Sony KDL-32EX400, KDL-40EX400 Service Manual

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

Version

Date

Subject

iii) Add

New

Power Supply Cord and destinations

(Pg 54

), (Pg

)

SERVICE MANUAL

ORIGINAL MANUAL ISSUE DATE: 12/2009

1.0 12/2009 No revisions or updates are applicable at this time.

2.0 01/2010 Change Destination of General Area and replace Block Diagram.

3.0 04/2010 Add Base, Cover, Neck Information for KDL-40EX400 (Page 46)

4.0 08/2010 Add Support, Panel information (Page 38), (Page 41)

5.0 09/2010 Change Link of Disassembly Movie (Page 13)

6.0 10/2010 Add Note for Disassembly Movie download ( Page 13 )

7.0 11/2010 Add Troubleshooting Reference information ( Page 48 )

8.0 08/2011 Part Information Charge: i) Delete Power Supply Cord (Pg 39), (Pg 42). ii) Revised Old Power Supply Cord destinations ((Pg 53) (Pg 55).

iv) Plug Conversion Adaptor destination correction (Pg 44), (Pg 46).

v) Instruction Manual P/N Suffix Change and Destination Correction

(Pg 45), (Pg 47).

AZ1-L CHASSIS

Segment: 3a-2

LCD Digital Color TV

SERVICE MANUAL

AZ1-L CHASSIS

Segment: 3a-2

LCD Digital Color TV

MODEL LIST

KDL-32EX400 Black RM-GD015 Hong Kong KDL-32EX400 Blue RM-GD015 Hong Kong KDL-32EX400 Red RM-GD015 Hong Kong KDL-32EX400 Black RM-CD009 Taiwan KDL-32EX400 Blue RM-CD009 Taiwan KDL-32EX400 Red RM-CD009 Taiwan KDL-32EX400 Black RM-GD015 Australia, New

Zealand, Singapore ,

South Africa , GAA

KDL-32EX400 Blue RM-GD015 Aus tralia, New

Zealand, Singapore ,

South Africa , GAA

KDL-32EX400 Red RM-GD015 Australia, New

Zealand, Singapore ,

South Africa , GAA

KDL-40EX400 Black RM-GD015 Hong Kong KDL-40EX400 Black RM-CD009 Taiwan

KDL-40EX400 Black RM-GD015 New Zealand ,

Singapore , South Africa

MODEL COLOR COMMANDER DEST.MODEL COLOR COMMANDER DEST.

KDL-32/40EX400(HK/WB/GA)3

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 adequqate 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.

KDL-32/40EX400(HK/WB/GA)4

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 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.

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.

KDL-32/40EX400(HK/WB/GA)5

WARNINGS AND CAUTIONS

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).

KDL-32/40EX400(HK/WB/GA)6

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 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.

KDL-32/40EX400(HK/WB/GA)7

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. 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).

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

KDL-32/40EX400(HK/WB/GA)8

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 .

STBY LED

Flash time

2 MAIN_POWE Main Power Over Voltage Protection

4 BALANCER_ Panel Balancer Error

6 BACKLITE_ Back Light Error (Panel Inverter)

8-Not used

9-Not used

10 - Not used

11 - Not used

12 - Not used

- RGB_SEN RGB Sensor ACK Error

Service menu Item nam e

(Screeen Dsisplay)

DC_ALERT DC_ALERT

DTT_ WD T DTT Error

AUD_PROT Audio Abnormal Detection

TCON_ERR T-CON Error

HFR_ERR HFR Error

P_ID_ERR Panel ID NVM Error

TEMP_ERR Thermal Error

FAN_ERR FAN Error (Not De tected . Display Only)

Diagnos tic Item De s c ription

KDL-32/40EX400(HK/WB/GA)9

SELF DIAGNOSIS FUNCTION

DISPLAY OF STANDBY LED FLASH COUNT

0.5

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:

KDL-32/40EX400(HK/WB/GA)10

[SELF DIAGNOSTIC SCREEN DISPLAY]

SELF DIAGNOSIS FUNCTION

SELF CHECK(1)

002 MAIN P 003 DC_ALERT1 004 DC_ALERT2

006 BL 007 TEMP

009 FAN

12345-00333-06789

<1> NEXT PAGE->

0501210811 0412311234 0311111825 00 0000000000 0000000000 0000000000 00 0000000000 0000000000 0000000000 00

0000000000 0000000000 0000000000 00 0000000000 0000000000 0000000000 00

0000000000 0000000000 0000000000 00

Error count (00-99)

Error history (Last failure time beforehand)

Error history (Failure time before last)

Error history (The last failure time)

Item name

STBY LED flash time

Panel operation time by hour (MAX:65535)

Boot count (MAX:65535)

Total operation time by hour (MAX:65535)

KDL-32/40EX400(HK/WB/GA)11

SELF DIAGNOSIS FUNCTION

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”.

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.

KDL-32/40EX400(HK/WB/GA)12

SEC 1. DISASSEMBLY

1-1. MOVIE LIST

    

KDL--

        

Note:

1. This link does not work from outside Sony network.

2. The Disassembly movie can be downloaded from ORISS Service Manuals site.



KDL

KDL-32EX400

KDL--

KDL

KDL-40EX400

32EX400

40EX400

KDL-32/40EX400(HK/WB/GA)13

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. 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”

DIGITAL SERVICE

001 OP 000 VERS ---

Item number

Category number

CHASSIS SERVICE 000 CXD2813R 000 H_DET_NOSIG_CNT 1

Item name

Category name

Data

<MAIN> <SUB> DM1.301J00AA SM1.010W00AA M2.105C SB1.000W00AA DD1.016J00AA SD1.010W00AA (DM1.301J00AA) RF01.05 WP00.521J00AA ID1C117081 ID1C117081 LTY320AB01 PID04020000 WF:2.0.0.99 <BEM> WF:0B BM1.012W00LU Camera FW BB1.000W00LU Camera FW BD1.011J46LUX

---.---------

Press “OPTIONS” or “JUMP” button

KDL-32/40EX400(HK/WB/GA)14

4) How to use the remote commander.

Function The flow of control

Service mode on <Test>+<TV>/<Display><5><Vol Up><Power>

Service mode off <Other> / <Power off + on>

Item up / down <1>/<4>

Category up / down <2>/<5>

Data up / down <3>/<6>

Test reset <8> + <Mute> + <0>

Read data <9> + <0>

Execute <10 or 0>

Write data <Mute> + <0>

Change module <Jump> / <Option>

ADJUSTMENT

5) After entering service mode, then turn off the power switch.

KDL-32/40EX400(HK/WB/GA)15

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.

DIGITAL SERVICE 006 WB 000 WHITE_BALANCE ___

ADJUSTMENT

DIGITAL SERVICE 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

Gain

0: x 0.5, 128: x 1, 255: x1.5

Offset

128: offset 0

Please input WB items (0-255)

---

KDL-32/40EX400(HK/WB/GA)16

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.

ADJUSTMENT

CHASSIS WRITE 000 CXD2813R 000 H_DET_NOSIG_CNT 1

KDL-32/40EX400(HK/WB/GA)17

+ 39 hidden pages