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2006-7 Models:

PT-56DLX76
PT-61DLX76
PT-56DLX26

DLP PTV Repair Course


1.
2.
3.
4.

High Contrast Range (on/off Iris)


1080 P Native Resolution Picture
Ballast + PS + Light Engine Pkg.
Tuner Fan 1 runs 24/7 (TV guide, C card)

slide
Outline
Repair Policy
3
Disassembly / Layout / Connectors
Start Up Sequence
9
Power ON Sequence
Start Up Circuit Problems

2006
inception
year

TV Protection (Shutdown) 13
Error Code chart
Protect Circuits for board isolation

LEDs

Pwr temp lamp iris

IR in

Audio Troubleshooting
Video Troubleshooting
Service Information

26
27
36

Service Mode Information


White Balance
Digital Station S N R
TV Reset Operations

Adjustments after Engine Replace 42


Instructor: Herb Chin; National Training
Digital Light Processing and DLP are trademarks of Texas Instruments Incorporated.

Slide # 1

Access & Repair Policy


Two block Repair Policy:
1. TV Tuner Block
2. Projection Unit w
Pwr Supply & Ballast

1. TV Tuner
Blk.

Slide # 2

DLP
PT-xxDLX76

2.

Table of Contents - PTxxDLX76 Repair


Slide

Repair Policy
Disassembly
Connector Layouts
Start Up
o Power On Sequence
o Dead Set
o Power LED blinks continuously

3
4
7
9
10
11

TV Protection (shutdown)
o
o
o
o
o
o
o
o
o
o
o

Error Code List


Power LED 1X Code (excessive voltage)
Power LED 2X Code (no fan rotation)
Power LED 3X Code (no DT 5Vdc)
Power LED 5X Code (No Communication)
Power LED 6X Code (No Color Wheel)
Power LED 7X Code (Lamp Door Sw)
Power LED 8X Code (No Lgt Eng Cont.)
Temp LED continuous (Excess Temp)
Lamp LED 1X Code (No Lamp)
Lamp LED 2-4X Code (Lgt Eng Iris NG)

Slide # 3

13
14
15
16
17
18
19
20
22
23
24

Slide

No Audio
Video Problems
o No Video
o Identifying Misc Video Problems
Generating a Lgt Eng Pattern
Generating a Tuner Blk Pattern

26
27
29
31
32

Service Information
o
o
o
o
o

Operations Possible
Access
Navigation
White Balance
Digital Station SNR Level

Adjustments after Light


Engine Replacement.

36
37
38
39
40
42

Panasonic DLP PTV Disassembly - rear view


Disassembly: After removing the rear cover, either remove TV Tuner Block - located at the left from the back. Pull after removing screws a-e. or
Power Supply / Ballast Block (not shown) with the light Engine (shown located at the
right). Pull out after removing screws 1-5.

Note that the blocks are linked at the center with recessed screws.
The therm fuse, and 2 of the 3 fans are located in the light engine.
Slide # 4

DLP
PT-xxDLX76

TV Tuner & Projection Blocks


Woofer Box

Ballast unit

Power PCB

TV Blk
Projection Blk
Slide # 5

DLP
PT-xxDLX76

Table of Contents - PT-xxDLX76 Repair


Slide

9
9

Repair Policy
Disassembly
Connector Layouts
Start Up
o Power On Sequence
o Dead Set
o Power LED blinks continuously

3
4
7
9
10
11

TV Protection (shutdown)
o
o
o
o
o
o
o
o
o
o
o

Error Code List


Power LED 1X Code (excessive voltage)
Power LED 2X Code (no fan rotation)
Power LED 3X Code (no DT 5Vdc)
Power LED 5X Code (No Communication)
Power LED 6X Code (No Color Wheel)
Power LED 7X Code (Lamp Door Sw)
Power LED 8X Code (No Lgt Eng Cont.)
Temp LED continuous (Excess Temp)
Lamp LED 1X Code (No Lamp)
Lamp LED 2-4X Code (Lgt Eng Iris NG)

Slide # 6

13
14
15
16
17
18
19
20
22
23
24

Slide

No Audio
Video Problems
o No Video
o Identifying Misc Video Problems
Generating a Lgt Eng Pattern
Generating a Tuner Blk Pattern

26
27
29
31
32

Service Information
o
o
o
o
o

Operations Possible
Access
Navigation
White Balance
Digital Station SNR Level

Adjustments after Light


Engine Replacement.

36
37
38
39
40
42

Light Engine Connector Layout

Rear
View

Slide # 7

DLP
PT-xxDLX76

Table of Contents - PT-xxDLX76 Repair


Slide

9
9
9

Repair Policy
Disassembly
Connector Layouts
Start Up
o Power On Sequence
o Dead Set
o Power LED blinks continuously

3
4
7
9
10
11

TV Protection (shutdown)
o
o
o
o
o
o
o
o
o
o
o

Error Code List


Power LED 1X Code (excessive voltage)
Power LED 2X Code (no fan rotation)
Power LED 3X Code (no DT 5Vdc)
Power LED 5X Code (No Communication)
Power LED 6X Code (No Color Wheel)
Power LED 7X Code (Lamp Door Sw)
Power LED 8X Code (No Lgt Eng Cont.)
Temp LED continuous (Excess Temp)
Lamp LED 1X Code (No Lamp)
Lamp LED 2-4X Code (Lgt Eng Iris NG)

Slide # 8

13
14
15
16
17
18
19
20
22
23
24

Slide

No Audio
Video Problems
o No Video
o Identifying Misc Video Problems
Generating a Lgt Eng Pattern
Generating a Tuner Blk Pattern

26
27
29
31
32

Service Information
o
o
o
o
o

Operations Possible
Access
Navigation
White Balance
Digital Station SNR Level

Adjustments after Light


Engine Replacement.

36
37
38
39
40
42

Power ON Sequence
I Plug in Sequence
1. Pwr RL801 clicks on.
2. Main PS starts for sec.
3. Fan 1 runs for sec.
4. RL801 clicks off.

Slide # 9

DLP
PT-xxDLX76

II Power ON Sequence
1. Power Relay RL801 clicks on.
PS
2. Power LED blinks green.
3. Color Wheel starts turning.
cw
4. All 3 Fans come on.
5. Ballast Relay RL802 clicks on. lamp
6. Ballast / Lamp turns on.
7. Iris Shutter closes & opens (sound
is from left of the therm fuse).
8. Station LED on Tuner board lights.
9. Front panel blue Iris LED lights.
10. Power LED turns solid orange.
11. Audio & Video Unmute.

III Power Off Sequence


1. Audio and Video Mute.
2. Blue Iris LED goes off.
3. Power LED blinks red.
4. Lamp goes off.
5. Fans 2 & 3 go off.
6. Ballast relay RL802 clicks off.
7. Fan 1 and RL801 remain on
with AC input.
8. Tuner LED is lit only if on a
Dig Station.
9. TV is off.

PT-xxDLX76 series - Dead Set


Symptom TV set is dead, no response to either power on button. No relays click.
Cause: There is no standby voltage to the micro or the micro to the relay path is open.

Troubleshooting Both the TV tuner block and the Light Engine Block are suspect.
1. If the line cord AC plug pins do not measure approx 1.8k ohms or there is no voltage at power supply
CN1003/pins 1 or/and 2 at plug in, replace the power supply in the light engine assembly.
2. If there is no voltage at power supply CN1003/pin 3 when the power button is pressed, replace the TV
tuner block.
Slide # 10

DLP
PT-xxDLX76

Power LED blinks Continuously


Symptom: After powering on, the power LED continues to blink green as though starting up but never does.
Cause: Eventually the TV will shutdown and the LAMP LED will blink 1X (time) and repeat, indicating a lamp
failure.

CN2006

Troubleshooting:
The problem is either the TV tuner Block or the PS Board / Light Engine.
If the spark gap on the ballast board does not light, check for the two necessary voltages into the ballast. If
missing, follow the troubleshooting procedure in the Shutdown, Lamp LED blinks 1X.

Slide # 11

DLP
PT-xxDLX76

Table of Contents - PT-xxDLX76 Repair


Slide

9
9
9
9

Repair Policy
Disassembly
Connector Layouts
Start Up
o Power On Sequence
o Dead Set
o Power LED blinks continuously

3
4
7
9
10
11

TV Protection (shutdown)
o
o
o
o
o
o
o
o
o
o
o

Error Code List


Power LED 1X Code (excessive voltage)
Power LED 2X Code (no fan rotation)
Power LED 3X Code (no DT 5Vdc)
Power LED 5X Code (No Communication)
Power LED 6X Code (No Color Wheel)
Power LED 7X Code (Lamp Door Sw)
Power LED 8X Code (No Lgt Eng Cont.)
Temp LED continuous (Excess Temp)
Lamp LED 1X Code (No Lamp)
Lamp LED 2-4X Code (Lgt Eng Iris NG)

Slide # 12

13
14
15
16
17
18
19
20
22
23
24

Slide

No Audio
Video Problems
o No Video
o Identifying Misc Video Problems
Generating a Lgt Eng Pattern
Generating a Tuner Blk Pattern

26
27
29
31
32

Service Information
o
o
o
o
o

Operations Possible
Access
Navigation
White Balance
Digital Station SNR Level

Adjustments after Light


Engine Replacement.

36
37
38
39
40
42

Shutdown Error Codes


Shutdown Error Codes
Power
LED

Lamp
LED

Temp
LED

None

None

None

Check
Priority

Cause

Slide
#

Suspect
Block

No standby voltage

10

Tuner

DT12V, DT5V, 9V, 3.3V or 2.5V OVP or OCP.

14

both

No rotation detected in one of 3 fans.

15

both

Loss of DT5V line from the base board.

16

both

Loss of I2C reply from major ICs on the Main bd.

17

Tuner

No color wheel rotation detected.

18

both

Lamp cover switch not shorted.

19

both

Light Engines DLP IC is not ready.

20

both

Lamp ignition chain failure or thermal fuse is open.

23

both

Mech Iris failure - Brightness range is reduced.

24

Light
Eng.

Excessive temperature is detected.

22

both

1
2, 3,
or 4.
1

Check Priority means that if two error codes occur, the one with the lower priority number will display.
Slide # 13

DLP
PT-xxDLX76

TV Shutdown - Power LED blinks 1X


Symptom: After powering on, the TV shuts down then the power LED blinks 1X pauses and repeats.
Cause: Excessive voltage or excessive current (low voltage) detected on the DT+9V, DT+5V, Sw 2.5V, or
Sw 3.3V outputs sensed at the main board.

Troubleshooting:
The problem is either in the PS / Light Engine or TV tuner Blk.
1. At power on, if 9Vdc (normal) is present at CN2704/pin 2 before shutdown, replace the TV tuner block.
2. If there was less than 4V at CN2704/pin 2 or higher than the normal 9Vdc, replace the PS / light engine.

Slide # 14

DLP
PT-xxDLX76

TV Shutdown - Power LED blinks 2X


Symptom: After powering on, the TV shuts down then the power LED blinks 2X pauses and repeats.
Cause: Fan rotation has not been detected by one or more fans.

Troubleshooting:
The problem is either a defective fan, the TV tuner Blk., or Light Engine.
1. Fan Stopped? Fan 1 CN6010/pin 1 low? Replace the TV tuner blk. Normal ? Replace fan 1.
Fans 2 or 3 CN2008/pin 1 or CN2008/pin 1 voltage low? Replace light engine. Normal? Replace fan.
2. All fans rotate? Measure pin 3 of all the fan connectors (CN2007-8 & CN6010). The fan connector that does
not measure 0Vdc when the fans rotate (at turn on) indicates that fan is bad even though it is rotating.
3. If no fan rotates, and the 12V power supply voltage at CN1003/pin 9 is missing, replace the power board *. If
present, unplug CN2009 and press power on. If fan 1 rotates now, replace the light engine. Still no rotation?
Change the TV block. * If PR1001 is open suspect a short in the light engine or TV block.
Slide # 15

DLP
PT-xxDLX76

TV Shutdown - Power LED blinks 3X


Symptom: After powering on, the TV shuts down then the power LED blinks 3X pauses and repeats.
Cause: Loss of DT5V source or a load on the DT5V line to the tuner.

Troubleshooting:
The problem is either in the TV tuner Block or PS / Light Engine.
1. If voltage at light engine CN2001/pin 1 is 12Vdc (normal) before shutdown, replace the TV block.
2. If the voltage at power supply CN2001/pin 1 is 0Vdc (abnormal) at power on, unplug CN2001 and measure
power supply CN1201/pin 6 at power on. If this voltage is present, replace the light engine.
3. If CN1201/pin 6 is still 0V, check for an open PR1001 fuse on the power supply board. Fuse Open? Replace
the TV tuner block and the fuse. Fuse OK? Replace the power supply / light engine if the fuse is OK.
Slide # 16

DLP
PT-xxDLX76

TV Shutdown - Power LED blinks 5X


Symptom: After powering on, the TV shuts down then the power LED blinks 5X pauses and repeats.
Cause: The Main Microprocessor IC6001 is not able to communicate with 3 major video ICs all on the main
board.

Troubleshooting:
The problem is main board.
1. Replace the TV block that contains the main board.

Slide # 17

DLP
PT-xxDLX76

TV Shutdown, Power LED blinks 6 X (times)

Color Wheel & Motor


P/N = LSDL0354

Cause - No Color Wheel Rotation Detected


When color wheel rotation is beyond speed range or stops, the TV will turn off.
Troubleshooting start with the DC voltage measurement in step 1 then use a DVM set to measure AC voltages.
1. if +12Vdc is missing from CN2001/pin 1 (plug to the light engine) recheck it at PS CN1003/pin 6. Replace the
Power supply-Light Eng if missing voltage at both places or the TV tuner block if present only at one place. 2.
Replace the color wheel if there is AC input but no AC output signal - measure the AC voltage input at
CN2000/pins 1-3 (input) and at CN2006/pin 3 (output) . 3. Replace the light engine if input & output voltage are
both OK.
Slide # 18

DLP
PT-xxDLX76

TV Shutdown - Power LED blinks 7X


Symptom: After powering on, the TV shuts down then the power LED blinks 7X pauses and repeats.
Cause: The lamp door switch is open or the lamp door plastic is broken off.
Troubleshooting:
TV Front
The problem is Sw, TV tuner
Block or Light Engine.
1. Unplug the TV from AC. From
the front of the TV make sure the
lamp cover protrusion tab is still
present Reinstall the lamp cover.
2. If CN2003/pin 1 to ground is
not 0 ohms replace the cover
switch (chassis). If CN2002/pin
protrusion
Lamp
31 is not 0 ohms to ground,
replace the light engine. If
Cover Sw
CN2002/pin 31 is 0 ohms replace
the TV tuner block.

Light
engine
Bd.

p/n =
KOL1BA000114

31

Slide # 19

DLP
PT-xxDLX76

violet

TV Shutdown, Power LED blinks 8 X (times)


z Power LED eight blinks (IC6004)

Cause - Light Engine main DMD IC Controller IC detects a bad input condition.
When IC2008 (DMD control IC) does not send (H: ready) to IC6001, IC6001 judges there is something wrong
with IC2008 and IC6001 turns off the TV.
Troubleshooting Check power supply voltages at CN2001/pin 1& CN2009/pin 1. If all voltages are present, replace the Light
Engine Assembly.
If a voltage is missing, unplug the CN2001 connector and measure the plug end pin again (wire from the TV
block). If voltage is now present, replace the light engine. If the voltage is still missing, check fuse PR1001. 0
ohms (OK)? Replace the Pwr Supply Bd. Open? If CN2001/pin 1 to cold chassis gnd. is less than 1.5k ohms,
at the Lit Eng, replace the Light Engine. If the resistance is higher, replace the TV block. [Use the 2k ohm scale]
Slide # 20

DLP
PT-xxDLX76

Table of Contents - PT-xxDLX76 Repair


Slide

9
9
9
9

Repair Policy
Disassembly
Connector Layouts
Start Up
o Power On Sequence
o Dead Set
o Power LED blinks continuously

3
4
7
9
10
11

TV Protection (shutdown)
o
o
o
o
o
o
o
o
o
o
o

Error Code List


Power LED 1X Code (excessive voltage)
Power LED 2X Code (no fan rotation)
Power LED 3X Code (no DT 5Vdc)
Power LED 5X Code (No Communication)
Power LED 6X Code (No Color Wheel)
Power LED 7X Code (Lamp Door Sw)
Power LED 8X Code (No Lgt Eng Cont.)
Temp LED continuous (Excess Temp)
Lamp LED 1X Code (No Lamp)
Lamp LED 2-4X Code (Lgt Eng Iris NG)

Slide # 21

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Slide

No Audio
Video Problems
o No Video
o Identifying Misc Video Problems
Generating a Lgt Eng Pattern
Generating a Tuner Blk Pattern

26
27
29
31
32

Service Information
o
o
o
o
o

Operations Possible
Access
Navigation
White Balance
Digital Station SNR Level

Adjustments after Light


Engine Replacement.

36
37
38
39
40
42

TV Shutdown, Temp LED blinks continuously


z TEMP LED blinks

Color Wheel Assembly


P/N = LSEP3206A

Cause - TV / Color Wheel Temp = High


When the temperature is too high (64oC.) at the color wheel assembly where it is sensed, the TV will
turn off.
Troubleshooting procedure
1. Remove the CN2009/pin 8 wire from the plug and plug the connector back in (without pin 8).
2. Turn the TV on.
3. If the TV shuts down, the problem is on the Main board. Replace the TV block.

4. If the TV works OK now, replace the color wheel assembly that contains the temp IC.
Slide # 22

DLP
PT-xxDLX76

TV Shutdown, Lamp LED blinks 1 X (time)


z LAMP LED blinks
CN2006
Light Engine Top
DMD Bd.

Cause - No Lamp current Detected


Five seconds after the power button is pressed, the mercury vapor lamp should light. If the Lamp does not
light, CN9504/pin 1 = H is input to Microprocessor IC6001 to shut the TV off.
Troubleshooting / isolation procedure
1. The lamp is bad if the spark gap device on the ballast board lights (5 secs after power on).
2. If the spark gap does not light, measure the DC voltage at CN9504/pin 4 (3V to chassis gnd). and between
CN1301/pin 1 (380V) & pin 4 (H gnd). If the CN1301 voltage is missing, replace the Pwr Supply LE block.
3. If both voltages (CN9504 & CN1301) are correct, the ballast is bad. Replace the ballast / LE block.
4. If CN9504/pin 4 voltage is 4.2 - 5Vdc, check for 0.4Vac voltage at CN2006/pin 3 (light engine).
a) Present? - replace the TV block.
b) Missing? - replace the light engine.
Slide # 23

DLP
PT-xxDLX76

Lamp LED blinks 2-4 X (times), No Shutdown

Cause
The 30% brightness reduction Iris mechanism located in the Light Engine is not working. The electronically
controlled mechanical Iris mechanism works to achieve a high white to black picture contrast ratio.
Troubleshooting
This iris malfunction (2-4 blinks) will not shutdown the TV but will prevent the front panel blue Iris LED from
lighting. The Dynamic Iris can not be turned on from the customer menu [Menu / Picture 2of 2 page / Adv. Adj
/ Dynamic Iris / On]. The iris is spring loaded in the open position so a potential failure will leave the iris open.
If the TV functions otherwise (menu commands and channel changing) work, the serial data path is OK and the
problem is in the Light Engine. Replace the light engine. Prolonged non operation of the iris circuit will not
damage the TV.
Slide # 24

DLP
PT-xxDLX76

Table of Contents - PT-xxDLX76 Repair


Slide

9
9
9
9

Repair Policy
Disassembly
Connector Layouts
Start Up
o Power On Sequence
o Dead Set
o Power LED blinks continuously

3
4
7
9
10
11

9 TV Protection (shutdown)
o
o
o
o
o
o
o
o
o
o
o

Error Code List


Power LED 1X Code (excessive voltage)
Power LED 2X Code (no fan rotation)
Power LED 3X Code (no DT 5Vdc)
Power LED 5X Code (No Communication)
Power LED 6X Code (No Color Wheel)
Power LED 7X Code (Lamp Door Sw)
Power LED 8X Code (No Lgt Eng Cont.)
Temp LED continuous (Excess Temp)
Lamp LED 1X Code (No Lamp)
Lamp LED 2-4X Code (Lgt Eng Iris NG)

Slide # 25

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19
20
22
23
24

Slide

No Audio
Video Problems
o No Video
o Identifying Misc Video Problems
Generating a Lgt Eng Pattern
Generating a Tuner Blk Pattern

26
27
29
31
32

Service Information
o
o
o
o
o

Operations Possible
Access
Navigation
White Balance
Digital Station SNR Level

Adjustments after Light


Engine Replacement.

36
37
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39
40
42

No Audio

Symptom: No or distorted Audio. The picture is OK


Cause: Reduced supply voltage or audio process defect.
Troubleshooting: At power on, if the two voltages from the power supply are OK (CN1001/pin 2 = 18V &
CN1003/pin 6 = 12Vdc), replace the TV tuner block. This voltage is OK if the fans come on. If CN1001pin 2
voltage is low or missing, unplug that connector and re-measure the voltage at the power supply board
(CN1001/pin 2 socket) at TV on. If normal, replace the TV block, if still missing/low, replace the power supply
board / light engine.
Slide # 26

DLP
PT-xxDLX76

No Video
Symptom: TV powers on but the screen is white or black with sound.
Cause: A break anywhere in the video path.

Troubleshooting:
The problem can be in either the TV tuner block or light engine.
1. Press the menu button. If any image (menu or volume bar) appears on the screen the
light engine block is OK. Replace the TV tuner block.
2. Check other inputs for video. This can be done even though there is no picture by first
pressing channel button, then pressing the TV/Video button, then selecting the input
number from the list at the right. If there is video present, replace the TV tuner block. If
still no video, the light engine is suspect but input voltages must be confirmed in step 3.
3. If there is voltage at light engine CN2001/pin 1 and CN2009/pin 1, replace the light
engine. If a voltage is missing, replace the TV tuner block if power supply CN10016 is
correct at 12Vdc. 0Vdc? Change the power supply board/light engine.
Slide # 27

DLP
PT-xxDLX76

Inputs:
1. TV (press ch up once)
2. Component 1
3. Component 1
4. HDMI 1
5. HDMI 2
6. Video 1
7. Video 2
8. Video 3
9. PC

No Video, Audio OK
Symptom: After powering on, the TV audio comes on but the screen remains dark. The lamp only lights
momentarily at plug-in, turn-on. All 3 fans rotate.
Cause: Serial data or clock instruction is missing into to the light engine micro IC2008.

CN2006

Troubleshooting:
The problem is either the TV tuner Block or the PS Board / Light Engine.
If there is data & clock at the light engine CN2009/pins 8 & 9, replace the light engine assembly. If there is
no data or clock presence at power on, inspect the CN6000 / CN2009 cable and if good, replace the TV
tuner block if no OSD, video, or menu appears.

Slide # 28

DLP
PT-xxDLX76

No Color or Distorted Video (all inputs)


Symptom - Color loss, dominate color, missing color, color splotches, etc.
Troubleshooting strategy: If the internal pattern is OK, the video problem is before the point of pattern generation.
For example if the DDP pattern is OK, the problem is before in the TV block or the 31 pin cable. If the CW pattern
is OK, the problem is only in the TV block.
Main Bd.
Main

CW
Gen

Sub

Video
inputs

Digital Video

OSD

31 pin
cable

DDP
Gen

Light
Engine

TV Block
Patterns generated from the
Main Bd. in the Factory Service
Mode / Other / CW-Index Delay
OTHER

Patterns generated from the


Light Engine in the Factory
Service Mode / Other / DDP

1/1

OPT HPOSI
8000
OPT VPOSI
8000
CW INDEX DELAY 00ED
WB
DDP
GC : 05060101

OSD Location:

Work Service Mode / Factory Service Mode / Other / CW Index or DDP (press ASPECT)

Start: In the next 4 slides you will go to the Work Service Mode and navigate to the desired pattern.
Slide # 29

DLP
PT-xxDLX76

No Color or Distorted Video (all inputs)


CN2002
Video
inputs
Component &
Composite

lens

31 pin cable
TV tuner
Block

Video

Light Engine

screen

menu
Tuner / Menu
14 pin power
CN1003

DDP3021 Pattern Source


Troubleshooting:
PS
CW Index Pattern Source
The problem could be in the TV or Light Engine Blk.
Strategy - A white pattern can be generated at the TV tuner block just before leaving along the 31 pin
cable and another white pattern can be generated in the light engine block. If the symptom is not present
in the generated pattern, the problem is before the point where the good pattern is generated.
Generating the White patterns:
In the following steps you will enter the work service mode and select one of the white patterns.
1. Turn the TV on. 2. Work Mode Entry - Hold the TVs front panel Volume down button and the remotes
RECALL button for 5 seconds until Work Mode appears on the bottom of the TV screen.
3. Factory Service Mode Entry Press the remotes top VCR mode button and then the remotes RECALL
button to enter the Factory Service Mode. Press the top TV mode button and use the arrow down button to
highlight Other on the screen.
4. Press the OK button to enter/select Other. 5. Again use the arrow down button to highlight either the DDP
or CW pattern. 6. Press ASPECT to enter. 7. Press RECALL to return for the other pattern.
Conclusion 1. If the CW white pattern generated is clean without distortion, the problem is in the TV tuner block.
2. If the problem still appears on the DDP white screen, the problem is in the light engine.
3. If the CW white pattern has another problem (different than the original symptom), replace the TV tuner block.
Slide # 30

DLP
PT-xxDLX76

Actual DDP internal patterns from the Light Engine

Start:

BLUE

ASPECT

GRAY

WHITE

ASPECT

BLACK

ASPECT

y
An

To return:
Press any button except ASPECT.
OTHER

Blue
solid

1/1

For Focus adjustment


For DMD drive board
position adjustment
& verifying SP Gain

ASPECT

ASPECT

OPT HPOSI
8000
OPT VPOSI
8000
CW INDEX DELAY 00ED
WB
D D P 3021
SP GAIN ADJUST
SP DELAY ADJUST
CEC THEATER LINK ON

Green
solid

ASPECT

on
tt
bu

ASPECT

white

Red
solid

Slide # 31

ASPECT

2006
DLP
DLP
PT-xxDLX76

CROSS HATCH

ASPECT

Press ASPECT to switch each pattern.


Note: Wait about 3 seconds.
Then press ASPECT for next pattern.

Teal /
Cyan

Yell
solid

ASPECT

ASPECT

ASPECT

ASPECT

Main Board Generated Patterns


Location: Work Service Mode / Factory Service Mode / Other / CW Index Delay
OTHER

1/1

Red

Aspect

Blk

Aspect

S P E C

OPT HPOSI
8000
OPT VPOSI
8000
CW INDEX DELAY 00ED
WB
D D P 3021
GC : 05060101

Red

grn

white

Green

White

S P E C

RECALL

blue

Aspect

If these patterns are:


OK - Problem is the TV board block
NG - Problem is in the Digital Main board.
Blue

Slide # 32

DLP
PT-xxDLX76

No Color or Distorted Video (all inputs)


CN2002
Video
inputs
Component &
Composite

lens

31 pin cable
TV tuner
Block

Video

Light Engine

screen

menu
Tuner / Menu
14 pin power
CN1003

DDP3021 Pattern Source


Troubleshooting:
PS
CW Index Pattern Source
The problem could be in the TV or Light Engine Blk.
Strategy - A white pattern can be generated at the TV tuner block just before leaving along the 31 pin
cable and another white pattern can be generated in the light engine block. If the symptom is not present
in the generated pattern, the problem is before the point where the good pattern is generated.
Generating the White patterns:
In the following steps you will enter the work service mode and select one of the white patterns.
1. Turn the TV on. 2. Work Mode Entry - Hold the TVs front panel Volume down button and the remotes
RECALL button for 5 seconds until Work Mode appears on the bottom of the TV screen.
3. Factory Service Mode Entry Press the remotes top VCR mode button and then the remotes RECALL
button to enter the Factory Service Mode. Press the top TV mode button and use the arrow down button to
highlight Other on the screen.
4. Press the OK button to enter/select Other. 5. Again use the arrow down button to highlight either the DDP
or CW pattern. 6. Press ASPECT to enter. 7. Press RECALL to return for the other pattern.
Conclusion 1. If the CW white pattern generated is clean without distortion, the problem is in the TV tuner block.
2. If the problem still appears on the DDP white screen, the problem is in the light engine.
3. If the CW white pattern has another problem (different than the original symptom), replace the TV tuner block.
Slide # 33

DLP
PT-xxDLX76

Table of Contents - PT-xxDLX76 Repair


Slide

9
9
9
9

Repair Policy
Disassembly
Connector Layouts
Start Up
o Power On Sequence
o Dead Set
o Power LED blinks continuously

3
4
7
9
10
11

9 TV Protection (shutdown)
o
o
o
o
o
o
o
o
o
o
o

Error Code List


Power LED 1X Code (excessive voltage)
Power LED 2X Code (no fan rotation)
Power LED 3X Code (no DT 5Vdc)
Power LED 5X Code (No Communication)
Power LED 6X Code (No Color Wheel)
Power LED 7X Code (Lamp Door Sw)
Power LED 8X Code (No Lgt Eng Cont.)
Temp LED continuous (Excess Temp)
Lamp LED 1X Code (No Lamp)
Lamp LED 2-4X Code (Lgt Eng Iris NG)

Slide # 34

13
14
15
16
17
18
19
20
22
23
24

Slide

9 No Audio
9 Video Problems
o No Video
o Identifying Misc Video Problems
Generating a Lgt Eng Pattern
Generating a Tuner Blk Pattern

26
27
29
31
32

Service Information
o
o
o
o
o

Operations Possible
Access
Navigation
White Balance
Digital Station SNR Level

Adjustments after Light


Engine Replacement.

36
37
38
39
40
42

Service Operations
Service Operations
Operation

Service Mode

Steps

Comments

Reset to out of box


condition

None

Hold Vol (TV)


Hold OK (remote)

Turns off aft displaying


Shipment Setup

Lamp Time Reset

None

Hold Vol (TV)


Hold 0 (remote)

Lamp time resets to 0


hours.

Iris Mech test


16 step Brightness
change

Work S/M
(see S/M access
next)

Enter Work S/M


Press DVD,
RECALL (remote)

RECALL button drops iris


brightness (16 steps).

Lamp On time (since


reset)

Lamp Time S/M


page 1/4

See service mode


access & exit chart

Lamp Time = hrs


L On is # lamp-on times.

IR (remote) button
check

Lamp Time S/M


page 2/4

See service mode


access & exit chart

When a remote button is


recognized, 1 changes to 0

Last 3 Error Codes


(last code is first)

Lamp Time S/M


page 4/4

See service mode


access & exit chart

Error codes appear after


SAFE _ _ _ _ _ _

White Screen made


by the main board

Factory S/M

See service mode


access & exit chart

See Video troubleshooting


for details

White Screen made


by the light engine

Factory S/M

See service mode


access & exit chart

See Video troubleshooting


for details

Focus Pattern for


centering & focus

Factory S/M

See service mode


access & exit chart

See Focus adjustments


after light eng replacement.

Exit
Automatic TV turn
off.

Press TV, press


any (remote)
button.
Remote P/N =
EUR7737z10
Pwr
Sap

TV

Slide # 35

DLP
PT-xxDLX76

vcr
OK

recall

Service Mode Access


Service Mode Access & Exit
Service
Mode
Name

1. Start

1. Lamp
Time
2. Work
Mode
3. Factory
Adjust

Start with the


TV OFF
Start with
the TV ON
Start in Work
Mode

2. Access Hold the front panel &


remote buttons in for 5 seconds.
Front Panel
Remote button
button
VOLUME DOWN
TV/VIDEO
VOLUME DOWN

RECALL
1. VCR
2. RECALL

3. Exit
Power TV Off
Vol Dwn + Recall
(Panel + Remote)
RECALL X2 to
Work Mode
Remote P/N = EUR7737z10
Pwr
Sap

1. Lamp Mode

2. Work Mode
1/4

3. Factory Adjust Mode


FACTORY ADJUST
M:2.020
VIDEO ADJ
SOUND
FAN
OTHER
PARTIAL
DT BOARD
EEP COPY L DG
DEFAULT SET

Slide # 36

DLP
PT-xxDLX76

1/1

TV
vcr

Navigate
to Other

OK

recall

Service Mode Navigation


Service Mode Navigation
(How to get around in the Service Mode)
Operation

Press Button
(remote or front panel buttons)

Start: Begin Navigation

Press the remotes (top) TV mode button

Back to previous

Recall

Enter

OK (remote or front panel) or ASPECT (remote)

DLP Remote p/n =

EUR7737z10
Pwr

Sap

TV

Move up or down

Channel up or down

Data change

Volume up or down

Exit

Shut off the TV. Let the power LED stop


blinking before turning it back on.
If the TV still doesnt exit, repeat but unplug
for a minute after the blinking stops.

Slide # 37

DLP
PT-xxDLX76

vcr
OK

aspect

recall

White Balance Adjustment


Factory Adjustment Mode
OTHER
OPT HPOSI
8000
OPT VPOSI
8000
CW INDEX DELAY 00ED
WB
00
DDP
SP GAIN ADJUST
SP DELAY ADJUST
CEC THEATER LINK ON

1/1

-Input 100% white from generator to confirm WB.


-If adjustment is required, enter the Factory Service Mode.
Select one of 5 WB levels from reddish to bluish by
changing the WB data numbers with the Volume
buttons.

00

01

Original data

Reddish

05
Bluish (After adjustment)
(default : 00)

Slide # 38

DLP
PT-xxDLX76

PT-xxDLX76 /16 Digital Station SNR


Reset TV - 1. Turn the TV on. 2. Hold the Volume Dwn on the panel and 3. Hold the OK

button on the remote for 8 seconds. The TV will display Shipment Setup, reset then shut
off. At power on you will have to reload the active TV channels.
Reset lamp time - 1. With the TV OFF, hold the TVs Volume down button and the
remotes 0 button for 5 seconds. 2. The lamp time will be reset to 0 hours.

SNR of Digital TV stations - Hold the Volume UP button on the TV and Hold the
Volume UP
button
on the remote for 10 seconds.
FDC
Status
System At the left corner of the diagnostic OSD is
the SNR level
of the digital
station
in dB. ThisSoftware
screen only
appears
digital
air or cable
version:
1.4.0onOct
09 2003
Frequency:
78.00
MHz
Elapsed time: 4 days, 3 hr 6 min
Status:
Locked
stations, notLock
analog
stations.
ROM: 8192 KB RAM: 32768 KB
Rate: 1.544Mbps
POD Status: Present x: 0
Polarity: Non - Inverted
POD MAC: N/A
POD Net: N/A
SNR: 18 dB
Authorization status: 0x01
Packets 3331
Parental Block: No
Map: Available
VCM: OK MMS: OK
Video / Channel Status
DCM: OK CDS: OK
Type: Digital
Diagnostic
t:392 d:40 m: 38 f:0
PCR Status: Locked
screen
PCR pid: 0x0021
FAT Status
Video pid: 0x0021
Mode: 256 QAM
Audio pid: 0x0022
Frequency: 657.00 MHz
CC708 Activated
Lock Status: Locked
SNR: 35 dB -6
@dBmV
Press EXIT to return, OK for more information
Slide # 39

DLP
PT-xxDLX76

Table of Contents - PT-xxDLX76 Repair


Slide

9
9
9
9

Repair Policy
Disassembly
Connector Layouts
Start Up
o Power On Sequence
o Dead Set
o Power LED blinks continuously

3
4
7
9
10
11

9 TV Protection (shutdown)
o
o
o
o
o
o
o
o
o
o
o

Error Code List


Power LED 1X Code (excessive voltage)
Power LED 2X Code (no fan rotation)
Power LED 3X Code (no DT 5Vdc)
Power LED 5X Code (No Communication)
Power LED 6X Code (No Color Wheel)
Power LED 7X Code (Lamp Door Sw)
Power LED 8X Code (No Lgt Eng Cont.)
Temp LED continuous (Excess Temp)
Lamp LED 1X Code (No Lamp)
Lamp LED 2-4X Code (Lgt Eng Iris NG)

Slide # 40

13
14
15
16
17
18
19
20
22
23
24

Slide

9 No Audio
9 Video Problems
o No Video
o Identifying Misc Video Problems
Generating a Lgt Eng Pattern
Generating a Tuner Blk Pattern

26
27
29
31
32

9 Service Information
o
o
o
o
o

Operations Possible
Access
Navigation
White Balance
Digital Station SNR Level

Adjustments after Light


Engine Replacement.

36
37
38
39
40
42

After Light Engine Replacement 1/5


When the Light Engine is replaced:
1. Center the picture electrically and mechanically (optional).
2. Adjust mechanical focus
3. Adjust the color wheel colors in the Factory Service Mode
4. Adjust the 1080p SP Gain in the Factory Service Mode.
5. Optional transfer of White Balance & CW information from the new engine to the Main board EEprom.

1. Center the Picture (electrical)


a) Follow these steps to enter the Work Mode, then jump to the Factory Service Mode to display
the Focus Pattern used to check picture center:
1) Work Mode - Hold the TVs VOL DWN and the remotes RECALL button for 5 seconds.
2) Factory Service Mode - Press the remotes top VCR mode button, then press RECALL..
3) Select OTHER using the remotes Channel and OK buttons. (Press RECALL to return)
4) Opt Hposi is already selected. Press the TV/Video button for any input except TV or
PC (like component video 1). Press VOL to display the Focus Pattern.
5) Press the Volume buttons again to change the data and center the screen. Adjust so the
bars on the sides are equal in number.
FACTORY ADJUST
M:2.020
VIDEO ADJ
SOUND
FAN
OTHER
PARTIAL
DT BOARD

Pwr

1/1

Sap

TV
vcr
OK
aspect

EEP COPY L DG
DEFAULT SET

recall
DLP Remote p/n =

Work Mode
Slide # 41

Factory Adjust Mode


DLP
PT-xxDLX76

Focus Pattern

EUR7737z10

After Light Engine Replacement 2/5


1. Center the Picture (mechanical) optional
b) From the front of the TV remove the optical cover (next to the lamp door / cover).
c) Loosen the 4 screws at the sides of the projection lens (center).
d) Twist the center projection lens until the focus pattern is straight along the bottom
(parallel to the bezel) and not tilted.

2. Adjust Mechanical Focus - mandatory


a) At the right of the projection lens in the optical assembly, loosen the focus knob (CCW).
b) Watch the center of the internal focus pattern or a single scan line while moving the knob
up or down for best focus.
c) Tighten the screw (CW).
Projection lens

Centering
Icons data #
Focus knob

Tilt Adjustment
Slide # 42

DLP
PT-xxDLX76

bezel

Focus
pattern

After Light Engine Replacement 3/5


3. Adjust the Color Wheel Colors (to maintain solid colors) - optional
a) While still displaying the internal focus pattern, press RECALL to return to the Factory
Service Mode / Other Menu
b) Press CHANNEL down to select CW INDEX DELAY and press ASPECT to enter.
c) Use the VOLUME buttons to change the data so only solid red and black are shown.
d) Check in the other colors. Press RECALL.

OK
OTHER

1/1

Red
Blk

NG

Aspect

Red

S P EC

OPT HPOSI
8000
OPT VPOSI
8000
CW INDEX DELAY 00ED
WB
DDP
GC : 05060101

Green

Recall

S PEC

Aspect

White

Blue
Black
Blue

Aspect
Blue

Slide # 43

DLP
PT-xxDLX76

After Light Engine Replacement 4/5


4. Check / Adjust the 1080p SP Gain Adjustment (to avoid jagged horiz. lines) - mandatory
a) If still displaying the CW Index pattern, press RECALL to return to the Factory Service Mode / Other Menu
b) Press CHANNEL down to highlight SP GAIN ADJUST and press ASPECT to select. Wait 3 seconds for
the SP Gain Adj screen.
c) Use the VOLUME +/- buttons to change the data to make the lines straight as possible as shown.
d) Press ASPECT* again to return to the OTHER page. Go to step 5 to copy white balance info. or exit in 4e.
e) Press RECALL 2 times to SAVE by exiting from the Factory Service Mode into the Work Mode. Turn the
TV off to completely exit the service modes.
OTHER

1/1

OPT HPOSI
8000
OPT VPOSI
8000
CW INDEX DELAY 00ED
WB
DDP
SP GAIN ADJUST
SP DELAY ADJUST
CEC THEATER LINK ON

Aspect

OK
OK

3 sec delay

NG

Aspect
These two lines

These two lines

Factory Adjust Mode,


SP Gain Adjust Screen
should be in line. should be in line.
Other page
* Picture Inversion Note:
Symptom: The picture will invert and some buttons will not work if the RECALL button
is incorrectly used to return to the previous page or EXIT (step 4d).
Remedy: To correct, press the Power OFF button and the Power ON button (same
button) to restore normal operation.
Slide # 44

DLP
PT-xxDLX76

After Light Engine Replacement 4a/5


4. Check / Adjust the 1080p SP Gain Adjustment Concept (to avoid jagged horiz. lines)
DMD mirror position
(exaggerated)

1080p Concept:
Rear TV
mirror

video
60 Hz. osc

OTHER

lamp

Factory Adjust Mode,


Other page
Slide # 45

OK

1/1

OPT HPOSI
8000
OPT VPOSI
8000
CW INDEX DELAY 00ED
WB
DDP
SP GAIN ADJUST
SP DELAY ADJUST
CEC THEATER LINK ON

DLP
PT-xxDLX76

Doubling the number of lines


from 1080i to 1080p is
accomplished by oscillating
the mirror panel at 60Hz. This
adjustment is for mechanical
electrical sync.

Aspect

OK
3 sec delay

NG

Aspect

SP Gain Adjust Screen

These two lines These two lines


should be in line. should be in line.

After Light Engine Replacement 5/5


5. White Balance transfer (light engine to the main board) - optional
a) If still displaying the SP Gain Adjust Screen, press ASPECT to return to the Factory Service Mode / Other
Menu
b) Press the RECALL button to return to the main Factory Adjust Service Mode Screen.
c) Press CHANNEL down to highlight EEP COPY.
d) Hold down the OK button until the word OK appears on the screen (approx. 5 seconds). This completes
the transfer of the CW and White Balance information from the new light engine to the main board.
e) Press RECALL 2X to Save the information by returning to the Work Mode. Turn off the TV and Unplug the
TV to complete the operation. At power on, the TV will retrieve this new information from the main board
EEProm and insert it into the main board microprocessor operating memory.
OTHER

1/1

OPT HPOSI
8000
OPT VPOSI
8000
CW INDEX DELAY 00ED
WB
DDP
SP GAIN ADJUST
SP DELAY ADJUST
CEC THEATER LINK ON

OTHER Sub Menu

Slide # 46

Recall

OK

Picture Inversion Note:


Symptom: The picture will invert and some buttons will not work if the RECALL
button is incorrectly used to return to the previous page or EXIT (step 4d).
Remedy: To correct, press the Power OFF button and the Power ON button
(same button) to restore normal operation.
DLP
PT-xxDLX76

Table of Contents - PT-xxDLX76 Repair


Slide

Repair Policy
Disassembly
Connector Layouts
Start Up
o Power On Sequence
o Dead Set
o Power LED blinks continuously

3
4
7
9
10
11

TV Protection (shutdown)
o
o
o
o
o
o
o
o
o
o
o

Error Code List


Power LED 1X Code (excessive voltage)
Power LED 2X Code (no fan rotation)
Power LED 3X Code (no DT 5Vdc)
Power LED 5X Code (No Communication)
Power LED 6X Code (No Color Wheel)
Power LED 7X Code (Lamp Door Sw)
Power LED 8X Code (No Lgt Eng Cont.)
Temp LED continuous (Excess Temp)
Lamp LED 1X Code (No Lamp)
Lamp LED 2-4X Code (Lgt Eng Iris NG)

Slide # 47

13
14
15
16
17
18
19
20
22
23
24

Slide

No Audio
Video Problems
o No Video
o Identifying Misc Video Problems
Generating a Lgt Eng Pattern
Generating a Tuner Blk Pattern

26
27
29
31
32

Service Information
o
o
o
o
o

Operations Possible
Access
Navigation
White Balance
Digital Station SNR Level

Adjustments after Light


Engine Replacement.

36
37
38
39
40
42

Class End
Panasonic Thanks You for
sharing your time with us.

Herb Chin

Slide # 48