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Technical Training Manual
Including...
Down-to-1
High Speed Troubleshooting
V46
Chassis
Copyright © 2011 Mitsubishi Electric Visual Solutions America, Inc.
V46
L75-A94
All Rights Reserved
V45
Chassis
DLP
HOME CINEMA TV
V45C
V45
WD-73C11
WD-73640
V45+
V45++
WD-73740
WD-73840
WD-82740
WD-82840
WD-92840
T
ECHNICAL
RAINING
2011
2012
®
V45CA
WD-73CA1
V45CB
WD-82CB1

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   Summary of Contents for Mitsubishi Electric WD-73640

  • Page 1

    Technical Training Manual Including… Down-to-1 High Speed Troubleshooting L75-A94 Chassis ® HOME CINEMA TV Chassis V45C V45CA WD-73C11 WD-73640 WD-73CA1 V45+ V45++ V45CB WD-73740 WD-73840 WD-82CB1 WD-82740 WD-82840 WD-92840 Copyright © 2011 Mitsubishi Electric Visual Solutions America, Inc. All Rights Reserved...

  • Page 3: Table Of Contents

    MITSUBISHI ELECTRIC 2011-2012 Technical Training Manual Table of Contents Introduction ........................... 5 Product line ......................... 5 Features and Technologies ....................6 New Technologies ......................8 Chapter 1 - ...................... 15 LASERVUE Safety ..........................15 Disassembly and Parts Replacement ................17 Service Procedures ......................

  • Page 5: Introduction

    High Pressure Discharge Lamp The full TV Product Line is shown below by size, sub-chassis and model. LASERVUE SIZE 75” L75-A94 DLP Home Cinema SIZE V45C V45CA V45+ V45++ V45CB 73” WD-73C11 WD-73640 WD-73CA1 WD-73740 WD-73840 WD-82CB1 82” WD-82740 WD-82840 92” WD-92840...

  • Page 6: Features And Technologies

    Introduction This Introduction will discuss some of the newest features and technologies. The remainder of the manual is divided into 2 sections to cover the and DLP Home Cinema product categories separately. While LASERVUE this manual can be used as a service aid, always refer to the Service Manual for complete service information and safety instructions.

  • Page 7

    Introduction TECHNOLOGIES Mitsubishi’s 2011-2012 TV product line includes several technologies either new to the market place or introduced in the recent past. These technologies include:  3D with built in IR synchronization emitters.  Stream TV™ Internet Media  Wireless Internet Ready and Built-in Wireless Internet ®...

  • Page 8: New Technologies

    Introduction Stream TV™ Internet Media Introduced last year, internet media capabilities have been expanded to many more models this year by in- cluding an Ethernet port and wireless ready or wireless internet connections. This permits instant access to an extensive library of high quality entertainment and social media content. StreamTV provides consumers with over 100 different applications.

  • Page 9

    Introduction...

  • Page 10: Chapter 1 - Laservue

    Bluetooth and the Bluetooth trademarks are owned by Bluetooth SIG, Inc. iPhone is a registered trademark of Apple Inc. TORX is a registered trademark of Textron. 6-Color Processor™, DeepField Imager™, Easy Connect™, Net Command®, PerfectColor™, PerfecTint™, Plush 1080p®, EdgeEnhance™, Smooth120Hz™, True120Hz™. True240Hz™, StreamTV™, ™ are Mitsubishi Electric Visual LASERVUE Solutions America, Inc.

  • Page 11: Safety

    Chapter 1 SIZE 75” L75-A94 SAFETY Like the first generation V40 chassis, the V46 chassis includes laser technologies that have LASERVUE safety requirements that are separate and different than those in other TVs. Prior to servicing this type product, it is important to read and understand all safety requirements. The V40 Technical Training Man- ual includes a section on the Fundamentals of Laser and Laser Safety.

  • Page 12: Safety Precautions

    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 with the covers removed presents both a shock hazard and a hazard from laser radia- tion.

  • Page 13

    Caution: Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure. Use external or remote controls to operate the product. Connection to signal sources and power are accomplished through the external connectors. 1.

  • Page 14: Disassembly And Parts Replacement

    DISASSEMBLY & PARTS REPLACEMENT CAUTION: Prior to disassembly, remove AC power. Do not re-apply AC power until the set has been fully re-assembled and inspected for safety as described on page 12. IMPORTANT NOTES: 1. Disassembly beyond what is shown in this manual is not recommended. 2.

  • Page 15

    Rear Cabinet Frame Removal 1. Remove screws (A) from the Rear Cabinet Frame. 2. Remove the Rear Cabinet Support Frame from the TV.

  • Page 16

    Service Cover Removal (For Light Source Unit and Optical Engine Replacement) 1. Remove screws (A) indicated on the Service Cover by the arrows 2. Remove the Service Cover in the direction indicated. SERVICE COVER ELECTRICAL CHASSIS Electrical Chassis Removal 1. Disconnect all cables connecting to the chassis. 2.

  • Page 17

    Light Source Unit Removal NOTE: The Light Source Unit is supplied complete with fans and ducts. However the Exhaust Fans can be replaced individually. 1. Disconnect all cables connecting to the Light Source Unit. 2. Remove Screws (A) and (B). 3.

  • Page 18

    Fan Labels Facing Out Corner Cushions 3 Per Fan Light Source Exhaust Fan Removal NOTE: Disassemble Duct Assembly for Fan replacement only. Otherwise order the complete Light Source Unit. 1. Remove Screws (A). 2. Separate the Front and Rear Air Ducts. IMPORTANT: Do not disassemble the Light Source Unit any further.

  • Page 19

    Optical Engine Removal 1. Remove Screws (A). 2. Remove the Optical Engine from the cabinet. IMPORTANT: Do not disassemble the Optical Engine further than DMD Fan replacement. Optical Engine Replacement After a new Optical Engine is installed, perform the following procedures: 1.

  • Page 20

    COVER-FRONT Removal 1. Remove Back Cover and remove Screw (A). 2. Remove Screws (B). 3. Pull COVER-FRONT away from the front of the cabinet. COVER-FRONT (Example)

  • Page 21

    Screen Assembly Removal - Note: The Screen Assembly and screens are not considered to be field replaceable items. 1. Remove the COVER-FRONT. 2. Remove Screws (A) from the bottom front. 3. Remove Screws (B) from the rear sides. 4. Remove the Screen Assembly from the cabinet. IMPORTANT: Do not allow the rear of the screen to come into contact with any other surface including clean- ing cloths or fingers.

  • Page 22: Service Procedures

    SERVICE PROCEDURES REMOTE CONTROL USE FOR SERVICE Many service functions and adjustments are accessed using the Remote Control. See below.

  • Page 23

    OPTION MENU OPTION MENU 1. Press the <MENU> button on the remote control. Press the buttons <2-4-7-0>. The screen will display the Option Menu. Option Menu <MENU><2-4-7-0> Initialize Deactivate VUDU Power Restore Production Mode Digital Signal Strength <1~9> DM Software Vxx xxx.xx TV MAC Address xx:xx:xx:xx:xx:xx...

  • Page 24

    DIGITAL SIGNAL STRENGTH 1. Tune to a Digital Channel. 2. From the Option Menu, scroll down and highlight “Digital Signal Strength.” Press <ENTER>. The screen will display the Digital Signal Strength Menu. Digital Signal Strength Menu "Digital Signal Strength" <ENTER> Tuner Frequency(MHz) Signal Level...

  • Page 25

    RESET / INITIALIZATION SERVICE TIP: Many symptoms that are customer generated, intermittent or cannot be verified can be resolved by using the various Reset and Initialization options. Before visiting the customer’s home ask the customer to 1st perform a System Reset by pressing the <POWER>...

  • Page 26

    LED INDICATIONS AND SELF DIAGNOSTICS The front panel Power LED provides an indication of the set’s operation and the possible cause of a malfunction. NORMAL INDICATIONS STATUS LED Indication Condition Off (Standby) Green Power On Slow Blinking Green Power Off with Timer Set. Power On normally Fast Blinking Green 1 to 3 minutes after Power Boot-up.

  • Page 27: Error Codes

    ERROR CODES Error Codes, descriptions and corrective actions for the error are listed below: Error Description Corrective Actions Code No serious error since last main power on or last micro initialization. Cover-4 (Laser Unit) is open. Contact MDEA Technical Support 1-800-552-8324 Check JV-J6C00 circuitry or its Lead Wire / Check if Flat cable is dam- Strobe signal abnormal detection aged / Replace Engine or Chassis...

  • Page 28: Error Code Log

    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 <MENU> <3-5-6-4> Error Code Log <MENU><3-5-6-4> ***** PAGE (001/001) ***** CURRENT TIME: 01455 HOURS USAGE TIME CODE STATUS 00413 HRS HAPPENED...

  • Page 29

    SERVICE ADJUSTMENTS There are 2 Types of Service Adjustments, electrical and mechanical: Electrical Adjustments  Horizontal and Vertical Centering Adjustment  Index Delay Adjustment  Geometry Alignment  Data Transfer Functions Mechanical Adjustment  Top Mirror Adjustment ELECTRICAL ADJUSTMENTS Overview—Specific Adjust Procedures follow ...

  • Page 30

    Horizontal and Vertical Position Adjustment 1. Enter the Service Menu <MENU><2-4-5-7> . 2. Select the Geometry Test Pattern shown Play <  > Rewind <  > 3. If necessary, select the adjustment, “1.HVPOS” <VIDEO>. 4. After selecting the HVPOS adjustment item, ...

  • Page 31

    Select Calibration Table (after Light Source Unit replacement) 1. In the Customer’s Video Settings Menu select COLOR TEMP: HIGH 2. Enter the Service Menu <MENU-<2-4-5-7>. 3. Use the <VIDEO> button to select the adjustment, “61.BCMH” and note the data value (0, 1, 2, 3 or 4). 4.

  • Page 32

    RESTORE ENGINE DATA FROM BACKUP RESTORE GEOMETRY DATA FROM BACKUP MANUAL GEOMETRY ALIGNMENT SAVE ENGINE AND GEOME TRY SETTING TO B ACKUP BACKUP AND RESTORE ISF SETTINGS RED ONLY AND GREEN ONLY Cursor + Adjustment Points (20 Total) Align Cursor Flush With Bezel Edge Phase 1 - 20 Point Geometry Alignment 1.

  • Page 33

    Phase 2 - 4:3 and 16:9 Alignment 1. With the Manual Geometry Alignment activated, press <VIDEO> to enter the Left 4:3 Alignment Mode. The pattern below will be displayed. Note: Pressing <VIDEO> will toggle between the Left 4:3, Right 4:3, Top 16:9, Bottom 16:9 and the 20 Point Geometry Alignment modes.

  • Page 34

    4:3 MODE Select Straightest Red Line (Top) 4. In the Top 16:9 Alignment Mode, pressing <  > or <  > will cause the geometry pattern to be displayed with 30 different preset amounts of correction to the Top Red Line. Toggle through them until you find the one with the straightest Red Line.

  • Page 35

    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 Procedure: 1. Enter the Service Mode <MENU><2-4-5-7> Select the Data Transfer & Geometry Menu <0> Data Transfer &...

  • Page 36

    MECHANICAL ADJUSTMENTS Top Mirror Adjustment Note: After Top Mirror Adjustment, perform the Manual Geometry Alignment procedure. Activate the Service Menu <MENU><2-4-5-7>. From the Service Menu, press PLAY <  > to activate the internal test patterns (no indication will be given), then use <>...

  • Page 37

    Rotate the Mirror Adjustment Screws (B) in the direction indicated so the geometry is as square as possible in relation to the bottom edge of the bezel. After adjustment, tighten the 3 Mirror Locking Screws and replace the Top Mirror Adjustment Cover. Perform the Manual Geometry Alignment procedure.

  • Page 38: Down-to-1 Troubleshooting

    Down to 1 TROUBLESHOOTING The Down to 1 strategy is to have set troubleshooting methods that will best ensure an accurate diagnosis as quickly as possible. The following troubleshooting methods will help the service technician gain the Down to 1 advantage. USER LEVEL RESETS AND INITIALIZATION As in previous models, many symptoms (customer generated or intermittent) may be resolved by per- forming a reset or initialization.

  • Page 39: Chapter 2 - Dlp ® Home Cinema

    ® Chapter 2 HOME CINEMA ® DLP Home Cinema SIZE V45C V45CA V45+ V45++ V45CB 73” WD-73C11 WD-73640 WD-73CA1 WD-73740 WD-73840 WD-82CB1 82” WD-82740 WD-82840 92” WD-92840 DISASSEMBLY & PARTS REPLACEMENT BACK COVER REMOVAL Back Cover Removal 1. Remove screws (A) and remove the Lamp Cover.

  • Page 40

    HOME CINEMA ® CHASSIS - REMOVAL & DISASSEMBLY Chassis Removal 1. Remove screws (A). 2. Slide the chassis back and disconnect all cables. 3. Remove the chassis from the cabinet. Rear Terminal Cover Removal (To Replace PWB-MAIN) 1. Remove nut (A) from the ANT input. 2.

  • Page 41

    HOME CINEMA ® PWB-POWER Removal 1. Disconnect all cables from the PWB-POWER. 2. Remove screws (A). 3. Pinch the Retainer to release the PWB. Retainer 4. Lift the PWB-POWER from the chassis. (Pinch) PWB-MAIN Removal 1. Disconnect all cables to PWB-MAIN. 2.

  • Page 42

    HOME CINEMA ® PWB-BALLAST REMOVAL 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 up from the mounting bracket. 2. Slide the PWB-BALLAST out of the Engine Assembly. 3.

  • Page 43

    HOME CINEMA ® OPTICAL ENGINE ASSEMBLY REMOVAL (Continued) 1. Disconnect the PE and J12 connectors from the Engine. 2. Remove screws (A). 3. Slide the Engine Assembly back out of the cabinet. J12 (LVDS) (Engine Power) OPTICAL ENGINE ASSEMBLY - Disassembly 1.

  • Page 44

    HOME CINEMA ® Duct Interior Components Duct Interior Components are shown below. Notes:  When replacing the Optical Engine, transfer all Duct and Duct Interior Components from the old Engine to the new Engine.  The Exhaust Fan must be installed so the Label is facing inside the Duct. ...

  • Page 45

    HOME CINEMA ® Lower Duct Removal 1. Remove the Lamp Cartridge, Top Cover, Exhaust Fan and Sirocco Fan. 2. Disconnect the HV Lamp Wiring from the Ballast and loosen it from the guides. 3. Remove screw (A) on the rear of the lower duct. 4.

  • Page 46: Projection Lens Replacement

    HOME CINEMA ® PROJECTION LENS REPLACEMENT 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.

  • Page 47: Color Wheel Replacement

    HOME CINEMA ® COLOR WHEEL REPLACEMENT CAUTION: This procedure should be performed in a dust free environment. Any dust entering into the optical compartment can cause abnormalities in the picture. 1. Remove the Optical Engine Assembly. 2. Remove the Lens Collar and cover the projection lens to protect it from scratches. See previous page. 3.

  • Page 48

    HOME CINEMA ® SCREEN REPLACEMENT 73” Models Screen Assembly Removal and Replacement 1. V45C, V45, V45+ - Remove the Screw Caps to access screws (A). 2. V45++ - Remove the ORNAMENT LEFT & RIGHT first by pinching up and pulling away from the bottom. Then remove the ORNAMENT CENTER using the same method.

  • Page 49

    HOME CINEMA ® SCREEN REPLACEMENT 73” Models (continued) Screen Removal From the Bezel-Front 1) Remove screws (A) and remove the top, bottom and side rails. NOTE: The number and location of screws vary by model. 2) Lift the Fresnel Lens and Lenticular screen from the Bezel-Front. 3) During re-assembly replace screws in their original locations.

  • Page 50

    HOME CINEMA ® SCREEN REPLACEMENT 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.

  • Page 51

    HOME CINEMA ® SCREEN REPLACEMENT 82” & 92” Models Screen Assembly Removal 1. Remove screws (A) around the bottom rear edge. 2. (V45+) Remove the Pedestal cover and remove screws (B). 3. (V45++) Pull off ornamental Front Covers and Speaker Grill. 4.

  • Page 52

    HOME CINEMA ® SCREEN REPLACEMENT 82” & 92” 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.

  • Page 53

    HOME CINEMA ® SCREEN REPLACEMENT 82” & 92” 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 LENS LENTICULAR LENTICULAR SCREEN SCREEN FRESNEL FRONT HOLDER-SCREEN...

  • Page 54: Mirror Replacement

    HOME CINEMA ® MIRROR REPLACEMENT MIRROR REPLACEMENT - 73” Models 1. To access the Mirror for replacement, remove the Screen Assembly (See Screen Assembly Removal). 2. The Mirror slides down into the Left, Right and Bottom Brackets inside the cabinet. 3.

  • Page 55: Service Procedures

    V45CB V45C V45CA WD-73740 WD-73840 WD-82CB1 WD-73C11 WD-73640 WD-73CA1 WD-82740 WD-82840 WD-92840 REMOTE CONTROL USE FOR SERVICE Many service functions and adjustments are accessed using the Remote Control. The Type 1 remote does not have buttons such as PLAY, FWD and RVW that are associated with operating connected devices. Service Procedures are described assuming a Type 1 remote is being used.

  • Page 56

    HOME CINEMA ® OPTION MENU OPTION MENU 1. Press the <MENU> button on the remote control. Press the buttons <2-4-7-0>. The screen will display the Option Menu. Option Menu <MENU><2-4-7-0> Initialize Power Restore Production Mode Digital Signal Strength <1~9> NetCommand Software Vxx xxx.xx Total hours of use SERVICE LEVEL INITIALIZATION...

  • Page 57

    HOME CINEMA ® DIGITAL SIGNAL INFORMATION Information on the currently selected digital channel can be displayed on screen. 1. Enter the Option / Service Menu <MENU><2-4-7-0>. Option Menu <MENU><2-4-7-0> Initialize Power Restore Production Mode Digital Signal Strength <1~9> NetCommand Software Vxx xxx.xx Total hours of use 1.

  • Page 58: Service Menu

    HOME CINEMA ® SERVICE ADJUSTMENTS Service Adjustments include Adjustment Procedures and Data Transfer Functions. 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 •...

  • Page 59: Adjustment Procedures

    HOME CINEMA ® ADJUSTMENT PROCEDURES Horizontal and Vertical Position Adjustment 1. Enter the Service Menu <MENU><2-4-5-7>. > 2. Select the Geometry Test Pattern shown <2> <CH-DOWN>or < 3. If necessary, use the <VIDEO> button to select the adjustment, “1.HVPOS”. Vertical & Horizontal Position Adjustment >...

  • Page 60

    HOME CINEMA ® Manual Geometry Alignment 1. Entering the Manual Geometry Alignment Mode 1. Activate the Service Mode <MENU><2-4-5-7>. 2. From the Service Menu, press the <0> button. The Data Transfer & Geometry Menu will appear. Type 2 Data Transfer & Geometry Menu <MENU><2-4-5-7><0> RESTORE ENGINE DATA FROM BACKUP RESTORE GEOMETRY DATA FROM BACKUP MANUAL GEOMETRY ALIGNMENT...

  • Page 61

    HOME CINEMA ® 2. Manual Geometry Alignment Note: Upon entering the Manual Geometry Alignment Mode the first time, the geometry may appear distorted because all factory geometry correction is automatically disabled. Press <EXIT> to quit and re-enable the factory geometry correction. Pressing <1> <ENTER> and <EXIT> will cause the TV to operate with out factory geometry correction (distortion will be present).

  • Page 62

    HOME CINEMA ® Phase 3 - 4:3 and 16:9 Alignment 1. With the Manual Geometry Alignment activated, press <VIDEO> to enter the 4:3 Alignment Mode. The pat- tern below will be displayed. Note: Pressing <VIDEO> will toggle between the 4:3,16:9 (top, top-center, center & bottom) and 16 Point Ge- ometry Alignment modes.

  • Page 63

    HOME CINEMA ® /> Repeat the process of pressing <CH-UP/CH-DOWN> or < to display the 15 different preset amounts of correction to the Top-Center Red Line. When you find the pattern with the straightest line, press <VIDEO> to proceed to the Center Red Line. Repeat the process for the Center Line, followed by the Bot- tom Line.

  • Page 64: Data Transfer Functions

    HOME CINEMA ® DATA TRANSFER FUNCTIONS Data Transfer Service Data is duplicated and stored in separate EEPROMs in two locations.  PWB-MAIN - Working Service Data for TV operation  OPTICAL ENGINE - Backup Service Data The Optical Engine also includes data for the Index Delay setting for color wheel timing determined at the factory. The PWB-MAIN also includes User and/or ISF settings.

  • Page 65

    HOME CINEMA ® RESET / INITIALIZATION SERVICE TIP: Many symptoms that are customer generated, intermittent or cannot be verified can be resolved by using the various Reset and Initialization options. Before visiting the customer’s home ask the customer to 1st perform a System Reset. If this does not resolve the issue, they can perform an A/V Reset.

  • Page 66

    HOME CINEMA ® 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 (Standby) Green Power On Slow Blinking Green Power Off with Timer Set.

  • Page 67

    HOME CINEMA ® ERROR CODES Error Codes, descriptions and the most likely cause of failure are listed below: ERROR CODES Code Description Most Likely Cause Loss of 12V from PWB-POWER to Engine / I2C Communication loss between TV Micro and Engine Check PE &...

  • Page 68

    HOME CINEMA ® SPEAKER TRANSDUCER AND SPEAKER FREQUENCY TEST (V45++ Only) These procedures will test the TV’s speakers using an internal tone generator. 1. Press the <MENU> button on the remote control. The Customer Menu will appear. 2. Press the <2-4-5-7> buttons. The Service Menu will appear. 3.

  • Page 69: Circuit Block Diagrams

    HOME CINEMA ® CIRCUIT BLOCK DIAGRAMS...

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    HOME CINEMA ® CIRCUIT BLOCK DIAGRAMS...

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