AIWA CX-LEM400 Service Manual

CX-LEM400

SERVICE MANUAL

Ver 1.1 2004. 09

CX-LEM400 is the Amplifier, CD player, Tape
Deck and Tuner section in XR-EM400.

CD
Section

TAPE
Section

AEP Model

UK Model

Model Name Using Similar Mechanism NEW
CD Mechanism Type BU-30DBD64S
Optical Pick-up Name A-MAX. D
Model Name Using Similar Mechanism CX-LEM300
Tape Transport Mechanism T ype CMAL5Z220A

SPECIFICATIONS

TUNER

FM tuning range 87.5 MHz to 108 MHz
FM usable sensitivity (IHF) 16.8 dBf
FM antenna terminal 75 Ω (unbalanced)
MW tuning range 531 kHz to 1602 kHz
AM usable sensitivity 350 µV/m
AM antenna Loop antenna

AMPLIFIER

Power output Rated: 12 W + 12 W(6 Ω, T.H.D. 1 %,

1 kHz/DIN 45500)
Reference: 15 W + 15 W(6 Ω, T.H.D.
10 %, 1 kHz/DIN 45324)
MUSIC POWER

30 W + 30 W
Input AUX IN: 800 mV
Outputs SPEAKER: 6 Ω or more

PHONES: 32Ω or more

CASSETTE DECK

Track format 4 tracks, 2 channels stereo
Frequency response 50 Hz – 10000 Hz
Recording system AC bias
Heads Recording/playback × 1, erase × 1

CD PLAYER

Laser Semiconductor laser (λ = 780 nm)

Emission duration: continuous
D/A converter MULTI BIT
Signal-to-noise ratio 90 dB (1 kHz, 0 dB)
Wow and flutter Unmeasurable

GENERAL

Power requirements 230 V AC, 50/60 Hz
Power consumption 50 W
Power consumption in standby mode

with ECO mode on: 0.2 W

with ECO mode off: 9 W
Dimensions (w/h/d) Approx. 163 × 230.5 × 240 mm
Mass Approx. 3.5 kg

Supplied accessories: FM antenna (1)

AM antenna (1)

Remote commander (1)

Batteries (2)

Specifications and external appearance are subject to change
without notice.

9-961-011-02

2004I16-1
© 2004.09

MICRO HI-FI COMPONENT SYSTEM

Sony Corporation

Personal Audio Company
Published by Sony Engineering Corporation

CX-LEM400

TABLE OF CONTENTS

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

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

3. DISASSEMBLY

3-1. REAR CABINET ·························································· 7
3-2. CD CABINET SECTION,

FRONT PANEL SECTION···········································8
3-3. CD MECHANISM DECK ············································ 8
3-4. CONTROL BOARD, SUB CONTROL BOARD ········· 9
3-5. TAPE MECHANISM DECK ········································ 9
3-6. CASSETTE DOOR ASSY··········································10
3-7. POWER BOARD, MAIN BOARD·····························10
3-8. BD BOARD, OPTICAL PICK-UP (A-MAX. D) ······· 11

4. MECHANICAL ADJUSTMENTS ····························· 12

5. ELECTRICAL ADJUSTMENTS ······························· 12

6. DIAGRAMS······································································16

6-1. BLOCK DIAGRAM – CD SECTION – ···················· 17
6-2. BLOCK DIAGRAM – MAIN SECTION –··············· 18
6-3. PRINTED WIRING BOARD – BD SECTION – ······ 19
6-4. SCHEMATIC DIAGRAM – BD SECTION – ··········· 20
6-5. PRINTED WIRING BOARDS

– MAIN SECTION – ················································· 21
6-6. SCHEMATIC DIAGRAM

– MAIN SECTION – ················································· 22
6-7. PRINTED WIRING BOARD

– CONTROL SECTION – ·········································· 23
6-8. SCHEMATIC DIAGRAM

– CONTROL SECTION – ·········································· 24
6-9. PRINTED WIRING BOARD

– POWER SECTION – ·············································· 25
6-10.SCHEMATIC DIAGRAM

– POWER SECTION – ··············································· 25
6-11.IC PIN FUNCTION DESCRIPTION ························· 30

7. EXPLODED VIEWS

7-1. CABINET SECTION·················································· 32
7-2. FRONT PANEL SECTION········································· 33
7-3. CD CABINET SECTION ··········································· 34
7-4. BU-30DBD64S ··························································· 35

8. ELECTRICAL PARTS LIST ······································· 36

2

SECTION 1

SERVICING NOTES

CX-LEM400

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.

CAUTION

Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous
radiation exposure.

This appliance is classified as a CLASS 1 LASER product.
This label is located on the exterior.

Laser component in this product is capable of emitting radiation
exceeding the limit for Class 1.

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.

LASER DIODE AND FOCUS SEARCH OPERATION
CHECK

Carry out the “S curve check” in “CD section adjustment” and check
that the S curve waveforms is output three times.

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 .

3

CX-LEM400

Service Position of the CD Mechanism Deck

MAIN board

BD board

Service Position of the Tape Cassette Mechanism Deck

CONTROL board

MAIN board

POWER board

4

PARTS AND CONTROLS

Main unit: front

Refer to the pages indicated in parentheses for details.

4

1

2

3

1 POWER 6STANDBY/ON (7)

Switches the unit on and off (standby).

2 ECO (7)

Sets the ECO mode on or off.

SYNCHRO REC (17)

Starts recording and CD play simultaneously.

REC START/PAUSE (17)

Starts and pauses recording.

RDS (12-14)

Activates RDS features.

3 PHONES jack

Plug in optional headphones set with a stereo mini plug
(ø3.5 mm). Speaker output is cancelled.

4 OPEN (8)

Opens or closes the disc compartment.

5
6
7

8

SECTION 2

GENERAL

5 ECD (7-10)

Starts and pauses CD play.

TUNER/BAND (7, 12)

Selects tuner function and the tuner band.

cTAPE (REC MUTING) (7, 16, 17)

Starts playback.
Also used to enter 4-second blank spaces during
recording.

AUX (7)

Selects the function of external equipment connected to
AUX IN jacks.

6 VOLUME (15, 18)

Adjusts the volume.

7 f /r-, +t/g (8, 10, 14-16, 18,

19)

CD: skips to a previous or a succeeding track when
pressed, searches a track in fast forward or reverse
playback when held down.
Tape: rewinds or fast forwards the tape.
Tuner: manually tunes up or down within the band.

sSTOP (8-10, 16, 17)

CD and tape: stops playback.
Tuner: clears a preset station.

TONE (15)

Adjusts the bass or treble level.

8 zPUSH EJECT (16, 17)

Opens or closes the cassette holder.

CX-LEM400

This section is extracted
from instruction manual.

Main unit: rear

Refer to the pages indicated in parentheses for details.

1
2

3

4

5

1 AM jack and FM 75 Ω terminal (4)

Plug in the supplied AM and FM antennas.

2 AUX IN jacks

Accept analogue sound signals from external equipment.
Connect external equipment using an optional connecting
cable with RCA phono plugs (red plug to R jack, white
plug to L jack). Refer also to the operating instructions
for your equipment.
To switch function to external input, press AUX.

To change a source name in the display of the
AUX function.

Hold down AUX and press POWER while the power is
on.

AUX VIDEO TV

3 SUB WOOFER jack

Connect optional powered sub woofer with a built-in
amplifier to the jack.

4 SPEAKER terminals (4)

Connect the speaker cords of the supplied speakers.

5 AC power cord (4)

Remote commander

Refer to the pages indicated in parentheses for details.

1

2

3
4

5
6
7

Buttons with the same or similar names on the main unit
basically have the same function.

1 POWER (7)
2 1–10/0, >10 (8, 10, 12)

CD: selects a track of the specified number.
Tuner: tunes in the station with the specified preset
number.

The numbered buttons take on these functions when pressed with
SHIFT held down

CLOCK (7)

Selects clock mode.

TIMER (18)

Selects timer mode.

TUNER MODE (15)

Switches between stereo or monaural FM reception.

:

8

9

0

!
@

#

3 SHUFFLE/PROGRAM (8, 9)

Selects shuffle or programmed CD playback mode.

REPEAT (8)

Selects repeat CD playback mode.

4 ALBUM/PRESETN,M (10, 12)

MP3-CD: skips to a previous or succeeding album.
Tuner: tunes in a preset station.

f/r,t/g (8, 10)
ENTER (7, 12, 18, 19)

Determines the mode.
Stores the received station to preset.

5 ECD (7-9)

TUNER/BAND (7, 12)
dTAPE (7, 16)

Starts playback but cannot change the playback side.

AUX (7)

6 DISPLAY (8)

Changes the display in CD playback mode.

DIMMER (7)

Adjusts the display window brightness.

SLEEP (18)

Selects sleep-timer mode.

7 SHIFT

Hold down when pressing a numbered button to change
its function to that printed above the number.

8 MUTING (15)

To turn off the sound temporarily.

9 CLEAR (9, 12, 19)

CD: Clears a CD program.
Tuner: Clears a preset station.

0 TREBLE (15)

Adjusts the treble level.

BASS (15)

Adjusts the bass level.

! s (8-10, 16, 17)
@ FUNCTION (17)

Switches the active function among TAPE, TUNER, AUX
(VIDEO or TV) and CD.

# VOLUME +,- (15)

5

CX-LEM400

ADJUSTMENTS BEFORE OPERATION

POWER

6STANDBY/ON

ECO

Power

Tur ning the unit on

Press POWER 6STANDBY/ON (POWER on the remote ).
Alternatively, press cTAPE, TUNER/BAND, AUX or ECD.
Playback will start automatically if a disc or tape is loaded.

Tur ning the unit off

Press POWER 6STANDBY/ON again.
The unit goes into standby.

Dimmer

The display window brightness can be selected.

Press DIMMER on the remote repeatedly.

Each press of the button changes the following three levels:
"DIMMER 1 ", "DIMMER 2" and "DIMMER 0 ".
"DIMMER 0 " is the brightest.

ECD,
TUNER/
BAND,
cTAPE,
AUX

f,g

POWER

CLOCK

ECD,

TUNER/

BAND,

dTAPE,

AUX

SHIFT

DIMMER

ECO mode

Reduces power consumption in standby mode with the following
operations.

Press ECO.

Each press of the button changes the mode as follows;

ECO ON: Power economizing mode is activated.
When the unit turns off, everything in the display disappears
and only the red indicator on POWER lights to show that the
power is being supplied.
ECO OFF: Power economizing mode is cancelled.
When the unit turns off, the clock display appears.

Initial mode is ECO OFF.

Standby power consumption

ECO ON: 0.2 W
ECO OFF: 9 W

ENTER

f,g

Setting the clock

1

In stop mode, hold down SHIFT and press CLOCK
on the remote.

Go to step 3 when the hour of the clock display flashes.

2

Within 6 seconds, press ENTER.

The hour flashes in the display.

3

Press f or g to set the hour, then press
ENTER.

4

Press f or g to set the minute.

Each press changes the time in 1-minute steps.

5

Press ENTER.

The time display stops flashing and the clock starts from
00 seconds.

To display the time while the power is on

Hold down SHIFT and press CLOCK on the remote.
The time will be displayed for 6 seconds.

If "- -:- -" appears when the unit is turned off

There has been a power interruption. Reset the clock.

6

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

SET

REAR CABINET

CD CABINET SECTION,
FRONT PANEL SECTION

CX-LEM400

SECTION 3

DISASSEMBLY

CD MECHANISM DECK
(BU-30DBD64S)

OPTICAL PICK-UP
(A-MAX.D)

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

CONTROL BOARD,
SUB-CONTROL BOARD

3-1. REAR CABINET

6

four screws

×

5)

(+K3

TAPE MECHANISM DECK
(CMAL5Z220A)

CASSETTE DOOR ASSY

1

8

cabinet rear

POWER BOARD , MAIN BOARD

two screws
(+BVTP3 × 10)

2

four screws
(+BVTP3 × 10)

3

4

two screws
(+BVTP3

screw
(+B3

×

×

10)

10)

7

four screws
(+K3 × 5)

5

two screws
(+BVTP3 × 10)

7

CX-LEM400

3-2. CD CABINET SECTION, FRONT PANEL SECTION

5

w

ire (flat type)

(9core) (CN104)

2

claw

1

claw

4

(CN103)

7

w

ire (flat type)
(21core)
(CN303)

6

CD cabinet section

3

connector
(S800)

w

ire (flat type) (21core)

qa

two screws
(+BVTP3 × 10)

qd

claw

qf

front panel section

3-3. CD MECHANISM DECK

1

two screws
(+PWH2.6

×

10)

qs

claw

8

w

ire (flat type)
(19core)
(CN302)

3

two insulators (BU-30)

9

connector
(CN301)

0

screw
(+BVTP3 × 10)

5

CD mechanism deck

2

two screws
(+PWH2.6

4

two insulators (BU-30)

×

10)

8

3-4. CONTROL BOARD, SUB CONTROL BOARD

)

5

four screws
(+BTP3 × 10)

6

CONTROL board

1

knob volume

2

w

ire (flat type)

(19core) (CN807)

3

two screws
(+BVTP3 × 10)

4

SUB CONTROL board

CX-LEM400

3-5. TAPE MECHANISM DECK

1

w

ire (flat type) (7core) (CN101)

2

four screws
(+BVTP3

3

tape mechanism deck

×

10

9

CX-LEM400

d

3-6. CASSETTE DOOR ASSY

1

Open the cassette door assy.

3

cassette door assy

2

two claws

3-7. POWER BOARD, MAIN BOARD

7

MAIN board

6

screw
(+BVTP3

×

10)

5

screw
(+BVTP3

×

10)

2

connector
(CN901)

3

four screws
(+BVTP4

×

12)

1

2

connector
(AC IN)

4

POWER boar

10

3-8. BD BOARD, OPTICAL PICK-UP (A-MAX. D)

optical pick-up(A-MAX.D)

6

5

BD board

3

w

ire (flat type) (16 core)

(CN101)

CX-LEM400

1

Remove two
solders.

4

2

Remove two solders.

11

CX-LEM400

SECTION 4

MECHANICAL ADJUSTMENTS

SECTION 5

ELECTRICAL ADJUSTMENTS

• TAPE MECHANISM DECK SECTION

Precaution

1. Clean the following parts with a denatured alcohol-moistened
swab:

record/playback heads pinch rollers
erase head rubber belts
capstan idlers

2. Demagnetize the record/playback head with a head demagne­tizer.

3. Do not use a magnetized screwdriver for the adjustments.

4. The adjustments should be performed with the rated power
supply voltage unless otherwise noted.

Torque Measurement

Mode

FWD

FWD
back tension

FF/REW

FWD tension

Torque meter

CQ-102C

CQ-102C

CQ-201B

CQ-403A

Meter reading

2.94 mN • m to 7.84 mN • m
31 to 71 g • cm

(0.43 – 0.98 oz • inch)

0.14 mN • m to 0.59 mN • m

2 to 6 g • cm

(0.02 – 0.08 oz • inch)

6.86 mN • m to 17.64 mN • m
71 to 143 g • cm

(0.98 – 1.99 oz • inch)

more than 0.98 N • m

100 g or more

(3.53 oz or more)

DECK SECTION

Precaution

1. Demagnetize the record/playback head with a head demagne­tizer.

2. Do not use a magnetized screwdriver for the adjustments.

3. After the adjustments, apply suitable locking compound to the
parts adjust.

4. The adjustments should be performed with the rated power
supply voltage unless otherwise noted.

5. The adjustments should be performed in the order given in
this service manual. (As a general rule, playback circuit ad­justment should be completed before performing recording
circuit adjustment.)

6. The adjustments should be performed for both L-CH and R­CH.

7. Switches and controls should be set as follows unless other­wise specified.

•Test Tape

Tape Signal Used for

P-4-A100 10 kHz, – 10 dB Azimuth Adjustment

WS-48B 3 kHz, 0 dB Tape Speed Check

0 dB = 0.775 V

12

CX-LEM400

)

Note: Refer to “3-6. Cassette Door Assy” (see page 10)

adjustment screw

Record/Playback Head Azimuth Adjustment

Procedure:

1. Mode: Playback

test tape
P-4-A100
(10 kHz, – 10 dB)

MAIN board
SPEAKER terminal (J302
L-CH, R-CH

set

level meter

+
–

2. Turn the adjustment scre w and check output peaks. If the peaks
do not match for L-CH and R-CH, turn the adjustment screw
so that outputs match within 1dB of peak.

Output
level

within
1dB

L-CH
peak

R-CH
peak

within
1dB

Screw
position

L-CH
peak

Screw
position

R-CH
peak

Adjustment Location:Record/Playback/Erase Head

3. Mode: Playback

MAIN board
test tape
P-4-A100
(10 kHz, – 10 dB)

L-CH

set

R-CH

in phase 45°90°135°180

SPEAKER terminal (J302)

L-CH

R-CH

waveform of oscilloscope

good

oscilloscope

wrong

H

V

°

4. After the adjustments, apply suitable locking compound to the
parts adjusted.

Tape Speed Check

Mode: Playback

test tape
WS-48B
(3 kHz, 0 dB)

set

MAIN board
SPEAKER terminal (J302)
L-CH, R-CH

frequency counter

+
–

1. Insert the WS-48B into the deck.

2. Press the TAPE N button on the deck.

3. Confirm that the frequency counter reads 3,000 ± 90 Hz.

Sample value of Wow and Flutter: 0.3% or less W.RMS (JIS)

(WS-48B)

13