Sony KDL-32EX400 Service Manual
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Sony KDL-32EX400 Service Manual

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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
ORIGINAL MANUAL ISSUE DATE: 12/2009
Version
Version
Date
Date
1.0
12/2009
2.0
01/2010
3.0
04/2010
4.0
08/2010
5.0
09/2010
6.0
10/2010
7.0
11/2010
8.0
08/2011
Subject
Subject
No revisions or updates are applicable at this time.
Change Destination of General Area and replace Block Diagram.
Add Base, Cover, Neck Information for KDL-40EX400
Add Support, Panel information
Change Link of Disassembly Movie
Add Note for Disassembly Movie download
Add Troubleshooting Reference information
Part Information Charge:
i) Delete Power Supply Cord
ii) Revised Old Power Supply Cord destinations
iii) Add New Power Supply Cord and destinations
iii) Add New Power Supply Cord and destinations
iv) Plug Conversion Adaptor destination correction
v) Instruction Manual P/N Suffix Change and Destination Correction
(Pg 45), (Pg 47).
(Page 46)
(Page 38), (Page 41)
(Page 13)
( Page 13 )
( Page 48 )
(Pg 39), (Pg
42).
((Pg 53) (Pg 55).
(Pg 54), (Pg 55)
(Pg 54) (Pg 55)
(Pg 44), (Pg
AZ1-L
Segment: 3a-2
LCD Digital Color TV
46).
CHASSIS

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  • Page 1 HISTORY INFORMATION FOR THE FOLLOWING MANUAL: SERVICE MANUAL AZ1-L ORIGINAL MANUAL ISSUE DATE: 12/2009 CHASSIS Segment: 3a-2 Version Version Date Date Subject Subject 12/2009 No revisions or updates are applicable at this time. 01/2010 Change Destination of General Area and replace Block Diagram. 04/2010 Add Base, Cover, Neck Information for KDL-40EX400 (Page 46)
  • Page 2 SERVICE MANUAL AZ1-L CHASSIS Segment: 3a-2 LCD Digital Color TV...

  • Page 3: Model List

    MODEL LIST MODEL COLOR COMMANDER DEST. MODEL COLOR COMMANDER DEST. KDL-32EX400 Black RM-GD015 Hong Kong KDL-32EX400 Blue RM-GD015 Hong Kong KDL-32EX400 RM-GD015 Hong Kong KDL-32EX400 Black RM-CD009 Taiwan KDL-32EX400 Blue RM-CD009 Taiwan KDL-32EX400 RM-CD009 Taiwan KDL-32EX400 Black RM-GD015 Australia, New...

  • Page 4: Warnings And Cautions

    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.
  • Page 5 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.

  • Page 6: Use Caution When Handling The Lcd Panel

    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.

  • Page 7: Safety Check-Out

    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.
  • Page 8 SAFETY CHECK-OUT 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.

  • Page 9: Self Diagnosis Function

    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.

  • Page 10: Display Of Standby Led Flash Count

    SELF DIAGNOSIS FUNCTION DISPLAY OF STANDBY LED FLASH COUNT 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)
  • Page 11 SELF DIAGNOSIS FUNCTION [SELF DIAGNOSTIC SCREEN DISPLAY] <1> NEXT PAGE-> SELF CHECK(1) 002 MAIN P 0501210811 0412311234 0311111825 00 003 DC_ALERT1 0000000000 0000000000 0000000000 00 004 DC_ALERT2 0000000000 0000000000 0000000000 00 006 BL 0000000000 0000000000 0000000000 00 007 TEMP 0000000000 0000000000 0000000000 00 009 FAN 0000000000 0000000000 0000000000 00 Error count (00-99)
  • Page 12 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.

  • Page 13: Sec 1. Disassembly

    SEC 1. DISASSEMBLY 1-1. MOVIE LIST 32EX400 32EX400 KDL-32EX400 40EX400 40EX400 KDL-40EX400 Note: 1. This link does not work from outside Sony network. 2. The Disassembly movie can be downloaded from ORISS Service Manuals site. KDL-32/40EX400(HK/WB/GA)

  • Page 14: Sec 2. Adjustment

    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”...
  • Page 15 ADJUSTMENT 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>...
  • Page 16 ADJUSTMENT 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”.

  • Page 17: Save Changing Data

    ADJUSTMENT 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.

  • Page 18: Change Data

    ADJUSTMENT CHANGE DATA Note: “Digital” service mode don’t have to Save. (except “002 MODEL” category) 1) Change Data of “Digital” service mode. (except “003 DIG_SRV_MODE” category) DIGITAL SERVICE a. Press “2 / 5” on remote to select (up / down) category. 004 TUNER b.
  • Page 19 ADJUSTMENT 3) Write data for “Digital” service mode. ( “002 MODEL” category) Note: This procedure operation, when replaced the B board. DIGITAL SERVICE Note: Do not write a wrong segment or destination information in Product ID. 002 MODEL When the wrong setting is written, TV may not operate. 000 SEG 01 : 2a-3 Write...

  • Page 20: Set To Shipping Condition

    ADJUSTMENT SET TO SHIPPING CONDITION How to do shipping condition. a. Move to “Digital” service mode. Press “8” on remote. It shows green “SERVICE” changes to green “RST-”. Press “mute” on remote. Added green “EXE” after green “RST-” . d. Press “0” or “enter” on remote. Green “EXE-RST” changes to red “EXE-RST”. It indicate writing is processing. After a while, red “EXE-RST”...

  • Page 21: Sec 3. Trouble Shooting

    SEC 3. TROUBLE SHOOTING 3-1. TRIAGE CHART Note: Power board is different in name every inch. Therefore this section displays difference point in "*". Symptoms - Shutdown. Power LED Video - missing or distorted Remote Network Audio blinking red diagnostics sequences Power Reference No Green...

  • Page 22: Troubleshooting

    TROUBLE SHOOTING 3-2. FLOW CHART START Does the Power Led Is the network stay on when the No Power connection OK? Can’t connect network TV is switched on ? Is the Standby Led blink ? Standby LED Blink Is the Picture and Sound OK ? No Picture / No Sound Do the buttons...
  • Page 23 TROUBLE SHOOTING 3-3. NO POWER No Power Check STBY 3.3V Replace at 1 pin of CN3800 Between G* Board to G* Board on the BAL Board BAL Board Harness Harness BAL Board KDL-32/40EX400(HK/WB/GA)
  • Page 24 TROUBLE SHOOTING 3-4. STANDBY LED BLINK 1) 2 times blinkings (Main Power Error) 2 times Blinkings Check REG12V at 12V NG Replace pins 6/7 of Between G* Board to G* Board CN3800 on BAL Board Harness the BAL Board 12V OK BAL Board Harness KDL-32/40EX400(HK/WB/GA)
  • Page 25 TROUBLE SHOOTING 2) 3 times blinkings (DC Alert, Audio Error and Communication Error) AUDIO 3 times Blinkings Check +12.5V DC_ALERT at pin 2 of G* Board CN3800 on the BAL Board Check D+3.3V at F3700,IC3700,etc JL3715 or JL3716 (BAL Board) on the BAL Board Check +12.5V_AU1 F4200,IC4200,etc...
  • Page 26 TROUBLE SHOOTING 3) 4 times blinkings (Balancer Error) 4 times Blinkings Between 0.84V to 2.65V Check PANEL_FAIL at PANEL JL2565 (Balancer) on the BAL Board BAL Board KDL-32/40EX400(HK/WB/GA)
  • Page 27 TROUBLE SHOOTING 4) 5 times blinkings (T-con Error) 5 times Blinkings Check PANEL_VCC Panel (T-con) at JL3806 G* Board BAL Board change on the BAL Board Panel (T-con) LVDS Harness LVDS Harness check KDL-32/40EX400(HK/WB/GA)
  • Page 28 TROUBLE SHOOTING 5) 6 times blinkings (Backlight Error) 6) 7 times blinkings (Temperature Error) 7 times Blinkings 6 times Blinkings Under 2.65V Check Setting circumstance PANEL_FAIL at is OK? Set to another BAL Board JL2565 Temperature, Location, etc. on the BAL Board Ventilation, etc.
  • Page 29 TROUBLE SHOOTING 3-5. NO PICTURE No Picture about 12V BL_ON:H PANEL_VCC Check Press HOME Key Replace LCD Panel At JL3806 on the BL_ON at JL2566 XMB (Menu) displayed? the LVDS Harness (T-con) BAL Board on the BAL Board BL_ON: not H BAL Board Check Harness Harness...
  • Page 30 TROUBLE SHOOTING 3-6. NO SOUND No Sound “Audio System” Check the Change to “Speakers setting” “TV Speaker” “TV Speakers” Check the Speaker Replace BAL Board Harness the BAL Board Speaker Harness Speaker KDL-32/40EX400(HK/WB/GA)
  • Page 31 TROUBLE SHOOTING 3-7. TV COMMANDER BOTTONS MALFUNCTION 1) TV button malfunction Button malfunction on the TV B* to Switch Unit Switch Unit Switch Unit change harness check Harness BAL Board KDL-32/40EX400(HK/WB/GA)
  • Page 32 TROUBLE SHOOTING 2) IR remote commander malfunction TV isn’t controlled by remote commander Green LED blinks Green LED light at power indicator Mechanical at power indicator when using commander (ex. bezel) near sensor’s window Check the Harness between the BAL Board Sensor is broken and the HLR Board Exchange the Harness...
  • Page 33 TROUBLE SHOOTING 3-8. NETWORK MALFUNCTION 1) Wired Network malfunction 2) USB Wireless Network malfunction Wired Network Wireless Network on the TV on the TV Error Message appear Connection result BAL Board when the Wireless USB Dongle Cable Connection Network is selected? Is the radio field Connection result Ether net cable...

  • Page 34: Sec 4. Diagrams

    SEC 4. DIAGRAMS 4-1. BLOCK DIAGRAM A_RF_CV Tcon Board ASW_IN5_L/R Tuner D_IF LVDS VIDEO TITAN SCL0/SDA0 DiSEqC LVDS DIMMER_CTRL AEP only CI_ADD/DAT TCON CI_CTRL VSW_RF_Digital_CV VSW_SC1-V VSW_SCART1_OUT M_SCART1 AEP : SCART x 2 Video ASW_IN0_L/R M_MAIN_CVBS : D Terminal x 2 ASW_SCART1_LR GA : Composite x 1 VSW_SC2-V...

  • Page 35: Circuit Boards Location

    DIAGRAMS 4-2. CIRCUIT BOARDS LOCATION (1) KDL-32EX400 T-CON G2LE Board BAL Board Inverter Switch Unit Speaker (L) Speaker (R) HLR Board KDL-32/40EX400(HK/WB/GA)
  • Page 36 DIAGRAMS (2) KDL-40EX400 T-CON G2HE Board Inverter BAL Board Switch Unit Speaker (L) Speaker (R) HLR Board KDL-32/40EX400(HK/WB/GA)

  • Page 37: Sec 5. Exploded Views

    SEC 5. EXPLODED VIEWS • Items with no part number and no description are not stocked because they are seldom required for roution service. • The construction parts of an assembled part are indicated with a collation number in the remark colum. •...

  • Page 38: Exploded Views

    EXPLODED VIEWS 5-1. KDL-32EX400 REF.NO. PART NO. DESCRIPTION REMARK 4-167-326-01 BRACKET, VESA(S) 5-1-1. CHASSIS-1 4-115-101-41 COVER, ECS 4-157-976-01 COVER, UNDER(32) 4-169-309-01 COVER, UNDER(32) X-2546-977-1 REAR COVER (32) ASSY (BLACK , BLUE , RED ( AUSTRALIA, NEW ZEALAND, SINGAPORE , SOUTH AFRICA, GAA))
  • Page 39 EXPLODED VIEWS 5-1. KDL-32EX400 REF.NO. PART NO. DESCRIPTION REMARK A-1761-894-A BAL COMPL (SERVICE) (BLACK ,BLUE , RED ( AUSTRALIA, 5-1-2. CHASSIS-2 N ZEALAND, SINGAPORE, S AFRICA,GAA)) A-1761-436-A BAL COMPL (SERVICE) (BLACK(TAIWAN),BLUE(TAIWAN),RED(TAI WAN)) A-1760-283-A BAL COMPL (SERVICE) (BLACK(HONG KONG),BLUE(HONG KONG),RED(HONG KONG))
  • Page 40 EXPLODED VIEWS 5-1. KDL-32EX400 5-1-3. SCREWS PART No. DESCRIPTION 2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3 2-580-595-01 SCREW, +PSW M3X12 7-685-648-79 SCREW +BVTP 3X12 TYPE2 IT-3 2-580-608-01 SCREW, +PSW M5X16 2-580-592-01 SCREW, +PSW M3X8 4-159-298-01 SCREW, +PSW M4X10 KDL-32/40EX400(HK/WB/GA)
  • Page 41 EXPLODED VIEWS 5-2. KDL-40EX400 REF.NO. PART NO. DESCRIPTION REMARK 4-167-326-01 BRACKET, VESA (S) 5-2-1. CHASSIS-1 4-115-101-41 COVER, ECS 4-157-977-01 COVER, UNDER (37) 4-169-308-01 COVER, UNDER (37) X-2546-557-1 REAR COVER (40) ASSY (TAIWAN,HONG KONG) X-2546-981-1 REAR COVER (40) ASSY (N. ZEALAND, SINGAPORE, S. AFRICA) 1-487-733-11 SWITCH UNIT (TAIWAN)
  • Page 42 EXPLODED VIEWS (No 9(Power Supply Cord) please refer to : 5-2. KDL-40EX400 (Pg 55) for old part no. and revised destination details. REF.NO. PART NO. DESCRIPTION REMARK (Pg 55) for the new part no. and destination details. A-1761-436-A BAL COMPL (SERVICE) 5-2-2.
  • Page 43 EXPLODED VIEWS 5-2. KDL-40EX400 5-2-3. SCREWS PART No. DESCRIPTION 2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3 2-580-595-01 SCREW, +PSW M3X12 7-685-648-79 SCREW +BVTP 3X12 TYPE2 IT-3 2-580-608-01 SCREW, +PSW M5X16 2-580-592-01 SCREW, +PSW M3X8 4-159-298-01 SCREW, +PSW M4X10 KDL-32/40EX400(HK/WB/GA)
  • Page 44 EXPLODED VIEWS 5 3 OTHER PART 5-3. OTHER PART (KDL-32EX400) 5-3-2. PACKING 5-3-1. MISCELLANEOUS PART NO. PART NO. DESCRIPTION DESCRIPTION REMARK REMARK PART NO PART NO. DESCRIPTION DESCRIPTION REMARK REMARK X-2342-530-2 BAG ASSY, FALL LOCK BELT CONNECTOR (BLACK , BLUE, RED ( AUSTRALIA ,...

  • Page 45: Remote Commander

    EXPLODED VIEWS 5-3-4. REMOTE COMMANDER 5-3-3. ACCESSORIES PART NO. DESCRIPTION REMARK PART NO. DESCRIPTION REMARK 1-487-706-11 REMOTE COMMANDER (RM-GD015) 4-174-286-22 MANUAL, INSTRUCTION (HONG KONG, AUSTRALIA, N. ZEALAND (BLACK, BLUE, RED SINGAPORE, S. AFRICA, GAA) ( AUSTRALIA NEW ZEALAND ( AUSTRALIA, NEW ZEALAND, 1-487-708-11 REMOTE COMMANDER (RM-CD009) SINGAPORE, SOUTH AFRICA, GAA))
  • Page 46 EXPLODED VIEWS (KDL-40EX400) 5-3-5. MISCELLANEOUS 5-3-6. PACKING PART NO. DESCRIPTION REMARK PART NO. DESCRIPTION REMARK X-2342-530-3 BAG ASSY, FALL LOCK BELT CONNECTORS CONNECTORS (TAIWAN) * 1-910-060-16 CONNECTOR ASSY 14P (CN6402-BALANCER(1)) X-2342-530-2 BAG ASSY, FALL LOCK BELT (HONG KONG, N.ZEALAND, * 1-910-060-15 CONNECTOR ASSY 15P SINGAPORE, SOUTH AFRICA)
  • Page 47 EXPLODED VIEWS 5-3-8. REMOTE COMMANDER 5-3-7. ACCESSORIES PART NO. DESCRIPTION REMARK PART NO. DESCRIPTION REMARK 1-487-708-11 REMOTE COMMANDER (RM-CD009) 4-175-658-14 MANUAL, INSTRUCTION (TAIWAN) (TAIWAN) 1-487-706-11 REMOTE COMMANDER (RM-GD015) 4-174-669-12 MANUAL, INSTRUCTION ( HONG KONG, AUSTRALIA, N. ZEALAND, ( HONG KONG, AUSTRALIA, N. ZEALAND, (HONG KONG) (HONG KONG) SINGAPORE, S.
  • Page 48 Supplement Supplement AZ1 L AZ1-L CHASSIS CHASSIS SUBJECT : Troubleshooti ing Reference for BAL board Sec 3 : Tr roubleshooting bl h ti 3-9 Parts Loc cation Reference KDL-32/40EX400(HK/WB/GA)
  • Page 49 JL3715 & JL3716 JL3715 & JL3716 CN3800 Location CN3800 on board – at A side Location JL3715 on board – at A side Location JL3716 on board – at B side CN3800 JL3715 KDL-32/40EX400(HK/WB/GA)
  • Page 50 F4200 JL3731 & JL3732 Location JL3731 on board – at A side Location F4200 on board – at B side Location JL3732 on board – at B side F4200 JL3732 JL3732 KDL-32/40EX400(HK/WB/GA)
  • Page 51 IC5000 JL2565 Location on board – at B side Location IC5000 on board – at A side Alternative location on CN2561 pin 3 : BL_ERR Alternative location Pin 29 of for JL2565 IC5000 KDL-32/40EX400(HK/WB/GA)
  • Page 52 JL3806 JL2566 JL2566 Location on board – at B side Location on board – at B side Alternative location on CN3800 pin 8 : T-Con VCC Alternative location on CN2561 pin 4 : BL_ON Alternative Alternative Alternative location location for JL2566 for JL3806 KDL-32/40EX400(HK/WB/GA)
  • Page 53 CORRECTION EXPLODED VIEWS * Old part no and revised destinations details for Power Supply Cord 5-1. KDL-32EX400 5-1-2. CHASSIS-2 (See Pg 39) Model 32EX400/B 32EX400/L 32EX400/R 32EX400/B 32EX400/L 32EX400/R Colour Black Blue Black Blue Destination Hong Kong Taiwan Spec Code.
  • Page 54 EXPLODED VIEWS * New part no and destinations details for Power Supply Cord 5-1. KDL-32EX400 5-1-2. CHASSIS-2 (See Pg 39) Model 32EX400/B 32EX400/L 32EX400/R 32EX400/B 32EX400/L 32EX400/R Colour Bl k Black Blue Bl k Black Blue Destination Hong Kong Taiwan Spec Code.
  • Page 55 EXPLODED VIEWS * Old part no and revised destinations details for Power Supply Cord 5 2 KDL 40EX400 5-2. KDL-40EX400 5-2-2. CHASSIS-2 (See Pg 42) Model 40EX400 40EX400 40EX400 Colour Black Black Black Black Black Destination Spec Code. New Zealand South Africa Destination Area Hong Kong...
  • Page 56 English Sony Corporation 2009LL08-Data Sony EMCS (Malaysia) Sdn. Bhd. Made in Japan 9-888-262-08 TVEG © 2011.08 KDL-32/40EX400(HK/WB/GA)

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