XR-CA640X — Sony Car Audio Service Manual (repair manual)

Model
XR-CA640X
Pages
42
Size
3.18 MB
Type
PDF
Document
Service Manual
Brand
Device
Car Audio
File
xr-ca640x.pdf
Date

View Sony XR-CA640X Service Manual online

SERVICE MANUAL
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
Tuning 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)
Aerial terminal
External aerial connector
Intermediate frequency
10.7 MHz/450 kHz
Usable sensitivity
8 dBf
Selectivity
75 dB at 400 kHz
Signal-to-noise ratio
66 dB (stereo), 
72 dB (mono)
Harmonic distortion at 1 kHz
0.6 % (stereo),
0.3 % (mono)
Separation
35 dB at 1 kHz
Frequency response
30 – 15,000 Hz
MW
Tuning range
MW tuning interval:
9 kHz/10 kHz switchable
531 – 1,602 kHz
(at 9 kHz step)
530 – 1,710 kHz
(at 10 kHz step)
Sensitivity
30 
µ
V
SW
Tuning range
SW tuning interval:
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)
Speaker impedance
4 – 8 ohms
Maximum power output
52 W 
×
 4 (at 4 ohms)
General
Outputs
Audio outputs (front/rear)
Power aerial relay control 
terminal
Power amplifier control 
terminal
Inputs
Telephone ATT control 
terminal
BUS control input terminal
BUS audio input terminal
Remote controller input 
terminal
Aerial input terminal
Tone controls
Bass 
±
8 dB at 100 Hz
Treble 
±
8 dB at 10 kHz
Loudness
+8 dB at 100 Hz
+2 dB at 10 kHz
Power requirements
12 V DC car battery 
(negative earth)
Dimensions
Approx. 178 
×
 50 
×
 177 
mm (w/h/d)
Mounting dimensions
Approx. 182 
×
 53 
×
 161 
mm (w/h/d)
Mass
Approx. 1.2 kg
Supplied accessories
Card remote commander (1)
Parts for installation and 
connections (1 set)
Front panel case (1)
Note
This unit cannot be connected to a digital preamplifier 
or an equalizer.
Design and specifications are subject to change 
without notice.
Cassette type
Dolby B NR
Dolby NR off
TYPE II, IV
67 dB
61 dB
TYPE I
64 dB
58 dB
E model:
Soudi Arabia, Taiwan models:
87.5 – 108.0 MHz
E model:
531 – 1,602 kHz
Soudi Arabia, Taiwan models:
E model:
SW tuning interval:
SW1: 2,940 – 7,735 kHz
SW2: 9,500 – 18,135 kHz
(except for 10,140 – 11,575 
kHz)
Soudi Arabia, Taiwan models:
FM/MW/SW CASSETTE CAR STEREO
E Model
XR-CA640X
Ver 1.2  2003.01
9-873-620-03
Sony Corporation
2003A0500-1
e Vehicle Company
C
 2003.01
Published by Sony Engineering Corporation
Model Name Using Similar Mechanism
XR-CA440X
Tape Transport Mechanism Type
MG-25F-136
SPECIFICATIONS
2
XR-CA640X
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.
TABLE  OF  CONTENTS
1.
GENERAL
Location of Controls .......................................................
3
2.
DISASSEMBLY
2-1. Disassembly Flow ...........................................................
8
2-2. Sub Panel Assy ................................................................
8
2-3. Mechanism Deck (MG-25F-136) ...................................
9
2-4. MAIN Board ...................................................................
9
2-5. Heat Sink (2P) ................................................................. 10
3.
ASSEMBLY  OF  MECHANISM  DECK
3-1. Assembly Flow ................................................................ 11
3-2. Housing ........................................................................... 11
3-3. Arm (Suction) ................................................................. 12
3-4. Lever (LDG-A)/(LDG-B) ............................................... 12
3-5. Gear (LDG-FT) ............................................................... 13
3-6. Guide (C) ......................................................................... 13
3-7. Mounting Position of Capstan/Reel Motor (M901) ....... 14
4.
MECHANICAL  ADJUSTMENTS
....................... 15
5.
ELECTRICAL  ADJUSTMENTS
Tape Deck Section .......................................................... 15
Tuner Section .................................................................. 15
6.
DIAGRAMS
6-1. Block Diagram – TUNER/TAPE Section – ................... 17
6-2. Block Diagram – MAIN Section – ................................. 18
6-3. Block Diagram – DISPLAY/KEY CONTROL/BUS
CONTROL/POWER SUPPLY Section – ....................... 19
6-4. Note for Printed Wiring Boards and
Schematic Diagrams ....................................................... 20
6-5. Printed Wiring Board – MAIN Board – ......................... 21
6-6. Schematic Diagram – MAIN Board (1/3) – ................... 22
6-7. Schematic Diagram – MAIN Board (2/3) – ................... 23
6-8. Schematic Diagram – MAIN Board (3/3) – ................... 24
6-9. Printed Wiring Board – SUB Board – ............................ 25
6-10. Schematic Diagram – SUB Board – ............................... 25
6-11. Printed Wiring Board – KEY Board – ............................ 26
6-12. Schematic Diagram – KEY Board – .............................. 27
6-13. IC Pin Function Description ........................................... 30
7.
EXPLODED  VIEWS
7-1. Chassis Section ............................................................... 33
7-2. Front Panel Section ......................................................... 34
7-3. MAIN Board Section ...................................................... 35
7-4. Mechanism Deck Section (MG-25F-136) ...................... 36
8.
ELECTRICAL  PARTS  LIST
............................... 37
3
XR-CA640X
Location of controls
Refer to the pages listed for details.
a
MBP button 
 
16
b
MODE (
o
) button 
To change the operation.
c
DSPL (display mode change) button
d
Volume control dial 
e
Display window
f Z
 (eject) button 
(located on the front side 
of the unit, behind the front panel)
  9
g
MENU button 
To change the menus.
h
LIST button  12, 19, 20
i
OPEN button  7, 9
j
OFF (Stop/Power off) button
*
 7, 9
k
RESET button 
(located on the front side of 
the unit, behind the front panel)
  7
l
SOURCE (Power on/Tape/Radio/CD/
MD) button 
To select the source.
m
SCRL (scroll) button  18
n
Frequency select switch (located on 
the bottom of the unit)
See “Frequency select switch” in the 
Installation/Connections manual.
o
Receptor for the card remote 
commander
p
SOUND button  14
q
ENTER button
To enter a setting.
r
EQ7 button  16
*
Warning when installing in a car without 
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.
SOURCE
MBP
O
FF
SC
R
L
DSP
L
M
OD
E
SEEK
EQ7
S
O
UN
D
EN
TE
R
LIS
T
M
EN
U
D
IS
C/PRESE
T
OP
EN
D
IS
C/PRESE
T
s
DISC/PRESET buttons (+/–)
To receive preset stations, change the disc*
1
skip albums*
2
, and select a menu.
*1
When an optional CD/MD unit is connected.
*2
Available only when optional CD unit with the 
MP3 file control function is connected.
t
SEEK buttons (–/+)
To skip tracks, fast-forward, reverse a track, 
tune in stations automatically, find a station 
manually, and select a setting.
The corresponding buttons of the card 
remote commander control the same 
functions as those on this unit.
a
DSPL button
b
Number buttons
(1)
 REP
(2)
 SHUF
To store stations, receive stored stations.
c
MBP button
d
MENU button
e
SOURCE button
f
SEEK (
<
/
,
) buttons
g
SOUND button
h
OFF button
i
VOL (+/–) buttons
j
EQ7 button
k
MODE (
o
) button
l
LIST button
m
DISC (
M
/
m
) buttons
n
ENTER button
o
ATT button
Note
If the unit is turned off by pressing 
(OFF)
 for 
2 seconds, it cannot be operated with the card remote 
commander unless 
(SOURCE)
 on the unit is pressed, 
or a cassette tape is inserted to activate the unit first.
Tip
See “Replacing the lithium battery” on page 22 for 
details on how to replace the batteries.
SEEK
EQ7
S
O
UN
D
EN
TE
R
LIS
T
M
EN
U
D
IS
C/PRESE
T
OP
EN
D
IS
C/PRESE
T
SEEK
DI
SC/
PRE
S
E
T
D
IS
C
/PRESE
T
(SEEK)
(–): to select 
leftwards/
.
(SEEK)
(+): to select 
rightwards/
>
(DISC/PRESET)
(+): to select upwards
In menu mode, the currently selectable button(s) of 
these four are indicated with a “ 
M
” in the display.
(DISC/PRESET)
(–): to select downwards
Card remote commander RM-X119
DISC 
ATT
OFF
REP
SHUF
DSPL
1
4
MODE
2
5
3
6
SOURCE
DISC 
+
SEEK
+
SEEK
SOUND
ENTER
MENU
LIST
EQ7
MBP
VOL
SECTION  1
GENERAL
This section is extracted from
instruction manual.
4
XR-CA640X
Cautions
This unit is designed for negative earth 12 V
DC operation only.
• Do not get the wires under a screw, or caught
in moving parts (e.g. seat railing).
• Before making connections, turn the car
ignition off to avoid short circuits.
• Connect the 
yellow
 and 
red
 power input leads
only after all other leads have been connected.
Run all earth wires to a common earth
point.
• Be sure to insulate any loose unconnected
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.
• When no car circuits are rated high enough,
connect the unit directly to the battery.
Parts Iist (
1
)
The numbers in the list are keyed to those in the
instructions.
Caution
Handle the bracket 1 carefully to avoid injuring
your fingers.
Connection example (
2
)
Notes (
2
-A)
• Be sure to connect the earth cord before
connecting the amplifier.
• If you connect an optional power amplifier and do
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.
Connection diagram (
)
1
To a metal surface of the car
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
• It is not necessary to connect this lead if there 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.”
3
To AMP REMOTE IN of an optional power
amplifier
This connection is only for amplifiers. Connecting
any other system may damage the unit.
4
To the interface cable of a car telephone
5
To the +12 V power terminal which is energised
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.
• 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.”
6
To the +12 V power terminal which is energised
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.
• 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.
• A power aerial without relay box cannot be used
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.
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.
• Do not connect the speaker terminals to the car
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.
• 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.
• 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.
• Do not connect the unit’s speaker cords to each
other.
2
B
BUS AUDIO IN
BUS CONTROL IN
BUS CONTROL IN
BUS AUDIO IN
A
AUDIO OUT REAR
Source selector
Selector de fuente
*
*
not supplied
no suministrado
AUDIO OUT FRONT
3
Page of 42
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  • Schematics, wiring and block diagrams.
  • Printed wiring boards (PWB) and printed circuit boards (PCB).
  • Parts list (bill of materials).