Read Sony KP-51HW40 / KP-57HW40 Service Manual online
CHASSIS
SERVICE MANUAL
MODEL
COMMANDER
DEST. CHASSIS NO.
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MODEL
COMMANDER
DEST. CHASSIS NO.
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RA-6
KP-51HW40
RM-Y909
US
SCC-P65G-A
KP-51HW40
RM-Y909 Canadian
SCC-P65G-A
KP-57HW40
RM-Y909
US
SCC-P65F-A
KP-57HW40
RM-Y909 Canadian
SCC-P65F-A
COLOR REAR VIDEO PROJECTOR
RM-Y909
KP-51HW40/57HW40
– 2 –
KP-51HW40/57HW40
RM-Y909
RM-Y909
SAFETY CHECK-OUT
( US model only )
After correcting the original service problem, perfom the follow-
ing safety checks before releasing the set to the customer:
l.
Check the area of your repair for unsoldered or poorly-sol-
dered connections. Check the entire board surface for solder
splashes and bridges.
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.
certain that you have replaced all the insulators.
4. Look for unauthorized replacement parts, particularly tran-
sistors, that were installed during a previous repair. Point them
out to the customer and recommend their replacement.
out to the customer and recommend their replacement.
5. Look for parts which, through functioning, show obvious
signs of deterioration. Point them out to the customer and
recom mend their replacement.
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.
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 they are at the values specified.
Make sure your instruments are accurate;be suspicious of
your HV meter if sets always have low HV.
your HV meter if sets always have low HV.
9. Check the antenna temminals, metal trim, “metallized” knobs,
screws, and all other exposed metal parts for AC leakage.
Check leakage as described below.
Check leakage as described below.
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 0.5mA (500 microampers) . Leak-
age current can be measured by any one of three methods.
return to chassis, must not exceed 0.5mA (500 microampers) . Leak-
age 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
usc these instruments.
usc 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 0.75V, so analog meters must have an accurate low-
voltage scale. The Simpson 250 and Sanwa SH-63Trd are
examples of a passive VOM that is suitable. NearIy all bat-
tery operated digital multimeters that have a 2V AC range
are suitable. (See Fig. A)
tion is 0.75V, so analog meters must have an accurate low-
voltage scale. The Simpson 250 and Sanwa SH-63Trd are
examples of a passive VOM that is suitable. NearIy all bat-
tery operated digital multimeters that have a 2V AC range
are suitable. (See Fig. A)
HOW TO FIND A GOOD EARTH GROUND
A cold-water pipe is guaranteed earth ground;the cover-plate re-
taining 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-l00 watts trouble
light (not a neon lamp) between the hot side of the receptacle 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)
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-l00 watts trouble
light (not a neon lamp) between the hot side of the receptacle 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)
To Exposed Metal
Parts on Set
Parts on Set
AC
voltmeter
(0.75V)
voltmeter
(0.75V)
1.5k
Ω
Earth Ground
Fig. A. Using an AC voltmeter to check AC leakage.
1.5
µ
F
Fig. B. Checking for earth ground.
Trouble Light
AC Outlet Box
Ohmmeter
Cold-water Pipe
– 3 –
KP-51HW40/57HW40
RM-Y909
RM-Y909
(CAUTION)
THESE SERVICING INSTRUCTIONS ARE FOR USE BY QUALIFIED
SERVICE PERSONNEL ONLY. TO REDUCE THE RISK OF ELECTRIC
SHOCK, DO NOT PERFORM ANY SERVICING OTHER THAN THAT
CONTAINED IN THE OPERATING INSTRUCTIONS UNLESS YOU
ARE QUALIFIED TO DO SO.
SERVICE PERSONNEL ONLY. TO REDUCE THE RISK OF ELECTRIC
SHOCK, DO NOT PERFORM ANY SERVICING OTHER THAN THAT
CONTAINED IN THE OPERATING INSTRUCTIONS UNLESS YOU
ARE QUALIFIED TO DO SO.
WARNING!!
AN ISOLATION TRANSFORMER SHOULD BE USED DURING
ANY SERVICE TO AVOID POSSIBLE SHOCK HAZARD, BE-
CAUSE OF LIVE CHASSIS.
THE CHASSIS OF THIS RECElVER IS DIRECTLY CONNECTED
TO THE AC POWER LINE.
ANY SERVICE TO AVOID POSSIBLE SHOCK HAZARD, BE-
CAUSE OF LIVE CHASSIS.
THE CHASSIS OF THIS RECElVER IS DIRECTLY CONNECTED
TO THE AC POWER LINE.
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
THESECOMPONENTS WITH SONY PARTS WHOSE PART NUM-
BERS APPEAR AS SHOWN IN THIS MANUAL OR IN SUPPLE-
MENTS PUBLISHED BY SONY. CIRCUIT ADJUSTMENTS THAT
ARE CRITICAL TO SAFEOPERATION ARE IDENTIFIED IN THIS
MANUAL. FOLLOW THESE PROCEDURES WHENEVER CRITI-
CAL COMPONENTS ARE REPLACED OR IMPROPER OPERA-
TION IS SUSPECTED.
PARTS LIST ARE CRITICAL TO SAFE OPERATION. REPLACE
THESECOMPONENTS WITH SONY PARTS WHOSE PART NUM-
BERS APPEAR AS SHOWN IN THIS MANUAL OR IN SUPPLE-
MENTS PUBLISHED BY SONY. CIRCUIT ADJUSTMENTS THAT
ARE CRITICAL TO SAFEOPERATION ARE IDENTIFIED IN THIS
MANUAL. FOLLOW THESE PROCEDURES WHENEVER CRITI-
CAL COMPONENTS ARE REPLACED OR IMPROPER OPERA-
TION IS SUSPECTED.
(ATTENTION)
ATTENTION!!
AFIN D’EVITER TOUT RISQUE DELECTROCUTION PROVE-
NANT D’UN CHÁSSIS SOUS TENSION, UN TRANSFORMATEUR
D’ISOLEMENT DOIT ETRE UTILISÉ LORS DE TOUT DEPAN-
NAGE.
LE CHÁSSIS DE CE RECEPTEUR EST DIRECTEMENT RAC-
CORDÉ Á L’ALIMENTATION SECTEUR.
NANT D’UN CHÁSSIS SOUS TENSION, UN TRANSFORMATEUR
D’ISOLEMENT DOIT ETRE UTILISÉ LORS DE TOUT DEPAN-
NAGE.
LE CHÁSSIS DE CE RECEPTEUR EST DIRECTEMENT RAC-
CORDÉ Á L’ALIMENTATION SECTEUR.
ATTENTION AUX COMPOSANTS RELATIFS ÁLA
SÉCURITÉ!!
LES COMPOSANTS IDENTIFIÉS PAR UNE TRAME ET PAR UNE
MAPQUE ! SUR LES SCHÉMAS DE PRINCIPE, LES VUES EX-
MAPQUE ! SUR LES SCHÉMAS DE PRINCIPE, LES VUES EX-
PLOSÉES ET LES LISTES DE PIECES CONT D’UNEIMPORTANCE
CRITIQUE POUR LA SÉCURITÉ DU FONCTIONNEMENT. NE LES
REMPLACER QUE PAR DES COMPOSANTS SONY DONT LE
NUMÉRO DE PIÉCE EST INDIQUÉ DANS LE PRÉSENT MAN-
UEL OU DANS DES SUPPLÉMENTS PUBLIÉS PAR SONY. LES
RÉGLAGES DE CIRCUIT DONT L’IMPORTANCE EST CRITIQUE
POUR LA SÉCURITÉ DU FONCTIONNEMENT SONT IDENTIFIES
DANS LE PRÉSENT MANUEL. SUIVRE CES PROCÉDURES
LORS DE CHAQUE REMPLACEMENT DE COMPOSANTS CRI-
TIQUES, OU LORSQU’UN MAUVAIS FONCTIONNEMENT EST
SUSPECTÉ.
CRITIQUE POUR LA SÉCURITÉ DU FONCTIONNEMENT. NE LES
REMPLACER QUE PAR DES COMPOSANTS SONY DONT LE
NUMÉRO DE PIÉCE EST INDIQUÉ DANS LE PRÉSENT MAN-
UEL OU DANS DES SUPPLÉMENTS PUBLIÉS PAR SONY. LES
RÉGLAGES DE CIRCUIT DONT L’IMPORTANCE EST CRITIQUE
POUR LA SÉCURITÉ DU FONCTIONNEMENT SONT IDENTIFIES
DANS LE PRÉSENT MANUEL. SUIVRE CES PROCÉDURES
LORS DE CHAQUE REMPLACEMENT DE COMPOSANTS CRI-
TIQUES, OU LORSQU’UN MAUVAIS FONCTIONNEMENT EST
SUSPECTÉ.
CES INSTRUCTIONS DE SERVICE SONT À L’USAGE DU PERSONNEL
DE SERVICE QUALIFIÉ SEULEMENT. POUR PRÉVENIR LE RISQUE DE
CHOC ÉLECTRIQUE, NE PAS FAIRE L’ENTRETIEN AUTRE QUE CELUI
CONTENU DANS LE MODE D’EMPLOI À MOINS QUE VOUS SOYEZ
QUALIFIÉ FAIRE AINSI.
DE SERVICE QUALIFIÉ SEULEMENT. POUR PRÉVENIR LE RISQUE DE
CHOC ÉLECTRIQUE, NE PAS FAIRE L’ENTRETIEN AUTRE QUE CELUI
CONTENU DANS LE MODE D’EMPLOI À MOINS QUE VOUS SOYEZ
QUALIFIÉ FAIRE AINSI.
☛
☛
– 4 –
KP-51HW40/57HW40
RM-Y909
RM-Y909
TABLE OF CONTENTS
Section
Title
Page
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Section
Title
Page
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1. SELF DIAGNOSIS FUNCTION .............................
5
2. DISASSEMBLY
2-1.
REAR BOARD REMOVAL ....................................... 8
2-2.
CHASSIS ASSY REMOVAL ..................................... 8
2-3.
SERVICE POSITION ................................................. 8
2-4.
H2 BOARD REMOVAL ............................................. 8
2-5.
H1 BOARD REMOVAL ............................................. 9
2-6.
H3 BOARD REMOVAL ............................................. 9
2-7.
MIRROR COVER REMOVAL ................................... 9
2-8.
BEZNET ASSY REMOVAL ...................................... 9
2-9.
H4 BOARD AND S BOARD REMOVAL ............... 10
2-10.
AD BOARD AND B BOARD REMOVAL .............. 10
2-11.
G BOARD REMOVAL ............................................. 10
2-12.
A BOARD, D BOARD AND
U BOARD REMOVAL ............................................. 10
U BOARD REMOVAL ............................................. 10
2-13.
PICTURE TUBE REMOVAL ................................... 11
2-14.
HIGH-VOLTAGE CABLE INSTALLATION AND
REMOVAL ................................................................ 11
REMOVAL ................................................................ 11
3. SET-UP ADJUSTMENTS
3-2.
SCREEN (G2) ADJUSTMENT
(FINE ADJUSTMENT) ............................................ 12
(FINE ADJUSTMENT) ............................................ 12
3-1.
SCREEN VOLTAGE ADJUSTMENT
(COARSE ADJUSTMENT) ..................................... 12
(COARSE ADJUSTMENT) ..................................... 12
3-3.
DEFLECTION YOKE TILT ADJUSTMENT .......... 12
3-4.
FOCUS LENS ADJUSTMENT ............................... 12
3-6.
2-POLE MAGNET ADJUSTMENT ........................ 13
3-5.
FOCUS VR ADJUSTMENT ..................................... 13
3-7.
CENTERING MAGNET ADJUSTMENT ............... 13
3-8.
4-POLE MAGNET ADJUSTMENT ........................ 13
3-9.
DEFOCUS ADJUSTMENT (BLUE) ....................... 13
3-10
.ELECTRICAL ADJUSTMENT BY REMOTE
COMMANDER ........................................................ 14
COMMANDER ........................................................ 14
4. CIRCUIT ADJUSTMENTS
4-1.
P & P SUB CONTRAST
ADJUSTMENT (VIDEO) (SCON) .......................... 31
ADJUSTMENT (VIDEO) (SCON) .......................... 31
4-2.
P & P SUB CONTRAST
ADJUSTMENT (RF) (SCON) .................................. 31
ADJUSTMENT (RF) (SCON) .................................. 31
4-3.
P & P SUB-HUE AND
SUB-COLOR ADJUSTMENT (SHUE, SCOL) ...... 31
SUB-COLOR ADJUSTMENT (SHUE, SCOL) ...... 31
4-4.
P & P SUB-HUE AND
SUB-COLOR ADJUSTMENT (SHUE, SCOL) ....... 31
SUB-COLOR ADJUSTMENT (SHUE, SCOL) ....... 31
4-5.
BLUE OFFSET ADJUSTMENT .............................. 32
5. SAFETY RELATED ADJUSTMENTS
5-1.
HV REGULATION CIRCUIT CHECK AND
ADJUSTMENT ......................................................... 33
ADJUSTMENT ......................................................... 33
5-2.
HV HOLD DOWN CIRCUIT OPERATION
CHECK AND ADJUSTMENT ................................. 33
CHECK AND ADJUSTMENT ................................. 33
5-3.
+B MAX VOLTAGE CONFIRMATION .................. 33
5-4.
+B OVP CONFIRMATION ...................................... 33
6. DIAGRAMS
6-1.
BLOCK DIAGRAM (1) ............................................ 34
BLOCK DIAGRAM (2) ............................................ 35
BLOCK DIAGRAM (3) ............................................ 36
BLOCK DIAGRAM (4) ............................................ 37
BLOCK DIAGRAM (5) ............................................ 38
BLOCK DIAGRAM (6) ............................................ 39
BLOCK DIAGRAM (7) ............................................ 40
BLOCK DIAGRAM (8) ............................................ 41
BLOCK DIAGRAM (9) ............................................ 42
BLOCK DIAGRAM (10) .......................................... 43
BLOCK DIAGRAM (11) .......................................... 44
BLOCK DIAGRAM (2) ............................................ 35
BLOCK DIAGRAM (3) ............................................ 36
BLOCK DIAGRAM (4) ............................................ 37
BLOCK DIAGRAM (5) ............................................ 38
BLOCK DIAGRAM (6) ............................................ 39
BLOCK DIAGRAM (7) ............................................ 40
BLOCK DIAGRAM (8) ............................................ 41
BLOCK DIAGRAM (9) ............................................ 42
BLOCK DIAGRAM (10) .......................................... 43
BLOCK DIAGRAM (11) .......................................... 44
6-2. CIRCUIT BOARDS LOCATION ................................. 45
6-3. SCHEMATIC DIAGRAMS ........................................... 45
6-4. PRINTED WIRING BOARDS ...................................... 74
6-5. WAVEFORMS ............................................................... 88
6-6. IC BLOCK DIAGRAMS ............................................... 90
6-7. SEMICONDUCTORS ................................................... 94
6-3. SCHEMATIC DIAGRAMS ........................................... 45
6-4. PRINTED WIRING BOARDS ...................................... 74
6-5. WAVEFORMS ............................................................... 88
6-6. IC BLOCK DIAGRAMS ............................................... 90
6-7. SEMICONDUCTORS ................................................... 94
7. EXPLODED VIEWS
7-1.
COVER ..................................................................... 95
7-2.
CHASSIS .................................................................. 96
7-3.
PICTURE TUBE ....................................................... 97
8. ELECTRICAL PARTS LIST ................................
98