Pioneer VSX-1023-K, VSX-43, VSX-823-K AV Receiver Service Manual

Safety Information

This service manual is intended for qualified service technicians. Improperly performed repairs can adversely affect the safety and reliability of the product and may void the warranty. Refer repairs to a qualified service technician if you are not qualified.

WARNING: This product may contain a chemical known to the State of California to cause cancer, or birth defects or other reproductive harm (Health & Safety Code Section 25249.6 - Proposition 65).

1. Safety Precautions

Leakage Current Check: Measure leakage current to earth ground. Any current measured must not exceed 0.5 mA. Test all exposed metal surfaces, including with the plug reversed. Measurements not within limits indicate a potential shock hazard and must be corrected.

Product Safety Notice: Many electrical and mechanical parts have special safety-related characteristics, often not evident from visual inspection. These parts are identified by a '>' mark on schematics and parts lists. Use only Pioneer-recommended replacement parts to avoid shock, fire, or other hazards.

Contents

The manual is organized into the following sections:

• SAFETY INFORMATION
• 1. SERVICE PRECAUTIONS (Notes on Soldering, Replacing Parts, Service Notice)
• 2. SPECIFICATIONS (Amplifier, Audio, Video, Tuner, Digital In/Out, Network, Integrated Control, Miscellaneous)
• 3. BASIC ITEMS FOR SERVICE (Check Points After Servicing, Jigs List, Lubricants and Glues List)
• 4. BLOCK DIAGRAM (Overall Wiring, D-MAIN, Audio, Power Supply, GND)
• 5. DIAGNOSIS (Troubleshooting, Error Messages, Protection Circuit, IC Information)
• 6. SERVICE MODE (Test Mode, Default Settings)
• 7. DISASSEMBLY (Discharging, Front Panel, Heatsink, D-MAIN Assy, MAIN Assy)
• 8. EACH SETTING AND ADJUSTMENT (Idle Current Adjustment, Firmware Updating)
• 9. EXPLODED VIEWS AND PARTS LIST (Packing, Exterior Sections)
• 10. SCHEMATIC DIAGRAM (Various Assy sections including MAIN, D-MAIN, AUDIO, CPU, etc.)

1. Service Precautions

1.1 Notes on Soldering

Lead-free solder is used. Use lead-free solder and a soldering iron capable of meeting specifications for lead-free soldering. The tip temperature should be around 373°C. Do not use a soldering iron without temperature control.

Available lead-free solder parts: GYP1006 (1.0 mm dia.), GYP1007 (0.6 mm dia.), GYP1008 (0.3 mm dia.).

1.2 Notes on Replacing Parts

Certain parts, such as HDMI connectors and specific ICs (e.g., LAN Connector IC, HDMI Interface IC, DSP IC, Media Processor IC, LAN PHY IC, Apple Authentication IC, Power Supply ICs), are difficult to replace as discrete components and require replacement of the entire Assy.

1.3 Service Notice

Refer to Section 7. DISASSEMBLY for discharging procedures.

2. Specifications

Amplifier Section

• Continuous Average Power Output: 80 W per channel (min.) at 8 ohms, 20 Hz to 20 kHz, THD ≤ 0.08%.
• Power Output (1 kHz, 6 Ω, 1%): 140 W per channel.
• Guaranteed Speaker Impedance: 6 Ω to 16 Ω.

Audio Section

• Input Sensitivity/Impedance (LINE): 200 mV/47 kΩ.
• Signal-to-Noise Ratio (IHF, short circuited, A network, LINE): 98 dB.
• Signal-to-Noise Ratio (EIA, at 1 W, 1 kHz, LINE): 79 dB.

Video Section

• Composite Signal Level: 1 Vp-p (75 Ω).
• Component Video Signal Level (VSX-1023): Y: 1.0 Vp-p (75 Ω), PB/PR: 0.7 Vp-p (75 Ω).
• Component Video Max Resolution (VSX-1023): 1080p.

Tuner Section

• Frequency Range (FM): 87.5 MHz to 108 MHz.
• Antenna Input (FM): 75 Ω unbalanced.
• Frequency Range (AM): 530 kHz to 1700 kHz.
• Antenna (AM): Loop antenna.

Digital In/Out Section

• HDMI Terminal: Type A (19-pin).
• HDMI Output Type: 5 V, 100 mA.
• HDMI Input/MHL Terminal: 5 V, 900 mA.
• USB Terminal: USB2.0 High Speed (Type A) 5 V, 2.1 A.
• iPod Terminal: USB, and Video (Composite).
• ADAPTER PORT Terminal: 5 V, 100 mA.

Network Section

• LAN Terminal: 10 BASE-T/100 BASE-TX.

Integrated Control Section (VSX-1023, VSX-43)

• Control (IR) Terminal: Ø 3.5 Mini-jack (MONO).
• 12 V Trigger Terminal: Ø 3.5 Mini-jack (MONO).

Miscellaneous

• Power Requirements: AC 120 V, 60 Hz.
• Power Consumption: 520 W (VSX-1023, VSX-43), 450 W (VSX-823).
• Standby Power Consumption: 0.1 W (Normal), 0.3 W (HDMI Setup : ON).
• Dimensions: VSX-1023/VSX-43: 435 mm (W) x 168 mm (H) x 342.5 mm (D); VSX-823: 435 mm (W) x 168 mm (H) x 331.5 mm (D).
• Weight: VSX-1023: 9.2 kg; VSX-43: 9.3 kg; VSX-823: 8.5 kg.

Accessories

Included accessories vary by model and may include: Microphone (APM7011), Remote control, AM loop antenna, FM wire antenna, Dry cell batteries, Warranty card, Quick start guide, Safety Brochure, SPEAKER CAUTION Sheet, Operating instructions (CD-ROM).

Note: Specifications and design are subject to change without notice.

3. Basic Items for Service

3.1 Check Points After Servicing

After servicing, confirm the following items:

• Customer complaint resolution.
• Analog audio playback (all channels normal).
• Digital audio playback (all channels normal).
• Surround playback (all channels normal).
• Video outputs (normal).
• Tuner operations (AM/FM normal).
• Headphone output sound (normal, no noise).
• Product appearance (no scratches or dirt).

Detailed checks for video include block noise, distortion, horizontal noise, flicker, disturbed image, darkness, and mottled color. Audio checks include distortion, low/high volume, fluctuating volume, sound interruption.

3.2 Jigs List

Required jigs for service include RS-232C update jig, RS-232C cable, and various board-to-board extension jig cables for diagnosis.

Lubricants and Glues List

Silicon grease (GEM1057) and Silicon adhesive (GYA1011) are listed for use during disassembly/reassembly.

3.3 PCB Locations

Diagrams illustrate the physical layout of the various Printed Circuit Boards (PCBs) within the unit for both VSX-1023-K/VSX-43 and VSX-823-K models. Key assemblies include MAIN Assy, D-MAIN Assy, CPU Assy, AUDIO Assy, AMP Assy (AMP7/AMP5), FHDMI Assy, FRONT Assy, SMPS Assy, and others.

4. Block Diagram

The manual provides detailed block diagrams illustrating the internal architecture and signal flow:

• Overall Wiring Diagram: Shows the interconnection of major assemblies from AC input to various output stages.
• D-MAIN Block Diagram: Details the D-MAIN Assy's functions, including DSP, Direct path, Codec, HDMI, HD Audio, and connections to CPU, Network, and USB components.
• Audio Block Diagram: Illustrates the audio signal paths through different assemblies like FRONT, FHDMI, AUDIO, BT, HPMIC, and AMP sections.
• Power Supply Block Diagram: Depicts the power distribution from the SMPS Assy to various sections of the unit.
• GND Block Diagram: Shows the grounding scheme across different assemblies.

5. Diagnosis

5.1 Troubleshooting

The manual provides detailed troubleshooting guides for common issues:

• No Power: Guides users through checking standby status, DC protection, fuses, and voltage rails (+5.6V, +3.3V) to identify faults in the SMPS, MAIN, or CPU Assy.
• No FL Display: Outlines steps to diagnose display issues by checking voltages (2.3-2.5 Vac, -30V) and components like the transformer, FLT701, and FRONT Assy.
• No Sound: Provides flowcharts for diagnosing sound issues for headphones and speakers. It covers checking relays, audio output signals, +/-12V rails, and specific Assy components (HPMIC, BRI-2, CPU, AUDIO, MAIN, AMP).
• No Picture: Details troubleshooting for Composite and HDMI inputs/outputs, OSD issues, and checks for FHDMI, VIDEO, and D-MAIN Assy components.

5.2 Error Message

• Adapter Port Overcurrent Detection: Displays 'ADP ERR' if overcurrent is detected at the Adapter port.
• USB/iPod Error Message: Displays 'I/U ERR' for USB/iPod overcurrent errors.

5.3 Protection Circuit

Describes the unit's behavior when protection circuits are activated:

• Overload and DC Protection: Detects overcurrent or DC voltage on speaker outputs. The unit may turn off, flash an LED, or disable speaker outputs. DC error status can be canceled via a specific button combination.
• TEMP Protection: Monitors temperature signals. If overheating is detected, the unit may mute speakers, flash 'OVERHEAT', or power off.

5.4 IC Information

Provides detailed pin functions and descriptions for key Integrated Circuits (ICs), including the MAIN CPU (e.g., IC203 on CPU Assy), SUB CPU (e.g., IC101 on D-MAIN Assy), and other controllers.

6. Service Mode

6.1 Test Mode

Allows viewing and resetting protection detection counts. Specific key combinations during standby mode are used to enter these modes.

• Display Mode: Shows counts for DC, TEMP1, TEMP2, OVERLOAD errors.
• Reset Mode: Clears all protection detection counts.

6.2 Default Settings

Procedures are provided for resetting the receiver's settings to factory defaults using the front panel controls, and for resetting network connection settings.

7. Disassembly

General disassembly instructions are provided, emphasizing caution when disconnecting wires and connectors.

1. Discharging

Procedures for safely discharging high-voltage capacitors in the MAIN Assy and for the FL display (-30V) are detailed, requiring specific resistor values (47-100 ohms, 2W or higher) and testing for voltage reduction.

2. Disassembly Procedures

Step-by-step instructions are given for disassembling various sections of the unit (VSX-1023-K, VSX-43 and VSX-823-K models), including:

• Front Panel Section: Involves removing screws, releasing jumper wires, cutting binders, disconnecting cables (including HDMI), and unhooking catches.
• Heatsink Section: Requires removing screws, cutting binders, disconnecting cables, and carefully removing the heatsink assembly.
• D-MAIN Assy: Details removing screws, acetate tape, binders, and disconnecting various connectors and board-to-board connectors. It also notes the use of specific HDMI cables for diagnosis to prevent connector damage.
• MAIN Assy: Describes removing the back chassis, D-MAIN Assy, and then the MAIN Assy itself, involving screw removal, binder cutting, and disconnecting multiple cables and connectors.

The use of specific service jigs for diagnosis during disassembly is also noted.

8. Each Setting and Adjustment

8.1 Adjustment Required When the Unit is Repaired or Replaced

Idle current adjustment is required when the AMP7/AMP5 Assy or specific components within them are replaced. For other assemblies, no adjustment is typically needed. Replacing the D-MAIN Assy requires resetting the system and network functions.

8.2 Updating of the Firmware

Procedures are outlined for updating firmware for the Main microcomputer (via PC/RS-232C), Sub microcomputer (via USB memory), USB (BridgeCo) firmware, and DSP firmware. This involves specific file names, connection methods, and key sequences.

8.3 Idle Current Adjustment

Detailed procedures and circuit diagrams are provided for adjusting the idle current for each amplifier channel (FL, FR, SL, SR, SBL, SBR). This involves connecting a digital voltmeter to specific measurement points and turning adjustment VRs until the voltage reaches 2.0 mV ± 0.2 mV under no-signal, no-load conditions.

9. Exploded Views and Parts List

This section contains exploded views and parts lists for identifying and ordering replacement components. It includes sections for Packing, Exterior Sections, and detailed parts lists for various assemblies. Contrast tables highlight model-specific differences.

10. Schematic Diagram

The manual includes extensive schematic diagrams for all major assemblies, detailing the electronic circuitry. These diagrams cover:

• MAIN Assy (VSX-1023-K, VSX-43)
• MAIN Assy (VSX-823-K)
• D-MAIN Assy (multiple parts)
• OPTCO Assy
• BRI-1 Assy (VSX-1023-K, VSX-43 ONLY)
• CONCT Assy (VSX-823-K ONLY)
• VIDEO Assy (VSX-1023-K, VSX-43 ONLY)
• BT and BTCNT ASSYS (VSX-1023-K, VSX-43)
• BT Assy (VSX-823-K)
• BRI-2 ASSY (VSX-1023-K, VSX-43 ONLY)
• AUDIO ASSY (VSX-1023-K, VSX-43 ONLY)
• CPU ASSY (VSX-1023-K, VSX-43)
• CPU ASSY (VSX-823-K)
• AMP7 ASSY (VSX-1023-K, VSX-43)
• AMP5 ASSY (VSX-823-K)
• FHDMI, INSEL, FRONT and HPMIC ASSYS
• SMPS ASSY
• REG ASSY (VSX-823-K ONLY)

These schematics provide detailed circuit layouts for troubleshooting and repair.