Sharp XL-G5000DVD User manual

XL-G5000DVD/XL-G5000DVD(S)
SERVICE MANUAL
No. XXXXXXXXXXXXX
DVD MICRO SYSTEM
XL-G5000DVD
XL-G5000DVD(S)
MODEL
SHARP CORPORATION This document has been published to be used
for after sales service only.
The contents are subject to change without notice.
CHAPTER 1. GENERAL DESCRIPTION
[1] SPECIFICATIONS.........................................1-1
[2] NAMES OF PARTS.......................................1-2
CHAPTER 2. ADJUSTMENTS
[1] ADJUSTMENT...............................................2-1
[2] TEST MODE .................................................2-3
[3] Standard Specification of Stereo System
Error Message Display Contents..................2-10
CHAPTER 3. MECHANICAL DESCRIPTION
[1] REMOVING AND REINSTALLING THE
MAIN PARTS..................................................3-1
[2] DISASSEMBLY..............................................3-3
CHAPTER 4. DIAGRAMS
[1] BLOCK DIAGRAM .........................................4-1
CHAPTER 5. CIRCUIT DESCRIPTION
[1] WAVEFORMS OF DVD CIRCUIT..................5-1
[2] VOLTAGE.......................................................5-2
CHAPTER 6. CIRCUIT SCHEMATICS AND PARTS
LAYOUT
[1] NOTES ON SCHEMATIC DIAGRAM............6-1
[2] TYPES OF TRANSISTOR AND LED............6-1
[3] WIRING SIDE OF PWB/SCHEMATIC
DIAGRAM......................................................6-2
CHAPTER 7. FLOWCHART
[1] TROUBLESHOOTING ..................................7-1
CHAPTER 8. OTHERS
[1] FUNCTION TABLE OF IC.............................8-1
[2] FL DISPLAY ..................................................8-8
CHAPTER 9. ACTIVE SUBWOOFER DIAGRAM
[1] BLOCK DIAGRAM ........................................9-1
[2] WIRING SIDE OF PWB/SCHEMATIC
DIAGRAM......................................................9-3
Parts Guide
XL-G5000DVD DVD Micro System consisting of XL-G5000DVD
(Main Unit) and CP-G5000 (Front Speaker).
XL-G5000DVD(S) DVD Micro System consisting of XL-G5000DVD(S)
(Main Unit) and CP-G5000(S) (Front Speaker).
•
In the interests of user-safety the set should be restored to its original condition and only parts identical to those specified be used.
XL-G5000DVD(S) is silver color of XL-G5000DVD
XL-G5000DVD
and
XL-G5000DVD(S)
NTSC/PAL
SPEAKER SYSTEM
CP-G5000
CP-G5000(S)
MODEL
CP-G5000 Speaker System consisting of CP-SW5000 (Active
Subwoofer) and GBOXSA052AWM1 (Surround Speaker).
CP-G5000(S) Speaker System consisting of CP-SW5000(S) (Active
Subwoofer) and GBOXSA066AWM1 (Surround Speaker).
CONTENTS

XL-G5000DVD/XL-G5000DVD(S)
– i –
SAFETY PRECAUTION FOR SERVICE MANUAL
Precaution to be taken when replacing and servicing the Laser Pickup.
The AEL (Accessible Emission Level) of Laser Power Output for this model is specified to be lower than Class 1 Requirements.
However, the following precautions must be observed during servicing to protect your eyes against exposure to the Laser beam.
1. When the cabinet has been removed, the power is turned on without a compact disc, and the Pickup is on a position outer than the
lead-in position, the Laser will light for several seconds to detect a disc. Do not look into the Pickup Lens.
2. The Laser Power Output of the Pickup inside the unit and replacement service parts have already been adjusted prior to shipping.
3. No adjustment to the Laser Power should be attempted when replacing or servicing the Pickup.
4. Under no circumstances look directly into the Pickup Lens at any time.
5. CAUTION - Use of controls or adjustments, or performance of procedures other than those specified herein may result in
hazardous radiation exposure.
VOLTAGE SELECTION
Before operating the unit on mains, check the preset voltage. If the voltage is different from your local voltage, adjust the voltage
as follows.
Turn the selector with a screwdriver until the appropriate voltage number appears in the window (110V,127V,220V or 230V -
240V AC).
AC POWER SUPPLY CORD AND AC PLUG ADAPTOR
QACCE0015AW00
QACCA0008AW00
QPLGA0003AWZZ QPLGA0004AWZZ

XL-G5000DVD/XL-G5000DVD(S)
– ii –
AudioXL-HP404VService ManualXLHP404VMarketE
PRECAUTIONS FOR USING LEAD-FREE SOLDER
1. Employing lead-free solder
"VCD PWB" of this model employs lead-free solder. The LF symbol indicates lead-free solder, and is attached on the PWB and
service manuals. The alphabetical character following LF shows the type of lead-free solder.
Example:
Indicates lead-free solder of tin, silver and copper.
2. Using lead-free wire solder
When fixing the PWB soldered with the lead-free solder, apply lead-free wire solder. Repairing with conventional lead wire solder
may cause damage or accident due to cracks.
As the melting point of lead-free solder (Sn-Ag-Cu) is higher than the lead wire solder by 40 C, we recommend you to use a
dedicated soldering bit, if you are not familiar with how to obtain lead-free wire solder or soldering bit, contact our service station
or service branch in your area.
3. Soldering
As the melting point of lead-free solder (Sn-Ag-Cu) is about 220 C which is higher than the conventional lead solder by 40 C,
and as it has poor solder wettability, you may be apt to keep the soldering bit in contact with the PWB for extended period of
time. However, Since the land may be peeled off or the maximum heat-resistance temperature of parts may be exceeded,
remove the bit from the PWB as soon as you confirm the steady soldering condition.
Lead-free solder contains more tin, and the end of the soldering bit may be easily corrected. Make sure to turn on and off the
power of the bit as required.
If a different type of solder stays on the tip of the soldering bit, it is alloyed with lead-free solder. Clean the bit after every use
of it.
When the tip of the soldering bit is blackened during use, file it with steel wool or fine sandpaper.
Be careful when replacing parts with polarity indication on the PWB silk.
Lead-free wire solder for servicing
Ref No. DescriptionParts No.
PWB-D 92LPWB5619VCDS VCD

XL-G5000DVD/XL-G5000DVD(S)
1 – 1
AudioXL-DV555WService ManualXLDV555WMarketE
CHAPTER 1. GENERAL DESCRIPTION
[1] SPECIFICATIONS
FOR A COMPLETE DESCRIPTION OF THE OPERATION OF THIS UNIT, PLEASE REFER
TO THE OPERATION MANUAL
■ Cassette deck
Frequency response 50 - 14,000 Hz (normal tape)
Signal/noise ratio 50 dB (recording/playback)
Wow and flutter 0.3 % (WRMS)
■ DVD/VCD/CD player
Signal system NTSC/PAL
Supported disc types DVD, audio CD, CD-R, CD-RW, VCD, MP3/
WMA
Video output Output socket: Pin socket x 1
Output level: 1 Vp-p (75 ohms)
S-video output Y output level: 1 Vp-p (75 ohms)
C output level: 0.628 Vp-p (75 ohms)
Output socket: S-video connector x 1
Video signal Horizontal resolution: 500 lines
S/N ratio: 60 dB
Audio signal Frequency characteristics:
Linear PCM DVD:
4 Hz to 22 kHz (48 kHz sampling)
4 Hz to 44 kHz (96 kHz sampling)
CD: 4 Hz to 20 kHz
S/N ratio: 96 dB, 1 kHz (CD)
Dynamic range:
96 dB (Linear PCM DVD)
96 dB (CD)
Total harmonic distortion ratio:
0.006 % maximum
■
Tuner
Frequency range FM: 88.0 - 108.0 MHz
AM: 531 - 1,602 kHz
Type 2-way type speaker system
5 cm (2") tweeter
13 cm (5-1/8") woofer
Maximum input power 130 W
Rated input power 65 W
Impedance 8 ohms
Dimensions
Weight 3.0 kg (6.6 lbs.)/each
■ General
XL-G5000DVD
CP-G5000 (Front Speaker)
GBOXSA052AWM1 (Surround Speaker)
CP-SW5000 (Subwoofer)
Power source AC 110/127/220/230 - 240 V, 50/60Hz
Power consumption 90 W
Dimensions Width : 185 mm (7-1/4")
Height : 260 mm (10-1/4")
Depth : 307 mm (12")
Width : 165 mm (6-1/2")
Height : 260 mm (10-1/4")
Depth : 231mm (9-15/16")
Type
Maximum input power 70 W
Rated input power 35 W
Impedance 16 ohms
Dimensions
Weight 2.5 kg (5.5 lbs.)/each
Width : 120 mm (4-3/4")
Height : 260 mm (10-1/4")
Depth : 227mm (8-15/16")
Width : 320 mm (12-5/8")
Height : 260 mm (10-1/4")
Depth : 394mm (15-1/2")
Weight 7.1 kg (15.6 lbs.)
■ Amplifier
Output power Front speakers:
MPO: 256 W (128 W + 128 W) (10% T.H.D.)
RMS: 130 W (65 W + 65 W) (10% T.H.D.)
RMS: 122 W (81 W +81 W) (1% T.H.D.)
Specifications for this model are subject to change without prior notice.
MPO: 340 W (170W+170W)(10%T.H.D.)
RMS: 200 W (100 W + 100 W) (10% T.H.D.)
RMS: 140 W (70 W +70 W) (1% T.H.D.)
Full-range speaker system
8 cm (3 1/8") woofer (x2)
Output terminals
Input terminals
Power source AC 110/127/220/230 - 240 V, 50/60 Hz
Power consumption 90 W
Output power
Input terminals Subwoofer input (audio signal):
200 mV / 10 k ohms at 70 Hz
Speaker type 20 cm (7-7/8") woofer
Impedance 6 ohms
Dimensions
Weight 11.8 kg (26.0 lbs.)
Surround speakers:
MPO:128 W (64 W + 64 W) (10% T.H.D.)
RMS: 70 W (35 W + 35 W) (10% T.H.D.)
RMS: 60 W (30 W +30 W) (1% T.H.D.)
Speakers: 6 ohms
Headphones: 16 - 50 ohms (recommended:
32 ohms)
Subwoofer pre-output (audio signal):
200 mV/10 k ohms at 70 Hz
Video/auxiliary (audio input): 500 mV/47 k ohms
Microphone 1/2: 1 mV/600 ohms

XL-G5000DVD/XL-G5000DVD(S)
1 – 2
[2] NAMES OF PARTS
■ Front panel
1. Disc Trays
2. Illumination Light
3. Timer Set Indicator
4. On/Stand-by Button
5. Clock/Timer Button
6.
DVD/Video CD/CD/MP3/WMA Track Down or Fast Reverse, Tape
Fast Wind, Tuner Preset Down, Time Down Button
7. Tape Reverse Play Button
8. Tape Reverse Mode Select Button
9. Cassette Compartment
10. Headphone Socket
11. Disc Tray Open/Close Button
12. Disc Number Select Buttons
13.
DVD/Video CD/CD/MP3/WMA Direct Play Button
14. Volume Control
15.
DVD/Video CD/CD/MP3/WMA Track Up or Fast Forward,
Tape Fast Wind, Tuner Preset Up, Time Up Button
16. Memory/Set Button
17. Equalizer Mode Select Button
18. Extra Bass/Demo Mode Button
19.
DVD/Video CD/CD/MP3/WMA Play, Tape Forward Play Button
20.
DVD/Video CD/CD/MP3/WMA or Tape Stop Button
21.
DVD/Video CD/CD/MP3/WMA Button
22. Tuner (Band) Button
23. Tape Button
24. Video/Auxiliary Button
25. Tape Record Pause Button
26. Tuning Up Button
27. Tuning Down Button
28.
Mic Level
29. Mic 1 Socket
30. Mic 2 Socket
XL-G5000DVD
■ Display
1. Disc Number Indicators
2. DVD/Video CD/CD/MP3/WMA Play Indicator
3. DVD/Video CD/CD/MP3/WMA Pause Indicator
4. DVD/Video CD/CD/MP3/WMA Repeat Indicator
5. DVD Indicator
6. VCD Indicator
7. CD Indicator
8. MP3 Indicator
9. Extra Bass Indicator
10. Memory Indicator
11. DVD Angle Indicator
12. DVD Chapter Indicator
13. DVD Title Indicator
14. WMA Indicator
15. Virtual Surround Indicator
16. Tape Record Indicator
17. Timer Recording Indicator
18. Timer Play Indicator
19. Sleep Indicator
20. Tape Reverse Play Indicator
21. Tape Forward Play Indicator
22. Tape Reverse Mode Indicator
23. FM Stereo Mode Indicator
24. FM Stereo Receiving Indicator
25. Daily Timer Indicator
26. Tuner Receiving Frequency Indicators
27. Karaoke Mode Indicator

XL-G5000DVD/XL-G5000DVD(S)
1 – 3
■ Rear panel
1. Video Output Socket
2. S-Video Output Socket
3. Cooling Fan
4. AC Voltage Selector
5. Front Speaker Terminals
6. AC Power Lead
7. Audio Digital Out Socket
8. FM 75 Ohms Aerial Terminal
9. FM Aerial Earth Terminal
10. AM Loop Aerial Socket
11. Video/Auxiliary (Audio Signal) Input Sockets
12. Span Selector Switch
13. Subwoofer Pre-output Socket
14. Surround Speaker Terminals
OUT
S-VIDEO
OUT
DVD/CD
AUDIO
DIGITAL
OUT
FM
75 OHMS GND
RIGHT
LOOP
VIDEO/AUX
LEFT
50/9
100/10
FM/AM(kHz)
SPAN
SELECTOR
SUB WOOFER
PRE-OUT
LEFTLEFT RIGHTRIGHT
RATED SPEAKER IMPEDANCE :
8 OHMS MIN 16 OHMS MIN
SPEAKER
AC INPUT
RATED LINE
VOLTAGE
FRONT
SURROUND
Cooling fan:
This product is equipped with a cooling fan inside, which begins to run at a
specified volume level for better heat radiation.
VIDEO
OUT
S-VIDEO
OUT
DVD/CD
AUDIO
DIGITAL
OUT
ANTENA
FM
75 OHMS GND
RIGHT
AM
LOOP
VIDEO/AUX
LEFT
50/9
100/10
FM/AM(kHz)
SPAN
SELECTOR
SUB WOOFER
PRE-OUT
LEFTLEFT RIGHTRIGHT
RA TED SPEAKER IMPEDANCE :
8OHMSMIN 16OHMSMIN
SPEAKER
AC INPUT
RATED LINE
VOL
T AGE
FRONT
SURROUND
1
2
33
4
5
6
14
7
8
9
10
11
12
13
XL-G5000DVD
Active Subwoofer
1. Bass Reflex Duct
2. Subwoofer Unit
3. Speaker light up dimmer switch
4. Power Switch
5. Volume Control
6. Crossover Frequency Control
7. Cooling Fan
8. AC Power Lead
9. AC Voltage Selector
10. Subwoofer Input Socket
■ Front Speaker
1. Woofer
2. Tweeter
3. Bass Reflex Duct
Surround Speaker
1. Full-range Speaker
3
1
1
2
5
6
3
9
10 4
8
7
2
1
■
■
Cooling fan:
This product is equipped with a cooling
fan inside, which begins to run once the
power is on for better heat radiation.

XL-G5000DVD/XL-G5000DVD(S)
1 – 4
1
2
20
21
22
23
24
25
26
27
28
3
4
5
6
7
8
9
10
18
19
11
15 33 34 35 36
37 38 39 40
29 30 31 32
16 17
12 13 14
■ Remote control
1. Remote Control Transmitter
2. Disc Number Select Buttons
3. DVD Top Menu Button
4. Clock/Timer Button
5. Direct Search Button
6. Clear/Display Button
7. Enter Button
8. Cursor Left Button
9. Memory/Dimmer Button
10. Cursor Down Button
11. Tape Record Pause Button
12.
DVD Chapter Skip/DVD/Video CD/MP3/ WMA Fast Reverse/Video CD /
CD/MP3/WMA track down/Tape Fast Wind and Tuner Preset Down,
Time Down
13. DVD/Video CD/CD/MP3/WMA Pause Button
14.
DVD Chapter Skip/DVD/Video CD/MP3/WMA Fast Forward/Video CD/
CD/MP3/WMA track up/Tape Fast Wind and Tuner Preset Up,
Time Up
15. Tape Reverse Play Button
16. DVD/Video CD/CD/MP3/WMA/Tape Stop Button
17. DVD/Video CD/CD/MP3/WMA/Tape Play Button
18. Shift Button
19. Volume Up or Down Button
20. On/Stand-by Button
21. Echo Level Up/Down Button
22. DVD Direct Button
23. DVD Menu Button
24. Return Button
25. CD Random Button
26. Cursor Up Button
27. Cursor Right Button
28. DVD/Video CD Slow Button
29. DVD/Video CD/CD/MP3/WMA Repeat Button
30. DVD Subtitle Button
31. DVD Angle Button
32. DVD Zoom Button
33. DVD/Video CD/CD/MP3/WMA Button
34. Tuner (Band) Button
35. Tape Button
36. Video Button
37. Equalizer Mode Select Button
38. Extra Bass Button
39. DVD 3-D Virtual Surround Button
40. DVD On Screen Button
XL-G5000DVD
1
2
3
4
5
6
■ Remote control with shift button
1. Karaoke/Audio Mode Button
2. DVD Setup Button
3. DVD Sound Button
4. DVD Super Picture Button
5. DVD/Video CD/CD A-B Repeat Button
6. DVD Digital Gamma Button

XL-G5000DVD/XL5000DVD(S)
2 – 1
CHAPTER 2. ADJUSTMENTS
[1] ADJUSTMENT
1. MECHANISM SECTION
•Driving Force Check
•Torque Check
2. TUNER SECTION
fL: Low-range frequency
fH: High-range frequency
•AM IF/RF
Signal generator: 400 Hz, 30%, AM modulated
•FM RF
Signal generator: 1 kHz, 40 kHz dev., FM modulated
•FM IF
Signal generator: 10.7MHz FM modulated
•Tape Speed
Torque Meter Specified Value
Play: TW-2111 Over 80 g
Torque Meter Specified Value
Play: TW-2111 30 to 80 g.cm
Fast forward: TW-2231 70 to 180 g.cm
Rewind: TW-2231 70 to 180 g.cm
Test Stage Frequency Frequency
Display Setting/ Adjusting
Parts
Instrument
Connection
AM IF 450 kHz 1,602 kHz T351 *1
AM Band
Coverage — 531 kHz (fL): T306 1.1 ± 0.1 V *2
AM Tracking 990 kHz 990 kHz (fL): T303 *1
*1. Input: Antenna Output: TP302
*2. Input: Antenna Output: TP301
Test Stage Frequency Frequency
Display Setting/ Adjusting
Point
Instrument
Connection
FM OSC — 87.50 kHz T301 (fL):
1.3 ± 0.1 V *1
FM RF 98.00 MHz
(10-30 dB) 98.00 MHz L312 *2
*1. Input: Antenna Output: TP301
*2. Input: Antenna Output: Speaker terminal
Test Stage Frequency Frequency
Display Setting/ Adjusting
Point
Instrument
Connection
IF 10.7 MHz 98 MHz T302
(Turn the
core of trans-
former T302
fully counter-
clock wise)
*1
*1. Input: Antenna Output: TP301
Test Tape Adjusting
Point Specified Value Instrument Connection
Normal
speed MTT-111 Variable Resistor in
motor.
3,000 ± 30 Hz Speaker Ter-
minal (Load
resistance: 6
ohms)
Figure 1
Figure 2 ADJUSTMENT POINTS
TAPE MECHANISM
Tape
Motor
Variable Resistor in motor
AM
LOOP
ANTENNA
IC302
T351
T301
IC303
T303
T306
T302
L312
CNP301
SO302
IC301
TP302
TP301
AM TRACKING fL
AM BAND
COVERAGE fL
AM IF
FM RF
FM IF
FM OSC
FM ANTENNA
TERMINAL
TUNER PWB-C
20
R356
C393

XL-G5000DVD/XL5000DVD(S)
2 – 2
3. DVD SECTION
•Adjustment
Since this DVD system incorporates the following automatic adjust-
ment functions, readjustment is not needed when replacing the
pickup. Therefore, different PWBs and pickups can be combined
freely.
Each time a disc is changed, these adjustments are performed
automatically. Therefore, playback of each disc can be performed
under optimum conditions.
Items adjusted automatically
1) Offset adjustment (The offset voltage between the head amplifier
output and the VREF reference voltage is compensated inside the
IC.)
* Focus offset adjustment
* Tracking offset adjustment
2) Tracking balance adjustment
3) Gain adjustment (The gain is compensated inside the IC so that the
loop gain at the gain crossover frequency will be 0 dB.)
* Focus gain adjustment
* Tracking gain adjustment
4. DVD ERROR CODE DESCRIPTION
* 'CHECKING'
If Error is detected, 'CHECKING' will be displayed instead of 'ER-
CD**'. 'ER-CD**' display will only be displayed when error had been
detected for the 5th times.
Error Explanation
10* CAM error. Can't detect CAM switch when CAM is moving.
11* When it detect cam operation error during initialize process.
20* TRAY error. Can't detect TRAY switch when TRAY is mov-
ing.
21* When it detect TRAY operation error during initialize pro-
cess.
30 When it change to DVD function, DVD cannot start up.

XL-G5000DVD/XL5000DVD(S)
2 – 3
[2] TEST MODE
1. TEST Mode Functions
1.1. Entering the TEST Mode
While holding down both the button and the X-Bass button ofthe
main unit from the power-off state, press the ON/STAND-BY button
toenter the Test Menu Mode.
1.2. Test mode processing
When entering the TEST Mode, the ROM version are displayed as fol-
lows
Version on the FL display: “UD. ****” (****: Version No.)
1.3. TEST Mode Button
Press direct designation button during the version display to enter the
specified TEST Modes as shown below.
1.4. Canceling TEST Mode
1. Press the ON/STAND-BY button in each TEST Mode to display
“CLEAR AL” except SHIPPING TEST. Then reset and start. (Clear
RAM.)
2. It is necessary to plug,off the A/C cord after “FINISHED” is dis-
played on the FL for SHIPPING TEST.
2. Shipping TEST Mode
2.1. Outline
• ID command for initialization is sent to the DVD unit and EEPROM
in the unit is initialized.
• System micro computer and DVD changer is initialized.
2.2. TEST Mode Operation
When entering the Shipping TEST Mode:
1. “WAIT” is displayed on the FL display .
2. “FINISHED” shall be kept displaying after initialization is com-
pleted.
Manually plug off the A/C cord to get out of the TEST Mode.
When initialization is failed, ”INIT ERR” remains to be shown on the
FL display until plug off the A/C cord.
2.3. Supplementary Note
1. When entering this TEST Mode, it is prohibited to press any key
until the above processing is completed.
3. DVD TEST Mode
3.1. Outline
• To send key codes of the TEST Mode 1 to the DVD unit to start the
TEST Mode.
• Thereafter the system’s microcomputer only sends key codes to
the DVD unit.
• The main unit operation is started in the same way as the normal
startup of the DVD/CD Function.
• Only monitor (video) output is normally controlled. “MUTE ON”
remained.
• During this TEST Mode, “DVD TEST” is shown on the FL display
and change to “DVD****”. (****:DVD Version)
(Display is shown by OSD. Main unit display not available.)
3.2. TEST Mode Operation
1. The TEST Mode is started in the same way as the normal startup of
the DVD/CD Function. Then the DVD unit is normally started. Dur-
ing the TEST Mode, “DVD****” is continuously displayed.
No. TEST Mode Direct Designation Button
1 SHIPPING TEST OPEN/CLOSE
2 DVD TEST DVD/CD
3 DVD DISPLAY TEST DISC2