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.
C
CAUT
RISK
UTION
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XP
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IF
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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
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
Be
efore p
Be
press t
p
e
et bu
o
n
, ma
ke sur
e tha
t
the A
C co
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Th
ins
s LCD
pro
ction
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id
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n safe
rate i
o ope

- 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
●
L
Lamp
cov
e
swi
tch
C
OV
M
P C

- 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
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
LE
RIC
HO
ND
OCK.
T I
FIRE
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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
a
ing
re
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c
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ake
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A
A
i
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
C
Ca
Ca
C
or
U
s
s
i
i
i
ngng
g
g
g
t
t
t
h
h
he
h
LC
L
C
D
Pro
ojec
cti
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
10cm 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
i

Exhaust vents (Hot air exhaust)
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;
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
e
nic sol
panel
a
an
p
e
(thinn
pped
er
,
w
i
t
er
etc.)
h an
or an
electr
y kind
nic
of cle
rcuit
anse
e
v
e
on th
use
ese c
any liq
qui
nent
(wate
r,etc.)
to clean
●
O
Opti
O
al p
arts
s ca
re a
nd
clea
ani
ng
on
enti
atte
ial
pec
hsp
art
spa
h
dle
an
to h
re t
s
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 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
b
b
b
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ot
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ot
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s
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i
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es o
of th
he
co
ver
t
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
Tnormal : used time in the Normal, Auto and Eco1
mode
You can check the lamp replace counter following to
below procedure.
1Press 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
C
CC
B
B
B
B
A
AA
A
A
A
A
A
A
A
A
A
BRACKET(R)
BRACKET(L)
CABINET BOTTOM COVER
RATING SHEET
1Cabinet 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
A
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
A
A
APANEL 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
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
CC
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).
AA
AA
AA
BB
BB
B
B
SHAFT SHAFT
SHAFT
SHAFT
SHAFT
COVER SHAFT
COVER SHAFT
COVER SHAFT
COVER SHAFT
COVER SHAF
T
COVER(L)
COVER(R)
1. Remove the 6screws A(T3 X 10), remove the 3 Shaft covers
and remove the 3 Shaft from the Cover(R).
2. Remove the 6screws B(T3 X 10), remove the 3 Shaft covers
and remove the 3 Shaft from the Cover(L).
3Cover 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
AAA
A
AA
AAV 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 8screws A(T3X8) and remove the AV front board.
2. Remove the Earth bracket from the AV front board.
C
C
B
B
D
DBUTTON SELECT
BUTTON POWER
DEC INLAY LED
CAP BUTTON
4-3 Panel front unit disassemblies. (button)
1. Remove the 2screws B (T3X8), remove the Button power and
remove the Cap button.
2. Remove the 2screws C(T3X6) and remove the DEC inlay LED.
3. Remove the 2screws 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
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
AAA
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