Sony ICF-403L User manual

Ver 1.0 1999.07
MICROFILM
ICF-403L
SERVICE MANUAL
FM/MW/LW 3 BAND RADIO
SPECIFICATIONS
AEP Model
East European model
AEP 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
3 Screw (1.7x3)
2 Gear (A),tuning capacitor
1
CV shaf
t
Main board
Knob (tune)
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 (A), tuning capacitor onto the CV shaft in a
direction as a figure.
3Secure the gear (A), tuning capacitor with screw.
SECTION 4
ELECTRICAL ADJUSTMENTS
TUNER SECTION
MW/LW Section
Procedure :
BAND : MW/LW
VOLUME : MIN
FM Section
Procedure :
BAND : FM
VOLUME : MIN
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.
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
set
32 Ω
phone jack (J1)
level mete
r
• Repeat the procedures in each adjustment several times, and the
frequency coverage and tracking adjustments should be finally
done by the trimmer capacitors.
< > : East European 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.
L1-1 620kHz
CT1 1,400kHz
LW FREQUENCY COVERAGE ADJUSTMENT
Adjust for a maximum reading on level meter.
Confirm 145kHz
CT5 260kHz
LW TRACKING ADJUSTMENT
Adjust for a maximum reading on level meter.
L1-2 160kHz
CT6 240kHz
FM FREQUENCY COVERAGE ADJUSTMENT
Adjust for a maximum reading on level meter.
L4 86.5MHz <64.0MHz>
CT3 109.5MHz <109.5MHz>
FM TRACKING ADJUSTMENT
Adjust for a maximum reading on level meter.
L3 86.5MHz <68.0MHz>
CT2 109.5MHz <102.0MHz>
L5 : MW Frequency Coverage Adjustment
CT3 : FM Frequency Coverage Adjustment
L4 : FM Frequency Coverage Adjustment
CT5 : LW Frequency Coverage Adjustment
CT4 : MW Frequency Coverage Adjustment
L1-2 : LW Tracking Adjustment
T1 : AM IF Adjustment
L1-1 : MW Tracking Adjustment
CT1 : MW Tracking Adjustment
CT2 : FM Tracking Adjustment
CT6 : LW Tracking Adjustment
L3 : FM Tracking Adjustment
Adjustment Location : Main board (Component side)

– 7 – – 8 –
ICF-403L
5-1. PRINTED WIRING BOARDS
D1 B-7
D2 B-7
D3 A-2
IC1 C-4
Q1 C-5
Ref.No. Location
rSemiconductor
Location
SECTION 5
DIAGRAMS
02
21 3456789
A
B
C
D
D3
TUNE
S2
TONE
HIGH
LOW
JW16
RV1
POWER/VOL
R3 C23
C28
R6
C22 C25
C43 : EE MODEL
JC1 : AEP MODEL
C18
C46
R9
C40
R2
C27
C4
C37
C6 C5
C2
C13
C15 C44
C39
C31
C45
C10
C24
C47
R1
R7
R12
R5
R10
R11
DC IN 4.5V
[MAIN BOARD]
ANT1
FM TELESCOPIC ANTENNA
DRY BATTERY
SIZE "AA"
(IEC DESIGNATION R6)
3PCS, 4.5V
CT6
CT5
CV1-4
TUNING
L5
-1-2 -4
-3
S1
LW NMW NFM
L3
L4
JW1
JW7
BPF1
1
5
10
15 16
20
30
IC1
JW5
JW8
JW6
CF3
C14
C21
C26
C29
C16
C20 C19
C32
JW10
JW11
JW12
JW13
CF2
CF1 T1
BCE
Q1
D2 D1
L1
MW/LW FERRITE-ROD ANTENNA
21
(21)
1-674-016-
J2
SP1
SPEAKER
–
+
J1
@
JW9
CV1 CV2
CV3CV4
CT3
CT4
CT1 CT2
EE MODEL
EE MODEL
EE MODEL
-1 -2
Note:
•X: parts extracted from the component side.
•b: Pattern from the side which enables seeing.
• Abbreviation
EE : East European
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.
IC1 CXA1019S

– 9 – – 10 –
5-2. SCHEMATIC DIAGRAM
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.
ICF-403L
• 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) conditions.
no mark : FM
( ) : MW
<>:LW
• Voltages are taken with aVOM (Input impedance 10 MΩ).
Voltage variations may be noted due to normal production
tolerances.
• Signal path.
F: FM f: MW L: LW
• Abbreviation
EE : East European

– 11 – – 12 –
SECTION 6
EXPLODED VIEWS
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
EE : East European
1 3-037-016-01 CABINET (FRONT) (BLACK)
1 3-037-016-11 CABINET (FRONT) (WHITE) (AEP)
2 3-037-026-21 PLATE, TRANSPARENT (AEP)
2 3-037-026-31 PLATE, TRANSPARENT (EE)
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 (WHITE) (AEP)
ANT1 1-501-222-81 ANTENNA, TELESCOPIC (FM)
SP1 1-529-451-11 SPEAKER (7.7cm)
7
not supplied
6
8
11
1
2
3
4
5
4
12
10
9
ANT1
SP1
6
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
51 3-037-023-01 KNOB(TONE) (BLACK)
51 3-037-023-11 KNOB(TONE) (WHITE) (AEP)
*52 1-674-032-21 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-3663-364-A MAIN BOARD, COMPLETE (AEP)
*58 A-3663-383-A MAIN BOARD, COMPLETE (EE)
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)
D3 8-719-069-94 LED TLR124 (TUNE)
6-2. CHASSIS SECTION
63
64
65
62
66
51
52
55
56
58
59
60
61
57
53
54
D3

– 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
EE : East European
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
*A-3663-364-A MAIN BOARD, COMPLETE (AEP)
A-3663-383-A MAIN BOARD, COMPLETE (EE)
*********************
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
3-364-941-11 SCREW (+B) (2.6X5), NYLOK
3-880-990-00 SCREW (1.7X3),FLAT,(+) SPECIAL
< FILTER >
BPF1 1-233-452-11 FILTER, BAND PASS (EE)
BPF1 1-236-839-11 FILTER, BAND PASS (AEP)
< CAPACITOR >
C2 1-163-220-11 CERAMIC CHIP 3PF 0.25PF 50V
C4 1-163-121-00 CERAMIC CHIP 150PF 5% 50V
C5 1-163-222-11 CERAMIC CHIP 5PF 0.25PF 50V(EE)
C5 1-163-235-11 CERAMIC CHIP 22PF 5% 50V
(AEP)
C6 1-163-103-00 CERAMIC CHIP 27PF 5% 50V
(AEP)
C6 1-163-231-11 CERAMIC CHIP 15PF 5% 50V(EE)
C10 1-163-137-00 CERAMIC CHIP 680PF 5% 50V
C13 1-163-035-00 CERAMIC CHIP 0.047uF 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 1-126-964-11 ELECT 10uF 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 1-163-031-11 CERAMIC CHIP 0.01uF 50V
C25 1-164-346-11 CERAMIC CHIP 1uF 16V
C26 1-126-966-11 ELECT 33uF 20% 16V
C27 1-163-031-11 CERAMIC CHIP 0.01uF 50V
C28 1-164-346-11 CERAMIC CHIP 1uF 16V
C29 1-126-925-11 ELECT 470uF 20% 10V
C31 1-164-346-11 CERAMIC CHIP 1uF 16V
C32 1-126-925-11 ELECT 470uF 20% 10V
C37 1-163-089-00 CERAMIC CHIP 6PF 50V
C39 1-163-038-91 CERAMIC CHIP 0.1uF 25V
C40 1-163-222-11 CERAMIC CHIP 5PF 0.25PF 50V
C43 1-163-141-00 CERAMIC CHIP 0.001uF 5% 50V(EE)
C44 1-163-031-11 CERAMIC CHIP 0.01uF 50V(EE)
C45 1-163-031-11 CERAMIC CHIP 0.01uF 50V(EE)
C46 1-163-141-00 CERAMIC CHIP 0.001uF 5% 50V(EE)
C47 1-163-141-00 CERAMIC CHIP 0.001uF 5% 50V(EE)
< FILTER >
CF1 1-567-670-11 FILTER, CERAMIC
CF2 1-781-034-11 FILTER, CERAMIC
CF3 1-577-573-11 FILTER, CERAMIC
< TRIMMER >
CT1 1-141-462-11 CAP, VAR (MW TRACKING) (EE)
CT1 1-151-691-11 CAP, VAR (MW TRACKING) (AEP)
CT2 1-141-462-11 CAP, VAR (FM TRACKING) (EE)
CT2 1-151-691-11 CAP, VAR (FM TRACKING) (AEP)
CT3 1-141-462-11 CAP, VAR (FM FREQUENCY COVERAGE) (EE)
CT3 1-151-691-11 CAP, VAR (FM FREQUENCY COVERAGE) (AEP)
CT4 1-141-462-11 CAP, VAR (MW FREQUENCY COVERAGE) (EE)
CT4 1-151-691-11 CAP, VAR (MW FREQUENCY COVERAGE)(AEP)
CT5 1-141-604-11 CAP, ADJ (LW FREQUENCY COVERAGE)
CT6 1-141-604-11 CAP, ADJ (LW TRACKING)
< VARIABLE CAPACITOR >
CV1 1-141-462-11 CAP, VAR (TUNING) (EE)
CV1 1-151-691-11 CAP, VAR (TUNING) (AEP)
CV2 1-141-462-11 CAP, VAR (TUNING) (EE)
CV2 1-151-691-11 CAP, VAR (TUNING) (AEP)
CV3 1-141-462-11 CAP, VAR (TUNING) (EE)
CV3 1-151-691-11 CAP, VAR (TUNING) (AEP)
CV4 1-141-462-11 CAP, VAR (TUNING) (EE)
CV4 1-151-691-11 CAP, VAR (TUNING) (AEP)
< 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
MAIN

– 14 –
< JACK >
J1 1-770-666-11 JACK (@)
J2 1-580-681-21 JACK,DC(POLARITY UNIFIED TYPE)
(DC IN 4.5V)
< JUMPER RESISTOR >
JC1 1-216-295-00 METAL CHIP 0 5% 1/10W
(AEP)
< COIL >
L1 1-754-083-11 ANTENNA, FERRITE-ROD (LW.MW) (MW/LW
TRACKING)
L3 1-416-800-11 COIL, AIR-CORE (FM TRACKING) (EE)
*L3 1-422-320-11 COIL, AIR-CORE (FM TRACKING) (AEP)
L4 1-422-131-00 COIL, FM OSCILLATION (FM FREQUENCY
COVERAGE) (AEP)
L4 1-529-501-11 COIL, AIR-CORE (FM FREQUENCY COVERAGE)
(EE)
L5 1-406-028-00 COIL, OSC (MW) (MW 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
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
R7 1-216-049-91 RES,CHIP 1K 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
R12 1-216-089-91 RES,CHIP 47K 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, LW)
S2 1-552-370-00 SWITCH, SLIDE (TONE)
< TRANSFORMER >
T1 1-404-790-11 TRANSFORMER, IF (AM IF)
**************************************************************
MISCELLANEOUS
***************
*52 1-674-032-21 RACK RETAINER BOARD
ANT1 1-501-222-81 ANTENNA, TELESCOPIC (FM)
D3 8-719-069-94 LED TLR124 (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) (EE)
Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark
MAIN
ICF-403L
9-927-147-11 Sony Corporation
Personal Audio Company 99G0237-1
Printed in Japan © 1999.7
Published by General Engineering Dept.