Sony KDL-60R510A Service Manual
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Sony KDL-60R510A Service Manual

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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE MANUAL

RB2FK
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 7/2014
Segment: MB
Version
Date
Subject
1.0
7/2014
Original manual issue.
LCD Digital Color TV
9-888-165-01

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Summary of Contents for Sony KDL-60R510A

  • Page 1: Service Manual

    HISTORY INFORMATION FOR THE FOLLOWING MANUAL: SERVICE MANUAL RB2FK CHASSIS ORIGINAL MANUAL ISSUE DATE: 7/2014 Segment: MB Version Date Subject 7/2014 Original manual issue. LCD Digital Color TV 9-888-165-01...

  • Page 2: Model List

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

  • Page 3: Warnings And Cautions

    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.

  • Page 4: Use Caution When Handling The Lcd Panel

    Use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short. 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. KDL-60R510A(CN8, UC2, LA1)

  • Page 5: Safety Check-Out

    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)
  • Page 6 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). KDL-60R510A(CN8, UC2, LA1)

  • Page 7: Self Diagnosis Function

    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)
  • Page 8 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)

  • Page 9: Sec 1. Disassembly And Parts List

    • 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)

  • Page 10: Disassembly And Parts List

    DISASSEMBLY AND PARTS LIST 1-1. KDL-60R510A(CN8, UC2, LA1) REF.NO. PART No. DESCRIPTION MARK 4-545-732-01 STAND NECK ASSY (60) 1-1-1. STAND BLOCK 4-545-676-01 STAND BASE ASSY (60) 4-545-675-01 STAND COVER ASSY (60) 1-848-624-11 POWER-SUPPLY CORD For CN8 1-848-623-11 POWER-SUPPLY CORD For UC2/LA1...
  • Page 11 DISASSEMBLY AND PARTS LIST 1-1. KDL-60R510A(CN8, UC2, LA1) REF.NO. PART No. DESCRIPTION MARK 1-1-4. OVERALL 1-754-934-11 ANTENNA (L) 1-754-934-21 ANTENNA (R) 1-895-679-11 MOUNTED PWB POWER UNIT 1-895-674-21 MOUNTED PWB A For CN8 1-895-674-11 MOUNTED PWB A For UC2/LA1 1-895-676-21 MOUNTED PWB H...
  • Page 12 DISASSEMBLY AND PARTS LIST 1-1. KDL-60R510A(CN8, UC2, LA1) 1-1-5. LCM REF.NO. PART No. DESCRIPTION MARK 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...
  • Page 13 DISASSEMBLY AND PARTS LIST 1-1. KDL-60R510A(CN8, UC2, LA1) 1-1-7. PACKAGE 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...

  • Page 14: Wifi Module

    DISASSEMBLY AND PARTS LIST 1-2. KDL-60R510A(CN8, UC2, LA1) WIFI MODULE A BOARD A BOARD REF. No. PART No. DESCRIPTION MARK 1-895-409-11 MOUNTED PWB WF 4-470-610-01 SCREW, +PSW M2X3 KDL-60R510A(CN8, UC2, LA1)
  • Page 15 DISASSEMBLY AND PARTS LIST 1-3. OTHER PART 1-3-1. MISCELLANEOUS 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)

  • Page 16: Sec 2. Adjustment

    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”. KDL-60R510A(CN8, UC2, LA1)
  • Page 17 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 KDL-60R510A(CN8, UC2, LA1)

  • Page 18: Sec 3. Trouble Shooting

    Check the harness Replace the harness at 1 pin of CN201 Change PSU to M/B between PSU and on the Main board connection Main board Between 3.14~3.45V Symptom improvement Change Fix the harness Harness issue Main board connection KDL-60R510A(CN8, UC2, LA1)

  • Page 19: Troubleshooting

    Replace the harness CN201_Pin-3/8 on Change CN201_Pin-6 on PSU to M/B between PSU and Main board Main board connection Main board (11.8~13.2V) Symptom <2.6V improvement Fix the harness Change Change Harness issue connection Main board Main board KDL-60R510A(CN8, UC2, LA1)
  • Page 20 Main Board Change Main board (3.135~3.465V) AUDIO Check the speaker Check the harness Impedance at the M/B to Speaker Change Speaker SP Connector connection (8ohm+/-15%) Demo, Audio, Tuner, etc Fix the harness Change Main board connection KDL-60R510A(CN8, UC2, LA1)
  • Page 21 PSU and Panel connection on the Main board connection >=11.4V Replace the FFC(LVDS) FFC(LVDS) Between Check PANEL_EN# <=2V issue Change PSU and Panel at U4006_pin6 Main board on the Main board >=2V Change T-CON T-CON issue Change Panel KDL-60R510A(CN8, UC2, LA1)
  • Page 22 CN201_Pin-13 Main board on the Main board >=1.8V Replace PSU PSU issue Check the harness Fix the harness PSU to M/B connection connection Symptom Change improvement Panel Replace the harness Harness issue PSU to Main board KDL-60R510A(CN8, UC2, LA1)
  • Page 23 Fix the FFC(LVDS) Harness issue FFC(LVDS) issue Main board issue connection connection Change Equipment No display Change Or Player to check Main board TV display Change Change PSU Panel Signal or Equipment Symptom Problem improvement PSU issue KDL-60R510A(CN8, UC2, LA1)
  • Page 24 Change to set to Mute Un-mute “Audio System” Check the Change to “Speakers setting” “TV Speaker” “TV Speakers” Symptom improvement Change the speaker Replace Main board issue harness Main board Symptom improvement Speaker Harness Change issue Speaker KDL-60R510A(CN8, UC2, LA1)
  • Page 25 3-5. TV COMMANDER BUTTONS MALFUNCTION 1) TV button malfunction Button malfunction on the TV Symptom Replace the harness improvement Change between Main board Key module issue Key module and Key module Symptom improvement Change Harness issue Main board KDL-60R510A(CN8, UC2, LA1)
  • Page 26 Green LED light when using commander Remote Control at power indicator near sensor’s window battery Symptom improvement Change Main board to IR FFC IR board FFC issue Symptom improvement Change IR board IR board issue Change Main board KDL-60R510A(CN8, UC2, LA1)

  • Page 27: Sec 4. Diagrams

    (8 Ω/10W) VGA-R/L 120 Hz MEMC Line out APA2172 YPbPr/CVBS MT5396 Line out / HP SPDIF YPbPr-R/L/CVBS-R/L Ethernet PHY Ethernet IR/LED MHL IC HDMI 1 (MHL) SII1292 HDMI 2 (ARC) Keypad HDMI 3 USB 1 USB 1.1/2.0 WIFI KDL-60R510A(CN8, UC2, LA1)

  • Page 28: Connector Diagram

    DIAGRAMS 4-2. CONNECTOR DIAGRAM 4-2-2. KDL-60R510A(CN8, UC2, LA1) KDL-60R510A(CN8, UC2, LA1)

  • Page 29: Circuit Boards Location

    DIAGRAMS 4-3. CIRCUIT BOARDS LOCATION KDL-60R510A(CN8, UC2, LA1) GE60 Board A Board WF Board Switch Unit H Board KDL-60R510A(CN8, UC2, LA1)
  • Page 30 English Made in Japan 9-888-165-01 © 2014. 07 Sony Visual Products Inc. KDL-60R510A(CN8, UC2, LA1)
  • Page 31 APPENDIX-1 DISASSEMBLY OF REAR COVER AND SERVICE POSITION 1. LAY DOWN THE SET IN A FLAT TABLE Make sure no mess things under the front set. KDL-60R510A(CN8, UC2, LA1)
  • Page 32 APPENDIX-1 2. UNLOCK SCREWS 7-682-948-01 SCREW, +PSW M3X8 W8 18PCS 4-268-126-02 SCREW,ORNAMENTAL M6X12 5PCS 7-685-646-79 SCREW, +BVTP 3X8 TYPE2 IT-3 6PCS KDL-60R510A(CN8, UC2, LA1)

  • Page 33: Remove The Rear Cover

    APPENDIX-1 3. REMOVE THE REAR COVER Insert the AC cord thought the rear cover hole. Take off the AC cover first Take off the SP connector Lift up the rear cover from the bottom KDL-60R510A(CN8, UC2, LA1)
  • Page 34 APPENDIX-1 4. SET UP THE SET KDL-60R510A(CN8, UC2, LA1)
  • Page 35 APPENDIX-1 HOOK POSITION KDL-60R510A(CN8, UC2, LA1) Rear Cover KDL-60R510A(CN8, UC2, LA1)
  • Page 36 APPENDIX-1 HOOK POSITION KDL-60R510A(CN8, UC2, LA1) KDL-60R510A(CN8, UC2, LA1)

  • Page 37: Remove The Stand

    APPENDIX-2 DISASSEMBLY OF LCM AND SERVICE POSITION 1. REMOVE THE STAND Lay down the set. Unlock stand screws. Make sure no mess things under the front set. 2-580-607-01 SCREW, +PSW M5X12 4PCS Take off the stand KDL-60R510A(CN8, UC2, LA1)
  • Page 38 APPENDIX-2 2. REMOVE THE ORNAMENT PANEL. Take off the IR cable. Take off the ornament panel. Peel off bottom tape and Aluminum tape. 20*15mm 9PCS 60*15mm 4PCS 20*40mm 3PCS Remark: tape and Aluminum tape can not reuse. KDL-60R510A(CN8, UC2, LA1)
  • Page 39 APPENDIX-2 3. TURN THE SET. Cushion can’t touch this area, the height of cushion must more than 35mm.. KDL-60R510A(CN8, UC2, LA1)
  • Page 40 APPENDIX-2 4. UNLOCK THE SCREWS. 4-558-184-01 SCREW SILVER/M2.5 x 6 Ni/C1018 15PCS 4-558-185-01 SCREW SILVER/M2.5*L10 Ni/C1018 5PCS KDL-60R510A(CN8, UC2, LA1)

  • Page 41: Remove The Bezel

    APPENDIX-2 5. REMOVE THE BEZEL Take off Bezel top side firstly. KDL-60R510A(CN8, UC2, LA1)
  • Page 42 APPENDIX-2 6. REMOVE THE ALUMINUM TAPE,FC BRACKET. Please replace this photos , it too shinny, CONDUCTIVE for ESD/Size:30*20mm*0.085/SILVER 7PCS 7PCS FC BRACKET (60) Remark: FC Bracket and Aluminum tape can not reuse. KDL-60R510A(CN8, UC2, LA1)
  • Page 43 APPENDIX-2 7. UNLOCK SCREWS AND TAKE OFF FC BOTTOM BRACKET. Unlock screws. 4-558-185-01 SCREW SILVER/M2.5*L10 Ni/C1018 3PCS Take off FC bottom bracket. Remark: FC Bottom Bracket can not reuse. KDL-60R510A(CN8, UC2, LA1)
  • Page 44 APPENDIX-2 TAPE LAYOUT KDL-60R510A(CN8, UC2, LA1) PART No. DESCRIPTION MARK 20*15mm 9PCS 7-600-031-97 TAPE (3M 1350FB-1)15MMX66M BLK Can not reuse 60*15mm 32PCS 7-600-031-97 TAPE (3M 1350FB-1)15MMX66M BLK Can not reuse 4-545-730-01 CONDUCTIVE for ESD/Size:30*20mm*0.085/SILVER Can not reuse 20*40mm 3PCS KDL-60R510A(CN8, UC2, LA1)
  • Page 45 APPENDIX-2 CUSHION ON REAR COVER KDL-60R510A(CN8, UC2, LA1) NWF 20*8*0.25mm 2 PCS NWF 20*8*0.6mm 1 PCS NWF 55*8*0.25mm 2 PCS NWF 30*8*0.25mm 2 PCS Cushion 30*15*5mm 6 PCS KDL-60R510A(CN8, UC2, LA1)

  • Page 46: Software Data Update

    Entering product information of setting menu. Please use the latest software. 2: xxxxxxx 2. Serial Number MB (NA): [HOME] – [Settings] – [Setup] – [Product Support] – [Contact Sony] 3: vx.xxx 3. Software Version MB (CH): [HOME] – [Settings] – [Set-up] – [Product Information] Note: When changing Main board, Model Name and Serial Number will not be displayed.
  • Page 47 USB device, or switch off the TV set or remove the power. MB (NA): [HOME] – [Settings] – [Setup] – [Product Support] – [Contact Sony] MB (CH): [HOME] – [Settings] – [Set-up] – [Product Information] KDL-60R510A(CN8, UC2, LA1)

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