Sony KDL-40SL150 Service Manual

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-40SL150 KDL-40SL150
RM-YD028 MX/LATIN AMERICA
EX2R
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 3/2009
: UPDATED ITEM
REVISION DATE SUBJECT
3/2009 No revisions or updates are applicable at this time. 4/2009 Support Belt Kit, Screw Bag Assy and Screw, +PSW M5x16 moved from Accessories and Packing to Miscellaneous section. Added contents for Support Belt Kit and Screw Bag Assy. Replaced page 72. 9/2009 Updated Exploded View Section to remove LCD Panel specifi c information. Replaced page 52.
LCD DIGITAL COLOR TELEVISION
9-883-816-03
Self Diagnosis
Supported model
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-40SL150 KDL-40SL150
RM-YD028 MX/LATIN AMERICA
EX2R
CHASSIS
9-883-816-03
CCDISPLAY POWER
WIDE INPUT
TOOLS
KDL-40SL150 RM-YD028
LCD DIGITAL COLOR TELEVISION
KDL-40SL150

TABLE OF CONTENTS

SECTION TITLE PAGE SECTION TITLE PAGE
Specifi cations ................................................................................. 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 ............................................................... 13
1-1. Rear Cover Removal ............................................................ 13
1-2. Switch Unit Removal (Contains HSW3 Board) .................... 13
1-3. BM3 Board and IP1 (Power) Board Removal ...................... 14
1-4. Table-Top Stand Assembly and Under Cover Removal ....... 14
1-5. Structural Parts Removal ..................................................... 15
1-6. Loudspeaker, Under Bar, IR/LED Removal .......................... 15
1-7. LCD Panel Removal and Bezel Assembly Removal ............ 16
1-7-1. Cleaning the LCD Panel ............................................ 16
WIRE DRESSING ........................................................................ 17
SECTION 2: SERVICE ADJUSTMENTS ............................................. 26
2-1. Viewing Service Adjustment Data ........................................ 26
2-2. Accessing Service Mode ...................................................... 26
2-2-1. Entering the Serial Number after
changing the Main Board ......................................... 26
2-2-2. Resetting to Factory Defaults .................................. 27
SECTION 3: DIAGRAMS ..................................................................... 28
3-1. Circuit Boards Location ........................................................ 28
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 28
3-3. Block Diagram ...................................................................... 30
3-4. Schematics and Supporting Information .............................. 31
BM3 Board Schematic Diagram (1 of 9) .............................. 31
BM3 Board Schematic Diagram (2 of 9) .............................. 32
BM3 Board Schematic Diagram (3 of 9) .............................. 33
BM3 Board Schematic Diagram (4 of 9) .............................. 34
BM3 Board Schematic Diagram (5 of 9) .............................. 35
BM3 Board Schematic Diagram (6 of 9) .............................. 36
BM3 Board Schematic Diagram (7 of 9) .............................. 37
BM3 Board Schematic Diagram (8 of 9) .............................. 38
BM3 Board Schematic Diagram (9 of 9) .............................. 39
HLR1 Board Schematic Diagram ......................................... 41
HSR Board Schematic Diagram ........................................... 43
IP1 Board Schematic Diagram (1 of 2) ................................ 45
IP1 Board Schematic Diagram (2 of 2) ................................ 46
3-5. Semiconductors ................................................................... 48
SECTION 4: EXPLODED VIEWS ........................................................ 49
4-1. Rear Cover Assembly and Table-Top Stand Assembly ....... 49
4-2. Chassis ................................................................................ 50
4-3. Connectors ........................................................................... 51
4-4. Bezel Assembly and LCD Panel .......................................... 52
4-5. Screw Legend ...................................................................... 53
SECTION 5: ELECTRICAL PARTS LIST ............................................ 54
APPENDIX A: ENCRYPTION KEY COMPONENTS ..........................A-1
KDL-40SL150
3

SPECIFICATIONS

KDL-40SL150
Power Requirements
Power Consumption (W)
In Use (Max)
In Standby
120V AC, 60Hz
HDMI IN 1/2/3/4: HDMI: Video: 480i, 480p, 720p, 1080i,1080p, 1080/24p
Audio: Two channel linear PCM 32, 44.1 and 48 kHz, 16, 20 and 24 bits
200W
AUDIO
500 mVrms (Typical)
Less than 1 W
VIDEO (IN) 1/2: S VIDEO (4-Pin Mini DIN (VIDEO 2 Only)
Impedance: 47 kilohms
AUDIO OUT: 500 mVrms (Typical)
Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative C: 0.286 Vp-p (Burst signal), 75 ohms
VIDEO
DIGITAL AUDIO OUT (OPTICAL):
PCM optical signal
1 Vp-p, 75 ohms unbalanced, sync negative
AUDIO
500 mVrms (Typical)
PC IN: D-sub 15-pin, analog RGB, 0.7 Vp-p, 75 ohms, positive
Impedance: 47 kilohms
PC AUDIO INPUT: COMPONENT IN 1/2: YP
(Component Video)
BPR
Stereo mini jack, 500 mVrms (Typical)
Impedance: 47 kilohms 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 (Typical) Impedance: 47 kilohms
KDL-40SL150
Licensing Information
Macintosh is a trademark of Apple Inc., registered in the U.S. and other countries.
HDMI, the HDMI logo and High-Definition Multimedia Interface are trademarks or registered trademarks of HDMI Licensing, LLC.
Fergason Patent Properties, LLC: U.S. Patent No. 5,717,422 U.S. Patent No. 6,816,141
Manufactured under license from Dolby Laboratories. Dolby and the double-D symbol are trademarks of Dolby Laboratories.
TruSurround XT, SRS and (z) symbol are trademarks of SRS Labs, Inc. TruSurround XT technology is incorporated under license from SRS Labs, Inc.
Blu-ray Disc is a trademark.
“BRAVIA”, , BRAVIA Sync and are trademarks or registered trademarks of Sony Corporation.
“PLAYSTATION” is a registered trademark and “PS3” is a trademark of Sony Computer Entertainment Inc.
Design and specifi cations are subject to change without notice.
4
Speaker Output
3/4
Speaker/Full Range (2)
mm 35 X 175
in
Dimensions (W x H x D)
with stand
mm 990 x 684 x 271 mm
in
without stand
mm 990 x 638 x 93 mm
in
wall-mount hole pattern (mm) 300 x 300
wall-mount screw size (mm)
Mass
with stand
kg 18.5 kg
lbs 40.8 lbs
without stand
kg 16.8 kg
lbs 37.1 lbs
All measurements are approximations.
KDL-40SL150
7/16
1
X7
39 x 27 x 10
1/8
39 x 25
x 3
M6 x 8-12 mm
KDL-40SL150
in
3/4
in
Television system
NTSC American TV Standard ATSC (8VSB terrestrial) ATSC compliant 8VSB QAM on cable ANSI/SCTE 07 2000
Channel coverage
Analog 2-69 Terrestrial 1-135 Cable Digital 2-69 Terrestrial 1-135 Cable
Cable/Antenna
75-ohm external terminal for RF inputs
Panel System
LCD (Liquid Crystal Display) Panel
Display Resolution (horizontal x vertical)
1,920 dots x 1,080 lines
Screen Size (measured diagonally)
~ 40”
Supplied Accessories
Remote Commander RM-YD028 Two Size AA (R6) Batteries Cable Holder (1 attached to the TV) Operating Instructions Quick Setup Guide Warranty Card Safety and Regulatory Booklet Attaching the Table-Top Stand Flyer Screws (4)
Optional Accessories
Connecting Cables Wall-Mount Bracket SU-WL500
KDL-40SL150
5
KDL-40SL150

WARNINGS AND CAUTIONS - ENGLISH

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
Be sure to follow these guidelines to protect your property and avoid causing serious injury.
• Carry the TV with an adequqate 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.
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.
KDL-40SL150
6
KDL-40SL150

WARNINGS AND CAUTIONS - FRENCH

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
Tenez compte de ce qui suit pendant l’installation du téléviseur :
• Débranchez tous les câbles avant de transporter le téléviseur.
• Transportez le téléviseur avec le nombre de personnes approprié ; un téléviseur de grande taille doit être transporté par au moins deux personnes.
• Lors du transport du téléviseur, l’emplacement des mains est très important pour votre sécurité, ainsi que pour éviter de causer des dommages.
ALERTE!!
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-40SL150
7

SAFETY-RELATED COMPONENT WARNING

KDL-40SL150
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-40SL150
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-40SL150
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-40SL150
9

SAFETY CHECK-OUT

KDL-40SL150
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-40SL150
10
KDL-40SL150

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.
LED Indicators
PIC OFF / TIMER
STANDBY
POWER
Self Diagnosis
Supported model
Description of LED Indictors
LED LED Type Description
POWER LED
STANDBY LED
PIC OFF/ TIMER LED
Green LED
Red LED
Green or Amber
LED
2 times
5 times
LED ON 0.3 sec.
LED OFF 0.3 sec.
* Lights up in green when the TV set is turned on.
* Lights up in red when the function PC Power Management is activated and there is no signal received while in the PC input.
* If LED blinks continuously, this may indicate that the TV needs servicing.
* Lights up in amber when the Timer or Sleep functions are set. When timer is set, this LED remains lit even when the TV is turned off. * Lights up in green when the Backlight feature is activated to Off.
LED OFF
3 sec.
KDL-40SL150
11
LED Indicators
p
KDL-40SL150
Diagnostic Item
Descri
tion
Main Power 2 times Power Supply (IP1 Board)
DC Alert1 3 times
TCON Error 4 times LCD Panel
HDMI 5 times BM3 (Main) Board
Backlight 6 times LCD Panel
Temp 7 times BM3 (Main) Board
HFR Error 8 times LCD Panel
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.
NOTE: This is the same as accessing Service Adjustments.
The
displays.
Channel 5 Volume +
logo displays momentarily, then the Service Mode list
Number of times
STANDBY lamp flashes
TV POWER
.
3. To display the Self Diagnostic list, press
Service/ADC Auto Calibration
Version: ER2.6-C121 DTT: S255.P033.S077 Model: 40SL150 Serial : 8000016 Power on Time: 00000H
Diagnostic and Serial Update
ADC Auto Calibration Clone User Setting Direct Log to USB Factory Default
Change Back Exit
RETURN
4. To exit Service Mode, press .
Possible Location
BM3 (Main) Board Power Supply (IP1 Board)
.
Service Mode/Product Information
Version: ER2.6-C121 DTT: S255.P033.S077 Model: 40SL150 Power on Time: 00000H
Serial :
Diagnostic Information
2-MAIN POWER: 1
3-DC ALERT1: 0
8000016
1 indicates an error was detected 0 indicates no error was detected
4-TCON: 0 5-HDMI:
0
6-Backlight: 0 7-TEMP: 0 8-HFR: 0 101-WDT: 0
Change Back Exit
RETURN
KDL-40SL150
12

SECTION 1: DISASSEMBLY

KDL-40SL150
1-1.

REAR COVER REMOVAL

1
Remove 18 screws from Rear Cover
2
Remove 1 screw from Side Jack position
3
Remove 1 screw from Terminal position
4
Remove 4 screws from Rear Cover
NOTE: The Rear Cover is attached to the Bezel Assembly with three small tabs.
Use caution when removing the Rear Cover not to damage these tabs.
Tab Inserts
Bezel
Rear Cover
1
Screw, +BVTP2 4X16
2
Screw, +BVTP 3X12 TYPE IT-3
3
Screw, +BVTP 3X12 TYPE IT-3

1-2. SWITCH UNIT REMOVAL (CONTAINS HSW3 BOARD)

1
Slide out Switch unit from Bezel
2
Disconnect 1 connector from HSW3 Board
Bezel
1
4
Screw, +PSW M4X12
KDL-40SL150
2
Switch Unit (Contains HSW3 Board)
13
1-3. BM3 BOARD AND IP1 (POWER) BOARD REMOVAL
1
Unhook Side Jack Cover from Main Bracket
2
Disconnect 5 connectors from BM3 Board
3
Remove 9 screws from BM3 Board
4
Disconnect 5 connectors from IP1 Board
5
Remove 5 screws from IP1 Board
Main Bracket
2
Side Jack Cover
1
3 Screw,
BM3 Board
4
KDL-40SL150
+BVST 3X6
+BVST 3X6
5Screw,

1-4. TABLE-TOP STAND ASSEMBLY AND UNDER COVER REMOVAL

1
Gently place the TV set face down onto soft cloth
2
Remove 4 screws Table-Top Stand Assembly
3
Remove Under Cover from Bottom Frame
2 Screw,
+PSW M5X16
Ta bl e -To p
Stand Assembly
3
Under Cover
1
Bottom Frame
IP1 (Power) Board
KDL-40SL150
14

1-5. STRUCTURAL PARTS REMOVAL

1
Remove 1 screw from Main Bracket and Bezel
2
Remove 4 screws from Spine (L)
3
Remove 2 screws from IP1 Frame
4
Remove 4 screws from Spine (R)
5
Remove 3 screws from Bottom Frame
+BVTP 3X12
TYPE2 IT-3
KDL-40SL150
Main Bracket
1Screw,
2 Screw,
+PSW M4X8
Spine (L)
IP1 Frame
4 Screw,
+PSW M4X8
Spine (R)
+BVST 3X6

1-6. LOUDSPEAKER, UNDER BAR, IR/LED REMOVAL

1
Slide out both Speakers from Bezel
2
Remove 1 screw from Under Bar
3
Disconnect 1 connector from HLR1 Board and release from LED
4
Unhook and release LED from Bezel
5
Disconnect 1 connector from HSR Board and release from IR
6
Remove 1 screw and release IR from Bezel
3Screw,
1
Bottom Frame
5 Screw,
+BVTP2 4X16
2 Screw,
+BVTP2 4X16
Under Bar
KDL-40SL150
Speaker
HSR Board
5
6 Screw,
+BVTP 3X12 TYPE2 IT-3
IR
3
HLR1 Board
4
LED
Speaker
1
Bezel
15
1-7. LCD PANEL REMOVAL AND BEZEL ASSEMBLY REMOVAL
1
Remove LVDS cable and holder from T-CON and LCD panel
2
Remove 2 screws and release LCD panel from Bezel
3
Disconnect 2 connectors from Inverter Board
4
Carefully peel off Insulating Sheet from LCD Panel
NOTE: The Insulating Sheet is not included in LCD Panel unit.
For part number information, refer to the Exploded View Section of this manual.
Insulating Sheet (IP1) Detail
Double Sided Tape
KDL-40SL150
4
1
2
Screw, +BVTP2 4X16
3
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-40SL150
16
OVERALL ASSEMBLY
KDL-40SL150

WIRE DRESSING

KDL-40SL150
17
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21
CN3004 TO HSR, HLR1 SWITCH UNIT; CN2000 TO SPEAKER TERMINALS (CONTINUED)
LEGEND
ytQ
2
1
KDL-40SL150
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9
1
1
1
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tinu hctiws
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egde lenap
4
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.egde prahs lenap
KDL-40SL150
3
1RLH
22
CN3004 TO HSR, HLR1 SWITCH UNIT; CN2000 TO SPEAKER TERMINALS (CONTINUED)
LEGEND
ytQ
2
1
KDL-40SL150
noitpircseD
pmalC edilS
redloh SDVL
ni lobmyS
tnemucod
9
1
: snoitacidnI
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epat ddA- 6 dna 7 lanogaid ni
na lenap eht revo tekcarb niam d
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KDL-40SL150
5
7
6
23
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