Sony XR-C5120RA Service manual

XR-C5120RA

SERVICE MANUAL

SPECIFICATIONS

Cassette player section

Tape track 4-track 2-channel stereo Wow and flutter 0.08 % (WRMS) Frequency response 30 – 18,000 Hz Signal-to-noise ratio

Cassette type

TYPE II, IV 61 dB

TYPE I 58 dB

Tuner section

Tuning range 87.5 – 108.0 MHz Aerial terminal External aerial connector Intermediate frequency 10.7 MHz Usable sensitivity 9 dBf Selectivity 75 dB at 400 kHz Signal-to-noise ratio 65 dB (stereo),

Harmonic distortion at 1 kHz

Separation 35 dB at 1 kHz Frequency response 30 – 15,000 Hz

MW/LW

Tuning range MW: 531 – 1,602 kHz

Aerial terminal External aerial connector Intermediate frequency 10.7 MHz/450 kHz Sensitivity MW: 30 µV

68 dB (mono)

0.7 % (stereo),

0.4 % (mono)

LW: 153 – 281 kHz

LW: 50 µV

AEP Model

Model Name Using Similar Mechanism XR-C5100R Tape Transport Mechanism Type MG-25G-136

Power amplifier section

Outputs Speaker outputs

Speaker impedance 4 – 8 ohms Maximum power output 40 W × 4 (at 4 ohms)

General

Outputs Audio output

Tone controls Bass ±8 dB at 100 Hz

Power requirements 12 V DC car battery Dimensions Approx. 188 × 58 × 181 mm Mounting dimensions Approx. 182 × 53 × 164 mm

Mass Approx. 1.2 kg Supplied accessories

Design and specifications are subject to change without notice.

(sure seal connectors)

Power aerial relay control lead Power amplifier control lead Telephone ATT control lead

Treble ±8 dB at 10 kHz

(negative earth)

(w/h/d)

Parts for installation and connections (1 set) Front panel case (1)

UK Model

MICROFILM

FM/MW/LW CASSETTE CAR STEREO

TABLE OF CONTENTS

1. GENERAL

Location of controls ........................................................ 3

Resetting the unit ............................................................ 3

Detaching the front panel................................................ 3

Setting the clock.............................................................. 3

2. DISASSEMBLY ......................................................... 4

3. ASSEMBLY OF MECHANISM DECK........... 5

4. MECHANICAL ADJUSTMENTS ....................... 8

5. ELECTRICAL ADJUSTMENTS......................... 8

6. DIAGRAMS

6-1. Block Diagram – TUNER Section – .............................. 12

6-2. Block Diagram – TAPE/MAIN Section – ...................... 13

6-3. Block Diagram – DISPLAY/

KEY CONTROL/BUS CONTROL/

POWER SUPPLY Section – ........................................... 14

6-4. Note for Printed Wiring Boards and

Schematic Diagrams ....................................................... 15

6-5. Printed Wiring Board

– MAIN Board (Component Side) – .............................. 16

6-6. Printed Wiring Board

– MAIN Board (Conductor Side) – ................................ 17

6-7. Schematic Diagram – MAIN Board (1/2) – ................... 18

6-8. Schematic Diagram – MAIN Board (2/2) – ................... 19

6-9. Printed Wiring Board – KEY Board –........................... 20

6-10. Schematic Diagram – KEY Board – ............................. 21

6-11. IC Pin Function Description ........................................... 24

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.

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.

7. EXPLODED VIEWS................................................ 28

8. ELECTRICAL PARTS LIST ............................... 31

Location of controls

SECTION 1

GENERAL

Getting Started

This section is extracted from instruction manual.

Attaching the front panel

Attach part of the front panel to part of the unit as illustrated and push the left side into position until it clicks.

SOURCE

SOUND

OFF

SHIFT SET UP

MODE

SEEK / AMS

RELEASE

Refer to the pages listed for details.

1 SEEK/AMS (seek/Automatic Music

Sensor/manual search) control 6, 8, 10, 13, 19

2 MODE (o)button

During tape playback:

Playback direction change 6

During radio reception:

BAND select 7, 8

During CD or MD playback:

CD/MD unit select 18

3 SOURCE (TAPE/TUNER/CD/MD) button

6, 7, 8, 11, 18

4 Dial (volume/bass/treble/left-right/rear-

front control) 5, 16

5 SOUND button 16 6 Display window 7 DSPL (display mode change) button

6, 8, 9, 18

8 Z (eject) button 6 9 PTY button

RDS Programme 13

PRESET

–

DISC

PLAY MODE

0… PRESET/DISC button

During radio reception:

Preset stations select 8

During CD/MD playback:

Disc change 19

qa` AF/TA button

9, 10, 11, 12

qs“ RELEASE (front panel release) button

4, 21

qd Reset button (located on the front side

of the unit behind the front panel) 4

qf OFF button 4, 6 qg SHIFT button

PLAY MODE 7, 8, 10, 12, 19 SET UP 5, 13, 16, 18

qh POWER SELECT switch

(located on the bottom of the unit)

See “POWER SELECT switch” in the Installation/Connections manual.

qj Number buttons 8, 10, 12 qk D-BASS control 17

D-BASS

AF/TAPTYDSPL

OFF

564321

Resetting the unit

Before operating the unit for the first time or after replacing the car battery, you must reset the unit. Remove the front panel and press the reset button with a pointed object, such as a ballpoint pen.

Reset button

Note

Pressing the reset button will erase the clock setting and some memorized functions.

Detaching the front panel

You can detach the front panel of this unit to protect the unit from being stolen.

Press (OFF).

Press (RELEASE), then slide the front panel a little to the left, and pull it off towards you.

(RELEASE)

Notes

• Be sure not to drop the panel when detaching it from the unit.

• If you detach the panel while the unit is still turned on, the power will turn off automatically to prevent the speakers from being damaged.

• When carrying the front panel with you, use the supplied front panel case.

(OFF)

Notes

• Be sure not to attach the front panel upside down.

• Do not press the front panel too hard against the unit when attaching it.

• Do not press too hard or put excessive pressure on the display window of the front panel.

• Do not expose the front panel to direct sunlight or heat sources such as hot air ducts, and do not leave it in a humid place. Never leave it on the dashboard of a car parked in direct sunlight or where there may be a considerable rise in temperature.

Caution alarm

If you turn the ignition key switch to the OFF position without removing the front panel, the caution alarm will beep for a few seconds (only when the POWER SELECT switch on the bottom of the unit is set to the A position). If you connect an optional power amplifier and do not use the built-in amplifier, the beep sound will be deactivated.

Setting the clock

The clock uses a 24-hour digital indication.

Example: To set the clock to 10:08

Press (SHIFT), then press (2) (SET UP) repeatedly until “CLOCK” appears.

1 Press (4) (t).

The hour indication flashes.

2 Set the hour.

to go backward

to go forward

3 Press (4) (t).

The minute indication flashes.

4 Set the minute.

to go backward

to go forward

Press (SHIFT).

The clock starts.

Press (SHIFT).

After the clock setting is complete, the display returns to normal playback mode.

Note

If the POWER SELECT switch on the bottom of the unit is set to the B position, turn the power on first, then set the clock.

SECTION 2

DISASSEMBLY

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

SUB PANEL, MECHANISM DECK (MG-25G-136)

connector (CN302)

sub panel

screw (PTT2.6

flexible flat cable (CN301)

mechanism dec (MG-25G-136)

three screws (PTT2.6

MAIN BOARD, HEAT SINK

two ground point screws

main board

three screws (PTT2.6

rubber cap (25)

heat sink

screw (PTT2.6

three screws (PTT2.6

two screws (PTT2.6

12)

two screws (PTT2.6

SECTION 3

Move the arm (suction) in the arrow direction and fit on projection.

Fit the arm (suction) on the shaft.

projection

ASSEMBLY OF MECHANISM DECK

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

HOUSING

Fit projection on C part.

2

Install the hanger onto two claws of the housing.

Fit claw on B part.

Put the housing under

part.

housing

part

Holder the hanger by bending the claw.

Install the catch to the hanger.

hanger

Fit projection on D part.

Hold the hanger by bending the claw.

ARM (SUCTION)

part

LEVER (LDG-A) / (LDG-B)

)

shaft

Fit the lever (LDG-A) on shafts A – C and install it.

shaft

type-E stop ring 2.0

shaft

Fit the lever (LDG-B) on

shafts install it.

and B and

shaft

GEAR (LDG-FT)

hole

gear (LDG-D)

lever (LDG-A)

gear (LDG-FB)

Align hole in the gear (LDG-D) with hole the lever (LDG-A).

tension spring (LD-2)

gear (LDG-FT)

polyethylene washer

Move the lever (LDG-B

tension spring (LD-1)

in the arrow direction.

GUIDE (C)

guide (C)

three claws

MOUNTING POSITION OF CAPSTAN/REEL MOTOR (M901)

two precision screws

(P2

capstan/reel motor (M901)

30˚

SECTION 4

MECHANICAL ADJUSTMENTS

SECTION 5

ELECTRICAL ADJUSTMENTS

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

playback head pinch roller rubber belt capstan idler

2. Demagnetize the 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 power supply voltage unless otherwise noted.

• Tor que Measurement

Mode Torque Meter Meter Reading

Forward CQ-102C Forward

Back Tension (0.01 – 0.06 oz•inch) Reverse CQ-102RC Reverse

Back Tension (0.01 – 0.06 oz•inch) FF, REW CQ-201B

CQ-102C

CQ-102RC

30 – 65 g•cm

(0.42 – 0.90 oz•inch)

0.5 – 4.5g•cm

30 – 65 g•cm

(0.42 – 0.90 oz•inch)

0.5 – 4.5g•cm

60 – 200 g•cm

(0.83 – 2.78 oz•inch)

• Tape T ension Measurement

Mode Tension Meter Meter Reading

Forward CQ-403A

Reverse CQ-403R

more than 90 g

(more than 3.18 oz)

more than 90 g

(more than 3.18 oz)

TEST MODE

This set have the test mode function. In the test mode, FM Auto Scan/Stop Level and AM (MW) Auto Scan/Stop Level adjustments can be performed easier than it in ordinary procedure.

1. Set the “power select” switch (S501) is “A (ON)” position.

2. Turn ON the regulated power supply. (All LEDs on the set lights up, and the clock is displayed.)

Note: Press the [OFF] button, if the clock is not displayed.

3. Push the preset [4] button.

4. Push the preset [5] button.

5. Press the preset [1] button for more than two seconds.

6. Then the display indicates all lights, the test mode is set.

1. Push the [OFF] button.

2. Return the “power select” switch (S501) to initially set position.

See the adjustment location from on page 11 for the adjustment.

TAPE DECK SECTION

0 dB=0.775 V

Tape Speed Adjustment

Setting:

speed checker

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

frequency counte

10 k

Ω

set

AUDIO OUT jack (CNJ151)

+–

Procedure:

1. Put the set into the FWD PB mode.

2. Adjust adjustment resistor for inside capstan motor so that the reading on the speed checker or frequency counter becomes in specification.

Specification: Constant speed

Speed checker Frequency counter

–1.5 to +2.5% 2,955 to 3,075 Hz

Adjustment Location: See page 11.

TUNER SECTION

0 dB=1 µV

Cautions during repair

When the tuner unit is defective, replace it by a new one because its internal block is difficult to repair.

Note:

Adjust the tuner section in the sequence shown below.

1. FM Auto Scan/Stop Level Adjustment

2. FM Stereo Separation Adjustment

3. FM RDS S Meter Adjustment

4. MW Auto Scan/Stop Level Adjustment

FM Auto Scan/Stop Level Adjustment

Setting:

[SOURCE] button: FM

FM RF signal

generator

Carrier frequency : 98.0 MHz Output level : 22 dB (12.6 Mode : mono Modulation : 1 kHz, 22.5 kHz deviation (30%)

Procedure:

1. Set to the test mode. (See page 8)

2. Push the [SOURCE] button and set to FM.

antenna jack (J1)

0.01 µF

Display

set

FM Stereo Separation Adjustment

Setting:

[SOURCE] button: FM

FM RF signal

generator

Carrier frequency : 98.0 MHz Output level : 70 dB (3.2 mV) Mode : stereo Modulation : main: 1 kHz, 20 kHz deviation (26.7%)

antenna jack (J1)

0.01 µF set

sub: 1 kHz, 20 kHz deviation (26.7%)

: 19 kHz pilot: 7.5 kHz deviation (10%)

10 k

AUDIO OUT jack (CNJ151)

Procedure:

FM Stereo

signal generator

output channel

L-CH L-CH A

R-CH L-CH Adjust RV4 on TU1

R-CH R-CH C

L-CH R-CH Adjust RV4 on TU1

Level meter Level meter

connection reading (dB)

for minimum reading.

L-CH Stereo separation: A-B R-CH Stereo separation: C-D The separations of both channels should be equal.

level meter

Ω

+ –

SHUF

3. Adjust with the v olume RV2 on TU1 so that the “FM” indication turns to “FM0” indication on the display window. But, in case of already indicated “FM0”, turn the RV2 so that put out light “0” indication and adjustment.

Display

SHUF

Adjustment Location: See page 11.

Specification: Separation more than 30 dB

Adjustment Location: See page 11.

FM RDS S Meter Adjustment

(

)

Setting:

[SOURCE] button: FM

FM RF signal

generator

Carrier frequency : 98.00 MHz Output level : 35 dB (56.2 Mode : mono Modulation : no modulation

Procedure:

1. Set to the test mode. (See page 8)

2. Push the [SOURCE] button and set to FM.

3. Push the [6] button.

4. Adjust RV1 so that the display indication is “10.2”.

0.01 µF

Display

antenna jack (J1)

set

SHUF

MW Auto Scan/Stop Level Adjustment

Make this adjustment after “FM Auto Scan/Stop Level Adjustment”.

Setting:

[SOURCE] button: MW

Ω

15 pF

65 pF

AM RF signal

generator

AM dummy antenna (50 Ω)

Carrier frequency : 999 kHz 30% amplitude modulation by 1 kHz signal Output level : 33 dB

44.7 µV

Procedure:

1. Set to the test mode. (See page 8)

2. Push the

[SOURCE] button and set to FM.

3. Push the [MODE] button and set to MW.

set

antenna jack (J1)

Display

Specification: Display indication: 10.0 to 10.4

Adjustment Location: See page 11.

SHUF

Display

TP SHUF

4. Adjust with the volume RV1 on TU1 so that the “MW” indication turns to “MW0” indication on the display window. But, in case of already indicated “MW0”, turn the R V1 so that put out light “0” indication and adjustment.

Display

TP SHUF

Adjustment Location: See page 11.

Adjustment Location:

– SET UPPER VIEW –

Tape Speed Adjustment

TU1

RV1 MW Auto Scan/Stop Level Adjustmen

RV2 FM Auto Scan/Stop Level Adjustment

RV4 FM Stereo Separation Adjustment

RV1 FM RDS S Meter Adjustment

1111

+ 25 hidden pages