Mitsubishi WD-62825, WD-62725, WD-62525, WD-52825, WD-52725 Service Manual

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2004

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MITSUBISHI ELECTRIC

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Manual

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DIGITAL LIGHT PROCESSING™ PROJECTION TV

V26 CHASSIS

MODELS

V26 V26+ V26++ WD-52525 WD-52725 WD-52825 WD-62525 WD-62725 WD-62825

WD-52525

CAUTION:

Before servicing this chassis, it is important that the service person read the "SAFETY PRECAUTIONS" and "PRODUCT SAFETY NOTICE" contained in this manual.

SPECIFICATIONS

• Power Input : AC 120V, 60Hz

• Power Usage : 275W

• Light Engine : DLP 0.85" 1280 x 720p

• Lamp : 120W VIP Type

• Channel Frequencies : Air - VHF 2 ~ 13 UHF 14 ~ 69

Analog Cable - 1 ~ 125 Digital Cable - 1 ~ 135

• Antenna Input : 2 RF 75Ω unbalanced

• Tuning : 1 NTSC/ATSC/QAM64&256 1 CableCARD™ Slot 1 NTSC for PIP

• Cabinet Dimensions : [WD-52xxx] 37.2" x 49.6" x 17.4" [WD-62xxx] 43.7" x 58.3" x 19.9"

• Weight : [WD-52xxx] 132.4 lbs [WD-62xxx] 165.5 lbs

• Speakers (10Wx2) : 5" Coaxial x 2

• Input Level : VIDEO IN JACK (RCA Type)

1.0Vp-p 75Ω unbalanced AUDIO IN JACK (RCA Type) 500mV RMS full scale into 43kΩ, unbalanced

• Design specifications are subject to change without notice.

: S-VIDEO IN JACK

(Y/C separate type) Y:1.0 Vp-p C:0.286Vp-p(BURST) 75Ω unbalanced, 480i

: COMP / Y, Pr, Pb (RCA Type )

Y: 1.0 Vp-p Pr, Pb: 700mVp-p, 480i, 480p, 720p, 1080i

: DTV / Y(G), Pr(R), Pb(B), H, V (RCA

Type) Y: 1.0 Vp-p Pr, Pb: 700mVp-p, 75Ω, H, V: 3.0Vp-p, 480i, 480p, 720p, 1080i

: VGA / R,G,B,V,H (15 pin D) 640x480,

800x600, 1024x768, 720x1280, 60Hz

• Output Level : VIDEO OUT JACK (RCA Type)

1.0Vp-p 75Ω unbalanced

: AUDIO OUT JACK (RCA Type)

500mV RMS

full scale into 4.7kΩ, unbalanced

• Digital : IEEE-1394 I/O Jacks

Interface : AC-3 Digital Audio Output (RCA

Type)

: HDMI

: MonitorLink

: 4 Memory Card Reader Inputs

(+/-200mV)

1.5V RMS

Control/RS-232C

MITSUBISHI DIGITAL ELECTRONICS AMERICA, INC.

9351 Jeronimo Road, Irvine, CA 92618-1904

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

CONTENTS

INTRODUCTION ................................................................................................................................5

PRODUCT SAFETY NOTICE ...........................................................................................................5

SAFETY PRECAUTIONS .................................................................................................................6

DISASSEMBLY PROCEDURES ......................................................................................................... 7

Cabinet Front Disassembly ............................................................................................................. 7

Cabinet Rear Disassembly .............................................................................................................. 9

ELECTRICAL CHASSIS REPLACEMENT ........................................................................................ 10

OPTICAL ENGINE REPLACEMENT ................................................................................................. 13

DATA COPY PROCEDURE ............................................................................................................... 16

DIAMONDSHIELD™ REPLACEMENT .............................................................................................. 17

SERVICING THE LENTICULAR SCREEN AND FRESNEL LENS ..................................................... 18

INITIAL SETUP ................................................................................................................................ 20

FRONT PANEL LED DIAGNOSTICS ................................................................................................ 22

SERVICE ADJUSTMENTS ............................................................................................................... 24

Equipment .................................................................................................................................... 24

Circuit Adjustment Mode ............................................................................................................... 24

Adjustment Items and Initial Data Settings ................................................................................... 26

Electrical Adjustments .................................................................................................................. 27

Mechanical Adjustments ............................................................................................................... 27

REPLACEMENT PARTS .................................................................................................................. 30

SCREEN ASSEMBLY PARTS .......................................................................................................... 33

CIRCUITRY BLOCK DIAGRAMS ..................................................................................................... 35

PCB INTERCONNECT DIAGRAM

Page 3

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

Page 4

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

INTRODUCTION

This service manual provides service instructions for PTV Models and Chassis:

V26 Chassis V26+ Chassis V26++ Chassis WD-52525 WD-52725 WD-52825 WD-62525 WD-62725 WD-62825

This service manual includes:

1. Assembly and disassembly instructions for the front and rear cabinet components.

2. Servicing of the Lenticular Screen and Fresnel Lens.

3. Servicing down to major components, chassis, Optical Engine, Lamp Ballast, etc..

4. Electrical adjustments.

5. Optical Adjustments.

6. Chip parts replacement procedures.

7. Simplified circuit path diagrams.

8. Overall PCB interconnect block diagram.

The parts list section of this service manual includes:

1. Cabinet and screen parts.

2. Electrical parts.

Block diagrams of the above listed models are included in this service manual for better understanding of the circuitry.

PRODUCT SAFETY NOTICE

Many electrical and mechanical parts in television receivers have special safety related characteristics. These characteristics are often not evident from visual inspection nor can the protection afforded by them necessarily be obtained by using replacement components rated for higher voltage, wattage, etc.

Replacement parts which have special safety characteristics are identified in this service manual.

Electrical components having such features are identified by shading on the schematic diagram and by bold type in the parts list of this service manual. Therefore, the replacement for any safety part should be identical in value

and characteristics.

Digital Light Processing, Digital Micromirror Device and DLP are trademarks of Texas Instruments. CableCARD is a trademark of Cable Television Laboratories, Inc. HDMI, the HDMI logo and High-Definition Multimedia Interface are trademarks or registered trademarks of HDMI Licensing LLC.

Page 5

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

SAFETY PRECAUTIONS

NOTICE: Observe all cautions and safety related notes located inside the receiver cabinet and on the

receiver chassis.

WARNING:

1. Operation of this receiver outside the cabinet or with the cover removed presents a shock hazard from the receiver's power supplies. Work on the receiver should not be attempted by anyone who is not thoroughly familiar with the precautions necessary when working on high voltage equipment.

2. When service is required, observe the original lead dress. Extra precaution should be taken to assure correct lead dress in the high voltage area. Where a short-circuit has occurred, replace those components that indicate evidence of overheating.

WARNING ... RISK OF EYE INJURY Do not look into the light source, lens or mirror when operating the TV.

Leakage current check:

Before returning the receiver to the customer, it is recommended that leakage current be measured according to the following methods.

1. Cold Check

With the alternating current (AC) plug removed from the AC source, place a jumper across the two AC plug

prongs. Connect one lead of an ohm meter to the AC plug and touch the other lead to each exposed metal part (i.e. antennas, handle bracket, metal cabinet, screw heads, metal overlay, control shafts, etc.), particularly any exposed metal part that has a return path to the chassis. The resistance of the exposed metal parts having a return path to the chassis should be a minimum of 1Megohm. Any resistance below this value indicates an abnormal condition and requires corrective action.

2. Hot Check ...Use the circuit shown below to perform the hot check test.

1. Keep switch S1 open and connect the receiver to the measuring circuit. Immediately after

connection, and with the switching devices of the receiver in their operating positions, measure the

leakage current for both positions of switch S2.

2. Close switch S1, energizing the receiver. Immediately after closing switch S1, and with the

switching devices of the receiver in their operating positions, measure the leakage current for both positions of switch S2. Repeat the current measurements of items 1 and 2 after the receiver has

reached thermal stabilization. The leakage current must not exceed 0.5 milliampere (mA).

Page 6

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

Reusable Wire Ties

Do not cut wire ties during disassembly, reusable

wire ties are used in these models. Lift the tab to release the wire tie. During reassembly, re-use wire ties to ensure all wiring harnesses are properly bundled and dressed.

CABINET DISASSEMBLY (FRONT VIEW)

WD-52525 / WD-62525 / WD-52725 / WD-62725

*Refer to the Parts List for Part Numbers

Lift Tab to Release

Wire Tie

Front Cabinet Disassembly

1. Remove the SPEAKER-GRILLE by pulling forward.

2. Remove screws (a) to remove the COVER-FRONT.

3. Remove screws (b) on the rear of the upper back cover (4 across the top and 3 on each side).

4. Remove the 4 screws (c) holding the bottom of the Screen Assembly.

5. Unplug connector LN from the Control Panel.

6. Lift the Screen Assembly up slightly then pull towards the front to remove the assembly.

Page 7

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

CABINET DISASSEMBLY (FRONT VIEW)

WD-52825 /WD-62825

*Refer to the Parts List for Part Numbers

Front Cabinet Disassembly

1. Remove the SPEAKER-GRILLES by pulling forward.

2. Remove screws (a) to remove the COVER-FRONT.

3. Remove screws (b) to remove the GRILLE-BASE.

4. Remove screws (d) on the rear of the upper back cover (3 on each side and 4 across the top).

5. Remove the 4 screws (c) holding the bottom of the Screen Assembly.

6. Unplug connector LN from the Control Panel.

7. Lift the Screen Assembly up slightly then pull towards the front to remove the assembly

8. To disconnect the Card Reader and the Front Inputs:

• Unplug the Card Reader USB connector from the PCB-DM.

• Unplug the Front 1394 cable from the HDD Module (Hard Drive).

• Unplug the CC connector from the Front Inputs.

Page 8

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

(b)

CABINET DISASSEMBLY (REAR VIEW)

FILTER-COVER Removal

Remove 2 screws (d) to remove the Filter Cover.

COVER-BACK Removal

1) Remove 9 screws (a)

2) Remove 5 screws (b)

3) Remove 2 screws (c)

4) Pull the COVER-BACK from the cabinet.

Rear Plate Removal

1) Remove 6 screws (a)

2 Remove10 screws (b)

3) Pull the Rear Plate from the cabinet.

NOTE: To operate set with the Cover-Back and Rear Plate removed, re-install the Filter Cover and ensure the Exhaust Fan is connected.

(a)

(b)

(a)

Page 9

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

ELECTRICAL CHASSIS REPLACEMENT

1) Remove the 4 black screws (a) securing the chassis shown in the two diagrams below.

2) Unplug the USB and 1394 connectors from the Card Reader. NOTE: In the V26++ chassis the Card Reader 1394 connector plug into the Hard Drive Module.

3) Disconnect all cables to the front of the cabinet, the Optical Engine and the Lamp Ballast (see next page).

4) Carefully slide the chassis from the cabinet.

5) IMPORTANT: After Electrical Chassis replacement, perform the Data Copy Procedure (page 16).

Page 10

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

NOTE: To remove the chassis, the two connectors to the Lamp Ballast must be

disconnected at the Lamp Ballast.

Accessing & Disconnecting The Lamp Ballast

Removing the Right Support

Remove the 3 screws shown below.

3 Screws

Removing the Lamp Ballast Shield

(4 screws)

4 Screws

Unplug CN1 & CN2

Connectors

Unplug Connectors

Page 11

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

V26 Chassis PWB Locations

NOTE: The HDD is only in the V26++ models.

Page 12

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

Optical Engine Mounting

Optical Engine Replacement

The Optical Engine is mounted on the Adjuster assembly as shown in the above diagram.

1) Four screws (a) secure the bottom plate and Optical Engine to the Adjuster assembly.

2) The bottom plate tab (1) slides into slot (1) on the Adjuster.

3) The Optical Engine is secured to the bottom plate by 4 screws (b).

4) The Black Bracket is secured to the bottom plate and the Lamp Box with 4 screws (c).

5) To replace the Optical Engine, the Optical Engine, bottom plate and black bracket need to be removed together as an assembly. Refer to the following pages for exact replacement instructions.

Page 13

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

Removing the Optical Engine

1) Remove the Cabinet Back (refer to disassembly instructions).

2) Disconnect all connectors from the Optical Engine, Lamp Cartridge Housing and the PCB-DMD.

3) From the rear of the TV, remove the 4 screws (c), to remove the COVER-DUCT and DMD Fan cover.

4) From the rear of the TV, remove the 4 brass colored screws (a), shown below, securing the bottom plate to the Adjuster assembly.

5) Slide the Optical Engine/Lamp Cartridge Housing towards the rear to remove from the TV.

(a)

O ptic al Engine ( Re a r Vie w / Aird uct & DMD Fa n Cover Re moved)

Page 14

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

Remove the following parts from the Optical Engine

• DMD Thermal Sensor

• The Optical Engine bottom plate and black bracket

DMD Thermal Sensor Removal (Figure 1)

1) Remove screw (a) on the top of the DMD Fan.

2) Set the Thermal Sensor aside to install on the replacement Optical Engine.

(a)

Figure 1: DMD Thermal Sensor

Bottom Plate & Black Bracket Removal

1) Remove the 4 screws (B) from the Bottom Plate (Figure 2)

2) Remove the two screws (C), holding the Black Bracket to the Lamp Box. (Figure 3)

Heat Sensor

Thermal Sensor

(B)

Bottom V iew

Figure 2: Bottom Plate

Page 15

Bottom Pla te

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

Bla ck Bra cke t

(C)

Front View

Figure 3: Black Support Bracket

Installing the Optical Engine

1) Install the Bottom Plate, Black Support Bracket and the Heat Sensor, removed from the original Optical Engine, on the replacement Engine

2) Reverse the removal procedure to install the replacement Optical Engine in the cabinet.

3) The following adjustments may have to be performed after the installation. (See Service Manual)

• Horizontal and Vertical Electrical Centering Adjustment.

• Optical Unit Rotation Adjustment

• Optical Unit Keystone Distortion Adjustments.

4) IMPORTANT: After Optical Engine replacement, perform the Data Copy Procedure described below.

Data Copy Procedure

This procedure must be performed after replacing either the Electrical Chassis or Optical Engine.

1) To display the data copy menu press <TV MENU> <2-4-5-7> <0>

2) Use the cursor keys to yellow highlight “Copy Light Engine EEPROM to DM”

3) Press <ENTer>

4) After the copy procedure has been completed, exit the menu by pressing <HOME>

Copy Light Engine EEPROM to DM

Restore backup UPLOAD TERMINAL BOARD DATA

Page 16

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825

DIAMOND SHIELD REPLACEMENT

To Remove the Diamond Shield:

1. While wearing soft cotton gloves, loosen the sides of the Diamond Shield by pressing a small plastic card (the size of a standard credit card or a clean, plastic, putty knife) into the middle of the side slot. The Diamond Shield side will snap out of the top middle and bottom clips. Loosen both sides before proceeding to step 2.

2. After the sides are free, gently push down on the top of the Diamond Shield. It will slide out of the top channel.

3 Carefully pull the screen up to remove it from the

bottom channel. Store the Diamond Shield in a clean, dust free area, where it will not be scratched.

To Install the Diamond Shield:

4. Slide the Diamond Shield into the bottom channel, making sure it fits securely.

5. Press gently on the top of the Diamond Shield to slightly bow the screen towards you. Insert the top of the Diamond Shield into the top channel. It should fit securely.

6. At each side, gently press the top, middle and

bottom of the Diamond Shield to snap it back into place.

WARNING

Sharp edges! Always wear gloves to handle, lift, install and remove the Diamond Shield.

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