JVC KD-ADV5490J, KD-DV5400J, KD-DV4402EU, KD-DV4404UI, KD-DV4405U Service Manual

SERVICE MANUAL

DVD/CD RECEIVER

MA388<Rev.002>20085SERVICE MANUAL

KD-ADV5490J, KD-DV5400J, KD-DV4401E,

KD-DV4401EU, KD-DV4402E, KD-DV4402EU,

KD-DV4404UI, KD-DV4405U, KD-DV4405UN,

KD-DV4405UT, KD-DV4405A, KD-DV4406U,

KD-DV4406UN, KD-DV4406UT, KD-DV4406A,

KD-DV4407EE, KD-DV4408EE,KD-DV4488UF

only for

KD-ADV5490

KD-DV5400

COPYRIGHT © 2008 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)

only for
KD-DV4401
KD-DV4402

only for
KD-DV4407
KD-DV4408

TABLE OF CONTENTS

1 PRECAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

COPYRIGHT © 2008 Victor Company of Japan, Limited

No.MA388<Rev.002>

2008/5

SPECIFICATION

KD-ADV5490J/KD-DV5400J

AUDIO AMPLIFIER SECTION

Power Output 20 W RMS × 4 Channels at 4 Ω and < or = 1% THD+N
Signal-to-Noise Ratio 80 dBA (reference: 1 W into 4 Ω)
Load Impedance 4 Ω (4 Ω to 8 Ω allowance)

Tone Control Range Bass ±12 dB at 100 Hz

Treble ±12 dB at 10 kHz

Audio Output Level Digital (DIGITAL OUT: Optical) Signal wave length: 660 nm

Line-Out Level/Impedance (KD-ADV5490) 5.0 V/20 kΩ load (full scale)

Output Impedance 1 kΩ

Color system NTSC
Video Output (composite) 1 Vp-p/75 Ω

Other Terminal

TUNER SECTION

Frequency Range FM

FM Tuner Usable Sensitivity 11.3 dBf (1.0 µV/75 Ω)

AM Tuner Sensitivity 20 µV

Signal Detection System Non-contact optical pickup (semiconductor laser)

Number of Channels 2 channels (stereo)

Frequency Response DVD, fs=48 kHz/96 kHz 16 Hz to 22 000 Hz

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit
DivX/MPEG Video Video Max. Resolution 720 × 480 pixels (30 fps)

MP3 Bit Rate 32 kbps - 320 kbps

WMA Bit Rate 32 kbps - 320 kbps

WAV Quantization Bit Rate 16 bit

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 (32°F to 104°F)
Dimensions (W × H × D) Installation Size (approx) 182 mm × 52 mm × 159 mm (7-3/16” × 2-1/16” × 6-5/16”)

Mass (approx) 1.4 kg (3.1 lbs) (excluding accessories)

with channel interval set to 100 kHz or 200 kHz

with channel interval set to 50 kHz 87.5 MHz to 108.0 MHz

AM with channel interval set to 10 kHz 530 kHz to 1 710 kHz

with channel interval set to 9 kHz 531 kHz to 1 602 kHz

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 35 dB

Selectivity 35 dB

DVD/CD PLAYER SECTION

CD, fs=44.1 kHz 16 Hz to 20 000 Hz

Audio Bit Rate DivX: 32 kbps - 320 kbps

Sampling Frequency: DivX MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency: MPEG Video 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency 22.05 kHz, 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency 44.1 kHz

Panel Size (approx) 188 mm × 58 mm × 6 mm (7-7/16” × 2-5/16” × 1/4”)

Design and specifications are subject to change without notice.

Output level: -21 dBm to -15 dBm

(KD-DV5400) 2.5 V/20 kΩ load (full scale)

CD changer AUX (auxiliary) input jack Steering wheel remote input (for KD-ADV5490)

87.5 MHz to 107.9 MHz

720 × 576 pixels (25 fps)

MPEG Video: 32 kbps - 384 kbps

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

GENERAL

1-2 (No.MA388<Rev.002>)

KD-DV4401/KD-DV4402

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output
(RMS)

Load Impedance 4 Ω (4 Ω to 8 Ω allowance)

Tone Control Range Bass ±12 dB at 100 Hz

Signal to Noise Ratio 70 dB

Audio Output Level Digital (DIGITAL OUT: Optical) Signal wave length: 660 nm

Color system PAL
Video Output (composite) 1 Vp-p/75 Ω

Other Terminal AUX (auxiliary) input jack, LINE IN plugs

Frequency Range FM 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity 11.3 dBf (1.0 µV/75 Ω)

AM Tuner Sensitivity 20 µV

Signal Detection System Non-contact optical pickup (semiconductor laser)

Number of Channels 2 channels (stereo)

Frequency Response DVD, fs=48 kHz/96 kHz 16 Hz to 22 000 Hz

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit
DivX/MPEG Video Video Max. Resolution 720 × 480 pixels (30 fps)

MP3 Bit Rate 32 kbps - 320 kbps

WMA Bit Rate 32 kbps - 320 kbps

WAV Quantization Bit Rate 16 bit

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) Installation Size (approx.) 182 mm × 52 mm × 159 mm

Mass (approx.) 1.4 kg (excluding accessories)

Front/Rear 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8%

total harmonic distortion

Treble ±12 dB at 10 kHz

Output level: -21 dBm to -15 dBm

Line-Out Level/Impedance 2.5 V/20 kΩ load (full scale)
Output Impedance 1 kΩ

TUNER SECTION

AM (MW) 522 kHz to 1 620 kHz

(LW) 144 kHz to 279 kHz

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

Selectivity 35 dB

DVD/CD PLAYER SECTION

CD, fs=44.1 kHz 16 Hz to 20 000 Hz

720 × 576 pixels (25 fps)

Audio Bit Rate DivX: 32 kbps - 320 kbps

MPEG Video: 32 kbps - 320 kbps

Sampling Frequency: DivX MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

Sampling Frequency: MPEG Video 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

Sampling Frequency 22.05 kHz, 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency 44.1 kHz

GENERAL

Panel Size (approx.) 188 mm × 58 mm × 13 mm

Design and specifications are subject to change without notice.

(No.MA388<Rev.002>)1-3

KD-DV4404/KD-DV4405/KD-DV4406

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output
(RMS)

Load Impedance 4 Ω (4 Ω to 8 Ω allowance)

Tone Control Range Bass ±12 dB at 100 Hz

Signal to Noise Ratio 80 dB

Audio Output Level Digital (DIGITAL OUT: Optical) Signal wave length: 660 nm

Color system PAL/NTSC
Video Output (composite) 1 Vp-p/75 Ω

Other Terminal CD changer, AUX (auxiliary) input jack

Frequency Range FM 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity 11.3 dBf (1.0 µV/75 Ω)

AM Tuner Sensitivity 20 µV

Signal Detection System Non-contact optical pickup (semiconductor laser)

Number of Channels 2 channels (stereo)

Frequency Response DVD, fs=48 kHz/96 kHz 16 Hz to 22 000 Hz

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit
DivX/MPEG Video Video Max. Resolution 720 × 480 pixels (30 fps)

MP3 Bit Rate 32 kbps - 320 kbps

WMA Bit Rate 32 kbps - 320 kbps

WAV Quantization Bit Rate 16 bit

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) Installation Size (approx.) 182 mm × 52 mm × 159 mm

Mass (approx.) 1.4 kg (excluding accessories)

Front/Rear 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8%

total harmonic distortion

Treble ±12 dB at 10 kHz

Output level: -21 dBm to -15 dBm

Line-Out Level/Impedance 2.5 V/20 kΩ load (full scale)
Output Impedance 1 kΩ

TUNER SECTION

AM 531 kHz to 1 602 kHz

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

Selectivity 35 dB

DVD/CD PLAYER SECTION

CD, fs=44.1 kHz 16 Hz to 20 000 Hz

720 × 576 pixels (25 fps)

Audio Bit Rate DivX: 32 kbps - 320 kbps

MPEG Video: 32 kbps - 320 kbps

Sampling Frequency: DivX MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

Sampling Frequency: MPEG Video 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

Sampling Frequency 22.05 kHz, 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency 44.1 kHz

GENERAL

Panel Size (approx.) 188 mm × 58 mm × 6 mm

Design and specifications are subject to change without notice.

1-4 (No.MA388<Rev.002>)

KD-DV4407/KD-DV4408

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output
(RMS)

Load Impedance 4 Ω (4 Ω to 8 Ω allowance)

Tone Control Range Bass ±12 dB at 100 Hz

Signal to Noise Ratio 70 dB

Audio Output Level Digital (DIGITAL OUT: Optical) Signal wave length: 660 nm

Color system PAL
Video Output (composite) 1 Vp-p/75 Ω

Other Terminal AUX (auxiliary) input jack, LINE IN plugs

Frequency Range FM1/FM2 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity 11.3 dBf (1.0 µV/75 Ω)

AM Tuner Sensitivity 20 µV

Signal Detection System Non-contact optical pickup (semiconductor laser)

Number of Channels 2 channels (stereo)

Frequency Response DVD, fs=48 kHz/96 kHz 16 Hz to 22 000 Hz

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit
DivX/MPEG Video Video Max. Resolution 720 × 480 pixels (30 fps)

MP3 Bit Rate 32 kbps - 320 kbps

WMA Bit Rate 32 kbps - 320 kbps

WAV Quantization Bit Rate 16 bit

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) Installation Size (approx.) 182 mm × 52 mm × 159 mm

Mass (approx.) 1.4 kg (excluding accessories)

Front/Rear 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8%

total harmonic distortion

Treble ±12 dB at 10 kHz

Output level: -21 dBm to -15 dBm

Line-Out Level/Impedance 2.5 V/20 kΩ load (full scale)
Output Impedance 1 kΩ

TUNER SECTION

FM3 65.00 MHz to 74.00 MHz

AM (MW) 522 kHz to 1 620 kHz

(LW) 144 kHz to 279 kHz

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

Selectivity 35 dB

DVD/CD PLAYER SECTION

CD, fs=44.1 kHz 16 Hz to 20 000 Hz

720 × 576 pixels (25 fps)

Audio Bit Rate DivX: 32 kbps - 320 kbps

MPEG Video: 32 kbps - 320 kbps

Sampling Frequency: DivX MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

Sampling Frequency: MPEG Video 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

Sampling Frequency 22.05 kHz, 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency 44.1 kHz

GENERAL

Panel Size (approx.) 188 mm × 58 mm × 13 mm

Design and specifications are subject to change without notice.

(No.MA388<Rev.002>)1-5

KD-DV4488

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output
(RMS)

Load Impedance 4 Ω (4 Ω to 8 Ω allowance)

Tone Control Range Bass ±12 dB at 100 Hz

Signal to Noise Ratio 80 dB

Audio Output Level Digital (DIGITAL OUT: Optical) Signal wave length: 660 nm

Color system PAL/NTSC
Video Output (composite) 1 Vp-p/75 Ω

Other Terminal CD changer, AUX (auxiliary) input jack

Frequency Range FM 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity 11.3 dBf (1.0 µV/75 Ω)

AM Tuner Sensitivity 20 µV

Signal Detection System Non-contact optical pickup (semiconductor laser)

Number of Channels 2 channels (stereo)

Frequency Response DVD, fs=48 kHz/96 kHz 16 Hz to 22 000 Hz

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit
DivX/MPEG Video Video Max. Resolution 720 × 480 pixels (30 fps)

MP3 Bit Rate 32 kbps - 320 kbps

WMA Bit Rate 32 kbps - 320 kbps

WAV Quantization Bit Rate 16 bit

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) Installation Size (approx.) 182 mm × 52 mm × 159 mm

Mass (approx.) 1.4 kg (excluding accessories)

Front/Rear 19 W per channel into 4 Ω 40 Hz to 20 000 Hz at no more than 0.8%

total harmonic distortion

Treble ±12 dB at 10 kHz

Output level: -21 dBm to -15 dBm

Line-Out Level/Impedance 2.5 V/20 kΩ load (full scale)
Output Impedance 1 kΩ

TUNER SECTION

AM 531 kHz to 1 602 kHz

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

Selectivity 35 dB

DVD/CD PLAYER SECTION

CD, fs=44.1 kHz 16 Hz to 20 000 Hz

720 × 576 pixels (25 fps)

Audio Bit Rate DivX: 32 kbps - 320 kbps

MPEG Video: 32 kbps - 384 kbps

Sampling Frequency: DivX MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

Sampling Frequency: MPEG Video 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency MPEG-1: 32 kHz, 44.1 kHz, 48 kHz

MPEG-2: 16 kHz, 22.05 kHz, 24 kHz

Sampling Frequency 22.05 kHz, 32 kHz, 44.1 kHz, 48 kHz

Sampling Frequency 44.1 kHz

GENERAL

Panel Size (approx.) 188 mm × 58 mm × 6 mm

Design and specifications are subject to change without notice.

1-6 (No.MA388<Rev.002>)

1.1 Safety Precautions

SECTION 1

PRECAUTION

!

!

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.

(No.MA388<Rev.002>)1-7

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.

(caption)
Anti-static wrist strap

1M

Conductive material
(conductive sheet) or iron plate

(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 card wire is disconnected from the connector on the pickup unit.
(If the card 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 card wire.

Solder short part

1-8 (No.MA388<Rev.002>)

1.5 Important for laser products

1.CLASS 1 LASER PRODUCT

2.CAUTION :

(For U.S.A.) Visible and/or invisible class II laser radiation
when open. Do not stare into beam.
(Others) Visible and/or invisible class 1M laser radiation
when open. Do not view directly with optical instruments.

3.CAUTION : Visible and/or invisible laser radiation when
open and inter lock failed or defeated. Avoid direct
exposure to beam.

4.CAUTION : This laser product uses visible and/or 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.

!

Please use enough caution not to

see the beam directly or touch it

in case of an adjustment or operation

check.

REPRODUCTION AND POSITION OF LABELS and PRINT

WARNING LABEL and PRINT

(No.MA388<Rev.002>)1-9

SECTION 2

SPECIFIC SERVICE INSTRUCTIONS

This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.

SECTION 3

DISASSEMBLY

3.1 Main body (Used figure are KD-DV5400)

3.1.1 Removing the Bottom cover (See Fig.1)
(1) Disengage six hooks a engaged Bottom cover.

3.1.2 Removing the Front chassis (See Fig.2)
(1) Disengage four hooks b engaged both side of Front chassis.

3.1.3 Removing the Rear bracket (See Fig.3)
(1) Remove the three screws A, two screws B and two screws

C attaching the Rear bracket.

hook a

Fig.1

Fig.2

A

hook

b

1-10 (No.MA388<Rev.002>)

BC B

Fig.3

3.1.4 Removing the Main board (See Fig.4 to 6)

(1) Remove the two screws D, one screw E and two screws F

attaching the Heat sink. (See Fig.4)

(2) Remove the three screws G attaching the Main board.

(See Fig.5)

(3) Disconnect the card wire from Main board connected to

connector CN401

of the DVD front end board. (See Fig.6)

D

EF

Fig.4

GG

G

Fig.5

CN401 DVD mechanism

Fig.6

(No.MA388<Rev.002>)1-11

3.1.5 Removing the DVD mechanism (See Fig.7)
(1) Remove the three screws H attaching the DVD mechanism.

3.1.6 Removing the Switch board (See Fig.8)

(1) Remove the Volume knob.
(2) Remove the four screws J attaching the Rear cover.
(3) Disengage eleven hooks c engaged Rear cover.

H

H

Fig.7

hook

H

c

hook

c

JJ

Fig.8

1-12 (No.MA388<Rev.002>)

3.2 DVD mechanism

3.2.1 Removing the Traverse mechanism assembly (See Fig.1 to 6)

(1) Solder the short land section on the flexible wire of pickup.

(See Fig.1)

Caution:

* Solder the short land section on the flexible wire of pickup
before disconnecting the flexible wire form the connector

on the Front end board.

CN101

If the flexible wire is disconnected without attaching the
solder, the pickup may be destroyed by static electricity.
* When attaching the Traverse mechanism assembly, re­move the solder from the short land section after connection
the flexible wire to the connector CN101

on the Front end

board.

(2) Voltage supply to TP79 and TP81 approx DC 3.0V until

Clamper is shift to loading complete position. (See Fig.2)

(3) Disconnect the flexible wires from Traverse mechanism assembly

connected to connector CN101

and CN164 of the Front end

board. (See Fig.2)

(4) Remove the five screws A attaching the Top cover assembly.

(See Fig.3)

(5) From the bottom side, disconnect the connector wire from

Top cover assembly connected to connector CN2

of the

Front end board. (See Fig.4)

(6) From the bottom side, remove the spring from Traverse

mechanism assembly. (See Fig.5)

(7) From the top side, pull up the traverse mechanism and disengage

three dumper positions. (See Fig.6)

A

Fig.3

CN2

CN164

Fig.1

Fig.2

Solder short part

CN101

R312

R357

TP79

TP79 TP81

R317

TP67

R21

TP92

CENTER

WOOFER

DGND_7

TP81

D-

Voltage supply
position

Fig.4

Fig.5

Dumper

(same color spring)

Dumper

(Different color spring)

Fig.6

(No.MA388<Rev.002>)1-13

3.2.2 Removing the Front end board (See Fig.7)

(1) Remove the Motor wires from loading motor soldered to

TP79

and TP81 of the Front end board.

(2) Remove the two screws B attaching the Front end board.

3.2.3 Removing the Loading arm assembly (See Fig.8)

(1) Remove the Loading arm spring L from Loading arm assembly.
(2) Slide to left side and then disengage hook a then hook b.

hook b

B

TP79

Fig.7

TP81

Loading arm
assembly

B

hook

a

Loading arm spring L

Fig.8

1-14 (No.MA388<Rev.002>)

3.2.4 Removing the Gear base assembly (See Fig.9, 10)

(1) Remove the Loading arm spring L. (See Fig.9)
(2) Remove the two screws C attaching the Gear base assembly.

(See Fig.10)

Loading arm
spring L

Fig.9

C

3.2.5 Removing the Loading arm holder. (See Fig.11)

(1) Remove the two screws D attaching the Loading arm holder.
(2) Remove the Loading arm spring R.

Fig.10

D

Loading arm
holder

Loading arm
spring R

Fig.11

(No.MA388<Rev.002>)1-15

3.2.6 Removing the Loading moor assembly (See Fig.12)

(1) Remove the three screws E attaching the Loading motor

assembly.

3.2.7 Removing the Slide cam assembly (See Fig.13)

(1) Slide to backward the Slide cam assembly and the remove

the Slide cam spring.

(2) Slide to frontward the slide cam assembly, and then take

out it.

E

Fig.12

Slide cam assembly

3.2.8 Removing the Photo board (See Fig.14)

(1) Pressing the hook c and then slide to backward (slide to the

arrow side) the Disc plate.

(2) Remove the one screw F attaching the Photo board.

Photo board

Slide cam spring

Fig.13

hook

c

Fig.14

hook

F

c

1-16 (No.MA388<Rev.002>)

3.2.9 Removing the Loading motor (See Fig.15 to 18)

r

(1) Remove the A wheel gear. (See Fig.15)
(2) Remove the A worm gear, M connect gear and M wheel

gear by sequentially. (See Fig.16)

(3) Remove the two screws G attaching the Loading motor.

(Se Fig.17)

(4) When attaching the Loading motor, motor wire should arrange

to figure. (See Fig.18)

A Wheel gea

Fig.15

A worm gear

M connect gear

M wheel gear

Fig.16

G

Fig.17

Wire arrangement

Fig.18

(No.MA388<Rev.002>)1-17

3.2.10 Removing the Roller assembly (See Fig.19)

(1) Remove the Slit washer.
(2) Remove the R middle gear.
(3) Remove the R connect gear.
(4) Snap off the part a of the Roller assembly.
(5) Lift up the part b of the Roller assembly, and then release

part c (When release part c, R collar R is easy to come off,
does not lose it).

CAUTION:

When reattach the Roller assembly, Middle gear should keep
direction and Slit washer should be change new part.

Direction

R middle gear

R collar R

R connect gear

Slit washer

part c

part a

part b

3.2.11 Removing the Roller (See Fig.20)

(1) Remove the Slit washer.
(2) Pull out the Roller shaft.

CAUTION:

When reattach the Roller shaft, Slit washer should be change
new part.

Fig.19

slit

keep direction

keep direction

slit

1-18 (No.MA388<Rev.002>)

small side

Fig.20

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 : VT501 or VT502
(6) Extension cable : EXTXD001-50PF x 1
(7) Extension studs : STDV001-3P

4.2 Standard measuring conditions

Power supply voltage DC14.4V(10.5 to 16V)
Load impedance 20K.(2 Speakers connection)
Output Level Line out 2.5V (Vol. MAX)

4.5 How to connect the extension cable for adjusting

Caution:

Be sure to attach the heat sink and rear bracket onto the power amplifier IC and regulator IC respectively, before supply the power.
If voltage is applied without attaching these parts, the power amplifier IC and regulator IC will be destroyed by heat.

4.3 Standard volume position

Balance and Bass &Treble volume : lndication"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 antenna input.
The loss of 6dB need not be considered sincedirect reading of
figures are applied in this working standard.

Extension studs
STDV001-3P

Extension cable
EXTXD001-50PF

Extension studs
STDV001-3P

(No.MA388<Rev.002>)1-19

4.6 Service mode

Keep this state more than 2 seconds while
contimuing pressing the [SEL] button, [SOURCE]
button and [STANDBY/ON ATTENUATOR]
button sequentially.

The unit enters the service mode.

"INIT ALL" is
indicated on the LCD.

"VERSION" is
indicated on the LCD.

"AREA/RGN" is
indicated on the LCD.

"VIDEO" is
indicated on the LCD.

Press the [SEL] button

Press the [SEL] button

Press the [SEL] button

Press the [SEL] button

Initialize all data to the factory setting
:The system control EEPROM is
initialized entirely.

Micon version display
S-XXX-YY System control CPU
version/ROM correction version
DVD-XXX DVD version
*Exchanging it operate each indication with the
[DISC UP] button and [DISC DOWN] button.

Distination area/region display
SYS-XX System control destination
DVD-AXX DVD unit destination
DVDRGN X DVD unit region
*Exchanging it operate each indication with the
[DISC UP] button and [DISC DOWN] button.

Setting of NTSC or PAL
"NTSC" or "PAL" are indicated on the LCD.
*Exchanging it operate each indication with the
[DISC UP] button and [DISC DOWN] button.

Note:
There is the model that is not equipped with
this mode by a version.

"CLR ERR" is
indicated on the LCD.

"CD ERROR" is
indicated on the LCD.

1-20 (No.MA388<Rev.002>)

Press the [SEL] button

Press the [SEL] button

Clear loading/ejection error history
:The error history stored in the EEPROM is cleared.

Read loading and ejection error history
:The error history saved in the system control
is read and displayed.
TOT-XXXX : Total error count.
(A figure between 0 and 9999 is
displayed. 10000 or more is also
displayed as 9999.)
Enyyzzzz : Latest three error history
n: Counter
yy: Error code
zzzz: Detailed error code

0nyyzzz : First five error code
n: Counter
yy: Error code
zzzz: Detailed error code
*Exchanging it operate each indication with the
[DISC UP] button and [DISC DOWN] button.
(See section "Error code tables" for details.)

"DVD-TEMP" is
indicated on the LCD.

"SYS-TEMP" is
indicated on the LCD.

"CHK MODE" is
indicated on the LCD.

"RUNNING" is
indicated on the LCD.

"MEMCHECK" is
indicated on the LCD.

"INIT" is
indicated on the LCD.

Press the [SEL] button

Press the [SEL] button

Press the [SEL] button

Press the [SEL] button

Press the [SEL] button

Press the [SEL] button

Thermistor's temperature data readout
: Data in The temperatur sensor in the DVD unit is
read every 5 seconds and displayed in hex numbers.

Thermistor's temperature data readout
: Data in The temperatur sensor in the system control
is read every 5 seconds and displayed in hex
numbers.

DVD unit check mode
(See section "DVD check mode" for details.)

Running mode : For use in running tests.

Memory check
: The remaining data capacity of the disc is
displayed on the LCD.

Initialize user set data
: The system control EEPROM is initialized except
for The loading/ejection error history.

4.7 Error code tables

4.7.1 Mechanism error code

Error contents Details Error code Detailed error code

Disc loading error
D1 time out

Eject error
B1 time out
C1 time out

Error in loading wait Loading of a running mode

Disc was pulled out in a wait.

09

01
01
09

0013

0023
0024
0031

(No.MA388<Rev.002>)1-21

4.7.2 Disc error code

Error contents Details Error code Detailed error code

TOC read error 84TOC read movement of a CD is not completed. 0059
First track access error Even if TOC reading passes after the end with

CD running mode for 30 seconds, the first track

80 0060

access is not finished.

Last track access error Even if first track passes after the end with

CD running mode for 30 seconds, the last track

80 0061

access is not finished.

T1 access error

T12 access error Even if T12 access passes in a DVD running

T24 access error Even if T24 access passes in a DVD running

Read-in area read error Read-in area read operation of DVD is not

DVD L1 layer adjustment error Adjustment of L1 layer of DVD is not finished

DVD L0 layer adjustment error Adjustment of L0 layer of DVD is not finished

Even if T1 access passes in a DVD running
mode for 30 seconds, it is not finished.

mode for 30 seconds, it is not finished.

mode for 30 seconds, it is not finished.

completed.

normally. (including focus jump failure)

normally. (including focus jump failure)

80

80

80

80

80

80

NO DISC judgment 80Judgment eithout disc. 0090
It is NO DISC by start failure 80Start is impossible 0091
It is stopped by playback inability 80Stop in running mode playback 0093
Logic format NG

Seek access error

Logic format analysis inability or
non-correspondence logic format

It cannot arrive at an aim address even if it
passes for 15 seconds.

80

80

0069

0070

0071

0072

0074

0075

0094

0095

1-22 (No.MA388<Rev.002>)

4.8 DVD check mode

Change LCD indication with a [FF] button and a [REW] button.

Check item list

No. A/D key DVD unit operation Indication contents

1

[1]

Start at normal speed
(After start, it is measured JITTER on the
internal position)

Example of

LCD indication

NORMPLAY
CUR ****
JIT ****

Laser current value
Jitter value

2 [2] Tracking off on The outermost position of CD EF-BAL

OUTROFF

For EF phase error

3 [3] Tracking off on The innermost position of CD EF-BAL

INNTROFF

For EF phase error

4 [4] CD_LD lights and laser current is displayed CDLD ON

CUR ****
JIT ****

Laser current value
Jitter value

5 [5] DVD_LD lights and laser current is displayed DVDLD ON

6 [6] DVD x1 jitter measuring mode

(for use in mechanism measuremant)

CUR ****
JIT ****

DVDx1JIT
CUR ****
JIT ****

Laser current value
Jitter value

Laser current value
Jitter value

7 [DISP] Indication of EEPROM contents ROM DATA

ADDR ****
DATA ****

EEPROM address
EEPROM contents

8 [SRC] Initialization of EEPROM contents ROMCLEAR
9 [SEL] Indication of temperature TEMP

10 [MODE] Search & jitter measurement to an appointed

position of DVD

TEMP ****

DVD JIT
PLC ****
JIT ****

Temperature

(Position measured with
VT-501 jitter value)

11 [BAND] Setting of MONITOR terminal MONITOR

M1 ****
M2 ****

12 [DISC UP ] DVD x1 double speed start

(Afte start, it is measured JITER on the
internal position)

PLAY
CUR ****
JIT ****

Laser current value
Jitter value

13 [DISC DW ] Disc stopped & LD-OFF STOP
14 [EJECT] EJECT OPEN

Note In The case of The jitter measurement : Begin a service mode after insert a disc.
Press key [1] of No.1 before an item in which the No.2 or 3 key is pressed.
Press key [1] of No.1 or key [12] of No,12 before an item in which the No.10 key is pressed and confirm
The indication of jitter value on the LCD.
No.6 starts only a DVD1 layer disc. Even other discs start DVD1 layer.
When No.1 and No.12 are pushed after jitter indication, a focus jump is executed. (onlu DVD2 layer)
Stop a disc before OPEN, CLOSE by all means. (OPEN and CLOSE are not executed in disc turn.)
The check mode can be exited by pressing the [POWER] key or by resetting the unit.

(No.MA388<Rev.002>)1-23

SECTION 5

TROUBLESHOOTING

5.1 16 PIN CORD DIAGRAM (for KD-ADV5490, KD-DV5400,KD-DV4488)

8

7

6

5

4

3

2

1

1

16

2

8

GN

GN/BK

VI/BK

VI

NC

BL/WH

RD

BK

BK

YL

RD

GN

WH

WH/BK

GY/BK

GY

NC

YG

NC

YL

9

10

11

12

13

14

15

16

BK

RD

BL

Black

Red

Blue

WH White

VI

Violet

GN

GY

YG

YL

Green

Gray

YellowGreen

Yellow

GN/BK

7

VI

5

VI/BK

6

WH

9

WH/BK

10

GY

12

GY/BK

11

BL/WH

3

YG

14

1-24 (No.MA388<Rev.002>)

5.2 16 PIN CORD DIAGRAM (for KD-DV4401, KD-DV4402, KD-DV4407, KD-DV4408)

8

7

6

5

4

3

2

1

16 YL

GN

GN/BK

VI/BK

VI

NC

BL/WH

RD

BK

7 RD

1 BK

3 BL/WH

13 BR

8 GN

7 GN/BK

5 VI

6 VI/BK

9 WH

10 WH/BK

12 GY

11 GY/BK

14 YG

WH

WH/BK

GY/BK

GY

BR

YG

NC

YL

9

10

11

12

13

14

15

16

ACC

MEMORY

GND

REMOTE

TEL

RL+

RL-

RR+

RR-

FL+

FL-

FR+

FR-

PARKING

BK

RD

BL

WH

BR

Black

Red

Blue

White

Brown

GN

VI

GY

YL

YG

TEL MUTING

Green

Violet

Gray

Yellow

Yellow Green

RD

1

3

5

7

RD 7

YL 4

NC

NC

BL/WH

RD

8

5

2

7

8

1

2

5

6

3

4

BR

YL

NC

BK

2

4

6

8

PARKING
BRAKE

RR

FR

FL

RL

REMOTE

Rear Right

Front Right

Front Left

Rear Left

Remote

ACC

TEL

GND

MEMORY

PARKING

ACC Line

Telephone Muting

Ground

Memory Backup Battery+

Parking Brake

VI/BK

GY/BK

WH/BK

GN/BK

2

4

6

8

VI

1

GY

3

5

WH

GN

7

(No.MA388<Rev.002>)1-25