JVC KDR-400 Service manual

SERVICE MANUAL

CD RECEIVER

MA430<Rev.001>200812SERVICE MANUAL

KD-R400J, KD-R401E, KD-R401EX,

KD-R401EY, KD-R401EU, KD-R402EY,

KD-R407EE, KD-R501E, KD-R501EX,

KD-R501EY, KD-R501EU, KD-R504UI,

KD-R505U, KD-R505UN, KD-R505UT,

KD-R505UH, KD-R506U, KD-R506UN,

KD-R506UT, KD-R506UH, KD-R508UF

KD-R400 /R504 /R505 /R506

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

KD-R400

KD-R401/R402 /R407/R501

No.MA430<Rev.001>

2008/12

SPECIFICATION

KD-R400J

AUDIO AMPLIFIER SECTION

Power Output 20 W RMS × 4 Channels at 4 Ω and < or = 1%THD+N Amplifier Power Standard Signal-to-Noise Ratio 80 dBA (reference 1 W into 4 Ω) Load Impedance 4 Ω (4 Ω to 8 Ω allowance)

Tone Control Range Bass ±12 dB (60 Hz 80 Hz 100 Hz 200 Hz) Q1.0 Q1.25 Q1.5 Q2.0

Middle ±12 dB (0.5 kHz 1.0 kHz 1.5 kHz 2.5 kHz) Q0.75 Q1.0 Q1.25 Treble ±12 dB (10.0 kHz 12.5 kHz 15.0 kHz 17.5 kHz)

Q = Fixed

Frequency Response 40 Hz to 20 000 Hz

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 USB input jack AUX (auxiliary) input jack Steering wheel

remote input

TUNER SECTION

Frequency Range FM with channel interval set to 100 kHz or 200 kHz 87.5 MHz to 107.9 MHz

with channel interval set to 50 kHz 87.5 MHz to 108.0 MHz

AM with channel interval set to 10 kHz 530 kHz to 1 710 kHz

with channel interval set to 9 kHz 531 kHz to 1 602 kHz

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

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 35 dB

AM Tuner Sensitivity 20 µV

Selectivity 35 dB

CD PLAYER SECTION

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

USB Standard USB 1.1, USB 2.0 Data Transfer Rate (Full Speed) Max. 12 Mbps Compatible Device Mass storage class Compatible File System FAT 32/16/12 Playable Audio Format MP3/WMA Max. Current DC 5 V 500 mA

Power Requirement

Grounding System Negative ground

Allowable Operating Temperature 0 °C to +40 °C (32 °F to 104 °F)

Dimensions

(W × H × D) (approx.)

Mass 1.3 kg (2.9 lbs) (excluding accessories)

Design and specifications are subject to change without notice.

® Audio) Decoding Format Max. Bit Rate 320 kbps

USB SECTION

GENERAL

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

Installation Size 182 mm × 52 mm × 160 mm (7-3/16” × 2-1/16” × 6-5/16”) Panel Size 188 mm × 58 mm × 6 mm (7-7/16” × 2-5/16” × 1/4”)

1-2 (No.MA430<Rev.001>)

KD-R401E/EX/EY/EU KD-R402EY KD-R407EE KD-R501E/EX/EY/EU

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel Continuous Power Output

(RMS)

Load Impedance 4 Ω (4 Ω bis 8 Ω Toleranz)

Tone Control Range Bass ±12 dB (60 Hz 80 Hz 100 Hz 200 Hz) Q1.0 Q1.25 Q1.5 Q2.0

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 USB input 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)

MW Tuner Sensitivity 20 µV

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 93 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

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 1.3 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 (0.5 kHz 1.0 kHz 1.5 kHz 2.5 kHz) Q0.75 Q1.0 Q1.25 Treble ±12 dB (10.0 kHz 12.5 kHz 15.0 kHz 17.5 kHz)

Q = Fixed

TUNER SECTION

(KD-R407) FM-LO 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) 65 dB Frequency Response 40 Hz to 15 000 Hz Stereo Separation 30 dB

Selectivity 35 dB

CD PLAYER SECTION

(KD-R407) : 96 dB

® Audio) Decoding Format Max. Bit Rate 320 kbps

USB SECTION

GENERAL

Installation Size 182 mm × 52 mm × 160 mm Panel Size 188 mm × 58 mm × 12 mm

Design and specifications are subject to change without notice.

(No.MA430<Rev.001>)1-3

KD-R504UI KD-R505U/UN/UT KD-R506U/UN/UT KD-R508UF

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 (60 Hz 80 Hz 100 Hz 200 Hz) Q1.0 Q1.25 Q1.5 Q2.0

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 USB input 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

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 1.3 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 (0.5 kHz 1.0 kHz 1.5 kHz 2.5 kHz) Q0.75 Q1.0 Q1.25 Treble ±12 dB (10.0 kHz 12.5 kHz 15.0 kHz 17.5 kHz)

Q = Fixed

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) 65 dB Frequency Response 40 Hz to 15 000 Hz Stereo Separation 30 dB

Selectivity 35 dB

CD PLAYER SECTION

® Audio) Decoding Format Max. Bit Rate 320 kbps

USB SECTION

GENERAL

Installation Size 182 mm × 52 mm × 160 mm Panel Size 188 mm × 58 mm × 6 mm

1-4 (No.MA430<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.MA430<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.

1-6 (No.MA430<Rev.001>)

Mechanism control board

CN102

Flexible wire

Short land section

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.MA430<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 are KD-R400J)

3.1.1 Removing the bottom chassis (See Fig.1, 2)

(1) Remove the three screws A attaching the Heat sink. (See

Fig.1)

(2) Remove the two screws B and one screw C attaching the

Bottom chassis. (See Fig.2)

(3) Slide to backward and then remove the Bottom chassis.

Fig.1

3.1.2 Removing the Front chassis (See Fig.3)

(1) Disengage four hooks a engaged both side of the Front

chassis.

hook a

Fig.3

1-8 (No.MA430<Rev.001>)

Fig.2

3.1.3 Removing the Main board (See Fig.4 to 6)

(1) Remove the two screws D and one screw E attaching the

Side panel. (See Fig.4) (2) Remove the one screw F attaching the bracket. (See Fig.5) (3) Remove the three screws G attaching the main board and

then disconnect the board to board connector CN501

nected to CD mechanism. (See Fig.6)

con-

3.1.4 Removing the CD mechanism (See Fig.7)

(1) Remove the three screws H attaching the CD mechanism.

Fig.7

3.1.5 Removing the Switch board (See Fig.8)

(1) Remove the Volume knob. (2) Remove the four screws J attaching the Rear cover. (3) Disengage eleven hooks b engaged Rear cover.

CN501

Fig.4

Fig.5

hook b

Fig.8

Fig.6

(No.MA430<Rev.001>)1-9

3.2 CD MECHANISM assembly section

• Remove the CD MECHANISM assembly from the main body.

Removing the MECHANISM CONTROL BOARD

3.2.1 1

assembly (See Fig.

(1)

From the bottom side of CD MECHANISM assembly, remove the solders from the soldered sections (

) on the MECHANISM CONTROL BOARD assembly.

(See Fig.

(2) Remove the three screws A attaching the MECHANISM

CONTROL BOARD assembly. (See Fig.1.)

(3) Solder the short land sections on the pickup. (See Fig.2.)

Caution:

• Solder the short land sections on the pickup before

•

disconnecting the flexible wire from the connector

on the MECHANISM CONTROL BOARD as-

CN102

sembly. If the card wire is disconnected without attaching solder, the pickup may be destroyed by static electricity. (See Fig.2.) When attaching the MECHANISM CONTROL BOARD assembly, remove the solders from the short land sections after connecting the flexible wire to the connector CN102 CONTROL BOARD assembly.

and 2)

a, b

and

on the MECHANISM

Mechanism

control board

CN102

Fig.1

Mechanism control board

CN102

Flexible wire

Short land section

Pickup

Fig.2

1-10 (No.MA430<Rev.001>)

3.2.2 Removing the top cover (See Fig.3 to 5)

• Remove the MECHANISM CONTROL BOARD assembly. (1) From the front side of the CD MECHANISM assembly,

change the hook position of the two roller springs. (See Fig.3.)

(2) From the side of the CD MECHANISM assembly, remove

the six screws B attaching the top cover. (See Fig.3 and 4.)

(3) Take out the top cover in an upward direction. (See Fig.5.)

Top cover

Roller spring Roller spring

Fig.3

Top cover

Fig.5

3.2.3 Removing the roller (See Fig.6)

• Remove the MECHANISM CONTROL BOARD assembly and top cover. (1) From the bottom side of the top cover, remove the screw C

attaching the gear holder.

(2) Remove the R.holder assembly from disc plate, and then

take out the roller from R.holder assembly in the direction of the arrow.

Reference:

When attaching the R.ACT gear (2) and R.ACT gear (3), apply grease to the section d of R.holder assembly.

Roller coller

Fig.4

Gear holder

Roller gear

R.ACT gear(3)

R.ACT gear(2)

Top cover

R.holder assembly

Fig.6

Washer

Roller

Disc plate

(No.MA430<Rev.001>)1-11

3.2.4 Removing the PHOTO BOARD assembly (See Fig.7 and 8)

• Remove the MECHANISM CONTROL BOARD assembly and

top cover.

From the bottom side of the top cover, release the

(1)

projection

Fig.

(2) Take out the disc plate in the direction of the arrow. (See

Fig.7.)

(3) From the reverse side of the disc plate, remove the screw

D attaching the PHOTO BOARD assembly. (See Fig.8.)

from the notch of the disc plate. (See

SUS

spring

Mechanism section

Mecha frame

SUS

spring

Top cover

Fig.7

Disc plate

Photo board

Disc plate

Fig.8

3.2.5 Removing the mechanism section (See Fig.9 and 10)

• Remove the MECHANISM CONTROL BOARD assembly and

top cover. (1)

From the top side of the CD MECHANISM assembly, remove the two screws assembly. (See Fig.

(2) Remove the two roller springs on the top side of the mecha

frame. (See Fig.9.)

(3) Remove the four SUS springs on the top side of the mecha

frame. (See Fig.9.)

(4) Remove the link spring on the top side of the mecha frame.

(See Fig.10.)

(5) Release section f of the three dampers from the mecha

frame. (See Fig.10.)

Reference:

When attaching the roller spring and SUS spring, keep direction before remove.

Move the slide cam (R) assembly in the direction of the

(6)

arrow, and then take out the mechanism section in an upward direction. (See Fig.

Reference:

When attaching the mechanism section, apply grease to the section g. (See Fig.10.)

attaching the loading motor

10.)

SUS

spring

Roller spring

Loading motor assembly

Fig.9

Cam cover

Mecha frame

Fig.10

SUS

spring

1-12 (No.MA430<Rev.001>)

3.2.6 Removing the slide cam (L) (See Fig.11 to 13)

• Remove the MECHANISM CONTROL BOARD assembly, top

cover and mechanism section.

(1) From the top side of the mecha frame, remove the screw F

attaching the cam cover. (See Fig.11.) Take out the cam cover from mecha frame in an upward

(2)

direction. (See Fig.

(3) Take out the slide cam (L) in the direction of the arrow.

(See Fig.12.)

Reference:

When attaching the slide cam (L), apply grease to the section h. (See Fig.13.)

Slide cam(L)

Mecha frame

Cam cover

Fig.11

Mecha frame

Fig.12

Slide cam(L)

Fig.13

(No.MA430<Rev.001>)1-13

3.2.7 Removing the F.lock lever and slide cam (R) (See Fig.14 and 15)

• Remove the MECHANISM CONTROL BOARD assembly, top

cover and mechanism section. (1) From the top side of the mecha frame, take out the slide

cam (R) assembly in an upward direction. (See Fig.14.)

(2) Rotate the F.lock lever in the direction of the arrow 1, and

then take out the direction of the arrow 2. (See Fig.14.)

Reference:

When attaching the slide cam (R) assembly, the f.lock lever and the link arm apply grease to the section

(See Fig.

and 15.)

Slide cam(R) assembly

F.lock lever

3.2.8 Removing the damper (See Fig.16)

• Remove the MECHANISM CONTROL BOARD assembly, top cover and mechanism section. From the mechanism section, pull out the three dampers in the direction of the arrow.

Reference:

Before inserting the shaft to the dampers, apply IPA to the pocket j of damper.

Damper (Gray)

Damper (Brown)

Fig.16

Mecha frame

Fig.14

Link arm

Slide cam(R) assembly

Fig.15

3.2.9 Removing the clamper assembly (See Fig.17)

• Remove the MECHANISM CONTROL BOARD assembly, top

cover and mechanism section. (1) From the top side of the mechanism section, release the

clamper spring.

(2) Move the clamper assembly in the direction of the arrow,

and then release the joints (k and m). Take out the clamper assembly from the T.M chassis

(3)

assembly.

Clamper assembly

Clamper spring

1-14 (No.MA430<Rev.001>)

T.M. chassis assembly

Fig.17

+ 30 hidden pages