Sony ZS-D55 Service manual

ZS-D55

SERVICE MANUAL

Ver 1.1 2002. 02

TAPE Model Name Using Similar Mechanism ZS-D50
Section T ape Transport Mechanism T ype MF-ZSD55

CD
Section

US Model

Canadian Model

Model Name Using Similar Mechanism ZS-D50
MD Mechanism T ype CDM-2411AAA
Optical Pick-up Type DAX-01A2

SPECIFICATIONS

AUDIO POWER SPECIFICATIONS

POWER OUTPUT AND TOTAL HARMONIC DISTORTION
With 12 Ω loads, both channel driven from 150 - 6 300 Hz; rated 4 W per
channel-minimum RMS power, with no more than
10 % total harmonic distortion in AC operation.

Other Specifications
CD player section

System

Compact disc digital audio system

Laser diode properties

Material: GaAlAs
Wave length: 780 nm
Emission duration: Continuous
Laser output: Less than 44.6 µW (This output is the value measured
at a distance of about 200 mm from the objective lens surface on the
optical pick-up block with 7 mm aperture.)

Spindle speed

200 r/min (rpm) to 500 r/min (rpm) (CLV)

Number of channels

2

Frequency response

20 - 20 000 Hz +0.5/–1.2 dB

Wow and flutter

Below measurable limit

Radio section

Frequency range

FM: 87.6 - 108 MHz
AM: 530 - 1 710 kHz

Antennas

FM: Telescopic antenna
AM: Built-in ferrite bar antenna

Cassette-corder section

Recording system

4-track 2 channel stereo

Fast winding time

Approx. 112 s (sec.) with Sony cassette C-60

Frequency response

TYPE I (normal): 50 - 15 000 Hz

General

Speaker

Full range: 8 cm (3 1⁄4 in.) dia., 12 Ω,
cone type x 2

Input

LINE IN jack (stereo minijack)
Minimum input level 138 mV

Outputs

Headphones jack (stereo minijack)

For 8 - 32 Ω impedance headphones

LINE OUT jack (stereo minijack)

Rated output level 138 mV at load impedance
47 kΩ

OPTICAL DIGITAL OUT (CD) (optical output connector)

Wavelength: 630 - 690 nm

Power output (excluding US model)

4.5 W + 4.5 W (at 12 Ω, 10% harmonic distortion)

– Continued on page 2 –

PERSONAL AUDIO SYSTEM

9-927-927-12

2002B0200-1
© 2002.02

Sony Corporation

Personal Audio Company
Published by Sony Engineering Corporation

Power requirements

For personal audio system:
120 V AC, 60 Hz
12 V DC, 8 size D (R20) batteries

For memory back-up:
6 V DC, 4 size AA (R6) batteries

For remote control:
3 V DC, 2 size AA (R6) batteries

Power consumption

AC 22 W

Battery life

For personal audio system

FM recording

Sony R20P: approx. 6 h
Sony alkaline LR20: approx. 12 h

Tape playback

Sony R20P: approx. 3 h
Sony alkaline LR20: approx. 6 h

CD playback

Sony R20P: approx. 1.5 h
Sony alkaline LR20: approx. 3 h

Dimensions (incl. projecting parts)
Approx. 486 x 244 x 177 mm (w/h/d)

(17 1⁄10 x 9 3⁄5 x 6 9⁄10 inches)

Mass (incl. batteries)

Approx. 6.2 kg (13 lb. 11 oz)

Supplied accessories

AC power cord (1)
Remote control (1)

Design and specifications are subject to change without notice.

TABLE OF CONTENTS

Specifications ........................................................................... 1

1. SERVICE NOTE........................................................... 3

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

3. DISASSEMBLY

3-1. Cabinet Rear ASSY, Cabinet Front ASSY ................ 6

3-2. Power Board, P/T In Board, P/T Out Board,

BATT S Board ........................................................... 7

3-3. Tuner Board .............................................................. 7

3-4. Jack Board................................................................. 7

3-5. Audio Board .............................................................. 8

3-6. CD Board .................................................................. 8

3-7. TC Board................................................................... 9

3-8. Cabinet Top ASSY .................................................... 9

3-9. H/P Board ................................................................ 10

3-10.TC/M Board ............................................................ 10

3-11.MD Block ASSY ......................................................11

3-12.TC LED (L) Board, TC LED (R) Board,

TC Key Board .......................................................... 11

3-13.TC RF Board, Head Relay Board, Belt FR,

Belt BR, Capstan/Reel Motor (M691) .................... 12

3-14.CD Chassis ASSY ................................................... 12

3-15. CD Block Section ................................................... 13

3-16. Loading Board ........................................................ 13

3-17. “Tray ASSY, CD” ................................................... 14

3-18. Optical Pick-up Block, Pick-up Relay Board ......... 14

3-19. Panel DECO ASSY ................................................ 15

3-20.Control Board, JOG LED1 Board,

JOG LED2 Board.................................................... 15

3-21. Key Board............................................................... 16

3-22. BATT Board ........................................................... 16

4. TEST MODE................................................................ 17

5. ADJUSTMENTS

5-1. Mechanical Adjustmens............................................ 18

5-2. Electrical Adjustments.............................................. 19

6. DIAGRAMS

6-1. Explanation of IC Terminals................................... 22

6-2. Block Diagrams (Tape, Main Section) ................... 24

6-3. Block Diagrams (Tuner, CD Section) .................... 27

6-4. Printed Wiring Boards (Main Section) ................... 31

6-5. Schematic Diagram (Main Section) ....................... 35

6-6. Schematic Diagram (CD Section) .......................... 39

6-7. Printed Wiring Boards (CD Section)...................... 43

6-8. Printed Wiring Boards (Contorl Section) ............... 45

6-9. Schematic Diagram (Control Section).................... 47

6-10. Printed Wiring Boards (Tuner Section) .................. 51

6-11. Schematic Diagram (Tuner Section) ...................... 52

7. EXPLODED VIEWS

7-1. Rear Cabinet Section ................................................ 60

7-2. Front Cabinet Section ............................................... 61

7-3. CD Block Section ..................................................... 62

7-4. Top Cabinet Section.................................................. 63

7-5. Mechanism Deck Section (1/2) ................................ 64

7-6. Mechanism Deck Section (2/2) ............................... 65

7-7. CD Section................................................................ 66

7-8. Optical Pick-up Section ............................................ 67

8. ELECTRICAL PARTS LIST................................... 68

– 2 –

SAFETY CHECK-OUT (US Model)

SECTION 1

SERVICE NOTE

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 0.5mA (500 microampers).
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 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 AC voltmeter . The “limit” indication is 0.75V,
so analog meters must have 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 2V AC range are suitable. (See Fig. A)

To Exposed Metal
Parts on Set

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

The laser diode in the optical pick-up block may suffer electrostatic
breakdown because of the potential difference generated by the
charged electrostatic load, etc. on clothing and the human body.
During repair, pay attention to electrostatic breakdown 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 more than 30 cm away from the objective lens.

LASER DIODE AND FOCUS SEARCH OPERATION
CHECK

1. Close the tray for CD.

2. Press CD u button.

3. 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 once for the focus search.

0.15 µF

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

1.5kΩ

Earth Ground

AC
voltmeter
(0.75V)

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.

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.

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.

CAUTION DURING WHEN MOUNTING THE PULLEY
FOR THE LOADING MOTOR

Make the following adjustment when mounting the loading motor
(part number : 1-698-999-11) and motor pulley (part number : 2­627-174-01) of the CD section.

Specification : A = 0.9 to 1.1mm

ATTENTION AU COMPOSANT AYANT RAPPORT

À LA SÉCURITÉ!

LES COMPOSANTS IDENTIFIÉS 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 PIÈCES SONY
DONT LES NUMÉROS SONT DONNÉS DANS CE MANUEL OU
DANS LES SUPPLÉMENTS PUBLIÉS PAR SONY.

– 3 –

LOCATION AND FUNCTION OF CONTROLS

FRONT PANEL : CD/RADIO/TAPE section

qf
qd

qs
qa

0

SECTION 2

GENERAL

12 34

5

6
7

8
9

1 Tape operation buttons

z/X (REC/REC P AUSE)
m, M (FF/REW, AMS)
x (STOP)
b, B (PLAY)

2 Cassette lid
3 Z PUSH OPEN/CLOSE

FRONT PANEL: TIMER/COM section

e;

wl

wk
wj

wh

4 COUNTER RESET button
5 DIR MODE button
6 JOG dial
7 Z CD OPEN/CLOSE button
8 Radio operation buttons

Tune – m, M +

9 CD tray

qgqh qj qk qlw;wa

0 AUTO PRESET button
qa CANCEL button
qs CD DUB button
qd CD operation buttons

u (PLA Y/PAUSE)
x (STOP)

qf BAND button

ws
wd

wf
wg

qg STANDBY button
qh OPR/BATT indicator
qj Display window
qk DISPLAY button
ql Remote control receiver
w; CLOCK button
wa VOL +, – buttons
ws MEGA BASS button

wd MODE buttion
wf ENTER MEM button
wg TIMER button
wh SLEEP button
wj MD(LINE) button
wk SOUND button
wl POWER button
e; i (Headphones) jack (stereo mini jack)

– 4 –

REAR PANEL

ea es ed ef eg eh ej

ea LINE OUT jack
es LINE IN jack
ed OPTICAL DIGITAL OUT(CD) jack
ef OPTICAL DIGITAL OUT(CD) jack cover socket
eg FM telescopic antenna
eh AC IN - jack
ej Battery compartment

Remote commander

1

2

3

4

5

6

7

8

9
0

qa

1 FUNCTION button

Each time you pressed, the function changes in the order
CD – Tape – Radio – Line – CD

2 Z CD OPEN/CLOSE button
3 Number buttons
4 MODE button
5 Radio operation buttons

TUNE +, – button
BAND

6 CD operation buttons

., > (AMS/SEARCH)
N (PLAY)
X (P AUSE)
x (STOP)

7 Tape operation buttons

x (STOP)
b, B (PLAY)
z/X (REC/REC PAUSE)
m, M (FF/REW, AMS)

8 POWER button (AC only)

Active only when you use the set with AC power source.

9 MEGA BASS button
0 VOL +, – button
qa SOUND button

• • •

– 5 –

SECTION 3

4

DISASSEMBLY

z

The equipment can be remo ved using the f ollo wing pr ocedure .

< MAIN SECTION >

Cabinet Rear ASSY Power board, P/T in board, P/T out board, BATT S board

Set

Cabinet Front ASSY
BATT L board

< CD BLOCK SECTION >

CD block section

Note : Follo w the disassemb ly pr ocedure in the n umerical or der given.

“ Tray ASSY, CD ”
Loading board

<MAIN SECTION>

3-1. CABINET REAR ASSY, CABINET FRONT ASSY

Tuner board
Jack board

Audio board

Cabinet Top ASSY

CD chassis ASSY

Optical pick-up block, Pick-up relay board

CD board
TC board

Control board, JOG LED 1 board, JOG LED 2 board Key board

H/P board
TC/M board
MD block ASSY

TC key board, TC LED (L) board, TC LED (R) board
TC RF board, Head relay board, Belt FR, Belt BR, Motor (M691)

CD block section

Panel DECO ASSY

Cabinet front ASSY

Handle

3

Screws

+BVTP 3

5

4

×

14

2

Screws

+BVTP 3

1

×

10

3

Screws

+BVTP 3 × 1

Cabinet rear ASSY

– 6 –

3-2. POWER BOARD, P/T IN BOARD, P/T OUT BOARD , BATT S BOARD

Jack board

2

1

Claws

Cabinet front ASSY

Power board

2

1

Screws

+BVTP 3

×

10

4

3

7

5

6

Claw

P/T OUT board

3-3. TUNER BOARD

Tuner board

2

P/T IN board

BATT S board

Cabinet rear ASSY

3-4. JACK BOARD

1

Claws

Cabinet front ASSY

– 7 –

3-5. AUDIO BOARD

0

1

CNP310

1

CNP308

2

Wire parallel (FFC) (11core)

2

Wire parallel (FFC) (13core)

1

CNP305

4

1

1

CNP309

3

+BVTP 3

1

CNP311

CNP304

Screws

×

10

Audio board

3-6. CD BOARD

Cabinet front ASSY

1

Wire parallel (FFC) (21core)

1

Wire parallel (FFC) (13core)

4

2

Screws

+BVTP 3

CD board

3

CN701

×

1

Cabinet front ASSY

– 8 –

3

CN713

3-7. TC BOARD

0

0

2

TC board

1

Screws

+BVTP 3 × 1

3-8. CABINET TOP ASSY

Cabinet front ASSY

Cabinet top ASSY

3

Claws

4

2

1

CNP807

Screws

+BVTP 3

×

1

Cabinet front ASSY

– 9 –

3-9. H/P BOARD

0

Cabinet front ASSY

2

1

Screw

+BVTP 3 × 10

H/P board

3-10. TC/M BOARD

1

CNP808

3

Cabinet top ASSY

TC/M board

2

Screw

+BVTP 3 × 1

– 10 –

3-11. MD BLOCK ASSY

0

Y

Cabinet top

3

2

Screw

+BVTP 3

×

10

1

Screws

+B 3

3-12. TC LED (L) BOARD, TC LED (R) BOARD, TC KEY BOARD

MD block ASSY

2

Screws

+BVTP 3

×

8

×

1

Cabinet top ASS

3

Remove solder

TC key board

5

Screws

+P 2.6

1

Screws

+BVTP 3

Deck (B), bracket

6

4

×

8

3

2

×

10

TC LED (L) board

TC LED (R) board

Deck (A), bracket

4

2

Remove solder

5

Screws

+P 2.6

1

Screws

+BVTP 3

×

8

×

10

– 11 –

4

3-13. TC RF BOARD, HEAD RELAY BOARD, BELT FR, BELT BR, CAPSTAN/REEL MOTOR (M691)

TC RF board

8

Screws

3

7

Belt BR

5

Belt BR

6

Belt FR

Belt FR

4

Screw

Head relay board

1

Screws

2

Remove solder

3-14. CD CHASSIS ASSY

CD chassis ASSY

9

Capstan/reel motor (M691)

3

1

CNP301

MD block ASSY

2

Screws

+BVTP 3

×

1

Cabinet front ASSY

– 12 –

3-15. CD BLOCK SECTION

1

Screws

+BVTP 3

×

10

2

Chassis CD

< CD BLOCK SECTION >

3-16. LOADING BOARD

CD block section

1 Screws (+BV 3X10)

Loading board

2

CD block section

– 13 –

3-17. “ TRAY ASSY, CD ”

)

d

1 Screws
(+BV 3X10)

Cover (L), Side

Tray ASSY, CD

Slider (L)

Lid, CD

3 Screws (+BV 3X10)

Plate (L), Side

Loading chassis

2

4

6

5 Wire, Parallel (FFC) (21 core)

(CD board : CN711)

Slider (R)

4

3 Screws

(+BV 3X10)

Cover (R), Side

Plate (R), Side

2

1 Screws

(+BV 3X10

3-18. OPTICAL PICK-UP BLOCK, PICK-UP RELAY BOARD

2

Optical pick-up block

6

3

5

Claw

5

Tray (Top), CD

4 Wire, Parallel
(FFC) (21 core)

Pick-up relay boar

Claw

Tray (Bottom), CD

1 Screws (+B 2.6X8)

– 14 –

3-19. PANEL DECO ASSY

5

r

3

1

Screws

+P 2.6 × 10

2

Screws

+P 2 ×

Panel DECO ASSY

Cabinet front

3-20. CONTROL BOARD, JOG LED 1 BOARD, JOG LED 2 BOARD

Control board

2

CNP806

JPG LED 1 board

2

CNP805

5

Remove solder

6

Claw

7

4

7

3

+P 2.6 × 8

Screws

5

6

JPG LED 2 board

Remove solde

Claw

1

Dial JOG

Panel DECO sub ASSY

– 15 –

3-21. KEY BOARD

8

2

1

Screws

+P 2.6

Key board

×

3-22. BATT L BOARD

4

5

Panel DECO sub ASSY

2

1

Cabinet rear ASSY

Cover, wire

1

BATT L board

3

Screws

+PTPWH 3

×

10

Lid, Battery case

– 16 –

CD SECTION

7

606

5

4

e

1. Entering CD test mode

Connect power supply cord or insert dry batteries, short Test
point (TEST-1) on the key board. (You need a moment for the
short) (Power button is possible with both of ON or OFF to en­ter test mode).
The LCD display changes as in the diagram and the unit goes
into test mode.

SECTION 4

TEST MODE

z

RF LEVEL and jitter check

Test mode PLAY status

Connection Point : CD board (Conductor side)

[CD BOARD] (Conductor side)

TP(RF)

TP (RF)

oscilloscop

(AC range)

MEGA BASS

cd

h

When you press the u key , the CD rotates and when you press
theu key again, the CD plays (the track servo comes on) (but
no sound is issued).
Pressing the u key starts automatic adjustment and the value
changes, but ignore this value.

[KEY BOARD] (Conductor side)

R

R60

Q603

606

D602

x

JW

TEST-1

TEST-1

SHORT : TEST MODE
OPEN : NORMAL MODE

D603

BAND

R60

R60

JW610

1

R603

R602

CN806

4

S618

x

JW609

E C B

11

1-678-260-

(11)

PGM

JW741

(VC)

IC701

Check to see that the jitter is less than 9.0 nsec. and RF level is
between 0.7 – 1.1Vp-p.

VOLT/DIV : 200mV (using 10:1 probe)
TIME/DIV : 500ns

RF level:

0.7–1.1 Vp-p

2. Exiting test mode

With the unit in test mode, when you press the POWER button
to OFF, power is off and test mode ends.

– 17 –

z

B

e

TRAVERSE SIGNAL check

Test mode PLAY status

Connection Point : CD board (Conductor side)

[CD BOARD] (Conductor side)

TP(RF)

SECTION 5

ADJUSTMENTS

5-1. MECHANICAL ADJUSTMENTS

TAPE RECORDER SECTION

PRECAUTION

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

record/playback/erase head pinch roller
rubber belts capstan

2. Demagnetize the record/playback/erase 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.

IC701

IC701 rg pin(TO)
JW741 (VC)

oscilloscop

(AC range)

Press the M or m from test mode PLAY status.
Check to see that the traverse signal level is between 200 to
500mVp-p.

0V

Note:

Extend the sweep time
for easier view.

A

200 – 500mVp-p

B

A = B

A

0V

Torque Measurement

Torque Torque Meter Meter Reading

3.54 to 5.98 mN • m

Forward CQ-102C (36 to 61 g • cm)

(0.5 to 0.84 oz • inch)

Forward
Back Tension

Reverse CQ-102RC (36 to 61 g • cm)

Reverse
Back Tension

FF/REW CQ-201B (61 to 143 g • cm)

CQ-102C (2 to 6 g • cm)

CQ-102RC (2 to 6 g • cm)

0.2 to 0.58 mN • m

(0.028 to 0.083 oz • inch)

3.54 to 5.98 mN • m

(0.5 to 0.84 oz • inch)

0.2 to 0.58 mN • m

(0.028 to 0.083 oz • inch)

5.99 to 14.02 mN • m

(0.85 to 1.98 oz • inch)

T ape Tension Measurement

Mode Tension Meter Meter Reading

FWD CQ-403A

REV CQ-403A

more than 100g

(more than 3.53 oz)

more than 100g

(more than 3.53 oz)

– 18 –