Sony KDL-40R485A, KDL-32R435A, KDL-46R485A, KLV-40R472A, KLV- 32R422A Service Manual

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE MANUAL (COMMON)

ITC2 CHASSIS

Segment: BA

Version Date Subject

1	6/2013 1st Issue.

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)

ITC2 CHASSIS

Segment: BA

LCD TV

MODEL LIST

THIS SERVICE MANUAL CONTAINS COMMON INFORMATION FOR BELOW REGIONS AND MODELS:

REGION

ASIA AMERICA EUROPE

MODEL

KLV-24R402A	KLV-32R402A	KLV-40R452A	KLV-46R452A
KLV-24R422A	KLV-32R407A	KLV-40R457A	KLV-46R472A
	KLV-32R422A	KLV-40R472A	KDL-46R485A
	KDL-32R435A	KDL-40R485A

3

TABLE OF CONTENTS

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
3-2.	No Power……………….………………………………………......................	11
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 Troubleshooting Flow………………………………………………	43
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
3-12.	RTC Troubleshooting Flow………………………………………………….	55

Section Title		Page
4. SERVICE ADJUSTMENTS
4-1.	Accessing Service Mode .....................................................................	56
4-2.	Accessing Software Version……….……………………………………..	56
4-3.	Accessing Self Diagnostic History…………………………………..…….	57
4-4.	Accessing Self Diagnostic Menu……………………………………………	57
4-5.	Accessing Serial Number Edit………………………………………..	58
4-6.	Accessing Model Name Edit………………………………………………	59
4-7.	Updating the Software……………………………………………………..	61
5. DIAGRAMS
5-1.	Circuit Board Location .........................................................................	62
5-2.	Block Diagram......................................................................................	63
5-3.	Connector Diagram ………………………………………......................	65

Please refer Service Manual – Unique for below information : -Safety Warnings

-Wire Dressing

-Circuit Board Location

-Disassembly and Exploded View.

4

SECTION 1

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 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.

5) Components identified by shading and ! mark on the 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.

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.

3)Do not leave the module in high temperature 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 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 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	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.

3)Check all control knobs, shields, covers, ground straps and mounting 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 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, 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 prohibited.

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 not exceed 0.5mA (500 microamperes).

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 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 0.75V 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 operated digital multimeter that have a 2 VAC range are suitable.

(see Figure 2.)

Figure 2. AC voltmeter to check AC leakage

6

	Safety Notes	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.

2)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.

3) If a cold-water pipe is not accessible, connect a 60to 100-watt troublelight (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 3).

Figure 3. Checking for earth ground.

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

Figure 5: LF logo on circuit board

The 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.

1-7. Handling the FLEXIBLE FLAT CABLE (FFC)

When you insert / pull out FFC, please grasp a reinforcement board and main body of FFC.

Main Board	Main Board

< Insertion>

<Pull out>

7

Self Diagnostic Function

SECTION 2

SELF DIAGNOSTIC FUNCTION

2-1. Overview of Control Buttons

2-3. LED Pattern

When safety shutdown occurs, Standby LED display reports the cause by using the lightning

patterns as indicated below.

0.5sec	3.0sec	3.0sec

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.

						Amber = Red + Green
2-2. LED Display Control
		Status		LED Colour	Remarks
		Power Off		OFF	*1 power switch off (by
		( AC Off and *1)			touch button)
		Power On		Green
		Standby		Red
		( by remote control off only )
		Picture Off		Green
		Set "Sleep Timer"		Amber
		Set "On Timer"		Amber
		( Power On )
		Set "On Timer"		Amber
		( Standby )
		Picture Frame		Amber
		Failure		Red Blinking	The number of LED blinking
					indicates cause of failure.
		Error of panel ID		Amber/Green	Blinking:0.5sec Amber/
				Blinking	0.5sec Green
		Software Updating		Amber Blinking	Blinking: 1sec On / 1sec Off

2-4. Standby LED Error Display

The Number of	Detection Items	Board Error Item
Standby LED
(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

8

Self Diagnostic Function

2-5. Triage Chart

Blinking

No Picture

No Sound

Reference

Main

2

3

4

5

6

Tuner

USB

Video

Component

HDMI

MHL

HP

Video

Component

Tuner

HDMI

USB

Speaker

BB Board





































Light Source



Board

Open Cell













AC Adaptor



Speaker Unit















LS Harness

Main















Harness

FFC Cable















Most likely defective part

Note: Details refer to Troubleshooting Section.

Secondary possible defective part

9

ITC2 CHASSIS

R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

SECTION 3

TROUBLESHOOTING

3-1. Troubleshooting Flow

START

Does the Power Led

Open Detail

stay on when the

- No Power

TV is switched on ?

Is the Standby Led	Open Detail
blink ?	- Standby LED Blink

Green & Amber	- Panel ID Error
blink?	- Panel Not Supported

Is the Picture and	Open Detail
Sound OK ?	- Picture/Audio/Video

END

10

Troubleshooting	ITC2 CHASSIS
	R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

3-2. No Power

No Power

Check DC voltage at	Yes	•See DDCON
JL6001		Sheet
Is it 19.5V?

No

Take out adaptor

and test at adaptor Yes BB board output is it 19V – 19.5V?

(Refer Figure 1)

No

Change adaptor	OK
	Adaptor
and test again

NG

AC source

11

Troubleshooting

ITC2 CHASSIS

R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

3-2-1. DD Con

Start		DDCON
		OK
Check voltage at JL6003	No	Check F6001	NG
is it 3.3V?		& F6002	Fuse
Yes
Check voltage at JL6000	No	Change BB
					DDCON
is it 1.2V?		board
Yes					OK
Check voltage at JL6002	No	Change BB	Check voltage at JL6012.	No	Check F6003.
Is it 1.5V?		board	Is it 12V?		Is it ok.
Yes					NG
Check voltage at JL6005	No	Change BB			Fuse
is it 5V?		board

Yes	After checking, take note of
	NG condition & change BB board

12

Troubleshooting	ITC2 CHASSIS
	R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

Troubleshooting References (BB Board)

JL6002

JL6003

JL6000

JL6001

JL6006

	JL6005	JL6006	F6003

13

Troubleshooting	ITC2 CHASSIS
	R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

3-3. Standby LED Blinking

3-3-1. 2-times Blinking

2 times Blinking

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	Change BB
	board

Yes	Change BB
	board

14

Troubleshooting

ITC2 CHASSIS

R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

3-3. Standby LED Blinking

3-3-2. 3-times Blinking

START
3x blinking	No		Speaker impedance
Remove	3x blinking		≠ 6~8 Ω
Speaker Connector		Check Speaker harness		Change
at CN4000 & perform		and Speaker impedance		Speaker
AC OFF - ON			No connectivity
3x blinking			speaker
			Change
			Speaker
			Harness
3x blinking			Connect back

		No connectivity	Speaker Connector to CN4000
			& perform AC OFF - ON
		of F4000 Check
	F4000 broken		No 3x blinking
		of
		3x blinking
		& F4000 OK
		Audio IC
		IC4000
		Change BB
		board
		DONE

15

Troubleshooting	ITC2 CHASSIS
	R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

Troubleshooting References (BB Board)

F4000

IC4000

CN4000

JL6012

16

Troubleshooting	ITC2 CHASSIS
	R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

Troubleshooting References

	Board Name Board PWB (A side)	Detail

BB

CN4000

CN4000

CN4000

F4000

F4000

F4000

17

Troubleshooting

ITC2 CHASSIS

R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

3-3. Standby LED Blinking

3-3-3. 4-times Blinking

No 12V

No

Check F6003. Fuse

Is it ok?

	Yes
	Check JL6009.	No
		BB board
	Is it 3.3V?
	Yes
	Check JL6012.	No
	Is it 12V?	DDCON

Yes

LVDS

18

Troubleshooting	ITC2 CHASSIS
	R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

Troubleshooting References (BB Board)

LVDS FFC

CONNECTOR

JL6012

F6003

JL6009

19

Troubleshooting

ITC2 CHASSIS

R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

3-3. Standby LED Blinking

3-3-4. 5-times Blinking

	START
	Remove and reinsert LVDS Flat	TV Boot Up			TV Boot Up
		Normally	Incorrect FFC	Replace B-Board	Normally
	Flexible Cable (FFC) at					BB Board Issue
	BB Board and		Insertion
	Panel
	5x Blinking is Still			5x Blinking is Still Observed
	Observed
		TV Boot Up		** Replace	TV Boot Up
	Replace LVDS Flat	Normally	LVDS		Normally	O-Cell Issue
				O-Cell or Panel Module
	Flexible Cable (FFC)		Cable Issue

5x Blinking is Still Observed

END

** Not recommended at Service Side.

20

Troubleshooting	ITC2 CHASSIS
	R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488

Troubleshooting References (BB Board)

LVDS FFC

CONNECTOR

JL6007

21