Sanyo 40XR10F Schematic

FILE NO.

SERVICE MANUAL

LCD TV

LCD-40XR10F

PRODUCT CODE No.

PRODUCT CODE No.

1 682 349 44: PAL-BG(TV) DTV

REFERENCE No.:SM0915099

CONTENTS

Safety precautions………………………………………………………………………..…

Alignment instructions …………………………….…….…………………………………

Method of software upgrading instructions………………………………………………..

Working principle analysis of the unit……………………………….………….………….

Block diagram…………………………………..………………………………….…………

IC block diagram and instruction…………………………………………………………..……

Wiring diagram …………………………………………………………………………….

Troubleshooting guide ………………………………………………………………..……

Schematic diagram…………………………………………………………………………

APPENDIX-A: Main assembly list

APPENDIX-B: Exploded View

Assemble & Disassemble the Pedestal Base

Wall mounting instructions

3

5

12

15

18

19

26

27

30

Attention: This service manual is only for service personnel to take reference with. Before

servicing please read the following points carefully.

Safety precautions

1. Instructions

Be sure to switch off the power supply before replacing or welding any components or
inserting/plugging in connection wire Anti static measures to be taken (throughout the entire
production process!):
a) Do not touch here and there by hand at will;
b) Be sure to use anti static electric iron;
c) It’s a must for the welder to wear anti static gloves.
Please refer to the detailed list before replacing components that have special safety requirements.
Do not change the specs and type at will.

2. Points for attention in servicing of LCD

2.1 Screens are different from one model to another and therefore not interchangeable. Be sure to
use the screen of the original model for replacement.

2.2 The operation voltage of LCD screen is 700-825V. Be sure to take proper measures in
protecting yourself and the machine when testing the system in the course of normal operation or
right after the power is switched off. Please do not touch the circuit or the metal part of the module
that is in operation mode. Relevant operation is possible only one minute after the power is
switched off.

2.3 Do not use any adapter that is not identical with the TV set. Otherwise it will cause fire or
damage to the set.

2.4 Never operate the set or do any installation work in bad environment such as wet bathroom,
laundry, kitchen, or nearby fire source, heating equipment and devices or exposure to sunlight etc.
Otherwise bad effect will result.

2.5 If any foreign substance such as water, liquid, metal slices or other matters happens to fall into
the module, be sure to cut the power off immediately and do not move anything on the module lest it
should cause fire or electric shock due to contact with the high voltage or short circuit.

2.6 Should there be smoke, abnormal smell or sound from the module, please shut the power off at
once. Likewise, if the screen is not working after the power is on or in the course of operation, the
power must be cut off immediately and no more operation is allowed under the same condition.

2.7 Do not pull out or plug in the connection wire when the module is in operation or just after the
power is off because in this case relatively high voltage still remains in the capacitor of the driving
circuit. Please wait at least one minute before the pulling out or plugging in the connection wire.

2.8 When operating or installing LCD please don’t subject the LCD components to bending, twisting
or extrusion, collision lest mishap should result.

2.9 As most of the circuitry in LCD TV set is composed of CMOS integrated circuits, it’s necessary
to pay attention to anti statics. Before servicing LCD TV make sure to take anti static measure and
ensure full grounding for all the parts that have to be grounded.

2.10 There are lots of connection wires between parts behind the LCD screen. When servicing or
moving the set please take care not to touch or scratch them. Once they are damaged the screen

would be unable to work and no way to get it repaired.
If the connection wires, connections or components fixed by the thermotropic glue need to
disengage when service, please soak the thermotropic glue into the alcohol and then pull them out
in case of dagmage.

2.11 Special care must be taken in transporting or handling it. Exquisite shock vibration may lead to
breakage of screen glass or damage to driving circuit. Therefore it must be packed in a strong case
before the transportation or handling.

2.12 For the storage make sure to put it in a place where the environment can be controlled so as to
prevent the temperature and humidity from exceeding the limits as specified in the manual. For
prolonged storage, it is necessary to house it in an anti-moisture bag and put them altogether in one
place. The ambient conditions are tabulated as follows:

o

Temperature Scope for operation

5

~ +35

C

Scope for storage -15~ +45 oC

Humidity Scope for operation 20% ~ 80%

Scope for storage <= 80%

2.13 Display of a fixed picture for a long time may result in appearance of picture residue on the
screen, as commonly called “ghost shadow”. The extent of the residual picture varies with the
maker of LCD screen. This phenomenon doesn’t represent failure. This “ghost shadow” may remain
in the picture for a period of time (several minutes). But when operating it please avoid displaying
still picture in high brightness for a long time.

3. Points for attention during installation

3.1 The front panel of LCD screen is of glass. When installing it please make sure to put it in place.

3.2 For service or installation it’s necessary to use specified screw lest it should damage the screen.

3.3 Be sure to take anti dust measures. Any foreign substance that happens to fall down between
the screen and the glass will affect the receiving and viewing effect

3.4 When dismantling or mounting the protective partition plate that is used for anti vibration and
insulation please take care to keep it in intactness so as to avoid hidden trouble.

3.5 Be sure to protect the cabinet from damage or scratch during service, dismantling or mounting.

Alignment instructions

1. Safety Instructions

Be sure to switch off the power supply before replacing or welding any components or
inserting/plugging in connection wire Anti static measures to be taken (throughout the entire
production process!):
a) Do not touch here and there by hand at will;
b) Be sure to use anti static electric iron;
c) It’s a must for the welder to wear anti static gloves.
Please refer to the detailed list before replacing components that have special safety requirements.
Do not change the specs and type at will.

2. Test equipment

VG-848 (VGA, YPbPr signal generator)
VG-849 (HDMI digital video signal generator)
CA210 (color analyzer)

3 Alignment flow

3.1 Voltage of power supply test

According to the wiring of “9232KH4601JL”, connect main board, power board and IR board

correctly, then switch on the main power and press key “standby” to turn on the TV set.

a) Test voltage of socket X108 each pin in turn, please refer to voltage of Table 1:

X108 Pin1 2 3 4 5 6

Vol.

V

b) Test voltage of socket XV03 each pin in turn, please refer to voltage of Table 2:

>2.5

4.85 V ～

0

5.35 V

XV03

Vol. 0

Table 1 Voltage of X108 each pin

7 、89 、10

4.85 V ～

0

5.35 V

8.55 V～

9.45 V

0

11. 4 V ～

12.6 V

Table 2 Voltage of XV03 each pin

Pin1、2、3 4、5

23.8 V～25.2 V

11 12 13

0

3.2 V ～

3.4 V

4.9 V ～

5.1 V

3.2 Alignment flow chart shown as Fig. 1

Check if DDC, HDCP KEY, FLASH have been burned?

Combination alignment for general assembly

White balance alignment

Connect to central signal source, check if TV functions are normal-omitted channel, analog

parameters control, etc.? Check if the output of earphones and speakers are normal?

Input AV signal, check if AV functions are normal?

Input high-definition component signal (mode), check YPbPr functions are normal?

Input VGA signal, check if display and other functions are

normal - analog parameters control, H/V center, etc.?

Input HDMI signal, check if display and other functions are
normal - analog parameters control, H/V center, etc.?

Setup before shipment

Accessories checkup and packing

Fig. 1 Alignment flow chart

4 Alignment instructions

4.1 Unit adjustment

4.1.1 According to the wiring of “9232KH4601JL”, connect main board, power board and IR board

correctly, then switch on the main power and press key “standby” to turn on the TV set. Check if

display is normal?

4.1.2 Using method of factory menu

a) Press key “SOURCE” first, then press keys “2, 5, 8, 0” in turn to enter into initial factory

menu;

b) Press keys “▲” and “▼” to move cursor to each page of initial factory menu, then press “OK”

to enter into adjusting menu of each page;

c) Press keys “▲” and “▼” to move cursor upwards or downwards within any page;

d) Press keys “◄” and “►” to do adjustment when cursor is moved to any item;

e) Press key “MENU” to exit menu of any page to its superior factory menu;

f) Press key “EXIT” to exit factory menu in any case;

g) Press key “OK” to enter into inferior factory menu;

h) Factory menu item: ADC ADJUST, for ADC calibration of VGA and Component;

i) Factory menu item: W/B ADJUST, for white balance adjustment;

j) Factory menu item: POWER Mode, for setting power-on mode; the default setting is

“Standby” mode unless specified by customer;

Standby: TV set will be in “standby” mode after power-on;

MEM: TV set will keep states before last power-off;

ForceOn: TV set will turn on automatically; it also can be used as aging mode at factory;

k) Factory menu item: Other Setting->ISP Mode, the item will not be kept in memory, that

is, it will be always in “OFF” mode after turning on again;

“ON”: Upgrading unit software through VGA port while connecting to ISP device;

“OFF”: Normal DDC functions of VGA port will recover;

l) Factory menu item: EEPROM Init, for factory and customer data initialization; TV set will

reset and initial guiding interface will display after executing the item;

m) Factory menu item: Factory ChA., for factory channels presetting; it is necessary to

connect to central signal source before operating the item; now digital frequency of central
signal CH28（529.5 MHz）and CH33（564.5 MHz）

originally preset digital programs will not change along with the modification of central signal,

so please operate item “DTV” of menu “Channel” to search digital programs manually, which

will last about 15s;

n) Factory menu item: Shipment, all DTV/ATV programs for factory adjustment will be

cleared out first, then ATV channels will be preset according to customer requirements; the

item must be executed before shipment to clear out channels for factory adjustment;

o) Factory menu item: Other Setting->MST DEBUG, default setting is “OFF”, it will not be

kept in memory, that is, it will always in “OFF” mode after turning on the set again;

“OFF”: RS232 functions of some engineering machines can match design specifications;

“ON”: It is convenient for design tools to debug the software;

p) Factory menu item: Backlight, for adjusting brightness of backlight; test voltage of

X108-12# (PWM) while adjusting the item to meet the requirements of PWM voltage scope

corresponding to mixture brightness described by panel specification; the item need not

adjustment for it has been preset by software;

are distributed to Australia programs;

q) Factory menu item: Other Setting->SSC ADJUST, for expanded spectrum adjustment;

the item need not adjustment for it has been preset by software;

r) Factory menu item: Other Setting->AUDIO Curve Setting, for sound curve adjustment;

if without special customer requirements, the item need not adjustment commonly for it has

been preset by software;

Note: If software is upgraded or there have been date in EEPROM already, please execute item

“RESET ALL” to clear out all data before adjustment for the first time.

4.2 ADC calibration

4.2.1 ADC calibration of VGA

1） Switch “source” to VGA channel;
2） Press key “SOURCE”, then press keys “2, 5, 8, 0” in turn to enter into initial factory menu;
3） Move cursor to item “ADC ADJUST” and press key “OK” to enter into inferior factory menu;
4） Input VGA signal（VG848: Timing 856（1024×768/60 Hz）, Pattern 920 Gray 8 step(H)）;

move cursor to item “MODE ”，press keys “▲” and “▼” to select item “RGB”，then move

cursor to item “AUTO ADC” and press key “OK” to begin auto-adjustment until completing

the calibration.

4.2.2 ADC calibration of YPbPr

1） Switch “source” to YPbPr channel;
2） Press key “SOURCE”, then press keys “2, 5, 8, 0” in turn to enter into initial factory menu;
3） Move cursor to item “ADC ADJUST” and press key “OK” to enter into inferior factory menu;
4） Input Y/Pb/Pr signal（VG848 Timing 976（720P）,Pattern 918 SMPTE Color Bar）; move

cursor to item “MODE ”，press keys “▲” and “▼” to select item “YPbPr”，then move cursor to

item “AUTO ADC” and press key “ENTER” to begin auto-adjustment until completing the

calibration, prompt “SUCCESS” displaying below “AUTO ADC” means successful

auto-calibration.

4.3 White balance adjustment

Unless specified by customer, default color temperature “COOL” is 12000K and its chromatic

coordinates is (272, 278); color temperature “NORMAL” is 9300K and its chromatic coordinates is

(285, 293); color temperature “WARM” is 6500K and its chromatic coordinates is (323、329);

4.3.1 Adjustment procedure

TV set should be working over 30 mins to be in stabler state before white balance adjustment;

Use white balance apparatus CA210 and switch to its BBY channel.

1） Switch “source” to HDMI channel;
2） Press key “SOURCE”, then press keys “2, 5, 8, 0” in turn to enter into initial factory menu;
3） Move cursor to item “W/B ADJUST” and press key “OK” to enter into inferior factory menu;
4） Input DVI/HDMI signal (16 Gray Scale Signal: 1024×768/60Hz, TIMING: 856,

PATTERN:921); move cursor to item “MODE”, press keys “▲” and “▼” to select item

“HDMI1” or other HDMI channels, then move cursor to item “TEMPERATURE” and press

keys “▲” and “▼” to select item “COOL”;

th

5） Adjust items “R-GAIN, G-GAIN, B-GAIN” to set chromatic coordinates of 14

scale as

(272, 278);

th

6） Adjust items “R-OFFSET, G-OFFSET, B-OFFSET” to set chromatic coordinates of 4

scale

as (272, 278);

7） During adjustment, make sure that chromatic coordinates of bright scale are (X=272±10,

Y=278±10) and chromatic coordinates of dark scale are (X=272±10, Y=278±10);

8） Move cursor to item “COPY ALL” again to copy data of white balance to other channels

except DTV;

9） Check if chromatic coordinates of HDMI NORMAL and WARM meet the requirements of

error allowance (dark scale: ±10, bright scale: ±10) or not, otherwise adjust items

“R_GAIN/B_GAIN/R_OFF/B_OFF” to meet them and then save the data;

10) Switch to other channels (AT V, AV，COMPONENT，D-SUB), check if chromatic coordinates

of COOL, NORMAL and WARM meet the requirements or not, if not, adjust them

respectively in the same way of HDMI and with 16 gray scale signal; exit menu “W/B

ADJUST” after adjustment, the data will be save automatically;

11) DTV adjustment: switch to DTV channel, select 16 gray scale program, enter into factory

menu, do adjustment following above step 5, 6, 7;

12) Please refer to the adjusting rules as follows:

B Gun: coordinates of X and Y will increase when B gun is adjusted downwards;

coordinates of X and Y will decrease when B gun is adjusted upwards;

R Gun: adjusting R gun will effect coordinate of X, and value of Lv slightly;

coordinate of X will increase when R gun is adjusted upwards;

coordinate of X will decrease when R gun is adjusted downwards;

G Gun: adjusting G gun will effect coordinate of Y

, and value of Lv greatly;

coordinate of Y will increase when G gun is adjusted upwards;

coordinate of Y will decrease when G gun is adjusted downwards;

Note: Default color temperature specified by SANYO customer is Normal, adjust chromatic

coordinates of Normal and Cool in Dynamic picture mode; adjust chromatic coordinates of Cool in

Dynamic picture mode for other customers.

5 Functions checkup

5.1 TV functions

Input central signal to RF port, enter into menu “CHANNEL” first, then search channels

automatically, check if there is any omitted channel, check if the output of speakers and the picture

are normal.

5.2 AV port

Input signal to AV port respectively, check if the picture and the sound are normal.

5.3 YPbPr/YCbCr port

Input YUV signal from VG848 signal generator with YUV formats listed as Table 3 respectively,

check if the picture and the sound are normal under the circumstances of power-on/off, switching

channel and format, etc..

Table 3 YUV signal formats

No.

1 720×480 15.734 60 13.5 480i(NTSC)

2 720×480 15.734 59.94 13.5 480i(NTSC)

3 720×576 15.625 50 13.5 576i(PAL)

4 720×480 31.469 60 27 480p(NTSC PROG)

5 720×480 31.469 59.94 27 480p(NTSC PROG)

Definition

H. - fre.（kHz） V. – fre.（Hz） Dot pulse fre.（MHz）

Note

No.

6 720×576 31.25 50 27 576p(PAL PROG)

7 1280×720 45 59.94 74.18 720p(59p)

8 1280×720 45 60 74.25 720p(60p)

9 1280×720 37.5 50 74.25 720p(50p)

10 1920×1080 33.75 59.94 74.25 1080i(59i)

11 1920×1080 33.75 60 74.25 1080i(60i)

12 1920×1080 28.125 50 74.25 1080i(50i)

13 1920×1080 67.5 59.94 148.35 1080p(59p)

14 1920×1080 67.5 60 148.5 1080p(60p)

15 1920×1080 56.25 50 148.5 1080p(50p)

16 1920×1080 - 23.94/24 - -

17 1920×1080 - 25 - -

18 1920×1080 - 29.97/30 - -

Definition

H. - fre.（kHz） V. – fre.（Hz） Dot pulse fre.（MHz）

Note

5.4 VGA port

Input signal from VG848 signal generator to VGA port with VGA signal formats listed in Table 4

respectively, check if the display and the sound are normal; if there is any H/V offset, enter into main

menu and select items “Picture->Screen->Auto Adjusting” in turn to make calibration automatically.

Table 4 VGA signal formats

No.

1 640×480 31.469 59.94 25.175 IBM

2 720×400 31.469 70.086 28.322 IBM

3 640×480 37.861 72.809 31.5 VESA

4 640×480 37.5 75 31.5 VESA

5 800×600 35.156 56.25 36 VESA

6 800×600 37.879 60.317 40 VESA

7 800×600 48.077 72.188 50 VESA

8 800×600 46.875 75 49.5 VESA

9 1024×768 48.363 60.004 65 VESA

10 1024×768 56.476 70.069 75 VESA

11 1024×768 60.023 75.029 78.75 VESA

12 1152×864 67.5 75 108 VESA

13 1280×960 60 60 108 VESA

14 1280×1024 63.98 60.02 108 VESA

15 1280×1024 80 75 135 SXGA

16 1440×900 - 60 - -

17 1680×1050 - 60 - -

18 1360×768 47.7 60 85.5 -

Definition

H. - fre.（kHz） V. – fre.（Hz） Dot pulse fre.（MHz）

Note

5.5 USB port

5.5.1 PVR function

Insert formatted USB memory containing recorded-program files, press key “record list” to

select and play program, check if the picture, the sound and other functions are normal.

5.5.2 Media playing function:

Insert USB memory containing files of picture, audio and video, check if the picture, the sound

and other functions are normal.

5.6 MUSIC port (only for SANYO model)

Input audio signal from sound output device to side music port, check if the sound is normal.

5.7 HDMI port

Input HDMI signal from VG849 signal generator to HDMI port with the formats listed in Table 3

and Table 4 respectively, check if the display and the sound (32 kHz, 44.1 kHz, 48 kHz) are normal

under the circumstances of power-on, switching channels or formats, etc

5.8 Other functions checkup

Check if functions - timing on/off, sleeping off, picture/sound mode, OSD, stereo and digital

audio ports, etc., are normal;

Check if pure audio program (RADIO) are normal when switching to digital programs;

Check if functions of LCN and OTA are normal.

6 User menu setup before shipment

Enter into page “LOCK” of user menu, select item “Restore Factory Default” to make setup

before shipment.

Main procedures as follows:

1）Clear out information of all programs;

2）Clear out information about VCHIP – parents control;

3）Default analog parameters setup for user;

4）Set Menu Language as “English”;

5）Set Power on mode as “Off”.

Method of software upgrading instructions

Factory software burned instructions listed as Table 5

Table 5 Factory software burned instructions

No. Part No. Part Type

Software

function

Burned

before SMT

Burning method

N803 5276405001 MX25L6405DMI-12G FLASH Yes

N804 5272404002 AT24C04 HDCP KEY Yes ALL11

NA04 5272402002 AT24C02 HDMI EDID Yes ALL11

NA05 5272402002 AT24C02 HDMI EDID Yes ALL11

HDMI EDID (for

example,

NA06 5272402002 AT24C02

N106 5272402002 AT24C02 VGA EDID Yes ALL11

supporting the

third channel

HDMI)

Yes ALL11

Use ALL11 with write-protect, refer

to Note 1 in detail.

Note 1: Method of write-protect setup: enter into burning interface of ALL-100, tick option “Config”,

press item “config Setting”, set option “Protect” as “All Protect”; make sure that option

“Config” must be ticked before burning software and write-protect must be reset after

ALL-100 burning software opened every time.

Note 2: Method of burning and upgrading software by using ISP burning device:

1） For main board upgrade: Connect the cable of ISP burning device to Debug port (X107) of main

board; for TV set upgrade, connect both VGA ports of ISP burning device and main board, enter

into factory menu and set item “ISP Mode” as “ON”;

2） Using Mstar online burning program (V4.4.2.0 or higher versions), enter into menu “Device”, tick

option “WP Pin pull to high during ISP” to ensure that hardware write-protect of Flash is

removed and erasing process is normal, please refer to Fig. 2;

Fig. 2 Write-protect setup

3） Press menu “Connect”, a dialog box “Device Type is MX25L64” will pop up, that is, connection

has been successful, please refer to Fig. 3;

Fig. 3 Successful connection to device MX25L64

If the connection is failed, press the first menu “Device” and select its option “MX25L64”, then

press menu “Connect” again;

4） Press menu “Read”, select the burning file, such as “MERGE.bin”, please refer to Fig. 4

Fig. 4 Burning file selection

5） Press menu “Auto”, tick options “All chip” and “program”, please refer option switches to Fig.5;

Fig. 5 Option switches

6） Press button “Run” to begin burning process, which includes two steps: Erase and Program;

Normal burning process is described as follows:

First, the step “Erasing…， Flash Status: 03” will last for some time, or it is failed if it is passed by
quickly, please confirm procedure 2）and begin burning process again; then the following step is
“Programming…，Flash Status:00”; at last, a prompt “Pass” will display.

7） A prompt “Pass” will display beside button “Run” if burning process is successful, please refer to

Fig. 6;

Fig. 6 A prompt “Pass” displaying beside button “Run” for successful burning process

8） If there are other machines to be burned, remain ISP burning interface and repeat procedures

3）and 5）only;

Note 3: Method of online burning and upgrade through USB:

1） Make sure that U disk is formatted as “FAT32”;

2） Copy firmware “Merge.bin” to U disk;

3） Power on TV set, be sure to be in channel of ATV or DTV and have not any OSD interface, insert

U disk into USB port of TV set;

a) First press key “SOURCE”, then press keys “2, 5, 8, 0” in turn to enter into initial factory

menu;

b) Select item “software update” to begin upgrade;

4） Upgrade process:

A、Read data from U disk, while data indicator light of U disk is twinkling at the same time;

B、Begin to burn Flash，the unit will be in “standby” mode after burning process completed;

5） Please restart the unit after power-off of hardware, then enter into factory menu, confirm software

parameters - version and time, execute item “RESET ALL” to complete the whole process.

*** USB burning method could not be sure to all kinds of U disks, so please try another U disk if one is

inapplicable.