Hallicrafters SR-400 CYCLONE II Manual
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Hallicrafters SR-400 CYCLONE II Manual

Repair & restoration
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REPAIR AND RESTORATION OF THE SR-400
REPAIR & RESTORATION
OF
HALLICRAFTERS
SR-400 CYCLONE II
SR-400A CYCLONE III
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7+( &29(56 25 &$6( ,6 5(029(' 2%6(59( 7+( )5((
+$1' 58/( 7+$7 ,6 $1< 7,0( 7+( 32:(5 ,6 $33/,(' ,)
<28 $5( 5,*+7 +$1'(' <285 /()7 +$1' ,6 ,1 <285 +,3
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,1 <285 +,3 32&.(7 <28 352&((' $7 <285 2:1 5,6.
This document is the intellectual property of the author, Walter A. Cates, WDØGOF, unless specifically
credited to a contributor. All processes, ideas, drawings, data sheets and opinions contained here-in are the
intellectual property of the author. Any reproduction of this document for profit will be vigorously pursued.
1
WDØGOF 6/22/20014

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  • Page 1 REPAIR AND RESTORATION OF THE SR-400 REPAIR & RESTORATION HALLICRAFTERS SR-400 CYCLONE II SR-400A CYCLONE III &$87,21 )$7$/ 92/7$*(6 $5( 23(1 $1' (;326(' 21&( 7+( &29(56 25 &$6( ,6 5(029(' 2%6(59( 7+( )5(( +$1' 58/( 7+$7 ,6 $1< 7,0( 7+( 32:(5 ,6 $33/,(' ,) <28 $5( 5,*+7 +$1'(' <285 /()7 +$1' ,6 ,1 <285 +,3...

  • Page 2: Introduction

    “why did I not include the SR-400 Cyclone”? The first generation 400 had too many things not quite correct. Mr. Orwin (Hallicrafters engineer) fixed those when he designed the Cyclone II. The best advice I can offer to owners of the original SR-400 is to upgrade it to the Cyclone II level. A document for upgrading a Cyclone to the Cyclone II is available.

  • Page 3: Table Of Contents

    REPAIR AND RESTORATION OF THE SR-400 TABLE OF CONTENTS INTRODUCTION ..............................2 1. SR-400 INITIAL INSPECTION AND TESTING..................... 5 1-1. VISUAL AND MECHANICAL INSPECTION ..................5 1-2. RECAPPING; .............................. 5 1-3. AFTER MARKET MODIFICATIONS ...................... 5 1-4. INITIAL POWER UP ..........................6 1-4-1.
  • Page 4 REPAIR AND RESTORATION OF THE SR-400 4-7. V6 RX FAULT ISOLATION........................17 4-8. V4A RX FAULT ISOLATION ......................... 18 4-9. V3 RX FAULT ISOLATION........................18 4-10 V2 RX MIXER FAULT ISOLATION ..................... 18 4-11 V1 RX FAULT ISOLATION........................18 5. TECH NOTES ..............................19 5-1.

  • Page 5: Sr-400 Initial Inspection And Testing

    REPAIR AND RESTORATION OF THE SR-400 1. SR-400 INITIAL INSPECTION AND TESTING. SO YOU JUST GOT AN SR-400 FROM E-BAY OR SOMEONE THAT SAID “IT WORKED FINE THE LAST TIME I TURNED IT ON”. NOW WHERE DO YOU START? THE FOLLOWING PROCESS HAS EVOLVED OVER YEARS OF REFURBISHING THE SR-400.

  • Page 6: Initial Power Up

    REPAIR AND RESTORATION OF THE SR-400 1-4. INITIAL POWER UP Note: When bench testing the SR-400 set the antenna switch (S2) to SEPARATE. Connect the load and wattmeter to ANTENNA (J1 or J2). Connect the signal generator to REC ONLY (J3). This will eliminate the possibility of transmitting into the signal generator.

  • Page 7: Check And Adjustment Of Oscillators

    REPAIR AND RESTORATION OF THE SR-400 1-5. CHECK AND ADJUSTMENT OF OSCILLATORS: Before starting any receiver or transmitter troubleshooting or the RF or I.F. alignment it is imperative that the xtal oscillators and the VFO are precisely on frequency. If you will devote the time to these considerations you will be rewarded with a rig that performs as well as any modern rig.

  • Page 8: Vfo

    REPAIR AND RESTORATION OF THE SR-400 1-5-4. VFO: The VFO is comprised of V13, V4B and associated circuitry, the VFO correction circuitry and the RIT/CAL circuitry. From the manual: Frequency Stability; Less than 250 cycles drift in the first hour, after a fifteen minute warm-up, and less than 100 cycles per hour thereafter.
  • Page 9 REPAIR AND RESTORATION OF THE SR-400 VFO ALIGNMENT CONTINUED: Proceed to section 8-8-A of the original manual and perform the mechanical indexing adjustments before you proceed. When the mechanical indexing adjustments have been completed connect the frequency counter to V4A pin 3. Record the VFO frequency every 100 KHz from 0 to 500 (black scale).

  • Page 10: Receiver Fault Isolation

    REPAIR AND RESTORATION OF THE SR-400 2. RECEIVER FAULT ISOLATION YOU MUST HAVE ALL THE OSCILLATORS TESTED AND ALIGNED BEFORE PROCEEDING. SEE SECTION 1-5. 2-1. EQUIPMENT REQUIRED. HF RF signal generator capable of 0.5 microvolts to 300 millivolts and covering 1600 KHZ to 30 MHZ Audio output meter (similar to General Radio 1840A).

  • Page 11: Receiver Fault Isolation Chart

    REPAIR AND RESTORATION OF THE SR-400 2-4. RECEIVER FAULT ISOLATION CHART Injection point Frequency Signal Audio If good go to next step. If not check suggestions below. injection output level V15 pin 7 1000 Hz 14 vpp ½ wt. Problem most likely V15 or associated circuitry. 1:1 probe See section 4-2 for details.

  • Page 12: Agc Test

    REPAIR AND RESTORATION OF THE SR-400 2-5 AGC TEST The following agc test results are dependent upon overall gain and sensitivity of the receiver. This assumes a fully functional receiver and proper alignment. If you are in the process of restoring to operation you may not get the agc figure of merit in spec.

  • Page 13: Transmitter Testing

    REPAIR AND RESTORATION OF THE SR-400 3. TRANSMITTER TESTING At the start of the receiver testing you replaced the power supply fuse with a 4 amp normal delay. It is time to re-insert the 5 amp slo-blow fuse. The goal of this section is not to get maximum power out of the radio. The goal is simply to prove that the major transmitter sections are functioning.

  • Page 14: Bias Adjust

    REPAIR AND RESTORATION OF THE SR-400 3-3. BIAS ADJUST (plate idle current adjustment) With the power off plug your meter into the test jacks on the power supply chassis + to the red jack – to the blue jack. CAUTION the meter leads will be attached to the PA high voltage, fatal shock hazard is present. Insure the front panel settings are in accordance with paragraph 3-2 then power up.

  • Page 15: Transmitter Fault Isolation

    REPAIR AND RESTORATION OF THE SR-400 3-5, TRANSMITTER FAULT ISOLATION The assumption at this point is that the receiver works. If it does not you need to back up to section 2 and clear the receiver faults. For the fault isolation tests preset the equipment as listed in 3-2. STANDARD TEST CONDITIONS.

  • Page 16: 3-5-2, Low Or No Power Across All Bands

    REPAIR AND RESTORATION OF THE SR-400 3-5-2, LOW OR NO POWER ACROSS ALL BANDS A. Set the band switch to 3.5 and the main tuning to 3.9MHZ. Set the PRESELECTOR near the upper end of the 80 meter band. Power up and warm up. Remove the shield from V18 and install the DRIVER CAPACITIVE PICK UP tool.

  • Page 17: Subsystem Troubleshooting And Testing

    REPAIR AND RESTORATION OF THE SR-400 4. SUBSYSTEM TROUBLESHOOTING AND TESTING 4-1 VFO DRIFT You have performed all the tests in section 1-5-4 and determined that you have a drift problem. Perform the drift test in receive, LSB mode. Then perform the same test in receive, USB mode. If you have the drift problem in USB but not LSB the most likely cause is CR12, C126 or C127.

  • Page 18: V4A Rx Fault Isolation

    REPAIR AND RESTORATION OF THE SR-400 SUBSYSTEM TROUBLESHOOTING AND TESTING 4-8. V4A RX FAULT ISOLATION Assumption: You have injected 35uv @ 6 – 6.5 MHz into pin 1 of V6 and there was ½ watt audio output. And, when you inject 100uv into pin 2 of V4 you do not get ½ watt output. Check for 260 Vdc pin 1 of V4. If there is no 260 Vdc check pin 1 and 2 of T6.

  • Page 19: Tech Notes

    REPAIR AND RESTORATION OF THE SR-400 5. TECH NOTES 5-1. BASIC TUNE UP The RF power out and PLATE current monitoring leaves a little to be desired in the SR-150 through the SR- 500. This short fall was corrected in the SR-2000 with the addition of a dedicated plate current meter in the power supply.

  • Page 20: Manual Section 5-4 Mark Up

    REPAIR AND RESTORATION OF THE SR-400 5-1-5. MANUAL SECTION 5-4 MARK UP: The following is a markup of section 5-4 in the original manual. “UHG OHWWHUV” are suggested deviations and cautions from original manual section 5-4. 5-4 BASIC TRANSMITTER TUNE-UP The Model SR-400 Transceiver can be tuned up on several frequency segments that are outside the amateur bands.
  • Page 21 REPAIR AND RESTORATION OF THE SR-400 TECH NOTES CONTINUED BASIC TUNE UP CONTINUED C. Set the OPERATION control to MOX. The idle monitoring the plate current move the OPERATION plate current of the final amplifier stage should control from REC to MOX. Slowly increase the RF indicate less than 100 milliamperes.

  • Page 22: Pa Neutralization

    REPAIR AND RESTORATION OF THE SR-400 TECH NOTES CONTINUED 5-2 PA NEUTRALIZATION Proper neutralization will enhance the proper operation, efficiency and life of your final tubes. Theory and opinions on the effects of interelectrode capacitance are as numerous as the writers of such articles. So to be very basic, we are attempting to neutralize the effects of the interelectrode capacitance of the PA final tubes.

  • Page 23: Optional 6 Meg If Alignment

    : This is a member only site. It is free to join and I strongly recommend joining if you are a Hallicrafters fan. In the files section of this site is the largest collection of Hallicrafters technical information I have found anywhere. With close to 1000 members any post to the group will result in expert answers to any questions but you will have to be a member to post.

  • Page 24: Data Sheets

    REPAIR AND RESTORATION OF THE SR-400 6. DATA SHEETS 6-1. VFO FREQUENCY CORRECTION BLACK SPEC TEST 1 TEST 2 TEST 3 TEST 4 TEST 5 TEST 6 DIAL 4.850 4.750 4.650 4.550 4.450 4.350 WDØGOF 6/22/20014...

  • Page 25: Performance Data

    REPAIR AND RESTORATION OF THE SR-400 6.2 PERFORMANCE DATA 6-2-1. RECEIVER PERFORMANCE DATA OWNER SERIAL # DATE Overall Sensitivity (gain) The receiver will produce a minimum of 500 mw audio out with 1 uv RF signal at the antenna terminal. Tests performed at center of General Class bands BAND TEST FREQ...

  • Page 26: Transmitter Performance

    REPAIR AND RESTORATION OF THE SR-400 6-2-2. TRANSMITTER PERFORMANCE Tests performed with 50ohm resistive load. Measurements made with BIRD avg power and PEP power meter. Hi voltage ________vdc B+ ________vdc Bias -________vdc Final amplifier bias set to 70 ma SSB mode zero drive. _________ Neutralization performed @ 21.3 MHZ.

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Sr-400a cyclone iii

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