Sony KDL-40W4100, KDL-46W4100, KDL-46W4150 Service Manual
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-40W4100
KDL-40W4100
KDL-40W4100
KDL-40W4100
KDL-46W4100
KDL-46W4100
KDL-46W4100
KDL-46W4100
KDL-46W4150
KDL-46W4150
RM-YD023 US
RM-YD023 CANADA
RM-YD023 MEXICO
RM-YD023 LATIN AMERICA
RM-YD023 US
RM-YD023 CANADA
RM-YD023 MEXICO
RM-YD023 LATIN AMERICA
RM-YD023 US
RM-YD023 CANADA
EX1
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 4/2008
:UPDATED ITEM
☛
REVISION DATE SUBJECT
4/2008 No revisions or updates are applicable at this time.
7/2008 Changed Stand Assembly Removal to Table-Top Stand Assembly Removal.
Replaced page 15.
Added “Cleaning the LCD Panel” instructions to Disassembly section. Replaced page 19.
Changed description for Stand Assembly to Table-Top Stand Assembly.
Updated information for screws that attach Table-Top Stand to TV. Replaced page 95.
Added PNs for BU Boards for Mexico and Latin America Models.
Identifi ed AC Inlet as a Critical Component. Replaced page 96.
Corrected screw description for Table-Top Stand in Screw Legend. Replaced page 100.
Added PNs for BU Boards for Mexico and Latin America Models.
Added PN for Screw to attach Table-Top Stand to Miscellaneous list. Replaced page 101-124.
LCD DIGITAL COLOR TELEVISION
9-883-779-02
Self Diagnosis
Supported model
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-40W4100
KDL-40W4100
KDL-40W4100
KDL-40W4100
KDL-46W4100
KDL-46W4100
KDL-46W4100
KDL-46W4100
KDL-46W4150
KDL-46W4150
RM-YD023 US
RM-YD023 CANADA
RM-YD023 MEXICO
RM-YD023 LATIN AMERICA
RM-YD023 US
RM-YD023 CANADA
RM-YD023 MEXICO
RM-YD023 LATIN AMERICA
RM-YD023 US
RM-YD023 CANADA
EX1
CHASSIS
9-883-779-02
KDL-40W4100 RM-YD023
LCD DIGITAL COLOR TELEVISION
KDL-40W4100/46W4100/46W4150
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 ............................................................ 13
1-3. Side Jack Bracket, BU Shield and BU Board Removal ........
1-4. Power Unit Removal ........................................................... 14
1-5. Table-Top Stand Removal .................................................... 15
1-6. Under Cover and AC Inlet Removal ..................................... 15
1-7. Structural Frames and Brackets Removal
(KDL-40W4100 Only) ........................................................... 16
1-8. Structural Frames and Brackets Removal
(KDL-46W4100/46W4150 Only) .......................................... 17
1-9 Speakers, Under Bar, H3E/H4 Board
and Light Guide Removal .................................................... 18
1-10. LCD Panel Removal ............................................................. 19
1-11. Balancer (MT Inverter) Board Removal ............................... 20
Wire Dressing ............................................................................... 21
KDL-40W4100 Only ............................................................. 21
KDL-46W4100/46W4150 Only ............................................. 42
SECTION 2: SERVICE ADJUSTMENTS ............................................. 64
2-1. Viewing Service Adjustment Data ........................................ 64
2-2. Accessing Service Adjustment Mode ................................... 64
2-3. Viewing the Service Menus .................................................. 64
2-4. Using the Remote Commander to View Service Data ......... 65
2-5. Resetting to Factory Defaults ............................................... 65
14
SECTION 3: DIAGRAMS ..................................................................... 66
3-1. Circuit Boards Location ........................................................ 66
3-2. Printed Wiring Boards
and Schematic Diagrams Information ................................. 66
3-3. Block Diagram ...................................................................... 68
3-4. Schematics and Supporting Information .............................. 69
BU Board Schematic Diagram (1 of 12) ............................... 69
BU Board Schematic Diagram (2 of 12) ............................... 70
BU Board Schematic Diagram (3 of 12) ............................... 71
BU Board Schematic Diagram (4 of 12) ............................... 72
BU Board Schematic Diagram (5 of 12) ............................... 73
BU Board Schematic Diagram (6 of 12) ............................... 74
BU Board Schematic Diagram (7 of 12) ............................... 75
BU Board Schematic Diagram (8 of 12) ............................... 76
BU Board Schematic Diagram (9 of 12) ............................... 77
BU Board Schematic Diagram (10 of 12) ............................. 78
BU Board Schematic Diagram (11 of 12) ............................. 79
BU Board Schematic Diagram (12 of 12) ............................. 80
H3E Board Schematic Diagram ........................................... 82
H4 Board Schematic Diagram .............................................. 84
IP5Z Board Schematic Diagram (1 of 2)
(KDL-40W4100 Only) ...................................................... 86
IP5Z Board Schematic Diagram (2 of 2)
(KDL-40W4100 Only) ...................................................... 87
IP5Z Board Schematic Diagram (1 of 2)
(KDL-46W4100/46W4150 Only) ..................................... 90
IP5Z Board Schematic Diagram (2 of 2)
(KDL-46W4100/46W4150 Only) ..................................... 91
3-5. Semiconductors ................................................................... 94
SECTION 4: EXPLODED VIEWS ........................................................ 95
4-1. Rear Cover Assembly and Table-Top Stand Assembly ....... 95
4-2. Chassis ................................................................................ 96
4-3. Connectors ........................................................................... 97
4-4. Bezel Assembly and LCD Panel
(KDL-40W4100 Only) ........................................................... 98
4-5. Bezel Assembly and LCD Panel
(KDL-46W4100/46W4150 Only) .......................................... 99
4-6. Screw Legend .................................................................... 100
KDL-40W4100/46W4100/46W4150
SECTION 5: ELECTRICAL PARTS LIST .......................................... 101
APPENDIX A: ENCRYPTION KEY COMPONENTS ..........................A-1
3
SPECIFICATIONS
KDL-40W4100/46W4100/46W4150
Power Requirements
Power Consumption (W)
In Use (Max)
In Standby
120V AC, 60Hz
230W (KDL-40W4100 Only)
275W (KDL-46W4100/46W4150 Only)
Less than 0.1W
VIDEO (IN) 1/2/3:
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, 75 ohms unbalanced, sync negative
Audio
500 mVrms (Typical)
Impedance:47 kilohms
COMPONENT IN 1/2:
YP
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
(Component Video)
BPR
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, Dolby Digital
AUDIO (for HDMI IN 4 only):
500 mVrms (Typical)
Impedance: 47 kilohms
AUDIO OUT:
500 mVrms (Typical)
DIGITAL OUT (OPTICAL):
PCM/Dolby Digital optical signal
PC IN:
D-sub 15-pin, analog RGB, 0.7 Vp-p, 75 ohms, positive
PC AUDIO INPUT:
Stereo mini jack, 500 mVrms (Typical)
Impedance: 47 kilohms
Trademark Information
KDL-40W4100/46W4100/46W4150
Blu-ray Disc is a trademark.
“BRAVIA” and , S-Force,
BRAVIA Sync, , DMe
trademarks or registered marks of Sony
Corporation.
x
and “x.v. Color” are
“XMB” and “XrossMediaBar” are the
trademarks of Sony Corporation and Sony
Computer Entertainment Inc.
“PLAYSTATION” is a registered trademark
and “PS3” is a trademark of Sony Computer
Entertainment Inc.
Adobe is a registered trademark or a trademark
of Adobe Systems Incorporated in United
States and/or other countries.
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 double-D symbol
are trademarks of Dolby Laboratories.
Design and specifi cations are subject to change without notice.
In the United States, TV Guide and other
related marks are registered marks of
Gemstar-TV Guide International, Inc. and/or
one of its affiliates. In Canada, TV Guide is a
registered mark of Transcontinental Inc., and is
used under license by Gemstar-TV Guide
International, Inc.
The TV Guide On Screen system is
manufactured under license from Gemstar-TV
Guide International, Inc. and/or one of its
affiliates.
The TV Guide On Screen system is protected
by one or more of the following United States
patents 4,908,713; 6,498,895; 6,850,693;
6,396,546; 5,940,073; 6,239,794 to
Gemstar-TV Guide International, Inc. and/or
its subsidiaries.
Gemstar-TV Guide International Inc. and/or its
related affiliates are not in any way liable for
the accuracy or availability of the program
schedule information or other data in the TV
Guide On Screen system and cannot guarantee
service availability in your area. In no event
shall Gemstar-TV Guide International, Inc.
and/or its related affiliates be liable for any
damages in connection with the accuracy or
availability of the program schedule
information or other data in the TV Guide On
Screen system.
4
KDL-40W4100/46W4100/46W4150
7/8
1/8
7/8
1/8
KDL-40W4100
KDL-46W4100
KDL-46W4150
Power Consumption
in use
in standby
Speaker Output
230W 275W
Less than 1W
10W+10W
mm 58 x 126 mm 65 X 150 mm
1/4
2
in
x 5 in 2
Dimensions (W x H x D)
with stand
mm 986 x 684 x 279 mm 1120 x 782 x 307 mm
38
in
x 27 x 11 in 44
without stand
mm 986 x 646 x 110 mm 1120 x 742 x 115 mm
in
38
7/8
x 25
1/2
3/8
x 4
in 44
1/8
wall-mount hole pattern 300 x 300 mm 300 x 300 mm
wall-mount screw size M6 x 12 - 18
Mass
with stand
kg 23 kg 30 kg
lbs 51 lbs 67 lbs
without stand
kg 20 kg 26 kg
lbs 45 lbs 58 lbs
All measurements are approximations.
1/2
x 30
x 29
x 5
x 12
1/4
7/8
x 4
in
5/8
in
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
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)
KDL-40W4100 - 40 inches
KDL-46W4100 - 46 inches
KDL-46W4150 - 46 inches
Supplied Accessories
Remote Commander RM-YD023
Two Size AA (R6) Batteries
AC Power Cord
Cable Holder (1 attached to the TV)
Operating Instructions
Quick Setup Guide
Warranty Card
Online Registration Card (USA and Canada only)
Safety and Regulatory Booklet
Attaching the Table-Top Stand
Installing the Wall-Mount Bracket
Optional Accessories
Connecting Cables
Suport Belt Kit
Wall-Mount Bracket
SU-WL500
TV-Stand
WS-S10LS/SU-FL300M
SU-FL300L (KDL-46W4100/46W4150 only)
KDL-40W4100/46W4100/46W4150
5
KDL-40W4100/46W4100/46W4150
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.
• Before carrying the TV, disconnect all cables.
• Carrying the large size TV requires two or more
people.
• When carrying the TV, place your hand as
illustrated and hold it securely. Do not subject the
TV to shocks, vibration, or excessive force.
• Lift the TV by placing your palm directly
underneath the panel but do not:
• squeeze the speaker grill area
• place your fingers in the groove above the
speaker grill area
• put stress on the LCD panel.
• Do not lift the TV from the bottom center.
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-40W4100/46W4100/46W4150
6
KDL-40W4100/46W4100/46W4150
A
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
ssurez-vous de suivre les consignes suivantes pour
protéger votre bien et éviter les blessures graves.
• Avant de transporter le téléviseur, débranchez
tous les câbles.
• Le transport d’un téléviseur de grande taille doit
être effectué par au moins deux personnes.
• Lorsque vous transportez le téléviseur, placez vos
mains tel qu’illustré et tenez solidement
l’appareil. Ne soumettez pas le téléviseur à des
chocs ou à des 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.
• Soulevez le téléviseur en plaçant la paume de votre
main directement en dessous du panneau, mais :
• n’appuyez pas sur la région de la grille de
haut-parleur
• ne placez pas vos doigts dans le sillon audessus de la région de la grille de haut-parleur
• n’imposez pas de charge sur le panneau ACL.
• ne soulevez pas le téléviseur en plaçant vos
mains en dessous au centre.
! 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-40W4100/46W4100/46W4150
7
SAFETY-RELATED COMPONENT WARNING
KDL-40W4100/46W4100/46W4150
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-40W4100/46W4100/46W4150
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-40W4100/46W4100/46W4150
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-40W4100/46W4100/46W4150
9
SAFETY CHECK-OUT
KDL-40W4100/46W4100/46W4150
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-40W4100/46W4100/46W4150
10
KDL-40W4100/46W4100/46W4150
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
STANDBY LED
PIC OFF/
TIMER
LED
PIC OFF/TIMER STANDBY PO WE
Green LED
Red LED
* Light when the TV set is on
* Lights up in red when TV is in PC standby mode.
* If LED blinks continuously, this may indicate
that the TV needs servicing.
Green or Orange
LED
* Lights up in green 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.
R
KDL-40W4100/46W4100/46W4150
11
KDL-40W4100/46W4100/46W4150
2 times
5 times
LED ON 0.3 sec.
LED OFF 0.3 sec.
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
LED OFF
3 sec.
.
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
005 PANEL_ALERT 00
006 BACKLIGHT 00
013 BACKLIGHT_BALANCE 00
00001 00027 00009 00000
3. Press the Channel 1 button on the Remote Commander to go to Page 2 of the Self Check list.
SELF CHECK PAGE 2
007 TEMP 00
008 SP_PROT 00
011 TRIDENT_IC 00
012 HFR_ERROR 00
012 TCON_ERROR 00
00001 00027 00009 00000
4. Press the Channel
NOTE: If the Service Menu display text is not completely visible, press the Menu
5. To exit Self Check display, turn the power off.
4
button on the Remote Commander to go back to Page 1 of the Self Check list.
button on the Remote Commander to refresh the display.
HOME
Clearing the Self Check Diagnostic List
1. In Service Mode, press the Channel 8 Channel 0.
KDL-40W4100/46W4100/46W4150
12
1-1. REAR COVER REMOVAL
1
Remove 2 screws from Terminal Position.
2
Remove 6 screws.
3
Remove 19 screws (KDL-40W4100 ONLY).
Remove 21 screws (KDL-46W4100/40W4150 ONLY).
KDL-40W4100/46W4100/46W4150
SECTION 1: DISASSEMBLY
Rear Cover
1
1-2. SWITCH UNIT REMOVAL
1
Remove from bezel.
2
Disconnect 1 connector.
2
3
Switch Unit
2
Bezel
1
KDL-40W4100/46W4100/46W4150
13
1-3. SIDE JACK BRACKET, BU SHIELD AND BU BOARD REMOVAL
1
Release hook and slide out Side Jack Bracket from BU Board.
2
Remove 2 HEX screws.
3
Disconnect 6 connectors.
4
Remove 9 screws.
Main Bracket
KDL-40W4100/46W4100/46W4150
4
1-4. POWER UNIT REMOVAL (IP5Z BOARD)
1
Disconnect 5 connectors.
2
Remove 6 screws.
3
Release 4 Board Holders.
BU Board
1
3
Side Jack Bracket
BU Shield
2
KDL-40W4100/46W4100/46W4150
Corner
Cover
3
2
Power Unit
(IP5Z Board)
1
14
1-5. TABLE-TOP STAND REMOVAL
☛
1
Remove 4 screws.
KDL-40W4100/46W4100/46W4150
1
Table-Top Stand Assembly
Under Cover
1-6. UNDER COVER AND AC INLET REMOVAL
1
Remove 1 screw.
2
Remove 2 screws.
3
Remove 1 screw.
AC Bracket
Under Cover
3
AC Inlet
2
Bottom Bracket
1
KDL-40W4100/46W4100/46W4150
15
KDL-40W4100/46W4100/46W4150
1-7. STRUCTURAL FRAMES AND BRACKETS REMOVAL (KDL-40W4100 ONLY)
1
Remove 4 screws from Top Vesa Brackets.
2
Remove 1 screw from Main Bracket and Bezel.
3
Remove 4 screws from Main Bracket.
4
Remove 6 screws from Spine Frames.
5
Remove 4 screws from Bottom Vesa Brackets.
6
Remove 4 screws from Bottom Frame.
2
1
3
Spine Frame
4
Vesa (Bottom)
5
Vesa (Top)
6
Bottom Frame
KDL-40W4100/46W4100/46W4150
16
KDL-40W4100/46W4100/46W4150
1-8. STRUCTURAL FRAMES AND BRACKETS REMOVAL (KDL-46W4100/46W4150 ONLY)
1
Remove 1 screw from Main Bracket.
2
Remove 3 screws from Main Bracket and Spine Frame.
3
Remove 2 screws from Top Vesa Bracket.
4
Remove 2 screws from G Board Support.
5
Remove 2 screws from Center Frame.
6
Remove 10 screws from Spine Frames.
7
Remove 4 screws from both Bottom Vesa Brackets.
8
Remove 4 screws from Bottom Bracket.
9
Remove 1 screw from Bottom Bracket.
1
Main Bracket
2
Spine Frame
Top Vesa Bracket
3
G Board
Suport
6
5
Spine Frame
4
Bottom Vesa Bracket
Center Frame
7
8
9
Bottom Bracket
KDL-40W4100/46W4100/46W4150
Bezel
17
KDL-40W4100/46W4100/46W4150
1-9 SPEAKERS, UNDER BAR, H3E/H4 BOARD AND LIGHT GUIDE REMOVAL
1
Slide out Speaker (L) Unit from Bezel.
2
Slide out Speaker (R) Unit from Bezel.
3
Remove 2 screws from Under Bar.
4
Disconnect 1 connector and slide out H3E Board from Clear Panel.
5
Release hooks and remove from Bezel.
6
Remove 1 screw and release hooks from Clear Panel.
7
Disconnect 1 connector and slide out H4 Board from Light Guide.
8
Disconnect 1 connector and remove Illumination Module from Bezel.
3
Under Bar
1
Speaker Unit (L)
H4 Board
8
6
7
Illumination
Module
4
H3E Board
5
Clear Panel
Light Guide
2
Speaker Unit (R)
Bezel
KDL-40W4100/46W4100/46W4150
18
1-10. LCD PANEL REMOVAL
NOTE: The LVDS cable can only be installed one way. There is colored tape on the cable to determine which side is attached
on Page 36 for KDL-40W4100 and Page 58 for KDL-46W4100/46W4150 and “LVDS Cable Routing Caution” on Page 37.
1
2
to the TCON and which side is attached to the BU Board. Refer to Wire Dressing Illustration “LVDS Cable Routing”
Disconnect 2 connectors.
Remove 2 screws.
KDL-40W4100/46W4100/46W4150
2
LCD Panel
Bezel
1
KDL-40W4100/46W4100/46W4150
19
1-11. BALANCER (ETC-INVERTER MT) BOARD REMOVAL
G
P
NOTE: The LVDS cable can only be installed one way. There is colored tape on the cable to determine which side is attached
to the TCON and which side is attached to the BU Board. Refer to Wire Dressing Illustration “Installation Procedure”
on Page 38 for KDL-40W4100 and Page 60 for KDL-46W4100/46W4150.
1
Remove 8 screws (KDL-40W4100 ONLY).
Remove 7 screws (KDL-46W4100/46W4150 ONLY).
2
Pull out the board from Lamp Socket.
LCD Panel
WARNIN
NEVE R REMOVE TH E
SCREWS SEC URING THE
LASTIC STRIP HOLDING
THE LAMP SOC KETS
DAMAGE TO THE
BACK LIGHT TUB ES WI LL
OCC UR!
!
KDL-40W4100/46W4100/46W4150
2
Balancer Board
(ETC-Inverter MT) Board
REMOVE SCREWS
SECURING
SHIELD
Cover
1
WARNING
NEVER REMOVE THE
SCREWS SECURING THE
PLASTIC STRIP HOLDING
THE LAMP SOCKETS
DAMAGE TO TH E
BACKLIGHT TUBES WILL
OCC UR!
!
.
Balancer (ETC-Inverter MT) Board
REMOVE
CONNECTOR AND
PULL BOARD TO
THE RIGHT
SHIE LD REMOVAL
END VIEW
SOCKET
KDL-40W4100/46W4100/46W4150
BALANCER (ETC-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.
20
KDL-40W4100 ONLY
H Boards/Speaker Harness
KDL-40W4100/46W4100/46W4150
WIRE DRESSING
Apply harness to Panel TOP edge. To center Harness, position
RED UL tape over center of panel. Use screw on panel as
Reference where center of panel is. Apply Sheet core C over
Red UL tape once harness is centered. Apply Sheet Core C
over Black UL Tape on Harness (guides).
3
KDL-40W4100/46W4100/46W4150
1
2
Center of panel
21
KDL-40W4100 ONLY
H Boards/Speaker Harness: Lighted Sony Logo
Apply LCD Tape over panel
sharp edge and connect harness
to Lighted Sony Logo.
KDL-40W4100/46W4100/46W4150
KDL-40W4100/46W4100/46W4150
1
22
KDL-40W4100 ONLY
Combination H Boards/Speaker Harness
Apply Sheet Core C to Harness. Use BLACK UL
TAPE on Harness as guide where to apply
Sheet Core C. Apply LCD Tape over speaker wires.
Use Black UL tape as guide where to apply tape.
DO NOT apply LCD tape over hole in speaker!
KDL-40W4100/46W4100/46W4150
4
KDL-40W4100/46W4100/46W4150
2
23
KDL-40W4100 ONLY
Combination H Boards/Speaker Harness – Attach H3/H4 Connector
KDL-40W4100/46W4100/46W4150
4
3
3
H4-Bd
Apply LCD Tape over panel
sharp edge.
KDL-40W4100/46W4100/46W4150
H3E-Bd
24
KDL-40W4100 ONLY
Combination H Boards/Speaker Harness: H3-Board routing
4
KDL-40W4100/46W4100/46W4150
3
KDL-40W4100/46W4100/46W4150
Keep wires from
Crossing over edge of
Bezel (pinch point)
25
KDL-40W4100 ONLY
Balancer Board Cable Routing
KDL-40W4100/46W4100/46W4150
Fix 7P harness with Sheet Core C.
NOTE:
Wires are routed UNDER Spine Frame
to avoid sharp metal edge.
CAUTION:
Make sure there is sufficient
Slack on wire so there is very little
Stress on connector!
KDL-40W4100/46W4100/46W4150
5
6
26
KDL-40W4100 ONLY
KDL-40W4100/46W4100/46W4150
CAUTION:
7P Connector Assy CAUTION
6
3
Keep wires away from capacitor C6729
on IP5-Bd. (No Touch)
Use plastic Pin on Panel as guide to apply
Himelon tape Sheet Core C.
KDL-40W4100/46W4100/46W4150
6
27
KDL-40W4100 ONLY
LEFT Speaker Harness Dressing
1
KDL-40W4100/46W4100/46W4150
Apply LCD tape (2 Places) to secure Left
Speaker wires. Dress speaker wires in
Slide Clamp as shown. No Need to apply
LCD Tape over speaker.
2
4 5
KDL-40W4100/46W4100/46W4150
28
KDL-40W4100 ONLY
BU Board
Support Bracket
Dress harness in slide clamps
as shown (3 places).
KDL-40W4100/46W4100/46W4150
3
KDL-40W4100/46W4100/46W4150
1
2
4
5
29
KDL-40W4100 ONLY
KDL-40W4100/46W4100/46W4150
BU Board Support Bracket
CAUTION
3
CAUTION:
Dress 30P Harness as shown to keep
JIG connectors CLEAR of obstructions.
KDL-40W4100/46W4100/46W4150
30
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