JVC KD-DV5000 User manual

SERVICE MANUAL
COPYRIGHT © 2003 VICTOR COMPANY OF JAPAN, LIMITED No.49879
2003/8
DVD/CD RECEIVER
4987920038KD-DV5000
TABLE OF CONTENTS
1 PRECAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2 SPECIFIC SERVICE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
5 TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Area Suffix
E ----------- Continental Europe

1-2 (No.49879)
SPECIFICATION
• Design and specifications are subject to change without notice.
• If a kit is necessary for your car, consult a telephone directory for the nearest car audio speciality shop.
• Mistracking may result from driving on extremely rough roads. This does not damage the unit and the disc, but will be annoying.
We recommend that you stop disc play while driving on such rough roads.
AUDIOAMPLIFIER
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.
0.8% total harmonic distortion.
Load Impedance 4 Ω(4 Ωto 8 Ωallowance)
Equalizer Control Range Frequencies 60 Hz, 150 Hz, 400 Hz, 1 kHz, 2.4 kHz, 6 kHz,
12 kHz
Level ±10 dB
Signal-to-Noise Ratio 70 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 2.0 V/20 kΩload (full scale)
Output Impedance 1 kΩ
Color system NTSC
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 1620 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 15000 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 16 Hz to 22000 Hz
DVD, fs=96 kHz 16 Hz to 44000 Hz
VCD, CD, MP3 16 Hz to 20000 Hz
Dynamic Range 96 dB
Signal-to-Noise Ratio 98 dB
Wow and Flutter Less than measurable limit
MP3 recording format MPEG 1/2 Audio Layer 3
Max. Bit rate 320 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 ×12 mm
(7-7/16" ×2-5/16" ×1/2")
Mass (approx.) 1.7 kg (3.8 lbs) (excluding accessories)

(No.49879)1-3
SECTION 1
PRECAUTION
1.1 Safety 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.

1-4 (No.49879)
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 mechanism unit.
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.
(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 CN10 on the front end board, solder the short-circuit point on the flex-
ible wire.
Caution:
If you do not follow this instruction, the DVD pickup may be damaged.
(2) Disconnect the flexible wire from the connector CN10 on the front end board.
(3) Remove the solders from the short-circuit point on the flexible wire after replacing the DVD pickup.
(4) Connect the flexible wire to the connector CN10 on the front end board.
1M
(caption)
Anti-static wrist strap
Conductive material
(conductive sheet) or iron plate
Front end board
CN10
Flexible wire
Short-circuit point

(No.49879)1-5
SECTION 2
SPECIFIC SERVICE INSTRUCTIONS
This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.

1-6 (No.49879)
SECTION 3
DISASSEMBLY
3.1 Main body section
3.1.1 Removing the front panel assembly
(See Fig.1)
(1) Push the detach button in the lower left part of the front
panel assembly and remove the front panel assembly.
Fig.1
3.1.2 Removing the bottom cover
(See Fig.2)
• Prior to performing the following procedures, remove the front
panel assembly as required.
(1) Turn over the main body and remove the two screws Aat-
taching the bottom cover.
(2) Release the two joints a, two joints band joint c.
Caution:
Do not damage the main board when releasing the joints using
a screwdriver or a similar tool.
Fig.2
Front panel assembly
Detach button
Bottom cover
Joint b
Joint b
Joint a
Joint a
Joint c
A A

(No.49879)1-7
3.1.3 Removing the front chassis assembly
(See Figs.3 and 4)
• Prior to performing the following procedures, remove the front
panel assembly and bottom cover.
(1) From the both sides of the main body, remove the two
screws Battaching the front chassis assembly. (See
Fig.3.)
(2) From the front side of the main body, remove the two
screws Cattaching the front chassis assembly. (See
Fig.4.)
(3) From the both sides of the main body, release the two joints
dand two joints e. (See Fig.3.) Fig.3
Fig.4
3.1.4 Removing the heat sink
(See Fig.5)
• Prior to performing the following procedure, remove the front
panel and front chassis assemblies as required.
(1) From the left side of the main body, remove the two screws
Dand three screws Eattaching the heat sink.
Fig.5
3.1.5 Removing the rear bracket
(See Fig.6)
• Prior to performing the following procedures, remove the bot-
tom cover.
(1) From the back side of the main body, remove the three
screws F, five screws G, two screws H, screw J, screw K
and screw Lattaching the rear bracket.
(2) Remove the rear bracket.
Note:
When attaching the screws Kand L, attach the AV cable and
antenna cable holders with them.
Fig.6
Joint d
Joint d
Front chassis assembly
B
Joint e
Joint e
B
C
Front chassis assembly
D
EHeat sink
G
Rear bracket
FL
K
F
JHG
F
Antenna
cable
holder
AV cable holder

1-8 (No.49879)
3.1.6 Removing the main board
(See Fig.7)
• Prior to performing the following procedures, remove the front
panel assembly, bottom cover, front chassis assembly, heat
sink and rear bracket.
(1) Remove the two screws Mattaching the main board.
(2) Disconnect the connectors CN781 and CN782 on the main
board from the DVD mechanism assembly.
Reference:
Remove the fan unit as required.
(Disconnect the fan unit wire from the connector CN531 on the
main board and remove the fan unit.)
Fig.7
3.1.7 Removing the DVD mechanism assembly
(See Fig.8)
• Prior to performing the following procedure, remove the front
panel assembly, bottom cover, front chassis assembly, heat
sink, rear bracket and main board.
(1) From the inside of the top chassis, remove the three
screws Nattaching the DVD mechanism assembly.
Fig.8
CN782
M
M
CN781
Fan unit
CN531
Main board
NN
N
DVD mechanism assembly
Top chassis

(No.49879)1-9
3.1.8 Removing the back end board
(See Figs.9 to 11)
• Prior to performing the following procedures, remove the front
panel assembly, bottom cover, front chassis assembly, heat
sink, rear bracket, main board and DVD mechanism assembly.
(1) From the top side of the DVD mechanism assembly, re-
move the two screws Pattaching the heat sink (MECHA).
(See Fig.9.)
(2) Remove the two screws Qattaching the shield. (See
Fig.9.)
(3) Remove the shield and heat sink (MECHA) from the DVD
mechanism assembly.
(4) Remove the two screws Rattaching the heat sink (P). (See
Fig.10.)
(5) Release the two joints f and then release the two joints g.
(See Fig.10.)
(6) Disconnect the card wire from the connector CN506 on the
back end board. (See Fig.10.)
(7) Remove the four screws Sand screw S’ attaching the back
end board. (See Fig.10.)
(8) Release the three joints hand then take out the back end
board from the DVD mechanism assembly. (See Fig.11.)
Reference:
When attaching the screw S’, attach the earth wire with it. (See
Fig.11.)
Fig.9
Fig.10
Fig.11
Q
DVD mechanism assembly Shield
P
Heat sink(MECHA)
Heat sink(P)
Back end board
Card wire
CN506
Joint f
Joint f
Joints g
R
Fig.11
Back end board
DVD mechanism assembly
Earth wire
Joint hJoint h
Joint h
S
S'
S

1-10 (No.49879)
3.1.9 Removing the front board
(See Figs. 12 to 14)
• Prior to performing the following procedures, remove the front
panel assembly.
(1) From the back side of the front panel assembly, remove the
six screws Tattaching the rear cover. (See Fig.12.)
(2) Release the ten joints iattaching the rear cover to the front
panel assembly. (See Fig.13.)
(3) Take out the front board from the front panel assembly.
(See Fig.14.)
Note:
Do not lose the springs when removing the front board. Fig.12
Fig.13
Fig.14
T
T
T
T
Rear cover
Front panel assembly
Joints i
Joints i
Rear cover
Joint iJoint i
Front board Front panel assembly
Spring Spring

(No.49879)1-11
3.2 DVD mechanism assembly
3.2.1 Removing the front end 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 point on the
flexible wire extending from the DVD pickup.
(2) Disconnect the flexible wire from connector CN10 on the
front end board.
(3) Disconnect the flexible wire from connector CN201 on the
front end board.
(4) Disconnect the flexible wire from connector CN202 on the
front end board.
(5) Unsolder two soldering aon the front end board and dis-
connect the wire extending from the feed motor.
(6) Remove the three screws Aattaching the front end board.
Caution:
As the flexible wire to be connected to CN10, make sure to at-
tach it to the front end board using a double tape.
Caution:
After reassembling, unsolder the short-circuit point.
Fig.1
Double tape
Feed motor
Solder point
Front end board
CN202
CN10
A
a.
A
A
CN201
Flexible wire
Short-circuit point

1-12 (No.49879)
3.2.2 Removing the top cover
(See Fig.2)
(1) Remove the two screws Battaching the top cover on the
back of the body. Remove the top cover upward.
Reference:
When reassembling, set part bof the top cover under the
bending part cof the chassis frame.
3.2.3 Removing the mechanism section
(See Fig.2 ~ 4)
• Prior to performing the following procedure, remove the top
cover.
(1) Remove the two screws Cattaching the right and left stop-
pers on the front side.
(2) Remove the two floating springs on the bottom of the body.
(3) Move the mechanism section upward and remove from the
chassis frame.
The three damper springs come off from the dampers.
Caution:
When reassembling, reattach the damper spring to the damp-
er respectively and insert the three shafts on the bottom of the
mechanism to the dampers.
Caution:
Before inserting the shaft to the dampers, apply IPA to the hole
of damper.
Fig.2
Fig.3
Fig.4
B
Top cover
Stopper
Stopper
C
C
㨎
c
Floating spring
Mechanism section
Damper
(Purple)
Damper
(Black)
Damper
(Black)
Chassis frame
Damper SP.(F)
(Silver)
Damper SP.(F)
(Silver)
Damper SP.(R)
(Red)

(No.49879)1-13
3.2.4 Removing the clamper unit
(See Fig.5 ~ 9)
• Prior to performing the following procedure, remove the top
cover and the mechanism section.
(1) Remove the clamper spring on the bottom of the mecha-
nism section.
(2) Release part dof the clamper spring from the bending part
of the chassis base assembly.
(3) Move the clamper unit in the direction of the arrow and turn.
Release the two joints eand f, then remove the clamper
unit upward.
3.2.5 Reattaching the clamper unit
(See Fig.5 ~ 9)
(1) Attach the clamper spring to the clamper unit.
(2) Move the clamper unit to set the side joints eand fto each
boss of the chassis base. Make sure that part gis inserted
to the notch of the chassis base.
(3) Move the clamper spring dto the outside of the bending
part of the chassis base.
Caution:
When reattaching, temporarily hook the end of the clamper
spring as shown in the figure to make the work easy.
Fig.5
Fig.6
Fig.7
Fig.8
Fig.9
Clamper unit
Clamper spring
Clamper2 spring
g
f
e
Chassis base
Clamper2 spring
Clamper spring
Chassis base
d
Clamper unit
Clamper spring
Notch
g
Clamper unit

1-14 (No.49879)
3.2.6 Removing the front unit
(See Fig.10 ~ 12)
• Prior to performing the following procedure, remove the top
cover and the mechanism section.
(1) Disconnect the flexible wire from connector CN202 on the
front end board at the bottom of the body.
(2) Remove the screw Dattaching the front unit on top of the
body.
(3) Move the front unit toward the front to release joint h, and
release two joints iand jon the right side of the chassis
base. Then remove the front unit upward.
(4) Remove the two screws Eattaching the switch board.
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 a double tape.
Fig.10
Fig.11
Fig.12
D
Front unit
h
h
Front unit
Switch board
j
D
E
i
Double tape
Front-end board
Flexible wire
CN202

(No.49879)1-15
3.2.7 Removing the loading arm S.A.
(See Fig.13, 14)
• Prior to performing the following procedure, remove the top
cover, the mechanism section and the front unit.
(1) From top of the body, move the loading arm S.A. from the
front side upward, and release the bosses from the right
and left joints kand lof the chassis base.
(2) Release the boss from notch m of the connect arm on the
right side of the body, and release the boss from notch n of
the slide cam ass'y on the left side.
Fig.13
Fig.14
km
l
Loading arm SA
k
m
l
Loading arm SA
n
Side cam
ass'y
Connect arm

1-16 (No.49879)
3.2.8 Removing the rod (L)(R)/roller assembly
(See Fig.15 ~ 17)
• Prior to performing the following procedure, remove the top
cover, the mechanism section, the front unit and the loading
arm S.A.
(1) Release the rod (L) and (R) from the joints at the bottom of
the loading arm S.A.
(2) Remove the roller assembly from the loading A.ass'y.
(3) Remove the two collars and washer from the roller assem-
bly.
Caution:
After attaching the loading A.ass'y to the roller assembly, at-
tach the rod (L) and (R). Attach the rods to the right and left col-
lars of the roller as shown in Fig.16-1 and Fig.16-2.
When reattaching the rod (L) and (R) to the loading A.ass'y,
engage each joint as shown in Fig.15. As joint nof the rod (L),
let the rod through nbefore reattaching it.
Fig.15
Fig.17
Joint n
Joint n
Joint n Joint n
Joint n
Joint n
Rod(R) Loading A. ass'y
Rod(L)
Collar Collar
Fig.16-1 Fig.16-2
Rod(R) Rod(L)
Roller ass'y
Washer
Collar
Collar
Rod(L)
Loading A. ass'y
Rod(R)

(No.49879)1-17
3.2.9 Removing the DVD pickup assembly
(See Fig.18 ~ 20)
• Prior to performing the following procedure, remove the front
end board.
(1) At the bottom of the body. turn the feed gear in the direction
of the arrow to move the DVD pickup outwards.
(2) Remove the screw Fattaching the thrust spring.
(3) Remove the DVD pickup assembly upward on the L.S.gear
side and release from sub shaft at joint o. Move the lead
screw of the DVD pickup assembly in the direction of the
arrow to release from joint p.
Caution:
When releasing the lead screw at joint p, the L.S.collar
comes off at the end of the lead screw. When reassem-
bling, reattach the L.S.collar to the lead screw and en-
gage joint p.
Caution:
When reattaching the L.S.collar, reattach it to the point p
of the lead screw, and to the lod (M). Make sure that the
L.S.collar is set on the lod (M) spring.
(4) Remove the screw Gattaching the rack spring/ rack plate
on the DVD pickup.
(5) Pull out the lead screw.
Caution:
Perform adjustment after replacing the pickup.
Fig.18
Fig.19
Fig.20
F
Feed gear
Thrust spring
DVD Pickup ass'y
O
PL.S.Collar
Lod(M)
L.S.Gear
Lead screw
Sub shaft
DVD Pickup ass'y
G
Rack spring
Rack plate
L.S.Collar
DVD Pickup
Lead screw
L.S.Gea
r

1-18 (No.49879)
3.2.10 Removing the spindle motor
(See Fig.21)
• Prior to performing the following procedure, remove the front
end board.
(1) Remove the two screws Hattaching the spindle motor on
the bottom of the body.
Caution:
Perform adjustment when reattaching the spindle motor.
Fig.21
3.2.11 Removing the FL motor S.A.
(See Fig.22, 23)
• Prior to performing the following procedure, remove the front
end board.
(1) Remove the feed TRI.spring on the bottom of the body.
(2) Remove the two screws Iattaching the FL motor SA.
(3) Remove the slit washer from the motor H.ass'y and pull out
the worm wheel.
(4) Remove the two screws Jattaching the FL motor.
Fig.22
Fig.23
H
Spindl motor
I
FL Motor SA
F.T.Spring
FL Moto
r
Motor H.ass'y
Worm wheel
J
Slit washer

(No.49879)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 cable for check
(8) Extension studs and FFC extension cable
4.2 Standard measuring conditions
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 For comfirmation of the Main board and mechanism movements
Connecting diagram 1 of extension cable
Power supply voltage : DC14.4V(11V to 16V)
Load impedance : 4 Ω(2 Speakers connection)
Line output : 20k Ω
Main board
Extension cable
EXTGS004-26PL
Extension studs
STDV001-3P
Extension stud
STDV001-3P
Heat sink Rear bracket
Extension cable
EXTDV001-20P

1-20 (No.49879)
4.4 For the adjustment of the jitter after replacing the pickup
Connecting diagram 2 of extension cable
Procedure
Remove the screws attaching the backend board from the mechanism side, connect the backend board to the connectors (26pins/
20pins) on the main board.
After attaching the top chassis and front panel assemblies to the main board, attach the extension studs (STDV001-3P) on the
top chassis and then attach the mechanism assembly with the nuts.
Main board
Extension stud
STDV001-3P
FFC extension cable
EXTDV001-50PF
Backend board
Extension stud
STDV001-3P
Nut
Disconnect the FFC cable