Toshiba 72HM195, 62HM195, 56HM195 User Manual

FILE NO. 020-200523

DOCUMENT CREATED IN JAPAN, Sept., 2005

SERVICE MANUAL

Projection Television

56HM195 62HM195 72HM195

TOSHIBA CORPORATION 2005

Published in Japan Sep. 2005 (YC)

TABLE OF CONTENTS

SAFETY INSTRUCTIONS .............................................................................................................................................. 3

SERVICE MODE ............................................................................................................................................................ 4

SETTING & ADJUSTING DATA ...................................................................................................................................... 9

LAMP UNIT REPLACEMENT ....................................................................................................................................... 10

LIGHT ENGINE REPLACEMANT.................................................................................................................................

PARTS REPLACEMENT IN LIGHT ENGINE...............................................................................................................

EXPLODED VIEW ........................................................................................................................................ ................ 17

MECHANICAL DISASSEMBLY .................................................................................................................................... 18

CHASSIS REPLACEMENT PARTS LIST ..................................................................................................................... 19

PC BOARDS TOP AND BOTTOM VIEW ..................................................................................................................... 29

TERMINAL VIEW OF TRANSISTORS ......................................................................................................................... 47

CIRCUIT BLOCK DIAGRAM ........................................................................................................................................ 52

APPENDIX:

CIRCUIT DIAGRAM

SAFETY INSTRUCTIONS

SAFETY PRECAUTION

WARNING: Service should not be attempted by anyone unfamiliar with the necessary precautions on this receiver. The following are the necessary precautions to be observed before servicing this chassis.

1. An isolation transformer should be connected in the power line between the receiver and the AC line before any service is performed on the receiver.

2. When replacing a chassis in the cabinet, always be certain that all the prospective devices are put back in place, such as; non-metallic control knobs, insulating covers, shields, isolation resistor-capacitor network etc.

PRODUCT SAFETY NOTICE

Many electrical and mechanical parts in this chassis have special safety-related characteristics. These characteristics are often passed unnoticed by a visual inspection and the protection afforded by them cannot necessarily be obtained by using replacement components rated for higher voltage, wattage, etc. Replacement parts which have these special safety characteristics are identified in this manual and its supplements; electrical components having such features are identified by the international hazard symbols on the schematic diagram and the parts list. Before replacing any of these components, read the parts list in this manual carefully. The use of substitute replacement parts which do not have the same safety character istics as specified in the parts list may create shock, fire, or other hazards.

SERVICE MODE

1. ENTERING SERVICE MODE

1) Press MUTE button twice on Remote Control.

MUTE

2) Press MUTE button again and keep pressing.

2. DISPLAYING THE ADJUSTMENT MENU

1) Press MENU button on Remote Control.

Service mode

Press

Adjustment mode

3. SELECTING THE ADJUSTING ITEMS

1) Every pressing of CHANNEL button in the service mode changes the adjustment items in the order of table-2. ( button for reverse order)

Refer to table-1 for preset data of adjustment mode. (See SETTING & ADJUSTING DATA on page 9)

3) While pressing the MUTE button, press MENU button on TV set.

(Service mode display)

4. ADJUSTING THE DATA

1) Pressing of VOLUME or button will change the value of data in the range from 00H to FFH. The variable range depends on the adjusting item.

5. EXIT FROM SERVICE MODE

1) Pressing POWER button to turn off the TV once.

6. SELF DIAGNOSTIC FUNCTION

1) Press “9” button on Remote Control during display of adjustment menu in the service mode.

The diagnosis will begin to check if interface among IC’s is executed properly.

2) During diagnosis, the following displays are shown.

Firmware :

Version information of microprocessor

In case of file name : HM195 and Version : 1401 indicates[HM195_1401].

Time : Total brightness hour of the projection lamp. (Unit : H)

Bus line : --"OK" is normal

"SCL-GND"(Red indication) : SCL-GND short circuit

"SDA-GND"(Red indication) : SDA-GND short circuit

"SCL-SDA"(Red indication) : SCL-SDA short circuit

Bus cont : --- "OK" is normal.

NG is abnormal(Red indication), when type name of semiconductor indicates.

Block

UV : TV reception mode

V1 : VIDEO 1 input mode

V2 : VIDEO 2 input mode

V3 : VIDEO 3 input mode

V4 : ColorStream HD-1 IN V5 : ColorStream HD-2 IN

V6 : HDMI IN 1

V7 : HDMI IN 2

DLP : Thermal sensor values information that indicates both of nearby the projection lamp and DMD

microprocessor into the unit.

-5-

7. VERSION CHECK MODE

1) Press “9” button twice on Remote Control during display of adjustment menu in the service mode. The version of main

MPU will begin to check.

2) During Version Check, the following displays are shown.

3 4

7 8

MAIN MPU :

Version information of microprocessor

In case of file name : HM195, Version 1401 for Code Program Version

and (U15) for OSD Version indicates [HM195_1401(U15)]

EEPROM :

Version information of EEPROM : Display 1 byte data.

SUB MPU :

Version information of SUB MPU : Display 1 byte data.

OPTION :

Option information : Display six numbers of 1 byte data.

HDMI ID :

HDMI ID information : Display 4 byte data.

DMD :

Version information of DMD optical engine : Display 1 byte data.

MALIBU :

MALIBU information : Display two numbers of 1 byte data.

MALIBU STATUS :

MALIBU STATUS information : Display four numbers of 1 byte data.

-6-

8. STATUS CHECK MODE

1) Press “9” button thrice on Remote Control during display of adjustment menu in the service mode. The status of this

model will begin to check.

2) During Status Check, the following displays are shown.

1 2 3

MAIN :

Main source information :

Display RF position number (1 - 135) on the main screen, or Input Source (HDMI1/2, DVI, AUDIO etc.)

MAIN FORMAT :

Display Video and PC format information

MAIN PLL :

Main PLL information : Display 1 byte data at five.

SCREEN SIZE :

Display the screen size as follows.

Theater Wide 1

Theater Wide 2

Theater Wide 3

FULL

NATURAL

OTHER STATUS :

Other status information : Display three numbers of 2 byte data.

-7-

9. LED indications

The yellow and blue LED lights on the TV (at the bottom center of the TV) indicate the TV’s status, as described below: ´ Blue ON (solid) and Yellow OFF = The TV power cord is

plugged in.

´ Yellow ON (solid) and Blue OFF = A recording is in

progress while the TV is OFF.

´ Blue ON (solid) and Yellow ON (solid) = A recording is in

progress while the TV is ON. Yellow and/or Blue blinking (see table below).

Note: If the TV loses A/C power (e.g., a power outage oc-

curs or the power cord is unplugged), when power is restored, the yellow LED will blink while the TV is booting until the remote control is usable. This is normal and is not a sign of malfunction.

Blue LED

Yellow LED

TV front

LED

Yellow blinks continuously at 3-

second intervals.

Blue blinks continuously at 0.5-

second intervals.

Yellow blinks continuously at 0.5-

second intervals;

Blue is ON (solid).

Yellow and Blue blink continu-

ously at 1-second intervals.

Yellow is OFF;

Blue blinks at 0.2-second inter-

vals 4 times (repeat).

Yellow is OFF;

Blue blinks continuously at 0.5-

second intervals.

Yellow is OFF;

Blue blinks continuously at 1-

second intervals.

Yellow is OFF;

Blue blinks at 0.2-second inter-

vals 3 times (repeat).

Condition

The lamp unit door is not seated

properly.

The lamp is not working properly.

The lamp is not working properly

after the eighth automatic restart

(see item #2).

An abnormal temperature

increase has occurred.

Abnormal operation

(including cooling fan stop).

Abnormal operation of BUS line.

The color wheel has stopped.

Solution

Turn OFF the TV and unplug the power cord.

Review “How to replace the lamp unit” on

pages 10–12 to ensure that the lamp door is

installed securely.

The TV will automatically try to restart itself

eight times (see item #3).

Turn the TV OFF and then ON again. If the

problem persists, replace the lamp unit (see

pages 10–12).

Turn OFF the TV. Check to make sure all

slots and openings in the TV cabinet are not

covered, blocked, or dusty. Turn ON the TV

again. If the problem persists, contact a

Toshiba Authorized Service Center.

Turn OFF the TV and unplug the power cord.

Plug the power cord in again and turn ON

the TV.

Turn OFF the TV and unplug the power cord.

Plug the power cord in again and turn ON

the TV.

Turn OFF the TV and unplug the power cord.

Plug the power cord in again and turn ON

the TV.

– 8 –

SETTING & ADJUSTING DATA

SERVICE MODE

ADJUSTING ITEMS AND DATA IN THE SERVICE MODE:

Item Name of adjustment

RCUT R CUT OFF GCUT G CUTOFF BCUT B CUT OFF GDRV G DRIVE BDRV B DRIVE RDRV

BRTC

∗

COLC

∗

UVTT

∗

CNTX

∗

CNTCG G CONTRAST CENTER CNTCR R CONTRAST CENTER CNTCB B CONTRAST CENTER HPOS H-POSITION 00H

Note:

The image system data of ∗mark items are different by each image format. The RF-Signal value is indicated in the table. Retention the HPOS and VPOS data to EEPROM of Malibu. Retention the CWDH and CWDL data to EEPROM of DMD.

R DRIVE

BRIGHTNESS CENTER COLOR CENTER BASE BAND TINT CONTRAST MAX

Preset Data

00H 00H 00H 80H 80H 80H FDH C8H FEH 80H

64H 64H 64H

Table-1

Item Name of adjustment

VPOS V-POSITION CWDH CWDL DMDB DMD BIAS OPT1 TV SET OPTION 1 OPT2 TV SET OPTION 2 OPT3 TV SET OPTION 3 PLLW0 PLL WAIT TIME PLLW1 PLL WAIT TIME PLLW2 PLL WAIT TIME PLLW3 PLL WAIT TIME PLLW4 PLL WAIT TIME PLLW5 PLL WAIT TIME

COLOR WHEEL DELAY (HIGH) COLOR WHEEL DELAY (LOW)

Preset Data

00H 00H 74H 03H 74H 00H 01H 14H 03H 0FH 05H 14H 04H

-9 -

LAMP UNIT REPLACEMENT

Cautions when replacing LAMP UNIT (E998Z; PJ-D95-LMP)

The light source for this TV is a mercury lamp with internal atmospheric pressure that increases during use. The lamp has a limited service life that varies depending on user settings. If you use the lamp beyond its service life:



you may notice a reduction in the colors and/or brightness of the picture; and



the strength of the quartz glass in the lamp will be reduced and the lamp may rupture (often making a loud noise when this happens). If the lamp reputres, the TV will not operate until the lamp unit is replaced.

Note: The lamp unit is designed so broken lamp glass remains se-

curely inside the lamp unit.

CAUTION: Always handle the lamp unit with care.

The lamp unit in this TV was designed for safe replacement by consumers; however, if the lamp unit is subjected to intentional abuse (such as excessive mechanical abuse or handling by children or pets), the unit may break, exposing edges or pinch points.

When to replace the lamp unit

You should replace the lamp unit:



if the picture darkens and/or colors fade;



if the lamp does not light; or



If you hear a loud noise and the picture goes black, which may indicate a lamp rupture (LED indication #8). See LED indications on page 6.

Note: Be sure wear the gloves before replacing the lamp unit.

1. Turn off the TV and unplug the power cord.

2. STOP! Allow the lamp to cool for at least one (1) hour before replacing it.

3. On the lamp unit door on the side of the TV, loosen the

screw using a manual screw driver, and then remove the lamp unit door.

TV back

Lamp unit door detail

loosen screw using manual screwdriver

5. Grasp the lamp unit handle and gently pull the lamp unit straight out of the TV. Set the old lamp unit aside.

Note: Wear soft, lint-free gloves

when replacing

the lamp unit.

6. Carefully insert the new lamp unit straight into the TV until it is fully seated.

Note :

Never subject the lamp unit to excessive shock. Never touch the lamp unit glass or otherwise get it dirty. Doing so may affect the image quality and reduce the service life of the lamp. See “Cleaning the lamp unit glass” below.

4. Using a manual screwdriver, loosen the two screws on the lamp unit.

Lamp unit screws

7. Using a manual screwdriver, tighten two lamp unit screws. Note:Hand-tighten only. Do not use an electric screwdriver.

Lamp unit screws

(use manual screwdriver only)

8. Reattach the lamp unit door, making sure to insert the hooks on the left side of the lamp unit door inside the opening in the TV cabinet.

Insert the hooks inside the TV cabinet opening.

Lamp unit door

9. Replace the screw and hand-tighten using a manual

screwdriver.

Hand tighten using manual screwdriver

Lamp unit door

NOTE :

Make sure

the lamp unit door is installed securely; otherwise, the TV may not turn on.

10. Plug in the power cord and turn on the TV. After the initial warmup period (which may take several seconds for full picture brightness), the TV should operate normally. If any of the following conditions exist, turn off the TV, unplug the power cord, and repeat steps 1-9 to ensure that the lamp unit and lamp unit door are installed correctly:

No picture Dark picture TV will not turn on

-12-

LIGHT ENGINE REPLACEMENT

Cautions when replacing LIGHT ENGINE

LIGHT ENGINE UNIT:

A271 : LV-682 TB

(Including with E998Z, SK01 to SK04, SK06,SK08 and SK09.)

LIGHT ENGINE is a heart of the TV and emits high heat. Make sure to replace it after turning off the TV and wait for sufficient cool down. (More than one hour is recommended.) Do not impact during replacement; otherwise, some parts may be damaged. Do not touch optical lens. Adhesion of dirt may deteriorate its performance. Do not loosen any screw other than those to be removed for adjustment or replacement. LIGHT ENGINE emits ultraviolet rays when the TV is ON. Make sure to be careful.

PARTS REPLACEMENT IN LIGHT ENGINE

1. Replacement of Lamp FAN (SK01)

1-1. Replace the FAN for cooling Lamp (SK01), remove the

4 screws on the FAN Hood, and remove the 4 pins by

pressing toward allows using a screwdriver, and the

remove the FAN for cooling Lamp.

NOTE:

Reinstalling the FAN for cooling Lamp, attach the 4 pins

by using removed them after replace the FAN.

4 screws

FAN Hood

2. Replacement of Ballast FAN (SK03)

2-1. Replace the FAN for cooling Ballast Power Unit (SK03),

remove the Ballast Hood, and remove the 2 screws on the

Ballast Case Cover.

2-2. Remove the 4 pins by pressing toward inside of the FAN

using a screwdriver, and then remove the 4 pins toward

allows as figure.

Remove the FAN for cooling Ballast Power Unit.

NOTE:

Reinstalling the FAN for cooling Ballast Power Unit,

attach the 4 pins by using removed them after replacing

the FAN.

Ballast Hood

4 pins

2 screws

Ballast Case Cover

– 14 –

+ 31 hidden pages