Sony TC-EX66 User manual

MICROFILM
TC-EX66
STEREO CASSETTE DECK
SERVICE MANUAL
This set is the cassette deck section
in MHC-EX66.
Dolby noise reduction manufactured under license
from Dolby Laboratories Licensing Corporation.
“DOLBY”andthedouble-Dsymbolaaretrademarks
of Dolby Laboratories Licensing Corporation.
SPECIFICATIONS
Model Name Using Similar Mechanism NEW
Tape Transport Mechanism Type
TCM-ACLM578
AEP Model
UK Model
E Model

– 2 –
TABLE OF CONTENTS
Servicing Notes ............................................................... 2
1. GENERAL
Playing a Tape ................................................................ 3
Recording on a Tape Manually....................................... 4
Recording the favorite CD Tracks on a Tape.................. 5
2. DISASSEMBLY ........................................................ 6
3. MECHANICAL ADJUSTMENTS ...................... 10
4. ELECTRICAL ADJUSTMENTS ........................ 10
5. DIAGRAMS
5-1. Printed Wiring Boards .................................................... 15
5-2. Schematic Diagram ........................................................ 19
5-3. IC Pin Function .............................................................. 25
6. EXPLODED VIEWS ............................................... 27
7. ELECTRICAL PARTS LIST............................... 32
SERVICING NOTES
How to operate with a single unit.
Normally, this set is not operated with its own.
The exclusive jig (J-2501-078-A) and service box (PFJ-1) are nec-
essary to operate the set with a single unit.
Turn the power set of the service box ON. Then press the
ENTER/NEXT button and SLEEP button at the same time to
turn the power on.
Connection:
• KEY/FL tube/LED check mode.
To enter KEY/FL tube/LED check mode, press the ENTER/NEXT
and REC buttons at the same time.
Under mode, every time when press any key or turn
MULTI CONTROLLER knob, change to next situation.
1All LED indicators light on
2All FL tube indicators light on
3A part of FL tube light on mode 1. (Indicated ST-SEG)
4A part of FL tube light on mode 2. (Indicated RDS-SEG)
5KEY check mode
Note:
1) All LED light on mode is kept, when buttons which is pressed
to enter all LED light on mode, release same time.
When release them separate timing, it is moved to next All
LED light on mode.
2) After all LED light on mode, light on point remove one by one,
when any button pressed or MULTI CONTROLLER knob
turned.
3) Under KEY check mode, every time buttons pressed numeri-
cal value of “KEY” in FL tube increase.
And that time, numerical value of “ECDR” increase when
MULTI CONTROLLER button turn to + direction, and it
decrease turn to – direction.
When you want to finish this mode, unplug the power of amplifier
or turn off PFJ-1 of POWER switch.
POWER SW
FH-E939, 838,937
CDP/TC CN904
17P CN902 7P CN101 7P
JIG
(J-2501-078-A)
SERVICE BOX (PFJ-1)
SET
SYSTEM CONTROL
CORD WITH CONNECTOR 7P
(
attached to set
)
CORD WITH CONNECTOR 17P
(
attached to PFJ-1
)

– 3 –
This section is extracted
from instruction manual.
SECTION 1
GENERAL

– 4 –

– 5 –

– 6 –
SECTION 2
DISASSEMBLY
• This set can be disassembled in the order shown below.
Note: Follow the disassembly procedure in the numerical order given.
CASE, FRONT PANEL
CASE,
FRONT PANEL
(Page 6) MECHANISM DECK
(Page 7)
MAIN BOARD
(Page 7)
MECHANISM
CHASSIS SECTION
(Page 8)
TRY ASS’Y
(Page 8)
CAPSTAN MOTOR
(Page 9)
1 two screws
(case TP2)
3 flat cable
(5 core)
(CN301)
5 two screws
(BVTP 3
× 8)
5 screw
(BVTP3
× 8)
6 three claws
7 front panel
4 flat cable
(27 core)
(CN802)
1 two screws
(case 3 TP 2)
2 case
8 lid (R-TC)

– 7 –
MECHANISM DECK
2 four screws
(BVTP3
× 8)
3 mechanism deck
1 two connectors
(CN803, 804)
1 connector
(CN351)
MAIN BOARD 2
three connectors
(CN351, 803, 804)
3 two screws
(BVTP3
× 8)
1 Slide the tray to
deviation of the arrow
A .
A
5 two PCB holders
4 two screws
(BVTP3
× 10)
6 main board

– 8 –
TRAY ASS’Y
1 screw
(M1.7
× 8.2)
4 arm 576
5 tray ass’y
3 boss
2 tension spring
MECHANISM CHASSIS SECTION
3 mechanism chassis section
2 screw (P3 × 8)
1 four screws
(BK3
× 6)

– 9 –
CAPSTAN MOTOTR 7
capstan motor
5 Hang the belt.
6 three motor
screws.
4 Remove the solder
of motor lead wire.
1 step screw
3 control board
2 two claws
2 two claws

– 10 –
SECTION 4
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 switch : A
•Standard record position
Deliver the standard input signal level to input jack and set
the REC LEVEL (RV301) control to obtain the standard
output signal level as follows.
– Record Mode –
set
AF OSC
attenuator
600
Ω
10 k Ω
LINE IN
+
–
LINE OUT
47 k
Ω
level meter
Mode Torque Meter Meter Reading
CQ-102C
30-65 g•cm
FWD (0.42-0.90 oz•inch)
FWD 1.5-6 g•cm
Back tension (0.021-0.083 oz•inch)
CQ-102RC
30-65 g•cm
REV (0.42-0.90 oz•inch)
REV 1.5-6 g•cm
Back tension (0.021-0.083 oz•inch)
70-130 g•cm
FF, REW CQ-201B (0.98-1.80 oz•inch)
SECTION 3
MECHANICAL ADJUSTMENTS
PRECAUTION
1. Clean the following parts with a denatured-alcohol-moistened
swab:record/playback/earth head pinch roller
rubber belts capstan
idlers
2. Demagnetize the record/playback head with a head demagne-
tizer. (Do not bring the head demagnetizer close to the erase
head.)
3. Do not use a magnetized screwdriver for the adjustments.
4. After the adjustments, apply suitable locking compound to the
parts adjusted.
5. The adjustments should be performed with the rated power sup-
ply voltage unless otherwise noted.
Torque Measurement
Standard Input Level
Input terminal LINE IN
source impedance 10 kΩ
input signal level 0.5 V (– 3.8 dB)
Standard Output Level
Output terminal LINE OUT (L-CH)
load impedance 47 kΩ
output signal level 0.5 V (– 3.8 dB)
Test Tape
Type Signal Used for
P-4-A100 10 kHz, – 10 dB Azimuth Adjustment
P-4-L300 315 Hz, 0 dB PB Level Adjustment
WS-48B 3 kHz, 0 dB Tape Speed Adjustment
0 dB = 0.775 V
Test Mode
With the POWER turned OFF, short the test point CN801 (2P) on
the MAIN board (making IC801 pin &¢ “L”) and turn the POWER
ON. Thus, the TEST mode will be activated.
If a recording is done in the TEST mode, the REC MEMORY
mode becomes active where the tape is rewound by the amount of
recording when a rewinding is executed after recording.
After adjustment, make the CN801 (2P) open to release the TEST
mode.

– 11 –
Record/Playback Head Azimuth Adjustment
Procedure:
1. Mode: REV playback
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.
+
–
set
LINE OUT
frequency counte
r
test tape
WS-48B
(3 kHz, 0 dB) 47 k
Ω
1. Set to FWD playback mode.
2. Adjust Variable resistor on the motor (M902) so that the fre-
quency counter reading becomes
3,000 ± 90 Hz.
3. Confirm that the deviation between tape top and tape end is
within 3%.
Adjustment Location: CAPSTAN/REEL motor (M902)
Screw
position
L-CH
peak
within
1dB
output
level
L-CH peak R-CH peak
within
1dB
angl
e
R-CH
peak
3. Phase Check
Mode: REV playback
+
–
VH
+
–
Screen pattern
Good Wrong
in phase 45
° 90 ° 135 ° 180 °
LINE OUT
set
R-CH
L-CH 47 k
Ω
47 k Ω
oscilloscope
test tape
P-4-A100
(10 kHz, –10 dB)
4. Set in the FWD mode and repeat the step 1 to 3.
5. After the adjustment, lock the screw with locking compound.
Adjustment Location: Record/Playback head
              
FWD side REV side
Adjustment screw
+
–
set
47 k
Ω
LINE OUT
level mete
r
test tape
P-4-A100
(10 kHz, – 10 dB)
Tape Speed Adjustment
Procedure:
Mode: FWD playback
M902
adjustable resistor
Sample Value of Wow and flutter: 0.3% or less W. RMS
(WS-48B)

– 12 –
Record Level Adjustment
Setting:
REC LEVEL control: Standard record position (See page 10)
set to the TEST mode (REC MEMRY mode) (See page 10)
Procedure:
1. Mode :Record
+
–
set
LINE OUT
47 k
Ω
test tape
P-4-L300
(315 Hz, 0 dB) level mete
r
Adjust RV151 (L-CH) and RV251 (R-CH) so that the reading on
level meter meets the adjustment limits below.
Adjustment Limits:
LINE OUT level: – 7.7 ± 0.5 dB (0.301 to 0.338 V)
Level difference between channels: within 2 dB
Check that the LINE OUT level does not change even if Playback
and Stop operation is repeated several times.
Adjustment Location: MAIN board (See page 13)
Playback Level Adjustment
Procedure:
Mode: FWD playback
Record BIAS Adjustment
Setting:
REC LEVEL control: Standard record position (See page 10)
Set to the TEST mode (REC MEMRY mode) (See page 10)
Procedure:
1. Mode: Record
set
AF OSC
attenuator
600
Ω
10 k Ω
blank tape
CS-123
LINE IN
1) 315 Hz
2) 10 kHz 50 mV (– 23.8 dB)
2. Mode: Playback
+
–
set
LINE OUT
47 k
Ω
recorded portion level mete
r
3. Confirm playback the signal recorded in step 1 become ad-
justment level as follows.
4. If these levels do not adjustment level, adjust the RV152 (L-
CH) and RV252 (R-CH) to repeat step 1 and 2.
Adjustment Level: Playback output of 10 kHz to playback
output of 315 Hz: ± 0.5 dB.
Adjustment Location: MAIN board (See page 13)
set
AF OSC
attenuator
600
Ω
10 k Ω
blank tape
CS-123
LINE IN
315 Hz, 50 mV (– 23.8 dB)
2. Mode: Playback
+
–
set
LINE OUT
47 k
Ω
recorded portion level mete
r
3. Confirm playback the signal recorded in step 1 become ad-
justment level as follows.
4. If these levels do not adjustment level, adjust RV153 (L-CH)
and RV253 (R-CH) to repeat step 1 and 2.
Adjustment Level: – 23.8 ± 0.5 dB (47 to 53 mV)
Adjustment Location: MAIN board (See page 13)

– 13 –
•Adjustment Parts Location
CN801
TEST Mode RV152
Record BIAS (L-CH)
RV252
Record BIAS (R-CH)
RV253
Record Level (R-CH)
RV153
Record Level (L-CH)
RV151
Playback Level (L-CH)
RV251
Playback Level (R-CH)
J301CN11
[MAIN BOARD] (Component Side)

– 14 –
•IC Block Diagrams
12 3 45 6 7 8
91016 15 14 13 12 11
GP GL GH I REF VCC IN (R) GND (R) OUT (R)
IN
(
L
)
GND
(
L
)
OUT
(
L
)
f/Q fQ fM REF
GND VEE
CONTROL
EQ
EQ
12 3 45 6 7 8 9 10
GND
MOTOR
DRIVE
NOISE
FILTER
CLAMP
FWD.IN
REV.IN
VCC 1 VCC 2
NOISE
FILTER
MOTOR
DRIVE
MOTOR
DRIVE
MOTOR
DRIVE
T.S.D O.C.P
FWD/REV/STOP
CONTROL LOGIC
IC304 CXA1198AP
IC804 LB1641
ON/OFF CURRENT
LIMITER START CIRCUIT
VREF
OVER HEAT
PROTECT
ON/OFF
CURRENT
LIMITER
12 3 45 6 7 8 9 10
VCC
VMUTE VCC
VREF
ERROR
AMP
VREF
ERROR
AMP
VO1 VCC CN1
EN
EN DISPLAY
GND
NC
CN2
VEE
VO2
~_1.8V
~_140uA
COMPARATER
IC805 LA5617
SECTION 5
DIAGRAMS

– 25 –
1 PULSE I Pulse signal input
2 NO-USE – Not used (Fixed at “L”)
3 METER-L I Digital peak level meter signal input (L-ch)
4 METER-R I Digital peak level meter signal input (R-ch)
5 AD-GND – Ground for A/D converter
6 TEST I Not used (Fixed at “L”)
7 NO-USE – Not-used (Open)
8 NO-USE – Not-used (Fixed at “L”)
9 SYS-GND – Ground for system
10 OSC-OUT O System clock output (4 MHz)
11 OSC-IN I System clock input (4 MHz)
12 RESET I Reset signal input
13 AUB-IN I Audio bus input
14 AUB-OUT O Audio bus output
15 NO-USE – Not used (Fixed at “L”)
16 NO-USE – Not used (Fixed at “L”)
17 NO-USE – Not used (Fixed at “L”)
18 NO-USE – Not used (Fixed at “L”)
19 NO-USE – Not used (Fixed at “L”)
20 DOLBY C/B O DOLBY B/C select signal output “L”: DOLBY B, “H”: DOLBY C
21 DOLBY ON/OFF O DOLBY on/off select signal output “L”: DOLBY off, “H”: DOLBY on
22 CDSYNC-LED O Control output to CD SYNC LED (D851)
23 SEG17 O Segment signal output to fluorescent indicator tube (FLT851)
24 SEG16 O Segment signal output to fluorescent indicator tube (FLT851)
25 SEG15 O Segment signal output to fluorescent indicator tube (FLT851)
26 SEG14 O Segment signal output to fluorescent indicator tube (FLT851)
27 SEG13 O Segment signal output to fluorescent indicator tube (FLT851)
28 SEG12 O Segment signal output to fluorescent indicator tube (FLT851)
29 SEG11 O Segment signal output to fluorescent indicator tube (FLT851)
30 SEG10 O Segment signal output to fluorescent indicator tube (FLT851)
31 SEG9 O Segment signal output to fluorescent indicator tube (FLT851)
32 SEG8 O Segment signal output to fluorescent indicator tube (FLT851)
33 SEG7 O Segment signal output to fluorescent indicator tube (FLT851)
34 SEG6 O Segment signal output to fluorescent indicator tube (FLT851)
35 SEG5 O Segment signal output to fluorescent indicator tube (FLT851)
36 SEG4 O Segment signal output to fluorescent indicator tube (FLT851)
37 SEG3 O Segment signal output to fluorescent indicator tube (FLT851)
38 SEG2 O Segment signal output to fluorescent indicator tube (FLT851)
39 SEG1 O Segment signal output to fluorescent indicator tube (FLT851)
40 FL-GND I Ground for fluorescent indicator tube (Fixed at “L” (–20 V))
41 GRID 1 O Grid signal output to fluorescent indicator tube (FLT851)
42 GRID 2 O Grid signal output to fluorescent indicator tube (FLT851)
43 GRID 3 O Grid signal output to fluorescent indicator tube (FLT851)
44 GRID 4 O Grid signal output to fluorescent indicator tube (FLT851)
45 GRID 5 O Grid signal output to fluorescent indicator tube (FLT851)
5-3. IC PIN FUNCTION DESCRIPTION
•MAIN BOARD IC801 HD6433724E66F (SYSTEM CONTROL)
Pin No. Pin Name I/O Function

– 26 –
46 NO-USE – Not used (Open)
47 NO-USE – Not used (Open)
48 NO-USE – Not used (Open)
49 TYPE IV O Tape type output “H”: Metal Position
50 TYPE II O Tape type output “H”: High position
51 TYPE I O Tape type output “H”: Normal position
52 REC MUTE O Recording mute on/off control output “H”: Mute on
53 RELAY O Relay drive output “H”: On
54 NC – Not used (Open)
55 REC/PB O Mode control output to DOLBY NR amplifier (IC301) “L”: Record
56 PB MUTE O Playback mute on/off control output “H”: Mute on
57 SYS-VCC I Power supply for system
58 OPTION O Not used (Fixed at “L”)
59 NO-USE – Not used (Fixed at “L”)
60 POWER-OUT O Audio and mechanism power on/off output “H”: On
61 BIAS O Control output to recording bias switch (Q352) “L”: On
62 POW-IN I Primary power on/off input “H”: On
63 CLOSE SW I Close detection input from S901 “L”: Close
64 OPEN-SW I Open detection input from S902 “L”: Open
65 SOLENOIDE O Plunger (PMxxx) drive output “H”: On
66 LINE-MUTE O Line mute on/off control output “L”: Mute on
67 CHORM-SW I Tape type detection input from Sxxx “L”: Type I
68 METAL-SW I Tape type detection input from Sxxx “L”: Type IV
69 REC-REV-SW I Record proof detection input from Sxxx (REV side) “H”: Not nail
70 REC-FW-SW I Record proof detection input from Sxxx (FWD side) “H”: Not nail
71 CAPSTAN O Capstan/reel motor (M902) drive output “H”: On
72 CLOSE O Loading motor (M901) drive output *1
73 OPEN O Loading motor (M901) drive output *1
74 TEST I Test mode terminal
75 MODE-SW I Head sensor input from Sxxx
76 AD-VCC I Power supply for A/D converter
77 KEY 1 I Key input (A/D convert input)*2
78 KEY 2 I Key input (A/D convert input)*2
79 HALF-SW I Cassette half detection input from Sxxx
80 AMS-IN I AMS input
Pin No. Pin Name I/O Function
*1 Loading Motor (M901)
IN OUT BRAKE
CLOSE &™ HLH
OPEN &£ LHH
Voltage
Input port 0 V 0.45 V 1.19 V 2.19 V 3.2 V 3.98 V 4.48 V 5.0 V
Pin &•, KEY 2 Open/Close STOP PAUSE FWD REV CD —Not key input
§p P·ªSYNC
Pin &¶, KEY 1 POWER REW FF REC RESET DIRECTION DOLBY NR Not key input
ON/OFF 0) r
*2 Key Input

– 27 –
NOTE:
•-XX and -X mean standardized parts, so they
may have some difference from the original
one.
•Color Indication of Appearance Parts
Example:
KNOB, BALANCE (WHITE) . . . (RED)
↑↑
Parts Color Cabinet's Color
•Items marked “*” are not stocked since they
are seldom required for routine service. Some
delay should be anticipated when ordering
these items.
•The mechanical parts with no reference num-
ber in the exploded views are not supplied.
•Hardware (# mark) list is given in the last of
the electrical parts list.
SECTION 6
EXPLODED VIEWS
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
1 4-985-926-01 KNOB
2 X-3373-604-1 PANEL ASSY, FRONT
3 4-962-708-01 EMBLEM (4-A), SONY
4 3-939-648-01 WINDOW (TC)
5 3-939-646-01 BUTTON (REC) (CD SYNC, rREC)
6 3-939-647-01 INDICATOR (TC)
7 4-951-620-01 SCREW (2.6X8), +BVTP
8 3-012-560-01 BUTTON (EJECT) (§OPEN/CLOSE)
9 3-939-642-01 BUTTON (PLAY) (ª, ·, p)
10 3-939-643-01 BUTTON (FF) (0, ))
*11 A-2007-722-A PANEL BOARD, COMPLETE
12 1-782-490-11 WIRE (FLAT TYPE) (5 CORE)
13 1-773-257-11 WIRE (FLAT TYPE) (27 CORE)
14 3-012-561-01 LID (R-TC)
15 3-363-099-01 SCREW (CASE 3 TP2)
*16 3-939-652-11 CASE
(1) CASE, FRONT PANEL SECTION
3
not
supplied
not
supplied
5
6
4
2
1
#1
#1
89
10
7
11
12
13
14 15
16
15
7
not
supplied

– 28 –
(2) CHASSIS SECTION
TCM-ACLM578 #1
#1
55
#2
#2
#2
54
52
51
#2
not
supplied
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
51 4-977-699-11 LEG (F)
52 4-965-822-01 FOOT
*53 3-350-847-31 HOLDER, PCB
*54 A-2007-721-A MAIN BOARD, COMPLETE
*55 3-012-563-02 PANEL, BACK
not supplied
53