Introduction

The power supply is what transforms the alternating current electricity from a wall outlet into a lower voltage direct current that is usable by the projector. There are many sensitive electronics in a power supply, and a power surge or other electrical issue can fry capacitors and other delicate components, breaking the power supply and preventing the projector from turning on.

The power supply in this projector has an enclosure which the speaker and main fan are mounted on, and the base of the enclosure with the attached power supply can be removed and replaced.

Place the projector on its back (buttons down) with the lens facing away from you. Remove the two 84mm screws in the upper left and right corners of the projector using the Phillips #2 screwdriver.
  • Place the projector on its back (buttons down) with the lens facing away from you.

  • Remove the two 84mm screws in the upper left and right corners of the projector using the Phillips #2 screwdriver.

  • Remove the remaining three 8.5mm screws using the Phillips #1 screwdriver.

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Use the plastic opening tools to push down the clips holding the lamp cover in place, and remove it. There is no lamp assembly in the projector used in this guide, yours may appear different.
  • Use the plastic opening tools to push down the clips holding the lamp cover in place, and remove it.

  • There is no lamp assembly in the projector used in this guide, yours may appear different.

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Remove the two 8.5mm rear screws holding the rear case plate to the projector using the Phillips #1 screwdriver. Pull the rear plate straight off and set it aside.
  • Remove the two 8.5mm rear screws holding the rear case plate to the projector using the Phillips #1 screwdriver.

  • Pull the rear plate straight off and set it aside.

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Flip the projector over and turn around so that the lens faces you. Twist the gray zoom adjustment ring clockwise and extend the lens all the way out, and then slide the zoom adjustment ring all the way towards the end of the lens as far as it will go. Slide the front case plate towards the loosened zoom adjustment ring, until the top plate of the projector is freed from underneath the lip of the front case plate.
  • Flip the projector over and turn around so that the lens faces you.

  • Twist the gray zoom adjustment ring clockwise and extend the lens all the way out, and then slide the zoom adjustment ring all the way towards the end of the lens as far as it will go.

  • Slide the front case plate towards the loosened zoom adjustment ring, until the top plate of the projector is freed from underneath the lip of the front case plate.

  • The front case plate will not come all the way off due to the zoom adjustment ring obstructing it. It will merely slide forward a bit.

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Lift away the top case plate and set it aside. Lift away the top case plate and set it aside.
  • Lift away the top case plate and set it aside.

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Remove the four T10 Torx 8.5 mm screws holding the DLP board in place.
  • Remove the four T10 Torx 8.5 mm screws holding the DLP board in place.

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Unplug the small ribbon cable attaching the DLP board to the motherboard.
  • Unplug the small ribbon cable attaching the DLP board to the motherboard.

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Detach the DLP board from where it is connected to the motherboard by a large 100 pin connector. Pry up gently while wiggling from left to right if needed.
  • Detach the DLP board from where it is connected to the motherboard by a large 100 pin connector.

    • Pry up gently while wiggling from left to right if needed.

  • The ribbon cable on the other side of the board could break if pulled too hard.

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Remove the 2 remaining T10 Torx 8mm screws securing the motherboard to the power supply.
  • Remove the 2 remaining T10 Torx 8mm screws securing the motherboard to the power supply.

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Remove all other cables connected to the motherboard.
  • Remove all other cables connected to the motherboard.

    • Remove the Speaker Cable

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Remove Secondary Fan Cable
  • Remove Secondary Fan Cable

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Flip up the DLP board, leaving it attached to the large ribbon cable.
  • Flip up the DLP board, leaving it attached to the large ribbon cable.

  • Remove DLP Power Cable.

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Pry out the DLP support piece by gently wiggling it side to side while applying a steady pull. It will slide out. Pry out the DLP support piece by gently wiggling it side to side while applying a steady pull. It will slide out.
  • Pry out the DLP support piece by gently wiggling it side to side while applying a steady pull. It will slide out.

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Remove the two 1/4" screws using the nut driver. The second screw is located behind the right side of the 100 pin connector. Gently pry up the motherboard from the connector on top of the power supply.
  • Remove the two 1/4" screws using the nut driver.

    • The second screw is located behind the right side of the 100 pin connector.

  • Gently pry up the motherboard from the connector on top of the power supply.

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Disconnect the lamp power supply cables from the top of the lamp housing, by gently pulling the two wires in opposite directions. Disconnect the lamp power supply cables from the top of the lamp housing, by gently pulling the two wires in opposite directions.
  • Disconnect the lamp power supply cables from the top of the lamp housing, by gently pulling the two wires in opposite directions.

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Use your thumbs to pry the sides of the external shell away from the power supply so it can be lifted out. Use your thumbs to pry the sides of the external shell away from the power supply so it can be lifted out. Use your thumbs to pry the sides of the external shell away from the power supply so it can be lifted out.
  • Use your thumbs to pry the sides of the external shell away from the power supply so it can be lifted out.

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Rotate the power supply so that the main fan enclosure faces to the right, with the motherboard mounting pegs on top. Remove the two #2 Phillips 7mm screws on the side of the power supply. Remove two more #2 Phillips 7mm screws on the opposite side of the power supply.
  • Rotate the power supply so that the main fan enclosure faces to the right, with the motherboard mounting pegs on top.

  • Remove the two #2 Phillips 7mm screws on the side of the power supply.

  • Remove two more #2 Phillips 7mm screws on the opposite side of the power supply.

  • Rotate the power supply so the fan faces towards you, and remove a fifth #2 Phillips 7mm screw from just under the foam pad.

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Use a plastic prying tool to push the white molex connector through the fan enclosure. Use a plastic prying tool to push the white molex connector through the fan enclosure.
  • Use a plastic prying tool to push the white molex connector through the fan enclosure.

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Flip the power supply over so that the motherboard mounting pegs are on the bottom. Carefully open the power supply, and be mindful of the cable that will be pulled taut that needs to be disconnected.
  • Flip the power supply over so that the motherboard mounting pegs are on the bottom.

  • Carefully open the power supply, and be mindful of the cable that will be pulled taut that needs to be disconnected.

    • It may be easier to disconnect this cable if you orient the power supply with the speaker down, so you can reach in more easily.

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The base of the power supply should now be free.
  • The base of the power supply should now be free.

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Conclusion

To reassemble your device, follow these instructions in reverse order.

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Andrew Kennedy

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Cal Poly, Team 20-3, Maness Winter 2013 Member of Cal Poly, Team 20-3, Maness Winter 2013

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