Service Manual

Model: KSDT863
 CONTENTS
1. Main Board Maintain Manual ..............................................................................................................................1
1.1 Main Board Block Diagram Introduction ....................................................................................................1
1.2 Detail Introduction of Main Board Principle Diagram .................................................................................2
1.2.1 Main Board Power Supply ...............................................................................................................2
1.2.2 CPU Peripheral Circuit ....................................................................................................................4
1.2.3 Storage Device ................................................................................................................................5
1.2.4 Video & Audio Output ......................................................................................................................6
1.2.5 USB Module ....................................................................................................................................7
1.2.6 DEMO Circuit ..................................................................................................................................9
1.2.7 TUNER Circuit ...............................................................................................................................10
1.2.8DEMO Crystal Circuit of Demodulation ..........................................................................................10
1.2.9 Crystal Circuit of Demodulation ..................................................................................................... 11
1.3 Common Fault Analysis ........................................................................................................................... 11
1.3.1 Unbootable, No Video Output ....................................................................................................... 11
1.3.2Reboot............................................................................................................................................12
1.3.3Searching Failure ...........................................................................................................................13
1.3.4Output Black Screen or Stunk On Booting Screen .........................................................................13
1.3.5Front Panel or Remote Control Failure ..........................................................................................13
2. Power Board Maintain Manual..........................................................................................................................14
2.1Electrical Block Diagram and Principle Description ..................................................................................14
2.2 Fault Type and Maintenance Procedure ..................................................................................................14
2.3 Complimentary Close ..............................................................................................................................17
2.4 Schematic Circuit Diagram ......................................................................................................................17
3. Repairing Environment .....................................................................................................................................17
3.1 List of repairing tools ...............................................................................................................................17
3.1.1 Necessary Tools ............................................................................................................................18
3.1.2 Optional Tools ...............................................................................................................................19
3.2 Repairing Environment ............................................................................................................................20
3.2.1 Basic Maintenance Environment ...................................................................................................20
3.2.2 Senior Maintenance Environment .................................................................................................22
 1. Main Board Maintain Manual

This chapter will introduce the principle of CP 35018836（KHDT863-A-0） motherboard and

the main function of each part of the components on the circuit and board.

1.1 Main Board Block Diagram Introduction

Introduction of main module and chipset:

1) CPU:MSD7816
2) NOR Flash 4MB: Module: W25Q32BV. Use for storing the firmware, channels’ information
etc.. After the resetting, the CPU will load firmware from NOR FLASH to accomplish the
function of STB.
3) DDR2 512MB: Module: W9751G6KB-18. Use for storing the data generated by the STB at
running. After the resetting, CPU will load data from the NOR FLASH and store the data in the
DDR2 and buffering the data such as video content.
4) Front Control Panel: Connect the control panel and the CPU through the flex cable to get
signal from control panel button and the remote control, and executes the corresponding
function.
5) Power Supply: There are 1 groups of power supply from the power board: 5V, The chapter 2
will introduce the detail function of each power supply.

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6) Video, Audio, HDMI, USB: The signal output interface of video and audio, and USB interface.
7) Tuner:Module: FTM-RT00IB1. Digital satellite television signal tuner. For demodulating
modulated signal from the relevant satellite digital signal frequency and send the signal to the
CPU for the demodulation decoding working in the next step.

1.2 Detail Introduction of Main Board Principle Diagram

1.2.1 Main Board Power Supply

1) The following diagram is the interface part of the main board power flex cable:

 DC-DC IC reduces 5V to 3.3V. 3.3V provides power supply to CPU (MSD7816), DEMO
(ATBM8869), TUNER (FTM-RT00IB1) and etc.
 DC-DC IC reduces 5V to 1.8V. 1.8V provides power supply to DDR2.
 DC-DC IC reduces 5V to 1.26V. 1.26V provides power supply for the CPU core.
2) The Switching Circuit of 5V to 3.3V

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 This circuit provides all the 3.3V power supply of the main board. If the 3.3V circuit is abnormal,
the STB will cannot boot up.

3) The Switching Circuit of 5V to 1.26V

This circuit provides power supply for the CPU core. The range of voltage between
1.26V~1.36V can be regarded as normal. If the voltage is abnormal, the STB cannot boot up. The
most likely damaged components are L33, U9, L34 or CPU. CPU damage can cause this
outputting short circuit to the ground.

4) The Switching Circuit of 5V to 1.8V

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 This circuit provides power supply to DDR2. The range of voltage between 1.75V~1.85V can
be regarded as normal.If the voltage is abnormal, the STB cannot boot up. The most likely
damaged components are L35, U10,L36or DDR2. DDR2 damage can cause this outputting short
circuit to the ground.

1.2.2 CPU Peripheral Circuit

1) CPU Crystal Oscillator Circuit

CPU runs on the accurate clock signal which provide by 24M crystal. If the crystal is failure, it
will cause unbootable issue. Check the 2 pins’ voltage of Y1 by multi-meter ( DC voltage position ),
if the value between 1.35V~1.65V means the oscillator is working normally.
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2) Serial Communication Circuit

This part of circuit converts the electrical level of CPU serial port to suitable for the connection
of STB to the PC serial port. Used for the transmission of debug log information, firmware update
and so on.

1.2.3 Storage Device

1) 8MB FLASH Memory

The U15 (W25Q32BV) is a 4MB NOR FLASH Memory device. Used for stores firmware,
channel information, channel setting information, CA information and so on. If this device is
damage, it will cause unbootable issue.

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2) DDR2 Memory
The U3 W9751G6KB-18 is a random access memory, to provide enough working space for
the CUP running the program. If this device is damaged, will leads to unbootable problem. If the
unbootable issue happen, please check the 1.8V power supply( The normal working voltage is
between 1.75V to 1.85V ). If the DDR2chip has abnormal heat, it means this chip is damage.

1.2.4 Video & Audio Output

1) Video Outputting Circuit

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 If this part of circuit is damaged, may cause the video abnormal too bright, too dark, no output
or such as failure. Please check the RCA (CN4) or RF modulator (TU13).

2) Audio Amplifier Circuit

This circuit is audio amplifier circuit. If the 5V power supply for the audio amplifier IC is
abnormal, it may cause volume too low or no volume issue. Please check the U18.

1.2.5 USB Module

1) 5V Power Supply Protection Circuit

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The F1 is thermistor which material is 1206-1/4W-0Ω, namely fuse. When a short circuit happens
on USB device, the F2 turns off the 5V output to prevent damage of the internal power supply
module. The F2 can self-restore after the short circuit is removed.

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1.2.6 DEMO Circuit

If the STB cannot lock the signal, Please check the power supply is normal, The most likely
damaged components are L23, L51, U2,U6 or U16.

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1.2.7 TUNER Circuit

If the STB cannot lock the signal, please check the power supply of the 11 pin of the TU13.
The normal voltage is 3.3V the mostly issue may be the TU13 itself. If the voltage is abnormal,
check the 5V to 3.3V.
3/4 Channel OUTPUT: If the TV cannot lock the 3/4CH signal, please check the power supply
of the 7 pin of the TU13. The normal voltage is 3.3V the mostly issue may be the TU13 itself. If the
voltage is abnormal, check the 5V to 3.3V or TL13.

1.2.8DEMO Crystal Circuit of Demodulation

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 If the crystal is abnormal, it will cause cannot lock the signal issue. Please check the DC
voltage of the 2 pins. The normal voltage is nearly 0.65-0.95V.

1.2.9 Crystal Circuit of Demodulation

CPU is connected to the control on front panel by this part of circuit. If the control panel failure
or remote control does not work, please check the flex cable’s connection of this part.

1.3 Common Fault Analysis

1.3.1 Unbootable, No Video Output

1.3.1.1 Check Power Board

Check whether each power supply of power board is normal (Please refer to chapter 1.2.1 for
the normal working voltage). If the power LED on control panel is flashing, that means there is
short circuit on the main board. If the power LED does not blink, that needs to check no output or
low voltage failure on power board. If there is no output or low voltage, please replace normal
power board and check the booting is OK.

1.3.1.2 Check Critical Voltage on Main Board

If the power supply from power board is normal. Need to check the CPU core voltage 1.26V,
other voltage 3.3V. If the power supply is abnormal, please check the device of the power supply
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circuit. Replace the damaged component, check the booting is OK.

1.3.1.3 Check DDR Power Supply

Check the 1.8V of DDR power supply. Check if there is dry joint, short circuit or such as failure
on the resistance between the CUP and DDR. Check again after the failure is excluded.
If there is abnormal, please replace the damaged component.

1.3.1.4 All Power Supply Normal

Please check whether the crystal is working. The checking method is as follows: Set the multi-
meter at DC voltage position, check whether the voltage on the two pins of Y1 crystal is about 1.5V.
If there is no voltage, means the crystal is not working. May be the CPU or the crystal is damaged.
Please replace the damaged component.

1.3.1.5 Flash Power Supply

Check the power supply of flash chip.If the flash chip is damaged, replace the chip and check
whether the booting is normal.

1.3.2Reboot

1.3.2.1 Power Board Abnormal

Connect the 12V pin of power flex cable by multi-meter. Check if there is greater volatility
(drops to less than 10V) when the power on process. If there is great volatility, please replace the
power board.

1.3.2.2 FLASH or DDR I Damage

Connect the STB to PC by serial port. Check the debug information. If there is always the
same content when auto-reboot, may be the data in the NOR FLASH or the DDR is damaged.
Please check dry joint or damage on DDR I or FLASH chipset. If there is no dry joint, please
replace the DDR I or FLASH chip.

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1.3.3Searching Failure

1.3.3.1 Software Configuration

Check the frequency, software configurationand etc.

1.3.3.2 Power Supply Abnormal

Check the power supply of TUNER LNB. If it is abnormal, check the 24V voltage output of
power board. If is normal, please refer to chapter 1.2.1 to check power supply component on main
board.

1.3.3.3 Tuner Damage

Check whether the Tuner suffers damage or malfunction caused by lighting, surge or other
satellite TV FAQ. Please replace the Tuner.

1.3.4Output Black Screen or Stunk On Booting Screen

1.3.4.1
Check the 3.3V power supply of Tuner. Check the power supply of LNB. If is abnormal, please
refer chapter 1.2.1 to check the power supply component on main board.

1.3.4.2
Check or replace the DDR chip.

1.3.5Front Panel or Remote Control Failure

2.5.1
If the Power LED or digital LED display is blank, please check the 5V power supply of the
control panel.

2.5.2
If button failure. Please check the damage of button, broken or fall off of flex cable. Besides,
check if each pin of the button is short circuit to the ground. If there is short circuit, that may be a
ESD damage lead the damage of IO port on CUP. Please replace the main board or the CPU chip.

2.5.3
If the remote control failure,please check the 5V power supply of control board or if the flex
cable is broken or fall off. If all the above is normal, please replace the remote receiver and check

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again.

2.5.4
If the digital LED is blank or blinking,please check whether the flex cable is broken or fall off. If
the flex cable is normal, please check whether the IC1 on the control board is dry joint or burnout.
Or replace the IC1. If all the above is OK, please check the digital LED itself.

2. Power Board Maintain Manual

2.1Electrical Block Diagram and Principle Description

Power circuit is consisting of the parts as follows: voltage input rectifier filtering, transformer
rectifier outputting, voltage feedback, PWM control. It means the 220V alternating voltage
transform to the direct voltage by rectifier filter of the diode, reduction voltage of transformer,
rectification of rectifier, filtering of outputting capacitance. And the outputting direct voltage
feedback the voltage signal which from the backward stage to the primary PWM chip set by the
sampling and feedback of circuit. The PWM chip set controls the duty ratio to output stable voltage
by the value of feedback voltage.

Voltage input  Transformer 
220V Alternating Inputting
rectifier,  rectifier 
filter portion  output portion 

PWM  Voltage 
Control Unit  feedback 
portion 

2.2 Fault Type and Maintenance Procedure

First of all, we connect the inputting voltage and check the existing of outputting voltage and
the value of the outputting voltage. Can use the corresponding method and technological process
for the maintenance according to the different fault phenomenon as follows (The actual circuit can
reference electric schematic diagram ):
Type 1. No Voltage Outputting

No voltage outputting 

Yes 
Check the damage of the  Yes  Change  the 
Check fuse F1 conduction 
U19  PI  TNY177PN    and  U19  and 
the  peripheral  Peripheral  14
 Non‐conducting 

No  No 
Check  the  damage  of 
TNR1  D15、D16、D19、
Check  the  Yes  Change  U32 
D20、 U19 
damage  of  U31 

Yes  U32  U31

Change  the  F2 、 Yes 

THR1 、 D15 、 Output OK 
D16、D19、D20、
U19 and check 

Notice: To avoid unnecessary short circuit, please confirm matters as follows: Before the
power on, check whether the rectifier bridge D15、D16、D19、D20 are damage by multi-meter,
whether there is any resistance on each side of AC inputting ( It normally must be infinity great on
diode position ), and check whether the C303(22UF/450V ) electrolytic capacitor is reverse by
eyes.

Type 2. Low Outputting Voltage or Unstable Outputting

Low  outputting  voltage  or 

unstable outputting 

Yes 
Accessing load board or normal main board to  Backward  stage  main  board  or 
check the outputting voltage.  other  circuit  problem  or 
outputting short circuit, etc. 

No 
Yes 
Check  the  damage  of 
the  U19  TNY177PN 

No 
Yes 

Check  the  damage  of  Change  or 

Yes  repair 
welding 
Check  the  damage  or  loose 
welding  of  the  R384  R387  and 
the  peripheral  component  of 
Outputting OK 
U32 U31 

Notice: This type of damage can be caused by primary side circuit or secondary side circuit.
So, it is an important step to judges and determines which side causes the fault. The efficient and
fast judgment can save a lot of time and greatly improve efficiency. Here introduce a way for
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reference and the steps as follows:
Step 1. Connect the power wire, open AC power and to check the output voltage value at
unloaded state. (That is estimate the percentage of the current output voltage to the rated output
voltage.)
Step 2. Add right amount load, normal is 10% to 20% of the rated output electric current load.
Can add more load if the output voltage is high.
Step 3. Short circuit the 2 pins on the secondary side of the optocoupler (Notice: It must
monitor each group of output voltage by multi-meter at this moment. If the voltage rise violently,
must to remove the short circuit immediately, otherwise, the backward electrolytic capacitor will be
destroyed) . If the voltage rises, for example: rises more than 50% of the rated voltage, normally,
the fault happens on the secondary side. If the voltage not rise or rise a little, the fault may happen
on the primary side.
Step 4. According the Step 3 to detect and check the circuit carefully.

Type 3. Add Reload Unstable or Add Reload Noise

Add  reload  unstable  or  add 

reload noise 

Yes
Check the damage of the U4 TNY177PN 
and  the  Peripheral  Component 
( Especially the C303 

No 
Yes
Check the damage of the U32 U31 
Change  or 
and  the  damage  or  loose  weld  of 
repair 
the  peripheral  component
（ Especially the C307 R386 ） 
Yes
No 

Check  each  group  of  capacitance 

or whether is loose welded.  Outputting OK 

Notice: Generally speaking, this type of fault may be caused by incorrect parameters of
compensation circuit element on primary or secondary side or short circuit, missing part, etc. It
may be caused add reload noise if the dip tank badly of transformer. But this phenomenon is rare
and easily to eliminate. So the first object to be detected is relevant compensating circuit.

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2.3 Complimentary Close

For an entry-level technical engineer, there is often no know where to start the maintain at the
beginning of time. The reason for this matter is very simple, because it always works in a closed-
loop. The primary side will affect each kind of output voltage on secondary side. The final result is
the abnormal of output voltage and output electricity. So, it is the method which need to know well
and also is the difficult point in the process of master of how to break the closed-loop and judge
the fault point by the output voltage after the breaking. Understanding each unit circuit’s function in
the circuit and each component’s function in each unit circuit will deepen and faster the
understanding of the difficult point.

2.4 Schematic Circuit Diagram

3. Repairing Environment

3.1 List of repairing tools

In order to guarantee the quality of maintenance and operability, we recommend using the
following tools and equipment for the maintenance.
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3.1.1 Necessary Tools

1) Thermostat soldering station: Used for welding and dismantle PCB board of the various
types of components. Temperature can be finely adjusted. Good ESD protection function
can protect components one PCB from electrostatic damage during the maintenance

Thermostat soldering station

2) Hot Air Gun: Used to dismantle the board QFN QFP TSSOP48 etc pin much and intensive
element. Having the function of air volume adjustment, air temperature adjustment and so
on.

Hot Air Gun

The hot air gun needs special spearhead to suitable for different packaging devices. Small
round head is used for desoldering small SMT components. Double row flat head can be
used for desoldering TSOP encapsulation SMT components.

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 Spearhead of Hot Air Gun
3) Digital Multimeter:Mainly used in the detection of PCB circuit, the impedance of signal wire,
voltage, element resistance or capacity value and other a variety of purposes.

Multimeter

3.1.2 Optional Tools

1） Oscilloscope: Used to detecting the changes of PCB board signal level.

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 Oscilloscope
2） BGA Rework Station：To replace the BGA packaging components on the main board such as
CPU. Because the price is expensive, we rank it as optional tool.。

BGA Rework Station

3.2 Repairing Environment

3.2.1 Basic Maintenance Environment

To ensure the reliability of the maintenance, all the maintenance tools (soldering stations hot
air gun, etc.) need reliable grounding. To avoid the static electricity on the case cannot be
released so that to protect the other components on the main board from the secondary damage.
At the same time, maintenance environment need to add other auxiliary equipment, to avoid the
damage from the static electricity. For example:
1) As far as possible laid anti-static cloth on the maintenance table. The antistatic tablecloth
conductive rubber and other materials. The grounding wire of the antistatic tablecloth

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connecting the antistatic tablecloth to the ground. It can release the static to the ground to
avoid the damage to the components.

The Antistatic Tablecloth

The grounding wire of the antistatic tablecloth

2) The engineer need wares anti-static wrist strap and connects the metallic clamp to the
ground wire. This way can release the static electricity on human body to the ground to avoid
the secondary damage to the other components on PCB board.

Anti-static Wrist Strap

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3.2.2 Senior Maintenance Environment

1) Smoking Device: It sucked and filters the soldering waste gases to ensure the engineer’s
healthy.

Smoking Device

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