Mitsubishi Electric WD-Y57 User manual

• Design specifications are subject to change without notice.
MITSUBISHI DIGITAL ELECTRONICS AMERICA, INC.
9351JeronimoRoad,Irvine,CA 92618-1904
Copyright © 2006 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
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ManualManual
ManualManual
Manual
20062006
20062006
2006
MITSUBISHIELECTRIC
DLPPROJECTIONHDTV
V33Y & V33+ CHASSIS
SPECIFICATIONS
• Power Input : AC 120V, 60Hz
•Power Usage : See table on page 5
• LightEngine : DLPTM (1920 x 1080 pixels)
6 Primary Color System (57" & 65" only)
3 Pimary Color System (73" ONLY)
• Light Source : 150W (57" & 65" models)
180W (73" model)
• 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
1 Out of Band for CableCARDTM
• Cabinet Dimensions : See Table on page 5
• Weight : See table on page 5
• Speakers (4Ω 10W) : Two5½"x2¼"Oval
• Input Level : VIDEOINJACK(RCAType)
1.0Vp-p 75Ωunbalanced
: AUDIOIN JACK(RCAType)
-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 : VIDEOOUTJACK (RCAType)
1.0Vp-p 75Ωunbalanced
: AUDIOOUT JACK (RCAType)
-4.7dBm 4.7kΩ unbalanced
• Digital : IEEE-1394 I/O Jacks
: AC-3 Digital Audio Output
(RCAType)
: HDMITM
:IR Blaster Output
:Memory Card Reader (V33+ Only)
: PC- DVI-I
: Lead-Free solder PWBs
WD-52327
V33Y Chassis
WD-Y57
WD-Y65
WD-52527
Pb Solder
Pb Solder
WD-73732
V33+ Chassis
WD-57732
WD-65732
WD-73732

Page 3
MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
INTRODUCTION ................................................................................................................................5
Dimensions,weight, powerusage, etc............................................................................................5
PRODUCTSAFETY NOTICE ............................................................................................................. 5
SAFETY PRECAUTIONS .................................................................................................................6
DISASSEMBLY ..................................................................................................................................7
RearCoverRemoval ........................................................................................................................8
ChassisRemovaland Disassembly ................................................................................................7
57”& 65” OpticalEngine Removal................................................................................................. 12
73”OpticalEngineRemoval .......................................................................................................... 13
57” & 65” Front Disassembly ........................................................................................................ 14
57”&65” ScreenRemoval & Replacement ................................................................................... 15
73”Front Disassembly .................................................................................................................. 16
73”Screen Removal& Replacement ............................................................................................. 18
ADJUSTMENTS ...............................................................................................................................20
OptionMenu, Remote Controland Digital SignalInfo .................................................................... 20
Initialization................................................................................................................................... 21
Defaults ........................................................................................................................................ 22
LEDIndicator Diagnostics............................................................................................................. 24
ErrorCodesOperationalCheck..................................................................................................... 24
ErrorCodes .................................................................................................................................. 25
57”&65” models LampTroubleshooting ....................................................................................... 26
73”modelsLampTroubleshooting................................................................................................. 28
CableCARD™Troubleshooting ..................................................................................................... 30
ServiceAdjustmentMode ............................................................................................................. 31
ServiceAdjustment Mode Operation .................................................................................... 31
Transferringdata .................................................................................................................. 32
OpticalEngineAdjustment............................................................................................................ 33
TestSignal activation ........................................................................................................... 33
Preliminary .......................................................................................................................... 33
57” & 65” Rotation and Keystone DistortionAdjustment ....................................................... 35
Aftercompleting adjustmentss............................................................................................. 35
73”AdjustmentPreliminary .................................................................................................. 36
73”Adjustment..................................................................................................................... 37
Horizontal & Vertical Position............................................................................................... 37
USINGLEAD FREE SOLDER .......................................................................................................... 38
CHIPPARTSREPLACEMENT ......................................................................................................... 39
REPLACEMENTPARTS .................................................................................................................. 40
PartsOrdering .............................................................................................................................. 40
Criticaland WarrantyParts Designation........................................................................................40
PartsToleranceCodes.................................................................................................................. 40
QuickReference List ........................................................................................................................ 41
SERVICE PARTS LIST .................................................................................................................... 42
SCREENASSEMBLY PARTSLIST.................................................................................................. 50
CIRCUITRYBLOCK DIAGRAMS ..................................................................................................... 52
CONTENTS

MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 4
MainPower Supply ....................................................................................................................... 52
xHD5Light Engine & Fan Power Supplies .................................................................................... 53
xHD5Light Engine & Fan Power Supplies .................................................................................... 53
PowerDistribution......................................................................................................................... 54
PWB-SIGNALVideo Path............................................................................................................. 55
PWB-DM Video Path .................................................................................................................... 56
SoundSelect Circuitry .................................................................................................................. 57
SoundSignal Path ........................................................................................................................ 58
OverallControlCircuitry ................................................................................................................ 59
CommandInputCircuitry............................................................................................................... 60
57”& 65”Lamp ControlCircuitry ................................................................................................... 61
57” & 65” Engine Protect Circuitiry................................................................................................ 61
73”LampControl Circuitry ............................................................................................................ 62
73”Engine ProtectCircuitry .......................................................................................................... 62
AutoInput Detection ..................................................................................................................... 63
Short Protect Circuit ..................................................................................................................... 64
SCHEMATICDIAGRAMS ....................................................................................................................................
CableCARD is a trademark of Cable Television Laboratories, Inc.
Digital Light Processing, Digital Micro Mirror Device and DLP are Trademarks of Texas Instruments.
Dolby and Dolby digital are registered trademarks of Dolby Laboratories.
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.
TV GUIDE and other related marks are registered marks of Gemstar-TV Guide International, Inc. and/or on of its affiliates.

MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 5
INTRODUCTION
This service manual provides service instructions for the V33Y and V33+ chassis type. The specific models for each
chassistype, dimensions and weight are listed below. Service personnel should read this manual thoroughly before
servicingthese chassis.
Thisservice manualincludes:
1. Assembly and disassembly instructions for cabinet and chassis components.
2. Servicingof the Lenticular Screenand FresnelLens.
3. Servicingprinted circuitboards (PCBs).
4. Electrical and Mechanical adjustments.
6. Chipparts replacementprocedures.
7. Circuitpath diagrams.
The parts list section of this service manual includes:
1. Cabinetand screen 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, and by marking on the supplementary sheet for this chassis to be issued subsequently. Therefore,
the replacement for any safety part should be identical in value and characteristics.
Pb Solder
The PWBs used in the V33+ and V33Y chassis are constructed using Lead-Free solder. When
servicing use only recommended Lead-Free solder (refer to page 38).
MODEL CHASSIS HEIGHT WIDTH DEPTH WEIGHT POWER
USAGE
WD-Y57 V33Y 36.26" 51.5" 18" 87.5 lbs 250w
WD-Y65 " 40.8" 58.5" 19.8" 103.7 lbs "
WD-57732 V33+ 36.26" 58.5" 19.8" 95.7 lbs 250w
WD-65732 " 40.8" 58.5" 19.8" 103.7 lbs "
WD-73732 " 44.8" 69.9" 21.5" 187.5 lbs "

Page 6
MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
SAFETY PRECAUTIONS
NOTICE: Observe all cautions and safety related notes located inside the receiver cabinet and on the
receiverchassis.
WARNING:
1. Operationof this receiver outside the cabinetor withthe coverremoved presentsa 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. Whenservice is 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).

MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 7
Rear Cover Removal
73” Models Rear Cover Removal Procedure
1) Remove8 screws (A) fromthe rear cover..
2) Remove5 screws(B) from the external input frame.
3) Remove3 screw (C)for the LampCover Doorframe.
3) Pull the rear cover from theTV.
57” & 65” Models
73” Models
Rear Cover Removal Procedure
1) Remove8 screws (A) from the External Input
frame.
2) Remove10 screws (B) from the rear cover.
3) Remove2 screw (C)and the LampCover.
(Preventspossible LampSwitch breakage)
3) Pull the rear cover from theTV.
Rear Cover Installation
Reversetheremoval procedure but install
the Lamp Cover Last.

Page 8
MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Chassis Disassembly
57” and 65” Chassis Removal
1) Removetwo screws (a)
2) Disconnect all cables connecting
to the chassis.
3) Carefully slide the chassis out of
theCabinet.
57” & 65” Models
Chassis
73” Chassis Removal
1) Removetwo screws (b)
2) Disconnect all cables connecting
to the chassis.
3) Carefully slide the chassis out of
theCabinet.
73” Models
Chassis

MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 9
Chassis (Exploded View)
PWB-POWER
Chassis box cover
PWB-E2P
PWB-DM
Chassis box
Main Terminal cover
PWB-SIGNAL
Terminal shield
PWB-TERMINAL
DVI connector
Main Terminal Shield Removal
1) Remove 6 screws (A), 8 screws (B), 2 screws (C) and 5 screws (D) from the Terminal Shield.
2) Remove 2 nuts (E).
3) Pull the Terminal Shield from the chassis.

Page 10
MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
PWB-TERMINAL Removal
1) Remove2 screws(A) from the
TerminalCover.
2) Carefullypull upward toremove the
PWB-TERMINALandCoverfrom
the chassis.
PWB-POWER Removal
1) Remove8 screws(B) from the
PWB-POWER.
2) Disconnect all leads to the PWB-
POWER and lift it from the chas-
sis.
Chassis Box Top Cover Removal
1) Remove3 screws (C).
2) Lift the cover from the chassis box.
Chassis (top shield removed)
PWB-SIGNAL Removal
Afterremoving PWB-POWER the chassis
boxcover:
1) Remove7 screws (A) from PWB-
SIGNAL.
2) Disconnect all cables going to the
PWB-SIGNAL.
3) Lift PWB-SIGNAL from the chassis
box.
Chassis (top shield removed)

PWB-DM Removal
AfterremovingPWB-SIGNAL:
1) Remove9screws (A)from the
PWB-DM.
2) Remove2 hex screws (B) from
theDVI connector.
3) Lift the PWB-DM from the
chassis box.
Chassis (top view)
Exhaust Fan Replacement
1) Remove4screws(A) and
removethe exhaust duct cover.
2) Slide the Exhaust Fan from the
ductand unplug the JF connec-
tor.
Note: Savethe rubbercush-
ions, they do not come with a
newfan.
3) Wheninstalling the fan ensure
the leads come out the bottom
of the fan as shown in the
picture.
A
Exhaust
Fan
A
A
A
If PWB-DM is replaced, transfer the PWB-E2P
from the old DM to the new DM.
Then perform the data transfer procedures
"Copy Light Engine E2PROM to DM"
and "Download WB Alignment to FMT"
described on page 32.
A
A
A
B
MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 11

Page 12
MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Engine Removal
57” & 65” Engine (xHD5) Removal from cabinet
xHD5 Engine Removal Procedure
1) Remove2 locking screws (b).
2) Loosen one adjust screws (a). Less
adjustmentwill berequired when the
Engine is installed.
3) Disconnect all leads to the Engine,
Lamp Box and Ballast.
4) Carefully slide the Engine, with the
bottom plate from the cabinet.
57” & 65” Engine Removal from base plate
Removing the xHD5
Engine from the Plate
1) Removethe 2 screws
(a), and 4 screws (b).
2) Carefullylift the
enginefrom the base
plate.
After Replacing Engine
Copy Engine Data to DM
Referto data transferon page32.
NOTE: AfterEngine replacement, verifythe foam gasket around thelens is properlypositioned andthat it doesnot block
thelightpath. Theside portholes ofthecabinet can beusedforvisual confirmation. Theprotholescan also beusedtoclean
the lens, mirror and screen.

MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 13
“73” Engine (xHD4) Removal
1) Remove2 screws (A) toremove theLamp
access duct.
2) Remove3 screws (B).
3) Disconnect all cables to the engine and
carefullyremove the Engine and bottom
plate from the cabinet..
4) Fromthe top of the Engine, remove 4
screws (C) and lift the Engine from the
bottom plate.
(Top View)
Note: The Engine has no individual
service parts available. Attempting
to disassemble the Engine may void
the warranty.

MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 13a
(3)
(4)
(2)
(1)
(5)
Installing the “73” Engine
1) Reversethe“73” Removal Procedure.
2) To minimize any interference, tape the cables to the Engine at the 5 points shown below.
(UseTAPE-CABLE Part# 620D082080)
AfterEngine replacement, performthe Data
TransferProcedure“CopyLightEngine
E2PROMto DM”described on page 33.

Page 14
MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
57” and 65” Models Front Disassembly
57” & 65 Models Screens Removal from Frame
1) From the rear of the Screen Frame remove screws (a) from the top and bottom rails.
2) Remove screws (b) from each side rail and remove the side rails with cushions..
3) Carefully lift the Screen assembly from the Frame.
57” & 65” Models Screen Frame Removal
1) Pull off the Speaker Grill.
2) Removeall the screws (b) from the upper rear cover
(exceptone at an upper corner to support the frame).
3) Removescrews (a)from thefront of the screen frame.
4) Removethe remaining screw(b) (supportingthe frame).
Carefullypull the Screen Frame from the TV and discon-
nect the ES and LE connectors.

MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 15
57” and 65” Models 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 must face the rear.
Lenticular Screen and Fresnel Lens Removal
1) Removethe top, bottom and side HOLDER-SCREEN rails and their cushions from the Screen Frame.
2) Lift the screens as a single unit from the frame.
3) Separatethe Lenticular 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.

Page 16
MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
WD-73732 Front Disassembly
FRONTDISASSEMBLYPROCEDURE
1) Pull the two PANEL-FRONTs from the cabinet.
2) From the rear, remove the six GRILL-SIDE panel screws (A) on each side (outer screws).

MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 17
3) Removetwo screws (b)from theGRILLE-
SIDELEFTandGRILL-SIDERIGHT
4) Pull the two GRILLE-SIDEs from the unit.
WD-73732 Front Disassembly (continued)
SCREEN-ASSY REMOVAL
1) Fromthe rear,remove 17screws (C),
5 along the top and 6 (inner screws)
on each side.
2) Fromthe front,remove twoscrews (d)
on the bottom on the SCREEN-ASSY.
3) Lift the SCREEN-ASSY slightly and
pull it away from the TV.

Page 18
MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
73” MODELS SCREEN REMOVAL & 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 Removal
1. Remove the screen assembly as shown in the Cabinet Disassembly procedure.
2. Removethe four screws (a) toremove thebottom ofthe SCREEN-FRAME-BOTTOM .
3. From the rear of the screen assembly, carefully slide the Lenticular Screen and Fresnel Lens combination
fromthe ScreenFrame.
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.

MODEL: WD-Y57 / WD-Y65 / WD-57732 / WD-65732 / WD-73732
Page 19
73” SCREEN REMOVAL & REPLACEMENT (continued)
Lenticular Screen and Fresnel Lens Installation
Note: Store the Lenticular Screen and Fresnel Lens in a cool dry place. High humidity may
deformthe Lenticular Screenand FresnelLens.
1. Apply double coated tape (Part #LENS-TAPE) along the top rear edge of the Lenticular Screen, as shown
below.
2. Sandwich the Fresnel Lens and Lenticular Screen together. The Lenticular Screen label must be towards
thefront and the Fresnel Lens label towards the rear.
3. Apply pressure at the top edge to bond the screens together.
4. Reversethe Screen Removal procedureand insert the screens in the Screen FameAssembly.