Sanyo PLV-Z3 User manual

PRODUCT CODE
1 122 268 00 PLV-Z3 (S) (M4SA)
1 122 269 00 PLV-Z3 (S) (P4SA)
1 122 269 02 PLV-Z3 (S) (P4SC)
1 122 268 20 PLV-Z3 (K) (M4SAA)
1 122 269 20 PLV-Z3 (K) (P4SAA)
1 122 269 22 PLV-Z3 (K) (P4SCA) REFERENCE NO. SM5110679-00
Multimedia Projector
SERVICE MANUAL
FILE NO.
Model No. PLV-Z3
(U.S.A., Canada, Europe
Asia, Africa, U.K. )
Chassis No. M4S-Z300
M4S-Z3S00
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.
Original Version

-2-
■Contents
■Safety Instructions ..........................................................................................................3
■Specifications ..................................................................................................................4
■Circuit Protections ..........................................................................................................5
■Lamp Replacement ........................................................................................................7
■Cleaning ..........................................................................................................................8
■Mechanical Disassemblies ............................................................................................10
■Optical Parts Disassemblies..........................................................................................15
■LCD Panel/Prism Ass'y Replacement ..........................................................................19
■Adjustments After Parts Replacement ..........................................................................20
■Optical Adjustment ........................................................................................................21
■Electrical Adjustment ....................................................................................................23
●Service Adjustment Menu Operation ..................................................................23
●Circuit Adjustments ............................................................................................24
●Service Adjustment Data Table ..........................................................................27
●Location of Test Points........................................................................................36
■Waveform ......................................................................................................................37
■Chassis Block Diagram ................................................................................................38
■Power Supply Lines ......................................................................................................43
■Troubleshooting ............................................................................................................44
●No Power ............................................................................................................44
●No Picture ..........................................................................................................46
■Control Port Functions ..................................................................................................48
■IC Block Diagrams ........................................................................................................51
■Service Parts List ..........................................................................................................56
●Electrical parts list ..............................................................................................56
●Mechanical parts list............................................................................................75
●Optical parts list ..................................................................................................78
Drawings & Diagrams ........................................................................................ A1-A13
■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

-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
identified with the line ( ) in the schematic diagram. For continued product safety and protection of person-
nel 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
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 - 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.
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.
■Safety Instructions

■Specifications
-4-
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.
The CE Mark is a Directive conformity mark of the European Community (EC).
Pixelworks ICs used.
0.7” wide TFT Active Matrix type, 3 panels
Multimedia Projector
9.0 lbs (4.1 kg)
14.13" x 4.59" x 10.77" (359mm x 116.7mm x 273.5mm) (not including raised portions)
1280 x 720 dots
2,764,800 (1280 x 720 x 3 panels)
PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N
H-sync. 15 ~ 80 KHz, V-sync. 50 ~ 100 Hz
Adjustable from 31” to 200”
41 ˚F ~ 95 ˚F (5 ˚C ~ 35 ˚C)
14 ˚F ~ 140 ˚F (-10 ˚C ~ 60 ˚C)
Owner’s Manual
AC Power Cord
Remote Control and Batteries
Video Cable
Projector Type
Net Weight
Dimensions (W x H x D)
Panel Resolution
Number of Pixels
Color System
Scanning Frequency
Projection Image size (Diagonal)
Operating Temperature
Storage Temperature
Accessories
LCD Panel System
●The specifications are subject to change without notice.
F 2.04 ~ 2.54 lens with f 21.5 mm ~ 27.7 mm with manual zoom and focus
3.9’ ~ 20.0’ (1.2 m ~ 6.1 m)
135 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)
Projection Lens
Throw Distance
Projection Lamp
Video Input Jacks
(VGA) HDB 15 Terminal x 1
Computer Input Terminal
HDMI terminal 19 pin x 1
HDMI Input Terminal
0˚ to 11.8˚
Feet Adjustment
Power Source : AA, UM3 or LR06 1.5V ALKALINE Type x 2
Operating Range : 16.4’ (5m) / ±30˚
Dimensions : 1.97” x 1.06” x 6.61” (50mm x 27mm x 168mm)
Net Weight : 4.4oz (126g) (including batteries)
Remote Control
480i, 480p, 575i, 575p, 720p, 1035i, and 1080i
High Definition TV Signal
AC 100 ~ 120 V (2.4 A Max. Ampere), 50 / 60 Hz (The U.S.A. and Canada)
AC 200 ~ 240 V (1.3 A Max. Ampere), 50 / 60 Hz (Continental Europe and The U.K.)
Voltage and
Power Consumption
●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.
Te c hnical Specifications
●The On-Screen Menu and figures in this manual may differ slightly from the product.
Mini DIN 8 pin x 1
Service Port Connector

●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 ass’y, place the lamp cover correctly
otherwise the projector can not turn on.
●Thermal switch
This function (thermostat switch SW902) will not operate,
while the temperature monitor is operating normally. When
the internal temperature reaches near 90˚C, it cuts off the
AC main power supply .
If it has operated, it needs to be reset manually. Disconnect
the AC cord first and investigate the cause of overheating.
After servicing, reset the thermostat switch (SW902) as
shown in a figure.
CAUTION:
Before press the reset button, make sure that the AC
cord must be disconnected from the AC outlet.
●Fuse
-5-
■Circuit Protections
This projector is equipped with the following protections to operate in safety. If the abnormality occurs
inside the projector, it will turn off the projector by operating one of the following protections.
The fuse is located on the ass'y-Inlet. When either the
LAMP indicator or the READY indicator is not illuminated,
fuse may be opened. Check the fuse as following steps.
1. Remove the ass'y-Inlet following to “Mechanical
Disassemblies”.
2. Remove the fuse from fuse holder.
3. Check the resistance of fuse by using the tester.
To install the fuse, take reversed step in the above.
It should be used the specified fuse as parts
list.
Fuse
Ass’y Inlet
SW902
Lamp Cover
Lamp Cover Switch (SW8803)

●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 fol-
lowing 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.
- 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)
●Front cover switch (Door switch)
When the front cover is closed, the ready indicator lights
orange and the projector cannot be turned on.
While operating the projector, if the front cover is closed,
turn off the projector.
-6-
Circuit Protections
Door SW (inside the cabinet)
The LAMP REPLACE indicator will light when the total
lamp used time reaches 3,000 hours. This is to indi-
cate 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 the Eco mode
Tnormal: used time in the Normal mode
You can check the lamp replace counter following to
below procedure.
1Press and hold the POWER ON-OFF button on the
projector or the remote control unit for more than 20
seconds.
2The projector used time and lamp used time will be
displayed on the screen briefly.
How to check lamp used time
Counter
Projector 525H
Lamp
Normal 100H
Eco 375H
Total 525H
Total lamp used time
Projector used time

-7-
■Lamp Replacement
■Lamp Replacement
■Lamp Replacement Counter
When the life of the projection lamp of this projector draws to
an end, the LAMP REPLACE indicator lights yellow. If this
indicator lights yellow, replace the lamp with a new one
promptly.
Follow these steps to replace the lamp.
Lamp
Lamp Cover
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-Z3
●Replacement Lamp Type No. : POA-LMP86
(Service Parts No. 610 317 5355)
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.
POWER
WARNING
LAMP
REPLACE
This indicator lights yellow
when the life of the projection
lamp draws to an end.
Top Control
CAUTION
Screw
Screw
Turn off the projector and disconnect the AC plug. Allow the
projector to cool for at least 45 minutes.
Loosen 2 screws of the lamp with a screwdriver and pull out the
lamp by grasping the handle.
1
3
Replace the lamp with a new one and tighten the 2 screws back
into position. Make sure that the lamp is set properly. Replace
the lamp cover and tighten the screw.
4
Turn over the projector. Loosen the screw with a screwdriver,
and remove the lamp cover.
2
Connect the AC power cord to the projector and turn on the
projector.
6Reset the Lamp replace counter.
See “Lamp Replace Counter” on the next page .
5Handle
Screw
CAUTION
Be sure to reset the lamp replace counter after the lamp is replaced. When the lamp replace counter is reset, the LAMP
REPLACE indicator stops lighting.
Turn the projector on, press the MENU button, and the On-
Screen Menu will appear. Select the Setting Menu with the
Point Up/Down button and press the Point Right button to
enter the sub-menu.
Select the Lamp counter reset item and then press the
SELECT button. The message "Lamp replace counter
Reset?" is displayed. Choose [Yes] and then press the
SELECT button.
1
2
Another confirmation dialog box appears and choose [Yes] to
reset the Lamp replace counter.
3
NOTE
●Do not reset the Lamp replace counter without implementation of lamp replacement. Be sure to reset the Lamp
replace counter only after replacing the lamp.
Lamp counter reset

-8-
● Cleaning with air spray
1. Remove the cabinet top following to “Mechanical
Disassemblies”.
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 per-
formed when the unit is considerable dirty and cannot
be sufficiently cleaned by air spraying alone.
Be sure to readjust the optical system after per-
forming 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 clean-
ing, 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 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.
● Cleaning with the cleaning function
1. Press MENU button to display the On-Screen Menu
and select the Setting menu by pressing the Point
Up/Down button. Then press Point Right button to
enter the sub-menu.
2. Press Point Up/Down button to select the Cleaning
function then press SELECT button to select the
item, and then the image is blacked out temporary.
3. Turn over the projector then pull one of the hole cov-
ers upward gently, and put the blower nozzle in the
hole.
Note:
When you look at the screen
- When red spots (dust) are the most remarkable, put
the nozzle in the R panel cleaning holes.
- When Green spots (dust) are the most remarkable,
put the nozzle in the G panel cleaning holes.
- When Blue spots (dust) are the most remarkable,
put the nozzle in the B panel cleaning holes.
4. While watching the position of the dust on the
screen, blow air into the projector by the blower.
5. When finishing, pull the blower out and put the hole
cover back tightly.
Note:
When putting back the hole cover, starts from the
outside hole to make the operation easier and prevent
the hole cover from damaging.
6. Turn over the projector again, then press any button
on the top control or on the remote control to cancel
the Cleaning function.
The nozzle will be stopped
by the stoppers when
being put in the hole. Do
not try to force the nozzle
into further. The nozzle
could be break and fall into
inside of the projector.
When cleaning, wave the nozzle inside of the projector
back and forth. (Do not try to force the nozzle to bend.)
Caution: Use only supplied blower nd nozzle.
■Cleaning

-9-
Cleaning
After removing the air filter from the projector as
described above, remove the replacement filter
from the holder.
Holds the air filter with both hands, and remove
the replacement filter by pulling it up.
1
2
When there is much dust and dirt on the air filter, replace it with a new one following the steps below.
Install a new replacement filter and put the air
filter back into the projector.
3
Replacing the Air Filter
Replacement Filter
Install the replace-
ment filter securely.
Remove the
replacement filter as
shown this figure.
Holder
Turn off the projector and disconnect the AC power cord from
the AC outlet.
Turn over the projector. Put the projector on a soft cloth not to
scratch the surface.
1
2
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 internal heat build up
and adversely affect the life of the projector. Clean the air filters according to the following steps below.
Cleaning the Air Filter
Air Filter 2
Air Intake Vent
Air Filter 1
(Intake Vent)
3
4
Latch
Air Filter 2
Pull the latches on both edges upward.
3
Remove dust and dirt with a soft brush or vacuum cleaner. Be
careful not to damage the air filters and do not clean the air
filters with water. When there is much dust and dirt on the air
filter, replace it with a new one. (See next page for replacing
the air filter. )
4
Put the air filters back into position. Make sure that the air
filters are properly and fully inserted.
5
Cleaning the Air Filter 1
Remove dust and dirt with a soft brush or vacuum cleaner. Be
careful not to damage the air filter and do not clean the air filter
with water. Clean the air intake vent with a vacuum cleaner at
the same time.
3
Put the air filter back into the position with pushing the top of
the tub. Do not push the delicate filter part. Make sure that the
air filters are properly and fully inserted.
4
Push the latch and lift the air filter. Do not try to pull the delicate
filter part.
Cleaning the Air Filter 1
6
Pull the Air Filter horizontally not to break the inside latch.
5
6
Cleaning the Air Filter 2

■Mechanical Disassemblies
-10-
1. CABINET - TOP REMOVAL
1. Remove 6 screws to take the Cabinet Top upward off.
3. MAIN BOARD AND THERMAL BARRIER PLATE REMOVAL
1. Remove 7 screws Ato take the Main Board upward off.
2. Remove 2 screws Bto take the thermal barrier plate
upward off.
Fig. 1
Fig. 3
A
A
A
A
A
A
B
Main Board
Thermal
Barrier
Plate
2. CABINET - FRONT REMOVAL
1. Open the door.
2. Remove a screw to take the Cabinet Front off.
Fig. 2
Cabinet Top
Cabinet Front
Door
[Attention] This LCD projector is used the different kind of screw. The using correct screw is needed to prevent
the damage.
A
B
Holder

-11-
Mechanical Disassemblies
4. DOOR ASS'Y REMOVAL
1. Remove 6 screws to take the Door Ass'y off.
Note: Can be removed Door itself. See below.
5. DOOR LEG AND DOOR SWITCH BOARD REMOVAL
1. Remove a screw to take each leg off.
2. Slide the Door Switch Board out.
Fig. 4
Door Ass'y
Door
Door Switch Board
Door Leg
Fig. 5
6. AV BOARD REMOVAL
1. Remove 1 screw Aand 1 screw Bto take the AV Ass'y
(Board with Panel) upward off.
2. Remove 2 screws C,4 screws Dand 1 screw Eto
take the AV Board off from the AV Panel.
AV Board
Fig. 6
AV Panel
D
A
B
DD
D
E
C
C

Mechanical Disassemblies
-12-
7. LAMP BALLAST UNIT REMOVAL
1. Remove 4 screws Ato take the Filter Holder off.
2. Remove 3 screws Bto take the Filter Board off.
3. Remove 3 screws Cto take the Inlet Board off.
Filter Board
Fig. 7-1
AA
A
A
B
B
B
C
Filter Holder
8. OPTICAL UNIT AND FAN REMOVAL
1. Remove a screw Ato take the Thermostat Switch
upward off.
2. Remove a screw Bto take the Lamp Socket off.
3. Remove 3 screws Cto take the Fan Cover off.
4. Remove 8 screws Dto take the Optical Unit off.
5. Remove 2 screws Eand 2 screws Fto take the Fan
(FAN903) off.
Fig. 8-1
Thermostat
Switch
A
B
CC
D
D
Lamp Socket
FN903
Inlet Board
Fig. 7-2
Fan
Cover
C
E
Rib
Fig. 8-2
D
D
D
D
D
D
E
F
F
Slit
Mounting
Exhaust Fan

-13-
Mechanical Disassemblies
9. POWER BOARD REMOVAL
1. Remove 2 screws Ato take the Lamp SW Board off.
2. Remove a screw Band 4 screws Cto open the Power
Board Cover and take the R/C Board off.
3. Remove 4 screws Dto take the Power Board off.
Note: For fixing Lamp SW Board, insert the guide to the
guide hole of Lamp SW Board and fix the screw of
below figure in the beginning.
Fig. 9
D
R/C Board
D
B
C
C
D
A
C
C
Guide Hole
10. LAMP BALLAST AND FAN REMOVAL
1. Remove 2 screws Ato take the Lamp Ballast Unit
upward off.
2. Remove 3 screws Bto take the Power Board Holder
off.
3. Remove 4 screws Cto take the Fan (FN901) off.
Fig. 10
A
A
C
B
B
B
C
Lamp Ballast
FN901
Power Board
Power Board
Cover
Lamp SW Board
AD
Fix in the
beginning.
Power Board
Holder
C
C
Note: Remove the Lamp Cover before fixing the
Lamp SW board to prevent the damage of
Lamp SW board.

Note:
The wire from the inlet is the most
important ground. It should be
attached separately as shown
below.
Mechanical Disassemblies
-14-
11. FANS REMOVAL
1. Remove 2 screws Aand 5 screws Bto take the Fan
Cover off.
2. Remove a screw Cto take the Sensor Board off from
the Fan Cover.
3. Remove 2 screws Dto take the Duct Cover-A off.
4. Remove 2 screws Eto take the Duct Cover-B and Fan
(FN902) off.
5. Remove a screw Fto take Fan (FN904) or Fan (FN905)
off.
Fig. 11
D
Fan Cover
E
E
A
C
A
D
B
B
FN904
FN902
F
F
Sensor Board
Duct Cover-A
Duct
Duct Cover-B
FN905
12. DRESSING GROUNDING WIRE
The grounding wires should be dressed
as below figure.

-15-
■Optical Parts Disassemblies
Before taking this procedure, remove Cabinet Top and Main board following to the “Mechanical
Disassemblies”.
Disassembly requires a 2.0mm hex wrench and a screwdriver.
1. PROJECTION LENS REMOVAL
1. Remove 2 screws Ato slide the Lens Spacer off.
2. Remove 2 screws Bto take the Mounting Lens Spacer
off.
3. Remove 4 screws Cto take the Projection Lens off.
Fig. 1
Projection Lens
Lens Spacer
2. INTEGRATOR LENS REMOVAL
1. Remove 2 screws and pull the Integrator Lens Ass’y
upward.
2. Remove the Stopper and bend four hooks and then
take the Lens off from the Holder.
Integrator Lens
Stopper
Lens Holder
Fig. 2
Integrator Lens Ass’y
Note:
Should be placed the lens as the rugged surface side
of it comes to the holder side.
A
A
B
A
B
C
Zoom Lever
Slit
Fig. 7-2
Note: Remove the lens spacer with fitting the
zoom lever of projection lens to the slit of
lens spacer.

Optical Parts Disassemblies
-16-
3. RELAY LENS REMOVAL
1. Remove 2 screws Aand pull the Relay Lens Ass’y
upward.
2. Remove 2 screws Bto take the Lens off from the
Holder.
Relay Lens
Relay Lens Ass’y
Fig. 3
A
B
AB
4. POLARIZED GLASS-IN REMOVAL
1. Remove each screw and pull the Polarized Glass-In
Ass’y upward.
2. Unhook the stoppers and take the glass off upward.
Polarized Glass Ass’y
Polarized
Glass-In
Phase Sheet
Hook
Note:
Should be placed the glass as the film attached side
come to the prism side.
Fig. 4
Polarized
Glass-In
Phase Sheet
Hook
Red & Green
Blue
R
G
B

-17-
Optical Parts Disassemblies
5. POLARIZED GLASS-OUT AND WIDE VIEW PLATE REMOVAL
1. Remove 4 screws Aand take the LCD Panel/Prism
Ass’y upward from the Optical Unit.
2. Remove the stopper and take the glass off upward.
LCD Panel/Prism Ass’y
Note:
1. Should be replaced the glass as the film attached
side comes to the LCD panel side.
Fig. 5
Polarized
Glass-Out Film
Note 1
A
A
AA
6. OPTICAL UNIT TOP REMOVAL
1. Remove Cabinet Top, Cabinet Front, Main Board, AV
Board and Filter Ass'y.
2. Remove 8 screws to take the Optical Unit Top off
upward.
Fig. 6
Stopper
Optical Unit
Top

Optical Parts Disassemblies
-18-
7. LOCATIONS IN OPTICAL UNIT
When mounting or assembling the optical parts in the optical unit, the parts must be mounted specified location as shown
in figure below.
6
1
2
3
4
5
7
8
9
10
11
11
12
13
15
14
16
17
18
Marking
Marking
Cut Face
Cut Face
1Lens (Condenser G)
2Lens (Condenser R)
3Prism Beam Splitter (PBS)
4Condenser Lens (Out)
5Condenser Lens (B)
6Relay Lens (In)
7Relay Lens (Out)
8Integrator Lens (In)
9Integrator Lens (Out)
10 Mirror (R)
11 Mirror (B)
12 Optical Filter (R, G)
13 Optical Filter (UV Cut)
14 Polarized Glass (IN/R)
15 Polarized Glass (IN/B)
16 Polarized Glass (IN/G)
17 Dichroic Mirror (G)
18 Dichroic Mirror (R)
Key No. Description

-19-
■LCD Panel/Prism Ass'y Replacement
1. LCD PANEL/PRISM ASS'Y REMOVAL
1. Remove Cabinet Top and Main Board.
2. Remove 4 screws by a 2.0mm hex wrench to take the
Panel/Prism Ass'y off from the Optical Unit.
Note: Do not replace the LCD panel separately other-
wise it can not obtain proper picture. Do not
touch the prism, the LCD panel and the elec-
trode of flexible cable.
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 adjustments.
- Check the “Condenser Lens Adjustment” and “Relay Lens Adjustment” following to chapter “Optical
Adjustment”.
- Check the “White Balance Adjustment” and “Common Center Adjustment” following to chapter
“Electrical Adjustment”.
- Check the white uniformity on the screen.
If you find the color shading, please adjust the white uniformity by using the proper computer and “Color
Shading Correction” software supplied separately. The software can be ordered as follows;
COLOR SHADING CORRECTION
Service Parts No. 645 075 9611
1. Tighten 4 screws by a 2.0mm hex wrench to fix the
Panel/Prism Ass'y to the Optical Unit.
2. LCD PANEL/PRISM ASS'Y ATTACHMENT
LCD
Panel/Prism
Ass'y

■Adjustments After Parts Replacement
-20-
● : Adjustment necessary ❍ : Check necessary
Contrast Adjustment
R-Contrast adjustment ❍●
G-Contrast adjustment ❍●
B-Contrast adjustment ❍●
Integrator Lens Adjustment ❍●
Relay Lens Adjustment ❍●
Fan Minimum Adjustment ●●
Signal Center Adjustment ●
Reference Adjustment ●
480p Offset Adjustment ●
PC Pedestal Adjustment ●
Sub Gain Adjustment ●
Common Center Adjustment ●●
Gamma Adjustment ●●
White Balance Adjustment ❍●
Disassembly / Replaced Parts
LCD/
Prism
Ass’y
Condenser
Lens
Polarized glass
RGB
Optical Adjustments
Electrical Adjustments
Main
Board
Relay
Lens
Power
Board
IC1371 on the main board stores the data for the ser-
vice adjustments, and should not be replaced except
for the case of defective device.
If replaced, it should be performed the re-adjustments
following to the “Electrical Adjustments”.
The data of lamp replacement monitor timer is stored
in the IC1371.
Please note that the lamp replace counter is reset
when the memory IC (IC1371) is replaced.
(Lamp replace counter can not be set to the previous
value.)
● Caution to memory IC replacement
When IC1371 is replaced with new one, the CPU
writes down the default data of the service adjust-
ments to the replaced IC, refer to the service adjust-
ment table. As these data are not the same data as
factory shipped data, it should be required to perform
the re-adjustments following to the “Electrical
Adjustments”.
Please note that in this case the lamp replace counter
will be reset.
● Caution of Main Board replacement (in the case
IC1371 is not defective)
When the main board is replaced, IC1371 should be
replaced with the one on previous main board. After
replacement, it should be required to perform the re-
adjustments following to the “Electrical Adjustments”.
In this case, the lamp replace counter can be kept the
value as before.
■MEMORY IC REPLACEMENT