LG DK-855, DK-854, DK-867, DV-840 Service manual

DVD-VIDEO PLAYER

SERVICE MANUAL

MODEL: DK867/DK855/DK854/DV840

CAUTION

BEFORE SERVICING THE UNIT, READ THE “SAFETY PRECAUTIONS” IN THIS MANUAL.

MODEL: DK867/DK855/DK854/DV840

SERVICE MANUAL

P/NO : AFN35874449 DECEMBER,2007

Website http://biz.lgservice.com

Internal Use Only

CONTENTS

SECTION 1.........SUMMARY

SECTION 2.........CABINET & MAIN CHASSIS

SECTION 3.........ELECTRICAL

SECTION 4.........MECHANISM (DP-12V)

SECTION 5.........REPLACEMENT PARTS LIST

LGE Internal Use Only

SECTION 1

SUMMARY

CONTENTS

PRODUCT SAFETY SERVICING GUIDELINES FOR DVD PRODUCTS..................................1-3

SERVICING PRECAUTIONS....................................................................................................................1-4

• GENERAL SERVICING PRECAUTIONS

• INSULATION CHECKING PRODEDURE

• ELECTROSTATICALLY SENSITIVE (ES) DEVICES

THE PROCESS OF DISC DOWNLOAD ...............................................................................................1-5

SPECIFICATIONS ........................................................................................................................................1-7

LGE Internal Use Only

1-2

Only for training and service purposes

PRODUCT SAFETY SERVICING GUIDELINES FOR DVD PRODUCTS

IMPORTANT SAFETY NOTICE

This manual was prepared for use only by properly trained audio-video service technicians. When servicing this product, under no circumstances should the original design be modified or altered without permission from LG Corporation. All components should be replaced only with types identical to those in the original circuit and their physical location, wiring and lead dress must conform to original layout upon completion of repairs.

Special components are also used to prevent x-radiation, shock and fire hazard. These components are indicated by the letter “x” included in their component designators and are required to maintain safe performance. No deviations are allowed without prior approval by LG Corporation. Circuit diagrams may occasionally differ from the actual circuit used. This way, implementation of the latest safety and performance improvement changes into the set are not delayed until the new service literature is printed.

CAUTION

customized installations without manufacturer’s approval. Unauthorized modifications will not only void the warranty, but may lead to property damage or user injury.

Service work should be performed only after you are thoroughly familiar with these safety checks and servicing guidelines.

: Do not attempt to modify this product in any way. Never perform

GRAPHIC SYMBOLS

The exclamation point within an equilateral triangle is intended to alert the service personnel to important safety information in the service literature. The lightning flash with arrowhead symbol within an equilateral triangle is intended to alert the service personnel to the presence of noninsulated “dangerous voltage” that may be of sufficient magnitude to constitute a risk of electric shock. The pictorial representation of a fuse and its rating within an equilateral triangle is intended to convey to the service personnel the following fuse replacement caution notice: CAUTION: FOR CONTINUED PROTECTION AGAINST RISK OF FIRE, REPLACE ALL FUSES WITH THE SAME TYPE AND RATING AS MARKED NEAR EACH FUSE.

SERVICE INFORMATION

While servicing, use an isolation transformer for protection from AC line shock. After the original service problem has been corrected, make a check of the following:

FIRE AND SHOCK HAZARD

1. Be sure that all components are positioned to avoid a possibility of adjacent component shorts. This is especially important on items trans-ported to and from the repair shop.

2. Verify that all protective devices such as insulators, barriers, covers, shields, strain reliefs, power supply cords, and other hardware have been reinstalled per the original design. Be sure that the safety purpose of the polarized line plug has not been defeated.

3. Soldering must be inspected to discover possible cold solder joints, solder splashes, or sharp solder points. Be certain to remove all loose foreign particles.

4. Check for physical evidence of damage or deterioration to parts and components, for frayed leads or damaged insulation (including the AC cord), and replace if necessary.

5. No lead or component should touch a high current device or a resistor rated at 1 watt or more. Lead tension around protruding metal surfaces must be avoided.

6. After reassembly of the set, always perform an AC leakage test on all exposed metallic parts of the cabinet (the channel selector knobs, antenna terminals, handle and screws) to be sure that set is safe to operate without danger of electrical shock. DO NOT USE ALINE ISOLATION TRANSFORMER DURING THIS TEST. Use an AC voltmeter having 5000 ohms per volt or more sensitivity in the following manner: Connect a 1500 ohm, 10 watt resistor, paralleled by a .15 mfd 150V AC type capacitor between a known good earth ground water pipe, conduit, etc.) and the exposed metallic parts, one at a time. Measure the AC voltage across the combination of 1500 ohm resistor and .15 mfd capacitor. Reverse the AC plug by using a non-polarized adaptor and repeat AC voltage measurements for each exposed metallic part. Voltage measured must not exceed 0.75 volts RMS. This corresponds to 0.5 milliamp AC. Any value exceeding this limit constitutes a potential shock hazard and must be corrected immediately.

TIPS ON PROPER INSTALLATION

1. Never install any receiver in a closed-in recess, cubbyhole, or closely fitting shelf space over, or close to, a heat duct, or in the path of heated air flow.

2. Avoid conditions of high humidity such as: outdoor patio installations where dew is a factor, near steam radiators where steam leakage is a factor, etc.

3. Avoid placement where draperies may obstruct venting. The customer should also avoid the use of decorative scarves or other coverings that might obstruct ventilation.

4. Wall- and shelf-mounted installations using a commercial mounting kit must follow the factory-approved mounting instructions. A product mounted to a shelf or platform must retain its original feet (or the equivalent thickness in spacers) to provide adequate air flow across the bottom. Bolts or screws used for fasteners must not touch any parts or wiring. Perform leakage tests on customized installations.

5. Caution customers against mounting a product on a sloping shelf or in a tilted position, unless the receiver is properly secured.

6. A product on a roll-about cart should be stable in its mounting to the cart. Caution the customer on the hazards of trying to roll a cart with small casters across thresholds or deep pile carpets.

7. Caution customers against using extension cords. Explain that a forest of extensions, sprouting from a single outlet, can lead to disastrous consequences to home and family.

1-3

LGE Internal Use Only

SERVICING PRECAUTIONS

CAUTION: Before servicing the DVD covered by this service data and its supplements and addends, read and follow the SAFETY PRECAUTIONS. NOTE: if unforeseen circumstances create conflict between the following servicing precautions and any of the safety precautions in this publication, always follow the safety precautions. Remember Safety First :

General Servicing Precautions

1. Always unplug the DVD AC power cord from the AC power source before: (1) Removing or reinstalling any component, circuit board,

module, or any other assembly.

(2) Disconnecting or reconnecting any internal electrical

plug or other electrical connection.

(3) Connecting a test substitute in parallel with an

electrolytic capacitor. Caution: A wrong part substitution or incorrect polarity installation of electrolytic capacitors may result in an explosion hazard.

2. Do not spray chemicals on or near this DVD or any of its assemblies.

3. Unless specified otherwise in this service data, clean electrical contacts by applying an appropriate contact cleaning solution to the contacts with a pipe cleaner, cottontipped swab, or comparable soft applicator. Unless specified otherwise in this service data, lubrication of contacts is not required.

4. Do not defeat any plug/socket B+ voltage interlocks with which instruments covered by this service manual might be equipped.

5. Do not apply AC power to this DVD and / or any of its electrical assemblies unless all solid state device heat sinks are correctly installed.

6. Always connect the test instrument ground lead to an appropriate ground before connecting the test instrument positive lead. Always remove the test instrument ground lead last.

Insulation Checking Procedure

Disconnect the attachment plug from the AC outlet and turn the power on. Connect an insulation resistance meter (500V) to the blades of the attachment plug. The insulation resistance between each blade of the attachment plug and accessible conductive parts (Note 1) should be more than 1Mohm. Note 1: Accessible Conductive Parts include Metal panels, Input terminals, Earphone jacks,etc.

Electrostatically Sensitive (ES) Devices

Some semiconductor (solid state) devices can be damaged easily by static electricity. Such components commonly are called Electrostatically Sensitive (ES) Devices. Examples of typical ES devices are integrated circuits and some field effect transistors and semiconductor chip components. The following techniques should be used to help reduce the incidence of component damage caused by static electricity.

1. Immediately before handling any semiconductor component or semiconductor-equipped assembly, drain off any electrostatic charge on your body by touching a known earth ground. Alternatively, obtain and wear a commercially available discharging wrist strap device, which should be removed for potential shock reasons prior to applying power to the unit under test.

2. After removing an electrical assembly equipped with ES devices, place the assembly on a conductive surface such as aluminum foil, to prevent electrostatic charge buildup or exposure of the assembly.

3. Use only a grounded-tip soldering iron to solder or unsolder ES devices.

4. Use only an anti-static solder removal device. Some solder removal devices not classified as “anti-static” can generate electrical charges sufficient to damage ES devices.

5. Do not use freon-propelled chemicals. These can generate an electrical charge sufficient to damage ES devices.

6. Do not remove a replacement ES device from its protective package until immediately before you are ready to install it. (Most replacement ES devices are packaged with leads electrically shorted together by conductive foam, aluminum foil, or comparable conductive material).

7. Immediately before removing the protective material from the leads of a replacement ES device, touch the protective material to the chassis or circuit assembly into which the device will be installed.

Caution: Be sure no power is applied to the chassis or circuit, and observe all other safety precautions.

8. Minimize bodily motions when handling unpackaged replacement ES devices. (Normally harmless motion such as the brushing together of your clothes fabric or the lifting of your foot from a carpeted floor can generate static electricity sufficient to damage an ES device.)

LGE Internal Use Only

1-4

Only for training and service purposes

THE PROCESS OF DISC DOWNLOAD

Please follow the below process to download a program with disc

1. Turn on the DVD-player. (Note. Be sure that there is no disc in DVD-player)

2. Press “SETUP” button on Remote control.

3. Choose a “display” menu by using the cursor button and then choose a “TV Aspect” menu. And choose “16:9” menu.

4. Press the 1 --> 3 --> 9 --> 7 --> 1 --> 3 --> 9(numerical button) --> Enter key on remote control to confirm the system information.

5. Remember or write the model name.

6. Change the program file name of new version to the model name Ex> New ver. program file->LG_DV_LV80F7FC10EMSMIS_V014.ROM

Model name -> LG_DV_LV81F7FC00EMS

Change New ver. program file like this --> LG_DV_LV81F7FC00EMSMIS.ROM

(NOTICE) You must add “MIS” at the end of model name

If you don”t change the file name like that, Disc download isn”t be worked.

1-5

LGE Internal Use Only

7. Copy the changed file to a disc.

8. Insert the copied disc to DVD-player.

9. If the below picture appears on the screen, Press “ ” key.

10.After the below picture appears on the screen, Disc will emerge from DVD-player automatically.

Ta ke the disc out of the DVD-player.

11. After Disc download is completed, DVD-player turns off and then turns on automatically.

12.Do it again the process 1, 2, 3, 4 to confirm the version.

LGE Internal Use Only

1-6

Only for training and service purposes

SPECIFICATIONS

• GENERAL

Power requirements AC 110V ~ 240V, 50/60Hz

Power consumption 8W

Dimensions (Approx.) 360 x 35 x 195mm

(W x H x D) without foot

Net Weight (Approx.) 2.3kg

Operating temperature: 5°C to 35°C

Operating humidity 5% to 90%

Laser Semiconductor laser

Signal system PAL / NTSC

• OUTPUTS

Video Output 1.0V (p-p), 75Ω, sync negative,

RCA jack x 1

Component Video Output (Y) 1.0V (p-p), 75Ω,

sync negative, RCA jack x 1

(Pb)/(Pr) 0.7V (p-p),

75Ω, RCA jack x 2

Audio Output 2.0Vrms (1kHz, 0dB), 600Ω,

RCA jack (L, R) x 1 /

Digital Output (Coaxial) 0.5V (p-p), 75Ω, RCA jack x 1

1-7

LGE Internal Use Only

MEMO

LGE Internal Use Only

1-8

Only for training and service purposes

SECTION 2

CABINET & MAIN CHASSIS

CONTENTS

EXPLODED VIEWS .....................................................................................................................................2-2

1. CABINET AND MAIN FRAME SECTION ..................................................................................................2-2

2. DECK MECHANISM SECTION (DP-12V).................................................................................................2-3

3. PACKING ACCESSORY SECTION...........................................................................................................2-4

2-1

LGE Internal Use Only

EXPLODED VIEWS

1. CABINET AND MAIN FRAME SECTION

460

OPTIONAL PARTS

462

460

A26

462

2 46

A46

250

CABLE2

A48

5.1CH

SCART

283

CABLE1

MAIN

2 46

463

1 46

52 4

CN801

75 2

452

A49

TIMER

MPS S

P101

CN802

USB

KARAOKE &

A41

A47

300

A44

465

261

467

276

320

462

61 2

260

61 2

262

LGE Internal Use Only

A43

CN903

452

A42

KEY

280

2-2

79 2

Only for training and service purposes

2. DECK MECHANISM SECTION (DP-12V)

A26

026

A02

017

013

015

435

439

015B

015A

001

A01

002

003

018

014

020

016

010

440

442

A03

442

012

2-3

012

442

012

037

019

LGE Internal Use Only

3. PACKING ACCESSORY SECTION

808 Battery

900 Remocon

803 Packing

OPTIONAL PARTS

810Cable Set Ass'y

832 Disc

806 RF Cable

811Plug Ass'y 1way(Yellow)

812 Plug Ass'y 2way

820Plug Ass'y 1way(Black)

801 Owner's Manual

804 Packing Sheet

803 Packing

802 Box Carton

LGE Internal Use Only

2-4

Only for training and service purposes

SECTION 3

ELECTRICAL

CONTENTS

ELECTRICAL TROUBLESHOOTING GUIDE.....................................................................................3-2

1. SMPS TROUBLESHOOTING FLOW ......................................................................................................3-2

2. POWER CHECK FLOW ..........................................................................................................................3-4

3. SYSTEM OPERATION FLOW.................................................................................................................3-5

4. SYSTEM TEST FLOW ...........................................................................................................................3-6

DETAILS AND WAVEFORMS ON SYSTEM TEST AND DEBUGGING...................................3-12

1. SYSTEM 27MHZ CLOCK, RESET, FLASH R/W SIGNAL ....................................................................3-12

2. SDRAM CLOCK ...................................................................................................................................3-14

3. TRAY OPEN/CLOSE SIGNAL ...............................................................................................................3-14

4. SLED CONTROL RELATED SIGNAL (NO DISC CONDITION)............................................................3-15

5. LENS CONTROL RELATED SIGNAL (NO DISC CONDITION) ..........................................................3-15

6. LASER POWER CONTROL RELATED SIGNAL (NO DISC CONDITION) ..........................................3-16

7. SPINDLE CONTROL WAVEFORM (NO DISC CONDITION) ...............................................................3-16

8. FOCUS ON WAVEFORM ......................................................................................................................3-17

9. TRACKING CONTROL RELATED SIGNAL (SYSTEM CHECKING) ....................................................3-18

10. MT1389L AUDIO COAXIAL OUTPUT (SPDIF) .....................................................................................3-19

11. MT1389L VIDEO OUTPUT WAVEFORM ..............................................................................................3-19

12. AUDIO OUTPUT FROM MT1389L ........................................................................................................3-20

CONNECTOR PICTURE ..........................................................................................................................3-21

1. ALL CONNECTOR PICTURE ................................................................................................................3-21

2. CN201 CONNECTOR PICTURE...........................................................................................................3-22

3. CN202 CONNECTOR PICTURE...........................................................................................................3-22

4. CN601 CONNECTOR PICTURE...........................................................................................................3-23

5. CN602 CONNECTOR PICTURE...........................................................................................................3-23

6. CN605 CONNECTOR PICTURE...........................................................................................................3-24

7. CN701 CONNECTOR PICTURE...........................................................................................................3-24

BLOCK DIAGRAMS ..................................................................................................................................3-25

1. OVERALL BLOCK DIAGRAM ...............................................................................................................3-25

2. POWER (SMPS) BLOCK DIAGRAM.....................................................................................................3-26

3. SYSTEM BLOCK DIAGRAM .................................................................................................................3-27

4. SERVO BLOCK DIAGRAM ...................................................................................................................3-28

5. VIDEO BLOCK DIAGRAM.....................................................................................................................3-29

6. AUDIO BLOCK DIAGRAM.....................................................................................................................3-30

CIRCUIT DIAGRAMS................................................................................................................................3-31

1. POWER (SMPS) CIRCUIT DIAGRAM ..................................................................................................3-31

2. SYSTEM (MPEG) CIRCUIT DIAGRAM.................................................................................................3-33

3. SERVO CIRCUIT DIAGRAM.................................................................................................................3-35

4. AV (JACK) CIRCUIT DIAGRAM ............................................................................................................3-37

5. 5.1CH CIRCUIT DIAGRAM (OPTION) ..................................................................................................3-39

6. KARAOKE & USB CIRCUIT DIAGRAM (OPTION)...............................................................................3-41

7. KEY CIRCUIT DIAGRAM ......................................................................................................................3-43

8. TIMER CIRCUIT DIAGRAM ..................................................................................................................3-45

• CIRCUIT VOLTAGE CHART.........................................................................................................3-53

PRINTED CIRCUIT BOARD DIAGRAMS...........................................................................................3-55

1. MAIN P.C.BOARD..................................................................................................................................3-55

2. POWER (SMPS) P.C.BOARD ...............................................................................................................3-57

3. 5.1CH & SCART P.C.BOARD (OPTIONAL PART) ................................................................................3-57

4. KARAOKE & USB P.C.BOARD (OPTIONAL PART) .............................................................................3-59

5. KEY P.C.BOARD ...................................................................................................................................3-63

6. TIMER P.C.BOARD ...............................................................................................................................3-63

3-1

LGE Internal Use Only

ELECTRICAL TROUBLESHOOTING GUIDE

1. SMPS TROUBLESHOOTING FLOW

No 3.3VA

YES

Is the FR101 normal?

YES

Is the D105/D106/D107/

D108 normal?

YES

Is the Vcc (about 17V)

supplied to IC101 Pin2?

YES

Is the D121 normal?

YES

Is there about 2.5V at the

IC103 Pin1?

YES

Replace the FR101

(Use the same ICW)

Replace the

D105/D106/D107/D108

Check or Replace the IC101

Replace the D121

Replace the IC103

Is the D123 normal?

Is the D125 normal?

Power Line of Main

PCB(DVD) is short

LGE Internal Use Only

YES

3-2

Replace the D123

Replace the D125

Only for training and service purposes

ELECTRICAL TROUBLESHOOTING GUIDE

No REG 5.0V

YES

Is the Vcc(=5.6V)

•

supplied to Q126

Collector?

YES

Is the Vcc(=12V)

•

supplied to Q126

Base?

YES

Check or Replace the Q126

No 12V

YES

Is the Vcc(=14V)

•

supplied to Q123

Collector?

Check or Replace the D123

Check the ‘PWR CTL “H”’

signal from µ-com

Check or Replace the D125

YES

Is the Vcc(=12V)

•

supplied to Q126

Base?

YES

Check or Replace the Q123

3-3

Check the ‘PWR CTL “H”’

signal from µ-com

LGE Internal Use Only

ELECTRICAL TROUBLESHOOTING GUIDE

2. POWER CHECK FLOW

A. B.

No 5V No 3.3VA.

Is 3.3VA

section working?

YES

Is 5.6V present at

collector of Q126?

YES

No 3.3VA

Replace Q126. Check FR101 Replace Q121.

Is there a DC voltage at

cathode of D105 or D107?

Is 3.3VA

section working?

YES

Is 3.3V

present at emitter

of Q121?

YES

Check D105/D106/D107/

D108 and replace.

YES

Replace IC101.

LGE Internal Use Only

3-4

Only for training and service purposes

ELECTRICAL TROUBLESHOOTING GUIDE

3. SYSTEM OPERATION FLOW

Power on

1. 8032 initializes SERVO,DSP & RISC registers

2. Write RISC code to SDRAM

3. Reset RISC

Show LOGO

YES

Tray closed?

Tray close to closed position

SLED at inner side?

SLED moves to inner position

1. Judge whether have disc and disc type

2. Jump to related disc reading procedure

Recieve OPEN/CLOSE Key?

YES

1. Execute pressed Key & IR key

2. System operation routine loop

1. Stop playback & open Tray

2. Display tray open message & LOGO

Receive CLOSE Key?

3-5

YES

LGE Internal Use Only

ELECTRICAL TROUBLESHOOTING GUIDE

4. SYSTEM TEST FLOW

TEST

Check the AC

Voltage Power PCBA (110V

or 220V)

YES

Switch on the power PCBA

Is the DC

voltage outputs OK?

(5V, 3.3V, 12V, 5.6V

MOTOR)

YES

Make sure the main PCBA don't

short on VCCs and switch it on.

YES

Is 3.3V

and 1.8V DC outputs normal

on main PCBA?

YES

Replace power PCBA or AC transformer.

Repair or Replace power PCBA

Check the regulators or related diodes.

Connect to PC RS232 cable and

update the FLASH memory code.

Update FLASH

successfully?

YES

LGE Internal Use Only

1. Check 27MHz system clock.

2. Check system reset circuit.

3. Check FLASH R/W enable signal PRD, RWR.

4. Check RS232 SIGNALS.

5. Check FLASH Memory related circuit.

3-6

Only for training and service purposes

ELECTRICAL TROUBLESHOOTING GUIDE

RESET or power on.

Show LOGO?

YES

Does

Tray move inside

when it is not at closed

position?

NO NO

Flash

memory operates

properly?

YES

SDRAM

works properly?

YES

MT1389L

VIDEO outputs

properly?

YES

Have TV

signal output?

YES

Check AV cable

connection to TV set.

OPEN_SW & CLOSE_

Normal

SW signals?

YES

Check connection lines

between FLASH & MT1389L

and the FLASH access time

whether is suitable or not.

Check connection lines between SDRAM & MT1389L and the SDRAM is damaged.

Check the related circuit of

MT1389L.

Check the filtering and amp

circuit of TV signal.

Check the load OPEN &

CLOSE switch

YES

Normal

OPEN & CLOSE

signal?

YES

Normal

FAN_TRAY+ & FAN_

TRAY- signal?

YES

Check the cable connection

between main PCBA and loader.

3-7

Check the Tray control IO

pins on MT1389L & AM5890S.

Check the Tray control

amplifying circuit on Motor driver.

LGE Internal Use Only

ELECTRICAL TROUBLESHOOTING GUIDE

Does

the SLED move

to inner side when it is

at outter position?

YES

Do not put in disc and

tray close.

Optical Lens has

movements for searching

focus?

Motor

Driver DR_MUTE

Pin is High?

YES

Is SLD_

PWM DC Level Higher

than 1.65V?

YES

FAN_SLD+

& FAN_SLD- output

properly?

YES

Check the cable connection

with MECHA.

Proper

FOD outputs to motor

driver?

YES

NONO

Check the connection line of

DR_MUTE signal.

Check the related circuit of

SLD_PWM

Check the amp circuit on

motor driver.

Check FOD connection on

MT1389L and motor driver.

LGE Internal Use Only

YES

Proper

FCS+ & FCS-

outputs?

YES

Check cable connect on

with pick-up head.

3-8

Check the amp circuit on

motor driver.

Only for training and service purposes

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