Sony TRINITRON KV-21FK120 User manual

TRINITRON®COLOR TELEVISION
SERVICE MANUAL BA-6 CHASSIS
MODEL NAME REMOTE COMMANDER DESTINATION CHASSIS NO.
9-965-980-01
KV-21FK120 RM-Y194 LATIN NORTH SCC- S73H-A
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
ORIGINAL MANUAL ISSUE DATE: 4/2005
REVISION DATE SUBJECT
4/2005 No revisions or updates are applicable at this time.

TRINITRON®COLOR TELEVISION
SERVICE MANUAL BA-6 CHASSIS
MODEL NAME REMOTE COMMANDER DESTINATION CHASSIS NO.
9-965-980-01
KV-21FK120 RM-Y194 LATIN NORTH SCC- S73H-A
Self Diagnosis
Supported model
KV-21FK120 RM-Y194

3
KV-21FK120
KV-21FK120
TABLE OF CONTENTS
SECTION TITLE PAGE
Specifications ............................................................................................................................................................................. 4
Warnings and Cautions .............................................................................................................................................................. 5
Safety Check-Out ....................................................................................................................................................................... 6
Self-Diagnostic Function............................................................................................................................................................. 7
SECTION 1: DISASSEMBLY............................................................................................................................................................. 9
1-1. Rear Cover Removal.......................................................................................................................................................... 9
1-2. Chassis Assembly Removal............................................................................................................................................... 9
1-3. Service Position ............................................................................................................................................................... 10
1-4. Picture Tube Removal.......................................................................................................................................................11
Anode Cap Removal Procedure .......................................................................................................................................11
Wire Dressings................................................................................................................................................................. 12
SECTION 2: SET-UP ADJUSTMENTS............................................................................................................................................ 17
2-1. Beam Landing .................................................................................................................................................................. 17
2-2. Convergence.................................................................................................................................................................... 18
2-3. Focus ............................................................................................................................................................................... 19
2-4. Screen (G2)...................................................................................................................................................................... 20
SECTION 3: SAFETY RELATED ADJUSTMENTS......................................................................................................................... 21
3-1.
X R565 Confirmation Method (HV Hold-Down Confirmation) and Readjustments ........................................................21
3-2. B+ Voltage Confirmation and Adjustment ........................................................................................................................ 21
SECTION 4: CIRCUIT ADJUSTMENTS.......................................................................................................................................... 23
4-1. Remote Adjustment Buttons and Indicators..................................................................................................................... 23
4-2. Accessing Service Adjustment Mode ............................................................................................................................... 23
4-3. White Balance Adjustments ............................................................................................................................................. 24
4-4. Memory Write Confirmation Method ................................................................................................................................ 24
4-5. Service Data List .............................................................................................................................................................. 25
4-6. ID Map Table .................................................................................................................................................................... 33
4-7. A Board Adjustments........................................................................................................................................................ 34
SECTION 5: DIAGRAMS................................................................................................................................................................. 37
5-1. Circuit Boards Location .................................................................................................................................................... 37
5-2. Printed Wiring Board and Schematic Diagram Information.............................................................................................. 37
5-3. Block Diagram and Schematics ....................................................................................................................................... 38
A Board Schematic Diagram............................................................................................................................................ 39
CV Board Schematic Diagram ......................................................................................................................................... 41
KR Board Schematic Diagram ......................................................................................................................................... 42
HK Board Schematic Diagram ......................................................................................................................................... 44
5-4. Semiconductors ............................................................................................................................................................... 45
SECTION 6: EXPLODED VIEWS .................................................................................................................................................... 46
6-1. Picture Tube ..................................................................................................................................................................... 46
6-2. Chassis ............................................................................................................................................................................ 47
SECTION 7: ELECTRICAL PARTS LIST....................................................................................................................................... 48

4
KV-21FK120
KV-21FK120
SPECIFICATIONS
1) 1 Vp-p 75 ohms unbalanced, sync negative
2) Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative;
P
B: 0.7 Vp-p, 75 ohms
P
R: 0.7 Vp-p, 75 ohms
3) 500 mVrms (100% modulation), Impedance: 47 kilohms
4) This specification is maximum wattage.
Television system
American TV standard, NTSC
Channel coverage
VHF: 2-13/ UHF: 14-69/ CATV: 1-125
Picture tube
FD Trinitron
®
tube
Visible screen size
20-inch picture measured diagonally
Actual screen size
21-inch measured diagonally
Antenna
75 ohm external terminal for VHF/UHF
Supplied Accessories
Remote Commander RM-Y194
Two Size AA (R6) Batteries
Antenna, Telescopic
Microphone
Converter
Cord with Connector
Video 2 Cable Adaptor
Design and specifications are subject to change without notice.
KV-21FK120
Power Requirements 120V, 60Hz
Number of Inputs/Outputs
Video 1) 2
Y,PB, PR
2) 1
Audio 3) 3
Microphone 2
S
p
eaker Out
p
ut
(
W
)
10W x 2
Head
p
hones 1
Power Consumption (W)
In Use (Max) 140W
In Standby (Max) 4) 1W
Dimensions (W x H x D)
mm 631 x 468 x 491 mm
in 24 7/8 x 18 3/8 x 19 1/4 in
Mass
kg 25.4 kg
lbs 56 lbs
En calidad de compañía asociada a ENERGY
STAR
®
, Sony ha determinado que este producto
cumple con las directrices de uso eficiente de
energía de ENERGY STAR
®
.
ENERGY STAR
®
es una marca registrada de
EEUU.
Fabricado bajo licencia de SRS Labs, Inc. WOW y los
símbolos SRS son marcas registradas de SRS Labs,
Inc.
Bajo licencia de BBE Sound, Inc. Licenciado de BBE
Sound, Inc. sobre el numero USP4638258, 5510752 y
5736897. BBE y el símbolo de BBE son marcas
registradas de BBE Sound, Inc.
Sony, WEGA, FD Trinitron, Intelligent Picture y Steady Sound son
marcas comerciales de Corporación Sony.

5
KV-21FK120
KV-21FK120
WARNINGS AND CAUTIONS
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.
WARNING!!
An isolation transformer should be used during any service to avoid possible shock hazard, because of live chassis. The chassis of
this receiver 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 for safe
operation. Replace these components with Sony parts whose part numbers appear as shown in this manual or in supplements
published by Sony. Circuit adjustments that are critical for safe operation are identified in this manual. Follow these procedures
whenever critical components are replaced or improper operation is suspected.

6
KV-21FK120
KV-21FK120
SAFETY CHECK-OUT
After correcting the original service problem, perform the following
safety checks before releasing the set to the customer:
1. Check the area of your repair for unsoldered or poorly soldered
connections. Check the entire board surface for solder splashes and
bridges.
2. Check the interboard wiring to ensure that no wires are “pinched” or
touching 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.
4. Look for unauthorized replacement parts, particularly transistors,
that were installed during a previous repair. Point them out to the
customer and recommend their replacement.
5. Look for parts which, though functioning, show obvious signs of
deterioration. Point them out to the customer and recommend 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 B+ and HV to see if they are specified values. Make sure
your instruments are accurate; be suspicious of your HV meter if sets
always have low HV.
8. Check the antenna terminals, metal trim, “metallized” knobs, screws,
and all other exposed metal parts for AC leakage. 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 0.5 mA (500 microamperes).
Leakage 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 use these
instructions.
2. A battery-operated AC milliampmeter. 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” indication is 0.75
V, so analog meters must have an accurate low voltage scale.
The Simpson’s 250 and Sanwa SH-63TRD are examples of
passive VOMs that are suitable. Nearly all battery-operated digital
multimeters that have a 2 VAC range are suitable (see Figure A).
How to Find a Good Earth Ground
A cold-water pipe is a guaranteed earth ground; the cover-plate
retaining 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- to 100-watt
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 on the line; the lamp should light at normal brilliance if the screw
is at ground potential (see Figure B).
To Exposed Metal
Parts on Set
0.15 F1.5 KΩAC
Voltmeter
(0.75 V)
Earth Ground
Trouble Light
AC Outlet Box Ohmmeter
Cold-water Pipe
Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.

7
KV-21FK120
KV-21FK120
Detected Symptoms
SELF-DIAGNOSTIC FUNCTION
*If a +B overcurrent is detected, stoppage of the vertical deflection is detected simultaneously. The symptom that is diagnosed first by the
mircrocontroller is displayed on the screen.
**Refer to Screen (G2) Adjustments in Section 2-4. of this manual.
Display of Standby/Timer LED Flash Count
2 times
4 times
5 times
LED ON 0.3 sec.
LED OFF 0.3 sec. LED OFF
3 sec.
Standby/Timer LED
Diagnostic Item Flash Count*
+B Overcurrent 2 times
I-Prot 4 times
IK (AKB) 5 times
*One flash count is not used for self-diagnostic.
Stopping the Standby/Timer LED Flash
Turn off the power switch on the TV main unit or unplug the power cord from the outlet to stop the STANDBY/TIMER LAMP from flashing.
Self Diagnosis
Supported model
The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY/TIMER LED will automatically begin to flash. The number
of times the LED flashes translates to a probable source of the problem. A definition of the STANDBY/TIMER LED flash indicators is listed in the
instruction manual for the user’s knowledge and reference. 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.
Diagnostic Test Indicators
When an error occurs, the STANDBY/TIMER LED will flash a set number of times to indicate the possible cause of the problem. If there is more than
one error, the LED will identify the first of the problem areas.
Results for all of the following diagnostic items are displayed on screen. No error has occurred if the screen displays a “0”.
Power does not turn on
+B overcurrent (OCP)*
I-Prot
IK (AKB)
Does not light
2 times
4 times
5 times
2:0 or 2:1
4:0 or 4:1
5:0 or 5:1
• Power cord is not plugged in.
• Fuse is burned out (F601). (A Board)
• H.OUT (Q506) is shorted. (A Board)
•RGB Amp (IC1751) is shorted.
(CV Board)
• +13V is not supplied. (A Board)
• IC545 is faulty. (A Board)
• Video OUT (IC545) is faulty.
(A Board)
• IC001 is faulty. (A Board)
• Screen (G2) is improperly adjusted.**
No. of times
STANDBY/ TIMER
lamp flashes
Diagnostic Item Descrip-
tion
Self-Diagnositc
Display/ Diagnos-
tic Result
Probable Cause Location
• Power does not come on.
• No power is supplied to the TV.
• AC Power supply is faulty.
• Power does not come 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 stopped.
• No raster is generated.
• CRT Cathode current detection reference pulse
output is small.

8
KV-21FK120
KV-21FK120
Self-Diagnostic Screen Display
For errors with symptoms such as “power sometimes shuts off” or “screen sometimes goes out” that cannot be confirmed, it is possible to bring up
past occurrences of failure on the screen for confirmation.
To Bring Up Screen Test
In standby mode, press buttons on the Remote Commander sequentially, in rapid succession, as shown below:
DISPLAY Channel 5 Sound Volume - POWER
Self-Diagnostic Screen Display
SELF DIAGNOSTIC
2: +B OCP 0
3: +B OVP N/A
4: VSTOP 0
Numeral “0” means that no fault was detected.
5: AKB 1 Numeral “1” means a fault was detected one time only.
101: WDT N/A
Handling of Self-Diagnostic Screen Display
Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screen during repairs. When you
have completed the repairs, clear the result display to “0”.
Unless the result display is cleared to “0”, the self-diagnostic function will not be able to detect subsequent faults after completion of the repairs.
Clearing the Result Display
To clear the result display to “0”, press buttons on the Remote Commander sequentially when the diagnostic screen is displayed, as shown below:
Channel 8
ENT
Quitting the Self-Diagnostic Screen
To quit the entire self-diagnostic screen, turn off the power switch on the Remote Commander or the main unit.
Self-Diagnostic Circuit
ABOARD
IC001
Y/CHROMA JUNGLE
ABOARD
IC545
V. OUT
ABOARD
IC001
SYSTEM
ABOARD
IC002
MEMORY
IK-AKBIN
FROM
CV BOARD
IC1751 PIN 5
I-HLDWN
FROM
ABOARD
IC561
PIN 7
72 O-LED
REF I-Prot
IO-BDAT
BDA
DISPLAY
51 378
79
53 5
+B overcurrent (OCP)
Occurs when an overcurrent on the +B (135V) line is detected by pin 72 of IC001 (A Board). If the voltage of pin 72 of IC001 (A Board) is less than 1V
when V.SYNC is more than seven verticals in a period, the unit will automatically turn off.
I-Prot
Occurs when an absence of the vertical deflection pulse is detected by pin 78 of IC001 (A Board). Power supply will shut down when waveform
interval exceeds 2 seconds.
IK (AKB)
If the RGB levels* do not balance within 2 seconds after the power is turned on, this error will be detected by IC001 (A Board). TV will stay on, but
there will be no picture.
*(Refers to the RGB levels of the AKB detection Ref pulse that detects 1K).

9
KV-21FK120
KV-21FK120
1-1. REAR COVER REMOVAL
SECTION 1: DISASSEMBLY
1-2. CHASSIS ASSEMBLY REMOVAL
7 Screws +BVTP 4X16
Rear Cover
3 Screws +BVTP 3 x 12
Chassis Assembly
Claw

10
KV-21FK120
KV-21FK120
1
Depress the PC Board clips to release
KR Board.
2
Disconnect the CN515 cable
3
Press on catch tab to release A Board
and gently pull away from the set.
1-3. SERVICE POSITION
CV Board
A Board

11
KV-21FK120
KV-21FK120
1. Discharge the anode of the CRT and remove the anode cap.
2. Unplug all interconnecting leads from the deflection yoke, neck
assembly, degaussing coils and CRT grounding strap.
3. Remove the CV 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 tension devices.
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].
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
ANODE CAP REMOVAL PROCEDURE
WARNING: 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 coated earth ground strap of CRT.
NOTE: After removing the anode cap, short circuit the anode of the picture tube and the anode cap to either the metal chassis, CRT shield, or carbon
painted on the CRT.
REMOVAL PROCEDURES
HOW TO HANDLE AN ANODE CAP
1. Do not use sharp objects which may cause damage to the surface of the anode
cap.
2. To avoid damaging the anode cap, do not squeeze the rubber covering too
hard. A material fitting called a shatter-hook terminal is built into the rubber.
3. Do not force turn the foot of the rubber cover. This may cause the shatter-hook
terminal to protrude and damage the rubber.
Turn up one side of the rubber cap in
the direction indicated by arrow a.
Use your thumb to pull the rubber
cap firmly in the direction indicated
by arrow b.
When one side of the rubber cap separates from
the anode button, the anode cap can be removed
by turning the rubber cap and pulling it in the
direction of arrow c.
a
b
Anode Button
c
1-4. PICTURE TUBE REMOVAL
10
5
4
3
1
2
8
7
9
6

12
KV-21FK120
KV-21FK120
WIRE DRESSINGS
- Fix RGB harness (A/CN301~CV/CN1752) to rotation
coil using a 9mm purse lock (3-703-982-02).
- Dress heaters harness (A/CN586~CV/CN1751) over
rotation coil's lead wire as shown in picture.
- Install rotation coil lead wire connection under DY clip
Under clip
Dress DY's lead wire using a DGC purse lock (4-
081-411-02).
Make a loop as shown in picture.
NOTE: Use CRT carbon paint as a reference

13
KV-21FK120
KV-21FK120
Twist G2 wire without stressing it
Dress focus lead and HV cable together using 5mm purse lock
(3-703-981-02), install purse lock 100mm from HV cable's cap.
Dress focus lead through CV board's hook.
100mm

14
KV-21FK120
KV-21FK120
- Dress earth ground wire behind DGC and through
DY's cilp together with rotation coil.
- Dress left speaker wire through DGC band hook (4-
080-810-22).
- Dress Video harness (A/CN200~A/CN201), 5P
(A/CN402~KR/CN4401), 4P (A/CN403~KR/CN4402) audio
harnesses under tuner's F-Pin.

15
KV-21FK120
KV-21FK120
- Dress Video harness (A/CN200~A/CN201) and lightning
wire through CLP001.
- Dress Audio harness (HK/CN2402~KR/CN4403) & video
harness (A/CN200~A/CN201) using a 9mm purse lock (3-703
-
982-02), No lightening wire.
- Dress 5P (A/CN402~KR/CN4401), 4P
(A/CN403~KR/CN4402) & 6P (HK/CN2402~KR/CN4403)
Audio harnesses using a 5mm purse lock (3-703-981-02).
IMPORTANT: Following operations must be done with A bord on its final
position
1.- Dress Left and right speaker wire into CRT support, red wire with two
loop as shown in picture.
2.- Dress left speaker wire through DGC band(4-080-810-22) upper hook.
Note: This operation must be performed after (1)
Dress AC-Cord and DGC lead wire through DGC band(4-080-810-22)
lower hook.
3.- Dress AC-Cord into bottom board standing purse lock(4-382-296-11).
1
2
3

16
KV-21FK120
KV-21FK120
20mm
For Chile model
Install Ferrite clamp
(
1-500-586-11
)
on Chilean AC-Cord one loo
p
.
Left and Right speakers with terminal on the bottom.

17
KV-21FK120
KV-21FK120
The following adjustments should be made when a complete
realignment is required or a new picture tube is installed.
These adjustments should be performed with rated power supply
voltage unless otherwise noted.
Set the controls as follows unless otherwise noted:
VIDEO MODE: Pro
PICTURE CONTROL: Normal
BRIGHTNESS CONTROL: Normal
SECTION 2: SET-UP ADJUSTMENTS
Perform the adjustments in order as follows:
1. Beam Landing
2. Convergence
3. Focus
4. Screen (G2)
5. White Balance
Note Test Equipment Required:
1. Color Bar Pattern Generator
2. Degausser
3. DC Power Supply
4. Digital Multimeter
2-1. BEAM LANDING
Before beginning adjustment procedure:
1. Feed in the white pattern signal.
Adjustment Procedure
1. Input a raster signal with the pattern generator.
2. Loosen the deflection yoke mounting screw, and set the purity control
to the center as shown below:
Purity Control
3. Turn the raster signal of the pattern generator to green.
4. Move the deflection yoke backward, and adjust with the purity control
so that green is in the center and red and blue are even on both
sides.
Blue Red
Green
5. Move the deflection yoke forward, and adjust so that the entire
screen becomes green.
6. Switch over the raster signal to red and blue and confirm the
condition.
7. When the position of the deflection yoke is determined, tighten it with
the deflection yoke mounting screw.
8. If landing at the corner is not right, adjust by using the disk magnets.
a
c
b
d
b
a
cd
Purity control
corrects this area.
Disk magnets
or rotatable disk
magnets correct
these areas (a-d).
Deflection yoke positioning
corrects these areas.

18
KV-21FK120
KV-21FK120
2-2. CONVERGENCE
Before starting convergence adjustments:
1 Perform FOCUS, VLIN and VSIZE adjustments.
2. Set BRIGHTNESS control to minimum.
3. Feed in dot pattern.
Vertical Static Convergence
1. Adjust V. STAT magnet to converge red, green and blue dots in the
center of the screen (Vertical movement adjust S V.STAT RV1750 to
converge).
B
G
R
Center dot
V.STAT magnet
RV1750
V.STAT
B
G
R
2. Tilt the V. STAT magnet and adjust static convergence to open or
close the V. STAT magnet.
When the V. STAT magnet is moved in the direction of arrow a and b,
red, green, and blue dots move as shown below:
B
R
G
B
R
G
RGB
BGR
1
2
b
bb
b
b
b
b
aab
a
a
aa
3
R
G
B
B
G
R
Horizontal Static Convergence
If the blue dot does not converge with the red and green dots, peform
the following:
1. Move BMC magnet (a) to correct insufficient H.Static convergence.
2. Rotate BMC magnet (b) to correct insufficient V.Static convergence.
3. After adjusting the BMC magnet, repeat Beam Landing Adjustment.
BMC MAGNET
PURITY
V. S TAT
b
BMC magnet
a

19
KV-21FK120
KV-21FK120
Dynamic Convergence Adjustment
Before performing this adjustment, perform Horizontal and Vertical
Static Convergence Adjustment.
1. Slightly loosen deflection yoke screw.
2. Remove deflection yoke spacers.
3. Move the deflection yoke for best convergence as
shown below:
BGR GB
R
GB
R
R
R
G
B
GB
G
B
R
BGR G
B
G
B
R
R
G
BG
G
B
RB
R
R
4. Tighten the deflection yoke screw.
5. Install the deflection yoke spacers.
TLH Plate Adjustment
1. Input crosshatch pattern.
2. Adjust PICTURE QUALITY to standard, PICTURE and
BRIGHTNESS to 50%, and OTHER to standard.
3 Adjust the Horizontal Convergence of red and blue dots by tilting the
TLH plate on the deflection yoke.
YCH TLV
CV
Board
RV1750
V.STAT
TLH Plate
B R R B
(R)(B) (B)(R)
TLH+
TLH-
4. Adjust XCV core to balance X axis.
5. Adjust YCH VR to balance Y axis.
6. Adjust vertical red and blue convergence with V.TILT (TLV VR.)
Note: Perform adjustment 3-6 while tracking items 1 and 2.
Screen-Corner Convergence
1. Affix a permalloy assembly corresponding to the misconverged areas:
ba
cd
a
b
d
a-d: screen-corner
misconvergence
c
2-3. FOCUS
1. Adjust FOCUS control for best pictures.
Focus (FV)
Screen (G2)

20
KV-21FK120
KV-21FK120
2-4. SCREEN (G2)
1. Input a dot pattern.
2. Set the PICTURE and BRIGHTNESS controls at minimum and
COLOR control at normal.
3. Adjust SBRT, GCUT, BCUT in service mode with an oscilloscope as
shown below so that voltages on the red, green, and blue cathodes
are 160 ± 2VDC.
Pedestal
160 –2VDC
Ground
±
4. Observe the screen and adjust SCREEN (G2) VR in FBT to obtain
the faintly visible background of dot signal.