Sony XR-CA400 Service Manual
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Sony XR-CA400 Service Manual

Sony XR-CA400 Service Manual

Fm/am cassette car stereo
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3 7 63 1515 0
SERVICE MANUAL
Ver 1.2 2001.06
AUDIO POWER SPECIFICATIONS (US model)
TE
POWER OUTPUT AND TOTAL HARMONIC DISTORTION
L 13942296513
23 watts per channel minimum continuous average power into 4
ohms, 4 channels driven from 20 Hz to 20 kHz with no more than
5 % total harmonic distortion.
Other specifications
Cassette player section
Tape track
Wow and flutter
Frequency response
Signal-to-noise ratio
Tuner section
FM
Tuning range
XR-CA400 :
XR-CA420X :
Antenna terminal
Intermediate frequency
Usable sensitivity
Selectivity
www
.
Sony Corporation
9-870-236-13
2001F0500-1
e Vehicle Company
C 2001.6
Shinagawa Tec Service Manual Production Group
http://www.xiaoyu163.com
XR-CA400/CA420X
Signal-to-noise ratio
Harmonic distortion at 1 kHz
4-track 2-channel stereo
0.08 % (WRMS)
30 – 18,000 Hz
Separation
Frequency response
Cassette type
AM
TYPE II, IV
61 dB
Tuning range
TYPE I
58 dB
XR-CA400 :
XR-CA420X :
87.5 – 107.9 MHz
FM tuning interval:
Antenna terminal
50 kHz/200 kHz
Intermediate frequency
switchable
Sensitivity
87.5 – 108.0 MHz
(at 50 kHz step)
Power amplifier section
87.5 – 107.9 MHz
(at 200 kHz step)
Outputs
External antenna connector
10.7 MHz
Speaker impedance
11 dBf
Maximum power output 50 W × 4 (at 4 ohms)
75 dB at 400 kHz
x
ao
y
i
http://www.xiaoyu163.com
8
Photo: XR-CA400
Model Name Using Similar Mechanism
Tape Transport Mechanism Type
SPECIFICATIONS
Q Q
3
6 7
1 3
65 dB (stereo),
68 dB (mono)
0.7 % (stereo),
0.5 % (mono)
33 dB at 1 kHz
30 – 15,000 Hz
530 – 1,710 kHz
AM tuning interval:
9 kHz/10 kHz switchable
531 – 1,602 kHz
(at 9 kHz step)
530 – 1,710 kHz
(at 10 kHz step)
External antenna connector
10.7 MHz/450 kHz
30 µV
Speaker outputs
(sure seal connectors)
4 – 8 ohms
FM/AM CASSETTE CAR STEREO
u163
.
2 9
9 4
2 8
Canadian Model
XR-C5300X/C5600X
MG-25F-136
1 5
0 5
8
2 9
9 4
General
Outputs
Audio output
Power antenna relay
control lead
Power amplifier control
lead
Tone controls
Bass ±10 dB at 20 Hz
XR-CA400 :
Treble ±10 dB at 20 kHz
Bass ±9 dB at 100 Hz
XR-CA420X :
Treble ±9 dB at 10 kHz
Power requirements
12 V DC car battery
(negative ground)
Approx. 178 × 50 × 178 mm
Dimensions
(7
(w/h/d)
Approx. 182 × 53 × 161 mm
Mounting dimensions
(7
(w/h/d)
Mass
Approx. 1.2 kg (2 lb 10 oz)
Supplied accessories
Parts for installation and
connections (1 set)
Front panel case (1)
Design and specifications are subject to change
without notice.
m
co
9 9
US Model
XR-CA400
E Model
XR-CA420X
2 8
9 9
× 2 × 7
1
1
/
/
in.)
8
8
× 2
× 6
1
/
1
/
3
/
in.)
4
8
8

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  • Page 1 3 7 63 1515 0 SERVICE MANUAL US Model Canadian Model Ver 1.2 2001.06 XR-CA400 E Model XR-CA420X Photo: XR-CA400 Model Name Using Similar Mechanism XR-C5300X/C5600X Tape Transport Mechanism Type MG-25F-136 SPECIFICATIONS AUDIO POWER SPECIFICATIONS (US model) POWER OUTPUT AND TOTAL HARMONIC DISTORTION...

  • Page 2: Table Of Contents

    XR-CA400/CA420X 3 7 63 1515 0 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 Setting the Clock .............

  • Page 3: General

    XR-CA400/CA420X SECTION 1 This section is extracted from instruction manual. 3 7 63 1515 0 GENERAL Location of controls Setting the clock The clock uses a 12-hour digital indication. Example: To set the clock to 10:08 Press (DSPL) for two seconds.
  • Page 4 XR-CA400/CA420X 3 7 63 1515 0 Parts Iist (1) Connection diagram (3) To a metal surface of the car The numbers in the list are keyed to those in the First connect the black earth lead, then connect instructions.
  • Page 5 XR-CA400/CA420X 3 7 63 1515 0 Supplied with XA-C30 Suministrado con el XA-C30 Supplied with the CD/MD changer Source selector Selector de fuente Suministrado con el cambiador de CD/MD BUS AUDIO IN BUS CONTROL IN from car aerial adaptor del adaptador de antena de automóvil...
  • Page 6 En tal caso, consulte a su •Avoid installing the unit in areas subject to • Evite instalar la unidad donde pueda quedar your Sony dealer. proveedor Sony. dust, dirt, excessive vibration, or high sometida a altas temperaturas, como a la luz temperatures, such as in direct sunlight or near solar directa o al aire caliente de calefacción, o...
  • Page 7 XR-CA400/CA420X 3 7 63 1515 0 TOYOTA NISSAN max. size max. size 5 × 8 mm to dashboard/center console to dashboard/center console 5 × 8 mm al salpicadero/consola central al salpicadero/consola central Tamaño máx. Tamaño máx. M5 × 8 mm M5 ×...

  • Page 8: Disassembly

    XR-CA400/CA420X SECTION 2 DISASSEMBLY 3 7 63 1515 0 Note: Follow the disassembly procedure in the numerical order given. 6 mechanism deck 5 screw (PTT2.6 × 6) MECHANISM DECK (MG-25F-136) (MG-25F-136) 4 connector (CN351) 3 flexible board (CNP301) 2 sub panel assy 1 screw (PTT2.6 ×...
  • Page 9 XR-CA400/CA420X 3 7 63 1515 0 HEAT SINK (ISO) 2 heat sink (ISO) 1 seven screws (PTT2.6 × 10) L 13942296513 u163 http://www.xiaoyu163.com...

  • Page 10: Assembly Of Mechanism Deck

    XR-CA400/CA420X SECTION 3 ASSEMBLY OF MECHANISM DECK 3 7 63 1515 0 Note: Follow the assembly procedure in the numerical order given. HOUSING 7 Hold the hanger by bending the claw. 5 Fit projection on C part. 1 Install the catch to the hanger.
  • Page 11 XR-CA400/CA420X 3 7 63 1515 0 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 XR-CA400/CA420X 3 7 63 1515 0 GUIDE (C) 2 guide (C) 1 three claws L 13942296513 MOUNTING POSITION OF CAPSTAN/REEL MOTOR (M901) two precision screws (P2 × 2) capstan/reel motor (M901) Note: Mount the motor so that the u163...

  • Page 13: Mechanical Adjustments

    XR-CA400/CA420X SECTION 4 SECTION 5 MECHANICAL ADJUSTMENTS 3 7 63 1515 0 ELECTRICAL 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...

  • Page 14: Diagrams

    XR-CA400/CA420X SECTION 6 DIAGRAMS 3 7 63 1515 0 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 XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 • IC Block Diagrams IC330 LC75421M-TLM – MAIN Board – IC1 TB2118F-EL-S 35 34 33 32 31 27 26 25 24 23 22 21 20 19 – 24 23...

  • Page 16: Printed Wiring Board - Main Board

    XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 6-2. PRINTED WIRING BOARD – MAIN Board – L100 1 3 9 4 2 2 9 6 5 1 3 • Semiconductor Location Ref. No. Location Ref. No. Location...

  • Page 17: Schematic Diagram - Main Board (1/3)

    XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 6-3. SCHEMATIC DIAGRAM – MAIN Board (1/3) – • • See page 14 for Waveform. See page 15 for IC Block Diagrams. 10µH 1 3 9 4 2 2 9 6 5 1 3 10µH...

  • Page 18: Schematic Diagram - Main Board (2/3)

    XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 6-4. SCHEMATIC DIAGRAM – MAIN Board (2/3) – • • See page 14 for Waveforms. See page 15 for IC Block Diagrams. (Page 17) 1 3 9 4 2 2 9 6 5 1 3...

  • Page 19: Schematic Diagram - Main Board (3/3)

    XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 6-5. SCHEMATIC DIAGRAM – MAIN Board (3/3) – • See page 15 for IC Block Diagrams. (Page 17) (Page 21) 1 3 9 4 2 2 9 6 5 1 3...

  • Page 20: Printed Wiring Board - Key Board

    XR-CA400/CA420X 6-6. PRINTED WIRING BOARD – KEY Board – 3 7 6 3 1 5 1 5 0 • Semiconductor Location Ref. No. Location LED907 1 3 9 4 2 2 9 6 5 1 3 (Page 16) PL902...

  • Page 21: Schematic Diagram - Key Board

    XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 6-7. SCHEMATIC DIAGRAM – KEY Board – • See page 14 for Waveform. (Page 19) 1 3 9 4 2 2 9 6 5 1 3 w w w u 1 6 3 http://www.xiaoyu163.com...

  • Page 22: 6-8. Ic Pin Function Description

    FM/AM tuner unit (TU1) BUSON Bus on/off control signal output to the SONY bus interface (IC581) “L”: bus on “L” is input in the FM stereo mode, or “L” is output in the forced monaural mode...
  • Page 23 XR-CA400/CA420X 3 7 63 1515 0 Pin No. Pin Name Description Motor drive signal output to the loading motor drive (IC351) “H” active LMLOD (For the loading direction and forward side operation) *1 Motor drive signal output to the loading motor drive (IC351) “H” active...

  • Page 24: Exploded Views

    XR-CA400/CA420X SECTION 7 EXPLODED VIEWS 3 7 63 1515 0 NOTE: • Items marked “*” are not stocked since they • -XX and -X mean standardized parts, so they may have some difference from the original are seldom required for routine service. Some one.
  • Page 25 3-224-860-01 PANEL, FRONT (CA400) * 63 3-224-895-01 REFLECTOR (LCD) 3-224-860-11 PANEL, FRONT (CA420X) 3-224-861-01 PANEL, FRONT BACK 3-042-504-01 EMBLEM (NO.2.5), SONY 3-224-868-01 BUTTON (EJECT/U) (Z) 3-224-863-01 BUTTON (+/-) (CA400) 3-224-865-01 BUTTON (L/U) (MBP. D. OFF) u163 3-224-863-11 BUTTON (+/-) (CA420X) LCD901 1-804-298-11 DISPLAY PANEL, LIQUID CRYSTAL 3-224-866-01 BUTTON (R/U) (SRC.
  • Page 26 XR-CA400/CA420X 3 7 63 1515 0 (3) MECHANISM DECK SECTION (MG-25F-136) HP901 M901 L 13942296513 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)

  • Page 27: Electrical Parts List

    XR-CA400/CA420X SECTION 8 3 7 63 1515 0 ELECTRICAL PARTS LIST NOTE: When indicating parts by reference • Due to standardization, replacements in the • Items marked “*” are not stocked since they number, please include the board. parts list may be different from the parts speci- are seldom required for routine service.
  • Page 28 XR-CA400/CA420X 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark LSW918 1-786-106-21 SWITCH, TACTILE (WITH LED) (BL SKIP, 5) R934 1-216-819-11 METAL CHIP 1/16W (CA400) (CA400) R934 1-216-817-11 METAL CHIP 1/16W...
  • Page 29 XR-CA400/CA420X 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < SWITCH > C107 1-162-915-11 CERAMIC CHIP 10PF 0.5PF C109 1-162-915-11 CERAMIC CHIP 10PF 0.5PF S907 1-771-884-11 SWITCH, TACTILE (ATT)
  • Page 30 XR-CA400/CA420X 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C305 1-107-823-11 CERAMIC CHIP 0.47uF C611 1-124-233-11 ELECT 10uF C612 1-124-233-11 ELECT 10uF C306 1-162-970-11 CERAMIC CHIP 0.01uF C614 1-124-233-11 ELECT...
  • Page 31 XR-CA400/CA420X 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark D703 8-719-109-97 DIODE RD6.8ESB2 JC251 1-216-296-11 SHORT JC302 1-216-295-11 SHORT D704 8-719-109-97 DIODE RD6.8ESB2 D705 8-719-109-97 DIODE RD6.8ESB2 JC303 1-216-295-11 SHORT...
  • Page 32 XR-CA400/CA420X 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark L100 1-424-759-11 COIL (AM ANT) R151 1-216-821-11 METAL CHIP 1/16W R152 1-216-837-11 METAL CHIP 1/16W L501 1-410-501-11 INDUCTOR 2.2uH R171...
  • Page 33 XR-CA400/CA420X 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R520 1-216-821-11 METAL CHIP 1/16W R585 1-216-841-11 METAL CHIP 1/16W R521 1-216-821-11 METAL CHIP 1/16W R590 1-216-845-11 METAL CHIP 100K...
  • Page 34 XR-CA400/CA420X 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark 1-693-511-11 FM/AM TUNER UNIT (FAE347-A13) PARTS FOR INSTALLATION AND CONNECTIONS ************************************************************ ************************************** X-3373-602-1 FRAME ASSY ************** HARDWARE LIST X-3368-725-1 SCREW ASSY, FITTING (CA400)
  • Page 35 XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 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 36 XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 PRINTED WIRING BOARD – MAIN Board – IC751 L100 IC581 IC330 IC611 1 3 9 4 2 2 9 6 5 1 3 • Semiconductor Location Ref. No. Location Ref.
  • Page 37 XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 SCHEMATIC DIAGRAM – MAIN Board (1/3) – 1 3 9 4 2 2 9 6 5 1 3 w w w u 1 6 3 (Page 4) (Page 5)
  • Page 38 XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 SCHEMATIC DIAGRAM – MAIN Board (2/3) – (Page 3) 1 3 9 4 2 2 9 6 5 1 3 (Page 5) w w w u 1 6 3...
  • Page 39 XR-CA400/CA420X SCHEMATIC DIAGRAM – MAIN Board (3/3) – 3 7 6 3 1 5 1 5 0 (Page 3) (ORIGINAL SERVICE MANUAL Page 20) 1 3 9 4 2 2 9 6 5 1 3 (Page 4) w w w u 1 6 3 http://www.xiaoyu163.com...
  • Page 40 XR-CA400/CA420X 3 7 6 3 1 5 1 5 0 MAIN MAIN ELECTRICAL PARTS LIST Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark NOTE: C241 1-124-233-11 ELECT 10uF C365 1-162-915-11 CERAMIC CHIP 10PF 0.5PF • Due to standardization, replacements in the •...
  • Page 41 XR-CA400/CA420X 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < COMPOSITION CIRCUIT BLOCK > < SHORT/CAPACITOR/RESISTOR > 1-803-902-21 PROTECTOR CHIP, SURGE 1-216-295-11 SHORT JC18 1-216-296-11 SHORT < DIODE >...
  • Page 42 XR-CA400/CA420X 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark JC582 1-216-295-11 SHORT JC584 1-216-296-11 SHORT 1-216-830-11 METAL CHIP 5.6K 1/16W JC585 1-216-296-11 SHORT 1-216-821-11 METAL CHIP 1/16W JC586 1-216-296-11 SHORT...
  • Page 43 XR-CA400/CA420X 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R306 1-216-849-11 METAL CHIP 220K 1/16W R560 1-216-845-11 METAL CHIP 100K 1/16W R331 1-216-831-11 METAL CHIP 6.8K 1/16W R562 1-216-833-11 METAL CHIP...
  • Page 44 XR-CA400/CA420X 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < SWITCH > S530 1-571-478-11 SWITCH, SLIDE (FREQUENCY SELECT) (CA420X) S551 1-692-431-21 SWITCH, TACTILE (RESET) < THERMISTOR > TH501 1-803-350-21 THERMISTOR, POSITIVE <...
  • Page 45 XR-CA400/CA420X 3 7 63 1515 0 MEMO L 13942296513 u163 http://www.xiaoyu163.com...
  • Page 46 XR-CA400/CA420X 3 7 63 1515 0 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.

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