Sony KDL-46Z5588 Schematic

SERVICE MANUAL

EX2L CHASSIS

MODEL	COMMANDER					DEST.	MODEL	COMMANDER	DEST.
KDL-46Z5588	RM-SD004					Chinese	KDL-46Z5599	RM-SD004	Chinese
KDL-52Z5588	RM-SD004					Chinese	KDL-52Z5599	RM-SD004	Chinese

RM-SD004	KDL-46/52Z5588
	KDL-46/52Z5599

LCD Digital Colour TV

SPECIFICATIONS

Model name

KDL-52Z5588

KDL-46Z5588

KDL-52Z5599

KDL-46Z5599

System

Panel System

LCD (Liquid Crystal Display) Panel

TV System

Analogue: D/K, I, B/G, M

Digital: GB20600-2006

Colour System

Analogue: PAL, PAL60, SECAM, NTSC4.43, NTSC3.58

Digital:

MPEG-2 MP@ML MP@HL

Channel Coverage

Analogue: D/K: VHF: C1 to C12, R1 to R12/ UHF: C13 to C57, R21 to R60/

CATV: S01 to S03, S1 to S41, Z1 to Z39

I: UHF: B21 to B69/ CATV: S01 to S03, S1 to S41

B/G: VHF: E2 to E12/ UHF: E21 to E69/ CATV: S01 to S03, S1 to S41

M: VHF: A2 to A13/ UHF: A14 to A79/ CATV: A-8 to A-2, A to W+4,

W+6 to W+84

Digital:

GB20600-2006

Sound Output

8.5 W + 8.5 W (at 7% distortion)

Input/Output jacks

Aerial/Antenna/Cable

75 ohm external terminal for VHF/UHF

1

S video input (4-pin mini DIN)

1

Video input/Video output

1

Audio input/Audio output

2

Video input

2

Audio input: 500 mVrms, 47 kilohms

Component IN 1/

3

Component IN 1:

Supported formats: 1080p (50/60 Hz), 1080i (50/60 Hz), 720p (50/60 Hz), 576p, 576i,

480p, 480i

Y: 1 Vp-p, 75 ohms, 0.3 V negative sync/PB/CB: 0.7 Vp-p, 75 ohms/

PR/CR: 0.7 Vp-p, 75 ohms

3:

Video input

Component IN 1/

3

Audio input: 500 mVrms, 47 kilohms

Component IN 2

Supported formats:1080p (50/60 Hz), 1080i (50/60 Hz), 720p (50/60 Hz), 576p, 576i,

480p, 480i

Y: 1 Vp-p, 75 ohms, 0.3 V negative sync/PB/CB: 0.7 Vp-p, 75 ohms/

PR/CR: 0.7 Vp-p, 75 ohms

Component IN 2

Audio input: 500 mVrms, 47 kilohms

HDMI INPUT1, 2, 3, 4

Video: 1080/24p, 1080p (50/60 Hz), 1080i (50/60 Hz), 720p (50/60 Hz), 576p, 576i,

480p, 480i

Audio: Two channel linear PCM 32, 44.1 and 48 kHz, 16, 20 and 24 bits

Analogue audio input (minijack): 500 mVrms, 47 kilohms (HDMI IN 1 only)

PC Input

DIGITAL AUDIO OUT (OPTICAL)

Digital optical jack (Two channel linear PCM)

Audio output

PC IN

PC Input (D-sub 15-pin)

G: 0.7 Vp-p, 75 ohms, non Sync on Green/B: 0.7 Vp-p, 75 ohms/

R: 0.7 Vp-p, 75 ohms/HD: 1-5 Vp-p/VD: 1-5 Vp-p

PC audio input (minijack)

USB

USB port

Headphones

Headphones jack

LAN

10BASE-T/100BASE-TX connector (Depending on the operating environment of the

network, connection speed may differ. 10BASE-T/100BASE-TX communication rate

and communication quality are not guaranteed for this TV.)

Power and others

Power Requirements

220 V AC, 50 Hz

Viewing Screen Size (diagonal)*

132 cm (52 inches)

117 cm (46 inches)

132 cm (52 inches)

117 cm (46 inches)

Display Resolution

1,920 dots (horizontal) × 1,080 lines (vertical)

Power Consumption

330 W

241 W

330 W

241W

Standby Power Consumption**

Less than 0.2 W (16.5 W when “Quick Start” is set to “On”)

KDL-46/52Z5588, 46/52Z5599 (CH) 2

Model name		KDL-52Z5588	KDL-46Z5588	KDL-52Z5599	KDL-46Z5599
Dimensions*	with Table-Top Stand	1,240 × 821 × 358	1,091 × 725 × 330	1,243 × 821 × 358	1,094 × 725 × 330
(w × h × d)	(mm)
	without Table-Top Stand	1,240 × 767 × 86	1,091 × 672 × 86	1,243 × 745 × 85	1,094 × 657 × 85
	(mm)
Mass*	with Table-Top Stand	31.3	25.3	30.1	24.4
	(kg)
	without Table-Top Stand	27.2	21.9	26.0	21.0
	(kg)
Product usage condition
Environment Temperature		5°C - 35°C
Humidity		20% - 80%
Air Pressure		86 kPa - 106 kPa

*Dimensions and mass are approximate values.

**Specified standby power is reached after the TV finishes necessary internal processes.

	Model name		KDL-52Z5588		KDL-46Z5588		KDL-52Z5599	KDL-46Z5599
	Display Spec
	Luminance*		350 cd/m2**
	Contrast*		150:1**
	Viewing angle (L0/3)*		Horizontal	85° Vertical		65°
	Definition	analog RF	Horizontal	350, Vertical		400 TVL**
	(TV Line)*
		SDTV	Horizontal	450, Vertical		450 TVL**
		HDTV	Horizontal	720, Vertical		720 TVL**
	Colour gamut*		32 % **
	Smearing time of motion picture*		20 ms **
	Audio characteristic*		Sound pressure THD in rated input 10%**

*Refer to SJ/T11348-2006 <Methods of measurement for digital television flat panel displays>.

**These values are required by SJ/T11343-2006 <General specification for digital television LCD displays> in normal temperature.

Design and specifications are subject to change without notice.

KDL-46/52Z5588, 46/52Z5599 (CH) 3

PC input signal reference chart for (RGB) PC and HDMI IN 1, 2, 3, 4

Resolution
Signals	Horizontal	×	Vertical	Horizontal	Vertical	Standard
	(Pixel)		(Line)	frequency (kHz)	frequency (Hz)
VGA	640	×	480	31.5	60	VESA
	640	×	480	37.5	75	VESA
	720	×	400	31.5	70	VESA
SVGA	800	×	600	37.9	60	VESA
	800	×	600	46.9	75	VESA
XGA	1024	×	768	48.4	60	VESA
	1024	×	768	56.5	70	VESA
	1024	×	768	60.0	75	VESA
WXGA	1280	×	720	45.0	60	EIA
	1280	×	768	47.4	60	VESA
	1280	×	768	47.8	60	VESA
	1280	×	960	60.0	60	VESA
	1360	×	768	47.7	60	VESA
SXGA	1280	×	1024	64.0	60	VESA
HDTV	1920	×	1080	66.6	60	VESA*
	1920	×	1080	67.5	60	EIA*

*1080p timing when applied to the HDMI input will be treated as a video timing and not a PC timing. This affects the “Video Settings” menu and “Screen” menu settings.

To view PC contents, set “Wide Mode” to “Full” and “Display Area” to “Full Pixel.”

•This TV’s PC input does not support Sync on Green or Composite Sync.

•This TV’s PC input does not support interlaced signals.

•If input signal is not shown in above chart, then this signal may not be displayed properly or cannot be displayed according to your setting.

•For the best picture quality, it is recommended to use the signals in the above chart with a 60 Hz vertical frequency (boldfaced).

KDL-46/52Z5588, 46/52Z5599 (CH) 4

WARNINGS AND CAUTIONS

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.

!SAFETY-RELATED COMPONENT

WARNING!!

Replace all components with Sony parts whose part numbers appear as shown in this manual or in supplements

published by Sony.

SAFETY-RELATED COMPONENT

WARNING

It is essential that all critical parts be replaced only with the part number specified in the electrical parts list to prevent electric shock, fire, or other hazard.

NOTE: Do not modify the original design without obtaining written permission from the manufacturer or you will void the original parts and labor guarantee.

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).

KDL-46/52Z5588, 46/52Z5599 (CH) 5

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.

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 60to 100-watt troublelight (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

Trouble Light

Ohmmeter

AC Outlet Box

AC

0.15 F Voltmeter

(0.75V)

Cold-water Pipe

Earth Ground

FigureA. Using an AC voltmeter to check AC leakage.

Figure B. Checking for earth ground.

KDL-46/52Z5588, 46/52Z5599 (CH) 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.

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 .

	Number of times standby	Monitoring Items	Diagnostic Item Description
	LED (Red) blinks	(Screen Display)
	2 times	DC_DET	BA Board
			Power Unit (G7N) (46"/52")
	5 times	DC_ALART	BA Board
	6 times	BACKLIGHT	BA Board
			LCD Panel
			Power Unit (G7N) (46"/52")
			D1N/D2N Board (46"), D3N/D4N Board (52")
	7 times	INTERNAL TEMP	BA Board
	8 times	AUDIO	BA Board
			Power Unit (G7N) (46"/52")
			Speaker
	10 times	DIGITAL FE/DE	BA Board
	12 times	HFR	BA Board
			LCD Panel
	13 times	BALANCER	BA Board
			Power Unit (G7N) (46"/52")
			D1N/D2N Board (46"), D3N/D4N Board (52")
	14 times	T_CON	BA Board
			LCD Panel

KDL-46/52Z5588, 46/52Z5599 (CH) 7

DISPLAY OF STANDBY LIGHT FLASH COUNT

2 sec

KDL-52Z5588/46Z5588

STANDBY INDICATOR

KDL-52Z5599/46Z5599

STANDBY INDICATOR

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:

[To Bring Up Screen Test]

In standby mode, press buttons on the remote commander sequentially in rapid succession as shown below:

*

5

* : Note that this differs from entering the service mode (volume +)

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.

KDL-46/52Z5588, 46/52Z5599 (CH) 8

TABLE OF CONTENTS

SPECIFICATIONS ....................................................				2	3.	DIAGRAMS .....................................................			3-1
						3-1.	BLOCK DIAGRAM ..............................................		3-1
SAFETY CHECK-OUT .............................................				6		3-2.	CIRCUIT BOARDS LOCATION .........................		3-2
							(1)	KDL-46Z5588/46Z5599 ..................................	3-2
SELF DIAGNOSIS FUNCTION ................................				7			(2)	KDL-52Z5588/52Z5599 ..................................	3-2
TABLE OF CONTENTS ...........................................				9	4.	EXPLODED VIEWS ........................................			4-1
						4-1. KDL-46Z5588/46Z5599 ........................................			4-2
1.	DISASSEMBLY ...............................................			1-1		4-1-1.		REAR COVER AND STAND ASSY .............	4-2
	1-1. KDL-46Z5588/46Z5599 ........................................			1-1		4-1-2.		CHASSIS-1 ......................................................	4-3
	1-1-1.		REAR COVER REMOVAL ............................	1-1		4-1-3.		CHASSIS-2 ......................................................	4-4
	1-1-2.		STAND ASSSY REMOVAL ..........................	1-1		4-1-4.		CONNECTOR ASSY ......................................	4-5
	1-1-3.		SWITCH UNIT REMOVAL ...........................	1-2		4-2. KDL-52Z5588/52Z5599 ........................................			4-6
	1-1-4.		D1N BOARD AND POWER UNIT (G7N)			4-2-1.		REAR COVER AND STAND ASSY .............	4-6
			REMOVAL ......................................................	1-2		4-2-2.		CHASSIS-1 ......................................................	4-7
	1-1-5.		BA AND D2N BOARDS REMOVAL ...........	1-3		4-2-3.		CHASSIS-2 ......................................................	4-8
	1-1-6.		SPEAKER REMOVAL ...................................	1-3		4-2-4.		CONNECTOR ASSY ......................................	4-9
	1-1-7.		AC INLET AND FRAME REMOVAL ..........	1-4		4-3.	PACKING MATERIALS ....................................		4-10
	1-1-8.		HL1A (HL5) AND HSN BOARDS, LCD			4-3-1.		KDL-46Z5588/46Z5599 ................................	4-10
			PANEL REMOVAL ........................................	1-4		4-3-2.		KDL-52Z5588/52Z5599 ................................	4-11
	1-2. KDL-52Z5588/52Z5599 ........................................			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.		D3N BOARD AND POWER UNIT (G7N)
			REMOVAL ......................................................	1-6
	1-2-5.		BA AND D4N 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 (HL5) AND HSN BOARDS, LCD
			PANEL REMOVAL ........................................	1-8
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

KDL-46/52Z5588, 46/52Z5599 (CH) 9

SECTION 1

DISASSEMBLY

1-1. KDL-46Z5588/46Z5599

1-1-1. REAR COVER REMOVAL

3 Two screws (+BVTP 3X12)

1 Eight screws	2 Five screws
(+BVTP 4X16)	(+PSW M5X12)

4 Rear cover (46)

2 Two screws (+PSW M5X12)

Note: Please note that replacing the rear cover, refer to “APPENDIX/1. REMOVAL AND INSTALLATION OF REAR COVER PROCEDURE”.

1-1-2. STAND ASSSY REMOVAL

	1 Four screws	2 Stand assy (L3A)
	(+PSW M5X16)

KDL-46/52Z5588, 46/52Z5599 (CH) 1-1

KDL-46Z5588/46Z5599

1-1-3. SWITCH UNIT REMOVAL

1 Switch unit

2 Power switch

Note: Please note that replacing switch unit, refer to “APPENDIX/2. REMOVAL OF SWITCH UNIT PROCEDURE”

1-1-4. D1N BOARD AND POWER UNIT (G7N) REMOVAL

	1 Two screws	4 Four screws
	(+PSW M3X8)
		(+PSW M3X8)
	2 D1N board	5 Power unit (G7N)

3 Insulating sheet (46D)

6 Insulating sheet (G7)

KDL-46/52Z5588, 46/52Z5599 (CH) 1-2

KDL-46Z5588/46Z5599

1-1-5. BA AND D2N BOARDS REMOVAL

1 Two screws	6 Side jack bracket	7 Eight screws
(+PSW M3X8)		(+PSW M3X8)

4 Two screws (+PSW M3X8)

2 D2N board

8 BA board

	3 Insulating sheet	4 One screw
		(+PSW M3X8)
	(46D)
		5 Read wire with
		connector (LVDS)

1-1-6. SPEAKER REMOVAL

5 Loudspeaker

3 One screw

(+PSW M3x8)

6 Loudspeaker

3 Loudspeaker

(Tweeter)

3 One screw (+PSW M3x8)

4 Loudspeaker

(Tweeter)

KDL-46/52Z5588, 46/52Z5599 (CH) 1-3

KDL-46Z5588/46Z5599

1-1-7. AC INLET AND FRAME REMOVAL

KDL-46Z5599		KDL-46Z5588
	1 Two screws	2 Under cover	1 Two screws
2 Under cover			(+BVTP 4X16)
	(+BVTP 4X16)
			3 One screw
	7 One screw		(+KTT 3X10 (S TYPE))
			5 One screw
	(+PSW M5X12)
			(+PSW M5X12)
0 VESA bracket			6 AC inlet bracket
9 VESA bracket			4 AC inlet filter
			8 Bottom frame

			qs VESA bracket
			qa VESA bracket
1-1-8. HL1A (HL5) AND HSN BOARDS, LCD PANEL REMOVAL
8 One screw
(+PSW M3X8)			6 Five screws
9 Heat sink			(+BVTP 4X16)
(T-CON SLIM)
0 Radiation sheet
(T-CON SLIM)
qa One screw
(+PSW M3X8)			7 LCD panel
qs Heat sink	qd Radiation sheet		5 Top stay
(T-CON SLIM)		(T-CON SLIM)
KDL-46Z5599		KDL-46Z5588	4 Illumination module
2 Illumination module			1 HL1A board
			2 HSN board
1 HL5 board			3 light guide

Front cabinet assy (46)

Front cabinet assy (46)

Note: 1. Please note that when replacing the LCD Panel, be sure to remove the heat sink (T-CON SLIM) and radiation sheet (T-CON SLIM) from the original LCD panel and then attach them to a new LCD panel.

2.Please note that replacing top stay, refer to “APPENDIX/3. REMOVAL AND INSTALLATION OF TOP STAY PROCEDURE”.

KDL-46/52Z5588, 46/52Z5599 (CH) 1-4