Sony ICF-R40 User manual

MICROFILM
SERVICE MANUAL
FM/AM RADIO
Tourist Model
SPECIFICATIONS
ICF-R40
Ver 1.0 1999. 03

– 2 –
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.
CF2
CF3
mark
Mark Center frequency
red 10.70 MHz
blue 10.67 MHz
orange 10.73 MHz
black 10.64 MHz
white 10.76 MHz
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
This section is extracted from
instruction manual.

– 3 –
CABINET (REAR)
MAIN BOARD
Note: Follow the disassembly procedure in the numerical order given.
SECTION 2
DISASSEMBLY
1 Pull out the ear receiver.
9 claw
3 two screws
(DIA. 1.4
× 4)
4 screw
(M1.7
× 10)
9 claw
8 claw
S1
6 claw
7 claw
6 claw
C
7 claw
2 Open the “lid, battery case”
in the direction of arrows
A to B .
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.
!¡ Remove two solders
of reel assy.
8 claw
knob
(earphone/spaeker)
!º claw
A
B
!™ cabinet (rear)
Note: On installation of cabinet (rear),
adjust the knob (earphone/speaker)
and S1.
3 knob (2 band)
2 knob (noise cut)
1 knob (power)
4 Remove two solders
of speaker leads.
5 MAIN boar
d

– 4 –
REEL ASSY
4 reel assy
2 three screws
(B1.4
× 3)
3 Draw the ear receiver
in the direction of the arrow.
1 blind plate

– 5 –
SECTION 3
DIAL POINTER SETTING
Note: Follow the assembly procedure in the numerical order given.
A
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)
cabinet (front) assy
cabinet (front) assy
the tip of pointer
pointer
marking
2 Set the tip of pointer to the marking
of cabinet (front) assy.
8 Rotate the gear
(tuning capacitor) fully
in the direction of the arrow C .
C
B
9
MAIN board
Note: On installation of MAIN board,
set the outline of gear
(tuning capacitor). boss
oval
6 To install the gear
fixing each oval shape,
set the boss of the gear
(tuning capacitor) as the figure.
7 screw
(1.7 × 3)
5 Rotate the tuning capacitor
shaft fully in the direction of
the arrow B .
cabinet (front) assy

– 6 –
[FM]
Setting:
POWER switch: AUTO OFF
Band switch: FM
Output select switch: @(earphone)
[AM]
Setting:
POWER switch: AUTO OFF
Band switch: AM
Output select switch: @(earphone)
• 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:
FM FREQUENCY COVERAGE ADJUSTMENT
Adjust for a maximum reading on level meter.
L3 75 MHz
CT1-3 109.5 MHz
FM TRACKING ADJUSTMENT
Adjust for a maximum reading on level meter.
L2 75 MHz
CT1-4 109.5 MHz
AM IF ADJUSTMENT
Adjust for a maximum reading on level meter.
T1 455 kHz
AM FREQUENCY COVERAGE ADJUSTMENT
Adjust for a maximum reading on level meter.
L4 515 kHz
CT1-1 1,650 kHz
AM TRACKING ADJUSTMENT
Adjust for a maximum reading on level meter.
L1 600 kHz
CT1-2 1,400 kHz
SECTION 4
ELECTRICAL ADJUSTMENTS
FM RF signal
generator
22.5 kHz frequency
deviation by 400 Hz
signal
Output level: as low as possible
+
–
level meter
@ (earphone) jack (J1)
set
TP
(FM IN)
16 Ω
0.01 µ F
AM RF signal
generator
30% amplitude
modulation by
400 Hz signal
Output level: as low as possible
Put the lead-wire
antenna close to
the set.
+
–
level meter
set
16 Ω
@
(earphone) jack (J1)
CT1-4
L2 FM Tracking Adjustment
CT1-3
L3
CT1-2
L1
AM Frequency Coverage
Adjustment CT1-1
T1 AM IF Adjustment
L4 AM Frequency Coverage Adjustment
TP (FM IN)
J1
@ (earphone) jack
– MAIN BOARD (Component Side) –
FM Frequency Coverage
Adjustment
AM Tracking Adjustment
0 dB=1 µV

ICF-R40
– 7 – – 8 –
SECTION 5
DIAGRAMS
13
10
15 18
11
6 8
FM
FRONT-END FM
IF AMP AF
POWER AMP
AM IF AMP,
AGC, DET
AM
FRONT-END 17
20
FM RF
IN MIX
OUT CF2
10.7MHz
CF1
455kHz
CF3
10.7MHz Q1
TONE CONTROL
SWITCH
FM RF
FM IF
3FM
DISCRIMINATOR
TUNING METER
DISCRI
28
AF
OUT SP1
(SPEAKER)
AF
IN
24
16
25
DET
AM IF
METER
VOL
5
BAND
REG
AM OSC
L4
AM OSC
L3
FM OSC
L1
AM FERRITE-ROD
ANTENNA
FM OSC
AM
ANT
L2
FM RF
FM/AM FRONT-END,
FM/AM IF AMP, DET, AGC, AF AMP
IC1
TIMER
IC2
CT1-2
++
CT1-3, L3
FM FREQUENCY
COVERAGE
CT1-1, L4
AM FREQUENCY
COVERAGE
CT1-4, L2
FM TRACKING
CT1-2, L1
AM TRACKING
T1
AM IF
• SIGNAL PATH
: FM
: AM
05
9
DRY BATTERY
SIZE “AAA”
(IEC DESIGNATION R03)
2PCS. 3V
FM/AM TUNER
(IC1) B+
J1
(EARPHONE)
@
EP1
(EARPHONE)
B+ SWITCH
Q3
BAND-PASS
FILTER
Q2
CR
OSCILLATOR
COUNTER OSC
CHATTERING
PROTECTOR
CONTROL
B+
OUT
SET
RESET
D5
C33, R15 – 17
VDD
OSC1 – OSC3
8
7
6
5
1 – 3
ON
OFF
AUTO OFF
S2
POWER
D2
TUNE
RV1
VOL
CV1
TUNE
CV1
TUNE
AM
FM
S4
BAND
S5
NOISE CUT
ON OFF
CT1-4
CT1-3
CV1-2
CV1-4
CT1-1
CV1-1
CV1-3
S1
@/™
EARPHONE SPEAKER
27
REG
B+
(1.25V)
VCC
5-1. BLOCK DIAGRAM

ICF-R40
– 9 – – 10 –
• Semiconductor
Location
Ref. No. Location
D1 C-3
D2 B-1
D5 B-3
IC1 F-2
IC2 B-3
Q1 C-2
Q2 C-2
Q3 B-3
Note on PrintedWiring 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: Partsonthepattern facesideseen from
(Conductor Side) the pattern face are indicated.
Parts face side: Parts on the parts face side seen from
(Component Side) the parts face are indicated.
5-2. PRINTED WIRING BOARD

ICF-R40
– 11 – – 12 –
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 Ωand 1/4W or less unless otherwise
specified.
•¢: internal component.
•C: panel designation.
•U: B+ Line.
•H: adjustment for repair.
• Power voltage is dc 3V 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
• Voltagesare taken withaVOM(Input impedance10 MΩ).
Voltage variations may be noted due to normal produc-
tion tolerances.
• Signal path.
F: FM
f: AM
5-3. SCHEMATIC DIAGRAM
• IC Block Diagrams
IC1 CXA1280N
IC2 BU2305F-E2
GND
GND
AF OUT
VCC
RIPPLE FILTER
AF IN
DET AFC AGC AFC AGC GND METER NC FM IF
AM IF
BAND
GND
GND
DISCRI
NF
VOL
AM OSC
AFC
FM OSC
REG
FM RF
AM ANT
NC
FM RF IN
GND
MIX OUT
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
12 13 14 158 9 10 114 5 61 2 3 7
AF POWER
AMP AM IF AMP,
DET, AGC
TUNING
METER FM IF
AMP
AM
FRONT-END
FM
FRONT-END
FM
DISCRIMINATOR
OSC1
OSC2
OSC3
GND
VCC
SET
RESET
OUT
8
4
5
6
1
2
3
7
23 BIT
COUNTER
CHATTERING
PROTECTOR
CONTROL

– 13 – – 14 –
SECTION 6
EXPLODED VIEW
• 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 num-
ber in the exploded views are not supplied.
• Accessories and packing materials are given
in the last of the electrical parts list.
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
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
SECTION 7
ELECTRICAL PARTS LIST
Ref. No. Part No. Description Remark
NOTE:
• Due to standardization, replacements in the
parts list may be different from the parts speci-
fied 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
• Items marked “*” are not stocked since they
are seldom required for routine service.
Some delay should be anticipated when order-
ing 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
Ref. No. Part No. Description Remark
When indicating parts by reference
number, please include the board.
MAIN
1 A-3638-700-A CABINET (FRONT) ASSY
2 3-034-344-01 POINTER
3 3-034-347-01 GEAR (MIDWAY)
4 3-034-348-01 KNOB (TUNE)
5 3-895-823-11 SCREW (B1.4X3), TAPPING
6 A-3638-697-A REEL ASSY
7 3-032-525-01 SCREW
8 3-032-492-01 PLATE (REWIND)
9 3-034-341-21 CABINET (REAR)
10 3-034-349-01 KNOB (POWER)
11 3-015-033-01 SCREW (DIA. 1.4X4), PRECISION
12 3-034-352-01 LID, BATTERY CASE
13 3-034-357-01 COMBINED (KNOB) (including
KNOB (REWIND), KNOB (EARPHONE/
SPEAKER),KNOB (NOISE CUT),
KNOB (2 BAND))
14 3-910-816-01 SCREW (M1.7x10)
15 3-034-212-01 TERMINAL (+/–), BATTERY
16 3-034-210-01 TERMINAL (+), BATTERY
17 3-034-211-01 TERMINAL (–), BATTERY
*18 A-3683-046-A MAIN BOARD, COMPLETE
19 3-034-358-01 COMBINED (BLIND PLATE) (including
BLIND PLATE, HOLDER (BAR ANTNNA))
20 3-880-990-00 SCREW (1.7X3), FLAT, (+) SPECIAL
21 3-034-346-01 GEAR (TUNING CAPACITOR)
22 3-384-797-01 SCREW (1.4X4)
23 3-036-666-01 SPRING (ELECTROSTATIC)
24 9-911-816-01 CLOTH, BATTERY PICK
25 3-831-441-99 CUSHION (A)
L1 1-754-049-11 ANTENNA, FERRITE-ROD (AM)
SP1 1-529-187-11 SPEAKER (2.8cm)
4 A
r B
r C
r D
(including
r B, r C, r D
)
(including 4 A)
L1
SP1
1
2
3
45
6
78
9
10 11 12
13
14
15
24
16
17 18
19
21
22
20
23
25
*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
<CAPACITOR>
C1 1-162-970-11 CERAMIC CHIP 0.01uF 10% 25V
C2 1-126-157-11 ELECT 10uF 20% 16V
C4 1-162-919-11 CERAMIC CHIP 22PF 5% 50V
C5 1-162-922-11 CERAMIC CHIP 39PF 5% 50V
C7 1-162-917-11 CERAMIC CHIP 15PF 5% 50V
C9 1-164-275-91 CERAMIC CHIP 9PF 5% 50V
C11 1-162-927-11 CERAMIC CHIP 100PF 5% 50V
C12 1-164-346-11 CERAMIC CHIP 1uF 16V
C13 1-162-970-11 CERAMIC CHIP 0.01uF 10% 25V
C14 1-164-156-11 CERAMIC CHIP 0.1uF 25V
C15 1-164-346-11 CERAMIC CHIP 1uF 16V
C16 1-135-151-21 TANTALUM CHIP 4.7uF 20% 4V
C17 1-126-157-11 ELECT 10uF 20% 16V
C18 1-164-227-11 CERAMIC CHIP 0.022uF 10% 25V
C19 1-126-157-11 ELECT 10uF 20% 16V
C20 1-164-346-11 CERAMIC CHIP 1uF 16V
C21 1-164-346-11 CERAMIC CHIP 1uF 16V
C22 1-127-569-11 TANTAL. CHIP 100uF 20% 4V
C23 1-124-434-00 ELECT 220uF 20% 4V
C24 1-162-927-11 CERAMIC CHIP 100PF 5% 50V
C25 1-165-176-11 CERAMIC CHIP 0.047uF 10% 16V
C26 1-164-346-11 CERAMIC CHIP 1uF 16V
C27 1-164-156-11 CERAMIC CHIP 0.1uF 25V
C28 1-164-227-11 CERAMIC CHIP 0.022uF 10% 25V
C29 1-164-677-11 CERAMIC CHIP 0.033uF 10% 16V
C30 1-164-227-11 CERAMIC CHIP 0.022uF 10% 25V
C31 1-162-964-11 CERAMIC CHIP 0.001uF 10% 50V
C32 1-164-156-11 CERAMIC CHIP 0.1uF 25V
C33 1-162-968-11 CERAMIC CHIP 0.0047uF 10% 50V
C34 1-164-156-11 CERAMIC CHIP 0.1uF 25V
C35 1-164-346-11 CERAMIC CHIP 1uF 16V
<CERAMIC FILTER>
CF1 1-567-177-00 FILTER, CERAMIC (455kHz)
CF2 1-579-632-51 FILTER, CERAMIC (10.7MHz)
CF3 1-579-632-51 FILTER, CERAMIC (10.7MHz)
<VARIABLE CAPACITOR>
CT1 1-141-607-11 CAP, VAR
CV1 1-141-607-11 CAP, VAR (TUNE)
<DIODE>
D1 8-719-800-76 DIODE 1SS226
D2 8-719-062-42 LED BR1111R-TR (TUNE)
D5 8-719-046-91 DIODE MA2S111
<IC>
IC1 8-752-036-29 IC CXA1280N
IC2 8-759-583-17 IC BU2305F-E2
<JACK>
J1 1-785-506-11 JACK (@)
<COIL>
L1 1-754-049-11 ANTENNA, FERRITE-ROD (AM)
L2 1-419-109-11 COIL, AIR-CORE
L3 1-419-108-11 COIL, AIR-CORE
L4 1-406-255-11 COIL (OSC)
L5 1-412-971-31 INDUCTOR 0.22uH
L7 1-412-947-11 INDUCTOR 4.7uH
L8 1-412-947-11 INDUCTOR 4.7uH
L11 1-412-947-11 INDUCTOR 4.7uH
L12 1-412-947-11 INDUCTOR 4.7uH
<TRANSISTOR>
Q1 8-729-037-71 TRANSISTOR UN9210J-(TX).SO
Q2 8-729-037-92 TRANSISTOR 2SD2216J-R(TX).SO
Q3 8-729-800-71 TRANSISTOR 2SB815B7-TB
<RESISTOR>
R1 1-216-813-11 METAL CHIP 220 5% 1/16W
R3 1-216-845-11 METAL CHIP 100K 5% 1/16W
R4 1-216-817-11 METAL CHIP 470 5% 1/16W

– 15 –
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
MAIN
R5 1-216-805-11 METAL CHIP 47 5% 1/16W
R6 1-216-833-11 METAL CHIP 10K 5% 1/16W
R7 1-216-825-11 METAL CHIP 2.2K 5% 1/16W
R8 1-216-839-11 METAL CHIP 33K 5% 1/16W
R9 1-216-837-11 METAL CHIP 22K 5% 1/16W
R10 1-216-845-11 METAL CHIP 100K 5% 1/16W
R11 1-216-829-11 METAL CHIP 4.7K 5% 1/16W
R12 1-216-829-11 METAL CHIP 4.7K 5% 1/16W
R13 1-216-829-11 METAL CHIP 4.7K 5% 1/16W
R15 1-216-853-11 METAL CHIP 470K 5% 1/16W
R16 1-216-857-11 METAL CHIP 1M 5% 1/16W
R17 1-216-845-11 METAL CHIP 100K 5% 1/16W
R18 1-216-825-11 METAL CHIP 2.2K 5% 1/16W
R19 1-216-841-11 METAL CHIP 47K 5% 1/16W
R20 1-216-821-11 METAL CHIP 1K 5% 1/16W
R30 1-216-821-11 METAL CHIP 1K 5% 1/16W
R31 1-216-821-11 METAL CHIP 1K 5% 1/16W
R32 1-216-827-11 METAL CHIP 3.3K 5% 1/16W
R33 1-216-821-11 METAL CHIP 1K 5% 1/16W
R34 1-216-825-11 METAL CHIP 2.2K 5% 1/16W
R35 1-216-821-11 METAL CHIP 1K 5% 1/16W
<VALIABLE RESISTOR>
RV1 1-225-779-11 RES, VAR 20K (VOL)
<SWITCH>
S1 1-572-922-11 SWITCH, SLIDE (@/™)
S2 1-762-651-11 SWITCH, SLIDE (POWER)
S4 1-572-922-11 SWITCH, SLIDE (BAND)
S5 1-572-922-11 SWITCH, SLIDE (NOISE CUT)
<TRANSFORMER>
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)

– 16 –
ICF-R40
Sony Corporation
Parsonal A&V Products Company9-926-942-11
99C05031-1
Printed in Japan © 1999. 3
Published by Quality Engineering Dept.
(Shinagawa)