PIONEER PRO-111FD/KUCXC Service Manual

PIONEER PRO-111FD/KUCXC Service Manual
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Service Manual for PIONEER PRO-111FD/KUCXC, downloadable as a PDF file.

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Sample pages

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 2008

2008 Printed in Japan

PDP-5020FD

ARP3476

FLAT PANEL TV

PDP-5020FD

THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).

Model

Type

Power Requirement

Remarks

PDP-5020FD

KUCXC

AC 120 V

For details, refer to "Important Check Points for good servicing".

T-IZS-001 MAY

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 2008

2008 Printed in Japan

PDP-5020FD

ARP3476

FLAT PANEL TV

PDP-5020FD

THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).

Model

Type

Power Requirement

Remarks

PDP-5020FD

KUCXC

AC 120 V

For details, refer to "Important Check Points for good servicing".

T-IZS-001 MAY

PDP-5020FD

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 certain electrical parts contain chemicals which are known to the state of California to

cause cancer, birth 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.

SAFETY PRECAUTIONS

NOTICE : Comply with all cautions and safety related notes

located on or inside the cabinet and on the chassis.

The following precautions should be observed :

1. When service is required, even though the PDP UNIT an

isolation transformer should be inserted between the power line

and the set in safety before any service is performed.

2. When replacing a chassis in the set, all the protective devices

must be put back in place, such as barriers, nonmetallic knobs,

adjustment and compartment covershields, isolation resistor-

capacitor, etc.

3. When service is required, observe the original lead dress. Extra

precaution should be taken to assure correct lead dress in the

high voltage circuitry area.

4. Always use the manufacture's replacement components.

Especially critical components as indicated on the circuit

diagram should not be replaced by other manufacture's.

Furthermore where a short circuit has occurred, replace those

components that indicate evidence of overheating.

5. Before returning a serviced set to the customer, the service

technician must thoroughly test the unit to be certain that it is

completely safe to operate without danger of electrical shock,

and be sure that no protective device built into the set by the

manufacture has become defective, or inadvertently defeated

during servicing. Therefore, the following checks should be

performed for the continued protection of the customer and

servicetechnician.

6. Perform the following precautions against unwanted radiation

and rise in internal temperature.

· Always return the internal wiring to the original styling.

· Attach parts (Gascket, Ferrite Core, Ground, Rear Cover,

Shield Case etc.) surely after disassembly.

7. Perform the following precautions for the PDP panel.

· When the front case is removed, make sure nothing hits the

panel face, panel corner, and panel edge (so that the glass does

not break).

· Make sure that the panel vent does not break. (Check that the

cover is attached.)

· Handle the FPC connected to the panel carefully.

Twisting or pulling the FPC when connecting it to the

connector will cause it to peel off from the panel.

8. Pay attention to the following.

· Pay extreme caution when the front case and rear panel are

removed because this may cause a high risk of disturbance to

TVs and radios in the surrounding.

PDP-5020FD

Leakage Current Cold Check

With the AC plug removed from an AC power source, place a

jumper across the two plug prongs. Turn the AC power switch on.

Using an insulation tester (DC 500V), connect one lead to the

jumpered AC plug and touch the other lead to each exposed metal

part (input/output terminals, screwheads, metal overlays, control

shafts, etc.), particularly any exposed metal part having a return

path to the chassis. Exposed metal parts having a return path to

the chassis should have a minimum resistor reading of 4 M

The below 4 M

resistor value indicate an abnormality which

require corrective action. Exposed metal parts not having a return

path to the chassis will indicate an open circuit.

Leakage Current Hot Check

Plug the AC line cord directly into an AC power source (do not

use an isolation transformer for this check).

Turn the AC power switch on.

Using a "Leakage Current Tester (Simpson Model 229

equivalent)", measure for current from all exposed metal parts of

the cabinet (input/output terminals, screwheads, metal overlays,

control shaft, etc.), particularly any exposed metal part having a

return path to the chassis, to a known earth ground (water pipe,

conduit, etc.). Any current measured must not exceed 1 mA.

ANY MEASUREMENTS NO T WITHIN THE LIMITS

OUTLINED ABOVE ARE INDICATIVE OF A POTENTIAL

SHOCK HAZARD AND MUST BE CORRECTED BEFORE

RETURNING THE SET TO THE CUSTOMER.

PRODUCT SAFETY NOTICE

Many electrical and mechanical parts in PIONEER set have

special safety related characteristics. These are often not evident

from visual inspection nor the protection afforded by them

necessarily can be obtained by using replacement components

rated for higher voltage, wattage, etc. Replacement parts which

have these special safety characteristics are identified in this

Service Manual.

Electrical 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 dose not

ha v e 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 information, always

consult the current PIONEER Service Manual. A subscription to,

or additional copies of, PIONEER Service Manual may be

obtained at a nominal charge from PIONEER.

Leakage

current

tester

Reading should

not be above

1 mA

Device

under

test

Test all

exposed metal

surfaces

Also test with

plug reversed

(Using AC adapter

plug as required)

Earth

ground

AC Leakage Test

PDP-5020FD

[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.

a 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.

PDP-5020FD

CONTENTS

SAFETY INFORMATION.......................................................................................................................................................... 2

1. SERVICE PRECAUTIONS .................................................................................................................................................... 6

1.1 NOTES ON SOLDERING ............................................................................................................................................... 6

1.2 CHARGED SECTION AND HIGH VOLTAGE GENERATING POINT ............................................................................. 7

2. SPECIFICATIONS................................................................................................................................................................. 8

2.1 ACCESSORIES .............................................................................................................................................................. 8

2.2 SPECIFICATIONS ........................................................................................................................................................ 10

2.3 PANEL FACILITIES....................................................................................................................................................... 12

3. BASIC ITEMS FOR SERVICE ............................................................................................................................................ 16

3.1 CHECK POINTS AFTER SERVICING ......................................................................................................................... 16

3.2 QUICK REFERENCE ................................................................................................................................................... 17

3.3 PCB LOCATIONS ......................................................................................................................................................... 19

3.4 JIGS LIST ..................................................................................................................................................................... 20

4. BLOCK DIAGRAM .............................................................................................................................................................. 22

4.1 OVERALL WIRING DIAGRAM (1/2) ............................................................................................................................. 22

4.2 OVERALL WIRING DIAGRAM (2/2) ............................................................................................................................. 24

4.3 OVERALL BLOCK DIAGRAM (1/2) .............................................................................................................................. 26

4.4 OVERALL BLOCK DIAGRAM (2/2) .............................................................................................................................. 28

4.5 POWER SUPPLY UNIT ................................................................................................................................................ 30

4.6 50F X DRIVE ASSY...................................................................................................................................................... 32

4.7 50F Y DRIVE, 50F SCAN A and B ASSYS .................................................................................................................. 33

4.8 POWER SUPPLY BLOCK of 50F X, Y DRIVE and 50F SCAN A and B ASSYS ......................................................... 34

4.9 50F ADDRESS L and S ASSYS................................................................................................................................... 35

4.10 50F DIGITAL ASSY .................................................................................................................................................... 36

4.11 MAIN ASSY (DTV BLOCK DIAGRAM)....................................................................................................................... 37

4.12 POWER SUPPLY BLOCK of MAIN ASSY .................................................................................................................. 38

4.13 IO_AUDIO ASSY ........................................................................................................................................................ 40

4.14 LED and IR ASSYS .................................................................................................................................................... 42

5. DIAGNOSIS ........................................................................................................................................................................ 43

5.1 POWER SUPPLY OPERATION.................................................................................................................................... 43

5.2 DIAGNOSIS FLOWCHART OF FAILURE ANALYSIS .................................................................................................. 49

5.3 DIAGNOSIS OF PD (POWER-DOWN)......................................................................................................................... 72

5.4 DIAGNOSIS OF SD (SHUTDOWN) ............................................................................................................................. 76

5.5 NON-FAILURE INFORMATION .................................................................................................................................... 80

5.6 OUTLINE OF THE OPERATION .................................................................................................................................. 82

5.7 OUTLINE OF RS-232C COMMAND ............................................................................................................................ 87

5.8 LIST OF RS-232C COMMANDS .................................................................................................................................. 88

5.9 DETAILS OF EACH COMMANDS ................................................................................................................................ 97

6. SERVICE FACTORY MODE ............................................................................................................................................. 111

6.1 OUTLINE OF THE SERVICE FACTORY MODE ........................................................................................................ 111

6.2 DETAILS OF FACTORY MENU .................................................................................................................................. 119

6.3 DIGITAL TUNER SERVICE MENU............................................................................................................................. 144

7. DISASSEMBLY ................................................................................................................................................................. 146

7.1 FLOWCHART OF REMOVAL ORDER ....................................................................................................................... 146

7.2 DISASSEMBLY ........................................................................................................................................................... 147

7.3 PRECAUTIONS FOR SPEAKER SYSTEM................................................................................................................ 157

8. EACH SETTING AND ADJUSTMENT .............................................................................................................................. 158

8.1 ADJUSTMENT REQUIRED WHEN THE UNIT IS REPAIRED OR REPLACED ........................................................ 158

8.2 BACKUP OF THE EEPROM (DIGITAL ASSY) ........................................................................................................... 161

8.3 HOW TO CLEAR HISTORY DATA .............................................................................................................................. 164

8.4 ADJUSTMENT WHEN THE SERVICE PANEL ASSY IS REPLACED ....................................................................... 165

8.5 ADJUSTMENT WHEN THE DRIVE ASSYS ARE REPLACED.................................................................................. 176

8.6 HOW TO UPDATE USB.............................................................................................................................................. 179

8.7 ADJUSTMENT WHEN THE MAIN OR IO_AUDIO ASSY IS REPLACED.................................................................. 181

9. EXPLODED VIEWS AND PARTS LIST............................................................................................................................. 182

9.1 PACKING SECTION ................................................................................................................................................... 182

9.2 REAR SECTION......................................................................................................................................................... 184

9.3 FRONT SECTION ...................................................................................................................................................... 186

9.4 CHASSIS SECTION (1/2)........................................................................................................................................... 188

9.5 CHASSIS SECTION (2/2)........................................................................................................................................... 190

9.6 PANEL CHASSIS SECTION....................................................................................................................................... 192

9.7 MULTIBASE SECTION............................................................................................................................................... 194

9.8 PDP SERVICE ASSY ................................................................................................................................................. 196

9.9 TABLE TOP STAND.................................................................................................................................................... 198

9.10 SPEAKER SYSTEM (PACKING) .............................................................................................................................. 199

9.11 SPEAKER SYSTEM ................................................................................................................................................. 200