Sharp LC-80LE642U Service Manual

TopPage

LC-80LE642U

SERVICE MANUAL

No. S73B9LC80LE64

LCD COLOR TELEVISION

MODEL

In the interests of user-safety (Required by safety regulations in some countries) the set should be restored to its original condition and only parts identical to those specified should be used.

LC-80LE642U

CONTENTS

SAFETY PRECAUTION

IMPORTANT SERVICE SAFETY PRE-

CAUTION ............................................................i

PRECAUTIONS A PRENDRE LORS DE

LA REPARATION...............................................ii

PRECAUTIONS FOR USING LEAD-FREE

SOLDER ........................................................... iii

OUTLINE

MAJOR SERVICE PARTS ................................iv

CHAPTER 1. SPECIFICATIONS

[1] SPECIFICATIONS ......................................... 1-1

CHAPTER 2. OPERATION MANUAL

[1] OPERATION MANUAL .................................. 2-1

CHAPTER 3. DIMENSIONS

[1] DIMENSIONS ................................................ 3-1

CHAPTER 5. ADJUSTMENT

[1] ADJUSTMENT PROCEDURE ......................5-1

[2] PUBLIC MODE SETTING PROCEDURE......5-15

CHAPTER 6. TROUBLESHOOTING TABLE

[1] Failure diagnosis by LED in front of cabinet........6-1

[2] LED flashing specification at the time of an

error (Center icon LED used) ........................6-1

[3] TROUBLESHOOTING TABLE ......................6-4

CHAPTER 7. MAJOR IC INFORMATIONS

[1] MAJOR IC INFORMATIONS .........................7-1

CHAPTER 8. OVERALL WIRING/SYSTEM BLOCK DIAGRAM

[1] OVERALL WIRING DIAGRAM ......................8-1

[2] SYSTEM BLOCK DIAGRAM .........................8-2

Parts Guide

CHAPTER 4. REMOVING OF MAJOR PARTS

[1] REMOVING OF MAJOR PARTS ................... 4-1

[2] The location putting on the heat measure

sheet .............................................................. 4-9

[3] Precautions for assembly............................. 4-10

Parts marked with " " are important for maintaining the safety of the set. Be sure to replace these parts with specified ones for maintaining the safety and performance of the set.

This document has been published to be used for after sales service only. The contents are subject to change without notice.

LC-80LE642U

SAFETY PRECAUTION

Service Manual

IMPORTANT SERVICE SAFETY PRECAUTION

Service work should be performed only by qualified service technicians who are thoroughly familiar with all safety checks and the servicing guidelines which follow:

WARNING

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

2. Disconnect AC power before servicing.

CAUTION: FO R C O N T I N U E D PROTECTION AGAINST A RISK OF FIRE REPLACE ONLY WITH SAME TYPE FUSE.

F7003 (250V 6.3A)

BEFORE RETURNING THE RECEIVER (Fire & Shock Hazard)

Before returning the receiver to the user, perform the following safety checks:

3. Inspect all lead dress to make certain that leads are not pinched, and check that hardware is not lodged between the chassis and other metal parts in the receiver.

4. Inspect all protective devices such as non-metallic control knobs, insulation materials, cabinet backs, adjustment and compartment covers or shields, isolation resistor-capacitor networks, mechanical insulators, etc.

5. To be sure that no shock hazard exists, check for leakage current in the following manner.

• Plug the AC cord directly into a 120 volt AC outlet.

• Using two clip leads, connect a 1.5k ohm, 10 watt resistor paral-

leled by a 0.15µF capacitor in series with all exposed metal cabinet parts and a known earth ground, such as electrical conduit or electrical ground connected to an earth ground.

• Use an AC voltmeter having with 5000 ohm per volt, or higher, sensitivity or measure the AC voltage drop across the resistor.

• Connect the resistor connection to all exposed metal parts having a return to the chassis (antenna, metal cabinet, screw heads, knobs and control shafts, escutcheon, etc.) and measure the AC voltage drop across the resistor.

All checks must be repeated with the AC cord plug connection reversed. (If necessary, a nonpolarized adaptor plug must be used only for the purpose of completing these checks.)

Any reading of 0.75 Vrms (this corresponds to 0.5 mA rms AC.) or more is excessive and indicates a potential shock hazard which must be corrected before returning the monitor to the owner.

DVM

AC SCALE

1.5k ohm 10W

0.15µF

TEST PROBE

TO EXPOSED METAL PARTS

CONNECT TO KNOWN EARTH GROUND

///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

SAFETY NOTICE

Many electrical and mechanical parts in LCD color television have special safety-related characteristics.

These characteristics are often not evident from visual inspection, nor can protection afforded by them be necessarily increased by using replacement components rated for higher voltage, wattage, etc.

Replacement parts which have these special safety characteristics are identified in this manual; electrical components having such features

are identified by " " and shaded areas in the Replacement Parts List and Schematic Diagrams.

For continued protection, replacement parts must be identical to those used in the original circuit.

The use of a substitute replacement parts which do not have the same safety characteristics as the factory recommended replacement parts shown in this service manual, may create shock, fire or other hazards.

LC-80LE642U

PRECAUTIONS A PRENDRE LORS DE LA REPARATION

Ne peut effectuer la réparation qu' un technicien spécialisé qui s'est parfaitement accoutumé à toute vérification de sécurité et aux conseils suivants.

•

AVERTISSEMENT

N'entreprendre aucune modification de tout circuit. C'est dangereux.

Débrancher le récepteur avant toute réparation.

PRECAUTION: POUR LA PROTECTION CONTINUE CONTRE LES RISQUES D'INCENDIE, REMPLACER LE FUSIBLE

F7003 (250V 6.3A)

A l'aide de deux fils à pinces, brancher une résistance de 1.5 kΩ 10 watts en parallèle avec un condensateur de 0.15µF en série avec toutes les pièces métalliques exposées du coffret et une terre connue comme une conduite électrique ou une prise de terre branchée à la terre.

•

Utiliser un voltmètre CA d'une sensibilité d'au moins 5000Ω/V pour mesurer la chute de tension en travers de la résistance.

•

Toucher avec la sonde d'essai les pièces métalliques exposées qui présentent une voie de retour au châssis (antenne, coffret métallique, tête des vis, arbres de commande et des boutons, écusson, etc.) et mesurer la chute de tension CA en-travers de la résistance. Toutes les vérifications doivent être refaites après avoir inversé la fiche du cordon d'alimentation. (Si nécessaire, une prise d'adpatation non polarisée peut être utilisée dans le but de terminer ces vérifications.) La tension de pointe mesurèe ne doit pas dépasser 0.75V (correspondante au courant CA de pointe de 0.5mA). Dans le cas contraire, il y a une possibilité de choc électrique qui doit être supprimée avant de rendre le récepteur au client.

VERIFICATIONS CONTRE L'INCEN-DIE ET LE CHOC ELECTRIQUE

Avant de rendre le récepteur à l'utilisateur, effectuer les vérifications suivantes.

Inspecter tous les faisceaux de câbles pour s'assurer que les fils ne soient pas pincés ou qu'un outil ne soit pas placé entre le châssis et les autres pièces métalliques du récepteur.

Inspecter tous les dispositifs de protection comme les boutons de commande non-métalliques, les isolants, le dos du coffret, les couvercles ou blindages de réglage et de compartiment, les réseaux de résistancecapacité, les isolateurs mécaniques, etc.

S'assurer qu'il n'y ait pas de danger d'électrocution en vérifiant la fuite de courant, de la facon suivante:

•

Brancher le cordon d'alimentation directem-ent à une prise de courant de 120V. (Ne pas utiliser de transformateur d'isolation pour cet essai).

AUX PIECES METALLIQUES EXPOSEES

DVM

ECHELLE CA

1.5k ohm 10W

0.15

SONDE D'ESSAI

BRANCHER A UNE TERRE CONNUE

AVIS POUR LA SECURITE

De nombreuses pièces, électriques et mécaniques, dans les téléviseur ACL présentent des caractéristiques spéciales relatives à la sécurité, qui ne sont souvent pas évidentes à vue. Le degré de protection ne peut pas être nécessairement augmentée en utilisant des pièces de remplacement étalonnées pour haute tension, puissance, etc. Les pièces de remplacement qui présentent ces caractéristiques sont identifiées dans ce manuel; les pièces électriques qui présentent ces particularités sont identifiées par la marque " " et hachurées dans la liste des pièces de remplacement et les diagrammes schématiques.

Pour assurer la protection, ces pièces doivent être identiques à celles utilisées dans le circuit d'origine. L'utilisation de pièces qui n'ont pas les mêmes caractéristiques que les pièces recommandées par l'usine, indiquées dans ce manuel, peut provoquer des électrocutions, incendies, radiations X ou autres accidents.

LC-80LE642U

PRECAUTIONS FOR USING LEAD-FREE SOLDER

Employing lead-free solder

• “PWBs” of this model employs lead-free solder. The LF symbol indicates lead-free solder, and is attached on the PWBs and service manuals. The alphabetical character following LF shows the type of lead-free solder.

Example:

Indicates lead-free solder of tin, silver and copper. Indicates lead-free solder of tin, silver and copper.

Using lead-free wire solder

• When fixing the PWB soldered with the lead-free solder, apply lead-free wire solder. Repairing with conventional lead wire solder may cause damage or accident due to cracks.

As the melting point of lead-free solder (Sn-Ag-Cu) is higher than the lead wire solder by 40 °C, we recommend you to use a dedicated soldering bit, if you are not familiar with how to obtain lead-free wire solder or soldering bit, contact our service station or service branch in your area.

Soldering

• As the melting point of lead-free solder (Sn-Ag-Cu) is about 220 °C which is higher than the conventional lead solder by 40 °C, and as it has poor solder wettability, you may be apt to keep the soldering bit in contact with the PWB for extended period of time. However, Since the land may be peeled off or the maximum heat-resistance temperature of parts may be exceeded, remove the bit from the PWB as soon as you confirm the steady soldering condition.

Lead-free solder contains more tin, and the end of the soldering bit may be easily corroded. Make sure to turn on and off the power of the bit as required.

If a different type of solder stays on the tip of the soldering bit, it is alloyed with lead-free solder. Clean the bit after every use of it.

When the tip of the soldering bit is blackened during use, file it with steel wool or fine sandpaper.

• Be careful when replacing parts with polarity indication on the PWB silk.

Lead-free wire solder for servicing

PARTS CODE

ZHNDAi123250E BL J φ0.3mm 250g (1roll) ZHNDAi126500E BK J φ0.6mm 500g (1roll) ZHNDAi12801KE BM J φ1.0mm 1kg (1roll)

PRICE RANK

PART

DELIVERY

DESCRIPTION

iii

OUTLINE

Service Manual

MAJOR SERVICE PARTS

PWB Unit

Ref NO. PARTS CODE DESCRIPTION

N DKEYMF953FM06 MAIN Unit N DUNTKF975FM18 LCD CONTROL Unit N DUNTKF494FM01 R/C OPC Unit N DUNTKF770FM02 ICON Unit N DUNTKF800FM53 KEY Unit N RUNTKA936WJQZ Wi-Fi Unit N RUNTKB096WJQZ POWER/DRIVE Unit

NOTE: *1 Replace MAIN PWB Unit (DKEYMF953FM06) in case of IC3103 and IC3104 failure.

*2 Replace LCD CONTROL PWB Units (DUNTKF975FM18) in case of IC5803(Flash) failure.

OTHER Unit

Ref NO. PARTS CODE DESCRIPTION

N R1LK800D3GW10Z 80" LCD Panel Module Unit (LK800D3GW10Z)

IC For Exclusive Use Of The Service

LC-80LE642U

Ref No. Parts No. Description Q’ty

IC2004 RH-iXD515WJN7Q IC (Monitor Microprocessor) 1

Service Jigs

Ref No. PARTS CODE DESCRIPTION N

N QCNW-C222WJQZ Connecting Cord L=1000mm 80pins, LCD Control Unit to LCD Panel Unit, x2 2 N QCNW-N560WJPZ CoConnecting Cord L=650mm 41pins, Main to LCD Control Unit (LW) 1 N QCNW-M539WJQZ Connecting Cord L=1200mm 24pins, Power Unit Main Unit (PD) 1

LC-80LE642U

CHAPTER 1. SPECIFICATIONS

[1] SPECIFICATIONS

Service Manual

1 – 1

CHAPTER 2. OPERATION MANUAL

[1] OPERATION MANUAL

LC-80LE642U

Service Manual

2 – 1

LC-80LE642U

2 – 2

LC-80LE642U

2 – 3

LC-80LE642U

2 – 4

CHAPTER 3. DIMENSIONS

[1] DIMENSIONS

LC-80LE642U

Service Manual

3 – 1

LC-80LE642U

CHAPTER 4. REMOVING OF MAJOR PARTS

Service Manual

[1] REMOVING OF MAJOR PARTS

1. Removing of Stand Unit and Rear Cabinet Assy.

1. Remove the 4 lock screws and detach the Stand Unit .

2. Disconnect AC wire and detach the AC cord.

3. Remove the 10 lock screws and 26 lock screws and detach the Rear Cabinet Assy .

䎤䎦䎃䎦䏒䏕䏇

2Stand Unit

[Precautions when mounting and removing the rear cabinet]

If the rear cabinet is removed with the set upright, the speakers may fall; it results in connector disconnection. Therefore, never remove the rear cabinet with the set upright.

Be sure to remove the rear cabinet with the screen side down.

䎾䎤䎦䏀

Rear Cabinet Assy

Tighten together with the Rear Cabinet Assy.

Fix with the 80" LCD Panel Module Unit.

4 – 1

Only one side (outer) can come off.

[How to remove Rear Cabinet Assy]

* Please do following works by 2 persons

Do following works as → → →

1) Please grasp the swelling of a speaker and pull back with pushing down.

Remove one hook under an operation.

LC-80LE642U

2) Put a hand in terminal area and pull it back, and the other hand holds top side of TV set.

Remove all-right hand side hook.

2WVCJCPFDGVYGGPVGTOKPCNCPINGCPF4GCT %CDKPGV#UU[CPFRWNNVJGODCEM

4 – 2

LC-80LE642U

3) Hold left side of TV set by one hand, and put the other hand between bottom cover and Rear Cabinet Assy.

And pull Rear Cabinet Assy.

Remove all-left hand side hook.

4) Two persons stand on the both sides of TV SET, and have a Front Cabinet Assy and a Rear Cabinet Assy by each hand.

Two persons pull a Rear Cabinet Assy horizontally back, simultaneously and remove it.

4 – 3

[Precautions for assembly]

Push

CAUTION

Set it so that there may not be a clearance between Front Cabinet Assy and Rear Cabinet Assy.

LC-80LE642U

There is a gap without the fingernail fitting in completely only when covering with Rear Cabinet Assy.

(Front Cabinet Assy/Rear Cabinet Assy fingernail fixation place)

The fingernail is surely fixed when Rear cabinet Assy is firmly pushed, and the gap disappears.

4 – 4

LC-80LE642U

2. Removing of Speaker (L/R) and KEY Unit.

1. Disconnect the SP wire.

2. Remove the 2 lock screws and detach the Speaker (L) , Speaker (R) .

3. Disconnect the RC wire.

4. Detach the KEY Unit Assy .

5. Disconnect the KM wire.

6. Remove the 2 lock screws and detach the Key Button from Key Button Cover .

7. Detach the KEY Unit from Key Button .

MAIN Unit

KEY Unit Assy

[SP]

KEY Unit

[RC]

[SP]

31Speaker (R) 2

Speaker (L)

[KM]

6 Key Button

[How to remove KEY Unit Assy]

1) When you remove KEY Unit Assy, please be sure to remove harness from WH, and to hold the bottom of KEY Unit Assy.

Key Button Cover

4 – 5

3. Removing of Connectors, 80” LCD Panel Module Unit Assy.

1. Disconnect the following connectors from the MAIN Unit. (LV, PD, UB)

2. Disconnect the following connectors from the POWER/DRIVE Unit. (L1, L2, PD)

3. Disconnect the following connectors from the LCD Control Unit. (PL, LW)

4. Remove the 27 Hooks and detach the 80” LCD Panel Module Unit Assy .

5. Detach the 2 Bottom cover .

Hock

LC-80LE642U

Hock

[L1] [L2]

POWER/DRIVE Unit

[PD]

Hock

[PL]

LCD Control Unit

2Bottom cover

MAIN Unit

[PD]

Hock

1 80" LCD Panel

Module Unit Assy

[LW]

MAIN Unit

[LV]

[UB]

4 – 6

LC-80LE642U

4. Removing of LCD CONTROL Unit, MAIN Unit, POWER/DRIVE Unit.

1. Remove the 2 Connecting Cords , 2 Ferrite Cores , 6 lock screws and detach the LCD CONTROL Unit .

2. Remove the 2 lock screws and detach the Terminal Angle (Side) .

3. Remove the 6 lock screws and detach the MAIN Unit and Terminal Angle (Bottom) .

4. Remove the 6 lock screws and detach the POWER/DRIVE Unit .

5. Remove the 12 lock screws and detach the 2 Stand Angles .

6. Remove the 16 lock screws and detach the 4 VESA Angle Assys .

POWER/ DRIVE Unit

Assy

Stand Angle

15VESA Angle

LCD Control Unit

2 Ferrite

Core

1 FFC

15 VESA Angle Assy

Stand Angle

80" LCD Panel Module Unit

MAIN Unit

Terminal

Angle (Side)

Terminal Angle (Bottom)

4 – 7

5. Removing of R/C OPC Unit, ICON Unit, Wi-Fi Unit.

1. Detach the R/C OPC Unit .

2. Disconnect the RC wire.

3. Detach the ICON Unit .

4. Disconnect the CI wire.

5. Detach the Wi-Fi Unit .

6. Disconnect the UB wire.

7. Detach the Wi-Fi Attachment .

Front Cabinet Assy

LC-80LE642U

Wi-Fi Attachment

[CI]

[UB]

[RA]

3ICON Unit 2 Wi-Fi Unit 1 R/C OPE Unit

4 – 8

LC-80LE642U

[2] The location putting on the heat measure sheet

1. MAIN PWB Unit

PSPAZC871WJKZ MAIN-CPU COOL(B)

4 – 9

LC-80LE642U

[3] Precautions for assembly

1. Points to be checked and precautions when servicing the unit

Mount the main PWB Assy on the backlight chassis and check that the EMI-prevention parts are not peeled and twisted from the access holes. (The EMI-prevention parts, conductive nonwoven fabric gaskets, must be seen from the access holes.)

[Countermeasure]

Attach the conductive nonwoven fabric gaskets on the shielded case on the main PWB.

LANGKD292WJ3W (TERM ANG INFERIOR)

PMLT-A680WJQZ (GASKET MShield ) 190x5x5.5

LANGKD145WJFW TERM ANG SIDE

PMLT-A678WJQZ GASKET

4 – 10

LC-80LE642U

The following is a drawing mounting the main PWB Assy on the backlight chassis. (The parts indicated by -> are the access holes for confirmation.)

(Main PWB Assy => State where the shielded case and RF terminal angle are mounted on the main PWB)

4 – 11

LC-80LE642U

CHAPTER 5. ADJUSTMENT

Service Manual

[1] ADJUSTMENT PROCEDURE

The adjustment values are set to the optimum conditions at the factory before shipping. If a value should become improper or an adjustment is required due to part replacement, make an adjustment according to the following procedure.

1. After replacement of any PWB unit and/or IC for repair, please note the following.

• When replacing the following units, make sure to prepare the new units loaded with updated software.

MAIN Unit: DKEYMF953FM06

• When replacing the LCD control PWB, perform the VCOM adjustment.

2. Upgrading of each microprocessor software

CAUTION: Never “POWER OFF” the unit when software upgrade is ongoing.

Otherwise the system may be damaged beyond recovery.

2.1. Software version upgrade

The model employs the following software.

• Main software (please use a software version after OKLA_LE857_xxx.USB).

• Monitor microprocessor software (please use a software version after OKLAMxxx.SMB.)

The main software, monitor microprocessor software can be upgraded by using a general-purpose USB Memory.

The followings are the procedures for upgrading, explained separately for the main software, monitor microprocessor software.

2.2. Main software version upgrade

2.2.1 Get ready before you start

• USB Memory of 128MB or higher capacity.

• PC running on Windows 98/98SE/ME/2000/XP operating system.

• USB Memory reader/writer or PC with a USB port.

• The file system of a USB memory is FAT. (FAT32 supports)

• Use the USB memory without other functions. (lock and memory reader...etc)

2.2.2 Preparations

To upgrade the main software, it is necessary to get ready the USB Memory for version upgrade before you start.

Follow the steps below and create the USB Memory for version upgrade.

1. Copy the file OKLA_LE857_xxx.USB for version upgrade to the root directory (folder) of the USB Memory.

NOTE: In the USB Memory drive, do not store other folders or unrelated files, or more than one file for version upgrade.

Now the USB Memory for version upgrade is ready.

5 – 1

LC-80LE642U

2.2.3 How to upgrade the software

1. Unplug the AC cord.

2. Insert the USB Memory for version upgrade into the service socket.

3. Plug in the AC cord with power button pressed down.

4. After 5 seconds, unpress the power button.

5. After the unit startup, the system upgrade screen as shown below within 20-40 seconds.

Software Update

MAIN Version

SUB MICOM Version

PANEL EEPROM

3D IR MICOM Version

MAIN

SUB MICOM

PANEL EEPROM

3D IR MICOM

26%

SAME VERSION

NO DATA

103U1301111

㧙㧙㧙㧙㧙

㧙㧙㧙㧙

80LE642U

6. Even a single failure in the process will trigger the upgrade failure screen.

Software Update

MAIN Version

SUB MICOM Version

PANEL EEPROM

3D IR MICOM Version

UPGRADE FAILURE

MAIN

SUB MICOM

PANEL EEPROM

3D IR MICOM

Project ID

NO DATA

㧙㧙㧙㧙㧙

㧙㧙㧙㧙

80LE642U

NOTE: In the event of a failure, repeat the upgrade process. If the process repeatedly fails, it is likely that the hardware need fixing.

7. Upon completion of the whole process, the upgrade success screen as shown below appears. You can check the new software version on this screen. The version information appears after the upgrade is complete.

Software Update

MAIN Version

SUB MICOM Version

PANEL EEPROM

3D IR MICOM Version

UPGRADE SUCCESS

MAIN

SUB MICOM

PANEL EEPROM

3D IR MICOM

100%

SAME VERSION

NO DATA

103U1301111

㧙㧙㧙㧙㧙

㧙㧙㧙㧙

80LE642U

8. Unplug the AC cord and remove the USB Memory for version upgrade.

9. Now the software version upgrade is complete.

NOTE: When you are done with the software version upgrade, start the set, go to the top page of the adjustment process screen and check the main

software version information.

5 – 2

+ 54 hidden pages