Sony KDL40S5600, KDL 32 37 40S5600 Schematic

HISTORY

Model Name :
SERVICE MANUAL

Click on Page Number to display detail of changes.

KDL-32/37/40S5600

Date Part Number Description of Revisions

Version

1.09-883-454-01 2009.05

Original Manual.

2.09-883-454-02 2009.06

Add 32” Inverter Board to the Exploded Views.

(P38)

3.09-883-454-03 2009.07

Commonize ‘B’ Board.

(P37 / P42)

2010.08 9-883-454-04 How to Delete “Error History” (P9) 4.0

- 1 -

SERVICE MANUAL

EX2N-Peppermint

CHASSIS

MODEL DEST

RM-ED017

KDL-32S5600 OIRT / UK / WE
KDL-37S5600 OIRT / UK / WE
KDL-40S5600 OIRT / UK / WE

- 2 -

TABLE OF CONTENTS

Section Title Page Section Title Page

1. GENERAL

Caution ................................................................ 3

Specifications ...................................................... 6

Connectors ........................................................... 8

Self Diagnosis ..................................................... 9

2. DISASSEMBLY

2-1. Rear Cover Removal (Step 1) ............................... 10

2-2. Rear Cover Removal (Step 2) ............................... 10

2-3. Stand Assy Removal .............................................. 10

2-4. Under Cover Removal ........................................... 10

2-5. Switch Unit Removal ............................................. 11

2-6. Loudspeaker Removal ........................................... 11

2-7. Side Bracket Removal ........................................... 11

2-8. B Board Removal ................................................... 11

2-9. H1 Board Removal ................................................ 12

2-10. G2 Board Removal (32 inches) ........................... 12

2-11. G4 Board Removal (37 inches) ........................... 12

2-12. IP1F Board Removal (40 inches) ......................... 12

3. SERVICE MENUS

3-1. How to enter the Service Mode .......................... 13

3-2. Service Menu Structure ...................................... 13

3-2-1. Service General Menu .................................. 13

3-2-2. White Balance Adjustment ........................... 13

3-2-3. OSD Service Menu ...................................... 14

3-2-4. Country Selection ......................................... 14

3-2-5. Factory Reset ................................................ 14

3-3. TT Mode ............................................................. 15

4. DIAGRAMS

4-1. Block Diagram ................................................... 16

4-2. Circuit Board Location ....................................... 17

4-3. Schematic Diagrams and Printed Wiring

Boards ................................................................. 17

B Board Schematic Diagram ........................... 18

H1 Board Schematic Diagram ........................... 30

IP1F Board Schematic Diagram (40 inches) ..... 31

B Printed Wiring Board ....................................... 33

H1 Printed Wiring Board ..................................... 34

IP1F Printed Wiring Board (40 inches) ............... 35

5. EXPLODED VIEWS

5-1. Chassis ................................................................ 37

5-2. Bezel Assy & Stand Assy ................................... 39

5-3. Rear Cover & Power Supply Cords .................... 40

6. PARTS LIST

............................................................... . 41

SAFETY-RELATED COMPONENT WARNING !!

COMPONENTS IDENTIFIED BY SHADING AND MARKED £ 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.

WARNING !!

AN ISOLATION TRANSFORMER SHOULD BE USED DURING ANY
SERVICE WORK TO AVOID POSSIBLE SHOCK HAZARD DUE TO
LIVE CHASSIS, THE CHASSIS OF THIS RECEIVER IS DIRECTLY
CONNECTED TO THE POWER LINE.

- 3 -

SECTION 1 GENERAL

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.

Lead Free Soldered Boards

example

Lead Free Solder material must be used to comply with environmental requirements of new solder joints. Lead Free Solder is available
under the following part numbers :

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

Partnumber Diameter Remarks

7-640-005-19 0.3mm 0.25Kg
7-640-005-20 0.4mm 0.50Kg
7-640-005-21 0.5mm 0.50Kg
7-640-005-22 0.6mm 0.25Kg
7-640-005-23 0.8mm 1.00Kg
7-640-005-24 1.0mm 1.00Kg
7-640-005-25 1.2mm 1.00Kg
7-640-005-26 1.6mm 1.00Kg

CAUTION

SECTION 1 GENERAL

How to replace the fuse.
Open the fuse compartment with
a screwdriver blade and replace
the fuse.

FUSE

WARNING (UK Models only)

The flexible mains lead is supplied connected to a

B.S. 1363

fused
plug having a fuse of the correct rating for the set. Should the fuse
need to be replaced, use a fuse of the same rating approved by ASTA
to

BS 1362

, ie one that carries the

ASA

T

mark.

mark.

IF THE PLUG SUPPLIED WITH THIS APPLIANCE IS NOT SUITABLE
FOR THE OUTLET SOCKETS IN YOUR HOME, IT SHOULD BE CUT
OFF AND AN APPROPRIATE PLUG FITTED. THE PLUG SEVERED
FROM THE MAINS LEAD MUST BE DESTROYED AS A PLUG WITH

BARED WIRES IS DANGEROUS IF ENGAGED IN A LIVE SOCKET.

When an alternative type of plug is used, it should be fitted with the
correct rating fuse, otherwise the circuit should be protected by the
same rating fuse at the distribution board.

UK PLUG W ARNING

LCD PANEL CAUTION

Whilst working on this product, it is not recommended to lay the TV set face down when powered up, as this can result in panel problems.
If it is necessary to power up the TV set when face down, the time should be minimised as much as possible.

- 4 -

CAUTION

1. MDF-61 Connector (Removal)

Slide the slider to release slider

lock.

Press the centre lock tab to

release the lock and pull the

connector up

Remove connector

2. MDF-61 Connector (Refiitting)

Hold the centre of connector Press centre of connector to insert Slide the slider to lock connector

- 5 -

3. The harness must not be crossed or twisted

4. Wire Dressing at connector

The harness must not bend more
than 45 degrees from the direction of
the connector base to avoid crossing
or twisting.

5. Wire distance at connector

The distance between each wire must
be wider than 4mm to ensure isola­tion from lamp voltage.

- 6 -

SPECIFICATIONS

Model name KDL-40S56/P56/P36xx KDL-37S56/P56xx KDL-32S56/P56/P36xx

System

Input/Output jacks

i

Power and others

- 7 -

PC Input Signal Reference Chart for PC IN

PC Input Signal Reference Chart for HDMI IN 1, 2 and 3

Signals Horizontal (Pixel)Vertical (Line)

Horizontal
frequency
(kHz)

Vertical
frequency (Hz)

Standard

Signals Horizontal (Pixel)Vertical (Line)

Horizontal
frequency
(kHz)

Vertical
frequency (Hz)

Standard

- 8 -

CONNECTORS

21 Pin Connector (SCART)

HDMI Connector

15 Pin D Sub Connector (PC)

Pin No AV-1 AV- 2 Signal Signal Level

1 • • Audio Output B

(Right)

Standard Level: 0.5V rms
Impedance: less than 1K



*

2 • • Audio Input B

(Right)

Standard Level: 0.5V rms
Impedance: more than 10K



*

3 • • Audio Output A

(Left)

Standard Level: 0.5V rms
Impedance: less than 1K



*

4 • • Ground (Audio)

5 • • Ground (Blue)

6 • • Audio Input A (Left) Standard Level: 0.5V rms

Impedance: more than 10K



*

7 • • Blue Input 0.7V +/- 3dB, 75



, positive

8 • • Function Select

(AV control)

High State (9.5~12V): AV mode
Low State (0~2V): TV mode
Impedance: more than 10K



*

Capacitance: less than 2nF

9 • • Ground (Green)

10 - • AV Link

11 • • Green Input 0.7V +/- 3dB, 75



positive

12 - • Open

13 • • Ground (Red)

14 • • Ground (Blanking)

15

• • Red Input 0.7V +/- 3dB, 75



positive

• • S signal Chroma Input 0.3V +/-3dB, 75



positive

16 • • Blanking Input

(Y Signal)

High State (1~3V)
Low State (0~0.4V)
Impedance: 75



17 • • Ground

(Video Output)

18 • • Ground

(Video Input)

19 • • Video Output 1V +/-3dB, positive sync 0.3V (-3+10dB)

20

• • Video Input 1V +/-3dB, positive sync 0.3V (-3+10dB)

• • Video Input Y
(S Signal)

1V +/-3dB, positive sync 0.3V (-3+10dB)

21

• • Common Ground
(Shield)

1

3

5

7

9

11

13

15

17

19

21

2

4

6

8

10

12

14

16

18

20

19 17 15 13 11 9 7 5 3 1

18 16 14 12 10 8 6 4 2

5 4 3 2 1

10 9 8 7 6

15 14 13 12 11

Pin No Signal Assignment Pin No Signal Assignment Pin No Signal Assignment

1 Red Output 6 Red Return 11 Monitor IDO in display

2 Green Output 7 Green Return (Ground) 12 DCC Serial Data

3 Blue Output 8 Blue Return (Ground) 13 Horizontal Sync

4 Unused 9 +5V DC 14 Vertical Sync

5 Ground 10 Sync Return (Ground) 15 DCC Serial Clock

Pin No Signal Assignment Pin No Signal Assignment

1 TMDS Data2+ 11 TDMS Clock Shield

2 TMDS Data2 Shield 12 TMDS Clock-

3 TMDS Data2- 13 CEC

4 TMDS Data1+ 14 Reserved (N.C. on device)

5 TMDS Data1 Shield 15 SCL

6 TMDS Data1- 16 SDA

7 TMDS Data0+ 17 DDC/CEC Ground

8 TMDS Data0 Shield 18 +5V power

9 TMDS Data0- 19 Hot Plug Detect

10 TMDS Clock+

- 9 -

EX2N SELF DIAGNOSTIC SOFTWARE

The identification of errors within the EX2N chassis is triggered in one of two ways :- 1: Busy or 2: Device failure to respond to IIC. In the
event of one of these situations arising the software will first try to release the bus if busy (Failure to do so will report with a continuous flash­ing LED) and then communicate with each device in turn to establish if a device is faulty. If a device is found to be faulty the relevant device
number will be displayed through the LED (Series of flashes which must be counted).

LED Error Codes and Descriptions

Number of LED

Flashes

Error Description Checked Action

02 Balancer error. In normal and factory mode. Goes into standby.
03 Power supply protection error. In normal and factory mode. Goes into standby.
04 Inverter error. In nor mal and factory mode. Goes into standby.
05 NVM error. In initialisation state. Adds error to error menu.
06 IIC error. In normal and factory mode. Adds error to error menu.
08 Audio error. In normal and factory mode. Adds error to error menu.
09 Tuner error. In initialisation state. Adds error to error menu.
18 COFDM error. In digital mode and initialisation state. Adds error to error menu.
19 USB error. In normal and factory mode. Adds error to error menu.
20 CI error. In normal and factory mode. Adds error to error menu.

Delete “Error History” in Service Menu

1. Confirm latest software version is fitted.

2. Enter Factory Mode : TT19

3. Set Shipping Condition : TT08

4. Confirm Error History deleted

Ver 4.0

- 10 -

2-1. Rear Cover Removal (Step 1)

SECTION 2 DISASSEMBLY

2-2. Rear Cover Removal (Step 2)

2-3. Stand Assy Removal

2-4. Under Cover Removal

To remove the ‘Under Cover’ first remove the Rear Cover
(See Sec 2-2-1 & 2-2-2) and then remove the Stand Assy
(See Sec 2-2-3). Then remove the 1 screw circled and gently
pull the ‘Under Cover’ away from the back of the TV set.

=>

1

=>

=>

1

=>

1

=>

1

=>

1

=>

1

=>

1

=>

Remove the rear cover fixing screws indicated and refer to
Sec 2-2-2.

Screw Part number(s) and Description(s)

1) 2-580-640-01 SCREW, +BVTP2 4X16 (32/37” = 12pcs, 40” = 11pcs)

2) 7-685-648-79 SCREW, +BVTP 3X12 (32/37/40” = 2pcs)

3) 2-580-602-01 SCREW, +PSW M4X12 (32” = 2pcs, 37/40” = 4pcs)

Remove the 4 stand fixing screws indicated and lift the TV
set up and away from the ‘Stand Assy’.

Screw Part number(s) and Description(s)

2-580-608-01 SCREW, +PSW M5X16

1

1

1

=>

=>

=>

=>

=>

=>

2

1

=>

=>

3

=>

3

=>

1

=>

3

=>

3

=>

2

Screw

Screw Part number(s) and Description(s)

2-580-602-01 SCREW, +PSW M4X12

To remove the ‘Rear Cover’ lift the ‘Rear Cover’ up slightly
from the bottom and then gently push the ‘Switch Unit’ in
by the side controls whilst lifting the ‘Rear Cover’ up fully
from the bottom.

Push point.

- 11 -

2-8. B Board Removal

To remove the ‘B’ board disconnect all the connectors and
then remove the 9 screws circled and ease the board gently
away from the back of the TV set.

Screws Screws

Screw Part number(s) and Description(s)

2-580-629-01 SCREW, +BVST 3X8

2-6. Loudspeaker Removal

To remove the ‘Loudspeaker’ first disconnect the speaker
cables and then remove the screws circled (32/37” = 4 pcs,
40” = 2 pcs).

Screw Part number(s) and Description(s)

2-580-639-01 SCREW, +BVTP2 4X12 (37 inches)
2-580-654-01 SCREW, +PWTP2 4X16 (40 inches)

Screws

2-7. Side Jack Bracket Removal

Release the 2 clips indicated and gently pull the bracket away
from the ‘B’ board in the direction of the arrow.

Clip

Clip

32 & 37 inches

Screws

40 inches

2-5. Switch Unit Removal

2WUJVJKURQUKVKQPVQTGOQXG
DWVVQPOQTGGCUKN[

To remove the ‘Switch Unit’ lift the bottom of the bracket
towards the TV set. Push the top of the bracket in the shaded
area in the photograph. The bracket will then release from its
boss and can be removed from the TV set.

- 12 -

2-10. G2 Board Removal (32 inches)

To remove the ‘G2’ board disconnect all the connectors
and then remove the 4 screws circled and ease the board
gently away from the back of the TV set.

Screw Part number(s) and Description(s)

2-580-629-01 SCREW, +BVST 3X8

Screws

2-12. IP1F Board Removal (40 inches)

Screws

Screw Part number(s) and Description(s)

2-580-629-01 SCREW, +BVST 3X8

To remove the ‘IP1F’ board disconnect all the connectors and
then remove the 4 screws circled and ease the board gently
away from the back of the TV set.

Note:

Refer to page 4 - Hirose MDF61 connector.

2-11. G4 Board Removal (37 inches)

To remove the ‘G4’ board disconnect all the connectors
and then remove the 4 screws circled and ease the board
gently away from the back of the TV set.

Screw Part number(s) and Description(s)

2-580-629-01 SCREW, +BVST 3X8

Screws

2-9. H1 Board Removal

Clip

To remove the ‘H1’ board first remove the ‘Rear Cover’
(See Sec 2-2-1 & 2-2-2) and then remove the ‘Loudspeaker’
(See Sec 2-2-6). The ‘H1’ board can then be removed by
disconnecting the connector indicated and releasing the clip
circled.

Connector

- 13 -

3-1. How to enter the Service Mode

Service adjustments to this model can be performed using the
supplied Remote Commander RM-ED017.

SECTION 3 SERVICE MENUS

3. The following menu appears on the screen (See Pic.1).

4. Move to the corresponding adjustment item using the
‘ ’ or ‘ ’ arrow buttons on the Remote Commander.

5. Press the ‘ ’ arrow button to enter into the required menu
item.

6. Adjust the data value using the ‘ ’ or ‘ ’ arrow buttons on
on the Remote Commander.

7. To go back at any time press the ‘ ’ button on the Remote
Commander.

8.

Ensure you return to the top level menu, shown above in
Pic 1, and press the Green button on the Remote
Commander to Store all the adjustments.

9. Press the Red button or ‘Menu’ button on the Remote
Commander to quit the Service Mode when all adjustments
have been completed.

1. Turn on the power to the TV set.

2. Press the following sequence of buttons on the Remote
Commander.

Pic.1

3-2. Service Menu Structure

The following descriptions show the items that can be
viewed and/or adjusted using the Service Menu.

Pic.2

Pic.3



After carrying out the service adjustments, to prevent the
customer accessing the ‘Service Menu’ switch the TV set
OFF and then ON again.

3-2-1. Service General Menu

The following menu appears on the screen when you enter
the ‘Service General Menu’ (See Pic.2). This menu allows
you to view the product information, set the TV into Aging
Mode and perform Software Upgrade to the TV set.

3-2-2. White Balance Adjustment

The following menu appears on the screen when you enter
the ‘White Balance Adjustment’ menu (See Pic.3). This menu
allows adjustment of the TV picture levels. These adjustments
are set during manufacture and should not normally require
further adjustment.

I/

TV

i+

5

+

(ON SCREEN (DIGIT 5) (VOLUME +) (TV)
DISPLAY)

(TV STANDBY)

(ON SCREEN
DISPLAY)

(DIGIT 5) (VOLUME +)

- 14 -

The following menu appears on the screen when you enter
the ‘OSD Service Menu’ (See Pic.4). This menu allows
viewing and adjustment of the AGC and viewing of the
Sound Status.

3-2-3. OSD Service Menu

Pic.4

The following menu appears on the screen when you enter
the ‘Country Selection’ menu (See Pic.5). Using this menu
the destination country of the TV can be set.

3-2-4. Country Selection

Pic.5

3-2-5. Factory Reset

Pic.6

Selection of ‘Factory Reset’ (See Pic.6) allows the TV to be
reset to factory shipping condition. This will restore all
settings to those which were contained in the TV on first
shipment.

- 15 -

The TT modes described below are available by selecting the two
relevant digits. You can exit the ‘TT Mode’ by entering 00, by
pressing the ‘Analog’ or the ‘Digital’ button, by switching the TV
set into Stand-by mode, or by Powering the TV set off.

3-3. TT MODE

00

'TT' mode off

03

Set volume to 35%

04

Set volume to 50%

05

Set volume to 65%

06

Set volume to 80%

07

Ageing mode on

08

Shipping Condition

09

WB Levels Check

19

Factory toggle mode (ON/OFF)

27

CBA mode toggle (ON/OFF)

31

ECS mode toggle (ON/OFF)

32

Set BCN channels preset

36

Full HD HDMI EDID Write

37

WXGA HDMI EDID Write

41

Re-initialise NVM

43

Select Dual Sound "A"

44

Select Dual Sound "B"

45

Select Dual Sound "Mono"

46

Select Dual Sound "Stereo"

48

Set NVM as non-virgin

49

Set NVM as virgin

59

Stop Main IIC Micro

69

WXGA /FHD Panel Selection

75

Set Centred Balance

76

Set Volume to Max

77

Set Volume to Min

78

Set Balance Full Left

79

Set Balance Full Right

81

Digital BER Display

84

TS CI Path Through

87

Front Panel Button Test

89

LED Test

92

TS CI Path Through With Reed Solomon Off

Note :



To place the Remote Commander in ‘TT Mode’ press the

following buttons together for approximately five seconds.



To use the Remote Commander in ‘TT Mode’ press the

‘Red’ text button on the Remote Commander twice.

TT will then appear in the bottom right hand corner of the TV.

i+

5

+

(ON SCREEN (DIGIT 5) (VOLUME +) (TV)
DISPLAY)

(ON SCREEN
DISPLAY)

(DIGIT 5) (VOLUME +)

(EXTERNAL INPUT) (DIGIT 5) (VOLUME +)



To take the Remote Commander out of ‘TT Mode’ press the

same buttons together for approximately five seconds.

TT Button

- 16 -

4-1. BLOCK DIAGRAM

CA module

Main Processor

AV Switch

Color Decoder

3D Comb

PC/HD ADC

Audio Decoder

MPEG2 Decoder

4-Field MADI

Scaler

Noise Reduction

HDMI/DVI with HDCP

CI

Dual LVDS

USB2.0

Full Audio Process

10 bit Video Process

SCART 1 SCART 2

D

V

B-T

D

E

M

O

D

U

L

A

T

O

R

HDMI 2

Component

PC

TUNER

HDMI 1

HDMI 3

IF

TS

Line Out

Headphones

USB

PANEL

LVDS

PC/DVI

audio

SCART1_RGB

SCART1_CVBS_OUT

SCART1_LR_IN

SCART1_CVBS

SCART2_CVBS

SCART2_RGB

SCART2_CVBS_OUT

SCART2_LR_IN

SCART1_LR_OUT

YPbPr

LR_IN

HDMI

SWITCH

HDMI

CVBS_LR

RGB/HV

LAST RF

OUT

MON

OUT

Audio

Amp

L Speaker

R Speaker

CI connector

TS

CONTROL

DDR2 DDR2

NAND

FLASH

SPI

KEYBOARD

IR/LED BOARD

CVBS TUNER

A

U

D

I

O S

W

I

T

C

H

+

A

U

D

I

O B

U

F

F

E

R

SCART2_LR_OUT

NVM

- 17 -

5-2. CIRCUIT BOARD LOCATION

5-3. SCHEMATIC DIAGRAMS AND
PRINTED WIRING BOARDS

Note :

•All capacitors are in µF unless otherwise noted.

•pF : µµF 50WV or less are not indicated except for
electrolytic types.

•Indication of resistance, which does not have one for
rating electrical power, is as follows.

Pitch : 5mm
Electrical power rating : 1/4W

•Chip resistors are 1/10W

• All resistors are in ohms.
k = 1000 ohms, M = 1000,000 ohms

• : nonflammable resistor.

• : fusible resistor.

• : internal component.

• : panel designation or adjustment for repair.

• All variable and adjustable resistors have
characteristic curve B, unless otherwise noted.

•All voltages are in Volts.

•Readings are taken with a 10Mohm digital mutimeter.

•Readings are taken with a color bar input signal.

•Voltage variations may be noted due to normal production
tolerences.

• : B + bus.

• : B - bus.

• : RF signal path.

• : earth - ground.

• : earth - chassis.

Reference Information

RESISTOR RN

: METAL FILM

RC

: SOLID

FPRD

: NON FLAMMABLE CARBON

FUSE

: NON FLAMMABLE FUSIBLE

RS

: NON FLAMMABLE METAL OXIDE

RB

: NON FLAMMABLE CEMENT

RW

: NON FLAMMABLE WIREWOUND
: ADJUSTMENT RESISTOR

COIL LF-8L

: MICRO INDUCTOR

CAPACITOR TA

: TANTALUM

PS

: STYROL

PP

: POLYPROPYLENE

PT

: MYLAR

MPS

: METALIZED POLYESTER

MPP

: METALIZED POLYPROPYLENE

ALB

: BIPOLAR

ALT

: HIGH TEMPERATURE

ALR

: HIGH RIPPLE

Les composants identifiés par une trame et
par une marque sont d'une importance
critique pour la sécurité. Ne les remplacer
que par des pièces de numéro spécifié.
specified.

Note :

The components identified by shading
and marked are critical for safety.
Replace only with the part numbers
specified in the parts list.

Note :

CVM Board

A Board

S1 Board

VM

C

H

D1

A

J

A2

N

D

A1

D2

C

A

4-2. CIRCUIT BOARD LOCATION

4-3. SCHEMATIC DIAGRAMS AND
PRINTED WIRING BOARDS

Note :

The components identified by mark

contain

confidential information.

Strictly follow the instructions whenever the

components are repaired and/or replaced.

NOTE: The G2 and G4 boards are not Sony boards so their schematic diagrams and
printed wiring boards are not shown in this Service Manual.
Schematic diagrams are for reference only. Please refer to the electrical parts
list for the correct value and part number of components.

G2 / G4 / IP1F

B

H1