Mitsubishi WD-60C9 User manual

Page 3
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
INTRODUCTION ................................................................................................................................5
Dimensions,weight,powerusage,etc............................................................................................5
PRODUCTSAFETYNOTICE .............................................................................................................5
SAFETYPRECAUTIONS ................................................................................................................... 6
DISASSEMBLY ..................................................................................................................................7
BackCoverRemoval .......................................................................................................................7
ChassisRemoval ............................................................................................................................ 7
RearTerminalCoverRemoval ..........................................................................................................8
PowerSupplyShield Removal
PWB-POWERRemoval ..................................................................................................................8
TopChassisBracketsRemoval.......................................................................................................9
PWB-MAINRemoval.......................................................................................................................9
OpticalEngineAssemblyComponentsandConnectorLocations ................................................. 10
PWB-BALLASTRemoval .............................................................................................................. 10
OpticalEngineAssemblyRemoval................................................................................................ 11
DuctAssemblyRemoval ............................................................................................................... 11
OpticalEngineReplacement......................................................................................................... 13
ColorWheelReplacement ............................................................................................................ 14
ProjectionLensReplacement ....................................................................................................... 15
SCREENREPLACEMENT ................................................................................................................ 16
ScreenReplacement60”65” 73” ................................................................................................... 16
ScreenReplacement82”............................................................................................................... 19
MIRRORREPLACEMENT ................................................................................................................ 22
SPEAKER & PWB-SBL Replacement ............................................................................................ 23
INITIALIZATION, INITIAL SETTINGS & TROUBLESHOOTING....................................................... 22
RemoteControl............................................................................................................................. 24
OptionMenu ................................................................................................................................. 25
ResetandInitialization.................................................................................................................. 26
Initial Settings ............................................................................................................................... 27
A/V Reset..................................................................................................................................... 28
LED Indications & Self Diagnostics............................................................................................... 29
ErrorCodes .................................................................................................................................. 30
ErrorCodeLog.............................................................................................................................. 30
SERVICEADJUSTMENTS ............................................................................................................... 31
Equipment & Test Signals............................................................................................................. 31
ServiceMode ................................................................................................................................31
Horizontal & Vertical PositionAdjustment ..................................................................................... 32
IndexDelayAdjustment ................................................................................................................ 32
ManualGeometryAlignment ......................................................................................................... 33
Phase 1 - 16 PointAlignment............................................................................................... 33
Phase 2 - 4:3 and 16:9Alignment ........................................................................................ 33
Phase 3 - Touch UpAlignment ............................................................................................. 35
DataTransfer ....................................................................................................................... 36
USINGLEAD FREESOLDER .......................................................................................................... 37
CONTENTS

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
Page 4
CHIPPARTS REPLACEMENT ......................................................................................................... 38
REPLACEMENTPARTS .................................................................................................................. 39
PartsOrdering .............................................................................................................................. 39
CriticalandWarrantyPartsDesignation........................................................................................39
PartsTolerance Codes.................................................................................................................. 39
PARTSQUICK REFERENCELIST ................................................................................................... 40
SERVICE PARTS LIST .................................................................................................................... 41
SCREENASSEMBLYPARTS LIST.................................................................................................. 47
MIRRORKITSAND PREPARATION ................................................................................................ 49
CIRCUITRYBLOCK DIAGRAMS ..................................................................................................... 51
MainPowerSupply....................................................................................................................... 51
DCto DC Supplies........................................................................................................................ 52
PowerControl ............................................................................................................................... 53
SystemControl............................................................................................................................. 54
LampControl ................................................................................................................................55
Audio/VideoSignalPath ............................................................................................................... 56
SCHEMATICDIAGRAMS
Digital Light Processing®, Digital Micro Mirror Device and DLP® are Trademarks of Texas Instruments.
HDMI, the HDMI logo and High-Definition Multimedia Interface are trademarks or registered trademarks of HDMI Licensing, LLC..

Page 5
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
INTRODUCTION
This service manual provides service instructions for the V41C, V41 and V41+ chassis types. The specific models for
each chassis type, dimensions and weight are listed below. Service personnel should read this manual thoroughly
beforeservicingthese chassis.
Thisservicemanualincludes:
1. Assembly and disassembly instructions for cabinet and chassis components.
2. Servicingof the Lenticular Screen and Fresnel Lens.
3. Servicingprinted circuit boards (PCBs).
4. Electrical and Mechanical adjustments.
6. Chipparts replacement procedures.
7. Circuitblock diagrams.
The parts list section of this service manual includes:
1. Cabinetand screen parts.
2. Electrical parts.
Schematicand block diagrams of the abovelistedmodelsare included in this service manual forbetterunderstanding
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
usingreplacementcomponentsrated for higher voltage, wattage, etc.
Replacementparts which have special safety characteristicsareidentified in this service manual.
Electrical components having such features are identified by shading on the schematic diagram and parts list of this
service manual. The replacement for any safety part should be identical in value and characteristics.
Pb Solder
The PWBs used in this chassis are constructed using Lead-Free Solder. When servicing use
only recommended Lead-Free Solder. Refer to the section “Using Lead Free Solder.”
MODEL CHASSIS HEIGHT WIDTH DEPTH WEIGHT POWER
USAGE
WD-60C9 V41C 36.7" 53.9" 14.4" 64.9 lbs 260W
WD-60737 V41 36.7" 53.9" 14.4" 64.9 lbs 260W
WD-65C9 V41C 39.5" 58.2" 15.3" 72.2 lbs 260W
WD-65737 V41 39.5" 58.2" 15.3" 72.2 lbs 260W
WD-65837 V41+ 39.5" 58.2" 15.3" 72.2 lbs 260W
WD-73C9 V41C 43.6" 65.2" 17.5" 92.84 lbs 260W
WD-73737 V41 43.6" 65.2" 17.5" 92.84 lbs 260W
WD-73837 V41+ 43.6" 65.2" 17.5" 92.84 lbs 270W
WD-82737 V41 48.5" 73.2" 22.7" 139.7 lbs 270W
WD-82837 V41+ 48.5" 73.2" 22.7" 139.7 lbs 270W

Page 6
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
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 cabinet or with the cover removed presents a shock hazard
fromthereceiver's power supplies. Work on the receiver should not be attemptedbyanyonewhois
notthoroughlyfamiliarwiththeprecautionsnecessary when working on high voltage equipment.
2. Whenservice is required, observe the original lead dress. Where a short-circuit has occurred, replace
thosecomponentsthatindicate evidence ofoverheating.
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
abnormalconditionandrequires 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,andwiththeswitchingdevices 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
switchingdevicesofthereceiverintheiroperatingpositions,measuretheleakagecurrentforboth
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).
GWG - Green Wire Ground
(Earth Ground)
S2
S1
OPEN
GROUND
SUPPLY CONNECTOR GROUND
RECEIVER
INSULATED TABLE
TOUCH ALL
EXPOSED
METAL PARTS
AC MA
METER
L
N

Page 7
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
BACK COVER REMOVAL
Back Cover Removal
1) Removescrews(A)fromthebackcover.
2) RemovethebackcoverfromtheTV.
CHASSIS REMOVAL & DISASSEMBLY
Chassis Removal
1) Removefivescrews(A),oneside,fourrear.
2) Disconnect all cables connecting to the chassis.
3) Slide the chassis out of the cabinet.
DISASSEMBLY
LAMP
COVER
A
A
AA
BACK
COVER
A73" & 82" Models
Only
A
A
SideView
A

Page 8
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
Rear Terminal Cover Removal
1) Removenut(A)fromtheANTinput.
2) Disconnect connector PG2 from the rear of the RS232C assembly (V41+ only).
3) Removescrews(C)and(D).
4) RemovetheTerminal Cover from the chassis.
Power Supply Shield Removal
1) Removescrew(A).
2) RemovethePowerSupplyShield
from the chassis.
PWB-POWER Removal
1) Removescrews(B).
2) Disconnect all cables from the
PWB-POWER.
3) Lift the PWB-POWER from the
chassis.
PWB-POWER Installation
NOTE: The PWB-POWER should
be re-installed so the Heat Sink is
oppositethe Power Supply Shield.
CHASSIS REMOVAL & DISASSEMBLY(Continued)
A
PWB
POWER
SUPPLY
SHIELD
POWER
B
SINK
HEAT
D
C
D
A
(V41+)
PG2
(Rear)
RS232C

Page 9
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
Top Chassis Brackets Removal
NOTE:Removal of the Power Supply ShieldandPWB-POWERis not required to remove theTopChassis
Brackets.
1) Removescrews(A).
2) Disconnect all cables from the PWB-POWER.
3) Lift the Top Chassis Brackets from the chassis.
CHASSIS REMOVAL & DISASSEMBLY(Continued)
PWB-MAIN Removal
1) Disconnect all cables to PWB-MAIN.
2) Removescrews(A)fromtheDVI
connector.
3) Removescrews(B)fromthe Side
Terminals.
4) Removescrew(C)fromtheSide
HDMIconnector(V41+ only).
5) Removescrews(D).
6) Lift the PWB-MAIN out of the
chassis.
PWB-MAIN Installation
1) Install screws (A) (B) and (C) first.
2) Theninstallscrews(D).
3) Perform “Restore Engine DataFromBackup” (SeeDataTransferin ServiceAdjustmentssection).
4) Perform “Restore Geometry DataFromBackup” (SeeData TransferinServiceAdjustmentssection).
A
A
A
TOP CHASSIS
BRACKETS
D
DVI
HDMI
A
(V41+)
C
B

Page 10
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
OPTICAL ENGINE ASSEMBLY - COMPONENT AND CONNECTOR LOCATIONS
(Rear View)
OPTICAL ENGINE ASSEMBLY
PWB-BALLAST REPLACEMENT
Note: To remove the PWB-Ballast, it is not necessary to remove the Engine or Lamp Cartridge.
1) Release the Latch to lift the PWB-BALLAST from the mounting bracket.
2) Slide the PWB-Ballast out of the Engine Assembly.
3) Disconnect connectorsCJ1,CJ3 and CJ4, the HV Lamp connector.
4) To reinstall, first connect the connectors.Then slide the PWB under the Retaining Hooks. Then press the
rear edge of the PWB down onto the guide pins to engage the latch.
LAMP
CARTRIDGE
BALLAST
DMD FAN
J3
THERMAL
SENSOR
J8
SIROCCO
FAN J4
EXHAUST
FAN J5
DMD
FAN
J9
SMOOTH
PICTURE
J10
DYNAMIC
BLACK
J12
DVI
OPTICAL
ENGINE
PE2
POWER
CJ1
BALLAST CJ3
LAMP
POWER CONTROL
CD
LAMP
DOOR
SWITCH
DUCT
ASSEMBLY
LATCH
(HV To Lamp)
CJ3
CJ1
CJ4
RETAINING
HOOKS

Page 11
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
OPTICAL ENGINE REPLACEMENT
OPTICAL ENGINE ASSEMBLY REMOVAL
1) Remove 3 screws (A) from the Optical Engine.
2) Disconnect all cables to the Optical Engine Assembly.
3) Slide the Optical Engine assembly out of the cabinet.
DUCT ASSEMBLY REMOVAL
Figure 1: Duct Assembly (Rear View)
Upper Duct Assembly Removal Procedure
1) Loosentwoscrews(A)andremovetheLamp Cartridge.
2) Disconnect the Exhaust and Sirocco Fan Connectors (J4
and J8) from the back of the Engine and loosen the wiring
harnessesfromthelooms,refertoprevious page for
connectorlocations.
3) Removescrew(B) from the top of the upperductand
release the latches shown in Figure 2.
4) RemovetheUpper Duct assembly from the Optical
Engine.
LAMP
CARTRIDGE
BALLAST
A
DUCT
LOWER
DUCT
UPPER
LAMP
CARTRIDGE
BALLAST
J12
DVI
OPTICAL
ENGINE
PE2
POWER
CJ1
BALLAST CJ3 LAMP
POWER CONTROL
CD
LAMP
DOOR
SWITCH
A

Page 12
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
Figure 2: Duct Assembly (Top View)
DUCT INTERIOR COMPONENTS
1) Figure3 shows the Duct Interior Components.
2) The Upper Duct must be removed to replace the Lamp Door Switch PWB, Sirocco Fan, Exhaust Fan and
ThermalSensor(1screw).
3) Whenreplacingthe Engine, transfer the Duct InteriorComponentsfromoldEngine to the new Engine.
Note: There are three Exhaust Fan Holders, one on the top and two on the bottom of the Exhaust Fan.
Note: The Exhaust Fan must be installed so the Label is facing inside the Duct.
Note: The Sirocco Fan must be installed so the Label is facing upwith the Flanges aligned onto the Guide Pins.
Figure 3: Lower Duct (Top View)
OPTICAL ENGINE REPLACEMENT (Continued)
B
Latches
Latch
Latch
SIROCCO FAN
(Label Facing Up)
THERMAL
SENSOR EXHAUST
FAN
(Behind Lamp Housing)
EXHAUST FAN
HOLDERS (3)
(1 Top - 2 Bottom)
LAMP DOOR
SWITCH
PWB
(Label Facing Inside)
FLANGES Align
Onto GUIDE PINS

Page 13
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
Figure 4: Lower Duct Rear Mounting Screw
Figure 5: Lower Duct Front Mounting Screw
LOWER DUCT REMOVAL
1) RemoveUpperDuct,Fans,FanHolders,ThermalSensorandLampCartridge.Seepreviouspage.
2) Remove the 2 screws (C) one in front and one in the rear of the lower duct, refer to Figures 4 and 5.
3) CarefullyremovethelowerductfromtheEngine.
ENGINE Replacement (Reverse the Removal Procedure)
1) Install DuctAssembly on the new Engine.
2) Remove the Protective Lens Cover from the face of the Lens and place it on the old Engine.
3) Install the EngineAssembly in the cabinet.
4) Afteranew Engine is installed, perform the “RestoreIndexDelay”and “Save Engine and Geometry Setting
to Backup” procedures as described in the Data Transfer section of the ServiceAdjustments.
5) Ifneeded.performtheHorizontaland Vertical CenteringAdjustmentandManualGeometryAlignment
describedinServiceAdjustments.
OPTICAL ENGINE REPLACEMENT (Continued)
C
DUCT
UPPER
OPTICAL
ENGINE C
DUCT
LOWER

Page 14
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
COLOR WHEEL REPLACEMENT
SYMPTOMS
• Noise(BadMotorBearing)
• Solarized Picture NOTE: Before replacing the Color Wheel, check the Index DelayAdjustment.
COLOR WHEEL REPLACEMENT PROCEDURE
CAUTION: Thisprocedureshouldbeperformedinadustfreeenvironment.
Any dust entering into the color wheel chamber can cause abnormalities in the picture.
1) Remove EngineAssembly and cover the projection lens to protect it from scratches.
2) RemovetheTOPDUCT.
3) Remove the 2 screws (A) shown in Figure 1.
4) Disconnect the 2 connectors J6 & J7 shown in Figure 1.
5) Lift the top cover off of the color wheel chamber.
Figure 1: Color Wheel Cover and Connectors
6) Remove 3 screws (B) shown in Figure 2.
7) Use the Handle to lift the Color Wheel from the chamber.
8) Forinstallation,reversetheprocedureabove.
CAUTION: Usecare to prevent scratching the ColorWheel.
NOTE: Do not twist the ribbon cable to J6 (the shiny silver
contacts must be facing up).
9) Afterre-assembly, perform theIndexDelayAdjustment de-
scribed in the ServiceAdjustments section.
Figure 2: Color Wheel
COLOR
WHEEL
HANDLE
B
A
COVER
COLOR WHEEL
J6 J7

Page 15
MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737
WD-65837 / WD-73837 / WD-82837
PROJECTION LENS REPLACEMENT PROCEDURE
CAUTION: Any dust or fingerprints in the optics can cause abnormalities in the picture.
Thisprocedureshouldbeperformedinadustfreeenvironment.
Wearlintfreecotton or rubber gloves while performing this procedure.
1) RemoveEngineAssembly.
2) Remove screws(A)and rotate the Lens Collar off theLensin the direction indicated while carefully releasing
thefoamadhesivefromtheLens
PROJECTION LENS REPLACEMENT