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Date 1/2010 2/2010 5/2010 6/2010 Version 1.0 2.0 3.0 4.0 KDL-32/37/40/46/55EX500 Series(AEP/UK) No revisions or updates are applicable at this time. Amend 32”(P.42) & 37”(P.45) EX504 ‘BAL’ board part number. Add updated Panel Caution Note (P.6). Add Inverter and Tcon Board Part Numbers (P.42,45,48,51,54). Add illustration showing location of neck to base screws (P.43,46,49,52,55). Add ‘Support, Panel’ Part Numbers (P.41,44,47,50,53). Add ‘Hotel Assy’ to Exploded Views (P.41,44,47,50,53). Add ‘Hotel Addendum’ for B2B Models (P.59). Su b j e c t O R I G I N A L M A N U A L ISSUE DA T E : 1 / 2 0 1 0 SERVICE MANUAL Segment: 3a-1 AZ1-L CHASSIS 9-888-265-04 LCD Digital Color TV HISTORY INFORMATION FOR THE FOLLOWING MANUAL: KDL-32/37/40/46/55EX500 Series(AEP/UK) SERVICE MANUAL 9-888-265-04 LCD Digital Color TV Segment: 3a-1 AZ1-L CHASSIS COLOR Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black COMMANDER RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED033 RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED033 RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED035 RM-ED035 KDL-32/37/40/46/55EX500 Series(AEP/UK) MODEL KDL- 3 2 E X 5 0 0 KDL- 3 2 E X 5 0 1 KDL- 3 2 E X 5 0 3 KDL- 3 2 E X 5 0 4 KDL- 3 2 E X 5 0 5 KDL- 3 2 E X 5 0 8 KDL- 3 7 E X 5 0 0 KDL- 3 7 E X 5 0 3 KDL- 3 7 E X 5 0 4 KDL- 3 7 E X 5 0 5 KDL- 4 0 E X 5 0 0 KDL- 4 0 E X 5 0 1 KDL- 4 0 E X 5 0 3 KDL- 4 0 E X 5 0 5 KDL- 4 0 E X 5 0 8 KDL- 4 6 E X 5 0 0 KDL- 4 6 E X 5 0 1 KDL- 4 6 E X 5 0 3 KDL- 4 6 E X 5 0 5 KDL- 5 5 E X 5 0 0 KDL- 5 5 E X 5 0 3 KDL- 5 5 E X 5 0 5 MODEL LIST DEST. AEP AEP UK AEP AEP AEP AEP UK AEP AEP AEP AEP UK AEP AEP AEP AEP UK AEP AEP UK AEP MODEL COLOR COMMANDER DEST. 3 - EN GLI SH KDL-32/37/40/46/55EX500 Series(AEP/UK) Components identified 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 identified in this manual. Follow these procedures whenever critical components are replaced or improper operation is suspected. SAFETY-RELATED COMPONENT WARNING!! Be sure to follow these guidelines to protect your property and avoid causing serious injury. • Carry the TV with an adequate number of people; larger size TVs require two or more people. • Correct hand placement while carrying the TV is very important for safety and to avoid damages. CARRYING THE TV 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. WARNING!! 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. CAUTION WARNINGS AND CAUTIONS 4 - FRENCH KDL-32/37/40/46/55EX500 Series(AEP/UK) 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. ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!! Afi n d’eviter tout risque d’electrocution provenant d’un chassis sous tension, un transformateur d’isolement doit etre utilise lors de tout depannage. Le chassis de ce recepteur est directement raccorde a l’alimentation du secteur. ALERTE!! Tenez compte de ce qui suit pendant l’installation du téléviseur : • Débranchez tous les câbles avant de transporter le téléviseur. • Transportez le téléviseur avec le nombre de personnes approprié ; un téléviseur de grande taille doit être transporté par au moins deux personnes. • Lors du transport du téléviseur, l’emplacement des mains est très important pour votre sécurité, ainsi que pour éviter de causer des dommages. POUR TRANSPORTER LE TÉLÉVISEUR 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. WARNING!! 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. ATTENTION!! WARNINGS AND CAUTIONS 5 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 power 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). It is recommended not to exceed 1 hour of Power-On nor Burn-in period with LCD panel face down condition, in repair activity. KDL-32/37/40/46/55EX500 Series(AEP/UK) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) When repairing the LCD panel, be sure you are grounded by using a wrist band. When repairing the LCD panel on the wall, the LCD panel must be secured using the 4 mounting holes on the rear cover. USE CAUTION WHEN HANDLING THE LCD PANEL W A R N I N GS AND CA U T I ONS 6 KDL-32/37/40/46/55EX500 Series(AEP/UK) 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. 8. For safety reasons, repairing the Power board and/or Inverter board is prohibited. After correcting the original service problem, perform the following safety checks before releasing the set to the customer: SAFETY CHECK-OUT 7 KDL-32/37/40/46/55EX500 Series(AEP/UK) 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). 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). Leakage Test 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. SAFETY CHECK-OUT 8 KDL-32/37/40/46/55EX500 Series(AEP/UK) DIAGNOSTIC TEST INDICATORS When 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 . RGB_SEN 11 - - 10 12 - 9 FAN Error (Not Detected. Display Only) FAN_ERR RGB Sensor ACK Error Not used Not used Not used Not used Not used Thermal Error TEMP_ERR - Back Light Error (Panel Inverter) BACKLITE_ Panel ID NVM Error 8 6 7 HFR Error HFR_ERR P_ID_ERR T-CON Error AUD_PROT TCON_ERR Audio Abnormal Detection DTT_WDT Panel Balancer Error DTT Error DC_ALERT BALANCER_ DC_ALERT MAIN_POWE 2 3 4 5 Main Power Over Voltage Protection Service menu Item name (Screen Display) STBY LED Flash time Diagnostic Item Description 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 to reveal past problems and how often these problems occur. SELF DIAGNOSIS FUNCTION 9 3 KDL-32/37/40/46/55EX500 Series(AEP/UK) [To Bring Up Screen Test] In standby mode, press buttons on the remote commander sequentially in rapid succession as shown below: SELF-DIAGNOSTIC SCREEN DISPLAY For errors with symptoms such as “power sometimes shuts off” or “screen sometimes goes out” that cannot be confirmed, it is possible to bring up past occurrences of failure for confirmation on the screen: 0.5 0.5 DISPLAY OF STANDBY LED FLASH COUNT 10 SELF DIAGNOSIS FUNCTION 0000000000 0000000000 0000000000 00 0000000000 0000000000 0000000000 00 0000000000 0000000000 0000000000 00 0 0 6 BL 0 0 7 TEMP 0 0 9 FAN KDL-32/37/40/46/55EX500 Series(AEP/UK) 12345-00333-06789 0501210811 0412311234 0311111825 00 0000000000 0000000000 0000000000 00 0000000000 0000000000 0000000000 00 < 1 > NEXT PAGE-> 0 0 2 MAI N P 0 0 3 DC_ A LER T 1 0 0 4 DC_ A LER T 2 SELF CHECK ( 1 ) [SELF DIAGNOSTIC SCREEN DISPLAY] Total operation time by hour (MAX:65535) Boot count (MAX:65535) Panel operation time by hour (MAX:65535) STBY LED flash time Item name Error history (The last failure time) Error history (Failure time before last) Error history (Last failure time beforehand) Error count (00-99) 11 SELF DIAGNOSIS FUNCTION KDL-32/37/40/46/55EX500 Series(AEP/UK) Exiting the Self-diagnostic screen To exit the Self Diagnostic screen, turn off the power to the TV by pressing the POWER button on the remote or the POWER button on the TV. Clearing the Self Check Diagnostic List 1. Error history and Error count : Press the Channel 8 => Channel 0 . 2. Panel operation time : Press the Channel 7 => Channel 0 . Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screen. After you have completed the repairs, clear the result display to “0”. 12 SELF DIAGNOSIS FUNCTION KDL-55EX500 KDL-55EX500 Series Series KDL-46EX500 KDL-46EX500 Series Series KDL-40EX500 KDL-40EX500 Series Series KDL-37EX500 KDL-37EX500 Series Series KDL-32EX500 KDL-32EX500 Series Series KDL-32/37/40/46/55EX500 Series(AEP/UK) 1-1. MOVIE LIST SEC 1. DISASSEMBLY 13 KDL-32/37/40/46/55EX500 Series(AEP/UK) <BEM> BM1.012W00LU BB1.000W00LU BD1.011J46LUX ---.--------- <SUB> SM1.010W00AA SB1.000W00AA SD1.010W00AA RF01.05 ID1C117081 LTY320AB01 --- 001 OP 000 VERS <MAIN> DM1.301J00AA M2.105C DD1.016J00AA (DM1.301J00AA) WP00.521J00AA ID1C117081 PID04020000 WF:2.0.0.99 WF:0B Camera FW Camera FW SERVICE DIGITAL Press “OPTIONS” or “JUMP” button Category number Item number CHASSIS 000 000 3) Service mode display. Note: First of all, when you enter Service Mode, you can see “Digital” service mode. Whenever you press “OPTIONS” or “JUMP” on remote, each service mode is changed. “Digital” -> “Chassis” -> “Sub” HOW TO ENTERING SERVICE MODE 1) Turn on the main power switch to place this set in standby mode. 2) Press the buttons on the remote commander as follows, and entering service mode. SEC 2. ADJUSTMENT SERVICE CXD2813R H_DET_NOSIG_CNT 1 Data 14 Item name Category name <Test>+<TV>/<Display><5><Vol Up><Power> <Other> / <Power off + on> <1>/<4> <2>/<5> <3>/<6> <8> + <Mute> + <0> <9> + <0> <10 or 0> <Mute> + <0> <Jump> / <Option> Service mode on Service mode off Item up / down Category up / down Data up / down Test reset Read data Execute Write data Change module KDL-32/37/40/46/55EX500 Series(AEP/UK) 5) After entering service mode, then turn off the power switch. The flow of control Function 4) How to use the remote commander. 15 A D JUSTMENT KDL-32/37/40/46/55EX500 Series(AEP/UK) DIGITAL SERVICE 006 WB 000 WHITE_BALANCE ___ WHITE BALANCE ADJUSTMENT Change Data of “Digital” service mode. (“006 WB” category) a. Press “0” or “10” on remote to enter WB adjustment mode. b. Press number key “1”~”6” directly. “*” stamp move. c. Press “12 / enter / select” to decide and advance next step. When returning on the previous page, press “return”. d. Change data by number key “0”~”9” directly. (0-255) e. Press “12 / enter / select” to save data. It shows red “WRITE”. It indicate writing is processing. f. Writing process is done at this point. Please input WB items (0-255) --- DIGITAL WB *1 R_DRV 128 2 G_DRV 128 3 B_DRV 128 4 R_BKG 128 5 G_BKG 128 6 B_BKG 128 128: offset 0 Offset 0: x 0.5, 128: x 1, 255: x1.5 Gain SERVICE 16 A D JUSTMENT KDL-32/37/40/46/55EX500 Series(AEP/UK) CHASSIS 000 000 WRITE CXD2813R H_DET_NOSIG_CNT 1 SAVE CHANGING DATA 1) Change Data of “Chassis” or “Sub” service mode 2) Write data for “Chassis” or “Sub” service mode a. Press “Mute” on remote. It shows green “SERVICE” changes to green “WRITE”. b. Press “0” or “enter” on remote. Green “WRITE” changes to red “WRITE”. It indicate writing is processing. c. After a while, red “WRITE” changes to green “SERVICE”. Writing process is done at this point. 3) TV reboot is necessary for applying data change. 17 A D JUSTMENT KDL-32/37/40/46/55EX500 Series(AEP/UK) 2) Change Data of “Digital” service mode. ( “003 DIG_SRV_MODE” category) “003 DIG_SRV_MODE” is one category of “Digital” service mode. Please note because this operation is special. a. Press “2 / 5” on remote to select “003 DIG_SRV_MODE”. b. Press “1 / 4” on remote to select (up / down) Item. c. Press “0 / 10” on remote to select item. d. Press number key “1”~”9” directly. “*” stamp move. e. Press “12 / enter / select” to decide and advance next step. Press “return”, when returning on the previous page. CHANGE DATA Note: “Digital” service mode don’t have to Save. (except “002 MODEL” category) 1) Change Data of “Digital” service mode. (except “003 DIG_SRV_MODE” category) a. Press “2 / 5” on remote to select (up / down) category. b. Press “1 / 4” on remote to select (up / down) Item. c. Press “0 / 10” on remote to select item. --- SERVICE 001 SERVICE *1 Video 2 Audio TEST_PATTERN DIGITAL(DIG_SRV_MODE) SERVICE DIGITAL 003 DIG_SRV_MODE 000 TEST_PATTERN DIGITAL 004 TUNER 000 A_NOSIG_DET 18 A D JUSTMENT KDL-32/37/40/46/55EX500 Series(AEP/UK) 000 SEG nnnProduct ID - segment information 001 DESTnnnProduct ID – destination information a. Change data for each model. b. Press “0” or “enter” on remote. It shows red “WRITE”. It indicate writing is processing. c. Writing process is done at this point. 3) Write data for “Digital” service mode. ( “002 MODEL” category) Note: This procedure operation, when replaced the B board. Note: Do not write a wrong segment or destination information in Product ID. When the wrong setting is written, TV may not operate. DIGITAL 002 MODEL 000 SEG 01 : 2a-3 Write SERVICE 19 A D JUSTMENT Standby KDL-32/37/40/46/55EX500 Series(AEP/UK) <Another way> You can set to shipping condition w/o entering Service Mode. -> “Cursor Up” on remote + “Power Key” on Front panel. TIMER POWER SET TO SHIPPING CONDITION How to do shipping condition. a. Move to “Digital” service mode. Press “8” on remote. It shows green “SERVICE” changes to green “RST-”. Press “mute” on remote. Added green “EXE” after green “RST-” . d. Press “0” or “enter” on remote. Green “EXE-RST” changes to red “EXE-RST”. It indicate writing is processing. After a while, red “EXE-RST” changes to green “SERVICE”. And all LED lights. Writing process is done at this point. 20 A D JUSTMENT POWER 2 POWER DTT AUDIO 3 KDL-32/37/40/46/55EX500 Series(AEP/UK) : Few possibility : doubtful part Problem LCD PANEL LVDS CABLE D1 BOARD WiFi MODULE HLR BOARD G* BOARD BAL BOARD Reference POWER 4 PANEL (INVERTER) (TCON) 6 PANEL 5 Symptoms - Shutdown. Power LED blinking red diagnostics sequences TEMP 7 No Video - missing or distorted Power No Green Stationary No video No video Power LED colored lines one of Inputs all Inputs (Dead Set) or dots Note: Power board is different in name every inch. Therefore this section displays difference point in "*". 3-1. TRIAGE CHART SEC 3. TROUBLE SHOOTING No Remote Remote Audio 21 Wireless can't No Audio connect Network No No No No KDL-32/37/40/46/55EX500 Series(AEP/UK) Yes Do the buttons on the TV & Remote Commander work properly? Yes Is the Picture and Sound OK ? Yes Is the Standby Led blink ? Yes Does the Power Led stay on when the TV is switched on ? START 3 - 2 . F LOW CHART See TV/ Commander button malfunction See No Picture / No Sound See Standby LED Blink See No Power END Yes Is the network connection OK? No See Can’t connect network 22 TROUBLE SHOOTING No Power BAL Board OK Check STBY 3.3V at 1 pin of CN3800 on the BAL Board KDL-32/37/40/46/55EX500 Series(AEP/UK) 3 - 3 . N O P OWER NG Harness OK Replace Between G* Board to BAL Board Harness NG G* Board 23 TROUBLE SHOOTING KDL-32/37/40/46/55EX500 Series(AEP/UK) BAL Board 12V OK Check REG12V at pins 6/7 of CN3800 on the BAL Board 2 times Blinkings 1) 2 times blinkings (Main Power Error) 3-4. STANDBY LED BLINK 12V NG Harness OK Replace Between G* Board to BAL Board Harness NG G* Board 24 TROUBLE SHOOTING NG NG KDL-32/37/40/46/55EX500 Series(AEP/UK) OK Check Speaker Impedance at SP Connector OK NG Check +5V_MAIN at JL3731 or JL3732 on the BAL Board OK Check D+3.3V at JL3715 or JL3716 on the BAL Board 3 times Blinkings AUDIO Speaker F3701,IC3701,etc (BAL Board) F3700,IC3700,etc (BAL Board) DC_ALERT 2) 3 times blinkings (DC Alert, Audio Error and Communication Error) IC9000,etc (BAL Board) Pin: High Check X_ASW_PROTECT at pin 29 of IC5000 on the BAL Board OK Check +12.5V_AU1 at F4200 on the BAL Board OK Check +12.5V at pin 2 of CN3800 on the BAL Board IC4200,etc (BAL Board) F4200,IC4200,etc (BAL Board) G* Board FE/BE Communication Pin: Low NG NG AUDIO 25 TROUBLE SHOOTING KDL-32/37/40/46/55EX500 Series(AEP/UK) 3) 4 times blinkings (Balancer Error) BAL Board Check PANEL_FAIL at JL2565 on the BAL Board 4 times Blinkings PANEL (Balancer) Between 0.84V to 2.65V 26 TROUBLE SHOOTING NG NG about 12V NG KDL-32/37/40/46/55EX500 Series(AEP/UK) OK LVDS Harness check OK Between G* to Panel harness check OK Check PANEL_VCC at JL3806 on the BAL Board 5 times Blinkings 4) 5 times blinkings (T-con Error) LVDS Harness Harness G* Board Panel (T-con) OK Panel (T-con) change NG BAL Board 27 TROUBLE SHOOTING NG KDL-32/37/40/46/55EX500 Series(AEP/UK) G* Board OK Change G* Board NG Change D1 Board OK Under 2.65V Over 2.65V Check PANEL_FAIL at JL2565 on the BAL Board 6 times Blinkings 5) 6 times blinkings (Backlight Error) Panel (T-con) Inverter (D1 Board) BAL Board BAL Board OK Change BAL Board, and Aging a few hours YES Setting circumstance is OK? Temperature, Ventilation, etc. 7 times Blinkings NG NO 6) 7 times blinkings (Temperature Error) Panel Set to another Location, etc. 28 TROUBLE SHOOTING NO about 12V G* Board NO PANEL_VCC At JL3806 on the BAL Board KDL-32/37/40/46/55EX500 Series(AEP/UK) BAL Board YES Press HOME Key XMB (Menu) displayed? No Picture 3-5. NO PICTURE Check BL_ON at JL2566 on the BAL Board BAL Board OK Change BAL Board OK Check Harness (Between G* Board to BAL Board) BL_ON: not H YES NG NG G* Board Harness (G* to BAL) BL_ON:H Harness (LVDS) OK Replace the LVDS Harness NG LCD Panel (T-con) 29 TROUBLE SHOOTING “Audio System” KDL-32/37/40/46/55EX500 Series(AEP/UK) Speaker Harness NG Check the Speaker Harness OK “TV Speakers” Check the “Speakers setting” No Sound 3-6. NO SOUND Speaker NG Replace the BAL Board Change to “TV Speaker” OK BAL Board 30 TROUBLE SHOOTING KDL-32/37/40/46/55EX500 Series(AEP/UK) BAL Board Harness Switch Unit change NG OK NG BAL to Switch Unit harness check Button malfunction on the TV 1) TV button malfunction 3-7. TV COMMANDER BUTTONS MALFUNCTION OK Switch Unit 31 TROUBLE SHOOTING OK OK OK OK KDL-32/37/40/46/55EX500 Series(AEP/UK) BAL Board NG Exchange the HLR Board NG Exchange the Harness NG Check the Harness between the BAL Board and the HLR Board NG Green LED light at power indicator TV isn’t controlled by remote commander 2) IR remote commander malfunction HLR Board Harness Sensor is broken NG Green LED blinks at power indicator when using commander near sensor’s window OK Mechanical (ex. bezel) 32 TROUBLE SHOOTING NG NG NG KDL-32/37/40/46/55EX500 Series(AEP/UK) Connection result Internet Access OK Connection result Local Access OK Connection result Cable Connection Wired Network on the TV 1) Wired Network malfunction 3-8. NETWORK MALFUNCTION Proxy setting Ether net cable BAL Board BAL Board NO Is the radio field Strength too weak or even No signal? NO Error Message appear when the Wireless Network is selected? Wireless Network on the TV YES YES 2) USB Wireless Network malfunction Access Point USB Dongle 33 TROUBLE SHOOTING KDL-32/37/40/46/55EX500 Series(AEP/UK) 4 - 1 . B L OCK DIAGRAM SEC 4. DIAGRAMS 34 Speaker (R) KDL-32/37/40/46/55EX500 Series(AEP/UK) Switch Unit Inverter G2ME Board (1) KDL-32EX500 Series 4 - 2 . C I RCUIT BOARDS LOCATION T-CON HLR Board Speaker (L) BAL Board 35 D I A G R A MS Speaker (R) KDL-32/37/40/46/55EX500 Series(AEP/UK) Switch Unit Inverter G2HE Board (2) KDL-37EX500 Series T-CON HLR Board 36 Speaker (L) BAL Board D I A G R A MS Speaker (R) KDL-32/37/40/46/55EX500 Series(AEP/UK) Switch Unit Inverter G2HE Board (3) KDL-40EX500 Series T-CON HLR Board 37 Speaker (L) BAL Board D I A G R A MS Speaker (R) KDL-32/37/40/46/55EX500 Series(AEP/UK) Switch Unit Inverter GD2 Board (4) KDL-46EX500 Series T-CON HLR Board 38 Speaker (L) BAL Board D I A G R A MS Speaker (R) KDL-32/37/40/46/55EX500 Series(AEP/UK) Switch Unit Inverter G5E Board D1Board (5) KDL-55EX500 Series T-CON HLR Board Speaker (L) 39 BAL Board D I A G R A MS KDL-32/37/40/46/55EX500 Series(AEP/UK) • Items with no part number and no description are not stocked because they are seldom required for roution service. • The construction parts of an assembled part are indicated with a collation number in the remark colum. • Items marked " * " are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items. SEC 5. EXPLODED VIEWS 40 KDL-32/37/40/46/55EX500 Series(AEP/UK) 11a 5-1-1. CHASSIS-1 5-1. KDL-32EX500 SERIES 11 11a REMARK 41 LOUDSPEAKER (12.5x4.5CM) BRACKET, SP (32L) BRACKET, SP (32R) SWITCH UNIT COVER, UNDER (32) NECK (M3) COVER (M3) ASSY BASE (M3) ASSY REAR COVER (TR32) ASSY REAR COVER (32_SAT) ASSY EX505,508 COVER,ECS HOTEL ASSY See Hotel Addendum BRACKET, VESA (S) SUPPORT, PANEL DESCRIPTION Whenever removing the ‘Rear Cover’ on B2B models remember to remove the connector inside the ‘Hotel Assy’ on the ‘R2’ board first. Note: 4-167-326-01 4-166-118-11 10 PART No. 1-858-364-22 4-166-121-11 4-166-122-11 1-487-728-11 4-166-124-11 4-158-349-01 X-2546-541-1 X-2546-980-1 X-2546-624-1 X-2547-420-1 *3-106-546-51 1 2 3 4 5 6 7 8 9 REF. No. EXPLOD ED VI EWS KDL-32/37/40/46/55EX500 Series(AEP/UK) 5-1-2. CHASSIS-2 5-1. KDL-32EX500 SERIES 18 19 20 13 14 15 16 17 12 REF. No. X-2546-599-1 X-2546-744-1 A-1753-636-A 4-166-268-01 1-811-054-11 1-474-201-21 A-1760-331-A A-1768-994-A A-1769-581-A A-1780-319-A 1-837-454-11 1-857-634-11 1-489-034-11 PART No. BEZEL ASSY (32TR_MET) BEZEL ASSY (32TR_BCK) HLR MOUNT BRACKET, SIDE JACK LCD PANEL (S32TDP) STATIC CONVERTER (TV) BAL BOARD COMPLETE BAL BOARD COMPLETE BAL BOARD COMPLETE BAL BOARD COMPLETE POWER-SUPPLY CORD INVERTER BOARD TCON BOARD DESCRIPTION EX500,501 EX503 EX505,508 EX504 42 EX500,503,504,505 EX501,EX508 REMARK EXPLOD ED VI EWS DESCRIPTION SCREW, +BVTP 4X16 TYPE2 IT-3 SCREW, +PSW M3X12 SCREW +BVTP 3X12 TYPE2 IT-3 SCREW, +PSW M5X16 SCREW, +PSW M3X8 SCREW, +PSW M4X10 KDL-32/37/40/46/55EX500 Series(AEP/UK) PART No. 2-580-640-01 2-580-595-01 7-685-648-79 2-580-608-01 2-580-592-01 4-159-298-01 5-1-3. SCREWS 5-1. KDL-32EX500 SERIES 43 EXPLOD ED VI EWS KDL-32/37/40/46/55EX500 Series(AEP/UK) C 5-2-1. CHASSIS-1 5-2. KDL-37EX500 SERIES 8 8a REMARK 44 SWITCH UNIT COVER, UNDER (37) NECK (ML3) COVER (M3) ASSY BASE (ML3) ASSY REAR COVER (TR37) ASSY REAR COVER (37_SAT) ASSY EX505 COVER,ECS HOTEL ASSY See Hotel Addendum BRACKET, VESA (S) SUPPORT, PANEL DESCRIPTION Whenever removing the ‘Rear Cover’ on B2B models remember to remove the connector inside the ‘Hotel Assy’ on the ‘R2’ board first. Note: 4-167-326-01 4-166-118-01 7 PART No. 1-487-728-11 4-166-123-11 4-158-350-01 X-2546-541-1 X-2541-845-1 X-2546-655-1 X-2547-422-1 *3-106-546-51 1 2 3 4 5 6 REF. No. EXPLOD ED VI EWS KDL-32/37/40/46/55EX500 Series(AEP/UK) 5-2-2. CHASSIS-2 5-2. KDL-37EX500 SERIES 15 16 17 18 19 20 9 10 11 12 13 14 REF. No. X-2546-657-1 A-1753-636-A 4-166-268-01 1-811-077-11 1-474-202-21 A-1760-331-A A-1768-994-A A-1769-581-A A-1780-319-A 1-837-454-11 1-858-364-22 4-166-121-11 4-166-122-11 1-857-701-11 1-857-700-11 PART No. BEZEL ASSY (TR37_MET) HLR MOUNT BRACKET, SIDE JACK LCD PANEL (A37V9) STATIC CONVERTER (TV) BAL BOARD COMPLETE BAL BOARD COMPLETE BAL BOARD COMPLETE BAL BOARD COMPLETE POWER-SUPPLY CORD LOUDSPEAKER (12.5x4.5CM) BRACKET, SP (37L) BRACKET, SP (37R) INVERTER BOARD TCON BOARD DESCRIPTION EX500,501 EX503 EX505 EX504 REMARK 45 EXPLOD ED VI EWS DESCRIPTION SCREW, +BVTP 4X16 TYPE2 IT-3 SCREW, +PSW M3X12 SCREW +BVTP 3X12 TYPE2 IT-3 SCREW, +PSW M5X16 SCREW, +PSW M3X8 SCREW, +PSW M4X10 KDL-32/37/40/46/55EX500 Series(AEP/UK) PART No. 2-580-640-01 2-580-595-01 7-685-648-79 2-580-608-01 2-580-592-01 4-159-298-01 5-2-3. SCREWS 5-2. KDL-37EX500 SERIES 46 EXPLOD ED VI EWS KDL-32/37/40/46/55EX500 Series(AEP/UK) C 5-3-1. CHASSIS-1 5-3. KDL-40EX500 SERIES 4-167-326-01 4-166-118-01 1-487-728-11 4-166-123-11 4-158-350-01 X-2546-541-1 X-2541-845-1 X-2546-618-1 X-2547-412-1 *3-106-546-51 PART No. SWITCH UNIT COVER, UNDER (37) NECK (ML3) COVER (M3) ASSY BASE (ML3) ASSY REAR COVER (TR40) ASSY REAR COVER (TR40_SAT) ASSY COVER,ECS HOTEL ASSY BRACKET, VESA (S) SUPPORT, PANEL DESCRIPTION 47 See Hotel Addendum EX505,508 REMARK Whenever removing the ‘Rear Cover’ on B2B models remember to remove the connector inside the ‘Hotel Assy’ on the ‘R2’ board first. Note: 8 8a 7 1 2 3 4 5 6 REF. No. EXPLOD ED VI EWS KDL-32/37/40/46/55EX500 Series(AEP/UK) 5-3-2. CHASSIS-2 5-3. KDL-40EX500 SERIES 16 17 18 19 20 15 10 11 12 13 14 9 REF. No. X-2546-615-1 X-2546-769-1 A-1753-636-A 4-166-268-01 1-811-055-12 1-474-202-21 A-1760-331-A A-1768-994-A A-1769-581-A 1-837-454-11 1-837-455-11 1-858-364-22 4-166-119-11 4-166-120-11 1-857-640-11 1-857-648-11 PART No. BEZEL ASSY (TR40_MET) BEZEL ASSY (TR40_BCK) HLR MOUNT BRACKET, SIDE JACK LCD PANEL (S40TDP) STATIC CONVERTER (TV) BAL BOARD COMPLETE BAL BOARD COMPLETE BAL BOARD COMPLETE POWER-SUPPLY CORD POWER-SUPPLY CORD (UK) LOUDSPEAKER (12.5x4.5CM) BRACKET, SP (40L) BRACKET, SP (40R) INVERTER BOARD TCON BOARD DESCRIPTION EX503 EX500,501 EX503 EX505,508 EX500,503,505 EX501,508 REMARK 48 EXPLOD ED VI EWS DESCRIPTION SCREW, +BVTP 4X16 TYPE2 IT-3 SCREW, +PSW M3X12 SCREW +BVTP 3X12 TYPE2 IT-3 SCREW, +PSW M5X16 SCREW, +PSW M3X8 SCREW, +PSW M4X10 KDL-32/37/40/46/55EX500 Series(AEP/UK) PART No. 2-580-640-01 2-580-595-01 7-685-648-79 2-580-608-01 2-580-592-01 4-159-298-01 5-3-3. SCREWS 5-3. KDL-40EX500 SERIES 49 EXPLOD ED VI EWS KDL-32/37/40/46/55EX500 Series(AEP/UK) C 5-4-1. CHASSIS-1 5-4. KDL-46EX500 SERIES 1-842-008-11 4-167-326-01 4-166-118-01 1-487-728-11 4-166-123-31 4-158-350-01 X-2546-541-1 X-2541-846-1 X-2546-628-1 X-2547-418-1 *3-106-546-51 PART No. REMARK 50 SWITCH UNIT COVER, UNDER (37) NECK (ML3) COVER (M3) ASSY BASE (L3) ASSY REAR COVER (TR46) ASSY REAR COVER (46_SAT) ASSY EX505 COVER,ECS HOTEL ASSY See Hotel Addendum AC INLET FILTER BRACKET, VESA (S) SUPPORT, PANEL DESCRIPTION Whenever removing the ‘Rear Cover’ on B2B models remember to remove the connector inside the ‘Hotel Assy’ on the ‘R2’ board first. Note: 8 9 9a 7 1 2 3 4 5 6 REF. No. EXPLOD ED VI EWS KDL-32/37/40/46/55EX500 Series(AEP/UK) 5-4-2. CHASSIS-2 5-4. KDL-46EX500 SERIES 17 18 19 20 21 16 11 12 13 14 15 10 REF. No. X-2546-629-1 X-2546-746-1 A-1753-636-A 4-166-268-01 1-811-056-12 1-474-205-11 A-1760-331-A A-1768-994-A A-1769-581-A 1-837-639-11 1-837-640-11 1-858-371-11 4-157-973-11 4-157-974-11 1-857-643-11 1-857-650-11 PART No. BEZEL ASSY (TR46_MET) BEZEL ASSY (TR46_BCK) HLR MOUNT BRACKET, SIDE JACK LCD PANEL (S46TDP) STATIC CONVERTER (TV)-GD2 BAL BOARD COMPLETE BAL BOARD COMPLETE BAL BOARD COMPLETE POWER-SUPPLY CORD POWER-SUPPLY CORD LOUDSPEAKER (20x4.5CM) BRACKET, SP (46L) BRACKET, SP (46R) INVERTER BOARD TCON BOARD DESCRIPTION EX500,501 EX503 EX505 EX500,501,505 EX503 EX500,503,505 EX501 REMARK 51 EXPLOD ED VI EWS DESCRIPTION SCREW, +BVTP 4X16 TYPE2 IT-3 SCREW, +PSW M3X12 SCREW +BVTP 3X12 TYPE2 IT-3 SCREW, +PSW M5X16 SCREW, +PSW M3X8 SCREW, +PSW M4X10 SCREW, +BVST 3X8 SCREW, +PWTP2 4X16 KDL-32/37/40/46/55EX500 Series(AEP/UK) PART No. 2-580-640-01 2-580-595-01 7-685-648-79 2-580-608-01 2-580-592-01 4-159-298-01 2-580-629-01 4-167-964-01 5-4-3. SCREWS 5-4. KDL-46EX500 SERIES 52 EXPLOD ED VI EWS KDL-32/37/40/46/55EX500 Series(AEP/UK) C 5-5-1. CHASSIS-1 5-5. KDL-55EX500 SERIES 1-842-009-11 4-167-326-01 4-156-946-01 4-166-118-11 1-487-749-11 4-157-979-11 4-158-351-01 X-2546-543-1 X-2541-847-1 X-2546-580-1 X-2547-421-1 *3-106-546-51 PART No. SWITCH UNIT COVER, UNDER (55) NECK (LL3) COVER LL3) ASSY BASE (LL3) ASSY REAR COVER (55TR) ASSY REAR COVER (55 SAT) ASSY COVER,ECS HOTEL ASSY AC INLET FILTER BRACKET, VESA (S) BRACKET, VESA (XL) SUPPORT, PANEL DESCRIPTION 53 See Hotel Addendum EX505 REMARK Whenever removing the ‘Rear Cover’ on B2B models remember to remove the connector inside the ‘Hotel Assy’ on the ‘R2’ board first. Note: 8 9 10 10a 7 1 2 3 4 5 6 REF. No. EXPLOD ED VI EWS KDL-32/37/40/46/55EX500 Series(AEP/UK) 5-5-2. CHASSIS-2 5-5. KDL-55EX500 SERIES 20 21 18 19 11 12 13 14 15 16 17 REF. No. X-2546-579-1 A-1753-636-A 4-166-268-01 1-811-057-12 1-474-203-11 1-474-206-11 A-1760-331-A A-1768-994-A A-1769-581-A 1-858-354-11 1-837-639-11 1-837-640-11 1-857-653-11 1-857-652-11 PART No. BEZEL ASSY (TR55_MET) HLR MOUNT BRACKET, SIDE JACK LCD PANEL (S55TDP) STATIC CONVERTER (TV) STATIC CONVERTER (TV)-D1 BAL BOARD COMPLETE BAL BOARD COMPLETE BAL BOARD COMPLETE LOUDSPEAKER POWER-SUPPLY CORD POWER-SUPPLY CORD INVERTER BOARD TCON BOARD DESCRIPTION EX500,501,505 EX503 EX500,EX501 EX503 EX505 REMARK 54 EXPLOD ED VI EWS DESCRIPTION SCREW, +BVTP 4X16 TYPE2 IT-3 SCREW, +PSW M3X12 SCREW +BVTP 3X12 TYPE2 IT-3 SCREW, +PSW M5X16 SCREW, +PSW M3X8 SCREW, +PSW M4X10 SCREW, +BVST 3×8 KDL-32/37/40/46/55EX500 Series(AEP/UK) PART No. 2-580-640-01 2-580-595-01 7-685-648-79 2-580-608-01 2-580-592-01 4-159-298-01 2-580-629-01 5-5-3. SCREWS 5-5. KDL-55EX500 SERIES 55 EXPLOD ED VI EWS CONNECTOR ASSY 15P (CN6401-CN2561,CN3800) CONNECTOR ASSY 14P (CN6402-BALANCER) CONNECTOR ASSY 6P (CN6403-TCON) *1-910-060-11 *1-910-060-12 *1-910-060-13 HARNESS ASSY (CN2602,CN4300-CN001,SW,SP) CONNECTOR ASSY 15P (CN6401-CN2561,CN3800) CONNECTOR ASSY 14P (CN6402-BALANCER) CONNECTOR ASSY 6P (CN6403-TCON) *1-910-060-14 *1-910-060-15 *1-910-060-16 *1-910-060-17 KDL-32/37/40/46/55EX500 Series(AEP/UK) *1-910-060-24 FLEXIBLE FLAT CABLE (CN2600-TCON) 1-837-521-11 *1-910-060-26 *1-910-060-25 CONNECTOR ASSY 15P (CN6201-CN2561,CN3800) *1-910-060-23 40 INCHES CONNECTOR ASSY 6P (CN6401-CN6703) CONNECTOR ASSY 6P (CN6403-TCON) CONNECTOR ASSY 5P (CN6702-BALANCER) HARNESS ASSY 15P (CN2602,CN3400-CN001,SW,SP) FLEXIBLE FLAT CABLE (CN6200-TCON) CONNECTOR ASSY (CN6704-BALANCER) CONNECTOR ASSY (CN6705-BALANCER) CONNECTOR ASSY (CN6301-CN6600) CONNECTOR ASSY 6P (CN6151-TCON) CONNECTOR ASSY 5P (CN6702-BALANCER) CONNECTOR ASSY 15P (CN6150-CN2561,CN3800) HARNESS ASSY (CN2602,CN4300-CN001,SW,SP) FLEXIBLE FLAT CABLE (CN2600-TCON) *1-910-060-22 1-837-524-11 *1-837-324-11 *1-837-322-11 HARNESS ASSY (CN2602,CN4300-CN001,SW,SP) *1-910-060-10 *1-910-060-21 *1-836-742-11 CONNECTOR ASSY 6P (CN6403-TCON) *1-910-060-09 *1-910-060-20 FLEXIBLE FLAT CABLE (CN2600-TCON) CONNECTOR ASSY 14P (CN6402-BALANCER) *1-910-060-08 *1-910-060-19 1-837-519-11 CONNECTOR ASSY 15P (CN6401-CN2561,CN3800) *1-910-060-07 1-837-523-11 *1-910-060-18 55 INCHES HARNESS ASSY (CN2602,CN4300-CN001,SW,SP) 46 INCHES 37 INCHES FLEXIBLE FLAT CABLE (CN2600-TCON) 1-837-517-11 *1-910-060-06 32 INCHES 5 - 6 - 1. ACCESSORI ES an d CONNECT ORS 5-6. OTHER PARTS 56 MANUAL, INSTRUCTION *4-174-990-11 REMOTE COMMANDER (RM-ED033) 1-487-758-11 HDMI CONNECTOR (SIDE) OPTICAL OUT CONNECTOR D SUB CONNECTOR ETHERNET CONNECTOR(8P) USB CONNECTOR CARD CONNECTOR (PCMCIA CARD) 1-822-484-11 1-822-525-21 1-821-827-21 1-821-868-11 1-821-834-12 1-822-579-31 KDL-32/37/40/46/55EX500 Series(AEP/UK) HDMI CONNECTOR (REAR) 1-822-482-11 5 - 6 - 4. MI SCELLANEO US REMOTE COMMANDER (RM-ED035) EX503 EX508 EX505,EX508 EX500,EX501 EX500,EX501,EX504 1-487-700-11 5 - 6 - 3. REM OT E COM M ANDER MANUAL, INSTRUCTION MANUAL, INSTRUCTION *4-174-985-31 *4-174-989-71 MANUAL, INSTRUCTION *4-174-985-21 5 - 6 - 2. I NST RUCT I ON MANUALS 1-842-096-11 1-822-524-21 1-842-010-11 1-822-581-12 1-822-580-41 PHONO JACK 5P PHONO JACK 2P JACK MULTIPLE PHONO JACK 4P CONNECTOR DUAL SCART 57 KDL-32/37/40/46/55EX500 Series(AEP/UK) 9-888-265-04 END Sony Corporation Sony UK Service Promotions Dept. 58 English 10FP7100-1 Made in U.K. © 2010.6 Ready For Hotel Assembly – R2 Board Paste ID Label onto R/C First Use Fingers to Pull Wire to the Outside *** Production line need to create pull gauge for operator use Use a Gauge to Pull the Wire (1-910-057-37) to the Outside Hotel Assembly SOP For B2B Model Finished Assembly Put R2 Board into bottom cover Fix VGA Screws (2-580-626-01) to R2 Board (A-1565-554-A) Tilt, Angle Director to Bottom Cover Hotel Assembly SOP For B2B Model Correct Align Hole Press R2 Board into Bottom Cover Correct 2 Assembly Hole Director Outside Don’t Touch IR Pass-Through & Connector Hotel Assembly SOP For B2B Model Attention : The Screws are different to the side cover & I/O T3 Screw different to Side Cover Use & I/O Wrong Assembly Hole Director Inside Hole Not Aligned (Part Number 7-685-649-79) Fix T3 Screw * 2 Pcs (14mm)To R/C Wrong Hotel Assembly SOP For B2B Model Insert Wire into R2 Board Finished Fix Top Cover to Hotel Assy ( No need to use a screw ) Hotel Assembly SOP For B2B Model Finished Use finger to Pull the Top Cover Edge Push The Top Cover Edge Hotel Assembly SOP For B2B Model - Separation