Sony KP-41S5 User manual

CHASSIS RE-2SERVICE MANUAL
KP-41S5 RM-862 AEP SCC-N60C-A
KP-41S5B RM-862 French SCC-N63B-A
KP-41S5G RM-862 Greek SCC-N60D-A
KP-41S5K RM-862 OIRT SCC-N62D-A
KP-41S5R RM-862 Russian SCC-N62C-A
KP-41S5U RM-862 UK SCC-N61B-A
MICROFILM
∗Please file according to model size. .......
41
PROJECTION TV
MODEL COMMANDER DEST. CHASSIS NO. MODEL COMMANDER DEST. CHASSIS NO.
................. ........................... ............ .......................... ................. ........................... ............ ..........................

– 2 –
KP-41S5/41S5B/41S5G/
41S5K/41S5R/41S5U
RM-862
B/G/H E2..12 21..69 C02 C03 C04..C12 C21..C69
CABLE TV (1) S1..41 S01 S02..S41
CABLE TV (2) S01..S05 M1..M10 U1..U10 S42..S46 S01..S10 S11..S20
ITALY A B C D E F G H H1 H2 21..69 C11..C69
D/K R01..R12 R21..R69 C02..C12 C21..C69
CABLE TV (1) S01 S02..S41
CABLE TV (2) S42 S43..S46
CABLE TV B.. O S21..41 S02.S03..S17.
S21..S41
L F2..F10 F21 F69 C01..C12 C21..C69
I B21..B68 C21..C68
Iudication on the screen
Receivable channel
Receivable Channel and Channel Displays
Television system B/G/H,D/K,I,L
Colour system PAL/SECAM
NTSC 3.58/NTSC4.43(VIDEO IN)
Channel coverage See " Receivable channels and channel
displays " on this page.
Projected picture size 41 inches
Approx. 103cm measured diagonally
Terminals
Rear Center speaker input terminals, 2 terminals
(L, R), audio outputs-phono jack
W1 21-pin Euro connector
(CENELEC standard)
- inputs for audio and video signals
- inputs for RGB
- outputs of TV audio and video signals
:2/ q2 21-pin EURO connector
- inputs for audio and video signals
- inputs for S Video
- outputs for audio and video signals
(selectable)
:3/ q3 21-pin Euro connector
- inputs for audio and video signals
- inputs for S video
- outputs for audio and video signals
(selectable, the same output source as the
:2/ q2 connector)
SPECIFICATIONS
Front q3 S video input-4-pin DIN
…3 video inputs-phono jack
– (L.R), Audio inputs-phono jacks
"2 Headphone jack -stereo minijack
Sound output 2 x 30W (music power)
2 x 15W (RMS)
Centre SP input 30W (RMS)(using as the centre speaker)
Power consumption 155W
Dimensions(WxHxD) 948x992x 511 mm
(373/8 x 391/8x 201/8inches)
Mass Approx. 43kg (94 lbs 13 oz)
Supplied accessories See page 6.
Other features Digital comb filter (High resolution)
FASTEXT
Design and specifications are subject to change without notice.

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KP-41S5/41S5B/41S5G/
41S5K/41S5R/41S5U
RM-862
TABLE OF CONTENTS
(CAUTION)
SHORT CIRCUIT THE ANODE OF THE PICTURE TUBE AND
THE ANODE CAPTO THE METAL CHASSIS, CRT SHIELD, OR
CARBON PAINTED ON THE CRT, AFTER REMOVINGTHE AN-
ODE.
SAFETY-RELATED COMPONENT WARNING!!
COMPONENTS IDENTIFIED BY SHADING AND MARK !ON
THE SCHEMATIC DIAGRAMS, EXPLODEDVIEWS AND INTHE
PARTS LIST ARE CRITICALTO SAFE OPERATION. REPLACE
THESECOMPONENTSWITH SONY PARTSWHOSE PART NUM-
BERS APPEAR AS SHOWN IN THIS MANUAL OR IN SUPPLE-
MENTS PUBLISHED BY SONY. CIRCUIT ADJUSTMENTSTHAT
ARE CRITICALTO SAFEOPERATION ARE IDENTIFIED INTHIS
MANUAL.FOLLOWTHESE PROCEDURESWHENEVER CRITI-
CAL COMPONENTS ARE REPLACED OR IMPROPER OPERA-
TION IS SUSPECTED.
Section Title Page
1. GENERAL
Overview ..............................................................................................................4
Getting Started
Step 1 Preparation ................................................................................................ 5
Step 2 Tuning in to TV Stations ........................................................................... 5
Step 3 Adjusting Colour Registration (Convergence) ..........................................6
Additional Presetting Functions ...........................................................................7
Operating Instructions
Watching the TV .................................................................................................. 9
Adjusting and Setting the TV Using the Menu .................................................. 10
Teletext ..............................................................................................................11
Connecting and Operating Optional Equipment ................................................ 12
ForYour Information .......................................................................................... 14
Optimum Viewing Area .................................................................................... 14
Troubleshooting................................................................................................ 14
2. DISASSEMBLY
2-1. Rear Board Removal ................................................................................. 15
2-2. Main Bracket Section Removal ................................................................. 15
2-3. Service Position .........................................................................................15
2-4. G Board Removal ......................................................................................15
2-5. AE Board and UE Board Removal............................................................16
2-6. H1 Board, H2 Board and Resistor (HighVoltage)Removal ......................16
2-7. BEZNET Section Removal ....................................................................... 17
2-8. High-Voltage Cable Installation and Removal .......................................... 17
2-9. Mechasel Assy Removal ............................................................................17
2-10.Chassis Block Removal ............................................................................. 18
3. SET-UP ADJUSTMENTS
3-1. Screen Voltage Adjustment ........................................................................ 19
3-2. Focus Lens Adjustment ............................................................................. 19
3-3. SCREEN (G2) Adjustment ........................................................................19
3-4. Focus VR Adjustment................................................................................ 19
3-5. DeflectionYoke Tilt Adjustment ............................................................... 20
3-6. 2-Pole Magnet Adjustment ........................................................................ 20
3-7. 4-Pole Magnet Adjustment ........................................................................ 20
3-8. Defocus Adjustment (Blue) ....................................................................... 20
4. SAFETY RELATED ADJUSTMENT
4-1. HV Hold Down Adjustment ......................................................................21
5. CIRCUIT ADJUSTMENTS
5-1. Electrical Adjustments...............................................................................22
How to enter into service mode................................................................. 22
5-2. Service list .................................................................................................24
5-3. Registration (Convergence) Adjustment Method .................................... 27
PAL Registration Adjustment .................................................................... 27
Center Adjustment ..................................................................................... 27
Size Adjustment ......................................................................................... 27
5-4. Geometry ...................................................................................................27
Main Deflection Adjustment ..................................................................... 27
Sub Deflection Adjustment Item ...............................................................28
Vertical Line Adjustment ........................................................................... 28
Horizontal Line Adjustment ...................................................................... 29
Size and Linearity Adjustment .................................................................. 29
Horizontal Size Adjustment ...................................................................... 29
Green Vertical Linearity Adjustment ......................................................... 29
Green Vertical Size Adjustment ................................................................. 30
Green Horizontal Trapezoidal Distortion Adjustment ..............................30
Green Horizontal Quaternary Adjustment.................................................30
Green Horizontal Asymmetrical Pin Distortion Adjustment.....................30
Green Horizontal Symmetrical Pin Distortion Adjustment.......................31
Green Vertical Wave (3rd-Order) Distortion Adjustment ..........................31
Green Vertical 4th Order Distortion Adjustment ...................................... 31
Green Vertical Trapezoidal Distortion Adjustment ................................... 31
Green Vertical Asymmetrical Pin Distortion (2nd-Order Distortion)
Adjustment ................................................................................................32
Green VerticalAsymmetrical Pin Distortion Adjustment .........................32
Green and Red RegistrationAdjustment ................................................... 32
Green and Blue Adjustment ...................................................................... 32
Registration Data Write .............................................................................32
5-5. AGC Adjustment ....................................................................................... 32
5-6. White Balance Adjustment ........................................................................ 33
5-7. Text Position Adjustment .......................................................................... 33
6. DIAGRAMS
6-1. Block Diagram (1)..................................................................................... 35
Block Diagram (2) .....................................................................................39
6-2. Frame Schematic Diagram ........................................................................ 43
6-3. Circuit Boards Location ............................................................................46
6-4. Printed Wiring Boards and Schematic Diagrams ......................................46
• G Board ...................................................................................................47
• AE(1/2) Board ......................................................................................... 55
• AE(2/2) Board ......................................................................................... 60
• H1 Board .................................................................................................65
• H2 Board .................................................................................................66
• E Board ................................................................................................... 67
• D Board ...................................................................................................73
• ZR Board................................................................................................. 80
• ZG Board ................................................................................................ 81
• CR Board ................................................................................................ 83
• CG Board ................................................................................................84
• CB Board ................................................................................................ 86
• UE Board ................................................................................................ 87
6-5. Semiconductors .........................................................................................88
7. EXPLODED VIEWS
7-1. SCREEN AND COVER ............................................................................. 90
7-2. CABINET AND PANEL BLOCK ..............................................................91
7-3. CHASSIS AND PICTURE TUBE..............................................................92
8. ELECTRICAL PARTS LIST.......................................................... 93
Section Title Page

– 4 –
The operating instructions mentioned here partial abstracts from the
Operating Instructions Manual. The page numbers of the Operating
Instruction Manual remain as in the manual
SECTION 1
GENERAL

– 5 –

– 6 –

– 7 –

– 8 –

– 9 –

– 10 –

– 11 –

– 12 –

– 13 –

– 14 –
Troubleshooting
Here are some simple solutions to some problems which may affect the picture and sound.
Problem Solution
No picture (screen is dark), no sound • Plug in the TV in.
• Press Uon the TV (if uindicator is on, press ;or a programme number
on the Remote Commander).
• Check the aerial connection.
• Check if the selected video source is on.
• Turn the TV off for 3 or 4 seconds then turn it on again using U.
Poor or no picture (screen is dark), but good sound • Press Íto enter the PICTURE CONTROL menu and adjust the brightness,
contrast and colour.
The menu and picture disappear • Press MENU on the Remote Commander or on the front panel of the TV set.
(if contrast and brightness are minimum)
Good picture but no sound • Press Á+.
• Check if “ Center in ” is selected on the SOUND CONTROL menu.
• If ¤is displayed on the screen, press ¤.
No colour for colour programmes • Press Íto enter the PICTURE CONTROL menu, select RESET, then press
the joystick to confirm.
Remote Commander does not function • The batteries are weak.
If you continue to have problems, have your TV serviced by qualified personnel. Never open the casing yourself.

– 15 –
KP-41S5/41S5B/41S5G/
41S5K/41S5R/41S5U
RM-862
SECTION 2
DISASSEMBLY
2-1. REAR BOARD REMOVAL
2Rear board
1Thirteen screws
(Hexagon head)
3Purse lock
2-2. MAIN BRACKET SECTION REMOVAL
2Two screws
(+ BVTP 4X16)
1Optical sheld
3Main bracket section
Main bracket section
2-3. SERVICE POSITION
2-4. G BOARD REMOVAL
1Three Printed circuit
board holders
2G Board

– 16 –
KP-41S5/41S5B/41S5G/
41S5K/41S5R/41S5U
RM-862
2-5. AE BOARD AND UE BOARD REMOVAL
9AE board
1Five screws
(+ BVTP 4X16)
3Two screws
(+ BVTP 3X12)
2Screw
(+ BVTP 4X16)
7Two claws
8UE board
6Bracket (A)
4Terminal board (Euro)
5claw
2-6. H1 BOARD, H2 BOARD AND RESISTOR (HIGHTVOLTAGE) REMOVAL
2Five screws
(Hexagon head)
4Two screws
(+ BVTP 4X16)
!™ Screw (+ BVTP 4X16)
6Two screw (+ BVTP 4X16)
8Screw
(+ BVTP 3X12)
!º Screw (+ BVTP 3X12)
9H1 board
!¡ H2 board
7Bracket (H)
5Control panel assembly
1Speaker grille 3Front board
!£ Resistor (Hight voltage)


– 17 –
KP-41S5/41S5B/41S5G/
41S5K/41S5R/41S5U
RM-862
2-7. BEZNET SECTION REMOVAL
1Screws
(+ BVTP 4X16)
2Seven screws
(+ BVTP 4X16)
3Four screws
(+ BVTP 4X16)
5Four screws
(+ BVTP 4X12)
4Beznet assembly
8Screen holder (H)
9Screen holder (V)
0Screen holder (H)
!¡ Screen holder (V)
!™ Duffusion plate (F)
!£ Duffusion plate (L)
!¢ Contrast screen
6Four screws
(+ BVTP 4X12)
7Eight screws
(+ BVTP 4X12) !∞ Mirror cover
2-9. SLANT MECHASEAL ASSEMBLY REMOVAL
1Rubber cap
2HV cable
turn 90°
2Rubber cap
1HV cable
Hook
Gutter
(1) Removal
(2) Installation
2-8. HIGH-VOLTAGE CABLE
INSTALLATION AND REMOVAL
1Four screws
(+ BVTP 4X16) 5Four screws
(+ BVTP 4X16)
2CR board
3Neck assembly
4Deflection yoke
6Slant mechaseal
assembly (R)
7Extension spring
Removing the arrow-marked screw is strictly inhibited.
If removed, it may cause liquid spill

– 18 –
KP-41S5/41S5B/41S5G/
41S5K/41S5R/41S5U
RM-862
2-10. CHASSIS BLOCK REMOVAL
1Two screws
(+ BVTP 4X16)
2Control panel assembly
3Three connectors
4Four connectors
5Screw
(+ BVTP 4X6)
6Resister (High voltage)
1Two screws
(Hexagon head)
3Set the main
bracket. 2Pull the main bracket, and
remove each connectors on main bracket.
1Six screws
(Hexagon head)
2Pull out the
chassis block.
(3) CHASSIS BLOCK REMOVAL(1) H1, H2 BOARDS AND AND RESISTOR
REMOVAL
(2) MAIN BRACKET REMOVAL Pull out the chassis block by gripping the handles as shown
in the diagram.
At this time, pay particular attention to the components
removed in (1).
Pay particular attention to the wires of each Printed circuit
boards when puling out the main bracket.

– 19 –
KP-41S5/41S5B/41S5G/
41S5K/41S5R/41S5U
RM-862
3-1. SCREEN VOLTAGE ADJUSTMENT
(ROUGH ALIGNMENT)
1. Receive the Monoscope signal.
2. Set 50% BRIGHTNESS and minimum PICTURE.
3. Turn the red VR on the FOCUS block all the way to the left
and then gradually turn it to the right until the point where
you can see the retrace line.
4. Next gradually turn it to the left to the position where the
retrace line disappears.
3-3. SCREEN (G2) ADJUSTMENT
1. Connect jig (A) to 200V. In TP732, CG Board.
2. Connect jig (B) to GND. In TP733, CG Board.
3. Select with Power ON,VIDEO mode without signals.
4. Connect jig (C) to the TP701 (K.CR), TP731 (K:CG), or
TP761 (K.CB) of CR, CG, and CB Board.
5. Adjust R, G, and B screen voltage to until retrace line just
appears with screen VR on the Focus block
3-4. FOCUS VR ADJUSTMENT
1. Set in service mode.
2. Use GH (GSEL) on the service mode menu to shown only
the green color.
3. Press the Commander Menu button (convergence) and out-
put the test signal (crosshach).
4. Rotate the green VR on the FOCUS block and align to ob-
tain the optimal focus point.
5. Use GH (GSEL) from the service mode menu to set to green
and red.
6. Output the test signal and rotate the red VR to obtain the
optimum focus at the point where the red and green spots
overlap.
7. Use BH (BSEL) from the service mode menu to set to red
and blue.
8. Output the test signal and rotate the blue VR aligning to ob-
tain the optimum focus at the point where the blue and green
spots overlap.
R G B
SCREEN
R G B
FOCUS
FOCUS block
Fig. 3-1
Fig. 3-3
Scanning line visible.
A
B
Minimize bothA and B.
Fig. 3-5
Lens
Fig. 3-4
3-2. FOCUS LENS ADJUSTMENT
1. Loose the lens screw.
2. Set in service mode.
3. Use GH (GSEL) on the service mode menu to shown only
the green color.
4. Press the Commander Menu button and selectTEST MENU
and CONVERGENCE to display the test signal (crosshatch)
on the screen.
5. Rotate the green lens and align with the optimal focus point
from the test signal.
6. Use GH (GSEL) from the service mode menu to set to green
and red.
7. Output the test signal and rotate the red lens to obtain the
optimum focus at the point where the red and green spots
overlap.
8. Use BH (BSEL) from the service mode menu to set to red
and blue.
9. Output the test signal and rotate the blue lens to obtain the
optimum focus at the point where the blue and red spots over-
lap.
10. Tighten the lens screw.
Fig. 3-2
Minimize both A and B.
B
A
Scanning line visible.
Test signal
SECTION 3
SET-UP ADJUSTMENTS
(B) GND
(A)
200V
KR-KG-KB (C)
2.2k / 3W x2
5.6k / 3W
2.2k / 3W

– 20 –
KP-41S5/41S5B/41S5G/
41S5K/41S5R/41S5U
RM-862
3-5. DEFLECTIONYOKETILT ADJUSTMENT
1. Set to receive the Monoscope signal.
2. Set in service mode.
3. Place the caps on the red and blue lens so that only the green
color.
4. Loosen the deflection yoke setscrew and align the tilt of the
DeflectionYoke sothat thebars at the centerof themonoscope
pattern are horizontal.
5. After aligning the deflection yoke, fasten it securely to the
funnel-shaped portion (neck) of the CRT.
6. The tilt of the deflection yoke for red and Blue is aligned the
same as was done for green.
Fig. 3-6
3-6. 2-POLE MAGNET ADJUSTMENT
1. Set in service mode.
2. Set to receive the Dot signal.
3. Place the caps on the red and blue lens so that only the green
color is shown.
4. Turn the green VR on the focus block to the right and set to
overfocus to enlarge the spot.
5. Now align the 2-Pole Magnet so that the enlarged spot is in
the center of the Just Focus spot.
6. Align the green focus VR and set for just (precise) focus.
7. Perform the same alignment for red and blue.
Fig. 3-7
3-7. 4-POLE MAGNET ADJUSTMENT
1. Set in service mode.
2. Set to receive the Dot signal.
3. Place the caps on the red and blue lens so that only the green
color is shown.
4. Turn the green VR on the focus block to the left and set to
underfocus to enlarge the spot.
5. Now align the 4-Pole Magnet so that the enlarged spot be-
comes a perfect circle.
6. Perform the same alignment for red and blue.
NG OK NG
Fig. 3-8
3-8. DEFOCUS ADJUSTMENT (Blue)
1. Receive the Dot signal.
2. Place the caps on the red and green lens so that only the blue
color is shown.
3. Rotate the blue focus volume on the focus pack and adjust to
obtain best electrical focus.
4. Rotate Blue focus volume of focus pack clocwise, so that
diameter of the Dot see Caution.
[How to Blue defocus.]
÷
1
Just Focus : 1.2
Fig. 3-9
[Change Blue Defocus]
Fig. 3-10
5mm Max.
Use the center dot
Use the center dot
Neck Assy
2-pole magnet 4-pole magnet
Deflection yoke
Anode cap
Deflection yoke should be as more close to
CRT as possible.