembly of traverse lock
spring

" Follow the (Step 1) to (Step 5) of item 8.4.1.

" Follow the (Step 1) to (Step 3) of item 8.4.2.

" Follow the (Step 1) to (Step 4) of item 8.4.3.

" Follow the (Step 1) of item 8.4.4.

" Follow the (Step 1) to (Step 4) of item 8.4.5.

Step 1: Release the traverse lock spring as arrows shown to
remove it.

Note: Keep the traverse lock spring in a safe place.

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8.5. Assembling Procedure

8.5.1. Assembly of traverse lock spring

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8.5.2. Assembly of traverse slide plate

Step 1: Hold both points (A) and (B) of the traverse slide plate,
slot it into the grooves.

Step 1: Fix the traverse lock spring as arrows shown
respectively.

Caution:

Make sure the traverse lock spring is fully catched onto the
traverse slide plate as shown.

Step 2: Release the guide.

Step 3: Push the traverse slide plate (rib) in to secure the
traverse slide plate.

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8.5.3. Assembly of tray drive gear 3

Step 1: Insert the tray drive gear 3 into the slot as shown, press
down until hear a “click” sound is heard.

8.5.4. Assembly of tray

Step 1: Slide the traverse slide plate right to the end.

Step 2: Slide the tray in as arrows shown.

Note: Ensure the tray is underneath both guides.

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Step 3: Slide the tray in fully.

Note: Ensure the groove below the tray is aligned with the
traverse slide plate’s guide when sliding the tray in.

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8.5.5. Assembly of clamp plate unit

Step 1: Align the clamp plate unit as shown.

Step 2: Push the clamp plate unit as arrow shown until the
catches are properly catched.

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8.5.6. Assembly of traverse unit

Caution:

" Do ensure that the traverse unit is in the conditiion to be

assembled, please refer to section 8.3.1.

" Removal of the short pin is necessary for replacement

of new traverse unit.

Step 1: Release the guide.

Step 2: Push the traverse slide plate (rib), ensure both grooves
are opened.

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Step 3: Slot the traverse unit at approximately 45° into the
mecha chassis as arrow shown.

Note: Ensure the bosses fix exactly onto the guides.

Step 6: Release the guide.

Step 7: Push the traverse slide plate (rib) to lock the traverse
unit in.

Step 4: Place down the traverse unit.

Step 5: Place the FFC as arrows shown.

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DLS6

9 Disassembly Flow

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10 DLS6 Mechanism Reliability

Purpose: To test the DLS6 mechanism unit operation by using the Reliability P.C.B. before installation into the main unit.

10.1. Setup Connection

Below diagram shows the set-up necessary to carry out the reliability of mechanism.

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Equipments required for the set up preparation:

- Power supply

- Reliab ility P.C.B. (RFKZCR14)

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10.2. Jig’s Flow Diagram

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" Refer following for the suggested location for the mounting of the outer-switch (Part No. K0L1BA000134).

Location of outer-switch

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10.2.1. Flow operation

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11 Exploded Views

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12 Replacement Parts List

Notes:

" Important safety notice:

Components identified by

Furthermore, special parts which have purposes of fire-retardant (resistors), high-quality sound (capacitors), low-noise
(resistors), etc. are used.

When replacing any of these components, be sure to use only manufacturers’s specified parts shown in the parts list.

" [M] Indicates in the Remarks columns indicates parts that are supplied by PAVCSG.

Ref.

No.

301 RD-DDTX001-V TRAVERSE UNIT [M]

301 RD-DDTX003-V TRAVERSE UNIT [M]

302 RMGX0049 FRONT DAMPER [M]

Part No. Part Name & Description Remarks

TRAVERSE DECK

Note:

" *1 denotes models applied as below:-

SA-PT460EB/EG/EF/GCP/GN-K

SA-PT465E-S

SA-PT465GC/GCS/GCT/GS/EE/GT/E-K

SA-PT467EG/EB-K

SA-PT560E/EB/EG/EE/GN/GCP-K

SA-PT560E/EG/EE-S

SA-PT565GC/GS/GCS/GCT-K

SA-PT860E/EB/EG/EE-K

SA-PT865GC/GS/GCS/GCT/GN-K.

mark have special characteristics important for safety.

*1

*2

Ref.

No.

303 RXQX0046 CLAMP PLATE UNIT [M]

304 RDGX0041A TRAY DRIVE GEAR 3 [M]

305 RXQX0086 MECHA CHASSIS ASS’Y [M]

306 RMEX0046 TRAVERSE LOCK SPRING [M]

307 RMMX0013-1 TRAVERSE SLIDE PLATE [M]

308 VMG1719 DAMPER [M]

309 RMRX0064-K1 TRAY [M]

Part No. Part Name & Description Remarks

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" *2 denotes models applied as below:-

SA-PM86DEE/GCS/GN/E/EB/EG/EF-K

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FLE0801