Jvc Kw-xc777 - radio / cd User manual

SERVICE MANUAL

CD/CASSETTE RECEIVER

No.49687

Feb. 2002

KW-XC777

Contents

Safety precaution

Preventing static electricity

Disassembly method

Adjustment method

Flow of functional operation

untill TOC read

Maintenance of laser pickup

Replacement of laser pickup

Description of major ICs

1- 2

1- 3

1- 4

1-23

1-27

1-29

1-30~47

Area Suffix

U Other Areas

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KW-XC777

1-2

!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.

Safety precaution

!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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KW-XC777

1-3

Front bracket

CD mechanism

control board

Damper bracket

CD mechanism ass’y

FD screw

Feed motor ass’y

FD gear Pickup unit

Preventing static electricity

1.Grounding to prevent damage by 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.

2.About the earth processing for the destruction prevention 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.

2-1 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.

2-2 Ground yourself

Use an anti-static wrist strap to release any static electricity built up in your body.

3. Handling the optical pickup

1. 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.)

2. 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.

4.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

Soldering

Attention when traverse unit is decomposed

1.Solder is put up before the card wire is removed from connector on

the CD substrate as shown in Figure.

(When the wire is removed without putting up solder, the CD pick-up

assembly might destroy.)

2.Please remove solder after connecting the card wire with

when you install picking up in the substrate.

*Please refer to "Disassembly method" in the text for pick-up and how to

detach the substrate.

(caption)

Anti-static wrist strap

Conductive material

(conductive sheet) or iron plate

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KW-XC777

1-4

Remove the four screws Aon both sides of the

body.

Release four joints aon both sides of the body using

a screwdriver and remove the front panel assembly

toward the front. The connector which connects the

front panel assembly with the rear section comes off.

1.

2.

Disassembly method

Removing the front panel assembly

(See Fig.1 to 3)

When reassembling, make sure that

connector CN501 on the front panel

assembly is securely connected to

CN701 on the main board (See Fig.3).

CAUTION:

A

CN701

CN501

Joint a

Front panel assembly

Fig.1

Fig.2

Joint a

Front panel assembly

Fig.3

Front panel assembly

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KW-XC777

1-5

Prior to performing the following procedure, remove

the front panel assembly.

Remove the twelve screws B retaining the system

control board.

Remove the five screws Cretaining the switch

board.

Unsolder WR501 and WR502 of the wires

connecting the system control board with the switch

board.

1.

2.

3.

Removing the system control board /

switch board (See Fig.4 to 5)

B

Switch board

System control board

CC

B

WR502

WR501

WR502

Fig.4

Fig.5

System control board

B

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KW-XC777

1-6

Prior to performing the following procedure, remove

the front panel assembly.

Remove the ten screws D, the screw Eand F

attaching the rear panel on the back of the body.

Remove the three screws Gand the two screws H

attaching the heat sink on the left side.

Remove the three screws Iattaching the CD player

section and the cassette player section on the both

sides of the body.

Disconnect the card wire from connector CN702 on

the main board in the CD player section on the back

of the body.

Remove the CD player section upward.

1.

2.

3.

4.

5.

Removing the CD player section /

cassette player section (See Fig.6 to 10)

When reassembling, joint the CD player

section and the cassette player section

at four joints b.

CAUTION:

D

E

D

G

I

CN702 CD player section

Cassette player section

Joint b

F

H

Heat sink

Rear panel

Fig.6

Fig.7

Fig.8

Fig.10Fig.9

Joint b

CD player section

Joints b

Cassette player section

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KW-XC777

1-7

Remove the three screws Jattaching the main

board. The connector CN601 on the main board is

disconnected from the CD mechanism control board.

1.

Removing the main board (See Fig.11)

Prior to performing the following procedure, remove

the main board.

Remove the three screws Kattaching the CD

mechanism assembly.

1.

Removing the CD mechanism assembly

(See Fig.12)

Prior to performing the following procedure, remove

the front panel assembly, the CD player section and

the cassette player section.

When reassembling, securely connect

connector CN601 on the main board to

the connector on the CD mechanism

control board.

CAUTION:

CN601

J

CD mechanism assembly

K

KK

Fig.11

Fig.12

Main board

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KW-XC777

1-8

Prior to performing the following procedure, remove

the main board.

Disconnect the card wire from connector CN972 on

the main board.

Remove the four screws Mfrom the bottom cover of

the cassette player section.

1.

2.

Removing the cassette mechanism

assembly (See Fig.13 and 14)

Disconnect the card wire from connector CN972 on

the main board.

Remove the two screws Lattaching the main board.

1.

2.

Removing the main board (See Fig.13)

Prior to performing the following procedure,

remove the cassette mechanism assembly.

Remove the screw Nand move the connector

board in the direction of the arrow to release the

two joints c.

Disconnect the wire from connector CJ402 and

the card wire from CN403 on the connector

board respectively.

1.

2.

Removing the connector board

(See Fig.15)

Prior to performing the following procedures, remove

the front panel assembly, the CD player section and

the cassette player section. LL

CN972

Cassette mechanism assembly

Bottom cover

MM

Fig.13

Fig.14

Fig.15

Main board

Joints c

Connector board

CN403

CJ402

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KW-XC777

1-9

Unsolder the part aand bon the CD mechanism

control board.

Remove the stator fixing the CD mechanism control

board and the damper bracket (To remove the stator

smoothly, pick up the center part).

Remove the screw Aattaching the CD mechanism

control board.

Remove the CD mechanism control board in the

direction of the arrow while releasing it from the two

damper bracket slots dand the front bracket slot e.

Disconnect the flexible wire from connector on the

pickup unit.

1.

2.

3.

4.

5.

Removing the CD mechanism control

board (See Fig.1 and 2)

Turn the FD gear in the direction of the

arrow to move the entire pickup unit to

the appropriate position where the

flexible wire of the CD mechanism unit

can be disconnected easily.

(Refer to Fig.2)

ATTENTION:

Prior to performing the following procedure, remove

the CD mechanism control board.

Remove the two springs fattaching the CD

mechanism assembly and the front bracket.

Remove the two screws Band the front bracket

while pulling the flame outward.

Remove the belt and the screw Cfrom the loading

motor.

1.

2.

3.

Removing the loading motor

(See Fig.3 to 5)

Fig.2

Fig.3

Fig.4

Shift the lock

Flexible wire

Pickup unit

FD gear

CD mechanism control board

Loading motor Front bracket

Front bracket Pull outward

Pull outward

Flame

f

B

f

B

Fig.5

C

Loading motor

Belt

Fig.1

Front bracket

CD mechanism

control board

Damper bracket

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DD

D

CD mechanism assembly

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KW-XC777

1-10

Prior to performing the following procedure, remove

the CD mechanism control board and the front

bracket (loading motor).

Remove the three screws Dand the damper

bracket.

Raise the both sides fix arms and move the fix plates

in the direction of the arrow to place the four shafts g

as shown in Fig.8 and 9.

Remove the CD mechanism assembly and the two

springs hattaching the flame.

Remove the two screws Eand both sides rear

damper brackets from the dampers. Detach the CD

mechanism assembly from the left side to the right

side.

1.

2.

3.

4.

Removing the CD mechanism assembly

(See Fig.1, 6 to 9)

The CD mechanism assembly can be

removed if only the rear damper

bracket on the left side is removed.

ATTENTION:

Fig.6

Fig.7

Fig.8

Fig.9

Rear damper bracket

Fix arm (R)

Damper

DD

Damper bracket

CD mechanism

assembly

Flame h

h

D

Fig.5

Front bracket

CD mechanism

control board

Damper bracket

h

c

d

b

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DD

D

CD mechanism

assembly

Ae

Fix plate (L)

g

Rear damper bracket

Fix arm (L)

Damper

E

Fix plate(R)

E

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KW-XC777

1-11

Prior to performing the following procedure, remove

the CD mechanism control board, the front bracket

(loading motor) and the CD mechanism assembly.

Remove the two screws Fand the feed motor

assembly.

1.

Removing the feed motor assembly

(See Fig.10)

Prior to performing the following procedure, remove

the CD mechanism control board, the front bracket

(loading motor), the CD mechanism assembly and

the feed motor assembly.

Detach the FD gear part of the pickup unit upward.

Then remove the pickup unit while pulling out the

part iof the FD screw.

1.

Remove the screw Gattaching the nut push spring

plate and the pickup mount nut from the pickup unit.

Pull out the FD screw.

2.

Removing the pickup unit

(See Fig.10 and 11)

When reattaching the pickup unit,

reattach the part jof the pickup unit,

then the part iof the FD screw.

ATTENTION:

Prior to performing the following procedure, remove

the CD mechanism control board, the front bracket

(loading motor), the CD mechanism assembly and

the feed motor assembly.

Turn up the CD mechanism assembly and remove

the two springs kon both sides of the clamper arms.

Open the clamper arm upward.

Turn the turn table, and remove the two screws H

and the spindle motor.

1.

2.

Removing the spindle motor

(See Fig.12 and 13)

Fig.10

Fig.11

Fig.12

Fig.13

Spindle motor

kk

Pickup unit

Part i

FD screw

Feed motor assembly

FD gear Pickup unit

Part j

F

Nut push spring plate

Pickup mount nut

Pickup unit

FD screw

G

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KW-XC777

1-12

Turn the mode gear to set to RVS play or

subsequent mode.

Remove the cassette guide from the main chassis

while releasing each two joint tabs ain the direction

of the arrow.

1.

2.

Removing the cassette guide (See Fig.2)

Prior to performing the following

procedures, turn the mode gear on the

bottom of the body until the respective part

comes to the EJECT position (Refer to

Fig.1).

REFERENCE:

Remove the E-washer attaching the load arm.

Move the load arm in the direction of the arrow and

release the joint bon the cassette catch.

1.

2.

Removing the load arm (See Fig.3)

Fig.1

Fig.2

Mode gear

Cassette guide

Tab a

Fig.3

Load arm

E-washer

Joint b

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KW-XC777

1-13

Check the mode is set to EJECT. Push down the

front part of the cassette holder and move in the

direction of the arrow to release the joint c.

Move the rear part of the cassette hanger assembly

in the direction of the arrow to release it from the two

joint bosses d.

Release the holder stabilizer spring from the hooks e

and f, then pull out from the cassette hanger

assembly.

Bring up the rear side of the cassette hanger

assembly to release the joint g and h.

Pull out the cassette catch from the cassette hanger

assembly.

1.

2.

3.

4.

5.

Removing the cassette hanger assembly /

cassette holder (See Fig.4 to 7)

Fig.4

Fig.5

Fig.7

Fig.6

Cassette holder assembly

Side bracket

Joints c

Cassette holder assembly

Cassette hanger assembly

Cassette hanger

assembly

Boss d

Cassette hanger assembly

Cassette stabilizer spring

Hook f

Hook h

Hook e

Hook g

Cassette holder

assembly Cassette catch

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KW-XC777

1-14

Remove the screw Aattaching the side bracket

assembly.

Detach the front side of the side bracket assembly

upward and pull out forward to release the joint iand

jin the rear.

1.

2.

Removing the side bracket assembly

(See Fig.8 to 10)

When reassembling, make sure that the

boss kof the main chassis is set in the

notch of the load rack under the side

bracket assembly. Do not reattach the

load rack on the boss k.

CAUTION:

After reattaching the side bracket

assembly, confirm operation.

CAUTION:

Fig.9

Fig.10

Fig.8

A

Side bracket assembly

Joint i

Joint j

Side bracket assembly

Boss k

Load rack

Boss k

Load rack

Joint i

Joint j

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KW-XC777

1-15

Remove the polywasher and pull out the pinch arm

(F) assembly.

Remove the compulsion spring.

1.

2.

Removing the pinch arm (F) assembly

(See Fig.11 and 12)

Remove the polywasher and pull out the pinch arm

(R) assembly.

1.

Removing the pinch arm (R) assembly

(See Fig.11 and 13)

Move the slide chassis assembly in the direction of

the arrow to release the two joints land remove from

the main chassis.

Remove the rack link.

1.

2.

Removing the slide chassis assembly

(See Fig.14 and 15)

When reassembling, first reattach the rack

link, and next fit the boss mand hook nof

the slide chassis assembly to the hole of

the main chassis, and engage the two joints

l.

CAUTION:

It is not necessary to remove the head

and the tape guide.

REFERENCE:

Fig.11

Fig.15

Fig.12

Fig.13

Fig.14

Polywasher

Polywasher Pinch arm

(F) assembly

Pinch arm

(R) assembly

Polywasher

Pinch arm (F) assembly

Compulsion spring

Pinch arm

(R) assembly Polywasher

Slide chassis assembly

Joint l

Boss m

Hook n

Rack link

Head

Tape guide

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KW-XC777

1-16

Remove the band attaching the wire to the head.

Remove the two screws B, the head and the head

support spring.

Remove the pinch arm spring from the tape guide.

Remove the tape guide and the pinch spring arm.

1.

2.

3.

4.

Removing the head / tape guide

(See Fig.16 and 17)

Remove the belt at the bottom.

Remove the two polywashers on the upper side.

Pull out each flywheel assembly downward.

1.

2.

3.

Removing the flywheel assembly (F) & (R)

(See Fig.18 and 19)

When reattaching the pinch arm spring, set

both end of it to the pinch spring arm (

remarked o).

CAUTION:

When reattaching the head, set the wires

into the groove of the tape guide (Fig.16).

CAUTION:

It is not necessary to remove the slide

chassis assembly.

REFERENCE:

It is not necessary to remove the slide

chassis assembly.

REFERENCE:

Fig.17

Fig.19

Fig.16

Fig.18

B

Slide chassis assembly

Head Tape guide

B

Pinch arm spring

Head

Head support spring

Tape guide

Pinch spring arm

Slid chassis assembly

Flywheel assembly (F)

Flywheel assembly (R)

Belt Polywasher

Polywasher

Flywheel assembly (F)

Flywheel assembly (R)

o

w

.

x

i

a

o

y

u

1

6

3

.

c

o

m

Q

3

7

6

3

1

5

1

5

0

9

2

8

9

4

2

9

8

T

E

L

1

3

9

4

2

9

6

5

1

3

9

2

8

9

4

2

9

8

0

5

1

5

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Q

TEL 13942296513 QQ 376315150 892498299

http://www.xiaoyu163.com

KW-XC777

1-17

Push and turn counterclockwise the spring holder (F)

to release the three joints pon the bottom of the

flywheel.

The spring holder (F), the TU spring and the friction

gear play come off.

Remove the polywasher and felt.

1.

2.

3.

Disassembling the flywheel assembly (F)

(See Fig.20 and 21)

Push and turn clockwise the spring holder (R) to

release the three joints qon the bottom of the

flywheel.

The spring holder (R), the FF spring and the friction

gear FF come off.

Remove the polywasher and the felt.

1.

2.

3.

Disassembling the flywheel assembly (R)

(See Fig.20 and 22)

Remove the two screws Cattaching the reel board.

Move the reel board in the direction of the arrow to

release the joint r.

Unsolder the wires if necessary.

1.

2.

3.

Removing the reel board

(See Fig.23 and 24)

When reattaching, confirm operation of

the MODE switch and the ST-BY switch.

The mode position between EJECT and

ST-BY is optimum for reattaching.

Connect the card wire extending from

the reel board to the FFC pad before

reattaching the reel board.

CAUTION:

Fig.24

Fig.20

Fig.21 Fig.22

Fig.23

Flywheel assembly (F) Flywheel assembly (R)

Joints p

Joint p

Joints q

Joint q

Polywasher

Spring holder (F)

TU spring

Polywasher

Spring holder (R)

FF spring

Friction gear play

Friction gear FF

Flywheel assembly (F) Flywheel assembly (R)

FFC pad

Joint r

Reel board

C

CT-1 switch

ST-BY switch

Soldering

MODE switch

Felt Felt

w

.

x

i

a

o

y

u

1

6

3

.

c

o

m

Q

3

7

6

3

1

5

1

5

0

9

2

8

9

4

2

9

8

T

E

L

1

3

9

4

2

9

6

5

1

3

9

2

8

9

4

2

9

8

0

5

1

5

1

3

6

7

3

Q

TEL 13942296513 QQ 376315150 892498299

http://www.xiaoyu163.com

KW-XC777

1-18

Move the gear base arm in the direction of the arrow.

Insert a slotted screwdriver to the gear base spring

under the gear base arm, and release the gear base

arm upward from the boss on the gear base

assembly.

Remove the gear base arm from the main chassis

while releasing the two joints s.

Move the gear base link assemby in the direction of

the arrow to release the two joints t.

1.

2.

3.

4.

Removing the gear base arm / gear base

link assembly (See Fig.25 to 27)

Push each joint hook uof the FFC pad and remove

toward the bottom.

1.

Removing the FFC pad

(See Fig.27 and 29)

When reattaching the gear base arm,

make sure that the boss on the gear

base assembly is inside the gear base

spring.

REFERENCE:

Fig.25

Fig.26

Fig.27

FFC pad

Gear base link assembly Gear base arm

Gear base

link assembly

Gear base arm

FFC pad

Joint t

Joints s

Hook u

Gear base arm

Screwdriver

Gear base spring

w

.

x

i

a

o

y

u

1

6

3

.

c

o

m

Q

3

7

6

3

1

5

1

5

0

9

2

8

9

4

2

9

8

T

E

L

1

3

9

4

2

9

6

5

1

3

9

2

8

9

4

2

9

8

0

5

1

5

1

3

6

7

3

Q

TEL 13942296513 QQ 376315150 892498299

http://www.xiaoyu163.com

KW-XC777

1-19

Remove the polywasher on the bottom and pull out

the mode gear.

1.

Removing the mode gear

(See Fig.28 and 31)

Move the mode rack assembly in the direction of the

arrow to release the two joints b’ and the joint c’.

1.

Removing the mode rack assembly

(See Fig.29 and 30)

Remove the polywasher attaching the direction link.

Bring up the direction link to release the three joints

x, yand zat a time.

Move the direction plate in the direction of the arrow

to release the two joints a’.

1.

2.

3.

Removing the direction link / direction

plate (See Fig.29 to 31)

When reattaching, set the two b’ on the

bottom of the mode rack assembly into the

slots of the main chassis and move in the

direction of the arrow (See Fig.30).

REFERENCE:

Pull out the mode switch actuator at the bottom.1.

Removing the mode switch actuator

(See Fig.28, 29 and 31)

When reattaching the mode switch

actuator to the main chassis, make sure to

set on the shaft and insert vinto the slot w.

REFERENCE:

When reattaching the direction plate,

engage the two joints a’ and move in the

direction of the arrow (Refer to Fig.30).

REFERENCE:

When reattaching the direction link,

move the direction plate in the direction

of the arrow and engage the three joint

x, yand zat a time (Refer to Fig.31).

REFERENCE:

Fig.28

Fig.30

Fig.31

Fig.29

Polywasher

Mode switch actuator Mode gear

Direction plate Direction link

Mode rack assembly

Slot w

Direction plate

Joints a'

Joint z

Direction link Polywasher

Joint y Joint x

Direction plate Mode rack assembly

Joint c'

Joint b'

Polywasher

Mode gear

Mode switch actuator

Direction link

Direction plate

Mode rack assembly

v

Joints a'

w

.

x

i

a

o

y

u

1

6

3

.

c

o

m

Q

3

7

6

3

1

5

1

5

0

9

2

8

9

4

2

9

8

T

E

L

1

3

9

4

2

9

6

5

1

3

9

2

8

9

4

2

9

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0

5

1

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1

3

6

7

3

Q

TEL 13942296513 QQ 376315150 892498299

http://www.xiaoyu163.com

KW-XC777

1-20

Push in the pin d’of the gear base assembly on the

upper side of the body and move the reflector gear

toward the bottom, then pull out.

Remove the polywasher on the bottom and pull out

the take up gear.

Move the gear base assembly in the direction of the

arrow to release it from the two slots e’of the main

chassis.

1.

2.

3.

Removing the gear base assembly / take

up gear / reflector gear (See Fig.32 to 34)

Draw out the reel driver from the shaft on the main

chassis and remove the reel driver spring and the

reel spindle respectively.

1.

Removing the reel driver / reel spindle

(See Fig.34)

The reel driver is damaged when

removed. Please replace with a new

one.

CAUTION:

The parts are damaged when removed.

Please replace with new ones.

REFERENCE:

Fig.32

Fig.33

Fig.34

Gear base assembly

Pin d'

Slot e'

Polywasher

Reflector gear

Take up gear

Reel driver spring

Reel driver

Reel spindle

Gear base assembly

Slots e’

Main chassis

Reflector gear Polywasher

Take up gear

w

.

x

i

a

o

y

u

1

6

3

.

c

o

m

Q

3

7

6

3

1

5

1

5

0

9

2

8

9

4

2

9

8

T

E

L

1

3

9

4

2

9

6

5

1

3

9

2

8

9

4

2

9

8

0

5

1

5

1

3

6

7

3

Q

TEL 13942296513 QQ 376315150 892498299

http://www.xiaoyu163.com

JVC KW-XC777 - Radio / CD User manual

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