SONY XR-CA440H Service Manual

XR-CA440H

SERVICE MANUAL

Ver 1.0 2002.10

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

Tuner section

Tuning range FM tuning interval:

Aerial terminal External aerial connector Intermediate frequency 10.7 MHz Usable sensitivity 11 dBf Selectivity 75 dB at 400 kHz Signal-to-noise ratio 65 dB (stereo),

Harmonic distortion at 1 kHz

Separation 33 dB at 1 kHz Frequency response 30 – 15,000 Hz

Cassette type

TYPE II, IV 61 dB TYPE I

50 kHz/200 kHz switchable

87.5 – 108.0 MHz (at 50 kHz step)

87.5 – 107.9 MHz (at 200 kHz step)

68 dB (mono)

0.7 % (stereo),

0.5 % (mono)

58 dB

Tuning range MW tuning interval:

Sensitivity 30 µV

Tuning range SW tuning interval:

Aerial terminal External aerial connector Intermediate frequency 10.7 MHz/450 kHz Sensitivity 40 µV

Power amplifier section

Outputs Speaker outputs Speaker impedance 4 – 8 ohms

Maximum power output 50 W × 4 (at 4 ohms)

9 kHz/10 kHz switchable 531 – 1,602 kHz (at 9 kHz step) 530 – 1,710 kHz (at 10 kHz step)

SW1: 2,940 – 7,735 kHz SW2: 9,500 – 18,135 kHz (except for 10,140 – 11,575 kHz)

(sure seal connectors)

E Model

Model Name Using Similar Mechanism XR-CA440X Tape Transport Mechanism T ype MG-25F-136

General

Outputs Audio outputs

Inputs BUS control input term ina l

Tone controls Bass ±9 dB at 100 Hz Power requirements 12 V DC car battery Dimensions Approx. 178 × 50 × 178 Mounting dimensions Approx. 182 × 53 × 161 Mass Approx. 1.2 kg

Supplied accessories Parts for installation and

Note

This unit cannot be connected to a digital preamplifier or an equalizer.

Design and specifications are subject to change without notice.

Power aerial relay control lead Power amplifier contro l lead

BUS audio input terminal Aerial input terminal

Treble ±9 dB at 10 kHz (negative eart h )

mm (w/h/d) mm (w/h/d)

connections (1 set) Front panel case (1)

9-874-206-01 Sony Corporation

2002J0500-1 e Vehicle Company C 2002.10 Published by Sony Engineering Corporation

FM/MW/SW CASSETTE CAR STEREO

XR-CA440H

1. GENERAL

Location of Controls ....................................................... 3

Setting the Clock ............................................................. 3

2. DISASSEMBLY

2-1. Disassembly Flow ........................................................... 4

2-2. Collar ............................................................................... 4

2-3. Cover ............................................................................... 5

2-4. Mechanism Deck (MG-25F-136) ................................... 5

2-5. MAIN Board ................................................................... 6

2-6. Heat Sink ......................................................................... 6

3. ASSEMBLY OF MECHANISM DECK

3-1. Assembly Flow................................................................ 7

3-2. Housing ........................................................................... 8

3-3. Arm (Suction) ................................................................. 8

3-4. Lever (LDG-A)/(LDG-B) ............................................... 9

3-5. Gear (LDG-FT) ............................................................... 9

3-6. Guide (C)......................................................................... 10

3-7. Mounting Position of Capstan/Reel Motor (M901)....... 10

4. MECHANICAL ADJUSTMENTS....................... 11

5. ELECTRICAL ADJUSTMENTS

Tape Dec k Section .......................................................... 11

Tuner Section .................................................................. 11

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.

6. DIAGRAMS

6-1. Note for Printed Wiring Boards and

Schematic Diagrams ....................................................... 13

6-2. Printed Wiring Board – MAIN Board – ......................... 14

6-3. Schematic Diagram – MAIN Board (1/3) – ................... 15

6-4. Schematic Diagram – MAIN Board (2/3) – ................... 16

6-5. Schematic Diagram – MAIN Board (3/3) – ................... 17

6-6. Printed Wiring Board – KEY Board –............................ 18

6-7. Schematic Diagram – KEY Board – .............................. 19

6-8. IC Pin Function Description ........................................... 21

7. EXPLODED VIEWS

7-1. Chassis Section ............................................................... 24

7-2. Front Panel Section ......................................................... 25

7-3. MAIN Board Section ...................................................... 26

7-4. Mechanism Deck Section (MG-25F-136) ...................... 27

8. ELECTRICAL PARTS LIST ............................... 28

SECTION 1

GENERAL

XR-CA440H

This section is extracted from instruction manual.

Location of controls

Refer to the pages listed for details.

ATT

MODE

SEL

VOL

DISC

—

SENS

123456

SOURCE

RELEASE

a SOURCE (Power on/Tape/Radio/CD/

MD) select button

b MODE (o) button

Selecting the source.

c VOL +/– button d AT T (attenuate) button e Display window f Z (eject) button 8 g SEEK/AMS button

Tap e: Fast-forwarding, reversing a tape Radio: Tuning in stations automatically. Finding a station manually. CD (MP3 files)/MD: Skipping tracks.

h MBP (My Best sound Position) button

i D-BASS button 12 j RELEASE (front panel release) button k SEL (select) button

Selecting items.

l RESET button (located on the front side of

the unit, behind the front panel) 6

m SENS button

Storing the stations with the strongest signals.

SEEK

D-BASS

AMS

REP

SHUF BL

SKIP/ ALBM

-+/ATA

MTL

BTM

MBP

OFFDSPL

n Number buttons

Tap e:

(3): REP (Repeat) (5): BL SKIP (Blank Skip) (6): ATA (Automatic Tuner Activation)

Radio: Storing the desired station on each number button. CD (MP3 files)/MD:

(1): DISC – (2): DISC + (3): REP (Repeat) (4): SHUF (Shuffle)

MP3 files:

(5): ALBM – (6): ALBM +

o Frequency select switch (located on

the bottom of the unit)

See “Frequency select switch” in the Installation/Connections manual.

p BTM/MTL (Best Tuning Memory/Metal)

button 9

q DSPL (display mode change) button r OFF (Stop/Power off) button*

* Warning when installing in a car without

an ACC (accessory) position on the ignition switch

After turning off the ignition, be sure to press (OFF) on the unit for 2 seconds to turn off the clock display.

Otherwise, the clock display does not turn off and this causes battery drain.

Setting the clock

The clock uses a 12-hour digital indication.

Example: To set the clock to 10:08

Press (DSPL) for 2 seconds.

The hour indication flashes.

1Press either side of (VOL) to set the

hour.

to go forward

VOL

to go back

2Press (SEL).

The minute indication flashes.

3Press either side of (VOL) to set the

minute.

to go forward

VOL

to go back

Press (DSPL).

The clock starts.

After the clock setting is completed, the display returns to normal play mode.

XR-CA440H

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

2-1. DISASSEMBLY FLOW

Note 1: The process described in can be performed in any order. Note 2: Without completing the process described in , the next process can not be performed. Note 3: Illustration of disassembly is omitted.

SECTION 2

DISASSEMBLY

SET

FRONT PANEL SECTION

(Note 3)

2-4. MECHANISM DECK (MG-25F-136)

(Page 5)

2-5. MAIN BOARD

(Page 6)

2-6. HEAT SINK

(Page 6)

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

2-2. COLLAR

(Page 4)

2-3. COVER

(Page 5)

Remove the bracket

screw (K5 × 8)

in the direction of arrow A.

collar

Remove the bracket in the direction of arrow B.

screw (K5 × 8)

2-3. COVER

)

screw (PTT2.6 × 5)

XR-CA440H

cove

2-4. MECHANISM DECK (MG-25F-136)

connector (CN351)

sub panel assy

mechanism deck (MG-25F-136)

screw (PTT2.6 × 6

flexible board (CN301)

screw (PTT2.6 × 6)

four screws (PTT2.6 × 6)

XR-CA440H

)

2-5. MAIN BOARD

main board

two ground point screws

rubber cap (25)

screw (PTT2.6 × 10)

two screws (PTT2.6 × 10

2-6. HEAT SINK

heat sink

seven screws (PTT2.6

ASSEMBLY OF MECHANISM DECK

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

3-1. ASSEMBLY FLOW

XR-CA440H

SECTION 3

3-2. HOUSING

(Page 8)

3-3. ARM (SUCTION)

(Page 8)

3-4. LEVER (LDG-A)/(LDG-B)

(Page 9)

3-5. GEAR (LDG-FT)

(Page 9)

3-6. GUIDE (C)

(Page 10)

3-7. MOUNTING POSITION

OF CAPSTAN/REEL MOTOR (M901) (Page 10)

XR-CA440H

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

3-2. HOUSING

5 Fit projection on C part.

2 Install the hanger onto

two claws of the housing.

4 Fit claw on B part.

7 Hold the hanger by bending the claw.

1 Install the catch to the hanger.

hanger

3 Put the housing

under A part.

housing

A part

6 Fit projection on D part.

C part

8 Hold the hanger by

bending the claw.

D part

B part

3-3. ARM (SUCTION)

2 Move the arm (suction) in the arrow

direction and fit on projection.

projection

1 Fit the arm (suction) on the shaft.

3-4. LEVER (LDG-A) / (LDG-B)

)

XR-CA440H

shaft A

1 Fit the lever (LDG-A) on

shafts A – C and install it.

shaft B

shaft C

shaft A

shaft B

3 type-E stop ring 2.0

2 Fit the lever (LDG-B) on

shafts A and B and install it.

3-5. GEAR (LDG-FT)

hole

4 Align hole in the gear (LDG-D)

with hole the lever (LDG-A).

2 tension spring (LD-2)

gear (LDG-D)

6 polyethylene washer

5 gear (LDG-FT)

lever (LDG-A)

gear (LDG-FB)

2 tension spring (LD-1)

3 Move the lever (LDG-B

in the arrow direction.

XR-CA440H

3-6. GUIDE (C)

2 guide (C)

1 three claws

3-7. MOUNTING POSITION OF CAPSTAN/REEL MOTOR (M901)

Note: Mount the motor so that the

angle between of the motor and the hole for the screw becomes 30 shown in this figure.

two precision screw (P2 × 2)

capstan/reel motor (M901)

30˚

SECTION 4

MECHANICAL ADJUSTMENTS

XR-CA440H

SECTION 5

ELECTRICAL ADJUSTMENTS

1. Clean the f ollowing 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. The adjustments should be performed with the power supply voltage (14.4 V) unless otherwise noted.

TORQUE MEASUREMENT

Mode Torque Meter Meter Reading

Forward CQ-102C (30 – 65 g•cm)

Forward Back Tension

Reverse CQ-102RC (30 – 65 g•cm)

Reverse Back Tension

FF, REW CQ-201B (60 – 200 g•cm)

CQ-102C (0.5 – 4.5g•cm)

CQ-102RC (0.5 – 4.5g•cm)

2.95 – 6.37 mN•m

(0.42 – 0.90 oz•inch)

0.05 – 0.44 mN•m

(0.01 – 0.06 oz•inch)

2.95 – 6.37 mN•m

(0.42 – 0.90 oz•inch)

0.05 – 0.44 mN•m

(0.01 – 0.06 oz•inch)

5.89 – 19.61 mN•m

(0.83 – 2.78 oz•inch)

TAPE DECK SECTION

0 dB=0.775 V

TAPE SPEED ADJUSTMENT

Setting:

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

set

frequency counte

10 kΩ

+ –

AUDIO OUT jack (J331)

Procedure:

1. Put the set into the FWD PB mode.

2. Adjust adjustment resistor for inside capstan motor so that the reading on the frequency counter becomes 3,000 Hz.

Specified Value: Constant speed

Frequency counter

2,955 to 3,075 Hz

Adjustment Location:

– SET UPPER VIEW –

TAPE TENSION MEASUREMENT

Mode Tension Meter Meter Reading

Forward CQ-403A

Reverse CQ-403R

(more than 2.12 oz)

Tape Speed Adjustment

more than 60 g

TUNER SECTION

Tuner section adjustments are done automatically in this set.

+ 25 hidden pages

SONY XR-CA440H Service Manual

TABLE OF CONTENTS

GENERAL

2-1. DISASSEMBLY FLOW

DISASSEMBLY

collar

2-3. COVER

mechanism deck (MG-25F-136)

main board

heat sink

ASSEMBLY OF MECHANISM DECK

3-1. ASSEMBLY FLOW

housing

3-3. ARM (SUCTION)

3-4. LEVER (LDG-A) / (LDG-B)

5 gear (LDG-FT)

2 guide (C)

3-7. MOUNTING POSITION OF CAPSTAN/REEL MOTOR (M901)

MECHANICAL ADJUSTMENTS

ELECTRICAL ADJUSTMENTS

TAPE DECK SECTION

TUNER SECTION