Sony KP-HR53KR User manual

CHASSIS RA-4BSERVICE MANUAL
MODEL COMMANDER DEST. CHASSIS NO.
–––––––– ––––––––––––––– –––––– ––––––––––––––
MODEL COMMANDER DEST. CHASSIS NO.
–––––––– ––––––––––––––– –––––– ––––––––––––––
53 61
∗Please file according to model size. .......
PROJECTION TV
KP-HR53KR1 RM-Y902K Korean SCC-P35A-A
KP-HR61KR1 RM-Y902K Korean SCC-P35B-A
KP-HR53KR1
RM-Y902K KP-HR61KR1
TV
2
5
8
0
1
4
7
3
6
9
DISPLAY TV/VIDEO ANT
JUMP
ENTER
MENU
RESET
VOL CH
MUTING TV
OFF
AUDIO SWAP
TV/DBS
PICTURE
MODE
GUIDE ACTIVE
POTITION
LEFT RIGHT
ZOOM IN
FREEZE
POWER
SYSTEM
OFF
DVD/
VTR
DBS
CABLE
FUNCTION
DVD/VTR DBS/CABLE TV
CC

– 2 –
KP-HR53KR1/HR61KR1
RM-Y902KRM-Y902K
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 F1.1
Television system
American TV standard
Channel coverage
VHF: 2– 13/ UHF: 14– 69/ CATV: 1– 125
Antenna
75 ohm external terminal for VHF/ UHF
Screen size (measured diagonally)
53 inches (KP- HR53KR1)
61 inches (KP- HR61KR1)
Inputs/ outputs
VIDEO 1/ 3 IN
VIDEO 2 INPUT
S VIDEO IN (4- pin mini DIN):
Y: 1 Vp- p, 75- ohms unbalanced, sync negative
C: 0.286 Vp- p (Burst signal), 75 ohms
VIDEO (phono jack): 1 Vp- p, 75- ohms unbalanced, sync
negative
AUDIO (phono jacks): 500 mVrms (100% modulation),
Impedance: 47 kilohms
VIDEO 4 IN
S VIDEO IN (4- pin mini DIN):
Y: 1 Vp- p, 75- ohms unbalanced, sync negative
C: 0.286 Vp- p (Burst signal), 75 ohms
VIDEO (phono jack): 1 Vp- p, 75- ohms unbalanced, sync
negative
Y: 1 Vp- p, 75 ohms, sync negative
P B : 0. 7 Vp- p, 75 ohms
P R : 0. 7 Vp- p, 75 ohms
AUDIO (phono jacks): 500 mVrms (100% modulation),
Impedance: 47 kilohms
VIDEO 5 (DTV) IN
Maximum scanning rate: 1080i
Y: 1 Vp- p, 75 ohms, negative or tri- level sync
P B : 0.7 Vp- p, 75 ohms
P R : 0.7 Vp- p, 75 ohms
or
G: 0.7 Vp- p, 75 ohms
B: 0.7 Vp- p, 75 ohms
R: 0.7 Vp- p, 75 ohms
HD: 0.5– 5 Vp- p, 2.2 kilohms
VD: 0.6– 5 Vp- p, 2.2 kilohms
Note:
The VIDEO 5 (DTV) IN jacks are not compatible with a
computer’s 5BNC (R/ G/ B/ HD/ VD) video output connectors.
AUDIO (phono jacks): 500 mVrms (100% modulation),
Impedance: 47 kilohms
SELECT OUT
VIDEO (phono jack): 1 Vp- p, 75- ohms unbalanced, sync
negative
AUDIO (phono jacks): 470 mVrms (100% modulation),
Impedance: 47 kilohms
AUDIO (VAR) OUT (phono jacks): 700 mVrms (100%
modulation)
AUDIO (FIX) OUT (phono jacks): 500 mVrms (100%
modulation)
CONTROL S IN/ OUT: minijacks
Speaker
Front (Tweeter): 66 mm (25/8”)x2
Front (Woofer):
130 mm (51/8”)x2 (KP- HR53KR1)
160 mm (61/8”) x2 (KP- HR61KR1)
Speaker output
Front: 20 Wx2
Power requirement
220 V AC, 60 Hz
Power consumption
In use (Max.): 240 W
In standby: 1 W
Dimensions (W/ H/ D)
1,218x1,459x635 mm (48x571/2x25 inches)
(KP- HR53KR1)
1,372x1,558x670 mm (541/8x613/8x261/2 inches)
(KP- HR61KR1)
Mass
84 kg (185 lbs 3 oz) (KP- HR53KR1)
102 kg (224 lbs 14 oz) (KP- HR61KR1)
Supplied accessories
Remote control RM- Y902K (1)
Batteries size AA (R6) (2)
Design and specifications are subject to change without
notice.

– 3 –
KP-HR53KR1/HR61KR1
RM-Y902KRM-Y902K
SELF DIAGNOSIS FUNCTION
* : 000 the range of values for number of operations is 000-255. For 256 or higher there is
no count up and the number remains at 255.
3. Blinking count display of TIMER/STAND BY indicator
1. Summary of Self-Diagnosis Function
• This device includes a self-diagnosis function.
• In case of abnormalities, the TIMER/STAND BY indicator automatically blinks. It is possible to predict the abnormality location
by the number of blinks. The Instruction Manual describes blinking of the TIMER/STAND BY indicator.
• If the symptom is not reproduced sometimes in case of a malfunction, there is recording of whether a malfunction was generated
or not. Operate the remote command to confirm the matter on the screen and to predict the location of the abnormality.
2. Diagnosis Items and Prediction of Malfunction Location
• When a malfunction occurs the TIMER/STAND BY indicator only blinks for one of the following diagnosis items. In case of
two or more malfunctions, the item which first occurred blinks. If the malfunctions occurred simultaneously, the item with the
lower blink count blinks first.
• The screen display displays the results regarding all the diagnosis items listed below. The display “ 0 ” means that no malfunc-
tions occurred.
Lamp OFF :
3.0 seconds
Lamp ON : 0.3 seconds
Lamp OFF : 0.3 seconds
Release of TIMER/STAND BY indicator blinking.
•The TIMER/STAND BY indicator blinking display is released by turning OFF the power switch
on the TV main unit or removing the plug from the power.
*One blink is not used for self-diagnosis.
•EXAMPLE
<Diagnosis Items> <Number of Blinks>
•+B overcurrent 2 times
•+B overvoltage 3 times
•Vertical deflection stop 4 times
< FRONT PANEL >
TIMER/STAND BY indicator
metisisongaiD
YBDNATS/REMIT
retacidnI
sknilbforebmuN
noitcnuflamdesoppuSnoitidnoC
sisongaid-fleS
,yalpsidneercs
stluseR:metisisongaiD
NOtonrewoP•0
]metsySylppuSrewoPybdnatS[
.nepo1006F
.nepo2106R
.nekorbsi1006CI
]metsySylppuSrewoPniaM[
.nepo2006F
.nekorbera8006,7006,4006Qdna3006,2006CI
.tiucric-trohs2006,1006DV
.rewopehtnonruttonnaC
.knilbt'nseodDEL
noitcetedPCOB+semit2.tiucrichcaenimetsysylppusrewopfotiucrictrohS edomybdnatsehtotseoG
enilB+fotiucrictrohS 000PCOB+:2
noitcetedPVOB+semit3 .nekorbsi5006CI
.nekorbsi1016CI
edomybdnatsehtotseoG
tiucricylppusrewopfonoitcnuflaM 000PVOB+:3
potsnoitcelfedlacitreVsemit4 .nekorbsi)tuoV(4005CI
.nekorbsi)PSDV(215CI .yllatnozirohenilenootseogretsaR000potSV:4
noitcetedytilamronbatuooediVsemit5
nisrehtodna1037,1027,1017CI,tuooediV
.tiucricsdraobBCdnaGC.RC
)draobA(425,615,015Q
,sdnoces03.xorppasknilbDELYBDNATS/REMIT
.sisongaidflesehtrofsknilbnehtdna 000BKA:5
potsnoitcelfedlatnoziroHsemit6 .nekorbsi)TUOH(3105Q
.nekorbsi)elgnuJH(705CI .raeppat'nseodretsaR000potSH:6
ytilamronbaegatlovhgiH
noitceted semit7nekorbsi8008Q .raeppat'useodretsaR000VH:7
noitcetedytilamronbaoiduAsemit8 .nekorbera3062,2062,1062CI
.nekorbera4016,3016SP
.tuotonsidnuosehT
edomybdnatsehtotseoG 000oiduA:8

–4 –
KP-HR53KR1/HR61KR1
RM-Y902KRM-Y902K
4. Self-diagnosis screen displays
•In cases of malfunctions where it is not possible to determine the symptom such as when the power goes off occasionally or when
the screen disappears occasionally, there is a screen display on whether the malfunction occurred or not in the past (and whether
the detection circuit operated or not) in order to allow confirmation.
<Screen Display Method>
•Quickly press the remote command button in the following order from the standby state.
5. Self-Diagnosis Screen Display
•The results display is not automatically cleared. In case of repairs and after repairs, check the self-diagnosis screen and be sure
to return the results display to “0 ”.
•If the results display is not returned to “0 ”it will not be possible to judge a new malfunction after completing repairs.
<Method of Clearing Results Display>
<Method of Ending Self Diagnosis Screen>
•When ending the self-diagnosis screen completely, turn the power switch OFF on the remote commander or the main unit.
˘
Be aware that this differs from the method of
entering the service mode (volume + ).
DISPLAY bChannel 5 bVOL – bPOWER
Self Check
2 : +B OCP 000
2 : +B OCP 000
3 : +B OVP 000
4 : V Stop 000
5 : AKB 000
6 : H Stop 000
7 : HV 000
8 : Audio 000
9 : WDT 000
000 the range of values for number of
operations is 000-255.
For 256 or higher there is no count up
and the number remains at 255.
Diagnosis
Results
÷
Self-diagnosis screen display
1. Power off (Set to the standby mode)
2. DISPLAY bChannel 5 bVOL + bPOWER (Service Mode)
3. Channel 8 bENTER (Test reset = Factory preset condition)

–5 –
KP-HR53KR1/HR61KR1
RM-Y902KRM-Y902K
6. Self-diagnosis function operation
OCP Low B and +B line detect DET SHORT, and shut-down POWER ON RELAY.
Reset by turning power on/off.
In case of +B is loaded approx. 1.5A or more, microcomputer detects it via IC6102.
OVP In case of +B becomes approx. 150V or more, POWER ON RELAY shuts down and microcomputer detects it via IC6102.
Reset by turning power on/off just the same as OCP.
V Stop In case of V Drive disappeared, Q5005 detecs it and shut-down POWER ON RELAY. Microcomputer detects it and makes LED
blinking.
AKB IK detection. Makes LED blinking in case of microcomputer doesn’t detect IK returns of IC511 (CXA2101AQ) 30 seconds or
more.
H Stop In case of H DRIVE is disappeared, Q5006 detects it and shut-down POWER ON RELAY shuts down.
Microcomputer receives H Stop data from Q5006 and makes LED blinking.
HV Stop In case of HV becomes 33KV or more. IC8006 and IC8010 detect it and shut-down
POWER ON RELAY. Microcomputer makes LED blinking.
Audio In case of DC component overlaps the output of Audio Amp., POWER ON RELAY shuts down.
Microcomputer detects it and makes LED blinking.
Self-diagnosis block diagram
53
4850
3
4
5 6713
49
47
50
55
27
28
33
5. AKB
5. AKB
3. OVP
2. OCP
4. V.STOP (V Pulse)
6. H.STOP
7. HV.STOP
8. Audio
2. OVP
3. OCP
4. V.STOP
6. H.STOP
7. HV STOP
8. AUDIO
IC1008
MAIN-CPU
IC1009
OSD-CPU
IC511
CXA2101AQ
MCP
D3102
TIMER/STANDBY
R1802
IC1007
EEPROM
Q5006
H PULSE
Detector
IC8006,8010
HV Detector
IC512
CXD2018Q
VDSP
Q5005
V Pulse Detector
IC6102
OVP Buffer
OCP Buffer
C Board
DC Detect
IC5004
V Drive
IC2002
6. H STOP
BUS
BUS
56
48
OVP DETECT
OCP DETECT
16
22
Audio AMP

– 6 –
KP-HR53KR1/HR61KR1
RM-Y902KRM-Y902K
TABLE OF CONTENTS
Section Title Page
–––––– –––– –––– Section Title Page –––––– –––– ––––
SELF DIAGNOSIS FUNCTION ............................................ 3
1. GENERAL
Remote Control ....................................................................... 8
Before You Begin .................................................................... 8
Installing and Connecting the Projection TV ........................ 11
Basic Set Up .......................................................................... 18
Using Your New Projection TV............................................. 19
Adjusting Your SET UP (menus) .......................................... 23
Additional Operations ........................................................... 29
Additional Information .......................................................... 30
2. DISASSEMBLY
2-1. Rear Board Removal ................................................. 32
2-2. Main Bracket Removal .............................................. 32
2-3. Service Position ......................................................... 32
2-4. G Board Removal ...................................................... 32
2-5. Terminal Board and U Board Removal ..................... 33
2-6. BM, BR and BD Board Removal .............................. 33
2-7. K Board Removal ...................................................... 33
2-8. BA Board Removal ................................................... 33
2-9. DS Board Removal .................................................... 34
2-10. A and D Board Removal ........................................... 34
2-11. Beznet ASSY Removal ............................................. 34
2-12. HC and S Board Removal ........................................ 35
2-13. Mirror Cover Removal .............................................. 35
2-14. HA Board Removal ................................................... 35
2-15. Picture Tube Removal ............................................... 36
2-16. High-Voltage Cable Installation and Removal .......... 36
3. SET-UP ADJUSTMENTS
3-1. Screen Voltage Adjustment (Coarse Adjustment) ..... 37
3-2. Screen (G2) Adjustment (Fine Adjustment) .............. 37
3-3. Deflection York Tilt Adjustment ............................... 37
3-4. Focus Lens Adjustment ............................................. 37
3-5. Focus VR Adjustment ............................................... 38
3-6. 2-Pole Magnet Adjustment (Green, Red) .................. 38
3-7. 4-Pole Magnet Adjustment ........................................ 38
3-8. Defocus Adjustment (Blue) ....................................... 38
3-9. Electrical Adjustment by Remote Commander ......... 39
3-10. Registration Adjustment (PJE) .................................. 45
3-11. Auto Registration Error Code List ............................ 48
4. SAFETY RELATED ADJUSTMENTS
4-1. HV Regulation Circuit Check and Adjustment ......... 49
4-2. HV Hold Down Circuit Operation Check and
Adjustment ................................................................ 49
4-3. +B Max Voltage Confirmation .................................. 49
4-4. +B OVP Confirmation............................................... 49
5. CIRCUIT ADJUSTMENTS
5-1. TV Input Sub Contrast Adjustment
(MCD1 SCON) ......................................................... 50
5-2. Video Input Sub-Contrast Adjustment
(MCD3-SCON) ......................................................... 50
5-3. P & P Sub-Contrast Adjustment (MCD2-SCON) ..... 50
5-4. P & P Sub-Contrast Adjustment (MCD4-SCON) ..... 50
5-5. Sub-Contrast Adjustment(MCP2-SCON) ................ 51
5-6. Video 5 Input Sub-Contrast Adjustment
(MCP3-SCON) .......................................................... 51
5-7. Sub-HUE and Sub-Color Adjustment
(MCD1-SHUE,SCOL) .............................................. 51
5-8. Video Input Sub-HUE and Sub-Color Adjustment
(MCD3-SHUE,SCOL) .............................................. 51
5-9. P & P Sub-HUE and Sub-Color Adjustment
(MCD2-SHUE,SCOL) .............................................. 52
5-10. P & P Sub-HUE and Sub-Color Adjustment
(MCD4-SHUE,SCOL) .............................................. 52
5-11. P & P Sub Contrast Adjustment (SCD1-SCON)....... 52
5-12. P & P Sub Contrast Adjustment (SCD2-SCON)....... 52
5-13. P & P Sub-HUE and Sub-Color Adjustment
(SCD1-SHUE,SCOL) ............................................... 53
5-14. P & P Sub-HUE and Sub-Color Adjustment
(SCD2-SHUE,SCOL) ............................................... 53
5-15. Video 5 Input Sub-HUE and Sub-Color Adjustment
(MCP3-SHUE,SCOL) ............................................... 53
6. DIAGRAMS
6-1. Block Diagram (1) ..................................................... 55
Block Diagram (2) ..................................................... 58
Block Diagram (3) ..................................................... 61
Block Diagram (4) ..................................................... 63
Block Diagram (5) ..................................................... 65
Block Diagram (6) ..................................................... 68
Block Diagram (7) ..................................................... 71
Block Diagram (8) ..................................................... 73
6-2. Frame Schematic Diagram ........................................ 75
6-3. Circuit Boards Location ............................................ 78
6-4. Printed Wiring Boards and Schematic Diagrams ...... 78
• S Board ................................................................... 79
• A (1/4) Board .......................................................... 83
• A (2/4) Board .......................................................... 87
• A (3/4) Board .......................................................... 91
• A (4/4) Board .......................................................... 94
• BA Board ................................................................ 97
• BM Board ............................................................. 101
• BR Board .............................................................. 107
• BD Board .............................................................. 113
• DS Board .............................................................. 119
• D(1/2) Board ......................................................... 121
• D(2/2) Board ......................................................... 124
• K Board ................................................................. 133
• CR Board .............................................................. 137
• CG Board .............................................................. 138
• CB Board .............................................................. 139
• ZR Board .............................................................. 141
• ZG Board .............................................................. 142
• ZB Board .............................................................. 144
• U Board ................................................................. 145
• HA Board .............................................................. 147
• HC Board .............................................................. 147
• G Board ................................................................. 151
6-5. Semiconductors ....................................................... 154
7. EXPLODED VIEWS
7-1. Cover (KP-HR53KR1) ............................................ 156
7-2. Cover (KP-HR61KR1) ............................................ 157
7-3. Cabinet .................................................................... 158
7-4. Chassis ..................................................................... 159
7-5. Picture Tube ............................................................ 160
8. ELECTRICAL PARTS LIST ...................................... 161

– 7 –
KP-HR53KR1/HR61KR1
RM-Y902KRM-Y902K
(CAUTION)
SHORT CIRCUIT THE ANODE OF THE PICTURE TUBE AND THE
ANODE CAP TO THE METAL CHASSIS, CRT SHIELD, OR CAR-
BON PAINTED ON THE CRT, AFTER REMOVING THE ANODE.
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.
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.

– 8 –
SECTION 1
GENERAL
The operating instructions mentioned here are partial abstracts from the
Operating Instructions Manual. The page numbers of the Operating
Instruction Manual remain as in the manual. (Part no : 4-074-163-11)

– 9 –

– 10 –

– 11 –

– 12 –

– 13 –

– 14 –

– 15 –

– 16 –

– 17 –

– 18 –

– 19 –

– 20 –