Sony PS-FL77 Repair Parts

Size-Sensor Bulb LED Replacement

The “size_sensor_led_holder.3mf” is the part that holds the new LED. It directly replaces the plastic holder that previously held the bulb.

Required Parts and Tools:

• A 5mm LED and a Resistor for 12V operation (can be bought pre-soldered)
• size_sensor_led_holder.3mf
• size_sensor_led_sanding_guide.3mf
• heat shrink tubing
• Soldering Iron
• File or Sandpaper

Preparation:

1. Put the LED in the sanding guide and use a file or sandpaper to sand the angle of the guide into it. (Photo is pre-sanding)
   

Installation:

1. Open the bottom of the record player and remove the top cover according to the service manual.
2. Slide out the tray by hand to give you more working room.
3. Unscrew the original holder from the bottom with these two screws
   
    
4. Take out the original holder. The bulb should now dangle from the wire and can be pulled through the hole to the backside.
5. Cut off the bulb, we don't need it anymore.
6. Use wire-strippers to expose some of the old bulb-wires.
7. Connect the record player to power and turn it on. The tray-motor will start turning when you do that. That's expected behavior. Press the tray close limit switch and it will stop.
   
    
8. Use a multimeter to measure the polarity of the cables. According to the Service Manual it should be -11.4V. 
   Since it's negative voltage, the anode will be connected to (chassis-)ground and the cathode to -11.4V.
9. Temporarily twist the cables from the record player and the LED together to make sure you got them the right way around.
10. Unplug the record player and untwist the LED cable.
11. Put the LED into the new holder and check if the angle of the sanding is roughly equal to the angle of the transparent plastic-piece in the original part.
    
     
12. Bend the Cable of the LED downwards and insert it with the adapter in the right hole.
    (Sorry, don't have a picture of that, but here's a screenshot from the service manual.)
    
13. Screw the holder in with the original screws. It helps to put the record player on its side while doing so.
14. Cut the LED wire to length and solder it to the bulb-cables. Insulate it with some heat shrink tubing.
15. Screw the bottom plate and the top cover back on.
16. Test if the light turns on and the size-detection feature of the record player works.

Front Flap Arm repair

Required Parts and Tools:

• frontlid_arm_cut_template.3mf
• frontlid_arm_repair_piece.3mf
• Something to remove plastic (Dremel, File, Sandpaper, etc.)
• Super Glue

Print Recommendation:

Print the frontlid_arm_repair_piece.3mf standing up like this with a low layer height (I used 0.12mm).
Everything else can be printed as you see fit.
All parts are made to fit the right-hand side of the flap. If the left-hand side is broken, you have to mirror the models in your slicer before printing.

Installation:

1. Unscrew the front flap on each side.
2. Place the cutting template over the broken Arm.
   
3. Use your preferred method to remove the plastic that sticks out above the arm.
4. Remove the cutting template and test-fit the repair piece in the grooves. 
   Make sure the end-pieces touch the front side of the flap.
   
5. Put some super glue between the 3D printed part and the original piece to fix it in place.
6. Screw the front flap back in.

I wrote a blog post about repairing this record player. If you're interested in some more in-depth repair stuff you can check it out here: https://dekkia.zip/blog/post/f7f6d97e-13a4-42a8-a353-1672ad85ff63.html