Sony ZSX-10 Service manual

ZS-X10

SERVICE MANUAL

Ver. 1.1 2005.02

SPECIFICATIONS

AUDIO POWER SPECIFICATIONS
(US model only)

POWER OUTPUT AND TOTAL
HARMONIC DISTORTION
With 3.2-ohm loads, both channels driven
from 100 - 10 000 Hz; rated 1.7 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/–1 dB

Wow and flutter

Below measurable limit

Radio section

US model:
Frequency range

FM: 87.5 - 108 MHz
AM: 530 - 1 710 kHz

Antennas

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

Singapore and Australian models:
Frequency range

FM: 87.5 - 108 MHz
AM: 531 - 1 611 kHz (9 kHz step)

530 - 1 610 kHz (10 kHz step)

IF

FM: 10.7 MHz
AM: 450 kHz

Antennas

FM: Telescopic aerial
AM: Built-in ferrite bar

General

Speaker

Full range: 8 cm (3
type (2)
Passive radiator: 8 cm (3

Outputs

Headphones jack (stereo minijack)
For 16 - 64 Ω impedance headphones

Power output

2.3 W + 2.3 W (at 3.2 Ω, 10% harmonic
distortion)
Power requirements

DC IN 9V jack accepts:
Supplied AC power adaptor for use with

− 120VAC, 60 Hz (US model)

− 240VAC, 50 Hz (Australian model)

− 230VAC, 50 Hz (Singapore model)

9 V DC, 6 size C (R14) batteries

1

⁄4 inches) dia., 3.2 Ω, cone

1

⁄4 inches) dia. (2)

US Model

E Model

Austr alian Model

Model Name Using Similar Mechanism NEW
Optical Pick-up Block Name KSM-213CAP
Optical Pick-up Name KSS-213C

Battery life

CD playback

Sony R14P: approx. 2 h
Sony alkaline LR14: approx. 6 h

Radio play

Sony R14P: approx. 12 h
Sony alkaline LR14: approx. 40 h

Dimensions

Approx. 511 × 154 × 244 mm (w/h/d)

1

⁄8 × 6 1⁄8 × 9 5⁄8 inches) (incl. projecting parts)

(20

Mass

Approx. 3.4 kg (7 lb. 5 oz) (incl. batteries)

Supplied accessory

AC power adaptor (1)

Design and specifications are subject to change
without notice.

9-879-391-02

2005B05-1
© 2005.02

PERSONAL AUDIO SYSTEM

Sony Corporation

Personal Audio Group
Published by Sony Engineering Corporation

ZS-X10

r

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.

About CD-Rs/CD-RWs

This player can play CD-Rs/CD-RWs
recorded in the CD-DA format*, but
playback capability may vary depending on
the quality of the disc and the condition of
the recording device.

* CD-DA is the abbreviation for Compact

Disc Digital Audio. It is a recording
standard used for Audio CDs.

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. Follo w the manufacturers’ instructions to use these
instruments.

2. A battery-operated A C 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 oltage
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

TABLE OF CONTENTS

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

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

3. DISASSEMBLY

3-1. Disassembly Flow ........................................................... 6

3-2. Cabinet (Lower)............................................................... 7

3-3. Main Chassis Section ...................................................... 7

3-4. AUDIO Board, BATTERY Board ................................... 8

3-5. TUNER Board, CONTROL Board ................................. 8

3-6. CD Block Section ............................................................ 9

3-7. CD Lid Sub Assy............................................................. 9

3-8. Cabinet Front (L)/(R) Assy.............................................. 10

3-9. Cabinet Front (L) Sub Assy............................................. 10

3-10. Cabinet Front (R) Sub Assy............................................. 11

3-11. Optical Pick-up (KSS-213C)........................................... 11

4. TEST MODE.............................................................. 12

5. ELECTRICAL ADJUSTMENTS

TUNER Section............................................................... 13

CD Section ...................................................................... 15

6. DIAGRAMS

6-1. Block Diagram – CD SERVO Section – ........................ 16

6-2. Block Diagram – TUNER Section – .............................. 17

6-3. Block Diagram – MAIN Section –................................. 18

6-4. Printed Wiring Board – CD Section – ............................ 20

6-5. Schematic Diagram – CD Section –............................... 21

6-6. Printed Wiring Board – TU Section – ............................ 22

6-7. Schematic Diagram – TU Section – ............................... 23

6-8. Printed Wiring Board – CONTROL Section – ............... 24

6-9. Schematic Diagram – CONTROL Section –.................. 25

6-10. Printed Wi ring Boards – PANEL Section –.................... 26

6-11. Schematic Diagram – PANEL Section – ........................ 27

6-12. Printed Wiring Boards – AUDIO Section –.................... 28

6-13. Schematic Diagram – AUDIO Section – ........................ 29

7. EXPLODED VIEWS

7-1. Cabinet (Lower) Section.................................................. 34

7-2. CD Lid Section ................................................................ 35

7-3. Cabinet Front Section ...................................................... 36

7-4. Cabinet (Upper) Section .................................................. 37

7-5. Main Chassis Section ...................................................... 38

7-6. CD Block Section ............................................................ 39

7-7. Optical Pick-up Section (KSM-213CAP) ....................... 40

8. ELECTRICAL PARTS LIST................................ 41

0.15 µF

1.5 k

Ω

Earth Ground

AC
voltmete
(0.75 V)

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

2

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.

SECTION 1

SERVICING NOTES

ZS-X10

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.

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.

LASER DIODE AND FOCUS SEARCH OPERATION
CHECK

During normal operation of the equipment, emission of the laser
diode is prohibited unless the upper lid is closed while turning ON
the S801. (push switch type)
The following checking method for the laser diode is operable.

• Method
Emission of the laser diode is visually checked.

1. Open the upper lid.

2. Push the S801 as shown in Fig.1.

Note: Do not push the detection lever strongly , or it may be bent or damaged.

3. Press the u button.

4. Check the object lens for confirming normal emission of the
laser diode. If not emitting, there is a trouble in the automatic
power control circuit or the optical pick-up.
In this operation, the object lens will move up and down 2
times along with inward motion for the focus search.

S801

Fig.1 Method to push the S801

On power sources

• For AC operation,
use the supplied
AC power
adaptor; do not
use any other type.

• The player is not disconnected from the
AC power source (mains) as long as it is
connected to the wall outlet, even if the
player itself has been turned off.

•Unplug the player from the wall outlet
when it is not to be used for an extended
period of time.

• For battery operation, use six size C (R14)
batteries.

•When the batteries are not to be used,
remove them to avoid damage that can be
caused by battery leakage or corrosion.

• The nameplate indicating operating
voltage, etc. is located at the bottom.

Polarity of
the plug

3

ZS-X10

d

HARNESS SETTING

: Tape or cushion

control board

speaker (8cm) (L)/(R)

control board

audio board

audio boar

push switch

audio board

control board

2mm+

4

Location of controls

Loading a CD

SECTION 2

GENERAL

ZS-X10

This section is extracted from
instruction manual.

Note

When inserting a CD, place the player horizontally.
If the player is not level, you cannot open or close the CD compartment lid.

MEGA BASS

Display

CD

Total track number Programed track Playing order

With the labeled side up

OPR/BATT

Total playing time

POWER

VOL +*, –

Display

PUSHZ
OPEN/CLOSE

RADIO
BAND
AUTO PRESET

MODE

DSPL
ENTER
MEMORY

DC IN 9V

x

*The button has a tactile dot.

i

u*

5

ZS-X10

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

3-1. DISASSEMBLY FLOW

SET

3-2. CABINET (LOWER)

(Page 7)

3-3. MAIN CHASSIS SECTION

(Page 7)

SECTION 3

DISASSEMBLY

3-6. CD BLOCK SECTION

(Page 9)

3-7. CD LID SUB ASSY

(Page 9)

3-8. CABINET FRONT (L)/(R) ASSY

(Page 10)

3-9. CABINET FRONT (L) SUB ASSY

(Page 10)

3-4. AUDIO BOARD, BATTERY BOARD

3-11.OPTICAL PICK-UP (KSS-213C)

(Page 8)

(Page 11)

3-10.CABINET FRONT (R) SUB ASSY

(Page 11)

3-5. TUNER BOARD, CONTROL BOARD

(Page 8)

6

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

3-2. CABINET (LOWER)

7

two screws (B3)

5

two screws (B3)

4

screw (M3)

8

two screws (B3)

9

cabinet (lower)

6

two screws (B3)

3

battery case lid.

1

Open the CD lid.

ZS-X10

3-3. MAIN CHASSIS SECTION

3

flexible flat cable
(11 core) (CN801)

6

two screws (B3)

8

connector
(push switch)

7

0

telescopic antenna

4

connector (CN302) (from speaker Lch)

5

2

screw (B3)

connector (CN304) (from speaker Rch)

9

connector (CN303)

0

connector

qa

main chassis section

2

flexible flat cable
(14 core) (CN804)

1

flexible flat cable
(21 core) (CN803)

7

ZS-X10

3-4. AUDIO BOARD, BATTERY BOARD

7

claw

6

AUDIO board

8

BATTERY board

3-5. TUNER BOARD, CONTROL BOARD

1

tape

2

four screws (B3)

3

two screws (B3)

5

4

TU board

1

connector
(CN305)

2

screw (B3)

flexible flat cable

5

(18 core) (CN301)

4

flexible flat cable (11 core)
(CNP1)

8

3

7

three screws (B3)

flexible flat cable (18 core)

6

(CN802)

8

CONTROL board

3-6. CD BLOCK SECTION

1

tension coil spring (CD)

2

four screws (B2.6)

3

CD block section

ZS-X10

3-7. CD LID SUB ASSY

7

CD lid sub assy

6

Remove two bosses.

5

4

screw (B3)

3

damper

spring (CD)

1

two screws (B3)

2

CD lid bracket

9

ZS-X10

y

3-8. CABINET FRONT (L)/(R) ASSY

8

screw (B3)

9

cabinet front (L) assy

7

screw (B3)

5

rubber (speaker)

6

screw (B3)

3-9. CABINET FRONT (L) SUB ASSY

qa

cabinet front (L) sub assy

2

two screws
(B3)

5

passive speaker (8cm) (SP3) (Lch)

4

four screws
(B3)

4

1

rubber (speaker)

1

three screws
(B3)

3

screw (B3)

cabinet front (R) ass

10

0

speaker (8cm)
(SP2) (Lch)

7

bracket (SP B) (L)

9

bracket (L) speaker

6

two screws
(B3)

8

two screws
(B3)

3

speaker box (L)

2

three screws
(B3)

3-10. CABINET FRONT (R) SUB ASSY

y

2

three screws
(B3)

3

speaker box (R)

8

two screws

6

two screws
(B3)

(B3)

9

speaker bracket (R)

1

three screws
(B3)

0

speaker (8cm)
(SP1) (Rch)

4

four screws
(B3)

5

passive speaker (8cm) (SP4) (Rch)

qa

cabinet front (R) sub ass

ZS-X10

7

bracket (SP B) (R)

3-11. OPTICAL PICK-UP (KSS-213C)

3

sled shaft

5

optical pick-up
(KSS-213C)

1

CD cover

4

flexible flat cable (16 core)

2

gear (A)

11

ZS-X10

SECTION 4

TEST MODE

CD TEST MODE

procedure:

1. Insert the disc (YEDS-18) (Part No. 3-702-101-01) (CD) or
(TCD-W082L) (Part No. J-2502-063-2) (CD-RW).

2. Press the [POWER] button to turn the power on. (TOC read
ended)

3. Set the test mode by momentarily shorting both of T AP (TEST ­A) on the LCD board. (The message “88” is displayed on the
liquid crystal display)

4. To release the test mode, press the [POWER] button to turn the
power off.

LCD TEST MODE

procedure:

1. Press the [POWER] button to turn the power on.

2. Set the test mode by momentarily shorting both of T AP (TEST ­B) on the LCD board.

LCD DISPLAY

1 All lighting (4 seconds)

t

r

2 COM0 lighting (2 seconds)

r

3 COM1 lighting (2 seconds)

r

4 COM2 lighting (2 seconds)

r

5 COM3 lighting (2 seconds)

3. It repeats until any button is pressed.

Connecting Location:

– PLAY BOARD (Conductor Side) –

TP

(TEST A)

TP

(TEST B)

12

SECTION 5

r

ELECTRICAL ADJUSTMENTS

ZS-X10

Ver. 1.1

PRECAUTION

1. Setting
MEGA BASS : OFF

TUNER SECTION 0 dB=1 µV

[AM]

Setting:

Function: RADIO
Band: AM

AM RF signal

generator

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

[FM]

Setting:

Function: RADIO
Band: FM

FM RF signal

generator

75 kHz frequency
deviation by 1 kHz
signal
Output level:
as low as possible

Put the lead-wire
antenna close to
the set.

set

TU board
TP (ANT)

0.01 µF
set

TU board
TP (GND)

AUDIO board
CN302 pin 1

level meter

3.2 Ω

AUDIO board
CN302 pin 2

AUDIO board
CN302 pin 1

level meter

3.2 Ω

AUDIO board
CN302 pin 2

AM IF ADJUSTMENT

Adjust for a maximum reading on level meter

T1 450 kHz

( ): Singapore and Australian models

AM VCO VOLTAGE ADJUSTMENT

Adjustment Part Frequency Display Reading on Digital Voltmeter

L4 530 kHz (531 kHz) 1.0 ± 0.05 V

Confirmation

Adjust for a maximum reading on level meter

L3 620 kHz (621 kHz)

+
–

CT3 1,400 kHz (1,404 kHz)

Adjust for a minimum reading on level meter

T2 10.7 MHz

Adjustment Part Frequency Display Reading on Digital Voltmeter

L2 108 MHz 3.0 ± 0.2 V

Confirmation 87.5 MHz 1.3 ± 0.3 V

Adjust for a maximum reading on level meter

L1 87.5 MHz

CT1 108 MHz

1,710 kHz

(1,611 kHz)

AM TRACKING ADJUSTMENT

FM IF ADJUSTMENT

FM VCO VOLTA GE ADJUSTMENT

FM TRACKING ADJUSTMENT

5.3 ± 0.7 V (4.8 ± 0.7 V)

( ): Singapore and Australian models

Adjustment and Connecting Location: TU board

+

–

(See page 14)

digital voltmete

TU board

TP (VT)

TP (GND)

100 kΩ

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

• Remove FM antenna in FM adjustment.

13

ZS-X10

Adjustment and Connecting Location:

– TU BOARD (Component Side) –

AM VCO Voltage Adjustment

FM VCO Voltage Adjustment

AM T rac king Adjustment

L4

L2

CT3
L3

– TU BOARD (Conductor Side) –

TP

(VT)

TP

(ANT)

T2 FM IF Adjustment

T1 AM IF Adjustment

L1

FM T rac king Adjustment

CT1

TP

(GND)

14

ZS-X10

B

CD SECTION

Perform all CD section check in the test mode.

TRAVERSE CHECK

procedure:

1. Connect an oscilloscope to TP (TE) and TP (VC) on the CD
board.

2. Set the CD test mode. (Refer to CD TEST MODE (See page

12))

3. Press the u button once. (LCD DISPLAY “F –”)

4. Confirm that the center of the oscilloscope waveform is at 0 V.

5. Confirm that the oscilloscope waveform Vp-p v alue is at 0.95
± 0.4 V.

6. To check CD-RW, turn the power off. Change discs to CD­RW (TCD-W082L) (Part No. J-2502-063-2), then set the CD
test mode again. (Refer to CD TEST MODE (See page 12))

VOLT/DIV: 0.2 V (with the 10:1 probe in use)
TIME/DIV: 1 ms

A

0 V

Vp-p=A+

B

FOCUS BIAS CHECK

procedure:

1. Connect the oscilloscope to TP (RF) and TP (VC) on the CD
board.

2. Set the CD test mode. (Refer to CD TEST MODE (See page

12))

3. Press the u button twice. (LCD DISPLAY “P –”)

Note: If this check is performed continuously after the TRAVERSE

CHECK, press the u button once.

4. Confirm that the oscilloscope waveform is as shown in the
figure below. (eye pattern)
A good eye pattern means that the diamond shape (◊) in the
center of the waveform can be clearly distinguished.

5. To check CD-RW, turn the power off. Change discs to CD­RW (TCD-W082L) (Part No. J-2502-063-2), then set the CD
test mode again. (Refer to CD TEST MODE (See page 12))

• RF signal reference waveform (eye pattern)

VOLT/DIV: 0.2 V (with the 10: 1 probe in use.)
TIME/DIV: 500 ns

CD:

±

0.3 Vp-p

1.0
CD-RW:

1.0

±

0.4 Vp-p

MEMO

When observing the eye pattern, set the oscilloscope
for AC range and raise vertical sensitivity.

Connecting Location:

– CD BOARD (Conductor Side) –

TP

(TE)

TP

(RF)

TP

(VC)

ZS-X10

1515