Sony KP-57XBR10W - 57" Projection Tv Reference manual

Model: KP-57XBR10W, KP-65XBR10W No. 531
Subject: Improved Service Adjustment Procedure
For The RA-4W Chassis Models Date: April 27, 2001
Solution:
(1330) Procedure to Improved picture Quality
The procedures below should be followed if the customer is complaining of poor picture quality. Although
these procedures were written for the RA-4W chassis they can also be applied to the RA-3 & RA-4 chassis in
most cases.
Note: Test equipment required:
1. Pattern Generator (with component (Y, Pb, Pr) outputs)
Ex. Leader 408 or Quantum Data 801GG
Important Notes:
•Pre-Aging of the TV: Age the TV set before attempting to adjust the set (especially focus) by one of
the recommended amounts below. Aging Conditions: Apply an all white signal 100-IRE, minimum 30
min to a maximum of 1 hr. (over an hour, causes the CRTs to heat past the optimum adjustment
point), OR TV signal (with moving picture) minimum 2 hrs (no maximum time applies). If this method
of aging is used, be sure to coordinate with the customer/dealer beforehand so that the set is ready
upon your arrival. Use Vivid picture mode setting on TV.
•Order of Adjustments: Please follow the order of adjustments as stated in this document. This will
maximize results while minimizing readjustment.
•Confirmation / Adjustment Method: This procedure first instructs the technician to confirm whether
an adjustment is necessary. The technician should only perform the adjustment if the confirmation
indicates that it is required.
•Method on how to Turn Off the CRTs: To perform some adjustments, it will be necessary to turn off
the CRTs, which can be done in the Service mode by doing the following: Select adjustment category
"MCP1", adjustment item # 07 "RON", #08 "GON", or #09 "BON". The applicable CRT is on when its
data is "01", and off when its data is "00".
•Accessing the internal generator through the service mode. Select Category PJE MODE using
the 2 or 5 remote button. Repeated pressing of the remote button #6 will allow you to cycle through
the crosshatch, dots, and white signal video pattern.
Continue on next page
CSV-1
Sony Service Company
National Technical Services
A Division of Sony Electronics Inc.
Park Ridge, New Jersey 07656
CONFIDENTIAL
Service Bulletin
TV Products
S
Reference: PJ Eng. PRINTED IN USA

TV Products Service Bulletin No. 531
Service data adjustment to Improve Edge Enhancement in NTSC mode:
Change the Service data in both categories MCP4 and MCP5. (Categories)
The adjustment item “SYS” data should be changed from 2 to 1 in both TV and Video modes.
Write the new Service data settings.
Screen Adjustment G-2/ Sub-bright adjustment:
Equipment required: Darkened Room and/or a heavy blanket to cover the set.
Signal Applied/Input: Select Video 1 input / No signal applied
Adjust points: G2 (Screen Controls) VRs for RGB and Sub-Brightness register
Conditions: Darken Room preferred. If not possible, a blanket must cover the front of the screen.
•Standard Picture Mode (reset mode to ensure proper setting of this mode)
•Turn off ALL the CRT outputs in Service mode.
Confirmation Procedure:
1. To confirm proper setting (with all 3 CRTs OFF), the screen should ALMOST be at cut-off.
2. If not, check Sub-Bright Data in the service mode. Service data Range is usually 21 to 25 in the
Service menu, category "MCP2", adjustment item 01 "SBRT".
3. If the picture is still not at almost cut-off, proceed to the adjustment procedure below.
Important Notes on G2 setup: It is crucial that the G2 adjustment be done as accurately as possible. If it is
off even slightly, white balance and focus can be greatly affected. Also, if the G2 is set incorrectly, it may
cause an intermittent video shutdown condition, due to the affect on the IK circuit.
Therefore, the following procedure must be adhered to:
•The room should be as dark as possible.
•Also, a blanket (standard heavy mover’s blanket used to protect furniture) is required
for this procedure. The blanket must be placed over the technician and the front of the TV
screen to minimize the ambient light. Only with this method can the technician see the correct
adjustment level.
Adjustment Procedure:
1. Turn the green screen control on the Focus Block until retrace lines appear and gradually turn it back
until the point where you can see the retrace line disappears, just before cutoff.
2. Turn the red screen control on the Focus Block until retrace lines appear and gradually turn it back
until the point where you can see the retrace line disappears, just before cutoff.
3. Turn the blue screen control on the Focus Block until retrace lines appear and gradually turn it back
until the point where you can see the retrace line disappears, just before cutoff.
4. If the screen still appears too bright after proper G-2 adjustment, please adjust the sub-bright
control down until screen cut-off. (Service data Range is usually 21 to 25 in the Service menu,
category "MCP2", adjustment item 01 "SBRT").
Screen Controls Located on Focus Block

TV Products Service Bulletin No. 531
Green, Red & Blue CRT 2 Pole Magnet Confirmation / Adjustment:
Equipment required: Pattern Generator
Signal Applied/Input: Dot Hatch Pattern (100-IRE) / Video 1 input
Adjust points: Confirmation: RGB Focus VRs Adjustment: 2 Pole Magnets on CRTs
Conditions: Brightness to 50% and Picture to 100%
Confirmation/ Adjustment Procedure for 2 Pole Magnet Adjustment:
1. Turn off Red and Blue CRTs.
2. Turn G VR to the CCW (over-focus) and view the center luminance point, which must be in the center
of the dot. (See diagram below).
3. Rotate the VR back and forth to verify that the luminance point remains in the center. If it does, this
adjustment is not required. If the luminance point does not remain in the center, you must perform the
2 Pole Magnet adjustment. Note: In the large majority of cases, this adjustment will not be needed.
4. Adjust the 2-Pole Magnet on the CRT to center the luminance spot.
5. Set the VR for best focus
6. Perform the same procedures for the Red and Blue CRTs.
4-Pole Magnet Confirmation / Adjustment for the Green & Red & Blue CRTs:
(Same setup/conditions as for the 2-Pole magnet adjustment)
1. Turn off the red and blue CRTs.
2. Turn the green focus control on the Focus Block to the CW and the spot will become larger.
3. The dot should be round. If it is oval, perform the following steps.
4. Adjust the two tabs (the tabs towards the bell of the CRT) until the spot becomes round.
5. Red Adjustment: Perform the same procedure for the Red CRT 4-Pole Magnet. Adjust if necessary,
see following illustration.
6. Blue Adjustment: Perform the same procedure as the Green CRT, however the shape should be a
slight vertical oval (not round) in the center of the screen. Adjust if necessary, see the following
illustration.
Correct setting: Bright
point in the center

TV Products Service Bulletin No. 531
Blue De-Focus adjustment (The blue focus needs to be slightly defocused so to produce a more
pleasing picture). Same setup/conditions as for the previous adjustment, except select the Vivid mode (reset
the Vivid Mode to ensure proper settings).
Confirmation / Adjustment:
1. Adjust the blue focus VR to the CW (under focus) slightly while looking at the left side of the screen.
2. When the blue horizontal luminance line (not flare) starts to increase in size, stop turning the VR. The
Vertical or Horizontal width of the blue luminance line should be no larger than x1.5 the size of the
green line.
3. Turn the green CRT back on to confirm the size of blue in reference to green.
NOTE: This adjustment will of course make a slight blue outline visible on the white lines, however an
additional blue flare may be seen (halo around the blue luminance lines). If the additional blue flaring is seen,
(see picture below) it may be necessary to adjust the blue lens mechanical focus. The blue flare should be
minimized as much as possible; adjust to best position, which has the least amount of flare.
See photo below: Far left side should have a slight blue edge in Vivid mode with a 100-IRE hatch.
Example:
If too much blue flare is
seen, then adjust blue
mechanical lens focus
Blue Flaring
Red and Green dot should be
round
The Blue dot should be Oval in
shape. The vertical should be 1.5
x the horizontal size
Correct: blue dot in center of
the screen has a vertical oval
Incorrect: blue dot in center of
the screen has a horizontal oval

TV Products Service Bulletin No. 531
CRT/ Lens Focus adjustment:
Equipment required: Pattern Generator
Signal Applied/Input: All white 100-IRE signal for aging & crosshatch for adjustments
Adjust points: Mechanical lens adjust and adjustment of the electrical focus VRs
Conditions: Set must be pre-aged as describe in the front section of this document, under
Important Notes.
1. Apply a crosshatch pattern to one of the video inputs.
2. Start with the Green CRT, therefore turn off the other two CRTs in the Service mode.
3. Two persons, one to adjust the lens, and one to watch the front of the picture will
achieve better overall adjustment results. If a second person is not available, apply a
white sheet of paper on the inside of the screen. Then by looking at the paper’s
reflection in the sets mirror, adjusting the mechanical lens as in the next step.
4. Adjust the mechanical lens of the Green CRT first (loosen the wing nut on the lens.
Adjust the lens to achieve proper (equal) balance between left and right sides of the
picture, while also achieving good center focus. Focus in the center area of the
screen should be better than in the corner areas.
5. If proper balance cannot be achieved, then loosen all lens screws and re-seat the
lens (see the drawing below for the locations of the lens screws). Then create a just-
snug condition (each screw's washer is slightly compressed) with the screws and try
to adjust the focus again.
ONLY IF PROPER BALANCE STILL CANNOT BE ACHIEVED, remove lens screws and
rotate the lens 90°. Reinstall the lens screws in the new pilot holes. The new pilot holes will
not have had screws installed previously, so you should expect to feel some resistance
while installing the screws. Tighten the screws by following torque sequence shown in the
drawing below, but do not completely seat the screws (over-torque). Perform lens re-
adjustment again. With a 100-IRE crosshatch pattern, you may see a slight amount of blue
or red halo on the green crosshatch lines. This is caused by the prism effect of the green
CRT lens. However, try to minimize the amount of blue or green flare seen on the screen
while maintaining sharper more defined lines. If red halo is seen on the green lines re-adjust
the focus lens to eliminate reddish colored flare.
2 4
3 1
1. IMPORTANT: After the mechanical focus is performed, adjust the electrical focus on
the focus block for a final touch-up. Once again, try to achieve proper balance
between center and corners while keeping center slightly better.
2. Red mechanical lens adjustment should apply the same method as described for
green, except for the color of the flare, which will be red to a yellowish red. Try to
←Torque sequence applied to lens. If slight tilt / rocking
motion is noticed, lean lens to the # 3 or # 4 position and
begin torque sequence. Start at position No.1 and tighten
until each screw's washer is slightly compressed.

TV Products Service Bulletin No. 531
minimize or eliminate this flare as much as possible.
White balance adjustment:
Equipment required: pattern generator with 100 IRE all white pattern.
Optional: white balance meter.
Signal Applied/Input: 100 IRE all white pattern
Adjust points: Registers accessed in the service mode
Conditions:
This adjustment must be done in Standard picture mode for both the Neutral and Warm
settings, however, please check color tracking to determine if this adjustment is necessary.
To do this, apply a B&W signal and check it at both high and low brightness settings to
verify the grayscale and white levels do not have color tinting. If the set checks good for
color tracking, it is not necessary to do this procedure. Please note if the G2 was adjusted, it
is most likely the white balance should be adjusted.
Provided below are two methods to adjust white balance. One with a white balance meter
(preferred) and one without.
Preliminary setup for White Balance Confirmation / Adjustment
In Standard picture mode
All other user controls at their reset condition. To reset the user controls, press the rest
button on the remote control while Standard picture mode is active. Under the Standard
Mode Menu (customer menu/user controls), select "COLORTEMP" and set it to Neutral.
Check the white balance in both high (100-IRE) and low (20-IRE) IRE all white signal. If a
low IRE signal is not available, then reduce the picture level until an appearance of 20-IRE
signal is seen on the screen. This is approx. 3 bars (display dashes that illustrate level) up
from minimum picture adjustment on the picture bar-graph display on the screen. Proceed
to the adjustment section below if the color temperature (tracking) appears to be incorrect
for either the high or low IRE input signal. A white balance meter can be used to confirm the
white balance if available. If adjustment is required, perform the white balance adjustments
by either method below.
Adjustment with a white balance meter: (Preferred Method)
1. For the High-level IRE all white signal adjust R/G to 1.05 and B/G to 0.9. (Adjust by
RDRIV, BDRIV in MCP1)
2. For the Low-IRE adjustment, adjust picture level to 3 bars up from minimum on the
picture bar-graph display if the IRE input signal level cannot be adjusted to 20-IRE.
(Adjust RCUT, and BCUT in adjustment category "MCP1" the same as above, i.e.
R/G to 1.05 and B/G to 0.9.
3. After low-level white adjustment (cutoff adjustment) repeat the high level adjustment
to achieve proper white balance tracking.
4. Confirm the adjustment with COLORTEMP set to WARM mode. Picture should
become slightly more reddish; if not, repeat the adjustments shown above. In
addition, confirm adjustment by switching to a black and white broadcast movie if

TV Products Service Bulletin No. 531
available.
Adjustment without white balance meter:
1. The 100 IRE all-white signal must be adjusted by eye. Adjust RDRIV, BDRIV in
MCP1 to make the white as pure as possible.
2. Adjust picture level to 3 bars up from minimum on the picture bar-graph display if the
IRE input signal level cannot be adjusted to 20 IRE. Adjust RCUT, and BCUT in
adjustment category "MCP1" by eye to make the gray as pure as possible.
3. After low-level white adjustment (cutoff adjustment) repeat the high level adjustment
to achieve proper white balance tracking.
4. Confirm the adjustment with COLORTEMP set to WARM mode. The picture should
be slightly more reddish; if not, repeat the adjustments above. Please also confirm
adjustment by switching to black and white broadcast movie if available. If a B&W
signal is not available, turn the color off using the customer controls. In some sets,
the customer controls may not entirely eliminate all color, thus in this case, an
external B&W signal needs to be applied. Below are typical white balance data
ranges for each model.
ADJ. KP65XBR10W KP57XBR10W
RDRIV 28~33 35~40
BDRIV 22~23 15~20
RCUT 51~57 55~60
BCUT 40~42 32~38
Geometry/ Convergence adjustment:
Equipment required: pattern generator (should have 1080i Y,Pb,Pr capability)
Signal Applied/Input: Crosshatch (for 1080i adjustment, signal must be applied to Video 5
input)
Adjust points: Registers accessed in the service mode
Conditions: Multiple Modes will require to be checked for mis-convergence and geometry.
1. Normal/Full
2. Wide-Zoom
3. Zoom
4. 1080i mode: (Video 5 input Only)
IMPORTANT NOTE: For each mode, use the remote to enter the modes above (in the
order listed) and check for correct geometry and convergence. If adjustment is required, use
the Fine Adjustment Mode to correct the distortion. After adjusting each mode (while still in
the Fine Adjust Mode) write the data into memory (Muting, then Enter) and then activate the
Flash Focus (button on front of set) before going to the next mode.
•Either darken the room or shield the screen from ambient light so the Flash Focus
works properly.
•Do not adjust sizing, position or centering, as it may cause mis-operation of the Flash
Focus circuit, causing major convergence and geometry mis-adjustment.

TV Products Service Bulletin No. 531
Start with the Normal Mode (this will also adjust the Full mode simultaneously. Full and
Normal modes share the same adjustment data). Special Geometry adjustments are
required in Normal mode (4:3 mode with gray bars on sides):
1. Touch up top and bottom areas where the gray bars begin. Adjust these areas as
needed in the fine adjustment mode (see Fine Mode Adjust in the Reference
Section), green first, followed by red and blue. This will ensure gray bar edges are
straight in 4:3 mode. The inboard edges of the gray bars should be completely
straight, top to bottom. See following illustrations:
2. Change Normal mode to FULL mode and adjust all four corners to straighten out
vertical lines at the sides of the screen.
3. Also adjust the convergence as needed in all modes. Pay special attention to center
outside areas.
4. While still in the Fine adjust Mode, write the data into memory and then activate
Flash Focus on the front of the set.
Check / Adjust Wide Zoom Mode: If the mode checks OK, continue to other modes, if not,
please adjust in Fine Mode and Write the data into memory and then activate Flash Focus
on the front of the set.
Very Important:
If Wide Zoom mode needs to be adjusted and data is written into memory, the set
will automatically resets VSCO in category VDSP to 0 FOR ALL MODES. Wide
Zoom mode uses data 0 for VSCO, however, you must manually set the data back
to 7 in ALL the other modes or else the vertical size adjustment will be incorrect.
Check / Adjust Zoom Mode: If the mode checks OK, continue to other modes, if not,
please adjust in Fine Mode and Write the data into memory and then activate Flash Focus
on the front of the set.
Check / Adjust the 1080i Mode: To be able to check and adjust this mode, you must either
have a 1080i video signal or a 1080i generator. If you do not have either of these, you
cannot perform this adjustment, therefore proceed to the next adjustment. If you do have
either one of these items, then proceed with this adjustment.
Close-up showing the bending at top right
cor
n
er
Gray bars on each side of picture

TV Products Service Bulletin No. 531
Apply a 1080i signal to the Video 5 input and go into service mode. Turn on internal
crosshatch signal and adjust as needed. Please note, a 1080i signal MUST BE APPLIED to
the Video 5 input for the internal crosshatch generator to enter the 1080i mode. If this is not
done, the pattern displayed will not be 1080i but stay in the NTSC 480i mode. Please note:
If a 1080i crosshatch generator is available, use this signal to adjust rather than using the
internal pattern (this is a preferable method). If the mode checks OK, continue to the next
step, if not, adjust the set in the Fine Mode. After any new data is written (by pressing
"MUTING: then "ENTER"), press "Flash Focus" in service mode so that TV can calculate
the new offset data.
Final Check:
Now check each mode with a live video signal to verify correct operation. If problems
still exist, please readjust. If a 1080i source is available, please check this mode.
Final steps, please enter the menu and select the Video Icon and view the set in Standard
Picture Mode and then in the Vivid Picture mode. When Vivid is selected, please lower the
brightness level slightly (10%). Blacks should appear black, not gray. Please select the
mode that looks best to the dealer. Please Circle the Mode you selected to leave the set in:
Standard / Vivid ). Also, confirm that the Dynamic Picture Function is ON (in the Video
Icon Menu).
SUPPORT DOCUMENTATION SECTION:
KP-(57/65) XBR10W PICTURE QUALITY QUESTIONNAIRE
SERVICE MANUAL INFORMATION
•Method of setting the Service Adjustment Mode.
•Writing new data into memory
•Memory confirmation Method
•Adjustment buttons on the remote:
•Fine Adjustment Mode for Green, Red and Blue Convergence and Geometry
•Auto-Registration Error Code list

TV Products Service Bulletin No. 531
•Method of setting the Service Adjustment Mode.
3. The screen displays the item being adjusted.
4. The category is reached by using the remote buttons 2 and 5.
5. The Adjustment item is selected using remote buttons 1 and 4.
6. The Data is changed using remote buttons 3 and 6.
Using the remote 2 or 5 button you will search through the category shown in the chart below.
The acronyms above are the titles of the different adjustment categories. See the Service Mode charts for the
definition of the various categories. Example: VDSP (Vertical Deflection Signal Processor).
1. If you want to recover the original data (if you did not save any changes) press the 0then Enter button on
the remote.
Writing new data into memory.
1. After adjusting the data it must be placed into memory (writing). This is done using the
muting button (the data turns red) then the Enter button. (The data turns green)
Memory confirmation Method:
1. After finishing all adjustments and saving the data changes, remove the AC plug from the outlet, and then
plug in again.
2. Turn unit on to Service Mode.

TV Products Service Bulletin No. 531
3. Check the data and confirm it retained the changes you made.
Adjustment buttons on the remote:
RM-Y907
Note: When the category PJE is selected, which displays an internally generated
signal, several buttons on the remote commander will have different functions then
listed above. Therefore, when in the PJE Mode, refer to section Registration
Adjustment (PJE). Function of buttons of remote commander for PJE mode
Registration Adjustments (PJE)
Function of the Remote Buttons in PJE Mode
CAUTION
Do not use 7 enter.
This will reset to
before factory
adjustments were
made.
8 Enter will reset the
customer settings to the
factory settings. Also
will reset the service
Data to the last saved
data entries.

TV Products Service Bulletin No. 531
IMPORTANT:
Separate adjustments are required for the multiple modes and MUST be done in the following order. (Each
mode will require a separate adjustment.)
Full (Normal) Mode
Wide Zoom Mode
Zoom Mode
1080I (video 5 input mode)
In all these modes, both color and geometry adjustments are required.
In order to do the 1080I (Video 5) mode adjustment, you must follow this procedure.
Connect green component from the 1080 generator to the green video 5 input.
Video 5 forced 1080I mode setting OP 03 1080 to 001 in the
Service Mode.
Fine Adjustment Mode for Green, Red and Blue Convergence and
Geometry:
1. Press the 9 button on the remote. This puts you in the fine mode.
The green cursor (in the green mode) appears on the center of the screen.
(Pressing the 3 button will change the mode to Red or Blue)
2. Using the remotes 1 or 4 button, or the remote joystick, moves the cursor
(See below) around the screen in a square-pattern.
Pressing the remote joystick the cursor turns green to white. When it is white the cursor can be moved up and
down left or right around the screen.
Press once again the joystick button and the cursor stops and returns green, and you can adjust the miss-
convergence in the cursor area.

TV Products Service Bulletin No. 531
Press the remote 9 button again to exit the fine mode and revert back to the coarse mode.
Store the new adjustment data values by using the remote buttons Muting then Enter.
IMPORTANT:
The adjustments above must be repeated for the different modes in the order below.
Full (Normal) Mode
Wide Zoom Mode
Zoom Mode
1080I (video 5 input mode)
In all these modes, both color and geometry adjustments are required.
Final Check:
1. Store the new adjustment data values by using the remote buttons Muting then Enter.
2. Press the FLASH FOCUS button on the front panel.
(The Offset values are now automatically stored.)
3. Check that no error message appears.
4. If you get an error check the centering adjustment.
5. See the Auto Registration Error Code List for an explanation of the error code displayed.

TV Products Service Bulletin No. 531