Sony KDL-40R485A, KDL-32R435A, KDL-46R485A, KLV-40R472A, KLV- 32R422A Service Manual
...
HISTORY INFORMAT ION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL (COMMON)
Version Date Subject
1 6/2013 1stIssue.
ITC2CHASSIS
Segment: BA
LCD TV
9-888-144-01
For SM - Unique , please refer :
9-888-144-P1 ( Pan Asia )
9-888-144-A1 ( America )
9-888-144-E1 ( Europe)
SERVICE MANUAL (COMMON)
ITC2CHASSIS
LCD TV
Segment: BA
MODEL LIST
N
KLV
24R402A
KLV
32R402A
KLV
40R452A
KLV
46R452A
KLV
32R422A
KLV
40R472A
KDL
46R485A
THIS SERVICE MANUAL CONTAINS COMMON INFORMATION FOR BELOW REGIONS AND MODELS:
REGIO
ASIA AMERICA EUROPE
MODEL
-
-
-
-
KLV-24R422A KLV-32R407A KLV-40R457A KLV-46R472A
-
-
-
KDL-32R435A KDL-40R485A
3
TABLE OF CONTENTS
A
A
4
3. Accessing Self Diagnostic History…………………………………..…….
57
A
A
A
5. DIAGRAMS
3-2. No P
11
g
g
3
12.
RTC
Troubleshooting Flow
………………………………………………….
55
Circuit Board Location
Section Title Page
1. SAFETY NOTES
1-1. Warnings and Caution………………………………………………………. 5
1-2. Caution Handling of LCD Panel ......…………….................................... 5
1-3. Safety Check Out ........................……………......................................... 6
1-4. Leakage Test .......................................................................................... 6
1-5. How to Find a Good Earth Ground………………………………………… 7
1-6. Lead Free Information….…………………………………………………… 7
1-7. Handling the Flexible Flat Cable (FFC)……………………………………. 7
2. SELF DIAGNOSTIC FUNCTION
2-1. Overview of Control Buttons ................................................................... 8
2-2. LED Display Control ………..................................................................... 8
2-3. LED Pattern………………........................................................................ 8
2-4. Standby LED Error Display…………………………………………………. 8
2-5. Triage Chart ............................................................................................ 9
3. TROUBLE SHOOTING
3-1. Troubleshooting Flow…….…………………………………………………… 10
ower……………….………………………………………......................
3-3. Standby Led Blinking……………………………........................................ 14
3-4. No Picture............................................................................................. ... 25
3-5. Audio Problem.......................................................................................... 27
3-6. Troubleshooting Video Problem…………………………………………… 35
3-7. HDMI Troubleshootin
3-8. MHL No Picture…………………………………………………………….. 47
3-9. Tuner Troubleshooting Flow………………………………………………… 50
3-10. IR Troubleshooting Flow…………………………………………………….. 53
3-11. Switch Unit Troubleshooting Flow………………………………………… 54
-
Flow……………………………………………… 43
Section Title Page
4. SERVICE ADJUSTMENTS
4-1.
4-2.
4-4.
4-5.
4-6.
4-7. Updating the Software…………………………………………………….. 61
5-1. Circuit Board Location ......................................................................... 62
5-2. Block Diagram...................................................................................... 63
5-3. Connector Diagram ………………………………………...................... 65
ccessing Service Mode ..................................................................... 56
ccessing Software Version……….…………………………………….. 56
ccessing Self Diagnostic Menu…………………………………………… 57
ccessing Serial Number Edit……………………………………….. 58
ccessing Model Name Edit……………………………………………… 59
Please refer Service Manual – Unique for below information :
-Safety Warnings
-Wire Dressing
-
-Disassembly and Exploded View.
4
SECTION 1
3) Do not leave the module in high temperature or in areas of high humidity for
r
t
handpl
hil
TV
i
t
for
8) Use care when handling the wires or connectors of the inverter circuit
components
with
Sony
parts
whose
part
numbers
appear
as
shown
in
this
operation
is
suspected
.
SAFETY NOTES
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
1-1. Warnings and Caution
1) These servicing instructions are for use by qualified service personnel only.
2) 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.
3) 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.
4) Be sure to follow these guidelines to protect you
avoid causing serious injury :
• Carry the TV with an adequate number of people; larger size TVs require
two or more people.
•Correc
safety and to avoid damages.
5) Components identified by shading and mark on the exploded views,
and in the parts list are critical for safe operation. Replace these
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
acementw
e carryingthe
!
property and
sveryimportan
1-2. Caution Handling of LCD Panel
When repairing the LCD Panel, make sure you are grounded with a wrist band.
When repairing the LCD Panel on the wall, the panel must be secured using the
4 mounting holes on the rear cover.
1) Do not press 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.
an extended period of time.
4) Do not expose the LCD panel to direct sunlight.
5) Avoid contact with water. It may cause 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.
.
Damaging the wires may cause a short circuit.
9) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
10) During the repair, DO NOT leave the Power On or Burn-in period for more
than 1 hour while the TV is face down on a cloth.
Do not leave Power ON > 1 hour
Figure 1. TV is faced down on a cloth during repair.
5
Safety Notes
not exceed 0.5mA (500 microamperes)
multimeter
is suitable for this job
3
)Check
l
knob
operated digital multimeter that have a 2 VAC range are suitable
d
their
h
li
d
toth
hibited
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
1-3 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 inter board wiring to ensure that no wires are pinched or
contact high-wattage resistors.
allcontro
hardware have been replaced. Be absolutely certain 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
recommen
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
replacementofany suc
7) Check the antenna terminals, metal trim, metalized knobs, screws and all
other exposed metal parts for AC leakage. Check leakage test as described
next.
8. For safety reasons, repairing the Power board and/or Inverter board is
pro
.
s, shields, covers, groundstraps andmounting
ne cor
ecustomer.
1-4.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
.
Leakage current can be measured by any one of the three methods:-
1) A commercial leakage tester such as the SIMPSON 229 or RCA WT540A.
Follow the manufacturers instructions to use those instructions.
2) A battery-operated AC milliampmeter The DATA PRECISION 245 digital
.
3) Measuring the voltage drop across a resistor by means of a VOM or battery
operated AC voltmeter. The 'limit' indication is 0.75V so analog meters must
have an accurate low voltage scale. The SIMPSON'S 250 and SANWA SH63TRD are examples of passive VOMs that are suitable. Nearly all battery
.
(see Figure 2.)
Figure 2. AC voltmeter to check AC leakage
6
Safety Notes
2) If the retaining screw is to be used as your earth ground, verify that it is at
retaining screw. Try both slots, if necessary, to locate the hot side on the line;
Th
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
1-5. How to Find a Good Earth Ground
1) A cold-water pipe is a guaranteed earth ground; the cover-plate retaining
screw on most AC outlet boxes is also at earth ground.
ground by measuring the resistance between it and a cold-water pipe with an
ohmmeter. The reading should be zero ohms.
3) If a cold-water pipe is not accessible, connect a 60- to 100-watt troublelight (not a neon lamp) between the hot side of the receptacle and the
the lamp should light at normal brilliance if the screw is at ground potential
(see Figure 3).
Figure 3. Checking for earth ground.
1-7. Handling the FLEXIBLE FLAT CABLE (FFC)
When you insert / pull out FFC, please grasp a reinforcement board and main body of
FFC.
1-6. Lead Free Information
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.
Figure 4: LF Logo
e servicing of these boards requires special precautions. It is strongly
recommended to use Lead Free Solder material in order to guarantee optimal
quality of new solder joints.
Figure 5: LF logo on circuit board
< Insertion>
Main Board
Main Board
<Pull out>
7
Self Diagnostic Function
2-1. Overview of Control Buttons
2
3. LED Pattern
Standby LED
(
)
(y)
Blinking
0.5sec Green
SECTION 2
SELF DIAGNOSTIC FUNCTION
-
When safety shutdown occurs, Standby LED display reports the cause by using the lightning
patterns as indicated below
.
2-2. LED Display Control
Status LED Colour Remarks
Power Off
( AC Off and *1)
Power On Green
Standby
( by remote control off only )
Picture Off Green
Set "Sleep Timer" Amber
Set "On Timer"
( Power On )
Set "On Timer"
Standby
Picture Frame Amber
Failure Red Blinking
Error of panel ID
OFF
Red
Amber
Amber
Amber/Green
*1 power switch off (by
touch button)
The number of LED blinking
indicates cause of failure.
Blinking:0.5sec Amber/
Amber = Red + Green
0.5sec
Example: The figure above shows LED display when SHUTDOWN is caused by Audio
Error. It repeats flashing for a specified number of times in 0.5sec/cycle and has a 3 seconds
interval of lighting off. Please note that a 3 seconds interval of lighting off is fixed regardless of abnormal state types.
0.5sec
3.0sec 3.0sec
2-4. Standby LED Error Display
The Number of
(RED blinking)
2 Main Power Error AC adapter Error
3 Audio Error BB board Error
4 Panel Power Error BB board Error
5 Panel I2C COMM Error BB or Source board Error
6 Backlight Error BB board Error
Detection Items Board Error Item
Software Updating Amber Blinking Blinking: 1sec On / 1sec Off
8
Self Diagnostic Function
Ref
A
r
2-5. Triage Chart
erence
23456Tuner USB Video Component HDMI MHL
Blinking
No Picture No Sound
Main
Speaker
HP Video Component Tuner HDMI USB
BB Board
Light Source
Board
Open Cell
C Adapto
Speaker Unit
LS Harness
Main
Harness
FFC Cable
Most likely defective part
Secondary possible defective part
Note: Details refer to Troubleshooting Section.
9
3-1. Troubleshooting Flow
No Power
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
SECTION 3
TROUBLESHOOTING
START
Does the Power Led
stay on when the
TV is switched on ?
Is the Standby Led
blink ?
Green & Amber
blink?
Is the Picture and
Sound OK ?
Open Detail
-
Open Detail
- Standby LED Blink
- Panel ID Error
- Panel Not Supported
Open Detail
- Picture/Audio/Video
END
10
Troubleshooting
Sheet
Tak
NG
3-2. No Power
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
No Power
Figure 1: How to test DC voltage
at adaptor output
Check DC voltage at
JL6001
Is it 19.5V?
No
e out adaptor
and test at adaptor
output is it 19V – 19.5V?
(Refer Figure 1)
No
Change adaptor
and test again
AC source
Yes
Yes
OK
•See DDCON
BB board
Adaptor
11
Troubleshooting
Change BB
Yes
NG
NG condition & change
board
3-2-1. DD Con
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Start
Check voltage at JL6003
is it 3.3V?
Yes
Check voltage at JL6000
is it 1.2V?
Yes
Check voltage at JL6002
Is it 1.5V?
No
No
DDCON
OK
Check F6001
& F6002
board
Change BB
board
NGNo
Fuse
DDCON
OK
Check voltage at JL6012.
Is it 12V?
No
Check F6003.
Is it ok.
Check voltage at JL6005
is it 5V?
No
Yes
Fuse
Change BB
board
After checking, take note of
BB
12
Troubleshooting
Troubleshooting References (BB Board)
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
JL6002
JL6003
JL6000
JL6006
JL6005 JL6006 F6003
JL6001
13
Troubleshooting
3-3
Standby LED Blinking
board
.
3-3-1. 2-times Blinking
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
2 times Blinking
Figure 1: How to test DC voltage
at adaptor output
Check DC voltage at
JL6001
Is it 18V - 19.5V?
No
Take out adaptor
and test at adaptor
output is it 18V – 19.5V?
(Refer Figure 1)
No
Change
adaptor
Yes
Yes
Change BB
Change BB
board
14
Troubleshooting
3-3
Standby LED Blinking
S
Change
.
3-3-2. 3-times Blinking
3x blinking
at CN4000 & perform
3x blinking
START
Remove
peaker Connector
AC OFF - ON
No
3x blinking
Check Speaker harness
and Speaker impedance
No connectivity for
speaker harness
Speaker
Harness
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Speaker impedance
≠ 6~8 Ω
Change
Speaker
F4000 broken
No connectivity
of F4000
Check connectivity
3x blinking
& F4000 OK
Audio IC problem,
IC4000 damage
Change BB
3x blinking
of F4000.
board
DONE
Connect back
Speaker Connector to CN4000
& perform AC OFF - ON
No 3x blinking
15
Troubleshooting
Troubleshooting References (BB Board)
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
JL6012
F4000
IC4000
CN4000
16
Troubleshooting
F4000
F4000
F4000
Troubleshooting References
BoardName Board PWB(Aside) Detail
BB
CN4000
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
CN4000
CN4000
17
Troubleshooting
3-3
Standby LED Blinking
N
.
3-3-3. 4-times Blinking
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
No 12V
Check F6003.
Is it ok?
Yes
Check JL6009.
Is it 3.3V?
Yes
Check JL6012.
Is it 12V?
Yes
LVDS
No
Fuse
No
BB board
o
DDCON
18
Troubleshooting
JL6009
Troubleshooting References (BB Board)
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
LVDS FFC
CONNECTOR
JL6012
F6003
19
Troubleshooting
3-3
Standby LED Blinking
Remove and reinsert LVDS Flat
TV Boot Up
TV Boot Up
.
3-3-4. 5-times Blinking
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
START
Remove and reinsert LVDS Flat
Flexible Cable (FFC) at
BB Board and
Panel
5x Blinking is Still
Observed
Replace LVDS Flat
Flexible Cable (FFC)
5x Blinking is Still Observed
TV Boot Up
Normally
Normally
Incorrect FFC
Insertion
LVDS
Cable Issue
Replace B-Board
5x Blinking is Still Observed
** Replace
O-Cell or Panel Module
END
TV Boot Up
Normally
Normally
BB Board Issue
O-Cell Issue
** Not recommended at Service Side.
20
Troubleshooting
Troubleshooting References (BB Board)
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
LVDS FFC
CONNECTOR
JL6007
21
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