Sony AZ3FK User manual

SERVICE MANUAL
Version Date Subject
1.0 8/2012 Original manual issue.
2.0 10/2012 Addition model of KDL-60EX640(AUS).
LCD Digital Color TV
9-888-516-02
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
ORIGINAL MANUAL ISSUE DATE: 8/2012 AZ3FK CHASSIS
Segment: P-2

SERVICE MANUAL
LCD Digital Color TV
AZ3FK CHASSIS
Segment: P-2
9-888-516-02

KLV-60EX640(PA)/KDL-60EX640(AUS) 3
MODEL LIST
MODEL COLOR COMMANDER DEST.MODEL COLOR COMMANDER DEST.
KLV-60EX640 Black RM-GA023 AFRICA
MIDDLE EAST
PACIFIC ISLAND
SAUDI ARABIA
KDL-60EX640 Black RM-GD024 AUSTRALIA

KLV-60EX640(PA)/KDL-60EX640(AUS) 4
WARNINGS AND CAUTIONS -ENGLISH
CAUTION
These servicing instructions are for use by qualified service personnel only.
To reduce the risk of electric shock, do not perform any servicing other than that contained in the operating instructions 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.

KLV-60EX640(PA)/KDL-60EX640(AUS) 5
WARNINGS AND CAUTIONS -FRENCH
ATTENTION!!
Ces instructions de service sont à l’usage du personnel de service qualifi é seulement.
Pour prévenir le risque de choc électrique, ne pas faire l’entretien autre que celui contenu dans le Mode d’emploi à moins que vous soyez qualifi é faire ainsi.
WARNING!!
Afi n d’eviter tout risque d’electrocution provenant d’un chássis sous tension, un transformateur d’isolement doit etre utilisé lors de tout dépannage. Le chássis de ce récepteur est
directement raccordé à l’alimentation du secteur.
POUR TRANSPORTER LE TÉLÉVISEUR
Tenez compte de ce qui suit pendant l’installation du téléviseur :
• Débranchez tous les câbles avant de transporter le téléviseur.
• Transportez le téléviseur avec le nombre de personnes approprié ; un téléviseur de grande taille doit être transporté par au moins deux personnes.
• Lors du transport du téléviseur, l’emplacement des mains est très important pour votre sécurité, ainsi que pour éviter de causer des dommages.
ALERTE!!
Afi n d’eviter tout risque d’electrocution provenant d’un chassis sous tension, un transformateur d’isolement doit etre utilise lors de tout depannage. Le chassis de ce recepteur est
directement raccorde a l’alimentation du secteur.
ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!!
Les composants identifi es par une trame et par une marque ! sur les schemas de principe, les vues explosees et les listes de pieces sont d’une importance critique pour la securite du
fonctionnement. Ne les remplacer que par des composants Sony dont le numero de piece est indique dans le present manuel ou dans des supplements publies par Sony. Les reglages
de circuit dont l’importance est critique pour la securite du fonctionnement sont identifi es dans le present manuel. Suivre ces procedures lors de chaque remplacement de
composants critiques, ou lorsqu’un mauvais fonctionnement suspecte.

KLV-60EX640(PA)/KDL-60EX640(AUS) 6
WARNINGS AND CAUTIONS
USE CAUTION WHEN HANDLING THE LCD PANEL
When repairing the LCD panel, be sure you are grounded by using a wrist band.
When repairing the LCD panel on the wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.
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 temperatures or in areas of high humidity for an extended period 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 condition, in repair activity.

KLV-60EX640(PA)/KDL-60EX640(AUS) 7
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 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.

KLV-60EX640(PA)/KDL-60EX640(AUS) 8
SAFETY CHECK-OUT
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).

KLV-60EX640(PA)/KDL-60EX640(AUS) 9
SELF DIAGNOSIS FUNCTION
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 .
The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY 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 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.
STBY LED
Fla s h tim e
Service menu Item
name
(Screen Display)
Diagnostic Item Description
12V_AMP Error
12V_SW Error
24V_Error
DC_ALERT1 3V3/5V Error
AUDIO_PROT Audio Error
4 BALANCER_ERR Not used
TCON_ERR T-con Error
PANEL_ID_NVM_ERR Panel ID Error
6 BACKLIGHT_ERR Back Light Error
7TEMP_ERR Not used
8-Notused
9-Notused
10 - Not used
11 - Not used
12 - Not used
3
2MAIN_POWER
5
0.5
0.5 3
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:
5
*: Note that this differs from entering the service mode (volume +)
*
Info TV POWERChannel Volume

KLV-60EX640(PA)/KDL-60EX640(AUS) 10
SELFCHECK
BACK <<
002MAIN_POWER 000
003DC_ALERT1 000
003AUDIO_PROT 000
004BALANCER_ERR 000
005TCON_ERR 000
005PANEL_ID_NVM_ERR 000
006BACKLIGHT_ERR 000
007TEMP_ERR 000
12345‐67891‐23456
[Home]Exit
SELF DIAGNOSIS FUNCTION
[SELF DIAGNOSTIC SCREEN DISPLAY]
Error count
Item name
STBY LED flash time
Total operation time by hour
Boot count
Panel 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.

KLV-60EX640(PA)/KDL-60EX640(AUS) 11
• 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 colum.
• Items marked " * " are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items.
SEC 1. DISASSEMBLY AND PARTS LIST
Note: LCD panel have points installing with some tapes.
About the procedure of those disassembly and assembly methods, please refer to “APPENDIX-2”.
Note: When removing the rear cover, to prevent damaging the rear cover, please refer “APPENDIX-1”.

KLV-60EX640(PA)/KDL-60EX640(AUS) 12
1-1. KLV-60EX640/KDL-60EX640
1-1-1. HEAD STAND, NECK AND BASE STAND
REF. No. PART No. DESCRIPTION MARK
1 4-298-239-02 STAND, HEAD (ML9)
2 4-444-067-01 NECK TP (60NK2)
3 4-444-068-01 STAND, BASE TP (60NK2)
4-421-427-01 SCREW, +PSW M5X16 LOCK
DISASSEMBLY AND PARTS LIST
1
2
3

KLV-60EX640(PA)/KDL-60EX640(AUS) 13
DISASSEMBLY AND PARTS LIST
1-1. KLV-60EX640/KDL-60EX640
1-1-2. REAR COVER AND AC COVER
REF. No. PART No. DESCRIPTION MARK
4 4-436-774-01 REAR COVER (60NK2)
5 4-299-530-01 AC COVER
2-580-639-01 SCREW, +BVTP 4x12
4-445-507-01 SCREW, +PWH M3x8 W12
4-167-019-12 SCREW, +PSW M3x8
7-685-646-79 SCREW, +BVTP 3x8 TYPE2 IT-3
4-400-043-01 JOINT SCREW
4
5

KLV-60EX640(PA)/KDL-60EX640(AUS) 14
DISASSEMBLY AND PARTS LIST
1-1. KLV-60EX640/KDL-60EX640
1-1-3. OVERALL
REF. No. PART No. DESCRIPTION MARK
6 1-489-986-11 SWITCH UNIT
7 1-858-715-11 LOUDSPEAKER (3X15CM)
8 1-846-307-11 POWER-SUPPLY CORD (WITH CONN.) PA
1-846-308-11 POWER-SUPPLY CORD AUS
9 1-895-315-11 MOUNTED PWB GE60
10 1-910-107-06 CONNECTOR ASSY 60 LVDS 51P
11 1-910-107-05 CONNECTOR ASSY 60 LVDS 41P
12 1-910-107-04 CONNECTOR ASSY 60 MB-PSU 15P
13 1-895-307-41 MOUNTED PWB A PA
1-895-307-51 MOUNTED PWB A AUS
14 1-910-107-03 CONNECTOR ASSY 60 MB-SP-IR-KEY
15 4-428-235-01 BRACKET, SIDE JACK
16 4-436-780-01 BRACKET, KEY (60NK2)
17 4-436-785-01 BRACKET, MB RT (60NK2)
18 4-436-782-01 BRACKET, MB LT (60NK2)
19 4-436-784-01 BRACKET, MB M (60NK2)
20 4-436-786-01 BRACKET, MB RB (60NK2)
21 4-436-783-01 BRACKET, MB LB (60NK2)
2-990-421-41 SCREW (+PSW) (M3x6)
4-445-505-01 SCREW, +PSH M3x6 W12
4-445-506-01 SCREW, H M3x5 H6
6
16
913
15
7 7
8
17 18
19
20 21
14
12
10 11

KLV-60EX640(PA)/KDL-60EX640(AUS) 15
DISASSEMBLY AND PARTS LIST
1-1. KLV-60EX640/KDL-60EX640
1-1-4. BOTTOM FRAME AND VESA BRACKET
REF. No. PART No. DESCRIPTION MARK
22 4-436-779-01 FRAME, BOTTOM (60NK2)
23 4-436-778-01 BRACKET, VESA (60NK2)
2-580-593-01 SCREW, +PSW M3x8
22
23
23

KLV-60EX640(PA)/KDL-60EX640(AUS) 16
DISASSEMBLY AND PARTS LIST
1-1. KLV-60EX640/KDL-60EX640
1-1-5. PANEL BRACKET, BEZEL, H BOARD AND LCD PANEL
REF. No. PART No. DESCRIPTION MARK
24 4-436-776-01 BRACKET, PANEL H (60NK2)
25 4-436-777-01 BRACKET, PANEL V (60NK2)
26 4-436-773-01 BEZEL (60NK2)
27 1-895-176-11 MOUNTED PWB H PA
1-895-176-21 MOUNTED PWB H AUS
28 1-811-710-11 LCD PANEL
4-256-393-01 SCREW, +PSW M3x6 W12
24
25 25
26
27
28

KLV-60EX640(PA)/KDL-60EX640(AUS) 17
1-2. OTHER PART
PART No. DESCRIPTION MARK PART No. DESCRIPTION MARK
1-490-490-11 REMOTE COMMANDER (RM-GA023) PA 4-436-998-01 CARTON,INDIVIDUAL (IRS60)(S)
1-490-491-11 REMOTE COMMANDER (RM-GD024) AUS 4-440-421-01 CUSHION,UPPER (60NK2)(S)
4-440-422-01 CUSHION,LOWER (60NK2)(S)
4-262-708-04 CLAMPER, CABLE 4-440-423-01 CUSHION,SIDE CENTER L (60NK2)(S)
4-436-791-11 MANUAL, INSTRUCTION (GB) PA 4-440-424-01 CUSHION,SIDE CENTER R (60NK2)(S)
4-436-791-31 MANUAL, INSTRUCTION (AR) PA 4-440-426-01 TRAY (60NK2)(S)
4-436-791-41 MANUAL, INSTRUCTION (PR) PA
4-436-791-51 MANUAL, INSTRUCTION (RU) PA
4-436-791-61 MANUAL, INSTRUCTION (FR) PA
4-436-792-11 MANUAL, INSTRUCTION (GB) AUS
4-440-925-01 LABEL,HIGH VOLTAGE AUS
1-2-1. MISCELLANEOUS
DISASSEMBLY AND PARTS LIST
1-2-2. PACKING

KLV-60EX640(PA)/KDL-60EX640(AUS) 18
SEC 2. ADJUSTMENT
HOW TO ENTERING SERVICE MODE
1) Turn on the main power switch to place this set in standby mode.
2) Press the buttons on the remote commander as follows, and entering service mode.
3) Service mode display.
ServiceMode
StatusInformation >>
Selfdiagnosishistory >>
PanelSelection <[ 94_55OHJO4]>
NO_SIGNAL_MUTE <[ Off ]>
TUNINGSYSTEM <[ AUTO ]>
LVDSSpectrum(%o) <[ 25 ]>
LowofHPD <[ 5 ]>
UARTSelection <[ Factory ]>
SERIALNUMBEREDID 00180LG
MODELNAMEEDID KLV‐60EX640/KDL‐60EX640
[</>]Set[Home]Exit
5
Info TV POWERChannel Volume
4) How to use the remote commander.
5) After entering service mode, then turn off the power switch.
<Info><5><Vol Up><Power>Service mode on
<Other> / <Power off + on>Service mode off
/
/
The flow of control
Data Value up / down
Adjustment Item up / down
Function

KLV-60EX640(PA)/KDL-60EX640(AUS) 19
SEC 3. DIAGRAMS
3-1. BLOCK DIAGRAM

KLV-60EX640(PA)/KDL-60EX640(AUS) 20
DIAGRAMS
3-2. CONNECTOR DIAGRAM
MB
51Pin
LVDS
(CN4004)
41Pin
LVDS
(CN4005)
PSU
15 Pin
(CN201)
4 Pin
(CN3)
5 Pin
(CN4)
15 Pin
(CN2)
14 Pin
(CN4003)
Speaker
2 Pin
Panel
Connector
Key
Pad
3
Pin
4 Pin
(CN8001)
IR
10 Pin
(CN951)
T-con
51Pin
LVDS
41Pin
LVDS
Speaker
2 Pin
2 Pin
(CN1)