Sony Bravia KDL-60R510A User manual

SERVICE MANUAL
Version Date Subject
1.0 7/2014 Original manual issue.
LCD Digital Color TV
9-888-165-01
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
ORIGINAL MANUAL ISSUE DATE: 7/2014 RB2FKCHASSIS
Segment: MB

KDL-60R510A(CN8, UC2, LA1)
MODEL LIST
MODEL COLOR COMMANDER DEST. MODEL COLOR COMMANDER DEST.
KDL-60R510A Black RM-SD022 CN8
KDL-60R510A Black RM-YD096 UC2
KDL-60R510A Black RM-YD096 LA1
2

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.
KDL-60R510A(CN8, UC2, LA1) 3

KDL-60R510A(CN8, UC2, LA1)
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.
4

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 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.
5

KDL-60R510A(CN8, UC2, LA1)
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” indicationis 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 retainingscrew. 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).
6

KDL-60R510A(CN8, UC2, LA1)
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
Flash time
Service menu Item
name
(ScreenDisplay)
Diagnostic Item Description
2MAIN_POWER Detectpower board 12V. (V_DROP_DET)
TUNER_ERR Notused
AUDIO_PROT Detect Audio Speaker Error.
AUDIO_PROT DetectAudio Amp Error.
DC_ALERT1 Detect+3.3V+5VDrop.(V_DROP_DET)
4BALANCER_ERR Notused
TCON_ERR Detect12V_TCON(12V_TCON_DROP_DET)
PANEL_POWE Notused
6 BACKLIGHT_ERR Detectpanel backlightready.
7TEMP_ERR Notused
8 - Notused
9 - Notused
10 -Notused
11 -Notused
12 -Notused
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:
7

KDL-60R510A(CN8, UC2, LA1)
SELF CHECK
BACK <<
002 MAIN_POWER 000
003 TUNER_ERR 000
003 AUDIO_PROT 000
003 DC_ALERT1 000
004 BALANCER_ERR 000
005 TCON_ERR 000
005 PANEL_POWE 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.
8

KDL-60R510A(CN8, UC2, LA1)
• 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.
SEC 1. DISASSEMBLY AND PARTS LIST
Note: About the wire dressing, disassembly of rear cover and service position, please refer to “APPENDIX-1”.
9

2
-580-607-01 SCREW, +PSW M5X12
7
-682-961-01 SCREW, +PSW M4x8 W8
7
-685-245-14 SCREW,F,CROSS,T.T-3*6,BLK-ZN.
7
-682-948-01 SCREW, +PSW M3X8 W8
4
-268-126-02 SCREW,ORNAMENTAL M6X12
7
-685-646-79 SCREW, +BVTP 3X8 TYPE2 IT-3
KDL-60R510A(CN8, UC2, LA1)
1-1. KDL-60R510A(CN8, UC2, LA1)
1-1-1. STAND BLOCK
DISASSEMBLY AND PARTS LIST
1-1-2. STAND COVER ASSY AND STAND BASE ASSY AND NECK
5
4
1-1-3. AC COVER AND REAR COVER
6
2
1
3
10
REF.NO.
PART No.
DESCRIPTION
MARK
1
4
-545-732-01
STAND NECK
ASSY (60)
2
4
-545-676-01
STAND BASE ASSY (60)
3
4
-545-675-01
STAND COVER ASSY (60)
4
1
-848-624-11
POWER
-SUPPLY CORD
For CN8
1
-848-623-11
POWER
-SUPPLY CORD
For
UC2/LA1
5
4
-450-049-01
COVER AC
For
CN8
4
-299-528-01
COVER AC
For UC2/LA1
6
4
-545-670-11
COVER, REAR (60)
For
CN8
4
-545-670-01
COVER, REAR (60)
For UC2/LA1

KDL-60R510A(CN8, UC2, LA1)
DISASSEMBLY AND PARTS LIST
1-1-4. OVERALL
7
22
24
26
8
13
10
12
21
25
23
9
15
14
1-1. KDL-60R510A(CN8, UC2, LA1)
11
20
REF.NO. PART No. DESCRIPTION MARK
7 1-754-934-11 ANTENNA (L)
8
1-754-934-21 ANTENNA (R)
9 1-895-679-11 MOUNTED PWB POWER UNIT
10 1-895-674-21 MOUNTED PWB A For CN8
1-895-674-11 MOUNTED PWB A For UC2/LA1
11 1-895-676-21 MOUNTED PWB H For CN8
1-895-676-11 MOUNTED PWB H For UC2/LA1
12 1-895-677-21 MOUNTED PWB KEY For CN8
1-895-677-11 MOUNTED PWB KEY For UC2/LA1
13 1-895-678-11 MOUNTED PWB WF
14 1-910-109-81 CONNECTOR ASSY 15P (MB-PSU)
15 1-910-109-82 CONNECTOR ASSY 4P (MB-SPK)
16 1-910-109-83 CONNECTOR ASSY 4P (SPK)
17 1-910-109-84 FFC CABLE 60 MB-TCON 41P
18 1-910-109-85 FFC CABLE 60 MB-TCON 51P
19 1-910-109-86 FFC CABLE 60 MB-IR 10P
20 1-910-109-87 FFC CABLE 60 MB-KEY 6P
21 1-859-068-11 LOUDSPEAKER (10W) (L)
22 1-859-068-21 LOUDSPEAKER (10W) (R )
23 4-545-733-01 SHEET, INSULATION (60)
24 4-545-677-01 ORNAMENTAL PANEL (60)
* 25 4-545-671-01 BRACKET, VESA (60)
26 N/A BRACKET, BOTTOM (60)
27 4-549-789-01 EVA CUSHION 40*20
28 4-549-790-01 CUSHION W25*T5
29 4-549-788-01 CLAMP, CABLE
16
17
18
19
2
-990-421-41
SCREW(PSW)(M3X6)
7
-682-948-01
SCREW, +PSW M3X8 W8
4
-314-843-03
SCREW,B,CROSS,W/W
-SPR,T4*12, ZN,ROHS. For CN8
4
-459-864-01
SCREW, +PWTP2 4X10
For UC2/LA1
28
27
29
11

KDL-60R510A(CN8, UC2, LA1) 12
DISASSEMBLY AND PARTS LIST
1-1-5. LCM
1-1. KDL-60R510A(CN8, UC2, LA1)
30
31
34
35
REF.NO. PART No. DESCRIPTION MARK
30 A-2060-901-A LCM PANEL (S600FHB-1)
* 31 4-545-658-01 BEZEL (60)
* 32 4-545-659-01 FC BRACKET TOP ASSY (60) Can not reuse
* 33 4-549-791-01 FC BRACKET SIDE ASSY(60) Can not reuse
* 34 4-545-660-01 FC BTM BRACKET (60) Can not reuse
35 4-545-730-01 TAPE,CONDUCTIVE Can not reuse
1-1-6. LCM (W/O BEZEL)
32
33

KDL-60R510A(CN8, UC2, LA1) 13
1-1-7. PACKAGE
1-1. KDL-60R510A(CN8, UC2, LA1)
DISASSEMBLY AND PARTS LIST
36 37 38
39 40 41
42
43
44
REF.NO. PART No. DESCRIPTION
MARK
* 36 4-545-678-01 CUSHION,UPPER LEFT (60)
For UC2/LA1
* 37 4-545-679-01 CUSHION,UPPER CENTER (60)
For UC2/LA1
* 38 4-545-680-01 CUSHION,UPPER RIGHT(60)
For UC2/LA1
* 39 4-545-681-01 CUSHION,LOWER LEFT (60)
For UC2/LA1
* 40 4-545-682-01 CUSHION,LOWER CENTER (60)
For UC2/LA1
* 41 4-545-683-01 CUSHION,LOWER RIGHT(60)
For UC2/LA1
* 42 4-545-684-01 CUSHIO,RIGHT (60)
For UC2/LA1
* 43 4-545-685-01 CUSHION,LEFT (60)
For UC2/LA1
* 44 4-549-724-01 SUPPORT,CUSHION (60MB)
For UC2/LA1
N/A SUPPORT,CUSHION (60MB)
For CN8
* 45 N/A EPE, CENTER BAR (60MB)
For CN8
* 46 N/A EPE, SUPPORT BAR (60MB)
For CN8
47 4-409-919-32 BAG,PROTECTION PEHD(1720*1050)
* 48 4-543-463-01 CARTON,INDIVIDUAL
For UC2/LA1
47
48
ASSESSORY BAG
46
45

KDL-60R510A(CN8, UC2, LA1)
1-2. KDL-60R510A(CN8, UC2, LA1)
WIFI MODULE
DISASSEMBLY AND PARTS LIST
A BOARD A BOARD
1
REF. No. PART No. DESCRIPTION MARK
11-895-409-11 MOUNTED PWB WF
4-470-610-01 SCREW, +PSW M2X3
14

KDL-60R510A(CN8, UC2, LA1)
1-3. OTHER PART
1-3-1. MISCELLANEOUS
DISASSEMBLY AND PARTS LIST
15
PART No.
DESCRIPTION
MARK
1-492-292-11
REMOTE COMMANDER (RM
-SD022) For CN8
1-492-291-11
REMOTE COMMANDER (RM
-YD096) For UC2 / LA1

KDL-60R510A(CN8, UC2, LA1)
SEC 2. ADJUSTMENT
HOW TO ENTERING SERVICE MODE
1) Turn on the main power switch to place this set in power on mode.
2) Press the buttons on the remote commander as follows, and entering service mode.
<LEFT>,<RIGHT>,<MUTE>,<+>,<MUTE>,<VOL+>
3) Service mode display.
Service Mode
Sound Adjust... >>
Wide Band Tuning >>
Range Scan... >>
Self diagnosis history >>
Status Information >>
LVDS Spectrum (%o) <[ 25 ]>
Low of HPD <[ 5 ]>
TVD_MCDONE_CNT <[ 20 ]>
Demo Special >>
Panel Selection <[ 46_JE600D3LC7N_US ]>
UART Selection <[ Usb Fact ]>
SERIAL NUMBER EDID 0027R2L
MODEL NAME EDID KDL-60R510A
[</>]Set[Home]Exit
Panel Selection MODEL
NAME EDID MARK
46_JE600D3LC7N_US KDL-60R510A For UC2 / LA1
47_JE600D3LC7N_CHD KDL-60R510A For CN8
- When replace Main Board or panel, please confirm "Panel Selection" and "MODEL NAME EDID" in service mode.
If they are different, please select a suitable thing.
- Change of SERIAL NUMBER EDID and MODEL NAME EDID are possible only once when they are white character.
Note: About the software data update, please refer to “APPENDIX-2”.
16

KDL-60R510A(CN8, UC2, LA1)
ADJUSTMENT
4) How to use the remote commander.
Function The flow of control
Service mode on <LEFT>,<RIGHT>,<MUTE>,<+>,<MUTE>,<VOL+>
Service mode off <Return> / <Menu>
Adjustment Item up / down /
Data Value up / down /
17

SEC 3. TROUBLE SHOOTING
No power
Check SB_3.3V
at 1 pin of CN201
on the Main board
Between 3.14~3.45V
Harness issue
Change
PSU
Replace the harness
between PSU and
Main board
Change
Main board
NG
OK
NG
Symptom
improvement
Long AC off(> 15 min.)
and then
Power On
Enter Service Mode and check
Self diagnosis history
NG
OK
Check the harness
PSU to M/B
connection
NG
OK
Fix the harness
connection
IF MAIN_POWER > 0 or
DC_ALERT1 > 0
IF AUDIO_PROT > 0
IF TCON_ERR > 0 or
BACKLIGHT_ERR > 0
Change
Main board
Change
Panel
Change
Main board
OK
No
No
Yes
Yes
Yes
3-1. NO POWER
KDL-60R510A(CN8, UC2, LA1) 18

KDL-60R510A(CN8, UC2, LA1)
1) 2 times blinking (Main Power Error)
TROUBLE SHOOTING
3-2. STANDBY LED BLINK
Harness issue
Change
PSU
OK Symptom
improvement
<2.6V
Change
Main board Change Main board
2-time blinking
Check REG+12V at
CN201_Pin-3/8 on
Main board
(11.8~13.2V)
Replace the harness
between PSU and
Main board
NG NG
Check PSU_EN# at
CN201_Pin-6 on
Main board
>=2.6V Check the harness
PSU to M/B
connection
NG
OK
Fix the harness
connection
OK
19

KDL-60R510A(CN8, UC2, LA1)
TROUBLE SHOOTING
2) 3 times blinking (Main Board Error)
3-time blinking
Check PWM_5V at
L202 pin-2 on Main board
(4.75~5.25V)
U202, L202, etc
Change Main board
Change Speaker
Check SYS_3.3V
at U204_Pin-6
on Main Board
(3.135~3.465V)
Check the speaker
Impedance at the
SP Connector
(8ohm+/-15%)
U204, etc
Change Main board
Demo, Audio, Tuner, etc
Change Main board
DC_ALERT
NG
OK
NG
OK
AUDIO
NG
OK
Check the harness
M/B to Speaker
connection
NG
OK
Fix the harness
connection
20