Sony TCM-500DV User manual

SERVICE MANUAL
CASSETTE-CORDER
US Model
Canadian Model
AEP Model
E Model
Tourist Model
Model Name Using Similar Mechanism New
Tape Transport Mechanism Type MT-500-175
SPECIFICATIONS
TCM-500DV
Ver 1.2 2004. 04
Recording system
2-track 1 channel monaural
Tape speed
4.8 cm/s or 2.4 cm/s
Frequency range
350 - 6 300 Hz using nomal (TYPE I) cassette (with REC
TIME/PLAY MODE switch at “NORMAL”)
Speaker Approx. 3.6 cm (1 7/16 in.) dia.
Power output
450 mW + 450 mW (at 10 % harmonic distortion)
Input Microphone input jack (minijack)
sensitivity 0.2 mV for 3kΩ or lower impedance microphone
Output Earphone jack (minijack) for 8 -300Ωearphone
Variable range of the tape speed
From approx. +30% to –15% (with REC TIME/PLAY
MODE switch at “NORMAL”)
Power requirements
• 3 V DC, batteries AA(R6) x 2
• External DC 3 V power sources
Dimensions (w/h/d) (incl. projecting parts and controls)
Approx. 87.6 x 113.0 x 37.1 mm
(3 1/2x 4 1/2x 1 1/2in.)
Mass (main unit only)
Approx. 215 g (7.6 oz.)
Design and specifications are subject to change without notice.
9-877-111-03
2004D02-1
© 2004.04
Sony Corporation
Personal Audio Company
Published by Sony Engineering Corporation

TCM-500DV
2
TABLE OF CONTENTS
1. GENERAL ................................................................... 2
2. SERVICING NOTES ................................................ 2
3. DISASSEMBLY ......................................................... 3
3-1. Cabinet Rear Assy (500), Lid Assy (500),
Cassette .................................................................. 3
3-2. MAIN Board .......................................................... 4
3-3. Mechanism Deck ................................................... 4
3-4. Head, Magnetic (Rec/PB/Erase) (HRPE901),
Belt (AR), Capstan/Reel (M601) .......................... 5
3-5. LED Board ............................................................. 5
3-6. SP Board ................................................................ 6
4. MECHANICAL ADJUSTMENTS ....................... 7
5. ELECTRICAL ADJUSTMENTS ......................... 7
6. DIAGRAMS
6-1. Block Diagrams ...................................................... 8
6-2. Printed Wiring Board –MAIN Board (Side A) – ... 9
6-3. Printed Wiring Board –MAIN Board (Side B) –... 10
6-4. Schematic Diagram –MAIN Board (1/2) – ........... 11
6-5. Schematic Diagram –MAIN Board (2/2) – ........... 12
6-6. Printed Wiring Board –LED, SP Board – .............. 13
6-7. IC BLOCK DIAGRAMS ....................................... 14
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.
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.
SECTION 1
GENERAL
REC TIME/PLAY MOD
E
VOR
TAPE COUNTER
z
REC
x STOP
REW/REVIEW
FF/CUE
VOL
Flat Mic
Microphone affleurant
PAUSE
.
nN
PLAY
n DIR N
REC, BATT, E lamps
Témoins REC, BATT,
E
MIC (PLUG IN POWER) EAR
SPEED CONTROL
SECTION 2
SERVICING NOTES
In this set, the S102 (POWER) detects REC/PLAYBACK on.
It is mounted on the MAIN board, and therefore the REC/PLAYBACK on cannot be detected with the MAIN board removed.
When making an operation check and voltage check of mechnical deck with the MAIN board removed, fix the S102 at turn on.
S102
ON
*
–MAIN BOARD (side A) – –MAIN BOARD (side B) –
SL101
7. EXPLODED VIEWS ................................................ 15
7-1. Cabinet Section ...................................................... 15
7-2. Cassette Holder Section ........................................ 16
7-3. Mechanism Deck Section-1 (MT-500-175) .......... 17
7-4. Mechanism Deck Section-2 (MT-500-175) .......... 18
8. ELECTRICAL PARTS LIST ............................... 19
Also, soldering the lands SL101 bridge makes S102 to turn on.
This section is extracted from
instruction manual.

TCM-500DV
3
3-1.CABINET REAR ASSY (500), "LID ASSY (500), CASSETTE"
Note: Follow the disassembly procedure in the numerical order given.
SECTION 3
DISASSEMBLY
• This set can be disassembled in the order shown below.
Cabinet (Front) assy (500) MAIN board
Lid assy (500), Casette
Head, Magnetic (Rec/Pb/Erase) (HRPE901), Belt (AR),
Capstan/Reel Motor (M601)
LED board
SP board
Set
Cabinet Rear assy (500)
Mechanism Deck
qa
5
qg Lid assy (500), cassette
6 Flexible doard (CN201)
Cabinet (front) assy (500)
2 Screws (B1.7 x 9)
3 Screws (1.7 x 16)
4 Claws
8 Strap, hand
1 Foot (B)
7 Cabinet rear assy (500)
0 Screw (B1.7 x 3)
9 Flexible board (CN401)
Returning lever
Note on Assembling "Lid Assy (500),
Cassette"
On assembling the lid assy (500),
cassette, insert the one side of the l
id spring to the hole on the lid assy,
and fit the other side to the cabinet
(front) assy (500) as shown in the
figure.
qs Remove the "lid assy (500),
cassette" while pushing the
pivot with a phillips-head
screwdriver or the like.
qd Remove the returning lever from the
pivot of the "lid assy (500), cassette"
while inserting a screwdriver between
the "lid assy (500), cassette" and the
returning lever.
qf Remove the "lid assy (500), cassette"
while pushing the pivot with a phillips-
head screwdriver or the like.

TCM-500DV
4
3-3. MECHANISM DECK
6
3
5 Screws (M1.4 x 2.5)
7 Mechanism deck (MT-500-175
)
4 Jack (600)
1 Belt (counter)
2 Screw (M1.4 x 2.5)
Cabinet (front) assy (500)
3-2. MAIN BOARD
4
Cabinet (front) assy (500)
Orange
Black
Red
White
1 Remove four solders of capstan/reel moto
r
3 Screws (M1.4)
5 MAIN board
2 Flexible board (CN101)

TCM-500DV
5
3-4.HEAD, MAGNETIC (REC/PB/ERASE) (HRPE901), BELT (AR), CAPSTAN/REEL MOTOR (M601)
3Belt (AR)
How to attach a belt
4Screw (M1.4)
5Capstan/reel motor (M601)
2Head, magnetic (rec/pb/erase) (HRPE901)
1Screw (M1.4)
3
Lid assy (500) cassette
4 Flexible board (CN402)
9 LED board
6 Remove two solders of mic
1 Screws
7 Sprng (500), ground
8 Mic 901
2 Screws
5 Spring (earth)
3-5.LED BOARD

TCM-500DV
6
3-6. SP BOARD
6
4 Screw
9 SP board
5 Claws
2 Claw
3 Knob (speed) (600)
Cabinet rear assy (500)
1 Remove a claw of knob
(speed) (600) by a screwdriver
7 Flexible board (CN202)
8 Remove four solders of speaker leads

TCM-500DV
77
SECTION 4
MECHANICAL ADJUSTMENTS
TapeTension Measurement
1. Clean the following parts with a denatured-alcohol-moistened
swab: record/playback/erase head pinch roller
capstan rubber belt
2. Demagnetize the record/playback/erase head with a head demag
netizer.
3. Do not use a magnetized screwdriver for the adjustments.
4. The adjustments should be performed with the rated power supply
voltage (3 V) unless otherwise noted.
Mode Torque Meter Meter Reading
1.97 – 3.92mN•m
FWD (20 – 40 g•cm)
CQ-102C (0.28 – 0.55 oz•inch)
FWD
Back Tension 0.05 – 0.49 mN•m
REV (0.5– 5 g•cm)
REV (0.007 – 0.069 oz•inch)
Back Tension
FF, REW CQ-201B more than 4.91 mN•m
(more than 50 g•cm)
(more than 0.69 oz•inch)
Mode Tension Meter Meter Reading
FWD CQ-403A more than 50 g
(more than 1.76 oz)
Torque Measurement
SECTION 5
ELECTRICAL ADJUSTMENTS
Tape Speed Adjustment
Mode: playback
Procedure:
1. Set [REC TIME] switch (S401) to NORMAL (4.8 cm/s) posi-
tion, and playback the tape (WS-48A) .
2. Adjust RV602 so that frequency counter reading becomes 3,010
Hz.
3. Set [REC TIME] switch (S401) to DOUBLE (2.4 cm/s) posi-
tion.
4.Playback the tape from the beginning for two minutes, then ad-
just RV601 so that frequency counter reading becomes 1,505 Hz.
Confirm that deflection of the frequency counter reading between
the beginning and the end of tape is within 2% (NORMAL: approx.
60 Hz, DOUBLE: approx. 30 Hz) .
Setting:
•Supplied voltage: 3 V (DC)
•Switch and control position
VOL contorl (RV101) : mechanical center
REC SPEED switch (S401) : normal (4.8cm/s)
PAUSE switch (S601) : OFF
SPEED CONTROL (RV201) : center click
VOR switch (S402) : OFF
0 dB=0.775 V
Type Signal Used for
WS-48A 3 kHz, 0 dB tape speed adjustment
frequency
counter
test tape
WS-48A
(3 kHz, 0 dB) 16 Ω
EAR jack (J102)
set +
–
TestTape
Regulation Level
input level Mic –60dBs
output level earphone 16Ω, –20dBs
Adjustment Location:
– MAIN BOARD (Conductor Side) –
IC601
10
11
RV602
RV601
Tape Speed Adjustmen
t
Tape Speed Adjustment
(Normal Speed)
(Double Speed)
1
20
Ver 1.2

TCM-500DV
88
6-1. BLOCK DIAGRAMS
S101 (4/6)
REC
R
PB
S101 (2/6)
REC
R
PB
S101(6/6)
PB
r
REC
S101 (1/6)
REC
R
PB
Q801
REC B+
S103
FWD
r
REV
RV101
wVOL
S101(3/6)
REC
R
PB
P.B+
B+ 3V BATT B+
S102
(POWER)
6
7
4
VOLTAGE DET
IC401
MIC901
FLAT MIC
J101
MIC
(PLUGIN POWER)
15 14
11
1
16
4
MIC/EARPHONE AMP
IC101
LPF
IC301
POWER AMP
IC103
PRE
DRIVE
OUTPUT
SOFT
SWITCH
WAVEFORM
DETECT
SPEED
DETECT
BIAS
OSC
CURRENT
DETECT
MOTOR
BRAKE
Q602
MOTOR
BRAKE
Q604
INITIAL
SWITCH
Q603,605
LED
DRIVE
Q404
B+
SWITCH
Q403,405
LED
DRIVER
Q401
ATT
ALC
ATT
REC B+
SWITCH
Q705
INITIAL
DETECT
Q709,710
MUTE
Q701
MUTE DRIVE
Q703
3
6
1 4 5
6
9
5
J102
EAR
SP902
SPEAKER
(R-CH)
SP901
SPEAKER
(L-CH)
B+3V
L-CH
-1
-2
-3
FWD
REV
R-CH
L-CH
R-CH
HRPE901
(REC/PB/ERASE HEAD)
S401 (2/2)
REC TIME/PLAY MODE
NORMAL
r
DOUBLE
5
6
1
V•O•R
LEVEL
DETECT
IC501
4
11
13
14
16 17
12
5
6
SERVO
CONTROL
IC601
D801
S402
V·O·R
ON
R
OFF
15 IN+
THP601
S401(1/2)
Q702, 704
MUTE OR
Q201
VDD
BATT B+
IN(A) +OUT(A)
-OUT(A)
+OUT(B)
-OUT(B)
IN(B)
SHUT
DOWN
VREF
UOUT
VOUT
WOUT
S/S
VSP
OSC
COM
OUT
M
M601
CAPSTAN/REEL
MOTOR
BATT B+
U
V
W
Q601
INVERTER
Q402(2/2)
LED ON/OFF
Q402(1/2)
LED ON/OFF
Q708
B+3V
B+3V
REC B+
P.B+
L401
S101(5/6)
REC
R
PB
DRY BATTERY
SIZE "AA"
(IEC DESIGNATION LR6)
2PCS, 3V
DC IN 3V
!
J103
S104
PAUSE .
OFF
r
ON
REC
BATT
E
D402
D401
D403
RV201
SPEED CONTROL
REC TIME/PLAY MODE
DOUBLE
R
NORMAL
RV601
TAPE SPEED 2.4cm
RV602
TAPE SPEED 4.8cm
REC B+
OR
Q202
MUTE
SWITCH
3
16
417
18
15
1
INITIAL
DETECT
Q707
POWER
DETECT
Q706
•Signal path.
E: PB
a: REC
SECTION 6
DIAGRAMS

TCM-500DV
99
6-2. PRINTED WIRING BOARD –MAIN BOARD (SIDE A)–
Note:
•X: parts extracted from the component side.
•a: Through hole.
•: Pattern from the side which enables seeing.
(The other layers' patterns are not indicated.)
Caution:
Pattern face side: Parts on the pattern face side seen
(Side B) from the pattern face are indicated.
Pattern face side: Parts on the parts face side seen
(Side A) from the parts face are indicated.
C138
S102
(POWER)
11
(11)
1-687-887-
(SIDE A)
MAIN BOARD
23 4 5 6 7 8
A
1
B
C
D
E

TCM-500DV
10 10
R709
R706
R126
R125
R104
R129
R703
R127
R119
R105
R103
R135
R101
R132
S101
-6 -5 -4
-3 -2 -1
R102
C501
R111
R128 R130
C702
C118
C131
C137
C115
R813
R811
R131
C128
C127
C126
R123
C132
C117
C110
C106
C105
C119 C116
C113
C129
C104
C103
C101
C102
C703
C121
C120
C124
C125
D101
D102
D801
D701
R206
R210
R211
R810
R806
R805
R710
R711
R203
R208
R215
SL201
R216
R401
C134
C207
CN201
R503
R506
R505
R502
C503
R504
R501
C402
C505
C506
C502
C504
R213
R310 R309
R209
R116
R118
R117
C106
C109
R312
C308
R301
C303
C206
R702
R121
R707
S103
R122
R133 R114
R112
R110
R308
R311
R207
R205
R212
C111
C107
C114
C701
C123
C122
C136
C135
C305
C304
C309
C133
C202
C201 C203
C130
Q603
Q601
Q706
Q405 Q403
Q401
Q402
Q404
J103
ECB
ECB
Q708
Q605
Q602
Q604
ECB
ECB
ECB
THP601
RV602
RV601
IC601
IC401
1
1
10
20 11
4
5
8
IC103
IC301
S104
PAUSE
Q703
Q707
Q709
Q710
ECB ECB ECB ECB
Q704
Q202 Q201
Q702
Q705
Q701
Q801
ECB
ECB
ECB
ECB ECB
ECB
1
10
20
11
IC101
1
16
8
9
IC501
1
45
8
CN401
CN101
RV101
J101
J102
DC IN 3V
DRY BATTERY
SIZE "AA"
(IEC DESIGNATION LR6)
2PCS, 3V
R611
R616
R612
R412
R613
R618
R617
R609
R606
R614
R411
R607
C704
R708
R713
R712
R704
R610
R603
R705
C606
C608
C609
C607
C604
C610
C601
C405 C602
C605
C603
R608
R414 R413
R416
R415
R601
R602
R605
R615
R406
R403
R405
E B C
C B E
R402
R408
C403 R404
R409
R407 C404
R420 R419
R417 R418
L401 W
V
U
COM
M601
CAPSTAN/REEL
MOTOR
(SIDE B)
MAIN BOARD
11
(11)
1-687-887-
REC
PB
r
CB
E
B
C
1
2
3
115
115
FWD tREV
TO HRPE901
(REC/PB/ERASE HEAD)
ALED
BOARD
(Page 13)
B
SP
BOARD
(Page 13)
EAR
N
MIC
(PLUGIN POWER)
VOL
BCE
BCE
BCE
BCE
BCE
BCE
23 4 5 6 7 89
A
1
B
C
D
E
6-3. PRINTED WIRING BOARD –MAIN BOARD (SIDE B)–
D101 B-5
D102 D-2
D701 B-2
D801 C-3
IC101 B-3
IC103 D-5
IC301 C-5
IC401 D-7
IC501 E-3
IC601 C-8
Q201 D-5
Q202 D-5
Q401 C-6
Q402 D-6
Q403 C-6
Q404 D-7
Q405 C-6
Q601 C-7
Q602 C-8
Q603 C-7
Q604 C-8
Q605 C-8
Q701 C-3
Q702 C-5
Q703 B-2
Q704 C-4
Q705 D-3
Q706 B-6
Q707 B-3
Q708 B-7
Q709 B-3
Q710 B-3
Q801 C-3
Ref. No. Location
• Semiconductor
Location
Note:
•X: parts extracted from the component side.
•a: Through hole.
•: Pattern from the side which enables seeing.
(The other layers' patterns are not indicated.)
Caution:
Pattern face side: Parts on the pattern face side seen
(Side B) from the pattern face are indicated.
Pattern face side: Parts on the parts face side seen
(Side A) from the parts face are indicated.

TCM-500DV
11 11
6-4. SCHEMATIC DIAGRAM –MAIN BOARD (1/2)– • Refer to page 14 for Notes.
CN201 CN202
CN101
R101
R102
R103
R104
R105
R135
R805
Q701
C102
C103
C104
C105 C119
D101
R110 R112
C137
C117
R125
C115
C118
C124 C125
R126
R127 R128
R129
R130
C131
C106
C110
C111
C114
C116
R121
R122
C122
C123
C701
R702
C135 C136 R133
R711
R703
R709
C132
D701
C201 C203 R205
R206
R210
R211
C207 C134
C202
R203
R207 R208 C206
R813
R811
C126 D102
R131
R132
C127
C128
C129
R311
R312
C308
C309
C303
C304
C133
R301 R308
R309
R310
C107
C305
R810
S101(3/6)
S101(4/6) S101(1/6)
R209
C120
C121
R119
S101(2/6)
R111
C101
J101
MIC
(PLUGIN POWER)
SP901
SP902
R806
RV101
S104
J102
EAR
C113
IC101
Q702
Q704 Q201
Q202
R710
S101(5/6)
R215
R216
Q801
Q705
Q703
IC103
R707
C109
C108
R116
R118 R117
R114
S101(6/6)
RV201
SPEED CONTROL
R212
R213
R123
15P 15P
9P
4.7k
2.2k
22k
10k
470
470
470
2SC4213
0.1
0.01
0.01
22
4V
22
4V
02DZ2.4
10k 10k
1
1000p
47
10
10V
0.1
0.01 10
10V
4.7
2.2k 2.2k
2.2
2.2M
1
0.47
0.47
0.22
4700p
4700p
10k
4.7k
10
10V 0.01
1
47k
47
4V
47
4V 47k
220k
4.7k
220k
10
10V
MA2ZD14001S0
10.047 22k
10k
100k
220k
220
4V
10
10V
0.047
10k
22k 220k 0.22
100
100
1000p MA8056
10k
22
1000p
1000p
1000p
22k
220k
1
1000p
0.022
0.022
10
10V
1k 1k
22k
22k
10
10V
0.047
470k
100k
10
10V
1
1k
220
0.1
220
10k
VOL
1
20V
NJM2128M
UN9214J
MUTE OR
UN9214J
MUTE OR UN9214J
INV.
UN9214J
MUTE
SWITCH
1k
22k
47k
UN9215J
SWITCH
2SA1774
REC B+
SWITCH
2SA1774
MUTE
DRIVE
LM4863MTX
POWER AMP
100k
0.022
0.047
10k
10k 2.2k
220
30k
1k
1k
2.2k
GND 2
GND 1
SPD CTL
GND 3
9
10
7
8
3
4
(Page 12)
5
6
1
2
OFF PAUSE
PAUSE
MUTE
SPEAKER
(L-CH)
SPEAKER
(R-CH)
R-CH
L-CH
FWD
REV
R-CH
L-CH
PB REC
PB REC PB REC
FWD REV
PB REC
SHUT
DOWN
GND
+OUT(A)
VDD
-OUT(A)
-IN(A)
GND
+IN(A)
GND
GND GND
GND
GND
HP-IN
+OUT(B)
-OUT(B)
-IN(B)
+IN(B)
VDD
BYPASS
V+
OUTPUT
+INPUT
GND
-INPUT
PB
REC
S103
-
+
-
+
HEAD
ERASE
PLAYBACK/
RECORD/
HRPE901
IC301
NJU7013F-TE2
MIC/EARPHONE AMP
LPF
PB
REC
-1
-2
-3
-4

TCM-500DV
12 12
6-5. SCHEMATIC DIAGRAM –MAIN BOARD (2/2)– • Refer to page 14 for Notes.
CN401
CN402
Q603
Q605
Q602
Q604
JC1
JC2
JC3
C602 C603 C605 C606 C608
C609
R606
R609
C601
C604 R612
R616
C607
R618
R617
C610
R613 R614
R615
R607
R608
R611
R610
R601
R602
THP601
R603
R605
R704
R705
C404
C405
R411 R412 R413 R414
R415
R416
L401
100µH
R417
R419
R420
C403
C501
C401
R401 R402
R403
R405
R406
R404
R407
R408
R409
R501
R502
R503
R505
R506
C503
C504
C505
C506
C702
C703
R706
D801
RV601
RV602
D401
D402
R504
R418
S402
S401
D403
J103
C130
R712
S102
Q403
Q405
Q401
Q402
Q404
Q708
IC501
Q706
MIC901
IC401
Q601
Q710
Q709
IC601
R708
Q707
R713
C704
C138
C502
15P
15P
UN9214J
2SA1774
2SA1745
2SA1745
0.047 0.047 10
10V
0.047 0.047
0.22
1k
100k
0.47
2.2 47k
100k
0.047
47k
10k
10
10V
100 100
10k
1M
1M
1M
1k
100
1k
10k
22k
1k
220k
10
10V
0.1
100 220 470k 1M
220k
10k
47k
1k
470
0.47
1000p
1
1k 1M
470
1k
2.2k
2.2k
1k
1k
470
47k
100k
100k
22k
4.7k
4700p
0.01
1000p
22
6.3V
1
1
470k
MA111
4.7k
4.7k
SML-310LTT86
SML-310LTT86
10k
47k
SML-311YTT86
1000p
47k
(POWER)
UN9114J
B+ SWITCH
UN9214J
B+ SWITCH
XP4601
LED DRIVER
XP1210
LED ON/OFF
2SC4116
LED DRIVE
2SC4213
SPEED
SWITCH
NJM2072M
2SA1774
POWER
DETECT
MM1251BFBE
VOLTAGE DET
UN9214J
UN9214J
UN9214J
LB1979VS-TLM
470k
UN9214J
220k
1
220 4V
0.047
GND 1
GND 2
SPD CTL
GND 3
1
2
3
4
5
6
7
8
9
10
DRY BATTERY
SIZE"AA"
2PCS,3V
MOTOR
BRAKE
SWITCH
INITIAL
MOTOR
CAPSTAN/REEL
VCC
OUT2
OUT1
IN
GND
GAIN CTL
AMP OUT
RCV TIME
NC
CT
GND
OUT HYS
VS
VCC
NC
TAPE SPEED
TAPE SPEED
2.4cm/s
4.8cm/s M601
DC IN 3V
DETECT
Q601,709,710
INITIAL
DETECT
INITIAL
Q603,605
Q602,604
DETECT
LEVEL
(IEC DESIGNATION LR6)
Flat
Mic
NORMAL
DOUBLE
REC TIME/PLAY MODE
OFF
REC BATT
ON
SERVO
CONTROL
(Page 11)

TCM-500DV
13 13
6-6. PRINTED WIRING BOARD –LED, SP BOARD –
D401
REC
D402
BATT NORMAL
DOUBLE
REC TIME/PLAY MODE
D403
S402
V • O • R
OFF
ON
S401
CN402
LED BOARD
11
(11)
1-687-889-
t
Flat Mic
MIC901
1
15
A
MAIN
BOARD
(Page 10)
CN201
RV201
SPEED CONTROL
+
-
+
-
SPEAKER(L)
SP901
SPEAKER(R)
SP902
SP BOARD
11
(11)
1-687-888-
115
B
MAIN
BOARD
(Page 10)
t
23 4 5 6
A
1
B
C
D
E
Note:
•X: parts extracted from the component side.
•a: Through hole.
•: Pattern from the side which enables seeing.
(The other layers' patterns are not indicated.)
D401 C-2
D402 C-2
D403 D-2
Ref. No. Location
• Semiconductor
Location

TCM-500DV
14 14
Note on schematic diagrams
•All capacitors are in µF unless otherwise noted. pF: µµF
50 WV or less are not indicated except for electrolytics
and tantalums.
•All resistors are in Ωand 1/4W or less unless otherwise
specified.
•A: B+ Line.
•H: adjustment for repair.
•Power voltage is dc 3V and fed with regulated dc power
supply frombattery terminal .
•Voltages are dc with respect to ground under no-signal
conditions.
no mark : PLAY
( ) : REC
•Voltages are taken with a VOM (Input impedance 10 MΩ).
Voltage variations may be noted due to normal produc-
tion tolerances.
•Signal path.
E: PB
a: REC
IC101 NJM2128M-TE2
6-7. IC BLOCK DIAGRAMS
IC103 LM4863MTX
IC401 MM125BFBE
+
–
+
–
7
8
1
9ALCIN
PRE
AMP
+
–
POWER
AMP
POWER
AMP
PRE +N
2
SGND
3
POWER +INA
POWER -INB
POWER +INB
RFOUT
RFIN
4
POWER -INA
11 POWER OUTB
10 TC
12 POWER GND
15 PREOUT
16 PRE -IN
V+
13
POWER OUTA
14
5
6
RIPPLE
FILTER ALC
7
8
1
9
GND
GND
SHUTDOWN
2
GND
3
+OUT (A)
-OUT (A)
-IN (A)
GND
+IN (A)
GND
GND
4
VDD
20k 20k
20k
20k
20k
50k
50k
VDD
11
BYPASS
10
+IN (B)
12
-IN (B)
VDD
VDD/Z
15
GND
16
HP-IN
-OUT (B)
+OUT (B)
14
19
18
17
20
20k
5
AMP 2A
+ –
AMP 1A
+ –
AMP 2B
+ –
AMP 1B
+ –
6
13
BOOSTER
CIRCUIT
NC
CT
GND
OUT
NC VCC VS HYS
21 3 4
678 5
+
–
+
–
IC501 NJM2072M (TE2)
1
2
3
4
8
7
6
5
GND
AMP OUT
GAIN CONT
INPUT VCC
OUTPUT2
OUTPUT1
RECOVERY
TIME CAP
IC601 LB1979VS-TLM
235
4678910
1
11
12
13
14
15
16
17
181920
SOFT
SW MIX
CURRENT/MOTIVE
LOGIC
WAVEFORM
DETECT
PRE
DRIVER
OUTPUT
CURRENT DETECT
SPEED
DETECT REFERENCE VOLTAGE
FOR SPEED CONTROL
POWER SUPPLY
BIAS
REFERENCE
VOLTAGE
OSCILLATOR
CIRCUIT
MOTIVE POWER
DETECT
+
–
FC GND FC RI OUT VSP IN+ VREF S/S COM OSC
WB
VCC
NC
U OUT
V OUT
W OUT
P-GND
VB
UB
GND

15
TCM-500DV
SECTION 7
EXPLODED VIEWS
7-1. CABINET SECTION
NOTE:
•-XX, -X mean standardized parts, so they may have
some difference from the original one.
•Items marked “*” are not stocked since they are
seldom required for routine service. Some delay
should be anticipated when ordering these items.
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
•The mechanical parts with no reference number in
the exploded views are not supplied.
•Hardware (# mark) list and accessories are given
in the last of this parts list.
not supplied
SP901
SP902
9
8
76
54
3
2
1
30
29
24 23
22
21
20
19
17
16
19
25
28 27
26
2
12
15
13
14
11
10
13-248-424-31 JACK (600)
23-704-197-21 SCREW (M1.4X2.5), SPECIAL HEAD
33-225-570-11 BUTTON (FF)
43-225-571-11 BUTTON (REW)
53-225-568-11 BUTTON (PLAY) (L-CH)
63-225-569-11 BUTTON (STOP)
73-245-736-21 BUTTON (REC)
8X-3382-992-1 CABINET (FRONT) ASSY (500)
9 3-925-231-01 REFLECTOR
10 3-704-260-61 SCREW (M1.4)
11 3-248-418-11 LID, BATTERY
12 3-248-440-01 SPRING, LID
13 3-248-439-01 SPRING (-), BATTERY
14 3-248-438-01 SPRING (+), BATTERY
*15 A-3663-938-A MAIN PC BOARD ASSY
16 3-345-648-01 SCREW (M1.4X3)
17 3-328-319-01 STRAP, HAND
19 3-034-792-11 SCREW, TAPPING (B2.0)
20 X-3383-510-1 CABINET REAR ASSY (500) (U)
21 3-248-436-11 FOOT (B)
22 3-318-203-91 SCREW (B1.7X9), TAPPING
23 3-248-422-11 KNOB (SPEED) (600)
24 3-035-255-11 SCREW (1.7X16)
25 3-831-441-99 SPACER, KNOB
26 1-687-886-11 FLEXIBLE BOARD
*27 A-3663-941-A SP PC BOARD ASSY
28 3-375-114-71 SCREW
29 3-234-858-01 BELT (COUNTER)
30 1-548-582-11 COUNTER, TAPE (SMALL TYPE)
SP901 1-825-350-11 SPEAKER (3.6CM) (L-CH)
SP902 1-825-350-11 SPEAKER (3.6CM) (R-CH)

16
TCM-500DV
7-2. CASSETTE HOLDER SECTION
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
MIC901
57
54
53
52
51
51
59
58
56
55
56
51 3-375-114-71 SCREW
52 3-248-449-01 CUSHION (500), MICROPHONE
53 3-250-387-01 SPRING (500), GROUND
54 3-250-382-01 SPRING (600), GROUND
55 3-248-446-01 GRILLE (500), MICROPHONE
56 3-893-942-41 SCREW (1.7X3), TAPPING (B)
57 X-3383-511-1 LID ASSY (500) (U), CASSETTE
58 1-687-886-11 FLEXIBLE BOARD
*59 A-3663-937-A LED MOUNTED PC BOARD
MIC901 1-476-484-31 MICROPHONE UNIT, ELECTRET CAP

17
TCM-500DV
7-3. SMECHANISM DECK SECTION-1 (MT-500-175)
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
A (Included in No.151)
HRPE901
M601
110
111
112
103
101
102
113
104
105
114
115
105
108
109 107
107
106
106
z
101 3-704-197-01 SCREW (M1.4), SPECIAL HEAD
102 3-225-429-01 BELT (AR)
103 3-225-390-03 PULLEY (REVERSE)
104 X-3380-830-2 FLY ASSY (AR5.0), CAPSTAN
105 3-386-694-01 WASHER
106 3-029-278-01 WASHER
107 3-029-275-01 WASHER (STOPPER N)
108 3-042-480-01 SCREW (M1.4)
109 X-3379-882-3 PINCH (N) ASSY, ARM
110 3-019-776-03 GEAR (REEL-S)
111 3-225-399-04 LEVER (N SHUT OFF)
112 X-3379-883-4 PINCH (R) ASSY, ARM
113 X-3379-877-2 FLY ASSY (AR), CAPSTAN
114 3-350-949-61 SHEET (SYSTEM CONTROL SCREW)
115 3-234-856-03 LEVER (PAUSE)
HRPE901 1-500-685-21 HEAD, MAGNETIC (REC/PB/ERASE)
M601 1-763-772-12 MOTOR, DC (CAPSTAN/REEL)
(INCLUDING PULLEY)

18
TCM-500DV
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
7-4. MECHANISM DECK SECTION-2 (MT-500-175)
(Including A)
152
153
154
155
156
157
159
160
161
162
163
164
165
166
167
169
170
171
151
z
151 X-3382-924-1 CHASSIS ASSY (ARS)
152 3-225-385-03 GEAR (B)
153 3-229-063-01 SPRING (UD) (R), COMPRESSION
154 3-019-778-03 SLEEVE (MS)
155 3-728-091-01 WASHER, STOPPER
156 3-225-427-01 WASHER, LEVER
157 3-225-384-02 GEAR (A)
159 3-225-395-04 LEVER (REW ROTARY)
160 X-3380-677-3 LEVER (E DETECTION) ASSY
161 3-229-064-01 WASHER, STOPPER
162 3-225-393-03 LEVER (SHUT/OFF)
163 3-225-448-02 SPRING (SHUT OFF), TORSION
164 3-321-813-71 WASHER, COTTER POLYETHYLENE
165 X-3379-881-3 CLUTCH ASSY (AR)
166 3-315-384-31 WASHER, STOPPER
167 3-225-438-01 SPRING (NR SLIDER), TORSION
169 3-225-388-04 GEAR (D)
170 3-225-394-04 LEVER (FF ROTARY)
171 3-225-444-01 SPRING (FR ROTARY), TENSION

19
TCM-500DV
• SEMICONDUCTORS
In each case, u: µ, for example:
uA...: µA..., uPA...: µPA..., uPB...: µPB...,
uPC...: µPC..., uPD...: µPD...
•CAPACITORS
uF : µF
•COILS
uH : µH
•Abbreviation
CND :Canadian
JEW :Tourist
•Due to standardization, replacements in the parts list
may be different from the parts specified in the
diagrams or the components used on the set.
•-XX, -X mean standardized parts, so they may have
some difference from the original one.
•Items marked “*” are not stocked since they are
seldom required for routine service. Some delay
should be anticipated when ordering these items.
•RESISTORS
All resistors are in ohms
METAL: Metal-film resistor
METAL OXIDE: Metal Oxide-film resistor
F : nonflammable
SECTION 8
ELECTRICAL PARTS LIST
Note:
When indicating parts by reference
number, please include the board
name.
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
LED
*A-3663-937-A LED BOARD, COMPLETE
*****************
1-687-886-11 FLEXIBLE BOARD
< CONNECTOR >
CN402 1-573-355-11 CONNECTOR, FFC/FPC 15P
< DIODE >
D401 8-719-064-07 DIODE SML-310LTT86 (REC)
D402 8-719-064-07 DIODE SML-310LTT86 (BATT)
D403 8-719-060-92 DIODE SML-311YTT86 (E)
< SWITCH >
S401 1-571-277-51 SWITCH, SLIDE (REC TIME/PLAY MODE)
S402 1-572-922-11 SWITCH, SLIDE (V.O.R)
******************************************************
*A-3663-938-A MAIN BOARD, COMPLETE
******************
3-248-438-01 SPRING (+), BATTERY
3-248-439-01 SPRING (-), BATTERY
< CAPACITOR >
C101 1-107-826-11 CERAMIC CHIP 0.1uF 10% 16V
C102 1-107-826-11 CERAMIC CHIP 0.1uF 10% 16V
C103 1-162-970-11 CERAMIC CHIP 0.01uF 10% 25V
C104 1-162-970-11 CERAMIC CHIP 0.01uF 10% 25V
C105 1-104-847-11 TANTAL.CHIP 22uF 20% 4V
C106 1-113-619-11 CERAMIC CHIP 0.47uF 10V
C107 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C108 1-165-176-11 CERAMIC CHIP 0.047uF 10% 16V
C109 1-164-227-11 CERAMIC CHIP 0.022uF 10% 25V
C110 1-113-619-11 CERAMIC CHIP 0.47uF 10V
C111 1-165-128-11 CERAMIC CHIP 0.22uF 16V
C113 1-135-177-21 TANTALUM CHIP 1uF 20% 20V
C114 1-162-968-11 CERAMIC CHIP 0.0047uF 10% 50V
C115 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C116 1-162-968-11 CERAMIC CHIP 0.0047uF 10% 50V
C117 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C118 1-107-826-11 CERAMIC CHIP 0.1uF 10% 16V
C119 1-104-847-11 TANTAL.CHIP 22uF 20% 4V
C120 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C121 1-115-156-11 CERAMIC CHIP 1uF 10V
C122 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C123 1-162-970-11 CERAMIC CHIP 0.01uF 10% 25V
C124 1-162-970-11 CERAMIC CHIP 0.01uF 10% 25V
C125 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C126 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C127 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C128 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C129 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C130 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C131 1-115-156-11 CERAMIC CHIP 1uF 10V
C132 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C133 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C134 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C135 1-126-607-11 ELECT CHIP 47uF 20% 4V
C136 1-126-607-11 ELECT CHIP 47uF 20% 4V
C137 1-115-156-11 CERAMIC CHIP 1uF 10V
C138 1-126-246-11 ELECT CHIP 220uF 20% 4V
C201 1-115-156-11 CERAMIC CHIP 1uF 10V
C202 1-164-361-11 CERAMIC CHIP 0.047uF 16V
C203 1-164-361-11 CERAMIC CHIP 0.047uF 16V
C206 1-165-128-11 CERAMIC CHIP 0.22uF 16V
C207 1-126-246-11 ELECT CHIP 220uF 20% 4V
C303 1-164-227-11 CERAMIC CHIP 0.022uF 10% 25V
C304 1-164-227-11 CERAMIC CHIP 0.022uF 10% 25V
C305 1-164-361-11 CERAMIC CHIP 0.047uF 16V
C308 1-115-156-11 CERAMIC CHIP 1uF 10V
C309 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C401 1-115-156-11 CERAMIC CHIP 1uF 10V
C403 1-113-619-11 CERAMIC CHIP 0.47uF 10V
C404 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C405 1-107-826-11 CERAMIC CHIP 0.1uF 10% 16V
C501 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C502 1-165-176-11 CERAMIC CHIP 0.047uF 10% 16V
C503 1-162-968-11 CERAMIC CHIP 0.0047uF 10% 50V
C504 1-162-970-11 CERAMIC CHIP 0.01uF 10% 25V
C505 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C506 1-124-778-00 ELECT CHIP 22uF 20% 6.3V
C601 1-117-863-11 CERAMIC CHIP 0.47uF 10% 6.3V
C602 1-165-176-11 CERAMIC CHIP 0.047uF 10% 16V
C603 1-165-176-11 CERAMIC CHIP 0.047uF 10% 16V
C604 1-125-838-11 CERAMIC CHIP 2.2uF 10% 6.3V
C605 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C606 1-165-176-11 CERAMIC CHIP 0.047uF 10% 16V
C607 1-165-176-11 CERAMIC CHIP 0.047uF 10% 16V
C608 1-165-176-11 CERAMIC CHIP 0.047uF 10% 16V
C609 1-115-467-11 CERAMIC CHIP 0.22uF 10% 10V
C610 1-104-851-11 TANTAL.CHIP 10uF 20% 10V
C701 1-115-156-11 CERAMIC CHIP 1uF 10V
C702 1-115-156-11 CERAMIC CHIP 1uF 10V
C703 1-115-156-11 CERAMIC CHIP 1uF 10V
MAIN
Ver 1.1 2003.04

20
TCM-500DV
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
MAIN
C704 1-115-156-11 CERAMIC CHIP 1uF 10V
< CONNECTOR >
CN101 1-573-349-21 CONNECTOR, FFC/FPC 9P
CN201 1-573-355-11 CONNECTOR, FFC/FPC 15P
CN401 1-573-355-11 CONNECTOR, FFC/FPC 15P
< DIODE >
D101 8-719-064-90 DIODE 02DZ2.4-X(TPH3)
D102 8-719-977-03 DIODE DTZ5.6B
D701 8-719-072-70 DIODE MA2ZD14001S0
D801 8-719-404-50 DIODE MA111-TX
< IC >
IC101 8-759-339-54 IC NJM2128M-TE2
IC103 8-759-597-59 IC LM4863MTX
IC301 8-759-528-80 IC NJU7013F-TE2
IC401 8-759-399-49 IC MM1251BFBE
IC501 8-759-701-51 IC NJM2072M(TE2)
IC601 8-759-638-51 IC LB1979VS-TLM
< JACK >
J101 1-785-791-11 JACK (MIC (PLUG IN POWER))
J102 1-695-514-11 JACK (SMALL TYPE) 1P (EARPHONE)
J103 1-794-615-11 JACK,DC(POLARITY UNIFIED TYPE) (DC IN 3V)
< COIL >
L401 1-414-404-41 INDUCTOR 100uH
< TRANSISTOR >
Q201 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q202 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q401 8-729-427-74 TRANSISTOR XP4601
Q402 8-729-426-51 TRANSISTOR XP1210-TXE
Q403 8-729-037-62 TRANSISTOR UN9114J-(TX).SO
Q404 8-729-230-63 TRANSISTOR 2SC4116-YG
Q405 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q601 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q602 8-729-823-86 TRANSISTOR 2SA1745
Q603 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q604 8-729-823-86 TRANSISTOR 2SA1745
Q605 8-729-928-19 TRANSISTOR 2SA1774R
Q701 8-729-013-37 TRANSISTOR 2SC4213-AB-TE85L
Q702 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q703 8-729-928-19 TRANSISTOR 2SA1774R
Q704 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q705 8-729-928-19 TRANSISTOR 2SA1774R
Q706 8-729-928-19 TRANSISTOR 2SA1774R
Q707 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q708 8-729-013-37 TRANSISTOR 2SC4213-AB-TE85L
Q709 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q710 8-729-037-75 TRANSISTOR UN9214J-(TX).SO
Q801 8-729-037-76 TRANSISTOR UN9215J-(TX).SO
< RESISTOR >
R101 1-216-829-11 METAL CHIP 4.7K 5% 1/10W
R102 1-216-825-11 METAL CHIP 2.2K 5% 1/10W
R103 1-216-837-11 METAL CHIP 22K 5% 1/10W
R104 1-216-833-11 METAL CHIP 10K 5% 1/10W
R105 1-216-817-11 METAL CHIP 470 5% 1/10W
R110 1-216-833-11 METAL CHIP 10K 5% 1/10W
R111 1-216-813-11 METAL CHIP 220 5% 1/10W
R112 1-216-833-11 METAL CHIP 10K 5% 1/10W
R114 1-216-813-11 METAL CHIP 220 5% 1/10W
R116 1-216-833-11 METAL CHIP 10K 5% 1/10W
R117 1-216-825-11 METAL CHIP 2.2K 5% 1/10W
R118 1-216-833-11 METAL CHIP 10K 5% 1/10W
R119 1-216-821-11 METAL CHIP 1K 5% 1/10W
R121 1-216-833-11 METAL CHIP 10K 5% 1/10W
R122 1-216-829-11 METAL CHIP 4.7K 5% 1/10W
R123 1-216-825-11 METAL CHIP 2.2K 5% 1/10W
R125 1-216-805-11 METAL CHIP 47 5% 1/10W
R126 1-216-793-11 METAL CHIP 4.7 5% 1/10W
R127 1-216-825-11 METAL CHIP 2.2K 5% 1/10W
R128 1-216-825-11 METAL CHIP 2.2K 5% 1/10W
R129 1-216-789-11 METAL CHIP 2.2 5% 1/10W
R130 1-216-861-11 METAL CHIP 2.2M 5% 1/10W
R131 1-216-833-11 METAL CHIP 10K 5% 1/10W
R132 1-216-801-11 METAL CHIP 22 5% 1/10W
R133 1-216-841-11 METAL CHIP 47K 5% 1/10W
R135 1-216-817-11 METAL CHIP 470 5% 1/10W
R203 1-216-833-11 METAL CHIP 10K 5% 1/10W
R205 1-216-837-11 METAL CHIP 22K 5% 1/10W
R206 1-216-833-11 METAL CHIP 10K 5% 1/10W
R207 1-216-837-11 METAL CHIP 22K 5% 1/10W
R208 1-216-849-11 METAL CHIP 220K 5% 1/10W
R209 1-216-845-11 METAL CHIP 100K 5% 1/10W
R210 1-216-845-11 METAL CHIP 100K 5% 1/10W
R211 1-216-849-11 METAL CHIP 220K 5% 1/10W
R212 1-216-821-11 METAL CHIP 1K 5% 1/10W
R213 1-216-821-11 METAL CHIP 1K 5% 1/10W
R215 1-216-837-11 METAL CHIP 22K 5% 1/10W
R216 1-216-841-11 METAL CHIP 47K 5% 1/10W
R301 1-216-821-11 METAL CHIP 1K 5% 1/10W
R308 1-216-821-11 METAL CHIP 1K 5% 1/10W
R309 1-216-837-11 METAL CHIP 22K 5% 1/10W
R310 1-216-837-11 METAL CHIP 22K 5% 1/10W
R311 1-216-837-11 METAL CHIP 22K 5% 1/10W
R312 1-216-849-11 METAL CHIP 220K 5% 1/10W
R401 1-216-821-11 METAL CHIP 1K 5% 1/10W
R402 1-216-857-11 METAL CHIP 1M 5% 1/10W
R403 1-216-817-11 METAL CHIP 470 5% 1/10W
R404 1-216-825-11 METAL CHIP 2.2K 5% 1/10W
R405 1-216-821-11 METAL CHIP 1K 5% 1/10W
R406 1-216-825-11 METAL CHIP 2.2K 5% 1/10W
R407 1-216-821-11 METAL CHIP 1K 5% 1/10W
R408 1-216-821-11 METAL CHIP 1K 5% 1/10W
R409 1-216-817-11 METAL CHIP 470 5% 1/10W
R411 1-216-809-11 METAL CHIP 100 5% 1/10W
R412 1-216-813-11 METAL CHIP 220 5% 1/10W
R413 1-216-853-11 METAL CHIP 470K 5% 1/10W
R414 1-216-857-11 METAL CHIP 1M 5% 1/10W
R415 1-216-849-11 METAL CHIP 220K 5% 1/10W
R416 1-216-833-11 METAL CHIP 10K 5% 1/10W
R417 1-216-841-11 METAL CHIP 47K 5% 1/10W
R418 1-216-841-11 METAL CHIP 47K 5% 1/10W
R419 1-216-821-11 METAL CHIP 1K 5% 1/10W
R420 1-216-817-11 METAL CHIP 470 5% 1/10W
R501 1-216-841-11 METAL CHIP 47K 5% 1/10W
R502 1-216-845-11 METAL CHIP 100K 5% 1/10W
R503 1-216-845-11 METAL CHIP 100K 5% 1/10W
R504 1-216-833-11 METAL CHIP 10K 5% 1/10W