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Sony XR-CA800 Service Manual

Fm/mw/lw cassette car stereo
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SERVICE MANUAL
Ver 1.1 2001.05
Cassette Player section
Tape track
Wow and flutter
Frequency response
Signal-to-noise ratio
Tuner section
FM
Tuning range
Aerial terminal
Intermediate frequency
Usable sensitivity
Selectivity
Signal-to-noise ratio
Harmonic distortion at 1 kHz
Separation
Frequency response
MW/LW
Tuning range
Aerial terminal
Intermediate frequency
Sensitivity
Power amplifier section
Outputs
Speaker impedance
Maximum power output
Sony Corporation
9-873-502-12
2001E0500-1
e Vehicle Company
C 2001.5
Shinagawa Tec Service Manual Production Group
SPECIFICATIONS
General
Outputs
4-track 2-channel stereo
0.08 % (WRMS)
30 – 18,000 Hz
Inputs
Cassette type
TYPE II, IV
61 dB
TYPE I
58 dB
Tone controls
Loudness
87.5 – 108.0 MHz
External aerial connector
Power requirements
10.7 MHz/450 kHz
8 dBf
Dimensions
75 dB at 400 kHz
66 dB (stereo),
Mounting dimensions
72 dB (mono)
Mass
0.6 % (stereo),
Supplied accessories
0.3 % (mono)
35 dB at 1 kHz
30 – 15,000 Hz
MW: 531 – 1,602 kHz
LW: 153 – 279 kHz
Note
External aerial connector
This unit cannot be connected to a digital preamplifier
10.7 MHz/450 kHz
or an equalizer.
MW: 30 µV
LW: 40 µV
Design and specifications are subject to change
without notice.
Speaker outputs
(sure seal connectors)
4 – 8 ohms
FM/MW/LW CASSETTE CAR STEREO
50 W × 4 (at 4 ohms)
XR-CA800
Model Name Using Similar Mechanism
Tape Transport Mechanism Type
Audio outputs (Rear)
Power aerial relay control
lead
Power amplifier control lead
Telephone ATT control lead
BUS control input
connector
BUS audio input connector
Remote controller input
connector
Aerial input connector
Bass ±8 dB at 100 Hz
Treble ±8 dB at 10 kHz
100 Hz +8 dB
10 kHz +2 dB
12 V DC car battery
(negative earth)
Approx. 178 × 50 × 176 mm
(w/h/d)
Approx. 182 × 53 × 161 mm
(w/h/d)
Approx. 1.2 kg
Parts for installation and
connections (1 set)
Front panel case (1)
Rotary commander
RM-X5S
Card remote commander
RM-X116
AEP Model
UK Model
XR-C5300R
MG-25G-136

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  • Page 1 XR-CA800 SERVICE MANUAL AEP Model UK Model Ver 1.1 2001.05 Model Name Using Similar Mechanism XR-C5300R Tape Transport Mechanism Type MG-25G-136 SPECIFICATIONS General Cassette Player section Outputs Audio outputs (Rear) Tape track 4-track 2-channel stereo Power aerial relay control Wow and flutter 0.08 % (WRMS)

  • Page 2: Table Of Contents

    XR-CA800 TABLE OF CONTENTS Notes on chip component replacement • Never reuse a disconnected chip component. • Notice that the minus side of a tantalum capacitor may be dam- GENERAL aged by heat. Location of Controls ............3 Flexible Circuit Board Repairing DISASSEMBLY •...

  • Page 3: General

    XR-CA800 SECTION 1 This section is extracted from instruction manual. GENERAL Location of controls Refer to the pages listed for details. Card remote commander RM-X116 : During tape playback TAPE : During radio reception RADIO : During menu mode MENU...

  • Page 4: Using The Rotary Commander

    XR-CA800 Main unit OPEN XR-CA800 a Power on/off button* 7 * Warning when installing in a car without b Display window an ACC (accessory) position on the c Z (eject) button (located on the front side ignition switch of the unit, behind the front panel) 9...
  • Page 5 XR-CA800 By pressing buttons Note for the aerial connecting Nota per il collegamento dell’antenna If your car aerial is an ISO (International Se l’antenna della macchina è di tipo ISO Turn the dial to change the Organisation for Standardisation) type, use...
  • Page 6 XR-CA800 Dashboard Fire wall Armaturenbrett Motorraumtrennwand Tableau de bord Paroi ignifuge Cruscotto Parete tagliafiamma Dashboard Brandschot 1 8 2 Bend these claws outward for a tight fit, 5 3 m if necessary. Falls erforderlich, diese Klammern für einen sicheren Halt hochbiegen.

  • Page 7: Disassembly

    XR-CA800 SECTION 2 DISASSEMBLY • This set can be disassembled in the order shown below. 2-1. DISASSEMBLY FLOW Note 1: The process described in can be performed in any order. Note 2: Without completing the process described in , the next process can not be performed.

  • Page 8: Main Board

    XR-CA800 2-3. MAIN BOARD 3 rubber cap (25) 2 three ground point screws (PTT2.6 × 6) 1 three screws (PTT2.6 × 8) 4 main board 2-4. HEAT SINK (ISO2P) 1 three screws (PTT2.6 × 8) 3 heat sink (ISO2P) 2 two screws (PTT2.6 ×...

  • Page 9: Assembly Of Mechanism Deck

    XR-CA800 SECTION 3 ASSEMBLY OF MECHANISM DECK • This set can be assembled in the order shown below. 3-1. ASSEMBLY FLOW 3-2. HOUSING (Page 10) 3-3. ARM (SUCTION) (Page 10) 3-4. LEVER (LDG-A)/(LDG-B) (Page 11) 3-5. GEAR (LDG-FT) (Page 11) 3-6.

  • Page 10: Housing

    XR-CA800 Note: Follow the assembly procedure in the numerical order given. 3-2. HOUSING 7 Hold the hanger by bending the claw. 5 Fit projection on C part. 1 Install the catch to the hanger. 2 Install the hanger onto two claws of the housing.

  • Page 11: Lever (Ldg-A)/(Ldg-B)

    XR-CA800 3-4. LEVER (LDG-A) / (LDG-B) shaft A shaft A shaft B shaft B shaft C 1 Fit the lever (LDG-A) on 3 type-E stop ring 2.0 shafts A – C and install it. 2 Fit the lever (LDG-B) on shafts A and B and install it.

  • Page 12: Guide (C)

    XR-CA800 3-6. GUIDE (C) 2 guide (C) 1 three claws 3-7. MOUNTING POSITION OF CAPSTAN/REEL MOTOR (M901) two precision screws (P2 × 2) capstan/reel motor (M901) Note: Mount the motor so that the angle between of the motor and the hole for the becomes 30 °...

  • Page 13: Mechanical Adjustments

    XR-CA800 SECTION 4 MECHANICAL ADJUSTMENTS 1. Clean the following parts with a denatured-alcohol-moistened TAPE DECK SECTION 0 dB=0.775 V swab: playback head pinch roller Tape Speed Adjustment rubber belt capstan Setting: idler 2. Demagnetize the playback head with a head demagnetizer.

  • Page 14: Diagrams

    XR-CA800 SECTION 6 DIAGRAMS 6-1. NOTE FOR PRINTED WIRING BOARDS AND SCHEMATIC DIAGRAMS Note on Printed Wiring Board: Note on Schematic Diagram: • All capacitors are in µF unless otherwise noted. pF: µµF • X : parts extracted from the component side.

  • Page 15: Printed Wiring Board - Main Board

    XR-CA800 6-2. PRINTED WIRING BOARD – MAIN Board – BUS AUDIO AUDIO OUT (REMOTE IN) REAR FM/AM CN581 ANTENNA IN BUS CONTROL MAIN BOARD CN781 (FRONT VIEW) CN781 F781 14 13 IC751 REAR RCH+ FRONT RCH+ FRONT LCH+ REAR LCH+ GRN/BLK REAR LCH–...

  • Page 16: Schematic Diagram - Main Board (1/3)

    XR-CA800 6-3. SCHEMATIC DIAGRAM – MAIN Board (1/3) – • • See page 14 for Waveform. See page 22 for IC Block Diagrams. (Page 17) (Page 18)

  • Page 17: Schematic Diagram - Main Board (2/3)

    XR-CA800 6-4. SCHEMATIC DIAGRAM – MAIN Board (2/3) – • • See page 14 for Waveforms. See page 22 for IC Block Diagrams. (Page 16) (Page 18)

  • Page 18: Schematic Diagram - Main Board (3/3)

    XR-CA800 6-5. SCHEMATIC DIAGRAM – MAIN Board (3/3) – • See page 22 for IC Block Diagrams. (Page 16) (Page 19) (Page 17)

  • Page 19: Printed Wiring Board - Sub Board

    XR-CA800 6-6. PRINTED WIRING BOARD – SUB Board – 6-7. SCHEMATIC DIAGRAM – SUB Board – SUB BOARD (COMPONENT SIDE) TAPE DECK ILLUMINATION LED801 K1 S2 K2 A1 S1 A2 LSW801 (Page 21) 1-676-603- (21) MAIN BOARD (Page 15) CN701...

  • Page 20: Printed Wiring Board - Key Board

    XR-CA800 6-8. PRINTED WIRING BOARD – KEY Board – KEY BOARD (COMPONENT SIDE) LSW921 C905 LED910 LSW921 R971 POWER LED911 LCD901 ON/OFF LIQUID CRYSTAL DISPLAY C902 LED911, 913 LED910, 912 (LCD BACK LIHGT) (LCD BACK LIHGT) D900 LED912 LED913 C900...

  • Page 21: Schematic Diagram - Key Board

    XR-CA800 6-9. SCHEMATIC DIAGRAM – KEY Board – • See page 14 for Waveforms. • See page 23 for IC Block Diagram. C908 R903 R902 C907 R919 270k 120k 330p LED900 C906 R918 RRX9000-0501 0.01 REMOTE CONTROL RECEIVER SIRCS CONTROLLER...
  • Page 22 XR-CA800 • IC Block Diagrams IC331 TDA7406T – MAIN Board – IC51 SAA6588T-118 MIXER POWER SUPPLY PAUSE SPECTRUM & RESET DETECTOR SACLK MULTI ANALYZER PATH 57kHz DETECTOR 8th ORDER BAND-PASS FILTER CLOCKED SIGNAL QUALITY COMPARATOR DECODER CLOCK CLOCK FRONT REAR...

  • Page 23: Key Board

    XR-CA800 IC351 LB1930M-TLM IC581 MM1175XFF BUS ON BUFFER RESET RESET RESET OUT1 MOTOR SWITCH CONTROL DRIVE CIRCUIT CIRCUIT OUT2 BUS ON BATT BATT SWITCH BUFFER S-GND P-GND BATT VREF CHECK DATA DATA IN IN/OUT DATA OUT IC611 BA4908-V3 REGULATOR OVER VOLTAGE PROTECT –...

  • Page 24: 6-10. Ic Pin Function Description

    Reset signal output to the SONY bus interface (IC581) “L”: reset BUSON Bus on/off control signal output to the SONY bus interface (IC581) “L”: bus on Input of acknowledge signal for the key entry Acknowledge signal is input to accept function KEYACK and eject keys in the power off status On at input of “H”...
  • Page 25 BUSSI Serial data input from the SONY bus interface (IC581) BUSCKO Serial data transfer clock signal output to the SONY bus interface (IC581) Two-way data IIC bus with the FM/AM tuner unit (TU1), RDS decoder (IC51) and electrical IIC SIO...
  • Page 26 XR-CA800 Pin No. Pin Name Description Power on/off control signal output of the illumination LED and liquid crystal display driver ILLON (IC900) “H”: power on Rotation detection signal input from supply reel sensor and take-up reel sensor on the mechanism...
  • Page 27 XR-CA800 • KEY BOARD IC903 RRX9000-0401R#01 (SIRCS CONTROLLER) Pin No. Pin Name Description — Power supply terminal (+5V) — Ground terminal System clock input terminal (4 MHz) XOUT System clock output terminal (4 MHz) CNVSS — Ground terminal RESET Reset signal input trminal “L”: reset...

  • Page 28: Exploded Views

    XR-CA800 SECTION 7 EXPLODED VIEWS NOTE: • -XX and -X mean standardized parts, so they • Items marked “*” are not stocked since they may have some difference from the original are seldom required for routine service. Some one. delay should be anticipated when ordering •...

  • Page 29: 7-2. Front Panel Section

    XR-CA800 7-2. FRONT PANEL SECTION not supplied not supplied not supplied not supplied (KEY board) not supplied LCD901 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark X-3380-575-1 PANEL ASSY (SVX), FRONT 1-694-780-11 CONDUCTIVE BOARD, CONNECTION * 52...

  • Page 30: Mechanism Deck Section (Mg-25G-136)

    XR-CA800 7-3. MECHANISM DECK SECTION (MG-25G-136) HP901 M901 not supplied Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark A-3291-667-A CLUTCH (FR) ASSY 3-933-346-01 CATCHER * 152 3-019-130-01 LEVER (LDG-A) 3-933-344-01 GUIDE (C) * 153 3-019-131-01 LEVER (LDG-B)

  • Page 31: Electrical Parts List

    XR-CA800 SECTION 8 ELECTRICAL PARTS LIST NOTE: • Due to standardization, replacements in the • Items marked “*” are not stocked since they When indicating parts by reference number, please include the board. parts list may be different from the parts speci- are seldom required for routine service.
  • Page 32 XR-CA800 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R971 1-216-029-00 METAL CHIP 1/10W 1-163-133-00 CERAMIC CHIP 470PF R972 1-216-027-00 METAL CHIP 1/10W 1-163-227-11 CERAMIC CHIP 10PF 0.5PF 1-107-823-11 CERAMIC CHIP 0.47uF R973 1-216-029-00 METAL CHIP...
  • Page 33 XR-CA800 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C352 1-165-319-11 CERAMIC CHIP 0.1uF 8-719-976-99 DIODE UDZ-TE-17-5.1B D351 8-719-977-22 DIODE UDZ-TE-17-9.1B C353 1-163-031-11 CERAMIC CHIP 0.01uF D352 8-719-970-02 DIODE 1SR139-400T-32 C354 1-124-233-11 ELECT 10uF D502 8-719-056-83 DIODE UDZ-TE-17-6.8B...
  • Page 34 XR-CA800 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark 1-216-296-11 SHORT Q351 8-729-015-11 TRANSISTOR 2SD1802FAST-TL 1-216-296-11 SHORT Q352 8-729-047-76 TRANSISTOR FMC2A-T148 JC10 1-216-295-11 SHORT Q353 8-729-900-53 TRANSISTOR DTC114EKA-T146 JC11 1-216-295-11 SHORT Q354 8-729-106-60 TRANSISTOR 2SB1132-T100-R...
  • Page 35 XR-CA800 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R242 1-216-049-11 RES-CHIP 1/10W R552 1-216-097-11 RES-CHIP 100K 1/10W R270 1-216-025-11 RES-CHIP 1/10W R555 1-208-806-11 RES-CHIP 0.5% 1/10W R557 1-247-807-31 CARBON 1/4W R271 1-216-025-11 RES-CHIP 1/10W...
  • Page 36 XR-CA800 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < THERMISTOR > ACCESSORIES & PACKING MATERIALS ******************************* TH501 1-803-350-21 THERMISTOR, POSITIVE 1-476-547-11 WIRELESS REMOTE COMMANDER (RM-X116) < TUNER UNIT > 1-476-589-11 WIRELESS ROTARY COMMANDER (RM-X5S)
  • Page 37 XR-CA800 Ver 1.1 2001.05 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark PARTS FOR INSTALLATION AND CONNECTIONS ************************************** X-3373-602-1 FRAME ASSY X-3366-405-1 SCREW ASSY (EXP), FITTING 3-040-979-01 COLLAR 3-934-325-01 SCREW, +K (5X8) TAPPING 3-233-644-01 SPRING, FITTING 1-465-459-21 ADAPTER, ANTENNA 1-782-381-11 CORD (WITH CONNECTOR) (ISO P&S)
  • Page 38 XR-CA800 REVISION HISTORY Clicking the version allows you to jump to the revised page. Also, clicking the version at the upper right on the revised page allows you to jump to the next revised page. Ver. Date Description of Revision 2001.05...

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