Sony TCWE-435 Service manual

	TC-WE435
SERVICE MANUAL	US Model
Ver 1.1 2001. 05	Canadian Model
	AEP Model
	UK Model
	E Model
	Australian Model
	Chinese Model

Dolby noise reduction extension manufactured under license from Dolby Laboratories Licensing Corporation.

HX Pro originated by Bang & Olufsen. “DOLBY”, the double-D symbol a and “HX PRO” are trademarks of Dolby Laboratories Licensing Corporation.

Model Name Using Similar Mechanism TC-WE425/WE525/WR681

DECK A TCM-230ASR3/HSR3

Transport Mechanism Type

DECK B TCM-230ASR4/HSR4

SPECIFICATIONS

— Continued on next page —

STEREO CASSETTE DECK

9-928-829 -12	Sony Corporation
2001E0200-1	Personal Audio Company
© 2001.5	Shinagawa Tec Service Manual Production Group

– 1 –

SAFETY CHECK-OUT

After correcting the original service problem, perform the following safety checks before releasing the set to the customer:

Check the antenna terminals, metal trim, “metallized” knobs, screws, and all other exposed metal parts for AC leakage. Check leakage as described below.

LEAKAGE

The AC leakage from any exposed metal part to earth Ground and from all exposed metal parts to any exposed metal part having a return to chassis, must not exceed 0.5 mA (500 microampers). Leakage current can be measured by any one of three methods.

1. A commercial leakage tester, such as the Simpson 229 or RCA WT-540A. Follow the manufacturers’ instructions to use these instruments.

2. A battery-operated AC milliammeter. The Data Precision 245 digital multimeter is suitable for this job.

3. Measuring the voltage drop across a resistor by means of a VOM or battery-operated AC voltmeter. The “limit” indication is 0.75 V, so analog meters must have an accurate low-voltage scale. The Simpson 250 and Sanwa SH-63Trd are examples of a passive VOM that is suitable. Nearly all battery operated digital multimeters that have a 2V AC range are suitable. (See Fig. A)

To Exposed Metal

Parts on Set

AC 0.15µF 1.5kΩ voltmeter

(0.75V)

Earth Ground

Fig. A. Using an AC voltmeter to check AC leakage.

SAFETY-RELATED COMPONENT WARNING!!

COMPONENTS IDENTIFIED BY MARK ! OR DOTTED LINE

WITH MARK ! ON THE SCHEMATIC DIAGRAMS AND IN

THE PARTS LIST ARE CRITICAL TO SAFE OPERATION.

REPLACE THESE COMPONENTS WITH SONY PARTS WHOSE

PART NUMBERS APPEAR AS SHOWN IN THIS MANUAL OR

IN SUPPLEMENTS PUBLISHED BY SONY.

ATTENTION AU COMPOSANT AYANT RAPPORT À LA SÉCURITÉ!!

LES COMPOSANTS IDENTIFIÉS PAR UNE MARQUE !SUR LES

DIAGRAMMES SCHÉMATIQUES ET LA LISTE DES PIÈCES SONT

CRITIQUES POUR LA SÉCURITÉ DE FONCTIONNEMENT. NE

REMPLACER CES COMPOSANTS QUE PAR DES PIÈCES SONY

DONT LES NUMÉROS SONT DONNÉS DANS CE MANUEL OU

DANS LES SUPPLÉMENTS PUBLIÉS PAR SONY.

– 2 –

MODEL IDENTIFICATION

–Back panel–

Part No.

PARTS No.		MODEL
3-032-413-0¹		US model
3-032-413-1¹		CND model
3-032-413-2¹		AEP model
3-032-413-3¹		UK model
3-032-413-4¹		AUS model
3-032-413-5¹		SP, MY model
3-032-413-6¹		CH model
• Abbreviation
CND	: Canadian model
SP	: Singapore model
MY	: Malaysia model
AUS	: Australian model
CH	: Chinese model

TABLE OF CONTENTS
1. GENERAL ..........................................................................	4
2. DISASSEMBLY
2-1. Case ......................................................................................	5
2-2. Front Panel Assembly ...........................................................	5
2-3. Cassette Lid Assembly (Deck A/B) ......................................	6
2-4. Mechanism Deck Assembly (Deck A/B) ..............................	6
2-5. Leaf SW (PB) Board (Deck A),
Leaf SW (REC/PB) Board (Deck B) ....................................	7
2-6. Pinch Lever (FWD)/(REV) Assembly (Deck A/B) ...............	8
2-7. Flywheel (FWD)/(REV) Assembly (Deck A/B) ...................	8
2-8. Mechanical Block Assembly (Deck A/B) .............................	9
2-9. Head Relay (PB) Board (Deck A),
Head Relay (REC/PB) Board (Deck B) ................................	9
3. SERVICE MODE ............................................................	10
4. MECHANICAL ADJUSTMENTS ...............................	11
5. ELECTRICAL ADJUSTMENTS ...............................	11
6. DIAGRAMS
6-1. Circuit Boards Location ......................................................	15
6-2. Printed Wiring Board – Main Section – ..............................	17
6-3. Schematic Diagram – Main Section – (1/4) ........................	19
6-4. Schematic Diagram – Main Section – (2/4) ........................	21
6-5. Schematic Diagram – Main Section – (3/4) ........................	23
6-6. Schematic Diagram – Main Section – (4/4) ........................	25
6-7. Printed Wiring Board – Deck A Section – ..........................	27
6-8. Schematic Diagram – Deck A Section – .............................	27
6-9. Printed Wiring Board – Deck B Section – ..........................	28
6-10. Schematic Diagram – Deck B Section – ...........................	28
6-11. Schematic Diagram – Display Section – ...........................	29
6-12. Printed Wiring Board – Display Section – .......................	31
6-13. Schematic Diagram – Panel Section – ..............................	33
6-14. Printed Wiring Board – Panel Section – ...........................	35
6-15. Schematic Diagram – Power Section – .............................	37
6-16. Printed Wiring Board – Power Section – .........................	39
6-17. IC Pin Function ................................................................	41
7. EXPLODED VIEWS
7-1. Case Section ........................................................................	43
7-2. Chassis Section ...................................................................	44
7-3. Cassette Holder Section ......................................................	45
7-4. Front Panel Section .............................................................	46
7-5. Tape Mechanism Section
(Deck A: TCM-230ASR3/HSR3)
(Deck A: TCM-230ASR4/HSR4) .......................................	47
8. ELECTRICAL PARTS LIST ........................................	48

– 3 –

SECTION 1

GENERAL

Front Panel

1

2

3

4

5

6

7

8

9

31

30

10

	29	26 25	22 21201918 17		12	11
		28 27	24 23	16 15	14 13
LOCATION OF PARTS AND CONTROLS
1	Ubutton		18	§(Eject) (Deck B) button
2	RESET (Deck A) button		19	REC MUTING Rbutton
3	MEMORY (Deck A) button		20	PAUSE Pbutton
4	RESET (Deck B) button		21	p(Deck B) button
5	MEMORY (Deck B) button		22	DOLBY NR OFF B/C switch
6	AUTO REC LEVEL indicator		23	·(Deck A) button
7	REC LEVEL knob		24	ª(Deck A) button
8	FADER button		25	§(Eject) (Deck A) button
9	ARL button		26	p(Deck A) button
10	SYNCHRO button		27	(AMS) )(Deck A) button
11	PHONES jack		28	0(AMS) (Deck A) button
12	HIGH/NOMAL button		29	PITCH CONTROL knob
13	(AMS) )(Deck B) button		30	PITCH CONTROL button
14	0(AMS) (Deck B) button		31	DIRECTION switch
15	·(Deck B) button		• AMS is the abbreviation for Automatic Music Sensor.
16	ª(Deck B) button
17	REC rbutton

– 4 –

SECTION 2

DISASSEMBLY

Note : Follow the disassembly procedure in the numerical order given.

2-1. CASE

3 Two Screws	4 Case
(Case 3 TP2)	1 Screw
	(BVTT 3x6)

2 Two Screws

(Case 3 TP2)

2-2. FRONT PANEL ASSEMBLY

	1 CN5802
2 CN807	3 CN803
!¡ CN002
	4 CNA806
5 Flat type wire !§ Claw
(Deck A)
9 CN1002	7 Screw

(BVTP 3x8)

8Wire

!• Front panel assy

		0 CN1003	!° Claw
	!¢ Screw	6 Flat type wire	!¶ Two screws
		(Deck B)
	(BVTP 3x8)		(BVTT 3x6)
		!£ Screw
		(BVTP 3x8)
		!™ Screw
		(BVTP 3x8)

– 5 –

2-3. CASSETTE LID ASSEMBLY (DECK A/B)

1 Push the EJECT button.

3 Cassette lid assy

2 Four claws

2-4. MECHANISM DECK ASSEMBLY (DECK A/B)

3 Mechanism deck assy

1 Two screws (BVTP 2.6x8)

2 Two screws (BVTP 2.6x8)

– 6 –

2-5. LEAF SW (PB) BOARD (DECK A), LEAF SW (REC/PB) BOARD (DECK B)

1 Two screws (PS 2.6x6)

5 Screw	2 Capstan motor assy
(BVTT 2x4)

	4 Screw
		(BVTT 2x4)
7 LEAF SW (PB) board	a	3 Wires
(Deck A)	b
LEAF SW (REC/PB) board		8 Belt (capstan)
(Deck B)

		When installing,
	Claws	pull the belt (capstan)
		put around claws.

b a

6 Claws

– 7 –

2-6. PINCH LEVER (FWD)/(REV) ASSEMBLY (DECK A/B)

4 Pinch lever (FWD) assy

2 Pinch lever (REV) assy

1 Claw

3 Claw

2-7. FLYWHEEL (FWD)/(REV) ASSEMBLY (DECK A/B)

1 Belt (FR2)

3 Flywheel (FWD) assy

6 Flywheel (REV) assy

4 Washer

7 Washer

2 Stopper washer

5 Stopper washer

– 8 –

2-8. MECHANICAL BLOCK ASSEMBLY (DECK A/B)

3 Two screws	2 Two screws
(BVTT 2x3.5)	(BVTT 2x3.5)

4 Mechanical block assy

1 Torsion spring

5 Reverse slider

2-9. HEAD RELAY (PB) BOARD (DECK A), HEAD RELAY (REC/PB) BOARD (DECK B)

3 Tension spring (HEAD)

4 Head deck assy

2HEAD RELAY (PB) board

(Deck A)

HEAD RELAY (REC/PB) board

(Deck B)

1Screw (BVTT 2x4)

– 9 –

SECTION 3

SERVICE MODE

KEY CHECK & DISPLAY CHECK MODE

While pressing the ª(A deck) and REC MUTING R buttons with the power off, press the U button to turn on the power. The fluorescent indicator tube displays the number or special message corresponding to the button pressed.

The message displayed differs according to the position of the switch.

	A deck side			B deck side
Button		Display	Button		Display
RESET		0	RESET		0
MEMORY		1	MEMORY		1
0(AMS)		2	HIGH/NOMAL		2
(AMS) )		3	0(AMS)		3
p		Grid check display (*1)	(AMS) )		4
ª		4	p		Segment check display (*2)
·		5	ª		5
DIRECTION MODE switch			·		6
A		ª	PAUSE P		7
d		PLAY	REC MUTING R		8
RELAY		·	REC r		9
			FADER		A
			ARL		b
			SYNCHRO		All lit
			DOLBY NR switch
			OFF		ª
			B		PLAY
			C		·

Grit check display (*1)

RMS

Segment check display (*2)

– 10 –

SECTION 4

MECHANICAL ADJUSTMENTS

PRECAUTION

1. Clean the following parts with a denatured alcohol-moistened

swab :
record/playback/erase head	pinch roller
rubber belts	capstan
idlers

2.Demagnetize the record/playback head with a head demagnetizer.

3.Do not use a magnetized screwdriver for the adjustment.

4.After the adjustments, apply suitable locking compound to the parts adjusted.

5.The adjustments should be performed with the rated power supply voltage unless otherwise noted.

Torque Measurement

	Mode	Torque meter	Meter reading
	Forward	CQ-102C	30 to 65 g • cm
			(0.42 to 0.90 oz • inch)
			DECK A : 1 to 6 g • cm
	Forward		(0.014 to 0.083 oz • inch)
	back	CQ-102C
	tension		DECK B : 2 to 9 g • cm
			(0.028 to 0.125 oz • inch)
	Reverse	CQ-102RC	30 to 65 g • cm
			(0.42 to 0.90 oz • inch)
	Reverse		1 to 6 g • cm
	back	CQ-102RC
			(0.014 to 0.083 oz • inch)
	tension
	FF/REW	CQ-201B	70 to 120 g • cm
			(0.97 to 1.67 oz • inch)

SECTION 5

ELECTRICAL ADJUSTMENTS

PRECAUTION

1.The adjustment should be performed in the publication. (Be sure to male playback adjustment at first.)

2.The adjustments and measurement should be performed for both L-CH and R-CH.

• Switch position

DOLBY NR switch : OFF DIRECTION MODE switch : A

• Standard record position :

Deliver the standard input signal level to input jack and set the REC LEVEL knob to obtain the standard output signal level as follows.

– Record Mode–

AF OSC

		level meter
attenuator	10 k½	47 k½
		+
		set
		–
	600 ½
	LINE IN	LINE OUT

Standard Input Level

Input terminal	LINE IN
source impedance	10 kΩ
input signal level	0.5 V (–3.8 dB)

Standard Output Level

Input terminal	LINE IN
source impedance	10 kΩ
input signal level	0.5 V (–3.8 dB)

Test Tape

Tape	Contents	Use
P-4-A100	10 kHz, –10 dB	Azimuth Adjustment
WS-48B	3 kHz, 0 dB	Tape Speed Adjustment
P-4-L300	315 Hz, 0 dB	PB Level Adjustment

0 dB = 0.775 V

Test Mode

1.While pressing the · (DECK A) and REC MUTING R buttons with the power off, press the U button to turn on the power. The fluorescent display tube lights up for about one sec-

ond, and the test mode is set. The test mode performs the following two special functions.

• Playback speed switching function

Pressing the HIGH/NORMAL button switches the playback speed between standard/double speed.

• Counter RESET & MEMORY function

Resets the counter when recording starts. When rewound with the 0(AMS) button after recording, stops at the point where recording started.

2. To release the test mode, turn OFF the power switch.

– 11 –

Record/Playback Head Azimuth Adjustment

DECK A DECK B

Procedure:

1. Forward Playback Mode

test tape

P-4-A100 level meter (10 kHz, –10 dB)

47 k½

set

LINE OUT

2.Turn the adjustment screw for the maximum output levels. If these levels do not match, turn the adjustment screw until both of output levels match together within 1 dB.

L-CH	output	within			within
	level	1 dB
peak					1 dB
R-CH
peak					screw position
screw			L-CH	R-CH
position
			peak	peak
3. Playback Mode
test tape
P-4-A100
(10 kHz, –10 dB)				oscilloscope
	L-CH			47 k½
	set			V	H
	R-CH			47 k½
			LINE OUT
		Screen Pattern
In phase		45˚	90˚	135˚ 180˚
	good			wrong

4.Change the reverse playback mode and repeat the steps 1 to 3.

5.After the adjustment, lock the adjustment screws with suitable locking compound.

Adjustment Location: – record/playback head –

reverse side

forward side

adjustment screws

Tape speed Adjustment DECK A DECK B

Adjust DECK A first Procedure:

– Forward Playback Mode –

test tape
WS-48B
(3 kHz, 0 dB)	frequency counter
	47 k½
	set

LINE OUT

(High speed adjustment)

1.Press the PITCH CONTROL button to set to OFF .

2.Set to test mode. (Refer to page 11.)

3.Press the · button to playback.

4.Press the HIGH/NORMAL button to playback at double speed.

5.Adjust RV316 (DECK A), RV416 (DECK B) so that the frequency counter reading becomes 5,980 ± 180 Hz.

(Normal speed adjustment)

6.Press the · button to playback.

7.Press the HIGH/NORMAL button to playback at normal speed.

8.Adjust RV317 (DECK A), RV417 (DECK B) so that the frequency counter reading becomes 3,000 ± 90 Hz.

(Pitch control adjustment) (DECK A)

9.Press the PITCH CONTROL button to set to ON .

10.Set PITCH CONTROL knob to mechanical center.

11.Press the · button to playback.

12.Adjust RV318 so that the frequency counter reading becomes 2,990 ± 90 Hz.

Adjustment Location: MAIN board (See page 14.)

Sample value of wow and flutter

W.RMS (JIS) less than 0.3% . (test tape : WS-48B)

Playback Level Adjustment DECK A DECK B

Procedure:

– Forward Playback Mode –

test tape

P-4-L300 level meter (315 Hz, 0 dB)

47 k½

set

LINE OUT

Adjust DECK A : RV111 (L-CH), RV211 (R-CH) and

DECK B : RV121 (L-CH), RV221 (R-CH) so the level meter reading becomes the adjustment limits below.

Adjustment Value:

LINE OUT level : –7.7 ± 0.5 dB (0.301 to 0.338 V)

Level difference between channels : within 0.5 dB

Confirm that the LINE OUT level does not change in playback mode while changing the mode from playback to stop several times.

Adjustment Location: MAIN board (See page 14.)

– 12 –

Bias Consumption Current Adjustment DECK B

This adjustment should be performed when replacing the head assy or the bias oscillator transformer (T141, T241).

Setting:

REC LEVEL knob : standard recording position (See page 11.)

Procedure:

digital blank tape voltmeter CS-413

	set
LINE IN	R-CH			L-CH
no signal				TP441
	1	2	3

1.Connect the digital voltmeter to test point TP441.

2.Set RV141 (L-CH), RV241 (R-CH) to mechanical center.

3.Press the · button to playback.

4.Adjust T141 (L-CH), T241 (R-CH) so that the digital voltmeter reading becomes minimum.

Adjustment Value: Maximum 220 mV

Adjustment Location: MAIN board (See page 14.)

Record Bias Adjustment DECK B

Setting:

REC LEVEL knob : standard record position (See page 11.)

Procedure:

1.Set to test mode (See page 11.)

2.Insert a tape into deck B, press the REC r button and then press the · button to start recording.

3.Record Mode

AF OSC
10 k½	blank tape
	CS-123

	attenuator
			set
	600 ½
	LINE IN
	1) 315	Hz	50 mV (–23.8 dB)
	2) 10 kHz

4. Playback Mode

	recorded	level meter
	portion
		47 k½
		set

LINE OUT

5.Confirm playback the signal recorded in step 2 become adjustment level as follows.

If the selevels do not adjustment level, adjust the RV141 (L-CH) and RV241 (R-CH) to repeat steps 3 and 4.

Adjustment level:

The palyback output of 10 kHz level difference against 315 Hz reference should be ± 0.5 dB.

Adjustment Location: MAIN board (See page 14.)

Record Level Adjustment DECK B

Setting:

REC LEVEL knob : standard record position (See page 11.)

Procedure:

1.Set to test mode (See page 11.)

2.Insert a tspe into deck B, press the REC r button and then press the · button to start recording.

3.Record Mode

AF OSC

	blank tape
10 k½	CS-123

attenuator

set

600 ½ LINE IN

315 Hz, 50 mV (–23.8 dB)

4. Playback Mode

	recorded	level meter
	portion
		47 k½
		set

LINE OUT

5.Confirm playback the signal recorded in step 2 become adjustment level as follows.

If the selevels do not adjustment level, adjust the RV101 (L-CH) and RV201 (R-CH) to repeat steps 3 and 4.

Adjustment Value:

LINE OUT level : –23.8 ± 0.5 dB (47.2 to 53.0 mV)

Adjustment Location: MAIN board (See page 14.)

– 13 –