LG DK867 User 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

Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE 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

SECTION 1
SUMMARY
CONTENTS
1-2 Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
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

1-3
Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
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 : Do not attempt to modify this product in any way. Never perform
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.
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 A LINE 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.

1-4 Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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, cotton-
tipped 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.)

1-5
Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
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.

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.
Take 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.
1-6 Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only

1-7
Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
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

1-8 Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
MEMO

2-1
Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
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

OPTIONAL PARTS
A
D
A
C
B
460
460
462
460
250
462
462
A46
P101
A47
300
CB
462
A26
283
467
A48
MAIN
SMPS
5.1CH
SCART
276
463
KARAOKE &
USB
A43
280
279
KEY
CN903
452
D
A49
CABLE1
TIMER
452
452
462
A44
261
261
260
262
320
465
261
A42
A41
CABLE2
461
275 CN801
CN802
EXPLODED VIEWS
2-2 Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
1. CABINET AND MAIN FRAME SECTION

2-3
Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
2. DECK MECHANISM SECTION (DP-12V)
442
442
010
442
012
012
037
012
019
026
440
015
017
013
439
018
A02
A26
A01
001
002
003
014
015A
015B 016
020
435
A03

2-4 Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
3. PACKING ACCESSORY SECTION
808 Battery
810Cable Set Ass'y
OPTIONAL PARTS 832 Disc
806 RF Cable
811Plug Ass'y 1way(Yellow)
820Plug Ass'y 1way(Black)
801 Owner's Manual
804 Packing Sheet
803 Packing
812 Plug Ass'y 2way
900 Remocon
803 Packing
802 Box Carton

3-1
Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
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

3-2 Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
1. SMPS TROUBLESHOOTING FLOW
No 3.3VA
Replace the FR101
(Use the same ICW)
YES
YES
NO
Power Line of Main
PCB(DVD) is short
Is the FR101 normal?
Replace the
D105/D106/D107/D108
YES
NO
Is the D105/D106/D107/
D108 normal?
Check or Replace the IC101
YES
NO
Is the Vcc (about 17V)
supplied to IC101 Pin2?
Replace the D121
YES
NO
Is the D121 normal?
Replace the IC103
YES
NO
Is there about 2.5V at the
IC103 Pin1?
Replace the D123
YES
NO
Is the D123 normal?
Replace the D125
YES
NO
Is the D125 normal?
ELECTRICAL TROUBLESHOOTING GUIDE

3-3
Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
No REG 5.0V
Check or Replace the D123
YES
YES
NO
Check or Replace the Q126
Is the Vcc(=5.6V)
supplied to Q126
Collector?
Check the ‘PWR CTL “H”’
signal from µ-com
YES
NO
Is the Vcc(=12V)
supplied to Q126
Base?
ELECTRICAL TROUBLESHOOTING GUIDE
•
•
•
•
No 12V
Check or Replace the D125
YES
YES
NO
Check or Replace the Q123
Is the Vcc(=14V)
supplied to Q123
Collector?
Check the ‘PWR CTL “H”’
signal from µ-com
YES
NO
Is the Vcc(=12V)
supplied to Q126
Base?
•
•
•
•

3-4 Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
ELECTRICAL TROUBLESHOOTING GUIDE
Is 5.6V present at
collector of Q126?
No 3.3VA
YES YES
YES YES
No 5V No 3.3VA.
Replace Q126. Check FR101 Replace Q121.
YES
Is there a DC voltage at
cathode of D105 or D107?
YES
NO
NO
NO
NO
Replace IC101.
2. POWER CHECK FLOW
A. B.
Check D105/D106/D107/
D108 and replace.
Is 3.3VA
section working?
Is 3.3VA
section working?
Is 3.3V
present at emitter
of Q121?

3-5
Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
ELECTRICAL TROUBLESHOOTING GUIDE
Power on
1. 8032 initializes SERVO,DSP & RISC registers
2. Write RISC code to SDRAM
3. Reset RISC
Show LOGO
Tray close to closed position
SLED moves to inner position
1. Judge whether have disc and disc type
2. Jump to related disc reading procedure
1. Execute pressed Key & IR key
2. System operation routine loop
1. Stop playback & open Tray
2. Display tray open message & LOGO
NO
YES
YES
NO
YES
YES
NO
NO
3. SYSTEM OPERATION FLOW
Tray closed?
SLED at inner side?
Recieve OPEN/CLOSE Key?
Receive CLOSE Key?

3-6 Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
4. SYSTEM TEST FLOW
TEST
Replace power PCBA or AC transformer.
YES
NO
Switch on the power PCBA
Repair or Replace power PCBA
YES
NO
Make sure the main PCBA don't
short on VCCs and switch it on.
YES
Check the regulators or related diodes.
YES
NO
Connect to PC RS232 cable and
update the FLASH memory code.
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.
NO
A
YES
Check the AC
Voltage Power PCBA (110V
or 220V)
Update FLASH
successfully?
Is the DC
voltage outputs OK?
(5V, 3.3V, 12V, 5.6V
MOTOR)
Is 3.3V
and 1.8V DC outputs normal
on main PCBA?
ELECTRICAL TROUBLESHOOTING GUIDE

3-7
Copyright © 2008 LG Electronics. Inc. All right reserved.
Only for training and service purposes
LGE Internal Use Only
RESET or power on.
NO NO
YES
Check connection lines
between FLASH & MT1389L
and the FLASH access time
whether is suitable or not.
NO
YES
Check connection lines
between SDRAM & MT1389L
and the SDRAM is damaged.
NO
YES
Check the related circuit of
MT1389L.
NO
YES
Check the filtering and amp
circuit of TV signal.
Check AV cable
connection to TV set.
NO NO
YES
Check the load OPEN &
CLOSE switch
NO
YES
Check the Tray control IO
pins on MT1389L & AM5890S.
NO
YES
Check the Tray control
amplifying circuit on Motor driver.
Check the cable connection
between main PCBA and loader.
YES
YES
Show LOGO?
Flash
memory operates
properly?
MT1389L
VIDEO outputs
properly?
Normal
OPEN_SW & CLOSE_
SW signals?
Normal
OPEN & CLOSE
signal?
Normal
FAN_TRAY+ & FAN_
TRAY- signal?
Does
Tray move inside
when it is not at closed
position?
SDRAM
works properly?
Have TV
signal output?
A
B
ELECTRICAL TROUBLESHOOTING GUIDE