Self Diagnosis

Supported model

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

REPAIR MANUAL
RB2G Chassis
Segment: HM

MODEL COMMANDER DESTINATION

KDL-40W590B RM-YD103 US/CND

KDL-40W600B RM-YD103 US/CND

KDL-48W590B RM-YD103 US/CND

KDL-48W600B RM-YD103 US/CND

KDL-48W590B

Version Date Subject

1.0 02/25/2014 Original Manual Release Date.
2.0 07/01/2014 Updated Adjustments Procedure on Section 3 - Repair Information. Pages 12 -16 replaced.

LCD Digital Color TV

9-883-590-02
TABLE OF CONTENTS

Cautions and Warnings...................................

......................................................................
................................................ii
.............ii Section 4 - Exploded View/Part Number Information .................................17
.................................17
Table Top Stand ......................................................................
...........................................................................................17
.....................17
Section 1 - Specifcations and Layouts .........................................................1
KDL-40W590B/48W600B..............................
..................................................................
..............................................18
..........18
Specications ...............................
..................................................................
.................................................................1
..............................1
Connectors ....................................
.......................................................................
..............................................................21
...........................21
Checking the Accessories......................................................................................1
Screws...............................
...................................................................
.......................................................................
......................................22
...22
Board Layout ...............................................................................
.................................................................................................2
..................2
KDL-40W590B/48W600B ......................................................................................2 Section 5 - Accessories/Part Number Information .....................................23
.....................................23
KDL-48W590B/48W600B ......................................................................................2 Accessories and Packaging
Packaging ................................
...................................................................
........................................23
.....23
Wire Dressing ..................................................................
................................................................................................3
..............................3 Miscellaneous...............................
...................................................................
...............................................................23
...........................23
KDL-40W590B/40W600B ......................................................................................3 Optional Accessories.........................................................................
...................................................................................23
..........23
KDL-48W590B/48W600B ......................................................................................3 Remote Commander .........................................................................
...................................................................................23
..........23
Section 2 - Troubleshooting ...........................................................................4
...........................................................................4 Appendix A: Encryption Key Components .....................................
...............................................
.......... A-1
Diagnosing the Error .....................................................................................4
.....................................................................................4
Viewing the Self Check Diagnosis
Diagnosis History ...................... ......................... .............. 4
Triage Chart................................................................
...................................................................................................5
...................................5
Flowcharts and Diagrams....................................
.......................................................................
..........................................6
.......6
Overall Block Diagram ...........................................................................................6
Power and Control Block Diagram.........................................................................7
No Power Flowchart ..............................................................................................8
Standby LED Blinking Flowchart ...........................................................................9
Video Distortion Flowchart ...................................................................................10

Section 3 - Repair Information ...................................

......................................................................11
...................................11
Repairing the TV.................................
TV ....................................................................
.........................................................11
......................11
Removing the Table Top Stand.................................
....................................................................11
...................................11
Removing the Lower Cover ..............................................................
.........................................................................
........... 11
Replacing the Main Board / Tuner Board ....................................................12
....................................................12
Removing the Speakers .......................................................
..............................................................................16
.......................16
Replacing the Switch Unit ...........................................................................16
...........................................................................16

KDL-40W590B/40W600B/48W590B/48W600B i
CAUTIONS AND WARNINGS

CAUTION!! ATTENTION!!
These servicing instructions are for use by qualied service personnel only
only.. Ces instructions de service sont à l’usage du personnel de service qualié
To reduce the risk of electric shock, do not perform any servicing other than seulement. Pour prévenir le risque de choc électrique, ne pas faire l’entretien
that contained in the operating instructions unless you are qualied to do so. autre que celui contenu dans le Mode d’emploi à moins que vous soyez
qualié faire ainsi.

WARNING!!
ALERTE!!
An isolation
isolation transformer
transformer should be used during any
any service to avoid possible
shock hazard, in case of live chassis. An d’eviter tout risque d’electrocution provenant d’un
d’un chássis
chássis sous tension,
un transformateur d’isolement doit etre utilisé lors de tout dépannage.

! SAFETY-RELATED COMPONENT WARNING!!

! ATTENTION AUX COMPOSANTS
There are critical components used in LCD color TVs that are important for
safety. These components are identied with shading and ! mark on the
RELATIFS A LA SECURITE!!
schematic diagrams and the parts list. It is essential that these critical parts Les composants identies par une trame et par une marque ! sur les
be replaced only with the part number specied in the parts list to prevent schemas de principe, les vues explosees et les listes de pieces sont d’une
electric shock, re or other hazard. importance critique pour la securite du fonctionnement. Ne les remplacer
que par des composants Sony dont le numero de piece est indique dans le
NOTE: Do not modify the original design without obtaining written permission present manuel ou dans des supplements publies par Sony. Les reglages
from the manufacturer or you will void the original parts and labor warranty. de circuit dont l’importance est critique pour la securite du fonctionnement
sont identies dans le present manuel. Suivre ces procedures lors de
chaque remplacement de composants critiques, ou lorsqu’un mauvais
ATTENTION!! fonctionnement suspecte.

For safety reasons, component level repair of the Power Supply Boards ATTENTION!!
and/or the Inverter Boards is prohibited.
Pour des raisons de sécurité, Interdire de réparer ou remplacer les
composantes dans les blocs d’alimentation et/ou sur les modules d’inverseur.
d’inverseur.

KDL-40W590B/40W600B/48W590B/48W600B ii
 CAUTIONS AND WARNINGS

SAFETY CHECK-OUT 3. Measuring the

the voltage drop across a resistor by means of a VOM
VOM
or battery-operated AC voltmeter. The “limit” indication is 0.75 V, so
After correcting the original service problem, perform the following safety analog meters must have an accurate low voltage scale. Nearly all
checks before releasing the set to the customer: battery-operated digital multimeters that have a 2 VAC range are
suitable. (see Figure A)
1. Check the area of your repair for unsoldered or poorly soldered
connections. Check the entire board surface for solder splashes To Exposed Metal
and bridges. Parts on Set

2. Check the interboard wiring

wiring to ensure that no wires are “pinched”
“pinched” or
touching high-wattage resistors.
3. Check that
that all control
control knobs,
knobs, shields, covers, ground
ground straps and
mounting hardware have been replaced. Be absolutely certain that AC
you have replaced all the insulators. 0.15 µF Voltmeter
(0.75V)
4. Look for unauthorized
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,
which, though functioning, show obvious
obvious signs of Earth Ground
deterioration. Point them out to the customer and recommend their
Figure A. Use an AC voltmeter to check AC leakage.
replacement.
6. Check the line cords for
for cracks and abrasion.
abrasion. Recommend
Recommend the
the
replacement of any such line cord to the customer
customer.. HOW TO FIND A GOOD EARTH GROUND
7. Check the antenna
antenna terminals,
terminals, metal trim, “metallized”
“metallized” knobs,
knobs, screws
screws The cover-plate retaining screw on most AC outlet boxes is at earth ground.
and all other exposed metal parts for AC leakage. Check leakage Verify the AC outlet box retaining screw ground by connecting a 60W to
as described in “Leakage Test”.
Test”. 100W incandescent (not a neon or uorescent lamp) between the hot side of
the receptacle and the retaining screw. Try both slots, if necessary
necessary,, to locate
the hot side on the line; the lamp should light at normal brilliance if the screw
LEAKAGE TEST is at ground potential. (see Figure B)

The AC leakage from any exposed metal part to earth ground and from all Trouble Light
exposed metal parts to any exposed metal part having a return to chassis,
AC Outlet Box
must not exceed 0.5 mA (500 microamperes). Leakage current can be
measured by any one of three methods.
1. A commercial leakage tester.
Follow the manufacturers’ instructions provided with the tester.
2. A battery-operated AC milliammeter
milliammeter..
Figure B. Checking for earth ground.

KDL-40W590B/40W600B/48W590B/48W600B iii
SECTION 1 - SPECIFICATIONS AND LAYOUTS

SPECIFICATIONS
System
Television system NTSC: American TV standard Model name KDL-48W6
W600
00B/4
B/48W590B KDL-4
KDL-40W
0W60
600B/
0B/40
40W5
W590B
90B
ATSC (8VSB terrestrial): ATSC compliant 8VSB
QAM on cable: ANSI/SCTE 07 2000 (Does not include CableCARD functionality)
Power and others
Channel coverage Analog terrestrial: 2 - 69 / Digital terrestrial: 2 - 69 Powerrequirement 19.5 V DC with AC adapter
Analog Cable: 1 - 135 / Digital Cable: 1 - 135 Rating: Input 110-240 V AC, 50/60 Hz (U.S.A./Canada 120 V AC, 60 Hz)
Panel system LCD (Liquid Crystal Display) Panel, LED Backlight Power in use 75 W
consumption in standby Less than 0.4 W with 120 V AC and less than 0.5 W with 240 V AC
Speaker output 8W+8W
Wireless technology Protocol IEEE802.11a/b/g/n Screen size * 47.6 inches 40 inches
(inches measured diagonally) (48 class)
Input/Output jacks
Display resolution 1,920 dots (horizontal) × 1,080 lines (vertical)
CABLE/ANTENNA 75-ohm external terminal for RF inputs
Dimensions * with stand (mm) 1,086 × 675 × 181 926 × 584 × 162
VIDEO IN 1 Video / Audio input (phono jacks)
(inches) 42 7 /8 × 26 5
/8 × 7 1 /4 36 1 /2 × 23 × 6 1 /2
COMPONENT IN YP B P R (Component Video): 1080p (60 Hz), 1080i (60 Hz), 720p (60 Hz), 480p, 480i
Audio input (phono jacks) without stand (mm) 1,086 × 646 × 90 926 × 556 × 89
VIDEO IN 2 Video input (common phono pin with Y input) (inches) 42 7 /8 × 25 1
/2 × 3 5 /8 36 1/2 × 22 × 3 5/8
HDMI IN 1/2/3/4 Video: 1080p (30, 60 Hz), 1080/24p, 1080i (60 Hz), 720p (30, 60 Hz), 720/24p, 480p, wall-mount hole
480i, PC Formats pattern (mm) 300 × 200 300 × 300
Audio: 5.1 channel linear PCM: 32, 44.1 and 48 kHz, 16, 20 and 24 bits, Dolby Digital
ARC (Audio Return Channel) (HDMI IN 2 only) wall-mount screw
M6 (8 -10 mm)
size (mm)
MHL Video: 1080p (30 Hz), 1080/24p, 1080i (60 Hz), 720p (30, 60 Hz), 720/24p, 480p, 480i
(Common with HDMI IN 1) Audio: 5.1 channel linear PCM: 32, 44.1 and 48 kHz, 16, 20 and 24 bits, Dolby Digital Mass * with stand
(kg)/(lb) 10. 3 / 22. 7 7. 9 / 17. 5
AUDIO OUT/ i Audio output (stereo mini jack)
Headphone jack without stand
(kg)/(lb) 9. 9 / 21. 9 7. 4 / 16. 3
(supports Subwoofer out)

DIGITAL AUDIO OUT Digital optical jack Operating temperature 32 ºF – 104 ºF (0 ºC – 40 ºC)
(OPTICAL) (Two channel linear PCM, Dolby Digital)
* Screen size, dimensions
dimensions and mass are approximate
approximate values.
LAN 10BASE-T/100BASE-TX connector (Connection speed may differ depending on the • Optional accessories availability depends on countries/region/TV model/stock.
model/stock.
network environment. 10BASE-T/100BASE-TX communication rate and
• Design and specifications are subject to change without notice.
communication quality are not guaranteed for this TV)
• This TV set incorporates
incorporates MHL 2.
USB/DLNA Refer to the i-Manual for supported formats
AC adapter input (DC 19.5 V)

Others
Optional accessories Camera and Microphone Unit: CMU-BR200/CMU-BR100 CHECKING THE ACCESSORIES
Wireless Subwoofer: SWF-BR100
MHL Cable: DLC-MB10/DLC-MB20/DLC-MC20
- Remote Control* - Wall-mount Adapter accessories
- Size AAA batteries (2) - Operating Instructions and
- AC Power Cord (1) other documents
documents
- AC Adapter (1)
- Fixing Screws for Table-Top * Refer
Refer to the model
model name printe
printed
d on
Stand (M5 × 20) (2) the remote control.

KDL-40W590B/40W600B/48W590B/48W600B 1
 SECTION 1 - SPECIFICATIONS AND LAYOUTS

BOARD LAYOUT

KDL-40W590B/48W600B KDL-48W590B/48W600B

TUNER BOARD
(TUS BOARD) TUNER BOARD
MAIN BOARD (TUS BOARD) MAIN BOARD
(BAXL BOARD) (BAXL BOARD)

LD BOARD LD BOARD

SWITCH SWITCH
UNIT
UNIT

WIRELESS HJM BOARD WIRELESS HJM BOARD

LAN CARD LAN CARD

KDL-40W590B/40W600B/48W590B/48W600B 2
 SECTION 1 - SPECIFICATIONS AND LAYOUTS

WIRE DRESSING

KDL-40W590B/40W600B KDL-48W590B/48W600B

KDL-40W590B/40W600B/48W590B/48W600B 3
SECTION 2 - TROUBLESHOOT
TROUBLESHOOTING
ING Self Diagnosis
Supported model

DIAGNOSING THE ERROR

StandBy LED
Blink Count
Before servicing the Television: Date and Time Display*
Diagnosis
Item
1. Verify the TV has the symptom the customer
customer indicated.
indicated.
2. Check to see if the latest Software
Software is installed.
SELF CHECK
a. If not, install the latest version.
000 RESERVED ---------------------
--------------------- ------------
---------------------
--------- -------------
---------------------
-------- 00
3. Determine the replacement part required. 000 RESERVED ---------------------
--------------------- ------------
---------------------
--------- -------------
---------------------
-------- 00
002 MAIN_POWE -------------
---------------------
-------- ---------------------
--------------------- --------------------
---------------------- 00
003 DC_ALERT
DC_ALERT ---------------------
--------------------- -------------
---------------------
-------- ------------
---------------------
--------- 00
VIEWING THE SELF CHECK DIAGNOSIS HISTORY 003 AUD_PROT ---------------------
--------------------- ------------
---------------------
--------- -------------
---------------------
-------- 00
003 HDMI_EQ ---------------------
--------------------- -----------
---------------------
---------- ------------
---------------------
--------- 00
When an error is detected, the Self Check screen records the number of
003 TU_DEMOD ---------------------
--------------------- -------------
---------------------
-------- --------------
---------------------
------- 00
times the error occurred. This is helpful in conrming past occurrences of 004 VLED --------
-------------
---------
--------
---- ----
--------
--------
--------
--------
------ ----
--------
---------
---------
--------
---- 00
an error and for determining if an error is intermittent when the customer is 004 LD_ERR ---------------------
--------------------- ------------
---------------------
--------- -------------
---------------------
-------- 00
not sure what is causing the television to shut down. If the screen displays 005 HFR_ERR ---------------------
--------------------- -------------
---------------------
-------- ------------
---------------------
--------- 00
Error Count
a “0”, no error has occurred. 005 TCON_ERR 120123132522 120123113645
120123113645 ---------------------
--------------------- 02
(00-99)
005 P_ID-ERR ---------------------
--------------------- -------------
---------------------
-------- ------------
---------------------
--------- 00
1. Press POWER to turn on the TV and then turn it off again. 006 BACKLITE ---------------------
--------------------- -------------
---------------------
-------- ------------
---------------------
--------- 00
007 TEMP_ERR ---------------------
--------------------- -------------
---------------------
-------- ------------
---------------------
--------- 00
2. Press the following
following buttons on the Remote Commander within 1 007 FAN_ERR ---------------------
--------------------- -------------
---------------------
-------- ------------
---------------------
--------- 00
second of each other: 010 EMITTER ---------------------
--------------------- -------------
---------------------
-------- ------------
---------------------
--------- 00
101 VPC_WDT ---------------------
--------------------- -------------
---------------------
-------- -----------
---------------------
---------- 00

DISPLAY Channel 5 Volume - Power I/0 102 MEPS_WDT ---------------------

--------------------- ---------------
---------------------
------ ------------------
---------------------
--- 00
103 HOST_WDT ---------------------
--------------------- ------------
---------------------
--------- -------------
---------------------
-------- 00
104 STBY_WDT ---------------------
--------------------- -------------
---------------------
-------- ------------
---------------------
--------- 00

NOTE: This differs from accessing Service Adjustments Mode (Volume +). 00345 000333 06789

Panel operation time by hour (MAX:65535)

Boot count (MAX:65535)
Total operation time by hour (MAX:65535)

*Format of Error History = YYMMDDhhmmss example 120123132522= Jan 23, 2012 13:25:22 (1:25:22PM)
NOTE: date and time must be set for this to work

SAMPLE SELF CHECK DIAGNOSIS PAGE

KDL-40W590B/40W600B/48W590B/48W600B 4
 SECTION 2 - TROUBLESHOOTING

TRIAGE CHART
Use this general Triage Chart to determine what may possibly be causing the error before going out to the customers location.
1. Confirm the symptom
symptom from the customer.
customer. Red Dot: (Primary) Most likely defective part.
2. Select that symptom
symptom from the chart. Blue Triangle:
Triangle: (Secondary) Possible defective
defective part.
3. Bring the primary component listed for that symptom.
symptom.
4. Follow the associated flowcharts in the Training
Training Manual to isolate the
the board.
5. Chart Color Code.

Symptoms - Shutdown. Power LED blinking No Smart

Video Remote Network Audio
red diagnostics sequences Power Core
Board Reference
No White Steady No Video Wireless Bluetooth
No Video No
2X 3X 4X 5X 6X 7X 8X 9X 10X Power lines or One of
All Inputs
No Remote can't can't
Audio
No LED
LED dots Inputs connect connect

MAIN BOARD ▲  ▲ ▲   ▲ ▲   ▲ ▲ ▲  ▲
TUNER BOARD ▲ ▲  ▲   ▲
LCD PANEL    ▲  ▲
TCON ▲  ▲ ▲ ▲ ▲
LVDS FFC ▲ ▲ ▲ ▲
H BOARD  
SPEAKER ▲ 
LD BOARD  ▲
BT BOARD 
WIFI  

AUDIO/ BACK- SOFT- EMIT-

Problem POWER LD TCON TEMP
POWER LIGHT WARE TER

*NOTE: REFER TO LCD PANELS SERVICE MANUAL IN REFERENCE LIBRARY DATABASE

FOR CORRECT REPLACEMENT PARTS BASED ON SERIAL NUMBER.

To access
access the most recent
recent version of the Triage documents for the models listed
listed in this manual,
manual, login into the Sony Authorized Service Portal
at http://www.sony.com/asp .

KDL-40W590B/40W600B/48W590B/48W600B 5
 SECTION 2 - TROUBLESHOOTING

FLOWCHARTS AND DIAGRAMS

OVERALL BLOCK DIAGRAM

MAIN BOARD

HDMI 1 / MHL
HDMI
HDMI 2 /ARC L
SWITCH
HDMI 3 EQ
AUDIO
AMP
HDMI 4
A/V
R
ETHER DECODER
ETHERNET
PHY
VIDEO
LCD PANEL
USB
PROCESS

USB
USB
HUB HFR
LVDS
TCON

LED BACKLIGHTS

HEADPHONES
AUDIO
TUNER OUT
SWITCH
AMP
TUNER BOARD DEMODULATOR
UNIT
ADC / DACAMP

VIDEO 1 CVBS
OPTICAL
VIDEO 2 CVBS/COMP
AUDIO OUT
OUT

LOCAL DIMMING
LD
TUNER
RF

BAXL

IR RX
SWITCH
WIFI LED’s
UNIT
HJM

AC IN AC ADAPTOR

KDL-40W590B/40W600B/48W590B/48W600B 6
 SECTION 2 - TROUBLESHOOTING

POWER AND CONTROL BLOCK DIAGRAM

LOCAL DIMMING MAIN BOARD

CN2001 CN9101
PWM0 20 2 2 28 B L_
L_ ER
ER R
PWM1 19 3 14 25 GND
IP_REF 18 8 12 24 GND
PWM2 17 4 10 23 GND
AC_MON 16 12 8 22 GND
MAIN_PWR 15 11 4 21 +19.
+1 9.5V
5V(1
(12V
2V))
GND 14 25 3 20 +19.
+1 9.5V
5V(1
(12V
2V))
STBY_+3.3V 13 14 7 19 +19.5V
+19 .5V_SS
_SS(12
(12V) V)
GND 12 24 9 18 +19.5V
+19 .5V_H
_HOLD
OLD(12 (12V)
V)
REG+12V 11 17 11 17 R EG
EG +1
+1 2V
2V
GND 10 23 6 16 GND
19.5V_HOLD 9 18 5 15 GND
GND 8 22 13 14 STBY
ST BY+3+3.3
.3V
V
16 12 AC_O
AC _OFF_
FF_DEDETT PANEL
19.5V_SS 7 19
15 11 POWE
PO WER_ R_ON
ON MODULE
GND 6 16
GND 5 15 1 9 L D_
D_S TB
TBY
+19.5V 4 21 18 8 IP_REF
+19.5V 3 20 17 4 LD_PWM_2
LD_P WM_2 / SPI0_SPI0_2(DATA
2(DATAF)
F)
LD_ERR 2 28 19 3 LD_PWM
LD_ PWM_1 _1 / SPI
SPI0_1
0_1(LA
(LATF)
TF)
LD_STBY 1 9 20 2 LD_PWM_0
LD_PW M_0 /SPI/SPI0_0(E
0_0(EMIT
MIT IN)
NC 30 GND
NC 29 GND
NC 27 BL _O
_ON
NC 26 DIGITA
DIG ITAL_S
L_STBY
TBY
NC 13 T CO
CO N_
N_ ON
ON
NC 10 S A_
A_ MO
MO DE
DE
AC_IN NC 7 F B_
B_REF
1 DC-IN NC 6 LD_PWR_4
LD_PW R_4 / SPI0_
SPI0_RDATA
RDATA / BLU_TE
BLU_TEMP
MP
DC IN
2 DC_GND NC 5 LD_PW
LD_ PWM_3
M_3 / SPI SPI0_3
0_3(CL
(CLKF)
KF)
NC 1 L D_
D_ MO
MO DE
DE _S
_S W
LD

BAXL

KDL-40W590B/40W600B/48W590B/48W600B 7
 SECTION 2 - TROUBLESHOOTING

NO POWER FLOWCHART

No Power

Substitute 19.5V AC
Adaptor with another.

No No Check STBY 3.3V Yes

Does TV turn ON? Is red light blinking Pin 13 CN2001 Is Pin 13 CN2001 Main Board*
on front of TV? LD Board. on 3.3 volts?

Yes Yes

See Standby LED LD Board*

AC Adaptor*
Blinking chart

*For Part Number information, refer to “Section 4 - Exploded View/Part Number Information” on page 17.
17.

KDL-40W590B/40W600B/48W590B/48W600B 8
 SECTION 2 - TROUBLESHOOTING

STANDBY LED BLINKING FLOWCHART

Protect
Shutdown.
Yes TCON
Standby LED 10X
10X Placa
HEM3Principal*
Board
(LCD Panel)*
Blinking

No

Yes
2X Main Board* Yes
10X
9X TunerPrincipal*
Placa
HEM3 Board*
Board

No

No

Yes
3X Main Board* Yes Main Board /
10X
8X HEM3 Board
Wireless LAN Card*

No

No

After a while
while
No No No
4X 5X 6X 7X Check ventilation

Yes Yes Yes Immediately

LCD Panel / TCON

LCD Panel * Main Board*
LD Board * (LCD Panel)*

*For Part Number information, refer to “Section 4 - Exploded View/Part Number Information” on page 17.
17.

KDL-40W590B/40W600B/48W590B/48W600B 9
 SECTION 2 - TROUBLESHOOTING

VIDEO DISTORTION FLOWCHART

Video Distortion

Lines
Is distortion Yes Improper or No Vertical lines Yes move when Yes
across entire missing wide-mode Main Board*
or bars?
screen? colors? changed?

No Yes No No

TCON*
Main Board*
(LCD Panel)

Yes
Any horizontal LCD Panel*
lines?

No

Any single or Yes

isolated vertical LCD Panel*
lines?

No

More than 1 Yes TCON*

vertical band? (LCD Panel)

*For Part Number information, refer to “Section 4 - Exploded View/Part Number Information” on page 17.
17.

KDL-40W590B/40W600B/48W590B/48W600B 10
SECTION 3 - REPAIR INFORMATION

REPAIRING THE TV REMOVING THE LOWER COVER

If the latest Software does not correct the issue, complete the following: 1. Locate and remove all screws from Lower
Lower Cover.
1. Verify the television
television has the symptom the customer
customer indicated.
2. Replace part causing
causing the symptom.
3. Install the latest version of Software
Software (Required for ALL repairs).
4. Perform the required service adjustments
adjustments and checks.
5. Verify the repair resolved the issue.
issue.
K DL
DL -4
-4 0W
0W 59
59 0B
0B /K
/K DL
DL -4
-4 0W
0W 60
60 0B
0B K DL
DL -4
-4 8W
8W 59
59 0B
0B /K
/K DL
DL -4
-4 8W
8W 60
60 0B
0B

2. Firmly detach from areas shown to remove Lower Cover from the TV.
REMOVING THE TABLE TOP STAND
1. Place TV face down on a soft and at surface.

2. Remove 2 screws from Stand Shaft and carefully

carefully detach as shown.

KDL-40W590B/40W600B/48W590B/48W600B 11
 SECTION 3 - REPAIR INFORMATION

REPLACING THE MAIN BOARD / TUNER BOARD

The Main Board used in these models is available for repair. For Part Number 5. Locate and remove screws from the
the Tuner Board and Main Board,
information refer to Section 4 - Exploded View/Part Number Information on then lift to detach.
page 17.
1. Disconnect Harness
Harness from the Main Board.
Board.

6. Install the new Main Board and/or Tuner

Tuner Board and screws.
2. Locate and disconnect all remaining
remaining connectors. 7. Reconnect the LVDS
LVDS Cable and all other connectors.

3. Press down the 2 locking clips and pull LVDS

LVDS cable to release.
8. Update the Software.
After ALL repairs UPDATE
UPDATE the SOFTWARE
SOFTWARE to the latest version.
version.
Instructions are included with the Software package on the Sony
Authorized Service Portal
Portal website.
a. Insert the USB device with the latest Software
Software into one of the TVs’
USB ports.
4. Slide brackets to detach
detach from Main Board.
b. Connect TV to AC power.
power.

Side
c. Wait at least 20 seconds.
seconds.
Bracket

d. Press the Power button

button I/0 on the TV to turn it ON.

e. Wait until the

the Software update is completed.
Under Bracket

KDL-40W590B/40W600B/48W590B/48W600B 12
 SECTION 3 - REPAIR INFORMATION

9. To access Service Mode, turn TV ON and OFF again then press 13. Press MUTE then 0 to save the changes.
the following buttons within 1 second of each other:

DIGITAL SERVICE
DISPLAY Channel 5 Volume + Power I/0
002 MODEL
002 DEST ATSC_UC_BASE
10. When the DIGITAL Menu appears, press 2 until 002 MODEL
category displays. WRITE

14. Press 1 until 003 MODELNAME displays.

DIGITAL SERVICE
002 MODEL
000 BOARD CHECK DIGITAL SERVICE
002 MODEL
003 MODELNAME _________
11. Press 1 until 002 DEST item displays.

DIGITAL SERVICE
15. Press 3 until the model displayed matches the model of the TV.
002 MODEL CAUTION: The Model Name can only be selected once. Be sure
002 DEST ATSC_UC_BASE to verify the information is correct before saving the changes.
16. Press MUTE then 0 to save the changes.

CAUTION: If the incorrect Destination Data Value is selected,

it may corrupt the Sofware requiring a Main Board replacement. DIGITAL SERVICE
002 MODEL
12. Press 3 until the correct destination of the TV displays.
0 03
03 M OD
OD EL
EL NA
NAM E K DL
DL -4
-4 8W
8W5 90
90B
(Use the table below for reference).
WRITE
Model Name Destination Data Value

KDL-40W590B US/CND ATSC_UC_BASE

17. Locate the Serial Number for the TV on the side of the Rear Cover.
KDL-48W600B US/CND ATSC_UC_BASE

KDL-40W590B US/CND ATSC_UC_BASE MODEL NO

KDL-48W600B US/CND ATSC UC BASE KDL-48W590B

SERIAL NO
5000001

KDL-40W590B/40W600B/48W590B/48W600B 13
 SECTION 3 - REPAIR INFORMATION

18. Press 1 until 004 SERIAL item displays. 23. Press 1 until 006 VAR_TYPE item displays.

DIGITAL SERVICE DIGITAL SERVICE

002 MODEL 002 MODEL
004 SERIAL 006 VAR_TYPE

19. Press 0 to display the Serial Number Edit option. 24. Press 3 until UC option displays.

DIGITAL (MODEL) SERVICE

DIGITAL SERVICE
SerialNumberEdit
002 MODEL
*1 SerialNumber 006 VAR_TYPE UC

20. Press to display the Serial Number input screen.

25. Press MUTE then 0 to save the changes.
DIGITAL (MODEL) SERVICE
SerialNumberEdit
*1 SerialNumber DIGITAL SERVICE
Please Input serial number 002 MODEL
(0000000-99999999) 006 VAR_TYPE UC
_______
WRITE
CAUTION: The Serial Number can only be selected once. Be sure
to verify the information is correct before saving the changes.
26. Cycle AC Power (Unplug and plug AC Cord from the outlet).
21. Enter the Serial Number of the TV.
27. Access Service Mode, by pressing the following buttons within
NOTE: If the incorrect Serial Number is entered, press RETURN 1 second of each other:
to go back to the Serial Number input screen and re-enter
the correct number. DISPLAY Channel 5 Volume + Power I/0

22. Press to save the Serial Number

Number..

DIGITAL (MODEL) SERVICE

SerialNumberEdit
*1 SerialNumber

5000001 WRITE

KDL-40W590B/40W600B/48W590B/48W600B 14
 SECTION 3 - REPAIR INFORMATION

28. When the DIGITAL Menu appears, press 2 until 002 MODEL
category displays. DIGITAL (MODEL) SERVICE
Board Check
DIGITAL SERVICE OK
002 MODEL TUNER BOARD OPTION: PCA / HTL
000 BOARD CHECK TUNER BOARD OPTION is changed correctly

CAUTION: If the Main Board is a mismatch to the Tuner Board,

29. Press 0 to select the 000 BOARD CHECK item. a “NG: WRONG COMBINATION OF MAIN BOARD AND TUNER
BOARD” message will display.

DIGITAL (MODEL) SERVICE 31. Press RETURN on the Remote Commander.

Board Check
1. Replace MAIN BOARD (and TUNER BOARD)
When replacing the Tuner Board only:
2. Replace TUNER BOARD only
32. Press 2 to verify the Tuner Board replacement results.

When replacing the Main Board and/or Tuner Board: DIGITAL (MODEL) SERVICE

30. Press 1 to verify the Main Board replacement results. Board Check
OK
NOTE: Either one of the following messages indicates
TUNER BOARD OPTION: STANDARD
a correct process.
CAUTION: If the Tuner Board is a mismatch to the Main Board,
DIGITAL (MODEL) SERVICE a “NG: DIFFERENT KIND OF TUNER BOARD HAS BEEN
CONNECTED” message will display.
Board Check
OK RETURN
33. Press on the Remote Commander.
TUNER BOARD OPTION: STANDARD
34. Turn the TV OFF.

35. Pres
Presss on the Remote Commander and Power button I/0 on TV
to set unit to Shipping Condition.

KDL-40W590B/40W600B/48W590B/48W600B 15
 SECTION 3 - REPAIR INFORMATION

36. Clear the Self Check screen. REMOVING THE SPEAKERS

a. Press POWER to exit Service Mode. 1. Disconnect connectors
connectors from each Speaker,
Speaker, then lift to detach.
b. Press the following
following buttons on the Remote Commander within
1 second of each other:

DISPLAY Channel 5 Volume - Power I/0

SELF CHECK

000 RESERVED --------------------- --------------------- --------------------- 00

000 RESERVED --------------------- --------------------- --------------------- 00 REPLACING THE SWITCH UNIT
002 MAIN_POWE --------------------- ---------------------
--------------------- --------------
---------------------
------- 00
003 DC_ALERT --------------------- --------------------- --------------------- 00
003 AUD_PROT
AUD_PROT --------------------- --------------------- --------------------- 00
1. Disconnect connector
connector from Switch Unit, then lift to detach.
003 HDMI_EQ --------------------- --------------------- --------------------- 00
003 TU_DEMOD --------------------- --------------------- --------------------- 00
004 VLED ----------
---------------
-----------
------ -----
-----------
------------
----------
---- ------
-----------
----------
----------
----- 00
004 LD_ERR
LD_ERR ----------
----------------
-----------
----- -----
-----------
------------
----------
---- -----
----------
----------
-----------
------ 00
005 HFR_ERR --------------------- --------------------- --------------------- 00
005 TCON_ERR 120123132522 120123113645 ---------------------
--------------------- 02 Error Count

005 P_ID-ERR --------------------- --------------------- --------------------- 00

006 BACKLITE --------------------- --------------------- -------------------- 00
007 TEMP_ERR --------------------- --------------------- --------------------- 00
007 FAN_ERR --------------------- --------------------- --------------------- 00 2. Install the new Switch Unit and connector.
connector.
010 EMITTER --------------------- --------------------- --------------------- 00
101 VPC_WDT --------------------- --------------------- --------------------- 00
102 MEPS_WDT --------------------- --------------------- --------------------- 00
103 HOST_WDT --------------------- --------------------- --------------------- 00
104 STBY_WDT
STBY_WDT --------------------- --------------------- --------------------- 00

00345 000333 06789

c. To clear the error history and error count press 8 0 .

d. Press Power I/0 to exit Self Check Mode.

37. Cycle AC Power (Unplug and plug AC Cord from the outlet).

KDL-40W590B/40W600B/48W590B/48W600B 16
SECTION 4 - EXPLODED VIEW/PART NUMBER INFORMATION

Components not identied by a part number or description The component parts of an assembly are indicated by the reference numbers in
TABLE TOP STAND are not stocked because they are seldom required for routine the far right column of the parts list and within the dotted lines of the diagram.
service.
NOTE: The components identied by shading and ! NOTE: The components
components identied
identied by a red outline
outline and a mark contain condential
mark are critical for safety. information. Specic instructions
instructions must be adhered to whenever these components are
Replace only with part number specied. repaired and/or replaced. (See Appendix A)

REF. NO. PART NO. DESCRIPTION

1 4-484-942-01 STAND SHAFT (M)

(KDL-40W590B/40W600B ONLY)
1 4-484-943-01 STAND SHAFT (ML)
(KDL-48W590B/48W600B ONLY)

KDL-40W590B/40W600B/48W590B/48W600B 17
 SECTION 4 - EXPLODED VIEW/PART NUMBER INFORMATION

NOTE: The components identied by shading and ! NOTE: The components

components identied
identied by a red outline
outline and a mark contain condential
KDL-40W590B/48W600B mark are critical for safety.
Replace only with part number specied.
information. Specic instructions
instructions must be adhered to whenever these components are
repaired and/or replaced. (See Appendix A)

REF. NO. PART NO. DESCRIPTION

51 4-476-162-01 BRACKET, SP
52 1-858-963-11 SPEAKER BOX (LEFT)

53 4-532-487-01 LOWER COVER (UNDER COVER 40)

(KDL-40W590B/40W600B ONLY)
53 4-532-488-01 LOWER COVER (UNDER COVER 48)
(KDL-48W590B/48W600B ONLY)

! 54 1-838-955-41 POWER SUPPLY CORD

! 55 1-492-734-11 AC ADAPTOR (85W)
56 1-858-963-21 SPEAKER BOX (RIGHT)

51 *Metal
56
Bridge
Right

*Metal
Bridge
Left

52 51

54

55

53

* Reinstall Metal Bridge Right and Metal Bridge Left

when replacing the LCD Panel.
(KDL-48W590B/48W600B ONLY)

KDL-40W590B/40W600B/48W590B/48W600B 18
 SECTION 4 - EXPLODED VIEW/PART NUMBER INFORMATION

NOTE: The components identied by shading and ! NOTE: The components

components identied
identied by a red outline
outline and a mark contain condential
KDL-40W590B/48W600B mark are critical for safety.
Replace only with part number specied.
information. Specic instructions
instructions must be adhered to whenever these components are
repaired and/or replaced. (See Appendix A)

REF. NO. PART NO. DESCRIPTION

101 1-474-560-11 SWITCH UNIT

102 4-476-164-01 STAND BRACKET

103 4-440-057-01 SHEET, THERMAL (AYU2)

ORDER THIS PART WHEN REPLACING THE MAIN BOARD
AND/OR LD BOARD.
104 4-528-972-01 BRACKET, SIDE

105 A-2037-764-A BAXL BOARD, COMPLETE

AFTER REPLACING THE MAIN BOARD, YOU MUST UPDATE
UPDATE
THE SOFTWARE TO THE LATEST VERSION.

106 4-528-973-01 BRACKET, UNDER

107 A-1998-231-A TUS BOARD, COMPLETE

102
AFTER REPLACING THE TUNER BOARD, YOU MUST UPDATE
103
THE SOFTWARE TO THE LATEST VERSION.
108

108 A-1983-521-A LD BOARD, MOUNTED

(KDL-40W590B/40W600B ONLY)
102
103 108 A-1983-522-A LD BOARD, MOUNTED
107
(KDL-48W590B/48W600B ONLY)
Main Board Plate*
101

106 105
104

* Reinstall Main Board Plate

when replacing the LCD Panel.

KDL-40W590B/40W600B/48W590B/48W600B 19
 SECTION 4 - EXPLODED VIEW/PART NUMBER INFORMATION

NOTE: The components identied by shading and ! NOTE: The components

components identied
identied by a red outline
outline and a mark contain condential
KDL-40W580B/48W580B mark are critical for safety.
Replace only with part number specied.
information. Specic instructions
instructions must be adhered to whenever these components are
repaired and/or replaced. (See Appendix A)

REF. NO. PART NO. DESCRIPTION [ASSEMBLY

[ASSEMBLY INCLUDES]

! 151 NA PANEL MODULE [152, 153]

FOR LCD PANEL AND TCON BOARD PART NUMBER
INFORMATION REFER TO THE LCD PANELS SERVICE MANUAL.

152 4-476-157-11 PANEL, ORNAMENTAL L

(KDL-40W590B ONLY)
152 4-476-157-61 PANEL, ORNAMENTAL L
151
(KDL-40W600B ONLY)

152 4-476-156-11 PANEL, ORNAMENTAL LL

(KDL-48W590B ONLY)
152 4-476-156-61 PANEL, ORNAMENTAL LL
152 (KDL-48W600B ONLY)

153
153 4-527-493-01 BEZEL (40)
(KDL-40W590B/40W600B ONLY)
153 4-527-494-01 BEZEL (48)
(KDL-48W590B/48W600B ONLY)

154 4-476-160-01 COVER, OP L

(KDL-40W590B/40W600B ONLY)
154 4-476-159-01 COVER, OP LL
(KDL-48W590B/48W600B ONLY)

155 A-1979-006-A HJM BOARD, MOUNTED

156
156 1-458-723-11 WIRELESS LAN CARD
155
154

KDL-40W590B/40W600B/48W590B/48W600B 20
 SECTION 4 - EXPLODED VIEW/PART NUMBER INFORMATION

NOTE: The components identied by shading and ! NOTE: The components

components identied
identied by a red outline
outline and a mark contain condential
CONNECTORS mark are critical for safety.
Replace only with part number specied.
information. Specic instructions
instructions must be adhered to whenever these components are
repaired and/or replaced. (See Appendix A)

REF. NO. PART NO. DESCRIPTION

201 1-910-804-48 CONNECTOR ASSEMBLY 20P

202 1-848-217-11 (LVDS) FLEXIBLE FLAT CABLE 51P

(KDL-40W590B/40W600B ONLY)
202 1-848-218-11 (LVDS) FLEXIBLE FLAT CABLE 51P
(KDL-48W590B/48W600B ONLY)

203 1-910-804-49 HARNESS ASSEMBLY

(KDL-40W590B/40W600B ONLY)
203 1-910-804-52 HARNESS ASSEMBLY
(KDL-48W590B/48W600B ONLY)
201

202 203

KDL-40W590B/40W600B/48W590B/48W600B 21
 SECTION 4 - EXPLODED VIEW/PART NUMBER INFORMATION

NOTE: The components identied by shading and ! NOTE: The components

components identied
identied by a red outline
outline and a mark contain condential
SCREWS mark are critical for safety.
Replace only with part number specied.
information. Specic instructions
instructions must be adhered to whenever these components are
repaired and/or replaced. (See Appendix A)

P/N DESCRIPTION KDL-40W590B/40W600B KDL-48W590B/48W600B

Bracket Under to Lower Cover (1) Bracket Under to Lower Cover (1)
2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3
Bracket Side to Lower Cover (1) Bracket Side to Lower Cover (1)

2-990-421-41 SCREW (+PSW) (M3X6) Main Board (6), LD Board (4) Main Board (6), LD Board (4)

Tuner Board (4)

4-256-393-01 SCREW, +PSW M3X6 W12 Tuner Board (4)
Metal Bridge Right (2), Metal Bridge Left (2)

Wireless Lan Card (2), Lower Cover (7),

Lower Cover (6), Main Board Plate (5),
NA 7-685-647-79 SCREW, +BVTP 3X10 TYPE IT-3 OP Cover a Bezel (2), Stand Brackets (2),
OP Cover a Bezel (3), Stand Brackets (2) Main Board Plate (5)

4-159-298-21 SCREW, +PSW M4X10 Brackets Vesa (2) , Stand Brackets (2) Brackets Vesa (2) , Stand Brackets (2)

NA 3-452-815-21 SCREW, +PSW M5X20 Stand to TV (2) Stand to TV (2)

Arm Left
Left to Stand Shaft
Shaft (2),
(2),
NA 2-580-611-01 SCREW, +PSW M6X16 Wall Mount Adapter (3)
Arm Right
Right to Stand Shaft (2)

KDL-40W590B/40W600B/48W590B/48W600B 22
SECTION 5 - ACCESSORIES/PART NUMBER INFORMATION
ACCESSORIES AND PACKAGING
PACKAGING OPTIONAL ACCESSORIES
PART NO. DESCRIPTION PART NO. DESCRIPTION

3-452-815-21 SCREW, +PSW M5X20 4-414-470-01 SUPPORT BELT KIT

(SCREWS TO ATTACH TABLE TOP STAND TO LCD TV)
For product protection and safety reasons, Sony strongly recommends
that you use the screws provided with the TV.
REMOTE COMMANDER
CAUTION: These screws cannot be used to secure the TV
PART NO. DESCRIPTION
to the Wall Mount Brackets.
1-492-767-11 REMOTE COMMANDER (RM-YD103)
4-535-392-01 SCREW, +PSW M6X16
(SCREWS TO ATT
ATTACH
ACH TV TO WALL MOUNT)
4-531-135-01 WALL HUNG BRACKET ASSEMBLY L

4-484-526-01 BRACKET, VESA

4-428-537-01 CLAMPER, AC ADAPTER
3-299-071-08 FLYER, SAFETY

4-489-955-11 MANUAL, INSTRUCTION (ENGLISH VERSION)

4-489-956-31 MANUAL, INSTRUCTION (SPANISH VERSION)
(KDL-40W600B/48W600B ONLY)

MISCELLANEOUS
PART NO. DESCRIPTION

4-100-136-01 SHEET (CORE), C

4-256-454-02 SPACER (G A)

7-600-031-97 TAPE (3M 1350FB-1) 15MMX66M BLK

7-600-031-96 TAPE (3M 1350FW-1) 15MMX66M WHT
3-876-036-71 UNI-LABEL, BLANK

KDL-40W590B/40W600B/48W590B/48W600B 23
APPENDIX A: ENCRYPTION KEY COMPONENTS
Encryption key components developed by Sony Corporation contain condential information and shall be handled under the non-disclosure obligations provided
in the applicable agreement with Sony Corporation (and/or its subsidiary).
As part of this agreement specic instructions must be adhered to whenever
whenever a Circuit
Circuit Board containing encryption key components is repaired and/or replaced
replaced
pursuant to the following:
1. In the service manual the Circuit Board(s) containing encryption key components shall be identied with a red outline and a .
2. Only repair boards or components listed
listed in the service manual
manual shall be utilized
utilized for replacement
replacement and/or repair.
repair.
3. Disassembly,, decryption
Disassembly decryption or reverse-engineering
reverse-engineering component(s) is strictly prohibited.
4. Any board in which
which the Servicer replaces
replaces an encryption key
key component must be placed back into
into the set it orignally
orignally came from and the replaced
defective component MUST BE DESTROYED. Boards cannot be swapped.
5. If a Circuit Board identied with a red outline and a in the service manual is deemed to be defective:
a. and if a core charge is imposed and is covered under the product warranty,
warranty, the defective un-repaired or modied board MUST BE RETURNED to
Sony.
b. and if the core charge is NOT covered under the product warranty, the defective un-repaired or modied board MUST BE DESTROYED.
6. If a unit is destroyed (such as eld scrap), the Circuit Board identied with a red outline and a in the service manual MUST BE DESTROYED.

is a trademark of Sony Electronics.

Reproduction in whole or part without written permission is prohibited. All rights reserved.
Sony Corporation
Sony SSOA English
TV Service Engineering 2014BJ74WEB-1
9-883-590-02 Service Publications Department © 2014.2

KDL-40W590B/40W600B/48W590B/48W600B A-1