Mitsubishi Electric WD-60735 User manual

• Design specifications are subject to change without notice.
MITSUBISHI DIGITAL ELECTRONICS AMERICA, INC.
9351JeronimoRoad,Irvine,CA 92618-1904
Copyright © 2008 Mitsubishi Digital ElectronicsAmerica, Inc.
AllRightsReserved
CAUTION:
Before servicing this chassis, it is important that the service person read the "SAFETY PRECAUTIONS" and
"PRODUCTSAFETYNOTICE" containedinthis manual.
SerSer
SerSer
Servicevice
vicevice
vice
ManualManual
ManualManual
Manual
2008
MITSUBISHIELECTRIC
DLPPROJECTIONHDTV
V39, V39+, V39++ & V39- CHASSIS
• Input Level : AUDIOINJACK(RCAType)
(continued) -4.7dBm 43kΩunbalanced
: S-VIDEOIN JACK
(Y/C separate type)
Y:1.0 Vp-p C:0.286Vp-p(BURST)
75Ωunbalanced
: COMP/Y, Cr,Cb (RCAType)
Y: 1.0 Vp-p Cr, Cb: 700mVp-p
• Output Level : AUDIOOUTJACK(RCAType)
-4.7dBm 4.7kΩ unbalanced
• Digital : AC-3 Digital Audio Output
(RCAType)
: HDMITM
:IR Blaster Output (V39+/ V39++ only)
:USB
: PC - use HMDITM \
:Wired IR Input (V39+/V39++ only)
WD-52327
V39 Chassis
WD-60735
WD-65735
WD-73735
WD-52527
Pb Solder
V39+ Chassis
WD-65736
WD-73736
V39- Chassis
WD-60C8
WD-65C8
WD-73C8
V39++ Chassis
WD-65835
WD-73835
SPECIFICATIONS
• Power Input : AC 120V, 60Hz
•Power Usage : See table on page 5
• LightEngine : DLPTM (1920 x 1080 pixels)
5 Primary Color System
• Light Source : 180W
• Channel Range : Air VHF - 2~13, UHF - 14~69
Analog Cable - 1~125
Digital Cable - 1~135
•Antenna Input : 2 RF 75Ω unbalanced
• Tuning : 1NTSC/ATSC/QAM
• Cabinet Dimensions : See Table on page 5
• Weight : See table on page 5
•Speakers (4Ω 10W) : Two 5½"x2¼" Oval
• Input Level : VIDEOINJACK (RCAType)
1.0Vp-p 75Ωunbalanced

Page 3
MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
INTRODUCTION ................................................................................................................................5
Dimensions,weight, powerusage, etc............................................................................................5
PRODUCTSAFETYNOTICE ............................................................................................................. 5
SAFETY PRECAUTIONS .................................................................................................................6
DISASSEMBLY ..................................................................................................................................7
BackCoverRemoval ....................................................................................................................... 7
ChassisRemoval ............................................................................................................................7
RearInputCoverRemoval ...............................................................................................................8
PWB-POWERRemoval ..................................................................................................................8
ChassisCoverRemoval .................................................................................................................. 9
PWB-HDMI-FRONTRemoval ..........................................................................................................9
PWB-MAINRemoval..................................................................................................................... 10
OPTICALENGINE............................................................................................................................ 11
OpticalEngineRemoval from cabinet............................................................................................ 11
OpticalEngine Removal from DuctAssembly ............................................................................... 12
UpperDuctRemoval ..................................................................................................................... 12
LowerDuctwithUpper Duct removed............................................................................................ 12
LowerDuctRemoval ..................................................................................................................... 13
EngineReplacement..................................................................................................................... 13
BallastRemoval ............................................................................................................................ 14
SCREENDISASSEMBLY ................................................................................................................. 14
WD-65835&WD-73835 EscutcheonRemoval .............................................................................. 14
ScreenAssembly(Bezel)Removal ............................................................................................... 14
ScreenRemovalFrom Bezel......................................................................................................... 16
ScreenReplacement. ................................................................................................................... 18
SPEAKER & PWB-SBL Replacement ............................................................................................ 19
SpeakerReplacement ................................................................................................................... 19
INITIALSETTINGS,INITIALIZATION & TROUBLESHOOTING....................................................... 20
OptionMenu & RemoteControl ....................................................................................................20
DigitalSignal Strength................................................................................................................... 20
Resetand Initialization .................................................................................................................. 21
Initial Settings ............................................................................................................................... 22
A/V Reset..................................................................................................................................... 23
LEDIndication Diagnostics ........................................................................................................... 24
ErrorCodeOperation .................................................................................................................... 25
ColorWheelReplacement ............................................................................................................ 26
SERVICEADJUSTMENTS ............................................................................................................... 28
Equipment & Test Signals............................................................................................................. 28
CircuitAdjustmentMode............................................................................................................... 28
Horizontal& Vertical CenteringAdjustment ................................................................................... 28
ManualKeystone GeometryAlignment ......................................................................................... 29
FullAdjustmentModeActivation .......................................................................................... 30
4x3and LetterboxAlignmentmodes .................................................................................... 31
TouchUpAdjustmentMode ................................................................................................. 32
DataTransfer ....................................................................................................................... 32
CONTENTS

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 4
USINGLEADFREESOLDER .......................................................................................................... 33
CHIPPARTSREPLACEMENT ......................................................................................................... 34
REPLACEMENTPARTS .................................................................................................................. 35
PartsOrdering .............................................................................................................................. 35
Criticaland WarrantyParts Designation........................................................................................35
PartsToleranceCodes.................................................................................................................. 35
Quick Reference List...................................................................................................................... 36
SERVICE PARTS LIST .................................................................................................................... 37
SCREENASSEMBLY PARTSLIST.................................................................................................. 43
MIRRORREPLACEMENT ................................................................................................................ 44
CIRCUITRYBLOCKDIAGRAMS ..................................................................................................... 47
MainPower Supply ....................................................................................................................... 47
DCto DC Supplies........................................................................................................................ 48
AnalogVideo Signal Path ............................................................................................................. 49
Digital Video Signal Path .............................................................................................................. 50
OverallSoundSignal Path ............................................................................................................ 51
OverallControlCircuitry ................................................................................................................ 52
AutoInput/Output Detect Circuitry ................................................................................................ 53
LampControlCircuitry .................................................................................................................. 54
Short Detect Circuitry ................................................................................................................... 55
Engine Protect Circuitry ................................................................................................................ 55
System 5 / Wired Remote I/O....................................................................................................... 56
SCHEMATICDIAGRAMS .....................................................................................................................
Digital Light Processing®, Digital Micro Mirror Device and DLP® are Trademarks of Texas Instruments.
DTV Link is a trademark of Consumer Electronics Association
HDMI, the HDMI logo and High-Definition Multimedia Interface are trademarks or registered trademarks of HDMI Licensing, LLC..

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 5
INTRODUCTION
This service manual provides service instructions for the V39, V39-, V39+ and V39++ chassis types. The specific
models for each chassis type, dimensions and weight are listed below. Service personnel should read this manual
thoroughlybefore servicing these chassis.
Thisservice manualincludes:
1. Assembly and disassembly instructions for cabinet and chassis components.
2. ServicingoftheLenticular Screenand Fresnel Lens.
3. Servicingprintedcircuitboards (PCBs).
4. Electrical and Mechanical adjustments.
6. Chippartsreplacementprocedures.
7. Circuitpathdiagrams.
The parts list section of this service manual includes:
1. Cabinetandscreen parts.
2. Electrical parts.
Schematicand block diagrams of the above listed models are included in this service manual for better understanding
of the circuitry.
PRODUCT SAFETY NOTICE
Manyelectrical 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
usingreplacement componentsrated for higher voltage, wattage, etc.
Replacementparts 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 parts list of this
service manual. Therefore, the replacement for any safety part should be identical in value and characteris-
tics.
Pb Solder
The PWBs used in the V39, V39+. V39++ and V39- chassis are constructed using Lead-Free
solder. When servicing use only recommended Lead-Free solder (refer to page 33).
MODEL CHASSIS WIDTH HEIGHT DEPTH WEIGHT POWER
USAGE
WD-60735 V39 53.9 in 36.7 in 14.4 in 64.4 lbs 240W
WD-60C8 V39-"""""
WD-65735 V39 58.2 in 39.5 in 15.3 in 72.2 lbs 270W
WD-65736 V39+"""""
WD-65835 V39++"""""
WD-65C8 V39-"""""
WD-73735 V39 65.2 in 43.6 in 17.5 in 93 lbs "
WD-73736 V39+"""""
WD-73835 V39++ " " " 95.2 lbs "
WD-73C8 V39-"""""
DLP Models DIMENSIONS

Page 6
MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
SAFETY PRECAUTIONS
NOTICE: Observe all cautions and safety related notes located inside the receiver cabinet and on the
receiverchassis.
WARNING:
1. Operationofthis receiver outsidethe cabinetor withthe coverremoved presents a shock hazard
fromthe receiver's power supplies. Work onthe receiver should not beattempted by anyone who is
notthoroughly familiar withthe precautionsnecessary when workingon highvoltage equipment.
2. Whenserviceis required, observe the original lead dress. Where a short-circuit has occurred, replace
thosecomponentsthat indicate evidenceofoverheating.
SAFETYPRECAUTION
To protect your eyes, do not look directly into the lamp, or light coming directly from the lamp, lens or
mirror.
Leakage current check
Before returning the receiver to the customer, it is recommended that leakage current be measured according to the
followingmethods.
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 1Meg Ohm. Any resistance below this value indicates an
abnormalconditionand requires correctiveaction.
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, andwith 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
switchingdevices of the receiver in their operating positions, measure the leakage current forboth
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).

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 7
Back Cover Removal
Back Cover Removal Procedure
1) RemovetheLampCover.
2) Removescrews(A) from the back cover.
3) Pull the back cover from the TV.
Back Cover Installation
Reversetheremoval procedure but install
the Lamp Cover Last.
Chassis Removal
Chassis Removal
1) Removefourscrews(A)
2) Disconnect all cables connecting to the chassis.
3) Carefully slide the chassis out of the Cabinet.
DISASSEMBLY

Page 8
MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Chassis Disassembly
Rear Inputs Cover Removal
Rear Inputs Cover Removal Procedure
1) Remove 2 nuts (B) from the RF inputs.
2) Removescrews (A) that secure the cover
to the chassis.
3) Pull the Inputs Cover from the chassis..
PWB-POWER Removal
1) Removefivescrews(B)
2) Disconnect all cables to the PWB-
POWER.
3) Releaseclips (C).
4) Carefully lift the PWB-POWER from the
chassis box.
PWB-POWER Installation
1) Reversetheremoval procedureto installa
new PWB-POWER.
2) Nodata transfer is required.
DO NOT use a
power driver
on this screw.

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 9
Chassis Disassembly (continued)
Chassis Cover Removal
1) Remove3screws (C).
2) Lift the Chassis Cover from the chassis box.
PWB-HDMI-FRONT Removal
1) Disconnect all cables to PWB-
HDMI-FRONT
2) Removethreescrews (D).
3) Carefullylift the PWB-HDMI-
FRONT from the chassis box.
4) To removePWB-HDMI,remove
two screws (E) and slide the PWB
out the rear of the shield.

Page 10
MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
PWB-MAIN Removal
1) Disconnect all cables to PWB-MAIN
2) Removetwoscrews (D).
3) Removescrews(E).
4) Carefully lift the PWB-MAIN from the chassis
box.
PWB-MAIN Installation
1) Install two screws (D) first
2) Theninstall screws (E).
3) TransferIndexData from Engine
(refertopage 32)
4) RestoreAlignment and White Balance Settings.
5) RestoreKeystone Geometry from Backup.

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 11
OPTICAL ENGINE REMOVAL
OPTICAL ENGINE ASSEMBLY REMOVAL
1) Remove3 screws (C) from the Optical Engine.
2) Disconnect all cables to the Optical EngineAssembly.
3) Carefully slide the Optical Engine assembly from the cabinet.
OPTICAL ENGINE ASSEMBLY AND CONNECTOR LOCATIONS
(Rear View)

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 12
OPTICAL ENGINE REMOVAL FROM THE DUCT ASSEMBLY
Figure 1: Duct Assembly (Rear View) Figure 2: Duct Assembly (Top View)
Upper Duct Assembly Removal Procedure
1) Disconnect the Ballast Fan and Lamp Fan from the back of the Engine (connectors J4 and J8) and loosen
wiring harnesses from the looms, refer to page 11 for connector locations.
1) Loosen two screws (a) to remove the Lamp Cartridge, refer to Figure 1.
3) Remove 3 screws (b) from the top of the upper duct and release the 7 snaps shown in Figure 2.
4) Carefullyremovethe upper Duct assembly
LOWER DUCT (Upper Duct Removed)
1) Figure 3 shows the components in the Lower Duct.
2) The Sirocco Fan and Exhaust Fan can be replaced. The Engine and Upper Duct do not have to be removed
to replace the Ballast.
3) Ifreplacing the Engine, removethe Thermal Sensor from the Engine (1 screw) Figure 3.
Figure 3: Lower Duct (Top View)
Ballast
Exhaust
Fan
Exhaust Fan
Holders (3)
Sirocco Fan
Thermal
Sensor

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 13
Figure 4: Lower Duct rear Mounting Screw
Figure 5: Lower Duct front Mounting Screw
LOWER DUCT REMOVAL
1) Remove the 2 screws (C) one in front and one in the rear of the lower duct, refer to Figures 4 and 5.
2) Carefullyremovethe lower duct from the Engine.
ENGINE REPLACEMENT (Reverse the Removal Procedure)
1) Install Duct assembly on the new Engine.
2) RemovetheProtective Lens Cover from the face of the Lens.
3) Install the EngineAssembly in the cabinet.
4) After a new Engine is installed Load Index Delay Data from the Engine and Copy Settings to
Backup(page 32).
5) Adjust Raster Centering (page 28) and Manual Keystone Geometry Alignment (page 29) if
needed.

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 14
BALLAST ASSEMBLYREMOVAL
REMOVAL PROCEDURE
1) Removescrew (A) from the Ballast support
and screw (B) if the Engine is still mounted
in the cabinet.
2) Slide the BallastAssembly out the rear of
theEngine assembly and unplug the Lamp
connector (C) at the Ballast.
3) Disconnectconnectors CJ1 and CJ3.
4) Removescrew(D) toremove thePWB-
BALLAST from the Ballast Support.
Reverse the procedure to install a new
Ballast .
SCREEN REMOVAL & REPLACEMENT
Screen Assembly (Bezel) Removal
1) Remove all rear screws (B) except one in an upper corner (To support the
screenassembly while removing the front mounting screws).
60 Inch Models
WD-65835 & WD-73835 Only
Escutcheon Removal
Before Removing the Screen Assembly
(V39++ Models Only)
1) Remove2 screws (A) at the lower rear corner on
the right side.
2) Remove thesmall escutcheoncover to access the
SB1connector
3) Unplug the SB1 connector. This disconnects the
PWB-SBL-R & PWB-SBL-L.

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 15
65 inch Models
SCREEN REPLACEMENT (continued)
73 inch Models

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 16
SCREEN REPLACEMENT (continued)
Screen Assembly Removal
(continued)
2) Openthe Control Panel door and removetwo screws (A).
3) Removethe remaining rear screw in the upper corner and carefully pull the screen assembly
fromthe cabinet.
Screen Removal From the BEZEL-FRONT
1) Remove the screws (A) from the top, bottom and side rails.
2) Liftthe Fresnel Lens andLenticular screen from the BEZEL-FRONT.

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 17
SCREEN REPLACEMENT (continued)

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 18
Screen Replacement
CAUTION: Wear gloves when handling the LenticularScreen and Fresnel Lens.
This prevents cuts and finger prints. Do not place Fresnel Lens in the sun.
Thismay cause fire and heat related injuries.
Lenticular Screen and Fresnel Lens Replacement
1) Apply LENS-TAPE along the rear top edge of the Lenticular Screen.
2) Place the Fresnel Lens on top of the Lenticular Screen, and apply pressure along the top edge.
3) Place the screens in the screen frame and reinstall the cushions, top, bottom and side rails.
NOTE: The Lenticular Screen label must face the front and the Fresnel Lens label face the rear.
4) Reversethe Screen Removal Procedure and insert the screens in the Bezel.
Lenticular Screen and Fresnel Lens Removal
1) Remove the top, bottom and side HOLDER-SCREEN rails and their cushions from the Bezel.
2) Lift the screens as a single unit from the frame.
2. SeparatetheLenticular Screen and Fresnel Lens.
Note: Whenseparating theLenticular Screen from the Fresnel Lens, use caution
while prying the Screen and Lens apart. Use a slot type screw driver, and
removethepressure sensitive doublesided tape.

MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
Page 19
Speaker Replacement
1) Remove the Bezel screen assembly to access the speakers.
2) Remove 2 screws (A) and carefully slide the SpeakerAssembly from the cabinet.
3) Disconnect the leads to the speaker.
4) Remove4 screws (B) to remove thespeaker from the speaker cover.
5) Reversethe procedure to installareplacement speaker.
WD-65835 & WD-73835 (Only)
PWB-SBL-R & PWB-SBL-L Replacement
1) The screen BezelAssembly must be removed to access the PWBs-SBL (refer to the V38 Bezel Removal
Procedure).
2) Remove 2 screws (A) to remove the PWB-SBL assembly from the Bezel.
3) Remove 4 screws (B) to remove the PWB from the assembly.
4) Reversethe procedure to install a replacement PWB-SBL.
SPEAKER
ASSEMBLY
V39++ SBL
ASSEMBLY

Page 20
MODELS: WD-60735 / WD-60C8 / WD-65735 / WD-65736 / WD-65835 / WD-65C8 / WD-73735 /
WD-73736 / WD-73835 / WD-73C8
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.)
REMOTE CONTROL
DigitalSignal Strength
1.Tune to a Digital Channel
2. From the Option menu scroll down and highlight Digital Signal Strength
3. Press Enter
SNRRecommendedLevels:
VSB = 15 to 35
64 QAM = 22 to 34
256 QAM = 27 to 37
ExampleofDigitalSignalStrengthDisplay
SignalQuality
Index (0-100)
SignalNoise
Ratio
Tuner 0 Tuner1 OOB Tuner
Frequency (MHz): 597 0 0
Signal Level: 8 0 0
Modulation: 256 QAM Unknown Unknown
Carrier Lock: Locked Unknown Unknown
SQI 100 0 0
SNR 34.3 0 0
Correctable errors: 0 0 0
UnCorrectabel errors: 0 0 0
V39OPTIONMENU
V39+& V39++ OPTIONMENU