FILE NO. SERVICE MANUAL Multimedia Projector Model No. PLC-XL51 U.S.A, Canada, Europe, U.K, original Version Chassis No. KV7-XL5100 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, additional Service Literature is required.
Contents SERVICE MANUAL ................. 1 System control .................7 Contents .................... Lamp control ..................73 Safety Instructions ................3 Audio circuit ..................74 Safety Precautions ................3 Power supply & protection circuit ..........75 Product Safety Notice ..............3 Fan control circuit ................76 Service Personnel Warning ............
Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacture’s instructions. Replace Battery With SANYO Electric Co., Ltd., Part No. 645 089 8587 Only. Use of Another Battery May Present A Risk Of Fire or Explosion.
technical Specifications Mechanical Information Projector Type Multi-media Projector Dimensions (W x H x D) 14.7” x 7.75” x 19.49” (374.0 mm x 196.8 mm x 495.0 mm) (Not including Rear leg) Net Weight 16.9 lbs (7.7 kg) Feet Adjustment 0˚ to 1.0˚ Panel Resolution LCD Panel System 0.8”...
■ Circuit Protections This projector provides the following circuit protections to operate in safety. If the abnormality occurs inside the projector, it will automatically turn off by operating one of the following protection circuits. Fuse A fuse is located inside of the projector. When the POWER indicator is not lightning, the fuse may be opened.
Circuit Protects Lamp cover switch Lamp cover switch (SW901) The lamp cover switch (SW901) cuts off the drive signal to the lamp circuit when the lamp cover is removed or not closed com- pletely. After opening the lamp cover for replacing the lamp ass’y, place the lamp cover correctly otherwise the projector can not turn on.
Circuit Protects 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 cool- ing 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.
■ Maintenance and Cleaning Cleaning the Air Filter The air filter prevents dust from accumulating on the surface of the optical elements inside the projector. Should the air filter become clogged with dust particles, it will reduce cooling fans’ effectiveness and may result in a buildup of internal heat and adversely affects the life of the projector.
Maintenance and Cleaning Cleaning the Projection Window CAUtIoN This projector is equipped with a projection window. Do not rub the projection window with a hard fiber cloth or hit it with a something hard to prevent the projection window from scratching. Do not use a chemical cleaner (liquid and solid) to avoid deteriorating the projection window. Unplug the AC power cord before cleaning.
Maintenance and 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.
REPLACEMENt LAMP Replacement lamp can be ordered through your dealer. When ordering a projection lamp, give the following information to the dealer. Model No. of your projector : PLC-XL51 ● Replacement Lamp type No. : PoA-LMP121 ●...
Lamp Replacement Lamp Replacement Counter Reset Be sure to reset the Lamp replacement counter after the lamp is replaced. When the Lamp replacement counter is reset, the LAMP REPLACE indicator stops lighting. Turn the projector on and press the MENU button to display the On-Screen Menu.
Lamp Replacement How to check Lamp Used time The LAMP REPLACE indicator will light yellow when the total lamp used time (Corresponding value) reaches 3,000 hours. This is to indicate that lamp replacement is required. The total lamp used time is calculated by using the below expression, Total lamp used time (Corresponding value) = eco + ( normal x 1.5)
■ Security Function Notice Security Function disable This projector provides security functions such as "Key lock", "PIN code lock" and "Logo PIN code lock". When the projector 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.
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Replace the rechargeable battery pack Use only the specified battery for this projector. Using other types of battery may cause accident or fire hazard. Replacement Battery: SANYO Ni-MH BATTERY PACK Part No. 645 089 8587 Note: • The PIN code and settings you have changed are effective even after the battery is changed.
■ Network Easy Setup Function Network Easy Setup function by using the Sd memory card 1. outline This projector provides a function to setup the network automatically by reading the network setting file (PJ_Network.ini) stored in the top directory of the SD memory card. By using the function, network setup can be done easily. Setting Procedure 1.
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Network Easy Setup Function 2-1-1 Used LAN No. Used LAN No. is specified. Setting Object LANNO Item type LAN No. 1 to 6 * If out of range value is specified, the setting is invalid. 2-1-2 Basic Network Setting Basic network setting is specified. LAN1 LAN LAN3...
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Network Easy Setup Function 2-1-4 Wireless LAN (WEP key) Setting WEP key of Wireless LAN are specified. WIRELESS4-WEP WIRELESS5-WEP Setting Object WEP64 / SHARED-WEP64 WEP18 / SHARED-WEP18 WEP key (1) WEP key () Item types 5 characters for ASCII 13 characters for ASCII (4 items) 10 characters for HEX 6 characters for HEX...
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Network Easy Setup Function description Describe "Example of setting file" as below; Used LAN No. Setting Object LAN No. LANNO LAN1 is specified for used LAN No. If the projector provides the SD memory card, LAN1 is selected forcibly. If this item is not specified, this function is disable.
■ Mechanical disassemblies Disassemble should be made following procedures in numerical order. Following steps show the basic procedures, therefore unnecessary step may be ignored. Caution: The parts and screws should be placed exactly the same position as the original other- Screws Expression wise it may cause lose of performance and product safety.
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Mechanical disassemblies 2. Remove the 2 DEC Legs. 3. Remove the 2 screws-B (M3x35). 4. Remove the 2 Stand Legs and Cap Stand Legs. DEC Leg DEC Leg Stand Leg Stand Plate Stand Leg Cap Stand Leg Cap Stand Leg Stand (accessory) Removal.
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Mechanical disassemblies Lamp Unit and Alarm Battery removal. 1. Remove the screw-A(M3x8) and remove the Lamp cover. 2. Loosen the 2 screws-B and remove the Lamp uint. 3. Remove the screw-C (M3x8) and remove the Battery cover. 4. Remove the Battery. 5.
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Mechanical disassemblies Cabinet top ass'y removal. 1. Remove the 9 screws-A(M3x8) and remove the Cabinet top ass'y. 2. Remove the screw-B(T3x8), remove the R/C board, R/C pipe and remove the Decoration R/C. 3. Remove the Control board and Control Button. 4.
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Mechanical disassemblies Main Board ass'y removal. 1. Remove the 2 screws-A(M2.5x6) and remove the Antenna board, Shield antenna. 2. Remove the 4 screws-B(M2.5x6), screw-C(M4x6), 2 screws-D(T3x10) and remove the Main board ass'y. Antenna board Shield antenna Main board ass'y Hook Press this part - 24 -...
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Mechanical disassemblies 3. Remove the 3 screws-E(T3x6) and AV panel. 4. Remove the 4 nuts-F and Holder AV. 5. Remove the screw-G(M3x4), remove the LED board and remove the Decoration LED. Main Board Ass'y LED board Decoration LED Holder AV AV Panel - 25 -...
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Mechanical disassemblies 6. Remove the 2 screws-H(M2.5x6) and remove thenetwork board ass'y. Main board AV board Network board ass'y - 26 -...
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Mechanical disassemblies 7. Remove the 3 screws(T3x8) and disassembly the network board ass'y. Network board ass'y (T3x8) x3 Module board Shield MCI - B Shield MCI - A Network board - 27 -...
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Mechanical disassemblies Exhaust Fan ass'y removal. 1. Remove the exhaust Fan ass'y(FN903, FN904) upward. 2. Remove the 2 screws-A(T3x8), remove the stopper exhaust Fan and remove the FN903, FN904. Exhaust Fan ass'y Mounting exhaust duct FN904 Exhaust Fan ass'y Stopper exhaust fan FN903 - 28 -...
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Mechanical disassemblies Power supply ass'y removal. 1. Remove the screw-A(M3x8) and remove the Lamp connector. 2. Remove the screw-B(M2.5x6) ,remove the Ballast trigger holder and shield plate. 3. Remove the 2 screws-C(T3x8), remove the screw-D(T3x8) and remove the Power Supply ass'y. Ballast trigger holder Power supply ass'y Shield plate...
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Mechanical disassemblies Power supply ass'y disassemble. Insulation sheet -A Insulation sheet -B M2.5x6 T3x6 Power supply ass'y Power board T3x6 T3x6 Ballast unit Holder - 30 -...
Mechanical disassemblies Optical unit removal. 1. Remove the 5 screws-A(T3x8) and remove the Optical unit. Optical unit Caution ; Do not lose these parts. (4 pieces) (damper and Washer). - 31 -...
Mechanical disassemblies Line filter board removal. 1. Remove the 3 screws-A(T3x8) and remove the Line filter board ass'y. 2. Remove the Shield plate. Shield plate Line filter board ass'y Holder Line filter board M3x6 M3x6 Line filter board ass'y InsulatIion sheet AC-A InsulatIion sheet AC-B...
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Mechanical disassemblies Lamp Cover Switch removal. 1. Remove the 2 screws-A(T3x8), remove the Spacer sheet, remove the Holder-SW and remove the Thermal Switch (SW902) 2. Remove the screw-B(T3x8) and remove the Lamp cover switch (SW901). Spacer sheet Holder -SW Thermal SW(SW902) Lamp cover SW(SW901) - 33 -...
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Mechanical disassemblies Duct ass'y removal. 1. Remove the 6 screws-A(T3x30), remove the screw-B(T3x8) and remove the Duct ass'y. 2. Remove the 2 screws-C(T3x8) and remove the Duct top-A, Duct top-B. 3. Remove the Fans(FN901, FN902, FN905) and Temp board. Duct ass'y Duct top-A Duct top-B Duct ass'y...
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Mechanical disassemblies Alarm ass'y removal. 1. Remove the 2 screws(T3x8) and remove the Alarm ass'y. Alarm ass'y Buzzer board Alarm ass'y - 35 -...
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Mechanical disassemblies Speaker unit removal. 1. Remove the 2 screws-A (T3x12) and remove the speaker unit. Speaker unit M3x4 M3x4 Speaker Damper Damper Holder Spacer - 36 -...
■ Optical disassemblies Optical unit Projection lens removal. 1. Remove the 4 screws (M4x12), remove the shield plate remove the 4 spacer and remove the projection lens. Shield plate Projection lens Spacer Spacer Caution ; Do not lose these parts (damper). - 37 -...
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Optical disassemblies LCD panel/prism ass'y removal. 1. Remove the 4 screws-A (M2.5x8) and remove the LCD panel/prism unit. 2. Remove the 2 screws-B (M2.5x4), remove the screw-C (M3x10) and remove the LCD panel/prism ass'y. LCD panel/prism unit LCD panel/prism ass'y Damper Mounting prism Damper...
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Optical disassemblies R-Type LCD Panel/Prism Ass'y L-Type LCD Panel/Prism Ass'y There are 2 types of LCD Panel/Prism Ass'y for this model. Either L-Type or R-Type LCD Panel/Prism Ass'y is used on the projec- tor. Check which type of LCD Panel/Prism Ass'y is used with the figure. The optical-characteristics is different between L-Type and R-Type LCD Panel/Prism Ass'y.
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Optical disassemblies Integrator Lens ass'y and Relay Lens ass'y removal. 1. Remove the 2 screws-A (M2.5x5) and remove the Integrator Lens ass'y. 2. Remove the 2 screws-B (M2.5x5), remove the Relay Lens ass'y. Relay lens ass'y Integrator lens ass'y Relay lens ass'y Integrator lens ass'y Hooks Spring...
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Optical disassemblies Polarized glass ass'y removal. 1. Remove the screw-A (M2.5x5) and remove the Polarized glass ass'y (R, G, B). Polarized glass ass'y Green Blue Green, Blue Polarized glass ass'y Red Polarized glass ass'y Holder Film side Do not touch this surface and back surface.
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Optical disassemblies Optical base top removal. 1. Remove the Optical base top-B. 2. Remove the 2 screws (T3x8) and remove the Optical base top-A. Optical base top-A Optical base top-B Hook - 42 -...
■ Optical Adjustments Before taking optical adjustments below, remove the Cabinet Top following to the “Mechanical Disassembly”. Adjustments require a 2.0mm 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 2.0mm hex wrench and a slot screwdriver.
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 unifor- mity in white. 1) If the shading appears on the left or right of the screen as shown in White Fig.2-1 , loosen 1 screw...
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 uniformity in white. Fig.3 If the shading appears on the left or right of the screen as shown in loosen 1 screw , and adjust the slot to make color uniformity in white...
Optical Adjustments Projection lens focus adjustment Projection lens [ Before Adjustment ] The projector is set from the screen to 8 cm. The hole of the focus ring is set to the position of figure by operating the focus lever. (Screen size 78") Input a cross pattern.
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Optical Adjustments Loosen the 4 screws-A (A1, A2, A3, A4). Right and left focus under the screen is adjusted by using slot B. (Pre-adjustment) The screws-A1, A2 are lightly tightened and temporary is fixed. Focus on the entire screen is adjusted. Tighten the 4 screws-A (A1, A2, A3, A4).
Refer to the “Service Adjustment Data Table” for further description of adjustment group no., item no. and data value. To exit the service mode ON/STAND-BY button To exit the service mode, press the ON / STAND-BY button MENU button Service Mode SANYO Input Video Data Group COMPUTER NETWORK COMPONENT Ver.
Circuit Adjustments CAUTION: The each circuit has been made by the fine adjustment at factory. Do not attempt to adjust the following adjust- ments except requiring the readjustments in servicing otherwise it may cause loss of performance and product safety. Note: Before adjustment, turn on the projector more than 10 minutes.
Service Adjustment Output Voltage adjustment 1. Fan minimum voltage adjustment Equipment Digital voltmeter After replacing the Power Board readjust the Output voltage adjustment as follows. 1. Enter the service mode. 2. Change data values of each test points to adjust the fan 1.
Service Adjustment 4. Auto Calibration adjustment [Video] 7. Gamma Correction adjustment 1. Enter the service mode. This adjustment must use the service tool. 2. Receive the 16-step grey scale composite video signal Adjust the gamma curve correction by using the proper Video [Video] with mode.
Service Adjustment 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 following to the “Electrical adjustments”. Other items should be used with the initial data value.
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Service Adjustment Item Name Function Initial Range Note Group/Item Group 200 Option 0 Logo Prohibition (Forced No Logo Prohibition (0: Menu, 1: Forced, 0 - 1 Effective after AC On Brand) 3-9: not used) 0: 19200bps, 1: 9600bps, 2: 1 RS232C Baudrate Baud Rate 0 - 2 115200bps...
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Service Adjustment Item Name Function Initial Range Note Group/Item Uniformity adjustment Method 0: Output = Input x (kH+kV) /2 3 SEL 0 - 1 Setting 1: Output = Input x (kH+kV) 0 : Normal 1 : R/L reverse 2: U/D 4 HANTEN Adrres Reverse Setting 0 - 3...
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Service Adjustment Item Name Function Initial Range Note Group/Item Group 250 FAN Cntorol 0 FAN1 MIN ADJUST (DAC) 0 - 255 1 FAN1 MAX ADJUST (DAC) 0 - 255 DAC Output for Fan 2 FAN2 MIN ADJUST (DAC) Adjust the tolerance of DAC and Fan 0 - 255 Volage.
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Service Adjustment Item Name Function Initial Range Note Group/Item Group 254 Fan Control Range Setting (Temp./Voltage) Normal Ceiling Down 0 Not used 1 Not used 2 Not used 3 Not used 4 Not used 5 Not used 6 Not used 7 Not used 8 Not used 9 Not used...
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Service Adjustment Item Name Function Initial Range Note Group/Item With Onstart on. At the time of Power on after Cooling imperfect. 11 OnStart Cooling Start Threshold 0-100 Cooling The temperature set point for existence judgement 12 After shutdown cooling Cooling after shutdown (0: No, 1: Yes) Group 256 Fan Lamp Voltage Down Setting Current Lamp Voltage (0.1V)(Read...
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Service Adjustment Item Name Function Initial Range Note Group/Item CR - Offset Acquiring Area H-Start 4 CR - OFFSET AREA H START 0 - 1000 If not used: use Y's value Position CR - Offset Acquiring Area V-Start 5 CR - OFFSET AREA V START 0 - 1000 If not used: use Y's value Position 6 Y - GAIN AREA H START...
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Service Adjustment Item Name Function Initial Range Note Group/Item 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095 4 Disp Line 0 ~ 4095 7 Overscan Not used 0 - 255 8 VSBEG Not used 0 - 15 Group 511 SCART (575i)
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Service Adjustment Item Name Function Initial Range Note Group/Item Group 526 YCbCr (1080i - 60) 0 Total Dots 2200 0 ~ 4095 * Read only 1 Disp Dots 1872 0 ~ 4095 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095 4 Disp Line 1052...
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Service Adjustment Item Name Function Initial Range Note Group/Item 8 VSBEG Not used 0 - 15 Group 545 RGB Video (720P - 50 ) 0 Total Dots 1980 0 ~ 4095 1 Disp Dots 1246 0 ~ 4095 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095...
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Service Adjustment Item Name Function Initial Range Note Group/Item 4 Disp Line 1064 0 ~ 4095 7 Overscan Not used 0 - 255 8 VSBEG Not used 0 - 15 Group 553 RGB Video (1080P - 24) 0 Total Dots 2750 0 ~ 4095 1 Disp Dots...
■ Troubleshooting Indicators and Projector Condition Check the indicators for projector condition. Indicators LAMP Projector Condition POWER WARNING 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 be- ing cooled down.
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.
Troubleshooting No Picture Check following steps. No picture with all of Check signal processing stage and LCD driving stage; input sources Check power supply circuit 15.5V_PNL, 3.3V_DI and peripheral circuit. Check ICs IC501, IC531, IC561, IC401, IC301 and peripheral circuits. Check PC1/PC2-switching stage;...
Troubleshooting No Sound Check following steps. Check if the audio signal Check IC5001 and peripheral circuit. is observed at pins 10 and Check 9V_AUDIO, 16V power supply. 21 of IC5001. Check if the audio signal Check IC5041, 9V_AUDIO and peripheral circuit. is observed at pins 5 and Check the Mute signal at pin 7 of IC5041.
Control Port Functions Scaler I/O Port Functions (PW190) Pin No. Name Function Name Function Switch DDC-SW2 DDC mode switch OFF:L Switch DDC-SW1 DDC mode switch OFF:L Switch COMP_SW Component switch DE_MCI MCI data enable CK_MCI MCI clock VS_MCI MCI H-sync HS_MCI MCI V-sync Switch...
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Scaler I/O Port Functions (PW190) Continue Function Pin No. Name Function Name COMPONENT Component Video signal ANALOG RGB Analog RBG ANALOG RGB Analog RBG ANALOG RGB Analog RBG VIDEO VIDEO GSYNC ANALOG RGB SCART_CV H1-IN S-VIDEO S-VIDEO S_CHROMA ON_15.5V_PW 15.5V Power drive Power ON : H LAMP BLAST_AC Power control, Power ON : H...
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.
Mechanical Parts List Mechanical Parts Layout Optical Unit...
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Mechanical Parts Layout STAND STAND (ACCESS0RY) M19-1 M19-1 M19-1 M19-2 M19-1 M19-1 M19-2 M19-1...
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Optical Parts Layout L11-1 Optical Unit Polarized Glass -IN Polarized Glass (Red) Red: L02R GREEN BLUE Polarized Glass (Green, Blue) Green: L02G Blue : L02B The Polarized glass of Green and Blue include the holder.
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Optical Parts Layout Relay Lens out Integrator Lens In...
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Optical Parts Layout Optical unit inside...
PLC-XL51 KV7-XL5100 These schematic diagrams and printed wiring board drawings are part of the service manual original for chassis No. KV7_XL5100 models PLC-XL51. File with the service manual No. SM5110989-00 Note: All the information of part numbers and values indicated on these diagrams are at the beginning of production.
KV7-XL5100 Parts description and reading in schematic diagram 1. The parts specification of resistors, capacitors and coils Resistor Reading are expressed in designated code. Please check the parts Example 1/2 D J 10K B description by the following code table. 2.
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 1. D o not touch the part on hot side (primary circuit) or both parts on hot and cold sides (secondary circuit) at the same time. 2. Do not shorten the circuit between hot and cold sides. 3. T he grounding lead must be connected to the ground of the same circuit when measuring of voltages and waveforms. KEY SW (SIDE : B) KEY SW (SIDE : A) KEYSTONE...
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POWER (SIDE : A) POWER (SIDE : B) R684 C683 C685 C611 C611 C691 C681 C683 T601 C685 T601 L616 L611 R679 B SIDE D682 D681 L614 L603 D681 D682 FB601 L603 FB601 R614 MAIN A30C5 R648 R650 R613 Q601 Q602 D654 “K8R” D604 PC602 C607 R613 Q602 Q601...
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R/C (SIDE : A) R/C (SIDE : B) MODULE (SIDE : A) MODULE (SIDE : B) A SIDE(1st Re ow) B SIDE(2nd Re ow) ANTENNA A30C5 C2901 MAIN "K9901K" C9504 R9506 "K8D" R2901 IC9501 Q9501 R9501 K9501 L9501 AV (SIDE : A) NETWORK "K9301K" SW8753 SW8754 SW8751 SW8752 K40A K20A K40B ANTENNA (SIDE : A) ANTENNA (SIDE : B) K20B A SIDE(1st Re ow) A30C5 AV (SIDE : B) MODULE...
Note on Soldering Do not use solder containing lead. Solder This product has been manufactured using lead-free solder Use solder with the metal content and composition ratio 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 when which do not meet these conditions.