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3M 9800 Service Manual

3M 9800 Service Manual

Overhead projector
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9800
Overhead Projector

Service Manual

3M Visual Systems Division
6801 River Place Boulevard
Austin, Texas 78726-9000
Printed in U.S.A.
E3M 7/96
78-6970-5568-5 Rev. C

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  • Page 1: Service Manual

    9800 Overhead Projector Service Manual 3M Visual Systems Division 6801 River Place Boulevard Austin, Texas 78726-9000 Printed in U.S.A. E3M 7/96 78-6970-5568-5 Rev. C...

  • Page 2: Table Of Contents

    5-3-4. How to Replace the Lamp Socket 9800 Service Manual E 3M 1996 ............
  • Page 3 ..............9800 Service Manual E 3M 1996 .

  • Page 4: Overview

    11. Accessory Outlets (design varies by country) 12. Cord Wrap 13. Circuit Breaker (5 amps) 14. Power Cord 9800 Service Manual E 3M 1996 It is written for the service technician who has basic electrical knowledge and technical skills. Refer to the Illustrated Parts Breakdown (Publication 78-6970-5567-7) to cross-reference part numbers required to order replacement parts.

  • Page 5: Physical Dimensions

    (9.9 in.) Figure 1-2. Physical Dimensions 9800 Service Manual E 3M 1996 1-1-3. Safety Features All versions of the 9800 projectors include: Interlock – Shuts off power to projector when the top cover is opened. 16.9 in. Thermostat – Shuts off power to the lamp if 16.6 in.

  • Page 6: Principles Of Operation

    Projection Mirror Lamps Light illuminates from the lamp and is reflected along the optical path. All 9800 projectors use lamp type EVD 400W 36V. Avoid excessive vibration or jarring of the projector when the lamp is on. Because the lamp filament becomes more brittle at the operating temperature, shocks may cause premature failure of the lamp.

  • Page 7: Cooling

    The focal length of the projection lens is 342 mm (13.5 in.). The 9800 projector has an open head design with triplet lens and 1.3X magnifier lens. Figure 1-4. Open Head Triplet Lens FL=342 mm, 13.5 in.

  • Page 8: Lamp Changer And High/Low Controls

    1-2-3. Lamp Changer and High/Low Controls Lamp Changer The 9800 projector has a lamp changer feature. The lamp changer dial is accessed by lifting the control panel door. Rotate the lamp changer dial left or right to select the alternate lamp.

  • Page 9: Calculating Projector-To-Screen Distance For Desired Image Size

    FOCAL LENGTH OF HEAD SCREEN SIZE STAGE/LCD PANEL APERTURE SIZE 9800 Service Manual E 3M 1996 Section 1 – Introduction For example: To fill a 152 cm x152 cm (60 in. x 60 in.) screen, how far from the screen should you position a 285 mm (11.2 in.) stage projector with an...
  • Page 10 9800 EVD FL = 292 mm (11.5 in.) (11.5 in.) Figure 1-6. Projector-To-Screen Distances 9800 Service Manual E 3M 1996 127 cm 152 cm 127 cm 152 cm 50 in. x 50 in. 60 in. x 60 in. 70 in. x 70 in. 84 in. x 84 in. 96 in. x 96 in.
  • Page 11 3Mt Overhead Projector 9800 Series Section 1 – Introduction This page intentionally left blank 9800 Service Manual E 3M 1996...

  • Page 12: Set-Up Procedure

    (4) for clearest image. Figure 2-2. Adjust Mirror and Focus 9800 Service Manual E 3M 1996 Section 2 – Operating The 9800 Projector 5. Rotate color tuning knob for color-free image. See Color Tuning for details. 9800-81I...

  • Page 13: Fold Down Procedure

    Figure 2-4. Raise Head, Lift Post Latch and Fold Post 9800 Service Manual E 3M 1996 Section 2 – Operating The 9800 Projector 5. Rotate focus knob (6) counterclockwise to lower head until it stops.

  • Page 14: Operating Instructions

    5. Adjust angle of projection mirror (2) to raise or lower the image on the screen. Figure 2-8. 9800 Service Manual E 3M 1996 Section 2 – Operating The 9800 Projector 6. For best results, tilt projection screen (3) toward projector until the top and bottom of the projected image appear square and without distortion.

  • Page 15: High/Low Lamp Setting

    Lamp will not illuminate unless control panel door is closed. 9800 Service Manual E 3M 1996 Section 2 – Operating The 9800 Projector 2-5. High/Low Lamp Setting Activate the High/Low switch to select High (bright) or Low (normal) lamp illumination.

  • Page 16: Lamp Replacement

    3. Allow lamp to cool before replacing. Lamp and adjacent metal parts are hot. Allow lamp to cool before replacing. 9800 Service Manual E 3M 1996 Section 2 – Operating The 9800 Projector 4. Release spring catch (1) and open condenser lens frame. Figure 2-13.
  • Page 17 3MtOverhead Projector 9800 Series Section 2 – Operating The 9800 Projector This page intentionally left blank 9800 Service Manual E 3M 1996...

  • Page 18: Cleaning

    1. To remove surface dirt, use a soft brush or compressed air. Figure 3-2. 2. To remove smudges or fingerprints, dampen a cotton ball or soft, lint-free cloth with 3M overhead cleaner and gently rub mirror surface. Figure 3-3. Caution The projection mirror is a front surface mirror.

  • Page 19: Projection Head Lens, Magnifier Lens Stage Glass

    9800 Service Manual E 3M 1996 Section 3 – Maintenance 3-1-3. Fresnel Lens In the 9800 projector, the Fresnel Lens is a doublet lens with a smooth surface on both sides. Do not clean the Fresnel Lens by immersing or flushing in water.

  • Page 20: Setting Up A Test Facility

    (Figure 4-1). 2. Set the overhead projector on the test stand so that it points towards the wall. 9800 Service Manual E 3M 1996 Section 4 – Adjustments Figure 4-1. Test Facility Layout 3. Measure the vertical distance from the floor to the center of the front projection lens (Figure 4-2).
  • Page 21 9800 Service Manual E 3M 1996 Section 4 – Adjustments Required Tools The following tools are required to service 9800 Overhead Projectors: 1. Screwdriver (standard and #2 Phillips) 2. Box-End Wrench, 11 mm (7/16 in.) 3.

  • Page 22: Optical Alignment

    Post Alignment Head Alignment d Square Image d Centered Image Color Tuning 9800 Service Manual E 3M 1996 Section 4 – Adjustments 4-2-1. Lamp Position Check the lamp position to verify it is aligned and centered in the optical path.

  • Page 23: Head Alignment (Square Image)

    There are no adjustments to correct a bent post. 9800–059I Figure 4-5. Post Nut 9800 Service Manual E 3M 1996 4-2-3. Head Alignment (Square Image) If the image is not square and focused in all four corners, the projection head could be out of alignment.

  • Page 24: Head Alignment – Centered Image

    Machines built after February 1995, Mfg. Code C1, Serial # 603075 or higher have the split head as shown in Figure 4-8. 9800 Service Manual E 3M 1996 4-2-4. Head Alignment – Centered Image The projection head needs alignment when...

  • Page 25: Color Tuning Adjustment

    To remove blue corners, rotate dial to the left (counterclockwise). b. To remove yellow/orange to brown corners, rotate dial to the right (clockwise). 9800 Service Manual E 3M 1996 remove blue Color Tuning External Figure 4-11. Color Tuning Dial Section 4 –...

  • Page 26: Open Projection Head Assembly

    5-1. Open Projection Head Assembly Retaining Screw Screw Clip Projection Mirror Upper Lens Bracket Figure 5-1. Open Projection Head Assembly 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly Triplet Lens Head Cover Plastic Washer Lower Lens Bracket Washer 9800–63I...

  • Page 27: How To Replace The Mirror Assembly

    Apply 4-5 in.-lbs. of torque to mirror retaining screws. 7. Remove protective film from the Mirror. 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5-1-2. How to Replace the Triplet Lens 1. Remove head cover and mirror assembly. See Section 5-1-1.

  • Page 28: How To Replace The Fresnel Lens

    When replacing the hinge bracket, be certain the button on the bracket is fitted inside the hole in the base. See Figure 5-3. 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5-2-2. How to Replace the Fresnel Lens 1.

  • Page 29: How To Replace The Top Cover Latch

    There is a tension spring (not shown) attached to the plastic peg on the back side of the latch. Figure 5-6. Top Cover Latch 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5-2-4. How to Replace the Stage Glass 1.

  • Page 30: How To Replace The Power Switch Button

    1. Open the top cover. 2. Remove the power switch button by spreading apart the hinge holders. See Figure 5-8. Figure 5-8. Replacing Power Switch 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5-2-6. How to Replace the On/Off Switch Actuator 1.

  • Page 31: How To Replace The Power Switch Interlock

    2. Open top cover. 3. Remove wire connectors. Figure 5-11. 4. Remove two retaining screws to free the interlock switch. 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5. Reassemble in reverse order. Screws Figure 5-11. Power Switch Interlock...

  • Page 32: How To Disassemble The Optical/Lamp Assembly

    Figure 5-13. Mounting Bracket Retaining Screw Figure 5-13. Lamp Control Module 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 6. Disconnect lamp assembly wires from the lamp control module. 7. Remove the e-ring and unhook the secondary lamp changer rod.

  • Page 33: How To Replace The Hot Mirror

    6. Carefully, lift the hot mirror bracket to separate it from the condenser lens bracket. This will free the hot mirror. Figure 5-16. 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly Figure 5-16. Open Hot Mirror Bracket 7. Reassemble in reverse order.

  • Page 34: How To Replace The Condenser Lens

    É É É É É É É Bowed side toward hot mirror Figure 5-18. Condenser Lens Orientation 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5-3-4. How to Replace the Lamp Socket Unplug projector power cord before performing any maintenance to electrical components.

  • Page 35: How To Replace The Reflector

    Section 5-3-1. 3. Squeeze reflector spring clips to free them from the reflector bracket. 4. Pull straight down to remove reflector. 5. Reassemble in reverse order. 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly Reflector Bracket Reflector...

  • Page 36: How To Replace The Overvoltage Protector Circuit Board (Opc)

    Section 6-2. Stand Off Spring Latch Baffle Bracket Figure 5-21. Circuit Board and Thermostat 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5-4-2. How to Replace the Transformer Unplug projector power cord before performing any maintenance to electrical components.

  • Page 37: How To Replace The Internal Voltage Switch

    Spring Latch Wire Terminal Figure 5-23. Internal Voltage Switch 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5-4-4. How to Replace the Interlock Switch Unplug projector power cord before performing any maintenance to electrical components. All projectors have an interlock switch located on the inside wall of the projector next to the top cover release latch.

  • Page 38: How To Replace The Circuit Breaker

    Å Å Å Å Å Å Figure 5-25. Baffle Bracket Retaining Screws 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5-4-6. How to Replace the Circuit Breaker Unplug projector power cord before performing any maintenance to electrical components.

  • Page 39: How To Replace The Accessory Outlets

    6. Remove outlet from projector body. a. Squeeze spring latches and pull outlet straight out. Figure 5-29. –OR– 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly b. Pry off plastic frame, unscrew retaining screws and pull outlet inward into projector cavity.

  • Page 40: How To Replace The Power Cord

    4. Open top cover. 5. Remove three wire connectors, slide strain relief off end of power cord and remove cord from projector body. 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 6. Reassemble in reverse order. Outlet Shield...

  • Page 41: How To Replace Fan Blade And Motor

    Do not over tighten the retaining screws. Excess torque will flatten the vibration isolation pads. Caution Be sure that wires are not pinched when reassembling. 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly Mounting Bracket Rubber Figure 5-33. Fan/Blade Assembly...

  • Page 42: How To Disassemble The Post Assembly

    Caution When reassembling, be sure a washer is placed on each side of the Post. Figure 5-35. Figure 5-34. Post Lock Assembly 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly 5-6-2. How to Disassemble the Post Lock Assembly 1.

  • Page 43: How To Disassemble The Focus Assembly

    If the Rack is replaced, be certain that the open side faces the direction of the knob. Figure 5-37. Screws Figure 5-36. Post Nut 9800 Service Manual E 3M 1996 Section 5 – Disassembly/Reassembly Figure 5-37. Focus Assembly Cover Focus Knob 9800–73I...

  • Page 44: Troubleshooting Matrix

    Neither lamp nor fan will energize. c. Is stage cover closed? d. Is power switch working? 3M 9800 Service Manual Solution: Identifies corrective actions required to overcome each problem. Section: Specifies the section numbers in this manual describing the corrective procedure.
  • Page 45 Vertical Keystoning: Projected image is wider at the top than at the bottom. 3M 9800 Service Manual Things To Check a. Is lamp fully seated in a. Seat lamp squarely into socket? b. Is lamp burned out? b.
  • Page 46 Projected image does not have uniform brightness. Double images appear. Fan motor does not run but lamp illuminates. 3M 9800 Service Manual Things To Check a. Image is offset because a. Rotate projector left or light beam is not projected at 90_ angle to screen? b.

  • Page 47: How To Check The Overvoltage Protector Circuit Board (Opc)

    6. Verify the jumpers are set to the correct SPS for the line voltage at the transformer. Figure 6-1. Switch Point Setting (SPS) Values 3M 9800 Service Manual Section 6 – Troubleshooting Min/Max SPS Value * Country SPS Setting 100.5-103V...

  • Page 48: Technical Assistance

    6-3. Technical Assistance For technical assistance call: U.S. and Canada: (7:30 am to 5:30 pm central time) 800-328-1371 In other locations: Contact your local 3M Sales Office. Technical Assistance Center: For information or technical support on any 3M Visual Systems Division product, contact the Technical Assistance Center via telephone, fax, Profs or Internet.
  • Page 49 9800 Overhead Projector Section 6 – Troubleshooting This page intentionally left blank 3M 9800 Service Manual...

  • Page 50: Section 7 - Electrical Diagrams

    9800 Overhead Projector 7-1. Electrical LEGEND 7-2. Wiring Wire jumpers are identified by numbered callouts. Refer to the 9800 Illustrated Parts Breakdown manual for the corresponding part number. 3M 9800 Service Manual 9800 – Electrical Section 7 – Electrical Diagrams...
  • Page 51 9800 Overhead Projector Section 7 – Electrical Diagrams This page intentionally left blank 3M 9800 Service Manual...
  • Page 52 3M Visual Systems Division 6801 River Place Boulevard Austin, Texas 78726-9000 Printed on recycled paper. Printed in U.S.A. E 3M 7/96 78-6970-5568-5 Rev. C...

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