Download SERVICE MANUAL

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