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Sony KDL-40VL160 Service Manual
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Sony KDL-40VL160 Service Manual

Lcd digital color television, ex1 chassis
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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME
KDL-40VL160
KDL-40VL160
KDL-46VL160
KDL-46VL160
ORIGINAL MANUAL ISSUE DATE: 4/2009
REVISION DATE
4/2009
9-883-820-01
REMOTE COMMANDER
RM-YD024
RM-YD024
RM-YD024
RM-YD024
SUBJECT
No revisions or updates are applicable at this time.
DESTINATION
US
CANADA
US
CANADA
LCD DIGITAL COLOR TELEVISION
EX1
CHASSIS

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  • Page 1 HISTORY INFORMATION FOR THE FOLLOWING MANUAL: SERVICE MANUAL CHASSIS MODEL NAME REMOTE COMMANDER DESTINATION KDL-40VL160 RM-YD024 KDL-40VL160 RM-YD024 CANADA KDL-46VL160 RM-YD024 KDL-46VL160 RM-YD024 CANADA ORIGINAL MANUAL ISSUE DATE: 4/2009 REVISION DATE SUBJECT 4/2009 No revisions or updates are applicable at this time.
  • Page 2 Self Diagnosis Supported model SERVICE MANUAL CHASSIS MODEL NAME REMOTE COMMANDER DESTINATION KDL-40VL160 RM-YD024 KDL-40VL160 RM-YD024 CANADA KDL-46VL160 RM-YD024 KDL-46VL160 RM-YD024 CANADA KDL-46VL160 RM-YD024 LCD DIGITAL COLOR TELEVISION 9-883-820-01...

  • Page 3: Table Of Contents

    BU Board Schematic Diagram (12 of 12) ......69 1-7. VESA Frames and Bottom Bracket Removal ....... 15 D3Z-40 Board Schematic Diagram (KDL-40VL160 ONLY) ..........71 1-8. LCD Panel Removal ............. 16 D3Z-46 Board Schematic Diagram 1-8-1. Cleaning the LCD Panel .......... 16 (KDL-46VL160 ONLY) ..........

  • Page 4: Specifications

    Guide International, Inc. and/or one of its “PLAYSTATION” is a registered trademark affiliates. and “PS3” is a trademark of Sony Computer The TV Guide On Screen system is protected Entertainment Inc. by one or more of the following United States Adobe is a registered trademark or a trademark patents 4,908,713;...
  • Page 5 Suport Belt Kit Wall-Mount Bracket Panel System SU-WL500 LCD (Liquid Crystal Display) Panel TV-Stand WS-S10LS Display Resolution (horizontal x vertical) SU-FL71M 1,920 dots x 1,080 lines Screen Size (measured diagonally) ~ 40 inches (KDL-40VL160 Only) ~ 46 inches (KDL-46VL160 Only) KDL-40VL160/46VL160...

  • Page 6: Warnings And Cautions - English

    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...

  • Page 7: Warnings And Cautions - French

    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.

  • Page 8: Safety-Related Component Warning

    KDL-40VL160/46VL160 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...
  • Page 9 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-40VL160/46VL160...

  • Page 10: Safety Check-Out

    KDL-40VL160/46VL160 SAFETY CHECK-OUT The AC leakage from any exposed metal part to earth ground and After correcting the original service problem, perform the following from all exposed metal parts to any exposed metal part having a safety checks before releasing the set to the customer: return to chassis, must not exceed 0.5 mA (500 microamperes).

  • Page 11: Self-Diagnostic Function

    KDL-40VL160/46VL160 Self Diagnosis SELF-DIAGNOSTIC FUNCTION Supported model 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.
  • Page 12 KDL-40VL160/46VL160 LED Indicators Number of times Diagnostic Item STANDBY lamp Possible Location Description flashes Main Power 2 times Power Supply Board Main Board DC Alert 3 times Power Supply Board Panel Alert 5 times LCD Panel Main Board Backlight 6 times...

  • Page 13: Section 1: Disassembly

    SECTION 1: DISASSEMBLY 1-1. REAR COVER AND SWITCH UNIT (CONTAINS H1 BOARD) REMOVAL Remove 2 screws from Terminal Position Remove 4 screws Remove 15 screws (KDL-40VL160 ONLY) Remove 17 screws (KDL-46VL160 ONLY) Disconnect 1 connector and slide out Switch Unit Rear Cover...

  • Page 14: G4 (Power Unit) Board And D3Z Board Removal

    KDL-40VL160/46VL160 1-3. G4 (POWER UNIT) BOARD AND D3Z BOARD REMOVAL Disconnect 3 connectors Remove 6 screws Release board holders Disconnect 4 connectors Remove 6 screws G4 (Power Unit) Board D3Z Board 1-4. TABLE-TOP STAND AND UNDER COVER REMOVAL Gently place the TV set face down onto soft cloth...

  • Page 15: Ac Inlet And Ac Bracket Removal

    KDL-40VL160/46VL160 1-5. AC INLET AND AC BRACKET REMOVAL AC Inlet Remove 2 screws Remove 2 screws AC Bracket Soft Cloth 1-6. SPEAKERS, UNDER BAR, SCREW CAPS, H3V BOARD, AND H4 BOARD REMOVAL Speaker Remove 2 screws from Under Bar Slide out Speaker units from Bezel...

  • Page 16: Lcd Panel Removal

    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-40VL160 models and on Page 52 for KDL-46VL160 models. Insulating Sheet (G4)

  • Page 17: Baffles, Ir Guide And Clear Panel Removal

    KDL-40VL160/46VL160 1-9. BAFFLES, IR GUIDE AND CLEAR PANEL REMOVAL Remove 2 screws from Baffl es (KDL-46Z4100/B & 46Z4100/S ONLY) Remove 3 screws Remove 2 screws Disconnect one connector and slide out from Bezel Baffle Clear Panel IR Guide Baffle Illumination...

  • Page 18: Wire Dressing

    KDL-40VL160/46VL160 WIRE DRESSING KDL-40VL160 ONLY LEGEND 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. Center of panel...
  • Page 19 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND 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).
  • Page 20 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND H BOARD/SPEAKER HARNESS: LIGHTED SONY LOGO Apply LCD Tape over panel sharp edge and connect harness to Lighted Sony Logo. KDL-40VL160/46VL160...
  • Page 21 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND H BOARD/SPEAKER HARNESS Apply Sheet Core C to Harness. Use BLACK UL TAPE on Harness as guide where to apply Sheet Core C. Apply LCD Tape over speaker wires. KDL-40VL160/46VL160...
  • Page 22 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND COMBINATION H BOARD/SPEAKER HARNESS MAKE SURE wires are routed On SIDE of Panel. KDL-40VL160/46VL160...
  • Page 23 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND MAIN HARNESS ROUTING/DRESSING Apply Sheet Core C as shown. Make sure harness wires are BELOW Top edge of panel! Center of Panel KDL-40VL160/46VL160...
  • Page 24 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND MAIN HARNESS ROUTING/DRESSING (CONTINUED) Apply LCD Tape to secure Switch Assy wires to SIDE of Panel. (2 Places) KDL-40VL160/46VL160...
  • Page 25 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND BALANCER BOARD CABLE ROUTING Gently push wires down to make sure Level of the wires are below the Metal panel shield case. KDL-40VL160/46VL160...
  • Page 26 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND LEFT SPEAKER HARNESS DRESSING 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-40VL160/46VL160...
  • Page 27 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND BU BOARD WIRE ROUTING/DRESSING BU-Bd Wire Routing/Dressing Dress harness in slide Clamps as shown. (2 places) KDL-40VL160/46VL160...
  • Page 28 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND MAIN HARNESS ROUTING 40Z Main Harness Routing CAUTION Make sure Main Harness wires do NOT cross over Terminal Jacks (Pinch Point with Rear Cover) KDL-40VL160/46VL160...
  • Page 29 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND 3P HIGH VOLTAGE CONN ASSY ROUTING KDL-40VL160/46VL160...
  • Page 30 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND MAIN HARNESS, D3Z HARNESS ROUTING AND DRESSING Apply Sheet Core C as shown. Use Plastic “button” on panel as guide for tape placement. KDL-40VL160/46VL160...
  • Page 31 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND LVDS CABLE ROUTING KDL-40VL160/46VL160...
  • Page 32 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND INSTALLATION PROCEDURE FOR MDF-61 CONNECTOR STEP1: ALIGN CONNECTOR STEP3: PUSH DOWN ON BLACK STEP2: INSTALL CONNECTOR LOCK TAB TO SEAT CONNECTOR. WHEN CONNECTOR IS SEATED IT WILL “CLICK” INTO PLACE. “HRS” LOGO WILL BE VISIBLE WHEN STEP4: PULL LOCK BLACK LOCK CONNECTOR IS PROPERLY LOCKED.
  • Page 33 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND HIGH VOLTAGE MDF-61 WIRE ROUTING a l l o i t i l A t t u i f n “ . ” s . y l i l S t a l e r i...
  • Page 34 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND 2P AC INLET Apply Sheet Core C as shown. KDL-40VL160/46VL160...
  • Page 35 KDL-40VL160/46VL160 KDL-40VL160 ONLY LEGEND BEZEL GROUNDING WIRE KDL-40VL160/46VL160...

  • Page 36: Kdl-46Vl160 Only

    KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND 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 bottom as Reference where center of panel is. Center of panel KDL-40VL160/46VL160...
  • Page 37 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND 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).
  • Page 38 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND H BOARD/SPEAKER HARNESS: LIGHTED SONY LOGO Apply LCD Tape over panel sharp edge and connect harness to Lighted Sony Logo. KDL-40VL160/46VL160...
  • Page 39 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND COMBINATION H BOARD/SPEAKER HARNESS Apply Sheet Core C to Harness. Use BLACK UL TAPE on Harness as guide where to apply Sheet Core C. H3V-Bd MAKE SURE wires are routed on SIDE of Panel. KDL-40VL160/46VL160...
  • Page 40 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND COMBINATION H BOARD/SPEAKER HARNESS: H3 BOARD ROUTING Apply LCD Tape to secure Wires to SIDE of panel. Use UL tape and split in harness as a guide where to place LCD Tape. KDL-40VL160/46VL160...
  • Page 41 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND MAIN HARNESS ROUTING/DRESSING Apply LCD Tape to secure Switch Assy wires to SIDE of Panel. (2 Places) KDL-40VL160/46VL160...
  • Page 42 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND MAIN HARNESS ROUTING/DRESSING (CONTINUED) Apply Sheet Core C as shown. KDL-40VL160/46VL160...
  • Page 43 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND BU BOARD WIRE ROUTING AND DRESSING BU-Bd Wire Routing & Dressing Dress harness in slide Clamps as shown. (2 places) KDL-40VL160/46VL160...
  • Page 44 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND 13P HARNESS DRESSING 13P Harness Dress Dress 13P Conn Assy in Slide Clamp as shown. Apply Sheet Core C Tape to Cable as shown. Make sure wires have Slack between connector and Sheet Core C tape.
  • Page 45 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND BU BOARD WIRE ROUTING AND DRESSING CAUTION POINT Keep Area in Red Box CLEAR of any Cables. Connector needs to be CLEAR to Plug in JIG CONNECTOR. KDL-40VL160/46VL160...
  • Page 46 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND BALANCER BOARD CABLE ROUTING Gently push wires down to make sure Level of the wires are below the Metal panel shield case. Apply Sheet Core C as shown. KDL-40VL160/46VL160...
  • Page 47 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND LEFT SPEAKER HARNESS DRESSING Apply LCD tape to secure Left Speaker wires. NOTE: LEFT Speaker wires are NOT dressed in slide clamp. KDL-40VL160/46VL160...
  • Page 48 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND MAIN HARNESS ROUTING CAUTION Make sure Main Harness wires do NOT cross over Terminal Jacks (Pinch Point with Rear Cover) KDL-40VL160/46VL160...
  • Page 49 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND 2P HIGH VOLTAGE CONN ASSY ROUTING KDL-40VL160/46VL160...
  • Page 50 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND MAIN HARNESS, D3Z HARNESS AND AC INLET ROUTING AND DRESSING Apply Sheet Core C as shown. Place Sheet Core C adjacent to LCD Tape on D3Z Harness. DO NOT place Sheet Core C on top LCD Tape.
  • Page 51 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND LVDS CABLE ROUTING KDL-40VL160/46VL160...
  • Page 52 KDL-40VL160/46VL160 KDL-46VL160 ONLY LEGEND INSTALLATION PROCEDURE FOR MDF-61 CONNECTOR STEP1: ALIGN CONNECTOR STEP3: PUSH DOWN ON BLACK STEP2: INSTALL CONNECTOR LOCK TAB TO SEAT CONNECTOR. WHEN CONNECTOR IS SEATED IT WILL “CLICK” INTO PLACE. STEP4: PULL LOCK BLACK LOCK TAB IN DIRECTION INDICATED ON...

  • Page 53: Section 2: Service Adjustments

    KDL-40VL160/46VL160 SECTION 2: SERVICE ADJUSTMENTS 2-1. VIEWING SERVICE ADJUSTMENT DATA SERVICE There are no adjustments necessary for these models. All data has COLOR ADJ 00100 been set for optimal viewing for our customers. The following sections R_DRV are for informational purposes only.

  • Page 54: Using The Remote Commander To View Service Data

    KDL-40VL160/46VL160 2-4. USING THE REMOTE COMMANDER TO TV POWER VIEW SERVICE DATA Use the buttons on the Remote Commander to access the service menu items and adjust the data values. 1. Access Service Mode. Press the following buttons on the Remote Commander within a...

  • Page 55: Section 3: Diagrams

    KDL-40VL160/46VL160 SECTION 3: DIAGRAMS 3-1. CIRCUIT BOARDS LOCATION G4 (POWER UNIT) BOARD Illumination Module SWITCH UNIT (Contains H1 Board) 3-2. PRINTED WIRING BOARDS AND SCHEMATIC DIAGRAMS INFORMATION All capacitors are in μF unless otherwise noted. pF : μμF 50WV or All voltages are in V.
  • Page 56 KDL-40VL160/46VL160 REFERENCE INFORMATION Terminal name of semiconductors in silk screen printed circuit ( RESISTOR CAPACITOR : RN METAL FILM : TA TANTALUM Circuit Device Printed symbol Terminal name : RC SOLID : PS STYROL Collector Transistor : FPRD NONFLAMMABLE CARBON...

  • Page 57: Block Diagram

    KDL-40VL160/46VL160 3-3. BLOCK DIAGRAM r a l ) r a ] l o / . r KDL-40VL160/46VL160...

  • Page 58: Schematics And Supporting Information

    KDL-40VL160/46VL160 3-4. SCHEMATICS AND SUPPORTING INFORMATION BU BOARD SCHEMATIC DIAGRAM (1 OF 12) A_V1_IN_C,A_V1_IN_S2SW,A_V1_IN_SSW,A_V1_IN_V,A_V1_IN_Y A_V1_IN_Y — R1021 *J1201 D3.3V 1/10W VD1001 RN-CP A_LINEOUT 0.5% A_SPDIF_OUT A_V1_IN_C R1004 C1204 0 . 1 1/10W D3.3V RN-CP A_V1_IN_S2SW 1005 VD1002 Opt/Audio Output C1001...

  • Page 59: Bu Board Schematic Diagram (2 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (2 OF 12) — AU_13V F2001 D3.3V AUDIO_13V C2070 L2001 F2000 1.6A AWF_AMP C2009 C2072 *RB2029 0 . 0 0 1 C2128 0 . 0 1 1005 — 1005 C2003 C2004 SW_FAULT 0 . 0 1...

  • Page 60: Bu Board Schematic Diagram (3 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (3 OF 12) STBY3.3V_2 << STBY3.3V >> FL3001 STBY3.3V FB3001 M24256-BWMN6TP(A) IC3003 RESET R3018 R3011 EEPROM 2 . 2 k 1/16W — 1/16W CHIP R3010 RN-CP C3006 0.5% 1/16W 0 . 1 CHIP JL3003 C3013...

  • Page 61: Bu Board Schematic Diagram (4 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (4 OF 12) D3.3V HP_VCC_33 — EGPA0 AC26 WX2_RXO_N0 RXO_N0 VL1.0 DPA_0 TA1M FL4701 EGPA1 WX2_RXO_P0 RXO_P0 AC25 DPA_1 TA1P VDDF DVDD1 EGPA2 WX2_RXO_N1 RXO_N1 FB4703 DPA_2 C4728 C4741 C4748 0 . 1 0 . 0 0 1...

  • Page 62: Bu Board Schematic Diagram (5 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (5 OF 12) — DDR_1.8V WX2_DDR_1.8V FB4902 DDR2_A_DQ0 AA23 VDDM FB4900 AA24 DDR2_A_DQ1 DDR2_A0 DDR2_A_DQ0 C4901 C4928 C4929 C4930 C4931 VDDM 0 . 0 1 0 . 0 0 1 0 . 0 0 1 0 .

  • Page 63: Bu Board Schematic Diagram (6 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (6 OF 12) HDMI5V HDMI3.3V — PC-R CL5007 PC_R FB5001 PC-G PCA9517DP CL5008 IC5211 PC_G FB5002 PC-B CL5009 VCCA VCCB PC_B FB5003 C5211 SCLA SCLB DDC_SCL 0 . 0 1 R5001 R5003 R5005 SDAA SDAB...

  • Page 64: Bu Board Schematic Diagram (7 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (7 OF 12) R7082 C7066 1/16W 330p RN-CP 0.5% R7094 1/16W — CHIP R7070 R7076 R7083 R7090 REG12V 100k 1/16W 1/16W 1/16W 1/16W RN-CP RN-CP CHIP RN-CP D1.8V 0.5% 0.5% 0.5% F7003 R7080 C7070 C7045...

  • Page 65: Bu Board Schematic Diagram (8 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (8 OF 12) — D1.2V D3.3V D3.3V_IO — FL7200 VDDC VDDR3 MSCLK C7200 C7215 C7229 C7258 C7250 C7317 C7271 C7301 C7269 C7279 C7300 VDDC VDDR3 4 . 7 4 . 7 MSDATA(0) 6.3V 6.3V 6.3V 6.3V...

  • Page 66: Bu Board Schematic Diagram (9 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (9 OF 12) D1.8V JL7409 FB7401 C7406 0 . 1 DDR2 (x16) — 1005 VDDR_MEM_1.8V IC7401 HYB18TC1G160CF-2.5 MEM_DQ0 DQA_0 FAD5_PAD MEM_DQ1 VDD1 DQA_1 MEM_DQ2 DQA_2 — MEM_DQ3 VSS1 DQA_3 MEM_A12 MEM_DQ4 VSSQ1 DQA_4 MEM_QS#1 FAD(0)

  • Page 67: Bu Board Schematic Diagram (10 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (10 OF 12) USB1.1 PORTA C7505 — 100p USB1.1_/OVRCUR USB1.1VBUS JL7521 1005 USB_OVRCURb R7505 USB1.1N JL7522 1/16W USB1.1PA CHIP USB1.1P JL7523 USBPA USB1.1NA USB1.1GND JL7524 USBNA DVICLK D5V_USB USB1.1PB DVIDATA(0) V2_DET USBPB C7566 DVIDATA(1) HPD_DET2 USB1.1NB...

  • Page 68: Bu Board Schematic Diagram (11 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (11 OF 12) PLACE THIS FILTER CLOSE TO THE TUNER C7688 C7677 1005 L7611 C7635 0.27uH 0 . 1 C7680 1005 — 1005 1005 R7600 AK20 FAT_IFP 1/16W CHIP AK19 FAT_IFM C7681 C7636 0 . 1 L7612 0.27uH...

  • Page 69: Bu Board Schematic Diagram (12 Of 12)

    KDL-40VL160/46VL160 BU BOARD SCHEMATIC DIAGRAM (12 OF 12) — TXOUT_L0N TXOUT_L0P TXOUT_L1N TXOUT_L1P — TXOUT_L2N TXOUT_L2P EGPHSI EGPHSI TXCLK_LN TXCLK_LP EGPVSI D3.3V FB7850 EGPVSI TXOUT_L3N EGPPCI — EGPPCI TXOUT_L3P C7855 TC74VCX162374(EL,F 1608 IC7850 TXOUT_L4N TXOUT_L4P DVOCLK0 1/OE EGPG7 EGPG3_FF EGPG3 D2.5V_2...
  • Page 70 KDL-40VL160/46VL160 [VIDEO SW & I, O, AUDIO, BE MICRO, TRIDENT WX-2, TRIDENT DDR SDRAM, HDMI, PC, POWER SUPPLY, X245 GND, PWR, XTAL, PLL, RESET, PERIPHERAL, X245 DDR2, FLASH, NVM, FLEXBUS, STRAP, X245 AUDIO IF, USB1.1, USB 2.0, ETHERNET, X245 FRONTEND, ADC, GPIOC, TUNER, X245 DVO OUTPUT (ITU656.GRAPHICS)

  • Page 71: D3Z-40 Board Schematic Diagram (Kdl-40Vl160 Only)

    KDL-40VL160/46VL160 D3Z-40 BOARD SCHEMATIC DIAGRAM (KDL-40VL160 ONLY) JW6601 EY6600 EY6601 L6600 68uH JL6600 JW6602 FB6600 FB6602 CN6600 1.1uH 1.1uH EY6622 EY6602 — C6600 PFC_OUT 450V PRI_GND EY6604 EY6623 EY6603 *D6604 EY6714 S3K60 EY6605 C6797 JL6601 JW6611 450V JW6603 EY6710 R6700 JW6604 4 .

  • Page 72: D3Z-46 Board Schematic Diagram (Kdl-46Vl160 Only)

    KDL-40VL160/46VL160 D3Z-46 BOARD SCHEMATIC DIAGRAM (KDL-46VL160 ONLY) JW6601 EY6600 EY6601 L6600 68uH JL6600 JW6602 FB6600 FB6602 CN6600 1.1uH 1.1uH EY6622 EY6602 C6600 PFC_OUT — 450V EY6604 PRI_GND EY6623 EY6603 *D6604 EY6714 S3K60 C6797 JL6601 EY6605 JW6611 450V JW6603 EY6710 R6700 JW6604 4 .
  • Page 73 KDL-40VL160/46VL160 [INVERTER] [INVERTER] COMPONENT SIDE CONDUCTOR SIDE — EY6705 EY6641 — A6601 C6711 EY6651 EY6650 CN6707 C6711 FB6604 — — EY6623 D6614 EY6635 FB6605 FB6607 EY6622 JW6611 D6705 FB6611 — — D6613 Q6601 EY6640 D6603 D6607 EY6704 C6603 D6615 EY6600...

  • Page 74: G4 Board Schematic Diagram

    KDL-40VL160/46VL160 G4 BOARD SCHEMATIC DIAGRAM — — — — — — — — — — — — — — — KDL-40VL160/46VL160...
  • Page 75 KDL-40VL160/46VL160 [POWER] COMPONENT SIDE — — — — — — — — KDL-40VL160/46VL160...
  • Page 76 KDL-40VL160/46VL160 [POWER] CONDUCTOR SIDE — — — — — — — — KDL-40VL160/46VL160...

  • Page 77: H3V Board Schematic Diagram

    KDL-40VL160/46VL160 H3V BOARD SCHEMATIC DIAGRAM — CL307 CL306 — R302 CL301 CL302 JL303 CL305 1/16W 0.5% RN-CP D308 FR1105W — Q301 Q305 Q302 Q303 UNR52A1G0LS0 UNR52A1G0LS0 UNR52A1G0LS0 UNR52A1G0LS0 IOUTGND VCC — PICTURE OFF[RED&GREEN] POWER[GREEN] STANDBY[RED] TIMER[RED] Q306 ISA1602AM1TP-1EF — Optical Sensor IR/LED —...
  • Page 78 KDL-40VL160/46VL160 [LED, IR] COMPONENT SIDE 1-876-418-11 (172963711) A-1494- 141-A — CN301 [LED, IR] CONDUCTOR SIDE TREC — (172963711) STBY 1-876-418-11 PICOFF DATA TIMER KDL-40VL160/46VL160...

  • Page 79: H4 Board Schematic Diagram

    KDL-40VL160/46VL160 H4 BOARD SCHEMATIC DIAGRAM — — CL403 SIRCS CL401 STBY3.3V R402 CL402 C402 1/16W 6.3V CHIP CHIP *CN401 1/16W 2012 — R401 1005 220p C401 — SIRCS — A-1494-139-A <EX1> H4 — KDL-40VL160/46VL160...
  • Page 80 KDL-40VL160/46VL160 [SIRCS] COMPONENT SIDE cam15 cam15 — CL403 CL403 CN401 CN401 R452 R452 — CL401 CL401 CL402 CL402 R451 R451 R450 R450 — — [SIRCS] CONDUCTOR SIDE — — — KDL-40VL160/46VL160...

  • Page 81: Semiconductors

    KDL-40VL160/46VL160 3-5. SEMICONDUCTORS – KDL-40VL160/46VL160...

  • Page 82: Section 4: Exploded Views

    (SCREWS TO ATTACH TABLE-TOP STAND TO TV) A-1728-138-A TABLE-TOP STAND (SVC) ASSY (L-V) [9-13] For product protection and safety reasons, Sony strongly recommends that (KDL-46VL160 ONLY) you use the screws provided with the TV. NOTE: The Table-Top Stand Assy PN’s listed above include packaging) CAUTION: These screws cannot be used to secure the TV to Wall Mount Brackets.

  • Page 83: Chassis

    [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] 4-2. CHASSIS (Check the Sony Electronics Service Information website for any additional service related issues for this model.) KDL-40VL160 ONLY 8-597-661-00 TUNER, FSS BTF-CA422T 1-474-089-11 G4 BOARD (POWER UNIT), COMPLETE 7-682-948-01...

  • Page 84: Connectors

    REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] 4-3. CONNECTORS 1-835-185-11 CONNECTOR ASSY (Check the Sony Electronics Service Information website for any additional service related issues for this model.) 1-835-264-12 (LVDS) LEAD WIRE WITH CONNECTOR (KDL-40VL160 ONLY) 2-580-591-01 SCREW, +PSW M3X5 1-835-433-11...

  • Page 85: Bezel Assembly And Lcd Panel

    PART NO. DESCRIPTION [ASSEMBLY INCLUDES] 4-4. BEZEL ASSEMBLY AND LCD PANEL KDL-40VL160 ONLY (Check the Sony Electronics Service Information website for any additional service related issues for this model.) X-2349-469-1 BEZEL ASSY (40G) [152-154] (KDL-40VL160 ONLY) SERIAL RANGE 8,000,001 TO 8,100,000 ONLY...

  • Page 86: Screw Legend

    See Appendix A: Encryption Key Components in the back of this manual. 4-5. SCREW LEGEND (Check the Sony Electronics Service Information website for any additional service related issues for this model.) KDL-40VL160 DESCRIPTION REMARKS...

  • Page 87: Section 5: Electrical Parts List

    REF. NO. PART NO. DESCRIPTION VALUES C1102 1-114-130-11 CERAMIC CHIP 1μF 6.3V C1103 1-114-130-11 CERAMIC CHIP 1μF 6.3V KDL-40VL160 ONLY C1104 1-114-130-11 CERAMIC CHIP 1μF 6.3V SERIAL RANGE 8,000,001 TO 8,100,000 ONLY C1201 1-112-066-11 CERAMIC CHIP 10μF C1202 1-100-916-11 CERAMIC CHIP 0.1μF...
  • Page 88 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C2001 1-100-916-11 CERAMIC CHIP 0.1μF C2052 1-114-214-81 CERAMIC CHIP 470pF C2003 1-112-777-11 CERAMIC CHIP 0.01μF C2053 1-100-909-11 CERAMIC CHIP 10μF 6.3V C2054 1-100-764-21 ELECT CHIP 4.7μF C2004...
  • Page 89 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C3512 1-162-912-11 CERAMIC CHIP 0.50pF 50V C2120 1-114-130-11 CERAMIC CHIP 1μF 6.3V C3514 1-112-066-11 CERAMIC CHIP 10μF C2121 1-114-130-11 CERAMIC CHIP 1μF 6.3V C3515 1-100-916-11 CERAMIC CHIP 0.1μF...
  • Page 90 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C4758 1-100-905-11 CERAMIC CHIP 0.001μF 10% C4931 1-100-905-11 CERAMIC CHIP 0.001μF 10% C4760 1-100-905-11 CERAMIC CHIP 0.001μF 10% C4932 1-100-905-11 CERAMIC CHIP 0.001μF 10% C4933 1-100-905-11 CERAMIC CHIP 0.001μF 10%...
  • Page 91 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C7043 1-114-334-11 CERAMIC CHIP 10μF C7093 1-114-334-11 CERAMIC CHIP 10μF C7045 1-114-334-11 CERAMIC CHIP 10μF C7094 1-114-334-11 CERAMIC CHIP 10μF C7095 1-114-334-11 CERAMIC CHIP 10μF C7046 1-164-862-11...
  • Page 92 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C7151 1-114-325-11 CERAMIC CHIP 0.1μF C7219 1-114-130-11 CERAMIC CHIP 1μF 6.3V C7152 1-112-781-11 CERAMIC CHIP 1μF C7220 1-100-916-11 CERAMIC CHIP 0.1μF C7221 1-100-916-11 CERAMIC CHIP 0.1μF C7153...
  • Page 93 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C7265 1-100-916-11 CERAMIC CHIP 0.1μF C7413 1-114-130-11 CERAMIC CHIP 1μF 6.3V C7266 1-100-916-11 CERAMIC CHIP 0.1μF C7414 1-114-130-11 CERAMIC CHIP 1μF 6.3V C7415 1-114-130-11 CERAMIC CHIP 1μF 6.3V...
  • Page 94 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C7543 1-100-916-11 CERAMIC CHIP 0.1μF C7655 1-100-916-11 CERAMIC CHIP 0.1μF C7544 1-100-916-11 CERAMIC CHIP 0.1μF C7658 1-114-320-11 CERAMIC CHIP 0.22μF 6.3V C7661 1-100-766-21 ELECT CHIP 47μF C7545...
  • Page 95 KDL-40VL160/46VL160 NOTE: Les composants identifi es per un trame et une NOTE: The components identifi ed by shading marque sont critiques pour la securite. Ne les remplacer mark are critical for safety. Replace only que par une piece portant le numero specifi e.
  • Page 96 KDL-40VL160/46VL160 NOTE: Les composants identifi es per un trame et une NOTE: The components identifi ed by shading marque sont critiques pour la securite. Ne les remplacer mark are critical for safety. Replace only que par une piece portant le numero specifi e.
  • Page 97 KDL-40VL160/46VL160 NOTE: Les composants identifi es per un trame et une NOTE: The components identifi ed by shading marque sont critiques pour la securite. Ne les remplacer mark are critical for safety. Replace only que par une piece portant le numero specifi e.
  • Page 98 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R1105 1-218-989-11 RES-CHIP 1/16W R1420 1-218-983-11 RES-CHIP 330K 1/16W R1106 1-218-957-11 RES-CHIP 2.2K 1/16W R1421 1-218-971-11 RES-CHIP 1/16W R2006 1-218-990-81 SHORT CHIP R1107 1-218-989-11 RES-CHIP 1/16W R1108...
  • Page 99 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R3402 1-208-703-11 METAL CHIP 6.8K 0.50% 1/16W R4911 1-208-911-11 METAL CHIP 0.50% 1/16W R3403 1-208-711-11 METAL CHIP 0.50% 1/16W R5000 1-216-864-11 SHORT CHIP R5001 1-211-990-11 METAL CHIP 0.50% 1/10W...
  • Page 100 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R7063 1-208-935-11 METAL CHIP 100K 0.50% 1/16W R7118 1-216-864-11 SHORT CHIP R7064 1-218-965-11 RES-CHIP 1/16W R7130 1-208-711-11 METAL CHIP 0.50% 1/16W R7131 1-208-911-11 METAL CHIP 0.50% 1/16W...
  • Page 101 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R7401 1-208-683-11 METAL CHIP 0.50% 1/16W R7573 1-218-965-11 RES-CHIP 1/16W R7402 1-208-683-11 METAL CHIP 0.50% 1/16W R7574 1-218-929-11 RES-CHIP 1/16W R7575 1-208-905-11 METAL CHIP 5.6K 0.50% 1/16W...
  • Page 102 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R7681 1-218-953-11 RES-CHIP 1/16W RB2042 1-239-674-81 RESISTOR, NETWORK 100 R7682 1-218-945-11 RES-CHIP 1/16W RB3003 1-234-372-11 RES, NETWORK 100 (1005X4) RB3004 1-234-372-11 RES, NETWORK 100 (1005X4) R7683 1-218-941-81...
  • Page 103 KDL-40VL160/46VL160 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES RB5161 1-239-706-81 RESISTOR, NETWORK 47K VD1006 1-802-493-21 VARISTOR, NETWORK (1005X2) RB5162 1-234-369-21 RES, NETWORK 10 (1005X4) VD1007 1-802-493-21 VARISTOR, NETWORK (1005X2) VD1051 1-802-078-11 VARISTOR (SMD) RB5164 1-234-369-21...
  • Page 104 C6749 1-100-566-91 CERAMIC CHIP 0.1μF C6751 1-162-927-11 CERAMIC CHIP 100pF A-1536-221-B D3Z-40 BOARD, COMPLETE C6752 1-162-927-11 CERAMIC CHIP 100pF (KDL-40VL160 ONLY) C6754 1-100-566-91 CERAMIC CHIP 0.1μF A-1536-222-B D3Z-46 BOARD, COMPLETE C6755 1-162-964-11 CERAMIC CHIP 0.001μF 10% (KDL-46VL160 ONLY) C6756 1-100-566-91 CERAMIC CHIP 0.1μF...
  • Page 105 KDL-40VL160/46VL160 NOTE: Les composants identifi es per un trame et une NOTE: The components identifi ed by shading marque sont critiques pour la securite. Ne les remplacer mark are critical for safety. Replace only que par une piece portant le numero specifi e.
  • Page 106 1-216-049-11 RES-CHIP 1/10W R6635 1-216-049-11 RES-CHIP 1/10W R6756 1-218-823-11 METAL CHIP 0.50% 1/10W R6700 1-216-793-11 METAL CHIP 1/10W (KDL-40VL160 ONLY) R6701 1-216-809-11 METAL CHIP 1/10W R6756 1-211-991-11 METAL CHIP 0.50% 1/10W (KDL-46VL160 ONLY) R6702 1-216-809-11 METAL CHIP 1/10W R6757 1-218-871-11 METAL CHIP 0.50% 1/10W...
  • Page 107 PART NO. DESCRIPTION VALUES R6795 1-216-841-11 METAL CHIP 1/10W R6796 1-218-823-11 METAL CHIP 0.50% 1/10W IC301 6-600-680-01 PHOTO DIODE BH1690FVC-TR (KDL-40VL160 ONLY) R6796 1-211-991-11 METAL CHIP 0.50% 1/10W TRANSISTOR (KDL-46VL160 ONLY) Q301 6-551-815-01 TRANSISTOR UNR52A1G0LS0 R6797 1-216-829-11 METAL CHIP 4.7K...
  • Page 108 2-678-266-01 BAG, PROTECTION (SCREWS TO ATTACH TABLE-TOP STAND TO TV) (KDL-46VL160 ONLY) For product protection and safety reasons, Sony strongly recommends that 3-287-548-11 BAG, PROTECTION (STAND) you use the screws provided with the TV. CAUTION: These screws cannot be used to secure the TV to...

  • Page 109: Appendix A: Encryption Key Components

    MUST BE RETURNED to Sony. b) and if the core charge is NOT covered under the product warranty, the defective un-repaired or modifi...
  • Page 110 In an effort to reduce the size of this pdf fi le the tiled schematics are not attached to this Service Manual. To receive a complete set of the tiled schematics for this manual please submit a request to the Service Promotion Department at Service_Promotion@am.sony.com.

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