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DIGITAL HIGH DEFINITION PROJECTION TV
SERVICE MANUAL
RA-5A CHASSIS
MODEL NAME
REMOTE COMMANDER
DESTINATION
CHASSIS NO.
9-965-432-04
KDP-57XBR2
RM-Y185
US
SCC-P69B-A
KDP-57XBR2
RM-Y185
Canadian
SCC-P69B-A
KDP-65XBR2
RM-Y185
US
SCC-P69A-A
KDP-65XBR2
RM-Y185
Canadian
SCC-P69A-A
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
ORIGINAL MANUAL ISSUE DATE: 7/2001
ALL REVISIONS AND UPDATES TO THE ORIGINAL MANUAL ARE APPENDED TO THE END OF THE PDF FILE.
REVISION DATE
REVISION TYPE
SUBJECT
7/2001
No revisions or updates are applicable at this time.
11/2001
Supplement - 1
Adjustment Manual Added
1/2002
Correction - 1
Exploded View - Screen Frame Block P/N Corrected
7/2002
Supplement - 2
B Board, Q-Box Assembly P/N Correction; IC001 P/N Correction


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SERVICE MANUAL
MODEL
COMMANDER
DEST.
CHASSIS NO.
CHASSIS
RA-5A
DIGITAL HIGH DEFINITION PROJECTION TV
KDP-57XBR2 RM-Y185
US
SCC-P69B-A
KDP-57XBR2 RM-Y185
Canadian SCC-P69B-A
KDP-65XBR2 RM-Y185
US
SCC-P69A-A
KDP-65XBR2 RM-Y185
Canadian SCC-P69A-A
RM-Y185


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­ 2 ­
KDP-57XBR2/65XBR2
RM-Y185
SPECIFICATIONS
Projection System
3 picture tubes, 3 lenses, horizontal in-line system
Picture Tube
7-inch high-brightness monochrome tubes (6.3 raster size),
with optical coupling and liquid cooling system
Projection Lenses
High performance, large diameter hybrid lens F1.05
Antenna
75 ohm external terminal for VHF/UHF
Television System
NTSC, American TV Standard, ATSC
Channel Coverage
DTV
2-69
VHF
2-13
UHF
14-69
CATV
1-125
Power Requirements
120V AC, 60 Hz
Number of Inputs/Outputs
Video (IN)
4 total (1 on front panel)
1 Vp-p, 75 ohms unbalanced, sync negative
S Video (IN)
4 (1 on front panel)
Y: 1 Vp-p, 75 ohms unbalanced, sync negative
C: 0.286 Vp-p, (Burst signal), 75 ohms
Component Video Input
2 (Y, P
B, PR)
Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative
PB: 0.7 Vp-p, 75 ohms
P
R: 0.7 Vp-p, 75 ohms
Audio (IN)
6 total (1 on front panel)
500 mVrms (100% modulation)
Impedance: 47 kilohm
Audio (OUT)
1
More than 408 mVrms at the maximum volume setting (Variable)
More than 408 mVrms (Fixed)
Impedance (output): 2 kilohms
Subwoofer (Out)
1
More than 408 mVrms at the maximum volume setting
Impedance (output): 2 kilohms
Cutoff frequency: 100 Hz
SELECT OUT
1 Video
1 Vp-p, 75 ohms unbalanced, sync negative
1 Audio
More than 408 mVrms (100% modulation)
Impedance (output): 2 kilohms
Digital Audio Optical Output
1
Optical Rectangular (1)
Dolby Digital/PCM
CONTROL S (IN/OUT)
1
i.LINK S200
2
4-pin S200 i.LINK terminal (2)
Supplied Accessories
Remote Control
RM-Y185
AA (R6) Batteries
2 supplied for remote control
Optional Accessories
AV Cable
VMC-810/820/830 HG
Audio Cable
RKC-515HG
i.LINK Cable
VMC-IL4415 (4-pin to 4-pin, 1.5 meters), VMC-IL4435 (4-pin to 4-pin, 3.5 meters)
Component Video Cable
VMC-10/30 HG
Rear Speakers
SS-MB115
Screen Size
57 in measured diagonally (KDP-57XBR2)
65 in measured diagonally (KDP-65XBR2)
Speakers
Tweeter
100 mm (4")
× 2
Woofer
160 mm (6 3/8")
× 2
Center
100 mm (4")
× 2
Speaker Output
Front
20 W
× 2
Center
20 W
× 1
Rear
20 W
× 2
Dimensions (W
× H × D)
1380
× 1400 × 680 mm (54 3/8 × 55 1/8 × 26 7/8 in) (KDP-57XBR2)
1558
× 1574 × 735 mm (61 3/8 × 62 × 29) (KDP-65XBR2)
Mass
126 kg (277 lbs) (KDP-57XBR2)
148 kg (326 lbs) (KDP-65XBR2)
Power Consumption
In Use
280 W
In Standby
0.9 W
In i.LINK Standby
24 W
Design and specifications are subject to change without notice.


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­ 3 ­
KDP-57XBR2/65XBR2
RM-Y185
SAFETY CHECK-OUT
(US Model only)
LEAKAGE TEST
The AC leakage from any exposed metal part to earth ground
and from all exposed metal parts to any exposed metal part having a
return to chassis, must not exceed 0.5 mA (500 microamperes).
Leakage current can be measured by any one of three methods.
1. A commercial leakage tester, such as the Simpson 229 or
RCA WT-540A. Follow the manufacturers' instructions to
use these instruments.
2. A battery-operated AC milliammeter. The Data Precision 245
digital multimeter is suitable for this job.
3. Measuring the voltage drop across a resistor by means of a
VOM or battery-operated AC voltmeter. The "limit" indica-
tion is 0.75 V, so analog meters must have an accurate low-
voltage scale. The Simpson 250 and Sanwa SH-63Trd are ex-
amples of a passive VOMs that are suitable. Nearly all battery
operated digital multimeters that have a 2 V AC range are suit-
able. (See Fig. A)
HOW TO FIND A GOOD EARTH GROUND
A cold-water pipe is guaranteed earth ground; the cover-plate
retaining screw on most AC outlet boxes is also at earth ground. If
the retaining screw is to be used as your earth-ground, verify that it
is at ground by measuring the resistance between it and a cold-
water pipe with an ohmmeter. The reading should be zero ohms. If
a cold-water pipe is not accessible, connect a 60 ­ 100 watts
trouble light (not a neon lamp) between the hot side of the recep-
tacle and the retaining screw. Try both slots, if necessary, to locate
the hot side of the line, the lamp should light at normal brilliance if
the screw is at ground potential. (See Fig. B)
After correcting the original service problem, perform the fol-
lowing safety checks before releasing the set to the customer:
1. Check the area of your repair for unsoldered or poorly-sol-
dered connections. Check the entire board surface for solder
splashes and bridges.
2. Check the interboard wiring to ensure that no wires are
"pinched" or contact high-wattage resistors.
3. Check that all control knobs, shields, covers, ground straps,
and mounting hardware have been replaced. Be absolutely
certain that you have replaced all the insulators.
4. Look for unauthorized replacement parts, particularly transis-
tors, that were installed during a previous repair. Point them
out to the customer and recommend their replacement.
5. Look for parts which, though functioning, show obvious signs
of deterioration. Point them out to the customer and recom-
mend their replacement.
6. Check the line cords for cracks and abrasion. Recommend the
replacement of any such line cord to the customer.
7. Check the condition of the monopole antenna (if any).
Make sure the end is not broken off, and has the plastic cap on
it. Point out the danger of impalement on a broken antenna to
the customer, and recommend the antenna's replacement.
8. Check the B+ and HV to see if they are specified values. Make
sure your instruments are accurate; be suspicious of your HV
meter if sets always have low HV.
9. Check the antenna terminals, metal trim, "metallized" knobs,
screws, and all other exposed metal parts for AC Leakage.
Check leakage as described below.
1.5 k
0.15 µF
AC
Voltmeter
(0.75 V)
To Exposed Metal
Parts on Set
Earth Ground
Fig. A. Using an AC voltmeter to check AC leakage.
Trouble Light
AC Outlet Box Ohmmeter
Cold-water Pipe
Fig. B. Checking for earth ground.


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­ 4 ­
KDP-57XBR2/65XBR2
RM-Y185
1. SELF DIAGNOSIS FUNCTION ......................
6
2. DISASSEMBLY
2-1.
Rear Board Removal .........................................
9
2-2.
Main Bracket Block Removal ...........................
9
2-3.
Service Position .................................................
9
2-4.
Terminal board Removal ..................................
9
2-5.
G Board Removal ...............................................
10
2-6.
D Board Removal ...............................................
10
2-7.
AD, U, B and A Boards Removal ......................
11
2-8.
Q-box Assembly Removal .................................
11
2-9.
K Board Removal ...............................................
12
2-10. Resistor Assembly (Focus Pack) Removal ........
12
2-11. Screen Frame Block Assembly ..........................
13
2-12. S Board Removal ................................................
13
2-13. Control Panel Block Removal ...........................
14
2-14. HD Board Removal ............................................
14
2-15. Control Door Block Assembly ...........................
15
2-16. HB Board Removal ............................................
15
2-17. HA Board Removal ............................................
16
2-18. Picture Tube Block Removal .............................
16
2-19. High-Voltage Cable Removal and Installation ...
17
2-20. Picture Tube Removal ........................................
17
3. SET-UP ADJUSTMENTS
3-1.
Screen Voltage Adjustment
(Rough Alignment) ...........................................
18
3-2.
Screen (G2) Adjustment ....................................
18
3-3.
Deflection Yoke Tilt Adjustment ......................
18
3-4.
Focus Lens Adjustment ......................................
19
3-5.
Focus VR Adjustment .......................................
19
3-6.
2-Pole Magnet Adjustment ................................
19
3-7.
Centering Magnet Adjustment ..........................
20
3-8.
4-Pole Magnet Adjustment ................................
20
3-9.
Defocus Adjustment (Blue) ...............................
20
3-10. Electrical Adjustment
by Remote Commander ......................................
21
3-11. Registration Adjustment ...................................
40
3-11-1. Setup for Adjustment ....................................
40
3-11-2 Main Deflection Adjustment ........................
40
3-11-3. Operation Method
for Projectoe Engine Mode ............................
41
3-11-4. Projector Engine Adjustment
(Sub Deflection Adjustment) .........................
42
3-12. Auto Registration Offset ....................................
44
3-13. Auto Registration Error Code List .....................
45
4. CIRCUIT ADJUSTMENTS
4-1.
480p Y, PB, PR Gain Adjustment .....................
46
TABLE OF CONTENTS
4-2.
Main Y/C Level Adjustment
(for the DRC Path) .............................................
46
4-3.
Main Y/C Level Adjustment
(for the VDO Path) .............................................
46
4-4.
SUB Y/C Level Adjustment
(for the DRC Path) .............................................
47
4-5.
SUB Y/C Level Adjustment
(for the VDO Path) .............................................
47
4-6.
Main Decoder Sub Contrast Adjustment
(for Composite and Y/C Inputs) ........................
47
4-7.
Main Decoder Sub Color and Sub Hue
Adjustment (for Composite and Y/C Inputs) ....
47
4-8.
Sub Decoder Sub Contrast Adjustment
(for Y/C Input) ....................................................
48
4-9.
Sub Decoder Sub Color and Sub Hue
Adjustment (for Y/C Input) ................................
48
4-10. Sub Decoder Sub Contrast Adjustment
(for Composite Input) .........................................
48
4-11. Sub Decoder Sub Color and Sub Hue
Adjustment (for Composite Input) .....................
48
4-12. Main Decoder PB and PR Offset Adjustment ...
49
4-13. Sub Decoder PB and PR Offset Adjustment .....
49
4-14. Blue Offset Adjustment ......................................
49
4-15. Sub Contrast Adjustment ...................................
49
4-16. Sub Color and Sub Hue Adjustment ..................
50
4-17. RF Sub Contrast Adjustment .............................
50
4-18. RF Sub Color and Sub Hue Adjustment ............
50
5. SAFETY RELATED ADJUSTMENTS
5-1.
HV Regulation Circuit Check and
Adjustment .........................................................
51
5-2.
HV Hold Down Circuit Operation Check and
Adjustment .........................................................
51
5-3.
+B Max Voltage Confirmation ..........................
51
5-4.
+B OVP Confirmation .......................................
51
6. FIRMWARE UPGRADES
6-1.
Overview ............................................................
52
6-2.
Transferring the New Firmware
from the Memory Stick to the Q-Box ................
52
7. DIAGRAMS
7-1.
Block Diagram (1) ..............................................
53
Block Diagram (2) ..............................................
54
Block Diagram (3) ..............................................
55
Block Diagram (4) ..............................................
56
Block Diagram (5) ..............................................
57
Block Diagram (6) ..............................................
58
Block Diagram (7) ..............................................
59
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