Jvc KD-G635, KD-G634, KD-G632, KD-G631, KD-G638 Service Manual

SERVICE MANUAL

CD RECEIVER

MA29220071SERVICE MANUAL

KD-G631E,KD-G631EX,KD-G631EU,

KD-G631EY,KD-G632E,KD-G632EX,

KD-G632EU,KD-G632EY,KD-G635U,

KD-G635UN,KD-G635UH,KD-G635UT,

KD-G634UI,KD-G638UF

(for europe)

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 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

COPYRIGHT © 2007 Victor Company of Japan, Limited

No.MA292

2007/1

SPECIFICATION

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output
(RMS)

Tone Control Range Bass ±12 dB at 60 Hz

Frequency Range FM 87.5 MHz to 108.0 MHz

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

MW Tuner (for europe) Sensitivity/Selectivity 20 µV/35 dB
LW Tuner (for europe) Sensitivity 50 µV
AM Tuner (for asia) 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) Max. Bit Rate : 320 kbps

WMA (Windows Media® Audio) Decoding Format Max. Bit Rate : 192 kbps

Playable USB memory Format FAT 12/16/32

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

Dimensions (W × H × D)

(approx.)

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

monic distortion.

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

Mid-range ±12 dB at 1 kHz

Treble ±12 dB at 10 kHz

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

Other Terminals CD changer, Steering wheel remote input, USB input jack

TUNER SECTION

AM (for europe) MW: 522 kHz to 1 620 kHz

LW: 144 kHz to 279 kHz

AM (for asia) 531 kHz to 1 602 kHz

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

Alternate Channel Selectivity (400 kHz) 65 dB

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

Selectivity 35 dB

CD PLAYER / USB MEMORY SECTION

Storage Less than 4 GB (1 partition type)

Playable Audio Format MP3/WMA

Max. Current Less than 500 mA

GENERAL

Grounding System Negative ground

Allowable Operating Temperature 0°C to +40°C
Installation Size 182 mm × 52 mm × 150 mm
Panel Size 188 mm × 58 mm × 12 mm

Mass 1.4 kg (excluding accessories)

Design and specifications are subject to change without notice.

1-2 (No.MA292)

1.1 Safety Precautions

SECTION 1

PRECAUTIONS

!

!

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.MA292)1-3

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 CD players.
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 CD pickup unit.

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

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

Pickup

Wires

Push switch

1-4 (No.MA292)

Base board

Frame

Flexible wire

Connector

CD mechanism
assembly

Pickup

1.5 Important for laser products

REPRODUCTION AND POSITION OF LABELS and PRINT

WARNING LABEL and PRINT

(No.MA292)1-5

3.1 Main body

3.1.1 Removing the Bottom cover
(See Fig.1)

(1) Disengage the five hooks a engaged Bottom cover.

SECTION 3

DISASSEMBLY

Hook a Hook a Hook a

3.1.2 Removing the Front chassis
(See Fig.2)

(1) Remove the two screws A (both side) attaching the Front

chassis.

(2) Disengage the two hooks b (both side) engaged the Front

chassis.

3.1.3 Removing the Rear bracket
(See Fig.3)

(1) Remove the one screw B attaching the remote cable. (only

for Europe models)
(2) Remove the one screw C attaching the antenna jack.
(3) Remove the one screw D attaching the LINE OUT jack.
(4) Remove the one screw E attaching the CD-CH jack.
(5) Remove the one screw F attaching the IC bracket.
(6) Remove the two screws G attaching the 16pin connector

jack.
(7) Remove the three screws H attaching the Rear bracket.

Fig.1

A

Hook b

Fig.2

BEHHH

CD F GG

Fig.3

(No.MA292)1-7

3.1.4 Removing the Heat sink
(See Fig.4)

(1) Remove the two screws J and three screws K attaching the

Heat sink.

3.1.5 Removing the Main board assembly
(See Fig.5)

(1) Remove the three screws L attaching the Main board as-

sembly.

(2) Disconnect the connector CN501

board assembly and CD board assembly.

connected the Main

JK

JKK

Fig.4

LL

3.1.6 Removing the CD mechanism assembly
(See Fig.6)

(1) Remove the three screws M attaching the CD mechanism

assembly.

CN501

L

Fig.5

MMM

Fig.6

1-8 (No.MA292)

3.2 Front panel assembly

3.2.1 Removing the Rear cover

(See Fig.7)

(1) Remove the Volume knob from Front panel assembly.
(2) Remove the five screws N attaching the Rear cover.
(3) Disengage the twelve hooks c engaged Rear cover.

Hook

c

Hook

c

Hook

c

Hook

c

N

NN

Hook

c

3.2.2 Removing the Switch board assembly

(See Fig.8)

(1) Disengage the illumination lens from Front cover assem-

bly.

(2) Lift up the Switch board assembly and take out it.

CAUTION:

Detach knob and spring are easy to come off, do not lost them.

3.3 CD mechanism assembly

For CD mechanism, please refer mechanism manual TN2007-1010 (No.MY005

Hook

illumination lens

, No.MY005B).

c

Fig.7

Fig.8

N

Hook

N

c

(No.MA292)1-9

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 × 1

4.2 Standard measuring conditions

Power supply voltage : DC14.4V(10.5 - 16V)

Load impedance : 20KΩ(2 Speakers connection)

Output Level : Line out 2.0V (Vol. MAX)

4.5 How to connect the extension cable for adjustment

4.3 Standard volume position

Balance and Bass & Treble volume : Indication "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 since direct
reading of figures are applied in this working standard.

CAUTION :

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

Heat sink

Extension cable

EXTSH002-22P

Rear bracket

1-10 (No.MA292)

5.1 16 PIN CORD DIAGRAM (for Europe)

SECTION 5

TROUBLESHOOTING

8

7

6

BL/WH

5

4

3

2

1

7 RD

16 YL

15 OR/WH

8 BK

6 BL/WH

13 BR

BK

RD

NC

WH

GN

VI

GY

YL

OR/WH

NC

BR

WH/BK

GN/BK

VI/BK

GY/BK

16

15

14

13

12

11

10

9

ACC

MEMORY

ILL

GND

REMOTE

TEL

BK

RD

BL

WH

BR

Black

Red

Blue

White

Brown

GN

VI

GY

YL

OR

Green

Violet

Gray

Yellow

Orange

RD

1

3

5

7

RD 7

YL 4

BL/WH

6

8

5

2

NC

NC

RD

BR

YL

OR/WH

BK

2

4

6

8

RR

FR

FL

RL

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

RL+

RL-

RR+

RR-

FL+

FL-

FR+

FR-

ANT

ACC

TEL

GND

Auto Antenna

ACC Line

Telephone Muting

Ground

7

8

1

2

5

6

3

4

VI/BK

VI

1

3

GY

5

WH

GN

7

GY/BK

WH/BK

GN/BK

2

4

6

8

REMOTE

ILL

Remote

Illuminations Control

MEMORY

Memory Backup Battery+

(No.MA292)1-11

5.2 16 PIN CORD DIAGRAM (for Asia)

8

7

6

5

4

3

2

1

BK

RD

BL

BL/WH

WH

GN

VI

GY

YL

OR/WH

NC

BR

WH/BK

GN/BK

VI/BK

GY/BK

16 YL

8 BK

7 RD

15 OR/WH

13 BR

3 GN

10

16

15

14

13

12

11

BK

RD

BL

Black

Red

Blue

WH White

BR

9

MEMORY

GND

ACC

ILL

TEL

RL+

Brown

GN

Green

VI Violet

GY

YL

Gray

Yellow

OR Orange

GND

RR

FR

11 GN/BK

2 VI

10 VI/BK

4 WH

12 WH/BK

1 GY

9 GY/BK

5 BL/WH

6 BL

Rear Right

Front Right

RL-

RR+

RR-

FL+

FL-

FR+

FR-

REMOTE

ANT

REMOTE

CAUTION!

POWER

ANT

ACC

OUTPUT ONLY

ANTENNA

Auto Antenna

ACC Line

REMOTE

1-12 (No.MA292)

FL

RL

TEL

Front Left

Rear Left

Remote out

Telephone muting

ILL

GND

MEMORY

Illuminations Control

Ground

Memory Backup Battery+

5.3 16 PIN CORD DIAGRAM (for China)

YL1

OR/WH

NC

BR

WH/BK

GN/BK

VI/BK

GY/BK

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

BK

RD1

BL

BL/WH

WH

GN

VI

GY

BK

RD

BL

WH

BR

Black

Red

Blue

White

Brown

GN

VI

GY

YL

OR

Green

Violet

Gray

Yellow

Orange

1

NC

3

5

BL

7

RD2

BRNC

YL2

OR/WH

BK

2

4

6

8

7

16

8

6

15

13

3

11

2

10

4

12

1

9

5

RD1

YL1

BK

BL

OR/WH

BR

GN

GN/BK

VI

VI/BK

WH

WH/BK

GY

GY/BK

BL/WH

RD3

RD2

YL 2

7

4

8

5

6

2

7

8

1

2

5

6

3

4

VI

1

3

GY

5

WH

GN

7

VI/BK

2

GY/BK

4

WH/BK

6

GN/BK

8

(No.MA292)1-13