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2005 SXRD KDS-R60XBR1
Disassembly Manual
31 pgs5.38 Mb0

Sony 2005 SXRD KDS-R50XBR1, 2005 SXRD KDS-R60XBR1 Disassembly Manual

Training Manual
2005 SXRD Disassembly Manual
Models: KDS-R50XBR1 KDS-R60XBR1
Disassembly
Course: TVP-21D
Table of Contents
Overview ...........................................................................................................................1
Chapter 3 - Chassis Assembly Removal .................................................................................
Chapter 8 - ASU & G Boards Removal ..................................................................................
Chapter 9 - Wire Routing Diagrams .......................................................................................
21
24
5
Introduction
Overview
This manual presents complete and concise step-by-step procedures for the disassembly of the chas­sis assemblies and the removal of all boards included in the 2005 SXRD chassis. As it is with any chassis disassembly or assembly process, care must be taken to remove chassis components with­out damaging the boards, wiring, or the chassis itself.
The procedures in this manual guide you through effective and efficient disassembly and reassembly processes for all areas in the 2005 SXRD chassis.
How to use this manual:
1) The manual can be sequentially followed from Chapter 1 through Chapter 7 for removal of the major chassis assemblies and the individual boards.
Chapter 8 illustrates the Screen Frame Assembly Removal
Chapter 9 is a quick reference for wire routing throughout the chassis.
2) The chapters in the manual are also designed as stand alone procedures. Therefore, you can go directly to any specific chapter and proceed to remove that particular assemble or board. If the procedures in a previous chapter are necessary it is noted in steps 1 or 2 of the stand-alone procedure.
1
Chapter 1 - Screen Frame Removal
Screen Frame Removal
1
The lower front cover must be removed to access the screws that secure the two lower screen
-frame brackets Open the Lamp Door and remove 1 screw in the lower left hand corner when view from the rear of the unit . Slide front cover to the right and remove.
Lower Front cover
Slide to the Right
Screw
Lamp
Housing
2
Remove 4 screws securing the lower screen
-frame
brackets
.
Screws
2
Screws
Leave top -center
screw for last
3
Remove 9 screws to release front Screen Frame assembly.
CAUTION
: Leave the top-center
screw in place while removing the eight other screws. Go around to the front of the unit . Hold the screen frame assembly and the rear mirror assembly together at the top while removing the last top
-center screw. Pull the Screen Frame assembly off and lay down on a soft pad.
Screen Frame Removal (cont.)
4
Disconnect 2 connectors
CAUTION: Do not stand the Screen
Frame assembly on the metal brackets.
Connectors
Hold
Together
Metal
Brackets
1. Screen Frame Removal
3
Chapter 2 - Rear & Sub Plastic Cover Removal
Screws
Rear and Sub Plastic Cover Removal & ASU-Board Access
1
Remove 9 screws and pull rear plastic cover straight back and off.
Detach
AC Cord
2
Remove 5 screws and detach AC cord from the slot. Pull sub plastic cover slowly straight back and off.
NOTE
: Be careful of fan wire
and connector behind sub
­cover. Disconnect fan cable to completely remove cover
.
Screws
Shields
Screws
Release Wire Tie
Bracket
3
Remove 4 screws and release the one wire tie. Slide the bracket up slightly and pull off
. Disconnect the S1-Board Remove both shields to access the ASU-Board.
CN2006
CN2010
CN2100
4
The ASU-Board can be probed for troubleshooting at this point of the disassembly process. It can not be remove at this point . Reference “ASU &
G-Board
Removal” section
.
S1-Board
Disconnect
fan cable
behind cover
4
Chapter 3 - Chassis Assembly Removal
Screw
2 Screws
3 Screws
Disconnect
C-Brd
Connector
1
Remove 6 screws and disconnect the C
-Board ribbon
cable
(Gentle press the Tan tab on the side of the connector to release cable.
2
Remove the small cover (3 screw) and disconnect C
-Board cables.
CAUTION:
Be extremely careful not to damage C-Board cables while removing the Chassis Assembly.
Screws
Small
Cover
Disconnect C-
Board cables
3
Lift
Tabs
Lift the two locking tabs and slide chassis straight out until it is stopped by the vertical bracket (right side) .
CAUTION
:
Be extremely careful not to damage C-Board cables when sliding the chassis out. Gentle push cables under the DMB assembly
.
Becareful of
Cables
Removal of Complete Chassis Assembly
Vertical Bracket
Bracket stops
chassis
Tan Tab
DMB
5
4
Slide Chassis out until it is stopped by the vertical bracket. Before attempting to remove the Chassis assembly disconnect the wires as illustrated in the photo
.
Removal of Complete Chassis Assembly (cont.)
Disconnect
Cables on each side of the
chassis assembly
Disconnect
Fan
connector
5
Angle the left side of Chassis assembly out. Slide the Chassis to the left (around the vertical bracket and pull chassis out.
CAUTION
:
Do not remove the vertical bracket. This bracket is critical
support for the Upper mirror and screen block.
Angle out
Slide to
the left
Around vertical bracket
6
Completely remove the Chassis assembly and disconnect Lamp Power Supply Block cable.
Power Block cable
Vertical Bracket
3. Chassis Assembly Removal
6
1
Before the Optical Block can be removed the Fan assembly must be removed
. First, remove cable clamp and wire tape.
Tape
Clamp
2
Remove the 5 screws and the vertical bracket next to the fan assembly.
Screws
Vertical
Bracket
3
Detach the Power Supply Block from the fan housing. Disconnect the power supply cable. Remove wires from the two wire holders. Squeeze the small tabs at the top of the board to remove board and lay to the side
(the red wires will remain attached).
Squeeze Tabs
Disconnect
Power cable
Release
wires
Optics Block, Power Supply Block , and Fan Assembly Removal
Fan
Assembly
Chapter 4 - Optics Block & Fan Removal
7
Optics Block , Power Supply Block , and Fan Assembly Removal
(cont.)
4
Grasp the Fan assembly and pull out to remove
.
5
To access the Optics Block the gray plastic cover must first be removed. Remove the 8 screws securing the Optics cover
. Lift the 2 tabs, and carefully slide cover back
. Also remove vertical bracket (1 screw).
CAUTION:
Lift the C-Board cables and carefully feed them through the slot in the plastic cover.
Optical
Block Cover
Screws
Lift Tabs
Feed cabling
through the slot
Power Supply
Block
Screws
Bracket
4. Optical Block & Fan Removal
8
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