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SERVICE MANUAL

No.YA092B

2004/8

REAR PROJECTION TELEVISION

52096200302

HD-52Z575,

HD-52Z585,

HD-61Z575,

HD-61Z585

T A B L E O F C O N T E N T S

1 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

4 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

BASIC CHASSIS

RP2

REVISED

Summary of content (37 pages)

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REVISED SERVICE MANUAL REAR PROJECTION TELEVISION 02 52096 2003 HD-52Z575, HD-52Z585, HD-61Z575, HD-61Z585 BASIC CHASSIS RP2 TABLE OF CONTENTS 1 2 3 4 5 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 SPECIFIC SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . .
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SPECIFICATION Items Dimensions (W x H x D) Mass TV RF System Color System Sound System Teletext System VHF Low VHF High UHF CATV TV Receiving Channels and Frequency TV / CATV Total Channel Intermediate Video IF Frequency Sound IF Color Sub Carrier Power Input Power Consumption Projection Source Projection Device Resolution Screen Screen Size Speaker Audio Power Output Antenna Terminal (VHF/UHF) Video Audio S-Video [INPUT-1/3/4] External Input [INPUT-1/2/3/4] Contents HD-52Z575 HD-61Z575 HD-52Z585 HD-61Z58
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SECTION 1 PRECAUTIONS 1.1 SAFETY PRECAUTIONS (1) The design of this product contains special hardware, many circuits and components specially for safety purposes. For continued protection, no changes should be made to the original design unless authorized in writing by the manufacturer. Replacement parts must be identical to those used in the original circuits. Service should be performed by qualified personnel only. (2) Alterations of the design or circuitry of the products should not be made.
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1.2 INSTALLATION 1.2.1 HEAT DISSIPATION If the heat dissipation vent behind this unit is blocked, cooling efficiency may deteriorate and temperature inside the unit will rise. The temperature sensor that protects the unit will be activated when internal temperature exceeds the predetermined level and power will be turned off automatically.
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1.3 LAMP UNIT HANDLING CAUTION NOTE : • This message will appear every time turn on the TV, when the lamp needs to be replaced. Press the [OK] key to make the message disappear, or replace the lamp. LAMP NEEDS TO BE REPLACED. REFER TO OWNER'S MANUAL FOR REPLACEMENT INSTRUCTIONS. LAMP UNIT : TS-CL110UAA 1.3.1 PRECAUTION FOR LAMP UNIT The lamp emits high intensity white, ultraviolet and infrared light. Do not look directly at the light during service.
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1.4 SERVICE PARTS KIT INSTRUCTIONS 1.5 SCREEN HANDLING CAUTIONS 1.5.1 SCREEN STORAGE Store the SCREEN ASS'Y in a standing position in order to avoid deformation. If the screen is stored horizontally, there is risk of deforming the screen face. When necessary to place the SCREEN ASS'Y horizontally, position the screen side upwards and sure to place spacers between the screen and resting site (floor or stand etc.) to prevent the screen from sagging. 1.5.
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SECTION 2 SPECIFIC SERVICE INSTRUCTIONS 2.1 TECHNICAL INFORMATION 2.1.1 DIFFERENCE LIST Items HD-52Z575 / HD-61Z575 HD-52Z585 / HD-61Z585 SMART SOUND Non Built-in SMART CAPTION Non Built-in FRONT CABINET Silver Black 2.1.5 D-ILA DEVICE STRUCTURE R / G / B DEVICE (SIDE VIEW) 2.1.2 PROJECTION UNIT Glass substrate R DEVICE Incident light Projection light Back Plane B DEVICE Lamp unit FRONT Flat film G DEVICE Incident light Reflective pixel electrode 2.1.
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2.1.6 MAIN CPU PIN FUNCTION (IC7601 : M306V7FGF-088FP) [DIGITAL SIGNAL PWB ASS’Y] Pin 1 Port Pin name VHOLD1 VHOLD1 I Function Data slice for main screen closed caption Pin Port Pin name I/O Function 51 P4.3 O Not used 2 HFLT1 I/O LPF for main screen closed caption video input 52 P4.2 O Not used 3 P9.4 O Not used 53 P4.1 O Not used 4 P9.3 O Not used 54 P4.0 O Not used 5 P9.2 DIGRO O R [0] for OSD 55 P3.7 O Not used 6 P9.1 TB1IN I AC power for timer clock 56 P3.
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2.1.
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2.1.8 SYSTEM RESET When the DIGITAL SIGNAL PWB is replaced or the DIGITAL INPUT is not normal, reset the SYSTEM SETTING using the following procedure. (1) Set to 0 minutes using the [SLEEP TIMER] key. (2) Press the [VIDEO STATUS] key and [DISPLAY] key simultaneously to enter the SERVICE MODE. (3) When the Service Menu is displayed, press [2] key to enter the self check mode. (4) Turn off the power by pressing the [POWER] key on the remote control unit.
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SECTION 3 DISASSEMBLY 3.1 DISASSEMBLY PROCEDURE • Make sure that the power cord plug is pull out from the AC wall outlet. • Wait until the LAMP UNIT has cool down is completely. • While not in repair service, place the chassis back its original position. CAUTION AT DISASSEMBLY • Pay extra attention in the following matter when turning the power on with the BODY COVER removed. (1) Prior to disassembly, unplug the power cord from the AC outlet without fail. (Turn the power "off".
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SCREEN BRACKET SCREEN ASSY SCREEN BLOCK FRONT CABINET FRONT PANEL K L (52V: x20) (61V: x24) (52V: x16) (61V: x20) J (x10) I (x4) B (x1) FILTER COVER G (x2) LAMP UNIT SPEAKER A (x1) C (x4) LAMP COVER CUSHION E H (x1) (x2) CENTER PANEL F SPEAKER GRILL(L) (x2) FILTER COVER G (x2) FRONT LED PWB FRONT PANEL C (x4) SPEAKER D (x4) SPEAKER GRILL(R) 1-12 (No.
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3.1.11 MIRROR • Take out the SPEAKER GRILL both side. • Take out the FRONT PANEL. • Take out the SCREEN BLOCK. (1) Remove 12 screws [ A ] attaching the MIRROR HOLDER of the upper, left and right side. (2) Raise slightly to disengage of the MIRROR from the bottom holder. (3) Take out the MIRROR. 3.1.13 SIDE CONTROL PWB • Take out the SCREEN BLOCK. • Take out the SIDE CONTROL BASE. (1) Remove 4 screws [ C ] from rear side of SIDE CONTROL BASE. (2) Take out the SIDE CONTROL PWB. 3.1.
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3.1.15 BODY COVER (1) Remove 9 screws [ A ] (BODY). (2) Remove 6 screws [ B ] (AV TERMINAL BOARD). (3) Take out the BODY COVER. (3) Take out the connector [FJ:12pin], [SW:4pin], [SPR:2pin (black)], [SPL:2pin(white)], [FL:7pin]. (4) Remove 2 screws [ E ] from rear side. (5) Pull out the MAIN UNIT rear side. NOTE : • Do not leave the BODY COVER removed for long time to prevent soiling from dust.
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3.1.18 AV TERMINAL BOARD • Take out the BODY COVER. (1) Remove 5 screws [ A ]. (2) Remove 1 screw [ B ]. (3) Pull out the POWER CORD CLAMP. (4) Remove the nut [ C ] attaching the ANTENNA TERMINAL. (5) Take out the AV TERMINAL BOARD. 3.1.19 SUB DRIVE PWB • Take out the BODY COVER. • Take out the BODY BRACKET. • Take out the MAIN UNIT. (1) Remove 4 screws [ D ]. (2) Take out the PWB HOLDER. (3) Disconnect the connector [CN401] and [CN402]. (4) Remove 6 screws [ E ].
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FRONT BODY FRONT K (x4) RECEIVER PWB E (x6) SUB DRIVE PWB ANALOG SIGNAL PWB REGULATOR PWB L (x2) D ANALOG PWB BRACKET (x4) M (x4) PWB HOLDER J (x1) EARTH WIRE H REAR JACK PWB (x1) I N SHIELD COVER (x1) (x2) DIGITAL SIGNAL PWB F (x1) EARTH WIRE ANTENNA TERMINAL B (x1) UNIT BASE POWER PWB G POWER PWB BRACKET C (x5) POWER CORD CLAMP 1-16 (No.
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3.1.26 LAMP FAN DUCT & THERMOSTAT • Take out the BODY COVER. • Take out the BODY BRACKET. • Take out the MAIN UNIT. (1) Remove 4 screws [ A ]. (2) Take out the LAMP FAN DUCT. (3) Remove 2 screws [ B ]. (4) Take out the THERMOSTAT. 3.1.27 FAN CONTROL PWB • Take out the BODY COVER. • Take out the BODY BRACKET. • Take out the MAIN UNIT.
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TOP DUCT PLATE BODY FRONT H FRONT TOP DUCT (x2) SHIELD TOP CASE I (x4) REMOTE SENSOR PWB E D (x2) MAIN DRIVE PWB C (x1) (x1) SHIELD PLATE LAMP UNIT FAN CONTROL PWB FRONT SHADE COVER F (x2) FRONT SHADE BRACKET OPTICAL BLOCK B (x2) THERMOSTAT A G (x4) (x7) LAMP FAN DUCT OPTICAL / DRIVE ASS'Y TEMP SENSOR PWB N LAMP FAN BRACKET ASSY J (x3) L LAMP COOLING FAN (x3) BALLAST BRACKET TOP (x2) COOLING FAN (LAMP BALLAST UNIT) SIROCCO TOP CASE M P (x4) (x4)
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3.1.36 SHIELD PLATE ATTACHMENT PROCESS • Take out the TOP DUCT / TOP DUCT PLATE. • Take out the MAIN DRIVE PWB with SHIELD TOP CASE. < Assembly > (1) Copper film case with laminate surface to be top. (2) Fold 9 points ( 1 ~ 9 ) as shown in [ A ] an arrow view Fig.1. (3) Attach the double-faced tapes [ B ] as shown in Fig.1. (4) Stick the tape [ C ] as shown in Fig.1. (5) Make copper film case to be SHIELD PLATE (box-shape).
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3.2 MEMORY IC REPLACEMENT 3.2.1 MEMORY IC This memory IC stores data for proper operation of the video and Drive circuits. When replacing, be sure to use an IC containing this (initial value) data. 3.2.2 MEMORY IC REPLACEMENT PROCEDURE 1. Power off Switch off the power and disconnect the power cord from the wall outlet. 2. Replace the memory IC Initial value must be entered into the new IC. 3. Power on Connect the power cord to the wall outlet and switch on the power. SERVICE MENU SCREEN SERVICE MENU 1.
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3.2.4 SETTING OF FACTORY SHIPMENT 3.2.4.2 REMOTE CONTROL DIRECT OPERATION Setting item Setting position INPUT TV CHANNEL CABLE-02 VOLUME 10 MUTING OFF DISPLAY OFF SOUND A.H.S OFF BBE ON SMART SOUND OFF [HD-52Z585 / HD-61Z585] ASPECT REGULAR CLOSED CAPTION (C.C) OFF VIDEO STATUS DYNAMIC TWIN PICTURE SOURCE LEFT SIDE : CA02 RIGHT SIDE : INPUT1 3.2.4.1 BUTTON OPERATION Setting item Setting position POWER OFF INPUT TV CHANNEL CABLE-02 VOLUME 10 3.2.4.
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3.3 REPLACEMENT OF CHIP COMPONENT 3.3.1 CAUTIONS (1) Avoid heating for more than 3 seconds. (2) Do not rub the electrodes and the resist parts of the pattern. (3) When removing a chip part, melt the solder adequately. (4) Do not reuse a chip part after removing it. 3.3.2 SOLDERING IRON (1) Use a high insulation soldering iron with a thin pointed end of it. (2) A 30w soldering iron is recommended for easily removing parts. 3.3.3 REPLACEMENT STEPS 2. How to install Chip parts [Resistors, capacitors, etc.] 1.
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SECTION 4 ADJUSTMENTS 4.1 ADJUSTMENT PREPARATION (1) You can make the necessary adjustments for this unit with either the remote control unit or with the adjustment equipment and parts as given below. (2) Adjustment with the remote control unit is made on the basis of the initial setting values, however, the new setting values which set the screen to its optimum condition may differ from the initial settings. (3) Make sure that AC power is turned on correctly.
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4.5 BASIC OPERATION OF THE SERVICE MENU Operate the SERVICE MENU with the remote control unit. 4.5.1 HOW TO ENTER THE SERVICE MENU (1) Press the [SLEEP TIMER] key and while indication of "SLEEP TIMER 0 MIN." is being displayed, press [DISPLAY] key and [VIDEO STATUS] key simultaneously, and the SERVICE MENU screen of Fig.1 will be displayed. SERVICE MENU SERVICE MENU 1. ADJUST 2. SELF-CHECK 3. I2C STOP 4.5.
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4.5.7 DESCRIPTION OF STATUS DISPLAY The status display on the upper part of the SERVICE MENU screen is common. (1) SIGNAL SYSTEM (OSD) NTSC3 NTSC4 525I 525P 750P 1125I6 RGB5 D525I D525P D1256I6 H525I H525P H750P H1125I6 (2) ASPECT SINGLE 1409 1609 1609S FULL (EXPLAIN) : NTSC3.58 : NTSC4.48 : 525i : 525p : 750p : 1125i 60Hz : RGB 525i : digital 525i : digital 525p : digital 1125i 60Hz : HDMI 525i : HDMI 525p : HDMI 750p : HDMI 1125i 60Hz SERVICE MENU SERVICE MENU 1. ADJUST 2. SELF-CHECK 3.
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4.6 INITIAL SETTING VALUE OF SERVICE MENU (1) Adjustment of the SERVICE MENU is made on the basis of the initial setting values; however, the new setting values which set the screen in its optimum condition may differ from the initial setting. (2) Do not change the initial setting values of the setting items NOT LISTED IN ADJUSTMENT. CAUTION: Never change the initial setting value any adjustments except for those that are designated in the adjustment procedures.
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Item No. Item name D012 SV GN Variable range Setting value 0~3F 00 D060 (NO DISPLAY) 0~FF 00 Item No.
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Item No. Item name D108 (NO DISPLAY) Variable range Setting value 0~FF 00 Item No.
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4.7 ADJUSTMENT PROCEDURE 4.7.1 OPTICAL BLOCK / DRIVE CIRCUIT Measuring instrument Item LENS FOCUS adjustment Test point Hexagon wrench Adjustment part Description FOCUS knob [PROJECTION LENS] Projection lens FOCUS knob (1) Take out the FRONT PANEL, SPEAKER GRILL (L / R), CENTER PANEL and cushions. (2) Display the MENU screen. (3) Loosen the FOCUS LOCK screw. (4) Adjust the FOCUS knob so that the center screen may become the best focus. (5) Fix the focus lock screw by using the Hexagon wrench.
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Item Measuring instrument Test point Adjustment part Description (1) Input the center-cross signal pattern. (2) Set the [SLEEP TIMER] to 0 min. (3) Press the [DISPLAY] key and the [VIDEO STATUS] key simultaneously. (4) Press the [9] key to display the RGB box pattern. (5) Press the [DISPLAY] key twice to select the RGB mode. (6) Adjust the center-cross screen to be same on top and bottom (A=B) by pressing the [CH +] / [CH -] key.
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4.7.2 VIDEO CIRCUIT Item 525i A-D OFFSET adjustment Measuring instrument Test point Adjustment part Signal generator [1. ADJUST] S001: PREPARE Remote control unit S008: 5i CB OF (525i Cb offset) S009: 5i CR OF (525i Cr offset) Description (1) Input a 525i ramp pattern from COMPONENT VIDEO INPUT terminal. (2) Set VIDEO STATUS to [STANDARD]. (3) Set ASPECT to [FULL]. (4) Set COLOR TEMPERATURE to [LOW]. (5) Select [1.ADJUST] from the SERVICE MENU.
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Measuring instrument Item 1125i A-D OFFSET adjustment Test point Adjustment part Signal generator [1. ADJUST] S001:PREPARE Remote control unit S013:HD CB OF (1125i Cb offset) S014:HD CR OF (1125i Cr offset) S030:R DRIVE (Red drive) S031:G DRIVE (Green drive) S032:B DRIVE (Blue drive) Minimize the red and blue noises in the upper half of the screen. (No color or lightest color) SUB SCREEN A-D OFFSET adjustment Signal generator [1.
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Measuring instrument Item Test point Signal generator WHITE BALANCE (High light) adjustment Adjustment part [1. ADJUST] S030:R DRIVE (Red drive) Remote control unit S031:G DRIVE (Green drive) S032:B DRIVE (Blue drive) Description (1) Receive a NTSC all-white (75% white) pattern signal. (2) Set VIDEO STATUS to [STANDARD]. (3) Set ASPECT to [FULL]. (4) Set COLOR TEMPERATURE to [LOW]. (5) Select [1.ADJUST] from the SERVICE MENU.
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SECTION 5 TROUBLESHOOTING 5.1 SELF-CHECK FEATURE 5.1.1 OUTLINE This unit comes with the SELF-CHECK feature, which checks the operational state of the circuit and displays/saves it during failure. SELF-CHECK is performed when power is turned on, and information input to the main microcomputer is monitored at all time. SELF-CHECK is displayed in 2 ways via screen display and LED flashes. Failure detection is based on input state of I2C bus and the various control lines connected to the main microcomputer. 5.
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5.1.6 DETAILS Self-check is performed for the following items. Check item Display Description of detection Diagnosis signal (line) Means of detection Low bias line short protection LOB Low bias line (9V / 5V) short protector activated. Confirm the operation of the low bais protection circuit. [Q2802 /Q2801] (REGULATOR PWB) Protector Detection starts 3 seconds upon power on Turns off power if NG is detected within 400ms.
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5.1.7 DISPLAY METHOD WHEN RASTER IS NOT AVAILABLE In a state where a display screen does not appear due to the failure of this unit, the POWER LED (blue) and LAMP LED (orange) can light up and display a trouble mode. The factors in case the power is forcibly shut down at the time of failure are memorized and those are displayed.
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JVC SERVICE & ENGINEERING COMPANY OF AMERICA DIVISION OF JVC AMERICAS CORP. www.jvcservice.com(US Only) JVC CANADA INC. Head office : 21 Finchdene Square Scarborough, Ontario M1X 1A7 (No.