Akai TX-500 User manual

AKAT Service manuar
MINI STEREO COMPONENT SYSTEM
system TX-500/503R/505K
MODEL AC-500/503R/505K & SR-500
system TX-600/603R/605K
MODEL AC-600/603R/605K & SR-600

TABLE OF CONTENTS
SAFETY
INSTRUCTIONS
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3
PRECAUTIONS
DURING
SERVICING
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3
SAFETY
CHECK
AFTER
SERVICING
Qu...
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ase
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ses
3
MAKE
YOUR
CONTRIBUTION
TO
PROTECT
THE
ENVIRONMENT
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3
PRECAUTIONS
IN
REPAIRING
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3
INFORMATIONS
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4
SYMBOLS
FOR
PRIMARY
DESTINATION
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4
VOLTAGE
CONVERSION
(U5,
U8
and
Y7
version
models
OMly)
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4
TEST
MODE
SPECIFICATIONS.
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5
L.
DISASSEMBLY
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7
1-1.
Removal
of
UPPER
COVER
.........ccccccccccessscccecsssccecssasesseeeecenensceceesnsesesencecesesesaeececssssuseecssusesceessassesseaeaenntesesssaseoenseoeses
7
1-2.
Removal
of
FRONT
PANEL
.u........cc.ccccccceceesecececesceceseeseesececonerceceecessccesrcneceseseneseccssussesnessnreceeenateessaeesesseatepeaesneranseanesses
7
1-3.
Removal
of
the
CD
PLAYER
BLOCK
ou...
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8
H.
PRINCIPAL
PARTS
LOCATION
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9
ill.
DISASSEMBLY
OF
THE
MAIN
COMPONANTS
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13
824
CD
PEAVER:
BECO
i
iecicec
Sescst
ci
sarNie
ca
ccodccics
Cenc
abchepaecabveusnosaceasansoacueh
rosy
beceeulded
cosreda
be
uceceezscnaive
susteuas
envesseusessaaee’
13
3-2.
TAPE-]
&
TAPE-I|
MECHANISM
BLOCK
uuu...
ccccccecesscessecesssceecsceceseececaeceecececsese
saeasasensseseaeusnesensevensencseeeseeeseneecenteene
16
323
FRONT.
PANEL,
BLOCK
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sciseds
coschaniecusces
svssceevsaccenssocecestteseneis
sosonssassanessseosseeee
deueaai
aes
18
IV.
MECHANICAL
ADJUSTMENT
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20
4-1.
ADJUSTMENT
OF
THE
HEAD
AZIMUTH
ALIGNMENT
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20
V.
ELECTRICAL
ADJUSTMENT
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21
5-1,
TAPE
DECK
SECTION
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21
5-2.
$}D
PLAYER
SECTION
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nes
22
VI.
PARTS
LIST
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23
G1!
MUSIC
GENTER
cecciiccce
ce
iilb
ndevececvacessece
cd
cabled
seec
ie
cevc
cists
eeseccee
saveeuaentne
ds
ancn
sue
doe
suncunians
dedeasessorestaneustecsee-ceseavearsoagetehys
24
6-2,
SPEAKER
SYSTEM
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34
INDEX
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35
ABBREVIATION
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38
nnn SERVICE MENU
2

% SAFETY INSTRUCTIONS
PRECAUTIONS DURING SERVICING
1. Parts identified by the A symbol are critical for safety.
Replace them only with the parts number specified.
2. In addition to safety, other parts and assemblies are
specified for conformance with such regulations as those
applying to spurious radiation.
These must also be replaced only with the specified
replacements.
Examples : RF converters, tuner units, antenna selector
switches, RF cables, noise blocking capacitors,
noise blocking filters, etc.
3. Use specified internal wiring. Note especially :
1) Wires covered with PVC tubing
2) Double insulated wires
3) High voltage leads
4. Use specified insulating materials for hazardous live parts.
Note especially :
1) Insulation Tape
2) PVC tubing
3) Spacers (insulating barriers)
4) Insulation sheets for transistors
5) Plastic screws for fixing micro switches
5. When replacing AC primary side components (trans-
formers, power cords, noise blocking capacitors, etc.),
wrap the ends of the wires securely around the terminals
before soldering.
Be ho I~
6. Make sure that wires do not contact heat producing parts
(heat sinks, oxide metal film resistors, fusible resistors,
etc.).
7. Check that replaced wires do not contact sharp edged or
pointed parts.
8. Also check areas surrounding repaired locations.
9. Make sure that foreign objects (screws, solder droplets,
etc.) do not remain inside the set.
SAFETY CHECK AFTER SERVICING
After servicing, make measurements of leakage-current or
resistance in order to determine that exposed parts are
acceptably insulated from the supply circuit. The leakage-
current measurement should be done between accessible
metal parts (such as chassis, ground terminal, microphone
jacks, signal input/output connectors, etc.) and the earth
ground through a resistor of 1500 ohms paralleled with a
0.15 uF capacitor, under the unit's normal working conditions.
The leakage-current should be less than 0.5 mA rms AC.
The resistance measurement should be done between
accessible exposed metal parts and power cord plug prongs
with the power switch (if included) “ON”. The resistance
should be more than 2.2 M ohms.
SERVICE MANUAL
MAKE YOUR CONTRIBUTION TO PROTECT
THE ENVIRONMENT
Used batteries with the ISO symbol for recycling as
well as small accumulators (rechargeable batteries), LAY
mini-batteries (cells) and starter batteries should &
not be thrown into the garbage can.
Please leave them at an appropriate depot.
PRECAUTIONS IN REPAIRING
When repairing or adjusing the unit, please note the following
points.
1. Do not put excessive pressure on the mechanical part
(operation part), including the pick-up block, as extremely
high mechanical precision is required in these parts.
2. When the base is removed for repair or adjustment, make
sure that there are no metal obiects in the narrow gap
between the P.C. board or the mecha parts and the base.
3. The Micro-Computer and the CD signal processing ICs
can be damaged by static electricity or leakage from a
soldering iron during repairing. While soldering, please
take the precautions against leakage as in the illustration.
7
4. Do not loosen any screws in the pick-up block.
When handling the pick-up block, please refer to the
points to NOTE when replacing the pick up block.
5. To avoid hazardous invisible Laser Radiation, DO NOT
look at the Laser Beam (Objective lens) directly.
6. On models for some countries, laser warning labels are
affixed on the unit and inside of the unit, as shown below.
For your safety, read these labels carefully when repairing
or adjusting the unit.
CLASS 1. LASER PRODUCT
KLASSE 1 LASER PRODUKT
LUOKAN 1 LASER LAITE
KLASS 1 LASER APPARAT
Label affixed on the rear panel of the unit.
CAUTION : invisi8Lé LASER RADIATION WHEN OPEN
AND INTEALOCKS DEFEATED AVOID EXPOSURE TOBE AM.
ADVARSEL : usvNuG LASEASTAAUNG VED AB
NING NAR SIKKERHEOSAFBRYDERE ER LICE AF FUNKTION
UNOGA UDS4 TTELSE FOR STRALING.
VARO = AvATTAESSA JA SUOJALUXITUS OHITET
TAESSA OL ET ALT THNA NAKS MATT OMALLE LASEASATED
LYLLE.
ALK KATSO SATEESEEN +
VARNING : OsyNUG LASERSTRALNING NAR DENNA
DEL AR OPPNAD OCH SPARREN AR URKOPPLAC.
BETRAKTA Et STRALEN :
Label affixed on the left side of the CD PLAYER BLOCK of
the unit.

* INFORMATIONS
SYMBOLS FOR PRIMARY DESTINATION
Unit destinations are indicated with letters as shown below.
Symbols | Principal Destinations
U.S.A
Canada
Europe (except U.K.
Japan
Australia
German
UniversalArea
ustom version
o
Cc ~
‘?)
VOLTAGE CONVERSION
(U5,U8 and Y7 version models only)
Before connecting the power cord, set the VOLTAGE
SELECTOR, located on the rear panel of the unit, so that the
correct voltage for your area is indicated.
eo
AC IN
[ea]
VOLTAGE SELECTOR
00
® Fe mM
er SERVICE MANUAL
4
TEST MODE
Various kinds of test modes are installed in this unit's micro-
computer in order to test them on the production line.
Following test modes among the various test modes can be
used for adjustment, operation check or maintenance. To
terminate the test mode, simply press the “POWER ON/
STANDBY" button or disconnect the AC power cord from the
AC outlet.
1. DECK TEST MODE
This test mode can be used for tape speed adjustment as
well as bias oscillator frequency adjustment in the TAPE
DECK section.
While pressing and holding the “TAPE II" and “m” (stop)
buttons, connect the AC power cord to the AC inlet of this
unit. The function turns to “TAPE |" and “DUBX1” as well as
“| >", “ll B” tape direction indicators on the FLD light when
this mode is engaged.
Corresponding further information is shown on page 21.
2. DECK CLEANING MODE
This test mode can be used for cleaning the TAPE DECK
mechanism.
Because, this mode enables engaging of the playback, fast
forward (FF), and rewind (RWD) modes without a cassette
tape, it makes the cleaning (such as the capstan shaft,
magnetic head, pinch roller etc.,) easier.
(further more, the cassette lid remains open even if the
playback or FF, RWD made is engaged on the AC-600 series
models).
While pressing and holding the “TAPE |” and “wm” (stop)
buttons, connect the AC power cord to the AC inlet of this
unit. The “TAPE 1|”,“| >", “il” tape direction indicators on the
FLD light when this mode is engaged. (Further more, the
cassette lid will open automatically on the AC-600 series
models.)
3. CD TEST MODE
This mode can be used for the operation check (step by
step) or adjustment of the CD PLAYER section. Corresponding
further information is shown on page 22.
While pressing and holding the “CD 1” and “as" (stop)
buttons, connect the AC power cord to the AC inlet of this
unit. The “TEST” indicator on the FLD will light. Only the “1”
# OPEN/CLOSE button can be used for loading the DISC in
this mode, so the disc must be set on the “DISC 1” tray.

* SPECIFICATIONS
[Tuner section]
FM
RDS function
(AC-503R/603R only) ... PS/CT/AF/PTY/TP
Total harmonic distortion ..... 0.04 % (at 1 kHz)
Channel separation ............. 72 dB (at 1 kHz)
CD-G video signal .............. PAL/NTSC (AC-605K only)
Tuning frequency range........ 87.5 to 108 MHz {DECK section]
Usable
sensitivity
Track
system...
4
track
2
channel
system
(E.B)
ccc
17.2
dBf
(IHF,
3
%
THD)
Wow
&
Flutter...
0.09
%
(WRMS),
0.15
%
(DIN)
(S,U5,U8,Y6,Y7)
13.2
dBf
(IHF,
3
% THD)
Frequency response
Quieting
sensitivity
Normal
...........
eee
40
Hz
to
15
kHz
+3
dB
MONO
CO?
occ
eee
40
Hz
to
16
KHz
+3
dB
(E(B)
scsisecsehecsnceees
21.2
dBf
SIN
ratio
(S,U5,U8, Y6,Y7)
17.2
dBf
Dolby
B:...3.
cscs
63
dB (5
kHz)
STEREO
Dolby
off
oo...
ee
53
dB
(CrOz2
tape)
(EB) fcc aceheeeciess. 35.2 dBf
(S,U5,U8,Y6,Y7)........... 31.2 dBf
S/N ratio (IHF)
Total harmonic distortion ..... Less than0.5%
(normal tape, at 315 Hz)
Channel separation ............. 43 dB (normal tape)
STEREG isi ses.ccccceeesvesgtens [Amplifier section]
Frequency response ............ 30 Hz to 15 kHz + 1 dB Power output
Total harmonic distortion AC-500/503R/505K.......... 35W+35W
MONO
ese.
erscstecdee
tees:
0.3
%
{at
1
kHz)
(6
ohms,
1
kHz,
10
%
THD,
ElAd)
STEREO
.......eeececeeeeereees
0.7
%
(at
1
kHz)
30
W
+30
W
Selectivity
...........:
cee
70
dB
(+400
kHz)
(6
ohms,
1
kHz,
1
%
THD,
DIN)
Image rejection ..... ... 40 dB AC-600/603R/605K
Stereo separation . ...40 dB (at 1 kHz) 2 channel drive ........... 38 W +38 W
Capture
ratio
oe
2
dBt
(6
ohms,
1
kHz,
10
%
THD,
ElAu)
AM suppression .................. 60 dB 30 W +30 W
Spurious
rejection
................
80dB
(6
ohms,
1
kHz,
1%
THD,
DIN)
IF rejection 3 channel drive
(BiB)
niet
aie
70
dB
(Dolby
surround
ON)
..35
W
+
35
W
(8
ohms)
&
15
W
(8+8
(S,U5,U8,
Y6,Y7)...........
90
dB
ohms)
(1
kHz,
10
%
THD,
ElAJ)
28 W + 28 W (6 ohms) & 13 W (8+8
MW ohms) (1 kHz, 1.0 % THD, DIN)
Tuning frequency range Music power output
(B,E,S andY7) «0.0... 531 to 1602 kHz (9 kHz step) AC-500/503R/505K ......... 370 W (L/R total)
(U5,U8 and Y6) ............. 531 to 1602 kHz (9 kHz step) or AC-600/603R/6085K ......... 440 W (L/R total)
530 to 1710 kHz (10 kHz step) selectable Peak music power output
Usable
sensitivity
................
500
pVm
AC-500/503R/505K
.........
520
W
(L/R
total)
SIN
ratio...
eee
40
dB
AC-600/603R/605K
.........
610
W
(L/R
total)
Selectivity
.........
...25dB
Frequency
response
...........
10
Hz
to
100
kHz
Image
rejection
.
...35dB
(10
Hz
:—-4
dB,
100
kHz
:
-3
dB)
IF
rejection
...............
...60dB
Required
speaker
impedance
Front speaker ........... 6 to 16 ohms
LW (exceptAC-505K/605K & AC-500/600 Y7 version) Surround speaker ............... 8 to 16 ohms
Tuning frequency range Input sensitivity
(AC-500/600
B,E)
.............
144
to
288
kHz
(5
kHz
step)
PUK
ccssheiss
tere
asvtlesteeet
350
mV/47
k
ohms
(AC-503R/603R E) ........... 144 to 288 KHz (1 kHz step)
S/Niratiows iiiesevlnal ane 85 dB (A-weight)
Residual noise ........... v0.8 mV (A-weight)
Channel separation .... ..63dB
Super bass effects .............. 0 to 10 dB/70 Hz
Usable sensitivity ....... .... 800 pVm
S/N falid..... ivi. deiiese ice
Selectivity 00.
image rejection ....
IF rejection [General]
Power requirements
SW (AC-505K/605K Y7 version only) (BE) eccncencccenasicon AC 220 V to 230 V, 50 Hz
Tuning frequency range........ 3.8 to 12.5 MHz (5 kHz step) (S)Geiccttieinieracunqent AC 240 V, 50 Hz
Usable sensitivity .... 800 pVm (U5,U8, Y6,Y7) oe. AC 110/127/220 to 230/240 V, 50/60 Hz
S/N fAtiO 0. 30 dB Power consumption ............ 100 W (IEC65)
Selectivity
25
dB
Dimensions
...........0....0000.
270
(W)
x
307
(H)
x
343
(D)
mm
Image rejection ... ... 15dB Weight
IF rejection ...... ee 60dB AC-500/503R/505K ......... 7.5kg
AC-600/603R/605K ......... 8.0 kg
{CD section]
TYPO sikvcciiho vatecndetceuay ectgeens cot 3 discs auto changer Standard accessories
Pick up system.......... .... 3 beam laser pick-up Remote control unit ............ x1
Sampling frequency 44.1 kHz Batteries (UM-3) 0.0.00... x2
Error correction system ........ Cross interleave reed solomon Operator's manual .............. x1
Frequency response ............20 to 20,000 Hz +1 dB FM wire antenna
SIN rato wees 83 dB (A-weight) AM loop antenna
Dynamic range ................ 82dB Antenna Plug adapter .........
Wow & flutter oo... Less than measurable limits AC plug adapter
xx For improvement purposes, specifications and design are subject to change without notice.
3%
Manufactured
under
license
from
Dolby
Laboratories
Licensing
Corporation.
“DOLBY”
and
the
00
symbol
are
trademarks
of
Dolby Laboratories Licensing Corporation.
SERVICE MANUAL

a eee: eee eee: ee
[SPEAKER section]
System constructions
Woofer unit
Midrange unit
Tweeter unit
System impedance
Maximum power input
Sensitivity
Frequency range
Harmonic distortion
Enclosure type
Units layout
Front grille
Dimensions (with grille)
Net weight
Magnetically shield
Enclosure finish
3-Way, 3 speakers
135 mm P.cote cone type
57 mm cone type
20 mm cone type
6 ohms
50 W
87 dB ‘Wb/m
§5 Hz to 20 kHz
Less than 3 %
Bass reflex type
L/R mirror layout
Detachable grille (cloth)
180 (W) x 305 (H) x 290 (D)
3.4 kg/pe
Non
Black P.V.C.
3-Way, 3 speakers
135 mm cone type
57 mm cone type
40 mm cone type
6 ohms
55 W
87 dB Wh/m
50 Hz to 20 kHz
Less than 3 %
Front bass reflex
UR mirror layout
Detachable grille (cloth)
204 (W) x 305 (H) x 290 (D)
4.0 kg/pc
Yes
Black P.V.C.
% For improvement purposes, specifications and design are subject to change without notice.
— een ——n—n SERVICE MANUAL
6

ll. PRINCIPAL PARTS LOCATION
TABLE MOTOR DISC HOLDER LOADING TRAY
DISC CLAMPER CD PCB FRONT PANEL
BLOCK
Fig. 2-1 Top view
SERVICE MANUAL

VOLUME TRAY OPEN
MOTOR SWITCH TUNER/DECK PCB MAIN PCB
EJECT MAIN VR RADIATION POWER
MOTOR PCB FIN TRANSFORMER
Fig. 2-2 Side view

VOLUME MOTOR MAIN VR PCB CD-FLD PCB SYSTEM-FLD PCB OPERATION PCB
Fam — ies
EJECT TAPE-l| EJECT MOTOR TAPE-! CAPSTAN
CAM GEAR MECHANISM BLOCK MECHANISM BLOCK MOTOR
Fig. 2-3 FRONT PANEL (reverse side)
SURROUND-FLD PCB CASSETTE DOOR PANEL
Fig. 2-4 CASSETTE DOOR (AC-600 series only)
SERVICE MANUAL

TRAVERSE
MECHA.
SLED
MOTOR
SERVICE MANUAL
12
PICK UP
BLOCK
SPINDLE
MOTOR
LOADING
MOTOR
JUNCTION
PCB
CLAMP SW DISC
& CLOSE SW HOLDER
OPEN TABLE
SW MOTOR PCB
Fig. 2-5 CD PLAYER BLOCK
DISC HOLDER
RETAINING SCREW
TABLE DETECT
MOTOR PCB
LOADING TRAY

Ill. DSASSEMBLY OF THE MAIN COMPONENTS
3-1.CD PLAYER BLOCK
* Remove the CD PLAYER BLOCK before proceeding (refer
to section 1-3).
3-1-1. Removal of the TRAVERSE MECHA.
1) Remove the TRAVERSE COVER by releasing the two
tabs in the direction of the arrow as shown in Fig. 3-1.
TRAVERSE COVER
Fig. 3-1
2) Short the circuit on the PICK UP BLOCK with solder as
shown in Fig. 3-2.
Note :To protect the laser diode from damage caused by
high voltage static electricity, a part of the PCB on the
PICK UP BLOCK has to be shorted before
disconnecting the connectors. After replacement, be
sure to connect the two connectors and then remove
the solder of the shorted circuit before turning the
power ON.
PICK UP
BLOCK
Bottom view
SHORT POINT
\— Short
»—— with
solder
PCB
Fig. 3-2
—_—$——$—$—$—$—_— a SERVICE MANUAL
3) Disconnect the three connectors carefully (two connectors
are on the PICK UP'’s PCB and the other is on the
MOTOR PCB of the TRAVERSE MECHA.).
TRAVERSE
Fig. 3-3
4) Remove the four retaining screws, then remove the
TRAVERSE MECHA.
5) Proceed in the reverse order for installation but never
unsolder the shorted circuit before connecting the three
connectors.
3-1-2. Replacement of the SLED MOTOR
1) Remove the TRAVERSE MECHA (refer to section 3-1-1).
2) Unsolder the leads of the SLED and SPINDLE MOTORs
then remove the MOTOR PCB.
SOLDERING PART
SPINDLE
MOTOR
MOTOR PCB
SLED MOTOR
Fig. 3-4

3) Remove the two retaining screws, then remove the SLED
MOTOR.
Next, extract the plastic gear from the motor shaft and
attach it onto the new motor's shaft.
4) Reassemble in the reverse order.
About the SPINDLE MOTOR:
Replacement of the SPINDLE MOTOR itself is not
recommended, because adjustment of the TURN TABLE
height is quite critical and requires the use of a special jig.
3-1-3. Replacement of the PICK UP BLOCK
1) Remove the TRAVERSE MECHA (refer to section 3-1-1).
2) While pressing the @ stopper upwards, pull the SLIDE
SHAFT to the right to remove the PICK UP BLOCK, then
replace the PICK UP BLOCK.
SLED SHAFT
(A) STOPPER
PICK UP BLOCK TURN TABLE
Fig. 3-6
3) Reassemble in the reverse order.
3-1-4. Replacement of the LOADING MOTOR
1) Slide the protruding part of the GEAR HOLDER PART in
the direction of the arrow, then pull out the TRAY BLOCK.
Ss. ecco SERVICE MANUAL
2) Unhook the LOADING BELT with tweezers.
LOADING BELT
Fig. 3-8
3) Unsolder the lead wires of the LOADING MOTOR with a
soldering iron.
4) While releasing the LOADING MOTOR's three retaining
hooks, push the motor pully part down with your middle
finger to remove the LOADING MOTOR, then replace it.
GRAY STRIPE
LOADING
MOTOR
Fig. 3-9
5) Reassemble in the reverse order. Make sure that the wire
with the gray stripe is connected to the motor's O marked
terminal when soldering.
3-1-5. Removal of the TRAY BLOCK
1) lf the TRAY BLOCK is in the “in” position, slide the
protruding part of the GEAR HOLDER PART in the direction
of the arrow and pull out the TRAY BLOCK slowly (refer to
Fig. 3-7).
2) Disconnect the P310 connector on the CD PCB as shown
in Fig. 3-8 then unthread its cable on the TRAY BLOCK.
3) In order to disengage the two stoppers, carefully press
the ® part of the TRAY BLOCK downwards while pulling
the TRAY BLOCK out as shown in Fig. 3-10.

STOPPER
TRAY BLOCK
Fig. 3-10
4) Remove the TRAY BLOCK by pulling it out carefully.
5) Reassembie in the reverse order for installation. When
reattaching the TRAY BLOCK to the chassis, carefully
align the guides on both sides of the TRAY BLOCK with
their corresponding rails on the chassis. Also, make sure
that any one of the reference marks on the DISC HOLDER
aligns with the reference mark on the LOADING TRAY.
LOADING
TRAY
DISC
HOLDER
REFERENCE MARK
Fig. 3-11
Next, move the head of the GEAR HOLDER PART in the
direction of the arrow before engaging the stoppers as shown
in Fig. 3-12.
HEAD OF THE
GEAR HOLDER PART
Fig. 3-12
3-1-6. Replacement of the TABLE MOTOR
1) Remove the TRAY BLOCK (refer to section 3-1-5).
2) Remove the DISC HOLDER retaining screw then remove
the DISC HOLDER.
SERVICE MANUAL
TABLE GEAR JOINT DETECT WORM
MOTOR PART PCB GEAR
Fig. 3-13
3) Unsolder the leads of the TABLE MOTOR and remove the
TABLE MOTOR PCB.
TABLE
MOTOR
. HOOK
en TABLE
MOTOR PCB
Fig. 3-14
4) Remove the TABLE MOTOR by pulling it out while opening
the TABLE MOTOR retaining hook. Next, remove the
WORM GEAR BLOCK by pulling the GEAR JOINT PART
out and attach it to the new motor as shown in Fig. 3-13.
5) Reassemble in the reverse order.
e When soldering the TABLE MOTOR PCB on the TABLE
MOTOR, the TABLE MOTOR’s red mark must be visible
through the hole on the TABLE MOTOR PCB.
e When attaching the DISC HOLDER on the LOADING
TRAY, make sure to place the DISC HOLDER so that
any one of the three reference marks aligns with the
reference mark on the LOADING TRAY (any two
reference holes on the DISC HOLDER align with the
corresponding reference holes on the LOADING TRAY
accordingly). (Refer to Fig. 3-11)
15

3-2. TAPE-I & TAPE-Il MECHANISM BLOCK
* If CASSETTE MECHANISM BLOCK removal is intended,
press both the “EJECT” buttons on the FRONT PANEL to
open the CASSETTE HOLDERs and CASSETTE DOOR
before proceeding (AC-600/603R/605K only).
3-2-1. Removal of the MECHANISM BLOCK
[For AC-500/503R/505K models]
1) Remove the FRONT PANEL BLOCK (refer to section 1-2
on page 7).
2) Remove the four screws for each of the TAPE-! and
TAPE-lf MECHANISM BLOCKs then remove the
MECHANISM BLOCKs from the FRONT PANEL BLOCK.
TAPE -IZKEMECHA. BLOCK TAPE -I MECHA. BLOCK
Fig. 3-15
[For AC-600/603R/605K models]
1) Remove the FRONT PANEL BLOCK (refer to section 1-2
on page 7).
2) Unhock the DOOR SPRING on the TAPE-| MECHANISM
BLOCK.
(A) SCREW — DOOR
SPRING
Fig. 3-16
3) Remove the two ® screws and two screws (on the
bottom) for removal of the TAPE-| MECHANISM BLOCK
from the FRONT PANEL BLOCK. If the cassette holder is
closed at this point, turn the EJECT MOTOR's WORM
GEAR manually to open it
4) Remove the two © screws and two © screws (on the
bottom) for removal of the TAPE-I] MECHANISM BLOCK.
16
SERVICE MANUAL
3-2-2. Replacement of the EJECT MOTOR
(AC-600/603R/605K only)
1) Remove the ® graduated screw and remove the EJECT
ARM and the EJECT TORSION SPRING as shown in
Fig. 3-17.
: EJECT ARM
EJECT CAM
GEAR
SLIT
WASHER
EJECT
TORSION
SPRING
Fig. 3-17
2) Remove the slit washer and remove the EJECT CAM
GEAR.
3) Unsolder the two lead wires and remove the two retaining
screws then remove the EJECT MOTOR and extract the
WORM GEAR.
EJECT MOTOR
WORM
GEAR
Fig. 3-18
4) Attach the WORM GEAR onto the new EJECT MOTOR's
shaft and install it.
5) Reassemble in the reverse order for installation. Make
sure that the wire with small red dotted line is connected
to the motor's red marked terminal when soldering.

3-2-3. Replacement of the CAPSTAN MOTOR
NOTE : After replacement, tape speed adjustment must be
performed.
[For AC-500/503R/505K models]
1) Unsolder the flat cable on the CAPSTAN MOTOR with a
soldering iron.
2) While pressing the INTER-LOCK LEVER in the direction
of the arrow, remove the two ® screws and then remove
the CAPSTAN MOTOR.
SCREW
INTERLOCK
CAPSTAN MOTOR LEVER
Fig. 3-19
NOTE :Only the TAPE-I] MECHANISM BLOCK has the
INTER-LOCK LEVER on the left side of the
mechanism.
3) Install a new motor and re-assemble in the reverse order
for installation.
[For AC-600/603R/605K models]
1) Unsolder the flat cable on the CAPSTAN MOTOR with a
soldering iron.
2) Remove the ® graduated screw and remove the EJECT
ARM and the EJECT TORSION SPRING as shown in
Fig. 3-20)
(@) SCREW
(© SCREW
EJECT ARM
EJECT
TORSION
SPRING
CASSETTE
HOLDER
SIDE PLATE (R)
Fig. 3-20
SERVICE MANUAL
3) Remove the three © screws and remove the SIDE PLATE
(R).
4) Remove the CASSETTE HOLDER.
5) Remove the two screws then remove the CAPSTAN
MOTOR.
CAPSTAN MOTOR
Fig. 3-21
6) Install a new motor and re-assemble in the reverse order
for installation.
3-2-4. Replacement of the FR BELT
1) Remove the ® graduated screw and remove the EJECT
ARM and the EJECT TORSION SPRING as shown in
Fig. 3-20)
2) Remove the three © screws then remove the SIDE PLATE
(R) and CASSETTE HOLDER shown in Fig. 3-20.
3) Unthread the MAIN BELT and replace the FR BELT as
shown in Fig. 3-22.
4) Proceed in the reverse order for installation.
NOTE :steps 1) and 2) are for AC-600/603R/605K models
only.
3-2-5. Replacement of the MAIN BELT
1) Remove the CAPSTAN MOTOR (refer to section 3-2-3,
step 2) to 5) for AC-600 series models).
2) Replace the MAIN BELT and re-assemble in the reverse
order for installation.
FR BELT
MAIN BELT

3) After replacement, check the tape speed and if the result
is not satisfactory, tape speed adjustment must be
performed. ;
3-2-6. Replacement of the PINCH ROLLER BLOCK
1) Extract the PINCH ROLLER BLOCK upwards while
releasing the pinch roller retaining hook in the direction of
the arrow.
CAPSTAN
PINCH ROLLER BLOCK
Fig. 3-23
2) Replace the PINCH ROLLER BLOCK and re-assemble in
the reverse order. Attach the spring in the correct position
when placing the PINCH ROLLER BLOCK.
3-2-7. Replacement of the PB HEAD OR REC/PB HEAD
1) Remove the two® screws and remove the HEAD SHIELD
PLATE as shown in Fig. 3-24.
(A) SCREW HEAD
om SHIELD PLATE
CONNECTOR
Fig. 3-24
—_——]—————————— SERVICE MANUAL
18
2) Disconnect the connector on the CONNECTOR PCB and
remove the PCB retaining screw.
REC/PB HEAD
(OR PB HEAD)
CONNECTOR
PCB
Fig. 3-25
3) Remove the two head retaining screws and remove the
HEAD BLOCK.
4) Reassemble in the reverse order. After replacement, de-
magnetize the HEAD then perform head azimuth
adjustment.
3-3. FRONT PANEL BLOCK
3-3-1. Removal of the FRONT PANEL BLOCK
1) Remove the FRONT PANEL BLOCK (refer to section 1-2
on page 7).
3-3-2. Removal of the SYSTEM-FLD PCB
1) Disconnect the P4 connector on the SYSTEM-FLD PCB.
2) Remove the two @ screws and remove both the PCB
HOLDERs.
(A) SCREW
CD-FLD PCB
P4
sonew
SYSTEM-FLD PCB
Fig. 3-26
3) Remove the six ® screws then remove the SYSTEM-FLD
PCB by pulling it upwards carefully.
4) Disconnect the flat cable on the J10 connector on the
SYSTEM-FLD PCB (AC-600/603R/605K models only).
5) Re-assemble in the reverse order for installation.

3-3-3. Removal of the OPERATION PCB
1) Remove the SYSTEM-FLD PCB (refer to section 3-3-2).
2) Remove the “VOLUME” control knob by pulling it out and
then remove the VOLUME control retaining nut.
3) Remove the “BALANCE” and “MIXING” control volume
knobs by pulling them out.
4) Remove the ten © screws and remove the OPERATION
PCB.
FO SCREW
MAIN VR
PCB
=
OPERATION PCB
Fig. 3-27
5) Re-assemble in the reverse order for installation. When
reattching the SYSTEM-FLD PCB onto the OPERATION
PCB, carefully align the position of the three connectors.
NOTE :The BALANCE volume and J3 connector are for AC-
600 series models only.
3-3-4. Removal of the SURROUND-FLD PCB.
(AC-600/603R/605K models only)
1) Remove the TAPE-! and TAPE-Il MECHANISM BLOCK
(refer to section 3-2-1).
2) Remove the SYSTEM-FLD PCB and disconnect the J10
connector if necessary.
3) First, disengege the left DOOR STOPPER from the holder
on the FRONT PANEL.
= p =
LEFT < RIGHT
DOOR FLAT DOOR
STOPPER CABLE STOPPER
Fig. 3-28
Next, disengage the right DOOR STOPPER very carefully
from the holder while moving the left DOOR STOPPER in
the lower outward direction and remove the DOOR BLOCK
from the FRONT PANEL BLOCK.
SERVICE MANUAL
4) Remove the five retaining screws on the DOOR COVER
then remove the DOOR COVER.
DOOR COVER
Fig. 3-29
5) Remove the SURROUND-FLD PCB from the DOOR PART.
6) Proceed in the reverse order for installation. When placing
the SURROUND-FLD PCB on the DOOR PART, align the
two holes on the SURROUND-FLD PCB with their
corresponding bosses on the DOOR PART.
BOSS
CASSETTE DOOR PANEL
SURROUND-FLD PCB
Fig. 3-30
19

IV.
MECHANICAL
ADJUSTMENT
4-1. ADJUSTMENT OF THE HEAD AZIMUTH
ALIGNMENT
1)
Connect
an
oscilloscope
to
the
L-ch
and
R-ch
speaker
terminals
of
the
unit.
Set
the
VOLUME.
control
on
the
FRONT
PANEL
at
the
appropriate
level
(ie,
the
output
level
is
not
too
low
or
too
high).
2) Play back a 10 kHz (-15 dB), HEAD AZIMUTH
ALIGNMENT TEST TAPE (TF-106CH) then adjust the
HEAD AZIMUTH ALIGNMENT ® (FWD PLAY) and
(REV PLAY) SCREWs respectively so that the waveform
level of both the L-ch and R-ch are at maximum and also
they are in the same phase in both FWD and REV
directions. (Use a sharp edge philips type screwdriver that
is de-magnetized for adjustment.)
Perform the adjustment on both the TAPE-| and TAPE-II
heads if necessary.
SCREW (A) SCREW SCREW (A) SCREW
(REV) (FWD) (REV) (FWD)
TAPE -1 TAPE - I
Fig. 4-1
enemas
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RV
ICE
MANU
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mr
20

V. ELECTRICAL ADJUSTMENT
5-1. TAPE DECK SECTION
NOTE :
1) The following adjustment should be performed in
the “DECK test mode”.
To engage the DECK test mode, connect the AC
power cord to the AC outlet while pressing the
“TAPE-II" and “mm (stop)” buttons together.
When the “DECK test mode” is engaged, the
“DUBX1” indicator on the FL display will light.
2) When performing the tape speed adjustment,
observe the following notes.
e Adjustment should be started more than 30
seconds after the power is switched ON.
1. Test tape/input signal
2. Mode
3. Check point, adjustment part
4. Remarks (#) and result (*)
Adjustment Part
~~.
~e.
~
~
~
fs
Test Point
| 2 | TAPE-| NORMAL TAPE SPEED
| 1 | TAPE-I (X2) TAPE SPEED
[5 | BIAS OSC FREQUENCY
e Adjustment should be made on X2 speed mode
first then adjust the normal speed mode.
e Adjustment should be made in the forward
1. 3,150 Hz test tape (TF-110CT)
2. TAPE-i, PLAY
1. 3,150 Hz test tape (TF-110CT)
2. TAPE-I, PLAY
1. Normal type blank tape
2. TAPE-II, REC
3. P11 @ pin, T1
3. TP-R.OUT, VR302
4. e Connect a frequency counter to the TP-R.OUT
and press the “DUBBING” button again to
resume normal tape speed.
%* 3,150 + 10 Hz
3. TP-R.OUT, VR301
4. © Connect a frequency counter to the TP-R.OUT
(or L.OUT) and press the “DUBBING” button
to engage double speed.
* 6,340 + 20 Hz
direction.
3) To disengage the “DECK test mode”, press the
“POWER” button or unplug the AC power cord
from the AC outlet.
4. © Connect a frequency counter between P11 @
pin and GND. (10 : 1 probe should be used to
avoid affecting the measurement.)
e Start a recording (press the “REC” button then
press the “” button).
The “AUX” source indicator appears auto-
matically.
* 100.0 + 0.2 kHz
[3 [TAPE-I(X2)TAPE SPEED
1. 3,150 Hz test tape (TF-110CT)
2. TAPE-II, PLAY
3. TP-R.OUT, VR303
4. © Press the “TAPE-II” button and play back the
test tape.
© Connect a frequency counter to the TP-R.OUT
and press the “DUBBING” button to engage
double speed.
* 6,320 + 20 Hz
| 4 | TAPE-II NORMAL TAPE SPEED
1. 3,150 Hz test tape (TF-110CT)
2. TAPE-I, PLAY
3. TP-R.OUT, VR304
4. ¢ Connect a frequency counter to the TP-R.OUT
and press the “DUBBING” button again to
resume normal tape speed.
* 3,140 + 10 Hz
en
~~
b oe
TP L.OUT TP GND TP R.OUT
TUNER/DECK PCB
7 (PARTS SIDE) T
:
a
;
3
3
%
i
:
SERVICE MANUAL
21

5-2. CD PLAYER SECTION
TEST MODE FOR CD PLAYER’S OPERATION
Some adjustments of the CD PLAYER section are automatically carried out by the micro computer.
If the CD player section is defective and it is necessary to partially check the operation, the “CD TEST” mode can be
used while repairing.
Engaging the “CD TEST” mode
While pressing and holding both the “as” and “CD1” buttons, plug in the AC power cord to the AC outlet.
NOTE :
e During “CD TEST” mode, only the DISC “1” & open/close button can be used for loading. So, place a disc on “TRAY
1"
© Proceed testing by pressing the “CD1” button once for each testing step.
The testing step will return to “TEST” if the "1" & open/close button is pressed during steps “TEST-1” to “TEST-5”.
To repeat the check after the step number has reached “TEST-5”, open the tray once and repeat the procedure by
also pressing the “1" 4 open/close button.
© To disengage the “CD TEST” mode, press the “POWER ON/STANDBY" button or disconnect the AC power cord
from the AC outlet.
© Prepare a CR probe and connect an oscilloscope as shown below before adjustment of “E-F BALANCE”.
e Never connect the AC millivoltmeter's or oscilloscope's GND to the ground line of the unit during adjustment as it
may cause a “short circuit” of the VREF line to the ground.
CR PROBE
pescnesccscusonee= x
OSCILLOSCOPE
| DISPLAY.
Initial condition of the “CD TEST” mode.
Laser emission is ON.
Perform “focus search” then turn on the “focus servo".
TEST-3 | Tracking servo is off and CLV servo is on. Perform “E-F balance” adjustment manually (setting data
Bee value of the “E-F balance” is displayed on the FLD).
| TEST-4
Tracking gain adjustment is carried out automatically and its data value is displayed on the FLD.
TEST-5 Tracking servo is turned on and the normal playback mode is engaged.
FUNCTION
22
[1 [EFBALANCE
1. Test disc (SONY TYPE-III)
2. TEST-3 (test mode)
3. TP1 (TE), TP3 (VREF) & “«<","»»" button
4. © Connect an oscilloscope to TP1 and TP3 on
the CD PCB via CR probe.
* Press the “<<” or “>>” button so that the DC
level of the waveform is less than + 20 mV.
Disconnect the CR probe then press the CD1
button to memorize the data (shown in the
FLD) and proceed to “TEST-4”.
7
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TP3 (VREF)
CD “PGB
SERVICE MANUAL
TP2 (RF)
(PATTERN SIDE)
|2|FOCUSOFFSET Cid
1. Test disc (SONY TYPE-III)
2. TEST-5 (test mode)
3. TP2 (RF OUT), TP3 (VREF) & VR200-
4. e Connect the hot side probe of an AC
millivoltmeter or oscilloscope to TP2 on the CD
PCB and GND side probe to the TP3 (VREF).
(Never connect the AC millivoltmeter’s or
oscilloscope’s GND to the ground line of the
unit as it may cause a “short circuit” of the
VREF line to the ground.
* Adjust the VR200 on the CD PCB until the
waveform on the oscilloscope is most focused
and at its maximum level (or indication of the
AC millivoltmeter is maximum).