SONY HCD-G2500, HCD-XB20, HCD-XB22 Service Manual
HCD-G2500/XB20/XB22
SERVICE MANUAL
• This set is the tuner, deck, CD and amplifier
section in LBT-G2500/XB20/XB22.
*Dolby noise reduction manufactured under
license from Dolby Laboratories Licensing
Corporation.
“DOLBY” and the double-D symbol a are
trademarks of Dolby Laboratories Licensing
Corporation.
Photo : HCD-XB20
Model Name Using Similar Mechanism NEW
CD
SECTION
TAPE
DECK
SECTION
CD Mechanism Type CDM375BD29
Base Unit Type KSM-213ECM
Optical Pick-up Type KSS-213B/SN
Model Name Using Similar Mechanism HCD-GRX2/RX33
Tape Transpor
Mechanism Type
US Model
HCD-G2500
AEP Model
UK Model
HCD-XB20
E Model
Australian Model
HCD-XB22
DECK-A TK20FX-SW943-800
DECK-B TK20FX-SW943-800
SPECIFICATIONS
AUDIO POWER SPECIFICATIONS:
(U.S.A. model only)
POWER OUTPUT AND TOTAL HARMONIC DISTORTION:
With 6 Ω loads both channels driven, fr om 70 – 20,000 Hz; rated 60 W
per channel minimum RMS power, with no more than 0.9% total
harmonic distortion from 250 mW to rated output.
Amplifier section
North American model
Continuous RMS power output
70 W + 70 W (6 Ω at 1 kHz, 10% THD)
Total harmonic distortion
less than 0.09% (6 Ω at 1kHz, 30 W)
European model
DIN power output (Rated) 60 W + 60 W (6 Ω at 1 kHz, DIN)
Continuous RMS power output (Reference)
70 W + 70 W (6 Ω at 1 kHz, 10% THD)
Music power output (Reference)
120 W + 120 W (6 Ω at 1 kHz, 10%THD)
Other models
The following measured at AC 110,220 V 60 Hz;
DIN power output (Rated) 45 W + 45 W (6 Ω at 1 kHz, DIN)
Continuous RMS power output (Reference)
55 W + 55 W (6 Ω at 1 kHz, 10% THD)
The following measured at AC 120, 240 V 60Hz;
DIN power output (Rated) 50 W + 50 W (6 Ω at 1 kHz, DIN)
Continuous RMS power output (Reference)
60 W + 60 W (6 Ω at 1 kHz, 10% THD)
Peak music power output (Reference)
800 W
Inputs
PHONO IN (phone jacks):
sensitivity 3 mV, impedance 47 kilohms
Outputs
PHONES (stereo phone jack):
accepts headphones of 8 Ω or more
SPEAKER: accepts impedance of 6 to 16 Ω
CD player section
System Compact disc and degital audio system
Laser Semiconductor laser ( λ = 780 nm)
Emission duration: continuous
Laser output Max.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 response 20 Hz – 20 kHz (±0.5 dB)
Wavelength 780 – 790nm
Tape deck section
Recording system 4-track 2-channel stereo
Frequency response 60 – 13,000 Hz (±3 dB),
(DOLBY NR OFF) using a Sony TYPE I cassette
— Continued on next page —
MINI Hi-Fi COMPONENT SYSTEM
MICROFILM
Tuner section
FM stereo, FM/AM superheterodyne tuner
FM tuner section
Tuning range 87.5 – 108.0 MHz
Antenna FM lead antenna
Antenna terminals 75 Ω unbalanced
Intermediate frequency 10.7 MHz
AM tuner section
Tuning range
(2 band model)
North American model:
530 – 1,710 kHz
(with the tuning interval set at 10 kHz)
Other models: 531 – 1,602 kHz
(with the tuning interval set at 9 kHz)
530 – 1,710 kHz
(with the tuning interval set at 10 kHz)
(3 band model)
MW: 531 – 1,602 kHz
(with the tuning interval set at 9 kHz)
LW: 153 – 279 kHz
(with the tuning interval set at 3 kHz)
Antenna AM loop antenna
Antenna terminals External antenna terminal
Intermediate frequency 450 kHz
General
Power requirements
North American model:
120 V AC, 60 Hz
Mexican model: 120 V AC, 50/60 Hz
European model: 230 V AC, 50/60 Hz
Australian, South African and Thailand models:
220 – 240 V AC, 50/60 Hz
Other models: 110 – 120 V AC or 220 – 240 V AC,
50/60 Hz (adjustable with voltage selector)
Power consumption 130 W
Dimensions (w/h/d) incl. projecting parts and controls
Approx.355 × 423 × 440 mm
(14 × 16 3/4 × 17 3/8 in)
Mass Approx. 14.0 kg (30 lb 14 oz.)
Supplied accessories AM loop antenna (1)
Remote RM-SG5 (1)
FM lead antenna (1)
SERVICING NOTE
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.
Design and specifications are subject to change without notice.
CAUTION
Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous
radiation exposure.
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 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.
SAFETY-RELATED COMPONENT WARNING!!
COMPONENTS IDENTIFIED BY MARK ! OR DOTTED LINE WITH
MARK ! 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.
Laser component in this product is capable of emitting radiation
exceeding the limit for Class 1.
This appliance is classified as
a CLASS 1 LASER product.
The CLASS 1 LASER
PRODUCT MARKING is
located on the rear exterior.
This caution
label is located
inside the unit.
— 2 —
SAFETY CHECK-OUT
After correcting the original service problem, perform the following
safety checks before releasing the set to the customer:
Check the antenna terminals, metal trim, “metallized” knobs, screws,
and all other exposed metal parts for AC leakage. Check leakage as
described below.
LEAKAGE
The AC leakage from any exposed metal part to earth Ground and
from all exposed metal parts to any exposed metal part having a
return to chassis, must not exceed 0.5 mA (500 microampers).
Leakage current can be measured by any one of three methods.
1. A commercial leakage tester, such as the Simpson 229 or RCA
WT -540A. F ollow the manufactur ers’ instructions to use these
instruments.
2. A battery-operated AC milliammeter. The Data Precision 245
digital multimeter is suitable for this job.
3. Measuring the voltage drop across a resistor by means of a
VOM or battery-operated A C voltmeter . The “limit” indication
is 0.75 V, so analog meters must have an accurate low-v oltage
scale. The Simpson 250 and Sanwa SH-63Trd are e xamples of
a passive VOM that is suitable. Nearly all battery operated
digital multimeters that have a 2V AC range are suitable. (See
Fig. A)
T o Exposed Metal
Parts on Set
AC
0.15
µ
F
Fig. A. Using an A C v oltmeter to check A C leakage.
1.5 k
Ω
Earth Ground
Voltmeter
(0.75 V)
TABLE OF CONTENTS
1. GENERAL ·········································································4
—FRONT PANEL— ·························································4
—BACK PANEL—···························································· 5
2. DISASSEMBLY
2-1. Top Cover ··········································································· 6
2-2. Front Panel Assy·································································6
2-3. Main Board········································································· 7
2-4. Main Section······································································· 7
2-5. CD Mechanism Deck Section ············································ 8
2-6. Tape Mechanism Deck ······················································· 8
2-7. Cassette Door ····································································· 9
2-8. CD Door Assy ···································································· 9
2-9. Base Unit ·········································································· 10
2-10. Disc T able········································································· 10
3. MECHANICAL ADJUSTMENTS ·····························11
4. ELECTRICAL ADJUSTMENTS ······························· 11
5. DIAGRAMS
5-1. Circuit Boards Location ··················································· 16
5-2. Block Diagram —Deck Section— ··································· 17
5-3. Block Diagram —Tuner/CD Section— ··························· 19
5-4. Schematic Diagram —Main Section (1/2)— ··················· 21
5-5. Schematic Diagram —Main Section (2/2)—
(US, AUS, MX model) ····················································· 25
5-6. Printed Wiring Board —Main Section—
(US, AUS, MX model) ····················································· 29
5-7. Printed Wiring Board —Main Section—
(AEP, UK, E, SP, MY, AR model)····································34
5-8. Schematic Diagram —Main Section (2/2)—
(AEP, UK, E, SP, MY, AR model)····································39
5-9. Schematic Diagram —Display Section— ························ 43
5-10. Printed Wiring Board —Display Section— ·····················47
5-11. Printed Wiring Board —CD Section—···························· 52
5-12. Schematic Diagram —CD Section— ······························· 57
5-13. Schematic Diagram —Power Section— ·························· 60
5-14. Printed Wiring Board —Power Section— ······················· 63
5-15. IC Block Diagrams ···························································68
5-16. IC Pin Function Description············································· 71
— 3 —
6. EXPLODED VIEWS
6-1. Top Cover Section ···························································· 73
6-2. CD Door Section ······························································ 74
6-3. Panel Section ···································································· 75
6-4. Main Section····································································· 76
6-5. Cassette Button Section···················································· 77
6-6. Cassette Mechanism Deck Section··································· 78
6-7. CD Mechanism Deck Section ·········································· 79
6-8. Base Unit Section ····························································· 80
7. ELECTRICAL PARTS LIST ······································81
– FRONT PANEL –
SECTION 1
GENERAL
#§
#¶
#¡
$¢
$∞
#•
#ª
#™ #£
$ª
$§$£
$™
$º
#¢
%º
$•
$¶
$¡
#∞
1
2
3467
see
A
5
#º
@ª
@•
!¡
!¢
!•
@∞
89
!º
!™
!£
!∞
!§
!¶
!ª
@º
@¢
@£
@¶
@§
@¡
%¢ %¡
A
%£
@™
%™
1 I/u (POWER) button
2 DISPLA Y/DEMO button
3 SPECTRUM ANALYZER button
4 ENTER/NEXT button
5 TUNER MEMORY button
6 TUNING MODE button
7 TUNER/BAND button
8 TUNING – button
9 TUNING + button
0 STEREO/MONO button
!¡ TAPE button
!™ CD button
!£ PHONO button
!¢ DBFB button
!∞ VOLUME knob
!§ DOLBY NR button
!¶ SURROUND button
!• · button
!ª 0 button
@º ) button
@¡ 6p button
@™ P button
@£ 6 button
@¢ · button
@∞ DISC SKIP button
@§ P button
@¶ p button
@• ) button
@ª ≠ AMS ± button
#º 0 button
#¡ DISC1 button
#™ DISC2 button
#£ DISC3 button
#¢ DISC4 button
#∞ DISC5 button
#§ r button
#¶ · button
#• 0 button
#ª ) button
$º 6p button
$¡ P button
$™ PHONES jack
$£ ROCK button
$¢ POP button
$∞ JAZZ button
$§ SALSA button
$¶ FLAT button
$• SLEEP button
$ª t/CLOCK SET button
%º DAILY1 button
%¡ PLAY MODE button
%™ REPEAT button
%£ EDIT button
%¢ 1/ALL DISC button
— 4 —
– BACK PANEL –
1
2
1 ANTENNA terminal
2 PHONO jack
3 SPEAKER terminal
3
— 5 —
SECTION 2
DISASSEMBLY
Note : Follow the disassembly procedure in the numerical order given.
2-1. TOP COVER
1
Three screws
3
Top cover
2
Seven screws
1
Three screws
2-2. FRONT PANEL ASSY
3
Front panel assy
1
Screw
2
Four screws
— 6 —
2-3. MAIN BOARD
1
Two screws
2
Three screws
2
Three screws
2
Two screws
1
Three screws
3
Rear panel
7
MAIN board
6
Two screws
5
Two flat wires
4
Connector
2-4. MAIN SECTION
1
Two screws
2
Main section
1
Two screws
— 7 —
2-5. CD MECHANISM DECK SECTION
3
Five screws
(BVTP 3 × 8)
4
CD mechanism
deck section
2
Flat wire and
lead wire
2-6. TAPE MECHANISM DECK
1
Open the clamp.
1
Six screws
2
Tape mechanism deck
— 8 —
2-7. CASSETTE DOOR
3
Door spring
2
Cassette door (L)
2-8. CD DOOR ASSY
1
Cassette door (R)
7
Connector
5
3
Door spring
DOOR SW board
6
Four screws
8
CD door assy
4
Screw
— 9 —
3
Three flat wires
1
Three screws
2
PLAY SW board
2-9. BASE UNIT
t
3
Base unit
1
Yoke bracke
2-10. DISC TABLE
Note:
When the disc table is installed, adjust the positions
of roller cam and mark z as shown in the figure,
then set to the groove of disc table.
A
2
1
Screw
(BVTP 3 × 8)
2
Bracket (BU)
Boss
1
Screw
(BVTP 3 × 8)
3
Step screw
4
Disc table
— 10 —
A
SECTION 3
MECHANICAL ADJUSTMENTS
SECTION 4
ELECTRICAL ADJUSTMENTS
Precaution
1. Clean the following parts with a denatured alcohol-moistened
swab:
record/playback head 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. After the adjustments, apply suitable locking compound to the
parts adjusted.
5. The adjustments should be performed with the rated power
supply voltage unless otherwise noted.
Torque Measurement
Torque
FWD
FWD
back tension
FF/REW
Torque meter
CQ-102C
CQ-102C
CQ-201B
Meter reading
40 to 70 g • cm
(0.56 - 0.97 oz • inch)
1 to 5 g • cm
(0.01 - 0.07 oz • inch)
55 to 140 g • cm
(0.76 - 1.94 oz • inch)
DECK SECTION 0 dB=0.775V
1. Demagnetize the record/playback head with a head
damagnetizer.
2. Do not use a magnetized screwdriver for the adjustments.
3. After the adjustments, apply suitable locking compound to the
parts adjusted.
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.
Tape
P-4-A100
WS-48B
Record/Playback Head Azimuth Adjustment
(Deck A, Deck B)
Note: Perform this adjustments for both decks.
Procedure:
1. Mode : Playback
test tape
P-4-A100
(10kHz, –10dB)
Signal
10 kHz, –10 dB
3 kHz, 0 dB
SPEAKER
terminal (JK703)
Used for
Azimuth Adjustment
Tape Speed Adjustment
level meter
set
+
–
— 11 —
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 2 dB of peak.
L-CH
peak
screw
position
R-CH
peak
output
level
within
2dB
L-CH
peak
R-CH
peak
within 2dB
screw
position
4. After the adjustments, apply suitable locking compound to the
parts adjusted.
Adjustment Location:
Remove the cassette lid before adjustment (See page 9)
Adjustment screws
REC/PB head (deck A)
or PB head (deck B)
3. Mode: Playback
test tape
P-4-A100
(10kHz, –10dB)
in phase 45˚ 90˚ 135˚ 180˚
SPEAKER
terminal (JK703)
(L-CH)
L
set
R
SPEAKER
terminal (JK703)
(R-CH)
Waveform of oscilloscope
good
wrong
Tape Speed Adjustment (Deck A)
Procedure:
1. Mode: Playback
test tape
WS-48B
(3kHz, 0dB)
set
SPEAKER
terminal (JK703)
frequency counter
+
–
2. Adjust the SFR809 so that the frequency counter reads 3,000
Hz ± 90Hz.
Adjustment Location: MAIN board (See page 14)
Sample Value of Wow and flutter
W. RMS (JIS) within 0.3%
(test tape: WS-48B)
— 12 —
TUNER SECTION 0 dB=1µV
AM Tuning Voltage Adjustment
Main board
TP1
F
G
VT
DC voltmeter
+
–
Procedure:
1. Set the reception frequency of the unit to 530 kHz.
2. Adjust L105 for 1.2 ± 0.05 V reading on the DC voltmeter.
3. Set the reception frequency of the unit to 1,710 kHz.
4. Confirm that the voltage reading on the DC voltmeter is within
8.0 ± 0.5 V.
Adjustment Location: MAIN board (See page 14)
AM Tracking Adjustment
loop antenna
AM RF SSG
loop antenna
(Supplied accessories)
set
30% amplitude
modulation by
400 Hz signal
60 cm
Field strength dB (
µ
V/m) =SSG output level dB (µV/m) –26 dB.
Procedure:
1. Tune the set to 600 kHz.
2. Set the output of AM RF SSG so that the input le vel of the set
will become 60 dB (µV/m).
3. Adjust L104 so that when the waveform on the oscilloscope is
maximum, no noise appears.
4. Tune the set to 1,400 kHz.
FM Tuning Voltage Adjustment (US, Australian, Mexican model)
Main board
TP1
IF
G
VT
DC voltmeter
+
–
Procedure :
1. Set the reception frequency of the unit to 87.5 MHz.
2. Adjust L103 for 1.2 ± 0.05V reading on the DC voltmeter.
3. Set the reception frequency of the unit to 108 MHz.
4. Confirm that the voltage reading on the DC voltmeter is within
7.8 ± 0.5V.
AM ANTENNA
terminal (TM1)
5. Adjust TC102 so that when the waveform on the oscilloscope
is maximum, no noise appears.
• Repeat the procedures in each adjustment several times, and the
tracking adjustment should be finally done by the trimmer
capacitors.
Adjustment Location: MAIN board (See page 14)
Adjustment Location: MAIN board (See page 14)
— 13 —
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