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XP-ER800/ER800N/ER800R
US Model
XP-ER800/ER800N
Canadian Model
XP-ER800
AEP Model
XP-ER800/ER800R
UK Model
XP-ER800R
E Model
XP-ER800/ER800R
Australian Model
XP-ER800
SERVICE MANUAL
PORTABLE CD PLAYER
Sony Corporation
Personal Audio Company
Published by Sony Engineering Corporation
9-877-194-04
2003L16-1
© 2003.12
SPECIFICATIONS
Ver 1.3 2003. 12
Model Name Using Similar Mechanism
D-EJ985
CD Mechanism Type
CDM-3325ER
Optical Pick-up Name
DAX-25E
· Abbreviation
AUS : Australian model
CND : Canadian model
E13 : 220 ­ 230 V AC area in E model
HK : Hong Kong model
TW : Taiwan model
Photo : XP-ER800
System
Compact disc digital audio system
Laser diode properties
Material: GaAlAs
Wavelength:
= 780 nm
Emission duration: Continuous
Laser output: Less than 44.6
µW (This output is the value
measured at a distance of 200 mm from the objective lens
surface on the optical pick-up block with 7 mm aperture.)
Frequency range
10 kHz step:
TV: 2 - 13 ch
WB (weather band): 1 - 7 ch
FM: 87.5 - 108.0 MHz
AM: 530 - 1 710 kHz
9 kHz step:
TV: 2 - 13 ch
WB (weather band): 1 - 7 ch
FM: 87.5 - 108.0 MHz
AM: 531 - 1 602 kHz
Power requirements
· Two LR6 (size AA) batteries (not supplied): 3 V DC
· AC power adaptor (DC IN 4.5 V jack):
· Two Ni-MH rechargeable batteries (size AA): 1.2V
× 2 DC
Dimensions (w/h/d) (without projecting
parts and controls)
Approx. 136.0
× 20.4 × 139.0 mm (5 3/
8
× 13/
16
× 5 1/
2 in.)
Mass (excluding accessories)
Approx. 200 g (7 oz)
Operating temperature
5
°C ­ 35°C (41°F ­ 95°F)
Design and specifications are subject to change without
notice.
US, CND Models
US, CND Models
120 V, 60 Hz
US, CND, TW Models
AEP Model
FM: 87.5 - 108.0 MHz
AM: 531 - 1 602 kHz
220 - 230 V, 50 Hz
AEP Model
E13, AUS, HK, TW Models
FM: 87.5 - 108.0 MHz
AM: 530 - 1 710 kHz
E13, AUS, HK, TW Models
FM: 87.5 - 108.0 MHz
AM: 531 - 1 602 kHz
220 - 230 V, 50/60 Hz
E13 Model
230 V, 50 Hz
HK Model
AUS Model
240 V, 50/60 Hz


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2
XP-ER800/ER800N/ER800R
Flexible Circuit Board Repairing
·Keep the temperature of the soldering iron around 270 °C dur-
ing 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 dam-
aged by heat.
This appliance is classified as a CLASS 1 LASER product.
The CLASS 1 LASER PRODUCT MARKING is located on
the rear exterior.
CAUTION
Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous
radiation exposure.
On AC poweradaptor
·
Polarity of the plug
Use only the commercially-available AC power ad
output is 4.5 V DC, 500 mA. Do not use any othe
It may cause a malfunction.
TABLE OF CONTENTS
1. SERVICING NOTE ·························································· 3
2. GENERAL ·········································································· 4
3. DISASSEMBLY
3-1. Cabinet (REAR) Section ··············································· 6
3-2. Cabinet (Front) Sub Section ·········································· 7
3-3. Upper Lid ······································································ 8
3-4. CD Mechanism Deck (CDM-3325ER) ························· 9
3-5. MAIN Board ······························································· 10
3-6. Motor (turn table) Assy (M902),
Optical Pick-Up Assy ·················································· 11
4. ELECTRICAL ADJUSTMENT ·································· 12
5. DIAGRAMS ······································································ 17
5-1. Block Diagram ­ Main Section ­ ······························· 18
5-2. Block Diagram ­ TUNER (4Band) Section ­ ············ 19
5-3. Block Diagram ­ TUNER (2Band) Section ­ ············· 20
5-4. Printed Wiring Board
­ MAIN Board (4Band)(Side A) ­ ······························ 21
5-5. Printed Wiring Board
­ MAIN Board (4Band)(Side B) ­ ······························ 22
5-6. Printed Wiring Board
­ MAIN Board (2Band)(Side A) ­ ······························ 23
5-7. Printed Wiring Board
­ MAIN Board (2Band)(Side B) ­ ······························ 24
5-8. Schematic Diagram ­ MAIN Board (1/6) ­ ················ 25
5-9. Schematic Diagram ­ MAIN Board (2/6) ­ ················ 26
5-10. Schematic Diagram ­ MAIN Board (3/6) ­ ················ 27
5-11. Schematic Diagram ­ MAIN Board (4/6) ­ ················ 28
5-12. Schematic Diagram ­ MAIN Board (5/6) ­ ················ 29
5-13. Schematic Diagram ­ MAIN Board (6A/6) ­ ············· 30
5-14. Schematic Diagram ­ MAIN Board (6B/6) ­ ············· 31
5-15. IC Block Diagram ······················································· 32
5-16. IC Pin Function Description ········································ 35
6. EXPLODED VIEWS ······················································ 37
7. ELECTRICAL PARTS LIST ······································· 40
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.
ATTENTION AU COMPOSANT AYANT RAPPORT
À LA SÉCURITÉ!
LES COMPOSANTS IDENTIFÉS PAR UNE MARQUE 0 SUR LES
DIAGRAMMES SCHÉMATIQUES 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.
Ver 1.1 2003.06


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3
XP-ER800/ER800N/ER800R
SECTION 1
SERVICING NOTE
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,
observe from more than 30 cm away from the objective lens.
BEFORE REPLACING THE OPTICAL PICK-UP BLOCK
Please be sure to check thoroughly the parameters as par the "Optical
Pick-Up Block Checking Procedures" (Part No.: 9-960-027-11)
issued separately before replacing the optical pick-up block.
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 S302. (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. With a disc not set, turn on the S302 with a screwdriver having a
thin tip as shown in Fig.1.
3. Press the u button.
4. Observing the objective lens, check that the laser diode emits
light.
When the laser diode does not emit light, automatic power control
circuit or optical pickup is faulty.
In this operation, the objective lens will move up and down 4
times along with inward motion for the focus search.
NOTES ON HANDLING THE OPTICAL PICK-UP
BLOCK OR BASE UNIT
Fig. 1 Method to push the S302
detection lever
detection lever
MAIN board
S302


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4
XP-ER800/ER800N/ER800R
SECTION 2
GENERAL
This section is extracted
from instruction manual.
DC IN 4.5 V
(external power
input) jack
*The button has a tactile dot.
Strap holes
4SOUND
Display
8r/t
SKIP/SEARCH
0MODE
\
(headphones)
jack
!HOLD
@VOL +*/­
9ca*
567 s(stop)/OFF/CHARGE
3BAND
2PRESET CALL UP/DOWN
1ENTER/DISPLAY
A
OPEN
CD player (front)
Display on CD player
(4 Band)
Play mode
Track number/PRESET number
Sound mode
Playing time/
Frequency
PRESET
E·A·S·S
Remaining
battery power
Band
ST
VOL
CHG
Remote control (XP-ER800R only)
Display on CD player
(2 Band)
Play mode
Track number/PRESET number
Sound mode
Playing time/
Frequency
PRESET
E·A·S·S
Remaining
battery power
Band
ST
VOL
CHG
9ca
8tF SKIP
3BAND
@VOL
!HOLD
8rB SKIP
56s
Earphones jack


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5
XP-ER800/ER800N/ER800R
SECTION 3
DISASSEMBLY
SET
CABINET (REAR) SECTION
CABINET (FRONT)
SUB SECTION
UPPER LID
CD mechanism deck
(CDM-3325ER)
Motor (turn table) assy (M902),
optical pick-up assy
MAIN BOARD
Note :
Disassemble the unit in the order as shown below.