JVC KW-XC888 User manual

SERVICE MANUAL
COPYRIGHT © 2004 Victor Company of Japan, Limited No.MA081
2004/7
CD/CASSETTE RECEIVER
MA08120047
KW-XC888
TABLE OF CONTENTS
1 PRECAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Area suffix
UN --------------------------Asean

1-2 (No.MA081)
SPECIFICATION
Design and specifications are subject to change without notice.
AUDIO AMPLIFIER SECTION
Maximum Power Output (DC 16V) Front 50 W per channel
Rear 50 W per channel
Continuous Power Output (10% THD) Front 25 W per channel into 4 Ω.
Rear 25 W per channel into 4 Ω.
Load Impedance 4 Ω(4 to 8 Ωallowance)
TUNER SECTION
Frequency Range FM 87.5 MHz to 108.0 MHz
AM 531 kHz to 1 602 kHz
[FM Tuner] Usable Sensitivity 6 dBµV
Stereo Separation 28 dB
[AM Tuner] Sensitivity 30 dBµV
CD PLAYER SECTION
Type Compact disc player
Signal Detection System Non-contact optical pickup (semiconductor laser)
Number of channels 2 channels (stereo)
Frequency Response 30 Hz to 20 000 Hz
Signal-to-Noise Ratio 75 dB
Wow and Flutter Less than measurable limit
Channel Separation (1 kHz) 65 dB
CASSETTE DECK SECTION
Frequency Response 30 Hz to 16 000 Hz
Wow and Flutter 0.2 % (WRMS)
GENERAL
Power Requirement Operating Voltage DC 14.4 V (11 V to 16 V allowance)
Grounding System Negative ground
Dimensions (W ×H ×D) Installation Size 178 mm ×100 mm ×175 mm
Front Panel Size 183 mm ×103 mm ×15 mm
Mass 2.2 kg (excluding accessories)

(No.MA081)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.

1-4 (No.MA081)
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
Pickup
Short-circuit point
(Soldering)
Flexible wire
Pickup
Short-circuit point

(No.MA081)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

1-6 (No.MA081)
SECTION 2
SPECIFIC SERVICE INSTRUCTIONS
This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.

(No.MA081)1-7
SECTION 3
DISASSEMBLY
3.1 Main body section
3.1.1 Removing the front panel assembly
(See Figs.1 and 2)
(1) From the both side of the main body, remove the two
screws Aattaching the front panel assembly. (See Figs.1
and 2.)
(2) Release the four joints aand remove the front panel as-
sembly in the direction of the arrow. (See Figs.1 and 2.)
Fig.1
Fig.2
Front panel assembly
a
A
Front panel assembly
a
A

1-8 (No.MA081)
3.1.2 Removing the heat sink
(See Figs.3 and 4)
(1) From the back side of the main body, remove the six
screws Battaching the heat sink. (See Fig.3.)
(2) Remove the heat sink from the main body.
Note:
• Before attaching the heat sink, attach the cooling rubbers on
the power amplifier IC. (See Fig.4)
• When attaching the heat sink, set the projections bon the
rear bracket in the holes of the heat sink. (See Fig.3.)
3.1.3 Removing the rear bracket
(See Fig.4)
• Prior to performing the following procedures, remove the heat
sink.
(1) From the back side of the main body, remove the eight
screws Cattaching the rear bracket.
(2) Remove the rear bracket from the main body.
Fig.3
Fig.4
B
B
B
bb
Rear bracket heat sink
C
C
C
C
Rear bracket
Cooling rubbers
Power amplifier IC

(No.MA081)1-9
3.1.4 Removing the bottom chassis assembly
(See Fig.5)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink and rear bracket.
(1) From the bottom side of the main body, remove the four
screws Dattaching the bottom chassis assembly.
(2) Take out the bottom chassis assembly from the main body.
Reference:
When attaching the bottom chassis assembly, set the projec-
tions cof the main body in the holes of the bottom chassis as-
sembly.
Fig.5
3.1.5 Removing the mechanism control board
(See Fig.6)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink, rear bracket and bottom chassis
assembly.
(1) From the inside of the bottom chassis assembly, discon-
nect the card wire from the connector CN403 on the mech-
anism control board.
(2) Disconnect the wire from the connector CN402 on the
mechanism control board.
(3) Remove the three screws Eattaching the mechanism con-
trol board.
(4) Take out the mechanism control board from the bottom
chassis assembly.
Reference:
• When attaching the mechanism control board, set the pro-
jections dof the bottom chassis assembly in the holes of the
mechanism control board.
• After attaching the mechanism control board, fix the wire
with the wire clamp as before.
Fig.6
Bottom chassis assembly
c
DD
E
E
d
d
d
CN403CN402
Wire clamp
Mechanism control board
Bottom chassis assembly

1-10 (No.MA081)
3.1.6 Removing the cassette mechanism assembly
(See Fig.7)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink, rear bracket and bottom chassis
assembly.
(1) From the inside of the bottom chassis assembly, discon-
nect the card wire from the connector CN403 on the mech-
anism control board.
(2) Disconnect the wire from the connector CN402 on the
mechanism control board.
(3) Remove the four screws Fattaching the cassette mecha-
nism assembly.
Reference:
After attaching the mechanism control board, fix the wire with
the wire clamp as before.
Fig.7
3.1.7 Removing the middle chassis assembly
(See Fig.8)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink, rear bracket and bottom chassis
assembly.
(1) From the bottom side of the main body, remove the four
screws Gattaching the middle chassis assembly.
(2) Disconnect the connector CN501 of the main board on the
middle chassis assembly from the CD mechanism assem-
bly in an upward direction.
Fig.8
CN403
CN402
Wire clamp
Mechanism control board
Bottom chassis assembly
F
F
FCassette mechanism assembly
Main board
Middle chassis assembly
GG
CN501

(No.MA081)1-11
3.1.8 Removing the main board
(See Fig.9)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink, rear bracket, bottom chassis as-
sembly and middle chassis assembly.
(1) From the top side of the middle chassis assembly, remove
the four screws Hattaching the main board on the middle
chassis.
(2) Remove the main board from the middle chassis.
Reference:
When attaching the main board, set the projections eof the
middle chassis in the holes of the main board.
Fig.9
3.1.9 Removing the CD mechanism assembly
(See Fig.10)
• Prior to performing the following procedures, remove the front
panel assembly, heat sink, rear bracket, bottom chassis as-
sembly and middle chassis assembly.
(1) From the inside of the top chassis assembly, remove the
three screws Jattaching the CD mechanism assembly.
(2) Take out the CD mechanism assembly from the top chas-
sis.
Reference:
When attaching the CD mechanism assembly, set the projec-
tions fof the top chassis in the holes of the CD mechanism as-
sembly.
Fig.10
3.1.10 Removing the LCD switch board
(See Fig.11)
• Prior to performing the following procedures, remove the front
panel assembly.
(1) From the inside of front panel assembly, remove the ten
screws Kattaching the LCD switch board.
(2) Release the sections gwhile extending the lower section of
the front panel assembly in the direction of the arrow and
take out the LCD switch board.
Fig.11
Main board
Middle chassis
ee
H
H
H
JJ
CD mechanism assembly
Top chassis
f
f
J
K
KK
Front panel assembly LCD switch board
gg

1-12 (No.MA081)
3.2 CD Mechanism Assembly
3.2.1 Removing the top cover
(See Figs.1 and 2)
(1) Remove the two 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

(No.MA081)1-13
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 connector board.
(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 wire 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

1-14 (No.MA081)
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

(No.MA081)1-15
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

1-16 (No.MA081)
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

(No.MA081)1-17
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
assembly 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

1-18 (No.MA081)
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 f of 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 g to the slot of the feed rack and setting the part 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 g and 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
holder
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

(No.MA081)1-19
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 pand qat the slot of the chassis rivet
assembly respectively and join the joint k at 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

1-20 (No.MA081)
3.2.11 Removing the mode sw. / select lock arm
(See Figs.22 and 23)
• Prior to performing the following procedure, remove the top
plate assembly.
(1) Bring up the mode sw. to release from the link plate (joint t)
and turn in the direction of the arrow to release the joint u.
(2) Unsolder the wire of the mode sw. marked s if necessary.
(3) Turn the select lock arm in the direction of the arrow to re-
lease the two joints v.
(4) The select lock arm spring comes off the select lock arm at
the same time.
Fig.22
Fig.23
Mode sw.
Select lock arm
Joint t
Link plate
Joint u s
Top plate
Top plate
Select lock arm
Select lock
arm spring
Select lock arm
Link plate
Joints v
Hook w