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ICF-R40
SERVICE MANUAL
Ver 1.0 1999. 03
Tourist Model
SPECIFICATIONS
FM/AM RADIO
MICROFILM
SECTION 1 GENERAL
HOW TO CHANGED THE CERAMIC FILTERS This model is used two ceramic filters of CF2 and CF3. You must used same type of color marked ceramic filters in order to meet same specifications. Therefore, the ceramic filter must changed two pieces together since it's supply two pieces in one package as a spare parts.
Mark Center frequency
This section is extracted from instruction manual.
CF2 mark
red blue orange
10.70 MHz 10.67 MHz 10.73 MHz 10.64 MHz 10.76 MHz
CF3
black white
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.
2
SECTION 2 DISASSEMBLY
Note: Follow the disassembly procedure in the numerical order given.
CABINET (REAR)
B 1 Pull out the ear receiver. 2 Open the "lid, battery case" in the direction of arrows A to B.
3 two screws (DIA. 1.4 × 4)
A
9 claw !¡ Remove two solders of reel assy. !º claw
8 claw
!TM cabinet (rear) 7 claw 9 claw 8 claw 6 claw
knob (earphone/spaeker)
C
S1
4 screw (M1.7 × 10) 7 claw
6 claw
5 First, insert the flat-blade screwdriver into the cabinet and turn it in the direction of the arrow C to release two claws 6. Next, release all claws from 7 to 0 in numerical order. Note: Hold a cloth to the cabinet not to be damaged.
Note: On installation of cabinet (rear), adjust the knob (earphone/speaker) and S1.
MAIN BOARD
1 knob (power) 2 knob (noise cut) 4 Remove two solders of speaker leads.
3 knob (2 band)
5 MAIN board
3
REEL ASSY
2 three screws (B1.4 × 3)
4 reel assy
1 blind plate
3 Draw the ear receiver in the direction of the arrow.
4
SECTION 3 DIAL POINTER SETTING
Note: Follow the assembly procedure in the numerical order given. 4 knob (tune)
1 Insert the pointer in the groove of cabinet (front) assy and slide in the direction of the arrow A. 3 gear (midway)
A
pointer
2 Set the tip of pointer to the marking of cabinet (front) assy.
marking
the tip of pointer cabinet (front) assy
cabinet (front) assy
8 Rotate the gear (tuning capacitor) fully in the direction of the arrow C.
7 screw 9 MAIN board Note: On installation of MAIN board, (1.7 × 3) set the outline of gear (tuning capacitor). boss
6 To install the gear fixing each oval shape, set the boss of the gear (tuning capacitor) as the figure.
oval
5 Rotate the tuning capacitor shaft fully in the direction of the arrow B.
B C
cabinet (front) assy
5
SECTION 4 ELECTRICAL ADJUSTMENTS
0 dB=1 µV [FM] Setting: POWER switch: AUTO OFF Band switch: FM Output select switch: @ (earphone)
FM RF signal generator TP (FM IN) 16 set 22.5 kHz frequency deviation by 400 Hz signal Output level: as low as possible +
@(earphone) jack (J1) T1 FM FREQUENCY COVERAGE ADJUSTMENT Adjust for a maximum reading on level meter. L3 CT1-3 75 MHz 109.5 MHz
FM TRACKING ADJUSTMENT Adjust for a maximum reading on level meter. L2 CT1-4 75 MHz 109.5 MHz AM IF ADJUSTMENT Adjust for a maximum reading on level meter. 455 kHz
level meter
0.01 µF
AM FREQUENCY COVERAGE ADJUSTMENT Adjust for a maximum reading on level meter. L4 CT1-1 515 kHz 1,650 kHz
[AM] Setting: POWER switch: AUTO OFF Band switch: AM Output select switch: @ (earphone)
AM RF signal generator Put the lead-wire antenna close to the set. 16 set +
AM TRACKING ADJUSTMENT Adjust for a maximum reading on level meter. L1 CT1-2 600 kHz 1,400 kHz
level meter
30% amplitude @(earphone) jack (J1) modulation by 400 Hz signal Output level: as low as possible
· Repeat the procedures in each adjustment several times, and the frequency coverage and tracking adjustments should be finally done by the trimmer capacitors. Adjustment Location:
MAIN BOARD (Component Side)
AM Frequency Coverage Adjustment FM Frequency Coverage Adjustment
CT1-1 CT1-3 L3 CT1-2 L1
TP (FM IN)
J1 @ (earphone) jack
AM Tracking Adjustment
CT1-4 L2
FM Tracking Adjustment
L4
AM Frequency Coverage Adjustment
T1
AM IF Adjustment
6
ICF-R40 SECTION 5 DIAGRAMS
5-1. BLOCK DIAGRAM
· SIGNAL PATH : FM : AM
CT1-4, L2 FM TRACKING L2 FM RF CT1-4 CV1-4 CV1 TUNE FM RF IN 10 FM RF FM/AM FRONT-END, FM/AM IF AMP, DET, AGC, AF AMP IC1 5 CF2 10.7MHz 15 CF3 10.7MHz T1 11 AM ANT AM IF AM FRONT-END CF1 455kHz 17 CT1-2 CT1-2, L1 AM TRACKING TUNING METER CV1-2 AM OSC FM OSC METER AM IF AM IF AMP, AGC, DET BAND 16 S4 BAND VCC 27 REG 9 B+ 3 18 VOL EP1 (EARPHONE) RV1 VOL J1 @ (EARPHONE)
13
FM FRONT-END
+
MIX OUT
FM IF
FM IF AMP
+
DET
24
BAND-PASS FILTER Q2 S5
25
AF IN
AF POWER AMP
AF OUT
28
SP1 (SPEAKER) S1 @/TM EARPHONE SPEAKER
L1 AM FERRITE-ROD ANTENNA
DISCRI
FM DISCRIMINATOR
Q1 TONE CONTROL SWITCH
NOISE CUT ON OFF
FM AM
6
8
20
CT1-1, L4 L4 AM OSC CT1-1 CV1 TUNE CV1-1 CT1-3, L3 FM FREQUENCY COVERAGE L3 FM OSC CT1-3 CV1-3 TIMER IC2 ON OFF S2 POWER SET CHATTERING PROTECTOR 7 OUT 8 VDD 13 COUNTER OSC C33, R15 17 OSC1 OSC3 CR OSCILLATOR FM/AM TUNER (IC1) B+ B+ SWITCH Q3 AM FREQUENCY COVERAGE D2 TUNE
B+ (1.25V)
DRY BATTERY SIZE "AAA" (IEC DESIGNATION R03) 2PCS. 3V
6 D5 5
AUTO OFF
RESET
CONTROL
05
7
8
ICF-R40
5-2. PRINTED WIRING BOARD
· Semiconductor Location
Ref. No. D1 D2 D5 IC1 IC2 Q1 Q2 Q3 Location C-3 B-1 B-3 F-2 B-3 C-2 C-2 B-3
Note on Printed Wiring Board: · X : parts extracted from the component side. · Y : parts extracted from the conductor side. · W : indicates side identified with part number. r · : Through hole. ¢ · : internal component. · b : Pattern from the side which enables seeing. (The other layers' patterns are not indicated.) Caution: Pattern face side: (Conductor Side) Parts face side: (Component Side) Parts on the pattern face side seen from the pattern face are indicated. Parts on the parts face side seen from the parts face are indicated.
9
10
ICF-R40
5-3. SCHEMATIC DIAGRAM
· IC Block Diagrams IC1 CXA1280N
RIPPLE FILTER
AFC AGC
AFC AGC
AF OUT
METER
GND
VCC
30 29
28 27 26
25
24
23
22
21 20
19
18 17 16
AF POWER AMP
AM IF AMP, DET, AGC TUNING METER FM IF AMP
AM FRONT-END FM DISCRIMINATOR FM FRONT-END
1
2
3
4 5
6
7
8 9 10
11 12 13 14 15
DISCRI
IC2 BU2305F-E2
OSC1
1 23 BIT COUNTER
8 7
VCC OUT
OSC2
2
CHATTERING PROTECTOR
6
SET
OSC3 GND
3 4
CONTROL
5
RESET
Note on Schematic Diagram: · 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 and 1/4 W or less unless otherwise specified. ¢ · : internal component. · C : panel designation. · U : B+ Line. · H : adjustment for repair. · Power voltage is dc 3 V and fed with regulated dc power supply from battery terminal. · Voltages are dc with respect to ground under no-signal (detuned) conditions. no mark : FM ( ) : AM · Voltages are taken with a VOM (Input impedance 10 M). Voltage variations may be noted due to normal production tolerances. · Signal path. F : FM f : AM
11
12
FM RF IN
MIX OUT
AM OSC
FM OSC REG FM RF
GND
AFC
AM ANT
GND
GND
NF VOL
NC
BAND
FM IF
GND
AF IN
GND
DET
NC
AM IF
SECTION 6 EXPLODED VIEW
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 number in the exploded views are not supplied. · Accessories and packing materials are given in the last of the electrical parts list.
MAIN
NOTE: · 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 and -X mean standardized parts, so they may have some difference from the original one. · RESISTORS All resistors are in ohms. METAL: Metal-film resistor. METAL OXIDE: Metal oxide-film resistor. F: nonflammable
SECTION 7 ELECTRICAL PARTS LIST
· Items marked "*" are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items. · SEMICONDUCTORS In each case, u: µ, for example: uA. . : µA. . uPA. . : µPA. . uPB. . : µPB. . uPC. . : µPC. . uPD. . : µPD. . · CAPACITORS uF: µF · COILS uH: µH When indicating parts by reference number, please include the board.
10 9 6
11
rB
12
rC
Ref. No.
Part No.
Description
Remark
Ref. No.
Part No.
Description
Remark
7 8
4A
*
A-3683-046-A MAIN BOARD, COMPLETE ********************* 3-034-346-01 GEAR (TUNING CAPACITOR) 3-034-358-01 COMBINED (BLIND PLATE) (including BLIND PLATE, HOLDER (BAR ANTENNA)) 3-384-797-01 SCREW (1.4X4) 3-880-990-00 SCREW (1.7X3), FLAT, (+) SPECIAL C1 C2 C4 C5 C7 C9 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34 C35 1-162-970-11 1-126-157-11 1-162-919-11 1-162-922-11 1-162-917-11 1-164-275-91 1-162-927-11 1-164-346-11 1-162-970-11 1-164-156-11 1-164-346-11 1-135-151-21 1-126-157-11 1-164-227-11 1-126-157-11 1-164-346-11 1-164-346-11 1-127-569-11 1-124-434-00 1-162-927-11 1-165-176-11 1-164-346-11 1-164-156-11 1-164-227-11 1-164-677-11 1-164-227-11 1-162-964-11 1-164-156-11 1-162-968-11 1-164-156-11 CERAMIC CHIP ELECT CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP TANTALUM CHIP ELECT CERAMIC CHIP ELECT CERAMIC CHIP CERAMIC CHIP TANTAL. CHIP ELECT CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP CERAMIC CHIP 0.01uF 10uF 22PF 39PF 15PF 9PF 100PF 1uF 0.01uF 0.1uF 1uF 4.7uF 10uF 0.022uF 10uF 1uF 1uF 100uF 220uF 100PF 0.047uF 1uF 0.1uF 0.022uF 0.033uF 10% 20% 5% 5% 5% 5% 5% 10% 25V 16V 50V 50V 50V 50V 50V 16V 25V 25V 16V 4V 16V 25V 16V 16V 16V 4V 4V 50V 16V 16V 25V 25V 16V 25V 50V 25V 50V 25V 16V CF1 CF2 CF3
25
rD
1-567-177-00 FILTER, CERAMIC (455kHz) 1-579-632-51 FILTER, CERAMIC (10.7MHz) 1-579-632-51 FILTER, CERAMIC (10.7MHz)
24 4 23 3 5 15 16 17 18
14
CT1 CV1
1-141-607-11 CAP, VAR 1-141-607-11 CAP, VAR (TUNE)
(including rB, rC, rD) L1
13
D1 D2 D5
8-719-800-76 DIODE 1SS226 8-719-062-42 LED BR1111R-TR (TUNE) 8-719-046-91 DIODE MA2S111
2
SP1
21 20
(including 4 A)
IC1 IC2
8-752-036-29 IC CXA1280N 8-759-583-17 IC BU2305F-E2
19
20% 20% 10% 20%
J1
1-785-506-11 JACK (@)
1
22
Remark Ref. No. 14 15 16 17 * 18 19 20 21 22 23 24 25 L1 SP1 Part No. 3-910-816-01 3-034-212-01 3-034-210-01 3-034-211-01 A-3683-046-A Description SCREW (M1.7x10) TERMINAL (+/), BATTERY TERMINAL (+), BATTERY TERMINAL (), BATTERY MAIN BOARD, COMPLETE Remark
Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13
Part No. A-3638-700-A 3-034-344-01 3-034-347-01 3-034-348-01 3-895-823-11 A-3638-697-A 3-032-525-01 3-032-492-01 3-034-341-21 3-034-349-01
Description CABINET (FRONT) ASSY POINTER GEAR (MIDWAY) KNOB (TUNE) SCREW (B1.4X3), TAPPING REEL ASSY SCREW PLATE (REWIND) CABINET (REAR) KNOB (POWER)
20% 20% 5% 10%
L1 L2 L3 L4 L5 L7 L8 L11 L12
1-754-049-11 1-419-109-11 1-419-108-11 1-406-255-11 1-412-971-31 1-412-947-11 1-412-947-11 1-412-947-11 1-412-947-11
ANTENNA, FERRITE-ROD (AM) COIL, AIR-CORE COIL, AIR-CORE COIL (OSC) INDUCTOR 0.22uH INDUCTOR INDUCTOR INDUCTOR INDUCTOR 4.7uH 4.7uH 4.7uH 4.7uH
3-034-358-01 COMBINED (BLIND PLATE) (including BLIND PLATE, HOLDER (BAR ANTNNA)) 3-880-990-00 SCREW (1.7X3), FLAT, (+) SPECIAL 3-034-346-01 GEAR (TUNING CAPACITOR) 3-384-797-01 SCREW (1.4X4) 3-036-666-01 SPRING (ELECTROSTATIC) 9-911-816-01 3-831-441-99 1-754-049-11 1-529-187-11 CLOTH, BATTERY PICK CUSHION (A) ANTENNA, FERRITE-ROD (AM) SPEAKER (2.8cm)
10% 10%
3-015-033-01 SCREW (DIA. 1.4X4), PRECISION 3-034-352-01 LID, BATTERY CASE 3-034-357-01 COMBINED (KNOB) (including KNOB (REWIND), KNOB (EARPHONE/ SPEAKER),KNOB (NOISE CUT), KNOB (2 BAND))
0.022uF 10% 0.001uF 10% 0.1uF 0.0047uF 10% 0.1uF 1uF
Q1 Q2 Q3
8-729-037-71 TRANSISTOR UN9210J-(TX).SO 8-729-037-92 TRANSISTOR 2SD2216J-R(TX).SO 8-729-800-71 TRANSISTOR 2SB815B7-TB
1-164-346-11 CERAMIC CHIP
R1 R3 R4
1-216-813-11 METAL CHIP 1-216-845-11 METAL CHIP 1-216-817-11 METAL CHIP
220 100K 470
5% 5% 5%
1/16W 1/16W 1/16W
13
14
MAIN
Ref. No. R5 R6 R7 R8 R9 R10 R11 R12 R13 R15 R16 R17 R18 R19 R20 R30 R31 R32 R33 R34 R35 Part No. Description 47 10K 2.2K 33K 22K 100K 4.7K 4.7K 4.7K 470K 1M 100K 2.2K 47K 1K 1K 1K 3.3K 1K 2.2K 1K 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% 5% Remark 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W 1/16W Ref. No. Part No. Description Remark
1-216-805-11 METAL CHIP 1-216-833-11 METAL CHIP 1-216-825-11 1-216-839-11 1-216-837-11 1-216-845-11 1-216-829-11 1-216-829-11 1-216-829-11 1-216-853-11 1-216-857-11 1-216-845-11 1-216-825-11 1-216-841-11 1-216-821-11 1-216-821-11 1-216-821-11 1-216-827-11 1-216-821-11 1-216-825-11 1-216-821-11 METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP METAL CHIP
RV1 1-225-779-11 RES, VAR S1 S2 S4 S5 1-572-922-11 1-762-651-11 1-572-922-11 1-572-922-11 SWITCH, SLIDE (@/TM) SWITCH, SLIDE (POWER) SWITCH, SLIDE (BAND) SWITCH, SLIDE (NOISE CUT) T1 1-404-444-31 TRANSFORMER, IF ************************************************************ MISCELLANEOUS ************* 6 A-3638-697-A REEL ASSY SP1 1-529-187-11 SPEAKER (2.8cm) ************************************************************ ACCESSORIES & PACKING MATERIALS ******************************* 3-036-916-21 CASE, CARRYING 3-865-825-11 MANUAL, INSTRUCTION (JAPANESE,ENGLISH,KOREAN,CHINESE) 20K (VOL)
15
ICF-R40
Sony Corporation
9-926-942-11
Parsonal A&V Products Company
16
99C05031-1 Printed in Japan © 1999. 3 Published by Quality Engineering Dept. (Shinagawa)