Harman Kardon AVR-300 Service manual

harman/kardon

AVR300

A/V DOLBY DIGITAL RECEIVER

SERVICE MANUAL

SPECIFICATIONS…………………..…….…..2
ESD WARNING…………………..….……… .4

LEAKAGE TESTING………………...….…....5

CONTROLS AND FUNCTIONS….…….…. .6
SERVICE PROCEDURE……………..….…..9
ALIGNMENT PROCEDURE…………….… .9
IDLE CURRENT/DC OFFSET..…………….10
ALIGNMENT/TEST POINTS………..….…. 11
CIRCUIT DESCRIPTION……………….…. 13
BLOCK DIAGRAM……………………… …16
BULLETIN HK2000-05…………..…...…. …17

harman/kardon, Inc.

250 Crossways Park Dr.

Woodbury, New York 11797 Rev0 – 6/2002

CONTENTS

BULLETIN HK2000-02 Rev1…..………..….18
DISASSEMBLY PROCEDURE…..……...…21
UNIT EXPLODED VIEW………………..…..22
MECHANICAL PARTS LIST…………..……23
PCB DRAWINGS……………………………25
ELECTRICAL PARTS LIST……………..….30
INTEGRATED CIRCUIT DRAWINGS…..…52
SCHEMATICS………………….…..……..…80
SEMICONDUCTOR PINOUTS………….…89
WIRING DIAGRAM…………………….…...90
PACKAGE………………………………..…..91

300

Some semiconductor (solid state) devices can be damaged easily by static electricity. Such components commonly are called

Electrostatically Sensitive (ES) Devices. Examples of typical ES devices are integrated circuits and some field effect transistors and

semiconductor "chip" components.

The following techniques should be used to help reduce the incidence of component damage caused by static electricity.

1. Immediately before handling any semiconductor component or semiconductor-equipped assembly, drain off any electrostatic charge on

your body by touching a known earth ground. Alternatively, obtain and wear a commercially available discharging wrist strap device,

which should be removed for potential shock reasons prior to applying power to the unit under test.

2. After removing an electrical assembly equipped with ES devices, place the assembly on a conductive surface such as aluminum foil, to

prevent electrostatic charge build-up or exposure of the assembly.

3. Use only a grounded-tip soldering iron to solder or unsolder ES devices.

4. Use only an anti-static solder removal device. Some solder removal devices not classified as "anti-static" can generate electrical charges

sufficient to damage ES devices.

5. Do not use freon-propelled chemicals. These can generate electrical change sufficient to damage ES devices.

6. Do not remove a replacement ES device from its protective package until immediately before you are ready to install it. (Most replacement

ES devices are packaged with leads electrically shorted together by conductive foam, aluminum foil or comparable conductive material.)

7. Immediately before removing the protective material from the leads of a replacement ES device, touch the protective material to the

chassis or circuit assembly into which the device will be installed.

CAUTION :

8. Minimize bodily motions when handling unpackaged replacement ES devices. (Otherwise harmless motion such as the brushing together

or your clothes fabric or the lifting of your foot from a carpeted floor can generate static electricity sufficient to damage an ES devices.

Be sure no power is applied to the chassis or circuit, and observe all other safety precautions.

Each precaution in this manual should be followed during servicing.

Components identified with the IEC symbol in the parts list are special significance to safety. When replacing a component identified with

, use only the replacement parts designated, or parts with the same ratings or resistance, wattage, or voltage that are designated in the

parts list in this manual. Leakage-current or resistance measurements must be made to determine that exposed parts are acceptably

insulated from the supply circuit before retuming the product to the customer.

-4-

Before returning the unit to the user, perform the following safety checks :

1. lnspect all lead dress to make certain that

leads are not pinched or that hardware is not

lodged between the chassis and other metal

parts in the unit.

2. Be sure that any protective devices such as

nonmetallic control knobs, insulating fish-

papers, cabinet backs, adjustment and

300

compartment covers or shields, isolation

resistor-capacity networks, mechanical

insulators, etc. Which were removed for the

servicing are properly re-installed.

3. Be sure that no shock hazard exists ; check for leakage

current using Simpson Model 229 Leakage Tester, standard

equipment item No. 21641, RCA Model WT540A or use

alternate method as follows : Plug the power cord directly

Into a 120 volt AC receptacle (do not use an Isolation

Transformer for this test). Using two clip leads, connect a

1500 ohms, 10watt Resistor paralleled by a 0.15uF capacitor, in series with all exposed metal cabinet parts and a known earth ground, such

as a water pipe or conduit. Use a VTVM or VOM with 1000 ohms per volt, or higher sensitivity to measure the AC voltage drop across the

resistor. (See diagram) Move the resistor connection to each exposed metal part having a return path to the chassis (antenna, metal, be

performed with the 0.35 volt RMS or more is excessive and indicates a potential shock hazard which must be corrected before returning the

unit to the owner.

-5-

AVR300

300

SERVICE PROCEDURE

1. All Clear

This service program can clear all memorized operations and functions.
When the POWER ON, press the "AM/FM" button while pressing the "PRO LOGIC"button.
After this, Preset memory will be set to these frequencies.

FM

AM

VERSION

120

230RDS

VERSION

120

230RDS

P1

87.5

87.50

P9

520

522

P2

88.0

88.00

P10

600

594

P3

90.0

90.00

P11

610

999

2. VFD segment illumination & text

This set do not have VFD segment check function because lack of u-com memory size
So For your checking VFD states according to each function
Please refer to owners manual process.

TEST EQUIPMENT REQUIRED

1) AM/FM Signal generator

2) Digital Multimeter

3) Distortion lever meter

P4

95.0

95.00

P12

1000

1395

P5

98.0

98.00

P13

1400

1611

P6

99.0

99.00

P14

1500

P7

106.0

106.00

P15

1710

P8

108.0

108.00

4. FM STEREO Separation Adjustment

Input Signal Source

step

1

2

Connection

Signal generator

output to FM

antenna

terminal.(750hm)

Signal

Frequency

98MHz

4. AM OSC Adujstment

Input Signal Source

step

1

Connection

Signal Generator

output to transmission

loop antenna

(standard required loop)

Signal

Frequency

522kHz

(230,230RDS)

520kHz(120)

Source Signal Output Level and

Modulation

same specification as

distortion adjustment.

Input only L channel

same specification as

distortion adjustment.

Input only R channel

Source Signal Output Level and

Modulation

5mV/m(74dBu)

MOD.30%

FM STEREO

FM STEREO

400Hz

Reception

Frequency

98MHz

(P5)

98MHz

(P5)

Reception

Frequency

522kHz

(230,230RDS)

520kHz

(120)

(P9)

Adjustment

Point

VR803

VR803

Adjustment

Point

T802

Adjustment

Value

Output level

at TAPE-OUT

channel R

Output level

at TAPE-OUT

channel R

Adjustment

Value

1.1V 1.2V

Minimum

Minimum

ALIGNMENT PROCEDURES

1. FM MONO. Distortion adjustment

Input Signal Source

step

1

2

Connection

Signal generator

output to FM

antenna

terminal.(750hm)

Signal

Frequency

98MHz

Source Signal Output Level and

Modulation

1000uV/m (60dBu)

MONO 1kHz/

Dev. 75kHz

2. FM MUTING LEVEL ADJUSTMENT

Turn variable resistor VR801 and stop at position "TUNED" is not shown (not indicated), then again turn the variable resistor VR801 to the
opposite revolution and stop at a position "TUNED" is shown.

Input Signal Source

step

1

2

Connection

Signal generator

output to FM

antenna

terminal.(750hm)

Signal

Frequency

98MHz

Source Signal Output Level and

Modulation

10uV/m (20dBu)

MONO 1kHz/

Dev. 75kHz

Reception

Frequency

98MHz

(P5)

Reception

Frequency

98MHz

(P5)

AUTO

SCAN

Adjustment

Point

T804

T805

Adjustment

Point

VR801

Only confirm

Adjustment

Value

0mV 0.5mV

(R831)

Distortion

level

Minimum

TAPE-OUT

Adjustment

indicate on VFD

indicate on VFD

at

Value

"TUNED"

"TUNED"

5. AM-Tracking Adjustment (MW)

Input Signal Source

step

1

2

Connection

Signal Generator

output to transmission

loop antenna

(standard required loop)

Frequency

(230,230RDS)

600kHz(120)

(230,230RDS)
1400kHz(120)

6. AM IF Adjustment

Input Signal Source

step

1

Connection

Signal Generator

output to transmission

loop antenna

(standard required loop)

Frequency

(230,230RDS)
1000kHz(120)

Signal

594kHz

1395kHz

Signal

999kHz

Source Signal Output Level and

Modulation

5mV/m(74dBu)

400Hz

MOD.30%

Source Signal Output Level and

Modulation

5mV/m(74dBu)

400Hz

MOD.30%

Reception

Frequency

594kHz

(230,230RDS)

600kHz(120)

Reception

Frequency

999kHz

(230,230RDS)

1000kHz

(120)

Adjustment

Point

T801

CT801

Adjustment

Point

T803

Adjustment

Value

Output level(L or R)

Minimum

TAPE-OUT

Output level(L or R)

Minimum

TAPE-OUT

Adjustment

Output level(L or R)

Maximum

TAPE-OUT

Output level(L or R)

Maximum

TAPE-OUT

at

at

Value

at

at

-9-

300

7. AM auto stop Adjustment

9. Main Amp DC OFFSET VOLTAGE Adjustment

Input Signal Source

step

1

2

Connection

Signal Generator

output to transmission

loop antenna

(standard required loop)

Signal

Frequency

999kHz

(230,230RDS)

1000kHz

(120)

8. Main Amp ldling current Adjustment

(1) SET CONDITION

1) SEMI VOLUME POSITION at MAIN/SURROUND AMP Board; CENTER

MAIN : VR401, VR402, VR501

SURROUND : VR601, VR602

2) NO signal / NO LOAD

3) AC LINE VOLTAGE : 120V/60Hz, 230V/50Hz

Source Signal Output Level and

Modulation

1000uV/m(60dBu)

400Hz

MOD.30%

Reception

Frequency

999kHz
(230,230RDS)
1000kHz(120)

AUTO SCAN

Adjustment

Point

VR802

Only

Confirm

Adjustment

Value

"TUNED"

indicate on

VFD

"TUNED"

indicate on

VFD

(1) SET CONDITION

1) SEMI VOLUME POSITION at MAIN/SURROUND AMP Board; CENTER

MAIN : VR403, VR404, VR502

SURROUND : VR603, VR604

2) NO signal / NO LOAD

3) AC LINE VOLTAGE : 120V/60Hz, 230V/50Hz

(2) After turning on the unit, keep it over than 5MIN. (Keep the Power/Drive TR as normal temperature)

(3) Adjust the voltage value of primary & secondary of wafer to be 10mV by rotating the semi-volume

of each channel to the right

CHANNEL ADJUSTMENT MEASUREMENT OTHERS

FRONT-L ch

FRONT-R ch

CENTER ch

SURROUND-L ch

SURROUND-R ch

VR403

VR404

VR502

VR603

Vr604

JK401

JK402

JK501

JK601

JK601

VOLAGE

0mV

0mV

0mV

0mV

0mV

(2) After turning on the unit, keep it over than 5MIN. (Keep the Power/Drive TR as normal temperature)

(3) Adjust the voltage value of primary & secondary of wafer to be 10mV by rotating the semi-volume

of each channel to the right

CHANNEL ADJUSTMENT MEASUREMENT OTHERS

FRONT-L ch

FRONT-R ch

CENTER ch

SURROUND-L ch

SURROUND-R ch

(4) CAUTION

1) In case that POWER TR or DREVE TR is needed to be replaced for repairing, the corresponding channel

should be adjusted again

* FRONT AMP : Q433~Q440

* CENTER AMP : Q517~Q520

* SURROUND AMP : Q633~Q640

VR401

VR402

VR501

VR601

VR602

WA401

WA402

WA501

WA601

WA602

VOLAGE

10 3mV

10 3mV

10 3mV

10 3mV

10 3mV

R401:22.7mA

R472:22.7mA

R501:22.7mA

R601:22.7mA

R602:22.7mA

(4) CAUTION

1) In case that POWER TR or DREVE TR is needed to be replaced for repairing, the corresponding channel

should be adjusted again

* FRONT AMP : Q401~Q440, Q411~Q414

* CENTER AMP : Q501, Q502, Q506, Q507

* SURROUND AMP : Q601~Q604, Q611~Q614

10. Cautions for main Amp adjustment

(1) At MAIN/SURROUND BOARD, use the below condensors after discharging for sufficent time

for preventing possible damage from electrical spark.

MAIN BOARD C481, C482 (10000/63V, 8200uF/63V)

SURROUND BOARD C691, C692 (6800/63V, 6800uF/50V)

(2) The checker for MAIN/SURROUND BOARD should have the discharging circuit.

Discharge over 30sec. through (407ohm 10w) resistor after turning off

-10-

12

harman/kardon Service Bulletin

17

Service bulletin # H/K2000-05 May 2000 Warranty labor rate: MAJOR repair

To: All harman/kardon Service Centers

Models: AVR300, AVR500

Subject: Volume Level Changes

On early versions of the AVR300 or AVR500 the volume level may change by itself, or when the volume knob
is tapped. This may happen on an occasional random basis and depends on where the volume control knob is
positioned after a volume adjustment. During a running production change, new volume encoders were
installed.

In the event you receive an AVR300 or AVR500 with the complaint “The volume on my receiver
changes by itself”, perform the following procedure:

REPLACE VR901 VOLUME ENCODER

1) Remove the top cover, (14) Black Phillips screws.

2) Remove the (11) Black Phillips screws holding the plastic front panel to the chassis.

3) Remove the single Phillips screw on both right & left side of the chassis with a dual black ground wire.

4) Remove the volume, bass, treble and balance knobs by pulling them straight off.

5) Remove the single nut holding the volume encoder to the front panel.

6) Pull the loaded front panel off the chassis; cut any plastic cable ties necessary to fully disengage it

7) Lift and set the receiver on its right side for the remainder of the procedure.

8) Remove molex connector CN983 at the power switch; see Figure 1.

9) Pull the front panel as far away as the remaining connecting wires will allow.

10) Unsolder the connections at the rear of the front PCB to the volume encoder.

11) Using a “stubby” Phillips screwdriver, remove the (19) Black Phillips screws holding the front PCB to the
front panel; two plated screws at the rear of the headphone jack also must be removed.

12) Pull the front PCB away from the front panel.

13) Remove and replace the volume encoder with h/k part# J32612050102; resolder the new encoder in place.

14) Replace the front PCB and reassemble the receiver in reverse order, following the instructions above.
Replace all cable ties that were cut, and reattach any connectors that were unplugged. Make sure the two
ground wires on both sides of the receiver are reattached.

15) Power up receiver, and test volume control to assure it no longer changes settings by itself, or when the
volume knob is tapped.

harman/kardon Incorporated 250 Crossways Park Drive, Woodbury New York 11797 [phone]

harman/kardon Service Bulletin

18

Service bulletin # H/K2000-02 Rev1 January 2001 Warranty labor rate: MAJOR repair

To: All harman/kardon Service Centers

Models: AVR300, AVR500

Subject: Random Noise, Erratic Output in DTS Mode

In the event you receive an AVR300 or AVR500 receiver with the complaint “there is distortion, random
noise or gaps in the program material when in the DTS mode”, perform the following procedure:

REMOVAL AND MODIFICATION OF THE DSP BOARD

1) Remove the top cover, (14) Black Phillips screws.

2) Locate the DSP PC Board; Figure 1. Remove the two metal braces at the top of the unit. If necessary, cut
the cable ties attached to the braces to move any wires away from the area.

3) Pull the white 22 conductor ribbon cable at the rear of the DSP PC Board straight out of its receptacle.

4) Unplug the white 5 conductor molex cable at the top of the DSP PC Board.

5) Remove the (33) plated Phillips screws on the left side of the rear backplate; see Figure 2. Do not remove
any additional screws on the right side. If using a power tool, use care and minimum effort to avoid damaging
the various plastic receptacles.

6) Remove all three black plastic plugs that cover the optical inputs at the rear of the DSP PC Board.

7) Pull on the left side of the rear backplate, away from the receiver chassis; you should be able to pull it away
enough to allow the DSP PC Board to be pulled straight up and out of the receiver.

8) Proceed with the modifications on page 2.

Model Serial Number

120V

AVR300

AVR500

AVR300

AVR500

TH0001-01000

To

TH0001-13886

TH0002-01000

To

TH0002-10460

TH0001-13887

Or higher

TH0002-10461

Or higher

Serial Number

230V RDS

TH0005-01000

To

TH0005-03317

TH0006-01000

To

TH0006-02795

TH0005-03318

Or higher

TH0006-02796

Or higher

STATUS ACTION

Random Noise, Erratic

Output or Gaps in Program

Material when in DTS Mode

Modified by factory NONE REQUIRED

Modifications to DSP Board:

Add ground wire;

Change R756 & R755

from 600W resistor or Capacitor

to 33W resistor

harman/kardon Incorporated 250 Crossways Park Drive, Woodbury New York 11797 [phone]

Models: AVR300, AVR500 Subject: Random Noise, Erratic Output in DTS Mode

19

9) Ground Reinforcement:

Using an insulated 16AWG wire, Connect Negative sides of the following capacitors on the bottom side of the
PCB as shown below. Negative side of each cap will have a white mark on the component side of the PCB.

A. Negative polarity of C746 Elec Cap (1uF/50V) in the proximity of ROM IC709
B. Negative polarity of C749 Elec Cap (1uF/50V) in the proximity of IC708 DSP IC
C. Negative polarity of C744 Elec Cap (1uF/50V) in the proximity of IC710 74VHC574

C B A

10) Replace:

R756 & R755. Original parts may be 600W resistors, or Capacitors. Change both to 33W 1/10W
SMD resistors (h/k part#

292-33.2). See location below.

11) Replace DSP PC Board back into its (3) receptacle plugs atop the MAIN PCB.

12) Replace all screws, braces, and any cable ties that were cut during disassembly. Before tightening the
screws, make sure all PCB’s and their RCA jacks are firmly seated in their respective holes in the rear
backplate. If using a power tool, use care and minimum effort to avoid damaging the various plastic
receptacles.

13) Plug both the 22 conductor ribbon cable and the 5 conductor molex cable back into their receptacles.

14) Replace the top cover and optical plugs.

15) Test unit by powering up the receiver and playing a source with DTS encoded material; confirm the complaint
of Random Noise or Erratic Output is no longer occurring.

harman/kardon Incorporated 250 Crossways Park Drive, Woodbury New York 11797 [phone]

Models: AVR300, AVR500 Subject: Volume Level Changes

20

Model Serial Number

120V

AVR300

AVR500

AVR300

AVR500

TH0001-01000

To

TH0001-08402

TH0002-01000

To

TH0002-05565

TH0001-08403

Or higher

TH0002-05566

Or higher

Serial Number

230V RDS STATUS ACTION

TH0005-01000

To

TH0005-01001

TH0006-01000

To

TH0006-01001

TH0005-01002

Or higher

TH0006-01002

Or higher

Volume level changes by

itself or when volume

knob is tapped

Modified by factory NONE REQUIRED

Change VR901
Rotary encoder

harman/kardon Incorporated 250 Crossways Park Drive, Woodbury New York 11797 [phone]

DISASSEMBLY PROCEDUREDISASSEMBLY PROCEDURE

1. Removingthe top cover, and
Removescrews

2. Removingthe front panel, and
Removescrews

4. Removingthe main PCBblock, and
Removescrews

5. Removingthe power PCBblock, and
Remove

3. Removingthe rear panel, and
Removescrews

MAIN AMP PCB BLOCKMAIN AMP PCB BLOCK

1. Removeall of the screwson Rearpanel.

2. Removethe Rearpanel.

3. RemovePCBBrk t and Guide

4. Removeall of the screwsthat connect with main Assy.

5. Removethe Main PCBblock.

POWER PCB BLOCKPOWER PCB BLOCK

1. RemovePCBBrk t and Guide

2. Remove4 screwsfor Power PCBmounting

3. Removethe POWERPCBblock.

SUB PCB BLOCKSUB PCB BLOCK

1. Remove4 screwson Rearpanel.

2. Removethe Rearpanel.

3. RemovePCBBrk t and Guide

4. Removethe SUBPCBblock.

Brk t from Main Assy.

Brk t from Main Assy.

Brk t from Main Assy.

6. Removingthe sub PCBblock, and
Removescrews

FRONT PCB BLOCKFRONT PCB BLOCK

1. RemoveMain

2. Removevolume and rotary knob from the front

3. Removeall of the screwson back sideof Front function PCB.

4. Removethe Front function PCB.

Assy.

Assy.

-21

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