Sony XR-C540RDS Service Manual
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Sony XR-C540RDS Service Manual

Sony XR-C540RDS Service Manual

Fm/mw/lw cassette car stereo
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3 7 63 1515 0
SERVICE MANUAL
Ver 1.1 2001.06
For RM-X2S (Remote Commander),
please refer to RM-X2S/X3S Service
Manual (9-960-039-S) previously issued.
Dolby noise reduction manufactured under license
from Dolby Laboratories Licensing Corporation.
"DOLBY" and the double-D symbol ; are trademarks
of Dolby Laboratories Licensing Corporation.
Cassette player section
Tape track
Wow and flutter
Frequency response
TE
L 13942296513
Signal-to-noise ratio
Tuner section
FM
Tuning range
Antenna terminal
Intermediate frequency
Usable sensitivity
Selectivity
Signal-to-noise ratio
Harmonic distortion at 1 kHz
Separation
Frequency response
Capture ratio
MW/LW
Tuning range
Antenna terminal
Intermediate frequency
Sensitivity
www
.
Sony Corporation
9-925-543-12
2001F0500-1
e Vehicle Company
C 2001.6
Shinagawa Tec Service Manual Production Group
http://www.xiaoyu163.com
XR-C540RDS
4-track 2-channel stereo
0.08% (WRMS)
30 – 18,000 Hz
64 dB (Dolby B NR)
58 dB (Dolby NR off)
87.5 – 108.0 MHz
External antenna connector
10.7 MHz
8 dBf
75 dB at 400 kHz
65 dB (stereo),
70 dB (mono)
0.5% (stereo),
0.3% (mono)
35 dB at 1 kHz
30 – 15,000 Hz
4 dB
MW: 531 – 1,602 kHz
LW: 153 – 281 kHz
External antenna connector
10.71 Mhz/450 kHz
MW: 30 µV
LW: 50 µV
x
ao
u163
y
i
http://www.xiaoyu163.com
2 9
8
Model Name Using Similar Mechanism
Tape Transport Mechanism Type
SPECIFICATIONS
Power amplifier section
Outputs
Q Q
Speaker impedance
3
6 7
1 3
1 5
Maximum power output
General
Outputs
Tone controls
Power requirements
Dimensions
Mounting dimensions
Mass
Supplied accessories
Design and specifications are subject to change without notice.
FM/MW/LW CASSETTE CAR STEREO
co
.
9 4
2 8
AEP Model
UK Model
MG-52B-136
Speaker outputs
(sure seal connectors)
4 – 8 ohms
0 5
8
2 9
9 4
2 8
35 W × 4 (at 4 ohms)
Power amplifier control lead
Rear line out (1)
Bass ± 8 dB at 100 Hz
Treble ± 8 dB at 10 kHz
12 V DC car battery (negative ground)
Approx. 188 × 58 × 181 mm (w/h/d)
Approx. 182 × 53 × 164 mm (w/h/d)
Approx. 1.2 kg
Parts for installation and connections
(1 set)
Rotary commander RM-X2S
Front panel case (1)
m
9 9
NEW
9 9

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  • Page 1 XR-C540RDS 3 7 63 1515 0 SERVICE MANUAL AEP Model UK Model Ver 1.1 2001.06 For RM-X2S (Remote Commander), please refer to RM-X2S/X3S Service Manual (9-960-039-S) previously issued. Dolby noise reduction manufactured under license Model Name Using Similar Mechanism from Dolby Laboratories Licensing Corporation.

  • Page 2: Table Of Contents

    http://www.xiaoyu163.com 3 7 63 1515 0 TABLE OF CONTENTS SERVICING NOTES GENERAL Flexible Circuit Board Repairing • Keep the temperature of the soldering iron around 270 ˚ C dur- Location of Controls ............3 Setting the Clock ............. 3 ing repairing. •...
  • Page 3 http://www.xiaoyu163.com SECTION 1 This section is extracted from instruction manual. GENERAL 3 7 63 1515 0 L 13942296513 u163 – 3 – http://www.xiaoyu163.com...
  • Page 4 http://www.xiaoyu163.com 3 7 63 1515 0 L 13942296513 u163 – 4 – http://www.xiaoyu163.com...
  • Page 5 http://www.xiaoyu163.com 3 7 63 1515 0 L 13942296513 u163 – 5 – http://www.xiaoyu163.com...
  • Page 6 http://www.xiaoyu163.com 3 7 63 1515 0 L 13942296513 u163 – 6 – http://www.xiaoyu163.com...
  • Page 7 http://www.xiaoyu163.com 3 7 63 1515 0 L 13942296513 u163 – 7 – http://www.xiaoyu163.com...
  • Page 8 http://www.xiaoyu163.com 3 7 63 1515 0 L 13942296513 u163 – 8 – http://www.xiaoyu163.com...

  • Page 9: Disassembly

    http://www.xiaoyu163.com SECTION 2 3 7 63 1515 0 DISASSEMBLY Note: Follow the disassembly procedure in the numerical order given. FRONT PANEL ASS’Y 1 Push the button (release). 2 Remove the front panel ass’y to the direction of the arrow A . L 13942296513 COVER ASS’Y 3 cover ass’y...
  • Page 10 http://www.xiaoyu163.com 3 7 63 1515 0 SUB PANEL, MECHANISM DECK (MG-25B-136) 5 screw (PTT2.6 × 6) 3 connector (CN302) 6 mechanism deck (MG-25B-136) 4 flexible flat cable (CN301) 2 sub panel 1 three screws (PTT2.6 × 8) 1 three screws (PTT2.6 ×...

  • Page 11: Assembly Of Mechanism Deck

    http://www.xiaoyu163.com 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. 2 Install the hanger onto 1 Install the catch to the hanger.
  • Page 12 http://www.xiaoyu163.com 3 7 63 1515 0 LEVER (LDG-A) / (LDG-B) shaft A shaft A shaft B shaft C shaft C 1 Fit the lever (LDG-A) on 4 type-E stop ring 2.0 shafts A – C and install it. 2 Pull the lever in the arrow direction.
  • Page 13 http://www.xiaoyu163.com 3 7 63 1515 0 GUIDE (C) 2 guide (C) 1 three claws L 13942296513 u163 – 13 – http://www.xiaoyu163.com...

  • Page 14: Mechanical Adjustments

    http://www.xiaoyu163.com SECTION 4 MECHANICAL ADJUSTMENTS 3 7 63 1515 0 1. Clean the following parts with a denatured-alcohol-moistene See the adjustment location from on page 17 for the swab: adjustment. playback head pinch roller rubber belt capstan TAPE DECK SECTION 0 dB=0.775 V idlers 2.

  • Page 15: Tuner Section

    http://www.xiaoyu163.com 3 7 63 1515 0 FM Noise Focus Adjustment TUNER SECTION 0 dB=1 µV Setting: SOURCE button: FM Cautions during repair When the tuner unit is defective, replace it by a new one be- cause its internal block is difficult to repair. FM RF signal level meter antenna jack (J1)
  • Page 16 http://www.xiaoyu163.com 3 7 63 1515 0 FM Signal Meter Adjustment MW Auto Scan/Stop Level Adjustment Setting: Make this adjustment after “FM Auto Scan/Stop Level Adjustment”. SOURCE button: FM Setting: SOURCE button: MW FM RF signal generator 30 Ω 15 pF antenna jack (J1) 0.01 µ...
  • Page 17 http://www.xiaoyu163.com 3 7 63 1515 0 Adjustment Location: – SET UPPER VIEW – Tape Speed Adjustment RV1 MW Auto Scan/Stop level Adjustment RV2 FM Auto Scan/Stop level Adjustment RV3 FM Noise Focus Adjustment RV4 FM Stereo separation Adjustment L 13942296513 RV301 RV401 (R-CH)

  • Page 18: Diagrams

    http://www.xiaoyu163.com SECTION 6 DIAGRAMS 3 7 63 1515 0 • IC Block Diagrams – MAIN Section – IC1 TB2114F (EL) 24 23 21 20 14 13 RIPPLE FILTER – – SEEK/RECP SEEK/RECP 4BIT MODULAS SWALLOW COUNTER PRESCALER 12BIT PHASE PROGRAMABLE COMPARATOR COUNTER REFERENCE...
  • Page 19 http://www.xiaoyu163.com 3 7 63 1515 0 – LFIN – – – LFOUT – LSELO LROUT – – – VREF SHIFT DECODER LATCH CONTROL REGISTER – – – RROUT RSELO – RFOUT – – – – RFIN 6 7 8 9 10 L 13942296513 120µ/ 70µ...
  • Page 20 http://www.xiaoyu163.com 3 7 63 1515 0 IC360 MM1322XFBE 8 OUT2 OUT1 IC601 BA3918-V2 REGULATOR OVER VOLTAGE PROTECT L 13942296513 – 2 3 4 IC701 BA8270F-E2 BUS ON BUS ON SWITCH RESET SWITCH BUS ON CLK IN BATTERY BATT BU IN SWITCH VREF DATA...
  • Page 21 http://www.xiaoyu163.com 3 7 63 1515 0 • Waveforms 1 IC @¢ (X1) 3 IC501 8 (X_IN) 752 mVp-p 3.08 Vp-p 138 nsec 124 nsec 1 IC3 !º (X1) 4 IC501 !¡ (XT_IN) 2.2 Vp-p 2.68 Vp-p 30.4 µ sec 230 nsec L 13942296513 u163 –...
  • Page 22 http://www.xiaoyu163.com 3 7 6 3 1 5 1 5 0 1 3 9 4 2 2 9 6 5 1 3 w w w u 1 6 3 http://www.xiaoyu163.com...
  • Page 23 http://www.xiaoyu163.com w w w http://www.xiaoyu163.com...
  • Page 24 http://www.xiaoyu163.com http://www.xiaoyu163.com...

  • Page 25: 6-5. Ic Pin Function Description

    http://www.xiaoyu163.com 3 7 63 1515 0 6-5. IC PIN FUNCTION DESCRIPTION • MAIN BOARD IC501 MN1886426S4H (SYSTEM CONTROLLER) Pin No. Pin Name Function TUNMUT Tuner muting control pin At muting: “H” AMPON Power amp power supply control pin Illumination power supply control pin At PW SEL on: ACC on: “H”...

  • Page 26: Tel 13942296513

    A/D reference voltage input pin (connected to GND in this set) AVSS – L 13942296513 – BUSON BUS ON control signai output pin (for SONY BUS) SYSRST System reset signal output pin (for SONY BUS) SEKOUT SEEK control signal output pin TUNON...

  • Page 27: Exploded Views

    http://www.xiaoyu163.com SECTION 7 EXPLODED VIEWS 3 7 63 1515 0 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.
  • Page 28 http://www.xiaoyu163.com 3 7 63 1515 0 (2) FRONT PANEL SECTION not supplied (KEY board) L 13942296513 LCD901 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark 3-010-396-01 KNOB (D-BASS) 3-010-387-01 BUTTON (PRESET)(6. 1. 2. 3. 4. 5. 6. DSPL) 3-010-398-01 BUTTON (RELEASE) 3-010-388-01 BUTTON (P.
  • Page 29 http://www.xiaoyu163.com 3 7 63 1515 0 (3) MECHANISM DECK SECTION (MG-25B-136) HP901 M901 L 13942296513 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark A-3291-667-A CLUTCH (FR) ASSY 3-008-874-02 CATCHER 3-701-437-21 WASHER 3-933-344-01 GUIDE (C) * 203 3-008-883-01 LEVER (LDG-A) 3-927-100-01 SCREW (+PS 2X10), SPECIAL * 204...

  • Page 30: Electrical Parts List

    http://www.xiaoyu163.com SECTION 8 ELECTRICAL PARTS LIST 3 7 63 1515 0 NOTE: • Due to standardization, replacements in the • Items marked “*” are not stocked since they When indicating parts by reference parts list may be different from the parts speci- are seldom required for routine service.
  • Page 31 http://www.xiaoyu163.com MAIN 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R925 1-216-053-00 METAL CHIP 1.5K 1/10W 1-164-161-11 CERAMIC CHIP 0.0022uF 10% 100V 1-124-584-00 ELECT 100uF 20% 10V R926 1-216-053-00 METAL CHIP 1.5K 1/10W 1-163-809-11 CERAMIC CHIP...
  • Page 32 http://www.xiaoyu163.com MAIN 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C224 1-126-096-11 ELECT 10uF 20% 35V < CONNECTOR > C301 1-163-009-11 CERAMIC CHIP 0.001uF 10% 50V C302 1-163-263-11 CERAMIC CHIP 330PF CN351 1-766-260-11 CONNECTOR, FFC/FPC (ZIF) 7P C303...
  • Page 33 http://www.xiaoyu163.com MAIN 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark IC701 8-759-449-89 IC BA8270F-E2 JC76 1-216-296-00 CONDUCTOR, CHIP (3216) JC77 1-216-296-00 CONDUCTOR, CHIP (3216) < JACK > JC78 1-216-296-00 CONDUCTOR, CHIP (3216) JC79 1-216-296-00 CONDUCTOR, CHIP...
  • Page 34 http://www.xiaoyu163.com MAIN 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R108 1-216-077-00 METAL CHIP 1/10W R109 1-216-077-00 METAL CHIP 1/10W R525 1-216-097-00 METAL GLAZE 100K 1/10W R110 1-216-077-00 METAL CHIP 1/10W R526 1-216-097-00 METAL GLAZE 100K...
  • Page 35 http://www.xiaoyu163.com MAIN POWER 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < SWITCH > < RESISTOR > S601 1-692-431-21 SWITCH, TACTILE (RESET) R801 1-216-198-00 METAL GLAZE 1/8W R802 1-216-198-00 METAL GLAZE 1/8W <...
  • Page 36 http://www.xiaoyu163.com 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark PARTS FOR INSTALLATION AND CONNECTIONS ************************************** 3-916-161-31 FRAME ASSY X-3370-077-1 SCREW ASSY (AE.KEY), FITTING 3-386-828-01 SCREW, FITTING 3-349-410-01 BUSHING 3-388-078-01 KEY 1-777-989-21 CORD (WITH CONNECTOR) (AMP REM) 1-782-093-11 CORD (WITH CONNECTOR) (SPEAKER) 1-782-092-11 CORD (WITH CONNECTOR) (POWER) 1-775-543-11 CORD, GROUND...
  • Page 37 XR-C540RDS 3 7 63 1515 0 AEP Model UK Model SERVICE MANUAL Ver 1.1 2001.06 SUPPLEMENT-1 File this supplement with the service manual. Subject: MAIN Board Modification (SPM-01012) In this set, following board has been changed in the midway of production.
  • Page 38 XR-C540RDS 3 7 63 1515 0 DIAGRAMS 2-1. NOTE FOR PRINTED WIRING BOARD AND SCHEMATIC DIAGRAMS Note on Printed Wiring Board: Note on Schematic Diagram: • X : parts extracted from the component side. • All capacitors are in µF unless otherwise noted. pF: µµF •...
  • Page 39 3 7 6 3 1 5 1 5 0 • Semiconductor Location Ref. No. Location CN701 CNJ150 BUS CONTROL IN BUS AUDIO LINE OUT (FOR SONY BUS) REAR G-14 (ORIGINAL SERVICE MANUAL Page 24) (ORIGINAL SERVICE MANUAL Page 24) D150 POWER BOARD POWER BOARD D151 CN803...
  • Page 40 XR-C540RDS 3 7 6 3 1 5 1 5 0 2-3. SCHEMATIC DIAGRAM – MAIN Board (1/3) – FM/AM TUNER UNIT CNJ150 BUS AUDIO IN LINE OUT REAR C124 R118 R151 C151 C153 25V 3.3k 4.7k 0.47 0.022 R119...
  • Page 41 XR-C540RDS 3 7 6 3 1 5 1 5 0 2-4. SCHEMATIC DIAGRAM – MAIN Board (2/3) – (Page 4) C408 C308 R408 JC58 R351 C306 R305 C305 R307 C309 330k 0.22 2.2k 1000p C410 2200p R303 R308 C310...
  • Page 42 MA8068-H BATTERY CHECK Q610 2SC2412K-QR C701 D605 C610 R607 0.022 MA8056-M D701 MA8180-M R603 C612 CN701 BUS CONTROL IN (FOR SONY BUS) R708 JC33 R704 UNISI 100k UNISO JC34 BUS.ON B.DATA w w w UNICLK B.CLK BUSON JC35 JC79 D703...
  • Page 43 XR-C540RDS 3 7 63 1515 0 MAIN 3. ELECTRICAL PARTS LIST NOTE: • Items marked “*” are not stocked since they • Due to standardization, replacements in the 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 44 XR-C540RDS MAIN 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C351 1-163-251-11 CERAMIC CHIP 100PF < DIODE > C353 1-124-465-00 ELECT 0.47uF 8-719-991-65 DIODE SB02W03C C354 1-163-021-11 CERAMIC CHIP 0.01uF...
  • Page 45 XR-C540RDS 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < CHIP CONDUCTOR > JC80 1-216-296-00 CONDUCTOR, CHIP JC81 1-216-296-00 CONDUCTOR, CHIP 1-216-295-00 CONDUCTOR, CHIP 1-216-295-00 CONDUCTOR, CHIP < COIL >...
  • Page 46 XR-C540RDS MAIN 3 7 63 1515 0 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R111 1-216-077-00 METAL CHIP 1/10W R526 1-216-097-00 METAL CHIP 100K 1/10W R528 1-216-097-00 METAL CHIP 100K 1/10W R112 1-216-129-00 METAL CHIP 2.2M...
  • Page 47 XR-C540RDS 3 7 63 1515 0 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < SWITCH > S601 1-692-431-21 SWITCH, TACTILE (RESET) < TUNER UNIT > 1-693-373-11 FM/AM TUNER UNIT < VIBRATOR > 1-567-848-11 VIBRATOR, CRYSTAL (7.2MHz) 1-579-242-41 VIBRATOR, CRYSTAL (4.332MHz)
  • Page 48 XR-C540RDS 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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