Sony MDR-IF540R User manual

1
SERVICE MANUAL
US Model
Canadian Model
E Model
Tourist Model
MDR-IF540R
HEADPHONES
Ver 1.0 2003. 03
9-877-225-01
2003C0400-1
© 2003. 03
Sony Corporation
Personal Audio Company
Published by Sony Engineering Corporation
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.
Headphones
Power source Supplied rechargeable
nickel-metal hydride
batteries BP-HP550 or
commercially available
(size AAA) dry batteries
Mass Approx. 285 g (11 oz.)
including batteries
Design and specifications are subject to change without
notice.
SPECIFICATIONS
SRS is a trademark of SRS Labs Inc.
SRS Headphones are manufactured under
license from SRS Labs. Inc.
•The MDR-IF540R is the headphones
that comprises the MDR-IF540RK.
• MDR-IF540RK consists of the following models respectively.
Headphones MDR-IF540R
Transmitter TMR-IF540R

2
TABLE OF CONTENTS
1. GENERAL
Charging the supplied rechargeable batteries .......................... 3
Listening to a programme........................................................ 6
2. DISASSEMBLY
2-1. Front Plate (R) Assy ............................................................ 8
2-2. RX Board ............................................................................ 9
2-3. Hanger (R)........................................................................... 9
2-4. Wiring on the Right Side ................................................... 10
2-5. Front Plate (L) Assy .......................................................... 10
2-6. BATT Board ...................................................................... 11
2-7. Hanger (L) ......................................................................... 11
2-8. Wiring on the Left Side ..................................................... 12
2-9. Hanger Lid (L) .................................................................. 12
2-10. Wiring on the SW Board ................................................... 13
2-11. Hang the Tension Spring ...................................................13
3. ELECTRICAL ADJUSTMENTS
Tuning Adjustment ................................................................ 14
Mute ON Position Adjustment .............................................. 14
4. DIAGRAMS
4-1. Circuit Boards Location .................................................... 16
4-2. Block Diagram – Receiver Section – ................................ 17
4-3. Printed Wiring Boards – Receiver Section (1/2) – ............ 18
4-4. Printed Wiring Board – Receiver Section (2/2) –.............. 19
4-5. Printed Wiring Boards – Power Section (1/2) – ................ 20
4-6. Printed Wiring Board – Power Section (2/2) – ................. 21
4-7. Schematic Diagram – Receiver Section – ......................... 22
4-8. IC Block Diagrams............................................................ 23
5. EXPLODED VIEWS
5-1. Housing (L) Assy Section ................................................. 24
5-2. Housing (R) Assy Section ................................................. 25
6. ELECTRICAL PARTS LIST ........................................ 26
MDR-IF540R

3
MDR-IF540R
SECTION 1
GENERAL This section is extracted
from instruction manual.

4
MDR-IF540R

5
MDR-IF540R

6
MDR-IF540R

7
MDR-IF540R

8
MDR-IF540R
Note : This set can be disassemble according to the following sequence.
SECTION 2
DISASSEMBLY
2-1. FRONT PLATE (R) ASSY
Note : Follow the disassembly procedure in the numerical order given.
2-1. FRONT PLATE (R) ASSY
(Page 8)
2-2. RX BOARD
(Page 9)
SET
2-5. FRONT PLATE (L) ASSY
(Page 10)
2-3. HANGER (R)
(Page 9)
2-4. WIRING ON THE
RIGHT SIDE
(Page 10)
2-8. WIRING ON THE
LEFT SIDE
(Page 12)
2-10. WIRING ON THE
SW BOARD
(Page 13)
2-11. HANG THE
TENSION SPRING
(Page 13)
2-6. BATT BOARD
(Page 11)
2-7. HANGER (L)
(Page 11)
2-9. HANGER LID (L)
(Page 12)
3 P 2.6x6
5 front plate (R) assy
4 Removal the solder at 2 places.
Note for installation : Solder the leads at the
places shown below with
attention to their colors.
housing (R) assy
driver (R-CH) side
natural
red from RX board
1 ear pad (R)
2 P 2.6x6

9
MDR-IF540R
2-2. RX BOARD
2-3. HANGER (R)
3 RX board
2
housing (R) assy
Note : Insert this in the LED hole
in the housing (R) assy
when installing.
natural
natural
white
green
to driver
to motor
natural
natural
red
red red G/N
blue
black
S1
S301
red
1 Removal the solder at 12 places.
Note for installation : Solder the leads at the
places shown below with
attention to their colors.
2
3
4
1 P 2.6x6
5 hanger (R)
hanger lid (R)
projection
Pay attention to the leads
when assembling.
Pay attention to the leads
when assembling.

10
MDR-IF540R
2-4. WIRING ON THE RIGHT SIDE
2-5. FRONT PLATE (L) ASSY
PD2 board
(R-CH front) PD1 board
(R-CH rear)
3 P 2.6x6
5 front plate (L) assy
housing (L) assy driver (L-CH) side
natural
green from RX board
1 ear pad (L)
2 P 2.6x6
4 Removal the solder at 2 places.
Note for installation : Solder the leads at the
places shown below with
attention to their colors.

11
MDR-IF540R
2-6. BATT BOARD
2-7. HANGER (L)
3 BATT board
housing (L) assy to motor
natural
red
red
red
red
red
black
G/N
blue
2 P 2x6
1 Removal the solder at 8 places.
Note for installation : Solder the leads at the
places shown below with
attention to their colors.
1 P 2.6x6
2
3
4
5 hanger (L)
hanger lid (L)
projection
Pay attention to the leads
when assembling.
Pay attention to the leads
when assembling.

12
MDR-IF540R
2-8. WIRING ON THE LEFT SIDE
2-9. HANGER LID (L)
PD2 board
(L-CH rear) PD1 board
(L-CH front)
1 P 2.6x6
2 P 2.6x6
3 head band
4 hanger lid (L)

13
MDR-IF540R
2-10. WIRING ON THE SW BOARD
2-11. HANG THE TENSION SPRING
head ban
d
SW board
SW board
S103
suspender assy
suspender assy
tension spring
hanger lid (L)
housing (L) assy
Note for installation : Insert the end of the
suspender assy under the
S103 on the SW board.

14
MDR-IF540R SECTION 3
ELECTRICAL ADJUSTMENTS
PRECAUTION
1. These adjustments should be performed in the order in which
they appear. It is required as a rule to adjust the transmitter
section (TMR-IF540R) before adjusting the headphone
section (MDR-IF540R).
2. Adjustment and measurement should be made on each channel
unless otherwise specified.
3. Adjust on the left channel before adjusting on the right
channel.
4. Supply a power voltage of 9V to the transmitter section (TMR-
IF540R) and a power voltage of 2.4 V to the headphones
section (MDR-IF540R).
Headphones Section 0 dBV = 315 mVrms
Note:
1. Use the transmitter section (TMR-IF540R) as a jig for
adjusting the headphones section (MDR-IF540R).
Tuning Adjustment
Preparation:
low-frequency
oscillator attenuator jig
trans-
mitter
INPUT B
jack (J1)
1 kHz 315 mV (-10 dBV)
stabilized
power (9 V dc)
600
Ω
1. Apply the input to the jig (TMR-IF540R), and connect a
stabilized power to the DC IN 9V jack (J3).
2. Supply 2.4V dc between BATT (+) and BATT (–) on the BATT
board.
3. Set the RV2 (volume control) on the RX board to the minimum
level.
Connection:
+
+
100 µ F/16 V
RX board
TP5 (L-ch)
TP4 (R-ch)
distortion meter
Adjustment Method:
1. Connect a distortion meter to TP5 (L-ch) or TP4 (R-ch) on the
RX board.
2. Adjust the L5 (L-ch) or L6 (R-ch) so as to minimize the
reading on the distortion meter.
L-ch L5 Minimum
R-ch L6 Minimum
FM RF
signal generator
Carrier frequency : 2.8 MHz
Modulation : 1 kHz, 16 kHz deviation
Output level : 34 dB
µ V (EMF)
set
SIG
TP1 (GND)
0.1
µ F
10 k
Ω
+
RX board
level meter
TP4 (R-ch)
Mute ON Position Adjustment
Preparation:
Connection:
Adjustment Method:
1. Connect a level meter to TP4 (R-ch) on the RX board.
2. Short between TP2 and TP3 on the RX board.
3. Write down the reading on the level meter at this time.
4. Remove the short between TP2 and TP3 made in item 2.
5. Adjust the RV1 on the RX board so that the reading on the
level meter is 5 dB to 10 dB below the value written down in
item 3.

15
MDR-IF540R
BATT ( )
BATT (+)
BATT board (side A) RX board (side B)
TP2
TP3
RV301
RV2
VOL
L5
TUNING ADJ
(L-ch)
L6
TUNING ADJ
(R-ch)
TP5
(L-ch) TP4 (R-ch)
RV1
MUTE ON
POSITION
ADJ
Adjustment Location:

16
MDR-IF540R SECTION 4
DIAGRAMS
THIS NOTE IS COMMON FOR PRINTED WIRING
BOARDS AND SCHEMATIC DIAGRAMS.
(In addition to this, the necessary note is
printed in each block.)
for schematic diagram:
•All capacitors are in µF unless otherwise noted. pF: µµF
50 WV or less are not indicated except for electrolytics
and tantalums.
•All resistors are in Ωand 1/4W or less unless otherwise
specified.
•C: panel designation.
•A: B+ Line.
•H: adjustment for repair.
•Powervoltageis dc 2.4 Vandfed with regulated dcpower
supply from battery terminal.
•Voltage is dc with respect to ground under no-signal
(detuned) conditions.
•Voltagesaretakenwitha VOM (Inputimpedance10 MΩ).
Voltage variations may be noted due to normal produc-
tion tolerances.
•Signal path.
F: ANALOG
J: RF
for printed wiring boards:
•X: parts extracted from the component side.
•Y: parts extracted from the conductor side.
•a: Through hole.
•: Pattern from the side which enables seeing.
(The other layer’s patterns are not indicated.)
Caution:
Pattern face side: Partsonthepatternface sideseenfromthe
(Side B) pattern face are indicated.
Parts face side: Parts on the parts face side seen from the
(Side A) parts face are indicated.
4-1. CIRCUIT BOARDS LOCATION
RX board
BATT boar
d
SW board
PD1 board
(L-CH front)
PD1 board
(R-CH rear)
PD2 board
(L-CH rear)
PD2 board
(R-CH front)

MDR-IF540R
17 17
4-2. BLOCK DIAGRAM — RECEIVER SECTION —
1
3 5 6
11
DET
24
10
DET 12
1
16
HPF
2
15
3
MODE
CONTROL
Q1,2
RF AMP
Q3
BUFFER
FL1
2.3MHz
BPF
20 1322 14 1871615 17 8
FL2
2.8MHz
BPF
EXT
FILTER
BIAS
10
9
7
7
9
4
5
6
2
6 7 3 1 3 1 10 8
13 14 6
57
2 1
21
5
14
+1.5V
D1
L-CH FRONT
SECTION
D2
L-CH REAR
SECTION
D3
R-CH REAR
SECTION
D4
R-CH FRONT
SECTION
FOR IC302
IC304
D1-4
IR
RECEIVER
CHARGE
TERMINAL
M301
MOTOR
L-CH
VIBRATION
M302
MOTOR
R-CH
VIBRATION
14
13
RV1
MUTE ON
POSITION
L6
(2.8MHz DET)
TUNING
VREF
VCC
1.5V
L5
(2.3MHz DET)
TUNING
V+/2
REFIN
RIN
WIN
WOUT
LIN
VREF
MODE
4
+3.3V
+3.3V
BYPASS
BYPASS
SRS
SRS
ROUT
LOUT
OUT2
OUT1
+V
VCC
MATRIX
IC2
SRS SURROUND PROCESSOR
IC3
DRIVER AMP
IN1
IN2
REF
MDD1
DRIVER
(L-CH)
MDD2
DRIVER
(R-CH)
Q101,102
AUTO ON/OFF
S101
(BATT DET) D101
S102
(BATT DET)
RECHARGEABLE
BATTERY
(BP-HP550)
1.2V 550mAh
X2
IC101
BATTERY
DOWN
DET
SW103
(AUTO ON/OFF) IC102
+3.3V
SWITCHING REG
IC201
L101 D102
+3.3V
+1.5V
+2.4V
IC303 (1/2)
ADD AMP
IC303 (2/2)
LPF
RV301
VIBRATION
(VOL)
IC302 (1/4)
BUFFER
IC302 (2/4)
INVERTER
IC302 (4/4)
COMPARATOR
IC302 (3/4)
COMMUTATION
S301
VIBRATION
D302
D303
IC1
MIXER/LIMITER/
DEMODULATION
+2.4V
+2.4V
+3.3V
VCC
S1
( )
OFF
ON
Q302
INITIAL
MUTE Q301
VIBRATION
MOTOR DRIVE
Q304
BUFFER
Q303
MUTE
VCC
-2 -1
M
M
RV2
VOL
-1
L
-2
R
L
R
+1.5V
REG
• Signal path
: ANALOG
: RF
OFF ON

MDR-IF540R
1818
4-3. PRINTED WIRING BOARDS — RECEIVER SECTION (1/2) — • Refer to page 16 for Common Note on Printed Wiring Boards and Circuit Boards Location.
1
A
B
C
D
E
F
G
H
I
J
234567891011121314
3.3V
MDD2
MDD1
B+
D4
D3
D1
D2
SIG
GND
M302
D1-4
IR RECEIVER
(Page 20) (Page 20)
D1 F-13
D2 F-11
D3 C-13
D4 C-11
• Semiconductor
Location (Side A)
Ref. No. Location

MDR-IF540R
19 19
1
A
B
C
D
E
F
G
H
I
J
234567891011121314
C30
C37
R22
R23
R5
R1
C3 FB1 B+
C24
R16
C10
C2
C202
IC1
R3
R6
C14
C34
R9
C44
C23
C42
C45
R25
C15
C5
R14
R17
C26
C13
C46
C28
C29
C31
R307
C35
C32
C40 C39
R20
R21
R15
R18
TP307
R314 R315
R316
R317
C309
C311
R313
R13
C36
C323
R12
C27
C9
C25
L5
C1
C4
C8
R11
FL1
FL2
C310
C313
C18
C204
C7
R4
C33
R2
R7
C22
C6
R10
C16
C205
R24
R8
C17
Q3
C317
IC303
TP3
C201
C312
IC2
D302
Q2
TP2
R312
R310
R311
TP9
R301
C308
R304
R305
C307
TP7
TP8
TP4
TP5
R306
TP305
TP304
R303 R302
Q301
Q1
IC302
C43
C316
D303
R321
TP6
TP1
SIG
R19
C203
R318
C318
R309
RV1
C320
C319
R325
R329
R326
R327
TP309
R323
C315
R322
R201
IC3
Q304
L6
Q303
Q302
C305
C306
TP10
IC201
C38
C321
C324
L1
L2
L3
L4
C325
D201
RV2
RV301
S301
S1
4-4. PRINTED WIRING BOARD — RECEIVER SECTION (2/2) — • Refer to page 16 for Common Note on Printed Wiring Boards and Circuit Boards Location.
D201 G-6
D302 E-8
D303 E-8
IC1 D-7
IC2 E-4
IC3 C-4
IC201 H-5
IC302 E-8
IC303 F-6
Q1 B-8
Q2 B-7
Q3 A-6
Q301 G-8
Q302 F-9
Q303 E-9
Q304 E-9
• Semiconductor
Location (Side B)
Ref. No. Location

MDR-IF540R
2020
4-5. PRINTED WIRING BOARDS — POWER SECTION (1/2) — • Refer to page 16 for Common Note on Printed Wiring Boards and Circuit Boards Location.
1
A
B
C
D
E
F
G
H
I
J
2345678910111213
SW103
M301
BATT (–)
BATT (+)
(Page 18)
(Page 18)