Page 1
CD Changer input cord 40 × 40 × 27 mm Dimensions × 1 × 1 in.) (w/h/d) Mass 140 g (5 oz.) COMPACT DISC CHANGER SYSTEM Sony Corporation 9-870-223-13 2002C0500-1 e Vehicle Company C 2002.03 Published by Sony Engineering Corporation...
OPERATION. REPLACE THESE COMPONENTS WITH DE FONCTIONNEMENT. NE REMPLACER CES COM- SONY PARTS WHOSE PART NUMBERS APPEAR AS POSANTS QUE PAR DES PIÈCES SONY DONT LES SHOWN IN THIS MANUAL OR IN SUPPLEMENTS PUB- NUMÉROS SONT DONNÉS DANS CE MANUEL OU LISHED BY SONY.
CDX-540RF/545XRF/545XRF Ver 1.2 SECTION 1 SERVICING NOTES JIG ON REPAIRING NOTES ON HANDLING THE OPTICAL PICK- When repairing this set, connect the jig (cord) for RF output ex- UP BLOCK OR BASE UNIT tract (Part No. J-2502-058-1) and power supply (Part No. J-2502- 058-2) as the figure shown below.
Installing the battery Installation de la pile Replace the battery with a Sony CR2025 or Duracell DL-2025 lithium battery. Use of another battery may Remplacez la pile par une pile au lithium CR2025 Sony ou DL-2025 Duracell. L’utilisation d’une autre pile present a risk of fire or explosion.
Page 5
Features Caractéristiques The CDX-540RF is a compact disc changer system comprised of the wired and wireless remote Le CDX-540RF est un système de changeur de disques compacts comprenant des télécommandes avec et commanders, the relay box, and the CD changer. The CD changer modulates the audio signal into the RF sans fil, une boîte de relais et un changeur CD.
Operation Fonctionnement Precautions Précautions • This unit cannot be used with a car audio without FM tuner. • Cet appareil ne peut être utilisé avec un autoradio sans syntoniseur FM. • If your car was parked in direct sunlight resulting in a considerable rise in temperature inside the car, allow the unit to •...
Page 7
Réglage de la courbe des graves Adjusting the bass curve Changing the output level Changement du niveau de sortie Appuyez plusieurs fois de suite sur Press (D-BASS) repeatedly to select the desired bass (D-BASS) pour sélectionner la courbe des graves curve.
Installation Installation How to install the CD changer Installation du changeur de CD •When you install the CD changer, be careful not to damage wiring or equipment on the other side of the •Quand vous installez le changeur de CD, veillez à ne pas endommager les câbles ou les instruments qui mounting surface.
Connections Connexions Caution Précautions •This unit is designed for negative ground 12 V •Veillez à raccorder le fil rouge d‘entrée •Be sure to connect the red power input lead to the •Cet appareil est uniquement conçu pour DC operation only. positive 12 V power terminal which is powered fonctionner sur 12 V CC avec une masse d‘alimentation à...
SECTION 3 DISASSEMBLY Note: Follow the disassembly procedure in the numerical order given. CASE (UPPER T), FRONT PANEL ASSY 3 screw (PTT2.6 × 6) 3 screw (PTT2.6 × 6) 4 lever (FLT) 5 case (upper T) 3 screw (PTT2.6 × 6) 4 lever (FLT) 1 screw (PTT2.6 ×...
Page 11
FM BOARD 2 screw 4 cover (FM) (ground) 1 screw (BVTT2.6 × 6) 5 FM board 3 cover (FM connector.T) MAIN BOARD, SLIDE VARIABLE RESISTOR (ELEVATOR HEIGHT SENSOR ) (RV202) 1 main flexible board (CNJ101) 5 two screws (FP) 6 screw 7 main board (PTT2 ×...
Page 12
ELJ MOTOR ASSY (ELEVATOR) (M104) 1 screw (PTT2 × 4) 2 bracket (EVM.S) 3 ELJ motor assy (elevator) (M104) ESCUTCHEON (T) 3 two claws 2 Remove the claw in the direction of arrow A . 4 Remove the ditch in the direction of arrow B . 5 Remove the escutcheon (T) in the direction of arrow C .
Page 13
CHASSIS (U.S) SUB ASSY 2 Remove the edge in the direction 1 three screws of arrow A . (PTT2 × 4) 1 two screws (PTT2 × 4) 5 chassis (U.S) sub assy 1 screw (PTT2 × 4) 4 spring (SUT) CHASSIS ASSY 6 chassis assy 5 spring (stopper.lower)
Page 14
RF BOARD 3 two screws (PS2 × 4) 4 RF board 3 two screws (PS2 × 4) 2 Remove four solders of the LSW board leads and spindle motor leads (M102). 2 Remove two solders of the sled motor leads 1 OP flexible board (CN102).
Page 15
LSW BOARD, SPINDLE MOTOR (S) SUB ASSY (M102) 8 two precision screws (P1.7 × 2.2) 3 spring (chucking) 6 retainer (disc) 1 precision screw (P2 × 2.5) 4 precision screw (P2 × 2.2) 5 bracket (CP) 2 LSW board 9 Remove the spindle motor (S) sub assy (M102) in the direction of the arrow.
SECTION 4 MECHANISM DECK ASSEMBLY Note: Follow the assembly procedure in the numerical order given. OPTICAL PICK-UP COMPLETE ASSY 1 Move the lever (LOCK 3A) in the direction of arrow A , and return it a little in the direction of arrow B from the position where the chuck plate is moved chuck plate down to the lower limit.
OPERATION CHECK 1 Confirm that the slider moves in the direction of arrow C to move down the chuck plate if the gear (LOAD CAM) is rotated in the direction of arrow A or the chuck plate moves up and the slider moves in the direction of arrow D if the gear is rotated in the direction of arrow B .
SECTION 5 MECHANICAL ADJUSTMENT • Elevator Height (Address) Adjustment Adjustment Method: Note: This adjustments is necessary when the system controller (IC201), variable resistor (RV201), slider (R), slider (L), or chassis (ELV) 1. Load a disc magazine, and place the set vertically as shown was replaced for any repair.
SECTION 6 ELECTRICAL CHECK Note: FOCUS BIAS CHECK 1. This adjustment is performed with the set placed horizontally. 2. Power supply voltage: DC14.4 V (more than 3 A). Connection: 3. Be sure to use the disc “YEDS-18” parts code: 3-702-101-01, but only –...
Page 20
TRACKING OFFSET CHECK Connection: – RF BOARD (Component Side) – oscilloscope (DC range) – TP (VC) IC101 TP (TE) Procedure: 1. Connect the oscilloscope to TP (TE) and TP (VC) on the RF board. 2. Put the set into play mode by loading the disc (YEDS-18). 3.
7-3. NOTE FOR PRINTED WIRING BOARDS AND SCHEMATIC DIAGRAMS • Circuit Boards Location FM board 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 •...
SCHEMATIC DIAGRAM – RF/LSW Boards – • • See page 32 for for Waveforms. See page 32 for IC Block Diagrams. CDX-540RF/545RF/545XRF (Page 28) The components identified by mark 0 or dotted Les composants identifiés par une marque 0 sont line with mark 0 are critical for safety.
Page 27
CDX-540RF/545RF/545XRF 7-7. PRINTED WIRING BOARDS – MAIN (Conductor Side)/SW Boards – • See page 23 for Circuit Boards Location. • Semiconductor Location Ref. No. Location IC304 IC305...
Page 28
CDX-540RF/545RF/545XRF 7-8. SCHEMATIC DIAGRAM – MAIN Board (1/2) – • See page 32 for Waveforms. (Page 25)
Page 29
CDX-540RF/545RF/545XRF 7-9. SCHEMATIC DIAGRAM – MAIN (2/2)/SW Boards – • • See page 32 for Waveforms. See page 32 for IC Block Diagrams. (Page 31)
Page 34
IC301 LB1930M-TLM IC304 NJM2395F08 IC305 NJM2395F05 BUFFER OUT1 CONTROL MOTOR CONTROL DRIVE CIRCUIT CIRCUIT OUT2 BUFFER S-GND P-GND – FM Board – IC701 BA1405F-E2 17 16 15 13 12 11 10 BUFFER BUFFER OSC 38kHz 5 6 7 8 IC781 BU2611AFS-E2 MAIN 1/16, PHASE DET,...
Page 35
7-12. IC PIN FUNCTION DESCRIPTION • MAIN BOARD IC201 CXP740056-010R (SYSTEM CONTROLLER) Pin No. Pin Name Description 1 to 3 — Not used (open) AMUTE Audio line muting on/off control signal output “H”: muting on CDXLT Serial data latch pulse signal output to the CXD2598Q (IC101) CDDATA Serial data output to the CXD2598Q (IC101) CDCLK...
Page 36
Pin No. Pin Name Description Save end detect switch (SW2) input terminal LOAD2 “L”: When completion of the disc save operation 67 to 70 — Not used (open) Motor drive signal (save direction) output to the chucking motor drive (IC201) CH.F “L”...
Page 37
SECTION 8 EXPLODED VIEWS NOTE: • -XX and -X mean standardized parts, so they • Items marked “*” are not stocked since they The components identified by mark 0 or dotted line with mark may have some difference from the original are seldom required for routine service.
Page 38
(2) GENERAL SECTION-2 MG-251A-137 RV202 supplied supplied not supplied not supplied Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark 3-047-852-01 DAMPER (T) * 61 1-676-722-11 SW BOARD * 52 X-3378-122-1 CASE (LOWER.T) ASSY (540RF) 3-042-244-11 SCREW (T) X-3378-123-1 CASE (LOWER.T) ASSY (545RF/545XRF) 3-041-218-21 ESCUTCHEON (T) * 53...
Page 39
(2) MECHANISM DECK SECTION-1 (MG-251A-137) Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark X-3378-091-1 CHASSIS (U. S) SUB ASSY 3-011-997-01 SPRING (STOPPER. LOWER) 3-024-161-11 SPRING (SUT)
Page 40
(4) MECHANISM DECK SECTION-2 (MG-251A-137) M104 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark 3-024-170-01 SPRING (SB), TENSION X-3378-092-1 CHASSIS (D. S) SUB ASSY * 152 3-040-790-01 BRACKET (EVM. S) M104 A-3301-123-A ELJ MOTOR ASSY (ELEVATOR)
Page 42
(6) MECHANISM DECK SECTION-4 (MG-251A-137) not supplied M102 not supplied M101 not supplied The components identified by Les composants identifiés par une mark 0 or dotted line with marque 0 sont critiques pour la mark 0 are critical for safety. sécurité.
Page 43
SECTION 9 ELECTRICAL PARTS LIST NOTE: The components identified by • Due to standardization, replacements in the • Items marked “*” are not stocked since they mark 0 or dotted line with mark 0 are critical for safety. are seldom required for routine service. parts list may be different from the parts speci- Replace only with part number fied in the diagrams or the components used...
Page 44
MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark Q782 8-729-120-28 TRANSISTOR 2SC1623-L5L6 X781 1-760-838-21 VIBRATOR, CRYSTAL (7.2MHz) ************************************************************** < RESISTOR > 1-676-524-13 LSW BOARD R301 1-216-057-00 METAL CHIP 2.2K 1/10W ********** R310 1-216-089-11 RES-CHIP 1/10W R311 1-216-085-00 METAL CHIP 1/10W...
Page 45
MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C318 1-126-382-11 ELECT 100uF R115 1-216-833-11 METAL CHIP 1/16W C319 1-164-360-11 CERAMIC CHIP 0.1uF C320 1-162-970-11 CERAMIC CHIP 0.01uF R116 1-216-837-11 METAL CHIP 1/16W R117 1-216-845-11 METAL CHIP 100K 1/16W C401...
Page 46
MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < SWITCH > R201 1-216-826-11 METAL CHIP 2.7K 1/16W R202 1-216-833-11 METAL CHIP 1/16W SW201 1-529-565-41 SWITCH, PUSH (1 KEY) (MAGAZINE DETECT) R203 1-216-833-11 METAL CHIP 1/16W R204 1-216-842-11 METAL CHIP 1/16W...
Page 47
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark PARTS FOR INSTALLATION AND CONNECTIONS ************** HARDWARE LIST ************************************** ************** 3-040-583-21 BRACKET 7-685-862-09 SCREW +BVTT 2.6X6 (S) * 502 X-3369-824-1 SCREW ASSY 7-685-792-09 SCREW +PTT 2.6X6 (S) not supplied 7-685-781-09 SCREW +PTT 2X4 (S) 4-916-258-01 TAPE, MAGIC (for RM-X81RF) 7-624-104-04 STOP RING 2.0, TYPE -E...
Page 49
CDX-540RF/545RF/545XRF US Model Canadian Model SERVICE MANUAL CDX-540RF E Model CDX-545RF/545XRF Ver 1.1 2001.06 SUPPLEMENT-1 File this supplement with the service manual. Subject: Change of MAIN/SW boards (ECN-CSA03709) In this set, MAIN and SW boards have been changed in the midway of production.
Page 50
CDX-540RF/545RF/545XRF 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. • Y : parts extracted from the conductor side.
Page 55
CDX-540RF/545RF/545XRF MAIN ELECTRICAL PARTS LIST Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark IC304 8-759-833-13 IC NJM2395AF08 R305 1-216-841-11 METAL CHIP 1/16W NOTE: When indicating parts by reference IC305 8-759-833-12 IC NJM2395AF05 R306 1-216-844-11 METAL CHIP 1/16W •...
Page 56
CDX-540RF/545RF/545XRF US Model Canadian Model SERVICE MANUAL CDX-540RF E Model CDX-545RF/545XRF Ver 1.2 2002.03 SUPPLEMENT-2 File this supplement with the service manual. Subject: Change of FM board (ECN-CSA04972) In this set, FM board has been changed in the midway of production.
1560423 or later CDX-545XRF 1520774 or later Note: When a former type MAIN board (CDX-540RF US model: serial No. 1559072 or before, CDX-545RF: serial No. 1560422 or be- fore, CDX-545XRF: serial No. 1520773 or before) is replaced as a whole, replace FM board with a new type one (Part No. A-3340-...
CDX-540RF/545RF/545XRF 2-2. BLOCK DIAGRAM – MAIN Section – RV701 TRANSMITTER MODULATION CN703 SENSITIVITY L, R PRE-EMPHASIS L. P. F. & LIMITER OUTPUT RF IN RF OUT (page 3) MUTING RF AMP L. P. F. PRE-EMPHASIS L. P. F. & LIMITER...
2-3. NOTE FOR PRINTED WIRING BOARDS AND SCHEMATIC DIAGRAMS • IC Block Diagram – FM Board – Note on Printed Wiring Board: Note on Schematic Diagram: IC701 BH1415F-E2 • All capacitors are in µF unless otherwise noted. pF: µµF • X : parts extracted from the component side. •...
CDX-540RF/545RF/545XRF EXPLODED VIEW 4. ELECTRICAL PARTS LIST DIFFERENCE PARTS LIST NOTE: : Indicates changed portion. When indicating parts by reference • Due to standardization, replacements in the • Items marked “*” are not stocked since they number, please include the board.
Page 68
CDX-540RF/545RF/545XRF MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R310 1-216-841-11 METAL CHIP 1/16W C121 1-164-360-11 CERAMIC CHIP 0.1uF R311 1-216-839-11 METAL CHIP 1/16W C122 1-115-566-11 CERAMIC CHIP 4.7uF R312 1-216-841-11 METAL CHIP 1/16W R313 1-216-829-11 METAL CHIP 4.7K...
Page 69
CDX-540RF/545RF/545XRF MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < DIODE > R146 1-216-833-11 METAL CHIP 1/16W D201 8-719-978-33 DIODE DTZ-TT11-6.8B R147 1-216-833-11 METAL CHIP 1/16W D202 8-719-978-33 DIODE DTZ-TT11-6.8B R201 1-216-821-11 METAL CHIP 1/16W...
CDX-540RF/545RF/545XRF 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 2000.12...