Roadstar CD-910DVD User manual

Service Manual - CD-910DVD
R
CD-910DVD
Service Manual - CD-910DVD

2
CONTENTS
Page
Disassembly Instructions ..................................................................................................................................... 3
Disassembly Diagram.......................................................................................................................................... 4
Operation Check.................................................................................................................................................. 5
Block Diagram ..................................................................................................................................................... 6
Alignment Locations ............................................................................................................................................ 7
Alignment Procedures ......................................................................................................................................... 8
Printed Circuit Boards........................................................................................................................................ 10
Wiring Diagram .................................................................................................................................................. 17
Exploded Views (Panel)..................................................................................................................................... 18
Exploded View Parts Lists (Panel)..................................................................................................................... 19
Exploded Views (Cabinet) ................................................................................................................................. 20
Exploded View Parts Lists (Cabinet) ................................................................................................................. 21
Schematic Diagram ........................................................................................................................................... 23
Electrical Parts List ............................................................................................................................................ 29
Specifications..................................................................................................................................................... 34

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 Cabinet Top then remove the Cabinet Top.
3. Remove two screws (B) located on the Cabinet Bottom then remove the Cabinet Bottom.
4. Remove two screws (C) (one located at the left side and one located at the right side of the front cabinet) then
remove two Hooks.
6. Remove the screw (D) from on the left side of the left bracket and remove the screw (E) from on the right side
of the right bracket.
7. Remove two screws (F) from on the rear bracket then remove the Deck.
8. Take Out the Panel and the Ring.
Remove two screws (G) from each side of the base then remove the Base.
9. Remove two screws (H) from on the right bracket then remove the Tooth Bracket and the Tune Top Tooth.
Slide off the Nut and the Stop Washer then remove the Brass Bush and the Tuning Shaft /Tuner.
9. Remove the screw (I) and two screws (J) from on the right bracket then remove the Tune FIX Support.
Remove the screw (K) from on the right bracket and remove three screws (L) from under the right bracket and
remove the 2BND Tuner and the Tuner Support.
10. Remove two screws (M) from on the back of the rear bracket and Slide off two Nuts then remove the DC FAN
12V.
Remove five screws (N) from on the back of the heat sink then remove the Heat Sink and the Heat Sink
Adaptor.
Remove two screws (O) from on the back of the rear bracket then remove the 22PIN Socket.
11. Remove the screw (P) from on the left bracket then remove the Transistor Holder.
12. Remove three screws (Q) from under the main board then remove the Main Board.
13. Remove two screws (R) from on the left bracket then remove the Left Bracket.
14. Remove two screws (S) from the right bracket then remove the Right Bracket and the Rear Bracket.

4
DISASSEMBLY DIAGRAM

5
OPERATION CHECK
GENERAL SPECIFICATIONS OF SIGNAL
Standard frequency
Signal output
Modulation
FM
MW
FM
MW
MW
FM Stereo
98.1 MHz (87.5, 108 MHz)
1000 kHz (522, 1620 kHz)
1 mV
5 mV
400 Hz 30% MOD.
1 kHz 75 kHz DEV.
46%forLonlyorR
onlypilotlevel8%.
AF output level FM/MW
Power source voltage DC 14.4V (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 AND PROCEDURES
FM IF/RF ADJUSTMENT
Equipment required
●FM IF/RF signal generator
●Oscilloscope
●FM Stereo signal generator
●Solid-state voltmeter (SSVM)
●Regulated DC power supply
●Distortion meter
FM IF and RF 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 dipping
Step Generator
Coupling
Generator
Setting
Display
Setting
Adjustment Remark
IF FM RF signal
Generator to
Antenna
Input.
10.7 MHz
Sweep output
30dB/µV
98.1 MHz T102 Adjust so that
maximum AF
output power and
minimum
distortion
76 kHz pilot
Modulation
Signal generator
to antenna
receptacle
75 kHz Dev.
90% for L only
or R only pilot
level 10%
98.1 MHz VR2 Adjust to
76 kHz
Stereo
Separation
Signal
Generator to
antenna
98.1 MHz
int. 1 kHz
Dev. 75 kHz
L + R = 92%
Pilot = 8%
98.1 MHz VR1 Adjust AF
Output power
For maximum
Separation
Note: The tuner module is well-aligned and adjustment is not recommended

8
AM IF/RF ADJUSTMENT
Equipment required
zAM IF/RF signal generator
zSolid-state voltmeter (SSVM)
zRegulated DC power supply
z2-CH voltmeter
zDistortion meter
AM IF and RF Alignment Using AM Signal Generator
Note: Press the 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 Remark
IF AM RF
Signal
Generator to
Antenna.
450 kHz Sweep
Output
60dB/µV
530 kHz T101 Adjust so that
maximum left and
right are
symmetrical
FREQ.
Low
FREQ.
High
530 kHz
1710 kHz
T106
CT103
RF Signal
Generator
to antenna
receptacle
600 kHz Int.
400Hz 30%
Mod output
20dB/mV
600 kHz T107
CT102
Adjust AF output
power for
maximum
RF
Count
Signal Generator
To antenna
receptacle
1000kHz Int.
400Hz 30% mod.
Output 20 dB/mV
1400 kHz VC101 Adjust AF output
power for
maximum
Note: The tuner module is well-aligned and adjustment is not recommended.

9
PRINTED CIRCUIT BOARDS
MAIN BOARD
TOP VIEW

10
MAIN BOARD
BOTTOM VIEW

11
KEY BOARD
TOP VIEW

12
KEY BOARD
BOTTOM VIEW

13
DISPLAY BOARD
TOP VIEW

14
DISPLAY BOARD
BOTTOM VIEW

15
REMOTE BOARD
TOP VIEW

16
REMOTE BOARD
BOTTOM VIEW

17
WIRIN DIAGRAM

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
Lens; DVD218 RM/SW (S. OP1202) ROADSTAR
Top Panel (S. OP1202)
Panel Bottom For LED Back Light 777D
Tuning Knob (S. OP1202)
TUNE Bottom Tooth
Encode Knob (S. OP1202)
SEL Knob (S. OP1202) (L-Up)
Spring Ring
EQ/DSP Knob (L-Up) (S. OP1202)
MODE/RDM/MON Knob (S. OP1202) (L-Up)
BND/EJ/PWR Knob (L-Up) (S. OP1202)
REL Knob (S. OP1202)
RE Knob Spring
Back Light For EQ/DSP Knob SPY WHT
Key Board
Encoder SRGP200200 (ALPS)
Screw Ø2.6X6 PH/ST Black
Screw Ø2X8 BH/ST Black
53-C1844-819
51-C1824-80S
51-C1826-00
52-C1833-80S
52-C1839-00
52-C1832-80S
52-C1828-82S
52-C1842-00
52-C1829-81S
52-C1827-86S
52-C1830-81S
52-C1831-80S
36-11852-00
52-C1834-01
11-02180-337
18-00163-00
40-12606-20
40-12008-01