Sony ZS-D55 User manual

Ver 1.0 2000.07
ZS-D55
SERVICE MANUAL
PERSONAL AUDIO SYSTEM
SPECIFICATIONS
AEP Model
UK Model
Tourist Model
TAPE Model Name Using Similar Mechanism NEW
Section Tape Transport Mechanism Type MF-ZSD55
CD Model Name Using Similar Mechanism ZS-D50
Section MD Mechanism Type CDM-2411AAA
Optical Pick-up Type DAX-01A2
– Continued on page 2 –
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 : 87.5 - 108 MHz
MW : 531 - 1602 kHz
LM : 153 - 279 kHz
IF FM : 10.7 MHz
MW/LW : 450 kHz
Aerials
FM : Telescopic aerial
MW/LW : Built-in ferrite bar aeraial
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 Ωimpedance 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
Maximum power output
5 W + 5 W

– 2 –
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 ChassisASSY ................................................... 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
TABLE OF CONTENTS
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
Power requirements
For personal audio system:
230VAC, 50 Hz
12 V DC, 8 R20 (size D) batteries
For memory back-up:
6 V DC, 4 R6 (sizeAA) batteries
For remote control:
3 V DC, 2 R6 (sizeAA) batteries
Power consumption
AC 20 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 3⁄5x 6 9⁄10 inches)
Mass (incl. batteries)
Approx. 6.2 kg (13 lb. 11 oz)
Supplied accessories
Mainns Lead (1)
Remote control (1)
Design and specifications are subject to change without notice.

– 3 –
NOTES ON HANDLINGTHE 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 pick-
up block. Therefore, when checking the laser diode emission, ob-
serve 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 ubutton.
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.
CAUTION DURING WHEN MOUNTINGTHE PULLEY
FORTHE LOADING MOTOR
Make the following adjustment when mounting the loading motor
(part number : 1-698-999-11) and motor pulley (part number : 2-
627-174-01) of the CD section.
Specification : A = 0.9 to 1.1mm
SECTION 1
SERVICE NOTE

–4 –
SECTION 2
GENERAL
LOCATION AND FUNCTION OF CONTROLS
FRONT PANEL : CD/RADIO/TAPE section
1Tape operation buttons
z/X(REC/REC PAUSE)
m, M(FF/REW, AMS)
x(STOP)
b, B(PLAY)
2Cassette lid
3ZPUSH OPEN/CLOSE
4COUNTER RESET button
5DIR MODE button
6JOG dial
7ZCD OPEN/CLOSE button
8Radio operation buttons
Tune – m, M+
9CD tray
FRONT PANEL:TIMER/COM section
0AUTO PRESET button
qa CANCEL button
qs CD DUB button
qd CD operation buttons
u(PLAY/PAUSE)
x(STOP)
qf BAND button
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)
12 34
5
6
7
8
9
qf
qd
qs
qa
0
qgqh qj qk qlw;wa
ws
wd
wf
e;
wl
wk
wj
wh wg

–5 –
REAR PANEL
1FUNCTION button
Each time you pressed, the function changes in the order
CD –Tape –Radio –Line –CD •••
2ZCD OPEN/CLOSE button
3Number buttons
4MODE button
5Radio operation buttons
TUNE +, –button
BAND
6CD operation buttons
., >(AMS/SEARCH)
N(PLAY)
X(PAUSE)
x(STOP)
7Tape operation buttons
x(STOP)
b, B(PLAY)
z/X(REC/REC PAUSE)
m, M(FF/REW, AMS)
8POWER button (AC only)
Active only when you use the set with AC power source.
9MEGA BASS button
0VOL +, –button
qa SOUND button
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
3
2
1
4
5
6
7
8
9
0
qa
ea es ed ef eg eh ej

–6 –
SECTION 3
DISASSEMBLY
Note:Follo wthedisassemb lypr ocedureinthen umericalor dergiven.
3-1. CABINET REAR ASSY, CABINET FRONT ASSY
zTheequipmentcanberemo vedusingthef ollo wingpr ocedure .
Cabinet Front ASSY
BATT L board
Cabinet Rear ASSY Power board, P/T in board, P/T out board, BATT S board
Tuner board
Jack board
TC board
CD board
CD block section
CD block section “Tray ASSY, CD ”
Loading board
< CD BLOCK SECTION >
< MAIN SECTION >
Panel DECO ASSY
Audio board
Set
Cabinet Top ASSY MD block ASSY
TC/M board
CD chassis ASSY
Optical pick-up block, Pick-up relay board
Control board, JOG LED1 board, JOG LED2 board Key board
TC RF board, Head relay board, Belt FR, Belt BR, Motor (M691)
TC key board, TC LED (L) board, TC LED (R) board
H/P board
Cabinet front ASSY
Cabinet rear ASSY
Handle
2 Screws
+BVTP 3
× 10
3 Screws
+BVTP 3
× 14
3 Screws
+BVTP 3 × 1
4
5
4
1
<MAIN SECTION>

–7 –
3-3.TUNER BOARD
3-2. POWER BOARD, P/T IN BOARD, P/T OUT BOARD , BATT S BOARD
P/T OUT board
P/T IN board BATT S board
Power board
1 Screws
+BVTP 3
× 10
6 Claw
3
4
5
7
2
Cabinet rear ASSY
Tuner board
2
1 Claws
Cabinet front ASSY
3-4. JACK BOARD
Jack board
2
1 Claws
Cabinet front ASSY

–8 –
3-5. AUDIO BOARD
Audio board
3 Screws
+BVTP 3
× 10
4
1 CNP308
1 CNP310
1 CNP311
1 CNP305
1 CNP304
2 Wire parallel (FFC) (11core)
2 Wire parallel (FFC) (13core)
1 CNP309
Cabinet front ASSY
3-6. CD BOARD
CD board
2 Screws
+BVTP 3
× 1
0
4
1 Wire parallel (FFC) (21core)
Cabinet front ASSY
3 CN701
3 CN713
1 Wire parallel (FFC) (13core)

–9 –
3-7.TC BOARD
3-8. CABINETTOP ASSY
TC board
Cabinet front ASSY
1 Screws
+BVTP 3 × 1
0
2
Cabinet top ASSY
Cabinet front ASSY
2 Screws
+BVTP 3
× 1
0
4
3 Claws
1 CNP807

–10 –
H/P board
Cabinet front ASSY
1 Screw
+BVTP 3 × 10
2
3-9. H/P BOARD
3-10.TC/M BOARD
TC/M board
2 Screw
+BVTP 3 × 1
0
3
Cabinet top ASSY
1 CNP808

–11 –
3-11. MD BLOCK ASSY
MD block ASSY
2 Screws
+BVTP 3
× 1
0
2 Screw
+BVTP 3
× 10
1 Screws
+B 3
× 8
3
Cabinet top
3-12.TC LED (L) BOARD, TC LED (R) BOARD, TC KEY BOARD
TC key board
TC LED (R) board
TC LED (L) board
Deck (B), bracket
5 Screws
+P 2.6
× 8
5 Screws
+P 2.6
× 8
1 Screws
+BVTP 3
× 10
1 Screws
+BVTP 3
× 10
3 Remove solder
3 Remove solder
2
2
4
4
6
Cabinet top ASS
Y
Deck (A), bracket

–12 –
3-14. CD CHASSIS ASSY
6 Belt FR
2 Remove solder
9 Capstan/reel motor (M691)
Head relay board
3
5
4 Screw
1 Screws
8 Screws
MD block ASSY
TC RF board
7 Belt BR
Belt FR
Belt BR
2 Screws
+BVTP 3
× 1
4
3
1
CNP301
CD chassis ASSY
Cabinet front ASSY
3-13.TC RF BOARD, HEAD RELAY BOARD, BELT FR, BELT BR, CAPSTAN/REEL MOTOR (M691)

–13 –
3-15. CD BLOCK SECTION
< CD BLOCK SECTION >
3-16. LOADING BOARD
1 Screws
+BVTP 3
× 10
2
Chassis CD
CD block section
CD block section
1Screws (+BV 3X10)
2
Loading board

–14 –
3-18. OPTICAL PICK-UP BLOCK, PICK-UP RELAY BOARD
3-17.“TRAY ASSY, CD ”
3Screws
(+BV 3X10)
1Screws
(+BV 3X10
)
5Wire, Parallel (FFC) (21 core)
(CD board : CN711)
2
4
6
4
2
3Screws (+BV 3X10)
Loading chassis
Plate (L), Side
Cover (L), Side
Cover (R), Side
Plate (R), Side
Slider (R)
Slider (L)
Tray ASSY, CD
1Screws
(+BV 3X10)
Lid, CD
Tray (Top), CD
1Screws (+B 2.6X8)
4Wire, Parallel
(FFC) (21 core)
2
36
5
5
Pick-up relay boar
d
Claw
Claw
Optical pick-up block
Tray (Bottom), CD

–15 –
3-20. CONTROL BOARD, JOG LED 1 BOARD, JOG LED 2 BOARD
3-19. PANEL DECO ASSY
2 Screws
+P 2 ×
5
1 Screws
+P 2.6 × 10
3
Cabinet front
Panel DECO ASSY
3 Screws
+P 2.6 × 8
5 Remove solde
r
5 Remove solder
2 CNP805
1 Dial JOG
4
Panel DECO sub ASSY
JPG LED 1 board
JPG LED 2 board
Control board
6 Claw
7
7
6
Claw
2 CNP806

–16 –
3-22. BATT L BOARD
3-21. KEY BOARD
1 Screws
+P 2.6
×
8
2
Panel DECO sub ASSY
Key board
3 Screws
+PTPWH 3
× 10
5
1
1
2
4
Cover, wire
BATT L board Lid, Battery case
Cabinet rear ASSY

– 17 –
zRF LEVEL and jitter check
Test mode PLAY status
Connection Point : CD board (Conductor side)
Check to see that the jitter is less than 9.0 nsec. and RF level is
between 0.7 – 1.1Vp-p.
SECTION 4
TEST MODE
CD SECTION
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 en-
ter test mode).
The LCD display changes as in the diagram and the unit goes
into test mode.
When you press the ukey, the CD rotates and when you press
theukey again, the CD plays (the track servo comes on) (but
no sound is issued).
Pressing the ukey starts automatic adjustment and the value
changes, but ignore this value.
[KEY BOARD] (Conductor side)
h
PGM
MEGA BASS
cd
RF level:
0.7–1.1 Vp-p
VOLT/DIV : 200mV (using 10:1 probe)
TIME/DIV : 500ns
E C B
JW610
JW606
D603
D602
R60
7
R
606
R60
5
R60
4
R603
R602
Q603
S618
JW609
CN806
BAND
x
x
11
(11)
1-678-260-
TEST-1
1
4
TEST-1
SHORT :TEST MODE
OPEN : NORMAL MODE
TP(RF)
IC701
oscilloscop
e
(AC range)
TP (RF)
JW741
(VC)
[CD BOARD] (Conductor side)
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.

–18 –
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 therecord/playback/eraseheadwitha head demag-
netizer.
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 sup-
ply voltage unless otherwise noted.
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)
0.2 to 0.58 mN •m
Forward CQ-102C (2 to 6 g •cm)
Back Tension (0.028 to 0.083 oz •inch)
3.54 to 5.98 mN •m
Reverse CQ-102RC (36 to 61 g •cm)
(0.5 to 0.84 oz •inch)
0.2 to 0.58 mN •m
Reverse CQ-102RC (2 to 6 g •cm)
Back Tension (0.028 to 0.083 oz •inch)
5.99 to 14.02 mN •m
FF/REW CQ-201B (61 to 143 g •cm)
(0.85 to 1.98 oz •inch)
TapeTension Measurement
Mode Tension Meter Meter Reading
FWD CQ-403A more than 100g
(more than 3.53 oz)
REV CQ-403A more than 100g
(more than 3.53 oz)
SECTION 5
ADJUSTMENTS
zTRAVERSE SIGNAL check
Test mode PLAY status
Connection Point : CD board (Conductor side)
Press the Mor mfrom test mode PLAY status.
Check to see that the traverse signal level is between 200 to
500mVp-p.
Note:
Extend the sweep time
for easier view.
200 –500mVp-p
AA
B
B
A = B
0V
0V
TP(RF)
IC701
[CD BOARD] (Conductor side)
oscilloscop
e
(AC range)
IC701 rg pin(TO)
JW741 (VC)

–19 –
3. Phase Check
Mode : FWD playback
4. Change the reverse playback mode and repeat the step 1 to 3.
5. After the adjustment, lock the adjustment screw with suitable
locking compound.
Adjustment Location : –record/playback/erase head –
VH
in phase 90°
45°135°180°
good wrong
set
L-CH
R-CH
screen pattern
test tape
P-4-A100
(10kHz, –10dB) Osilloscope
LINE OUT
47kΩ
47kΩ
5-2. ELECTRICAL ADJUSTMENTS
TAPE RECORDER SECTION 0dB = 0.775V
1. The adjustnemts should be performed in the order in the service
manual. (As a general rule playback circuit adjustment should
be completed beforeming recording circuit adjustment.)
2. The adjustments should be performed for bothe L-CH and R-
CH unless otherwise indicated.
Standard Intput Level
Input terminal LINE IN
source impedance 10kΩ
input signal level 0.5V (–3.8dB)
Standard Output Level
Output terminal LINE OUT
load impedance 47kΩ
output signal level 0.5V (–3.8dB)
TestTape
Type Signal Used for
P-4-A100 10kHz, –10dB Azimuth Adjustment
WS-48B 3kHz, 0dB Tape Speed Adjustment
Record/Playback/Erase Head Azimuth Adjustment
Procedure :
1. Mode : FWD playback
2. Turn the adjustment screw for the maximum output levels. If
these levels do not match, turn the adjustment screw until both
of output levels match together within 1dB.
set
LINE OUT
47kΩ
level mete
r
test tape
P-4-A100
(10kHz, –10dB)
L-CH
peak R-CH
peak
L-CH
peak
R-CH
peak
Screw
position
output
level within
1 dB within
1 dB
screw positio
n
FWD side REV side
adjustment screw

–20 –
FM Section
RADIO BAND button : FM
Volume : MIN
Adjustment Location : Tuner board (See page 21)
Mechanism dec
k
Tape speed adjustment
M691 (capstan/reel motor)
•Repeat the procedures in each adjustment several times, and the
frequency coverage and tracking adjustments should be finally
done by the trimmer capacitors.
AM IF ADJUSTMENT
Adjust for a maximum reading on level meter.
T1 450kHz
MW FREQUENCY COVERAGE ADJUSTMENT
Adjust part Frequency display reading on digital
voltmeter.
Confirmation 531kHz Standard value : 0.5 –1.5V
1,611kHz Standard value : 4.6 –5.8V
MW TRACKING ADJUSTMENT
Adjust for a maximum reading on level meter.
L3 –1 621kHz
CT3 1,404kHz
TUNER SECTION
AM Section
RADIO BAND button : MW or LW
Volume : MIN
FM RF signal
generator
22.5kHz frequency deviation by
400Hz signal.
Output level : as low as possible
telescopi
c
antenna
terminal
0.01 µF
AM RF signal
generator
30% amplitude modulation by 400Hz
signal.
Output level : as low as possible
Put the lead-wire
antenna close to
the set.
set
47kΩ
+
–
LINE OUT
level mete
r
0dB = 1µV
Tape Speed Adjustment
Procedure :
–FWD Playback Mode –
set
test tape
WS-48B
(3kHz, 0dB) frequency counter
LINE OUT
47kΩ
1. Set to FWD playback mode.
2. Adjust M691 (capstan/reel motor) so that the frequency counter
reading becomes 3,000Hz.
Standard value : 2,970 to 3,030Hz
3. Set to REV playback mode.
Confirm the frequency should be within the standard value.
4. Confirm the frequency difference between beginning and the
end of tape should be within 1.5% (45Hz).
Adjustment Location : M691 (capstan/reel motor)
LW FREQUENCY COVERAGE ADJUSTMENT
Adjust part Frequency display reading on digital
voltmeter
Confirmation 153kHz Standard value : 0.2 –0.9V
L4 279kHz Adjustment value : 5.0V
Standard value : 4.9 –5.1V
LW TRACKING ADJUSTMENT
Adjust for a maximum reading on level meter.
L3 –2 162kHz
CT5 261kHz