JVC KD-DV5100 User manual

SERVICE MANUAL
COPYRIGHT © 2005 Victor Company of Japan, Limited No.MA149
2005/2
DVD/CD RECEIVER
MA14920052
KD-DV5100
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
Area suffix
J --------------- Northern America

1-2 (No.MA149)
SPECIFICATION
Design and specifications are subject to change without notice.
AUDIO AMPLIFIER SECTION
Power Output 20 W RMS ×4 Channels at 4 Ωand [< or =] 1% THD+N
Signal to Noise Ratio 80 dBA (reference: 1 W into 4 Ω)
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, 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 kΩload (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)

(No.MA149)1-3
SECTION 1
PRECAUTIONS
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.MA149)
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.
(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 mechanism control board, solder the short-circuit points
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 on the mechanism control board.
(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 on the mechanism control board.
1M
(caption)
Anti-static wrist strap
Conductive material
(conductive sheet) or iron plate
Mechanism control board
CN101
Flexible wire
Short-circuit points

(No.MA149)1-5
SECTION 2
SPECIFIC SERVICE INSTRUCTIONS
This service manual does not describe SPECIFIC SERVICE INSTRUCTIONS.

1-6 (No.MA149)
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 as-
sembly and remove the front panel assembly.
Fig.1
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 band 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.
Fig.2
Front panel assembly
Detach button
Bottom cover
b
b
a
a
c

(No.MA149)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 Aattaching the front chassis assembly. (See
Fig.3.)
(2) From the both sides of the main body, remove the two
screws Battaching the front chassis assembly. (See
Fig.4.)
(3) Release the two joints dand two joints e. (See Fig.4.)
Fig.3
Fig.4
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 Cand
three screws Dattaching the side heat sink.
Fig.5
A
Front chassis assembly
d
d
Front chassis assembly
B
e
e
B
C
D
Side heat sink

1-8 (No.MA149)
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 Gand three
screws Hattaching 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.
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 Hattaching the main board. (See Fig.6.)
(2) From the bottom side of the main body, remove the three
screws Jattaching the main board. (See Fig.7.)
(3) Disconnect the connector CN961 on the main board from
the DVD mechanism assembly and take out the main
board from the main body. (See Fig.7.)
Fig.6
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 Kattaching the DVD mechanism assembly.
(2) Take out the DVD mechanism assembly from the top chas-
sis.
Fig.8
Rear bracket
G
H
E'
Cable holder
F
H
H
E
E'
Cable holder
Wire holder
Slot
LINE IN cable
Rear bracket
E
CN961
J
J
Main board
J
KK
K
DVD mechanism assembly
Top chassis

(No.MA149)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 as-
sembly.
(1) From the top side of the DVD mechanism assembly, re-
move the two screws Lattaching 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 fin the
holes of the dust cover before attaching the screws L.
(See Fig.9.)
(3) Release the lock of the connector CN962 on the main sub
board and disconnect the card wire. (See Fig.10.)
(4) Bend the joint gin the direction of the arrow. (See Fig.10.)
(5) Remove the two screws Mattaching 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 hin 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 Nattaching the support
bracket. (See Fig.11.)
• Remove the card wire from the connector CN401 as re-
quired. (See Fig.11.)
Fig.9
Fig.10
Fig.11
L
L
DVD mechanism assembly
Dust cover
f
f
Card wire
g
M
h
h
CN962
Lock
Main sub board
DVD mechanism assembly
Card wire
N
Support bracket
CN401

1-10 (No.MA149)
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 Pattaching 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 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.) Fig.12
Fig.13
Fig.14
P
P
Rear cover
Front panel assembly
P
i
i
Rear cover
ii
Switch board Front panel assembly
Compression spring
Compression spring

(No.MA149)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 on the
mechanism control board.
(3) Disconnect the card wire from connector CN201 on the
mechanism control board.
(4) Disconnect the flexible wire from connector CN202 on the
mechanism control board.
(5) Unsolder two soldered points aon the mechanism control
board and remove the wire extending from the feed motor.
(6) Remove the screw Aattaching the lug wire.
(7) Remove the two screws Band screw Cattaching the
mechanism control board.
Caution:
• As the flexible wire to be connected to CN101, make sure to
attach it to the mechanism control board using a double
tape.
• After reassembling, unsolder the short-circuit points.
Fig.1
Double tape
Feed motor
Mechanism control board
CN202
CN101
B
a
C
B
CN201
Flexible wire
Short-circuit points
A
Lug wire

1-12 (No.MA149)
3.2.2 Removing the top cover
(See Fig.2)
(1) Remove the two screws Dattaching the top cover on the
back of the body.
(2) 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 to 4)
• Remove the top cover.
(1) From the bottom of the body, remove the screw Eattaching
the lug wire. (See Fig.2.)
(2) Remove the two screws Fattaching 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 bot-
tom of the mechanism to the dampers.
• Before inserting the shaft to the dampers, apply IPA to the
hole of damper.
Fig.2
Fig.3
Fig.4
D
Top cover
Stopper
Stopper
F
F
b
cE
Lug wire
D
Floating spring
Mechanism section
Damper (R)
(Purple)
Damper (F)
(Black)
Damper (F)
(Black)
Chassis frame
Damper SP.(F)
(Silver)
Damper SP.(F)
(Silver)
Damper SP.(R)
(Red)

(No.MA149)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 dof 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 eand 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 eand 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 dof 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.)
Fig.5
Fig.6
Fig.7
Clamper unit
Clamper spring
Clamper2 spring
g
f
e
Chassis base assembly
Clamper2 spring
Chassis base assembly
Clamper spring
Chassis base assembly
d

1-14 (No.MA149)
Fig.8
Fig.9
Clamper unit
Clamper spring
Notch
g
Clamper unit

(No.MA149)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 Gattaching 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 iand jon the right side of the chassis
base assembly. Then remove the front unit upward. (See
Figs.11 and 12.)
(4) Remove the two screws Hattaching 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.)
Fig.10
Fig.11
Fig.12
Mechanism control board
Flexible wire
CN202
Double tape
G
Front unit
h
h
Front unit
Switch board
j
G
H
i
Double tape

1-16 (No.MA149)
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 kand m of the chassis base assem-
bly.
(2) Release the boss from notch nof the connect arm on the
right side of the body, and release the boss from notch pof
the slide cam assembly on the left side.
Fig.13
Fig.14
kn
m
Loading arm assembly
k
n
m
Loading arm assembly
p
Side cam
assembly
Connect arm

(No.MA149)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 qat 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 assem-
bly, 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 as-
sembly, engage each joint as shown in Fig.15. As joints qof
the rod (L), let the rod through qbefore reattaching it.
Fig.15
Fig.16
q
q
qq
q
q
Rod(R)
Loading arm assembly
Rod(L)
Collar Collar
Rod(R) Rod(L)
Roller assembly
Washer
Collar
Collar
Rod(L)
Loading arm assembly
Rod(R)

1-18 (No.MA149)
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 Jattaching 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 reas-
sembling, 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
sof 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 Kattaching 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.
Fig.17
Fig.18
Fig.19
J
Feed gear
Thrust spring
DVD Pickup assembly
r
s
L.S.collar
Rod(M)
L.S.gear
Lead screw
Sub shaft
DVD Pickup assembly
K
Rack spring
Rack plate
L.S.collar
DVD Pickup
Lead screw

(No.MA149)1-19
3.2.10 Removing the spindle motor
(See Fig.20)
• Remove the mechanism control board.
Remove the two screws Lattaching the spindle motor on the
bottom of the body.
Caution:
Perform adjustment when reattaching the spindle motor.
Fig.20
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 Mattaching 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 Nattaching the feed motor. (See
Fig.22.)
Fig.21
Fig.22
L
Spindle motor
M
Feed motor assembly
Feed TRI. spring
Feed moto
r
Motor H. assembly
Worm wheel
Slit washer
N

1-20 (No.MA149)
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
4.2 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 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.
Power supply voltage DC14.4V(11 to 16V)
Load impedance 4Ω(2 Speakers connection)
Line Output 20KΩ
Main board
Extension cable
EXTDV002-30P
Extension studs
STDV001-3P
Extension stud
STDV001-3P
Heat sink Rear bracket