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

2MAIN_POWER

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:

*: 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.

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