Sony HCD-XG500 - Bookshelf System User manual

SERVICE MANUAL
COMPACT DISC DECK RECEIVER
US Model
Canadian Model
AEP Model
UK Model
HCD-XG500
E Model
HCD-XG60
SPECIFICATIONS
HCD-XG60/XG500
Photo: HCD-XG60
Ver 1.0 2001.02
9-929-577-11 Sony Corporation
2001B0500-1 Audio Entertainment Group
C2001.2 General Engineering Dept.
HCD-XG60/XG500 is the amplifier, CD
player, tape deck and tuner section in
LBT-XG60/XG500.
Dolby noise reduction manufactured under license
from Dolby Laboratories Licensing Corporation.
“DOLBY” and the double-D symbol ;are trade-
marks of Dolby Laboratories Licensing Corporation.
Model Name Using Similar Mechanism HCD-LX6/LX50/LX70
CD CD Mechanism Type CDM37M-5BD32L
Section Base Unit Name BU-5BD32L
Optical Pick-up Name KSS-213DH
TAPE Model Name Using Similar Mechanism NEW
Section Tape Transport Mechanism Type TCM-230PWR42
AUDIO POWER SPECIFICATIONS:
(US model only)
POWER OUTPUT AND TOTAL
HARMONIC DISTORTION
With 6 ohm loads both channels driven, from
120-10,000 Hz; rates 140 watts per channel
minimum RMS power, with no more than 10%
total harmonic distortion.
Amplifier section
Canadian model:
Continuous RMS power output (reference)
160 + 160 watts (6 ohms at
1 kHz, 10% THD)
Total harmonic distortion less than 0.07%
(6 ohms at 1 kHz, 70 W)
AEP, UK models:
DIN power output (rated) 110 + 110 watts
(6 ohms at 1 kHz, DIN)
Continuous RMS power output (reference)
140 + 140 watts
(6 ohms at 1 kHz, 10% THD)
Music power output (reference)
240 + 240 watts
(6 ohms at 1 kHz, 10% THD)
Other models:
The following measured at AC 120/220/240V, 50 Hz
DIN power output (rated) 150 + 150 watts
(6 ohms at 1 kHz, DIN)
Continuous RMS power output (reference)
200 + 200 watts
(6 ohms at 1 kHz, 10% THD)
Inputs
DJ MIX*:
(phono jacks) sensitivity 250 mV,
impedance 47 kilohms
GUITAR IN:
(phone jack) sensitivity 75 mV,
impedance 470 kilohms
PHONO IN:
(phono jacks) sensitivity 3 mV,
impedance 47 kilohms
MIX MIC:
(phone jack) sensitivity 1 mV,
impedance 10 kilohms
VIDEO IN:
(phono jacks) sensitivity 250 mV,
impedance 47 kilohms
GAME IN:
(phono jacks) sensitivity 250 mV,
impedance 47 kilohms
MD IN:
(phono jack) sensitivity 450 mV,
impedance 47 kilohms
Outputs
DJ MIX*:
(phono jacks) sensitivity 250 mV,
impedance 1 kilohms
PHONES:
(stereo phone jack) accepts headphones of 8
ohms or more
VIDEO OUT:
(phono jack) voltage 250 mV
impedance 1 kilohm
MD OUT:
(phono jacks) voltage 250 mV
impedance 1 kilohm
FRONT SPEAKER: accepts impedance of 6 to
16 ohms
* US, Canadian, AEP, UK, and Mexican models
only
CD player section
System Compact disc and digital
audio system
Laser Semiconductor laser
(λ=780nm), Emission
duration: continuous
Wavelength 780 – 790 nm
Frequency response 2 Hz – 20 kHz (±0.5 dB)
Signal-to-noise ratio More than 90 dB
Dynamic range More than 90 dB
CD OPTICAL DIGITAL OUT
(Square optical connector jack, rear panel)
Wavelength: 660 nm
Output level –18 dBm
– Continued on next page –

2
HCD-XG60/XG500
Tape player section
Recording system 4-track 2-channel stereo
Frequency response 40 –13,000 Hz (±3 dB),
(DOLBY NR OFF)
using Sony TYPE I cassette
40 –14,000 Hz (±3 dB),
using Sony TYPE II cassette
Tuner section
FM stereo, FM/AM superheterodyne tuner
FM tuner section
Tuning range
US, Canadian models: 87.5 –108.0 MHz (100
kHz step)
Other models: 87.5 –108.0 MHz
(50 kHz step)
Antenna FM lead antenna
Antenna terminals 75 ohm unbalanced
Intermediate frequency 10.7 MHz
AM tuner section
Tuning range
US, Canadian, Mexican, Argentina models:
530 –1,710 kHz
(with the interval set at 10
kHz)
531 –1,710 kHz
(with the interval set at 9
kHz)
Other models: 531 –1,602 kHz
(with the interval set at 9
kHz)
Singapore model: 531 –1,602 kHz
(with the interval set at 9
kHz)
530 –1,710 kHz
(with the interval set at 10
kHz)
Antenna AM loop antenna
Antenna terminals External antenna terminal
Intermediate frequency 450 kHz
General
Power requirements
US, Canadian models: 120 V AC, 60 Hz
AEP, UK models: 230 V AC, 50/60 Hz
Mexican model: 120 V AC, 50/60 Hz
Other models: 120 V, 220 V or 230 –240
V AC, 50/60 Hz
Adjustable with voltage
selector
Power consumption
US model: 240 watts
Canadian model: 320VA
AEP, UK models: 220 watts
0.6 watts (at the power
saving mode)
Other models: 180 watts
Dimensions (w/h/d) Approx. 355 x 425 x 450
mm
Mass :
HCD-XG500 Approx. 13.5 kg
HCD-XG60 Approx. 15.0 kg
Supplied accessories: AM loop antenna (1)
FM lead antenna (1)
Speaker cords (2)
Speaker pads (8)
Remote commander (1)
Batteries (2)
Design and specifications are subject to change
without notice.

3
HCD-XG60/XG500
TABLE OF CONTENTS
1. SERVICING NOTES ................................................ 5
2. GENERAL
Location of Controls ....................................................... 6
Setting the Time .............................................................. 7
3. DISASSEMBLY
3-1. Disassembly Flow ........................................................... 8
3-2. Case ................................................................................. 8
3-3. Front Panel Section ......................................................... 9
3-4. Cover (TC), Tape Mechanism Deck
(TCM-230PWR42) ......................................................... 9
3-5. MAIN Board, Fan, D.C. (M901)
(Except AEP, UK Models) .............................................. 10
3-6. MAIN Board (AEP, UK Models) ................................... 10
3-7. CD Mechanism Deck (CDM37M-5BD32L) .................. 11
3-8. Base Unit (BU-5B32L) ................................................... 12
3-9. Disc Table........................................................................ 12
4. TEST MODE.............................................................. 13
5. MECHANICAL ADJUSTMENTS....................... 15
6. ELECTRICAL ADJUSTMENTS
Deck section .................................................................... 15
CD Section ...................................................................... 18
7. DIAGRAMS
7-1. Block Diagram –CD SERVO Section –....................... 19
7-2. Block Diagram –TUNER/TAPE DECK Section –...... 20
7-3. Block Diagram –MAIN Section –................................ 21
7-4. Block Diagram –DISPLAY/KEY CONTROL/
POWER SUPPLY Section –........................................... 22
7-5. Note for Printed Wiring Boards and
Schematic Diagrams ....................................................... 23
7-6. Printed Wiring Board –BD Board –............................. 24
7-7. Schematic Diagram –BD Board –................................ 25
7-8. Printed Wiring Boards –CD MOTOR Section –.......... 26
7-9. Schematic Diagram –CD MOTOR Section –.............. 27
7-10. Printed Wiring Board –AUDIO Board –...................... 28
7-11. Schematic Diagram –AUDIO Board –......................... 29
7-12. Printed Wiring Board –LEAF SW Board –.................. 30
7-13. Schematic Diagram –LEAF SW Board –..................... 30
7-14. Schematic Diagram –MAIN Board (1/3) –.................. 31
7-15. Schematic Diagram –MAIN Board (2/3) –.................. 32
7-16. Schematic Diagram –MAIN Board (3/3) –.................. 33
7-17. Printed Wiring Board –MAIN Board –........................ 34
7-18. Printed Wiring Board –PA Board –.............................. 36
7-19. Schematic Diagram –PA Board –................................. 37
7-20. Printed Wiring Boards –MIC/FRONT INPUT/
HEADPHONES Boards –............................................... 38
7-21. Schematic Diagram –MIC/FRONT INPUT/
HEADPHONES Boards –............................................. 39
7-22. Printed Wiring Board –PANEL FL Board –................ 40
7-23. Schematic Diagram –PANEL FL Board –................... 41
7-24. Printed Wiring Boards
–PANEL VR/ILLUMINATION Boards –..................... 42
7-25. Schematic Diagram
–PANEL VR/ILLUMINATION Boards –..................... 43
7-26. Printed Wiring Boards –TC-A/TC-B/CD-L/
CD-R (1)/CD-R (2) Boards –......................................... 44
7-27. Schematic Diagram –TC-A/TC-B/CD-L/
CD-R (1)/CD-R (2) Boards –......................................... 45
7-28. Printed Wiring Board –TRANSFORMER Section–.... 46
7-29. Schematic Diagram –TRANSFORMER Section–....... 46
7-30. IC Pin Function Description ........................................... 50
8. EXPLODED VIEWS
8-1. Case, Back Panel Section................................................ 55
8-2. Front Panel Section-1...................................................... 56
8-3. Front Panel Section-2...................................................... 57
8-4. Chassis Section ............................................................... 58
8-5. Tape Mechanism Deck Section-1
(TCM-230PWR42) ......................................................... 59
8-6. Tape Mechanism Deck Section-2
(TCM230PWR42)........................................................... 60
8-7. CD Mechanism Deck Section (CDM37M-5BD32L) .... 61
8-8. Base Unit Section (BU-5BD32L) ................................... 62
9. ELECTRICAL PARTS LIST ............................... 63

4
HCD-XG60/XG500
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.
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.
CAUTION
Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous ra-
diation exposure.
SAFETY CHECK-OUT
After correcting the original service problem, perform the follow-
ing safety check before releasing the set to the customer:
Check the antenna terminals, metal trim, “metallized”knobs,
screws, and all other exposed metal parts for AC leakage.
Check leakage as described below.
LEAKAGE TEST
TheAC 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-operatedAC milliammeter. The Data Precision 245
digital multimeter is suitable for this job.
3. Measuring the voltage drop across a resistor by means of a
VOM or battery-operated AC voltmeter. The “limit”indica-
tion is 0.75 V, so analog meters must have an accurate low-
voltage scale. The Simpson 250 and Sanwa SH-63Trd are ex-
amples of a passive VOM that is suitable. Nearly all battery
operated digital multimeters that have a 2V AC range are suit-
able. (See Fig. A)
Fig. A. Using an AC voltmeter to check AC leakage.
1.5 k Ω 0.15 µ FAC
voltmete
r
(0.75 V)
To Exposed Metal
Parts on Set
Earth Ground
ATTENTION AU COMPOSANT AYANT RAPPORT
À LA SÉCURITÉ!
LES COMPOSANTS IDENTIFIÉS PAR UNE MARQUE 0
SUR LES DIAGRAMMES SCHÉMATIQUES ET LA LISTE
DES PIÈCES SONT CRITIQUES POUR LA SÉCURITÉ
DE FONCTIONNEMENT. NE REMPLACER CES COM-
POSANTS QUE PAR DES PIÈCES SONY DONT LES
NUMÉROS SONT DONNÉS DANS CE MANUEL OU
DANS LES SUPPLÉMENTS PUBLIÉS PAR SONY.
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 PUB-
LISHED BY SONY.
The following caution label is located inside the unit.
This appliance is classified as
a CLASS 1 LASER product.
The CLASS 1 LASER
PRODUCT MARKING is
located on the rear exterior.

5
HCD-XG60/XG500
NOTES ON HANDLING THE OPTICAL PICK-UP
BLOCK OR BASE UNIT
The laser diode in the optical pick-up block may suffer electro-
static break-down 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 emis-
sion, observe from more than 30 cm away from the objective lens.
LASER DIODE AND FOCUS SEARCH OPERATION
CHECK
Carry out the “S curve check” in “CD section adjustment” and
check that the S curve waveforms is output three times.
SECTION 1
SERVICING NOTES
• MODEL IDENTIFICATION
– Rear Panel –
PART No.
MODEL PART No.
US model 4-232-087-0[]
AEP and UK models 4-232-087-1[]
120 V AC area in E and
Argentina models 4-232-087-2[]
Singapore model 4-232-087-3[]
Mexican model 4-232-087-4[]
Saudi Arabia model 4-232-087-5[]
Canadian model 4-232-087-6[]

6
HCD-XG60/XG500 SECTION 2
GENERAL This section is extracted from
instruction manual.
CD SYNC qg (16,17)
DIRECT EQUALIZER 5(18)
SALSA
REGGAE
SAMBA
TANGO
MOVIE
GUITAR
ROCK
JAZZ
DANCE
GAME
DIRECTION eh (15,16,17)
DISC SKIP qk (9,10,17)
DISC 1~5 wj (9)
DISPLAY3(8,11,13)
DOLBY NR eh (15,16)
EDIT wl (17)
ENTER wh (12,27)
ENTER/NEXT qd (8,14,17,19,22)
FLAT qd (18)
FLASH e; (11)
FUNCTIONq; (7,9,10,16,17,23,24)
GAME qa (21)
AUDIO L w; (23)
AUDIO R ql (23)
VIDEO wa (23)
GROOVE r; (18)
GUITAR DISTORTION wh (21)
GUITAR jack es (21)
GUITAR LEVEL eg (21)
H SPEED DUB qg (16)
Jog dial (AMS./>) qj
(9,10,11,17)
LOOP ea (7,11)
MIC LEVEL ef (20)
MIX GUITAR/KARAOKE ej (20,21)
MIX MIC jack ed (20)
NON STOP wk (10)
P.FILE qd (18,19)
PLAY MODE qk (9,10,17)
PHONES jack qh
POWER SAVE/DEMO
(STANDBY) 2(8)
PTY ws (14) (AEP, UK models)
PUSH OPEN wf (9)
REPEAT qk (9)
SPECTRUM ANALYZER 4(20)
SLEEP 7(21)
STEREO/MONO ws (13)
SUPER WOOFER el (18)
SUPER WOOFER MODE ek (18)
SURROUND ra(16,18)
TUNER/BAND wd(12,13,16)
TUNER MEMORY wh (12)
TIMER SELECT 8(22)
TUNING MODE ws (12,13)
VOLUME control qs (9,13,15)
BUTTON DESCRIPTIONS
@/1 1
c/CLOCK SET 6
v/V/b/B9
z REC qf
Xqf
m/M, AMS./> qfeh
h,Hqfeh
xqfqkeh
HX qk
+/– wd
A EJECT Z/Z B EJECT wg
wawswdwfwgwjwkwl
e;
ea
es
ed
ef
eg
ej
el
ek
r;
ra
eh
wh w;ql
qd
qs
qa
234 5 6 789
q;
qf
qg
qh
qj
qk
1
LOCATION OF CONTROLS
– Front Panel –

7
HCD-XG60/XG500
1ANTENNA terminal
2DJ MIX RETURN/SEND jack
(US, Canadian, AEP, UK Mexican models)
3PHONO IN jack
4MD IN/OUT jack
5VIDEO/AUDIO IN jack
6VIDEO OUT jack
7FRONT SPEAKER terminal
8CD DIGITAL OUT OPTICAL terminal
9VOLTAGE SELECTOR switch
(120 V AC area in E, Saudi Arabia, Singapore, Argentina models)
– Rear Panel –
2
1
3
5
8
9
7
4
6
Setting the time
1
Turn on the system.
2Press c/CLOCK SET.
When you set the time for the first time,
skip to the step 5.
3Press v/Vrepeatedly to select SET
CLOCK.
4Press ENTER/NEXT.
5Press v/Vrepeatedly to set the hour.
6Press ENTER/NEXT.
The minute indication flashes.
7Press v/Vrepeatedly to set the minute.
8Press ENTER/NEXT.
The clock starts working.
Tip
If you’ve made a mistake or want to change the time,
start over from step 1.
Note
The clock settings are canceled when you disconnect
the power cord or if a power failure occurs.
Remote control
AMS ./>, PRESET+/–5
(9,13,14,15)
CD Nwa (9)
CHECK 8(10)
CLEAR 7(10)
DECK A Nql (15)
DECK B Nqk (15)
DISC SKIP 1(9,10,17)
FILE SELECT ON/OFF qf (18)
FILE SELECT F/f qg (11)
FLASH qs (11)
FUNCTION qa
(7,9,10,16,17,23,24)
LOOP qh (11)
MD Nqj
MD X0
MD x9
SLEEP 2(21)
TUNER/BAND w;(12,16)
VOL +/–qd (9,13,15)
BUTTON DESCRIPTIONS
@/1 3
x4
m/M6
Xws
ql
qk
qj
qh
qg
qf
ws
wa
w;
6
7
8
9
q;
4
5
qd
qs
qa
123

8
HCD-XG60/XG500
• This set can be disassembled in the order shown below.
3-1. DISASSEMBLY FLOW
SECTION 3
DISASSEMBLY
Note: Follow the disassembly procedure in the numerical order given.
3-2. CASE
3-2. CASE
(Page 8)
3-3. FRONT PANEL SECTION
(Page 9)
3-4. COVER (TC),
TAPE MECHANISM DECK
(TCM-230PWR42)
(Page 9)
3-7. CD MECHANISM DECK
(CDM37M-5BD32L)
(Page 11)
3-8. BASE UNIT
(BU-5BD32L)
(Page 12) 3-9. DISC TABLE
(Page 12)
3-6. MAIN BOARD
(AEP, UK MODELS)
(Page 10)
3-5. MAIN BOARD,
FAN, D.C. (M901)
(EXCEPT AEP, UK MODELS)
(Page 10)
SET
1 three screws
(CASE3 TP2)
1 three screws
(CASE3 TP2)
2 five screws
(BVTT3
× 6)
3 two screws
(BVTP3
× 8
)
4
4
5
5
6 case

9
HCD-XG60/XG500
3-3. FRONT PANEL SECTION
3-4. COVER (TC), TAPE MECHANISM DECK (TCM-230PWR42)
1 wire (flat type)
(15 core) (CN303)
2 two connectors
(CN452, 702)
1 wire (flat type)
(17 core) (CN304)
1 wire (flat type)
(13 core) (CN431)
3 screw
(BVTP3
× 8
)
4 two lugs
4 lug
2 connector
(CN806)
5 screw
(BVTP3
× 8)
6 claw
5 four screws
(BVTP3
× 8)
7 front panel section
3 two screws
(BVTP3
× 8)
1 five claws
2 cover (TC)
4 two screws
(BVTP3
× 8)
3 wire (flat type) (17 core)
(CN1001)
3 wire (flat type) (15 core
)
(CN601)
4 two screws
(BVTP3
× 8)
5 tape mechanism deck
(TCM-230PWR42)

10
HCD-XG60/XG500
3-5. MAIN BOARD, FAN, D.C. (M901) (EXCEPT AEP, UK MODELS)
3-6. MAIN BOARD (AEP, UK MODELS)
9 wire (flat type) (19 core)
(CN411)
7 fan, D.C.
(M901)
8 back panel
1 wire (flat type)
(13 core) (CN441)
3 eight screws
(BVTP3
× 8)
3 three screws
(BVTP3
× 8)
3 three screws
(BVTP3
× 8)
6 two screws
(BVTP3
× 8)
3 screw
(BVTP3
× 8)
2 jumper plug
US, Canadian, Mexican models
3 three screws
(BVTP3
× 8)
qa two screws
(BVTP3
× 8)
qs two connectors
(CN803, 804)
0 connector
(CN412)
4
5
connector (CN903)
qd MAIN board
6 wire (flat type) (19 core)
(CN411)
5 back panel
1 wire (flat type)
(15 core) (CN441)
3 seven screws
(BVTP3
× 8)
3 three screws
(BVTP3
× 8)
3 three screws
(BVTP3
× 8)
3 screw
(BVTP3
× 8
)
2 jumper plug
3 three screws
(BVTP3
× 8)
8 two screws
(BVTP3
× 8)
9 two connectors
(CN803, 804)
7 connector
(CN412)
4
0
MAIN board

11
HCD-XG60/XG500
3-7. CD MECHANISM DECK (CDM37M-5BD32L)
2 connector
(CN412)
4 three screws
(BVTP3
× 8)
5
6
5
1
wire (flat type)
(19 core) (CN411)
3 four screws
(BVTP3
× 8)
4 two screws
(BVTP3
× 8)
7 Open the cable clamp.
9 CD mechanism deck
(CDM37M-5BD32)
8 five screws
(BVTP3 × 8)

12
HCD-XG60/XG500
3-8. BASE UNIT (BU-5BD32L)
3base unit
(BU-5BD32L)
1BU fitting scre
w
2boss
3-9. DISC TABLE
Note: When the disc table is installed, adjust the positions of roller cam
and mark B as shown in the figure, then set to the groove of disc
table.
1two screws
(BVTP3 ×8)
A
2two brackets (BU)
3step screw
4disc tabl
e
A

13
HCD-XG60/XG500
[CD Delivery Mode]
• This mode moves the optical pick-up to the position durable to
vibration. Use this mode when returning the set to the customer
after repair.
Procedure:
1. Press the ?/1button to turn the power ON.
2. Press the [LOOP] and ?/1buttons simultaneously.
3. A message “LOCK” is displayed on the fluorescent indicator
tube, and the CD delivery mode is set.
[LED and Fluorescent IndicatorTube All Lit, Key Check
Mode]
Procedure:
1. Press three buttons of [ /CLOCK SET], [ENTER/NEXT],
and [DISC 2] simultaneously.
2. LEDs and fluorescent indicator tube are all turned on.
Press the [DISC 2] button, and the key check mode is acti-
vated.
3. In the key check mode, the fluorescent indicator tube displays
“K 0 J0 V0”. Each time a button is pressed, “K” value in-
creases. However, once a button is pressed, it is no longer taken
into account.
“J” value increases like 1, 2, 3 ... if turn the JOG dial clock-
wise, or it decreases like 0, 9, 8 ... if turn the JOG dial counter-
clockwise.
“V” value increases like 1, 2, 3 ... if turn the [VOLUME] dial
clockwise, or it decreases like 0, 9, 8 ... if turn the JOG dial
counterclockwise.
4. To release from this mode, press three buttons in the same
manner as step 1, or disconnect the power cord.
c
[MC Cold Reset]
• The cold reset clears all data including preset data stored in the
RAM to initial conditions. Execute this mode when returning
the set to the customer.
Procedure:
1. Turn the power ON or set to the DEMO mode.
2. Press three buttons of [ /CLOCK SET], [ENTER/NEXT], and
?/1simultaneously.
3. The set is reset, and displays “COLD RESET”, then becomes
DEMO mode.
[MC Hot Reset]
• This mode resets the set with the preset data kept stored in the
memory. The hot reset mode functions same as if the power
cord is plugged in and out.
Procedure:
1. Turn the power ON or set to the DEMO mode.
2. Press three buttons of [ /CLOCK SET], [ENTER/NEXT],
and [DISC 1] simultaneously.
3. The set is reset, and becomes standby state.
[Change-over the AMTuning Interval]
(EXCEPT AEP, UK, and Saudi Arabia models)
• The AM tuning interval can be changed over 9 kHz or 10 kHz.
Procedure:
1. Press the ?/1button to turn the power ON.
2. Select the function “TUNER”, and press the [TUNER/BAND]
button to select the BAND “AM”.
3. Press the ?/1button to turn the power OFF.
4. Press the [ENTER/NEXT] and ?/1buttons simultaneously,
and the display on the fluorescent indicator tube changes to
“AM 9 K STEP” or “AM 10 K STEP”, and thus the tuning
interval is changed over.
c
SECTION 4
TEST MODE
c

14
HCD-XG60/XG500
[Aging Mode]
This mode can be used for operation check of tape deck section.
Tape deck section work in parallel.
• If an error occurred:
The aging operation stops and display then status.
• If no error occurs:
The aging operation continues repeatedly.
Procedure:
1. Load the tapes into the decks A and B respectively.
2. Press the [FUNCTION] button to select the function “CD”.
3. Press the [PLAY MODE] button to set the “ALL DISCS” mode,
and press the [REPEAT] button to “REPEAT” off.
4. Press three buttons of [ /CLOCK SET], [ENTER/NEXT],
and [DISC 4] simultaneously.
5. The aging mode is activated, if the indicator of disc tray num-
ber on the fluorescent indicator tube is blinking.
6. To release from the aging mode, press the ?/1button to turn
the power OFF and operate the cold reset. (Refer to the “MC
Cold Reset”)
1. Display at the Aging Mode
• Display operating state of tape deck section alternately.
• If an error occurred, stop display.
2. Tape Deck Section
• The sequence during the aging mode is following as below.
• If an error occurred, stop display that step.
Aging mode sequence (Tape deck section) :
Rewind the tape A and B
“TAPE A AG-1”
Shut off
FWD play the tape A
“TAPE A AG-2”
2 minutes
Fast forward the tape A
“TAPE A AG-3”
Shut off or 20 seconds
REV play the tape A
“TAPE A AG-4”
2 minutes
Rewind the tape A
“TAPE A AG-5”
Shut off
FWD play the tape B
“TAPE B AG-2”
2 minutes
Fast forward the tape B
“TAPE B AG-3”
Shut off or 20 seconds
REV play the tape B
“TAPE B AG-4”
2 minutes
Rewind the tape B
“TAPE B AG-5”
Shut off
Note: “TAPE *AG-*” is display of each step.
c

15
HCD-XG60/XG500
SECTION 5
MECHANICAL ADJUSTMENTS SECTION 6 ELECTRICAL ADJUSTMENTS
Precaution
1. Clean the following parts with a denatured alcohol-moistened
swab:
record/playback heads pinch rollers
erase head rubber belts
capstan idlers
2. Demagnetize the record/playback head with a head demagne-
tizer.
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 rated power sup-
ply voltage unless otherwise noted.
Torque Measurement
Mode Torque Meter Meter Reading
3.1~6.96 mN•m
FWD CQ-102C (31 to 71 g•cm)
(0.43 – 0.98 oz•inch)
FWD 0.20~0.58 mN•m
back tension CQ-102C (2 to 6 g•cm)
(0.03 – 0.08 oz•inch)
3.1~6.96 mN•m
REV CQ-102RC (31 to 71 g•cm)
(0.43 – 0.98 oz • inch)
REV 0.20~0.58 mN•m
back tension CQ-102RC (2 to 6 g•cm)
(0.03 – 0.08 oz • inch)
6.97~14.02 mN•m
FF/REW CQ-201B (71 to 143 g•cm)
(0.99 – 1.99 oz • inch)
9.80 mN•m
FWD tension CQ-403A (100 g or more)
(3.53 oz or more)
9.80 mN•m
REV tension CQ-403A (100 g or more)
(3.53 oz or more)
Precaution
1. Demagnetize the record/playback head with a head demagne-
tizer.
2. Do not use a magnetized screwdriver for the adjustments.
3. After the adjustments, apply suitable locking compound to the
parts adjust.
4. The adjustments should be performed with the rated power
supply voltage unless otherwise noted.
5. The adjustments should be performed in the order given in
this service manual. (As a general rule, playback circuit ad-
justment should be completed before performing recording
circuit adjustment.)
6. The adjustments should be performed for both L-CH and R-
CH.
7. Switches and controls should be set as follows unless other-
wise specified.
8. Set to the DOLBY NR OFF.
9. Set to the test mode.
(1) Press the ?/1button to turn the power ON.
(2) Select the function “TAPE A or B”.
(3) Press the button of [ /CLOCK SET], [ENTER/NEXT],
and [DISC 3] simultaneously, to set the tape deck test mode
and displays “TEST MODE” on the fluorescent indicator
tube.
(4) To release from the test mode, press the ?/1button.
• Test Tape
Tape Signal Used for
P-4-A100 10 kHz, – 10 dB Azimuth Adjustment
WS-48B 3 kHz, 0 dB Tape Speed Adjustment
P-4-L300 315 Hz, 0 dB Playback Level Adjustment
0 dB = 0.775 V
DECK SECTION
c

16
HCD-XG60/XG500
Tape Speed Adjustment DECK B
Mode: Playback
1. Insert the WS-48B into the deck B.
2. Press the Hbutton on the deck B.
3. Press the [H SPEED DUB] button in playback mode.
Then at HIGH speed mode.
4. Adjust RV1001 on the LEAF SW board do that frequency
counter reads 6,000 ±180 Hz.
5. Press the [H SPEED DUB] button.
Then back to NORMAL speed mode.
6. Adjust RV1002 on the LEAF SW board so that frequency
counter reads 3,000 ±90 Hz.
Adjustment Location: LEAF SW board
Sample value of Wow and Flutter: 0.3% or less W.RMS (JIS)
(WS-48B)
Playback Level Adjustment DECK A DECK B
Procedure:
Mode: Playback
Deck A is RV311 (L-CH), Deck B is RV301 (L-CH) so that ad-
justment within specification values as follows.
Specification Values:
J101 PB level: 301.5 to 338.3 mV (– 8.2 to – 7.2 dB) level
difference between the channels: within ±0.5 dB
Adjustment Location: AUDIO board
2. Turn the adjustment screw and check output peaks. If the peaks
do not match for L-CH and R-CH, turn the adjustment screw
so that outputs match within 1dB of peak.
3. Mode: Playback
4. Repeat step 1 to 3 in playback (REV) mode.
5. After the adjustments, apply suitable locking compound to the
pats adjusted.
Screw
position
L-CH
peak
within
1dB
Output
level
L-CH
peak
R-CH
peak
within
1dB
Screw
position
R-CH
peak
set
test tape
P-4-A100
(10 kHz, – 10 dB)
R-CH
oscilloscope
L-CH
R-CH
VH
waveform of oscilloscope
in phase 45°90°135°180 °
good wrong
MAIN board
MD OUT jack (J701)
L-CH
+
–
set
test tape
WS-48B
(3 kHz, 0 dB)
MAIN board
MD OUT jack (J701)
L-CH, R-CH
frequency counter
+
–
set
test tape
P-4-L300
(315 Hz, 0 dB)
MAIN board
MD OUT jack (J701)
L-CH
level mete
r
Record/Playback Head Azimuth Adjustment
Note: Perform this adjustments for both decks
Procedure:
1. Mode: Playback (FWD)
DECK A DECK B
set
MAIN board
MD OUT jack (J701)
L-CH, R-CH
+
–
level mete
r
test tape
P-4-A100
(10 kHz, –10 dB)
Adjustment Location:Playback Head (Deck A).
Record/Playback/Erase Head (Deck B).
reverse
forward

17
HCD-XG60/XG500
REC Bias Adjustment DECK B
Procedure:
1. Mode: Record
FUNCTION: VIDEO
2. Mode: Playback
3. Confirm playback the signal recorded in step 1 become speci-
fication values as follows.
If these values are out of specification values, adjust the RV341
(L-CH) and RV441 (R-CH) on the AUDIO board to repeat
steps 1and 2.
Specification values: Playback output of 315 Hz to playback
output of 10 kHz: ±0.5 dB
Adjustment Location: AUDIO board
REC Level Adjustment DECK B
Procedure:
1. Mode: Record
FUNCTION: VIDEO
2. Mode: Playback
3. Confirm playback the signal recorded in step 1 become speci-
fication values as follows.
If these values are out of specification values, adjust the RV301
(L-CH) and RV351 (R-CH) on the MAIN board to repeat steps
1 and 2.
Specification values:
J101 PB level: 47.2 to 53.0 mV (– 24.3 to – 23.3 dB)
Adjustment Location: MAIN board
attenuator
set
MAIN board
VIDEO AUDIO IN jack (J701)
L-CH, R-CH
1) 315 Hz
2) 10 kHz 50 mV (–23.8 dB)



600 Ω
blank tap
e
CN-123
AF OSC
+
–
set
recorded
portion
MAIN board
MD OUT jack (J701)
L-CH, R-CH
level mete
r
set
MAIN board
VIDEO AUDIO IN jack (J701)
L-CH, R-CH
315 Hz, 50 mV (–23.8 dB) blank tape
CS-123
600
Ω
attenuator
AF OSC
+
–
set
recorded
portion
MAIN board
MD OUT jack (J701)
L-CH, R-CH
level mete
r
RV301 RV341 RV311
IC602 CN601
RL
  
RV441
PB LEVEL
(L)
–DECK B –
REC BIAS PB LEVEL (L)
–DECK A –
– AUDIO BOARD (Component Side) –
TAPE SPEED
RV1002 RV1001
(NORMAL) (HIGH)
CN1001
         
–LEAF SW BOARD (Component Side) –
MD OUT
L/R
IC301 REC LEVEL
RV301
L-CH
RV351
R-CH
VIDEO
AUDIO IN
L/R
J701
          









–MAIN BOARD (Conductor Side) –

18
HCD-XG60/XG500
Note:
1. CD Block is basically designed to operate without adjustment. There-
fore, check each item in order given.
2. Use YEDS-18 disc (3-702-101-01) unless otherwise indicated.
3. Use an oscilloscope with more than 10 MΩimpedance.
4. Clean the object lens by an applicator with neutral detergent when the
signal level is low than specified value with the following checks.
S-Curve Check
Procedure:
1. Connect oscilloscope to TP (FE) and TP (VC).
2. Connect between TP (FE1) and TP (VC) by lead wire.
3. Connect between TP (AGCCON) and TP (GND) by lead wire.
4. Turn the power ON.
5. Load a disc (YEDS-18) and actuate the focus search. (In con-
sequence of open and close the disc tray, actuate the focus
search)
6. Cofirm that the oscilloscope waveform (S-curve) is symmetri-
cal between A and B. And confirm peak to peak level within
4 ±1 Vp-p.
S-curve waveform
7. After check, remove the lead wire connected in step 2 and 3.
Note: • Try to measure several times to make sure than the ratio ofA : B
or B : A is more than 10 : 7.
• Take sweep time as long as possible and light up the brightness
to obtain best waveform.
RF Level Check
Procedure:
1. Connect oscilloscope to TP (RF) and TP (VC).
2. Connect between TP (AGCCON) and TP (GND) by lead wire.
3. Turn the power ON.
4. Load a disc (YEDS-18) and press the HXbutton to play.
5. Confirm that the oscilloscope waveform is clear and check RF
signal level is correct or not.
6. After check, remove the lead wire connected in step 2.
Note: Clear RF signal waveform means that the shape “ ” can be clearly
distinguished at the center of the waveform.
CD SECTION
+
–
BD board
TP (FE)
TP (VC)
oscilloscop
e
A
B
symmetry
within 4 ±1 Vp-p
+
–
BD board
TP (RF)
TP (VC)
oscilloscop
e
(AC range)
VOLT/DIV: 200 mV
TIME/DIV: 500 ns
(with the 10: 1 probe
in use)
level:
1.45 ±0.3 Vp-p
E-F Balance (1Track Jump) Check
Procedure :
1. Connect oscilloscpe to TP (TE) and TP (VC).
2. Turn the power ON.
3. Load a disc (YEDS-18) and playback the number five track.
4. Press the HXbutton. (Becomes the 1 track jump mode)
5. Confirm that the level B and A (DC voltage) on the oscillo-
scope waveform.
1 track jump waveform
Specified level: ×100 = less than ±22%
6. After check, remove the lead wire connected in step 1.
Checking Location:
A
B
+
–
BD board
TP (TE)
TP (VC)
oscilloscope
(DC range)
A (DC voltage
)
center of
waveform
B
0V
level = 1.3 ±0.6 Vp-p symmetry
–BD BOARD (Side B) –
TP (VC)
TP (FE)
TP (FE1)
TP (TE)
TP (RF)
TP (AGCCON)
TP (GND)
IC102
IC103

HCD-XG60/XG500
1919
SECTION 7
DIAGRAMS
7-1. BLOCK DIAGRAM – CD SERVO Section –
SQSO SQCK
A/D
CONVERTER
CH1OUTF
CH1OUTR
5
4
7
2
1
5
10
6
6
7
8
16
14
13
10
11
22
4
3
51
49
48
43
24
41
40 39
64 15
28
29
30
31
32
33
24
25
23
5
6
2
3
17
18
15
16
E
B
C
D
A
CD D+5V
F
DETECTOR
A
B
C
D
RF
SUMMING
AMP
FOCUS
ERROR AMP
RF EQ
AMP
TRACKING
ERROR AMP
RFO
FE
RF AMP,
FOCUS/TRACKING ERROR AMP
IC103
TE
E
FF I-V AMP
E I-V AMP
AUTOMATIC
POWER
CONTROL
Q101
APC LD
AMP APC PD
AMP
LD
LD
PD
LASER DIODE
RFAC
ASYO
ASYI
ASYMMETRY
CORRECTION
DIGITAL
PLL
DIGITAL SIGNAL PROCESSOR,
DIGITAL FILTER, D/A CONVERTER
IC101 (1/2)
DATA
XLAT
CLOK
14 5 6
MDP
26 78
XLON
3
XRST
DIGITAL
CLV
D/A
INTERFACE
SE
TE
FE
RFDC
FOCUS/TRACKING/SLED
SERVO DSP
FOCUS/TRACKING/SLED
PWM GENERATOR
SFDR
CH3FIN
CH4SIN
CH3RIN
CH3OUTF
CH3OUTR
CH2FIN
CH2RIN
CH1FIN
CH1RIN
20
MUTE
SRDR
TFDR
TRDR
FFDR
FRDR
S101
(LIMIT)
EMPH
WFCK GFS
MIRR/DFCT/
FOK
DETECTOR
SERVO AUTO
SEQUENCER
SERVO
INTERFACE
CPU INTERFACE
18
63
62
61
19
SENS
20
35
57
58
37
56
19
SCOR
SQ-DATA
SQ-CLK
CD-DATA
XLT
CD-CLK
SENS
SCOR
1 2
32
33
SCLK
COUT
9 21
SSTP
27
FOK
22
23
MIRR
DFCT
TO SERVO INTERFACE
CH4OUTF
CH4OUTR
M101
(SPINDLE)
MOTOR
DRIVE
MOTOR
DRIVE
COIL
DRIVE
CH2OUTF
CH2OUTR
COIL
DRIVE
M
M
M102
(SLED)
FOCUS/TRACKING COIL DRIVE,
SPINDLE/SLED MOTOR DRIVE
IC102
2-AXIS
DEVICE
(TRACKING)
(FOCUS)
DIGITAL SERVO
PROCESSOR
IC101 (2/2)
OPTICAL PICK-UP BLOCK
(KSS-213DH)
LDON
21
HOLD SW
PD
I-V AMP
12
11
13
14
54 56 53 55
FILTER
FILO
PCO
CLTV
FILI
EFM
DEMODULATOR
SERIAL
IN
INTERFACE
DIGITAL
FILTER,
NOISE SHAPER
PWM
&
INTEGRATOR
BUFFER
CLOCK
GENERATOR
OPTICAL
TRANSCEIVER
IC781
IC781
CD DIGITALOUT
OPTICAL
TIMING
LOGIC
DIGITAL
OUT
INTERNAL BUS
16K
RAM
ERROR
CORRECTOR
SUBCODE
PROCESSOR
60
HOLD
59 XRST
XTAI
X101
16.9344MHz
AIN1
AIN2 R-CH
CD-L
AOUT1
AOUT2
TO MIRR/DFCT/
FOK DETECTOR
PCMD
BCK
LRCK
C2PO
DOUT
66
XTAO 67
70
77
LOUT1
LOUT2
72
75
71
76
: CD PLAY (ANALOG OUT)
: CD PLAY (DIGITAL OUT)
SYSTEM CONTROLLER
(CD MECHANISM CONTROL)
IC501 (1/4)
When the optical pick-up
is inner position.
ON :
(Page 21)
A
• SIGNAL PATH
• R-ch is omitted due to same as L-ch.
TBL-L
TBL-R
M
TABLE MOTOR DRIVER
IC201
OUT1
OUT2
IN1
IN2 M201
(TABLE)
DISC TABLE
SENSOR
IC202
ENC3/UP-SW
S201
(UP)
T-SENS
MOTOR
DRIVE
61
68
65
63
ENC2/DISC-LED 69
9
1
7
3
LED DRIVE
Q201
D201
(DISC No.)
J705
L
R
L
R
SEND
RETURN
DJ MIX
R-CH
R-CH
(EXCEPT XG60 : Mexican/XG500)
(XG60 : Mexican/XG500)

HCD-XG60/XG500
2020
7-2. BLOCK DIAGRAM – TUNER/TAPE DECK Section –
PB EQ AMP
(DECK A)
IC611 (2/2)
PB LEVEL (L)
(DECK A)
REC-L
PB-L
CAPSTAN MOTOR
CONTROL SWITCH
Q1001
CAPSTAN
MOTOR DRIVE
Q336, 339
1
B
(Page 21)
(Page 21)
L-CH
R-CH
HP101
(PLAYBACK)
PB EQ AMP
(DECK B)
IC601 (2/2)
L-CH
R-CH R-CH
R-CH
R-CH
HRPE101 (1/2)
(RECORD/PLAYBACK)
ALC REC
EQ AMP
AMS
CIRCUIT
DOLBY NR
AMP
CIRCUIT
BIAS
CONTROL
CIRCUIT
DOLBY PASS
R-CH
R-CH
L.P.F.
BUFFER
Q335
MM1
(CAPSTAN)
HRPE101 (2/2)
(ERASE)
BIAS OSC
T621
A+7V
R-CH
3
28
36
40
35 34 39
26
77
19 15 16 18 20 22 23 24 2517
85 84 83 82 81 80 79 78
31
33
32
+
48
4
2
RV311
PB LEVEL (L)
(DECK B)
RV301
TAPE SPEED
(NORMAL)
RV1002
TAPE SPEED
(HIGH)
RV1001
REC LEVEL (L)
(DECK B)
RV301
REC BIAS (R)
(DECK B)
RV441
REC BIAS (L)
(DECK B)
BIAS OSC
Q621, 622
REC BIAS
SWITCH
Q623
ROTATION
DETECT SENSOR
(DECK A)
IC1001
RV341
BIAS
TRAP
C331, L331
REC/PB SWITCHING
IC602
SYSTEM CONTROLLER
(CD MECHANISM CONTROL)
IC501 (2/4)
DECK PROCESS,
DECK A/B SELECT, PB/REC EQ AMP,
DOLBY NR AMP, ALC, AMS
IC301
A IN (L)
B IN (L)
A IN (R)
B IN (R)
MAOUT
PB OUT (L)
EQ OUT
(L)
MSIN
MSOUT
BIAS ON/OFF
70
120
BIAS (N)
BIAS (C)
BIAS (M)
S1004
A 120/70
B NORM/CROM ALC ON/OFF
PB A/B
NORM/HIGH
NR ON/OFF
RM ON/OFF
REC/PB/PASS
LM ON/OFF
(DECK A 120/70)
88
S1003
(DECK A HALF)
S1001
(DECK A PLAY)
S1002
(DECK B PLAY)
S1008
(DECK B 120/70)
27
REC OUT (L)
R OUT (L)
R IN (L)
ALC (L)
EQ IN (L) ALC IN (L)
44 38
100
AMS-IN
91
A-SHUT
ROTATION
DETECT SENSOR
(DECK B)
IC1002
90
B-SHUT
TRIGGER
PLUNGER DRIVE
(DECK A)
Q333, 334
73
A-TRG
TC-MUTE
R/PB/PAS
NR-ON/OFF
REC-MUTE
BIAS
EQ-H/N
PB-A/B
ALC
TC-RELAY
A-PLAY-SW B-PLAY-SW A-HALF
89
S1006
(DECK B HALF)
S1009
(DECK B REC)
S1005
(DECK A REC)
B-HALF
TRIGGER PLUNGER
DECK A
TRIGGER
PLUNGER DRIVE
(DECK B)
Q331, 332
72
B-TRG
76
74
CAP-M-H/L
CAPM-CNT2
TRIGGER PLUNGER
DECK B
87 86
C
•SIGNAL PATH
: PLAYBACK (DECK A)
: PLAYBACK (DECK B)
: RECORD
: TUNER (FM/AM)
D+5V
(UNSW)
R-CH
FM/AM TUNER UNIT
ANTENNA
ST-L
FM ANT
FM ANT
AM ANT
AM ANT
ST-R
ST-MUTE
STEREO
TUNED
ST-DIN
ST-DOUT
ST-CLK
ST-CE
FM
75Ω
AM
COAXIAL
FM 75Ω
(AEP, UK)
(EXCEPT AEP, UK)
RDS-DATA
RDS-INT
49 50 51 54 53 55 52 21 20
RDS-INT RDS-DATA ST-CE ST-CLK ST-DOUT ST-DIN TUNED STEREO ST-MUTE
RDS-INT RDS-DATA ST-CE ST-CLK ST-DOUT ST-DIN TUNED STEREO ST-MUTE
(AEP, UK)
(Page 21)
D
CT-L
•R-ch is omitted due to same as L-ch.
46
51
53
43
ST-MUTE
STEREO
TUNED
ST-DIN
ST-DOUT
ST-CLK
ST-CE
RDS-DATA
RDS-INT
(AEP, UK)
PB EQ AMP
(DECK A)
IC611 (1/2)
PB EQ AMP
(DECK B)
IC601 (1/2)