7-3.Bezenet and Mirror Cover Block ............................ 156
7-4.Main Bracket and Picture Tube Block .................... 157
8. ELECTRICAL PARTS LIST........................................ 158
OPERATING INSTRUCTIONS
CAUTION
SHORT CIRCUIT THE ANODE OF THE PICTURE TUBE AND THE
ANODE CAP TO THE METAL CHASSIS, CRT SHIELD, OR
CARBON PAINTED ON THE CRT, AFTER REMOVING THE
ANODE.
SAFETY-RELATED COMPONENT WARNING!!
COMPONENTS IDENTIFIED BY SHADING AND MARK ! ON THE
SCHEMATIC DIAGRAMS, EXPLODED VIEWS AND IN THE
PARTS LIST ARE CRITICAL TO SAFE OPERATION. REPLACE
THESE COMPONENTS WITH SONY PARTS WHOSE PART
NUMBERS APPEAR AS SHOWN IN THIS MANUAL OR IN
SUPPLEMENTS PUBLISHED BY SONY.
– 3 –
KP-FR43M31/FR43M91
RM-GA001
SECTION 1
SELF DIAGNOSTIC FUNCTION
The unit in this manual contain a self-diagnostic function. If an error occurs, the STANDBY/TIMER LED will automatically
begin to flash.
The number of times the LED flashes translates to a probable source of the problem. A defination of the STANDBY/TIMER
LED flash indicators is listed in the intruction manual for the user’s knowledge and reference. If an error symptom cannot be
reproduced, the remote commander can be used to review the failure occurrence data stored in memory to reveal past
problems and how often these problems occur.
1-1. DIAGNOSTIC TEST INDICATORS
When an error occurs, the STANDBY/TIMER LED will flash a number of times to indicate the possible cause of the
problem. If there is more than one error, the LED will identify the first of the problem areas.
Result for all of the following diagnostic items are displayed on screen. If the screen displays a “0”, no error has occurred.
Diagnostic
Item
Description
•Power does not
turn on
• +B overcurrent
(OCP)
• +B overvoltage
(OVP)
•Vertical deflection
stopped
• White balance
failure
(not balanced)
•LOW B down***
• Horizontal
deflection
stopped
•Audio Protection
• Zero crossing
detector
• HV protection
No. of times
STANDBY/TIMER
LED flashes
Does not light
2 times
3 times
4 times
5 times
6 times
7 times
8 times
9 times
10 times
Self-diagnostic
display/
Diagnostic result
—
Item 2:1
or more than 1
Item 3:1
or more than 1
Item 4:1
or more than 1
Item 5:1
or more than 1
Item 6:1
or more than 1
Item 7:1
or more than 1
Item 8:1
or more than 1
Item 9:1
or more than 1
Item 10:1
or more than 1
Probable Cause Location
•Power cord is not plugged
in.
• Fuse (F6000) is burned out.
(A board)
• H.OUT (Q5001) is shorted.
• +B PWM (Q5201) is
shorted. (D board)
• IC6503 is faulty. (D board)
• 15V is not supplied.
(D board)
• IC5101 is faulty. (D board)
• Video Out
(IC9101,IC9201,IC9301)
is faulty. (CR,CG,CB board)
•CRT drive (IC0401) is faulty.
(MG board)
• G2 is impropenrly adjustd.**
• +5V line is overloaded.
(A, BM, MG boards)
• +5V line is shorted.
(A, BM, MG boards)
• IC6201 is faulty. (A board)
• Q5006 is broken. (D board)
• IC0401 is faulty. (MG board)
•+ or - 22V audio supply
is not present - Check
PS2001 & PS2000.
• D6166 or D6114 is open.
(A board)
• Q8014 or Q6013 have
shorted replace along with
R8051 on D board.
• IC8005 is damaged.
(D board)
Symptoms
•Power does not come on.
• No power is supplied to the PJ.
•AC power supply is faulty.
•Power does not turn on.
• Load on power line is shorted.
• Has entered standby mode.
• Has entered standby mode
after horizontal raster.
•Vertical deflection pulse is
stopped.
•Power line is shorted or power.
• No raster is generated.
•CRT cathode current detection
reference pulse output is small.
• No picture.
• No picture.
• No picture.
• No picture.
• No picture.
*If a +B overcurrent is detected, stoppage of the vertical detection is detected simultaneously. The symptom that is
diagnosed first by the microcontroller is displayed on the screen.
**Refer to screen (G2) adjustment (fine adjustment) in section 2 of this manual.
***Is STANDBY/TIMER LED flashes six (6) times, unplug the unit and wait 10 seconds before performing the adjustment.
Number 1
means a fault was detected one time only.
Number 0
means that no fault detected.
SELF DIAGNOSTIC
RM-GA001
1-2. DISPLAY OF STANDBY/TIMER LIGHT FLASH
COUNT
Diagnostic items Flash count
+B Overcurrent 2 tims
Low +B Overvoltage 3 tims
Vert deflection stopped 4 tims
White balance failure 5 tims
Low +B OVP/OCP 6 tims
Horiz. deflection stopped 7 tims
Audio protection 8 tims
Zero crossing detector 9 tims
HV protection 10 tims
* One flash counts is not used for silf-diagnostic.
LED ON 0.3 sec.
LED OFF 0.3 sec.
LED OFF 3 sec.
1-3. STOPPING THE STANDBY/TIMER FLASH
Tu rn off the power switch on the TV main unit or unplug the
power cord from the outlet to stop the STANDBY/TIMER
lamp from flashing.
Self-Diagnosis is screen display:
1-5. HANDLING OF SELF-DIAGNOSTIC SCREEN
DISPLAY
5
ON SCREEN
()
DISPLAY
2 –
*(VOLUME)(POWER)(DIGIT 5)
*: Note that this differs from entering the service mode
(volume +)
Since the diagnostic results displayed on the screen are
not automatically cleared, always check the selfdiagnostic screen.
After you have completed repairs, clear the result display
to “0”
:/1
STANDBY/TIMER
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:
[To Bring Up Screen Test]
In standby mode, press buttons on the remote commander
sequentially in rapid succession as shown below:
[Clearing the result display]
To clear the result display to “0”, press button on the remote
commander sequentially as shown below when the
diagnostic screen is being displayed.
8 button
Press
(It will indicate “CLEAR” on the screen.)
Press - button
(The “CLEAR” display change to red color.)
[Quitting Self-diagnostic screen]
To quit the entire self-diagnostic screen, turn off the power
switch on the remote commander or the main unit.
– 5 –
KP-FR43M31/FR43M91
RM-GA001
1-6. SELF-DIAGNOSTIC CIRCUIT
MG BOARD
IC0001
STBY-LED
MAIN MICRO
22
STBY-LED
5
OCP
6
OVP
87
LOW B ERR
33
HV PROT
CLKO
DATO
AC RLY
24
56
57
Q6105
CRT
VDY-
Q6102
D6803
D6122
D6121
RY6000
<+B OCP>
<+B OVP>
<P_SW(-)
<IK PROT2>
+B>
+12V
Q5202
+B>
< H PLS
IC6801
1
< +B
D6805
+15V
<
2
Q6802
3
AKB
V PROT
14
13
36
53 SCL
52 SDA
Q6108
HG PROT
IC6201
1
2
3
< +15V
IC8001
1
Q6803
<+B OCP>
A BOARDD BOARD
+B overcurrent (OCP)Occurs when excessive current flows through R6812.
The increase in voltage across Q6803 causes it to turn on which sends a high
signal to the micro.
+B overvoltage (OVP)IC6801 detects +B OVP condition and Q6802.
This sends a high signal to the micro and also shuts down the AC relay.
V-STOPOccurs when an absence of the vertical deflection pulse is detected by pin 56
of IC0404. (MG board)
Power supply will shut down when waveform interval exceeds 2 seconds.
While balance failureIf the RGB levels* do not balance within 2 seconds after the power is turned
on, this error will be detected by IC0401.
TV will stay on, but there will be no picture.
Low +B OCP/OVPOccurs when set 5V is out.
Horizontal deflection stoppedOccurs when either:
1) a +B overcurrent is detected (Q6803), or
2) IC0401 (MG board) is damaged.
– 6 –
DISASSEMBLY
2 Rear board
SECTION 2
2-2. MAIN BRACKET REMOVAL2-1. REAR COVER REMOVAL
KP-FR43M31/FR43M91
RM-GA001
1 Optical shield
2 Two screws
(Tapping screw
hexagon head)
1 Fourteen screws
(Tapping screw
hexagon head)
2-3. FRONT PANEL ASSY REMOVAL
Three screws
(tapping screw
hexagon head)
Three screws
(tapping screw
hexagon head)
3 PWB block assy
2-4. HA1, HB1, HC1 AND HX
BOARDS REMOVAL
2 HA1 board
1 Two screws
(BVTP 3x12
Type2 IT-3)
3 HB1 board
Three screws
(BVTP 3x12
Type2 IT-3)
4 HC1 board
5 HC1 bracket
6 HX board
Front panel (43) assy
Front panel assy
– 7 –
KP-FR43M31/FR43M91
RM-GA001
REMOVAL
2-6. BEZNET ASSY REMOVAL2-5. MIRROR COVER AND BEZNET BLOCK
5 Beznet block
4 Four screws
(BVTP 4x12)
3 Mirror cover
2 Four screws
2 Six screws
(BVTP 4x16)
1 Four screws
(Hexagon head)
2 Four screws
(BVTP 4x16)
6 Diffusion plate (F)
7 Diffusion plate (L)
8 Contrast screen
9 Beznet assy
2-8. UG BOARD REMOVAL2-7. TERMINAL BRACKET REMOVAL
3 Six screws
(BVTP 4x16 Type2 IT-3)
4 Screen holder (side)
5 Twelve screws
(BVTP 4x16 Type2 IT-3)
2 Holder Bracket (43L)
qf Screen holder
(TOP)
0 Screen holder
(LOW)
Mirror cover
qa Four screws
(BVTP 4x16
Type2 IT-3)
qs Screen holder
(SIDE)
qd Holder
Bracket (43R)
PWB block assy
RF splitter
4 Terminal bracket
3 Screw
(PSW 3x8)
2 Four screws
(BVTP 3x12
Type2 IT-3)
1 Two screws
(Hexagon head)
Main bracket section
1 Two screws
(PSW 3x8)
2 B bracket
3 UG board
– 8 –
1 T board
6 MG Board
2 BH board
5 AD Board
3 Two screws
(BVTP 3x12
Type2 IT-3)
4 DS board
2-10. A, D AND G1 BOARDS REMOVAL2-9. AD, BH, DS, MG AND T BOARDS REMOVAL
7 Six screws
(BVTP 3x12)
8 D board
5 Six screws
(BVTP 3x12)
KP-FR43M31/FR43M91
RM-GA001
1 Two screws
(BVTP 3x12
Type2 IT-3)
2 G1 board
3 Three screws
(BVTP 3x12
Type2 IT-3)
4 G1 bracket
6 A board
Main bracket section
2-11. CRT AND PWB BLOCK REMOVAL
1 Two screws
(BVTP 4x16)
5 Three screws
2 Three screws
(Hexagon head)
(4x20)
3 Picture tube block assy
(Hexagon head)
(4x20)
6 Two screws
(BVTP 4x16)
4 Two screws
(Hexagon head)
(4x20)
Main bracket section
PWB block assy
– 9 –
KP-FR43M31/FR43M91
RM-GA001
2-12. HIGH-VOLTAGE CABLE INSTALLATION AND REMOVAL
(1) Remover(2) Installation
1 Rubber cap
1 Rubber cap
2 HV cable turn 90
2-13. MECHANICAL ASSY REMOVAL
2 HV cab
Hook
Gutter
Removing the arrow-marked screw (gold color) is strictly inhibited.
If removed, it may cause liquid spill.
1 Four screws
(BVTP 4x16)
5 Four screws
(BVTP 4x16)
6 Mechaseal assy (R)
4 Deflection yoke
3 Neck assy
2 CR board
– 10 –
SECTION 3
SET-UP ADJUSTMENTS
KP-FR43M31/FR43M91
RM-GA001
3-1. SCREEN VOLTAGE ADJUSTMENT
(ROUGH ALIGNMENT)
1. Receive the Monoscope signal.
2. Set 50% BRIGHTNESS and minimum PICTURE.
3. Turn the red VR on the focus pack all the way to the left
and then gradually turn it to the right until the point
where you can see the retrace line.
4. Next gradually turn it to the left to the position where the
retrace line disappears.
Focus Pack
FOCUS
BRG
SCREEN
BRG
Fig. 3-1
3-2. SCREEN (G2) ADJUSTMENT
(FINE ADJUSTMENT)
1. Turn on the power of the set.
2. Select VIDEO1 and make no signal input.
3. Supply DC (177.5 0.5V) from external power supply to
KR. (Fig. 3-2)
4. Turn red of G2 VR clockwise, then retrace line appear.
5. Turn G2 VR counter clockwise and set retrace line just
disappear. (Fig. 3-3)
6. Add DC voltage DC (174 0.5V) to KR.
7. Confirm if retrace can be seen.
8. Adjust green and blue at the same method.
Power
Supply
+
–
Dummy Resister
3k ohm 20W
3-3. BLUE OFFSET ADJUSTMENT
This adjustment item must be ending the G2 adjustment.
1. Input the HD (1080i/60Hz Black) signal into component
in terminal.
2. Set PICTURE 100%, others are normal,
DRC 1250/60Hz.
3. Adjust with SLN so that the blue reference pulse peak
voltage of B terminal (CN1504) enters into standard.
BLUE REFERENCE PULSE
(UG board CN1504 B5 B)
2.15
0.05V
GND (0V)
V
Item: DE F2 03 SLN
4. Write the adjustment value in the NVM area of
widezoom mode after the adjustment.
3-4. FOCUS ROUGH ADJUSTMENT
1. Connect VIDEO-1 terminal.
2. Receive video dot hatch pattern.
3. Use lens-cover to red and blue.
4. Adjust electric focus. (roughly)
5. Rotate the green lens and adjust to obtain the best lens
focus.
6. Rotate the green focus volume on the focus pack and
adjust to obtain best electrical focus.
7. If focus is not good, repeat 4 process.
8. Repeat above process for red and blue lenses and
electric focus.
9. Fix lens screw.
Scanning line visible.
Fig. 3-2
Test signal
Fig. 3-3
– 11 –
A
Minimize both A and B.
Lens
B
Fig. 3-4Fig. 3-5
KP-FR43M31/FR43M91
j
RM-GA001
3-5. DEFLECTION YOKE TILT ADJUSTMENT
1. Receive the Monoscope signal.
2. Place the caps on the red and blue lens so that only the
green color.
3. Loosen the deflection yoke setscrew and align the tilt of
the Deflection yoke so that the bars at the center of the
monoscope pattern are horizontal.
4. After aligning the deflection yoke, fasten it securely to
the funnel-shaped portion of the CRT.
5. The tilt of the deflection yoke for red and blue is aligned
the same as was done for green.
4-Pole Magnet
2-Pole Magnet
VM Coil Assy
Deflection Yoke
Anode Cap
Centering Magnet
Fig. 3-6
3-6-3. Blue left side dot adjustment of 2-pole Magnets
1. Turn blue focus volume of fucus pack counter-clockwise,
so that diameter of the dot becomes large, and can see
bright core position.
2. Pay attentio to left side dot of the screen. (Fig. 3-10)
3. Adjustment 2 pole magnet, so that bright core position of
dot become center position of dot. (Fig. 3-11)
Blue 2 Pole magnet
Adjustment Position
Fig. 3-10
Use the center dotBright Core
3-6. 2-POLE AND 4-POLE MAGNET ADJUSTMENT
3-6-1. Adjustment of 2-pole magnets
1. Receive the Dot signal (1080i/50Hz) from HD/DVD 1
terminal.
2. Place the caps on the red and blue lens so that only the
green color is shown.
3. Turn the green focus volume of focus pack counterclock-wise, so that diameter of the dot become large.
4. Adjust the 2-pole magnet, counter-clockwise and
clockwise center of the dot doesn’t move. (Use focus
volume)
5. Center position is changed by 2-pole magnet
adjustment. So, center magnet adjustment and 2-pole
magnet adjustment are needed tracking adjustment.
6. Repeat same adjustment method for red and blue.
Use the center dot
Left-end dot
(BLUE)
NG
OK
Fig. 3-7Fig. 3-8
Right-end dot
(BLUE)
Fig. 3-11
3-7. BLUE DEFOCUS ADJUSTMENT
1. Receive 1080i/50Hz dot signal from HD/DVD 1 terminal.
2. Set “VIVID” and PICTURE 100%, other 50% and white
balance “COOL” (VM OFF), PIOF: 0.
3. Blue 4 pole: make round in the center of screen.
4. Confirm that center dot focus is adjusted in focus.
(Fig. 3-12a)
5. Adjust blue electrical focus to make the left side spot
nearly round by minimizing width and height. (Slight
overfocus is OK) (Fig. 3-12b)
6. Confirm that the green to blue spot size is within spec.
Blue center dot height shall be 1.2 times the g reen dot
height.
7. Return data to original condition.
Blue 2 Defocus
Adjustment Position
ust focus
3-6-2. Green, Red, Blue adjustment of 4-pole magnets
Fig. 3-12a
1. Turn Green focus volume of focus pack clockwise.
2. By using 4 pole magnets make the spot size round.
3. Repeat for red and blue.
4. Turn focus pack counter-clockwise and “Just Focus” red,
green and blue.
OK
Fig. 3-12b
NGNGOK
Fig. 3-9
– 12 –
3-8. GREEN, RED AND BLUE FOCUS
ADJUSTMENT
3-8-1. Green, Red, Blue Lens focus adjustment
1. Input a cross hatch signal into VIDEO 1. (composite
video input)
2. Place a lens cover over red and blue lenses and project
only green.
3. Rotate the green lens and adjust to obtain the best lens
focus at the center area.
4. Fix lens screw.
5. Repeat above proces for red and blue.
Adjust Point center
Fig. 3-13
KP-FR43M31/FR43M91
RM-GA001
85%70%
Monochromatic flare (mm)
ModelCenter85% circle
531.02.5
431.02.5
3-8-1. Green and Red electrical focus adjustment
1. Input a cross-hatch signal into VIDEO 1.
2. Project only Green.
3. Rotate the green focus volume on the focus pack and
adjust to obtain the best focus at the center screen.
4. Repeat above process for red.
Adjust Point
Fig. 3-14
3-9. FINAL FOCUS CHECK
1. Receive 1080i/50Hz dot signal from HD/DVD 1 terminal.
2. Set “CUSTOM” MODE and PICTURE 100%.
3. Cap Red and blue lens.
4. Confirm that Green Resolution is within spec.
5. Receive HD (1080i) Hatch signal.
6. Confirm center and corner monochromatic flare within
spec.
7. Repeat process for Red if resolution is without spec
readjust focus.
Resolution (TV Line)
ModelCenter85% circle
53750600
43750600
or NG set
1. Adjust Focus Again.
2. If NG again, rotate Green Lens 180 degree.
3. Still NG, then judge with below standard.
Center “750”
85% circle: “600” at 3 points, and “550” at 1 point
4. Replace Green, Red Lens.
We mark this Lens, try to fit this Lens with another set.
If NG again in another set, this Lens is leaved.
3-10. ADJUSTMENTS WITH COMMANDER
Service adjustment to this model can performed with the
supplied remote commander RM-GA001.
3-10-1. How to Enter Service Mode
1. Turn on the main power switch to place this set in
standby mode. (LED will light in red.)
2. Press the buttons on the commander as follows, and
enter service mode.
5
ON SCREEN
()
DISPLAY
3. After entering service mode, reset current adjustment
data. Then turn off the power switch.
2 –
(VOLUME +)(DIGIT 5)
8
(ENTER)(DIGIT 8)
4. Turn on the main power switch and enter mode again as
step 2 above.
:/1
TV
()
STANDBY
Enter the
“Reset”
Enter the
“Service mode”
– 13 –
KP-FR43M31/FR43M91
RM-GA001
3-10-2. Method of Cancellation from Service Mode
1. Set the standby mode (Press “!/1 (TV STANDBY)”
button on the commander), then press “!/1
(TV STANDBY)” button again, hereupon it becomes TV
Mode.
3-10-3. How to Adjustments
1. Set in the service mode, the following screen will
appear.
Category NameItem Name Mode
Item No. Data
SERVICE 60 CH 6320OSDOSV
000Q 3.1M 0010 0000 20 00 00 0000
Suffix No.
Software
Version
Total Power On time
(Hours)
50 : PAL, SECAM
60 : NTSC
2. Press “1” or “4” button on the commander to select the
adjustment item.
3. Press “3” or “6” button on the commander to change
the adjustment data.
4. Move “
When move “
” up or down to select the adjustment category.
” up (category up), service mode
changes in the order as shown below.
PIC
SOU
YCTM
YCTS
MID1
MID2
DDEV
PJE*
PFOP
GUID
3-10-4. How to Write the Data
1. Set in the service mode.
2. Press “1” or “4” button on the commander, select the
adjustment item, and press “3” or “6” button to change
the data.
3. Press “% (MUTE)” button on the commander and it will
indicate “WRITE” on the screen.
4. Press “-” button on the commander to write into
memory. (The “WRITE” display will be changed to red
color while executing, and back to “SERVICE”.)
Commander Function (Except PJE mode)
ButtonModeDescription
% + -WRITEWrites data to NVM.
7 + -READReads data from NVM.
8 + -NORMALAll user control goes to the
standard.
5 + -INITIALService data initialization.
Not stored.
(Be sure not to use usually)
2 + -COPYDo not operate with a remote
commander.
+ -WRT5060(The data vary with among
mode.)
Note : Before changing to other modes, press “% (MUTE)”
+ “-” buttons on the commander to write the data.
(Omission of this operation causes the data to be
returned to the data before adjustment.)
: Confirm the adjustment mode before writing data for
data values because to vary in each adjustment
mode.
: The adjustment item that there are no relations in the
adjustment is not to change data values because all
items are written in each adjustment mode.
DRC
LUMA
COLR
CLTY
MIDE
CCPM
COMB
YCTC
MCP
DEF1
DEF2
DEF3
DEF4
DEF5
MID3
VSW
CRNR
RNR
BNR
SNNR
AWID
GRN
AP
MSMO
OSDP
ASEL
VSEL
PFID
* : When it moves from PJE to other categorys,
repeat 1 or 4 button and press it.
POWR
OPM
OPB
SRV
OSD
MSP
TEXT
3-10-5. Memory Write Confirmation Method
1. After adjustment, turn off the AC main power switch off.
2. Turn the power switch ON and set in the service mode.
3. Call the adjustment items again to confirm adjustments
were made.
Auto TV System0: TV System Fixed1: TV System Auto Detect (Stereo Decoder)
Main-Tuner Stereo0: Monaural1: Stereo
NICAM0: not available1: available
HDEV (High Deviation Switch)0: Auto Stereo Only1: Auto Stereo/Fixed Monaural Select
Korean stereo0: not available1: available
US stereo0: not available1: available
SECAM0: not available1: available
Center Speaker0: not available1: available
Video NTSC3.580: Video 1-4 Multi Col Sys1: Video 1-4 col Sys NTSC3.58 fixed
HD/DVD input0: No HD/DVD input1: HD/DVD1
2: HD/DVD 1,2,33: HD/DVD 1,2,3
AVIN0: No Video1: Video 1
2: Video 1,2,33: Video 1,2,3,4
Msys miss (miss detect c/m)0: not available1: available
Band Edge (c/m)0: not available1: available
Language Korea0: not available1: available
Language Taiwanese0: not available1: available
Language Thai0: not available1: available
Language Arabic0: not available1: available
Language S-Chinese0: not available1: available
IK Blanking (Test Bit)0: Not used1: Used
Memory Stick Off Blanking0: Normal1: long blanking
DRC palette (DRC-MF_V1)0: not available1: available
DRC 3 Mode0: 2 Mode (DRC 1250/Prog)1: 3 Mode (DRC 1250/DRC100/Prog)
Memory Stick0: not available1: available
Multi-Pic0: Single1: Quick-PAP
2: TWIN, INDEX3: Quick-PAP & TWIN, INDEX
Power Wide/Narrow (for CTV)0: Narrow CTV/CPJ1: Wide CTV
Wide0: 4:3 Model1: 16:9 Model
Front Key0: Front 7 key1: Front 8 key (CPJ)
2: Front 12 key3: Reserved (Front 12 key)
Eco-Standy0: Standby not sleep1: Standby sleep available
Zero Cross0: NG Power On1: NG Power Off
CPJ0: TV1: CPJs