9. ELECTRICAL PARTS LIST ........................................... 126
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.
– 2 –
KV-DA322M64/M66
SELF DIAGNOSTIC FUNCTION
The units in this manual contain a self-diagnostic function. If an 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. 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. DIAGNOSTIC TEST INDICATORS
When an error occurs, the STANDBY/TIMER lamp will flash a number of times to indicate the possible cause of the
problem. If there is more than one error, the lamp will identify the first of the problem areas.
Result for all of the following diagnostic items are displayed on screen. No error has occured if the screen displays a “0”.
RM-GA001
Diagnostic
Item
Description
•Power does not
turn on
• +B overcurrent
(OCP)
• Horizontal
deflection failure
• +B overvoltage
(OVP)
•Vertical deflection
failure
• White balance
failure (no
PICTURE)
• 5V/9V failure
• Micro reset
No. of times
STANDBY/TIMER
lamp flashes
Does not light
2 times
3 times
4 times
5 times
8 times
—
Self-diagnostic
display/Diagnostic
result
—
002:000 or
002:001~255
003:000 or
003:001~255
004:000 or
004:001~255
005:000 or
005:001~255
008:000 or
008:001~225
101:00 or
101:001~225
Probable
Cause
Location
•Power cord is not plugged
in.
• Fuse is burned out F1601
(F1 Board)
• H.OUT Q6802 is shorted.
• PH6602 faulty.
D6644 faulty
• 11V is not supplied.
(D board)
•V.OUT IC6801 faulty
D6827 faulty
D6817 faulty
• G2 is improperly adjusted.
•CRT problem.
• Video OUT IC9001, 9002,
9003 are faulty. (C board)
• IC4301 CXA2170Q (A
board) are faulty.
• 5V regulator (IC2601) faulty.
• 9V regulator (IC2600) faulty.
•CRT Discharge (C Board)
• Static discharge
• External noise
Detected
Symptoms
•Power does not turn on.
• No power is supplied to the
TV.
•AC power supply is faulty.
•Power does not turn on.
• Load on power line is
shorted.
•H pulse output is too high.
•Power does not come on.
•Vertical deflection pulse is
stopped.
•Vertical size is too small.
•Vertical deflection stopped.
• No raster is generated.
•CRT cathode current
detection reference pulse
output is small.
• TV Blank
• No Raster
•Power is shut down shortly,
after this return back to
normal.
• Detect Micro latch up.
2. STANDBY INDICATOR BLINKING PROCESS
Lamp ON 300ms
Lamp OFF 300ms
The example above represents for 4 times blink
Lamp OFF 3 seconds
3. STANDBY INDICATOR ON TV FRONT PANEL
Standby indicator
– 3 –
KV-DA322M64/M66
RM-GA001
4. SELF DIAGNOSTIC SCREEN DISPLAY
SELF DIAGNOSTIC
2 : 000
3 :N/A
4 :000
5 :001
8 :002
101 :N/A
5. HANDLING SELF DIAGNOSTIC SCREEN DISPLAY
No.DescriptionMethod
1.Display self diagnostic screen[Display] t [Channel ] t [Volume ] t [Power / TV]
2.Stop standby flashi) Turn off power switch on main.
4.Quit self diagnostic screenTurn off power switch of remote commander or main unit.
"0" means no fault has been detected.
"1" means a fault has been detected.
"2" means two faults has been detected.
"N/A" means not available for this models.
5
Note: The above must be performed while TV is on standby mode.
ii) Unplug power cord from the outlet.
8
Note: Diagnostic results display on screen is not automatically cleared. Therefore,
clear result after completion of repair.
6. SELF-DIAGNOSTIC CIRCUIT
FROM
CRT (IK)
[OCP] Q6804, D6821
[H] D6808, D6809
[V] Q6808
IC4301
RGB JUNGLE
IK_IN
57
H PROT
56
V PROT
CXA2170AQ
OVP
SDA
SYSTEM
2
9V
IC001
84
RED LED
5V
14,47,
82
IC004
MEMORY
SDA
7
524
[+B overcurrent OCP ]Occurs when an overcurrent on the +B(135) line is detected by Q6804.
[High voltage protector of Horizontal Deflection]If Q6804 go to ON, the voltage to the pin57 of IC4301 go to "HIGH".
The unit will automatically turn off.
Occurs when an overvoltage of horizontal pulse is detected by D6809.
If the voltage of anode D6809, Q6814 and D6808 goes to High, the voltage
to pin57 of IC4301 go to "HIGH".
The unit will automatically turn off.
[+B overvoltage OVP ]Occurs when an overvoltage on the +B(135) line is detected by D6635 and
Q6606. If Q6606 go to ON, the voltage to pin2 of IC001 go to "HIGH". The
unit will automatically turn off.
[Vertical deflection failure]Occurs when an absence of the vertical deflection pulse is detected by
Q6808. Shut down the power supply.
[White balance failure]If the RGB levels do not balance or become low level within 5 seconds. This
error will be detected by IC4301.
TV will stay on, but there will be no picture.
[5V/9V failure]Occurs when 5V/9V is not supplied to Micon (IC001).
No raster will be detected or no picture.
– 4 –
SECTION 1
DISASSEMBLY
KV-DA322M64/M66
RM-GA001
1-1. REAR COVER REMOVAL
2 Rear cover
1 Fourteen screws
(+BVTP 4 × 16
TYPE2 IT-3)
1-2. SPEAKER REMOVAL
1 Two screws
(+BVTP 4 × 16
TYPE2 IT-3)
2 Two screws
TAPPING SCREW
(+PWH 4X16)
1-3. CHASSIS ASSY REMOVAL1-4. SERVICE POSITION
1-5. TERMINAL BRACKET REMOVAL
5 One screw
(+BVTP 3 × 12)
4 One screw
(+BVTP 3 × 12)
3 Terminal bracket
2 Four screws
(+BVTP 3 × 12
TYPE2 IT-3)
1 One screw
(+BVTP 4 × 16
TYPE2 IT-3)
1-6. J1 BOARD REMOVAL
1 J1 Board
2 Four screws
(+BVTP 3 × 12 TYPE2 IT-3)
– 5 –
KV-DA322M64/M66
RM-GA001
1-7. BH1, BP1 AND BC1 BOARDS REMOVAL
1-8. F1 BOARD REMOVAL
Note: Access to the BH1 board is possible after
removal of the shiledcase. Remove the
shiledcase by removing 2 screws +BVTP 3x12
Type2 IT-3
5 BH1 Board
4 BC Board
6 Two clips
3 Two clips
2 BP1 Board
2 F1 Board
1 Two clips
1-9. WL BOARD REMOVAL1-10. DL BOARD REMOVAL
2 Three screws
+BVTP 3X12 TYPE2 IT-3
1 Four hooks
2 WL Board
1 Three clip
2 DL Board
1 Three clip
1-11. H2 AND H3 BOARDS REMOVAL1-12. A AND D BOARDS REMOVAL
5 One screw
(Washer Head)
(3 × 12)(+)(BVTAP)
2 Five screws
(3 × 12)(+) BVTAP
4 H2 Board
3 Four hooks
1 Five hooks
3 One screw
(3X12)(+)BVTAP
2 H3 Board
3 Two hooks
7 D Board
– 6 –
4 A Board
6 Five hooks
KV-DA322M64/M66
1-13. PICTURE TUBE REMOVAL
Note:
• Please make sure the TV set is not in standing position before removing necessary CRT support located on bottom right
and left.
1) Remove the Rear Cover.
2) Unplug all interconnecting leads from the Deflection yoke, Neck assy, Degaussing Coil and CRT grounding strap. Remove
Chassis Assy.
3) Place the TV set with the CRT face down on a cushion jig.
RM-GA001
qf Screw Tapping 7 +
Crown Washer (L40) (X4)
qa Earth Coating Assy
0 Degaussing Coil
9 Holder, DGC
Removal (x2)
qs Supports, CRT
Removal (x2)
8 Spring Tension(2)
Removal
qd Loosen the Deflection Yoke
fixing screw and remove
4 Anode Cap Removal
7 Band, DGC Removal
6 Loosen the Neck Assembly
fixing screw and remove
Neck Assy & VM1 board
5 C Board Removal
• REMOVAL OF ANODE-CAP
Note:
• After removing the anode, short circuit the anode of the picture tube and the anode cap to the metal chassis, CRT shield
or carbon paint on the CRT.
•REMOVING PROCEDURES
a
a
1 Turn up one side of the rubber cap in the direction
indicated by the arrow a.
b
b
2 Using a thumb pull up the rubber cap firmly in the direction
indicated by the arrow b.
c
anode button
3 When one side of the rubber cap is separated from the
anode button, the anode-cap can be removed by turning
up the rubber cap and pulling it up in the direction of the
arrow c.
•HOW TO HANDLE AN ANODE-CAP
1 Do not damage the surface of anode-caps with sharp
shaped objects.
2 Do not press the rubber too hard so as not to damage
the inside of anode-cap.
A metal fitting called the shatter-hook terminal is built
into the rubber.
3 Do not turn the foot of rubber over too hard.
The shatter-hook terminal will stick out or damage the
rubber.
– 7 –
KV-DA322M64/M66
RM-GA001
2-1. JIGS REQUIRED FOR SERVICING
DESCRIPTIONQUANTITYPART NO. REMARK
TOOL(50P-A),SERVICE13-702-765-01 For A to BH1 board extension
SECTION 2
SERVICE JIG
SAMPLE
WL Board
DL Board
SECTION 3
CIRCUIT BOARDS LOCATION
C Board
H2 Board
BH1 Board
A Board
J1 Board
D Board
BP1 Board
H3 Board
VM1 Board
BC1 Board
F1 Board
– 8 –
KV-DA322M64/M66
SECTION 4
ADVANCE OPERATION
4-1. "RESET" FUNCTION
1. Purpose
If a customer faces some setting problem that cannot be solved, using the "RESET" function some items will be
reset to its original setting or factory setting (shipping condition)
2. How to Operate
The following is to show on how to access to the "RESET" Function:-
User selection = press 'WEGA GATE' t selectt 'SETTING' t go to 'SETUP' page t select 'FACTORY
SETTINGS' t select 'YES'
3. Subsequent of Operation
RM-GA001
Sequential to the resetting operation, TV set would shut down once and automatically turn on again. The power-off
duration is expected to be about 500msec. Initial Setup Menu is displayed.
As a result, some items will be reset to their initial conditions (shipment condition) wheareas some others remain
at the last user selection.
Items that remain at the last user selection
Program No., PICTURE POSITION (included PICTURE
ROTATION and PICTURE V-POSITION), OSD Language, Fine
tuning,TV System, Skip, Program label, Program sorting, Video
label.
Reset Items
CategoryDefaultCategoryDefault
Video inputRF user last setting
Main Volume25
DRC-MFDRC1250
Picture modeVIVID
3D Intelligent Picture ON
Sound modeDYNAMIC
Intelligent volumeOFF
SurroundOFF
Wide mode4.3
Auto wideON
TwinOFF
Program IndexOFF
* Program BlockReset particular displayed
channel to unblock
WEGA Theatre Setup
Direct InputHD/DVD 1
SpeakerMain
Game modeOFF (Video) *Not available in RF
mode
*Color SystemRF = Reset to Auto at the particular/displayed Video
= MI Reset to Auto CH, others keep user setting
Eco modeOFF
Wide modeWide zoom
Auto wideON
4.3 DefaultWide zoom
V Center00
V Size00
MuteOFF
OSD Display status OFF
Center-in volume25
Initial setup menuReactivate/ON
Twin sizeCenter
*= Will reset only if watched/displayed during RESET operation
- For Multi model only
– 9 –
KV-DA322M64/M66
RM-GA001
SECTION 5
SET-UP ADJUSTMENTS
The following adjustments should be made when a complete
realignment is required or a new picture tube is installed.
Perform the adjustments in order as follows :
1. Beam Landing
2. Convergence
3. Focus
The controls and switch should be set as follows unless
otherwise noted:
S_ _: for SONY
A_ _: for AIWA
L_ _: BX1L Full
B_ _: BX1L Basic
D_ _: DVD Combo
C_ _: CX1
Z_ _: Sound special
_ _ _01 : Serial no. of the M/P release for each
_ _ _10 ~: use for FY04 BX1
_ _SB: Sub Hercules
softwareservice datareservedpower on time
For BP1 Board Version; and PF Engine Version;
Category and release ID will be different.
The rest are the same.
destination
BP1 Board Version
categoryin decimalname
SUBP000IDXH
release IDversion
CBP010.06
PF Engine Version
categoryin decimalname
9090000UOF
release IDversion
PF 0018M
item no.item
software
item no.item
software
b. METHOD OF CANCELLATION FROM SERVICE MODE
Set the standby condition (Press [POWER] button on the commander), then press [POWER] button again, hereupon it becomes
TV mode.
c. METHOD OF WRITE INTO MEMORY
1. Set to Service Mode.
2. Press 1 (UP) and 4 (DOWN), to select the adjustment item.
3. Change item by pressing 3, 6.
4. Press [MUTING] button to indicate WRITE on the screen.
5. Press - button to write into memory.
1, 4Select the adjustment item.
r
3, 6Raise/lower the data value.
r
[MUTING]Writes.
r
-Executes the writing.
– 15 –
KV-DA322M64/M66
RM-GA001
d. MEMORY WRITE CONFIRMATION METHOD
1. After adjustment, pull out the plug from AC outlet, and then plug into AC outlet again.
2. Turn the power switch ON and set to Service Mode.
3. Call the adjusted items again to confirm adjustments were made.
e. OTHER FUNCTION VIA REMOTE COMMANDER
7, -All the data becomes the values in memory.
8, -All user control goes to the standard state.
Display, -Service data initialization (Be sure not to use usually.)
2, 5Select Device or Category
6-2.ADJUSTMENT METHOD
Item Number 000 HPOS
This explanation uses H POSITION as an example.
1. Select "000 HPOS" with the 1 and 4 buttons, or 2 and 5.
2. Raise/lower the data with the 3 and 6 buttons.
3. Select the optimum state. (The standard is IF for PAL reception.)
4. Write with the [MUTING] button. (The display changes to WRITE.)
5. Execute the writing with the - button. (The WRITE display will be changed to red color while executing, and back to
SERVICE.)
Example on screen display :-
GREEN
WHBL000WBP000 SERVICE 50 VIDEO 1
Adjusted with [3] and [6] buttons.
GREEN
WHBL000WBP000 WRITE50 VIDEO 1
write with [MUTING].
RED
WHBL000WBP000 WRITE50 VIDEO 1
Write executed with [0].
The WRITE display
then returns to green
SERVICE
Use the same method for all Items. Use 1 and 4 to select the adjustment item, use 3 and 6 to adjust, write with
[MUTING], then execute the write with -.
Note : 1. In [WRITE], the data for all items are written into memory together.
2. For adjustment items that have different standard data between 50Hz or 60Hz, be sure to use the respective input
signal after adjustment.
a) In the initial value (detailed) colomn, the data after the slash mark ("/") refers to NTSC model data.
No ("/") means data is common for Multi and NTSC model.
b) Item remarked "*" and "**", please refer page 32 for the data.
c)
shaded items are no data.
d) Standard data listed on the Adjustment Item Tab le are reference values, therefore it may be different for each model and for each mode.
e) Note for the Different Data those are the standard data values written on the microprocessor. Therefore, the data values of the models are stored respectively in the memory.
In the case of a device replacement, adjustment by rewriting the data value is necessary for some items.