JVC KW-XC828 Service Manual
SERVICE MANUAL
CD/CASSETTE RECEIVER
KW-XC828
KW-XC828
SOUND
ATT
U
SOURCE
F
R
D
VOL
VOL
Contents
Safety precaution
Disassembly method
Adjustment method
Flow of functional
operation unit TOC read
1-2
1-3
1-30
1-31
DIRECTORY
E
X
Area Suffix
U Ather Areas
Maintenance of laser pickup
Replacement of laser pickup
Description of major ICs
1-33
1-33
1-36
COPYRIGHT 2002 VICTOR COMPANY OF JAPAN, LTD.
No.49729
Apr. 2002
KW-XC828
Safety precaution
CAUTION
!
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.
Please use enough caution not to see the beam directly or touch it in case of an
adjustment or operation check.
1-2
KW-XC828
Disassembly method
Removing the front panel assembly
(See Fig.1 ~ 3)
1.
Remove the four screws A on both sides of the
body.
2.
Release four joints a on both sides of the body using
a screwdriver and remove the front panel assembly
toward the front. The connector which connects the
front panel assembly with the rear section comes off.
CAUTION:
When reassembling, make sure that
connector CN501 on the front panel
assembly is securely connected to
CN701 on the main board (See Fig.3).
Joint a
A
A
Joint a
Front panel assembly
Fig.1
Joint a
A
CN501
A
Joint a
Front panel assembly
Fig.2
Front panel assembly
CN701
Fig.3
1-3
KW-XC828
Removing the system control board /
switch board (See Fig.4 , 5)
Prior to performing the following procedure, remove
the front panel assembly.
1.
Remove the twelve screws B retaining the system
control board.
2.
Remove the five screws C retaining the switch
board.
3.
Unsolder WR501 and WR502 of the wires
connecting the system control board with the switch
board.
B
B
WR502
System control board
WR502
B
Switch board
Fig.4
B
B
WR501
WR502
System control board
CC
Switch board
Fig.5
WR501
1-4
KW-XC828
Removing the CD player section /
cassette player section (See Fig.6 ~ 10)
Prior to performing the following procedure, remove
the front panel assembly.
1.
Remove the ten screws D, the screw E and F
attaching the rear panel on the back of the body.
2.
Remove the three screws G and the two screws H
attaching the heat sink on the left side.
3.
Remove the three screws I attaching the CD player
section and the cassette player section on the both
sides of the body.
4.
Disconnect the card wire from connector CN702 on
the main board in the CD player section on the back
of the body.
5.
Remove the CD player section upward.
CAUTION:
When reassembling, joint the CD player
section and the cassette player section
at four joints b.
D
G
Rear panel
Heat sink
H
E
Fig.6
Fig.7
D
F
D
G
I
CD player section
CN702
I
CD player section
I
Fig.8
Joint b
Joint b
Joint b
Cassette player section
Cassette player section
Fig.10Fig.9
1-5
KW-XC828
<CD player section>
Prior to performing the following procedure, remove
the front panel assembly, the CD player section and
the cassette player section.
Removing the main board (See Fig.11)
1.
Remove the three screws J attaching the main
board. The connector CN601 on the main board is
disconnected from the CD mechanism control board.
CAUTION:
When reassembling, securely connect
connector CN601 on the main board to
the connector on the CD mechanism
control board.
Removing the MP3 board
(See Fig.12)
Prior to performing the following procedure, remove
the main board.
J
J
MP3 board
Main board
CN601
J
Fig.11
K
1.
Disconnect the wire from connector CN601on the
MP3 board.
2.
Remove the five screws K and the MP3 board,
releasing the joint c and d.
Removing the CD mechanism assembly
(See Fig.13)
Prior to performing the following procedure, remove
the main board and MP3 board.
1.
Remove the three screws L attaching the CD
mechanism assembly.
Joint c
CN601
Joint d
K
Fig.12
L
1-6
L
CD mechanism assembly
Fig.13
L
KW-XC828
<Cassette player section>
Prior to performing the following procedures, remove
the front panel assembly, the CD player section and
the cassette player section.
Removing the main board (See Fig.14)
1.
Disconnect the card wire from connector CN972 on
the main board.
2.
Remove the two screws M attaching the main
board.
Removing the cassette mechanism
assembly (See Fig.14 , 15)
Prior to performing the following procedure, remove
the main board.
N
M
CN972
Cassette mechanism assembly
Fig.14
Bottom cover
Main board
M
N
1.
Disconnect the card wire from connector CN972 on
the main board.
2.
Remove the four screws N from the bottom cover of
the cassette player section.
Removing the connector board
(See Fig.16)
Prior to performing the following procedure,
remove the cassette mechanism assembly.
1.
Remove the screw O and move the connector
board in the direction of the arrow to release the
two joints e.
2.
Disconnect the wire from connector CJ402 and
the card wire from CN403 on the connector
board respectively.
CJ402
Fig.15
O
Fig.16
Connector board
Joint e
CN403
1-7
KW-XC828
< CD mechanism section >
Removing the top cover
(See Fig.1 and 2)
1.
Remove the two screws A on each side of the body.
2.
Lift the front side of the top cover and move the
cover backward to release the two joints a.
Removing the connector board
(See Fig.3 to 5)
Top cover
A
A
Joints a
CAUTION:
1.
Remove the screw B fixing the connector board.
2.
Solder the short-circuit point on the connector board.
Disconnect the flexible wire from the pickup.
3.
Move the connector board in the direction of the
arrow to release the two joints b.
4.
Unsolder the wire on the connector board if
necessary.
CAUTION:
Before disconnecting the flexible wire
from the pickup, solder the short-circuit
point on the pickup. No observance of
this instruction may cause damage of
the pickup.
Unsolder the short-circuit point after
reassembling.
A
Fig.1
Joints a
Top cover
Fig.2
DET switch
B
1-8
Flexible wire
Frame
Connector board
B
Connector board
Joints b
Flexible wire
Short-circuit
Fig.3
Fig.4Fig.5
Pickup
Short-circuit point
(Soldering)
Pickup
Removing the DET switch
(See Fig.3 and 6)
1.
Extend the two tabs c of the feed sw. holder and pull
out the switch.
2.
Unsolder the DET switch wire if necessary.
Removing the chassis unit
(See Fig.7 and 8)
Prior to performing the following procedure, remove
the top cover and the connector board.
B
Connector board
Joints b
Short-circuit
Fig.3
KW-XC828
DET switch
Pickup
1.
Remove the two suspension springs (L) and (R)
attaching the chassis unit to the frame.
CAUTION:
The shape of the suspension spring (L)
and (R) are different. Handle them with
care.
CAUTION:
When reassembling, make sure that the
three shafts on the underside of the
chassis unit are inserted to the dampers
certainly.
Chassis unit
Suspension spring (R)
Suspension spring (L)
Frame
DET switch
Chassis unit
Tab c
Feed sw. holder
Tab c
Fig.6
Shaft
Suspension spring (R)
Suspension spring (L)
Shafts
Damper
Damper
Damper
Frame
Fig.8Fig.7
1-9
KW-XC828
Removing the clamper assembly
(See Fig.9 and 10)
Prior to performing the following procedure, remove
the top cover.
1.
Remove the clamper arm spring.
2.
Move the clamper assembly in the direction of the
arrow to release the two joints d.
Removing the loading / feed motor
assembly (See Fig.11 and 12)
Prior to performing the following procedure, remove
the top cover, the connector board and the chassis
unit.
1.
Remove the screw C and move the loading / feed
motor assembly in the direction of the arrow to
remove it from the chassis rivet assembly.
Clamper arm
spring
Joint d
Joint d
Clamper assembly
Fig.9
Clamper arm spring
Chassis rivet
assembly
Joint d
Clamper assembly
Joint d
2.
Disconnect the wire from the loading / feed motor
assembly if necessary.
CAUTION:
When reassembling, connect the wire
from the loading / feed motor assembly
to the flame as shown in Fig.11.
Chassis rivet assembly
Fig.10
Loading / feed motor assembly
C
1-10
Loading / feed motor assembly
Fig.12Fig.11
KW-XC828
Removing the pickup unit
(See Fig.13 to 17)
Prior to performing the following procedure, remove
the top cover, the connector board and the chassis
unit.
1.
Remove the screw D and pull out the pu. shaft
holder from the shaft.
2.
Remove the screw E attaching the feed sw. holder.
3.
Move the part e of the pickup unit upward with the
shaft and the feed sw. holder, then release the joint f
of the feed sw. holder in the direction of the arrow.
The joint g of the pickup unit and the feed rack is
released, and the feed sw. holder comes off.
4.
Remove the shaft from the pickup unit.
5.
Remove the screw F attaching the feed rack to the
pickup unit.
Reattaching the pickup unit
(See Fig.13 to 16)
Joint f
Shaft
D
Joint e
Pu. shaft holder
Feed sw. holder
Pickup unit
Fig.13
Pickup unit
E
Joint f
Joint e
1.
Reattach the feed rack to the pickup unit using the
screw F.
2.
Reattach the feed sw. holder to the feed rack while
setting the joint tab g to the slot of the feed rack and
setting the part f of the feed rack to the switch of the
feed sw. holder correctly.
3.
As the feed sw. holder is temporarily attached to the
pickup unit, set to the gear of the joint g and to the
bending part of the chassis (joint h) at a time.
CAUTION:
4.
Reattach the feed sw. holder using the screw E.
5.
Reattach the shaft to the pickup unit. Reattach the
pu. shaft holder to the shaft using the screw D.
Make sure that the part i on the underside
of the feed rack is certainly inserted to the
slot j of the change lock lever.
F
Feed rack
Feed rack
E
Joint g
Feed sw. holder
Part i
Pickup unit
Slot j
Joint g
Feed sw. holder
Fig.14
Shaft
Joint f
Joint h
Fig.15
D
Pu. shaft holder
Pickup unit
Pickup unit
Feed rack
Joint f
Feed sw. holder
Fig.17Fig.16
1-11
KW-XC828
Removing the trigger arm
(See Fig.18 and 19)
Prior to performing the following procedure, remove
the top cover, the connector board and the clamper
unit.
1.
Turn the trigger arm in the direction of the arrow to
release the joint k and pull out upward.
Joint k
Trigger arm
CAUTION:
When reassembling, insert the part l and
m of the trigger arm into the part n and
o at the slot of the chassis rivet
assembly respectively and join the joint
k at a time.
Chassis rivet assembly
Chassis rivet assembly
Trigger arm
Fig.18
Part n
Part o
Part l
Part m
Fig.19
Removing the top plate assembly
(See Fig.20)
Prior to performing the following procedure, remove
the top cover, the connector board, the chassis unit,
and the clamper assembly.
1.
Remove the screw H.
2.
Move the top plate assembly in the direction of the
arrow to release the two joints p.
3.
Unsolder the wire marked q if necessary.
1-12
H
Top plate assembly
Joints p
q
Fig.20
KW-XC828
Removing the select arm (L) / select lock
arm (See Fig.21 and 22)
Prior to performing the following procedure, remove
the top plate assembly.
1.
Bring up the select arm (L) to release from the link
plate (joint r) and turn in the direction of the arrow to
release the joint s.
2.
Unsolder the wire of the select arm (L) marked q if
necessary.
3.
Turn the select lock arm in the direction of the arrow
to release the two joints t.
The select lock arm spring comes off the select lock
arm at the same time.
Reassembling the select arm (L) / select
lock arm (See Fig.23 to 25)
Select arm (R)
Joint z
Link plate spring
Top plate
Joint a'
Joint y
Link plate
Joint z
Joint s
Fig.21
Select lock arm
Select lock arm
Joint b'
Joint r
Select arm (L)
Select lock arm
q
Top plate
Hook u
Select lock
arm spring
Joints t
REFERENCE:
1.
Reattach the select lock arm spring to the top plate
Reverse the above removing procedure.
and set the shorter end of the select lock arm spring
to the hook u on the top plate.
2.
Set the other longer end of the select lock arm spring
to the boss v on the underside of the select lock arm,
and join the select lock arm to the slots (joint t). Turn
the select lock arm as shown in the figure.
3.
Reattach the select arm (L) while setting the part r to
the first peak of the link plate gear, and join the joint
s.
CAUTION:
When reattaching the select arm (L),
check if the points w and x are correctly
fitted and if each part operates properly.
Joint r
Link plate
Link plate
Select lock arm spring
Boss v
Select arm (R)
Joint a'
Fig.22
Hook u
Joint t
Joint t
Select lock arm
Fig.23
Link plate spring
Select arm (L)
Joint b'
Joint r
Fig.25Fig.24
Joint s
Select
lock arm
Point x
1-13
KW-XC828
Removing the select arm (R) / link plate
(See Fig.21 and 22)
Prior to performing the following procedure, remove
the top plate assembly.
1.
Bring up the select arm (R) to release from the link
plate (joint y) and turn as shown in the figure to
release the two joints z and joint a’.
2.
Move the link plate in the direction of the arrow to
release the joint b’. Remove the link plate spring at
the same time.
REFERENCE:
Before removing the link plate, remove
the select arm (L).
Reattaching the Select arm (R) / link
plate (See Fig.25 and 26)
REFERENCE:
Reverse the above removing procedure.
Select arm (R)
Joint z
Link plate spring
Top plate
Joint a'
Part y
Link plate
Joint z
Joint s
Fig.21
Select lock arm
Select lock arm
Joint b'
Joint r
Select arm (L)
Select lock arm
q
Top plate
Hook u
Select lock
arm spring
1.
Reattach the link plate spring.
2.
Reattach the link plate to the link plate spring while
joining them at joint b’.
3.
Reattach the part y of the select arm (R) to the first
peak of the link plate while joining the two joints z
with the slots. Then turn the select arm (R) as shown
in the figure. The top plate is joined to the joint a’.
CAUTION:
When reattaching the select arm (R),
check if the part c’ is correctly fitted and
if each part operates properly.
Select arm (R)
Joint z
Link plate
Link plate spring
Joint a'
Part y
Part y
Fig.22
Joint b'
Joint z
Fig.25
Joints t
Select arm (L)
Select
lock arm
Point x
1-14
Link plate
Fig.26
KW-XC828
Removing the loading roller assembly
(See Fig.27 to 29)
Prior to performing the following procedure, remove
the clamper assembly and the top plate assembly.
1.
Push inward the loading roller assembly on the gear
side and detach it upward from the slot of the joint d’
of the lock arm rivet assembly.
Detach the loading roller assembly from the slot of
the joint e’ of the lock arm rivet assembly.
The roller guide comes off the gear section of the
loading roller assembly.
Remove the roller guide and the washer from the
shaft of the loading roller assembly.
2.
Remove the screw I attaching the lock arm rivet
assembly.
3.
Push the shaft at the joint f’ of the lock arm rivet
assembly inward to release the lock arm rivet
assembly from the slot of the slide plate. Extend the
lock arm rivet assembly outward and release the
joint g’ from the boss of the chassis rivet assembly.
The roller guide springs on both sides come off.
Roller guide
Washer
Loading roller assembly
Roller guide
Joint e'
Roller guide spring
Roller guide spring
Joint d'
Loading roller assembly
Roller guide spring
Lock arm rivet assembly
Fig.27
Loading roller assembly
Roller guide
spring
CAUTION:
When reassembling, reattach the left
and right roller guide springs to the lock
arm rivet assembly before reattaching
the lock arm rivet assembly to the
chassis rivet assembly. Make sure to fit
the part h’ of the roller guide spring (L)
inside of the roller guide (Refer to
Fig.30).
Roller guide
Washer
Roller shaft assembly
Joint h'
Loading roller assembly
Roller guide
spring
Fig.28-1
Fig.28-2
Chassis rivet assembly
Boss
Slide plate
Roller guide spring
I
Frame
Loading roller
Roller guide spring
Lock arm rivet assembly
Joint f'
Part g'
Fig.29Fig.30
1-15
KW-XC828
Removing the loading gear (5), (6) and
(7) (See Fig.31 and 32)
Prior to performing the following procedure, remove
the top cover, the chassis unit and the top plate
assembly.
1.
Remove the screw J attaching the loading gear
bracket. The loading gear (6) and (7) come off the
loading gear bracket.
2.
Pull out the loading gear (5).
Loading gear bracket
J
Loading gear (6)
Loading gear (5)
Loading gear (3)
Fig.31
J
Loading gear bracket
Loading gear (5)
Loading gear (6)
Loading gear (7)
Fig.32
1-16
Removing the gears (See Fig.33 to 36)
Prior to performing the following procedure, remove
the top cover, the chassis unit, the top plate
assembly and the pickup unit.
1.
Pull out the feed gear.
KW-XC828
Slot j'
Slide plate
2.
Move the loading plate assembly in the direction of
the arrow to release the slide plate from the two slots
j’ of the chassis rivet assembly.
3.
Detach the loading plate assembly upward from the
chassis rivet assembly while releasing the joint k’.
Remove the slide hook and the loading plate spring
from the loading plate assembly.
4.
Pull out the loading gear (2) and remove the change
lock lever.
5.
Remove the E-washer and the washer attaching the
changer gear (2).
6.
The changer gear (2), the changer gear spring and
the adjusting washer come off.
7.
Remove the loading gear (1).
8.
Move the hang plate rivet assembly in the direction
of the arrow to release from the three shafts of the
chassis rivet assembly upward.
9.
Detach the loading gear plate rivet assembly from
the shaft of the chassis rivet assembly upward while
releasing the joint l’.
Feed gear
Change plate
rivet assembly
Shafts
E-washer
Loading plate assembly
Joint k'
Slot j'
Fig.33
Joint l'
Loading gear (4)
Loading gear plate
rivet assembly
Loading gear (2)
Loading gear (1)
Change gear (2)
10.
Pull out the loading gear (4).
Loading plate assembly
Loading plate spring
Slot j'
Chassis rivet assembly
Joint k'
Slide hook
Slide plate
Slot j'
E-washer
Washer
Loading gear (2)
Loading plate spring
Adjusting washer
Change plate
rivet assembly
Chassis rivet assembly
Fig.34
Loading gear (1)
Loading gear (2)
Change lock lever
Loading gear (4)
Loading gear plate rivet assembly
Fig.36Fig.35
1-17
KW-XC828
Removing the turn table / spindle motor
(See Fig.37 and 38)
Prior to performing the following procedure, remove
the top cover, the connector assembly and the
chassis / clamper assembly.
1.
Remove the two screws K attaching the spindle
motor assembly through the slot of the turn table on
top of the body.
2.
Unsolder the wire on the connector board if
necessary.
K
Turn table
Fig.37
K
Turn table
1-18
Spindle motor
Fig.38
KW-XC828
REFERENCE:
Prior to performing the following
procedures, turn the mode gear on the
bottom of the body until the respective part
comes to the EJECT position (Refer to
Fig.1).
Removing the cassette guide (See Fig.2)
1.
Turn the mode gear to set to RVS play or
subsequent mode.
2.
Remove the cassette guide from the main chassis
while releasing each two joint tabs a in the direction
of the arrow.
Mode gear
Fig.1
Cassette guide
Removing the load arm (See Fig.3)
1.
Remove the E-washer attaching the load arm.
2.
Move the load arm in the direction of the arrow and
release the joint b on the cassette catch.
Load arm
E-washer
Tab a
Joint b
Tab a
Fig.2
Fig.3
1-19
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