Panasonic pt51hx41e, pt51hx41ce, pt56hx41e, pt56hx41ce, pt61hx41e Diagram

...

ORDER NO. MTNC010417C1 B2

Service Manual

HDTV MONITOR

Main Manual

(P5P)

Panasonic

Models

Chassis

PT-51HX41E AP820 PT-51HX41CE AP820 PT-56HX41E AP820 PT-56HX41CE AP820 PT-61HX41E AP820 PT-61HX41CE AP820

This Service manual is issued as a service guide for the models of the P5P family listed above. Included in this manual are a set of schematics, alignment procedures, disassembly procedures and a complete parts list.

“WARNING! This Service Manu al is des igned for ex perienced re pair techni cians only and is n ot designed for use by the general public. It does not contain warnings or cautions to advise non-technical individuals of potential dangers in attempting to service a product. Products powered by electricity should be se rviced or repaired only by experienced profess ional technicians. Any attem pt to service or repair the product or products dealt with in this Service Manual by anyone else could result in serious injury or death.”

The service technician is required to read and follow the “Safety Precautions” and “Important Safety Notice” in the Ma in Ma nual.

and distribution is a violation of law.

Important Safety Notice

Special components a re used in this projection tel evision which are important for safety. These components are identified on the schematic diagram by the symbol and printed in BOLD TYPE on the replacement part list. It is

essential that these c ritical parts are replaced with the manu facturer ’s spe cified replac ement par t to prevent x -ray radiation, shock, fire or other hazards. Do not modify the original design without the manufacturer’s permission.

Safety Precautions

General Guidelines

isolation transformer

during the servicing of a PTV whose chassis is not isolated from AC power line. Use a transformer of adequate power rating a s this protects the techn ician from accidents resulting in personal injury from electrical shocks. It will also p rotect the PTV from being damaged by accidental shorting that may occur during servicing. When servicing, observe the original lead dress, especially in the high voltage circuit. Replace all damaged parts (also parts that show signs of overheating.) Always replace protective devices, such as fishpaper, isolation resistors and capacitors, and shields after servicing the PTV. Use only manufacturer ’s recommended rating for fuses, circu its breakers, etc. High potentials, as high as 32.5kV, are present when this PTV is operating. Ope rat io n of the PTV without the rear cover introduces danger for electrical shock. Servicing should not be performed by anyone who is not thoroughly familiar wit h the necessary precautions when servicing high-voltage equipment.

Extreme care should be practic ed when handling the

picture tube

due to atmospheric pressure. (14.7 lbs. per sq. in.). Do not nick or scratch the glass or subject it to any undu e pressure. When handling, use safety goggles and heavy gloves for protection. Discharge the picture tube by shorting the anode to chassis ground (not to the cabinet or to other mounting hardware). When discharging connect cold ground (i.e. DAG ground lead) to the anode wi th a well insulated wir e or use a grounding probe.

. Rough handling may caus e it to implod e

should always be used

X-ray Precautions

The front area (between the projection tube and the lens) is enclosed by a metal box to ensure positive safety during normal and abnormal conditions when checking and repairing. To fully ensure safety, the following precautions must be observed.

1. Do not remove the lens or metal box.

2. Make sure to turn the power OFF when the le ns is removed or when checkin g the cleanliness of the lens.

3. Do not remove the lens or metal box to check the projection tube for operation by w atching it directly. Use a mirror or paper to view the image.

Before returning a se rviced PTV to the owner, the service technician must thoroughly test the unit to ensure that is completely safe to operate. Do not use a

line isolation transformer when testing.

Leakage Current Cold Check

Unplug the AC cord and connect a jumper between the two plug prongs. Press the POW ER swit ch ON. Measure the resistance between the jumpered AC plug and expose metallic parts such as screw heads,

Service Manual

antenna terminals, control shafts, etc. If the exposed metallic part has a return path to the chassis, the reading should be between 240kΩ and 5.2MΩ. If the exposed metall ic part does not have a re turn path to the chassis, the re adi ng sh oul d be infinite.

Leakage Current Hot Check (See Figure 1)

Plug the AC cord directly into the AC outlet. Do not use an isolation transformer during the check. Connect a 1.5kΩ 10 watt resistor in parallel with a

0.15µF capacitor between and exposed metallic part and ground. Use earth ground, for example a water pipe. Using a DVM with a 1000 ohms/volt sensitivity or higher, measure the AC potential across the resistor. Repeat the procedure and measure the voltage present with all other expose metallic parts. Verify any potential does not exceed 0.75 vo lt RMS. A leakage current tester (such a Simpson Model 229, Sencore Model PR57 or equivalent) may be used in the above procedure, in which case any current measure must not exceed 0.5 milliamp. If any measurement is out of the specified limits, there is a possibility of a shock hazard and the PTV must be repaired and rechecked before it is returned to the customer.

AC VOLTMETER

COLD WATER PIPE (GROUND)

0.15µF

TO INSTRUMENT’S EXPOSED METAL PARTS

Figure 1. Hot Check Circuit

1500Ω,10W

Insulation Test

Connect an insulation tester between an exposed metallic part and AC line. Apply 1080VAC/60Hz for 1 second. Confirm that the current measurement is 0.5mA ~ 2.0mA. Repeat test with other metallic exposed parts.

X-ray Radiation

WARNING: The potential source of X-ray radiation in the

PTV is in the high voltage section and the picture tube.

Note: It is important to use an accurate, calibrated

high voltage meter.

Set brightness, picture, sharpness and color controls to Minimum. Measure the High Voltage. The high should be

31.5kV ± 1.0kV. If the upper limit is out of tolerance, immediate servic e and correction is requ ired to insure safe operation and to prevent the possibility of premature component failure .

- 2 -

Important Safety Tests

Measuring H.V.

The anode caps are cemented to the CRTs. To gain access for high vo ltage measurem ent, remove the re d CRT’s anode lead from the flyback transformer distributor. Grasp the anode lead protective cap at its bottom and squeeze it against the locking cap body inside, Rotate 1/4 turn count er clockwise and pull the anode lead sleeve out of the FBT distributor. Connect a high voltage lead (+) from your H.V. meter to the FBT

distributor, and the common (-) to cold ground ( ). (See Figure 2).

Grasp protective

Anode lead

rubber cap

Push & rotate

Discharge to CRT Chassis

cap counterclockwise to remove

FBT Distributor

Figure 2. Removal of FBT leads

Note: Reinsert the anode lead into the FBT

distributor until it is tightly and fully seated. T urn the locking cap clockwise to lock in place.

(EHT) Protector Operation Check

With the cabinet ba ck removed, apply a n ominal 120V AC to the PTV.

Over Voltage Test Preparation:

1. Turn PTV “OFF”

2. Connect an NTSC signal generator to the antenna terminal.

3. Connect DVM (+) TPD50 and (-) TPD51 on D Board. (See Figure 4)

4. Connect a H.V. meter (static type, class 0.1 ) with high voltage leads to high voltage distributor on FBT. (See Figure 4)

TPD51 TPD50

D-Board

DVM

D-Board

IC802 PIN 2

OR TPD8

Variable Power Supply

MA150

100Ω 1/2 W

(+)

(15~25DC)

(-)

HEAT SINK OF Q551

Figure 4. DVM & Power supply connection.

5. Connect the 15 ~ 25 V DC variable power supply to (+) TPD8 or IC802 pin 2 (D-Board) and (-) heat sink of Q551 (See Figure 4).

Procedures:

1. Apply a monoscope pattern.

2. Turn PTV ON.

3. Adjust the Picture or Brightness controls so that the DVM reads 16.5 volts ± 0.5 volts.

4. Increase the variabl e power supply until set turns off. The set should turn off at 16.5 volts ± 0.5 volts (DVM) and high voltage le ss th an 3 6.4k V.

5. If the DVM reading is other than 16.5 volts (± 0.5 volts), readjust picture or brightness control and repeat steps 3.

6. Turn off the variable supply and confirm that the set will turn on with the Remote Control.

H.V. METER

Cold Ground

FBT Distributor

CRT

CHASSIS

Figure 3. Measuring H.V.

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Service Manual

Important Safety Notice. . . . . . . . . . . . . . . . . . . 2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . 2

General Guidelines . . . . . . . . . . . . . . . . . 2

X-ray Precautions . . . . . . . . . . . . . . . . . . 2

Leakage Current Cold Check . . . . . . . . . 2

Leakage Current Hot Check . . . . . . . . . . 2

Insulation Test . . . . . . . . . . . . . . . . . . . . . 2

X-ray Radiation . . . . . . . . . . . . . . . . . . . . 2

Important Safety Tests. . . . . . . . . . . . . . . . . . . . 3

Measuring H.V. . . . . . . . . . . . . . . . . . . . . 3

(EHT) Protector Operation Check . . . . . . 3

Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Leadless Chip Component

(surface mount). . . . . . . . . . . . . . . . . 5

Component Removal. . . . . . . . . . . . . . . . 5

Chip Component Installation . . . . . . . . . . 5

How to Replace Flat-IC . . . . . . . . . . . . . . 5

Feature Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Boards Designation . . . . . . . . . . . . . . . . . . . . . . 7

PTV - Location of Controls . . . . . . . . . . . . . . . . 8

Quick Reference Control Operation . . . . 8

Remote - Location of Controls . . . . . . . . . . . . . 9

Serviceman Mode (Electronic Controls) . . . . 25

Quick Entry to Serviceman Mode:. . . . . 25

To toggle between Aging

and Serviceman modes . . . . . . . . . 25

Exiting the Serviceman Mode:. . . . . . . . 25

To Check Purity: . . . . . . . . . . . . . . . . . . 25

Instructional Flow Cha rt

for Serviceman Mode . . . . . . . . . . . 28

HV_Feedback Voltage. . . . . . . . . . . . . . 30

Bright Adjustment (BRIGHT) . . . . . . . . . 30

Sub-Contrast (CONT), Sub-Bright

(FINAL) Adjustment. . . . . . . . . . . . . 30

Tint Adjustment (TINT) . . . . . . . . . . . . . 30

Red, Green & Blue Screen Cutoff . . . . . 31

White Balance Adjustment . . . . . . . . . . 31

Tint and Color Check. . . . . . . . . . . . . . . 31

MTS Circuit Adjustments. . . . . . . . . . . . 31

Input Level Adjustment (MTSIN) . . . . . . 31

Stereo Separation Adjustment

(SEP AL & SEPAH) . . . . . . . . . . . . . 31

Clock Adjustment (CLOCK). . . . . . . . . . 32

Audio Signal Path Block Diagram. . . . . . . . . . 33

Video-Chroma Signal Path Block Diagram . . 34

IIC Connection . . . . . . . . . . . . . . . . . . . . . . . . . 35

Description of Connectors . . . . . . . . . . . . . . . 36

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chassis & Boards Layout . . . . . . . . . . . . . . . . 10

Board Description . . . . . . . . . . . . . . . . . 10

Disassembly for Service . . . . . . . . . . . . . . . . . 11

Speaker Grill Removal. . . . . . . . . . . . . . 11

Keyboard Removal . . . . . . . . . . . . . . . . 11

Speakers Replacement . . . . . . . . . . . . . 11

Cabinet Back Lower Removal. . . . . . . . 11

Cabinet Back Cover Removal . . . . . . . . 11

Cabinet Front Removal . . . . . . . . . . . . . 12

Screen Assembly. . . . . . . . . . . . . . . . . . 12

Main Chassis Block. . . . . . . . . . . . . . . . 12

Disassembly for CRT Replacement . . . 13

X-RAYS SHIELD . . . . . . . . . . . . . . . . . . 13

CRT Replacement . . . . . . . . . . . . . . . . 13

Optical Block Position Adjustment. . . . . 14

PTV Screen Assemblies . . . . . . . . . . . . 15

B+ Voltages Table . . . . . . . . . . . . . . . . . 15

CRT Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dynamic Focus Adjustments. . . . . . . . . 16

Electrical Adjustment. . . . . . . . . . . . . . . 16

Focus - Optical Lens Adjustment. . . . . . 17

Optical Adjustments. . . . . . . . . . . . . . . . 17

Electric & VM Focus Adjustment,

Complete adjustment . . . . . . . . . . .17

Vertical Size Adjustment (VSIZE) . . . . . 18

Horizontal Phase Adjustment (H-POS) . 18

Trapezoid Adjustment (EWTRA) . . . . . . 18

Pincushion Adjustment (PC C). . . . . . . .19

Centering Magnets Adjustment . . . . . . . 19

Horizontal Size Adjustment (H WID) . . . 19

Convergence Adjustment . . . . . . . . . . .19

Coarse Adjustment Mode (COARSE) . . 20

Fine Adjustment Mode (FINE). . . . . . . .22

Horizontal and Vertical Size Check . . . . 24

Convergence Alignment Template. . . . . 24

D-Board layout . . . . . . . . . . . . . . . . . . . . . . . . . . 49

D-Board schematic (left portion). . . . . . . . . . . . . 50

D-Board schematic (right portion). . . . . . . . . . . . 51

A-Board schematic (left portion) . . . . . . . . . . . . . 52

A-Board schematic (left middle) . . . . . . . . . . . . . 53

A-Board schematic (right middle) . . . . . . . . . . . . 54

A-Board schematic (right portion). . . . . . . . . . . . 55

DH-Board schematic . . . . . . . . . . . . . . . . . . . . . 56

K, G & R-Board schematics & layouts . . . . . . . . 57

LR-Board schematic, layout & voltages . . . . . . . 58

LB-Board schematic, layout & voltages . . . . . . . 59

LG-Board schematic, layout & voltages . . . . . . . 60

A & D-Board voltages. . . . . . . . . . . . . . . . . . . . .61

Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Service Manual

- 4 -

Service Notes

Note: These components are affixed with glue. Be careful not to break or damage any foil under the

component or at the pins of the ICs when removing. Usually applying heat to the component for a short time while twisting with tweezers will break the component loose.

Leadless Chip Component (surface mount)

Chip components must be replaced with identical chips due to critical foil track sp acing. There are no holes in the board to mount standard transistors or diodes. Some chip capacitor or resistor board solder pads may have holes through the board, however the hole diameter limits standard resistor replacement to 1/8 watt. Standard capacitor may also be limited for the same reason. It is recommended that identical components be used. Chip resistor have a three digit numerical resistance code - 1st and 2nd significant digits and a multiplier. Example: 162 = 1600 or 1.6kΩ resistor, 0 = 0 Ω (jumper). Chip capacitors generally do not have the value indicated on the capacitor. The color on the component indicates the general range of the capa ci tan ce . Chip transistors are identified by a two letter code . The first letter indica ted the type an d the second letter, the grade of transistor. Chip diodes have a two lette r i den tif ic ati on code as per the code chart and are a dual diode pack with either common anode or comm on cathode. Check the parts list for correct di ode num ber.

Component Removal

1. Use solder wick to remove s older fr om compo nent

end caps or termin al.

2. Without pulling up, carefully twist the component

with tweezers to break the adhesive.

3. Do not reuse removed leadless or chip

components since they are subject to stress

fracture during removal.

Chip Component Installation

1. Put a small amount of solder on the board

soldering pads.

2. Hold the chip component against the soldering

pads with tweezers or with a miniature alligator clip

and apply heat to the pad area with a 30 watts iron

until solder flows. Do not appl y heat for more than

3 seconds.

TYPE

Chip Components

GRADE

SOLDER CAPS

How to Replace Flat-IC

- Required Tools -

• Soldering iron • De-solder braids

• Sharp pliers (wire cutters and long nose)

1. Cut the pins of the defective IC with the wire cutter pliers, and remove it completely away from the board. If the IC is g lued to the b oard, apply h ot air to complete the remova l. CAUTION- Do not pull or twist the pliers, i t may damage the soldering pads in the board.

Flat-IC

2. Using the Soldering Iron and the lo ng nose pliers, remove the IC pins that are still attached to the board.

3. Using the De-solde r braid and the Soldering Iron , remove the solder from the board soldering pads.

4. Position the new Flat-IC in pl ace (apply the pins of the Flat-IC to the soldering pads where the pins need to be soldered). Properly determine the positions of the soldering pads and pins by correctly aligning the polarity symbol. St ar t alig ning and soldering Pin No .1, then align and solder th e pin in the apposite corner of the IC, this will help to align the rest of the pins.

Polarity Symbol

• Magnifier

Soldering Iron

De-Solder Braid

Soldering Iron

ANODES

MH DIODE

TRANSISTOR

COMMON CATHODE

SOLDER CAPS

CAPACITOR

1ST DIGIT

RESISTOR

2ND DIGIT

MULTIPLIER =1600 = 1.6k

5. Solder all pins to the soldering pads using a fine tipped soldering iro n.

Solder

Soldering Iron

6. Check with a magnifier fo r solder bridge between the pins or for dry joint between pins and soldering pads. To remove a solder brid ge, use a de-solder braid as shown in the figure below.

De-Solder Braid

- 5 -

Solder Bridge

Service Manual

Soldering Iron

Service Notes (Continued)

IMPORTANT: To protect against possible damage to

the solid state devices due to arcing or static discharge, make cer tain that all ground wi res an d CRT DAG wire are secu re ly conne cted.

CAUTION: The power supply circuit is above earth ground and the chassis cannot be polarized. Use an isolation transformer when s ervicing the PTV to avoid damage to the test equipment or to the chassis. Connect the test equipment to the proper ground (( )

or ( )) when servicing, or incorrect voltages will be measured.

WARNING: This PTV has been designed to meet or exceed applicable safety and X-ray radiation protection

Feature Table

as specified by gover nment a gencies and ind ependen t testing laboratories.

To maintain original product safety design standards relative to X-ray radiation and shock and f ire hazard,

parts indicated with th e symbol on the schematic must be replaced with identical parts. Order parts from

the manufacturer’s parts center using the parts numbers listed in this service manual, or provide the chassis number and the part reference number.

For optimum performance and readability, all other parts should be replaced with components of identical specification.

PT-51HX41E/CE

FEATURE

PT-56HX41E/CE PT-61HX41E/CE

Chassis P5P Tunning system 256K # of channels 181 Menu language Eng/Span/Fr Closed Caption (CC) X V-Chip (USA/CANADA) X Picture In Picture (PIP) 2T split VIDEO INPUT MEMORY/SKIP SKIP 2RF X Remote control # EUR7603Z20 Screen protector X Comb filter 3D Y/C COLOR TEMP X NEW YNR X VM X V/A norm Both DIGITAL SCAN RATE 1080i, 480p NTSC LINE-DOUBLER 480i MTS/SAP/DBX X Bass/Bl/Treb control X AI sound X SURROUND X Spatializer/BBE BBE Built-in audio power 15W/CH (10%) # of speakers 2 A/V in (rear/front) 4 (3/1) S-VHS in (rear/front) 2/1 Audio out Fixed & Variable

PT-51HX41E/CE

FEATURE

PT-56HX41E/CE PT-61HX41E/CE

COMPONENT INPUT (Y, Pb, Pr) 2 DOLBY CENTER CHANNEL IN X 51” Dimensions mm

WxDxH in 51” Weight (kg/lbs) 90/198.4 56” Dimensions mm

WxDxH in 56” Weight (kg/lbs) 111.5/245.8 61” Dimensions mm

WxDxH in 61” Weight (kg/lbs) 117.5/259.0 Power source (V/Hz) 120V 60Hz Anode voltage 31.5kV ± 1.0kV

Video input jack Audio input jack 500mV RMS 47kΩ

1137x653x1361.0

44.8x25.7x53.6

1197x685x1418

47.1x27.0x55.8

1316x708x1516

51.8x27.9x59.7

1Vp-p 75Ω, phono

jack

Table 1: Feature Table (Continued)

Specifications are subj ec t to c hange without notice or obl ig ati on. Dimensions and weights are approximate.

Service Manual

Table 1: Feature Table

- 6 -

Boards Designation

BOARD PART NUMBER BOARD DESCRIPTION

G-BOARD TNP2AA088 FRONT A/V INPUTS K-BOARD TNP2AA087 KEYBOARD R-BOARD TNPA0615AB IR S ENSOR LR-BOARD TNPA1810 RED DRIVER LG-BOARD TNPA1811 GREEN DRIVER LB-BOARD TNPA1812 BLUE DRIVER

MAIN CHASSIS , VIDEO PROCESSI NG,

A-BOARD TNPH0370

CONVERGENCE, AUDIO PROCESSING

DH-BOARD TNPA2033

D-BOARD TNPH0371

Table 2: Boards Designation

Note: The A-Board (

Non-Serviceable. Except for A-Board both Tuners, IC2302,

IC7001, IC7002 and IC870. If any of these components or boards is defective r eplea ce it with a n ew on e and take bac k the defective board to the service center.

Notice: When ordering any Board, add and ” S” after the Board

TNPH0370S

suffix applic ati on.

PIP PROCESSING, SPLIT, SEARCH, FORMATS

POWER SUPPLY, VERTICAL OUT, HORIZONTAL OUT

) and DH-Board (

TNPA2033S)

are

Example: If Order A-Board, should be ordered as:

- 7 -

TNPH0370

Service Manual

PTV - Location of Controls

POWER VOLUME CHANNEL ACTION TV/VIDEO

1 2 4 53

Figure 5. Location of Controls PTV

Quick Reference Control Operation

Power - Press to turn ON or OFF.

Volume - Press to adjust Sound Level, or to adjust Audio Men us, Video Menus, and

select operating features when menus are displayed Channel - Press to s elect programm ed channels. Pr ess to highlight desired features

when menus are displayed. Also use to select Cable Converter box channels after programming Remote Control Infra-red codes (the TV/AUX/CABLE switch must be set in CABLE position).

Service Manual

Action - Press to displ ay Main Menu and access On Screen f eature and Ad justment

Menus. TV/Video - Press to select TV or one of the Video Inputs, for the Main Picture or the

PIP frame (when PIP frame is displayed).

- 8 -

Remote - Location of Controls

POWER Button Press to turn ON and OFF. MUTE Button Press to mute sound.

A second press resumes sound. Press also to access and delete Closed Caption display.

TV, VCR, DVD, CBS/CBL Component function buttons VOL (volume) Buttons Press to adjust TV sound level.

Use with Channel buttons to navigate in menus.

R-TUNE (Rapid Tune) Button. Press to switch to the previous

channel. ACTION Button Press to display Main Men u and access or

exit On Screen features and Adjustment Menus.

REW, PLAY, FF, TV/VCR, STOP, PAUSE, REC & VCR CHANNEL Buttons

Component function buttons. DBS EXIT& DBS GUIDE Buttons DBS function buttons. LIGHT Button Press to light remote control buttons. SAP Access second audio program ASPECT Select picture size (ratio) to match

programming format MOVE, PIP, SPLIT/SIZE, FREEZE, SWAP ,

SEARCH, PIP CHANNEL PIP function buttons

Figure 6. Location of Controls (EUR7603Z20 Remote)

For additional information for this rem ote please refer to the Remote Guide, listed on the parts li st.

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Service Manual

Chassis & Bo ar ds Layout

Front Corner View

Back View

Figure 7. Chassis & Boards Layout.

Board Description

A Main Chassis , Video Processing, Co nvergence,

Audio Processing D Power Supply, Vertical Out, Horizontal Out DH PIP Processing, Split, Search, Formats

LB Blue CRT Output LG Green CRT Output LR Red CRT Output R IR Sensor

Service Manual

- 10 -

Disassembly for Service

Note:

Speaker Grille Removal

(Figure 8 .)

1. The 2 Speaker Grilles are se cured to the wooden

2. The Center Front Cover is secured by 4 screws.

Keyboard Removal (7-Key Button)

(Figure 8 )

1. Remove the Speaker Grill. (see Figure 8)

2. Unplug the cables (2) from the Keyboard

Speakers Replacement

1. Remove the speaker s grill. (see Figure 8)

2. Each speaker set is s ec ur ed t o th e c abi net wit h ( 4)

3. Disconnect the R & L speaker lead connectors

Board ground wires may have to b e discon nected to dis assembl e some board s. Al l ground w ires must b e reconnected using jumper leads, if necessary, before power is applied to PTV for service.

base of PTV. Grip each panel from the sides and botton part, gently pull forward to remove. When reassembling, make certain to firmly press on the panel where the insertion points (4) are located, one on each corner.

Panasonic

Front Cover

Speaker Grill

Figure 8. Speaker Grill Remova l.

assembly. Remove the 2 screws from the left and right sides of Keyboard assembly. Tilt the Keyboard assembly upward and release it from the screen frame assembly.

screws. from the speaker units.

2. Remove (3) screws from ar ound the A/V terminal board (marked with arrows).

Figure 9. Lower Cabinet Back Removal

Cabinet Back Cover Removal

(Figure 10)

1. First remove the Cabinet Back Lower Cover.

2. The top back cover is secured with (16) screws around its perimeter (See Figure 10 for screws location).

3. Be careful not to damage the mirror attached to the underside of cover.

Cabinet Back Lower Removal

(Figure 9 )

1. Remove (7) hex screws around its perimeter marked with arrows. (See Figure 9 for screw location).

- 11 -

Figure 10. Cabinet Back Cover Removal

Service Manual

Disassembly for Service (Continued)

Cabinet Front Removal

(Figure 11)

1. First remove the Speaker Grill and the center cover, then remove the keyboard, then rem ove th e bottom back cover and then the top back cover.

2. At this point the front cabinet is only held by two hex screws shown below, be careful not to push the cabinet to front.

3. Remove (2) hex cabinet screws (See Figure 11)

the center

Cabinet Screw

Keyboard Screws

Cabinet Screw

CENTER FRONT COVER

cover is held by four screws

Panasonic

Figure 11. Fr ont Cabinet Removal

Screen Assembly

(Figure 12)

1. First remove the Front Cabinet (See Fro nt Cabinet Removal procedure)

2. Place Front cabinet face down on a soft surface.

3. Remove screen brac kets from all sides an d corner brackets

Note: Notice upper, lower, left and right brackets

painted in bla ck (permanent mar ker) on edge, to avoid reflection on image.

4. Note exact orientation of each screen. The orientation and order of the screens is critical for projecting pictures properly. Detailed screen assembly can be seen in Figur e20.

Main Chassis Block (Light-B ox)

(Figure 13)

1. Remove the Speaker Grill (Figure 8)

2. Remove the cabinet back lower. (Figure 9)

3. The main chassis block is secured to the cabinet by screws (2 at front, b ehind the dec orative panel , 4 inside on the bottom of the optical frame).

4. Remove the horizontal barrie r panel at the back of the cabinet.

5. Unplug connectors (K1, G1 and speaker connectors) and pull out the main chassis block.

Main Chassis Block

Figure 13. Chassis Removal (Light-Box)

Velcro

Dot

Rear View

Figure 12. Screen Assembly

Service Manual

Screen Brackets

Protective Screen

Lenticular Screen

Fresnel Screen

Velcro

Dot

Note: Main Chassis block can be serviced

either in normal p os iti on or laying on its back (Protect hookup terminal from damage).

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Disassembly for Service (Continued)

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Disassembly for CRT Replacement

To facilitate CRT replacement, the complete CRT mounting chassis does not need to be removed.

1. Remove the main chassis block from the cabinet (Figure 13).

2. Remove the Optical bracket metal cover (rear side) by removing (6) scr ews from back, (2) screws from top, and (2) screws fr om each side. (Figure 14)

REAR VIEW

Screws (6) places

Pull Down

Figure 14. CRT Replacement

3. Remove the defective CRT anode lead from the high voltage distributor block that is mounted on the Flyback Transformer. Discharge to CRT chassis.

4. Unplug connectors from the B-Board. (See board layout.) B9 for red, B10 for green, or B11 for blue.

5. Unplug the defective CRT black DAG ground connector from the CRT Board.

6. Remove the CRT Board from the defective CRT neck.

7. Remove (2) screws from the defective CRT housing (Figure 15).**

CAUTION: Do not remove the (4) CRT

lens screws.

8. Release CRT anode lead from CRT chassis wire clamp and all other wires from holders.

9. Loosen a screw that secured the DY and remove i t from the CRT neck.

Optical Bracket

X-RAYS SHIELD

10. To insure X-Rays radiation protection, the lens must be mounted in place at all times when power is applied to the PTV.

Optical Bracket Cover

Figure 15. CRT Replacement.

** CAUTION: Support the CRT Assembly

when loosening screws.

CRT Replacement

1. Remove CRT focus lens assembly (4 screws).

Lens (4) Screws

Figure 16. CRT Assembly.

2. Lay CRT face down on a soft cloth.

3. Note position of yoke with centering tabs and remove from defective CRT.

4. Remove CRT DAG ground from defective CRT. Mount it on the replacement CRT exactly as it was on the defective CRT.

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Note: Replacement CRT is supplied with H.V.

anode lead attached.

When replacing CRTs, please see the part number on the CRT to be repl aced and order with same part number on that CRT.

Service Manual

5. Wire the anode lead wire.

Optical Bracket (Front)

7. Press yoke against bell of CRT and tighten the clamp just snug enough so it will not easily shift.

8. Assemble CRT focus lens asse mbly to new CRT with (4) screws. Make sure focus lens adjustment nut is in the same locati on as on other CRT focus lens.

RED CRT GREEN CRT BLUE CRT

Figure 17. Wire Guide.

6. Install yoke with other CRT neck assemblies on CRT neck in the same order and position as removed from the defective CRT.

Optical Block Position Adjustment

Figure 18. CRT Screw Tightening Order.

Note: Please assemble with screws in the order

shown and tighten with the same torque.

Figure 19. Optical Block Position.

The optical block mo unting has holes to allow for the different size projection screens. These mounts will adjust to 61 inch & 51 inch projection screens.

51/61

If the optical block is removed for service or is replaced, it is important that the correct mounting holes are used.

Service Manual

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PTV Screen Assemblies

Label on lower left corner (front side)

Labels on opposite sides

Label on lower left corner (rear side)

REAR

Protective Screen

FRONT

Front Cabinet

Lenticular Screen

(note vertical ridges)

Fresnel Screen

(note circular ridges)

Figure 20. Screen Assemblies.

B+ Voltages Table

Preparation:

Set the following controls

Picture..........................Normal.

Bright ...........................Normal.

Volume.........................Min. (0).

Procedure:

1. Apply a monoscope pattern.

2. Connect the (-) Lead o f the Digit al Voltmeter to TP GND1 (Cold Ground).

3. Connect the (+) Lead of the Digital Voltmeter to each Test Poi nt and confirm th e B+ Voltages (See Table 3).

No. Test Point (D-Board) Voltage

1 TPD14 138.6±1.0 2 TPD13 19.0 3 TPD12 19.0±1.5 4 TPD11 -19.0 5 TPD10 22.0±1.5 6 C845 (-) -22.5

No. Test Point (A-Board) Voltage

1TPA031 9.0±0.5 2 TPA030 5.0±0.5

Table 3: B+ Voltages Table

±1.5

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Service Manual

CRT Set Up

CAUTION: Insure yoke plugs on the A -Board

are reconnected before turning the PTV ON to prevent damage to the horizontal output transistor and/or CRTs.

1. Connect test generator to the antenna terminal an d set for a monoscope pattern.

2. Loosen yoke clamp , seat yo ke aga inst bell o f CRT and rotate to correc t yo ke ti lt (co mpare to adjac ent CRT). Tighten yoke clamp.

3. Remove adhesive from centering tabs and set centering tabs for zero correction. (Figure 21)

Centering Magnets

Figure 21. Adhesive Removal

4. Cover replacement CRT lens and stati c converge the tubes not replaced, i f needed. Check size and linearity of pattern and adjust as required.

5. Uncover replacement CRT lens and cover other two CRT lenses. Adjust electrical and optical focus (lens), if required.

6. Uncover all CRT lenses and use yoke centering magnet to converge replacement CRT (in center area of screen only) with other two CRTs. Disregard non-convergence in areas other than center area.

7. Perform White Balance adjustments.

Dynamic Focus Adjustments

1. Focus adjustments should be performed after 1 hour of aging.

2. Use oscilloscope with 100 : 1 probe.

3. Apply monoscope pattern.

4. Adjust the red, blue and green focus VR on the focus block for best focus of overall picture of each CRT. (Figure 24)

Adhesive

16.7ms (V Rate)

Procedure:

1. Enter to Service mode and set the following default DATA:

•H-PAR to +263

•V-SAW to -35

• V-PAR to +117

2. Connect the scope probe to TPD30, GND to TPD31.

3. Confirm that level of A i s 60 0_V ± 100_V, adjust HPAR DAC to set to specification level.

4. Confirm that level of B is 280_V ± 50_V, adjust VPAR DAC to set to specification level.

5. Confirm that level of C is more tha 20 V, ad just HPAR DAC to set to specification level.

6. Confirm that the waveform shown in D appears (See Figure 22)

Focus - Electrical & Optical Adjustments

(use for minor adjustment or for final adjustment, for complete adjustment see following section.)

Electrical Ad just me nt

1. Apply NTSC monoscope pattern.

Adjust electric focus VR

and lens focus on this circle

Figure 23. Lens focus adjustment

Table 4: Focus Points

RED GREEN BLUE

Electric focus B A/B A Optical Focus B A/B A

280_V ± 100_V

> 20_V

600_V ± 100_V

GND

Figure 22. D. Focus Adjustment Waveform

5. To change DA F DATA, e nter to service mode, then press POWER on remote to display DACs menu, then select DAC by pressing CH (RIGHT/LEFT) and VOL (UP/DOWN), then press ACTION to enter to DAC, then adjust by pressing VOL (RIGHT/ LEFT); press ACTION, to save press ACTION again or OTHER to exit without saving.

Service Manual

2. Cover the green and blue CRTs, projecting red only. The electrical focus controls are located on the front (Figure 23). Adjust the red focus VR for best focus as indicated in Table 4).

Screen

Focus

Figure 24. Focus Pack

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3. Adjust red lens focus (mechanical) until focus is best.

4. Adjust red focus VR again.

5. Repeat for blue focus VR while projecting blue only.

6. Repeat for green.

Focus - Optical Lens Adjustment Optical Adjustments

Note: This adjustment normally should not require

resetting unless th e lens has been rep laced or adjustment has changed.

1. Optical focus adjustment is located on the top of each CRT lens system. Loosen the adjustment knurled locking knob. (Figure 25)

Adjustment kn ur le d

locking knobs

B G R

4. Position the longer tab of the four-pole magnet to 90 degrees (uncorrected position). (See Figure 27).

6-pole magnet (Dummy

4-pole magnet Alignment magnet

ring)

Figure 26. VM Coil with focus

correction magnet

Set 90 degrees

Figure 27. 4-pole magnet

5. Position the long tab of all alig nment magnets and of the dummy ring together in an uncorrected position. (See Figure 28).

REAR VIEW

Figure 25. Optical Lens focus Adjustment

2. Turn the PTV ON. Apply and view a monoscope pattern.

3. Adjust each lens focus for best focus while viewing each CRT.

4. Cover the red and blue CRT, projecting green only. Rotate the green lens for best focus around screen center area.

5. Do the same for the red focus le ns wh il e pr oj ecting red only.

6. Repeat for blue.

Electric & VM Focus Adjustment, Complete adjustment

(Perform this adjustment when a CRT is replaced or when major adjustment is required)

Preparation:

1. NTSC monoscope pattern.

2. NTSC cross hatch pattern with dots (pincushion).

3. Set DAC MUTE from 0 to 1 (disabling digital convergence.)

Figure 28. Alignment magnet

(or dummy ring)

Procedure:

1. Apply an NTSC cross hatch pattern with dots.

2. Assure that digital convergence is disabled (Dac MUTE from 0 to 1).

3. Project red only. (Cover green and blue CRTs.)

4. Turn the red electrical focus adjustment VR (on focus pack) fully counterclockwise and note the position of the dots at the center of the picture.

5. Turn the red electrical focus adjustment VR fully clockwise.

6. If the position of the dots at the center of the screen moves from the position noted in step 4., adjust the four pole magnets until the dots are in the same position as noted in step4.

7. Turn the red electrical focus adjustment VR (on focus pack) fully counte rclockwise and confirm that the position of the dots at the c enter of the screen did not move from their position noted in ste p6.

8. If the position of the dots at the center of screen moved, repeat from step 4.

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Service Manual

9. If the position of the dots moved after repeated adjustments, adjust unt il the movemen t of the dots is minimized.

10. Turn the red focus VR fully clockwise.

11. Adjust the 4-pole magnets until the shape of the dots at the center of the screen is circular.

12. Adjust red focus VR until optimum focus is achieved.

13. Apply NTSC mo noscope pattern.

14. If the center of the monoscope pattern is not insi de the 15.0mm circle, shown in Figure 29, adjust the centering magnets. Repeat the ali gnment magnet adjustments and four pole magnet adjustments (step 1. ~ step 12.).

Figure 29. Centering magnet

15. Apply an NTSC cross hatch pattern with dots.

16. Cover red and blue lenses projecting green only.

17. Repeat above procedures for the green.

18. Enable digital convergence by changing DAC MUTE from 1 to 0.

19. Following adjustments, paint position of DY centering magnets and fix the centering magnets of DY, dummy rings of V M coil, four pole magn ets of VM coil and the alignment magnets of VM coil to prevent them from movi ng.

Note: Please See “Serviceman Mode (Electronic

Controls)” on page 25 for entering and exit ing Service Mode.

V ertical Size Adjustme nt (V SIZE)

1. Apply an NTSC monoscope pattern.

2. Cover red and blue lenses.

3. Set DAC MUTE from 0 to 1 (disabling digital convergence).

4. Adjust centering magnets so that the center of pattern get aligned with screen frame center.

5. Adjust DAC (VSIZE) until vertical size is 3.5±0.1 on top and bottom lines. (See Figure 30)

6. Remove lens covers and enable digital convergence by changing DAC MUTE from 1 to 0.

3.0

1.0

Figure 30. Vertical Size Adjustment

Horizontal Phase Adjustment (H-POS)

1. Apply a crosshatch pattern.

2. Set DAC MUTE from 0 to 1 (disabling digital convergence).

3. Cover both red and blue lens so that only the green lens is projecting the monoscope pattern.

4. Turn Green deflection yoke until line is perfectly horizontal.

5. Adjust H-POS DAC data so that pattern is in the center of sc reen.

Picture Area

Screen Frame

Deflecting Area

Figure 31. H Phase Adjustment

6. Enable digital convergence by changing DAC MUTE from 1 to 0.

7. Remove lens covers.

Trapezoid Adjustment (EWTRA)

Procedures:

1. Cover Red and Blue Lenses.

1. Apply a crosshatch pattern.

2. Set DAC MUTE from 0 to 1 (disabling digital convergence).

3. Adjust DAC EWTRA (trapezoid) by pressing VOL right-left to co rrect image, less than 30mm on top and bottom left side(See Figure 32).

Service Manual

Correct Adjustment Incorrect Adjustment

Figure 32. Trapezoid Adjustment

4. Enable digital convergence by changing DAC MUTE from 1 to 0 and remove caps from lenses.

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Pincushion Adjustment (PCC)

Procedure:

1. Cover Red and Blue Lenses.

2. Apply a crosshatc h patt er n.

3. Set DAC MUTE from 0 to 1 (disabling digital convergence).

4. Adjust DAC PCC (Pincushion) by pressing VOL right/left and confirm that size is 17±5mm at “A” (See Figure 33)

“A”

Figure 33. Pincushion Adjustment

5. If Trapezoid adjustment is required after this adjustment, perform trapezoid adjustment.

6. Enable digital convergence by changing DAC MUTE from 1 to 0 and remove caps from lenses.

Centering Magnets Adjustment

Procedures:

1. Apply a monoscope pattern.

2. Cover the red and blue lens so only the green lens is projecting the monoscope pattern.

3. Set DAC MUTE from 0 to 1 (disabling digital convergence).

4. Loosen the deflection coil screw on the green CRT.

5. Adjust green deflection coil until the horizontal center li ne is horizontal.

6. Adjust centering magn ets until the gr een pattern is equal on left and right. Adjust also for horizontal and vertical tilt.

9. Transfer lens cover from blue to red, so that blue is projected.

10. Adjust blue deflection coil until the horizontal center line match es the pattern of the grid and is leveled.

1 1. Adjust blue centering magnets until the monoscope

pattern center is at the appropriate distance as indicated on Figure 34.

12. Enable digital convergence by changing DAC MUTE from 1 to 0.

13. Following the adjustment, make sure that all deflection coils are pus hed completely toward the CRT cones and that all screws are tightened.

Horizontal Size Adjustment (H WID)

This is the manual adjust ment of hori zontal siz e that is included in the automatic convergence adjustment.

1. Apply a monoscope pattern.

2. Set DAC MUTE from 0 to 1 (disabling digital convergence).

3. Cover both red and blue lens.

4. In service mode, adjust H-WID DAC until the

0.2 lines at left side

picture horizontal s ize is 5.0 of screen.

5. Enable digital convergence by changing DAC MUTE from 1 to 0.

6. Remove lens covers.

Convergence Adjustment

Note: It is strongly rec ommended to first read and

understand the following section prior to make any adjustment.

T ur n PTV on and allow it to warm up for 30 minutes prior to making adjustments (WHITE PATTERN).

Note: Push deflection coil to top of CRT neck,

then tighten deflection screw after adjusting each CRT centering and Tilt.

7. Transfer lens cover from r ed to green and proj ect red only. Adjust deflection coil un til the horizontal center line matches the pattern of the grid and is leveled.

8. Adjust red centeri ng magnets unt il the mono scope pattern center is at the appropriate distance as indicated on Figure 34.

d measured in mm

28 mm

Figure 34. Centering Magnets Adjustment.

Note: This PTV uses the scheme described

below to correct for misconvergence of the three CRT projection tubes. There are various modes to this operation.

Preparation:

Place the Convergence Alignment Template (see “Convergence Alignment Template” on page 24) over the PTV screen. Align the ce nter lines of the template with the mechanical center markers on the PTV screen frame. If the template is not available, create one using the dimensions provided in “Convergence Alignment Template” on page 24. Remote control must be used during the procedure.

Note: Apply the Conv ergenc e Alignm ent Template to

the PTV screen frame to co nverge the Green Raster only. Remove the Convergence Alignment Template following this alignment. The red and blue r asters can then be a ligned to the green raster.

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Service Manual

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