Jvc KD-DV5100 Service Manual

SERVICE MANUAL

DVD/CD RECEIVER

MA14920052

KD-DV5100

Area suffix

J --------------- Northern America

TABLE OF CONTENTS

1 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

No.MA149

2005/2

SPECIFICATION

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)

Equalizer Control Range Frequencies 60 Hz, 150 Hz, 400 Hz, 1 kHz, 2.4 kHz, 6 kHz, 15 kHz

Level ±10 dB

Audio Output Level Analog (2nd AUDIO OUT) 6 mW (at 16 Ω)

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

Output level: -21 dBm to -15 dBm

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

Color System NTSC

Video Output (composite) 1 Vp-p/75 Ω

Other Terminals LINE IN, CD changer

TUNER SECTION

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

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

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

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

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

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

Capture Ratio 1.5 dB

AM Tuner Sensitivity 20 µV

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/96 kHz 16 Hz to 22 000 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) Max. Bit Rate: 320 kbps

WMA (Windows Media Audio) Max. Bit Rate: 192 kbps

GENERAL

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 × 158 mm (7-3/16" × 2-1/16" × 6-1/4")

Panel Size (approx.) 188 mm × 58 mm × 11 mm (7-7/16" × 2-5/16" × 7/16")

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

Design and specifications are subject to change without notice.

1-2 (No.MA149)

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.MA149)1-3

1.2 Preventing static electricity

Electrostatic discharge (ESD), which occurs when static electricity stored in the body, fabric, etc. is discharged, can destroy the laser diode in the traverse unit (optical pickup). Take care to prevent this when performing repairs.

1.2.1 Grounding to prevent damage by static electricity

Static electricity in the work area can destroy the optical pickup (laser diode) in devices such as CD players. Be careful to use proper grounding in the area where repairs are being performed.

(1) Ground the workbench

Ground the workbench by laying conductive material (such as a conductive sheet) or an iron plate over it before placing the traverse unit (optical pickup) on it.

(2) Ground yourself

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

(caption) Anti-static wrist strap

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) Before disconnecting the flexible wire from the connector CN101

on the flexible wire.

Caution:

If you do not follow this instruction, the DVD pickup may be damaged.

(2) Disconnect the flexible wire from the connector CN101 (3) Remove the solders from the short-circuit points on the flexible wire after replacing the DVD pickup. (4) Connect the flexible wire to the connector CN101

Flexible wire

CN101

on the mechanism control board.

on the mechanism control board, solder the short-circuit points

1-4 (No.MA149)

Short-circuit points

Mechanism control board

SECTION 2

SPECIFIC SERVICE INSTRUCTIONS

This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.

(No.MA149)1-5

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.2)

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.

Detach button

Front panel assembly

Fig.1

Bottom cover

Fig.2

1-6 (No.MA149)

3.1.3 Removing the front chassis assembly

(See Figs.3 and 4)

• Remove the front panel assembly and bottom cover.

(1) From the front side of the main body, remove the two

screws A attaching the front chassis assembly. (See Fig.3.)

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

screws B attaching the front chassis assembly. (See Fig.4.)

(3) Release the two joints d and two joints e. (See Fig.4.)

Front chassis assembly

Fig.3

3.1.4 Removing the side heat sink

(See Fig.5)

Reference:

Remove the front panel and front chassis assemblies as re-

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

Front chassis assembly

Fig.4

Side heat sink

Fig.5

(No.MA149)1-7

3.1.5 Removing the rear bracket (See Fig.6)

• Remove the bottom cover.

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

screws E, two screws E', screw F, two screws G and three screws H attaching the rear bracket.

(2) Remove the LINE IN cable from the rear bracket in the di-

rection of the arrow.

Reference:

• When attaching the LINE IN cable, insert it in a slot of the rear bracket and hang it on a wire holder.

• When attaching the screws E', attach the cable holders with them.

LINE IN cable

Rear bracket

Cable holder

Slot

Wire holder

HEE'

Cable holder

Rear bracket

3.1.6 Removing the main board (See Figs.6 and 7)

• 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 H attaching the main board. (See Fig.6.)

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

screws J attaching the main board. (See Fig.7.)

(3) Disconnect the connector CN961

the DVD mechanism assembly and take out the main board from the main body. (See Fig.7.)

3.1.7 Removing the DVD mechanism assembly (See Fig.8)

• 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

E' H

CN961

DVD mechanism assembly

Fig.6

Main board

Fig.7

1-8 (No.MA149)

Fig.8

Top chassis

3.1.8 Removing the main sub board

(See Figs.9 to 11)

• 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 L attaching the dust cover. (See Fig.9.)

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

bly. (See Fig.9.)

Reference:

When attaching the dust cover, align the joints f in the holes of the dust cover before attaching the screws L. (See Fig.9.)

(3) Release the lock of the connector CN962

board and disconnect the card wire. (See Fig.10.) (4) Bend the joint g in the direction of the arrow. (See Fig.10.) (5) Remove the two screws M attaching the main sub board

and remove the main sub board from the DVD mechanism

assembly. (See Fig.10.)

Reference:

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

holes of the main sub board before attaching the screws M. (See Fig.10.)

• When the resolution of DVD mechanism assembly is done

sequentially, remove the two screws N attaching the support bracket. (See Fig.11.)

• Remove the card wire from the connector CN401

quired. (See Fig.11.)

on the main sub

as re-

DVD mechanism assembly

Dust cover

Fig.9

DVD mechanism assembly

CN962

Lock

Main sub board

Fig.10

Support bracket

CN401

Fig.11

Card wire

(No.MA149)1-9

3.1.9 Removing the switch board (See Figs. 12 to 14)

• Remove the front panel assembly.

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

five screws P attaching the rear cover. (See Fig.12.)

(2) Release the ten joints i attaching the rear cover to the front

panel assembly. (See Fig.13.)

(3) Take out the switch board while lifting the switch board

from the front panel assembly little by little. (See Fig.14.)

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.14.)

Rear cover

Front panel assembly

Fig.12

Rear cover

Switch board

Compression spring

Fig.13

Front panel assembly

Compression spring

Fig.14

1-10 (No.MA149)

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

, make sure to

Flexible wire

Double tape

CN101

Short-circuit points

Lug wire

CN201

Feed motor

CN202

Mechanism control board

Fig.1

(No.MA149)1-11

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

Top cover

Stopper

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

1-12 (No.MA149)

Fig.2

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

Clamper2 spring

Chassis base assembly

Fig.7

Fig.5

(No.MA149)1-13

Clamper unit

Clamper spring

Fig.8

1-14 (No.MA149)

Fig.9

Notch

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

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

on the

Front unit

Fig.11

CN202

Double tape

Fig.10

Flexible wire

Double tape

Switch board

Front unit

Fig.12

(No.MA149)1-15

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.

Loading arm assembly

Side cam assembly

Fig.13

Loading arm assembly

Connect arm

1-16 (No.MA149)

Fig.14

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

Rod(R) Rod(L)

Collar

Rod(L)

Rod(R)

Loading arm assembly

Fig.15

Roller assembly

Loading arm assembly

Rod(L)

Collar

Washer

Rod(R)

Fig.16

(No.MA149)1-17

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

Feed gear

Thrust spring

Fig.17

L.S.collar

Rod(M)

Lead screw

Sub shaft

L.S.collar

L.S.gear

Fig.18

Rack spring

Lead screw

Rack plate

DVD Pickup

Fig.19

1-18 (No.MA149)

3.2.10 Removing the spindle motor

(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

Fig.20

Feed motor assembly

Fig.21

Slit washer

Worm wheel

Feed moto

Motor H. assembly

Fig.22

(No.MA149)1-19

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

1-20 (No.MA149)

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