Toshiba TV-GEN-03 Installation guide

TOSHIBA AMERICA CONSUMER PRODUCTS, INC.
NATIONAL SERVICE DIVISION
1420-B TOSHIBA DR.
LEBANON, TN 37087
TECHNICAL TRAINING
TV-GEN-03
Subject: Digital Convergence Alignment
Product: PROJECTION TELEVISION, Rear CRT
Chassis: All Toshiba rear CRT projection televisions with digital convergence
Model Year: All
Models: All
Prerequisites: None
Purpose:
Upon completion of this Training Module, the technician will be able to properly
converge a Toshiba CRT-based rear projection television set. Using the correct digital
convergence alignment procedures will enable the technician to identify symptoms
requiring more in-depth troubleshooting.
These skills will help improve servicing picture quality issues.
Objectives:
1. While performing a convergence alignment, specify when and when not to reload
convergence backup data 100% of the time.
2. Following a written procedure, correctly reload the convergence backup data
from the DCU memory.
3. Given the TV model number and picture size, identify the correct convergence
overlay and grid 100% of the time.
4. Following a written procedure, and using the correct overlay(s), align the
convergence to factory specifications.
5. While performing a convergence alignment, identify visual symptoms which
indicate further troubleshooting is required, at least 80% of the time.
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.
2002 Toshiba America Consumer Products, Inc.

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Digital Convergence Alignment
Module No. TV-GEN-03
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Consider this:
Toshiba CRT based rear projection televisions allow convergence adjustments to be
made in two areas:
1. User convergence area - This area can be accessed through the customer
picture menu by using the remote control or the front panel keys.
Adjustments can only be made by remote control.
2. Service Mode convergence area – This area should only be accessed by
qualified service technicians. A remote control is required for both access
and adjustment.
Readme: Qualified technicians should always align convergence in the Service
Mode.
First things first - Overlays:
Convergence overlays are service tools available for purchase through Toshiba
National Parts or Toshiba authorized parts distributors. The overlays are recommended
as guides following a “worst-case” situation, such as a CRT or Digital Convergence Unit
(DCU) replacement. While an overlay can also be used to perform a minor alignment,
this module will assume the worst-case scenario.
Each overlay kit contains all grids relative to the screen size and aspect ratio of the unit
to be aligned. Many older 4:3 aspect ratio units have only one grid to adjust. Newer 4:3
units of the same screen size also require adjustment in High Definition (HD)
compressed mode. This mode can be accessed through the customer menu.
Widescreen (16:9 aspect ratio) units built prior to 2001 have up to six different picture
size modes that require adjustment: 1. Full/Standard/Natural
2. Wide 1
3. Wide 2
4. Wide 3
5. HD Full
6. HD Standard
Widescreen units built before the HD revolution have only picture size modes 1 through
4. Widescreen units built in 2001 and later are only adjustable in FULL mode. The
settings for all other picture size modes are calculated from the FULL mode information
by the DCU microprocessor.
The overlays come as one complete sheet and will have to be trimmed following the
included instructions. Each kit also contains step-by-step, centering, focusing, and
convergence alignment instructions. These instructions vary according to the type of
unit. Kits used for more than one type contain instructions for all types covered.
Readme:In many cases, convergence problems have been corrected by
exactly following the supplied instructions.

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Module No. TV-GEN-03
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When using an overlay kit, it is important to know the type of unit it is designed for use
with and the kit part number. The availability and part numbers of the overlay kits are
subject to change as screen sizes are added or discontinued. Table 1 details the
currently available overlay kit part numbers.
Part
Number Screen Size Aspect Ratio Picture Size Model Year
PSOL40X1 40” 16:9 All All
PSOL42W1 42” 16:9 Full 2002+
PSOL43X1 43” 4:3 All All
PSOL4801 48” 4:3 N/A All
PSOL50X1 50” 4:3 All All
PSOL50W1 50” 16:9 Full 2002+
PSOL53X1 53” 4:3 All 2002+
PSOL55X1 55” 4:3 All All
PSOL56X1 56” 16:9 All All
PSOL57W1 57” 16:9 Full 2002+
PSOL61X1 61” 4:3 All All
PSOL65X1 65” 16:9 All All
PSOL7101 71” 4:3 N/A All
Table 1
Each kit part number begins with the acronym PSOL, meaning Protective Screen Over
Lay. Following the acronym are a series of alpha-numeric characters identifying the
screen size and intended unit type. In Example 1, “40” identifies the kit for use with a 40
inch screen size. “X1” indicates the kit contains all grids for any unit in that screen size.
Example 1: PSOL40X1
In some cases there are models with different aspect ratios within a screen size
category. In such cases, the letter “W” in the kit part number indicates use with wide
screen (16:9 aspect ratio) units. See Example 2 for details:
Example 2
PSOL50X1 is used with any 50 inch unit with a 4:3 aspect ratio screen.
PSOL50W1 is used with any 50 inch unit with a 16:9 aspect ratio screen.
Readme: The overlay dimensions are contained in the appropriate unit Service
Manual, as shown in Figure 1. If a particular overlay kit is not available, or there
is an urgent need for a complete convergence alignment before the kit can be
delivered, strings and low-tack tape can be used to achieve the desired results.

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Module No. TV-GEN-03
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Figure 1
And then… Accessing Service Mode:
Once the correct overlay is placed on the screen, the unit must be put into Service
Mode before any alignment adjustments are made. There are currently two methods of
Service Mode entry, dependant upon the model and type of set. The methods are
described as follows:
1. All digital convergence equipped units built prior to 2001 and all interlaced
scan units:
a. With the unit powered “ON”, press and release the MUTE key on the
remote control.
b. Press the MUTE key a second time and hold.
c. While holding the MUTE key, press the MENU key on the front panel.
A pale blue “S” will appear in the upper right corner of the screen, as
shown in Figure 2.
d. Press the MENU key on the front panel a second time. RCUT will
appear in the upper left corner of the screen.
Figure 2

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Digital Convergence Alignment
Module No. TV-GEN-03
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Readme:RCUT is a data address in the system EEPROM. The hexadecimal
data contained in the address will be shown just below it, as shown in Figure 3.
Figure 3
2. All progressive scan units built from 2001 forward:
a. With the unit powered “ON”, press and release the MUTE key on the
remote control two times.
b. Press the MUTE key a third time and hold.
c. While holding the MUTE key, press the MENU key on the front panel.
A pale blue “S” will appear in the upper right corner of the screen.
d. Press the MENU key on the front panel a second time. RCUT will
appear in the upper left corner of the screen.
Readme:Important parameters of the set can be accessed and adjusted from
Service Mode. Use caution whenever working in this area.
The rubber meets the road - Convergence Alignment:
Readme: Always allow the set to warm up for at least 15 minutes before making
any adjustments.
Convergence alignment instructions vary according to the unit type. The instructions
assume a worst-case scenario, such as replacing all three CRTs or the digital
convergence board, and the use of an overlay kit. All versions of the instructions are
included as Appendices A through C of this document.
Readme:If the set requires only minor convergence adjustments, enter the
procedure where you feel it is necessary.
1. Optical and electrical focus
a. Remove or raise the screen to gain access to the CRTs.
b. Reverse the lenses if necessary.
c. Enter the convergence alignment service mode.
d. Optically and electrically focus each CRT.
2. Mechanical tilt
a. Check each CRTs tilt.
b. Adjust if necessary.
c. Store the data.

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Module No. TV-GEN-03
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3. User convergence and magnetic centering
a. Disconnect any input to Video 1.
b. Enter the user convergence area.
c. Vertically and horizontally center all 3 colors in all adjustable areas.
d. Exit the user convergence area.
e. Enter the convergence alignment service mode.
f. Mechanically center all 3 colors.
i. Stretch 2 pieces of string diagonally across the screen
ii. Rotate the centering rings on each CRTs neck
g. Lock the centering rings with adhesive.
h. Exit the service mode.
4. Electrical centering
a. Use a signal generator.
i. Crosshatch pattern
b. Enter service mode.
c. Adjust HPOS to center horizontally.
d. Adjust VPOS to center vertically.
5. Green geometry
a. Enter the convergence alignment service mode.
b. Secure the appropriate overlay to the screen.
c. Adjust the green geometry to match the overlay.
i. Start in the center of the screen
ii. Work clockwise around the screen
6. Red convergence
a. Align to green.
7. Blue convergence
a. Align to green.
8. HD convergence
a. Progressive scan 4:3 units only.
b. Component video signal to HD 1 input.
c. 1080i picture on or HD image shape compressed.
9. White balance
a. Set white balance according to the appropriate Service Manual.
b. Check picture quality using a live video signal.
10.Width, height, and vertical linearity
a. Adjust if the memory IC (QA02) has been replaced.
b. Adjust if the crosshatch pattern is not reasonably close to the overlay
pattern.
Readme: The convergence alignment may not be complete at this point.
Depending on the year of production and the type of unit being adjusted, there
could be several different picture size modes that require adjustment.

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Module No. TV-GEN-03
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End of the line? Specifications
Once all conceivable picture size modes have been aligned, verify the convergence
meets factory specifications. The specifications listed in Table 2 reflect the maximum
allowable misconvergence, in any direction, referencing either red or blue to green.
ZoneScreen
Size A B C D E F G H J
40 0.5mm 3.5mm 2.5mm 3.5mm 2mm 3.5mm 2.5mm 3.5mm 2mm
42 0.5mm 3.5mm 2.5mm 3.5mm 2mm 3.5mm 2.5mm 3.5mm 2mm
43 0.5mm 3.5mm 2.5mm 3.5mm 2.5mm 3.5mm 2.5mm 3.5mm 2.5mm
48 0.5mm 4mm 3mm 4mm 3mm 4mm 3mm 4mm 3mm
50 (4:3) 0.5mm 4mm 3mm 4mm 3mm 4mm 3mm 4mm 3mm
50(16:9) 0.5mm 3.8mm 2.7mm 3.8mm 2.3mm 3.8mm 2.7mm 3.8mm 2.3mm
53 0.5mm 4.5mm 3.2mm 4.5mm 3.2mm 4.5mm 3.2mm 4.5mm 3.2mm
55 0.5mm 4.5mm 3.2mm 4.5mm 3.2mm 4.5mm 3.2mm 4.5mm 3.2mm
56 0.5mm 4.5mm 3mm 4.5mm 2.5mm 4.5mm 3mm 4.5mm 2.5mm
57 0.5mm 4.5mm 3mm 4.5mm 2.5mm 4.5mm 3mm 4.5mm 2.5mm
61 0.5mm 5mm 3.5mm 5mm 3mm 5mm 3.5mm 5mm 3mm
65 0.5mm 5mm 3.5mm 5mm 3mm 5mm 3.5mm 5mm 3mm
71 0.5mm 5mm 3.5mm 5mm 3mm 5mm 3.5mm 5mm 3mm
Table 2
Zones A through J are the areas of the screen referenced by the specifications. The
zones are illustrated in Figure 4.
H Q J K B
G P A L C
F N E M D
Figure 4
If the convergence cannot be aligned to factory specifications, further troubleshooting is
required.
Don’t Worry:
Beginning with the 2002 production year, HD Compatible units include a service feature
that allows a qualified technician to restore factory convergence data from a back-up
memory location.

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Module No. TV-GEN-03
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Readme: Backup data should be loaded only if corruption of the original data
is suspected or if the set is severely misconverged. Minor misconvergence
issues should be corrected by performing the appropriate alignment procedure.
To load back up data:
1. Enter Service Mode as described in the appropriate Service Manual.
2. Enter convergence alignment mode by pressing the “7” key on the remote.
3. Display vertical stripes by pressing the “9” key on the remote.
4. Load the backup by pressing the “1” key on the remote.
a. The following message will appear on screen for:
ENTER: TO LOAD BACKUP DATA
EXIT: TO EXIT
5. Press the “ENTER” key on the remote, as shown in Figure 5, to load the backup
data.
a. The displayed net pattern will misconverge briefly, then return to a normal
state.
Figure 5
6. Following the alignment procedure in the service manual, make any necessary
convergence adjustments.
7. Write the new data to convergence memory by pressing the “7” key on the
remote one time.
8. Press the “Touch Focus” key on the front panel of the unit.
a. The Touch Focus pattern will scroll across the screen two times. Once
quickly, then slowly.
9. “CALIBRATION FINISHED” will display on screen and the unit will exit to service
mode.
a. The new convergence data is saved to memory and new backup data is
created.
10.Power the unit off to exit service mode.

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Module No. TV-GEN-03
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Readme: Do not attempt to load backup data if the digital convergence PCB has
been replaced. Backup data in the new PCB memory is not created until
convergence has been adjusted and the CALIBRATION procedure has been
completed.
Something to think about:
It is important to know when a convergence alignment will not correct the unit problem.
If after following the correct procedure, the convergence cannot be aligned to factory
specifications, further troubleshooting is required. Table 3 lists a few of the many
possible symptoms.
Repeated Touch Focus errors
Intermittent loss of convergence
Repeated convergence drift of any color
Selected color will not adjust in either direction
Convergence crosshatch pattern will not display
Convergence crosshatch pattern is severely distorted
Touch Focus pattern is not displayed
Touch Focus pattern is severely distorted
Back up data will not load
Cannot enter Service Mode
Data cannot be saved after alignment
Table 3
Points to remember:
Familiarity and practice help the technician develop confidence in performing a digital
convergence alignment or determining the need for further troubleshooting. Having the
knowledge and necessary tools available are an important first step in the process of
gaining experience. While taking this first step, it is best to follow the alignment
instructions carefully and exactly. Back up data, if available, is a useful tool if problems
occur. It can provide a good starting point in certain cases, but it should not be viewed
as a “cure-all” for convergence problems. In most cases, only minor adjustments will be
necessary. Focus and centering adjustments will not be needed and the procedure can
begin in the GEOMETRY stage. Minor adjustments made in this way do not require
the use of back up data or an overlay kit. Simply make the needed adjustments, save
the new data accordingly, exit the service mode, and you’re outta there!

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Module No. TV-GEN-03
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Appendix A
Interlaced Scan Units with 4:3 Aspect Ratio
Section 1: OPTICAL & ELECTRICAL FOCUS
1. Follow the appropriate disassembly instructions to gain access to the CRTs.
2. If the wing nuts on the lenses are pointed toward the screen, reverse the lenses
on each tube so the wing nuts are facing the back of the set. Leave the lenses in
this position after servicing. Put the screen assembly back on.
3. From the Service Mode press the 7 key on the remote control to display the
convergence crosshatch pattern.
4. Push the 100 key to turn off the red tube, and the CH RTN/ENT key to turn off
the blue tube.
5. Position a mirror for viewing the screen from the rear of the set. From the rear of
the set, loosen the wing nut on the green lens, and adjust the lens for the best
focus in the center area of the screen.
6. From the front of the set, adjust the electrical focus control for best focus in the
center of the screen.
7. Repeat the optical focus, and then tighten the wing nut.
8. Repeat the electrical focus.
9. Push the 100 key to turn on the red tube, and the 0 key to turn off the green tube.
10. Adjust the red optical and electrical focus in the same manner.
11. Push the CH RTN/ENT key to turn on the blue tube, and the 100 key to turn off
the red tube.
12. Adjust the blue optical and electrical focus in the same manner. Electrically
defocus the blue slightly, to maintain uniform brightness.
Section 2: MECHANICAL TILT ADJUSTMENT
1. With the set still in convergence mode, and the convergence overlay on the
screen, check each CRT’s tilt. If a CRT’s pattern is tilted, loosen the appropriate
yoke with a non-magnetic screwdriver. Rotate the yoke until the pattern is
aligned vertically and horizontally. Re-tighten the yoke.
2. Press the 7 key on the remote to store the convergence data.
3. After the data is stored, press the 7 key on the remote again to exit the
convergence crosshatch pattern.
4. The unit will return to service mode and display a normal picture with the letter
“S” in the upper right corner.
5. Power the unit OFF to exit service mode.
Section 3: USER CONVERGENCE AND MAGNETIC CENTERING ADJUSTMENTS
1. Disconnect any source at the Video 1 input.
2. Turn the power on.
3. Enter the user convergence screen through the customer menu.
4. Move the red vertical cross hair as far as it will go to the right. Note the location.
Move the red vertical cross hair as far as it will go to the left. Note that location.
Set the red vertical cross hair to the center of the two extremes.