Pioneer AVH-P5900DVD/XN/UC User manual

ORDER NO.
PIONEER CORPORATION 4-1, Meguro 1-chome, Meguro-ku, Tokyo 153-8654, Japan
PIONEER ELECTRONICS (USA) INC. P.O. Box 1760, Long Beach, CA 90801-1760, U.S.A.
PIONEER EUROPE NV Haven 1087, Keetberglaan 1, 9120 Melsele, Belgium
PIONEER ELECTRONICS ASIACENTRE PTE. LTD. 253 Alexandra Road, #04-01, Singapore 159936
PIONEER CORPORATION 2007
AVH-P5900DVD/XN/UC
CRT3915
DVD AV RECEIVER
AVH-P5900DVD /XN/UC
DVD RDS AV RECEIVER
AVH-P5900DVD /XNEW5
AVH-P5900DVD /XN/RE
This service manual should be used together with the following manual(s):
Model No. Order No. Mech.Module Remarks
CX-3212 CRT3896 MS5 DVD Mech. Module : Circuit Descriptions, Mech. Descriptions, Disassembly
For details, refer to "Important Check Points for Good Servicing".
K-ZZU. MAY 2007 Printed in Japan
"DTS" and "DTS Digital Surround" are registered trademarks of Digital Theater Systems,Inc.
Dolby noise reduction manufactured under license from Dolby Laboratories Licensing Corporation.
"Dolby" and the double-D symbol are trademarks of Dolby Laboratories Licensing Corporation.

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SAFETY INFORMATION
CAUTION
This service manual is intended for qualified service technicians; it is not meant for the casual do-it-yourselfer.
Qualified technicians have the necessary test equipment and tools, and have been trained to properly and safely repair
complex products such as those covered by this manual.
Improperly performed repairs can adversely affect the safety and reliability of the product and may void the warranty.
If you are not qualified to perform the repair of this product properly and safely, you should not risk trying to do so
and refer the repair to a qualified service technician.
1. Safety Precautions for those who Service this Unit.
Follow the adjustment steps in the service manual when servicing this unit.When check -
ing or adjusting the emitting power of the laser diode exercise caution in order to get safe, reliable results.
Caution:
1. During repair or tests, minimum distance of 13 cm from the focus lens must be kept.
2. During repair or tests, do not view laser beam for 10 seconds or longer .
2. The triangular label is attached to the mechanism
unit frame.
On the top of the player.
The backlighting lamp of LCD in this equipment contains mercury. Disposal of this material may be
regulated due to environmental considerations according to Local, State or Federal Laws. For disposal
or recycling information, please contact your local authorities or the Electronics Industries
Alliance: www.eiae.org
This product contains mercury. Disposal of this material may be regulated due to environmental considerations.
For disposal or recycling information, please contact your local authorities or the Electronics Industries
Alliance: www.eiae.org.
WARNING
This product contains lead in solder and certain electrical parts contain chemicals which are known to the state of
California to cause cancer, birth defects or other reproductive harm.
Health & Safety Code Section 25249.6 - Proposition 65

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CAUTION
Danger of explosion if battery is incorrectly replaced.
Replaced only with the same or equivalent type recommended by the manufacture.
Discord used batteries according to the manufacture's instructions.
WARNING!
The AEL (accessible emission level )of the laser power output is less than CLASS 1
but the laser component is capable of emitting radiation exceeding the limit for
CLASS 1.
A specially instructed person should do servicing operation of the apparatus.
Laser diode characteristics
Wave length:
DVD:640 nm to 660 nm
CD:770 nm to 810 nm
DVD : 2.48 mW(Emitting period :9 sec.)
CD : 705 W(Emitting period : unlimited)
Additional Laser Caution
Transistors Q1101 and Q1102 in PCB drive the laser diodes for DVD and CD
respectively. When Q1101 or Q1102 is shorted between their terminals,
the laser diodes for DVD or CD will radiate beam. If the top cover is removed
with no disc loaded while such short-circuit is continued, the naked eyes may
be exposed to the laser beam.

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[Important Check Points for Good Servicing]
In this manual, procedures that must be performed during repairs are marked with the below symbol.
Please be sure to confirm and follow these procedures.
1. Product safety
Please conform to product regulations (such as safety and radiation regulations), and maintain a safe servicing environment by
following the safety instructions described in this manual.
1Use specified parts for repair.
Use genuine parts. Be sure to use important parts for safety.
2Do not perform modifications without proper instructions.
Please follow the specified safety methods when modification(addition/change of parts) is required due to interferences such as
radio/TV interference and foreign noise.
3Make sure the soldering of repaired locations is properly performed.
When you solder while repairing, please be sure that there are no cold solder and other debris.
Soldering should be finished with the proper quantity. (Refer to the example)
4Make sure the screws are tightly fastened.
Please be sure that all screws are fastened, and that there are no loose screws.
5Make sure each connectors are correctly inserted.
Please be sure that all connectors are inserted, and that there are no imperfect insertion.
6Make sure the wiring cables are set to their original state.
Please replace the wiring and cables to the original state after repairs.
In addition, be sure that there are no pinched wires, etc.
7Make sure screws and soldering scraps do not remain inside the product.
Please check that neither solder debris nor screws remain inside the product.
8There should be no semi-broken wires, scratches, melting, etc. on the coating of the power cord.
Damaged power cords may lead to fire accidents, so please be sure that there are no damages.
If you find a damaged power cord, please exchange it with a suitable one.
9There should be no spark traces or similar marks on the power plug.
When spark traces or similar marks are found on the power supply plug, please check the connection and advise on secure
connections and suitable usage. Please exchange the power cord if necessary.
aSafe environment should be secured during servicing.
When you perform repairs, please pay attention to static electricity, furniture, household articles, etc. in order to prevent injuries.
Please pay attention to your surroundings and repair safely.
2. Adjustments
To keep the original performance of the products, optimum adjustments and confirmation of characteristics within specification.
Adjustments should be performed in accordance with the procedures/instructions described in this manual.
4. Cleaning
For parts that require cleaning, such as optical pickups, tape deck heads, lenses and mirrors used in projection monitors, proper
cleaning should be performed to restore their performances.
3. Lubricants, Glues, and Replacement parts
Use grease and adhesives that are equal to the specified substance.
Make sure the proper amount is applied.
5. Shipping mode and Shipping screws
To protect products from damages or failures during transit, the shipping mode should be set or the shipping screws should be
installed before shipment. Please be sure to follow this method especially if it is specified in this manual.

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CONTENTS
SAFETY INFORMATION .....................................................................................................................................2
1. SERVICE PRECAUTIONS................................................................................................................................6
2. SPECIFICATIONS.............................................................................................................................................8
2.1 SPECIFICATIONS ......................................................................................................................................8
2.2 DISC/CONTENT FORMAT....................................................................................................................... 11
2.3 PANEL FACILITIES ..................................................................................................................................12
2.4 CONNECTION DIAGRAM........................................................................................................................14
3. BASIC ITEMS FOR SERVICE ........................................................................................................................15
3.1 CHECK POINTS AFTER SERVICING .....................................................................................................15
3.2 PCB LOCATIONS.....................................................................................................................................16
3.3 JIG CONNECTION DIAGRAM .................................................................................................................17
4. BLOCK DIAGRAM ..........................................................................................................................................20
5. DIAGNOSIS ....................................................................................................................................................33
5.1 OPERATIONAL FLOW CHART................................................................................................................33
5.2 CONNECTOR FUNCTION DESCRIPTION .............................................................................................34
5.3 BACK END SECTION FLOW...................................................................................................................35
6. SERVICE MODE.............................................................................................................................................57
6.1 DVD TEST MODE ....................................................................................................................................57
7. DISASSEMBLY ...............................................................................................................................................61
8. EACH SETTING AND ADJUSTMENT............................................................................................................68
8.1 DVD ADJUSTMENT .................................................................................................................................68
8.2 VIDEO LEVEL ADJUSTMENT .................................................................................................................73
8.3 MOTHER UNIT ADJUSTMENT................................................................................................................75
8.4 INVERTER ADJUSTMENT ......................................................................................................................77
8.5 MONITOR ADJUSTMENT........................................................................................................................79
8.6 MONITOR TEST MODE...........................................................................................................................85
8.7 CALIBRATION TEST................................................................................................................................91
9. EXPLODED VIEWS AND PARTS LIST ........................................................................................................100
9.1 PACKING................................................................................................................................................100
9.2 EXTERIOR(1) .........................................................................................................................................104
9.3 EXTERIOR(2) .........................................................................................................................................106
9.4 EXTERIOR(3) ......................................................................................................................................... 110
9.5 EXTERIOR(4) ......................................................................................................................................... 112
9.6 DVD MECHANISM MODULE................................................................................................................. 114
10. SCHEMATIC DIAGRAM.............................................................................................................................. 116
10.1 MOTHER UNIT(SYSTEM PART)(GUIDE PAGE)................................................................................. 116
10.2 MOTHER UNIT(POWER SUPPLY PART)(GUIDE PAGE) ...................................................................122
10.3 KEYBOARD UNIT ................................................................................................................................128
10.4 MONITOR PCB(MONITOR PART)(GUIDE PAGE) ..............................................................................130
10.5 MONITOR PCB(OSD & µCON PART)(GUIDE PAGE).........................................................................136
10.6 DVD CORE UNIT(1/2)(GUIDE PAGE) .................................................................................................142
10.7 DVD CORE UNIT(2/2)..........................................................................................................................148
10.8 COMPOUND UNIT(A) AND COMPOUND UNIT(B) .............................................................................150
10.9 RCA PCB..............................................................................................................................................151
10.10 UPPER PCB.......................................................................................................................................152
10.11 OPT PCB ............................................................................................................................................153
10.12 MAIN PCB UNIT(SERVICE), SWITCH PCB UNIT AND VOLUME PCB UNIT ..................................154
10.13 WAVEFORMS.....................................................................................................................................156
11. PCB CONNECTION DIAGRAM ..................................................................................................................158
11.1 MOTHER UNIT .....................................................................................................................................158
11.2 KEYBOARD UNIT.................................................................................................................................162
11.3 MONITOR PCB.....................................................................................................................................164
11.4 DVD CORE UNIT..................................................................................................................................168
11.5 COMPOUND UNIT(A) AND COMPOUND UNIT(B) .............................................................................172
11.6 RCA PCB ..............................................................................................................................................173
11.7 UPPER PCB .........................................................................................................................................174
11.8 OPT PCB ..............................................................................................................................................175
11.9 MAIN PCB UNITSERVICE), SWITCH PCB UNIT AND VOLUME PCB UNIT......................................176
12. ELECTRICAL PARTS LIST.........................................................................................................................177

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1. SERVICE PRECAUTIONS
-Service Precautions
1) You should conform to the regulations governing the product (safety, radio and noise, and other regulations),
and should keep the safety during servicing by following the safety instructions described in this manual.
2) Be careful in handling ICs. Some ICs such as MOS type are so fragile that they can be damaged by electrostatic
induction.
3) Before disassembling the unit, be sure to turn off the power. Unplugging and plugging the connectors
during power-on mode may damage the ICs inside the unit.
4)To protect the pickup unit from electrostatic discharge during servicing, take an appropriate treatment
(shorting-solder) by referring to "the DISASSEMBLY" .
5) After replacing the pickup unit, be sure to skew adjustment.
6)During disassembly, be sure to turn the power off since an internal IC might be destroyed when a connector
is plugged or unplugged.
7) In case the internal fuse has blown, check the voltage of the rear stage.
8) Handling instructions for touch panel
Please handle the touch panel with care as it contains glass.
Dropping or giving a strong shock may break the panel.
Wear gloves, etc. to protect your hands from the glass edges that are not deburred.
9) Remove a small board (2 screws) provided for pulling out an RCA line, before removing the mother board.
10) Hot areas
Red area: Hot area. Be careful not to burn yourself
Red-circled area: The heat from hot parts on the B-side of the board is removed from the product bottom through a heat
transfer sheet.
Be careful not to burn yourself with the hot area.
Moter Unit(Side A)
Bottom
Moter Unit(Side B)
is a trademark of DVD Format/Logo Licensing Corporation.

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NOTES ON SOLDERING
For environmental protection, lead-free solder is used on the printed circuit boards mounted in this unit.
Be sure to use lead-free solder and a soldering iron that can meet specifications for use with lead-free solders for repairs
accompanied by reworking of soldering.
Compared with conventional eutectic solders, lead-free solders have higher melting points, by approximately 40 C.
Therefore, for lead-free soldering, the tip temperature of a soldering iron must be set to around 373 C in general, although
the temperature depends on the heat capacity of the PC board on which reworking is required and the weight of the tip of
the soldering iron.
Compared with eutectic solders, lead-free solders have higher bond strengths but slower wetting times and higher melting
temperatures (hard to melt/easy to harden).
The following lead-free solders are available as service parts:
Parts numbers of lead-free solder:
GYP1006 1.0 in dia.
GYP1007 0.6 in dia.
GYP1008 0.3 in dia.

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2. SPECIFICATIONS
2.1 SPECIFICATIONS
-AVH-P5900DVD/XN/UC

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-AVH-P5900DVD/XNEW5

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-AVH-P5900DVD/XN/RE

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2.2 DISC/CONTENT FORMAT

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2.3 PANEL FACILITIES

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JGZ20P070FTC

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2.4 CONNECTION DIAGRAM
-Connection Diagram

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3. BASIC ITEMS FOR SERVICE
3.1 CHECK POINTS AFTER SERVICING
CHECK POINTS AFTER SERVICING (AVH)
To keep the product quality after servicin
g
, please confirm followin
g
check points.
kcehCserudecorP.oN
p
krameRstnio
1 Confirm whether the customer complain has
been solved.
If the customer complain occurs with the
specific media, use it for the operation
check.
The customer complain must not be
reappeared.
Display, video, audio and operations must
be normal.
2 Flap-mecha Check the operation of the flap mechanism. The flap mechanism operation must be
smooth without making the noise and
When flap-mecha
exists
3 DVD Measure playback error rates at the
innermost and outermost tracks by using the
test mode with the following disc.
DVD test disc (GGV1025)
Deterioration of mecha-drive can be
checked.
The error rates must be less than 2.5e-4.
4 DVD Play back a DVD.
(
Menu o
p
eration
;
Title/cha
p
ter search
)
Display, video, audio and operations must
be normal.
5 CD Play back a CD.
(
Track search
)
Display, audio and operations must be
normal.
6 FM/AM tuner Check FM/AM tuner action.
(Seek, Preset)
S
witch band to check both FM and AM.
Display, audio and operations must be
normal.
7 TV tuner Check TV tuner action.
(
Seek
;
Preset
)
Display, video, audio and operations must
be normal.
8 Check whether no disc is inside the product. The media used for the operating check
must be e
j
ected.
retfaecnaraeppastinotridrosehctarcsoNkcehcecnaraeppA9
receivin
g
it for service.
See the table below for the items to be checked re
g
ardin
g
video and audio:
Item to be checked regarding video Item to be checked regarding audio
noitrotsiDesion-kcolB
esioNesionlatnoziroH
wolootemuloVesiontoD
Disturbed ima
g
e (video jumpiness) Volume too hi
g
h
nitautculfemuloVkradooT
g
Too bri
g
detpurretnidnuoSth
Mottled color
scratches.

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3.2 PCB LOCATIONS
Monitor PCB
Upper PCB
Keyboard Unit
Mother Unit
Main PCB Unit
(SERVICE)
H
DVD Core Unit
D
Compound Unit (A)
ECompound Unit (B)
F
C
B
K
J
A
L
OPT PCB
I
RCA PCB
G
Switch PCB Unit
Volume PCB Unit
Unit Number : CXC7508(UC)
Unit Number : CXC7506(EW5)
Unit Number : CXC7507(RE)
Unit Name : DVD Amp Assy
Unit Number : CWN2330
Unit Name : Monitor Unit
Unit Number : CXX2316
Unit Name : Main PCB Unit(SERVICE)
Unit Number : CZW5029
Unit Name : Switch PCB Unit
Unit Number : CZW5028
Unit Name : Volume PCB Unit
Monitor Unit
Consists of
Monitor PCB
Upper PCB
DVD Amp Assy
Consists of
Mother Unit
OPT PCB
RCA PCB
Unit Number : YWX5005
Unit Name : DVD Core Unit
Unit Number : CWX3154
Unit Name : Compound Unit(A)
Unit Number : CWX3394
Unit Name : Compound Unit(B)

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3.3 JIG CONNECTION DIAGRAM
40-Pin FFC BBR GGD1284 DVD Mechanism Module <--> DVD Amp Assy
33-Pin Relay PCB GGF1462 DVD Amp Assy <--> Monitor Unit
33-Pin FFC GGD1262 DVD Amp Assy <--> Monitor Unit
40-Pin + 20-Pin Relay PCB GGF1461 DVD Amp Assy <--> Main PCB Unit
20-Pin FFC GGD1209 DVD Amp Assy <--> Main PCB Unit
Disc GGV1018 Skew adjustment
TORX driver(T2) GGK1095 Skew adjustment
Bond GEM1033 Skew adjustment
Cord
CDE8384
Main PCB Unit
Monitor PCB Mother Unit
GGD1284
40-Pin FFC BBR
GGF1461
40-Pin + 20-Pin Relay PCB
GGF1462
33-Pin Relay PCB
GGD1262
33-Pin FFC
GGD1209
20-Pin FFC
DVD Mechanism Module
Bracket

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Before shipping out the product, be sure to clean the following portions by using the prescribed cleaning tools:
Portions to be cleaned Cleaning tools
DVD pickup lenses Cleaning liquid : GEM1004
Cleaning paper : GED-008
Portions to be cleaned Cleaning tools
Fans Cleaning paper : GED-008
-Grease List
CLEANING
Name
Grease
Grease
Grease
Grease
Locking agents
Grease
Grease
Grease
Grease
Jig No.
GEM1024
GEM1043
GEM1045
GEM1050
1401M
GEM1011
GEM1047
GEM1071
GEM1072
Remarks
DVD Mechanism Module and Chassis
DVD Mechanism Module and Chassis
DVD Mechanism Module
DVD Mechanism Module
DVD Mechanism Module (1401M:produced by THREE BOND)
Chassis
Chassis
Chassis
Chassis

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4. BLOCK DIAGRAM
1/2
A
2/2
A
A
MOTHER UNIT
B
KEYBOARD UNIT
J K L
DRIVE UNIT
SYSTEM PART
POWER SUPPLY PART
1/2
C
2/2
C
C
MONITOR PCB
H
UPPER PCB
MONITOR PART
OSD & CON PART
G
RCA PCB
I
OPT PCB
μ