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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
ORIGINAL MANUAL ISSUE DATE: 2/2012
AZ3WKCHASSIS
Version Date Subject
1.0 2/2012 Original manual issue.
2.0 8/2012 Addition of models for AFRICA/MIDDLE EAST/PACIFIC ISLAND. (P.3, P.14, P.15, P.17, P.18, P.20)
3.0 9/2012 Addition of models for GENARAL AREA. (P.3, P.14~20)
LCD Digital Color TV
Segment: P-2F
9-888-467-03
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SERVICE MANUAL
LCD Digital Color TV
AZ3WKCHASSIS
Segment: P-2F
9-888-467-03
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MODEL LIST
KDL-32BX350 Black RM-ED049 SINGAPORE
AUSTRALIA
AFRICA
MIDDLE EAST
PACIFIC ISLAND
GENERAL AREA
KDL-40BX450 Black RM-ED049 SINGAPORE
AUSTRALIA
AFRICA
MIDDLE EAST
PACIFIC ISLAND
GENERAL AREA
MODEL COLOR COMMANDER DEST.MODEL COLOR COMMANDER DEST.
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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WARNINGS AND CAUTIONS -ENGLISH
CAUTION
These servicing instructions are for use by qualified service personnel only.
To reduce the risk of electric shock, do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so.
WARNING!!
An isolation transformer should be used during any service to avoid possible shock hazard, because of live chassis.
The chassis of this receiver is directly connected to the ac power line.
CARRYING THE TV
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.
SAFETY-RELATED COMPONENT WARNING!!
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.
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WARNINGS AND CAUTIONS -FRENCH
ATTENTION!!
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.
WARNING!!
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.
POUR TRANSPORTER LE TÉLÉVISEUR
Tenez compte de ce qui suit pendant l’installation du téléviseur :
• Débranchez tous les câbles avant de transporter le téléviseu r.
• Transportez le téléviseur avec le nombre de personnes appr oprié ; 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.
ALERTE!!
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.
ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!!
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.
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USE CAUTION WHEN HANDLING THE LCD PANEL
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.
1) Do not press on the panel or frame edge to avoid the risk of electric shock.
2) Do not scratch or press on the panel with any sharp objects.
3) Do not leave the module in high temperatures or in areas of high humidity for an extended period of time.
4) Do not expose the LCD panel to direct sunlight.
5) Avoid contact with water. It may cause a short circuit within the module.
6) Disconnect the AC power when replacing the backlight (CCFL) or inverter circuit. (High voltage occurs at the inverter circuit at 650Vrms.)
7) Always clean the LCD panel with a soft cloth material.
8) Use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short.
9) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
10) It is recommended not to exceed 1 hour of Power-On nor Burn-in period with LCD panel face down condition, in repair activity.
WARNINGS AND CAUTIONS
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SAFETY CHECK-OUT
After correcting the original service problem, perform the following safety checks before releasing the set to the customer:
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 cer tain 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 deterio ration. 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.
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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.
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. T he 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).
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).
SAFETY CHECK-OUT
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SELF DIAGNOSIS FUNCTION
The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY LED will automatically begin to flash.
The number of times the LED flashes translates to a probable source of the problem.
A definition of the STANDBY LED flash indicators is listed in the instruction manual for the user’s knowledge and reference.
If an error symptom cannot be reproduced, the remote commander can be used to review the failure occurrence data stored in memory to reveal past problems and how often these
problems occur.
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 .
DISPLAY OF STANDBY LED FLASH COUNT
0.5
0.5
3
STBY LED
Fla sh time
2 MAIN_POWER Main Power Over Voltage P rotection
3
4 BALANCER_ERR Balancer Error
5
6 BACKLIGHT_ERR Back Light Error (Panel Inverter)
7
8 - Not used
9 - Not used
10 - Not used
11 - Not used
12 - Not used
Service menu Item name
(Screen Di splay)
DC_ALERT1 DC_ALERT
AUDI O_PROT Audio A bnormal Detection
TCON_ERR Detect TCON_RDY
PANEL_ID__NV M_ERR Panel ID NVM E rror
TEMP_ERR Thermal Error
Diagnostic Item Description
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:
[To Bring Up Screen Test]
In standby mode, press buttons on the remote commander sequentially in rapid succession as shown below:
*
Info TV POWERChannel Volume
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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* : Note that this differs from entering the service mode (volume +)
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[SELF DIAGNOSTIC SCREEN DISPLAY]
SELF DIAGNOSIS FUNCTION
Item name
SELFCHECK
BACK <<
002MAIN_POWER 000
003DC_ALERT1 000
003AUDIO_PROT 000
STBY LED flash time
004BALANCER_ERR 000
005TCON_ERR 000
005PANEL_ID_NVM_ERR 000
006BACKLIGHT_ERR 000
007TEMP_ERR 000
12345‐67891‐23456
[Home]Exit
Panel operation time by hour
Boot count
Total operation time by hour
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”.
Error count
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 .
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.
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SERVICE POSITION
As for this model, the stands are attached the rear cover side.
Therefore assemble the stand assy to the main unit according to the following procedure when performing adjustment and operation check after the part replacement.
<32 inch>
1. Disassemble of the Bottom frame from the Rear cover (Three screws)
2. Assemble of the Bottom frame to LCD panel (Three screws)
3. Assemble of the Stand to main unit (Three screws)
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<40 inch>
SERVICE POSITION
1. Disassemble of the Bottom frame from the Rear cover (Three screws)
2. Assemble of the Bottom frame to LCD panel (Three screws)
3. Assemble of the Stand to main unit (Three screws)
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SEC 1. DISASSEMBLY AND PARTS LIST
• 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.
Note: When removing the rear cover, to prevent damaging the rear cover, please refer to “APPENDIX-1”.
Note: Bezel and LCD panel have points installing with double sided tape.
About the procedure of those disassembly and assembly methods, please refer to “APPENDIX-2”.
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1-1. KDL-32BX350
DISASSEMBLY AND PARTS LIST
1-1-1. BASE STAND
1-1-2. AC COVER AND AC CORD
REF. No . PAR T No . DESCRI P TI O N MARK
1 4-419-586-01 STAND, BASE(M)
2 4-400-568-01 COVER AC (APOW)
3 1-838-984-11 PO W ER SUPPLY CORD (f or SP/AF)
1-839-911-11 PO WER SUPPLY CORD (for AUS)
1
2
1-839-909-21 PO WER SUPPLY CORD (for GA)
4-167-019-01 SCREW, +PSW M3X8
2-580-608-11 SCREW, +PSW M5X16
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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1-1. KDL-32BX350
DISASSEMBLY AND PARTS LIST
1-1-3. REAR COVER
1-1-4. G9 BOARD, A BOARD, SPEAKER AND SWITCH UNIT
6
7
REF. No . PART No . DESCRI P TI O N MAR K
4 4-419-547- 1 1 REAR COVER (32APOW)
5 1- 490-176-11 SWITCH UNIT
6 1-474-381-12 G 9(CH) STATI C CONVERT ER (TV) (for SP/ AUS/AF)
4
8
1-474-381-31 G9(ID) STATIC CONVERTER ( TV) (for GA)
7 1-895-168-21 MOUNTED PWB A (for SP/AUS)
A-1885-671-A MOUNTED PWB A (WXGA) (for AF/GA)
8 4-410-589-01 BRACKET, SI DE (APOW PAD)
9 1-858-770-11 SPEAKER 4X10
2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3
7-682-948-01 SCREW, +PSW 3X8
7-685-648-79 SCREW + BVTP 3X12 TYPE2 IT-3
4-159-298-01 SCREW, +PSW M4X10
5
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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1-1. KDL-32BX350
DISASSEMBLY AND PARTS LIST
1-1-5. H BOARD
10
1-1-6. PANEL SUPPORT, LCD PANEL AND BEZEL
11
REF. No . PAR T No . DESCRI P TI O N MARK
10 1-895-170-21 MOUNTED PWB H
11 4-417-048-01 PANEL SUPPO RT (E)
12 4-419-544-01 BEZEL (32APOW) (for SP/AUS/AF)
4-419-544-21 BEZEL (32APOW) (for GA)
13 1-811-602-11 PANEL, LCD (W32)
14 1-910-105-27 CONNECT OR ASS Y FFC, 32
15 1-910-103-73 CONNECT OR ASS Y 12P IR
16 1-910-103-74 CONNECT OR ASS Y 3P MB-KEY
17 1-910-103-75 CONNECT OR ASS Y 14P INV
18 1-910-103-76 CONNECT OR ASS Y 16P PS
19 1-910-103-77 CONNECT OR ASS Y 4P SP
2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3
13
17
16 19
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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18
14
15
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1-2. KDL-40BX450
DISASSEMBLY AND PARTS LIST
1-2-1. BASE STAND
1-2-2. AC COVER AND AC CORD
REF. No . PAR T No . DESCRI P TI O N MARK
1 4-419-587-01 STAND, BASE(ML)
2 4-400-568-01 COVER AC (APOW)
3 1-838-984-11 PO W ER SUPPLY CORD (f or SP/AF)
1-839-911-11 PO WER SUPPLY CORD (for AUS)
1
2
1-839-909-21 PO WER SUPPLY CORD (for GA)
4-167-019-01 SCREW, +PSW M3X8
2-580-608-11 SCREW, +PSW M5X16
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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1-2. KDL-40BX450
DISASSEMBLY AND PARTS LIST
1-2-3. REAR COVER
1-2-4. W40 BOARD, A BOARD, SPEAKER AND SWITCH UNIT
REF. No . PA RT No . DESCRI P TI O N MAR K
4 4-419-548- 1 1 REAR COVER (40APOW PAD)
5 1- 490-176-11 SWITCH UNIT
6 1- 895-171-11 MOUNTED PWB W40
4
7 1-895-168-11 MOUNTED PWB A (f or SP/AUS)
A-1885-680-A MOUNTED PWB A (FHD) (for AF/GA)
8 4-410-589-01 BRACKET, SI DE (APOW PAD)
9 1-858-770-11 SPEAKER 4X10
2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3
7-682-948-01 SCREW, +PSW 3X8
7-685-648-79 SCREW + BVTP 3X12 TYPE2 IT-3
4-159-298-01 SCREW, +PSW M4X10
6
5
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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8
9
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1-2. KDL-40BX450
DISASSEMBLY AND PARTS LIST
1-2-5. H BOARD
10
1-2-6. PANEL SUPPORT, LCD PANEL AND BEZEL
11
13
REF. No . PART No . DESCRI P TI O N MARK
10 1-895-170-21 MOUNTED PWB H
11 4-417-086-01 PANEL SUPPORT (F)
12 4-419-545-01 BEZEL (40APOW)
4-419-545-22 BEZEL (40APOW)
13 1-811-603-11 PANEL, LCD (W40)
14 1-910-105-26 CONNECTOR ASS Y FFC 40
15 1-910-103-73 CONNECTOR ASS Y 12P IR
16 1-910-103-78 CONNECTOR ASS Y 3P MB-KEY
17 1-910-103-79 CONNECTOR ASS Y 16P PS
18 1-910-103-80 CONNECTOR ASS Y 4P SP
2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3
(for S P/A US/AF)
(for GA )
16
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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17
14
1518
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1-3. OTHER PART
1-3-1. MISCELLANEOUS
PART No . DESCRI P T I ON MARK
4-418-597-01 CUSHIN, UPPER (32APOW) (for SP/AUS/AF)
4-412-980-01 CUSHIN, UPPER (32APOW) (for GA)
4-418-599-01 CUSHIN, UPPER (40APOW) (for SP/AUS/AF)
4-412-982-01 CUSHIN, UPPER (40APOW) (for GA)
4-418-598-01 CUSHIN, LOWER (32APOW) (for SP/AUS/AF)
4-412-981-01 CUSHIN, LOWER (32APOW) (for GA)
4-418-600-01 CUSHIN, LOWER (40APOW) (for SP/AUS/AF)
4-412-983-01 CUSHIN, LOWER (40APOW) (for GA)
4-421-104-01 CARTON, INDIVI DUAL (APO 32) (for SP/AUS/AF)
4-421-104-11 CARTON, INDIVI DUAL (APO 32) (for GA)
4-421-105-01 CARTON, INDIVI DUAL (APO 40) (for SP/AUS/AF)
4-421-105-11 CARTON, INDIVI DUAL (APO 40) (for GA)
A-1869-239-A MANUAL, INSTRUCTION (for SP/AUS)
A-1913-679-A MANUAL, INSTRUCTION (for AF)
4-415-185-31 MANUAL, INSTRUCTION (for GA)
1-489-992-11 REMOT E COM MANDER (RM-ED049)
DISASSEMBLY AND PARTS LIST
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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SEC 2. ADJUSTMENT
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.
3) Service mode display.
Info TV POWERChannel Volume
StatusInformation >>
Selfdiagnosishistory >>
PanelSelection <[ 10 W_SE32 ]>
NO_SIGNAL_MUTE <[ Off ]>
TUNINGSYSTEM <[ AUTO ]>
LVDSSpectrum(%o) <[ 30 ]>
LowofHPD <[ 5 ]>
SERIALNUMBEREDID 002EJ0S
MODELNAMEEDID KDL‐32BX350
LoadServiceTable <[ Off ]>
5
ServiceMode
[</>]Set[Home]Exit
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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4) How to use the remote commander.
ADJUSTMENT
Function
Adjustment Item up / down
Data Value up / down
5) After entering service mode, then turn off the power switch.
The flow of control
<Info><5><Vol Up><Power>Service mode on
<Other> / <Power off + on>Service mode off
/
/
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SEC 3. DIAGRAMS
3-1. BLOCK DIAGRAM
3-1-1. BLOCK
Tuner
Component/
Video
SCART
PC
PC/HDMI
Audio
HDMI
HDMI2
USB
Demodulator
MT5306
ATCS
NTSC/
PAL/
SECAM
ATD
Video
ADC×4
HDMI Rx
Audio
Demod
Audio
DAC
SPDIF
In
JTAG IrDA I2C USB2.0 PWM Watchdog SerialFlash ServoADC T8032
PCR RTC Smart Card UART SDIO NAND XTAL CKGEN
TS
Demux
TV
Decoder
Audio
Input
JPEG/MP2/MP4/
DivX/VC-1
RM/AVS Decoders
VP6/VP8 Decoders
De-
interlace
Video
Input
Audio
DSP
ARM11
L2 Cashe
LVDS/mini-
LVDS/TCON/OD
EP1
PIP
Vplane
scaler
2D
Graphic
Audio I/F Audio DAC
Post Processing
OSD Scaler
DDR2
DDR3
Controller
DDR3
1GB
NAND
512MB
CI
Panel
STA381
BWS
Line out /
Side HP
SPDIF
8W
8W
H Board
Tact Key
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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3-2. CONNECTOR DIAGRAM
3-2-1. KDL-32BX350
DIAGRAMS
Panel
T-Con Board
Inverter
CN6401
CN6402
G9
Power Board
CN2001
CN4903
CN1003
CN8002 CN1004
CN9101
Main Board
IR Board
Key Pad
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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3-2-2. KDL-40BX450
DIAGRAMS
Panel
Control Board
CN2
DPS166DP
LIPS
CN2001
CN4904
CN1003
CN8002 CN1004
CN9101
Main Board
IR Board
Key Pad
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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3-3. CIRCUIT BOARDS LOCATION
DIAGRAMS
Switch Unit
KDL-32BX350
G9 Board
A Board
Switch Unit
H Board
KDL-40BX450
W40 Board
A Board
H Board
KDL-32BX350/40BX450(SP/AUS/AF/GA)
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END
9-888-467-03
KDL-32BX350/40BX450(SP/AUS/AF/GA)
Sony Corporation
Home Entertainment
Business Group
English
2012BL08-Data
Made in Japan
© 2012. 02
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APPENDIX-1
PROCEDURE TO REMOVAL OF REAR COVER
1. Remove all screws on Rear Cover and AC Cover.
2. Open Rear Cover in order as below.
32 inch
1 2
Disassemble the AC cover Pull the AC cord connector
40 inch
46 inch
KDL-32BX350/40BX450(SP/AUS/AF/GA)
3 4
Hold the panel from the hole of the AC cover,
and have the center of the rear cover bottom.
Lift rear cover in the direction of the arrow.
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APPENDIX-2
1. PROCEDURE TO REMOVE LCD PANEL FROM BEZEL ASSY
Peel off double sided tapes between bezel assembly and LCD panel when exchanging LCD panel, etc, allow below instruction.
2.Peel off double sided tape1.Put off “Bracket, Panel”
(1) Disassemble 2 screws (2) Unplug the IR wire
A
B
Use tool to loosen the hook as “A”, Pull out
the hook as “B”.
(3) Remove the panel from the bezel
KDL-32BX350/40BX450(SP/AUS/AF/GA)
Lift the panel up to disassemble the bezel.
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2. EXCHENGE DOUBLE SIDED TAPES
Because double sided tape’s strength weaken when tapes once peeled off, peel off all tapes from bezel assembly, and stick new ones (P/N: 4-281-014-01).
APPENDIX-2
1.Peel off double sided tapes from Panel.
(Possibly remain on Bezel side)
2.Stick double sided tapes
Peel off separate papers before panel puts on.
32”
1position
230 x 12mm, t=0.4
40”
2position
230 x 12mm, t=0.4
KDL-32BX350/40BX450(SP/AUS/AF/GA)
1position
230 x 12mm, t=0.4
30
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