KV-HG21M80 - Sony TV Service Manual (repair manual)

Model
KV-HG21M80
Pages
65
Size
6.75 MB
Type
PDF
Document
Service Manual
Brand
Device
TV
File
kv-hg21m80.pdf
Date

View Sony KV-HG21M80 Service Manual online

REVISION HISTORY
BX1S
MODEL
KV-HG21M80
KV-HG21M88
PART NO. : 
9-872-974-01
CHASSIS
NO.
SUFFIX
DATE
SUPP / CORR
DESCRIPTION
1
-01
2007/07
_ _
1st Issue
MODEL
COMMANDER   DEST.
MODEL
COMMANDER   DEST.
KV-HG21M80
RM-GA002 Pakistan
KV-HG21M88
RM-GA002 Pakistan
TRINITRON 
®
 
COLOR TV
SERVICE MANUAL
BX1S
CHASSIS
RM-GA002
– 2 –
KV-HG21M80/M88
RM-GA002
TABLE OF CONTENTS
SELF DIAGNOSTIC FUNCTION ................................. 3
1. DISASSEMBLY
1-1.
Rear Cover Removal .............................................. 5
1-2.
Speaker Removal ................................................... 5
1-3.
Chassis Assy Removal ........................................... 5
1-4.
Service Position ..................................................... 5
1-5.
H3 Board Removal ................................................ 5
1-6.
A Board Removal .................................................. 5
1-7.
Picture Tube Removal ............................................ 6
2. WIRE DRESSING
2-1.
H3 Board Caution Point ........................................ 7
2-2.
UL wire P/N 1-923-082-52 dressing
on A Board ............................................................. 7
2-3.
Mount Caution for Connector Assy, 5P(200V) ..... 7
2-4.
Wire dressing on C board ...................................... 8
2-5.
Wire dressing on A board ...................................... 8
2-6.
Conn Assy, 5P (YUV) & Lead Assy,
Jumper dressing ..................................................... 8
2-7.
AC Power Cord, Lead Assy, Earth,
Lead Assy & Speaker (Right & Left) dressing ..... 9
2-8.
Earth Coating Assy installation at CRT ................ 9
2-9.
Earth Assy, Coating dressing ............................... 10
2-10. AC Power Cord, Lead Assy, Earth, Lead Assy,
Speaker (Right & Left) & DGC Conn dressing .. 10
2-11. Lead Assy, Speaker (Right) & DGC
Conn dressing ...................................................... 10
2-12. Lead Assy, Speaker (Left), AC Power Cord
and Front Control wire dressing .......................... 11
2-13. DY Conn & Conn Assy, 5P (200V) dressing ...... 11
2-14. Lead Assy, G2 & Focus dressing ......................... 12
2-15. Conn Assy, 7P, UL Wire (1-923-000-81), Lead
Assy, Earth & Rotational Coil Conn dressing .... 12
2-16. HV Cap Assy dressing ......................................... 13
2-17. AC Power Cord dressing ..................................... 13
3. SET-UP ADJUSTMENTS
3-1.
Beam Landing Adjustment .................................. 14
3-2.
Convergence Adjustment ..................................... 14
3-3.
Focus Adjustment ................................................ 16
3-4.
G2 (SCREEN) Adjustments ................................ 16
3-5
White Balance Adjustment .................................. 16
3-6
Sub Bright Adjustment ........................................ 16
Section
Title
Page
Section
Title
Page
4. CIRCUIT ADJUSTMENTS
4-1.
Adjustments With Commander ........................... 17
4-2.
Adjustment Method ............................................. 18
4-3.
Picture Quality Adjustment ................................. 34
4-3-1.  P Max/Contrast Adjustment .................... 34
4-3-2.  Sub Color Adjustment ............................. 34
4-3-3.  Sub Hue Adjustment ................................ 34
4-4.
Geometry Adjustment .......................................... 34
4-4-1.  General Setting ........................................ 34
4-4-2.  Pal 50Hz Normal Mode ........................... 35
5. DIAGRAMS
5-1.
Block Diagram ..................................................... 36
5-2.
Circuit Boards Location ...................................... 37
5-3.
Schematic Diagram Information ......................... 37
5-3-1. A Board — (Block 001) .......................... 38
5-3-2. A Board — (Block 002) .......................... 40
5-3-3. A Board — (Block 003) .......................... 42
5-3-4. A Board — (Block 004) .......................... 44
5-3-5. A Board — (Block 005) .......................... 46
5-3-6. A Board — (Block 006) .......................... 48
5-3-7. A Board —(Block 007) ........................... 50
5-3-8. C Board Schematic Diagram ................... 51
5-3-9. H3 Board Schematic Diagram ................. 52
5-4.
Voltage Measurement and Waveforms ................ 53
5-5.
Printed Wiring Boards ......................................... 56
5-6.
Semiconductors .................................................... 59
6. EXPLODED VIEWS
6-1.
Chassis ................................................................. 61
7. ELECTRICAL PARTS LIST ........................................ 63
OPERATING INSTRUCTIONS
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.
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.
– 3 –
KV-HG21M80/M88
   RM-GA002
The units in this manual contain a self diagnostic function. If an error occurs, the STANDBY (1) indicator will automatically
begin to flash. The number of times the STANDBY (1) indicator 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 errors occurs, the STANDBY (1) indicator will flash a set number of times to indicate the possible cause of the
problem. If there is more than one error, the indicator will identify the first of the problem areas.
Result for all of the following diagnosis items are displayed on screen. No error has occurred if the screen displays a "0".
SELF DIAGNOSTIC FUNCTION
Diagnosis
Item
Description
No Power
+B overcurrent
(OCP)
V-Protect (OVP)
IK (AKB)
Power supply
NG (+5V) for
Video Processor
No. of timer
STANDBY (1)
indicator flashes
Does not light
2 times
4 times
5 times
8 times
Diagnostic Result
on screen display
2:0
or
2:1 ~ 255
4:000
or
4:1 ~ 255
5:0
or
5:1 ~ 255
8:0
or
8:1 ~ 255
Probable Cause
Location
• Power cord is not plugged
in.
• Fuse is burned out (F600)
A board.
• H OUT (Q805) is shorted.
(A board)
• IC751 is shorted. (C board)
• +13V is not supplied.
(A board)
• IC804 is faulty. (A board)
• Video OUT is faulty.
• IC001 is faulty. (A board)
• Screen (G2) is improperly
adjusted.
• IC604 faulty.
• IC602 faulty.
Detected
Symptoms
• Power does not turn on.
• No power is supplied on
TV.
• AC Power supply is faulty.
• Power does not turn on.
• Load on power line is
shorted.
• Has entered standby state
after horizontal raster.
• Vertical deflection pulse is
stopped.
• Power line is shorted or
power supply is shorted.
• No raster is generated.
• CRT Cathode current
detection reference pulse
output is small.
• No power supply to CRT
ANODE.
• No RASTER is generated.
2. STANDBY INDICATOR BLINKING PROCESS
The example above represents for 4 times blink
Lamp OFF 3 seconds 
Lamp ON 300ms
Lamp OFF 300ms
3. STANDBY INDICATOR ON TV FRONT PANEL
Standby indicator
– 4 –
KV-HG21M80/M88
RM-GA002
[+B overcurrent $OCP%]
Occurs when an overcurrent on the +B(135V) line is detected by pin 32 of IC001 (A board).
If the voltage of pin 32 of IC001 (A board) is more than 4V, the unit will automatically go to
standby.
[V-PROTECT]
Occurs when an absence of the vertical deflection pulse is detected by pin 13 of IC001
(A board).
[IK $AKB%]
If the RGB levels* do not balance within 15 sec after the power is turned on, this error will be
detected by IC001 (A board). TV will stay on, but there will be 5 times LED blinking.
Occurs when IC001 internal HV protect detects an abnormal H-Pulse (frequency) due to
improper power supply to IC001. TV cuts off high voltage power of anode CRT. No picture will be
detected. eg: IC602, IC604 go faulty.
* (Refers to the RGB levels of the AKB detection Ref pulse that detects IK.)
A BOARD
IC001
Y/CHROMA JUNGLE
A BOARD
IC804
V.OUT
A BOARD
IC001
SYSTEM
A BOARD
IC003
MEMORY
FROM
C BOARD
IC751 PIN 5
IK
EHTO
RED LED
DISPLAY
SDA0
V.GUARD
SDA
5
F.B-PLS
3
13
84
32
122
A BOARD
FROM
Q816
COLLECTOR
109
POWER SUPPLY NG (+5V)
for VIDEO PROCESSOR
4. SELF DIAGNOSTIC SCREEN DISPLAY
5. HANDLING SELF DIAGNOSTIC SCREEN DISPLAY
6. SELF-DIAGNOSTIC CIRCUIT
2 OCP
: 0
3 OVP
: N/A
4 VSTOP : 1
5 AKB
: 0
8 SVP
: 0
101 WDT : N/A
"0" means no fault has been detected.
"1" means a fault has been detected.
"N/A" means not available for this models.
SELF DIAGNOSTIC
5
8
No.
Description
Method
1.
Display self diagnostic screen
[Display] t [Channel    ] t [Volume    ] t [Power / TV]
Note: The above must be performed while TV is on standby mode.
2.
Stop standby flash
i) Turn off power switch on main.
ii) Unplug power cord from the outlet.
3.
Clear fault result
In self diagnostic screen,press
[Channel    ] t 
-
Note: Diagnostic results display on screen is not automatically cleared. Therefore,
clear result after completion of repair.
4.
Quit self diagnostic screen
Turn off power switch of remote commander or main unit.
– 5 –
KV-HG21M80/M88
   RM-GA002
SECTION 1
DISASSEMBLY
1-2.
SPEAKER REMOVAL
1-3.
CHASSIS ASSY REMOVAL
1-4.
SERVICE POSITION
1-5.
H3 BOARD REMOVAL
1-1.
REAR COVER REMOVAL
1-6.
A BOARD REMOVAL
1 Nine screws
    (+BVTP 4 
× 16
 
 Type2 IT-3)
2 Rear cover
2
Two screws
(Washer Head)
(+P4 
× 16)
1
Two screws
(+BVTP 4 
× 16
      Type2 IT-3)
1
 Three screws
 
(+BVTP 3 
× 12 Type2 IT-3)
2
 H3 Board
 A Board
– 6 –
KV-HG21M80/M88
RM-GA002
1-7.
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.
4
 Anode Cap Removal
8
 Degaussing Coil
6
 Loosen the Neck Assembly 
 
fixing screw and remove
 
Neck Assy
7
 Loosen the Deflection Yoke
 
fixing screw and remove
5
 C Board Removal
9
 Spring Extension 
 
Removal (x2)
qa
 Screw Tapping 7+ Crown Washer (x4)
q;
 Supports, CRT
 
Removal (x2)
• 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
Turn up one side of the rubber cap in the direction
indicated by the arrow a.
Using a thumb pull up the rubber cap firmly in the direc-
tion indicated by the arrow b.
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
Do not damage the surface of anode-caps with
sharp shaped objects.
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.
Do not turn the foot of rubber over too hard.
The shatter-hook terminal will stick out or damage
the rubber.
b
b
a
a
c
anode button
– 7 –
KV-HG21M80/M88
   RM-GA002
SECTION 2
WIRE DRESSING
CAUTION :
1.  Do not overpull the wires during dressing
--> avoid disconnection of wires.
2.  Make sure wires are kept away from
sharp edges, heatsinks & other
high-temperature parts.
2-3.  Mount Caution for Connector Assy, 5P (200V)
2-1.  H3 Board Caution Point
2-2.  UL wire P/N 1-923-082-52 dressing 
 
on A Board
 
 
 
 
R82
R829
R889
 
Connector Assy,
3P P/N: 1-910-031-76
Refer to
printing:
GRAY wire to
Pin 3 (KEY)
W068
W069
UL wire
P/N 1-923-082-52
Refer to
printing:
WHITE wire
to
Pi 1 (GND)
CAUTION:
Make sure Connector Assy,
3P (P/N: 1-910-031-76) is
inserted to correct pins:
--> WHITE wire to Pin 1
--> GRAY wire to Pin 3
--> Pin 2 is NOT connected
CAUTION:
Prevent tie, cable from
touching rear cover or any
enclosures by turning them
away from it
--> avoid rattle sound. Also
prevent tie, cable's end from
touching solder side of 
board.
CAUTION:
Prevent tie, cable from touching
rear cover or any enclosures by
turning them away from it
--> avoid rattle sound. Also
prevent tie, cable's end from
touching solder side of board.
CAUTION:
Dress & control mounted wires on C boards
if necessary :
--> ensure wires do not get trapped during
solder dip process
--> ensure wires do not get punched by ICT
jig. (modify ICT jig if applicable)
Dress UL Wire (1-923-082-52) according to Figure 1(b) as 
shown
Note : Ensure UL wire does not touch high temperature 
resistors R828, R829 & R889
Ensure UL wire does not touch high
temperature resistors R828, R829 & R889
C/M for picture bending
due to introduction of
Sparkling Wega 2 Features
(DCN : S0062)
Note : Please check/confirm for the latest
and/or updated Part Number.
– 8 –
KV-HG21M80/M88
RM-GA002
2-4.  Wire dressing on C board
2-5.  Wire dressing on A board
2-6.  Conn Assy, 5P (YUV) & Lead Assy, Jumper dressing
 
R121
 
 
)
OK
NG
Dress Conn Assy, 7P (RGB) with
Cable Tie at alignment hole, A as shown.
Make sure Conn Assy, 7P (RGB)
does not direct contact with heat
sink of IC751
Conn Assy, 7P
(RGB)
Lead Assy, Focus
FBT Flange
Make sure Conn Assy, 5P
does not touch resistor, R121
Lead Assy, Jumper
Conn Assy, 5P (YUV)
Pin, Wire A021
Figure 5
Figure 5(a)
Figure 5(b)
Shield case
Shield case
C/M for OSD drift from RF to no signal
Make sure the Connector Assy, 5P
(YUV) is press down towards the
board
1) Dress Conn Assy, 5P (YUV) & Lead Assy, Jumper with Pin, Wire A021 as shown.
2) Dress Lead Assy, Jumper according to the route shown in the Figure..
Note : Ensure Lead Assy, Jumper is dress away from shield case in the boxed area in Figure 5.
 
Ensure Lead Assy, Jumper is dress below Conn Assy, 5P (YUV).
Make sure rubber cap is pushed
down to make sure it covers
the FBT flange completely
Cable Tie, A
CAUTION:
Prevent tie, cable from touching
rear cover or any enclosures by
turning them away from it
--> avoid rattle sound. Also
prevent tie, cable's end from
touching solder side of board.
HV Cap Assy
FBT Flange
TVSR Requirement :
All Connectors must be kept away from FBT area by a minimum distance of
10mm
Make sure the UL tape is positioned
at the sharp edge of shield case to
prevent wire from being scratched
Conn Assy, 5P (YUV)
Lead Assy,
CAUTION:
1) Dress Lead Assy, Jumper according to the route shown
in the Figure 5.
=> Ensure Lead Assy, Jumper is dress away from shield
case in the boxed area.
=> Ensure Lead Assy, Jumper is dress below Conn Assy,
5P (YUV).
– 9 –
KV-HG21M80/M88
   RM-GA002
2-7.  AC Power Cord , Lead Assy, Earth, Lead Assy & Speaker (Right & Left) dressing
2-8.  Earth Coating Assy installation at CRT
 
1) Dress AC Power Cord, Lead Assy, Earth and Lead Assy, Speaker (Right) inside standing purse lock.
 
Note : Do not lock the standing purse lock. (will be lock after putting in DGC Conn in Overall Assy)
 
Keep bunch of wires above of RY600 to avoid wires from being sandwiched with front jack and pushed against relay.
2) Dress AC Power Cord and Lead Assy, Speaker (Left) with Pin, Wire A016 as shown.
 
Note : Dress AC Power Cord & Lead Assy, Speaker (Left) above the surrounding capacitors to prevent from touching high-temp parts.
Lead Assy,
Lead Assy, Speaker
Figure 6(a)
AC Cord Holder
540 ± 5 mm
Heat Sink, A004
Dress AC Power Cord & Lead Assy,
Speaker (Left) above the surrounding
capacitors to prevent from touching high-
temp parte.
AC Power
RY600
Standing
Lead Assy, Speaker
Pin, Wire
Earth Assy,
Coating
Make sure the
round
side of spring
tension
is installed to Earth
Assy, coating

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