Sony XR-C540RDS Service manual
XR-C540RDS
SERVICE MANUAL
Ver 1.1 2001.06
For RM-X2S (Remote Commander),
please refer to RM-X2S/X3S Service
Manual (9-960-039-S) previously issued.
AEP Model
UK Model
Dolby noise reduction manufactured under license
from Dolby Laboratories Licensing Corporation.
“DOLBY” and the double-D symbol ; are trademarks
of Dolby Laboratories Licensing Corporation.
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 64 dB (Dolby B NR)
58 dB (Dolby NR off)
Tuner section
FM
Tuning range 87.5 – 108.0 MHz
Antenna terminal External antenna connector
Intermediate frequency 10.7 MHz
Usable sensitivity 8 dBf
Selectivity 75 dB at 400 kHz
Signal-to-noise ratio 65 dB (stereo),
70 dB (mono)
Harmonic distortion at 1 kHz 0.5% (stereo),
0.3% (mono)
Separation 35 dB at 1 kHz
Frequency response 30 – 15,000 Hz
Capture ratio 4 dB
MW/LW
Tuning range MW: 531 – 1,602 kHz
LW: 153 – 281 kHz
Antenna terminal External antenna connector
Intermediate frequency 10.71 Mhz/450 kHz
Sensitivity MW: 30 µV
LW : 50 µV
SPECIFICATIONS
Power amplifier section
Outputs Speaker outputs
Speaker impedance 4 – 8 ohms
Maximum power output 35 W × 4 (at 4 ohms)
General
Outputs Power amplifier control lead
Tone controls Bass ± 8 dB at 100 Hz
Power requirements 12 V DC car battery (negative ground)
Dimensions Approx. 188 × 58 × 181 mm (w/h/d)
Mounting dimensions Approx. 182 × 53 × 164 mm (w/h/d)
Mass Approx. 1.2 kg
Supplied accessories Parts for installation and connections
Design and specifications are subject to change without notice.
Model Name Using Similar Mechanism NEW
T ape Transport Mechanism Type
(sure seal connectors)
Rear line out (1)
Treble ± 8 dB at 10 kHz
(1 set)
Rotary commander RM-X2S
Front panel case (1)
MG-52B-136
FM/MW/LW CASSETTE CAR STEREO
9-925-543-12 Sony Corporation
2001F0500-1 e Vehicle Company
C 2001.6 Shinagawa Tec Service Manual Production Group
TABLE OF CONTENTS
SERVICING NOTES
1. GENERAL
Location of Controls ........................................................ 3
Setting the Clock ............................................................. 3
Using the Rotary Remote ................................................ 3
Adjusting the Sound Characteristics ............................... 4
Muting the Sound ............................................................ 4
Changing the Sound and Beep Tone................................ 4
Installation ....................................................................... 5
Connections ..................................................................... 6
2. DISASSEMBLY.......................................................... 9
3. ASSEMBLY OF MECHANISM DECK............. 11
4. MECHANICAL ADJUSTMENTS ....................... 14
5. ELECTRICAL ADJUSTMENTS
Test Mode ........................................................................ 14
Tape Deck Section ........................................................... 14
Tuner Section................................................................... 15
6. DIAGRAMS
6-1. Printed Wiring Boards –Main Section–.......................... 22
6-2. Schematic Diagram –Main Section– .............................. 25
6-3. Schematic Diagram –Panel Section–.............................. 30
6-4. Printed Wiring Board –Panel Section–........................... 33
6-5. IC Pin Function Description ............................................ 35
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.
7. EXPLODED VIEWS ................................................ 37
8. ELECTRICAL PARTS LIST................................ 40
– 2 –
SECTION 1
GENERAL
This section is extracted
from instruction manual.
– 3 –
– 4 –
– 5 –
– 6 –
– 7 –
– 8 –
SECTION 2
DISASSEMBLY
Note: Follow the disassembly procedure in the numerical order given.
FRONT PANEL ASS’Y
1
Push the button
(release).
A
2
Remove the front panel ass’y
to the direction of the arrow A.
COVER ASS’Y
1
2
3
cover ass’y
2
1
– 9 –
SUB PANEL, MECHANISM DECK (MG-25B-136)
3
connector
(CN302)
2
sub panel
1
three screws
(PTT2.6 × 8)
5
screw
(PTT2.6 × 6)
6
mechanism deck (MG-25B-136)
4
flexible flat cable
(CN301)
1
three screws
(PTT2.6 × 8)
MAIN BOARD, HEAT SINK
2
two ground point
screws
3
main board
1
5
heat sink
4
seven screws
(PTT2.6 × 8)
screw
(PTT2.6 × 8)
– 10 –
1
two screws
(PTT2.6 × 8)
SECTION 3
ASSEMBLY OF MECHANISM DECK
Note: Follow the assembly procedure in the numerical order given.
HOUSING
4
Fit claw on B part.
3
2
Install the hanger onto
two claws of the housing.
Put the housing
under A part.
housing
A
part
5
Fit projection on C part.
C
part
7
Hold the hanger by bending the claw.
1
Install the catch to the hanger.
hanger
6
Fit projection on D part.
8
Hold the hanger by
bending the claw.
D
part
ARM (SUCTION)
B
projection
part
2
Move the arm (suction) in the arrow
direction and fit on projection.
1
Fit the arm (suction) on the shaft.
– 11 –
LEVER (LDG-A) / (LDG-B)
shaft
A
shaft
1
Fit the lever (LDG-A) on
shafts A – C and install it.
B
shaft
C
4
type-E stop ring 2.0
shaft
A
shaft
C
2
3
Fit the lever (LDG-B) on
shafts A and C and
install it.
Pull the lever in the
arrow direction.
GEAR (LDG-FT)
hole
hole
gear (LDG-D)
lever (LDG-A)
gear (LDG-FB)
4
gear (LDG-FT)
5
polyethylene washer
1
2
Move the lever (LDG-B)
in the arrow direction.
tension spring (lever LDG)
3
Align hole in the gear (LDG-D)
with hole in the lever (LDG-A).
– 12 –
GUIDE (C)
1
three claws
2
guide (C)
– 13 –
r
r
SECTION 4
MECHANICAL ADJUSTMENTS
1. Clean the following parts with a denatured-alcohol-moistene
swab:
playback head pinch roller
rubber belt capstan
idlers
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.
• T orque Measurement
Mode Torqu Meter Meter Reading
Forward CQ-102C
Forward
Back Tension (0.01 – 0.06 oz•inch)
CQ-102C
Reverse CQ-102RC
Reverse
Back Tension (0.01 – 0.06 oz•inch)
CA-102RC
FF, REW CQ-201B
30 – 65 g•cm
(0.42 – 0.90 oz•inch)
0.5 – 4.5 g•cm
30 – 65 g•cm
(0.42 – 0.90 oz•inch)
0.5 – 4.5 g•cm
60 – 200 g•cm
(0.83 – 2.78 oz•inch)
See the adjustment location from on page 17 for the
adjustment.
0 dB=0.775 VTAPE DECK SECTION
Tape Speed Adjustment
Procedure:
1. Put the set into the FWD PB mode.
speed checker
or
test tape
WS-48A
(3 kHz, 0 dB)
set
speaker out terminal
frequency counte
4
Ω
+–
Specification: Constant speed
Speed checker Frequency counter
–1.5 to +2.5% 2,955 to 3,075 Hz
Adjustment Location: See page 17.
• T ape Tension 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)
SECTION 5
ELECTRICAL ADJUSTMENTS
TEST MODE
This set have the test mode function. In the test mode, FM Auto
Scan/Stop Level and AM (MW) Auto Scan/Stop Lev el adjustments
can be performed easier than it in ordinary procedure.
<Set the Test Mode>
1. Set the “power select” switch (S801) is “A” 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.
DOLBY Level Adjustment
Setting:
Preset 3 (DOLBY) button : OFF
SEL (VOL) button : Maximum
test tape
P-4-D400
(400 Hz, 0 dB)
set
MAIN board
TP (DOLBY)
level mete
+
–
L-CH
R-CH
Pocedure:
1. Put the set into the FWD PB mode.
2. Adjust RV401 (L-CH) and RV301 (R-CH) so that level meter
reading is – 6 ± 1 dB (0.35 to 0.43 V).
3. Select the REV play mode, and confirm that level meter reading is within the specification given above.
Adjustment Location: See page 17.
<Release the Test mode>
1. Push the OFF button.
2. Return the “power select” switch (S801) to initially aet position.
– 14 –
TUNER SECTION
FM RF signal
generator
Carrier frequency : 98.00 MHz
Output level : 60 dB (1 mV)
Mode : mono
Modulation : 1 kHz, 75 kHz deviation (100%)
0.01 µF
set
antenna jack (J1)
+
–
speaker out terminal
level meter
4
Ω
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 Noise Focus Adjustment
3. FM Stereo Separation Adjustment
4. FM Signal Meter Adjustment
5. MW Auto Scan/Stop Level Adjustment
FM Auto Scan/Stop Level Adjustment
Setting:
SOURCE button: FM
FM RF signal
generator
Carrier frequency : 98.00 MHz
Output level : 22 dB (12.6
Mode : mono
Modulation : 1 kHz, 22.5 kHz deviation (30%)
antenna jack (J1)
0.01 µF
set
µ
V)
FM Noise Focus Adjustment
Setting:
SOURCE button: FM
Procedure:
1. Tune the 98.00 MHz.
2. The then output level is supposing that (A) dB.
3. Adjust with the volume RV3 on TU1 so that the output level is
(A) –32 ± 3 dB then signal generator input set to –20 dB.
Adjustment Location: See page 17.
FM Stereo Separation Adjustment
Setting:
SOURCE button: FM
Procedure:
1. Set to the test mode. (See page 14).
2. Push the SOURCE button and set to FM.
Display
REG
FM
INTRO
3. Adjust with the volume R V2 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
REG
INTRO
Adjustment Location: See page 17.
FM RF signal
generator
Carrier frequency : 98.00 MHz
Output level : 70 dB (3.2 mV)
Mode : stereo
Modulation : main: 1 kHz, 20 kHz deviation (22.6%)
antenna jack (J1)
0.01 µF
set
sub: 1 kHz, 20 kHz deviation (22.6%)
19 kHz pilot: 7.5 kHz deviation (10%)
4
Ω
speaker out terminal
level meter
Procedure:
FM Stereo
signal generator
output channel
Level meter Level meter
connection reading (dB)
L-CH L-CH A
B
R-CH L-CH Adjust RV4 on TU1
for minimum reading.
R-CH R-CH C
D
L-CH R-CH Adjust RV4 on TU1
for minimum reading.
+
–
L-CH Stereo separation: A-B
R-CH Stereo separation: C-D
The separations of both channels should be equal.
Specification: Separation more than 30 dB
Adjustment Location: See page 17.
– 15 –
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