JVC HD-56ZR7, HD-70ZR7 Schematic

SERVICE MANUAL

D-ILA PROJECTION TELEVISION

YA38520063

HD-56ZR7J, HD-56ZR7U, HD-70ZR7J, HD-70ZR7U

BASIC CHASSIS

RP4

LAMP/PROGRA

POWER

TABLE OF CONTENTS

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

2 SPECIFIC SERVICE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

No.YA385

2006/3

SPECIFICATION

× 3

Contents

PAL, NTSC 3.58/4.43 [EXT only]

NICAM ( I ) NICAM (B/G, I, D/K, L),

32.9MHz (6.0MHz :I) 33.4MHz (5.5MHz :B/G)

70" (178 cm) Measured diagonally H:155.5 cm × V:87.2 cm

PAL, SECAM, NTSC 3.58/4.43 [EXT only]

A2 (B/G, D/K)

32.9MHz (6.0MHz :I)

32.4MHz (6.5MHz :D/K)

Ω

× 2

Items

Dimensions ( W Mass 42 kg 69 kg TV RF System CCIR ( I ) CCIR (B/G, I, D/K, L) CCIR ( I ) CCIR (B/G, I, D/K, L) Colour System PAL, NTSC 3.58/4.43

Stereo System NICAM ( I ) NICAM (B/G, I, D/K, L),

Teletext System FLOF (Fastext level 2.5), TOP, WST(World Standard system) Receiving Frequency VHF: 47MHz - 470MHz (Except UK)

Intermediate Frequency

Colour Sub Carrier Frequency

Power Input AC220V - AC240 V, 50 Hz Power Consumption 179 W (Standby: 2.6 W) Projection Source 110W High-pressure mercury lamp Projection Device D-ILA device (Reflection active matrix type LCD) x 3(R / G /B) Resolution Total=H:1312 Screen Transparent screen (unitized fresnel lens / lenticular lens), aspect ratio 16:9 Screen Size Audio Power Output 10 W + 10 W Speaker 10 cm round type Aerial terminal (VHF/UHF) 75 EXT-1 / EXT-2 / EXT-3 (Input / Output) 21-pin Euro connector (SCART socket) EXT-4 (Input) Component Video

EXT-5 (Input) S-Video

Digital Input Video

PC (RGB) Input D-sub 3-row 15pin

Audio Out 0 to 1000mV(rms), low impedance, RCA pin jack Headphone Jack 3.5mm Stereo mini jack Remote Control Unit RM-C1811H (AA/R6 / UM-3 battery

× H × D ) 131.8 cm × 96.8 cm × 43.9 cm 162.6 cm × 116.7 cm × 51.9 cm

VIF 38.9MHz ( I ) 38.9MHz (B/G, I, D/K, L) 38.9MHz ( I ) 38.9MHz (B/G, I, D/K, L) SIF 32.9MHz (6.0MHz :I) 33.4MHz (5.5MHz :B/G)

PAL 4.43MHz

SECAM ---- 4.40625MHz / 4.25MHz ---- 4.40625MHz / 4.25MHz

NTSC 3.58MHz / 4.43MHz

1125i / 750p

625p / 525p / 625i / 525i

Audio

Video Audio

Audio

HD-56ZR7J HD-56ZR7U HD-70ZR7J HD-70ZR7U

PAL, SECAM, NTSC 3.58/4.43

[EXT only]

UHF: 470MHz - 862MHz

[EXT only]

A2 (B/G, D/K)

32.9MHz (6.0MHz :I)

32.4MHz (6.5MHz :D/K)

× V:800 [ Effective =H:1280 × V:720 ]

56" (142 cm) Measured diagonally H:12 4 cm × V:69.7 cm

× 2

Ω unbalanced, coaxial

RCA pin jack Y : 1V (p-p) (Sync signal: ±0.35V(p-p), 3-value sync.), 75 Pb/Pr : ±0.35V(p-p), 75 Y : 1V (p-p), Positive (Negative sync provided), 75 Ω Cb/Cr : 0.7V(p-p), 75 Ω 500mV(rms) (-4dBs), high impedance, RCA pin jack × 2

Mini-DIN 4-pin Y : 1V(p-p), positive, negative sync, 75 C : 0.286V(p-p) (burst signal), 75 1V(p-p), positive, negative sync provided, 75Ω, RCA pin jack × 1 500mV(rms) (-4dBs), high impedance, RCA pin jack

HDMI 2-row 19pin connector (Digital-input terminal is not compatible with picture signals of personal computer) Digital: HDMI 2-row 19pin connector Analog: 500mV(rms) (-4dBs), high impedance, RCA pin jack

× 3

Ω

× 1

Ω

× 1

R/G/B : 0.7V (p-p), 75 HD / VD : 1V (p-p) to 5V (p-p), high impedance < Available signal > VGA : 640 pixels XGA : 1024 pixels

Ω

× 480 pixels (Horizontal : 31.5kHz / Vertical : 60Hz)

× 768 pixels (Horizontal : 48.4kHz / Vertical : 60Hz)

× 1

× 2)

Design & specifications are subject to change without notice.

1-2 (No.YA385)

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 which 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) 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 the LIVE side GND and ISOLATED (NEUTRAL) side GND or EARTH side GND at the same time with a measuring apparatus (oscilloscope etc.). If above note will not be kept, a fuse or any parts will be broken.

(5) When service is required, observe the original lea d 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 evi dence of overheating should be replaced. Always use the manufacturer's replacement components.

(6) 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, screw heads, 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 3000V AC (r.m.s.) for a period of one second. (. . . . Withstand a voltage of 1100V AC (r.m.s.) to an appliance rated 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 a test equipment not generally found in the service trade.

b) Leakage Current Chec k

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 1000Ω per volt or more sensitivity in the following manner. Connect a 1500Ω 10W resistor paralleled by a 0.15µF AC-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 ac ross 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.).

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

0.15 F AC-TYPE

GOOD EARTH GROUND

1500 10W

PLACE THIS PROBE ON EACH EXPOSED METAL PART

(No.YA385)1-3

1.2 INSTALLATION

D*** 01 1 01 00000001

1.2.1 HEAT DISSIPATION

If the heat dissipation vent behind this unit is blocked, cooling efficiency may deteriorate and temperature inside the unit will rise. The temperature sensor that protects the unit will be activated when internal temperature exceeds the predetermined level and power will be turned off automatically. Therefore, please make sure pay attention not to block the heat dissipation vent as well as the ventilation outlet behind the unit and ensure that there is room for ventilation around it.

Do not put foreign objects near the ventilation holes as this can result in fire or electrical hazards. Do not block the ventilation holes as this may cause the internal temperature to rise and po ss ibly result fire.

1.3 LAMP UNIT HANDLING CAUTION

LAMP UNIT : TS-CL110EAA

1.3.1 PRECAUTION FOR LAMP UNIT The lamp emits high intensity white, ultraviolet and infrared light. Do not look directly at the light during service. Also, do not touch the lamp directly as it presents a burn hazard. Handle with extra care. This lamp emits high heat and contains high-pressure during use. Do not give any impact as this may cause the broken lamp.

Intake hole

*Diagram differs from actual appearance.

Exhaust hole

1.2.2 INSTALLATION REQUIREMENTS

Ensure that the minimal distance is maintained, as specified fingure, between the unit with and the surrounding walls, as well as the floor etc. Install the unit on stable flooring. Take precautionary measures to prevent the unit from tipping in order to protect against accidents and earthquakes.

CAUTION FOR INSTALLATION

• Do not tilt the TV towards the left or right, or toward the back.

• Install the TV in a corner on the floor so as to keep cords out of the way.

• The TV will generate a slight amount of heat during operation. Ensure that sufficient space is available around the TV to allow satisfactory cooling.

200mm

50mm

150mm

200mm

150mm

1.3.2 HOW TO CONFIRM LAMP OPERATING TIME

• MAXIMUM COUNT TIME= 65535 hours (1) Press the [INFORMATION] key and [MUTING] key

simultaneously, then enter the SERVICE MODE.

(2) When the Main Menu is displayed, press [4] key to enter

the setting display for designing.

(3) Press [CH+] / [CH-] key to select the addresses (items).

NOTE:

• Confirmation of the information can be done by selecting

addresses (items) below. Display position is in the far right side in the 2nd row from the top, as displayed below.

D070 : Lamp operating time high byte D071 : Lamp operating time low byte

D*** 01 1 01 00000001

*Diagram differs from actual appearance.

1-4 (No.YA385)

Operating time in binary number notation

Operating time in hexadecimal number notation

Operating time in decimal number notation (Max. 255)

< Calculation example >

D070 (decimal number notation) = 003 D071 (decimal number notation) = 232

(3 x 256) + 232 = 1000 hours

1.3.3 LAMP UNIT REPLACEMENT

(1) The lamp replacement message wil l appea r when need to

change the lamp. After replace the lamp, need to reset the timer which is built into TV.

(2) Life of the lamp unit is about 6500 ho urs over. Lamp use

time can be check at the lamp message MENU.

(3) If Fig.1 message appe ars when turn the TV on, need to

replace the lamp.

(4) Use the lamp timer reset only after replacing the lamp.

NOTE:

• This message will appear every time turn on the TV, when the lamp needs to be replaced. Press the [OK] key to make the message disappear, or replace the lamp.

LAMP REPLACEMENT MESSAGE

LAMP NEEDS TO BE REPLACED. PLEASE REFER TO THE MANUAL FOR REPLACEMENT INSTRUCTIONS.

AFTER REPLACING THE LAMP, PLEASE RESET THE TIMER IN THE TV MENU.

PRESS OK, IF YOU DO NOT WANT TO SEE THIS MESSAGE AGAIN.

1.3.6 PRECAUTION FOR REPLACEMENT

• Do not replace the LAMP UNIT immediately after the projector has been used.

• The temperature of the LAMP UNIT is still high and could cause a burn.

• Allow a cooling period of 1 hour or more before performing replacement.

• Before starting LAMP UNIT replacement work, turn off the MAIN POWER switch, and disconnect the AC power cord plug from the wall outlet.

• If touched, the lamp glass surface may rupture and burns may result. Do not touch the glass portion or metal portion. Handle only plastic handle.

• The replaced old lamp can be discarded in the same manner as a fluorescent lamp. Check local ordinances and dispo se o f the used lamp as prescribed.

Fig.1

1.3.4 HOW TO REPLACE THE LAMP UNIT

• Refer to the "USERS GUIDE" for a detailed operating description. (1) Turn off the TV power. (2) After the LAMP LED light has stopped blinking, disconnect

the power cord from the AC outlet.

(3) Loosen 1 screw then take out the lamp cover below the left

side of the TV. (4) Loosen 2 screws then take out the lamp unit. (5) Install the new lamp unit. (6) Re-install the lamp cover.

NOTE:

• After installing the new lamp unit, do not forget to reset the

lamp timer.

1.3.5 HOW TO RESET THE LAMP TIMER

• Refer to the "USERS GUIDE" for a detailed operating description. (1) Press the [MENU] key to select SET UP. (2) Select the <LAMP TIMER RESET> with [] / [] keys. (3) Enter the <LAMP TIMER RESET> mode,and the message

will appears.

(4) Press the [OK] key while the above message appears on

the screen. (5) Turn off the power, then turn on the power. (6) The lamp timer has now been reset, as before the HOW TO

CONFIRM LAMP OPERATING TIME.

(No.YA385)1-5

1.4 SERVICE PARTS KIT INSTRUCTIONS Due to the character of this product, these OPTICAL /DRIVE

ASS'Y are prepared. Please note these OPTICAL/DRIVE ASS'Y when replacing or ordering the parts.

OPTICAL / DRIVE ASS'Y

1.4.1 PART NUMBER AND CONSTRUCTION Kit parts number Kit part name

TS-COP7E-SAA OPTICAL / DRIVE ASS'Y

1.4.2 OPTICAL / DRIVE ASS'Y CONSTRUCTION

(1) OPTICAL BLOCK

(Included D-ILA DEVICE, PROJECTION LENS) (2) OPTICAL BASE (3) MAIN DRIVE PWB ASS'Y

This PWB is mounted with 2 memory ICs saved with

adjustment, setting data of the drive circuit. (4) SHIELD COVER *The following parts without the kits part.

• REMOTE SENSOR PWB ASS'Y

• FAN CONTROL PWB ASS'Y

• LAMP UNIT

• LAMP FAN DUCT

• THERMOSTAT

1.5 SCREEN HANDLING CAUTIONS

1.5.1 SCREEN STORAGE

Store the SCREEN ASS'Y in a standing position in order to avoid deformation. If the screen is stored horizonta lly, 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.

1.5.2 SCREEN SURFACE

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

1.5.3 PRECAUTIONS FOR CLEANING AND REPLACEMENT

• The SCREEN ASS'Y is made from the lenticular lens and fresnel lens. The anti static proceeding and the surface of the lenticular lens. Rubbing the surface with something hard, the coating may peel off.

• When the screen is dirty, gently wipe it with a soft cloth. If the screen is very dirty, wipe it down with a cloth dipped in a diluted kitchen cleaner (neutrality detergent) and thoroughly wrung-out. Then wipe immediately after with clean, dry cloth. Never use the organic solvent such as the alcohol or benzine.

• The SCREEN ASS'Y replacement is required if the coating was peel off. Alkaline detergent or acidity detergent can not be be used.

• The notched side of the lenticular lens and the fresnel lens are faced each other.

• Do not rub the screen when cleaning it or replaceing it. Rubbing the screen may cause of the scratch of the screen by its notch.

1.4.3 PRECAUTION FOR USING

(1) In the case of the followi ng defects/problems, replace this

kit (OPTICAL/DRIVE ASS'Y)

a) Picture defect caused by optical system/D-ILA device

related parts.

b) Picture defect caused by drive circuit.

(2) The MAIN DRIVE PWB ASS'Y is mounted with a memory

IC [IC3741/IC3742] saved with adjustment/setting data (GAMMA, SHADING, etc.) of the drive circuit. The data of this memory IC is in the optimal state according to individual D-ILA devices and each section of the OPTICAL BLOCK.

(3) When replace the MAIN DRIVE PWB ASS'Y, take off the 2

memory ICs from the original board and replace with new one. When replace the MAIN DRIVE PWB ASS'Y, do same manner. Replace 2 memory ICs.

(4) After the replacement of the OPTI CAL BLOCK, projection

lens focus adjustment and drive convergence / projection adjustment are required.

1-6 (No.YA385)

2.1 SYSTEM SETTEING

SERVICE MENU

1.ADJUST

2.SELF CHECK

3.I2C STOP

LOB OK FAN OK SYNC M:OK S:OK HD:OK TIM OK MSM OK DIGI OK MEM OK AVSW OK YC OK AIO OK TUN OK GCR OK 1 IP OK RGB OK 8 DVI OK HDMI OK

SECTION 2

SPECIFIC SERVICE INSTRUCTIONS

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

(1) Press the [INFORMATION] key and [MUTING] key

simultaneously, then enter the SERVICE MODE.

(2) When the Main Menu is displayed, p ress [2] key to enter

the self check mode.

(3) Turn off the power by pressing the [POWER] key on the

remote control unit.

2.2 FEATURES D.I.S.T. (Digital Image Scaling Technology)

This system uses line interpolation to double the number of scanning lines and achieve high resolution, flicker-free picture.

COLOUR MANAGEMENT

This function ensures dull colours are compensated to produce natural hues.

PICTURE MANAGEMENT

This function makes it easier to see the dark areas when a picture has many dark areas, and makes it easier to see the bright areas when a picture has many bright areas.

ZOOM

This function can change the screen size according to the picture aspect ratio.

2.3 MAIN DIFFERENCE LIST

SERVICE MENU SCREEN

SERVICE MENU

1.ADJUST

2.SELF CHECK

3.I2C STOP

SELF CHECK MODE SCREEN

LOB OK FAN OK SYNC M:OK S:OK HD:OK TIM OK MSM OK DIGI OK MEM OK AVSW OK YC OK AIO OK TUN OK GCR OK 1 IP OK RGB OK 8 DVI OK HDMI OK

DIGITAL VNR

This function cuts down the amount of noise in the original picture.

SUPER DIGIPURE

This function uses the latest in digital technology to give you a natural-looking picture.

MOVIE THEATRE

This function displays a cinema film picture more smoothly and naturally on the screen.

3D SOUND

You can enjoy sounds with a widerambience.

Item HD-56ZR7J HD-56ZR7U HD-70ZR7J HD-70ZR7U

TV RF System CCIR ( I ) CCIR (B/G, I, D/K, L) CCIR ( I ) CCIR (B/G, I, D/K, L) Colour System

PAL, NTSC 3.58/4.43 [EXT only]

Stereo System NICAM ( I ) NICAM (B/G, I, D/K, L),

POWER CORD UK Type (3 Pins) EU Type (2 Pins) UK Type (3 Pins) EU Type (2 Pins) DIGITAL SIGNAL PWB SRP0D704A-M2 SR P0D702A-M2 SRP0D703A-M2 SRP0D701A-M2

PAL, SECAM, NTSC 3.58/4.43 [EXT only]

A2 (B/G, D/K)

PAL, NTSC 3.58/4.43 [EXT only]

PAL, SECAM NTSC 3.58/4.43 [EXT only]

NICAM ( I ) NICAM (B/G, I, D/K, L),

A2 (B/G, D/K)

(No.YA385)1-7

2.4 21-PIN EURO CONNECTOR (SCART) : EXT-1 / EXT-2 / EXT-3 Pin No. Signal designation Matching value EXT-1 EXT-2 EXT-3

1 AUDIO R output 500mV(rms) (Nominal), Low impedance Used (TV OUT) Used (LINE OUT) Not used 2 AUDIO R input 500mV(rms) (Nominal), High impedance Used (R1) Used (R2) Used (R3) 3 AUDIO L output 500mV(rms) (Nominal), Low impedance Used (TV OUT) Used (LINE OUT) Not used 4 AUDIO GND --- Used Used Used 5 GND (B) --- Used Used Used 6 AUDIO L input 500mV(rms) (Nominal), High impedance Used (L1) Used (L2) Used (L3) 7 B input 700mV 8 FUNCTION SW

(SLOW SW)

Low : 0V-3V High : 8V-12V, High impedance

, 75Ω Used Used Not used

(B-W)

Used Used Used

9 GND (G) --- Used Used Used

10 SCL / T-V LINK --- Not used Used

Not used

(SCL2 / TV-LINK)

11 G input 700mV

, 75Ω Used Used Not used

(B-W)

12 SDA --- Not used Used (SDA2) Not used 13 GND (R) --- Used Used Used 14 GND (YS) --- Used Not used Not used 15 R / C input R : 700mV

C : 300mV

(B-W) (P-P)

, 75Ω

Used (R) Used (C2/R) Not used

16 Ys input (FAST SW) Low : 0V-0.4V, High : 1V-3V, 75Ω Used Used Not used 17 GND (VIDEO output) --- Used Used Used 18 GND (VIDEO input) --- Used Used Used 19 VIDEO output 1V 20 VIDEO / Y input 1V

(Negative sync), 75Ω Used (TV OUT) Used (LINE OUT) Not used

(P-P)

(Negative sync), 75Ω Used Used Used

(P-P)

21 COMMON GND --- Used Used Used

(P-P= Peak to Peak, B-W= Blanking to white peak)

[Pin assignment]

20 18 16 14 12 10 8 6 4 2

21 19 17 15 13 11 9 7 5 3 1

1-8 (No.YA385)

2.5 TECHNICAL INFORMATION

2.5.1 D-ILA DEVICE SPECIFICATION Item Content

Resolution H:1312 × V:800 Pixel number about 1050000 Pixel size H :12.0µm × V :12.0µm Aspect ratio 16:9 Contrast ratio 1000:1 Aperture ratio 93% or more Effective pixel measurement 0.7 inch

2.5.2 PROJECTION UNIT

R DEVICE

B DEVICE

2.5.4 D-ILA DEVICE STRUCTURE

R / G / B DEVICE (SIDE VIEW)

Back

Plane

Flat film

Reflective pixel electrode

Liquid crystal

Glass substrate

Incident light Projection light

FRONT

Transparent electrode

G DEVICE

2.5.3 IMAGE LIGHT FLOW

DEVICE UNIT SECTION (TOP VIEW)

Projection

light

BRG

Device

Mirror

Incident light

Lamp unit

FRONT

Device

BRG

Incident

light

PIXEL VIEW (FRONT VIEW)

12.0 m Pixel

12.0 m

Device

MirrorMirror

(No.YA385)1-9

2.5.5 MAIN CPU PIN FUNCTION [IC7501

Pin Pin name I/O Function Pin Pin name I/O Function

1 TCK O Test purpose 65 D2 I/O Program ROM data for main CPU 2 TMS I Test purpose 66 D12 I/O Program ROM data for main CPU 3 TDI I Test purpose 67 D10 I/O Program ROM data for main CPU 4 TDO O Test purpose 68 VSS33 - GND 5 P2.8 O Half tone control for IC4001 69 VDD33 I 3.3V 6 P2.9 O Blue for OSD 70 D4 I/O Program ROM data for main CPU 7 P2.10 O Blue for OSD 71 D3 I/O Program ROM data for main CPU 8 P2.11 O Blue for OSD 72 D11 I/O Program ROM data for main CPU

9 P2.12 O Blue for OSD 73 RSTIN I Reset 10 P2.13 O Blue for OSD 74 POWER O Sleep state release for chassis CPU [Relese : L] 11 P2.14 I TV-LINK data 75 P3.1 O Not used 12 P2.15 O Request for chassis CPU communication 76 REMOCON I Remote control 13 VSS33 - GND 77 P3.3 I Clock for OSD 14 VDD33 I 3.3V 78 P3.4 O Red for OSD 15 P4.5 O TV-LINK data 79 P3.5 O Red for OSD 16 A20 O Program ROM address for main CPU 80 P3.6 O Red for OSD 17 A19 O Program ROM address for main CPU 81 P3.7 O Red for OSD 18 A18 O Program ROM address for main CPU 82 MTST O Data transmission for chassis CPU communication 19 A17 O Program ROM address for main CPU 83 MTSR I Data receive for chassis CPU communication 20 VSS25 - GND 84 VSS33 - GND 21 VDD25 I 2.5V 85 VDD33 I 3.3V 22 A16 O Program ROM address for main CPU 86 VSS25 - GND 23 A8 O Program ROM address for main CPU 87 V DD25 I 2.5V 24 A7 O Program ROM address for main CPU 88 TXD0 O Not used: Communication for adjustment 25 A9 O Program ROM address for main CPU 89 RXD0 I Not used: Communication for adjustment 26 A6 O Program ROM address for main CPU 90 P3.12 O Red for OSD 27 A5 O Program ROM address for main CPU 91 CLK O Clock for chassis CPU communication 28 A10 O Program ROM address for main CPU 92 P3.15 O Not used 29 A11 O Program ROM address for main CPU 93 P5.14 O Green for OSD 30 A12 O Program ROM address for main CPU 94 P5.15 O Green for OSD 31 VSS33 - GND 95 TRIG_IN O Green for OSD 32 VDD33 I 3.3V 96 TRIG_OUT O Green for OSD 33 A4 O Program ROM address for main CPU 97 P6.2 O Green for OSD 34 A3 O Program ROM address for main CPU 98 P 6.3 O I 35 A2 O Program ROM address for main CPU 99 P6.4 I/O I 36 A1 O Program ROM address for main CPU 100 P6.5 O Teletext signal select [Analog RGB : H / Digital RGB : L] 37 A0 O Program ROM address for main CPU 101 IRQ O Not used (NC) 38 A13 O Program ROM address for main CPU 102 VSYNC I Vertical sync 39 RAS/A14 O Program ROM address for main CPU 103 HSYNC I Horizontal sync 40 CAS/A15 O Program ROM address for main CPU 104 41 VSS33 - GND 105 BLANK O Ys for OSD / Teletext 42 VDD33 I 3.3V 106 VDD33 I 3.3V 43 MEMCLK O Clock for memory 107 VSS33 - GND 44 CSSDRAM O Chip select for memory 108 XTAL1 I 6MHz for system clock 45 CLKEN O Clock enable for memory 109 XTAL2 O 6MHz for system clock 46 CSROM O Chip select for memory 110 VSSA - GND 47 RD O Read for memory 111 VDDA I 2.5V 48 UDQM O Control buffer of memory 112 R O R for OSD / Teletext 49 LDQM O Control buffer of memory 113 G O G for OSD / Teletext 50 WR O Write for memory 114 B O B for OSD / Teletext 51 D15 I/O Program ROM data for main CPU 115 VSSA - GND 52 VSS33 - GND 116 VDDA I 2.5V 53 VDD33 I 3.3V 117 CVBS2 I Not used 54 D7 I/O Program ROM data for main CPU 118 VSSA - GND 55 D0 I/O Program ROM data for main CPU 119 VDDA I 2.5V 56 D14 I/O Program ROM data for main CPU 120 CVBS1B I Not used 57 D8 I/O Program ROM data for main CPU 121 CVBS1A I Video for Teletext 58 D6 I/O Program ROM data for main CPU 122 VSSA - GND 59 D1 I/O Program ROM data for main CPU 123 VDDA I 2.5V 60 VSS33 - GND 124 KEY1 I Key scan data 1 [ON : H] 61 VDD33 I 3.3V 125 KEY2 I Key scan data 2 [ON : H] 62 D13 I/O Program ROM data for main CPU 126 MECA_SW I Main power ON / OFF control [ON : L] 63 D9 I/O Program ROM data for main CPU 127 P5.3 I Not used (NC) 64 D5 I/O Program ROM data for main CPU 128 TMODE I Test purpose

: DIGITAL SIGNAL PWB ASS'Y]

COR/RSTOUT

C bus clock (for main memory)

C bus Data (for main memory)

O Not used (N C)

1-10 (No.YA385)

2.5.6 SUB (CHASSIS) CPU PIN FUNCTION [IC7001

Pin Pin name I /O Function Pin Pin name I/O Function

1 LCD_PRO I Not used 51 BS_TXD O 2 P_MU O Picture muting [Muting = H] 52 BS_RXD I Not used : Data receive for digital tuner communication 3 FUNC_LED O Not used 53 CD_INT O Not used : Data transmission for CARD data 4 A_MUTE O Audio muting [Muting = H] 54 VREF+ I 3.3V power supply 5 M_MUTE O Audio muting (for DUBBING OUT) [Muting = H] 55 PDP_TX O 6 PC_SEL O RGB(PC) INPUT select 56 PDP_RX I Data receive for SUB (DRIVE) CPU communication

DIMMER_LED

7 8 ILA0 O Not used : LCD back light lighting 58 SCL0 O Clock for Inter IC (serial) bus : EEP-ROM (IC7002)

9 ILA1 O Not used : LCD panel overshoot refresh timing 59 SDA_DVI I/O 10 ILA2 O Not used 60 SCL_DVI O 11 POW_LED O POWER LED lighting [ON = L] 61 AVSS - GND 12 WORD O Not used 62

13 MI_CK I Clock for MAIN (OSD) CPU communication 63 AGC I AGC voltage level detection 14 MI_TX I Data receive for MAIN (OSD) CPU communication 64 EXT_YS1 I External YS1 signal detection 15 MI_RX O 16 MI_REQ O 17 VDD I 3.3V power supply 67 DIGI_PRO O Not used: for DIGITAL-IN (HDMI) 18 FOSC O Not used (NC) 68 GR_RST O Not used (NC) 19 VSS - GND 69 GRON O Not used (NC) 20 X1 I Not used : Low speed oscillatior 70 SYNC_SEL O Not used : Sync select for digital tuner 21 X0 O Not used : Low speed oscillatior 71 CD_SCL O 22 VDD I 3.3V power supply 72 CD_SDA O 23 OSC1 I System clock osillation (crystal) : 16MHz 73 SBD5 I/O 24 OSC0 O System clock osillation (crystal) : 16MHz 74 SBT5/RT5 I 25 MODE I Single chip mode [H = Fixed] 75 NMI I 3.3V power supply 26 BS1.5CTL O Not used : Digital tuner power / reset control 76 COMP I Not used : AV COMPULINK lll control 27 A92RES O 28 BS_RST O 29 LIP_RST O Not used: Reset for Sound delay (Lip sync) 79 WAKE I 30 DIN_DTB O Not used 80 31 VMUTE I Interrupt detection [Detect = H] 81 REC_LED O LAMP LED lighting [ON = L] 32 VOUTENB O Not used : Video cutoff for digital tuner [OFF = L] 82 RESET I Reset for sub(chassis) CPU [Reset = L] 33 MDR_CON I Not used : System cable connection monitor for PDP 83 VDD I 3.3V power supply 34 AVDD I 3.3V power supply 84 SCL3A O Clock for Inter IC (serial) bus control 35 PFC_POWE O Not used : Digital tuner power control 85 SDA3A I/O Data for Inter IC (serial) bus control

DsyncSW2

36 37 LB_POWE O Power control for low bias line 87 SDA3B I/O D ata for Inter IC (serial) bus control 38 NC O Not used (NC) 88 39 HOTPLUG I 40 MECA_SW I Mechanical monitor for POWER switch 90 DIGI_HP I Reset for HDMI process [Reset = L ] 41 MAIN_PW O Main power control [ON = L] 91 DVI_RST O Not used : Reset for DVI format conversion 42 MSP_RST O 43 VREF- I Not used 93 SCL5055 O 44 AFT2 I Not used : AFT voltage for sub tuner 94 45 AFT1 I AFT voltage for VHF/UHF tuner 95 SDA5055 I/O Data for Inter IC (serial) bus : IC3001 (DIST process) 46 KEY2 I Not used 96 OSD_SEL O Not used : OSD mode select 47 KEY1 I Not used 97 NC O Not used (NC) 48 NC O Not used 98 MCmp/OTH O Main video select

REC_RSV_LED

49 50 AC_IN I Not used : AC 50/60Hz detect 100 57 BUSY I Busy monitor for IC4001 (New DIST process)

O POWER INDICATOR (LED) brightness [LOW = L] 57 SDA0 I/O Data for Inter IC (serial) bus : EEP-ROM (IC7002)

Data transmission for MAIN (OSD) CPU communication Data request for MAIN (OSD) CPU communication [Request = L]

Reset for IC1001(3D YC SEP / COLOUR DEMODULAT) [Reset = H] Not used : Reset for Digital tuner power / reset control [Reset = L]

O Sync select for DIGITAL-IN [Cotrolled with 99-pin] 86 SCL3B O Clock for Inter IC (serial) bus control

Not used : Video communiation monitor for receiver unit (PDP)

Reset for IC1101(MULTI SOUND PROCESS) [Reset = L]

O Not used 99 DsyncSW1 O Sync select for DIGITAL-IN [Cotrolled with 36-pin]

: DIGITAL SIGNAL PWB ASS'Y]

DIGI_PHOT

65 EXT_YS2 I External YS2 signal detection 66 VDD I 3.3V power supply

77 REMO I Remote control 78 MICON_V I V. sync pulse

POWERGOOD

DIGI_SYNCSEL

89 DIGI_LRSW O For DIGITAL-IN (HDMI)

92 VSS - GND

VFORMSEL

I Photo sensor for DIGITAL-IN illegal copy protection

I Power error detection [NG = H]

O Not used

O Not used : Digital tuner clock control

Not used : Data transmission for digital tuner communication

Data transmission for SUB (DRIVE) CPU communication

Not used : Data for Inter IC (serial) bus for panel communication Not used : Clock for Inter IC (serial) bus for panel communication

Not used : Clock for Inter IC (serial) bus for CARD comunication Not used : Data for Inter IC (serial) bus for CARD comunication Data for writing on board (connect CN01P : for Frash ROM type) Clock for writing on board (connect CN01P : for Frash ROM type)

Reset for sub(chassis) CPU from MAIN CPU [Reset = L]

Clock for Inter IC (serial) bus : IC3001 (DIST process)

(No.YA385)1-11

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.

• Wait until the LAMP UNIT has cool down is completely.

• While not in repair service, place the chassis back its original position.

3.1.1 FRONT SIDE DISASSEMBLY [HD-56ZR7]

3.1.1.1 REMOVING THE SPEAKER GRILL (Fig.1)

(1) Remove the 2 screws [A]. (2) Remove the SPEAKER GRILL by pressing it downward.

3.1.1.2 REMOVING THE FRONT LED PWB (Fig.1)

• Remove the SPEAKER GRILL. (1) Remove the 1 screw [B]. (2) Remove the FRONT LED PWB.

3.1.1.3 REMOVING THE CENTRE COVER (Fig.1)

• Remove the SPEAKER GRILL. (1) Remove the 2 screws [C]. (2) Remove the CENTRE COVER.

3.1.1.4 REMOVING THE SPEAKER (Fig.1)

• Remove the SPEAKER GRILL. (1) Remove the 8 screws [D]. (2) Remove the SPEAKER.

3.1.1.5 REMOVING THE FRONT PANEL (Fig.1 )

• Remove the SPEAKER GRILL.

• Remove the SPEAKER. (1) Remove the 12 screws [E] and the 10 screws [F]. (2) Remove the FRONT PANEL.

CAUTION :

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

recommended for removal and reassemble.

3.1.1.6 REMOVING THE SCREEN BLOCK (Fig.1)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL. (1) Remove the 8 screws [G]. (2) Remove the SCREEN BLOCK.

CAUTION :

• Place the SCREEN BLOCK 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 supporting the SCREEN BLOCK, avoid grasping the

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

• Do not leave the SCREEN BLOCK removed for long time to

prevent soiling from dust.

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

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK. (1) Remove the 12 screws [H]. (2) Remove the SCREEN BRACKET from the FRONT

BRACKET.

(3) Remove the SCREEN ASS’Y.

1-12 (No.YA385)

SCREEN BRACKET

FRONT BRACKET

SCREEN BLOCK

SCREEN ASS'Y

BACK COVER

SCREEN BLOCK

FRONT PANEL

SPEAKER

FRONT

FRONT LED PWB

SPEAKER GRILL

MAIN BODY

CENTRE COVER

SPEAKER

Fig.1

(No.YA385)1-13

3.1.1.8 REMOVING THE MIRROR (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK. (1) Remove the 4 screws [A] attaching the MIRROR HOLDER

(top).

(2) Remove the 6 screws [B] attaching the MIRROR HOLDER

(side).

(3) Raise slightly to disengage of the MIRROR from the bottom

holder.

(4) Remove the MIRROR.

NOTE :

• Do not touch the front of the MIRROR.

• Do not shock the the MIRROR.

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

recommended for removal and reassemble.

3.1.1.9 REMOVING THE SIDE CONTROL PWB (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK. (1) Remove the 2 screws [C]. (2) Remove the SIDE CONTROL BASE. (3) Remove the 2 screws [D]. (4) Remove the SIDE CONTROL PWB.

3.1.1.10 REMOVING THE SUPPORT HOLDER (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK. (1) Remove the 2 screws [E]. (2) Remove the SUPPORT HOLDER.

3.1.1.11 REMOVING THE BACK COVER (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK.

• Remove the SUPPORT HOLDER. (1) Remove the 6 screws [F], the 2 screws [G] and the 2

screws [H].

(2) Remove the BACK COVER.

CAUTION :

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

recommended for removal and reassemble.

3.1.1.12 REMOVING THE SPEAKER BOX (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK.

• Remove the SUPPORT HOLDER.

• Remove the BACK COVER. (1) Remove the 2 screws [J]. (2) Remove the SPEAKER BOX.

3.1.1.13 REMOVING THE FILTER (Fig.2)

(1) Remove the 2 screws [K]. (2) Remove the FILTER COVER with the FILTER. (3) Remove the FILTER.

1-14 (No.YA385)

FILTER COVER

FILTER

MIRROR HOLDER(top)

BACK COVER

MIRROR HOLDER (side)

MIRROR

MIRROR HOLDER (side)

FILTER

FILTER COVER

FRONT

SPEAKER BOX

SUPPORT HOLDER

SIDE CONTROL PWB

MAIN BODY

SIDE CONTROL BASE

SPEAKER BOX

Fig.2

(No.YA385)1-15

3.1.2 FRONT SIDE DISASSEMBLY [HD-70ZR7]

3.1.2.1 REMOVING THE SPEAKER GRILL (Fig.3)

(1) Remove the 1 screw [A] and the 1 screw [B]. (2) Remove the SPEAKER GRILL.

3.1.2.2 REMOVING THE CENTRE PANEL (Fig.3)

• Remove the SPEAKER GRILL. (1) Remove the 2 screws [C], then remove the CENTRE

PANEL.

3.1.2.3 REMOVING THE FRONT LED PWB (Fig.3)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL. (1) Remove the 1 screw [D]. (2) Remove the FRONT LED PWB.

3.1.2.4 REMOVING THE CENTRE COVER (Fig.3)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL. (1) Remove the 2 screws [E]. (2) Remove the CENTRE COVER.

3.1.2.5 REMOVING THE SPEAKER (Fig.3)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL. (1) Remove the 8 screws [F]. (2) Remove the SPEAKER.

3.1.2.7 REMOVING THE SCREEN BLOCK (Fig.3)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the FRONT PANEL. (1) Remove the 6 screws [J] and the 8 screws [K]. (2) Remove the SCREEN BLOCK.

CAUTION :

• Place the SCREEN BLOCK 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 supporting the SCREEN BLOCK, avoid grasping the

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

• Do not leave the SCREEN BLOCK removed for long time to

prevent soiling from dust.

3.1.2.8 REMOVING THE SCREEN ASS'Y (Fig.3)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK. (1) Remove the 11 screws [L]. (2) Remove the SCREEN BRACKET from the FRONT

BRACKET.

(3) Remove the SCREEN ASS'Y.

3.1.2.6 REMOVING THE FRONT PANEL (Fig.3 )

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the SPEAKER (1) Remove the 18 screws [G] and the 10 screws [H]. (2) Remove the FRONT PANEL.

CAUTION:

Because of the large size, at least 2 persons are recommended for removal and reassemble.

1-16 (No.YA385)

SCREEN ASS'Y

FRONT BRACKET

SCREEN BLOCK

SCREEN BRACKET

BACK COVER

SPEAKER

GRILL

FRONT

FRONT PANEL

SPEAKER

CENTRE PANEL

FRONT

LED PWB

SPEAKER GRILL

SPEAKER

Fig.3

MAIN BODY

SCREEN BLOCK

CENTRE COVER

(No.YA385)1-17

3.1.2.9 REMOVING THE MIRROR (Fig.4)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK. (1) Remove the 2 screws [A]. (2) Remove the MIRROR HOLDER STOPPER. (3) Remove the 2 screws [B] and the 2 screws [C]. (4) Remove the MIRROR HOLDER(top). (5) Remove the 4 screws [D]. (6) Remove the MIRROR HOLDER BRACKET(top). (7) Remove the 6 screws [E] and the 2 screws [F]. (8) Remove the MIRROR HOLDER(side). (9) Raise slightly to disengage of the MIRROR from the bottom

holder.

(10) Remove the MIRROR.

NOTE:

• Do not touch the front of the MIRROR.

• Do not shock the MIRROR.

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

recommended for removal and reassemble.

3.1.2.10 REMOVING THE BACK COVER BRACKET (Fig.4)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK. (1) Remove the 6 screws [G] and the 1 screw [H]. (2) Remove the BACK COVER BRACKET(REAR). (3) Remove the 8 screws [J], the 4 screws [K] and the 1 screw

[L].

(4) Remove the BACK COVER BRACKET(both L/R and

FRONT).

3.1.2.13 REMOVING THE BACK COVER (Fig.4)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK.

• Remove the BACK COVER BRACKET.

• Remove the SPEAKER BOX. (1) Remove the 4 screws [Q] and the 2 screws [R]. (2) Remove the BACK COVER.

CAUTION:

Because of the large size, at least 2 persons are recommended for removal and reassemble.

3.1.2.11 REMOVING THE SIDE CONTROL PWB (Fig.4)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK. (1) Remove the 4 screws [M]. (2) Remove the SIDE CONTROL BASE. (3) Remove the 2 screws [N]. (4) Remove the SIDE CONTROL PWB.

3.1.2.12 REMOVING THE SPEAKER BOX (Fig.4)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK.

• Remove the BACK COVER BRACKET. (1) Remove the 6 screws [P]. (2) Remove the SPEAKER BOX.

1-18 (No.YA385)

MIRROR HOLDER STOPPER

BACK COVER

MIRROR HOLDER(top)

MIRROR HOLDER

BRACKET(top)

MIRROR

HOLDER

(side)

BACK COVER

BRACKET

(REAR)

BACK COVER

BRACKET

(FRONT)

BACK COVER

BRACKET

(L/R)

MIRROR

MIRROR HOLDER

(side)

SIDE

CONTROL

PWB

SIDE

CONTROL

BASE

MAIN BODY

SPEAKER BOX

FRONT

SPEAKER BOX

Fig.4

(No.YA385)1-19

3.1.3 REAR SIDE DISASSEMBLY

3.1.3.1 REMOVING THE LAMP UNIT (Fig.5)

(1) Remove the 1 screw [A]. (2) Remove the LAMP COVER. (3) Remove the 2 screws [B]. (4) Pull out the LAMP UNIT.

NOTE :

• Do not leave the LAMP COVER removed for long time to

prevent dirt and dust form covering the lens.

• Make sure that the LAMP COVER is completely installed.

3.1.3.2 REMOVING THE BODY COVER (Fig.5)

(1) Remove the 5 screws [C] and the 9 screws [D]. (2) Remove the 2 screws [E] [HD-56ZR7]. (3) Remove the BODY COVER.

CAUTION :

In case of HD-70ZR7, the 2 screws [E] are not used, an d do not install screws in these screw holes by force.

NOTE:

Do not leave the BODY COVER removed for long time to prevent soiling from dust.

3.1.3.3 REMOVING THE MAIN UNIT (Fig.5)

• Remove the LAMP COVER.

• Remove the BODY COVER. (1) Remove the 4 screws [F]. (2) Remove the BODY BRACKET. (3) Remove the 2 screws [G]. (4) Remove the connectors "FL", "FJ", "SW" and "SP&HJ". (5) The MAIN UNIT is pulled out to the back side.

CAUTION :

• Except for confirmation of projection 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. Do not leave the MAIN UNIT removed for long time to prevent soiling from dust.

• 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 projection lens.

• Do not look directly at the light during service.

• Do not touch the lamp directly as it presents a burn hazard.

NOTE :

• When not performing repair work, attach the cap on the lens

to preventing dust from covering.

• When mounting to the set, make sure the front of the lens is

in contact with the cushion on the set (body) side.

• Make sure that FRONT LED PWB connector is completely

connect to the RECEIVER PWB connector.

• 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.

3.1.3.4 REMOVING THE POWER PWB (Fig.5)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the POWER CORD. (2) Remove the 5 screws [H]. (3) Remove the POWER PWB.

3.1.3.5 REMOVING THE AV TERMINAL BOARD (Fig.5)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the POWER CORD. (2) Remove the 2 screws [J], the 2 screws [K] , the 4 screws

[L] and the 2 hex screws [M].

(3) Remove the 1 screw [N] and the nut attaching the

ANTENNA TERMINAL.

(4) Remove the AV TERMINAL BOARD.

3.1.3.6 REMOVING THE REAR JACK PWB (Fig.5)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the AV TERMINAL BOARD. (1) Remove the 2 screws [P]. (2) Remove the REAR JACK PWB.

3.1.3.7 REMOVING THE RECEIVER PWB (Fig.5)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the AV TERMINAL BOARD.

• Remove the REAR JACK PWB. (1) Remove the 4 screws [Q]. (2) Remove the PWB HOLDER. (3) Remove the 1 screw [R]. (4) Remove the ANALOG PWB BRACKET with PWB. (5) Remove the 4 screws [S]. (6) Remove the RECEIVER PWB.

3.1.3.8 REMOVING THE ANALOG SIGNAL PWB (Fig.5)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the AV TERMINAL BOARD.

• Remove the REAR JACK PWB.

• Remove the PWB HOLDER.

• Remove the RECEIVER PWB. (1) Remove the 2 screws [T]. (2) Remove the ANALOG SIGNAL PWB.

1-20 (No.YA385)

3.1.3.9 REMOVING THE REGULATOR PWB (Fig.5)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the AV TERMINAL BOARD.

• Remove the REAR JACK PWB.

• Remove the PWB HOLDER.

• Remove the RECEIVER PWB. (1) Remove the 4 screws [U]. (2) Remove the REGULATOR PWB.

3.1.3.10 REMOVING THE DIGITAL SIGNAL PWB (Fig.5)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the AV TERMINAL BOARD.

• Remove the PWB HOLDER. (1) Remove the 1 screw [V]. (2) Remove the EARTH WIRE. (3) Remove the 1 screw [W]. (4) Remove the DIGITAL SIGNAL PWB.

CAUTION :

• Make sure to perform the "SYSTEM SETTEING" , when

DIGITAL SIGNAL PWB is replaced.

• Especially, because the value of S039 (ILA COM) might

been changed, go through next steps to confirm the setting value with the remote control unit. (1) Press [INFORMATION] key and [MUTING] key

simultaneously, to enter the SERVICE MODE.

(2) Press [1] key to enter the ADJUSTMENT MODE. (3) Select [S039]. (4) Confirm the value to "0", and set it to "0" when not

"0".

(5) Press [MUTING] key, to memorize the data. (6) Press [BACK] key twice to exit the SERVICE MODE.

(No.YA385)1-21

FRONT

MAIN BODY

LAMP UNIT

LAMP COVER

EARTH WIRE

DIGITAL SIGNAL PWB

PWB HOLDER

SHIELD COVER

ANALOG SIGNAL PWB

ANALOG PWB BRACKET

BODY BRACKET

REAR JACK PWB

RECEIVER PWB

T U

REGULATOR PWB

POWER PWB

AV TERMINAL BOARD

ANTENNA TERMINAL

MAIN UNIT

POWER CORD

BODY COVER

Fig.5

1-22 (No.YA385)

3.1.3.11 REMOVING THE LAMP COVER SW PWB (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 2 screws [A]. (2) Remove the LAMP COVER SW BRACKET with PWB. (3) Remove the 1 screw [B]. (4) Remove the LAMP COVER SW PWB.

3.1.3.12 REMOVING THE FAN CONTROL PWB (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 1 screw [C]. (2) Remove the FAN CONTROL PWB.

3.1.3.13 REMOVING THE THERMOSTAT (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 2 screws [D]. (2) Remove the THERMOSTAT.

3.1.3.14 REMOVING THE LAMP BALLAST BLOCK (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 1 screw [E]. (2) Remove the LAMP BALLAST BLOCK. (3) Remove the 2 screws [F]. (4) Remove the LAMP BALLAST DUCT. (5) Remove the 2 screws [G]. (6) Remove the LAMP BALLAST UNIT.

3.1.3.15 REMOVING THE LAMP COOLING FAN-1 (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 1 screw [H]. (2) Remove the LAMP COOLING FAN-1.

3.1.3.16 REMOVING THE LAMP COOLING FAN-2 (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the LAMP BALLAST DUCT. (1) Remove the 4 screws [J]. (2) Remove the LAMP FAN DUCT. (3) Remove the 2 screws [K]. (4) Remove the COOLING FAN BRACKET. (5) Remove the 4 fan mounts [L]. (6) Remove the LAMP COOLING FAN-2.

3.1.3.17 REMOVING THE OPTICAL / DRIVE ASS’Y (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the FAN CONTROL PWB.

• Remove the LAMP FAN DUCT. (1) Remove the 5 screws [M], 6 screws [N] and the 1 screw

[P].

(2) Remove the OPTICAL / DRIVE ASS'Y.

NOTE:

• The OPTICAL / DRIVE ASS'Y contains precision optical

components. Handle carefully and avoid imparting strong shock.

• OPTICAL / DRIVE ASS'Y construction

(1) Optical block:

(D-ILA device, PBS, Field lens, Integrater, Mirror etc.) (2) Projection lens (3) Optical base (4) MAIN DRIVE PWB (5) Top duct (6) Shield cover

• When not performing repair work, attach the cap on the lens to preventing dust from covering.

• When mounting to the set, make sure the front of the lens side is in contact with the cushion on the body side.

• Do not leave the OPTICAL / DRIVE ASS'Y removed for long time to prevent soiling from dust.

(No.YA385)1-23

3.1.3.18 REMOVING THE MAIN DRIVE PWB (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Slide the TOP DUCT PLATE and remove it. (2) Remove the 1 screw [Q] and the 1 screw [R]. (3) Remove the TOP DUCT. (4) Remove the SHIELD TOP CASE. (5) Remove the 3 screws [T] and the 1 screw [U]. (6) Remove the MAIN DRIVE PWB.

3.1.3.19 REMOVING THE PROJECTION LENS (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 5 screws [V]. (2) Remove the PROJECTION LENS.

3.1.3.20 REMOVING THE OPTICAL BLOCK COOLING FAN

(Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the FAN CONTROL PWB.

• Remove the LAMP FAN DUCT.

• Remove the OPTICAL / DRIVE ASS'Y. (1) Remove the 2 screws [W]. (2) Remove the SIROCCO TOP CASE. (3) Remove the 2 screws [X]. (4) Remove the OPTICAL BLOCK COOLING FAN.

3.1.3.21 REMOVING THE REMOTE SENSOR PWB (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 1 screw [Y]. (2) Remove the REMOTE SENSOR PWB.

1-24 (No.YA385)

FRONT

LAMP BALLAST BLOCK

LAMP BALLAST DUCT

REMOTE SENSOR PWB

LAMP BALLAST UNIT

OPTICAL / DRIVE ASS’Y

TOP DUCT PLATE

TOP DUCT

SHIELD TOP CASE

LAMP FAN DUCT

THERMOSTAT

LAMP COOLING FAN-1

COOLING FAN HOLDER

TEMP. SENSOR PWB

SIROCCO TOP CASE

LAMP BALLAST BRACKET

MAIN DRIVE PWB

SHIELD COVER

PROJECTION LENS

LAMP COOLING FAN-2

OPTICAL BLOCK

COOLING FAN BRACKET

FAN CONTROL PWB

LAMP COVER SW BRACKET

OPTICAL BLOCK COOLING FAN

LAMP COVER SW PWB

UNIT BASE

Fig.6

(No.YA385)1-25

3.2 MEMORY IC REPLACEMENT

S001 PREPARE 0 PAL50 1409 STD H

SERVICE MENU

1.ADJUST

2.SELF CHECK

3.I2C STOP

• This model uses the memory IC.

• This memory IC stores data for proper operation of the video and drive circuits.

• When replacing, be sure to use an IC containing this (initial value) data.

3.2.1 MEMORY IC LIST

Simbol Number of pins Mounting PWB Main content of data

IC4003 IC4004 IC7002 IC7602

32-pin DIGITAL SIGNAL PWB Programme (video process) of IC4001(DIST) is memorized.

8-pin DIGITAL SIGNAL PWB Setting value of IC4001(DIST) is memorized. 8-pin DIGITAL SIGNAL PWB Setting value of IC7001(SUB [CHASSIS] CPU) is memorized. 8-pin DIGITAL SIGNAL PWB Setting value of IC7501 (MAIN CPU) is memorized.

3.2.2 MEMORY IC REPLACEMENT PROCEDURE

1. Power off

Switch off the power and disconnect the power plug from the AC outlet.

2. Replace the memory IC

Be sure to use the memory IC written with the initial setting values.

3. Power on

Connect the power plug to the AC outlet and switch on the power.

4. Receiving channel setting

Refer to the OPERATING INSTRUCTIONS and set the receive channels (Channels Preset) as described.

5. User setting

Check the user setting items according to the given in page later. Where these do not agree, refer to the OPERATING INSTRUCTIONS and set the items as described.

6. SERVICE MODE setting

Verify what to set in the SERVICE MODE, and set whatever is necessary (Fig.1). Refer to the SERVICE ADJUSTMENT for setting.

3.2.3 SERVICE MODE SETTING

SERVICE MODE SCREEN

MAIN MENU SCREEN

SERVICE MENU

1.ADJUST

2.SELF CHECK

3.I2C STOP

ADJUSTMENT MODE SCREEN

S001 PREPARE 0 PAL50 1409 STD H

SETTING ITEM

Setting items Settings Item No.

Video system setting Adjust S001 - S039 Audio system setting Fixed T001 - T010 Panel control system setting Fixed P001 - P010 Drive system setting Fixed D001 - D187 Main CPU system setting Fixed Z001 - Z010

1-26 (No.YA385)

Fig.1

3.2.4 SETTINGS OF FACTORY SHIPMENT

3.2.4.1 BUTTON OPERATION 3.2.4.2 REMOTE CONTROL DIRECT OPERATION Setting item Setting position

POWER Off CHANNEL PR1 VOLUME 10 TV/AV TV

3.2.4.3 REMOTE CONTROL MENU OPERATION

(1) PICTURE

Setting item Setting position

PICTURE MODE BRIGHT COLOUR TEMP. COOL

FEATURES

DIGITAL VNR AUTO (LOW) Super DigiPure AUTO MOVIE THEATRE AUTO COLOUR MANAGEMENT ON PICTURE MANAGEMENT ON COLOUR SYSTEM TV Depends on PR/CH

EXT AUTO

4:3 AUTO ASPECT PANORAMIC

(2) SOUND

Setting item Setting position

STEREO / I•II Stereo sound BASS Centre TREBLE Centre BALANCE Centre 3D SOUND OFF BBE ON

CHANNEL PR1 VOLUME 10 ZOOM AUTO 3D SOUND OFF

(3) FEATURES

SLEEP TIMER OFF CHILD LOCK ID NO.0000, All CH off APPEARANCE TYPE D BLUE BACK ON FAVOURITE SETTING Reset ILLUMINATION BRIGHT

(4) SET UP

AUTO PROGRAM TV channel automatically set EDIT/MANUAL PRESET CH only LANGUAGE ENGLISH DECODER (EXT-2) OFF COMPONENT AUTO SELECT ON HDMI SETTING AUTO

EXT SETTING

S-IN BLANK ID BLANK DUBBING EXT-1 → EXT-2

Setting item Setting position

(No.YA385)1-27

3.3 REPLACEMENT OF CHIP COMPONENT

3.3.1 CAUTIONS

(1) Avoid heating for more than 3 seconds. (2) Do not rub the electrodes and the resist parts of the pattern. (3) When removing a chip part, melt the solder adequately. (4) Do not reuse a chip part after removing it.

3.3.2 SOLDERING IRON

(1) Use a high insulation soldering iron with a thin pointed end of it. (2) A 30w soldering iron is recommended for easily removing parts.

3.3.3 REPLACEMENT STEPS

1. How to remove Chip parts

2. How to install Chip parts

[Resistors, capacitors, etc.]

(1) As shown in the figure, push the part with tweezers and

alternately melt the solder at each end.

(2) Shift with the tweezers and remove the chip part.

[Transistors, diodes, variable resistors, etc.]

(1) Apply extra solder to each lead.

SOLDER

[Resistors, capacitors, etc.]

(1) Apply solder to the pattern as indicated in the figure.

(2) Grasp the chip part with tweezers and place it on the

solder. Then heat and melt the solder at both ends of the chip part.

[Transistors, diodes, variable resistors, etc.]

(1) Apply solder to the pattern as indicated in the figure. (2) Grasp the chip part with tweezers and place it on the

solder.

(3) First solder lead A as indicated in the figure.

(2) As shown in the figure, push the part with tweezers and

alternately melt the solder at each lead. Shift and remove the chip part.

NOTE :

After removing the part, remove remaining solder from the pattern.

1-28 (No.YA385)

(4) Then solder leads B and C.

SECTION 4

SERVICE MENU

1.ADJUST

2.SELF CHECK

3.I2C STOP

ADJUSTMENT

4.1 ADJUSTMENT PREPARATION

(1) The adjustment using the REMOTE CONTROL UNIT is

made on the basis of the initial setting values. The setting values which adjust the screen to the optimum condition can be different from the initial setting values.

(2) Make sure that connection is correctly made AC to AC

power source.

(3) Turn on the power of the TV and measuring instruments for

warning up for at least 30 minutes before starting adjustments.

(4) If the receive or input signal is not specified, use the most

appropriate signal for adjustment.

(5) Never touch the parts (such as variable resistors, trans-

formers and condensers) or setting items/values not shown in the adjustment items of this service adjustment.

4.2 PRESET SETTING BEFORE ADJUSTMENTS

Unless otherwise specified in the adjustment items, preset the following functions with the REMOTE CONTROL UNIT.

Setting item Settings position

PICTURE MODE STANDARD PICTURE adjustments Centre COLOUR TEMP. NORMAL DIGITAL VNR MIN Super DigiPure AUTO MOVIE THEATRE AUTO COLOUR MANAGEMENT ON PICTURE MANAGEMENT ON SOUND adjustments Centre BBE OFF 3D SOUND OFF ZOOM FULL

4.3 MEASURING INSTRUMENT AND FIXTURES

• Signal generator (Pattern generator)

[PAL / 625i / 625p / 1125i(50Hz)]

• Remote control unit

4.4 BASIC OPERATION OF SERVICE MODE

4.4.1 HOW TO ENTER THE SERVICE MODE

(1) Press the [INFORMATION] key and [MUTING] key

simultaneously, to enter the SERVICE MODE. (Fig.1)

SERVICE MENU

1.ADJUST

2.SELF CHECK

3.I2C STOP

Fig.1

NOTE:

• Before entering the SERVICE MODE, confirm that the setting of VCR/TV/DVD switch of the REMOTE CONTROL UNIT is at the "TV" side. If the switch has not been properly set, you cannot enter the SERVICE MODE.

• When a number key other than the [1] or [9] keys is pressed in the SERVICE MENU SCREEN, the other relevant screen may be displayed. This is not used in the adjustment procedure. Press the

[MENU] key to return to the SERVICE MENU SCREEN.

4.4.2 HOW TO EXIT THE SERVICE MODE Press the [ BACK ] key to exit the Service mode.

4.4.3 SERVICE MODE SELECT KEY LOCATION

MUTING

NUMBER

VCR/TV/DVD switch

INFORMATION

ZOOM (Red)

3D SOUND (Green)

MENU FUNCTION /

FUNCTION /

BACK

CH + / -

VOL + / -

(No.YA385)1-29

4.4.4 ADJUSTMENT MODE

S001 PREPARE 0 PAL50 1409 STD H

This mode is used to adjust the VIDEO CIRCUIT.

4.4.4.1 HOW TO ENTER THE ADJUSTMENT MODE When the SERVICE MENU SCREEN of SERVICE MODE is displayed, press [1] key to enter the ADJUSTMENT MODE (Fig.2).

4.4.4.2 DESCRIPTION OF STATUS DISPLAY OF ADJUSTMENT MODE

ADJUSTMENT MODE

SETTING VALUE (DATA)SETTINGITEM No. SETTING ITEM

S001 PREPARE 0 PAL50 1409 STD H

SIGNAL SYSTEM

ZOOM MODE

Fig.2

(1) SIGNAL SYSTEM

The signal displayed on the screen is displayed.

PAL50 : PAL50Hz (Composite / S-video) PAL60 : PAL60Hz (Composite / S-video) SECAM : SECAM NTSC3 : NTSC3.58 NTSC4 : NTSC4.43 525I : 525 i (Component) 525P : 525p 625I : 625 i (Component) 625P : 625p 1125I5 : 1125i 50Hz 1125I6 : 1125i 60Hz RGB5 : RGB 525i RGB6 : RGB 625i PCVGA : PC (VGA) PCXGA : PC (XGA) H525I : HDMI 525i H525P : HDMI 525p H625I : HDMI 625i H625P : HDMI 625p H750P : HDMI 750p H125I5 : HDMI 1125i 50Hz H125I6 : HDMI 1125i 60Hz

(2) ZOOM MODE

State of the SCREEN SIZE or MULTI PICTURE is displayed.

SINGLE SCREEN

FULL : FULL PANO : PANORAMIC 1609 : 16:9 ZOOM 1609S : 16:9 ZOOM SUBTITLE 1409 : 14:9 ZOOM REGU : REGULAR

MULTI SCREEN

M2 : 2-picture s multi M12 : 12-pictures multi

COLOUR TEMP.

PICTURE MODE

(3) PICTURE MODE

STD : STANDARD BRI : BRIGHT SOFT : SOFT

(4) WHITE BALANCE

H: COOL M : NORMAL L: WARM

(5) SETTING ITEM NAME

Setting item name are displayed. The setting item numbers to be displayed are listed below.

Item No. Setting item

S001 - S039 Video system setting T001 - T010 Audio system setting P001 - P010 Panel control system setting D001 - D187 Drive system setting Z001 - Z010 Main CPU system setting

(6) SETTING ITEM NO.

Setting item numbers are displayed. For the setting item names to be displayed, refer to "Initial setting value of adjustment mode".

(7) SETTING VALUE (DATA)

The SETTING VALUE is displayed.

4.4.4.3 CHANGE AND MEMORY OF SETTING VALUE SELECTION OF SETTING ITEM

• [CH+] / [CH-] key. For change of the setting items up/ down.

S001... ↔ T001... ↔ P001... ↔ D001... ↔ Z001...

CHANGE OF SETTING VALUE (DATA)

• [VOL+] / [VOL-] key. For change of the setting values up/down.

MEMORY OF SETTING VALUE (DATA)

Changed setting value is memorized by pressing [MUTING] key.

1-30 (No.YA385)

+ 121 hidden pages