Sony HCD-GX45 - System Components User manual

1
Ver 1.0 2003. 07
Model Name Using Similar Mechanism NEW
CD CD Mechanism Type CDM74F-K6BD71A
Section Base Unit Name BU-K6BD71A
Optical Pick-up Name KSS-213DCP
Tape Deck Model Name Using Similar Machanism CX-JT8
Section Tape Transport Mechanism Type CWM43FF-13
SERVICE MANUAL
US Model
Canadian Model
HCD-GX45
AEP Model
UK Model
Australian Model
HCD-RG440
HCD-GX45/RG440
AUDIO POWER SPECIFICATIONS
(HCD-GX45 USA model only)
POWER OUTPUT AND TOTAL HARMONIC
DISTORTION:
With 6 ohm loads, both channels driven, from
120 – 10,000 Hz; rated 120 watts per channel
minimum RMS power, with no more than 10 %
total harmonic distortion from 250 milliwatts to
rated output.
Amplifier section
North American models:
HCD-GX45:
Front speaker
Continuous RMS power output (reference):
120 + 120 watts (6 ohms at
1 kHz, 10% THD)
Total harmonic distortion less than 0.07% (6 ohms at
1 kHz, 60 W)
Sub woofer
Continuous RMS power output (reference):
120 watts (6 ohms at
60 Hz, 10% THD)
Total harmonic distortion less than 0.07% (6 ohms at
60 Hz, 60 W)
European and Russian models:
HCD-RG440:
Front speaker
DIN power output (rated): 80 + 80 watts
(6 ohms at 1 kHz, DIN)
Continuous RMS power output (reference):
100 + 100 watts (6 ohms at
1 kHz, 10% THD)
Music power output (reference):
200 + 200 watts (6 ohms at
1 kHz, 10% THD)
SPECIFICATIONS
Sub woofer
DIN power output (rated): 80 watts (6 ohms at
60 Hz, DIN)
Continuous RMS power output (reference):
100 watts (6 ohms at
60 Hz, 10% THD)
Music power output (reference):
200 watts (6 ohms at
60 Hz, 10% THD)
Other models:
HCD-RG440:
The following measured at AC 120, 220, 240 V,
50/60 Hz
DIN power output (rated): 80 + 80 watts
(6 ohms at 1 kHz, DIN)
Continuous RMS power output (reference):
100 + 100 watts (6 ohms at
1 kHz, 10% THD)
Inputs
GAME INPUT AUDIO L/R (phono jacks):
voltage 250 mV,
impedance 47 kilohms
GAME INPUT VIDEO (phono jack):
1 Vp-p, 75 ohms
Outputs
PHONES (stereo mini jack):
accepts headphones of
8 ohms or more
Sony Corporation
Home Audio Company
Published by Sony Engineering Corporation
9-961-068-01
2003G04-1
© 2003. 07
– Continued on next page –
COMPACT DISC DECK RECEIVER
•HCD-GX45/RG440 is the
tuner, deck, CD and amplifier
section in MHC-GX45/RG440S. (Photo: HCD-GX45)

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HCD-GX45/RG440
VIDEO OUT (phono jack):max. output level
1 Vp-p, unbalanced, Sync
negative, load impedance
75 ohms
SPEAKER: accepts impedance of 6 to
16 ohms
SUB WOOFER OUT: accepts impedance of 6 to
16 ohms
CD player section
System Compact disc and digital
audio system
Laser Semiconductor laser
(λ=780 nm)
Emission duration:
continuous
Frequency response 2 Hz – 20 kHz (±0.5 dB)
Wavelength 780 – 790 nm
Signal-to-noise ratio More than 90 dB
Dynamic range More than 90 dB
Tape deck section
Recording system 4-track 2-channel, stereo
Frequency response 50 – 13,000 Hz (±3 dB),
using Sony TYPE I
cassettes
Tuner section
FM stereo, FM/AM superheterodyne tuner
FM tuner section
Tuning range
Russian models 65.0 – 74.0 MHz
(There is no stereo effect)
87.5 – 108.0 MHz
Other models 87.5 – 108.0 MHz
Antenna FM lead antenna
Antenna terminals 75 ohms unbalanced
Intermediate frequency 10.7 MHz
AM tuner section
Tuning range
Pan-American models: 530 – 1,710 kHz (with the tuning
interval set at 10 kHz)
531 – 1,710 kHz (with the tuning
interval set at 9 kHz)
European, Russian, Middle Eastern and Philippine models:
531 – 1,602 kHz (with the tuning
interval set at 9 kHz)
Other models: 530 – 1,710 kHz (with the tuning
interval set at 10 kHz)
531 – 1,602 kHz (with the tuning
interval set at 9 kHz)
Antenna AM loop antenna
Antenna terminals External antenna terminal
Intermediate frequency 450 kHz
Speaker
North American models:
Front speaker SS-RG440 for HCD-GX45:
Speaker system 3-way, 3-unit, bass-reflex
type
Speaker units
Sub Woofer: 13 cm, cone type
Woofer: 13 cm, cone type
Tweeter: 5 cm, cone type
Nominal impedance 6 ohms
Dimensions (w/h/d) Approx. 240 ×325 ×243 mm
Mass Approx. 4.3 kg net per
speaker
Sub woofer speaker SS-WG990 for HCD-GX45:
Speaker system Bass-reflex type
Speaker units
Woofer: 20 cm, cone type
Nominal impedance 6 ohms
Dimensions (w/h/d) Approx. 265 ×325 ×350 mm
Mass Approx. 6.4 kg
European and Russian models:
Front speaker SS-RG440 for HCD-RG440:
Speaker system 3-way, 3-unit, bass-reflex
type
Speaker units
Woofer: 13 cm, cone type
Sub Woofer: 13 cm, cone type
Tweeter: 5 cm, cone type
Nominal impedance 6 ohms
Dimensions (w/h/d) Approx. 240 ×325 ×243 mm
Mass Approx. 4.3 kg net per
speaker
Sub woofer speaker SS-WG990 for HCD-RG440:
Speaker system Bass-reflex type
Speaker units
Woofer: 20 cm, cone type
Nominal impedance 6 ohms
Dimensions (w/h/d) Approx. 265 ×325 ×350 mm
Mass Approx. 6.4 kg
General
Power requirements
North American models: 120V AC, 60 Hz
European and Russian models:
230 V AC, 50/60 Hz
Australian model: 230 – 240 VAC, 50/60 Hz
Argentine model: 220 VAC, 50/60 Hz
Mexican model: 127 VAC, 60 Hz
Saudi Arabian model: 120 – 127 V/220 V or
230 – 240 VAC,
50/60 Hz
Adjustable with voltage
selector
Korean model: 220 VAC, 60 Hz
Other models: 120 V, 220 V or 230 –
240 V AC, 50/60 Hz
Adjustable with voltage
selector
Power consumption
USA model:
HCD-GX45: 180 watts
European and Russian models:
HCD-RG440: 150 watts
0.35 watts (at the Power
Saving Mode)
Other models:
HCD-RG440: 150 watts
Dimensions (w/h/d) Approx. 280 ×325 ×407 mm
Mass
NorthAmerican models:
HCD-GX45: Approx. 9.0 kg
European and Russian models:
HCD-RG440: Approx. 9.0 kg
Supplied accessories: AM loop antenna (1)
Remote Commander (1)
Batteries (2)
FM lead antenna (1)
Speaker pads (12)
Design and specifications are subject to change without
notice.
SAFETY-RELATED COMPONENT WARNING!!
COMPONENTS IDENTIFIED BY MARK 0OR DOTTED LINE
WITH MARK 0ON THE SCHEMATIC DIAGRAMS AND IN
THE PARTS LIST ARE CRITICAL TO SAFE OPERATION.
REPLACE THESE COMPONENTS WITH SONY PARTS WHOSE
PART NUMBERS APPEAR AS SHOWN IN THIS MANUAL OR
IN SUPPLEMENTS PUBLISHED BY SONY.
ATTENTION AU COMPOSANT AYANT RAPPORT
À LA SÉCURITÉ!!
LES COMPOSANTS IDENTIFIÉS PAR UNE MARQUE 0SUR LES
DIAGRAMMES SCHÉMATIQUES ET LA LISTE DES PIÈCES
SONT CRITIQUES POUR LASÉCURITÉ DE FONCTIONNEMENT.
NE REMPLACER CES COMPOSANTS QUE PAR DES PIÈCES
SONY DONT LES NUMÉROS SONT DONNÉS DANS CE MANUEL
OU DANS LES SUPPLÉMENTS PUBLIÉS PAR SONY.

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CAUTION
Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous
radiation exposure.
HCD-GX45/RG440
NOTES ON HANDLING THE OPTICAL PICK-UP BLOCK
OR BASE UNIT
The laser diode in the optical pick-up block may suffer electrostatic
breakdown because of the potential difference generated by the
charged electrostatic load, etc. on clothing and the human body.
During repair, pay attention to electrostatic break-down and also
use the procedure in the printed matter which is included in the
repair parts.
The flexible board is easily damaged and should be handled with
care.
NOTES ON LASER DIODE EMISSION CHECK
The laser beam on this model is concentrated so as to be focused on
the disc reflective surface by the objective lens in the optical pick-
up block. Therefore, when checking the laser diode emission,
observe from more than 30 cm away from the objective lens.
Laser component in this product is capable
of emitting radiation exceeding the limit for
Class 1.
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 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.
SETTING AND RELEASING THE CD DISC TRAY LOCK
FUNCTION
This set has a disc tray lock function to prevent discs for
demonstration at shops from theft. While this lock function is set,
the tray will not be delivered out even when the OPEN/CLOSE
button is pressed.
Setting method:
Press the OPEN/CLOSE button while pressing the STOP button.
After a few seconds, the message “LOCKED” will appear on the
fluorescent indicator tube with the tray locked.
Releasing method:
Just as the lock is set, press the OPEN/CLOSE button while
pressing the STOP button.
After a few seconds, the message “UNLOCKED” will appear with
the lock released.
To Exposed Metal
Parts on Set
0.15µF 1.5k
Ω
AC
voltmeter
(0.75V)
Earth Ground
Fig. A. Using an AC voltmeter to check AC leakage.
SAFETY CHECK-OUT
After correcting the original service problem, perform the following
safety check before releasing the set to the customer:
Check the antenna terminals, metal trim, “metallized” knobs, screws,
and all other exposed metal parts forAC leakage. Check leakage as
described below.
LEAKAGE TEST
The AC leakage from any exposed metal part to earth ground and
from all exposed metal parts to any exposed metal part having a
return to chassis, must not exceed 0.5 mA (500 microamperes).
Leakage current can be measured by any one of three methods.
1. A commercial leakage tester, such as the Simpson 229 or RCA
WT-540A. Follow the manufacturers’ instructions to use these
instruments.
2. A battery-operated AC milliammeter. The Data Precision 245
digital multimeter is suitable for this job.
3. Measuring the voltage drop across a resistor by means of aVOM
or battery-operatedAC voltmeter. The “limit” indication is 0.75
V, so analog meters must have an accurate low-voltage scale. The
Simpson 250 and Sanwa SH-63Trd are examples of a passive
VOM that is suitable. Nearly all battery operated digital
multimeters that have a 2V AC range are suitable. (See Fig. A)
LASER DIODE AND FOCUS SEARCH OPERATION
CHECK
Carry out the“S curvecheck”in “CDsection adjustment”andcheck
that the S curve waveforms is output three times.

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TABLE OF CONTENTS
HCD-GX45/RG440
1. GENERAL
Main Unit ................................................................................ 5
Remote Control ....................................................................... 5
2. DISASSEMBLY
2-1. Case (Top) ........................................................................... 7
2-2. CD Door .............................................................................. 7
2-3. CD Mechanism Block ......................................................... 8
2-4. Front Panel Section .............................................................9
2-5. Tape Mechanism Deck ...................................................... 10
2-6. Panel Board, 6 Stream Led Board, Remote Board............ 10
2-7. Game Jack Board, H/P Jack Board ................................... 11
2-8. Back Panel Section............................................................ 11
2-9. Main Board ....................................................................... 12
2-10. PowerAmp Board, Subwoofer Board............................... 12
2-11. SW Board, Driver Board ................................................... 13
2-12. CD Block Assy .................................................................. 13
2-13. Sensor Board ..................................................................... 14
2-14. Motor (TB) Board ............................................................. 14
2-15. Motor (LD) Board .............................................................15
2-16. BD Board .......................................................................... 15
2-17. Optical Pick-up ................................................................. 16
3. TEST MODE ..................................................................... 17
4. ELECTRICAL ADJUSTMENTS................................. 20
5. DIAGRAMS
5-1. IC Pin Descriptions ........................................................... 21
5-2. Block Diagram –CD Section–........................................... 25
5-3. Block Diagram –Tuner/Tape/Panel Section– .................... 26
5-4. Block Diagram –Amp/Power Supply Section–................. 27
5-5. Block Diagram –Sub Woofer Section– ............................. 28
5-6. Note for Printed Wiring Boards
and Schematic Diagrams .................................................. 29
5-7. Waveforms......................................................................... 29
5-8. Circuit Boards Location .................................................... 29
5-9. Printed Wiring Board –CD Mechanism Section (1/2)– .... 30
5-10. Schematic Diagram –CD Mechanism Section (1/2)– ....... 31
5-11. Printed Wiring Boards –CD Mechanism Section (2/2)– ... 32
5-12. Schematic Diagram –CD Mechanism Section (2/2)– ....... 33
5-13. Schematic Diagram –Main Section (1/4)– ........................ 34
5-14. Schematic Diagram –Main Section (2/4)– ........................ 35
5-15. Schematic Diagram –Main Section (3/4)– ........................ 36
5-16. Schematic Diagram –Main Section (4/4)– ........................ 37
5-17. Printed Wiring Board –Main Section– .............................. 38
5-18. Printed Wiring Boards and Schematic Diagram
–Jack Section– ................................................................... 39
5-19. Printed Wiring Boards –Panel Section– ............................ 40
5-20. Schematic Diagram –Panel Section– ................................ 41
5-21. Printed Wiring Board –Sub Woofer Section– ................... 42
5-22. Schematic Diagram –Sub Woofer Section– ...................... 43
5-23. Schematic Diagram –PowerAmp Section (1/2)– ............. 44
5-24. Schematic Diagram –PowerAmp Section (2/2)– ............. 45
5-25. Printed Wiring Board –PowerAmp Section– ................... 46
5-26. Printed Wiring Board
–Transformer Section– ...................................................... 47
5-27. Schematic Diagram –Transformer Section– ..................... 48
5-28. IC Block Diagrams............................................................ 49
6. EXPLODED VIEWS
6-1. Main Section ..................................................................... 52
6-2. Front Panel Section (1)......................................................53
6-3. Front Panel Section (2)......................................................54
6-4. Front Panel Section (3)......................................................55
6-5. Main Board Section .......................................................... 56
6-6. CD Mechanism Deck Section (1) ..................................... 57
6-7. CD Mechanism Deck Section (2) ..................................... 58
6-8. Base Unit Section .............................................................. 59
7. ELECTRICAL PARTS LIST ........................................ 60
MODEL IDENTIFICATION
– BACK PANEL –
MODEL PARTS No.
GX45: US, CND 4-244-697-31
RG440: AEP, UK, AUS 4-244-697-41
•Abbreviation
CND : Canadian model
AUS : Australian model
PARTS No.

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HCD-GX45/RG440
SECTION 1
GENERAL This section is extracted
from instruction manual.

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HCD-GX45/RG440 SECTION 2
DISASSEMBLY
Note : Disassemble the unit in the order as shown below.
2-1. CASE (TOP)
(Page 7)
2-2. CD DOOR
(Page 7)
SET
2-3. CD MECHANISM BLOCK
(Page 8)
2-8. BACK PANEL SECTION
(Page 11)
2-9. MAIN BOARD
(Page 12)
2-12. CD BLOCK ASSY
(Page 13)
2-16. BD BOARD
(Page 15)
2-10. POWER AMP BOARD,
SUBWOOFER BOARD
(Page 12)
2-4. FRONT PANEL SECTION
(Page 9)
2-5. TAPE MECHANISM DECK
(Page 10)
2-6. PANEL BOARD,
6 STREAM LED BOARD,
REMOTE BOARD
(Page 10)
2-13. SENSOR BOARD
(Page 14)
2-14. MOTOR (TB) BOARD
(Page 14)
2-15. MOTOR (LD) BOARD
(Page 15)
2-11. SW BOARD,
DRIVER BOARD
(Page 13)
2-7. GAME JACK BOARD,
H/P JACK BOARD
(Page 11)
2-17. OPTICAL PICK-UP
(Page 16)

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HCD-GX45/RG440
2-2. CD DOOR
Note : Follow the disassembly procedure in the numerical order given.
2-1. CASE (TOP)
case (side-R)
case (side-L)
5
qd
qs
qs
qs
qs
q;
6
two screws (case 3 TP2)
qf case (top)
8 screw
(+BVTP 3
× 10)
3 screw
(+BVTP 3
× 10
)
9 screw
(+BVTP 3
× 10)
4 screw
(+BVTP 3
× 10)
1 two screws
(case 3 TP2)
qa two screws (+BVTP 3 × 10)
7 screw (case 3 TP2)
2 screw (case 3 TP2)
2 Pull-out the disc tray.
4 CD door
1 Turn the pulley to the direction of the arrow.
pulley
Front panel side
CD mechanism deck (CDM74F-K6BD71B)
3

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HCD-GX45/RG440
2-3. CD MECHANISM BLOCK
1 CN701
7 CN312
(flat type)
5
6
2
three screws
(+BVTP 3
× 10)
8 CD mechanism block
4 screw
(+BVTP 3
× 10
)
3 screw
(+BVTP 3
× 10)
MAIN board
MAIN board

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HCD-GX45/RG440
2-4. FRONT PANEL SECTION
1 CN003
2 CN304
(flat type)
4 CN305
5 CN203
6 CN202
7 CN310
3 CN311
(flat type)
TRANS board
9 three screws (+BVTP 3 × 8 )
0 front panel section
8 screw
(+BVTP 3
× 8)

10
HCD-GX45/RG440
2-5. TAPE MECHANISM DECK
2 six screws
(+BVTP 2.6
× 8
)
3 tape mechanism deck
1 connector
2-6. PANEL BOARD, 6 STREAM LED BOARD, REMOTE BOARD
1 volume knob
7 PANEL board
9 6 STREAM LED board
qa REMOTE board
0 CN607
2 three screws
(+BVTP 2.6
× 8)
3 two screws
(+BVTP 2.6
× 8)
4 two screws
(+BVTP 2.6
× 8
)
8 two screws
(+BVTP 2.6
× 8)
6 two screws
(+BVTP 2.6
× 8)
5 three screws
(+BVTP 2.6
× 8)