3-4.Screen (G2), White Balance....................17
4. CIRCUIT ADJUSTMENTS
4-1.Electrical Adjustments....................18
4-2.Test Mode 2....................20
5. DIAGRAMS
5-1.Circuit Board Location....................22
5-2.Block Diagrams....................23
5-3.Schematic Diagrams and
Printed Wiring Boards....................22
* C Board....................27
* A Board....................29
5-4.Semiconductors....................37
5-5.IC Blocks....................39
6. EXPLODED VIEWS
6-1.Chassis....................40
6-2.Picture Tube....................41
CAUTION
SHORT CIRCUIT THE ANODE OF THE PICTURE TUBE AND THE
ANODE CAP TO THE METAL CHASSIS, CRT SHIELD, OR THE
CARBON PAINTED ON THE CRT, AFTER REMOVAL OF THE
ANODE CAP.
WARNING !!
AN ISOLATION TRANSFORMER SHOULD BE USED DURING ANY
SERVICE WORK TO AVOID POSSIBLE SHOCK HAZARD DUE TO
LIVE CHASSIS, THE CHASSIS OF THIS RECEIVER IS DIRECTLY
CONNECTED TO THE POWER LINE.
SAFETY-RELATED COMPONENT WARNING !!
COMPONENTS IDENTIFIED BY SHADING AND MARKED
THE SCHEMATIC DIAGRAMS, EXPLODED VIEWS AND IN THE
PARTS LIST ARE CRITICAL FOR SAFE OPERATION. REPLACE
THESE COMPONENTS WITH SONY PARTS WHOSE PART
NUMBERS APPEAR AS SHOWN IN THIS MANUAL OR IN
SUPPLEMENTS PUBLISHED BY SONY.
£
ON
7. ELECTRICAL P ARTS LIST....................42
ATTENTION
APRES AVOIR DECONNECTE LE CAP DE’LANODE,
COURT-CIRCUITER L’ANODE DU TUBE CATHODIQUE ET CELUI
DE L’ANODE DU CAP AU CHASSIS METALLIQUE DE L’APPAREIL,
OU AU COUCHE DE CARBONE PEINTE SUR LE TUBE
CATHODIQUE OU AU BLINDAGE DU TUBE CATHODIQUE.
ATTENTION !!
AFIN D’EVITER TOUT RISQUE D’ELECTROCUTION PROVENANT
D’UN CHÁSSIS SOUS TENTION, UN TRANSFORMATEUR
D’ISOLEMENT DOIT ETRE UTILISÈ LORS DE TOUT DÈPANNAGE
LE CHÁSSIS DE CE RÈCEPTEUR EST DIRECTMENT RACCORDÈ
Á L’ALIMENTATION SECTEUR.
ATTENTION AUX COMPOSANTS RELATIFS Á
LES COMPOSANTS IDENTIFIÈS PAR UNE TRAME ET PAR UNE
MARQUE
EXPLOSÈES ET LES LISTES DE PIECES SONT D’UNE IMPOR-
TANCE CRITIQUE POUR LA SÈCURITÈ DU FONCTIONNEMENT,
NE LES REMPLACER QUE PAR DES COMPSANTS SONY DONT LE
NUMÈRO DE PIÈCE EST INDIQUÈ DANS LE PRÈSENT MANUEL
OU DANS DES SUPPLÈMENTS PUBLIÈS PAR SONY.
The flexible mains lead is supplied connected to a B.S. 1363 fused plug
having a fuse of 13 AMP rating. Should the fuse need to be replaced,
use a 13 AMP FUSE approved by ASTA to BS 1362, ie one that
carries the
IF THE PLUG SUPPLIED WITH THIS APPLIANCE IS NOT SUITABLE
FOR THE OUTLET SOCKETS IN YOUR HOME, IT SHOULD BE CUT
OFF AND AN APPROPRIATE PLUG FITTED. THE PLUG SEVERED
FROM THE MAINS LEAD MUST BE DESTROYED AS A PLUG WITH
BARED WIRES IS DANGEROUS IF ENGAGED IN A LIVE SOCKET.
When an alternative type of plug is used, it should be fitted with a
13 AMP FUSE, otherwise the circuit should be protected by a 13 AMP
FUSE at the distribution board.
ASA
T
mark.
How to replace the fuse.
Open the fuse compartment with
a screwdriver blade and replace
the fuse.
The identification of errors within the AE-5A chassis is triggered in one of two ways :- 1: Busy or 2: Device failure to respond to IIC. In the event of
one of these situations arising the software will first try to release the bus if busy (Failure to do so will report with a continuous flashing LED) and
then communicate with each device in turn to establish if a device is faulty. If a device is found to be faulty the relevant device number will be
displayed through the LED (Series of flashes which must be counted) See table 1., non fatal errors are reported using this method.
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Flash Timing Example : e.g. error number 3
StBy LED
ONONON
OFF
6
OFF
Error Detection Monitor
Device acknowledge is used to check IIC errors. Device acknowledge is checked by sending an IIC start sequence during CRT power on. Each
device is checked three times, if there is no acknowledge after each attempt, it will be regarded as an error.
There are three steps to check for errors.
1.IIC line 0
If all devices except the NVM have errors, IIC line 0 error is displayed.
2.Board check
If all devices mounted on one board have errors, board error is displayed.
3.Each device check
If IIC line error and board error are not detected then the device with the error is displayed.
The detected errors can be displayed as follows :
1.Error Monitor Menu.
2.Error Reader.
1. Error Monitor Menu
ERROR MONITOR
1. IGNORE ERRORS OFFONOFF
Operating Time :000075h15min
Stored Errors :
1.D1 - B CXA1875 or MB88141
2.No Error Occured
3.No Error Occured
4.No Error Occured
5.No Error Occured
Current Error :
Start Error Sequence
Last menu Enter Item
7
2. Error Reader Display
The error reader display is connected to the service connector to read actual error codes. The part number for the error reader display is
S-188-900-10. Once an error has been detected it will then be displayed on the two digit error reader. The errors displayed refer to the following
table.
L/G/S/I RCA connectors, variable output for audio signals
R/D/D/D
RF In
Video input -phono jacks
Audio inputs - phono jacks
S video input - 4 pin DIN
Headphones jack - minijack stereo
4
4
4
s
Front Terminals
Channel Display Table
IB21..B69C21..C69
15
SECTION 2DISASSEMBLY
2-1. Rear Cover Removal
Remove the rear cover fixing screws indicated. Take care
when removing the rear cover not to damage the speaker
cables [Disconnect the speaker connector] as speakers are
fitted inside the rear cover.
2-2. Speaker Connector Disconnection
Before completely removing the rear cover disconnect the
speaker connector which is located on the inside.
2-3. Chassis Removal and Refitting
To remove lift the main bracket rear slightly and slide the
chassis away from the beznet. Ensure that the interconnecting
leads are released from their purse locks to prevent damage
being caused.
When refitting the chassis ensure that the main
bracket is located in the beznet guide slots before
sliding the chassis forwards. Refit the
interconnecting leads in their respective purse locks.
16
2-4. Service Position2-5. D1 Board Removal
Position the PWB as indicated to access the solder side.
To gain access to the D Board follow the instructions on page
19. [Removal and Replacement of the main bracket bottom
plates ].
2-6. J Board Removal
Clip
Release the two metal bracket support clips located on either
side of the chassis. Tilt the bracket very slightly away from the
shield case indicated. Release the J board board socket
retaining clip and carefully lift the complete assembly vertically.
Shield
case
To remove the D1 Board release the clip circled and gently
remove the board in a vertical direction.
2-7. B3 Board Removal
Follow the steps indicated in removal of the J board. With the
assembly removed access to the B3 board shield is possible. To
remove the shield locate and remove the two screws positioned on
either side and at opposite ends of the shield. Release the B3 board clip
and remove in a vertical direction. Please ensure that the screws are
refitted after service.
Screw
Note :
Removal of the B3, E, and M1 printed circuit boards follows the
same procedure of releasing the securing clips as indicated
in the fig for D1 board removal.
Take care not to apply to great a pressure to the clips as this may
cause damage.
17
2-8. Front Control Module Removal2-9. F3 and H6 Board Removal
Remove the two screws fixing the user control module to the
front underside of the set. The control module drops down to
To remove the F3 and H6 Boards release the clips circled and
ease the boards gently away from the main support bracket.
allow access to the boards.
Screws
Clips
2-10. H5 Board Removal
To remove the H5 Board, first remove the control door from
bracket by releasing the clips circled and pushing them
through the main support bracket.
Clips
Removal of H5 Board follows the same procedure as removal
of the F3 and H6 Boards.
2-11. Service Connector for H5 Board
If there is a requirement to use the front video and audio
sockets when the chassis is placed in its service position, it
would be necessary to use an extender board and extension
cable as indicated below.
From H5 Board
To CN 1703 on
A Board
Extender board assembly A-1647-037-A
The Extender board and extension cable are available as a
service part by ordering the part number as indicated.
18
2-12. Picture Tube Removal
WARNING:
BEFORE REMOVING
THE ANODE CAP
High voltage remains in the CRT even
after the power is disconnected. To
avoid electric shock, discharge CRT
before attempting to remove the anode
cap. Short between anode and CRT
coated earth ground strap.
Coated Earth
Ground Strap
8
9
1
3
7
2
6
10
5
4
1.Discharge the anode of the CRT and remove the anode cap.
2.Unplug all interconnecting leads from the Deflection yoke, neck
assy, degaussing coils and CRT grounding strap.
3.Remove the C Board from the CRT.
4.Remove the chassis assembly.
5.Loosen the Neck assembly fixing screw and remove.
6.Loosen the Deflection yoke fixing screw and remove.
7.Place the set with the CRT face down on a cushion and remove
the Degaussing Coil holders.
8.Remove the Degaussing Coils.
9.Remove the CRT grounding strap and spring tentioners.
10. Unscrew the four CRT fixing screws [ located on each CRT
corner ] and remove the CRT.
[Take care not to handle the CRT by the neck.]
Removal of the Anode-Cap
* REMOVING PROCEDURES.
a
1
Turn up one side of the rubber cap in
the direction indicated by the arrow a
b
2 Using a thumb pull up the rubber cap
firmly in the direction indicated by the
arrow b
How to handle the Anode-Cap
1.To prevent damaging the surface of the anode-cap do not use
sharp materials.
2.Do not apply too great a pressure on the rubber, as this may cause
damage to the anode connector.
3.A metal fitting called a shatter hook terminal is fitted inside the
rubber cap.
4.Do not turn the rubber foot over excessively, this may cause damage
if the shatter hook sticks out.
c
b
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
19
For safety reasons, on no account should the plates be
removed and not refitted after servicing.
£
Because the plates differ in size it is important that the correct plates are refitted in their original
location.
Please note that the plates need to be rotated 180 degrees from their cut position to allow the
(2) REFITTING THE PLATES
tabs to be fitted into their catch positions.
Catch
Ta b
REMOVAL AND REPLACEMENT OF THE MAIN-BRACKET
BOTTOM PLATES.
Only remove the necessary plate to gain access to the printed wiring board.
In the event of servicing being required to the solder side of the D Board printed wiring board,
the bottom plates fitted to the main chassis bracket require to be removed.
This is performed by cutting the gates with a sharp wire cutter at the locations indicated by the
arrows.
(1) REMOVING THE PLATES
Note : There are 3 plates fitted to the main bracket and secured by3 gates.
20
SECTION 3SET-UP ADJUSTMENTS
•When complete readjustment is necessary or a new picture tube is
installed, carry out the following adjustments.
•Unless there are specific instructions to the contrary, carry out
these adjustments with the rated power supply.
•Unless there are specific instructions to the contrary, set the
controls and switches to the following settings :
Contrast.................................. normal
Brightness .................................. normal
3-1. Beam Landing
Preparation :
1.In order to reduce the influence of geomagnetism on the set’s
picture tube, face it in an easterly or westerly direction.
2.Switch on the TV set’s power and degauss with a degausser.
(1) Adjustment of Neck Assembly and Y-Splitting Axis.
1.Position the neck assembly as indicated in Fig.3-2.
2.Loosen the deflection yoke fixing screw.
6.Position the Y-splitting axis correction magnets located on the neck
assembly as indicated in Fig 3-1.
Fig.3-1
Y-splitting axis correction magnet
Carry out the adjustments in the following order :
4.Move the deflection yoke backwards and adjust with the purity
magnet so that the red is at the centre and it aligns
symmetrically [See Fig.3-6].
5.Move the deflection yoke forward to the point where the entire
screen just becomes red [Mark its position].
6.Move the deflection yoke further forward until the screen just
changes colour at the edges. [Mark its position]
7.Position the deflection yoke between the two marks indicated
above.
8.Input a crosshatch pattern from the pattern generator and rotate the
deflection yoke so that the horizontal lines are parallel with the top
and bottom of the screen.
9.When the position of the deflection yoke has been determined,
fasten it with its fixing screw.
10. Adjust the upper and lower pin symmetrically by tilting the DY
up and down then insert a DY wedge at the top. Use the Y- splitting
axis magnets to finely adjust the pin balance. [Fig.3-3].
11. Adjust the H-trap by moving the DY left or right. Insert DY
wedges at top and bottom left and top and bottom right. Finely
adjust using the H-trap VR on the DY assembly. [See Fig.3-4].
12. Switch the pattern generator to green then blue and confirm the
purity.
13. If the beam does not land correctly in all the corners of the screen,
use disk magnets to correct it. [Confirm the corner landing for
green and blue]
Caution :
High voltages are present on the Deflection yoke terminals - take care
when handling the Deflection yoke whilst carrying out adjustments.
(2) Landing
Note : Before carrying out the following adjustments adjust the
magnets as indicated below [See Fig.3-5].
1.Input a crosshatch signal from the signal generator.
2.Rough-adjust the focus and horizontal convergence.
3.Switch from the crosshatch pattern to an all-red pattern.
21
Fig.3-2
Fig.3-3
G1
G2
+
G3
Neck assy
Align the edge
of the neck assy with
the edge of the G2 grid
on the G3 side.
B
G
R
B
G
R
Fig.3-4
Fig.3-5
DY Wedges
Purity magnets
Align pips on
each magnet
DY
Align both Purity magnets
to the vertical position
Purity control magnets
3-2. Convergence
(1) Screen centre convergence [Static convergence]
1.Input a dot pattern signal from the pattern generator.
2.Normalize the picture setting.
3.[Moving vertically], adjust the V.STAT magnet so that the
vertical red, green and blue dots coincide at the centre of the
screen.
Fig.3-6
GREEN
RED
BLUE
Purity control corrects
this area
a
cd
b
Deflection yoke positioning
corrects these areas
Disk magnets or
rotatable disk
magnets correct
these areas (a-d)
Center dot
R
G
B
R
G
B
H STAT
convergence
control
V.STAT Vertical Static Magnet
C Board
RV5375 (H STAT)
H STAT Convergence
(on mount side)
By opening or closing the V.STAT magnet, the red green and blue
dots move in the direction indicated below.
Disk Magnets
Note:Do not adjust the H.STAT by rotating the V.STAT
magnets as this can affect the focus setting.
22
4.Correction for HMC [Horizontal mis-convergence] and VMC
+
+
+
YCH VR
Deflection Yoke
+
+
+
TLV VR
Deflection Yoke
HTRAP VR
+
+
+
Deflection Yoke
[Vertical mis-convergence] by using the BMC [Hexapole] magnet.
a). HMC correction by BMC [Hexapole] magnet and movement of
the electron beam.
HMC correction(A)HMC correction(B)
A < B
RG B
A > B
RGB
HTIL correction can be performed by adding a THL correction
assembly to the Deflection yoke.
A = B
RG B
A = B
RG B
b). VMC correction by BMC [Hexapole] magnet and movement of
the electron beam.
VMC correction(A)VMC correction(B)
C < D
C
D
C = DC > DC = D
R
G
B
R
C
G
D
B
R
G
B
R
G
B
HAMP Adjustment
YCH Adjustment
TLV Adjustment
Adjust the HAMP using HAMPL and HAMPR registers in the
Dynamic Convergence section of the service menu.
HTIL Adjustment
THL Correction assy
H-TRAP Adjustment
The H-TRAP should not be adjusted unless absolutely necessary as it
affects the TLV settings.
23
Layout of each control
Purity magnet
BMC (Hexaploe) magnet
V STAT convergence magnet
Y-splitting axis correction magnet
Note : If you are unable to adjust the corner convergence properly,
this can be corrected with the use of permalloy magnets.
3-3. Focus Adjustment
1.Receive a television broadcast signal.
2.Normalize the picture setting.
3.Adjust the focus control located on the flyback transformer to
obtain the best focus at the centre of the screen.
Bring only the centre area of the screen into focus, the magentaring appears on the screen. In this case, adjust the focus to
optimize the screen uniformly.
Focus
Control
a
a-d: screen-corner
convergence defect
c
Install the permalloy assembly
for the area that needs correcting.
b
Permalloy Assy
X-4387-214-1
d
Convergence adjustment with permalloy
b
d
3-4. Screen (G2), White Balance
[Adjustment in the service mode using the remote
commander]
G2 adjustment [RV5376]
1.Input a dot signal from the pattern generator.
2.Set the Picture, Brightness and Colour to minimum.
3.Apply 170V DC from an external power supply to the R, G and B
cathodes of the CRT.
4.Whilst watching the picture, adjust the G2 control RV5376
[SCREEN] located on the C Board to the point just before the
flyback return lines disappear.
a
White balance adjustment for TV mode
1.Input an all-white signal from the pattern generator.
2.Enter into the ‘Service Mode’ by pressing ‘TEST’, ‘TEST’ and
‘MENU’ ‘MENU’ on the Service Commander.
3.Select ‘Backend’ from the on screen menu display and press
‘OK’.
4.The ‘Backend’ menu will appear on the screen.[See Page 26]
5.Set the ‘Contrast’ to MAX.
6.Set the ‘R-Drive’ to 41.
7.Adjust the ‘G-Drive’ and the ‘B-Drive’ so that the white
balance becomes optimum.
8.Press the ‘OK’ button to write the data for each item.
9.Set the ‘Contrast’ to MIN.
10. Set the ‘R-Cutoff’ to 31.
11. Adjust the ‘G-Cutoff’, and the ‘B-Cutoff’ with the left and
right buttons on the remote commander so that the white balance
c
becomes optimum.
12. Press the ‘OK’ button to write the data for each item.
24
SECTION 4 CIRCUIT ADJUSTMENTS
4-1. Electrical Adjustments
Service adjustments to this model can be performed using the supplied Remote Commander RM-893.
How to enter into the Service Mode
1.Turn on the main power switch of the set while pressing P + (plus) and P - (minus) buttons on the front drop down control panel.
+
P
s
4
L/G/S/I R/D/D/D
4
MONO
4
2.‘TT’ will appear in the upper right corner of the screen.
3.Press the ‘MENU’ button twice on the remote commander to obtain the service menu on the screen.
Initialising
Reset Devices
Monitoring
Device Register Setting
Special Adjustment
Select :
Next Menu
4.Push the joystick up or down on the remote commander to select the adjustment item.
5.Push the right button to proceed to the next menu.
6.If the required adjustment item is ‘Deflection’, push the down button to move to ‘Deflection’.
7.Push the joystick to the right to enter into ‘Deflection’.
8.Change the data in order to comply with each standard.
INITIALISING
Model Setting
Destination Setting
Basic Setting
Feature Setting
MONITORING
Device Status monitor
Error Monitor
Production Monitor
NVM Monitor
Format Monitor
CNI Monitor
Note :
•Before performing any adjustments ensure that the correct model has been selected in the ‘Model Setting’ menu.
•After carrying out the service adjustments, to prevent the customer accessing the ‘Service Menu’ switch the TV set OFF and then ON.
25
Initialising Menu
Basic Setting
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Model Setting
The menu contains a list with all the available models of this software to
set up the TV set in an easy way. The selection of a model is setting data
for its features and hardware resources which cannot be detected by the
automatic power on H/W detection as well as a special model byte to get
an unique model identification for models which cannot be differed by
features and hardware resources (e.g. KV-28FC60 and
KV-28FC60Z)
Before data is set, the user will be asked if he really wants to set a new
model. If the user agrees, automatically the destination setting menu is
shown.
1.Enter into the service mode and select ‘Deflection’ from the
menu. The ‘Deflection’ adjustment menu will be displayed.
2.Select and adjust each item to obtain the optimum image.
4-2. Volume Electrical Adjustments
Sub Colour Adjustment
1.Input a PAL colour bar signal.
2.Connect an oscilloscope to CN5400 pin 5 located on the C Board.
3.Enter into the ‘Service Mode’.
4.Choose ‘Backend’ from the menu.
5.Adjust ‘Sub Colour’ data so that the right sides of the waveform
are of equal height.
Same Level
B-Out Waveform
AFC V ANGLE
H LOWER COR
29
4-3. TEST MODE 2:
Is available by pressing the ‘TEST’ button twice, OSD ‘TT’ appears. The functions described below are available by selecting the two numbers. To
release the ‘Test mode 2’, press 0, 10, 20 ... twice or switch the TV set into Stand-by mode. Pressing the two Local Control buttons (+ and -) during
power ON will also switch into ‘TT’ mode.
In ‘TT’ mode, it is possible to remove the Menu from the screen by pressing the Speaker Off button once. Pressing the Speaker OFF button a
second time will cause the Menu to reappear. The function is kept even when the menu is not displayed on screen !!.