Panasonic PT-43LCX64, PT-50LCX64, PT-60LCX64 Service Manual

Multi Media Display

PT-43LCX64 PT-50LCX64 PT-60LCX64

ORDER NO. MKE0409853C1

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

CONTENTS

Page Page

1 SAFETY PRECAUSIONS 3

1.1. GENERAL GUIDELINES

1.2. LEAKAGE CURRENT COLD CHECK

1.3. LEAKAGE CURRENT HOT CHECK

1.4. UV-PRECAUTION

2 PREVENTION OF ELECTROSTATIC DISCHARGE (ESD) TO

ELECTROSTATICALLY SENSITIVE (ES) DEVICES 3 ABOUT LEAD FREE SOLDER (PbF) 4 SERVICE NOTES 5 DISASSEMBLY / ASSEMBLY PROCEDURES

5.1. CABINET SECTION

6 ADJUSTMENT PROCEDURES 1 7 TROUBLESHOOTING HINTS FOR BLOCK LEVEL REPAIR 8 BLOCK DIAGRAMS 9 SCHEMATIC DIAGRAMS

9.1. SCHEMATIC DIAGRAM AND CIRCUIT BOARD LAYOUT NOTES

9.2. INTERCONNECTION SCHEMATIC DIAGRAM

9.3. FRONT JACK SCHEMATIC DIAGRAM

9.4. NETWORK / THERMISTOR 1 / THERMISTOR 2 / OPERATION / COVER SWITCH SCHEMATIC DIAGRAMS

48 51 57 69

69 70 71

3 3 3 3

4 5 6

9.5. AUDIO AMP SCHEMATIC DIAGRAM

9.6. VOLTAGE CHART

10 CIRCUIT BOARD LAYOUT

10.1. FRONT JACK C.B.A. / OPERATION C.B.A. / NETWORK C.B.A.

10.2. AUDIO AMP C.B.A. / THERMISTOR 1 C.B.A. / THERMISTOR 2 C.B.A. / COVER SWITCH C.B.A.

11 EXPLODED VIEWS

11.1. MAIN PARTS SECTION

11.2. FRONT AND BASE SECTION

11.3. DISPLAY SECTION

11.4. SCREEN SECTION

11.5. PROJECTION SECTION

11.6. TV AND TUNER SECTION

11.7. PACKING PARTS AND ACCESSORIES SECTION

12 REPLACEMENT PARTS LIST

12.1. REPLACEMENT NOTES

12.2. MECHANICAL REPLACEMENT PARTS LIST

12.3. OPTIONAL ACCESSORY REPLACEMENT PARTS LIST

12.4. ELECTRICAL REPLACEMENT PARTS LIST

73 74

77 78 79 81 83 84 85

86 87

88 89

1 SAFETY PRECAUSIONS

1.1. GENERAL GUIDELINES

1. For continued safety, no modification of any circuit should be attempted.

2. Disconnect AC Plug before disassembling this unit.

3. It is advisable to use an isolation transformer in the AC supply before servicing.

4. When servicing, observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.

5. After servicing, see to it that all the protective devices such as insulation barriers, insulation papers, shield, and isolation R-C combinations etc. are properly installed.

6. After servicing, be sure to restore the wires, leads, insulation barriers, shields, etc.

7. After servicing, make the leakage current checks to prevent the customer from being exposed to shock hazards.

Caution:

Use a separate Isolation Transformer for this unit when servicing.

1.2. LEAKAGE CURRENT COLD

CHECK

1. Unplug the AC cord and connect a jumper between the two prongs on the plug.

2. For physically operated power switches, turn power on. Otherwise skip step 2.

3. Measure the resistance value, with an ohmmeter, between the jumpered AC plug and each exposed metallic cabinet part on the receiver, such as screwheads, connectors, etc. When the exposed metallic part has a return path to the chassis, the readingshouldbe between 1 MΩ and 12 MΩ. When the exposed metal does not have a return path to the chassis, the reading must be infinity.

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

not exceed 1/2 mA. In case a measurement is outside of the limits specified, there is a possibility of shock hazard, and thereceivershould be repaired and rechecked before it is returned to the customer.

Figure 1

1.4. UV-PRECAUTION

1. Be sure to disconnect the AC Plug when replacing the lamp.

2. Since the lamp reaches a very high temperature during its operation, wait until it has completely cooled off when replacing the Lamp Unit.

3. The lamp emits small amounts of UV-Radiation. Avoid direct-eye contact by covering the Lamp and wearing

the UV cut protective glass.

4. The high pressure lamp involves a risk of explosion.

1.3. LEAKAGE CURRENT HOT CHECK

1. Plug the AC cord directly into the AC outlet.

Do not use a isolation transformer for this check.

2. Connect a 1.5 kΩ, 10 W resistor, in parallel with a 0.15 µF

capacitor, between each exposed metallic part on the set and a good earth ground, as shown in Figure 1.

3. Use an AC voltmeter, with 1 kΩ/V or more sensitivity, to

measure the potential across the resistor.

4. Check each exposed metallic part, and measure the

voltage at each point.

5. Reverse the AC plug in the AC outlet and repeat each of the

above measurements.

6. The potential at any point should not exceed 0.75 V RMS.

A leakage current tester (Simpson Model 229 equivalent) may be used to make the hot checks. Leakage current must

Figure 2

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

2 PREVENTION OF

ELECTROSTATIC DISCHARGE (ESD) TO 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 transistorsandsemiconductor "chip" components. The following techniques should be used to help reduce the incidence of component damage caused by electro static discharge (ESD).

1. Immediately before handling any semiconductor component or semiconductor-equipped assembly, drain off any ESD on your body by touching a known earth ground. Alternatively, obtain and wear a commercially available discharging ESD wrist strap,whichshould be removed for 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 antistatic solder removal device. Some solder removal devices not classified as "antistatic (ESD protected)" can generate electrical charge 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 comparableconductivematerial).

7. Immediately before removing the protective material from the leads 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 (ESD)sufficientto damage an ES device).

3 ABOUT LEAD FREE SOLDER (PbF)

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

4 SERVICE NOTES

LED INDICATIONS FOR ERROR CONDITION

Each LED indication facilitates finding the cause of the error. When an error is detected, the Lamp comes off and the LED on the front will flash.

POWER LED

TV/VIDEO

TEMP LED

LAMP LED

(Note 2) (Note 3)

Error InformationError No. LAMP OFFLAMP LED OSD

Fan1, Fan2 or Fan3 stopped

Lamp Cover open

Temperature Sensor shorted or open

(Thermistor 1 C.B.A.) Abnormal Temperature

(Thermistor 1 C.B.A.) Ballast Error (abnormal Lamp or Ballast)

Ballast Error (abnormal Lamp voltage)

Ballast Error (abnormal temperature)

Ballast Error (other causes)

Abnormal Voltage on 33 V line

10)

Abnormal Voltage on 9 V line

Abnormal Voltage on 5 V line

11)

Abnormal Voltage on 3.3 V line

12)

Abnormal Voltage on -5 V line

13)

Abnormal Voltage on 6.5 V line

14)

Temperature Sensor shorted or open

15)

(Thermistor 2 C.B.A.)

16)

Abnormal Temperature (Thermistor 2 C.B.A.)

Clogged air filter

17)

DTV Tuner Power

18)

Error

flashes orange once every 5 seconds

flashes orange twice every 5 seconds

flashes orange 5 times every 5 seconds

flashes orange 6 times every 5 seconds

flashes orange 7 times every 5 seconds

flashes orange 8 times every 5 seconds

flashes orange 9 times every 5 seconds

flashes orange 10 times every 5 seconds

flashes green all the time

TEMP LEDPOWER LED

flashes once every 5 seconds

flashes twice every 5 seconds

flashes once every 5 seconds

flashes twice every 5 seconds

flashes 3 times every 5 seconds

flashes 4 times every 5 seconds

flashes 5 times every 5 seconds

flashes 6 times every 5 seconds

flashes 3 times every 5 seconds

flashes 4 times every 5 seconds

flashes 5 times every 5 seconds

flashes once every 5 seconds

flashes twice every 5 seconds

flashes 3 times every 5 seconds

flashes 4 times every 5 seconds

flashes once every 5 seconds

flashes twice every 5 seconds

flashes 3 times every 5 seconds

flashes 4 times every 5 seconds

flashes 5 times every 5 seconds

flashes 6 times every 5 seconds

Note:

1.When two or more errors have occurred at the same time, the LED will alternate flash patterns as shown above every 5 seconds.

2.Warning OSD appears when the air filter is clogged.

3.LAMP OFF: The LED will flash immediately after the Lamp comes off.

MAIN PARTS LOCATION

Network C.B.A.

Lamp Cover

Cover Switch C.B.A.

Optical Cover

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

TEMP LED

LAMP LED

Network C.B.A.

Front Cover Unit

Front Jack C.B.A.

Operation C.B.A.

Ballast C.B.A.

POWER LED

Projection Unit

Thermal Fuse Unit

Thermistor 1 C.B.A.

Air Filter Fan Case Unit (Fan 1)

Air Filter

Thermistor 2 C.B.A.

Fan 3

Fan 2

LCD Drive C.B.A.

Main C.B.A.

Tuner C.B.A.

Digital Tuner Power C.B.A.

Audio Amp C.B.A.

Power C.B.A.

TV/Tuner Unit

DTV Tuner Unit

Fan 5

Fan 4

Rear Cover

Rear Jack C.B.A.

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

SERVICE MODE

In this mode, the following information can be confirmed on the screen:

Service Mode (1/3)

• Total Lamp elapsed time

• Current Lamp elapsed time

• The number of Lamp ON (For reference only)

• BKSV number read-out

Service Mode (2/3)

• Key detection check

• Communication check for IIC bus on the Main C.B.A.

• Communication check for serial bus on the Main C.B.A.

• EEPROM IC6006 version and build version

• EEPROM IC6306 version and build version

• IC6003 software version and build version

• IC6302 software version and build version

Service Mode (3/3)

• IC6003 Port information

• IC6302 Port information

Note:

IC6003: Main Microcontroller on the Main C.B.A. IC6302: Sub Microcontroller on the Main C.B.A.

(For reference only)

(For reference only) (For reference only) (For reference only)

Service Mode Map

Enter :

VOLUME DOWN button + TV/VIDEO key

(on the front) (on the remote)

(for more than 5 seconds in power off condition)

Power ON

SERVICE Mode 1/3

LAMP OPERATION TIME TOTAL : 12345h CURRENT LAMP: 2000h OSD DISP : ON LON COUNT : 153 BKSV: B0 3A 59 CD 66

< Service Mode (1/3) >

CH DOWN key CH UP key

SERVICE Mode 2/3 IR:1 UNIT:1 IC3501:1 3601:1 3602:1 5005:1 5009:1 5504:1 5803:1 6005:1 6006:1 7101:1 7501:1 8000:1 IC5302:1 5306:1 9002:1 E:040716 F:6306639 IC6003 V:0030280 IC6302 V:0020050

< Service Mode (2/3) >

CH DOWN key

CH UP key

BKSV number

SERVICE Mode P6:11100110 3/3 IC6003 PORT P3:00000000 P0:11100110 P4:11100110 P1:00001110 P5:00001110 P2:11100110 P7:00001110 IC6302 PORT P8:11100110 P0:001-1111 P5:-----001 P1:-0-0-0-1 P6:11011001 P2:---00111 P7:11101111 P3:00000111 P8:----0101 P4:11110011 PA:----1111

< Service Mode (3/3) >

Exit:

CH DOWN key

Power OFF. (When turning the power on again after once turning off, wait for approx. 10 seconds. Or, the unit can not be released from Service Mode.)

Fig. 1-1

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

BEFORE REMOVING THE MAIN C.B.A. OR THE TV/TUNER UNIT FROM THE UNIT AT THE USER’S LOCATION

Note:

The TV/Tuner Unit includes the Main C.B.A.

CAUTION:

Be sure to make a note of the CURRENT LAMP value

(value A) in Service Mode (1/3):

SERVICE Mode 1/3

LAMP OPERATION TIME TOTAL : 12345h CURRENT LAMP: 2000h OSD DISP : ON LON COUNT : 153 BKSV: 4B 7E 3D CA FB

Fig. 2

LAMP OPERATION TIME is stored in EEPROM on the Main C.B.A. Therefore, before removing the Main C.B.A. or the TV/Tuner Unit at the user’s location, make a note of the CURRENT LAMP value (value A) in Service Mode (1/3). Then, after installing the new Main C.B.A. or the TV/Tuner Unit at the user’s location, set the CURRENT LAMP value to the original value (value A) in Service Mode. Otherwise, OSD and LED Lamp replacement indications will be displayed at the wrong time.

Note: In case it is impossible to make a note of the CURRENT LAMP value because of a defective Main C.B.A., ask the

customer their daily average use and the approximate age of the current Lamp. Then, calculate the CURRENT LAMP value as follows and make a note.

Daily average use

(hours) (days) (hours)

Approx. age CURRENT LAMP

Note:

The TOTAL value can be set to the original value in Service Mode (1/3) by similar method: Before removing the Main C.B.A. at the user’s location, make a note of the TOTAL value in Service Mode (2/3). Then, after installing the new Main C.B.A. at the user’s location, set the TOTAL value to the original value in Service Mode.

Value A

(Changeable)

WHEN REINSTALLING THE MAIN C.B.A. OR THE TV/TUNER UNIT INTO THE UNIT AT THE USER’S LOCATION

CAUTION:

1. Set CURRENT LAMP value to original value as follows.

1) Select CURRENT LAMP in Service Mode (1/3).

2) Press the VOLUME UP/DOWN key on the remote to change to the original value (value A) that was noted before removing the Main C.B.A. or the TV/Tuner Unit at the user’s location.

SERVICE Mode 1/3

LAMP OPERATION TIME TOTAL : 12345h CURRENT LAMP: 2000h OSD DISP : ON

Value A

(Changeable)

LON COUNT : 153 BKSV: 48 BF 9D 72 B5

Fig. 3

Service Mode Map

Enter :

VOLUME DOWN button + TV/VIDEO key

(on the front) (on the remote)

(for more than 5 seconds in power off condition)

Power ON

SERVICE Mode 1/3

LAMP OPERATION TIME TOTAL : 12345h CURRENT LAMP: 2000h OSD DISP : ON LON COUNT : 153 BKSV: B0 3A 59 CD 66

< Service Mode (1/3) >

CH DOWN key CH UP key

SERVICE Mode 2/3 IR:1 UNIT:1 IC3501:1 3601:1 3602:1 5005:1 5009:1 5504:1 5803:1 6005:1 6006:1 7101:1 7501:1 8000:1 IC5302:1 5306:1 9002:1 E:040716 F:6306639 IC6003 V:0030280 IC6302 V:0020050

CH DOWN key

< Service Mode (2/3) >

CH UP key

< Service Mode (3/3) >

BKSV number

Exit:

CH DOWN key

Power OFF. (When turning the power on again after once turning off, wait for approx. 10 seconds. Or, the unit can not be released from Service Mode.)

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

REPLACEMENT OF LAMP

Lamp Time Reset Procedure:

Be sure to reset the Lamp time to "0" after replacing the new Lamp.

1. Plug in the AC Cord, and turn on the power by pressing the POWER button.

2. Press and hold the VOLUME DOWN button on the unit and the PIP key on the remote together for over 5 seconds in power on condition. When the reset is finished, the display as shown in Fig. 51 appears and the LAMP LED goes out.

Fig. 5-1

Note:

1. The unit will detect when the Lamp’s end of life is

approaching and the following message will be displayed. And the LAMP indicator light will be lit when the Lamp’s end of life is approaching.

Lamp Replacement Procedure:

1. Press the POWER button on the remote to turn off the power.

2. Wait for about 1 minute until the cooling fan stops.

Note:

The lamp cooling fan will continue to operate for about 1 minute after the power is turned off. Do not unplug the AC Cord from the outlet until the fan has stopped. Avoid interrupting the power by using circuit breakers or switchable power strips.

3. After the cooling fan has stopped, unplug the AC Cord from the outlet.

Note:

Please wait more than one hour before replacing the lamp.

[ Forced cooling function ] If you need to replace the lamp more urgently:

• The Projection display has a forced cooling feature.

After the POWER button is turned OFF, and sometime during about the first minute of the normal cooling fan operation, press the VOLUME UP button on the unit and CH UP key on the remote at the same time for more than 5 seconds. The cooling fan will operate for about 10 minutes. (LAMP LED will flash 5 times every 5 second and POWER LED will flash red for 10 minutes.)

4. Remove the Front Cover Unit from the latches.

5. Remove the Lamp Cover by loosening the Screw.

Lamp Cover

Screw

Fig. 5-2

2. Influences of frequent lighting, continuous light use for over 24 hours, the number of times lit, the length of time between lightings, etc. may shorten lamp life. (Because of this, we recommend having a replacement lamp on hand.)

WARNING:

• The lamp could rupture if dropped and lamp fragments could cause injury.

• Because the lamp unit is hot immediately after its use, touching it may cause burns. Please allow the lamp to cool before handling or replacing the lamp unit.

• If replacement of the lamp unit becomes necessary during the operation of the Device Display, follow the procedure to turn off the power and wait until the lamp unit cools completely.

Cautions for Lamp Unit Replacement:

• Do not disassemble the Lamp.

• The lamp may be hot. Be careful when handling. Wear

gloves.

• Under no circumstance should you touch the actual bulb. At this high operating temperature the natural oil on your finger can cause the glass to weaken where touched and the bulb can crack or explode.

Fig. 5-3

6. Loosen the Screw on the Lamp. Then, pull the Lamp.

Note:

Because the Lamp may still be hot, use caution when handling.

Lamp

Screw

Fig. 5-4

7. Install the new Lamp, and tighten the Screw.

8. Install the Lamp Cover securely, and tighten the Screw.

9. Install the Front Cover Unit.

Note:

After replacing the Lamp, use caution to reset the Lamp time.

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

CLEANING METHOD

THE SCREEN UNIT AND THE MIRROR

•THE SCREEN UNIT (Lenticular Screen, Fresnel Lens)

It is strongly recommended that the Lenticular Screen surface (outside) and the Fresnel Lens surface (inside) should be wiped gently with a clean, soft, dry cloth to remove the dirt.

Note:

1. If the dirt cannot be removed by wiping with a clean, soft, dry cloth, use a clean, soft, dry cloth moistened with diluted neutral pH liquid cleanser or a lens cleaner (usually containing a small amount of ethyl alcohol) and wipe lightly. Take care not to leave any streaks. Do not use cleaning materials containing methyl alcohol, acetone, or dichloromethane.

2. Use an air blower to clean the inner surface of the Lenticular Screen and the outer surface of the Fresnel Lens (the surfaces that one another). These surfaces must not be wiped with a cloth.

•THE MIRROR

Remove any dirt with an air blower or wipe with a clean, soft, dry cloth. If wiped too forcefully, the surface of the Mirror can be damaged. If wiping with a clean, dry cloth does not remove the dirt, the Mirror must be replaced.

Mirror

THE FILTER ON THE PROJECTION UNIT CAUTION:

Operating with torn or damaged Air Filter may cause damage to the Projection unit. Remove the Projection Unit from rear. Then, clean the filters on the Projection Unit. Gently remove any accumulated dust from filter with a vacuum cleaner.

Air Filter

Screen Unit

Fresnel Lens surface (inside)

Lenticular Screen surface (outside)

Fig. 6-1

THE LAMP

Gently wipe the surface of the glass of the Lamp with cleaning paper or soft cloth.

Surface of glass

Fig. 6-3

THE PROJECTION LENS

Use lens cleaning paper and cleaner available at your local camera shop, etc. Dampen the cleaning paper with cleaner and gently wipe the surface of the lens from the center outward to remove dust.

Lens

Fig. 6-4

THE POLARIZER UNIT, THE FIELD LENS, THE RELAY LENS, THE CONDENSER LENS, THE DICHROIC MIRROR, THE FULL MIRRORS, THE INTEGRATOR AND THE P/S CONVERTER

Make sure that no dust gets on the optical components such as the Polarizer Unit, the Field Lens, the Relay Lens, the Condenser Lens, the Dichroic Mirror, the Full Mirrors, the Integrator and the P/S Converter. Clean these optical components with cleaning paper moistened with pure ethyl alcohol or a lens cleaner which contains no water or oil.

Fig. 6-2

THE LCD PANEL OF THE LCD/PRISM UNIT

1) Clean the surface of the LCD Panel of the LCD/Prism Unit with an air blower or wipe with a clean, or soft blush lightly.

2) If any dirt remains, lightly wipe the surface with a cotton swab moistened with pure ethyl alcohol or a lens cleaner which contains no water or oil. Use a new swab after each wiping so that dirt will not be re-deposited on the surface.

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

TO DISTINGUISH THE PROJECTION LENS UNIT OR THE PROJECTION UNIT

The only difference between the 43 inch model and the 50 inch model of the Projection Unit is the Projection Lens. To distinguish, see marking (Z or A) on the Projection Lens. And the 60 inch model of the Projection Unit is placed label on the Projection Lens.

43/50 inch model as shown

X X X A

Z with red: for 43 inch model A with black: for 50 inch model

Z or A

And also, see the stamp on the Lamp Wall of the Projection Unit. (The stamp has been added on a running change basis.)

Stamp

43"LSXA0571 50"LSXA0572 60"LSXA0573

: for 43 inch model

: for 50 inch model

: for 60 inch model

60 inch model as shown

LSDL0248

LSDL0248 with Yellowish green label: for 60 inch model

Note:

LSDL0248 is not the part numbers of the Projection Lens as a replacement part.

MODEL

PT-43LCX64 PT-50LCX64 PT-60LCX64 NOT USED

MARK

A B C

Note:

Refer to Item 3 of Schematic Diagram Notes of Schematic Diagram and Circuit Board Layout Notes, for mark "PT."

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

RESET USER’S MEMORY FUNCTIONS

Be sure to reset the user’s memory:

• After replacing the DTV Tuner Unit (included in the TV/

Tuner Unit)

• If the secret code of V-chip is forgotten.

• When moving the unit to a new location.

1. Turn on the power.

2. Press and hold the VOLUME DOWN button on the unit and the OK key on the remote for more than 5 seconds. When reset is finished, power shuts off automatically (the user’s memory is reset).

CLOGGED AIR FILTER DETECTION

When a dirty or clogged air filter is detected, the OSD display appears for 1 minute. And then the Lamp is turned OFF. When this OSD display appears, remove the Projection Unit from rear, and clean the air filters gently on the Projection Unit.

AIR FILTER CLEANING IS RECOMMANDED AT THIS TIME. FIRST TURN THE UNIT OFF. PLEASE CALL FOR SERVICE.

UNIT WILL BE TURNED OFF AFTER 1 MINUTE.

DO NOT UNPLUG AC CORD DURING COOLING OPERATION

The lamp cooling fan will continue to operate for approximately 1 minute after the power is turned off. At the same time, the POWER LED will flash red. Do not disconnect the AC Cord from the power outlet and do not open any circuit breakers while the cooling fan is still operating.

HOT CIRCUIT

Primary circuit exists on the Audio Amp C.B.A., the Ballast C.B.A. and the Power C.B.A. This circuit is identified as "HOT" on the C.B.A. and in the Service Manual. Use extreme care to prevent accidental shock when servicing.

MODEL NO. IDENTIFICATION MARK

Use Marks shown in the chart below to distinguish the different models included in this Service Manual.

BEFORE REMOVING THE PROJECTION UNIT FROM THE UNIT AT THE USER’S LOCATION

1. When removing the Projection Unit, remove the Lamp from the Projection Unit and keep it. Then, reinstall this Lamp into the new Projection Unit.

2. When removing the Projection Unit, remove the Fan 3 Unit, the Top Duct 3 Unit and the 20-pin Cable from the Projection Unit and keep them. Then, reinstall the Fan 3 Unit, the Top Duct 3 Unit and the 20-pin Cable into the new Projection Unit.

Projection Unit

Screw for lamp

Lamp

P2904

Clamper

402

Top Duct 3 Unit

421

Fan 3 Unit

GND Wire

402

421

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

WIRE AND LEAD POSITION DIAGRAM OF THE UNIT

After servicing, make sure that all wires, leads, and clampers are placed in their original position. It is important for the best operation of the unit. Note: Use extreme care especially for the following.

Fan 5

Antenna A, B terminal

AC Cord

Clamper

Fan 4

Fig. 9-1

Clamper

Thermal Fuse Unit

Fan 3

GND Wire

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

P2303 (From Thermistor 1 C.B.A.)

P2902 (From Fan 1)

Thermistor 2 C.B.A.

P2501 (From Main C.B.A.)

P2901 (From Main C.B.A.)

P2904 (From Fan 3)

Lamp Cable

Lamp Sockets

P2502 (From Cover Switch C.B.A.)

Clamper

P1306 (From Thermal Fuse Unit)

Fig. 9-2

P2903 (From Fan 2)

Ballast C.B.A.

P2304 (From Thermistor 2 C.B.A.)

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

Speaker Connector Leads

No connection

P6305 (From Operation C.B.A.)

P5501 (From Front Jack C.B.A.)

P7002 (From Digital Tuner Power C.B.A.)

P7008 (From Fan 5)

No connection

Clampers

Clamper

P4503 (Speaker)

P6002 (From Ballast C.B.A.)

P4501 (From Power C.B.A.)

Clamper

P6003 (From Tuner C.B.A.)

P5601 (From Tuner C.B.A.)

P3604 (From Tuner C.B.A.)

P3503 (From Tuner C.B.A.)

P3502 (From Front Jack C.B.A.)

No connection

P3603 (From Audio Amp C.B.A.)

P3401 (From Power C.B.A.)

Clampers

Fig. 9-3

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

P1001 (To Ballast C.B.A.)

P805 (To Ballast C.B.A.)

P807/P808 (To Digital Tuner Power C.B.A.)

P4501 (To Audio Amp C.B.A.)

P1006 (To Fan 4)

P1009 P1010 P1011

P1008

Fig. 9-4

P1007

AC Cord

Clampers

P804

P3401 (To Main

C.B.A.) P2901 (To LCD Drive C.B.A.)

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

5 DISASSEMBLY / ASSEMBLY PROCEDURES

5.1. CABINET SECTION

CABINET SECTION

DISASSEMBLY METHOD OF CABINET SECTION

Cabinet section contains following removal procedures:

REMOVAL OF THE BALLAST C.B.A. AND THE TV/TUNER UNIT FROM THE CABINET REMOVAL OF THE PROJECTION UNIT FROM THE CABINET REMOVAL OF THE TUNER C.B.A., THE DTV TUNER UNIT, THE MAIN C.B.A., THE DIGITAL TUNER POWER C.B.A., THE REAR JACK

C.B.A., THE AUDIO AMP C.B.A., THE POWER C.B.A. FROM THE TV/TUNER UNIT REMOVAL OF THE SCREEN UNIT AND THE SPEAKER FROM THE DISPLAY REMOVAL OF THE MIRROR FROM THE BACK COVER REMOVAL OF THE FRONT JACK C.B.A. AND THE OPERATION C.B.A. FROM THE CABINET REMOVAL OF THE COVER SWITCH C.B.A. FROM THE CABINET

DISASSEMBLY FLOWCHART

This flow chart indicates the disassembly steps of the cabinet parts and the P.C.Boards in order to gain access to item (s) to be serviced. When reassembling, perform the step (s) in the reverse order. Bend, route and dress the wires as they were originally.

OPERATION C.B.A.

FRONT JACK C.B.A.

TV/TUNER UNIT

Digital Tuner Power C.B.A.

AUDIO AMP

C.B.A.

REAR COVER

BALLAST C.B.A.

TUNER C.B.A.

DTV Tuner Unit

MAIN C.B.A.

REAR JACK C.B.A.

POWER C.B.A.

PROJECTION UNIT

THERMISTOR 2 C.B.A.

THERMAL FUSE UNIT TOP DUCT 3 UNIT

THERMISTOR 1 C.B.A.

(LCD/PRISM UNIT, LIGHT IN POLARIZER, ETC)

FAN 3 UNIT

FRONT COVER UNIT

OPTICAL COVERLAMP COVER NETWORK C.B.A.

SCREEN UNIT

MIRROR

BACK PANEL

(DISPLAY)

SPEAKER

COVER SWITCH C.B.A.

Note :

a. Place a cloth or some other soft material under the P.C. Boards or Unit to prevent damage. b. When reinstalling, ensure that the connectors are connected firmly and electrical components have not been damaged. c. Do not supply power to the unit during disassembly and reassembly.

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

REMOVAL OF THE BALLAST C.B.A. AND THE TV/TUNER UNIT FROM THE CABINET

1. (PT-43LCX64/PT-50LCX64) Remove the Rear Cover by removing the 18 Screws (401).

Rear Cover

1. (PT-60LCX64) Remove the Rear Cover by removing the 20 Screws (401, 464).

Rear Cover

401

Fig. D1-1-1

Fig. D1-1-2

401

464

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

2. Remove the Rear Support Plate by removing the 4 Screws (401, 452).

Rear Support Plate

401

Fig. D1-2

401

452

3. 1) Remove the 5 Screws (402) and remove Clamper-1.

2) Remove the 2 Screws (451) on the Lamp Socket.

3) Disconnect the Lamp Connector.

4) Avoiding the Ballast C.B.A., disconnect Connector P1306 (Thermal Fuse Unit) inside of the Ballast C.B.A.

5) Remove the Clamper from the Ballast C.B.A.

Clamper-1

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

402

451

Clamper

Lamp Socket

Lamp Connector

Note: Do not remove the Thermal Fuse Unit.

Ballast C.B.A.

Clamper-1

451

P1306

Fig. D1-3

Replacement Note of Ballast C.B.A.:

These parts will be necessary when replacing the Ballast C.B.A. Set aside, and keep and re-use.

• The Clamper on Ballast C.B.A.

• The Thermal Fuse Unit

402

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

4. 1) Disconnect Connector P2901and release them from the clamper.

2) Disconnect Connector P2501 (20-pin Cable) and release it from the clamper. CAUTION: Take extreme care not to damage the 20-pin Cable when disconnecting.

5. 1) Disconnect Connectors P3502, P5501, P4503, P6305 and release them from the clampers.

2) Remove the Screw (452) on the GND Plate A.

3) Remove the Screw (401) on the TV/Tuner Ass’y.

4) Lift up and slide the TV/Tuner Ass’y by releasing the 7 Guide Tabs. CAUTION: Do not slide the TV/Tuner Unit before removing the 20-pin Cable.

P6305

Clamper

P4503

Slot

GND Plate A

452

CAUTION:

20-pin Cable

P5501

P3502

Clampers

401

Fig. D1-4

P2501

P2901

452

TV/Tuner Ass’y

holes

Fig. D1-5

Replacement Note of TV/Tuner Unit:

These parts will be necessary when replacing the TV/Tuner Unit. Set aside, and keep and re-use.

• 20-pin Cable

TV/Tuner Ass'y

Guide Tabs (X5)

Guide Tabs (X2)

Rear

6. 1) Pull off the TV/Tuner Ass’y with the Ballast C.B.A. while taking care with the cables.

2) Remove the GND Plate A from the TV/Tuner Unit by removing the Screw (452).

3) Remove the SD Door Unit from the TV/Tuner Unit by releasing the 2 Locking Tabs.

holes

Locking Tabs

Slide

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

Ballast C.B.A.

SD Door Unit

GND Plate A

452

TV/Tuner Unit

Fig. D1-7-1

Reassembly Note: When installing the SD Door Unit, install the SD Door Unit with the 2 Locking Tabs from the front of the cabinet

after installing the TV/Tuner Unit into the cabinet.

Reassembly Note:

Locking Tabs

SD Door Unit

Fig. D1-7-2

Replacement Note of TV/Tuner Unit:

These parts will be necessary when replacing the TV/Tuner Unit. Set aside, and keep and re-use.

• The GND Plate A

• The SD Door Unit

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

7. 1) Disconnect Connectors P6002, P805, P1001 and release them from the clampers.

2) Then, remove the Ballast C.B.A.

P6002

Clamper

P1001

Ballast C.B.A.

Clamper

P805

Fig. D1-8

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

REMOVAL OF THE PROJECTION UNIT FROM THE CABINET

1. Remove the Ballast C.B.A. and the TV/Tuner Unit. Refer to Steps 1~6 in "REMOVAL OF THE BALLAST C.B.A. AND THE TV/ TUNER UNIT FROM THE CABINET."

2. 1) Disconnect Connector P2502. Then, hook the P2502 cable to the pin.

2) Remove the 7 Screws (401) on the Projection Unit.

3) Lift up and slide the Projection Unit by releasing the 5 Guide Tabs.

Tips on removal of the Projection Unit:

First, slide the Projection Unit to the rear (approx. 1.5 inch (4 cm)). Then, lift up the front and the rear portions of the Projection Unit by both hand to release the Guide Tabs. Then, slide out the Projection Unit. Or, remove the Fan 3 Unit from the Projection Unit at first. Refer to Fig. D2-3.

CAUTION: Disconnect Connector P2502 and hook it as follows.

P2502

Cable

Cover Switch C.B.A.

P2502

Boss

401

Fig. D2-1

Tips on removal of the Projection Unit

Slide

Up Up

Lift up and slide the Projection Unit by approx. 1.5 inch (4 cm).

Lift up the front portion.

Lift up the rear portion.

Slide out the Projection Unit.

Guide Tabs (X5)

Rear

Projection Unit

holes

Slide

Cover Switch C.B.A.

P2502 Cable

CAUTION: Disconnect Connector P2502 and hook it as follows.

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

Reassembly Note:

Before installing the Projection Unit, confirm that the P2502 cable is hooked to the pin. Then, install the Projection Unit to the cabinet.

Fig. D2-2

PT-43LCX64 / PT-50LCX64 / PT-60LCX64

3. 1) Disconnect Connector P2904, and remove the Fan 3 Unit by removing the 2 Screw (402).

2) Remove the Top Duct 3 Unit by removing the 4 Screws (421).

CAUTION:

When removing the Screws (421) on the Top Duct 3 Unit, plastic dust may be produced. Therefore, confirm that there is no dust on the Top Duct 3 Unit. If there is dust, clean the Top Duct 3 Unit with a brush, etc. Otherwise, dust may adhere to the inside of the screen.

3) Remove the Lamp from the Projection Unit by loosening the Screw.

Projection Unit

Screw for lamp

Lamp

P2904

Clamper

Fan 3 Unit

402

421

GND Wire

402

Top Duct 3 Unit

421

Fig. D2-3

Replacement Note of Projection Unit (Ref. No. 21):

These parts will be necessary when replacing the Projection Unit (Ref.No. 21). Set aside, and keep and re-use.

• Fan 3 Unit

• Top Duct 3 Unit

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