Sony KDL-32L504 Service Manual
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-32L504
RM-YD028 US
EX2K
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 7/2009
: UPDATED ITEM
☛
REVISION DATE SUBJECT
7/2009 No revisions or updates are applicable at this time.
9/2009 Updated Exploded View Section to remove LCD Panel specifi c information. Replaced page 47.
9/2009 Updated Exploded View Section to include Accessories and Packing, Miscellaneous and
Remote Commander Sections. Replaced page 50.
LCD DIGITAL COLOR TELEVISION
9-883-836-03
Self Diagnosis
Supported model
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDL-32L504
RM-YD028 US
EX2K
CHASSIS
9-883-836-03
KDL-32L504 RM-YD028
LCD DIGITAL COLOR TELEVISION
KDL-32L504
TABLE OF CONTENTS
SECTION TITLE PAGE SECTION TITLE PAGE
Specifi cations ................................................................................. 4
Warnings and Cautions .................................................................. 6
Safety-Related Component Warning .............................................. 7
Safety Check-Out ........................................................................... 9
Self-Diagnostic Function ............................................................... 10
SECTION 1: DISASSEMBLY ............................................................... 12
1-1. Rear Cover Removal ............................................................ 12
1-2. Switch Unit Removal (Contains H1 Board) .......................... 12
1-3. A Board and G2BE (Power) Board Removal ....................... 13
1-4. Table-Top Stand Assembly and Under Cover Removal ....... 13
1-5. Loudspeaker Removal ......................................................... 14
1-6. Brackets and Spine Removal ............................................... 15
1-7. H2 Board and LCD Panel Removal ..................................... 16
1-7-1. Cleaning the LCD Panel ............................................ 16
1-8. ETC-Inverter MT Board Removal ......................................... 17
WIRE DRESSING ........................................................................ 18
SECTION 2: SERVICE ADJUSTMENTS ............................................. 19
2-1. Resetting to Factory Defaults ............................................... 19
SECTION 3: DIAGRAMS ..................................................................... 20
3-1. Circuit Boards Location ........................................................ 20
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 20
3-3. Block Diagram ...................................................................... 22
3-4. Schematics and Supporting Information .............................. 23
A Board Schematic Diagram (1 of 17) .................................. 23
A Board Schematic Diagram (2 of 17) .................................. 24
A Board Schematic Diagram (3 of 17) .................................. 25
A Board Schematic Diagram (4 of 17) .................................. 26
A Board Schematic Diagram (5 of 17) .................................. 27
A Board Schematic Diagram (6 of 17) .................................. 28
A Board Schematic Diagram (7 of 17) .................................. 29
A Board Schematic Diagram (8 of 17) .................................. 30
A Board Schematic Diagram (9 of 17) .................................. 31
A Board Schematic Diagram (10 of 17) ................................ 32
A Board Schematic Diagram (11 of 17) ................................ 33
A Board Schematic Diagram (12 of 17) ................................ 34
A Board Schematic Diagram (13 of 17) ................................ 35
A Board Schematic Diagram (14 of 17) ................................ 36
A Board Schematic Diagram (15 of 17) ................................ 37
A Board Schematic Diagram (16 of 17) ................................ 38
A Board Schematic Diagram (17 of 17) ................................ 39
G2BE (Power) Board Schematic Diagram ........................... 41
H1 Board Schematic Diagram .............................................. 42
H2 Board Schematic Diagram .............................................. 44
SECTION 4: EXPLODED VIEWS ........................................................ 46
4-1. Rear Cover Assembly and Table-Top Stand Assembly ....... 46
4-2. Chassis ................................................................................ 47
4-3. Bezel Assembly and LCD Panel .......................................... 48
4-4. Screw Legend ...................................................................... 49
APPENDIX A: ENCRYPTION KEY COMPONENTS ..........................A-1
KDL-32L504
3
SPECIFICATIONS
KDL-32L504
Power Requirements
120V - 240V AC, 50/60Hz
VIDEO (IN) 1/2:
S Video (4-Pin Mini DIN) (Video 2 only)
Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative
C: 0.286 Vp-p (Burst signal), 75 ohms
Video
1 Vp-p, 75 ohms unbalanced, sync negative
Audio
500 mVrms (Typical)
Impedance:47 kilohms
COMPONENT IN 1/2:
YP
(Component Video)
BPR
Y:1.0 Vp-p, 75 ohms unbalanced, sync negative
PB:0.7 Vp-p, 75 ohms
PR:0.7 Vp-p, 75 ohms
Signal format: 480i, 480p, 720p, 1080i, 1080p
Audio
500 mVrms (Typical)
Impedance: 47 kilohms
HDMI IN 1/2/3:
HDMI
Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p
Audio: Two channel linear PCM 32, 44.1, and 48 kHz,
16, 20 and 24 bits, Dolby Digital
Audio (HDMI IN 1 only):
500 mVrms (Typical)
Impedance: 47 kilohms
AUDIO OUT:
500 mVrms (Typical)
DIGITAL AUDIO OUT (OPTICAL):
PCM/Dolby Digital optical signal
PC IN:
Analog RGB (D-sub 15-pin):
0.7 Vp-p, 75 ohms, positive
PC AUDIO INPUT:
Stereo mini jack
500 mVrms (Typical)
Impedance: 47 kilohms
Licensing Information
Macintosh is a trademark of Apple Inc., registered in the U.S. and other
countries.
HDMI, the HDMI logo and High-Definition Multimedia Interface are
trademarks or registered trademarks of HDMI Licensing LLC.
Fergason Patent Properties, LLC:
U.S. Patent No. 5,717,422
U.S. Patent No. 6,816,141
Manufactured under license from Dolby Laboratories. Dolby and the
double-D symbol are trademarks of Dolby Laboratories.
Blu-ray Disc is a trademark.
“BRAVIA”, and are trademarks or registered trademarks of
Sony Corporation.
“PLAYSTATION” is a registered trademark and “PS3” is a trademark of
Sony Computer Entertainment Inc.
Your BRAVIA TV is ENERGY STAR qualified in the ‘Home” mode.
It meets strict energy efficiency guidelines set by the U.S. Environmental
Protection Agency and Department of Energy. ENERGY STAR is a joint
program of these government agencies, designed to promote energy effieient
products and practices.
- When the TV is initially set up, it is designed to meet ENERGY STAR
requirements.
- Changes to certain features, settings, and function alities of this TV
(i.e. Picture/Sound, Light Sensor, Power Savings) can slightly change
the power consumption.
Depending upon such changed settings, the power consumption may
increase which possibly could exceed the limits requird for the
ENERGY STAR qualification.
KDL-32L504
Design and specifi cations are subject to change without notice.
4
KDL-32L504
)
Power Consumption
in use
in standby Less than 0.5 W
Speaker Output (W)
10W + 10W
Speaker/Full Range(2
mm 34 X 160 mm
in
1
Dimensions (W x H x D)
with stand
mm
in
807 x 557 x 222 mm
7/8
31
without stand
mm
in
807 x 508 x 94 mm
7/8
31
wall-mount hole pattern (mm) 200 x 200
wall-mount screw size (mm) M6 8-12
Mass
with stand
kg
lbs
28 lbs 0 oz
without stand
kg
lbs 25 lbs 3 oz
All measurements are approximations.
135W
3/8
1/3
x 6
x 22 x 8
x 20 x 3
12.7 kg
11.4 kg
in
3/4
3/4
KDL-32L504
in
in
Television system
NTSC American TV Standard
ATSC (8VSB terrestrial) ATSC compliant 8VSB
QAM on cable ANSI/SCTE 07 2000
Channel coverage
Analog Digital
Terrestrial 2-69 2-69
Cable 1-135 1-135
Antenna
75-ohm external terminal for RF inputs
Panel System
LCD (Liquid Crystal Display) Panel
Display Resolution (horizontal x vertical):
1,366 dots x 768 lines
Screen Size (measured diagonally)
approx. 31.5 inches
Supplied Accessories
Remote Commander RM-YD028
Two Size AA (R6) Batteries
Operating Instructions
Quick Setup Guide
Warranty Card
Safety and Regulatory Booklet
Attaching to the Table-Top Stand
Screws (4)
Optional Accessories
Connecting Cables
Support Belt Kit
Wall-Mount Bracket
SU-WL500
KDL-32L504
5
KDL-32L504
WARNINGS AND CAUTIONS
CAUTION
These servicing instructions are for use by qualifi ed 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 qualifi ed to do so.
CARRYING THE TV
• Disconnect all cables when carrying the TV.
• Carry the TV with the adequate number of people; larger size TVs require two or more people.
• Placement of the hands carrying the TV is very important for safety and to avoid damage.
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.
! SAFETY-RELATED COMPONENT WARNING!!
Components identifi ed by shading and ! mark on the schematic diagrams, exploded views, and in the parts list are critical for safe operation. Replace
these components with Sony parts whose part numbers appear as shown in this manual or in supplements published by Sony. Circuit adjustments that
are critical for safe operation are identifi ed in this manual. Follow these procedures whenever critical components are replaced or improper operation is
suspected.
KDL-32L504
6
SAFETY-RELATED COMPONENT WARNING
KDL-32L504
There are critical components used in LCD color TVs that are important for safety. These components are identifi ed with shading and
mark on the schematic diagrams and the electrical parts list. It is essential that these critical parts be replaced only with the part number
specifi ed in the electrical parts list to prevent electric shock, fi re, or other hazard.
NOTE: Do not modify the original design without obtaining written permission from the manufacturer or you will void the original parts and
labor guarantee.
!
USE CAUTION WHEN HANDLING THE LCD PANEL
When repairing the LCD panel, be sure you are grounded by using a wrist band.
When installing the LCD panel on a wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.
To avoid damaging the LCD panel:
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 adapter 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).
LEAKAGE CURRENT HOT CHECK CIRCUIT
KDL-32L504
7
The circuit boards used in these models have been processed using
Lead Free Solder. The boards are identified by the LF logo located
close to the board designation e.g. H1 etc [ see example ]. The
servicing of these boards requires special precautions to be taken as
outlined below.
KDL-32L504
example 1
It is strongly recommended to use Lead Free Solder material in order to guarantee optimal quality of new solder joints.
Lead Free Solder is available under the following part numbers :
rebmuntraP retemaiD skrameR
91-500-046-7mm3.0gK52.0
02-500-046-7mm4.0gK05.0
12-500-046-7mm5.0gK05.0
22-500-046-7mm6.0gK52.0
32-500-046-7mm8.0gK00.1
42-500-046-7mm0.1gK00.1
52-500-046-7mm2.1gK00.1
62-500-046-7mm6.1gK00.1
Due to the higher melting point of Lead Free Solder the soldering iron tip temperature needs to be set to 370 degrees centigrade.
This requires soldering equipment capable of accurate temperature control coupled with a good heat recovery characteristics.
For more information on the use of Lead Free Solder, please refer to
http://www.sony-training.com
KDL-32L504
8
SAFETY CHECK-OUT
KDL-32L504
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.
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).
Leakage Test
0.15 F
Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.
To Exposed Metal
Parts on Set
Earth Ground
AC
Voltmeter
(0.75V)
Trouble Light
AC Outlet Box
Ohmmeter
Cold-water Pipe
KDL-32L504
9
KDL-32L504
SELF-DIAGNOSTIC FUNCTION
The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY LED indicator will automatically begin to fl ash. The number
of times the LED fl ashes translates to a probable source of the problem. A defi nition of the STANDBY LED fl ash indicators is listed in the instruction
manual for the user’s knowledge and reference. 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.
1. Diagnostic Test Indicators
When an error occurs, the STANDBY LED indicator will fl ash a set number of times to indicate the possible cause of the problem. If there is more than
one error, the indicator will identify the fi rst of the problem areas.
LED Indictors
Description of LED Indictors
LED LED Type Description
POWER LED
STANDBY LED
PIC OFF/
TIMER
LED
PIC OFF / TIMER
Green LED
Red LED
Green or Orange
LED
2 times
STANDBY
POWER
* Lights up in green when the TV set is turned on.
* Lights up in red when TV is in PC power saving
mode.
* If LED blinks continuously, this may indicate
that the TV needs servicing.
* Lights up in orange when the sleep timer is set.
* Lights up in green when Power Saving is set to
Picture Off.
KDL-32L504
5 times
LED ON 0.3 sec.
LED OFF 0.3 sec.
LED OFF
3 sec. => 2 sec.
10
POWER/STANDBY/LED Diagnostic Description
A
K
y
K
KDL-32L504
Diagnostic Item
Description
Low B Error 3 times
TCON Power Error
Backlight Error 6 times
Audio Abnormal Detection 8 times
Viewing the Self Check Diagnostic List
1. TV must be in standby mode. (Power off).
2. Press the following buttons on the Remote Commander within a second of each other:
DISPLAY
The Self Check list displays. This differs from accessing Service Adjustments.
Results for all of the following diagnostic items are displayed on screen. No error has occurred if the screen displays a “0”.
NOTE: If the Service Menu display text is not completely visible, press the Menu
Channel 5 Volume -
POWER
Number of times
STANDBY lamp
Possible Location
flashes
A Board (Main)
G2BE (Power) Board
5 times LCD Panel
G2BE (Power) Board
.
button on the Remote Commander to refresh the display.
HOME
LCD Panel
Board (Main)
Speaker
SELF CHEC
BAC
003 LOW B ERROR 1 000
005 T-CON POWER ERROR 001
006 BACKLIGHT ERROR 000 (Red indicates the last error that was detected)
008 AUDIO ABNORMAL DETECTION 000
Í 0 indicates no error was detected
Í 1 indicates an error was detected
00000 00012 00000 [Menu]Exit
Ï
Ï
ÏÏ
Ï 00000: Panel Operation Time by Hour (max 99999)
Ï Ï Deletion of Panel Operation Time by <7> - > <0> ke
Ï 00012: Boot Count (max 99999)
00000: Total Operation Time by Hour (max 9999)
3. To exit Self Check display, turn the power off. Press [Menu] Exit.
4. To return to Service Mode screen select the BACK button.
Clearing the Self Check Diagnostic List
1. In Service Mode, press the Channel
Channel 0.
8
KDL-32L504
11
1-1. REAR COVER REMOVAL
1
Remove 12 screws from Rear Cover
Remove 1 screw from Side Jack position
2
Remove 2 screws from Terminal position
3
Remove 2 screws from Rear Cover
4
Push side of Power Switch to release tab while removing Rear Cover
5
KDL-32L504
SECTION 1: DISASSEMBLY
Bezel
Rear Cover
1
2
3
5
1-2. SWITCH UNIT REMOVAL (CONTAINS H1 BOARD)
Push side of Power Switch and release Bezel tab while lifting up Switch Unit
1
from Bezel
Slide out Switch unit from Bezel, then disconnect 1 connector from
2
Switch Unit (Contains H1 Board)
Bezel
4
KDL-32L504
1
2
Switch Unit (Contains H1 Board)
12
1-3. A BOARD AND G2BE (POWER) BOARD REMOVAL
Lift top and bottom latches from Side Jack Bracket to unhook from Main Bracket
1
Disconnect 7 connectors from A Board
2
Remove 9 screws from A Board
3
Disconnect 3 connectors from G2BE (Power) Board
4
Remove 6 screws from G2BE (Power) Board
5
Main Bracket
Latches
2
Side Jack Cover
1
A Boar d
Main Shield
4
KDL-32L504
3
G2BE (Power) Board
5
1-4. TABLE-TOP STAND ASSEMBLY AND UNDER COVER REMOVAL
Gently place the TV set face down onto a soft cloth
1
Remove 1 screw from Under Cover
2
Remove 4 screws Table-Top Stand Assembly
3
Slide Table-Top Stand Assembly out away from Bottom Bracket
4
2
Under Cover
Bottom Bracket
1
3
Stand Assembly
Ta bl e -To p
4
KDL-32L504
Soft Cloth
13
1-5. LOUDSPEAKER REMOVAL
Remove 1 screw from each Speaker Baffl e Plate (2 total)
1
Remove 4 screws from each loudspeaker (8 total)
2
Disconnect speaker wire
3
KDL-32L504
Speaker Baffle Plate (L)
1
2
Loudspeakers
Speaker Baffle Plate (R)
3
3
Soft Cloth
KDL-32L504
14
1-6. BRACKETS AND SPINE REMOVAL
Remove 1 screw from Main Bracket and Bezel
1
Remove 2 screws from Spine (L) and Top Bracket
2
Remove 2 screws from Top Bracket
3
Remove 2 screws from Spine (R)
4
Remove 2 screws from Bottom Bracket
5
Main Bracket
1
KDL-32L504
Spine (L)
Top Bracket
2
4
3
Spine (R)
5
Bottom Bracket
Soft Cloth
KDL-32L504
15
1-7. H2 BOARD AND LCD PANEL REMOVAL
Disconnect LVDS connector from TCON
1
Remove 2 screws from bottom of panel and release LCD panel from Bezel
2
Disconnect 1 connector from Inverter Board
3
Disconnect 1 connector from H2 Board
4
Remove 1 screw from H2 Board
5
KDL-32L504
LCD Panel
Bezel
1
2
3
5
4
H2 Board
Soft Cloth
1-7-1. CLEANING THE LCD PANEL
CAUTION: When cleaning the TV, be sure to unplug the power cord to avoid any chance of electric shock.
Clean the cabinet of the TV with a dry soft cloth.
Wipe the LCD screen gently with a soft cloth.
Stubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water.
If using a chemically pretreated cloth, please follow the instruction provided on the package.
Never use strong solvents such as a thinner, alcohol or benzine for cleaning.
Periodic vacuuming of the ventilation openings is recommended to ensure to proper ventilation.
KDL-32L504
16
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