JVC HD-Z56RF7, HD-Z56RF7-A, HD-Z56RF7-S, HD-Z61RF7, HD-Z61RF7-A Service Manual

...

SERVICE MANUAL

REAR PROJECTION TELEVISION

YA46020069

HD-Z56RF7, HD-Z56RF7/A, HD-Z56RF7 HD-Z61RF7

/S, HD-Z61RF7, /A, HD-Z61RF7/S,

HD-Z70RF7, HD-Z70RF7 HD-Z70RF7

/A,

BASIC CHASSIS

RA2

TABLE OF CONTENTS

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

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

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

4 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

No.YA460

2006/9

SPECIFICATION

Items

Dimensions ( W × H × D ) 129.2 cm × 94.4 cm × 45 cm 140.3 cm × 101.6 cm × 48.4 cm 162.6 cm × 116.7 cm × 51.9 cm

Mass 41 kg 45 kg 70 kg

TV RF System B, G, I, D, K, K1, M

Colour System PAL / SECAM / NTSC 3.58 / NTSC 4.43

Stereo System A2 (B/G, D/K), NICAM (B/G, I, D/K)

Teletext System FLOF (Fastext), WST (World Standard System)

Receiving Frequency

Intermediate Frequency

Colour Sub Carrier PAL

Power Input AC110V - AC240 V, 50 Hz / 60 Hz

Power Consumption 195 W (Standby: 0.9 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:1952 × V:1088 [ Effective =H:1920 × V:1080 ]

Screen Transparent screen (unitized fresnel lens / lenticular lens), aspect ratio 16:9

Screen Size 56" (142 cm) Measured diagonally

Audio Power Output 10 W + 10 W

Speaker 8.5 cm × 12.5 cm oval type × 2 (Oblique corn) Aerial terminal (VHF/UHF) 75 Ω unbalanced, coaxial

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

Digital Input Video

PC (RGB) Input D-sub 3-row 15pin × 1

Monitor / Rec Output S-Video

Headphone Jack 3.5mm stereo mini jack × 1 AV COMPULINK lll 3.5mm mini jack × 1 Remote Control Unit RM-C1855 (AAA/LR03/UM-4 battery × 2)

Component Video

625p / 525p / 625i /

VHF Low

VHF High

SECAM

[INPUT-1/3]

1125i / 750p

S-Video

[INPUT-1/2/4]

46.25MHz - 140.25MHz

147.25MHz - 423.25MHz

431.25MHz - 863.25MHz

UHF

Mid (X - Z+2, S1 - S10) / Super (S11 - S20) / Hyper (S21 - S41) bands

CATV

VIF

38.0MHz (B, G, I, D, K, M)

SIF

32.26MHz (5.74MHz: B), 32.15MHz (5.85MHz: G), 31.45MHz (6.55MHz: I)

32.15MHz (5.85MHz: D), 32.15MHz (5.85MHz: K)

4.43MHz

4.40625MHz / 4.25MHz

3.58MHz / 4.43MHz

NTSC

H:124 cm × V:69.8 cm

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

525i

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

Video

500mV (rms), high impedance, RCA pin jack × 8

Audio

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

Audio

Anarog: 500mV(rms) (-4dBs), high impedance, RCA pin jack × 2

R/G/B : 0.7V (p-p), 75Ω

HD / VD : 1V (p-p) to 5V (p-p), high impedance <Available signal>

VGA : 640 pixels × 480 pixels (Horizontal : 31.5kHz / Vertical : 60Hz) XGA : 1024 pixels × 768 pixels (Horizontal : 48.4kHz / Vertical : 60Hz)

Mini-DIN 4pin × 1 Y: 1V (p-p), 75Ω C: 0.286V(p-p) (burst signal), 75Ω 1V (p-p), 75Ω, RCA pin jack × 1

Video

250mV(rms) (-10dBs), Fs-18dB low impedance, RCA pin jack × 2

Audio

HD-Z56RF7 HD-Z61RF7 HD-Z70RF7

61" (155 cm) Measured diagonally

H:135 cm × V:76 cm

Contents

70" (178 cm) Measured diagonally

H:155.5 cm × V:87.2 cm

10 cm round type × 2 (Oblique corn)

Design & specifications are subject to change without notice.

1-2 (No.YA460)

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 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.

(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 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 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 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.).

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

0.15 F AC-TYPE

GOOD EARTH GROUND

1500 10W

PLACE THIS PROBE ON EACH EXPOSED ME TAL PAR T

(No.YA460)1-3

1.2 INSTALLATION

SERVICE MENU

1. ADJUST

2. SELF CHECK

3. I2C STOP

LOB 0 FAN 0 AUD 0

ANA 9 DIG 9

0000 0 0

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 possibly result fire.

1.3 LAMP UNIT HANDLING CAUTION

LAMP UNIT : TS-CL110CA

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.

150 mm

200 mm

LAMP

POWER

150 mm

200 mm

INPUT

OPERATE

INPUT-4

CHANNEL

VIDEO

L/MONO

VOLUME

R AUDIO

50 mm

1.3.2 HOW TO CONFIRM LAMP OPERATING TIME

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

simultaneously, then enter the SERVICE MODE.

(2) When the SERVICE MENU SCREEN is displayed, press

[2] key to enter the SELF CHECK MODE.

(3) The use time of a lamp is displayed on middle of the screen

by the hexadecimal number of 4 figures.

SERVICE MENU SCREEN

SERVICE MENU

1. ADJUST

2. SELF CHECK

3. I2C STOP

SELF CHECK MODE SCREEN (Page 1)

LOB 0 FAN 0 AUD 0

ANA 9 DIG 9

0000 0 0

*Diagram differs from actual appearance.

1-4 (No.YA460)

Lamp operation time (Hexadecimal)

CALCULATION EXAMPLE OF LAMP USE TIME

Ex. Display number=12EF

1x16

+2x162+Ex16+Fx1=1x4096+2x256+14x16+154847 hours

1.3.3 LAMP UNIT REPLACEMENT

(1) The lamp replacement message will appear when need to

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

(2) Lamp use time can be check at the lamp message MENU.

If lamp use time exceeds 6500 hours, the message of Fig.1 will be displayed on a screen.

(3) If Fig.1 message appears 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 replaced. Refer to instructions book for replacement instructions.

After replacing the Lamp, please reset 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 dispose of the used lamp as prescribed.

Fig.1

1.3.4 HOW TO REPLACE THE LAMP UNIT

• Refer to the "INSTUCTION BOOK" 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 "INSTUCTION BOOK" 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, the following

message will appears.

PRESS OK TO RESET THE LAMP TIMER

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

the screen.

(5) The lamp timer has now been reset, and the following

message will appear.

THE LAMP TIMER IS RESET SUCCESSFULLY

(No.YA460)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

COP15A-SA 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) DRIVE PWB ASS'Y

This PWB is mounted with 1 memory IC saved with

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

• REMOTE SENSOR 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 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.

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 following 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 DRIVE PWB ASS'Y is mounted with a memory IC

[IC3753 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 DRIVE PWB ASS'Y, take off the 1

memory IC from the original board and replace with new one. When replace the DRIVE PWB ASS'Y, do same manner. Replace 1 memory IC.

(4) After the replacement of the OPTICAL BLOCK, projection

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

1-6 (No.YA460)

] saved with adjustment/setting data(GAMMA,

2.1 SYSTEM SETTEING

SERVICE MENU

1. ADJUST

2. SELF CHECK

3. I2C STOP

LOB 0 FAN 0 AUD 0

ANA 9 DIG 9

0000 0 0

SECTION 2

SPECIFIC SERVICE INSTRUCTIONS

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

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

simultaneously, then enter the SERVICE MODE.

(2) When the Main Menu is displayed, press [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.

SUPER DIGIPURE

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

SERVICE MENU SCREEN

SERVICE MENU

1. ADJUST

2. SELF CHECK

3. I2C STOP

SELF CHECK MODE SCREEN

LOB 0 FAN 0 AUD 0

ANA 9 DIG 9

0000 0 0

MPEG Noise Reduction

This function effects the block noise removal and mosquito NR simultaneously.

MaxxBass

This function emphasizes the bass sound.

VOICE ENHANCEMENT

Gives a clearer sound quality of the voices in what you are watching.

CINEMA SURROUND

You can enjoy an enhanced sound for wider audience.

PULL DOWN

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

2.3 MAIN DIFFERENCE LIST

Item HD-Z56RF7 HD-Z56RF7/A HD-Z56RF7/S HD-Z61RF7 HD-Z61RF7/A HD-Z61RF7/S

POWER CORD EU Type (2 Pins) AU Type (2 Pins) UK Type (3 Pins) EU Type (2 Pins) AU Type (2 Pins) UK Type (3 Pins)

DIGITAL PWB SRA-0D503A ←←SRA-0D502A ←←

Item HD-Z70RF7 HD-Z70RF7/A HD-Z70RF7/S

POWER CORD EU Type (2 Pins) AU Type (2 Pins) UK Type (3 Pins)

DIGITAL PWB SRA-0D501A ←←

(No.YA460)1-7

2.4 TECHNICAL INFORMATION

2.4.1 D-ILA DEVICE SPECIFICATION

Item Content

Resolution H: 1952 × V:1088

Pixel number about 2123776

Pixel size H : 8.1µm × V :8.1µm

Aspect ratio 16 : 9

Contrast ratio 5000 : 1

Aperture ratio 89% or more

Effective pixel measurement 0.7 inch

2.4.2 PROJECTION UNIT

R DEVICE

B DEVICE

2.4.4 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

OPTICAL IRIS

2.4.3 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)

8.1 m

Pixel

8.1 m

1-8 (No.YA460)

Device

MirrorMirror

2.4.5 MAIN CPU PIN FUNCTION [IC7301 : DIGITAL PWB ASS'Y]

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 Not used 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 AV COMPULINK lll control 75 P3.1 O Not used 12 P2.15 I 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 Not used 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 VDD25 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 P6.3 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 OSD/Teletext signal select 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

COR/RSTOUT

C bus clock (for main memory)

C bus Data (for main memory)

O Not used (NC)

(No.YA460)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.

• 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-Z56RF7, HD-Z61RF7]

3.1.1.1 REMOVING THE SPEAKER GRILL (Fig.1)

(1) Remove the 4 screws [A]. (2) Remove the 2 claws under the SPEAKER GRILL. (3) 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 3 screws [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.

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

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL with SCREEN ASS'Y. (1) Remove the 10 screws [F]. (2) Remove the 8 screws [G]. (3) Remove the SCREEN BRACKET. (4) Remove the SCREEN ASS'Y from the FRONT PANEL

NOTE:

• When replacing the SCREEN ASS'Y, confirm each

SPACER is fit on the SCREEN BRACKET and the FRONT PANEL without fail.

• Do not touch the front of the SCREEN ASS'Y.

• Do not shock the SCREEN ASS'Y.

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

recommended for removal and reassemble.

3.1.1.4 REMOVING THE FRONT PANEL WITH SCREEN ASS'Y (Fig.1)

• Remove the SPEAKER GRILL.

(1) Remove the 8 screws [D]. (2) Remove the 10 screws [E]. (3) Remove the FRONT PANEL with SCREEN ASS'Y.

CAUTION:

• Place the FRONT PANEL with 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.

• Do not leave the FRONT PANEL with SCREEN ASS'Y removed for long time to prevent soiling from dust.

3.1.1.6 REMOVING THE SPEAKER (Fig.1)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL with SCREEN ASS'Y. (1) Remove the 4 screws [H]. (2) Remove the SPEAKER. (3) Remove the opposite SPEAKER by the same method.

1-10 (No.YA460)

CENTRE

COVER

FRONT PANEL

SPACER

SPEAKER

FRONT LED

PWB

SPACER

SCREEN BRACKET

SPACER

SCREEN BRACKET

SCREEN

SPACER

ASS'Y

SPEAKER

FRONT

CLAW

SPEAKER GRILL

Fig.1

(No.YA460)1-11

3.1.1.7 REMOVING THE MIRROR (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL with the SCREEN ASS'Y. (1) Remove the 4 screws [A] attaching the MIRROR HOLDER

of the upper side.

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

of left and right side.

(3) Loosen the 4 screws [C] attaching the MIRROR HOLDER

of bottom side.

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

MIRROR HOLDER.

(5) 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.

3.1.1.8 REMOVING THE SIDE CONTROL PWB (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL with the SCREEN ASS'Y. (1) Remove the 3 screws [D]. (2) Remove the SIDE CONTROL PWB from the SIDE CONTROL BASE.

NOTE:

The SIDE CONTROL BASE is taken out by removing 6 claws.

3.1.1.10 REMOVING THE BACK COVER (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL with the SCREEN ASS'Y.

• Remove the SUPPORT BRACKET. (1) Remove the 2 screws [F] and 2 screws [G] from rear side. (2) Remove the 4 screws [H]. (3) Remove the BACK COVER.

CAUTION :

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

3.1.1.11 REMOVING THE SHADE COVER (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL with the SCREEN ASS'Y.

• Remove the SUPPORT BRACKET.

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

3.1.1.12 REMOVING THE FILTER (Fig.2)

(1) Remove the 1 screw [K]. (2) Remove the FILTER COVER. (3) Remove the FILTER from FILTER COVER. (4) Remove the opposite FILTER by the same method.

3.1.1.9 REMOVING THE SUPPORT BRACKET (Fig.2)

• Remove the SPEAKER GRILL.

• Remove the FRONT PANEL with the SCREEN ASS'Y. (1) Remove the 3 screws [E]. (1) Remove the SUPPORT BRACKET. (2 ) Remove the opposite SUPPORT BRACKET by the same method.

1-12 (No.YA460)

MIRROR HOLDER

SUPPORT

PLATE

FILTER COVER

FILTER

BACK COVER

FILTER

MIRROR HOLDER

MIRROR

MIRROR HOLDER

SUPPORT BRACKET

MIRROR HOLDER

MAIN BODY

MIRROR HOLDER

SUPPORT BRACKET

SIDE

CONTROL

PWB

FILTER COVER

SUPPORT

PLATE

CLAW

SIDE

CONTROL

BASE

FRONT

SHADE COVER

Fig.2

(No.YA460)1-13

3.1.2 FRONT SIDE DISASSEMBLY [HD-Z70RF7]

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 4 screws [F]. (2) Remove the SPEAKER. (3) Remove the opposite SPEAKER by the same method.

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.

3.1.2.7 REMOVING THE SCREEN BLOCK (Fig.3)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the SPEAKER.

• 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 SPEAKER.

• 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.

NOTE:

• When replacing the SCREEN ASS'Y, confirm each

SPACER is fit on the SCREEN BRACKET without fail.

• Do not touch the front of the SCREEN ASS'Y.

• Do not shock the SCREEN ASS'Y.

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

recommended for removal and reassemble.

1-14 (No.YA460)

SCREEN ASS'Y

FRONT BRACKET

SPACER

SCREEN BLOCK

SCREEN BRACKET

SPACER

BACK COVER

FRONT PANEL

SPEAKER GRILL

SPEAKER

FRONT

LED PWB

MAIN BODY

SCREEN BLOCK

CENTRE COVER

FRONT

CENTRE PANEL

SPEAKER GRILL

SPEAKER

Fig.3

(No.YA460)1-15

3.1.2.9 REMOVING THE MIRROR (Fig.4)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the SPEAKER.

• 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(UPPER). (5) Remove the 4 screws [D]. (6) Remove the MIRROR HOLDER BRACKET. (7) Remove the 6 screws [E] and the 2 screws [F]. (8) Remove the MIRROR HOLDER(both L/R 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 front of 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 SPEAKER.

• 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). (1) Remove the 8 screws [J] and the 1 screw [K]. (2) Remove the BACK COVER BRACKET(both L/R).

3.1.2.13 REMOVING THE BACK COVER (Fig.4)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the SPEAKER.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK.

• Remove the BACK COVER BRACKET.

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

CAUTION:

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

3.1.2.14 REMOVING THE SHADE COVER (Fig.4)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the SPEAKER.

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK.

• Remove the BACK COVER BRACKET.

• Remove the SPEAKER BOX.

• Remove the BACK COVER. (1) Remove the 2 screws [R]. (2) Remove the SHADE COVER.

3.1.2.11 REMOVING THE SIDE CONTROL PWB (Fig.4)

• Remove the SPEAKER GRILL.

• Remove the CENTRE PANEL.

• Remove the SPEAKER.

• Remove the FRONT PANEL.

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

• Remove the FRONT PANEL.

• Remove the SCREEN BLOCK.

• Remove the BACK COVER BRACKET. (1) Remove the 3 screws [N]. (2) Remove the SPEAKER BOX. (3) Remove the opposite SPEAKER BOX by the same

method.

1-16 (No.YA460)

MIRROR HOLDER

BRACKET

MIRROR HOLDER

(L)

BACK COVER

BRACKET

(REAR)

MIRROR

HOLDER

STOPPER

MIRROR HOLDER (UPPER)

MIRROR HOLDER

BRACKET

BACK COVER

MIRROR

HOLDER

(R)

MIRROR

BACK COVER

BRACKET

(FRONT)

SIDE

CONTROL

PWB

BACK COVER

BRACKET

(L/R)

SIDE

CONTOROL

BASE

MAIN BODY

SPEAKER BOX

FRONT

SHADE COVER

SPEAKER BOX

Fig.4

(No.YA460)1-17

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 7 screws [C]. (2) Remove the 4 screws [D]. [only HD-Z70RF7] (3) Remove the 5 screws [E]. (4) Remove the BODY COVER.

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) 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 ANALOG 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 AV TERMINAL BOARD (Fig.5)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 3 screws [H], 3 screws [J] and the 7 screws [K]. (2) Remove the 2 hex screws [L]. (3) Remove the AV TERMINAL BOARD.

3.1.3.5 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 7 screws [M]. (3) Remove the POWER PWB.

3.1.3.6 REMOVING THE TUNER 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 1 screw [N]. (2) Remove the HANGER BRACKET with TUNER PWB. (3) Remove the 3 screws [P]. (4) Remove the TUNER PWB.

3.1.3.7 REMOVING THE ANALOG 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 POWER PWB and TUNER PWB. (1) Remove the 4 screws [Q]. (2) Remove the ANALOG PWB.

1-18 (No.YA460)

3.1.3.8 REMOVING THE DIGITAL 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 POWER PWB and TUNER PWB.

• Remove the ANALOG PWB. (1) Remove the 1 screw [R]. (2) Remove the DIGITAL PWB BRACKET with DIGITAL PWB. (3) Remove the 7 screws [S]. (4) Remove the DIGITAL PWB SHIELD COVER. (5) Remove the 9 screws [T]. (6) Remove the DIGITAL PWB.

CAUTION :

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

DIGITAL PWB is replaced.

• Especially, because the value of <F001> (DD) might been

changed, go through next steps to confirm the setting value with the remote control unit.

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

simultaneously, then enter the SERVICE MODE. (2) Press [1] key to enter the ADJUSTMENT MODE. (3) Select <F001>. (4) Confirm the value to "000", and set it to "000" when

not "000". (5) Press [MUTING] key to memorize the data. (6) Press [BACK] key twice to exit the SERVICE MODE.

(No.YA460)1-19

MAIN BODY

FRONT

POWER PWB

HANGER BRACKET

TUNER PWB

ANALOG PWB

LAMP COVER

LAMP UNIT

BODY BRACKET

DIGITAL PWB

DIGITAL PWB BRACKET

DIGITAL PWB SHIELD COVER

MAIN UNIT

AV TERMINAL BOARD

POWER CORD

BODY COVER

1-20 (No.YA460)

Fig.5

3.1.3.9 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 LAMP

COVER SW PWB. (3) Remove the 1 screw [B]. (4) Remove the LAMP COVER SW PWB.

3.1.3.10 REMOVING THE TERMOSTAT (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

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

3.1.3.11 REMOVING THE LAMP FAN DUCT (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the THERMOSTAT. (1) Remove the 5 screws [D]. (2) Remove the LAMP FAN DUCT.

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 [H]. (2) Remove the LAMP BALLAST BLOCK. (3) Remove the 2 screws [J]. (4) Remove the LAMP BALLAST DUCT. (5) Remove the 2 screws [K]. (6) Remove the LAMP BALLAST UNIT.

3.1.3.15 REMOVING THE IRIS PWB (Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 2 screws [L]. (2) Remove the IRIS PWB.

3.1.3.16 REMOVING THE REMOCON PWB(Fig.6)

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT. (1) Remove the 1 screw [M]. (2) Remove the REMOCON PWB.

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

• Remove the LAMP COVER.

• Remove the BODY COVER.

• Remove the BODY BRACKET.

• Remove the MAIN UNIT.

• Remove the LAMP FAN DUCT. (1) Remove the 2 screws [E]. (2) Remove the COOLING FAN BRACKET by pulling

transversally. (3) Remove the 1 screw [F]. (4) Remove the LAMP COOLING FAN-1.

3.1.3.13 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 FAN DUCT.

• Remove the COOLING FAN BRACKET. (1) Remove the 4 screws [G]. (2) 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 LAMP FAN DUCT. (1) Remove the 7 screws [N], 6 screws [P] and 1 screw [Q]. (2) Remove the OPTICAL / DRIVE ASS'Y.

• OPTICAL BLOCK (D-ILA device, PBS, Field lens, Integrater, Mirror etc.)

• PROJECTION LENS

• Optical base

• DRIVE PWB

• IRIS PWB

• TOP DUCT

• SHIELD COVER

NOTE :

• The OPTICAL / DRIVE ASS'Y contains precision optical components.

• Handle carefully and avoid imparting strong shock.

• OPTICAL / DRIVE ASS'Y construction

• 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.YA460)1-21

3.1.3.18 REMOVING THE 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 [R] and the 1 screw [S]. (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 DRIVE PWB.

3.1.3.19 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 LAMP FAN DUCT.

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

3.1.3.20 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 4 screws [X]. (2) Remove the PROJECTION LENS.

1-22 (No.YA460)

PROJECTION LEN

FRONT

REMOCON PWB

LAMP BALLAST BLOCK

LAMP BALLAST

DUCT

LAMP BALLAST BRACKET

LAMP BALLAST UNIT

OPTICAL / DRIVE ASS'Y

TOP DUCT PLATE

TOP DUCT

SHIELD TOP CASE

DRIVE PWB

SHIELD COVER

IRIS PWB

THERMOSTAT

LAMP FAN DUCT

LAMP COOLING FAN-1

COOLING FAN HOLDER

LAMP COOLING

FAN-2

COOLING FAN BRACKET

THERMO PWB

SIROCCO TOP CASE

OPTICAL BLOCK COOLING FAN

PROJECTION

LEN

LENS

OPTICAL BLOCK

LAMP COVER SW BRACKET

LAMP COVER SW PWB

Fig.6

UNIT BASE

(No.YA460)1-23

3.2 MEMORY IC REPLACEMENT

SERVICE MENU

1. ADJUST

2. SELF CHECK

3. I2C STOP

S001 R DRIVE 138 PAL50 FULL STD M

• 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 TABLE

Simbol Number of pins Mounting PWB Main content of data

IC3753

IC7201

IC7602

8-pin DRIVE PWB Adjustment and setting data (GAMMA, SHADING, etc.) of

(DRIVE CPU) are memorized.

IC3701

48-pin DIGITAL PWB Progaram(Video process) of IC6001(System CPU) is memorized.

8-pin DIGITAL PWB Setting value of IC7301(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

SERVICE MENU SCREEN

SERVICE MENU

1. ADJUST

2. SELF CHECK

3. I2C STOP

ADJUSTMENT MODE SCREEN

S001 R DRIVE 138 PAL50 FULL STD M

SETTING ITEM

Setting items Settings Item No.

Video system setting Adjust S001 - S009

Audio system setting Fixed T001 - T003

Main CPU system setting Fixed M001 - M224

Drive system setting Fixed F001 - F002

(NOT USED) Fixed D001

(NOT USED) Fixed Z001

1-24 (No.YA460)

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/VIDEO TV

3.2.4.3 REMOTE CONTROL MENU OPERATION

(1) PICTURE

Setting item Setting position

PICTURE MODE BRIGHT

WHITE BALANCE COOL

FEATURES

Super DigiPure AUTO

PULL DOWN AUTO

COLOUR MANAGEMENT ON

PICTURE MANAGEMENT ON

ADVANCED SMART PICTURE

MPEG NOISE REDUCTION ON

COLOUR SYSTEM MAIN Depends on PR/CH

4:3 AUTO ASPECT PANORAMIC

(2) SOUND

Setting item Setting position

STEREO / I•II Stereo sound

BASS Centre

TREBLE Centre

BALANCE Centre

CINEMA SURROUND OFF

MaxxBass LOW

VOICE ENHANCER OFF

OFF

SUB AUTO

CHANNEL PR1

VOLUME 10

ZOOM PANORAMIC

CINEMA SURROUND OFF

SUB PICTURE VIDEO-2

(4) FEATURES

SLEEP TIMER OFF

CHANNEL GUARD ID NO.0000, All CH off

APPEARANCE TYPE A

BLUE BACK ON

CHILD LOCK OFF

AUTO SHUTOFF OFF

FAVORITE SETTING RESET

ILLUMINATION BRIGHT

(5) SET UP

AUTO PROGRAM TV channel automatically set

EDIT/MANUAL PRESET CH only

LANGUAGE ENGLISH

VIDEO-1 SETTING COMPONENT

VIDEO-3 SETTING COMPONENT

AI VOLUME ON

TELETEXT LANGUAGE GROUP-1

HDMI SETTING HDMI-1 SIZE AUTO

Setting item Setting position

AUDIO AUTO

HDMI-2 SIZE AUTO

(No.YA460)1-25

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.

1-26 (No.YA460)

(4) Then solder leads B and C.

SECTION 4

ADJUSTMENT

4.1 ADJUSTMENT PREPARATION

(1) There are 2 ways of adjusting this TV : One is with the

REMOTE CONTROL UNIT and the other is the conventional method using adjustment parts and components.

(2) 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.

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

power source.

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

warning up for at least 30 minutes before starting adjustments.

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

appropriate signal for adjustment.

(6) Never touch the parts (such as variable resistors,

transformers and condensers) 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

PICTURE MODE STANDARD

PICTURE adjustments Centre

WHITE BALANCE MID

Super DigiPure AUTO

PULL DOWN AUTO

COLOUR MANAGEMENT ON

PICTURE MANAGEMENT ON

Advanced Smart Picture OFF

MPEG Noise Reduction OFF

SOUND adjustments Centre

CINEMA SORROUND OFF

MaxxBass OFF

Voice Enhancer OFF

ZOOM FULL

4.3 MEASURING INSTRUMENT AND FIXTURES

• Signal generator (Pattern generator) [PAL /625i / 1125i]

• Remote control unit

4.4 ADJUSTMENT ITEMS

 FOCUS

• LENS FOCUS adjustment

 DRIVE CIRCUIT

• DRIVE CONVERGENCE adjustment

• DRIVE CENTRE POSITION adjustment

 VIDEO CIRCUIT

• WHITE BALANCE (HIGHLIGHT) adjustment

(No.YA460)1-27

4.5 BASIC OPERATION OF SERVICE MODE

SERVICE MENU

1.ADJUST

2.SELF CHECK

3.I2C STOP

S001 R DRIVE 138 PAL50 FULL STD M

4.5.1 HOW TO ENTER THE SERVICE MODE

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

simultaneously, then enter the SERVICE MODE.

(2)

SERVICE MENU SCREEN

SERVICE MENU

1.ADJUST

2.SELF CHECK

3.I2C STOP

Fig.1

NOTE:

• Before entering the self check mode, confirm that the MODE SW of the REMOTE CONTROL UNIT is set to "TV". If the switch has not been properly set, you cannot enter the self check 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.

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

4.5.3 SERVICE MODE SELECT KEY LOCATION

MUTING

NUMBER

RETURN+

(red)

MODE switch

FUNCTION /

VOL -

DISPLAY

CH -

ZOOM

POWER

(blue)

CH + MENU VOL +

FUNCTION / BACK

4.5.4 ADJUSTMENT MODE

This mode is used to adjust the VIDEO CIRCUIT.

4.5.4.1 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).

4.5.4.2 DESCRIPTION OF STATUS DISPLAY OF ADJUSTMENT MODE

ADJUSTMENT MODE

SETTING VALUE (DATA)SETTING ITEM No. SETTING ITEM

S001 R DRIVE 138 PAL50 FULL STD M

SIGNAL SYSTEM SCREEN MODE PICTURE 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 : 525i (Component) 525P : 525p 625I : 625i (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

WHITE BALANCE

1-28 (No.YA460)

(2) SCREEN 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 : TWIN, FREEZE screen M12 : INDEX screen

(3) PICTURE MODE

STD : STANDARD BRI : BRIGHT SOFT : SOFT

4.5.5 RGB BOX PATTERN MODE

This mode is used to adjust the DRIVE CIRCUIT.

4.5.5.1 HOW TO ENTER THE RGB BOX PATTERN MODE

When the SERVICE MENU SCREEN of SERVICE MODE is displayed, press [9] key to enter the RGB BOX PATTERN

MODE (Fig3).

4.5.5.2 DESCRIPTION OF STATUS DISPLAY OF RGB BOX PATTERN MODE

RGB BOX PATTERN MODE

(4) WHITE BALANCE

H : COOL M: MID 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 - S009 Video system setting

T001 - T003 Audio system setting

M001 - M224 Main CPU system setting

F001 - F002 Drive system setting

D001 (NOT USED)

Z001 (NOT USED)

(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.

4.5.4.3 CHANGE AND MEMORY OF SETTING VALUE

SELECTION OF SETTING ITEM

• [CH+] / [CH-] key. Change the setting items up/ down.

S001... ↔ T001... ↔ M001... ↔ F001... ↔ D001... ↔ Z001...

RGB

ADJUSTMENT COLOUR MODE

Fig.3

(1) RGB BOX PATTERN

The checkered pattern is displayed. White is a synthesis of RGB.

(2) ADJUSTMENT COLOUR MODE

Presently selected ADJUSTMENT COLOUR MODE is displayed.

SELECTION OF SETTING ITEM

• [CH+] / [CH-] key. Move the selected RGB BOX PATTERN up/ down pixel by pixel.

• [VOL+] / [VOL-] key. Move the selected RGB BOX PATTERN left/ right pixel by pixel.

• [blue] key. Adjust the data reset.

• [DISPLAY] key. Adjust the selected ADJUSTMENT COLOUR MODE of RGB BOX PATTERN.

R → B → RGB

• [BACK] key. Return to the SERVICE MENU SCREEN from the RGB BOX PATTERN MODE.

CHANGE OF SETTING VALUE (DATA)

• [VOL+] / [VOL-] key. Change the setting values up/down.

MEMORY OF SETTING VALUE (DATA)

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

MEMORY OF SETTING VALUE (DATA)

With the RGB BOX PATTERN MODE, the changed date is written in the MEMORY instantly.

(No.YA460)1-29

4.6 INITIAL SETTING VALUES IN THE SERVICE MODE

• Perform fine-tuning based on the "initial values" using the remote control when in the Service mode.

• The "initial values" serve only as an indication rough standard and therefore the values with which optimal display can be achieved may be different from the default values. But, don't change the values that are not written in "ADJUSTMENT PROCEDURE". They are fixed values.

4.6.1 VIDEO SYSTEM SETTING

Item No. Item Variable range Setting value

S001 R DRIVE 0 - 255 138

S002 G DRIVE 0 - 255 138

S003 B DRIVE 0 - 255 121

S004 RESREV 0 - 255 0

S005 RESREV 0 - 255 2

S006 RESREV 0 - 255 2

S007 RESREV 0 - 255 2

S008 RESREV 0 - 255 2

S009 RESREV 0 - 255 2

4.6.2 AUDIO SYSTEM SETTING (Fixed values)

Item No. Item Variable range Setting value

T001 RESREV 0 - 15 2

T002 RESREV 0 - 63 2

T003 RESREV 0 - 63 2

4.6.3 MAIN CPU SYSTEM SETTING (Fixed values)

Item No. Item Variable range Setting value

M001 1E00 00 - FF 00

M002 1E01 00 - FF 00

M003 1E02 00 - FF 05

M004 1E03 00 - FF 01

M005 1E04 00 - FF 00

M006 1E05 00 - FF 00

M007 1E06 00 - FF 00

M008 1E07 00 - FF 00

M009 1E08 00 - FF 00

M010 1E09 00 - FF 00

M011 1E0A 00 - FF 01

M012 1E0B 00 - FF 00

M013 1E0C 00 - FF 01

M014 1E0D 00 - FF 00

M015 1E0E 00 - FF 00

M016 1E0F 00 - FF 00

M017 1E10 00 - FF 01

M018 1E11 00 - FF 00

M019 1E12 00 - FF 00

M020 1E13 00 - FF 01

M021 1E14 00 - FF 01

M022 1E15 00 - FF 00

M023 1E16 00 - FF 00

M024 1E17 00 - FF 00

M025 1E18 00 - FF 00

M026 1E19 00 - FF 00

M027 1E1A 00 - FF 00

Item No. Item Variable range Setting value

M028 1E1B 00 - FF 00

M029 1E1C 00 - FF 00

M030 1E1D 00 - FF 00

M031 1E1E 00 - FF 00

M032 1E1F 00 - FF 00

M033 1E20 00 - FF 00

M034 1E21 00 - FF 00

M035 1E22 00 - FF 00

M036 1E23 00 - FF 00

M037 1E24 00 - FF 00

M038 1E25 00 - FF 00

M039 1E26 00 - FF 00

M040 1E27 00 - FF 00

M041 1E28 00 - FF 00

M042 1E29 00 - FF 00

M043 1E2A 00 - FF 00

M044 1E2B 00 - FF 00

M045 1E2C 00 - FF 00

M046 1E2D 00 - FF 00

M047 1E2E 00 - FF 00

M048 1E2F 00 - FF 00

M049 1E30 00 - FF 00

M050 1E31 00 - FF 02

M051 1E32 00 - FF 01

M052 1E33 00 - FF 00

M053 1E34 00 - FF 00

M054 1E35 00 - FF 00

M055 1E36 00 - FF 01

M056 1E37 00 - FF 00

M057 1E38 00 - FF A8

M058 1E39 00 - FF 4E

M059 1E3A 00 - FF 01

M060 1E3B 00 - FF 30

M061 1E3C 00 - FF 00

M062 1E3D 00 - FF 00

M063 1E3E 00 - FF 00

M064 1E3F 00 - FF 00

M065 1E40 00 - FF 00

M066 1E41 00 - FF 00

M067 1E42 00 - FF 03

M068 1E43 00 - FF 36

M069 1E44 00 - FF 00

M070 1E45 00 - FF 20

M071 1E46 00 - FF 03

M072 1E47 00 - FF 01

1-30 (No.YA460)

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