PIONEER PDP-R05G Service Manual

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Service Manual for PIONEER PDP-R05G, 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 2004
POWER
ON
STANDBY
PDP-R05G
PROVISIONAL
MEDIA RECEIVER
PDP-R05G
THIS MANUAL IS APPLICABLE TO THE FOLLOWINGMODEL(S) AND TYPE(S).
Please connect it to the PLASMA DISPLAY PDP-505PG or PDP-435PG for adjustment and
operation inspection.
Model
Type
Power Requirement
Remarks
PDP-R05G
TLDPFR
AC110-240V
For details, refer to "Important Check Points for Good Servicing".
T-ZZK NOV. 2004 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 2004
POWER
ON
STANDBY
PDP-R05G
PROVISIONAL
MEDIA RECEIVER
PDP-R05G
THIS MANUAL IS APPLICABLE TO THE FOLLOWINGMODEL(S) AND TYPE(S).
Please connect it to the PLASMA DISPLAY PDP-505PG or PDP-435PG for adjustment and
operation inspection.
Model
Type
Power Requirement
Remarks
PDP-R05G
TLDPFR
AC110-240V
For details, refer to "Important Check Points for Good Servicing".
T-ZZK NOV. 2004 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
Service 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 Check Points for Good Servicing]
In this manual, procedures that must be performed during repairs are marked with the below symbol.
Please be sure to confirm and follow these procedures.
1. Product safety
Please conform to product regulations (such as safety and radiation regulations), and maintain a safe servicing environment by
following the safety instructions described in this manual.
1 Use specified parts for repair.
Use genuine parts. Be sure to use important parts for safety.
2 Do not perform modifications without proper instructions.
Please follow the specified safety methods when modification(addition/change of parts) is required due to interferences such as
radio/TV interference and foreign noise.
3 Make sure the soldering of repaired locations is properly performed.
When you solder while repairing, please be sure that there are no cold solder and other debris.
Soldering should be finished with the proper quantity. (Refer to the example)
4 Make sure the screws are tightly fastened.
Please be sure that all screws are fastened, and that there are no loose screws.
5 Make sure each connectors are correctly inserted.
Please be sure that all connectors are inserted, and that there are no imperfect insertion.
6 Make sure the wiring cables are set to their original state.
Please replace the wiring and cables to the original state after repairs.
In addition, be sure that there are no pinched wires, etc.
7 Make sure screws and soldering scraps do not remain inside the product.
Please check that neither solder debris nor screws remain inside the product.
8 There should be no semi-broken wires, scratches, melting, etc. on the coating of the power cord.
Damaged power cords may lead to fire accidents, so please be sure that there are no damages.
If you find a damaged power cord, please exchange it with a suitable one.
9 There should be no spark traces or similar marks on the power plug.
When spark traces or similar marks are found on the power supply plug, please check the connection and advise on secure
connections and suitable usage. Please exchange the power cord if necessary.
0 Safe environment should be secured during servicing.
When you perform repairs, please pay attention to static electricity, furniture, household articles, etc. in order to prevent injuries.
Please pay attention to your surroundings and repair safely.
2. Adjustments
To keep the original performance of the products, optimum adjustments and confirmation of characteristics within specification.
Adjustments should be performed in accordance with the procedures/instructions described in this manual.
4. Cleaning
For parts that require cleaning, such as optical pickups, tape deck heads, lenses and mirrors used in projection monitors, proper
cleaning should be performed to restore their performances.
3. Lubricants, Glues, and Replacement parts
Use grease and adhesives that are equal to the specified substance.
Make sure the proper amount is applied.
5. Shipping mode and Shipping screws
To protect products from damages or failures during transit, the shipping mode should be set or the shipping screws should be
installed before shipment. Please be sure to follow this method especially if it is specified in this manual.
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CONTENTS
SAFETY INFORMATION ..................................................................................................................................... 2
1. SPECIFICATIONS ............................................................................................................................................ 5
2. EXPLODED VIEWS AND PARTS LIST ............................................................................................................ 6
2.1 PACKING SECTION .................................................................................................................................. 6
2.2 EXTERIOR SECTION................................................................................................................................ 8
2.3 FRONT PANEL SECTION ....................................................................................................................... 10
3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM ..........................................................................................12
3.1 BLOCK DIAGRAM ................................................................................................................................... 12
3.1.1 SIGNAL ROUTE ................................................................................................................................... 12
3.1.2 MR MAIN BOARD ASSY................................................................................................................... 14
3.1.3 AV BOARD ASSY ................................................................................................................................. 16
3.1.4 POWER SUPPLY UNIT......................................................................................................................... 18
3.2 OVERALL WIRING CONNECTION DIAGRAM........................................................................................ 20
3.3 MR MAIN BOARD ASSY (1/13)............................................................................................................... 22
3.4 MR MAIN BOARD ASSY (2/13)............................................................................................................... 24
3.5 MR MAIN BOARD ASSY (3/13)............................................................................................................... 26
3.6 MR MAIN BOARD ASSY (4/13)............................................................................................................... 28
3.7 MR MAIN BOARD ASSY (5/13)............................................................................................................... 30
3.8 MR MAIN BOARD ASSY (6/13)............................................................................................................... 32
3.9 MR MAIN BOARD ASSY (7/13)............................................................................................................... 34
3.10 MR MAIN BOARD ASSY (8/13)............................................................................................................. 36
3.11 MR MAIN BOARD ASSY (9/13)............................................................................................................. 38
3.12 MR MAIN BOARD ASSY (10/13)........................................................................................................... 40
3.13 MR MAIN BOARD ASSY (11/13)........................................................................................................... 42
3.14 MR MAIN BOARD ASSY (12/13)........................................................................................................... 44
3.15 MR MAIN BOARD ASSY (13/13)........................................................................................................... 46
3.16 AV BOARD ASSY (1/8).......................................................................................................................... 48
3.17 AV BOARD ASSY (2/8).......................................................................................................................... 50
3.18 AV BOARD ASSY (3/8).......................................................................................................................... 52
3.19 AV BOARD ASSY (4/8).......................................................................................................................... 54
3.20 AV BOARD ASSY (5/8).......................................................................................................................... 56
3.21 AV BOARD ASSY (6/8).......................................................................................................................... 58
3.22 AV BOARD ASSY (7/8).......................................................................................................................... 60
3.23 AV BOARD ASSY (8/8).......................................................................................................................... 62
3.24 MDR ASSY ............................................................................................................................................ 64
3.25 SR ASSY ............................................................................................................................................... 66
3.26 FRONT ASSY (1/2)................................................................................................................................ 68
3.27 FRONT ASSY (2/2)................................................................................................................................ 70
3.28 LED ASSY ............................................................................................................................................. 71
3.29 REG ASSY............................................................................................................................................. 72
3.30 POWER SUPPLY UNIT.......................................................................................................................... 74
3.31 WAVEFORMAS and VOLTAGES............................................................................................................ 76
4. PCB CONNECTION DIAGRAM ..................................................................................................................... 80
4.1 AC SW and MDR ASSYS ........................................................................................................................ 80
4.2 REG ASSY............................................................................................................................................... 81
4.3 MR MAIN BOARD ASSY ......................................................................................................................... 82
4.4 AV BOARD and SR ASSYS..................................................................................................................... 86
4.5 FRONT and LED ASSYS......................................................................................................................... 90
5. PCB PARTS LIST ........................................................................................................................................... 92
6. ADJUSTMENT ............................................................................................................................................... 99
6.1 HOW TO ENTER SERVICE FACTORY MODE........................................................................................ 99
6.2 POSSIBLE CASES WHERE READJUSTMENT IS REQUIRED ............................................................. 99
6.3 USING RS-232C COMMANDS.............................................................................................................. 100
6.4 ADJUSTMENT ITEMS ........................................................................................................................... 101
6.5 TRAP SWITCH ...................................................................................................................................... 104
6.6 SERVICING USING ONLY THE MEDIA RECEIVER ............................................................................. 105
6.7 SERVICE FACTORY MODE .................................................................................................................. 106
6.8 LIST OF RS-232C COMMANDS ........................................................................................................... 120
6.9 OUTLINE OF COMMANDS ................................................................................................................... 123
7. GENERAL INFORMATION ........................................................................................................................... 128
7.1 DIAGNOSIS ........................................................................................................................................... 128
7.1.1 TROUBLE SHOOTING .................................................................................................................... 128
7.1.2 DISASSEMBLY................................................................................................................................ 138
7.2 EXPLANATION ...................................................................................................................................... 140
7.2.1 PROCESSING IN ABNORMALITY..................................................................................................... 140
7.3 PARTS.................................................................................................................................................... 144
7.3.1 IC ..................................................................................................................................................... 144
7.4 CLEANING............................................................................................................................................. 177
8. PANEL FACILITIES ...................................................................................................................................... 178
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1. SPECIFICATIONS
Item
Media Receiver, Model: PDP-R05G
Color System
PAL/SECAM/NTSC/4.43 NTSC//PAL-M/PAL-N
TV Function
Receiving System
PAL: B/G, D/K, I, M, N
SECAM: B/G, D/K
NTSC: M
4.43NTSC: M
Tuner
VHF/UHF
44.25-863.25 MHz
CATV
Hyper-band, S1­S41ch
Auto Channel Preset
99 ch (Normal), 68 ch (Air, US type), 125 ch (Cable, US type), Auto Preset
Audio multiplex
NICAM/A2/BTSC System
Terminals
Rear
INPUT 1
COMPONENT VIDEO in, S-VIDEO in, AV in
INPUT 2
SS-VIDEO in, AV in
INPUT 3
COMPONENT VIDEO in, S-VIDEO in, AV in, HDMI in
1
Antenna
75
Din Type for VHF/UHF in
Front
INPUT 4
S-VIDEO, AV in
PC
15 Pin mini D-Sub, Audio in
MONITOR OUTPUT Terminal (Rear)
S-VIDEO out, AV out
Power Requirement
110-240 V ~ , 50/60 Hz, 35 W (0.4 W Standby)
Dimensions
420 (W)
× 90 (H) × 295 (D) mm
Weight
4.9 kg
Operating instructions
Remote control unit
(AXD1492)
Screw x 4 (PMB40P120FZK)
(for stand)
Screw hole cap x 4
(AMR3363)
Stand (AXG1013)
System cable (3 m) (ADF1026)
AA size battery x 2
(Manganese battery)
(VEM1031)
· Accessories
· Design and specifications are subject to change without notice.
Trademarks
· FOCUS, WOW, SRS and
symbol are trademarks of SRS Labs, Inc.
FOCUS and SRS technologies are incorporated under license from SRS Labs, Inc.
· This product includes FontAvenue® fonts licensed by NEC Corporation.
FontAvenue is a registered trademark of NEC Corporation.
· Microsoft is a registered trademark of Microsoft Corporation.
· HDMI, the HDMI logo and High-Definition Multimedia Interface are trademarks or registered trademarks of HDMI
Licensing LLC.
· The names of the companies or institutions are trademarks or registered trademarks of the respective companies or
institutions.

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