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TDP-P6 Service Manual

51

Optical engine

The

optical engine (535-0017-xx)

fastens to the bottom case. The engine comprises all parts in the light

path with the exception of the lamp module.

A new optical engine includes a rear IR ECA. The rear IR ECA is also available in the

Hardware Kit (802-

0036-xx)

.

1

Remove the following items:

Lamp door and lamp (page 25)

Zoom tab and focus ring (page 28)

Top enclosure, I/O bezel and side vent (page 31)

Controller ECA (page 43)

2

On the outside of the projector, remove the black M2.5x4 Torx screw that fastens the optical

engine to the bottom enclosure.

3

Turn the projector right side up on the work surface.

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Summary of Contents for TDP-P6

Page 1: ...SERVICE MANUAL FILE NO 330 200311 DLP PROJECTOR TDP P6 Document Created in Japan Sep 2003 ...

Page 2: ...ge 20 Keypad Problems 21 Remote Control Problems 22 Audio Problems 23 Parts Removal and Replacement 24 Removable Parts Hierarchy 24 Lamp Module 25 Focus ring and zoom tab 28 Top enclosure 31 Elevator foot 37 Ballast 38 Blower assembly 40 Controller ECA 43 Optical engine 51 Power supply 54 Front and rear IR receivers 59 Speaker 63 Bottom enclosure 65 Performing functional tests 66 Parts Lists 70 Il...

Page 3: ...rmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense WARNING Changes or modifications made to this equipment not expressly approved by Toshiba or parties authorized by Toshiba could void the user s authority to operate the equipment ...

Page 4: ...le operation of the product and to protect it from overheating and these openings must not be blocked or covered The openings should never be blocked by placing the product on a bed sofa rug or other similar surface This product should not be placed in a built in installation such as a bookcase or rack unless proper ventilation is provided or the manufacturer s instructions have been adhered to IM...

Page 5: ...ely result in a solution The solutions begin with the most simple and progress to the most complex Go to the section you want Power problems including lamp issues partial power up shutdown and no power page 6 Image problems including no image bad color dim image and other picture distortions page 18 Keypad problems page 21 Remote problems page 22 Audio problems page 23 In addition to the troublesh...

Page 6: ... NOTE We strongly suggest that you follow the entire power diagnosis sequence Power Diagnostics Part 1 on the left LED Status LED flashes green The projector is starting up after the Power button was pressed or the projector is shutting down after the Power button was pressed LED is solid green The projector is ready to light the lamp when the Power button is pressed Or the lamp is lit and the pro...

Page 7: ...ain Confirm that unit is good by starting again Power Diagnostics part 1 Solve the problem Yes Yes No Replace top enclosure includes keypad ECA page 31 Note A solid green LED means the projector is either waiting for a command or is operating normally A flashing green LED means the projector is either attempting to light the lamp or is shutting down Check the voltages at the controller power suppl...

Page 8: ... does not light Replace top enclosure includes keypad EDA page 31 Repeat process to confirm the problem fixed Run the projector long enough to ensure that the problem is solved If the lamp goes out and the LED turns red go to error codes page 9 No The lamp does not light and the LED begins blinking red The lamp attempts to strike five times at 30 second intervals After 2 1 2 minutes the projector ...

Page 9: ...r detects high internal temperature Diagnose thermal problems page 13 On Off 4 flashes Blower has stopped Check the blower assembly page 12 On Off 3 flashes The projector detected an internal error and shutdown the lamp Diagnose lamp shutdown page 11 On Off 2 flashes The lamp timer registers lamp use of 2000 hours or more Replace the lamp page 25 On Off 1 flash The lamp failed to strike after five...

Page 10: ...estarting the Power Diagnosis process page 7 Voltages good at power supply controller connector page 16 No Replace the lamp module page 25 Yes Replace the ballast page 38 Replace controller ECA page 43 Replace power supply page 54 Ensure that the lamp sync cable page 35 is connected to the controller ECA and the ballast Solve the problem No Yes LAMP WON T STRIKE LCD Message RETRYING WAIT Repeats ...

Page 11: ...that the lamp won t strike Click here to go to solve failure to strike problems page 10 Replace the lamp page 25 Solve the problem No Yes Run the projector long enough to ensure that the problem is solved Yes Repeat the diagnostic process to ensure that the problem is solved page 7 Note If the projector is operated in a hot environment especially at high altitudes the unit may overheat and shut do...

Page 12: ...SHUTDOWN 10 LCD Message The lamp was operating but shut down or it did not start at all The status LED flashes a repeated red four flash sequence Check the voltages on the blower ECA page 16 Voltages OK No Replace the controller ECA page 44 Replace the blower assembly page 41 Yes ...

Page 13: ...o Run the projector long enough to confirm the problem issolved Repeat the diagnosis process page 7 Yes Note If the projector is operated in a hot environment especially at high altitudes the unit may overheat and shut down when the thermal switch opens The only solution for this is to let the projector cool down The TDP P6 should not be used where ambient temperatures are over 95º F 35º C OVER TE...

Page 14: ...Power button you should hear a brief high pitched sound of the color wheel starting up You can also do a visual check by starting the projector with the top off No Reseat the color wheel cable page 15 If the color wheel does not start replace the controller ECA page 44 Does the color whee spin and the lamp light No Replace the optical engine page 52 Yes To confirm that the problem is solved restar...

Page 15: ...ration If the color wheel is not spinning the first item to check is the color wheel cable connection and then reseat it if necessary To check color wheel operation and reseat the cable do the following 1 Power up the projector with the top off NOTE The lamp and the lamp door must be in place to start the projector with the top case removed 2 Examine the color wheel to see if it is spinning The co...

Page 16: ...TDP P6 Service Manual 16 Controller and Power Supply Voltages ...

Page 17: ...TDP P6 Service Manual 17 Controller voltage locations ...

Page 18: ...sing tint or color Missing logo VGA composite video or S video Distorted image noisy rolling torn frozen plaid repeated or shifted image page 19 Flash the projector with the latest software Confirm that all image adjustments are set to the factory defaults Select Factory Reset from the Settings Service menu Confirm that the cables and the source signals are good If in doubt feed the signal to a go...

Page 19: ... the image correct No Replace the optical engine page 51 Bad colors Bad or missing tint or color Missing startup screen VGA composite video or S video Distorted image excess noise rolling image torn image frozen image plaid image repeated single image or shifted image Make sure cables are good Is the image correct No Replace the controller ECA page 43 ...

Page 20: ...n good lamp page 25 Replace the lamp Is the image brighter Yes Substitute a known good controller ECA page 43 Replace the controller ECA Is the image brighter Yes No Replace the optical engine page 51 The lamp takes about 90 seconds to achieve full brightness No ...

Page 21: ...ar of the projector Make sure you try the remote through both lenses If one or both IR receivers do not work go to Remote problems page 22 Keypad does not respond to key presses Does the remote control work No Replace the controller ECA page 43 Yes Replace the top enclosure page 31 ...

Page 22: ... both of the IR receivers on the projector There are IR receivers on the front and rear of the projector Issue a remote command to each receiver Replace the controller ECA page 43 Responds to the front receiver but not the rear Replace the front IR ECA page 59 Does not respond to either receiver Solve the problem No Responds to the rear receiver but not the front Replace the rear IR ECA page 61 ...

Page 23: ... distorted Is there sound Yes No Is the sound acceptable Replace the controller ECA page 43 No Replace the speaker page 63 Make sure the speaker cable is connected to the controller ECA page 44 Note that the speaker is small and can sound distorted if the volume is too high ...

Page 24: ...parts on the first level the lamp door for example are accessible without removing any other parts The more levels down a part are the more parts you need to remove Lamp door Start Ballast Side vent Optical engine Lamp module Top enclosure Blower assembly Front IR ECA Power supply ControllerECA Focus tab zoom ring I O bezel Bottom enclosure Speaker Rear IR ECA Elevator foot ...

Page 25: ... affixes to the lamp door The certification label is included in the label kit 802 0035 xx The lamp module TLPLP6 consists of a metal housing an enclosed reflector assembly and an arc tube CAUTION The lamp module gets very hot during operation Allow the lamp to cool for 60 minutes before handling it 1 Place the projector upside down on a soft work surface 2 To remove the lamp door loosen the two c...

Page 26: ...in the projector To do this press down on the latch on the top of the connector while pulling the connector out of the plug 2 Lift the handle on the lamp to release the latch that holds the lamp in place Then lift the latch off the tab inside the projector 3 To remove the lamp lift the handle upward and slightly back to disengage the alignment tab and fan ducting If necessary gently press down on ...

Page 27: ...ll the lamp door insert the two tabs on the door into the matching slots near the front of the projector Swing the lamp door shut pressing it into place so that the lamp connector on the door engages Tighten the captive screws to 3 in lbs 329 Nm If you installed a new lamp door affix a new certification label to the door If you installed a new lamp reset the lamp timer To do this press and hold th...

Page 28: ...the focus ring It includes a tether which anchors to the top enclosure The lens cap is a User Replaceable Part Focus ring Zoom tab Lens cap and tether 1 Place the projector on the work surface with the lens pointing upward 2 To remove the zoom tab insert a small bladed screwdriver between the tab and the front bezel Place one finger on the tab while prying up with the screwdriver Take care when yo...

Page 29: ...three matching pins on the lens barrel To install the ring place on the lens barrel then turn it until you feel the slots align with the pins Then press the ring into place The focus ring should appear as illustrated below when it is properly installed To install the zoom tab insert it into the alignment slots on the inner zoom ring and then press it into place In the illustration below the alignm...

Page 30: ...TDP P6 Service Manual 30 ...

Page 31: ... enclosure The side vent 505 1294 21 and the I O bezel 505 1764 xx cover the two ends of the projector The vent and bezel are held in place by the top enclosure and once the enclosure is removed both are no longer fastened to the projector The I O bezel requires an I O label from the Label Kit 802 0035 xx Side vent I O bezel The I O bezel covers the I O connectors on the side of the projection len...

Page 32: ...ess to the keypad cable connector on the controller ECA 5 Unplug the keypad cable and remove the top enclosure 6 Lift the side vent and the I O bezel out from the projector The two pieces are not fastened to the projector You may need to flex the bottom enclosure outward slightly to disengage a tab on the top of each part ...

Page 33: ... install the top enclosure without the gap pads in place Both sizes of gap pads are available in the Hardware Kit 802 0036 xx To install the top enclosure do the following 1 Place the side vent in the bottom enclosure The single long tab fits at the bottom mating with a matching tab on the bottom enclosure Two tabs on the top mate with two slots in the top Make sure the tab on the rear of the vent...

Page 34: ...l in the bottom enclosure A slotted tab at the bottom of the bezel engages a matching tab on the bottom enclosure Flex the bottom enclosure outward to engage the tab on the top of the bezel The seams are smooth when the bezel is properly installed ...

Page 35: ... fastened together 4 Plug the keypad cable into its connector on the top of the controller ECA 5 Engage the slots in the top enclosure with the matching tabs on the bottom enclosure Then swing the top enclosure closed As you do this push in on the ballast and hold the side vent in place Two tabs on the top of the side vent mate with two slots in the top enclosure 6 As you close the top make sure t...

Page 36: ...ottom and sides fit properly install the middle screw on the bottom case first Then install the other two screws Torque the screws to 3 in lbs 329 Nm 9 If you removed the elevator make sure to reinstall it To install the elevator press the elevator button down and then slide the elevator shaft into its slot When you release the elevator button the foot and shaft will stay in place If you re replac...

Page 37: ...nclosure 1 Remove the following items Zoom tab and focus ring page 28 Top enclosure page 31 2 Press the elevator button to lower the elevator shaft all the way 3 Press the retaining tab on the top of the elevator shaft and then withdraw the foot and shaft If the shaft is broken you may need to use a pick to push it down far enough to release it Assembly Note It is easier to install the elevator wi...

Page 38: ...e power supply to ignite the lamp The ballast is comprised an ECA insulating paper and a bracket 1 Remove the following items Focus ring zoom tab page 28 Top enclosure and side vent page 31 2 Lift the ballast up slightly and swing the side closest the middle of the projector outward to access the lamp sync cable and the power supply ballast cable Unplug the cables ...

Page 39: ...allast protector then lift it off Assembly Notes Install the IR assembly first and then plug the cables into their connectors in the reverse order When you install the ballast make sure that it remains secured to the black plastic protector and that the paper insulator remains in place Four pins in the protector fit into four matching holes in the main ballast ECA The entire assembly snaps togethe...

Page 40: ...p module lamp door page 25 Zoom tab focus ring page 28 Top enclosure and side vent page 31 2 Lift the blower assembly up and then rotate it so that it so that the blower ports face the front of the projector and that top of the blower rests on the ballast 3 Unplug the blower cable from its connector on the bottom of the blower ECA See the illustration above NOTE When you remove the blower assembly...

Page 41: ... plug the blower power cable into its connector See step 2 above 1 Rotate the blower as you lower it into the bottom enclosure making sure that the following surfaces mate properly 2 The feet fit into the matching round guides in the bottom enclosure 3 The portion of the ECA above the blower power cable connector fits beneath the controller ECA Note that there is a dampening pad that fits between ...

Page 42: ...TDP P6 Service Manual 42 4 Once the blower assembly is installed make sure that the two rubber gaskets on the outside blower ports are oriented properly and are fully mated to the blower ports ...

Page 43: ...gine WARNING Be sure to take proper ESD precautions while working near the controller ECA It can be easily damaged by static electricity ECAs damaged by static electricity require replacement 1 Remove the following items Lamp lamp door page 25 Zoom tab focus ring page 28 Top enclosure and I O bezel page 31 ...

Page 44: ...ss to the cables that connect to the ballast The lamp sync cable connects between the ballast and controller ECA Disconnect the cable on the ballast side 3 Unplug the color wheel cable and the speaker cable 4 Remove the three M2 5x4 Torx screws that fasten the controller ECA to the engine See the illustration above ...

Page 45: ... 45 5 Lift the controller upward to disconnect the engine controller connector and the controller power supply connector Lift at the points shown below 6 Unplug the color wheel power cable from the bottom of the controller ...

Page 46: ...make sure the blower assembly turns too 8 Do one of the following If you need to replace the optical engine power supply speaker rear IR ECA or bottom enclosure continue to the procedure for the part Or If you need to replace the controller ECA with a new one do the following 1 Clip the tie wrap that retains the IR and blower assembly cables to the controller ECA then unplug the two cables Also un...

Page 47: ...TDP P6 Service Manual 47 ...

Page 48: ...as shown in step 8 above Adhere the dampening gasket to the bottom of the controller as shown in step 8 above Do not install the controller ECA without the pads and gaskets Damage to the projector may occur 2 Plug the front IR blower assembly and lamp sync cables into their connectors on the controller ECA Fasten a new tie wrap to retain the cables See step 7 above Spare tie wraps are available in...

Page 49: ...ce Manual 49 2 Make sure that the two rubber feet on the blower assembly fit into the round guides in the bottom enclosure 3 Make sure that the ECA on the blower assembly and the controller ECA meet as shown below ...

Page 50: ...ne connectors Ensure that the color wheel is centered in the cutout on the controller Then press the controller firmly as shown below to fully engage the connectors Fasten the controller to the optical engine with the three M2 5x4 screws Torque the screws to 3 in lb 329 Nm Plug in the speaker and color wheel cables See step 3 of the disassembly procedure ...

Page 51: ...a rear IR ECA The rear IR ECA is also available in the Hardware Kit 802 0036 xx 1 Remove the following items Lamp door and lamp page 25 Zoom tab and focus ring page 28 Top enclosure I O bezel and side vent page 31 Controller ECA page 43 2 On the outside of the projector remove the black M2 5x4 Torx screw that fastens the optical engine to the bottom enclosure 3 Turn the projector right side up on ...

Page 52: ...ure 6 If you are replacing the engine with a new one do the following 1 Remove the dampening gasket on the end of the formatter ECA as shown below You will install the gasket on the new engine If the gasket is missing or damaged a new one is available in the Hardware Kit 802 0036 xx 2 Place the old engine in the plastic clamshell in which the new engine was packaged ...

Page 53: ...e in the bottom enclosure make sure the alignment pin on the boss in the bottom enclosure fits into the matching hole on the tab on the engine Torque the two M2 5x4 Torx screws that fasten the engine inside the bottom enclosure to 6 in lbs 68 Nm Torque the black M2 5x4 screw on the outside of the enclosure to 3 in lbs 34 Nm ...

Page 54: ...fs gap pads and a paper insulator are included with a new bottom enclosure These items must be in place to ensure that the power supply does not get damaged and to prevent any chance of electrical shock to users When you replace the power supply make sure all the items are in place before installing the part 1 Remove the following items Lamp door and lamp page 25 Zoom tab and focus ring page 28 To...

Page 55: ... the outside of the lamp door To do this press the locking tab on the outside of the plastic connector Withdraw the connector from the inside of the projector 4 Use a T 8 driver to remove the two M2 5x4 screws that fasten the power supply to the bottom enclosure and M2 5x5 screw that fasten the color wheel shroud to the power supply Then remove the shroud ...

Page 56: ... supply out of the projector you may need to trim the tabs on a sleeve that fits on a boss in the bottom enclosure The power supply fits over the sleeve and boss and the optical engine fastens to the boss The sleeve is located adjacent to the 82mF capacitor ...

Page 57: ...TDP P6 Service Manual 57 ...

Page 58: ...e illustration in step 6 above for locations Align the power supply over the sleeve and tabs and press it over the tabs so they snap into place Install the color wheel shroud Torque the screws to 3 in lbs 34 Nm Make sure that you route the safety switch cable through the eye at the front left side of the chassis Route the power supply cable along the edge of the bottom enclosure so that it does no...

Page 59: ...naps into place on the outside end of the ballast The receiver connects to the bottom of the controller ECA The cable is secured to the controller with tie wrap While the IR receiver can be removed easily to access the cable connector and to reinstall the cable require that several parts be removed 1 Remove the following items Lamp door and lamp page 25 Zoom tab and focus ring page 28 Top enclosur...

Page 60: ...front IR assembly release a hook that secures the assembly to the plastic ballast protector then lift it off Assembly Note Plug the IR cable into its connector on the controller ECA first Then bundle the IR and the blower cables and install a new cable tie It is important that the cables be kept away from the lamp module NOTE Fasten the tie wrap so that the joint is on the bottom or the side of th...

Page 61: ...r IR receiver 1 Remove the following items Lamp door and lamp page 25 Zoom tab and focus ring page 28 Top enclosure side vent and I O bezel page 31 Controller ECA page 43 Optical engine page 51 2 Unplug the IR cable from the formatter ECA on the optical engine 3 To remove the IR ECA press the center shaft of the push rivet inward That allows you to work the rivet out from the top of the ECA ...

Page 62: ...TDP P6 Service Manual 62 Assembly Note You can reuse the rivet Replacements are available in the Hardware Kit 802 0036 xx ...

Page 63: ...e speaker you slide out the mount and speaker and then separate the two The speaker mount is not available separately It is included in a new bottom enclosure 1 Remove the following items Lamp door and lamp page 25 Zoom tab and focus ring page 28 Top enclosure side vent and I O bezel page 31 Controller ECA page 43 Optical engine page 51 2 Use a pick or a small screwdriver to flex the plastic speak...

Page 64: ...he mount Assembly Notes Insert the speaker cable through the hole in the top of the mount Note the orientation in the illustration below Align the outside of the speaker mount with the guides in bottom enclosure Then slide the speaker mount and speaker into place The mount should lock into position ...

Page 65: ...Lamp door and lamp page 25 Zoom tab and focus ring page 28 Top enclosure side vent and I O bezel page 31 Controller ECA page 43 Optical engine page 51 Ballast page 38 Blower assembly page 40 Power supply page 54 2 Remove the serial number label from the certification label on the old bottom enclosure To do this carefully use a heat gun or hair drier to soften the adhesive on the back of the label ...

Page 66: ...rce The VCR must include an S video connector in addition to a composite connector Commercially produced video to test S video composite video and audio You ll need the video in DVD laser disc or videocassette format Toshiba strongly suggests you use Video Essentials Optimizing Your Audio Video System DVD International 1997 Audio Video cables Use the AV cable that came with the projector You also ...

Page 67: ...at the elevator and leveling foot are functional Verify that the focus and zoom rings operate properly Verify cosmetics Video source On the keypad press the Video button display the S video source Verify that the video automatically synchronizes If it doesn t press the Video button on the keypad Verify there is no distortion noise or other abnormalities Verify that the audio plays clearly Audio fr...

Page 68: ...res 5 After focusing on the green squares on the middle icon turn the zoom ring to make the largest image and then repeat the focus tests Verify that all four corner icons have clear resolution Verify that the white space is visible on all 5 bar line icon areas between green Verify that the image focuses through the full zoom range Verify that the image remains in focus when the Image Shift knob i...

Page 69: ...mage Verify that there are no noise tint duplicating columns or other general image abnormalities present Power Down After all tests are complete turn the power off and disconnect all cables Attach the lens cap Verify unit is powered off before disconnecting cables ...

Page 70: ...val and replacement instructions NOTE Before you order a part make sure that you confirm the correct part number in the online parts list for this product Part Part name in service guide Part name in parts pricing list Part number Side vent S A BEZEL EXHAUST 505 1294 21 Top enclosure S A UPPER ENCLOSURE W MECH TDP P6 505 1762 xx Bottom enclosure S A LOWER ENCLOSURE W MECH TDP P6 505 1763 xx I O be...

Page 71: ...xx Controller ECA ECA GECKO SYSTEM CONTROLLER 510 1733 xx Speaker S A SPEAKER GECKO 526 0145 xx Blower assembly S A BLOWER GECKO 526 0159 xx Optical engine CS PACKAGED ENGINE KIT 535 0017 xx See Hardware Kit contents page 73 Hardware kit HARDWARE KIT TDP P6 802 0036 xx See Label Kit contents page 74 Label kit LABEL KIT TDP P6 802 0035 xx ...

Page 72: ...TDP P6 Service Manual 72 Exploded View ...

Page 73: ...of the controller ECA above the blower gasket 10 Blower gasket between blower ECA and controller ECA 10 4 gap pad 5 5 gap pad 5 Cable tie 5 Lamp connector bracket 1 Power supply standoff 5 Zoom tab lever black 10 Power supply post sleeve 4 Focus ring black 5 Elevator foot black 5 Rear IR ECA 5 Front IR ECA 5 M2x2 T 6 pan machine screw 10 M2 5x4 T 8 screw 10 M2 5x6 T 6 black machine screws 10 M2 5x...

Page 74: ...DP P6 Service Manual 74 Label Kit Label name Quantity TDP P6 certification label 5 I O bezel label 5 TDP P6 rear label 5 TDP P6 front label 5 Generic certification label 5 Plated Toshiba top nameplate 5 ...

Page 75: ...T O S H I B A C O R P O R A T I O N 1 1 SHIBAURA 1 CHOME MINATO KU TOKYO 105 8001 JAPAN ...

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