Table of Contents

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S e rv ice Ma n u a l
020-101694-03
Roadie 4K35 and 4K45

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Summarization of Contents

Introduction
Site requirements
Outlines necessary conditions for safe projector installation and operation.
Physical operating environment
Details the ambient temperature specifications for projector operation.
Power connection
Explains the requirements for permanent wiring and power cord connections.
Service guidelines
Ordering parts
Provides instructions for ordering replacement parts, including required information.
Interconnections and line drawings
Explains the purpose of interconnect diagrams and line drawings for installation.
Replacing modules
Guides on ensuring correct module replacement and checking procedures.
Servicing live equipment
Details safety procedures for working with powered-on projector equipment.
Safety and warning guidelines
Lists critical safety warnings for projector installation and operation.
AC/power precautions
Outlines essential safety measures and requirements for AC power connections.
Lamp precautions
Details safety procedures and hazards associated with handling projector lamps.
Product safety labels
Explains the meaning and importance of various safety symbols used on the projector.
Maintenance and cleaning
Ventilation and Cooling
Describes how vents and louvers maintain optimal operating temperatures.
Inspecting and cleaning the airflow interlocks
Details checks for airflow interlocks to remove dust.
Inspecting and cleaning the lamp blower
Guides on inspecting and cleaning the lamp blower for optimal airflow.
Inspecting and cleaning the fan extractor
Details checks for the fan extractor to prevent overheating.
Inspecting and filling the coolant reservoir
Outlines procedures for inspecting and refilling the coolant reservoir.
Inspecting the rear exhaust assembly
Describes inspection of the rear exhaust assembly for blockages.
Filtration
Explains the role of filters in protecting the projector from foreign materials.
Inspecting the light engine air filter
Details inspection of the air filter located behind the air filter cover.
Inspecting the laminar airflow device filter
Guides on inspecting the filter attached to the light engine assembly.
Inspecting and cleaning lamps
Provides guidance on inspecting and cleaning projector lamps for brightness.
Removing dust from the lamp
Instructions for removing dust from the lamp to maintain image brightness.
Removing fingerprints, smudges, or oil from the lamp
Procedures for cleaning lamps to ensure optimal image brightness.
Inspecting and cleaning optics
Guides on inspecting and cleaning optical components like lenses and reflectors.
Tools recommended for removing dust or grease
Lists recommended tools for cleaning optical components.
Removing dust from the projection lens
Instructions for cleaning dust from the projector's projection lens.
Removing fingerprints, smudge, or oil from the projection lens
Procedures for cleaning projection lenses of smudges.
Service setups
Turning the projector on
Details the procedure for powering the projector on and activating lamps.
Turning the projector off
Outlines steps for safely powering down and disconnecting the projector.
Adjusting horizontal boresight
Guides on adjusting lens mount tilt for screen-to-projector alignment.
Adjusting vertical boresight
Details adjusting lens mount tilt to compensate for screen-to-projector tilt.
Adjusting the fold mirror
Explains how to re-adjust the fold mirror if image parts are missing.
Aligning the integrator module
Guides on aligning the integrator module for focus and illumination.
Converging the image
Details aligning red, green, and blue image components for accurate color.
DMD convergence
Explains the importance of aligning DMD panels for accurate color representation.
Evaluating the image convergence
Provides steps to evaluate image convergence using test patterns.
Adjusting the image convergence
Guides on altering formatters to achieve pure white lines and proper overlap.
Image convergence assessment criteria
Lists criteria to determine satisfactory alignment and convergence.
Red image non-uniformity
Describes issues with red image over-sizing and how to minimize them.
Troubleshooting
Projector does not power on
Provides resolutions for the projector not powering on despite AC connection.
Lamp does not ignite
Offers solutions when the projector is on but the lamp fails to ignite.
Lamp suddenly turns off
Lists possible causes and solutions for unexpected lamp shutdowns.
Flicker, shadows, or dimness
Addresses image issues like flickering, shadows, or dimness during projection.
LampLOC not working
Details troubleshooting steps when the LampLOC function is not operational.
Touch panel controller is blank
Solutions for when the projector's touch panel controller display is blank.
Blank screen, no display of image
Steps to resolve issues where the screen is blank with no image.
Cannot communicate with the projector
Troubleshooting network communication problems with the projector.
Inaccurate display colors
Guides to correct issues with projected image colors not displaying accurately.
Display is not rectangular
Steps to fix image display that is not rectangular on the screen.
Display has suddenly frozen
Solutions for when the projected image on the screen freezes.
Display is jittery or unstable
Addresses problems with projected images appearing jittery or unstable.
Parts and module replacement
Maintenance prerequisites
Lists tasks to perform before commencing any projector servicing.
Tools required for service
Lists essential tools needed for performing projector maintenance and repairs.
Index of parts and modules
Provides a list of parts and their corresponding part numbers for replacement.
Shutting down for maintenance
Details essential steps before starting any projector inspection or maintenance.
Projector covers
Instructions on how to remove various projector covers for access.
Removing the touch panel controller
Step-by-step guide for removing the projector's touch panel controller.
Removing the projector shroud (optional)
Procedure for removing the lens side shroud for access.
Removing the front top cover
Instructions for removing the front top cover for component access.
Removing the light engine cover
Steps for removing the light engine cover to access the light engine.
Removing the rear top lid
Procedure for removing the rear top cover for component access.
Removing the front lamp-side cover
Guides on removing the front lamp-side cover.
Removing the lamp door
Instructions for removing the lamp door to access the lamp compartment.
Removing the front lens-side cover
Steps for removing the front lens-side cover.
Removing the rear lens-side cover
Procedure for removing the rear lens-side cover for access.
Removing the rear cover
Guides on removing the rear cover for access to various components.
Removing the front cover
Detailed steps for removing the main front cover of the projector.
Filtration
Explains the importance of filters and precautions for their use and maintenance.
Removing the light engine air filter
Procedure for removing and cleaning the light engine air filter.
Ventilation and Cooling
Replacing the card cage exhaust fans-bottom (fan #1 and 2)
Instructions for replacing specific card cage exhaust fans.
Replacing the radiator fan (fan #3)
Procedure for replacing the radiator fan component.
Replacing the laminar airflow device fan (fan #4)
Guides on replacing the laminar airflow device fan.
Replacing the light engine fan pack (fan #5, 6, 7, and 8)
Instructions for replacing the light engine fan pack.
Replacing the light engine fan (fan # and15)
Procedure for replacing specific light engine fans.
Replacing the card cage fan-back (fan #9)
Guides on replacing the card cage fan-back.
Replacing the card cage intake fans-top (fan #10, 11 and 12)
Instructions for replacing top card cage intake fans.
Replacing the igniter fan (fan #16)
Procedure for replacing the igniter fan.
Replacing the HIP fan (fan #13)
Guides on replacing the HIP fan component.
Replacing the liquid cooling pump fan (fan #14)
Instructions for replacing the liquid cooling pump fan.
Replacing the IMCB fan (fan #18)
Procedure for replacing the IMCB fan.
Removing the main AC blower
Steps for removing the main AC blower unit.
Replacing the extractor fan
Guides on replacing the projector's extractor fan.
Removing the starter capacitor
Procedure for removing the starter capacitor component.
Removing the liquid cooling reservoir
Instructions for removing the liquid cooling reservoir.
Removing the radiator
Guides on removing the radiator assembly from the projector.
Replacing the main AC blower vane switch
Procedure for replacing the AC blower vane switch.
Replacing the remote temperature sensor module
Instructions for replacing temperature sensor modules.
Removing the low profile extractor
Guides on removing the low profile extractor unit.
Replacing the red FPGA blower (fan #19)
Procedure for replacing the fan cooling the red FPGA board.
Replacing the firewall fan (fan #20)
Instructions for replacing the firewall fan for cooling.
Optics
Removing the lamp
Detailed procedure for safely removing the projector lamp.
Installing the lamp
Step-by-step guide for correctly installing a new projector lamp.
Replacing the light engine
Instructions for replacing the projector's light engine assembly.
Replacing the illumination optic system
Procedure for replacing the entire illumination optic system.
Replacing the cold mirror
Guides on removing and replacing the cold mirror component.
Replacing the fold mirror
Instructions for removing and replacing the fold mirror.
Replacing the integrator snood
Procedure for replacing the integrator snood assembly.
Replacing the integrator assembly
Guides on removing and replacing the integrator assembly.
Replacing the light sensor module
Instructions for removing and replacing the light sensor module.
Replacing the UV filter
Procedure for removing and replacing the UV filter component.
Electronics
Replacing the backplane
Instructions for removing and replacing the projector's backplane.
Replacing the high speed image processor
Guides on removing and replacing the high-speed image processor board.
Replacing the MCPU board
Procedure for removing and replacing the MCPU board.
Replacing the option cards
Instructions for removing and replacing various option cards.
Replacing the primary environmental board
Guides on removing and replacing the primary environmental board.
Replacing the secondary environmental board
Procedure for removing and replacing the secondary environmental board.
Replacing the integrated motor control board
Instructions for replacing the integrated motor control board.
Replacing the lamp adjuster
Guides on replacing the projector's lamp adjuster assembly.
Replacing the centrifugal fan interface board
Procedure for replacing the centrifugal fan interface board.
Replacing the igniter
Instructions for removing and replacing the igniter component.
Replacing the AC line filter
Guides on removing and replacing the AC line filter.
Replacing the AC breaker switch
Procedure for removing and replacing the AC breaker switch.
Replacing the AC relay
Instructions for removing and replacing the AC relay.
Replacing the low voltage power supply
Guides on removing and replacing the low voltage power supply.
Replacing the standby power supply
Procedure for removing and replacing the standby power supply.
Lenses
Removing the projection lens
Detailed steps for correctly removing the projector's projection lens.
Replacing the lens mount
Instructions for removing and replacing the projector lens mount.
Replacing the anode yoke
Guides on removing and replacing the anode yoke assembly.
Replacing the douser motor
Procedure for removing and replacing the douser motor.
Replacing the ceramic douser plate
Instructions for removing and replacing the ceramic douser plate.
Replacing the reflector and heat dump
Guides on removing and replacing the reflector and heat dump.
Testing ground continuity and dielectric strength
Outlines procedures for testing electrical safety after maintenance.
Preparing the lamp power supply for testing
Steps to prepare the lamp power supply for electrical safety tests.
Testing ground continuity
Details on performing ground continuity tests for electrical safety.
Testing dielectric strength
Guides on performing dielectric strength tests for insulation integrity.

Table of Contents