OSRAM Lamp Replacement Instructions:
The installation of the lamp is very straightforward, and requires some basic tools, and a few items you may need to source from hardware store.
- OSRAM 69471 Lamp
- 22-18 gauge Metal Ring Terminals (or remove nylon- see below)
- (2) 3mmx5mm Screws OR (2) 3mmx6mm Screws
- (2) 3mm Washers/Lock Washers
- Isopropyl Alcohol- Rubbing Alcohol (Optional)
PUT ON YOUR GLOVES! You do not want to get oils from your skin on the lamp.
Open the lamp door by removing the single phillips screw from the lamp door (labeled with CAUTION/ATTENTION sticker), and remove the lamp by removing 2 phillips screws on either side of the lamp.
Remove the 4 Screws holding the cage together and remove the back cover. Then remove the 2 mounting screws from the cage, as well as the 2 metal retainer clips.
The original factory wires are soldered to the lamp connectors, so you will need to cut the wire coming from the connector as close to the lamp as you can, then remove the old lamp from the cage (it is held in with a little pressure, but will pull right out).
You will need to have metal ring terminals, which I couldn't find at Home Depot, so I purchased regular nylon 22/18 gauge crimp terminals, and just cut off the nylon to expose the bare metal.
Strip back the ends of the wires about 1/4" and crimp on the metal ring terminals
Install the new lamp back into the cage
NOTE: the lamp is labeled TOP on one end, but the wires will not reach the connector locations without being extended. The bulb will technically be installed upside-down inside the cage, but I'm not particularly worried about this, as it will always be upside-down/right-side-up depending on how you have the projector mounted. That being said, it would not be difficult to extend the wires by soldering or using all metal crimps and some 14g wire.
Screw the wires to the new lamp using 3mmx5mm/3mmx6mm screws and washers. The shorter wire will connect to the terminal that has a wire lead to the center of the bulb. I used both a washer and a lock washer, so I had 3mmx6mm screws. If you only use a single washer, just be careful to make sure the screw does not go all the way through the terminal to the bulb.
Reassemble the cage by installing the metal retainer clips, mounting screws, and back cover.
Take advantage of this opportunity to CLEAN YOUR PRISM! If you look straight in the opening where you're about to shove your lamp, you will see the glass prism. Take Isopropyl alcohol wipes, or use a microfiber wet with isopropyl alcohol, and clean the prism. Then wipe down with a clean microfiber or lens cleaner. I didn't think mine looked too bad until I saw what was on the cloth
Once the prism has dried, reinstall the lamp using the 2 mounting screws, then screw on the lamp door.
Reset your lamp counter, and have fun re-calibrating the bright and beautiful picture!