LG RL-44SZ20RD, RE-44SZ20RD Service Manual
VIDEOS-VIDEO
L/MONORAUDIO TV/AV MENUOK VOL PR
ON/OFF
AV4
DLP Projection TV
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE CHASSIS,
READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
CHASSIS : MB-02JA
MODEL : RE/RL-44SZ20RD
website:http://biz.LGservice.com
e-mail:http://www.LGEservice.com/techsup.html
- 2 -
CONTENTS
CONTENTS ..................................................................................................................... 2
SAFETY PRECAUTIONS ................................................................................................3
SERVICING PRECAUTIONS .......................................................................................... 4
CONTROL DESCRIPTIONS ............................................................................................6
REPLACINIG LAMP ......................................................................................................10
SPECIFICATIONS ..........................................................................................................11
ADJUSTMENT INSTRUCTIONS ....................................................................................12
BLOCK DIAGRAM..........................................................................................................13
EXPLODED VIEW ......................................................................................................... 18
EXPLODED VIEW PARTS LIST .....................................................................................19
REPLACEMENT PARTS LIST .......................................................................................20
SVC. SHEET ......................................................................................................................
- 3 -
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 lsolation 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 circuitary 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 positioin, 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 esposed 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 sepcified, 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
- 4 -
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.
c.
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 nonabrasive 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.
9. 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 fieldeffect
transistors and semicounductor "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
electostatic 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 sufficent to demage ES devices.
5. Do not use freon-propelled chemicals. These can generate
electrical charges sufficient to damage ES devices.
6. Do not remove a repalcement 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 bruching 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 maintan 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. Thorohly 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
circuiboard 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
- 5 -
c. Qulckly 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 parapraphs 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 boare.
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 perpendicula 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
involoves 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.
- 6 -
CONTROL DESCRIPTIONS
All the functions can be controlled with the remote control handset.
Some functions can also be adjusted with the buttons on the front
panel of the set.
Remote control handset
Before you use the remote control handset, please install the batteries. See the next page.
1. POWER
switches the set on from standby or off to standby.
2. ARC (Aspect Ratio Control)
changes the picture format.
3. MUTE
switches the sound on or off.
4. PIP BUTTONS
PIP
switches the sub picture on or off.
PR +/
-
selects a program for the sub picture.
SWAP
alternates between main and sub picture.
INPUT
selects the input mode for the sub picture.
SIZE
adjusts the sub picture size.
STILL
freezes motion of the sub picture.
POSITION
relocates the sub picture in clockwise direction.
5. MENU
selects a menu.
6.
DD/EE
(Program Up/Down)
selects a program or a menu item.
switches the set on from standby.
FF / GG (Volume Up/Down)
adjusts the volume.
adjusts menu settings.
OK
accepts your selection or displays the current mode.
7. NUMBER BUTTONS
switches the set on from standby or directly select a number.
8. PSM (Picture Status Memory)
recalls your preferred picture setting.
9. I/II
selects the language during dual language broadcast.
selects the sound output.
10. VCR BUTTONS
control a LG video cassette recorder.
123
456
7
PSM SSM
8
0
POSITION
STILL
MIX
I/II
REVEAL
?
TIME
LIST
MODE
STOP REC
P/STILL
REW FF
PLAY
9
POWER
ARC TV/AV
MUTE SLEEP
PIP TEXT
PR - PR +
INPUTSWAP
MENU PR
VOL
OK
VOL
PR
CANCEL/EXIT
INDEX
M
SIZE
1
2
3
4
5
8
9
10
7
6
- 7 -
11. TV/AV
selects the remote operating mode.
switches the set on from standby.
12. SLEEP
sets the sleep timer.
13. TELETEXT BUTTONS
These buttons are used for teletext.
For further details, see the ÔTeletextÕ section.
14. CANCEL/EXIT
Clears all on-screen displays and returns to TV viewing from any
menu.
15. SSM (Sound Status Memory)
recalls your preferred sound setting.
16. LIST
displays the program table.
Note : In teletext mode, the PR +/-, SWAP and INPUT buttons are
used for teletext function.
Battery installation
The remote control handset is powered by two AAA type batteries.
To load the batteries, turn the remote control handset over and
open the battery compartment. Install two batteries as indicated by
the polarity symbols ( and ) marked inside the compartment.
Note : To avoid damage from possible battery leakage, remove the
batteries if you do not plan to use the remote control handset for an
extended period of time.
+
-
1 2 3
4 5 6
7
PSM SSM
8
0
POSITION
STILL
MIX
I/II
REVEAL
?
TIME
LIST
MODE
STOP REC
P/STILL
REW FF
PLAY
9
POWER
ARC TV/AV
MUTE SLEEP
PIP TEXT
PR - PR +
INPUTSWAP
MENU PR
VOL
OK
VOL
PR
CANCEL/EXIT
INDEX
M
SIZE
11
12
13
14
15
16
- 8 -
1. MAIN POWER (ON/OFF)
switches the set on or off.
2. TV/AV
selects TV or AV mode.
switches the set on from standby.
3. MENU
selects a menu.
4. OK
accepts your selection or displays the current
mode.
5.
FF/GG
(Volume Down/Up)
adjusts the volume.
adjusts menu settings.
6.
DD/EE
(Program Up/Down)
selects a program or a menu item.
switches the set on from standby.
7. OPERATION INDICATOR (Refer to p.7)
8. LAMP INDICATOR (Refer to p.7)
9. TEMPERATURE INDICATOR (Refer to p.7)
10. REMOTE CONTROL SENSOR (Refer to p.7)
11. AUDIO/VIDEO IN SOCKETS (AV4)
Connect the audio/video out sockets of external equipment to these sockets.
S-VIDEO/AUDIO IN SOCKETS (S-VIDEO)
Connect the S-VIDEO out socket of an VCR
to the S-VIDEO socket.
Connect the audio out sockets of the VCR to
the audio sockets as in AV4.
Front panel
VIDEOS-VIDEO
L/MONOR AUDIO TV/AV MENU OK VOL PR
ON/OFF
AV4
ON/OFF
VIDEO S-VIDEO
L/MONO RAUDIO TV/AV MENU OK VOL PR
AV4
176543211 8 9
10
Lamp indicator, operation indicator, and temperature indicator, located side the front panel controls
reveal the operating status of the DLP(Digital Light Processing) projection TV.
- 9 -
UPGRADE PORT
ANT IN
75Ω
AV1
AV2
AV3
L
R
AUDIO
OUT
SERIAL
ANT IN
75Ω
1
2
3
L
R
AUDIO
OUT
Rear panel
AERIAL SOCKET
UPGRADE PORT
This port is used to upgrade the
software version and debug
without changing the hardware.
Be careful not to use this port.
Just contact your dealer or service centre.
AUDIO OUT SOCKETS
EURO SCART SOCKETS
Off Power cord is not connected.
Red Power Cord is connected, unit is on standby.
Green On
Orange (flashing) Preparing operation in standby.
Orange Projection lamp is reaching the end of its life and
needs to be replaced with a new lamp.
Green (flashing) The lamp cover is not closed.
Orange The projector is overheating.
Red The projector shut down due to overheating.
Red (flashing) The projector shut down, check the cooling fan.
Operation Indicator
Lamp Indicator
Temperature Indicator
¥Status Indicators
- 10 -
* Contact your dealer or LG service center for replacing the new lamp.
You must replace the lamp when;
¯ The set image get darker or start to be deteriorated.
¯ The lamp indicator is orange.
¯ The message ÒLAMP REPLACEÒ appears on the screen.
* Replace the lamp as below sequence
1. Turn off the projection and unplug the power cable.
(Cool the lamp for more than 1 hour.)
2. Remove the two retainging screws on the lamp cover with a screwdriver of Ò+Ò
type and then lift off the lamp cover.(refer to fig.1)
3. After lifting the lamp cover off, remove the two retaining screw on lamp case with
screwdriver of Ò-Ò type. (refer to fig.2)
4. Pull out the handle slowly and remove the lamp.(refer to fig.3)
5. Insert the new lamp gently into the correct position. Make sure it is inserted correctly.
6. Tighten the screw you removed in step 3.
7. Replace the lamp cover and tighten the cover screws.
REPLACING THE LAMP
< Fig. 1>
< Fig. 2>
< Fig. 3>
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