Hughes Jvc 220 Projector Service Manual

							Chapter 3 Service Adjustments 
 Command: loadboot 
 Boot Manager software update procedure 
 ***WARNING: IMPROPER USE MAY MAKE THIS 
SYSTEM UNBOOTABLE*** (This warning relates 
to the Flash Memory updating that occurs 
in Step 11D. Do not turn projector power 
off while the Flash Memory is updating)  
 Memory buffer reset to 0xff 
 Begin your S-Record upload now (Esc to 
abort). 
11B. From the Windows Terminal Menu (normally in 
Accessories window), select Transfers/Send Text File, 
then select List Files of Type:All Files, and select the 
disk and/or directory with the Model 220 software. You 
should see a file named boot.hex. Select this file and 
press the OK button to begin the upload. 
11C. During upload, a progress indicator updates the number 
of records received. At the completion of the upload, the 
system will display the following (numerical values are for 
example only and depend on the  Boot Manager version): 
 S-Records processed: 823 
 Upload Successful 
 Address Range: 0x00000000-0x00006687 
 Bytes Loaded:  26248 
 ***WARNING: FLASH WILL NOW BE UPDATED*** 
 Press Enter to continue, Esc to abort. 
11D. The system has verified that the load module is correct 
and is ready to update the Flash. Press Enter to perform 
the update (press Esc now to abort the update with no 
changes). While the Flash memory is being updated (15-
30 seconds), DO NOT turn off the projector circuit breaker 
or the machine could be made unbootable, requiring a 
new set of flash chips to be installed. When the update is 
complete, the system will display the following: 
 Reprogramming Flash Sector 0 1 
Boot Manager software update successful 
 Command: _ 
The Boot software has been successfully updated. To restart 
the projector under control of the updated boot manager, enter 
the reboot command while depressing the service mode 
switch (Figure 5-1). The projector will now restart with the 
updated boot manager software. You should see the following 
displayed (where y.y.0 is the updated Boot Managers version. 
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							Chapter 3---Service Adjustments 
 Boot Manager Ver y.y.0 (Service Mode 
Startup) 
Copyright (c) 1994-1996 Hughes-JVC 
Technology 
 Command: _ 
12. To update the System Software from the Boot Manager prompt: 
12A. Type in the command “loadsys” at the prompt. The 
following should be displayed: 
 Command: loadsys 
 System software update procedure 
***WARNING: IMPROPER USE MAY MAKE THIS 
SYSTEM UNBOOTABLE*** (NOTE: This warning 
relates to the Flash Memory updating that 
occurs in Step 12D below. Do not turn 
projector power off while the Flash Memory 
is updating.) 
 Memory buffer reset to Oxff 
 Begin your S-Record upload now (Esc to 
abort) 
12B. Select “Transfers/Send Text File” from the Windows 
Terminal Menu (normally in Accessories window). In the 
“Send Text File Dialog” box, select “List Files of Type: All 
Files” and select the disk and/or directory with the Model 
220 software. Select file named “zsys.hex”. Press OK to 
start upload. 
12C. During upload, a progress indicator updates the number 
of records received. When the upload is complete, the 
system will display the following (numerical values are for 
example only and depend on the System Software 
version): 
 S-Records processed:11282 
Upload Successful 
Address Range: 0x00020000-0x000781cf  
Bytes Loaded:360912  
 ***WARNING: FLASH WILL NOW BE UPDATED*** 
 Press Enter to continue, Esc to abort 
12D. At this point the system has verified that the load module 
is correct and is ready to update the Flash memory. Press 
Enter to perform the update (Esc will abort the update 
process with no changes). While the Flash is being 
updated (approx 15-30 seconds), DO NOT turn off the 
projector circuit breaker, this may make the machine 
unbootable, requiring a new set of flash chips to be 
installed. When the update is complete, the system will 
display the following: 
 Reprogramming Flash Sector 2 3 4 5 6 7 8 9 
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							Chapter 3 Service Adjustments 
3-18 Model 220 Service Manual 
  System software update successful 
 Command: _ 
The software update is complete. To restart the projector, type in 
the “reboot” command and press Enter. The projector will now 
restart with the updated System Software. 
3.12  Cleaning Lenses, ILA® Assemblies and Mirrors 
The projection lens is the only item that requires periodic cleaning. 
Other assemblies are covered to prevent dust entering or finger 
smudging. Cleaning may be needed for special circumstances 
such as replacing an assembly. Cleaning should only require 
removing excessive dust (use canned air such as “Office Duster” o\
r 
Aero Duster) or removing fingerprint smudges (use “Kodak Lens 
paper”, or equivalent) from the projection lens. As much as 
possible, clean the optics only when absolutely necessary. 
Projection Lens: Use lens paper and wipe the lens clean in a 
vertical motion from top to bottom. Use compressed air to blow 
excess dust from the lens. An optical lens cleaning solution can 
also be used to remove finger smudges.  
ILA® Assembly: Clean the ILA® assembly faces with compressed 
air only. Do not wipe the ILA assembly faces.  
CRT Faces:  Use compressed air to blow dust off and lens paper 
to clean face.  
Relay Lens: Same as Projection Lens. 
Mirrors and Polarizing Beam Splitter Windows:  The Optical 
Shield covers the Dichroic Mirror Assembly and Polarizing Beam 
Splitter windows. Normally cleaning is not needed. Clean only if 
absolutely necessary using compressed air. Do not wipe mirrors.   
						

							 Chapter 4---Maintenance (Removal/Replacement) 
4.0   Maintenance (Removal/Replacement) 
  Contents 
4.1   Introduction........................................................................\
......4-1 
4.2   Projector Covers......................................................................4-4 
4.3   Air Filters........................................................................\
..........4-5 
4.4   Arc Lamp Assembly.................................................................4-5 
4.5   Ignitor Assembly......................................................................4-7 
4.6   Arc Lamp Power Supply..........................................................4-8 
4.7   Low Voltage Power Supply......................................................4-9 
4.8   High Voltage Power Supply.....................................................4-10 
4.9   Raster Timing, System Controller, Video Processor PCBs.....4-12 
4.10 Convergence/Deflection PCB..................................................4-13 
4.11 Horizontal/Vertical Deflection PCB..........................................4-14 
4.12 Video Input Cards (VICs).........................................................4-15 
4.13 Video Amplifier PCB................................................................4-15 
4.14 Scan Reversal PCB.................................................................4-18 
4.15 CRT/Yoke Assembly................................................................4-18 
4.16 ILA® Assembly........................................................................\
.4-20 
4.17 Relay Lens........................................................................\
.......4-21 
4.18 Projection Lens........................................................................\
4-22 
4.19 Prism Assembly.......................................................................4-23 
 
4.1  Introduction 
NOTE: Before removing the front or rear cover or replacing 
any components or subassemblies, please review the Safety 
Chapter at the front of this manual. Removal and replacement 
procedures in this chapter must be performed by Hughes-
JVC certified technicians and engineers only. 
When performing any maintenance, protect yourself and the 
equipment by following these guidelines: 
• Turn the projector off with the remote. 
• After the cooling fans have automatically stopped running, turn 
off the circuit breaker. 
• Allow a discharge time of at least one minute for the high 
voltage to bleed off, then unplug the power cord from the AC 
wall outlet. 
• Observe all Cautions and Warnings 
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							Chapter 4---Maintenance (Removal/Replacement) 
Tools required to perform removal and replacement of projector 
components and subassemblies are listed in Chapter 1, 
Introduction. 
WARNING!!! Various procedures in this 
chapter involve the removal and replacement of system 
subassemblies. Ensure that the projector circuit breaker is 
turned off and the AC power plug is removed from the AC 
outlet PRIOR to attempting any of these procedures. 
When performing any maintenance procedures in this chapter, 
follow the guidelines below: 
Left/Right Orientation: When left and right is mentioned in this 
chapter, it is with reference to standing at the rear of the projector, \
facing the screen. 
Connectors on subassemblies and PCBs have tabs that must be 
released first before pulling on the connector. The proper 
procedure is to push slightly IN on the connector, then squeeze 
the tab, then pull the connector out.  
NOTE: While performing any maintenance procedures, check the 
prism diaphragm for dryness, crazing, cracking, or possible 
leaking. If any problems are observed, call HJT. 
When references are made in this chapter to assemblies and 
components, refer to Figures 4-1 and 4-14 for their locations. 
4-2  Model 220 Service Manual  
						

							 
Chapter 4---Maintenance (Rem
oval/Replacem
ent) 
 
Figure 4-1.
   Major components of the Model 220 Projector.
 
Model 220 Service Manual 
 
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							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. 
 
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 in the 
tilted up position! 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 3 polyurethane air filters in the Model  220 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 metal-framed filter in the front-left-bottom cover accessible 
with the front cover off (Figure 4-11). 
4.4  Arc Lamp 
The Arc Lamp consists of a Xenon Arc Lamp and heat sync. It is 
removed and replaced separately from the other components on 
the Arc Lamp Base Assembly. 
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.  
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							Chapter 4---Maintenance (Removal/Replacement) 
To remove the Arc Lamp from the Arc Lamp Base Assembly 
(Refer to Figure 4-3): 
1.   Remove the front cover (Section 4.2). 
2.   CAUTION! Ensure all fans have stopped running. 
3.   Remove the lower-right-front-side panel (5screws). 
4.   Remove the Optical Shield (1 screw on top, 2 screws 
on lower right side, 1 screw at rear on bottom). 
 
Figure 4-3.   Arc Lamp Assembly  
5.   Remove the hex screw pin that holds the Arc Lamp fan 
to the housing. Swing the fan outward to the right and 
out of the way. 
 
6.   Disconnect the Arc Lamp cable and pull it through the 
hole in the top of the Arc Lamp housing so the Arc 
Lamp will have clearance to be removed. 
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							 Chapter 4---Maintenance (Removal/Replacement) 
7. Remove the 2 screws that secure the slide support 
bracket. Lift the support bracket upward to remove it. 
8.   Grasp the handle on the Arc Lamp and carefully slide it 
out of the housing. NOTE: Some earlier units may not 
be equipped with the handle. These units can be 
removed by gripping the circular cooling fins and 
pulling the lamp out. HINT: If the Arc Lamp is difficult to 
remove, use pliers and grasp one of the three heatsink 
screws and pull out. 
9.   Place the Arc Lamp on a safe, level surface with the 
handle and cable connection facing upward.  
10. Remove the 2 screws securing the Arc Lamp to the 
heat sink frame. (CAUTION! When these screws are 
removed the Arc Lamp is loose and can fall out.) 
Pull upward on the handle while pushing down on the 
heat sink to remove the Arc Lamp from the frame. 
11. Reinstall the Arc Lamp in reverse order from above. 
When inserting the Arc Lamp into the heat sink frame, 
be sure the screw holes in the heat sink and the heat 
sink frame are aligned. Be sure the Arc Lamp is fully 
secured into its socket connector when installing. Push 
the lamp in firmly (similar to inserting a PCB). 
12. After reinstalling the Arc Lamp, perform the Arc Lamp 
Focus and Current Setting procedures as shown in 
Sections 3.1 and 3.2. 
4.5  Ignitor Assembly 
The Ignitor Assembly includes the Ignitor and the Laser Power 
Supply. When either of these two components require replacing, 
the Ignitor Assembly is returned and replaced as a unit. 
To remove the Ignitor Assembly (Refer to Figure 4-3 and 4-4): 
1.   Remove the front cover (Section 4.2). 
2.   Disconnect and label the positive and negative cables 
attached to the Ignitor. 
3.   Remove the 2 screws at the base of the Laser Power 
Supply. 
NOTE: The Ignitor is attached to the Arc Lamp Housing 
wall with a double-backed adhesive.  
4.   Use a thin-bladed knife or screwdriver and carefully pry 
the Ignitor away from the Arc Lamp wall. The 
replacement Ignitor will have new adhesive backing. 
5.   Replace Ignitor Assembly in reverse order. 
 
Model 220 Service Manual  4-7