LG DR165 User manual

DVD RECORDER
SERVICE MANUAL
MODEL: DR165/DR175/DR676X
CAUTION
BEFORE SERVICING THE UNIT, READ THE “SAFETY PRECAUTIONS”
IN THIS MANUAL.
MODEL: DR165/DR175/DR676XSERVICE MANUAL

CONTENTS
SECTION 1 . . . . SUMMARY
SECTION 2 . . . . CABINET & MAIN CHASSIS
SECTION 3 . . . . ELECTRICAL
SECTION 4 . . . . RS-01A LOADER PART
SECTION 5 . . . . REPLACEMENT PARTS LIST

1-1
SECTION 1
SUMMARY
CONTENTS
PRODUCT SAFETY SERVICING GUIDELINES FOR VIDEO PRODUCTS.............. 1-2
SERVICING PRECAUTIONS .................................................................................................. 1-3
• General Servicing Precautions
• Insulation Checking Prodedure
• Electrostatically Sensitive Devices
SERVICE INFORMATION FOR EEPROM IC SETTING.................................................. 1-4
FLASH UPGRADE...................................................................................................................... 1-5
LOADER UPGRADE.................................................................................................................. 1-7
SPECIFICATIONS ...................................................................................................................... 1-9

1-21-2
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 Electronics
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 haz-
ard. These components are indicated by the letter “x” included in their compo-
nent designators and are required to maintain safe performance. No deviations
are allowed without prior approval by LG Electronics 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 is 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 modi-
fications 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 equi-
lateral 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 fromAC line shock.
After the original service problem has been corrected, make a check of the fol-
lowing:
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 par-
ticles.
4. Check for physical evidence of damage or deterioration to parts and compo-
nents, 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 TRANS-
FORMER DURING THISTEST. Use anAC 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 metal-
lic 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 consti-
tutes 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 tilt-
ed 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 cast-
ers 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 conse-
quences to home and family.
A.C. Voltmeter
1500 OHM
10 WATT
Place this probe
on each exposed
metal part.
Good Earth Ground
such as the Water
Pipe, Conduit, etc.
0.15uF
PRODUCT SAFETY SERVICING GUIDELINES FOR VIDEO PRODUCTS

1-3
SERVICING PRECAUTIONS
CAUTION : Before servicing the DVD Recorder 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 servic-
ing precautions and any of the safety precautions in this pub-
lications, always follow the safety precautions.
Remembers Safety First:
General Servicing Precautions
1. Always unplug the DVD RecorderAC power cord from the
AC power source before:
(1)Removing or reinstalling any component, circuit board,
module, or any other assembly.
(2)Disconnection or reconnecting any internal electrical
plug or other electrical connection.
(3)Connecting a test substitute in parallel with an elec-
trolytic 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 Recorder 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
whitch instruments covered by this service manual might
be equipped.
5. Do not apply AC power to this DVD Recorder and/or any
of its electrical assemblies unless all solid-state device
heat sinks are cerrectly installed.
6. Always connect test instrument ground lead to the
appropriate ground before connection 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 resis-
tance between each blade of the attachment plug and acces-
sible conductive parts (Note 1) should be more than 1M-
ohm.
Note 1 : Accessible Conductive Parts including Metal pan-
els, 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 compo-
nent or semiconductor-equipped assembly, drain off any
electrostatic charge on your body by touching a known
earth ground. Alternatively, obtain and wear a commer-
cially 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 grouned-tip soldering iron to solder or unsolder
ES devices.
4. Use only an anti-static solder removal device. Some
solder removal devices not classified a “anti-static”can
generate electrical charges sufficient to damage ES
devices.
5. Do not use freon-propelled chemicals. These can
generate electrical charge sufficient to damage ES
devices.
6. Do not remove a replacement ES device from its protec
tive 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 elec-
tricity sufficient to damage an ES device.)

1-4
SERVICE INFORMATION FOR EEPROM IC SETTING
MICOM START
Press the "CLEAR" key on the
Remote controller and the
"PROG. - " key one the Front Panel
the same time, then it goes in to
Tracking initial mode.
EEPROM ID CHECK
2 BYTE(B3,248,249) NAME HEX BINARY
OPT1 D9 00000000
OPT2 00 00000000
OPT3 60 00000000
OPT4 41 00000000
OPT5 4B 00000000
OPT6 2C 00000000
OPT7 46 00000000
OPT8 12 00000000
WRITE : OK EXIT : MP
MOVE : < > EDIT :
MASK : 00 , EEP : FF(0R), D17
(Each mask ,eeprom, It shows a
development release version.)
*** EEPROM INITIAL ***
- SETUP is displayed in the field if pressing the Front PROG. - & + Key with the Remocon number "clear" key pressed in the status of
powering on.
- AUTO SEARCH is done since the initial screen of ACMS is serviced if powering on.
DETECT NEW EEPROM (OPTION EDIT SCREEN)
OPTION condition of Present time the
CHECK There is a Possibility of doing and
the OPTION the REWRITE it is possible.
OPTION DATA READ
5TIME & COMPARE
MICOM NORMAL
OPERATION START
ID OK?
OPTION CONFIRMATION MODE
Yes
Yes
No
No

1-5
FLASH UPGRADE
1. MAKING UPGRADE DISC
1) Do Physical format as ISO9660 or JOLIET file system.
2) Don’t care about the CD Volume label.
3) Write DR100 BE Upgrade File on Root.
2. UPGRADE FLASH
1) Put Flash Upgrade Disc on the Set.
2) After Disc Reading, you can see below screen.
3) Press REC KEY 3 times. It will start Inspection.
* OPTIONAL PARTS
•DR100 8601 64M NTSC) :
LG_DR100_8601NT64_UPDATE.590
•DR100 860164M (PAL ) :
LG_DR100_8601PAL64_UPDATE.590
•DR100 860132M (NTSC) :
LG_DR100_8601NT_UPDATE.590
•DR100 860132M (PAL ) :
LG_DR100_8601PAL_UPDATE.590
•DR100 8603 64M (NTSC) :
LG_DR100_8603NT_UPDATE.590
•DR100 8603 64M (PAL ) :
LG_DR100_8603PAL_UPDATE.590
< example- Nero Burning Rom >

1-6
4) You can see both current and upgrade version.
Press REC KEY.
5) Upgrading.
6) After Upgrading, you can see the below screen. And automatically open tray.
Eject the Disc. Reboot the set.

1-7
LOADER UPGRADE
1.MAKING UPGRADE DISC
1) Do Physical format as ISO9660 or JOLIET file system
2) Make a Volume label as “DRIVE_UP”.
3) Write DvdSLXX.rs1, YASMSLXX.BIN on Root like below.(XX is Version)
2. LOADER UPGRADE
1) Put Loader Upgrade Disc on Set.
2) After Disc Reading, you can see the below screen.
3) Press REC KEY 3 times.
< example- Nero Burning Rom >

1-8
4) After Tray open, pick the disc up and close the tray.
5) It shows both the current version and upgrade version.
Press REC KEY.
6) Upgrading.
7) After finishing Upgrade, it shows the below screen and is tuned off

1-9
SPECIFICATIONS
•GENERAL
Power requirements AC 200-240V, 50/60 Hz
Power consumption 25W
Dimensions (approx.) 430 X 54 X 275 mm (w x h x d) without foot
Mass (approx.) 4.1 kg
Operating temperature 5°C to 35°C
Operating humidity 5 % to 90 %
Television system PAL I, B/G, I/I, SECAM D/K, K1, SECAM L color system
Recording format PAL
•RECORDING
Recording format DVD Video Recording, DVD-VIDEO
Recordable media DVD-ReWritable, DVD-Recordable,
DVD+ReWritable, DVD+Recordable
Recordable time DVD (4.7GB): Approx. 1 hour 20 minutes (XP mode),
2 hours (SP mode), 4 hours (LP mode),
6 hours (EP mode)
Video recording format
Sampling frequency 27MHz
Compression format MPEG 2 (VBR support)
Audio recording format
Sampling frequency 48kHz
Compression format Dolby Digital
•PLAYBACK
Frequency response DVD (PCM 48 kHz): 8 Hz to 22 kHz, CD: 8 Hz to 20 kHz
DVD (PCM 96 kHz): 8 Hz to 44 kHz
Signal-to-noise ratio More than 100 dB (AUDIO OUT connector)
Harmonic distortion Less than 0.008% (AUDIO OUT connector)
Dynamic range More than 95 dB (AUDIO OUT connector)
•INPUTS
AERIAL IN Aerial input, 75 ohms
VIDEO IN 1.0 Vp-p 75 ohms, sync negative, RCA jack x 2 / SCART x 2
AUDIO IN 2.0 Vrms more than 47 kohms, RCA jack (L, R) x 2 / SCART x 2
S-VIDEO IN (Y) 1.0 V (p-p), 75 Ω, sync negative, Mini DIN 4-pin x 1
(C) 0.3 V (p-p) 75 Ω
DV IN 4 pin (IEEE 1394 standard)
•OUTPUTS
VIDEO OUT 1 Vp-p 75 Ω, sync negative, RCA jack x 1 / SCART x 2
S-VIDEO OUT (Y) 1.0 V (p-p), 75 Ω, sync negative, Mini DIN 4-pin x 1
(C) 0.3 V (p-p) 75 Ω
COMPONENT VIDEO OUT (Y) 1.0 V (p-p), 75 Ω, sync negative, RCA jack x 1
(Pb)/(Pr) 0.7 V (p-p), 75 Ω, RCA jack x 2
Audio output (digital audio) 0.5 V (p-p), 75 Ω, RCA jack x 1
Audio output (optical audio) 3 V (p-p), 75 Ω, Optical connector x 1
Audio output (analog audio) 2.0 Vrms (1 KHz, 0 dB), 600 ߟ, RCA jack (L, R) x 1 / SCART x 2

2-1
SECTION 2
CABINET & MAIN CHASSIS
CONTENTS
EXPLODED VIEWS ....................................................................................................................2-2
1. Cabinet and Main Frame Section ..........................................................................................2-2
2. Deck Mechanism Section(RS-01A) .......................................................................................2-3
3. Packing Accessory Section ...................................................................................................2-4

2-2
EXPLODED VIEWS
1. Cabinet and Main Frame Section
A
A
B
B
463
468
468
268
465
465
260
261
261
267
265
467
264
320
468
468
471
468
463
250
272
274
322
463
463
251
275
275
280
452
452
452
251
300
463
A47
A60
A43
A44
A50
A46
A52
OPTIONAL PART
CABLE9
CABLE5
CABLE3
CABLE1
SMPS
JUNCTION
MAIN
I/O TU701
A55
468
273
NOTES) THE EXCLAMATION POINT WITHIN AN
EQUILATERAL TRIANGLE IS INTENDED
TO ALERT THE SERVICE PERSONNEL
TO THE PRESENCE OF IMPORTANT
SAFETY INFORMATION IN SERVICE
LITERATURE.
A
5
4
3
2
1
BCD

2-32-3
2. DECK MECHANISM SECTION(RS-01A)
1034
1030
1025
1041
1432
1437
1434
1032
1033
1038
1011
1432
1020
1036
1432
Main C.B.A
1001
1431
1003 1002
1026
A001
A60
A002
1016
1433
1017
1013
1015
1012
1439
1047
1048
1046
1014
1018
1019 1043 1045
1044
1042
A005

2-4
808 Battery
Cable, Coaxial
Plug Ass'y, 1Way
Plug Ass'y, 2Way
Bag
Packing
Remote Control
Instruction Ass'y
Packing
Box
806
804
803
811
Plug Ass'y, 1Way
814
812
801
900
802
803
810 CABLE ASS'Y 821 SCART CABLE
FLAT CABLE
822
OPTIONAL PARTS
3. Packing Accessory Section
832 DISC

3-1
SECTION 3
ELECTRICAL
CONTENTS
VDR PART
ELECTRICAL TROUBLESHOOTING GUIDE...................................................................................3-2
1. POWER SUPPLY ON SMPS BOARD........................................................................................3-2
2. POWER SUPPLY ON I/O BOARD..............................................................................................3-4
3. SYSTEM CIRCUIT PART..........................................................................................................3-11
4. DISC NOT RECOGNIZED ........................................................................................................3-11
5. WHEN PLAYING DISC, NO AUDIO OUTPUT..........................................................................3-12
6. NO OPTICAL / DIGITAL OUTPUT............................................................................................3-13
7. NO TUNER AUDIO OUTPUT ...................................................................................................3-14
8. NO EXTERNAL AUDIO INPUT.................................................................................................3-15
9. NO RGB / COMPONENT VIDEO SIGNAL WHEN PLAY DISC ...............................................3-16
10. NO COMPOSITE / S-VIDEO SIGNAL WHEN PLAY DISC ....................................................3-17
11. NO TV, EXTERNAL INPUT VIDEO SIGNAL...........................................................................3-18
12. NO DV(IEEE 1394) INPUT (VIDEO/AUDIO) SIGNAL............................................................3-19
BLOCK DIAGRAMS........................................................................................................................3-20
1. SMPS BLOCK DIAGRAM.........................................................................................................3-20
2. MAIN POWER BLOCK DIAGRAM ...........................................................................................3-22
3. VIDEO IN BLOCK DIAGRAM ...................................................................................................3-24
4. VIDEO OUT BLOCK DIAGRAM ...............................................................................................3-26
5. AUDIO IN BLOCK DIAGRAM ...................................................................................................3-28
6. AUDIO OUT BLOCK DIAGRAM ...............................................................................................3-30
7. SYSTEM MAIN BLOCK DIAGRAM ..........................................................................................3-32
8. I/O µ-COM BLOCK DIAGRAM................................................................................................. 3-34
9. SCART BLOCK DIAGRAM(SCART MODEL ONLY) ................................................................3-36
CIRCUIT DIAGRAMS ......................................................................................................................3-38
1. SMPS CIRCUIT DIAGRAM.......................................................................................................3-38
2. MAIN POWER CIRCUIT DIAGRAM.........................................................................................3-40
3. MPEG CIRCUIT DIAGRAM......................................................................................................3-42
4. A.LATCH/FLASH/DDR CIRCUIT DIAGRAM.............................................................................3-44
5. LOADER/DV CIRCUIT DIAGRAM............................................................................................3-46
6. I/O µ-COM CIRCUIT DIAGRAM ...............................................................................................3-48
7. TUNER/MPX/ADC/DAC/JACK CIRCUIT DIAGRAM ................................................................3-50
8. DECODER CIRCUIT DIAGRAM...............................................................................................3-52
9. TIMER CIRCUIT DIAGRAM ( 6, 7 TOOL ONLY ).....................................................................3-54
10. KEY CIRCUIT DIAGRAM ( 6, 7 TOOL ONLY ).......................................................................3-56
•WAVEFORMS.............................................................................................................................3-58
•CIRCUIT VOLTAGE CHART.......................................................................................................3-60
PRINTED CIRCUIT DIAGRAMS......................................................................................................3-64
1. MAIN P.C.BOARD(TOP SIDE) .................................................................................................3-64
2. MAIN P.C.BOARD(BOTTOM SIDE)..........................................................................................3-66
3. I/O P.C.BOARD.........................................................................................................................3-68
4. JUCTION P.C.BOARD ..............................................................................................................3-68
5. KEY P.C.BOARD.......................................................................................................................3-70
6. TIMER P.C.BOARD...................................................................................................................3-70
7. POWER P.C.BOARD ................................................................................................................3-71

3-2
ELECTRICAL TROUBLESHOOTING GUIDE
VDR PART
Replace the BD101
Replace the F101
(Use the same Fuse)
No .5.3VA
Is the F101 Normal?
Is the R101 Normal?
Is the BD101
Normal?
NO
NO
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
NOYES
YES
YES
YES
YES
YES
Replace the R101
Is the D102 normal?
Check or Replace
the D102
Replace the D123
Replace the IC103
Replace the IC102
Is the D121 Normal?
Is there about 2.5V
at the IC103 Pin1?
Is the IC102 Normal?
Replace the D124
Replace the D125
Is the D124 Normal?
Is the D125 Normal?
NO
YES
YES
Replace the D127
Is the D127 Normal?
Power Line of I/O
PCB is short
Is Vcc (10V - 16V)
supplied to IC101 Pin7?
1. POWER SUPPLY ON SMPS BOARD

3-3
No 12V
Is the Vcc(14.0V) supplied to IC131 pin 1?
YES
Check or Replace the D127
NO
Is the IC131 pin4 ‘H’?
YES
Check the PWR CTL “H”signal
from µ-com
NO
Check or Replace the IC131
YES
No 5V
Is the Vcc(5.5V) supplied to IC132 pin 1?
YES
Check or Replace the D125
NO
Is the IC132 pin4 ‘H’?
YES
Check the PWR CTL “H”signal
from µ-com
NO
Check or Replace the IC132
YES

3-4
2. POWER SUPPLY ON I/O BOARD
No 12V
Is the VCC (14V) supplied to Q164
Collector?
YES
Check D124 on SMPS Board and
Replace
NO
Is there about 12.5V at ZD151 & Q164
Base ?
YES
Check Q164 and Replace
NO
Check D126 on SMPS Board and
Replace
NO
Check Q162 and Replace
NO
Check the ‘PWR CTL H’signal from
µ-COM
NO
Is the VCC (33V) supplied to Q162
Emitor ?
YES
Is there about 0V at Q162 Base ?
YES
Is there about 5V at R171 and 0.7V at
Q156 Base?
YES
Check Q156 and Replace
YES

3-5
No 5.2V
Is the VCC (5.3V) supplied to Q151
Emitor ?
YES
Check 5.3VA on SMPS Board
NO
Is there about 0V at D153 and Q156
Collector ?
YES
Check Q151 and Replace
NO
Check the ‘PWR CTL H’signal from
µ-COM
NO
Is there about 5V at R171 and 0.7V at
Q156 Base ?
YES
Check Q156 and Replace
YES
No 5VT
Is the VCC (5.3V) supplied to Q155
Emitor ?
YES
Check 5.3VA on SMPS Board
NO
Is there about 0V at D152 and Q152
Collector?
YES
Check Q155 and Replace
NO
Check the ‘TIMER H’signal from µ-COM
NO
Is there about 5V at R180 and 0.7V at
Q152 Base?
YES
Check Q152 and Replace
YES