Sony TC-K222ESG User manual

Dolby noise reduction manufactured under license from
Dolby Laboratories Licensing Corporation.
“DOLBY” and the double-D symbol 99 are trademarks of
Dolby Laboratories Licensing Corporation.
of
soe
cone
US Model
Canadian Model
UK Model
West Germany Model
TC-K850ES
E Model
TC-K222ESG
TC-K850ES
Model Name Using Similar Mechanism
Tape Transport Mechanism Type TCM - 200D2
SPECIFICATIONS
Recording system 4-track 2-channel stereo Outputs
Bias AC bias Line outputs Rated output level | 0.44 V (—5 dB) at a
Heads Erase head x1 (S & F head) (phono jacks) load impedance
Recording head x 1 (Permalloy head)
Playback head x 1 (LA head)
Motors Capstan motor x 1
(direct drive linear torque BSL motor)
Reel motor x 1 (DC motor)
DC motor x 1
Wow and flutter 0.024% WRMS (NAB), +0.065% (DIN)
Fast-forward and rewind time
Approx. 90 sec. (with C-60 cassette)
Frequency response (DOLBY NR OFF)
TYPE IV cassette 15-21,000 Hz (+3 dB, DIN)
(Sony METAL-ES) 15~16,000 Hz (OVU recording)
TYPE Il cassette 15~-19,000 Hz (+3 dB, DIN)
(Sony UX-S)
TYPE I cassette 15-17,000 Hz (+3 dB, DIN)
(Sony HF-S)
-Signal-to-noise ratio (at peak level)
asset NR suite NR switch B-TYPE C-TYPE
ON ON
—— IV
(Sony METAL-ES) 61 dB 70 dB 76 dB
Total harmonic distortion
1.0% (with Sony METAL-ES cassette)
Sensitivity 77.5 mV (—20 dB)
Input impedance 50k ohms
Inputs
Line inputs
(phono jacks)
CD DIRECT input
(phono jacks)
47k ohms
Load impedance Over 10k ohms
Output level 0-2.5 mW at a load
: impedance of 32
ohms
Headphones
(stereo phone jack)
General
Power requirements West Germany model:
220 V AC, (or 240 V AC adjustable
by Sony personnel), 50/60 Hz
US, Canadian model :
120 V AC, 60 Hz
UK model :
240 V AC (or 220 V AC adjustable
by Sony personnel), 50/60 Hz
E model :
120, 220, or 240 V AC adjustable,
50/60 Hz
Power consumption 23 W
Dimensions Approx. 430 x 135 x 350 mm (w/h/d)
(17 x 53/4, 137/, inches)
Approx. 470 x 135 x 350 mm (w/h/d)*
(184/, x 53/4, x 1374 inches) *
Weight Approx. 6.9 kg (15 Ibs 4 02)
Approx. 7.9 kg (17 Ibs 7 o2z)*
* including projecting parts. controls and wooden side paneis
Supplied accessory Audio connecting cord (2)
Optional accessory Wireless remote control unit RM-J701
Design and specifications subject to change without notice.
Note
This appliance conforms with EEC Directive 87/308/EEC regarding
interference suppression.
STEREO CASSETTE DECK
SONY.

TC-K222ESG/K850ES
TABLE OF CONTENTS
Section Title Page
SPECIFICATIONS + +ccccccccccccccescsssccceecvccesces 1
MODEL IDENTIFICATION «ccccccccccccecceccssevces 3
SAFETY ‘CHECK =ODUT «sss s0se0vewavausey ees coum eaes 3
1. GENERAL sitet corieetieuimivangs fess ears vores 4
2. DISASSEMBLY ---- occ e cece cece ccc ereesssecccenes 5
3. ADJUSTMENTS
3-1. Mechanical Adjustments -++-+++ssrsreeeeeers 7
3-2. Electrical Adjustments --++s+ssssrseeeeeeees 10
4. DIAGRAMS
4-1. Block Diagram :++s+etreeee cece ree ceeeecees 15
4-2. Semiconductor Lead Layouts :+:-++++++++e+ 17
4-3. Circuit Boards Location --+++++++seseeeeeee 18
4-4, IC Block Diagrams:++++++seseeseeseeeeeeees 18
4-5. Printed Wiring Boards
— Main Section — ccerecsceessccececvcccccee 20
4-6. Schematic Diagram
— Main Section — ecrseceecreecccceeccevcees 25
4-7. Schematic Diagram
— Panel section — crrrrrcscecccseeteecreeece 30
4-8, Printed Wiring Boards
— Panel Section —errererecseccerscscecnvens 33
. EXPLODED VIEWS
5-1. Overall Section-:sssccscrececscreeencvescvce 35
5-2. Panel Section «eccsssccrccssccccccescevvvece 36
5-3. Mechanism Section (1) srrresreerereeseeeee 37
5-4, Mechanism Section (2) s++++rrrereereseeeee 38
. ELECTRICAL PARTS Ry So 22
SAFETY-RELATED COMPONENT WARNING!!
COMPONENTS IDENTIFIED BY MARK A OR DOTTED
LINE WITH MARK A 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 PUB-
LISHED BY SONY.
Flexible Circuit Board Repairing
* Keep the temperature of the soldering iron around
270°C during 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,
Notes on chip component replacement
e Never reuse a disconnected chip component.
*« Notice that the minus side of a tantalum capacitor may
be damaged by heat,
Dolby noise reduction and HX Pro headroom extension
manufactured under license from Dolby Laboratories
Licensing Corporation. HX Pro originated by Bang &
Olufsen.
Oyel-Te-stlare melt ele (=
Before connecting the unit to the power source, check
that the operating voltage of your unit is the same as the
local power supply.
If your model has a voltage selector on the rear panel
and it must be reset, disconnect the AC power cord
and set the selector to the appropriate voltage.
VOLTAGE
ATTENTION AU COMPOSANT AYANT RAPPORT
A LA SECURITE!
LES COMPOSANTS IDENTIFIES PAR UNE MARQUE /\
SUR LES DIAGRAMMES SCHEMATIQUES ET LA LISTE
DES PIECES SONT CRITIQUES POUR LA SECURITE
DE FONCTIONNEMENT. NE REMPLACER CES COM.
POSANTS QUE PAR DES PIECES SONY DONT LES
NUMEROS SONT DONNES DANS CE MANUEL OU
DANS LES SUPPLEMENTS PUBLIES PAR SONY.

MODEL IDENTIFICATION
— Specification Label —
TC- K222ESG
TC- K850ES
SONY:
moDEL
no.
LZ
STEREO
CASSETTE
DECK
UMMM hth
SERIAL NO.
MADE IN JAPAN
US, Canadian Models: AC: 120V 60Hz 23W
West Germany Model: AC: 220V \,50/60Hz 23W
UK Model: AC: 240V ™U50/60Hz 23W
E Model: AC: 120, 220, 240V
50/60Hz 23W
| TC-K222ESG/K850ES
SAFETY CHECK-OUT
After correcting the original service problem,
perform the following safety check 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 TEST
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 0.5mA (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-S540A. Follow the
manufacturers’ instructions to use these instru-
ments.
tr
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 volt-
meter. 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
voltmeter
| | (0.78)
= Earth Ground
Fig. A. Using an AC voltmeter to check AC leakage.

TC-K222ESG/K850ES |
SECTION 1
GENERAL
LOCATION AND FUNCTION OF CONTROLS
[1 ]POWER switch
| 2 | Cassette holder
[3 |DISPLAY MODE button
[4 | COUNTER buttons
RESET button/MEMORY button
[5 |i<i<i >D>1 AMS (Automatic Music Sensor) buttons
[6 |LINEAR COUNTER and PEAK PROGRAM METER
MONITOR button
[8 |MPX FILTER button
19 |Remote sensor *
[10] HX PRO button
REC LEVEL (recording level) control
INPUT button
13] CALIBRATION button
BALANCE control
REC LEVEL (recording level) control
(for calibration)
BIAS (bias adjust) control
117] DOLBY NR switch
* You can remotely control this cassette deck with:
— A remote commander that has an 2 mark and comes
with a Sony amplifier or receiver and which can be used
to control a cassette deck.
— An optional Sony remote commander that has an
mark.
[18] Tape operation buttons and indicators
<@<q (rewind) button
m (stop) button
pw (play) button and indicator
pe (fast-forward) button
@ REC (record) button and indicator
f8 PAUSE button and indicator
© REC MUTE (record muting) button
4 OPEN/CLOSE button
20] HEADPHONES jack (stereo phone jack)
PHONE LEVEL (headphone level) control
TIMER switch

SECTION 2
DISASSEMBLY
NOTE: Follow the disassembly procedure in the numerical order given.
JOINT LEVER .
CASSETTE HOLDER @ SPRING 4) és
@ CASSETTE
HOLDER
ORNAMENTAL PLATE
@ORNAMENTAL PLATE
oo ~~
+B
2.
;
oy
PINCH
LEVERLEVER
FR/HEAD
6x6
(2
pes.)
Q@— @: PINCH LEVER S
[1], : PINCH LEVER T
ZA\ A\: LEVER FR
.
Z\ STOPPER WASHER 1.5
Yds 7, 4
Sey se DBI SS. A\ LEVER FR
SS uy
Pos
SCREW [2] PINCH LEVER T
2 +BVTT 3x5 1a
O sprING —~G VP LEAF SPRING O~— [7] stopPER WASHER 23
@ LEVER PS
@ PINCH LEVER S

COMPARATOR BOARD//CAPSTAN BOARD//FLYWHEELS,/FG BOARD
&
SCREWS,
+PS
3x6
(2
pes)
A\
.A\
:
COMPARATOR
BAORD
.< @— @ : CAPSTAN BOARD
WASHER
[1]—[3] : FG BOARD (after removal of 1 and 2)
Note: To remove the whole unit assembled on CAPSTAN
: ZZ & CAPSTAN DECK (D1) ASSY
DECK (D1) ASSY, remove 4 screws marked x.
( “A
FLYWHEEL (S)
© SCREWS,+ BVTT 3x5 (2 pes.)
REW 7 ‘ 4
x ae see CAPSTAN BELT
(Bines) : @CAPSTAN BOARD
@ THRUST RETAINER D BRACKET ASSY
@ SCREWS, + PS 3x6 (2 pes.)
FG BOARD
SCREW,+PS 2.6x6
FLYWHEEL (DT) - /A\ COMPARATOR BOARD
MD BOARD
“Ge—_ /\ SCREWS, + BVTT 3x5 (2pcs.)
@ SCREWS, + BTP 2x 18 (3 pes.) @ SCREWS, + PS 3x6 (2 pes.)
comenn(9
!
D
ROTARY
ENCODER
(S1001)
Q
27
Align A— mark to the line
when reassembling .
MODE CAM eens pp SELECTION LEVER @ SCREWS, + B2.6 x 6 (4 pes.)
TERR i als \-— MODE CAM
\ Align the line on MODE CAM to
ramoorarily when the tip of SELECTION LEVER.
reassembling. ;
REEL MOTOR BOARD
@ASSIST MOTOR (M1002)
Soldering
SPACER (MOTOR)
@REEL MOTOR (M1001)
Soldering
MD BOARD
@REEL MOTOR BAORD

SECTION 3
ADJUSTMENTS
3-1. MECHANICAL ADJUSTMENTS
PRECAUTION
1. Clean the following parts with a denatured-
alcohol-moistened swab:
record/playback head pinch roiler
erase head rubber belts
capstan idlers
2. Demagnetize the record/playback and erase head
with a head demagnetizer.
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 supply voltage unless otherwise
noted.
capstan
tape guide (S)
pinch roller (S)
erase head REC/PB head
FLYWHEELS T/S THRUST ADJUSTMENT
1, FLYWHEEL T THRUST ADJUSTMENT :
Insert 3mm — thick spacer guage into the
clearance between magnet of FLYWHEEL T and
CAPSTAN Board, and adjust THRUST SCREW
so that thrust play is 0.2—-0.4mm .
2. FLYWHEELS THRUST ADJUSTMENT :
Tighten THRUST SCREW lightly until the
flywheel has no play and then loosen the screw
by 1/2-—3/4 turns.
3. After adjustments, apply locking compounce to
_ the screws.
pinch roller (T)
Pinch Roller Pressing Force Measurement
Mode: playback
Hook needle of the tension gauge to the pinch roller
shaft and push back pinch roller to detach it from
capstan. Then, return it gradually to capstan and
read the gauge when the pinch roller begins turnning.
Standard Limits :
Tape-up side: 270 — 350g (9.5 — 120z)
Supply side: 180 — 280g (6.4 ~ 9.90z)
capstan
pinch roller
tension gauge
THRUST SCREW
CAPSTAN BOARD
THRUST SCREW
LI ao |
9)
Take up side
REAR VIEW OF MECHANISM

Tape Path Adjustment
¢ Refer to Adjustment Position on page 10.
Note: When using the adjustment methods for other
than replacement reasons, please do not
tamper unnecessarily with the adjustment
screws or the erasehead because either the
supply pinch roller guide or the record/
playback head will be made the standard tape
paths. Moreover, when it is necessary to
adjust and replace two or more of any of the
heads and/or pinch rollers, replace them one
by one, completely taking out the first tape
path, and then replacing the second one.
Preparation :
1. Mirror cassette CQO09C 8-909~-708-01
(or CQ012C 8-909-708-02)
If one does not have this, cut out the sections of
a 120-minute cassette shell as indicated below
and use that cassette.
2. Phillips screwdriver (medium-size) :
For the head adjustment screws
Blade-type screwdriver (large-size) :
For the supply pinch roller adjustment screws
3. Pen light
WS-~48B (3 kHz, 0 dB)
5. P-4-A100 (10 kHz,-10 dB)
at
Definition of Terms: The figures are of a record/
playback head.
Height Declination Depth Azimuth
F
Adjustment Method :
Supply Pinch Roller
Note: Only perform this adjustment when the supply
pinch roller is to be replaced.
1. Insert the mirror cassette and put the unit in
record/ playback mode.
2. Check to see whether the tape is curling at the
record/ playback head guide or the pinch roller
guide.
If it is curling, remove the curl by adjusting the @
tape curl adjustment screw. Then, check that the
tape is running past the middle of the erasehead.
Record/ playback Head
Note : Only perfom this adjustment when the record
/playback head is to be replaced.
1. Insert the mirror cassette and put the unit in
record/ playback mode.
2. (Height Adjustment) Check to see if the tape is
curling at the tape guide of the head. If it is
curling, tighten screws 4, ®, and @, respectively
by the same angle, moving the head so that it
remains at the same angle throughout the
procedure. If it curls on the bottom side of the
mirror cassette (actually the inner side), tighten
all the screws equally ; but loosen them if the
tape begins to curl on the top side (outer side).
inside 1...,, outside Re | ' fl
— | ie- ' 1 ' t
normal Curling on the Curling on the
(record/ playback head inner side. outer side.
as seen from the side Tighten screws Loosen screws
of the erasehead.) ,®, and @. , ®, and @.
3. (Declination Adjustment) While in the record/
playback position, set the back tension to 0 (wind
the supply reel with something thin like a pencil
in a counterclockwise direction) and make sure
there is no curling or shifting (shifting up/
shifting down) at the guide of the record/
playback head.
Because shifting can only occur due to a difference
in the width of the tape and that of the tape guides
(curling will otherwise occur), it is necessary to pay
close attention since it can be easily overlooked.
When there is a shift, tighten screws ® and © equally
and change the declination of the head. If the tape
is shifting up, tighten the screws, and if it is shifting
down, loosen them.
A, Repeat the adjustments in steps 2 and 3 and fine
adjust the height and the declination.

| TC-K222ESG/K850ES
(Preliminary Azimuth Adjustment) 3. (Height adjustment) Turn screws ®,@, and @ all
After demagnetizing and cleaning the adjustment by the same angle so that the portions of the
head, play back WS-48B (3 kHz, 0 dB). erasehead visible at top and bottom are nearly
Turn screw @ so that the reading on the level of equal width. If the width at the top is greater,
meter of the unit or that of the level meter tighten the screws; if the width at the bottom
connected to LINE OUT is maximized. is greater, loosen the screws.
If the screw . turned at least half a revolution, Erasehead (The erasehead as seen through the
repeat the adjustments from step 1. :
mirror cassette.)
6. (Tape Path Check) Connect the oscilloscope to
LINE OUT and play back P-4-A100 (10 kHz, -10 a a
dB) to display a resurge waveform. After 20
seconds of record/playback (after the tension
within the loop has been increased sufficiently),
make sure the variation in the resurge is within
+ 90 degrees (within + 45 degrees is desired).
If the variation is greater than this, it is because
the declination and/or the height adjustment is A,
not perfect. Repeat the adjustments from step 1.
Tape —»
Se ee aes
Make these the same width.
(Declination Adjustment) Leaving it in the
playback position, put the back tension to 0 and
make certain the erasehead part and supply pinch
roller guide part do not shift. If there is a shift,
turn the screw ® and change the declination.
Looking at it using the mirror cassette, if the
tape shifts up, tighten the screw, and if it shifts
down, loosen the screw.
5. Repeat the adjustments beginning with step 2 and
fine adjust the height and declination. And make
sure the tape does not curl up on the pinch roller
guide or the guide part of the record/ playback
head.
6. (Depth Adjustment) In order to make the entire
head play the tape smoothly, and to make sure
the depth of the erasehead is neither too shallow
nor too deep, loosen screw @ a bit.
test tape
P-4-100S :
(10 kHz, —10 dB) Oscilloscope
L-CH 47kQ
UNE CUT
Oscilloscope Resurge Waveform
OOAO®VO®
In Phase 45° eee ee, 180°
eer he
Good Bad,
a Gal 0.56 mm
Note:
Only
perform
this
adjustment
when
the
Normal
TO
erasehead is to be replaced. i
head
1. Insert the mirror cassette and put the unit in
record/ playback mode. |
2.
(Azimuth
Adjustment)
Adjust
the
azimuth
of
the
Not
deep
enough
Too
deep
erasehead by adjusting screws @ and @ so that
the tape runs as evenly as possible.
pay be — |
Check to make sure that there are no curls or
shifts throughout the whole tape path and that
the tape runs smoothly.
2. Reapply the locking compound to the adjusted
e : ; screws. (The locking compound should only be
Normal Tighten @ Tighten @ applied to screw © after the azimuth has been
Loosen @ Loosen @ adjusted.)
(The erasehead as seen when erasing the mirror
cassette.)

TC-K222ESG/K850ES
Standard Output Level
OVS)
VTVM
) attenuator '*® mo {LI
OO
1-000 set |
esi
6008) INE INPUT LINE OUTPUT
Adjustment Position: As seen from the cassette,
side (top) and MD as seen
head on (bottom).
Takeup pinch Torque Adjustment and Measurement
1. Load a torque meter cassette CQ-102C and push
Supply pinch
roller
Erasehead
Record/playback
roller
head > button.
2. Adjust RV803 so that the reading on the torque
meter is 40+3g*cm (0.56 + 0.0420z inch).
3. After the adjustment, apply suitable locking
compound to RV803.
3-2. ELECTRICAL ADJUSTMENTS
Note: The adjustment should be performed in the order
given in this service manual.
The adjustments should be performed for both L-CH
and R-CH.
@ Simultaneous REC/PB Mode:
Input the signals to LINE IN terminal and set to
REC mode. Set the monitor switch to TAPE,
and monitor the recorded signal from LINE OUT
terminal,
@ Switch Position:
DOLBY NRevecccrsscecersscesecensscnensersssceuneeseeens OFF
MPX FILTER coccccecssceeeecceesscceeccseeseseeensseues OFF
TIME Recccccesscctssceeeneccetseceessceescsenssceusessenees OFF
MONITOR crosceesccssceceecectsouecescesceerseenscenens TAPE
HX PRO corccsecrascentscessccescencsesconsceescererscenees OFF
CALIBRATION «cccesecctteceerececcescssatsnsesassceonee OFF
CD DIRECT rreccrsseeccecseeecteenesseeseecanesseenanees OFF
BY AS cessaevedwcsnlvereatzccnanonsidyereya CENTER CLICK
REC LEVEL «oresssssressseesceeseeees CENTER CLICK
BALANCEeersrcccresceceectescsesecenes CENTER CLICK
@ Standard Record:
Deliver the standard input signal level to the input
jack and set the REC LEVEL control to obtain the
standard output signal level.
Standard Input Level
025 v (1008
FWD
Back tension
FF/REW CQ-201B
70 — 120g*cm (0.97 — 1.670z*inch)
Playback Head Azimuth Adjustment
Procedure:
1. Mode: playback
test tape
P-4-A100
(10 kHz ~10d8)
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 1dB.
L-CH output
peak level within
within 1 dB
R-CH
peak
screw
ition —© lock-nut
positio Beak R-CH ae
peak
—10—
FWD CQ-102C |37—43g+*cm (0.51 — 0.600z* inch)
CQ-102C |8- 10.5g*cm (0.11 —0.150z*inch)