Sony DVP-K800D User manual

Chinese Model
E Model
Hong kong Model
Spanish Model
Taiwan Model
SERVICE MANUAL
CD/DVD PLAYER
MICROFILM
SPECIFICATIONS
DVP-K800D
RMT-D106E
• Refer to the OPERATION MANUAL (9-921-669-21) and
DVD MECHANISM OPERATION MANUAL (9-921-669-31)
for DVD mechanism.

— 2 —
SAFETY-RELATED COMPONENT WARNING!!
COMPONENTS IDENTIFIED BY MARK !OR DOTTED LINE WITH
MARK !ON THE SCHEMATIC DIAGRAMS AND IN THE PARTS
LIST ARE CRITICAL TO SAFE OPERATION. REPLACE THESE
COMPONENTS WITH SONY PARTS WHOSE PART NUMBERS
APPEAR AS SHOWN IN THIS MANUAL OR IN SUPPLEMENTS
PUBLISHED BY SONY.
1. Check theareaofyourrepair for unsolderedor poorly-soldered
connections. Checkthe entire boardsurface for solder splashes
and bridges.
2. Check the interboard wiring to ensure that no wires are
"pinched" or contact high-wattage resistors.
3. Look for unauthorized replacement parts, particularly
transistors, that were installed during a previous repair. Point
them out to the customer and recommend their replacement.
4. Look for parts which, through functioning, showobvious signs
of deterioration. Point them out to the customer and
recommend their replace-ment.
5. Check the B+ voltage to see it is at the values specified.
6. Flexible Circuit Board Repairing
• Keep the temperature of the soldering iron around 270˚C
during repairing.
• Do not touch the soldering iron on the same conductor of the
circuit board (within 3 times).
• Be careful not to apply force on the conductor when soldering
or unsoldering.
SAFETY CHECK-OUT
After correcting the original service problem, perform the following
safety checks before releasing the set to the customer.
WARNING!!
WHEN SERVICING, DO NOT APPROACH THE LASER
EXIT WITH THE EYE TOO CLOSELY. IN CASE IT IS
NECESSARY TO CONFIRM LASER BEAM EMISSION,
BE SURE TO OBSERVE FROM A DISTANCE OF MORE
THAN 25cm FROM THE SURFACE OF THE OBJECTIVE
LENS ON THE OPTICAL PICK-UP BLOCK.
CAUTION:
The use of optical instrument with this product will increase eye
hazard.
CAUTION
Use of controls or adjustments or performance procedures other
than those specified herein may result in hazardous radiation
exposure.

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TABLE OF CONTENTS
SERVICE NOTE
1. DISK REMOVAL PROCEDURE (at POWER OFF) .................... 4
2. NOTE ON MOUNTING SLED MOTOR ................................. 4
3. REPLACING OPTICAL PICK-UP ............................................... 5
3-1. Handling .......................................................................................... 5
4. NOTE ON ASSEMBLING MECHANICAL DECK.................. 6
4-1. Application of Grease ..................................................................... 6
4-2. Cleaning Spindle Motor Turntable ................................................. 7
4-3. Aligning Phase of Cam Gear and Drive Gear ................................ 7
4-4. Deformation of Insulator................................................................ 7
4-5. Note on connecting OPT Harness .................................................. 7
4-6. Note on Mounting FG-43 Board .................................................... 8
4-7. Note on Mounting TK-47 Board.................................................... 8
5. EMERGENCY CODE INDICATION ........................................... 8
5-1. Users are expected to take of the followings by thermselves
--- “C” code .................................................................................... 8
5-2. Consult Sony Service --- “E” code, E :YY: ZZ ............................. 8
1. GENERAL
Getting Started
Unpacking...........................................................................................................1-1
Hooking Up the System......................................................................................1-1
Necessary Setup Before Using the Player ..........................................................1-1
Selecting the Language for On-screen Display ..................................................1-1
Basic Operations
Playing a DVD .................................................................................................... 1-2
Playing a CD/VIDEO CD ..................................................................................1-3
Enjouing Karaoke
Using Karaoke .................................................................................................... 1-4
Reserving Karaoke .............................................................................................1-4
Additing Richness toYour Voice (Karaoke Star) ............................................... 1-5
Plaing Karaoke withAny Stereo Disc (Karaoke Pon) ........................................ 1-5
Using the On-Screem Dosplay ........................................................................... 1-5
Playing Discs in Various Modes
Using the On-Screen Display .............................................................................1-4
Using the Front Panel Display ............................................................................ 1-5
Playing Repeatedly (Repeat Play) ...................................................................... 1-6
Playing in Random Order (Shuffle Play) ...........................................................1-5
CreatingYour Own Program (Program Play) .....................................................1-6
Resuming Playback from the Point Where
You Stopped a Disc (Resume Play) ....................................................................1-7
Reducing the Picture Noise
(DNR: Digital Video Noise Reduction)..............................................................1-7
Changing the Sounds ..........................................................................................1-7
Displaying the Subtitles...................................................................................... 1-7
Changing the Angles........................................................................................... 1-7
Limiting Playback by Children (Parental Control) ............................................1-7
Controlling the TV or the amplifier with
the Supplied Remote...........................................................................................1-8
Settings and Adjustments
Using the Setup Display ..................................................................................... 1-8
Setting the Language for Displaying and Sound (LANGUAGE SETUP) ......... 1-9
Settings for Display (INITIAL SETUP 1)..........................................................1-9
Settings for Sound (INITIAL SETUP 2) ............................................................1-9
Dolby Digital Surround
What is Dolby Digital Surround? ....................................................................... 1-9
Speaker System Hookups ...................................................................................1-9
Speaker Setup ...................................................................................................1-10
Setting for Dolby Digital Surround .................................................................. 1-10
Additional Information
Precautions .......................................................................................................1-11
Notes on Discs ..................................................................................................1-11
Troubleshooting ................................................................................................ 1-11
Self-diagnosis Function ....................................................................................1-12
Index to Parts and Controls ..............................................................................1-12
Setup Display Item List ....................................................................................1-13
Language Code List.......................................................................................... 1-13
2. DISASSEMBLY
2-1. UPPER CASE ............................................................................. 2-1
2-2. FRONT PANEL BLOCK ASSEMBLY ......................................2-1
2-3. AU-217 BOARD .........................................................................2-2
2-4. MB-78 BOARD .......................................................................... 2-2
2-5. KR-35 BOARD ...........................................................................2-3
2-6. POWER BLOCK ........................................................................ 2-3
2-7. TK-47 BOARD ...........................................................................2-4
2-8. HP-116 BOARD, MC-115/VR-68 BOARD BLOCK,
FL-106 BOARD, FR-156 BOARD............................................. 2-4
2-9. CIRCUIT BOARDS LOCATION............................................... 2-5
3. BLOCK DIAGRAMS
3-1. OVERALL BLOCK DIAGRAM ................................................ 3-1
3-2. RF/SERVO BLOCK DIAGRAM................................................ 3-3
3-3. AUDIO BLOCK DIAGRAM ..................................................... 3-5
3-4. VIDEO BLOCK DIAGRAM ...................................................... 3-7
3-5. SYSTEM CONTROL BLOCK DIAGRAM............................... 3-9
3-6. MODE CONTROL BLOCK DIAGRAM ................................. 3-11
3-7. AC3 BLOCK DIAGRAM ......................................................... 3-13
3-8. POWER SUPPLY BLOCK DIAGRAM................................... 3-15
4. PRINTED WIRING BOARDS AND
SCHEMATIC DIAGRAMS
4-1. FRAME SCHEMATIC DIAGRAM ...........................................4-1
4-2. PRINTED WIRING BOARDS AND
SCHEMATIC DIAGRAMS ........................................................ 4-3
• TK-47 (RF, SERVO) PRINTED WIRING BOARD ................ 4-4
• TK-47 (RF, SERVO) SCHEMATIC DIAGRAM .....................4-7
• MB-78 (VIDEO, SERVO/SYSTEM CONTROL,AUDIO)
PRINTED WIRING BOARD ...................................... 4-12
• MB-78 (DSP) SCHEMATIC DIAGRAM ..............................4-17
• MB-78 (AV DECODER) SCHEMATIC DIAGRAM ............4-20
• MB-78 (VIDEO ENCODER) SCHEMATIC DIAGRAM .....4-23
• MB-78 (INTERFACE) SCHEMATIC DIAGRAM ................4-26
• MB-78 (MOTOR DRIVE) SCHEMATIC DIAGRAM ..........4-29
• MB-78 (POWER SUPPLY) SCHEMATIC DIAGRAM ........4-31
• MB-78 (DIGITAL PROCESS 1)
SCHEMATIC DIAGRAM ...........................................4-33
• MB-78 (DIGITAL PROCESS 2)
SCHEMATIC DIAGRAM ...........................................4-37
• MB-78 (AC3 DECODER)
SCHEMATIC DIAGRAM ...........................................4-41
• AU-217 (VIDEO/AUDIO INPUT/OUTPUT)
SCHEMATIC DIAGRAM ...........................................4-44
• AU-217 (VIDEO/AUDIO INPUT/OUTPUT)
PRINTED WIRING BOARD ...................................... 4-47
• FL-106 (DISPLAY, OPERATION SWITCHES)
PRINTED WIRING BOARDS .................................... 4-49
• FL-106 (DISPLAY, OPERATION SWITCHES)
SCHEMATIC DIAGRAM ...........................................4-51
• FG-43 (SLED MOTOR)
PRINTED WIRING BOARDS .................................... 4-54
• FG-43 (SLED MOTOR)
SCHEMATIC DIAGRAMS .........................................4-55
• HP-116 (PHONES JACK)
PRINTED WIRING BOARDS .................................... 4-56
• HP-116 (PHONES JACK)
SCHEMATIC DIAGRAMS .........................................4-57
• KR-35 (KARAOKE DSP/MIC 3, 4)
SCHEMATIC DIAGRAMS .........................................4-59
• KR-35 (KARAOKE DSP/MIC 3, 4)
PRINTED WIRING BOARDS .................................... 4-61
• MIC-115 (MIC 1, 2)
SCHEMATIC DIAGRAMS .........................................4-63
• MIC-115 (MIC 1, 2)
PRINTED WIRING BOARDS .................................... 4-65
• FR-156 (POWER SWITCH)
SCHEMATIC DIAGRAMS .........................................4-67
• FR-156 (POWER SWITCH)
PRINTED WIRING BOARDS .................................... 4-69
• VR-68 (MIC/ECHO LEVEL)
SCHEMATIC DIAGRAMS .........................................4-71
• VR-68 (MIC/ECHO LEVEL)
PRINTED WIRING BOARDS .................................... 4-73
• POWER BLOCK HS-930SH (SWITCHING REGULATOR)
PRINTED WIRING BOARD ...................................... 4-75
• POWER BLOCK HS-930SH (SWITCHING REGULATOR)
SCHEMATIC DIAGRAM ...........................................4-77
• POWER BLOCK HS-930SF (SWITCHING REGULATOR)
PRINTED WIRING BOARD ...................................... 4-79
• POWER BLOCK HS-930SF (SWITCHING REGULATOR)
SCHEMATIC DIAGRAM ...........................................4-81

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5. TEST MODE
5-1. How to Enter Test Mode ............................................................. 5-1
5-2. System Control Diagnosis........................................................... 5-1
5-2-1. Selection of Check Items ............................................................ 5-2
5-2-1-1. Testing the Selected Item .......................................................... 5-2
5-2-1-2. Testing All Items....................................................................... 5-3
5-2-2. Error Display ............................................................................... 5-3
5-2-3. Diagnosis Check Item List .......................................................... 5-4
5-2-4. Brief Description of Check Procedures ......................................5-5
5-2-5. Diagnosis Error Code Table ...................................................... 5-17
5-3. Drive Auto Adjustment ............................................................. 5-18
5-3-1. [0] ALL ..................................................................................... 5-18
5-3-2. [1] DVD Single Layer Disc.......................................................5-19
5-3-3. [2] CD disc ................................................................................ 5-20
5-3-4. [3] DVD dual layer disc ............................................................5-20
5-4. Drive Manual Operation............................................................ 5-21
5-4-1. Setup Displays In Accordance With
Selected Disc Type .................................................................... 5-21
5-4-2. Manual Control (1).................................................................... 5-22
5-4-3. Manual Control (2).................................................................... 5-22
5-4-4. Manual Control (3).................................................................... 5-23
5-4-5. Manual Adjustment (1) ............................................................. 5-24
5-4-6. Manual Adjustment (2) ............................................................. 5-25
5-4-7. Automatic Adjustment .............................................................. 5-25
5-4-8. Check ........................................................................................ 5-26
5-5. Mechanism Aging .................................................................... 5-27
5-6. History of Emergencies............................................................. 5-27
5-6-1. Hour Meter Display ..................................................................5-27
5-6-2. History of Emergencies Display ...............................................5-28
5-6-3. Initialization of Emergency History ..........................................5-28
5-7. Other Checks ............................................................................. 5-28
5-8. Appendix ................................................................................... 5-29
5-8-1. Emergency Code Table ............................................................. 5-29
5-8-2. Drive Mechanism Mode Table .................................................. 5-30
5-8-3. Disc Status Table ....................................................................... 5-30
5-8-4. System Control Microprocessor Operation Mode Table...........5-30
6. ELECTRICAL ADJUSTMENT
6-1. POWER SUPPLY CHECK (MB-78 board) ............................... 6-1
6-2. LEDs, DISPLAY CHECK .......................................................... 6-1
6-3. SYSTEM CONTROL ADJUSTMENT ......................................6-2
6-3-1. 27MHz Free Run (MB-78 board) ............................................... 6-2
6-4. VIDEO SYSTEMADJUSTMENT ............................................6-2
6-4-1. Video Level Adjustment (AU-217, MB-78 boards) ....................6-2
6-4-2. S-terminal Output Check (AU-217 board) .................................. 6-2
6-4-3. Checking Composite Video Output Y (AU-217 board) .............. 6-3
6-4-4. Checking S Video Output S-C (AU-217 board) .......................... 6-3
6-4-5. Checking S Video Output DC Level (AU-217 board)................. 6-3
6-5. ADJUSTMENT RELATED PARTSARRANGEMENT ...........6-4
7. REPAIR PARTS LIST
7-1. EXPLODED VIEWS
7-1-1. FRONT PANEL BLOCK ASSEMBLY SECTION .................... 7-1
7-1-2. CHASSIS SECTION .................................................................. 7-2
7-1-3. DVD MECHANISM CHASSIS BLOCK ASSEMBLY (1) ....... 7-3
7-1-3. DVD MECHANISM CHASSIS BLOCK ASSEMBLY (2) ....... 7-4
7-2. ELECTRICAL PARTS LIST ......................................................7-5

— 5 —
SERVICE NOTE
1. DISK REMOVAL PROCEDURE (at POWER OFF)
1) Insert a cross-tip screwdriver into a hole at the bottom, and rotate the cam gear 1in direction A. (See Fig. 1)
Note: To prevent a damage of cam gear, rotate it in direction Aby 1/4 turn.
2) Draw out the tray 2in direction Bby hand, and remove a disk. (See Fig. 1)
2. NOTE ON MOUNTING SLED MOTOR
1) Push the sled motor assy 1toward direction A. (See Fig. 2)
2) Tighten two screws 2(M1.7 ×2.5).
Fig. 2
3) Raising the MD block assy 390 º with the side down. confirm that the optical pick-up 4falls by self weight. (See Fig. 3)
4) Further, with the front side of MD block assy 3up, confirm that the optical pick-up falls by self weight.
DVP-K800D
Fig. 3
1 Sled motor assy
2 Two screws (M1.7 × 2.5)
3 MD block assy
4 Optical pick-up
Lower
Upper
Front side Lower
Upper Front side
A
B
⊕
Screw Driver
1 Cam gear
2 Tray
Fig. 1

— 6 —
3. REPLACING OPTICAL PICK-UP
3-1. Handling
1) A red laser diode for DVD requires more attention to static
electricity than general infrared laser diodes for CD.
Because its durability to static electricity is far weaker than
that of infrared laser diodes, always use an earth band when
handling the optical pick-up block as service parts.
2) As for the flexible board KHS-180A (RP) packed as service
parts, the short lands have been soldered to protect from static
electricity.Accordingly, remove solders when replacing optical
pick-up. (See Fig. 4)
Fig. 4 Flexible board
3) In handling the KHS-180A (RP), do not touch inhibited parts
shown in Fig. 5, but grip the slide base bearing and U-shaped
guide.
Touch inhibited parts
• Objective lens
• Skew sensor
• Laser holder
• Laser coupler
• Flexible board
• OEIC
• Lens actuator covers
Fig. 5 KHS-180A (RP)
DVD short land
CD short land
Slide base bearing
Skew sensor
Lens actuator
covers
Objective lense
s
U-shaped guide
OEIC
Laser holder
Flexible board
Connecto
r
Laser coupler

— 7 —
4. NOTE ON ASSEMBLING MECHANICAL DECK
4-1. Application of Grease
1) Grease must be applied if the following parts are replaced. (See Fig. 6)
Note 1: Recommended grease is Foil KG-70MP.
Note 2: In applying grease, take care not to allow grease to stick to other parts (particularly, rubber belt, spindle motor, and optical pick-up).
Fig. 6
Base unit holder
2 bosses
Loading pulley shaft
NOTE:Add grease if tray
generates noise
periodically.
Tray 3 grooves
NOTE:Add grease if tray
moves slowly.
Slide base Skew cam
Cam gear

— 8 —
4-2. Cleaning Spindle Motor Turntable
1) Remove the tray. (Refer to 2-2)
2) Clean thespindle motor turntable if discantiskid rubber (black)
is dirty. (See Fig.7)
Fig. 7
4-3. Aligning Phase of Cam Gear and Drive Gear
1) Align triangle marks when assembling the cam gear and drive
gear. (See Fig. 8)
Fig. 8
Spindle motor
Turntable
Drive gear Cam gear
Align triangle marks.
4-4. Deformation of Insulator
1) Assemble the spindle base into the base unit.
2) Lock with 4 shoulder screws. (See Fig. 9)
3) Check if 4 insulators deformed. (See Fig. 9)
Fig. 9
4-5. Note on Connecting OPT Harness
1) The optical pick-up could be destroyed unless the OPT harness
is connected normally to the connector. (See Fig. 10)
Fig. 10
NG
Four step screws
Two insulators
Two insulators Insulator
Good
Good NG
OPT harness
Connector

— 9 —
4-6. Note on Mounting FG-43 Board
1) Align two bosses. (See Fig.11)
2) Fix theboard securelywith screws(PTPWH 2 ×5). (The sensor
will not function normally if the board floats up.)
Fig. 11
4-7. Note on Mounting TK-47 Board
1) Align two bosses. (See Fig.12)
2) Align four tabs. (See Fig.12)
3) Fix the board securely with 3 screws (BV 3 ×10). (The sensor
will not function normally if the board floats up.)
Fig.12
Screw
(PTPWH2
× 5)
FG-43 board
Two bosses
Three screws
(BV3
× 10 )
TK-47 board
Boss
Two claws
Boss
Two claws
5. EMERGENCY CODE INDICATION
5-1. Users are expected to take care of the
followings by themselves – – – – “C” code
“C : 13 : XX Clean the disc”
“C : 31 : XX Remove and insert the disc again”
XX
00
10
20
30
40
50
61
62
63
60
70
80
90
PON ready
Stop
Trace
Pause
Drvcon Unit
Mecha Unit
Spin Up
Tracking offset
Jitter/Gain
TOC/Control Data Read
Others
Spin Down
Seek
Error Recovery
5-2. Consult Sony Service – – – “E” code,
E : YY : ZZ
Refer to the item “5-8. Appendix” for details.
YY
01
02
03
04
06
07
10
16
21
30
31
32
33
34
35
40
41
42
60
61
62
63
EEPROM reading: NG (Check Sum has abnormality)
EEPROM writing: NG (Check Sum has abnormality)
EEPROM BUSYisdisplayed continuously exceeding
the specified time.
The pointer that shows the newest Emg History has
abnormality.
Communication between the HI microprocessor and
the SYS microprocessor is interrupted for a specified
time.
HI microprocessor cannot detect V-sync.
EEPROM CHECK NG
DSP CHECK NG
Sled driver has abnormal voltage.
Hy Det Level adjustment has abnormality.
Sled Offset Cancel adjustment has abnormality.
Focus Gain adjustment is faulty.
Tracking Offset adjustment is faulty.
Tracking Gain adjustment is faulty.
JITTER NG (only during the automatic adjustment)
Focus Servo does not lock in.
Focus Jump failed.
DSP Error Code (not used)
Mis-chucking when disc is inserted.
When disc started rotation, it did not reach the target
speed within 3 seconds.
Spindle runs away/does not stop.
Lock Check (in the service mode only)

— 10 —
YY
64
65
66
70
71
72
73
80
81
82
83
84
85
86
87
88
89
90
96
97
A0
A1
A2
A3
A4
A5
A6
A7
B0
B1
B2
B3
B4
B5
B6
B7
B8
C0
C1
D0
D1
E0
E1
CLV servo does not lock in within the specified time.
FG servo does not reach the target speed within the
specified time.
Spindle is not rotating at x1 speed. (RF Edge)
System control requests address that does not exist.
System control requests time code that is not used.
System control requests track No. that is not used.
The lock-in operation is not completed within the
specified number of times.
Continuity of address has abnormality. (DVD)
Cannot read address even retry is executed. (CD)
TOCreadis not completed within the specified period
of time.
PhysicalInformation Read Error ( CTRL DATA ECC
ERR)
Physical Information Read Error ( CTRL DATA
INSA ERR)
Physical Information Read Error ( CTRL DATA
FULL ERR)
PhysicalInformation Read Error ( CTRL DATA RUN
OVER)
PhysicalInformation Read Error( CTRL DATA Time
Out)
Layer No has abnormality.
CD Text Data Read Error
Servo recovery has failed when starting a disc.
Auto Sequence Time Out
Auto Sequence has exceeded the specified times.
Stop request from drive microprocessor
Did not return to the mode for a specified time.
Feed error. Retry is impossible.
GetInfo error. Stop
An attempt is made to playback a DVD-R Disc
Failed to execute Decrypt
SlowR. Target address of searching is illegal.
Feed error. Stop
Due to feeder.
Due to video hang-up
Error in DMX
Waiting for data from SlowR
Navi Pack sector address is different during SlowR
mode
Video hang-up during SlowR mode
Time out while waiting for ending of SlowR Gttgt
Waiting for data during FF/FR
Waiting for video data during FF/FR
Theinstalled HI microprocessorROM does notmatch
the destination.
HI microprocessor UART1 communication port has
abnormality.
EMGcode is notpresent upon power-offrequestfrom
drive microprocessor
Cannot return t stop mode. Power Off
Drive microprocessor - system error (STATUS ERR)
Drive microprocessor - system error (MECHAM
MODE ERR)
ZZ
FF
00
01
02
12
03
13
04
14
05
15
UNKONWN
NO DISC
CD 12 cm
CD 8 cm
SINGLE DVD 12 cm
SINGLE DVD 8 cm
DUAL 12 cm
CDR 12 cm
CDR 8 cm
DVDR 12 cm
DVDR 8 cm

1-1
DVP-K800D
SECTION 1
GENERAL This section is extracted from
instruction manual.

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10