42HP16
SERVICE MANUAL
42" DIGITAL PLASMA
COLOR TELEVISION
DOCUMENT CREATED IN JAPAN, July, 2006 GREEN
42HP16
(MFR’S VERSION B)
FILE NO. 050-200622GR
The above model is classified as a green product (*1), as indicated by the underlined serial number.
This Service Manual describes replacement parts for the green product. When repairing this green
product, use the part(s) described in this manual and lead-free solder (*2).
For (*1) and (*2), see the next page.
(*1) GREEN PRODUCT PROCUREMENT
The EC is actively promoting the WEEE & RoHS Directives that define standards for recycling
and reuse of Waste Electrical and Electronic Equipment and for the Restriction of the use of
certain Hazardous Substances. From July 1, 2006, the RoHS Directive will prohibit any
marketing of new products containing the restricted substances.
Increasing attention is given to issues related to the global environmental. Toshiba Corporation
recognizes environmental protection as a key management tasks, and is doing its utmost to
enhance and improve the quality and scope of its environmental activities. In line with this,
Toshiba proactively promotes Green Procurement, and seeks to purchase and use products,
parts and materials that have low environmental impacts.
Green procurement of parts is not only confined to manufacture. The same green parts used in
manufacture must also be used as replacement parts.
(*2) LEAD-FREE SOLDER
This product is manufactured using lead-free solder as a part of a movement within the consumer
products industry at large to be environmentally responsible. Lead-free solder must be used in
the servicing and repair of this product.
WARNING
This product is manufactured using lead free solder .
DO NOT USE LEAD BASED SOLDER TO REPAIR THIS PRODUCT !
The melting temperature of lead-free solder is higher than that of leaded solder by 86°F to 104°F
(30°C to 40°C). Use of a soldering iron designed for lead-based solders to repair product made
with lead-free solder may result in damage to the component and or PCB being soldered. Great
care should be made to ensure high-quality soldering when servicing this product especially
when soldering large components, through-hole pins, and on PCBs as the level of heat
required to melt lead-free solder is high.
A1-1
A1-2
SERVICING NOTICES ON CHECKING
1. KEEP THE NOTICES
As for the places which need special attentions,
they are indicated with the labels or seals on the
cabinet, chassis and parts. Make sure to keep the
indications and notices in the operation manual.
3. USE THE DESIGNATED PARTS
2. AVOID AN ELECTRIC SHOCK
There is a high voltage part inside. Avoid an
electric shock while the electric current is
flowing.
The parts in this equipment have the specific
characters of incombustibility and withstand
voltage for safety. Therefore, the part which is
replaced should be used the part which has
the same character.
Especially as to the important parts for safety
which is indicated in the circuit diagram or the
table of parts as a mark, the designated
parts must be used.
5. PUT PARTS AND WIRES IN THE
ORIGINAL POSITION AFTER
ASSEMBLING OR WIRING
There are parts which use the insulation
material such as a tube or tape for safety, or
which are assembled in the condition that
these do not contact with the printed board.
The inside wiring is designed not to get closer
to the pyrogenic parts and high voltage parts.
Therefore, put these parts in the original
positions.
PERFORM A SAFETY CHECK AFTER
SERVICING
6.
Confirm that the screws, parts and wiring which
were removed in order to service are put in the
original positions, or whether there are the
portions which are deteriorated around the
serviced places serviced or not. Check the
insulation between the antenna terminal or
external metal and the AC cord plug blades.
And be sure the safety of that.
(INSULATION CHECK PROCEDURE)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Unplug the plug from the AC outlet.
Remove the antenna terminal on TV and turn
on the TV.
Insulation resistance between the cord plug
terminals and the eternal exposure metal
[Note 2] should be more than 2.5M ohm by
using the 500V insulation resistance meter
[Note 1].
If the insulation resistance is less than 2.5M
ohm, the inspection repair should be
required.
[Note 1]
If you have not the 500V insulation
resistance meter, use a Tester.
[Note 2]
External exposure metal: Antenna terminal
Screw
21pin jack
Side RCA jack
Rear RCA jack
Headphone jack
4. BE CAREFUL WITH THE PDP PANEL
When you handle the PDP Filter you must
wear the gloves twice, because, you are to
avoid soil it by your sweat and dust.
When you lift the PDP Filter you should hold it
with the palm of your hand.
Don’t pick up it with your fingers.
The back side of PDP Filter tends to damaged.
Since there is no coating.
Therefore, it put into the packing box at the
time of delivery, without piling up even at the
time of unused.
Also, when you take out it from a packing box,
be careful of the rubbing.
When the surface becomes dirty, wipe it with a
soft cloth as you draw a circle.
When it is dirty hardly, wipe it with a cloth
ethanol infiltrated.
Don’t use ethanol for the back side.
Do not apply it to direct sunshine so that the
characteristic may change.
When you inspect the surface (the scratch, the
dirt and the air bubble), use the fluorescent
light.
When you use SCREW DRIVER and SCREW,
be careful of a metallic powder being mixed.
Do not damage the PDP Module with a
DRIVER.
Do Handling with the PDP Module by 2
persons.
There is a step difference between the cover
and PDP Module.
So, when you remove the screws, place a
cushion on it so that the PDP Module is not
being scratched.
Then remove the screws carefully.
11.
12.
13.
14.
When you remove the cover, do not scratch the
FPC on both ends of PDP Module.
Hold the four ends holder and be careful not to
touch the glass area.
Take care for the damage of vacuum exhaust
pipe due to a collision.
Moisture condensation may damage the PDP
Module.
So, leave it for 48 hours at the service room.
1.
2.
3.
4.
A1-3
HOW TO ORDER PARTS
When you exchange IC and Transistor with a heat sink, apply silicon grease (YG6260M) on the contact
section of the heat sink. Before applying new silicon grease, remove all the old silicon grease.
(Old grease may cause damage to the IC and Transistor).
IMPORTANT
PANEL LOCK
Turn Unit ON.
Press and hold the ‘VOLUME DOWN’ key on the front panel for more than 10 seconds.
The Panel Lock has now been cleared.
1.
2.
3.
To unlock the Panel Lock, please follow the steps below.
Please include the following informations when you order parts. (Particularly the VERSION LETTER.)
1. MODEL NUMBER and VERSION LETTER
The MODEL NUMBER can be found on the back of each product and the VERSION LETTER can be
found at the end of the SERIAL NUMBER.
2. PART NO. and DESCRIPTION
You can find it in your SERVICE MANUAL.
TABLE OF CONTENTS
GREEN PRODUCT PROCUREMENT ........................................................................................
LEAD-FREE SOLDER ................................................................................................................
SERVICING NOTICES ON CHECKING.....................................................................................
HOW TO ORDER PARTS ..........................................................................................................
IMPORTANT ...............................................................................................................................
PANEL LOCK..............................................................................................................................
TABLE OF CONTENTS..............................................................................................................
GENERAL SPECIFICATIONS ...................................................................................................
DISASSEMBLY INSTRUCTIONS
1.EXCHANGE METHOD OF PDP MODULE...........................................................................
2. REMOVAL AND INSTALLATION OF FLAT PACKAGE IC..................................................
SERVICE MODE LIST ................................................................................................................
WHEN REPLACING EEPROM (MEMORY) IC ..........................................................................
RE-WRITE FOR DIGITAL SOFT FIRMWARE...........................................................................
FUNCTION OF PCB ....................................................................................................................
ELECTRICAL ADJUSTMENTS..................................................................................................
TROUBLESHOOTING GUIDE ...................................................................................................
BLOCK DIAGRAM
SCALER/LVDS/MICON/ADC/ADC 2/AV SWITCH/REGULATOR .........................................
AV SWITCH/AV SWITCH2/AV JACK/STEREO/SOUND AMP/JACK....................................
TUNER/DIGITAL/POWER.......................................................................................................
INTERFACE.............................................................................................................................
MICON2 ...................................................................................................................................
PRINTED CIRCUIT BOARDS
AV/REMOCON ........................................................................................................................
SCALER...................................................................................................................................
DIGITAL ...................................................................................................................................
SIDE JACK/OPERATION/FILTER ..........................................................................................
SCHEMATIC DIAGRAMS
AV SWITCH2 ...........................................................................................................................
TUNER/OUT JACK..................................................................................................................
AV JACK ..................................................................................................................................
STEREO ..................................................................................................................................
SOUND AMP/HEADPHONE AMP ..........................................................................................
POWER ...................................................................................................................................
AV JACK2 ................................................................................................................................
IR PASS ...................................................................................................................................
TUNER.....................................................................................................................................
MICON .....................................................................................................................................
SCALER...................................................................................................................................
ADC..........................................................................................................................................
ADC2........................................................................................................................................
LVDS........................................................................................................................................
JACK ........................................................................................................................................
AV SWITCH .............................................................................................................................
REGULATOR...........................................................................................................................
INTERFACE_HDMI IC ............................................................................................................
HDMI MICON2.........................................................................................................................
ASIC.........................................................................................................................................
SDRAM ....................................................................................................................................
FLASH .....................................................................................................................................
FRONT END ............................................................................................................................
AV OUT....................................................................................................................................
POWER2 .................................................................................................................................
OPERATION/SIDE JACK/FILTER ..........................................................................................
WAVEFORMS .............................................................................................................................
MECHANICAL EXPLODED VIEWS...........................................................................................
MECHANICAL REPLACEMENT PARTS LIST .........................................................................
ELECTRICAL REPLACEMENT PARTS LIST...........................................................................
A1-1
A1-1
A1-2
A1-3
A1-3
A1-3
A2-1
A3-1~A3-5
B1-1~B1-8
B2-1, B2-2
C-1
C-2
C-3
C-4
D-1~D-5
E-1~E-7
F-1, F-2
F-3, F-4
F-5, F-6
F-7, F-8
F-9, F-10
G-1~G-4
G-5~G-8
G-9, G-10
G-11, G-12
H-1, H-2
H-3, H-4
H-5, H-6
H-7, H-8
H-9, H-10
H-11, H-12
H-13, H-14
H-15, H-16
H-17, H-18
H-19, H-20
H-21, H-22
H-23, H-24
H-25, H-26
H-27, H-28
H-29, H-30
H-31, H-32
H-33, H-34
H-35, H-36
H-37, H-38
H-39, H-40
H-41, H-42
H-43, H-44
H-45, H-46
H-47, H-48
H-49, H-50
H-51, H-52
I-1~I-3
J-1~J-3
K1-1~K1-3
K2-1~K2-8
A2-1
GENERAL SPECIFICATIONS
G-1 TV PDP PDP Size / Visual Size 42.32 inch / 1074.9 mmV
System Number of Pixels(H x V) 1024(H) x 768(V)
Color System NTSC
Speaker 4 Speaker
Position Front
Main Size 2.2 x 5.0 inch
Impedance 4 ohm
Tweeter Size 2.0 inch
Impedance 8 ohm
Sound Output MAX 10W + 10W
10%(Typical) ---
G-2 Tuning Broadcasting System Analog
System Digital ATSC(8VSB)/QAM
Tuner and System 1Tuner
Receive CH Destination USA(W/ CABLE)
CH Coverage 2 - 69, 4A, A-5 - A-1,
A - I, J - W, W+1 - W+84
Intermediate Digital 44.00MHz
Frequency Analog Picture(FP) 45.75MHz
Sound(FS) 41.25MHz
FP-FS 4.50MHz
Preset CH
No
Stereo/Dual TV Sound US-Stereo
Tuner Sound Muting Yes
G-3 Signal Video Signal Input Level 1 V p-p/75 ohm
Output Level 1 V p-p/75 ohm
S/N Ratio (Weighted) --
Horizontal Resolution at DVD Mode --
--
RGB Signal Output Level --
Audio Signal Input Level -8.0dBm/50k ohm
Output Level at DVD --
at TV -8 dBm/1k ohm (0dBm=0.775Vrms)
0-600mV /1k ohm (Variable out mode)
Digital Output Level 0.5 V p-p/75 ohm
S/N Ratio at DVD (Weighted) --
Harmonic Distortion 0.02% (1KHz)
Frequency Response : at DVD --
at Video CD --
at SVCD --
at CD --
G-4 Power Power Source AC 120V AC 60Hz
DC ---
Power Consumption at AC 360 W at AC 120 V 60 Hz
at DC --
Stand by (at AC) 1 W at AC 120 V 60 Hz
Per Year -- kWh/Year
Energy Star Yes
Protector Power Fuse Yes
Safety Circuit Yes
IC Protector(Micro Fuse) No
G-5 Regulation Safety UL
Radiation FCC
X-Radiation ---
G-6 Temperature Operation +/-0oC ~ +40oC
Storage -20oC ~ +60oC
G-7 Operating Humidity Less than 80% RH
G-8 Clock and Clock Yes
Timer Sleep Timer Max Time 120 Min
Step 10 Min
On Timer Program Yes
Off Timer Program No
Game Timer
Yes
Wake Up Timer No
Timer Back-up (at Power Off Mode) more than -- Min Sec
US System M
A3-1
GENERAL SPECIFICATIONS
G-9 Remote Unit RC-KK
Control Glow in Dark Remocon Yes
Remocon Format TOSHIBA
Format TOSHIBA
Custom Code
40-BF h
Power Source Voltage(D.C) 3V
UM size x pcs UM-4 x 2 pcs
Total Keys
Keys
Power
Yes
Input
Yes
Display
Yes
Mute
Yes
1
Yes
2
Yes
3
Yes
4
Yes
5
Yes
6
Yes
7
Yes
8
Yes
9
Yes
0
Yes
100 / +10
Yes
CH Return / Ent
Yes
CH +
Yes
CH -
Yes
VOL +
Yes
VOL -
Yes
SLEEP
Yes
Picture Size
Yes
UP
Yes
LEFT / FAV -
Yes
MENU/ENTER/DVD MENU
Yes
RIGHT / FAV +
Yes
DOWN
Yes
EXIT
Yes
Multi Brand Keys
TV
Yes
CBL/SAT
Yes
VCR
Yes
DVD
Yes
ENTER
Yes
PAUSE
Yes
PLAY
Yes
STOP
Yes
REW
Yes
FF
Yes
SKIP/SEARCH|<<
Yes
SKIP/SEARCH>>|
Yes
TOP MENU
Yes
REC
Yes
CLEAR
Yes
TV/VCR
Yes
44
A3-2
GENERAL SPECIFICATIONS
G-10 Features Auto Shut Off Yes
Power On Memory Yes
Auto Search No
DNR Yes
3D
Comb Filter Yes
3D
Just Clock Function No
Game Position No
Auto Setup(Language/CH Program) Yes
Picture Setting(TV) Yes
Mode(Picture Preference) Yes
Brightness , Contrast , Color Yes
Tint Yes
Sharpness Yes
Color Temperature Yes
Cable Clear Yes
Picture Setting(PC) Yes
BRIGHTNESS , CONTRAST Yes
HOR POSITION , VER POSITION Yes
PHASE , CLOCK Yes
AUTO ADJUST No
RED , GREEN , BLUE Yes
Audio MTS Yes
Tone Control (Bass/Treble/Balance) Yes
Stable Sound Yes
Surround No
BBE No
SRS WOW (SRS 3D/Focus/Tru Bass) Yes
Valiable Audio Out Yes
Tuning CH Program Yes
TV/Cable Yes
ADD/ERASE Yes
Screen Saver Inversion(Reverse) Yes
Full White(White) Yes
Screen Saver(Picture Shift) Yes
Side Panel Color Yes
Label CH Label Yes
Video Label Yes
Favorite CH Yes
V-Chip
Yes
RRT Setup
Yes
Lock Hotel Lock No
Channel Lock Yes
Video Lock Yes
Panel Lock Yes
OSD Language
Closed Caption
Yes
CC Advanced
Yes
Picture Size Yes
Picture Scroll Yes
Aspect Yes
Backlight No
PFC(Power Factor circuit) Yes
Freeze frame No
PIP/POP No
Digital Out Dolby Digital Yes
MPEG No
PCM Yes
DTS No
PC Monitor Input Yes
VGA (640x480) Yes (60Hz)
VGA (720x400) No
WVGA (848x480) Yes (60Hz)
SVGA (800x600) Yes (60Hz)
XGA (1024x768) Yes (60Hz)
WXGA (1280x768) Yes (60Hz)
WXGA (1280x720) Yes (60Hz)
WXGA (1360x768) Yes (60Hz)
SXGA (1280x1024) No
English French Spanish
A3-3
GENERAL SPECIFICATIONS
HDMI Input Yes
VGA (640x480) Yes (60Hz)
720x480i (4:3) Yes (60Hz)
720x480i (16:9) Yes (60Hz)
720x480p (4:3) Yes (60Hz)
720x480p (16:9) Yes (60Hz)
720x576i (4:3) No
720x576i (16:9) No
720x576p (4:3) No
720x576p (16:9) No
1280x720p Yes (60Hz)
1920x1080i Yes (60Hz)
Component Input Yes
720x480i (4:3) Yes (60Hz)
720x480i (16:9) Yes (60Hz)
720x480p (4:3) Yes (60Hz)
720x480p (16:9) Yes (60Hz)
720x576i (4:3) No
720x576i (16:9) No
720x576p (4:3) No
720x576p (16:9) No
1280x720p Yes (60Hz)
1920x1080i Yes (60Hz)
G-11 Accessories Owner's Manual Language English
w/Guarantee Card Yes
Remote Control Unit Yes
Rod Antenna
No
Poles -
Terminal -
Loop Antenna (W/ Antenna Change Plug)
No
Terminal -
U/V Mixer
No
DC Car Cord (Center+)
No
Guarantee Card
No
Warning Sheet
No
Circuit Diagram
No
Antenna Change Plug
No
Service Facility List
No
Important Safeguard
No
Dew/AHC Caution Sheet
No
Quick Set-up Sheet Yes
Battery Yes
UM size x pcs UM-4 x 2 pcs
OEM Brand No
AC Adapter
No
AC Cord (for AC Adapter)
No
AC Cord Yes
AV Cord (2Pin-1Pin)
No
HDMI-DVI Cable
No
Registration Card Yes
300 ohm to 75 ohm Antenna Adapter
No
Information Sheet Yes
Information Sheet(for IMPORTANT NOTICE) Yes
Information Sheet(for PICTURE SHIFT) Yes
A3-4
GENERAL SPECIFICATIONS
G-12 Interface Switch Side Power (Tact) Yes
System Select No
Main Power SW No
Channel Up/Menu Up Yes
Channel Down/Menu Down Yes
Volume Up/Menu > Yes
Volume Down/Menu < Yes
Input Select Yes
Menu No
Main Power SW No
Indicator Power / Stand-by Yes(GREEN / RED)
On Timer No
Terminals Rear Video Input 1 RCA x 1
Audio Input
RCA x 2(L/MONO, R)
S- Input
Yes
Video Input 2 RCA x 1
Audio Input
RCA x 2(L/MONO, R)
S- Input
Yes
Video Output RCA x 1
Audio Output RCA x 2(Variable L, R)
Component In 1
RCA x 3
Audio Input (Component In use)
RCA x 2(L/MONO, R)
Component In 2
RCA x 3
Audio Input (Component In use)
RCA x 2(L/MONO, R)
Other Terminal No
Euro Scart (21Pin) No
PC Monitor Input (D-Sub)
Yes
Audio Input
RCA x 2(L/MONO, R)
HDMI Input 1
Yes
Audio Input(DVI 1) PC Monitor Audio Input Alternative
HDMI Input 2
Yes
Audio Input(DVI 2) Mini Pin Jack(d:3.5), STEREO
Sub Woofer Out No
Diversity No
Digital Audio Out (Coaxial)
Yes
Digital Audio Out (Optical)
Yes
IR Pass Through
Yes
Ext Speaker No
DC Jack 12V(Center +) No
VHF/UHF Antenna Input(Digital/Analog)
F Type
AC Inlet
Yes
Side Video Input 3 RCA x 1
Audio Input RCA x2(L/MONO,R)
S- Input
Yes
Other Terminal No
G-13 Set Size Approx. W x D x H (mm) 1,070 x 350 x 779.5
G-14 Weight Net Approx. 38.4kg (84.7 lbs)
Gross Approx. 45.4kg (100.1 lbs)
G-15 Carton Master Carton
No
Content --- Sets
Material --- / ---
Dimensions W x D x H(mm) ---
Description of Origin ---
Gift Box Material Double/Brown
Dimensions W x D x H(mm) 1,180 x 440 x 895
Design As per Buyer's
Description of Origin Yes
Drop Test
Natural Dropping At 1 Corner / 2 Edges
/ 4 Surfaces
Height (cm) 50(ORION SPEC:31)
Container Stuffing 100
Sets/40' container
G-16 Material Cabinet Cabinet Front ABS 94V0 Non-DECABROM
Cabinet Rear Steel
PCB Non-Halogen
No
Eyelet Yes
G-17 Environment Environmental standard requirement Green procurement of TOSHIBA
Pb-free Phase3(Phase3A)
A3-5
B1-1
DISASSEMBLY INSTRUCTIONS
1. EXCHANGE METHOD OF PDP MODULE
1.
NOTE
Do handling with the PDP Module by 2 persons.
REMOVAL METHOD OF PDP MODULE
Remove the screw.
Remove the Cabinet Back and Cover Back.
1-1: CABINET BACK/COVER BACK
1-2: STAND ASS'Y
1.
2.
Spread a sheet on the plane table and place the PDP Module carefully with the panel face down.
Remove the screw.
Remove the Stand Ass'y.
1.
2.
3.
Stand Ass'y
Cover Back
Cabinet Back
B1-2
DISASSEMBLY INSTRUCTIONS
Disconnect the connector.
Remove the screw.
Remove the Chassis Ass'y.
1-3: CHASSIS BLOCK
1.
2.
3.
Remove the screw.
Remove the Side Jack.
Hold the Frame Main carefully and remove the PDP Module.
1-4: PDP MODULE
1.
2.
3.
1.
NOTE
When removing the PDP Module, raise the cushion carefully so that you do not scratch the face.
Chassis Ass'y
PDP Module
Frame Main
Frame Main
Side Jack
Raise the cushion.
B1-3
DISASSEMBLY INSTRUCTIONS
Remove the screw.
Remove the Shield Main.
Remove the PDP Filter.
1-5: PDP FILTER
1.
2.
3.
Shield Main Top
Shield Main L
Shield Main R
Shield Main Bottom
PDP Filter
B1-4
DISASSEMBLY INSTRUCTIONS
INSTALLATION METHOD OF PDP MODULE
1.
2.
3.
4.
5.
6.
When you handle the PDP Filter, you must wear gloves to avoid soiling it with sweat and dust.
When you lift the PDP Filter, use the palm of your hand. Don’t pick it up with your fingers.
The back side of the PDP Filter tends to get damaged, since there is no coating. Therefore, it needs to be put into the
packing box at the time of delivery, even if it is not being used at the time. Also, when you take it out of the packing box, be
careful not to rub the appearance.
When the surface becomes dirty, use a cloth which is soft and dust free and wipe it in a circular motion.
When very dirty, lightly use alcohol on the cloth to wipe. Do not use alcohol for the back side.
Do not apply it to direct sunlight, the characteristics may change.
When you inspect for scratches and dirt, use a light to check for air bubbles on the PDP Filter surface.
NOTES FOR NEW PDP FILTER HANDLING
1-6: PDP FILTER (PREPARATION)
Fix the cushion. (Order the cushion new.)1.
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Rear side (No coating)
Cushion
Cushion
Cushion
Cushion
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3mm
3mm
Apply the cushion on
the light brown paint
with 3mm on both
sides of the cushion.
[4 ends common]
B1-5
DISASSEMBLY INSTRUCTIONS
Handle the PDP Module with 2 people.
There is a step difference between the cover and the PDP Module, so when you remove the screws, place a cushion on it
to keep the PDP Module from being scratched. Then remove the screws carefully.
When you remove the cover, do not scratch the FPC on both ends of PDP Module.
Hold all four ends of the holder and be careful not to touch the glass area.
Be careful not to damage the vacuum exhaust pipe.
Moisture condensation may damage the PDP Module, so leave it in the service room for 48 hours.
Reuse the cover, vinyl sheet and screws when returning the PDP Module.
1.
2.
3.
4.
5.
6.
7.
NOTES FOR NEW PDP MODULE HANDLING
Vacuum Exhaust Pipe
FPC
B1-6
DISASSEMBLY INSTRUCTIONS
Remove the fixing screw of Power PCB. Then fix the Wiring Clip. (Use the clips on defective PDP Module)
Fix the Cord Clip. (Use the clips on defective PDP Module)
Fix the Wiring Clip. (Use the clips on defective PDP Module)
1-7: PDP MODULE (PREPARATION)
1.
2.
3.
Wiring Clip
Cord Clip
45˚
Cord Clip
Set SW501 (24V)
B1-7
DISASSEMBLY INSTRUCTIONS
Assemble the Frame Main. (Use the clips on defective PDP Module)
Install the PDP Filter on the set.
Install the Shield Main on the set.
Hold the Frame Main carefully and install the New PDP Module on the set.
Install the Side Jack on the set.
1-8: PDP MODULE
1.
2.
3.
4.
5.
[4 ends common]
Pile up the cushion.
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Cushion
Do not smash the cusion. (For all 2 positions)
[NG]
B1-8
DISASSEMBLY INSTRUCTIONS
Do the wire fixing as shown in the photo, then install the Chassis Ass'y.
Install the Stand Ass'y.
1-9: CHASSIS BLOCK
1.
2.
1.
2.
3.
4.
Check if the wire handlings are correct.
Check if the cushion positions are correct.
Check if the tape positions are correct.
Install the Cabinet Back and Cover Back.
1-10: CABINET BACK/COVER BACK
Band Cord Clamp
Sheet Earth Mark
Earth wire of AC Inlet.
Band Cord Clamp
Earth wire
B2-1
Masking Tape
(Cotton Tape)
DISASSEMBLY INSTRUCTIONS
2.
REMOVAL
IC
Put Masking Tape (cotton tape) around the Flat Package
IC to protect other parts from any damage.
(Refer to Fig. 2-1.)
1.
Fig. 2-1
NOTE
REMOVAL AND INSTALLATION OF
FLAT PACKAGE IC
Some ICs on the PCB are affixed with glue, so be
careful not to break or damage the foil of each IC leads
or solder lands under the IC when removing it.
NOTE
Masking is carried out on all the parts located within 10
mm distance from IC leads.
Blower type IC
desoldering machine
IC
Heat the IC leads using a blower type IC desoldering
machine. (Refer to Fig. 2-2.)
2.
Fig. 2-2
NOTE
Do not rotate or move the IC back and forth , until IC
can move back and forth easily after desoldering the
leads completely.
When IC starts moving back and forth easily after
desoldering completely, pickup the corner of the IC using a
tweezers and remove the IC by moving with the IC
desoldering machine. (Refer to Fig. 2-3.)
3.
Blower type IC
desoldering
machine
IC
Fig. 2-3
Tweezers
Peel off the Masking Tape.4.
Absorb the solder left on the pattern using the Braided
Shield Wire. (Refer to Fig. 2-4.)
5.
NOTE
Do not move the Braided Shield Wire in the vertical
direction towards the IC pattern.
Braided Shield Wire
Soldering Iron
Fig. 2-4
IC pattern
B2-2
DISASSEMBLY INSTRUCTIONS
Supply soldering
from upper position
to lower position
IC
Supply the solder from the upper position of IC leads
sliding to the lower position of the IC leads.
(Refer to Fig. 2-6.)
2.
Fig. 2-6
Soldering IronSolder
IC
Absorb the solder left on the lead using the Braided Shield
Wire. (Refer to Fig. 2-7.)
3.
Fig. 2-7
Soldering Iron
Braided Shield Wire
NOTE
Do not absorb the solder to excess.
IC
When bridge-soldering between terminals and/or the
soldering amount are not enough, resolder using a Thin-tip
Soldering Iron. (Refer to Fig. 2-8.)
4.
Fig. 2-8
Thin-tip Soldering Iron
NOTE
When the IC leads are bent during soldering and/or
repairing, do not repair the bending of leads. If the
bending of leads are repaired, the pattern may be
damaged. So, always be sure to replace the IC in this
case.
Finally, confirm the soldering status on four sides of the IC
using a magnifying glass.
Confirm that no abnormality is found on the soldering
position and installation position of the parts around the IC.
If some abnormality is found, correct by resoldering.
5.
Solder temporarily
Soldering Iron
INSTALLATION
Take care of the polarity of new IC and then install the new
IC fitting on the printed circuit pattern. Then solder each
lead on the diagonal positions of IC temporarily.
(Refer to Fig. 2-5.)
1.
Fig. 2-5
Solder temporarily
C-1
SERVICE MODE LIST
This unit is provided with the following SERVICE MODES so you can repair, examine and adjust easily.
To enter to the SERVICE MODE function, press and hold both buttons simultaneously on the main unit and on the remote
control for more than the standard time in the appropriate condition. (See below chart.)
Releasing of V-CHIP PASSWORD.
Initialization of factory TV data.
NOTE:
If you set factory initialization, the memories are reset
such as the channel setting, and the POWER ON total
hours.
Can be checked of the INITIAL DATA of MEMORY IC.
Refer to the "WHEN REPLACING EEPROM (MEMORY) IC".
Set Key Operations
VOL. DOWN
(Minimum)
Remocon
Key
0 2 sec.
VOL. DOWN
(Minimum)
1 2 sec.
Standard
Time
VOL. DOWN
(Minimum)
6 2 sec.
VOL. DOWN
(Minimum)
9 2 sec.
Set
Condition
TV mode
TV mode
ALL mode
TV mode
Display of the Adjustment MENU on the screen.
Refer to the "ELECTRICAL ADJUSTMENT" (On-Screen Display
Adjustment).
VOL. DOWN
(Minimum)
8
ALL mode
Check of the SUM DATA, POWER ON total hours, MICON
VERSION and DIGITAL TV MICON FIRMWARE on the screen.
Refer to the "WHEN REPLACING EEPROM (MEMORY) IC".
2 sec.
C-2
CONFIRMATION OF CHECK SUM, POWER ON TOTAL HOURS, MICON VERSION AND
DIGITAL TV MICON FIRMWARE
Initial total of MEMORY IC, POWER ON total hours, MICON VERSION and Digital TV MICON Firmware can be checked on
the screen. Total hours are displayed in 16 system of notation.
NOTE:
1.
2.
3.
4.
Turn on the POWER, and set to the TV mode.
Set the VOLUME to minimum.
Press both VOL. DOWN button on the set and Channel
button (8) on the remote control for more than 2 seconds.
After the confirmation of each check sum, POWER ON
total hours, MICON VERSION and Digital TV MICON
Firmware, turn off the power.
*1 DVP1 is different according to each set.
WHEN REPLACING EEPROM (MEMORY) IC
If you set a factory initialization, the total hours is reset to "0".
Please refer to "CONFIRMATION OF INITIAL DATA" when SUM DATA is not corresponding.
4.
5.
6.
7.
8.
9.
10.
11.
12.
The unit will now have the correct DATA for the new MEMORY IC.
ADDRESS is now selected and should "blink". Using the UP/DOWN buton on the remote, step through the ADDRESS
until required ADDRESS to be changed is reached.
Press RIGHT/LEFT button to select DATA. When DATA is selected, it will "blink".
Again, step through the DATA using UP/DOWN button until required DATA value has been selected.
Pressing RIGHT/LEFT button will take you back to ADDRESS for further selection if necessary.
Repeat steps 4 to 6 until all data has been checked.
When satisfied correct DATA has been entered, turn POWER off (return to STANDBY MODE) to finish DATA input.
After the data input, set to the initializing of shipping.
Turn POWER on.
Press both VOL. DOWN button on the set and Channel button (1) on the remote control for more than 2 seconds.
After the finishing of the initializing of shipping, the unit will turn off automatically.
FIG. 2
If a service repair is undertaken where it has been required to change the MEMORY IC, the following steps should be taken to
ensure correct data settings while making reference to INITIAL SETTING TABLE (Attached "INITIAL DATA").
1.
2.
3.
Turn on the POWER, and set to the TV mode.
Set the VOLUME to minimum.
Press both VOL. DOWN button on the set and Channel button (6) on the remote control for more than 2 seconds.
ADDRESS and DATA should appear as FIG 2.
CONFIRMATION OF INITIAL DATA
INIT : 618D
VOLUME : 2E25
ROM : 5D80
ADC : BFDE
DVP1 : EF2A *1
DVP2 : D172
PICENH : 5626
PDP ON :0001
OEC7147B_007
Initial setting data check sum.
POWER ON total hours.
= (16 x 16 x 16 x thousands digit value)
+ (16 x 16 x hundreds digit value)
+ (16 x tens digit value)
+ (ones digit value)
MICON Version
Rom correction data check sum.
AD CONVERTER data check sum.
SCALER data check sum.
INIT 0001 B4
PDP ON 0001
OEC7147B_007
DTV d-l63131
INIT :0000
ROM : 0000
VOLUME : 2E25
ADDRESS DATA
VOLUME CURVE data check sum.
DV1000 data check sum.
FIG. 1
C-3
SET (REAR)
RE-WRITE FOR DIGITAL SOFT FIRMWARE
Ref. No.
Part No. Parts Name
Remarks
JG176
Up-Date of the Firmware
APJG176095
JG176
USA HD DTV ROM
DISC
NOTE:
USA HD DTV ROM
DISC
The operating manual for Re-writing is included in USA HD DTV ROM DISC (JG176).
Prepare the following tools for Up-Date of the Firmware.
1 Computer of WINDOWS2000
2 USB Flash Memory (Use only SanDisk Cruzer Mini USB Flash Drive 256Mb)
USB CONNECTOR
Y SUS
TDRV TOP
YDRV BOT
42 SANKEN PSU
POWER
Z SUS
XRLT
CTRL
42 SANKEN PSU :
Y SUS :
Z SUS :
CTRL :
XRLT :
XRRT :
TDRV TOP :
TDRV BOT :
FUNCTION OF PCB
C-4
A supplier which supplies voltage and current to each PCB and Panel.
According to the timing provided from Panel Control, switches FETs and
generates driving waveform signal which is provided to Y electrode through
Scan Driver IC of TDRV TOP and TDRV BOT.
According to the timing provided from Panel Control, switches FETs and
generates driving waveform signal which is provided to Z electrode through
Connector.
Controls Y electrode, Z electrode, and ADDRESS electrode.
Generates Address electrode and supplies to Address electrode by Driver IC.
Generates Address electrode and supplies to Address electrode by Driver IC.
Generates Scan electrode and supplies to Y electrode by Driver IC.
Generates Scan electrode and supplies to Y electrode by Driver IC.
XRRT
ELECTRICAL ADJUSTMENTS
D-1
1. ADJUSTMENT PROCEDURE
Read and perform these adjustments when repairing the
circuits or replacing electrical parts or PCB assemblies.
CAUTION
On-Screen Display Adjustment
1.
2.
Set the VOLUME to minimum.
Press the VOL. DOWN button on the set and the
channel button (9) on the remote control for more than
2 seconds to display adjustment mode on the screen as
shown in Fig. 2-1.
Fig. 2-1
3.
4.
5.
Use the Channel UP/DOWN button or Channel button
(0-9) on the remote control to select the options shown
in Fig. 2-2.
Press the MENU button on the remote control to end
the adjustments.
To display the adjustment screen for AV, YUV, HDMI
and PC mode, press the INPUT button on the remote
control to set to the AV, YUV, HDMI and PC mode.
Press the VOL.DOWN button on the set and the
channel (9) on the remote control for more than 2
seconds.
FUNCTION
H POSI OSD
V POSI OSD
R DRIVE (N)
R CUT OFF (N)
G DRIVE (N)
G CUT OFF (N)
B DRIVE (N)
B CUT OFF (N)
R DRIVE (C)
R CUT OFF (C)
G DRIVE (C)
G CUT OFF (C)
B DRIVE (C)
B CUT OFF (C)
R DRIVE (W)
R CUT OFF (W)
G DRIVE (W)
G CUT OFF (W)
NO.
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
•
•
•
Use an isolation transformer when performing any
service on this chassis.
When removing a PCB or related component, after
unfastening or changing a wire, be sure to put the wire
back in its original position.
When you exchange IC and Transistor with a heat sink,
apply silicon grease on the contact section of the heat
sink. Before applying new silicon grease, remove all the
old silicon grease. (Old grease may cause damage to the
IC and Transistor).
2. BASIC ADJUSTMENTS
NO.
19
20
22
24
28
29
30
31
35
36
37
38
39
40
FUNCTION
B DRIVE (W)
B CUT OFF (W)
H POSI 60Hz
V POSI 60Hz
BRIGHT CENT
BRIGHT MAX
BRIGHT MIN
TINT
CONTRAST CENTER
CONTRAST MAX
CONTRAST MIN
COLOR CENT
COLOR MAX
COLOR MIN
Prepare the following measurement tools for electrical
adjustments.
1. Pattern Generator
Fig. 2-2
2-1: CONTRAST MAX
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Receive the monoscope pattern. (VIDEO Input)
Press the INPUT button on the remote control to set to the
AV mode.
Activate the adjustment mode display of Fig. 2-1 and press
the channel button (36) on the remote control to select
"CONTRAST MAX".
Press the VOL UP/DOWN button on the remote control
until the contrast step No. becomes "155".
Check if the picture is normal.
Receive the monoscope pattern. (RF Input)
Press the INPUT button on the remote control to set to the
TV mode.
Activate the adjustment mode display of Fig. 2-1 and press
the channel button (36) on the remote control to select
"CONTRAST MAX".
Press the VOL UP/DOWN button on the remote control
until the contrast step No. becomes "145".
Check if the picture is normal.
Receive the digital broadcast. (RF Input)
Perform the above adjustments 3 and 5.
Playback the DVD(480i) disc. (COMPONENT Input)
Press the INPUT button on the remote control to set to the
YUV mode.
Activate the adjustment mode display of Fig. 2-1 and press
the channel button (36) on the remote control to select
"CONTRAST MAX".
Press the VOL UP/DOWN button on the remote control
until the contrast step No. becomes "162".
Check if the picture is normal.
Playback the DVD(480i) disc. (HDMI Input)
Press the INPUT button on the remote control to set to the
HDMI mode.
Activate the adjustment mode display of Fig. 2-1 and press
the channel button (36) on the remote control to select
"CONTRAST MAX".
Press the VOL UP/DOWN button on the remote control
until the contrast step No. becomes "130".
Check if the picture is normal.
TV
01 H POSI OSD
AUTO
180
ELECTRICAL ADJUSTMENTS
D-2
2-2: WHITE BALANCE
1.
2.
3.
4.
5.
6.
7.
8.
Place the set in Aging Test for more than 15 minutes.
Receive the gray scale pattern from the Pattern
Generator.
Press the INPUT button on the remote control to set to
the AV mode.
Using the remote control, set the brightness and contrast
to normal position.
Activate the adjustment mode display of Fig. 2-1 and
press the channel button (03) on the remote control to
select “R DRIVE (N)”.
Press the CH. UP/DOWN button on the remote control to
select the “R CUTOFF (N)”, “B.DRIVE(N)”, “B CUTOFF
(N)”, “R DRIVE (C)”, “R CUTOFF (C)”, “B.DRIVE(C)”, “B
CUTOFF (C)”, “R DRIVE (W)”, “R CUTOFF (W)”,
“B.DRIVE(W)” or “B CUTOFF (W)”.
Adjust the VOL. UP/DOWN button on the remote control
to whiten the R CUTOFF (N), B.DRIVE(N), B CUTOFF
(N), R DRIVE (C), R CUTOFF (C), B.DRIVE(C), B
CUTOFF (C), R DRIVE (W), R CUTOFF (W),
B.DRIVE(W) and B CUTOFF (W) at each step tone
sections equally.
Perform the above adjustments 6 and 7 until the white
color is looked like a white.
2-3: BRIGHT CENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Receive the monoscope pattern. (VIDEO Input)
Press the INPUT button on the remote control to set to
the AV mode.
Set the screen mode to FULL.
Using the remote control, set the brightness and contrast
to normal position.
Activate the adjustment mode display of Fig. 2-1 and
press the channel button (28) on the remote control to
select "BRIGHT CENT".
Press the VOL. UP/DOWN button on the remote control
until the white 8.1% is starting to be visible.
Receive the monoscope pattern. (RF Input)
Press the INPUT button on the remote control to set to
the TV mode. Then perform the above adjustments 4~6.
Receive the digital broadcast. (RF Input)
Perform the above adjustments 4~6.
Playback the DVD(480i) disc. (COMPONENT Input)
Press the INPUT button on the remote control to set to
the YUV mode. Then perform the above adjustments
4~6.
Playback the DVD(480i) disc. (HDMI Input)
Press the INPUT button on the remote control to set to
the HDMI mode. Then perform the above adjustments
4~6.
2-4: Confirmation of Fixed Value (Step No.)
Please check if the fixed values of each the adjustment items are set correctly referring below. (TV/AV/YUV/HDMI/PC/DTV)
VGA SVGA XGA WVGA WXGA
480i 480p 720p 1080i 480i 480p 720p 1080i 60*480 800*600 1024*768 1280*768 1280*720 848*480 1360*768
NO. FUNCTION
1 H POSI OSD 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180
2 V POSI OSD 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80
3 R DRIVE (N) 133 133 133 133 133 133 133 133 133 133 120 120 120 120 120 120 120 133
4 R CUT OFF (N) 129 129 129 129 129 129 129 129 129 129 ... ... ... ... ... ... ... 129
5 G DRIVE (N) 128 128 128 128 128 128 128 128 128 128 122 122 122 122 122 122 122 128
6 G CUT OFF (N) 128 128 128 128 128 128 128 128 128 128 ... ... ... ... ... ... ... 128
7 B DRIVE (N) 116 116 116 116 116 116 116 116 116 116 128 128 128 128 128 128 128 116
8 B CUT OFF (N) 135 135 135 135 135 135 135 135 135 135 ... ... ... ... ... ... ... 135
9 R DRIVE (C) 123 123 123 123 123 123 123 123 123 123 ... ... ... ... ... ... ... 123
10 R CUT OFF (C) 130 130 130 130 130 130 130 130 130 130 ... ... ... ... ... ... ... 130
11 G DRIVE (C) 128 128 128 128 128 128 128 128 128 128 ... ... ... ... ... ... ... 128
12 G CUT OFF (C) 128 128 128 128 128 128 128 128 128 128 ... ... ... ... ... ... ... 128
13 B DRIVE (C) 124 124 124 124 124 124 124 124 124 124 ... ... ... ... ... ... ... 124
14 B CUT OFF (C) 134 134 134 134 134 134 134 134 134 134 ... ... ... ... ... ... ... 134
15 R DRIVE (W) 135 135 135 135 135 135 135 135 135 135 ... ... ... ... ... ... ... 135
16 R CUT OFF (W) 129 129 129 129 129 129 129 129 129 129 ... ... ... ... ... ... ... 129
17 G DRIVE (W) 128 128 128 128 128 128 128 128 128 128 ... ... ... ... ... ... ... 128
18 G CUT OFF (W) 128 128 128 128 128 128 128 128 128 128 ... ... ... ... ... ... ... 128
19 B DRIVE (W) 107 107 107 107 107 107 107 107 107 107 ... ... ... ... ... ... ... 107
20 B CUT OFF (W) 137 137 137 137 137 137 137 137 137 137 ... ... ... ... ... ... ... 137
22 H POSI 60Hz 282 282 282 142 312 260 278 140 268 218 47 214 158 190 189 110 365 294
24 V POSI 60Hz 24 24 24 24 24 24 24 24 24 24 22 22 22 20 20 22 20 24
28 BRIGHT CENT 107 107 107 115 115 115 95 95 95 95 50 50 50 50 50 50 50 115
29 BRIGHT MAX 185 185 185 185 185 185 185 185 185 185 100 100 100 100 100 100 100 185
30 BRIGHT MIN 60 60 60 60 60 60 60 60 60 60 30 30 30 30 30 30 30 60
31 TINT 117 121 121 126 126 126 123 123 123 123 ... ... ... ... ... ... ... 137
35 CONTRAST CENTER 128 128 128 128 128 128 128 128 128 128 130 130 130 130 130 130 130 128
36 CONTRAST MAX 145 155 162 155 155 155 130 130 130 130 150 150 150 150 150 150 150 155
37 CONTRAST MIN 70 70 70 70 70 70 70 70 70 70 90 90 90 90 90 90 90 70
38 COLOR CENT 80 88 106 56 56 56 78 78 78 78 ... ... ... ... ... ... ... 60
39 COLOR MAX 180 180 180 180 180 180 180 180 180 180 ... ... ... ... ... ... ... 180
40 COLOR MIN 0000000000.....................0
ELECTRICAL ADJUSTMENTS
Step No.
TV AV DTV
WXGA
YUV PCHD-MI
D-3 D-4
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