Sony 2005 SXRD KDS-R50XBR1, Disassembly Manual

Page 1: ...2005 SXRD Disassembly Manual Models KDS R50XBR1 KDS R60XBR1 Disassembly Course TVP 21D Training Manual ...

Page 2: ... 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 ...

Page 3: ...nd 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 desi...

Page 4: ... 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 ...

Page 5: ...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 ...

Page 6: ...re 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 I...

Page 7: ...e 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 Cabl...

Page 8: ...de of the chassis assembly Disconnect Fan connector 5 Angle 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 L...

Page 9: ...ext 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 F...

Page 10: ... 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 ...

Page 11: ...g the Optics Block CAUTION Do Not Touch the 6 screws mounted in the black plastic under the lower front cover Lower Front cover Screw Lamp Housing Slide to the Right Screws 6 The Power Supply Block must be removed with the Optics Block because they are attached by 1 internal screw inside the Lamp Housing The left edge also blocks the Optics Block from being removed To remove the Lamp Housing lift ...

Page 12: ...l cabling must be removed from Optics Block The cabling does not come as part of a new Optics Block Optics Block Power Supply Block and Fan Assembly Removal cont Screw 8 CAUTION Take care not to damage black plastic divider light shield when removing and installing the Optics Block Do not remove or damage black tape on the lens The black tape reduces glare and reflections Plastic divider Tape ...

Page 13: ... and dismount the Power Supply Block Power Supply Block Only Removal 2 Lay the Power Supply Block face down to the side of the unit Remove 1 screw securing the cable guide Remove 1 screw to dismount the Lamp plug CAUTION Be careful not to damage the Lamp plug detector switch when removing and installing the Power Supply Block Squeeze Tabs Disconnect Cables Release Cables Dismount Lamp Jack Screw S...

Page 14: ...t Direct the Lamp Jack out 3 The Power Supply Block including the Lamp Plug Cable Guide is pull out underneath the Fan assembly Carefully direct the Lamp Plug through the slot in the Lamp housing Note cable loop when re installing Ballast CAUTION Be careful not to damage Lamp Plug detector switch ...

Page 15: ... the chassis Remove all wires from wire holders Disconnect USB cable Slide Out Wire Holders Wire Holders USB Cable 2 Remove 16 screws Small Cover and the Connector Cover to remove DMB outer shield When all screws are removed pull the left side of the shield out first to clear the i link connectors on the right side of the shield Once i link connectors are clear pull shield straight off DMB Outer S...

Page 16: ...st disconnect the CableCard ribbon cable Remove 2 white cable clamps that hold down the ribbon cable Disconnect the cable from the CableCard board by lifting the Tan connector tab CAUTION Make sure that the blue heat sink pads remain in place Also insure that black plastic wire protector remains in place Disconnect the LVDS cable located at the bottom of the Q Box assembly under the gray tape Disc...

Page 17: ...e CAUTION Be carefully not to pull too far out and damage the wires still connected Screws Peel Back tape custom 6 Disconnect all cables on the Q Box module except for the CableCard ribbon cable This cable remains apart of the Q Box NOTE Reattach all wires before securing the replacement Q Box to the chassis assembly Disconnected Wires Disconnected Wires Unscrew RF connector Disconnected Wires Pul...

Page 18: ...16 6 Q Box PD Board Removal Access Removal of Q Box PD Board cont Digital Module Block DMB 7 Q Box assembly includes the QM QI QT and QH boards ...

Page 19: ...r 3 Chassis Assembly Removal DSU Board Removal 2 After removing the Chassis assembly remove 16 screws and the Connector Cover to remove DMB outer shield When all screws are removed pull the left side of the shield out first to clear the i link connectors on the right side of the shield Once i link connectors are clear pull shield straight off Screws Connector Cover ...

Page 20: ...of the framing holding the Q Box and PD Board Push the framing to the left until the two connectors between the ASU Board and the DSU Board completely separate DSU Board Under Shield Separate Connectors 4 Release wire wrap and disconnect the two RF connectors at the antenna switch Connectors PD Board Wire wrap ...

Page 21: ...ocedure Detach CableCard assembly from the Chassis assembly Remove 3 screws Lay the CableCard assembly to the side Screws Connector 6 Grasp the top and bottom of the DSU Board shield on the far left side of the Chassis assembly and pull out The Q Box PD Board and DSU board will swing outward together Pull Pull Swing out ...

Page 22: ...es to the right Remove 6 screws and squeeze the two white tabs to release the DSU Board from the shield CAUTION Do not attempt to pull board off at this point because connectors on both sides of the board must first be disconnected Disconnect all connectors on front and back sides of the DSU Board Screws Connectors Tabs Front Side LVDS Cables under tape Front Side Connectors ...

Page 23: ...hields on the ASU Board Reference Chapter 2 Rear and Sub Plastic Cover Removal ASU G Board Removal 2 Remove 5 screws from the DMB shield This will free the DMB and DSU Board assembly so the connectors in step 4 can be separated Release 2 wire holders and disconnect wires behind the ASU Board as shown in the picture inset Wire Holders Release wires Disconnect Disconnect Shields Screws ...

Page 24: ...re with the other side of the Chassis assembly until the connector is completely separated Lift the complete ASU Borad DMB and DSU Board assembly off the G Board assembly and set to the side Pull up Pull up Holder Down Connector DMB ASU Board G Board 4 To remove the ASU Board first remove connector cover 2 screws indicate by red circles and separate the connectors between the ASU Board and the DMB...

Page 25: ... Disconnect all cables on the ASU Board Remove 4 screws squeeze the 2 white tabs and lift ASU Board off assembly Disconnect Screws Tabs ASU Board G Board Tabs 6 To removal the G Board press the 4 gray tabs in and lift G Board off the lower chassis frame ...

Page 26: ...24 Chapter 9 Wire Routing Diagrams Wire Routing Diagrams ...

Page 27: ...25 9 Wire Routing Diagrams Wire Routing Diagrams cont ...

Page 28: ...26 9 Wire Routing Diagrams Wire Routing Diagrams cont ...

Page 29: ...27 9 Wire Routing Diagrams Wire Routing Diagrams cont ...

Page 30: ...28 9 Wire Routing Diagrams Wire Routing Diagrams cont ...

Page 31: ...ks of Sony Electronics 2004 Sony Electornics Inc EMCSA A Service Company 1 Sony Drive Park Ridge New Jersey 07656 Reproduction in whole or part without written permission is prohibited All rights reserved TVP21D1005 10 14 05 ...