Mitsubishi Electric WD-52525 User manual

CAUTION:
Before servicing this chassis, it is important that the service person read the "SAFETY PRECAUTIONS" and
"PRODUCT SAFETY NOTICE" contained in this manual.
• Design specifications are subject to change without notice.
MITSUBISHI DIGITAL ELECTRONICS AMERICA, INC.
9351 Jeronimo Road, Irvine, CA 92618-1904
Copyright © 2004 Mitsubishi Digital Electronics America, Inc.
All Rights Reserved
MITSUBISHI ELECTRIC
SerSer
SerSer
Servicevice
vicevice
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ManualManual
ManualManual
Manual
2004
DIGITAL LIGHT PROCESSING™ PROJECTION TV
V26 CHASSIS
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 (RCAType)
1.0Vp-p 75Ω unbalanced
AUDIO IN JACK (RCA Type)
500mV RMS full scale into 43kΩ,
unbalanced
: 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 (+/-200mV)
full scale into 4.7kΩ, unbalanced
• Digital : IEEE-1394 I/O Jacks
Interface : AC-3 Digital Audio Output (RCA
Type) 1.5V RMS
: HDMITM
:MonitorLinkTM Control/RS-232C
: 4 Memory Card Reader Inputs
WD-52525
V26 V26+ V26++
WD-52525 WD-52725 WD-52825
WD-62525 WD-62725 WD-62825
MODELS

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
Page 3
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
CONTENTS

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
Page 5
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 charac-
teristics 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 6
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.
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).
WARNING ... RISK OF EYE INJURY
Do not look into the light source, lens or mirror when operating the TV.

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
Page 7
CABINET DISASSEMBLY(FRONT VIEW)
WD-52525 / WD-62525 / WD-52725 / WD-62725
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.
*Refer to the Parts List for Part Numbers
Reusable Wire Ties
Do not cut wire ties during disassembly, reusable
wire ties are used in these models. Lift the tab to re-
lease the wire tie. During reassembly, re-use wire ties to
ensure all wiring harnesses are properly bundled and
dressed.
Wire Tie
Lift Tab to Release

Page 8
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.

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
Page 9
CABINET DISASSEMBLY(REAR VIEW)
(a) (a)
(b)
(
b
)
(a) (a)
(b)
(
b
)
(b)
FILTER-COVER Removal
Remove 2 screws (d) to remove the Fil-
ter 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.

Page 10
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).

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
Page 11
Accessing & Disconnecting The Lamp Ballast
Removing the Right Support
Remove the 3 screws shown below.
Removing the Lamp Ballast Shield
(4 screws)
Unplug CN1 & CN2
Connectors
NOTE: To remove the chassis, the two connectors to the Lamp Ballast must be
disconnected at the Lamp Ballast.
4 Screws
Unplug
Connectors
3 Screws

Page 12
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.

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
Page 13
Optical Engine Replacement
Optical Engine Mounting
The Optical Engine is mounted on theAdjuster 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 14
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)
OpticalEngine (Rear View / Airduct & DMD Fan Cover Removed)

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
Page 15
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.
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)
Figure 2: Bottom Plate
(a)
Heat Sensor
(B)
Bottom View
Bottom Pla te
Thermal Sensor

Page 16
MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
Figure 3: Black Support Bracket
Front View
Black Bracket
(C)
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

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
Page 17
DIAMOND SHIELD REPLACEMENT
92
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.
1b
1a
11
2
3
66
5
4
6
6
6
6
1
1
1
1

Page 18
MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
SERVICING THE LENTICULAR SCREEN AND FRESNEL LENS
CAUTION: Wear gloves when handling the Lenticular Screen and Fresnel Lens.
This prevents cuts and finger prints. Do not place Fresnel Lens in the sun.
This may cause fire and heat related injuries.
Lenticular Screen and Fresnel Lens Removal
1. Remove the screen assembly shown in the Cabinet Disassembly procedure.
2. Remove the four screws (a) to remove the bottom of the SCREEN-FRAME-BOTTOM .
3. Carefully slide the Lenticular Screen and Fresnel Lens combination from the Screen Frame assembly.
Note: When separating the Lenticular Screen from the Fresnel Lens, use caution
while prying the Screen and Lens apart. Use a slot type screw driver, and
remove the pressure sensitive double sided tape.

MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
Page 19
SERVICING THE LENTICULAR SCREEN AND FRESNEL LENS
Lenticular Screen and Fresnel Lens Installation
Note: Store the Lenticular Screen and Fresnel Lens in a cool dry place. High heat and humidity may
deform the Lenticular Screen and Fresnel Lens.
1. Apply double coated tape (Part #LENS-TAPE) along the top rear edge of the Lenticular Screen, as shown
below. Refer to the table below for the tape length.
2. Place the Fresnel Lens on top of the Lenticular Screen and apply pressure at the top edge
to bond them together.
3. Reverse the Screen Removal procedure to insert the screens in the Screen Frame Assembly.
MODEL SCREEN SIZE TAPE LENGTH
WD-52525 52 Inches 46.3 Inches
WD-52725 " "
WD-52825 " "
WD-62525 62 Inches 55.1 Inches
WD-62725 " "
WD-62825 " "
*X INCHES - Refer to the Tape Length in the table below

Page 20
MODEL: WD-52525 / WD-52725 / WD-52825 / WD-62525 / WD-62725 / WD-62825
OPTION MENU
1. Press the “MENU” button on the remote hand
unit.
2. Press the buttons “2”, “4”, “7” and “0” in order.
(The screen will change to the option menu.)
3. Select “Initialize” and press <ENTer> to restore
all Inital Main Menu Defaults and A/V Reset
Default settings to those listed in the following
two tables.
Setup Menu V-Violence Enable
Language English Programs Not Rated Enable
Combine Channel View -- Movie Rating PG
NetCommand Menu V-Chip Time
Edit -- Start 12:00pm
Transport Menu On Stop 12:00pm
Default Digital Record Device -- Lock by Time
Icon Order -- Lock by Time On
Antenna Menu Lock Time 12:00pm
Antenna 1 Unlock Time 12:00pm
Memorize -- Front Button Lock Off
Prefer Digital -- Audio/Video
Channel 3 A/V Memory Reset Ant-1
Memory Added Settings
Name -- Audio
SQV -- Bass 50%
Time Menu Treble 50%
Clock Setting Manual Balance 50%
Time 12:00pm Surround Off
Date -- Listen to (Analog Only) Stereo
Time Zone -- Level Sound (Analog Only) On
Daylight Savings Time -- Language (Digital Only) English
Tim er -- Video
Captions Menu Contrast 100%
Analog Captions On if Mute Brightness 50%
Background Gray Sharpness 50%
Digital Caption On if Mute Color 50%
Appearance Default Tint 50%
Digital Settings Color Temp High
Font Font 3 Video Noise Standard
Size Large Film Mode (Auto) On
Color White Define Edge On
Background Black Color Balance
Opacity Translucent Video Mute On
Background Opacity Translucent black Enhancement On
V-Chip Lock Menu TV Speakers On
V-Chip Off TV Volume 30%
TV Rat ing TV -P G PIP Source Ant 1 003
FV-Fantasy Violence Enable PIP Position Lower Right
D-Sexual Dialog Enable POP Position Right Half
L-Adult Language Enable PIP/POP Format Double W indow
S-Sexual Situations Enable Format Stretch
Initial Main Menu Defaults
OPTION MENU <TV MENU> <2-4-7-0>
Initialize
Power Restore: Off
DTV Port: AUTO
Direct Key Mode: Off
NetCommand Software: V26 XXX.XX
Digital Signal Strength: X
00000 00000 00000 00000 00000
Total TV
On Time
Current
Lamp
Tim e
Previous
Lamp
Tim e
Previous
Lamp
Tim e 2
Previous
Lamp
Tim e 3
INITIAL SETUP