Hitachi DV-DS163E User manual

SERVICE MANUAL
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
HDD/DVD RECORDER
May 2006
SM0607
DV-DS163E
DV-DS163E(UK)
DV-DS253E
DV-DS253E(UK)
DO NOT RESELL OR DIVERT IMPROPERLY.

Contents - 1
Table of Contents
1 Safety Precaution for Repair............ 1-1
1-1 Cautions ..................................................1-1
1-2 Electrostatic Protection Measures...........1-2
1-3 Cautions When Handling DVD Drive .......1-2
1-4 Cautions When Handling HDD................1-3
1-5 Lead-Free Solder..................................... 1-4
1-6 Notes When Using Service Manual......... 1-5
2 General Description.......................... 2-1
2-1 Overview .................................................2-1
2-1-1 Service method .................................... 2-1
2-1-2 Disc information....................................2-2
2-2 Specifications ..........................................2-4
2-3 Major Differences from Previous Model ..2-5
2-4 Function Differences from
Previous Model .......................................2-6
2-5 Names of Parts........................................ 2-7
2-6 HDMI Connection .................................... 2-10
2-7 List of Abbreviations and Terms for DVD
Recorder.................................................. 2-11
3 Details of Servicing and
Troubleshooting................................ 3-1
3-1 How to Remove Disc from Faulty
Recorder.................................................. 3-1
3-2 Initialization.............................................. 3-2
3-2-1 Factory Set .......................................... 3-2
3-2-2 HDD Format ........................................3-2
3-3 Troubleshooting HDD ..............................3-3
3-4 Checking Versions of Firmware and
Updating .................................................3-4
3-4-1 Version check procedure......................3-4
3-4-2 Method of starting up firmware update
program ................................................3-4
3-4-3 Main firmware updating procedure ......3-5
3-4-4 Loader firmware updating procedure ..3-6
3-4-5 Main/Loader firmware simultaneous
updating procedure .............................. 3-6
3-5 Troubleshooting .......................................3-7
3-5-1 Troubleshooting electronic system .......3-7
4 Disassembly and Reassembly......... 4-1
4-1 Order of Disassembly..............................4-1
4-2 Disassembly ............................................4-2
(1) Top Cover, Fan .......................................... 4-2
(2) Front Block ................................................ 4-3
(3) TIMER-1 P.C.B, TIMER-2 P.C.B,
Front Panel ................................................4-3
(4) MAIN P.C.B ...............................................4-4
(5) Power Cable, SMPS P.C.B ........................ 4-5
(6) HDMI Block, HDMI P.C.B ..........................4-6
(7) Front Frame, DVD Block, DVD Drive Unit,
LOADER P.C.B.......................................... 4-7
(8) HDD Block, HDD P.C.B, HDD ...................4-8
(9) CARD P.C.B ..............................................4-9
(10) I/O P.C.B..................................................4-10
(11) Rear Panel .............................................. 4-10
5 Exploded View and Parts List .......... 5-1
5-1 Exploded View......................................... 5-1
5-2 Parts List ................................................. 5-2
S Schematic, Wiring Diagrams............ S-1
S-1 Wiring Diagram........................................S-1
S-2 SMPS Schematic Diagram......................S-2
S-3
POWER Schematic Diagram (I/O P.C.B) ....S-3
S-4 TUNER/SYSTEM Schematic Diagram
(I/O P.C.B)................................................S-4
S-5 JACK Schematic Diagram
(I/O P.C.B) ......S-5
S-6 DECODER Schematic Diagrams
(I/O P.C.B)................................................S-6
S-7 TIMER-1,TIMER-2 Schematic Diagram
(TIMER-1,TIMER-2 P.C.B).......................S-7
S-8 HDMI Schematic Diagram
(HDMI P.C.B) ..S-8
-TO BE ADDED-
S-9 Circuit Waveforms .................................... S-9
S-10 Circuit Voltage Chart .............................. S-10
C Circuit Board Diagrams.................... C-1
C-1 I/O Circuit Board Diagram .......................C-1
C-2 SMPS Circuit Board Diagram..................C-3
C-3 TIMER-1 Circuit Board Diagram..............C-3
C-4 TIMER-2 Circuit Board Diagram..............C-3
C-5 HDMI Circuit Board Diagram...................C-4
C-6 HDD Circuit Board Diagram ....................C-4

Contents - 2
B Block Diagrams................................. B-1
B-1 Overall Block Diagram............................. B-1
B-2 SMPS Circuit Block Diagram...................B-2
B-3 POWER (I/O Board) Circuit Block
Diagram................................................... B-3
B-4 AUDIO/VIDEO Circuit Block Diagram...... B-4
B-5 SYSTEM Circuit Block Diagram .............. B-5

1 - 1
Safety Precaution for Repair
1
1-1 Cautions
CAUTION
There is a high-voltage section inside the DVD video
recorder. When repairing or inspecting it, take great care
to prevent electric shock: Use an isolating transformer,
wear gloves, etc.
Many electrical and mechanical parts have special safety-related characteristics. These are often not
evident from visual inspection nor can the protection afforded by them necessarily be obtained by using
replacement components rated for a higher voltage, wattage, etc. Replacement parts which have these
special safety characteristics are identified in this Service Manual. Electrical components having such
features are identified by marking with a on the schematics and the parts list in this Service Manual.
The use of a substitute replacement component which does not have the same safety characteristics as
the HITACHI 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 information, always consult the current HITACHI Service Manual.
A subscription to, or additional copies for, HITACHI Service Manual may be obtained at a nominal
charge from HITACHI SALES CORPORATION.
PRODUCT SAFETY NOTICE
CAUTION
This product contains a laser diode of
higher class than 1. To ensure contin-
ued safety, do not remove any covers
or attempt to gain access to the in-
side of the product. Refer all servicing
to qualified personnel.

1 - 2
Safety Precaution for Repair > Electrostatic Protection Measures / Cautions When Handling DVD Drive
1-2 Electrostatic Protection Measures
Semiconductor components can be damaged by static electricity charged on clothes, human
body, etc. Take great care when handling components to avoid electrostatic damage, and perform
servicing in an environment where grounding is complete.
(1) Grounding work bench
Lay out an antistatic mat on work bench, and then use the ground plate to ground the work bench.
Antistatic mat
Ground
1M ohm
1M ohm
Antistatic wrist strap
1-3 Cautions When Handling DVD Drive
The optical pickup in DVD drive has a high precision structure: Be sure to observe the following
cautions.
1) Do not subject optical pickups to any severe vibrations or
impact during movement, installation or disassembly.
2) When performing repair work, do not perform disassembly
any further than that described in this manual.
3) Never turn the semi-variable resistors for adjustment in
optical pickup or DVD drive.
4) NEVER look into the objective lens in optical pickup or
directly view the laser light: You could lose your eyesight.
Do not directly look at laser light
from pickup.
(2) Grounding human body
Use an antistatic wrist strap to discharge any static electricity charged on the body. Also, use a
tester for wrist strap to make sure that the wrist strap is working normally. Note, however, that
static electricity charged on clothes will not be discharged by wrist strap: Therefore do not allow
your clothes to touch the semiconductor components.

1 - 3
1-4 Cautions When Handling HDD (Hard Disk Drive)
HDD is a high precision device, and is very susceptible to vibrations or impact. Even if HDD
operates normally immediately after it has been subjected to vibrations or impact, a problem may
occur after it is used for a while: When servicing, take great care with the following.
There are two types of HDD: CSS format (head remains on disk regardless of operation status)
and ramp loading format (head moves away from disk during no operation). The impact resistance
characteristics are slightly different for the two. When servicing, observe the following cautions
regardless of the format:
(1) Cautions during unpacking
1) Do not subject the HDD to any impact when placing on desk: The head hitting against the desk
could result in damage.
2) If condensation occurs because of the environment, leave the HDD without being turned on for at
least 3 hours until it adapts to surrounding environment. If the HDD is turned on while the head
is sticking to disk because of condensation, the disk may be damaged.
(2) Cautions during transportation
An HDD is more susceptible to vibrations or impact when it is turned on or operating than during
no operation.
1) Do not move the HDD while it is turned on: If the HDD is subject to any impact while the disk is
rotating, i.e., the head hitting against the disk, breakage could result.
2) Move the HDD approximately 2 minutes (approximately 30 seconds for surveillance system
devices) after turning it off and unplugging its power cord from AC outlet. The disk will still be
rotating by inertia immediately after the HDD is turned off: Subjecting the HDD to movement at
this time could destroy it.
(3) Cautions during operation
1) Do not unplug the power cord from AC outlet during operation: This could damage the data on
HDD. Be sure to turn the HDD off before unplugging the power cord.
2) Do not hit the HDD: The head hitting the disk could result in breakage.
(4) Caution during packing
1) Use the packing material of relevant model: Material superior in impact resistance is used. Using
other packing materials could result in fault.
(5) Cautions when handling unassembled HDD
1) Hold the HDD at both sides so that the circuit board surface is facing below: Holding the HDD at
the top and bottom could cause the head to drift, which could result in fault.
2) Do not touch the terminal or pattern on circuit board.
3) Place HDD on a spot where cushion is pasted with the circuit board surface facing below.
4) Do not hold or place stacked HDDs.
5) Do not drop or hit HDD against anything: Dropping HDD from even 5 mm high on a work bench
with high stiffness could cause fault.
Safety Precaution for Repair > Cautions When Handling HDD (Hard Disk Drive)

1 - 4
1-5 Lead-Free Solder
The printed circuit board that uses lead-free solder is adopted. To protect the global environment,
use the recommended lead-free solder also during servicing.
Read and observe the following before soldering:
Caution
ALWAYS wear protective goggles during soldering so that no solder smoke or scattered solder enters
the eye. Lead-free solder may scatter at high temperatures of 600°C.
(1) Characteristics of lead-free solder
The melting point of lead-free solder is 30-40°C higher than that of lead based solder.
Point to be soldered Tip temperature
Surface-mounted (chip) parts [other than
those shown below]
320 ± 30°C
[heating time: less than 5 seconds]
Surface-mounted (chip) parts [for DVD
cameras, cellular phones only]
350 ± 10°C
[heating time: less than 3 seconds]
Discrete parts 380 ± 30°C
Chassis, metal shield, etc. 420 ± 30°C
(2) Lead-free solder for servicing
Use the following lead-free solder for servicing:
Recommended lead-free solder and composition of alloy (wt%): Sn-3.0Ag-0.5Cu or equivalent
Information:
For composition of alloy, Sn is tin; Ag is silver; Cu is copper; Bi is bismuth; Pb is lead.
(3) Soldering iron for servicing
The temperature of soldering iron tip must be adjusted according to the points to be soldered: Use
an antistatic soldering iron with thermal control function.
When removing components, take care not to damage any surrounding component or pattern. When
attaching components, observe the heating time in the following table so that the components are
not destroyed by heat.
Tip temperatures for different soldering points:
Safety Precaution for Repair > Lead-Free Solder
(4) Cautions when using lead based solder
It is recommended that you use lead-free solder when servicing, but it is also possible to service
using lead based solder. However, if lead based solder is used for servicing, take care with the
following:
1) Before using lead based solder, remove the lead-free solder completely from the point to be
soldered.
2) For additional soldering for repair, set the soldering iron tip temperature for lead-free solder,
mix lead based solder and lead-free solder sufficiently. Do not perform any repair using the
bare soldering iron tip without adding solder, since it will cause secondary failure due to lack of
strength.

1 - 5
(3) Identifying sides A/B in circuit board diagrams
1) Board with pattern on one side only and parts on both sides:
Side A: Shows discrete parts.
Side B: Shows leadless parts, viewed from the pattern side.
2) Board with patterns and parts on both sides:
Sides A and B are identified without any predetermined rules.
(4) Indicating model names
The indication of models is defined as follows:
1) The common parts of model names are omitted.
Example: When indicating VM-D975LA and VM-D875LA:
VM-D975LA/D875LA, D975LA/D875LA
2) If there is no difference in models going to different destinations, the indication of destination is
omitted.
Example: When indicating DZ-MV350E(AU) and DZ-MV350E(SW): DZ-MV350E
1-6 Notes When Using Service Manual
(1) Value units used in parts list
Certain symbols are indicated as shown below for value units of resistors, capacitors and coils in
parts list. When you read them, note the following regular indications:
(2) Values in schematic diagrams
The values, dielectric strength (power capacitance) and tolerances of the resistors (excluding
variable resistors) and capacitors are indicated in the schematic diagrams using abbreviations.
Certain symbols are indicated for value units: When you read them note the regular indications in
tables below:
Safety Precaution for Repair > Notes When Using Service Manual
Parts Indication in list Regular indication
Resistor KOHM ..........................................k
Capacitor UF .................................................F
PF..................................................pF
Coil UH ................................................H
MH ................................................ mH
[Resistors] [Capacitors]
[Coils]
Item Indication
Value No indication................................
K.................................................... k
M................................................... M
Tolerance No indication ................................ ±5%
(All tolerances other than ±5% are
indicated in schematic diagrams)
Power
capacitance
No indication................................ 1/8W
(1/16 W for leadless resistors with no
indication)
All capacitances other than the above
are indicated in schematic diagrams.
Item Indication
Value No indication................................ F
P.................................................... pF
Dielectric
strength
No indication ............................... 50V
(All dielectric strengths other than
50 V are indicated in schematic
diagrams)
Item Indication
Value .................................................... H
m ................................................... mH

2 - 1
General Description
2-1 Overview
The HDD/DVD recorder models DV-DS253E and DS163E all incorporate 250-GB and 160-GB
HDDs, made by Hitachi Global Storage Technologies.
The DVD recorder block contains a DVD multi-drive: It is compatible with recording and playback
of a variety of media – 5x DVD-RAM, 4x DVD-RW, 16x DVD-R, 4x DVD+RW, 16x DVD+R and 8x
DVD+R DL.
2-1-1 Service method
Basically, components are replaced when servicing the HDD/DVD recorder. However, the service
method is different for high-density packaging PCBs and precision components.
Refer to the following table and perform the designated, appropriate servicing. Any changes that
occur in the service method will be published using service bulletin, etc.
Do not perform any servicing other than that described in this manual.
2
Fig. 2-1-1 Component Location
Component Service method
(a) HDD Unit replacement
(b) TIMER-2 P.C.B Component replacement
(c) CARD P.C.B Component replacement
(d) DVD Drive Unit Unit replacement
(e) TIMER-1 P.C.B Component replacement
(f) MAIN P.C.B Circuit board assembly replacement
(g) HDMI P.C.B Component replacement
(h) I/O P.C.B Component replacement
(i) LOADER P.C.B Component replacement
(j) SMPS P.C.B Component replacement
(k) HDD P.C.B Component replacement
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(j)
(k)
(i)

2 - 2
General Description > Overview
2-1-2 Disc information
Recordable and Playable Discs
DVD-RAM
•DVD-RAM discs can be formatted for VR mode recording.
•These Discs can be recorded on repeatedly. Recordings can be erased, then you can record again on
the same Disc.
•Playable on DVD-RAM compatible players.
•Recordings can be extensively edited.
•Only DVD-RAM standard Version 2.0, 2.1 and 2.2 discs can be used in this unit.
•You cannot use the cartridge-type DVD-RAM disc in this unit.
DVD-RW
• DVD-RW discs can be formatted for VR mode recording or Video mode recording.
•These Discs can be recorded on repeatedly. Recordings can be erased, then you can record again on
the same Disc.
[VR mode]
•Recordings can be extensively edited
•Playable only on VR mode compatible players (after finalization)
[Video mode]
•Playable on regular DVD players (after finalization)
•Limited editing features
DVD-R
•These Discs can be recorded only once. After you finalize a DVD-R, you cannot record on it or edit it.
•DVD-R discs can be only formatted to Video mode.
•Playable on regular DVD players (after finalization).
•Limited editing features
DVD+RW
•These Discs can be recorded on repeatedly. Recordings can be erased, then you can record again on
the same Disc.
•Playable on DVD+RW compatible players (automatically finalization)
•The edited contents are playable on DVD+RW compatible players only after finalization
•Recordings can be edited the title/chapter
DVD+R
•These Discs can be recorded only once. After you finalize a DVD+R, you cannot record on it or edit it
any more.
•Playable on DVD+R compatible players (after finalization)
•Any edited contents are not be compatible on DVD+R compatible players. (Hide, chapter combine,
added chapter mark, etc.)
•Limited title/chapter editing features.
DVD+R DL
•These Discs can be recorded only once. After you finalize a DVD+R DL, you cannot record on it or
edit it any more.
•Storage space is nearly doubled with double layer DVD+R media, allowing consumers to record up to
8.5GB of video on a single DVD+R DL disc.
•Playable on DVD+R compatible players (after finalization)
•Any edited contents are not be compatible on DVD+R DL compatible players. (Hide, chapter combine,
added chapter mark, etc.)
•Limited title/chapter editing features.