Sony KDL-40Z5500 / KDL-46Z5500 / KDL-52Z5500 (serv.man2) Service Manual ▷ View online
KDL-40/46/52Z5500 (WB) 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-40/46/52Z5500 (WB) 6
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) blinks
LED (Red) blinks
Monitoring Items
(Screen Display)
(Screen Display)
Diagnostic Item Description
2 times
5 times
6 times
7 times
8 times
10 times
12 times
13 times
14 times
DC_DET
DC_ALART
BACKLIGHT
INTERNAL TEMP
AUDIO
DIGITAL FE/DE
HFR
BALANCER
T_CON
BA Board
Power Board (G6N Board (40"/46"), Power Unit (52"))
BA Board
BA Board
LCD Panel
Power Board (G6N Board (40"/46"), Power Unit (52"))
D1N/D2N Board (40"/46"), D3N/D4N Board (52")
BA Board
BA Board
Power Board (G6N Board (40"/46"), Power Unit (52"))
Speaker
BA Board
BA Board
LCD Panel
BA Board
Power Board (G6N Board (40"/46"), Power Unit (52"))
D1N/D2N Board (40"/46"), D3N/D4N Board (52")
BA Board
LCD Panel
KDL-40/46/52Z5500 (WB) 7
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.
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:
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.
<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.
2 sec
STANDBY INDICATOR
5
*
* : Note that this differs from entering the service mode (volume +)
KDL-40/46/52Z5500 (WB) 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-40Z5500 ........................................................ 1-1
1-1-1.
REAR COVER REMOVAL ............................ 1-1
1-1-2.
STAND ASSSY REMOVAL .......................... 1-1
1-1-3.
SWITCH UNIT REMOVAL ........................... 1-2
1-1-4.
D1N AND G6NS BOARDS REMOVAL ....... 1-2
1-1-5.
BA AND D2N BOARDS REMOVAL ........... 1-3
1-1-6.
SPEAKER REMOVAL ................................... 1-3
1-1-7.
AC INLET AND FRAME REMOVAL .......... 1-4
1-1-8.
HL1A AND HSN BOARDS, LCD PANEL
REMOVAL ...................................................... 1-4
1-2.
KDL-46Z5500 ........................................................ 1-5
1-2-1.
REAR COVER REMOVAL ............................ 1-5
1-2-2.
STAND ASSSY REMOVAL .......................... 1-5
1-2-3.
SWITCH UNIT REMOVAL ........................... 1-6
1-2-4.
D1N BOARD AND POWER UNIT (G7NS)
REMOVAL ...................................................... 1-6
1-2-5.
BA AND D2N BOARDS REMOVAL ........... 1-7
1-2-6.
SPEAKER REMOVAL ................................... 1-7
1-2-7.
AC INLET AND FRAME REMOVAL .......... 1-8
1-2-8.
HL1A AND HSN BOARDS, LCD PANEL
REMOVAL ...................................................... 1-8
1-3.
KDL-52Z5500 ........................................................ 1-9
1-3-1.
REAR COVER REMOVAL ............................ 1-9
1-3-2.
STAND ASSSY REMOVAL .......................... 1-9
1-3-3.
SWITCH UNIT REMOVAL ......................... 1-10
1-3-4.
D3N BOARD AND POWER UNIT (G7NS)
REMOVAL .................................................... 1-10
1-3-5.
BA AND D4N BOARDS REMOVAL ......... 1-11
1-3-6.
SPEAKER REMOVAL ................................. 1-11
1-3-7.
AC INLET AND FRAME REMOVAL ........ 1-12
1-3-8.
HL1A AND HSN BOARD, LCD PANEL
REMOVAL .................................................... 1-12
2. TROUBLESHOOTING .................................... 2-1
2-1.
TRIAGE CHART ................................................... 2-1
2-2.
FLOW CHART ...................................................... 2-2
2-3.
NO POWER ........................................................... 2-3
2-4.
STANDBY LED BLINK ....................................... 2-4
1)
2 times Blinkings ............................................. 2-4
2)
5 times Blinkings ............................................. 2-4
3)
6 times Blinkings ............................................. 2-4
4)
7 times Blinkings ............................................. 2-5
5)
8 times Blinkings ............................................. 2-5
6)
10 times Blinkings ........................................... 2-5
7)
12 times Blinkings ........................................... 2-5
8)
13 times Blinkings ........................................... 2-6
9)
14 times Blinkings ........................................... 2-6
2-5.
NO PICTURE ......................................................... 2-7
2-6.
NO SOUND ............................................................ 2-8
3. DIAGRAMS ..................................................... 3-1
3-1.
BLOCK DIAGRAM .............................................. 3-1
3-2.
CIRCUIT BOARDS LOCATION ......................... 3-2
(1)
KDL-40Z5500 .................................................. 3-2
(2)
KDL-46Z5500 .................................................. 3-2
(3)
KDL-52Z5500 .................................................. 3-2
4. EXPLODED VIEWS ........................................ 4-1
4-1.
KDL-40Z5500 ........................................................ 4-2
4-1-1.
REAR COVER AND STAND ASSY ............. 4-2
4-1-2.
CHASSIS ......................................................... 4-3
4-1-3.
CONNECTOR ASSY ...................................... 4-4
4-2.
KDL-46Z5500 ........................................................ 4-5
4-2-1.
REAR COVER AND STAND ASSY ............. 4-5
4-2-2.
CHASSIS ......................................................... 4-6
4-2-3.
CONNECTOR ASSY ...................................... 4-7
4-3.
KDL-52Z5500 ........................................................ 4-8
4-3-1.
REAR COVER AND STAND ASSY ............. 4-8
4-3-2.
CHASSIS 1 ...................................................... 4-9
4-3-3.
CONNECTOR ASSY .................................... 4-10
4-4.
PACKING MATERIALS .................................... 4-11
4-4-1.
KDL-40Z5500 ................................................ 4-11
4-4-2.
KDL-46Z5500 ................................................ 4-12
4-4-3.
KDL-52Z5500 ................................................ 4-13
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