Sony KDL-40D3000, KDL-32XBR4 Service Manual
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-32XBR4
KDL-40D3000
RM-YD014 US/CANADA
RM-YD014 US/CANADA
WAX3
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 5/2007
REVISION DATE SUBJECT
5/2007 No revisions or updates are applicable at this time.
9/2007 Corrected note under BH Board. Replaced pages 108 & 113.
LCD DIGITAL COLOR TELEVISION
9-883-751-02
Self Diagnosis
Supported model
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-32XBR4
KDL-40D3000
RM-YD014 US/CANADA
RM-YD014 US/CANADA
WAX3
CHASSIS
9-883-751-02
KDL-40D3000 RM-YD014
LCD DIGITAL COLOR TELEVISION
KDL-32XBR4/40D3000
TABLE OF CONTENTS
SECTION TITLE PAGE SECTION TITLE PAGE
Specifi cations ................................................................................. 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 Cover Removal ............................................................ 12
1-2. H1 Board Removal ............................................................... 12
1-3. Stand Assembly and VESA Arm Assembly Removal
(KDL-32XBR4 Only) ............................................................. 13
1-4. Stand Assembly and VESA Arm Assembly Removal
(KDL-40D3000 Only) ............................................................ 13
1-5. U2 Board, DTT Shield, and Jack Holder Removal ............... 14
1-6. BU2 Board Removal ............................................................ 14
1-7. Speaker, H3 Board, and H4 Board Removal ....................... 15
1-8. G1H Board (Power Unit) Removal (KDL-32XBR4 Only) ...... 15
1-9. D1 Board and G3 Board (Power Unit) Removal
(KDL-40D3000 Only) ............................................................ 16
1-9-1. Replacing the Inverter Connector Assembly
(KDL-40D3000 Only) ............................................... 16
1-10. BH Board Removal .............................................................. 17
1-11. AC Inlet Removal (KDL-32XBR4 Only) ................................ 18
1-12. AC Inlet Removal (KDL-40D3000 Only) ............................... 18
1-13. LCD Panel, LED and Guide Light Removal
(KDL-32XBR4 Only) ............................................................. 19
1-14. LCD Panel, LED and Guide Light Removal
(KDL-40D3000 Only) ............................................................ 20
1-15. Inverter Board Removal ....................................................... 21
Wire Dressing ............................................................................... 22
KDL-32XBR4 Only ............................................................... 22
KDL-40D3000 Only .............................................................. 44
SECTION 2: SERVICE ADJUSTMENTS ............................................. 69
2-1. Using the Remote Commander
for Electrical Adjustments ..................................................... 69
2-2. Accessing Service Adjustment Mode ................................... 69
2-3. Viewing the Service Menus .................................................. 69
2-4. Using the Remote Commander to View Service Data ......... 70
2-4-1. Changing Service Data ............................................ 70
2-4-2. Exiting Service Mode ............................................... 70
2-5. Verifying Service Data Changes .......................................... 71
2-6. Resetting to Factory Defaults ............................................... 71
SECTION 3: DIAGRAMS ..................................................................... 72
3-1. Circuit Boards Location ........................................................ 72
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 73
3-3. Block Diagram ...................................................................... 74
Signal Flow Diagram ............................................................ 74
Connection Diagram (KDL-32XBR4 Only) ........................... 75
Connection Diagram (KDL-40D3000 Only) .......................... 76
3-4. Schematics and Supporting Information .............................. 77
BU2 Board Schematic Diagram (1 of 12) ............................. 77
BU2 Board Schematic Diagram (2 of 12) ............................. 78
BU2 Board Schematic Diagram (3 of 12) ............................. 79
BU2 Board Schematic Diagram (4 of 12) ............................. 80
BU2 Board Schematic Diagram (5 of 12) ............................. 81
BU2 Board Schematic Diagram (6 of 12) ............................. 82
BU2 Board Schematic Diagram (7 of 12) ............................. 83
BU2 Board Schematic Diagram (8 of 12) ............................. 84
BU2 Board Schematic Diagram (9 of 12) ............................. 85
BU2 Board Schematic Diagram (10 of 12) ........................... 86
BU2 Board Schematic Diagram (11 of 12) ........................... 87
BU2 Board Schematic Diagram (12 of 12) ........................... 88
D1 Board Schematic Diagram (KDL-40D3000 Only) ........... 90
G1H Board Schematic Diagram (Power Supply)
(KDL-32XBR4 Only) ................................................ 93
G3 Board Schematic Diagram (Power Supply)
(KDL-40D3000 Only) ............................................... 94
H1 Board Schematic Diagram .............................................. 96
H3 Board Schematic Diagram .............................................. 98
H4 Board Schematic Diagram ............................................ 100
U2 Board Schematic Diagram (1 of 2) ............................... 102
U2 Board Schematic Diagram (2 of 2) ............................... 103
3-5. Semiconductors ................................................................. 106
SECTION 4: EXPLODED VIEWS ...................................................... 107
4-1. Rear Cover and Stand Assembly ...................................... 107
4-2. Chassis .............................................................................. 108
4-3. Bezel Assembly and LCD Panel ....................................... 109
4-4. Connectors (KDL-32XBR4 Only) .......................................110
4-5. Connectors (KDL-40D3000 Only) .....................................111
4-6. Speakers ............................................................................112
SECTION 5: ELECTRICAL PARTS LIST ...........................................113
APPENDIX A: ENCRYPTION KEY COMPONENTS ..........................A-1
KDL-32XBR4/40D3000
3
SPECIFICATIONS
KDL-32XBR4/40D3000
Power Requirements
120V-240V AC, 50/60Hz
Video (IN) 1/2/3
S Video (4-Pin Mini DIN (VIDEO 1/2 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, 75ohms unbalanced, sync negative
Audio
500 mVrms (100% modulation)
Impedance:47 kilohms
COMPONENT IN 1/2
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, 1080p
AUDIO
500 mVrms (100% modulation)
Impedance: 47 kilohms
HDMI IN 1/2/3:
HDMI: Video:480i, 480p, 720p, 1080i, 1080p
Audio: Two channel linear PCM 32, 44.1 and
48 kHz, 16, 20 and 24 bits
AUDIO: (HDMI IN 3 only) 500 mVrms (100% modulation)
Impedance: 47 kilohms
AUDIO OUT:
500 mVrms (100% modulation)
More than 1 Vrms at the maximum volume setting (Variable)
More than 500 mVrms (Fixed)
PC IN:
D-sub 15-pin, analog RGB, 0.7 Vp-p, 75 ohms, positive
PC AUDIO INPUT:
Stereo mini jack, 0.5 Vrms, 1 kilohm
HEADPHONES:
Stereo mini jack, 500 mVrms, 1 kilohm
Impedance: 16 ohms
Trademark Information
“BRAVIA” and , S-Force,
BRAVIA Theatre Sync, and DMe
trademarks or registered marks of Sony Corporation.
Blu-ray Disc is a trademark.
“XMB”, “XrossMediaBar” and “PS3” are
trademarks of Sony Corporation and/or
Sony Computer Entertainment Inc.
HDMI, the HDMI logo and High-Definition Multimedia Interface are
trademarks or registered trademarks of HDMI Licensing, LLC.
Macintosh is a trademark licensed to Apple Computer, Inc., registered in
the U.S.A and other countries.
Manufactured under license from Dolby
Laboratories. “Dolby” and the double-D symbol are
trademarks of Dolby Laboratories.
As an ENERGY STAR
determined that this product meets the ENERGY ST AR
guidelines for energy efficiency.
ENERGY STAR
KDL-32XBR4/40D3000
x
are
This TV incorporates High-Definition
Multimedia Interface (HDMI™) technology.
®
Partner, Sony Corporation has
®
is a U.S. registered mark.
®
Design and specifi cations are subject to change without notice.
4
Power Consumption
in standby
Speaker Output (W)
Dimensions (W x H x D)
with stand
without stand
wall-mount hole pattern
Mass
with stand
without stand
KDL-32XBR4 KDL-40D3000
in use
mm
in
mm
in
mm
in
mm
kg
31
190W 205W
Less than 0.1W
10W + 10W
42 x 150 mm 55 x 150 mm
11/16
1
x 6 in 2
790 x 577 x 214 mm 981 x 692 x 265 mm
1/8
x 22
3/4
x 8
1/2
in 38
5/8
790 x 530 x 100 mm 981 x 643 x 110 mm
31
1/8
x 20
7/8
x 4 in 38
5/8
200 X 200 300 X 200
18 kg 25.5 kg
lbs 40 lbs 57 lbs
kg
15.5 kg 21.5 kg
lbs 35 lbs 48 lbs
1/4
x 27
x 25
x 6 in
1/4
x 10
3/8
x 4
3/8
1/2
KDL-32XBR4/40D3000
in
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 1-125 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)
31.5 inches (KDL-32XBR4 Only)
40 inches (KDL-40D3000 Only)
Supplied Accessories
Remote Commander RM-YD014
Two Size AA (R6) Batteries
AC Power Cord
Suport Belt, Securing Screw, and Wood Screw
Cable Holder
Operating Instructions
Quick Setup Guide
Warranty Card
Optional Accessories
Headphones Plug Adapter
Connecting Cables
Wall-Mount Bracket
SU-WL500
TV Stand
RHT-G800
KDL-32XBR4/40D3000
5
KDL-32XBR4/40D3000
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.
CARRYING THE TV
To avoid dropping the TV and causing serious injury, be sure to follow
these guidelines:
s Before carrying the TV, disconnect all cables.
s Carrying the large size TV requires two or more people.
s When you carry the TV, place your hand as illustrated and hold it
securely. Do not put stress on the LCD panel.
KDL-32XBR4/KDL-40D3000
s When lifting or moving the TV, hold it firmly from the bottom. Place
your palm directly under the panel.
s When carrying, do not subject the TV to shocks or vibration, or
excessive force.
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.
POUR TRANSPORTER LE TÉLÉVISEUR
Assurez-vous de suivre ces consignes pour éviter de laisser tomber le
téléviseur et de provoquer des blessures graves :
s Avant de transporter le téléviseur, débranchez tous les câbles.
s Le transport du téléviseur doit être effectué par au moins deux
personnes.
s Lorsque vous le transportez, placez vos mains tel que cela est illustré
et tenez solidement l’appareil. N’appliquez pas de pression sur
l’écran ACL.
KDL-32XBR4/KDL-40D3000
s Lorsque vous levez ou déplacez le téléviseur, assurez-vous de tenir
solidement de la base. Placez la paume des mains directement sous
le panneau.
s Lorsque vous transportez le téléviseur, ne le soumettez pas à des
chocs ou vibrations, ni à une force excessive.
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-32XBR4/40D3000
6
SAFETY-RELATED COMPONENT WARNING
KDL-32XBR4/40D3000
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-32XBR4/40D3000
7
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-32XBR4/40D3000
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-32XBR4/40D3000
8
SAFETY CHECK-OUT
KDL-32XBR4/40D3000
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 μF
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-32XBR4/40D3000
9
KDL-32XBR4/40D3000
g
SELF-DIAGNOSTIC FUNCTION
The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY LED indicator will automatically begin to fl ash. The number
of times the LED fl ashes translates to a probable source of the problem. A defi nition of the STANDBY LED fl ash indicators is listed in the instruction
manual for the user’s knowledge and reference. If an error symptom cannot be reproduced, the Remote Commander can be used to review the failure
occurrence data stored in memory to reveal past problems and how often these problems occur.
1. Diagnostic Test Indicators
When an error occurs, the STANDBY LED indicator will fl ash a set number of times to indicate the possible cause of the problem. If there is more than
one error, the indicator will identify the fi rst of the problem areas.
Control Buttons
Self Diagnosis
Supported model
Description of LED Indictors
LED LED Type Description
POWER LED Green LED
STANDBY LED Red LED
PIC OFF/TIMER
LED
Display of STANDBY LED Flash Count
Amber/Green LED
LED ON 0.3 sec.
LED OFF 0.3 sec.
PIC OFF/TIMER STANDBY POWER
* Light is green when the TV set is on
* Lights is red when the TV is in PC standby mode
* Blinks red when indicating the TV may need servicing
* Li
ht is green when the Picture Offfeature is activated
* Light is amber when the timer is set
2 times
5 times
LED OFF
3 sec.
KDL-32XBR4/40D3000
10
KDL-32XBR4/40D3000
Viewing the Self Check Diagnostic List
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
The Self Check list displays. This differs from accessing Service Adjustments.
Results for all of the following diagnostic items are displayed on screen. No error has occurred if the screen displays a “0”.
Channel 5 Volume -
TV POWER
.
SELF CHECK PAGE 1
002 MAIN_POWER 01
003 DC_ALERT1 00
Í 1 indicates an error was detected
Í 0 indicates no error was detected
004 DC_ALERT2 00
005 DC_ALERT3 00
006 BACK_LIGHT 00
013 BACK_LIGHT_BALANCE 00
00009-00019-00009
3. Press the Channel 1 button on the Remote Commander to go to Page 2 of the Self Check list.
SELF CHECK PAGE 2
008 SP_PROT 01
007 TEMP 00
011 TRIDENT_IC 00
010 DIGITAL 00
009 NA 00
007 HFR_OVERHEAT 00
012 HFR_ERROR
00009-00019-00009
4. Press the Channel
Clearing the Self Check Diagnostic List
1. In Service Mode, press the Channel 8 Channel 0.
4
button on the Remote Commander to go back to Page 1 of the Self Check list.
KDL-32XBR4/40D3000
11
1-1. REAR COVER REMOVAL
1
Remove 3 screws from Terminals, +BVTP 3X12 TYPE2 IT-3
Remove 2 screws (KDL-32XBR4), 4 screws (KDL-40D3000)
2
from Rear Cover arm positions, +PSW M5X16
3
Remove 14 screws (KDL-32XBR4), 15 screws (KDL-40D3000),
from Rear Cover, +BVTP2 4X16
KDL-32XBR4/40D3000
SECTION 1: DISASSEMBLY
1
2
3
Rear Cover
1-2. H1 BOARD REMOVAL
1
Remove from bezel
2
Disconnect one connector
3
Release hooks and remove H1 Board
Bezel Assembly
Multi Button Assembly
1
H1 Board
2
3
KDL-32XBR4/40D3000
12
1-3. STAND ASSEMBLY AND VESA ARM ASSEMBLY REMOVAL
(KDL-32XBR4 ONLY)
1
Remove 2 screws from bottom of Arms, +PSW M5X16
2
Remove 3 screws from bottom bracket and Stand,
+PSW M5X16
VESA Arm Assembly
1
2
KDL-32XBR4/40D3000
Stand Assembly
Under Cover
Bottom Bracket
1-4. STAND ASSEMBLY AND VESA ARM ASSEMBLY REMOVAL
(KDL-40D3000 ONLY)
1
Remove 4 screws from bottom of Arms, +PSW M5X16
2
Remove 4 screws from bottom bracket and Stand, +PSW
M5X16
VESA Arm Assembly
1
Stand Assembly
2
Under Cover
Bottom Bracket
KDL-32XBR4/40D3000
13
1-5. U2 BOARD, DTT SHIELD, AND JACK HOLDER REMOVAL
1
Disconnect two connectors
2
Remove three screws, +BVTP 3X12 TYPE2 IT-3
3
Release hooks and remove U2 Board
4
Remove Jack holder from Bezel.
5
Release hooks to remove DTT Shield from BU2 bottom shield.
1
KDL-32XBR4/40D3000
U2 Board
2
1-6. BU2 BOARD REMOVAL
1
Remove 2 screws, +PSW M3X5
2
Remove 2 screws, HEX
3
Disconnect 8 connectors
4
Remove 7 screws, +BVST 3X8
5
Remove 5 screws, +PSW M3X5
DTT Shield
5
DTT Top Shield
3
4
2
1
Side Jack Holder
KDL-32XBR4/40D3000
BU2 Board
DTT Bottom Shield
43
5
14
1-7. SPEAKER, H3 BOARD, AND H4 BOARD REMOVAL
1
Slide out Speaker and Baffl e from Bezel
2
Disconnect one connector from H3 Board
3
Remove 2 screws, (B) (+)PWH Tapping
4
Disconnect one connector from H4 Board
5
Remove 2 screws, (B) (+)PWH Tapping
1
H3 Board
KDL-32XBR4/40D3000
Speaker
Baffle
2
3
LED Guide
1-8. G1H BOARD (POWER UNIT) REMOVAL (KDL-32XBR4 ONLY)
1
Remove 4 screws, +PSW 3SG
2
Disconnect 3 connectors
Power Unit
G1 Bracket
1 2
5
H4 Board
4
Light
Guide
KDL-32XBR4/40D3000
15
1-9. D1 BOARD AND G3 BOARD (POWER UNIT) REMOVAL (KDL-40D3000 ONLY)
1
Disconnect 5 connectors
2
Remove 4 screws, +PSW 3SG
3
Disconnect 4 connectors
4
Remove 4 screws, +PSW 3SG
D1 Board
1
4
3
2
G3 Board
G3 Bracket
KDL-32XBR4/40D3000
1-9-1. REPLACING THE INVERTER CONNECTOR ASSEMBLY (KDL-40D3000 ONLY)
Use the following procedure to confirm that the connector is securely attached to the In
1
After inserting the connector
into the Inverter board,
push the middle section
of the inverter connector to
lock on the terminal.
Push the right section of
23
the inverter connector and
confirm it is securely
connected.
Push the left section of
the inverter connector and
confirm it is securely
connected.
KDL-32XBR4/40D3000
16
1-10. BH BOARD REMOVAL
1
Remove one screw, +PSW M3X5
2
Remove 2 screws, +BVST 3X8
3
Disconnect 2 connectors
4
Remove 4 screws , +PSW M3X5
5
Remove 4 screws , +PSW M3X5
KDL-32XBR4/40D3000
1
HFR Lower Shield
2
BH Board
5
HFR Upper Shield
3
4
KDL-32XBR4/40D3000
17
1-11. AC INLET REMOVAL (KDL-32XBR4 ONLY)
r
1
Remove 2 screws, +BVTP2 4X16
2
Remove 2 screws, +KTT 3X10
KDL-32XBR4/40D3000
1
Under Cover
2
AC Inlet
1-12. AC INLET REMOVAL (KDL-40D3000 ONLY)
1
Remove 2 screws, +BVTP2 4X16
2
Remove 2 screws, +KTT 3X10
AC Inlet
1
Under Cove
2
KDL-32XBR4/40D3000
18
1-13. LCD PANEL, LED AND GUIDE LIGHT REMOVAL (KDL-32XBR4 ONLY)
1
Remove 2 screws, +PSW M4X8
2
Remove 2 screws, +BVTP2 4X16
3
Remove 2 screws, +BVTP2 4X16
4
Remove 2 screws, +PSW M4X8
5
Remove 3 screws, +BVTP2 4X16
3
KDL-32XBR4/40D3000
1
Top Bracket
Bottom Bracket
2
4
5
LCD Panel
Bezel
KDL-32XBR4/40D3000
19
1-14. LCD PANEL, LED AND GUIDE LIGHT REMOVAL (KDL-40D3000 ONLY)
1
Remove 2 screws from Bezel and Top Brackets, +BVTP2 4X16
2
Remove 4 screws from Top Brackets, +PSW M5X8
3
Remove 4 screws from Bottom Brackets, + PSW M5X12
4
Remove 4 screws from Stand Holders, +PSW M5X16
5
Remove 2 screws from LCD Panel, +BVTP2 4X16
3
Stand Holder
4
Bottom Bracket(L)
KDL-32XBR4/40D3000
Bezel
Top Bracket
1
2
Bottom Bracket(R)
5
LCD Panel
KDL-32XBR4/40D3000
20
1-15. INVERTER BOARD REMOVAL
CAUTION:
Be sure to identify the inverter cover screws before proceeding. DO NOT remove the screws securing the plastic strip holding the
lamp sockets.
1
Remove screws securing the inverter cover.
2
Remove screws securing the inverter board
Plastic Strip
holding
Lamp Socket
DO NOT
REMOVE
BACKLIGHT
SCREWS
KDL-32XBR4/40D3000
2
REMOVE SCREWS
SECURING
SHIELD
Inverter Cover
WARNING
NEVER REMOVE THE
SCREWS SECURING THE
PLASTIC STRIP HOLDING
THE LAMP SOCKETS
DAMAGE TO TH E
BACKLIGHT TUBES WILL
OCCUR!
!
.
1
Plastic Strip
Inverter Board
holding
Lamp Socket
REMOVE
CONNECTOR AND
PULL BOARD TO
THE RIGHT
KDL-32XBR4/40D3000
SHIELD REMOVAL
END VIEW
SOCKET
BACKLIGHT
INVERTER BOARD REMOVAL
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. The example shown
is a 32” model but applies to all models.
21
KDL-32XBR4 ONLY
OVERALL VIEW
KDL-32XBR4/40D3000
WIRE DRESSING
KDL-32XBR4/40D3000
22
KDL-32XBR4 ONLY
H3 BOARD HARNESS
1
KDL-32XBR4/40D3000
OPERATION PROCESS
1. Apply Sheet Core C to edge of Panel to
cover sharp edge of panel.
2. Use ribs on bezel (w/o screw boss) as a
guide to center tape.
2
3
Use panel edge to align Himelon Tape.
Make sure Cushion D is Centered over the
H3 Harness.
Use UL Tapes as Reference to Position Harness
over panel,
Place bottom of UL tape on "Cross" etched in
the panel for alignment.
Use ribs on bezel as reference
to center Sheet Core C when applying
to panel edge.
KDL-32XBR4/40D3000
23
KDL-32XBR4 ONLY
H3 BOARD HARNESS (CONTINUED)
KDL-32XBR4/40D3000
OPERATION PROCESS
Apply Sheet Core C to edge of Panel to
cover sharp edge of panel.
Use ribs on bezel (w/o screw boss) as a
guide to center tape.
1
Make sure Sheet Core C is
CENTERED over H3 Wires.
Use Bottom of UL Tape to align Sheet Core C.
2
Use DTT Shield Case Supports as guides for
the H3 Wires. DO NOT Cross wires over the
Supports (pinch points).
2
Use Score Line to align the
bottom edge of the Sheet Core C.
Align UL tape to DTT Shield
Support on Panel.
DO NOT allow wires to cross
over the support on the panel.
KDL-32XBR4/40D3000
24
KDL-32XBR4 ONLY
H3 BOARD HARNESS (CONTINUED)
KDL-32XBR4/40D3000
OPERATION PROCESS
Apply Sheet Core C to edge of Panel to
cover sharp edge of panel.
Use ribs on bezel (w/o screw boss) as a
guide to center tape.
1
3
2
Apply LCD Tape to hold BOTH
Rt. Speaker and H4 wires.
KDL-32XBR4/40D3000
25
KDL-32XBR4 ONLY
H4 BOARD
1
3
2
KDL-32XBR4/40D3000
OPERATION PROCESS
1. Install H4-Bd BEFORE Installing the
speakers/baffles.
2. Apply LCD Tape on SIDE of the magnet
on Rt. Speaker to hold the H4 Cables.
3. MAKE SURE there is slack in the cable
between the H4 Connector and LCD Tape.
Tension on the cable will cause the
Connector to lift or break.
KDL-32XBR4/40D3000
26
KDL-32XBR4 ONLY
H4 BOARD AND RIGHT SPEAKER
1
Dress BOTH H4/Speaker Cables in plastic
clips on G-Bracket.
NOTE: Speaker cables are NOT dressed inside
far left clip on G-Bracket.
2
KDL-32XBR4/40D3000
OPERATION PROCESS
Wire Dress Rt. Speaker wires and H4
cables in G-Bracket clips.
NOTE: Rt. Spkr. Wires are NOT dressed
in far LEFT G-Bracket clip!
KDL-32XBR4/40D3000
27
KDL-32XBR4 ONLY
H4 BOARD AND RIGHT SPEAKER (CONTINUED)
1
2
NOTE BOTH H4-Bd and Rt. Speaker
cables are dressed UNDER AC Inlet
CAUTION: DO NOT Push hard on AC
inlet wires after routing inside G1 bracket!!
Wire Insulation can be CUT by plastic edges!
NOTE:
Running Change will be implemented later.
(PCN/ECN to add M3 clamp).
KDL-32XBR4/40D3000
OPERATION PROCESS
1. Wire Dress Right Speaker wires and H4
cables in side clamps (white) and G3-Bd
bracket clips (black).
NOTE: H4-Bd/Rt. Speaker cables are
dressed UNDER AC Inlet.
2. Dress AC Inlet cables as shown.
Make sure Green/Yellow Earth Gnd. Is
screwed into lower LCD Bracket
(w/4x8mm screw)
KDL-32XBR4/40D3000
NOTE Angle of Earth Gnd. Wire.
(Ring terminal touches "dimple" on plate)
H4 and Speaker cables are NOT dressed
in small clips! Too difficult to dress with
gloves on operator's hands.
NOTE: H4-Bd/Right Speaker cables
ARE dressed in plastic clip.
Clip NOT Eliminated!
28
KDL-32XBR4 ONLY
CORE BLOCK HARNESS
KDL-32XBR4/40D3000
OPERATION PROCESS
Route/Dress Harnesses connected to
Core Block as Shown
NOTE Order & Direction of Cables in
plastic Clip on Shield Case.
DRESS CABLES 1st
DRESS CABLES LAST
ON TOP ALL CABLES.
NOTE order and direction of cables!
2
DRESS CABLES 3rd
DRESS CABLES 2nd
1
DRESS CABLES 4th
3
1
Keep Cables BELOW level
of Shield Case (Pinch Points)
KDL-32XBR4/40D3000
29
KDL-32XBR4 ONLY
CORE BLOCK HARNESS (CONTINUED)
1 1
KDL-32XBR4/40D3000
OPERATION PROCESS
Route/Dress Core-Block cables as shown
Put Attention on DIRECTION of cables
in G-Bracket.
Put Attention on the position of the
Side Clamps and routing of the Cables
between Core Block and G1-Bracket.
NOTE Routing of cables and position
of side clamps (HF Cover has marks
for 32" clamp position)
KDL-32XBR4/40D3000
NOTE direction of wires dressed in G-Bracket.
30
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