JVC KDDV-5101 Service manual

SERVICE MANUAL

DVD/CD RECEIVER

MA15120052

KD-DV5101

Area suffix

E ------------- Southern Europe
EU ------------------------- Turkey

TABLE OF CONTENTS

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

2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

COPYRIGHT © 2005 Victor Company of Japan, Limited

No.MA151

2005/2

SPECIFICATION

AUDIO AMPLIFIER SECTION

Maximum Power Output Front 50 W per channel

Rear 50 W per channel

Continuous Power Output (RMS) Front 19 W per channel into 4 Ω, 40 Hz to 20 000 Hz at no more

than 0.8% total harmonic distortion.

Rear 19 W per channel into 4 Ω, 40 Hz to 20 000 Hz at no more

than 0.8% total harmonic distortion.

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

Signal-to-Noise Ratio 70 dB

Audio Output Level 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 PAL

Video Output (composite) 1 Vp-p/75 Ω

TUNER SECTION

Frequency Range FM 87.5 MHz to 108.0 MHz

AM (MW) 522 kHz to 1 620 kHz

(LW) 144 kHz to 279 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

MW Tuner Sensitivity 20 µV

Selectivity 35 dB

LW Tuner Sensitivity 50 µV

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

Panel Size (approx.) 188 mm × 58 mm × 11 mm

Mass (approx.) 1.7 kg (excluding accessories)

Design and specifications are subject to change without notice.

1-2 (No.MA151)

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

b

Front panel assembly

Fig.1

Bottom cover

a

a

b

c

Fig.2

(No.MA151)1-7

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

A

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.

d

B

d

Front chassis assembly

Fig.4

e

B

e

C

1-8 (No.MA151)

D

Side heat sink

Fig.5

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, three screws E', two screws F and three screws
G 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 holders

Slot

Wire holder

GEE'

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 G attaching the main board. (See Fig.6.)

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

screws H 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.)

on the main board from

E'

G

H

E'

E

G

F

Fig.6

CN961

H

H

Main board

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 J attaching the DVD mechanism assembly.

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

sis.

Fig.7

DVD mechanism assembly

J

Top chassis

J

J

Fig.8

(No.MA151)1-9

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 K 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 K.
(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 L 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 L.
(See Fig.10.)

• When the resolution of DVD mechanism assembly is done

sequentially, remove the two screws M 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

h

f

K

f

K

Lock

g

L

M

h

Main sub board

Fig.10

Support bracket

CN401

Card wire

Card wire

1-10 (No.MA151)

Fig.11

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 N 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

N

Front panel assembly

N

N

Fig.12

i

i

Rear cover

Switch board

Compression spring

i

i

Fig.13

Front panel assembly

Compression spring

Fig.14

(No.MA151)1-11

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

1-12 (No.MA151)

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.MA151)1-13

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

1-14 (No.MA151)

Clamper unit

Clamper unit

Clamper spring

Fig.8

Fig.9

g

Notch

(No.MA151)1-15

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

1-16 (No.MA151)

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.MA151)1-17

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)

1-18 (No.MA151)

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.MA151)1-19