Sony ICF-403S User manual

Ver 1.0 1999.08
MICROFILM
ICF-403S
SERVICE MANUAL
FM/MW/SW 3 BAND RADIO
SPECIFICATIONS
AEP Model
E Model
Australian Model
Saudi Arabia model
AEP, Australian model

– 2 –
Specifications ........................................................................... 1
1. GENERAL
Location and Function of Controls .................................... 2
2. DISASSEMBLY
2-1. Cabinet (Rear)............................................................. 3
2-2. Cabinet (Front) ........................................................... 3
2-3. Main Board, Chassis................................................... 4
3. DIAL POINTER INSTALLATION ........................... 5
4. ELECTRICAL ADJUSTMENTS............................. 6
5. DIAGRAMS
5-1. Printed Wiring Boards ................................................ 7
5-2. Schematic Diagram..................................................... 9
6. EXPLODED VIEWS ...................................................11
7. ELECTRICAL PARTS LIST................................... 13
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
• Never reuse a disconnected chip component.
• Notice that the minus side of a tantalum capacitor may be dam-
aged by heat.
TABLE OF CONTENTS
SECTION 1
GENERAL
Earphone jack (@)
DC IN 4.5V
LOCATION AND FUNCTION OF CONTROLS

– 3 –
SECTION 2
DISASSEMBLY
Note : Follow the disassembly procedure in the numerical order given.
2-1. CABINET (REAR)
2-2. CABINET (FRONT)
rThe equipment can be removed using the following procedure.
Cabinet (Front)
Cabinet (Rear)
Set Main board, Chassis
1 Screw
+P 2.6x8
Cabinet (front
)
Black (–)
Brown
(+)
Chassis
Main board
2 Remove solder
3
Black (–)
Brown (+)
1 Screws
+BTP 3x12
4 Screw
+P 2.6x8
3
Lug, 3
Cabinet (rear)
Cabinet (front)
2 Claws
1 Screws
+BTP 3x12

– 4 –
2-3. MAIN BOARD, CHASSIS
2 Claws
4 Knob(tune
)
3

1
Screw
+P 2.6x8
Chassis
Main board

– 5 – – 6 –
SECTION 3
DIAL POINTER INSTALLATION
Note : Follow the installation procedure in the numerical order given.
1 Rack
6

Rack
5 Knob (tone)
5
3
Knob (tune)
2 Pointer
Chassis
Chassis
4 Scribed line
Claws
Main board
S2
1Insert the rack into the chassis groove.
2Install the pointer.
3Install the knob (tune).
4Slide the rack and align it with the groove on the scribed
line.
5Align the knob (tone) and the S2.
6Install the chassis to the main board.
1Turn the CV shaft all thye way counterclockwise.
2Set the gear ASSY onto the CV shaft in a
direction as a figure.
3Secure the gear ASSY with screw.
Gear (A),tuning capacitor
4
2
1
3
Stopper
Spring
(gear)
Hole
A Projection
Gear (B),tuning capacitor
B Hole
Spring (gear)
3 Screw (1.7x3)
2 Gear ASSY
1
CV shaf
t
Main board
Knob (tune)
1Put a point of spring (gear) in a hole of “gear (A), tuning
capacitor” and install it.
2Install “gear (B), tuning capacitor” in a direction as a figure.
3Turn the “gear (B), tuning capacitor” till a position of Bfits
A.
4Hang the spring (gear) with a stopper.
SECTION 4
ELECTRICAL ADJUSTMENTS
TUNER SECTION
MW Section
Procedure :
BAND : MW
SW Section
Procedure :
BAND : SW
FM Section
Procedure :
BAND : FM
AM RF signal
generator
30% amplitude modulation by 400Hz
signal.
Output level : as low as possible
Put the lead-wire
antenna close to
the set.
• Repeat the procedures in each adjustment several times, and the
frequency coverage and tracking adjustments should be finally
done by the trimmer capacitors.
< > : Saudi Arabia model
AM IF ADJUSTMENT
Adjust for a maximum reading on level meter.
T1 455kHz
MW FREQUENCY COVERAGE ADJUSTMENT
Adjust for a maximum reading on level meter.
L5 520kHz
CT4 1,650kHz
MW TRACKING ADJUSTMENT
Adjust for a maximum reading on level meter.
L1 620kHz
CT1 1,400kHz
SW FREQUENCY COVERAGE ADJUSTMENT
Adjust for a maximum reading on level meter.
L6 5.8MHz
CT6 18.5MHz
SW TRACKING ADJUSTMENT
Adjust for a maximum reading on level meter.
L2 5.8MHz
CT5 18.5MHz
FM FREQUENCY COVERAGE ADJUSTMENT
Adjust for a maximum reading on level meter.
L4 86.5MHz <87.35MHz>
CT3 109.5MHz <108.25MHz>
FM TRACKING ADJUSTMENT
Adjust for a maximum reading on level meter.
L3 86.5MHz <87.35MHz>
CT2 109.5MHz <108.25MHz>
L6 : SW Frequency Coverage Adjustment
CT3 : FM Frequency Coverage Adjustment
L4 : FM Frequency Coverage Adjustment
L5 : MW Frequency Coverage Adjustment CT6 : SW Frequency Coverage Adjustment
CT4 : MW Frequency Coverage Adjustmen
t
T1 : AM IF Adjustment
L1 : MW Tracking Adjustment
CT1 : MW Tracking Adjustment
CT2 : FM Tracking Adjustment
CT5 : SW Tracking Adjustment
L2 : SW Tracking Adjustment
L3 : FM Tracking Adjustment
Adjustment Location : Main board (Component side)
AM RF signal
generator
12PF
30% amplitude modulation by
400Hz signal.
Output level : as low as possible
telescopi
c
antenna
terminal
set
32 Ω
phone jack (J1)
level mete
r
FM RF signal
generator
22.5kHz frequency deviation by
400Hz signal.
Output level : as low as possible
telescopi
c
antenna
terminal
0.01
µ F
0dB=1µV

– 7 – – 8 –
ICF-403S
5-1. PRINTEDWIRING BOARDS
D1 B-7
D2 B-7
D3 A-2
IC1 C-4
Q1 C-5
Ref. No. Location
rSemiconductor
Location
SECTION 5
DIAGRAMS
GND GND
FM DISCRI
NF
VOL
AM OSC
AFC
FM OSC
Reg OUT
FM RF
AM ANT
N. C
FM ANT
FE GND
MIX OUT
21222324252627282930
235
4678910
111 12 13 14 15
16
17
181920
AF POWER AMP
AM IF DET AGC
AM FE
FM
DISCRIMINATOR
FM FE
TUNING
METER
FM IF
GND GND AF OUT Vcc RIPPLE FILTER AF IN DET OUT AFC AGC AFC AGC IF GND LED N. C FM IF IN AM IF IN FM/AM BAND SELECT
rIC Block Diagram.
02
21 3 4 5 6 7 89
A
B
C
D
D3
TUNE
S2
TONE
HIGH
LOW
RV1
POWER/VOL
R3
C30
C23
R6
C22
C28
C25
R13
C18
R9
R2
C6 C5
C2
C1
C3
C9
C11
C27
C42
C13
C15
C31
C24
R1
R5
R10
R11
DC IN 4.5V
[MAIN BOARD]
ANT1
FM/SW TELESCOPIC ANTENNA
DRY BATTERY
SIZE "AA"
(IEC DESIGNATION R6)
3PCS, 4.5V
CT6
CT5
CV1-4
TUNING
L6
L2 L5
-1
-2
-4 -5
-6
-3
S1
SW NMW NFM
L3
L4
JW1
JW2
JW7
BPF1
1
5
10
15 16
20
26
30
IC1
JW5 JW4
JW8
JW3
JW6
JW15
JW14
C7
C8
CF3
C14
C21
C26
C29
C16
C20 C19
C32
JW10
JW11
JW12
JW13
CF2
CF1 T1
BCE
Q1
D2 D1
L1
MW FERRITE-ROD ANTENNA
11
(11)
1-674-016-
J2
SP1
SPEAKER
–
+
J1
@
JW9
CV1 CV2
CV3CV4
CT3
CT4
CT1 CT2
EXCEPT EA MODEL
Note:
•X: parts extracted from the component side.
•¢: internal component.
•b: Pattern from the side which enables seeing.
• Abbreviation
EA : Saudi Arabia
IC1 CXA1019S

– 9 – – 10 –
5-2. SCHEMATIC DIAGRAM ICF-403S
Note:
• 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.
•¢: internal component.
•U: B+ Line.
•H: adjustment for repair.
• Power voltage is dc 4.5V and fed with regulated dc power supply from
battery terminal (J2).
• Voltages are dc with respect to ground under no-signal (detuned) condi-
tions.
no mark : FM
( ) : MW
< > : SW
• Voltages are taken with a VOM (Input impedance 10 MΩ).
Voltage variations maybenoted due to normal productiontolerances.
• Signal path.
F: FM f: MW h: SW
• Abbreviation
EA : Saudi Arabia

– 11 – – 12 –
SECTION 6
EXPLODEDVIEWS
NOTE :
• -XX, -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.
• Hardware (# mark) list and accessories and
packing materials are given in the last of this
parts list.
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
6-1. CABINET SECTION
• Abbreviation
EA : Saudi Arabia
7
not supplied
6
8
11
1
2
3
4
5
4
12
10
9
ANT1
SP1
6
1 3-037-016-01 CABINET (FRONT) (BLACK)
1 3-037-016-11 CABINET (FRONT) (WHITE) (AEP)
2 3-037-026-01 PLATE, TRANSPARENT (EXCEPT EA)
2 3-037-026-11 PLATE, TRANSPARENT (EA)
3 3-037-029-01 PANEL(SPEAKER) (BLACK)
3 3-037-029-11 PANEL(SPEAKER) (WHITE) (AEP)
4 7-685-134-19 SCREW+P 2.6X8 TYPE2 NON-SLIT
5 7-623-508-01 LUG,3
6 7-685-548-14 SCREW +BTP 3X12 TYPE2 N-S
7 3-037-024-01 HANDLE (BLACK)
7 3-037-024-11 HANDLE (WHITE) (AEP)
8 3-037-017-01 CABINET (REAR) (BLACK)
8 3-037-017-11 CABINET (REAR) (WHITE) (AEP)
9 3-037-034-01 SPRING (HANDLE)
10 3-037-019-01 LID,BATTERY CASE (BLACK)
10 3-037-019-11 LID,BATTERY CASE (WHITE) (AEP)
11 3-372-124-01 CUSHION (BATTERY)
12 3-040-489-01 SHEET, SPEAKER
ANT1 1-501-222-81 ANTENNA, TELESCOPIC (FM, SW)
SP1 1-529-451-11 SPEAKER (7.7cm)
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
6-2. CHASSIS SECTION
63
64
65
62
66
67
51
52
55
56
58 59 60
61
69
68
57
53
54
D3
51 3-037-023-01 KNOB(TONE) (BLACK)
51 3-037-023-11 KNOB(TONE) (WHITE) (AEP)
*52 1-674-032-11 RACK RETAINER BOARD
53 3-037-021-01 KNOB(BAND) (BLACK)
53 3-037-021-11 KNOB(BAND) (WHITE) (AEP)
54 3-037-025-01 POINTER
55 3-369-170-01 RACK
*56 3-037-018-01 CHASSIS
57 3-037-030-01 TERMINAL (+), BATTERY
*58 A-3663-363-A MAIN BOARD, COMPLETE (EXCEPT EA)
*58 A-3663-380-A MAIN BOARD, COMPLETE (EA)
59 3-037-028-01 HOLDER, LED
60 7-685-134-19 SCREW +P 2.6X8 TYPE2 NON-SLIT
61 3-364-941-11 SCREW (+B) (2.6X5), NYLOK
62 3-037-027-01 GEAR(A), TUNING CAPACITOR
63 3-037-031-01 TERMINAL (-), BATTERY
64 3-037-020-01 KNOB(VOL) (BLACK)
64 3-037-020-11 KNOB(VOL) (WHITE) (AEP)
65 3-880-990-00 SCREW (1.7X3),FLAT,(+) SPECIAL
66 3-037-022-01 KNOB(TUNE) (BLACK)
66 3-037-022-11 KNOB(TUNE) (WHITE) (AEP)
67 3-037-523-01 PIN(TUNING CAPACITOR)
68 3-037-033-01 SPRING (GEAR)
69 3-037-032-01 GEAR(B), TUNING CAPACITOR
D3 8-719-069-94 LED TLR124 (TUNE)

– 13 –
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, -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
• 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
• Abbreviation
EA : Saudi Arabia
When indicating parts by reference num-
ber, please include the board.
SECTION 7
ELECTRICAL PARTS LIST
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
MAIN
*A-3663-363-A MAIN BOARD, COMPLETE (EXCEPT EA)
*A-3663-380-A MAIN BOARD, COMPLETE (EA)
*********************
3-037-020-01 KNOB (VOL) (BLACK)
3-037-020-11 KNOB (VOL) (WHITE) (AEP)
3-037-027-01 GEAR (A), TUNING CAPACITOR
3-037-028-01 HOLDER, LED
3-037-032-01 GEAR (B), TUNING CAPACITOR
3-037-033-01 SPRING (GEAR)
3-037-523-01 PIN (TUNING CAPACITOR)
3-364-941-11 SCREW (+B) (2.6X5), NYLOK
3-880-990-00 SCREW (1.7X3),FLAT,(+) SPECIAL
< FILTER >
BPF1 1-236-839-11 FILTER, BAND PASS
< CAPACITOR >
C1 1-163-133-00 CERAMIC CHIP 470PF 5% 50V
C2 1-163-096-00 CERAMIC CHIP 13PF 5% 50V
C3 1-163-222-11 CERAMIC CHIP 5PF 0.25PF 50V
C5 1-163-235-11 CERAMIC CHIP 22PF 5% 50V
C6 1-163-103-00 CERAMIC CHIP 27PF 5% 50V
(EXCEPT EA)
C6 1-163-105-00 CERAMIC CHIP 33PF 5% 50V
(EA)
C7 1-104-732-11 FILM 390PF 5% 100V
C8 1-136-682-11 FILM 0.0039uF 5% 100V
C9 1-163-103-00 CERAMIC CHIP 27PF 5% 50V
C11 1-163-097-00 CERAMIC CHIP 15PF 5% 50V
C13 1-163-021-91 CERAMIC CHIP 0.01uF 10% 50V
C14 1-124-589-11 ELECT 47uF 20% 16V
C15 1-163-031-11 CERAMIC CHIP 0.01uF 50V
C16 1-126-964-11 ELECT 10uF 20% 50V
C18 1-163-031-11 CERAMIC CHIP 0.01uF 50V
C19 1-126-963-11 ELECT 4.7uF 20% 50V
C20 1-126-960-11 ELECT 1uF 20% 50V
C21 1-126-964-11 ELECT 10uF 20% 50V
C22 1-163-037-11 CERAMIC CHIP 0.022uF 10% 25V
C23 1-163-035-00 CERAMIC CHIP 0.047uF 50V
C24 1-163-021-91 CERAMIC CHIP 0.01uF 10% 50V
C25 1-164-346-11 CERAMIC CHIP 1uF 16V
C26 1-126-966-11 ELECT 33uF 20% 16V
C27 1-163-033-91 CERAMIC CHIP 0.022uF 50V
C28 1-164-346-11 CERAMIC CHIP 1uF 16V
C29 1-126-925-11 ELECT 470uF 20% 10V
C30 1-163-009-11 CERAMIC CHIP 0.001uF 10% 50V
C31 1-164-346-11 CERAMIC CHIP 1uF 16V
C32 1-126-925-11 ELECT 470uF 20% 10V
C42 1-163-251-11 CERAMIC CHIP 100PF 5% 50V
< FILTER >
CF1 1-567-670-11 FILTER, CERAMIC
CF2 1-577-588-11 FILTER, CERAMIC
CF3 1-577-573-11 FILTER, CERAMIC
< TRIMMER >
CT1 1-141-612-11 CAP, VER (MW TRACKING)
CT2 1-141-612-11 CAP, VER (FM TRACKING)
CT3 1-141-612-11 CAP, VER (FM FREQUENCY COVERAGE)
CT4 1-141-612-11 CAP, VER (MW FREQUENCY COVERAGE)
CT5 1-141-601-21 CAP, ADJ (SW TRACKING)
CT6 1-141-601-21 CAP, ADJ (SW FREQUENCY COVERAGE)
< VARIABLE CAPACITOR >
CV1 1-141-612-11 CAP, VER (TUNING)
CV2 1-141-612-11 CAP, VER (TUNING)
CV3 1-141-612-11 CAP, VER (TUNING)
CV4 1-141-612-11 CAP, VER (TUNING)
< DIODE >
D1 8-719-991-33 DIODE 1SS133T-77
D2 8-719-991-33 DIODE 1SS133T-77
D3 8-719-069-94 LED TLR124 (TUNE)
< IC >
IC1 8-752-037-02 IC CXA1019S
< JACK >
J1 1-770-666-11 JACK (@)
J2 1-580-681-21 JACK,DC(POLARITY UNIFIED TYPE)
(DC IN 4.5V)
< COIL >
L1 1-402-568-31 ANTENNA, FERRITE-ROD (MW)
(MW TRACKING)

– 14 –
Ref. No. Part No. Description Remark
MAIN
ICF-403S
9-927-158-11 Sony Corporation
Personal Audio Company 99H0261-1
Printed in Japan © 1999.8
Published by General Engineering Dept.
L2 1-424-529-21 COIL (SW TRACKING)
*L3 1-422-320-11 COIL, AIR-CORE (FM TRACKING)
L4 1-422-131-00 COIL, FM OSCILLATION (FM FREQUENCY
COVERAGE) (EXCEPT EA)
L4 1-459-954-21 COIL (WITH CORE) (FM FREQUENCY
COVERAGE) (EA)
L5 1-406-092-31 COIL, OSC (MW) (MW FREQUENCY
COVERAGE)
L6 1-406-093-31 COIL, OSC (SW) (SW FREQUENCY
COVERAGE)
< TRANSISTOR >
Q1 8-729-027-53 TRANSISTOR DTC124TKA-T146
< RESISTOR >
R1 1-216-049-91 RES,CHIP 1K 5% 1/10W
R2 1-216-061-00 METAL CHIP 3.3K 5% 1/10W
(EXCEPT EA)
R3 1-216-071-00 METAL CHIP 8.2K 5% 1/10W
R5 1-216-057-00 METAL CHIP 2.2K 5% 1/10W
R6 1-216-045-00 METAL CHIP 680 5% 1/10W
R9 1-216-065-91 RES,CHIP 4.7K 5% 1/10W
R10 1-216-057-00 METAL CHIP 2.2K 5% 1/10W
R11 1-216-017-91 RES,CHIP 47 5% 1/10W
R13 1-216-049-91 RES,CHIP 1K 5% 1/10W
< VARIABLE RESISTOR >
RV1 1-241-555-11 RES, VAR, CARBON 50K (POWER/VOL)
< SWITCH >
S1 1-771-748-11 SWITCH, SLIDE (FM, MW, SW)
S2 1-552-370-00 SWITCH, SLIDE (TONE)
< TRANSFORMER >
T1 1-404-790-11 TRANSFORMER, IF (AM IF)
**************************************************************
MISCELLANEOUS
*************
*52 1-674-032-11 RACK RETAINER BOARD
ANT1 1-501-222-81 ANTENNA, TELESCOPIC (FM, SW)
D3 8-719-069-94 LEDTLR124 (TUNE)
SP1 1-529-451-11 SPEAKER (7.7cm)
**************************************************************
ACCESSORIES & PACKING MATERIALS
********************************
3-867-127-11 MANUAL, INSTRUCTION (ENGLISH, FRENCH,
GERMAN, SPANISH, DUTCH, ITALIAN,
PORTUGUESE) (AEP)
3-867-127-21 MANUAL, INSTRUCTION (ENGLISH, FRENCH,
SPANISH, POLISH, HUNGARIAN, RUSSIAN,
CHINESE, ARABIC) (7AEP,AUS,EA)