JVC KD-G631E User manual

SERVICE MANUAL
COPYRIGHT © 2007 Victor Company of Japan, Limited No.MA292
2007/1
CD RECEIVER
MA29220071SERVICE MANUAL
KD-G631E,KD-G631EX,KD-G631EU,
KD-G631EY,KD-G632E,KD-G632EX,
KD-G632EU,KD-G632EY,KD-G635U,
KD-G635UN,KD-G635UH,KD-G635UT,
KD-G634UI,KD-G638UF
COPYRIGHT © 2007 Victor Company of Japan, Limited
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)
TABLE OF CONTENTS
1 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
(for europe)

1-2 (No.MA292)
SPECIFICATION
Design and specifications are subject to change without notice.
AUDIO AMPLIFIER SECTION
Maximum Power Output Front/Rear 50 W per channel
Continuous Power Output
(RMS)
Front/Rear 19 W per channel into 4 Ω, 40 Hz to 20 000 Hz at no more than 0.8% total har-
monic distortion.
Load Impedance 4 Ω(4 Ωto 8 Ωallowance)
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
Signal-to-Noise Ratio 70 dB
Line-Out Level/Impedance 2.5 V/20 kΩload (full scale)
Output Impedance 1 kΩ
Other Terminals CD changer, Steering wheel remote input, USB input jack
TUNER SECTION
Frequency Range FM 87.5 MHz to 108.0 MHz
AM (for europe) MW: 522 kHz to 1 620 kHz
LW: 144 kHz to 279 kHz
AM (for asia) 531 kHz to 1 602 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 30 dB
MW Tuner (for europe) Sensitivity/Selectivity 20 µV/35 dB
LW Tuner (for europe) Sensitivity 50 µV
AM Tuner (for asia) Sensitivity 20 µV
Selectivity 35 dB
CD PLAYER / USB MEMORY SECTION
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
Playable USB memory Format FAT 12/16/32
Storage Less than 4 GB (1 partition type)
Playable Audio Format MP3/WMA
Max. Current Less than 500 mA
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)
(approx.)
Installation Size 182 mm ×52 mm ×150 mm
Panel Size 188 mm ×58 mm ×12 mm
Mass 1.4 kg (excluding accessories)

(No.MA292)1-3
SECTION 1
PRECAUTIONS
1.1 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.

1-4 (No.MA292)
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.
(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.
1M
(caption)
Anti-static wrist strap
Conductive material
(conductive sheet) or iron plate
Wires Push switch
Pickup
Base board
Pickup
Connector
Flexible wire
Frame CD mechanism
assembly

(No.MA292)1-5
1.5 Important for laser products
REPRODUCTION AND POSITION OF LABELS and PRINT
WARNING LABEL and PRINT

(No.MA292)1-7
SECTION 3
DISASSEMBLY
3.1 Main body
3.1.1 Removing the Bottom cover
(See Fig.1)
(1) Disengage the five hooks aengaged Bottom cover.
Fig.1
3.1.2 Removing the Front chassis
(See Fig.2)
(1) Remove the two screws A(both side) attaching the Front
chassis.
(2) Disengage the two hooks b(both side) engaged the Front
chassis.
Fig.2
3.1.3 Removing the Rear bracket
(See Fig.3)
(1) Remove the one screw Battaching the remote cable. (only
for Europe models)
(2) Remove the one screw Cattaching the antenna jack.
(3) Remove the one screw Dattaching the LINE OUT jack.
(4) Remove the one screw Eattaching the CD-CH jack.
(5) Remove the one screw Fattaching the IC bracket.
(6) Remove the two screws Gattaching the 16pin connector
jack.
(7) Remove the three screws Hattaching the Rear bracket.
Fig.3
Hook aHook aHook a
Hook b
A
BEHHH
CD F GG

1-8 (No.MA292)
3.1.4 Removing the Heat sink
(See Fig.4)
(1) Remove the two screws Jand three screws Kattaching the
Heat sink.
Fig.4
3.1.5 Removing the Main board assembly
(See Fig.5)
(1) Remove the three screws Lattaching the Main board as-
sembly.
(2) Disconnect the connector CN501 connected the Main
board assembly and CD board assembly.
Fig.5
3.1.6 Removing the CD mechanism assembly
(See Fig.6)
(1) Remove the three screws Mattaching the CD mechanism
assembly.
Fig.6
JK
JKK
LL
L
CN501
MMM

(No.MA292)1-9
3.2 Front panel assembly
3.2.1 Removing the Rear cover
(See Fig.7)
(1) Remove the Volume knob from Front panel assembly.
(2) Remove the five screws Nattaching the Rear cover.
(3) Disengage the twelve hooks cengaged Rear cover.
Fig.7
3.2.2 Removing the Switch board assembly
(See Fig.8)
(1) Disengage the illumination lens from Front cover assem-
bly.
(2) Lift up the Switch board assembly and take out it.
CAUTION:
Detach knob and spring are easy to come off, do not lost them.
Fig.8
3.3 CD mechanism assembly
For CD mechanism, please refer mechanism manual TN2007-1010 (No.MY005, No.MY005B).
NN
N
N
N
Hook c Hook c Hook c Hook c
Hook c
Hook c
Hook c
illumination lens

1-10 (No.MA292)
SECTION 4
ADJUSTMENT
4.1 Test instruments required for adjustment
(1) Digital oscilloscope (100MHz)
(2) Electric voltmeter
(3) Digital tester
(4) Tracking offset meter
(5) Test Disc JVC: CTS-1000
(6) Extension cable for check
EXTSH002-22P ×1
4.2 Standard measuring conditions
Power supply voltage : DC14.4V(10.5 - 16V)
Load impedance : 20KΩ(2 Speakers connection)
Output Level : Line out 2.0V (Vol. MAX)
4.3 Standard volume position
Balance and Bass & Treble volume : Indication "0"
Loudness : OFF
4.4 Dummy load
Exclusive dummy load should be used for AM, and FM. For FM
dummy load, there is a loss of 6dB between SSG output and an-
tenna input. The loss of 6dB need not be considered since direct
reading of figures are applied in this working standard.
4.5 How to connect the extension cable for adjustment
CAUTION :
Be sure to attach the heat sink and rear bracket onto the
power amplifier and regulator respectively, before supply the
power.
If voltage is applied without attaching those parts, the power
amplifier IC and regulator IC will be destroyed by heat.
Heat sink
Rear bracket
EXTSH002-22P
Extension cable

(No.MA292)1-11
SECTION 5
TROUBLESHOOTING
5.1 16 PIN CORD DIAGRAM (for Europe)
8
7
6
5
16
15
14
13
4
3
2
1
12
11
10
9
BK
RD
NC
BL/WH
WH
GN
VI
GY
YL
OR/WH
NC
BR
WH/BK
GN/BK
VI/BK
GY/BK
7 RD
16 YL
15 OR/WH
8 BK
6 BL/WH
13 BR
3 GN
11 GN/BK
2 VI
10 VI/BK
12 WH/BK
1 GY
9 GY/BK
RD
RD 7
YL 4
6
8
5
2
7
8
1
2
5
6
3
4
4 WH
1
3
5
7
2
4
6
8
NC BR
NC YL
BL/WH
OR/WH
RD BK
1
3
5
7
2
4
6
8
VI
GY
WH
GN
VI/BK
GY/BK
WH/BK
GN/BK
BK
RD
BL
WH
BR
Black
Red
Blue
White
Brown
GN Green
VI Violet
GY Gray
YL Yellow
OR Orange
RR Rear Right
FR Front Right
FL Front Left
RL Rear Left
REMOTE
Remote
ILL Illuminations Control
ANT
ACC
TEL
Auto Antenna
ACC Line
Telephone Muting
GND Ground
MEMORY
Memory Backup Battery+
RR+
RR-
RL+
RL-
FL+
FL-
FR+
FR-
ACC
MEMORY
ILL
GND
REMOTE
TEL