Sony KDL-46R485A, Service Manual

Page 1: ...LLOWING MANUAL SERVICE MANUAL COMMON SERVICE MANUAL COMMON ITC2 CHASSIS Segment BA Version Date Subject 1 6 2013 1st Issue LCD TV 9 888 144 01 For SM Unique please refer 9 888 144 P1 Pan Asia 9 888 144 A1 America 9 888 144 E1 Europe ...

Page 2: ...SERVICE MANUAL COMMON SERVICE MANUAL COMMON ITC2 CHASSIS Segment BA LCD TV LCD TV ...

Page 3: ... MODELS REGION ASIA AMERICA EUROPE MODEL KLV 24R402A KLV 32R402A KLV 40R452A KLV 46R452A KLV 24R402A KLV 32R402A KLV 40R452A KLV 46R452A KLV 24R422A KLV 32R407A KLV 40R457A KLV 46R472A KLV 32R422A KLV 40R472A KDL 46R485A KLV 32R422A KLV 40R472A KDL 46R485A KDL 32R435A KDL 40R485A 3 ...

Page 4: ...DIAGNOSTIC FUNCTION 2 1 Overview of Control Buttons 8 2 2 LED Display Control 8 2 3 LED Pattern 8 5 DIAGRAMS 5 1 Circuit Board Location 62 5 2 Block Diagram 63 5 3 Connector Diagram 65 2 4 Standby LED Error Display 8 2 5 Triage Chart 9 3 TROUBLE SHOOTING 3 1 Troubleshooting Flow 10 3 2 N P 11 3 2 No Power 11 3 3 Standby Led Blinking 14 3 4 No Picture 25 3 5 Audio Problem 27 3 6 Troubleshooting Vid...

Page 5: ...erty and avoid causing serious injury Carry the TV with an adequate number of people larger size TVs require two or more people C t h d l t hil i th TV i i t t f 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 connector...

Page 6: ... a resistor by means of a VOM or battery operated AC voltmeter The limit indication is 0 75V 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 multimeter that have a 2 VAC range are suitable 3 Check all control knobs shields covers ground straps and mounting hardware have ...

Page 7: ...onnect 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 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 3 1 6 Lead Free Information Figure 3 Checking for e...

Page 8: ... Error Display The Number of Standby LED Detection Items Board Error Item 2 2 LED Display Control Status LED Colour Remarks Power Off AC Off and 1 OFF 1 power switch off by touch button Amber Red Green Standby LED RED blinking 2 Main Power Error AC adapter Error 3 Audio Error BB board Error Power On Green Standby by remote control off only Red Picture Off Green 4 Panel Power Error BB board Error 5...

Page 9: ... 6 Tuner USB Video Component HDMI MHL Main Speaker HP Video Component Tuner HDMI USB BB Board Light Source Board Open Cell AC Adaptor Speaker Unit LS Harness Main Harness C C FFC Cable Note Details refer to Troubleshooting Section Secondary possible defective part Most likely defective part 9 ...

Page 10: ...Troubleshooting Flow START Does the Power Led stay on when the Open Detail No Power TV is switched on Is the Standby Led No Power Open Detail blink Standby LED Blink Green Amber blink Panel ID Error Panel Not Supported Is the Picture and Sound OK Open Detail Picture Audio Video END 10 ...

Page 11: ... Power Check DC voltage at JL6001 Yes See DDCON Sheet Is it 19 5V No Sheet T k t d t Take out adaptor and test at adaptor output is it 19V 19 5V Refer Figure 1 BB board Yes No Change adaptor and test again Adaptor NG OK AC source NG Figure 1 How to test DC voltage at adaptor output 11 ...

Page 12: ...se Yes Check voltage at JL6000 No Change BB is it 1 2V Yes OK Change BB board DDCON Check voltage at JL6002 Is it 1 5V Check voltage at JL6012 Is it 12V Check F6003 Is it ok No Yes NG No Change BB board Check voltage at JL6005 is it 5V No Yes NG Change BB board Fuse Yes After checking take note of NG condition change BB board 12 NG condition change BB board ...

Page 13: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board JL6002 JL6001 JL6003 JL6000 JL6006 JL6005 JL6006 F6003 13 ...

Page 14: ... Standby LED Blinking 3 3 1 2 times Blinking 2 times Blinking Check DC voltage at JL6001 Yes Change BB board Is it 18V 19 5V No board Take out adaptor and test at adaptor output is it 18V 19 5V Refer Figure 1 Change BB board Yes Change adaptor No Figure 1 How to test DC voltage at adaptor output 14 ...

Page 15: ...ng Speaker Connector at CN4000 perform AC OFF ON 3x blinking Check Speaker harness and Speaker impedance No connectivity for speaker harness Change Change Speaker Change Speaker Harness Connect back 3x blinking F4000 broken Check connectivity of F4000 No connectivity of F4000 Speaker Connector to CN4000 perform AC OFF ON No 3x blinking 3x blinking F4000 OK Audio IC problem IC4000 damage Change BB ...

Page 16: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board F4000 IC4000 CN4000 JL6012 16 ...

Page 17: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References Board Name Board PWB A side Detail BB CN4000 F4000 CN4000 CN4000 F4000 F4000 F4000 F4000 F4000 17 ...

Page 18: ...R452 R457 R472 R488 Troubleshooting 3 3 Standby LED Blinking 3 3 Standby LED Blinking 3 3 3 4 times Blinking No 12V Check F6003 Is it ok No Fuse Yes Check JL6009 Is it 3 3V BB board No Yes N Check JL6012 Is it 12V DDCON No Yes LVDS 18 ...

Page 19: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board LVDS FFC CONNECTOR JL6012 F6003 JL6009 19 JL6009 ...

Page 20: ...e Cable FFC at BB Board and Panel Replace B Board BB Board Issue Incorrect FFC Insertion TV Boot Up Normally TV Boot Up Normally 5x Blinking is Still Observed 5x Blinking is Still Observed TV Boot Up TV Boot Up Replace LVDS Flat Flexible Cable FFC LVDS Cable Issue Replace O Cell or Panel Module O Cell Issue TV Boot Up Normally TV Boot Up Normally END 5x Blinking is Still Observed Not recommended a...

Page 21: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board LVDS FFC CONNECTOR JL6007 21 ...

Page 22: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board Probing Points JL9522 BL_ON A Side A Side Note PANEL_VCC_SW 12V 0 8V 22 JL6007 PANEL_VCC_SW ...

Page 23: ...s Blinking 6x blinking 6x blinking Check if LED harness FFC CN9500 CN9502 is connected properly NG Connect LED harness Change BB Board Symptom gone BB board 6x blinking Able to repair Panel Module No 6x blinking Change Panel Module Yes Change Harness Harness Symptom gone 6x blinking Replace LS Bar Not recommended at Service Side 23 ...

Page 24: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board CN9500 CN9502 24 ...

Page 25: ...CC_SW 12V 0 8V 12V OK MHL HDMI Video Component p Harness _ _ JL6007 on B Board Picture OK HIGH OK LOW NG NG No 12V Input NG LVDS FFC Harness Problem Adaptor or 12V DDCON Problem Picture OK Backlight or LED Driver Problem Replace Input Source put G Replace B Board Panel Module O C ll Still No Picture END Replace B Board or O Cell Problem Picture OK END Picture OK B Board Issue O Cell or Panel Modul...

Page 26: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board LVDS FFC CONNECTOR R5037 JL6007 26 ...

Page 27: ...eaker No Sound HP Out No Sound Refer Main Speaker No Sound Refer HP Out HP Out No Sound Video Component or HDMI 2 AUDIO IN d No Sound Refer Analog Audio Input N S d no sound Analog RF no sound No Sound Refer Analog RF No Sound HDMI Audio no sound No Sound Refer HDMI Audio No Sound USB Audio no sound Refer USB Audio No Sound 27 ...

Page 28: ...Harness Check Speaker Harness connectivity No connectivity for speaker harness Sound Sound No Sound No Sound Change Speaker Harness Speaker Impedance 6 8 Ω Check Speaker Impedance No Sound No Sound Sound Sound No Sound No Sound No Sound No Sound Change Speaker F4000 broken Check fuse connectivity at F4000 No Sound No Sound No connectivity of F4000 No Sound No Sound Audio IC problem IC4000 damage N...

Page 29: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board F4000 IC4000 F4000 IC4000 CN4000 29 ...

Page 30: ...roblem 3 5 2 Headphone HP Out No Sound START Sound Headphone HP No Sound Do a Factory Setting Headphone No Sound Sound HP IC IC4001 or Main IC IC5000 Use another Headphone Headphone problem No Sound No Sound Headphone OK Change BB Board HP IC IC4001 or Main IC IC5000 problem DONE Change BB Board 30 ...

Page 31: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board IC5000 IC4001 CN4000 31 ...

Page 32: ...le ok Change HDMI cable NG Sound Sound HDMI source ok Change HDMI source NG No Sound No Sound HDMI cable OK Sound Sound HDMI sound format ok Change to supported format NG Sound Sound No Sound No Sound HDMI source OK Main IC IC5000 or Audio IC IC4000 problem No Sound No Sound HDMI format OK Please refer to IM for supported HDMI audio format Change BB Board IC4000 problem 32 DONE ...

Page 33: ...Problem 3 5 4 Analog RF no sound Analog RF input no sound RF cable ok Change RF cable UI setting ok TV System AFT Audio Filter Correct UI NG NG RF source ok Change RF source channel y OK NG OK Raster sound ok Refer Speaker No Sound OK NG Tuning ok Refer Tuner Change BB Board NG OK OK ok Problem 33 ...

Page 34: ...ange to t d f t NG Sound Sound No Sound No Sound Check USB thumbdrive format Change USB supported format NG No Sound No Sound USB format OK Sound Sound Condition g thumbdrive No Sound No Sound USB condition OK Main IC IC5000 or Audio IC Change BB Board IC4000 problem DONE 34 Confirm with OSD on bottom panel if playback not support Please refer to IM for detail supported USB audio format ...

Page 35: ...Yes Backlight turns ON times blink BLINK 6x times blinking No No Refer to IM Eco Tuner OK Refer Tuner Problem Yes Yes No Check Eco Power Saving ON Refer to IM Eco Power Saving Setting No Yes Change BB_PAA board Video OK Refer Video Problem Yes No Component Refer Component No HDMI OK Refer HDMI MHL Problem Yes No OK Component Problem Yes Finish MHL OK Refer HDMI MHL Problem Yes Yes No 35 Finish ...

Page 36: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting 3 6 1 Component Video HDMI Block Diagram MT5309 Component Video 5V Input detection IC5000 Component Video 75ohm HDMI1 HDMI2 MHL 36 ...

Page 37: ...Video NG No picture signal source or cable NG Check Input jack J3002 connection NG OK input signal 0 7Vp p at R3018 NG OK OK OK IC5000 defect at C3015 face to IC5000 same as Ref1 CB input pattern Video Signal Source problem or cable problem Make sure jack proper connection to board R3010 connection defect Confirm R3018 C3015 ti NG C3015 connection and value 37 ...

Page 38: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board R3018 C3015 J3002 JL6012 R3010 38 ...

Page 39: ... Ref2 Ref4 Confirm waveform at IC5000 defect OK OK Check input signal 0 7Vp p at R3018_Y0P line R3020_PB0P line R3021_PR0P line C3015 face to IC5000 same as Ref2 Confirm waveform at C3017 face to IC5000 same as Ref3 Confirm waveform at C3018 face to IC5000 NG NG same as Ref4 Input CB pattern R3010 R3011 or R3012 connection defect Confirm R3010 C3010 R3018 C3015 Y0P line connection and value Confir...

Page 40: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board R3018 R3020 R3021 R3010 C3010 R3011 C3011 C3015 C3017 C3017 R3012 C3012 J3002 40 ...

Page 41: ...488 Troubleshooting 3 6 4 Auto Switching Component Video Troubleshooting Flow Auto switching NG Input Pr input at J3002 and check at R5033 IC5000 defect OK Take out Pr input at J3002 and check at OK R5033 5V NG NG R5033 0V R3022 defect J3002 defect 41 ...

Page 42: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board R5033 42 ...

Page 43: ...MI input NG HDMI Signal Source Problem or p source signal or cable OK g cable problem Confirm HDMI input source format resolution supported by Change HDMI input source to TV t d f t NG NG Check HDMI OK Change BB PAA format resolution supported by TV supported format Check HDMI jack OK C a ge board Change board circuit 43 ...

Page 44: ...B3606 RB3607 NG Check input source R3710 R3709 R3601 RB3601 R3740 Q3602 and Q3603 connectivity Check RB3606 RB3607 RB3602 RB3603 connectivity Check RB3606 RB3607 RB3602 and RB3603 all pins condition Check 5V on CN3600 pin18 15 16 HPD JL5008 Check CN3600 pin1 3 4 6 7 9 10 12 3 3V HDMI2 MHL no picture Change Board OK OK OK Short Circuit Check RB3608 RB3604 RB36 09 RB3605 Power Check input source Che...

Page 45: ...R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board Q3602 Q3603 R3709 R3710 R3601 R3740 Q3602 CN3601 Pin19 R3709 RB3603 Pin1 RB3607 RB3602 RB3606 CN3600 Pin1 RB3605 Pin19 RB3609 RB3604 RB3608 45 ...

Page 46: ...ng Item OK NG 1 and 2 Check RB3602 RB3603 RB3606 RB3607 RB3604 1 and 2 Check RB3602 RB3603 RB3606 RB3607 RB3604 RB3605 RB3608 RB3609 Pin 1 Pin 2 Pin 2 Pin 3 Pin 3 Pin 4 No Short No Short No Short No Short Short Short Short Short Pin 5 Pin 6 Pin 6 Pin 7 Pin 7 Pin 8 No Short No Short No Short Short Short Short 46 ...

Page 47: ...HL phone spec and OS support etc YES Change MHL cable NO Use supported MHL cable cab e Q3605 NG NG YES Check MHL_SENSE lt 2 5Vd IC3603 or IC5000 NG Q3605 G OK voltage 2 5Vdc Check VBUS voltage NG Check MHL EN voltage Change BB PAA Board IC5000 NG OK Check VBUS voltage 5Vdc OK Check MHL_EN voltage CL3605 3 3Vdc IC5000 NG Change BB PAA Board IC5000 NG 47 ...

Page 48: ...R422 R435 R452 R457 R472 R488 Troubleshooting 3 8 1 MHL Cannot charging No charging Check VBUS voltage at IC3603 PIN 6 5Vdc Change MHL cable YES IC3603 NG YES Check IC3603 pin3 voltage 3 3Vdc NO NO Ch B B d Change B Board 48 ...

Page 49: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board IC3603 Pin6 IC3603 Pin6 CL3605 49 ...

Page 50: ...log RF input no picture Change RF cable and antenna Check RF source cable and antenna OK NG OK Check JL1001 3 3V Change BB OK NG Raster OK OK NG Tuning OK Check LVDS harness connection b t BB OK NG NG Change BB Reconnect LVDS cable or change new LVDS between BB board OK OK A 50 g or change new LVDS cable ...

Page 51: ... OK FB1002 FB1003 C1002 C1003 R1011 R1012 R1015 C1012 RF level dBm RF level dBuV IFAGC1 V 80 35 0 050 70 45 0 250 60 55 0 380 OK NG R1012 R1015 C1012 R1001 R1003 C1016 R1013 Confirm RF level and IFAGC1 V 60 55 0 380 50 65 0 470 40 75 0 590 30 85 0 770 20 95 0 940 OK V of Analog RF Fig 1 20 95 0 940 10 105 1 090 IFAGC1 V tolerance 0 05 Please re upgrade Firmware NG Change BB PKG Check again Picture...

Page 52: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Troubleshooting Troubleshooting References BB Board C1002 FB1003 R1001 R1003 C1016 JL1001 FB1002 C1003 C1012 R1013 R1011 R1015 R1012 52 ...

Page 53: ...D bli k t P i di t OK NG Green LED light at Power LED indicator Green LED blinks at Power indicator when using commander near sensor s window OK NG Mechanical ex Bezel Guidelight Confirm Harness connection OK on BB Board and HB Board Harness loose connection OK Change Harness Harness NG NG OK Change Harness Harness NG NG Change HB board HB board NG OK Change BB board NG 53 ...

Page 54: ...ge Voltage range NG Check Wire Harness And Connector Connectivity Change Wire Harness And connect properly average 0 000 0 00000 0 82353 1 114 0 83451 1 37255 Check 3 3V in Pin2 CN1 OK NG Check 3 3V in Pin 1 CH Input 1 693 1 383529 2 03137 No Input 2 420 2 04235 2 80000 in Pin2 CN1 Switch Unit OK OK CN5000 on BB Board Change Switch Unit NG Check Pin 1 Voltage Level in CN1 OK Change BB Board NG 54 ...

Page 55: ...2 R407 R422 R435 R452 R457 R472 R488 Troubleshooting 3 12 RTC Troubleshooting Flow SU model only Time in Photo Frame does not memorize after AC off on self diagnosis RTC_ ERR 1 RTC IC NG Yes No SW NG Change BB Board 55 ...

Page 56: ... Software Version 1 Press Enter or button on Remote to enter status information 2 4 Remote Commander 1 3 Remote Commander Screen Sample Service Mode Status Information Self diagnosis history NO SIGNAL MUTE Off 2 Press Enter button on Remote to back to Service Mode _ _ TUNING SYSTEM AUTO Low of HPD 5 UART Selection CLI SERIAL NUMBER EDIT MODEL NAME EDIT MODEL NAME EDIT TEST RESET Off Set Home Exit ...

Page 57: ...Remote Commander Back 000 RTC_ERR 000 000 TOUCHSNSR_ERR 000 000 002 MAIN_POWER 000 003 AUDIO_PROT 000 005 PANEL_POWER_ERR 000 005 PANEL_ID_NVM_ERR 000 006 BACKLIGHT ERR 001 Screen Sample 0 indicates no error was detected 1 indicates an error was detected 006 BACKLIGHT_ERR 001 00002 00083 00002 Home Exit Screen Sample 2 Press Enter button on Remote to back to Service Mode Total Operation Time h Boo...

Page 58: ...ER EDIT is grayed out and the serial number that has been input is displayed User will not able to edit anymore The font color of YES is change to black when it is selected Remote Commander 3 Serial Number can be set ONLY ONCE After user input data press Enter Pop dialog will appear to inform user to confirm data Press or button to select YES or NO Select YES if input data is correct Screen Sample...

Page 59: ...ill edit the Serial Number 1 Press button on Remote to edit Model Name 4 6 Accessing Model Name Edit Remote Commander S S l Screen Sample Note The font color of NO is change to black when it is selected Screen Sample 2 Press or button on Remote to select character p Screen Sample Remote Commander 59 Screen Sample Screen Sample Note The font color of SERIAL NUMBER is white after NO is selected ...

Page 60: ...AME is change to orange after YES is selected Screen Sample Note The font color of YES is change to 5 If NO is selected the input data is not saved into EEPROM The model name that has been input is displayed User can still edit the Model Name after YES is selected black when it is selected 4 If YES is selected the input data is saved into EEPROM Model Name EDIT is grayed out and the model name tha...

Page 61: ...odel is available with the system OR 2 Please check with Software Upgrade Manual in Service Website f th d d h it i i f th ft d ti for the procedure and when it is require for the software updating 3 The software updates may not be ready yet in the Website after the 1st Issue of Service Manual is released 4 Do check and keep updated with the Service Website for any information and or listed issues...

Page 62: ...ams SECTION 5 DIAGRAMS 5 1 1 24 5 1 2 32 BB BOARD SWITCH BB BOARD SWITCH UNIT HB BOARD SWITCH UNIT 5 1 3 40 HB BOARD 5 1 4 46 5 1 3 40 5 1 4 46 BB BOARD BB BOARD BB BOARD SWITCH UNIT HB BOARD BB BOARD SWITCH UNIT 62 HB BOARD HB BOARD ...

Page 63: ...b WXGA FHD Panel EEPROM 128kb Component1 Video Component Video MT5309 Audio2 HDMI1 ARC HDMI1 HDMI2 HDMI2 Li O t Sid HP AL R0 MT5309 HDMI2 Audio MHL Line Out Side HP AL R0 Tuner H Board Side Key LED driver Only HDM2 support DVI Audio Line out Side HP AMP TPA6138A2PWR A l Audio Amp 5W 5W USB Analog Tuner H Board Tact Key USB 63 ...

Page 64: ...A SU NAND EEPROM Component1 Video 512Mb 128kb Component Video Audio2 HDMI1 ARC HDMI1 HDMI2 MT5309 HDMI2 Audio HDMI2 MHL Line Out Side HP AL R0 Tuner H Board LED driver Only HDM2 support DVI Audio Line out Side HP AMP TPA6138A2PWR Audio Amp 5W 5W Side Key USB Analog Tuner Clock RTC H Board Tact Key USB 64 ...

Page 65: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Diagrams 5 3 Connector Diagram 5 3 1 24 5 3 1 24 65 ...

Page 66: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Diagrams 5 3 Connector Diagram 5 3 2 32 AUO 5 3 2 32 AUO 66 ...

Page 67: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Diagrams 5 3 Connector Diagram 5 3 3 32 LGD 5 3 3 32 LGD 67 ...

Page 68: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Diagrams 5 3 Connector Diagram 5 3 4 40 5 3 4 40 68 ...

Page 69: ...ITC2 CHASSIS R402 R407 R422 R435 R452 R457 R472 R488 Diagrams 5 3 Connector Diagram 5 3 5 46 5 3 5 46 69 ...

Page 70: ...Sony Corporation 70 English 2013 06 Sony Corporation Sony EMCS Malaysia Sdn Bhd HESRDM 9 888 144 01 ...