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3M

Overhead Projector 9800 Series

Section 5 – Disassembly/Reassembly

5-15

9800 Service Manual

3M 1996

5-4-8. How to Replace the Power Cord

!

Unplug projector power cord before performing
any maintenance to electrical components.

1. Unplug power cord from electrical outlet.

2. Use a torx screwdriver to unscrew two retaining

screws securing outlet shield. Figure 5-27.

3. Unscrew retaining screw securing plastic strain

relief.

4. Open top cover.

5. Remove three wire connectors, slide strain relief

off end of power cord and remove cord from
projector body.

6. Reassemble in reverse order.

Outlet
Shield

9800-96I

Power
Cord

Strain
Relief

Strain
Relief
Screw

Figure 5-31. Replacing Power Cord

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Summary of Contents for 9800

Page 1: ...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 9800 Overhead Projector Service Manual ...

Page 2: ... 1 4 1 1 Permanent Viewing Screen 4 1 4 1 2 Test Facility Layout 4 1 4 2 Optical Alignment 4 3 4 2 1 Lamp Position 4 3 4 2 2 Post Alignment 4 4 4 2 3 Head Alignment Square Image 4 4 4 2 4 Head Alignment Centered Image 4 5 4 2 5 Color Tuning Adjustment 4 6 5 1 Open Projection Head Assembly 5 1 5 1 1 How to Replace the Mirror Assembly 5 2 5 1 2 How to Replace the Triplet Lens 5 2 5 2 Stage Assembly ...

Page 3: ...he Thermostat 5 13 5 4 6 How to Replace the Circuit Breaker 5 13 5 4 7 How to Replace the Accessory Outlets 5 14 5 4 8 How to Replace the Power Cord 5 15 5 5 Fan Blade Fan Motor 5 16 5 5 1 How to Replace Fan Blade and Motor 5 16 5 6 Post Lock Assembly 5 17 5 6 1 How to Disassemble the Post Assembly 5 17 5 6 2 How to Disassemble the Post Lock Assembly 5 17 5 7 Focus Assembly 5 18 5 7 1 How to Disas...

Page 4: ...18 20a 20c 14 19 21 20b 23 Figure 1 1 9800 Projector 1 1 1 Parts Identification 1 Open Projection Head 2 Projection Mirror 3 Triplet Projection Lens 4 1 3X Magnifier Lens 5 Arm 6 Focus Knob 7 Post 8 Post Latch 9 Post Cradle 10 Carrying Handle 11 Accessory Outlets design varies by country 12 Cord Wrap 13 Circuit Breaker 5 amps 14 Power Cord 15 Stage Glass 16 Top Cover 17 Top Cover Release Latch wit...

Page 5: ...0 lbs 14 7 kg 32 3 lbs Stage Aperture 286 mm x 286 mm 11 25 in x 11 25 in 1 1 3 Safety Features All versions of the 9800 projectors include Interlock Shuts off power to projector when the top cover is opened Thermostat Shuts off power to the lamp if unsafe operating temperature should occur 9800 77I 13 9 in 16 6 in 422mm 353mm 23 2 in 589mm 11 3 in 287mm 9800 78I 16 9 in 429mm 17 0 in 432mm 29 3 i...

Page 6: ...by the fingers during replacement The oils on the skin may combine with the glass and shorten the life of the lamp Reflector The reflector is positioned under the lamp and collects light from the lamp then directs it upward into the condenser lens Condenser Lens The condenser lens collects the light from the lamp and directs it upward through the hot mirror Hot Mirror The hot mirror filters the li...

Page 7: ...iplet Lens FL 342 mm 13 5 in 9800 51I 1 3X Magnifier Lens FL 292 mm 11 5 in Figure 1 4 Projection Heads Projection Mirror The projection mirror redirects the light from the projection lens to the projection screen The angle of the mirror determines the height of the projected image on the projection screen The distance from the projection mirror to the projection screen determines the size of the ...

Page 8: ... be closed to illuminate the lamp High Low Lamp Brightness The High Low lamp brightness switch is located under the control panel door High is recommended for LCD projection panels and Low is recommended for normal use Early machines used a knob Starting with serial number 615042 a switch replaced the knob Note Use the Low setting to extend lamp life 1 2 4 Color Tuning Color tuning adjusts the dis...

Page 9: ... TO SCREEN DISTANCE F FOCAL LENGTH OF HEAD S SCREEN SIZE A STAGE LCD PANEL APERTURE SIZE 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 342 mm 13 5 in focal length D 34 2 cm 152 cm 1 28 5 cm D 217 cm 86 in To use Figure 1 6 locate the specific screen size on the right and read the corresponding projecto...

Page 10: ...2 mm 13 5 in x 21 3 cm 8 4 in 239 cm 94 in 279 cm 110 in 320 cm 126 in 377 cm 148 in 426 cm 168 in x 24 1 cm 9 5 in 215 cm 85 in 251 cm 99 in 287 cm 113 in 338 cm 133 in 381 cm 150 in x 26 4 cm 10 4 in 199 cm 78 in 232 cm 91 in 265 cm 104 in 311 cm 122 in 351 cm 138 in 9800 EVD FL 292 mm 11 5 in x 21 3 cm 8 4 in 203 cm 80 in 238 cm 94 in 273 cm 107 in 321 cm 126 in 363 cm 143 in 11 5 in x 24 1 cm ...

Page 11: ...3M Overhead Projector 9800 Series Section 1 Introduction 1 8 9800 Service Manual 3M 1996 This page intentionally left blank ...

Page 12: ...lift the post 1 until it locks into place Figure 2 1 Lift Post 2 Plug power cord 2 into an electric outlet 3 Push power switch to the On position 4 Adjust mirror 3 to position image on screen and rotate focus knob 4 for clearest image 3 4 9800 81I Figure 2 2 Adjust Mirror and Focus 5 Rotate color tuning knob for color free image See Color Tuning for details ...

Page 13: ...osition 1 3X Magnifier Lens 3 Rotate focus knob 4 clockwise to raise projection head to maximum position Figure 2 4 4 Release post latch 5 and lower post until it rests and locks in the post cradle Figure 2 4 Raise Head Lift Post Latch and Fold Post 5 Rotate focus knob 6 counterclockwise to lower head until it stops Figure 2 5 Lower Head To Projector Body 6 To move projector lift from bottom or us...

Page 14: ...To Screen 5 Adjust angle of projection mirror 2 to raise or lower the image on the screen Figure 2 8 6 For best results tilt projection screen 3 toward projector until the top and bottom of the projected image appear square and without distortion Figure 2 8 7 Place film transparency or LCD projection panel on the stage glass 4 8 Set lamp brightness to High or Low position See High Low Lamp Setting...

Page 15: ...otate the Lamp Changer Dial 3 to position 1 or 2 3 Close control panel door to restore power and illuminate lamp Note The red X will light when a lamp is either defective or missing Important Lamp will not illuminate unless control panel door is closed 2 5 High Low Lamp Setting Activate the High Low switch to select High bright or Low normal lamp illumination 1 Open control panel door 1 Power to l...

Page 16: ...w lamp to cool before replacing Lamp and adjacent metal parts are hot Allow lamp to cool before replacing 4 Release spring catch 1 and open condenser lens frame Figure 2 13 5 Remove old lamp 2 and discard Figure 2 13 6 Insert new lamp Push lamp fully and squarely into socket Figure 2 13 Note Do not touch bulb glass with fingers Figure 2 13 Removing Lamps 7 Close condenser lens frame and secure wit...

Page 17: ...3M Overhead Projector 9800 Series Section 2 Operating The 9800 Projector 2 6 9800 Service Manual 3M 1996 This page intentionally left blank ...

Page 18: ...se 3M Overhead Cleaner 676 Figure 3 1 to remove surface dirt from the stage glass and projector lens Figure 3 1 3M Overhead Cleaner 676 3 1 1 Projection Mirror 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...

Page 19: ...ntly rub surface 3 Remove excess cleaner and dry surface with a clean soft lint free cloth 9800 56I Figure 3 4 Cleaning Lens Stage Glass Body Mirror 3 1 3 Fresnel Lens In the 9800 projector the Fresnel Lens is a doublet lens with a smooth surface on both sides Caution Do not clean the Fresnel Lens by immersing or flushing in water 1 Remove the Fresnel Lens see Section 5 2 2 for instructions 2 Damp...

Page 20: ...king electrical connections to the projector 4 1 2 Test Facility Layout To eliminate vertical and horizontal keystoning it is very important to align the projector to be perfectly square with the viewing screen Keystoning will result in unequal focusing of projected images at the four corners and will especially affect resolution Use the steps below to set up a test facility that will provide the ...

Page 21: ...us 7 With all adjustments completed the image should be perfectly square and focused in all corners Figure 4 3 9800 57I Figure 4 3 Square and Focused Image Repeat steps 3 6 as needed until the image is perfectly aligned and focused a Mark the exact location of the test stand on the floor with permanent marker b For a permanent test facility securely attach the stand to the floor c Mark the exact p...

Page 22: ...p position to verify it is aligned and centered in the optical path 1 Push power switch On then Off again to illuminate lamp 2 As the lamp image fades out look in the projection mirror The lamp filament and its reflection should be aligned and centered squarely in the optical path Figure 4 4 Do not look directly into the projection mirror when the lamp is fully illuminated Wait until the lamp imag...

Page 23: ...rs the projection head could be out of alignment Distorted Image Image Square Image Focused 9800 60I Figure 4 6 Square and Focused Image The axis of the projected image must be perpendicular to the screen surface to check the head alignment 1 Set the projector on a test stand or bench see Section 4 1 for details 2 Turn the projector on and focus an image on the screen Check to see that the sides o...

Page 24: ...in one or two but not all four of the corners of a sharply focused image with properly adjusted color tuning Color in one corner of image 9800 61I Figure 4 9 Colors in Corners of Image 1 Turn the projector on to illuminate the lamp 2 Push the power switch on and off to illuminate the lamp 3 As the image of the lamp fades out look in the projection mirror to check the position of the lamp filament ...

Page 25: ...ity of very small or very large projected images that fall outside of the Color Free Range Figure 4 10 Model Adjustable Color Free Range Color Tuning 9800 114 305 cm 45 120 in External Figure 4 10 Color Free Range Table 1 Rotate the exterior Color Tuning dial Figure 4 11 a To remove blue corners rotate dial to the left counterclockwise b To remove yellow orange to brown corners rotate dial to the ...

Page 26: ...6 5 1 Open Projection Head Assembly 9800 63I Clip Retaining Screw Triplet Lens Head Cover Cover Retaining Screw Projection Mirror Screw Plastic Washer Upper Lens Bracket Lower Lens Bracket Lower Lens Bracket Upper Lens Bracket Damping Pad Screw Washer Spacer Figure 5 1 Open Projection Head Assembly ...

Page 27: ...e the projection mirror and lens bracket 9800 69I 2 3 4 1 4 5 5 Figure 5 2 Removing the Head Cover 5 Remove mirror retaining screws clip and plastic washer on each side to free the mirror from the lens bracket Figure 5 1 6 Reassemble in reverse order Note When attaching the new mirror remember to place the plastic washer between the lens bracket and clip Apply 4 5 in lbs of torque to mirror retain...

Page 28: ... in the base See Figure 5 3 5 2 2 How to Replace the Fresnel Lens 1 Remove the top cover Figure 5 3 Caution Both sides of the Fresnel Lens are easily scratched Remove with care 2 Push on two retainer tabs to free Fresnel Lens and carefully remove Figure 5 4 9800 70I Figure 5 4 Fresnel Lens Retainer Clip 3 Assemble in the reverse order Caution Handle the Fresnel Lens by the edges ONLY Important Be ...

Page 29: ...d snap the other side of the latch into place Note 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 5 2 4 How to Replace the Stage Glass 1 Remove the Fresnel Lens See 5 2 2 2 Carefully remove the damaged glass 3 Remove the metal retainer to free the glass Figure 5 4 4 When replacing the stage glass make sure the beveled edges ...

Page 30: ...e Figure 5 8 Hinge Holders Figure 5 8 Replacing Power Switch 5 2 6 How to Replace the On Off Switch Actuator 1 Open the top cover 2 Remove the purple power switch button by spreading apart the hinge holders See Figure 5 8 3 Carefully pry open the clip holding the actuator in place and remove See Figure 5 9 Figure 5 9 Actuator Clip 4 Insert the new actuator See Figure 5 10 for correct orientation F...

Page 31: ...Unplug projector power cord before performing any maintenance to electrical components 1 Unplug power cord from electrical outlet 2 Open top cover 3 Remove wire connectors Figure 5 11 4 Remove two retaining screws to free the interlock switch 5 Reassemble in reverse order Interlock Screws Wire Connectors 9800 92I Figure 5 11 Power Switch Interlock ...

Page 32: ...ng Screws 3 From the outside of the projector pry off the color tuning knob Figure 5 14 4 Open top cover 5 Unscrew two retaining screws securing lamp control module bracket Figure 5 13 Retaining Screw Mounting Bracket 9800 93 Figure 5 13 Lamp Control Module 6 Disconnect lamp assembly wires from the lamp control module 7 Remove the e ring and unhook the secondary lamp changer rod Figure 5 14 9800 6...

Page 33: ...e 5 15 4 Lift and hold top assembly together and unscrew two hot mirror bracket retaining screws Figure 5 15 Figure 5 15 Hot Mirror Condenser Lens Brackets 5 Gently lower top assembly to the closed position 6 Carefully lift the hot mirror bracket to separate it from the condenser lens bracket This will free the hot mirror Figure 5 16 Figure 5 16 Open Hot Mirror Bracket 7 Reassemble in reverse orde...

Page 34: ...rtant Install the condenser lens with the bowed side facing the hot mirror Figure 5 18 ÉÉÉÉÉÉÉ Bowed side toward hot mirror Hot Mirror Condenser Lens 9800 97I Figure 5 18 Condenser Lens Orientation 5 3 4 How to Replace the Lamp Socket Unplug projector power cord before performing any maintenance to electrical components 1 Unplug power cord from electrical outlet 2 Open the top cover 1 Release the ...

Page 35: ...ming any maintenance to electrical components 1 Unplug power cord from electrical outlet 2 Remove optical lamp assembly from projector body 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 Reflector Spring Clip Reflector Bracket Reflector 9800 91I Figure 5 20 Reflector ...

Page 36: ...ibed in Section 6 2 9800 67I Thermostat Spring Latch Retaining Screw Circuit Board Baffle Bracket Stand Off Figure 5 21 Circuit Board and Thermostat 5 4 2 How to Replace the Transformer Unplug projector power cord before performing any maintenance to electrical components 1 Unplug power cord from outlet 2 Open the top cover 3 Label and disconnect all wire connectors hooked to transformer Figure 5 ...

Page 37: ...ull up to free switch from transformer bracket Spring Latch Transformer Bracket Internal Voltage Switch Wire Terminal 9800 74I Figure 5 23 Internal Voltage Switch 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 re...

Page 38: ...everse order 9800 66I Baffle Bracket Screws Rubber Foot Bottom View of Projector ÅÅÅ ÅÅÅ Å Å Å Ventilation Slots Figure 5 25 Baffle Bracket Retaining Screws 5 4 6 How to Replace the Circuit Breaker Unplug projector power cord before performing any maintenance to electrical components 1 Unplug power cord from electrical outlet 2 Open the top cover 3 Use a torx screwdriver and unscrew two retaining ...

Page 39: ...w Head Figure 5 27 Outlet Shield Retaining Screws 3 Open top cover 4 From inside projector body remove metal outlet shield Outlet Shield Caution Label 9800 90I Figure 5 28 Outlet Shield 5 From inside projector body disconnect wire connectors leading to outlet 6 Remove outlet from projector body a Squeeze spring latches and pull outlet straight out Figure 5 29 OR b Pry off plastic frame unscrew ret...

Page 40: ...er cord from electrical outlet 2 Use a torx screwdriver to unscrew two retaining screws securing outlet shield Figure 5 27 3 Unscrew retaining screw securing plastic strain relief 4 Open top cover 5 Remove three wire connectors slide strain relief off end of power cord and remove cord from projector body 6 Reassemble in reverse order Outlet Shield 9800 96I Power Cord Strain Relief Strain Relief Sc...

Page 41: ...crews 3 Disconnect wire connectors and remove fan blade assembly from projector body Figure 5 33 4 Reassemble in reverse order Note The fan assembly has five vibration isolation pads on the bottom of the mounting bracket and heat tape on the side toward the lamp assembly 5 Tighten the fan assembly retaining screws with 7 8 inch pounds of torque Important Do not over tighten the retaining screws Ex...

Page 42: ...her is placed on each side of the Post Figure 5 35 Post Latch Post Nut 9800 62I Figure 5 34 Post Lock Assembly 5 6 2 How to Disassemble the Post Lock Assembly 1 Remove post nut See Figure 5 34 2 Unscrew stop screw and slide lock and spring off bottom of post 3 To remove post mount pivot and bracket pivot unscrew post mount screw 4 Reassemble in reverse order 9800 72I Stop Screw Spring Screw Post M...

Page 43: ...knob straight off to remove Figure 5 36 2 To replace focus assembly parts unscrew retaining screws and remove cover 3 See the Illustrated Parts Breakdown manual for parts detail Note If the Rack is replaced be certain that the open side faces the direction of the knob Figure 5 37 Focus Knob Cover Screws 9800 73I Figure 5 36 Post Nut Focus Knob Side Figure 5 37 Focus Assembly ...

Page 44: ...nt for the type of failure b Is there high line voltage a Monitor actual lamp life to note type of lamp failure See Recurring Lamp Failure b Set internal voltage switch to low Set wire jumper on Overvoltage Protector circuit board to lower setting 6 2 Recurring lamp failure a Is there arcing failure b Is a piece of the filament missing c Is bulb lamp darkened on inside due to leaking seal Test wit...

Page 45: ...s b Color tuning setting c Is lamp type EVD Open stage cover check label d Is lamp squarely seated in socket e Is lamp changer dial fully engaged a Realign Optics b Adjust Color Tuning c Use lamp type EVD as specified on label d Fully seat lamp in socket to center filament in optical path e Rotate lamp changer dial fully into left or right posi tion 4 2 4 2 5 2 6 4 2 1 2 4 Top bottom or sides of t...

Page 46: ...ing d Seat Fresnel lens squarely in frame with bowed side up 3 1 2 6 5 4 3 5 2 2 Image is vibrating a Is fan mounted properly b Is fan motor running properly c Is fan blade or motor hitting an obstruction a Check vibration pads under fan bracket b Replace defective motor c Remove foreign objects from inside projector 5 5 5 5 1 2 2 Projected image does not have uniform brightness a Is lamp alignmen...

Page 47: ...lightly 5 If the LED indicator stays red a Measure the AC line voltage at the transformer The voltage should be above the switch point setting SPS See step 6 b If the AC line voltage is below the SPS the relay could be sticking Tap the top of the relay and test again c If the LED remains red replace the circuit board 6 Verify the jumpers are set to the correct SPS for the line voltage at the trans...

Page 48: ... 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 Telephone 1 800 328 1371 Fax 512 984 5105 Profs VSD EPS SERVICE CENTER Internet scvsdeps mmm com ...

Page 49: ...9800 Overhead Projector Section 6 Troubleshooting 6 6 3M 9800 Service Manual This page intentionally left blank ...

Page 50: ... Manual 7 1 Electrical 9800 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 1 2 3 4 6 7 8 15 14 16 17 18 19 25 24 21 22 23 27 28 29 5 30 31 32 13 13 16 20 26 ...

Page 51: ...9800 Overhead Projector Section 7 Electrical Diagrams 7 2 3M 9800 Service Manual This page intentionally left blank ...

Page 52: ...3M Visual Systems Division 6801 River Place Boulevard Austin Texas 78726 9000 Printed in U S A 3M 7 96 78 6970 5568 5 Rev C Printed on recycled paper ...

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