Page 1: Service Manual
FILE NO. SERVICE MANUAL Model No. PLC-XL50 Multimedia Projector U.S.A, Canada, Europe, U.K, original Version Chassis No. KM3-XL5000 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.
Page 2: Table Of Contents
Contents SERVICE MANUAL ................. 1 Alarm circuit ..................7 Contents .................... IIC bus control circuit ..............73 Safety Instructions ................3 Troubleshooting .................74 Safety Precautions ................3 Indicators and Projector Condition ..........74 Product Safety Notice ..............3 No Power ...................75 Service Personnel Warning ............3 No Picture ..................76 Battery Replacement Notice............
Page 3: Safety Instructions
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.
Page 4: Specifications
technical Specifications Mechanical Information Projector Type Multi-media Projector Dimensions (W x H x D) 14.7” x 7.75” x 19.49” (374 mm x 196.8 mm x 495 mm) (Not including Rear leg) Net Weight 16.74 lbs (7.6 kg) Feet Adjustment 0˚ to 1.0˚ Panel Resolution LCD Panel System 0.8”...
Page 5: Circuit Protections
■ Curcuit 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.
Page 6: Lamp Cover Switch
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.
Page 7: Warning Temperature And Power Failure Protection
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.
Page 8: Maintenance And Cleaning
■ 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.
Page 9: Cleaning The Projection Window
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.
Page 10: 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.
Page 11: Lamp Replacement
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-XL50 ● Replacement Lamp type No. : PoA-LMP121 ●...
Page 12: Lamp Replacement Counter
Lamp Replacement Lamp Replacement Counter 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.
Page 13: How To Check Lamp Used Time
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)
Page 14: Security Function Notice
■ 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.
Page 15: Mechanical Disassemblies
■ 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.
Page 16 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. 5.
Page 17 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. Remove the Air Filter upward. Battery Cover Lamp Cover Battery...
Page 18 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.
Page 19 Mechanical disassemblies Main Board ass'y removal. 1. Remove the 3 screws-A(M2.5x6), screw-B(T3x8), screw-C(M4x6) and remove the Main board ass'y. Main board ass'y Hook Press this part - 19 -...
Page 20 Mechanical disassemblies Main board ass'y 2. Remove the 2 screws-D(M2.5x6). 3. Remove the 3 screws-E(T3x6) and AV panel. 4. Remove the 4 nuts-F and Holder AV. AV board Main board Holder AV AV Panel - 20 -...
Page 21 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 - 21 -...
Page 22 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...
Page 23 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 - 23 -...
Page 24 Mechanical disassemblies Optical unit removal. 1. Remove the 5 screws-A(T3x8) and remove the Optical unit. Optical unit - 24 -...
Page 25 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...
Page 26 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) - 26 -...
Page 27 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 screw-C(T3x8) and remove the Duct-top. 3. Remove the Fans(FN901, FN902, FN905) and Temp board. Duct ass'y Duct top Duct ass'y FN902 FN901 FN905...
Page 28 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 - 28 -...
Page 29 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 - 29 -...
Page 30: Optical Disassemblies
■ Optical disassemblies Optical unit Projection lens removal. 1. Remove the 4 screws (M4x12), remove the shield plate and remove the projection lens. Shield plate Projection lens - 30 -...
Page 31 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...
Page 32 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 below. When replacing the LCD Panel/Prism Ass'y, you need to take "Panel Type Check and Setting"...
Page 33 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...
Page 34 Optical disassemblies Polarized grass ass'y removal. 1. Remove the screw-A (M2.5x5) and remove the Polarized grass ass'y (R, G, B). Polarized grass ass'y Polarized grass ass'y Polarized grass-IN Film sheet Hooks - 34 -...
Page 35 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-B Optical base top-A Hook - 35 -...
Page 36: Optical Parts Location And Direction
■ Optical Parts Location and direction Parts Name INTEGRATOR LENS (OUT) CONDENSER LENS (OUT) NC CONDENSER LENS (G) CONDENSER LENS (B) CONDENSER LENS (R) RELAY LENS (IN) MIRROR (B) MIRROR (R) PRISM (PBS) DICHROIC MIRROR (B) DICHROIC MIRROR (G) Rugged surface Print marker this top side.
Page 37: Adjustments
■ Adjustments Adjustments after Parts Replacement : Adjustment necessary : Check necessary ● ❍ Disassembly / Replaced Parts Polarized Glass LCD/ Projection Integrator Relay Power Main Prism lens Lens (IN) Lens (OUT) Board Board Ass’y Contrast Adjustment R-Contrast adjustment ● G-Contrast adjustment ●...
Page 38: Optical Adjustments
■ 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.
Page 39: 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 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...
Page 40: Relay Lens-Out Adjustment
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...
Page 41: Projection Lens Focus Adjustment
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.
Page 42 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).
Page 43: Electrical Adjustments
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 Ver. R 1.00...
Page 44: Circuit Adjustments
Service Adjustment 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.
Page 45 Service Adjustment 2. Panel Type Check and Setting Below adjustments are performed when the above auto calibration is failed. * Before setting, you need to check which type of LCD panel is Pedestal adjustment [PC] placed on the projector according to the item "LCD Panel/Prism Ass'y removal"...
Page 46 Service Adjustment 4. Auto Calibration adjustment [Video] 5. Auto Calibration adjustment [Component] 1. Enter the service mode. 1. Enter the service mode. Video 2. Receive the 16-step grey scale composite video signal 2. Receive the Color Bar 480i-component signal with Video [Video] [Component] with...
Page 47: Common Center Adjustment
Service Adjustment 6. Common Center adjustment 9. 50% White adjustment [Video] 1. Enter the service mode. 1. Enter the service mode. 2. Receive the 50%-Whole Gray computer signal with 2. Receive the 16-step grey scale composite video signal Video[Video] Computer1 [RGB] mode. with mode.
Page 48: Note On White Uniformity Adjustment
Service Adjustment 11. Gamma Correction adjustment [PC] This adjustment must use the service tool. Adjust the gamma correction by using the proper computer and "PROJECTOR SERVICE TOOL" software supplied sepa- rately. 12. Gamma Correction adjustment [Video] This adjustment must use the service tool. Adjust the gamma correction by using the proper computer and "PROJECTOR SERVICE TOOL"...
Page 49: Test Points And Locations
Service Adjustment Test Points and Locations MAIN BOARD ONLY IC561 IC501 K35G IC1802 IC801 K7301 K401A - 49 -...
Page 50: Service Adjustment Data Table
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.
Page 51 Service Adjustment Group/ Item Name Function Initial Range Note Item 162 PreCoast YCbCr 1080i 60Hz 0 - 63 163 PostCoast YCbCr 1080i 60Hz 0 - 63 164 PreCoast YCbCr 1080i 50Hz 0 - 63 165 PostCoast YCbCr 1080i 50Hz 0 - 63 166 PreCoast YCbCr 1035i 0 - 63 167 PostCoast YCbCr 1035i...
Page 52 Service Adjustment Group/ Item Name Function Initial Range Note Item 3 Noise Region 2 <NSREGIONY2> / <NSREGIONUV2> 0 - 1023 4 Noise Gain Level <NSFILTERY**> / <NSFILTERUV**> 0 - 255 Group 47 Noise Reduction (Time) Effective only for N.R L1 0 Noise Pixel Range <NSRANGEY>...
Page 53 Service Adjustment Group/ Item Name Function Initial Range Note Item PCStandard/PCDynamic/PCReal/PC- 2048/2096/1860/1860/1860/2048/209 ColorBoard/PCBlackBoard/AVStandard/ 2 B-SubGain 0-4095 AVDynamic/AVCinema/AVcolorBoard/ 1860/1860/1860 AVBlackBoard PCStandard/PCDynamic/PCReal/PC- 2048/2048/2088/2088/2088/2048/204 ColorBoard/PCBlackBoard/AVStandard/ 3 G-SubBright 0-4095 AVDynamic/AVCinema/AVcolorBoard/ 2088/2088/2088 AVBlackBoard PCStandard/PCDynamic/PCReal/PC- 2048/2048/2088/2088/2088/2048/204 ColorBoard/PCBlackBoard/AVStandard/ 4 R-SubBright 0-4095 AVDynamic/AVCinema/AVcolorBoard/ 2088/2088/2088 AVBlackBoard PCStandard/PCDynamic/PCReal/PC- 2048/2048/2088/2088/2088/2048/204 ColorBoard/PCBlackBoard/AVStandard/ 5 B-SubBright 0-4095 AVDynamic/AVCinema/AVcolorBoard/...
Page 54 Service Adjustment Group/ Item Name Function Initial Range Note Item 56 GhostB-Cent 0-2047 (MIN<-->MAX Cyclic Operation) 57 GhostB-Start 0-255 58 GhostB-End 0-255 59 BlockR1 0-2047 (MIN<-->MAX Cyclic Operation) 60 BlockG1 0-2047 (MIN<-->MAX Cyclic Operation) 61 BlockB1 0-2047 (MIN<-->MAX Cyclic Operation) 62 BlockR2 0-2047 (MIN<-->MAX Cyclic Operation) 63 BlockG2...
Page 55 Service Adjustment Group/ Item Name Function Initial Range Note Item 125 G-DCOffset-N9 0-2047 (MIN<-->MAX Cyclic Operation) 126 G-DCOffset-N10 0-2047 (MIN<-->MAX Cyclic Operation) 127 G-DCOffset-N11 0-2047 (MIN<-->MAX Cyclic Operation) 128 G-DCOffset-N12 1980 / 1980 0-2047 (MIN<-->MAX Cyclic Operation) 129 B-DCOffset-NGain 0-2047 (MIN<-->MAX Cyclic Operation) 130 B-DCOffset-N1 2044 / 2044 0-2047 (MIN<-->MAX Cyclic Operation)
Page 56 Service Adjustment Group/ Item Name Function Initial Range Note Item 194 G_V_INPUT_STEP_0 0-1023 (MIN<-->MAX Cyclic Operation) 195 G_V_INPUT_STEP_512 0-1023 (MIN<-->MAX Cyclic Operation) 196 G_V_INPUT_STEP_1024 0-1023 (MIN<-->MAX Cyclic Operation) 197 G_V_INPUT_STEP_1536 0-1023 (MIN<-->MAX Cyclic Operation) 198 G_V_INPUT_STEP_2048 0-1023 (MIN<-->MAX Cyclic Operation) 199 G_V_INPUT_STEP_2560 0-1023 (MIN<-->MAX Cyclic Operation) 200 G_V_INPUT_STEP_3072...
Page 57 Service Adjustment Group/ Item Name Function Initial Range Note Item 2 PJLink Enable PJLink 0 - 1 0: Disable 1: Enable 3 Shipping Setting 0 - 20 Default set when the value is set to 10 4 CABLE SW Long Cable 0 - 1 0: Disable, 1: Enable 0:Disable (Serial Command Eanble)
Page 58 Service Adjustment Group/ Item Name Function Initial Range Note Item 6 Green Gain Green Gain Setting 128/120/120/94/118 0 - 255 Normal/Red/Blue/Yellow/Green 7 Blue Gain Blue Gain Setting 128/128/106/128/128 0 - 255 Normal/Red/Blue/Yellow/Green 8 Table Uniformity adjustment table setting 0 - 7 Group 205 Spread Spectrum 0 Enable Spread ON/OFF...
Page 59 Service Adjustment Group/ Item Name Function Initial Range Note 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) 0 - 255 Adjust the tolerance of DAC and Fan 3 FAN2 MAX ADJUST (DAC) Volage.
Page 60 Service Adjustment Group/ Item Name Function Initial Range Note 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...
Page 61 Service Adjustment Group/ Item Name Function Initial Range Note Item Group 256 Fan Lamp Voltage Down Setting Current Lamp Voltage (0.1V)(Read 0 Lamp Voltage 0-255 only) Threshold to judge Lamp Voltage 1 Lamp Vol Threshold 30-90 Down ( V×10) 2 Fan1 Speed Gain 0-255 3 Fan2 Speed Gain 0-255...
Page 62 Service Adjustment Group/ Item Name Function Initial Range Note Item 8 CB - GAIN AREA H START 0 - 1000 9 CB - GAIN AREA V START 0 - 1000 10 CR - GAIN AREA H START 0 - 1000 11 CR - GAIN AREA V START 0 - 1000 12 Image AREA H WIDTH...
Page 63 Service Adjustment Group/ Item Name Function Initial Range Note Item 3 V Back Porch 0 ~ 4095 4 Disp Line 0 ~ 4095 Group 511 SCART (575i) 1 Disp Dots 0 ~ 4095 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095 4 Disp Line...
Page 64 Service Adjustment Group/ Item Name Function Initial Range Note Item 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095 4 Disp Line 1012 0 ~ 4095 Group 540 RGB Video (480i) 0 Total Dots 0 ~ 4095 1 Disp Dots 0 ~ 4095 2 H Back Porch...
Page 65 Service Adjustment Group/ Item Name Function Initial Range Note Item 1 Disp Dots 1868 0 ~ 4095 2 H Back Porch 0 ~ 4095 3 V Back Porch 0 ~ 4095 4 Disp Line 1012 0 ~ 4095 Group 550 RGB Video (1080P - 50) 0 Total Dots 2640 0 ~ 4095...
Page 66: Chassis Block Diagram
Chassis Block Diagrams Chassis over view 18,17,16 28,29,135 DHS,DVS,DCLK RXD1/TXD1 124,368 IRRCVR0 331,161 IC5301 SYNC SEP. <BA7078> IC5041 AUDIO OUTPIT IC5201 <TDA7056at> PC1/PC2-SW <AN5870> IC5001 AUDIO CONTROL <NJW1141> IC4011 IC4001 AUDIO - 66 -...
Page 67: System Control
Chassis Block Diagrams System control IC891 INVERTER <MH74LVC> IC3501 <M62334> IC301 SCALER <PW190> - 67 -...
Page 68: Lamp Control
Chassis Block Diagrams Lamp control - 68 -...
Page 69: Audio Circuit
Chassis Block Diagrams Audio circuit - 69 -...
Page 70: Power Supply & Protection Circuit
Chassis Block Diagrams Power supply & protection circuit IC651 POWER OSC. <STR-Z2156> IC601 P.F.CONTROL <FA5502> BLAST_AC FAN_ERR IC301 SCALER <PW190> - 70 -...
Page 71: Fan Control Circuit
Chassis Block Diagrams Fan control circuit TPFANA FN901 S16V FAN_A D3622 D3621 FN902 IC7811 D3624 Q7813 TPFANB FN903 FAN_B D3627 FN904 D3626 IC7841 D3629 Q7864 Q3601 P_FAIL P_FAIL P_Fail: H Power Error: On FAN_ERR TPFANC FN905 FAN_C D3632 D3631 IC7871 Q7841 Q3601 P_FAIL...
Page 72: Alarm Circuit
Chassis Block Diagrams Alarm circuit RECHARGABLE BATTERY - 72 -...
Page 73: Iic Bus Control Circuit
Chassis Block Diagrams IIC bus control circuit - 73 -...
Page 74: Troubleshooting
■ 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 being cooled down.
Page 75: 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 a ll of LED indicators are not lighting, the symptom indicates that the primary power supply circuit does not operate properly.
Page 76: 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 TP35B, TP35G, TP35R1. Check power supply circuit 15.5V and peripheral circuit. Check ICs IC501, IC531, IC561, IC2501, IC2531, IC2561, IC401, IC301 and peripheral circuits.
Page 77: No Sound
Troubleshooting No Sound Check following steps. Check if the audio sig- Check IC5001 and peripheral circuit. nal is observed at pins Check 9V_AUDIO, 16V power supply. 10 and 21 of IC5001. Check if the audio sig- Check IC5041, 9V_AUDIO and peripheral circuit. nal is observed at pins 5 Check the Mute signal at pin 7 of IC5041. The Mute signal is output from and 7 of IC5041.
Page 78: Control Port Functions
Control Port Functions Scaler I/O Port Functions (PW190) PIN NO. PORT NO. PORT NAME FUNCTION SIGNAL NAME DESCRIPTION PORTA0 XSTDBYEN Standby mode Enable/disable PORTA1 XRESET I/O Expander Reset PORTA2 WAKE UP for I/O Expander PORTA3 LAMP LAMP_DC_ON Lamp Control, Power On: H PORTA4 LAMP BLAST_AC...
Page 79: Iic Bus D/A Converter Port Functions (M6334)
Control port functions Scaler I/O Port Functions (PW190) (Continue) PIN NO. PORT NO. PORT NAME FUNCTION SIGNAL NAME DESCRIPTION PORTH1/TXD[0] SIGNAL TZD_PW UART TXD PORTH2 SIGNAL SCL1 IIC Bus SCL1 PORTH3 SIGNAL SDA1 IIC Bus SDA1 PORTH4 SIGNAL IIC Bus SCL2 IIC Bus SCL2 PORTH5 SIGNAL...
Page 80: Waveform
Waveform VIDEO signal <VIDEO> HSYNC signal VSYNC signal HSYNC signal <TPDHS> VSYNC signal <TPDVS> R-S&H signal <TP35R> G-S&H signal <TP35G> B-S&H signal <TP35B> - 80 -...
Page 81: Ic Block Diagrams
IC Block Diagrams ● AN5870 <Signal Switch, IC5201> ● BA7078 <Sync Separator, IC5301> - 81 -...
Page 82 IC Block disgrams ● FA5502 <P.F. Control, IC601> ● HIN202EIB <RS-232C Driver, IC3801> - 82 -...
Page 83 IC Block disgrams ● L3E06150 <D/A, S/H-LCD Driver, IC501, IC531, IC561> ● L3E07110 <LCD Driver & Gamma Correction, IC401> - 83 -...
Page 84 IC Block disgrams ● L3E01060 <Level Shift, IC2501, IC2531, IC2561> ● M62334 <DAC, IC3501> - 84 -...
Page 85 IC Block disgrams ● NJW1141 <Audio Control, IC5001> ● PW190 <Scaler, IC301> - 85 -...
Page 86 IC Block disgrams ● STR-Z2156<Power OSC, IC651> - 86 -...
Page 87: Electrical Parts List
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 88: Electrical Parts Location
Elecrical Parts List ● Assemblied Board A2101 A601 A2901 BUZZER BOARD POWER BOARD R/C BOARD A6801 KEY SW BOARD A901 BALLAST UNIT A690 A2001 LAMP COVER SW BOARD AV BOARD A4831 A602 TEMP BOARD LINE FILTER BOARD A1001 MAIN BOARD ●...
Page 89: Electrical Parts List
KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description MISCELLANEOUS Assemblied Board K20A 645 089 9041 SOCKET,DIN 4P 610 335 8161 ASSY,PWB,AV KL3A K20B 945 068 3740 JACK,RCA-3 K40A 945 006 4792 JACK,PHONE D3.6 610 335 7867 ASSY,PWB,BUZZER KL3A K40B 945 006 4792 JACK,PHONE D3.6...
Page 90 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 305 173 9717 TR 2SA1235A1F Q3601 305 014 4512 TR 2SC2412K T146 R 405 220 3115 TR ISA1235AC1E 305 014 4611 TR 2SC2412K T146 S 405 220 3016 TR ISA1235AC1F 305 015 8727 TR 2SC2812-L6-TB...
Page 91 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 305 015 8727 TR 2SC2812-L6-TB 305 015 8727 TR 2SC2812-L6-TB 305 015 8925 TR 2SC2812-L7-TB 305 015 8925 TR 2SC2812-L7-TB 305 163 1615 TR 2SC2812N-L6-TB0 305 163 1615 TR 2SC2812N-L6-TB0 305 173 9816 TR 2SC3928A1R...
Page 92 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 305 015 8925 TR 2SC2812-L7-TB IC8708 310 596 5205 IC S-1000C27-M5T1G 305 163 1615 TR 2SC2812N-L6-TB0 IC8712 309 482 3817 IC NJM2360AM(TE2) 305 173 9816 TR 2SC3928A1R IC891 310 337 0605 IC HD74LVC14T...
Page 93 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C1583 303 276 1911 CERAMIC 22P J C326 303 409 3426 CERAMIC 0.1U K C1584 303 276 1911 CERAMIC 22P J C327 303 409 3426 CERAMIC 0.1U K C1586 303 276 1911...
Page 94 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C366 303 409 3426 CERAMIC 0.1U K C455 303 409 3426 CERAMIC 0.1U K C367 303 409 3426 CERAMIC 0.1U K C456 303 409 3426 CERAMIC 0.1U K C368 303 409 3426...
Page 95 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description 303 407 3517 ELECT 470U M C5617 303 417 9912 CERAMIC 4.7U K 403 458 5017 ELECT 470U M C5618 303 417 9912 CERAMIC 4.7U K C5224 303 441 9810 CERAMIC...
Page 96 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description C7271 303 433 1112 CERAMIC 1U K R1012 301 224 8814 MT-GLAZE 100 JA 1/16W C7272 303 358 3215 CERAMIC 10U K 6.3V R1021 301 260 4115 MT-GLAZE 75 JA 1/3W...
Page 97 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R2016 301 224 9316 MT-GLAZE 1K JA 1/16W R349 301 224 9712 MT-GLAZE 22 JA 1/16W R2017 301 224 8814 MT-GLAZE 100 JA 1/16W R3501 301 224 8913 MT-GLAZE 100K JA 1/16W R2022...
Page 98 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R427 301 225 0213 MT-GLAZE 3.3K JA 1/16W R5226 301 224 9316 MT-GLAZE 1K JA 1/16W R434 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R5227 301 226 1516 MT-GLAZE 0.000 ZA 1/16W R435...
Page 99 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R6216 301 224 9019 MT-GLAZE 10K JA 1/16W R7313 301 225 8110 MT-GLAZE 10 JA 1/16W R6803 301 224 9019 MT-GLAZE 10K JA 1/16W R7314 301 225 8110 MT-GLAZE 10 JA 1/16W R6813...
Page 100 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R8733 301 224 8814 MT-GLAZE 100 JA 1/16W RB405 945 036 0986 R-NETWORK 47X4 1/32W R8746 301 224 8913 MT-GLAZE 100K JA 1/16W 945 037 0831 R-NETWORK 47X4 1/16W R8747 301 225 9018...
Page 101 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description L301 301 150 6014 MT-GLAZE 0.000 ZA 1/10W 307 149 0810 DIODE 1SS355-TE-17 L302 301 150 6014 MT-GLAZE 0.000 ZA 1/10W D3617 307 163 0414 DIODE 1SS352-(TPH3) L303 301 150 6014 MT-GLAZE...
Page 102 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description SC3051 945 076 3503 SURGE-ABSORBER 305 173 9816 TR 2SC3928A1R SC3052 945 076 3503 SURGE-ABSORBER 305 173 9915 TR 2SC3928A1S SC5608 945 076 3503 SURGE-ABSORBER Q682 305 014 4512 TR 2SC2412K T146 R SW841...
Page 103 KM3-XL5000 Electrical Parts List Key. No. Part No. Description Key. No. Part No. Description R626 301 152 3219 MT-GLAZE 330 JA 1/10W D682 307 202 9801 DIODE FMB-26L R627 301 265 0914 MT-GLAZE 4.7 JA 1/10W 307 253 7504 DIODE RB085T-60 R628 301 255 6513 MT-GLAZE...
Page 104: Mechanical Parts List
Mechanical Parts List S3 S3 - 104 -...
Page 105 19-1 19-1 19-1 19-2 19-1 19-1 19-2 19-1...
Page 106 Mechanical Parts List Polarized Grass Red: 114 Green: 115 Blue: 116 - 106 -...
Page 107 Mechanical Parts List Integrator Lens In - 107 -...
Page 108 Mechanical Parts List - 108 -...
Page 109: Mechanical Parts List
KM3-XL5000 Mechanical Parts List Key. No. Part No. Description Key. No. Part No. Description CABINET PARTS PACKING MATERIALS 610 338 9455 CUSHION SPACER BTM-KM3A 610 335 4088 CABINET TOP-KM3A 610 336 8689 CARTON CASE-KM3A 610 335 4132 CABINET BOTTOM-KM3A 610 336 2595 CAP FOCUS LEVER-KM3A 610 336 8207 CUSHION SPACER-KM3A...
Page 112 SM5110903-00 (PLC-XL50) Dec. 2007 DC 350 Printed in Japan...
Page 113: Diagrams & Drawings
PLC-XL50 KM3-XL5000 These schematic diagrams and printed wiring board drawings are part of the service manual original for chassis No. KM3_XL5000 models PLC-XL50. File with the service manual No. SM5110903-00 Note: All the information of part numbers and values indicated on these diagrams are at the beginning of production.
Page 114: Parts Description And Reading In Schematic Diagram
KM3_XL5000 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.
Page 115: Schematic Diagrams
Schematic Diagrams MIRROR LENS 1AV4Z10B54400 S3.3V D6804 P-RIGHT SW6803 S10B3530G SW803_1 R6806 1/16GJ15KA P-LEFT SW6804 S10B3530G SW804_1 R6807 380V 1/16GJ6.8KA KEYSTONE P-DOWN SW6800 SW6806 S10B3530G S10B3530G LP900 LAMP SW801_0 SW806_1 R6808 R6800 1/16GJ3.9KA 1/16GJ3.9KA SELECT P-UP BALLAST SW6801 SW6807 SW902 S10B3530G S10B3530G PTH651...
Page 116 L1001 SC1001 R1001 F34DG407G 1/3GJ75 R1_IN R1002 D6201 IC3801 1/16GJ100A RB521S-30G L1011 SP232AENP SC1011 R1011 F34DG407G 1/3GJ75 L6201 G1_IN L26B3470G 5VPC_A C3802 5VPCDDC_A C3806 IC6201 D6202 6.3KM2.2MN 10KK1MN R1012 RB521S-30G 24LC21A/SNP 1/16GJ C6203 C3801 100A K30A 6.3KK10BA 6.3KM2.2MN SC1021 L1021 J11B8382N R1021 F34DG407G...
Page 117 R327 FROM IC301 ROMWE ROMOE S2.5V_PW LAMP USHIO OSRAM PHILIPS R324 8.2K 4.7K R1871 R325 1/16GJ1MA P_FAIL C1871 10KK1MN BLAND SANYO S3.3V_PW S3.3V_PW R326 R389 8.2K 4.7K 1/16GJ BLAND R324 4.7KA R391 1/16GJ R389 68KA IC891 1/16GJ68KA R391 R325 R327...
Page 118 IC7201 D3633 3.3V_FPGA QXXAVC871M 1SS355 P_FAIL IC7261 R7267 D3634 QXXAVC927P 1/10GZ0.0 1SS355 IC1411 3.3V_A 3.3V_A 3.3V_A 3.3V_FPGA P_FAIL QXXAVC923P C7262 C7266 1.0V C7264 1.0V C7223 6.3KK10BA 6.3EM471V 16KK0.1MN C7202 IC1401 16KK 16KK 0.1MN 0.1MN 3.3V_B R7263 PQ070XZ02ZPP 3.3V_B R7201 1/16GF1.8KA C1412 C1413 1/16GJ...
Page 119 3.3V_SH_B R504 R527 DRB_DIRX R503 TPSHCLKB J30B1640G 1/16GJ10KA DB_FRP DG_ENBY2 C3508 R3509 FROM IC401(7111) DB_SHCLK 25EM FROM IC401 1/10GZ0.0 DG_ENBY1 473T (7111) 15V_PB DB_XFR 15.5V_PNL CLYOUT C510 C515 C3509 16KK0.1MN DRGB_DY 25KK1GQ L521 C3500 L501 L26B3470G 3.3V_SH_B C516 25EM K35B L26B3470G 16KK0.1MN 15.5V_PNL...
Page 120 D3612 1SS355 TE5001 P_FAIL J30B1640G R5649 R5654 C5653 1/16GJ L26B4110G 30KA 9V_AUDIO Q6846 R5651 2SA1203Y D6831 LAMP REPLACE(Y) R5644 1/16GJ 30KA 1/16GJ D6832 TEMP WARNING(R) R6863 D6833 STAND-BY (RED ON) 1/16GJ R5641 1.5KA LAMP ON (GREEN ON) 1/16GJ R6857 R6864 1/16GJ R6858 Q5651...
Page 121: Printed Wiring Board Diagrams
Printed Wiring Board Diagrams ■ ! CAUTION This projector is isolated from AC line by using the internal converter transformer. AV (SIDE : A) Please pay attention to the following notes in servicing 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 122 R/C (SIDE : A) MAIN (SIDE : A) LAMP BALLAST SPEAKER “CN2” 1AA4B10C6090D KEY SW ??? *** A SIDE(1st Re ow) "K6801A" K29D D8751 L4813 C4812 R8751 C6814 C5643 R5641 L4812 R4861 R5644 IC5642 C5648 R5624 C5622 R8749 R8747 R8757 R8758 R5622 Q8701 Q8702 Q5651 R689 Q9602 C9882 D6842 D5651 D6841...
Page 123 MAIN (SIDE : B) POWER BUZZER “K6R” “K2100” C4808 L5601 C5617 C5619 Q4801 R5608 Q9881 SC5608 C5618 C9647 FB603 R9881 C5606 R9624 C5601 R9882 R5621 R9657 C5623 R9621 R9661 C5616 R9622 R9659 R697 C9603 D3612 R9629 R9658 C5653 R5649 C8707 K20C C8705 L8701 R6863 R6864 Q2091...
Page 124 POWER (SIDE : A) POWER (SIDE : B) R684 C683 C685 C611 C683 C685 C611 C691 C681 T601 L616 T601 L611 R679 1AA4B10C6100A 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...
Page 125: Pin Description Of Diode, Transistor And Ic
KM3_XL5000 Pin description of diode, transistor and IC ● Diode ● Transistor/FET ● IC...
Page 126: Note On Soldering
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.

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