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PSG0905004CE

Vol.1

Product Color: (K)...Black Type

PAGE

PAGE

1 Safety Precautions----------------------------------------------- 4

1.1. GENERAL GUIDELINES -------------------------------- 4
1.2. Before Repair and Adjustment ------------------------- 4
1.3. Protection Circuitry ---------------------------------------- 4

1.4. Safety Parts Information---------------------------------- 6

2 Warning -------------------------------------------------------------- 7

2.1. Prevention of Electrostatic Discharge (ESD)

to Electrostatic Sensitive (ES) Devices--------------- 7

2

2.2. Precaution of Laser Diode -------------------------------8
2.3. Service caution based on Legal restrictions---------9
2.4. Handling Precautions for Traverse Unit ------------ 10

3 Service Navigation---------------------------------------------- 12

3.1. Service Information -------------------------------------- 12

4 Specifications ---------------------------------------------------- 13
5 Location of Controls and Components------------------ 15

5.1. Remote Control Key Button Operations ------------ 15
5.2. Main Unit Key Button Operations -------------------- 16
5.3. Speaker Connections ----------------------------------- 17
5.4. Connections to a Set Top Box, etc. ------------------ 18
5.5. Network connection-------------------------------------- 19
5.6. Media Information (Disc, SD Card and USB

device) ------------------------------------------------------ 20

5.7. Using the iPod -------------------------------------------- 24
5.8. Using BD-LIVE or BONUSVIEW in BD-Video ---- 26

6 Operating Instructions ---------------------------------------- 27

6.1. Door Assembly Unit Jam ------------------------------- 27

7 Self-Diagnosis and Special Mode Setting -------------- 28

7.1. Service Mode Summary Table ------------------------ 28
7.2. Special Mode Setting------------------------------------ 31
7.3. Service Mode at glance -------------------------------- 33

8 Service Fixture & Tools --------------------------------------- 38

8.1. Service Tools and Equipment ------------------------- 38

9 Disassembly and Assembly Instructions --------------- 39

9.1. Disassembly Flow Chart-------------------------------- 41
9.2. Main Components and P.C.B. Locations ----------- 42
9.3. Disassembly of Door Assembly ---------------------- 43
9.4. Disassembly of Left Ornament & Right

Ornament--------------------------------------------------- 44

9.5. Replacement of Rear Cabinet ------------------------ 45
9.6. Disassembly of  Top Ornament Assembly --------- 46
9.7. Disassembly of Power Button and Volume

Button P.C.B. ---------------------------------------------- 47

9.8. Disassembly of Rear Shield --------------------------- 48
9.9. Disassembly of Fan Sub Assembly ----------------- 49

9.10. Disassembly of SMPS Sub Block -------------------- 50

9.11. Disassembly of Tuner Pack --------------------------- 51

9.12. Disassembly of SMPS and AC Inlet P.C.B.-------- 53
9.13. Replacement of Switching Regulator IC

(IC5701) ---------------------------------------------------- 54

9.14. Replacement of Rectifier Diode (D5702)----------- 55
9.15. Replacement of Regulator Diode (D5801)--------- 56
9.16. Replacement of Regulator Diode (D5802)--------- 57
9.17. Replacement of Regulator Diode (D5803)--------- 58
9.18. Disassembly of Main P.C.B. --------------------------- 59
9.19. Disassembly of SD USB Wireless Assembly ----- 61
9.20. Disassembly of Wireless Adapter P.C.B.----------- 63
9.21. Disassembly of  SD USB P.C.B.---------------------- 64
9.22. Disassembly of  D-Amp P.C.B. ----------------------- 65
9.23. Replacement of  Audio Amplifier Driver IC

(IC5001) ---------------------------------------------------- 66

9.24. Disassembly of  Digital P.C.B. ------------------------ 67
9.25. Disassembly of  BD Mechanism Assembly-------- 69
9.26. Disassembly of  Motor P.C.B. ------------------------- 72
9.27. Disassembly of  Door Switch P.C.B.----------------- 73
9.28. Disassembly of  FL P.C.B. ----------------------------- 74
9.29. Disassembly of  Mechanism Switch P.C.B.-------- 74
9.30. Disassembly of iPod Fan P.C.B.---------------------- 75
9.31. Disassembly of iPod Fan  ------------------------------ 76
9.32. Disassembly of iPod Switch P.C.B.  ----------------- 76

9.33. Disassembly of iPod Docking Tub Assembly  ---- 77
9.34. Disassembly of iPod P.C.B. --------------------------- 79
9.35. Disassembly of IR P.C.B.  ----------------------------- 80

10 Service Position------------------------------------------------- 82

10.1. Checking & repairing of Main P.C.B.---------------- 82
10.2. Checking & repairing of Digital P.C.B. -------------- 84
10.3. Checking & repairing of D-Amp P.C.B. ------------- 87
10.4. Checking & repairing of SMPS P.C.B.-------------- 88
10.5. Checking & reparing of FL P.C.B. ------------------- 89
10.6. Checking & reparing of BD Mechanism------------ 89

11 Voltage & Waveform Chart ---------------------------------- 91

11.1. Digital P.C.B. (1/5) --------------------------------------- 91
11.2. Digital P.C.B. (2/5) --------------------------------------- 92
11.3. Digital P.C.B. (3/5) --------------------------------------- 93
11.4. Digital P.C.B. (4/5) --------------------------------------- 94
11.5. Digital P.C.B. (5/5) --------------------------------------- 95
11.6. Main P.C.B. (1/6)----------------------------------------- 96
11.7. Main P.C.B. (2/6)----------------------------------------- 97
11.8. Main P.C.B. (3/6)----------------------------------------- 98
11.9. Main P.C.B. (4/6)----------------------------------------- 99

11.10. Main P.C.B. (5/6)---------------------------------------- 100

11.11. Main P.C.B. (6/6)---------------------------------------- 101

11.12. FL P.C.B.  ------------------------------------------------- 101
11.13. D-Amp P.C.B. -------------------------------------------- 102
11.14. iPod Fan P.C.B.  ---------------------------------------- 102
11.15. Power Button P.C.B. ----------------------------------- 102
11.16. SMPS P.C.B.  -------------------------------------------- 103
11.17. Waveform Table (1/2) ---------------------------------- 104
11.18. Waveform Table (2/2) ---------------------------------- 105

12 Illustration of ICs, Transistor and Diode --------------- 106
13 Block Diagram -------------------------------------------------- 107

13.1. Digital (1/2) ----------------------------------------------- 107
13.2. Digital (2/2) ----------------------------------------------- 108
13.3. IC Terminal (Digital) Chart (1/2) --------------------- 109
13.4. IC Terminal (Digital) Chart (2/2) --------------------- 110
13.5. Digital (Audio IO)---------------------------------------- 111
13.6. Digital (Video Out) -------------------------------------- 112
13.7. Digital (Regulator) -------------------------------------- 113
13.8. Main (DSP) ----------------------------------------------- 114
13.9. IC Terminal Main (DSP) Chart----------------------- 115

13.10. Main (System Control)--------------------------------- 116

13.11. Main (Audio) --------------------------------------------- 117

13.12. D-Amp ----------------------------------------------------- 118
13.13. Power ------------------------------------------------------ 119

14 Wiring Connection Diagram ------------------------------- 120
15 Schematic Diagram Notes ---------------------------------- 121
16 Schematic Diagram ------------------------------------------- 123

16.1. Digital Circuit--------------------------------------------- 123
16.2. Main Circuit----------------------------------------------- 145
16.3. Tuner & FL Circuit -------------------------------------- 153
16.4. Power Button, Volume Button, Door Switch &

Mechanism Switch Circuit ---------------------------- 154

16.5. IR, Motor, SD USB & iPod Switch Circuit--------- 155
16.6. iPod, iPod Fan, Wireless Adapter & AC Inlet

Circuit ------------------------------------------------------ 156

16.7. D-Amp Circuit-------------------------------------------- 157
16.8. Relay Circuit --------------------------------------------- 161
16.9. SMPS Circuit--------------------------------------------- 162

17 Printed Circuit Board----------------------------------------- 164

17.1. Digital P.C.B. --------------------------------------------- 164
17.2. Main P.C.B.----------------------------------------------- 166

3

17.3. Tuner, FL, Power Button, Volume Button &

Door Switch P.C.B. ------------------------------------- 168

17.4. Mechanism Switch, IR, Motor, SD USB, iPod

Switch & iPod P.C.B.----------------------------------- 169

17.5. iPod Fan, Wireless Adapter & Relay P.C.B. ----- 170
17.6. D-Amp P.C.B. -------------------------------------------- 171
17.7. SMPS & AC Inlet P.C.B. ------------------------------ 172

18 Terminal Function of ICs ------------------------------------ 173

18.1. IC6001 (C0HBB0000057): IC FL Driver ---------- 173

19 Exploded View and Replacement Parts List --------- 175

19.1. Exploded View and Mechanical Replacement

Part List --------------------------------------------------- 175

19.2. Electrical Replacement Part List-------------------- 183

4

1. When servicing, observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or

damaged by the short circuit.

2. After servicing, see to it that all the protective devices such as insulation barriers, insulation papers shields are properly

installed.

3. After servicing, carry out the following leakage current checks to prevent the customer from being exposed to shock hazards.

1. Unplug the AC cord and connect a jumper between the two prongs on the plug.
2. Measure the resistance value, with an ohmmeter, between the jumpered AC plug and each exposed metallic cabinet part on

the equipment such as screwheads, connectors, control shafts, etc. When the exposed metallic part has a return path to the
chassis, the reading should be between 1M

Ω

 and 5.2M

Ω

.

When the exposed metal does not have a return path to the chassis, the reading must be 

1. Plug the AC cord directly into the AC outlet. Do not use an isolation transformer for this check.
2. Connect a 1.5k

Ω

, 10 watts resistor, in parallel with a 0.15

µ

F capacitors, between each exposed metallic part on the set and a

good earth ground such as a water pipe, as shown in Figure 1.

3. Use an AC voltmeter, with 1000 ohms/volt or more sensitivity, to measure the potential across the resistor.
4. Check each exposed metallic part, and measure the voltage at each point.
5. Reverse the AC plug in the AC outlet and repeat each of the above measurements.
6. The potential at any point should not exceed 0.75 volts RMS. A leakage current tester (Simpson Model 229 or equivalent)

may be used to make the hot checks, leakage current must not exceed 1/2 milliamp. In case a measurement is outside of the
limits specified, there is a possibility of a shock hazard, and the equipment should be repaired and rechecked before it is
returned to the customer.

Figure 1

Disconnect AC power to discharge unit AC Capacitors as such (C5700, C5701, C5702, C5704, C5705) through a 10 

Ω

, 10 W resis-

tor to ground.
Caution:

DO NOT SHORT-CIRCUIT DIRECTLY (with a screwdriver blade, for instance), as this may destroy solid state devices.

After repairs are completed, restore power gradually using a variac, to avoid overcurrent.
Current consumption at AC 230 - 240 V, 50 Hz in NO SIGNAL mode volume minimal should be ~ 500 mA.

The protection circuitry may have operated if either of the following conditions are noticed:

• No sound is heard when the power is turned on.