JVC KD-G801 User manual
SERVICE MANUAL
COPYRIGHT © 2004 VICTOR COMPANY OF JAPAN, LIMITED No.MA070
2004/3
CD RECEIVER
MA07020043
KD-G801,KD-G807
TABLE OF CONTENTS
1 PRECAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
STEERING CABLE
KD-G801 EE/EX KD-G807 E
Area suffix
EE --------- Russian Federation
KD-G807
Area suffix
E ----------- Continental Europe
EX --------------- Central Europe
KD-G801
KD-G807
SOUND
VOL VOL
SOURCE
RF
U
D
ATT
KD-G801
SOUND
VOL VOL
SOURCE
RF
U
D
ATT
KD-G801
KD-G807
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1-2 (No.MA070)
SPECIFICATION
Design and specifications are subject to change without notice.
AUDIO AMPLIFIER SECTION
Maximum Power Output Front 50 W per channel
Rear 50 W per channel
Continuous Power Output
(RMS)
Front 19 W per channel into 4 Ω, 40 Hz to 20 000 Hz at no more than 0.8%
total harmonic distortion.
Rear 19 W per channel into 4 Ω, 40 Hz to 20 000 Hz at no more than 0.8%
total harmonic distortion.
Load Impedance 4 Ω(4 Ωto 8 Ωallowance)
Equalizer Control Range Low ±12 dB (60 Hz, 80 Hz, 100 Hz, 120 Hz)
Mid ±12 dB
High ±12 dB (8 kHz, 10 kHz, 12 kHz, 15 kHz)
Frequency Response 40 Hz to 20 000 Hz
Signal-to-Noise Ratio 70 dB
Line-Out Level/Impedance 2.0 V/20 kΩload (full scale)
Output Impedance 1 kΩ
TUNER SECTION
Frequency Range FM 87.5 MHz to 108.0 MHz
FM1,2 (for KD-G807) 87.5 MHz to 108.0 MHz
FM3 (for KD-G807) 65.0 MHz to 74.0 MHz
AM (MW) 522 kHz to 1 620 kHz
(LW) 144 kHz to 279 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
Capture Ratio 1.5 dB
[MW Tuner] Sensitivity 20 µV
Selectivity 35 dB
[LW Tuner] Sensitivity 50 µV
CD PLAYER 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
GENERAL
Power Requirement Operating Voltage DC 14.4 V (11 V to 16 V allowance)
Grounding System: Negative ground
Allowable Operating Temperature 0ºC to +40ºC
Dimensions (W ×H ×D) Installation Size (approx.) 182 mm ×52 mm ×159 mm
Panel Size (approx.) 188 mm ×58 mm ×12 mm
Mass (approx.) 1.5 kg (excluding accessories)
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(No.MA070)1-3
SECTION 1
PRECAUTION
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.
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1-4 (No.MA070)
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 laser products.
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 pickup unit.
• Apply solder to the short land before the flexible wire is disconnected from the connector on the pickup unit.
(If the flexible wire is disconnected without applying solder, the 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
Pickup
Short-circuit point
(Soldering)
Flexible wire
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(No.MA070)1-5
1.5 Important for laser products
1.CLASS 1 LASER PRODUCT
2.DANGER : Invisible laser radiation when open and inter
lock failed or defeated. Avoid direct exposure to beam.
3.CAUTION : There are no serviceable parts inside the
Laser Unit. Do not disassemble the Laser Unit. Replace
the complete Laser Unit if it malfunctions.
4.CAUTION : The CD,MD and DVD player uses 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.
REPRODUCTION AND POSITION OF LABELS
!
Please use enough caution not to
see the beam directly or touch it
in case of an adjustment or operation
check.
WARNING LABEL
CAUTION : Visible and Invisible
laser radiation when open and
interlock failed or defeated.
AVOID DIRECT EXPOSURE TO
BEAM. (e)
VARNING : Synlig och
osynling laserstrålning när
den öppnas och spärren är
urkopplad. Betrakta ej
strålen. (s)
VARO : Avattaessa ja suojalukitus
ohitettuna tai viallisena olet alttiina
näkyvälle ja näkymättömälle
lasersäteilylle. Vältä säteen
kohdistumista suoraan itseesi. (f)
ADVARSEL : Synlig og usynlig
laserstråling når maskinen er
åben eller interlocken fejeler.
Undgå direkte eksponering til
stråling. (d)
CLASS 1
LASER PRODUCT
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1-6 (No.MA070)
SECTION 2
SPECIFIC SERVICE INSTRUCTIONS
This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.
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(No.MA070)1-7
SECTION 3
DISASSEMBLY
3.1 Main body section
3.1.1 Removing the front panel assembly
(See Fig.1)
(1) Push the detach button in the lower right part of the front
panel assembly.
(2) Remove the front panel assembly.
Fig.1
3.1.2 Removing the heat sink
(See Fig.2)
(1) From the left side of the main body, remove the two screws
Aand three screws Battaching the heat sink.
Reference:
Remove the front panel assembly as required.
Fig.2
Front panel assembly
Detach button
Heat sink
AAB
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1-8 (No.MA070)
3.1.3 Removing the top chassis assembly
(See Figs.3 to 6)
• Prior to performing the following procedures, remove the front
panel assembly and heat sink.
(1) From the bottom side of the main body, remove the two
screws Cattaching the top chassis assembly to the bottom
chassis assembly. (See Fig.3.)
(2) From the both and rear sides of the main body, remove the
four screws Dattaching the top chassis assembly to the
bottom chassis assembly. (See Figs.4 to 6.)
(3) Lift the top chassis assembly in the direction of the arrow,
disconnect the connector CN501 on the mechanism con-
trol board from the connector CN101 on the main board.
(See Fig.5.)
(4) Take out the top chassis assembly from the bottom chassis
assembly.
Fig.3
Fig.4
Fig.5
Fig.6
Top chassis assembly
C
C
Bottom chassis assembly
Bottom chassis assembly
Top chassis assembly
D
Top chassis assembly
D
Bottom chassis assembly
Mechanism control board
Main board CN101
CN501
Top chassis assembly
Bottom chassis assembly
D
D
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(No.MA070)1-9
3.1.4 Removing the front chassis
(See Figs.7 and 8)
• Prior to performing the following procedure, remove the front
panel assembly, heat sink and top chassis assembly.
(1) From the both sides of the top chassis assembly, remove
the two screws Eattaching the front chassis.
Fig.7
Fig.8
3.1.5 Removing the mechanism control board
(See Fig.9)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink and top chassis assembly.
(1) Disconnect the card wire from the connector CN601 on the
mechanism control board.
(2) Remove the five screws Fattaching the mechanism control
board.
(3) Release the joints aand b, remove the mechanism control
board.
Fig.9
Top chassis assembly
Front chassis
E
Top chassis assembly
Front chassis
E
Mechanism control board CN601
F
F
F
ab
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3.1.6 Removing the CD mechanism assembly
(See Fig.10)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink and top chassis assembly.
Reference:
Remove the mechanism control board as required.
(1) From the inside of the top chassis assembly, remove the
three screws Gattaching the CD mechanism assembly.
(2) Take out the CD mechanism assembly from the top chas-
sis.
Fig.10
3.1.7 Removing the main board
(See Figs.11 and 12)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink and top chassis assembly.
(1) From the rear side of the bottom chassis assembly, remove
the two screws Hattaching the rear bracket to the bottom
chassis assembly. (See Fig.11.)
(2) From the top side of the bottom chassis assembly, remove
the two screws Jattaching the main board to the bottom
chassis assembly. (See Fig.12.)
(3) Release the stopper of the connector CN702 on the main
board in an upward direction, disconnect the card wire from
the connector CN702. (See Fig.12.)
(4) Disconnect the wire from the connector of the gear bracket
unit. (See Fig.12.)
(5) Disconnect the wire from the connector CN951 on the main
board. (See Fig.12.)
Reference:
After connecting the wires, fix the wires with the wire
holders.
(6) Take out the main board from the bottom chassis assem-
bly.
Fig.11
Fig.12
Top chassis G
GG
CD mechanism assembly
Rear bracket
H
Bottom chassis assembly
Connector
Wire holders CN702
Stopper
Bottom chassis assembly
J
J
CN951 Wires
Main board
Card wire
Gear bracket unit
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(No.MA070)1-11
3.1.8 Removing the rear bracket
(See Fig.13)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink, top chassis assembly and main
board.
(1) From the rear side of the main board, remove the cables
from the rear bracket in the direction of the arrow.
(2) Remove the two screw K, screw Land screw Mattaching
the rear bracket to the main board.
Reference:
After attaching the rear bracket to the main board, pass the ca-
bles through the wire holder and insert them into the slots of
the rear bracket.
Fig.13
3.1.9 Removing the front door mechanism assembly
(See Fig.14.)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink, top chassis assembly and main
board.
(1) From the top side of the bottom chassis assembly, remove
the screw Nattaching the FPC guide to the bottom chassis.
(2) Remove the five screws Pattaching the gear bracket unit
to the bottom chassis.
Reference:
When attaching the screws Nand P, apply a locking
agent them.
(3) Take out the gear bracket unit from the bottom chassis.
Fig.14
Rear bracket
L M
K
Main board
Wire holde
r
Slots
Cable (KD-G801)
Rear bracket
Cable
Bottom chassis
PP
N
FPC guide
Gear bracket unit
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1-12 (No.MA070)
3.1.10 Removing the front board
(See Figs.15 to 17)
• Prior to performing the following procedures, remove the front
panel assembly.
(1) From the back side of the front panel assembly, remove the
four screws Qattaching the rear cover assembly to the
front panel assembly. (See Fig.15.)
(2) Release the twelve joints cof the front panel assembly and
remove the rear cover assembly. (See Fig.16.)
(3) Take out the front board from the front panel assembly.
(See Fig.17.)
Note:
When removing the rear cover assembly and front board, be
careful not to lose the comp. spring. (See Fig.17.) Fig.15
Fig.16
Fig.17
QRear cover assembly Q
Q
Rear cover assembly
joints c joints c
joints c joints c
Front board
Front panel assembly
Comp. spring
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(No.MA070)1-13
3.2 CD Mechanism section
3.2.1 Removing the top cover
(See Figs.1 and 2)
(1) Remove the four screws Aon the both side of the body.
(2) Lift the front side of the top cover and move the top cover
backward to release the two joints a.
Fig.1
Fig.2
A
A
A
Joints a
Top cover
Joints a
Top cover
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1-14 (No.MA070)
3.2.2 Removing the connector board
(See Figs.3 to 5)
CAUTION:
Before disconnecting the flexible wire from the pickup, solder
the short-circuit point on the pickup. No observance of this in-
struction may cause damage of the pickup.
(1) Remove the screw Bfixing the connector board.
(2) Solder the short-circuit point on the pickup.
(3) Disconnect the flexible wire from the pickup.
(4) Move the connector board in the direction of the arrow to
release the two joints b.
(5) Unsolder the wires on the connector board if necessary.
CAUTION:
Unsolder the short-circuit point after reassembling.
Fig.3
Fig.4
Fig.5
B
Connector board
Pickup
Short-circuit point
Joints b
Wires
Pickup
Short-circuit point
(Soldering)
Flexible wire
B
Flexible wire
Connector board
Frame
w
w
w
.
x
i
a
o
y
u
1
6
3
.
c
o
m
Q
Q
3
7
6
3
1
5
1
5
0
9
9
2
8
9
4
2
9
8
T
E
L
1
3
9
4
2
2
9
6
5
1
3
9
9
2
8
9
4
2
9
8
0
5
1
5
1
3
6
7
3
Q
Q
TEL 13942296513 QQ 376315150 892498299
TEL 13942296513 QQ 376315150 892498299
http://www.xiaoyu163.com
http://www.xiaoyu163.com
(No.MA070)1-15
3.2.3 Removing the DET switch
(See Figs.6 and 7)
(1) Extend the two tabs cof the feed sw. holder and pull out
the switch.
(2) Unsolder the DET switch wire if necessary.
Fig.6
Fig.7
Connector
board
DET
switch
Pickup
DET switch Tab c
Tab c
DET switch wire
Feed sw. holder
w
w
w
.
x
i
a
o
y
u
1
6
3
.
c
o
m
Q
Q
3
7
6
3
1
5
1
5
0
9
9
2
8
9
4
2
9
8
T
E
L
1
3
9
4
2
2
9
6
5
1
3
9
9
2
8
9
4
2
9
8
0
5
1
5
1
3
6
7
3
Q
Q
TEL 13942296513 QQ 376315150 892498299
TEL 13942296513 QQ 376315150 892498299
http://www.xiaoyu163.com
http://www.xiaoyu163.com
1-16 (No.MA070)
3.2.4 Removing the chassis unit
(See Figs.8 and 9)
• Prior to performing the following procedure, remove the top
cover and connector board.
(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 dif-
ferent. Handle them with care.
• When reassembling, make sure that the three shafts
on the underside of the chassis unit are inserted to the
dampers certainly.
Fig.8
Fig.9
Suspension spring (L)
Suspension spring (L)
Suspension spring (R)
Suspension spring (R)
Chassis unit
Frame
Chassis unit
Frame
Shafts
Shaft
Dampe
r
Damper
Damper
w
w
w
.
x
i
a
o
y
u
1
6
3
.
c
o
m
Q
Q
3
7
6
3
1
5
1
5
0
9
9
2
8
9
4
2
9
8
T
E
L
1
3
9
4
2
2
9
6
5
1
3
9
9
2
8
9
4
2
9
8
0
5
1
5
1
3
6
7
3
Q
Q
TEL 13942296513 QQ 376315150 892498299
TEL 13942296513 QQ 376315150 892498299
http://www.xiaoyu163.com
http://www.xiaoyu163.com
(No.MA070)1-17
3.2.5 Removing the clamper assembly
(See Figs.10 and 11)
• 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.
Fig.10
Fig.11
Clamper arm
spring
Chassis rivet
assembly
Joint d
Joint d Clamper assembly
Clamper arm spring
Clamper assembly
Joint d
Joint d
Chassis rivet assembly
w
w
w
.
x
i
a
o
y
u
1
6
3
.
c
o
m
Q
Q
3
7
6
3
1
5
1
5
0
9
9
2
8
9
4
2
9
8
T
E
L
1
3
9
4
2
2
9
6
5
1
3
9
9
2
8
9
4
2
9
8
0
5
1
5
1
3
6
7
3
Q
Q
TEL 13942296513 QQ 376315150 892498299
TEL 13942296513 QQ 376315150 892498299
http://www.xiaoyu163.com
http://www.xiaoyu163.com
1-18 (No.MA070)
3.2.6 Removing the loading / feed motor assembly
(See Figs.12 and 13)
• Prior to performing the following procedure, remove the top
cover, connector board and chassis unit.
(1) Remove the screw Cand move the loading / feed motor as-
sembly in the direction of the arrow to remove it from the
chassis rivet assembly.
(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.12.
Fig.12
Fig.13
Loading / feed motor assembly
Loading / feed motor assembly
C
w
w
w
.
x
i
a
o
y
u
1
6
3
.
c
o
m
Q
Q
3
7
6
3
1
5
1
5
0
9
9
2
8
9
4
2
9
8
T
E
L
1
3
9
4
2
2
9
6
5
1
3
9
9
2
8
9
4
2
9
8
0
5
1
5
1
3
6
7
3
Q
Q
TEL 13942296513 QQ 376315150 892498299
TEL 13942296513 QQ 376315150 892498299
http://www.xiaoyu163.com
http://www.xiaoyu163.com
(No.MA070)1-19
3.2.7 Removing the pickup unit
(See Figs.14 to 18)
• Prior to performing the following procedure, remove the top
cover, connector board and chassis unit.
(1) Remove the screw Dand pull out the pu. shaft holder from
the pu. shaft.
(2) Remove the screw Eattaching the feed sw. holder.
(3) Move the part eof the pickup unit upward with the pu. shaft
and the feed sw. holder, then release the joint fof the feed
sw. holder in the direction of the arrow. The joint gof the
pickup unit and the feed rack is released, and the feed sw.
holder comes off.
(4) Remove the pu. shaft from the pickup unit.
(5) Remove the screw Fattaching the feed rack to the pickup
unit.
3.2.8 Reattaching the pickup unit
(See Figs.14 to 17)
(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 gto the slot of the feed rack and setting the joint f
of the feed rack to the switch of the feed sw. holder correct-
ly.
(3) As the feed sw. holder is temporarily attached to the pickup
unit, set to the gear of the joint gand to the bending part of
the chassis (joint h) at a time.
CAUTION:
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.
(4) Reattach the feed sw. holder using the screw E.
(5) Reattach the pu. shaft to the pickup unit. Reattach the pu.
shaft holder to the pu. shaft using the screw D.
Fig.14
Fig.15
Fig.16
Fig.17
Fig.18
Feed sw. holder
E
D
Joint g
Joint f
Part e
Pickup unit
Pu. shaft holder
Pu. shaft
Feed sw. holder
Part e
Pickup unit
Feed rack
Feed sw. holder
D
E
Joint f
Pu. shaft holde
r
Pu. shaft
Pickup unit
Joint h
Part i
Slot j
Joint g
FFeed rack
Pickup unit
Joint f
Joint g
Feed rack
Pickup unit
Feed sw. holder
w
w
w
.
x
i
a
o
y
u
1
6
3
.
c
o
m
Q
Q
3
7
6
3
1
5
1
5
0
9
9
2
8
9
4
2
9
8
T
E
L
1
3
9
4
2
2
9
6
5
1
3
9
9
2
8
9
4
2
9
8
0
5
1
5
1
3
6
7
3
Q
Q
TEL 13942296513 QQ 376315150 892498299
TEL 13942296513 QQ 376315150 892498299
http://www.xiaoyu163.com
http://www.xiaoyu163.com
1-20 (No.MA070)
3.2.9 Removing the trigger arm
(See Figs.19 and 20)
• Prior to performing the following procedure, remove the top
cover, connector board and clamper unit.
(1) Turn the trigger arm in the direction of the arrow to release
the joint kand pull out upward.
CAUTION:
When reassembling, insert the part m and n of the trigger
arm into the part p and q at the slot of the chassis rivet
assembly respectively and join the joint kat a time.
Fig.19
Fig.20
3.2.10 Removing the top plate assembly
(See Fig.21)
• Prior to performing the following procedure, remove the top
cover, connector board, chassis unit, and clamper assembly.
(1) Remove the screw H.
(2) Move the top plate assembly in the direction of the arrow to
release the two joints r.
(3) Unsolder the wire marked s if necessary.
Fig.21
Joint k
Trigger arm
Chassis rivet assembly
Trigger arm
Chassis
rivet
assembly
Part p
Part m
Part n
Part q
Top plate assembly
Joints
r
s
H
w
w
w
.
x
i
a
o
y
u
1
6
3
.
c
o
m
Q
Q
3
7
6
3
1
5
1
5
0
9
9
2
8
9
4
2
9
8
T
E
L
1
3
9
4
2
2
9
6
5
1
3
9
9
2
8
9
4
2
9
8
0
5
1
5
1
3
6
7
3
Q
Q
TEL 13942296513 QQ 376315150 892498299
TEL 13942296513 QQ 376315150 892498299
http://www.xiaoyu163.com
http://www.xiaoyu163.com
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