Toshiba DR-5 Service manual

SERVICE MANUAL

REVISED.01

DOCUMENT CREATED IN JAPAN, SEPT., 2006

DVD VIDEO RECORDER

FILE NO. 810-200602GR

DIGITAL VIDEO

D-R5SC D-R5SU

The above models are classified as green products (*1), as indicated by the underlined serial numbers. This Service Manual describes replacement parts for the green products. When repairing these green product(s), use the part(s) described in this manual and lead-free solder (*2).

For (*1) and (*2), see the next page.

Mar.,2006 GREEN

(*1) GREEN PRODUCT PROCUREMENT

The EC is actively promoting the WEEE & RoHS Directives that define standards for recycling and reuse of Waste Electrical and Electronic Equipment and for the Restriction of the use of certain Hazardous Substances. From July 1, 2006, the RoHS Directive will prohibit any marketing of new products containing the restricted substances.

Increasing attention is given to issues related to the global environmental. Toshiba Corporation recognizes environmental protection as a key management tasks, and is doing its utmost to enhance and improve the quality and scope of its environmental activities. In line with this, Toshiba proactively promotes Green Procurement, and seeks to purchase and use products, parts and materials that have low environmental impacts.

Green procurement of parts is not only confined to manufacture. The same green parts used in manufacture must also be used as replacement parts.

(*2) LEAD-FREE SOLDER

This product is manufactured using lead-free solder as a part of a movement within the consumer products industry at large to be environmentally responsible. Lead-free solder must be used in the servicing and repair of this product.

WARNING

This product is manufactured using lead free solder .

DO NOT USE LEAD BASED SOLDER TO REPAIR THIS PRODUCT !

The melting temperature of lead-free solder is higher than that of leaded solder by 86°F to 104°F (30°C to 40°C). Use of a soldering iron designed for lead-based solders to repair product made with lead-free solder may result in damage to the component and or PCB being soldered. Great care should be made to ensure high-quality soldering when servicing this product  especially when soldering large components, through-hole pins, and on PCBs  as the level of heat required to melt lead-free solder is high.

LASER BEAM CAUTION LABEL

When the power supply is being turned on, you may not remove this laser cautions label. If it removes, radiation of a laser

may be received.

PREPARATION OF SERVICING

Pickup Head consists of a laser diode that is very susceptible to external static electricity.

Although it operates properly after replacement, if it was subject to electrostatic discharge during replacement, its life might be shortened. When replacing, use a conductive mat, soldering iron with ground wire, etc. to protect the laser diode from damage by static electricity.

And also, the LSI and IC are same as above.

Ground conductive wrist strap for body.

Soldering iron with ground wire or ceramic type

Conductive mat

Manufactured under license from Dolby Laboratories. “Dolby” and the double-D symbol are trademarks of Dolby Laboratories.

“DTS” and “DTS Digital Out” are trademarks of Digital Theater Systems, Inc.

HDMI, the HDMI logo and Hight-Definition Multimedia Interface are trademarks or registered trademarks of HDMI Licensing LLC.

Manufactured under license from QSound Labs, Inc. U.S. patent Nos. 5,105,462, 5,208,860 and 5,440,638 and various foreign counterpart.

The ground resistance between the ground line and the ground is less than 10W.

SAFETY NOTICE

SAFETY PRECAUTIONS

LEAKAGE CURRENT CHECK

Plug the AC line cord directly into a 120V AC outlet (do

not use an isolation transformer for this check). Use an

AC voltmeter, having 5000 Ω per volt or more sensitivity.

Connect a 1500 Ω 10 W resistor, paralleled by a 0.15 µF

150V AC capacitor between a known good earth ground

(water pipe, conduit, etc.) and all exposed metal parts of

cabinet (antennas, handle bracket, metal cabinet

screwheads, metal overlays, control shafts, etc.).

READING SHOULD NOT EXCEED 0.3V

Measure the AC voltage across the 1500 Ω resistor.

The test must be conducted with the AC switch on and

then repeated with the AC switch off. The AC voltage

indicated by the meter may not exceed 0.3 V. A reading

exceeding 0.3 V indicates that a dangerous potential

exists, the fault must be located and corrected.

Repeat the above test with the DVD VIDEO RECORDER

power plug reversed.

NEVER RETURN A DVD VIDEO RECORDER TO

THE CUSTOMER WITHOUT TAKING NECESSARY

CORRECTIVE ACTION.

DVD VIDEO RECORDER

AC OUTLET

Test all exposed metal. Voltmeter Hook-up for Leakage Current Check

AC VOLTMETER

(5000 Ω per volt or more sensitivity)

Good earth ground

such as a water pipe, 1500 Ω 10 W

0.15 µF 150V AC

conduit, etc.

The lightning flash with arrowhead symbol, within an

equilateral triangle, is intended to alert the user to the

presence of uninsulated “dangerous voltage” within the

product’s enclosure that may be of sufficient magnitude to

constitute a risk of electric shock to persons.

The exclamation point within an equilateral triangle is

intended to alert the user to the presence of important

operating and maintenance (servicing) instructions in the

literature accompanying the appliance.

CONTENTS

1. LOCATION OF MAIN PARTS 1-1. Location of Main Parts 1-2. Location of PC Boards

2. WIRING CONNECTION DIAGRAM

3. PRINTED WIRING BOARD AND SCHEMATIC DIAGRAM

4. BLOCK DIAGRAMS 4-1. MPEG & SYSTEM Block Diagram 4-2. Power Supply Block Diagram

5. CIRCUIT DIAGRAMS 5-1. Power Supply Circuit Diagram 5-2. Front Display & Power Switch Circuit Diagram 5-3. Audio & Video Tuner Circuit Diagram 5-4. Digital Circuit Diagram 5-4-1. Audio Output Circuit Diagram 5-4-2. Decorder & SDRAM Circuit Diagram 5-4-3. HDMI Circuit Diagram 5-4-4. Audio & Video Input Circuit Diagram 5-4-5. 1394 Circuit Diagram 5-4-6. Encoder & SDRAM Circuit Diagram 5-4-7. ATAPI Interface Circuit Diagram 5-4-8. Power Supply Circuit Diagram 5-4-9. Video Output Circuit Diagram

6. PC BOARDS 6-1. DV/AV Input PC Board 6-2. Power Switch PC Board 6-3. Front Display PC Board 6-4. AV Tuner Unit PC Board 6-5. Digital PC Board

7. EXPLODED VIEWS 7-1. Packing Assembly 7-2. Chassis Assembly

8. PARTS LIST

1. LOCATION OF MAIN PARTS

1-1. Location of Main Parts

RAM DRIVE

Fig. 1-1-1

1-2. Location of PC Boards

DV/AV Input PC board

Front Display PC board

Power Switch PC board

Digital PC board

AV Tuner Unit PC board

Power PC board

Fig. 1-1-2

2. WIRING CONNECTION DIAGRAM

After the servicing is complete, return the wiring to its original state by using the diagram below as a reference.

AV Tuner Unit PC board

W301 W303

Digital PC board

W104

Ta pe

W501

W106

Ta pe

W802

Ta pe

Power PC board

W105

W107

Power Switch PC board

DV/AV Input PC board

: Flexible cable

: Tape

RAM Drive

Fig. 2-2-1

W101

W804

W803

Front Display PC board

3. PRINTED WIRING BOARD AND SCHEMATIC DIAGRAM

W802

FLAT WIRE 2.54 9P

9 8 7 6 5 4 3 2 1

CN302

ON/OFF 5V

+3.3 V +3.3 V

GND

ON/OFF 5V

AP+12 V AN-12 V

GND

+33 V

CN303

8765432

AV-TUNER

123456789

CN301

Power

CN804

123

ON/OFF 5V

CN803

12345

CN802

+3.3 V +3.3 V

GND

AP+12 V AN-12 V

GND

+33 V

1121314151

GND

Back up

P-ON

EVER+5 V

FLAT WIRE 2mm 4P

W804

M+12 V

M+5 V

GND

12345

Mechanism

W803

FLAT WIRE 2mm 6P

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

W501

FLAT WIRE 0.5mm 40P

DRVRSTGND ATCDD7 ATCDD8

ATCDD6 ATCDD9 ATCDD5 ATCDD10 ATCDD4 ATCDD11 ATCDD3 ATCDD12 ATCDD2 ATCDD13 ATCDD1 ATCDD14 ATCDD0 ATCDD15 GND NC ATCD MARQ GND ATCD IOWGND ATCD IORGND ACTIOR DY GND ATCD MACK-

GND ACTINITRQ NC

ATCDA1

NC ATCDA0 ATCDA2 ATCCSOATCCSNC

GND

W303

FLAT WIRE 2.54 8P

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20

CN504

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

ON/OFF 5V

AP+12 V

AP-12 V

1234567

CN509

CN508

12345

ON/OFF 5V

GND

+3.3 V

GND

65432

W301

A IN L

A IN R

FLAT WIRE 1mm 16P

123456789

Digital

CN501

GND

SC IN

GND

CVBS IN

V-GND

SY IN

CN503

987654321

SCL

SDA

SAP MUTE

AFC OUT

213141

CN507

VFV

GND

A L TV

A R TV

432

CN102

Front Display

CN101

1 2 3 4 5 6 7 8 9

W101

FLAT WIRE 2mm 9P

STB CLK DATA GND IR HOST-RESET KEY2 KEY4 POWER LED+

W106

FLAT WIRE 2mm 6P

1 2 3 4 5

CN103

6 7 8 9

STB

CLK

DATA

12345

CN106

GND

W105

GNDIRHOST RESET

FLAT WIRE 2mm 6P

12345

DV/AV INPUT

TPBI-

TPBI+

TPAI-

TPAI+

GND

W104

Y-F

GND

C-F

FLAT WIRE 2mm 9P

123456789

CN104CN105

W107

FLAT WIRE 2mm 4P

Power Switch

GND

CVBS-F

GND

AR-F

CN107

123

GND

KS3

123

CN108

GND

KEY2

AL-F

LED+

Fig. 3-3-1

4. BLOCK DIAGRAM

32M CLOCK

4-1. MPEG & SYSTEM Block Diagram

FRONT

Video

Y/C

REAR

Video

Y/C

TV-CVBS

Video

BA7607

IC517

CVBS

BA7653

IC518

IC502

IC503

FR .Y/C IN

CVBS IN

128M SDRAM

ZR35100-PQCG

ENCORDER

IC506

IC504

IC507

IC511

128M SDRAM

32M FLASH

SERIAL BITSTREAM OUTPUT

SBCLK

SBVALID

SBDAT

SBREQ

Digital Video Output

: : :

ZR36750-BGCG-V

Main Cpu(Decorder)

<BGA>

Digital Audio Out

WM8776

DAC

IC513 2/2

Digital Video I/F

SPD IF

IC514

CV BS Out

Y/C Out

SPDIF-OPTICAL

Y/U/V Out

HDMI

ZR35162

4558

J502

L OUT R OUT

CV BS

Y/C

J504

J501

Y/U/V OUT

J503

HDMI Out

FRONT

L/R IN

REAR

L/R IN

Audio

WM8776

ADC

IC513 1/2

Digital Audio I/F

ADCMCLK

ADCBLCK

ADCLRCK

DOUT

ISO I/F HOST I/F

ZR35162-BGCG

1394

<BGA>

IC505

DV INPUT

JC101

27MHZ

IC509

SPI

32M CLOCK

FRONT

Driver

DAV-WR532

TV CVBS

EEPROM

IC510

U24

AN5832

U301

AFC OUT

I C

IC516

RF In

TUNER

SIF

Fig. 4-4-1

4-2. Power Supply Block Diagram

D101-D104 C105

RECTIFIER

SMOOTHING

L101

AC FILTER

Q101

SW IC

CONTROL IC

RECTIFIER

SMOOTHING

D107 C109

IC101

T101

TRANS

D301 C301

RECTIFIER

SMOOTHING

D201 C201

RECTIFIER

SMOOTHING

D401 C404

RECTIFIER

SMOOTHING

12V SW

32V SW

5V SW

PHOTO

COUPLER

D403 D404

ADJUST

POWER ON SIG

AP+12V

+32V

3.3V

ON/OFF A+5V

AC 100-120V

50/60Hz

PC101

PHOTO

COUPLER

RECTIFIER

SMOOTHING

D601 C601

AN-12V

Fig. 4-4-2

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