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
1
&&MP######$$
DV-868AVi-S
WYXJ
AC220-240V
2
&&MP######$$
DV-668AV-S
WYXJ
AC220-240V
2
&&MP######$$
For details, refer to "Important symbols for good services".
T-ZZE DEC. 2003 printed in Japan
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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
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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
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[ 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.
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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