Sony KDL-46Z4100S, KDL-40Z4100S, KDL-46Z4100B, KDL-40Z4100B Service Manual
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-40Z4100/B
☛
☛
KDL-40Z4100/B
☛
KDL-40Z4100/S
KDL-40Z4100/S
☛
KDL-46Z4100/B
☛
☛
KDL-46Z4100/B
☛
KDL-46Z4100/S
☛
KDL-46Z4100/S
RM-YD024 US/CND
RM-YD024 MX/LATIN AMERICA
RM-YD024 US/CND
RM-YD024 MX/LATIN AMERICA
RM-YD024 US/CND
RM-YD024 MX/LATIN AMERICA
RM-YD024 US/CND
RM-YD024 MX/LATIN AMERICA
EX1
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 5/2008
:UPDATED ITEM
REVISION DATE SUBJECT
5/2008 No revisions or updates are applicable at this time.
8/2008 Reissue entire manual due to multiple updates.
8/2008 Updated reference to LCD Panels service manual. Replaced pages 84, 86, & 88.
Removed Appendix B. Replaced page 3.
9-883-786-03
LCD DIGITAL COLOR TELEVISION
Self Diagnosis
Supported model
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-40Z4100/B
☛
☛
KDL-40Z4100/B
☛
KDL-40Z4100/S
KDL-40Z4100/S
☛
KDL-46Z4100/B
☛
☛
KDL-46Z4100/B
☛
KDL-46Z4100/S
☛
KDL-46Z4100/S
RM-YD024 US/CND
RM-YD024 MX/LATIN AMERICA
RM-YD024 US/CND
RM-YD024 MX/LATIN AMERICA
RM-YD024 US/CND
RM-YD024 MX/LATIN AMERICA
RM-YD024 US/CND
RM-YD024 MX/LATIN AMERICA
EX1
CHASSIS
9-883-786-03
KDL-46Z4100 RM-YD024
LCD DIGITAL COLOR TELEVISION
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
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 and Switch Unit (Contains H1 Board) Removal 13
1-2. Side Jack Bracket, BU Bracket, BU Shield and
BU Board Removal
1-3. G4 Board (Power Unit) Removal ......................................... 14
1-4. Table-Top Stand and Under Cover Removal ........................ 14
1-5. AC Inlet and AC Bracket Removal ....................................... 15
1-6. Speakers, Under Bar, Screw Caps, H3V Board, and
H4 Board Removal ............................................................... 15
1-7. VESA Frames and Bottom Bracket Removal ....................... 16
1-8. LCD Panel Removal ............................................................. 16
1-8-1. Cleaning the LCD Panel .......................................... 16
1-9. Balancer (ETC-Inverter) MT Board Removal ....................... 17
1-10. Baffl es, IR Guide and Clear Panel Removal ........................ 18
WIRE DRESSING ........................................................................ 19
KDL-40Z4100/B & 40Z4100/S ONLY ................................... 19
KDL-46Z4100/B & 46Z4100/S ONLY ................................... 37
SECTION 2: SERVICE ADJUSTMENTS ............................................. 54
2-1. Viewing Service Adjustment Data ........................................ 54
2-2. Accessing Service Adjustment Mode ................................... 54
2-3. Viewing the Service Menus .................................................. 54
2-4. Using the Remote Commander to View Service Data ......... 55
2-5. Resetting to Factory Defaults ............................................... 55
.............................................................. 13
SECTION 3: DIAGRAMS ..................................................................... 56
3-1. Circuit Boards Location ........................................................ 56
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 56
3-3. Block Diagram ...................................................................... 58
3-4. Schematics and Supporting Information .............................. 59
BU Board Schematic Diagram (1 of 12) ............................... 59
BU Board Schematic Diagram (2 of 12) ............................... 60
BU Board Schematic Diagram (3 of 12) ............................... 61
BU Board Schematic Diagram (4 of 12) ............................... 62
BU Board Schematic Diagram (5 of 12) ............................... 63
BU Board Schematic Diagram (6 of 12) ............................... 64
BU Board Schematic Diagram (7 of 12) ............................... 65
BU Board Schematic Diagram (8 of 12) ............................... 66
BU Board Schematic Diagram (9 of 12) ............................... 67
BU Board Schematic Diagram (10 of 12) ............................. 68
BU Board Schematic Diagram (11 of 12) ............................. 69
BU Board Schematic Diagram (12 of 12) ............................. 70
D3Z-40 Board Schematic Diagram
(KDL-40Z4100/B & 40Z4100/S ONLY) .................... 72
D3Z-46 Board Schematic Diagram
(KDL-46Z4100/B & 46Z4100/S ONLY) .................... 73
G4 Board Schematic Diagram ............................................ 75
H3V Board Schematic Diagram ........................................... 78
H4 Board Schematic Diagram .............................................. 80
3-5. Semiconductors ................................................................... 82
SECTION 4: EXPLODED VIEWS ........................................................ 83
4-1. Rear Cover Assembly and Table-Top Stand Assembly ....... 83
4-2. Chassis ................................................................................ 84
4-3. Connectors ........................................................................... 85
4-4. Bezel Assembly and LCD Panel .......................................... 86
4-5. Screw Legend ...................................................................... 87
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
SECTION 5: ELECTRICAL PARTS LIST ............................................ 88
APPENDIX A: ENCRYPTION KEY COMPONENTS ..........................A-1
3
SPECIFICATIONS
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
Power Requirements
Power Consumption (W)
In Use (Max)
In Standby
120V AC, 60Hz
225W (KDL-40Z4100/B & 40Z4100/S ONLY)
285W (KDL-46Z4100/B & 46Z4100/S 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
(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 (Typical)
Impedance: 47 kilohms
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):
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
LAN (10/100):
10 BASE-T/100-TX Connector
DMPORT:
Audio
500 mVrms (Typical)
Impedance:47 kilohms
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 double-D symbol
are trademarks of Dolby Laboratories.
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.
USB:
Hi-Speed USB
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.
Blu-ray Disc is a trademark.
“BRAVIA” and , S-Force,
Motionflow, BRAVIA Sync, , DMe
MICRO VAULT, and “x.v. Color” are
trademarks or registered marks of Sony
Corporation.
“XrossMediaBar” is a trademark of Sony
Corporation. “XMB” is a trademark 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.
®
DLNA
, the DLNA Logo and DLNA
CERTIFIED™ are trademarks, service marks,
or certification marks of the Digital Living
Network Alliance.
x
,
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
Design and specifi cations are subject to change without notice.
4
Speaker Output
1/4
3/4
1/2
1/8
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
KDL-40Z4100/B & 40Z4100/S KDL-46Z4100/B & 46Z4100/S
10W+10W 10W+10W
mm 45 X 200 mm 45 X 200 mm
3/4
in
1
7/8
x 7
in 1
Dimensions (W x H x D)
with stand
mm 994 x 654 x 279 mm 1,079 x 734 x 307 mm
in
x 25
x 11 in 42
37
without stand
mm 994 x 608 x 72 mm 1,079 x 686 x 74 mm
in
37
1/4
x 24 x 2
7/8
in 42
1/2
wall-mount hole pattern 300 x 300 mm 300 x 300 mm
Mass
with stand
kg 21.5 kg 26 kg
lbs 48 lbs 58 lbs
without stand
kg 18 kg 22 kg
lbs 40 lbs 49 lbs
All measurements are approximations.
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-40Z4100/B & 40Z4100/S Only ~ 40 inches
KDL-46Z4100/B & 46Z4100/S Only ~ 46 inches
Supplied Accessories
Remote Commander RM-YD024
Two Size AA Batteries
AC Power Cord
Cable Holder (1 attached to the TV)
Operating Instructions
Quick Setup Guide
Warranty Card
Online Registration Card
Safety and Regulatory Booklet
Attaching the Table-Top Stand
Installing the Wall-Mount Bracket
Stand Rear Cover
Optional Accessories
Connecting Cables
Suport Belt Kit
Wall-Mount Bracket
SU-WL500
TV-Stand
WS-S10LS
SU-FL300M
SU-FL300L (KDL-46Z4100/B & 46Z4100/S Only)
3/4
7/8
x 7
x 29 x 12
1/8
x 27
x 3 in
in
in
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
5
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
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-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
6
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
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-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
7
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
SAFETY-RELATED COMPONENT WARNING
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-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
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-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
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-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
9
SAFETY CHECK-OUT
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
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-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
10
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
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
0)#/&&4)-%2
Green LED
Red LED
Green or Orange
LED
2 times
34!.$"9 0/7%2
* Lights up in green when the TV set is turned on.
* Lights up in red when TV is in PC standby mode.
* If LED blinks continuously, this may indicate
that the TV needs servicing.
* 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.
5 times
LED ON 0.3 sec.
LED OFF 0.3 sec.
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LED OFF
3 sec.
11
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LED Indicators
Diagnostic Item
Description
Main Power 2 times Power Supply Board
DC Alert 3 times
Panel Alert 5 times LCD Panel
Backlight 6 times
Temp 7 times Main Board
SP Prot 8 times Main Board
Trident IC 11 times Main Board
TCON Error 12 times LCD Panel
Backlight Balance 13 times
HFR Error 14 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. This differs from accessing Service Adjustments.
Channel 5 Volume -
Number of times
STANDBY lamp
flashes
TV POWER
.
Possible Location
Main Board
Power Supply Board
Main Board
Power Supply Board
Balancer Board (ETC-Inverter MT Board)
LCD Panel
Balancer Board (ETC-Inverter MT Board)
Results for all of the following diagnostic items are displayed on screen. No error has occurred if the screen displays a “0”.
NOTE: If the Service Menu display text is not completely visible, press the Menu
button on the Remote Commander to refresh the display.
HOME
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
Í Displays as 12 Blinks, but is actually 14 Blinks
012 TCON_ERROR 00
00001 00027 00009 00000
ÏÏ Total Panel Hours
Ï
Ï Total Hours of Operation
Ï
Ï Boot Count
4. Press the Channel
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.
Clearing the Self Check Diagnostic List
1. In Service Mode, press the Channel 8 Channel 0.
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
12
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
SECTION 1: DISASSEMBLY
1-1. REAR COVER AND SWITCH UNIT (CONTAINS H1 BOARD) REMOVAL
1
Remove 2 screws from Terminal Position
2
Remove 4 screws
3
Remove 2 Screw Caps from Rear Cover
4
Remove 15 screws (KDL-40Z4100/B & 40Z4100/S ONLY)
Remove 17 screws (KDL-46Z4100/B & 46Z4100/S ONLY)
5
Disconnect 1 connector and slide out Switch Unit
Rear Cover
1
2
3
Screw Cap
4
Switch Unit
5
1-2. SIDE JACK BRACKET, BU 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 5 connectors
4
Remove 9 screws
5
Remove 3 screws
BU Bracket
1
4
Side Jack Bracket
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
5
BU Board
BU Shield
3
2
13
1-3. G4 BOARD (POWER UNIT) REMOVAL
1
Disconnect 3 connectors
2
Remove 6 screws
3
Release board holders
4
Disconnect 4 connectors
5
Remove 6 screws
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
5
4
1-4. TABLE-TOP STAND AND UNDER COVER REMOVAL
☛
1
Remove 4 screws
2
Remove 2 screws
1
Under Cover
1
D3Z Board
2
G4 Board (Power Unit)
3
Table-Top Stand Assembly
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
2
14
1-5. AC INLET AND AC BRACKET REMOVAL
1
Remove 2 screws
2
Remove 2 screws
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
2
1-6. SPEAKERS, UNDER BAR, SCREW CAPS, H3V BOARD, AND H4 BOARD REMOVAL
☛
AC Inlet
1
AC Bracket
1
Remove 2 Screw Caps from Under Bar
2
Remove 2 screws from Under Bar
3
Slide out Speaker units from Bezel
4
Disconnect 1 connector and release IR Guide hooks to remove H4 Board
5
Disconnect 1 connector and Slide out H3V Board from Bezel
1
Speaker
3
Screw Cap
5
2
Under Bar
3
Speaker
4
H4 Board
H3V Board
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
15
1-7. VESA FRAMES AND BOTTOM BRACKET REMOVAL
1
Remove 4 screws from VESA Frames
2
Remove 4 screws
3
Remove 4 screws
1
1-8. LCD PANEL REMOVAL
1
Disconnect 2 connectors
2
Remove 3 screws (KDL-40Z4100/B & 40Z4100/S ONLY)
Remove 5 screws (KDL-46Z4100/B & 46Z4100/S ONLY)
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 on Page 32 for
KDL-40Z4100/B & 40Z4100/S models and on Page 52 for KDL-46Z4100/B & 46Z4100/S models.
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
VESA Frame
2
3
Bottom Frame
1-8-1. CLEANING THE LCD PANEL
☛
CAUTION: When cleaning the TV, be sure to unplug the power cord to avoid any chance of electric shock.
1
Clean the cabinet of the TV with a dry soft cloth.
2
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.
LCD Panel
1
2
Bezel
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
16
1-9. BALANCER (ETC-INVERTER) MT BOARD REMOVAL
1
Remove 6 screws from board cover
2
Remove 1 screw
3
Slide out Inverter Board from Light Sockets
LCD Panel
1
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
3
2
Balancer Board
REMOVE SCREWS
SECURING
SHIELD
Cover
Light Sockets
REMOVE
CONNECTOR AND
PULL BOARD TO
THE RIGHT
SHIE LD REMOVAL
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
END VIEW
SOCKET
BALANCER (ETC-INVERTER) BOARD REMOVAL
Only remove the screws securing the inverter
cover which may be metal or plastic.
The sockets for the fluorescent backlights should never be
loosened. The backlights will pop out of the
sockets and/or break the backlight requiring a
LCD panel replacement.
17
1-10. BAFFLES, IR GUIDE AND CLEAR PANEL REMOVAL
1
Remove 2 screws from Baffl es (KDL-46Z4100/B & 46Z4100/S ONLY)
2
Remove 3 screws
3
Remove 2 screws
4
Disconnect one connector and slide out from Bezel
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
1
4
Illumination
Module
Baffle
2
Clear Panel
3
IR Guide
1
Baffle
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
18
WIRE DRESSING
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
KDL-40Z4100/B & 40Z4100/S ONLY
H BOARD/SPEAKER HARNESS
Apply harness to Panel SIDE edge. To center Harness, position
YELLOW UL tape over center of panel. Use screw on panel as
Reference where center of panel is.
LEGEND
).lviuqe ro 10-110-886-2( C EROC TEEHS
7=YTQ
).lviuqe ro 10-260-886-2( EPAT DCL
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
Center of panel
19
KDL-40Z4100/B & 40Z4100/S ONLY
H BOARD/SPEAKER HARNESS (CONTINUED)
Apply harness to Panel SIDE edge. To center Harness, position
YELLOW UL tape over center of panel. Use screw on panel as
Reference where center of panel is. Apply Sheet Core C over
Black UL Tape on Harness (2 places).
MAKE SURE wires are routed on the SIDE of the panel and that
wires DO NOT cross over top edge of panel.
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
).lviuqe ro 10-110-886-2( C EROC TEEHS
7=YTQ
).lviuqe ro 10-260-886-2( EPAT DCL
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
2
1
Center of panel
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
20
KDL-40Z4100/B & 40Z4100/S ONLY
H BOARD/SPEAKER HARNESS: LIGHTED SONY LOGO
Apply LCD Tape over panel
sharp edge and connect harness
to Lighted Sony Logo.
1
1
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
).lviuqe ro 10-110-886-2( C EROC TEEHS
7=YTQ
).lviuqe ro 10-260-886-2( EPAT DCL
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
21
KDL-40Z4100/B & 40Z4100/S ONLY
H BOARD/SPEAKER HARNESS
4
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
7=YTQ
4=YTQ
2=YTQ
3
1=YTQ
1=YTQ
)11-077-056-2( PMALC EDILS
)10-494-888-2( EPATbaF-ohC
)10-062-166-2( EPAT NOLEMIH
).lviuqe ro 10-110-886-2( C EROC TEEHS
).lviuqe ro 10-260-886-2( EPAT DCL
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
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.
22
KDL-40Z4100/B & 40Z4100/S ONLY
COMBINATION H BOARD/SPEAKER HARNESS
4
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
7=YTQ
4=YTQ
3
2=YTQ
1=YTQ
1=YTQ
)11-077-056-2( PMALC EDILS
)10-494-888-2( EPATbaF-ohC
)10-062-166-2( EPAT NOLEMIH
).lviuqe ro 10-110-886-2( C EROC TEEHS
).lviuqe ro 10-260-886-2( EPAT DCL
MAKE SURE wires are routed
On SIDE of Panel.
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
23
KDL-40Z4100/B & 40Z4100/S ONLY
MAIN HARNESS ROUTING/DRESSING
Apply Sheet Core C as shown.
Make sure harness wires are BELOW
Top edge of panel!
1 5
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
).lviuqe ro 10-110-886-2( C EROC TEEHS
7=YTQ
).lviuqe ro 10-260-886-2( EPAT DCL
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
Center of Panel
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
24
KDL-40Z4100/B & 40Z4100/S ONLY
MAIN HARNESS ROUTING/DRESSING (CONTINUED)
Apply LCD Tape to secure Switch
Assy wires to SIDE of Panel.
(2 Places)
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
).lviuqe ro 10-110-886-2( C EROC TEEHS
7=YTQ
).lviuqe ro 10-260-886-2( EPAT DCL
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
4
3
2
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
25
KDL-40Z4100/B & 40Z4100/S ONLY
BALANCER BOARD CABLE ROUTING
Gently push wires down to make sure
Level of the wires are below the
Metal panel shield case.
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
).lviuqe ro 10-110-886-2( C EROC TEEHS
7=YTQ
).lviuqe ro 10-260-886-2( EPAT DCL
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
26
KDL-40Z4100/B & 40Z4100/S ONLY
LEFT SPEAKER HARNESS DRESSING
1
5
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
).lviuqe ro 10-110-886-2( C EROC TEEHS
7=YTQ
).lviuqe ro 10-260-886-2( EPAT DCL
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
4
Apply Sheet Core C to Secure Main Harness
to panel lower edge.
Apply LCD tape to secure Left Speaker wires.
DO NOT Dress speaker wires in Slide Clamp.
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
27
KDL-40Z4100/B & 40Z4100/S ONLY
BU BOARD WIRE ROUTING/DRESSING
40Z
BU-Bd Wire
Routing/Dressing
Dress harness in slide
Clamps as shown.
(2 places)
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
).lviuqe ro 10-110-886-2( C EROC TEEHS
7=YTQ
).lviuqe ro 10-260-886-2( EPAT DCL
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
2
1
5
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
4
28
KDL-40Z4100/B & 40Z4100/S ONLY
MAIN HARNESS ROUTING
40Z Main Harness Routing
CAUTION
OK
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
7=YTQ
2
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
).lviuqe ro 10-110-886-2( C EROC TEEHS
).lviuqe ro 10-260-886-2( EPAT DCL
NG
Make sure Main Harness wires do
NOT cross over Terminal Jacks
(Pinch Point with Rear Cover)
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
1
29
KDL-40Z4100/B & 40Z4100/S ONLY
3P HIGH VOLTAGE CONN ASSY ROUTING
1-835-185-11 H.V. Connector Assy.
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
LEGEND
).lviuqe ro 10-110-886-2( C EROC TEEHS
7=YTQ
).lviuqe ro 10-260-886-2( EPAT DCL
4=YTQ
)11-077-056-2( PMALC EDILS
2=YTQ
)10-494-888-2( EPATbaF-ohC
1=YTQ
)10-062-166-2( EPAT NOLEMIH
1=YTQ
KDL-40Z4100/B//40Z4100/S//46Z4100/B//46Z4100/S
30
Loading...