Hughes Jvc 200 Projector Service Manual

							Chapter 4---Maintenance (Removal/Replacement) 
4.2  Projector Covers 
Prior to removing either cover, review the chapter on Safety and 
adhere to all warnings and cautions. 
 
Latch Levers 
Holding Slots 
Interlock Switch. 
Pull up immediately after 
removing front or rear cover 
to reapply power to Arc 
Lamp cooling fans. 
Figure 4-2   Rollbar Assembly. 
To remove the front or rear covers (refer to Figure 4-2): 
1.   Disconnect the projector power plug. 
2.   Loosen the two pozidrive spring screws at the front of 
the front cover or the rear of the rear cover. 
3.   Tilt up the front or rear cover. 
CAUTION! Do not leave either cover tilted 
up! The covers can fall from this tilted up position and possibly 
damage projector components. Remove the cover and set it 
aside when servicing the projector. 
4.   Release the two Latch Levers on the Rollbar assembly 
that hold the cover in place. Place the ends of the 
Latch Levers into the holding slots.  
CAUTION! Immediately after removing the front or 
rear cover, pull up the power interlock switch. This allows 
power to be reapplied to the fans to cool the Arc Lamp. 
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							 Chapter 4---Maintenance (Removal/Replacement) 
The power interlock switches for both covers are attached 
to each cover hinge. 
5.   When the Latch Levers are inserted into the holding 
slots, lift the cover off. Be careful not to brush against 
any of the internal components of the projector when 
removing the cover. If any undue resistance is felt, stop 
to locate the source before proceeding.  
6.   Replace the covers in reverse order from above. When 
replacing either cover, make sure the slot in the cover 
fits over the bottom of the projector case or the cover 
will not close correctly. 
4.3  Air Filters 
Air filters should be cleaned whenever necessary. In extremely 
dusty or dirty conditions, the filters should be cleaned more 
frequently. Remove the filters and vacuum them or blow them 
clean with compressed air. They may also be washed with soap 
and water. 
There are 4 polyurethane air filters in the Model 200 that require 
periodic cleaning. They are located as follows: 
• 1 metal-framed filter in the rear of the projector in  the bottom 
cover-accessible when the rear cover is off (Figure 4-1). 
• 1 filter on the bottom of the projector-slides out from the 
middle-left side of the projector (grasp the hole in the filter 
frame). The filter can be peeled off the Velcro on the frame, if 
necessary (Figure 4-11). 
• 1 filter under the front cover, on top of the Arc Lamp and 
Optical Assemblies-accessible with the front cover off (Figure 
4-1). This filter is also a peel-off type. 
• 1 metal-framed filter in the front-left-bottom cover accessible 
with the front cover off (Figure 4-11). 
4.4  Arc Lamp Assembly 
The Arc Lamp Assembly consists of the Arc Lamp, the Ignitor, and 
the Laser Power Supply housed inside a Lamphouse Dock. An 
Arc Lamp can be removed and replaced separately from the entire 
assembly. The Ignitor and Laser Power Supply are sent back 
together as part of the Lamphouse Dock. 
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							Chapter 4---Maintenance (Removal/Replacement) 
WARNING!!! Dangerous light exists in 
this area of the projector. Before proceeding with the removal 
of any subassemblies below, verify that the circuit breaker at 
the rear of the projector is turned off and the power plug is 
removed from the AC outlet.  
To remove the Arc Lamp from the Lamphouse Dock: 
1.   Remove the front cover (Section 4.2). 
2.   Disconnect the fan connector from the Arc Lamp 
exhaust fan. 
3.   Loosen (½ turn) the large retainer screw at the bottom 
of the Arc Lamp assembly cover (Figure 4-3).  
 
Figure 4-3  Arc Lamp cover. 
4.   Lift the Arc Lamp assembly cover up and tilt it back. 
5.   Remove and label the two Arc Lamp cables at the 
Ignitor side (these two connections are shown inside 
the heavy circles in Figure 4-4). Leave these cables 
connected to the Arc Lamp when returning it to the 
factory. 
6.   Loosen the three Arc Lamp holding bolts (Figure 4-4). 
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							 Chapter 4---Maintenance (Removal/Replacement) 
 
Figure 4-4.   Lamphouse Dock and Arc Lamp with cover off. 
7.   When reinstalling the Arc Lamp, be sure that the 
Safety Shutter tab on the left side (Figure 4-4) engages 
the left side of the housing so that the Arc Lamp 
cooling door opens when the Arc Lamp is installed. 
8.   After reinstalling the Arc Lamp, perform the Arc Lamp 
Focus, Alignment and Current Setting procedures as 
shown in Sections 3.1 and 3.2. 
To remove the Lamphouse Dock (Ignitor and Laser PS): 
1.   Remove the Arc Lamp as shown in the above 
procedure. Store the Arc Lamp in a safe place. 
2.   Remove the 5 pozidrive screws securing the 
projector’s lower-right-side panel (Figure 4-1) and 
remove the panel. 
3.   Disconnect the fan connector from the Arc Lamp 
cooling fan. 
4.   Disconnect and label the positive and negative cables 
from the Arc Lamp Power Supply terminals marked 
“DC OUTPUT” (Figure 3-3). 
5.   Remove the Arc Lamp Air Filter and cover by removing 
the 3 pozidrive screws that secure it to the Lamphouse 
Dock Assembly. 
6.   Remove the 3 hex screws at the inside-rear of the 
Lamphouse Dock (1 on top and 2 on bottom). The 
Lamphouse Dock is now free to return for repair.  
7.   Replace the Lamphouse Dock in reverse order. NOTE: 
When replacing the Lamphouse Dock, be sure the 2 
pins on the Collimator Lens line up with the holes on 
the rear of the Lamphouse Dock. 
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							Chapter 4---Maintenance (Removal/Replacement) 
4.5  Arc Lamp Power Supply 
To remove the Arc Lamp Power Supply: 
1.   Remove the front cover (Section 4.2). 
2.   Remove the lower-right-front-side panel by removing 
the 5 pozidrive screws securing it. 
3.   Remove the 2 pozidrive screws from the bottom of the 
EMI shield and slide it out of the way to the left. 
4.   Remove and label the cables from the DC OUTPUT 
terminal, J74.  
5.   Disconnect J71 (AC Input). 
6.   Disconnect J72 (SIGNAL CABLE). 
7.   Remove J73. 
8.   Remove the 2 screws at the bottom of the ALPS and 
carefully slide it out of the projector. 
9.   Replace the Arc Lamp Power Supply in reverse order 
from above. NOTE: When replacing the cables on the 
± terminals on J74, a mechanical pickup tool is very 
useful to start the screws.  
10. Perform the Arc Lamp Focus, Alignment, and Current 
Setting procedures as shown in Section 3.1 and 3.2. 
4.6  Low Voltage Power Supply 
To remove the Low Voltage Power Supply: 
1.   Remove the front cover. 
2.   Remove the lower-right-side panel by removing the 5 
pozidrive screws securing it. 
3.   Remove the 2 pozidrive screws securing the EMI 
Shield. Slide the shield to the left and remove it. 
4.   Remove J76 (DC Output) and J75 (AC Input) from the 
left side of the Low Voltage Power Supply. NOTE: 
These connectors may be difficult to remove and it may 
be necessary to angle the LVPS partly out of the 
chassis in order to get a firmer grip on the connectors. 
5.   Remove the 2 screws on the bottom side of the LVPS 
and carefully slide it out of the projector. 
6.   Reinstall the LVPS in reverse order. After the LVPS is 
installed, recheck Timing, Geometry, Electronic Focus, 
ILA® Bias/Sensitivity, Convergence, G2, and Shading. 
4.7  High Voltage Power Supply 
To remove the High Voltage Power Supply: 
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							 Chapter 4---Maintenance (Removal/Replacement) 
1.   Remove the front and rear covers (Section 4.2). 
2.   Remove the High Voltage Power Supply cover (Figure 
4-5) by removing the 2 pozidrive screws that secure 
the HVPS at the top of the cover and loosening the 1 
pozidrive screw at the bottom of the front flap (Do not 
remove this bottom screw-it is difficult to reinstall. The 
HVPS will slide up and over it). 
 
Figure 4-5.    High Voltage Power Supply cover. 
 
Figure 4-6   High Voltage Power Supply. 
3.   Carefully slide the cover upward and outward to 
remove it. 
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							Chapter 4---Maintenance (Removal/Replacement) 
NOTE:  For the remainder of this procedure refer to Figure 
4-6 above. 
4.   Disconnect the 3 CRT anode cables. 
5.   Disconnect P44-G2 Out (at the middle-front of the 
HVPS). 
6.   Unsnap the cable clamp at the top of the HVPS. 
7.   Remove the anode cables and the P44 cable from the 
cable clamp. 
8.   Disconnect P45 (“Control”) at upper left of HVPS. 
9.   Disconnect and label the 3 Focus cables. The square 
tabs on these cables (see Figure 4-6) may have to be 
lifted up by gently prying with a flathead screwdriver. 
10. Remove all cables from the slot in the cable guide at 
the left side of the HVPS. 
11. Verify that all plugs and cables are removed and out of 
the way so the HVPS is free to be removed. 
12. Loosen (do not remove) the 2 pozidrive screws (at the 
bottom of the HVPS) that secure the HVPS metal 
housing to the projector. 
13. Remove the 2 pozidrive screws that hold the top of the 
HVPS metal housing to the projector frame. 
14. Grasp the HVPS at the bottom and lift upward and 
outward so that it slides away from the bottom screws. 
15. Reinstall the HVPS in the reverse order from above. 
When reinstalling, be sure that the HVPS slides over 
the bottom screws and the lip at the top of the projector 
frame. Make sure each anode cable “snaps” back into 
its receptacle. The receptacles are about 2” inside the 
hole where the cable fits into. Also, be sure the rear 
flap on each focus cable connector snaps over the 
square socket securely-wiggle the connector a little to 
make it fit over. 
16. Replace the HVPS cover. After the HVPS is replaced, 
recheck CRT Mech Focus, Yoke Alignment, G2, and 
Electronic Focus.  
17. Replace the projector covers. 
4.8  Raster Timing, System Controller, Video Processor 
PCBs 
All electrical connections to the Raster Timing Generator, System 
Controller, and Video Processor boards are routed through the 
backplane board. There are no connectors to remove. 
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							 Chapter 4---Maintenance (Removal/Replacement) 
To remove the Raster Timing Generator, Video Processor, or 
System Controller PCBs: 
1.   Turn off power at the remote control and at the circuit 
breaker on the projector rear panel. 
2.   Remove the projector rear cover. 
3.   For the Raster Timing Generator and Video Processor 
PCBs, grasp the card extractor tabs at both ends of the 
boards and pull out. To remove the System Controller 
Board, use a small, flathead screwdriver and remove 
the screw in the bracket in the center of the System 
Controller Board (this bracket holds the SCB to the 
card cage). Grasp the bracket and pull out the SCB. 
4.   When replacing boards, verify that power is off at the 
circuit breaker, the power plug is disconnected and 
there are no bent pins on any connectors. Make sure 
the board is properly and securely seated before 
reapplying power. 
 
NOTE: To remove connectors on the printed circuit boards 
below, push the connector in slightly, then squeeze the tab and 
pull the connector out. 
4.9   Convergence/Deflection PCB. 
The Convergence/Deflection PCB is located on the bottom side of 
the Electronic Module card cage. 
To remove the Convergence/Deflection PCB: 
1.   Remove the rear cover (Section 4.2). 
2.   Tilt the Electronic Module up. (Section 3.3). 
3.   Disconnect 6 connectors; J31, J32, J33, J38, J39, and 
J40. (Figure 4-6). Move the cables out of the way. 
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							Chapter 4---Maintenance (Removal/Replacement) 
 
Figure 4-7.   Convergence/Deflection PCB. 
4.   Loosen (not necessary to remove) the 5 screws that 
secure the Convergence Deflection PCB to the electronic 
module card cage (see Figure 4-7).  
5.   Remove the Convergence Deflection PCB by sliding it 
upward so the mounting screws will clear the access 
holes, then angle the right side outward. NOTE: In order 
to get the right side out, it may be necessary to first move 
the board out enough to clear the access holes, then 
angle the left side out just enough for the top 2 fins of the 
heat sync to fit over the electronic module frame lip (this 
will allow a little more clearance for the right side to be 
removed), then maneuver the right side out. 
6.   Reinstall the Convergence/Deflection PCB by lowering 
the right side in first  until it clears the electronic module 
edge, then lowering the left side in. NOTE: it may be 
necessary to fit the top 2 fins of the heat sync over the 
electronic module frame lip at the left to get enough 
clearance for the right side to be installed. Carefully fit the 
board over the mounting screws and slide the board into 
position. Tighten the screws and reconnect the 
connectors. 
4.10   Horizontal/Vertical Deflection PCB 
The Horizontal/Vertical (H/V) Deflection PCB is located in the upper 
portion of the Electronic Module card cage. 
To remove the Horizontal/Vertical (H/V) Deflection PCB: 
1.   Remove the rear cover (Section 4.2). 
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							 Chapter 4---Maintenance (Removal/Replacement) 
2.   Disconnect 6 connectors; J34, J35, J36, J41, J42, and 
J43. (see Figure 4-8). Move the cables out of the way. 
3.   Loosen (not necessary to remove) the 5 pozidrive screws 
that secure the H/V Deflection Board to the electronic 
module cage.  
4.   Remove the H/V Deflection PCB by sliding it toward the 
left side of the projector (this is the upward direction if the 
electronic module is raised up) so that the mounting 
screws clear the access holes. Then lift the side of the 
board that is nearest the front of the projector first and 
angle it upward so that the side closest to the rear clears 
the lip of the electronic module frame. Be careful when 
removing or reinstalling the board to avoid gouging it on 
the fan screws or cable clamps. 
5.   Reinstall the HV Deflection PCB by lowering the side that 
is nearest to the rear of the projector in first until it clears 
the electronic module edge, then lowering the other side. 
Carefully fit the board over the mounting screws and slide 
the board into position. Tighten the screws and reconnect 
the connectors. 
 
Figure 4-8.   Horizontal/Vertical Deflection PCB. 
 
4.11   Video Input Cards (VICs) 
The 4 types of Video Input Cards, RGB Standard, 4X RGB Mux (4 
RGB Input), Quad Decoder, and HDTV (YPbPr) are all removed and 
inserted in the same manner.  
To remove a VIC: 
1.   Disconnect all video input connections from the VIC to be 
removed. 
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