Sanyo PLC-XU116 User manual

Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
PLC-XU116
1 122 503 00 (KC8AC)
1 122 503 04 (KC8EC)
1 122 504 00 (LC8AC)
1 122 504 02 (LC8CC)
1 122 504 03 (LC8DC)
Original Version
REFERENCE NO. SM5111214-00
FILE NO.
Model No. PLC-XU116
U.S.A, Canada,
Europe, U.K, Asia
Brazil
Chassis No. KC8-XU11600
Match the Chassis No. on the rating label of the projector
with the Chassis No. in the Service Manual.
If the Chassis No. in the Original Service Manual does
not match the projector's, additional Service Literature
is required. You must refer to "Notices" to the Original
Service Manual prior to the servicing.

-2-
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
Thermal switch ........................................................... 5
Lamp cover switch ...................................................... 5
Fuse............................................................................ 5
Warning temperature and power failure protection..... 6
Maintenance.................................................................. 7
Cleaning the Filter ...................................................... 7
Resetting the Filter Counter........................................ 7
Attaching the Lens Cap .............................................. 8
Cleaning the Projection Lens...................................... 8
Cleaning the Projector Cabinet................................... 8
Lamp Replacement .................................................... 9
Resetting the Lamp Counter..................................... 10
How to check Lamp Used Time ................................ 10
Cleaning ................................................................... 11
Security Function Notice.............................................. 12
Security Function Disable......................................... 12
Standby mode Notice .................................................. 13
Mechanical Disassembly ............................................. 14
Optical Parts Disassembly........................................... 18
Adjustments................................................................. 24
Adjustments after Parts Replacement ...................... 24
Optical Adjustments..................................................... 25
Contrast adjustment.................................................. 25
Integrator lens adjustment ........................................ 26
Relay lens-Out adjustment ....................................... 27
Electrical Adjustments ................................................. 28
Service Adjustment Menu Operation........................ 28
Memory IC (IC1371) Replacement........................... 28
Circuit Adjustments................................................... 29
Test Points and Locations......................................... 33
Service Adjustment Data Table................................. 34
Chassis Block Diagrams.............................................. 51
Chassis over view..................................................... 51
System control.......................................................... 52
Lamp control............................................................. 53
Audio circuit .............................................................. 54
Power supply & protection circuit.............................. 55
Fan control circuit ..................................................... 56
IIC bus control circuit ................................................ 57
Network (MCI) circuit ................................................ 58
Troubleshooting ........................................................... 59
Indicators and Projector Condition ........................... 59
No Power .................................................................. 60
No Picture................................................................. 61
No Sound.................................................................. 62
Control Port Functions................................................. 63
Scaler I/O Port Functions (PW190) .......................... 63
I/O Expander Port Functions (TE7783) ................... 64
IC Block Diagrams....................................................... 65
Electrical Parts List...................................................... 69
Electrical Parts Location ........................................... 70
Electrical Parts List ................................................... 71
Mechanical Parts List .................................................. 98
Cabinet Parts Location ............................................. 98
Optical Parts Location .............................................. 99
Mechanical Parts List ............................................. 103
Diagrams & Drawings..................................................A1
Parts description and reading in schematic diagram...A2
Schematic Diagrams ...................................................A3
Printed Wiring Board Diagrams .................................A11
Pin description of diode, transistor and IC.................A15
Note on Soldering......................................................A16

-3-
Safety Instructions
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 per-
sonnel injury, servicing should be made with qualified personnel.
The following precautions must be observed.
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
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-
ment covers or shields, barriers, etc.
DO NOT OPERATE THIS PROJECTOR WITHOUT
THE PROTECTIVE SHIELD IN POSITION AND PR
OPERLY 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.
DO NOT ATTEMPT TO SERVICING THE REMOTE CONTROL UNIT.
Laser Beam may be leaked out when in disassemble the Unit. As the Laser Beam
used in this Remote control unit is harmful to the eyes.
If the Remote Control unit is failed, please replace it with a new one.

-4-
Specifications
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.
Mechanical Information
Projector Type Multi-media Projector
Dimensions (W x H x D) 13.16" x 3.09" x 10.14" (334.2 x 78.4 x 257.5mm) (Not including protrusions)
Net Weight 7.7 lbs (3.5 kg)
Feet Adjustment 0˚ to 8.9˚
Panel Resolution
LCD Panel System 0.8" TFT Active Matrix type, 3 panels
Panel Resolution 1,024 x 768 dots
Number of Pixels 2,359,296 (1024 x 768x 3 panels)
Signal Compatibility
Color System PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N
SD/HD TV Signal 480i, 480p, 575i, 575p, 720p, 1035i and 1080i
Scanning Frequency H-sync. 15 kHz–100 kHz, V-sync. 50–100 Hz
Optical Information
Projection Image Size (Diagonal) Adjustable from 40” to 300”
Throw Distance 3.1' (0.93m) - 37.6' (11.5m)
Projection Lens F1.7–2.5 lens with f=19.2 mm–30.2 mm with manual zoom and focus
Projection Lamp 275 W
Interface
Video Input Jack RCA Type x 1
S-video Input Jack Mini DIN 4 pin x 1
Audio Input Jacks RCA Type x 2
Computer 1 Component/
Computer2 Audio Input Jacks Mini Jack x 2
Computer In 1/ Component Input Terminal Mini D-sub 15 pin x 1
MONITOR OUT Terminal Mini D-sub 15 pin x 1
Computer In 2/DVI-I Input DVI-I Terminal x 1
Control port D-sub 9 pin x 1
USB Connectors USB connector (Series A x1, Series B x 1)
Audio Output Jack Mini Jack (stereo) x 1 (variable)
LAN Connection Terminal 100 Base-TX (100Mbps)/10 Base-T (10Mbps), RJ45
Audio
Internal Audio Amp 1.0 W RMS
Built-in Speaker 1 speaker, ø1.10" (28 mm)
Power
Voltage and Power Consumption AC 100–120 V (4.1A Max. Ampere), 50/60 Hz (The U.S.A and Canada)
AC 200–240 V (2.1A Max. Ampere), 50/60 Hz (Continental Europe and The U.K.)
Operating Environment
Operating Temperature 41˚F–95˚F (5 ˚C–35 ˚C)
Storage Temperature 14˚F–140˚F (-10˚C–60 ˚C)
Remote Control
Battery AAA or LR03 Type x 2
Operating Range 5 m/±30˚
Dimensions 45 mm (W) x 23 mm (H) x 145 mm (D)
Net Weight 3.5 oz 99 g (including batteries)
Laser Pointer Class II Laser (Max. Output: 1 mW/Wave length: 640–660 nm)
●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.

-5-
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 follow-
ing steps.
The fuse should be used with the following type;
Fuse Part No.: 323 025 1204
TYPE 8A 250V FUSE
LITTLE FUSE INC. TYPE 215008
How to replace the fuse
1. The fuse is placed on the filter board under the main board. Re-
move the cabinet top and main board.
2. Take the fuse off, and replace the new one with the specified type.
Lamp cover switch
The lamp cover switch (SW901) 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 ass’y, place the
lamp cover correctly otherwise the projector can not turn on.
Thermal switch
There is the thermal switch (SW902) inside of the projector to detect
the internal temperature rising abnormally. When the internal tem-
perature reaches near 100˚C, the thermal switch opens to stop the
operation of the power supply circuit.
The thermal switch cannot be reset itself automatically even if the
internal temperature becomes normal. Reset the thermal switch fol-
lowing to the below procedure.
How to reset the thermal switch
1. Insert the sharp tool like a screwdriver into a hole on the cabinet
from the cabinet bottom.
2. Press the reset button on the thermal switch with the screwdriver.
CAUTION:
Before press the reset button, make sure that the AC cord must be
disconnected from the AC outlet.
This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the projec-
tor, it will automatically turn off by operating one of the following protection circuits.
Thermal switch (SW902)
Fuse
Circuit Protections
Lamp cover switch
(SW901)

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Circuit Protections
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 follow-
ing 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 Chassis Block Diagram
section.
Possible causes
- Air filters are clogged with dust particles. Remove dust from the air filters 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)
The projector is shut down and the WARNING
indicator lights red.
When the projector detects an abnormal condition, it is auto-
matically shut down to protect the inside of the projector and
the WARNING indicator lights red. In this case, unplug the
AC power cord and reconnect it, and then turn the projector
on once again to verify operation. If the projector cannot be
turned on and the WARNING indicator still lights red, it may
defect the cooling fans or power supply circuits.
CAUTION
DO NOT LEAVE THE PROJECTOR WITH THE AC
POWER CORD CONNECTED UNDER AN AB-
NORMAL CONDITION. IT MAY RESULT IN FIRE
OR ELECTRIC SHOCK.
Top Control
WARNING
lights red
Warning temperature and power failure protection

-7-
RECOMMENDATION
We recommend avoiding dusty/smoky environments when
you operate the projector. Usage in these environments may
cause 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.
✔Note:
• When reinserting this filter, be sure that the slit
part is facing the outer side.
Be sure to reset the Filter counter after cleaning or replacing the filter.
Press the MENU button to display the On-Screen Menu.
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
to Filter counter and then press the SELECT button. A
dialog box appears showing the total accumulated time
of the filter use, a timer setting option, and the reset op-
tion. Select Reset and the “Filter counter Reset?” ap-
pears. Select [Yes] to continue.
1
2
Resetting the Filter Counter
Another confirmation dialog box appears, select [Yes] to
reset the Filter counter.
3
Cleaning the Filter
Maintenance
Turn off the projector, and unplug the AC power cord
from the AC outlet.
Turn the projector over and remove the filters by pulling
the latches upward.
1
2
Filters prevents dust from accumulating on the optical elements inside the projector. Should the filters become
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. If a “Filter warning” icon appears on the screen, clean the filters
immediately. Clean the filter by following the steps below.
Gently clean the filters by using a brush or rinse them
softly.
3
When rinsing the filters, dry them well. Replace the
filters properly. Make sure that the filters are fully
inserted to the projector.
4
CAUTION
Do not operate the projector with the filters
removed. Dust may accumulate on the optical
elements degrading picture quality.
Do not put anything into the air vents. Doing so
may result in malfunction of the projector.
Filters
Pull up and remove.
Filter counter
Filter counter
Reset?
appears.
Select Yes,
then another
confirmation
box appears.
Select Yes
again to reset
the Filter
counter.
H

-8-
Maintenance
Cleaning the Projector Cabinet
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 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.
Unplug the AC power cord before cleaning.
Gently wipe the projector body with a soft dry cleaning cloth.
When the cabinet is heavily soiled, use a small amount of
mild detergent and finish with a soft dry cleaning 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 the projector in an
appropriate carrying case to protect it from dust and
scratches.
When moving this projector or while not using it over an
extended period of time, replace the lens cap.
Attach the lens cap according to the following procedures.
Pass the string through a hole of the lens cap.
Turn over the projector and remove the screw with a
screwdriver.
Attaching the Lens Cap
Attach the string with lens cap to a hole at the bottom of
the projector and secure it with a screw.
1
2
3
Lens Cap
String for the lens cap
Secure it to the hole
with a screw.
Hole
CAUTION
Do not use any flammable solvents or air sprays
on the projector and in its vicinity. The explosion
or fire hazard may occur even after the AC power
cord is unplugged because the temperature inside
the projector is extremely high due to the lamps. In
addition, there is a risk that the internal parts may
be damaged not only by the flammable air spray but
also by the cold air.

-9-
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 yellow. Replace the lamp with a new
one promptly. The timing when the LAMP REPLACE indicator
should light is depending on the lamp mode.
Follow these steps to replace the lamp.
For continued safety, replace with a lamp of the
same type. Do not drop a lamp or touch a glass
bulb! The glass can shatter and may cause injury.
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.
CAUTION
Turn off the projector and unplug the AC power cord. Let
the projector cool for at least 45 minutes.
Loosen the two (2) screws that secure the lamp. Lift the
lamp out of the projector by using the handle.
1
3
Replace the lamp with a new one and secure the two (2)
screws. Make sure that the lamp is set properly. Close
the lamp cover.
4
Remove the one (1) screw on the lamp cover and open
the lamp cover.
2
Connect the AC power cord to the projector and turn on
the projector.
6Reset the lamp counter.
See “Resetting the Lamp Counter” on the next page.
5
Lamp Replacement
CAUTION
WARNING:
TURN OFF THE UV LAMP BEFORE OPEN-
ING THE LAMP COVER
Top Control
LAMP REPLACE
indicator
Lamp replacement icon
✔Note:
• The Lamp replacement icon will not appear when
the Display function is set to “Off”, during “Freeze”,
or “No show”.
ORDER REPLACEMENT LAMP
Type No. POA-LMP111
Service Parts No. 610 333 9740
Maintenance
Lamp
Screw
Handle
Screw
Lamp Cover
Press here and pull upward.
Screw

-10-
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 1.2) + (Thigh x 1.5)
Teco: used time in the Eco mode
Tnormal : used time in the Normal mode
Thigh : used time in the High mode
You can check the lamp used time following to the below procedure.
1Press and hold the ON/STAND-BY button on the projector or remote control for more than 20 seconds.
2The projector used time and lamp used time will be displayed on the screen briefly as follows.
Counter
Projector 750 H
Lamp
High 200 H
Normal 250 H
Eco 300 H
Corresponding value 900 H
Total lamp used time
Projector used time
How to check Lamp Used Time
Resetting the Lamp Counter
✔Note:
• Do not reset the Lamp counter without implementing lamp
replacement. Be sure to reset the Lamp counter only after
replacing the lamp.
Maintenance
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.
Lamp replacement
counter Reset?
appears.
Select Yes, then
another confirmation
box appears.
Select Yes again
to reset the Lamp
counter.
Lamp replacement counter
Reset?
Press the MENU button to display the On-Screen
Menu. Use the Point ed buttons to select Setting and
then press the Point 8 or the SELECT button.
Use the Point ed buttons to select Lamp counter
and then press the SELECT button. Use the Point ed
buttons to select Lamp counter reset and then press
SELECT button. Lamp replacement counter Reset?
appears. Select Yes to continue.
1
2
Another confirmation dialog box appears, select Yes to
reset the Lamp counter.
3
Lamp replacement counter
Reset?

-11-
Cleaning
Cleaning with air spray
1. Remove the cabinet top following to “Mechanical Dis-
assemblies”.
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 resin-
based 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.
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.
Disassembly Cleaning
Disassembly cleaning method should only be performed
when the unit is considerable dirty and cannot be suf-
ficiently cleaned by air spraying alone.
Be sure to readjust the optical system after perform-
ing 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, re-
move the LCD panel unit following to “LCD panel re-
placement”.
3. Clean the optical parts with a soft cloth. Clean ex-
tremely dirty areas using a cloth moistened with al-
cohol.
Caution:
The surface of the optical components consists of mul-
tiple 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 cir-
cuit, never use any liquids (water, etc.) to clean the unit.
Use of liquid may cause the unit to malfunction.
Maintenance

-12-
Security Function Notice
This projector provides security functions such as "Key lock", "PIN code lock" and "Logo PIN code lock". When the pro-
jector 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.
Resetting procedure
1. Disconnect the AC power cord from the AC outlet.
2. As pressing the SELECT button, connect the AC power cord into an AC outlet again.
3. Keep pressing the SELECT button and then press the ON/STAND-BY button.
4. Release the ON STAND-BY button first and then release the SELECT button.
- The PIN code lock and Logo PIN code lock will be 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.
Function Description
Key lock
Locks operation of the top control or the remote con-
trol.
If the Key lock is enabled with top control lock, the pro-
jector can no longer be started.
Initial setting: Key lock function is disabled
PIN code lock
Prevents the projector from being operated by an un-
authorized person.
Initial code: “1234”
Logo PIN code lock
Prevents an unauthorized person for changing the
start-up logo and captured image on the screen.
Initial code: “4321”
Security Function Disable

-13-
This function is available when operating the projector via network.
Network......Supply the power to the network function even after turning off the projector.You can turn on/ off the
projector via network, modify network environment, and receive an e-mail about projector status while
the projector is powered off.
Eco............. Select “Eco” when you do not use the projector via network. The projector’s network function will stop
when turning off the projector.
When "Eco" is selected, several functions will be restricted.
(Power consumption when standing by increases in the state of "Network". )
Restricted Function at the Eco mode
Standby mode Notice
Function Eco mode
Serial command control X
Network Function X
Monitor Out X
Audio Out X
On start
Wired Remote Control
(When wired remote con-
trol code is same as the
remote control code set in
projector setting menu)
Wired Remote Control
(When wired remote con-
trol code is different from
the remote control code set
in projector setting menu)
X

-14-
1. Cabinet Top, Front, R/C Board removal
Mechanical disassembly should be made following procedures in numerical or-
der.
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.
Screws Expression
(Type Diameter x Length) mm
T type M Type
A (T3x10)x5
Cabinet front Fig.1
B (M2.5x6)x2
Cabinet top
E (T2x6)x2
1. Remove 5 screws A(T3x10) to remove the cabinet top.
2. Remove 2 screws B(M2.5x6) and 2 screws C(T3x8) to
the Cabinet front.
3. Remove screw D(M2.5x6), 2 screws E( T2x6) and screw
F(M2.5x6) to remove the Lens spacer sheet and Front
shield.
4. Remove 2 screws G(T2x8) to remove the
Antenna board.
5. Remove screw H(T2x8) to remove the R/C Board.
Control Buttons
C(T3x8)x2
A
A
A
B
A
C
Front shield
Lens spacer sheet
E
Dec Inlay LED
D (M2.5x6)
F (M2.5x6)
Mechanical Disassembly
R/C Board
G (T2x8)x2
H (T2x8)
G
Antenna Board
DEC Inlay LED front

-15-
Mechanical Disassembly
2. Main Board, AV Board, Rear Panel and Fans removal
Main board
Rear panel
A (M2.5x6)
Fig.2
AV board
B (M2.5x6)x6
Side grill
D (T3x6)x2
C (T3x6)x2
1. Remove screw A (M2.5x6) to remove the Lamp top shield.
2. Remove 6 screws B(M2.5x6) to remove the Main board.
3. Release 4 hooks to remove the Rear panel and remove 2 screws
C(T3x6) to remove the Rear panel and AV board.
4. Remove 2 screws D(T3x6) to remove fans (FN901, FN902).
FN901
FN902
B (T3x8)
A (M3x8)
FN903
1. Remove screw A(M3x8) to disconnect
the lamp ballast socket.
2. Remove screw B(T3x8) to remove
fan (FN903).
Fig.3
3. Fan (FN903) removal
Trigger
Trigger Duct
* Trigger should be mounted as the
figure above.
Ballast
socket
B
BC
D
Lamp top shield
B
Hooks
B
B

-16-
Mechanical Disassembly
4. Optical unit, Network board, TMP board, Filter board, Fans and Speaker removal
Fig.4
TMP board
SP901
Noise filter
Optical unit
E (T3x6)x2
C (T3x8)
F (T3x6)
Filter board
FN904
FN907
FN905 Duct bottom
1. Remove 5 screws A(T3x8) to remove the the Optical unit.
2. Remove 3 screws B (T3x8) to remove the Network board.
3. Remove 3 screws C (T3x8) and 4 hooks on the duct to remove
the Duct. top and bottom.
4. Remove screw D(T3x8) to remove the fan(FN904).
5. Remove 2 screws E(T3x6) and screw F(T3x6) to remove the filter
board and TMP board.
6. Remove fans (FN905, FN907) and speaker (SP901).
Duct top
A(T3x8)x5
AA
AA
E
CC
Hook
Hook
Hook Hook
D (T3x8)
B (T3x8)x3
BB
Network board

-17-
Mechanical Disassembly
Fig.5
5. Power, Ballast, SW Board, Thermal Sw(SW902) removal
Isolation sheets
SW board
Themal switch
(SW902)
Power board
C (T3x6)
E (T3x6)
D (T3x6)x2
F (T3x6)
Ballast board
1. Remove two Isolation sheets.
2. Remove 2 screws A(T3x6) and 2 screws B(T3x8) to remove the Power
board holder.
3. Remove screw C(T3x6) to remove the Power board.
4. Remove 2 screws D(T3x6) to remove the Ballast board.
5. Remove screw E(T3x6) to remove the SW board and remove screw F(T3x6)
to remove the thermal switch (SW902).
A (T3x6)x2
A
B (T3x8)x2
B
D
Power board holder

-18-
Optical Parts Disassembly
Before taking this procedure, remove Cabinet Top , Cabinet Front and Main Board following to the “Mechanical Disas-
sembly”.
Disassembly requires a 2.0mm hex wrench.
1. Projection lens disassembly
(M2.5x8)x4
Fig.1
2. Integrator lens-in disassembly
Hooks
Integrator lens-in
Integrator Lens-In Ass'y
(M2.5x5)x2
Fig.2
* Rugged surface
(Behind)
Projection lens
Optical unit
Note: The optical unit should be removed from the cabinet bottom before removing the projection lens.

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Optical Parts Disassembly
4. Polarized glass-in disassembly
Polarized glass
Polarized glass-in Ass'y
(M2.5x5)x3
Fig.4
Film sheet
3. Relay lens disassembly
Relay lens
Relay lens Ass'y
(M2.5x5)x2
Fig.3
Spring
* Mount the polarized
glass as the film at-
tached side faces the
prism side.
Hooks

-20-
Optical Parts Disassembly
LCD Panel/
Prism Ass’y
Fig.5-1
5. LCD Panel/Prism Ass’y removal
(M2.5x4)x2
(M3x10)
(Bottom side)
IMPORTANT NOTICE on LCD Panel/Prism Ass'y Replacement
LCD panels used for this model can not 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.
After replacing LCD Panel/Prism ass’y, please check the following points.
- Check that there is no color shading at the top, bottom, left or right of the screen. If there is, try to remove the
shading following to the chapter “Optical Adjustment”.
- Check the white balance. If it needs the adjustment, adjust the white balance following to the “White Balance ad-
justment” , “Gamma adjustment” and “Common Center adjustment” in the chapter “Electrical Adjustment”.
- Check the white uniformity on the screen.
If you find the color shading at the some part of the screen, it needs to take the color shading adjustment. This
adjustment should be performed by a computer and it also requires a special software “Projector service tool”. The
software will be supplied separately and can be ordered as follows;
PROJECTOR SERVICE TOOL Ver. 4.20
Service Parts No. 610 343 5596