Sony Bravia KDL-40S4100 User manual

LCD DIGITAL COLOR TELEVISION
SERVICE MANUAL FX CHASSIS
MODEL NAME REMOTE COMMANDER DESTINATION
9-883-778-02
KDL-40S4100 RM-YD025 CANADA
KDL-40S4100 RM-YD025 MEXICO
KDL-40S4100 RM-YD025 US
KDL-46S4100 RM-YD025 CANADA
KDL-46S4100 RM-YD025 MEXICO
KDL-46S4100 RM-YD025 US
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
ORIGINAL MANUAL ISSUE DATE: 4/2008
☛
:UPDATED ITEM
REVISION DATE SUBJECT
4/2008 No revisions or updates are applicable at this time.
5/2008 Reissue entire service manual to include PWBs.

LCD DIGITAL COLOR TELEVISION
SERVICE MANUAL FX CHASSIS
MODEL NAME REMOTE COMMANDER DESTINATION
9-883-778-02
KDL-40S4100 RM-YD025 CANADA
KDL-40S4100 RM-YD025 MEXICO
KDL-40S4100 RM-YD025 US
KDL-46S4100 RM-YD025 CANADA
KDL-46S4100 RM-YD025 MEXICO
KDL-46S4100 RM-YD025 US
Self Diagnosis
Supported model
KDL-40S4100 RM-YD025

3
KDL-40S4100/46S4100
KDL-40S4100/46S4100
TABLE OF CONTENTS
Specifications ................................................................................. 4
Warnings and Cautions - ENGLISH ............................................... 6
Warnings and Cautions - FRENCH ................................................ 7
Safety-Related Component Warning .............................................. 8
Safety Check-Out ......................................................................... 10
Self-Diagnostic Function................................................................11
SECTION 1: DISASSEMBLY............................................................... 12
1-1. Rear Cover Removal............................................................ 12
1-2. Function Key Removal ......................................................... 12
1-3. A Board and G Board Removal............................................ 13
1-4. Stand Assembly and Under Cover Removal........................ 14
1-5. AC Inlet and Bracket Removal ............................................. 14
1-6. Structural Frames and Brackets Removal
(KDL-40S4100 Only)............................................................ 15
1-7. Structural Frames and Brackets Removal
(KDL-46S4100 Only)............................................................ 16
1-8. LoudspeaKer Removal......................................................... 17
1-9. Bottom Cover, H2 Board, H3 Board and Lens LED Removal17
1-10.LCD Panel Removal............................................................. 18
1-11. Balancer (ETC-Inverter MT) Board Removal ....................... 19
Wire Dressing ............................................................................... 20
Overall View ......................................................................... 20
SECTION 2: SERVICE ADJUSTMENTS............................................. 21
2-1. Resetting to Factory Defaults after Board Replacement...... 21
SECTION 3: DIAGRAMS..................................................................... 22
3-1. Circuit Boards Location ........................................................ 22
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 22
3-3. Block Diagram...................................................................... 24
3-4. Schematics and Supporting Information .............................. 25
A Board Schematic Diagram (1 of 19).................................. 25
A Board Schematic Diagram (2 of 19).................................. 26
A Board Schematic Diagram (3 of 19).................................. 27
A Board Schematic Diagram (4 of 19).................................. 28
A Board Schematic Diagram (5 of 19).................................. 29
A Board Schematic Diagram (6 of 19).................................. 30
A Board Schematic Diagram (7 of 19).................................. 31
A Board Schematic Diagram (8 of 19).................................. 32
A Board Schematic Diagram (9 of 19).................................. 33
A Board Schematic Diagram (10 of 19)................................ 34
A Board Schematic Diagram (11 of 19)................................ 35
A Board Schematic Diagram (12 of 19)................................ 36
A Board Schematic Diagram (13 of 19)................................ 37
A Board Schematic Diagram (14 of 19)................................ 38
A Board Schematic Diagram (15 of 19)................................ 39
A Board Schematic Diagram (16 of 19)................................ 40
A Board Schematic Diagram (17 of 19)................................ 41
A Board Schematic Diagram (18 of 19)................................ 42
A Board Schematic Diagram (19 of 19)................................ 43
G Board Schematic Diagram (1 of 3) ................................... 46
G Board Schematic Diagram (2 of 3) ................................... 47
G Board Schematic Diagram (3 of 3) ................................... 48
H1 Board Schematic Diagram.............................................. 51
H2 Board Schematic Diagram.............................................. 52
H3 Board Schematic Diagram.............................................. 53
SECTION 4: EXPLODED VIEWS........................................................ 54
4-1. Rear Cover Assembly and Stand Assembly ........................ 54
4-2. Chassis ................................................................................ 55
4-3. Bezel Assembly and LCD Panel (KDL-40S4100 Only) ........ 56
4-4. Bezel Assembly and LCD Panel (KDL-46S4100 Only) ........ 57
4-5. Screw Legend ...................................................................... 58
APPENDIX A: ENCRYPTION KEY COMPONENTS..........................A-1
SECTION TITLE PAGE SECTION TITLE PAGE

4
KDL-40S4100/46S4100
KDL-40S4100/46S4100
SPECIFICATIONS
Design and specifications are subject to change without notice.
120V - 240V AC, 50/60Hz
VIDEO (IN) 1/2:
S Video (4-Pin Mini DIN) (Video 1 only)
Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative
C: 0.286 Vp-p (Burst signal), 75 ohms
Video
1 Vp-p, 75 ohms unbalanced, sync negative
Audio
500 mVrms (100% modulation)
Impedance:47 kilohms
COMPONENT IN 1/2:
YPBPR(Component Video)
Y:1.0 Vp-p, 75 ohms unbalanced, sync negative
P
B:0.7 Vp-p, 75 ohms
P
R:0.7 Vp-p, 75 ohms
Signal format: 480i, 480p, 720p, 1080i, 1080p
Audio
500 mVrms (100% modulation)
Impedance: 47 kilohms
Power Requirements HDMI IN 1/2/3:
HDMI
Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p
Audio: Two channel linear PCM 32, 44.1, and 48 kz,
16, 20 and 24 bits
Audio (HDMI IN 1 only):
500 mVrms (100% modulation)
Impedance: 47 kilohms
AUDIO OUT:
500 mVrms (100% modulation)
More than 500 mVrms (Fixed)
DIGITAL AUDIO OUT (OPTICAL):
Optical Digital Audio Output (PCM/Dolby Digital)
PC IN:
Analog RGB (D-sub 15-pin):
0.7 Vp-p, 75 ohms, positive
Audio (Stereo mini jack):
500 mVrms
Impedance: 47 kilohms
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5
KDL-40S4100/46S4100
KDL-40S4100/46S4100
KDL-40S4100 KDL-46S4100
in use 210W 260W
in standby Less than 1.0 W Less than 1.0 W
10W + 10W 10W + 10W
mm 57.5 x 126 65 x 147
in 23/8 x 5 2 5/8 x 5 7/8
with stand
mm 997 x 689 x 276 1130 x 784 x 308 mm
in 39 3/8 x 27 1/4 x 10 7/8 44 1/2 x 30 7/8 x 12 1/4
without stand
mm 997 x 652 x 111 1130 x 746 x 115
in 39 3/8 x 253/4 x 43/8 44 1/2 x 29 3/8 x 4 5/8
Mass
with stand
kg 22.7kg 30kg
lbs 50 lbs 1 oz 66 lbs 3 oz
without stand
kg 19.9kg 26.5 kg
lbs 43 lbs 14 oz 58 lbs 7 oz
All measurements are approximations.
Dimensions (W x H x D)
Power Consumption
Speaker Output (W)
Dimensions (W x H x D)
Television system
NTSC American TV Standard
ATSC (8VSB terrestrial) ATSC compliant 8VSB
QAM on cable ANSI/SCTE 07 2000
Channel coverage
Analog Digital
Terrestrial 2-69 2-69
Cable 1-135 1-135
Antenna
75-ohm external terminal for VHF/UHF
Panel System
LCD (Liquid Crystal Display) Panel
Display Resolution (horizontal x vertical):
1,920 dots x 1,080 lines
Screen Size (measured diagonally)
approx. 40 inches (KDL-40S4100 only)
approx. 46 inches (KDL-46S4100 only)
Supplied Accessories
Remote Commander RM-YD025
Two Size AA (R6) Batteries
AC Power Cord
Table-Top Stand
Screws (4)
Cable Band
Operating Instructions
Quick Setup Guide
Warranty Card
Online Registration Card (US only)
Optional Accessories
Connecting Cables
Support Belt Kit
Wall-Mount Bracket
SU-WL500
TV Stand
WS-S10LS/SU-FL300M (KDL-40S4100 only)
WS-S10LS/SU-FL300M/SU-FL300L (KDL-46S4100 only)

6
KDL-40S4100/46S4100
KDL-40S4100/46S4100
WARNINGS AND CAUTIONS - ENGLISH
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.
CARRYING THE TV
To avoid dropping the TV and causing serious injury, be sure to follow
these guidelines:
Before carrying the TV, disconnect all cables.
Carrying the large size TV requires two or more people.
When you carry the TV, place your hand as illustrated and hold it
securely. Do not put stress on the LCD panel.
When lifting or moving the TV, hold it firmly from the bottom. Place
your palm directly underneath but do not squeeze the panel’s speaker
grille area.
When carrying, do not subject the TV to shocks or vibration, or
excessive force.
When carrying the TV, to avoid pinching your hands or fingers do not
put your hands between the TV and stand, or hold the bottom corner
of the TV.
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!!
Components identified by shading and ! mark on the schematic diagrams, exploded views, and in the parts list are critical for safe operation. Replace
these components with Sony parts whose part numbers appear as shown in this manual or in supplements published by Sony. Circuit adjustments that
are critical for safe operation are identified in this manual. Follow these procedures whenever critical components are replaced or improper operation is
suspected.

7
KDL-40S4100/46S4100
KDL-40S4100/46S4100
WARNINGS AND CAUTIONS - FRENCH
ATTENTION!!
Ces instructions de service sont à l’usage du personnel de service qualifié seulement. Pour prévenir le risque de choc électrique, ne pas faire
l’entretien autre que celui contenu dans le Mode d’emploi à moins que vous soyez qualifié faire ainsi.
TRANSPORTER LE TÉLÉVISEUR
Pour éviter d’échapper le téléviseur et de causer des blessures graves,
assurez-vous de suivre ces directives :
Il faut deux personnes ou plus pour transporter le téléviseur de grande
dimension.
Lorsque vous transportez le téléviseur, placez votre main tel qu’illustré
et tenez-le fermement. N’imposez pas de charge sur le panneau ACL.
Lorsque vous transportez le téléviseur, ne le soumettez pas à des chocs,
à des vibrations ou à une force excessive.
Lorsque vous soulevez ou déplacez le téléviseur, tenez-le fermement à
partir du bas. Placez votre paume directement en dessous, mais
n’appuyez pas sur le panneau avant ou la région encastrée.
Lorsque vous transportez le téléviseur, pour éviter de pincer vos mains
ou vos doigts, ne placez pas vos mains entre le téléviseur et le suppor
ou ne tenez pas le coin inférieur du téléviseur.
Avant de transporter le téléviseur, débranchez tous les câbles.
Afin d’eviter tout risque d’electrocution provenant d’un chássis sous tension, un transformateur d’isolement doit etre utilisé lors de tout dépannage. Le
chássis de ce récepteur est directement raccordé à l’alimentation du secteur.
!ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!!
Les composants identifies par une trame et par une marque ! sur les schemas de principe, les vues explosees et les listes de pieces sont d’une
importance critique pour la securite du fonctionnement. Ne les remplacer que par des composants Sony dont le numero de piece est indique dans le
present manuel ou dans des supplements publies par Sony. Les reglages de circuit dont l’importance est critique pour la securite du fonctionnement
sont identifies dans le present manuel. Suivre ces procedures lors de chaque remplacement de composants critiques, ou lorsqu’un mauvais
fonctionnement suspecte.

8
KDL-40S4100/46S4100
KDL-40S4100/46S4100
SAFETY-RELATED COMPONENT WARNING
There are critical components used in LCD color TVs that are important for safety. These components are identified with shading and
!
mark on the schematic diagrams and the electrical parts list. It is essential that these 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 installing the LCD panel on a wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.
To avoid damaging the LCD panel:
 do not press on the panel or frame edge to avoid the risk of electric shock.
do not scratch or press on the panel with any sharp objects.
do not leave the module in high temperatures or in areas of high humidity for an extended period of time.
do not expose the LCD panel to direct sunlight.
avoid contact with water. It may cause a short circuit within the module.
disconnect the AC adapter when replacing the backlight (CCFL) or inverter circuit.
(High voltage occurs at the inverter circuit at 650Vrms.)
always clean the LCD panel with a soft cloth material.
use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short.
protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
LEAKAGE CURRENT HOT CHECK CIRCUIT

9
KDL-40S4100/46S4100
KDL-40S4100/46S4100
The circuit boards used in these models have been processed using
Lead Free Solder. The boards are identified by the LF logo located
close to the board designation e.g. H1 etc [ see example ]. The
servicing of these boards requires special precautions to be taken as
outlined below.
example 1
It is strongly recommended to use Lead Free Solder material in order to guarantee optimal quality of new solder joints.
Lead Free Solder is available under the following part numbers :
Due to the higher melting point of Lead Free Solder the soldering iron tip temperature needs to be set to 370 degrees centigrade.
This requires soldering equipment capable of accurate temperature control coupled with a good heat recovery characteristics.
For more information on the use of Lead Free Solder, please refer to
http://www.sony-training.com
rebmuntraP retemaiD skrameR
91-500-046-7mm3.0gK52.0
02-500-046-7mm4.0gK05.0
12-500-046-7mm5.0gK05.0
22-500-046-7mm6.0gK52.0
32-500-046-7mm8.0gK00.1
42-500-046-7mm0.1gK00.1
52-500-046-7mm2.1gK00.1
62-500-046-7mm6.1gK00.1

10
KDL-40S4100/46S4100
KDL-40S4100/46S4100
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 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).
To Exposed Metal
Parts on Set
0.15 μF
Earth Ground
AC
Voltmeter
(0.75V)
Trouble Light
AC Outlet Box Ohmmeter
Cold-water Pipe
Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.

11
KDL-40S4100/46S4100
KDL-40S4100/46S4100
SELF-DIAGNOSTIC FUNCTION
Self Diagnosis
Supported model
IMPORTANT:
The units in this manual DO NOT contain a self-diagnostic function. If an error occurs, the TV will not stay on. It is our recommendation that if a repair
is required for this set, the technician should bring both the A Board and the G Board to the customer location.
Control Buttons
TIMER STANDBY POWER
Description of LED Indictors
The units in this manual DOES NOT contain a self-diagnostic function.

12
KDL-40S4100/46S4100
KDL-40S4100/46S4100
1-1. REAR COVER REMOVAL
SECTION 1: DISASSEMBLY
1Remove 2 screws from HDMI connectors
2Remove 2 screws from terminal positions
3Remove 6 screws
4Remove 19 screws
1-2. FUNCTION KEY REMOVAL
1Remove 2 screws
2Release hooks and remove Function Key and H1 Board
3Disconnect 1 connector
4Remove 1 screw and release Ground Wire
Rear Cover
3
4
2
1
Bezel
Key Cover
Function Key
H1 Board
2
3
4
1

13
KDL-40S4100/46S4100
KDL-40S4100/46S4100
1-3. A BOARD AND G BOARD REMOVAL
1Disconnect 4 connectors
2Remove 1 screw from Side Bracket
3Remove 1 screw from HDMI position
4Remove 2 screws
5Remove 8 screws
6Remove Hexagon Nut from tuner
7Remove 1 screw
8Remove 9 screws (KDL-40S4100 ONLY)
Remove 10 screws (KDL-46S4100 ONLY)
9Disconnect 4 connectors
10 Remove 8 screws (KDL-46S4100 ONLY)
11 Disconnect 6 connectors (KDL-46S4100 ONLY)
12 Remove 8 screws (KDL-40S4100 ONLY)
13 Disconnect 6 connectors (KDL-40S4100 ONLY)
5
4
2
3Main Shield
Side Bracket
A Board
Main Bracket
Bezel
8
9
7
6
10
11
13
12
1
G Board G Board
KDL-40S4100 KDL-46S4100

14
KDL-40S4100/46S4100
KDL-40S4100/46S4100
1-5. AC INLET AND BRACKET REMOVAL
1Remove 1 screw
2Remove 1 screw and release Earth Terminal
3Remove AC Inlet from Bracket
1-4. STAND ASSEMBLY AND UNDER COVER REMOVAL
1Remove 4 screws
2Remove 2 screws
2
1
Stand Assembly
Bottom Bracket
Under Cover
3
1
2
Earth Terminal
Bottom Bracket
AC Inlet
AC Bracket

15
KDL-40S4100/46S4100
KDL-40S4100/46S4100
1-6. STRUCTURAL FRAMES AND BRACKETS REMOVAL (KDL-40S4100 ONLY)
1Remove 1 screw from Main Bracket
2Remove 4 screws from Main Bracket and Spine frame
3Remove 4 screws from both Top Vesa Brackets
4Remove 2 screws from Vesa Bracket Support
5Remove 4 screws from both Spine Frames
6Remove 2 screws from both Spine Frames
7Remove 1 screw from G Board Support
8Remove 4 screws from both Bottom Vesa Brackets
9Remove 4 screws from Bottom Bracket
12
3
7
56
9
4
8
Main Bracket
Vesa Bracket (Top)
Spine Frame
Vesa Bracket
Support
Vesa Bracket (Bottom)
G Board Support
Bezel

16
KDL-40S4100/46S4100
KDL-40S4100/46S4100
1-7. STRUCTURAL FRAMES AND BRACKETS REMOVAL (KDL-46S4100 ONLY)
1Remove 1 screw from Main Bracket
2Remove 2 screws from Main Bracket and Spine frame
3Remove 2 screws from Top Vesa Bracket
4Remove 2 screws from G Board Support 1
5Remove 2 screws from G Board Support 2
6Remove 2 screws from Vesa Bracket Support
7Remove 10 screws from Spine Frames
8Remove 4 screws from both Bottom Vesa Brackets
9Remove 4 screws from Bottom Bracket
1
2
5
4
3
6
7
8
Main Bracket
Top Vesa Bracket
G Board
Suport 2
G Board
Support 1
Vesa Bracket
Support
9
Bezel
Bottom Bracket
Bottom Vesa Bracket
Spine Frame
Spine Frame

17
KDL-40S4100/46S4100
KDL-40S4100/46S4100
1-8. LOUDSPEAKER REMOVAL
1Remove 4 screws from each speaker
1-9. BOTTOM COVER, H2 BOARD, H3 BOARD AND LENS LED REMOVAL
1Remove 2 screws
2Disconnect 1 connector and slide out H3 (LED) Board
3Disconnect 1 connector and remove 1 screw from H2 (IR) Board
4Remove 4 screws
Speakers
1
1
Bottom Cover
H3 (LED) Board
H2 (IR) Board
Lens LED 2
1
4
3

18
KDL-40S4100/46S4100
KDL-40S4100/46S4100
1-10. LCD PANEL REMOVAL
1Disconnect 2 connectors
2Remove 2 screws
Bezel
LCD Panel
12

19
KDL-40S4100/46S4100
KDL-40S4100/46S4100
1-11. BALANCER (ETC-INVERTER MT) BOARD REMOVAL
1Remove 8 screws (KDL-40S4100 ONLY)
Remove 7 screws (KDL-46S4100 ONLY)
2Pull out the board from Lamp Socket
1
2
Cover
Balancer Board
LCD Panel
Balancer (ETC-Inverter MT) Board
(ETC-Inverter MT) Board
WARNIN
G
NEVER REMOVE THE
SCREWS SECURING THE
PLASTIC STRIP HOLDING
THE LAMP SOCKETS
DAMAGE TO THE
BACKLIGHT TUBES WILL
!
OCCUR!
REMOVE SCREWS
SECURING
SHIELD
SHIELD REMOVAL
BALANCER (ETC-INVERTER) BOARD REMOVAL
WARNING
NEVER REMOVE THE
SCREWS SECURING THE
PLASTIC STRIP HOLDING
THE LAMP SOCKETS
DAMAGE TO THE
BACKLIGHT TUBES WILL
Only remove the screws securing the inverter
cover which may be metal or plastic. The
remaining plastic strip contains sockets for the
fluorescent backlights and should never be
loosened. The backlights will pop out of the
sockets and/or break the backlight requiring a
LCD panel replacement.
REMOVE
CONNECTOR AND
PULL BOARD TO
THE RIGHT
!
.
OCCUR!
END VIEW
SOCKET

20
KDL-40S4100/46S4100
KDL-40S4100/46S4100
WIRE DRESSING
OVERALL VIEW
INV
G
T-CON
H2
SP
SP
A
7P
14P
7P
3P
6P
6P
H1
4P
2P2P
9P6P
7P
14P
4P
H3