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
THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).
This service manual should be used together with the following manual(s).
AC220 - 240V
AC220 - 240V
SCHEMATIC DIAGRAM, PCB CONNECTION DIAGRAM
For details, refer to "Important symbols for good services".
T-ZZY AUG. 2004 printed in Japan
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.
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
(FOR CANADIAN MODEL ONLY)
(fast operating fuse) and/or
(slow operating fuse) on PCB indicate that replacement parts
must be of identical designation.
(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.
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-
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
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
· 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.
· When the front case is removed, infrared ray is radiated and
may disturb reception of the remote control unit.
· 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.
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 0.3M
and a maximum resistor reading of 5M
. Any resistor value
below or above this range indicates an abnormality which
requires 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 0.5mA.
ANY MEASUREMENTS NOT 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
Electrical components having such features are identified by
marking with a
on the schematics and on the parts list in this
The use of a substitute replacement component which dose 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 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.
not be above
Also test with
(Using AC adapter
plug as required)
AC Leakage Test
Fig.1 Charged Section and High Voltage Generating Point (Rear View)
The places where the commercial AC power is used without
passing through the power supply transformer.
If the places are touched, there is a risk of electric shock. In
addition, the measuring equipment can be damaged if it is
connected to the GND of the charged section and the GND of the
non-charged section while connecting the set directly to the
commercial AC power supply. Therefore, be sure to connect the
set via an insulated transformer and supply the current.
1. AC Power Cord
2. AC Inlet with Filter
3. Power Switch (S1)
4. Fuse (In the POWER SUPPLY Unit)
5. STB Transformer and Converter Transformer
(In the POWER SUPPLY Unit)
6. Other primary side of the POWER SUPPLY Unit
High Voltage Generating Point
The places where voltage is 100V or more except for the charged
places described above. If the places are touched, there is a risk of
1. POWER SUPPLY Unit................................................... (215V)
2. 43 X DRIVE Assy .......................................... (235V to 215V)
3. 43 Y DRIVE Assy .......................................................... (345V)
4. 43 SCAN A Assy ............................................................ (345V)
5. 43 SCAN B Assy ............................................................ (345V)
6. X CONNECTOR AAssy ................................ (235V to 215V)
7. X CONNECTOR B Assy ............................... (235V to 215V)
: Part is the High Voltage Generating Points
other than the Charged Section.
: Part is Charged Section.
POWER SUPPLY Unit
43 Y DRIVE Assy
43 SCAN B Assy
43 SCAN A Assy
43 X DRIVE Assy
AC Inlet with Filter
Discharge the VSUS voltage, as shown below:
[Method for discharging the VSUS voltage]
1. Set DRF_SW on the DIGITAL VIDEO Assy to ON (Drive
OFF status). *1, 2
2. Leave the switch at that position for about 20-30 seconds.
3. If the power is on, turn it off. Then return DRF_SW to the OFF
*1: You can also set the unit to "Drive OFF status" by sending the
"DRF" RS232C command from the PC.
*2: DRF_SW can be switched whether the power is on or off.
*3: Power-down will occur if DRF_SW is set to OFF while the
power is on. (See "7.1.6 Power on/off function for the large-
[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.
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.
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.