FILE NO. 030-200301
SERVICE MANUAL
COLOUR TELEVISION
ZP38 Chassis
36ZP38B, 32ZP38B
PUBLISHED IN JAPAN,
Mar., 2003
So
2
GENERAL
ADJUSTMENTS
SPECIFIC
INFORMATIONS
TABLE OF CONTENTS
CHAPTER 1 GENERAL ADJUSTMENTS
SAFETY INSTRUCTIONS ........................................................................................................................................ 3
SET-UP ADJUSTMENT ............................................................................................................................................ 4
SERVICE MODE ...................................................................................................................................................... 6
DESIGN MODE ........................................................................................................................................................ 9
ELECTRICAL ADJUSTMENTS .............................................................................................................................. 10
CIRCUIT CHECK .................................................................................................................................................... 17
CHAPTER 2 SPECIFIC INFORMATIONS
SETTING & ADJUSTING DATA .............................................................................................................................. 18
LOCATION OF CONTROLS ................................................................................................................................... 19
CHASSIS AND CABINET REPLACEMENT PARTS LIST ......................................................................................21
PC BOARDS BOTTOM VIEW ................................................................................................................................. 35
TERMINAL VIEW OF TRANSISTORS ................................................................................................................... 44
CIRCUIT BLOCK DIAGRAM .................................................................................................................................. 46
SPECIFICATIONS .............................................................................................................................................. END
APPENDIX:
CIRCUIT DIAGRAM
3
GENERAL
ADJUSTMENTS
SPECIFIC
INFORMATIONS
CHAPTER 1 GENERAL ADJUSTMENTS
SAFETY INSTRUCTIONS
WARNING: BEFORE SERVICING THIS CHASSIS, READ THE "X-RAY RADIATION PRECAUTION", "SAFETY PRECAU-
TION" AND "PRODUCT SAFETY NOTICE" INSTRUCTIONS BELOW.
X-RAY RADIATION PRECAUTION
1. Excessive high voltage can produce potentially hazard-
ous X-RAY RADIATION. To avoid such hazards, the high
voltage must not be above the specified limit. The nominal
value of the high voltage of this receiver is (A) kV at zero
beam current (minimum brightness) under a (C) V AC power
source.The high voltage must not, under any circumstances,
exceed (B) kV.
Refer to table-1 for high voltage (A), (B) & AC voltage (C).
(See SETTING & ADJUSTING DATA on page 18)
Each time a receiver requires servicing, the high voltage
should be checked following the HIGH VOLTAGE CHECK
procedure in this manual. It is recommended that the read-
ing of the high voltage be recorded as a part of the service
record. It is important to use an accurate and reliable high
voltage meter.
2. The only source of X-RAY RADIATION in this TV receiver
is the picture tube. For continued X-RAY RADIATION pro-
tection, the replacement tube must be exactly the same
type tube as specified in the parts list.
3. Some part in this receiver have special safety-related char-
acteristics for X-RAY RADIATION protection. For contin-
ued safety, parts replacement should be undertaken only
after referring to the PRODUCT SAFETY NOTICE below.
SAFETY PRECAUTION
WARNING : Service should not be attempted by anyone unfamiliar with the necessary precautions on this receiver. The following
are the necessary precautions to be observed before servicing this chassis.
1. An isolation transformer should be connected in the power line between the receiver and the AC line before any service is
performed on the receiver.
2. Always discharge the picture tube anode to the CRT conductive coating before handling the picture tube. The picture tube
is highly evacuated and if broken, glass fragments will be violently expelled. Use shatter proof goggles and keep picture tube
away from the unprotected body while handling.
3. When replacing a chassis in the cabinet, always be certain that all the protective devices are put back in place, such as; non-
metallic control knobs, insulating covers, shields, isolation resistor-capacitor network etc.
PRODUCT SAFETY NOTICE
Many electrical and mechanical parts in this chassis have special safety-related characteristics. These characteristics are
often passed unnoticed by a visual inspection and the protection afforded by them cannot necessarily be obtained by using
replacement components rated for higher voltage, wattage, etc. Replacement parts which have these special safety char-
acteristics are identified in this manual and its supplements; electrical components having such features are identified by
the international hazard symbols on the schematic diagram and the parts list.
Before replacing any of these components, read the parts list in this manual carefully. The use of substitute replacement
parts which do not have the same safety characteristics as specified in the parts list may create shock, fire, X-ray
radiation or other hazards.
4
GENERAL
ADJUSTMENTS
SPECIFIC
INFORMATIONS
WARNING: BEFORE SERVICING THIS CHASSIS, READ THE "X-RAY RADIATION PRECAUTION", "SAFETY PRECAU-
TION" AND "PRODUCT SAFETY NOTICE" ON PAGE 3 OF SERVICE MANUAL.
SET-UP ADJUSTMENT
I The following adjustments should be made when a complete realignment is required or a new picture tube is installed.
Perform the adjustments in order as follows :
1. Color Purity
2. Convergence
3. White Balance
Note: The PURITY/CONVERGENCE MAGNET assembly and rubber wedges need mechanical positioning.
Refer to figure 1.
COLOR PURITY ADUSTMENT
(1)Let the screen face in the installing direction or toward the east (when it is to be moved), bring up the service mode
screen after demagnetizing (front, left, right, and top) with the degaussing coil, receive white signals by pressing the
[TV/VIDEO] button, and then the receiver should be operated for more than 40 minutes.
(2)Perform rough adjustment of the central convergence with the P/C magnet according to the adjustment item.
(3)Receive built-in green signals, loosen set screws on the deflection yoke, remove rubber wedges, and shift the deflection
yoke to toward front.
(4)Move alternately the two 2-pole magnets of the P/C magnets so that the green raster can come to the center of the
screen.
Figure 1.
(5)Receive built-in red and blue signals, check that there is no inclination of the single color raster toward one side, and if
each color tilts to a great extent, make adjustment with the 2-pole magnet so that the 3 colors will come to the center
evenly.
(6)Receive the green raster, shift the deflection yoke from a
foremost position (hitting against the picture tube) to a
backward position horizontally, stop the deflection yoke
at a position where it begins to become a green raster,
and perform accurate marking on the picture tube.
(7)Shift the deflection yoke further backward, and perform
accurate marking at a position where the green raster
begins to being luck.
(8)Fix the deflection yoke at a position 60% forward within
the range marked in items (6) and (7) above.
CONVERGENCE ADJUSTMENTS
* Adjust the convergence magnet to get vest convergence in the the order to (1) ~ (5).
I CENTER CONVERGENCE:
(1)Receive the white crosshatch or dot pattern from the service signal generator.
(2)Use the 2 pieces of main 4-pole magnets of P/C magnets, change the open angle, and align the red and blue vertical
lines on the screen center.
(3)Freeze the open angle of the main 4-pole magnets, turn them simultaneously, and align the horizontal lines.
(4)Take the same steps for items (2) and (3) above and align red/blue with green on the screen center using two 6-pole
magnets.
A
P/C magnet installing position A
· 30"=26.5 mm
· 32"=30.5 mm or 32.5 mm
· 34"=37 mm
· 34"=39 mm
Green Belt
2-pole purity magnet
(27": Magnet is fixed with deflection yoke.)
Main 4-pole convergence magnet (30" : 32")
6-pole convergence magnet (34")
Sub-4-pole convergence magnet (32" : 34")
Sub-4-pole convergence magnet (to be installed on deflection yoke for 30", 32")
6-pole convergence magnet (30" : 32")
Main 4-pole convergence magnet (34")
Fix the deflection yoke at a position 60% forward from a
point between (6) and (7)
Picture tube
Shift deflection yoke
(6)
(8)
(7) Perform marking of each point
on the tape of picture tube
CRT-D board
P/C Mag
100 60 0%
5
GENERAL
ADJUSTMENTS
SPECIFIC
INFORMATIONS
(5)Adjust the sub-4-pole magnets only in case there is any deviation of Xv bow-shaped convergence. (To be usually set at
the initial position)
Align both sides with the sub-4-pole magnets and minimize the deviation of blue and red with the main 4-pole magnets.
blue
blue
red
red
Main 4-pole magnet
red/blue
red/blue
green
green
6-pole magnet
Xv bow-shaped deviation of convergence
blue
red
Sub-4-pole magnet
I CIRCUMFERENCE CONVERGENCE:
* Perform correction in the following manner.
A
D
E
F
A
B
C
B
C
S
N
D
E
F
A
B
C
D
E
F
N
S
VR3
YV YHC
GH
GH
VR2 VR1
blue
green
red
· Adjust coils and minimize deviation
(The 27" unit has coils underneath it)
blue
green
red
(Parts code:23 948 274) TC-S
Blue color or blue mark
*Insert the correction piece between the
picture tube and the deflection yoke.
(Insertion position of correction
piece)
Bonded surface
blue
green
red
(Parts code:23 948 464)
Bonded surface
Adjust VR 1 and minimize the deviation of YH. *Only 27", 30" and 32".
Red
green
blue
Red
green
blue
Red
green
blue
Red
green
blue
Adjust VR 2 (YHC) and minimize the deviation of YH.
Red
green
blue
Red
green
blue
Red
green
blue
Red
green
blue
Adjust VR 3 (YV) and minimize the deviation of YV.
Red
blue
green
Red
blue
green
Red
blue
green
Red
blue
green
Red
blue
green
blue
red
green
Red
blue
green
blue
red
green
I 30", 27", 32"
I 34"
27" (Part No. 23 947 371)
32", 30" (Part No. 23 947 121)
34" (Part No. 23 993 080)
Perform correction by inserting the
correction piece into the clear-
ance of terminal board coils of
the deflection yoke.
Note:
Perform insertion by turning the
metal side to the terminal board
side of the deflection yoke.