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Ser vice
2006
Manual
MITSUBISHI ELECTRIC
LCD PROJECTION HDTV
V32/V32L CHASSIS
V32 Chassis V32L Chassis
WD-52327 WD-52531 WD-62530
WD-62531
Pb Solder
WD-52531
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 · Input Level : VIDEO IN JACK (RCA Type)
· Power Usage : 225W 1.0Vp-p 75 unbalanced
: AUDIO IN JACK (RCA Type)
· Light Engine : 3 LCD (1280 x 720 pixels) -4.7dBm 43k unbalanced
· Light Source : 132 Watts : S-VIDEO IN JACK
(Y/C separate type)
· Antenna Input : 2 RF 75 unbalanced Y:1.0 Vp-p C:0.286Vp-p(BURST)
· Tuning : 1 NTSC/ATSC/QAM 75 unbalanced
: COMP / Y, Cr, Cb (RCA Type)
· Cabinet Dimensions : [WD-52531] Y: 1.0 Vp-p Cr, Cb: 700mVp-p
33.1"(H) x 47.1"(W) x 16.9"(D)
: [WD-62530] · Output Level : VIDEO OUT JACK (RCA Type)
39.1"(H) x 55.9"(W) x 19.2"(D) 1.0Vp-p 75 unbalanced
: [WD-62531] : AUDIO OUT JACK (RCA Type)
39.1"(H) x 55.9"(W) x 19.2"(D)) W -4.7dBm 4.7k unbalanced
· Weight : [WD-52531] · Digital : AC-3 Digital Audio Output
82.5 lbs (RCA Type)
: [WD-62530] [WD-62531] : HDMITM
99.3 lbs
: Lead-Free solder PWBs
· Speakers (4 Ohms 10W) Pb Solder
: 2-5 ½ x 2 ¼ inch
· Design specifications are subject to change without notice.
MITSUBISHI DIGITAL ELECTRONICS AMERICA, INC.
9351 Jeronimo Road, Irvine, CA 92618-1904
Copyright © 2006 Mitsubishi Digital Electronics America, Inc.
.
All Rights Reserved
MODEL: WD-52531 / WD-62531 / WD-62530
CONTENTS
INTRODUCTION ................................................................................................................................ 5
Dimensions, weight, power usage, etc. ........................................................................................... 5
PRODUCT SAFETY NOTICE ............................................................................................................. 5
SAFETY PRECAUTIONS ................................................................................................................. 6
DISASSEMBLY .................................................................................................................................. 7
Rear Cover Removal ........................................................................................................................ 7
Chassis Removal and Disassembly ................................................................................................ 7
LCD Engine Removal .................................................................................................................... 10
Front Disassembly ........................................................................................................................ 13
Lenticular Screen and Fresnel Lens Removal and Replacement .................................................... 14
ADJUSTMENTS ............................................................................................................................... 15
Option Menu & Remote Control .................................................................................................... 15
Digital Signal Strength ................................................................................................................... 15
Front Panel Initialization ................................................................................................................ 16
Defaults ........................................................................................................................................ 17
A/V Defaults ................................................................................................................................. 18
LED Indicator Diagnostics ............................................................................................................. 18
Error Codes Operational Check ..................................................................................................... 19
Error Codes List ................................................................................................................... 19
Lamp Troubleshooting ................................................................................................................... 20
Lamp Control diagram .......................................................................................................... 21
Lamp Troubleshooting Flow Chart ........................................................................................ 21
Service Adjustment Mode ............................................................................................................. 22
Service Adjustment Mode Operation .................................................................................... 23
Transferring data .................................................................................................................. 23
Optical Engine Adjustment ............................................................................................................ 23
Test Signal activation ........................................................................................................... 23
Preliminary .......................................................................................................................... 23
Rotation and Keystone Distortion Adjustment ............................................................................... 24
After completing Light Engine Adjustments .......................................................................... 24
Horizontal & Vertical Position ............................................................................................... 25
USING LEAD FREE SOLDER .......................................................................................................... 26
CHIP PARTS REPLACEMENT ......................................................................................................... 27
REPLACEMENT PARTS .................................................................................................................. 28
Parts Ordering .............................................................................................................................. 28
Critical and Warranty Parts Designation........................................................................................ 28
Parts Tolerance Codes .................................................................................................................. 28
Quick Reference List ........................................................................................................................ 29
SERVICE PARTS LIST .................................................................................................................... 30
SCREEN ASSEMBLY PARTS LIST .................................................................................................. 37
CIRCUITRY BLOCK DIAGRAMS ..................................................................................................... 38
Main Power Supply ....................................................................................................................... 38
LCD Light Engine & Fan Power Supplies ...................................................................................... 39
DC to DC Supplies ........................................................................................................................ 39
Analog Video Signal Path ............................................................................................................. 40
Page 3
MODEL: WD-52531 / WD-62531 / WD-62530
Digital Video Signal Path .............................................................................................................. 41
Sound Signal Path ........................................................................................................................ 42
Overall Control Circuitry ................................................................................................................ 43
Command Input Circuitry ............................................................................................................... 44
Lamp Control Circuitry .................................................................................................................. 44
LCD Engine Protect Circuitry ........................................................................................................ 45
Short Protect Circuit ..................................................................................................................... 45
Auto Input Detection ..................................................................................................................... 46
SCHEMATIC DIAGRAMS .....................................................................................................................
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.
Page 4
MODEL: WD-52531 / WD-62531 / WD-62530
INTRODUCTION
This service manual provides service instructions for LCD Projection TV Models WD-52531 and WD-62531 using the
V32 chassis, and WD-62530 using the V32L chassis.
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, PWBs, Light Engine, Lamp Ballast, etc..
4. Electrical adjustments.
5. Optical Adjustments.
6. Lead Free Soldering.
7. Chip parts replacement procedures.
8. Simplified circuit path diagrams.
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.
The PWBs used in the V32 chassis are constructed using Lead-Free solder. When servicing use
Pb Solder only recommended Lead-Free solder (refer to page 26).
Page 5
MODEL: WD-52531 / WD-62531 / WD-62530
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 1Meg Ohm. 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-52531 / WD-62531 / WD-62530
BACK-COVER Removal
1) Remove 2 screws (A) to remove the Lamp Cover
2) Remove 12 screws (B).
3) Pull the COVER-BACK from the cabinet.
NOTE: To operate the TV the Lamp Cover must be reinstalled after the back cover is removed.
Chassis Removal
1) Remove 2 screws (C).
2) Disconnect all cables connected to the
chassis.
3) Carefully slide the chassis from the
cabinet
C
C
Page 7
MODEL: WD-52531 / WD-62531 / WD-62530
Rear Plate & PWB-INTERFACE Removal
1) Remove 4 screws (a) and pull off the rear plate.
2) Remove 3 screws (b) to remove the PWB-INTERFACE
PWB-POWER & Power Bracket
Removal
1) Remove 4 screws (A) and lift PWB-
POWER from the chassis.
2) Remove 8 screws (B) to remove the
Power Bracket.
Page 8
MODEL: WD-52531 / WD-62531 / WD-62530
PWB-SIGNAL Removal PWB-DM Removal
1) Remove 6 screws (c). 1) Remove 6 screws (D).
2) Unplug all connecting cables. 2) Unplug all connecting cables.
3) Remove PWB-SIGNAL 3) Lift PWB-DM from the chassis.
If PWB-SIGNAL is replaced, see page 22 to If PWB-DM is replaced, see page 22 to
perform "Download WB Data to FMT" perform "Copy Light Engine E2PROM to DM"
Exhaust Fan Replacement
1) Remove 7 screws (A) to
remove the lamp duct rear A
cover. A A
A
2) Slide the Exhaust Fan from
the duct and unplug the JF
connector. Remove the A
rubber fan holders, they do
not come with the replace-
ment fan.
3) When installing the fan
insert the fan in the re- A
moved cover first.
4) Insure the leads come out
the bottom of the fan and
the label on the fan is A
facing upwards.
Page 9
MODEL: WD-52531 / WD-62531 / WD-62530
Light Engine Replacement
Light Engine and Associated Components
The picture below shows the LCD Engine without added components, and the bottom picture shows the added
components and the Engine mounted on the Engine Plate.
Polarized
Beam
Splitter
Side hole for
lamp cooling.
LCD panel
area.
Two induction
fans.
LCD Engine Note: The Engine has no individual
service parts available. Attempting
to disassemble the Engine may void
the warranty.
PWB-MTR-DRIVE
(Relay Board)
Induction
cover
Engine
Plate
LCD Engine on engine plate
Page 10
MODEL: WD-52531 / WD-62531 / WD-62530
Light Engine & Engine Plate removal from the Cabinet
Preliminary
Refer to the chassis removal procedure and remove the BACK-COVER.
Removal Procedure
1) Remove the 2 locking screwss (A).
2) Loosen one (B) adjustment screw. (c)
(With only one (B) screw loose less
adjustment is required when
installing a new Engine.)
3) Partially slide the Engine and
bottom plate out of the cabinet.
4) Loosen screw (C) and unplug the
DVI cable from the Engine.
5) Disconnect all leads to the Engine,
Lamp Box and Ballast.
6) Carefully slide the Engine and
bottom plate from the cabinet.
Light Engine removal from the
Bottom Plate
1) Remove 2 screws (D) secure the support plate
to the Engine.
(D)
Page 11
MODEL: WD-52531 / WD-62531 / WD-62530
Light Engine removal from the Bottom Plate (continued)
2) To remove the Engine from
the bottom plate, remove 3
screws (a), and carefully lift
the Engine from the bottom
plate.
3) To remove the COVER-
INDUCTION from the Engine
5 screws (b).
Light Engine Installation
CABLE
1) Reverse the removal procedure to CLAMP
install a new light engine.
2) Tighten the DVI cable screw to 2-4 kgfcm.
3) Route the DVI cable and the KA-CN201
leads through the cable clamp as shown on
the right.
If Light Engine is replaced, see page 22 to perform
"Copy Light Engine E2PROM to DM"
Page 12
MODEL: WD-52531 / WD-62531 / WD-62530
Front Disassembly
Screen Frame Removal
1) Pull off the Speaker Grill.
2) Remove all screws (B) from the upper rear cover (except one screw at a upper corner). The remaining screw
supports the screen frame while removing the front screws.
3) Remove all screws (A) from the front of the screen frame.
4) Carefully pull the Screen Frame from the TV and disconnect the ES and LE connectors.
Page 13
MODEL: WD-52531 / WD-62531 / WD-62530
Screen Replacement
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 28 screws (A) to remove the top, bottom and side HOLDER-SCREEN rails and their SPACERS from
the Screen Frame. (36 screws in the 62" model)
2) Lift the screens as a single
unit from the frame.
3) Separate the Lenticular Screen
and Fresnel Lens.
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.
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) Reverse the Screen Removal Procedure and insert the
screens in the Bezel.
Page 14
MODEL: WD-52531 / WD-62531 / WD-62530
V32/V32L REMOTE CONTROL
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.)
V32/v32L Remote Button Name Changes
Previous Model Name New Name
HOME EXIT
PIP/POP SPLIT
SQV FAV
DEVICE INPUT
Digital Signal Strength
1. Tune to a Digital Channel
2. From the Option menu scroll down and highlight Digital
Signal Strength
3. Press Enter
Example using on ANT1
Signal Quality Tuner 0 Tuner 1 OOB Tuner
Index (0-100) Frequency(MHz): 597 0
Signal Level: 8 0
Modulation: 256 QAM Unknown
Carrier Lock: Locked Unknown
SQI: 100 0
SNR: 34.3 0
Signal Noise
Ratio Correctable errors: 0 0
UnCorrectable errors: 0 0
SNR Recommended Levels:
VSB = 15 to 35
64 QAM = 22 to 34
256 QAM = 27 to 37
Page 15
MODEL: WD-52531 / WD-62531 / WD-62530
Front Panel Initialization
While the unit is ON, pressing the FORMAT and INPUT buttons simultaneously will immediately start the Initialization
sequence. The TV will reboot once the initialization sequence is completed. Front Panel Initialization will reset ALL
user settings to the factory setting.
SERVICE TIP:
Many customer generated symptoms, intermittent symptoms or no symptom found can be resolved by system reset
or initialization. Before visiting the customer's home ask the customer 1st to try the System Reset button on the
control panel and if this does not resolve the issue, then they can use the front panel initialization by pressing the
FORMAT and INPUT buttons simultaneously
NOTE: During Initialization, the set will
reboot. Wait until the Power LED stops
flashing before unplugging or powering
ON the TV.
RESET / INITIALIZE GUIDE
Reset Name When to use How to use Resulting Action
Remote Control TV Returns the remote control TV (1) Set the slide switch to TV position. Once the valid code has been entered
Layer Reset layer to normal operation. (2) Press and hold the POWER button until it and confirmed, the remote control has
(3) flashes twice then release the button. been reset.
(3) Enter the code 0 0 9 3 5.
Remote Control TV Returns the volume and mute (1) Set the slide switch to TV position. The remote will now operate the TV's
Volume/Mute functions of the remote control to (2) Press and hold the POWER button until it volume and mute when the slide switch
functions TV volume and mute for TV, (3) flashes twice then release the button. is in the TV, CABLE/SAT, VCR or DVD
Cable/Sat, VCR and DVD layers (3) Enter the code 9 9 3 VOL UP. positions.
after the audio lock for AV
Receivers feature has been used.
A/V Memory Reset, When the audio and or video MENU --> Audio/Video--> AV Reset All Audio and Video settings for the
single input settings for a single input seems individual input are reset except for the
to incorrect Listen To and Language, audio
Balance and Closed Caption settings.
A/V Reset, all To reset audio and video While viewing the TV, press the front panel All Audio and Video settings including
inputs adjustments for all inputs to the buttons GUIDE and FORMAT at the same Listen To and Language , Closed
original factory settings. time. Captions settings and Format settings
are returned to the original factory
settings.
System Reset To reset the TV when it does not Press the SYSTEM RESET button on the The changes you made most recently,
turn on or off, does not respond front panel with a pointed object such as before using the SYSTEM RESET, may
to the remote control, front panel the point of pencil or end tip of a paperclip. be lost. Changes you made previously,
buttons or has audio but no however, are not lost.
video.
TV Reset To reset all customer settings Press MENU-1-2-3-ENTER All customer settings except V-Chip are
reset.
Initialize - User To reset all consumer adjusted Press FORMAT and INPUT buttons on the All memories and settings outlined in
Level settings and memories to the front control panel at the same time. the Owner's Guide will need to be set
original factory defaults. again.
Initialize - Service To reset all consumer adjusted MENU + 2470. Highlight INITIALIZE and All memories and settings outlined in
Level settings and memories to the press ENTER the Owner's Guide will need to be set
original factory defaults. again. Also erases V-CHIP password
Factory Restore To recover from data/adjustment MENU + 2457 + 0. Highlight RESTORE All service, user, ISF data is set back to
errors in the ISF menu FACTORY DEFAULTS and press ENTER factory defaults.
Page 16
MODEL: WD-52531 / WD-62531 / WD-62530
DEFAULTS AFTER INITIALIZATION
Setup Menu TV Rating :TV-PG
Language :English FV-Fantasy/Violence --
Memorize Channels -- D-Sexual Dialog --
Ant1 Air -- L-Adult Language --
Ant1 Cable -- S-Sexual Situations --
Ant2 Air -- V-Violence --
Ant2 Cable -- Programs not rated --
Clock Movie Rating PG
Clock Setting Manual V-Chip Time
Time 12:00pm Start :12:00pm
Date 1/01/04 Stop :12:00pm
Time Zone :Eastern Lock by Time :Off
Daylight Savings :Applies Lock Time :12:00pm
Timer :Gray Out Unlock Time :12:00pm
Timer :Off From Button Lock :Off
Day :Everyday Audio/Video
Time :12:00pm A/V Memory Reset :Ant1
Device :Ant1 Audio/Video
Channel :2 Bass :50%
Software Version V32 xxx.xx Treble :50%
Record Balance :50%
Record Surround :Off
Channel :2 Listen To :Stereo
Record to -- Level Sound :Off
Duration :1 hr Language (Digital Signal Only) :English
Start Time -- Video
Day -- Picture Mode :Brillant
Record List -- Bright/Natural :Bright
Default Record Device :Gray out Brillant Contrast :100%
Analog Recordings :Anamorphic Brillant Brightness :50%
Channel Color :50%
Antenna :1 Tint :50%
Prefer Digital Sharpness :50%
Channel :2 Brillant Color Temp :High
Memory :Added Color :Manual Center
Name Video Noise :Standard
FAV Video Mute :On
Signal Strength :Digital only TV Speakers :On
Captions Menu TV Volume :30%
Analog Captions :On if Mute PIP Source Ant1 002
Background :Gray PIP Position :Lower Right
Digital Captions :On if Mute POP Position :Right Half
Appearance :Default PIP/POP Format Double Window
Digital Settings Format
Font :Font 3 Ant 1 or 2 480i/480p :Stretch
Size :Large Ant 1 or 2 HD Digital :Standard
Color :White Input 1, 2, 3 :Standard
Background :Black Comp 1, 2 :Standard
Opacity :Translucent HDMI 1, 2 (Only HDMI 1 in V32L) :Standard
Backgroung Opacitry :Translucent Auto Input Detect
Parental Lock Input 1, 2, 3 :On
V-Chip Componet 1, 2 :On
US Ratings :Off
Page 17
MODEL: WD-52531 / WD-62531 / WD-62530
AV RESET DEFAULTS
Component
A/V Memory Antenna 1&2 Input 1/2/3 HDMI 1/*2
1/2
Brillant/Bright/Natural Bright Bright Bright Bright
Bright Contrast Maximum Maximum Maximum Maximum
Bright Brightness Center Center Center Center
Color Center Center Center Center
Tint Center Center Center Center
Sharpness Center Center Center Center
Color Temp. High High High High
Perfect Color Manual Center Manual Center Manual Center Manual Center
Video Noise Standard Standard Standard N/A
Bass Center Center Center Center
Treble Center Center Center Center
Balance Center Center Center Center
Surround Off Off Off Off
Listen To Stereo N/A N/A N/A
Level Sound On On N/A N/A
Language** English N/A N/A N/A
* HDMI 2 in V32 only.
A. A/V Memory
Each of the external inputs has its' own Audio/Video Memory. A change in an A/V setting at a specific input is
stored in memory for that specific input.
B. A/V Reset
1. The front panel AV Reset (pressing the "Guide" and "Format" buttons at the same time) initializes all A/V
Memories.
2. The AV Reset in the user's menu initializes only the selected input's A/V Memory.
LED Indicator Diagnostics
The front panel LEDs provide an indication of the sets operation, and the possible cause of a malfunction. There
are three front panel LEDs, "Power", "Status" and "Lamp". Which LED is lit, the color and whether it is blinking or
steady indicate the current status, or a possible malfunction.
Normal LED Indications
POWER STATUS LAMP Power
Condition
LED LED LED Status
Off Off Off Stby Off
Green Off Off P-0N Power On
Blinks After Turn
Off Off Lamp Fan On for 1 minute
Green Off
Blinks
Off Off Stby Booting after AC applied
Green
Slow Blinks
Off Off Stby On Timer is set
Green
Page 18
MODEL: WD-52531 / WD-62531 / WD-62530
ABNORMAL LED INDICATIONS
Power/Timer
Status Indicator Lamp Indicator Condition
Indicator
Off Yellow Off Temperature high room temperature too hot.
Temperature sensor is disconnected.
Off Off Yellow Lamp usage warning (over 5000 hours)
Off Off Blinking yellow Lamp cover is open.
Off Red Lamp fails to turn on
Off Blinking Red Off Fan Stop
Circuit failure (short)
Off Red. Off DVI cable between DM and Engine disconnected
Ballast problem detected by ballast UART (temperature,
short circuit, did not ignite, low voltage)
3. Error Code Operational Check
Note: The TV must be in "Shut Down" and not have been switched Off, to perform the Error Code Opera-
tional Check. When the TV is switched Off, the code automatically resets to "12" No Error.
Pressing the front panel "DEVICE" and "MENU" buttons at the same time, and holding for 5 seconds,
activates the Error Code Mode. The LED flashes denoting a two digit Error Code, or indicating no problem
has occurred since the last Initialization.
Note: The front panel buttons must be used, NOT those on the Remote Control.
· The number of flashes indicates the value of the MSD (tens digit) of the Error Code.
· The flashing then pauses for approximately 1/2 second.
· The LED then flashes indicating the value of the LSD (ones digit) of the Error Code.
· The Error Code is repeated a total of 5 times.
Example: If the Error Code is "23", the LED will flash two times, pause, and then flash three times.
4. Error Codes
The Error Code designations indicating malfunction, or no malfunction, are listed below:
ERROR CODES
Code Description
12 No Error found
32 Lamp cover is open.
34 Lamp turns Off while the TV is playing.
36 Lamp ballast fan failed.
37 Engine PBS fan failed.
38 Lamp temperature abnormally high.
39 LCD temperature abnormally high.
41 Standby Short Detected.
42 Exhaust (lamp) fan failed.
44 Check for disconnected DVI cable between PWB-DM and Engine.
45 LCD fan failed.
46 LCD Temperature sensor not detected.
48 Engine power supply short is detected. (P-ON short)
66 Lamp did not turn on at P-ON sequence
Lamp Troubleshooting
Use the above Error Code Table, and the Lamp Control Block diagram and Troubleshooting flow chart on the following pages
to determine the cause of a lamp problem.
Page 19
MODEL: WD-52531 / WD-62531 / WD-62530
Lamp Control
Block Diagram
Lamp Lights Replace
then goes out Lamp
Lamp Troubleshooting Code 34
Lamp does
Flow Chart not Light
· Install Lamp Cover with no Lamp Check Cable
· Monitor Ballast spark gap. Check No OK
Connections Circuit
· Press "POWER' Ballast
DVI, FC & Problem
· Spark gap arc? Striking
CN101
Yes
Code 66 Replace Press Install Lamp
Lamp "POWER" & Lamp Cover
· H for 5 sec. · H for 4 sec.
Pulses Check
Ballast Yes · L for 10 sec. Pulses · L for 10 sec.
LAMP-EN
DC Supply? · H for 1 sec> · Repeats
(FC pin 23)
· Stays Low several times
Yes No Pulse
Code
PL (1 to 5)=340V Replace
FB pin 3=5vs Ballast Code 66 66
No
No KA Connector Check Yes
Replace PB Connector Engine
(1~4)=3.3V? Replace
PWB-POWER (1~2)=18V? Power
(7~8)=18V? Lamp
OK
Yes OK
Code 34
Check Check
PWBs Signal & Interface PWB-SIGNAL
Page 20
MODEL: WD-52531 / WD-62531 / WD-62530
SERVICE ADJUSTMENTS
There are only 5 Service Adjustments required in these models:
Two Electrical Adjustments
· Horizontal Centering
· Vertical Centering
Three Mechanical Adjustment
· Picture Rotation
· Horizontal Keystone Distortion
· Vertical Keystone Distortion
Measuring equipment and Jigs
· No additional Test Equipment is required.
· Conventional Electrical Hand Tools.
Test signal
An internally generated Test Signal is used, no additional external signals are required.
Circuit Adjustment Mode
On these models, the Circuit Adjustment Mode is used only for:
· Test Signal activation
· Horizontal Centering
· Vertical Centering the following adjustments may only be performed using the remote hand unit.
1. Activating the adjustment mode
1. Press the "MENU" button on a remote hand unit.
(The "MENU" display will appear.)
2. Press the buttons "2", "4", "5" and "7" in that order.
(The screen will change to the adjustment mode.)
If not changed to the adjustment mode, repeat steps
1 and 2.
2. Test Signal Activation
When in the Circuit Adjustment mode, use the "REWIND"
and "FAST FORWARD" buttons on the remote
control to toggle through the test patterns. These patterns are used
for both electrical and mechanical
adjustments.
3. Adjustment Function Selection
Use the "AUDIO" button to select a specific Adjustment Function.
NOTE: The only Service Adjustment Modes are Format (fmt) and Doubler.
Doubler Functions fmt
Page 21
MODEL: WD-52531 / WD-62531 / WD-62530
4. Adjustment Selection
Use the "VIDEO" button to select a specific electrical adjustment, "1 HPOS" or "2 VPOS".
5. Adjusting Data
After selecting an adjustment item, use the "UP" and "DN" buttons to change adjustment data.
· If the "UP" button is pressed, the adjustment data increases.
· If the "DN" button is pressed, the adjustment data decreases.
6. Saving data
Press "ENTER" to save the adjustment data in memory.
The display characters go red for approximately one second in this step.
Note: If the circuit adjustment mode is terminated without pressing
"ENTER", changes in adjustment data are not saved.
7. Terminating the circuit adjustment mode
Press the "MENU" button on the remote hand unit twice to terminate the adjustment mode.
Note: The adjustment mode can be also terminated by turning the
power off.
Transferring Data
1) Enter the Service Adjustment Mode ... Press "MENU-2-4-5-7"
2) Press "0" when in the Service Mode ... Three choices appear at the top of the screen.
3) Use the UP & DN keys to highlight the desired choice, then Press "ENTER"
DATA TRANSFER MENU-2-4-5-7-0
Display Description
Copy Engine E2PROM to DM After Replacing Engine or PWB-DM
Restore factory data Restores factory set values
Copies WB data from E2P to FMT
DOWNLOAD WB ALIGNMENT TO FMT
(after PWB-SIGNAL replacement)
Page 22
MODEL: WD-52531 / WD-62531 / WD-62530
Light Engine Adjustments
Test Signal Activation
1) Press "MENU-2-4-5-7" (Service Mode)
2) Press "FF/FWD" (Test Pattern).
Red = 4% overscan
White = 5% overscan
Green = 6% overscan
Cyan = 7% overscan
Yellow = 10% overscan
Preliminary (refer to the diagram below)
1) Remove the Lamp Cover and Back Cover (page 7)
2) Tape Lamp Cover Switch in the forward position (to operate the TV with the back off).
3) Loosen locking screws [A-1] and [A-2].
4) Loosen Adjust screw [A-3] and [A-4],
Page 23
MODEL: WD-52531 / WD-62531 / WD-62530
Trapezoid Distortion Adjustment
1) For Distortion at the top of the picture,
rotate [A-5] counter clockwise (the
picture will move upward).
3) For distortion at the bottom of the
picture, rotate [A-5] clockwise (the
picture will move upward).
Rotation Adjustment
Clockwise Rotation Needed
1) Loosen [A-3] and adjust [A-4].
2) Tighten [A-3] after adjusting [A-4].
Counter Clockwise Rotation Needed.
1) Loosen [A-4] and adjust [A-3].
2) Tighten [A-4] after adjusting [A-3].
After Adjustment (refer to previous page)
1) Insure [A-3] and [A-4] are hand tight.
2) Tighten Lock Screw [A-1] (20 kg;cm)
3) Tighten Lock Screw [A-2] (20 kg.cm)
NOTE: If horizontal or vertical centering shifts during keystone or rotation adjustments
perform the centering adjustment on the following page.
Page 24
MODEL: WD-52531 / WD-62531 / WD-62530
[Format Circuit] Purpose: To center the picture on the screen.
Horizont/Vertical Position Adjust- Symptom: Picture is off center.
ment
Measuring
Instrument 1. Press "MENU-2-4-5-7", activates the Service Mode..
Test Point ---- 2. Press "ff/fwd", activates the Overscan Test Pattern
3. Select the "FORMAT" function (AUDIO button).
------
Ext. Trigger 4. Select "Item 1" HPOS (VIDEO button).
------ 5. Use the ADJUST buttons to center the picture horizontally.
Measuring
Range 6. Press ENTER to save the new setting.
Input Signal 7. Select "Item 2" VPOS (VIDEO button).
Internal Test Pattern.
8. Use the ADJUST buttons to center the picture vertically.
Input Terminal Video 9. Press ENTER to save the new setting.
10. Press MENU to exit the Service Mode.
Page 25
MODEL: WD-52531 / WD-62531 / WD-62530
Using Lead Free Solder
Pb Solder · The time required for a good solder connection may
take longer.
The above symbol indicates Lead (Pb) Free solder was · Poor wet-ability can cause solder balls.
used during the construction of PWBs. Only Lead · Higher temperatures can cause flux spattering.
Free solder should be used when servicing these · Soldering iron tip life is shortened.
PWBs. · Dull finish solder joints (not shiny) can appear to be
a "cold" solder joint.
Solder must be compatible with that used by the
manufacturer. Leaded solder can not be used on In general a tip temperature of 700° F will usually provide
PWBs manufactured with Pb-free solder. The Mitsub- good results.
ishi standard for service requires the use of Tin-Silver-
Copper (Sn-96.5, Ag-3.0, Cu-0.5). It can be obtained
through the Parts Department.
Displays used to indicate Pb-free
Order part number: PB FREE SOLDER PCBs will be marked, indicating the level of Pb-free con-
struction. Table 1 defines the levels by phase and shows
Lead Free solder has a higher melting point, and does the different symbols that will be displayed on the PCB.
not "wet" as well as leaded solder. This means it does Additionally, a PCB constructed using Pb-free solder may
not adhere as readily to the solder iron tip, and the be simply marked LFS.
surface to be soldered. To counteract this, the flux
used is more corrosive. When possible, the indication will be placed close to the
part number that is screened onto the PCB (not the part
The following cautions must be taken when using Pb label). Figure 1 is an example of a PCB showing the
Free solder. display and its location.
· Higher temperatures can cause the PWB to
warp, detaching surface mount Pb-Free Short Display (When the
components. Phase Definition Display area is too small)
· Higher temperatures may Phase-1 PCB's constructed using
cause thermal damage to
components.
Pb-free solder.
Pb Solder Pb S
· Higher temperatures can cause
Phase-2 Solder, PCB surface
plastics, such as connectors,
finishing and component
relays, LEDs electrolytic
capacitors, etc. to melt or warp.
lead plating is Pb-free.
Components may have
Pb Joints Pb J
· Higher temperatures can cause internal Pb.
surface oxidation resulting in Phase-3 Solder, PCB surface
poor solder spread-ability and
wet-ability.
finishing and components
are Pb-free. (100% Pb- Pb PCA Pb P
free)
· The flux is more corrosive.
Table 1: Pb-Free Phases and Symbols
Pb-Free
Display
Figure 2: Pb-Free display on PWB
PAGE 26
MODEL: WD-52531 / WD-62531 / WD-62530
CHIP PARTS REPLACEMENT
Some resistors, shorting jumpers (0 Ohm resistors), Chip Parts Removal (Transistors)
ceramic capacitors, transistors and diodes are chip parts. 1. Melt the solder of one lead and lift the side of
The following precautions should be taken when replacing that lead upward.
these parts. 2. Simultaneously melt the solder of the other
two leads and lift the part from the PCB.
Cautions:
1. Use a fine tipped, well insulated soldering iron
and tweezers.
2. Melt the solder and remove the chip parts
carefully so as not to tear the copper foil from
the printed circuit board.
3. Discard removed chips; do not reuse them.
4. Do not apply heat for more than 3 (three)
seconds to new chip parts.
5. Avoid using a rubbing stroke when soldering.
6. Take care not to scratch, or damage the chip
parts when soldering.
7. Supplementary cementing is not required.
Chip Parts Removal (Resistors, Capacitors, etc.)
1. Grasp the part with tweezers. Melt the solder
at both sides alternately, and remove one side
of the part with a twisting motion.
2. Melt the solder at the other side and remove
the part.
Replacement
1. Presolder the contact points on the circuit
pattern.
2. Press the part downward with tweezers and
apply the soldering iron as shown.
PAGE 27
MODEL: WD-52531 / WD-62531 / WD-62530
REPLACEMENT PARTS
Parts Ordering
To expedite delivery of replacement parts orders, specify the following:
1. Model Number/Serial Number
2. Part Number and description
3. Quantity
Note: Unless complete information is supplied, delay in processing of orders will result.
Critical and Warranty Parts Designation
Critical Electrical Components are indicated by Bold Type in the Parts List, and in the schematic
diagrams by shading.
Warranty Return Parts are indicated in the Parts List with an (*).
Parts Tolerance Codes
Refer to the following chart for tolerance characteristics of electrical components.
MARK B C D F G J K
Tolerance % ± 0.1 ± 0.25 ± 0.5 ±1 ±2 ±5 ± 10
MARK M N V X Z P Q
Tolerance % ± 20 ± 30 ± 10 + 40 + 80 + 100 + 30
-20 -20 -0 -10
MARK M N V X Z
Tolerance (pF) ± 0.1 ± 0.25 ± 0.5 ±1 ±2
PAGE 28
MODEL: WD-52531 / WD-62531 / WD-62530
QUICK REFERENCE FOR COMMON PARTS
Major PWB Assemblies
PWB PART NO MODELS
PWB-POWER 934B933001 ALL
PWB-SIGNAL 934C216001 WD-52531 / WD-62531
" 934C216002 WD-62530
PWB-DM 934C218001 WD-52531 / WD-62531
" 934C218002 WD-62530
PWB-FRONT 935D885001 ALL
PWB-SW-LAMP 935D887001 ALL
PWB-CONT 935D888001 ALL
PWB-INTERFACE 934C220001 ALL
PWB-PREAMP 935D884001 ALL
ASSY-MOTOR-DRIVER-PWB 938P042010 ALL
0
OPTICAL COMPONENTS
Component Part No. Models
OPTICAL ENGINE 52" LCD 938P054010 WD-52531
OPTICAL ENGINE 62" LCD 938P054020 WD-62531 / WD-62530
BALLAST-LAMP PWR 938P055010 ALL
LAMP CARTRIDGE 915P043010 ALL
MIRROR & SCREEN PARTS
LENTICULAR
MODEL MIRROR FRESNEL LENS
SCREEN
WD-52631 767D083020 491P199050 491P202090
WD-62530/1 767D083040 491P199060 491P202060
MISCELLANEOUS PARTS
Exhaust Fan Engine LV Engine PBS Remote
MODEL