Sony XR-CA440 / XR-CA440X / XRS-CA500 Service Manual ▷ View online
SERVICE MANUAL
XR-CA440X: AEP, UK Model
FM/AM CASSETTE CAR STEREO
XR-CA440/CA440X: E Model
FM/MW/SW CASSETTE CAR STEREO
AEP Model
UK Model
XR-CA440X
E Model
XR-CA440/CA440X
SPECIFICATIONS
XR-CA440/CA440X
Photo: XR-CA440
Ver 1.1 2003.01
9-873-497-02
Sony Corporation
2003A0500-1
e Vehicle Company
C
2003.01
Published by Sony Engineering Corporation
Model Name Using Similar Mechanism
NEW
Tape Transport Mechanism Type
MG-25F-136
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
Tuner section
FM
T
(XR-CA440/
CA440X: E models)
(XR-CA440/
CA440X: E models)
(XR-CA440X: AEP,
UK, Saudi Arabia
and Taiwan models)
UK, Saudi Arabia
and Taiwan models)
uning range
FM tuning interval:
50 kHz/200 kHz switchable
87.5 – 108.0 MHz
(at 50 kHz step)
87.5 – 107.9 MHz
(at 200 kHz step)
50 kHz/200 kHz switchable
87.5 – 108.0 MHz
(at 50 kHz step)
87.5 – 107.9 MHz
(at 200 kHz step)
Aerial terminal
External aerial connector
Intermediate frequency
10.7 MHz
Usable sensitivity
11 dBf
Selectivity
75 dB at 400 kHz
Signal-to-noise ratio
65 dB (stereo),
68 dB (mono)
68 dB (mono)
Harmonic distortion at 1 kHz
0.7 % (stereo),
0.5 % (mono)
0.5 % (mono)
Separation
33 dB at 1 kHz
Frequency response
30 – 15,000 Hz
MW
(XR-CA440/CA440X: E, Saudi Arabia
and Taiwan models)
(XR-CA440/CA440X: E, Saudi Arabia
and Taiwan models)
T
(XR-CA440/
CA440X: E Models)
(XR-CA440/
CA440X: E Models)
uning range
MW tuning interval:
9 kHz/10 kHz switchable
531 – 1,602 kHz
(at 9 kHz step)
530 – 1,710 kHz
(a
9 kHz/10 kHz switchable
531 – 1,602 kHz
(at 9 kHz step)
530 – 1,710 kHz
(a
NW tuning interval:
531 – 1,602 kHz
531 – 1,602 kHz
t 10 kHz step)
Se
Tuning range
(XR-CA440X:
Saudi Arabia
and Taiwan models)
(XR-CA440X:
Saudi Arabia
and Taiwan models)
nsitivity
30
µ
V
SW
(XR-CA440/CA440X: E, Saudi Arabia
and Taiwan models)
(XR-CA440/CA440X: E, Saudi Arabia
and Taiwan models)
Tuning range
SW tuning interval:
SW1: 2,940 – 7,735 kHz
SW2: 9,500 – 18,135 kHz
(except for 10,140 – 11,575
kHz)
SW1: 2,940 – 7,735 kHz
SW2: 9,500 – 18,135 kHz
(except for 10,140 – 11,575
kHz)
Aerial terminal
External aerial connector
Intermediate frequency
10.7 MHz/450 kHz
Sensitivity
30
µ
V
Power amplifier section
Outputs
Speaker outputs
(sure seal connectors)
(sure seal connectors)
Speaker impedance
4 – 8 ohms
Maximum power output
50 W
×
4 (at 4 ohms)
General
Outputs
Audio outputs
Power aerial relay control
lead
Power amplifier control lead
Power aerial relay control
lead
Power amplifier control lead
Inputs
BUS control input terminal
BUS audio input terminal
Aerial input terminal
BUS audio input terminal
Aerial input terminal
Tone controls
Bass
±
9 dB at 100 Hz
Treble
±
9 dB at 10 kHz
Power requirements
12 V DC car battery
(negative earth)
(negative earth)
Dimensions
Approx. 178
×
50
×
178
mm (w/h/d)
Mounting dimensions
Approx. 182
×
53
×
161
mm (w/h/d)
Mass
Approx. 1.2 kg
Supplied accessories
Parts for installation and
connections (1 set)
Front panel case (1)
connections (1 set)
Front panel case (1)
Note
This unit cannot be connected to a digital preamplifier
or an equalizer.
This unit cannot be connected to a digital preamplifier
or an equalizer.
Design and specifications are subject to change
without notice.
without notice.
Cassette type
TYPE II, IV
61 dB
TYPE I
58 dB
Tuning range
FM tuning interval:
87.5 – 108.0 MHz
87.5 – 108.0 MHz
AM
(XR-CA440X: AEP and UK models)
(XR-CA440X: AEP and UK models)
Tuning range
AM tuning interval:
531 – 1,602 kHz
531 – 1,602 kHz
Sensitivity
30
µ
V
Aerial terminal
External aerial connector
Intermediate frequency
10.7 MHz/450 kHz
2
XR-CA440/CA440X
TABLE OF CONTENTS
1.
GENERAL
Location of Controls .......................................................
3
Setting the Clock .............................................................
3
Installation /Connection ..................................................
4
2.
DISASSEMBLY
2-1. Disassembly Flow ...........................................................
8
2-2. Cover ...............................................................................
8
2-3. Mechanism Deck (MG-25F-136) ...................................
9
2-4. MAIN Board ...................................................................
9
2-5. Heat Sink ......................................................................... 10
3.
ASSEMBLY OF MECHANISM DECK
3-1. Assembly Flow ................................................................ 11
3-2. Housing ........................................................................... 12
3-3. Arm (Suction) ................................................................. 12
3-4. Lever (LDG-A)/(LDG-B) ............................................... 13
3-5. Gear (LDG-FT) ............................................................... 13
3-6. Guide (C) ......................................................................... 14
3-7. Mounting Position of Capstan/Reel Motor (M901) ....... 14
3-2. Housing ........................................................................... 12
3-3. Arm (Suction) ................................................................. 12
3-4. Lever (LDG-A)/(LDG-B) ............................................... 13
3-5. Gear (LDG-FT) ............................................................... 13
3-6. Guide (C) ......................................................................... 14
3-7. Mounting Position of Capstan/Reel Motor (M901) ....... 14
4.
MECHANICAL ADJUSTMENTS
....................... 15
5.
ELECTRICAL ADJUSTMENTS
Tape Deck Section .......................................................... 15
Tuner Section .................................................................. 15
Tuner Section .................................................................. 15
6.
DIAGRAMS
6-1. Note for Printed Wiring Boards and
Schematic Diagrams ....................................................... 15
6-2. Printed Wiring Board – MAIN Board – ......................... 16
6-3. Schematic Diagram – MAIN Board (1/3) – ................... 17
6-4. Schematic Diagram – MAIN Board (2/3) – ................... 18
6-5. Schematic Diagram – MAIN Board (3/3) – ................... 19
6-6. Printed Wiring Board – KEY Board – ............................ 20
6-7. Schematic Diagram – KEY Board – .............................. 21
6-8. IC Pin Function Description ........................................... 24
6-3. Schematic Diagram – MAIN Board (1/3) – ................... 17
6-4. Schematic Diagram – MAIN Board (2/3) – ................... 18
6-5. Schematic Diagram – MAIN Board (3/3) – ................... 19
6-6. Printed Wiring Board – KEY Board – ............................ 20
6-7. Schematic Diagram – KEY Board – .............................. 21
6-8. IC Pin Function Description ........................................... 24
7.
EXPLODED VIEWS
7-1. Chassis Section ............................................................... 27
7-2. Front Panel Section ......................................................... 28
7-3. MAIN Board Section ...................................................... 29
7-4. Mechanism Deck Section (MG-25F-136) ...................... 30
7-2. Front Panel Section ......................................................... 28
7-3. MAIN Board Section ...................................................... 29
7-4. Mechanism Deck Section (MG-25F-136) ...................... 30
8.
ELECTRICAL PARTS LIST
............................... 31
Notes on chip component replacement
• Never reuse a disconnected chip component.
• Notice that the minus side of a tantalum capacitor may be dam-
• 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.
3
XR-CA440/CA440X
SECTION 1
GENERAL
This section is extracted from
instruction manual.
instruction manual.
Location of controls
Refer to the pages listed for details.
a
SOURCE (Power on/Tape/Radio/CD/
MD) select button
MD) select button
b
MODE (
o
) button
Selecting the source.
c
VOL +/– button
d
ATT (attenuate) button
e
Display window
f Z
(eject) button 8
g
SEEK/AMS button
Tape:
Fast-forwarding, reversing a tape
Radio:
Tuning in stations automatically.
Finding a station manually.
CD (MP3 files)/MD:
Skipping tracks.
Fast-forwarding, reversing a tape
Radio:
Tuning in stations automatically.
Finding a station manually.
CD (MP3 files)/MD:
Skipping tracks.
h
MBP (My Best sound Position) button
12
12
i
D-BASS button 12
j
RELEASE (front panel release) button
k
SEL (select) button
Selecting items.
l
RESET button
(located on the front side of
the unit, behind the front panel)
6
m
SENS button
Storing the stations with the strongest
signals.
signals.
n
Number buttons
Tape:
(3)
(3)
: REP (Repeat)
(5)
: BL SKIP (Blank Skip)
(6)
: ATA (Automatic Tuner Activation)
Radio:
Storing the desired station on each number
button.
CD (MP3 files)/MD:
(1)
Storing the desired station on each number
button.
CD (MP3 files)/MD:
(1)
: DISC –
(2)
: DISC +
(3)
: REP (Repeat)
(4)
: SHUF (Shuffle)
MP3 files:
(5)
(5)
: ALBM –
(6)
: ALBM +
o
Frequency select switch (located on
the
(XR-CA440/CA440X: E models)
the
(XR-CA440/CA440X: E models)
bottom of the unit)
See “Frequency select switch” in the
Installation/Connections manual.
Installation/Connections manual.
p
BTM/MTL (Best Tuning Memory/Metal)
button 9
button 9
q
DSPL (display mode change) button
r
OFF (Stop/Power off) button
*
*
Warning when installing in a car without
an ACC (accessory) position on the
ignition switch
After turning off the ignition, be sure to press
an ACC (accessory) position on the
ignition switch
After turning off the ignition, be sure to press
(OFF)
on the unit for 2 seconds to turn off
the clock display.
Otherwise, the clock display does not turn off
and this causes battery drain.
and this causes battery drain.
XR-CA440X
XR-CA440
XR-CA440
SOURCE
ATT
VOL
SENS
DISC
REP
SHUF BL SKIP/ ALBM
-
+ /ATA
MTL
–
+
MODE
SEL
RELEASE
1
2
3
4
5
6
D-BASS
SEEK
AMS
BTM
MBP
OFF
DSPL
Setting the clock
The clock uses a 12-hour digital indication.
Example: To set the clock to 10:08
1
Press (DSPL) for 2 seconds.
The hour indication flashes.
1
Press either side of (VOL) to set the
hour.
hour.
2
Press (SEL).
The minute indication flashes.
3
Press either side of (VOL) to set the
minute.
minute.
2
Press (DSPL).
The clock starts.
After the clock setting is completed, the
display returns to normal play mode.
display returns to normal play mode.
VOL
to go forward
to go back
VOL
to go forward
to go back
4
XR-CA440/CA440X
Parts Iist (
1
)
The numbers in the list are keyed to those in the
instructions.
instructions.
Caution
Handle the bracket 1 carefully to avoid injuring
your fingers.
your fingers.
Cautions
•
This unit is designed for negative earth 12 V
DC operation only.
DC operation only.
•
Do not get the wires under a screw, or caught
in moving parts (e.g. seat railing).
in moving parts (e.g. seat railing).
•
Before making connections, turn the car
ignition off to avoid short circuits.
ignition off to avoid short circuits.
•
Connect the yellow and red power input leads
only after all other leads have been connected.
only after all other leads have been connected.
•
Run all earth wires to a common earth
point.
point.
•
Be sure to insulate any loose unconnected
wires with electrical tape for safety.
wires with electrical tape for safety.
Notes on the power supply cord (yellow)
•
When connecting this unit in combination with
other stereo components, the connected car
circuit’s rating must be higher than the sum of
each component’s fuse.
other stereo components, the connected car
circuit’s rating must be higher than the sum of
each component’s fuse.
•
When no car circuits are rated high enough,
connect the unit directly to the battery.
connect the unit directly to the battery.
Connection example (
2
)
Notes (2-A)
•
Be sure to connect the earth cord before
connecting the amplifier.
connecting the amplifier.
•
If you connect an optional power amplifier and do
not use the built-in amplifier, the beep sound will
be deactivated.
not use the built-in amplifier, the beep sound will
be deactivated.
Tip (2-B-
)
For connecting two or more CD/MD changers, the
source selector XA-C30 (optional) is necessary.
source selector XA-C30 (optional) is necessary.
Connection diagram (
3
)
1
To a metal surface of the car
First connect the black earth lead, then connect
the yellow and red power input leads.
First connect the black earth lead, then connect
the yellow and red power input leads.
2
To the power aerial control lead or power
supply lead of aerial booster amplifier
Notes
supply lead of aerial booster amplifier
Notes
•
It is not necessary to connect this lead if there
is no power aerial or aerial booster, or with a
manually-operated telescopic aerial.
is no power aerial or aerial booster, or with a
manually-operated telescopic aerial.
•
When your car has a built-in FM/MW/SW aerial
in the rear/side glass, see “Notes on the control
and power supply leads.”
in the rear/side glass, see “Notes on the control
and power supply leads.”
3
To AMP REMOTE IN of an optional power
amplifier
This connection is only for amplifiers. Connecting
any other system may damage the unit.
amplifier
This connection is only for amplifiers. Connecting
any other system may damage the unit.
4
To the +12 V power terminal which is energised
in the accessory position of the ignition key
switch
Notes
in the accessory position of the ignition key
switch
Notes
•
If there is no accessory position, connect to the
+12 V power (battery) terminal which is
energised at all times.
Be sure to connect the black earth lead to it
first.
+12 V power (battery) terminal which is
energised at all times.
Be sure to connect the black earth lead to it
first.
•
When your car has a built-in FM/MW/SW aerial
in the rear/side glass, see “Notes on the control
and power supply leads.”
in the rear/side glass, see “Notes on the control
and power supply leads.”
5
To the +12 V power terminal which is energised
at all times
Be sure to connect the black earth lead to it first.
at all times
Be sure to connect the black earth lead to it first.
Notes on the control and power supply leads
•
The power aerial control lead (blue) supplies +12 V
DC when you turn on the tuner.
DC when you turn on the tuner.
•
When your car has built-in FM/MW/SW aerial in
the rear/side glass, connect the power aerial
control lead (blue) or the accessory power input
lead (red) to the power terminal of the existing
aerial booster. For details, consult your dealer.
the rear/side glass, connect the power aerial
control lead (blue) or the accessory power input
lead (red) to the power terminal of the existing
aerial booster. For details, consult your dealer.
•
A power aerial without relay box cannot be used
with this unit.
with this unit.
Memory hold connection
When the yellow power input lead is connected,
power will always be supplied to the memory circuit
even when the ignition key is turned off.
When the yellow power input lead is connected,
power will always be supplied to the memory circuit
even when the ignition key is turned off.
Notes on speaker connection
•
Before connecting the speakers, turn the unit off.
•
Use speakers with an impedance of 4 to 8 ohms, and
with adequate power handling capacities to avoid its
damage.
with adequate power handling capacities to avoid its
damage.
•
Do not connect the speaker terminals to the car
chassis, or connect the terminals of the right speakers
with those of the left speaker.
chassis, or connect the terminals of the right speakers
with those of the left speaker.
•
Do not connect the earth lead of this unit to the
negative (–) terminal of the speaker.
negative (–) terminal of the speaker.
•
Do not attempt to connect the speakers in parallel.
•
Connect only passive speakers. Connecting active
speakers (with built-in amplifiers) to the speaker
terminals may damage the unit.
speakers (with built-in amplifiers) to the speaker
terminals may damage the unit.
•
To avoid a malfunction, do not use the built-in speaker
wires installed in your car if the unit shares a common
negative (–) lead for the right and left speakers.
wires installed in your car if the unit shares a common
negative (–) lead for the right and left speakers.
•
Do not connect the unit’s speaker cords to each other.
Equipment used in illustrations (not supplied)
Equipo utilizado en las ilustraciones (no suministrado)
Equipo utilizado en las ilustraciones (no suministrado)
Front speaker
Altavoces delanteros
Altavoces delanteros
Rear speaker
Altavoces traseros
Altavoces traseros
2
B
A
BUS AUDIO IN
BUS CONTROL IN
AUDIO OUT REAR
BUS CONTROL IN
BUS AUDIO IN
Source selector
*
Selector de fuente
Power amplifier
Amplificador de potencia
Amplificador de potencia
CD/MD changer
Cambiador de CD/MD
Cambiador de CD/MD
1
*
not supplied
no suministrado
no suministrado
Installation/Connection
