JVC KWXG-500 Service manual

SERVICE MANUAL

CD RECEIVER

MA34520076SERVICE MANUAL

KW-XG500J, KW-XG504UI, KW-XG505U,

KW-XG505UN, KW-XG505UH, KW-XG506U,

KW-XG506UN, KW-XG506UH, KW-XG508UF

(for KW-XG500)

COPYRIGHT © 2007 Victor Company of Japan, Limited

* Please refer to the mechanism manual (model TN2007-1010 (No.MY005
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)

and No.MY005B)) for the CD mechanism.

TABLE OF CONTENTS

1 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

COPYRIGHT © 2007 Victor Company of Japan, Limited

No.MA345

2007/6

SPECIFICATION

KW-XG500

AUDIO AMPLIFIER SECTION

Power Output 20 W RMS × 4 Channels at 4 Ω and [< or =] 1% THD+N
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 at 60 Hz

Mid-range ±12 dB at 1 kHz

Treble ±12 dB at 10 kHz

Frequency Response 40 Hz to 20 000 Hz

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 CD changer, Steering wheel remote input, Subwoofer input, AUX (auxilliary) in-

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

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

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

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 (32°F to 104°F)
Dimensions (W × H × D)

(approx.)

Mass 1.8 kg (4.0 lbs) (excluding accessories)

Installation Size 178 mm × 100 mm × 158 mm (7-1/16" × 3-15/16" × 6-1/4")
Set Size 178 mm × 100 mm × 178 mm (7-1/16" × 3-15/16" × 7-1/16")

put jack

TUNER SECTION

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

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

CD PLAYER SECTION

GENERAL

Design and specifications are subject to change without notice.

1-2 (No.MA345)

KW-XG504

AUDIO AMPLIFIER SECTION

Maximum Power Output Front and 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

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 CD changer, Subwoofer input, AUX (auxilliary) 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) Max. Bit Rate: 320 kbps

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

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 1.8 kg (excluding accessories)

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

monic distortion.

Mid-range ±12 dB at 1 kHz

Treble ±12 dB at 10 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) 65 dB

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

Selectivity 35 dB

CD PLAYER SECTION

GENERAL

Installation Size 178 mm × 100 mm × 158 mm
Set Size 178 mm × 100 mm × 178 mm

Design and specifications are subject to change without notice.

(No.MA345)1-3

KW-XG506/KW-XG505

AUDIO AMPLIFIER SECTION

Maximum Power Output Front and 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

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 CD changer, Subwoofer input, AUX (auxilliary) 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) Max. Bit Rate: 320 kbps

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

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 1.8 kg (excluding accessories)

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

monic distortion.

Mid-range ±12 dB at 1 kHz

Treble ±12 dB at 10 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) 65 dB

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

Selectivity 35 dB

CD PLAYER SECTION

GENERAL

Installation Size 178 mm × 100 mm × 158 mm
Set Size 178 mm × 100 mm × 178 mm

Design and specifications are subject to change without notice.

1-4 (No.MA345)

KW-XG508

AUDIO AMPLIFIER SECTION

Maximum Power Output Front and 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 CD changer, Subwoofer input, AUX (auxilliary) 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) Max. Bit Rate: 320 kbps

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

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 1.8 kg (excluding accessories)

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

monic distortion.

Mid-range ±12 dB at 1 kHz

Treble ±12 dB at 10 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) 65 dB

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

Selectivity 35 dB

CD PLAYER SECTION

GENERAL

Installation Size 178 mm × 100 mm × 158 mm
Set Size 178 mm × 100 mm × 178 mm

Design and specifications are subject to change without notice.

(No.MA345)1-5

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.

1-6 (No.MA345)

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

Base board

Frame

Flexible wire

Connector

CD mechanism
assembly

Pickup

(No.MA345)1-7

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

1-8 (No.MA345)

SECTION 2

SPECIFIC SERVICE INSTRUCTIONS

This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.

(No.MA345)1-9

SECTION 3

DISASSEMBLY

3.1 MAIN BODY

3.1.1 Removing the FRONT PANEL assembly
(See Fig.1)

(1) From the bottom side of main body, remove the two screws

A attaching the both side of the FRONT PANEL assembly.

(2) Disengage two hooks a engaged CHASSIS assembly.

hook a hook a

A

Fig.1

1-10 (No.MA345)

3.1.2 Removing the HEAT SINK

(See Fig.2)

(1) Remove the five screws B and one screw C attaching the

HEAT SINK.

3.1.3 Removing the REAR BRACKET

(See Fig.3)

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

F attaching the REAR BRACKET.

D

BBC

Fig.2

E

3.1.4 Removing the BOTTOM CHASSIS assembly

(See Fig.4)

(1) Remove the four screws G attaching the BOTTOM CHAS-

SIS assembly.

DD

Fig.3

F

GG

Fig.4

(No.MA345)1-11

3.1.5 Removing the FUNC BOARD assembly
(See Fig.5)

(1) Remove the one screw H attaching the FUNC BOARD as-

sembly.

(2) Disconnect the connecter wire from MAIN BOARD assem-

bly connected to connector CN322
assembly.

(3) Straighten hook b attaching the FUNC BOARD assembly.

3.1.6 Removing the MIDDLE CHASSIS
(See Fig.5)

(1) Remove the four screws J attaching the MIDDLE CHAS-

SIS.

(2) Disconnect the connector CN501

MIDDLE CHASSIS from the CD mechanism assembly in
an upward direction.

3.1.7 Removing the MAIN BOARD assembly
(See Fig.6)

(1) Remove the four screws K attaching the MAIN BOARD as-

sembly.

of the FUNC BOARD

of the main board on the

CN322

CN501

JJ

hook b

H

Fig.5

K

K

Fig.6

1-12 (No.MA345)

3.1.8 Removing the CD MECHANISM assembly

(See Fig.7)

(1) Remove the three screws L attaching the CD MECHA-

NISM assembly.

3.1.9 Removing the SWITCH BOARD assembly

(See Fig.8)

(1) Remove the volume knob from the front side of the FRONT

PANEL assembly.

(2) Remove the thirteen screws M and two screws N attaching

the SWITCH BOARD assembly.

L

L

Fig.7

MM

N

3.2 CD MECHANISM assembly

For CD MECHANISM ASSEMBLY, please refer MODEL TN2007-1010 (No.MY005

M

Fig.8

and No.MY005B).

(No.MA345)1-13