Jvc KD-G547-EE, KD-G545, KD-G544-UI, KD-G541, KD-G546 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

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

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

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

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

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

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

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

Fig.3

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

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

Fig.5

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.

Fig.7

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)

Fig.9

hook b

Fig.10

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

3.2 CD mechanism assembly

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

Fig.1

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.)

Base board

Frame

Wires

Push switch

Flexible wire

Connector

Fig.3

Pickup

CD mechanism assembly

Pickup

Base board

Flexible wire

Frame

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

Frame

Rear suspension spring Rear suspension spring

Fig.5

Chassis unit

Shaft

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

Clamper assembly

Chassis unit

Fig.7

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

Chassis unit

Loading/feed motor assembly

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

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

Pickup

Feed sub holder

Pickup

Rail

Feed nut spring

Fig.12

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

Select arm R

Chassis unit

Top plate assembly

Chassis unit

Trigger arm base

Trigger arm

Fig.14

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 L

ac ac

Link gear L

Fig.16

Mode switch

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

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