Sony TC-WE635 Service Manual
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Sony TC-WE635 Service Manual

Stereo cassette deck
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SERVICE MANUAL
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.
MICROFILM
TC-WE635
Model Name Using Similar Mechanism
Transport Mechanism Type
SPECIFICATIONS
STEREO CASSETTE DECK
– 1 –
US Model
Canadian Model
AEP Model
UK Model
E Model
Australian Model
Chinese Model
TC-WE425/WE525/WR681
TCM-230ASR4/HSR4
— Continued on next page —

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  • Page 1 TC-WE635 SERVICE MANUAL US Model Canadian Model AEP Model UK Model E Model Australian Model Chinese Model Dolby noise reduction extension manufactured under license Model Name Using Similar Mechanism TC-WE425/WE525/WR681 from Dolby Laboratories Licensing Corporation. Transport Mechanism Type TCM-230ASR4/HSR4 HX Pro originated by Bang & Olufsen. “DOLBY”, the double-D symbol a and “HX PRO”...
  • Page 2 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.

  • Page 3: Table Of Contents

    MODEL IDENTIFICATION TABLE OF CONTENTS 1. GENERAL –Back panel– ................4 2. DISASSEMBLY 2-1. Case ..................5 Part No. 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.

  • Page 4: General

    SECTION 1 GENERAL Front Panel 33 32 23 21 LOCATION OF PARTS AND CONTROLS 22 REC MUTING R (Deck B) button 1 U button 23 PAUSE P (Deck B) button 2 RESET (Deck A) button 24 p (Deck B) button 3 MEMORY (Deck A) button 25 DOLBY NR B/C switch 4 RESET (Deck B) button...

  • Page 5: Disassembly

    SECTION 2 DISASSEMBLY Note : Follow the disassembly procedure in the numerical order given. 2-1. CASE 4 Case 3 Two Screws (Case 3 TP2) 1 Screw (BVTP 3x8) 2 Two Screws (Case 3 TP2) 2-2. FRONT PANEL ASSEMBLY 1 CN5802 2 CN807 3 CN803 !¡...

  • Page 6: Cassette Lid Assembly (Deck A/B)

    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 –...

  • Page 7: Leaf Sw (Rec/Pb) Board (Deck A/B)

    2-5. LEAF SW (REC/PB) BOARD (DECK A/B) 1 Two screws (PS 2.6x6) 5 Screw 2 Capstan motor assy (BVTT 2x4) 4 Screw (BVTT 2x4) 7 LEAF SW (REC/PB) board 3 Wires 8 Belt (capstan) When installing, pull the belt (capstan) Claws put around claws.

  • Page 8: Pinch Lever (Fwd)/(Rev) Assembly (Deck A/B)

    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...

  • Page 9: Mechanical Block Assembly (Deck A/B)

    2-8. MECHANICAL BLOCK ASSEMBLY (DECK A/B) 2 Two screws 3 Two screws (BVTT 2x3.5) (BVTT 2x3.5) 4 Mechanical block assy 1 Torsion spring 5 Reverse slider 2-9. HEAD RELAY (REC/PB) BOARD (DECK A/B) 3 Tension spring (HEAD) 4 Head deck assy 2 HEAD RELAY (REC/PB) board 1 Screw (BVTT 2x4)

  • Page 10: Service Mode

    SECTION 3 SERVICE MODE KEY CHECK & DISPLAY CHECK MODE While pressing the ª/BACK (A deck) and REC MUTING R (B deck) buttons with the power off, press the U button to turn on the power. The fluorescent display tube displays the number or special message corresponding to the button pressed. The message displayed differs according to the position of the switch.

  • Page 11: Mechanical Adjustments

    SECTION 4 SECTION 5 MECHANICAL ADJUSTMENTS ELECTRICAL ADJUSTMENTS PRECAUTION PRECAUTION 1. Clean the following parts with a denatured alcohol-moistened 1. The adjustment should be performed in the publication. swab : (Be sure to male playback adjustment at first.) record/playback/erase head pinch roller 2.
  • Page 12 Record/Playback Head Azimuth Adjustment Tape speed Adjustment DECK A DECK B DECK A DECK B Adjust DECK A first Procedure: Procedure: 1. Forward Playback Mode – Forward Playback Mode – test tape test tape P-4-A100 WS-48B level meter (10 kHz, –10 dB) (3 kHz, 0 dB) frequency counter 47 k Ω...
  • Page 13 Bias Consumption Current Adjustment Adjustment level: DECK A DECK B The palyback output of 10 kHz level difference against 315 Hz ref- erence should be ± 0.5 dB. This adjustment should be performed when replacing the head assy or the bias oscillator transformer (T131, T141),(T231, T241). Adjustment Location: MAIN board (See page 14.) Record Level Adjustment DECK A...
  • Page 14 Adjustment Location: main board [MAIN board] (Component side) RV221 RV121 PB LEVEL RV101 PB LEVEL DECK B (R) DECK B (L) LEVEL (L) IC551 RV201 IC801 RV111 RV211 PB LEVEL PB LEVEL LEVEL (R) DECK A (L) DECK A (R) BIAS CURRENT DECK B (L) RV202...

  • Page 15: Diagrams

    TC-WE635 SECTION 6 DIAGRAMS 6-1. CIRCUIT BOARDS LOCATION WAVEFORMS THIS NOTE IS COMMON FOR PRINTED WIRING – MAIN SECTION (3/4) – BOARDS AND SCHEMATIC DIAGRAMS. (In addition to this, the necessary note is printed TRANS (A) board ( 4 E) in each block.)

  • Page 16: Printed Wiring Board - Main Section

    TC-WE635 6-2. PRINTED WIRING BOARD – MAIN SECTION – • See page 15 for Circuit Boards Location. (Page 35) (Page 35) (Page 39) (Page 31) (Page 35) (Page 35) (Page 27) (Page 27) (Page 36) • Semiconductor Location Ref. No.

  • Page 17: Schematic Diagram - Main Section - (1/4)

    TC-WE635 6-3. SCHEMATIC DIAGRAM – MAIN (1/4) SECTION – (Page 23) (Page (Page 23) (Page 23) (Page (Page 25) (Page 23) (Page 21) (Page 21) (Page 25) – 19 – – 20 –...

  • Page 18: Schematic Diagram - Main Section - (2/4)

    TC-WE635 6-4. SCHEMATIC DIAGRAM – MAIN (2/4) SECTION – (Page 19) (Page 23) (Page 23) (Page 19) (Page (Page (Page (Page (Page (Page (Page – 21 – – 22 –...

  • Page 19: Schematic Diagram - Main Section - (3/4)

    TC-WE635 6-5. SCHEMATIC DIAGRAM – MAIN (3/4) SECTION – • See page 16 for Waveforms. • See page 17 for Printed Wiring Board. • See page 41 for IC Pin Functions. (Page 33) (Page 34) (Page 30) (Page (Page (Page...

  • Page 20: Schematic Diagram - Main Section - (4/4)

    TC-WE635 6-6. SCHEMATIC DIAGRAM – MAIN (4/4) SECTION – (Page 23, 24) (Page 20) (Page 24) (Page 23) (Page 24) (Page (Page (Page (Page (Page (Page – 25 – – 26 –...

  • Page 21: Printed Wiring Board - Deck Section

    TC-WE635 6-7. PRINTED WIRING BOARD – DECK SECTION – 6-8. SCHEMATIC DIAGRAM – DECK SECTION – • See page 15 for Circuit Boards Location. (Page 17, 18) (Page (Page – 27 – – 28 –...

  • Page 22: Schematic Diagram - Display Section

    TC-WE635 6-9. SCHEMATIC DIAGRAM – DISPLAY SECTION – (Page 23, – 29 – – 30 –...

  • Page 23: Printed Wiring Board - Display Section

    TC-WE635 6-10. PRINTED WIRING BOARD – DISPLAY SECTION – • See page 15 for Circuit Boards Location. (Page 18) • Semiconductor Location Ref. No. Location D904 D905 D906 D906 D907 D908 IC901 IC902 Q901 – 31 – – 32 –...

  • Page 24: Schematic Diagram - Panel Section

    TC-WE635 6-11. SCHEMATIC DIAGRAM – PANEL SECTION – (Page 26) (Page 23) (Page 23) (Page 19) (Page 21) – 33 – – 34 –...

  • Page 25: Printed Wiring Board - Panel Section

    TC-WE635 6-12. PRINTED WIRING BOARD – PANEL SECTION – • See page 15 for Circuit Boards Location. (Page 17) (Page 18) (Page 18) (Page 18) – 35 – – 36 –...

  • Page 26: Schematic Diagram - Power Section

    TC-WE635 6-13. SCHEMATIC DIAGRAM – POWER SECTION – (Page 24) – 37 – – 38 –...

  • Page 27: Printed Wiring Board - Power Section

    TC-WE635 6-14. PRINTED WIRING BOARD – POWER SECTION – • See page 15 for Circuit Boards Location. (Page 18) – 39 – – 40 –...

  • Page 28: Ic Pin Function

    TC-WE635 6-15. IC PIN FUNCTION • IC801 SYSTEM CONTROL (CXP82432A-007Q) (MAIN board) Pin No. Pin Name Function Pin No. Pin Name Function CD SYNC LED SYNCHRO LED driver “L”: ON PLAYSW (B) Play switch input (DECK B) CAP, M2 (B) 70U (B) 70µ...

  • Page 29: Exploded Views

    SECTION 7 EXPLODED VIEWS NOTE: The components identified by • Abbreviation • Items marked “*” are not stocked since they are mark ! or dotted line with mark CND : Canadian model seldom required for routine service. Some delay ! are critical for safety. : Singapore model should be anticipated when ordering these items.

  • Page 30: Chassis Section

    7-2. CHASSIS SECTION US, CND 4 E (Except SP,MY) T901 not supplied AEP, SP, MY not supplied Les composants identifiés par une The components identified by mark ! or dotted line with mark marque ! sont critiques pour la 4 B and 4 E are including into the mounted panel board (Ref. No.163). ! are critical for safety.

  • Page 31: Cassette Holder Section

    7-3. CASSETTE HOLDER SECTION TCM-230ASR4 TCM-230HSR4 TCM-230ASR4 TCM-230HSR4 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark X-3377-097-1 LID (A) ASSY, CASSETTE X-3375-107-1 HOLDER (L) ASSY, CASSETTE X-3376-716-1 LID (B) ASSY, CASSETTE 3-019-454-01 SPRING (L), LOADING 3-931-427-31 BUTTON (EJ) 3-022-410-01 DAMPER 3-019-453-01 LEVER (LOCK R) 3-019-450-01 PLATE (L), FULCRUM...

  • Page 32: Front Panel Section

    X-3376-711-1 PANEL ASSY, FRONT (EXCEPT US,CND) 3-931-429-41 BUTTON (POWER) X-3376-762-1 PANEL ASSY, FRONT (US,CND) 3-021-239-01 KNOB (REC) 3-380-952-21 BUTTON 4-996-698-41 EMBLEM, SONY 3-931-378-01 KNOB (F10) 4-977-593-01 RING (DIA. 50), ORNAMENTAL (EXCEPT US,CND) 1-769-950-11 WIRE (FLAT TYPE)(11 CORE) * 163 A-2007-812-A PANEL BOARD, COMPLETE (EXCEPT SP,MY)

  • Page 33: Tape Mechanism Section (Tcm-230Asr4/Hsr4)

    7-5. TAPE MECHANISM SECTION (TCM-230ASR4/HSR4) M1001 (Deck A) M1002 (Deck B) Deck B HRPE1 (Deck A) Deck A HRPE2 (Deck B) Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark 3-016-574-11 SPRING (HEAD), TENSION 3-016-575-11 SPRING, TORSION X-3374-156-1 PINCH LEVER (REV) ASSY X-3376-933-1 FLYWHEEL (REV) ASSY * 203...

  • Page 34: Electrical Parts List

    HEAD RELAY (REC/PB) SECTION 8 ELECTRICAL PARTS LIST LEAF SW (REC/PB) MAIN Note: • SEMICONDUCTORS When indicating parts by reference In each case, u: µ , for example: number, please include the board uA...: µ A..., uPA...: µ PA..., uPB...: µ PB..., name.
  • Page 35 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C208 1-130-495-00 MYLAR 0.1uF C442 1-136-173-00 FILM 0.47uF C443 1-130-299-00 FILM 0.012uF C209 1-137-375-11 FILM 0.068uF C444 1-137-436-11 FILM 0.0039uF 5% C210 1-126-964-11 ELECT 10uF C445 1-137-436-11 FILM 0.0039uF 5% C211 1-126-959-11 ELECT...
  • Page 36 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < DIODE > < FILTER > D306 8-719-911-19 DIODE 1SS119-25 LPF101 1-233-271-11 FILTER, LOW PASS D307 8-719-911-19 DIODE 1SS119-25 LPF201 1-233-271-11 FILTER, LOW PASS D318 8-719-911-19 DIODE 1SS119-25 D351 8-719-911-19 DIODE 1SS119-25 <...
  • Page 37 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark Q801 8-729-029-66 TRANSISTOR DTC114ESA R212 1-247-807-31 CARBON 1/4W < RESISTOR > R213 1-247-882-11 CARBON 130K 1/4W R214 1-247-850-11 CARBON 6.2K 1/4W R101 1-249-429-11 CARBON 1/4W R215 1-249-433-11 CARBON 1/4W R102 1-247-887-00 CARBON...
  • Page 38 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R364 1-249-425-11 CARBON 4.7K 1/4W F R571 1-249-418-11 CARBON 1.2K 1/4W F R371 1-249-417-11 CARBON 1/4W F R572 1-249-426-11 CARBON 5.6K 1/4W R372 1-249-429-11 CARBON 1/4W R573 1-249-427-11 CARBON 6.8K 1/4W F...
  • Page 39 The PANEL board is composed of following boards. MAIN PANEL (TRANS (A), TRANS (B), DIRECTION, H.P, POWER and RECVOL BOARD) Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R832 1-249-429-11 CARBON 1/4W < TRANSFORMER > R833 1-249-421-11 CARBON 2.2K 1/4W F...
  • Page 40 PANEL Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < IC > < VARIABLE RESISTOR > IC901 8-749-014-66 IC NJL56H400A RV901 1-225-707-11 RES, VAR, CARBON 20K IC902 8-759-547-59 IC M35500BGP RV902 1-225-619-11 RES, VAR, CARBON 10K <...
  • Page 41 Ref. No. Part No. Description Remark ! 53 1-777-107-11 CORD, POWER (AEP) ! 53 1-777-218-11 CORD, POWER (AUS) ! 53 1-783-108-11 CORD, POWER (CH) ! 53 1-783-531-51 CORD, POWER (US) 1-769-950-11 WIRE (FLAT TYPE)(11 CORE) FLT901 1-517-263-11 INDICATOR TUBE, FLUORESCENT HRPE1 A-2004-646-C DECK ASSY, HEAD (RECORD/PLAYBACK/ERASE)(DECK A)
  • Page 42 TC-WE635 Sony Corporation 99C0990-1 Printed in Japan © 1999. 3 9-928-828-11 Home A&V Products Company Published by Quality Assurance Dept. – 56 – (Shinagawa)

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