Sanyo M4G-3000 User manual

Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
(M4GA) 1 122 087 00
(P4GA) 1 122 088 00
(P4GC) 1 122 088 02
Original Version
REFERENCE NO. SM5110166
FILE NO.
Model No. PLV-30
U.S.A., Canada,
Europe, Asia, Africa
U.K
Chassis No. M4G-3000
NOTE: 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.

2
■Contents
■Safety instructions ________________________________________________3
■Specifications __________________________________________________ 4
■Note on Servicing ______________________________________________ 5
■Adjustments after parts replacement ________________________________ 5
■Circuit protections ______________________________________________ 6-7
Fuse ______________________________________________________ 6
Thermal switch ______________________________________________ 7
Warning temperature and power failure protection ____________________ 7
■Mechanical disassemblies ______________________________________ 8-13
■Optical parts disassemblies ____________________________________ 14-17
■LCD panel/prism ass’y replacement ________________________________ 18
■Lamp replacement ______________________________________________ 19
■Optical adjustments __________________________________________ 20-22
●Contrast adjustment ________________________________________ 20
●Integrator lens adjustment __________________________________ 21
●Relay lens adjustment ______________________________________ 22
■Electric adjustments __________________________________________ 23-31
●Service adjustment menu operation____________________________ 23
●Circuit adjustments ______________________________________ 24-28
●Service adjustment data table______________________________ 29-30
●Test points and locations ____________________________________ 31
■Troubleshooting ______________________________________________ 32-36
●No power ______________________________________________ 32-34
●No picture ________________________________________________ 35
●No sound ________________________________________________ 36
■Control port functions ____________________________________________ 37
■Waveforms __________________________________________________ 38-40
■Cleaning ______________________________________________________ 41
■IC block diagrams ____________________________________________ 42-50
■Pins description of ICs, transistors, diodes____________________________ 51
■Parts description in schematic diagram ______________________________ 52
■Service parts lists ____________________________________________ 53-77
●Electrical parts list ______________________________________ 53-71
●Mechanical parts list ____________________________________ 72-75
●Optical parts list ________________________________________ 76-77
■Circuit block diagram ____________________________________________ A1
■Power supply lines ______________________________________________ A2
■Schematic diagrams __________________________________________ A3-A9
■Printed wiring board diagrams ________________________________ A10-A12

3
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 iden-
tified 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.
■Safety Instructions
SAFETY PRECAUTIONS
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 PROTECTIVE 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.
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.
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.

Projector Type Multi-media Projector
Dimensions (W x H x D) 7.44” x 2.93” x 11.42” (189mm x 74.5mm x 290mm)
Net Weight 5.51 lbs (2.5 kg)
LCD Panel System 0.7” TFT Active Matrix type, 3 panels
Panel Resolution 800 x 600 dots
Number of Pixels 1,440,000 (800 x 600 x 3 panels)
Color System 6 color system (PAL, SECAM, NTSC, NTSC4.43, PAL-M and PAL-N)
High Definition TV SIgnals 480i, 480p, 575i, 575p, 720p. 1035i and 1080i
Scanning Frequency H-sync. 15 ~ 80kHz, V-sync. 50 ~ 100Hz
Projection Image Size (diagonal) Adjustable from 30” to 200”
Horizontal Resolution 500 TV lines
Projection Lens F 2.0 ~ 2.3 lens with f 28mm ~ 33.6mm Manual zoom and focus
Throw Distance 4.6’ ~ 26.3’ (1.4m ~ 8.0m)
Projection Lamp 120watt type
AV Input Jacks RCA Type x 3 (Video/Y, Cb/Pb, Cr/Pr) and Mini DIN 4 pin x 1(S-Video)
AV Audio Input Jack Mini Jack (stereo)
Computer Input Jack (VGA) HDB15 Terminal x 1
Computer Audio Jack Mini Jack (stereo)
Service Port Jack Mini DIN 8 pin x 1
Audio Output Jack Mini Jack (stereo)
Internal Audio Amp. 1W RMS (monaural)
Built-in Speaker 1 speaker, 1.57” x 1.18” (40mm x 30mm)
Feet Adjustment 0˚ to 7.6˚
Voltage and AC 100 ~ 120V (2.2A Max. Ampere), 50/60Hz (The U.S.A and Canada)
Power Consumption AC 200 ~ 240V (1.1A Max. Ampere), 50/60Hz (Continental Europe and The UK.)
Operating Temperature 41˚F ~ 95˚F (5˚C ~ 35˚C)
Storage Temperature 14˚F ~ 140˚F (-10˚C ~ 60˚C)
Remote Control Transmitters Wireless Remote Control, batteries AA, UM3 or R06 Type x 2
4
■Specifications
●The specifications are subject to change without notice.
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 stan-
dards against risk of fire, casualty and electrical hazards.

5
■Adjustments after Parts Replacement
Integrator Lens Adjustment ❍●
Relay Lens Adjustment ❍●
Contrast Adjustment
R-Contrast adjustment ●
G-Contrast adjustment ●
B-Contrast adjustment ●
Output voltage adjustment ●
FAN voltage adjustment ●●
PC offset adjustment ●
PC gain adjustment ●
Component gain adjustment ●
AV gain adjustment ●
NRS Adjustment ●
Signal center adjustment ●
PC Gamma off video adjustment ●
PC/AV signal adjustment-1 ●
PC/AV signal adjustment-2 ●
S/H clock adjustment ●
Common center adjustment ● ●
White balance adjustment ❍ ❍
Black balance adjustment ❍ ❍
Disassembly / Replaced Parts
LCD/
Prism
Ass’y
Integrator
lens
Polarized glass
RGB
Component
Board
Optical
Adjustments
Electrical Adjustments
● :Adjustment necessary ❍ :Check necessary
Power
Board Main Board
Relay
Lens
When you carry out the electrical, optical service adjustment or repairing with cabinet top removal, it should be done
under the service conditions listed below. If you can not keep the one of following conditions, the projector turns off
automatically by operating the protection circuit.
To set the Fan Control to maximum, follow the Fan Control Setting Procedure below;
Fan Control Setting Procedure
1. Enter to the service mode.
2. Select adjustment item no.<29> and change data value to <0> to <1>. Now the cooling fans operate in maxi-
mum.
3. Exit from the service mode.
After finishing the works, restore the service data to <0> following to the steps 1 to 3.
* Please refer to the “Service Adjustment Menu Operation” described on page 23 for how to entering the service
mode and changing the service data.
Service Conditions:
Operating Temperature : 41˚F ~ 81˚F (5˚C ~ 30˚C)
Fans Control : Maximum
AC Power Supply : 100 ~ 120V or 200V ~ 240V
■Note on Servicing

Thermal switch
There is the thermal switch (SW902) inside of the projector to prevent the internal temperature from rising abnor-
mally. When the internal temperature reaches near 100˚C, turn off the AC main power supply 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 the tester. If it has high impedance, thermal
switch may be in operative.
How to reset the thermal switch
1. Remove the cabinet top following to “Mechanical
Disassemblies”.
2. Press the reset button on the thermal switch.
CAUTION:
Before press the reset button, disconnect the AC cord from
the projector.
-6-
■Circuit Protections
This projector is equipped with 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
The fuse is located inside of the projector. When either the LAMP indicator or the READY indicator is not illuminat-
ed, fuse may be opened. Check the fuse as following steps.
It should be used the specified fuse as follows;
How to replace the fuse
1. Remove the cabinet top and main board following to
“Mechanical Disassemblies”.
2. Remove a screw and the line filter cover upward.
3. Remove the fuse from fuse holder.
To install the fuse, take reversed step in the above.
Fuse Part No.: 423 022 2102
TYPE T4.0AH 250V FUSE
LITTLE FUSE INC. TYPE 215004
Line Filter Cover
Fuse
Thermal switch (SW902)
Reset Button
Line Filter Board
Screw

-7-
Circuit Protections
Warning temperature and power failure protection
The TEMP WARNING indicator flashes red and the projector will automatically turn off when the internal tempera-
ture of the projector exceeds the normal temperature or when stopping cooling fans or when the internal power
supply lines are failed.
Check the following possible causes and wait until stopping the TEMP WARNING indicator flashing.
Possible causes
- Air filter is clogged with dust particles. Remove dust from the air filter by following instructions in the “Air filter
care and cleaning” below.
- 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)
If the TEMP WARNING indicator still continues to flash, there may be defects on cooling fans or power supply cir-
cuits. Please check fan operation and power supply lines referring to the “Power Supply Lines Chart”.
Air filter care and cleaning
The removable air filters prevents dust from accumulation on the surface of the projection lens and projection mir-
ror. Should the air filter become clogged with dust particles, it will reduce the cooling fan’s effectiveness and may
result in internal heat build up and reduce the life of the projector.
To clean up the air filters, follow the cleaning procedure
below:
1. Turn the power off, and disconnect the AC power cord
from the AC outlet.
2. Turn the projector up side down and remove 2 air filters
(Large and Small) by pulling the latches of them
upward.
3. Clean the air filters with brush or wash out the dust and
particles.
4. Replace each air filter properly. Make sure that the air
filters are fully inserted.
CAUTION:
Do not operate the projector with the air filter removed. The
dust is stuck on the LCD panel and the mirror, and it may
spoil the fine picture image.
Do not put the small parts into the air filter intake vents. It
result in the malfunction of the projector. The air filter is
small parts. Take care that children don’t eat or swallow it.
RECOMMENDATION
We recommend to avoid dusty, smoky place for operating the projector. Using in dusty place may cause the picture
of poor quality.
When using under the dusty or smoky conditions, dust may accumulate on the LCD panel and lens inside it, and
may resultantly be projected on the screen together with the picture.
When the above symptoms are noticed, please clean up the LCD panel and lens following to the “Cleaning
Method”.
Air filters
(Small)
Air filters
(Large)

-8-
Remove 5 screws and pull cabinet top upward.
1. CABINET TOP REMOVAL
■Mechanical Disassemblies
Mechanical 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 otherwise it may cause loss of
performance and product safety.
Fig.1
1) Remove 4 screws (2 top and 2 bottom) Aand take the cabinet front off
forward.
2) Remove 2 screws Band then remove RC
board and temp board.
3) Remove 4 screws Cand the speaker.
2. CABINET FRONT AND SPEAKER REMOVAL
Fig.2
C
B
A
A
A
RC Board
A
Temp Board
B

Remove a screw and pull the line filter cover upward and then replace the
fuse if required.
FUSE REMOVAL
-9-
Mechanical Disassemblies
Remove 9 screws and remove the main board upward.
3. MAIN BOARD REMOVAL
Fig.3
Fig.4
Line Filter Cover
Main Board
Fuse

-10-
Mechanical Disassemblies
1) Remove 3 screws Aand FPC cables,
and then take the component board off
upward.
2) Remove a screw Band a grounding
lead, and then take the AV board ass’y
off upward.
4. AV AND COMPONENT BOARD REMOVAL
Fig.5
B
A
A
A
Grounding Lead
Component Board
AV Board Ass’y
1) Remove a screw Aand remove a grounding lead.
2) Remove 2 screws Band take the line filter ass’y off upward.
3) Remove the line filter board from line filter holder.
5. LINE FILTER BOARD REMOVAL
A
B
B
Line Filter Board
Line Filter Holder
Fig.6
Line Filter Ass’y
Grounding Lead