SERVICE MANUAL
XR-CA440X: AEP, UK Model
FM/AM CASSETTE CAR STEREO
XR-CA440/CA440X: E Model
FM/MW/SW CASSETTE CAR STEREO
AEP Model
UK Model
XR-CA440X
E Model
XR-CA440/CA440X
SPECIFICATIONS
XR-CA440/CA440X
Photo: XR-CA440
Ver 1.1 2003.01
9-873-497-02
Sony Corporation
2003A0500-1
e Vehicle Company
C
2003.01
Published by Sony Engineering Corporation
Model Name Using Similar Mechanism
NEW
Tape Transport Mechanism Type
MG-25F-136
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
T
(XR-CA440/
CA440X: E models)
(XR-CA440X: AEP,
UK, Saudi Arabia
and Taiwan models)
uning 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
Usable sensitivity
11 dBf
Selectivity
75 dB at 400 kHz
Signal-to-noise ratio
65 dB (stereo),
68 dB (mono)
Harmonic distortion at 1 kHz
0.7 % (stereo),
0.5 % (mono)
Separation
33 dB at 1 kHz
Frequency response
30 15,000 Hz
MW
(XR-CA440/CA440X: E, Saudi Arabia
and Taiwan models)
T
(XR-CA440/
CA440X: E Models)
uning range
MW tuning interval:
9 kHz/10 kHz switchable
531 1,602 kHz
(at 9 kHz step)
530 1,710 kHz
(a
NW tuning interval:
531 1,602 kHz
t 10 kHz step)
Se
Tuning range
(XR-CA440X:
Saudi Arabia
and Taiwan models)
nsitivity
30
µV
SW
(XR-CA440/CA440X: E, Saudi Arabia
and Taiwan models)
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
µV
Power amplifier section
Outputs
Speaker outputs
(sure seal connectors)
Speaker impedance
4 8 ohms
Maximum power output
50 W
× 4 (at 4 ohms)
General
Outputs
Audio outputs
Power aerial relay control
lead
Power amplifier control lead
Inputs
BUS control input terminal
BUS audio input terminal
Aerial input terminal
Tone controls
Bass
±9 dB at 100 Hz
Treble
±9 dB at 10 kHz
Power requirements
12 V DC car battery
(negative earth)
Dimensions
Approx. 178
× 50 × 178
mm (w/h/d)
Mounting dimensions
Approx. 182
× 53 × 161
mm (w/h/d)
Mass
Approx. 1.2 kg
Supplied accessories
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
TYPE II, IV
61 dB
TYPE I
58 dB
Tuning range
FM tuning interval:
87.5 108.0 MHz
AM
(XR-CA440X: AEP and UK models)
Tuning range
AM tuning interval:
531 1,602 kHz
Sensitivity
30
µV
Aerial terminal
External aerial connector
Intermediate frequency
10.7 MHz/450 kHz
2
XR-CA440/CA440X
TABLE OF CONTENTS
1.
GENERAL
Location of Controls .......................................................
3
Setting the Clock .............................................................
3
Installation /Connection ..................................................
4
2.
DISASSEMBLY
2-1. Disassembly Flow ...........................................................
8
2-2. Cover ...............................................................................
8
2-3. Mechanism Deck (MG-25F-136) ...................................
9
2-4. MAIN Board ...................................................................
9
2-5. Heat Sink ......................................................................... 10
3.
ASSEMBLY OF MECHANISM DECK
3-1. Assembly Flow ................................................................ 11
3-2. Housing ........................................................................... 12
3-3. Arm (Suction) ................................................................. 12
3-4. Lever (LDG-A)/(LDG-B) ............................................... 13
3-5. Gear (LDG-FT) ............................................................... 13
3-6. Guide (C) ......................................................................... 14
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. Note for Printed Wiring Boards and
Schematic Diagrams ....................................................... 15
6-2. Printed Wiring Board MAIN Board ......................... 16
6-3. Schematic Diagram MAIN Board (1/3) ................... 17
6-4. Schematic Diagram MAIN Board (2/3) ................... 18
6-5. Schematic Diagram MAIN Board (3/3) ................... 19
6-6. Printed Wiring Board KEY Board ............................ 20
6-7. Schematic Diagram KEY Board .............................. 21
6-8. IC Pin Function Description ........................................... 24
7.
EXPLODED VIEWS
7-1. Chassis Section ............................................................... 27
7-2. Front Panel Section ......................................................... 28
7-3. MAIN Board Section ...................................................... 29
7-4. Mechanism Deck Section (MG-25F-136) ...................... 30
8.
ELECTRICAL PARTS LIST ............................... 31
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.
3
XR-CA440/CA440X
SECTION 1
GENERAL
This section is extracted from
instruction manual.
Location of controls
Refer to the pages listed for details.
a SOURCE (Power on/Tape/Radio/CD/
MD) select button
b MODE (o) button
Selecting the source.
c VOL +/ button
d ATT (attenuate) button
e Display window
f Z (eject) button 8
g SEEK/AMS button
Tape:
Fast-forwarding, reversing a tape
Radio:
Tuning in stations automatically.
Finding a station manually.
CD (MP3 files)/MD:
Skipping tracks.
h MBP (My Best sound Position) button
12
i D-BASS button 12
j RELEASE (front panel release) button
k SEL (select) button
Selecting items.
l RESET button (located on the front side of
the unit, behind the front panel) 6
m SENS button
Storing the stations with the strongest
signals.
n Number buttons
Tape:
(3): REP (Repeat)
(5): BL SKIP (Blank Skip)
(6): ATA (Automatic Tuner Activation)
Radio:
Storing the desired station on each number
button.
CD (MP3 files)/MD:
(1): DISC
(2): DISC +
(3): REP (Repeat)
(4): SHUF (Shuffle)
MP3 files:
(5): ALBM
(6): ALBM +
o Frequency select switch (located on
the
(XR-CA440/CA440X: E models)
bottom of the unit)
See "Frequency select switch" in the
Installation/Connections manual.
p BTM/MTL (Best Tuning Memory/Metal)
button 9
q DSPL (display mode change) button
r OFF (Stop/Power off) button*
* 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.
XR-CA440X
XR-CA440
SOURCE
ATT
VOL
SENS
DISC
REP
SHUF BL SKIP/ ALBM
-
+ /ATA
MTL
+
MODE
SEL
RELEASE
12345
6
D-BASS
SEEK
AMS
BTM
MBP
OFF
DSPL
Setting the clock
The clock uses a 12-hour digital indication.
Example: To set the clock to 10:08
1 Press (DSPL) for 2 seconds.
The hour indication flashes.
1
Press either side of (VOL) to set the
hour.
2
Press (SEL).
The minute indication flashes.
3
Press either side of (VOL) to set the
minute.
2 Press (DSPL).
The clock starts.
After the clock setting is completed, the
display returns to normal play mode.
VOL
to go forward
to go back
VOL
to go forward
to go back
4
XR-CA440/CA440X
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.
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.
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 (3)
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 +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."
5 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.
Equipment used in illustrations (not supplied)
Equipo utilizado en las ilustraciones (no suministrado)
Front speaker
Altavoces delanteros
Rear speaker
Altavoces traseros
2
B
A
BUS AUDIO IN
BUS CONTROL IN
AUDIO OUT REAR
BUS CONTROL IN
BUS AUDIO IN
Source selector
*
Selector de fuente
Power amplifier
Amplificador de potencia
CD/MD changer
Cambiador de CD/MD
1
* not supplied
no suministrado
Installation/Connection
5
XR-CA440/CA440X
BUS
AUDIO IN
AUDIO
OUT
Lista de componentes (1)
Los números de la lista corresponden a los de las
instrucciones.
Precaución
Tenga mucho cuidado al manipular el soporte 1
para evitar posibles lesiones en los dedos.
Precauciones
· Esta unidad ha sido diseñada para alimentarse
con cc 12 V, negativo a masa, solamente.
· No coloque los cables debajo de ningún tornillo,
ni los aprisione con partes móviles (p.ej. los raíles
del asiento).
· Antes de realizar las conexiones, desactive el
encendido del automóvil para evitar
cortocircuitos.
· Conecte los cables de entrada de alimentación
amarillo y rojo solamente después de haber
conectado los demás.
· Conecte todos los conductores de puesta a
masa a un punto común.
· Por razones de seguridad, asegúrese de aislar con
cinta eléctrica los cables sueltos que no estén
conectados.
Notas sobre el cable de suministro de
alimentación (amarillo)
· Cuando conecte esta unidad en combinación con
otros componentes estéreo, la capacidad nominal
del circuito conectado del automóvil debe ser
superior a la suma del fusible de cada
componente.
· Si no hay circuitos del automóvil con capacidad
nominal suficientemente alta, conecte la unidad
directamente a la batería.
Ejemplo de conexiones (2)
Notas (2-A)
· Asegúrese de conectar primero el cable de puesta
a masa antes de realizar la conexión al
amplificador.
· Si conecta un amplificador de potencia opcional y
no utiliza el incorporado, los pitidos se
desactivarán.
Consejo (2-B-
)
Cuando desee conectar dos o más CD/MD cambiadores,
necesitará un selector de fuente XA-C30 (opcional).
Diagramas de conexión (3)
1 A una superficie metálica del automóvil
Conecte primero el cable de masa negro, y después los
cables amarillo y rojo de entrada de alimentación.para
obtener información detallada.
2 Al cable de control de la antena motorizada o al cable
de fuente de alimentación del amplificador de antena
Notas
· Si no se dispone de antena motorizada ni de
amplificador de antena, o se utiliza una antena
telescópica accionada manualmente, no será
necesario conectar este cable.
· Si el automóvil incorpora una antena de FM/MW/SW
en el cristal trasero/lateral, consulte "Notas sobre los
cables de control y de fuente de alimentación".
3 Para conectar a AMP REMOTE IN del amplificador de
potencia opcional
Esta conexión es sólo para amplificadores.
La conexión de cualquier otra sistema puede dañar la
unidad.
4 Al terminal de alimentación de +12 V que recibe
energía en la posición de accesorios del interruptor de
la llave de encendido
Notas
· Si no hay posición de accesorios, conéctelo al
terminal de alimentación (batería) de +12 V que
recibe energía sin interrupción.
Asegúrese de conectar primero el cable de masa
negro.
· Si el automóvil incorpora una antena de FM/MW/SW
en el cristal trasero/lateral, consulte "Notas sobre los
cables de control y de fuente de alimentación".
5 Al terminal de alimentación de +12 V que recibe
energía sin interrupción
Asegúrese de conectar primero el cable de masa
negro.
Notas sobre los cables de control y de fuente de
alimentación
· El conductor de control de la antena motorizada (azul)
suministrará + cc 12 V cuando conecte la alimentación
del sintonizador.
· Si el automóvil dispone de una antena de FM/MW/SW
incorporada en el cristal trasero/lateral, conecte el cable
de control de antena motorizada (azul) o el cable de
entrada de alimentación auxiliar (rojo) al terminal de
alimentación del amplificador de antena existente. Para
obtener información detallada, consulte a su proveedor.
· Con esta unidad no es posible utilizar una antena
motorizada sin caja de relé.
Conexión para protección de la memoria
Si conecta el conductor de entrada amarillo, el circuito de
la memoria recibirá siempre alimentación, incluso aunque
ponga la llave de encendido en la posición OFF.
Notas sobre la conexión de los altavoces
· Antes de conectar los altavoces, desconecte la
alimentación de la unidad.
· Utilice altavoces con una impedancia de 4 a 8 ohmios, y
con la potencia máxima admisible adecuada, ya que de
lo contrario podría dañarlos.
· No conecte los terminales del sistema de altavoces al
chasis del automóvil, ni los del altavoz izquierdo a los del
derecho.
· No conecte el cable de puesta a tierra de esta unidad al
terminal negativo () del altavoz.
· No intente conectar los altavoces en paralelo.
· No conecte altavoces activos (con amplificadores
incorporados) a los terminales de altavoces de la unidad.
Si lo hiciese, podría dañar tales altavoces. Por lo tanto,
cerciórese de conectar altavoces pasivos a estos
terminales.
· Para evitar fallos de funcionamiento, no utilice los cables
de altavoz incorporados instalados en el automóvil si su
unidad comparte un cable negativo común () para los
altavoces derecho e izquierdo.
· No conecte los cables de altavoz de la unidad entre sí.
3
Supplied with XA-C30
Suministrado con el XA-C30
from car aerial
de antena de automóvil
Source selector
Selector de fuente
XA-C30
1
4
5
2
AMP REM
ANT REM
7
RCA pin cord (not supplied)
Cable con clavijas RCA (no suministrado)
Max. supply current 0.3 A
Corriente máx. de alimentación de 0,3 A
Max. supply current 0.1 A
Corriente máx. de alimentación de 0,1 A
Fuse (10 A)
Fusible (10 A)
Red
Rojo
Yellow
Amarillo
Black
Negro
Blue
Azul
Blue/white striped
Con raya azul/blanca
White
Blanco
Green
Verde
Purple
Púrpura
White/black striped
Con raya blanco/negro
Grey/black striped
Con raya gris/negro
Green/black striped
Con raya verde/negro
Purple/black striped
Con raya púrpura/negro
BUS CONTROL IN
AUDIO OUT REAR
Grey
Gris
Supplied with the CD/MD changer
Suministrado con el cambiador de CD/MD
3
Left
Izquierdo
Right
Derecho
Left
Izquierdo
Right
Derecho
XR-CA440X
XR-CA440
1
BUS AUDIO IN