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Sanyo PLC-XL40 Service Manual

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SERVICE MANUAL

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, addi-
tional Service Literature is required. You must
refer to "Notices" to the Original Service Manual
prior to servicing the unit.
!
RoHS
K
• This product does not contain any hazardous sub-
stances prohibited by the RoHS Directive. (You will
find "RSF" mark near the rating plate on the RoHS
compliant product.)
PRodUCt CodE
1 122 371 00
(KY6A)
1 122 372 00
(LY6A)
1 122 372 02
(LY6C)
Multimedia Projector
! WARNING
• You are requested to use RoHS compliant parts for
maintenance or repair.
• You are requested to use lead-free solder.
FILE NO.
Model No. PLC-XL40
U.S.A. Canada
Europe, U.K
original Version
Chassis No. KY6-XL4000
REFERENCE NO.
SM
5110816-00

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Summary of Contents for Sanyo PLC-XL40

  • Page 1: Service Manual

    FILE NO. SERVICE MANUAL Multimedia Projector Model No. PLC-XL40 U.S.A. Canada Europe, U.K original Version 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. KY6-XL4000 Chassis No.

  • Page 2: Table Of Contents

    Contents Safety Instructions ............3 Projection Lens Cleaning .......... 51 SAFETY PRECAUTIONS ........... 3 IC Block Diagrams ............5 PRODUCT SAFETY NOTICE........3 Electrical Parts List ............58 SERVICE PERSONNEL WARNING ......3 Electrical Parts Location ........... 59 Specifications ..............4 Mechanical Parts List ..........

  • Page 3: Safety Instructions

    Safety Instructions SAFETY PRECAUTIONS 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.

  • Page 4: Specifications

    Specifications Mechanical Information Projector Type Multi-media Projector Dimensions (W x H x D) 10.50" x 4.86" x 9.58" (320mm x 148mm x 292mm) (Not including adjustable feet) Net Weight 7 .3 lbs (3.3kgs) Feet Adjustment 0˚ to 10.0˚ Panel Resolution LCD Panel System 0.6" TFT Active Matrix type, 3 panels Panel Resolution 1,024 x 768 dots Number of Pixels 2,359,296 (1,024 x 768 x 3 panels) Signal Compatibility Color System PAL, SECAM, NTSC, NTSC4.43, PAL-M, PAL-N High Definition TV Signal 480i, 480p, 575i, 575p, 720p, 1035i, and 1080i Scanning Frequency H-sync. 15 ~ 100 KHz, V-sync. 50 ~ 100 Hz Optical Information Projection Image Size (Diagonal) Adjustable from 60" to 80" Projection Lens F 1.85 lens with f 8.1 mm ~ 27 mm with manual focus Throw Distance 2.49’ - 3.38’ (0.76m - 1.03m) Projection Lamp 200W Interface Video Input Jack RCA Type x 1 S-Video Input Jack Mini DIN 4 pin x 1...

  • Page 5: Circuit Protections

    Circuit Protections This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the projec- tor, it will automatically turn off by operating one of the following protection circuits. Thermal switch There is the thermal switch (SW90) inside of the projector to detect the internal temperature rising abnormally.

  • Page 6: Warning Temperature And Power Failure Protection

    Circuit Protections 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.

  • Page 7: Security Function Notice

    Security Function Notice This projector provides security functions such as "Key lock", "PIN code lock" and "Logo PIN code lock". When the pro- jector has set these security function on, you are required to enter correct PIN code to use the projector. If you do not know the correct PIN code to the projector, the projector can no longer be operated or started.

  • Page 8: Lamp Replacement

    Lamp Replacement Lamp replacement oRdER REPLACEMENt LAMP Type No. Service Parts No. WARNING: POA-LMP90 610 33 076 - For continued safety, replace with a lamp assembly of the same type. - Allow the projector to cool for at least 45 minutes before you open the Screw Lamp Cover lamp cover.

  • Page 9: Mechanical Disassembly

    Mechanical Disassembly Mechanical disassembly should be made following procedures in numerical or- Screws Expression der. (Type ) mm Diameter x Length Following steps show the basic procedures, therefore unnecessary step may T type M Type be ignored. Caution: The parts and screws should be placed exactly the same position as the original otherwise it may cause loss of performance and product safety.
  • Page 10 Mechanical disassembly Main Board, Rear Panel, Fan(FN905), SP901 removal (M.5x6)x Grounding (M.5x6)x8 (M4x5) lead Rear panel FN905 (T3x8) Main board SP901 Fig.2 -10-...
  • Page 11 Mechanical disassembly Power, Line Filte, Ballast Board, Thermal Sw(SW902), Fan(FN906) removal Isolation sheet Power board (T3x6)x4 (T3x6) (T3x6) (T3x6)x (T3x6)x4 (T3x6) Thermal switch (SW90) Line Filter board (T3x6) (M3x8) Ballast board FN906 Ballast socket (T3x6)(Black) (T3x6)(Black) Fig.3 -11-...
  • Page 12 Mechanical disassembly Optical Unit, Fans(FN903, FN904), Noise Filter removal (T3x8)x6 (T3x1)x Optical unit (T3x6) (T3x10)x4 (T3x6)x (T3x6)x3 FN904 (T3x8) Noise filter FN903 Fig.4 -1-...
  • Page 13 Mechanical disassembly Alarm-A and Alarm-B board removal Alarm-A Board (T3x6)x4 LED Spacer Alarm-B Board (T3x6) (T3x6) Battery Switch cover Battery cover (M3x8) (M3x8) Fig.5 -13-...

  • Page 14: Optical Parts Disassembly

    Optical Parts Disassembly Before taking this procedure, remove Cabinet Top , Cabinet Front and Main Board following to the “Mechanical Disassembly”. Disassembly requires a .0mm hex wrench. Projection lens removal (M3x8)x4 Fixing tape Projection lens Fig.1 Note on replaceing the Projection Lens - When the Projection Lens is replaced with the new one, make sure that the fixing tape must be removed as the figuer.
  • Page 15 optical Pats disassembly Relay lens disassembly (M.5x5)x Relay lens Ass'y (Mx3) Relay lens Fig.3 Polarized glass-in disassembly (M.5x5)x1 Polarized glass-in Ass'y Film side Polarized glass Fig.4 -15-...
  • Page 16 optical Parts disassembly LCD Panel/Prism Ass’y removal LCD Panel/ (M.5x4)x Prism Ass’y (M3x10) (Bottom side) Fig.5 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.

  • Page 17: Panel Type Check

    Panel Type Check There are  types of LCD/Prism Ass'y for this model. Either L-Type or R-Type LCD /Prism Ass'y is used on the projec- tor. Check which type of LCD/Prism Ass'y is used with the figure below. When replacing the LCD/Prism Ass'y, you need to take "Panel Type Check and Setting" on the Electrical Adjustment for the replaced LCD/Prism Ass'y.
  • Page 18 optical Parts disassembly Polarized glass, Pre-polarized glass removal (Mx) (Mx) (Green) Pre-Polarized Glass(G) Polarized Glass(G) (Red) (Mx4) (Mx) Pre-Polarized Glass(B) Film (Blue) Polarized Glass(R) Fig.6 Polarized Glass(B) * Mount the polarized glasses as the film attached side comes to the LCD Film panel side.

  • Page 19: Locations And Directions

    optical Parts disassembly Locations and Directions Parts Name When mounting or assembling the optical parts in the Integrator lens (OUT) optical unit, the parts must be mounted in the specified Prism beam splitter (PBS) location and direction as shown in figure below. Condenser lens (OUT) Dichroic mirror (B) Dichroic mirror (G) Condenser lens (G) Mirror (R) Condenser lens (R)

  • Page 20: Adjustments

    Adjustments Turning On the Projector If the PIN code is set on the projector, you cannot use the projector. The PIN code can be reset to the factory default setting (1234) according to the following procedure. When you reset the PIN code, the Logo PIN code and key lock will be reset, as well. 1.

  • Page 21: Optical Adjustments

    Optical Adjustments Before taking optical adjustments below, remove the Cabinet Top following to the “Mechanical Disassembly”. Adjustments require a .0mm hex wrench and a slot screwdriver. When you adjust Integrator lens or Relay lens adjustment, you need to disconnect FPC cables of LCD panels on the main board. Optical adjustment requires a .0mm hex wrench and a slot screwdriver.

  • Page 22: Integrator Lens Adjustment

    optical Adjustments Integrator lens adjustment Turn the projector on by a state of without FPC cables. Project all of lights on the screen. Adjust the adjustment base of integrator lens assy to make color uniformity in white. 1) If the shading appears on the left or right of the screen as White shown in Fig.2-1, loosen 1 screw , and adjust the slot...
  • Page 23 optical Adjustments Relay lens-Out adjustment Turn the projector on by a state of without FPC cables. Project all of lights on the screen. Adjust the adjustment base of relay lens assy to make color unifor- mity in white. If the shading appears on the left or right of the screen as shown White in Fig.3, loosen 1 screw , and adjust the slot...

  • Page 24: Electrical Adjustments

    Electrical Adjustments Service Adjustment Menu Operation to enter the service mode To enter the “Service Mode”, press and hold the MENU and INPUt buttons on the projector at the same time for more than 3 seconds. The service menu appears on the screen as follows. to adjust service data Select the adjustment group no.

  • Page 25: Circuit Adjustments

    Electrical Adjustments Circuit Adjustments CAUTION: The each circuit has been made by the fine adjustment at factory. Do not attempt to adjust the follow- ing adjustments except requiring the readjustments in servicing otherwise it may cause loss of perfor- mance and product safety. [Adjustment Condition] 16 steps gray scale pattern ●...
  • Page 26 Electrical Adjustments Pedestal adjustment [PC] Pedestal adjustment [1080i] 1. Receive the 16-step grey scale computer signal with 1. Receive the 16-step grey scale component signal Computer2 [RGB] mode. with Video [Component1080i] mode. . Enter the service mode. . Enter the service mode. tPG1 tPG1 3.

  • Page 27: Common Center Adjustment

    Electrical Adjustments Gain adjustment [Video] . Common Center adjustment 1. Receive the 16-step grey scale composite signal with 1. Receive the 1 line black/white pattern computer sig- Video [Video] mode. nal with Computer2 [RGB] mode. . Enter the service mode. .
  • Page 28 Electrical Adjustments ⁄2 50% White adjustment [Video] 1. Receive the 16-step grey scale composite video sig- nal with Video [Video] mode. . Enter the service mode. tPG1 3. Connect an oscilloscope to test point “ ” (+) and chassis ground (-). 4.

  • Page 29: Test Points And Locations

    Electrical Adjustments Test Points and Locations MAIN BoARd IC1801 -9-...

  • Page 30: Service Adjustment Data Table

    Electrical Adjustments Service Adjustment Data Table These initial values are the reference data written from the CPU ROM to memory IC when replaced new memory IC. The adjustment items indicated with “✻” are required to readjust fol- lowing to the “Electrical adjustments”. Other items should be used with the initial data value.
  • Page 31 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC CRDLY uPD64012 PHBDL uPD64012 PHRDL uPD64012 CBOFS uPD64012 CROFS uPD64012 FRCENY uPD64012 FRCENC uPD64012 DLYCTL uPD64012 OUTBITW uPD64012 CLKOINV uPD64012 RDOSEL uPD64012 SQCBCR uPD64012 ACTVH uPD64012 HPOSI uPD64012 HSPOS uPD64012...
  • Page 32 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC VIDEO S-VIDEO YCBCR SCART NTSC / PAL NSTC / PAL 480i / 575i 480i / 575i SBCNT uPD64012 109 / 111 106 / 108 119 / 118 118 / 118 SBCLRU uPD64012 SBCLRV uPD64012 YCONR uPD64012 CCONR uPD64012 YCORB uPD64012 YCOREN uPD64012 YCORH uPD64012 CCORB uPD64012...
  • Page 33 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC NRG Width L3E7072K0A OSD (Insert Position) L3E7072K0A OSD (pattern Selection) L3E7072K0A GAMMA(ON/OFF) L3E7072K0A ref_gate_pos(NRS Position) L3E7072K0A ref_gate_dur(NRS Width) L3E7072K0A gray_on L3E7072K0A Other Correction L3E7072K0A Whole Area Crosstalk Corr. EN L3E7072K0A DC Offset Corr. for V-line Shade E L3E7072K0A Offset Corr. For V-line Shade EN L3E7072K0A Normal:0/Rear:1 V-Line Shade BLSP_EN L3E7072K0A Normal:1/Rear:1 Sequential Ghost Correction EN L3E7072K0A Normal:1/Rear:1 Block Ghost Correction EN...
  • Page 34 L3E6100 SyncPosition L3E7072K0A Link with 9-131 SyncVideoPosition L3E7072K0A Link with 9-130 Color Shading SW L3E7072K0A Color Shading Correction, 0: Off, 1: On (Not memorized) Group 100 OPTION (Lamp Time, Service Port etc) RS232C Baudrate PW185B 0 : 19200bps 1: 9600bps PJLink Enable 0:Disable 1:Enable PW Debug Command Enable PW185B 0:Disable 1:Enable(Sanyo Serial Command Disable)(Not memorized) Device Refresh Disable PW185B 0:Enable 1:Disable(Not memorized) Projector Time Reset PW185B 0-20 Resets Projector time when the value is set to 10. Lamp Warning Time (NORMAL) PW185B 2000 0-10000 Normal lamp warning time Lamp Warning Time (ECO) PW185B 3000 0-10000 Eco lamp warning time Lamp life test enable PW185B 0:Disable 1:Enable For safety test purpose...
  • Page 35 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC DIMMER_CTRL_LEVEL3 PW185B Luminance Level3:Dimmer Level3 when less than the value. DIMMER_CTRL_LEVEL4 PW185B Luminance Level4:Dimmer Level4 when less than the value. DIMMER_CTRL_LEVEL5 PW185B Luminance Level5:Dimmer Level5 when less than the value. DIMMER_CTRL_LEVEL6 PW185B Luminance Level6:Dimmer Level6 when less than the value. DIMMER_CTRL_LEVEL7 PW185B Luminance Level7:Dimmer Level7 when less than the value. DIMMER_CTRL_LEVEL8 PW185B Luminance Level8:Dimmer Level8 when less than the value. DIMMER_CTRL_LEVEL9 PW185B Luminance Level9:Dimmer Level9 when less than the value. DIMMER_CTRL_LEVEL10 PW185B Luminance Level10:Dimmer Level10 when less than the value. DIMMER_CTRL_LEVEL11 PW185B Luminance Level11:Dimmer Level11 when less than the value. DIMMER_CTRL_LEVEL12 PW185B Luminance Level12:Dimmer Level12 when less than the value.
  • Page 36 Electrical Adjustments Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC NOR_VALU_FAN1_MAX M62398FP FAN1 Control Max at Normal NOR_VALU_FAN2_MIN M62398FP 0-255 FAN2 Control Min at Normal NOR_VALU_FAN2_MAX M62398FP FAN2 Control Max at Normal ECO_TEMP_FAN1_MIN PW185B FAN1 Control start temp.at Eco ECO_TEMP_FAN1_MAX PW185B FAN1 Control end temp. at Eco ECOTEMP_FAN2_MIN PW185B 0-255 FAN2 Control start temp.at Eco ECO_TEMP_FAN2_MAX PW185B FAN2 Control end temp. at Eco ECO_VALU_FAN1_MIN PW185B FAN1 Control Min at Eco ECO_VALU_FAN1_MAX PW185B FAN1 Control Max at Eco ECO_VALU_FAN2_MIN...
  • Page 37 Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC Gain Area Average [ Red ] PW185B 0 - 255 Read Only Gain Area Average [ Green ] PW185B 0 - 255 Read Only Gain Area Average [ Blue ] PW185B 0 - 255 Read Only Image LevelUpdate [ OFFSET ] PW185B 0 - 255 Upadte item 12/13, Link to item 14 Group 290 Panel Type Gamma L/R-Check 0 - 20 0: Gamma for L-Panel, 20: Gamma for R-Panel (Read only) Change for R-Panel when the value is set to 20. Gamma L/R-Change 0 - 20 Change for L-Panel when the value is set to 0. Group 300 General DeInterlacer bit 0 : Global Motion Enable (FILMODEN23 GMD) 3:2 PullDown Mode PW185B 1 - 3 bit 1 : Video Motion(VOFMODEN)
  • Page 38 Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC Clamp Pos AD9883 AD9883 Clamp Placement Clamp Width AD9883 AD9883 Clamp Duration Group 526 OverScan HDTV 575p Total Dots(HTOTAL) AD9883 1253 AD9883 PLL Div Disp Dots (HRES) PW185B Horizontal Resolution Horz Back Porch (HPOS) PW185B Horizontal Back Porch Vert Back Porch (VPOS) PW185B Vertical Back Porch Disp Line (VRES) PW185B Vertical Resolution Clamp Pos AD9883 AD9883 Clamp Placement Clamp Width AD9883 AD9883 Clamp Duration Group 528 OverScan HDTV 720p...
  • Page 39 Item No. NAME Device Range Description Component Video HDTV 480p 480i NTSC Clamp Pos AD9883 AD9883 Clamp Placement Clamp Width AD9883 AD9883 Clamp Duration Group 550 OverScan RGB 1035i Total Dots(HTOTAL) AD9883 2200 AD9883 PLL Div Disp Dots (HRES) PW185B 1874 Horizontal Resolution Horz Back Porch (HPOS) PW185B Horizontal Back Porch Vert Back Porch (VPOS) PW185B Vertical Back Porch Disp Line (VRES) PW185B 1012 Vertical Resolution Clamp Pos AD9883 AD9883 Clamp Placement Clamp Width AD9883 AD9883 Clamp Duration...

  • Page 40: Chassis Block Diagrams

    Chassis Block Diagrams Chassis over view TXD/RXD 265,202 IRRCVR0 65,63,211 IC8201 IC5301 SYNC SEP. <BA7078> IC5031 IC5201 AUDIO OUTPIT PC1/PC2-SW <LM4889> <AN5870> IC5001 AUDIO CONTROL <NJW1141> AUDIO -40-...

  • Page 41: System Control

    Chassis Block diagrams System control IC891 INVERTER <MH74LVC> MONIT_OUT IC3531 <M62398> IC301 IC1801 SYSTEM CONTROL I/O EXPANDER -41-...

  • Page 42: Power Supply & Protection Circuit

    Chassis Block diagrams Power supply & protection circuit IC631 POWER OSC. <STR-Z2156> IC621 P.F.CONTROL <FA5502> BLAST_AC FAN_ERR IC301 SYSTEM CONTROL -4-...

  • Page 43: Fan Control Circuit

    Chassis Block diagrams Fan control circuit TPFANA Q7812 FN904 S15.5V FANA D3621 D3613 Q7811 FN903 IC7811 D3622 Q7813 FN906 D3624 TPFANB D5621 Q7862 FN901 FANB D3623 FN902 Q7861 D3614 IC7861 Q7803 D3626 FAN_K8N Q7864 FN905 D3627 Q3601 P_FAIL P_FAIL P_Fail: H FAN_ERR Power Error: On SIGNAL/MODE...

  • Page 44: Troubleshooting

    Troubleshooting Indicators and Projector Condition Check the indicators for projector condition. Indicators LAMP Projector Condition WARNING PoWER REPLACE red/green yellow The projector is off. (The AC power cord is unplugged.) The projector is preparing for stand-by or the projection lamp is being cooled down.

  • Page 45: No Power

    troubleshooting No Power This projector provides a function which can be specified a defective area simply by indicating the LEDs. Connect the AC cord and press the Power button once and then check the LED indication. - When all of LEd indicators are not lighting, the symptom indicates that the primary power supply circuit does not operate properly.

  • Page 46: No Picture

    troubleshooting No Picture Check following steps. No picture with all of input sources Check signal processing stage and LCD driving stage; Check RGB S&H signals at test points TPB1, TPG1, TPR1. Check power supply circuit 15.5V and peripheral circuit. Check ICs IC501, IC531, IC561, IC401, IC301 and peripheral circuits. No picture with PC1 Check PC1/PC-switching stage;...

  • Page 47: No Sound

    troubleshooting No Sound Check following steps. Check if the audio sig- nal is observed at pins Check IC5001 and peripheral circuit. 10 and 21 of IC5001. Check 5V_AUDIO, 9V power supply. Check if the audio sig- Check IC5031 and peripheral circuit. nal is observed at pins 5 Check the Mute signal at pin 1 of IC5031.

  • Page 48: Control Port Functions

    Control Port Functions System Control I/O Port Functions (IC301) PIN No. PIN NAME PORT SIGNAL DESCRIPTION IN0GO3 BLAST_AC Ballast Drive Power-On: H IN0GO7 ON_3.3V 3.3V Drive On: H IN0GO5 15V_ON 15V Drive On: H IN0BO3 PANEL_OPT Panel Optioin H: XGA, L:SVGA IN0GO9 FAN_K8N Fan Drive On: H IN0BO4 CARD_IN IN0VS IN0HS GFBK IN0GO8 ON_5VA 5VA Drive On: H IN0BO5 W_LAN_IN Wireless LAN Option IN0CST...

  • Page 49: I/O Expander Port Functions (Ic1801)

    Control Port Functions I/O Expander Port Functions (IC1801) PIN NO. NAME FUNCTION ACTION S_SW Scart switch H: Scart WAKEUP WAKEUP RESET L - H: Reset XTAL IN XTAL OUT DDC_SW2 ECO_SW S/CV_SW S-Video/Video Switch H: Composite Video-in SC_SW SCART In Switch H: Scart In RESET_N LED_SW LED Drive Switch H: On USB_VBUS AIN1 Option Switch AIN2 Option Switch AIN3 Option Switch AIN4 Option Switch AIN5 Option Switch AIN6...

  • Page 50: Waveform

    Waveform CVBS <tCV> HSYNC signal <tGHS> VSYNC signal <tVGS> HSYNC signal <tdHS> VSYNC signal <tdVS> R-S&H signal <tPR1> G-S&H signal <tPG1> B-S&H signal <tPB1> -50-...

  • Page 51: Cleaning

    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.

  • Page 52: Ic Block Diagrams

    IC Block Diagrams ● Ad9883 <A/d, IC8201> CLAMP oUtA CLAMP oUtA CLAMP oUtA MIdSCV HSYNC dtACK SYNC CoASt PRoCESSING HSoUt ANd CLoCK CLAMP VSoUt GENERAtIoN SoGoUt FILt BYPASS SERIAL REGIStER Ad9883A PoWER MANAGEMENt ● AN5870 <RGB,SYNC-SW, IC5201> -5-...
  • Page 53 IC Block diagrams ● BA7078 <Sync Separator, IC5301> ● BA9743<ddC Control, IC5651> -53-...
  • Page 54 IC Block diagrams ● FA5502 <P.F. Control, IC621> ● L3E6100d <d/A, S/H-LCd driver, IC501, IC531, IC561> -54-...
  • Page 55 IC Block diagrams ● L3E07072 <LCd driver & Gamma Correction, IC401> ● M62399 <d/A, IC3531> -55-...
  • Page 56 IC Block diagrams ● NjW1141 <Audio Control, IC5001> ● StR-Z2156A <Power Switching, IC631> -56-...
  • Page 57 IC Block diagrams ● uPd64012 <Video decoder, IC101> -57-...

  • Page 58: Electrical Parts List

    KY6-XL4000 Electrical Parts List Product safety should be considered when a component replacement is made in any area of a projector. Components indicated by a mark in this parts list and the circuit diagram show components whose value have special significance to product safety. It is particularly recommended that only parts specified on the following parts list be used for components replacement pointed out by the mark.

  • Page 59: Electrical Parts Location

    KY6-XL4000 Electrical Parts List Electrical Parts Location ● Assemblied Boards Main Board Alarm-A Board Alarm-B Board Power Board Line Filter Board A901 Ballast Board R/C Board ● oUt oF CIRCUIt BoARd LF901 Noise Filter FN904 Cooling Fan(G) FN905 Cooling Fan(PBS) Batterry SP901 Speaker...
  • Page 60 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description Q642 305 014 4512 TR 2SC2412K T146 R 305 014 4611 TR 2SC2412K T146 S ASSEMBLIED BOARDS 305 015 8727 TR 2SC2812-L6-TB 305 015 8925 TR 2SC2812-L7-TB 910 323 0499 ASSY,PWB,POWER MT5A 305 163 1615 TR 2SC2812N-L6-TB0 910 326 1837 ASSY,PWB,LINE FILTER MT5A 305 173 9816 TR 2SC3928A1R 910 329 0905 ASSY,PWB,R/CS. LG6A 305 173 9915 TR 2SC3928A1S Q643 305 211 5807 TR 2SK3561 610 332 2902 ASSY,PWB,MAIN KY6A Q651...
  • Page 61 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C652 303 427 6245 ELECT 1000U M R658 301 150 6212 MT-GLAZE 1K JA 1/10W C653 303 437 4713 ELECT 470U M R659 301 150 6212 MT-GLAZE 1K JA 1/10W C654 303 164 0217 CERAMIC 0.1U Z R660 301 162 3711 MT-GLAZE 4.7K JA 1/10W C655 303 164 0217 CERAMIC...
  • Page 62 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description COIL 305 015 8925 TR 2SC2812-L7-TB 305 163 1615 TR 2SC2812N-L6-TB0 L 601 945 050 2232 LINE FILTER 305 173 9816 TR 2SC3928A1R MISCELLANEOUS 305 173 9915 TR 2SC3928A1S F 601 323 021 7804 FUSE 250V 6.3A Q2021 305 014 4512 TR 2SC2412K T146 R SW901 945 063 8078 SWITCH,PUSH 2P-2TX3 305 014 4611 TR 2SC2412K T146 S 305 015 8727...
  • Page 63 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 305 014 4611 TR 2SC2412K T146 S 305 163 1615 TR 2SC2812N-L6-TB0 305 015 8727 TR 2SC2812-L6-TB 305 173 9816 TR 2SC3928A1R 305 015 8925 TR 2SC2812-L7-TB 305 173 9915 TR 2SC3928A1S Q5032 305 014 4512 TR 2SC2412K T146 R 305 163 1615 TR 2SC2812N-L6-TB0 305 014 4611 TR 2SC2412K T146 S 305 173 9816 TR 2SC3928A1R 305 015 8727 TR 2SC2812-L6-TB 305 173 9915 TR 2SC3928A1S Q5251 305 217 5118 TR HN1A01FE-Y TE85L 305 015 8925...
  • Page 64 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description IC5651 309 555 6318 IC BA9743AFV-E2 305 015 8925 TR 2SC2812-L7-TB 305 163 1615 TR 2SC2812N-L6-TB0 IC5681 309 563 9615 IC SI-3012KS-TL 305 173 9816 TR 2SC3928A1R IC7811 309 531 6229 IC FA7701V-TE1 305 173 9915 TR 2SC3928A1S IC7861 309 531 6229 IC FA7701V-TE1 Q6844 305 014 4512 TR 2SC2412K T146 R IC801 410 626 3208 IC S29GL032A90TFIR30-0775 305 014 4611 TR 2SC2412K T146 S IC8201...
  • Page 65 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C3051 303 294 6110 CERAMIC 100P J C174 303 343 3718 CERAMIC 0.1U Z C3052 303 439 8412 CERAMIC 2.2U M 6.3V C175 303 394 1312 ELECT 100U M 6.3V C3053 303 343 3718 CERAMIC 0.1U Z 303 387 4917 ELECT 100U M 6.3V C1801 303 343 3718 CERAMIC...
  • Page 66 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 303 387 5112 ELECT 220U M 6.3V C419 303 449 1212 POS-SOLID 47U M 6.3V C5088 303 394 9318 ELECT 220U M 6.3V C421 303 441 9810 CERAMIC 0.01U K 303 387 5112 ELECT 220U M 6.3V C422 303 441 9810 CERAMIC 0.01U K C423 303 441 9810 CERAMIC...
  • Page 67 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C7811 303 314 6212 CERAMIC 2.2U K 303 387 5112 ELECT 220U M 6.3V C7813 303 381 5316 ELECT 100U M C5604 303 343 3718 CERAMIC 0.1U Z 303 369 3211 ELECT 100U M C5606 303 391 5115 ELECT 100U M 303 296 9515 ELECT 100U M C7814 303 381 5316 ELECT...
  • Page 68 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R1439 301 225 8110 MT-GLAZE 10 JA 1/16W C8832 303 276 3113 CERAMIC 33P J R1441 301 225 8110 MT-GLAZE 10 JA 1/16W C8833 303 343 3718 CERAMIC 0.1U Z R1442 301 225 8110 MT-GLAZE 10 JA 1/16W C891 303 343 3718 CERAMIC 0.1U Z C9882 303 343 3718...
  • Page 69 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R3621 301 224 9019 MT-GLAZE 10K JA 1/16W R2023 301 225 1418 MT-GLAZE 47K JA 1/16W R3622 301 224 9019 MT-GLAZE 10K JA 1/16W R2026 301 224 9316 MT-GLAZE 1K JA 1/16W R3623 301 224 9019 MT-GLAZE 10K JA 1/16W R2028 301 225 1418 MT-GLAZE 47K JA 1/16W...
  • Page 70 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R5312 301 224 9514 MT-GLAZE 2.2K JA 1/16W R5041 301 224 9316 MT-GLAZE 1K JA 1/16W R5313 301 224 9019 MT-GLAZE 10K JA 1/16W R5042 301 224 9316 MT-GLAZE 1K JA 1/16W R5314 301 225 8615 MT-GLAZE 560K JA 1/16W R5043 301 276 4710 MT-GLAZE 0.000 ZA 1/3W...
  • Page 71 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description R6813 301 224 9019 MT-GLAZE 10K JA 1/16W R8262 301 224 8814 MT-GLAZE 100 JA 1/16W R8263 301 224 8814 MT-GLAZE 100 JA 1/16W R6818 301 225 1517 MT-GLAZE 3.9K JA 1/16W R6819 301 225 0213 MT-GLAZE 3.3K JA 1/16W R8291 301 276 4710 MT-GLAZE 0.000 ZA 1/3W...
  • Page 72 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description 945 037 0824 R-NETWORK 22X4 1/16W DIODE RB367 945 034 5051 R-NETWORK 22X4 1/32W D2002 307 209 1214 ZD UDZS-TE-176.2B 945 037 0824 R-NETWORK 22X4 1/16W D2896 307 209 1214 ZD UDZS-TE-176.2B RB8251 945 034 5051 R-NETWORK 22X4 1/32W D2897 307 209 1214 ZD UDZS-TE-176.2B 945 037 0824 R-NETWORK 22X4 1/16W D3051 307 149 0810...
  • Page 73 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description FB608 945 041 1978 INDUCTOR,330 OHM D8751 307 204 0014 LED SML-210LT T86 L FB609 945 041 1978 INDUCTOR,330 OHM MISCELLANEOUS K10A 945 050 8012 SOCKET,D-SUB 15P SW8751 910 011 1791 SWITCH,PUSH K10B 945 050 8012 SOCKET,D-SUB 15P SW8752 910 011 1791 SWITCH,PUSH K20A 945 076 2735 JACK,RCA-2 SW8753 910 011 1791 SWITCH,PUSH K20B 945 067 6124...
  • Page 74 KY6-XL4000 Electrical Parts List Key No. Part No. Description Key No. Part No. Description C8705 303 391 5313 ELECT 47U M 6.3V IC8709 420 002 2602 PZ BZR PKM22EPPH4012 C8706 303 305 9918 CERAMIC 680P J IC8710 945 081 3857 SWITCH,SENSOR 2P-2T C8707 303 398 3817 ELECT 220U M Q8761TM 301 150 6014 MT-GLAZE 0.000 ZA 1/10W SW8702 945 063 5176 SWITCH,PUSH 2P-2TX3 RESISTOR R8701...

  • Page 75: Mechanical Parts List

    KY6-XL4000 Mechanical Parts List C03-b Cabinet Parts Location C3-a -75-...

  • Page 76: Optical Parts Location

    KY6-XL4000 Mechanical Parts List Optical Parts Location Integrator Lens-In (Integrator-In) Relay Lens-Out (Relay-out) -76-...
  • Page 77 KY6-XL4000 Mechanical Parts List Polarized Glass-In (Polarized-in-R) (Polarized-in-G) (Polarized-in-B) Projection Lens (Projection) -77-...
  • Page 78 KY6-XL4000 Mechanical Parts List Prism/LCD Panel Assy (Red) (Green) L01-d L01-b L01-e (Blue) L01-a L01-c (Prism/LCD panel Ass'y) -78-...
  • Page 79 KY6-XL4000 Mechanical Parts List In the Optical Unit -79-...

  • Page 80: Mechanical Parts List

    KY6-XL4000 Mechanical Parts List Mechanical Parts List Note: Parts order must contain Chassis No., Part No., and descriptions. Key No. Part No. description Key No. Part No. description CABINET PARTS L11 945 078 0814 MIRROR(R) C01 910 323 1779 ASSY,STAND LEG-MT5A L11 945 081 7657 MIRROR(R) L12 945 078 0845 PRISM(PBS) C02...
  • Page 81 KY6-XL4000 Mechanical Parts List -81-...
  • Page 82 SANYo Electric Co., Ltd. (KY6A) Oct. 006 DC 350 Printed in Japan...

  • Page 83: Diagrams & Drawings

    PLC-XL40 KY6-XL4000 these schematic diagrams and printed wiring board drawings are part of the service manual original for chassis No. KY6-XL4000 model PLC-XL40. File with the service manual No. SM5110816-00 Note: All the information of part numbers and values indicated on these diagrams are at the beginning of production.

  • Page 84: Parts Description And Reading In Schematic Diagram

    KY6-XL4000 Parts description and reading in schematic diagram 1. The parts specification of resistors, capacitors and Resistor Reading coils are expressed in designated code. Please check Example 1/2 D J 10K B the parts description by the following code table. 2.

  • Page 85: Schematic Diagrams

    SC311 25EM 1/3GJ47 -06G 1000ZV C643 R631 15.5V C657 C635 KZ0.22FA FFXAVB FOR SANYO SP This projector is isolated from AC line by using the internal converter transformer. Please pay 001SGJ J10EP031G 2000KK D633 KK330GQ R636 C652 220AHH UDZS12BG 1/3GJ 10EM attention to the following notes in servicing.
  • Page 86 R5239 R5238 1/10GJ 1/3GZ0 C5223 C5221 6.3EM IC5201 16KK10BB 2203T C5222 C5219 ;6.3EM220WD 25KZ0.1 AN5870SB 16KZ1FA PC1/PC2-SW L1002 RIN1 SC1001 F34DG407G R5201 C5201 1/16GJ 16KZ R1001 100A 2.2FA 1/3GJ75 R5233 1/16GJ R1002 RIN2 ROUT 1/16GJ C5202 100A 16KZ 2.2FA CGR/CR_AD L1012 R1011 R5228...
  • Page 87 IC301 SCAN CONVERTER & SYSTEM CONTROL OPTION SW FAN_A R1881 R1883 1/16GZ0A FAN_B R1885 TVPEN R1882 VPEN (TO IC301 IN1PEN) R1880 R1884 TVFLD VFIELD 1/16GZ0A VFIELD (TO IC301 IN1FIELD) TVBLK VBLK VBLK (TO IC301 IN1VBI) TVSYNC (TO IC301 IN1VS (VVS)) THSYNC C1822 (TO IC301 IN1HS (VHS))
  • Page 88 IC801 S29GL032A90TFIR30 S3.3V_PW S3.3V_PW A[17] R831 TICE A[16] R801 R832 R839 A[15] BYTE 1/16GJ3.3KA TEICE 1/16GJ10KA A[14] A[1] J30B1640G A[13] D[15] DQ15/A-1 A[12] D[7] D[0] D[8] A[11] D[14] D[1] D[9] DQ14 A[10] D[6] D[2] D[10] A[9] D[13] D[3] D[11] DQ13 R802 A[20] 1/16GZ0A...
  • Page 89 15.5VL 15.5V C2507 R513 C2506 TPBV1 Q2501 25KZ 1/16GJ100A R2501 P_FAIL 16EM2201V 2SA1203Y 0.1MNF REF_B B_V1 1/16GJ RF_B D3609 R519 1.5KA P_FAIL R529 1SS355 1/16GJ2.2KA R2502 1/16GJ R526 1/16GJ 1/16GJ 1.8KA 4.7KA C518 C2523 C522 16KK 25KZ 0.1MN 16KK ON_15V 0.1MNF 0.1MN Q2502...
  • Page 90 EXHAUST EXHAUST EXHAUST SIDE FRONT SIDE G/R-PNL B-PNL LAMP POWER FN901 FN906 FN902 FN904 FN903 FN905 60X25mm 52X15mm 60X15mm R6863 Q6846 1/16GJ1.5KA 2SA1203Y LED_SW R6864 1/16GJ 4.7KA J10EG J10EG J10EG J10EG LED_SW 035G 036G 035G J10EG J10EG 035G 035G 035G R6865 Q6847 1/16GJ...

  • Page 91: Printed Wiring Board Diagrams

    Printed Wiring Board Diagrams ! CAUTION This projector is isolated from AC line by using the internal converter transformer. Please pay attention to the following notes in servicing PoWER (SIdE:A) 1. Do not touch the part on hot side (primary circuit) or both parts on hot and cold sides (secondary circuit) at the same time.
  • Page 92 MAIN (SIdE:A) LAMP FN906 R/CS. “K9D” BALLAST UNIT R6864 R6866 R6863 R6865 1AA4B10C5430A Q6841 D6843 Q6847 R6846 R6843 C2897 D6833 FB2896 R4863 R6848 D4812 R2898 D6832 D6831 FB3623 D4813 R6849 D2897 D6844 R2896 C2896 Q6842 R2897 D2896 R6859 R5621 Q6844 R5622 IC9882 PB10...
  • Page 93 MAIN (SIdE:B) POWER “K6R” D841 IC841 C848 IC844 SC301 C852 R846 C847 SC303 IC8831 C851 R3626 FN90 B SIDE D3626 C5606 FB3622 C8831 C8832 C5609 D5612 R8831 R8832 SC5601 R5674 R5676 R5673 (2nd Reflow) C5676 R316 C493 R1421 R315 C5037 RB1401 C5033 L5611...
  • Page 94 LINE FILtER (SIdE:A) LINE FILtER (SIdE:B) ALARM-B (SIdE:A) ALARM-A POWER “K8703” “K6C” K8751 A30C5 1AA4B10C5480B A SIDE SW8754 SW8751 SW8752 SW8753 C602 C602 ALARM-B (SIdE:B) L601 1AA4B10C5480B B SIDE C601 C601 A30C5 R601 SW8752 SW8751 SW8754 SW8753 MAIN LF901 “K8S” ALARM-A (SIdE:A) ALARM-A (SIdE:B) MAIN...

  • Page 95: Pin Description Of Diode, Transistor And Ic

    KY6-XL4000 Pin description of diode, transistor and IC ● Diode ● Diode K: Cathode A: Anode ● Transistor/FET ● Transistor/FET C: Collector D: Drain B: Base G: Gate Index E: Emitter S: Source C1 C C1 C ● IC ● IC (GND) RESET (IN)

  • Page 96: Note On Sordering

    KY6-XL4000 Note on Sordering do not use solder containing lead. Solder This product has been manufactured using lead-free Use solder with the metal content and composition ratio solder in order to help preserve the environment. by weight given in the table below. Do not use solders Because of this, be sure to use lead-free solder which do not meet these conditions.

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