JVC KD-SD631, KD-SD636, KD-SD637 Service manual
SERVICE MANUAL
MA511<Rev.001>201112SERVICE MANUAL
KD-SD636UN, KD-SD636UP,
CD RECEIVER
KD-SD631E, KD-SD631EN,
KD-SD631EY, KD-SD636U,
KD-SD636UT, KD-SD637EE
DETACH PANEL
Model Parts number
CP-SD631ED
CP-SD631ED
CP-SD631ED
CP-SD636UD
CP-SD636UD
CP-SD636UD
CP-SD636UD
CP-SD637EED
For EUROPE
KD-SD631E
KD-SD631EN
KD-SD631EY
KD-SD636U
KD-SD636UN
KD-SD636UT
KD-SD636UP
KD-SD637EE
COPYRIGHT © 2011 JVC KENWOOD Corporation
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)
COPYRIGHT © 2011 JVC KENWOOD Corporation
No.MA511<Rev.001>
2011/12
SPECIFICATION
For ASIA
AUDIO AMPLIFIER SECTION
Maximum Power Output 50 W per channel
Continuous Power Output (RMS) 20 W per channel into 4Ω, 40 Hz to 20 000 Hz at less than 1% total harmonic distortion.
Load Impedance 4 Ω (4 Ω to 8 Ω allowance)
Frequency Response 40 Hz to 20 000 Hz
Signal-to-Noise Ratio 70 dB
Line-Out or Subwoofer-Out Level/Impedance 4.8 V/20 kΩ load (full scale)
Output Impedance ≤ 600Ω
TUNER SECTION
FM Frequency Range 87.5 MHz to 108.0 MHz
Usable Sensitivity 9.3 dBf (0.8 µV/75Ω)
50 dB Quieting Sensitivity 16.3 dBf (1.8 µV/75Ω)
Alternate Channel Selectivity
(400 kHz)
Frequency Response 40 Hz to 15 000 Hz
Stereo Separation 40 dB
AM Frequency Range 531 kHz to 1 611 kHz
Sensitivity/Selectivity 20 µV/40 dB
CD PLAYER SECTION
Signal Detection System Non-contact optical pickup (semiconductor laser)
Number of Channels 2 channels (stereo)
Frequency Response 5 Hz to 20 000 Hz
Signal-to-Noise Ratio 98 dB
Wow and Flutter Less than measurable limit
USB SECTION
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
Maximum Supply Current DC 5 V 1 A
SD SECTION
Compatible File System FAT 32/16/12
Storage Up to 32 GB
Playable Audio Format MP3/WMA
GENERAL
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)
Mass 1.2 kg (excluding accessories)
Installation Size approx. 182 mm × 52 mm × 158 mm
Panel Size approx. 188 mm × 59 mm × 14 mm
65 dB
• Subject to change without notice.
(No.MA511<Rev.001>)2/16
SPECIFICATION
For EUROPE
AUDIO AMPLIFIER SECTION
Maximum Power Output 50 W per channel
Continuous Power Output (RMS) 20 W per channel into 4Ω, 40 Hz to 20 000 Hz at less than 1% total harmonic distortion.
Load Impedance 4 Ω (4 Ω to 8 Ω allowance)
Frequency Response 40 Hz to 20 000 Hz
Signal-to-Noise Ratio 70 dB
Line-Out or Subwoofer-Out Level/Impedance 2.5 V/20 kΩ load (full scale)
Output Impedance ≤ 600Ω
TUNER SECTION
FM Frequency Range 87.5 MHz to 108.0 MHz
Usable Sensitivity 9.3 dBf (0.8 µV/75Ω)
50 dB Quieting Sensitivity 16.3 dBf (1.8 µV/75Ω)
Alternate Channel Selectivity
(400 kHz)
Frequency Response 40 Hz to 15 000 Hz
Stereo Separation 40 dB
AM Frequency Range MW : 531 kHz to 1 611 kHz
Sensitivity/Selectivity MW : 20 µV/40 dB
CD PLAYER SECTION
Signal Detection System Non-contact optical pickup (semiconductor laser)
Number of Channels 2 channels (stereo)
Frequency Response 5 Hz to 20 000 Hz
Signal-to-Noise Ratio 98 dB
Wow and Flutter Less than measurable limit
USB SECTION
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
Maximum Supply Current DC 5 V 1 A
SD SECTION
Compatible File System FAT 32/16/12
Storage Up to 32 GB
Playable Audio Format MP3/WMA
GENERAL
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)
Mass 1.2 kg (excluding accessories)
Installation Size approx. 182 mm × 52 mm × 158 mm
Panel Size approx. 188 mm × 59 mm × 14 mm
65 dB
LW : 153 kHz to 279 kHz
LW : 50 µV
• Subject to change without notice.
(No.MA511<Rev.001>)3/16
SECTION 1
PRECAUTION
1.1 Safety Precautions
(1) This design of this product contains special hardware and
many circuits and components specially for safety purposes. For continued protection, no changes should be made
to the original design unless authorized in writing by the
manufacturer. Replacement parts must be identical to
those used in the original circuits. Services should be performed by qualified personnel only.
(2) Alterations of the design or circuitry of the product should
not be made. Any design alterations of the product should
not be made. Any design alterations or additions will void
the manufacturers warranty and will further relieve the
manufacture of responsibility for personal injury or property
damage resulting therefrom.
(3) Many electrical and mechanical parts in the products have
special safety-related characteristics. These characteristics are often not evident from visual inspection nor can the
protection afforded by them necessarily be obtained by using replacement components rated for higher voltage, wattage, etc. Replacement parts which have these special
safety characteristics are identified in the Parts List of Service Manual. Electrical components having such features
are identified by shading on the schematics and by ( ) on
the Parts List in the Service Manual. The use of a substitute
replacement which does not have the same safety characteristics as the recommended replacement parts shown in
the Parts List of Service Manual may create shock, fire, or
other hazards.
(4) The leads in the products are routed and dressed with ties,
clamps, tubings, barriers and the like to be separated from
live parts, high temperature parts, moving parts and/or
sharp edges for the prevention of electric shock and fire
hazard. When service is required, the original lead routing
and dress should be observed, and it should be confirmed
that they have been returned to normal, after reassembling.
(5) Leakage shock hazard testing
After reassembling the product, always perform an isolation check on the exposed metal parts of the product (antenna terminals, knobs, metal cabinet, screw heads,
headphone jack, control shafts, etc.) to be sure the product
is safe to operate without danger of electrical shock.Do not
use a line isolation transformer during this check.
• Plug the AC line cord directly into the AC outlet. Using a
"Leakage Current Tester", measure the leakage current
from each exposed metal parts of the cabinet, particularly any exposed metal part having a return path to the
chassis, to a known good earth ground. Any leakage current must not exceed 0.5mA AC (r.m.s.).
• Alternate check method
Plug the AC line cord directly into the AC outlet. Use an
AC voltmeter having, 1,000Ω per volt or more sensitivity
in the following manner. Connect a 1,500Ω 10W resistor
paralleled by a 0.15µF AC-type capacitor between an exposed metal part and a known good earth ground.
Measure the AC voltage across the resistor with the AC
voltmeter.
Move the resistor connection to each exposed metal
part, particularly any exposed metal part having a return
path to the chassis, and measure the AC voltage across
the resistor. Now, reverse the plug in the AC outlet and
repeat each measurement. Voltage measured any must
not exceed 0.75 V AC (r.m.s.). This corresponds to 0.5
mA AC (r.m.s.).
AC VOLTMETER
(Having 1000
ohms/volts,
or more sensitivity)
0.15 F AC TYPE
Place this
probe on
1500 10W
Good earth ground
1.2 Warning
(1) This equipment has been designed and manufactured to
meet international safety standards.
(2) It is the legal responsibility of the repairer to ensure that
these safety standards are maintained.
(3) Repairs must be made in accordance with the relevant
safety standards.
(4) It is essential that safety critical components are replaced
by approved parts.
(5) If mains voltage selector is provided, check setting for local
voltage.
1.3 Caution
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.
1.4 Critical parts for safety
In regard with component parts appearing on the silk-screen
printed side (parts side) of the PWB diagrams, the parts that are
printed over with black such as the resistor ( ), diode ( )
and ICP ( ) or identified by the " " mark nearby are critical
for safety. When replacing them, be sure to use the parts of the
same type and rating as specified by the manufacturer.
(This regulation dose not Except the J and C version)
each exposed
metal part.
(No.MA511<Rev.001>)4/16
1.5 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.
1.5.1 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 palate
(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.
1.6 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) I t is not possible to adjust the semi-fixed resistor that adjusts the laser power. Do not turn it.
1.7 Attention when traverse unit is decomposed
*Please refer to "Disassembly method" in the text for the pickup unit.
• Apply solder to the short land sections before the card wire is disconnected from the connector on the servo board. (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 sections after connecting the card wire.
SOLDER
(No.MA511<Rev.001>)5/16
1.8 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
(No.MA511<Rev.001>)6/16
SECTION 2
SPECIFIC SERVICE INSTRUCTIONS
This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.
SECTION 3
DISASSEMBLY
3.1 Main body (Used model: KD-SD631E)
3.1.1 Removing the Bottom chassis (See Fig.1)
(1) Disengage the 7 hooks a engaging the Bottom chassis.
(2) Slide the Bottom chassis backward to remove it.
hook
a
hook
hook
a
Fig.1
3.1.2 Removing the Front chassis (See Fig.2)
(1) Disengage the 4 hooks b engaging both sides of the Front
chassis.
(2) Remove the 2 screws B attaching both sides of the Top
chassis. (See Fig.4)
B
Fig.4
(3) Remove the 3 screws C attaching the Main board. (See
a
Fig.5)
C
hook
b
Fig.2
3.1.3 Removing the Erectric unit (See Fig.3, 4 and 6)
(1) Remove the 1 screw A attaching the Rear bracket. (See
Fig.3)
A
Fig.3
(No.MA511<Rev.001>)7/16
Fig.5
(4) Disconnect the board to board connector CN502
ing the Main board and the CD mechanism. (See Fig.6)
CN502
Fig.6
connect-
3.1.4 Removing the CD mechanism (See Fig.7)
(1) Remove the 3 screws D attaching the CD mechanism.
3.2 CD mechanism assembly section
3.2.1 Removing the Mecha control board
(1) Solder the short land on the pickup. (See Fig. 1)
D
D
Fig.7
3.1.5 Removing the Switch unit (See Fig.8)
(1) Remove the Volume knob.
(2) Remove the 4 screws E attaching the Rear cover.
(3) Disengage the 14 hooks c engaging the Rear cover.
E
E
hook c
E
E
hook c
hook c
Fig.8
D
hook c
SOLDER
Fig.1
(2) Remove the 8 wires from the Mecha control board. (See
Fig.2)
BLACK
RED
WHITE
YELLOW
ORANGE
ORANGE
WHITE
YELLOW
Fig.2
(3) Disconnect the flexible wire from the pickup connected to
the connector CN102
Fig.3)
(4) Remove the 2 screws A attaching the Mecha control board.
(See Fig.3)
on the Mecha control board. (See
(No.MA511<Rev.001>)8/16
A
CN102
Fig.3
3.2.2 Removing the Traverse mechanism (See Fig.4, 5)
(1) Remove the 5 springs from the traverse mechanism. (See
Fig.4)
Fig.4
(2) Remove the 3 screws B attaching the bottom frame as-
sembly. (See Fig.5)
(3) Remove the 3 dumpers from the bottom frame assembly.
(See Fig.5)
B
(2) Remove the shaft from the TM base. (See Fig.7)
(3) Disengage the hook a on the pickup from the TM base.
(See Fig.7)
shaft
B
Fig.5
3.2.3 Removing the Pickup (See Fig.6, 7)
(1) Remove the 2 screws C attaching the feed bracket assem-
bly. (See Fig.6)
CC
Fig.7
3.2.4 Removing the Spindle motor (See Fig.8. 9)
(1) Remove the HC CL. Spring from the HC CL. base and the
TM base, and then lift up the HC CL. base. (See Fig.8)
HC CL. spring
[ SIDE VIEW ]
Fig.8
Fig.6
(No.MA511<Rev.001>)9/16
(2) Remove the HC CL. base from the holes on the TM base.
(See Fig.9)
Fig.9
(3) Remove the 2 screws D attaching the spindle motor. (See
Fig.10)
D
3.2.5 Removing the Loading motor
(1) Remove the roller arm assembly from the bottom frame as-
sembly. (See Fig.11)
Fig.11
(2) Remove the 2 screws E attaching the loading motor as-
sembly, and then remove the loading motor assembly in
the direction of the arrow. (See Fig.12)
Fig.10
E
Fig.12
(No.MA511<Rev.001>)10/16
SECTION 4
ADJUSTMENT
4.1 Service Test mode
Default status immediately after the mode activation
Operating Key : [MENU] → [DOWN] (7sec)
4.1.1 Mode content
Syscon shall display the following information after entering this mode. The operation shown below shall be workable.
Display content Detail
S R V T E S T
4.1.2 Common operation mode for all sources.
means Press aud hold.
Operation Display content Detail
EQ
MENU
UP
DOWN
BRIGHTNESS
/ TAG / iPod /
SD
BRIGHTNESS
/ TAG / iPod /
SD
CD error
information
display mode
Syscon version
display
Power ON
duration display
Disc operation
duration display
Disc eject
number of times 00001 - 99999 are displayed in "XXXXX"
Disc eject
number of times
clear
Force Power
OFF information
display
Force Power
OFF information
clear
Transit to CD error information display mode
S Y S #
P O N T M 0 H X X
P O N T M X X X X X
C D T M 0 H X X
C D T M X X X X X
E J C N T X X X X X
E J C N T 0 0 0 00
P O F F - --
P O F F P N L
P O F F - --
The display is released when another operation is executed.
# = Display of destination.
J = USA
@ @ @
R = EUROPE
E = EASTERN-EUROPE
U = OTHERS(e.g. ASIA)
@@@ = Syscon version number
00 - 50 are displayed in " XX ".
For less than 1 hour, the display is indicated
per 10 minutes.
00001 - 10922 are displayed in " XXXXX ".
MAX 10922 (hours).
00 - 50 are displayed in " X X ".
For less than 1 hour, the display is indicated
per 10 minutes.
00001 - 10922 are displayed in " XXXXX ".
MAX 10922 (hours).
Clear Disc Eject number of times by pressing
for 2 seconds when it is displayed.
No force Power OFF
Force Power OFF due to Syscon-Panel
commnication error.
Will not show in JK12 Models.
Clear Force Power OFF information by
pressing for 2 seconds when it is displayed.
Will not show in JK12 Models.
(No.MA511<Rev.001>)11/16
4.1.3 CD error information display mode
Operation Display content Detail
CD mecha error
log display
CD load error
information
display
CD eject error
information
display
Move
between DISP
(Forward
search)
item with
M E C H E R #AXX
L O A D E R # X X
E J E C T E R # X X
/
C N T L O S E
CD time code
error count
information
display (count
skip)
CD time code
error count
information
display (no count
update)
EQ CD error
informationclear
EQ Mode release CD error information display mode release Back to default status, All lights on
C D D A XX
C D R O M X X
C N T S T A Y
C D D A XX
C D R O M X X
CD error information all clear
M E C H A E R 1 - -
Mecha error history 1,2,3 (latest)
# = History No. (1,2,3)
XX : kind of errors, " -- " when there is none.
00: No Error
04: TOC read Error
05: Unknown CD
06: Heat Error
0A: Update Error
0D: Hold Error
15: Unknown Disc
99: Mecha Error
Load error switch 1,2
# = History No. (1,2)
XX: numbers of errors, " -- " when there is
none
History No. 2 is un-used
Eject error switch 1,2,3,4
# =History No. (1,2,3,4)
XX: numbers of errors, " -- "when there is
none
History No.3 is un-used
History No.1: Eject before SW1 is on.
History No.2: Eject until SW1 and SW2 is
on.
History No.3: Eject between SW2 on and
Eject end
CD-DA error count number information
CD-DA error count numbers
XX: numbers of errors and " -- " when there
is none
Can only be checked via debugger by jap
member
CD-ROM (compressed file) error count numbers
XX: numbers of errors and " -- " when there is
none
Can only be checked via debugger by jap
member
CD time code error count information (count
not updated) mode display
CD-DA error count numbers
XX: numbers of errors and " -- " when there is
none
CD-ROM (compressed file) error count numbers
XX: numbers of errors and " -- " when there is
none
Clear CD error information by pressing for 2
seconds when it is displayed.
(No.MA511<Rev.001>)12/16
4.2 DC error information mode
* The receiver is connected with the DC power supply (with the power supply turned off).
Operating Key : [MENU] → [UP] → [DC power supply turned ON]
4.2.1 Mode content
Syscon shall display the following information after entering this mode. The operation shown below shall be workable.
Display content Detail
D C E R R
D C O K
When DC error is detected (in case that one of capacitor leakage, wrong
connection or other detection is found).
When DC error is not detected (in case that none of capacitor leakage, wrong connection or other detection is found).
4.2.2 Mode operation specification
means Press aud hold
Operation Display content Detail
UP DC ERR1
display
UP DC ERR1
clear
DOWN DC ERR2
display
DOWN DC ERR2
clear
D C 1 E R R
D C 1 O K
D C 1 O K
D C 2 4
D C 2 0
When wrong connection & DC error in other detection
duration is detected.
When wrong connection & DC error in other detection
duration is not detected.
Clear detection information when wrong connection & DC error in other detection duration is displayed.(Clear data flash)
Display detecting number of times in capacitor leakage
detection duration (0~4)
Clear number of times for detection information in capacitor leakage detection duration.(Clear data flash)
(No.MA511<Rev.001>)13/16
4.3 DC Offset error description
A
4.3.1 DC Offset detection circuit design
• Purpose:
To prevent breakdown, burning and emitting smoke from customer's car speaker when occur DC offset between speaker
output "+" and "-".
•Target:
Detect DC offset, then stop the Power Amp operation and shift
to specified condition.
4.3.2 Possible causes of DC offset at speaker output lines
(1) Mis-connection for Speaker output for example touch to car
body or battery line.
(2) Current leak of coupling capacitor for Power IC input.
(3) Current leak of Ac-GND capacitor for Power IC Ac-GND.
(4) Capacitor shorted of above parts due to foreign object.
C-tc
E-Vol
Win_TC
Win_In
DC Error
C-in
C-in
R3
C-in
C-in
C-ac2C-ac1
Sw5V
R2
R1
C3
R4
Audio Pwr Amp
In 1
In 2
In 3
In 4
AcGnd
Offset Detect
Out
Micon
ADC In
4.3.5 Manipulate after detect DC Offset
• If detected error 10 consecutive times, and 10th error occurred
in "Mis-connect detection period", judge as "Mis-connect".
• If detected error 10 consecutive times, and 10th error occurred
in "Capacitor leak detection period", judge as "Capacitor leak ".
• If detected error 10 consecutive times, and 10th error occurred
in "Other detection period" and detected another 10 errors consecutively, then judge as "Other".
• If judge as "Mis-connect".
- turn off speaker output.
-display "MIS WIRING" → "CHK WIRING" → "THEN RESET"
→ "UNIT".
- key access disable except button of Eject, Reset and service
mode
- record error in EEPROM "DC1 ERR"
- Set is able to be recovered by Reset button.
• If judge as "Capacitor leak ".
- turn off speaker output.
-display "WIRING" → "CHK WIRING" → "THEN RESET" →
"UNIT".
- key access disable except button of Eject, Reset and service
mode
- record error in EEPROM "DC2 #" (# means counter number)
- Set can be recovered by pressing the Reset button before
the capacitor leak error counter reach "DC2 4".
After that, only clear the counter back to "0" can recover the
set.
• If judge as "Other" (manipulation same as mis-connect)
4.3.6 How to clear the DC offset error recorded in EEPROM
Refer to "DC error information mode".
4.3.3 Type of checking
4.3.3.1 To detect DC Offset Error
• Mis-connection
- Short any one speaker out line to GND or Vcc
• Capacitor leak
- Parallel 330kΩ to either any one of coupling cap or Ac-GND
cap (to simulate current leakage of capacitor)
- Shorted either any one of coupling cap or Ac-GND cap.
4.3.3.2 To avoid mis-judge music as DC offset error
• Low frequency signal (17Hz or 20Hz) is more prone to cause
mis-detection.
- Play 17Hz (or 20Hz) signal and make sure micon will not de-
tect and judge this as happen DC offset error.
4.3.4 Detection Timing chart
50ms
or more
PWIC_STBY
PWIC_MUTE
UD_MUTE
2.0sec or more
Missconnect
detection period
1.5sec or more
0.8sec
0.7sec or more
1.0sec
Capacitor leak
detection period
Other (miss detection etc.)
detection period
(No.MA511<Rev.001>)14/16
SECTION 5
TROUBLESHOOTING
This service manual does not describe TROUBLESHOOTING.
(No.MA511<Rev.001>)15/16
Loading...