TECHNICAL TRAINING

DLP-04-1
2004 DLP Projection Television

Course: 2004 DLP Projection Television

Model Year: 2004
Chassis: D4RS
Models: 46HM84, 52HM84, 62HM84, 46HM94, 52HM94, 62HM94,
52HMX84, 62HMX84, 52HMX94, and 62HMX94

Purpose:
Provide an overview of the 2004 DLP Projection Television general operations
and service procedures.

Objectives: Upon completion of this training module, the technician will:

1. Understand the basic principal of the Digital Light Process with 100%
accuracy.
2. Describe the inputs and major features with 100% accuracy.
3. Describe how to properly remove and replace the lamp module and
understand the major characteristics of the lamp with 100% accuracy.
4. Understand precautions of the light engine, LED codes and consumer
troubleshooting with 100% accuracy.

Product Specific Service Manuals:

This training is designed as an aid to the technician in servicing Toshiba products. It is not a replacement for the
appropriate service manual(s). Toshiba service manuals contain product and model specific information and must
be consulted prior to servicing any product.

Product Safety Precautions:

Product Safety Precautions are described in the Toshiba service manual(s) for products and models covered in this
training. All safety precautions and checks must be complied with before returning any product to the customer.
Servicers who defeat safety features or fail to perform safety checks may be liable for any resulting damages and
may expose themselves and others to possible injury.

National Service Division – 1420B Toshiba Drive – Lebanon, TN 37087

www.tacpservice.toshiba.com/tacp E-Mail: Technical_Training@tacp.com
 2004 Toshiba America Consumer Products, L.L.C.
 Toshiba PJTV
2004 DLP Television

Consider General Operations

Welcome to Toshiba’s Technical Training Course on our first DLP™ (Digital Light
Process1) rear-projection television. In order to make sure you have the correct
technical information for service repairs, Toshiba Technical Training has also
development this DLP-04-1 Training Module so you have the best understanding
of the general operation and features of this new product. It is best to
understand “how it works” before “why it works”.

We are proud to introduce the TALON™ (Toshiba Advanced Light Engine) and
many other features of the DLP™. Toshiba's 2004 DLP™ projection television
line-up is built upon our many years of projection television engineering and
production expertise. By focusing on our "core competencies" Toshiba has
created a product with performance and picture quality features, such as
PixelPure™ and the TALEN™ Light Engine, designed to redefine what an HDTV
picture should be.

Figure 1 DLP with optional stand

This training module will cover many important aspects of Toshiba’s DLP™
products. While some features will not be covered, all features are covered in the
Owner’s Manual for each model.

The DLP™ logo and DLP™ medallion are trademarks of Texas Instruments.
1

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2004 Model lineup

46HM84 62HM94
52HM84 52HMX84
62HM84 62HMX84
46HM94 52HMX94
52HM94 62HMX94

Figure 2

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Horsepower explained
DLP uses a high intensity lamp and a Digital Mirror Device (DMD) delivering
bright, crisp, realistic images.

Figure 3 TALEN Light Engine

The TALEN creates a phenomenal DLP picture unique to Toshiba. This superior
picture quality was made possible by years of engineering experience in both
Rear and Front Projection Televisions design. Internal to the engine, the Texas
Instruments HD2+ DLP™ chip set includes 1280 X720 mirrors to create a true
720p display with superior brightness and contrast.

Figure 4
(shown here with an Ant’s foot)

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Figure 5

These chips consist of over a million tiny mirrors that are hinged so that each
mirror can be individually moved. This movement allows the reflection of light or
absence of light. The 120-watt lamplight is projected through a multi-segment
color wheel, which creates a full color display, shown in Figure 5. The TALEN™
also incorporates a reduction of dithering noise by using 9-bit system with double
speed chip and enhanced algorithms.

Figure 6

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Exploring the DLP
The DLP rear projection television can be operated with the remote or via the
front control touch pad. The back and side panels provide all the terminal
connections for connecting other equipment. With the capability of over eight
inputs, the DLE offers a wide range of formats from composite to HDMI. The
integrated models also include five memory stick inputs for displaying images
taken from a digital camera.

Figure 7

ReadMe The green and red LEDs on the control touch pad indicate the
TV’s current status. If either light flashes, see “LED indications” in table 3.

Non-technical Tech Tip

From time to time an un-necessary service call maybe to a customers home
because a video input selection or a channel is blocked. This unit has a feature
called “VIDEO LOCK” and is capable of locking out input sources such as Video
1, Video 2, Video 3, ColorStream HD1, ColorStream HD2, HDMI and channels 3
and 4. The other is called “Locking Channels” and both of these features are

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detailed in the owner’s manual. Though these features are easily unlocked from
the main menu, it has frequently been construed to be a problem with the unit.

Understanding High-Definition Multimedia Interface2

The HDMI [1] (see “Define”) input on your TV receives uncompressed digital video
and audio from an HDMI device or uncompressed video from a DVI [2] device.
This input is designed to accept HDCP [3] program material in digital form from
EIA/CEA- 61/861B– compliant [4] consumer electronic devices (such as a settop
box or DVD player with HDMI or DVI output [5]). The HDMI input is designed for
best performance with 1080i high-definition video signals, but will also accept
and display 480i, 480p, and 720p signals. This TV is not intended for connection
to and should not be used with a PC (personal computer).

HDMI connection
To connect an HDMI device, it is required to have one HDMI cable (type A
connector). For proper operation, use a HDMI HDMI cable shorter than 16.4ft
(5m), of course, the shorter the better. HDMI cable transfers both video and
audio. Separate analog audio cables are not required (see Figure 8). Some
CDVs (Video CDs) may not output digital audio signals. In that case, you may
hear sound by connecting analog audio cables. However, if you connect analog
audio cables, the HDMI terminal on the TV will not receive the HDMI digital audio
signal and you will hear analog audio only.

Figure 8

2
HDMI, the HDMI logo and High Definition Multimedia Interface are trademarks or registered
trademarks of HDMI Licensing, L.L.C.

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DVI Connection
To connect a DVI device, it is required to have one HDMI–to–DVI adapter cable
(HDMI type A connector) and one pair of standard analog audio cables. For
proper operation, the length of an HDMI-to-DVI adapter cable should not exceed
9.8 ft (3m). The recommended length is 6.6 ft (2m). An HDMI-to-DVI adapter
cable transfers only video. Separate analog audio cables are required (see figure
9).

Figure 9
Define
[1] HDMI = High-Definition Multimedia Interface.
[2] DVI = Digital Video Interface.
[3] HDCP = High-bandwidth Digital Content Protection.
[4] EIA/CEA-861/861B compliance covers the transmission of uncompressed
digital video with high-bandwidth digital content protection, which is being
standardized for reception of high-definition video signals. Because this is
an evolving technology, it is possible that some devices may not operate
properly with the TV. It is good to recommend the consumer confirm that
the device they want to connect to the HDMI input will operate with the
input by testing the device with the TV.
[5] Consult Toshiba consumer service or a retailer for availability.

Some important notes to follow:

To ensure that the HDMI or DVI device is reset properly, it is recommended to
follow these procedures:
• When turning on electronic components, turn on the TV first, and then the
HDMI or DVI device.
• When turning off your electronic components, turn off the HDMI or DVI device
first, and then the TV.

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LED CODES / INDICATIONS

Figure 10

The green and red LED lights on the TV control touch pad (see figure 10)
indicate the TV’s current status, as follows:

• Green ON = Control touch pad being pressed.

• Red ON = Power ON.
• Green and/or Red blinking (see table 1 below for condition and solution).

Table 1 (Referenced from the 62HM84 Owner’s Manual)

If the unit experiences loss of AC power and immediately turn back on, the unit
may illustrate the LED indication shown in number 3 of Table 1. This is normal
and the unit will cycle through an automatic restart up to eight times. In most
cases a picture will be displayed after the 3rd or 4th automatic restart.

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LAMP UNIT
Quick Restart
Each time the unit is turned “on”, it may take up to several seconds to go from no
picture to full picture brightness. The DLP also has a feature called “Quick
Restart” and is selectable from the menu under the “Setup” icon. With the Quick
Restart feature “on”, the TV stays in standby mode and the green LED will flash
for several minutes after the TV is turned “off”. In standby mode, the lamp light
wattage is greatly reduced but not completely turned “off” and this allows a
quicker start time when the TV is turned back “on” within the standby period.
This time is approximately five to six minutes after the initial power “off”.

ReadMe During this standby mode, the TV may have the appearance of
an “after glow” effect in the display. Though this is only visible when
viewed in a very dark room, it is normal due to the lamp is not completely
turned off.

User-replaceable component
The light source for the DLE is a mercury lamp with internal atmospheric
pressure that increases during use. This is a user-replaceable component.
The lamp has a limited service life that varies depending on product use and user
settings. As is generally the case with all projection TV’s that use projection
lamps as a light source, the brightness of the lamp in this TV may vary somewhat
over the expected service life and will generally decrease over time. The average
useful service life for the lamp is approximately [8,000] hours in “LOW POWER”
mode or [6,000] hours in “HI BRIGHT” mode. Keep in mind these are averages;
some lamps will require earlier replacement.

If the lamp is beyond its service life:

• There maybe a reduction in the colors and/or brightness of the picture
• 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 ruptures, the TV will not operate until the lamp unit is replaced. The
lamp unit is designed so broken lamp glass remains securely inside the lamp
unit.

Warranty – Not a service repair

The lamp is warranted only for the periods and to the extent set forth in the
Limited Warranty applicable to the unit. See “Limited United States Warranty” in
the owner’s manual for details. This is a user replacement component, however,
in the rare event a service call is needed for lamp replacement, a concession will
need to be obtained from your Toshiba Field Service Engineer or Toshiba
Technical Support before the service call.

When to replace the lamp

The consumer should replace the lamp unit:

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• if the picture darkens and/or colors fade;
• if the screen (lamp) does not light (LED Indication 3); or
• if you hear a loud noise and the picture goes black, which may indicate a
lamp rupture (LED Indication 3).

ReadMe It is recommended to check the lamp status with the customer

before a service call is made to the home.

To obtain a replacement lamp unit

The consumer can obtain a replacement lamp by using the information in table 2.

Table 2

Use the replacement lamp unit model or stock number listed in the owner’s
manual only, Figure 11 illustrates this information. If the consumer has requested
a stock number from you, you must refer them to the owner’s manual.

Figure 11
(Referenced from the 42HM84 Owner’s Manual)

ReadMe Using any other lamp may cause damage to the TV and/or lamp.

Lamp replacement for 52” models

For all 52-inch models with the optional stand, the unit will need to be removed
from the stand. This will allow access to the door as shown in Figure 12.

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Figure 12
How to replace the lamp unit
Required tools: Manual Phillips screwdriver and gloves.
Optional tool: 5/32” or 4mm Allen wrench.

2. 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.

Figure 13

3. On the lamp unit door on the side of the TV, loosen the thumbscrew by hand
or by using a 5/32” or 4mm Allen wrench, and then remove the lamp unit door.

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Figure 14

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

Figure15

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

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Figure 16

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

Figure 17
Never subject the lamp unit to excessive shock and 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.

Cleaning the lamp unit glass

If the lamp unit glass is accidentally touched or if the lamp is dirty, it is
recommend wiping it with a lint-free lens cleaning cloth (such as a cloth for
cleaning camera lenses or eyeglasses).

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

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Figure 18

ReadMe The lamp and screws must be installed securely, otherwise the
unit may not turn “on” or the lamp life may be shortened.

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.

Figure 19

9. Replace the thumbscrew and hand-tighten.

Figure 20

10. Plug in the power cord and turn on the TV. After the initial warm-up period
(which may take up to several seconds for full picture brightness), the TV should
operate normally. If any of the following conditions exist, no picture, dark picture
or TV will not turn on, customer should turn off the TV, unplug the power cord,
and repeat steps 1–9 to ensure that the lamp unit and lamp unit door are

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installed correctly. If the problem still exists, after the consumer repeats steps 1–
9, it is recommend the customer call our Customer Service Department.

Lamp Unit Disposal

The lamp unit was designed for safe replacement by consumers, however, if the
lamp is subject to intentional or accidental abuse, the lamp may break, expose
sharp edges or pinch points. Always handle the lamp unit with care. Once the
used lamp is removed, place it in the empty box of the new lamp. The lamp unit
contains mercury and disposal of may be regulated due to environment
considerations in the area. For disposal or recycling information, we recommend
contacting the local authorities or the Electronic Industries Alliance at
www.eiae.org.

Light Engine Service and Replacement

The light engine is a replacement module. The following DLP-04 training
modules will cover the light engine troubleshooting and replacement.

Conclusion
Toshiba's 2004 DLP™ television line-up is built with performance and picture
quality features, designed upon our many years of projection television
engineering and production expertise. If you are called for service, you will be
working on one of the finest televisions on the market. Toshiba Technical
Training developed the DLP-04-1 Training Module so you have the best
understanding of the general operation and features of this new product. We feel
that in order for you to have the correct technical information when servicing; it is
best to understand “how it works” before “why it works”. We appreciate your
service support and hope you find Toshiba’s quality and standards meet your
expectations. If you have questions or comments, whether it is repair
troubleshooting, training or customer support, please feel free to contact us.

Training and Media Development; Email: technical_training@tacp.com

Technical Support; Email: technical_support@tacp.com

Fax: 615-443-2957

Technical Assistance for TASS; Please call 1-800-354-9785 (This requires a

Toshiba Service Account Number)

Customer Support: Please call 1-800-631-3811

Email: customer_support@tacp.com Fax: 615-444-0630

National Parts Center; Email: national_parts@tacp.com

Fax: 615-444-7481

Warranty and Accounts Receivable; Email: warranty_receivables@tacp.com

Fax: 615-444-7520

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Consumer Troubleshooting
Symptom
TV will not turn on
No picture or too dark
No picture, no sound
No sound, picture OK
Poor picture, sound OK
Poor reception of broadcast channels
Cannot receive above channel 13
Black box appears on the screen
Unable to select a certain channel
Multiple images
Poor color or no color
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Appendix A
Solution
• Make sure the power cord is plugged
in, and then press POWER.
• The remote control batteries may be
dead. Replace the batteries.
• If you have recently replaced the lamp
unit, make sure the lamp unit and lamp
unit door are installed properly.
• The lamp unit may need to be
replaced.
• The lamp unit may need to be
replaced.
• Check the antenna/cable connections
• The sound may be muted. Press
VOLUME.
• The station may have broadcast
difficulties. Try another channel.
• Make sure the SPEAKERS function in
the AUDIO menu is set properly.
• Check the antenna connections.
• The station may have broadcast
difficulties. Try another channel.
• Adjust the PICTURE menu.
• The station may have broadcast
difficulties. Try another channel.
• Check the antenna connections.
• If you are using a VCR, make sure
the TV/VCR button is set correctly.
• Make sure the TV/CABLE switch is
set to the mode that corresponds with
the signal source type (cable company
or outside antenna).
• The closed caption feature may be
set to one of the Text modes (T1, T2,
T3, or T4). Turn closed captioning
OFF.
• The channel may be locked with the
CH LOCK feature, or erased with the
ADD/ERASE feature.
• The station may have broadcast
difficulties. Try another channel.
• Antenna reception may be poor. Use
a highly directional outdoor antenna.
• The station may have broadcast
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difficulties. Try another channel.
• Adjust the TINT and/or COLOR in the
PICTURE menu.
• The lamp unit may need to be
replaced.
No stereo or SAP sound from a known • Make sure the MTS feature is set
MTS broadcast properly.
The screen lights dimly and the fan • The Quick Restart feature may be in
continues to run when the power is ON mode. Set to OFF if you do not
OFF. prefer this.
The remote control does not operate • Make sure the appropriate device
mode is selected.
• Remove all obstructions between the
remote control and the remote control
sensor in the TV.
• The remote control batteries may be
dead. Replace the batteries.
Cannot access signal input sources • Check the VIDEO LOCK feature.
(Video1, Video2, Video3, ColorStream
HD1/HD2, HDMI) and/or Channels 3
and 4.

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Appendix A