JVC KD-G541EX, KD-G541EY, KD-G541EU, KD-G544UI, KD-G545U SERVICE MANUAL

SERVICE MANUAL

CD RECEIVER

MA384<Rev.001>200712SERVICE MANUAL

KD-G541E, KD-G541EX, KD-G541EY,

KD-G541EU, KD-G544UI, KD-G545U,

KD-G545UN, KD-G545UT, KD-G545UH,

KD-G546U, KD-G546UN, KD-G546UT,

KD-G546UH, KD-G547EE

only for
KD-G541
KD-G547

COPYRIGHT © 2007 Victor Company of Japan, Limited

Lead free solder used in the board (material : Sn-Ag-Cu, melting point : 219 Centigrade)
Lead free solder used in the board (material : Sn-Cu, melting point : 230 Centigrade)

TABLE OF CONTENTS

1 PRECAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

COPYRIGHT © 2007 Victor Company of Japan, Limited

only for

KD-G547

No.MA384<Rev.001>

2007/12

SPECIFICATION

KD-G541

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output (RMS)

Load Impedance 4 Ω (4 Ω to 8 Ω allowance)

Tone Control Range Bass ±12 dB at 60 Hz

Frequency Response 40 Hz to 20 000 Hz

Signal-to-Noise-Ratio 70 dB

Line-Out Level/Impedance 2.5 V/20 kΩ load (full scale)
Output Impedance 1 kΩ
Subwoofer-Out Level/Impedance 2.5 V/20 kΩ load (full scale)

Other Terminal

Frequency Range FM 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity 11.3 dBf (1.0 µV/75 Ω)

MW Tuner Sensitivity/Selectivity 20 µV/35 dB
LW Tuner Sensitivity 50 µV

Type Compact disc player

Signal Detection System Non-contact optical pickup (semiconductor laser)

Number of Channels 2 channels (stereo)

Frequency Response 5 Hz to 20 000 Hz

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit

MP3 Decoding Format
(MPEG1/2 Audio Layer 3)

WMA (Windows Media® Audio)
Decoding Format

Power Requirement Operating Voltage DC 14.4 V (11 V to 16 V allowance)

Grounding System Negative ground

Allowable Operating Temperature 0°C to + 40°C

Dimensions (W × H × D) (approx.)

Mass 1.4 kg (excluding accessories)

Design and specifications are subject to change without notice.

Front/Rear 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8%

total harmonic distortion.

Middle ±12 dB at 1 kHz

Treble ±12 dB at 7.5 kHz

CD changer jack AUX (auxiliary) input jack Steering wheel remote input

TUNER SECTION

AM (MW) 522 kHz to 1 620 kHz

(LW) 144 kHz to 279 kHz

50 dB Quieting Sensitivity 16.3 dBf (1.8 µV/75 Ω)

Alternate Channel Selectivity (400 kHz)

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

CD PLAYER SECTION

Max. Bit Rate 320 kbps

Max. Bit Rate 320 kbps

Installation Size 182 mm × 52 mm × 160 mm

Panel Size 188 mm

65 dB

GENERAL

×

58 mm × 13 mm

1-2 (No.MA384<Rev.001>)

KD-G544/KD-G545/KD-G546

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output (RMS)

Load Impedance 4 Ω (4 Ω to 8 Ω allowance)

Tone Control Range Bass ±12 dB at 60 Hz

Frequency Response 40 Hz to 20 000 Hz

Signal-to-Noise-Ratio 70 dB

Line-Out Level/Impedance 2.5 V/20 kΩ load (full scale)
Subwoofer-Out Level/Impedance 2.5 V/20 kΩ load (full scale)
Output Impedance 1 kΩ

Other Terminal CD changer jack, AUX (auxiliary) input jack

Frequency Range FM 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity: 11.3 dBf (1.0 µV/75 Ω)

AM Tuner Sensitivity 20 µV

Type Compact disc player

Signal Detection System Non-contact optical pickup (semiconductor laser)

Number of Channels 2 channels (stereo)

Frequency Response 5 Hz to 20 000 Hz

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit

MP3 Decoding Format
(MPEG1/2 Audio Layer 3)

WMA (Windows Media® Audio)
Decoding Format

Power Requirement Operating Voltage DC 14.4 V (11 V to 16 V allowance)

Grounding System Negative ground

Allowable Operating Temperature 0°C to + 40°C

Dimensions (W × H × D) (approx.)

Mass 1.4 kg (excluding accessories)

Front/Rear 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8%

total harmonic distortion.

Middle ±12 dB at 1 kHz

Treble ±12 dB at 7.5 kHz

TUNER SECTION

AM 531 kHz to 1 602 kHz

50 dB Quieting Sensitivity 16.3 dBf (1.8 µV/75 Ω)

Alternate Channel Selectivity (400 kHz)

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

Selectivity 35 dB

CD PLAYER SECTION

Max. Bit Rate 320 kbps

Max. Bit Rate 320 kbps

Installation Size 182 mm × 52 mm × 160 mm

Panel Size 188 mm

65 dB

GENERAL

×

58 mm × 6 mm

Design and specifications are subject to change without notice.

(No.MA384<Rev.001>)1-3

KD-G547

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output (RMS)

Load Impedance 4 Ω (4 Ω to 8 Ω allowance)

Tone Control Range Bass ±12 dB at 60 Hz

Frequency Response 40 Hz to 20 000 Hz

Signal-to-Noise-Ratio 70 dB

Line-Out Level/Impedance 2.5 V/20 kΩ load (full scale)
Output Impedance 1 kΩ
Subwoofer-Out Level/Impedance 2.5 V/20 kΩ load (full scale)

Other Terminal AUX (auxiliary) input jack

Frequency Range FM1/FM2 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity 11.3 dBf (1.0 µV/75 Ω)

MW Tuner Sensitivity/Selectivity 20 µV/35 dB
LW Tuner Sensitivity 50 µV

Type Compact disc player

Signal Detection System Non-contact optical pickup (semiconductor laser)

Number of Channels 2 channels (stereo)

Frequency Response 5 Hz to 20 000 Hz

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit

MP3 Decoding Format
(MPEG1/2 Audio Layer 3)

WMA (Windows Media® Audio)
Decoding Format

Power Requirement Operating Voltage DC 14.4 V (11 V to 16 V allowance)

Grounding System Negative ground

Allowable Operating Temperature 0°C to + 40°C

Dimensions (W × H × D) (approx.)

Mass 1.4 kg (excluding accessories)

Design and specifications are subject to change without notice.

Front/Rear 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8%

total harmonic distortion.

Middle ±12 dB at 1 kHz

Treble ±12 dB at 7.5 kHz

TUNER SECTION

FM3 65.00 MHz to 74.00 MHz

AM (MW) 522 kHz to 1 620 kHz

(LW) 144 kHz to 279 kHz

50 dB Quieting Sensitivity 16.3 dBf (1.8 µV/75 Ω)

Alternate Channel Selectivity (400 kHz)

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

CD PLAYER SECTION

Max. Bit Rate 320 kbps

Max. Bit Rate 320 kbps

Installation Size 182 mm × 52 mm × 160 mm

Panel Size 188 mm

65 dB

GENERAL

×

58 mm × 13 mm

1-4 (No.MA384<Rev.001>)

1.1 Safety Precautions

SECTION 1

PRECAUTION

!

!

Burrs formed during molding may be left over on some parts of the chassis. Therefore,
pay attention to such burrs in the case of preforming repair of this system.

Please use enough caution not to see the beam directly or touch it in case of an
adjustment or operation check.

(No.MA384<Rev.001>)1-5

1.2 Preventing static electricity

Electrostatic discharge (ESD), which occurs when static electricity stored in the body, fabric, etc. is discharged, can destroy the laser
diode in the traverse unit (optical pickup). Take care to prevent this when performing repairs.

1.2.1 Grounding to prevent damage by static electricity

Static electricity in the work area can destroy the optical pickup (laser diode) in devices such as laser products.
Be careful to use proper grounding in the area where repairs are being performed.

(1) Ground the workbench

Ground the workbench by laying conductive material (such as a conductive sheet) or an iron plate over it before placing the
traverse unit (optical pickup) on it.

(2) Ground yourself

Use an anti-static wrist strap to release any static electricity built up in your body.

(caption)
Anti-static wrist strap

1M

Conductive material

(conductive sheet) or iron plate

(3) Handling the optical pickup

• In order to maintain quality during transport and before installation, both sides of the laser diode on the replacement optical
pickup are shorted. After replacement, return the shorted parts to their original condition.
(Refer to the text.)

• Do not use a tester to check the condition of the laser diode in the optical pickup. The tester's internal power source can easily
destroy the laser diode.

1.3 Handling the traverse unit (optical pickup)

(1) Do not subject the traverse unit (optical pickup) to strong shocks, as it is a sensitive, complex unit.
(2) Cut off the shorted part of the flexible cable using nippers, etc. after replacing the optical pickup. For specific details, refer to the

replacement procedure in the text. Remove the anti-static pin when replacing the traverse unit. Be careful not to take too long a

time when attaching it to the connector.
(3) Handle the flexible cable carefully as it may break when subjected to strong force.
(4) It is not possible to adjust the semi-fixed resistor that adjusts the laser power. Do not turn it.

1.4 Attention when traverse unit is decomposed

*Please refer to "Disassembly method" in the text for the pickup unit.

• Apply solder to the short land before the card wire is disconnected from the connector on the pickup unit.
(If the card wire is disconnected without applying solder, the pickup may be destroyed by static electricity.)

• In the assembly, be sure to remove solder from the short land after connecting the card wire.

Pickup

Wires

Push switch

1-6 (No.MA384<Rev.001>)

Base board

Frame

Flexible wire

Connector

CD mechanism
assembly

Pickup

1.5 Important for laser products

1.CLASS 1 LASER PRODUCT

2.CAUTION :

(For U.S.A.) Visible and/or invisible class II laser radiation
when open. Do not stare into beam.
(Others) Visible and/or invisible class 1M laser radiation
when open. Do not view directly with optical instruments.

3.CAUTION : Visible and/or invisible laser radiation when
open and inter lock failed or defeated. Avoid direct
exposure to beam.

4.CAUTION : This laser product uses visible and/or invisible
laser radiation and is equipped with safety switches which
prevent emission of radiation when the drawer is open and
the safety interlocks have failed or are defeated. It is
dangerous to defeat the safety switches.

5.CAUTION : If safety switches malfunction, the laser is able
to function.

6.CAUTION : Use of controls, adjustments or performance of
procedures other than those specified here in may result in
hazardous radiation exposure.

!

Please use enough caution not to

see the beam directly or touch it

in case of an adjustment or operation

check.

REPRODUCTION AND POSITION OF LABELS and PRINT

WARNING LABEL and PRINT

(No.MA384<Rev.001>)1-7

SECTION 2

SPECIFIC SERVICE INSTRUCTIONS

This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.

SECTION 3

DISASSEMBLY

3.1 Main body (used figure is KD-G343)

3.1.1 Removing the FRONT CHASSIS assembly (See Fig.1, 2)

(1) Remove the two screws A attaching the FRONT CHASSIS

assembly. (See Fig.1)

(2) Remove the two screws B attaching the both side of the

FRONT CHASSIS assembly.(See Fig.2)

(3) Disengage the four hooks a engaged the both side of the

FRONT CHASSIS assembly. (See Fig.2)

Fig.1

A

B

3.1.2 Removing the HEAT SINK (See Fig.3, 4)

(1) Remove the four screws C and the two screws D attaching

the HEAT SINK. (See Fig.3)

(2) Remove the two screws E and the one screw F attaching

the HEAT SINK. (See Fig.4)

hook a

Fig.2

C

D

Fig.3

F

1-8 (No.MA384<Rev.001>)

E

Fig.4

3.1.3 Removing the BOTTOM COVER (See Fig.5)

(1) Remove the one screw G attaching the BOTTOM COVER.
(2) Slide the BOTTOM COVER to backward.

3.1.4 Removing the MAIN BOARD assembly (See Fig.6, 7)

(1) Remove the two screws H and the two screws J attaching

the MAIN BOARD assembly. (See Fig.6, 7)

(2) Disconnect the connector CN501

BOARD assembly and CD MECHANISM assembly. (See
Fig.7)

connected to MAIN

G

Fig.5

H

Fig.6

CN501

3.1.5 Removing the CD MECHANISM assembly (See Fig.8)

(1) Remove the three screws K attaching the CD MECHANISM

assembly.

J

Fig.7

K

K

Fig.8

(No.MA384<Rev.001>)1-9

3.1.6 Removing the SWITCH BOARD assembly (See Fig.9, 10 )

(1) Remove the VOLUME KNOB.
(2) Remove the one screw L and the four screws M attaching

the REAR COVER. (See Fig.9, 10)

(3) Disengage the nine hooks b engaged the REAR COVER.

(See Fig.10)

L

Fig.9

M

M

hook b

M

hook b

Fig.10

1-10 (No.MA384<Rev.001>)

3.2 CD mechanism assembly

A

3.2.1 Removing the top cover
(See Figs.1 and 2)

(1) From the both side of the CD mechanism assembly, remove

the four screws A attaching the top cover. (See Fig.1.)

(2) Lift the front side of the top cover and move the top cover

backward to release the two joints a. (See Figs.1 and 2.)

Top cover

A

a

A

A

Fig.1

a

Top cover

Fig.2

(No.MA384<Rev.001>)1-11

3.2.2 Removing the push switch
(See Figs.3)

(1) From the bottom side of the CD mechanism assembly, remove

the screw B attaching the push switch.

(2) Take out the push switch from the CD mechanism assembly.

Reference:

Remove the wires from soldered sections b of the push switch
as required.

3.2.3 Removing the base board
(See Figs.3 and 4)

Caution:

Solder the short land c before the flexible wire is disconnected from
the connector on the pickup. If the flexible wire is disconnected
without applying solder, the pickup may be destroyed by static
electricity. (See Fig.3.)
(1) From the bottom side of the CD mechanism assembly, remove

the screw C attaching the base board. (See Figs.3 and 4.)
(2) Solder the short land c on the pickup. (See Fig.3.)
(3) Disconnect the flexible wire from the connector on the pickup.

(See Fig.3.)
(4) Remove the base board from the joints d of the frame in the

direction of the arrow. (See Figs.3 and 4.)

Reference:

Remove the wires from the soldered sections e on the base
board as required. (See Fig.3.)

Caution:

When reattaching the base board, be sure to remove solder
from the short land c after connecting the flexible wire. (See
Fig.3.)

e

C

Base board

Frame

Wires

B

b

d

Push switch

Flexible wire

Connector

Fig.3

Pickup

CD mechanism
assembly

Pickup

c

C

Base board

Flexible wire

Frame

d

Fig.4

1-12 (No.MA384<Rev.001>)

3.2.4 Removing the chassis unit
(See Figs.5 and 6)

• Remove the top cover and base board.

(1) From the top side of the CD mechanism assembly, remove

the front suspension springs and rear suspension springs
attaching the chassis unit to the frame. (See Fig.5.)

(2) Remove the chassis unit from the dampers on the frame in

an upward direction. (See Fig.6.)

Note:

• Pay attention to misuse and loss of each spring. (See Fig.5.)

• When reassembling, make sure that the three shafts on the
underside of the chassis unit are inserted to the dampers
certainly. (See Fig.6.)

Chassis unit

Front suspension spring

Front suspension spring

Frame

Rear suspension spring Rear suspension spring

Fig.5

Chassis unit

Shaft

Shaft

Damper F

Damper F

Damper R

Frame

Shaft

Fig.6

(No.MA384<Rev.001>)1-13

3.2.5 Removing the clamper assembly
(See Figs.7 and 8)

• Remove the top cover.

Move the clamper assembly in the direction of the arrow to release
the joints f from the chassis unit.

Chassis unit

f

Clamper assembly

Clamper assembly

Chassis unit

f

Fig.7

f

f

Fig.8

1-14 (No.MA384<Rev.001>)

3.2.6 Removing the loading/feed motor assembly

(See Fig.9)

• Remove the top cover, base board and chassis unit.
From the bottom side of the chassis unit, remove the screw D
and take out the loading/feed motor assembly in the direction of
the arrow.

Reference:

Remove the wires from the soldered sections g of the loading/
feed motor assembly as required.

Loading/feed motor assembly

g

Chassis unit

Loading/feed
motor
assembly

D

Fig.9

(No.MA384<Rev.001>)1-15

3.2.7 Removing the pickup
(See Figs.10 to 12)

• Remove the top cover, base board and chassis unit.

(1) From the bottom side of the chassis unit, remove the screw

E attaching the pu. shaft holder B and pull the pu. shaft out
of the pu. shaft holder A. (See Fig.10.)

(2) Remove the screw F attaching the pu. shaft holder A. (See

Fig.10.)

(3) Take out the pickup with pu. shaft holder A and feed screw

assembly from the chassis unit. (See Fig.11.)

(4) Remove the section h of the pu. shaft holder A in the direction

of the arrow. (See Fig.11.)

(5) Remove the feed screw assembly from the section j of the

pickup in the direction of the arrow. (See Fig.11.)

(6) Remove the screw G attaching the feed screw holder to the

pickup. (See Fig.12.)

Reference:

Remove the feed nut spring from the feed screw holder
as required. (See Fig.12.)

(7) Release the claw k in the direction of the arrow to remove

the feed sub holder. (See Fig.12.)

Pickup

Feed screw assembly

Feed screw holder

Pu. shaft holder A

Fig.11

G

h

j

Feed screw
holder

3.2.8 Reattaching the pickup
(See Figs.10 to 13)

(1) Reattach the feed sub holder to the pickup. (See Fig.12.)
(2) Reattach the feed screw holder to the pickup using the

screw G. (See Fig.12.)

(3) Reattach the feed screw assembly and pu. shaft holder A

to the pickup as before. (See Fig.11.)

(4) Set the section m of the pickup to the rail of the chassis unit

at first and attach the pickup to the chassis unit with the

screw F as before. (See Figs.10 and 13.)
(5) Attach the pu. shaft to the pickup as before. (See Fig.10.)
(6) Attach the pu. shaft holder B to the chassis unit with the

screw E as before. (See Fig.10.)

Chassis unit

Pu. shaft holder A

Pu. shaft

F

Pickup

k

Feed sub holder

Pickup

Rail

Feed nut
spring

Fig.12

m

F

E

Pu. shaft holder B

1-16 (No.MA384<Rev.001>)

Fig.10

Pickup

Chassis unit

Fig.13

3.2.9 Removing the trigger arm
(See Fig.14)

• Remove the top cover, base board, chassis unit and clamper

assembly.
(1) From the top side of the chassis unit, remove the trigger

arm spring from the sections (n, p).

(2) From the bottom side of the chassis unit, release the claws q

of the trigger arm base in the direction of the arrow to remove
them from the sections r of the chassis unit to the other side.

Note:

When releasing the claws q, take care not to break them.

(3) From the top side of the chassis unit, move the select arm R

and select lock arm in the direction of the arrow to remove
the trigger arm base from the section s in the direction of the
arrow.

(4) Remove the trigger arm from the section t.

3.2.10 Removing the top plate assembly
(See Fig.15)

• Remove the top cover, base board, chassis unit, clamper assembly

and trigger arm.
(1) Remove the screw H attaching the top plate assembly.
(2) Move the top plate assembly in the direction of the arrow to

release the joints (u, v).

Reference:

Remove the wires from the soldered sections w of the top plate
assembly as required.

Note:

When reassembling, solder the wires as before.

Select lock arm

Trigger arm
spring

u

v

Select arm R

s

n

t

p

Chassis unit

Top plate assembly

Chassis unit

Trigger arm base

Trigger arm

q

r

Fig.14

H

w

Wire(Red)

Fig.15

(No.MA384<Rev.001>)1-17

Wire(White)

Wire(Brown)

3.2.11 Removing the mode switch
(See Fig.16)

• Remove the top cover, base board, chassis unit, clamper assembly,

trigger arm and top plate assembly.
(1) From the top side of the top plate assembly, remove the

link gear spring from the sections x of the link gear L and
link gear R.

(2) Remove the link gear L in an upward direction while releasing

the claws y of the link gear L in the direction of the arrow.

(3) Move the mode switch in the direction of the arrow 1 to remove

the sections z of the top plate assembly.

(4) Move the mode switch in the direction of the arrow 2 and

remove the mode switch from the sections (aa, ab).

Note:

When reattaching the link gear L, attach it after aligning the
hole ac of the link gear L to the hole ac of the link gear R.

Reference:

When reassembling, reverse the above removing procedure.

Top plate assembly

Link gear spring

Link gear R

Link
gear R

Link
gear L

ac ac

aa

Link gear L

Fig.16

Mode switch

x

1

2

z

y

y

ab

1-18 (No.MA384<Rev.001>)

3.2.12 Removing the select arm R and select lock arm

(See Figs.17 and 18)

• Remove the top cover, base board, chassis unit, clamper assembly,

trigger arm and top plate assembly.
(1) From the top side of the top plate assembly, remove the

link gear spring from the sections ad of the link gear L and
link gear R. (See Fig.17.)

(2) Remove the link gear R in an upward direction while releasing

the claws ae of the link gear R in the direction of the arrow.
(See Fig.17.)

(3) Move the select arm R in the direction of the arrow 1 to remove

the sections af of the top plate assembly. (See Fig.17.)

(4) Move the select arm R in the direction of the arrow 2 and

remove the select arm R from the sections ag. (See
Fig.17.)

(5) From the bottom side of the top plate assembly, remove

the select lock arm spring from the section ah. (See
Fig.18.)

(6) From the top side of the top plate assembly, remove the section

aj of the select lock arm from the top plate assembly at first and
remove the sections (ak, am) of the select lock arm from the top
plate assembly. (See Fig.18.)

Note:

• When removing the select lock arm spring, be careful not to
lose it. (See Fig 18.)

• When reattaching the link gear R, attach it after aligning the
hole an of the link gear R to the hole an of the link gear L.
(See Fig.17.)

Reference:

When reassembling, reverse the above removing procedure.

ak

ae

2

af

ae

Select arm R

ad

1

ag

Link gear R

Select lock arm

aj

Link gear spring

Top plate assembly

Link gear L

Link
gear R

an an

Fig.17

Top plate assembly

Link
gear L

Select lock
arm spring

ah

am

Fig.18

(No.MA384<Rev.001>)1-19

3.2.13 Removing the loading roller assembly
(See Figs.19 to 21)

• Remove the top cover, base board, chassis unit, clamper assembly

and top plate assembly.
(1) From the left side of the chassis unit, remove the screw J

attaching the lock arm assembly. (See Fig.19.)

(2) Remove the projection ap of the lock arm assembly from

the joint aq while opening the cam plate R in the direction
of the arrow. (See Fig.19.)

(3) Remove the lock arm assembly from the projection ar of

the chassis unit. (See Fig.19.)

(4) Remove the projection as of the lock arm assembly from

the joint at of the cam plate L assembly. (See Fig.19.)

(5) From the right side of the lock arm assembly, remove the

loading roller spring L from the section au. (See Fig.20.)

(6) From the top side of the lock arm assembly, remove the loading

roller spring R in the direction of the arrow and remove the loading
roller assembly. (See Fig.20.)

(7) Remove the roller guide R, HL washer and roller guide L

from the both ends of the loading roller assembly. (See
Fig.21.)

aq

J

ap

Lock arm assembly

Loading roller assembly

Cam plate R

Fig.19

Chassis unit

Cam plate L assembly

ar

Loading roller spring R

at

as

Lock arm assembly

Loading roller
spring L

au

Fig.20

Roller guide L Roller guide R

HL washer

Loading roller assembly

Fig.21

1-20 (No.MA384<Rev.001>)

3.2.14 Removing the loading gear 1, loading gear 2, loading gear 3 and feed gear 1

(See Fig.22)

• Remove the top cover, base board and chassis unit.

(1) From the bottom side of the chassis unit, pull out the loading

gear 1.
(2) Take out the loading gear 2.
(3) Pull out the loading gear 3.
(4) Pull out the feed gear 1.

3.2.15 Removing the loading gear 4, loading gear 5 and
loading gear 6
(See Fig.22)

• Remove the top cover, base board and chassis unit.

(1) From the bottom side of the chassis unit, remove the screw

K attaching the loading gear bracket.

(2) Take out the loading gear bracket and remove the loading

gear 5 and loading gear 6 from the loading gear bracket.

(3) Pull out the loading gear 4.

Loading gear bracket

Loading gear 3

Feed gear 2

Loading gear 6

Loading gear
bracket

Loading gear 4

Loading gear 1

Loading
gear 5

K

3.2.16 Removing the change gear 2, change gear 3A and
change gear 3B
(See Figs.22 and 23)

• Remove the top cover, base board and chassis unit.

(1) From the bottom side of the chassis unit, pull out the loading

gear 1. (See Fig.22.)
(2) Pull out the change gear 2. (See Fig.22.)
(3) Pull out the change arm. (See Fig.22.)
(4) Move the change gear plate rivet assembly in the direction

of the arrow 2 to remove the section av of the change gear

plate rivet assembly from the chassis unit while moving the

change lock lever in the direction of the arrow 1. (See

Fig.23.)
(5) Pull out the change gear 3A and change gear 3B from the

change gear plate rivet assembly. (See Fig.23.)

3.2.17 Removing the cam plate L assembly
(See Fig.24)

• Remove the top cover, base board, chassis unit, clamper assembly,

top plate assembly and loading roller assembly.
(1) From the left side of the chassis unit, slide the cam plate L

assembly in the direction of the arrow.

(2) Remove the cam plate L assembly from the slots aw of the

chassis unit.

Feed gear 1

Chassis unit

Fig.22

Change gear plate rivet assembly

Change gear 3B

1

Chassis unit

Change lock lever

Fig.23

Chassis unit

Change arm

Change gear plate
rivet assembly

2

av

Loading gear 2

Change
gear 3A

Change gear 3B

Change gear 3A

aw

aw

Cam plate L assembly

Fig.24

(No.MA384<Rev.001>)1-21

3.2.18 Removing the cam plate R
(See Fig.25)

• Remove the top cover, base board, chassis unit, clamper assembly,

top plate assembly and loading roller assembly.
From the right side of the chassis unit, remove the cam plate R
from the slots ax of the chassis unit.

Reference:

When a slide hook rivet assembly and a trigger rack spring have

come off from the chassis unit, attach them before attaching the

cam plate R.

3.2.19 Removing the trigger rack plate

(See Figs.25 and 26)

• Remove the top cover, base board, chassis unit, clamper assembly,

top plate assembly, loading roller assembly and cam plate R.

(1) Remove the slide hook rivet assembly and trigger rack

spring from the chassis unit. (See Fig.25.)

(2) From the bottom side of the chassis unit, pull out the loading

gear 1. (See Fig.26.)

(3) Remove the trigger control spring from the sections (ay,

az). (See Fig.26.)

(4) Take out the trigger rack plate from the chassis unit. (See

Fig.26.)

Reference:

When attaching the trigger rack plate, insert the projection a'

of the chassis unit in the slot b' on the bottom side of the trigger

rack plate as before. (See Fig.26.)

Chassis unit

ax

Cam plate R

b'

Trigger rack spring

Slide hook rivet assembly

ax

Fig.25

Trigger control spring

az

a'

Trigger
rack plate

Trigger rack plate

Loading gear 1

ay

Chassis unit

Fig.26

1-22 (No.MA384<Rev.001>)

3.2.20 Removing the spindle motor assembly
(See Figs.27 and 28)

• Remove the top cover, base board, chassis unit and clamper

assembly.
(1) From the top side of the chassis unit, turn the turn table from

side to side and remove the two screws M attaching the
spindle motor assembly through the hole of the turn table.
(See Fig.27.)

(2) From the bottom side of the chassis unit, turn the change

gear 2 in the direction of the arrow 2 while pulling the trigger
arm in the direction of the arrow 1 and let the pickup move
in the direction of the arrow 3. (See Fig.28.)

(3) Slide the spindle motor assembly in the direction of the arrow

and take out it in an upward direction from the chassis unit.
(See Fig.28.)

Reference:

Remove the wires from the soldered sections c' on the base
board and remove them from the sections (d', e') on the chassis
unit as required.

Chassis unit

Wire(black)

Wire(red)

M

Fig.27

Spindle motor assembly

d'

Turn table

e'

Change gear 2

c'

Base board

3

Pickup

2

1

Trigger arm

Chassis unit

Fig.28

(No.MA384<Rev.001>)1-23

SECTION 4

ADJUSTMENT

4.1 Test instruments required for adjustment

(1) Digital oscilloscope (100MHz)
(2) Electric voltmeter
(3) Digital tester
(4) Tracking offset meter
(5) Test Disc JVC :CTS-1000
(6) Extension cable for check

EXTSH002-22P x 1

4.2 Standard measuring conditions

Power supply voltage DC14.4V(10.5 to 16V)
Load impedance 20K.(2 Speakers connection)
Output Level Line out 2.5V (Vol. MAX)

4.5 How to connect the extension cable for adjusting

Caution:

Be sure to attach the heat sink and rear bracket onto the power amplifier IC and regulator IC respectively, before supply the power.
If voltage is applied without attaching these parts, the power amplifier IC and regulator IC will be destroyed by heat.

4.3 Standard volume position

Balance and Bass &Treble volume : lndication"0"
Loudness : OFF

4.4 Dummy load

Exclusive dummy load should be used for AM,and FM.
For FM dummy load, there is a loss of 6dB between SSG output
and antenna input.
The loss of 6dB need not be considered sincedirect reading of
figures are applied in this working standard.

Extension cable
EXTSH002-22P

1-24 (No.MA384<Rev.001>)

TROUBLESHOOTING

5.1 16PIN CORD DIAGRAM (for KD-G541, KD-G547)

8
7

6

5

4
3
2
1

BK

RD

NC

BL/WH

WH

GN

VI

GY

YL

NC

NC

BR

WH/BK

GN/BK

VI/BK

GY/BK

16
15

14
13

12
11
10

9

BK

RD

BL

WH

BR

SECTION 5

Black

Red

Blue

White

Brown

GN

VI

GY

YL

Green

Violet

Gray

Yellow

BR

NC

1

NC

3

BL/WH

5

RD

7

YL

NC

BK

2

4

6

8

RR

FR

FL

RL

7 RD

16 YL

8 BK

5 BL/WH

13 BR

3 GN

11 GN/BK

2 VI

10 VI/BK

4 WH

12 WH/BK

1 GY

9 GY/BK

Rear Right

Front Right

Front Left

Rear Left

ACC

TEL

GND

MEMORY

RD

ACC Line

Telephone Muting

Ground

Memory Backup Battery+

RD 7

YL 4

8

5

2

7

8

1

2

5

6

3

4

VI/BK

VI

1

GY

3

WH

5

GN

7

GY/BK

WH/BK

GN/BK

2

4

6

8

REMOTE

ILL

Remote

Illuminations Control

ANT

Auto Antenna

(No.MA384<Rev.001>)1-25

5.2 16 PIN CORD DIAGRAM (for KD-G544, KD-G545, KD-G546)

BK

RD

BL

WH

Black

Red

Blue

White

8

7

6

5

4

3

2

1

8

16

BL/WH

BK

YL

BK

RD

BL

WH

GN

VI

GY

GN

VI

GY

YL

YL

NC

NC

NC

WH/BK

GN/BK

VI/BK

GY/BK

Green

Violet

Gray

Yellow

16

15

14
13

12

11

10

9

BL

6

BL/WH

5

RD

7

GN

3

GN/BK

11

VI

2

VI/BK

10

WH

4

WH/BK

12

GY

1

GY/BK

9

1-26 (No.MA384<Rev.001>)