sony_wm-ex631.pdf

WM-EX631 AEP Model UK Model E Model Chinese Model Tourist Model SERVICE MANUAL CASSETTE PLAYER SPECIFICATIONS Model Name Using Similar MechanismWM-EX621 Tape Transport Mechanism TypeMT-WMEX610-162 Ver 1.0 2002. 10 Sony Corporation Personal Audio Company Published by Sony Engineering Corporation 9-874-181-01 2002J1600-1 2002.10 Frequency response Playback: 30 - 18 000 Hz Output Headphones (i jack) Load impedance 8 - 300 Power requirements 1.5 V Rechargeable battery One R6 (size AA) battery Dimensions (w/h/d) Approx. 77.1 108.1 20.4 mm (excl. projecting parts and controls) Mass Approx. 142 g (main unit only) Supplied accessories Battery case (1) AC power adaptor (1) Charging stand (1) Stereo headphones or earphones with remote control (1) Rechargeable battery (NH-10WM, 1.2 V, 900 mAh (MIN), Ni-MH) (1) Carrying pouch (1) Rechargeable battery carrying case (1) AC plug adaptor (1) (“Sony world model” only) Design and specifications are subject to change without notice. TABLE OF CONTENTS Notes on chip component replacement Never reuse a disconnected chip component. Notice that the minus side of a tantalum capacitor may be damaged by heat. Flexible Circuit Board Repairing Keep the temperature of soldering iron around 270C 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. Unleaded solder Boards requiring use of unleaded solder are printed with the lead free mark (LF) indicating the solder contains no lead. (Caution: Some printed circuit boards may not come printed with the lead free mark due to their particular size.) : LEAD FREE MARK Unleaded solder has the following characteristics. Unleaded solder melts at a temperature about 40C higher than ordinary solder. Ordinary soldering irons can be used but the iron tip has to be applied to the solder joint for a slightly longer time. Soldering irons using a temperature regulator should be set to about 350C. Caution: The printed pattern (copper foil) may peel away if the heated tip is applied for too long, so be careful! Strong viscosity Unleaded solder is more viscous (sticky, less prone to flow) than ordinary solder so use caution not to let solder bridges occur such as on IC pins, etc. Usable with ordinary solder It is best to use only unleaded solder but unleaded solder may also be added to ordinary solder. SAFETY-RELATED COMPONENT WARNING! COMPONENTS IDENTIFIED BY MARK 0 OR DOTTED LINE WITH MARK 0 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. WM-EX631 2 Notes on the AC power adaptor Use only the supplied AC power adaptor. Do not use any other AC power adaptor. Connect the AC power adaptor to an easily accessible AC outlet. Should you notice an abnormality in the AC power adaptor, disconnect it from the AC outlet immediately. Do not touch the AC power adaptor with wet hands. Polarity of the plug 1. SERVICE NOTE3 2. GENERAL 5 3. DISASSEMBLY 3-1. Case Sub Assy 6 3-2. Main Board 7 3-3. Belt (F4) 7 3-4. Motor (Capstan/Reel) (M901) 8 3-5. Lid Assy, Cassette 8 3-6. Ornament, Reel 9 3-7. Holder (FS) Assy 9 3-8. Lever (N)/(R) Assy, Pinch 10 3-9. Head, Magnetic (HP901) 10 4. MECHANICAL ADJUSTMENT 11 5. ELECTRICAL ADJUSTMENT 11 6. DIAGRAMS 6-1. Block Diagram 12 6-2. Note For Printed Wiring Boards and Schematic Diagrams 13 6-3. IC Block Diagrams 13 6-4. Schematic Diagram MAIN Board 14 6-5. Printed Wiring Board MAIN Board 15 6-6. IC Pin Function 16 7. EXPLODED VIEWS 7-1. Cabinet Block 17 7-2. Main Board Block 18 7-3. Mechanism Block 1 (MT-WMEX610-162) 19 7-4. Mechanism Block 2 (MT-WMEX610-162) 20 8. ELECTRICAL PARTS LIST 21 WM-EX631 3 SECTION 1 SERVICE NOTE Service Mode The service mode enables to operate the mechanism of WM-EX631 while the MAIN board is opened. Rotation of the idler gear (A) (S side) is detected using the photo- reflector (PH701) in the WM-EX631. PH701 is located on the MAIN board, therefore the rotation of the idler gear (A) (S side) cannot be detected by PH701 when the MAIN board is removed. As a result, the motor cannot be controlled and cannot run correctly. To repair the machine after the MAIN board is removed while the main power is turned on, follow the procedures as described below. 1. Setting 1)Remove the cabinets referring to section “3. DISASSEMBLY”. Open the MAIN board. 2)Connect the motor (M901) and the plunger solenoid (PM901) to the MAIN board using the jumper wires. When the extension jig (1-769-143-11) (10 wires as a set) is used, they can be connected easily. 3)Short the TAPE DETECT switch (S901-1) and the ATS switch (S901-2). 4)Connect an AF oscillator to TP53 (P. IN) and TP14 (GND). 5)Connect DC 1.3 V from external regulated power supply to 3 and # terminals of the battery. 2. PRE-SET status The PLAY, FF and REW modes can be entered only from the PRE- SET status. 1)Check that the slider (NR) is in the center position (S701)(See page 4 for illustration), and the FWD/REV switch (S701) is also in the center position. When these switches are not in the center position, set them to the PRE-SET status as follows. 2)Move the FWD/REV switch (S701) to the same position as the slider (NR) is set. 3)The slider (NR) can be moved when the main power of the regulated power supply is turned OFF once then back ON. Move the FWD/REV switch (S701) to the center position in synchronism with the timing when the slider (NR) is moved. 3. FF, REW modes 1)Check that the PRE-SET status is set. 2)Connect square wave or sine wave to TP53 (P. IN) and TP14 (GND). (See illustration below) 3)Press the x switch (S703) to enter the STOP mode. 4)Press the FF/CUE switch (S705) or REW/REVIEW switch (S706). 4. PLAY mode 1)Check that the PRE-SET status is set. 2)Connect square wave or sine wave to TP53 (P. IN) and TP14 (GND). (See illustration below) 3)Press the x switch (S703) to enter the stop mode. 4)When the nN switch (S704) of the MAIN board is pressed, the slider (N/R) moves once to the F side then moves to the R side. When the FWD/REV switch (S701) is pressed in the synchronism with the above timing, the machine can enter the PLAY (R side) mode. Press the nN switch (S704) again, and move the FWD/REV switch (S701) in the synchronism with the motion of slider (NR). It enables the machine to enter into the PLAY (F side) mode. (See page 4 for illustration) Note 1: When you fail to enter the PLAY mode, re-start from step 2) PRE-SET status. Note 2: Regarding the nN (S704), x (S703), FF/CUE (S705) and REW/REVIEW (S706) switches, use these switches of the remote control unit as much as possible. Note 3: If a headphones are used, the beep sound shows the timing of the FWD/REV switch (S701). MAIN BOARD (SIDE B) TAPE DETECT SWITCH (S901-1) ATS SWITCH (S901-2) Short Plunger (PM901) AF OSC Battery terminal # Battery terminal 3 TP14 (GND) S701 FWD STOP REV YREPEAT (S704) x(S703) REW/REVIEW (S706) FF/CUE (S705) PH701 M901 TP53 (P.IN) Square-wave (sine wave) 10 Hz, -3.5 dB M WM-EX631 4 Slider (NR) Tape drive mechanism Tape drive mechanism in PLAY mode Tape drive mechanism in FF modeTape drive mechanism in REW mode Insert Flywheel (N) Insert Flywheel (R) Pulley (Reverse) Clutch Assy (F) Gear (Y) Cam Gear Gear (REEL) (S side) Motor Pulley Idler Gear (A) (S side) Gear (FR) (REW:Right side) Insert Flywheel (N) Insert Flywheel (R) Pulley (Reverse) Clutch Assy (F) Gear (Y) Cam Gear Gear (REEL) (T side) Motor Pulley Idler Gear (A) (T side) Gear (FR) (FF:Left side) Insert Flywheel (N)Insert Flywheel (R) Pulley (Reverse) Clutch Assy (F) Idler Gear (B) Gear (Y) Cam Gear Gear (REEL) (T side) Gear (REEL) (S side) Motor Pulley Idler Gear (A) (T side)Idler Gear (A) (S side) Gear (NR) (FWD:Left side REV:Right side) Slider (NR) F side R side Center WM-EX631 5 SECTION 2 GENERAL This section is extracted from instruction manual. REV FWD Plug in firmly. VOL REW () HOLD FF (+) SPEED CONTROL x HOLD VOL* YREPEAT* OPEN SOUND MODE Yx* REW/REVIEWAMS FF/CUEAMS *There is a tactile dot beside VOL on the main unit to show the direction to turn up the volume. * The button has a tactile dot. WM-EX631 6 SECTION 3 DISASSEMBLY Note : Follow the disassembly procedure as shown in the flow chart below. 3-1. Case Sub Assy Note : Follow the disassembly procedure in the numerical order given. CASE SUB ASSY LID ASSY, CASSETTE ORNAMENT, REEL BELT (F4) HOLDER (FS) ASSY MAIN BOARD HEAD, MAGNETIC (HP901) LEVER (N)/(R) ASSY, PINCH MOTOR (CAPSTAN/REEL) (M901)SET 1 lid,battery case 2 screw (M1.4 2.5) 3 two screws (M1.4 2.5) 4 two screws (M1.4 2.5) 5 Remove the case sub assy in the direction of the arrow. claw S707 knob (HOLD) Note : When assembling the case sub assy,align the knob (HOLD) with the position of S707. WM-EX631 7 3-2. MAIN Board 3-3. Belt (F4) SLIDER Note : When assembling the MAIN board, align the slider with the position of S701. 5 Remove soldering (four points) from motor. 4 Remove soldering (two points) from plunger solenoid. 2 Remove soldering (six points) from the head flexible boards. 8 MAIN board 7 screw (M1.4) head flexible board 1 shielded sheet 3 Remove soldering (four points) from the leaf switch. S701 6 two screws 3 belt (F4) motor pulley insert flywheel (R) insert flywheel (N) pulley (reverse) 2 terminal board (battery # ) 1Remove soldering from the battery terminal board. belt (F4) WM-EX631 8 3-4. Motor (Capstan/Reel) (M901) 3-5. Lid Assy, Cassette 2 motor (capstan/reel) (M901) 1 two screws (M1.4) 2 two screws (M1.4 2.0) 2 screw (M1.4 2.0) 4 lid assy, cassette 1 Open the cassette lid. 3 shaft WM-EX631 9 3-6. Ornament, Reel 3-7. Holder (FS) Assy 2 claw 4 two claws 1 two claws 3 boss 5 ornament, reel 9 Remove soldering from six head flexible boards. 0 Remove the holder (FS) assy in the direction of the arrow. 8 shielded sheet 1 two screws (ib lock) 3 lock lever (B) 2 shaft 7 bracket (cassette) assy 6 shaft 4 screw (M1.4) 5 shaft WM-EX631 10 3-8. Lever (N)/(R) Assy, Pinch 3-9. Head, Magnetic (HP901) 1 claw 2 Remove the pinch lever (R) assembly in the direction of the arrow. 4 Remove the pinch lever (N) assembly in the direction of the arrow. holder (FS) assy 3 claw 1 two claws 2 Remove the magnetic head. (HP901) holder (FS) assy 1111 WM-EX631 PRECAUTION 1.Specified voltage: 1.3 V (DC) 2.Switch position HOLD: OFF Test Tape Tape Speed Adjustment Procedure: 1.Enter the FWD playback mode. 2.Adjust RV601 so that the value of the frequency counter reading becomes 3,000 Hz. Specification value: Frequency counter 2,970 Hz 3,030 Hz 3.Check that the frequency deviation at the beginning and ending of a tape is within 1.5 % (45 Hz). Adjustment Point: MAIN BOARD SIDE B PRECAUTION 1.Clean the following parts with a denatured-alcohol-moistened swab: playback headpinch roller rubber beltscapstan 2.Demagnetize the playback head with a head demagnetizer. 3.Do not use a magnetized screwdriver for the adjustments. 4.The adjustments should be performed with the rated power supply voltage unless otherwise noted. Torque Measurement Mode FWD FWD Back Tension REV REV Back Tension FF, REW Torque Meter CQ-102D CQ-102D CQ-102C CQ-102C CQ-201B Meter Reading 14.7 to 24.5 mNm (15 to 25 gcm) (0.22 to 0.34 ozinch) 0.294 to 1.96 mNm (0.3 to 2.0gcm) (0.007 to 0.020 ozinch) 14.7 to 24.5 mNm (15 to 25 gcm) (0.22 to 0.34 ozinch) 0.294 to 1.96 mNm (0.3 to 2.0 gcm) (0.007 to 0.020 ozinch) More than 34.3 mNm (More than 35 gcm) (More than 0.69 ozinch) SECTION 4 MECHANICAL ADJUSTMENT SECTION 5 ELECTRICAL ADJUSTMENT 3 RV601 Signal 3 kHz, 0 dB Used for Tape Speed Adjustment Tape WS-48A Test tape WS-48A (3kHz, 0dB) Set i REMOTE jack (J301) 16 Frequency counter + MEMO Waveforms 2.8 Vp-p 11 sec 1.3 Vp-p 30.5 sec 1 IC701 wk (XT0) 2 IC702 4 (LX) 1212 WM-EX631 6-1. Block Diagram SECTION 6 DIAGRAMS + PREAMP AMS AGC DET BEEP V/I EQ METAL CONTROL SPEED CONTROL DIRECTION CONTROL PHOTO REFLECTOR SWITCH & BUFFER Q702 PLUNGER DRIVE Q701 AVLS CONTROL SWITCH Q304 MEGA BASS/GROOVE SWITCHING Q303 RIPPLE FILTER Q301 RESET SIGNAL GENERATOR IC703 REGULATOR IC704 Q604 MOTOR CONTROL SWITCH ROTATION DETECT SENSOR PH701 CAPSTAN/REEL MOTOR DRIVE IC601 SYSTEM CONTROLLER IC701 M901 BATT B+ (CAPSTAN/REEL) HP901 (PLAYBACK) AUDIO MASTER AMP IC301 SIGNAL PATH : PLAYBACK R-ch is omitted due to same as L-ch. MOTOR DRIVE CIRCUIT SWITCH & LOGIC CIRCUIT BIAS REFERENCE VOLTAGE OSC CIRCUIT REVIVE/GROOVE SWITCHING Q302 DC/DC CONVERTER IC702 DRY BATTERY SIZE “AA” (IEC DESIGNATION R6) 1PC. 1.5V BATTERY PACK (NI-CD) (NC-10WM 1.2V) VDD B+ DDC B+ BATT B+ BATT B+X701 32.768kHz Q603 CUE/REVIEW SWITCH Q605 FF/REW CTL SWITCH TH601 TAPE SPEED RV601 SPEED CONTROL RV602 FAST SLOW START VREF IN+ COMPARATOR VSP OUT VCC DATA REMOTE GND BATT B+ BATT B+ BASE PW OUT-L PW OUT-R PW OUT-C POWER AMP POWER AMP POWER AMP PW NF-L BASS BOOST AMP PW IN-L PW IN-C BST OUT VOL RV301 HOLD S707 i J301 S901-2 (ATS) PRE OUT-L MTL DRV-L FWD IN-L REV IN-L L-CH R-CH FWD L-CH R-CH REV R-CH R-CH R-CH R-CH R-CH R-CH R-CH R-CH S701 (DIRECTION) OSC RESTART MOTOR MOTOR DIR AMS OUT F/R SW M/N SW 35 8 7 5 DR 6 10 9 11 W 3 V 1 U WV U 19 48 XT0 28 XT1 2946 18 VCC 19 RF OUT 17 20 22 21 29 EQ-L 30 40 BST SW 43 AGC IN 35 BEEP 39 28 32 33 AMS IN 12 7 8 4644 F/R CTL 9 CASSETTE SW 5 REV SW 4 CENTER SW 3 FWD SW 2 AUDIO ATT AVLS CTL 38 R-CH 47 MEGA BASS CTL 8 AMS IN 39 BOOST CTL 10 REVIVE CTL FF/REW CTL 7 1 SPEED CTL 44 MOTOR CTL 45 VDD 23 SET STOP 1 13 BEEP 36 MT SW 41 MUTE CTL 19 PW SW 42 AMP CTL 11 DATA/RMUM 6 KEY IN 16 HOLD 12 K2 (IN 2) 43 KO1 (OUT 1) 40 KO2 (OUT 2) 41 K1 (IN 1) 42 1 5 S901-1 (TAPE DETECT) + + + FWD STOP REV OFFON IN PHOTO37 PHOTO CTL18 PM CTL PM901 (PLUNGER) 17 DDC B+ DDC B+ SET STOP 2 14 BATT DET 15 SPCON C 20 RESET + CUE REVIEW VOLUME SWITCH Q306 S706 REW/REVIEW S703 x S704 Y S705 AMS FF/CUE 1313 WM-EX631 Note on Printed Wiring Board: X : parts extracted from the component side. Y : parts extracted from the conductor side. a: Through hole. : Pattern of the rear side. Caution: Pattern face side:Parts on the pattern face side seen from (SIDE B)the pattern face are indicated. Parts face side:Parts on the parts face side seen from (SIDE A)the parts face are indicated. 6-2. Note For Printed Wiring Board and Schematic Diagram. Note on Schematic Diagram: All capacitors are in F unless otherwise noted. pF: F 50 WV or less are not indicated except for electrolytics and tantalums. %: indicates tolerance. C : panel designation. Y : B+ Line. H : adjustment for repair. Power voltage is dc 1.5V and fed with regulated dc power supply from battery terminal. no mark : PB Waveforms are taken with a oscilloscope. Voltage variations may be noted due to normal produc- tion tolerances. Signal path. E: PB 6-3. IC Block Diagrams PRE APRE B MIX PW B PW A PW C BST MT TC BASE RF IN PW GND OUT B OUT C OUT A VCC RF OUT