PIONEER DV-59AVI/KUXJ/CA Service Manual

PIONEER DV-59AVI/KUXJ/CA Service Manual
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Service Manual for PIONEER DV-59AVI/KUXJ/CA, downloadable as a PDF file.

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Sample pages

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 2003

DV-59AVi

RRV2816

DVD PLAYER

DV-59AVi

DV-868AVi-S

DV-668AV-S

THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).

Model

Type

Power Requirement

Region No.

Serial No.

Confirm 3rd & 4th

alphabetical letters.

DV-59AVi

KUXJ/CA

AC120V

&&MP######$$

DV-868AVi-S

WYXJ

AC220-240V

&&MP######$$

DV-668AV-S

WYXJ

AC220-240V

&&MP######$$

For details, refer to "Important symbols for good services".

T-ZZE DEC. 2003 printed in Japan

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 2003

DV-59AVi

RRV2816

DVD PLAYER

DV-59AVi

DV-868AVi-S

DV-668AV-S

THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).

Model

Type

Power Requirement

Region No.

Serial No.

Confirm 3rd & 4th

alphabetical letters.

DV-59AVi

KUXJ/CA

AC120V

&&MP######$$

DV-868AVi-S

WYXJ

AC220-240V

&&MP######$$

DV-668AV-S

WYXJ

AC220-240V

&&MP######$$

For details, refer to "Important symbols for good services".

T-ZZE DEC. 2003 printed in Japan

DV-59AVi

1234

123

SAFETY INFORMATION

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.

WARNING

This product contains lead in solder and cer tain electrical par ts contain chemicals which are known to the state of California to

cause cancer, bir th defects or other reproductive harm.

Health & Safety Code Section 25249.6 Proposition 65

NOTICE

(FOR CANADIAN MODEL ONLY)

Fuse symbols

(fast operating fuse)

and/or

(slow operating fuse) on PCB indicate that replacement

parts must be of identical designation.

REMARQUE

(POUR MODÈLE CANADIEN SEULEMENT)

Les symboles de fusible

(fusible de type rapide)

et/ou

(fusible de type lent) sur CCI indiquent que

les pièces de remplacement doivent avoir la même désignation.

ANY MEASUREMENTS NOT WITHIN THE

LIMITS OUTLINED ABOVE ARE INDICATIVE

OF A POTENTIAL SHOCK HAZARD AND

MUST BE CORRECTED BEFORE RETURN-

ING THE APPLIANCE TO THE CUSTOMER.

2. PRODUCT SAFETY NOTICE

Many electrical and mechanical parts in the appliance

have special safety related character istics. These are

often not evident

from visual

inspection nor the

protection afforded by them necessarily can be obtained

by using replacement components rated for voltage,

wattage, etc. Replacement par ts which have these

special safety character istics are identified in this

Service Manual.

Electr ical components having such features are

identified by marking with a

on the schematics and

on the parts list in this Service Manual.

The use of a substitute replacement component which

does not have the same safety characteristics as the

PIONEER recommended replacement one, shown in the

parts list in this Service Manual, may create shock, fire,

or other hazards.

Product Safety is continuously under review and new

instructions are issued from time to time. For the latest

infor mation, always consult the current PIONEER

Service Manual. A subscription to, or

additional copies

of, PIONEER Ser vice Manual may be obtained at a

nominal charge from PIONEER.

(FOR USA MODEL ONLY)

1. SAFETY PRECAUTIONS

The following check should be perfor med for the

continued protection of the customer and ser vice

technician.

LEAKAGE CURRENT CHECK

Measure leakage current to a known ear th ground

(water pipe, conduit, etc.) by connecting a leakage

current tester such as Simpson Model 229-2 or

equivalent between the ear th ground and all exposed

metal par ts of the appliance (input/output ter minals,

screwheads, metal overlays, control shaft, etc.). Plug

the AC line cord of the appliance directly into a 120V

AC 60 Hz outlet and turn the AC power switch on. Any

current measured must not exceed 0.5 mA.

Device

under

test

Leakage

current

tester

Earth

ground

Reading should

not be above

0.5 mA

Also test with

plug reversed

(Using AC adapter

plug as required)

Test all

exposed metal

surfaces

AC Leakage Test

DV-59AVi

678

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

trainedto 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.

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

FOR DVD : MAXIMUM OUTPUT POWER : 5 mW

WAVELENGTH : 650 nm

FOR CD :

MAXIMUM OUTPUT POWER : 5 mW

WAVELENGTH : 780 nm

Additional Laser Caution

: See page 79.

LABEL CHECK [DV-868AVi-S and DV-668AV-S Only]

1. Loading-status detection switch (S101 on the LOAB assy) are detected

by the microprocessor (IC601 in the DVDM assy).

· To permit the laser diode to oscillate, it is required to set the loading-

status detection switch for the clamp position (the center terminal of

S101 is shorted to +3V).

When the voltage of IC101-pin 21 is +3V, IC601 (microprocessor)

-pin 83 is +3V and IC601-pin 84 is +3V, 650nm laser diode for DVD

oscillates in the DVDM Assy.

When the voltage of IC101-pin 21 is +3V, IC601 (microprocessor)

-pin 83 is 0V (GND) and IC601-pin 84 is +3V, 780nm laser diode for

CD oscillates in the DVDM Assy.

In the test mode * , the laser diode oscillates when microprocessor

detects a PLAY signal, or when the PLAY key is pressed (S104 ON in

the FLKY assy), with the above requirements satisfied.

2. When the cover is open, close viewing through the objective lens with

the naked eye will cause exposure to the laser beam.

Location: Printed on the Rear Panel

DV-59AVi

1234

123

[ Important symbols for good services ]

In this manual, the symbols shown-below indicate that adjustments, settings or cleaning should be made securely.

When you find the procedures bearing any of the symbols, be sure to fulfill them:

2. Adjustments

To keep the original performances of the product, optimum adjustments or specification confirmation is indispensable.

In accordance with the procedures or instructions described in this manual, adjustments should be performed.

3. Cleaning

For optical pickups, tape-deck heads, lenses and mirrors used in projection monitors, and other parts requiring cleaning,

proper cleaning should be performed to restore their performances.

5. Lubricants, glues, and replacement parts

Appropriately applying grease or glue can maintain the product performances. But improper lubrication or applying

glue may lead to failures or troubles in the product. By following the instructions in this manual, be sure to apply the

prescribed grease or glue to proper portions by the appropriate amount.For replacement parts or tools, the prescribed

ones should be used.

4. Shipping mode and shipping screws

To protect the product from damages or failures that may be caused during transit, the shipping mode should be set or

the shipping screws should be installed before shipping out in accordance with this manual, if necessary.

1. Product safety

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.

· Manufactured under license from Dolby

Laboratories. "Dolby" and the double-D symbol

are trademarks of Dolby Laboratories.

· "DTS" and "DTS Digital Out" are registered

trademarks of Digital Theater Systems, Inc.

· TruSurround and the

symbol are

trademarks of SRS Labs, Inc. TruSurround tech-

nology is incorporated under license from SRS

Labs, Inc.

DV-59AVi

678

CONTENTS

SAFETY INFORMATION......................................................................................................................................2

1. SPECIFICATIONS .............................................................................................................................................6

2. EXPLODED VIEWS AND PARTS LIST.............................................................................................................8

2.1 PACKING ....................................................................................................................................................8

2.2 EXTERIOR SECTION ..............................................................................................................................10

2.3 FRONT PANEL SECTION ........................................................................................................................14

2.4 LOADING MECHA. ASSY ........................................................................................................................16

2.5 TRAVERSE MECHA. ASSY-S ..................................................................................................................18

3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM ..........................................................................................20

3.1 BLOCK DIAGRAM ....................................................................................................................................20

3.1.1 BLOCK DIAGRAM 1/3 ...........................................................................................................................20

3.1.2 BLOCK DIAGRAM 2/3 ...........................................................................................................................22

3.1.3 BLOCK DIAGRAM 3/3 [POWER BLOCK] .............................................................................................24

3.2 LOAB ASSY and OVERALL WIRING DIAGRAM .....................................................................................26

3.3 DVDM ASSY 1/6 [FTS BLOCK]................................................................................................................28

3.4 DVDM ASSY 2/6 [FR BLOCK]..................................................................................................................30

3.5 DVDM ASSY 3/6 [EBY/AV1 BLOCK]........................................................................................................32

3.6 DVDM ASSY 4/6 [i.LINK BLOCK].............................................................................................................34

3.7 DVDM ASSY 5/6 [VIDEO BLOCK] ...........................................................................................................36

3.8 DVDM ASSY 6/6 [A-DSP/AQE/SACD BLOCK] ........................................................................................38

3.9 AJKB ASSY ..............................................................................................................................................40

3.10 VJKB ASSY ............................................................................................................................................42

3.11 SCRB ASSY ...........................................................................................................................................44

3.12 FLKY, KEYB and MSWB ASSYS ...........................................................................................................46

3.13 POWER SUPPLY UNIT ..........................................................................................................................48

3.14 WAVEFORMS.........................................................................................................................................50

4. PCB CONNECTION DIAGRAM ......................................................................................................................53

4.1 LOAB ASSY..............................................................................................................................................53

4.2 DVDM ASSY.............................................................................................................................................54

4.3 AJKB ASSY ..............................................................................................................................................58

4.4 VJKB ASSY ..............................................................................................................................................60

4.5 SCRB ASSY .............................................................................................................................................62

4.6 MSWB ASSY ............................................................................................................................................63

4.7 FLKY and KEYB ASSYS ..........................................................................................................................64

4.8 POWER SUPPLY UNIT ............................................................................................................................66

5. PCB PARTS LIST ............................................................................................................................................67

6. ADJUSTMENT ................................................................................................................................................77

6.1 ADJUSTMENT ITEMS AND LOCATION ..................................................................................................77

6.2 JIGS AND MEASURING INSTRUMENTS ...............................................................................................77

6.3 NECESSARY ADJUSTMENT POINTS ....................................................................................................78

6.4 TEST MODE .............................................................................................................................................79

6.5 MECHANISM ADJUSTMENT...................................................................................................................80

7. GENERAL INFORMATION .............................................................................................................................82

7.1 DIAGNOSIS ..............................................................................................................................................82

7.1.1 ID NUMBER AND ID DATA SETTING ...................................................................................................82

7.1.2 SELF-DIAGNOSIS FUNCTION OF PICKUP DEFECTIVE ...................................................................84

7.1.3 TEST MODE SCREEN DISPLAY ..........................................................................................................85

7.1.4 SELF-DIAGNOSIS FUNCTION .............................................................................................................87

7.1.5 FUNCTIONAL SPECIFICATION OF THE SERVICE MODE .................................................................88

7.1.6 ERROR DISPLAY ..................................................................................................................................89

7.1.7 TROUBLE SHOOTING ..........................................................................................................................92

7.1.8 FAILURE-TEST METHOD FOR THE HDMI TRANSMITTER IC ...........................................................94

7.1.9 DISASSEMBLY......................................................................................................................................95

7.2 IC ............................................................................................................................................................106

7.3 DISC / CONTENT FORMAT PLAYBACK COMPATIBILITY ....................................................................160

7.4 CLEANING .............................................................................................................................................161

8. PANEL FACILITIES .......................................................................................................................................162