Sony XR-3100R User manual

MICROFILM
SERVICE MANUAL
FM/MW/LW CASSETTE CAR STEREO
AEP Model
UK Model
SPECIFICATIONS
XR-3100R/C33R
Photo: XR-C33R
Model Name Using Similar Mechanism XR-C5100R
Tape Transport Mechanism Type MG-25G-136

2
TABLE OF CONTENTS
1. GENERAL
Location of controls ........................................................ 3
Resetteing the unit........................................................... 4
Detaching the front panel................................................ 4
Setting the clock.............................................................. 4
Installation....................................................................... 5
Connections ..................................................................... 6
2. DISASSEMBLY ......................................................... 10
3. ASSEMBLY OF MECHANISM DECK........... 11
4. MECHANICAL ADJUSTMENTS....................... 14
5. ELECTRICAL ADJUSTMENTS......................... 14
6. DIAGRAMS
6-1. Block Diagram – TUNER Section – .............................. 18
6-2. Block Diagram – TAPE/MAIN Section – ...................... 19
6-3. Block Diagram – DISPLAY/KEY CONTROL/
BUS CONTROL/POWER SUPPLY Section – .............. 20
6-4. Note for Printed Wiring Boards and
Schematic Diagrams ....................................................... 21
6-5. Printed Wiring Board
– MAIN Board (Component Side) – .............................. 22
6-6. Printed Wiring Board
– MAIN Board (Conductor Side) – ................................ 23
6-7. Schematic Diagram – MAIN Board (1/3) – ................... 24
6-8. Schematic Diagram – MAIN Board (2/3) – ................... 25
6-9. Schematic Diagram – MAIN Board (3/3) – ................... 26
6-10. Printed Wiring Board – KEY Board –........................... 30
6-11. Schematic Diagram – KEY Board – ............................. 31
6-12. IC Pin Function Description ........................................... 32
7. EXPLODED VIEWS................................................ 35
8. ELECTRICAL PARTS LIST ............................... 38
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.

3
SECTION 1
GENERAL This section is extracted from
instruction manual.

4

5

6

7
(XR-3100R)

8
(XR-C33R)

9

10
SUB PANEL, MECHANISM DECK (MG-25G-136)
MAIN BOARD, HEAT SINK
Note: Follow the disassembly procedure in the numerical order given.
SECTION 2
DISASSEMBLY
1 three screws
(PTT2.6
× 8)
2 sub panel
3 connector
(CN302)
5 screw
(PTT2.6
× 6)
6 mechanism dec
k
(MG-25G-136)
4 flexible flat cable
(CN301)
1 three screws
(PTT2.6
× 8)
3 two ground point
screws
5 screw
(PTT2.6
× 8) (C33R
)
5 screw
(PTT2.6
× 8) (C33R)
5 two screws
(PTT2.6
× 8)
6 three screws
(PTT2.6
× 12)
1 screw
(PTT2.6
× 8)
5 screw
(PTT2.6
× 8)
7 heat sink
2 rubber cap (25)
1 two screws
(PTT2.6
× 8)
4 main board

11
HOUSING
ARM (SUCTION)
Note: Follow the assembly procedure in the numerical order given.
SECTION 3
ASSEMBLY OF MECHANISM DECK
A part
C part
B part
D part
8 Hold the hanger by
bending the claw.
6 Fit projection on D part.
4 Fit claw on B part.
3 Put the housing
under
A part.
5 Fit projection on C part.
1 Install the catch to the hanger.
2 Install the hanger onto
two claws of the housing.
7 Holder the hanger by bending the claw.
hanger
housing
2 Move the arm (suction) in the arrow
direction and fit on projection.
1 Fit the arm (suction) on the shaft.
projection

12
LEVER (LDG-A) / (LDG-B)
GEAR (LDG-FT)
shaft A
shaft B
shaft C
1
Fit the lever (LDG-A) on
shafts A – C and install it.
shaft A
shaft B
2
Fit the lever (LDG-B) on
shafts
A and B and
install it.
3 type-E stop ring 2.0
gear (LDG-D)
5 gear (LDG-FT)
6 polyethylene washer
2 tension spring (LD-2)
2 tension spring (LD-1)
gear (LDG-FB)
lever (LDG-A)
hole
hole
4 Align hole in the gear (LDG-D)
with hole the lever (LDG-A).
3 Move the lever (LDG-B
)
in the arrow direction.
1

13
GUIDE (C)
MOUNTING POSITION OF CAPSTAN/REEL MOTOR (M901)
2 guide (C)
1 three claws
two precision screws
(P2
× 2)
capstan/reel motor
(M901)
30˚

14
SECTION 4
MECHANICAL ADJUSTMENTS SECTION 5 ELECTRICAL ADJUSTMENTS
TEST MODE
This set have the test mode function. In the test mode, FM Auto
Scan/Stop Level and MW Auto Scan/Stop Level adjustments can
be performed easier than it in ordinary procedure.
<Set the Test Mode>
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.
<Release the Test mode>
1. Push the [OFF] button.
2. Return the “power select” switch (S501) to initially set posi-
tion.
See the adjustment location from on page 17 for the
adjustment.
0 dB=0.775 V
Tape Speed Adjustment
Setting:
Speed checker Frequency counter
–1.5 to +2.5% 2,955 to 3,075 Hz
TAPE DECK SECTION
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
Adjustment Location: See page 17.
set +–
test tape
WS-48A
(3 kHz, 0 dB)
AUDIO OUT jack (CNJ151)
10 k Ω
speed checker
or
frequency counte
r
•TapeTension Measurement
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.
•Torque Measurement
Mode Torque Meter Meter Reading
Forward CQ-102C 30 – 65 g•cm
(0.42 – 0.90 oz•inch)
Forward CQ-102C 0.5 – 4.5g•cm
Back Tension (0.01 – 0.06 oz•inch)
Reverse CQ-102RC 30 – 65 g•cm
(0.42 – 0.90 oz•inch)
Reverse CQ-102RC 0.5 – 4.5g•cm
Back Tension (0.01 – 0.06 oz•inch)
FF, REW CQ-201B 60 – 200 g•cm
(0.83 – 2.78 oz•inch)
Mode Tension Meter Meter Reading
Forward CQ-403A more than 90 g
(more than 3.18 oz)
Reverse CQ-403R more than 90 g
(more than 3.18 oz)

15
TUNER SECTION 0 dB=1 µV
Cautions during repair
When the tuner unit is defective, replace it by a new one be-
cause 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
Procedure:
1. Set to the test mode. (See page 14)
2. Push the [SOURCE] button and set to FM.
Display
3. Adjust with the volume RV2 on TU1 so that the “FM” indica-
tion 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
Adjustment Location: See page 17.
FM Stereo Separation Adjustment
Setting:
[SOURCE] button: FM
Procedure:
FM Stereo Level meter Level meter
signal generator connection reading (dB)
output channel
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.
FM RF signal
generator
Carrier frequency : 98.0 MHz
Output level : 22 dB (12.6
µ V)
Mode : mono
Modulation : 1 kHz, 22.5 kHz deviation (30%)
0.01 µ F
set
antenna jack (J1)
SHUF
SHUF
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%)
sub: 1 kHz, 20 kHz deviation (26.7%)
:19 kHz pilot: 7.5 kHz deviation (10%)
0.01 µ F
set
antenna jack (J1)
+
–
AUDIO OUT jack (CNJ151)
level meter
10 k
Ω

16
MW Auto Scan/Stop Level Adjustment
Make this adjustment after “FM Auto Scan/Stop Level Adjust-
ment”.
Setting:
[SOURCE] button: MW
Procedure:
1. Set to the test mode. (See page 14)
2. Push the [SOURCE] button and set to FM.
3. Push the [MODE] button and set to MW.
Display
4. Adjust with the volume RV1 on TU1 so that the “MW” indi-
cation turns to “MW0” indication on the display window.
But, in case of already indicated “MW0”, turn the RV1 so that
put out light “0” indication and adjustment.
Display
FM RDS S-Meter 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
3. Push the [6] button.
4. Adjust RV1 on main board so that the display indication is
“10.8”. Display
Specification: Display indication: 10.6 to 11.0
Adjustment Location: See page 17.
Adjustment Location: See page 17.
FM RF signal
generator
Carrier frequency : 98.00 MHz
Output level : 35 dB (56.2
µ V)
Mode : mono
Modulation : no modulation
0.01 µ F
set
antenna jack (J1)
SHUF
SHUF
AM RF signal
generator
Carrier frequency : 999 kHz
30% amplitude
modulation by
1 kHz signal
Output level : 33 dB
(
44.7
µ
V
)
(50 Ω )set
AM dummy antenna
30 Ω
15 pF
65 pF
antenna jack (J1)
TP SHUF
TP SHUF

1717
Adjustment Location:
– SET UPPER VIEW –
Tape Speed Adjustment
TU1
RV1 MW Auto Scan/Stop Level Adjustmen
t
RV2 FM Auto Scan/Stop Level Adjustment
RV4 FM Stereo Separation Adjustment
RV1 FM RDS S-Meter Adjustment

1818
XR-3100R/C33R SECTION 6
DIAGRAMS
6-1. BLOCK DIAGRAM – TUNER Section –
1
4
2FM-ANT
AM-ANT
6
VCO
20
IF-COUNT/SEEK
19
SD
5
11 1920 15
56 4
25
13
26
VT
13
AM-XTAL-IN
CK
3
CE
DOUT
XTOUT, XTIN
DIN
PLLSI
PLLCE
53
VSM
SD-IN
20
ST-MONO
5
TUNMUTE
AM-CPOUT
18
FM-CPOUT
VT
FM-VCO
16
AM-VCO
IF IN
10
SEEK
2
OSC OUT
PLLSO
27 28
PLLCKO
50
NOISE DET
32
NOISE ON
4
18
S-METER
17
15
12
LCH-OUT
RCH-OUT
AM-DET
22
FM-DET
FILTER
X1
10.25MHz
FM/AM PLL
IC1
05
MUTING
Q151
BUFFER
Q51
MUTING
CONTROL SWITCH
Q61
MUTING
Q121
BAND-PASS
FILTER
IC90
R-CH
D61
R-CH
FM/AM TUNER UNIT
TU1
SYSTEM CONTROLLER
IC501 (1/3)
LO/DX
11
SEEK
21
ST
LO/DX
J1
(FM/AM ANTENNA)
8
+8V-FM
FM B+
10
+8V-AM
AM B+
D1
9
+8V-TU
152
MTP
75
DAVN
RDS DECODER
IC51
INTERFACE
REGISTER
IIC BUS
SLAVE
TRANSCEIVER
OSCILLATOR
& CLOCK
X51
4.332MHz
48
5
OSCI
OSCO
10
9
SDA
SCL
DAVN
57 kHz
BAND-PASS
FILTER
CLOCKED
COMPARATOR
RDS/RDBS
DEMODULATOR
& DECODER
SIGNAL
QUALITY
DECODER
16 18 19
MPX
CIN
4
5
SC
OUT
MULTI
PATH
DETECTOR
20 2
LVIN
MPTH
Q90
NOISE DET
DISCHARGE
SWITCH
FM RDS
S-METER
RV1
DATA
CLOCK
DATA, CLOCK (Page 19)
C
FM-L (Page 19)
A
AM (Page 19)
B
1, 24
SEEKOUT
• SIGNAL PATH
: FM
: AM (MW/LW)

1919
XR-3100R/C33R
6-2. BLOCK DIAGRAM –TAPE/MAIN Section –
05
TAPE EQUALIZER AMP, AMS
IC301
34
32
R-CH
PBF
IN1
FWD
L-CH
HP901
(PLAYBACK)
FWD
R-CH
REV
L-CH
REV
R-CH
PBR
IN1
R-CH
R-CH R-CH R-CH
R-CH
R-CH
EQ AMP 29 27 MUTE DOLBY
NR AMP
PB
OUT1
TAPE
IN1
AMS
DET
+
113 115 117 114
N-ROUT
MTLON
19
DRSW
18
TAPESW
17 16 20
INSW
TAPE MUTE
DOLBY
AMSON
103
AMSIN
MSSW
24
LINE
OUT1
14
MS
OUT
A
(Page 18)
B
(Page 18)
FM-L
AM
PDL
SE1L
SE3L
SE2L
SDA
SCL MUTE
1
11
28
12
VOLUME
CONTROL
CIRCUIT
LOUDNESS
CONTROL
CIRCUIT
DIGITAL CONTROL
CIRCUIT IIC BUS
LOUDNESS
CONTROL
CIRCUIT
INPUT
SELECTOR
R-CH
R-CH
INPUT SELECT,
ELECTRICAL VOLUME
IC401
CNJ151 (1/2)
BUS
AUDIO IN
SOFT
MUTE
TONE
CONTROL
CIRCUIT
FADER
FADER 20
2625 24
OUT RL
22
OUT FL
L
R
C
(Page 18) DATA, CLOCK DATA
CLOCK
SYSTEM CONTROLLER
IC501 (2/3)
60
EVOL MUTE
71
I2C CKO
70
I2C SIO
15
BEEP
CNJ151 (2/2)
AUDIO OUT
(LINE OUT)
R-CH
L
R
68AMP MUTE
65
MUTE
MUTING
CONTROL SWITCH
Q621
MUTING
CONTROL SWITCH
Q622
118
AMP ON
BATT B+
D622
D624
D621
FRONT L (+)
11
15
11
17
19
FL+
FL–
9
7
FR+
FR–
FL-IN
FR-IN
14
21
23
RL+
RL–
RL-IN
12
22
5
3
RR+
RR–
RR-IN
4
CN601 (1/2)
(POWER CONNECTOR)
POWER AMP
IC611
FRONT L (–)
10
FRONT R (+)
12
FRONT R (–)
13
REAR L (+)
9
REAR L (–)
8
REAR R (+)
15
REAR R (–)
14
MUTING
Q171
MUTING
Q271
MUTING
Q181
ST-BY MUTE
MUTING
Q281
R-CH
R-CH
CAPSTAN/REEL
MOTOR DRIVE
Q364
CM-ON
BATT B+
Q365
111
M
M901
(CAPSTAN/REEL)
REGULATOR
CONTROL SWITCH
Q362
LM-EJ TAPEON LM-LOD
VCC
REEL SENSOR B+ BATT B+
IN1
IN2
OUT1
OUT2
LOADING/TAPE OPERATION
MOTOR DRIVE
IC361
M7
9
MOTOR
DRIVE
4
2
3
110 109
REGULATOR
Q361
112
LOADING/TAPE
OPERATION
TAPE OPERATION
SWITCH
BUFFER
TAKE-UP
REEL
SENSOR
SUPPLY
REEL
SENSOR
REEL SENSOR BOARD
REEL
104
105 – 108
POS0 – POS3
TAPE
DETECT
EJECT/FF/REW/
REV/FWD MODE DETECT
+
+
• SIGNAL PATH
: AM (MW/LW)
: FM
: TAPE PLAY
: BUS AUDIO IN
(C33R)
BATT B+
(C33R)

2020
XR-3100R/C33R
6-3. BLOCK DIAGRAM – DISPLAY/KEY CONTROL/BUS CONTROL/POWER SUPPLY Section –
SYSTEM CONTROLLER
IC501 (3/3)
35
RE-IN1
KEYACK
76
KEYIN1
RE-IN0
36
37
KEYIN0
RC-IN0
RC-IN1
46
47
48
72
KEY ACTIVE
SWITCH
Q651, 652
D501
ENCODE –
ENCODE +
D653
AD-ON
LSW901 – 903, 905,
LSW906, 921 – 923,
LSW925 – 933, S901
ROTARY
ENCODER
RE901
BACKUP +5V
VOLUME/BASS/TREBLE/
BALANCE/FADER CONTROL
RE901
J501
REMOTE IN
80 NOSESW
D-BASS
DOORSW
12
51
CNP901
(FRONT PANEL SIDE)
CN500
(MAIN BODY SIDE)
15
4
S981
D-BASS
15
4
X1 X0
X1A X0A
93 92
73 74
X501
3.68MHz
X502
32.768kHz
SHIFT 3
DI
64
CL
63
60
CE
OSC
62
LCD SO 13
LCD CKO 14
16
LCD CE
LED DRIVE
Q945
ILL B+
LIQUID CRYSTAL DISPLAY DRIVER
IC901
4 – 47
S04 – S47
52 – 55
COM1 – COM4
LIQUID CRYSTAL
DISPLAY
LCD901
05
BACKUP +5V
RESET SIGNAL
GENERATOR
IC652
BATTERY DETECT
Q701
6
8
4
CLK
CLK IN
DATA OUT
DATA
2
RST
RESET
SWITCH
BUS ON
SWITCH
13
11
1
BUS ON
OUT
BUS
ON IN
12
9DATA IN
SONY BUS INTERFACE
IC701
BATT
BATT B+
BUS ON
DATA
CLK
RESET
7
6
5
4
2
RST
3
BATT
CLK
DATA-OUT
DATA-IN
RST
BUS ON
BU-IN
CLK
DATA-OUT
DATA-IN
RST
BUS ON
BU-IN
BATTERY
SWITCH
10 BU IN
77
10
19
UNICKO
17
UNISI
18
UNISO
86 HSTX
11
90
TH701
D702
D701
BATTERY DETECT
Q701 – 703
D707
RESET
SYSRST
BU-IN
BUS-ON
S503
(RESET)
(FOR SONY BUS)
CN701
BUS CONTROL IN
POWSEL
A (ON)
B (OFF)
56
ACCESSORY CHECK
Q661
ANT+B
FM8V
REGULATOR
IC671
COM8V
AM8V
MODE1 MODE2 STB
1
BATT
ANT REM
2
CN601 (2/2)
(POWER CONNECTOR)
REGULATOR
CONTROL SWITCH
Q82
COM +8V
(AUDIO CIRCUIT B+)
D662
AM B+
FM/AM TUNER UNIT
(TU1) B+
FM B+
VCC 7
5
ACC
+5V
REGULATOR
Q71
+5V
(TUNER CIRCUIT B+)
+9V
REGULATOR
Q81
+9V
(TUNER CIRCUIT B+)
REGULATOR
CONTROL SWITCH
Q633
+10V
REGULATOR
Q631
ILL B+
PL901, 902
(LCD BACK LIGHT)
23 4
9
BU+B
BACKUP +5V
D651
5
10
11
8
AMP+B
6
FM-ON
TU-ON
POWON 120
29
ILL-ON
6
7
BATT B+
POWER AMP
(IC611) B+
AMP REM
7
D673
D674
81
ACC IN
S501
POWER SELECT
LSW901 – 903, 905, 906,
LSW921 – 923,
LSW925 – 933
(C33R)
(3100R)
(C33R)