LG RD-JT91, RE-048A Service Manual

DLP PROJECTOR

SERVICE MANUAL

CAUTION

BEFORE SERVICING THE CHASSIS, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

CHASSIS : RE-048A

MODEL : RD-JT91

website:http://biz.LGservice.com

e-mail:http://www.LGEservice.com/techsup.html

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CONTENTS

CONTENTS.......................................................................................................................2

SAFETY PRECAUTIONS .................................................................................................3

SERVICING PRECAUTIONS............................................................................................4

CONTROL DESCRIPTIONS.............................................................................................6

REPLACING OF LAMP ..................................................................................................10

SPECIFICATIONS...........................................................................................................11

ADJUSTMENT INSTRUCTION.......................................................................................13

PRINTED CIRCUIT BOARD...........................................................................................18

BLOCK DIAGRAM..........................................................................................................21

EXPLODED VIEW...........................................................................................................22

EXPLODED VIEW PARTS LIST.....................................................................................23

REPLACEMENT PARTS LIST........................................................................................24

SVC. SHEET .......................................................................................................................

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SAFETY PRECAUTIONS

Many electrical and mechanical parts in this chassis have special safety-related characteristics. These parts are identified by in the Schematic Diagram and Replacement Parts List. It is essential that these special safety parts should be replaced with the same components as recommended in this manual to prevent X-RADIATION, Shock, Fire, or other Hazards. Do not modify the original design without permission of manufacturer.

General Guidance

An isolation Transformer should always be used during the servicing of a receiver whose chassis is not isolated from the AC power line. Use a transformer of adequate power rating as this protects the technician from accidents resulting in personal injury from electrical shocks.

It will also protect the receiver and it's components from being damaged by accidental shorts of the circuitry that may be inadvertently introduced during the service operation.

If any fuse (or Fusible Resistor) in this TV receiver is blown, replace it with the specified.

When replacing a high wattage resistor (Oxide Metal Film Resistor, over 1W), keep the resistor 10mm away from PCB.

Keep wires away from high voltage or high temperature parts.

Due to high vacuum and large surface area of picture tube, extreme care should be used in handling the Picture Tube. Do not lift the Picture tube by it's Neck.

X-RAY Radiation

Warning:

To determine the presence of high voltage, use an accurate high impedance HV meter.

Adjust brightness, color, contrast controls to minimum. Measure the high voltage. The meter reading should indicate

23.5

¡ 1.5KV: 14-19 inch, 26 ¡ 1.5KV: 19-21 inch,

29.0 ¡ 1.5KV: 25-29 inch, 30.0 ¡ 1.5KV: 32 inch If the meter indication is out of tolerance, immediate service and correction is required to prevent the possibility of premature component failure.

Before returning the receiver to the customer,

always perform an AC leakage current check on the exposed metallic parts of the cabinet, such as antennas, terminals, etc., to be sure the set is safe to operate without damage of electrical shock.

Leakage Current Cold Check(Antenna Cold Check)

With the instrument AC plug removed from AC source, connect an electrical jumper across the two AC plug prongs. Place the AC switch in the on position, connect one lead of ohm-meter to the AC plug prongs tied together and touch other ohm-meter lead in turn to each exposed metallic parts such as antenna terminals, phone jacks, etc. If the exposed metallic part has a return path to the chassis, the measured resistance should be between 1MΩ and 5.2MΩ. When the exposed metal has no return path to the chassis the reading must be infinite. An other abnormality exists that must be corrected before the receiver is returned to the customer.

Leakage Current Hot Check (See below Figure)

Plug the AC cord directly into the AC outlet.

Do not use a line Isolation Transformer during this check.

Connect 1.5K/10watt resistor in parallel with a 0.15uF capacitor between a known good earth ground (Water Pipe, Conduit, etc.) and the exposed metallic parts. Measure the AC voltage across the resistor using AC voltmeter with 1000 ohms/volt or more sensitivity. Reverse plug the AC cord into the AC outlet and repeat AC voltage measurements for each exposed metallic part. Any voltage measured must not exceed 0.75 volt RMS which is corresponds to 0.5mA. In case any measurement is out of the limits specified, there is possibility of shock hazard and the set must be checked and repaired before it is returned to the customer.

Leakage Current Hot Check circuit

The source of X-RAY RADIATION in this TV receiver is the High Voltage Section and the Picture Tube. For continued X-RAY RADIATION protection, the replacement tube must be the same type tube as specified in the Replacement Parts List.

1.5 Kohm/10W

To Instrument's exposed METALLIC PARTS

Good Earth Ground such as WATER PIPE, CONDUIT etc.

AC Volt-meter

IMPORTANT SAFETY NOTICE

0.15uF

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CAUTION: Before servicing receivers covered by this service manual and its supplements and addenda, read and follow the

SAFETY PRECAUTIONS

on page 3 of this publication.

NOTE:

If unforeseen circumstances create conflict between the following servicing precautions and any of the safety precautions on page 3 of this publication, always follow the safety precautions. Remember: Safety First.

General Servicing Precautions

1. Always unplug the receiver AC power cord from the AC

power source before; a. Removing or reinstalling any component, circuit board

module or any other receiver assembly.

b. Disconnecting or reconnecting any receiver electrical plug

or other electrical connection.

Connecting a test substitute in parallel with an electrolytic capacitor in the receiver. CAUTION: A wrong part substitution or incorrect polarity installation of electrolytic capacitors may result in an explosion hazard.

d. Discharging the picture tube anode.

2. Test high voltage only by measuring it with an appropriate

high voltage meter or other voltage measuring device (DVM, FETVOM, etc) equipped with a suitable high voltage probe. Do not test high voltage by "drawing an arc".

3. Discharge the picture tube anode only by (a) first connecting

one end of an insulated clip lead to the degaussing or kine aquadag grounding system shield at the point where the picture tube socket ground lead is connected, and then (b) touch the other end of the insulated clip lead to the picture tube anode button, using an insulating handle to avoid personal contact with high voltage.

4. Do not spray chemicals on or near this receiver or any of its

assemblies.

5. Unless specified otherwise in this service manual, clean

electrical contacts only by applying the following mixture to the contacts with a pipe cleaner, cotton-tipped stick or comparable non-abrasive applicator; 10% (by volume) Acetone and 90% (by volume) isopropyl alcohol (90%-99% strength) CAUTION: This is a flammable mixture. Unless specified otherwise in this service manual, lubrication of contacts in not required.

6. Do not defeat any plug/socket B+ voltage interlocks with

which receivers covered by this service manual might be equipped.

7. Do not apply AC power to this instrument and/or any of its

electrical assemblies unless all solid-state device heat sinks are correctly installed.

8. Always connect the test receiver ground lead to the

receiver chassis ground before connecting the test receiver positive lead. Always remove the test receiver ground lead last.

Use with this receiver only the test fixtures specified in this service manual.

CAUTION: Do not connect the test fixture ground strap to any heatsink in this receiver.

Electrostatically Sensitive (ES) Devices

Some semiconductor (solid state) devices can be damaged easily by static electricity. Such components commonly are called

Electrostatically Sensitive (ES) Devices.

Examples of

typical ES devices are integrated circuits and some field-effect

transistors and semiconductor "chip" components. The following techniques should be used to help reduce the incidence of component damage caused by static by static electricity.

1. Immediately before handling any semiconductor component or semiconductor-equipped assembly, drain off any electrostatic charge on your body by touching a known earth ground. Alternatively, obtain and wear a commercially available discharging wrist strap device, which should be removed to prevent potential shock reasons prior to applying power to the unit under test.

2. After removing an electrical assembly equipped with ES devices, place the assembly on a conductive surface such as aluminum foil, to prevent electrostatic charge buildup or exposure of the assembly.

3. Use only a grounded-tip soldering iron to solder or unsolder ES devices.

4. Use only an anti-static type solder removal device. Some solder removal devices not classified as "anti-static" can generate electrical charges sufficient to damage ES devices.

5. Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage ES devices.

6. Do not remove a replacement ES device from its protective package until immediately before you are ready to install it. (Most replacement ES devices are packaged with leads electrically shorted together by conductive foam, aluminum foil or comparable conductive material).

7. Immediately before removing the protective material from the ieads of a replacement ES device, touch the protective material to the chassis or circuit assembly into which the device will be installed. CAUTION:Be sure no power is applied to the chassis or circuit, and observe all other safety precautions.

8. Minimize bodily motions when handling unpackaged replacement ES devices. (Otherwise harmless motion such as the brushing together of your clothes fabric or the lifting of your foot from a carpeted floor can generate static electricity sufficient to damage an ES device.)

General Soldering Guidelines

1. Use a grounded-tip, low-wattage soldering iron and appropriate tip size and shape that will maintain tip temperature within the range or 500¡£F to 600¡£F.

2. Use an appropriate gauge of RMA resin-core solder composed of 60 parts tin/40 parts lead.

3. Keep the soldering iron tip clean and well tinned.

4. Throughly clean the surfaces to be soldered. Use a mall wirebristle (0.5 inch, or 1.25cm) brush with a metal handle. Do not use freon-propelled spray-on cleaners.

5. Use the following unsoldering technique a. Allow the soldering iron tip to reach normal temperature.

(500¡£F to 600¡£F) b. Heat the component lead until the solder melts. c. Quickly draw the melted solder with an anti-static,

suction-type solder removal device or with solder braid.

CAUTION: Work quickly to avoid overheating the circuit-

board printed foil.

6. Use the following soldering technique. a. Allow the soldering iron tip to reach a normal

temperature (500¡£F to 600¡£F)

b. First, hold the soldering iron tip and solder the strand

against the component lead until the solder melts.

SERVICING PRECAUTIONS

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c. Quickly move the soldering iron tip to the junction of the

component lead and the printed circuit foil, and hold it there only until the solder flows onto and around both the component lead and the foil. CAUTION: Work quickly to avoid overheating the circuit board printed foil.

d. Closely inspect the solder area and remove any excess

or splashed solder with a small wire-bristle brush.

IC Remove/Replacement

Some chassis circuit boards have slotted holes (oblong) through which the IC leads are inserted and then bent flat against the circuit foil. When holes are the slotted type, the following technique should be used to remove and replace the IC. When working with boards using the familiar round hole, use the standard technique as outlined in paragraphs 5 and 6 above.

Removal

1. Desolder and straighten each IC lead in one operation by gently prying up on the lead with the soldering iron tip as the solder melts.

2. Draw away the melted solder with an anti-static suctiontype solder removal device (or with solder braid) before removing the IC.

Replacement

1. Carefully insert the replacement IC in the circuit board.

2. Carefully bend each IC lead against the circuit foil pad and solder it.

3. Clean the soldered areas with a small wire-bristle brush. (It is not necessary to reapply acrylic coating to the areas).

"Small-Signal" Discrete Transistor Removal/Replacement

1. Remove the defective transistor by clipping its leads as close as possible to the component body.

2. Bend into a "U" shape the end of each of three leads remaining on the circuit board.

3. Bend into a "U" shape the replacement transistor leads.

4. Connect the replacement transistor leads to the corresponding leads extending from the circuit board and crimp the "U" with long nose pliers to insure metal to metal contact then solder each connection.

Power Output, Transistor Device Removal/Replacement

1. Heat and remove all solder from around the transistor leads.

2. Remove the heatsink mounting screw (if so equipped).

3. Carefully remove the transistor from the heat sink of the circuit board.

4. Insert new transistor in the circuit board.

5. Solder each transistor lead, and clip off excess lead.

6. Replace heatsink.

Diode Removal/Replacement

1. Remove defective diode by clipping its leads as close as possible to diode body.

2. Bend the two remaining leads perpendicular y to the circuit board.

3. Observing diode polarity, wrap each lead of the new diode around the corresponding lead on the circuit board.

4. Securely crimp each connection and solder it.

5. Inspect (on the circuit board copper side) the solder joints of the two "original" leads. If they are not shiny, reheat them and if necessary, apply additional solder.

Fuse and Conventional Resistor Removal/Replacement

1. Clip each fuse or resistor lead at top of the circuit board hollow stake.

2. Securely crimp the leads of replacement component around notch at stake top.

3. Solder the connections. CAUTION: Maintain original spacing between the replaced component and adjacent components and the circuit board to prevent excessive component temperatures.

Circuit Board Foil Repair

Excessive heat applied to the copper foil of any printed circuit board will weaken the adhesive that bonds the foil to the circuit board causing the foil to separate from or "lift-off" the board. The following guidelines and procedures should be followed whenever this condition is encountered.

At IC Connections

To repair a defective copper pattern at IC connections use the following procedure to install a jumper wire on the copper pattern side of the circuit board. (Use this technique only on IC connections).

1. Carefully remove the damaged copper pattern with a sharp knife. (Remove only as much copper as absolutely necessary).

2. carefully scratch away the solder resist and acrylic coating (if used) from the end of the remaining copper pattern.

3. Bend a small "U" in one end of a small gauge jumper wire and carefully crimp it around the IC pin. Solder the IC connection.

4. Route the jumper wire along the path of the out-away copper pattern and let it overlap the previously scraped end of the good copper pattern. Solder the overlapped area and clip off any excess jumper wire.

At Other Connections

Use the following technique to repair the defective copper pattern at connections other than IC Pins. This technique involves the installation of a jumper wire on the component side of the circuit board.

1. Remove the defective copper pattern with a sharp knife. Remove at least 1/4 inch of copper, to ensure that a hazardous condition will not exist if the jumper wire opens.

2. Trace along the copper pattern from both sides of the pattern break and locate the nearest component that is directly connected to the affected copper pattern.

3. Connect insulated 20-gauge jumper wire from the lead of the nearest component on one side of the pattern break to the lead of the nearest component on the other side. Carefully crimp and solder the connections. CAUTION: Be sure the insulated jumper wire is dressed so the it does not touch components or sharp edges.

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CONTROL DESCRIPTIONS

Names of parts

Main Body

Connecting Part

AUTO

SOURCE

POW

VOL

Indicators

Front remote control sensor

Power button

Foot adjusting button

Rear remote control sensor

Control panel

The projector is manufactured using high-precision technology. You may, however, see on the Projector screen tiny black points and/or bright points (red, blue, or green). This can be a normal result of the manufacturing process and does not always indicate a malfunction.

Focus ring

Zoom ring

Lens cover

* Push the lens cover into the inside after pulling it open into the

front. (If you mount on the ceiling, after pushing the cover, the lens cover is installed. If not, the cover may overlap projecting lens.)

DVI Input S-Video

USB(Service)

*This jack is only used for service.

Audio

RGB Input (PC/DTV)

Video

AC IN

Kensington Security System Connector

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Control Panel

AUTO

SOURCE

POWER

VOLVOL

KEYSTONE

POWER Button

, KEYSTONE+/- Button

MENU Button

Selects or closes menus.

AUTO Button

VOLUME Button

Adjusts volume level and functions of menus.

SOURCE Button

Switches to RGB, DVI, Video,S-Video mode.

A OK Button

Checks present mode and saves the change of functions.

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Remote Control

POWER

SOURCE

AUTO

BLANK ARC

MUTE

STILL

VOL

KEYSTONE

POWER Button

SOURCE Button

KEYSTONE+/-,

D / EButton

A OK Button

ARC Button

STILL Button

AUTO Button

BLANK Button

MUTE Button

*Switches the sound on or off.

VOL-/+, F / GButton

MENU Button

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* Lamp Indicator, operation indicator and temperature indicator at the top of the projector show the user the operating

status of the projector.

AUTO

SOURCE

POWER

VOL

Lamp Indicator

Temperature Indicator

Operation Indicator

Projector Status Indicators

Operation Indicator

Lamp Indicator

Temperature Indicator

Orange Green(flashing) Green Orange(flashing) Off

Red

Red(flashing) Green(flashing)

Orange Red Red (flashing)

Standby. The fan is running while the lamp preheats. The lamp is preheated and on. Projector lamp is cooling as power out (2 minutes) Power off. Projector lamp is reaching the end of its life and needs to be replaced with a new lamp. (over 2000 hours) The projector has trouble in the lamp or around it at power-on. Retry Power On again later. If lamp indicator is red (flashing) again, contact the service center. The lamp cover is not closed. The projector is in a high temperature condition. Turn off the power to the unit and check for proper ventilation. The projector is turned off due to the unit overheating. Power has turned off due to problem with the internal cooling fan. The fan is not operating.

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REPLACING OF LAMP

The projector lamp should lasts for about 2000 hours.You can see the lamp hours time in the selecting function section.You must replace the lamp when one or more of the following apply.

O The projected image gets darker or starts to become

distorted.

O The lamp indicator is red.(Red,flashing alternately) O The message “ LAMP REPLACE” appears on the screen

when turning the projector lamp on.

1. Turn off the projector and unplug the power cable. (allow the lamp to cool for more than 1 hour.)

2. Stand the projector on its side as below so that you can easily access the lamp cover.

3. Remove the two retaining screws on the lamp cover with a screwdriver and then lift off the lamp cover.

4. After lifting the lamp cover off, remove the two retaining screws on the lamp case with a screwdriver.

5. Lift up the fixed wire handle of the lamp.

6. Pull out the handle slowly and remove the lamp case.

7. Insert the new lamp gently into the correct position. Make sure it is inserted correctly.

8. Tighten the screws you removed in step 4.

9. Replace the lamp cover and tighten the cover screws. (Make sure the lamp cover is securely fastened. If the lamp cover is open, the lamp indicator flashes green and the projector will not turn on.)

Bottom of the Projector

SPECIFICATIONS

NOTE : Specifications and others are subject to change without notice for improvement

A Scope

This standard can be applied to the LCD Projector related to RE-048A Chassis.

A Test Condition

1) Temperature : 25°C¡ 5°C (Only CST is 40°C¡ 2°C )

2) Relative Humidity: 65¡ 10%

3) Power Voltage: Standard input voltage (AC 100 - 240V, 50/60Hz)

4) Use the parts only designated in B.O.M.,PARTS SPEC.,or drawings.

5) Follow each drawing or spec for spec and performance of parts,based upon P/N of B.O.M

6) Warm up TV set for more than 30min. before the measurement.

A Test and Inspection Method

1) performance:Follow the Standard of LG TV test

2) RCA JACK performance: Follow the standard of LG

3) Standards of Etc requirement SAFETY:CE (EN55020), Electric wave:CB (EN55013)

A General Specification

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No. Item

Video input applicable system

Power Input Voltage Market Screen size Aspect ratio Operating Temperature Operating Humidity Storage Temperature Storage Humidity

NTSC M NTSC 4.43 PAL PAL M PAL N SECAM NTSC-PB SMPS AC 100(-10%) - 240(+6%)V,50/60Hz World wide 4:3 / 16:9 4 : 3 0

-20

40 85 60 85

deg

3.579545 / 60Hz

4.433618 / 60Hz

4.433618 / 50Hz

3.575611 / 60Hz

3.582056 / 50Hz

4.286 / 50Hz

4.433618 / 60Hz

2 3 4 5 6 7 8 9

Specification

Min Typ Max Unit

Remark

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