Sony BRAVIA KDL-40XBR3 User manual

LCD DIGITAL COLOR TELEVISION
SERVICE MANUAL FIX CHASSIS
MODEL NAME REMOTE COMMANDER DESTINATION
9-883-717-01
KDL-40XBR3 RM-YD013 US/CANADA
KDL-46XBR3 RM-YD013 US/CANADA
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
ORIGINAL MANUAL ISSUE DATE: 8/2006
REVISION DATE SUBJECT
8/2006 No revisions or updates are applicable at this time.

LCD DIGITAL COLOR TELEVISION
SERVICE MANUAL FIX CHASSIS
MODEL NAME REMOTE COMMANDER DESTINATION
9-883-717-01
KDL-40XBR3 RM-YD013 US/CANADA
KDL-46XBR3 RM-YD013 US/CANADA
Self Diagnosis
Supported model
KDL-40XBR3 RM-YD013

3
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
TABLE OF CONTENTS
SECTION TITLE PAGE SECTION TITLE PAGE
Specifications ................................................................................. 4
Warnings and Cautions .................................................................. 6
Safety-Related Component Warning .............................................. 7
Safety Check-Out ........................................................................... 9
Self-Diagnostic Function ............................................................... 10
SECTION 1: DISASSEMBLY ............................................................... 12
1-1. Rear Cabinet Removal ............................................ 12
1-2. Stand Assembly Removal ........................................ 13
1-3. Speaker Removal .................................................... 14
1-4. H1 Board Removal .................................................. 14
1-5. H5 Board Removal .................................................. 15
1-6 G1 Board Removal .................................................. 16
1-7. D1 Board and D2 Board/D3 Board Removal ........... 17
1-8. AU Board Removal .................................................. 18
1-9. BE board, QM Board and HDMI Removal ............... 19
1-10. QT Board Removal .................................................. 20
1-11. H3 Board and H4 Board Removal ........................... 21
1-12. Chassis Bracket Assembly Removal ....................... 22
1-13. LCD Panel Removal ................................................ 23
Wire Dressing Diagrams ............................................................ 24
Overall Assembly (KDL-40XBR3 Only) ........................................ 24
D1 Board .............................................................................. 25
D1 Board and AU Board ....................................................... 26
D1 Board and BE2 Board ..................................................... 27
G1 Board .............................................................................. 28
H1 Board .............................................................................. 29
H4 Board .............................................................................. 30
H5 Board .............................................................................. 31
H5 Board (Continued) .......................................................... 32
Overall Assembly (KDL-46XBR3 Only) ........................................ 33
AC Inlet ................................................................................ 34
AU Board .............................................................................. 35
BE2 Board ............................................................................ 36
D2 Board .............................................................................. 37
D2 Board and G1 Board ....................................................... 38
D3 Board .............................................................................. 39
G1 Board and AU Board ...................................................... 40
H1 Board .............................................................................. 41
H4 Board .............................................................................. 42
H5 Board .............................................................................. 43
Under Heat Sink ................................................................... 44
SECTION 2: SERVICE ADJUSTMENTS ............................................. 45
2-1. Remote Adjustment Buttons and Indicators ......................... 45
2-2. Accessing Service Adjustments ........................................... 45
Service Menus ..................................................................... 47
2-3. White Balance Adjustment ................................................... 48
2-3-1. User Menu Adjustments ........................................... 48
2-3-2. Service Menu Adjustments ...................................... 49
SECTION 3: DIAGRAMS ..................................................................... 50
3-1. Circuit Boards Location ........................................................ 50
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 50
3-4. Block Diagram ...................................................................... 52
3-4. Schematics and Supporting Information .............................. 53
AU Board Schematic Diagram (1 of 7) ................................. 53
AU Board Schematic Diagram (2 of 7) ................................. 54
AU Board Schematic Diagram (3 of 7) ................................. 55
AU Board Schematic Diagram (4 of 7) ................................. 56
AU Board Schematic Diagram (5 of 7) ................................. 57
AU Board Schematic Diagram (6 of 7) ................................. 58
AU Board Schematic Diagram (7 of 7) ................................. 59
BE2 Board Schematic Diagram (1 of 13) ............................. 62
BE2 Board Schematic Diagram (2 of 13) ............................. 63
BE2 Board Schematic Diagram (3 of 13) ............................. 64
BE2 Board Schematic Diagram (4 of 13) ............................. 65
BE2 Board Schematic Diagram (5 of 13) ............................. 66
BE2 Board Schematic Diagram (6 of 13) ............................. 67
BE2 Board Schematic Diagram (7 of 13) ............................. 68
BE2 Board Schematic Diagram (8 of 13) ............................. 69
BE2 Board Schematic Diagram (9 of 13) ............................. 70
BE2 Board Schematic Diagram (10 of 13) ........................... 71
BE2 Board Schematic Diagram (11 of 13) ........................... 72
BE2 Board Schematic Diagram (12 of 13) ........................... 73
BE2 Board Schematic Diagram (13 of 13) ........................... 74
D1 Board Schematic Diagram (KDL-40XBR3 Only) ............ 77
D2 Board Schematic Diagram (KDL-46XBR3 Only) ............ 79
D3 Board Schematic Diagram (KDL-46XBR3 Only) ............ 81
G1 Board Schematic Diagram ............................................. 83
H1 Board Schematic Diagram .............................................. 86
H3 Board Schematic Diagram .............................................. 88
H4 Board Schematic Diagram .............................................. 90
H5 Board Schematic Diagram (1 of 2) ................................. 92
H5 Board Schematic Diagram (2 0f 2) ................................. 93
QM Board Schematic Diagram (1 of 5) ................................ 96
QM Board Schematic Diagram (2 of 5) ................................ 97
QM Board Schematic Diagram (3 of 5) ................................ 98
QM Board Schematic Diagram (4 of 5) ................................ 99
QM Board Schematic Diagram (5 of 5) .............................. 100
QT Board Schematic Diagram ........................................... 102
3-5. Semiconductors ................................................................. 105
SECTION 4: EXPLODED VIEWS ...................................................... 106
4-1. Rear Cabinet and Stand Assembly ................................... 106
4-2. Arm Assemblies and H Boards ......................................... 107
4-3. Chassis ............................................................................. 108
4-4. Chassis Bracket and Speakers .......................................... 109
4-5. LCD Panel ...........................................................................110
SECTION 5: ELECTRICAL PARTS LIST ...........................................111

4
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
SPECIFICATIONS
Design and specifications are subject to change without notice.
120V-240V AC, 50/60Hz
227W (KDL-40XBR3 Only)
277W (KDL-46XBR3 Only)
Less than 0.1W
VIDEO (IN) 1/2/4:
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
1.0 Vp-p, 75ohms unbalanced, sync negative
Audio
500 mVrms (100% modulation)
Impedance:47 kilohms
HD/DVD IN 5/6:
YPBPR (Component Video)
Y:1.0 Vp-p, 75 ohms unbalanced, sync negative
PB:0.7 Vp-p, 75 ohms
PR:0.7 Vp-p, 75 ohms
Signal format: 480i, 480p, 720p, 1080i
AUDIO
500 mVrms (100% modulation)
Impedance: 47 kilohms
Power Requirements
Power Consumption (W)
In Use (Max)
In Standby
HDMI IN 3/7/8:
HDMI: Video:480i, 480p, 720p, 1080i. 1080p
Audio: Two channel linear PCM 32, 44.1 and
48 kHz, 16, 20 and 24 bits
AUDIO (for HDMI IN 8):
500 mVrms (100% modulation) (Fixed)
Impedance: 47 kilohms
AUDIO OUT:
500 mVrms (100% modulation) (Fixed)
1 Vrms at the maximum volume setting (Variable)
DIGITAL OUT (OPTICAL):
PC IN:
D-sub 15-pin, analog RGB, 0.7 Vp-p, 75 ohms, positive
PC AUDIO INPUT:
Stereo mini jack, 500 mVrms (100% modulation),
Impedance: 47 kilohms
HEADPHONES:
Stereo mini jack
Impedance: 16 ohms
Trademark Information
TruSurround XT, SRS and ( ) symbol are trademarks of SRS Labs, Inc.
TruSurround XT technology is incorporated under license from SRS Labs,
Inc.
Manufactured under license from BBE Sound, Inc.
Licensed by BBE Sound, Inc. under one or more of the following US
patents: 5510752, 5736897. BBE and BBE symbol are registered
trademarks of BBE Sound, Inc.
Macintosh is a trademark licensed to Apple Computer, Inc., registered in
the U.S.A and other countries.
“BRAVIA” and are trademarks of Sony Corporation.
As an ENERGY STAR® Partner, Sony Corporation has
determined that this product meets the ENERGY STAR®
guidelines for energy efficiency.
ENERGY STAR® is a U.S. registered mark.
This TV incorporates High-Definition
Multimedia Interface (HDMI™) technology.
HDMI, the HDMI logo and High-Definition Multimedia Interface are
trademarks or registered trademarks of HDMI Licensing, LLC.
Manufactured under license from Dolby
Laboratories. “Dolby” and the double-D symbol are
trademarks of Dolb
y
Laboratories.

5
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
Television system
American TV Standard
ATSC (8VSB terrestrial) ATSC compliant 8VSB
QAM on cable ANSI/SCTE 07 2000
Channel coverage
Analog
2-69 Terrestrial
1-125 Cable
Digital
2-69 Terrestrial
1-135 Cable
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)
KDL-40XBR3 - 40 inches
KDL-46XBR3 - 46 inches
Supplied Accessories
Remote Commander RM-YD013
Two Size AA (R6) Batteries
75-ohm coaxial cable
AC Power Cord
HD15-HD15 Cable
Suport Belt, Securing Screw, and Wood Screw
Cable Holder
Operating Instructions
Quick Setup Guide
Warranty Card
Optional Accessories
Headphones Plug Adaptor
Connecting Cables
Wall-Mount Bracket
SU-WL51
 




  
 
!"

  
 

"#$  
 

"#$   
 
%
"#$  
 
"#$  
 


6
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
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!!
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.
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.
Afin d’evite�
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.

7
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
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 sc�
specified in the electrical parts list to prevent electric shock, fire, or other hazard.
NOTE: Do no�
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

8
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
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
91-500-046-7 mm3.0 gK52.0
02-500-046-7 mm4.0 gK05.0
12-500-046-7 mm5.0 gK05.0
22-500-046-7 mm6.0 gK52.0
32-500-046-7 mm8.0 gK00.1
42-500-046-7 mm0.1 gK00.1
52-500-046-7 mm2.1 gK00.1
62-500-046-7 mm6.1 gK00.1

9
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
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.

10
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
SELF-DIAGNOSTIC FUNCTION
Self Diagnosis
Supported model
Control Buttons
POWER
CHANNEL
VOLUME
TV/VIDEO
MENU
POWER
CHANNEL
VOLUME
TV/VIDEO
MENU
PIC OFF/TIMER STANDBY POWER
PIC OFF/TIMER STANDBY POWER
Description of LED Indictors
LED LED Type Description
* Light when the TV set is on
* Functions as failure indicator
STANDBY LED
PIC OFF/TIMER
LED
* Lights up in red when TV is in PC standby mode.
* Lights up when Picture Off is activated
* Lights up in orange when the timer is set
When timer is set, the LED remains lit even
when the TV is turned off.
POWER LED
Green LED
Green LED
Red LED

11
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
The units in this manual contain a self-diagnostic function. If an error occurs, the POWER 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 POWER LED flash indicators is listed in the instruction manual for
the user’s knowledge and reference. If an error symptom is difficult to reproduced use the Remote Commander to display the record that is stored at
the internal NVM to specify the cause of the failure.
Diagnostic Test Indicators
When an error occurs, the POWER 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. If the errors occur simultaneously, the one that corresponds to the fewest flashes is identified first.
Results for all of the following diagnostic items are displayed on screen. No error has occurred if the screen displays a “0”.
1. TV must be in standby mode. (Power off).
2. Press the following buttons on the Remote Commander within a second of each other:
DISPLAY Channel 5 Volume - TV POWER .
The Self Check list displays.
This differs from accessing Service Adjustments.
 




   
   
   
    
    
   
   
   
   
   


12
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
SECTION 1: DISASSEMBLY
1-1. REAR CABINET REMOVAL
Rear Cabinet Assembly
5
4
32
1
Two screws
(+PSW M5X12)
Two screws
(+BVST 4X12)
One screw
(+BVST 4X8)
One screw
(+BVTP 3X12)
Fourteen screws
(+BVTP2 4X16)

13
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
1-2. STAND ASSEMBLY REMOVAL
Stand assembly
Arm assembly (L)
Arm assembly (R)
1
2
3
Two screws
(+PSW M5X12)
1
Two screws
(+PSW M5X12)
Two screws
(+BVST 4X12)
2
Two screws
(+BVST 4X12)
One screw
(+BVST 4X12)
3
One screw
(+BVST 4X12)
Critical: Must be laying flat before removing brackets.

14
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
1-3. SPEAKER REMOVAL
1-4. H1 BOARD REMOVAL
Loudspeaker
Loudspeaker
1
One screw
(+PWTP2 4X16)
1
One screw
(+PWTP2 4X16)
Control button assembly
H1 Board
1
One screw
(+BVTP 4X16)
Disconnect CN3001 from H1 Board

15
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
1-5. H5 BOARD REMOVAL
Side terminal assembly
H5 board
1
Two screws
(+BVTP 4X12)
2
Two screws
(+BVTP 3X12 TYPE2 IT-3)
Release connector wire from wire holders
Disconnect CN3100

16
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
1-6 G1 BOARD REMOVAL
G1 board
1
Five screws
(+BVST 3X8)
Release wires from Wire Holders
on A6501, A6205 and A6013
Use tweezers pinch in white PCB holder
to release G1 Board
Disconnect CN6501, CN6502, CN6204,
CN6203, CN 6202 and CN6001

17
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
1-7. D1 BOARD AND D2 BOARD/D3 BOARD REMOVAL
D3 (46XBR3)
D2 (46XBR3)
D1 (40XBR3)
2
Two screws
(+BVST 3X8)
1
Two screws
(+BVST 3X8)
Release wires from
Wire Holder on A6604
Disconnect CN6700, CN6754, CN6752,
CN6753, CN6751 and CN6600
Use tweezers to pinch in
white PCB holder
to release D2(D1) Board
Use tweezers to pinch in
the white PCB holder
to release the D3 Board
Release wires from
Wire Holders on A6806
Disconnect CN6900,
CN6901, CN6902
and CN6800

18
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
1-8. AU BOARD REMOVAL
AU board
1
Six screws
(+BVST 3X8)
Disconnect CN8801, CN9204, CN9209, CN9210,
CN9211, CN9212 and CN9213

19
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
1-9. BE2 BOARD, QM BOARD AND HDMI REMOVAL
BE2 board
QM board
Digital shield (LOWER)
Digital shield (UPPER)
HDMI terminal holder
1
2
5
4
6
7
3
8
One screw
(+BVTP2 4X16)
Four screws
(+BVST 3X8)
Four screws
(+BVST 3X8)
Two screws
(+BVST 3X8)
One screw
(+BVTP2 4X16)
One screw
(+BVST 3X8)
Two screws
(+PSW M3X5)
Two screws
(+PSW M3X5)
Disconnect CN4001, CN4002,
CN4004 and CN4201
Disconnect CN7601, CN7306 and CN7802

20
KDL-40XBR3/46XBR3
KDL-40XBR3/46XBR3
1-10. QT BOARD REMOVAL
QT board
Antenna
Tuner shield (UPPER)
Tuner shield (LOWER)
1
2
Four screws
(+BVST 3X8)
Four screws
(+BVST 3X8)
Disconnect CN7803 and CN7800