Sony KDL-40Z4500 / KDL-46Z4500 / KDL-52Z4500 (serv.man4) Service Manual ▷ View online
KDL-40/46/52Z4500 (CH) 5
SAFETY CHECK-OUT
After correcting the original service problem, perform the
following safety checks before releasing the set to the customer:
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.
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.
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.
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.
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.
leakage. Check leakage as described below.
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.
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.
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).
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.
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 (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).
To Exposed Metal
Parts on Set
Parts on Set
0.15
µ
F
Earth Ground
AC
Voltmeter
Voltmeter
o
o
(0.75V)
Trouble Light
AC Outlet Box
Ohmmeter
Cold-water Pipe
FigureA. Using an AC voltmeter to check AC leakage.
Figure B. Checking for earth ground.
KDL-40/46/52Z4500 (CH) 6
STANDBY
LED
2 sec
SELF DIAGNOSIS FUNCTION
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.
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.
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 .
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 .
Number of times STANDBY
LED (Red) flashes
LED (Red) flashes
Monitoring Items
Diagnostic Item Description
2 times
DC_DET
Main Supply Voltage (12V) Error.
6 times
PANEL_DET
Panel detect Error.
7 times
TEMPERATURE
monitor an Increase of an Inside-temperature.
8 times
AUDIO
Audio error (SP protect).
9 times
HFR
High Frame Rate Error.
10 times
DEF
DEF (Digital Front End module) Error.
11 times
NVM
EEPROM Error (not read/write availble).
12 times
I2C
VCT I2C Bus Error.
13 times
BALANCER
Panel Balance Error.
14 times
HDMI
HDCP cannot be setup correctly.
15 times
TUNER
If circuit of PLL circuit do not respond to I2C commands.
16 times
I2C CH1
I2C CH1Error in MOUTON.
17 times
I2C CH0
I2C CH0 Error in MOUTON.
18 times
DIGITAL DEMOD
No Acknowledge detected.
19 times
USB
USB over current detected.
20 times
CI
CI Error
21 times
VCT
No DPI-I2C
22 times
MSP
MSP3410G IC does not respond to I2C commands.
When self diagnosis happens, STBY (Red) LED blinks and the history can be seen on display by self diagnosis mode.
DISPLAY OF STANDBY LIGHT FLASH COUNT
STOPPING THE STANDBY FLASH
Turn off the power switch on the TV main unit or unplug the power cord from the outlet to stop the STANDBY LED for flashing.
KDL-40/46/52Z4500 (CH) 7
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:
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:
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”.
After you have completed the repairs, clear the result display to “0”.
Clearing the result display
To clear the result display to “0”, press button on the remote commander sequentially as shown below when the diagnostic screen is being
displayed.
displayed.
<Delection of Error Count and Error History>
Press “
8
” button
,
Press “
-
” button
<Delection of Panel Operation Time>
Press “
7
” button
,
Press “
-
” button
Quitting Self-diagnostic screen
To quit the entire self-diagnostic screen, turn off the power switch on the remote commander or the main unit.
BALANCER
POWER
PANEL
NVM
NC
HDMI
DIGITAL
TUNER
SOUND
0
0
0
2
1
0
0
0
0
1/3
Monitoring Items
Error Count Record
[ SELF-DIAGNOSTIC SCREEN DISPLAY ]
DC_ALERT1
DC_ALERT2
RTC
DC_ALERT2
DEMOD
USB
CI
AU_PROT
DC_ALERT
0
0
0
2
1
0
0
0
0
VCTP
Reset
0
0
2/3
3/3
KDL-40/46/52Z4500 (CH) 8
TABLE OF CONTENTS
SPECIFICATIONS .................................................... 2
SAFETY CHECK-OUT ............................................. 5
SELF DIAGNOSIS FUNCTION ................................ 6
TABLE OF CONTENTS ........................................... 8
1. DISASSEMBLY ............................................... 1-1
1-1.
KDL-40Z4500 ........................................................ 1-1
1-1-1.
REAR COVER AND STANDBY ASSY
REMOVAL ...................................................... 1-1
1-1-2.
H1VM AND AWF BOARDS REMOVAL .... 1-1
1-1-3.
BGC BOARD REMOVAL .............................. 1-2
1-1-4.
D4Z AND G6 BOARDS REMOVAL ............ 1-2
1-1-5.
FRAME REMOVAL ....................................... 1-3
1-1-6.
AC INLET AND LOUDSPEAKER
REMOVAL ...................................................... 1-3
1-1-7.
LCD PANEL, H3VM BOARD AND
H4 BOARD REMOVAL ................................. 1-4
1-1-8.
LOUDSPEAKER REMOVAL ........................ 1-4
1-2.
KDL-46Z4500 ........................................................ 1-5
1-2-1.
REAR COVER AND STANDBY ASSY
REMOVAL ...................................................... 1-5
1-2-2.
H1VM AND AWF BOARDS REMOVAL .... 1-5
1-2-3.
BGC BOARD REMOVAL .............................. 1-6
1-2-4.
D4Z AND G6 BOARDS REMOVAL ............ 1-6
1-2-5.
FRAME REMOVAL ....................................... 1-7
1-2-6.
AC INLET AND LOUDSPEAKER
REMOVAL ...................................................... 1-7
1-2-7.
LCD PANEL, H3VM BOARD AND
H4 BOARD REMOVAL ................................. 1-8
1-2-8.
LOUDSPEAKER REMOVAL ........................ 1-8
1-3.
KDL-52Z4500 ........................................................ 1-9
1-3-1.
REAR COVER AND STANDBY ASSY
REMOVAL ...................................................... 1-9
1-3-2.
H1VM AND AWF BOARDS REMOVAL .... 1-9
1-3-3.
BGC BOARD REMOVAL ............................ 1-10
1-3-4.
D4Z AND G6 BOARDS REMOVAL .......... 1-10
1-3-5.
FRAME REMOVAL ..................................... 1-11
1-3-6.
AC INLET AND LOUDSPEAKER
REMOVAL .................................................... 1-11
1-3-7.
LCD PANEL, H3VM BOARD AND
H4 BOARD REMOVAL ............................... 1-12
1-3-8.
LOUDSPEAKER REMOVAL ...................... 1-12
2. TROUBLESHOOTING .................................... 2-1
2-1.
TRIAGE CHART ................................................... 2-1
2-2.
FLOW CHART ...................................................... 2-2
2-3.
No Power (Flow Chart_B) ..................................... 2-3
2-4.
Self Diagnosis (Flow Chart_C) .............................. 2-4
2-5.
Audio Problem (Flow Chart_D) .......................... 2-11
2-6.
Video Ploblem (Flow Chart_E) ........................... 2-12
3. DIAGRAMS ..................................................... 3-1
3-1.
BLOCK DIAGRAM .............................................. 3-1
3-2.
CIRCUIT BOARDS LOCATION ......................... 3-2
(1)
KDL-40Z4500 .................................................. 3-2
(2)
KDL-46Z4500 .................................................. 3-2
(3)
KDL-52Z4500 .................................................. 3-3
4. EXPLODED VIEWS ........................................ 4-1
4-1.
KDL-40Z4500 ........................................................ 4-2
4-1-1.
REAR COVER AND STAND ASSY ............. 4-2
4-1-2.
CHASSIS ......................................................... 4-3
4-1-3.
FRAME AND LOUDSPEAKER .................... 4-4
4-1-4.
BEZEL, LCD PANEL, H3VM BOARD
AND H4 BOARD ............................................ 4-5
4-1-5.
CONNECTOR ASSY ...................................... 4-6
4-2.
KDL-46Z4500 ........................................................ 4-7
4-2-1.
REAR COVER AND STAND ASSY ............. 4-7
4-2-2.
CHASSIS ......................................................... 4-8
4-2-3.
FRAME AND LOUDSPEAKER .................... 4-9
4-2-4.
BEZEL, LCD PANEL, H3VM BOARD
AND H4 BOARD .......................................... 4-10
4-2-5.
CONNECTOR ASSY .................................... 4-11
4-3.
KDL-52Z4500 ...................................................... 4-12
4-3-1.
REAR COVER AND STAND ASSY ........... 4-12
4-3-2.
CHASSIS ....................................................... 4-13
4-3-3.
FRAME AND LOUDSPEAKER .................. 4-14
4-3-4.
BEZEL, LCD PANEL, H3VM BOARD
AND H4 BOARD .......................................... 4-15
4-3-5.
CONNECTOR ASSY .................................... 4-16
4-4.
PACKING MATERIALS .................................... 4-17
4-4-1.
KDL-40Z4500 ................................................ 4-17
4-4-2.
KDL-46Z4500 ................................................ 4-18
4-4-3.
KDL-52Z4500 ................................................ 4-19
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