SONY KDL-22L4000 Service Manual
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-22L4000
KDL-22L4000
KDL-22L4000
KDL-22L4000
RM-YD025 US
RM-YD025 CANADA
RM-YD025 MEXICO
RM-YD025 LATIN AMERICA
CZ1R
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 9/2008
:UPDATED ITEM
☛
REVISION DATE SUBJECT
9/2008 No revisions or updates are applicable at this time.
10/2008 Removed Self Diagnosis logo from Front Cover and Self Diagnostic Function page.
Replaced pages 2 and 11.
LCD DIGITAL COLOR TELEVISION
9-883-801-02
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
CZ1R
CHASSIS
KDL-22L4000
KDL-22L4000
KDL-22L4000
KDL-22L4000
RM-YD025 US
RM-YD025 CANADA
RM-YD025 MEXICO
RM-YD025 LATIN AMERICA
9-883-801-02
KDL-22L4000 RM-YD025
LCD DIGITAL COLOR TELEVISION
KDL-22L4000
TABLE OF CONTENTS
SECTION TITLE PAGE SECTION TITLE PAGE
Specifi cations ................................................................................. 4
Warnings and Cautions .................................................................. 6
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 and H1 Board Removal .................................. 12
1-3. A Board and G Board Removal ............................................ 13
1-4. Table-Top Stand Assembly and Under Cover Removal ....... 13
1-5. Loudspeaker Removal ......................................................... 14
1-6. Bottom Cover, H2 Board, H3 Board, IR Lens and
LED Lens Removal .............................................................. 14
1-7. LCD Panel Removal ............................................................. 15
1-7-1. Cleaning the LCD Panel ............................................ 15
Wire Dressing ............................................................................... 16
SECTION 2: SERVICE ADJUSTMENTS ............................................. 17
2-1. Accessing Service (Factory) Mode ...................................... 17
2-2. Reviewing Service (Factory) Mode ...................................... 18
2-3. Resetting to Factory Defaults after Board Replacement ...... 18
2-4. Viewing Model Information ................................................... 19
SECTION 3: DIAGRAMS ..................................................................... 20
3-1. Circuit Boards Location ........................................................ 20
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 20
3-3. Block Diagram ...................................................................... 22
3-4. Schematics and Supporting Information .............................. 23
A Board Schematic Diagram (1 of 21) .................................. 23
A Board Schematic Diagram (2 of 21) .................................. 24
A Board Schematic Diagram (3 of 21) .................................. 25
A Board Schematic Diagram (4 of 21) .................................. 26
A Board Schematic Diagram (5 of 21) .................................. 27
A Board Schematic Diagram (6 of 21) .................................. 28
A Board Schematic Diagram (7 of 21) .................................. 29
A Board Schematic Diagram (8 of 21) .................................. 30
A Board Schematic Diagram (9 of 21) .................................. 31
A Board Schematic Diagram (10 of 21) ................................ 32
A Board Schematic Diagram (11 of 21) ................................ 33
A Board Schematic Diagram (12 of 21) ................................ 34
A Board Schematic Diagram (13 of 21) ................................ 35
A Board Schematic Diagram (14 of 21) ................................ 36
A Board Schematic Diagram (15 of 21) ................................ 37
A Board Schematic Diagram (16 of 21) ................................ 38
A Board Schematic Diagram (17 of 21) ................................ 39
A Board Schematic Diagram (18 of 21) ................................ 40
A Board Schematic Diagram (19 of 21) ................................ 41
A Board Schematic Diagram (20 of 21) ................................ 42
A Board Schematic Diagram (21 of 21) ................................ 43
G Board Schematic Diagram (1 of 2) ................................... 45
G Board Schematic Diagram (2 of 2) ................................... 46
H1 Board Schematic Diagram .............................................. 48
H2 Board Schematic Diagram .............................................. 50
H3 Board Schematic Diagram .............................................. 52
KDL-22L4000
SECTION 4: EXPLODED VIEWS ........................................................ 54
4-1. Rear Cover Assembly and Table-Top Stand Assembly ....... 54
4-2. Chassis ................................................................................ 55
4-3. Screw Legend ...................................................................... 56
APPENDIX A: ENCRYPTION KEY COMPONENTS ..........................A-1
3
SPECIFICATIONS
KDL-22L4000
Power Requirements
Power Consumption
In Use (Max)
In Standby
110V - 240 V AC, 50/60Hz
55W
Less than 1.0 W
VIDEO (IN) 1/2:
S VIDEO (4-Pin Mini DIN) (VIDEO 2 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, 75 ohms unbalanced, sync negative
AUDIO:
500 mVrms (100% modulation)
Impedance: 47 kilohms
COMPONENT IN:
YP
(Component Video):
BPR
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
HDMI IN:
HDMI: Video: 480i, 480p, 720p, 1080i, 1080p
Audio: Two channel linear PCM 32, 44.1
and 48 kHz, 16, 20 and 24 bits
AUDIO: 500 mVrms (100% modulation)
Impedance: 47 kilohms
AUDIO OUT:
500 mVrms (100% modulation)
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 (100% modulation)
Impedance: 47 kilohms
HEADPHONES:
Stereo mini jack
Impedance: > kilohms
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KDL-22L4000
Design and specifi cations are subject to change without notice.
4
)
SPECIFICATIONS (CONTINUED)
KDL-22L4000
Power Consumption
in use
in standby Less than 1.0 W
Speaker Output (W)
Speaker/Full Range(2
mm 50 x 90 mm
in
Dimensions (W x H x D)
with stand
mm
in
without stand
mm
in
wall-mount hole pattern (mm) 100 x 100
wall-mount screw size (mm) M4 10-12
Mass
with stand
kg
lbs
without stand
kg
lbs
5W + 5W
2 x 3
551 x 430 x 214 mm
3/4
21
x 17 x 8
551 x 392 x 76 mm
3/4
21
x 15
16 lbs 12
14 lbs 1
55W
5/8
1/2
7.6 kg
6.4 kg
in
1/2
x 3 in
1/8
oz
3/4
oz
KDL-22L4000
in
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):
1,366 dots x 768 lines
Screen Size (measured diagonally)
approx. 21.6 inches
Supplied Accessories
Remote Commander RM-YD025
Size AA Batteries (2)
AC Power Cord
Table-Top Stand
Screws (3)
Cable Band
Operating Instructions
Quick Setup Guide
Warranty Card
Online Registration Card
Optional Accessories
Headphones Plug Adapter
Connecting Cables
Support Belt Kit
Wall-Mount Bracket
SU-WL100
KDL-22L4000
5
KDL-22L4000
WARNINGS AND CAUTIONS
CAUTION
These servicing instructions are for use by qualifi ed 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 qualifi ed 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 identifi ed 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 identifi ed 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 qualifi é 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 qualifi é
faire ainsi.
Afi n 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 identifi es 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 identifi es dans le
present manuel. Suivre ces procedures lors de chaque remplacement de composants critiques, ou lorsqu’un mauvais
fonctionnement suspecte.
KDL-22L4000
6
WARNINGS AND CAUTIONS (CONTINUED)
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.
When you carry the TV, place your hand as illustrated and hold it securely.
Do not put stress on the LCD panel.
When carrying the TV, do not subject it to shocks or vibration, or excessive force.
KDL-22L4000
TRANSPORTER LE TÉLEVISÉUR
Pour éviter d échapper le téleviséur et de causer des blessures graves, assurez-vous
de suivre ces directives:
Avant de transporter le téleviséur, débranchez tous les càbles.
Lorsque vous transportez le téleviséur, placez votre main tel qu’ illustré et tenez-le
fermement. N’imposez pas de charge sur le panneau ACL.
Lorsque vous transportez le téleviséur ne le soumettez pas à des chocs,
à des vibrations ou à une force excessive.
KDL-22L4000
7
SAFETY-RELATED COMPONENT WARNING
KDL-22L4000
There are critical components used in LCD color TVs that are important for safety. These components are identifi ed 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
specifi ed in the electrical parts list to prevent electric shock, fi re, 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
KDL-22L4000
8
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.
KDL-22L4000
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 :
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
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
KDL-22L4000
9
SAFETY CHECK-OUT
KDL-22L4000
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.
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).
Leakage Test
0.15 F
Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.
To Exposed Metal
Parts on Set
Earth Ground
AC
Voltmeter
(0.75V)
Trouble Light
AC Outlet Box
Ohmmeter
Cold-water Pipe
KDL-22L4000
10
KDL-22L4000
SELF-DIAGNOSTIC FUNCTION
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 these sets, the technician should bring both the A Board and the G Board to the customer location.
Control Buttons
4)-%2 34!.$"9 0/7%2
Description of LED Indictors
The units in this manual DO NOT contain a self-diagnostic function.
KDL-22L4000
11
1-1. REAR COVER REMOVAL
1
Remove 13 screws from Rear Cover
KDL-22L4000
SECTION 1: DISASSEMBLY
Bezel
Rear Cover
1-2. FUNCTION KEY AND H1 BOARD REMOVAL
1
Slide out Function Key unit from Bezel
2
Release hooks and remove Function Key and H1 Board
3
Disconnect 1 connector
4
Remove 1 screw and release ground wire
Key Cover
Function Key
H1 Board
Bezel
1
1
2
4
3
KDL-22L4000
12
1-3. A BOARD AND G BOARD REMOVAL
1
Remove 2 HEX screws
2
Remove Hexagon Nut from tuner
3
Remove 8 screws from Main Shield
4
Release hooks and slide out Side Bracket
5
Disconnect 6 connectors and remove 7 screws from A Board
Disconnect 5 connectors and remove 5 screws from G Board
6
KDL-22L4000
Main Bracket
A Board
G Board
6
4
5
Side Jack Bracket
3
1
2
1-4. TABLE-TOP STAND ASSEMBLY AND UNDER COVER REMOVAL
1
Remove 3 screws
2
Remove 3 screws
1
Main Shield
KDL-22L4000
Ta bl e -To p
Stand Assembly
2
Main Bracket
Under Cover
Bottom Frame
13
1-5. LOUDSPEAKER REMOVAL
1
Remove 6 screws from each Speaker
KDL-22L4000
1
Speakers
1
1-6. BOTTOM COVER, H2 BOARD, H3 BOARD, IR LENS AND LED LENS REMOVAL
1
Remove 1 screw from Bottom Cover
2
Disconnect 1 connector and slide out H3 (LED) Board
3
Disconnect 1 connector and remove 1 screw from H2 (IR) Board
4
Remove 1 screw from IR Lens and slide out from Bezel
5
Remove 2 screws from LED Lens
Bottom Cover
5
LED Lens
1
2
H3 Board
3
H2 Board
4
IR Lens
KDL-22L4000
14
1-7. LCD PANEL REMOVAL
1
Remove 2 screws from Main Bracket and Bezel
Remove 4 screws and release LCD panel from Main Bracket
2
Main Bracket
2
KDL-22L4000
1
LCD Panel
Bezel
1-7-1. CLEANING THE LCD PANEL
CAUTION: When cleaning the TV, be sure to unplug the power cord to avoid any chance of electric shock.
Clean the cabinet of the TV with a dry soft cloth.
Wipe the LCD screen gently with a soft cloth.
→ Stubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water.
→ If using a chemically pretreated cloth, please follow the instruction provided on the package.
→ Never use strong solvents such as a thinner, alcohol or benzine for cleaning.
→ Periodic vacuuming of the ventilation openings is recommended to ensure to proper ventilation.
KDL-22L4000
15
WIRE DRESSING
OVERALL VIEW
KDL-22L4000
CN202
CN201
CN204
CN203
CN1101
CN13
CN9
CN3
CN12
CN15 CN16
KDL-22L4000
16
SECTION 2: SERVICE ADJUSTMENTS
2-1. ACCESSING SERVICE (FACTORY) MODE
Use the remote commander to access Service (Factory) mode after completing a repair to the TV set.
1. TV must be in standby mode. (Power on) mode.
2. To display the service menu, quickly press the following buttons on the Remote Commander:
➔ ➔ ➔ ➔ ➔
KDL-22L4000
1
6
3
2
4
5
KDL-22L4000
RM-YD025
17
KDL-22L4000
2-2. REVIEWING SERVICE (FACTORY) MODE
All of the necessary adjustment are contained in the boards for these models, therefore the following information is for informational purposes.
Factory Mode
Change source between
Video1,Video2 ,Component, PC, HDMI, & TV
Set “On” for White Balance adjust
Input Source <[ TV ]>
White Balance <[ Off ]>
Internal Pattern <[ 20 ]>
Color Temp.... >>
Set “On” for Aging mode start
Set “Off” to end aging mode.
Aging Mode <[ Off ]>
ADC Calibration >>
Auto Phase <[ Off ]>
Reset to Factory Defaults
Reset TV to Factory Defauts without resetting
Parental lock , Channel lists and other User settings.
To scan preset channels from
cable or antenna
Factory Reset <[ Off ]>
EDED WP <[ Protection ]>
User Reset <[ Off ]>
Recall Preset Ch <[ Off ]>
[</>]Set[EXIT]Exit
To Exit Service Mode, press
2-3. RESETTING TO FACTORY DEFAULTS AFTER BOARD REPLACEMENT
Traditional Service Mode is not available in this chassis, however, after replacing a board you should reset all of the settings to the Factory Default
from Service (Factory) Mode.
CAUTION: Resetting the
contact the customer to determine what adjustments they have made.
1. TV must be in Service (Factory) Mode.
2. Press
3. Press
4. When the Reset is complete, the text changes to No.
5. To exit “service mode”, press the
to select Factory Reset.
to select Yes.
TV to the Factory Defaults will over-write all customer settings including Parental Lock setting. Before performing this reset,
button
KDL-22L4000
18
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