Sanyo PLV-Z4000 User manual

FILE NO.
SERVICE MANUAL
REFERENCE NO. SM5111253-00
PRODUCT CODE :
1 122 447 20 U.S.A., Canada
1 122 447 24 Brazil
1 122 448 20 Asia, Africa
1 122 448 22 H.K.
1 122 448 23 Europe
Multimedia Projector
Chassis No. ME4-Z400000
NOTE: Match the Chassis No. on the rating
sheet on the cabinet with the Chassis
No. in the Service Manual.
If the Original Version Service
Man ual Chassis No. does not
match the unites, additional Service
Literature is required. You must refer
to “Notices” to the Original Service
Manual prior to servicing the unit.
MODEL NO. PLV-Z4000
U.S.A., Canada, Europe,
U.K. Asia, Africa, Brazil
Original Version

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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
Fuse............................................................................ 5
Thermal switch ........................................................... 5
Lamp cover switch...................................................... 6
Door switches for automatic slide shutter................... 6
Warning temperature and power failure protection .... 6
Maintenance and Cleaning............................................ 7
Cleaning the RGB panels .......................................... 8
Warning Indicator ..................................................... 10
Cleaning the Air Filters ............................................. 11
Resetting the Filter Counter...................................... 12
Cleaning the Projection Lens.................................... 12
Cleaning the Projector Cabinet................................. 12
Lamp Replacement ..................................................... 13
Lamp Replacement Counter..................................... 14
Service Port ................................................................. 16
Mechanical disassemblies........................................... 17
Optical disassemblies.................................................. 34
Adjustments................................................................. 44
Adjustments after Parts Replacement ...................... 44
Optical Adjustment ...................................................... 45
Electrical Adjustment ................................................... 47
Service Adjustment Menu Operation........................ 47
Circuit Adjustment .................................................... 48
Location of Test Points ............................................. 52
Service Adjustment Data Table ................................ 53
Chassis Block Diagram ............................................... 74
Chassis Overview ..................................................... 74
Video signal processing circuit and LCD panel driving
circuit ........................................................................ 75
System Controls ....................................................... 76
Fan control circuit ..................................................... 78
Fan and sensor location ........................................... 78
Power supply circuit and Protection circuit (1).......... 80
Power supply circuit and Protection circuit (2).......... 81
Motor driving circuit .................................................. 82
Troubleshooting........................................................... 85
Indicators and Projector Condition ........................... 85
No Power.................................................................. 86
No Picture................................................................. 88
Control Port Functions................................................. 90
Electrical Parts List...................................................... 92
Electrical Parts Location ........................................... 93
Mechanical Parts List ................................................ 116
Cabinet Parts Location ........................................... 116
Optical Parts Location ............................................ 118
Diagrams & Drawings..................................................A1
Parts description and reading in schematic diagram...A2
Schematic Diagrams ...................................................A3
Printed Wiring Board Diagrams...................................A9
Pin description of diode, transistor and IC.................A13
Note on Soldering......................................................A14

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WARNING:
The chassis of this projector is isolated (COLD) from AC line by using the converter transformer. Primary side of the con-
verter and lamp power supply unit circuit is connected to the AC line and it is hot, which hot circuit is identified with the
line ( ) in the schematic diagram. For continued product safety and protection of personnel injury, servicing
should be made with qualified personnel.
The following precautions must be observed.
SAFETY PRECAUTIONS
1: An isolation transformer should be connected in the
power line between the projector and the AC line
before any service is performed on the projector.
2: Comply with all caution and safety-related notes pro-
vided on the cabinet back, cabinet bottom, inside the
cabinet or on the chassis.
3: When replacing a chassis in the cabinet, always be
certain that all the protective devices are installed
properly, such as, control knobs, adjustment covers or
shields, barriers, etc.
DO NOT OPERATE THIS PROJECTOR WITHOUT THE PROTE
CTIVE SHIELD IN POSITION AND PROPERLY SECURED.
4: Before replacing the cabinet cover, thoroughly inspect
the inside of the cabinet to see that no stray parts or
tools have been left inside.
Before returning any projector to the customer, the serv-
ice personnel must be sure it is completely safe to oper-
ate 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 gener-
ates high voltages(15kV - 20kV) at its starts.
Since the lamp is very high temperature during units operation replacement of the lamp should be done at least 45
minutes after the power has been turned off, to allow the lamp cool-off.
PRODUCT SAFETY NOTICE
Product safety should be considered when a component replacement is made in any area of the projector. Components
indicated by mark in the parts list and the schematic diagram designate components in which safety can be of spe-
cial significance. It is, therefore, particularly recommended that the replacement of there parts must be made by exactly
the same parts.
Safety Instructions

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Technical Specifications
Specifications
●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.
Projector Type Multimedia Projector
Dimensions (W x H x D)
15.75” x 5.75”x 13.62” (400,0 mm x 146.0 mm x 346.0 mm) (not including raised portions)
Net Weight 16.5 lbs (7.5 kg)
LCD Panel System 0.74” wide TFT Active Matrix type, 3 panels
Panel Resolution 1920 x 1080 dots
Number of Pixels 6,220,800 (1920 x 1080 x 3 panels)
Color System PAL, SECAM, NTSC, NTSC4.43, PAL-M, and PAL-N
High Definition TV Signal 480i, 480p, 575i, 575p, 720p, 1080i, and 1080p
Scanning Frequency H-sync. 15 kHz – 80 kHz, V-sync. 50 Hz – 100 Hz
Projection Image size (Diagonal) Adjustable from 40”to 300”
Projection Lens F 2.0 – 3.05 lens with f 22.6 – 45.3 mm with manual zoom and focus
Throw Distance 3.9’– 60.4’ (1.2 m – 18.4 m)
Projection Lamp 165 W
Video Input Jacks 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)
Computer Input Terminal mini D-sub 15 pin x 1
HDMI Input Terminals HDMI terminal 19 pin x 2
Service Port Connector mini Din 8 pin x 1
Feet Adjustment 0˚ to 6.5˚
Voltage and AC 100 – 120 V (2.9 A Max. Ampere), 50/60 Hz (The U.S.A. and Canada)
Power Consumption AC 200 – 240 V (1.5 A Max. Ampere), 50/60 Hz (Continental Europe and The U.K.)
Operating Temperature 41˚F – 95˚F (5˚C – 35˚C)
Storage Temperature 14˚F – 140˚F (-10˚C – 60˚C)
Remote Control
Power Source : AA or LR6 1.5 V ALKALINE Type x 2
Operating Range : 16.4’ (5 m)/±30˚
Dimensions : 2.13” x 1.04” x 6.81” (54 mm x 26.3 mm x 173mm)
Net Weight : 3.4 oz (95.5 g) (not including batteries)

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Circuit Protections
This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the
projector, it will automatically turn off by operating one of the following protection circuits.
A fuse(F601) 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
Thermal switch
Fuse Part No. : 323 024 3209
TYPE T5.0AH 250V FUSE
LITTEL FUSE INC. TYPE 215005
How to replace the fuse
1. Remove the cabinet top following to "Mechanical
Disassemblies".
2. Remove the fuse from fuse holder on the Filter Board.
To install the fuse, take reversed step in the above.
There is the thermal switch (SW902) inside of the projector
to prevent the internal temperature rising abnormally.
When the internal temperature reaches near 100°C, the
thermal switch cuts off the drive signal to the lamp circuit
automatically. The thermal switch is not reset to normal
automatically, even if the internal temperature becomes
normal. Reset the thermal switch following procedure.
Check the resistance between terminals of thermal switch
by using a tester. If it has high impedance, thermal switch
may be open.
How to reset the thermal switch
1. Remove the Lamp cover following to "Mechanical
Disassemblies".
2. Press the reset button on the thermal switch with a
sharp-pointed tool.
CAUTION:
Before press the reset button, make sure that the AC cord
must be disconnected from the AC outlet.
Press
The switch(SW902) is
in the hole of cabinet.
Thermal switch (SW902)
Fuse (F601)

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Warning temperature and power failure protection
The projector will be automatically turned off when the internal temperature of the projector is abnormally high, or the
cooling fans stop spinning, or the power supplies in the projector are failed.
- If the WARNING indicator is flashing, it may detect the abnormal temperature inside the projector. Check the following
possible causes and wait until the WARNING indicator stops flashing, and then try to turn on the projector.
- If the WARNING indicator lights red, it may defect the cooling fans or power supply circuits. Check fans operation and
power supply lines referring to the chapter “Power supply & protection circuit” in the power Supply Lines section.
Possible causes
- Air filters are clogged with dust particles. Remove dust from the air filters.
- Ventilation slots of the projector are blocked. In such an event, reposition the projector so that ventilation slots are not
obstructed.
- Check if projector is used at higher temperature place (Normal operating temperature is 5 to 35˚C or 41 to 95˚F)
The lamp cover switch (SW8803) cuts off the drive signal
to the lamp circuit when the lamp cover is removed or not
closed completely.
After opening the lamp cover for replacing the lamp unit,
place the lamp cover correctly otherwise the projector can
not turn on.
The projector provides 2 door switches against an accident
of the automatic slide shutter.
The door switch-A(SW8801) turns ON when the slide
shutter is opened.
The door switch-B(SW8811) turns ON when the slide
shutter is closed.
If the slide shutter stops half-open after turning on, the
POWER indicator will blink orange and the projector goes
to stand-by mode after cooling. In this case, press the
POWER ON/STAND-BY button again.
If the slide shutter is closed during operation, the projector
is automatically turned off for safety.
In this case, be sure to check the position of the slide
shutter. After opening or closing the slide shutter
manually, press the POWER ON/STAND-BY button and the
projector turns on.
Door switches for automatic slide shutter
Slide shutter
Door switch-A
Door switch-B
Lamp cover switch
Circuit Protection
Lamp cover switch

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Maintenance and Cleaning
After long periods of use, dust and other particles will accumulate on the LCD panel, prism, mirror, polarized glass,
lens, etc., causing the picture to darken or color to blur. If this occurs, clean the inside of optical unit.
Remove dust and other particles using air spray. If dirt cannot be removed by air spray, disassemble and clean
the optical unit.
● Cleaning with air spray
1. Remove the cabinet top following to "Mechanical Disassemblies".
2. Clean up the LCD panel and polarized glass by using the air spray from the cabinet top opening.
Caution:
Use only the supplied air blower and nozzle to keep the projector from being out of oder or damaged. We could not guarantee
the malfunction or breakage caused by other tools.
Be vary careful not to damage optical parts with the nozzle tip. Never use any kind of cleanser on the unit. Also, never use
abrasive materials on the unit as this may cause irreparable damage.
● Disassembly Cleaning
Disassembly cleaning method should only be performed when the unit is considerable dirty and cannot be sufficiently
cleaned by air spraying alone.
Be sure to readjust the optical system after performing disassembly cleaning.
1. Remove the cabinet top and main units following to "Mechanical Disassemblies".
2. Remove the optical base top following to"Optical Unit Disassemblies". If the LCD panel needs cleaning, remove the LCD
panel unit following to "LCD panel/Prism ass'y replacement".
3. Clean the optical parts with a soft cloth. Clean extremely dirty areas using a cloth moistened with alcohol.
Caution:
The surface of the optical components consists of multiple dielectric layers with varying degrees of refraction.
Never use organic solvents (thinner, etc.) or any kind of cleanser on these components.
Since the LCD panel is equipped with an electronic circuit, never use any liquids (water, etc.) to clean the unit. Use of
liquid may cause the unit to malfunction.

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Cleaning the RGB panels
Blemishes such as dust and dirt on the internal optical components of the projector tend to degrade the brightness of
the screen and are likely to appear as a shadow on the screen, which can lead to deterioration of image quality.
This projector is equipped with the RGB panel cleaning holes on the bottom for cleaning of the internal parts (such
as optical components) of the projector. When you use the projector for a lengthy period of time or a shadow of dust
appears on the projected screen, clean the inside of the projector.
Using the supplied air blower and with the Cleaning function in the Setting Menu, you can remove the dusts from the
projector.
CAUTION IN USING THE AIR BLOWER AND THE NOZZLE
●Turn the projector over when using the blower.
●Use only the supplied air blower and nozzle to keep the projector from being out of oder or damaged. We
could not guarantee the malfunction or breakage caused by other tools.
● Never use a commercially available compressed air duster. It causes the interior of the projector to
malfunction with release of cold liquid propellant.
● Put the projector on a soft cloth to prevent scratching the surface.
●Open the hole cover only when you clean the inside of the projector.
●Do not look into the holes. A strong light could damage your eyes. (Do not look into the Air intake vent and
Exhaust vent, either.)
● Use the blower and nozzle only to clean the projector. Do not attempt to use them for other purposes. Do
not use the blower and nozzle against persons (particularly to eyes, mouth or ear, and so on). Be especially
careful to ensure that children do not put the blower and nozzle into their mouth and swallow them.
● Do not attempt to pull the nozzle out of the blower. If the nozzle happened to be pulled out, put it back
into the blower immediately.
● Do not use the blower supplied with this projector (model: Z700) to clean the other models: Z4, Z3, and
Z1X.
In the unlikely event that something goes wrong (smoke, a strange sound, an abnormal odor, and such) while you are
cleaning, turn off and unplug the projector immediately, then call the dealer where you purchased the projector or
service center.
✔Note:
• Dust might not be removed completely with these steps. In that case, contact the dealer where you purchased the
projector or service center.
If the nozzle is pulled out ....
The nozzle has the stopper. Put the stopper-side of the nozzle into the
blower. Put the nozzle firmly into the blower until the stopper becomes
invisible.
When putting the nozzle into the blower, hold near the stopper so that
it will not break.
Make sure not to attempt to pull the nozzle out of the blower.
Stopper
Hold near the stopper
of the nozzle.
BR
G
Put the nozzle in
until the stopper
becomes invisible.
Put this end of the
nozzle into the
blower.
CAUTION
PROHIBITED
Maintenance and Cleaning

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Turn the projector on and press the MENU button to display the
On-Screen Menu. Select the Setting Menu with the Point ed
buttons. Press the Point 8or OK buttons to access the submenu
items.
1
Put the blower’s nozzle into a hole.
2
Blow air into the projector with the blower watching the position
of the dust from the screen.
3
Set the projector back into the right position, then press any
button on the top control or on remote control to quit the
Cleaning function.
4
5
Clean by using the Cleaning function in the Setting Menu
Select Cleaning and then press the OK or Point 8buttons. The
screen is blacked out temporarily.
Turn the projector over. Put your finger on hole over's tab and
pull to open the hole cover.
When cleaning is done, pull the blower out of the hole and
replace the hole cover.
6
7
* Do not open the hole cover except when you clean the inside of the
projector to prevent foreign matters from getting into the projector.
If it is open especially while operating the projector, the optical parts
could damage.
Which hole to put the nozzle in?
When you look at the screen:
● When a red spot (dust) is showed up, put the nozzle into the R
panel cleaning holes.
● When a green spot (dust) is showed up, put the nozzle into
the G panel cleaning holes.
● When a blue spot (dust) is showed up, put the nozzle into the
B panel cleaning holes.
Wave the nozzle back and forth inside of the projector.
(Do not attempt to bend the nozzle.)
Use only the supplied blower and nozzle.
Do not use a commercially available compressed
air duster. It causes the interior of the projector to
malfunction with release of cold liquid propellant. We could
not guarantee the malfunction of breakage by using other
tools.
BR
G
BR
G
Green
Red
Blue
LCD Panel
LCD Panel
BOTTOM VIEW
Put your finger on the
hole cover’s tab and
pull.
The nozzle will go no
further than a certain
point when it is put
into the hole. Do not
attempt to push the
nozzle further in, or
it could break and be
stuck inside of the
projector.
Cleaning
Select Cleaning in the
Setting Menu.
Tab
Hole cover
Maintenance and Cleaning

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The WARNING indicator shows the state of the function that protects the projector. Check the state of the WARNING indicator and the
POWER indicator to take proper maintenance.
Warning Indicator
The projector is shut down and the WARNING indicator is blinking red.
When the temperature inside the projector reaches a certain level, the
projector is automatically shut down to protect its inside. The POWER
indicator is blinking while the projector is being cooled down. When
the projector has cooled down sufficiently (to its normal operating
temperature), it can be turned on again by pressing the POWER ON/
STAND-BY button.
✔Note:
• The WARNING indicator continues to blink even after the temperature
inside the projector returns to normal. When the projector is turned on
again, the WARNING indicator stops blinking.
Then check the items below.
– Did you provide appropriate space for the projector to be ventilated?
Check the installing condition to see if ventilation slots are not
blocked.
– Has the projector been installed near an Air-Conditioning/Heating
Duct or Vent? Move the installation of the projector away from the
duct or vent.
– Is the air filter clean? Clean the air filter periodically or replace it with a
new one.
The projector is shut down and the WARNING indicator lights red.
When the projector detects an abnormal condition, it is automatically
shut down to protect the inside of the projector and the WARNING
indicator lights red. In this case, unplug the AC power cord and plug
it, and then turn on the projector once again to verify operation. If the
projector cannot be turned on and the WARNING indicator lights red,
unplug the AC power cord and contact the service station.
CAUTION
DO NOT LEAVE PROJECTOR WITH AC POWER CORD
CONNECTED UNDER AN ABNORMAL CONDITION. IT MAY
RESULT IN FIRE OR ELECTRIC SHOCK.
WARNING
blinking red
TOP CONTROL
TOP CONTROL
WARNING
lights light
Maintenance and Cleaning

- 11 -
The air filters prevent dust from accumulating on the surface of the optical elements inside the projector. Should the air
filters become clogged with dust particles, it will reduce cooling fans’ effectiveness and may result in a buildup of internal
heat and adversely affect the life of the projector. Clean the air filters by following the steps below.
CAUTION
Do not operate the projector with the air filters removed. Dust
may accumulate on the LCD panel degrading the picture
quality of the projection mirror. Do not put anything into the air
intake vents. It may result in malfunction of the projector.
Cleaning the Air Filters
RECOMMENDATION
We recommend avoiding dusty/smoky environments when operating
the projector. Usage in these environment may cause a poor image
quality.
When using the projector under dusty or smoky conditions, dust
may accumulate on a lens, LCD panels, or optical elements inside the
projector degrading the quality of a projected image.
When the symptoms above are noticed, contact your authorized dealer
or service station for proper cleaning.
Press the latch and release it. Take off the filter cover.
1
Remove dust and dirt with a soft brush or a vacuum cleaner. Be
careful not to damage the air filter and do not clean it with water.
When the air filter gets dusty and dirty, replace it with a new one.
For ordering the replacement filter, contact your sales dealer.
3
Put the air filter back into the position. Do not push the delicate
filter part. Make sure that the air filter is properly and fully
inserted.
4
Pull out the air filter.
When taking out the air filter, put your fingers on the air filter’s
tabs and pull. Do not try to pull the delicate filter part.
2
Reset the filter counter .
5
Latch
Press the latch and take
off the filter covers.
Tab
Tab
Filter cover
Air filter
When putting back the air
filter, make sure that the
arrows on the filter are facing
towards the projector.
Close the filter cover.
6
Groove
Arrows
Push here when
you are putting
back the air filter.
Maintenance and Cleaning

- 12 -
Unplug the AC power cord before cleaning.
Gently wipe the projection lens with a cleaning cloth that contains
a small amount of non-abrasive camera lens cleaner, or use a lens
cleaning paper or a commercially available air blower to clean the
lens. Avoid using an excessive amount of cleaner. Abrasive cleaners,
solvents, or other harsh chemicals might scratch the surface of the
lens.
When the projector is not in use, make sure that the automatic slide
shutter is closed.
Cleaning the Projection Lens
Cleaning the Projector Cabinet
Unplug the AC power cord before cleaning.
Gently wipe the projector body with a dry soft cloth. When the
cabinet is heavily soiled, apply a small amount of mild detergent
and finish with a dry soft cloth. Avoid using an excessive amount of
cleaner. Abrasive cleaners, solvents, or other harsh chemicals might
scratch the surface of the cabinet.
When the projector is not in use, put it in an appropriate carrying case
to protect it from dust and scratches.
Be sure to reset the Filter counter after cleaning or replacing the air filter.
Resetting the Filter Counter
Filter counter
Turn the projector on and press the MENU button to display the
On-Screen Menu. Select the Setting Menu with the Point ed
buttons. Press the Point 8or OK buttons to access the submenu
items.
Select Filter counter and then use the Point 8 button to select
[Reset] and press the OK button.“Filter counter reset?”appears.
Select [Yes] and then press the OK button.
1
2
Another confirmation dialog box appears, and select [Yes] to
reset the Filter counter.
3
✔Note:
• Do not reset the Filter counter without cleaning or replacing the air filter. Be
sure to reset the Filter counter only after cleaning or replacing the air filter.
Select Filter counter and
use the Point 8 button to
select [Reset] and press the
OK button. “Filter counter
reset?” appears.
Select [Yes] and press
the OK button, then
another confirmation
box appears.
Select [Yes] again to reset
the lamp counter.
Maintenance and Cleaning

- 13 -
Lamp Replacement
When the projection lamp of this projector reaches its end of life,
the LAMP REPLACE indicator emits yellow light. If this indicator
lights yellow, replace the lamp with a new one promptly.
The time when the LAMP REPLACE indicator should light is
depending on the lamp mode.
Top Control
This indicator lights yellow
when the projection lamp
reaches its end of life.
For continued safety, replace the lamp with the same type
lamp. Do not drop the lamp or touch the glass bulb! The
glass can shatter and may cause injury.
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.
CAUTION
CAUTION
Follow these steps to replace the lamp.
Lamp
Lamp Cover
Screw
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. Pull out the lamp
by using the built in handle.
1
3
Replace the lamp with a new one and secure it with the two (2)
screws. Make sure that the lamp is set properly. Put the lamp
cover back and secure it with the screw.
4
Loosen the screw that secures the lamp cover, and then open the
lamp cover.
2
Connect the AC power cord to the projector and turn on the
projector.
6Reset the Lamp replacement counter.
5Handle
Screws
ORDER REPLACEMENT LAMP
Replacement lamp can be ordered through your dealer. When ordering a projection lamp, give the following information to the
dealer.
● Model No. of your projector: PLV-4000
●Replacement Lamp Type No.: POA-LMP135
(Service Parts No. 610 344 5120)

- 14 -
This projector uses a high-pressure lamp which must be handled carefully and properly. Improper handling may result in
accidents, injury, or create a fire hazard.
●Lamp lifetime may differ from lamp to lamp and according to the environment of use. There is no guarantee of the same
lifetime for each lamp. Some lamps may fail or terminate their lifetime in a shorter period of time than other similar lamps.
●If the projector indicates that the lamp should be replaced, i.e., if the LAMP REPLACE indicator lights up, replace the lamp
with a new one IMMEDIATELY after the projector has cooled down.
(Follow carefully the instructions in the Lamp Replacement section of this manual.) Continuous use of the lamp with the
LAMP REPLACE indicator lighted may increase the risk of lamp explosion.
●A Lamp may explode as a result of vibration, shock or degradation as a result of hours of use as its lifetime draws to an end.
Risk of explosion may differ according to the environment or conditions in which the projector and lamp are being used.
IF A LAMP EXPLODES, THE FOLLOWING SAFETY PRECAUTIONS SHOULD BE TAKEN.
If a lamp explodes, disconnect the projector’s AC plug from the AC outlet immediately. Contact an authorized service station
for a checkup of the unit and replacement of the lamp. Additionally, check carefully to ensure that there are no broken shards
or pieces of glass around the projector or coming out from the cooling air circulation holes. Any broken shards found should
be cleaned up carefully. No one should check the inside of the projector except those who are authorized trained technicians
and who are familiar with projector service. Inappropriate attempts to service the unit by anyone, especially those who are
not appropriately trained to do so, may result in an accident or injury caused by pieces of broken glass.
LAMP HANDLING PRECAUTIONS
Be sure to reset the lamp replacement counter after the lamp is replaced. When the lamp replacement counter is reset, the LAMP
REPLACE indicator stops lighting.
Lamp Replacement Counter
Turn the projector on and press the MENU button to display the
On-Screen Menu. Select the Setting Menu with the Point ed
buttons. Press the Point 8or OK buttons to access the submenu
items.
Select Lamp counter reset and then press the OK or Point 8
buttons.“Lamp replacement counter reset?” appears. Select [Yes]
and then press the OK button.
1
2
Another confirmation dialog box appears, and select [Yes] to
reset the Lamp replacement counter.
3
✔Note:
• Do not reset the Lamp replacement counter without implementing lamp
replacement. Be sure to reset the Lamp replacement counter only after
replacing the lamp.
Lamp counter reset
Select Lamp counter reset
and press the OK or Point 8
buttons.“Lamp replacement
counter reset?” appears.
Select [Yes] and press
the OK button, then
another confirmation
box appears.
Select [Yes] again to reset
the lamp counter.
Lamp Replacement

- 15 -
Lamp Replacement
The LAMP REPLACE indicator will light when the total
lamp used time reaches 3,000 hours. This is to indicate
that lamp replacement is required.
The total lamp used time is calculated by using the below
expression;
Total lamp used time = Teco + Tnormal x (1.5)
Teco: used time in Eco mode
Tnormal: used time in Normal/Auto1/Auto2 mode
You can check the lamp counter following procedure.
1Press and hold the POWER ON/STAND-BY button on
the projector or the remote control unit for more than
20 seconds.
2The projector used time and lamp used time will be dis-
played on the screen briefly.
You can also check "Lamp Time" in the "Information
Menu". This value is actual lamp used time.
"Lamp Time" = Teco + Tnormal
How to check lamp used time
Counter
Projector 475H
Lamp
Normal 100H
Eco 375H
Corresponding value 525H
Total lamp used time
Information Menu
Lamp Counter Display Projector used time
Total lamp used time (actual)
475

- 16 -
The service port is factory default set "OFF".
When the service port is used, the item of the service port of the setting menu is changed to "ON".
(The service port cannot be used in the state of "OFF". )
Change to "OFF" after servicing ends.
(Power consumption when standing by increases in the state of "ON". )
Filter counter Reset
Service port Off
Service Port
Service Port
Switch of standby mode
Service port "O" : Super standby mode
Service port "On" : Normal standby mode

- 17 -
Mechanical disassemblies
1Cabinet top ass'y removal.
Disassemble should be made following procedures in numerical order.
Following steps show the basic procedures, therefore unnecessary step may be
ignored.
Caution:
The parts and screws should be placed exactly the same position as the original other-
wise it may cause lose of performance and product safety.
The wiring method of the leads and ferrite cores should be returned exactly the same
state as the original, otherwise it may cause lose of performance and product safety.
Screws Expression
(Type Diameter x Length ) mm
T type M Type
Tapping screw Machine screw
1. Remove the 3 screws-A(M3x10) from the bottom side.
2. Remove the 3 screws-B(M3x8) and remove the Cabinet top ass'y.
3. Remove the 3 screws-C(T2.6x6), remove the Button and DEC. LED.
A
A
A
BB
B
Cabinet top assy
Cabinet top assy
Cabinet top
DEC. LED
Button
C
C
C

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Mechanical disassemblies
2Lamp cover ass'y removal.
1. Loosen the screw-A and remove the Lamp cover ass'y.
A
Lamp cover ass'y
3Filter removal.
1. Remove the Filter cover and Filter.
Filter cover
Filter

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Mechanical disassemblies
4AV panel removal.
1. Remove the 2 screws-A(M3x8), remove the screw-B(T3x8) and remove the AV panel.
B
AAV panel
A
5Main PWB shield plata(top) removal.
1. Remove the 2 screws-C(M3x6) and remove the Shield plate (Main board-front) .
2. Remove the 9 screws-A(M3x6), remove the screw-B(M3x10) and remove the Shield plate
(Main board-top) .
Shield plate
(Main board top)
A
B
A
AA
A
AA
A
A
C
CShield plate
(Main board front)

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Mechanical disassemblies
6Main PWB removal.
1. Remove the 3 screws-A (M3x6), remove the Main board and remove 1 screw-B(T3x8) and the Shield
plate (Main board-BTM).
2. Remove the screw-C (T3x8), remove the Filter Net board and remove the Main board holder.
Shield plate
(Main board BTM)
Main board
Caution;
Be carefull do not damage the
connector
Heat sink sheet (IC4401)
Caoution;
Do not lose the heat sink sheet.
A
AA
C
Heat sink sheet (IC5201)
Heat sink sheet (IC301)
Filter Net board
Main board holder
7-1Cover lens top removal.
1. Remove the screw-A (M3x6), 2 screwS-B (T3x8) and remove the
Shield plate (Cover lens).
A
B
B
Shield plate
(Cover Lens)
B