Sony 2005 SXRD KDS-R50XBR1 Installation instructions

2005 SXRD
Disassembly Manual
Models: KDS-R50XBR1
KDS-R60XBR1
Disassembly
Course: TVP-21D
Training Manual

Table of Contents
Introduction ................................................................................................................................1
Overview ...........................................................................................................................1
Chapter 1 - Screen Frame Removal .........................................................................................2
Chapter 2 - Rear & Sub Plastic Cover Removal .....................................................................4
Chapter 3 - Chassis Assembly Removal .................................................................................5
Chapter 4 - Optics Block & Fan Removal ................................................................................7
Chapter 5 - Power Supply Block Removal ............................................................................11
Chapter 6 - Q-Box & PD-Board Removal ...............................................................................13
Chapter 7 - DSU-Board Removal............................................................................................17
Chapter 8 - ASU & G Boards Removal ..................................................................................21
Chapter 9 - Wire Routing Diagrams .......................................................................................24

1
Introduction
Overview
This manual presents complete and concise step-by-step procedures for the disassembly of the chas-
sis 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 with-
out 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.

2
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

3
1. Screen Frame Removal
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

4
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

5
Chapter 3 - Chassis Assembly Removal
Screw
2 Screws
3 Screws
Disconnect
C-Brd
Connector
1Remove 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

6
3. Chassis Assembly Removal
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
5Angle 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

7
Chapter 4 - Optics Block & Fan Removal
1Before 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

8
4. Optical Block & Fan Removal
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