JVC AV-48P777 Service Manual

SERVICE MANUAL

REAR PROJECTION TELEVISION

YA45520068

AV-48P777/H, AV-48P787/H, AV-56P777

POWER

DVD

CATVVCR

INPUT

SLEEP

DISPLAY C.C.

TIMER

THEATER PRO

VIDEO STATUS

ASPECT

TUNE

RETURN+

SUB CH

/TV

ML/MTS SOUND GUIDE

FAVORITE

MUTING

CH +

VOL

–

CH –

BACK

VCR/DVD

VCR CHANNEL

TV/VCR

POWER

PREV NEXT

PLAY FFREW

REC

STOP PAUSE

OPEN/CLOSE

STILL/PAUSE

RM-C1272G

/H, AV-56P787/H

BASIC CHASSIS

SR2

TABLE OF CONTENTS

1 PRECAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

No.YA455

2006/8

SPECIFICATION

Contents

Items

Dimensions (W × H × D) 120.0cm × 118.9cm × 62.2cm

(47-1/4" × 46-7/8" × 24-1/2")

Mass 76.9kg (170 lds) 83.3kg (184 lds)

TV RF System (Analog / Digital) Analog : CCIR (M)

Digital : ATSC terrestrial / Digital cable

Color System (Analog) NTSC

Sound System (Analog) BTSC system (Multi Channel Sound)

Teletext System (Analog) Closed caption (T1-T4 / CC1-CC4)

Receiving Channels and Frequency (Analog)

TV / CATV Total Channel 191 Channels

Intermediate Frequency (Analog)

Color Sub Carrier (Analog) 3.58MHz

Power Input AC 120V, 60Hz

Power Consumption 240W (Max)

Screen Transparent screen (unitized fresnel lens / double lenticular lens)

Screen Size 48" (122cm) Measured diagonally

Projection Tube 17cm (6.7") tube × 3 ( R/G/B )

High Voltage 31.6kV [+1.0kV / -1.5kV] (at zero beam current)

Speaker 13cm round type × 2

Audio Power Output 7W+7W (Full range)

Antenna Terminal (VHF/UHF, ATSC / DIGITAL CABLE IN)

Video / Audio Input [INPUT-1/2/3/4]

Digital Input Video

Audio Output (FIX)

Digital Audio Optical Output Digital SPDIF × 1 Remote Control Unit RM-C1272G (AA/R6/UM-3 battery × 2)

Design & specifications are subject to change without notice.

VHF Low

VHF High

UHF

CATV 54MHz~864MHz

Video IF

Sound IF

Component Video

[INPUT-1/2]

1125i / 750p

525p / 525i

S-Video

[INPUT-1/3/4]

Video Audio

Audio

02ch~06ch : 54MHz~88MHz 07ch~13ch : 174MHz~216MHz 14ch~69ch : 470MHz~806MHz

Low Band : 02~06 High Band : 07~13 Mid Band : 14~22 Super Band : 23~36 Hyper Band : 37~64 Ultra Band : 65~94, 100~135 Sub Mid Band : 01, 96~99

45.75MHz

41.25MHz (4.5MHz)

(W:106.3 cm, H:59.8 cm), 16:9 ratio

75Ω unbalanced, coaxial, F-type connector × 1

RCA pin jack × 6 Y : 1V (p-p) (Sync signal: 0.35V(p-p), 3-value sync.), 75 Ω

Pb/Pr : ±0.35V(p-p), 75 Ω Y : 1V (p-p), positive (Negative sync provided), 75 Ω Pb/Pr : 0.7V(p-p), 75 Ω Mini-DIN 4 pin × 3 Y: 1V (p-p), positive (Negative sync provided), 75 Ω C: 0.286V (p-p) (Burst signal), 75 Ω 1V (p-p), positive (Negative sync provided), 75 Ω, RCA pin jack × 4 500mV (rms), high impedance, RCA pin jack × 8

HDMI 2-row 19pin connector × 2

(Digital-input terminal is not compatible with picture signals of personal computer)

Digital: HDMI 2-row 19pin connector × 2 Anarog: 500mV(rms) (-4dBs), high impedance, RCA pin jack × 2

500mV(rms) (-4dBs), low impedance (1kHz when modulated 100%), (RCA pin jack × 2)

AV-48P777 AV-48P787

AV-56P777 AV-56P787

136.8cm × 138.6cm × 66.7cm (53-7/8" × 54-5/8" × 26-3/8")

56" (142cm) Measured diagonally (W:124 cm, H:69.8 cm), 16:9 ratio

1-2 (No.YA455)

SECTION 1

PRECAUTION

1.1 SAFETY PRECAUTIONS

(1) The design of this product contains special hardware, many

circuits and components specially for safety purposes. For continued protection, no changes should be made to the original design unless authorized in writing by the manufacturer. Replacement parts must be identical to those used in the original circuits. Service should be performed by qualified personnel only.

(2) Alterations of the design or circuitry of the products should not be

made. Any design alterations or additions will void the manufacturer's warranty and will further relieve the manufacturer of responsibility for personal injury or property damage resulting therefrom.

(3) Many electrical and mechanical parts in the products have special

safety-related characteristics. These characteristics are often not evident from visual inspection nor can the protection afforded by them necessarily be obtained by using replacement components rated for higher voltage, wattage, etc. Replacement parts that have these special safety characteristics are identified in the parts list of Service manual. Electrical components having such features are

identified by shading on the schematics and by ( ) on the parts list in Service manual. The use of a substitute replacement

which does not have the same safety characteristics as the recommended replacement part shown in the parts list of Service manual may cause shock, fire, or other hazards.

(4) Use isolation transformer when hot chassis.

The chassis and any sub-chassis contained in some products are connected to one side of the AC power line. An isolation transformer of adequate capacity should be inserted between the product and the AC power supply point while performing any service on some products when the HOT chassis is exposed.

(5) Don't short between the LIVE side ground and ISOLATED

(NEUTRAL) side ground or EARTH side ground when repairing. Some model's power circuit is partly different in the GND. The difference of the GND is shown by the LIVE : ( ) side GND, the ISOLATED(NEUTRAL) : ( ) side GND and EARTH : ( ) side GND. Don't short between the LIVE side GND and ISOLATED (NEUTRAL) side GND or EARTH side GND and never measure with a measuring apparatus (oscilloscope etc.) the LIVE side GND and ISOLATED(NEUTRAL) side GND or EARTH side GND at the same time. If above note will not be kept, a fuse or any parts will be broken.

(6) The high voltage applied to the picture tube must conform with that

specified in Service manual. Excessive high voltage can cause an increase in X-Ray emission, arcing and possible component damage, therefore operation under excessive high voltage conditions should be kept to a minimum, or should be prevented. If severe arcing occurs, remove the AC power immediately and determine the cause by visual inspection (incorrect installation, cracked or melted high voltage harness, poor soldering, etc.). To maintain the proper minimum level of soft X-Ray emission, components in the high voltage circuitry including the picture tube must be the exact replacements or alternatives approved by the manufacturer of the complete product.

(7) If any repair has been made to the chassis, it is recommended that

the B1 setting should be checked or adjusted (See ADJUSTMENT OF B1 POWER SUPPLY).

(8) Do not check high voltage by drawing an arc. Use a high voltage

meter or a high voltage probe with a VTVM. Discharge the picture tube before attempting meter connection, by connecting a clip lead to the ground frame and connecting the other end of the lead through a 10k

(9) When service is required, observe the original lead dress. Extra

precaution should be given to assure correct lead dress in the high voltage circuit area. Where a short circuit has occurred, those components that indicate evidence of overheating should be replaced. Always use the manufacturer's replacement components.

Ω 2W resistor to the anode button.

(10) Isolation Check (Safety for Electrical Shock Hazard)

After re-assembling the product, always perform an isolation check on the exposed metal parts of the cabinet (antenna terminals, video/audio input and output terminals, Control knobs, metal cabinet, screwheads, earphone jack, control shafts, etc.) to be sure the product is safe to operate without danger of electrical shock.

a) Dielectric Strength Test

The isolation between the AC primary circuit and all metal parts exposed to the user, particularly any exposed metal part having a return path to the chassis should withstand a voltage of 1100V AC (r.m.s.) for a period of one second.

(. . . . Withstand a voltage of 1100V AC (r.m.s.) to an appliance rat-

ed up to 120V, and 3000V AC (r.m.s.) to an appliance rated 200V or more, for a period of one second.) This method of test requires test equipment not generally found in the service trade.

b) Leakage Current Check

Plug the AC line cord directly into the AC outlet (do not use a line isolation transformer during this check.). Using a "Leakage Current Tester", measure the leakage current from each exposed metal part of the cabinet, particularly any exposed metal part having a return path to the chassis, to a known good earth ground (water pipe, etc.). Any leakage current must not exceed 0.5mA AC (r.m.s.). However, in tropical area, this must not exceed 0.2mA AC (r.m.s.).

• Alternate Check Method

Plug the AC line cord directly into the AC outlet (do not use a line isolation transformer during this check.). Use an AC voltmeter having 1000 ner. Connect a 1500 type capacitor between an exposed metal part and a known good earth ground (water pipe, etc.). Measure the AC voltage across the resistor with the AC voltmeter. Move the resistor connection to each exposed metal part, particularly any exposed metal part having a return path to the chassis, and measure the AC voltage across the resistor. Now, reverse the plug in the AC outlet and repeat each measurement. Any voltage measured must not exceed 0.75V AC (r.m.s.). This corresponds to 0.5mA AC (r.m.s.). However, in tropical area, this must not exceed 0.3V AC (r.m.s.). This corresponds to 0.2mA AC (r.m.s.).

(11) High voltage hold down circuit check.

GOOD EARTH GROUND

After repair of the high voltage hold down circuit, this circuit shall be checked to operate correctly.See item "How to check the high voltage hold down circuit".

This mark shows a fast operating fuse, the letters indicated below show the rating.

Ω per volt or more sensitivity in the following man-

Ω 10W resistor paralleled by a 0.15µF AC-

AC VOLTMETER (HAVING 1000 /V, OR MORE SENSITIVITY)

0.15 F AC-TYPE

PLACE THIS PROBE

1500 10W

A V

ON EACH EXPOSED ME TAL PAR T

POWER CORD REPLACEMENT WARNING.

Connecting the white line side of power cord to "WHT" character side.

PWB

White line side

WHT

(No.YA455)1-3

1.2 INSTALLATION

1.2.1 INSTALLATION SITE

(1) The rear of this set is provided with ventilation openings.

Install the set more than 5 cm from a wall and in a location with good ventilation.

(2) Avoid the following types of locations.

a) Unstable locations (location must be able to with

stand heavy weight). b) Locations subjected to direct sunlight. c) Near stoves or other heating devices. d) Locations subjected to humidity or oily smoke. e) Dusty locations.

f) Locations with strong vibration.

1.2.2 INSTALLATION ADJUSTMENT

When installing, moving or changing the orientation of the set, perform static convergence adjustment according to the following procedure. Adjusting CRT color convergence have MANUAL and RESET. It adjust on the MENU screen.

NOTE :

Please you have TV on for at least 20 minutes before sing this feature. This adjustment will be needed only when the colors of the characters/lines are separated and lack in distinction. If not, please don't perform the adjustment.

MANUAL

(1) Press the [MENU] key, and select the "CONVERGENCE"

in the Picture Adjust menu with [function up/down] key.

(2) Press the [function left/right] key, the CONVERGENCE

menu appears.

(3) Press the [function up/down] key, and select the

"MANUAL".

(4) Press the [function left/right] key, then CONVERGENCE

adjustment screen appear. [Fig.1]

• If all the crosses are white, no convergence adjustment is needed.

(5) Select the location you want to adjust by using the [number

(2/4/5/6/8)] keys on the remote control unit. [Fig.2]

(6) Press the [SLEEP TIMER] key to change the color of the

box to the color of the cross you want to adjust (red or blue).

• You cannot adjust the green cross.

(7) Use the [function up/down] key and the [function left/

right] keys to adjust the position of the cross.

(8) Adjust the three colors crosses until they overlap and

appear as a single white cross.

(9) Press the [OK] key.

(more than 5cm)

Wall

VENTILATION OPENING

NOTE :

• When you adjust the convergence, make sure you start with the center position (position 5), and work your way around radial for best results.

• When you make the adjustment in the center (positions 5), you are making the adjustment for the whale screen. In other positions, you are making the adjustment only in that area.

• You can reset the adjustment if you do not like the results, See below.

(10) Press the [menu] key to end the convergence adjustment

procedure.

RESET

RESET in the CONVERGENCE menu resets all convergence adjustments to the factory default setting.

Fig.1

Fig.2

1-4 (No.YA455)

SECTION 2

SPECIFIC SERVICE INSTRUCTIONS

2.1 SYSTEM SETTEING

Be sure to carry out the following operation at the end of the procedure.

(1) Set to "0 minutes" using the [SLEEP TIMER] key. (2) While "0 minutes" is displayed, press the [VIDEO

STATUS] key and [DISPLAY] key imultaneously, then enter the SERVICE MODE.

(3) Press the [4] key (4.Diagnostics) in the SERVICE MENU

SCREEN.

(4) Press the [3] key (3.Self check) in the DIAGNOSTICS

MODE screen. (5) The SELF CHECK MODE screen is displayed. (6) Turn off the power by pressing the [POWER] key on the

remote control unit.

Press [4] key

SERVICE

Service Menu

1.Digital Service

2.TV-Micro Service

3.Conver Service

4.Diagnostics

Diagnostic MENU SCREEN

Diagnostic

1.I2C Bus Stop

2.Status Monitor

3.Self Check

4.Version

5.Save Config data to SD card

6.Load Config data

7.Boot from NFS

8.Debug Log

MENU SCREEN

2.2 FEATURES

Built in ATSC (Advanced Television Systems Committee) TUNER

This TV can receive both Digital broadcasting (ATSC) and Analog broadcasting.

SMART CAPTION

Smart caption will appear when you press the MUTING button, only on channels where the broadcast contains CLOSED CAPTION information.

SMART SOUND

Decreases high sound levels, giving a regulated sound level.

DIGITAL COMB FILTER

By the 3D digital comb filter, the refreshed image can be seen.

VIDEO STATUS

Expression of a favorite screen can be chosen by the VIDEO STATUS function.

DIGITAL INPUT

Digital-in will display when any picture signal in Digital-in is displayed.

V-CHIP

Since the V-CHIP is built in, it can choose, view and listen to a healthy program.

MTS STEREO

The voice multiplex function of the MTS system is built in. (MTS = Multi channel Television Sound system)

NATURAL CINEMA

Watching the movie or animation, press the Natural Cinema to adjust the out line of the images to make thin more sharp.

VIDEO INPUT LABEL

This function is used to label video input connections for the onscreen displays.

A.H.S.

Adds a more spacious surround sound. Music gives basic effect and movie for more effect.

Press [3] key

SELF CHECK MODE SCREEN

Self Check 1/2 X-RAY OK OCP OK LOB OK TIM OK PHOTO OK HostLink OK FAN ---

<> Previous/Next Page [BACK]Back [MENU]Exit

2.3 DIFFERENCE LIST

Item AV-48P777/H AV-48P787/H AV-56P777/H AV-56P787/H

BODY COLOR SILVER BLACK SILVER BLACK

(No.YA455)1-5

2.4 TECHNICAL INFORMATION

2.4.1 MAIN MICRO COMPUTER (CPU) FUNCTION

Pin name I/O Function Pin

No.

1 P60/SBT2 - Not used 51 ATSC_TX I Serial communication for ATSC tuner

2 P_MU O Not used : Picture muting [Muting: H] 52 ATSC_RX O Serial communication for ATSC tuner

3 M_MUTE O Audio output muting [Muting: H] 53 P85 - Not used

4 A_MUTE O Audio muting [Muting: H] 54 VREF+ I Reference voltage [+3.3V Fixed]

5 ROTATION_L O

6 ROTATION_R O

7 P52/TM14OA - Not used 57 SDA0 I/O I2C bus (data) for EEPROM

8 P53/TM14OB - Not used 58 SCL0 O I2C bus (clock) for EEPROM

9 DEF_RESET O Not used : Reset for deflection 59 P92/TM10IOB - Not used

10 RD_RQ I DTVM update 60 P93/TM10IOC - Not used

11 POW_LED O

12 DIMMER_LED O

13 P20/SBT2 O Not used : Clock for ATSC tuner communication 63 P95/AN1 - Not used

14 P21/SBI2 I

15 P22/SBO2 O

16 P23 O

17 VDD I +3.3V 67 DIGI_PRO O Not used : HDMI control

18 FOSC O Not used 68 P71/SBI0 - Not used

19 VSS - GND 69 P72/SBO0 - Not used

20 XI I Not used : Low speed oscillator 70 P73 - Not used

21 XO O Not used : Low speed oscillator 71 P74/SBI1 - Not used

22 VDD I +3.3V 72 P75/SBO1 - Not used

23 OSCI I Oscillation for system clock (16MHz) 73 SBD5 I/O On-board writing for flash memory

24 OSCO O Oscillation for system clock (16MHz) 74 SBT5 I On-board writing for flash memory

25 MODE I Single chip mode for CPU [H: Fixed] 75 NMI I +3.3V

26 TU_POWER O Not used : Power control for tuner 76 HDMI_CEC O Not used

27 P25 - Not used 77 REMOCON I Remote control

28 TU_RESET O Reset for tuner [Reset: H] 78 V_SYNC I V. sync signal

29 PANORAMA O Not used : Panorama mode for deflection 79 IRQ3/PA3 - Not used

30 P30/KI0 - Not used 80 POWERGOOD I Not used : Power error detection [NG: H]

31 P31/KI1 - Not used 81 PA5 - Not used

32 P32/KI2 - Not used 82 RST I CPU reset [Reset: L]

33 P33/KI3 - Not used 83 VDD I +3.3V

34 AVDD I +3.3V 84 SCL1 O I2C bus (clock) for RGB & DEF PROCESS (IC301)

35 P34/KI4 - Not used 85 SDA1 I/O I2C bus (data) for RGB & DEF PROCESS (IC301)

36 P35/KI5 - Not used 86 P02 - Not used

37 OCP I B1 over current protect detection [Protection: H] 87 P03 - Not used

38 B1_POWER O B1 relay control [Power on: L] 88 P04 - Not used

39 LOB_PRO I

40 MECA_SW I Machine SW interrupt detection [SW Pushing: L] 90 P06 - Not used

41 MAIN_POW O Main power control [Power on: L] 91 P07 - Not used

42 LB_POWER O Low-B power control [Power on: L] 92 VSS - GND

43 VREF- I Reference voltage [GND Fixed] 93 P10/TM8IOA - Not used

44 X-RAYPRO I X-ray protect detection [Protection: L] 94 P11/TM8IOB - Not used

45 P45/AN5 - Not used 95 P12/TM11IOA - Not used

46 KEY2 I Front key scan voltage (CH+, VOL+/-) 96 P13/TM11IOB - Not used

47 KEY1 I Front key scan voltage (CH-, MENU) 97 P14/TM11IC - Not used

48 P80/TM14OA - Not used 98 P15/TM12IOA - Not used

49 P81/TM14OB - Not used 99 P16/TM12IOB - Not used

50 AC_IN I AC 50/60Hz for timer clock 100 P17/TM12IC - Not used

Not used :

Lighting for Power/OnTimer LED [Power ON or TIMER ON: H]

Brightness control for Power/OnTimer LED

Not used : Data receive for ATSC tuner communication

Not used : Data transmission for ATSC tuner communication

Not used : Data request for ATSC tuner communication

Low-B protect detection [Protection: H]

Rotation control (left) 55 CONVER_TX I

Rotation control (right) 56 CONVER_RX O

No.

61 AVSS - GND

62 DIGI_PHOT I Photo sensor for DIGITAL-IN illegal copy protection

64 P96/AN2 - Not used

65 P97/AN3 - Not used

66 VDD I +3.3V

89 P05 - Not used

Pin name I/O Function

Serial communication for convergence control

1-6 (No.YA455)

2.5 MAIN PARTS LOCATION

2.5.1 PWB ASS'Y ARRANGEMENT

The PWB ASS'Y is indicated below.

No. PWB ASS'Y name AV-48P776 AV-48P786 AV-56P776 AV-56P786

1. MAIN PWB SSR-1510A-M2 ← SSR-1511A-M2 ←

2. ATSC TUNER PWB SSD-2311A-M2 ←←←

3. POWER PWB SSR-9010A-M2 ←←←

4. DEF & CONVERGENCE OUT PWB SSR-2510A-M2 ←←←

5. DIGITAL CONVERGENCE MODULE PWB SSR0K050A-M2 ← SSR0K051A-M2 ←

6. REMOTE SENSOR PWB SSR-8010A-M2 ←←←

7. R CRT SOCKET PWB SSR-3151A-M2 ←←←

8. G CRT SOCKET PWB SSR-3251A-M2 ←←←

9. B CRT SOCKET PWB SSR-3351A-M2 ←←←

10. FRONT CONTROL PWB SSR0L015A-M2 ←←←

11. USB PWB SSR-7561A-M2 ←←←

FRONT CONTROL ASS'Y

B CRT SOCKET

PWB

FRONT CONTROL

PWB

R CRT SOCKET PWB

REMOTE SENSOR PWB

DIGITAL CONVERGENCE MODULE PWB

POWER PWB

PROJECTION UNIT

G CRT SOCKET PWB

DEF & CONVERGENCE OUT PWB

G CRT SOCKET

PWB

MAIN PWB

ATSC TUNER PWB

USB PWB

AV TERMINAL BOARD

(This figure is only MAIN UNIT)

(No.YA455)1-7

2.6 SCREEN HANDLING CAUTIONS

2.6.1 SCREEN STORAGE Store the SCREEN ASS'Y in a standing position in order to avoid deformation. If the screen is stored horizontally, there is risk of

deforming the screen face. When necessary to place the SCREEN ASS'Y horizontally, position the screen side upwards and sure to place spacers between the screen and resting site (floor or stand etc.) to prevent the screen from sagging.

2.6.2 SCREEN SURFACE

Since the screen surface is easily scratched or soiled, use ample care when handling.

Leave the screen with protector, fresnel lens and double lenticular lens attached. If cannot

FRONT PANEL

be disassembled further.

SCREEN BRACKET

(TOP)

SCREEN BRACKET

(LEFT)

SCREEN

SCREEN BRACKET

(RIGHT)

(x 2)

[56 inch only]

SCREEN BRACKET

(BOTTOM)

(x 4)

[56 inch only]

(x 14)

1-8 (No.YA455)

2.7 PROJECTION UNIT REPLACEMENT

2.7.1 ADJUSTMENT DURING REPLACEMENT

When replacing the three R, G and B projection units, first replace the R and B units and perform focus / screen / raster centering adjustments with reference to the G unit. Then replace the G unit and perform G focus / screen / convergence adjustment. Finally perform R & B . Convergence adjustments. Use care to simultaneously removes all three-projection units.

2.7.2 DISASSEMBLY CAUTION

The projection units include locations that are not to be disassembled during service. When replacing projection unit parts, disassemble to the state indicated in the figure below. The figure indicates screws and wires that are not to be removed. Use care not to remove these.

Deflection yoke wires : to connector on DEF/CONVERGENCE OUT PWB ASS'Y. [R="RHV", G="GHV", B="BHV"] Convergence yoke wires : to connector on DEF/CONVERGENCE OUT PWB ASS'Y. [R="R", G="G", B="B"]

2/4 POLE

Check that tape is applied to the CRT neck. If absent, the deflection yoke can dislodge.

Do not remove screws

LENS ASS'Y

LENS ASS'Y SCREW ( x 4)

MAGNET

TAPE

CRT ASS'Y (COUPLER ASS'Y)

R CRT SOCKET PWB ASS'Y G CRT SOCKET PWB ASS'Y B CRT SOCKET PWB ASS'Y

DEF. / CONVER. YOKE

ANODE wires : to DIVIDER

Do not disassembly

(No.YA455)1-9

SECTION 3

DISASSEMBLY

3.1 DISASSEMBLY PROCEDURE

CAUTION AT DISASSEMBLY:

• Be sure to perform the SYSTEM SETTEING, at the end of the procedure.

• Make sure that the power cord is disconnected from the outlet.

• Pay special attention not to break or damage the parts.

• When removing each board, remove the connectors as required. Taking notes of the connecting points (connector numbers) makes service procedure manageable.

• Make sure that there is no bent or stain on the connectors before inserting, and firmly insert the connectors.

3.1.1 REMOVING THE SPEAKER GRILL (Fig.1)

(1) Remove 2 screws [A] from rear side. (2) Pull out the SPEAKER GRILL bottom to the front, and 4

claws which are fixing the SPEAKER GRILL are removed. (3) Remove the SPEAKER GRILL. (4) Remove the other side SPEAKER GRILL in the same

manner.

3.1.2 REMOVING THE SPEAKER (Fig.1)

• Remove the SPEAKER GRILL. (1) Remove 4 screws [B]. (2) Remove the SPEAKER. (3) Disconnect the speaker wire from speaker terminal. (4) Remove the other side SPEAKER in the same manner.

3.1.3 REMOVING THE FRONT PANEL (Fig.1)

• Remove the SPEAKER GRILL. (1) Remove 4 screws [C]. (2) The FRONT PANEL upper is pull out to the front, and 2

claws which are fixing the FRONT PANEL are removed.

(3) Remove the FRONT PANEL.

3.1.4 REMOVING THE FRONT CONTROL BOX (Fig.1)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL. (1) Remove 5 screws [D]. (2) Remove the FRONT CONTROL BOX.

3.1.5 REMOVING THE FRONT CONTROL PWB (Fig.1)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the FRONT CONTROL BOX. (1) Remove 2 screws [E]. (2) Remove 3 screws [F] from rear side of FRONT CONTROL

BOX.

(3) Remove the FRONT CONTROL PWB.

3.1.6 REMOVING THE SCREEN ASS'Y (Fig.1)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the FRONT CONTROL BOX. (1) Remove 4 screws [G] attaching the SCREEN ASS'Y. (2) Remove 10 screws [H] from rear side. (3) Remove the SCREEN ASS'Y.

NOTE :

• Please place the SCREEN ASS'Y on a flat table without fail.

• Because of the large size, at least 2 persons are

recommended for removal and reassemble.

• Use care not to scratch the screen during work.

• During assembly, be sure to engage the left and right tabs

with the cabinet mounting positions.

• When than supporting the SCREEN ASS'Y, avoid grasping

the top of the screen panel, instead grasp the left and right areas.

3.1.7 REMOVING THE MIRROR (Fig.1)

• Remove the SPEAKER GRILL

• Remove the FRONT PANEL.

• Remove the FRONT CONTROL BOX.

• Remove the SCREEN ASS'Y. (1) Remove 9 screws [J] attaching the mirror brackets of the

upper, left and right side.

(2) Raise slightly to disengage of the mirror from the bottom

bracket. (If necessary, loosen the screws attaching the bottom bracket)

(3) Remove the MIRROR.

NOTE :

• The MIRROR is front coated. Do not touch the front of the

MIRROR.

• At least 2 persons are recommended for removable and

reassemble.

1-10 (No.YA455)

3.1.8 REMOVING THE REAR COVER (Fig.1)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the FRONT CONTROL BOX.

• Remove the SCREEN ASS'Y. (1) Remove 2 screws [K]. (2) Remove 2 screws [L] from front side. (3) Slightly pull for backside to disengage of the REAR

COVER from hooks.

(4) Remove the REAR COVER.

NOTE :

• Because of the large size, at least 2 persons are

recommended for removal and reassemble.

3.1.9 REMOVING THE REAR PANEL (Fig.1)

(1) Remove 12 screws [M]. (2) Remove the REAR PANEL.

3.1.10 REMOVING THE PARTITION (Fig.1)

• Remove the REAR PANEL. (1) Pull out the PARTITION backward.

(No.YA455)1-11

SCREEN ASS’Y

REAR COVER

MIRROR BRACKET

MIRROR

MIRROR BRACKET

PARTITION

FRONT

REAR PANEL

FRONT CONTROL BOX

SPEAKER

BODY

SPEAKER GRILLE

1-12 (No.YA455)

FRONT PANEL

SPEAKER GRILLE

SPEAKER

FRONT CONTROL PWB

FRONT CONTROL BOX

Fig.1

3.1.11 REMOVING THE MAIN UNIT (Fig.3)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the FRONTCONTROL BOX.

• Remove the REAR PANEL. (1) Remove 4 screws [N] from front side of both sides. (2) Remove 2 screws [P] attaching the MAIN CHASSIS and

BODY. (3) Remove the SPEAKER CONNECTOR. (4) Pull out the MAIN UNIT to rear side.

NOTE :

• Except for confirmation of projection of images on the screen

and audio output through the speakers, the removed MAIN UNIT is still workable in the same state as if it is still built-in the TV set. Therefore, the MAIN UNIT can be removed, if necessary, for board diagnosis, electric testing, etc. apart from confirmation of screen images and audio output.

• When wire clamps are removed during work, use care to

restore them precisely to their original positions. Performance can be affected if these are not returned to the original positions.

• Because of the large size, at least 2 persons are

recommended for removal and reassemble.

• When carrying the MAIN UNIT, use care not to drop, shock

or shake it.

• Do not stain or damage the lens of the PROJECTION UNIT.

• Do not look the projection side of a PROJECTION UNIT

when the image is projected.

3.1.11.1 CHECKING THE P.W. BOARD (Fig.2)

When checking the MAIN PWB, POWER PWB, DEF & CONVERGENCE OUT PWB, etc., raise the MAIN UNIT with the front side down for the make of convenience.

3.1.12 REMOVING THE FOCUS PACK (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the FRONTCONTROL BOX.

• Remove the REAR PANEL.

• Remove the MAIN UNIT. (1) Remove 1 screw [Q]. (2) Remove the FOCUS PACK. (3) Remove wires connecting the FOCUS PACK.

3.1.14 REMOVING THE MAIN CHASSIS (Fig.2)

• Remove the REAR PANEL. (1) Remove 2 screws [V]. (2) Pull out the MAIN CHASSIS for backside.

NOTE :

• If necessary, remove the anode wires, connectors,

respectively.

3.1.15 REMOVING THE ATSC TUNER PWB (Fig.2)

• Remove the REAR PANEL.

• Remove the AV TERMINAL BOARD.

• Remove the MAIN CHASSIS. (1) Remove 1 screw [W]. (2) Pull out the ATSC TUNER PWB.

3.1.16 REMOVING THE DIGITAL CONVERGENCE MODULE

PWB (Fig.2)

• Remove the REAR PANEL.

• Remove the MAIN CHASSIS. (1) Remove 2 screws [X]. (2) Pull out the DIGITAL CONVERGENCE MODULE PWB.

3.1.17 REMOVING THE DEF & CONVERGENCE OUT PWB

(Fig.2)

• Remove the REAR PANEL.

• Remove the MAIN CHASSIS. (1) Remove 1 screw [Y]. (2) Remove the DEF & CONVERGENCE OUT PWB.

3.1.18 REMOVING THE POWER PWB (Fig.2)

• Remove the REAR PANEL.

• Remove the MAIN CHASSIS. (1) Remove 1 screw [Z]. (2) Remove the POWER PWB.

3.1.13 REMOVING THE AV TERMINAL BOARD (Fig.2)

• Remove the REAR PANEL. (1) Remove 6 screws [R], 2 screws [S] and 2 screws [T]. (2) Pull out the POWER CORD CLAMP from AV TERMINAL

BOARD to right side.

(3) Remove the AV TERMINAL BOARD.

3.1.13.1 REMOVING THE USB PWB (Fig.2)

• Remove the REAR PANEL.

• Remove the AV TERMINAL BOARD. (1) Remove 2 screws [U]. (2) Remove the USB PWB.

(No.YA455)1-13

3.1.19 REMOVING THE PROJECTION UNIT (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the FRONT CONTROL BOX.

• Remove the REAR PANEL.

• Remove the MAIN UNIT. (1) Remove the CRT SOCKET PWB. (2) Remove 4 screws [a]. (3) Pull out the PROJECTION UNIT upward.

NOTE :

• Refer to "PROJECTION UNIT REPLACEMENT" when tak-

ing out and replacing the PROJECTION UNIT.

• When wire clamps are removed during work, use care to re-

store them precisely to their original positions. Performance can be affected if these are not returned to the original positions.

3.1.20 REMOVING THE HV DIVIDER (Fig.2)

• Remove the REAR PANEL. (1) Remove 1 screw [b]. (2) Remove the HV DIVIDER.

NOTE :

• Wires of the transformer (FBT) and CRT of each PROJECTION UNIT can be removed by turning the connector portions.

• If necessary, remove the anode wires, and replacing the HV DIVIDER, take care to correctly engage the connector.

3.1.21 REMOVING THE REMOTE SENSOR PWB (Fig.2)

• Remove the REAR PANEL. (1) Remove 1 screw [c]. (2) Remove the REMOTE SENSOR PWB.

3.1.22 REMOVING THE COOLANT PAN (Fig.2)

• Remove the REAR PANEL. (1) Remove 2 screws [d]. (2) Remove the COOLANT PAN.

1-14 (No.YA455)

MAIN UNIT

BODY

PROJECTION UNIT

FOCUS PACK

MAIN UNIT

FRONT

COOLANT PAN

REMOTE SOENSOR PWB

SPEAKER

FRONT

CONNECTOR

REAR SIDE VIEW

MAIN UNIT

BODY

MAIN CHASSIS

FRONT

Fig.3

DIVIDER

DIGITAL CONVERGENCE MODULE PWB

ATSC TUNER PWB

MAIN PWB

POWER PWB

Fig.2

USB PWB

AV TERMINAL BOARD

DEF & CONVERGENCE OUT PWB

MAIN CHASSIS

POWER CORD CLAMP

POWER CORD

(No.YA455)1-15

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