Panasonic SCHC-4-GK, SCHC-4-GT Service manual

Compact Stereo System

Model No. SC-HC4GK

SC-HC4GT

Product Color: (S)...Silver Type

PSG0907003CE

TABLE OF CONTENTS

1 Safety Precautions----------------------------------------------- 3

1.1. General Guidelines---------------------------------------- 3

1.2. Before Repair and Adjustment------------------------- 4

1.3. Caution For Fuse Replacement------------------------ 4

1.4. Protection Circuitry ---------------------------------------- 4

1.5. Safety Part Information----------------------------------- 4

2 Warning-------------------------------------------------------------- 6

2.1. Prevention of Electro Static Discharge (ESD) to Electrostatically Sensitive (ES) Devices---------- 6

2.2. Precaution of Laser Diode------------------------------- 7

2.3. Service caution based on Legal restrictions-------- 8

3 Service Navigation----------------------------------------------- 9

3.1. Service Information --------------------------------------- 9

4 Specifications ----------------------------------------------------10 5 Location of Controls and Components ------------------11

5.1. Main Unit Key Button Operations---------------------11

5.2. Remote Control Key Button Operations ------------12

6 Operating Instructions-----------------------------------------13

PAGE PAGE

6.1. Disc and MP3 Information ----------------------------- 13

7 Self diagnosis and special mode setting --------------- 14

7.1. Service Mode Summary Table------------------------ 14

7.2. Service Mode Table ------------------------------------- 15

7.3. Error Code Table ----------------------------------------- 18

8 Troubleshooting Guide --------------------------------------- 19

8.1. CD Door Unit Jam--------------------------------------- 19

9 Disassembly and Assembly Instructions--------------- 21

9.1. Disassembly flow chart --------------------------------- 22

9.2. Type of Screw--------------------------------------------- 23

9.3. Main Parts Location Diagram ------------------------- 23

9.4. Disassembly of CD Door Unit------------------------- 24

9.5. Disassembly of Net Frame Assembly--------------- 26

9.6. Disassembly of Top Ornament------------------------ 28

9.7. Disassembly of Bottom Ornament------------------- 29

9.8. Disassembly of Speaker Unit (SP1)----------------- 30

9.9. Disassembly of Speaker Unit (SP2)----------------- 31

9.10. Disassembly of Panel 1 & Panel 2 P.C.B. --------- 33

9.11. Disassembly of Front Panel Block ------------------- 35

9.12. Disassembly of Tuner Pack --------------------------- 35

9.13. Disassembly of SMPS Unit ---------------------------- 36

9.14. Disassembly of AC IN P.C.B.-------------------------- 37

9.15. Disassembly of SMPS P.C.B. ------------------------- 39

9.16. Replacement of Switching Regulator IC (IC702)------------------------------------------------------ 40

9.17. Replacement of Diode (D702) ------------------------ 42

9.18. Replacement of Diode (D704) ------------------------ 44

9.19. Disassembly of Main P.C.B. --------------------------- 46

9.20. Disassembly of Fan--------------------------------------49

9.21. Disassembly of AUX / HP P.C.B.--------------------- 49

9.22. Disassembly of Traverse Deck -----------------------50

9.23. Disassembly of Traverse Cover & Traverse Unit-----------------------------------------------------------51

9.24. Disassembly of CD Servo P.C.B.--------------------- 52

9.25. Disassembly of D-Amp P.C.B. ------------------------53

9.26. Disassembly of Fan Unit (iPod) ---------------------- 53

9.27. Disassembly of USB Module Assembly------------ 55

9.28. Disassembly of USB P.C.B. --------------------------- 55

9.29. Disassembly of SD Lid---------------------------------- 56

9.30. Disassembly of FL P.C.B. ------------------------------ 57

9.31. Disassembly of iPod P.C.B.---------------------------- 58

9.32. Disassembly of Motor P.C.B. -------------------------- 61

9.33. Disassembly of Position SW P.C.B. ----------------- 62

9.34. Disassembly of iPod SW P.C.B. ---------------------- 63

9.35. Disassembly of IR P.C.B.------------------------------- 64

10 Service Position -------------------------------------------------66

10.1. Checking and Repairing Main P.C.B. --------------- 66

10.2. Checking and Repairing D-Amp P.C.B.------------- 73

10.3. Checking and Repairing FL P.C.B. ------------------ 74

10.4. Checking and Repairing CD Servo P.C.B. --------- 74

10.5. Checking and Repairing USB P.C.B.---------------- 75

10.6. Checking and Repairing AC IN P.C.B.-------------- 75

10.7. Checking and Repairing SMPS P.C.B. -------------78

11 Voltage Measurement & Waveform Chart--------------- 80

11.1. CD SERVO P.C.B. ---------------------------------------80

11.2. D-AMP P.C.B. ---------------------------------------------81

11.3. FL P.C.B. --------------------------------------------------- 81

11.4. MAIN P.C.B. (1/3) ---------------------------------------- 82

11.5. MAIN P.C.B. (2/3) ---------------------------------------- 83

11.6. MAIN P.C.B. (3/3) ---------------------------------------- 84

11.7. SMPS P.C.B. ---------------------------------------------- 84

11.8. USB P.C.B.-------------------------------------------------85

11.9. Waveform Chart ------------------------------------------86

12 Illustration of IC’s, Transistors and Diodes ------------88 13 Overall Simplified Block -------------------------------------- 89 14 Block Diagram --------------------------------------------------- 92

14.1. CD SERVO BLOCK DIAGRAM ---------------------- 92

14.2. MAIN (1/2) / TUNER / iPod / FL / MOTOR / USB BLOCK DIAGRAM-------------------------------- 93

14.3. MAIN (2/2) / D-AMP BLOCK DIAGRAM ----------- 94

14.4. PANEL1/2 / AUX/HP / IR / SMPS / AC IN BLOCK DIAGRAM--------------------------------------- 95

15 Wiring Connection Diagram --------------------------------- 96 16 Schematic Diagram Notes -----------------------------------97 17 Schematic Diagram---------------------------------------------98

17.1. CD SERVO CIRCUIT -----------------------------------98

17.2. MAIN CIRCUIT (1/4) ------------------------------------ 99

17.3. MAIN CIRCUIT (2/4) ---------------------------------- 100

17.4. MAIN CIRCUIT (3/4) ---------------------------------- 101

17.5. MAIN CIRCUIT (4/4) ----------------------------------- 102

17.6. FL CIRCUIT, PANEL 1 CIRCUIT and PANEL 2 CIRCUIT------------------------------------------------ 103

17.7. TUNER CIRCUIT, AUX/HP CIRCUIT, IR CIRCUIT, MOTOR CIRCUIT, POSITION SW CIRCUIT and iPod SW CIRCUIT------------------- 104

17.8. iPod CIRCUIT and AC IN CIRCUIT---------------- 105

17.9. D-AMP CIRCUIT----------------------------------------106

17.10. SMPS CIRCUIT -----------------------------------------107

17.11. USB CIRCUIT -------------------------------------------108

18 Printed Circuit Board----------------------------------------- 109

18.1. CD SERVO P.C.B.-------------------------------------- 109

18.2. MAIN P.C.B. (1/2)--------------------------------------- 110

18.3. MAIN P.C.B. (2/2)--------------------------------------- 111

18.4. TUNER P.C.B., FL P.C.B., PANEL 1 P.C.B., PANEL 2 P.C.B., AUX/HP P.C.B. and IR P.C.B. ------------------------------------------------------ 112

18.5. MOTOR P.C.B., POSITION SW P.C.B., iPod SW P.C.B., iPod P.C.B. and D-AMP P.C.B. ------ 113

18.6. SMPS P.C.B., AC IN P.C.B. and USB P.C.B. ---- 114

19 Terminal Function of IC’s -----------------------------------115

19.1. IC801 (RFKWMAHC4EP) MICRO PROCESSOR IC --------------------------------------- 115

19.2. IC7001 (MN6627954AMA) IC SERVO PROCESSOR ------------------------------------------- 116

19.3. IC7002 (BA5948FPE2) IC 4CH Drive ------------- 117

20 Exploded View and Replacement Parts List---------- 118

20.1. Exploded View and Mechanical replacement Parts List-------------------------------------------------- 118

20.2. Electrical Replacement Parts List ------------------124

1 Safety Precautions

1.1. General Guidelines

1. When servicing, observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.

2. After servicing, see to it that all the protective devices such as insulation barriers, insulation papers shields are properly installed.

3. After servicing, carry out the following leakage current checks to prevent the customer from being exposed to shock hazards.

1.1.1. Leakage Current Cold Check

1. Unplug the AC cord and connect a jumper between the two prongs on the plug.

2. measure the resistance value, with an ohmmeter between the jumpered AC plug and each exposed metallic cabinet part on the equipment such as screwheads, connectors, control shafts, etc. When the exposed metallic part has a return path to the chassis, the reading should be between 1MΩ and 5.2MΩ. When the exposed metal does not have a return path to the chas-

sis, the reading must be

1.1.2. Leakage Current Hot Check

1. Plug the AC cord directly into the AC outlet. Do not use an isolation transformer for this check.

2. Connect a 1.5kΩ, 10 watts resistor, in parallel with a 0.15μF capacitors, between each exposed metallic part on the set and a good earth ground such as a water pipe, as shown in Figure 1.

3. Use an AC voltmeter, with 1000 ohms/volt or more sensitivity, to measure the potential across the resistor.

4. Check each exposed metallic part, and measure the voltage at each point.

5. Reverse the AC plug in the AC outlet and repeat each of the above measurements.

6. The potential at any point should not exceed 0.75 volts RMS. A leakage current tester (Simpson Model 229 or equivalent) may be used to make the hot checks, leakage current must not exceed 1/2 milliamp. In case a measurement is outside of the limits specified, there is a possibility of a shock hazard, and the equipment should be repaired and rechecked before it is returned to the customer.

Figure. 1

1.2. Before Repair and Adjustment

Disconnect AC power, discharge unit AC Capacitors as such C702, C710, C725, C727, C728, C730 and C736 through a 10W, 1W resistor to ground. Caution : DO NOT SHORT-CIRCUIT DIRECTLY (with a screwdriver blade, for instance), as this may destroy solid state devices. After repairs are completed, restore power gradually using a variac, to avoid overcurrent.

• Current consumption at AC 110V, at 60Hz in NO SIGNAL mode (at volume min in FM Tuner mode) should be ~250 mA (For GT).

• Current consumption at AC 220V, at 50Hz in NO SIGNAL mode (at volume min in FM Tuner mode) should be ~250 mA (For GK).

1.3. Caution For Fuse Replacement

1.4. Protection Circuitry

The protection circuitry may have operated if either of the following conditions are noticed:

• No sound is heard when the power is turned on.

• Sound stops during a performance. The function of this circuitry is to prevent circuitry damage if, for example, the positive and negative speaker connection wires are "shorted", or if speaker systems with an impedance less than the indicated rated impedance of the amplifier are used. If this occurs, follow the procedure outlines below:

1. Turn off the power.

2. Determine the cause of the problem and correct it.

3. Turn on the power once again after one minute. Note: When the protection circuitry functions, the unit will not operate unless the power is first turned off and then on again.

1.5. Safety Part Information

Safety Parts List:

There are special components used in this equipment which are important for safety. These parts are marked by in the Schematic Diagrams, Exploded View & Replacement Parts List. It is essential that these critical parts should be replaced with manufacturer’s specified parts to prevent shock, fire or other hazards. Do not modify the original design without permission of manufacturer.

Table 1

Safety Ref. No. Part No. Part Name & Description Remarks

6 REXX0746-1 RED WIRE (AC INLET-SMPS)

7 REXX0747-1 BLACK WIRE (AC INLET-SMPS)

9 REXX0752-1 BLUE WIRE (AC INLET-SMPS)

30 RGNX0850M-1 NAME PLATE LABEL GT

30 RGNX0850N-2 NAME PLATE LABEL GK

101 REXX0771 SECONDARY WIRE (WHITE) ; JW708

102 REXX0772 SECONDARY WIRE (BROWN); JW707

300 RAE0165T-V TRAVERSE ASS’Y (RTL)

A2 K2CA2CA00020 AC CORD GK

A2 K2CA2CA00027 AC CORD GT

A3 RQTX0312-K O/I BOOK (Co) GT

A3 RQTX0313-K O/I BOOK (Cn) GK

A7 J0KG00000037 AC CLAMP FILTER GT

PCB5 REPX0755B SMPS P.C.B. (RTL) (GK)

PCB5 REPX0755M SMPS P.C.B. (RTL) (GT)

PCB14 REPX0755B AC IN P.C.B. (RTL) (GK)

PCB14 REPX0755M AC IN P.C.B. (RTL) (GT)

L702 G0B103G00015 LINE FILTER GT

L702 G0B333E00002 LINE FILTER GK

L703 G0B103G00015 LINE FILTER GT

L751 ELF15N035AN LINE FILTER

Safety Ref. No. Part No. Part Name & Description Remarks

T581 G4D1A0000117 SWITCHING TRANSFORMER

T701 G4DYA0000139 MAIN TRANSFORMER GT

T701 G4DYA0000155 MAIN TRANSFORMER GK

T751 ETS19AB221AG SUB TRANSFORMER

Z752 ERZV10V511CS ZNR GK

Z752 ERZVA5Z471 ZNR GT

PC701 B3PBA0000454 PHOTO COUPLER

PC751 B3PBA0000454 PHOTO COUPLER

RY701 K6B1AEA00017 RELAY

F751 K5D162BK0005 FUSE GK

F751 K5D302AQ0003 FUSE GT

FP581 K5H7512A0010 FUSE PROTECTOR

TH701 D4CAA5R10001 THERMISTOR GT

TH701 D4CAC8R00002 THERMISTOR GK

P751 K2AA2B000017 AC INLET

C702 ECQU2A104MLC 0.1uF

C710 F1BAF471A013 470pF

C725 ECQU2A104MLC 0.1uF

C727 F1BAF471A013 470pF

C728 F1BAF471A013 470pF

C730 F1BAF1020020 1000pF

C736 ECQU2A104MLC 0.1uF 250Vac

2Warning

2.1. Prevention of Electro Static Discharge (ESD) to Electrostatically Sensi-

tive (ES) Devices

Some semiconductor (solid state) devices can be damaged easily by static electricity. Such components commonly are called Electrostatically Sensitive (ES) Devices. Examples of typical ES devices are integrated circuits and some field-effect transistors and semiconductor “chip” components. The following techniques should be used to help reduce the incidence of component damage caused by electrostatic discharge (ESD).

1. Immediately before handling any semiconductor component or semiconductor-equiped assembly, drain off any ESD on your

body by touching a known earth ground. Alternatively, obtain and wear a commercially available discharging ESD wrist strap, which should be removed for potential shock reasons prior to applying power to the unit under test.

2. After removing an electrical assembly equiped with ES devices, place the assembly on a conductive surface such as alumin-

ium foil, to prevent electrostatic charge build up or exposure of the assembly.

3. Use only a grounded-tip soldering iron to solder or unsolder ES devices.

4. Use only an anti-static solder remover device. Some solder removal devices not classified as “anti-static (ESD protected)” can

generate electrical charge sufficient to damage ES devices.

5. Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage ES devices.

6. Do not remove a replacement ES device from its protective package until immediately before you are ready to install it. (Most

replacement ES devices are packaged with leads electrically shorted together by conductive foam, aluminium foil or comparable conductive material).

7. Immediately before removing the protective material from the leads of a replacement ES device, touch the protective material

to the chassis or circuit assembly into which the device will be installed.

Caution :

Be sure no power is applied to the chassis or circuit, and observe all other safety precautions.

8. Minimize bodily motions when handling unpackaged replacement ES devices. (Otherwise harmless motion such as the

brushing together of your clothes fabric or the lifting of your foot from a carpeted floor can generate static electricity (ESD) sufficient to damage an ES device).

2.2. Precaution of Laser Diode

CAUTION!

THIS PRODUCT UTILIZES A LASER. USE OF CONTROLS OR ADJUSTMENTS OR PERFORMANCE OF PROCEDURES OTHER THAN THOSE SPECIFIED HEREIN MAY RESULT IN HAZARDOUS RADIATION EXPOSURE.

Caution:

This product utilizes a laser diode with the unit turned "on", invisible laser radiation is emitted from the pickup lens. Wavelength: 795 nm (CD) Maximum output radiation power from pickup: 100 μW/VDE Laser radiation from the pickup unit is safety level, but be sure the followings:

1. Do not disassemble the pickup unit, since radiation from exposed laser diode is dangerous.

2. Do not adjust the variable resistor on the pickup unit. It was already adjusted.

3. Do not look at the focus lens using optical instruments.

4. Recommend not to look at pickup lens for a long time.

2.3. Service caution based on Legal restrictions

2.3.1. General description about Lead Free Solder (PbF)

The lead free solder has been used in the mounting process of all electrical components on the printed circuit boards used for this equipment in considering the globally environmental conservation.

The normal solder is the alloy of tin (Sn) and lead (Pb). On the other hand, the lead free solder is the alloy mainly consists of tin (Sn), silver (Ag) and Copper (Cu), and the melting point of the lead free solder is higher approx.30 degrees C (86°F) more than that of the normal solder.

Definition of PCB Lead Free Solder being used

The letter of “PbF” is printed either foil side or components side on the PCB using the lead free solder. (See right figure)

Service caution for repair work using Lead Free Solder (PbF)

• The lead free solder has to be used when repairing the equipment for which the lead free solder is used. (Definition: The letter of “PbF” is printed on the PCB using the lead free solder.)

• To put lead free solder, it should be well molten and mixed with the original lead free solder.

• Remove the remaining lead free solder on the PCB cleanly for soldering of the new IC.

• Since the melting point of the lead free solder is higher than that of the normal lead solder, it takes the longer time to melt the lead free solder.

• Use the soldering iron (more than 70W) equipped with the temperature control after setting the temperature at 350±30 degrees C (662±86°F).

Recommended Lead Free Solder (Service Parts Route.)

• The following 3 types of lead free solder are available through the service parts route. RFKZ03D01K-----------(0.3mm 100g Reel) RFKZ06D01K-----------(0.6mm 100g Reel) RFKZ10D01K-----------(1.0mm 100g Reel)

Note

* Ingredient: Tin (Sn), 96.5%, Silver (Ag) 3.0%, Copper (Cu) 0.5%, Cobalt (Co) / Germanium (Ge) 0.1 to 0.3%

3 Service Navigation

3.1. Service Information

This service manual contains technical information which will allow service personnel’s to understand and service this model. Please place orders using the parts list and not the drawing reference numbers.

If the circuit is changed or modified, this information will be followed by supplement service manual to be filed with original service manual.

1. Micro-processor:

• Micro-processor IC, (IC801) is supplied as assembled part (RFKWMAHC4EP).

4 Specifications

Q Amplifier Section RMS Output Power Stereo Mode Front Ch (both ch driven) 20 W per channel (6 Ω), 1 kHz, 10

Total RMS Stereo Mode power 40 W Phone jack Terminal Stereo, 3.5 mm jack Output level (CD, 1 kHz, -20 dB) max. 1.18 mW +1.18 mW, 32 Ω

Used PH Impedance 16 to 64 Ω (GK)

Aux (Rear) Sensitivity Normal level 630 mV, 12.4 kΩ High level 100 mV, 12.4 kΩ Terminal Stereo, 3.5 mm jack Q Tuner Section Preset memory FM 30 stations

Frequency Modulation (FM) Frequency range 87.50 MHz to 108.00 MHz

Antenna terminals 75 Ω (unbalanced) Amplitude Modulation (AM) Frequency range 522 kHz to 1629 kHz (9 kHz step) Q Disc Section Disc played [8 cm or 12 cm]

(1) CD-Audio (CD-DA) (2) CD-R/RW (CD-DA, MP3) (3) MP3* * MPEG-1 Layer 3, MPEG-2 Layer 3

Pick up (CD) Wavelength 795 nm Laser power CLASS 1 Audio output (Disc) Number of channels FL, FR, 2 channel Audio performance (CD-Audio) Frequency response 4 Hz to 20 kHz S/N ratio 95 dB Dynamic range 93 dB Total harmonic distortion 0.005 % Q USB Port Media file format support MP3 (*.mp3) USB device file system FAT12/16/32 USB port power Max 500 mA Bit rate 16 to 320 kbps (GK) Q Speaker Section Typ e 1 way, 1 speaker system (Bass

Speaker unit(s) Full range 6.5 cm Cone type Impedance 6 Ω Input power (IEC) 30 W (Max) Output sound pressure 79 dB/W (1.0m) Frequency range 55 Hz to 25 kHz (-16 dB)

90 Hz to 22 kHz (-10 dB)

Q General Power supply (For GT) AC 110 V, 60 Hz (For GK) AC 220 V, 50 Hz Power consumption 33 W (Total harmonic distortion 1%, AC 110 V) (For GT) Dimensions (W x H x D) 500 mm x 195 mm x 102.5 mm

(D = 69 mm minimum)

Mass Approx. 3 kg Operating temperature range 0°C to +35°C

% THD

AM 15 stations

(50 kHz step)

reflex)

85 W

Operating humidity range 35% to 80 % RH (no condensa-

tion)

Power consumption in standby mode 0.08 W (approx) (For GT) Power consumption in standby mode 0.2 W (approx) (For GK)

Notes :

1. Specifications are subject to change without notices. Mass and dimensions are approximate.

2. Total harmonic distortion is measured by the digital spectrum analyzer.

5 Location of Controls and Components

5.1. Main Unit Key Button Operations

5.2. Remote Control Key Button Operations

6 Operating Instructions

6.1. Disc and MP3 Information

7 Self diagnosis and special mode setting

This unit is equipped with features of self-diagnostic & special mode setting for checking the functions & reliability.

7.1. Service Mode Summary Table

The service modes can be activated by pressing various button combination on the main unit and remote control unit. Below is the summary for the various modes for checking:

Player buttons Remote control unit buttons Application Note

[4], [7] To Enter into Doctor Mode for vari-

ous checking

Player buttons Remote control unit buttons Mode Name Note

Note : Applicable in Doctor Mode [1] FL Display Test (Refer to the section “7.2.2 service

[6] CD and Tape Eject test (Refer to the section “7.2.2 service

[7] VOLUME setting (50dB) (Refer to the section “7.2.2 service

[8] VOLUME setting (29dB) (Refer to the section “7.2.2 service

[9] VOLUME setting (0dB) (Refer to the section “7.2.2 service

[ ], [1], [2]

[ ], [1], [3]

[SLEEP] Cold Start (Refer to the section “7.2.2 service

[2] USB Test Mode (Refer to the section “7.2.2 service

[ ], [2], [1]

CD Traverse Unit Test Mode (Refer to the section “7.2.2 service

CD Combination Test Mode (Refer to the section “7.2.2 service

Mecha sliding Panel Reliability (Refer to the section “7.2.2 service

(Refer to the section “7.2.1 Service Mode Table 1.)

mode Table 2 for more information.)

7.2. Service Mode Table

Below is the various special modes for checking:-

7.2.1. Service Mode Table 1

Item FL Display Key Operation

Mode Name Description Front Key

Self -Diagnostic Mode To enter into self diagnostic

checking for main unit.

Doctor Mode To enter into Doctor Mode

for checking of various items and displaying EEPROM and firmware version.

Note: The micro-processor version as shown is an example. It will be revise when there is an updates.

FL Display sequence Display 1 → 2

(Display 1)

Checksum : (Condition 1)

1. Select [ ] for CD mode (Ensure no CD inserted).

2. Press and hold [ ]button for 2 seconds follow by

[].

To exit Doctor Mode, press button on main unit or remote control.

In CD mode:

1. Press [ ] button on main unit follow by [4] and [7] on remote control.

To exit Doctor Mode, press button on main unit or remote control.

(a) If there is NO EEPROM header string OR (b) If there is no EEPROM ( no data is received by micro-processor) [NO] is displayed.

Checksum : (Condition 2)

If the version of the EEPROM does not match or not working properly [NG] is display.

Checksum : (Condition 3)

If the EEPROM version matches, checksum [YYYY] is displayed.

(Display 2)

The Checksum of EEPROM and firmware version will be display for 2 sec.

7.2.2. Service Mode Table 2

Item FL Display Key Operation

Mode Name Description Front Key

FL Display Test To check the FL segments

display (All segments will light up)

Volume Setting To check for volume setting

CD Traverse Unit Test Mode

during this mode, Bass & treble is set to 0dB & EQ is switch off.

To check for the traverse unit operation. In this mode, the first & last track is access & read. (TOC). It fails when TOC is not completed by IOS or the traverse is out of focus.

In Doctor Mode:

1. Press [1] button on remote control.

To cancel, press [0] button on remote control.

To exit Doctor Mode, press button on main unit or remote control. In Doctor Mode:

1. Press [7] button on remote control.

To exit Doctor Mode, press button on main unit or remote control.

In Doctor Mode:

2. Press [8] button on remote control.

To exit Doctor Mode, press button on main unit or remote control.

In Doctor Mode:

3. Press [9] button on remote control.

To exit Doctor Mode, press button on main unit or remote control. In Doctor Mode:

1. Press [ ], [1], [2] button on remote control.

To cancel, press [0] button on remote control.

To exit Doctor Mode, press button on main unit or remote control.

CD Combination Test Mode

Cold Start To activate cold start upon

USB Test Mode To Inspect USB Testing.

A combination of CD loading & traverse unit test.

next AC power up.

The display will appear after 3s,

In Doctor Mode:

1. Press [ ], [1], [3] button on remote control.

To cancel, press [0] button on remote control.

To exit Doctor Mode, press button on main unit or remote control.

In Doctor Mode:

1. Press [SLEEP] button on remote control.

To exit Doctor Mode, press button on main unit or remote control. In Doctor Mode:

1. Select to USB mode.

2. Press [2] button on remote control.

To exit Doctor Mode, press button on main unit or remote control.

Item FL Display Key Operation

Mode Name Description Front Key

Mecha Sliding Panel Reliability

To check the operation of sliding Panel. Sequence as follow :

1. Panel set to centre position.

2. CD Open & stop at left position for 1s.

3. CD Close & stop at centre position for 1s.

4. iPod open & stop at right position for 1s.

5. iPod close & stop at centre position for 1s.

In Doctor Mode:

1. Press [ ] follow by [2] & then [1] button on remote control.

To cancel, press [0] button on remote control.

To exit Doctor Mode, press button on main unit or remote control.

7.3. Error Code Table

Self-Diagnosis Function provides information on any problems occuring for the unit and its respective components by displaying error codes. Thesed error code such as U**, H** and F** are stored in memory and held unless it is cleared. The error code is automatically display after entering into self-diagnostic mode.

Error Code Diagnosis Contents Description of error Automatic FL Display Remarks

CD H15 CD Open Abnormal During operation

POS_SW_R On fail to be detected with 3 sec. Error No. shall be clear by force or during cold start.

CD H16 CD Closing Abnormal During operation

IPD H15 iPod Open Abnormal During operation

IPD H16 iPod Closing Abnormal During operation

F15 CD REST SW Abnormal CD traverse position intial

F26 Communication between

CD servo LSI and micro-p abnormal.

POS_SW_CEN On fail to be detected with 3 sec. Error No. shall be clear by force or during cold start.

POS_SW_L On fail to be detected with 3 sec. Error No. shall be clear by force or during cold start.

POS_SW_CEN On fail to be detected with 3 sec. Error No. shall be clear by force or during cold start.

setting operation failsafe counter (10 s) waiting for REST SW to turn on. Error No. shall be clear by force or during cold start. During switch to CD function, if SENSE = “L” within failsafe time of 20ms.

For CD Mechanism Unit Press [Q] on main unit for next error.

For iPod Press [Q] on main unit for next error.

For CD Mechanism Unit Press [Q] on main unit for next error.

F61/F76 Power Amp IC output

abnormal

During power-on, PDET1, PDET2 & MAINV_DET / TEMP_DET is “L” after 1 sec.

For power. Press [Q] on main unit for next error.

8 Troubleshooting Guide

8.1. CD Door Unit Jam

8.1.1. Removing the CD

Step 2 : Push the CD Door Unit as arrow shown until the CD is

fully in sight.

Step 3 : Remove the CD.

Step 1 : Insert a flathead screwdriver into the hole behind the

CD Door Unit and push the gear fixture from point A to B.

8.1.2. Removing the iPod

Step 2 : Push the CD Door Unit as arrow shown until the iPod

is fully in sight.

Step 3 : Remove the iPod.

Step 1 : Insert a flathead screwdriver into the hole behind the

CD Door Unit and push the gear fixture from point B to A.

9 Disassembly and Assembly Instructions

“ATTENTION SERVICER”

Be careful when disassembling and servicing. Some chassis components may have sharp edges

Special Note:

1. This section describes the disassembly procedures for all the major printed circuit boards and main components.

2. Before the disassembly process was carried out, do take special note that all safety precautions are to be carried out. (Ensure that no AC power supply is connected during disassembling.)

3. For assembly after operation checks or replacement, reverse the respective procedures. Special reassembly procedures are described only when required.

4. Do take note of the locators on each printed circuit board during reassembling procedures.

5. The Switch Regulator IC may have high temperature after prolonged use.

6. Use caution when removing the top cabinet and avoid touching heat sinks located in the unit.

7. Select items from the following index when checks or replacement are required.

• Disassembly of CD Door Unit

• Disassembly of Net Frame Assembly

• Disassembly of Top Ornament

• Disassembly of Bottom Ornament

• Disassembly of Speaker Unit (SP1)

• Disassembly of Speaker Unit (SP2)

• Disassembly of Panel 1 & Panel 2 P.C.B.

• Disassembly of Front Panel Block

• Disassembly of Tuner Pack

• Disassembly of SMPS Unit

• Disassembly of AC IN P.C.B.

• Disassembly of SMPS P.C.B.

• Replacement of Switching Regulator IC (IC702)

• Replacement of Diode (D702)

• Replacement of Diode (D704)

• Disassembly of Main P.C.B.

• Disassembly of Fan

• Disassembly of AUX / HP P.C.B.

• Disassembly of Traverse Deck

• Disassembly of Traverse Cover & Traverse Unit

• Disassembly of CD Servo P.C.B.

• Disassembly of D-Amp P.C.B.

• Disassembly of Fan Unit (iPod)

• Disassembly of USB Module Assembly

• Disassembly of USB P.C.B.

• Disassembly of SD Lid

• Disassembly of FL P.C.B.

• Disassembly of iPod P.C.B.

• Disassembly of Motor P.C.B.

• Disassembly of Position SW P.C.B.

• Disassembly of iPod SW P.C.B.

• Disassembly of IR P.C.B.

9.1. Disassembly flow chart

The following chart is the procedure for disassembling the casing and inside parts for internal inspection when carrying out the servicing. To assemble the unit, reverse the steps shown in the chart below.

9.2. Type of Screw

9.3. Main Parts Location Diagram

9.4. Disassembly of CD Door Unit

Step 1 : Insert a flathead screwdriver into the hole behind the

CD Door Unit and push the gear fixture from point A to B.

Step 3 : Lift up the CD Door Unit slightly as arrow shown and push it as arrow shown.

Step 4 : Remove the CD Door Unit. Caution : Avoid touching the lens during assembling / Dis-

assembly of the CD Door Unit.

Step 2 : Gentlely push the CD Door Unit manually until it is fully

extended.

• Assembly of CD Door Unit

Step 1 : Adjust the gear fixture as diagram shown.

Caution : Avoid touching the lens during assembling / Disassembly of the CD Door Unit.

Step 2 : Align the CD Door Unit with the (upper & lower rib),

guide reel (A & B) on the front panel. Step 3 : Gentlely push the CD Door Unit until it is fully closed.

9.5. Disassembly of Net Frame Assembly

• Disassembly of Net Frame Asembly (L)

Step 1 : Gently lift up Net Frame Assembly (L). Caution : During assembly ensure the net frame assembly

(L) is seated properly

Caution : During assembly ensure that the bosses are aligned to their respective holes in Front Speaker Assembly (L) as shown.

Step 2 : Remove Net Frame Assembly (L) as arrow shown.

• Disassembly of Net Frame Asembly (R)

Step 3 : Gently lift up Net Frame Assembly (R).

Caution : During assembly ensure that the bosses are aligned to their respective holes in Front Speaker Assembly (R) as shown.

Step 4 : Remove Net Frame Assembly (R) as arrow shown.

9.6. Disassembly of Top Ornament

• Follow the (Step 1) - (Step 4) of item 9.5.

Step 1 : Remove 4 screws.

Step 3 : Lift up the Top Ornament Unit. Caution : Avoid pulling when detaching the Top Ornament

or apply strong force it may lead to the broken of connecting cable.

Step 2 : Gently release the 2 catches on the Top Ornament

Unit.

Caution : Take extra care not to damage the Top Ornament Unit when releasing the catches during disassembling.

9.7. Disassembly of Bottom Ornament

• Follow the (Step 1) - (Step 4) of item 9.5.

Step 1 : Remove 4 screws.

Step 3 : Remove the Bottom Ornament.

Step 2 : Gently release the 4 catches on the Bottom Ornament. Caution : Take extra care not to damage the Bottom Orna-

ment during disassembling.

9.8. Disassembly of Speaker Unit (SP1)

• Follow the (Step 1) - (Step 4) of item 9.5.

• Follow the (Step 1) - (Step 3) of item 9.6.

• Follow the (Step 1) - (Step 3) of item 9.7.

Step 3 : Place the Front Speaker Assembly (L) on a support block as shown.

Step 1 : Remove 5 screws.

Step 2 : Using a flathead screwdriver, apply gentle force at the

4 holes in the Front Speaker Assembly (L) in order show to detach it from the Main Unit as arrows shown.

Caution : During assembling of the Front Speaker Assembly (L), insert the speaker wires into the hole in the Front Speaker Assembly (L).

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