sony_kdl-40w4000_kdl-46w4000_kdl-52w4000_chassis_eg1l

Ver. DATA CONTENTS

1.0 2008.06 Issued

1.1 2008.08 Addition of SEC. 2 TROUBLESHOOTING and 3-1. BLOCK DIAGRAM.

(P. 2-1, P. 3-1)

Correction and Addition of parts number for SEC. 4 EXPLODED VIEWS.

(P. 4-2, P. 4-3, P. 4-5, P. 4-6, P. 4-8, P. 4-9)

MODEL NAME : KDL-40/46/52W4000

SERVICE MANUAL

PARTS No. : 9-888-209-02

MODIFICATION HISTORY

* Blue characters are linking.

SERVICE MANUAL

LCD Digital Colour TV

Australia Model

EG1L CHASSIS

KDL-40W4000/46W4000/52W4000

RM-GD004 KDL-40W4000/46W4000/52W4000

KDL-40/46/52W4000 (AUS) 2

SPECIFICATIONS

Model name KDL-40W4000 KDL-46W4000 KDL-52W4000

Colour/video system

Channel coverage

Sound output

Input/Output jacks

1

1/ 2

PC IN

i

Display resolution

Dimensions*(w × h × d)

Optional accessories

SystemPanel systemTV system

Antenna

1, 2, 3

1, 2, 3

HDMI IN 1, 2, 3

(RGB)

DMPORT

Power and othersPower requirementsScreen size (measureddiagonally)

Power consumption(with Table-Top Stand)(without Table-Top Stand)

(with Table-Top Stand)(without Table-Top Stand)

LCD (Liquid Crystal Display) Panel

Analogue: B/G, I, D/KDigital: DVB-T

Analogue: PAL, PAL60, SECAM, NTSC3.58/4.43 (only video input)Digital: MPEG-2 MP@ML/HL

Analogue:B/G: VHF: E2 to E12 / UHF: E21 to E69 /CATV: S01 to S03, S1 to S41VHF: 0 to 12, 5A, 9A / UHF: 28 to 69 /CATV: S01 to S03, S1 to S44I: UHF: B21 to B69 / CATV: S01 to S03, S1 to S41D/K: VHF: C1 to C12, R1 to R12 /UHF: C13 to C57, R21 to R60 /

CATV: S01 to S03, S1 to S41, Z1 to Z39Digital: VHF/UHF

10 W + 10 W

75 ohm external terminal for VHF/UHF

S video input (4-pin mini DIN)

Video input (phono jack)

Audio input (phono jacks): 500 mVrms, Impedance: 47 kilohms

Supported formats: 1080p, 1080i, 720p, 576p, 576i, 480p, 480iY: 1 Vp-p, 75 ohms, 0.3V negative sync/PB/CB: 0.7 Vp-p, 75 ohms/PR/CR: 0.7 Vp-p, 75 ohmsVideo: 1080/24p, 1080p, 1080i, 720p, 576p, 576i, 480p, 480iAudio: Two channel linear PCM32, 44.1 and 48 kHz, 16, 20 and 24 bits

Analogue audio input (minijack): 500 mVrms, Impedance: 47 kilohms (HDMI IN 3 only)

Video output (phono jack)

DIGITAL AUDIO OUT (OPTICAL) (digital optical jack)/Audio output (phono jacks)

PC Input (D-sub 15-pin) G: 0.7 Vp-p, 75 ohms, non Sync on Green/B: 0.7 Vp-p, 75 ohms/R: 0.7 Vp-p, 75 ohms/HD: 1-5 Vp-p/VD: 1-5 Vp-p

PC audio input (minijack)

Headphones jack

USB port

DIGITAL MEDIA PORT

220 V – 240 V AC, 50 Hz

40 inches (Approx. 46 inches (Approx. 52 inches (Approx.101.6 cm) 116.8 cm) 132.2 cm)

1,920 dots (horizontal) × 1,080 lines (vertical)

Indicated on the rear of the TV.

986 × 684 × 279 mm 1,120 × 782 × 307 mm 1,262 × 871 × 347 mm

986 × 646 × 110 mm 1,120 × 742 × 115 mm 1,262 × 829 × 119 mm

22 kg 29 kg 38 kg

19 kg 25 kg 32 kg

SU-WL500/SU-WL50B Wall-Mount Bracket SU-WL500/SU-WL50B

SU-FL300M TV stand Wall-Mount Bracket

Mass*

*Dimensions and mass are approximate values.

Design and specifications are subject to change without notice.

KDL-40/46/52W4000 (AUS) 3

Resolution

×

PC input signal reference chart for HDMI IN 1, 2, 3 jack

rd

PC input signal reference chart for PC IN (RGB) jack

Signals Horizontal(Pixel)

Vertical(Line)

Horizontalfrequency (kHz)

Verticalfrequency (Hz)

Standard

Resolution×Signals Horizontal

(Pixel) Vertical(Line)

Horizontalfrequency (kHz)

Verticalfrequency (Hz)

Standard

VGA 640 × 480 31.5 60 VGA640 × 480 37.5 75 VESA

720 × 400 31.5 70 VGA-T

SVGA 800 × 600 37.9 60 VESA Guidelines800 × 600 46.9 75 VESA

XGA 1024 × 768 48.4 60 VESA Guidelines1024 × 768 56.5 70 VESA

1024 × 768 60.0 75 VESA

WXGA 1280 × 768 47.4 60 VESA1280 × 768 47.8 60 VESA1280 × 768 60.3 75

1360 × 768 47.7 60 VESASXGA 1280 × 1024 64.0 60 VESA

• This TV’s PC input does not support Sync on Green or Composite Sync.• This TV’s PC input does not support interlaced signals.• This TV’s PC input supports signals in the above chart with a 60 Hz vertical frequency. For other signals, you

will see the message “NO SYNC”.

VGA 640 × 480 31.5 60 VESA

SVGA 800 × 600 37.9 60 VESA Guidelines

XGA 1024 × 768 48.4 60 VESA Guidelines

WXGA 1280 × 768 47.4 60 VESA

1280 × 768 47.8 60 VESA

SXGA 1280 × 1024 64.0 60 VESA

KDL-40/46/52W4000 (AUS) 4

CAUTION

These servicing instructions are for use by qualified servicepersonnel only.To reduce the risk of electric shock, do not perform any servicingother than that contained in the operating instructions unless youare qualified to do so.

WARNING!!

An isolation transformer should be used during any service toavoid possible shock hazard, because of live chassis.The chassis of this receiver is directly connected to the ac powerline.

! SAFETY-RELATED COMPONENTWARNING!!

Replace all components with Sony parts whose part numbersappear as shown in this manual or in supplementspublished by Sony.

WARNINGS AND CAUTIONS SAFETY-RELATED COMPONENTWARNING

It is essential that all critical parts be replaced only with the partnumber specified in the electrical parts list to prevent electricshock, fire, or other hazard.

NOTE: Do not modify the original design without obtainingwritten permission from the manufacturer or you willvoid the original parts and labor guarantee.

USE CAUTION WHEN HANDLING THE LCD PANEL

When repairing the LCD panel, be sure you are grounded byusing a wrist band.

When repairing the LCD panel on the wall, the LCD panel mustbe secured using the 4 mounting holes on the rear cover.1) Do not press on the panel or frame edge to avoid the risk of

electric shock.2) Do not scratch or press on the panel with any sharp objects.3) Do not leave the module in high temperatures or in areas of

high humidity for an extended period of time.4) Do not expose the LCD panel to direct sunlight.5) Avoid contact with water. It may cause a short circuit within

the module.6) Disconnect the AC power when replacing the backlight (CCFL)

or inverter circuit.(High voltage occurs at the inverter circuit at 650Vrms.)

7) Always clean the LCD panel with a soft cloth material.8) Use care when handling the wires or connectors of the inverter

circuit. Damaging the wires may cause a short.9) Protect the panel from ESD to avoid damaging the electronic

circuit (C-MOS).

KDL-40/46/52W4000 (AUS) 5

SAFETY CHECK-OUT

After correcting the original service problem, perform thefollowing safety checks before releasing the set to the customer:

1. Check the area of your repair for unsoldered or poorlysoldered connections. Check the entire board surface forsolder 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 absolutelycertain that you have replaced all the insulators.

4. Look for unauthorized replacement parts, particularlytransistors, that were installed during a previous repair. Pointthem out to the customer and recommend their replacement.

5. Look for parts which, though functioning, show obvioussigns of deterioration. Point them out to the customer andrecommend their replacement.

6. Check the line cords for cracks and abrasion. Recommendthe 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 ACleakage. Check leakage as described below.

Leakage TestThe AC leakage from any exposed metal part to earth groundand from all exposed metal parts to any exposed metal parthaving a return to chassis, must not exceed 0.5 mA (500microamperes).Leakage current can be measured by any one of three methods.

1. A commercial leakage tester, such as the Simpson 229 orRCA WT-540A. Follow the manufacturers’ instructions touse these instructions.

2. A battery-operated AC milliampmeter. The Data Precision245 digital multimeter is suitable for this job.

3. Measuring the voltage drop across a resistor by means of aVOM or battery-operated AC voltmeter. The “limit”indication is 0.75 V, so analog meters must have an accuratelow voltage scale.The Simpson’s 250 and Sanwa SH-63TRD are examples ofpassive VOMs that are suitable. Nearly all battery-operateddigital multimeters that have a 2 VAC range are suitable (seeFigure A).

How to Find a Good Earth GroundA cold-water pipe is a guaranteed earth ground; the cover-plateretaining screw on most AC outlet boxes is also at earth ground.If the retaining screw is to be used as your earth ground, verifythat it is at ground by measuring the resistance between it and acold-water pipe with an ohmmeter. The reading should be zeroohms.

If a cold-water pipe is not accessible, connect a 60- to 100-watttrouble- light (not a neon lamp) between the hot side of thereceptacle and the retaining screw. Try both slots, if necessary,to locate the hot side on the line; the lamp should light at normalbrilliance if the screw is at ground potential (see Figure B).

To Exposed MetalParts on Set

0.15 µF

Earth Ground

ACVoltmeteroo(0.75V)

Trouble Light

AC Outlet BoxOhmmeter

Cold-water Pipe

FigureA. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.

KDL-40/46/52W4000 (AUS) 6

SELF DIAGNOSIS FUNCTION

The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY LED will automatically begin to flash.The number of times the LED flashes translates to a probable source of the problem.A definition of the STANDBY LED flash 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 toreveal past problems and how often these problems occur.

1-1. DIAGNOSTIC TEST INDICATORSWhen an error occurs, the STANDBY LED will flash a set number of times to indicate the possible cause of the problem.If there is more than one error, the LED will identify the first of the problem areas.Result for all of the following diagnostic items are displayed on screen.If the screen displays a “0”, no error has occurred .

1-2. DISPLAY OF STANDBY/TIMER LIGHT FLASH COUNT

1-3. STOPPING THE STANDBY FLASHTurn off the power switch on the TV main unit or unplug the power cord from the outlet to stop the STANDBY LED from flashing.

2 times

4 times

5 times

LED ON 0.3 sec.

LED OFF 0.3 sec. LED OFF2 sec.

[ FLASH COUNT ]

Note: One flash counts is not self-diagnostic.

STANDBY LED

KDL-40/46/52W4000 (AUS) 7

1-4. SELF-DIAGNOSTIC SCREEN DISPLAYFor errors with symptoms such as “power sometimes shuts off” or “screen sometimes goes out” that cannot be confirmed, it is possible tobring up past occurrences of failure for confirmation on the screen:

1-4-1. To Bring Up Screen TestIn standby mode, press buttons on the remote commander sequentially in rapid succession as shown below:

Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screenAfter you have completed the repairs, clear the result display to “0”.

1-5. Quitting Self-diagnostic screenTo quit the entire self-diagnostic screen, turn off the power switch on the remote commander or the main unit.

5

* : Note that this differs from entering the service mode (volume +)

( Number button ) * ( Volume ) ( TV standby )( Info/Text reveal )

BALANCERPOWERPANELNVMNCHDMIDIGITALTUNERSOUND

000210000

1/3

Monitoring ItemsError Count Record

[ SELF-DIAGNOSTIC SCREEN DISPLAY ]

DC_ALERT1DC_ALERT2RTCDC_ALERT2DEMODUSBCIAU_PROTDC_ALERT

000210000

VCTPReset

00

2/3

3/3

KDL-40/46/52W4000 (AUS) 8

TABLE OF CONTENTS

SAFETY CHECK-OUT ............................................. 5

SELF DIAGNOSIS FUNCTION ................................ 6

1. DISASSEMBLY ...............................................1-11-1. KDL-40W4000 ....................................................... 1-1

1-1-1. REAR COVER AND STAND ASSY

REMOVAL ...................................................... 1-1

1-1-2. AC INLET AND UNDER COVER

REMOVAL ...................................................... 1-2

1-1-3. BA1 AND IP5 BOARDS REMOVAL............ 1-3

1-1-4. FRAME REMOVAL ....................................... 1-4

1-1-5. SPEAKER (L) REMOVAL ............................. 1-5

1-1-6. SPEAKER (R) REMOVAL ............................. 1-5

1-1-7. LCD PANEL, H3E BOARD AND

H4 BOARD REMOVAL ................................. 1-6

1-2. KDL-46W4000 ....................................................... 1-7


REMOVAL ...................................................... 1-7


REMOVAL ...................................................... 1-8

1-2-3. BA1 AND IP5 BOARDS REMOVAL............ 1-9

1-2-4. FRAME REMOVAL ..................................... 1-10

1-2-5. SPEAKER (L) REMOVAL ........................... 1-11

1-2-6. SPEAKER (R) REMOVAL ........................... 1-11


H4 BOARD REMOVAL ............................... 1-12

1-3. KDL-52W4000 ..................................................... 1-13


REMOVAL .................................................... 1-13


REMOVAL .................................................... 1-14

1-3-3. BA1 AND IP5 BOARDS REMOVAL.......... 1-15

1-3-4. FRAME REMOVAL ..................................... 1-16

1-3-5. SPEAKER (L) REMOVAL ........................... 1-17

1-3-6. SPEAKER (R) REMOVAL ........................... 1-17


H4 BOARD REMOVAL ............................... 1-18

2. TROUBLESHOOTING ....................................2-12-1. No Power (Flow Chart_B) ..................................... 2-3

2-2. Self Diagnosis ......................................................... 2-4

2-2-1. Self Diagnosis (Flow Chart_C) ....................... 2-5

2-2-2. POWER_DET (RED 2 times blink) ................ 2-6

2-2-3. Back light Error (RED 6 times blink) ............. 2-6

2-2-4. Temp Error (RED 7 times blink) ..................... 2-7

2-2-5. Audio Error (RED 8 times blink) .................... 2-7

2-2-6. DEF Error (RED 10 times blink) ..................... 2-8

2-2-7. NVM Error (RED 11 times blink) ................... 2-8

2-2-8. I2C Error (RED 12 times blink) ...................... 2-8

2-2-9. Balancer Error (RED 13 times blink) .............. 2-9

2-2-10. HDMI Error (RED 14 times blink) .................. 2-9

2-2-11. Tuner Error (RED 15 times blink) ................... 2-9

2-2-12. I2C-CH1 Error (RED 16 times blink) ........... 2-10

2-2-13. I2C-CH0 Error (RED 17 times blink) ........... 2-10

2-2-14. Digital modulator Error

(RED 18 times blink) ..................................... 2-10

2-2-15. USB Error (RED 19 times blink) .................. 2-11

2-2-16. VCTP Error (RED 21 times blink) ................ 2-11

2-3. Audio Problem (Flow Chart_D) .......................... 2-12

2-4. Video Ploblem (Flow Chart_E) ........................... 2-13

3. DIAGRAMS .....................................................3-13-1. BLOCK DIAGRAM .............................................. 3-1

3-2. CIRCUIT BOARDS LOCATION ......................... 3-2

(1) KDL-40/46W4000 ........................................... 3-2

(2) KDL-52W4000 ................................................ 3-2

4. EXPLODED VIEWS ........................................4-14-1. KDL-40W4000 ....................................................... 4-2

4-1-1. REAR COVER AND STAND ASSY ............. 4-2

4-1-2. CHASSIS-1 ...................................................... 4-3

4-1-3. CHASSIS-2 ...................................................... 4-4

4-2. KDL-46W4000 ....................................................... 4-5


4-2-2. CHASSIS-1 ...................................................... 4-6

4-2-3. CHASSIS-2 ...................................................... 4-7

4-3. KDL-52W4000 ....................................................... 4-8


4-3-2. CHASSIS-1 ...................................................... 4-9

4-3-3. CHASSIS-2 .................................................... 4-10

4-4. PACKING MATERIALS .................................... 4-11

4-4-1. KDL-40W4000 .............................................. 4-11

4-4-2. KDL-46W4000 .............................................. 4-12

4-4-3. KDL-52W4000 .............................................. 4-13

KDL-40/46/52W4000 (AUS) 1-1

1-1. KDL-40W40001-1-1. REAR COVER AND STAND ASSY REMOVAL

SECTION 1DISASSEMBLY

3 Six screws (+BVTP2 4X16)

3 Four screws (+BVTP2 4X16)

3 Five screws (+BVTP2 4X16)

3 Two screws (+BVTP2 4X16)


6 Three screws (+BV 3X12)

4 Two screws (+PSW M5X12)


5Two screws (+PSW M5X12)

7 Rear cover

8 Switch unit

1 Four screws (+PSW M5X20)

2 Stand assy

KDL-40/46/52W4000 (AUS) 1-2

KDL-40W40001-1-2. AC INLET AND UNDER COVER REMOVAL


7 One screw (+BVST 3X8)

5 Two screws (+KTT 3X10)


4 Under cover

2 Under bar (L)

6 AC inlet

8 AC inlet bracket

KDL-40/46/52W4000 (AUS) 1-3

KDL-40W40001-1-3. BA1 AND IP5 BOARDS REMOVAL

1 Three screws (+BVST 3X8)


9 Side jack bracket assy qa BA1 board



4 Two screws (SP 4-4O UNC)


8 Lead wire with connector(LVDS)

qs Two screws (+BVST 3X8)

qs Two screws (+BVST 3X8)

qd Main bracket assy

0 Four screws (+BVST 3X8)

2 IP5 board


6 B shield assy


KDL-40/46/52W4000 (AUS) 1-4

KDL-40W40001-1-4. FRAME REMOVAL

qf Bottom frame assy

6 Spine frame assy

qs Spine frame assy


5 Three screws (+PSW M4X8)

qa Three screws (+PSW M4X8)


4 Vesa frame (BTM) assy


2 Vesa frame (TOP) 8 Vesa frame (TOP)



qd Four screws (+BVTP2 4X16)

KDL-40/46/52W4000 (AUS) 1-5

KDL-40W40001-1-5. SPEAKER (L) REMOVAL

1-1-6. SPEAKER (R) REMOVAL

1 Loudspeaker

Both

Both

1 Loudspeaker

Both

Both

KDL-40/46/52W4000 (AUS) 1-6

KDL-40W40001-1-7. LCD PANEL, H3E BOARD AND H4 BOARD REMOVAL

9 Bezel assy

5 Clear panel

4 Light guide

3 One screw (+BV 3X12)

8 LCD panel

6 Illumination module2 H4 board

1 H3E board

Both

Both


KDL-40/46/52W4000 (AUS) 1-7


6 Rear cover

7 Switch unit



3 Ten screws (+BVTP2 4X16)4 Two screws (+PSW M5X12)


2 Stand assy (L)

3 Five screws (+BVTP2 4X16)

5 Three screws (+BV 3X12)

KDL-40/46/52W4000 (AUS) 1-8


3 One screws (+BVST 3X8)

7 One Screw (+BVST 3X8)

5 Two screws (+KTT 3X10)

2 Under bar (L)

4 Under cover (L2)

6 AC inlet

8 AC inlet bracket


KDL-40/46/52W4000 (AUS) 1-9


qg Two screws (+PSW M5X8)


0 Side jack bracket assy

qh Vesa frame (TOP)

qf Main bracket assy

1 Three screws (+BVST 3X8)qd Two screws

(+BVST 3X8) 1 Three screws (+BVST 3X8)

2 IP5 board

qs BA1 board

qa One screw (+BVST 3X8)

qa One screw (+BVST 3X8)

4 Two screws (SP 4-4O UNC)

qa Four screws (+BVST 3X8)


6 B shield assy


8 Lead wire with connector (LVDS)

9 One screw (+BVTP2 4X16)

KDL-40/46/52W4000 (AUS) 1-10


qj Bottom frame assy

qf Spine frame assy


1 One screw (+PSW M5X8)

qs Five screws (+PSW M5X8)

7 Five screws (+PSW M5X8)

0 Two scxrews (+PSW M5X8)

qa Vesa frame (BTM) assy


2 Center frame

4 G5 frame

3 Two screws (+BVST 3X8)

qh Four screws (+BVTP2 4X16)


qd One screw (+BVTP2 4X16)

9 Spine frame assy


qg One screw (+PSW M5X8)

KDL-40/46/52W4000 (AUS) 1-11



1 Loudspeaker

2 Speaker cushion

Both

Both

1 Loudspeaker

2 Speaker cushion

Both

Both

KDL-40/46/52W4000 (AUS) 1-12


5 Clear panel

4 Light guide


8 LCD panel

6 Illumination module

9 Bezel assy

2 H4 board1 H3E board

Both

Both


KDL-40/46/52W4000 (AUS) 1-13



3 Nine screws (+BVTP2 4X16)





2 Stand assy (LL)

6 Rear cover

7 Switch unit

5 Two screws (+BV 3X12)

KDL-40/46/52W4000 (AUS) 1-14




5 Two screws (+KTT 3X10 (S TYPE))

2 Under bar (L)

4 Under cover (LL)

6 AC inlet

8 AC inlet bracket


KDL-40/46/52W4000 (AUS) 1-15



ws D4 board9 One screw (+BVST 3X8)

3 Four screws (+BVST 3X8)



4 D5 board

7 D5 frame

8 Side jack bracket assy

2 Vesa frame (TOP)

0 Lead wire with connector (LVDS)

qk Main bracket assy

qg Four screws (+BVST 3X8)

wa Four screws (+BVST 3X8)

qh BA1 board

qg One screw (+BVST 3X8) qg One screw

(+BVST 3X8)

qs Two screws (SP 4-4O UNC)

qj Four screws (+BVST 3X8)

qd Three screws (+BVST 3X8)

qf B shield assy

qa Four screws (+PSW M3X5)

w; G5 boardql Three screws (+BVST 3X8)

ql Three screws (+BVST 3X8)

KDL-40/46/52W4000 (AUS) 1-16


qh Bottom frame assy

qf Spine frame ASSY




qs Five screws (+PSW M5X8)

7 Five screws (+PSW M5X8)


qa Vesa frame (BTM) assy

6 Vesa frame(BTM) assy

2 Center frame

4 G5 frame

3 Two screws (+BVST 3X8)

qg Four screws (+BVTP2 4X16)


qd One screw (+BVTP2 4X16)

9 Spine frame assy

KDL-40/46/52W4000 (AUS) 1-17



1 Loudspeaker

2 Speaker cushionBoth

Both

1 Loudspeaker

2 Speaker cushion

Both

Both

KDL-40/46/52W4000 (AUS) 1-18E


4 Light guide



8 LCD pane

6 Illumination module

9 Bezel assy

2 H4 board

1 H3E board

Both

5 Clear panel

Both

KDL-40/46/52W4000 (AUS) 2-1

SECTION 2TROUBLESHOOTING

Reference Symptoms - (dead set)

2 6 7 8 10 11 12 13 14 15 16 17 18 19 21No PowerBlinks Blinks Blinks Blinks Blinks Blinks Blinks Blinks Blinks Blinks Blinks Blinks Blinks Blinks Blinks

BA1 COMPL

D5 COMPL (52")

D4 COMPL (52")

G5 COMPL (52")

IP5 COMPL (46")

IP5 COMPL (40")

Panel Module

Flowchart Reference C C C C C C C C C C C C C C C B

Problem Power_ Back I2C I2C I2C DDET Light

TEMP Audio DFE NVMVCT

Balancer HDMI TunerCH1 CH0 Demod

USB VCTP

Reference Video - distorted or missing

No Video No No Video NoBL OK Video BL OK Tuner No No

OSD OK No BL No OSD Video OK HDMI Audio

BA1 COMPL

D5 COMPL(52")

D4 COMPL(52")

G5 COMPL(52")

IP5 COMPL(46")

IP5 COMPL(40")

Panel Module

Flowchart Reference E E E E E D

Problem

: Doubtful part: just a few possibility

KDL-40/46/52W4000 (AUS) 2-2

Troubleshooting

YES

Set PowerNO See

2-1. No Power (Chart_B)

See2-3. Audio Problem (Chart_D)

See2-4. Video problem (Chart_E)

Audio Video

Red blinksLED

Green

See2-2. Self Diagnosis (Chart_C)

KDL-40/46/52W4000 (AUS) 2-3

No207-253VACInlet on Power Board 1)

Yes

3.3VDC(CN6401 3Pin on

BA1 board)

NO

Power Board 1)

(No STBY3.3V)

YES

NO

YES

AC cable or AC inlet

No Power(No relay clicks)

Does Powerbutton work?

BA1 board

2-1. No Power (Flow Chart_B)

Switch Unit

1) 40", 46" : IP5 BOARD52" : G5 BOARD

KDL-40/46/52W4000 (AUS) 2-4

VCT I2C Bus Trouble.I2C Error VCT12 times

DEF (Digital Front End Module) Trouble.Digital Error10 times

Audio Trouble.Audio Error (SP Protection)8 times

HFR Error (for EMH and Cumin).HFR Error9 times

Monitor an Increase of an Inside-Temperature.Internal Temperature Error7 times

Backlight Trouble.Panel Det Error6 times

Main Supply Voltage Trouble.Power_DET (12V Main Voltage)2 times

ContentsDisplay(Self Diagnosis mode)

Red LEDBlink

When self diagnosis happens, STBY (Red) LED blinks and the history can beseen on display by self diagnosis mode.

2-2. Self Diagnosis

EEPROM Error (notread/write available).NVM Error11 times

No Acknowledge detected.Digital Demod18 times

I2C Ch1 Error in VERD.I2C CH1 (VERD TAS)16 times

HDCP cannot be setup correctly.HDMI Error14 times

If circuit or PLL circuit do not respond to IIC commands.Tuner Error15 times

13 times

I2C Ch0 Error in VERD.I2C CH0 (VERD NVM/RTC)17 times

Panel Balance Trouble.Balance Error

MSP3410G IC does not respond to IIC commands.MSP Error22 times

CI Trouble. CI Error20 times

USB over current detected.USB Error19 times

No DPI-I2CVCT Error21 times

KDL-40/46/52W4000 (AUS) 2-5

NO

2 timesYES See

2-2-2. POWER_DET

RED LED Blinks

NO

6 timesYES See

2-2-3. Back light Error

NO

7 timesYES See

2-2-4. Temp Error

NO

13 timesYES See

2-2-9. Balancer Error

14 timesYES See

2-2-10. HDMI Error

NO

8 timesYES See

2-2-5 Audio Error

2-2-1. Self Diagnosis (Flow Chart_C)

NO

15 timesYES See

2-2-11. Tuner Error

NO

16 timesYES See

2-2-12. I2C-CH1 Error

NO

10 timesYES

See2-2-6. DEF Error

NO

11 timesYES See

2-2-7. NVM Error

NO

12 timesYES See

2-2-8. I2C Error

NO

17 timesYES See

2-2-13. I2C-CH0 Error

18 timesYES See

2-2-14. Digital modulator Error

NO

19 timesYES

NO

21 timesYES See

2-2-16. VCTP Error

See2-2-15. USB Error

KDL-40/46/52W4000 (AUS) 2-6

2-2-2. POWER_DET (RED 2 times blink)• This indicates DC_DET of Power Board 1).

• 12V line on Power Board 1).

• VERD micro (on BA1 board) Pin6 detects POWER_DET and shuts down chassis power to standby

status.

VERD micro Pin6 Normal condition: 1.3V - 2.5V

Error case: lower than 1.3V or higher than 2.5V

– Replace Power Board 1).

1) 40", 46" : IP5 BOARD 52" : G5 BOARD

2-2-3. Back light Error (RED 6 times blink)• This indicates panel power circuit error such as inverter.

• VERD micro (on BA! board) Pin40 detects PANEL_DET and shuts down chassis power to

standby status.

VERD micro Pin40 Normal condition: High / Error case: Low (lower than 0.8V)

– Replace Panel or Power1)/Inverter Board .

1) 40", 46" : IP5 BOARD 52" : G5 BOARD

KDL-40/46/52W4000 (AUS) 2-7

2-2-4. Temp Error (RED 7 times blink)

• This indicates high temperature inside chassis.

IC5507 on BA1 board is monitoring temperature.

IC5507 is controlled by VERD micro.

• When it happens:

– Check chassis environment.

– Check around IC5507 and replace BA1 board if temperature monitoring circuit

has problem.

– Check panel.

2-2-5. Audio Error (RED 8 times blink)• This indicates Audio Error (Protection).

• It happens:

– IC8200 on BA1 board, Audio Amp detects over current, thermal shut down

and/or low voltage of itself.

– DC voltage detected for audio line.

– VERD micro Pin5 Normal condition: High / Error case: Low

• Check UNREG15V at CN6401 Pin4 and Pin5 on BA1 board .

And F3401 on BA1 board has 13V or not.

• Check above and replace BA1 board.

KDL-40/46/52W4000 (AUS) 2-8

2-2-6. DEF Error (RED 10 times blink)• This indicates DEF communication error.

• [ communication error ]

– TVM micro (on BA1 board) is communicating with EMMA3SL (on BA1 board).

• Check above and replace BA1 board .

2-2-7. NVM Error (RED 11 times blink)• This indicates VERD NVM communication error.

• VERD micro (on BA1 board) is communicating with NVM (on BA1 board) .


2-2-8. I2C Error (RED 12 times blink)• This indicates I2C communication error.

• VCTP micro (on BA1 board) is communicating with each devices (on BA1 board).

• Check above and replace BA1 board .

KDL-40/46/52W4000 (AUS) 2-9

2-2-9. Balancer Error (RED 13 times blink)• This indicates panel power circuit error such as inverter.

• VERD micro (on BA1 board) Pin81 detects PANEL_DET and shuts down chassis power

to Standby status.

VERD micro Pin40 Normal condition: High / Error case: Mid (0.85 - 2.65V)

• Replace Panel or Power1)/Inverter board.

1) 40", 46" : IP5 BOARD 52" : G5 BOARD

2-2-10. HDMI Error (RED 14 times blink)• This indicates HDCP error.

• HDMI setting trouble matter on BA1 board.


2-2-11. Tuner Error (RED 15 times blink)• This indicates Tuner error.

• VCTP and EMMA3SL micro (on BA1 board) is communicating with Tuner

(TU2200) on BA1 board.


KDL-40/46/52W4000 (AUS) 2-10

2-2-12. I2C-CH1 Error (RED 16 times blink)• This indicates I2C communication error.

• VERD micro (on BA1 board) is communicating with Audio processor

(IC3201) on BA1 board.


2-2-13. I2C-CH0 Error (RED 17 times blink)• This indicates I2C communication error.

• VERD micro (on BA1 board) is communicating with Real time clock

(IC5502) on BA1 board.


2-2-14. Digital modulator Error (RED 18 times blink)• This indicates Tuner error.

• EMMA3SL micro is communicating with inside of the Tuner

(TU2200) on BA1 board.


KDL-40/46/52W4000 (AUS) 2-11

2-2-15. USB Error (RED 19 times blink)• This indicates USB error.

• EMMA3SL micro found out USB over current detection on BA1 board.


2-2-16. VCTP Error (RED 21 times blink)• This indicates VCTP error.

• VCTP micro (IC4701) does not work normaly.


KDL-40/46/52W4000 (AUS) 2-12

Here is trouble shooting flow related audio.

Audio problem

OnlySpeaker out?

YES

NO

UI settingcorrect?

Volume, SP off/OnHP Link

AnalogChannelProblem?

DigitalChannelProblem?

HDMIProblem?

Set correctly orreset by menu.

CheckSpeaker or BA1 board

NO

YES

NO NO

CheckBA1 board

CheckBA1 board

CheckBA1 board

YES YES YES

NO CheckBA1 board

2-3. Audio Problem (Flow Chart_D)

KDL-40/46/52W4000 (AUS) 2-13E

Here is trouble shooting flow related Video.

Video problem

All inputshave

problem?

YES

NOAnalog

ChannelProblem?

DigitalChannel

Problem?

HDMIProblem?

CheckLVDS harnessPower Board 1)

BA1 boardPanel Module

NO NO

CheckBA1 board

CheckBA1 board

CheckBA1 board

YES YES YES

NO CheckBA1 board

NO

CheckBA1 board

YES YESBack Lightturn on?

OSDappear?

NO

CheckLVDS harnessBA1 boardPanel Module

2-4. Video Ploblem (Flow Chart_E)

1) 40", 46" : IP5 BOARD 52" : G5 BOARD

SECTION 3DIAGRAMS

3-1. BLOCK DIAGRAM

KDL-40/46/52W4000 (AUS) 3-1

BA1 BOARD

SW

Audiofor DVIPC HDMI 1

Audiofor PC

Analog-Component/RGB

CVBSY/C

Digital-Component

Audio (Analog)Audio (Digital)

PC-RGB

Digital[0:15] 74MHz

Graphics CLK/Hs/Vs

NAND Flash256Mb

VCT PremiumA/V switch

Color Decoder3D Comb

PC/HD ADCAudio Dig Decoder

Audio DelayScaler

Noise ReductionHistogramTV control

TXT DecodingHDMI Decoder

WCGS-Force

Hs/

Vs

BASI(New Audio IC)

HDMI 3HDMI 2 L

HP

Audio Amp.TPA3100D2

RF UFE4

(S)Video1

Video3

Component1

Audio out(Var/Fix)

Video2 L

EMMAEMMA3SLMPEG/AVC decoder

DDR2 667512Mb

DDR2 667512Mb

Mon/RecOut

DM Port

STBY Micro

RTC

Temp Sensor

DDR2 667256Mb

DDR2 667256Mb

Line Out

HP Out

Mon/Rec Out

SP

TASS-Force

Graphics RGB[0:7] x3 around 30MHz

OpticalAudio Out

TS [0:7]

Digital RF CVBSAnalog RF CVBSSIF

LVDS

SW

USB 2.0

MS

New Decoder IC small package

New Audio IC input SW, buffer, HP amp

Main Micro

FHD capable. HDMI receiverand WCG block integrated,xvYCC capable

EQ

Panel

Backlight

Inverter

SCART->RCA Pin

Analog RF CVBSSIF

MPEG2/AVC-HD,USB,XMB

Less ST-BY power consum-ption, control of TAS

Graphics CLK/Hs/Vs

Component2

KDL-40/46/52W4000 (AUS) 3-2E

(2) KDL-52W4000

3-2. CIRCUIT BOARDS LOCATION(1) KDL-40/46W4000

Illumination module

H4 board

H3E board

Inverter board

BA1 board

IP5 board

Switch Unit

Illumination module

H4 board

H3E board

Inverter board

Inverter board

BA1 board

G5 board

D4 board

Switch Unit

D5 board

KDL-40/46/52W4000 (AUS) 4-1

SECTION 4EXPLODED VIEWS

NOTE: • Items with no part number and no description arenot stocked because they are seldom required forroution service.

• The construction parts of an assembled part areindicated with a collation number in the remarkcolum.

• Items marked " * " are not stocked since they areseldom required for routine service. Some delayshould be anticipated when ordering these items.

KDL-40/46/52W4000 (AUS) 4-2

4-1. KDL-40W40004-1-1. REAR COVER AND STAND ASSY

REF. No. PART No. DESCRIPTION MARK REF. No. PART No. DESCRIPTION MARK

1 2-580-640-01 SCREW, +BVTP2 4X162 2-580-607-01 SCREW, +PSW M5X123 3-452-815-01 SCREW, +PSW M5X204 ! 3-289-962-21 COVER, REAR (40)5 * 3-106-086-01 COVER, ECS

6 X-2189-410-1 STAND (ML) ASSY

#1 7-685-648-79 SCREW +BVTP 3X12 TYPE2 IT-3

11

1111

12

11 2

#1

3

5

6

5

4

KDL-40/46/52W4000 (AUS) 4-3

KDL-40W40004-1-2. CHASSIS-1


51 1-480-710-11 SWITCH UNIT52 1-835-699-11 LEAD WIRE WITH CONNECTOR

(LVDS)53 2-580-629-01 SCREW, +BVST 3X854 2-580-626-01 SCREW, SP 4-4O UNC55 A-1547-342-A BA1 MOUNT

56 2-596-649-01 +KTT 3X10 (S TYPE)57 ! 1-822-097-11 AC INLET58 2-580-640-01 SCREW, +BVTP2 4X1659 2-580-592-01 SCREW, +PSW M3X860 ! A-1549-337-C IP5 MOUNT

61 * 1-835-147-11 CONNECTOR ASSY, MDF61

51

53

53

52

53 55

5453

53

53

53

53

60

58

5361

56

57

53

53

59

KDL-40/46/52W4000 (AUS) 4-4


101 X-2318-222-1 BEZEL ASSY (EM40)102 1-826-888-11 LOUDSPEAKER103 ! 1-802-664-11 LCD PANEL (40INCH FHD TFT)104 1-480-680-11 ILLUMINATION MODULE105 2-580-600-01 SCREW, +PSW M4X8

106 2-580-606-01 SCREW, +PSW M5X8107 1-826-888-21 LOUDSPEAKER108 A-1510-351-A H4 MOUNT109 * 3-290-361-01 GUIDE, LIGHT110 A-1510-350-A H3E MOUNT

111 * 3-289-965-01 PANEL, CLEAR (40)112 2-580-640-01 SCREW, +BVTP2 4X16



112

101

102 103

108

110

111107

104

109

105

105

#1

106

106

112

KDL-40/46/52W4000 (AUS) 4-5



151 2-580-607-01 SCREW, +PSW M5X12152 2-580-640-01 SCREW, +BVTP2 4X16153 3-452-815-01 SCREW, +PSW M5X20154 X-2189-411-1 STAND (L) ASSY155 ! 3-293-587-21 COVER, REAR (46)

156 3-106-086-01 COVER, ECS


151

152

151

152

152

155156

156

153

154

#1

KDL-40/46/52W4000 (AUS) 4-6



201 1-480-710-11 SWITCH UNIT202 2-580-606-01 SCREW, +PSW M5X8203 A-1547-580-A BA1 MOUNT204 1-835-700-11 LEAD WIRE WITH CONNECTOR

(LVDS)205 2-596-649-01 +KTT 3X10 (S TYPE)

206 2-580-629-01 SCREW, +BVST 3X8207 ! A-1549-338-C IP5 MOUNT208 2-580-640-01 SCREW, +BVTP2 4X16209 2-580-592-01 SCREW, +PSW M3X8210 ! 1-822-097-11 AC INLET

211 2-580-626-01 SCREW, SP 4-4O UNC212 * 1-835-148-11 CONNECTOR ASSY, MDF61

201

202

208

208

202

202

202202

203

206

206

206

206

211

206

207

206

206

212

210

206

208

202

202208 205

206

206209

206204

KDL-40/46/52W4000 (AUS) 4-7


251 X-2318-223-1 BEZEL ASSY (EM46)252 1-480-680-11 ILLUMINATION MODULE253 1-826-887-11 LOUDSPEAKER (3CM, 6.5X15CM)254 1-826-887-21 LOUDSPEAKER (3CM, 6.5X15CM)255 ! 1-802-663-12 LCD PANEL (46INCH FHD TFT)

256 A-1510-350-A H3E MOUNT257 A-1510-351-A H4 MOUNT258 * 3-290-361-01 GUIDE, LIGHT259 * 3-293-434-01 PANEL, CLEAR (46)260 2-580-640-01 SCREW, +BVTP2 4X16



251

253

255

254

256 257

258

252

259

#1

260

KDL-40/46/52W4000 (AUS) 4-8



301 2-580-640-01 SCREW, +BVTP2 4X16302 2-580-607-01 SCREW, +PSW M5X12303 2-580-608-01 SCREW, +PSW M5X16304 X-2190-786-4 STAND ASSY (LL)305 * 3-106-086-01 COVER, ECS

306 ! 3-293-625-11 COVER, REAR (52)


303

304

305

305

306

#1

301

302

301301302

KDL-40/46/52W4000 (AUS) 4-9



351 1-480-710-11 SWITCH UNIT352 1-835-701-11 LEAD WIRE WITH CONNECTOR

(LVDS)353 2-580-629-01 SCREW, +BVST 3X8354 ! A-1511-383-B D5 COMPL355 A-1547-585-A BA1 COMPL

356 2-580-626-01 SCREW, SP 4-4O UNC357 2-580-591-01 SCREW, +PSW M3X5358 ! A-1545-447-C G5-A COMPL359 ! 3-284-269-02 COVER, UNDER (LL)360 2-580-606-01 SCREW, +PSW M5X8

361 2-596-649-01 +KTT 3X10 (S TYPE)362 ! 1-821-909-11 AC INLET363 ! A-1511-382-B D4 COMPL364 2-580-640-01 SCREW, +BVTP2 4X16365 2-580-592-01 SCREW, +PSW M3X8

351

362

353

353

353

356

355

353365

354353

360

353

353

358

363

359

353

353

364

361

353

352 353

353

357

KDL-40/46/52W4000 (AUS) 4-10


401 X-2318-224-1 BEZEL ASSY (EM52)402 1-480-680-11 ILLUMINATION MODULE403 1-826-887-11 LOUDSPEAKER (3CM, 6.5X15CM)404 ! 1-802-662-11 LCD PANEL (52INCH FHD TFT)405 2-580-640-01 SCREW, +BVTP2 4X16

406 2-580-606-01 SCREW, +PSW M5X8407 2-580-629-01 SCREW, +BVST 3X8408 * 3-293-431-11 PANEL, CLEAR (52)409 * 3-290-361-01 GUIDE, LIGHT410 * A-1510-351-A H4 MOUNT

411 * A-1510-350-A H3E MOUNT412 1-826-887-21 LOUDSPEAKER (3CM, 6.5X15CM)



410

#1

411

412

409 408

403

402

401

404

405

406

406

405

405

406

406

405

406406 407

KDL-40/46/52W4000 (AUS) 4-11

4-4. PACKING MATERIALS4-4-1. KDL-40W4000


451 * 3-295-296-01 CUSHION (LOWER)452 * 4-106-880-01 INDIVIDUAL CARTON453 * 3-295-295-01 CUSHION (UPPER)454 ! 1-835-167-11 POWER-SUPPLY CORD455 1-480-777-11 REMOTE COMMANDER (RM-GD004)

456 ! 3-876-436-11 MANUAL, INSTRUCTION457 3-876-827-11 MANUAL, INSTRUCTION

(WALL MOUNT)

451

453

455

454

456 457

452

KDL-40/46/52W4000 (AUS) 4-12

4-4-2. KDL-46W4000


501 ! 3-876-436-11 MANUAL, INSTRUCTION502 3-876-827-11 MANUAL, INSTRUCTION

(WALL MOUNT)503 * 3-295-300-01 CUSHION (LOWER)504 1-480-777-11 REMOTE COMMANDER (RM-GD004)505 ! 1-835-167-11 POWER-SUPPLY CORD

506 * 3-295-299-01 CUSHION (UPPER)507 * 4-106-881-01 INDIVIDUAL CARTON508 * 2-639-807-01 JOINT

501

503

502

504

505

506

508

507

KDL-40/46/52W4000 (AUS) 4-13E

4-4-3. KDL-52W4000


551 ! 3-876-436-11 MANUAL,INSTRUCTION552 3-876-827-11 MANUAL,INSTRUCTION

(WALL MOUNT)553 * 3-295-392-01 CUSHION LOWER554 1-480-777-11 REMOTE COMMANDER (RM-GD004)555 ! 1-835-167-11 POWER-SUPPLY CORD

556 * 3-295-391-01 CUSHION UPPER557 * 4-106-882-01 INDIVIDUAL CARTON558 * 2-639-807-01 JOINT

551 552

553

554

555

556

558

557

KDL-40/46/52W4000 (AUS) 55

Sony EMCS CorporationInazawa TEC

English2008HL08-DataMade in Japan

2008. 89-888-209-02

sony_kdl-40w4000_kdl-46w4000_kdl-52w4000_chassis_eg1l

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