Sanyo PLV-Z2000 Schematic

FILE NO.

SERVICE MANUAL

Original Version

Multimedia Projector

MODEL NO. PLV-Z2000

U.S.A., Canada, Europe,

U.K. Asia, Africa

Chassis No. MD4-Z200000

NOTE: Match the Chassis No. on the rating

sheet on the cabinet with the Chassis

No. in the Service Manual.

PRODUCT CODE :

PLV-Z2000 MD4A 1 122 400 00 U.S.A., Canada PLV-Z2000 PD4A 1 122 401 00 Europe, Asia, Africa PLV-Z2000 PD4C 1 122 401 02 U.K.

If the Or iginal Version Se r v i ce

Ma n ua l Ch as s is No. do es no t

match the unites, additional Service

Literature is required. You must refer

to “Notices” to the Original Service

Manual prior to servicing the unit.

REFERENCE NO. SM5110894-00

■ Contents

■ Safety Instructions ......................................................................................................................................3

■ Specifications ................................................................................................................................................4

■ Circuit Protections .......................................................................................................................................5

■ Maintenance and Cleaning......................................................................................................................7

■ Lamp Replacement.................................................................................................................................. 13

■ Mechanical disassemblies ..................................................................................................................... 16

■ Optical parts disassemblies .................................................................................................................. 33

● Optical parts location and direction ..................................................................................... 42

■ Adjustments After Parts Replacement ............................................................................................. 46

■ Optical Adjustment ................................................................................................................................. 47

■ Electrical Adjustment .............................................................................................................................. 55

● Service Adjustment Menu Operation ................................................................................... 55

● Circuit Adjustment ...................................................................................................................... 56

● Service Adjustment Data Table ............................................................................................... 59

● Location of Test Points ............................................................................................................... 71

■ Chassis Block Diagram ............................................................................................................................ 72

■ Power Supply Lines .................................................................................................................................80

■ Troubleshooting ....................................................................................................................................... 82

● Flow chart of projector condition .......................................................................................... 82

● No Power .........................................................................................................................................83

● No Picture ....................................................................................................................................... 85

■ Control Port Functions ........................................................................................................................... 87

■ Service Parts List ....................................................................................................................................... 89

● Electrical Parts List ..................................................................................................................... 89

● Mechanical and Optical Parts List ......................................................................................111

Drawings & Diagrams .................................................................................................................... A1-A14

■ Parts description and reading in schematic diagram ................................................................ A2

■ Schematic diagrams ........................................................................................................................ A3-A8

■ Printed wiring board diagrams ................................................................................................ A9-A12

■ Pins description of ICs, transistors, diodes .................................................................................. A13

■ Note on soldering ................................................................................................................................ A14

- 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.

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.

2: Comply with all caution and safety-related notes pro-

vided 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, adjustment covers or shields, barriers, etc.

DO NOT OPERATE THIS PROJECTOR WITHOUT THE PROTE CTIVE SHIELD IN POSITION AND PROPERLY SECURED.

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 spe-

cial 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 gener-

ates high voltages(15kV - 20kV) 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

Technical Specifications

Projector Type Dimensions (W x H x D) Net Weight LCD Panel System Panel Resolution Number of Pixels Color System High Definition TV Signal Scanning Frequency

Projection Image size (Diagonal)

Projection Lens Throw Distance Projection Lamp Video Input Jacks Computer Input Terminal HDMI Input Terminals Service Port Connector Feet Adjustment Voltage and

Power Consumption Operating Temperature Storage Temperature

Remote Control

Multimedia Projector

15.75” x 5.75” x 13.62” (400 mm x 146 mm x 346 mm)

16.1 lbs (7.3 kg

0.74” wide TFT Active Matrix type, 3 panels

1920 x 1080 dots

6,220,800 (1920 x 1080 x 3 panels)

PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N

480i, 480p, 575i, 575p, 720p, 1080i, and 1080p

H-sync. 15 kHz – 80 kHz, V-sync. 50 Hz – 100 Hz

Adjustable from 40” to 300”

F 2.0 – 3.05 lens with f 22.6 – 45.3 mm with manual zoom and focus

3.9’ – 60.4’ (1.2 m – 18.4 m)

165 W

RCA Type x 1 (Video), RCA Type x 3 (Y, Pb/Cb, Pr/Cr) x 2 and Mini DIN 4 pin x 1 (S-video)

mini D-sub 15 pin x 1

HDMI terminal 19 pin x 2

Mini DIN 8 pin x 1

0˚ to 6.5˚

AC 100 – 120 V (2.9 A Max. Ampere), 50/60 Hz AC 200 – 240 V (1.5 A Max. Ampere), 50/60 Hz

41˚F – 95˚F (5˚C – 35˚C)

14˚F – 140˚F (-10˚C – 60˚C)

Power Source : AA or LR6 1.5 V ALKALINE Type x 2 Operating Range : 16.4’ (5 m)/±30˚ Dimensions : 2.13” x 1.04” x 6.81” (54 mm x 26.3 mm x 173mm) Net Weight : 3.4 oz (95.5 g) (not including batteries)

)

(not including raised portions)

(The U.S.A. and Canada) (Continental Europe and The U.K.)

Owner’s Manual (CD-ROM) Quick Reference Guide

Accessories

● 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.

The CE Mark is a Directive conformity mark of the European Community (EC).

Pixelworks ICs used.

AC Power Cord Remote Control and Batteries Air Blower

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(F601) 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;

Fuse Part No. : 323 024 3206

TYPE T5.0AH 250V FUSE

LITTEL FUSE INC. TYPE 215005

How to replace the fuse

1. Remove the cabinet top following to "Mechanical

Disassemblies".

2. Remove the fuse from fuse holder on the Filter Board.

To install the fuse, take reversed step in the above.

● Thermal switch

There is the thermal switch (SW902) inside of the projector to prevent the internal temperature rising abnormally. When the internal temperature reaches near 100°C, the thermal switch cuts off the drive signal to the lamp circuit automatically. The thermal switch is not reset to normal automatically, even if the internal temperature becomes normal. Reset the thermal switch following procedure. Check the resistance between terminals of thermal switch by using a tester. If it has high impedance, thermal switch may be open.

Fuse (F601)

Thermal switch (SW902)

How to reset the thermal switch

1. Re m ove the Lam p cov er following to "M echanical

Disassemblies".

2. Press the reset button on the thermal switch with a sharp-pointed tool.

CAUTION:

Before press the reset button, make sure that the AC cord must be disconnected from the AC outlet.

- 5 -

Press

The switch(SW902) is in the hole of cabinet.

- 5 -

Circuit Protection

● Lamp cover switch

The lamp cover switch (SW8803) cuts off the drive signal to the lamp circuit when the lamp cover is removed or not closed completely. After opening the lamp cover for replacing the lamp unit, place the lamp cover correctly otherwise the projector can not turn on.

● Door switches for automatic slide shutter

The projector provides 2 door switches against an accident of the automatic slide shutter. The door swi tch-A(SW8801) turn s ON w hen the sli de shutter is opened. The door switch-B( SW8811 ) turns ON when the slide shutter is closed. If the slide shutter stops half-open after turning on, the POWER indicator will blink orange and the projector goes to stand-by mode after cooling. In this case, press the POWER ON/STAND-BY button again. If the slide shutter is closed during operation, the projector is automatically turned off for safety. In this case, be sure to check the position of the slide shutter. Af t e r ope n i n g or clos i n g th e slid e shut te r manually, press the POWER ON/STAND-BY button and the projector turns on.

Lamp cover switch

Door switch-A

Slide shutter

Door switch-B

● Warning temperature and power failure protection

The projector will be automatically turned off when the internal temperature of the projector is abnormally high, or the cooling fans stop spinning, or the power supplies in the projector are failed.

- If the WARNING indicator is flashing, it may detect the abnormal temperature inside the projector. Check the following possible causes and wait until the WARNING indicator stops flashing, and then try to turn on the projector.

- If the WARNING indicator lights red, it may defect the cooling fans or power supply circuits. Check fans operation and power supply lines referring to the chapter “Power supply & protection circuit” in the power Supply Lines section.

Possible causes

- Air filters are clogged with dust particles. Remove dust from the air filters.

- Ventilation slots of the projector are blocked. In such an event, reposition the projector so that ventilation slots are not obstructed.

- Check if projector is used at higher temperature place (Normal operating temperature is 5 to 35˚C or 41 to 95˚F)

- 6 -

■ Maintenance and 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 Disassemblies".

2. Clean up the LCD panel and polarized glass by using the air spray from the cabinet top opening.

Caution:

Use only the supplied air blower and nozzle to keep the projector from being out of oder or damaged. We could not guarantee

the malfunction or breakage caused by other tools.

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 Disassemblies".

2. Remove the optical base top following to"Optical Unit Disassemblies". If the LCD panel needs cleaning, remove the LCD

panel unit following to "LCD panel/Prism ass'y 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.

- 7 -

Maintenance and Cleaning

Cleaning the RGB panels

Blemishes such as dust and dirt on the internal optical components of the projector tend to degrade the brightness of

the screen and are likely to appear as a shadow on the screen, which can lead to deterioration of image quality.

This projector is equipped with the RGB panel cleaning holes on the bottom for cleaning of the internal parts (such

as optical components) of the projector. When you use the projector for a lengthy period of time or a shadow of dust

appears on the projected screen, clean the inside of the projector.

Using the supplied air blower and with the Cleaning function in the Setting Menu, you can remove the dusts from the

projector.

✔Note:

• Dust might not be removed completely with these steps. In that case, contact the dealer where you purchased the

projector or service center.

CAUTION IN USING THE AIR BLOWER AND THE NOZZLE

● Turn the projector over when using the blower.

● Use only the supplied air blower and nozzle to keep the projector from being out of oder or damaged. We

CAUTION

● Never use a commercially available compressed air duster. It causes the interior of the projector to

● Put the projector on a soft cloth to prevent scratching the surface.

PROHIBITED

● Open the hole cover only when you clean the inside of the projector.

● Do not look into the holes. A strong light could damage your eyes. (Do not look into the Air intake vent and

● Use the blower and nozzle only to clean the projector. Do not attempt to use them for other purposes. Do

● Do not attempt to pull the nozzle out of the blower. If the nozzle happened to be pulled out, put it back

●

In the unlikely event that something goes wrong (smoke, a strange sound, an abnormal odor, and such) while you are

cleaning, turn off and unplug the projector immediately, then call the dealer where you purchased the projector or service center.

could not guarantee the malfunction or breakage caused by other tools.

malfunction with release of cold liquid propellant.

Exhaust vent, either.)

not use the blower and nozzle against persons (particularly to eyes, mouth or ear, and so on). Be especially careful to ensure that children do not put the blower and nozzle into their mouth and swallow them.

into the blower immediately. Do not use the blower supplied with this projector (model: Z2000) to clean the other models: Z4, Z3, and Z1X.

If the nozzle is pulled out ....

The nozzle has the stopper. Put the stopper-side of the nozzle into the blower. Put the nozzle firmly into the blower until the stopper becomes invisible. When putting the nozzle into the blower, hold near the stopper so that it will not break. Make sure not to attempt to pull the nozzle out of the blower.

- 8 -

Put this end of the n oz z le i n to t h e blower.

Pu t t he noz zle in un til th e sto pper becomes invisible.

Stopper

Hold near the stopper of the nozzle.

Clean by using the Cleaning function in the Setting Menu

Turn the projector on and press the MENU button to display the

On-Screen Menu. Select the Setting Menu with the Point ed buttons. Press the Point 8 or OK buttons to access the submenu items.

Select Cleaning and then press the OK or Point 8 buttons. The

screen is blacked out temporarily.

Turn the projector over. Put your finger on hole over's tab and

pull to open the hole cover.

Maintenance and Cleaning

Cleaning

Put the blower’s nozzle into a hole.

Blow air into the projector with the blower watching the position

of the dust from the screen.

When cleaning is done, pull the blower out of the hole and

replace the hole cover.

Set the projector back into the right position, then press any

button on the top control or on remote control to quit the Cleaning function.

* Do not open the hole cover except when you clean the inside of the

projector to prevent foreign matters from getting into the projector. If it is open especially while operating the projector, the optical parts could damage.

Which hole to put the nozzle in?

When you look at the screen:

● When a red spot (dust) is showed up, put the nozzle into the R panel cleaning holes.

● When a green spot (dust) is showed up, put the nozzle into the G panel cleaning holes.

● When a blue spot (dust) is showed up, put the nozzle into the

B panel cleaning holes.

Select Cleaning in the Setting Menu.

Tab Put your finger on the hole cover’s tab and pull.

Hole cover

The nozzle will go no further than a certain point when it is put into the hole. Do not attempt to push the nozzle further in, or it could break and be stuck inside of the projector.

Wave the nozzle back and forth inside of the projector. (Do not attempt to bend the nozzle.)

malfunction with release of cold liquid propellant. We could not guarantee the malfunction of breakage by using other tools.

Use only the supplied blower and nozzle. Do not use a commercially available compressed air duster. It causes the interior of the projector to

Blue

LCD Panel

Red

LCD Panel

Green

BOTTOM VIEW

- 9 -

Maintenance and Cleaning

Warning Indicator

The WARNING indicator shows the state of the function that protects the projector. Check the state of the WARNING indicator and the POWER indicator to take proper maintenance.

The projector is shut down and the WARNING indicator is blinking red.

When the temperature inside the projector reaches a certain level, the projector is automatically shut down to protect its inside. The POWER indicator is blinking while the projector is being cooled down. When the projector has cooled down sufficiently (to its normal operating temperature), it can be turned on again by pressing the POWER ON/ STAND-BY button.

✔Note:

• The WARNING indicator continues to blink even after the temperature inside the projector returns to normal. When the projector is turned on again, the WARNING indicator stops blinking.

Then check the items below.

– Did you provide appropriate space for the projector to be ventilated?

Check the installing condition to see if ventilation slots are not blocked.

– Has the projector been installed near an Air-Conditioning/Heating

Duct or Vent? Move the installation of the projector away from the duct or vent.

– Is the air filter clean? Clean the air filter periodically or replace it with a

new one.

TOP CONTROL

WARNING

blinking red

The projector is shut down and the WARNING indicator lights red.

When the projector detects an abnormal condition, it is automatically shut down to protect the inside of the projector and the WARNING indicator lights red. 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 the WARNING indicator lights red, unplug the AC power cord and contact the service station.

CAUTION

DO NOT LEAVE PROJECTOR WITH AC POWER CORD CONNECTED UNDER AN ABNORMAL CONDITION. IT MAY RESULT IN FIRE OR ELECTRIC SHOCK.

TOP CONTROL

WARNING

lights light

- 10 -

Maintenance and Cleaning

Cleaning the Air Filters

The air filters prevent dust from accumulating on the surface of the optical elements inside the projector. Should the air

filters become clogged with dust particles, it will reduce cooling fans’ effectiveness and may result in a buildup of internal

heat and adversely affect the life of the projector. Clean the air filters by following the steps below.

Press the latch and release it. Take off the filter cover.

Pull out the air filter.

When taking out the air filter, put your fingers on the air filter’s tabs and pull. Do not try to pull the delicate filter part.

Remove dust and dirt with a soft brush or a vacuum cleaner. Be

careful not to damage the air filter and do not clean it with water. When the air filter gets dusty and dirty, replace it with a new one. For ordering the replacement filter, contact your sales dealer.

Put the air filter back into the position. Do not push the delicate

filter part. Make sure that the air filter is properly and fully inserted.

Latch

Press the latch and take off the filter covers.

Filter cover

Close the filter cover.

Reset the filter counter .

RECOMMENDATION

We recommend avoiding dusty/smoky environments when operating the projector. Usage in these environment may cause a poor image quality.

When using the projector under dusty or smoky conditions, dust may accumulate on a lens, LCD panels, or optical elements inside the projector degrading the quality of a projected image.

When the symptoms above are noticed, contact your authorized dealer or service station for proper cleaning.

CAUTION

Do not operate the projector with the air filters removed. Dust

may accumulate on the LCD panel degrading the picture

quality of the projection mirror. Do not put anything into the air

intake vents. It may result in malfunction of the projector.

Tab

Air filter

When putting back the air filter, make sure that the arrows on the filter are facing towards the projector.

Arrows

Push here when you are putting back the air filter.

Groove

- 11 -

Maintenance and Cleaning

Resetting the Filter Counter

Be sure to reset the Filter counter after cleaning or replacing the air filter.

Turn the projector on and press the MENU button to display the

On-Screen Menu. Select the Setting Menu with the Point ed buttons. Press the Point 8 or OK buttons to access the submenu items.

Select Filter counter and then use the Point 8 button to select

[Reset] and press the OK button. “Filter counter reset?” appears. Select [Yes] and then press the OK button.

Another confirmation dialog box appears, and select [Yes] to

reset the Filter counter.

✔Note:

• Do not reset the Filter counter without cleaning or replacing the air filter. Be sure to reset the Filter counter only after cleaning or replacing the air filter.

Filter counter

Select Filter counter and use the Point 8 button to select [Reset] and press the OK button. “Filter counter reset?” appears.

Select [Yes] and press the OK button, then another confirmation box appears.

Select [Yes] again to reset the lamp counter.

Cleaning the Projection Lens

Unplug the AC power cord before cleaning.

Gently wipe the projection lens with a cleaning cloth that contains a small amount of non-abrasive camera lens cleaner, or use a lens cleaning paper or a commercially available air blower to clean the lens. Avoid using an excessive amount of cleaner. Abrasive cleaners, solvents, or other harsh chemicals might scratch the surface of the lens.

When the projector is not in use, make sure that the automatic slide shutter is closed.

Cleaning the Projector Cabinet

Unplug the AC power cord before cleaning.

Gently wipe the projector body with a dry soft cloth. When the cabinet is heavily soiled, apply a small amount of mild detergent and finish with a dry soft cloth. Avoid using an excessive amount of cleaner. Abrasive cleaners, solvents, or other harsh chemicals might scratch the surface of the cabinet.

When the projector is not in use, put it in an appropriate carrying case to protect it from dust and scratches.

- 12 -

■ Lamp Replacement

When the projection lamp of this projector reaches its end of life, the LAMP REPLACE indicator emits yellow light. If this indicator lights yellow, replace the lamp with a new one promptly. The time when the LAMP REPLACE indicator should light is depending on the lamp mode.

This indicator lights yellow when the projection lamp reaches its end of life.

Top Control

CAUTION

Allow the projector to cool, for at least 45 minutes before you open the lamp cover. The inside of the projector can become very hot.

Follow these steps to replace the lamp.

Turn off the projector and unplug the AC power cord. Let the

projector cool for at least 45 minutes.

Loosen the screw that secures the lamp cover, and then open the

lamp cover.

Loosen the two (2) screws that secure the lamp. Pull out the lamp

by using the built in handle.

Replace the lamp with a new one and secure it with the two (2)

screws. Make sure that the lamp is set properly. Put the lamp cover back and secure it with the screw.

Connect the AC power cord to the projector and turn on the

projector.

Reset the Lamp replacement counter.

CAUTION

For continued safety, replace the lamp with the same type lamp. Do not drop the lamp or touch the glass bulb! The glass can shatter and may cause injury.

Screw

Lamp Cover

Handle

Lamp

Screws

ORDER REPLACEMENT LAMP

Replacement lamp can be ordered through your dealer. When ordering a projection lamp, give the following information to the

dealer.

● Model No. of your projector: PLV-Z2000

● Replacement Lamp Type No.: POA-LMP114

(Service Parts No. 610 336 5404)

- 13 -

Lamp Replacement

Lamp Replacement Counter

Be sure to reset the lamp replacement counter after the lamp is replaced. When the lamp replacement counter is reset, the LAMP REPLACE indicator stops lighting.

Lamp counter reset

Turn the projector on and press the MENU button to display the

On-Screen Menu. Select the Setting Menu with the Point ed buttons. Press the Point 8 or OK buttons to access the submenu items.

Select Lamp counter reset and then press the OK or Point 8

buttons. “Lamp replacement counter reset?” appears. Select [Yes] and then press the OK button.

Another confirmation dialog box appears, and select [Yes] to

reset the Lamp replacement counter.

✔Note:

• Do not reset the Lamp replacement counter without implementing lamp replacement. Be sure to reset the Lamp replacement counter only after replacing the lamp.

Select Lamp counter reset and press the OK or Point 8 buttons. “Lamp replacement counter reset?” appears.

Select [Yes] and press the OK button, then another confirmation box appears.

Select [Yes] again to reset the lamp counter.

LAMP HANDLING PRECAUTIONS

This projector uses a high-pressure lamp which must be handled carefully and properly. Improper handling may result in accidents, injury, or create a fire hazard.

● Lamp lifetime may differ from lamp to lamp and according to the environment of use. There is no guarantee of the same lifetime for each lamp. Some lamps may fail or terminate their lifetime in a shorter period of time than other similar lamps.

● If the projector indicates that the lamp should be replaced, i.e., if the LAMP REPLACE indicator lights up, replace the lamp with a new one IMMEDIATELY after the projector has cooled down.

(Follow carefully the instructions in the Lamp Replacement section of this manual.) Continuous use of the lamp with the

LAMP REPLACE indicator lighted may increase the risk of lamp explosion.

● A Lamp may explode as a result of vibration, shock or degradation as a result of hours of use as its lifetime draws to an end. Risk of explosion may differ according to the environment or conditions in which the projector and lamp are being used.

IF A LAMP EXPLODES, THE FOLLOWING SAFETY PRECAUTIONS SHOULD BE TAKEN.

If a lamp explodes, disconnect the projector’s AC plug from the AC outlet immediately. Contact an authorized service station for a checkup of the unit and replacement of the lamp. Additionally, check carefully to ensure that there are no broken shards or pieces of glass around the projector or coming out from the cooling air circulation holes. Any broken shards found should be cleaned up carefully. No one should check the inside of the projector except those who are authorized trained technicians and who are familiar with projector service. Inappropriate attempts to service the unit by anyone, especially those who are not appropriately trained to do so, may result in an accident or injury caused by pieces of broken glass.

- 14 -

How to check lamp used time

Counter Projector 475H Lamp Normal 100H Eco 375H Corresponding value

525H

Lamp Replacement

The LAMP REPLACE indicator will light when the total

lamp used time 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 = Teco + Tnormal x (1.5)

Teco: used time in Eco mode

Tnormal: used time in Normal/Auto1/Auto2 mode

You can check the lamp counter following procedure.

1 Press and hold the POWER ON/STAND-BY button on

the projector or the remote control unit for more than

20 seconds.

2 The projector used time and lamp used time will be dis-

played on the screen briefly.

You can also check "Lamp Time" in the "Information

Menu". This value is actual lamp used time.

"Lamp Time" = Teco + Tnormal

Lamp Counter Display

Information Menu

Projector used time

Total lamp used time

Total lamp used time (actual)

475

- 15 -

■ Mechanical disassemblies

Screws Expression

(Type Diameter x Length ) mm

T type M Type

Tapping screw Machine screw

Disassemble should be made following procedures in numerical order.

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 other-

wise it may cause lose 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.

Cabinet top ass'y removal.

1. Remove the 3 screws-A(M3x10) from the bottom side.

2. Remove the 3 screws-B(M3x8) and remove the Cabinet top ass'y.

3. Remove the 3 screws-C, remove the Button and DEC. LED.

Cabinet top assy

Cabinet top

DEC. LED

Button

- 16 -

Lamp cover ass'y removal.

1. Loosen the screw-A and remove the Lamp cover ass'y.

2. Remove the 2 screws-B(T3X8) and remove the shield plate.

Mechanical disassemblies

Lamp cover ass'y

Shield plate

Lamp cover

- 17 -

Mechanical disassemblies

Filter removal.

1. Remove the Filter cover and Filter.

Filter

Filter cover

AV panel removal.

1. Remove the 2 screws-A(M3x8), remove the screw-B(T3x8) and remove the AV panel.

- 18 -

AV panel

Main PWB shield plata(top) removal.

1. Remove the10 screws-A(M3x6) and remove the Shield plate (Main board-top) .

Mechanical disassemblies

Shield plate (Main board TOP)

Main PWB removal.

1. Remove the 3 screws (M3x6), remove the Main board and remove the Shield plate (Main board-BTM).

Main board

Shield plate (Main board BTM)

- 19 -

Mechanical disassemblies

Cover lens top removal.

1. Remove the Cover lens top upward.

Cover lens top

Cabinet front ass'y removal.

1. Remove the 2 screws (T3x8) and remove the Cabinet front ass'y forward.

Cabinet front ass'y

- 20 -

8-1

Cabinet front ass'y disassembly.

1. Remove the 2 screws-A(T3x8) and remove the Mounting front.

2. Remove the 2 screws-B(T3x8), remove the screw-C(M3x6), and remove the Cover lens bottom.

Mounting front

Mechanical disassemblies

8-2

Cabinet front ass'y disassembly.

1. Unhook and remove the R/C board.

2. Remove the screw-A(T3x8) and remove the Shutter SW-B board.

3. Remove the screw-B(T3x8) and remove the Shutter SW-A board.

R/C board

Cover lens bottom

Shutter SW-B

- 21 -

Shutter SW-A

Mechanical disassemblies

8-3

Cabinet front ass'y disassembly.

1. Remove the 2 screws-A (T3x8) and remove Shutter rail top unit.

2. Remove the 2 screws-B (T3x8) and remove the Shutter motor.

8-4

Cabinet front ass'y disassembly.

1. Remove the 5 screws (T3x8) and remove the Shutter rail bottom.

2. Remove the Shutter panel unit.

Shutter panel unit

Shutter rail bottom

Shutter motor

Shutter rail top unit

- 22 -

8-5

Cabinet front ass'y disassembly.

1. Remove the 3 screws-A (M2.5x6) and remove the Gear.

2. Remove the 2 screws-B (M2.5x6) and remove the Shutter panel.

3. Remove the 2 screws-C (M2.5x6) and remove the 2 spacers.

Mechanical disassemblies

8-6

Cabinet front ass'y disassembly.

1. Remove the screw (T3x8) and remove the Panel front-A.

2. Remove the Panel front-B.

Spacer

Gear

Spacer

Shutter panel

Panel front-A

Panel front-B

- 23 -

Mechanical disassemblies

9-1

Lamp unit removal.

1. Loosen the 2 screws-A and remove the Lamp unit.

2. Remove the screw-B (T3x8) and remove the Main board holder.

9-2

Lamp connector removal.

1. Remove the 2 screws(T3X6) and remove the Lamp connector.

Main board holder

Lamp unit

Ballast Cable

Caution:

When remove the Lamp ballast cable, be carefull not to damade the cable.

Lamp connector

- 24 -

9-3

Fan(FN902) removal.

1. Remove the 2 screws-A (T3x8) and remove the Fan unit.

2. Remove the 2screws-B (M3x8) and remove the Fan(FN902).

Mechanical disassemblies

Fan unit

A A

Fan(FN902)

- 25 -

Mechanical disassemblies

9-4

Lamp unit holder removal.

1. Remove the 2 screws-A (T3x8) and remove the Lamp unit holder.

2. Remove the screwB (T3x8) and remove the Lamp cover switch(SW8803) board.

3. Remove the 2screws-C (T3x8), remove the Spacer, remove the Cap and remove the Thermal switch(SW902).

Lamp unit holder

Lamp cover switch(SW8803) board

Spacer

Thermal switch(SW902)

- 26 -

Cap

Optical removal.

1. Remove the 5 screws (T3x10) and remove the Optical unit.

Optical unit

Mechanical disassemblies

11-1

Cover duct EXH removal.

1. Remove the 2 screws (T3x8) and remove the Cover duct EXH.

Cover duct EXH

- 27 -

Mechanical disassemblies

11-2

Exhaust Fan (FN901, FN903) removal.

1. Remove the 3 screws-A (T3x8) and remove the Exhaust fan unit.

2. Remove the 8 screws-B (M3x28) and remove the Exhaust fan FN901, FN903.

Exhaust fan unit

- 28 -

FN903

FN901

Power unit removal.

1. Remove the 6 screws-A (M3x6) and remove the Power & Ballast unit.

1. Remove the screw-B (M3x6) and remove the Power & Ballast unit.

Power & Ballast unit

Mechanical disassemblies

Ballast unit

Power unit

- 29 -

Mechanical disassemblies

Filter board unit removal.

1. Remove the 2 screws (M3x6) and remove the Filter unit.

Filter board unit

Spacer

Filter board

- 30 -

+ 105 hidden pages

Sanyo PLV-Z2000 Schematic

Specifications and Main Features

Frequently Asked Questions

User Manual

SERVICE MANUAL

■ Contents

■ Safety Instructions

■ Specifications

■ Circuit Protections

■ Maintenance and Cleaning

■ Lamp Replacement

■ Mechanical disassemblies