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SERVICE MANUAL AG-3X CHASSIS MODEL COMMANDER DEST. CHASSIS NO. MODEL COMMANDER DEST. CHASSIS NO. KP-FS57M31 RM-997 SCC-XXX-A KP-FS57M61 RM-997 SCC-XXX-A KP-FS57M90 RM-997 SCC-XXX-A KP-FS57M91 RM-997 SCC-XXX-A VIDEO DRC-MF V CENTER HD/DVD JUMP PROG OPTION RESET RM-997 KP-FS57M31/M61/M90/M91 PROJECTION TV...
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VIEWS AND IN THE PARTS LIST ARE CRITICAL TO REMOVING THE ANODE. SAFE OPERATION. REPLACE THESE COMPONENTS WITH SONY PARTS WHOSE PART NUMBERS AP- PEAR AS SHOWN IN THIS MANUAL OR IN SUPPLE- MENTS PUBLISHED BY SONY. – 2 –...
KP-FS57M31/M61/M90/M91 RM-997 TABLE OF CONTENTS Section Title Page Section Title Page 1. SELF DIAGNOSIS FUNCTION 3-11. Service List ............1-1. Diagnostic Test Indicators ......... 3-12. Registration Adjustment 1-2. Display of STANDBY/TIMER 3-12-1. Adjustment Flow ..........Light Flash Count ..........3-12-2. Setup for Adjustment ........
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KP-FS57M31/M61/M90/M91 RM-997 Section Title Page 6-5. Printed Wiring Boards ........144 6-6. Wave Forms ............168 6-7. IC Block Diagrams ..........172 6-8. Semiconductors ..........178 7. EXPLODED VIEWS 7-1. Front Panel Block ..........181 7-2. Cabinet Block (KP-FS53) ........ 182 7-3.
KP-FS57M31/M61/M90/M91 RM-997 SECTION 1 SELF DIAGNOSIS FUNCTION The unit in this manual contain a self-diagnostic function. If any error occurs, the STANDBY/TIMER lamp will automatically begin to flash. The number of times the lamp flashes translates to a probable source of the problem. A definition of the STANDBY/TIMER lamp flash indicators is listed in the instruction manual for the user's knowledge and reference.
KP-FS57M31/M61/M90/M91 RM-997 1-2. DISPLAY OF STANDBY/TIMER LIGHT FLASH COUNT 2 times 3 times Lamp ON 0.3 sec. Lamp OFF Lamp OFF 3 sec. 0.3 sec. 4 times 5 times 6 times 7 times Diagnostic Item Flash Count * +B overcurrent...
KP-FS57M31/M61/M90/M91 RM-997 1-4. SELF-DIAGNOSTIC SCREEN DISPLAY For errors with symptoms such as “power sometimes shuts off” or “screen sometimes goes out” that cannot be confirmed, it is possible to bring up past occurrences of failure for confirmation on the screen:...
KP-FS57M31/M61/M90/M91 RM-997 1-6. SELF-DIAGNOSTIC CIRCUIT From IC1203,1204 (A board) To H1 board From G board IC4300 IC001 SYSTEM Y/C JUNGLE From CRT (IK) 24 IKIN 5 OCP LED1 22 From IC8005,8006 57 XRAY 8 OVP IC003 (D board) MEMORY Q1209-1211...
KP-FS57M31/M61/M90/M91 RM-997 2-12. A, AD AND D BOARDS REMOVAL 1 A board 3 Five screws 2 AD board (BVTP 3X12) 4 D board 2-13. PICTURE TUBE REMOVAL 1 Two screws 2 Three screws (BVTP 4X16) (Hexagon head) 2 Three screws...
KP-FS57M31/M61/M90/M91 RM-997 2-14 HIGH-VOLTAGE CABLE 2-15. MECHASEAL INSTALLATION AND REMOVAL (1) Remover Removing the arrow-marked screw is strictly inhibited. If removed, it may cause liquid spill. 1 Rubber cap 7 Two screws 2 HV cable turn 90° (BVTP 4X16) 8 Heat sink...
KP-FS57M31/M61/M90/M91 RM-997 SECTION 3 SET-UP ADJUSTMENTS 3-1. SCREEN VOLTAGE ADJUSTMENT 5. Rotate the green lens and align to obtain the best lens focus (ROUGH ALIGNMENT) at the center area. 6. Rotate the green focus VR on the focus pack and align to 1.
KP-FS57M31/M61/M90/M91 RM-997 3-5. 2-POLE MAGNET ADJUSTMENT 3-8. DEFOCUS ADJUSTMENT (BLUE) 1. Receive the Dot signal. 1. Receive the Dot signal. 2. Place the caps on the red and blue lens so that only the green 2. Cover the both red and green picture lenses with the lens color is shown.
KP-FS57M31/M61/M90/M91 RM-997 3-10. ADJUSTMENTS WITH COMMANDER 3-10-1. How to Select Each Mode Service adjustment to this model can performed with the supplied remote commander RM-998 50 Hz 60 Hz WIDE 60 Hz WIDE 50 Hz (PAL) (NTSC) (NTSC) (PAL) DRC1250...
KP-FS57M31/M61/M90/M91 RM-997 3-10-3. Method of Cancellation from Service 3-10-5. How to Write the Data Mode 1. Set in the service mode. 1. Set the standby mode (Press “ (TV STANDBY)” button on 2. Press “1” or “4” button on the commander, select the ad- justment item, and press “3”...
KP-FS57M31/M61/M90/M91 RM-997 3-12. REGISTRATION ADJUSTMENT 3-12-2. Setup for Adjustment 1. Marking 1) At the 4 insides of the screen, locate the middle. Use a tape 3-12-1.ADJUSTME FLOW measure to identify the middle. START : midlle Turn on the power and wait for 10 minutes...
KP-FS57M31/M61/M90/M91 RM-997 1. Functions of Keys on Commander 6. Write “VPS, VSZ and HSZ” adjusted data to other mode • 1 : Changes adjustment item. (item No. moves up) service data. : Marker moves clockwise from center to outside. <Write “VPS”,“VSZ”,“HSZ”>...
KP-FS57M31/M61/M90/M91 RM-997 4) In the GRN, BLU, or RED mode, move “ ” up or down to • Fine adjustment can be made on the basis of marker position change the data in vertical direction, or move “ ” to the left using joystick key.
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KP-FS57M31/M61/M90/M91 RM-997 6) Select “GRN SKEW”, and correct the tilt of horizontal lines 9) Select “GRN MSIZ”, and correct the space intervals for the and vertical lines. horizontal section of the screen are equal. • GRN SKEW (horizontally/vertically) • GRN MSIZ (horizontally)
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KP-FS57M31/M61/M90/M91 RM-997 2. Red Adjustment 5. Size and Linearity Adjustment for DRC1250 NTSC W/Z mode by same 1) Place a cap on the blue lens so that green and red colors are prucedure as1~4. displayed. 2) Press “3” button on the commander to select RED mode.
KP-FS57M31/M61/M90/M91 RM-997 3-13. AUTO CONVERGENCE SETTING 3-15. WHITE BALANCE ADJUSTMENT This adjustment must be performed after the registration adjust- 1. Enter the monoscope signal. ment was made or after readjustment was made by any reason. 2. Set in the service mode.
KP-FS57M31/M61/M90/M91 RM-997 3-16. AUTO CONVERGENCE ERROR CODE LIST If an error code is displayed after the set has been fully adjusted, correctly, plese check the following items : position, tilt and sizing. If either of these adjustments are off, even slightli, the auto registration pattern will not hit the four sensors properly. This occurs when the internal generator patterns is being flashed on the screen for the sensor to read.
KP-FS57M31/M61/M90/M91 RM-997 SECTION 4 SAFETY RELATED ADJUSTMENT 4-1. HV ADJUSTMENT REGULATION 4-3.+B MAX VOLTAGE CONFIRMATION When replacing the following components marked with ] The following adjustments should always be performed on the schematic diagram, always check hold-down volt- when replacing IC6503.
KP-FS57M31/M61/M90/M91 RM-997 5-1-2. NTSC Video Input 5-1-3. NTSC RF Input 1. Enter the NTSC video color bar (White & color 75%) signal. 1. Enter the NTSC RF color bar (White & color 75%) signal. 2. Enter the service mode, and set respective items as follows.
KP-FS57M31/M61/M90/M91 RM-997 5-1-4. PAL Video Input 5-1-5. PAL RF Input 1. Enter the PAL video color bar (White & color 75%) signal. 1. Enter the PAL RF color bar (White & color 75%) signal. (i) SUB CONTRAST (i) SUB CONTRAST...
KP-FS57M31/M61/M90/M91 RM-997 SECTION 6 DIAGRAMS 6-1. BLOCK DIAGRAMS (1) A AND H2 BOARDS BLOCK DIAGRAMS TO J BOARD TO V2 BOARD TO B4 BOARD CN8304 CN1118 CN502 CN1121 Q105 VIDEO BUFFER +7.5V 7.5V TO V2 BOARD TU101(MAIN) CN5803 Q101 DET OUT...
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KP-FS57M31/M61/M90/M91 RM-997 (2) A1, V2, AND H3 BOARDS BLOCK DIAGRAMS IC8205 IC8207 CN1932 AUDIO CONTROL J1931 HP GND IC8200 L HP AUDIO L CN8102 HEAD R HP TO A BOARD PHONE AUDIO R L-SW 1 LIN LOUT OUTa CN1293 AUDIO L...
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KP-FS57M31/M61/M90/M91 RM-997 (3) AD AND SR BOARDS BLOCK DIAGRAMS (PJED-CPU,PHOTO SENSOR BUFFER) IC9422 3.3V REG IC9400 IC9401 +3.3V D+5V PJED-CPU CONV DSP IC9414(1/2) IC9416(1/2) 1V CONV. CN9603 CN9400 PEAK HOLD UPPER Q9402 UPPER I SEN R IN R OUT RE-R...
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KP-FS57M31/M61/M90/M91 RM-997 (4) B4(1/2) BOARD BLOCK DIAGRAM IC702 IC601 IC801 IC901 MID-XA D/A CONVERTER CN502(1/2) CN502(2/2) Q501,521 Q901,908 Y MAIN IN FL501 199 DIY0 DY02 CRCYIN0 DSPY0 FL901 Y 100 OUT Y0-7 DY0-7 G0-7 BUFF BUFF DIY7 DY09 CRCYIN7 DSPY7...
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KP-FS57M31/M61/M90/M91 RM-997 (5) B4(2/2) AND HM BOARDS BLOCK DIAGRAMS IC7201 IC403 CN7202 CN402 LVDS RECEIVER LVDS RECEIVER CN7201 +3.3V 3.3VD +3.3V 3.3VD DIN1 DOUT2- MS BS+ MS-BS MS BS+ CN401 L7201 MS BS- L405 MS BS- MS-SDIO MS SDIR+ VCLK...
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KP-FS57M31/M61/M90/M91 RM-997 (6) CR, CG, CB, E, AND VM BOARDS BLOCK DIAGRAMS (R OUTPUT) (Y/C/J) CN9107 IC9101 TO FOCUS CN4300 VIDEO OUT BLOCK J9101 CN9103 Q9105 CN4301 CN4305 V IN V OUT Q4313 BUFF Y 100 47 V IN R OUT 32...
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KP-FS57M31/M61/M90/M91 RM-997 (7) G AND H1 BOARDS BLOCK DIAGRAMS (POWER SW) AC IN L6702 L6703 110-240V F6701 50/60Hz CN6701 CN6703 CN1701 (POWER SUPPLY) 6.3A AC(L) AC OUT AC(W) AC OUT T6703 D6535 D6538 D6536 RECT S1700 D6534 CN6704 CN1700 POWER SW...
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KP-FS57M31/M61/M90/M91 RM-997 (9) D BOARD BLOCK DIAGRAM IC8001,8002,CONV OUT IC8001(3/3) CN8012 CN8026(1/2) RH OUT (HV,H/V-DEF,DY DRIVE) RV OUT TO DY(R) RV RET RH RET IC8001(2/3) CN8011 H SHIFT GH OUT TO AD BOARD RE-YS GV OUT CN9400 RE-B IC8002(3/3) TO DY(G)
KP-FS57M31/M61/M90/M91 RM-997 6-3. CIRCUIT BOARDS LOCATION 6-4. SCHEMATIC DIAGRAMS Note: Terminal name of semiconductors in silk screen • All capacitors are in µF unless otherwise noted. (pF: µµF) printed circuit ( Capacitors without voltage indication are all 50 V. • Indication of resistance, which does not have one for rating...
KP-FS57M31/M61/M90/M91 RM-997 (16) Schematic Diagrams of CR, CG, and CB Boards V901 PICTURE V903 HV BLOCK PICTURE TUBE HV BLOCK TUBE TO F.BLOCK TO F.BLOCK FGND CN9110 J9101 R9121 (R OUTPUT) :FASTON FGND TO F.BLOCK 1/2W (B OUTPUT) J9301 R9324...
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KP-FS57MM31/M61/M90/M91 RM-997 (17) Schematic Diagram of D(1/3) Board CN8008 CN8009 CN8012 CN8007 CN8010 CN8011 CN8013 :S-MICRO :S-MICRO :S-MICRO :S-MICRO :S-MICRO :S-MICRO TO DY(B) TO DY(R) TO DY(G) TO DY(B) TO DY(R) TO DY(G) TO G BOARD CN6503 CN8025 R8114 R8116 R8101 :S-MICRO IC8010...
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KP-FS57MM31/M61/M90/M91 RM-997 (18) Schematic Diagram of D(2/3) Board HV(R) TO PICTURE TUBE R V901(R) HV(G) TO PICTURE TUBE G V902(G) HV(B) TO PICTURE TUBE B CN8015 CN8016 V903(B) CN8006 :LARGE (HV BLOCK) :S-MICRO :S-MICRO TO D BOARD TO VM BOARD T5103 CN9001 +135V...
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KP-FS57MM31/M61/M90/M91 RM-997 (19) Schematic Diagram of D(3/3) Board +15V TO D3/3,D1/3_2 DF VCC R8030 TO D3/3,D1/3_3 +12V L8009 L8010 10µH 47µH TO D3/3,D1/3_4 R8037 :LHL08 :LAV35 D8005 R8068 R8034 1SS355 70.8 1/10W RECT 1/10W Q8007 C8045 :CHIP :CHIP 2SC4634LS-CB11 DF V AMP C8047 C8050 C8053...
KP-FS57MM31/M61/M90/M91 RM-997 (20) Schematic Diagram of E Board CN4302 CN4303 CN4304 TO VM BOARD TO VM BOARD TO VM BOARD CN9002 CN9002 CN9002 (FOR B) (FOR G) (FOR R) C4328 R4346 C4335 C4337 L4304 4.7k 10µH CH:1608 1/10W :LB2016 :CHIP F:1608 R4333 C4325...
KP-FS57MM31/M61/M90/M91 RM-997 (22) Schematic Diagrams of H1, H2, and H3 Boards CN1932 CN1934 CN1701 CN1700 WHT-L WHT-L WHT-L WHT-L :S-MICRO :S-MICRO TO A(3/3)BOARD TO J(1/4)BOARD TO G BOARD TO G BOARD CN6704 CN6703 CN1293 CN8301 D1930 RD9.1ES-T1B PROTECTOR S1700 POWER R1952 R1934 2.2k...
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KP-FS57MM31/M61/M90/M91 RM-997 (23) Schematic Diagram of J(1/5) Board CN8302 :TAB C8330 R8351 4.7k :CHIP F:CHIP R IN R8352 C8331 4.7k 1 10V F:CHIP :CHIP L IN C8300 0.47 10V B:CHIP Y IN C8349 4.7 10V F:CHIP CV IN R8348 2.2k :CHIP S IN C8382 0.1 16V B:CHIP...
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KP-FS57MM31/M61/M90/M91 RM-997 (24) Schematic Diagram of J(2/5) Board R8362 R8211 R8212 JL8302 :CHIP :CHIP :CHIP APCN R8353 TO J2/5,J1/5_20 :CHIP MAIN-C2 TO J2/5,J5/5_23 C-IN R8512 47 :CHIP MAIN-CV2 R8210 R8213 TO J2/5,J5/5_24 COMP V IN FL8303 :CHIP :CHIP TO J2/5,J1/5_2 +5VA R8410 C8372...
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KP-FS57MM31/M61/M90/M91 RM-997 (25) Schematic Diagram of J(3/5) Board C8892 (AUDIO OUT) J8306 R8887 R8885 0.47 :CHIP :CHIP B:CHIP VD8304 R8889 7.5V 2.2k :1608 :CHIP R8888 R8886 C8893 COMP L TO J3/5,J1/5_15 COMP R TO J3/5,J1/5_14 :CHIP :CHIP R8802 L8803 R8801 R8890 10µH VD8305...
KP-FS57M31/M61/M90/M91 6-5. PRINTED WIRING BOARDS RM-997 — A BOARD (COMPONENT SIDE) — [SYSTEM CONTROL, AUDIO AMP,TUNER] • A BOARD SEMICONDUCTOR LOCATION Q1207 Q1209 Component Conductor Q1210 Side Side Q1211 IC001 Q2200 IC002 Q2201 IC003 Q2603 IC005 Q2604 IC100 Q3300 IC1203...
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KP-FS57M31/M61/M90/M91 RM-997 [AUDIO CONTROL] — A1 BOARD (COMPONENT SIDE) — A1 BOARD Terminal name of semiconductors in silk screen printed circuit ( Ref. D8217 Q8101-Q8103 Q8218 : Refer to Terminal name of semicon- ductors in silk screen printed circuit (see page 81) —...
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KP-FS57M31/M61/M90/M91 RM-997 [CONV DSP, PJED-CPU, PHOTO SENSOR] — AD BOARD (COMPONENT SIDE) — — AD BOARD (CONDUCTOR SIDE) — • AD BOARD SEMICONDUCTOR LOCATION TRANSISTORQ DIODE Component Conductor Component Conductor Component Conductor Side Side Side Side Side Side IC9400 Q9400...
KP-FS57M31/M61/M90/M91 RM-997 SECTION 7 EXPLODED VIEWS NOTE: • Items marked " * " are not stocked since The components identified by shading they are seldom required for routine • Items with no part number and no ¡ and mark are critical for safety.
KP-FS57M31/M61/M90/M91 RM-997 7-4. MAIN BRACKET AND PICTURE TUBE BLOCK The components identified by shading ¡ and mark are critical for safety. Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK * A-1401-390-A CB BOARD, MOUNT...
KP-FS57M31/M61/M90/M91 RM-997 SECTION 8 ELECTRICAL PARTS LIST •The components identified by [ in this • Items marked " * " are not stocked since NOTE: they are seldom required for routine manual have been carefully factory- The components identified by shading selected for each set in order to satisfy service.
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KP-FS57M31/M61/M90/M91 RM-997 The components identified by shading ¡ and mark are critical for safety. Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK <SPARK GAP> <NEON LAMP> SG9101 1-517-729-31 GAP, SPARK NL9202 1-517-778-21 LAMP, NEON...
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KP-FS57M31/M61/M90/M91 RM-997 The components identified by shading ¡ and mark are critical for safety. Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK C9314 1-162-970-11 CERAMIC CHIP 0.01UF 10.00% 25V R9306 1-218-682-11 METAL CHIP 0.5%...
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KP-FS57M31/M61/M90/M91 RM-997 The components identified by shading ¡ and mark are critical for safety. VM G Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK C9012 1-137-528-11 MYLAR 0.1UF 10.00% 250V *************************************************************************************** C9013 1-164-156-11 CERAMIC CHIP 0.1UF...
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KP-FS57M31/M61/M90/M91 RM-997 The components identified by shading ¡ and mark are critical for safety. Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK C6714 1-162-974-11 CERAMIC CHIP 0.01UF D6702 8-719-022-99 DIODE D6SB60L D6704...
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KP-FS57M31/M61/M90/M91 RM-997 The components identified by shading ¡ and mark are critical for safety. Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK L6513 1-412-533-21 INDUCTOR 47UH R6528 1-216-837-11 METAL CHIP 1/10W L6514...
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KP-FS57M31/M61/M90/M91 RM-997 The components identified by shading ¡ and mark are critical for safety. Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK IC1203 8-759-553-45 IC TDA7481 D001 8-719-081-97 DIODE MMDL914T1 IC1204 8-759-553-45 IC TDA7481...
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KP-FS57M31/M61/M90/M91 RM-997 REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK R033 1-216-809-11 METAL CHIP 1/10W Q001 8-729-905-35 TRANSISTOR 2SC4081-R R034 1-216-813-11 METAL CHIP 1/10W Q002 8-729-905-35 TRANSISTOR 2SC4081-R R035 1-216-813-11 METAL CHIP 1/10W Q003 8-729-905-35 TRANSISTOR 2SC4081-R R036...
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KP-FS57M31/M61/M90/M91 RM-997 REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK R109 1-216-817-11 METAL CHIP 1/10W R1275 1-216-837-11 METAL CHIP 1/10W R110 1-216-818-11 METAL CHIP 1/10W R1276 1-216-837-11 METAL CHIP 1/10W R111 1-216-864-11 SHORT CHIP R1277 1-216-833-11 METAL CHIP...
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KP-FS57M31/M61/M90/M91 RM-997 The components identified by shading ¡ and mark are critical for safety. Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK <IC LINK> FB8021 1-410-397-21 FERRITE 1.1UH FB8021 1-410-397-21 FERRITE 1.1UH PS800 ! 1-533-595-31 IC LINK 3.15A...
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KP-FS57M31/M61/M90/M91 RM-997 REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK R8016 1-216-829-11 METAL CHIP 4.7K 1/10W R8084 1-216-833-11 METAL CHIP 1/10W R8085 1-214-808-11 METAL 1/2W R8017 1-216-829-11 METAL CHIP 4.7K 1/10W R8086 1-214-808-11 METAL 1/2W R8018 1-216-821-11 METAL CHIP...
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KP-FS57M31/M61/M90/M91 RM-997 • The components identified by [ in this manual have been carefully The components identified by shading factory-selected for each set in order to satisfy regulations ¡ regarding X-ray radiation. Should replacement be required, replace and mark are critical for safety.
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KP-FS57M31/M61/M90/M91 RM-997 REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK R9461 1-218-724-11 METAL CHIP 0.5% 1/10W R9557 1-216-821-11 METAL CHIP 1/10W R9558 1-216-821-11 METAL CHIP 1/10W R9462 1-218-724-11 METAL CHIP 0.5% 1/10W R9463 1-218-716-11 METAL CHIP 0.5% 1/10W...
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KP-FS57M31/M61/M90/M91 RM-997 The components identified by shading ¡ and mark are critical for safety. Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK <CONNECTOR> <CONNECTOR> CN1800 * 1-564-525-11 PLUG, CONNECTOR 10P CN1700 * 1-580-844-11 PIN, CONNECTOR (POWER) CN1701 * 1-580-844-11 PIN, CONNECTOR (POWER) <DIODE>...
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KP-FS57M31/M61/M90/M91 RM-997 The components identified by shading ¡ and mark are critical for safety. Replace only with part number specified. REF.NO. PART NO. DESCRIPTION REMARK REF.NO. PART NO. DESCRIPTION REMARK <JACK> FB7204 1-414-921-11 FERRITE J1931 1-691-293-31 JACK (HEADPHONE) J1932 1-750-517-11 JACK BLOCK, PIN 3P (VIDEO IN4) <IC>...