I have an Epson 5010, which had started making a grinding noise shortly after starting up or changing colour modes, this eventually led to an error on screen, "Error in the Epson cinema filter. For repairs contact your nearest Epson service provider"
However a few times I was able to continue using the PJ, but obviously something wasn't right. Shortly after this the PJ would power on, but wouldn't start up. The fan would come on very high speed for a few minutes then just shut down with the red lights blinking indicating an 'Internal error'
My PJ is out of warranty, so I decide to take matters into my own hands and see if I could find out what the problem was. I've had experience with stripping projectors down before, so here's what I did to fix the problem.
EDIT: The below mod only worked for a short while before the gear box failed again.
At the end of this post is a link to a post I made using a metal gear box.
It seems that the problem is related to the Cinema filter mechanism failing. It turns out the gearbox attached to the mechanism had developed a problem and this is what needed to be fixed.
1. First of all its best to remove the lamp. After this remove all the screws on the bottom of the PJ and at the rear.
Once this has been done the top case can be removed to reveal the motherboard and lens system. Also observe in the pic I had already removed the front panel, more on that later:
2. Next we need to remove the motherboard, firstly disconnecting all the connectors around the edges of the motherboard. Most will just pull out, but the the ones with flat ribbon cable have a special way of disconnecting. Basically The black piece needs to be carefully levered away from white part as you can see below. The same goes for the ones connected to the optical block.
Be very careful when removing the motherboard that these don't get snagged.
3. Here you can see the cinema filter assembly which we need to get to.
4. Remove the three screws circled then withdraw the Auto-Iris mechanism then remove the screws from the other parts circled and remove. Be sure to move the black wire for the temperature sensor out of the way.
5. Once these parts are removed the cinema filter can be carefully removed.
A pic of the Auto-Iris assembly:
6. With the filter removed we can see the motor and gearbox:
7. Next the front panel needs to removed, unfortunately I forgot to take a pic of this before I removed it, but basically there are a couple of screws on the top and some clips underneath. Once the screws are removed then it should just pull away with a bit of persuasion.
8. This will reveal the lens system, there are a couple of screws either side of it deep down that need to be removed.
You will notice there is a red area circled, this is a lever attached to the infared panel at the front of the PJ. This will need to be located properly when reassembling.
9. Now we need to remove the screws for the rest of the optical system so it can be withdrawn. There are 3 silver screws as circled:
10. Now we are ready to remove the optical assembly, but first we need to pull forward the door slider mechanism so it clears it. Observe the wires circled which need to be unwound to allow them to move.
11. We can now remove the whole optical assembly, just pull the whole thing up and out:
As you can see the optical block is exposed so I decided to cover this to prevent dust getting in, also you can see the motor and gear box which needs to be removed:
12. Now to remove the motor unscrew the 2 black screws and pull off the motor assembly.
13. The screws to remove the gearbox are underneath, so to get to them first we need to remove the 2 screws circled then there are 2 tiny screws holding the gearbox case on.
After these are removed hold the gearbox case upside down and remove the rest of the assembly.
14. In my case the part that was causing the problem is arrowed as it was worn and had a missing tooth. I guess this was causing the gears to slip.
15. These things are tiny, I'm not surprised they fail considering how much torque the gearbox produces from the little motor.
here you can see the missing tooth:
16. Moving on now to the actual repair. Basically what I did was make a little metal gear using my dremel tool which I could attached to the damage part to not only repair it, but hopefully strenghthen it too.
To make the metal gear I cut out a piece of metal then ground it into a circle and laid this over the top of the plastic gear. I attached it to the gear using the tiny screws from the gear box.
I then proceeded to carefully and painstakingly create the teeth using the dremel attachment below. This is a wafer thing disc which I then ground the edges with a carborundum stone to a knife edge.
Sorry about the dirty fingers and nails, but I was in the middle of rebuilding an engine that week.
17. After grinding and making the teeth I made a mark on both the metal gear and the plastic gear so I knew how the 2 joined together.
To attach the metal gear I first ground down some of the plastic gear the same thickness as the metal gear, made both mating surfaces rough with sandpaper then attached it using super glue being careful to line the marks up, I also put a small watchmakers screwdriver through the middle hole of both to ensure they both aligned properly. I then left it to dry for a while.
18. Here is the finished product:
All that is left is to put it back in the gearbox and reassemble it. Before I did I put plenty of high temp grease inside the gearbox on the gears.
19. Finally just need to reassemble everything the same way it came apart. When reassembling the Cinema filter ensure that the filter goes between the 2 switches when putting this part back on. These switches are what determines the correct position of the filter at first start up when the filter is cycled:
I now have no problems and the cinema filter mechanism is as quiet as ever. Hopefully this helps others.
I know that some people may not want to or be able to repair the gearbox so I have posted links below where the part is available:
Search for Article: 1452666
Also there is a very handy exploded diagram which helps identify which part is which and goes where:
EBAY: Search for Epson 1452666
Hope this helps
EDIT: This mod only worked for a short while before the gear box failed again.
Below is a link to a post I made using a metal gear box.