Sony KDL-40R450A / KDL-46R450A Repair Manual
History Information
Model Series: RB1FK Chassis, Segment: BA
Supported Models: KDL-40R450A, KDL-46R450A
Version: 1.0
Date: 01/28/2013
Subject: Original Manual Release Date.
Cautions and Warnings
CAUTION!!
These servicing instructions are for use by qualified 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 qualified to do so.
WARNING!!
An isolation transformer should be used during any service to avoid possible shock hazard, in case of live chassis.
⚠️ SAFETY-RELATED COMPONENT WARNING!!
There are critical components used in LCD color TVs that are important for safety. These components are identified with shading and a ⚠️ mark on the schematic diagrams and the parts list. It is essential that these critical parts be replaced only with the part number specified in the parts list to prevent electric shock, fire 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 warranty.
ATTENTION!!
For safety reasons, component level repair of the Power Supply Boards and/or the Inverter Boards is prohibited.
ATTENTION!! (French)
Ces instructions de service sont à l'usage du personnel de service qualifié 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 qualifié faire ainsi.
ALERTE!! (French)
Afin d'eviter tout risque d'electrocution provenant d'un chássis sous tension, un transformateur d'isolement doit etre utilisé lors de tout dépannage.
⚠️ ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!! (French)
Les composants identifies 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 identifies dans le present manuel. Suivre ces procedures lors de chaque remplacement de composants critiques, ou lorsqu'un mauvais fonctionnement suspecte.
ATTENTION!! (French)
Pour des raisons de sécurité, Interdire de réparer ou remplacer les composantes dans les blocs d'alimentation et/ou sur les modules d'inverseur.
Safety Check-Out and Leakage Test
After completing repairs, perform the following safety checks:
- Check for unsoldered or poorly soldered connections and solder splashes.
- Ensure interboard wiring is not pinched or touching high-wattage resistors.
- Verify all control knobs, shields, covers, ground straps, and mounting hardware are replaced, including all insulators.
- Identify and recommend replacement of unauthorized parts, especially transistors.
- Identify and recommend replacement of parts showing signs of deterioration.
- Check line cords for cracks or abrasion and recommend replacement if necessary.
- Check exposed metal parts for AC leakage, as described in the 'Leakage Test'.
Leakage Test:
AC leakage from any exposed metal part to earth ground, and from all exposed metal parts to any part with a chassis return, must not exceed 0.5 mA (500 microamperes). Leakage current can be measured using:
- A commercial leakage tester (follow manufacturer's instructions).
- A battery-operated AC milliammeter.
- A VOM or battery-operated AC voltmeter measuring voltage drop across a resistor (limit is 0.75 V). A diagram (Figure A) shows a circuit using a 0.15 µF capacitor and a 1.5 kΩ resistor in series with an AC voltmeter connected to the set's exposed metal parts and earth ground.
How to Find a Good Earth Ground:
The cover-plate retaining screw on AC outlet boxes is typically earth ground. Verify this by connecting a 60W-100W incandescent lamp between the hot side of the receptacle and the retaining screw. The lamp should light at normal brilliance if the screw is at ground potential. (See Figure B).
Section 1 - Specifications and Layouts
Specifications
| System | KDL-40R450A | KDL-46R450A |
|---|---|---|
| Television system | NTSC: American TV Standard; ATSC (8VSB terrestrial): ATSC Compliant 8VSB; QAM on cable: ANSI/SCTE 07 2000 | NTSC: American TV Standard; ATSC (8VSB terrestrial): ATSC Compliant 8VSB; QAM on cable: ANSI/SCTE 07 2000 |
| Channel coverage | Analog Terrestrial: 2 - 69 / Digital Terrestrial: 2 - 69; Analog Cable: 1 - 135 / Digital Cable: 1 - 135 | Analog Terrestrial: 2 - 69 / Digital Terrestrial: 2 - 69; Analog Cable: 1 - 135 / Digital Cable: 1 - 135 |
| Panel system | LCD (Liquid Crystal Display) Panel, LED Backlight | LCD (Liquid Crystal Display) Panel, LED Backlight |
| Speaker output | 8W + 8W | 8W + 8W |
| Input/Output jacks | CABLE/ANTENNA: 75-ohm external terminal for RF inputs; VIDEO IN: 1 Vp-p, 75 ohms unbalanced, sync negative; AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms | CABLE/ANTENNA: 75-ohm external terminal for RF inputs; VIDEO IN: 1 Vp-p, 75 ohms unbalanced, sync negative; AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms |
| COMPONENT IN | YPBPR (Component Video): 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 | YPBPR (Component Video): 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(ARC) | HDMI: Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p | HDMI: Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p |
| HDMI IN 2/MHL | MHL: Video: 480i, 480p, 720p, 720/30p, 1080i, 1080/30p, 1080/24p; Audio: Two channel linear PCM 32, 44.1 and 48 kHz, 16, 20 and 24bits, Dolby Digital | MHL: Video: 480i, 480p, 720p, 720/30p, 1080i, 1080/30p, 1080/24p; Audio: Two channel linear PCM 32, 44.1 and 48 kHz, 16, 20 and 24bits, Dolby Digital |
| PC Input | 500 mVrms (typical) | 500 mVrms (typical) |
| AUDIO OUT | ||
| DIGITAL AUDIO OUT (OPTICAL) | PCM/Dolby Digital Optical Signal | PCM/Dolby Digital Optical Signal |
| USB | Photo, Music and Video | Photo, Music and Video |
| Model name | KDL-40R450A | KDL-46R450A |
|---|---|---|
| Power requirement | 110-240 V AC, 50/60 Hz (USA/Canada/Mexico 120 V AC, 60 Hz) | 110-240 V AC, 50/60 Hz (USA/Canada/Mexico 120 V AC, 60 Hz) |
| Power consumption (in use) | 89 W | 109 W |
| Power consumption (in standby) | Less than 0.2 W with 120 VAC and less than 0.3 W with 240 VAC | Less than 0.2 W with 120 VAC and less than 0.3 W with 240 VAC |
| Screen size* (measured diagonally) | 40 inches (101.6 cm) | 46 inches (116.8 cm) |
| Display resolution | 1,920 dots (horizontal) × 1,080 lines (vertical) | 1,920 dots (horizontal) × 1,080 lines (vertical) |
| Speaker/Full range (2) | 40 x 100 mm (1 5/8 x 4 inches) | 40 x 100 mm (1 5/8 x 4 inches) |
| Dimensions* with stand | 923 x 567 x 181 mm (36 3/8 x 22 3/8 x 7 1/4 inches) | 1053 x 641 x 181 mm (41 1/2 x 25 1/4 x 7 1/4 inches) |
| Dimensions* without stand | 923 x 548 x 76 mm (36 3/8 x 21 5/8 x 3 inches) | 1053 x 622 x 76 mm (41 1/2 x 24 1/2 x 3 inches) |
| wall-mount hole pattern | 200 x 100 mm | 300 x 300 mm |
| wall-mount screw size | M4 (6.5~10 mm) | M6 (8~12 mm) |
| Mass* with stand | 7.1 kg (15.7 lb) | 9.4 kg (20.8 lb) |
| Mass* without stand | 7.1 kg (15.7 lb) | 9.4 kg (20.8 lb) |
| Supplied accessories | Remote control RM-YD092 (1), Size AAA batteries (2), Operating Instructions (1), Quick Setup Guide (1), Warranty Card (1), Safety and Regulatory Booklet (1), Software License (1), Stand installation guide (1), Table-Top Stand (1 set), Screws (2 for KDL-40R450A) / Screws (4 for KDL-46R450A), Attachment Parts (2 for KDL-46R450A only). | Remote control RM-YD092 (1), Size AAA batteries (2), Operating Instructions (1), Quick Setup Guide (1), Warranty Card (1), Safety and Regulatory Booklet (1), Software License (1), Stand installation guide (1), Table-Top Stand (1 set), Screws (4 for KDL-46R450A), Attachment Parts (2 for KDL-46R450A only). |
| Optional accessories | Connecting Cables, Support Belt Kit | Connecting Cables, Support Belt Kit |
Note: Optional accessories availability depends on stock. Design and specifications are subject to change without notice. Dimensions and mass are approximate values.
Board Layout
KDL-40R450A: The internal layout shows the POWER SUPPLY BOARD (GL4), SWITCH UNIT, TCON, H BOARD, and MAIN BOARD (A BOARD).
KDL-46R450A: The internal layout shows the POWER SUPPLY BOARD (GL5), SWITCH UNIT, TCON, H BOARD, and MAIN BOARD (A BOARD).
Wire Dressing
Visuals show the internal wiring configuration for both KDL-40R450A and KDL-46R450A models, illustrating how cables are routed within the chassis.
Section 2 - Troubleshooting
Diagnosing the Error
Before servicing, verify the TV's symptom with the customer, check for the latest software installation, and determine the required replacement part.
Viewing the Self Check Diagnosis History
The Self Check screen records error occurrences, aiding in identifying intermittent issues. If the screen displays '0', no error has occurred.
To access the history:
- Press the [POWER] button to turn the TV on and then off.
- Within 1 second, press the following buttons on the Remote Commander in sequence: [DISPLAY], [Channel 5], [Volume -], [POWER].
Note: This procedure differs from accessing Service Adjustments Mode (Volume +).
The 'SAMPLE SELF CHECK DIAGNOSIS PAGE' displays error codes (e.g., MAIN_POWER, DC_ALERT1, AUDIO_PROT) with corresponding counts. A count of '000' indicates no error, while other counts indicate an error has occurred.
Triage Chart
This chart helps identify potential causes of errors before visiting the customer's location. It involves confirming the symptom, selecting it on the chart, identifying the primary component, and following associated flowcharts. The chart uses color codes: RED Dot for (Primary) Most likely defective part, and BLUE Triangle for (Secondary) Possible defective part.
The chart categorizes issues by Board (MAIN BOARD, POWER SUPPLY, LCD PANEL, TCON) and by fault type (Protection Modes: 2X, 3X, 5X, 6X; Power: Dead set; Video: No Video, Whole Screen Distortion, Isolated Area Distortion; Audio: No Audio).
For part number information, refer to 'Section 4 - Exploded View/Part Number Information' on page 20.
Access to the latest Triage documents is available via the Sony Authorized Servicer Portal at http://www.sony.com/asp.
Flowcharts and Diagrams
Overall Block Diagram
This diagram illustrates the signal flow within the TV. RF, COMPONENT/COMPOSITE, HDMI 1, HDMI 2, PC HD15, and USB 1 inputs feed into the TUNER and then the MAIN BOARD (containing MT5389 A/V DECODER, A/V PROCESS, and CLASS D AUDIO AMP). The MAIN BOARD outputs audio signals (L, R, HEADPHONE AUDIO OUT, ANALOG AUDIO OUT, OPTICAL AUDIO OUT) and video signals via LVDS to the LCD PANEL, TCON, & LED BACKLIGHTS. The SWITCH UNIT and POWER SUPPLY (GL4 for 40", GL5 for 46") are also shown, receiving AC IN and providing power to the system.
Power and Control Block Diagram
This diagram details the power and control connections between the POWER SUPPLY board and the MAIN BOARD, as well as the connection to the LCD PANEL, TCON, & LED BACKLIGHTS.
- The POWER SUPPLY board receives AC IN and provides outputs like LED+ / LED- (CN6801) to the LCD Panel assembly.
- Internal connections from the POWER SUPPLY (CN6401) include GND, STBY 3.3V, POWER_ON, VCC_12V, AC_OFF_DET, BLKT_EN, AUDIO_12V, BL_CNTRL, BKL_ERR, and NC pins.
- These signals connect to the MAIN BOARD (CN201) which includes VCC-12V, BL PWM, AC_DET, POWER_ON, TCON_VCC, AUDIO_12V, BL_ERR, and BL_EN.
No Power Flowchart
This flowchart guides troubleshooting for a TV with no power:
- Start with 'No Power'. Unplug the TV, wait 20 seconds, and re-apply AC power.
- Check if the red standby LED is steady. If 'No', check if the standby LED is blinking. If blinking, refer to the 'See protection flowchart'. If not blinking, the issue is likely the Power Supply Board.
- If the standby LED is steady ('Yes'), press the power button while monitoring pin 4 of CN6401 on the power supply board.
- If pin 4 shows High (3.3V) ('Yes'), the issue is likely the Power Supply Board.
- If pin 4 shows Low ('No'), check if pin 6 of CN6401 shows High (3.3V). If 'Yes', the issue is the Main Board. If 'No', the issue is likely the Power Supply Board.
Standby LED Blinking Flowchart
This flowchart addresses 'Protect Shutdown' indicated by a blinking Standby LED:
- If the LED blinks 2 times ('2X'), the issue is likely the Power Supply Board.
- If it blinks 3 times ('3X'), the issue is likely the Main Board.
- If it blinks 5 times ('5X'), the issue is the LCD Panel.
- If it blinks 6 times ('6X'), check if the 'SONY' logo appears before shutdown. If 'No', the issue is likely the Power Supply Board. If 'Yes', the issue is the LCD Panel.
For Part Number information, refer to 'Section 4 - Exploded View/Part Number Information' on page 20.
No Video Flowchart
This flowchart helps diagnose 'No Video' issues:
- Check if backlights are turned on. If 'No', the issue is the LCD Panel.
- If backlights are on ('Yes'), check if any OSD graphics are present. If 'Yes', the issue is the Main Board.
- If no OSD graphics are present ('No'), unplug the LVDS connector at the TCON while the unit is running (this may need to be done multiple times).
- After unplugging, check if any flashes are seen on the screen. If 'No', the issue is the LCD Panel. If 'Yes', the issue is the Main Board.
For Part Number information, refer to 'Section 4 - Exploded View/Part Number Information' on page 20.
Video Distortion Flowchart
This flowchart addresses 'Video Distortion' symptoms:
- Is distortion across the entire screen? If 'Yes', check for improper or missing colors. If 'No', check for vertical lines or bars.
- If improper/missing colors ('Yes'), the issue is the Main Board.
- If vertical lines or bars ('Yes'), check if lines move when wide-mode is changed. If 'Yes', the issue is the Main Board. If 'No', the issue is the LCD Panel.
- If distortion is not across the entire screen ('No'), check for any horizontal lines. If 'Yes', the issue is the LCD Panel.
- If no horizontal lines ('No'), check for any single or isolated vertical lines. If 'Yes', the issue is the LCD Panel.
- If no single vertical lines ('No'), check for more than 1 vertical band. If 'Yes', check for uneven brightness. If 'Yes', the issue is the LCD Panel.
For Part Number information, refer to 'Section 4 - Exploded View/Part Number Information' on page 20.
Section 3 - Repair Information
Repairing the TV
If software updates do not resolve the issue, follow these steps:
- Verify the TV symptom with the customer.
- Replace the part causing the error.
- Install the latest version of Software (required for all repairs).
- Perform required service adjustments and checks.
- Verify the repair resolved the issue.
Starting the Repair
This section explains how to remove the Table-Top Stand and Rear Cover.
Removing the Table-Top Stand
- Place the TV face down on a soft, flat surface.
- Remove 2 screws from the Table-Top Stand and carefully detach it from the Rear Cover.
Removing the Cover Under
- Remove the 13 screws from the Cover Under.
- Hold the bottom of the Cover Under with both thumbs and flip it open.
- Grasp the Cover Under from the corner and lift to detach it from the bottom.
Replacing the Main Board
The Main Board is available for repair. For part number information, refer to Section 4 on page 20.
- Disconnect LVDS and FFC connectors: Press both sides to unclamp and pull to release; lift the black bar and pull blue FFC cables to release.
- Unplug other connectors from the Main Board.
- Remove 5 screws from the Main Board.
- Lift to detach the Main Board from the Rear Cover.
- Replace with the new Main Board.
- Reconnect LVDS, FFC Cables, and all connectors. Ensure connectors are properly seated and secured (e.g., by closing the black bar on FFC cables).
CAUTION: Ensure the black line on FFC cables is aligned to the connector when reinserting.
Replacing the Power Supply Board
- Remove screws and detach brackets.
- Remove 5 screws from the Power Supply Board.
- Disconnect the Power Cord from the Power Supply Board.
- Disconnect all connectors to detach the board from the Rear Cover.
- Confirm the latest software version is installed; update if necessary.
Removing the Switch Unit
- Disconnect the FFC cable from the Switch Unit.
- Insert a finger into the free space on the left side pocket where the Switch Unit is located and pull to detach it from the Rear Cover.
Removing the Bezel
- Remove screws and detach the Power Cord.
- Disconnect connectors from the TCON and H Board. Caution: Ensure the H Board is disconnected before removing the SPK BFL from the Rear Cover to avoid connector damage.
- Remove the harness assembly carefully.
- Gently lift up the cover and detach it from the LCD Panel.
- Flip the TV face up and press the gap between the LCD Panel and Bezel.
- Gently lift up and unhook the Bezel to detach it.
Software Update and Service Mode Procedures
Software Update:
- Turn the TV on to update the software. Instructions are available on the Sony Authorized Service Portal website.
- After the update, press [POWER] to turn off the TV.
Accessing Service Mode:
Within 1 second, press the following buttons on the Remote Commander: [DISPLAY], [Channel 5], [Volume +], [POWER].
Navigating Service Mode:
- Use the navigation buttons (e.g., arrow keys, [Set], [Home]) to select options like 'Sound Adjustment', 'Wide Band Tuning', 'Range Scan', 'Self diagnosis history', 'Status Information', 'LVDS Spectrum(%0)', 'Low of HPD', 'TVD_MCDONE_CNT', 'Demo Special', 'Bypass AVI Info Detect', 'Panel Selection', 'UART Selection', 'SERIAL NUMBER EDIT', and 'MODEL NAME EDIT'.
Checking Status Information:
- Navigate to and select 'Status Information'.
- The screen displays firmware versions (MAIN FW VER, MAIN NVM VER, etc.), model details, serial number (S/N), frequency, modulation, etc.
- Press [RETURN] to go back to the Service Mode screen.
Panel Selection:
- Navigate to and select 'Panel Selection'.
- Use the navigation buttons (e.g., left/right arrows) to select the correct Panel Code for the Panel ID from the provided table (e.g., KDL-40R450A uses 20_LSY400HM02, KDL-46R450A uses 22_LSY460HN01).
CAUTION: Selecting the correct Panel ID Code is crucial for proper picture display.
Serial Number Entry:
- Locate the TV's Serial Number on the side of the Rear Cover.
- Navigate to and select 'SERIAL NUMBER EDIT'.
- Use the navigation buttons (e.g., up/down, left/right arrows) to enter all digits of the Serial Number.
- CAUTION: The Serial Number can only be selected once. Verify the information is correct before saving.
- When the complete Serial Number is displayed, press [Set].
- On the confirmation screen, press navigation buttons to select 'YES' and then press [Set].
Model Name Entry:
- Navigate to and select 'MODEL NAME EDIT'.
- Use the navigation buttons (e.g., up/down, left/right arrows) to enter all characters of the Model Name (e.g., KDL-40R450A).
- CAUTION: The Model Name can only be selected once. Verify the information is correct before saving.
- When the complete Model Name is displayed, press [Set].
- On the confirmation screen, press navigation buttons to select 'YES' and then press [Set].
- Press [POWER] to exit Service Mode.
Section 4 - Exploded View/Part Number Information
Exploded View Diagram
The document includes exploded view diagrams showing the internal components of the KDL-40R450A and KDL-46R450A models. These diagrams are accompanied by a parts list referencing components by number, part number, and description.
Key components identified include:
- COVER, UNDER (Part No. 4-459-446-01 for 40", 4-459-473-01 for 46")
- PLASTIC, STAND (Part No. 4-459-511-01)
- LOUD SPEAKER (Part No. 1-858-888-11 for L, 1-858-888-21 for R)
- BRACKETS (various part numbers for SP, Stand A, VESA, VESA TOP A)
- A BOARD, COMPLETE (Part No. 1-895-371-11)
- POWER-SUPPLY CORD (Part No. 1-846-638-11 for 40", 1-846-638-31 for 46")
- Main Boards: GL4 BOARD, COMPLETE (Part No. 1-474-487-11 for 40") and GL5 BOARD, COMPLETE (Part No. 1-474-488-11 for 46")
- SWITCH UNIT (Part No. 1-492-329-11)
- BEZEL (Part No. A-1932-053-A for 40", A-1932-061-A for 46")
- LCD PANEL (Part No. NA, refer to LCD Panels Service Manual for details)
Note: Components identified by shading and ⚠️ are critical for safety and must be replaced with the specified part number. Components with red outlines and ⚠️ marks contain confidential information.
Connectors
Detailed lists of connectors and their associated part numbers are provided for both KDL-40R450A and KDL-46R450A models, including FFC cables, PSU connectors, ground cables, LVDS cables, and speaker connectors.
Screws
A table lists various screws by P/N, description, and the parts they are used to secure on both KDL-40R450A and KDL-46R450A models. Examples include screws for the Rear Cover, Brackets, RC Terminal, and Table Top Stand.
Section 5 - Accessories Part Number Information
Accessories and Packaging
- SCREW, +PSW M5X16 (Part No. 2-580-608-11) for attaching the table-top stand.
- SCREW, +PSW M4X12 (Part No. 2-580-602-01) for wall-mount brackets (KDL-46R450A only).
- Various Quick Setup Guides (English, French, Spanish, English/Spanish) and Instruction Manuals (English, French, Spanish).
- SUPPLEMENT (STAND INSTALLATION).
Note: Sony strongly recommends using provided screws for product protection and safety.
Miscellaneous
- FLYER, SAFETY (Part No. 3-299-071-06)
- GASKET (Part No. 4-464-002-01 for 40", 4-464-000-01 for 46")
Optional Accessories
- SUPPORT BELT KIT (Part No. 4-414-470-01)
Remote Commander
- REMOTE COMMANDER (RM-YD092) (Part No. 1-492-065-11)
Appendix A: Encryption Key Components
Encryption key components developed by Sony Corporation contain confidential information and must be handled under non-disclosure obligations. Specific instructions must be followed when repairing or replacing Circuit Boards with encryption key components:
- Such boards are identified with a red outline and a ⚠️ symbol in the service manual.
- Only repair boards or components listed in the service manual are to be used.
- Disassembly, decryption, or reverse-engineering of components is strictly prohibited.
- Any board with replaced encryption key components must be returned to its original set, and the defective component MUST BE DESTROYED. Boards cannot be swapped.
- If a board with encryption key components is deemed defective, it must be returned to Sony if a core charge is covered by warranty, or destroyed if not covered.
- If a unit is destroyed (e.g., field scrap), the Circuit Board with encryption key components MUST BE DESTROYED.
