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9 Service Fixture & Tools
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10 Disassembly and Assembly Instructions ---------------21
10.1. Disassembly flow chart --------------------------------- 22
10.2. Main Parts Location Diagram ------------------------- 23
10.3. Disassembly of Top Cabinet Assembly ------------- 24
10.4. Disassembly of Headphone P.C.B. ------------------ 25
10.5. Disassembly of iPod P.C.B.---------------------------- 26
10.6. Disassembly of Fr ont Panel Assembly ------------- 26
10.7. Disassembly of USB P.C.B. --------------------------- 27
10.8. Disassembly of Panel P.C.B. -------------------------- 28
10.9. Disassembly of FL Window---------------------------- 29
10.10. Disassembly of Centre Ornament ------------------- 30 10.11. Disassembly of CD Lid---------------------------------- 30
10.12. Disassembly of CD Mechanism Unit (DLS6C) --- 31
10.13. Disassembly of Power P.C.B. ------------------------- 32
10.14. Replacement of Power Amp IC (IC5101) ---------- 33
10.15. Disassembly of Main P.C.B. --------------------------- 34
10.16. Disassembly of Fan Unit ------------------------------- 36
10.17. Disassembly of Transformer P.C.B. ----------------- 37
10.18. Replacement of Transistor (Q5901) ----------------- 39
10.19. Disassembly of CD Servo P.C.B.--------------------- 40
11 Disassembly and Assembly of Traverse Unit ---------42
11.1. Disassembling Procedures ---------------------------- 42
11.2. Assembling Procedure---------------------------------- 43
12 Service Position ------------------------------------------------- 45
12.1. Checking & Repairing USB P.C.B. ------------------- 45
12.2. Checking & Repairing Panel P.C.B. ----------------- 47
12.3. Checking & Repairing CD Servo P.C.B. ------------ 48
12.4. Checking & Repairing Power P.C.B. ---------------- 49
12.5. Checking & Repairing Transformer P.C.B. --------- 50
12.6. Checking & Repairing Main P.C.B. ------------------ 51
13 Voltage Measurement & Waveform Chart ---------------52
13.1. USB P.C.B.------------------------------------------------- 52
13.2. CD SERVO P.C.B. --------------------------------------- 53
13.3. MAIN P.C.B. (1/2) ---------------------------------------- 54
13.4. MAIN P.C.B. (2/2) ---------------------------------------- 55
13.5. PANEL P.C.B. --------------------------------------------- 56
13.6. POWER P.C.B. ------------------------------------------- 56
13.7. TRANSFORMER P.C.B.-------------------------------- 56
13.8. Waveform Chart ------------------------------------------ 57
14 Illustration of ICs, Transistors and Diodes ------------58
15 Overall Simplified Block for PM38 -------------------------59
16 Block Diagram --------------------------------------------------- 60
16.1. CD SERVO BLOCK DIAGRAM ---------------------- 60
16.2. MAIN(1/2)/ PANEL/TRANSFORMER BLOCK DIAGRAM -------------------------------------------------- 61
16.3. MAIN(2/2)/ HEADPHONE/ iPod/ USB BLOCK DIAGRAM -------------------------------------------------- 62
17 Wiring Connection Diagram ---------------------------------63
18 Schematic Diagram Notes -----------------------------------64
19 Schematic Diagram --------------------------------------------- 65
19.1. CD SERVO CIRCUIT ----------------------------------- 65
19.2. MAIN CIRCUIT (1/4) ------------------------------------ 66
19.3. MAIN CIRCUIT (2/4) ------------------------------------ 67
19.4. MAIN CIRCUIT (3/4) ------------------------------------ 68
19.5. MAIN CIRCUIT (4/4) ------------------------------------ 69
19.6. PANEL CIRCUIT and HEADPHONE CIRCUIT --- 70
19.7. USB CIRCUIT --------------------------------------------- 71
19.8. iPod CIRCUIT and POWER CIRCUIT -------------- 72
19.9. TRANSFORMER CIRCUIT ---------------------------- 73
20 Printed Circuit Board ------------------------------------------ 7420.1. CD SERVO P.C.B. and TRANSFORMER
P.C.B. ------------------------------------------------------- 74
20.2. MAIN P.C.B. ----------------------------------------------- 75
20.3. PANEL P.C.B., HEADPHONE P.C.B. and POWER P.C.B. ------------------------------------------- 76
20.4. iPod P.C.B. and USB P.C.B. -------------------------- 77
21 Terminal Function of ICs ------------------------------------78
21.1. IC7001 (MN6627954AMA) IC SERVO PROCESSOR -------------------------------------------- 78
21.2. IC7002 (BA5948FPE2) IC 4CH Drive -------------- 79
21.3. IC800 (RFKWMPM38EG) IC MICRO- PROCESSOR -------------------------------------------- 79
22 Exploded View and Replacement Parts List -----------81
22.1. Exploded View and Mechanical replacement Parts List --------------------------------------------------- 81
22.2. Electrical Replac ement Parts List ------------------- 85
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1 Safety Precautions
1.1. General Guidelines
1. When servicing, observe the original lead dress. If a short circuit is found, replace all parts which have been overheated ordamaged by the short circuit.
2. After servicing, see to it that all the protective devices such as insulation barriers, insulation papers shields are properl y
installed.
3. After servicing, carry out the following leakage current checks to prevent the customer from being exposed to shock hazards.
(This Safety Precaution is applied only in U.S.A.) 1. Before servicing, unplug the power cord to prevent an electric shock.
2. When replacing parts, use only manufacturers recommended components for safety.
3. Check the condition of the power cord. Replace if wear or damage is evident.
4. After servicing, be sure to restore the lead dress, insulation barriers, insulation papers, shields, etc.
5. Before returning the serviced equipment to the customer, be sure to make the following insulation resistance test to preventthe customer from being exposed to a shock hazard.
1.1.1. Leakage Current Cold Check
1. Unplug the AC cord and connect a jumper between the two prongs on the plug.
2. measure the resistance value, with an ohmmeter between the jumpered AC plug and each exposed metallic cabinet part onthe equipment such as screwheads, connectors, control shafts, etc. When the exposed metallic part has a return path to the
chassis, the reading should be between 1M Ω and 5.2M Ω. When the exposed metal does not have a return path to the chas-
sis, the reading must be
1.1.2. Leakage Current Hot Check
1. Plug the AC cord directly into the AC outlet. Do not use an isolation transformer for this check.
2. Connect a 1.5k Ω, 10 watts resistor, in parallel with a 0.15 μF capacitors, between each exposed metallic part on the set and a
good earth ground such as a water pipe, as shown in Figure 1.
3. Use an AC voltmeter, with 1000 ohms/volt or more sensitivity, to measure the potential across the resistor.
4. Check each exposed metallic part, and measure the voltage at each point.
5. Reverse the AC plug in the AC outlet and repeat each of the above measurements.
6. The potential at any point should not exceed 0.75 volts RMS. A leakage current tester (Simpson Model 229 or equivalent) may be used to make the hot checks, leakage current must not exceed 1/2 milliamp. In case a measurement is outside of the
limits specified, there is a possibility of a shock hazard, and the equipment should be repaired and rechecked before it is
returned to the customer.
Figure. 1
