JVC KD-G541E Service Manual

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SERVICE MANUAL

2007

MA384<Rev.001>

KD-G541E, KD-G541EX, KD-G541EY,

KD-G541EU, KD-G544UI, KD-G545U,

KD-G545UN, KD-G545UT, KD-G545UH,

KD-G546U, KD-G546UN, KD-G546UT,

KD-G546UH, KD-G547EE

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)

Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Specific Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

CD RECEIVER

only for

KD-G541

KD-G547

No.MA384<Rev.001>

2007/12

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Page 1 SERVICE MANUAL CD RECEIVER MA384<Rev.001> 2007 SERVICE MANUAL KD-G541E, KD-G541EX, KD-G541EY, KD-G541EU, KD-G544UI, KD-G545U, KD-G545UN, KD-G545UT, KD-G545UH, KD-G546U, KD-G546UN, KD-G546UT, KD-G546UH, KD-G547EE only for only for KD-G541 KD-G547 KD-G547 COPYRIGHT © 2007 Victor Company of Japan, Limited Lead free solder used in the board (material : Sn-Ag-Cu, melting point : 219 Centigrade)
Page 2 SPECIFICATION KD-G541 AUDIO AMPLIFIER SECTION Maximum Power Output Front/Rear 50 W per channel 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8% Continuous Power Output (RMS) Front/Rear total harmonic distortion. 4 Ω (4 Ω to 8 Ω allowance) Load Impedance Tone Control Range Bass...
Page 3 KD-G544/KD-G545/KD-G546 AUDIO AMPLIFIER SECTION Maximum Power Output Front/Rear 50 W per channel 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8% Continuous Power Output (RMS) Front/Rear total harmonic distortion. 4 Ω (4 Ω to 8 Ω allowance) Load Impedance Tone Control Range Bass...
Page 4 KD-G547 AUDIO AMPLIFIER SECTION Maximum Power Output Front/Rear 50 W per channel 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8% Continuous Power Output (RMS) Front/Rear total harmonic distortion. 4 Ω (4 Ω to 8 Ω allowance) Load Impedance Tone Control Range Bass...
Page 5 SECTION 1 PRECAUTION Safety 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.
Page 6 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.
Page 7 Important for laser products 1.CLASS 1 LASER PRODUCT 5.CAUTION : If safety switches malfunction, the laser is able to function. 2.CAUTION : (For U.S.A.) Visible and/or invisible class II laser radiation 6.CAUTION : Use of controls, adjustments or performance of when open.
Page 8 SECTION 2 SPECIFIC SERVICE INSTRUCTIONS This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS. SECTION 3 DISASSEMBLY Main body (used figure is KD-G343) 3.1.1 Removing the FRONT CHASSIS assembly (See Fig.1, 2) (1) Remove the two screws A attaching the FRONT CHASSIS assembly.
Page 9 3.1.3 Removing the BOTTOM COVER (See Fig.5) (1) Remove the one screw G attaching the BOTTOM COVER. (2) Slide the BOTTOM COVER to backward. Fig.5 3.1.4 Removing the MAIN BOARD assembly (See Fig.6, 7) (1) Remove the two screws H and the two screws J attaching the MAIN BOARD assembly.
Page 10 3.1.6 Removing the SWITCH BOARD assembly (See Fig.9, 10 ) (1) Remove the VOLUME KNOB. (2) Remove the one screw L and the four screws M attaching the REAR COVER. (See Fig.9, 10) (3) Disengage the nine hooks b engaged the REAR COVER. (See Fig.10) Fig.9 hook...
Page 11 CD mechanism assembly 3.2.1 Removing the top cover (See Figs.1 and 2) (1) From the both side of the CD mechanism assembly, remove the four screws A attaching the top cover. (See Fig.1.) (2) Lift the front side of the top cover and move the top cover backward to release the two joints a.
Page 12 3.2.2 Removing the push switch (See Figs.3) (1) From the bottom side of the CD mechanism assembly, remove Pickup the screw B attaching the push switch. Wires (2) Take out the push switch from the CD mechanism assembly. Push switch Reference: Remove the wires from soldered sections b of the push switch as required.
Page 13 3.2.4 Removing the chassis unit (See Figs.5 and 6) • Remove the top cover and base board. Chassis unit (1) From the top side of the CD mechanism assembly, remove the front suspension springs and rear suspension springs Front suspension spring Front suspension spring attaching the chassis unit to the frame.
Page 14 3.2.5 Removing the clamper assembly (See Figs.7 and 8) • Remove the top cover. Chassis unit Move the clamper assembly in the direction of the arrow to release the joints f from the chassis unit. Clamper assembly Fig.7 Clamper assembly Chassis unit Fig.8 1-14 (No.MA384<Rev.001>)
Page 15 3.2.6 Removing the loading/feed motor assembly (See Fig.9) • Remove the top cover, base board and chassis unit. Loading/feed motor assembly From the bottom side of the chassis unit, remove the screw D and take out the loading/feed motor assembly in the direction of the arrow.
Page 16 3.2.7 Removing the pickup (See Figs.10 to 12) • Remove the top cover, base board and chassis unit. Pu. shaft holder A (1) From the bottom side of the chassis unit, remove the screw Pickup E attaching the pu. shaft holder B and pull the pu. shaft out of the pu.
Page 17 3.2.9 Removing the trigger arm (See Fig.14) • Remove the top cover, base board, chassis unit and clamper Select arm R assembly. Chassis unit (1) From the top side of the chassis unit, remove the trigger Select lock arm arm spring from the sections (n, p). (2) From the bottom side of the chassis unit, release the claws q of the trigger arm base in the direction of the arrow to remove them from the sections r of the chassis unit to the other side.
Page 18 3.2.11 Removing the mode switch (See Fig.16) • Remove the top cover, base board, chassis unit, clamper assembly, Top plate assembly Mode switch trigger arm and top plate assembly. (1) From the top side of the top plate assembly, remove the Link gear spring link gear spring from the sections x of the link gear L and link gear R.
Page 19 3.2.12 Removing the select arm R and select lock arm (See Figs.17 and 18) • Remove the top cover, base board, chassis unit, clamper assembly, trigger arm and top plate assembly. Select arm R (1) From the top side of the top plate assembly, remove the link gear spring from the sections ad of the link gear L and Link gear spring link gear R.
Page 20 3.2.13 Removing the loading roller assembly (See Figs.19 to 21) • Remove the top cover, base board, chassis unit, clamper assembly Cam plate R and top plate assembly. (1) From the left side of the chassis unit, remove the screw J attaching the lock arm assembly.
Page 21 3.2.14 Removing the loading gear 1, loading gear 2, loading gear 3 and feed gear 1 (See Fig.22) • Remove the top cover, base board and chassis unit. (1) From the bottom side of the chassis unit, pull out the loading Loading gear 6 gear 1.
Page 22 3.2.18 Removing the cam plate R (See Fig.25) • Remove the top cover, base board, chassis unit, clamper assembly, Chassis unit top plate assembly and loading roller assembly. From the right side of the chassis unit, remove the cam plate R Trigger rack spring from the slots ax of the chassis unit.
Page 23 3.2.20 Removing the spindle motor assembly (See Figs.27 and 28) • Remove the top cover, base board, chassis unit and clamper assembly. Turn table Chassis unit (1) From the top side of the chassis unit, turn the turn table from side to side and remove the two screws M attaching the spindle motor assembly through the hole of the turn table.
Page 24 Dummy load (4) Tracking offset meter Exclusive dummy load should be used for AM,and FM. (5) Test Disc JVC :CTS-1000 For FM dummy load, there is a loss of 6dB between SSG output (6) Extension cable for check and antenna input.
Page 25 SECTION 5 TROUBLESHOOTING 16PIN CORD DIAGRAM (for KD-G541, KD-G547) Black Green Violet Gray Blue BL/WH White Yellow WH/BK Brown GN/BK VI/BK GY/BK BL/WH RD 7 7 RD YL 4 16 YL 8 BK 5 BL/WH 13 BR 3 GN 11 GN/BK 2 VI 10 VI/BK 4 WH...
Page 26 16 PIN CORD DIAGRAM (for KD-G544, KD-G545, KD-G546) Black Green Violet Gray Blue White Yellow BL/WH WH/BK GN/BK VI/BK GY/BK BL/WH GN/BK VI/BK WH/BK GY/BK 1-26 (No.MA384<Rev.001>)
Page 27 (No.MA384<Rev.001>)1-27...
Page 28 Victor Company of Japan, Limited Mobile Entertainment Business Group Mobile Entertainment Category 10-1,1chome,Ohwatari-machi,Maebashi-city,371-8543,Japan (No.MA384<Rev.001>) Printed in Japan...
Page 29 SCHEMATIC DIAGRAMS CD RECEIVER KD-G541E,KD-G541EX,KD-G541EY KD-G541EU,KD-G544UI,KD-G545U KD-G545UN,KD-G545UT,KD-G545UH KD-G546U,KD-G546UN,KD-G546UT KD-G546UH,KD-G547EE CD-ROM No.SML200712 only for only for KD-G541 KD-G547 KD-G547 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)
Page 30 Safety 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.
Page 31 DETACH SW BUSSI, BUSSO, BUSSCK JBUS-SI/SO DIMOUT CHANGER BUSINT, BUS-I/O, /BUS-I/O (VDD5V) IC801 JBUS-SCK D645,D646 Q640,Q641 CONTROL JVC BUS DIMMER DIMMER CTRL Used for KD-G541, KD-G544, KD-G545, KD-G546 ILM.10V D603 D2441 to D2443 ACC5V POWER LED STEERING REMOTE Used for KD-G541 AUX.L/R...
Page 32 BUS-I/O R724 R755 4.7k R805 BUSINT R803 R756 4.7k BUSSCK R801 /BUS-I/O R757 4.7k R804 J801 3.9K QNZ0095-001 R802 JVC BUS L702 C717 4.7u A-GND DIMOUT R774 R807 R810 3.3K BUSSI 100K R704 C722 R703 100K 4.7/25 RESET SI/SO JBUS-SI/SO...
Page 33 CD section D501 CD8V CD_8V 1A3G-T1 CD-R QTE1H64-225Z 2.2/50 AGND C586 CD-L R584 R588 R590 VDD_5V BTL DRIVER C588 R586 150P 5.6k R509 100K R515 C506 NPWDOWN 0.01 L.P.F. NRST IC501 LA6242H-X STAT MDATA MCLK DGND R585 C587 RFGND 5.6k R583 150P R589...
Page 34 LCD & Key control section SWITCHING CIRCUIT Q6003 2SA1365/F/-X 9.88V 4.7K REMOCON LCD DISPLAY 9.21V R6004 Q6002 GREEN 2SA1365/F/-X IC602 OUT GND VDD NJL29H380A 4.8V 4.8V 9.94V Q6001 R6001 CN601 QGZ1201M1-17W ACC5V REMOCON ENC1 ENC2 LCD1 LCDCE QLD0519-001 LCDDA LCDCL KEY2 KEY1 KEY0...
Page 35 Printed circuit board Main board 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) CN901 C320 C901 Q251 D251 J801 C322 C324...
Page 36 Switch board 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) forward side D603 D616 S608 S617 D617 D602 LCD1 R612 S614...
Page 37 < M E M O >...
Page 38 Victor Company of Japan, Limited Mobile Entertainment Business Group Mobile Entertainment Category 10-1,1chome,Ohwatari-machi,Maebashi-city,Gumma-ken,371-8543,Japan Printed in Japan (No.MA384SCH)
Page 39 PARTS LIST KD-G541E,KD-G541EX,KD-G541EY KD-G541EU,KD-G544UI,KD-G545U KD-G545UN,KD-G545UT,KD-G545UH KD-G546U,KD-G546UN,KD-G546UT KD-G546UH,KD-G547EE * All printed circuit boards and its assemblies are not available as service parts. - Contents - 3- 2 Exploded view of general assembly and parts list (Block No.M1) 3- 6 CD mechanism assembly and parts list (Block No.MB) 3-11 Electrical parts list (Block No.01~03)
Page 40 Exploded view of general assembly and parts list Block No. Only UT ver. Except EE ver. Model : TN2007-1026 S/M : MY008 Function board Switch board...
Page 41 Only E series Main board Function board The parts without symbol number are not service.
Page 42 General Assembly Block No. [M][1][M][M]  Symbol No. Part No. Part Name Description Local GE10227-005A TOP CHASSIS 541E,541EX,541EY,541EU,544UI,545U,545UN,5 45UT,545UH,546U,546UN,546UT,546UH GE10227-006A TOP CHASSIS 547EE GE32823-007A HEAT SINK 541E,541EX,541EY,541EU GE32823-008A HEAT SINK 544UI,545U,545UN,545UT,545UH,546U,546UN,5 46UT,546UH,547EE GE20242-002A BOTTOM COVER GE33080-001A INSULATOR GE40395-001A SIDE PANEL QYSDST2604ZA TAP SCREW M2.6 x 4mm(x3)
Page 43  Symbol No. Part No. Part Name Description Local GE40403-001A JVC BADGE GE40202-012A COMPRESSION SPRING VKZ4777-011 MINI SCREW GE40398-002A VOL KNOB ASSY 541E,541EX,541EY,541EU,544UI,545U,545UN,5 45UT,545UH,546U,546UN,546UT,546UH GE40398-004A VOL KNOB ASSY 547EE GE40127-005A KNOB SPRING GE10226-002A REAR COVER VKZ4777-010 MINI SCREW (x4) VKZ4777-011...
Page 44 CD mechanism assembly and parts list TN2007-1026 Block No. 124 33...
Page 45 CD mechanism Block No. [M][B][M][M]  Symbol No. Part No. Part Name Description Local 30350101T FRAME 30350103T DAMPER F (x2) 30350104T DAMPER R 30350107T TOP COVER 30320513T CLAMPER SUB SPG 30350505T FRONT SUS SPG (x2) 30350506T REAR SUS SPRING (x2) 30350508T FEED NUT SPP 30350509T...
Page 46  Symbol No. Part No. Part Name Description Local 9P0420047T SCREW (x2) 9P0420067T SCREW 9P0420087T SCREW 9C0420257T SCREW 9W0513060T HL WASHER...
Page 47 Grease point 1/2 grease TNG-87 TN-4456 TNS-925R GP-501MK back side back side back side two sides...
Page 48 Grease point 2/2 grease TNG-87 TN-4456 TNS-925R G-322 out side back side TR CONTROL SPR side CHF LOCK PLT 3-10...
Page 49 Electrical parts list Main board  Symbol No. Part No. Part Name Description Local Block No. [0][1] Q977 or 2SB709A/QR/-X TRANSISTOR 541E,541EX,541EY, 541EU,544UI,545U,  Symbol No. Part No. Part Name Description Local 545UN,545UT,545U H,546U,546UN,546 UT,546UH  IC1 TEF6606T/V2-X 541E,541EX,541EY, Q977 or 2SB709A/R/-X TRANSISTOR 547EE...
Page 50  Symbol No. Part No. Part Name Description Local  Symbol No. Part No. Part Name Description Local NCB31HK-104X C CAPACITOR 0.1uF 50V K 541E,541EX,541EY, C319 NCB31EK-223X C CAPACITOR 0.022uF 25V K 541EU,547EE C320 NCB31EK-223X C CAPACITOR 0.022uF 25V K NCB31HK-102X C CAPACITOR 1000pF 50V K 544UI,545U,545UN, C326...
Page 51  Symbol No. Part No. Part Name Description Local  Symbol No. Part No. Part Name Description Local C784 QEKJ1CM-107Z E CAPACITOR 100uF 16V M R170 NRS181J-221X MG RESISTOR 220Ω 1/8W J C785 QEKJ0JM-107Z E CAPACITOR 100uF 6.3V M R171 NRS181J-221X MG RESISTOR 220Ω...
Page 52  Symbol No. Part No. Part Name Description Local  Symbol No. Part No. Part Name Description Local R702 NRSA63J-103X MG RESISTOR 10kΩ 1/16W J R807 NRSA63J-104X MG RESISTOR 100kΩ 1/16W J 541E,541EX,541EY, 541EU,544UI,545U, R703 NRSA63J-104X MG RESISTOR 100kΩ 1/16W J 545UN,545UT,545U R704 NRSA63J-104X...
Page 53  Symbol No. Part No. Part Name Description Local  Symbol No. Part No. Part Name Description Local L701 QQL231K-4R7Y INDUCTOR 4.7uH K D6001 MA111-X SI DIODE L702 QQL231K-4R7Y INDUCTOR 4.7uH K D6002 or 1SS355W-X SI DIODE L901 QQR1809-001 CHOKE COIL D6002 MA111-X SI DIODE...
Page 54  Symbol No. Part No. Part Name Description Local R6001 NRSA63J-332X MG RESISTOR 3.3kΩ 1/16W J R6002 NRSA63J-472X MG RESISTOR 4.7kΩ 1/16W J R6003 NRSA63J-472X MG RESISTOR 4.7kΩ 1/16W J R6004 NRSA63J-472X MG RESISTOR 4.7kΩ 1/16W J CN601 QGZ1201M1-17W CONNECTOR (1-17) EN601 QSW1231-001...
Page 55 <MEMO> 3-17...
Page 56 Packing materials and accessories parts list Only U KIT : A10,A11,A12, A13,A14 Only U series A1,A2,A3,A4,A5,A6, UH,UN,UT,UI A1,A4,A7 E,EU,EX,EY A1,A2,A4,A5,A7,A19, Only EE Only EU A1,A4,A7,A20 A1,A2,A4,A5,A7 The parts without symbol number are not service 3-18...
Page 57 Packing and Accessories Block No. [M][3][M][M]  Symbol No. Part No. Part Name Description Local GET0495-001A INST BOOK GER FRE ITA 541E GET0495-003A INST BOOK ENG FRE 541EX,541EU GET0495-006A INST BOOK ENG GER RUS 541EY GET0497-001A INST BOOK 544UI GET0496-001A INST BOOK ENG THA 545U,545UH,546U,546UH...

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JVC KD-G541E Service Manual

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