JVC KDDV-4200, KDDV-4202, KDDV-4201, KDDV-4204, KDDV-4205 Service manual

SERVICE MANUAL

DVD/CD RECEIVER

MA24820062

KD-DV4200J,KD-DV4201E,KD-DV4201EU,

KD-DV4202E,KD-DV4202EU,KD-DV4203UI,

KD-DV4204UI,KD-DV4205U,KD-DV4205UN,

KD-DV4205UT,KD-DV4205A,KD-DV4206U,

KD-DV4206UN,KD-DV4206UT,KD-DV4206A,

KD-DV4207EE

Lead free solder used in the board (material : Sn-Ag-Cu, melting point : 219 Centigrade)

TABLE OF CONTENTS

1 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

COPYRIGHT © 2006 Victor Company of Japan, Limited

No.MA248

2006/2

SPECIFICATION

KD-DV4200

AUDIO AMPLIFIER SECTION

Power Output 17 W RMS × 4 Channels at 4 Ω and 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 ±10 dB at 100Hz

Treble ±10 dB at 10kHz

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

Output level : -21 dBm to -15 dBm

Line-Out Level/Impedance 2.0 V/20 k

Output Impedance 1 k

Color System NTSC

Video Output (composite) 1 Vp-p/75 Ω

Other Terminals CD changer

TUNER SECTION

Frequency Range FM 87.5 MHz to 107.9 MHz (with channel interval set to 100 kHz or 200 kHz)

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

FM Tuner Usable Sensitivity 11.3 dBf (1.0

50 dB Quieting Sensitivity 16.3 dBf (1.8

Alternate Channel Selectivity (400 kHz) 65 dB

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 35 dB

AM Tuner Sensitivity 20

Selectivity 35 dB

DVD/CD PLAYER SECTION

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

Number of Channels 2 channels (stereo)

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

DVD, fs=96 kHz 16 Hz to 44 000 Hz

VCD, CD, MP3, WMA 16 Hz to 20 000 Hz

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit

MP3 (MPEG Audio Layer 3) Bit Rate 32 kbps - 320 kbps

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

WMA (Windows Media® Audio) Bit Rate 32 kbps -192 kbps

Sampling frequency 48 kHz, 44.1 kHz, 32 kHz

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

Mass (approx.) 1.7 kg (3.7 lbs) (excluding accessories)

× H × D) Installation Size (approx.) 182 mm × 52 mm × 158 mm

Panel Size (approx.) 188 mm

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

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

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

GENERAL

(7-3/16"

(7-7/16"

Ω load (full scale)

Ω

µV/75 Ω)
µV/75 Ω)

µV

× 2-1/16" × 6-1/4")

× 58 mm × 11 mm

× 2-5/16" × 7/16")

1-2 (No.MA248)

KD-DV4201/KD-DV4202

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 45 W per channel

Continuous Power Output
(RMS)

Load Impedance 4

Tone Control Range Bass/Treble ±10 dB at 100 Hz/±10 dB at 10 kHz

Frequency Response 40 Hz to 20 000 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

Other Terminals CD changer, Steering wheel remote input

Frequency Range FM 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity 11.3 dBf (1.0

MW Tuner Sensitivity/Selectivity 20

LW Tuner Sensitivity 50

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

Number of Channels 2 channels (stereo)

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

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit

MP3 Bit Rate 32 kbps - 320 kbps

WMA Bit Rate 32 kbps - 192 kbps

Power Requirement Operating Voltage DC 14.4 V (11 V to 16 V allowance)

Grounding System Negative ground

Allowable Operating Temperature 0

Dimensions (W

Mass (approx.) 1.6 kg (excluding accessories)

× H × D) Installation Size (approx.) 182 mm × 52 mm × 158 mm

Front/Rear 17 W per channel into 4

monic distortion

Ω (4 Ω to 8 Ω allowance)

Output level : -21 dBm to -15 dBm

Line-Out Level/Impedance 2.0 V/20 k

Output Impedance 1 k

Ω load (full scale)

Ω

Ω

TUNER SECTION

AM (MW) 522 kHz to 1 620 kHz

(LW) 144 kHz to 279 kHz

µV/75 Ω)

50 dB Quieting Sensitivity 16.3 dBf (1.8

Alternate Channel Selectivity (400 kHz) 65 dB

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

µV/75 Ω)

µV/35 dB
µV

DVD/CD PLAYER SECTION

DVD, fs=96 kHz 16 Hz to 44 000 Hz

VCD/CD/MP3/WMA 16 Hz to 20 000 Hz

Sampling Frequency 48 kHz, 44.1 kHz, 32 kHz

Sampling Frequency MPEG-1 : 48 kHz, 44.1 kHz, 33 kHz

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

GENERAL

°C to +40°C

Panel Size (approx.) 188 mm

× 58 mm × 11 mm

Ω, 40 Hz to 20 000 Hz at no more than 0.8% total har-

(No.MA248)1-3

KD-DV4203/KD-DV4204/KD-DV4205/KD-DV4206

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output
(RMS)

Load Impedance 4

Tone Control Range Bass/Treble ±10 dB at 100 Hz/±10 dB at 10 kHz

Frequency Response 40 Hz to 20 000 Hz

Signal-to-Noise Ratio 70 dB

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

Color System PAL/NTSC

Video Output (composite) 1 Vp-p/75

Other Terminal CD changer

Frequency Range FM 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity 11.3 dBf (1.0

AM Tuner Sensitivity/Selectivity 20

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

Number of Channels 2 channels (stereo)

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

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit

MP3 Bit Rate 32 kbps - 320 kbps

WMA Bit Rate 32 kbps - 192 kbps

Power Requirement Operating Voltage DC 14.4 V (11 V to 16 V allowance)

Grounding System Negative ground

Allowable Operating Temperature 0

Dimensions (W

Mass (approx.) 1.6 kg (excluding accessories)

× H × D) Installation Size (approx.) 182 mm × 52 mm × 158 mm

Front/Rear 19 W per channel into 4

total harmonic distortion

Ω (4 Ω to 8 Ω allowance)

Output level : -21 dBm to -15 dBm

Line-Out Level/Impedance 2.0 V/20 k

Output Impedance 1 k

Ω load (full scale)

Ω

Ω

TUNER SECTION

AM 531 kHz to 1 602 kHz

µV/75 Ω)

50 dB Quieting Sensitivity 16.3 dBf (1.8

Alternate Channel Selectivity (400 kHz) 65 dB

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

µV/75 Ω)

µV/35 dB

DVD/CD PLAYER SECTION

DVD, fs=96 kHz 16 Hz to 44 000 Hz

VCD/CD/MP3/WMA 16 Hz to 20 000 Hz

Sampling Frequency 48 kHz, 44.1 kHz, 32 kHz

Sampling Frequency MPEG-1 : 48 kHz, 44.1 kHz, 33 kHz

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

GENERAL

°C to +40°C

Panel Size (approx.) 188 mm

× 58 mm × 11 mm

Ω, 40 Hz to 20 000 Hz at no more than 0.8%

1-4 (No.MA248)

KD-DV4207

AUDIO AMPLIFIER SECTION

Maximum Power Output Front/Rear 50 W per channel

Continuous Power Output
(RMS)

Load Impedance 4

Tone Control Range Bass/Treble ±10 dB at 100 Hz/±10 dB at 10 kHz

Frequency Response 40 Hz to 20 000 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

Other Terminals CD changer

Frequency Range FM1 /FM2 87.5 MHz to 108.0 MHz

FM Tuner Usable Sensitivity 11.3 dBf (1.0

MW Tuner Sensitivity/Selectivity 20

LW Tuner Sensitivity 50

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

Number of Channels 2 channels (stereo)

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

Dynamic Range 96 dB

Signal-to-Noise Ratio 98 dB

Wow and Flutter Less than measurable limit

MP3 Bit Rate 32 kbps - 320 kbps

WMA Bit Rate 32 kbps - 192 kbps

Power Requirement Operating Voltage DC 14.4 V (11 V to 16 V allowance)

Grounding System Negative ground

Allowable Operating Temperature 0

Dimensions (W

Mass (approx.) 1.6 kg (excluding accessories)

× H × D) Installation Size (approx.) 182 mm × 52 mm × 158 mm

Front/Rear 19 W per channel into 4

total harmonic distortion

Ω (4 Ω to 8 Ω allowance)

Output level : -21 dBm to -15 dBm

Line-Out Level/Impedance 2.0 V/20 k

Output Impedance 1 k

Ω load (full scale)

Ω

Ω

TUNER SECTION

FM3 65.00 MHz to 74.00 MHz

AM (MW) 522 kHz to 1 620 kHz

(LW) 144 kHz to 279 kHz

µV/75 Ω)

50 dB Quieting Sensitivity 16.3 dBf (1.8

Alternate Channel Selectivity (400 kHz) 65 dB

Frequency Response 40 Hz to 15 000 Hz

Stereo Separation 30 dB

µV/75 Ω)

µV/35 dB
µV

DVD/CD PLAYER SECTION

DVD, fs=96 kHz 16 Hz to 44 000 Hz

VCD/CD/MP3/WMA 16 Hz to 20 000 Hz

Sampling Frequency 48 kHz, 44.1 kHz, 32 kHz

Sampling Frequency MPEG-1 : 48 kHz, 44.1 kHz, 33 kHz

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

GENERAL

°C to +40°C

Panel Size (approx.) 188 mm

× 58 mm × 11 mm

Ω, 40 Hz to 20 000 Hz at no more than 0.8%

(No.MA248)1-5

• "DVD Logo" is a trademark of DVD Format/Logo Licensing Corporation registered in the US, Japan and other countries.

• Microsoft and Windows Media are either registered trademarks or trademarks of Microsoft Corporation in the United States and/
or other countries.

• Manufactured under license from Dolby Laboratories. Dolby and the double-D symbol are trademarks of Dolby Laboratories.

• "DTS" and "DTS 2.0 + Digital Out" are registered trademarks of Digital Theater Systems, Inc.

• iPod is a trademark of Apple Computer, inc., registered in the U.S. and other countries.

• "SIRIUS" and the SIRIUS dog logo are registered trademarks of SIRIUS Satellite Radio Inc.

• XM and its corresponding logos are registered trademarks of XM Satellite Radio Inc.

• "SAT Radio," the SAT Radio logo and all related marks are trademarks of SIRIUS Satellite Radio Inc., and XM Satellite Radio, Inc.

• Design and specifi cations are subject to change without notice.

1-6 (No.MA248)

1.1 Safety Precautions

SECTION 1

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.

(No.MA248)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 DVD 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.

(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 DVD pickup unit.

• Apply solder to the short land before the flexible wire is disconnected from the connector on the DVD pickup unit.
(If the flexible wire is disconnected without applying solder, the DVD pickup may be destroyed by static electricity.)

• In the assembly, be sure to remove solder from the short land after connecting the flexible wire.

Flexible wire

1-8 (No.MA248)

CN101

Short-circuit points

Mechanism control board

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.

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

WARNING LABEL

CAUTION : Visible and Invisible

CLASS 1
LASER PRODUCT

laser radiation when open and
interlock failed or defeated.
AVOID DIRECT EXPOSURE TO
BEAM. (e)

ADVARSEL : Synlig og usynlig
laserstråling når maskinen er
åben eller interlocken fejeler.
Undgå direkte eksponering til
stråling. (d)

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)

(No.MA248)1-9

SECTION 2

SPECIFIC SERVICE INSTRUCTIONS

This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.

1-10 (No.MA248)

SECTION 3

DISASSEMBLY

3.1 Main body section

3.1.1 Removing the front panel assembly
(See Fig.1)

Push the detach button in the lower left part of the front panel as­sembly and remove the front panel assembly.

3.1.2 Removing the bottom cover
(See Fig.1)

Reference:

Remove the front panel assembly as required.
(1) Release the two joints a, two joints b and joint c.
(2) Remove the bottom cover from the main body.

Caution:

Do not damage the main board when releasing the joints using

a screwdriver or a similar tool.

Front panel assembly

Detach button

Fig.1

b

Bottom cover

a

3.1.3 Removing the front chassis assembly
(See Fig.3)

• Remove the front panel assembly and bottom cover.

(1) From the both sides of the main body, remove the two

screws A attaching the front chassis assembly.

(2) Release the two joints d and two joints e.

a

b

c

Fig.2

d

A

d

Front chassis assembly

Fig.3

A

e

e

(No.MA248)1-11

3.1.4 Removing the side heat sink
(See Fig.4)

Reference:

Remove the front panel and front chassis assemblies as re-

quired.
From the left side of the main body, remove the two screws B and
three screws C attaching the side heat sink.

B

3.1.5 Removing the rear bracket

(See Fig.5)

• Remove the bottom cover.

(1) From the back side of the main body, remove the screws

D, screw E, tow screws F, three screws G and screw H at­taching the rear bracket.

(2) Remove the rear bracket.

Reference:

The quantity of screws D differs by each model.

D

G

G

C

Fig.4

Cable holder

G

E

(For KD-DV4201 and KD-DV4202)

F

G

Side heat sink

Rear bracket

D

Rear bracket

D
G

H

D
G

1-12 (No.MA248)

E

F

Fig.5

D

H

3.1.6 Removing the main board
(See Figs.5 and 6)

• Remove the front panel assembly, bottom cover, front chassis

assembly and side heat sink.

Reference:

Remove the rear bracket as required.

(1) From the back side of the main body, remove the three

screws G attaching the main board. (See Fig.5.)

(2) From the bottom side of the main body, remove the three

screws J attaching the main board. (See Fig.6.)

(3) Disconnect the connector CN961

the DVD mechanism assembly and take out the main
board from the main body. (See Fig.6.)

3.1.7 Removing the DVD mechanism assembly
(See Fig.7)

• Remove the front panel assembly, bottom cover, front chassis

assembly, side heat sink and main board.
(1) From the inside of the top chassis, remove the three

screws K attaching the DVD mechanism assembly.

(2) Take out the DVD mechanism assembly from the top chas-

sis.

on the main board from

CN961

J

DVD mechanism assembly

K

J

J

Main board

Fig.6

K

K

Fig.7

Top chassis

(No.MA248)1-13

3.1.8 Removing the main sub board
(See Figs.8 to 10)

• Remove the front panel assembly, bottom cover, front chassis

assembly, side heat sink, main board and DVD mechanism as­sembly.
(1) From the top side of the DVD mechanism assembly, re-

move the two screws M attaching the dust cover. (See
Fig.8.)

(2) Remove the dust cover from the DVD mechanism assem-

bly. (See Fig.8.)

Reference:

When attaching the dust cover, align the joints f in the
holes of the dust cover before attaching the screws M.
(See Fig.8.)

(3) Release the lock of the connector CN962

board and disconnect the card wire. (See Fig.9.)
(4) Bend the joint g in the direction of the arrow. (See Fig.9.)
(5) Remove the two screws N attaching the main sub board

and remove the main sub board from the DVD mechanism

assembly. (See Fig.9.)

Reference:

• When attaching the main sub board, align the joints h in the

holes of the main sub board before attaching the screws N.
(See Fig.9.)

• When the resolution of DVD mechanism assembly is done

sequentially, remove the two screws P attaching the support
bracket. (See Fig.10.)

• Remove the card wire from the connector CN401

quired. (See Fig.10.)

on the main sub

as re-

DVD mechanism assembly

Dust cover

Fig.8

DVD mechanism assembly

CN962

h

M

Lock

f

M

f

g

N

P

h

Main sub board

Fig.9

Support bracket

CN401

Fig.10

1-14 (No.MA248)

3.1.9 Removing the switch board
(See Figs. 11 to 13)

• Remove the front panel assembly.

(1) From the back side of the front panel assembly, remove the

four screws Q attaching the rear cover. (See Fig.11.)

(2) Release the joints j attaching the rear cover to the front

panel assembly. (See Fig.12.)

(3) Release the joint k and take out the switch board while lift-

ing the switch board from the front panel assembly little by
little. (See Fig.13.)

Reference:

Remove the volume knob from the front side of the front panel
assembly at the same time.

Note:

Do not lose the compression springs when removing the
switch board. (See Fig.13.)

Q

Q

Rear cover

Q

Fig.11

Joints j

Joints j Joints j

Fig.12

Switch board

Joint

Fig.13

Joints j

Front panel assembly

k

(No.MA248)1-15

3.2 DVD mechanism assembly

3.2.1 Removing the mechanism control board
(See Fig.1)

Caution:

Before disconnecting the flexible wire extending from the DVD
pickup, solder the short-circuit point on the flexible wire using
a grounding soldering iron. If you do not follow this instruction,
the DVD pickup may be damaged.
(1) Turn over the body, and solder the short-circuit points on

the flexible wire extending from the DVD pickup.

(2) Disconnect the flexible wire from connector CN101

mechanism control board.

(3) Disconnect the card wire from connector CN201

mechanism control board.

(4) Disconnect the flexible wire from connector CN202

mechanism control board.

(5) Unsolder two soldered points a on the mechanism control

board and remove the wire extending from the feed motor.
(6) Remove the screw A attaching the lug wire.
(7) Remove the two screws B and screw C attaching the

mechanism control board.

Caution:

• As the flexible wire to be connected to CN101

attach it to the mechanism control board using a double
tape.

• After reassembling, unsolder the short-circuit points.

on the

on the

on the

, make sure to

Flexible wire

Double tape

CN101

B

Short-circuit points

A

Lug wire

B

CN201

Feed motor

a

C

CN202

Mechanism control board

Fig.1

1-16 (No.MA248)

3.2.2 Removing the top cover
(See Fig.2)

(1) Remove the two screws D attaching the top cover on the

back of the body.

(2) Remove the top cover upward.

Reference:

When reassembling, set part b of the top cover under the
bending part c of the chassis frame.

3.2.3 Removing the mechanism section
(See Fig.2 to 4)

• Remove the top cover.

(1) From the bottom of the body, remove the screw E attaching

the lug wire. (See Fig.2.)

(2) Remove the two screws F attaching the right and left stop-

pers on the front side. (See Fig.2.)

(3) Remove the two floating springs on the bottom of the body.

(See Fig.3.)

(4) Move the mechanism section upward and remove from the

chassis frame.
The three damper springs come off from the dampers.
(See Fig.4.)

Caution:

• When reassembling, reattach the damper spring to the
damper respectively and insert the three shafts on the bot­tom of the mechanism to the dampers.

• Before inserting the shaft to the dampers, apply IPA to the
hole of damper.

Floating spring

Fig.3

Mechanism section

Stopper

F

Top cover

Stopper

F

D

D

b

c

E

Lug wire

Damper SP.(F)

(Silver)

Damper (F)
(Black)

Damper SP.(F)

(Silver)

Damper (F)
(Black)

Fig.4

Damper SP.(R)

(Red)

Damper (R)
(Purple)

Chassis frame

Fig.2

(No.MA248)1-17

3.2.4 Removing the clamper unit
(See Fig.5 to 7)

• Remove the top cover and the mechanism section.

(1) Remove the clamper2 spring on the bottom of the mecha-

nism section. (See Figs.5.and 6.)

(2) Release the part d of the clamper spring from the bending

part of the chassis base assembly. (See Fig.7.)

(3) Move the clamper unit in the direction of the arrow and turn.

Release the two joints e and f, then remove the clamper
unit upward. (See Fig.6.)

3.2.5 Reattaching the clamper unit
(See Fig.5 to 9)

(1) Attach the clamper spring to the clamper unit. (See Fig.8.)
(2) Move the clamper unit to set the side joints e and f to each

boss of the chassis base assembly. Make sure that part g
is inserted to the notch of the chassis base assembly. (See
Figs.5 and 9.)

(3) Move the part d of the clamper spring to the outside of the

bending part of the chassis base assembly. (See Fig.7.)

(4) Attach the clamper2 spring to the chassis base assembly.

(See Figs.5 and 6.)

Caution:

When reattaching, temporarily hook the end of the clamper
spring as shown in the figure to make the work easy. (See
Fig.8.)

Clamper unit

Clamper2 spring

Chassis base assembly

Fig.6

Clamper spring

Clamper spring

f

Clamper2 spring

Chassis base assembly

g

d

Chassis base assembly

Fig.7

e

Fig.5

1-18 (No.MA248)

Clamper unit

Clamper unit

Clamper spring

Fig.8

Fig.9

g

Notch

(No.MA248)1-19

3.2.6 Removing the front unit
(See Fig.10 to 12)

• Remove the top cover and the mechanism section.

(1) Disconnect the flexible wire from connector CN202 on the

mechanism control board at the bottom of the body. (See
Fig.10.)

(2) Remove the screw G attaching the front unit on the top of

the body. (See Fig.11.)

(3) Move the front unit toward the front to release joint h, and

release two joints i and j on the right side of the chassis
base assembly. Then remove the front unit upward. (See
Figs.11 and 12.)

(4) Remove the two screws H attaching the switch board. (See

Fig.12.)

Reference:

You can remove the switch board only without removing the
front unit.

Caution:

When reassembling, attach the flexible wire extending from
the switch board using the double tape. (See Figs.10 and 12.)

Mechanism control board

G

Front unit

h

Fig.11

CN202

Double tape

Fig.10

Flexible wire

Double tape

j

i

H

Switch board

Front unit

G

1-20 (No.MA248)

h

Fig.12

3.2.7 Removing the loading arm assembly

(See Fig.13 , 14)

• Remove the top cover, the mechanism section and the front

unit.
(1) From the top of the body, move the loading arm assembly

from the front side upward, and release the bosses from
the right and left joints k and m of the chassis base assem­bly.

(2) Release the boss from notch n of the connect arm on the

right side of the body, and release the boss from notch p of
the slide cam assembly on the left side.

m

Loading arm assembly

Side cam
assembly

p

m

k

Fig.13

Loading arm assembly

k

n

n

Connect arm

Fig.14

(No.MA248)1-21

3.2.8 Removing the rod (L)(R)/roller assembly
(See Fig.15 and 16)

• Remove the top cover, the mechanism section, the front unit

and the loading arm assembly.
(1) Release the rod (L) and (R) from the joints q at the bottom

of the loading arm assembly (See Fig.15.)

(2) Remove the roller assembly from the loading arm assem-

bly. (See Fig.16.)

(3) Remove the two collars and washer from the roller assem-

bly. (See Fig.16.)

Caution:

After attaching the loading arm assembly to the roller assem­bly, attach the rod (L) and (R). Attach the rods to the right and
left collars of the roller. (See Fig.15.)
When reattaching the rod (L) and (R) to the loading arm as­sembly, engage each joint as shown in Fig.15. As joints q of
the rod (L), let the rod through q before reattaching it.

Collar

Collar

Rod(R) Rod(L)

q

q

q

Collar

Rod(L)

Rod(R)

q

Loading arm assembly

Fig.15

Roller assembly

Loading arm assembly

q

Rod(L)

q

Collar

Washer

Rod(R)

1-22 (No.MA248)

Fig.16

3.2.9 Removing the DVD pickup assembly

(See Fig.17 to 19)

• Remove the mechanism control board.

(1) From the bottom of the body, turn the feed gear in the di-

rection of the arrow to move the DVD pickup outwards.
(See Fig.17.)

(2) Remove the screw J attaching the thrust spring. (See

Fig.17.)

(3) Remove the DVD pickup assembly upward on the L.S.gear

side and release from sub shaft at joint r. Move the lead
screw of the DVD pickup assembly in the direction of the
arrow to release from joint s. (See Fig.18.)

Caution:

• When releasing the lead screw at joint s, the L.S.collar
comes off at the end of the lead screw. When reas­sembling, reattach the L.S.collar to the lead screw and
engage joint s. (See Fig.18.)

• When reattaching the L.S.collar, reattach it to the point
s of the lead screw, and to the rod (M). Make sure that
the L.S.collar is set on the rod (M) spring. (See Fig.18.)

(4) Remove the screw K attaching the rack spring/ rack plate

on the DVD pickup. (See Fig.19.)

(5) Pull out the lead screw. (See Fig.19.)

Caution:

Perform adjustment after replacing the pickup.

DVD Pickup assembly

DVD Pickup assembly

Feed gear

J

Thrust spring

Fig.17

s

L.S.collar

Rod(M)

Lead screw

Sub shaft

L.S.collar

r

L.S.gear

Fig.18

K

Rack spring

Lead screw

Rack plate

DVD Pickup

Fig.19

(No.MA248)1-23

3.2.10 Removing the spindle motor

r

(See Fig.20)

• Remove the mechanism control board.
Remove the two screws L attaching the spindle motor on the
bottom of the body.

Caution:

Perform adjustment when reattaching the spindle motor.

3.2.11 Removing the feed motor assembly

(See Fig.21 and 22)

• Remove the mechanism control board.
(1) Remove the feed TRI. spring on the bottom of the body.

(See Fig.21.)

(2) Remove the two screws M attaching the feed motor as-

sembly. (See Fig.21.)

(3) Remove the slit washer from the motor H. assembly and

pull out the worm wheel. (See Fig.22.)
Remove the two screws N attaching the feed motor. (See
Fig.22.)

Spindle motor

Feed TRI. spring

L

Fig.20

M

Feed motor assembly

1-24 (No.MA248)

Fig.21

Slit washer

Worm wheel

Feed moto

N

Motor H. assembly

Fig.22

SECTION 4

ADJUSTMENT

4.1 Test instruments required for adjustment

(1) Digital oscilloscope (100MHz)
(2) Jitter meter
(3) Digital tester
(4) Electric voltmeter
(5) Tracking offset meter
(6) Test Disc : VT501 or VT502
(7) Extension studs : STDV001-3P
(8) Extension cable : EXTDV002-30P

4.3 Connection method

Connection procedure

(1) Attach the front chassis assembly to the main board.
(2) Connect the front panel assembly to the main board.
(3) Attach the heat sink and rear bracket to the main board.
(4) Attach the extension studs to the DVD mechanism assembly.
(5) Connect the DVD mechanism assembly and the main board with a extension cable.

4.2 Standard measuring conditions

Power supply voltage DC14.4V(11 to 16V)

Load impedance 4Ω(2 Speakers connection)
Line Output 20KΩ

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.

Extension cable
EXTDV002-30P

Heat sink

Rear bracket

Main board

Extension stud
STDV001-3P

Extension studs
STDV001-3P

(No.MA248)1-25

After replacing the pickup, set the unit in the service mode to display a jitter value on the LCD. Confirm that the jitter value measured
with a jitter meter is within 12% of the jitter value displayed on the LCD. If it is within 12%, then adjustment is not necessary. Please
note that a jitter value displayed on the LCD is hex data. Refer to the corresponding decimal notation value using the Jitter Conversion
Table and confirm it with the measured value.
Fix the screws "a", "b" and "c" with screw lock paint.

If the measured jitter value is outside the 12% tolerance range, perform the following adjustments.

c

b

a

Jitter value adjustment procedure (Pickup horizontal level adjustment relative to the DVD recording surface)
(For the adjustment tool use a 3 mm wrench and not a screwdriver, this procedure will make the adjustment easier.

3 mm wrench

(1) Set the unit to the service mode and display a jitter value (hex data) on the LCD.
(2) Turn each of the screws a, b and c, by a half-turn per step, in the direction that reduces the jitter value in order to minimize it.

(Do not turn a screw more than a half turn at a time, but adjust the screw in the cycle of same level turn by pair of b+c→ pair of

a+b.)

(3) After completing the adjustment, secure the screws with screw lock paint.

1-26 (No.MA248)