PIONEER PDP-R04U Service Manual

Cover page of PIONEER PDP-R04U Service Manual

Service Manual for PIONEER PDP-R04U, downloadable as a PDF file.

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ORDER NO.
PIONEER CORPORATION 4-1, Meguro 1-chome, Meguro-ku, Tokyo 153-8654, Japan
PIONEER ELECTRONICS (USA) INC. P.O. Box 1760, Long Beach, CA 90801-1760, U.S.A.
PIONEER EUROPE NV Haven 1087, Keetberglaan 1, 9120 Melsele, Belgium
PIONEER ELECTRONICS ASIACENTRE PTE. LTD. 253 Alexandra Road, #04-01, Singapore 159936
PIONEER CORPORATION 2003
PDP-R04U
ARP3178
MEDIA RECEIVER
PDP-R04U
PRO-R04U
THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).
Please connect it to the PLASMA DISPLAY PDP-504PU, PDP-434PU, PRO-504PU or PRO-
434PU, for adjustment and operation inspection.
Model
Type
Power Requirement
Remarks
PDP-R04U
TUCK
AC120-240V
PRO-R04U
KUC
AC120V
For details, refer to "Important symbols for good services".
T-ZZK DEC. 2003 printed in Japan
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ORDER NO.
PIONEER CORPORATION 4-1, Meguro 1-chome, Meguro-ku, Tokyo 153-8654, Japan
PIONEER ELECTRONICS (USA) INC. P.O. Box 1760, Long Beach, CA 90801-1760, U.S.A.
PIONEER EUROPE NV Haven 1087, Keetberglaan 1, 9120 Melsele, Belgium
PIONEER ELECTRONICS ASIACENTRE PTE. LTD. 253 Alexandra Road, #04-01, Singapore 159936
PIONEER CORPORATION 2003
PDP-R04U
ARP3178
MEDIA RECEIVER
PDP-R04U
PRO-R04U
THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).
Please connect it to the PLASMA DISPLAY PDP-504PU, PDP-434PU, PRO-504PU or PRO-
434PU, for adjustment and operation inspection.
Model
Type
Power Requirement
Remarks
PDP-R04U
TUCK
AC120-240V
PRO-R04U
KUC
AC120V
For details, refer to "Important symbols for good services".
T-ZZK DEC. 2003 printed in Japan
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SAFETY INFORMATION
This service manual is intended for qualified service technicians; it is not meant for the casual
do-it-yourselfer. Qualified technicians have the necessary test equipment and tools, and have been
trained to properly and safely repair complex products such as those covered by this manual.
Improperly performed repairs can adversely affect the safety and reliability of the product and may
void the warranty. If you are not qualified to perform the repair of this product properly and safely, you
should not risk trying to do so and refer the repair to a qualified service technician.
WARNING
This product contains lead in solder and cer tain electrical par ts contain chemicals which are known to the state of California to
cause cancer, bir th defects or other reproductive harm.
Health & Safety Code Section 25249.6 ­ Proposition 65
NOTICE
(FOR CANADIAN MODEL ONLY)
Fuse symbols
(fast operating fuse)
and/or
(slow operating fuse) on PCB indicate that replacement
parts must be of identical designation.
REMARQUE
(POUR MODÈLE CANADIEN SEULEMENT)
Les symboles de fusible
(fusible de type rapide)
et/ou
(fusible de type lent) sur CCI indiquent que
les pièces de remplacement doivent avoir la même désignation.
ANY MEASUREMENTS NOT WITHIN THE
LIMITS OUTLINED ABOVE ARE INDICATIVE
OF A POTENTIAL SHOCK HAZARD AND
MUST BE CORRECTED BEFORE RETURN-
ING THE APPLIANCE TO THE CUSTOMER.
2. PRODUCT SAFETY NOTICE
Many electrical and mechanical parts in the appliance
have special safety related character istics. These are
often not evident
from visual
inspection nor the
protection afforded by them necessarily can be obtained
by using replacement components rated for voltage,
wattage, etc. Replacement par ts which have these
special safety character istics are identified in this
Service Manual.
Electr ical components having such features are
identified by marking with a
on the schematics and
on the parts list in this Service Manual.
The use of a substitute replacement component which
does not have the same safety characteristics as the
PIONEER recommended replacement one, shown in the
parts list in this Service Manual, may create shock, fire,
or other hazards.
Product Safety is continuously under review and new
instructions are issued from time to time. For the latest
infor mation, always consult the current PIONEER
Ser vice Manual. A subscription to, or
additional copies
of, PIONEER Ser vice Manual may be obtained at a
nominal charge from PIONEER.
(FOR USA MODEL ONLY)
1. SAFETY PRECAUTIONS
The following check should be perfor med for the
continued protection of the customer and ser vice
technician.
LEAKAGE CURRENT CHECK
Measure leakage current to a known ear th ground
(water pipe, conduit, etc.) by connecting a leakage
current tester such as Simpson Model 229-2 or
equivalent between the ear th ground and all exposed
metal par ts of the appliance (input/output ter minals,
screwheads, metal overlays, control shaft, etc.). Plug
the AC line cord of the appliance directly into a 120V
AC 60 Hz outlet and turn the AC power switch on. Any
current measured must not exceed 0.5 mA.
Device
under
test
Leakage
current
tester
Earth
ground
Reading should
not be above
0.5 mA
Also test with
plug reversed
(Using AC adapter
plug as required)
Test all
exposed metal
surfaces
AC Leakage Test
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[ Important symbols for good services ]
In this manual, the symbols shown-below indicate that adjustments, settings or cleaning should be made securely.
When you find the procedures bearing any of the symbols, be sure to fulfill them:
2. Adjustments
To keep the original performances of the product, optimum adjustments or specification confirmation is indispensable.
In accordance with the procedures or instructions described in this manual, adjustments should be performed.
3. Cleaning
For optical pickups, tape-deck heads, lenses and mirrors used in projection monitors, and other parts requiring cleaning,
proper cleaning should be performed to restore their performances.
5. Lubricants, glues, and replacement parts
Appropriately applying grease or glue can maintain the product performances. But improper lubrication or applying
glue may lead to failures or troubles in the product. By following the instructions in this manual, be sure to apply the
prescribed grease or glue to proper portions by the appropriate amount.For replacement parts or tools, the prescribed
ones should be used.
4. Shipping mode and shipping screws
To protect the product from damages or failures that may be caused during transit, the shipping mode should be set or
the shipping screws should be installed before shipping out in accordance with this manual, if necessary.
1. Product safety
You should conform to the regulations governing the product (safety, radio and noise, and other regulations), and
should keep the safety during servicing by following the safety instructions described in this manual.
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CONTENTS
SAFETY INFORMATION ..................................................................................................................................... 2
1. SPECIFICATIONS ............................................................................................................................................ 5
2. EXPLODED VIEWS AND PARTS LIST ............................................................................................................ 6
2.1 PACKING ................................................................................................................................................... 6
2.2 EXTERIOR SECTION................................................................................................................................ 8
2.3 FRONT SECTION.................................................................................................................................... 12
3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM ..........................................................................................14
3.1 BLOCK DIAGRAM AND SCHEMATIC DIAGRAM ................................................................................... 14
3.1.1 MR MAIN BOARD ............................................................................................................................. 14
3.1.2 AV BOARD ASSY.............................................................................................................................. 16
3.1.3 POWER SUPPLY UNIT ..................................................................................................................... 18
3.1.4 DTV TUNER BOARD......................................................................................................................... 19
3.2 OVERALL WIRING DIAGRAM................................................................................................................. 22
3.3 MR MAIN BOARD ASSY (1/13)............................................................................................................... 24
3.4 MR MAIN BOARD ASSY (2/13)............................................................................................................... 26
3.5 MR MAIN BOARD ASSY (3/13)............................................................................................................... 28
3.6 MR MAIN BOARD ASSY (4/13)............................................................................................................... 30
3.7 MR MAIN BOARD ASSY (5/13)............................................................................................................... 32
3.8 MR MAIN BOARD ASSY (6/13)............................................................................................................... 34
3.9 MR MAIN BOARD ASSY (7/13)............................................................................................................... 36
3.10 MR MAIN BOARD ASSY (8/13)............................................................................................................. 38
3.11 MR MAIN BOARD ASSY (9/13)............................................................................................................. 40
3.12 MR MAIN BOARD ASSY (10/13)........................................................................................................... 42
3.13 MR MAIN BOARD ASSY (11/13)........................................................................................................... 44
3.14 MR MAIN BOARD ASSY (12/13)........................................................................................................... 46
3.15 MR MAIN BOARD ASSY (13/13)........................................................................................................... 48
3.16 AV BOARD ASSY (1/7).......................................................................................................................... 50
3.17 AV BOARD ASSY (2/7).......................................................................................................................... 52
3.18 AV BOARD ASSY (3/7).......................................................................................................................... 54
3.19 AV BOARD ASSY (4/7).......................................................................................................................... 56
3.20 AV BOARD ASSY (5/7).......................................................................................................................... 58
3.21 AV BOARD ASSY (6/7).......................................................................................................................... 60
3.22 AV BOARD ASSY (7/7).......................................................................................................................... 62
3.23 BRIDGE ASSY....................................................................................................................................... 64
3.24 MDR ASSY ............................................................................................................................................ 66
3.25 SR ASSY ............................................................................................................................................... 68
3.26 FRONT ASSY (1/2)................................................................................................................................ 70
3.27 FRONT ASSY (2/2)................................................................................................................................ 72
3.28 LED ASSY ............................................................................................................................................. 73
3.29 AC SW ASSY and POWER SUPPLY UNIT ...........................................................................................74
3.30 WAVEFORMS ........................................................................................................................................ 76
3.31 VOLTAGES ............................................................................................................................................. 77
4. PCB CONNECTION DIAGRAM ..................................................................................................................... 81
4.1 AC SW and MDR ASSYS ........................................................................................................................ 81
4.2 MR MAIN BOARD ASSY ......................................................................................................................... 82
4.3 AV BOARD and SR ASSYS..................................................................................................................... 86
4.4 BRIDGE and MDR ASSYS ...................................................................................................................... 90
4.5 FRONT and LED ASSY ........................................................................................................................... 92
5. PCB PARTS LIST ........................................................................................................................................... 94
6. ADJUSTMENT ............................................................................................................................................. 102
6.1 HOW TO ENTER SERVICE FACTORY MODE...................................................................................... 102
6.2 POSSIBLE CASES WHERE READJUSTMENT IS REQUIRED ........................................................... 102
6.3 USING RS-232C COMMANDS.............................................................................................................. 103
6.4 ADJUSTMENT ITEMS ........................................................................................................................... 104
6.5 TRAP SWITCH ...................................................................................................................................... 108
6.6 SERVICING USING ONLY THE MEDIA RECEIVER ............................................................................. 109
6.7 SERVICE FACTORY MODE .................................................................................................................. 110
6.8 LIST OF RS-232C COMMANDS ........................................................................................................... 124
6.9 OUTLINE OF COMMANDS ................................................................................................................... 127
7. GENERAL INFORMATION ........................................................................................................................... 132
7.1 DIAGNOSIS ........................................................................................................................................... 132
7.1.1 TROUBLE SHOOTING .................................................................................................................... 132
7.1.2 DISASSEMBLY................................................................................................................................ 142
7.2 EXPLANATION ...................................................................................................................................... 145
7.2.1 PROCESSING IN ABNORMALITY ................................................................................................. 145
7.3 PARTS.................................................................................................................................................... 149
7.3.1 IC ..................................................................................................................................................... 149
7.4 CLEANING............................................................................................................................................. 171
8. PANEL FACILITIES ...................................................................................................................................... 172
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1. SPECIFICATIONS
Item
Media Receiver, Model: PDP-R04U, PRO-R04U
Reception System (Digital)
ATSC Digital TV system
Circuit type
8VSB demodulation
Tuner
VHF/UHF
VHF 2­13ch, UHF 14­69ch
CATV
2­125ch (Standard Channel Plan, 8VSB only)
Audio format
Dolby Digital
Reception System (Analog)
American TV standard NTSC system
Circuit type
Video signal detection PLL full synchronous detection, PLL digital
synthesizer system
Tuner
VHF/UHF
VHF 2­13ch, UHF 14­69ch
CATV
1­125ch
Audio multiplex
BTSC system
Terminals
Rear
DTV Antenna
75
UNBAL, F Type for DTV in
Antenna A
75
UNBAL, F Type for VHF/UHF/CATV in
Loop out
Antenna B
75
UNBAL, F Type for VHF/UHF/CATV in
Loop out
i.LINK (TS)
S400 (2)
INPUT 1
COMPONENT VIDEO in, S-VIDEO in, VIDEO in, AUDIO in, HDMI in
INPUT 2
S-VIDEO in, VIDEO in, AUDIO in
INPUT 3
COMPONENT VIDEO in, AUDIO in, HDMI in
Monitor Out
S-VIDEO out, VIDEO out, AUDIO out
Digital Audio Output
Optical (1)
VCR Control Output
1
CONTROL IN
1
CONTROL OUT
1
Front
INPUT 4
COMPONENT VIDEO in, S-VIDEO in, VIDEO in, AUDIO in,
PC
Analog RGB in, AUDIO in
OSD
English/French/Spanish/Korean(PDP-R04U)
Power Requirement
110­240 V AC, 50/60 Hz, 44.5 W (0.3 W Standby, 120 V) (PDP-R04U)
Dimensions
420 (W)
× 90 (H) × 297 (D) mm (16 /16 (W) × 3 /16 (H) × 11 /16 (D) inches)
99
11
Weight
5.7 kg (12.6 lbs.)
· Design and specifications are subject to change without notice.
Operating instruction
Power cord (2 m/6.6 feet)
(ADG1215)
Remote control unit
(PDP-R04U : AXD1478)
(PRO-R04U : AXD1484)
System cable (3 m/9.8 feet)
(ADF1021)
AA size battery x 2
(Alkaline battery)
Stand
(PDP-R04U : AXG1013)
(PRO-R04U : AXG1009)
Screw x 4 (for stand)
(PMB409120FZK)
Screw hole cap x 4
(PDP-R04U : AMR3363)
(PRO-R04U : AMR3386)
VCR controller x 1
(1.8 m/5.9 feet) (ADH1024)
Coaxial cable (0.15 m/0.49 feet) x 1
(Already set at the rear of the Media
Receiver) (ADE1190)

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