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Toshiba TDP-P5 Service Manual
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Toshiba TDP-P5 Service Manual

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TDP-P5 Service Manual
FILE NO. 330-200207

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  • Page 1 TDP-P5 Service Manual FILE NO. 330-200207...
  • Page 2 TDP-P5 Service Manual...

  • Page 3: Table Of Contents

    Wiring Diagram Controller voltages Check Controller Voltages at Connectors Ballast Voltage Check Points Check Fan Operation Check Speaker Resistance Parts Lists........................78 Exploded View FRUs by alphabetic listing FRUs by numeric listing Hardware Kit Contents Standard Accessories TDP-P5 Service Manual...

  • Page 4: Safety Precautions

    The exclamation point within an WARNING: Changes or modifications made to this equipment, not expressly approved by equilateral triangle is intended to Toshiba, or parties authorized by Toshiba, could void the user's authority to operate alert the user to the presence of the equipment.

  • Page 5: Important Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS CAUTION: PLEASE READ AND OBSERVE 1. Read Owner's Manual 3. Source of Light ALLWARNINGS AND After unpacking this product, read the Do not look into the lens while the lamp INSTRUCTIONS GIVEN IN THIS owner's manual carefully, and follow all is on.

  • Page 6: Parts Replacement

    The parts on the first level (the lamp module, for example) are accessible without removing any other parts. The more levels down that a part is, the more parts you need to remove in order to access it. TDP-P5 Service Manual...

  • Page 7: Remove And Replace The Lamp Module

    Remove the three M3x6 screws that fasten the lamp to the bottom case. Use a small flat blade screwdriver to gently pry up the edge of the lamp door, then pull the lamp module out of the projector. TDP-P5 Service Manual...
  • Page 8 1. Turn the projector on, then press Menu on the remote control or the keypad. 2. In the Basic menu, select Setup. 3. In the Setup menu, select Service. 4. In the Service menu, select Reset Lamptimer. TDP-P5 Service Manual...

  • Page 9: Remove And Replace The Top Case

    The top case encloses the top half of the projector. Remove the three M2.5x41.5 Plastite screws from the bottom case. Turn the projector right side up on the work surface. Gently lift the side of the top case. TDP-P5 Service Manual...
  • Page 10 Gently lift the top case away from the bottom case. Assembly Notes ♦ Ensure that the three tabs on the side of the top case fully engage the slots in the bottom case. ♦ Torque the three M2.5x41.5 Plastite screws to 5.3 in-lbs (0.6 Nm). TDP-P5 Service Manual...

  • Page 11: Remove And Replace The Leveling Foot

    Remove the lamp module (page 7) and the top case (page 9). Gently pry the leveling foot retainer from the groove around the top of the leveling foot. Extend the leveling foot until it separates from the bottom case. TDP-P5 Service Manual...
  • Page 12 Use a short section of 1/8" pipe to allow straight placement of the leveling foot retainer on the leveling foot. Tap the pipe gently to seat the retainer into the groove around the top of the leveling foot. TDP-P5 Service Manual...

  • Page 13: Remove And Replace The Keypad

    Gently peel the keypad away from the inside of the top case. Assembly Notes ♦ Ensure that the three alignment pins on the inside of the top case fully engage the holes in the keypad. ♦ Press the keypad down firmly to secure it in the top case. TDP-P5 Service Manual...

  • Page 14: Remove And Replace The Fan Assembly

    Controller ECA (partial removal) (see page 16) Disengage the DMD fan cable from the guide on top of the fan assembly. Disengage the high voltage lamp cable from the guide at the side of the fan assembly. TDP-P5 Service Manual...
  • Page 15 Ensure that the fan assembly engages the guides in the bottom case. ♦ Route the high voltage lamp cable through the guide at the side of the fan assembly. ♦ Route the DMD fan cable through the guide at the top of the fan assembly. TDP-P5 Service Manual...

  • Page 16: Partially Removing The Controller Eca To Access Other Parts

    Remove the fasteners that secure the I/O shield to the bottom case and the controller ECA. Place the fasteners aside. Each of the fasteners is also available in the hardware kit (see page 83). Remove the I/O shield and the M1 connector shield from the controller ECA. TDP-P5 Service Manual...
  • Page 17 Remove the three M2.5x5 Torx screws that fasten the controller ECA to the optical engine. Unplug the color wheel ribbon cable from the ZIF connector on the controller ECA. TDP-P5 Service Manual...
  • Page 18 As you lift the controller ECA, feed the color wheel ribbon cable through the slot in the board. Feed the entire length of cable through the slot. Don't remove the foam airflow gasket from the controller ECA. TDP-P5 Service Manual...
  • Page 19 Route the color wheel sensor cable over the top of the optical engine, avoiding pinch points at screw locations. ♦ Torque the three M2.5x5 Torx screws to 5.3 in-lbs (0.6 Nm). ♦ Torque the M3x7 Plastite screw to 6.2 in-lbs (0.7 Nm). ♦ Torque the #4-40 jack screws to 3.5 in-lbs (0.4 Nm). TDP-P5 Service Manual...

  • Page 20: Remove And Replace The Dmd Fan

    Remove the following items: Lamp module (see page 7) Top case (see page 9) Fan assembly (see page 14) Controller ECA (partial removal) (see page 16) Lift the DMD fan from the alignment pins on the optical engine. TDP-P5 Service Manual...
  • Page 21 Assembly Notes ♦ Ensure that the alignment pins on the optical engine engage the holes in the fan mounting frame. TDP-P5 Service Manual...

  • Page 22: Remove And Replace The Color Wheel

    Remove the two M3x7 Plastite screws that secure the color wheel shield to the bottom case. Then carefully lift the shield away from the color wheel. Place the shield aside for use with the replacement color wheel. The shield is also available in the hardware kit (see page 83). TDP-P5 Service Manual...
  • Page 23 Carefully lift the color wheel by the mounting bracket to remove it from the optical engine. Remove the three M2x3.6 screws that secure the color wheel to the mounting bracket. Separate the two parts. Save the mounting bracket for use with the replacement color wheel. TDP-P5 Service Manual...
  • Page 24 Assembly Notes ♦ Ensure that the color wheel ribbon cable aligns with the recess in the mounting bracket. ♦ Torque all screws to 5.3 in-lbs (0.6 Nm). TDP-P5 Service Manual...

  • Page 25: Remove And Replace The Color Wheel Sensor Eca

    Unplug the color wheel sensor cable from the color wheel sensor ECA. Remove the two M2.5x5 Plastite screws that secure the color wheel sensor ECA to the color wheel mounting bracket. Assembly Note ♦ Torque the two M2.5x5 Plastite screws to 6.2 in-lbs (0.7 Nm). TDP-P5 Service Manual...

  • Page 26: Remove And Replace The Optical Engine

    Top case (see page 9) Controller ECA (partial removal) (see page 16) Remove the two M3x7 Plastite screws that secure the color wheel shield to the bottom case. Then carefully lift the shield away from the color wheel. TDP-P5 Service Manual...
  • Page 27 If you need to replace the optical engine, remove the controller ECA (see page 28). Assembly Notes ♦ Ensure that the speaker cable is not pinched between the bottom of the optical engine and the bottom case. ♦ Torque the M3x7 Plastite screws to 5.3 in-lbs (0.6 Nm). TDP-P5 Service Manual...

  • Page 28: Remove And Replace The Controller Eca

    Lamp module (see page 7) Top case (see page 9) Controller ECA (partial removal - see page 16) Optical engine (see page 26) Gently pry the formatter ECA away from the optical engine until one side of the connector opens. TDP-P5 Service Manual...
  • Page 29 The replacement controller ECA may not contain current product software. Check the software version by navigating to the service menu. Then select “Info” to see the currently installed software version. Upgrade the software if necessary (see page 47). TDP-P5 Service Manual...

  • Page 30: Remove And Replace The Speaker

    NOTE The retainers are fragile. Avoid excessive force to compress them. With the retainer compressed, use a small flat blade screwdriver to pry the speaker away from the bottom case. TDP-P5 Service Manual...
  • Page 31 Position the speaker in the bottom case with the wire leads pointing toward the side of the case. ♦ Press the speaker down against the bottom case. The speaker is secure when both of the retainers snap into place over the ridge around the edge of the speaker. TDP-P5 Service Manual...

  • Page 32: Remove And Replace The Ballast/Power Supply

    Remove the lamp module (see page 7). Remove the top case (see page 9). Unplug the lamp control cable, the power supply control cable and the controller ECA power cable from their connectors on the controller ECA. TDP-P5 Service Manual...
  • Page 33 Disengage the high voltage lamp cable from the guide at the side of the fan assembly. Squeeze the retainer tabs on the lamp connector together to unlock it from the recess in the bottom case. Pull the connector out of the recess. TDP-P5 Service Manual...
  • Page 34 Lift and remove each of the four retainer rivets at the corners of the ballast. Lift the ballast away from the power supply. Then squeeze the locking tab on the ballast power supply connector and unplug the connector from the power supply. TDP-P5 Service Manual...
  • Page 35 Squeeze the locking tab on the lamp cable connector and unplug the connector from the ballast. Unplug the lamp control cable from the ballast. TDP-P5 Service Manual...
  • Page 36 Lift the power supply and check to see if any other retainer tabs prevent its removal. If other retainer tabs fail to release, gently pry them away from the power supply. Lift the power supply away from the bottom case. TDP-P5 Service Manual...
  • Page 37 Use the M3x8 screw with washer at the end of the power supply closest to the side of the bottom case. Use the M3x7 Plastite screw at the end of the power supply closest to the projection lens. TDP-P5 Service Manual...

  • Page 38: Remove And Replace The Elevator Foot

    Remove the elevator spring from the notch in the top of the elevator foot. Avoid disengaging the opposite end of the elevator spring from the bottom case. While pinching the elevator foot retainer tabs tightly together, depress the elevator actuator and pull the elevator foot out of the bottom case. TDP-P5 Service Manual...
  • Page 39 Assembly Notes ♦ Depress the elevator actuator before inserting the elevator foot into the bottom case. ♦ Once you insert the elevator foot into the bottom case, leave the foot fully extended until you attach the elevator spring. TDP-P5 Service Manual...

  • Page 40: Remove And Replace The Elevator Actuator

    Lift the EMI shield from the bottom case. Place the shield aside for use with the replacement elevator actuator. The shield is also available in the hardware kit (see page 83). Use a small flat blade screwdriver to compress the elevator actuator spring. Then remove the spring from the bottom case. TDP-P5 Service Manual...
  • Page 41 Lift the elevator actuator away from the bottom case. Assembly Notes ♦ Replace the elevator actuator before installing the actuator spring. ♦ Compress the spring using a small flat blade screwdriver. Then position the spring ends over the retainers before releasing compression. TDP-P5 Service Manual...

  • Page 42: Remove And Replace The Bottom Case

    Elevator foot (see page 38) Elevator actuator (see page 40) Lift the EMI shield from the bottom case. Place the shield aside for use with the replacement bottom case. The shield is also available in the hardware kit (see page 83). TDP-P5 Service Manual...
  • Page 43 Take care not to ruin the label by applying too much heat. Attach the serial number label to the new bottom case. ♦ Adhere labels (certification, power rating and model labels) to the bottom case. Also adhere the rubber foot to the bottom case. TDP-P5 Service Manual...

  • Page 44: Software

    The illustrations below refer to version 1.0 of the projector system software. The version of the software you download may be different. In the File Download box, select Save This Program To Disk option, then click OK. TDP-P5 Service Manual...
  • Page 45 The file downloads to your computer’s hard drive. Now you're ready to install the software on the computer. You can also transfer the file to a floppy disk to use on other computers. To install the system software on the computer, see the next page. TDP-P5 Service Manual...

  • Page 46: Install The Software On The Computer

    Find, then click Files or Folders. In the Find dialog box, enter the name of the file (for example, 70v10.exe). To extract the files, click Unzip. Click OK in the message box that appears, then click Close. Now you’re ready to upgrade the software in the projector. See the next page. TDP-P5 Service Manual...

  • Page 47: Upgrade The Software

    Do not attach the power cord on the projector yet. If the cord is plugged in at this stage the upgrade will not start. Now you're ready to upgrade the software. Upgrade the software Open Windows Explorer, navigate to the location where you stored the upgrade files, then double-click the utility. TDP-P5 Service Manual...
  • Page 48 The Upgrade Wizard appears, ready to begin the upgrade process. Click the Next button to open the Select File dialog box. Click Browse. TDP-P5 Service Manual...
  • Page 49 In the Open dialog box, select the .bin file, then click Open. The upgrade file appears in the Select File box. Click the Next button. TDP-P5 Service Manual...
  • Page 50 You may need to do this more than once to begin the upgrade. If the Upgrading dialog box does not show progress, unplug the projector and try again. If the upgrade fails after several tries, check the COM port setting and the cable connections. TDP-P5 Service Manual...
  • Page 51 In the Setup menu, select Service. In the Service menu, select Info. The Service Info dialog box displays the software build number (1.0 in this example) and the software version. These should match the build and upgrade filename you downloaded. TDP-P5 Service Manual...

  • Page 52: Functional Tests

    Make sure the video player has an S-video Out port and cables. The player should also have a Composite video output port (RCA). Toshiba strongly suggests you use a DVD player to test the video quality. DVD players reproduce colors better and project sharper images.
  • Page 53 On the keypad, press the Source/Select Verify that the video automatically synchronizes. key. Verify there is no distortion, noise or other video Manually select a connected source. abnormalities. Software Version / Lamptime Used Verify software version. TDP-P5 Service Manual...
  • Page 54 Image #2: Color Ramp Project the Color Ramp image. Verify there are no missing parts of the ramp. Verify that the bars are not flashing. Verify that the transitions from light to dark are smooth and gradual. TDP-P5 Service Manual...
  • Page 55 Navigate through the Basic menu to the Reset function. Select Reset. Power Down After all tests are complete turn the power Verify unit is powered off before disconnecting cables. off and disconnect all cables. Attach the lens cap. TDP-P5 Service Manual...

  • Page 56: Troubleshooting

    Controller voltage check points on page 72. ♦ Check controller voltages at connectors on page 73 ♦ Ballast voltage check point on page 74. ♦ Check fan operation on page 75. ♦ Check speaker resistance on page 77. TDP-P5 Service Manual...

  • Page 57: Troubleshooting Power Problems

    What is the problem? Lamp or projector No lamp. No signs of power. shuts off after At least some fans No fans, no LED running a short are running (page 58). period of time (page 59). (page 60). TDP-P5 Service Manual...
  • Page 58 No signs of power. No fans, no LED. Use a known good power cord. Does the projector Replace the power power up? cord. Replace the power supply (page 32). TDP-P5 Service Manual...
  • Page 59 Replace the fan assembly after a short period of time if the (page 14) or replace the motor fails to turn. DMD fan (page 20. Do the fans all run Problem resolved now? Replace the controller (page 28). TDP-P5 Service Manual...
  • Page 60 (page 14) motor fails to turn. or replace the DMD fan (page 20). Does the projector Problem resolved run properly? Replace the power supply (page 32). an out message appears TDP-P5 Service Manual...

  • Page 61: Troubleshooting Image Problems

    No image at all. Dim image composite video, or S-video. Vertical or horizontal lines. (page 63) Distorted image, noisy, Sparkly picture. rolling, torn, frozen, "plaid," Clusters of dark pixels repeated, or shifted image (page 6). (page 64). TDP-P5 Service Manual...
  • Page 62 No image. Vertical lines. Horizontal lines. Sparkly picture. Clusters of dark pixels. Replace the controller ECA (page 28). Image good? Problem resolved Replace the optical engine (page 26). TDP-P5 Service Manual...
  • Page 63 (Note: The lamp takes about 90 seconds to achieve full brightness.) Replace the lamp Image brighter? module (page 7). Substitute known good controller ECA (page 28). Replace the Image brighter? controller ECA (page 28). Replace the optical engine (page 26). TDP-P5 Service Manual...
  • Page 64 Bad or missing tint or color. Distorted image, excess noise, rolling image, torn image, frozen image, "plaid" image, repeated single image, or shifted image. Make sure cables are good. Problem resolved Image good? Replace the controller ECA (page 28). TDP-P5 Service Manual...

  • Page 65: Troubleshooting Audio Problems

    Troubleshooting Audio Problems No audio or distorted audio from the speaker Make sure cables are good. Is audio OK? Problem resolved What is the problem? No audio (see page 65) Audio is distorted (see page 67) TDP-P5 Service Manual...
  • Page 66 30 minutes. If the problem returns, than 4 ohms? replace both the controller ECA and the speaker if the resistance no longer measures between 7.5 and 8 ohms. Replace the speaker (page 30). TDP-P5 Service Manual...
  • Page 67 Audio sounds scratchy or distorted Verify that audio signal source and cables are good. Problem resolved Sound good? Connect a known good 8-ohm speaker in place of the existing speaker. Problem resolved Sound good? Replace the controller ECA (page 28). TDP-P5 Service Manual...

  • Page 68: Troubleshooting Remote Control Problems

    Infrared Remote Problem Install known good batteries in the remote. Does the remote Problem resolved work? Use a known good remote with the projector. Does the remote Replace the remote. work? Replace the controller ECA (page 28). TDP-P5 Service Manual...

  • Page 69: Troubleshooting Keypad Problems

    (page 28). Does the projector Does the projector Replace the Replace the respond to key respond to key controller ECA keypad presses? presses? (page 28). (page 13). Replace the Replace the keypad controller ECA. (page 13). (page 28). TDP-P5 Service Manual...

  • Page 70: Troubleshooting Menu Problems

    Does the menu doesn't, go to "Troubleshooting appear? "Troubleshooting Remote Control Keypad Problems" Problems" (page 69). (page 68). Flash or reflash the latest software into the projector. Does the menu appear? Replace the controller ECA (page 28). TDP-P5 Service Manual...

  • Page 71: Wiring Diagram

    Wiring Diagram TDP-P5 Service Manual...

  • Page 72: Controller Voltages

    To check voltages, you need to remove the top case (see page 9). Leave the lamp module installed in the projector. Then use the remote control or briefly short the power switch electrodes to power up the projector. You can also check voltages at connectors on the controller ECA (see the following page). TDP-P5 Service Manual...

  • Page 73: Check Controller Voltages At Connectors

    Then use the remote control or briefly short the power switch electrodes to power up the projector. The figure below shows connectors on the controller ECA that you can check to determine its operational state. You can also check voltages at points on the controller ECA (see the previous page). TDP-P5 Service Manual...

  • Page 74: Ballast Voltage Check Points

    Check to see if the ballast is receiving DC power from the power supply. You can also check voltages on the controller ECA (see page 72) to see if it is receiving DC power from the power supply. TDP-P5 Service Manual...

  • Page 75: Check Fan Operation

    Both fans in the fan assembly should start up and run for 5 - 10 seconds, then shut down (because there is no lamp installed). This is time enough to make sure the fans work properly. TDP-P5 Service Manual...
  • Page 76 Lift the controller ECA carefully and use a penlight to examine the DMD fan. The fan should start up and run for 5 - 10 seconds, then shut down (because there is no lamp installed). This is time enough to make sure the fan works properly. TDP-P5 Service Manual...

  • Page 77: Check Speaker Resistance

    Locate the speaker terminals on the back of the speaker in the bottom case. Use an ohmmeter to check the resistance between the terminals. A measurement between 7 and 8 ohms indicates a good speaker. If you read more or less resistance, the speaker is damaged. TDP-P5 Service Manual...

  • Page 78: Parts Lists

    Parts Lists Exploded View TDP-P5 Service Manual...

  • Page 79: Frus By Alphabetic Listing

    405912 (Spring foot) Fan assembly 505-1027-xx (S/A, fan 50x10) Fan, DMD 505-1028-xx (S/A fan 45x10) Hardware kit The hardware kit contains miscellaneous projector parts. 410442 (Mounting details D3) See page 83 for a list of kit contents. TDP-P5 Service Manual...
  • Page 80 Required for a new bottom case. For model TDP-P5-US 020-1475-xx (Label, bottom, cert) only. Label, certification 020-1607-xx Required for a new bottom case. For model TDP-P5-J only. (Label, bottom, cert) Label, model Required for a new bottom case. For model TDP-P5-US 020-1606-xx (Label, bottom, model) only.

  • Page 81: Frus By Numeric Listing

    410443 Includes attached foam airflow gasket (Controller board D3) Label, certification 020-1475-xx Required for a new bottom case. For model TDP-P5-US only. (Label, bottom, cert) Label, model 020-1477-xx Required for a new bottom case. For model TDP-P5-J only. (Label, bottom, model)
  • Page 82 505-1338-xx (S/A, keypad, D3) Color wheel 525-0037-xx Includes glass color wheel and drive motor. Speaker 526-0116-xx (S/A speaker, D3) Optical engine Includes projection lens, color wheel and color wheel sensor (Engine, optical, zoom, 530-0388-xx SGA, .7" DDR) TDP-P5 Service Manual...

  • Page 83: Hardware Kit Contents

    Screw, Plastite, M3x7mm Torx Shield, color wheel Plastic shroud encloses glass color wheel Lays in bottom case beneath optical engine and Shield, EMI power supply Shield, I/O EMI Surrounds I/O ports Shield, M1 port EMI Surrounds M1 port TDP-P5 Service Manual...

  • Page 84: Standard Accessories

    Standard Accessories Below is a list of accessories packaged with the projector. See Optional Accessories on the Toshiba web site for a complete list of optional accessories. Description Part Number Notes User's Guide 010-0341-xx For model TDP-P5-US (Manual, Users, TDP-P5)

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