Sanyo PLC-XU4000 User manual

Multimedia Projector
SERVICE MANUAL
PRODUCT CODE
PLC-XU4000
1 122 542 00 (KA2AC)
1 122 542 04 (KA2EC)
1 122 547 00 (LA2AC)
1 122 547 02 (LA2CC)
1 122 547 03 (LA2DC)
Original Version
REFERENCE NO. SM5111301-00
FILE NO.
Chassis No. KA2-XU400000
Model No. PLC-XU4000
U.S.A, Canada,
Europe, U.K, Asia
Brazil
Match the Chassis No. on the rating label of the projector
with the Chassis No. in the Service Manual.
If the Original Version Service Manual Chassis No. does
not match, additional Service Literature is required. You
must refer to “Notices” to the Original Service Manual prior
to 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
Replace the Filters...................................................... 7
Resetting the Filter Counter........................................ 7
Cleaning ..................................................................... 8
Cleaning the Projection Lens...................................... 8
Cleaning the Projector Cabinet................................... 8
Lamp Replacement ....................................................... 9
Lamp replacement...................................................... 9
How to check Lamp Used Time ................................ 10
Warning Message on the non-standard lamp used .. 10
Security Function Notice.............................................. 11
Resetting procedure ................................................. 11
Standby mode Notice .................................................. 12
Mechanical Disassembly ............................................. 13
Optical Parts Disassembly........................................... 19
Adjustments................................................................. 24
Adjustments after Parts Replacement ...................... 24
Note on Main Board Replacement ........................... 24
Optical Adjustments..................................................... 25
Contrast adjustment.................................................. 25
Optical center adjustment......................................... 26
Electrical Adjustments ................................................. 29
Service Adjustment Menu Operation........................ 29
Circuit Adjustments................................................... 30
Test Points and Locations......................................... 34
Service Adjustment Data Table................................. 35
Chassis Block Diagrams.............................................. 52
Chassis over view..................................................... 52
System control.......................................................... 53
Lamp control............................................................. 54
Audio circuit .............................................................. 55
Power supply & protection circuit.............................. 56
Fan control circuit ..................................................... 57
Troubleshooting ........................................................... 58
Indicators and Projector Condition ........................... 58
No Power .................................................................. 59
No Picture................................................................. 60
No Sound.................................................................. 61
Control Port Functions................................................. 62
Scaler I/O Port Functions (PW190) .......................... 62
IC Block Diagrams....................................................... 63
Parts Location Diagrams ............................................. 69
Mechanical Parts List .................................................. 76
Electrical Parts List...................................................... 77
Diagrams & Drawings..................................................A1
Parts description and reading in schematic diagram...A2
Schematic Diagrams ...................................................A3
Printed Wiring Board Drawings....................................A9
Pin description of diode, transistor and IC.................A13
Note on Soldering......................................................A14

-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, adjustment 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.

-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.
●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.
Mechanical Information
Projector Type Multi-media Projector
Dimensions (W x H x D) 13.78" x 3.44" x 10.02" (350.0 mm X 87.5 mm X 254.4 mm ) (Not including protrusions)
Net Weight 7.28 lbs (3.3 kg)
Feet Adjustment 0˚ to 12˚
Panel Resolution
LCD Panel System 0.63" 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 PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N
SD/HD TV Signal 480i, 480p, 575i, 575p, 720p, 1035i and 1080i
Input 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 4.6' ~ 41.7' (1.4 m ~ 12.7 m)
Projection Lens F 1.60 ~ 1.76 lens with f 22.3 mm ~ 26.8 mm with manual zoom and focus
Projection Lamp 245 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/Computer 2 Audio Input Jacks Mini Jack (stereo) x 2
Computer In 1/Component Input Terminal Mini D-sub 15 pin x 1
Computer In 2/Monitor Output Terminal Mini D-sub 15 pin x 1
Control Port D-sub 9 pin x 1
Audio Output Jack Mini Jack (stereo) x 1 (variable)
LAN Connection Terminal RJ-45
Audio
Internal Audio Amp 10.0 W RMS
Built-in Speaker 1 speaker, ø1.1"(37 mm)
Power
Voltage and Power Consumption AC 100–240 V (3.8-1.8 A Max. Ampere), 50/60 Hz
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 1.5V ALKALINE TYPE x 2
Operating Range 16.4' (5 m)/±30˚
Dimensions 2.0" (W) x 0.7" (H) x 4.3" (D) (52 mm x 18 mm x 110 mm)
Net Weight 2.37 oz (67 g) (including batteries)

-5-
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 115˚C, the thermal switch opens to stop the
operation of the power supply circuit.
When the internal temperature reaches near 75˚C, the thermal
switch returns automatically.
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)
Fuse
A fuse is located inside of the projector. When the POWER indicator
is not lighting, the fuse may be opened. Check the fuse as following
steps.
The fuse should be used with the following type;
Fuse Part No.: 323 021 7804
TYPE T6.3AH 250V FUSE
LITTEL FUSE INC. TYPE 21506.3
or
How to replace the fuse
1. The fuse is placed on the filter board. Remove the cabinet top
following the "Mechanical Disassembly" .
2. Take the fuse off from the fuse holder, and replace the new one
with the specified type.
Fuse Part No, : 423 034 4101
TYPE T6.3AH 250V FUSE
Hollyland Co, Ltd. TYPE 50CT063H

-6-
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.
Warning temperature and power failure protection
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 reconnect it, and then turn the
projector on once again to verify operation.
WARNING
DO NOT LEAVE THE PROJECTOR WITH THE AC POWER CORD CONNECTED UNDER AN
ABNORMAL CONDITION. IT MAY RESULT IN FIRE OR ELECTRIC SHOCK.
4Note:
- 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” and "Fan control circuit" in the
Chassis Block Diagram section.
When the temperature inside the projector reaches a certain level, the projector will be automatically shut down to
protect the inside of the projector and the WARNING and POWER indicators start blinking. When the projector has
cooled down enough (to its normal operating temperature), the POWER indicator stops blinking and lights red, The
projector can be turned on again by pressing the ON/STAND-BY button.
4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.
Check items
- Remove dust arround the air filter.
- 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 is blinking red.
LED indicator
WARNING
indicator
POWER
indicator

-7-
Replace the Filters
Maintenance
Resetting the Filter Counter
Turn off the projector and unplug the AC power cord
from the AC outlet.
Turn over the projector and pull out the filter cover
(bottom); pull up the handle and take out the whole
filter (bottom.)
Press up the latches and pull out the filter cover (side);
pull out the handle and take out the side filter.
1
2
Filter prevents dust from accumulating on the optical elements inside the projector. Should the filter 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, replace the filters
immediately. Replace the filters by following the steps below.
Put new filters back into the position. Make sure that
the filters are fully inserted to the projector.
3
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.
–Do not wash the filters with water or any other
liquid matter. Otherwise the filters may be
damaged.
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 center for proper
cleaning.
Be sure to reset the Filter counter after replacing the filters.
Press the MENU button to display the On-Screen Menu.
Use the Point ed buttons to select the Setting Menu
and then press the Point 8 or the SELECT button.
Use the Point ed buttons select Filter counter and
then press the Point 8or the SELECT button. Use the
Pointed buttons to select Filter counter reset and
then press the SELECT button. The Filter counter
Reset? appears. Select Yes to continue.
1
2
Filter counter
The Filter counter
Reset? appears.
Select Yes, then
another confirmation
box appears.
Select Yes again
to reset the Filter
counter.
Another confirmation dialog box appears, select Yes to
reset the Filter counter.
3
Filter cover (bottom)
Filter cover (side)
Connect the AC power cord to the projector and turn
on the projector.
Latches (press up) Handle (pull out)
4
Handle (pull up)



-8-
Maintenance
Cleaning
Cleaning the Projection 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.
Cleaning the Projector Cabinet
Cleaning with air spray
Remove the cabinet top following to “Mechanical Disassembly”. 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 very 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
sufficientlycleaned 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.
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.
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.

-9-
Lamp Replacement
Lamp replacement
WARNING:
- For continued safety, replace with a lamp assembly of the same type.
- 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.
- Do not drop the lamp module or touch the glass bulb! The glass can
shatter and cause injury.
WARNING : TURN OFF THE UV LAMP BEFORE OPENING THE LAMP COVER.
USE UV RADIATION EYE AND SKIN PROTECTION DURING SERVICING.
Unplug the AC power cord. Let the projector cool for at least 45
minutes.
Loosen the three (3) screws that secure the lamp. Lift the lamp
out of the projector by using the handles.
1
3
Replace the lamp with a new one and secure the three (3)
screws. Make sure that the lamp is set properly. Push the lamp
cover and secure the screw.
4
Loosen the screw and open the lamp cover.
2
Connect the AC power cord to the projector and turn on the
projector.
5
Procedure
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
CAUTION
CAUTION
When replacing the lamp because it has stopped illuminating, there is a possibility that the lamp may be
broken.
If replacing the lamp of a projector which has been installed on the ceiling, you should always assume that the
lamp is broken, and you should stand to the side of the lamp cover, not underneath it. Remove the lamp cover
gently. Small pieces of glass may fall out when the lamp cover is opened. If pieces of glass get into your eyes
or mouth, seek medical advice immediately.
ORDER REPLACEMENT LAMP
Type No. POA-LMP148
Service Parts No. 610 352 7949
Lamp
Screw
Handles
Screw
Lamp Cover
Screw
Screw

-10-
Lamp Replacement
How to check Lamp Used Time
The LAMP REPLACE indicator will light yellow
when the total lamp used time (Corresponding
value) reaches 5,000 hours. This is to indicate
that lamp replacement is required.
You can check the lamp used time following
to the below procedure.
1Press and hold the ON/STAND-BY
button on the projector or the remote control
for more than 20 seconds.
2 The projector used time and lamp used
time will be displayed on the screen briefly
as follows.
Counter
Projector 650H
Lamp
Auto 200H
Normal 150H
Eco1 250H
Eco2 250H
Corresponding value 750H
Total lamp used time
Projector used time
Warning Message on the non-standard lamp used
If the non-standard lamp is used, the warning and confirmation messages will appear on the screen every startup.
Some of the functions are limited when the non-standard lamp is used in spite of the warning.
Since the lamp is not standard,
projector failed to read lamp data.
Continue to use this lamp?
Yes
No
Cumulative
lamp
operating
time in each
mode.

-11-
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.
Security Function Notice
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 on the screen.
Initial code: “4321”

-12-
Standby mode Notice
Function Eco Network
Serial command control 4*1 4
Network Function -- 4
Monitor Out -- 4
Audio Out -- --
Mic Out (MIC Volume) -- 4*2
Direct on 4 4
This projector provides 2 types of standby mode, Eco standby and Network standby. According to the standby mode
"Eco" or "Network", several functions are restricted as shown in the table below. To change the standby mode, use the
projector's menu "Setting".
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.
Restricted Function in the standby mode
*1 Effective only power-on command "C00".
*2 MIC volume can be output when the Standby MIC Out function is set to On.

-13-
1. Filter cover (side), Cabinet Top, Front, RC Board removal
Mechanical Disassembly
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
B
RC Board
Fig.1
Cabinet top
1. Pull up two Latches to take off the Filter cover(side).
2. Loosen 1 screw-A to remove the Lamp Cover.
3. Remove 7 screws-B (M3x8) and 1 screw-C(M3x8) to remove the Cabinet Top.
4. Remove 3 screws-D (M3x8) and 3 screws-E (T3x8) to remove the Cabinet Front.
Control Buttons
Lamp Cover
A
B
B
D
D
D
F
Dec Inlay LED
Cabinet Front
G(T3x8)x2
G
Dec Lens
B
B
B
B
F(T3x8)x2
E
E
E
C
Filter cover(side)
Latches
Note on mounting the Cabinet top
When mounting the Cabinet top, mount
the Cabinet top first and then mount the
Lamp Cover, otherwise the Lamp Cover
switch(SW901) on the Fan holder may fail.

-14-
Mechanical Disassembly
AV Panel
1. Remove 3 screws-A (T3x8) and remove the fans (FN904 and FN905).
2. Remove 5 screws-B (M2.5x6) and 2 screws-C (M3x8) to remove the Main
Board.
3. Release the hooks to remove the AV Panel, remove 3 screws-D (T3x6)
and 2 hex screws E to remove the AV Board.
Fig.2
2. Main Board, AV Board and Fans(FN904 and FN905) removal
B
B
C
AV Board
A
Fan holder
FN904
SW901 A
A
B
B
B
C
D
D
D
Main Board
EEHooks
FN905
Fan shield
Label side

-15-
Mechanical Disassembly
1. Remove the 2 screws-A(T3x12) to remove the speaker holder.Remove the 2
screws-B(T3x8) to remove the speaker(SP901).
2. Loosen 3 screws-C to remove the Lamp assy (LP900).
3. Remove 4 screws-D (T3x8) to remove the Optical unit.
4. Remove 3 screws-E (T3x8) and 1 screw-F(M3x8) to remove the Lamp
holder. Remove 2 screws-G(T3x8) to remove the ID Connect board.
5. Remove 2 screws-H(T3x8) to remove the Sub Power board.
6. Remove 3 screws-K (M3x8) and 1 screw-J (T3x8) to remove the Filter board.
Fig.3
3. Speaker(SP901),Lamp assy(LP900), Optical Unit removal
Optical Unit
F
Lamp assy
(LP900)
C
ID Connect board
C
E
B
Speaker holder
B
Speaker
(SP901)
C
D
D
DD
G G
H
H
K
K
K
Sub Power
board
Filter board
Bushes
E
A
A
J
Inside light
shield
Outside
light shield
(T3x8)x2
E
Lamp
holder

-16-
Mechanical Disassembly
4. Fan (FN906) and Power Board removal
Fig.4
Power board
Ballast board
1. Remove 2 screws-A (T3x8) to remove the Cabinet front holder. Remove 1 screw-B (T3x8) to
remove the Sensor holder and Thermal Switch(SW902).
2. Remove 2 screws-C(T3x8) to remove the Lamp fan duct ass'y. Remove 2 screws-D (T3x12)
and 1 screw-E (T3x8) to remove the fan (FN906) and Lamp fan duct.
3. Remove 1 screw F (T3x8) and 2 screws-G (T3x8) to remove the Lamp Socket and Socket plug.
4. Remove 2 screws H (T3x8) and 1 screw-J (M3x8) to remove the Power board holder.
5. Remove 3 screws-K (T3x8) and 1 screw-L (M3x8) to remove the Power board.
B
A
D
H
Power board
holder
Power board
shield bottom
Cabinet front
holder
A
D
FN906
Lamp fan
holder
Lamp fan
duct
H
J
K
K
K
L
C
Lamp Socket
Socket plug
F
GG
EC
Sensor holder
SW902
Hooks

-17-
Mechanical Disassembly
Fig.5
5. Mounting Duct, Fans(FN901, FN902, FN903) and Side Filter removal
Filter Box(side)
1. Remove 5 screws-A (T3x8) and 2 screws-B (T3x12) to remove the Panel Mouting Duct top.
2. Remove 2 screws-C (T3x12) to remove fans (FN902 and FN903). Remove the Panel Mounting
Duct bottom.
3. Remove 3 screws-D (T3x8) to remove the Filter Mounting Duct and remove 2 screws-E(T3x12) to
remove fan (FN901).
4. Take out the Filter Box(side), and then remove 2 screws-F(T3x8) to remove the Side Filter Holder.
5. Take off the Filter Box(bottom) and Filter cover(bottom).
FN901
FN903
Panel Mounting
Duct top
Panel Mounting
Duct bottom
B (T3x12)x2
A (T3x8)x5
Filter cover(bottom)
Side Filter Holder
Filter Box(bottom)
F
AA
AB
C
C
D
D
D
E
E
F
FN902
Filter
Mounting
Duct
Panel Mounting
Duct top
Panel Mounting
Duct bottom
Hooks
Unhook the 8 hooks to removal the
panel mounting duct top and bottom.
Panel mounting duct top and bottom removal
A

-18-
Mechanical Disassembly
6. Cable Reforming
Reform cables as shown below.
Fig.6
Bottom view of the power box Bottom view of the panel mounting duct top
To POWER BOARD
To FILTER BOARD
Hook
Hook
Ferrite core
Fix the ferrite
core here.
BALLAST
BOARD SW902
Hook
Wires pass through
the slit.
Guide
Guide
Tape
Hook
FN902 FN903

-19-
Optical Parts Disassembly
Before taking this procedure, remove Cabinet Top and Main Board following to the “Mechanical Disassembly”.
Disassembly requires a 2.0mm hex wrench.
LCD Panel/
Prism Assy
Fig.1
1. LCD Panel/Prism Assy removal
(M3x10)
(Bottom side)
IMPORTANT NOTICE on LCD Panel/Prism Assy Replacement
LCD panels used for this model can not be replaced separately. Do not disassemble the LCD Panel/Prism Assy.
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 assy at once.
When replacing the LCD Panel/Prism assy, take the optical and electrical adjustments following to the chapter
"Adjustment".
*Note on handling the LCD Panel/Prism Assy
LCD Panel, Polarized glasses are very sensitive parts.
Never touch or wipe the surface. When removing the
dust on the surface, use a commercial (inert gas) air
spray to remove them.

-20-
Optical Parts Disassembly
2. Polarized glass-in assy removal
3. Projection lens removal
(M2.5x8)x4
Fig.3
Projection lens
Optical unit
Note: The optical unit should be removed from the cabinet bottom before
removing the projection lens.
Polarized glass-in
Polarized glass-in assy
(M2.5x6)x1
Fig.2
Note on mounting the Polarized glass-in assy
When mounting the R-Polarized glass-in assy and
B-Polarized glass-in assy, make sure thet mounting position
of the holder shuld be center.
*Polarized glass is not removed
from the mounting base.
*Note on handling the polarized glass
B-Polarized glass-in is very sensitive parts.
Never touch or wipe the surface. Grab the
mounting base when handling the polarized
glass assy. When removing the dust on the
surface, use a commercial (inert gas) air spray
to remove them. Never use organic solvents.