Sony KDL-40R354B User manual

SERVICE MANUAL
Version Date Subject
1.0 8/2014 Original manual issue.
2.0 9/2014 Add model KDL-32R304B
LCD Digital Color TV
9-888-164-02
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
ORIGINAL MANUAL ISSUE DATE: 9/2014 Chassis Name : RB2TP
Segment Name : MB

2
MODEL LIST
MODEL COLOR COMMANDER DEST. MODEL COLOR COMMANDER DEST.
KDL-40R354B Black RM-YD093 CHILE, PERU
KDL-32R304B Black RM-YD093 CHILE, PERU
KDL-32R304B CL3 /KDL-40R354B CL3

Table of content
3
Description Page
WARNINGS AND CAUTIONS………………………………………… 4
USE CAUTION WHEN HANDLING THE LCD PANEL…………… 5
SAFETY CHECK-OUT………………………………………………… 6
SELF DIAGNOSIS FUNCTION……………………………………… 8
SERVICE POSITION…………………………………………………… 9
SEC 1. DISASSEMBLY AND PARTS LIST…………………………… 11
1-1. KDL-32R304B CL3……………………………………………… 12
1-1-1. BASE STAND……………………………………………… 12
1-1-2. REAR COVER ……………………………………………… 13
1-1-3. POWER BOARD, A BOARD AND SPEAKER ………… 14
1-1-4. LCD PANEL, DECO and COVER, BOTTOM ………… 15
1-1-5. MISCELLANEOUS………………………………………… 16
1-2. KDL-40R354B CL3…………………………………………….… 17
1-2-1. BASE STAND……………………………………………… 17
1-2-2. REAR COVER ……………………………………………… 18
1-2-3. POWER BOARD, A BOARD AND SPEAKER ………… 19
1-2-4. LCD PANEL, DECO and COVER, BOTTOM ………… 20
1-2-5. MISCELLANEOUS………………………………………… 21
1-3. How to disassemble rear cover [KDL-32R304B CL3 /KDL-40R354B
CL3] …………………………………………………………….……….... 22
1-4. How to disassemble Deco [KDL-32R304B CL3 /KDL-40R354B
CL3] …………………………………………………….…………………. 23
1-5. How to disassemble LVDS cable [KDL-32R304B CL3 /KDL-
40R354B CL3] ……………………………………………………………. 24
1-6. How to disassemble IR Board [KDL-32R304B CL3 /KDL-40R354B
CL3] ……………………………………………………………………….. 25
KDL-32R304B CL3 /KDL-40R354B CL3
Description Page
1-7. How to assemble the Himeron Countermeasure of panel
[KDL-32R304B CL3 /KDL-40R354B CL3] ………………… 26
1-8. How to assemble the Himeron Countermeasure of panel[KDL-
32R304B CL3 /KDL-40R354B CL3] …………………………….…… 27
1-8-1. KDL-32R304B CL3 ……………………………………… 27
1-8-2. KDL-40R354B CL3……………………………………… 29
SEC 2. ADJUSTMENT…………………………………………………… 30
SEC 3. DIAGRAMS AND CHASSIS STRUCTURE………………… 32
3-1. BLOCK DIAGRAM……………………………………………… 32
3-2. CONNECTOR DIAGRAM……………………………………… 33
3-3. CIRCUIT BOARDS LOCATION……………………………… 34
3-4. Tape location……………………………………………………… 35
APPENDIX-1 Trouble analysis flow…………………………………… 37
APPENDIX-2 Software data update…………………………………… 38
APPENDIX-3 Operation Time, Boot Count, Panel Operation Time 42
APPENDIX-4 Edit MODEL NAME and Serial Number..…………… 43

4
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.
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.
CARRYING THE TV
Be sure to follow these guidelines to protect your property and avoid causing serious injury.
• Carry the TV with an adequate number of people; larger size TVs require two or more people.
• Correct hand placement while carrying the TV is very important for safety and to avoid damages.
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.
KDL-32R304B CL3 /KDL-40R354B CL3

5
WARNINGS AND CAUTIONS
USE CAUTION WHEN HANDLING THE LCD PANEL
When repairing the LCD panel, be sure you are grounded by using a wrist band.
When repairing the LCD panel on the wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.
1) Do not press on the panel or frame edge to avoid the risk of electric shock.
2) Do not scratch or press on the panel with any sharp objects.
3) Do not leave the module in high temperatures or in areas of high humidity for an extended period of time.
4) Do not expose the LCD panel to direct sunlight.
5) Avoid contact with water. It may cause a short circuit within the module.
6) Always clean the LCD panel with a soft cloth material.
7) Use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short.
8) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
9)It is recommended not to exceed 1 hour of Power-On nor Burn-in period with LCD panel face down condition, in repair activity.
10)Disconnect the AC power when replacing the parts.(FFC cable etc.).
KDL-32R304B CL3 /KDL-40R354B CL3

6
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.
8. For safety reasons, repairing the Power board and/or Inverter board is prohibited.
KDL-32R304B CL3 /KDL-40R354B CL3

7
SAFETY CHECK-OUT
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).
KDL-32R304B CL3 /KDL-40R354B CL3

8
SELF DIAGNOSIS FUNCTION
This model doesn’t support Self Diagnosis Function.
KDL-32R304B CL3 /KDL-40R354B CL3

9
SERVICE POSITION
< KDL-32R304B > 2. Remove all screws on the Rear Cover to
Bezel & Main Board & Bracket (thirteen screws)
1. Remove all screws on the Stand
to main unit (four screws)
3. After removing rear cover , lie down the main unit
to a surface for following test/repair.
2-580-603-01 SCREW, +PSW M4X16
2-345-219-11 +B IB 3X-- CM3 (SCREW M3X6)
2-580-638-01 SCREW, +BVTP2 4X8
7-682-903-19 SCREW +PWH 3X6
As for this model, the bottom of rear cover is installed between the stand assy and the panel.
Therefore according to the following procedure when performing adjustment and operation check after the part replacement.
Note: Remove rear cover, then assemble the stand to main unit. This
will cause the stand with main unit fit closely, scratch or deformation
may occurred easily on the stand or bezel deco.
Attention: This photo is based on Sony criteria for appearing standing the
main unit after removing back cover and assembling the stand. But
considering mechanical design of this models and normal service process,
it is not recommended to keep main unit standing by this status for
repairing/testing at repair center. Please pay attention for avoiding
possible scratch/deformation occurred.
KDL-32R304B CL3 /KDL-40R354B CL3

10
<KDL-40R354B>
2. Remove all screws on the Rear Cover to
Bezel & Main Board & Bracket (fifteen screws)
1. Remove all screws on the Stand
to main unit (four screws)
3. After removing rear cover , lie down the main unit
to a surface for following test/repair.
2-580-603-01 SCREW, +PSW M4X16
2-345-219-11 +B IB 3X-- CM3 (SCREW M3X6)
2-580-638-01 SCREW, +BVTP2 4X8
7-682-903-19 SCREW +PWH 3X6
Note: Remove rear cover, then assemble the stand to main unit. This
will cause the stand with main unit fit closely, scratch or deformation
may occurred easily on the stand or bezel deco . And Stand will be
interference with Speaker.
Attention: This photo is based on Sony criteria for appearing standing the
main unit after removing back cover and assembling the stand. But
considering mechanical design of this models and normal service process,
it is not recommended to keep main unit standing by this status for
repairing/testing at repair center. Please pay attention for avoiding
possible scratch/deformation occurred.
SERVICE POSITION
KDL-32R304B CL3 /KDL-40R354B CL3

11
• Items with no part number and no description are not stocked because they are seldom required for roution service.
• The construction parts of an assembled part are indicated with a collation number in the remark colum.
• Items marked " * " are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items.
SEC 1. DISASSEMBLY AND PARTS LIST
KDL-32R304B CL3 /KDL-40R354B CL3

1-1. KDL-32R304B
1-1-1. BASE STAND
DISASSEMBLY AND PARTS LIST
1
REF. No. PART No. DESCRIPTION MARK
14-538-444-01 STAND(32)
2-580-603-01 SCREW, +PSW M4X16
12
KDL-32R304B CL3 /KDL-40R354B CL3

REF. No. PART No. DESCRIPTION MARK
24-538-442-21 COVER REAR (32)
19 4-542-297-11 IOside label
13
DISASSEMBLY AND PARTS LIST
1-1-2. REAR COVER
2
2-345-219-11 +B IB 3X-- CM3 (SCREW M3X6)
2-580-638-01 SCREW, +BVTP2 4X8
7-682-903-19 SCREW +PWH 3X6
1-1. KDL-32R304B
19
KDL-32R304B CL3 /KDL-40R354B CL3

14
DISASSEMBLY AND PARTS LIST
1-1-3. POWER BOARD, A BOARD AND SPEAKER
7
4
10 13
3
6
REF. No. PART No. DESCRIPTION MARK
31-895-631-41 MOUNTED PWB POWER UNITfor SDC LCM
41-895-630-51 MOUNTED PWB A
51-895-629-11 MOUNTED PWB H
61-910-109-63 CONNECTOR ASSY6P
71-910-109-64 CONNECTOR ASSY4P
81-910-109-62 CONNECTOR ASSY14P
91-910-109-90 LVDS CABLE
10 4-542-284-01 SHEET, INSULATION (32)
11 4-538-884-01 BRACKET, SIDE
12 4-542-280-01 BKT_CONNECTOR SGCC
13 1-859-048-11 LOUDSPEAKER (8W)
4-466-882-01 SCREW, M3X6 SW (FANT)
2-580-628-01 SCREW, +BVTP S3X6 TYPE2
7-682-903-19 SCREW +PWH 3X6
2-580-592-01 SCREW, +PSW M3X8
1-1. KDL-32R304B
8
5
5
9
11
12
13
KDL-32R304B CL3 /KDL-40R354B CL3

15
DISASSEMBLY AND PARTS LIST
1-1-4. LCD PANEL, DECO and COVER, BOTTOM
REF. No. PART No. DESCRIPTION MARK
14 A-2065-292-A LCMASSY(32)(LVS3150AN02ADZ2S0X)
15 N/A BRACKET,STAND R 32
16 N/A BRACKET, STAND L 32
17 4-538-446-01 DECO (32)
18 4-538-445-01 COVER, BOTTOM (32)
4-542-283-01 BOLT, M3
1-1. KDL-32R304B
15
14
16
18
17
KDL-32R304B CL3 /KDL-40R354B CL3

16
PART No. DESCRIPTION MARK
1-492-066-31 REMOTE COMMANDER (RM-YD093)
1-846-428-52 CORD SET, POWER-SUPPLY
DISASSEMBLY AND PARTS LIST
1-1-5. MISCELLANEOUS
1-1. KDL-32R304B
KDL-32R330B/40R380B

1-2. KDL-40R354B
1-2-1. BASE STAND
DISASSEMBLY AND PARTS LIST
REF. No. PART No. DESCRIPTION MARK
14-538-449-01 STAND (40)
2-580-603-01 SCREW, +PSW M4X16
7-682-246-09 +K 3X6 SCREW +K 3X5
7-682-245-09 +K 3X6 SCREW +K 3X4
17
1
KDL-32R304B CL3 /KDL-40R354B CL3

REF. No. PART No. DESCRIPTION MARK
24-538-447-21 COVER, REAR (40)
19 4-542-297-11 IOside label
18
DISASSEMBLY AND PARTS LIST
1-2-2. REAR COVER
2
1-2. KDL-40R354B
2-345-219-11 +B IB 3X-- CM3 (SCREW M3X6)
2-580-638-01 SCREW, +BVTP2 4X8
7-682-903-19 SCREW +PWH 3X6
19
KDL-32R304B CL3 /KDL-40R354B CL3

19
DISASSEMBLY AND PARTS LIST
1-2-3. POWER BOARD, A BOARD AND SPEAKER
4
11
3
12
REF. No. PART No. DESCRIPTION MARK
31-895-632-31 MOUNTED PWB POWER UNIT
41-895-630-61 MOUNTED PWB A
51-895-629-11 MOUNTED PWB H
61-910-109-69 CONNECTOR ASSY6P
71-910-109-70 CONNECTOR ASSY4P
81-910-109-88 LVDS CABLE
91-910-109-68 CONNECTOR ASSY14P
10 4-542-282-01 SHEET, INSULATION (40)
11 4-542-280-01 BRACKET, MB
12 4-538-884-01 BRACKET, SIDE
13 1-859-048-11 LOUDSPEAKER (8W)
4-466-882-01 SCREW, M3X6 SW (FANT)
2-580-628-01 SCREW, +BVTP S3X6 TYPE2
7-682-903-19 SCREW +PWH 3X6
2-580-592-01 SCREW, +PSW M3X8
1-2. KDL-40R354B
13
10
5
5
13
6
7
8
9
KDL-32R304B CL3 /KDL-40R354B CL3

20
DISASSEMBLY AND PARTS LIST
1-2-4. LCD PANEL, DECO and COVER, BOTTOM
REF. No. PART No. DESCRIPTION MARK
14 A-2047-010-A LCMASSY(40)(INXV400HJ6) With Bezel
15 N/A BRACKET, Stand R (40)
16 N/A BRACKET,Stand L (40)
17 4-538-451-01 DECO (40)
18 4-538-450-01 COVER, BOTTOM(40)
1-2. KDL-40R354B
18
14
16
15
17 4-542-283-01 BOLT, M3
KDL-32R304B CL3 /KDL-40R354B CL3