Sony HCD-DX255 Service Manual

HCD-DX155/DX255

SERVICE MANUAL

Ver. 1.4 2007.10

Photo : HCD-DX255

HCD-DX155/DX255 are the amplifier, DVD/CD and tuner section in DAV-DX155/DX255.

This system incorporates with Dolby*1 Digital and Dolby Pro Logic (II) adaptive matrix surround decoder and the DTS*2 Digital Surround System. *1 Manufactured under license from Dolby Laboratories.

“Dolby,” “Pro Logic,” and the double-D symbol are trademarks of Dolby Laboratories.

*2 Manufactured under license from Digital Theater Systems, Inc.

“DTS” and “DTS Digital Surround” are trademarks of Digital Theater Systems, Inc.

US Model

Canadian Model

HCD-DX155/DX255

E Model

Australian Model

HCD-DX155

Model Name Using Similar Mechanism HCD-DX150 Mechanism T ype CDM81C-DVBU101 Optical Pick-up Name

KHM-310CAB/C2RP

AUDIO POWER SPECIFICATIONS for the US model

DX155

POWER OUTPUT AND TOTAL HARMONIC DISTORTION (FTC Output Power): FL/FR/LS/RS/C: 84 W/ch

DX255

POWER OUTPUT AND TOTAL HARMONIC DISTORTION (FTC Output Power): FL/FR/LS/RS/C: 84 W/ch

Amplifier section

DX155

US models: Surround mode (reference)

3 ohm at 170 - 20,000 Hz,

0.7 % THD SW: 80 W 3 ohm at 40 170 Hz, 0.7 % THD

3 ohm at 170 - 20,000 Hz,

0.7 % THD SW: 160 W 1.5 ohm at 40 170 Hz, 0.7 % THD

RMS output power, 10 % THD Front: 142 W + 142 W (with SS-TS52)

SPECIFICATIONS

Center*: 142 W (with SS-CT51) Surround*: 142 W + 142 W (with SS-TS51) Subwoofer*: 140 W

Mexican and other models: Stereo mode (rated) 108 W + 108 W (3 ohms at

Surround mode (reference)

Latin American models: Stereo mode (rated) 100 W + 100 W (3 ohms at

Surround mode (reference)

(with SS-WS52)

1 kHz, 1 % THD) RMS output power, 10 % THD Front: 142 W + 142 W (with SS-TS52)

Center*: 142 W (with SS-CT51) Surround*: 142 W + 142 W (with SS-TS51) Subwoofer*: 140 W (with SS-WS52)

1 kHz, 1 % THD) RMS output power, 10 % THD

DX255

US models: Surround mode (reference)

— Continued on next page —

Front: 133 W + 133 W (with SS-TS52) Center*: 133 W (with SS-CT51) Surround*: 133 W + 133 W (with SS-TS51) Subwoofer*: 135 W (with SS-WS52)

RMS output power, 10 % THD Front: 143 W + 143 W (with SS-TS52) Center*: 143 W (with SS-CT51) Surround*: 143 W + 143 W (with SS-TS51) Subwoofer*: 285 W (with SS-WS52B)

9-887-098-05

SUPER AUDIO CD/DVD RECEIVER

Sony Corporation

Audio Business Group Published by Sony Techno Create Corporation

HCD-DX155/DX255

Other models: Stereo mode (rated) 108 W + 108 W (3 ohms at

1 kHz, 1 % THD)

Surround mode (reference)

RMS output power, 10 % THD Front: 143 W + 143 W (with SS-TS52) Center*: 143 W (with SS-CT51) Surround*: 143 W + 143 W (with SS-TS51) Subwoofer*: 285 W (with SS-WS52B)

*Depending on the sound f ield settings and the source,

there may be no sound output.

Inputs TV/VCR (AUDIO IN) Sensitivity: 450/250 mV AUDIO IN/MIC Sensitivity: 250/125 mV Outputs (Analog) Phones Accepts low-and high-

impedance headphones.

DVD system

Laser Semiconductor laser

(DVD: λ = 650 nm) (CD: λ = 790 nm) Emission duration:

continuous Signal format system North American, Latin, and Mexican models:

NTSC Other models: NTSC/PAL

Tuner section

System PLL quartz-locked digital

synthesizer system FM tuner section Tuning range North American models: 87.5 – 108.0 MHz

(100 kHz step) Other models: 87.5 – 108.0 MHz

(50 kHz step) Antenna (aerial) FM wire antenna (aerial) Antenna (aerial) terminals 75 ohms, unbalanced Intermediate frequency 10.7 MHz AM tuner section Tuning range Middle Eastern models: 531-1,602 kHz (with the

interval set at 9 kHz) Asian models: 531-1,602 kHz (with the

interval set at 9 kHz)

530-1,710 kHz (with the

interval set at 10 kHz) North American and Latin American models:

530-1,710 kHz (with the

interval set at 10 kHz)

531-1,710 kHz (with the

interval set at 9 kHz) Antenna (aerial) AM loop antenna (aerial) Intermediate frequency 450 kHz

Video section

Outputs V

IDEO: 1 Vp-p 75 ohms S VIDEO: Y: 1 Vp-p 75 ohms C: 0.286 Vp-p 75 ohms COMPONENT: Y: 1 Vp-p 75 ohms

PB/CB, PR/CR: 0.7 Vp-p 75 ohms

General

Power requirements North American and Mexican models:

120 V AC, 60 Hz Latin American models: 110 – 240 V AC, 50/60 Hz Other models: 220 – 240 V AC, 50/60 Hz Power consumption On: 140 W (Latin

American models of

DX155), 150 W

(Mexican and other models

of DX155), 160 W (DX255)

Standby: 0.3 W (at the

Power Saving mode) Dimensions (approx.) 430 × 86 × 418 mm

(17 × 3

/2 × 16 3/4 inches) (w/h/d) incl. projecting parts

Mass (approx.) 5.0 kg (11 lb 1 oz)

Design and specifications are subject to change without notice.

MODEL IDENTIFICATION – Rear Panel –

SPEAKER

FRONT R FRONT L SUR R SUR LCENTER WOOFER

Model Part No.

DX155 : US model 2-661-240-0[] DX255 : US model 2-661-240-1[] DX155 : SP model 2-661-240-2[] DX155 : MX model 2-661-240-3[] DX155 : CND model 2-661-240-4[] DX255 : CND model 2-661-240-5[] DX155 : AUS model 2-661-240-6[] DX155 : E3 model 2-661-240-7[]

•Abbreviation AUS: Australian model CND : Canadian model E3 : 240V AC area in E model MX : Mexican model SP : Singapore model

MONITOR OUT

VIDEO

S VIDEO (DVD ONLY)

COMPONENT VIDEO OUT

YPB/CBPR/C

(DVD ONLY)

ANTENNA

TV/VCR

COAXIAL

RLAUDIO IN

Parts No.

HCD-DX155/DX255

SAFETY CHECK-OUT

After correcting the original service problem, perform the following safety check before releasing the set to the customer: Check the antenna terminals, metal trim, “metallized” knobs, screws, and all other exposed metal parts for AC leakage. Check leakage as described below.

LEAKAGE TEST

The AC leakage from any exposed metal part to earth ground and from all exposed metal parts to any exposed metal part having a return to chassis, must not exceed 0.5 mA (500 microamperes.). Leakage current can be measured by any one of three methods.

1. A commercial leakage tester, such as the Simpson 229 or RCA WT -540A. Follow the manufactur ers’ instructions to use these instruments.

2. A battery-operated AC milliammeter. The Data Precision 245 digital multimeter is suitable for this job.

3. Measuring the voltage drop across a resistor by means of a VOM or battery-operated AC v oltmeter. The “limit” indication is 0.75 V, so analog meters must hav e an accurate low-voltage scale. The Simpson 250 and Sanwa SH-63Trd are examples of a passive VOM that is suitable. Nearly all battery operated digital multimeters that have a 2 V AC range are suitable. (See Fig. A)

To Exposed Metal Parts on Set

Laser component in this product is capable of emitting radiation exceeding the limit for Class 1.

This appliance is classified as a CLASS 1 LASER product. This marking is located on the bottom exterior.

CAUTION

Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.

Notes on chip component replacement

• Never reuse a disconnected chip component.

• Notice that the minus side of a tantalum capacitor may be

damaged by heat.

Flexible Circuit Board Repairing

• Keep the temperature of the soldering iron around 270 °C during repairing.

• Do not touch the soldering iron on the same conductor of the circuit board (within 3 times).

• Be careful not to apply force on the conductor when soldering or unsoldering.

0.15 µF

1.5 k

Ω

Earth Ground

voltmete (0.75 V)

Fig. A. Using an AC voltmeter to check AC leakage.

SAFETY-RELATED COMPONENT WARNING!!

COMPONENTS IDENTIFIED BY MARK 0 OR DOTTED LINE WITH MARK 0 ON THE SCHEMATIC DIAGRAMS AND IN THE PARTS LIST ARE CRITICAL TO SAFE OPERATION. REPLACE THESE COMPONENTS WITH SONY PARTS WHOSE PART NUMBERS APPEAR AS SHOWN IN THIS MANUAL OR IN SUPPLEMENTS PUBLISHED BY SONY.

UNLEADED SOLDER

Boards requiring use of unleaded solder are printed with the leadfree mark (LF) indicating the solder contains no lead. (Caution: Some printed circuit boards may not come printed with

the lead free mark due to their particular size)

: LEAD FREE MARK

Unleaded solder has the following characteristics.

• Unleaded solder melts at a temperature about 40 °C higher than ordinary solder. Ordinary soldering irons can be used but the iron tip has to be applied to the solder joint for a slightly longer time. Soldering irons using a temperature regulator should be set to about 350 °C. Caution: The printed pattern (copper foil) may peel away if

the heated tip is applied for too long, so be careful!

• Strong viscosity Unleaded solder is more viscou-s (sticky, less prone to flow) than ordinary solder so use caution not to let solder bridges occur such as on IC pins, etc.

• Usable with ordinary solder It is best to use only unleaded solder but unleaded solder may also be added to ordinary solder.

ATTENTION AU COMPOSANT AYANT RAPPORT

LES COMPOSANTS IDENTIFIÉS PAR UNE MARQUE 0 SUR LES DIAGRAMMES SCHÉMATIQUES ET LA LISTE DES PIÈCES SONT CRITIQUES POUR LA SÉCURITÉ DE FONCTIONNEMENT. NE REMPLACER CES COM- POSANTS QUE PAR DES PIÈCES SONY DONT LES NUMÉROS SONT DONNÉS DANS CE MANUEL OU DANS LES SUPPLÉMENTS PUBLIÉS PAR SONY.

À LA SÉCURITÉ!

HCD-DX155/DX255

Ver. 1.4

1. SERVICING NOTE ................................................... 5

2. GENERAL ................................................................... 8

3. DISASSEMBLY

3-1. Disassembly Flow ........................................................... 11

3-2. Case, Front Panel Assy .................................................... 12

3-3. FL Board, SW Board....................................................... 13

3-4. JACK Board, LED Board ................................................ 13

3-5. I/O Board, Tuner.............................................................. 14

3-6. SPEAKER Board, D.C. Fan............................................ 14

3-7. MAIN Board .................................................................... 15

3-8. POWER Board ................................................................ 16

3-9. DVD Mechanism Deck (CDM81C-DVBU101) ............. 17

3-10. Tray.................................................................................. 18

3-11. MOTOR Board M761 (LD/ST Motor),

M762 (BU U/D Motor) ................................................... 18

3-12. Base Unit (DVBU101) .................................................... 19

3-13. Optical Pick-up (KHM-310CAB) ................................... 19

3-14. Gear (Sub Tray 1), Gear (Sub Tray 2) ............................. 20

3-15. Lever Assy ....................................................................... 20

3-16. Stocker Section ................................................................ 21

3-17. Cam (Stocker).................................................................. 21

3-18. Gear (Stocker 3) .............................................................. 22

3-19. Rotary Encoder (MD)...................................................... 22

3-20. Gear (BU2) ...................................................................... 23

4. TEST MODE ............................................................... 24

5. ELECTRICAL ADJUSTMENT ............................. 28

6. DIAGRAMS

6-1. Block Diagram – RF Section –....................................... 30

6-2. Block Diagram – AMP Section – ................................... 31

6-3. Block Diagram – AUDIO Section – ............................... 32

6-4. Block Diagram – VIDEO Section – ............................... 33

6-5. Block Diagram – POWER Section – .............................. 34

6-6. Printed Wiring Board – MAIN Board (Side A) –............ 35

6-7. Printed Wiring Board – MAIN Board (Side B) – ............ 36

6-8. Schematic Diagram – MAIN Board (1/10) – ................. 37

6-9. Schematic Diagram – MAIN Board (2/10) – ................. 38

6-10. Schematic Diagram – MAIN Board (3/10) – ................. 39

6-11. Schematic Diagram – MAIN Board (4/10) – ................. 40

6-12. Schematic Diagram – MAIN Board (5/10) – ................. 41

6-13. Schematic Diagram – MAIN Board (6/10) – ................. 42

6-14. Schematic Diagram – MAIN Board (7/10) – ................. 43

6-15. Schematic Diagram – MAIN Board (8/10) – ................. 44

6-16. Schematic Diagram – MAIN Board (9/10) – ................. 45

6-17. Schematic Diagram – MAIN Board (10/10) – ............... 46

6-18. Printed Wiring Board – I/O Board – ............................... 47

6-19. Schematic Diagram – I/O Board – ................................. 48

6-20. Printed Wiring Boards – PANEL Section –..................... 49

6-21. Schematic Diagram – PANEL Section – ....................... 50

6-22. Printed Wiring Board – SPEAKER Board – ................... 51

6-23. Schematic Diagram – SPEAKER Board – .................... 51

6-24. Printed Wiring Boards – CD Mechanism Section –....... 52

6-25. Schematic Diagram – CD Mechanism Section – .......... 53

6-26. Printed Wiring Board – POWER Board – ....................... 54

6-27. Schematic Diagram – POWER Board –........................ 55

7. EXPLODED VIEWS

7-1. Overall Section ................................................................ 67

7-2. Front Panel Section ......................................................... 68

7-3. Chassis Section................................................................ 69

7-4. DVD Mechanism Deck Section-1

(CDM81C-DVBU101) .................................................... 70

7-5. DVD Mechanism Deck Section-2

(CDM81C-DVBU101) .................................................... 71

7-6. DVD Mechanism Deck Section-3

(CDM81C-DVBU101) .................................................... 72

7-7. Base Unit (DVBU101) .................................................... 73

8. ELECTRICAL PARTS LIST .................................. 74

SECTION 1

SERVICING NOTE

HCD-DX155/DX255

NOTES ON HANDLING THE OPTICAL PICK-UP BLOCK OR BASE UNIT

The laser diode in the optical pick-up block may suffer electrostatic break-down because of the potential difference generated by the charged electrostatic load, etc. on clothing and the human body. During repair, pay attention to electrostatic break-down and also use the procedure in the printed matter which is included in the repair parts. The flexible board is easily damaged and should be handled with care.

NOTES ON LASER DIODE EMISSION CHECK

The laser beam on this model is concentrated so as to be focused on the disc reflective surface by the objective lens in the optical pickup block. Therefore, when checking the laser diode emission, observe from more than 30 cm away from the objective lens.

LASER DIODE AND FOCUS SEARCH

1. Open the cover and turn POWER on with no disc inserted.

2. Confirm that the following operation is performed while observing the objecting lens.

1)Confirm that laser beam is spread.

2)Up and down motion of the objective lens. (3 times)

DISC TRA Y LOCK

The disc tray lock function for the antitheft of an demonstration disc in the store is equipped.

Setting Procedure :

1. Press the ?/1 button to turn the set on.

2. Press the [FUNCTION] button to set DVD function.

3. Insert a disc.

4. Press the

x button and the A button simultaneously for five

seconds.

5. The message “LOCKED” is displayed and the tray is locked.

Releasing Procedure :

1. Press the x button and the A button simultaneously for five seconds again.

2. The message “UNLOCKED” is displayed and the tray is unlocked.

Note : When “LOCKED” is displayed, the tray lock is not released by

turning power on/off with the ?/1 button.

Self-diagnosis Function

(When letters/numbers appear in the display)

When the self-diagnosis function is activated to prevent the system from malfunctioning, a 5character service number (e.g., C 13 50) with a combination of a letter and 4 digits appears on the screen and the front panel display. In this case, check the following table.

C:13:50

First 3 characters of the service number

C 13 The disc is dirty.

C 31 The disc is not inserted correctly.

E XX (xx is a number)

When displaying the version number on the screen

When you turn on the system, the version number [VER.X.XX] (X is a number) may appear on the screen. Although this is not a malfunction and for Sony service use only, normal system operation will not be possible. Turn off the system, and then turn on the system again to operate.

Cause and/or corrective action

,Clean the disc with a soft cloth

,Restart the system, then re-insert

the disc correctly.

To prevent a malfunction, the system has performed the selfdiagnosis function.

,Contact your nearest Sony

dealer or local authorized Sony service facility and give the 5character service number.

Example: E 61 10

Note on MAIN board replacement

New part of EEP ROM (IC1103) on the MAIN board cannot be used. Therefore, if the mounted MAIN board (A-1151-985-A, etc.) is replaced,

exchange new EEP ROM (IC1103) with that used before the replacement.

VER.X.XX

HCD-DX155/DX255

HOW TO OPEN THE DISC TABLE WHEN POWER SWITCH TURNS OFF

tweezers

DVD lid

tape

Attach an adhesive tape on the DVD LID and draw it out.

gear

Insert tip of tweezers through the hole of bottom plate, and roate the gear in the counter-clockwise direction.

Discharge the charged electricity in capacitors to prevent electric shock as follows

When disassembling the machine, be sure to discharge the charged electricity in the following capacitors. Use a resistor of 800 ohms, 2 Watts for discharging the following capacitors.

POWER board C903 : 600V C932, C933, C939, CN902 : 30V

MAIN board CN3002 : 30 V

MAIN BOARD

(Parts face side)

Connect the specified resistor

between black and red leads

POWER BOARD

(Parts face side)

C932

CN3002

BLACK

RED

CN902

C933

C939

C903

Fix the capacitors with adhesive agent as follows

Fixing the capacitors with adhesive agent is required by the safety regulation. Be sure to fix the capacitors with adhesive agent when part or circuit board is replaced.

POWER BOARD

HCD-DX155/DX255

C910

C924 IC921

Precaution on the connector processing of the POWER board.

When processing the connectors of the POWER board, be sure to refer to section “3-8. POWER BOARD” (page 16).

PRECAUTION WHEN INSTALLING A NEW OP UNIT / PRECAUTION BEFORE UNSOLDERING THE STATIC ELECTRICITY PREVENTION SOLDER BRIDGE

C930

When installing a new OP unit, be sure to connect the flexible printed circuit board first of all before removing the static electricity prevention solder bridge by unsoldering. Remove the static electricity prevention solder bridge by unsoldering after the flexible printed circuit board has already been connected. (Do not remove nor unsolder the solder bridge as long as the OP unit is kept standalone.)

HCD-DX155/DX255

Front panel

SECTION 2

GENERAL

This section is extracted from instruction manual.

A "/1 (on/standby) (29) B Front panel display (92) C A (open/close) (29) D Disc operation (29) E FUNCTION (29) F (remote sensor) (9)

Rear panel

SPEAKER

FRONT R FRONT L SUR R SUR LCENTER WOOFER

A SPEAKER jacks (13) B MONITOR OUT (S VIDEO/VIDEO) jacks

(24)

C AM terminal (13)

G PHONES jack (29) H VOLUME control (29)

I AUDIO IN/A.CAL MIC jack (19, 31) J DISC 1-5 (29) K Disc tray (29)

ANTENNA

MONITOR OUT

VIDEO

S VIDEO

(DVD ONLY)

COMPONENT VIDEO OUT

YPB/CBPR/C

(DVD ONLY)

TV/VCR

RLAUDIO IN

COAXIAL

D COAXIAL FM 75Ω jack (13) E TV/VCR (AUDIO IN R/L) jacks (27) F COMPONENT VIDEO OUT jacks (24)

Front panel display

About the indications in the front panel display

HCD-DX155/DX255

A Lights up when the time information of

a title or chapter appears in the front panel display. (DVD only) (45)

B Lights up when the color system is set

to NTSC. (Asian, Australian, and Middle Eastern models only) (17)

C Lights up when a station is received.

(Radio only) (58)

D Monaural/Stereo effect (Radio only)

(58)

E Lights up when the sleep timer is set.

(62)

F Lights up when the music or movie

mode is selected. (Except for JPEG) (32)

G Playing status (DVD function only) H Lights up when the DYNAMIC BASS is

selected. (61)

I Lights up when CD is loaded. J Lights up when the system outputs

progressive signals (DVD function only). (25)

K Indicates the selected [SPEAKER

FORMATION]. (66)

L Current surround format (Except for

JPEG)

M Displays system’s status such as

chapter, title, or track number, time information, radio frequency, playing status, sound field, etc.

HCD-DX155/DX255

Remote control

ALPHABETICAL ORDER

A – O

AMP MENU wg (22, 31, 60, 62,

97) ANGLE 5 (47) AUDIO 4 (42) CLEAR ef (36, 58, 60, 71) D.TUNING wf (58) DISC SKIP qk (29) DISPLAY 3 (45, 59) DYNAMIC BASS wd (61) ENTER qd (19, 22, 31, 36, 57,

63) FUNCTION ws (25, 29, 31, 37,

57, 66) MENU wh (42, 57) MOVIE/MUSIC qj (32) MUTING 7 (29) Number buttons* qg (36, 58, 60,

63)

P – Z

PICTURE NAVI 6 (37, 60) PRESET +/– wk es (58) PROGRESSIVE eg (25) SLEEP ql (62) SOUND FIELD qh (33) SUBTITLE wf (48) THEATRE SYNC w; (61) TOP MENU qf (42) TUNING +/– 0 qs (57) TV e; (60) TV CH +/– wa (60) TV VOL +/– eh (60) TV/VIDEO 2 (60) VOLUME +/–* 8 (29, 58, 77)

BUTTON DESCRIPTIONS

[/1 (on/standby) 1 (19, 22, 29,

37, 58) TV [/1 (on/standby) ej (60) C/X/x/c qd(19, 22, 31, 36, 57,

63) REPLAY/

ADVANCE 9 (29)

./> es wk (29) m/M qs 0 (35)

SLOW qs 0 (35)

H (play)* ea (29, 37, 64)

STEP 9 (35)

x (stop) wl (30, 37, 63) X (pause) qa (30)

DISPLAY wj (20, 36, 63, 93)

O RETURN ed (37)

-/-- ef (60)

*The H, number 5, and

VOLUME + buttons have tactile dots. Use the tactile dots as references when operating the system.

HCD-DX155/DX255

3-3.FL BOARD, SW BOARD

(Page 13)

3-4.JACK BOARD, LED BOARD

(Page 13)

3-9.DVD MECHANISM DECK

(CDM81C-DVBU101)

(Page 17)

3-10.TRAY

(Page 18)

3-11.MOTOR BOARD

M761 (LD/ST MOTOR),

M762 (BU U/D MOTOR)

(Page 18)

3-12.BASE UNIT (DVBU101)

(Page 19)

3-13.OPTICAL PICK-UP

(KHM-310CAB)

(Page 19)

3-5.I/O BOARD, TUNER

(Page 14)

3-7.MAIN BOARD

(Page 15)

3-8.POWER BOARD

(Page 16)

3-6.SPEAKER BOARD,

D.C. FAN

(Page 14)

3-2.CASE, FRONT PANEL ASSY

(Page 12)

SET

3-14.GEAR (SUB TRAY 1),

GEAR (SUB TRAY 2)

(Page 20)

3-15.LEVER ASSY

(Page 20)

3-16.STOCKER SECTION

(Page 21)

3-19.ROTARY ENCODER (MD)

(Page 22)

3-17.CAM (STOCKER)

(Page 21)

3-20.GEAR (BU2)

(Page 23)

3-18.GEAR (STOCKER 3)

(Page 22)

SECTION 3

Ver. 1.4

DISASSEMBLY

3-1. DISASSEMBLY FLOW

•This set can be disassembled in the order shown below.

•The dotted square with arrow ( ) prompts you to move to the next job when all of the works within the dotted square ( ) are completed.

HCD-DX155/DX255

Note: Follow the disassembly procedure in the numerical order given.

3-2. CASE, FRONT PANEL ASSY

two

screws

(CASE3 TP2)

ire (flat type)

23core (CN509)

sheet

case

five

screws

(+BVTP 3

two

(CASE3 TP2)

screws

loading panel

connector (CN312)

tweezers

claw

front panel assy

gear

of bottom plate, and roate the gear in the counter-clockwise direction.

connector (CN3001)

four screws (+BV3)

Insert tip of tweezers through the hole

claw

When re-assembling, leave 30 mm between harnesses A and B for safety.

harnesses A

30mm

harnesses B

DVD lid

tape

Attach an adhesive tape on the DVD LID and draw it out.

clamp

3-3. FL BOARD, SW BOARD

rivet

four

screws (+BVTP 2.6)

two

screws (+BVTP 2.6)

three

screws (+BVTP 2.6)

wire (flat type)

23core (CN801)

connector (CN811)

connector (CNP801)

connector (CN805)

six

claws

hold plate (FFC)

shield plate (FC)

SW board

FL board

button (power)

When reassembling, route the harness and flexible cable as shown in the illustration.

HCD-DX155/DX255

3-4. JACK BOARD, LED BOARD

knob (vol)

nut

button (play)

button (disk),

indicator (disk)

LED board

button (disk)

eight

five indicators (disk)

screws (+BVTP 2.6)

JACK board

screw (+BVTP 2.6)

HCD-DX155/DX255

Ver. 1.2

3-5. I/O BOARD, TUNER

tuner

wire (flat type)

9core

two screws

(+BVTT 3 × 6)

connector

(CN312)

wire (flat type)

9core(CN203)

I/O board

wire (flat type)

13core(CN311)

wire (flat type)

7core(CN202)

wire (flat type)

13core(CN201)

Open the

back panel .

3-6. SPEAKER BOARD, D.C. FAN

SPEAKER board

two

(+BV3)

connector

(CN301)

screws

connector

(CN3000)

connector

(CN303)

connector

(CN302)

D.C. fan

two

screws

(+BVTT 3 × 8)

two

(+BVTP 4 × 8)

eight

(+BVTP 3 × 8)

screws

When assembling, clamp the three harnesses with a lead pin or a similar tool so that they do not touch this screw.

screws

screw

lead pin

three harnesses

3-7. MAIN BOARD

wire (flat type) 21core (CN508)

wire (flat type) 23core (CN509)

MAIN board

connector (CN1201)

connector

(CN303)

eight screws (+BV 3)

When re-assembling, attaching the two heat radiation sheets on the IC MAIN board first, and then attach the heat sink (AMP).

After twist the harness once, install the connector .

POWER board

MAIN board

heatsink (AMP)

radiation sheets

IC on the MAIN board

wire (flat type) 13core (CN507)

wire (flat type) 24core (CN1101)

wire (flat type) 7core (CN1302)

two radiation

sheets

wire (flat type) 13core (CN1301)

connector

(CN302)

connector

(CN301)

connector (CN3000)

connector (CN3001)

connector

(CN3002)

connector

(CN515)

two screws (+BVTP 3 × 8)

clamp

HEATSINK B board

heatsink (AMP)

HEATSINK A board

screw

(+BVTP 3

12)

two

screws

(+BV 3)

When re-assembling, leave 30 mm between harnesses A and B for safety.

harnesses A

harnesses B

clamp

30mm

screw

lead pin

When assembling, clamp the three harnesses with a lead pin or a similar tool so that they do not touch this screw.

three harnesses

HCD-DX155/DX255

Ver. 1.2

HCD-DX155/DX255

Ver. 1.2

3-8. POWER BOARD

five screws (+PWH 3 × 8)

POWER board

connector (CN515)

Installing the pc board holder

two claws

pc board holder

pc board

holder

two screws (+BV 3)

shield (H/L)

connector (CN3002)

connector (CN901)

(bottom side)

After twist the harness once, install the connector .

POWER board

INSTALLING THE POWER BOARD (DX155 : SP, AUS, E3)

two covers (FJ)

three washers

install the PC board holder

POWER board

five screws (+PWH 3 × 8)

MAIN board

When re-assembling, leave 30 mm between harnesses A and B for safety.

harnesses A

30mm

clamp

When re-assembling, attaching the heat radiation sheets on the chassis first, and then attach POWER board.

heat radiation sheets (DX155 : SP, AUS, E3)

heat radiation sheets (Except DX155 : SP, AUS, E3)

POWER board

heat radiation sheets

harnesses B

3-9. DVD MECHANISM DECK (CDM81C-DVBU101)

four

screws (+BV 3)

MD COVER

HCD-DX155/DX255

Remove the harness and flexible cable.

harness

flexible cable

wire (flat type) 21core (CN508)

four

screws

(+BVTP 3

(CDM81C-DVBU101)

10)

DVD mechanism deck

HCD-DX155/DX255

)

3-10. TRAY

two

screws

(+BTTP 2.6)

tray

bracket

two

screws

(+BTTP 2.6

3-11. MOTOR BOARD M761 (LD/ST MOTOR), M762 (BU U/D MOTOR)

screw

(+BTTP 2.6)

bracket

Remove soldering from the two points.

M762 (BU U/D MOTOR)

screw

(+BTTP 2.6)

MOTOR board

Remove soldering from the two points.

M761 (LD/ST MOTOR)

3-12. BASE UNIT (DVBU101)

base unit (DVBU101)

floating

(+PTPWH2.6)

screw

HCD-DX155/DX255

two floating

(+PTPWH2.6)

screws

3-13. OPTICAL PICK-UP (KHM-310CAB)

insulator

screw

optical pick-up

(KHM-310CAB)

holder (310) assy

insulator

screw

two

screws

(+BTP 2.6

)

two

screws

(+BTP 2.6

)

HCD-DX155/DX255

3-14. GEAR (SUB TRAY 1), GEAR (SUB TRAY 2)

PRECAUTION DURING GEAR (SUB TRAY 1/2) INSTALLATION

Align the marks of the gears as shown in the illustration.

(sub tray 1)

gear (sub tray 2)

gear (sub tray 1)

gear (sub tray 2)

(+PTPWH 2.6

three gears

gear (sub tray 2)

five screws

gear (sub tray 2)

3-15. LEVER ASSY

Before re-assembling, align the lever (release) and the lever (sub tray) with the lever (mode) as shown in the illustration.

dowel dowel

lever (mode)

lever (release)

lever (sub tray)

When re-assembling, insert the lever (sub tray) between the bosses of the shutter (tray).

boss

lever (sub tray)

lever (release)

floating screw

(+PTPWH M2.6)

boss

shutter (tray)

lever (sub tray)

screw

(+PTPWH 2.6 × 8)

shutter (tray)

lever (mode)

cam (BU)

Before re-assembling, slide the cam (BU) in the direction of the arrow.

two screws

(+PTPWH 2.6 × 8)

two cams

(stocker)

cam

(stocker)

cam (stocker)

hole

gear (stocker 2)

gear (stocker 3)

tension spring (SW)

lever (SW)

screw

(+PTPWH 2.6 × 8)

screw

(+PTPWH 2.6 × 8)

hook

PRECAUTION DURING CAM (STOCKER) INSTALLATION

Before installing the cams (stocker), fix the gear (stocker 3) in the manner so that the hole of the gear (stocker 3) should be aligned with the hole of the chassis located beneath the gear (stocker 3). Be sure to install the cams (stocker) in such a way that the grooves of the cams (stocker) face the direction of the arrows.

3-16. STOCKER SECTION

Rotate the gear (SS3) in the

direction of the arrow.

HCD-DX155/DX255

stocker section

3-17. CAM (STOCKER)

HCD-DX155/DX255

Ver. 1.4

3-18. GEAR (STOCKER 3)

screw

(+PTPWH 2.6

gear (stocker 3)

PRECAUTION DURING GEAR (STOCKER 3) INSTALLATION

Be sure to align the rib of the gear (stocker 3) with the groove of the rotary encoder.

groove

rib

rotary encoder (ST U/D encoder)

gear (stocker 3) (reverse-side)

3-19. ROTARY ENCODER (MD)

PRECAUTION DURING ROTARY ENCODER (MD) INSTALLATION

Slide the cam (BU) in the direction of the arrow so that the mark of the gear (BU2) can be seen. Engage the gears while aligning the mark of the gear (BU2) with the protruding part of the rotary encoder.

rotary encoder (MD)

protruding part

cam (BU)

mark

gear (BU2)

three screws

(+BTTP 2.6)

rotary encoder (MD)

3-20. GEAR (BU2)

PRECAUTION DURING GEAR (BU2) INSTALLATION

Before re-assembling, slide the cam (BU) in the direction of the arrow. Assemble the gear (BU2) in such a manner that the groove of the cam (BU) is aligned with the rib of the gear (BU2).

cam (BU)

screw

(+PTPWH 2.6

screw

(+PTPWH 2.6

HCD-DX155/DX255

Ver. 1.4

belt (sub tray)

screw

(+PTPWH 2.6 × 8)

pulley (BU)

gear (BU1)

rib

gear (BU2)

groove

gear (BU2)

HCD-DX155/DX255

Ver. 1.3

SECTION 4

TEST MODE

Note 1: Regarding the notification symbol “R”

Because the number of the operating buttons of this product are limited, some operations require use of the operating buttons of the remote commander, When a specific operation requires use of the operating buttons of the remote commander, “R” is added to the specific operating procedure in this manual. Example MENU/NO “R” The MENU/NO button of remote commander.

Note 2: Incorrect operations may be performed if the test mode is

not entered properly. In this case, press the ?/1 button to turn the po wer of f, and retry to enter the test mode.

1. Cold Reset

• The cold reset clears all data including preset data stored in the RAM to initial conditions. Execute this mode when returning the set to the customers.

Procedure:

1. Press the ?/1 button to turn the power on.

2. Press three buttons x , A and ?/1 simultaneously.

3. When this button is operated, display as “COLD RESET” for a while and all of the settings are reset.

2. Panel Test Mode

•This mode is used to check the software version, FL, LED and KEY.

2-1. Display Test Mode

Procedure:

1. Press the ?/1 button to turn the power on.

2. Press three buttons X , . and A simultaneously.

3. When the display test mode is activ ated, all segments and LEDs are turned on.

4. To exit from this mode, press three buttons X , . and A simultaneously.

2-2. V ersion T est Mode

Procedure:

1. When the display test mode is activ ated, press the . button and the message “DCX1” (DX155), “DCX1D” (DX255) are displayed, the version test mode is activated.

2. Whenever the . button is pressed, the display changes in the following order.

“DCX1” (Model name) t “U2*1” (Destination) t MC t SYS

TM T DSP T TA T ST T CDMB T CDMA T DVD T UI

*1: U2 changes depending on destination.

3. Press the > button and the date of the software production is displayed.

4. Press the > button again and the version is displayed.

5. To exit from this mode, press three buttons X , . and A simultaneously.

2-3. Key Test Mode

Procedure:

1. When the display test mode is activ ated, press the H button, to select the key test mode.

2. T o enter the KEY test mode, the fluorescent indicator displays “K0 V0”. Each time a button is pressed, “KEY” value increases. However, once a button is pressed, it is no longer taken into account. When all keys are pressed correctly, “K8 V0” is displayed.

3. When the VOLUME control is turned in the direction of (+), “V0” is changed to “V1”, then ... “V9”. When the V OLUME control is turned in the direction of (–), “V0” is changed to “V9”, then ... “V1”.

4. To exit from this mode, press three buttons X , . and A simultaneously.

3. Disc Tray Lock

The disc tray lock function for the antitheft of an demonstration disc in the store is equipped.

Setting Procedure :

1. Press the ?/1 button to turn the set on.

2. Press the FUNCTION button to set DVD function.

3. Insert a disc.

4. Press the x button and the A button simultaneously for five seconds.

5. The message “LOCKED” is displayed and the tray is locked.

Releasing Procedure :

1. Press the x button and the A button simultaneously for five seconds again.

2. The message “UNLOCKED” is displayed and the tray is unlocked.

Note: When “LOCKED” is displayed, the slot lock is not released by

turning power on/off with the ?/1 button.

4. DVD Ship Mode

• Use this mode when returning the set to the customer after repair.

Procedure:

1. Press the ?/1 button to turn the set on.

2. Press the FUNCTION button to set the function “DVD”.

Remove all discs, and then press two buttons x and simultaneously.

4. After a message “MECHA LOCK” is displayed on the fluorescent indicator tube, pull out the AC plug.

5. To exit from this mode, press the ?/1 button to turn the set on.

5. AM Step Change

•A step of AM channels can be changed over between 9 kHz and 10 kHz.

Procedure:

1. Press the ?/1 button to turn the set ON.

2. Select the function “TUNER”, and press FUNCTION button to select the BAND “AM”.

3. Press the ?/1 button to turn the set OFF.

4. Press two buttons > and ?/1 simultaneously, and the display of fluorescent indicator tube changes to “AM 9 k STEP” or “AM 10 k STEP”, and thus the channel step is changed over.

6. V olume Test Mode

Procedure:

1. Press the ?/1 button to turn the power on.

2. Press three buttons . , H and > simultaneously.

3. The message “VOLUME MAX” is displayed, when the VOLUME control is turned in the dirction of (+). The message “VOLUME MIN” is displayed, when the VOLUME control is turned in the dirction of (–).

4. To exit from this mode, press the ?/1 button to turn the set of f.

7. Product Out

This mode moves the optical pick-up to the position durable to vibration and clears all data including preset data stored in the RAM to initial conditions. Use this mode when returning the set to the customer after repair.

Procedure:

1. Press the ?/1 button to turn the power on.

2. Press the FUNCTION button to set the function “DVD”.

Remove all discs, and then ?/1 simultaneously.

4. After the “ST ANDBY” blinking display f inishes, the message “MECHA LOCK” is displayed on the fluorescent indicator tube disconnect the AC power plug, then the ship mode is set.disconnect the AC power plug, then the ship mode is set.

press three buttons > , A and

HCD-DX155/DX255

Ver. 1.3

DVD SECTION

8-1. GENERAL DESCRIPTION

The IOP measurement allows you to make diagnosis and adjustment simply by using the remote commander and monitor TV. The instructions, diagnosis results, etc. are given on the on-screen display (OSD). Be sure to execute the IOP measurement when a BU (Base Unit) is replaced.

8-2. HOW TO ENTER TEST MODE

While pressing the x and A buttons simultaneously, turn VOLUME + with the DVD player in power on. The T est Mode starts, then the menu shown belo w will be displayed on the TV screen. * The display of the “Model Name” of the “Remocon Diagnosis

Menu” change with the model and the destination. Refer to below on the model name.

DX155 : DCX1 DX255 : DCX1D

Remocon Diagnosis Menu

0. External Chip Check

1. Servo Parameter Check

2. Drive Manual Operation

3. Emergency History

4. Version Information

Model Name : DCX1_ XX IF-con : V Syscon : Ver.

*1: Changes depending on destination

The menu above is the Remocon Diagnosis Menu screen which consists of five main functions. At the bottom of the menu screen, the model name and IF-con version. To exit from the Test Mode, press the power button on the remote commander.

8-3. EXECUTING IOP MEASUREMENT

In order to execute IOP measurement, the following standard procedures must be followed.

(1) In power on, while pressing the x and A buttons

simultaneously, turn VOLUME + .

Remocon Diagnosis Menu

0. External Chip Check

1. Servo Parameter Check

2. Drive Manual Operation

3. Emergency History Check

4. Version information

Model Name IF-con : Ver. XX.XX (XXXX) Syscon : Ver. X.XXX

*1: Changes depending on destination

: DCX1_ XX

er. XX.XX (XXXX)

X.XXX

(2) Select “2. Drive Manual Operation” by pressing the 2 “R”

button on the remote commander. The screen will appear as shown.

Drive Manual Operation

1. Servo Control

2. Track/Layer Jump

3. Manual Adjustment

4. Tray Aging Mode

5. MIRR time adjust

0. Return to top Menu

(3) Select “3. Manual Adjustment” by pressing the 3 “R” button

on the remote commander. The screen will appear as shown.

Manual Adjust

1. Track Balance Adjust:

2. Track Gain Adjust:

3. Focus Balance Adjust:

4. Focus Gain Adjust:

5. Eq boost Adjust:

6. Iop:

7. TRV. Level:

8. S curve(FE) Level:

9. RFL(PI) Level:

0. MIRR Time:

o O Change Value [RETURN] Return to previous menu

(4) Select “6.IOP” by pressing the 6 “R” button on the remote

commander.

(5) Wait until a hexadecimal number appear.

Manual Adjust

1. Track Balance Adjust:

2. Track Gain Adjust:

3. Focus Balance Adjust:

4. Focus Gain Adjust:

5. Eq Boost Adjust:

6. Iop. 5B:

7. TRV. Level:

8. S curve(FE) Level:

9. RFL(PI) Level:

0. MIRR Time:

Change Value [0] Return to previous menu

(6) Convert each data from hexadecimal to decimal using

conversion table.

(7) Please find the label on the rear of the BU (Base Unit).

The default IOP value is written in the label.

(8) Subtract between these two values.

(9) If the remainder is smaller than 93 (decimal), then it is OK.

Ho wever if the v alue is higher than 93, then the BU is def ective and need to be change.

(10) Press the RETURN “R” button to return back to previous

menu.

(11) Press the 0 “R” button to return to Top Menu and power

off the DVD Player.

HCD-DX155/DX255

Ver. 1.3

8-4. EMERGENCY HISTORY

To check the emergency history, please follow the following procedure.

(1) From the Top Menu of Remocon Diagnosis Menu, select “3.

Emergency History Check” by pressing the 3 “R” button on the remote commander. The following screen appears on the on-screen display.

Emg.History Check

Laser Hours CD 999h 59min

1. 01 05 04 04 00 00 00 00 00 00 23 45

2. 02 02 01 01 00 A9 4B 00 00 00 00 00 00 00 23 45

Next Next Page Prev Prev Page

O Return to Top Menu

DVD 999h 59min

00 92 46 00

(2) Y ou can check the total time when the laser is turned on during

playback of DVD and CD from the above menu. The maximum time, which can be displayed are 999h 59min.

(3) You can check the error code of latest 10 emergency history

from the above menu. To view the previous or next page of emergency history , press . “R” or > “R” on the remote commander. The error code consists of the following three blocks. The first block indicates the error code. The second block indicates the parameter and the third block indicates the time of error code as shown below.

• Error Code

Emg.History Check

Laser Hours CD 999h 59min

*1*

1. 01 05 04 04 00 00 00 00 00 00 23 45

2. 02 02 01 01 00 A9 4B 00 00 00 00 00 00 00 23 45

Next Next Page Prev Prev Page

O Return to Top Menu

DVD 999h 59min

00 92 46 00

*1 : Error Code *2 : Parameter of error code *3 : Time of error code

The meaning of error code is as below:

01: Communication error (No reply from syscon) 02: Syscon hung up 03: Power OFF request when syscon hung up 19: Thermal shutdown 24: MoveSledHome error 25: Mechanical move error (5 Changer) 26: Mechanical move stack error 30: DC motor adjustment error 31: DPD offset adjustment error 32: TE balance adjustment error 33: TE sensor adjustment error 34: TE loop gain adjustment error 35: FE loop gain adjustment error 36: Bad jitter after adjustment 40: Focus NG 42: Focus layer jump NG 52: Open kick spindle error 51: Spindle stop error 60: Focus on error 61: Seek fail error 62: Read Q data/ID error 70: Lead in data read fail 71: TOC read time out (CD) 80: Can’t buffering 81: Unknown media type

8-4-1. Clear the Laser Hour

Press DISPLAY “R” button and then press CLEAR “R” button. The data for both CD and DVD data are reset.

Emg.History Check

Laser Hours CD 0h 0min

1. 01 05 04 04 00 00 00 00 00 00 23 45

2. 02 02 01 01 00 A9 4B 00 00 00 00 00 00 00 23 45

Next Next Page Prev Prev Page

O Return to Top Menu

DVD 0h 0min

00 92 46 00

8-4-2. Clear the Emergency History

Press TOP MENU “R” button and then press CLEAR “R” button. The error code for all emergency history would be reset.

Emg.History Check

Laser Hours CD 999h 59min

1. 00 00 00 00 00 00 00 00 00 00 00 00

2. 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00

Next Next Page Prev Prev Page

O Return to Top Menu

DVD 999h 59min

00 00 00 00

8-4-3. Clear the Initialize Setup Data

Press MENU “R” button and then press CLEAR “R” button on the remote commander.

8-4-4. Return to the Top Menu of Remocon Diagnosis

Press 0 “R” button on the remote commander.

• Check Version Information

To check the version information, please follow the following procedure.

(1) From the Top Menu of Remocon Diagnosis Menu, select “4.

Version Information” by pressing the 4 “R” button on the remote commander. The following screen appears on the onscreen display.

Version information

Firm (Main) : Ver. xxxxx Firm (Sub) : xxxxx RISC : xxxxx 8032 : xxxxx Audio DSP : xxxxx Servo DSP : xxxxx

HCD-DX155/DX255

Ver. 1.3

O Return to Top Menu

To return to the T op Menu of Remocon Diagnosis Menu, press 0 “R” on the remote commander.

HCD-DX155/DX255

)

Ver. 1.3

SECTION 5

ELECTRICAL ADJUSTMENT

DVD SECTION

When the base unit is replaced, perform the adjustment and the measurement as shown below in this order.

EXECUTING IOP MEASUREMENT (See page 25)

[TEST DISC LIST]

Be sure to use the DVD disc that matches the signal standards of your region.

• CD YEDS-18 (Part No.: 3-702-101-01)

PATD-012 (Part No.: 4-225-203-01)

• DVD SL (Single Layer) NTSC : HLX-503 (Part No.: J-6090-069-A)

HLX-504 (Part No.: J-6090-088-A)

PAL : HLX-506 (Part No.: J-6090-077-A)

• DVD DL (Dual Layer) NTSC : HLX-501 (Part No.: J-6090-071-A)

HLX-505 (Part No.: J-6090-089-A)

PAL : HLX-507 (Part No.: J-6090-078-A)

[RF Level Check]

Connection:

oscilloscope

MAIN board

CN1105 pin 6 (RFMON)

CN1105 pin 3 (GND)

+ –

Checking Location: MAIN board (Side A)

MAIN BOARD

CN1105 Pin 3 (GND)

CN1105 Pin 6 (RFMON)

(SIDE A)

CN1105

IC501

IC1103

Procedure:

1. Connect an oscilloscope to CN1105 pin 6 (RFMON) and CN1105 pin 3 (GND) on the MAIN board.

2. Turn the power on.

3. Insert the CD test disc (refer to the TEST DISC LIST), and press the H button to play the disc back.

4. Confirm that oscilloscope waveform is clear and check RF signal level is correct or not.

Note: A clear RF signal waveform means that the shape “◊” can be

clearly distinguished at the center of the waveform.

5. Eject the CD disc, and insert the DVD SL test disk (refer to the TEST DISC LIST), and press the H button to play the disc back.

RF signal waveform

VOLT/DIV: 200 mV TIME/DIV: 500 ns

level: 0.57 to 1.1 Vp-p (CD)

0.58 to 1.23 Vp-p (DVD

+ 64 hidden pages

Sony HCD-DX255 Service Manual

TABLE OF CONTENTS

3-1. DISASSEMBLY FLOW

3-2. CASE, FRONT PANEL ASSY

3-3. FL BOARD, SW BOARD

3-4. JACK BOARD, LED BOARD

3-5. I/O BOARD, TUNER

3-6. SPEAKER BOARD, D.C. FAN

3-7. MAIN BOARD

3-8. POWER BOARD

3-9. DVD MECHANISM DECK (CDM81C-DVBU101)

3-10. TRAY

3-11. MOTOR BOARD M761 (LD/ST MOTOR), M762 (BU U/D MOTOR)

3-12. BASE UNIT (DVBU101)

3-13. OPTICAL PICK-UP (KHM-310CAB)

3-14. GEAR (SUB TRAY 1), GEAR (SUB TRAY 2)

3-15. LEVER ASSY

3-16. STOCKER SECTION

3-17. CAM (STOCKER)

3-18. GEAR (STOCKER 3)

3-19. ROTARY ENCODER (MD)

3-20. GEAR (BU2)