PIONEER DVR-640H-S/KUCXV Service Manual

PIONEER DVR-640H-S/KUCXV Service Manual
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Service Manual for PIONEER DVR-640H-S/KUCXV, downloadable as a PDF file.

We also have owner's manual to this model.

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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 2006

DVR-640H-S

RRV3376

DVD RECORDER

DVR-640H-S

DVR-543H-S

DVR-540H-S

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

Model

Type

Power Requirement

Region No.

Serial No.

Please confirm 3rd & 4th

alphabetical letters.

DVR-640H-S

KUCXV

AC120 V

&&DL######$$

DVR-543H-S

KUCXV

AC120 V

&&DL######$$

DVR-540H-S

KUCXV

AC120 V

&&DL######$$

÷ When servicing this model, some service procedures may reset the customer settings

to the factory default settings. Make sure to explain this to the customer.

An HDD (Hard Disc Drive) is mounted in this product.

The HDD is a precision instrument very vulnerable to shock and electrostatic charges. Please read

"7.3 Cautions on Handling the HDD" in this manual and exercise sufficient caution when handling the

HDD itself, as well as the product with the HDD built in.

When an HDD becomes defective and inoperable, restoration of the user's data recorded on the HDD,

or copying of the user's recorded data to other media (such as a new HDD) is totally impossible.

Before servicing, OBTAIN THE USER'S PRIOR CONSENT to that effect.

The user must be made aware that all recorded data are deleted if the HDD is intialized.

For details, refer to "Important Check Points for Good Servicing" .

T-ZZV APR. 2006 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 2006

DVR-640H-S

RRV3376

DVD RECORDER

DVR-640H-S

DVR-543H-S

DVR-540H-S

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

Model

Type

Power Requirement

Region No.

Serial No.

Please confirm 3rd & 4th

alphabetical letters.

DVR-640H-S

KUCXV

AC120 V

&&DL######$$

DVR-543H-S

KUCXV

AC120 V

&&DL######$$

DVR-540H-S

KUCXV

AC120 V

&&DL######$$

÷ When servicing this model, some service procedures may reset the customer settings

to the factory default settings. Make sure to explain this to the customer.

An HDD (Hard Disc Drive) is mounted in this product.

The HDD is a precision instrument very vulnerable to shock and electrostatic charges. Please read

"7.3 Cautions on Handling the HDD" in this manual and exercise sufficient caution when handling the

HDD itself, as well as the product with the HDD built in.

When an HDD becomes defective and inoperable, restoration of the user's data recorded on the HDD,

or copying of the user's recorded data to other media (such as a new HDD) is totally impossible.

Before servicing, OBTAIN THE USER'S PRIOR CONSENT to that effect.

The user must be made aware that all recorded data are deleted if the HDD is intialized.

For details, refer to "Important Check Points for Good Servicing" .

T-ZZV APR. 2006 printed in Japan

DVR-640H-S

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 certain electrical parts 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 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

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

information, always consult the current PIONEER

Service Manual. A subscription to, or

additional copies

of, PIONEER Service Manual may be obtained at a

nominal charge from PIONEER.

(FOR USA MODEL ONLY)

1. SAFETY PRECAUTIONS

The following check should be performed for the

continued protection of the customer and service

technician.

LEAKAGE CURRENT CHECK

Measure leakage current to a known earth ground

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

current tester such as Simpson Model 229-2 or

equivalent between the earth ground and all exposed

metal parts of the appliance (input/output terminals,

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

DVR-640H-S

LABEL CHECK

IMPORTANT

THIS PIONEER APPARATUS CONTAINS

LASER OF CLASS 1.

SERVICING OPERATION OF THE APPARATUS

SHOULD BE DONE BY A SPECIALLY

INSTRUCTED PERSON.

CLAMP signals for detecting the loading state are detected

by the drive CPUs, and the design prevents laser diode

oscillation when the CLAMP signal turns OFF.

In normal operation, if no disc is clamped, the laser diode

oscillation is disabled.

However, the interlock does not always operate in the test

mode.

2. When the cover is opened, close viewing of the objective

lens with the naked eye will cause exposure to a Class 3A

laser beam.

Additional Laser Caution

1. The ON/OFF(ON:low level,OFF:high level) status of the

LASER DIODE CHARACTERISTICS

MAXIMUM OUTPUT POWER: 100 mW

WAVELENGTH: 654nm to 662 nm

LASER DIODE CHARACTERISTICS

MAXIMUM OUTPUT POWER: 5 mW

WAVELENGTH: 770nm to 810 nm

D/D

VRW2262

DVR-640H-S

[Important Check Points for Good Servicing]

In this manual, procedures that must be performed during repairs are marked with the below symbol.

Please be sure to confirm and follow these procedures.

1. Product safety

Please conform to product regulations (such as safety and radiation regulations), and maintain a safe servicing environment by

following the safety instructions described in this manual.

1 Use specified parts for repair.

Use genuine parts. Be sure to use important parts for safety.

2 Do not perform modifications without proper instructions.

Please follow the specified safety methods when modification(addition/change of parts) is required due to interferences such as

radio/TV interference and foreign noise.

3 Make sure the soldering of repaired locations is properly performed.

When you solder while repairing, please be sure that there are no cold solder and other debris.

Soldering should be finished with the proper quantity. (Refer to the example)

4 Make sure the screws are tightly fastened.

Please be sure that all screws are fastened, and that there are no loose screws.

5 Make sure each connectors are correctly inserted.

Please be sure that all connectors are inserted, and that there are no imperfect insertion.

6 Make sure the wiring cables are set to their original state.

Please replace the wiring and cables to the original state after repairs.

In addition, be sure that there are no pinched wires, etc.

7 Make sure screws and soldering scraps do not remain inside the product.

Please check that neither solder debris nor screws remain inside the product.

8 There should be no semi-broken wires, scratches, melting, etc. on the coating of the power cord.

Damaged power cords may lead to fire accidents, so please be sure that there are no damages.

If you find a damaged power cord, please exchange it with a suitable one.

9 There should be no spark traces or similar marks on the power plug.

When spark traces or similar marks are found on the power supply plug, please check the connection and advise on secure

connections and suitable usage. Please exchange the power cord if necessary.

0 Safe environment should be secured during servicing.

When you perform repairs, please pay attention to static electricity, furniture, household articles, etc. in order to prevent injuries.

Please pay attention to your surroundings and repair safely.

2. Adjustments

To keep the original performance of the products, optimum adjustments and confirmation of characteristics within specification.

Adjustments should be performed in accordance with the procedures/instructions described in this manual.

4. Cleaning

For parts that require cleaning, such as optical pickups, tape deck heads, lenses and mirrors used in projection monitors, proper

cleaning should be performed to restore their performances.

3. Lubricants, Glues, and Replacement parts

Use grease and adhesives that are equal to the specified substance.

Make sure the proper amount is applied.

5. Shipping mode and Shipping screws

To protect products from damages or failures during transit, the shipping mode should be set or the shipping screws should be

installed before shipment. Please be sure to follow this method especially if it is specified in this manual.

DVR-640H-S

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 ........................................................................................................................12

3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM ..........................................................................................14

3.1 BLOCK DIAGRAM ....................................................................................................................................14

3.1.1 OVERALL BLOCK DIAGRAM ............................................................................................................14

3.1.2 AUDIO BLOCK DIAGRAM..................................................................................................................16

3.1.3 POWER BLOCK .................................................................................................................................17

3.2 OVERALL WIRING DIAGRAM .................................................................................................................18

3.3 TUJB ASSY (1/3) ......................................................................................................................................20

3.4 TUJB ASSY (2/3) ......................................................................................................................................22

3.5 TUJB ASSY(3/3) .......................................................................................................................................24

3.6 FJKB, FLKY and KEYB ASSYS ...............................................................................................................26

3.7 MAIN ASSY(1/4).......................................................................................................................................28

3.8 MAIN ASSY(2/4).......................................................................................................................................30

3.9 MAIN ASSY(3/4).......................................................................................................................................32

3.10 MAIN ASSY(4/4).....................................................................................................................................34

3.11 USBB ASSY (Except DVR-540H-S) .......................................................................................................36

3.12 ATAB ASSY.............................................................................................................................................37

3.13 POWER SUPPLY UNIT ..........................................................................................................................38

3.14 WAVE FORMS........................................................................................................................................40

4. PCB CONNECTION DIAGRAM ......................................................................................................................43

4.1 TUJB ASSY ..............................................................................................................................................44

4.2 FJKB, FLKY and KEYB ASSYS ...............................................................................................................48

4.3 MAIN ASSY ..............................................................................................................................................50

4.4 USBB ASSY (Except DVR-540H-S) .........................................................................................................54

4.5 ATAB ASSY...............................................................................................................................................56

4.6 POWER SUPPLY UNIT ............................................................................................................................58

5. PCB PARTS LIST ............................................................................................................................................60

6. ADJUSTMENT ................................................................................................................................................65

7. GENERAL INFORMATION .............................................................................................................................67

7.1 DIAGNOSIS ..............................................................................................................................................67

7.1.1 MODEL SETTING ..............................................................................................................................69

7.1.2 CPRM ID NUMBER AND DATA SETTING .........................................................................................70

7.1.3 FIRMWARE DOWNLOADING METHOD ...........................................................................................74

7.1.4 VIDEO ADJUSTMENT FOR SPECIFIC AREA...................................................................................77

7.1.5 SERVICE MODE ................................................................................................................................81

7.1.6 AGING MODE ....................................................................................................................................93

7.1.7 HDD CHECK MODE...........................................................................................................................95

7.1.8 DIAGNOSIS OF THE MAIN ASSY ...................................................................................................101

7.1.9 NOTE ON REPLACEMENT OF THE SDRAM..................................................................................102

7.1.10 SETUP SEQUENCE.......................................................................................................................103

7.1.11 DISASSEMBLY...............................................................................................................................104

7.2 IC ............................................................................................................................................................109

7.3 CAUTIONS ON HANDLING THE HDD...................................................................................................118

7.4 DISC/CONTENT FORMAT .....................................................................................................................120

8. PANEL FACILITIES .......................................................................................................................................123