Sony RB2FK Service Manual

HISTORY INFORMATION FOR THE FOLLOWI NG MANUAL:

SERVICE MANUAL

ORIGINAL MANUAL ISSUE D ATE: 7/2014

Version Date Subject

1.0 7/2014 Original manual issue.

LCD Digital Color TV

RB2FK CHASSIS

Segment: MB

9-888-165-01

MODEL LIST

MODEL COLOR COMMANDER DEST.

KDL-60R510A Black RM-SD022 CN8 KDL-60R510A Black RM-YD096 UC2 KDL-60R510A Black RM-YD096 LA1

MODEL COLOR COMMANDER DEST.

KDL-60R510A(CN8, UC2, LA1)

WARNINGS AND CAUTIONS - ENGLISH

CAUTION

These servicing instructions are for use by qualified service personnel only. To reduce the ri sk o f el ec tr ic s hoc k, d o not per for m any s er vic ing other than tha t c ont ai ned in t he o p er at ing ins tr uct io ns unless you are qualified to do so.

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.

CARRYING THE TV

Be sure to follow these guidelines to protect your property and avoid causing serious injury.

• Carry the TV with an adequate number of people; larger size TVs require two or more people.

• Correct hand placement while carrying the TV is very important for safety and to avoid damages.

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.

KDL-60R510A(CN8, UC2, LA1)

USE CAUTION WHEN HANDLING THE L CD PANEL

When repair ing t he LCD p a nel , b e sure you ar e gro und ed b y using a wrist b and . When repair ing t he LCD p a nel on the wall , the LCD panel must b e secur e d usi ng the 4 mounting holes on the re ar c o ver .

1) Do not press on the panel or frame edge to avoid the risk of electric shock.

2) Do not scratch or press on the panel with any sharp objects.

3) Do not leave the module in high temperatur es or in areas of high humidity for an extende d p eri od of time.

4) Do not expose the LCD panel to direct sunlight.

5) Avoid contact with water. It may cause a short circuit within the module.

6) Disconnect the AC power when replacing the backlight (CCFL) or inverter circuit. (High voltage occurs at the inverter circuit at 650Vrms.)

7) Always clean the LCD panel with a soft cloth material.

8) Use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short.

9) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).

10) It is recommended not to exceed 1 hour of Power-On nor Burn-in period with LCD panel face down conditio n, in repair activity.

WARNINGS AND CAUTIONS

KDL-60R510A(CN8, UC2, LA1)

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 unauthorize d replacement parts, pa r ticularly transistors, tha t were installed during a p revious repair. Po int them out to the customer and recommend their replacement.

5. Look for parts which, though functi oni n g, show obvi ous signs o f d et er io r ati o n. P o int them out to the cust o mer a nd re c ommend 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 antenna terminals, metal trim, “metallized” knobs, screws, and all other exposed metal parts for AC leakage. Check leakage as described below.

8. For safety reasons, repairing the Power board and/or Inverter board is prohibited.

KDL-60R510A(CN8, UC2, LA1)

Leakage Test

The AC leakage from any exposed metal part to earth ground and from all exposed m etal 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 method s.

1. A commercial leak ag e tester, such as the Simpson 22 9 or RC A WT-540A. Follow the manufacturers’ instructions to use these instructions.

2. A battery-operated AC milliampmeter. The Data Precision 245 digital multim eter is suitable for this job.

3. Measuring the v oltage d rop across a resistor by means o f a VOM or battery-operated AC voltmeter. The “limit” indication is 0.75 V, so analog m eters must have an accurate low voltag e scale. The Simpson’s 250 and Sanwa SH-63TRD are examples o f passiv e VO Ms that are suitabl e. Nearly all battery-operated dig ital 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 box es is also at earth ground. If the retaining screw is to be used as y our earth g round , v erify that it is at ground by measuring the resistan ce 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).

SAFETY CHECK-OUT

KDL-60R510A(CN8, UC2, LA1)

SELF DIAGNOSIS FUNCTI ON

STBY LED

F lash time

Servi ce menu Item

name

(Screen Di spl ay)

D iag no st ic I t em Descrip t io n

2 MAIN_POWER Detec t power boar d 12V. ( V_DROP_DE T)

TUNER_ERR Not used AUDIO_PROT Detec t Audio S peak er Er r or . AUDIO_PROT Detec t Audio Amp Error.

DC_ALERT1 Detect +3.3V+5V Dr op. (V_DROP_DET)

BALANCER_ERR Not used

TCON_ERR Detec t 12V_T CON(12V _TCON_DROP_DE T)

PANEL_POWE Not used 6 BACKLIGHT_ERR Detect panel bac k light ready. 7

TEMP_ERR Not used 8 - Not used 9 - Not used

10 - Not used 11 - Not used 12 - Not used

The units in thi s manua l co ntain a self-diagnosti c function. If an error occurs, the ST ANDBY LED will automatically b egin to flash. The number of times the LED flashes translates to a probable source of the problem. A definition of the STANDBY 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 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. Result for all of the following diagnostic items are displayed on screen. If the screen displays a “0”, no error has occurred .

DISPLAY OF STANDBY LED FLASH COUNT

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 for confirmation on the screen:

[To Bring Up Screen Test]

In standby mode, press buttons on the remote commander sequentially in rapid succession as shown below:

KDL-60R510A(CN8, UC2, LA1)

[SELF DIAGNOSTIC SCREEN DISPLAY]

SELF DIAGNOSIS FUNCTION

Item name

BACK << 002 MAIN_POWER 000 003 TUNER_ERR 000 003 AUDIO_PROT 000 003 DC_ALERT1 000

SELF CHECK

STBY LED flash time

004 BALANCER_ERR 000

Error count

005 TCON_ERR 000 005 PANEL_POWE 000 006 BACKLIGHT_ERR 000 007 TEMP_ERR 000

12345-67891-23456 [Home] Exit

Panel operation time by hour Boot count Total operation time by hour

Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screen. After you have completed the repairs, clear the result display to “0”.

Clearing the Self Check Diagnostic List

1. Error history and Error count : Press the Channel 8 => Channel 0 .

2. Panel operation time : Press the Channel 7 => Channel 0 .

Exiting the Self-diagnostic screen

To exit the Self Diagnostic screen, turn off the power to the TV by pressing the POWER button on the remote or the POWER button on the TV.

KDL-60R510A(CN8, UC2, LA1)

SEC 1. DISASSEMBLY AND PARTS LIST

• Items with no part number and no description are not stocked because they are seldom required for routine service.

• The construction parts of an assembled part are indicated with a collation number in the remark column.

• Items marked " * " are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items.

Note: About the wire dressing, disassembly of rear cover and service position, please refer to “APPENDIX-1”.

KDL-60R510A(CN8, UC2, LA1)

DISASSEMBLY AND PARTS LIST

PART No.

DESCRIPTION

MARK

STAND NECK

STAND BASE ASSY (60)

STAND COVER ASSY (60)

POWER

For CN8

POWER

For

4 COVER AC

For

4 COVER AC

For UC2/LA1

COVER, REAR (60)

For

COVER, REAR (60) For UC2/LA1

1-1. KDL-60R510A(CN8, UC2, LA1)

1-1-1. STAND BLOCK

1-1-2. STAND COVER ASSY AND ST AND BAS E ASS Y AND NECK

REF.NO.

-545-732-01

-545-676-01 3 4

-545-675-01

-848-624-11

-848-623-11

-450-049-01

-SUPPLY CORD

-299-528-01

-545-670-11

-545-670-01

-580-607-01 SCREW, +PSW M5X12

-682-961-01

-685-245-14

SCREW, +PSW M4x8 W8

SCREW,F,CROSS,T.T-3*6,BLK-ZN.

-682-948-01 SCREW, +PSW M3X8 W8

-268-126-02 SCREW,ORNAMENTAL M6X12

-685-646-79 SCREW, +BVTP 3X8 TYPE2 IT-3

1-1-3. AC COVER AND REAR C O VE R

ASSY (60)

UC2/LA1 CN8

CN8

KDL-60R510A(CN8, UC2, LA1)

DISASSEMBLY AND PARTS LIST

SCREW(PSW)(M3X6)

SCREW, +PSW M3X8 W8

SCREW,B,CROSS,W/W

SCREW, +PWTP2 4X10

1-1. KDL-60R510A(CN8, UC2, LA1)

1-1-4. OVERALL

REF.NO. PART No. DESCRIPTION MARK

1-754-934-11 ANTENNA (L) 1-754-934-21 ANTENNA (R)

13 14

15 16 17

18 19 20

21 22 23 24

* 25

26 27 28 29

1-895-679-11 MOUNTED PWB POWER UNIT

1-895-674-21 MOUNTED PWB A

1-895-674-11 MOUNTED PWB A 1-895-676-21 MOUNTED PWB H 1-895-676-11 MOUNTED PWB H 1-895-677-21 MOUNTED PWB KEY 1-895-677-11 MOUNTED PWB KEY 1-895-678-11 MOUNTED PWB WF 1-910-109-81 CONNECTOR ASSY 15P (MB-PSU) 1-910-109-82 CONNECTOR ASSY 4P (MB-SPK) 1-910-109-83 CONNECTOR ASSY 4P (SPK) 1-910-109-84 FFC CABLE 60 MB-TCON 41P 1-910-109-85 FFC CABLE 60 MB-TCON 51P 1-910-109-86 FFC CABLE 60 MB-IR 10P 1-910-109-87 FFC CABLE 60 MB-KEY 6P 1-859-068-11 LOUDSPEAKER (10W) (L) 1-859-068-21 LOUDSPEAKER (10W) (R ) 4-545-733-01

SHEET, INSULATION (60) 4-545-677-01 ORNAMENTAL PANEL (60) 4-545-671-01 BRACKET, VESA (60) N/A BRACKET, BOTTOM (60) 4-549-789-01 EVA CUSHION 40*20 4-549-790-01 CUSHION W25*T5 4-549-788-01 CLAMP, CABLE

For CN8

For UC2/LA1 For CN8 For UC2/LA1 For CN8 For UC2/LA1

KDL-60R510A(CN8, UC2, LA1)

-990-421-41

-682-948-01

-314-843-03

-459-864-01

-SPR,T4*12, ZN,ROHS.

For CN8

For UC2/LA1

1-1. KDL-60R510A(CN8, UC2, LA1)

DISASSEMBLY AND PARTS LIST

1-1-5. LCM

1-1-6. LCM (W/O BEZEL)

REF.NO. PART No. DESCRIPTION MARK

30 * 31 * 32 * 33 * 34

A-2060-901-A LCM PANEL (S600FHB-1) 4-545-658-01 BEZEL (60) 4-545-659-01 FC BRACKET TOP ASSY (60) 4-549-791-01

FC BRACKET SIDE ASSY(60) 4-545-660-01 FC BTM BRACKET (60) 4-545-730-01 TAPE,CONDUCTIVE

Can not reuse Can not reuse Can not reuse Can not reuse

KDL-60R510A(CN8, UC2, LA1)

1-1. KDL-60R510A(CN8, UC2, LA1)

MARK

For UC2/LA1

For UC2/LA1 For CN8

For CN8

For UC2/LA1

1-1-7. PACKAGE

DISASSEMBLY AND PARTS LIST

REF.NO. PART No. DESCRIPTION

* 36 * 37 * 38 * 39 * 40 * 41 * 42 * 43 * 44

4-545-678-01 CUSHION,UPPER LEFT (60) 4-545-679-01 CUSHION,UPPER CENTER (60) 4-545-680-01 CUSHION,UPPER RIGHT(60) 4-545-681-01 CUSHION,LOWER LEFT (60) 4-545-682-01 CUSHION,LOWER CENTER (60) 4-545-683-01 CUSHION,LOWER RIGHT(60) 4-545-684-01 CUSHIO,RIGHT (60) 4-545-685-01 CUSHION,LEFT (60) 4-549-724-01 SUPPORT,CUSHION (60MB)

N/A SUPPORT,CUSHION (60MB) * 45 * 46

* 48

N/A EPE, CENTER BAR (60MB)

N/A EPE, SUPPORT BAR (60MB)

4-409-919-32

BAG,PROTECTION PEHD(1720*1050)

4-543-463-01 CARTON,INDIVIDUAL

KDL-60R510A(CN8, UC2, LA1)

ASSESSORY BAG

1-2. KDL-60R510A(CN8, UC2, LA1)

REF. No . PART No . DESCRIPTION MARK

1 1-895-409-11 MOUNTED PWB WF

4-470-610-01 SCREW, +PSW M2X3

WIFI MODULE

A BOARD

DISASSEMBLY AND PARTS LIST

A BOARD

KDL-60R510A(CN8, UC2, LA1)

1-3. OTHER PART

DESCRIPTION

REMOTE COMMANDER (RM

1-3-1. MISCELLANEOUS

DISASSEMBLY AND PARTS LIST

PART No.

1-492-292-11

1-492-291-11

MARK

-SD022)

-YD096)

For CN8

For UC2 / LA1

KDL-60R510A(CN8, UC2, LA1)

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