SON KDL-40EX645 Service Training Manual
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SON KDL-40EX645 Service Training Manual

Lcd digital color tv
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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE / TRAINING MANUAL
O R I G I N A L M A N U A L I S S U E D A T E : 8 / 2 0 1 2
V e r s i o n
D a t e
S u b j e c t
1.0
8/12/2012
Original Manual Release Date.
2.0
4/29/2013
Updated part number information on Section 4 - Dissasembly/Part Number Information.
AZ3FK
Chassis
Segment: P-2
LCD Digital Color TV
Self Diagnosis
Supported model
9-883-899-02

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Summary of Contents for SON KDL-40EX645

  • Page 1 Self Diagnosis Supported model HISTORY INFORMATION FOR THE FOLLOWING MANUAL: SERVICE / TRAINING MANUAL AZ3FK Chassis Segment: P-2 O R I G I N A L M A N U A L I S S U E D A T E : 8 / 2 0 1 2 V e r s i o n D a t e S u b j e c t...
  • Page 2 Self Diagnosis Supported model SERVICE / TRAINING MANUAL AZ3FK Chassis Segment: P-2 LCD Digital Color TV KDL-50EX645 9-883-899-02...
  • Page 3 MODEL LIST MODEL COMMANDER DESTINATION MODEL COMMANDER DESTINATION K D L - 4 0 E X 6 4 5 RM-YD075 K D L - 5 0 E X 6 4 5 RM-YD075 US/CND K D L - 4 6 E X 6 4 1 RM-YD075 K D L - 5 5 E X 6 4 5 RM-YD075...

  • Page 4: Table Of Contents

    LCD Panel Assembly ................6 Cleaning the LCD Panel .................24 Section 2 - Troubleshooting ................7 Connectors ....................25 Overview .......................7 KDL-40EX645 Only ................25 Updating the Software ................7 KDL-46EX641/46EX645 Only ..............25 Self Diagnosis Function .................7 KDL-50EX645 Only ................26 Standby LED Blink Count .................7 KDL-55EX645 Only ................26...
  • Page 5 Selecting the Panel ID Code ..............34 Adding the Serial Number ...............35 Adding the Model Name .................36 Completing Service Requirements When Replacing the LCD Panel ..38 Verifying the Panel ID Code ..............38 Resetting Panel Operation Time .............39 Appendix A: Encryption Key Components ..........A-1 KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 6: Cautions And Warnings

    For safety reasons, component level repair of the Power Supply Boards ATTENTION!! and/or the Inverter Boards is prohibited. 3RXU GHV UDLVRQV GH VpFXULWp ,QWHUGLUH GH UpSDUHU RX UHPSODFHU OHV composantes dans les blocs d’alimentation et/ou sur les modules d’inverseur. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...
  • Page 7 Damaging the wires may cause a short. Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS). 10. During the repair, DO NOT leave the Power On for more than 1 hour while the TV is face down on a cloth. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...
  • Page 8 Using any of these harsh cleaners may result in permanent damage to the screen. Do Not spray water or detergent directly onto the TV screen. If liquid drips into the bottom of the screen it may cause a failure. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...
  • Page 9 0.5 mA (500 microamperes). Leakage current can be measured by any one of three methods. A commercial leakage tester. Follow the manufacturers’ instructions provided with the tester. A battery-operated AC milliammeter. Figure B. Checking for earth ground. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 10: Section 1 - Features And Overview

    Sony Bravia® LCD televisions. This manual covers the following models: ATSC (8VSB terrestrial): ATSC compliant 8VSB QAM on cable: ANSI/SCTE 07 2000 (Does not include Cable CARD functionality) KDL-40EX645 Channel coverage Analog terrestrial: 2 - 69 / Digital terrestrial: 2 - 69...
  • Page 11 Screws (7) Optional accessories Connecting cables / Support Belt Kit / Wall-Mount Bracket: SU-WL500 • Optional accessories availability depends on its stock. • Design and speci cations are subject to change without notice. * Dimensions and mass are approximate values. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 12: Chassis Overview

    TCON Board and LD Board (50” model only). NOTE: For connector part number information, refer to “Connectors” on page 25. For Wire Dressing information, refer to “Wire Dressing” on page GL5A SWITCH UNIT TCON WIRELESS LAN CARD BOARD LAYOUT FOR KDL-40EX645 ONLY KDL-40EX645/46EX641/46EX645/50EX645/55EX645...
  • Page 13 SECTION 1 - FEATURES AND OVERVIEW GL5B SWITCH GE55 UNIT SWITCH UNIT TCON TCON WIRELESS LAN CARD WIRELESS LAN CARD BOARD LAYOUT FOR KDL-46EX641/46EX645 ONLY BOARD LAYOUT FOR KDL-55EX645 ONLY LD BOARD SWITCH GE50 UNIT TCON WIRELESS LAN CARD BOARD LAYOUT FOR KDL-50EX645 ONLY KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 14: Overall Circuit Description

    SWITCH UNIT HDMI4 input. Each HDMI input contains a dedicated EDI NVM (not shown) to provide display information data to any device connected via the HDMI This board contains the power, channel and volume up/down and menu inputs. buttons. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 15: Wireless Lan Card

    The TCON Board communicates between the LCD Panel and the microprocessor on the Main Board. NOTE: The TCON Board is not available as a replacement part for all models. To determine if the TCON Board is available as a replacement part, refer to the LCD Panels Manual. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 16: Section 2 - Troubleshooting

    LED OFF 0.3 sec. 3 sec. TV turns on and off by itself ” Loss of color ” Internet connectivity ” Certain features not working correctly ” Standby LED LED DISPLAY & BLINK COUNT SKRWR RU YLGHR ¿OH YLHZLQJ KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 17: Viewing The Self Check Diagnosis History

    The 5X blink protection mode indicates a communications error with the timing control circuits (TCON Board) has occurred. If the TCON Board is available for replacement, replace it, if not, replace the LCD Panel Assembly. In rare cases a loose or defective LVDS cable could also be the cause. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 18: Triage Chart

    REPLACEMENT PARTS BASED ON SERIAL NUMBER. z***Backlight Does NOT Turn ON before TV Shuts Off x 6HFRQGDU\ &RPSRQHQW To access the most recent version of the Triage documents for the models listed in this manual, login into the Sony Authorized Servicer Portal at http://www.sony.com/asp. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 19: Section 3 - Flow Charts And Diagrams

    PC HD15 LVDS LCD PANEL, TCON, & USB 1 LED BACKLIGHTS LVDS USB 2 Ethernet Power/Control Power/Control Power/Control IR BOARD SWITCH Power UNIT IR RX Power POWER SUPPLY AC IN GL5A (40") GL5B (46") GE55 (55") OVERALL BLOCK DIAGRAM KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 20: Kdl-50Ex645 Only

    WIRELESS LAN CARD HDMI 3 A/V PROCESS HDMI 4 PC HD15 LVDS LCD PANEL, TCON, & USB 1 LED BACKLIGHTS LVDS USB 2 Ethernet IR BOARD SWITCH UNIT IR RX POWER SUPPLY AC IN GE50 OVERALL BLOCK DIAGRAM FOR KDL-50EX645 KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 21: No Power

    REG 12V 5, 7, 9 POWER_ON AUDIO_12V AUDIO_12V AUDIO_GND DIMMER 6, 7 REG12V_GND BL_ERR 8, 9 REG12V BL_ON BL_ERR TCON_12V BL_ON AC_FF_DET DIMMER TCON_ON STBY 3.3V TCON_12V POWER_ON GL5A (40") TCON_ON GL5B (46") GE55 (55") POWER AND CONTROL BLOCK DIAGRAM KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 22: Kdl-50Ex645 Only

    STBY3.3V REG 12V 5, 7, 9 AC_OFF_DET POWER_ON AUDIO_12V AUDIO_12V DIMMER AUDIO_GND BL_ERR 6, 7 REG12V_GND BL_ON 8, 9 REG12V TCON_12V BL_ERR AC_FF_DET BL_ON TCON_ON DIMMER STBY 3.3V POWER_ON TCON_12V TCON_ON GE50 POWER AND CONTROL BLOCK DIAGRAM FOR KDL-50EX645 KDL-40EX645/46EX641/46EX645/50EX645/55EX645...
  • Page 23 VXSSO\ ERDUG <HV ,V VWDQGE\ /(' +LJK <HV 3URWHFWLRQ 6KXWGRZQ 0DLQ %RDUG EOLQNLQJ" RQ SLQ " IORZFKDUW 3RZHU 6XSSO\ 3RZHU 6XSSO\ %RDUG %RDUG NO POWER FLOWCHART *For Part Number information, Refer to “Section 4 - Disassembly/Part Number Information” on page KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 24: Standby Led Blinking

    After a While temperature and ventilation around unit Immediately Main Board* “SONY” logo Power Supply appears before LCD Panel* Board* shutdown? LCD Panel* PROTECTION SHUTDOWN FLOWCHART *For Part Number information, Refer to “Section 4 - Disassembly/Part Number Information” on page KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 25: No Video

    TCON while unit Any flashes is running. This seen on LCD Panel* may need to be screen? done more than once Main Board* NO VIDEO FLOWCHART *For Part Number information, Refer to “Section 4 - Disassembly/Part Number Information” on page KDL-40EX645/46EX641/46EX645/50EX645/55EX645...
  • Page 26 Any horizontal LCD Panel* lines? Any single or LCD Panel* isolated vertical lines? More than 1 LCD Panel* vertical band? TCON Board* VIDEO DISTORTION FLOWCHART *For Part Number information, Refer to “Section 4 - Disassembly/Part Number Information” on page KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 27: Section 4 - Disassembly/Part Number Information

    (SCREWS TO ATTACH TABLE-TOP STAND TO LCD TV) 4-415-102-01 STAND, BASE TP (ML) For product protection and safety reasons, Sony strongly recommends (KDL-40EX645 ONLY) that you use the screws provided with the TV. 4-415-097-01 STAND, BASE TP (L) CAUTION: These screws cannot be used to secure the TV to (KDL-46EX641/46EX645 ONLY) the Wall Mount Brackets.

  • Page 28: Rear Cover Removal

    AC Power Cord. Power Supply Cord B Remove the remaining screws from the Rear Cover. 18 from KDL-40EX645 20 from KDL-46EX641/46EX645 22 from KDL-55EX640 C Gently hold down the Rear Cover from the center, then carefully start to lift the Rear Cover from the bottom to create clearance between the Bezel and the Rear Cover.

  • Page 29: Kdl-50Ex645 Only

    E Lift the Rear Cover from the bottom and ´ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3 ° push forward to release the top hooks. 4-400-043-01 JOINT, SCREW (SCREWS USED WHEN STAND IS ATTACHED. NOT USED WITH WALL MOUNTS) ¯ 7-685-646-79 SCREW, +BVTP 3X8 TYPE2 IT-3 KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 30: Main Board (A) And Power Supply Board (Gl5A/Gl5B/Ge50/Ge55) Removal

    REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] 4-409-317-01 SHEET, INSULATION (NK2) 1-846-302-21 WIFI ANTENNA CABLE (W) (KDL-40EX645/46EX641/46EX645 ONLY) (KDL-40EX645 ONLY) ORDER THIS PART WHEN REPLACING THE LCD PANEL 1-846-299-21 WIFI ANTENNA CABLE (W) 1-895-173-12 GL5A STATIC CONVERTER (TV) (KDL-46EX641/46EX645/55EX645 ONLY)

  • Page 31: Kdl-50Ex645 Only

    SOFTWARE TO THE LATEST VERSION 4-440-965-01 SPACER, PSU (50NK2) 4-409-321-01 COVER, SIDE JACK(NK2) 1-489-986-11 SWITCH UNIT 1-858-715-11 LOUDSPEAKER (3X15CM) ³ 2-990-421-41 SCREW, (+PSW) (M3X6) 1-846-300-11 WIFI ANTENNA CABLE (W) 1-846-300-21 WIFI ANTENNA CABLE (W) 1-458-353-33 WIRELESS LAN CARD 1-895-176-11 H BOARD, MOUNTED KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 32: Lcd Panel Removal

    PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] 4-409-314-01 BEZEL (40NK2) 4-299-509-01 BRACKET, PANEL (V) (KDL-40EX645 ONLY) 4-409-323-02 FRAME, BOTTOM (40NK2) 4-409-324-01 BEZEL (46NK2) (KDL-40EX645/46EX641/46EX645 ONLY) (KDL-46EX641/46EX645 ONLY) 4-409-326-02 FRAME, BOTTOM (55NK2) 4-409-327-01 BEZEL (55NK2) (KDL-55EX645 ONLY) (KDL-55EX645 ONLY) ¶...

  • Page 33: Kdl-50Ex645 Only

    Using any of these harsh cleaners may result in permanent damage to the ² 4-159-298-01 SCREW, +PSW M4X10 screen. ³ 2-990-421-41 SCREW, (+PSW) (M3X6) Do Not spray water or detergent directly onto the TV screen. If liquid drips into the bottom of the screen it may cause a failure. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 34: Connectors

    QXPHUR VSHFL¿H See Appendix A: Encryption Key Components in the back of this manual. (Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues). KDL-40EX645 ONLY KDL-46EX641/46EX645 ONLY REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF.

  • Page 35: Kdl-50Ex645 Only

    368í/(' 3 1-910-106-99 CONNECTOR ASSEMBLY 50 MB-SP-IR-KEY 1-910-103-89 (LVDS) CONNECTOR ASSEMBLY 55 FFC 51P 1-910-107-32 CONNECTOR ASSEMBLY 55 MB-WIFIML 5P 1-910-107-02 (LVDS) CONNECTOR ASSEMBLY 50 51P FFC 1-910-107-29 CONNECTOR ASSEMBLY 50 MB-WIFIML 5P 1-910-103-88 (LVDS) CONNECTOR ASSEMBLY 55 FFC 41P KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 36: Screws

    ZLWK SDUW QXPEHU VSHFL¿HG QXPHUR VSHFL¿H See Appendix A: Encryption Key Components in the back of this manual. (Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues). KDL-40EX645 DESCRIPTION REMARKS TOTAL · 4-421-427-01 SCREW, +PSW M5X16 LOCK TABLE-TOP STAND(3), HEAD to NECK(1), NECK to BASE(3) ¶...

  • Page 37: Accessories And Packaging

    PART NO. DESCRIPTION 4-408-779-01 BAG, SCREW A (M) 4-436-788-11 MANUAL, INSTRUCTION (ENGLISH VERSION) 4-436-788-21 MANUAL, INSTRUCTION (FRENCH VERSION) (KDL-40EX645/50EX645/55EX645 ONLY) 4-171-791-12 MANUAL, INSTRUCTION (US/SP/FR/PT VERSION) (KDL-46EX641/46EX645/50EX645 ONLY) 4-438-562-11 GUIDE, QUICK SET UP (ENGLISH VERSION) 4-438-562-21 GUIDE, QUICK SET UP (FRENCH VERSION)

  • Page 38: Wire Dressing

    S E C T I O N 4 - D I S A S S E M B L Y / P A R T N U M B E R I N F O R M A T I O N WIRE DRESSING OVERALL WIRE DRESSING FOR KDL-40EX645 ONLY OVERALL WIRE DRESSING FOR KDL-50EX645 ONLY...

  • Page 39: Section 5 - Updates And Adjustments

    YHUVLRQ WKH 0DLQ %RDUG DQG RU WKH 7&21 FDQ EH UHSODFHG PRUH HI¿FLHQWO\ to updating the software in their products. If a customer contacts the Sony The software update and procedures for the software installation are located on the Sony Authorized Servicer Portal at http://www.sony.com/asp. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 40: Software Update Responsibility

    1 (877) 899-SONY (7669) Other Countries Contact Consult the Warranty Card Please have the following information available: Model Name: KDL-50EX645 Serial Number: 5000004 v0.006 Software Version: Device ID: b0:00:00:b3:72:fc Netflix ESN: SONYKDLEX63775-2C776-C841C580B16 EXAMPLE OF SOFTWARE VERSION LOCATED ON THE CONTACT SONY SCREEN KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 41: Accessing Service Adjustment Mode

    After replacing the Main Board or LCD Panel you MUST UPDATE the SOFTWARE to the latest version. Instructions for updating the software are included with the software package on the Sony Authorized Service Portal website. DISPLAY NAVIGATION BUTTONS SELECT BUTTON VOLUME+ RM-YD075 KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 42: Completing Service Requirements When Replacing The Main Board

    ]> DPMS <[ ]> Low of HPD <[ ]> TVD_MCDONE_CNT <[ ]> Demo Special >> Bypass AVI Info Detect <[ ]> Panel Selection <[ 9_500HK1 ]> UART Selection No Log SERIAL NUMBER EDIT MODEL NAME EDIT [</>]Set [Home] Exit KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 43: Selecting The Panel Id Code

    If the latest software is not installed, update the software Model Name Panel Code Panel Type Panel ID and then proceed to Selecting the Panel ID Code. LTY[ Z] 400HF10 88_400HF10 SLCD KDL-40EX645 KDL-46EX641 91_460HJ07 SLCD LTY[ Z] 460HJ07 91_460HJ07 SLCD KDL-46EX645 LTY[ Z] 460HJ07...

  • Page 44: Adding The Serial Number

    5 _ _ _ _ _ _ _ 16. Press WR EH DEOH WR VHOHFW WKH ¿UVW GLJLW MODEL NAME EDIT CAUTION: The Serial Number can only be selected once. [</>]Set [Home] Exit Be sure to verify the information is correct before saving the changes. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 45: Adding The Model Name

    20. When the complete Serial Number is displayed, press UART Selection No Log 21. :KHQ WKH FRQ¿UPDWLRQ VFUHHQ GLVSOD\V SUHVV to select SERIAL NUMBER EDIT 5000004 MODEL NAME EDIT YES and then press [</>]Set [Home] Exit 22. Proceed to Adding the Model Name. KDL-40EX645/46EX641/46EX645/50EX645/55EX645...
  • Page 46 <[ ]> Demo Special >> Bypass AVI Info Detect <[ ]> 9_500HK1 Panel Selection <[ ]> UART Selection No Log SERIAL NUMBER EDIT 5000004 MODEL NAME EDIT K _ _ _ _ _ _ _ _ [</>]Set [Home] Exit KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 47: Completing Service Requirements When Replacing The Lcd Panel

    Low of HPD <[ ]> [</>]Set [Home] Exit TVD_MCDONE_CNT <[ ]> Demo Special >> Bypass AVI Info Detect <[ ]> 9_500HK1 Panel Selection <[ ]> UART Selection No Log SERIAL NUMBER EDIT 5000004 MODEL NAME EDIT KDL-50EX645 [</>]Set [Home] Exit KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 48: Resetting Panel Operation Time

    Using the table below, verify the correct Panel Code for the Panel ID. SELF CHECK Model Name Panel Code Panel Type Panel ID Back << LTY[ Z] 400HF10 88_400HF10 SLCD KDL-40EX645 MAIN_ POWER KDL-46EX641 91_460HJ07 SLCD LTY[ Z] 460HJ07 DC_ALERT1 91_460HJ07 SLCD KDL-46EX645 LTY[ Z] 460HJ07 AUDIO_PROT...
  • Page 49 Sony Electronics Reproduction in whole or part without written permission is prohibited. All rights reserved Sony Corporation English 2012HJ74WEB-1 Sony LCSC Printed in USA Technical Services 9-883-899-02 © 2012.8 Service Publication Department KDL-40EX645/46EX641/46EX645/50EX645/55EX645...

  • Page 50: Appendix A: Encryption Key Components

    APPENDIX A: ENCRYPTION KEY COMPONENTS (QFU\SWLRQ NH\ FRPSRQHQWV GHYHORSHG E\ 6RQ\ &RUSRUDWLRQ FRQWDLQ FRQ¿GHQWLDO LQIRUPDWLRQDQG VKDOO EH KDQGOHG XQGHU WKH QRQ GLVFORVXUH REOLJDWLRQV SURYLGHG in the applicable agreement with Sony Corporation (and/or its subsidiary). $V SDUW RI WKLV DJUHHPHQW VSHFL¿F LQVWUXFWLRQV PXVW EH DGKHUHG WR ZKHQHYHU D &LUFXLW %RDUG FRQWDLQLQJ HQFU\SWLRQ NH\ FRPSRQHQWV LV UHSDLUHG DQG RU UHSODFHG pursuant to the following: ,Q WKH VHUYLFH PDQXDO WKH &LUFXLW %RDUG V FRQWDLQLQJ HQFU\SWLRQ NH\ FRPSRQHQWV VKDOO EH LGHQWL¿HG ZLWK D UHG RXWOLQH DQG D .

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