SONY HCD-EP404 Service Manual

HCD-EP404

SERVICE MANUAL

Ver 1.3 2003. 10

HCD-EP404 is the amplifler, CD
player, tape deck and tuner section in
CMT-EP404.

CD

SECTION

TAPE DECK

SECTION

SPECIFICATIONS

Amplifier section

DIN power output (rated) 6 + 6 W

(8Ω at 1 kHz, DIN)

Continuous RMS power output (reference)

8 + 8 W
(8Ω at 1 kHz, 10% THD)

Music power output (reference)

16 + 16 W
Outputs
PHONES: Accepts headphones of
(stereo mini jack) 8Ω or more
SPEAKER: Accepts impedance of 8 to

16Ω

AEP Model

UK Model

Model Name Using Similar Mechanism HCD-EP50
CD Mechanism Type CS-21SC-1280
Model Name Using Similar Mechanism NEW
Tape Transport Mechanism Type CFL4318

Tuner section

FM stereo, FM/AM superheterodyne tuner

FM tuner section

Tuning range 87.5 - 108.0 MHz
Antenna FM lead antenna
Intermediate frequency 10.7 MHz

AM tuner section

Tuning range 531 -1 602 kHz

(with the interval set at

9 kHz)
Antenna Built-in ferrite bar antenna
Intermediate frequency 450 kHz

9-873-940-04

2003J16-1
© 2003.10

CD player section

System Compact disc and digital

audio system

Laser Semiconductor laser

(λ =780 nm)
Emission duration:
continuous

Frequency response 20 Hz - 20 kHz (±0.5 dB)

Tape player section

Recording system 4-track 2-channel stereo
Frequency response 50 - 13 000 Hz (±3 dB),

using Sony TYPE I
cassette

Sony Corporation

Home Audio Company
Published by Sony Engineering Corporation

General

Power requirements 230 V AC, 50/60 Hz
Power consumption 38W

0.5 W (in the standby

mode)
Dimensions (w/h/d): Approx. 145 × 240 × 252 mm
Mass: 3.1 kg

Design and specifications are subject to change
without notice.

COMPACT DISC DECK RECEIVER

HCD-EP404

Ver 1.1 2002.07

TABLE OF CONTENTS

1. SERVICING NOTES······················································ 3

2. GENERAL ·········································································· 4

3. DISASSEMBLY ································································ 6

3-1. Front Panel Section······················································· 6
3-2. MAIN Board ·································································7
3-3. Tape Mechanism Deck (CFL4318)······························· 7
3-4. POWER Board, Power Transformer ····························· 8
3-5. DISPLAY Board, HEADPHONE Board ······················8
3-6. CD Cabinet Section ······················································ 9
3-7. CD Mechanism Deck (CS-21SC-1280)························ 9
3-8. Cassette Lid ································································ 10

4. MECHANICAL ADJUSTMENTS ····························· 11

5. ELECTRICAL ADJUSTMENTS ······························· 11

6. DIAGRAMS······································································ 15

6-1. Circuit Boards Location·············································· 15
6-2. Block Diagrams ·························································· 16

TUNER/TAPE DECK Section ··································· 16
AMP Section······························································· 17

DISPLAY/POWER Section········································ 18
6-3. Printed Wiring Board MAIN Section ························ 19
6-4. Schematic Diagram MAIN Section (1/3) ·················· 20
6-5. Schematic Diagram MAIN Section (2/3) ·················· 21
6-6. Schematic Diagram MAIN Section (3/3) ·················· 22
6-7. Printed Wiring Board PANEL Section ······················ 23
6-8. Schematic Diagram PANEL Section ························· 24
6-9. Printed Wiring Board POWER Section ····················· 25
6-10. Schematic Diagram POWER Section························ 26
6-12. IC Pin Function Description ······································· 29

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 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.

CAUTION

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

This appliance is classified as a CLASS 1 LASER product. The
CLASS 1 LASER PRODUCT MARKING is located on the rear
exterior.

The following caution label is located inside the unit.

7. EXPLODED VIEWS ······················································ 31

7-1. Cabinet Section ···························································31
7-2. Front Panel Section -1 ················································ 32
7-3. Front Panel Section -2 ················································ 33
7-4. CD Cabinet Section ···················································· 34

8. ELECTRICAL PARTS LIST ······································· 35

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.

2

SECTION 1

SW600

SERVICING NOTES

HCD-EP404

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 OPERATION
CHECK

1. Press the ?/1 button to the power ON with no disc inserted
and press the CD button.

2. Open the lid for CD.

3. Turn on SW600 as following figure.

4. Confirm the laser diode emission while observing the objecting
lens. When there is no emission, Auto Power Control circuit or
Optical Pick-up is broken.
Objective lens moves up and down five times for the focus
search.

3

HCD-EP404

Main unit

SECTION 2

GENERAL

This section is extracted
from instruction manual.

ALPHABETICAL ORDER

A – M

Cassette compartment qg (14)
CD 4 (8, 9, 15)
DISPLAY 2 (12, 19)
Display Window 5 (8, 9, 10,

11)
ENTER qh (7, 9, 10, 11, 13)
MEGA BASS 8 (17)
MUSIC MENU 9 (17)

P – Z

PHONES jack qk
PLAY MODE qj (8, 9)
PRESET +/– qd (11, 13)
Remote sensor 0
TAPE 3 (14)
TIMER indicator 1 (16, 18)
TUNER 6 (10, 11, 12, 15)
TUNER MEM qh (10, 11)
TUNING +/– qa (10, 11, 12, 13)
VOLUME control qs

BUTTON DESCRIPTIONS

@/1 (power) wd (7, 16, 18)

CD

.m (go back) qa (8, 9, 14)
M> (go forward) qa (8, 9,

14)

N (play) w; (8, 9)
X (pause) ws (8)
Z PUSH OPEN/CLOSE 7 (8)
x (stop) ql (8, 9)

TAPE

M> (fast forward) qa (14)
X (pause) ws (14)
N (play) w; (14)
z (recording) wa (15, 16)
.m (rewind) qa (14)
Z PUSH OPEN/CLOSE qf (14)
x (stop) ql (14, 15)

4

Remote control

HCD-EP404

ALPHABETICAL ORDER

A – M

CD wf (8, 9, 15)
CLOCK/TIMER +/– w; (16, 18)
CLOCK/TIMER ON/OFF 2

(16, 18)

CLOCK/TIMER SET 3 (7, 16,

18)
DISPLAY qa (12, 19)
ENTER qf (7, 9, 10, 11, 13, 18)
MEGA BASS qd (17)
MUSIC MENU +/– qh (17)
MUTING qg (17)

P – Z

PLAY MODE 7 (8, 9, 13, 14, 15)
PRESET +/– 9 (11, 13)
REPEAT 8 (8)
SLEEP 1 (17)
TAPE wd (14)
TUNER/BAND 5 (10, 11, 12,

15)
TUNER MEMORY qj (10, 11)
TUNING + q; (10, 11, 12, 13)
TUNING – qk (10, 11, 12, 13)
VOL (volume) +/– qs

BUTTON DESCRIPTIONS

m (rewind) M (fast forward)

ql (8, 14)

. (go back) > (go forward)

w; (7, 8, 14, 15)

X (pause) ws (8, 14)
N (play) wa (8, 9, 14, 15, 16)
`/1 (power) 4 (7, 16, 18)
x (stop) 6 (8, 9, 14, 15)

Setting the clock

1

Turn on the system.

2 Press CLOCK/TIMER SET on the

remote.

3 Press . or > on the remote

repeatedly to set the hour.

4 Press ENTER.
5 Press . or > on the remote

repeatedly to set the minute.

6 Press ENTER.

The clock starts working.

To adjust the clock

1 Press CLOCK/TIMER SET on the remote.
2 Press . or > on the remote to select

“SET CLK”, then press ENTER.

3 Do the same procedures as step 3 to 6 above.

Note

The clock settings are canceled when you disconnect
the power cord or if a power failure occurs.

5

HCD-EP404

t

Ver 1.1 2002.07

SECTION 3

DISASSEMBLY

• The equipment can be removed using the following procedure.

SET

3-1. FRONT PANEL SECTION

(Page 6)

3-2. MAIN BOARD

(Page 7)

3-3. TAPE MECHANISM DECK

(CFL4318)
(Page 7)

3-8. CASSETE LID

(Page 10)

3-4. POWER BOARD,
POWER TRANSFORMER

(Page 8)

3-5. DISPLAY BOARD,
HEADPHONE BOARD

(Page 8)

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

3-1. Front Panel Section

3

two screws
(+BTP2.6

3-6. CD CABINET SECTION

(Page 9)

3-7. CD MECHANISM DECK

(CS-21SC-1280)
(Page 9)

2

antenna cover cabine

×

10)

qa

connector
(CN201)

6

two screws
(+K3

8

claw

×

5)

9

qs

connector
(CN402)

qd

front panel section

q;

connector
(SW600)

7

two screws
(+K3

×

5)

5

two screws
(+K3

×

5)

1

screw
(+BVTP3

4

two screws
(+BVTP3

×

×

10)

10)

6

3-2. MAIN Board

)

8

screw
(+BTP2.6

HCD-EP404

Ver 1.1 2002.07

q;

MAIN board

×

8)

1

connector
(CN704)

2

connector
(CN705)

4

connector
(CN701)

3

connector
(CN601)

5

connector
(CN402)

9

claw

3-3. Tape Mechanism Deck (CFL4318)

3

tape mechanism deck (CFL4318)

7

connector
(CN702)

6

2

two screws
(+BVTP3

connector
(CN703)

×

10)

1

two screws
(+BVTP3

×

10

7

HCD-EP404

t

3-4. POWER Board, Power Transformer

rear cabinet assy

2

ac cord holder

1

screw
(+BVTP3

×

10)

9

power pwb mounting bkt

3

screw
(+BVTP3

×

10)

6

Remove four solderings.

4

four screws
(+BVTP3

×

12)

5

power transformer

3-5. DISPLAY Board, HEADPHONE Board

qa

HEADPHONE board

q;

earth wire

q;

7

Remove four solderings.

9

Remove the soldering.

7

screw
(+PTPWH2.6 × 10)

8

reteiner board

8

POWER board

screw
(+BTP2.6

4

×

8)

seven screws
(+BTP2.6 × 10)

5

main pwb mounting bk

1

vol. rotaly knob

8

3

nut

2

washer

6

DISPLAY board

3-6. CD Cabinet Section

)

2

CD cabinet section

1

two screws
(+BTP2.6 × 8

HCD-EP404

3-7. CD Mechanism Deck (CS-21SC-1280)

9

two spring clamps

qs

vibration proof rubber
(pink)

6

four fiber washers

5

four pulley screws

qd

vibration proof rubber
(orange)

7

3

qf

CD mechanism deck (CS-21SC-1280)

8

two spring clamps

q;

vibration proof rubber
(orange)

qa

vibration proof rubber
(pink)

1

two screws
(BVTP3 × 8)

2

Remove the connector.

4

CD cover housing

9

HCD-EP404

w

3-8. Cassette Lid

2

1

Push

open/close switch

3

claw

4

5

cassette lid

3

cla

10

SECTION 4

)

MECHANICAL ADJUSTMENTS

HCD-EP404

SECTION 5

ELECTRICAL ADJUSTMENTS

PRECAUTION

1. Clean the following parts with a denatured-alcohol-moistened
swab :

record/playback head pinch roller
erase head rubber belts
capstan idlers

2. Demagnetize the record/playback head with a head
demagnetizer.

3. Do not use a magnetized screwdriver for the adjustments.

4. After the adjustments, apply suitable locking compound to the
parts adjusted.

5. The adjustments should be performed with the rated power
supply voltage unless otherwise noted.

Torque Measurement

Mode Torque Meter Meter Reading

FWD CQ-102C (30 – 70 g•cm)

FWD
Back Tension

FF CQ-201B (more than 60 g•cm)

REW CQ-201B (more than 60 g•cm)

CQ-102C (1.5 – 5.5 g•cm)

2.95 – 6.86 mN•m

(0.42 – 0.97 oz•inch)

0.15 – 5.39 mN•m

(0.021 – 0.076 oz•inch)
more than 5.89 mN•m

(more than 0.83 oz•inch)
more than 5.89 mN•m

(more than 0.83 oz•inch)

PRECAUTION

1. Setting
MEGA BASS switch : OFF

TAPE DECK SECTION 0 dB=0.775 V

Test tape

Type Signal Used for

P-4-A100 10 kHz, –10 dB Head Azimuth Adjustment
WS-48B 3 kHz, 0 dB Tape Speed Adjustment

Record/Playback Head Azimuth Adjustment

Procedure:

1. Mode: Playback

test tape
P-4-A100
(10 kHz, –10 dB)

set

HEADPHONE board
PHONES jack (JK501

2. Turn the adjustment screw and check output peaks. If the peaks
do not match for L-CH and R-CH, turn the adjustment screw
so that outputs match within 1dB of peak.

32

level meter

Ω

+
–

Tape Tension Measurement

Mode Torque Meter Meter Reading

FWD CQ-403A

more than 100 g
(more than 3.53 oz)

L-CH
peak

Output
level

R-CH

Screw
position

peak

3. Mode: Playback

test tape
P-4-A100
(10 kHz, –10 dB)

L-CH

set

R-CH

within
1dB

L-CH
peak

HEADPHONE board
PHONES jack (JK501)

screen pattern

32

32

Ω

Ω

R-CH
peak

within
1dB

oscilloscope

V

H

+

+

–

–

Screw
position

in phase

45

°

good wrong

90

°

135 °180

°

4. After the adjustments, apply suitable locking compound to the
parts adjusted.

11

HCD-EP404

r

L

Tape Speed Adjustment

Setting:

Function: TAPE

test tape
WS-48B
(3 kHz, 0 dB)

set

frequency counte

32

Ω

+
–

HEADPHONE board
PHONES jack (JK501)

Procedure:

1. Playback WS-48B (tape center).

2. Adjsut the volume in CAPSTAN/REEL motor so that the
frequency counter reading becomes 3,000 Hz.

Specified V alue: 2,910 to 3,090 Hz

3. Confirm that the frequency at the beginning and that at the end
of tape winding are between 2,955 to 3,045 Hz.

Adjustment Location:

Tape Speed
Adjustment

Adjustment Location: Record/Playback Head.

adjustment screw

CAPSTAN/REE
motor

Note: Refer to “3-8. Cassette Lid” (see page 10)

12

HCD-EP404

)

)

TUNER SECTION 0 dB=1 µV

[AM]

Setting:

Function : TUNER
Band switch : AM

AM RF signal

generator

30% amplitude
modulation by
400 Hz signal
Output level: as low as possible

[FM]

Setting:

Function : TUNER
Band switch : FM

FM RF signal

generator

22.5 kHz frequency
deviation by 400 Hz
signal
Output level: as low as possible

Put the lead-wire
antenna close to
the set.

set

MAIN board

0.01 µF

FM ANT

set

digital voltmeter

level meter

32

Ω

+

–

HEADPHONE board
PHONES jack (JK501

level meter

32

Ω

+
–

HEADPHONE board
PHONES jack (JK501

AM FREQUENCY COVERAGE ADJUSTMENT

Adjustment Part Frequency Display Reading on Digital Voltmeter

Confirmation 531 kHz 1.5 ± 0.2 V

T101 1,602 kHz 7.3 ± 0.3 V

AM TRACKING ADJUSTMENT

Adjust for a maximum reading on level meter

L110 603 kHz

TC102 1,404 kHz

FM FREQUENCY COVERAGE ADJUSTMENT

Adjustment Part Frequency Display Reading on Digital Voltmeter

L103 87.5 MHz 2.1 ± 0.2 V

Confirmation 108 MHz 7.0 ± 0.4 V

FM TRACKING ADJUSTMENT

Adjust for a maximum reading on level meter

L102 89.9 MHz

TC101 105.9 MHz

Adjustment Location: MAIN board (See page 14)

MAIN board
TP (FM VT)
TP (AM VT)

•Repeat the procedures in each adjustment sev eral times, and the frequency
coverage and tracking adjustments should be finally done by the trimmer
capacitors.

100 k

Ω

13