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Copyright Notice
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,
without the written permission of Epson America, Inc.
Copyright 2005 Epson America, Inc.
3840 Kilroy Airport Way
Long Beach, CA 90806-2469
Trademark Information
EPSON, Epson PowerLite, and ESC/P are registered trademarks of SEIKO EPSON CORPORATION.
Epson Connection is a service mark of Epson America, Inc.
General Notice: Other product names used herein are for identification purposes only and may be
trademarks of their respective companies. EPSON disclaims any and all rights in those marks.
Warning
The connection of a non-shielded equipment interface cable to this equipment will invalidate the FCC
Certification of this device and may cause interference levels that exceed the limits established by the FCC
for this equipment. It is the responsibility of the user to obtain and use a shielded equipment interface cable
with this device. If this equipment has more than one interface connector, do not leave cables connected to
unused interfaces.
Changes or modifications not expressly approved by the manufacturer could void the users authority to
operate the equipment.
Preface
ii
Copyright Notice
Precautions
Precautionary notations throughout the text are categorized relative to personal injury (WARNING), and
damage to equipment (CAUTION).
W A R N IN G
C A U T IO N
General Precautions
The precautionary measures itemized below should always be observed when performing repair and
maintenance on this product.
W A R N IN G
Preface
Always disconnect the product from the power source and any peripheral
devices before performing any maintenance or repair procedures.
No work should be performed on the unit by persons unfamiliar with basic
safety measures as dictated for all electronics technicians in their line of work.
When performing testing as dictated within this manual, do not connect the
unit to a power source until instructed to do so. When the power supply cable
must be connected, use extreme caution in working on power supply and
other electronic components.
When disassembling or assembling a product, make sure to wear gloves to
avoid injury from metal parts with sharp edges.
iii
Precautions
C A U T IO N
Preface
iv
Preface
Service memo
Make notes of important technical information from Support Bulletins. For the latest Support Bulletins, go
to www.epsonsinsider.com.
Preface
vi
Table of Contents
Chapter 3 Troubleshooting
Before Troubleshooting...........................................................................................................42
Troubleshooting Tools and Equipment .............................................................................42
Field Replacement Parts ...................................................................................................42
Safety Instructions...................................................................................................................43
Maintaining Operator Safety .............................................................................................43
Maintaining the Projector in Good Condition.....................................................................43
Safety Testing ...................................................................................................................44
Requirements for Service Technicians .............................................................................46
Start-up Sequence Troubleshooting .......................................................................................47
Detailed Troubleshooting ........................................................................................................50
Exterior Examination .........................................................................................................50
Image Display and Quality ................................................................................................52
Audio Output .....................................................................................................................53
Control Panel ....................................................................................................................53
Remote Control Operation ................................................................................................54
Internal Cable Check.........................................................................................................55
Miscellaneous ...................................................................................................................56
Chapter 4
Disassembly / Assembly
Overview .................................................................................................................................58
Precautions .......................................................................................................................58
Tools and Equipment ........................................................................................................60
Projector-Specific Service Precautions .............................................................................60
Projector Disassembly and Assembly.....................................................................................62
Removing the Lens Cap Unit ............................................................................................63
Removing the Lamp Inner Unit .........................................................................................64
Removing the Air Filter......................................................................................................65
Removing the Foot Units...................................................................................................65
Removing the Remote Control Holder ..............................................................................66
Removing the Upper Case................................................................................................67
Removing the Speaker......................................................................................................69
Removing the Switch (SW) Board Assembly ....................................................................71
Removing the Lamp Shield Plate......................................................................................72
Removing the Main (MA) Shield Plate ..............................................................................73
Removing the Main (MA) Board, IF Panel and IF Label ...................................................73
Removing the Main Board Fixing Plate.............................................................................77
Removing the IF Board Assembly.....................................................................................78
Removing the Exhaust Fan Assembly ..............................................................................79
Disassembling the Exhaust Fan Assy...............................................................................80
Removing the RC Board Assembly...................................................................................81
Left MA Frame, Lower Shield Plate Removal ...................................................................82
Removing the Power Supply / Ballast Assembly ..............................................................82
Table of Contents
vii
Table of Contents
viii
Chapter 3 Troubleshooting
If you have replaced parts or components as part of a repair procedure, always be sure to re-check
whether any parts previously replaced are themselves operating correctly. Determine whether the problem is the result of a malfunctioning replacement part, an incorrectly installed part, or a loose cable.
Follow all troubleshooting instructions and procedures as written.
Follow the procedures given in Chapter 4 - Disassembly and Assembly - when replacing any projector
parts or components.
If you find problems when checking the operation of the projector, always check the external cable connections before proceeding to other checks. After the projector has been unplugged and cooled, check
the internal cable connections.
In order to confirm proper operation, use AC power from a known, clean source and use a power cable
in good condition.
Quantity.
Application
Projection screen
Tape measure (10 ft.)
Host computer
Video equipment
Multimeter
External speaker
Heat-resistant tape
General tools
1
1
1
1
1
1
1 foot
1 set
Projecting images
Measuring projection distances
Transmitting audio and image data
Transmitting audio and image data
Measuring resistance values and voltages (AC/DC)
Testing audio output (with audio cable connector)
Attaching parts
Tools and equipment listed in Chapter 4 Section 4.1.
C H E C K
P O IN T
The Optical Engine and MA Board are configured and adjusted together at the
factory. They are only available as a matched pair, and must always be replaced
together when either the Optical Engine or MA Board has a failure.
Many of the components that comprise a service unit have each been adjusted
in relation to each other. Therefore, when replacing parts during troubleshooting
or repair, do not disassemble service units in order to harvest and use
constituent components. This is especially critical for the components in the
optical engine (Light Guide Unit, Prism Unit and Light Valves) and the MA
Board.
Perform safety tests after replacing any parts. See Section 3.2.3 on page 44.
Troubleshooting
42
Before Troubleshooting
Turn off the power switch and disconnect the power cord from the AC outlet before performing any disassembly and assembly work on this projector.
If power needs to be supplied to the projector while the cover is removed (such as when making adjustments), remove all metallic objects such as wristwatches, shirt cuff buttons, rings and tie pins which
may pose the danger of coming into contact with the projector.
Prevent Injury
Projector components such as the Lamp Inner Housing and the area around it will remain hot after the
power has been turned off, even when the cool-down period is compete.
If removing the cover in order to carry out procedures while power is being supplied to the projector, be
careful not to touch the intake and exhaust fans.
Always wear gloves when disassembling and reassembling the projector in order to avoid injury from
metallic parts with sharp edges.
Do not look directly into the projector's lens while power is being supplied to the projector, otherwise
injury to the eyes may occur.
Prevent Accidents
Place the projector on a stable, level surface when carrying out any repair or adjustment work. Do not
place any tools or projector components on top of or underneath the projector.
Always use the supplied Epson power cord to connect the projector to an AC outlet, and make sure that
the AC outlet is properly grounded.
Troubleshooting
43
Safety Instructions
Ground terminal
Line terminal
Display
7.
8.
9.
Projector AC inlet
Measure Switch
Power supply
lines
Range Selection
Switch
(1)
(2)
Exposed metal
on the projector
c
VGA (Computer) connector
Troubleshooting
44
Safety Instructions
Locked
Unlocked
Release the connector locks before you disconnect the three light valve cables from their connectors.
Locked
Troubleshooting
connector lock
Unlocked
45
Safety Instructions
Troubleshooting
46
Safety Instructions
Always check the Epson Insider web site for the latest Support Bulletins for this
product. Support Bulletins provide up-to-date supplemental information on how to
troubleshoot and repair the product. Go to http://www.epsoninsider.com.
The following troubleshooting steps can be used with most Epson video projectors:
1. Plug the projector into AC power and listen for the power supply fan.
1.1 The power supply fan runs constantly while the projector is plugged into a live AC outlet. If the
fan can be heard running, then the power supply in the projector is probably working properly
(with very few exceptions).
1.2
If the fan does not begin to run when the projector is plugged in, check and replace the Power
Supply. See Section 4.2.18 on page 82.
Immediately after plugging the projector into AC power, the P Power Status indicator LED will
briefly flash in an amber color, then will turn solid (constant) amber. Once the P Power Status
LED is solid amber, the projector has checked main board functions and loaded its basic
instruction set from ROM. In general, the main board is functional at this point and is not likely to
be a cause of failure in the projector.
2.2
If the Fan is running but the P Power Status LED does not light or does not stop flashing, the MA
Board and Optical Engine need to be replaced. See Section 4.2.11 on page 73 and Section
4.2.21 on page 88.
2.3
Once the Power Status LED is amber and not blinking, the projector is in sleep mode - it has
performed power on diagnostics. The projector is ready to be powered on with the [Power] button
on the remote control or the control panel of the projector. This will activate the power-on
sequence from the ROM instructions.
3. Press the [Power] button and listen for intake and exhaust fans. The intake and exhaust fans start operating in high speed mode as soon as a power on request is made. This means the power on process has
started properly.
4. Observe the P Power Status indicator. If the power status indicator is blinking green, the projector is
warming up and trying to strike the lamp.
4.1 If the projector can be switched on with the Control Panel, but not the Remote Control, the
Remote Control batteries need to be replaced.
4.2
Conversely, if the Remote Control powers on the projector, but the Control Panel does not, there
is a problem with the Control Panel on the main unit. Try reconnecting the SW (Switch) Cable, or
replace the SW Board Assembly. See Section 4.2.8 on page 71.
4.3
If the Fans do not pick up speed when power is turned on, there is either a malfunction of one or
more fans, or a malfunction of the MA Board.
Observe the Status LEDs. A properly functioning MA Board can indicate a fan error on the Status
LEDs: the mo Lamp Temperature indicator LED will flash red at 1 second intervals, and the P
Power Status indicator will remain solid amber. If a fan error is indicated, check or replace the
fans. See Section 4.2.14 on page 79, Section 4.2.20 on page 86 and Section 4.2.24 on page 91.
4.4
If the fans are slow and no error is indicated by the LEDs, replace the MA Board and Optical
Engine.
Troubleshooting
47
5. Watch for light output. If there is no light output after approximately 40 seconds, observe
the mo Lamp Temperature indicator. See the table below for error indication definitions
and take the appropriate remedial steps in the order provided.
Table 3-2. Power and Lamp Temperature Status LED
Indicator Status
Flashing orange
Flashing orange
Lit orange
Flashing red
(0.5 second interval)
Lit orange
Flashing red
(1 second interval)
Lit orange
Projector Status
High-speed
cooling in
progress
Lamp problem
Fan problem,
Sensor problem,
or other internal
problem
High temperature
problem
Operating
normally.
Lit red
All extinguished
Check the Lamp Cover and Lamp Cover Switch. If the Lamp is broken, replace it. If
it is not broken, reinstall it.
6.2
If the Lamp Cover Switch is broken, replace it. See Section 4.2.26 on page 93.
7. If the mo Lamp Temperature Indicator is lit solid red, then there is a lamp failure, lamp
switch error (Lamp Cover Switch, Lamp Thermistor), or Ballast failure. Check and replace
those components.
7.1 See Chapter 2, Section 2.9.1 on page 35 for an overview of the switches and their
locations.
7.2
For Lamp Thermistor removal, see Section 4.2.15 on page 80. For Lamp Cover
Switch removal, see Section 4.2.26 on page 93.
Troubleshooting
48
7.3
To replace the Ballast, see Section 4.2.18 on page 82 and Section 4.2.19 on page 84.
8. If there is light output, look for video output. If there is no video output, check the video source selection on the projector, the cables connected to the video source and the video source itself.
8.1 If the wrong video source is selected on the projector, change it to the correct input selection.
8.2
If there still is no video output, test the video source by connecting it to another output device. If
there is a problem with the video source, no output will be seen on any display device regardless
of cables or settings used.
8.3
If there is a problem with the cable, the video source should fail with all display devices that use
that cable type.
8.4
If the video source works with another display device there is a problem with the video input
ports of the projector. Check and replace the I/F Board (Section 4.2.13 on page 78), and if there is
still no video output, replace the MA Board and Optical Engine (Section 4.2.11 on page 73 and
Section 4.2.21 on page 88).
Troubleshooting
49
Troubleshooting Area
Quick Check
Exterior Examination
Audio Output
Control Panel
Remote Control Oper- Test the operation of each button on the remote control.
ation
Internal Cable Check Remove the upper case and check the cable connections
on the MA board. Reconnect any loose cables.
Miscellaneous
Troubleshooting suggestions for abnormal noise, overheating, abnormal odor or smoke, and the Power Supply.
Section 3.4.1 on
page 50.
Section 3.4.2 on
page 52.
Section 3.4.3 on
page 53
Section 3.4.4 on
page 53
Section 3.4.5 on
page 54
Section 3.4.6 on
page 55
Section 3.4.7 on
page 56
The Upper Case should be installed correctly. To reinstall it, see Section 4.2.6 on page 67.
1.3
The remote signal receivers should be clean and free from tape, etc.
1.4
Troubleshooting
50
Detailed Troubleshooting
2. Control Panel
2.1
4. IF Panel
4.1 The Remote Control IR signal receiver should be clean and free of foreign materials such as tape.
4.2
There should be no damage, deformation or cracking due to external force. To replace it, see
Section 4.2.11 on page 73.
5. Lower Case
5.1 There should be no damage, deformation or cracking due to external force. Replacing the lower
case requires nearly complete disassembly. Start with Section 4.2 on page 62.
6. Air Filter
6.1 The Air Filter should be installed correctly.
6.2
Remove the Air Filter from the lower case to check that it is clean. Replace it if necessary. See
Section 4.2.3 on page 65.
Lamp Cover Detection Switch latch should be free from damage. Remove the lamp cover to
check. To replace or reinstall the Lamp Cover Detection Switch, see Section 4.2.26 on page 93.
The cable from the Lamp Inner Unit to the Ballast should be free from discoloration. To replace
the Lamp Inner Unit, see Section 4.2.2 on page 64. To replace the Ballast, see Section 4.2.18 on
page 82 and Section 4.2.19 on page 84.
8.3
The glass surface of the Lamp should be clean. Clean the Lamp with isopropyl alcohol to remove
contaminants such as fingerprints.
51
Detailed Troubleshooting
1. Press the [Power] button and wait approximately 40 seconds for an image to appear. NO SIGNAL
should appear in the bottom left of the screen.
1.1 If the lamp does not turn on, replace the Lamp Inner Unit. See Section 4.2.2 on page 64.
1.2
If the lamp will still not turn on, check the Lamp Thermistor, and if necessary, replace it. See
Section 4.2.15 on page 80.
1.3
If the lamp still does not light, try replacing the following in this order:
Ballast
Power Supply
MA Board and Optical Engine
2. With the lamp lit and nothing connected to the input connectors, the projector should display the words
NO SIGNAL on the screen.
2.1 If not, replace the MA Board and Optical Engine.
3. If the image appears, but is poor quality, do the following in the order below:
3.1 Adjust the height of the Front Foot.
3.2
3.3
3.4
3.5
If the image cannot be corrected using the above, replace the Optical Engine and MA Board.
4. Next, test the computer and video inputs. Connect a host computer to the Computer/Component Video
connectors and look for an image to be displayed. (Some computers, especially laptops, may require
activation of an external or secondary video output - usually by pressing a function-key combination.)
4.1 Press the [Source] button to change the display to Computer.
4.2
If there is no image on the screen, disconnect the video cable from the projector and connect the
cable to another display device, such as a monitor, to verify that the problem is not with the
source computer.
4.3 If the image displays on the monitor, but will not display on the projector, reconnect the projector
to the computer and replace the following in the order below, checking for a projected image at
each stage:
Computer video cable
I/F Board
MA Board and Optical Engine
5. Check the image quality. If it needs improving, and youve made all the adjustments in 3.1 through 3.4
above, take the following steps:
5.1 Press the [Auto] button.
5.2
Press the [Menu] button, and select the Video menu. From the Video menu, adjust the Brightness
and Contrast.
Troubleshooting
52
Detailed Troubleshooting
5.3
If the image quality still cannot be improved, replace the Optical Engine and MA Board.
6. Test the Video and S-Video by connecting a video source to each, and repeat all steps in 4 and 5 for
each.
7. Test the Monitor Out function. Connect a monitor to the Monitor Out connector on the projector.
7.1 If the projected image is not displayed on the monitor, replace the following in the order below,
checking the results at each step:
Replace the monitor cable
Replace the monitor
Replace the projectors IF Board
Replace the MA Board and Optical Engine
If there is no sound, first check that the [AV Mute] button is not muting the sound, and that the
volume is not turned completely down.
1.2
If there is still no sound, connect another speaker device, such as headphones or external
speakers, to the host computer audio to verify that the fault is not with the source computer
1.3
If the projectors speaker appears to be at fault, open the upper case and reconnect the speaker
cable to CN1701 on the MA Board. See Figure 3-1 on page 55 for a diagram of connectors on the
MA Board.
1.4
If reconnecting the cable does not solve the problem, replace the speaker.
1.5
1.6
2. Once the speaker is working, test the volume adjustment, tone adjustment and [AV Mute] function correctly. If not, replace the following in the order below, checking the results at each step:
IF Board
MA Board and Optical Engine
3. Repeat steps 1 and 2 for Video and S-Video source equipment. Remember to independently verify the
functionality of the source equipment by connecting it to other display devices capable of sound output.
Also remember to press the [Source] button on the projector to select the appropriate test source.
4. Connect external speakers to the projectors audio output connector. If no sound is output, replace the
IF Board.
1.2
The [Menu] button should cause the menu to be displayed by the projector.
1.3
The [Source] button should switch between Computer/Component Video, S-Video and Video input
sources.
Troubleshooting
53
Detailed Troubleshooting
1.4
The [Esc] button should, depending on where you are in a menu, either cancel the current
function, or return one level up to the previous menu much like a back key.
1.5
1.6
The [Keystone] buttons should adjust the image vertical display angle distortion.
2. If any of these keys fail to work, check and replace the following in the order below, checking functionality at each stage:
2.1 Reconnect the SW Board Cable to CN400 on the MA Board. Remember that CN400 is a locking
connector, and be sure that it is seated firmly in the connector before re-locking it. Check that the
other end of the cable is connected properly to the SW Board (Control Panel). See Section
4.2.8 on page 71.
2.2
2.3
Check that the Remote Control is being operated with a clear line-of-sight to the projector, and
within the specified range of 20 ft. Test both front and rear IR sensors on the projector.
1.3
Check whether functionality returns if the Remote Control is operated very close to the projector.
1.4
Replace the batteries in the Remote Control and repeat steps 1.2 and 1.3.
1.5
Replace the Remote Control and recheck. Check the remote control with another projector to
verify that it operates normally.
1.6
Test whether there is any difference in functionality between the Front IR sensor and the Rear IR
sensor. Check the cable connections for each. If the cable connections appear to be OK, replace
the sensors:
The Front IR sensor is on the RC Board, connected by cable to CN603 on the MA Board. See
Section 4.2.16 on page 81.
The Rear IR sensor is on the IF Board Assembly, which is connected by cable to CN600 on the
MA Board. Connector CN600 is on the underside of the MA Board, so removal of the MA Board
will be necessary to check the connection or replace the IF Board Assembly. See Section
4.2.11 on page 73 through Section 4.2.13 on page 78.
2. If the above repairs do not solve the problem, replace the MA Board and Optical Engine.
Troubleshooting
54
Detailed Troubleshooting
Turn off the power and disconnect the power cable before you begin the following
connector checks.
CN1600
CN1701
CN603
CN1400
CN704
CN1500
CN601
CN702
CN701
CN1800
CN400
CN602
CN600
(Underneath)
Connects to:
CN600
CN400
CN702
CN1500
CN1600
CN1701
CN603
Troubleshooting
55
MA Board
connector
Connects to:
CN1400
CN704
CN601
CN701
CN1800
CN602
Detailed Troubleshooting
3.4.7 Miscellaneous
1. Abnormal noise
1.1 Check for foreign objects around the Exhaust Fan, Intake Fan and Power Supply Fan.
1.2
Check whether the noise is being generated by the Power Supply (e.g. pulse transformer
vibration, etc.) or Ballast, and replace them if necessary.
2. Projector overheating
2.1 Check and replace the Air Filter.
2.2
Check the Exhaust Fan, Intake Fan and Power Supply Fan. Clean or replace as necessary.
2.1
2.2
If none of the above fix the overheating problem, replace the Optical Engine and MA Board.
Check cables for charring or discoloration. First, correct the cause of the overheating problem,
and then replace all discolored or damaged cables.
3.2
Burning dust causes abnormal odors, so be sure the air filter is clean and undamaged, and make
sure the Intake Duct is clean. Check for excessive heat.
If the cause is judged to be an internal problem, replace the power supply unit. If the newlyreplaced power supply unit also has a problem and the symptoms are the same as before, then the
cause of the problem is probably some external factor. Eliminate the external factor that is
causing the problem.
4.3
If the power supply unit is recoverable but is not working properly, for example if high
temperatures are causing the thermostat to shut down the power supply, or if the overcurrent
protection circuit has tripped, then there is no need to replace the power supply unit.
4.4
If the power supply unit is not recoverable and is not working properly, for example if an
overcurrent has repeatedly blown the fuse, replace the power supply unit.
4.5
If there is a problem with the power supply fan, the power supply will shut down after several
minutes of operation, and the LED indicators will switch off. If that happens, replace the power
supply unit.
Troubleshooting
56
Detailed Troubleshooting
CHAPTER 4
DISASSEMBLY / ASSEMBLY
4.1 Overview
This chapter describes the procedures for disassembling and assembling the main components of the
PowerLite S1/S1+ projector. Unless otherwise specified, reassembly is the reverse of the disassembly
procedure. Read the precautions described in the next section before starting.
4.1.1 Precautions
Some procedures require specific precautions that must be followed, and those will be noted throughout
this chapter. Note the following precaution definitions:
WARNING
W A R N IN G
Procedures which, if not strictly observed, could result in personal injury are
described under the heading WARNING.
CAUTION
C A U T IO N
CAUTION
REASSEMBLY
If assembly needs special attention or the procedure is different from the reversed
disassembly procedure, the correct procedure is described under the heading
REASSEMBLY.
CHECK POINT
C H E C K
P O IN T
Important tips for procedures are described under the heading CHECK POINT.
The precautions in the two lists below, WARNING and CAUTION, must always be followed during
disassembly and assembly. Before starting the disassembly work on this product, read and follow these
precautions.
Disassembly / Assembly
58
Precautions
W A R N IN G
C A U T IO N
Disassembly / Assembly
59
Precautions
Application
The Optical Engine and Main (MA) Board are paired together as a single service
part. Neither is available separately. For service that requires the replacement of
either the MA Board or the Optical Engine, both components must be replaced
together.
The component parts of the Optical Engine require mechanical installation
positions to be adjusted in relation to each other. In addition, the control circuit
also has its own unique characteristics, such as display signal output drivers, that
differ from projector to projector. There are also unique differences in each optical
system mechanism, such as in the light valves.
In order to obtain the optimum display, it is necessary to eliminate these
differences in electrical and mechanical characteristics as well as to make
mechanical adjustments. The various correction values are set at the time of
shipment from the factory and are stored in ROM on the MA Board.
Always replace the Optical Engine and MA Board together as a matched pair.
Do not disassemble the Optical Engine.
Do not replace the component parts of the Optical Engine with parts from other
Optical Engines.
Disassembly / Assembly
60
Disassembly / Assembly
61
PROJECTOR
AIR FILTER
4.2.3 page 65
UPPER CASE
4.2.6 page 67
REMOTE CONTROL
4.2.5 page 66
FOOT UNIT
4.2.4 page 65
SW BOARD ASSY.
4.2.8 page 71
MA SHIELD PLATE
4.2.10 page 73
SPEAKER
4.2.7 page 69
MA BOARD,
IF PANEL, IF LABEL
4.2.11 page 73
LAMP THERMISTOR
4.2.15 page 80
LEFT MA FRAME
4.2.17 page 82
MA FIXING PLATE
4.2.12 page 77
BALLAST ASSY.
4.2.19 page 84
POWER SUPPLY FAN
4.2.20 page 86
IF BOARD ASSY.
4.2.13 page 78
LOWER SHIELD PLATE
4.2.17 page 82
FAN 80
4.2.15 page 80
OUTER EXHAUST DUCT
4.2.15 page 80
OPTICAL ENGINE
4.2.21 page 88
FOCUS RING
4.2.22 page 89
REMOTE CONTROL
BOARD ASSY.
4.2.16 page 81
PROJECTION LENS
4.2.23 page 90
LOWER CASE
FAN 100
4.2.24 page 91
LAMP COVER
DETECTION SWITCH
4.2.26 page 93
HANDLE
4.2.27 page 94
Disassembly / Assembly
62
Lens Cap
Unit
Tether
Disassembly / Assembly
63
The lamp is very hot immediately after use. Be extremely careful when removing
the Lamp Inner Unit. Let the lamp cool a minimum of 30 minutes before
beginning the removal procedure. If the lamp breaks, handle the shards carefully
to avoid injury. In the unlikely event that the bulb has ruptured, small glass
fragments may be present and should be removed with caution.
While releasing the catches of the Lamp Lid, lift it in the direction of the arrow. Loosen the two screws that
secure the Lamp Inner Unit, and remove it.
Lamp Lid
Do not touch the glass surface of the lamp, and keep the lamp as clean as possible.
Clean off fingerprints and other contamination using isopropyl alcohol.
When installing the Lamp Inner Unit, check that it is fitted securely onto the guide
pins.
Guide Pins
Disassembly / Assembly
64
Air Filter
Disassembly / Assembly
65
Holder, Remote
Control
Remote
Control
Holder, Remote
Control
Disassembly / Assembly
66
Case, Upper
Speaker
Cable
SW Cable (Control
panel cable)
Disassembly / Assembly
67
3. Disconnect the Speaker Cable from connector CN1701 on the MA (Main) Board.
4. Unlock connector CN400 on the MA Board and disconnect the Switch (SW) Cable (Control Panel
Cable).
CN1701
CN400
Locked
Unlocked
Disassembly / Assembly
68
Spring, Speaker
Speaker
Case, Upper
Disassembly / Assembly
69
When installing the Speaker, make sure that the lead wire runs in the direction
shown in Figure 4-13.
Install the Speaker Spring so that it is in contact with the Shield Plate of the
Upper Case.
Disassembly / Assembly
70
Spring, SW Board
Spring, SW Board
SW Board
Connector
Button, SW
Cable, SW
LED Lens
Panel, SW
Disassembly / Assembly
71
When reinstalling the SW Board, replace the screws in the hole positions shown
in Figure 4-14.
Bend and route the SW Cable as shown in Figure 4-15.
72
Shield Plate, MA
Locked
Unlocked
Light Valve B
Connector
Light Valve R
Connector
Disassembly / Assembly
73
When connecting the cables to the R/G/B light valve connectors, insert the cables
squarely as far as they will go, as shown in Figure 4-19.
2. Disconnect the R, G and B Light Valve cables and the seven remaining MA Board cables.
Note: The cables for connectors CN1701 and CN400 were disconnected earlier in Section 4.2.6 on page
67. Connector CN600 is on the underside of the MA Board and will be disconnected in the next
section. All three of these are indicated by blue arrows below.
CN1600
CN1701
CN1400
CN603
CN704
CN1500
CN601
CN702
CN701
CN1800
CN400
CN602
CN600
(Underneath)
Disassembly / Assembly
74
When reinstalling the front IR sensors Remote Control (RC) Cable, secure it to
the Left MA Frame with heat-resistant tape as shown in Figure 4-21.
RC Cable
Heat-resistant tape
When wiring the Exhaust Fan Cable and Lamp Thermistor Cable, run the Lamp
Thermistor Cable under the projection of the Exhaust Fan and twist it twice
with the Exhaust Fan Cable as shown in Figure 4-22.
LAMP Thermistor
Cable
Figure 4-22. Routing the Exhaust Fan and Lamp Thermistor Cables
Disassembly / Assembly
75
3. Remove the 2 (C.B., 3x6, F/ZB) screws that secure the IF Panel and the (C.B, P-Tite, 3x10, F/ZN)
screw that secures the MA Fixing Plate, and remove the MA Board.
Panel, IF
MA Board
Panel, IF
Label, IF
Disassembly / Assembly
76
IF Board Assembly
Blue Side
CN600
CN3002
MA Board
Install the IF Board Assembly Cable with the solid white surface facing upward
as shown below.
When reinstalling the cable, secure it to the IF Board Assembly and connector
with heat-resistant tape as shown in Figure 4-26.
Heat-Resistant Tape
IF Assembly Cable
Solid White Surface
MA Board
Disassembly / Assembly
77
2. Remove the 4 (HSH 4-40) screws and 2 (C.B. 3x10, F/ZB) screws from the MA Fixing Plate, then
remove the plate from the MA Board.
Edge Guards
MA Board
Fixing Plate, MA
Disassembly / Assembly
78
Disassembly / Assembly
79
Fan 80
Duct, Exhaust, Inner
Lamp Thermistor
Figure 4-30. Removing the Lamp Thermistor, Fan 80, and Exhaust Ducts
Disassembly / Assembly
80
Cable, RC Board
Printed Circuit
Board Assy: RC-R1
Disassembly / Assembly
81
Frame, MA Left
Figure 4-32. Removing the Left MA Frame and Lower Shield Plate
Ferrite Core
Ballast Output
Cable
Thermostat
AC Inlet
82
C A U T IO N
When reconnecting the Ballast Output Cable, pay attention to the connector
orientation.
When installing the AC Inlet, pull the AC wires out of the Power Supply and loop
them to the left as shown in the blue circle in Figure 4-33.
2. Remove the 4 (C.B.P-TITE, 3x10, F/ZB) screws that secure the Power Supply/Ballast Assembly, and
remove the Power Supply/Ballast Assembly.
Power Supply /
Ballast Assembly
Disassembly / Assembly
83
Figure 4-35. Removing the Ballast Assembly from the Power Supply Assembly
Disassembly / Assembly
84
When reconnecting the Power Supply Assembly and Ballast Assembly with the
Ballast Input Cable, route the cable so that the ferrite core is located under the
Power Supply Fan.
.
Power Supply
Fan
Ferrite Core
SCI Cable
85
Power Supply
Fan
Power Supply
Fan Cable
Power Supply
Fan Connector
Disassembly / Assembly
86
2. Remove the 2 (C.P.B-Tite, 5x10, F/ZN) screws that secure the Power Supply Fan, and remove it.
Power Supply Fan
Heat-Resistant Tape
Disassembly / Assembly
87
Make sure that you remove only the correct 4 screws so as not to disassemble the
Optical Engine.
1. Remove the 4 (C.B.P-Tite, 3x10, F/ZB) screws that secure the Optical Engine to the projector.
2. Lift the Optical Engine straight up to remove it.
Screw
Screw
Screw
Optical Engine
Screw
Disassembly / Assembly
88
When reinstalling the Optical Engine, pay attention to the cable routing.
Fan 100
Cable
Optical Engine
Frame, MA
Right
Projection Lens
Unit
Lamp Cover
Detection Switch
Optical Engine
Tab
Disassembly / Assembly
89
When installing the Focus Ring, make sure that the tab on the outside of the Focus
Ring is facing upward. See Figure 4-43.
Optical Engine
Disassembly / Assembly
90
Cushion, Intake, B
Case, Lower
Disassembly / Assembly
91
Duct, Intake
Frame, MA Right
Cushion, Intake, A
Disassembly / Assembly
92
Lamp Cover
Detection Switch
93
Holder, Handle
Handle
Disassembly / Assembly
94
Case, Lower
Foot, Rubber
Disassembly / Assembly
95
Disassembly / Assembly
96