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The circuit boards used in these models have been processed using
Lead Free Solder. The boards are identified by the LF logo located
close to the board designation e.g. H1 etc [ see example ]. The
servicing of these boards requires special precautions to be taken as
outlined below.

It is strongly recommended to use Lead Free Solder material in order to guarantee optimal quality of new solder joints. 
Lead Free Solder is available under the following part numbers :

Due to the higher melting point of Lead Free Solder the soldering iron tip temperature needs to be set to 370 degrees centigrade. 
This requires soldering equipment capable of accurate temperature control coupled with a good heat recovery characteristics.

For more information on the use of Lead Free Solder, please refer to  http://www.sony-training.com

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1

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.

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).

Trouble Light

AC Outlet Box

Ohmmeter

Cold-water Pipe

Figure A. Using an AC voltmeter to check AC leakage.

Figure B. Checking for earth ground.

The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY LED indicator will automatically begin to fl ash. The number 
of times the LED fl ashes translates to a probable source of the problem. A defi nition of the STANDBY LED fl ash 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.

When an error occurs, the STANDBY LED indicator will fl ash a set number of times to indicate the possible cause of the problem. If there is more than 
one error, the indicator will identify the fi rst of the problem areas.

*  Lights up in green when the TV set is turned on.

* If LED blinks continuously, this may indicate
  that the TV needs servicing.

STANDBY LED

PIC OFF/
TIMER
LED

*  Lights up in red when the function PC Power Management 
   is activated and there is no signal received while in the 
   PC Input.

* Lights up in amber when the Timer or Sleep functions are set.
  When timer is set, this LED remains lit even
  when the TV is turned off.
* Lights up in green when the Backlight feature is activated to off.

POWER LED

Green or Amber

LED

Green LED

Red LED

Main Power

 2 times

Power Supply Board
G2BE Board (KLV-32S510A ONLY)
IP1 Board (KLV-40S510A ONLY)
IP2 Board (KLV-46S510A ONLY)
G5N Board (KLV-52S510A)

DC Alert1

3 times

BM3 (Main) Board 
Power Supply Board
G2BE Board (KLV-32S510A ONLY)
IP1 Board (KLV-40S510A ONLY)
IP2 Board (KLV-46S510A ONLY)
G5N Board (KLV-52S510A)

TCON Error

4 times

LCD Panel

HDMI

5 times

BM3 (Main) Board

Backlight

6 times

LCD Panel

Temp

7 times

BM3 (Main) Board

HFR Error

8 times

LCD Panel

3.  To display the Self Diagnostic list, press 

.

 

Service Mode/Product Information 

Version: ER2.6-C121  DTT: S255.P033.S077  
Model: 40S510A
Power on Time: 00000H   

Serial :   8000016 

Diagnostic Information

2-MAIN POWER: 

1

3-DC ALERT1:   

0

4-TCON:   0
5-HDMI:

  

 

0

6-Backlight:    

0

7-TEMP:   0
8-HFR:  

 

0

101-WDT:  

0

RETURN

Change Back

Exit

4.  To exit Service Mode, press 

.

Viewing the Self Check Diagnostic List
1.  TV must be in standby mode. (Power off).

2.  Press the following buttons on the Remote Commander within a second 

of each other: 

 

DISPLAY   

Channel 

5   

Volume 

+  

  POWER .

 

The Self Check list displays. 

          

 

 The 

 logo displays momentarily, then the Service Mode list 

displays.

 

Service/ADC Auto Calibration 

Version: ER2.6-C121  DTT: S255.P033.S077  
Model: 40S510A
Serial :  8000016
Power on Time: 00000H   

Diagnostic and Serial Update 

ADC Auto Calibration 
Clone User Setting 
Direct Log to USB 
Factory Default 

RETURN

Change Back

Exit