Sony HCDEX-5 Service manual

HCD-EX5

Amplifier section
For the U.S. model
AUDIO POWER SPECIFICATIONS

POWER OUTPUT AND TOTAL
HARMONIC DISTORTION:

With 4 ohms loads, both channels driven, from
120 - 10,000 Hz; rated 12 watts per channel
minimum RMS power, with no more than 10%
total harmonic distortion from 250 milli watts
to rated output.

North American model:

Continuous RMS power output (Reference):

15 + 15 W
(4 ohms at 1 kHz, 10%
THD)

European model:

DIN power output (Rated):12 + 12 W

(4 ohms at 1 kHz, DIN)

Continuous RMS power output (Reference):

15 + 15 W
(4 ohms at 1 kHz, 10%
THD)

Music power output (Reference):

15 + 15 W

Other models:

The following measured at 220 V AC, 60 Hz
DIN power output (Rated):

12 + 12 W
(4 ohms at 1 kHz, DIN,
110 V – 240 V AC)

Continuous RMS power output (Reference):

15 + 15 W
(4 ohms at 1 kHz, 10%
THD, 110 V – 240 V AC)

Inputs
PC/TAPE/MD IN (stereo mini jack):

voltage 450 mV (MD)/
250 mV (PC/TAPE),
impedance 47 kilohms

AM tuner section

Tuning range
Pan-American model: 530 – 1,710 kHz

(with the interval set at
10 kHz)
531 – 1,710 kHz
(with the interval set at
9kHz)

European model: 531 – 1,602 kHz

(with the interval set at
9kHz)

Other models: 530 – 1,710 kHz

(with the interval set at
10 kHz)
531 – 1,602 kHz
(with the interval set at
9kHz)

Antenna AM loop antenna, external

antenna terminal

Intermediate frequency 450 kHz

Outputs
PC/TAPE/MD OUT (stereo mini jack):

voltage 250 mV,
impedance 1 kilohm

PHONES (stereo mini jack):

accepts headphones with
an impedance of 8 ohms

or more
OPTICAL CD DIGITAL OUT (Supported sampling
frequency: 44.1 kHz)

CD player section

System Compact disc and digital

audio system
Laser Semiconductor laser

(λ = 795 nm)

Emission duration:

continuous
Frequency response 2 Hz – 20 kHz

Tuner section

FM stereo, FM/AM superheterodyne tuner

FM tuner section

Tuning range
North American model: 87.5 – 108.0 MHz

(100-kHz step)

Other models:

87.5

– 108.0 MHz

(50-kHz step)
Antenna FM wire antenna
Antenna terminals

75 ohms unbalanced
Intermediate frequency 10.7 MHz

SERVICE MANUAL

Ver 1.1 2003. 12

This set is the tuner, CD and amplifier
section in CMT-EX5

CD

SECTION

SPECIFICATIONS

US Model

Canadian Model

AEP Model

UK Model

E Model

Australian Model

Chinese Model

Model Name Using Similar Mechanism NEW
CD Mechanism Type CDM71C-31BD63A
Base Unit Type BU-31BD63A

9-874-036-02

2003L16-1
© 2003.12

Sony Corporation

Home Audio Company
Published by Sony Engineering Corporation

MICRO Hi-Fi COMPONENT SYSTEM

— Continued on next page —

HCD-EX5

General

Power requirements
North American model: 120 V AC, 60 Hz
European model: 230 V AC, 50/60 Hz
Mexican model: 120 V AC, 60 Hz
Australian model: 220 – 240 V AC,

Korean model: 220 V AC, 60 Hz
Chinese model: 220 V AC, 50/60 Hz
Other models: 110 – 240 V AC,

Power consumption
European model: See the nameplate

Other models: See the nameplate
Dimensions (w/h/d) Approx. 186 × 235 ×

Mass Approx. 3.0 kg

Design and specifications are subject to change
without notice.

50/60 Hz

50/60 Hz

0.25 W (at the Power
Saving Mode)

157 mm incl. projecting
parts and controls

SAFETY CHECK-OUT

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

LEAKAGE

The A C leakage from any e xposed 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. Follo w the manufacturers’ 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 A C voltmeter . The “limit” indication
is 0.75 V, so analog meters must have an accurate low-v olta ge
scale. The Simpson 250 and Sanwa SH-63Trd are e xamples of
a passive VOM that is suitable. Nearly all battery operated
digital multimeters that have a 2V AC range are suitable. (See
Fig. A)

To Exposed Metal

Parts on Set

AC

0.15 µF

Fig. A. Using an A C v oltmeter to check A C leakage.

1.5 kΩ

Earth Ground

Voltmeter
(0.75 V)

2

TABLE OF CONTENTS

1. SERVICING NOTES ······················································· 4

2. GENERAL ·········································································· 5

3. DISASSEMBLY ································································ 8

3-1. Case ··············································································· 9
3-2. OC Boad,OS Boad ························································ 9
3-3. Glass Windo w Assy (U) ·············································· 10
3-4. POWER Board ···························································· 10
3-5. BD Board····································································· 11
3-6. MAIN Board, Tunner ·················································· 11
3-7. CD Mechanism (CDM71C-31BD63A)·······················12
3-8. Base Unit(BU-31BD63A) ··········································· 12
3-9. Holder Assy, Sled Motor Assy (M102) ······················· 13
3-10.Case Button Assy, LID Board ····································· 13
3-11.LID (CD) ····································································· 14
3-12.Ornament (Mecha Panel)············································· 14
3-13.L.MOTOR Board························································· 15
3-14.C MOTOR Board, L.SENSOR Board························· 15
3-15.ENCODER Board, D.SENSOR Board ·······················16
3-16.RTR Pulley Assy, RTL Pulley Assy,

Belt (CDM71), Belt (Roller) (L) ································· 17

3-17.SPT Pulley Assy, Gear (RT) Assy, Gear (KT),

Belt (CDM71) ····························································· 19

4. TEST MODE····································································21

HCD-EX5

6. DIAGRAMS······································································ 25

6-1. Block Diagrams··························································· 25
6-2. Circuit Boards Location ·············································· 28
6-3. Schematic Diagram – BD Board – ······························29
6-4. Printed Wiring Board – BD Board (Side A) – ············· 30
6-5. Printed Wiring Board – BD Board (Side B) – ············· 31
6-6. Schematic Diagram – MAIN Section (1/2) – ·············· 32
6-7. Schematic Diagram – MAIN Section (2/2) – ·············· 33
6-8. Printed Wiring Board – MAIN Board (Side A) –········ 34
6-9. Printed Wiring Board – MAIN Board (Side B) – ········ 35
6-10.Printed Wiring Board – PANEL Section (Side A) –····36
6-11.Printed Wiring Board – PANEL Section (Side B) –···· 37
6-12.Schematic Diagram – MOTOR Section – ···················38
6-13.Printed Wiring Board – MOTOR Section – ················ 39
6-14.Printed Wiring Board – POWER Board (Side A) – ···· 40
6-15.Printed Wiring Board – POWER Board (Side B) – ···· 41
6-16.Schematic Diagram – POWER Section – ···················42
6-17.IC Pin Function Description········································ 43

7. EXPLODED VIEWS ······················································ 47

7-1. Case Section ································································ 47
7-2. Chassis Section-1 ························································48
7-3. Chassis Section-2 ························································49
7-4. Mechanism Section(CDM71C-31BD63A)-1·············· 50
7-5. Mechanism Section(CDM71C-31BD63A)-2·············· 51
7-6. Base Unit (BU-31BD63A) ·········································· 52

5. ELECTRICAL ADJUSTMENTS ······························· 24

8. ELECTRICAL PARTS LIST ······································· 53

3

HCD-EX5

SECTION 1

SERVICING NOTES

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 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. The
CLASS 1 LASER PRODUCT MARKING is located on the rear
exterior.

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.

ATTENTION AU COMPOSANT AYANT RAPPORT

À LA SÉCURITÉ!
LES COMPOSANTS IDENTIFÉS P AR UNE MARQUE 0 SUR LES
DIAGRAMMES SCHÉMA TIQUES ET LA LISTE DES PIÈCES SONT
CRITIQUES POUR LA SÉCURITÉ DE FONCTIONNEMENT. NE
REMPLACER CES COMPOSANTS QUE PAR DES PIÈSES SONY
DONT LES NUMÉROS SONT DONNÉS DANS CE MANUEL OU
DANS LES SUPPÉMENTS PUBLIÉS PAR SONY.

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.

This caution
label is
located inside
the unit.

CAUTION

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

4

Main unit

SECTION 2

GENERAL

HCD-EX5

This section is extracted
from instruction manual.

ALPHABETICAL ORDER

A – Q

Disc slot 2 (23)
Display window 4
DISPLAY qa (16, 19, 20)
FUNCTION 0 (9 - 13, 15, 22,

24)

R – Z

Remote sensor qs
TUNER/BAND 9 (13 - 15, 24)
TUNING +/– 6 (13 -15)
VOLUME +/– 5 (18)

BUTTON DESCRIPTIONS

@/1 (power) 1
Z 3
./> 6
m/M 6
x 7
NX 8

To open the front cover, push
down on the knob under the
display window.

5

HCD-EX5

Remote control

ALPHABETICAL ORDER

A – K

BASS +/– qj (17)
CD N ws (9 - 11, 23)
CLEAR 9 (10 - 12, 16)
CLOCK/TIMER SELECT 6

(19)
CLOCK/TIMER SET 7 (8, 18)
CURSOR T/t wd (8, 12)
DIMMER qk (19)
DISPLAY wg (16, 19, 20)
DSG qf (17)
ENTER/YES 8 (8, 10, 12 - 14,

16, 18, 19, 22)
FM MODE qd (15, 24)
FUNCTION ql (9 - 13, 15, 22,

24)

L – Z

Letter/Number buttons wf (10,

12, 15)
MENU/NO q; (12 - 14, 16, 22)
NAME EDIT/SELECT 3 (11,

16)

PLAY MODE w; (9 - 11, 13, 23,

25)
REPEAT qd (10)
SCROLL 5 (12, 20)
SLEEP 2 (17)
SURROUND qg (17)
TIME wh (11, 20)
TREBLE +/– qh (17)
TUNER BAND wa (13 -15)
TUNING MODE w; (13 - 15)
VOL +/– qs (18)

1 234

wh
wg

wf

wd
ws

wa
w;

ql

qk

BUTTON DESCRIPTIONS

Z 1
@/1 (power) 4
./> qa

+/– qa

X ws
x ws
m/M wd

5
6
7
8

9
0

qa

qs
qd

qf
qg

qhqj

6

HCD-EX5

Replacing the battery in
the remote

1

Slide out and remove the battery case.

2

Insert a new lithium battery CR2025
with the + side facing up.

A lithium battery CR2025

3

Slide the battery case back in.

Tip

When the remote no longer operates the system,
replace the battery with a new one.

Note

If you do not use the remote for a long period of time,
remove the battery to avoid possible damage from
battery leakage and corrosion.

Notes on lithium battery

• Keep the lithium battery out of the reach of
children. Should the battery be swallowed,
immediately consult a doctor.

• Wipe the battery with a dry cloth to assure a good
contact.

• Be sure to observe the correct polarity when
installing the battery.

• Do not hold the battery with metallic tweezers,
otherwise a short-circuit may occur.

Setting the clock

1

Turn on the system.

2

Press CLOCK/TIMER SET on the
remote.

The day indication flashes.

3

Press . or > on the remote
repeatedly to set the day, then press
ENTER/YES on the remote.

The hour indication flashes.

4

Press . or > on the remote
repeatedly to set the hour, then press
ENTER/YES on the remote.

The minute indication flashes.

5

Press . or > on the remote
repeatedly to set the minuite, then
press ENTER/YES on the remote.

If you made a mistake

Press TCURSOR or CURSORt on the remote
repeatedly until the indication you want to change
(day, hour, minuite) flashes, and then change the
setting.

To adjust the clock

1

Press CLOCK/TIMER SET on the remote.

2

Press . or > on the remote
repeatedly to select “CLOCK SET?”, then
press ENTER/YES on the remote.

3

Do the same procedures as steps 3 to 5
above.

WARNING

Battery may explode if you mistreated.
Do not recharge, disassemble or dispose of in fire.

7

HCD-EX5

SECTION 3

DISASSEMBLY

• The equipment can be removed using the following procedure.

SET (HCD-EX5) CASE

OC BOARD,OS BOARD

GLASS WINDOW ASSY (U)

POWER BOARD

BD BOARD

MAIN BOARD,TUNNER

CD MECHANISM

(CDM71C-31BD63A)

BASE UNIT (BU-31BD63A)

C MOTOR BOARD,
L.SENSOR BOARD

L.MOTOR BOARD

CASE BUTTON ASSY,LID BOARD

LID(CD)

HOLDER ASSY ,

SLED MOTOR ASSY (M102)

ENCODER BOARD,
D.SENSOR BOARD

(MECHA PANEL)

ORNAMENT

RTR PULLEY ASSY,RTL PULLEY ASSY,

BELT (CDM71), BELT (ROLLER) (L)

SPT PULLEY ASSY,GEAR (RT)ASSY,

GEAR (KT), BELT (CDM71)

8

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

e

3-1. Case

7

HCD-EX5

case

2

six screws (+BVTP 3

3-2. OC Boad,OS Boad

× 8

6

c

onnector

(CN621)

4

four

screws (+BVTP 3

3

cover (bottom)

)

× 8

)

5

1

cover (back)

6

OS board

1

5

two claws

two

screws (+BTP 2.6

× 8

4

guide disc assy

cas

7

two claws

8

OC board

3

bracket

)

2

screw (+BTP 2.6

× 8

)

9

HCD-EX5

)

3-3. Glass Window Assy (U)

4

retainer plate

3

t

hree screws (+BVTP 3

(L)

× 8

)

1

t

hree screws (+BVTP 3

× 8

)

3-4. POWER Board

5

6

four bushings (bracket)

four

step

screws (slider)

qf

shield (lower)

7

glass

window assy (U)

qg

insulator (power 1)

qh

2

retainer plate

POWER board

qd

five

screws (+BVTP 3

6

(R)

c

onnector

7

two

screws (+BVTP 3

× 8

)

qs

shield (upper)

qa

four

(+BVTP 3

× 8

screws

)

× 8

)

10

1

two

screws

(+BVTP 3

× 8

5

(15 core)

)

f

lat type wire

q;

(+BVTP 3

four

screws

× 8

)

8

(+BVTP 3

two

screws

× 8

3

clamp

2

three

screws

screws

)

× 8

× 8

)

(+BVTP 3

9

two

(+BVTP 3

4

three

(+BVTP 3

)

screws

× 8

3-5. BD Board

)

1

f

lat type wire (23 core)

2

(BLK)

(RED)

Remove solder (two portions ).

7

BD board

4

screw (+B 2

HCD-EX5

× 4

)

3-6. MAIN Board, Tunner

1

two

screws

(+BVTP 3

× 8

2

)

5

h

ook

f

ront panel assy

6

flxible

board

6

3

Remove solder (two portions ).

tunner

5

f

lat type wire

(11 core or 15 core)

3

seven

screws (+BVTP 3

× 8

7

connector

(CN601)

9

MAIN board

8

f

lat type wire

(23 core)

4

back panel

11

HCD-EX5

)

3-7. CD Mechanism (CDM71C-31BD63A)

7

CD mechanism (CDM71C-31BD63A)

3

f

lat type wire

(23 core)

4

connector (CN302)

6

four

screws (+BVTP 3

× 8

)

5

connector (CN303)

1

two

screws (+BVTP 3

× 8

)

3-8. Base Unit(BU-31BD63A)

Rotate the SPT pulley assy in the direction of to move the Base unit shaft
forward.

1

1

cam (A)

2

f

ront panel assy

2

screw

(+PTPWH M2.6)

5

base unit

(BU-31BD63A

12

SPT pulley assy

shaft

4

3

shaft

HCD-EX5

3-9. Holder Assy, Sled Motor Assy (M102)

9

two screws

(+PTPWH M2.6)

holder assy

7

coil spring (C) (holder)

5

BD board

q;

qs

screw

(+P 2

h

×

ook

8

screw

(+PTPWH M2.6)

qa

base unit

4

flxible

board

qd

sled motor assy (M102)

3)

6

coil spring (B) (holder)

1

Remove solder

(two portions ).

(RED)

(BLK)

3-10. Case Button Assy, LID Board

7

four

screws (+BVTP 3

qd

two

screws

(+KTP 2.6

× 6

)

8

3

screw

(+BTP 2

6

4

two

(+BVTP 3

× 8

)

× 8

)

frame (L)

screws

8

× 8

2

Remove solder

(two portions ).

)

5

two

hooks

3

frame (R)

2

two

hooks

qf

glass window assy (L)

q;

three

screws (+BTP 2.6

9

case button assy

qa

LID board

× 8

)

qs

two

screws (+KTP 2.6

× 6

1

)

screw (+BVTP 3

× 8

)

13

HCD-EX5

)

)

3-11. LID (CD)

4

three

(+BVTT 2.6

5

screws

× 4

)

retainer plate (L)

6

LID (CD)

2

three

(+BVTT 2.6

screws

×

4

)

3-12. Ornament (Mecha Panel)

2

ornament (mecha panel)

3

retainer plate (R)

1

tension coil spring (CD door

14

1

four

screws

(+BVTP 2.6

×

8

3-13. L.MOTOR Board

)

)

1

Remove solder (two portions ).

4

L.MOTOR board

2

two

screws

(+BVTP 2.6

×

HCD-EX5

8

3

(CN711)

3-14. C MOTOR Board, L.SENSOR Board

3

connector

(CN711)

5

(CN753)

connector

c

onnector

4

c

onnector

(CN754)

1

Remove solder

(two portions ).

6

c

onnector

(CN755)

9

L.SENSOR board (R)

8

screw

(+BTP M 2.6

×

7

6)

2

two screws

(+BTP M 2.6

C MOTOR board

×

6

15

HCD-EX5

Ver 1.1 2003.12

3-15. ENCODER Board, D.SENSOR Board

7

D.SENSOR board

4

6

(+BTP 2.6

screw (+PWH 2

5

ENCODER

screw

×

6)

×

6)

3

cover (encoder)

board

2

screw (+BTP 2.6

1

(+BTP 2.6

screw

× 8

)

×

6)

PRECAUTION DURING ENCODER board INSTALLATION

Rotate the pulley (LDG2) until the mark of the cam (A) becomes visible.
Install the ENCODER board in the way that it is sandwiched by
the cut-outs of the ENCODER board.

pulley (LDG2)

ENCODER board

cam (A)

16

3-16. RTR Pulley Assy, RTL Pulley Assy, Belt (CDM71), Belt (Roller) (L)

6

screw

7

D.SENSOR board

(+BTP 2.6

5

ENCODER

(When installing it, see the ENCODER board item.)

×

6)

3

cover (encoder)

4

screw (+PWH 2

board

2

screw (+BTP 2.6

×

1

screw

(+BTP 2.6

6)

× 8

×

HCD-EX5

)

6)

qf

RTL pulley assy

9

qg

gear (S1)

c

law

qh

belt (CDM71)

q;

8

pulley (RTR) assypulley (RTL) assy

c

law

q;

RTL pulley assy

qd

RTR pulley assy

qs

RTR pulley assy

qj

belt (ROLLER) (L)

qa

17

HCD-EX5

PRECAUTION DURING PULLEY (RTR) ASSY, PULLEY (RTL) ASSY INSTALLATION

pulley (RTR) assy

pulley (RTR) assy

gear (S2)

(9 o'clock position)

pulley (RTL) assy

claw

marks of the gear (S2)

Place the holes of the gear (S2) at the 9 o'clock position and install
the pulley (RTR) assy.
Install it in the way that the gear of the cut-out portion as shown is located in
between the marks of the gear (S2).

pulley (RTR) assy

claw

Then install the pulley (RTL) assy in the way that it can perform
the symmetrical movement with the pulley (RTR) assy.
Then lock both claws.

pulley (RTR) assy

pulley (RTL) assy

Confirm that the pulley (RTR) contacts the claws.
Opposite to it, the pulley (RTL) assy must
have clearance of 1 to 2 mm with the claw.
It should contact with claw.

If clearance is too large or it contacts with claw,
adjustment is necessary.

claw

1 to 2 mm

Method of adjustment is as follows.
Raise the right gear (S1) a little and perform adjustment
by moving the left gear (S1).

gear(S1)

18

3-17. SPT Pulley Assy, Gear (RT) Assy, Gear (KT), Belt (CDM71)

HCD-EX5

3

2

SPT pulley assy

4

gear (KT)

gear (RT) assy

Rotate the SPT pulley assy in the direction of , and remove your hands
at the position where the shaft agrees with the hole shape on the chassis.

SPT pulley assy

5

belt (CDM71 )

When installing, align the protruded portion of the KT gear with groove of the SPT
pulley assy.

1

1

19