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MITSUBISHI ELECTRIC

Ser vice Manual
DLP PROJECTION HDTV V41C, V41 & V41+ CHASSIS

2009

WD-52327 WD-52527

V41C Chassis WD-60C9 WD-65C9 WD-73C9 V41+ Chassis WD-65837 WD-73837 WD-82837

V41 Chassis WD-60737 WD-65737 WD-73737 WD-82737

Pb Solder
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 · Power Usage · Light Engine : AC 120V, 60Hz : See table on page 5 : DLPTM (1080p) 5 Primary Color System : 180W : Analog Cable - 1~125 Digital Cable - 1~135 : 1 RF 75 unbalanced : 1 NTSC/ATSC/QAM : See Table on page 5 : See table on page 5 · Output Level · Speakers · Input Level : Two 5½"x2¼" Oval (8 10W) : VIDEO IN JACK (RCA Type) 1.0Vp-p 75 unbalanced : AUDIO IN JACK (RCA Type) -4.7dBm 43k unbalanced : AUDIO OUT JACK (RCA Type) -4.7dBm 4.7k unbalanced : AC-3 Digital Audio Output (RCA Type) : HDMITM : IR Blaster Output (V41+ only) : USB : PC - use HMDITM \ : Wired IR Input (V41+ only)

· Light Source · Channel Range

· Digital

· Antenna Input · Tuning · Cabinet Dimensions · Weight

· Design specifications are subject to change without notice.

MITSUBISHI DIGITAL ELECTRONICS AMERICA, INC.
9351 Jeronimo Road, Irvine, CA 92618-1904 Copyright © 2009 Mitsubishi Digital Electronics America, Inc. All Rights Reserved

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

CONTENTS
INTRODUCTION ................................................................................................................................ 5 Dimensions, weight, power usage, etc. ........................................................................................... 5 PRODUCT SAFETY NOTICE ............................................................................................................. 5 SAFETY PRECAUTIONS ................................................................................................................... 6 DISASSEMBLY .................................................................................................................................. 7 Back Cover Removal ....................................................................................................................... 7 Chassis Removal ............................................................................................................................ 7 Rear Terminal Cover Removal .......................................................................................................... 8 Power Supply Shield Removal PWB-POWER Removal .................................................................................................................. 8 Top Chassis Brackets Removal ....................................................................................................... 9 PWB-MAIN Removal ....................................................................................................................... 9 Optical Engine Assembly Components and Connector Locations ................................................. 10 PWB-BALLAST Removal .............................................................................................................. 10 Optical Engine Assembly Removal ................................................................................................ 11 Duct Assembly Removal ............................................................................................................... 11 Optical Engine Replacement ......................................................................................................... 13 Color Wheel Replacement ............................................................................................................ 14 Projection Lens Replacement ....................................................................................................... 15 SCREEN REPLACEMENT ................................................................................................................ 16 Screen Replacement 60" 65" 73" ................................................................................................... 16 Screen Replacement 82" ............................................................................................................... 19 MIRROR REPLACEMENT ................................................................................................................ 22 SPEAKER & PWB-SBL Replacement ............................................................................................ 23 INITIALIZATION, INITIAL SETTINGS & TROUBLESHOOTING ....................................................... 22 Remote Control ............................................................................................................................. 24 Option Menu ................................................................................................................................. 25 Reset and Initialization .................................................................................................................. 26 Initial Settings ............................................................................................................................... 27 A/V Reset ..................................................................................................................................... 28 LED Indications & Self Diagnostics ............................................................................................... 29 Error Codes .................................................................................................................................. 30 Error Code Log .............................................................................................................................. 30 SERVICE ADJUSTMENTS ............................................................................................................... 31 Equipment & Test Signals ............................................................................................................. 31 Service Mode ................................................................................................................................ 31 Horizontal & Vertical Position Adjustment ..................................................................................... 32 Index Delay Adjustment ................................................................................................................ 32 Manual Geometry Alignment ......................................................................................................... 33 Phase 1 - 16 Point Alignment ............................................................................................... 33 Phase 2 - 4:3 and 16:9 Alignment ........................................................................................ 33 Phase 3 - Touch Up Alignment ............................................................................................. 35 Data Transfer ....................................................................................................................... 36 USING LEAD FREE SOLDER .......................................................................................................... 37

Page 3

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

CHIP PARTS REPLACEMENT ......................................................................................................... 38 REPLACEMENT PARTS .................................................................................................................. 39 Parts Ordering .............................................................................................................................. 39 Critical and Warranty Parts Designation........................................................................................ 39 Parts Tolerance Codes .................................................................................................................. 39 PARTS QUICK REFERENCE LIST ................................................................................................... 40 SERVICE PARTS LIST .................................................................................................................... 41 SCREEN ASSEMBLY PARTS LIST .................................................................................................. 47 MIRROR KITS AND PREPARATION ................................................................................................ 49 CIRCUITRY BLOCK DIAGRAMS ..................................................................................................... 51 Main Power Supply ....................................................................................................................... 51 DC to DC Supplies ........................................................................................................................ 52 Power Control ............................................................................................................................... 53 System Control ............................................................................................................................. 54 Lamp Control ................................................................................................................................ 55 Audio/Video Signal Path ............................................................................................................... 56 SCHEMATIC DIAGRAMS

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 4

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 before servicing these chassis.

M ODEL W D-60C9 W D-60737 W D-65C9 W D-65737 W D-65837 W D-73C9 W D-73737 W D-73837 W D-82737 W D-82837

CHASSIS V41C V41 V41C V41 V41+ V41C V41 V41+ V41 V41+

HEIGHT 36.7" 36.7" 39.5" 39.5" 39.5" 43.6" 43.6" 43.6" 48.5" 48.5"

W IDTH 53.9" 53.9" 58.2" 58.2" 58.2" 65.2" 65.2" 65.2" 73.2" 73.2"

DEPTH 14.4" 14.4" 15.3" 15.3" 15.3" 17.5" 17.5" 17.5" 22.7" 22.7"

W EIGHT 64.9 lbs 64.9 lbs 72.2 lbs 72.2 lbs 72.2 lbs 92.84 lbs 92.84 lbs 92.84 lbs 139.7 lbs 139.7 lbs

POW ER USAGE 260W 260W 260W 260W 260W 260W 260W 270W 270W 270W

This service manual includes: 1. Assembly and disassembly instructions for cabinet and chassis components. 2. Servicing of the Lenticular Screen and Fresnel Lens. 3. Servicing printed circuit boards (PCBs). 4. Electrical and Mechanical adjustments. 6. Chip parts replacement procedures. 7. Circuit block diagrams. The parts list section of this service manual includes: 1. Cabinet and screen parts. 2. Electrical parts. Schematic and 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 characteristics 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 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."

Page 5

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 receiver chassis.

WARNING: 1.

2.

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. When service is required, observe the original lead dress. Where a short-circuit has occurred, replace those components that indicate evidence of overheating.

SAFETY PRECAUTION 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 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).

OPEN GROUND S2 L N

TOUCH ALL EXPOSED METAL PARTS RECEIVER AC MA METER

S1

INSULATED TABLE SUPPLY CONNECTOR GROUND

GWG - Green Wire Ground (Earth Ground)

Page 6

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

DISASSEMBLY
BACK COVER REMOVAL

BACK COVER

A

A

A

LAMP COVER

A

Back Cover Removal
1) Remove screws (A) from the back cover. 2) Remove the back cover from the TV.

A 73" & 82" Models Only

CHASSIS REMOVAL & DISASSEMBLY

A

A

Side View
A

Chassis Removal
1) Remove five screws (A), one side, four rear. 2) Disconnect all cables connecting to the chassis. 3) Slide the chassis out of the cabinet.

Page 7

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

CHASSIS REMOVAL & DISASSEMBLY (Continued)
PG2 (Rear)

C

(V41+) RS232C A

D D

Rear Terminal Cover Removal
1) 2) 3) 4) Remove nut (A) from the ANT input. Disconnect connector PG2 from the rear of the RS232C assembly (V41+ only). Remove screws (C) and (D). Remove the Terminal Cover from the chassis.

POWER SUPPLY SHIELD
Power Supply Shield Removal
1) Remove screw (A). 2) Remove the Power Supply Shield from the chassis.

HEAT SINK

PWB-POWER Removal
1) Remove screws (B). 2) Disconnect all cables from the PWB-POWER. 3) Lift the PWB-POWER from the chassis.

PWB POWER B

PWB-POWER Installation
NOTE: The PWB-POWER should be re-installed so the Heat Sink is opposite the Power Supply Shield.

A

Page 8

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

CHASSIS REMOVAL & DISASSEMBLY (Continued)
TOP CHASSIS BRACKETS A A

A

Top Chassis Brackets Removal
NOTE: Removal of the Power Supply Shield and PWB-POWER is not required to remove the Top Chassis Brackets. 1) Remove screws (A). 2) Disconnect all cables from the PWB-POWER. 3) Lift the Top Chassis Brackets from the chassis.

PWB-MAIN Removal
1) Disconnect all cables to PWB-MAIN. 2) Remove screws (A) from the DVI connector. 3) Remove screws (B) from the Side Terminals. 4) Remove screw (C) from the Side HDMI connector (V41+ only). 5) Remove screws (D). B 6) Lift the PWB-MAIN out of the chassis.

A

DVI

D

C (V41+)

PWB-MAIN Installation
1) 2) 3) 4) Install screws (A) (B) and (C) first. Then install screws (D). Perform "Restore Engine Data From Backup" (See Data Transfer in Service Adjustments section). Perform "Restore Geometry Data From Backup" (See Data Transfer in Service Adjustments section). Page 9

HDMI

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

OPTICAL ENGINE ASSEMBLY
OPTICAL ENGINE ASSEMBLY - COMPONENT AND CONNECTOR LOCATIONS (Rear View)
J10 DYNAMIC BLACK J8 SIROCCO FAN

J9 SMOOTH PICTURE

J4 EXHAUST J5 FAN DMD FAN

J3 THERMAL SENSOR

DMD FAN
J12 DVI PE2 POWER

CD LAMP DOOR SWITCH

LAMP CARTRIDGE BALLAST

OPTICAL ENGINE

DUCT ASSEMBLY

CJ1 BALLAST POWER

CJ3 LAMP CONTROL

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 connectors CJ1, 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.

RETAINING HOOKS

CJ4 (HV To Lamp) CJ3 CJ1 LATCH

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 REPLACEMENT

OPTICAL ENGINE
J12 DVI PE2 POWER

CD LAMP DOOR SWITCH

CJ1 BALLAST POWER

CJ3 LAMP CONTROL

LAMP CARTRIDGE BALLAST

A

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 Upper Duct Assembly Removal Procedure
1) Loosen two screws (A) and remove the Lamp Cartridge. 2) Disconnect the Exhaust and Sirocco Fan Connectors (J4 and J8) from the back of the Engine and loosen the wiring harnesses from the looms, refer to previous page for connector locations. 3) Remove screw (B) from the top of the upper duct and release the latches shown in Figure 2. 4) Remove the Upper Duct assembly from the Optical Engine.

UPPER DUCT

LAMP CARTRIDGE A BALLAST

LOWER DUCT

Figure 1: Duct Assembly (Rear View)
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 (Continued)
Latch

Latches

B

Latch

Figure 2: Duct Assembly (Top View) DUCT INTERIOR COMPONENTS
1) Figure 3 shows the Duct Interior Components. 2) The Upper Duct must be removed to replace the Lamp Door Switch PWB, Sirocco Fan, Exhaust Fan and Thermal Sensor (1 screw). 3) When replacing the Engine, transfer the Duct Interior Components from old Engine 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.
FLANGES Align Onto GUIDE PINS
SIROCCO FAN (Label Facing Up) THERMAL SENSOR (Behind Lamp Housing) EXHAUST FAN HOLDERS (3) (1 Top - 2 Bottom) EXHAUST FAN (Label Facing Inside)

PWB LAMP DOOR SWITCH

Figure 3: Lower Duct (Top View)
Page 12

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

OPTICAL ENGINE REPLACEMENT (Continued)
UPPER DUCT

OPTICAL ENGINE

C

LOWER DUCT

Figure 4: Lower Duct Rear Mounting Screw

C

Figure 5: Lower Duct Front Mounting Screw LOWER DUCT REMOVAL
1) Remove Upper Duct, Fans, Fan Holders, Thermal Sensor and Lamp Cartridge. See previous page. 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) Carefully remove the lower duct from the Engine.

ENGINE Replacement (Reverse the Removal Procedure)
1) 2) 3) 4) Install Duct Assembly on the new Engine. Remove the Protective Lens Cover from the face of the Lens and place it on the old Engine. Install the Engine Assembly in the cabinet. After a new Engine is installed, perform the "Restore Index Delay" and "Save Engine and Geometry Setting to Backup" procedures as described in the Data Transfer section of the Service Adjustments. 5) If needed. perform the Horizontal and Vertical Centering Adjustment and Manual Geometry Alignment described in Service Adjustments.

Page 13

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 (Bad Motor Bearing) Solarized Picture NOTE: Before replacing the Color Wheel, check the Index Delay Adjustment.

COLOR WHEEL REPLACEMENT PROCEDURE
CAUTION: This procedure should be performed in a dust free environment. Any dust entering into the color wheel chamber can cause abnormalities in the picture. 1) Remove Engine Assembly and cover the projection lens to protect it from scratches. 2) Remove the TOP DUCT. 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.
A COLOR WHEEL COVER J6 J7

Figure 1: Color Wheel Cover and Connectors
B
6) Remove 3 screws (B) shown in Figure 2. 7) Use the Handle to lift the Color Wheel from the chamber. 8) For installation, reverse the procedure above. CAUTION: Use care to prevent scratching the Color Wheel. NOTE: Do not twist the ribbon cable to J6 (the shiny silver contacts must be facing up). 9) After re-assembly, perform the Index Delay Adjustment described in the Service Adjustments section.

COLOR WHEEL HANDLE

Figure 2: Color Wheel
Page 14

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

PROJECTION LENS REPLACEMENT
PROJECTION LENS REPLACEMENT PROCEDURE
CAUTION: Any dust or fingerprints in the optics can cause abnormalities in the picture. This procedure should be performed in a dust free environment. Wear lint free cotton or rubber gloves while performing this procedure. 1) Remove Engine Assembly. 2) Remove screws (A) and rotate the Lens Collar off the Lens in the direction indicated while carefully releasing the foam adhesive from the Lens

COLLAR A

3) Remove screws (B) from the Lens Mask and slide the mask off in the direction indicated. 4) Lift out the Projection Lens. 5) Install the replacement lens so the key is oriented towards the top as shown. For reassembly, reverse the disassembly procedure. Use thread locker to secure screws (B).

KEY

B LENS MASK
ve Remo
LENS

Page 15

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

SCREEN REPLACEMENT 60", 65" & 73" Models
Screen Assembly Removal and Replacement
1) Open the front control panel door. (V41+ Only) Pull away Speaker Covers followed by Center Escutcheon. 2) Remove three screws (A) (two screws WD-73837). 3) Remove screws (B) around the rear edge of the screen betzel. NOTE: Leave one screw secure at the top. Then support the assembly to prevent it from falling while removing the remaining screw. 4) During re-assembly replace screws in their original locations.

V41+

SPEAKER COVERS (ORNAMENT LEFT & RIGHT) CENTER ESCUTCHEON (ORNAMENT CENTER)

A

DOOR

B

B
60 INCH

B

B

B

B

B

65 INCH

73 INCH

B

B B

B

B

B

B

B

Page 16

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

Screen Removal From the Bezel-Front
1) Remove screws (A) and remove the top, bottom and side rails. 2) Lift the Fresnel Lens and Lenticular screen from the Bezel-Front. 3) During re-assembly replace screws in their original locations.

A

A

60 & 65 INCH
(Rear View)

A

A

A

A

73 INCH
(Rear View) A

Page 17

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

SCREEN REPLACEMENT 60", 65" & 73" Models (continued)
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) After removing the top, bottom and side HOLDER-SCREEN rails and their cushions from the Bezel, lift the screens as a single unit from the frame. 2) 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.

SCREEN LENTICULAR LENS FRESNEL LENS-TAPE BEZEL FRONT

HOLDER-SCREEN-T SPACER-SCREEN-T

COVER-HOLDER-T
LABEL

LABEL

SPACER-SCREEN-S HOLDER-SCREEN-B HOLDER-SCREEN-S SPACER-SCREEN-B
Page 18

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

SCREEN REPLACEMENT 82" Models
Front Cover and Pedestal Removal
1) Remove screws (A) around the bottom rear edge. 2) Open the front control panel door and remove screws (B). 3) Lift the Pedestal and Front Cover away from the front.

A

A

FRONT COVER

B

B

PEDESTAL

Screen Assembly Removal
1) Remove screws (C) from the bottom front of the screen assembly.. 2) Remove screws (D) from the top rear edge of the screen bezel. NOTE: Leave one screw secure at the top. Then support the assembly to prevent it from falling while removing the remaining screw.

D

D

D

C

Page 19

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

SCREEN REPLACEMENT 82" Models (continued)
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 four screws (A) in all four corners of the Screen Bezel. 2) Remove the Screen Bezel components from the Screen/Lens Assembly.

A X4

CORNER-S-T

SCREEN/LENS ASSEMBLY

COVER-HOLDER-T CORNER-S-T

CORNER-CAP TOP-L

HOLDER-SCREEN S-L

CORNER-CAP TOP-R FRONT HOLDER-SCREEN S-R LABEL

CORNER B-L HOLDER-SCREEN-B CORNER B-R

Page 20

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

SCREEN REPLACEMENT 82" Models (continued)
Lenticular Screen and Fresnel Lens Disassembly
1) Remove the HOLDER-SCREEN from the top, bottom and sides. 2) Separate the Lenticular Screen and Fresnel Lens.

HOLDER-SCREEN LENTICULAR SCREEN
LENS LENTICULAR SCREEN

HOLDER-SCREEN (TOP/BOTTOM)(SIDES)

FRESNEL LENS

FRONT

Label Position (Facing Outside)

Lenticular Screen and Fresnel Lens Replacement
1) Place the Fresnel Lens on top of the Lenticular Screen with the labels facing outside as shown. 2) Install the HOLDER-SCREEN, top, bottom and sides as shown above. 3) Reverse the disassembly procedure to reassemble and install the screen frame assembly. NOTE: The Lenticular Screen must face the front and the Fresnel Lens must face the rear.

Page 21

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

MIRROR REPLACEMENT
MIRROR REPLACEMENT - 60", 65" & 73" Models
1) 2) 3) 3) To access the Mirror for replacement, remove the Screen Assembly (See Screen Assembly Removal). The Mirror slides down into the Left, Right and Bottom Brackets inside the cabinet. For 73" models, a Top Bracket is installed. See the Mirror Parts section for instructions on preparing a replacement mirror.

TOP BRACKET (73" Models)

SUPPORT BRACKETS

MIRROR REPLACEMENT - 82" Models
1) To access the Mirror for replacement, remove screws (A) and lift away the Mirror Cover. 2) The Mirror rests in place below the Mirror Cover. 3) See the Mirror Parts section for instructions on preparing a replacement mirror.

A

A

MIRROR (Below Cover)

A

Page 22

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

SPEAKER REPLACEMENT
1) 2) 3) 4) 5) Remove the Screen Assembly to access the speakers. Remove screws (A) and remove the Speaker Assembly from the cabinet. Disconnect the leads to the speaker. Remove screws (B) to remove the speaker from the speaker cover. Reverse the procedure to install a replacement speaker.
B
SPEAKER SPEAKER COVER

B

CUSHIONS

SPEAKER ASSEMBLY

CUSHIONS

A

PWB-SBL REPLACEMENT
V41+ Models Only
1) 2) 3) 3) 4) Remove the Screen Assembly. Remove screws (A) to remove the PWB-SBL assembly. Disconnect the electrical connector. Release the latches to remove the PWB-SBL from the Holder. Reverse the procedure to install a replacement PWB-SBL.

V41+ SBL ASSEMBLY

A

PWB-SBL
Page 23

HOLDER

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

REMOTE CONTROL
REMOTE CONTROL USE FOR SERVICE
Many service functions and adjustments are accessed using the Remote Control. The V41 uses a new version remote. Service functions and adjustments can be performed with either the old or new versions. However, several buttons have different names or labels. The remote buttons associated with service that have been changed are shown below with the old buttons' name in parenthesis. For full remote instructions, refer to the Owner's Guide. NEW BUTTON NAME (OLD BUTTON NAME)

ACTIVITY (INPUT or DEVICE)

BACK (EXIT) PAGE UP (AUDIO) LAST (QV) PAGE DOWN (VIDEO)

Page 24

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

OPTION MENU
OPTION MENU
1. Press the button on the remote control. 2. Press the buttons <2-4-7-0>. The screen will display the Option Menu.

Option Menu <2-4-7-0>

Initialize Power Restore Production Mode Digital Signal Strength NetCommand Software Total hours of use

OFF OFF <1~9> Vxx xxx.xx 0

DIGITAL SIGNAL STRENGTH
1. Tune to a Digital Channel. 2. From the Option Menu, scroll down and highlight "Digital Signal Strength." 3. Press . The screen will display the Digital Signal Strength Menu.

Digital Signal Strength Menu "Digital Signal Strength"

Frequency(MHz) Signal Level Modulation Carrier Lock SNR Correctable errors Un Correct able errors

Tuner 749 <1~9> 8VSB Air Locked 29.09 0 0

SNR Recommended Levels: 8VSB = 16 to 33 64 QAM = 22 to 35 256 QAM = 27 to 38

Page 25

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

RESET / INITIALIZATION
SERVICE TIP: Many customer generated symptoms, intermittent symptoms or no symptom found can be resolved by using the various Reset and Initialization options. Before visiting the customer's home ask the customer 1st perform a System Reset by pressing the button on the front panel and holding it for 8 seconds. If this does not resolve the issue, they can perform an A/V Reset by pressing the + buttons on the front panel at the same time and holding for 10 seconds. Then, if necessary, perform a user level Initialization by pressing <1-23> with the remote. The customer should be made aware when settings and/or options will be reset. For more information, see the chart below.

Reset / Initialization Guide
Reset Name When to use
Remote Control TV Layer Res et Returns the remote control TV layer to normal operation. 1) 2) 2) 3) 3) 1) 2) 2) 3)

How to use
Set the s lide switch to TV position. Press and hold the button until it flashes twice then releas e the button. Enter the code <0-0-9-3-5>. (1) Set the slide switch to TV position. (2) Press and hold the button until it flashes twice then releas e the button. (3) Enter the code <9-9-3>< + >.

Resulting Action
Once the valid code has been entered and confirmed, the remote contrrol has been reset. The remote will now operate the TV's volume and mute when the slide s witch is in the TV, CABLE/SAT, VCR or DVD positions. All Audio and Video settings for the individual input are reset except for the Listen To, Language, Balance and Closed Caption settings. All Audio and Video settings are reset to the factory default settings. No other menu options are changed. TV Micro Re-boots. Note: The changes made during the current TV-On period may be lost. All other previous user settings are not lost. All customer menu options and A/V settings except V-Chip are reset to factory default. All customer menu options and A/V settings are reset to factory default. Password will be bypassed. If in the VChip menu, enter a new password. Front Panel becomes operational. Other VChip settings not changed. Note: Cannot be performed while in the Low Power mode and the set is Off.

Remote Control TV Volume/Mute functions

A/V Memory Reset, by individual input

Returns the volume and mute functions of the remote control to TV volume and mute for TV, Cable/Sat, VCR and DVD layers after the Audio Lock for AV Receiver feature has been used. When the audio and or video s ettings for a single input s eems to be incorrect.

MENU --> Audio/Video--> AV Reset

A/V Reset, all To reset audio and video While viewing the TV, press the front panel buttons inputs adjustments for all inputs to the + at the same time and hold original factory settings. for 10 seconds.

System Reset

To reset the TV when it does not Press the button on the front panel and turn on or off, does not respond hold it for 8 seconds. to the remote control, front panel buttons or has other unusual s ymptoms.

Initialize User To reset all customer settings Level except V-Chip

Press <1-2-3>

Initialize To reset all customer settings Service Level

<2-4-7-0>. Highlight INITIALIZE and press

V-Chip Password Bypass

If V-Chip password is not known Press <

>+<9> at the same time.

Unlock Front To unlock the front panel if it has Press and hold the front panel button Panel been locked in the V-Chip Menu. for 8 seconds.

Page 26

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

RESET / INITIALIZATION (Continued)
INITIAL SETTINGS Audio/Vide o Settings Video Picture M ode Brilliant Contrast Brilliant Brightness Color Tint Sharpness Brilliant Color Temp. Deep Field Imager (V41+) Video Noise (Off-Low-M id-High) Audio Speakers Bass Treble Balance Sound Mode Listen To (Analog only) Language (Digital only) Level Sound Global Video Noise(High-M ed-Low-Off) Video Mute Audio only screen saver Film Mode Test Picture Blue Glow (V41+ only) 3D Mode Ca ptions Me nu Closed Captions Analog Captions Background Digital Captions Digital Settings Font Font Size Font Color Font Opacity Background Color Background Opacity Pa re nta l Lock M e nu Lock TV Rating M ovie Rating Time Lock by Time Lock Tim e Unlock Time Front Panel Front Button Lock TV Volum e Se tup Me nu Language (idioma) English Scan Ant1 Air -Ant1 Cable -Start Edit Channel in Mem ory All Added Name -FAV1 ~ FAV6 unchecked Lock Unlock Clock Settings M anual Time 12:00PM Date 1/01/08 Time Zone Eastern Daylight Savings Applies Timer Timer Off Day Daily Time 12:00PM Input ANT-1 Channel 2 Energy Lam p Mode Standard 3D Mode Gray out Standard Inputs Me nu Name Ant-1 On Input-1 Gray out Input-2 Gray out Input-3 (Front) Gray out Comp-1 Gray out Comp-2 Gray out Comp-3 (Front) Gray out HDMI-1 Gray out HDMI-2 Gray out HDMI-3 Gray out HDMI-4 (Side) (V41+) Gray out Order Gray out Learn (V41+) Gray out A/V Receiver (V41+ ) Gray out Learn Gray out Learn/Name Ant-1 Ass ign Input 1 --(Gray out for Ant) Ass ign Input 2 Gray out until auto Ass ign Input 3 sensing Ass ign Input 4 -Form a t Ant-1 (HD Digital) Standard Input-1, 2, 3 Stretch HDMI-1, 2, 3, 4 (Video or PC) Standard USB Photo --

Brilliant 100% 50% 50% 50% 50% High On Medium (A/V Rec eiver) 50% 50% 50% Off --Normal English On Medium Medium Auto On Auto --On if TV On Gray out

On if Mute Gray On if Mute Default Large W hite Translucent Black Translucent Off Gray until On Gray until On Off 12:00PM 12:00PM Off 30

Page 27

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

RESET / INITIALIZATION (Continued)
A. A/V Memory
Each of the external inputs has it's 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. Press the front panel and buttons at the same time to initialize the A/V Settings for all Inputs. 2. The AV Reset in the user's menu initializes only the A/V Memory for the currently selected input.

A/V Initial Settings
A/V Memory Picture Mode Contrast Brightness Color Tint Sharpness Color Temp. Perfect Color Perfect Tint (V41+) Deep Field Imager (V41+) Video Noise Film Mode SharpEdge (V41+) Bass Treble Balance Sound mode Listed To Level Sound Language (Digital only) Vertical Position Horizontal Position Ant Brilliant MAX Center Center Center Center High Center Center On Medium Auto On Center Center Center Normal Stereo On English n/a n/a Input Brilliant MAX Center Center Center Center High Center Center On Medium Auto On Center Center Center Normal n/a On n/a n/a n/a Comp Brilliant MAX Center Center Center Center High Center Center On Medium Auto On Center Center Center Normal n/a On n/a n/a n/a HDMI (Video) Brilliant MAX Center Center Center Center High Center Center On Medium Auto On Center Center Center Normal n/a n/a n/a n/a n/a HDMI (PC) Bright MAX Center Center Center Center High Center Center n/a Medium n/a On Center Center Center Normal n/a n/a n/a Center Center HDMI (PC 3D) Bright MAX Center Center Center Center High Center Center n/a Medium n/a Off Center Center Center Normal n/a n/a n/a Center Center USB (JPEG) Brilliant MAX Center Center Center Center High Center Center On Medium n/a On Center Center Center n/a n/a n/a n/a n/a n/a

Page 28

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

LED INDICATIONS AND SELF DIAGNOSTICS
The front panel Status LED provides an indication of the set's operation and the possible cause of a malfunction.
NORMAL INDICATIONS STATUS LED Indication Condition Off Off (standby) Green Power On Slow Blink Green Power Off with Timer Set Fast Blink Green (80 seconds) > Off Power Off (Cooling fan still working, 80 sec) ABNORMAL INDICATIONS (For details perform Self Diagnostics procedure.) STATUS LED Indication Condition Red Lamp Failure Yellow TV Too Hot Slow Blink Red TV May Require Service Slow Blink Yellow Lamp Door Open or No Lamp Installed

-

VOL

+

-

CH

+

ACTIVITY

STATUS

POWER

ENTER

Front Panel (Location and Appearance Differs by Model) SELF DIAGNOSTICS
To activate, press the front panel + buttons at the same time and hold for 5 seconds. The STATUS LED will then flash denoting a two digit code. · 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. Note: The TV must be in "Shut Down" and the LED will probably be indicating an abnormal condition. If the TV is switched Off, AC is removed, or a System Reset is performed, the code automatically resets to "12" No Error. See the Error Code Log to retrieve a history of errors. Note: Use the front panel buttons, not the remote control. Note: If there is no response, the front panel may be locked by a V-Chip setting. To unlock, press and hold on the front panel for 5 seconds.

Page 29

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

ERROR CODES
Error Codes, descriiptions and the most likely cause of the error are listed below:

ERROR CODES
Code 12 17 18 32 34 36 37 38 39 42 44 48 Engine will not accept data (ASIC-READY signal from Engine is not detected). Lamp cover is open. Lamp turns Off while the TV is playing. Lamp failure (Lamp Enable signal from engine is lost) Exhaust Fan failed. Engine (DMD) fan failed. Lamp temperature abnormally high. DMD temperature abnormally high. Sirocco fan failed (Lamp fan). Check for disconnected DVI cable between PWB-MAIN and Engine. (Engine pulls DVI pin 14 Low) PON-SHORT 3.3V or 5V switched supply short Description No Error found Communication loss, TV Micro - Engine (3.3V-ENG-SDA & SCL) Most Likely Cause Loss of 12V from PWB-POWER to Engine (Loose PE or PE2 connector). Engine Failure Engine Failure Lamp Cover Switch (Loose CD connector) Lamp Cartridge Failure (Loose J4 connector) (Loose J5 connector) Poor Air Circulation (Loose J3 connector) Poor Air Circulation (Loose J8 connector) DVI Cable unplugged PWB-MAIN Failure Loss of 340V from PWB-POWER to Ballast (Loose PL or CJ1 connector); Loss of communications between PWB-MAIN and Ballast (Loose FB or CJ3 connector). Ballast Failure Bad Color Wheel (Loose J6 or J7 connector) (Loose CJ4 connector) No Lamp Inserted. HV connection or lead wire to lamp. Lamp Cartridge Failure

57

Ballast communication problem (ballast to chassis)

61 66

No LAMP-EN output from the engine to the ballast Lamp did not turn on at P-ON sequence (No Lamp inserted) (Disconnected cable between ballast and lamp) (Lamp-Enable goes to PWB-MAIN but not to Ballast)

Code 34 - Lamp Enable is generated to activate the Lamp Code 57 - Lamp Enable is generated during P-ON sequence, but no Lamplit signal is received from the Ballast. Code 61 - No Lamp Enable is received at the PWB-MAIN and Ballast. Code 66 - Lamp enable is received at the PWB-MAIN but not at the Ballast.

ERROR CODE LOG
The Error Code Log may be helpful to retrieve the code for an error that occurred in the past. To access the Error Code Log: Press <3-5-6-4> Error Code Definitions · PAGE - Current page number · CURRENT TIME - total hours of operational use. · LAMP TIME - usage hours when the error occurred. · CODE - the specific Error Code that occurred. · STATUS: HAPPENED - Indicates an error was recorded. Press to erase the Log. Note: Lamp Cover errors (32) are not recorded.

***** PAGE (001/001) *****
CURRENT TIME: 01455 HOURS LAMP TIME CODE STATUS
00413 HRS 00716 HRS 00905 HRS 57 17 66 HAPPENED HAPPENED HAPPENED Press Up t o Previo us Page Press Do w n t o Next Page Press Right t o Top Page Press Left t o Last Page Press CANCEL t o Init ialize Press M ENU t o Exit

NOTE: The Error Code Log is intended as a reference tool and is not meant to be used as a final determination of a
defective part. Page 30

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82827 WD-65837 / WD-73837 / WD-82837

SERVICE ADJUSTMENTS
There are 4 Service Adjustments:

Electrical Adjustments (there are no mechanical adjustments)
· · · · Horizontal and Vertical Centering Adjustment Index Delay Adjustment Geometry Alignment Data Transfer Functions

Test Equipment and Test Patterns
· · · Remote Control Internally generated Test Patterns No external test equipment or pattern generators are required.

SERVICE MODE
The Service Mode is used for all service adjustments. Service adjustments may only be performed using the remote control.

1. Activating the Service Mode
1. Press the button on a remote control. (The "MENU" display will appear.) 2. Press the buttons <2-4-5-7>. (The Service Mode On Screen Display will appear.) If no display appears, press and repeat steps 1 and 2.

Service Mode <2-4-5-7>

SE RVICE Function Adjustment TVM
1. HVPOS -3 4

Data (HPOS) Data (VPOS)

2. Test Pattern Activation
When in the Service Mode, press Play < > to activate the internal test patterns (no indication will be displayed initially). Use Fast Forward < > and Rewind < > to select a specific pattern.

3. Adjustment Function
Service adjustments are performed in the TVM mode. No other Adjustment Functions are available.

4. Adjustment Selection
Use the Page Down < > button to select a specific electrical adjustment, i.e. "1.HVPOS."

5. Adjusting Data
After selecting an adjustment item, use the Navigation < > buttons to perform the adjustment.

6. Saving Data
Press to save the adjustment data. The menu display will turn red for approximately one second. Note: If the circuit adjustment mode is terminated without pressing , changes in adjustment data are not saved.

7. Data Transfer & Geometry Menu
While in the Service Mode, press the <0> button to activate the Data Transfer & Geometry Menu. Page 31

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82827 WD-65837 / WD-73837 / WD-82837

Horizontal and Vertical Position Adjustment
1. Enter the Service Mode <2-4-5-7> . 2. Select the Geometry Test Pattern shown below < >< 3. If necessary, select the adjustment, "1.HVPOS" < >. > x2.

SERVICE TVM
1.HVPOS -3 4

Adjustment Data (HPOS) Data (VPOS)

4. After selecting the HVPOS adjustment item, use the Navigation < > buttons to center the display. · If a Up/Down < > button is pressed, the vertical position and VPOS adjustment data changes. · If a Right/Left < >button is pressed, the horizontal position and HPOS adjustment data changes. 5. Press to save the adjustment data.

Index Delay Adjustment
1. Enter the Service Mode <2-4-5-7> . 2. Select the Ramp Pattern shown below < >< 3. Select the adjustment, "60.IDL" < >. > x3.

SERVICE TVM
60.IDL 35

Adjustment Data

4. After selecting the IDL adjustment item, use the Navigation < > buttons to adjust the Ramp Pattern color bars so they are smooth and solid. HINT: The data value is typically in the mid 30's. 5. Press to save the adjustment data.

Page 32

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82827 WD-65837 / WD-73837 / WD-82837

Manual Geometry Alignment
Activate the Service Mode <2-4-5-7>. From the Service Menu, press the <0> button. The Data Transfer & Geometry Menu will appear. 2. Use the < > buttons to select "MANUAL GEOMETRY ALIGNMENT" and press . The Manual Keystone Geometry Alignment Pattern will appear. See below. Note: To remove all geometry correction, while the Geometry Alignment Pattern is displayed, press <1> then . This will null all correction data. Then re-enter the Manual Geometry Alignment mode by repeating step 2. Note: To restore the original factory correction data, select "RESTORE GEOMETRY DATA FROM BACKUP" and press . 1.

Data Transfer & Geometry Menu <2-4-5-7><0> RESTORE ENGINE DATA FROM BACKUP RESTORE GEOMETRY DATA FROM BACKUP MANUAL GEOMETRY ALIGNMENT RESTORE INDEX DELAY SAVE ENGINE AND GEOMETRY SETTING TO BACKUP Warning - Only use "SAVE ENGINE AND GEOMETRY SETTING TO BACKUP" after Optical Engine replacement.

Cursor +

+
Adjustment Points (16 Total)

Align Cursor + Flush With Bezel Edge

Phase 1 - 16 Point Geometry Alignment 1. 16 Adjustment Points are indicated by white dots around the edge of the raster. The adjustment position is indicated by a + cursor. 2. Starting from the upper left corner, use the < > buttons to align the + at each point in a straight line, flush with the bezel as a reference. See example above. Note: Only the cursor will move. The Geometry Pattern will not change. 3. After adjusting each point, use the < > button to shift the cursor to the next point clockwise and repeat until all 16 points have been adjusted. 4. After all 16 points are adjusted and the cursor is returned to the original starting point, press . Correction will be automatically calculated and saved and the Manual Geometry Alignment will be terminated. 5. Press to re-activate the Manual Geometry Alignment. The geometry pattern will appear with the corrections applied.

Page 33

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82827 WD-65837 / WD-73837 / WD-82837

Phase 2 - 4:3 and 16:9 Alignment 1. With the Manual Geometry Alignment activated, press < > to enter the 4:3 Alignment Mode. The pattern below will be displayed. Note: Pressing < > will toggle between the 4:3,16:9 (top & bottom) and 16 Point Geometry Alignment modes. 2. In the 4:3 Alignment Mode, continuing to press < > will cause the geometry pattern to be displayed with 11 different preset amounts of correction. Continue pressing < > or < > to cycle through the 11 patterns until you find the one with the straightest Blue 4:3 Lines. It may help to count the patterns as you cycle through them. When you find the pattern with the straightest Blue 4:3 Lines, press < >. The Top 16:9 Alignment Mode will then be activated as indicated by the Top Red 16:9 Line displayed in the pattern.

4:3 MOD E

Select Straightest Blue Lines
3. In the Top 16:9 Alignment Mode, continuing to press < > will cause the geometry pattern to be displayed with 15 different preset amounts of correction to the Top Red 16:9 Line. Continue pressing < > or < > to cycle through the 15 patterns until you find the one with the straightest Top Red 16:9 Line. Again, count the patterns as you cycle through them. When you find the pattern with the straightest line, press < >. The Bottom 16:9 Alignment Mode will then be activated as indicated by the Bottom Red 16:9 Line displayed in the pattern.

4:3 MOD E

Select Straightest Red Line (Top)

Page 34

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82827 WD-65837 / WD-73837 / WD-82837
4. In the Bottom 16:9 Alignment Mode, continuing to press < > will cause the geometry pattern to be displayed with 10 different preset amounts of correction to the Bottom Red 16:9 Line. Continue pressing < > or < > to cycle through the 10 patterns until you find the one with the straightest Bottom Red 16:9 Line. Again, count the patterns as you cycle through them. When you find the pattern with the straightest line, press to exit and save the 4:3 and 16:9 data. Select the Geometry Test Pattern (See HVPOS). If Geometry is acceptable, press to quit. To touchup the raster geometry, proceed.

5.

4:3 MOD E

Select Straightest Red Line (Bottom)
Phase 3 - Geometry Touch-up Alignment 1. Enter the Manual Geometry Alignment mode. 2. Use the < > or < > button to shift the cursor to the point needing correction. 3. Use the < > buttons to indicate the direction and amount of correction necessary at the particular point. Note: Only the cursor will move. The Geometry Pattern will not change. 4. Press the button to apply the correction. The Geometry Pattern will now show the correction. 5. Repeat steps 2, 3 and 4 as needed. 6. Press to save your changes. The Manual Geometry Alignment will be terminated. 7. Press to exit the alignment mode.

Page 35

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82827 WD-65837 / WD-73837 / WD-82837

Data Transfer
Service Data is duplicated and stored in separate EEPROMs in two locations. · PWB-MAIN - Working data for TV operation · OPTICAL ENGINE - Backup data The Optical Engine also includes data for the Color Wheel Index Delay setting determined at the factory. Procedure: 1. Enter the Service Mode <2-4-5-7> Select the Data Transfer & Geometry Menu <0>
Da ta Tra nsfe r & Ge om e try M e nu < 2-4-5-7>< 0> RESTO RE ENGINE DATA FROM BACKUP RESTO RE GEOM ETRY DATA FROM BACKUP MANUAL GEO METRY ALIGNMENT RESTO RE INDEX DELAY SAVE ENGINE AND GEOM ETRY SETTING TO BACKUP W a rning - Only use "SAVE ENGINE AND GEOMETRY SETTING TO BACKUP" after Optical Engine replacement.

Note: Besides MANUAL GEOMETRY ALIGNMENT, four data transfer choices are listed on screen. · RESTORE ENGINE DATA FROM BACKUP - copies backup factory adjustments HVPOS, White Balanceand Index Delay from the Optical Engine to the PWB-MAIN. · RESTORE GEOMETRY DATA FROM BACKUP - copies backup factory Geometry Alignment data from the Optical Engine to the PWB-MAIN. · RESTORE INDEX DELAY - copies factory Index Delay Adjustment data from the Optical Engine to the PWB-MAIN. · SAVE ENGINE AND GEOMETRY SETTING TO BACKUP - copies all working data from the PWBMAIN into backup memory on the Optical Engine. 2. Use the < > buttons to select the data transfer item and press . 3. Press to quit. After Engine Replacement: 1. Restore Index Delay. 2. Save Engine and Geometry Setting to Backup After PWB-MAIN Replacement: 1. Restore Engine Data From Backup 2. Restore Geometry Data From Backup.

Page 36

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

Using Lead Free Solder
The symbol shown below indicates Lead (Pb) Free solder was used during the construction of PWBs. Only Lead Free solder should be used when servicing these PWBs. Solder must be compatible with that used by the manufacturer. Leaded solder can not be used on PWBs manufactured with Pb-free solder. The Mitsubishi standard for service requires the use of Tin-SilverCopper (Sn-96.5, Ag-3.0, Cu-0.5). It can be obtained through the Parts Department. Order part number: PB FREE SOLDER Lead Free solder has a higher melting point, and does not "wet" as well as leaded solder. This means it does not adhere as readily to the solder iron tip, and the surface to be soldered. To counteract this, the flux used is more corrosive. · · · · Poor wet-ability can cause solder balls. Higher temperatures can cause flux spattering. Soldering iron tip life is shortened. Dull finish solder joints (not shiny) can appear to be a "cold" solder joint.

In general a tip temperature of 700° F will usually provide good results.

Displays used to indicate Pb-free
PCBs will be marked, indicating the level of Pb-free construction. Table 1 defines the levels by phase and shows the different symbols that will be displayed on the PCB. Additionally, a PCB constructed using Pb-free solder may be simply marked LFS. When possible, the indication will be placed close to the part number that is screened onto the PCB (not the part label). Figure 1 is an example of a PCB showing the display and its location.

The following cautions must be taken when using Pb Free solder. · Higher temperatures can cause the PWB to warp, detaching surface mount components. · Higher temperatures may cause Pb-Free Short Display (When the thermal damage to components. Phase Definition Display area is too small) · Higher temperatures can cause Phase-1 PCB's constructed using plastics, such as connectors, Pb-free solder. relays, LEDs electrolytic capacitors, etc. to melt or warp. · Higher temperatures can cause Phase-2 Solder, PCB surface finishing and component surface oxidation resulting in lead plating is Pb-free. poor solder spread-ability and Components may have wet-ability. internal Pb. · The flux is more corrosive. Phase-3 Solder, PCB surface finishing and components · The time required for a good are Pb-free. (100% Pbsolder connection may take free) longer. Table 1: Pb-Free Phases and Symbols

Pb Solder

Pb S

Pb Joints

Pb J

Pb PCA

Pb P

Pb-Free Display

Pb Solder

Figure 1: Pb-Free display on PWB
Page 37

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

CHIP PARTS REPLACEMENT
Some resistors, shorting jumpers (0 Ohm resistors), ceramic capacitors, transistors and diodes are chip parts. The following precautions should be taken when replacing these parts. 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.

Page 38

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

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. Safety Critical Parts Designation Safety Critical Components are indicated in the Parts List by Bold Type and a schematic diagrams by a red hatch and a .
987654321 987654321 987654321 987654321 987654321

icon, and in the

Parts Tolerance Codes

MARK Tolerance %

B ± 0.1

C ± 0.25

D ± 0.5

F ±1

G ±2

J ±5

K ± 10

MARK Tolerance %

M ± 20

N ± 30

V ± 10

X + 40 -20

Z + 80 -20

P + 100 -0

Q + 30 -10

MARK Tolerance (pF)

M ± 0.1

N ± 0.25

V ± 0.5

X ±1

Z ±2

Page 39

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837

QUICK REFERENCE
ALL MODELS
PART La mp-Ca rtridge La mp Ba lla st Speaker Fan-Exhaust Fan-Scirocco (Lam p) Fan-Engine (DMD) Sensor-Temperature Module-Color-W heel PART NUMBER 915B403001 938P127010 480P084020 299P335010 299P321010 299P339010 299P337010 938P137010

PRINTED CIRCUIT BOARDS
MODEL W D-60737 W D-60C9 W D-65737 W D-65C9 W D-73737 W D-73C9 W D-82737 W D-65837 W D-73837 W D-82837 PW B-MAIN 934C328001 " " " " " " 934C328002 " " PW B-POW ER PW B-LAMP-SW PW B-CONT 934C329001 934D059001 934D060001 " " " " " " " " " " " " " " " 934D060002 " " " " " " " " " PW B-LED 934D057001 " " " " " X X X X PW B-RS232 PW B-PREAMP X 934D058001 X " X " X " X " X " X " 934D062001 934D058002 " " " "

OPTICAL EN GINE & MISC . PARTS
MODEL W D-60737 W D-60C9 W D-65737 W D-65837 W D-65C9 W D-73737 W D-73C9 W D-73837 W D-82737 W D-82837 OPTICAL ENGINE 938P158010 " 938P158020 955B378003 938P158020 938P158030 " 955B378004 938P158040 955B378005 FRESNEL LENS 491P218010 " 491P218020 " " 491P218030 " " 491P231010 " LENTICULAR SCREEN 491P217040 " 491P217050 " " 491P217060 " " 491P231010 " M IRROR KIT KIT-MIR V41 " KIT-MIR V41 " " KIT-MIR V41 " " KIT-MIR V41 " 60" 65" PROJECTION LENS 491P 240010 " " " " " " " " " REMOTE 290P175010 " " " " " " " " "

73"

82"

Page 40

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837
[#] Model Legend: (a) WD-60737, (b) WD-60C9, (c) WD-65737, (d) WD-65837, (e) WD-65C9, (f) WD-73737, (g) WD-73837, (h) WD-73C9, (i) WD-82737, (j) WD-82837 Ref # Part # Part Name & Description [#] Ref # Part # Part Name & Description [#]

INTEGRATED CIRCUITS
IC1B01 271P171010 IC - MIC2040-1YMM IC1B02 265P151010 VARISTOR - AVF16C225A000F405 IC2A01 276P726010 IC-C-MOS - SiI9287CNU IC2A51 276P742020 IC-C-MOS - PST8428NR IC3A00 276P733010 IC-C-MOS - YDA156-VZ IC3C00 276P741010 IC-C-MOS - AK4420ETP IC4A01 276P742020 IC-C-MOS - PST8428NR IC4A02 276P687010 IC-C-MOS - BCM3549LKFSB5G IC4F01 276P744010 IC-C-MOS - NT5TU64M16DG-AC IC4F02 271P033020 IC - LP2996LQNOPB IC4F03 276P744010 IC-C-MOS - NT5TU64M16DG-AC IC4G01 271P251040 IC - MM1662FHBE IC4L01 276P485010 IC-C-MOS - SC16C652BIB48 IC4L02 276P740010 IC-C-MOS - LC4064ZE-7TN48C IC4L03 276P545090 IC-C-MOS - NAND01GW3B2CN6E-P IC4L05 276P628010 IC-C-MOS - PL671-33-120SC-R IC5A01 276P722010 IC-C-MOS - UPD808526F1-S11-MNJ-A IC5A02 271P319010 IC - MM1701AHBE IC5A03 271P319010 IC - MM1701AHBE IC6C00 276P336010 IC-C-MOS - SiI7170CMHU IC6C02 271P251020 IC - MM1663DHBE IC7A01 276P576010 IC-C-MOS - UPD78F1178GF(S)-GAT-AX IC7A03 276P578020 IC-C-MOS - MM3376A33NRE IC7E01 276P519010 IC-C-MOS - 74HC132DB IC8300 276P525010 IC-C-MOS - MAX4489ASA+T IC9010 267P324010 HIC - STR-W6754 IC9020 271P142010 IC - RT9H301C IC9030 271P315010 HIC - STR-A6159 IC9031 271P142010 IC - RT9H301C IC9A01 271P254010 IC - ISL6545ACBZ-TS2698 IC9A02 271P254010 IC - ISL6545ACBZ-TS2698 IC9A03 271P254010 IC - ISL6545ACBZ-TS2698 IC9A04 276P578020 IC-C-MOS - MM3376A33NRE IC9A06 271P321010 IC - PST8242NR IC9A07 271P321010 IC - PST8242NR IC9E01 275P989010 IC-C-MOS - MAX3223ECAP IC9G80 271P171010 IC - MIC2040-1YMM D2A11 D2A12 D2A13 D2A21 D2A22 D2A23 D2A31 D2A32 D2A33 D2A41 D2A42 D2A43 D2A52 D4A03 D4A04 D4A05 D4A06 D4A07 D4A08 D7A03 D7A04 D8000 D8200 D8300 D8301 D8701 D8702 D8703 D8704 D8705 D8706 D8707 D8708 D9001 D9005 D9006 D9008 D9009 D9010 D9011 D9012 D9013 D9014 D9018 D9019 D9020 D9022 D9023 D9024 D9026 D9031 D9A01 D9A02 D9A03 D9A04 D9A06 D9A08 D9A09

DIODES
262P880080 DIODE-CHIP - MAZ8051GHL 262P830010 D-CHIP - MC2850-T111-1 262P830010 D-CHIP - MC2850-T111-1 262P880080 DIODE-CHIP - MAZ8051GHL 262P830010 D-CHIP - MC2850-T111-1 262P830010 D-CHIP - MC2850-T111-1 262P880080 DIODE-CHIP - MAZ8051GHL 262P830010 D-CHIP - MC2850-T111-1 262P830010 D-CHIP - MC2850-T111-1 262P880080 DIODE-CHIP - MAZ8051GHL 262P830010 D-CHIP - MC2850-T111-1 262P830010 D-CHIP - MC2850-T111-1 262P830010 D-CHIP - MC2850-T111-1 262P163010 D-CHIP - MALS068X0L 262P163010 D-CHIP - MALS068X0L 262P830010 D-CHIP - MC2850-T111-1 262P830010 D-CHIP - MC2850-T111-1 262P163010 D-CHIP - MALS068X0L 262P163010 D-CHIP - MALS068X0L 262P830010 D-CHIP - MC2850-T111-1 262P828020 D-CHIP - MC2836-T112-1 264P584020 DIODE-LE - SML1216W-C,D 264P584020 DIODE-LE - SML1216W-C,D 262P828010 D-CHIP - MC2838-T112-1 268P100010 DIODE-PHOTO - SFH235FA 262P855010 D-LE-CHIP - LB E6SG-S2U1-35-1 262P855010 D-LE-CHIP - LB E6SG-S2U1-35-1 262P855010 D-LE-CHIP - LB E6SG-S2U1-35-1 262P855010 D-LE-CHIP - LB E6SG-S2U1-35-1 262P855010 D-LE-CHIP - LB E6SG-S2U1-35-1 262P855010 D-LE-CHIP - LB E6SG-S2U1-35-1 262P855010 D-LE-CHIP - LB E6SG-S2U1-35-1 262P855010 D-LE-CHIP - LB E6SG-S2U1-35-1 262P200010 DIODE - D6SB80-7001 262P170010 DIODE - SARS01 262P203070 DIODE - UF4007 262P201060 DIODE - 1N4006 262P201060 DIODE - 1N4006 262P201060 DIODE - 1N4006 262P201060 DIODE - 1N4006 264P045080 DIODE - 1S2076A/1S2471OM 262P084010 DIODE - 31DQ06 264P774020 DIODE - MTZJ4.7A,B,CQLF 264P045080 DIODE - 1S2076A/1S2471OM 264P045080 DIODE - 1S2076A/1S2471OM 264P045080 DIODE - 1S2076A/1S2471OM 264P775080 DIODE - MTZJ6.2CQLF 262P085010 DIODE - 11EFS2N-TA2B5 262P085010 DIODE - 11EFS2N-TA2B5 262P208010 DIODE - FCHS10A12-15A 262P210010 DIODE - 30PHA20-FC5 262P852010 D-CHIP - BAT54S 262P852010 D-CHIP - BAT54S 262P882020 DIODE-CHIP - MAZ8160GHL 262P882010 DIODE-CHIP - MAZ8150GHL 262P828010 D-CHIP - MC2838-T112-1 262P828010 D-CHIP - MC2838-T112-1 262P900010 DIODE - FLZ3V9A T&R 2500/reel

dgj dgj dgj

dgj dgj

dgij abcefh dgj dgj dgj dgj dgj dgj dgj dgj dgj dgj

dgj

TRANSISTORS
CHIP Type Transistors (Listed by Part No.)

Part No. 261P842080 261P844010 261P845010 261P875010 261P877010 261P878010 261P881010 261P889010

Description 2SC3052-T112-1E;F RT1N436C-T112-1 RT1P241C-T1112-1 FDS8984 FDC655BN RT3Y97M-T111-1 2SB1424T100R ISA1235AC1-T112A-1E,1F

PAGE 41

MODELS: WD-60C9 / WD-65C9 / WD-73C9 / WD-60737 / WD-65737 / WD-73737 / WD-82737 WD-65837 / WD-73837 / WD-82837
[#] Model Legend: (a) WD-60737, (b) WD-60C9, (c) WD-65737, (d) WD-65837, (e) WD-65C9, (f) WD-73737, (g) WD-73837, (h) WD-73C9, (i) WD-82737, (j) WD-82837 Ref # Part # Part Name & Description [#] Ref # L5F07 L6C00 L6C01 L6C02 L6C03 L6C04 L6C05 L6C06 L6C08 L6C14 L6C24 L6C46 L6C94 L7A01 L7A02 L7C02 L7C03 L8300 L9001 L9002 L9005 L9A01 L9A02 L9A03 L9A05 L9A06 L9A07 L9A11 L9A12 L9A13 L9A14 L9A15 L9A16 L9A17 L9A18 L9E03 L9G80 L9G81 T4G01 T4G02 T4G03 T4G04 T4G05 T4G06 T6C01 T6C02 Part # Part Name & Description [#]

COILS
L1A02 L1A04 L1B01 L1B02 L1B03 L2A01 L2A92 L3A11 L3A13 L3A25 L3A28 L3A33 L3A36 L3C12 L4A01 L4A06 L4F01 L4F02 L4G01 L4G02 L4G03 L4G04 L4G05 L4G06 L4G07 L4G08 L4G09 L4G10 L4G11 L4G12 L4G15 L4G16 L4G17 L4G18 L4G19 L4G20 L4G21 L4G24 L4G25 L4L01 L4L02 L4L03 L4L04 L4L05 L5A01 L5A02 L5F06 409P975010 325C420070 409P975010 409P975010 409P979010 409P974010 409P975010 409P974010 409P9740