Toshiba 42HP66 Schematic

FILE NO. 050-200611GR

(MFR’S VERSION A)

SERVICE MANUAL

42" DIGITAL PLASMA COLOR TELEVISION

42HP66

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.

DOCUMENT CREATED IN JAPAN, March, 2006 GREEN

(*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

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.

2. AVOID AN ELECTRIC SHOCK

There is a high voltage part inside. Avoid an electric shock while the electric current is flowing.

3. USE THE DESIGNATED PARTS

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.

11.

When you remove the cover, do not scratch the FPC on both ends of PDP Module.

12.

Hold the four ends holder and be careful not to touch the glass area.

13.

Take care for the damage of vacuum exhaust pipe due to a collision.

14.

Moisture condensation may damage the PDP Module. So, leave it for 48 hours at the service room.

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.

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.

10.

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.

PERFORM A SAFETY CHECK AFTER

SERVICING

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)

Unplug the plug from the AC outlet.

1. Remove the antenna terminal on TV and turn

2. on the TV. Insulation resistance between the cord plug

3. 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

4. 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 Rrar RCA jack Headphone jack

A1-2

HOW TO ORDER PARTS

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.

IMPORTANT

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).

PANEL LOCK

To unlock the Password of Panel Lock, please follow the steps below.

Turn Unit ON.

1. Press and hold the ‘VOLUME DOWN’ key on the front panel for more than 10 seconds.

2. The Panel Lock has now been cleared.

A1-3

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/JACK/AV SWITCH1/REGULATOR.........................................

AV SWITCH2/STEREO/SOUND AMP....................................................................................

TUNER/DIGITAL/POWER.......................................................................................................

INTERFACE.............................................................................................................................

MICON2 ...................................................................................................................................

PRINTED CIRCUIT BOARDS

AV/REMOCON ........................................................................................................................

SCALER...................................................................................................................................

DIGITAL ...................................................................................................................................

OPERATION/SIDE JACK/FILTER ..........................................................................................

SCHEMATIC DIAGRAMS

AV SWITCH2 ...........................................................................................................................

TUNER/OUT JACK..................................................................................................................

AV JACK ..................................................................................................................................

STEREO ..................................................................................................................................

SOUND AMP/HEADPHONE AMP ..........................................................................................

POWER ...................................................................................................................................

AV JACK2 ................................................................................................................................

IR PASS ...................................................................................................................................

TUNER.....................................................................................................................................

MICON .....................................................................................................................................

SCALER...................................................................................................................................

ADC1........................................................................................................................................

ADC2........................................................................................................................................

LVDS........................................................................................................................................

JACK ........................................................................................................................................

AV SWITCH1 ...........................................................................................................................

REGULATOR...........................................................................................................................

INTERFACE_HDMI IC ............................................................................................................

HDMI MICON2.........................................................................................................................

ASIC.........................................................................................................................................

SDRAM ....................................................................................................................................

FLASH .....................................................................................................................................

FRONT END ............................................................................................................................

AV OUT....................................................................................................................................

POWER2 .................................................................................................................................

OPERATION/SIDE JACK/FILTER ..........................................................................................

INTERCONNECTION DIAGRAM ...............................................................................................

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 H-53, H-54 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)

G-2 Tuning Broadcasting System Analog

System Digital ATSC(8VSB)/QAM

G-3 Signal Video Signal Input Level 1 V p-p/75 ohm

G-4 Power Power Source AC 120V AC 60Hz

G-5 Regulation Safety UL/CSA

G-6 Temperature Operation +/-0oC ~ +40oC

G-7 Operating Humidity Less than 80% RH G-8 Clock and Clock

Timer Sleep Timer Max Time 120 Min

Color System NTSC Speaker 4 Speaker

Main Size 2.2 x 5.0 inch

Tweeter Size 2.0 inch

Sound Output MAX 10W + 10W

Tuner and System 1Tuner Receive CH Destination USA(W/ CABLE)

Intermediate Digital 44.00MHz Frequency Analog Picture(FP) 45.75MHz

Preset CH Stereo/Dual TV Sound US-Stereo Tuner Sound Muting Yes

RGB Signal Output Level -Audio Signal Input Level -8.0dBm/50k ohm

Power Consumption at AC 360 W at AC 120 V 60 Hz

Protector Power Fuse Yes

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

Position Front

Impedance 4 ohm

Impedance 8 ohm

10%(Typical) ---

US System M

CH Coverage 2 - 69, 4A, A-5 - A-1,

A - I, J - W, W+1 - W+84

Sound(FS) 41.25MHz

FP-FS 4.50MHz

Output Level 1 V p-p/75 ohm S/N Ratio (Weighted) -Horizontal Resolution at DVD Mode --

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 --

DC ---

at DC -Stand by (at AC) 1 W at AC 120 V 60 Hz Per Year -- kWh/Year Energy Star Yes

Safety Circuit Yes IC Protector(Micro Fuse) No

Radiation FCC/IC X-Radiation ---

Storage -20oC ~ +60oC

Yes

Step 10 Min

A3-1

GENERAL SPECIFICATIONS

G-9 Remote Unit RC-KK

Control Glow in Dark Remocon Yes

Remocon Format TOSHIBA Format TOSHIBA Custom Code Power Source Voltage(D.C) 3V

Total Keys 44 Keys

Multi Brand Keys

UM size x pcs UM-4 x 2 pcs

Power Input Display Mute 1 2 3 4 5 6 7 8 9 0 100 / +10 CH Return / Ent CH + CH VOL + VOL SLEEP Picture Size UP LEFT / FAV MENU/ENTER/DVD MENU RIGHT / FAV + DOWN EXIT TV CBL/SAT VCR DVD ENTER PAUSE PLAY STOP REW FF SKIP/SEARCH|<< SKIP/SEARCH>>| TOP MENU REC CLEAR TV/VCR

40-BF h

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

A3-2

GENERAL SPECIFICATIONS

English

G-10 Features Auto Shut Off Yes

Power On Memory Yes Auto Search No DNR Yes

Comb Filter Yes

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 RRT Setup Lock Hotel Lock No

Channel Lock Yes Video Lock Yes Panel Lock Yes

OSD Language Closed Caption CC Advanced 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

Yes

Yes Yes

A3-3

GENERAL SPECIFICATIONS

HDMIIn put Yes

Component Input Yes

G-11 Accessories Owner's Manual Language English / French / Spanish

Remote Control Unit Yes Rod Antenna

Loop Antenna (W/ Antenna Change Plug)

U/V Mixer DC Car Cord (Center+) Guarantee Card Warning Sheet Circuit Diagram Antenna Change Plug Service Facility List Important Safeguard Dew/AHC Caution Sheet Quick Set-up Sheet Battery Yes

AC Adapter AC Cord (for AC Adapter) AC Cord Yes AV Cord (2Pin-1Pin) HDMI-DVI Cable Registration Card Yes 300 ohm to 75 ohm Antenna Adapter Information Sheet Yes Information Sheet(for IMPORTANT NOTICE) Yes Information Sheet(for PICTURE SHIFT) Yes

VGA (640×480) 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)

w/Guarantee Card Yes

No Poles Terminal -

No Terminal -

UM size x pcs UM-4 x 2 pcs OEM Brand No

A3-4

GENERAL SPECIFICATIONS

G-12 Interface Switch Power (Tact) Yes

Indicator Power / Stand-by Yes(GREEN / RED)

Terminals Rear Video Input 1 RCA x 1

Side Video Input 3 RCA x 1

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)

G-15 Carton Master Carton

Gift Box Material Double/Brown

Drop Test

Container Stuffing 100

G-16 Material Cabinet Cabinet Front ABS 94V0 Non-DECABROM

PCB Non-Halogen

G-17 Environment Environmental standard requirement Green procurement of TOSHIBA

Pb-free Phase3(Pha

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

On Timer No

Audio Input S- Input Video Input 2 RCA x 1 Audio Input S- Input Video Output RCA x 1 Audio Output RCA x 2(Variable L, R) Component In 1 Audio Input (Component In use) Component In 2 Audio Input (Component In use) Other Terminal No Euro Scart (21Pin) No PC Monitor Input (D-Sub) Audio Input HDMI Input 1 Audio Input(DVI 1) PC Monitor Audio Input Alternative HDMI Input 2 Audio Input(DVI 2) Sub Woofer Out No Diversity No Digital Audio Out (Coaxial) Digital Audio Out (Optical) IR Pass Through Ext Speaker No DC Jack 12V(Center +) No VHF/UHF Antenna Input(Digital/Analog) AC Inlet

Audio Input RCA x2(L/MONO,R) S- Input Other Terminal No

Gross Approx. 45.4kg (100.1 lbs)

Content --- Sets Material --- / --Dimensions W x D x H(mm) --Description of Origin ---

Dimensions W x D x H(mm) 1,180 x 440 x 895 Design As per Buyer's Description of Origin Yes

Height (cm) 50(ORION SPEC:31)

Cabinet Rear Steel

Eyelet Yes

RCA x 2(L/MONO, R) Yes

RCA x 3 RCA x 2(L/MONO, R) RCA x 3 RCA x 2(L/MONO, R)

Yes RCA x 2(L/MONO, R) Yes

Yes Mini Pin Jack(3.5), STEREO

Yes Yes Yes

F Type Yes

Yes

Natural Dropping At 1 Corner / 2 Edges /

4 Surfaces

Sets/40' container

A3-5

DISASSEMBLY INSTRUCTIONS

1. EXCHANGE METHOD OF PDP MODULE

NOTE

Do handling with the PDP Module by 2 persons.

REMOVAL METHOD OF PDP MODULE

1-1: CABINET BACK/COVER BACK

Remove the screw.

Remove the Cabinet Back and Cover Back.

Cabinet Back

Cover Back

1-2: STAND ASS'Y

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.

Stand Ass'y

B1-1

DISASSEMBLY INSTRUCTIONS

1-3: CHASSIS BLOCK

Disconnect the connector.

Remove the screw. Remove the Chassis Ass'y.

3. Chassis Ass'y

1-4: PDP MODULE

Remove the screw.

Remove the Side Jack.

Hold the Frame Main carefully and remove the PDP Module.

NOTE

When removing the PDP Module, raise the cushion carefully so that you do not scratch the face.

Frame Main

Raise the cushion.

PDP Module

Frame Main

B1-2

Side Jack

1-5: PDP FILTER

Remove the screw. Remove the Shield Main.

Remove the PDP Filter.

DISASSEMBLY INSTRUCTIONS

Shield Main L

Shield Main Top

PDP Filter

Shield Main R

Shield Main Bottom

B1-3

DISASSEMBLY INSTRUCTIONS

12345678901234567890123456789012123456789012345678

INSTALLATION METHOD OF PDP MODULE

NOTES FOR NEW PDP FILTER HANDLING

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.

1-6: PDP FILTER (PREPARATION)

Fix the cushion. (Order the cushion new.)1.

Cushion

Rear side (No coating)

Cushion

B1-4

[4 ends common]

Apply the cushion on the light brown paint with 3mm on both sides of the cushion.

23456789012345678901234

3mm

DISASSEMBLY INSTRUCTIONS

NOTES FOR NEW PDP MODULE HANDLING

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.

Vacuum Exhaust Pipe

FPC

B1-5

DISASSEMBLY INSTRUCTIONS

1-7: PDP MODULE (PREPARATION)

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)

Wiring Clip

Set SW501 (24V)

Cord Clip

45˚

Cord Clip

B1-6

DISASSEMBLY INSTRUCTIONS

1-8: PDP MODULE

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.

[NG]

Do not smash the cusion. (For all 2 positions)

[4 ends common]

Cushion

2345678901234

Pile up the cushion.

B1-7

DISASSEMBLY INSTRUCTIONS

1-9: CHASSIS BLOCK

Do the wire fixing as shown in the photo, then install the Chassis Ass'y.

Install the Stand Ass'y.

Sheet Earth Mark

Earth wire of AC Inlet.

Band Cord Clamp

1-10: CABINET BACK/COVER BACK

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.

Band Cord Clamp

Earth wire

B1-8

DISASSEMBLY INSTRUCTIONS

REMOVAL AND INSTALLATION OF FLAT PACKAGE IC

REMOVAL

Put Masking Tape (cotton tape) around the Flat Package

IC to protect other parts from any damage.

(Refer to Fig. 2-1.) NOTE

Masking is carried out on all the parts located within 10 mm distance from IC leads.

When IC starts moving back and forth easily after

3. 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.)

NOTE

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.

Blower type IC desoldering machine

Masking Tape (Cotton Tape)

Heat the IC leads using a blower type IC desoldering

machine. (Refer to 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.

Blower type IC desoldering machine

Fig. 2-1

Tweezers

Peel off the Masking Tape.4. Absorb the solder left on the pattern using the Braided

5. Shield Wire. (Refer to Fig. 2-4.)

NOTE

Do not move the Braided Shield Wire in the vertical direction towards the IC pattern.

Fig. 2-3

Braided Shield Wire

Soldering Iron

Fig. 2-2

IC pattern

Fig. 2-4

B2-1

DISASSEMBLY INSTRUCTIONS

INSTALLATION

Take care of the polarity of new IC and then install the new

1. IC fitting on the printed circuit pattern. Then solder each lead on the diagonal positions of IC temporarily.

(Refer to Fig. 2-5.)

Soldering Iron

Solder temporarily

Supply the solder from the upper position of IC leads

2. sliding to the lower position of the IC leads. (Refer to Fig. 2-6.)

Solder temporarily

Fig. 2-5

When bridge-soldering between terminals and/or the

4. soldering amount are not enough, resolder using a Thin-tip Soldering Iron. (Refer to Fig. 2-8.)

Thin-tip Soldering Iron

Fig. 2-8

Finally, confirm the soldering status on four sides of the IC

5. 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.

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.

Soldering IronSolder

Supply soldering from upper position to lower position

Fig. 2-6

Absorb the solder left on the lead using the Braided Shield

3. Wire. (Refer to Fig. 2-7.)

NOTE

Do not absorb the solder to excess.

Soldering Iron

Braided Shield Wire

Fig. 2-7

B2-2

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.)

Set

Condition

TV mode

ALL mode

Set Key Operations

VOL. DOWN

(Minimum)

VOL. DOWN

(Minimum)

VOL. DOWN

(Minimum)

VOL. DOWN

(Minimum)

VOL. DOWN

(Minimum)

Remocon

Key

0 2 sec.

1 2 sec.

6 2 sec.

9 2 sec.

Standard

Time

2 sec.

Releasing of V-CHIP PASSWORD.

Initialization of factory TV data. NOTE:

Can be checked of the INITIAL DATA of MEMORY IC. Refer to the "WHEN REPLACING EEPROM (MEMORY) IC".

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".

Display of the Adjustment MENU on the screen. Refer to the "ELECTRICAL ADJUSTMENT" (On-Screen Display Adjustment).

If you set factory initialization, the memories are reset such as the channel setting, and the POWER ON total hours.

C-1

WHEN REPLACING EEPROM (MEMORY) IC

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:

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.

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.

MICON Version

INIT : 6082 VOLUME : 2E25 ROM : 0000 ADC : BFDE DVP1 : EE40 *1 DVP2 : D172 PICENH : 5626 PDP ON :0001

OEC7147A_079

Initial setting data check sum. VOLUME CURVE data check sum.

Rom correction data check sum. AD CONVERTER data check sum. SCALER data check sum.

DV1000 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)

CONFIRMATION OF INITIAL DATA

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").

Turn on the POWER, and set to the TV mode.

1. Set the VOLUME to minimum.

2. Press both VOL. DOWN button on the set and Channel button (6) on the remote control for more than 2 seconds.

3. ADDRESS and DATA should appear as FIG 2.

ADDRESS DATA

INIT 0000 B4 PDP ON 0001 OEC7147A_079 DTV d-l62155 INIT :0000 ROM : 0000 VOLUME : 2E25

FIG. 2

ADDRESS is now selected and should "blink". Using the UP/DOWN buton on the remote, step through the ADDRESS

4. until required ADDRESS to be changed is reached. Press RIGHT/LEFT button to select DATA. When DATA is selected, it will "blink".

5. Again, step through the DATA using UP/DOWN button until required DATA value has been selected.

6. Pressing RIGHT/LEFT button will take you back to ADDRESS for further selection if necessary.

7. Repeat steps 4 to 6 until all data has been checked.

8. 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.

10. Press both VOL. DOWN button on the set and Channel button (1) on the remote control for more than 2 seconds.

11. After the finishing of the initializing of shipping, the unit will turn off automatically.

12.

The unit will now have the correct DATA for the new MEMORY IC.

C-2

RE-WRITE FOR DIGITAL SOFT FIRMWARE

JG176

Ref. No.

JG176

NOTE:

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)

USA HD DTV ROM DISC

Part No. Parts Name

APJG176095

The operating manual for Re-writing is included in USA HD DTV ROM DISC (JG176).

USA HD DTV ROM DISC

Up-Date of the Firmware

SET (REAR)

Remarks

USB CONNECTOR

C-3

FUNCTION OF PCB

TDRV TOP

YDRV BOT

Y SUS

XRLT

42 SANKEN PSU

POWER

Z SUS

XRRT

42 SANKEN PSU : Y SUS :

Z SUS :

CTRL : XRLT : XRRT : TDRV TOP : TDRV BOT :

CTRL

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.

C-4

ELECTRICAL ADJUSTMENTS

1. ADJUSTMENT PROCEDURE

Read and perform these adjustments when repairing the circuits or replacing electrical parts or PCB assemblies.

CAUTION

•

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.

•

Prepare the following measurement tools for electrical adjustments.

1. Pattern Generator

2. BASIC ADJUSTMENTS

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.

AUTO

01 H POSI OSD

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.

Fig. 2-1

NO.

FUNCTION

NO.

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)

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

Fig. 2-2

2-1: CONTRAST MAX

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".

10.

Check if the picture is normal.

11.

Receive the digital broadcast. (RF Input)

12.

Perform the above adjustments 3 and 5.

13.

Playback the DVD(480i) disc. (COMPONENT Input)

14.

Press the INPUT button on the remote control to set to the YUV mode.

15.

Activate the adjustment mode display of Fig. 2-1 and press the channel button (36) on the remote control to select "CONTRAST MAX".

16.

Press the VOL UP/DOWN button on the remote control until the contrast step No. becomes "162".

17.

Check if the picture is normal.

18.

Playback the DVD(480i) disc. (HDMI Input)

19.

Press the INPUT button on the remote control to set to the HDMI mode.

20.

Activate the adjustment mode display of Fig. 2-1 and press the channel button (36) on the remote control to select "CONTRAST MAX".

21.

Press the VOL UP/DOWN button on the remote control until the contrast step No. becomes "130".

22.

Check if the picture is normal.

D-1

ELECTRICAL ADJUSTMENTS

2-2: WHITE BALANCE

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)”and “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

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)

10.

Perform the above adjustments 4~6.

11.

Playback the DVD(480i) disc. (COMPONENT Input)

12.

Press the INPUT button on the remote control to set to the YUV mode. Then perform the above adjustments 4~6.

13.

Playback the DVD(480i) disc. (HDMI Input)

14.

Press the INPUT button on the remote control to set to the HDMI mode. Then perform the above adjustments 4~6.

D-2

ELECTRICAL ADJUSTMENTS

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)

YUV PCHD-MI

TV AV DTV

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 80 133 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

40COLOR MIN 0000000000.....................0

Step No.

VGA SVGA XGA WVGA WXGA

WXGA

D-3 D-4

ELECTRICAL ADJUSTMENTS

3. ELECTRICAL ADJUSTMENT PARTS LOCATION GUIDE (WIRING CONNECTION)

PDP PANEL

SPEAKER

J2275

CP301

CP303

J4201

CP901

J4202

J4205

REMOCON PCB

OPERATION PCB

J4211

AV PCB

CP2251

CP3801

CP4201

J4204

CP3803

CP3807

CP2203

CP3802

DIGITAL PCB

TU5801

CP3804

CP4202

CP4204

CP4203

CD4203

CD4204

CP2200

CP802

CP803

CP7202

CP4302

SCALER PCB

SIDE JACK PCB

J4209

CP4200

J4208

J4207

J4206

CP3901

CP3900

CP3201

J4301

CP3601

CP3602

CP3603

J3601

D-5

FILTER PCB

CD3810

AC IN

POWER DOES NOT TURN ON

TROUBLESHOOTING GUIDE

IS F3900 BROKEN ?

IS THERE VOLTAGE AT PIN 11 OF CP3201 5V ?

YES

IS THERE VOLTAGE AT PIN 2 OF IC3804 AT3.3V ?

YES

CHANGE SCALER PCB.

YES

CHANGE F3900.

CHECK CP3201 AND CP3804.

CHECK IC3804 AND PERIPHERAL CIRCUIT. OR CHANGE AV PCB.

E-1

THE PICTURE DOES NOT APPEAR (1).

TROUBLESHOOTING GUIDE

IS CD3201 CONNECTED ?

YES

IS CD7204 CONNECTED ?

YES

IS THERE SIGNAL AT IC7202 ?

YES

CHECK IC801. OR CHANGE SCALER PCB.

CONNECT CP3201.

CONNECT CD7202.

CHANGE IC7202.

E-2

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