Sanyo PLV-55WR1Z User manual

FILE NO.

SERVICE MANUAL

LCD Projection TV

REFERENCE NO. SM 5110666-00

PRODUCT CODE :

PLV-55WR1Z P8FLZ 1 122 235 30

PLV-45WR1Z P8GLZ 1 122 244 30

Original Version

MODEL NO. PLV-55WR1Z

PLV-45WR1Z

( Asia / Middle East / Australia )

Chassis No. PLV-55WR1Z-00

PLV-45WR1Z-00

NOTE: Match the Chassis No. on the rating

sheet on the cabinet with the Chassis

No. in the Service Manual.

If the Original Version Service

Manual Chassis No. does not match

the unites, additional Service

Literature is required. You must refer

to “Notices” to the Original Service

Manual prior to servicing the unit.

Give complete “CHASSIS NO." for parts order

or servicing, it is shown on the rating sheet on

the cabinet of the LCD Projection TV.

Chassis series : ZRA-A

NO

E

F

- 2 -

■ CONTENTS

■ Safety Instructions ..................................................................................................3

■ Specifications .........................................................................................................4

■ Circuit Protections ..................................................................................................5

● Fuse for circuit protection .............................................................................5

● Thermal switch reset ....................................................................................5

● Electric shock protection(Lamp cover switch) ............................................ 6

■ Maintenance and Cleaning.....................................................................................7

● Warning Indicator .........................................................................................7

● Air filter care and cleaning............................................................................8

● Cleaning the LCD Projection TV ..................................................................9

● Optical parts care and cleaning..................................................................12

■ Lamp replacement................................................................................................13

■ Mechanical disassemblies....................................................................................16

● Optical parts location and direction ............................................................46

● Sensors and Switches location ..................................................................49

■ Adjustments after Parts Replacement..................................................................50

■ Optical adjustment................................................................................................51

● Preparation for Adjustments.......................................................................51

● Condenser lens adjustment........................................................................54

● Relay lens adjustment ................................................................................55

● Contrast adjustment ...................................................................................56

● Picture image and focus adjustment ..........................................................57

■ Electrical Adjustments ..........................................................................................63

● Service adjustment menu operation...........................................................63

● Circuit Adjustments ....................................................................................64

● Service Adjustment Data table...................................................................67

● Test points and Locations...........................................................................72

■ Chassis Block Diagrams.......................................................................................73

■ Power Supply Lines..............................................................................................80

■ Troubleshooting ....................................................................................................81

● Indicators and Condition.............................................................................81

● No power....................................................................................................82

● No picture...................................................................................................84

● No sound................................................................................................... 86

■ Waveforms............................................................................................................87

■ Special function ....................................................................................................88

■ Control Port Functions..........................................................................................89

■ IC Block Diagrams................................................................................................93

■ Service parts lists...............................................................................................104

● Mechanical parts list.................................................................................104

● Electrical parts list ....................................................................................115

● Differences parts list (PLV-45WR1Z)........................................................116

Drawings & Diagrams ...................................................................................A1~A16

■ Parts description and reading in schematic diagram ........................................A2

■ Schematic diagrams...................................................................................A3~A8

■ Printed wiring board diagrams..................................................................A9~A14

■ Pins description of ICs, transistors, diodes .....................................................A15

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- 3 -

WARNING:

The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side of

the converter and lamp power supply unit circuit is connected to the AC line and it is hot, which hot circuit is

identified with the line ( ) in the schematic diagram. For continued product safety and protection of person-

nel injury, servicing should be made with qualified personnel.

The following precautions must be observed.

SAFETY PRECAUTIONS

1: An isolation transformer should be connected in the power line between the LCD projection TV and the

AC line before any service is performed on the LCD projection TV.

2: Comply with all caution and safety-related notes provided on the cabinet top, cabinet bottom, inside the

cabinet or on the chassis.

3: When replacing a chassis in the cabinet, always be certain that all the protective devices are installed

properly, such as, control knobs, adjustment covers or shields, barriers, etc.

DO NOT OPERATE THIS LCD PROJECTION TV WITHOUT THE PROTECTIVE SHIELD IN POSITION

AND PROPERLY SECURED.

4: Before replacing the cabinet, thoroughly inspect the inside of the cabinet to see that no stray parts or tools

have been left inside.

Before returning any LCD projection TV to the customer, the service personnel must be sure it is completely

safe to operate without danger of electric shock.

■ Safety Instructions

PRODUCT SAFETY NOTICE

Product safety should be considered when a component replacement is made in any area of the LCD projec-

tion TV. Components indicated by mark in the parts list and the schematic diagram designate components

in which safety can be of special significance. It is, therefore, particularly recommended that the replacement

of the parts must be made by exactly the same parts.

Caution:

The parts and screws should be placed exactly the same position as the original otherwise it may cause lose of

performance and product safety.

The wiring method of the leads should be returned exactly the same state as the original otherwise it may cause

lose of performance and product safety.

SERVICE PERSONNEL WARNING

Eye damage may result from directly viewing the light produced by the Lamp used in this equipment. Always

turn off Lamp before opening cover. The Ultraviolet radiation eye protection is required during this servicing.

Never turn the power on without the lamp to avoid electric-shock or damage of the devices since the stabilizer

generates high voltages at its starts.

Since the lamp is very high temperature during units operation. Replacement of the lamp should be done at

least 45 minutes after the power has been turned off, to allow the lamp cool-off.

CAUTION

RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE.

DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS.

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- 4 -

■ Specifications

0.7” wide TFT Active Matrix type, 3 panels

Rear Projection

33.8 kg (PLV-45WR1Z), 40.4 kg (PLV-55WR1Z)

1,114mm (W) x 802mm (H) x 348mm (D) PLV-45WR1Z

1,352mm (W) x 939.6mm (H) x 407.5mm (D) PLV-55WR1Z

1280 x 720 dots

2,764,800 (1280 x 720 x 3 panels)

PAL, SECAM, NTSC, and NTSC4.43

H-sync. 15 ~ 100 KHz, V-sync. 50 ~ 100 Hz

45" (PLV-45WR1Z), 55" (PLV-55WR1Z)

5 ˚C ~ 35 ˚C

-10 ˚C ~ 60 ˚C

Owner’s Manual

AC Power Cord

Remote Control and Batteries

Replacement Lamp

Projector Type

Net Weight

Dimensions (W x H x D)

Panel Resolution

Number of Pixels

Color System

Scanning Frequency

Screen Size (Diagonal)

Operating Temperature

Storage Temperature

Accessories

LCD Panel System

● The specifications are subject to change without notice.

ø 100 mm x 2 speakers, 15W + 15W (RMS)

150 W

DVI-D Terminal (Digital) (HDCP compatible)

Audio – RCA Type x 2

D-SUB(HDB 15 pin)

Audio – Mini Jack(Stereo)

Built-in Speakers and Output

Projection Lamp

Computer Input PC1

PC2

D-Sub (HDB 9) x 1

Service Port Connector

Power Source : AA, UM3 or R06 Type DC1.5V x 2

Operating Range : 5m / ±30˚

Dimensions : 53mm x 26mm x 199mm

Net Weight : 132g (including batteries)

Remote Control

480i, 480p, 575i, 575p, 720p, and 1080i

High Definition TV Signal

100 - 120V~, 200 - 240V~, 50/60Hz

280W

Voltage and

Power Consumption

● LCD panels are manufactured to the highest possible standards. Even though 99.99% of the pixels are effective, a

tiny fraction of the pixels (0.01% or less) may be ineffective by the characteristics of the LCD panels.

● The On-Screen Menu and figures in this manual may differ slightly from the product.

Mini Jack (stereo) x 1

Headphone Jack

RCA Type x 1

Woofer Output Jack

Video – RCA Type x 1and Mini DIN 4 pin x 1 (S-Video)

Audio – RCA Type x 2

Video – RCA Type x 3 (Video/ Y,Pb/Cb,Pr/Cr)

Audio – RCA Type x 2

Video Input VIDEO1

VIDEO2, 3

Video – RCA Type x 1 and Mini DIN 4 pin x 1 (S-Video)

Audio – RCA Type x 2

Output

75 Ω

Aerial Input Impedance

B/G, D/K, M/M, and I

Television System

VHF: E2–E12, A2–A13, R1–R12, J1–J12, K1–K9

UHF: 21–69, A14–A69, J13–J62

CATV: S1–S41, X, Y, Z, Z+1, Z+2

Channel Coverage

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- 5 -

■ Circuit Protections

This LCD projection TV provides the following circuit protections to operate in safety. If the abnormality occurs

inside the LCD projection TV, it will automatically turn off by operating one of the following protection circuits.

A fuse(F601) is located inside of the LCD projection TV.

When the POWER indicator is not lightning, the fuse may be

opened. Check the fuse as following steps.

The fuse should be used with the following type;

● Fuse

● Thermal switch

Fuse

FILTER UNIT

PRESS

Thermal Switch

(Reset button)

Fuse Part No. : 423 022 2102

TYPE T4.0AH 250V FUSE

LITTEL FUSE INC. TYPE 215004

How to replace the fuse

1. Remove the cabinet bottom cover and Filter unit following to

"Mechanical Disassemblies".

2. Remove the fuse from fuse holder on the Filter Board.

To install the fuse, take reversed step in the above.

There is the thermal switch (SW902) inside of the LCD

projection TV to prevent the internal temperature rising

abnormally. When the

internal temperature reaches near 80°C, turn off the AC

main power supply automatically.

The thermal switch is not reset to normal automatically

even if the internal temperature becomes normal. Reset

the thermal switch following procedure.

Check the resistance between terminals of thermal switch

by using a tester. If it has high impedance, thermal switch

may be in open.

How to reset the thermal switch

1. Remove the optical / chassis unit following to "Mechanical

Disassemblies".

2. Press the reset button on the thermal switch with a sharp-

pointed tool.

CAUTION:

Before press the reset button, make sure that the AC cord

must be disconnected from the AC outlet.

Fig. A-1

Fig. A-2

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- 6 -

● Lamp cover switch

LAMP COVER SWITCH

(SW1861)

LAMP COVER

The lamp cover switch (SW1861) cuts off the drive signal to the lamp circuit

when the lamp cover is removed or no close completely.

After opening the lamp cover for replacing the lamp unit, place the lamp cover

correctly otherwise the LCD projection TV can not turn on.

Fig. A-3

●

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- 7 -

The WARNING indicator shows the state of the function which protects the LCD Projection TV. Check the state

of the WARNING indicator and the POWER indicator to take proper maintenance.

LAMP

REPLACE

WARNING

blinking red

FRONT CONTROL

The LCD Projection TV is shut down and the WARNING indicator is blinking red

When the temperature inside the LCD Projection TV exceeds the

normal temperature, the LCD Projection TV is automatically shut

down to protect the LCD Projection TV. The POWER indicator is

blinking red and the LCD Projection TV is being cooled down.

When the temperature inside the LCD Projection TV returns to

normal, the POWER indicator lights red and the LCD Projection TV

can be turned on.

NOTE;

Even after the temperature inside the LCD Projection TV returns to

normal, the WARNING indicator may keep blinking.

The WARNING indicator stops blinking when the LCD Projection

TV is turned on again,.

Then check the items below.

LAMP

REPLACE

WARNING

FRONT CONTROL

The LCD Projection TV is shut down and the WARNING indicator lights red

When the LCD Projection TV detects an abnormal condition, it is

automatically shut down to protect the inside and the WARNING

indicator lights red. In this case, disconnect the AC power cord

and reconnect it, and then turn the LCD Projection TV on once

again for check. If the LCD Projection TV is turned off again and

the WARNING indicator lights red, disconnect the AC power cord

and contact the service station for check and repair.

CAUTION;

DO NOT LEAVE THE LCD PROJECTION TV WITH

THE AC POWER CORD CONNECTED UNDER THE

ABNORMAL CONDITION. IT MAY RESULT IN FIRE

OR ELECTRIC SHOCK.

● Warning Indicator

■ Maintenance and Cleaning

WARNING

lights red

✓ Did you provide appropriate space for the LCD Projection TV to

be ventilated? Check the installing condition to see if ventilation

slots are not blocked.

✓ Is the LCD Projection TV not installed near the ventilation duct

of air-conditioning equipment which may be hot? Install the LCD

Projection TV away from the ventilation duct of air-conditioning

equipment.

✓ Is the air filter clean? Clean the air filter or replace it with a new

one.

OR E

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- 8 -

RECOMMENDATION;

We recommend avoiding dusty/smoky environments when

operating the LCD Projection TV. When using under dusty or

smoky conditions, dust may accumulate on the optical

elements inside the LCD Projection TV and the screen surface.

This condition may degrade the quality of a projected image.

When the above symptoms are noticed, contact your

authorized dealer or service station for proper cleaning.

Turn off the LCD Projection TV and disconnect the AC

power cord from the AC outlet.

1

2

The Air Filter prevents dust from accumulating on the optical elements inside the LCD Projection TV. Should the

Air Filter become clogged with dust particles, it will reduce the Cooling Fans' effectiveness and may result in

internal heat building up and effect on the life of the LCD Projection TV.

To clean the Air Filter, follow the cleaning procedures below:

Remove the Air Filter from the Air Filter Holder, and clean

the Air Filter with a brush or a vacuum cleaner.

If the Air Filter is clogged extremely or broken, replace it

with the new one.

3

Fit the Air Filter back in the Air Filter Holder and then

replace it to the LCD Projection TV. Make sure that the Air

Filter fits the place where it should be.

4

CAUTION;

Do not operate the LCD Projection TV with the Air

Filter removed. The dust is stuck in the LCD

Projection TV and it may degrade the clear picture

reproduction performance.

Replace the right front cover to the LCD Projection TV.

5

Push downward with a forefinger on the Air Filter Holder

and pull the Air Filter Holder off the LCD Projection TV.

6

Remove the Right front cover of the LCD Projection TV.

a. Hold right upper side of the cover and slightly pull

forward.

b. Hold both sides of the cover and remove it.

Right Front Cover

Air Filter Holder

Pull this

part first.

Air Filter Holder

Air Filter

● Air filter care and cleaning

●

A

Air fi

er

a

an

dc

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ing

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A

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A

i

- 9 -

Care for Using the LCD Projection TV

When using the LCD Projection TV, the following

precautions should be taken. Otherwise, the screen can

be damaged:

●

Do not push or hit the screen surface.

●

Do not write, paint or affix anything on the screen.

●

Do not put anything on the LCD Projection TV.

NOTE:

Black dots or bright points of light (red, green, or blue) may

appear on the screen. This is a characteristic of the LCD

panels, not a malfunction of the LCD Projection TV.

Do not push or hit

the screen.

Be sure to disconnect the AC Power cord from the AC outlet

before cleaning the LCD Projection TV.

●

Gently wipe the screen and the cabinet with a soft dry clean

cloth.

●

When it is heavily soiled, wipe the screen and the cabinet

with a soft cloth dampened with warm water and finish with

a soft, dry clean cloth.

CAUTION;

DO NOT USE BENZENE, THINNER, OR ANY

VOLATILE SUBSTANCES TO CLEAN THE LCD

PROJECTION TV. THESE CHEMICALS MAY CAUSE

DAMAGE TO THE PRODUCT

.

● Cleaning the LCD Projection TV

●

Cle

an

gt

he L

CD

Pr

e

tio

nTV

C

Ca

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or

U

s

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on

Installing the LCD Projection TV

Openings in the cabinet are provided for ventilation and to

ensure reliable operation of the product and to protect it

from overheating, and these openings must not be blocked

or covered.

● Take appropriate space on the top, sides and rear of the

LCD Projection TV

cabinet for allowing air circulation and

cooling the

LCD Projection TV

. Minimum distance should

be taken. If the projector is to be built into a compartment

or similarly enclosed, the minimum distances must be

maintained. Do not cover the ventilation slot on the

LCD

Projection TV

. Heat build-up can reduce the service life of

your

LCD Projection TV

, and can also be dangerous.

Air Circulation

Placing and Settling the LCD Projection TV

BE SURE TO USE OR PLACE THE PROJECTOR

IN THE TEMPERATURE INDICATED BELOW:

Place the LCD Projection TV on flat places or with an exclu-

sive LCD Projection TV stand. Placing on unflat places may

cause picture tilt or distortion.

Do not place the LCD Projection TV under direct sunlight.

This may have a damaging effect on picture quality and the

screen surface of the LCD Projection TV.

5°C ~ 35°C

–10°C ~ 60°C

Operating Temperature

Storage Temparature

10cm

50cm

- 10 -

CAUTION;

When placing the LCD Projection TV, the spaces for ventilation must be maintained.

SIDE and TOP REAR

en surfa

rface o

rfa

of

of the L

of

ojectio

on

TV.

acin

g and

i

Exhaust vents (Hot air exhaust)

Very hot air exhaust

- 11 -

This LCD Projection TV is equipped with cooling fans for

protection from overheating. Pay attention to following to

ensure proper ventilation and avoid a possible risk of fire

and malfunction.

- Do not cover vent slots.

- Keep front lower part clear any objects.

Obstructions may block cooling air.

Hot air is exhausted from the exhaust vent.

When using or installing the LCD Projection TV, the

following precautions should be taken.

– Do not put any flammable objects near the vent.

– Keep the exhaust vent at least 1.5’(50cm) away

from any objects.

– Do not touch a peripheral part of the exhaust vent,

especially screws and metallic part. This area will

become hot while the LCD Projection TV is being

used.

Cooling fans are provided to cool down the LCD

Projection TV. This LCD Projection TV monitors inter-

nal temperature and control the running speed of the

cooling fans.

Caution;

Air intake vents

BACK OF CABINET

EXHAUST VENTS

FRONT OF CABINET

air intake vents

The lower part of the speaker grill cover is an air intake.

Do not cover vent slots.

V

e

ry h

ot ai

exh

aus

ON

OF

CABI

ET

- 12 -

Condenser lens

Integrator lens

Prism

Screen

Cleaning Procedure

(When no good, progress to next step.)

1. Clean surface of optical parts using air spray.

2. Wipe the dry cleaning with wiping cloth and the wiper.

3. Soak a few medicines in the cloth as follows and wipe up them lightly. After that,always wipe the dry cleaning

cloth.

Optical parts

Medicines Remarks

LCD panel Iso-propyl-alcohol

Be sure to handle this part with special attention.

Pay attention to static electricity. Do not touch

the electrode of flexible cables.

Polarized glass

(Glass with plastics sheet)

Methanol

Synthetic detergent

Iso-paraffin liquid

Wipe up lightly.

Because there is fear that the film comes off the

substrate when wiping up by the strong power.

Dichroic mirror

Optical filter

(Glass with the surface coat)

Alcohol

(methanol:ethel=8:2)

Ethanol

Recommendation medicine

Wipe the dry cleaning with wiping cloth and the wiper.

Soak a few medicines in the cloth as follows and wipe

up them lightly.

After that,always wipe the dry cleaning cloth.

Projection lens Ethanol

Disassembly Cleaning

Disassembly cleaning method should only be performed when the unit is considerable dirty and cannot be suffi-

ciently cleaned by air spraying alone.

Be sure to readjust the optical system after performing disassembly cleaning.

Caution :

The surface of the optical components consists of multiple dielectric layers with varying degrees of refraction.

Never use organic solvents (thinner, etc.) or any kind of cleanser on these components.

Since the LCD panel is equipped with an electronic circuit, never use any liquids (water,etc.) to clean the unit.

Use of liquid may cause the unit to malfunction.

After long periods of use,dust and other particles will accumulate on the LCD panel,prism,mirror,polarized glass,

lens,etc.,causing the picture to darken or color to blur. If this occurs,clean the inside of optical unit.

Remove dust other particles using air spray. If dirt cannot be removed by air spray, disassemble and clean the

optical unit.

Caution:

Use a commercial (inert gas) air spray designed for cleaning camera and computer equipment.

Use a resinbased nozzle only. Be very careful not to damage optical parts with the nozzle tip. Never use any kind

of cleanser on the unit. Also, never use abrasive materials on the unit as this may cause irreparable damage.

● Optical parts care and cleaning

Synthetic detergent

ver u

ce the

e

orga

LCD

se organ

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nic sol

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a

an

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e

(thinn

pped

er

,

w

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y kind

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rcuit

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e

v

e

on th

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ese c

any liq

qui

nent

(wate

r,etc.)

to clean

●

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al p

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Be

- 13 -

When the life of the projection lamp of this LCD Projection TV

draws to an end, the LAMP REPLACE indicator lights orange.

If this indicator lights orange, replace the lamp with a new one

promptly.

LAMP

REPLACE

WARNING

O

N-OFF

This indicator lights orange

when the life of the projection

lamp draws to an end.

Front Control

Turn off the LCD Projection TV and disconnect the AC

plug. Allow the LCD Projection TV to cool for at least 45

minutes.

Loosen 4 screws that secure the Lamp Cover with a

screwdriver and remove the Lamp Cover.

1

3

Loosen the 2 screws that secure the lamp with a

screwdriver and pull out the Lamp by grasping the handle.

4

Replace the Lamp with a new one and tighten the 2

screws. Make sure that the Lamp is correctly secured into

the Lamp compartment. Refer to ordering the

replacement lamp.

5

Remove the Left front cover of the LCD Projection TV.

a. Hold left upper side of the cover and slightly pull

forward.

b. Hold both sides of the cover and remove it.

2

Connect the AC Power Cord to the LCD Projection TV and

turn on the LCD Projection TV.

Follow these steps to replace the lamp assembly.

Put the Lamp Cover back and tighten the 4 screws, and

then replace the Left front cover.

6

Reset the Lamp replace counter.

See “Lamp replace counter reset” on the next page .

For continued safety, replace with a lamp of the

same type. Do not drop a lamp or touch a glass

bulb! The glass can shatter and may cause injury.

Allow a LCD Projection TV to cool, for at least 45

minutes before you open the Lamp cover. The

inside of the LCD Projection TV can become very

hot.

CAUTIONCAUTION

CAUTION;

When installing the new Lamp into the Lamp compartment,

make sure the Lamp socket is securely plugged into the com-

partment socket. Improper or loosen socket connection may

cause arc discharge resulting fire hazard.

7

8

Left Front

Cover

Screws

Lamp Cover

Handle

Pull this

part first.

■ Lamp replacement

par

partmen

a

nt sock

di

en

h

prope

l

r

o

i

et

r loos

fi

en so

cket

d.

onne

the

ction

com

may

Wh

the

e

he p

oject

nla

mp o

is

CD P

ojec

b

.

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ldld

b

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es o

of th

he

co

ver

t

.

- 14 -

The LAMP REPLACE indicator will light orange when

the total lamp used time reaches 5000 hours

. This is

to indicate that lamp replacement is required.

The total lamp used time is calculated by using the

below expression;

T

otal lamp used time = Teco + Tnormal (1+1/2)

Teco : used time in the Eco2 mode

T

normal : used time in the Normal, Auto and Eco1

mode

You can check the lamp replace counter following to

below procedure.

1 Press and hold the MENU and OK button on the TV

set for more than 3 seconds.

2 The LCD projection TV used time and lamp used

time will be displayed on the screen briefly.

Counter

Rearprojection TV

:

Lamp

Normal

Eco

Total

0175H

0050H

0100H

0175H

:

Total lamp used time

● How to check Lamp Used Time

Rear-projection TV used time

Be sure to reset the lamp replace counter after the lamp is replaced. When the lamp replace counter is reset,

the LAMP REPLACE indicator stops lighting.

Turn the LCD Projection TV on, press the MENU

button, and the On-Screen Menu will appear. Select

the Setting Menu with the Point Up/Down button and

press the Point Right button to enter the sub-menu.

Select the Lamp counter reset item and then press the

OK button. The message "Lamp replace counter

Reset?" is displayed. Choose [Yes] and then press the

OK button.

1

2

Another confirmation dialog box appears and choose

[Yes] to reset the Lamp replace counter.

3

NOTE:

● Do not reset the Lamp replace counter without

implementation of lamp replacement. Be sure to reset the

Lamp replace counter only after replacing the lamp.

Lamp counter reset

● Lamp replace counter reset

●

L

Lamp

rep

a

eco

oun

er

ese

- 15 -

This LCD Projection TV uses a high-pressure lamp which must be handled carefully and properly.

Improper handling may result in accidents, injury, or create a fire hazard.

● Lamp lifetime may differ from lamp to lamp and according to the environment of use. There is no

guarantee of the same lifetime for each lamp. Some lamps may fail or terminate their lifetime in a

shorter period of time than other similar lamps.

● If the LCD Projection TV indicates that the lamp should be replaced, i.e., if the LAMP REPLACE

indicator lights up, replace the lamp with a new one IMMEDIATELY after the LCD Projection TV has

cooled down.

( Follow carefully the instructions in the Lamp Replacement section of this manual. ) Continuous use

of the lamp with the LAMP REPLACE indicator lighted may increase the risk of lamp explosion.

● A Lamp may explode as a result of vibration, shock or degradation as a result of hours of use as its

lifetime draws to an end. Risk of explosion may differ according to the environment or conditions in

which the LCD Projection TV and lamp are being used.

IF A LAMP EXPLODES, THE FOLLOWING SAFETY PRECAUTIONS SHOULD BE TAKEN.

If a lamp explodes, disconnect the LCD Projection TV’s AC plug from the AC outlet immediately. Contact

an authorized service station for a checkup of the unit and replacement of the lamp. Additionally, check

carefully to ensure that there are no broken shards or pieces of glass around the LCD Projection TV or

coming out from the cooling air circulation holes. Any broken shards found should be cleaned up

carefully. No one should check the inside of the LCD Projection TV except those who are authorized

trained technicians and who are familiar with LCD Projection TV service. Inappropriate attempts to

service the unit by anyone, especially those who are not appropriately trained to do so, may result in an

accident or injury caused by pieces of broken glass.

LAMP HANDLING PRECAUTIONS

ORDER REPLACEMENT LAMP

Replacement lamp can be ordered through your dealer. When ordering a projection lamp, give the following

information to the dealer.

●

Model No. of your LCD Projection TV : PLV-45WR1Z

PLV-55WR1Z

● Replacement Lamp Type No. : POA-LMP76A

(Service Parts No. 610 318 7266)

pp

- 16 -

C

B

A

BRACKET(R)

BRACKET(L)

CABINET BOTTOM COVER

RATING SHEET

1

Cabinet bottom cover removal.

Disassemble should be made following procedures in numerical order.

Following steps show the basic procedures, therefore unnecessary step may be ignored.

Caution:

The parts and screws should be placed exactly the same position as the origi-

nal otherwise it may cause lose of performance and product safety.

The wiring method of the leads and ferrite cores should be returned exactly

the same state as the original otherwise it may cause lose of performance and

product safety.

Caution:

Never disassemblies the cabinet back and cabinet front unless it is absolutely necessary!

If the cabinet back is to be disassembled, readjustment of the screen and Miller are required.

Screws Expression

(Type

Diameter x Length) mm

T type M Type

Tapping screw Machine screw

■ Mechanical disassemblies

1. Remove the 12 screws A (T4 x 16) and remove the Cabinet bottom cover.

2. Remove the 4 screws B (T4 x 14) and remove the Bracket(R).

3. Remove the 4 screws C (T4 x 14) and remove the Bracket(L).

Fig. 1

A

Disas

F

ollow

ssemb

wing s

s

shou

d b

made

b

e follo

wing

proce

ure

in nu

meric

i

b

- 17 -

COVER UNIT (R)

COVER UNIT (L)

Pull the upper side of the cover and remove.

Pull this

part

Pull this

part

1. Remove the Cover unit(R) and Cover unit(L) of the Cabinet

Front.

(Hold right(left) upper side of the cover and pull forward.)

2-1

Cover unit(R) and Cover unit(L) removal.

A

PANEL FRONT UNIT

1. Remove the 4 screws A (M4 x 8) and remove the

Panel Front unit.

2

-2

Panel front unit removal.

2-3

Remove the 2 screws B inside of a Cabinet.

1. Remove the 2 screws B (T4 x 14) from the inside of the cabinet.

(It fixed Optical / Chassis unit.)

Optical / Chassis unit removal. (front side screws)

B

Mechanical disassemblies

Fig. 2-1

Fig. 2-2

Fig. 2-3a

Fig. 2-3b

Re

mo

the 2

screw

s B insi

2

-

1R

Cov

mo

un

the

t(R) a

Cover

nd C

nit(

over

)an

unit(L

Cov

) rem

run

oval.

L) o

- 18 -

C

Optical / Chassis unit

1. Remove the 3 screws C (T4 x 14) and remove the

Optical / Chassis unit.

2-4

Optical / Chassis unit removal (rear side screws).

A

B

SHAFT

COVER SHAFT

COVER SHAF

T

COVER(L)

COVER(R)

1. Remove the 6 screws A (T3 X 10), remove the 3 Shaft covers

and remove the 3 Shaft from the Cover(R).

2. Remove the 6 screws B (T3 X 10), remove the 3 Shaft covers

and remove the 3 Shaft from the Cover(L).

3

Cover unit(R) and Cover unit(L) disassemblies.

Mechanical disassemblies

Fig. 2-4

Fig. 3

B

COV

1

2

-4

O

. Rem

Optica

O

ve th

/ Cha

3

sis

ews

unit r

C

(T4

emov

14

al (r

and

ar sid

mo

e sc

e the

ews)

4

2-

Fig.

F

C

- 19 -

4-1

Panel front unit disassemblies. (door)

DOOR

Push the this part and open the door.

Hook

A

AV FRONT BOARD

EARTH BRACKE

T

1. Push and open the Door.

Pull the Door and remove.

(Unhook the Panel front unit and take the Door off.)

4-2

Panel front unit disassemblies. (AV front board)

1. Remove the 8 screws A (T3X8) and remove the AV front board.

2. Remove the Earth bracket from the AV front board.

C

B

D

BUTTON SELECT

BUTTON POWER

DEC INLAY LED

CAP BUTTON

4-3

Panel front unit disassemblies. (button)

1. Remove the 2 screws B (T3X8), remove the Button power and

remove the Cap button.

2. Remove the 2 screws C (T3X6) and remove the DEC inlay LED.

3. Remove the 2 screws D (T3X8) and remove the Button select.

Mechanical disassemblies

Fig. 4-1

Fig. 4-2

Fig. 4-3

D

BU

TT

SELEC

T

4

-

P

ane

1P

fro

sh

t uni

dop

t disa

n the

sse

oo

blies

(do

r)

- 20 -

H

G

E

F

TEMP. SENSOR BOARD

SPACER SHEET

BRIGHT SENSOR BOARD

DEC SENSOR

DEC FRONT (R)

DEC FRONT (L)

1. Remove the screw H (T3X8) and remove the Bright sensor board.

2. Remove the screw E (T3X8), remove the Spacer sheet and remove the

DEC front(R).

3. Remove the screw F (T3X6), remove the Spacer sheet, remove the DEC

sensor and remove the DEC front(L).

4. Remove the screw G (T3X6) and remove the Temp. sensor board.

5-1

Cover duct LCD top removal.

A

COVER DUCT LCD TOP

OPTICAL / CHASSIS UNIT

1. Remove the 4 screws A (M3 x 8) and remove the

Cover duct LCD top.

4-4

Panel front unit disassemblies. (decorations and sensor boards)

Mechanical disassemblies

Fig. 4-4

Fig. 5-1

4

-4

P

1. Re

P

anel

P

ove t

ont u

es

td

ew

H

sasse

(T3X

embli

an

es. (

rem

ecora

et

tion

eBri

and

ht se

sens

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