Sony Xr-c540rds User manual

9-925-543-12 Sony Corporation

2001F0500-1 e Vehicle Company

C2001.6 ShinagawaTec Service Manual Production Group

XR-C540RDS

AEP Model

UK Model

SERVICE MANUAL

FM/MW/LW CASSETTE CAR STEREO

SPECIFICATIONS

Model Name Using Similar Mechanism NEW

Tape Transport Mechanism Type

MG-52B-136

For RM-X2S (Remote Commander),

please refer to RM-X2S/X3S Service

Manual (9-960-039-S) previously issued.

Dolby noise reduction manufactured under license

from Dolby Laboratories Licensing Corporation.

“DOLBY”andthe double-Dsymbol;aretrademarks

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

Power amplifier section

Outputs Speaker outputs

(sure seal connectors)

Speaker impedance 4 – 8 ohms

Maximum power output 35 W ×4 (at 4 ohms)

General

Outputs Power amplifier control lead

Rear line out (1)

Tone controls Bass ± 8 dB at 100 Hz

Treble ± 8 dB at 10 kHz

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

(1 set)

Rotary commander RM-X2S

Front panel case (1)

Design and specifications are subject to change without notice.

Ver 1.1 2001.06

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TABLE OF CONTENTS

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

7. EXPLODED VIEWS ................................................ 37

8. ELECTRICAL PARTS LIST................................ 40

SERVICING NOTES

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.

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SECTION 1

GENERAL This section is extracted

from instruction manual.

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– 9 –

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

SECTION 2

DISASSEMBLY

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

2

1

2

3

cover ass’y

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– 10 –

5

screw

(PTT2.6

×

6)

6

mechanism deck (MG-25B-136)

4

flexible flat cable

(CN301)

1

three screws

(PTT2.6

×

8)

1

three screws

(PTT2.6

×

8)

2

sub panel

3

connector

(CN302)

MAIN BOARD, HEAT SINK 4

seven screws

(PTT2.6

×

8)

2

two ground point

screws

1

two screws

(PTT2.6

×

8)

3

main board

5

heat sink

1

screw

(PTT2.6

×

8)

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

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

2

Install the hanger onto

two claws of the housing.

1

Install the catch to the hanger.

7

Hold the hanger by bending the claw.

A

part

B

part

C

part

D

part

8

Hold the hanger by

bending the claw.

3

Put the housing

under

A

part.

4

Fit claw on

B

part.

6

Fit projection on

D

part.

5

Fit projection on

C

part.

hanger

HOUSING

housing

SECTION 3

ASSEMBLY OF MECHANISM DECK

2

Move the arm (suction) in the arrow

direction and fit on projection.

1

Fit the arm (suction) on the shaft.

projection

ARM (SUCTION)

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– 12 –

1

Fit the lever (LDG-A) on

shafts

A

–

C

and install it.

shaft

A

shaft

C

4

type-E stop ring 2.0

shaft

A

shaft

C

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

shaft

B

GEAR (LDG-FT)

3

Align hole in the gear (LDG-D)

with hole in the lever (LDG-A).

gear (LDG-FB)

hole

gear (LDG-D)

lever (LDG-A)

2

Move the lever (LDG-B)

in the arrow direction.

1

tension spring (lever LDG)

4

gear (LDG-FT)

5

polyethylene washer

hole

2

Pull the lever in the

arrow direction.

3

Fit the lever (LDG-B) on

shafts

A

and

C

and

install it.

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GUIDE (C)

2

guide (C)

1

three claws

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– 14 –

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 Frequency counter

–1.5 to +2.5% 2,955 to 3,075 Hz

Specification: Constant speed

Adjustment Location: See page 17.

DOLBY Level Adjustment

Setting:

Preset 3 (DOLBY) button : OFF

SEL (VOL) button : Maximum

set +–

test tape

WS-48A

(3 kHz, 0 dB)

speaker out terminal

4

Ω

speed checker

or

frequency counte

r

set

test tape

P-4-D400

(400 Hz, 0 dB)

MAIN board

TP (DOLBY)

+

–

level mete

r







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 read-

ing is within the specification given above.

Adjustment Location: See page 17.

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.

•Torque Measurement

Mode Torqu Meter Meter Reading

Forward CQ-102C 30 – 65 g•cm

(0.42 – 0.90 oz•inch)

Forward CQ-102C 0.5 – 4.5 g•cm

Back Tension (0.01 – 0.06 oz•inch)

Reverse CQ-102RC 30 – 65 g•cm

(0.42 – 0.90 oz•inch)

Reverse CA-102RC 0.5 – 4.5 g•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)

•Tape Tension Measurement

SECTION 5

ELECTRICAL ADJUSTMENTS

TEST MODE

This set have the test mode function. In the test mode, FM Auto

Scan/Stop Level andAM (MW)Auto Scan/Stop Level adjustments

can be performed easier than it in ordinary procedure.

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.

1. Push the OFF button.

2. Return the “power select” switch (S801) to initially aet posi-

tion.

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INTRO

REG

FM INTRO

REG

FM RF signal

generator

Carrier frequency : 98.00 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)

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 Noise Focus Adjustment

3. FM Stereo SeparationAdjustment

4. FM Signal Meter Adjustment

5. 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 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

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

µ

F

set

antenna jack (J1)

+

–

speaker out terminal

level meter

4

Ω

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 : 98.00 MHz

Output level : 70 dB (3.2 mV)

Mode : stereo

Modulation : main: 1 kHz, 20 kHz deviation (22.6%)

sub: 1 kHz, 20 kHz deviation (22.6%)

19 kHz pilot: 7.5 kHz deviation (10%)

0.01

µ

F

set

antenna jack (J1)

+

–

speaker out terminal

level meter

4

Ω

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– 16 –

999 INTRO

999

MW

INTRO

MW Auto Scan/Stop Level Adjustment

Make this adjustment after “FMAuto Scan/Stop LevelAdjustment”.

Setting:

SOURCE button: MW

Procedure:

1. Set to the test mode. (See page 14.)

2. Push the SOURCE button and set to MW.

Display

FM Signal Meter Adjustment

Setting:

SOURCE button: FM

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)

3. Push the preset 6 button.

4. Adjust RV1 on MAIN board so that the display indication is

“160”.

Display

Procedure:

1. Set to the test mode. (See page 14.)

2. Push the SOURCE button and set to FM.

Display

Specification: Display indication: 158 to 162

Adjustment Location: See page 17.

INTRO

REG

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)

3. Adjust with the volume RV1 on TU1 so that the “MW” indica-

tion 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

Adjustment Location: See page 17.

INTRO

REG

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– 17 –

Adjustment Location:

– SET UPPER VIEW –

RV1 MW Auto Scan/Stop level Adjustment

RV2 FM Auto Scan/Stop level Adjustment

RV3 FM Noise Focus Adjustment

RV4 FM Stereo separation Adjustment

RV1

FM Signal Meter

Adjustment

TU1











RV301

(R-CH) RV401

(L-CH)

DOLBY Level

Adjustment

– MAIN BOARD (Conductor Side) –

TU1

CN602

CN351

IC351 IC3

R-CH

L-CH











TP (DOLBY)

DOLBY level

Adjustment

Tape Speed Adjustment

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y

u

1

6

3

.

c

o

m

Q

3

7

6

3

1

5

1

5

0

9

2

8

9

4

2

9

8

T

E

L

1

3

9

4

2

9

6

5

1

3

9

2

8

9

4

2

9

8

0

5

1

5

1

3

6

7

3

Q

TEL 13942296513 QQ 376315150 892498299

http://www.xiaoyu163.com

– 18 –

SECTION 6

DIAGRAMS

•IC Block Diagrams – MAIN Section –

IC1 TB2114F (EL)

VDD

SEEK/RECP

1234567 8 9 10

24 23 22 21 20 19 18 17 16 15

11 12

14 13

BUFFER

XTOUT

O

SC OUT

CE

DIN

CK

DOUT

SR

I/O-1

I/O-2

OUT-1

OUT-2

OUT-3

AM/FM IF

VDD

FM IN

AM IN

D-GND

FM CP OUT

VT

AM CP OUT

VCC

RF

A-GND

XTIN

BUS INTERFACE I/O PORTS OUT PORTS

OSC IN

OR

X'TAL OSC

ON/OFF

REFERENCE

COUNTER

PHASE

COMPARATOR

20BIT

IF COUNTER

2

MODULAS

PRESCALER

12BIT

PROGRAMABLE

COUNTER

AMPAMPAMP

+

–

RIPPLE

FILTER

18BIT

18BIT 22BIT

40BIT

SHIFT

RESISTER

REF

VCC +

–

SIG

SEEK/RECP

4BIT

SWALLOW

COUNTER

PSC

N

DATA

IC3 TDA7330BD-013TR

COSTAS

LOOP

PLL

57kHz

PHASE

DECODER

DIFF

DECODER

CLOCK

RECOVERY

PLL

1.4675kHz

ON/OFF

OSCILLATOR

fx DIVIDER

TEST LOGIC

8th ORDER

SC-BANDPASS

FILTER

2nd ORDER

ANTIALIAS

FILTER

+

–

20 19 18 17 16 15 14 13 12 11

10986 73 45

12

POR

TM

FSEL

T7

VCC

ARI

OUAL

RODA

ROCL

T57

MPXIN

VREF

CMP

FILOUT

GND

T1

T3

T4

OSCOUT

OSCIN

VCC

w

.

x

i

a

o

y

u

1

6

3

.

c

o

m

Q

3

7

6

3

1

5

1

5

0

9

2

8

9

4

2

9

8

T

E

L

1

3

9

4

2

9

6

5

1

3

9

2

8

9

4

2

9

8

0

5

1

5

1

3

6

7

3

Q

TEL 13942296513 QQ 376315150 892498299

http://www.xiaoyu163.com

– 19 –

+

–

+

–

+–

+

–

+–

12345 6 7 8 9 10

20

19

18

17

16

15

14

13

12

11

2122232627282930

31

32

33

34

37

38

39

40

2425

PBFB2

PBRIN2

PBREF2

PBFIN2

35

36

PBGND

VCT

PBFIN1

PBREF1

PBRIN1

PBFB1

PBEQ2

PBOUT2

VCC

TAPEIN2

AUXIN2

MSLPF

LINEOUT2

TCH2

NC

PLAY

FF

MSTC

DGND

MSOUT

NC

NRSW

INSW

TAPESW

MSMODE

DRSW

MSSW

NC

TCH1

LINEOUT1

DIREF

AUXIN1

TAPEIN1

PBEQ1

PBOUT1

GND

F2

120µ/

70µ

X1

VCT

+

F1

120µ/

70µNR

OFF/B

F3

LPF

VCC

DETECT

MS ON/

OFF

NR

MODE

FWD/RVS

TAPE EQ

TAPE/AUX

NR BIAS

NR

MS

MODE

OFF/B

T2

T1

+

–

+

–

+

–

+

–+

–

+

–

+

–

+

–

+

–

+

–

+

–

+

–+

–

+

–

+

–

+

–

DECODER LATCH SHIFT

REGISTER CONTROL

–

+

–

12 3 45 6 7 8 9 10

20

19

18

17

16

15

14

13

12

11

21

22

2324252627282930313233

34

35

36

37

38

39

40

41

42

43

44

LSELO

L4

L3

L2

L1

VDD

R1

R2

R3

R4

RSELO

RVRIN

RCOM

RT1

RT2

RT3

RTOUT

RSIN

RS1

RS2

RS3

RSOUT

RFIN

RFOUT

RROUT

VSS

CL

DI

CE

VREF

LROUT

LFOUT

LFIN

LSOUT

LS3

LS2

LS1

LSIN

LTOUT

LT3

LT2

LT1

LCOM

LVRIN

w

.

x

i

a

o

y

u

1

6

3

.

c

o

m

Q

3

7

6

3

1

5

1

5

0

9

2

8

9

4

2

9

8

T

E

L

1

3

9

4

2

9

6

5

1

3

9

2

8

9

4

2

9

8

0

5

1

5

1

3

6

7

3

Q

TEL 13942296513 QQ 376315150 892498299

http://www.xiaoyu163.com

– 20 –

+

–

+

–

+

–

+

–

OVER VOLTAGE

PROTECT

REGULATOR

12 3 45 6 7 8 9 10 1211

NC

MODE2

MODE1

STB

VDD

AMP

VCC

ANT

COM

AM

FM

GND

1

2

3

4

5

6

7 8

9

10

14

13

12

11

BUS ON

SWITCH

RESET

SWITCH

BATTERY

SWITCH

BUS ON

RST

BATT

CLK

VREF

DATA

GND

VCC

RST

BUS ON

CLK IN

BU IN

DATA IN

DATA OUT

IC360 MM1322XFBE

1

2

3

4

5

6

7

8OUT2

VS

OUT1

GND

IN1

VCC

IN2

GND

CONTROL CIRCUIT

IC601 BA3918-V2

IC701 BA8270F-E2

w

.

x

i

a

o

y

u

1

6

3

.

c

o

m

Q

3

7

6

3

1

5

1

5

0

9

2

8

9

4

2

9

8

T

E

L

1

3

9

4

2

9

6

5

1

3

9

2

8

9

4

2

9

8

0

5

1

5

1

3

6

7

3

Q

TEL 13942296513 QQ 376315150 892498299

http://www.xiaoyu163.com

Sony XR-C540RDS User manual

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