Roadstar CD-804MPBT User manual

Service Manual - CD-804MPBT
R
CD-804MPBT
Service Manual - CD-804MPBT

2
CONTENTS
Page
Disassembly Instructions..................................................................................................................................... 3
Disassembly Diagram.......................................................................................................................................... 4
Operation Check.................................................................................................................................................. 5
Block Diagram ..................................................................................................................................................... 6
Alignment Locations ............................................................................................................................................ 7
Alignment Procedures ......................................................................................................................................... 8
Printed Circuit Boards.......................................................................................................................................... 9
Exploded Views (Panel) .................................................................................................................................... 18
Exploded View Parts Lists (Panel) .................................................................................................................... 19
Exploded Views (Cabinet) ................................................................................................................................. 20
Exploded View Parts Lists (Cabinet) ................................................................................................................. 21
Exploded Views (Deck) ..................................................................................................................................... 24
Exploded View Parts Lists (Deck) ..................................................................................................................... 25
Schematic Diagram ........................................................................................................................................... 27
Electrical Parts List ............................................................................................................................................ 31
Specifications..................................................................................................................................................... 40

3
DISASSEMBLY INSTRUCTIONS
1. Using the unlock key that came with the unit or a similar tool, unlock the Mounting Box and remove toward
the rear of the unit.
2. Remove two screws (A) located on the rear of the top cabinet then remove the Top Cabinet.
3. Remove two screw (B) located on the rear of the bottom cabinet then remove the Bottom Cabinet.
4. Remove the screw (C) from on the front side of the base.
5. Remove two screws (D) from on the right side of the rear bracket.
Remove the screw (E) and the screw (F) from on the left side of the side bracket.
6. Remove two screws (G) from under the front deck bracket then remove the Front Deck Bracket.
Remove two screws (H) from under the rear deck bracket then remove the Rear Deck Bracket.
7. Take out the Panel and remove the Ring.
Remove two screws (I) from each side of the base then remove the Base.
8. Remove two screws (J) from on the Heat Sink then remove the Spring Sheet.
9. Remove five screws (K) from on the Heat Sink then remove the Heat Sink.
10. Remove the screw (L) from on the back of the side bracket then remove the Antenna Clip.
11. Remove the screw (M) from on the back of the side bracket.
Remove two screws (N) from on the main board then remove the Heat Sink (7809/DB435).
12. Remove two screws (O) from on the back of the side bracket then remove the Wire Clip.
13. Remove the screw (P) from on the right side of the side bracket then remove the IC Mounting Bracket.
14. Remove three screws (Q) from under the main board then remove the Main Board.

4
DISASSEMBLY DIAGRAM

5
OPERATION CHECK
GENERAL SPECIFICATIONS OF SIGNAL
Standard frequency
Signal output
Modulation
FM
AM
FM
AM
AM
FM Stereo
98.1 MHz (87.5, 107.9 MHz)
1000 kHz (530, 1710 kHz)
1mV
5 mV
400 Hz 30% MOD.
1 kHz 75kHz DEV.
46% for L only or
Ronlypilotlevel8%
AF output level FM/AM
Power source voltage DC 14.0V (Backup voltage is the same as this)
AF load impedance 4 ohm pure resistance
Balance Center position of level
Tone Center position
The signal strength read in this section is voltage on the antenna.
TestDiagram
4-SPEAKER
VTVM
DISTORTION
METER
2-SPEAKER
FRONT
SPK.
SPK.
FL.
RL.
SPR.
MAIN UNIT
AM SG
VTVM ANTANNA
DUMMY
FM SG
MODULATOR
STEREOS
MPX
ANT
FRONT
SPK.
SPE.
FR.
RR.
4-SPEAKER
SPK.
2-SPEAKER
POWER ANTANNA
ACC (DV14.4V)
GROUND
BACK UP (14.4V)

6
BLOCK DIAGRAM

7
ALIGNMENT LOCATIONS
FM/MW/LW TUNER

8
ALIGNMENT PROCEDURES
FM ADJUSTMENT
Equipment Required
zAM IF/RF signal generator
zSolid-state voltmeter (SSVM)
zRegulated DC power supply
z2-CH voltmeter
zDistortion meter
FM Alignment Using FM Signal Generator
Note: Press the radio power switch to on the radio. Signal generator output must be kept as low as possible
to avoid overload and clipping.
Step Generator
Coupling
Generator Display
Setting
Adjustment Remarks
IF FM RF Signal
Generator to
Antenna
input.
10.7 MHz
Sweep
output
60 dBµV
98.1 MHz T101
Adjust so that
maximum AF
output power and
minimum distortion
76 kHz
Pilot
Modulation
Signal
Generator
to antenna
receptacle
75 kHz Dev
45% for L only
or R only pilot
level 10%
98.1 MHz VR105 Adjust to
76 kHz
-3 dB
Limiting
Sens.
Signal
Generator
to antenna
receptacle
60 dBµV
Output. 98.1 MHz VR101
Adjust VR101
Making –14dB
(±2dB) Limiting
Sensitivity.
FM SNC
Adjustment
98.1 MHz
Dev. 45 kHz
L+R=90 %
Int. 1 kHz
60dBµV output
98.1 MHz
@ 40 dBµ
98.1 MHz VR106
VOR - VOL = 10 dB
(±3 dB)
FM Stereo
S/N
Signal Generator
Connected to
Antenna
98.1MHz
Int. 1kHz
Dev. 75kHz.
98.1MHz VR104
Adjust VR104 FM
Stereo S/N is the
optimum.
Auto Stop
Sens.
Signal Generator
Connected to
Antenna.
98.1 MHz
Int. 1kHz
Dev. 75kHz
28 dBµV
98.1 MHz VR107
Adjustment
AF to stop station.
Note: The tuner module is well-adjust and adjustment is not recommended.

9
PRINTED CIRCUIT BOARDS
MAIN BOARD
TOP VIEW

10
MAIN BOARD
BOTTOM VIEW

11
FM TUNER BOARD

12
KEY BOARD
TOP VIEW

13
KEY BOARD
BOTTOM VIEW

14
CD SERVO BOARD
TOP VIEW

15
CD SERVO BOARD
BOTTOM VIEW

16
BLUETOOTH PCB BOARD
TOP VIEW

17
BLUETOOTH PCB BOARD
BOTTOM VIEW

18
EXPLODED VIEW
PANEL

19
EXPLODED VIEW PARTS LIST
PANEL
Ref. No. Description RS Part No. Mfr’s Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Lens-B (S. OPC0000) MP3 VFD
Lens-S (S. OPC0000)
MAT Panel Top (Silver) X20.11 BT
Panel Top (S. OP1202)
Panel Bottom (F) /777
Open Key/F (E-Silver)
RE Knob Spring
DECARING (S. OP1202)
VOL Back Light
VOL Knob (E-Silver)
Power Key (Crystal)
SEL Key (Crystal)
EQ Key (Crystal)
Knob-3 Left
AS/PS~6 Key (L-Up) (S. OP1202)
Button Back Light
TA Key (Crystal)
PTY Key (Crystal)
AF Key (Crystal)
Knob-3 Right
BND/DSP (F) Knob (E-Silver)
7/MOD Key (L-Up) (S. OP1202)
MANU-SKIP 8-/9+ Key (L-Up) (S. OP1202)
SKIP Back Light
Key Board
ENCODER SRGP200200 (ALPS)
LCD racket Real (E)
CD100 LCD TN COLOR NEG 22X84 PIN
CD1007 B.LIGHT /WHITE
Axis Post
Right Side Block
Contact Spring
Left Side Block
E-Ring Ø1.5X4X0.4MM
Screw Ø2X8 BA/ST Black
53-G1240-31Y
53-G1239-30
61-G2101-86B
51-G2122-80
51-F2123-00
52-G2137-90E
36-11852-00
52-G2123-80
52-G2130-00
52-G2135-90E
52-G2132-01B
52-G2132-02B
52-G2132-03B
52-G2125-00
52-G2124-81
52-G2133-00
52-G2132-04B
52-G2132-05B
52-G2132-06B
52-G2129-00
52-G2138-90E
52-G2127-81
52-G2126-01
52-G2134-00
11-21730-319
18-00163-00
39-E2004-00
27-10000-01Y
02-01007-09
34-24601-00
52-E2128-00
36-78008-00
52-E2129-00
35-00001-00
40-12008-21

20
EXPLODED VIEW
CABINET