Sanyo PLCXP-100-L Service manual
FILE NO.
SERVICE MANUAL
Multimedia Projector
Model No. PLC-XP100L
U.S.A, Canada,
Europe, U.K, Asia
Original Version
* Projection lens is optional.
PRODUCT CODE
1 122 380 20 (KC3AL)
1 122 381 20 (LC3AL)
1 122 381 22 (LC3CL)
Chassis No. KC3-XP100L00
Match the Chassis No. on the unit's back cover with the
Chassis No. in the Service Manual.
If the Original Version Service Manual Chassis No. does
not match the unit’s, additional Service Literature is required. You must refer to “Notices” to the Original Service
Manual prior to servicing the unit.
REFERENCE NO. SM5110873-00
Contents
SERVICE MANUAL ....................................................... 1
Contents ........................................................................ 2
Safety Instructions ......................................................... 3
Safety Precautions ..................................................... 3
Product Safety Notice ................................................. 3
Service Personnel Warning ........................................ 3
Specifications ................................................................ 4
Circuit Protections .........................................................5
Fuse ............................................................................ 5
Thermostat (SW905) .................................................. 5
Mechanical sensor switches (SW1891,SW1861) ........6
Temperature sensors, wind sensors .......................... 7
Power failure and fan lock detection .......................... 8
Maintenance .................................................................. 9
Replacing the Filter Cartridge .................................... 9
Resetting the Filter Counter ..................................... 10
Resetting the Scroll Counter .................................... 10
Lamp Replacement .................................................. 11
Resetting the Lamp Counter .................................... 12
How to check Lamp Used Time ............................... 12
Cleaning ................................................................... 13
Quick maintenance ................................................... 14
Security Function Notice ............................................. 15
Mechanical Disassembly............................................. 16
Mechanical disassembly flow chart .......................... 16
Mechanical disassembly .......................................... 17
Optical Parts Disassembly .......................................... 28
Adjustments ................................................................. 38
Adjustments after Parts Replacement ...................... 38
Optical Adjustments .................................................... 39
Contrast adjustment ................................................. 39
Electrical Adjustments ................................................. 40
Service Adjustment Menu Operation ....................... 40
Memory IC (IC301, IC802) Replacement .................
Circuit Adjustments .................................................. 41
Test Points and Locations ........................................ 44
Service Adjustment Data Table ................................ 45
Chassis Description ....................................................64
Chassis over view ..................................................... 64
Input & signal processing stage ...............................65
LCD drive stage ........................................................ 66
40
Lamp control stage ................................................... 67
Fan control stage ...................................................... 68
Motor control stage ................................................... 69
Bus control stage ...................................................... 70
LED drive & RC control stage ................................... 71
Power supply & power failure circuit ......................... 72
Indicators and Projector Condition ........................... 73
Power failure detection system ................................ 75
Error information table .............................................. 75
Power failure detection tree ...................................... 76
Error History Log ...................................................... 77
Diagnosis of Power Failure with RS-232C port ........
Diagnosis procedure ................................................78
Serial Control Interface ............................................. 79
Control Port Functions................................................. 81
System Control I/O Port Functions (SH7727) ..........
Parallel I/O Expander (TIC81592GP) .......................
IIC Bus 8Bits 8ch 5V D/A Converter (M62393FP No.1
Fan Control) .............................................................. 83
Parallel Output Expander (74LCX574) ..................... 83
Waveform ....................................................................84
IC Block Diagrams....................................................... 85
Electrical Parts List ...................................................... 96
Electrical Parts Location ........................................... 97
Electrical Parts List ................................................... 99
Mechanical Parts List ................................................ 131
Cabinet Parts Location ........................................... 131
Mechanical Parts List ............................................. 136
Diagrams & Drawings .................................................. A1
Parts description and reading in schematic diagram ..A2
Schematic Diagrams ...................................................A3
Printed Wiring Board Diagrams ................................. A13
Pin description of diode, transistor and IC ................ A17
Note on Soldering ...................................................... A18
78
81
81
-2-
Safety Instructions
Safety Precautions
WARNING:
The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side
of the converter and lamp power supply unit circuit is connected to the AC line and it is hot, which hot circuit is
identified with the line ( ) in the schematic diagram. For continued product safety and protection of personnel injury, servicing should be made with qualified personnel.
The following precautions must be observed.
ment covers or shields, barriers, etc.
1: An isolation transformer should be connected in
the power line between the projector and the AC
line before any service is performed on the projector.
DO NOT OPERATE THIS PROJECTOR WITHOUT
THE PROTECTIVE SHIELD IN POSITION AND PR
OPERLY SECURED.
2: Comply with all caution and safety-related notes
provided on the cabinet back, cabinet bottom, inside
the cabinet or on the chassis.
3: When replacing a chassis in the cabinet, always
be certain that all the protective devices are
installed properly, such as, control knobs, adjust-
4: Before replacing the cabinet cover, thoroughly
inspect the inside of the cabinet to see that no stray
parts or tools have been left inside.
Before returning any projector to the customer, the
service personnel must be sure it is completely safe
to operate without danger of electric shock.
Product Safety Notice
Product safety should be considered when a component replacement is made in any area of the projector.
Components indicated by mark ! in the parts list and the schematic diagram designate components in which
safety can be of special significance. It is, therefore, particularly recommended that the replacement of there
parts must be made by exactly the same parts.
Service Personnel Warning
Eye damage may result from directly viewing the light produced by the Lamp used in this equipment. Always
turn off Lamp before opening cover. The Ultraviolet radiation eye protection required during this servicing.
Never turn the power on without the lamp to avoid electric-shock or damage of the devices since the stabilizer
generates high voltages (15kV - 25kV) at its starts.
Since the lamp is very high temperature during units operation replacement of the lamp should be done at least
45 minutes after the power has been turned off, to allow the lamp cool-off.
-3-
Specifications
Mechanical Information
Projector Type Multi-media Projector
Dimensions (W x H x D) 14.56” x 7.36” x 17.32” (370 mm x 187 mm x 440 mm) (Not including raised portions)
Net Weight 25.8 lbs (11.7 kg)
Feet Adjustment 0˚ to 6.5˚
Panel Resolution
LCD Panel System 1.3” TFT Active Matrix type, 3 panels
Panel Resolution 1,024 x 768 dots
Number of Pixels 2,359,296 (1,024 x 768 x 3 panels)
Signal Compatibility
Color System
High Definition TV Signal 480i, 480p, 575i, 575p, 720p, 1035i, and 1080i
Scanning Frequency H-sync. 15 kHz–100 kHz, V-sync. 50 Hz–100 Hz
Optical Information
Projection Lamp 330 W NSH lamp
Interface
Input 1 Digital (DVI-D) x 1, Analog (Mini D-sub 15 pin) x 1
Monitor Out
Input 2 BNC Type x 5 (G or Video/Y, B or Cb-Pb, R or Cr-Pr, HV and V)
Input 3 RCA Type x 1, Mini DIN 4 pin x 1
R/C Jack Mini Type (Wired Remote) x 1
Control Port Mini DIN 9 pin x 1
USB Connector USB Series B x 1
Option Network Terminal x 1
Analog RGB (Mini D-sub 15 pin) Terminal x 1
Power
Voltage and Power Consumption AC 100–120 V (4.6A Max. Ampere), 50/60 Hz (The U.S.A and Canada)
AC 200–240 V (2.3A Max. Ampere), 50/60 Hz (Continental Europe and The U.K.)
Operating Environment
Operating Temperature 41˚F–104˚F (5˚C–40˚C)
Storage Temperature 14˚F–140˚F (-10˚C–60˚C)
Remote Control
Battery AAA or LR03 Type x 2
Operating Range 16.4’ (5 m/±30˚)
Dimensions 1.8” (W) x 1.0” (H) x 5.7” (D) (45 mm x 25 mm x 145 mm)
Net Weight 3.5 oz (99 g) (including batteries)
PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N
● The specifications are subject to change without notice.
● LCD panels are manufactured to the highest possible standards. Even though 99.99% of the pixels are effective, a tiny
fraction of the pixels (0.01% or less) may be ineffective by the characteristics of the LCD panels.
This symbol on the nameplate means the product is Listed by Underwriters
Laboratories Inc. It is designed and manufactured to meet rigid U.L. safety standards against risk of fire, casualty and electrical hazards.
-4-
Circuit Protections
This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the projector, it will automatically turn off by operating one of the following protection circuits.
Fuse
A fuse is located inside of the projector. When the POWER
indicator is not lightning, the fuse may be opened. Check
the fuse as following steps.
The fuse should be used with the following type;
Screw
Fuse Part No. : 323 027 2605
TYPE T10AH 250V
LITTEL FUSE INC. TYPE 215010
How to replace the fuse
1. Turn the projector up and down.
2. Remove 1 screw and take the fuse cover off.
3. Remove the fuse from fuse holder on the power board.
To install the fuse, take reversed step in the above.
Thermostat (SW905)
There is the thermostat switch (SW905) inside of the projector to detect the internal temperature rising abnormally. When
the internal temperature reaches near 90˚C, the thermostat
opens to stop the operation of the power supply circuit.
The thermostat will automatically return to normal condition when the internal temperature becomes normal (about
50
˚C)
.
Fuse cover
Fuse
-5-
Thermostat
(SW905)
Circuit Protections
Mechanical sensor switches (SW1891,SW1861)
This projector provides 2 mechanical sensor switches, the one is for
filter cartridge sensor switch (SW1891) and the other one is for lamp
cover sensor switch (SW1861). The filter cartridge sensor switch
detects whether the filter cartridge is installed correctly. If the filter
cartridge is not installed correctly, the projector cannot turn on.
The lamp cover sensor switch detects whether the lamp cover is
closed securely. If lamp cover is opened or not closed completely,
the drive signal to the lamp circuit is cut off. After opening the lamp
cover for replacing the lamp ass’y, place the lamp cover correctly
otherwise the projector cannot turn on.
Filter cartridge
Filter cartridge sensor
switch (SW1891)
Lamp cover sensor
switch (SW1861)
-6-
Circuit Protections
Temperature sensors, wind sensors
The projector provides 3 temperature sensor ICs, 2 sensors on the Main board and 1 sensor on the RC front board,
and 1 wind sensor on the intake duct. The sensor ICs monitor surrounding temperature of the lamp house and panels/prism, and room temperature, and the wind sensor monitors airflow passed through the air filter in the intake
duct.
- Internal temperature sensor A (IC1816) (around the lamp house)
- Internal temperature sensor B (IC1814) (around the panels/prism)
- Room temperature sensor C (IC1692) (around the front cabinet)
- Wind sensor D (S901) (intake duct)
IC1692
IC1814
(Behind)
S901
IC1816
(Behind)
The projector is shut down and the WARNING TEMP. indicator is blinking red.
When the temperature inside the projector reaches a certain
level, the projector will be automatically shut down to protect
the inside of the projector. The POWER indicator is blinking
while the projector is being cooled down. When the projector
has cooled down enough (to its normal operating temperature), it can be turned on again by pressing the ON/STANDBY button.
✔Note:
• The WARNING TEMP. indicator continues to blink even after
the temperature inside the projector returns to normal. When
the projector is turned on again, the WARNING TEMP. indicator stops blinking.
LED indicators
WARNING TEMP.
blinking red
-7-
Circuit Protections
Power failure and fan lock detection
The projector provides the detection circuits of the power failure and the fan lock. When the detection circuit detects
an error at the power supply line or at the fan operation circuit, the projector will turn into the standby mode to protect
the other circuits defective.
The projector is shut down; and the LAMP indicator is
lighting and other four indicators are blinking.
When the projector detects an abnormal condition, it will be
automatically shut down to protect the inside of the projector
and all five indicators on the top panel blink. In this case, unplug the AC power cord and plug it, and then turn on the projector once again to verify operation. If the projector cannot
be turned on and these indicators are still blinking, unplug
the AC power cord.
CAUTION
DO NOT LEAVE THE PROJECTOR WITH THE
AC POWER CORD CONNECTED UNDER AN ABNORMAL CONDITION. IT MAY RESULT IN FIRE
OR ELECTRIC SHOCK.
LED indicators
LAMP indicator lights on
and other four indicators
blink
-8-
Maintenance
Replacing the Filter Cartridge
Filter prevents dust from accumulating on the optical elements inside the projector. Should the filter becomes clogged
with dust particles, it will reduce cooling fans’ effectiveness and may result in internal heat buildup and adversely
affect the life of the projector. This projector has an electrically operated filter which helps you to replace the filter
easily. The projector monitors the condition of the filter at all time and replaces a filter with a new one automatically
when it detects the clogging.
If the projector detects that the filter is clogged and no scroll is left in the filter cartridge, a Filter cartridge replacement
icon appears on the screen and the WARNING FILTER indicator on the top panel lights up. When you see this icon,
replace the filter cartridge and reset the Filter counter and the Scroll counter.
Filter cover
Turn off the projector, and unplug the AC power cord
1
from the AC outlet.
First, clean up the dust on the projector and around the
2
air vents.
Press d on the filter cover to release the latch and open
3
the filter cover.
Pull out the filter cartridge. When taking out the filter
4
cartridge, put your finger on the filter cartridge’s tab and
then pull.
Put the new one back into the position and close the
5
filter cover. Make sure that the filter cartridge is properly
and fully inserted.
Connect the AC power cord to the projector and turn
6
on the projector.
Reset the filter counter and the scroll counter.
7
CAUTION
Do not operate the projector with the filter removed.
Dust may accumulate on the optical elements degrading the picture quality.
Do not put anything into the air vents. Doing so may
result in malfunction of the projector.
RECOMMENDATION
We recommend avoiding dusty/smoky environments
when operating the projector. Usage in these environments may cause a poor image quality.
Latch
When using the projector under dusty or smoky conditions,
dust may accumulate on a lens, liquid crystal panels, or optical elements inside the projector. Such condition may degrade the quality of the projected image.
When the symptoms above are noticed, contact your authorized dealer or service station for proper cleaning.
ORDER REPLACEMENT FILTER CARTRIDGE
Service Parts No.: 610 334 3747
-9-
Tab
Filter cartridge
Resetting the Filter Counter
Be sure to reset the Filter counter after replacing the filter and
the filter cartridge.
Press the MENU button to display the On-Screen Menu.
1
Use the Point 7 8 buttons to move the red frame point-
er to the Setting Menu icon.
Use the Point ed buttons to move the red frame point-
2
er to Filter counter and then press the SELECT button.
A dialog box appears showing the Used time option and
the Scrolls remaining option. Use the Point ed buttons
to select Used time.
Used time shows the total accumulated time of the filter
3
use, a timer setting option, and the Reset option. Select
Reset and the “Filter counter Reset?” appears. Select
[Yes] to continue.
Another confirmation dialog box appears, select [Yes]
4
to reset the Filter counter.
Filter counter
Select “Used time” and the dialogue box below appears.
Select Reset and the “Filter
counter Reset?” appears.
Select [Yes],
then another
confirmation
box appears.
Resetting the Scroll Counter
Be sure to reset the Scroll counter after replacing the filter
cartridge.
Press the MENU button to display the On-Screen Menu.
1
Use the Point 7 8 buttons to move the red frame pointer to the Setting Menu icon.
Use the Point ed buttons to move the red frame point-
2
er to Filter counter and then press the SELECT button.
A dialog box appears showing the Used time option and
the Scrolls remaining option. Use the Point ed buttons
to select Scroll(s) remaining.
Scroll(s) remaining shows the number of the remain-
3
ing scrolls and the Reset option. Select Reset and the
“Scroll counter Reset?” appears. Select [Yes] to continue.
Another confirmation dialog box appears, select [Yes]
4
to reset the Scroll counter.
Select [Yes] again to reset
the Filter counter.
Scroll counter
Select “Scrolls remaining” and
the dialogue box below appears.
Select Reset and the “Scroll
counter Reset?” appears.
Select [Yes],
then another
confirmation
box appears.
-10-
Select [Yes] again to reset
the Scroll counter.
Maintenance
Lamp Replacement
When the projection lamp of the projector reaches its end of life, the Lamp replacement icon appears on the screen
and LAMP REPLACE indicator lights orange. Replace the lamp with a new one promptly. The timing when the LAMP
REPLACE indicator should light is depending on the lamp mode.
Top Panel
Lamp replacement icon
LAMP REPLACE indicator
Follow these steps to replace the lamp.
Turn off the projector and unplug the AC power cord.
1
Let the projector to cool for at least 45 minutes.
Open the filter cover.
2
Filter cover
Lamp cover
Screw
Loosen the screw and open the lamp cover and pull
3
out the lamp by using the built in handle.
Replace the lamp with a new one. Make sure that
4
the lamp is properly and fully inserted.
Close the lamp cover and secure the screw, and
5
close the filter cover.
Connect the AC power cord to the projector and turn on
6
the projector.
Reset the Lamp replacement counter
7
Note:
• Be sure to insert the lamp in the correct direction.
• Do not reset the Lamp replacement counter when the pro
jection lamp is not replaced.
CAUTION
Allow a projector to cool for at least 45 minutes
before you open the lamp cover. The inside of the
projector can become very hot.
Lamp
-
Handle
CAUTION
For continued safety, replace with a lamp of the
same type. Do not drop the lamp or touch the glass
bulb! The glass can shatter and may cause injury.
ORDER REPLACEMENT LAMP
Type No. POA-LMP108
Service Parts No. 610 334 2788
-11-
Counter
Projector 500 H
Lamp
Normal 200 H
Eco 300 H
Corresponding value 600 H
Maintenance
Resetting the Lamp Counter
Be sure to reset the Lamp counter after the lamp is replaced. When the Lamp counter is reset, the LAMP REPLACE indicator stops lighting and the Lamp replacement icon disappears.
Press the MENU button to display the On-Screen Menu.
1
Use the Point 7 8 buttons to move the red frame pointer
to the Setting Menu icon
Use the Point ed buttons to move the red frame pointer
2
to Lamp counter and then press the SELECT button. A
dialog box appears showing the total accumulated time
of the lamp usage and the reset option. Select Reset
and the “Lamp replacement counter Reset?” appears.
Select [Yes] to continue.
Another confirmation dialog box appears and select
3
[Yes] to reset the Lamp replacement counter.
Note:
• Do not reset the Lamp counter without replacing the lamp. Be
sure to reset the Lamp replacement counter only after replacing
the lamp.
How to check Lamp Used Time
Lamp counter
Select Reset and the “Lamp
replacement counter Reset?”
appears.
Select [Yes], then another
confirmation box appears.
Select [Yes] again
to reset the lamp
counter.
The LAMP REPLACE indicator will light yellow when the total lamp used time (Corresponding value) reaches 3,000
hours. This is to indicate that lamp replacement is required.
The total lamp used time is calculated by using the below expression,
Total lamp used time (Corresponding value) = Teco + (Tnormal x 1.5)
Teco: used time in the Eco mode
Tnormal : used time in the Normal mode
You can check the lamp used time following to the below procedure.
1 Press and hold the ON/STAND-BY button on the projector for more than 20 seconds.
2 The projector used time and lamp used time will be displayed on the screen briefly as follows.
Projector used time
Lamp mode
Total lamp used time
-12-
Maintenance
Cleaning
After long periods of use, dust and other particles will accumulate on the LCD panel, prism, mirror, polarized glass,
lens, etc., causing the picture to darken or color to blur. If this occurs, clean the inside of optical unit.
Remove dust and other particles using air spray. If dirt cannot be removed by air spray, disassemble and clean the
optical unit.
Cleaning with air spray
1. Remove the cabinet top following to “Mechanical Disassembly”.
2. Clean up the LCD panel and polarizing plate by using
the air spray from the cabinet top opening.
Caution:
Use a commercial (inert gas) air spray designed for
cleaning camera and computer equipment. Use a resinbased nozzle only. Be vary careful not to damage optical
parts with the nozzle tip. Never use any kind of cleanser
on the unit. Also, never use abrasive materials on the
unit as this may cause irreparable damage.
Disassembly Cleaning
Disassembly cleaning method should only be performed
when the unit is considerable dirty and cannot be sufficiently cleaned by air spraying alone.
Be sure to readjust the optical system after performing disassembly cleaning.
1. Remove the cabinet top and main units following to
“Mechanical Disassembly”.
2. Remove the optical base top following to “Optical
Unit Disassembly”. If the LCD panel needs cleaning,
remove the LCD panel unit following to “LCD panel
replacement”.
3. Clean the optical parts with a soft cloth. Clean extremely dirty areas using a cloth moistened with alcohol.
Caution:
The surface of the optical components consists of multiple dielectric layers with varying degrees of refraction.
Never use organic solvents (thinner, etc.) or any kind of
cleanser on these components.
Since the LCD panel is equipped with an electronic circuit, never use any liquids (water, etc.) to clean the unit.
Use of liquid may cause the unit to malfunction.
-13-
Maintenance
Quick maintenance
This projector provides a cabinet front cover on the cabinet top to enhance the service maintenance. This enables
service personnel to align the optical adjustment or replace the optical parts without disassembly the cabinet top.
1. Press and hold the release button the cabinet front cover and slide the cover frontward to take it off.
2. Remove 2 screws A on the prism shield cover and take prism shield cover off.
3. Loosen 4 screws B and take the LCD Panel/Prism ass'y upward off.
4. Remove 1 screw C on each stopper of the optical filter ass'y and take the optical filter ass'y upward off.
See chapter "Optical Parts Disassembly" for further information of optical parts disassembly.
Release button
A
Prism shield cover
A
Green
-14-
B
B
C
Security Function Notice
This projector provides security functions such as "Key lock", "PIN code lock" and "Logo PIN code lock". When the
projector has set these security function on, you are required to enter correct PIN code to use the projector. If you
do not know the correct PIN code to the projector, the projector can no longer be operated or started. In this case,
you must reset those function first according to the resetting procedure described below and then check up on the
projector.
Function Description
Locks operation of the side control or the remote control.
Key lock
PIN code lock
Logo PIN code lock
If the Key lock is enabled with side control lock, the
projector can no longer be started.
Initial setting: Key lock function is disabled
Prevents the projector from being operated by an unauthorized person.
Initial code: “1234”
Prevents an unauthorized person for changing the
start-up logo on the screen.
Initial code: “4321”
Resetting procedure
1 Disconnect the AC power cord from the AC outlet.
2 As pressing the SELECT button on the projector, connect the AC power cord into an AC outlet again. Keep
pressing the SELECT button until the POWER indicator lights continuously.
This is complete the resetting of the security function. The PIN code lock and Logo PIN code lock are reset
as the initial PIN code at the factory and the Key lock function is disabled.
Please refer to the owner's manual for further information of the security functions.
-15-
Mechanical Disassembly
Mechanical disassembly flow chart
Mechanical disassembly should be made by following procedures chart.
Following steps show the basic procedures, therefore unnecessary step may
be ignored.
Caution:
The parts and screws should be placed exactly the same position as the original otherwise it may cause loss of performance and product safety.
The wiring method of the leads and ferrite cores should be returned exactly the
same state as the original, otherwise it may cause lose of performance and
product safety.
Screws Expression
(Type Diameter x Length) mm
T type M Type
1 Cabinet front cover removal
2 Cabinet top removal
3 Control ass'y and filter cover removal
4 Main board removal
5 Cabinet back & lamp cover removal
6 Power box removal
1-1 Cabinet front disassembly
2-1 LED board removal
3-1 Control board fan (FN907) disassembly
5-1 AV board removal
5-2 Fans (FN904, FN905, FN906) removal
6-1 Power box disassembly
7 Optical unit removal
8 Cabinet front & ballast box removal
9 Filter box removal
10 Fan (FN902, FN903) & duct removal
7-1 Lens shift motor ass'y removal
8-1 Ballast box disassembly
9-1 Filter box and fan (FN901) disassembly-
9-2 Filter box disassembly-2
-16-
1
Mechanical Disassembly
Mechanical disassembly
1 Cabinet front cover removal
1 Press the release button and slide the lamp cover to
the arrow direction and remove it.
Release Button
1-1 Cabinet front cover disassembly
1 Remove 2 screws A(T3x8) and take the release button,
button holder and spring off.
A
Fig. 1-1
Release button
Spring
Button holder
A
-17-
Mechanical Disassembly
2 Cabinet top removal
1 Open the filter cover and remove 1 screw A (M3x8).
2 Remove 1 screw B (M3x8) and open the lamp cover
and remove 1 screw C (M3x8).
3 Remove 4 screws D (M3x8) on the cabinet top and 2
screws E (M3x8) on the cabinet back.
4 Release the hooks by pressing the side part of cabinet
bottom indicated with the arrows and take the cabinet
top off.
Cabinet top
D
D
D
D
Press here to unhook
LED board
F
F
E
E
B
C
A
2-1 LED board removal
1 Remove 2 screws F (M3x8) and take the LED board
and LED holder off.
Fig. 1-2
-18-
Mechanical Disassembly
3 Control board ass’y and covers removal
1 Remove 2 screws A (T3x8) and take the control board &
fan ass’y upward off.
2 Open the filter cover and take the filter cartridge off.
3 Remove the filter cover off by using a flat screw driver as
shown in the figure.
A
A
Control board &
fan(FN907) ass'y
Filter cartridge
Flat screwdriver
Turn the flat screwdriver in the arrow
direction to unhook the filter cover's
hinges.
Note: Be careful not to scratch the filter
cover and holder.
Filter cover
-19-
Mechanical Disassembly
3-1 Control board and fan (FN907) disassembly
1 Remove 2 screws B (M3x6) and take the control board/
button holder off
2 Unhook 4 hooks C on the button holder and take the con-
trol board off.
3 Remove 2 screws D (M3x10) and take fan (FN907) off.
C
Control buttons
C
Control board
4 Main board removal
1 Remove 2 screws A (M3x6) and take the prism shield
cover top off.
2 Remove 6 screws B (M3x6) and take the main shield cover
top off.
3 Remove 1 screw C (M3x6) and take the main board off.
4 Remove 2 screws D (M3x6) and take the main shield cov-
er bottom off.
B
B
FN907
D
B
B
B
B
B
B
A
A
-20-
C
Main
board
D
D
Mechanical Disassembly
5 Cabinet back ass’y removal
1 Remove 3 screws A (T3x8) and 1 screw B (M3x6) and
take the cabinet back ass’y upward off.
A
A
B
A
Lamp cover
5-1 AV board removal
1 Remove 5 screws D (T3x8) and 4 screws E (T3x10-
black) and take the AV board off.
E
D
AV board
5-2 Fans (FN904, FN905, FN906) removal
1 Remove 6 screws F (T3x8) and take the fans (FN904,
FN905, FN906) off.
FN905
FN906
FN904
F
-21-
Mechanical Disassembly
6 Power Box removal
1 Remove the 3 covers A and B on the cabinet.
2 Remove 1 screw C (T3x12) and take thermal switch
(SW905) off
3 Disconnect the socket D (K6B) on the power board.
4 Remove 2 screws E (M4x8) and take the power box
upward off.
E
E
D
C
B
Thermal switch
(SW905)
A
6-1 Power box disassembly
1 Remove 6 screws F (M3x6) and take the power box
cover off.
2 Remove 5 screws G (M3x6), 1 screw H (M4x8), 2
screws J (T3x5) and take the power board off.
J
H
G
Isolation sheet
Power board
G
F
Isolation sheet
Note:
The isolation sheet must be placed
as shown in the figure above.
Isolation sheet
G
F
G
G
F
F
F
-22-
F
Mechanical Disassembly
7 Optical unit removal
1 Remove 7 screws A (T4x12) and 2 screws B (T3x8),
disconnect ballast socket and take the optical unit upward off.
A
A
A
A
A
A
B
B
7-1 Lens shift motor ass’y removal
1 Remove 2 screws B (M3x6) and take the lens shift mo-
tor ass’y off.
2 Remove 1 screw C (T3x6) and take the lens shift sen-
sor board off.
3 Remove 2 screws D (T2x4) and take the lens shift mo-
tor off
Lens shift motor
Lens shift motor
Sensor board
D
C
B
B
B
B
D
Sensor board
C
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Mechanical Disassembly
8 Cabinet front and ballast box removal
1 Remove 4 screws A (T3x8) and take the cabinet front
upward off.
2 Remove 1 screw B (T3x8) and take the RC front board
off.
3 Remove 1 screw C (M4x8) and pull the ballast box
backward and remove it off.
RC front board
A
C
A
B
Ballast box
A
A
8-1 Ballast box disassembly
1 Remove 2 screws D (M3x6) and take the shield case
top off
2 Remove ballast board from the shield case bottom.
Isolation sheet
Ballast board
D
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D
Mechanical Disassembly
9 Filter box removal
1 Remove 1 screws A (T3x8), 2 screws B (T4x40) and take
filter box upward off.
Filter box
B
B
A
9-1 Filter box and fan (FN901) disassembly-1
1 Remove 3 screws C (T4x35), and take fan (FN901) and
holder off.
2 Remove 1 screw D (T3x14) and take the wind sensor
(S901) off.
C
C
C
FN901
D
S901
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Mechanical Disassembly
9-2 Filter box disassembly-2
1 Remove 2 screws E (T3x8) and take the filter cover off.
2 Take the filter cover latch off by pulling it.
3 Remove 3 screws F (T3x8) and take the filter bottom cover
off.
4 Take the filter switch board off, and remove 1 screw G and
take the filter round sensor board off.
5 Remove 2 screws H (T4x8) and filter motor off.
E
E
Filter shaft
holder
Filter round
sensor board
Filter bottom
cover
G
H
Latch
H
Filter switch
board
Filter motor
F
F
F
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Mechanical Disassembly
10 Fans (FN902, FN903) and duct removal
1 Remove fan (FN902) upward off.
2 Remove 2 screws A (T3x8) and take duct (prism) up-
ward off.
3 Remove 3 screws B (3x8) and take duct (PBS) upward
off.
4 Remove lamp cover switch board upward off.
5 Remove fan (FN903) upward off.
A
A
B
B
Lamp cover
switch board
FN902
FN903
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Optical Parts Disassembly
Disassembly requires a 2.0mm or 2.5mm hex wrench and a slot screwdriver.
1 Projection lens removal
1 Shift the Projection lens to the low end by the lens shift
function.
2. Press and hold the release button on the cabinet front
cover and slide it in the arrow direction as shown in the
figure and open it.
3 Slide the lens lock lever A on the projector to “UN-
LOCK” (UPPER) position and remove the Projection
Lens ass’y off.
Note : When making unlocking, attach your hand to pre-
vent the lens fall.
Release button
Lever A
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Optical Parts Disassembly
2-1 LCD panel/Prism ass'y removal
Prism shield cover
1 Remove 2 screws A (M3x6) and take the prism shield
cover off.
2 Remove 4 screws B (M2.5 x6) and take the LCD panel/
prism assembly upward off.
B
B
LCD panel/prism
B
B
assembly
A
A
B
B
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Optical Parts Disassembly
2-2 Polarized glasses-out removal
1 Remove 1 screw C (M2.5x6) on each stopper and take
the polarized glasses upward off.
C
Pre-Polarized glass (B)
Polarized glass-out (B)
(Blue)
C
(Green)
Pre-Polarized glass (G)
Polarized glass-out (G)
C
Pre-Polarized glass (R)
Polarized glass-out (R)
* Mount the glasses as the film
attached side comes to the LCD
panel side.
(Red)
Note; Do not replace the LCD panel separately otherwise it cannot obtain
proper picture. Do not touch the prism, the LCD panel and electrode
of flexible cable.
IMPORTANT NOTICE on LCD Panel/Prism Ass'y Replacement
LCD panels used for this model cannot be replaced separately. Do not disassemble the LCD Panel/Prism Ass’y.
These LCD panels are installed with precision at the factory. When replacing the LCD panel, should be replaced
whole of the LCD panels and prism ass’y at once.
When replacing LCD Panel/Prism ass’y, take the optical and electrical adjustments following to the chapter "Adjustment".
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