Sony Kdl-40ex645 40ex641 46ex645 50ex645 55ex645 Chassis Az3fk

Self Diagnosis
Supported model
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE / TRAINING MANUAL

AZ3FK Chassis
ORIGINAL MANUAL ISSUE DATE: 8/2012 Segment: P-2
Version Date Subject

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.
LCD Digital Color TV
9-883-899-02
Self Diagnosis
Supported model
SERVICE / TRAINING MANUAL

AZ3FK Chassis
Segment: P-2
KDL-50EX645
LCD Digital Color TV
9-883-899-02
MODEL LIST
MODEL COMMANDER DESTINATION MODEL COMMANDER DESTINATION
KDL-40EX645 RM-YD075 CND KDL-50EX645 RM-YD075 US/CND
KDL-46EX641 RM-YD075 US KDL-55EX645 RM-YD075 CND
KDL-46EX645 RM-YD075 US
9-883-899-02
TABLE OF CONTENTS
Cautions and Warnings ..................................................................................iii Section 4 - Disassembly/Part Number Information ....................................18

Table-Top Stand Removal ...........................................................................18
Section 1 - Features and Overview ................................................................1
Rear Cover Removal ...................................................................................19
Features ........................................................................................................1
6SHFL¿FDWLRQV ................................................................................................1 All Models Except KDL-50EX645 ...........................................................19
Chassis Overview ..........................................................................................3 KDL-50EX645 Only ................................................................................20

Overall Circuit Description .............................................................................5 Main Board (A) and Power Supply Board (GL5A/GL5B/GE50/GE55)
Removal ......................................................................................................21
Main Board ...............................................................................................5
All Models Except KDL-50EX645 ...........................................................21
Power Supply Board .................................................................................5
KDL-50EX645 Only ................................................................................22
IR Board....................................................................................................5
LCD Panel Removal ....................................................................................23
Switch Unit ................................................................................................5
Wireless LAN Card ...................................................................................6
KDL-50EX645 Only ................................................................................24
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
Viewing the Self Check Diagnosis History ................................................8 Screws .........................................................................................................27
Triage Chart...................................................................................................9 Accessories and Packaging ........................................................................28
Section 3 - Flow Charts and Diagrams ........................................................10 Miscellaneous ..............................................................................................28
Block Diagram .............................................................................................10 Optional Accessories ...................................................................................28
All Models Except KDL-50EX645 ...........................................................10 Remote Commander ...................................................................................28
KDL-50EX645 Only ................................................................................ 11 Wire Dressing ..............................................................................................29
No Power .....................................................................................................12
KDL-50EX645 Only ................................................................................13
Standby LED Blinking ..................................................................................15
No Video ......................................................................................................16
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 i
TABLE OF CONTENTS
Section 5 - Updates and Adjustments .........................................................30

Overview .....................................................................................................30
Software Updates for Customers ................................................................30
Software Updates for Servicers ...................................................................30
Software Update Responsibility ..............................................................31
Checking the Software Version...............................................................31
Examples of Software Correctable Symptoms .......................................31
Accessing Service Adjustment Mode ..........................................................32
Completing Service Requirements When Replacing the Main Board .........33
Viewing the Status Information ...............................................................33
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 ii
CAUTIONS AND WARNINGS
CAUTION!! ATTENTION!!
7KHVH VHUYLFLQJ LQVWUXFWLRQV DUH IRU XVH E\ TXDOL¿HG VHUYLFH SHUVRQQHO RQO\ &HV LQVWUXFWLRQV GH VHUYLFH VRQW j O¶XVDJH GX SHUVRQQHO GH VHUYLFH TXDOL¿p
To reduce the risk of electric shock, do not perform any servicing other than VHXOHPHQW 3RXU SUpYHQLU OH ULVTXH GH FKRF pOHFWULTXH QH SDV IDLUH O¶HQWUHWLHQ
WKDW FRQWDLQHG LQ WKH RSHUDWLQJ LQVWUXFWLRQV XQOHVV \RX DUH TXDOL¿HG WR GR VR autre que celui contenu dans le Mode d’emploi à moins que vous soyez
TXDOL¿p IDLUH DLQVL
WARNING!!
ALERTE!!
An isolation transformer should be used during any service to avoid possible
shock hazard, in case of live chassis. $¿Q G¶HYLWHU WRXW ULVTXH G¶HOHFWURFXWLRQ SURYHQDQW G¶XQ FKiVVLV VRXV WHQVLRQ
XQ WUDQVIRUPDWHXU G¶LVROHPHQW GRLW HWUH XWLOLVp ORUV GH WRXW GpSDQQDJH
! SAFETY-RELATED COMPONENT WARNING!!

! ATTENTION AUX COMPOSANTS
There are critical components used in LCD color TVs that are important for
VDIHW\ 7KHVH FRPSRQHQWV DUH LGHQWL¿HG ZLWK VKDGLQJ DQG ! mark on the
RELATIFS A LA SECURITE!!
schematic diagrams and the parts list. It is essential that these critical parts /HV FRPSRVDQWV LGHQWL¿HV SDU XQH WUDPH HW SDU XQH PDUTXH ! sur les
EH UHSODFHG RQO\ ZLWK WKH SDUW QXPEHU VSHFL¿HG LQ WKH SDUWV OLVW WR SUHYHQW schemas de principe, les vues explosees et les listes de pieces sont d’une
HOHFWULF VKRFN ¿UH RU RWKHU KD]DUG 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. Les reglages
NOTE: Do not modify the original design without obtaining written permission
de circuit dont l’importance est critique pour la securite du fonctionnement
from the manufacturer or you will void the original parts and labor warranty.
VRQW LGHQWL¿HV GDQV OH SUHVHQW PDQXHO 6XLYUH FHV SURFHGXUHV ORUV GH
chaque remplacement de composants critiques, ou lorsqu’un mauvais
ATTENTION!! fonctionnement suspecte.
For safety reasons, component level repair of the Power Supply Boards
and/or the Inverter Boards is prohibited. ATTENTION!!
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 iii
SETTING UP AND CARRYING THE TV

” Disconnect all cables when carrying the TV.
” Carry the TV with the 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 damage.
USE CAUTION WHEN HANDLING THE LCD PANEL

When repairing the LCD panel, be sure you are grounded by using a wrist band.
When installing the LCD panel on a 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.
2. Do not scratch or press on the panel with any sharp objects.
3. Do not leave the module in high temperatures 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 a short circuit within the module.
6. Disconnect the AC power when replacing the backlight 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.
9. 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 iv
CLEANING THE LCD PANEL

CAUTION: When cleaning the TV, be sure to unplug the power cord to avoid any chance of electric shock.
Clean the cabinet of the TV with a dry soft cloth.

Wipe the LCD screen gently with a soft cloth.
; Stubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water.
; If using a chemically pretreated cloth, please follow the instruction provided on the package.
; Never use strong solvents such as a thinner, alcohol or benzine for cleaning.
; Periodic vacuuming of the ventilation openings is recommended to ensure proper ventilation.
; Do Not use paper towels, any type of abrasive pad, rags, rubber or vinyl materials to clean the screen. Using these materials could easily scratch the
screen which may result in permanent damage.
; Do Not use any cleaning product containing alkaline/acid cleaner, scouring powder or volatile solvent, such as alcohol, ammonia, benzine, thinner or
insecticide. 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 v
SAFETY CHECK-OUT 3. Measuring the voltage drop across a resistor by means of a VOM
or battery-operated AC voltmeter. The “limit” indication is 0.75 V, so
After correcting the original service problem, perform the following safety analog meters must have an accurate low voltage scale. Nearly all
checks before releasing the set to the customer: battery-operated digital multimeters that have a 2 VAC range are
suitable. (see Figure A)
1. Check the area of your repair for unsoldered or poorly soldered
connections. Check the entire board surface for solder splashes To Exposed Metal
and bridges. Parts on Set
2. Check the interboard wiring to ensure that no wires are “pinched” or

touching high-wattage resistors.
3. Check that all control knobs, shields, covers, ground straps and
mounting hardware have been replaced. Be absolutely certain that AC
0.15 µF Voltmeter
you have replaced all the insulators. (0.75V)
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 Earth Ground
deterioration. Point them out to the customer and recommend their
Figure A. Use an AC voltmeter to check AC leakage.
replacement.
6. Check the line cords for cracks and abrasion. Recommend the
replacement of any such line cord to the customer. HOW TO FIND A GOOD EARTH GROUND
7. Check the antenna terminals, metal trim, “metallized” knobs, screws The cover-plate retaining screw on most AC outlet boxes is at earth ground.
and all other exposed metal parts for AC leakage. Check leakage Verify the AC outlet box retaining screw ground by connecting a 60W to
as described in “Leakage Test”. : LQFDQGHVFHQW QRW D QHRQ RU ÀXRUHVFHQW ODPS EHWZHHQ WKH KRW VLGH RI
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
LEAKAGE TEST is at ground potential. (see Figure B)
The AC leakage from any exposed metal part to earth ground and from all Trouble Light
exposed metal parts to any exposed metal part having a return to chassis, AC Outlet Box
must not exceed 0.5 mA (500 microamperes). Leakage current can be
measured by any one of three methods.
1. A commercial leakage tester.
Follow the manufacturers’ instructions provided with the tester.
2. A battery-operated AC milliammeter.
Figure B. Checking for earth ground.
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 vi
SECTION 1 - FEATURES AND OVERVIEW
FEATURES SPECIFICATIONS
The AZ3FK chassis is one of several designs for the 2012 model line of System
Television system NTSC: American TV standard
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
Analog Cable: 1 - 135 / Digital Cable: 1 - 135
KDL-46EX641 Panel system LCD (Liquid Crystal Display) Panel LED backlight
S p e a ke r outp ut 1 0 W + 10 W 8W+8W
KDL-46EX645 (KDL-55EX645/50EX645) (KDL-46EX645/46EX641/40EX645)
Input/Output jacks
KDL-50EX645 CABLE/ANTENNA 75-ohm external terminal for RF inputs
KDL-55EX645 VIDEO IN 1/2 VIDEO: 1 Vp-p, 75 ohms unbalanced, sync negative

AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms
COMPONENT IN YP B P R (Component Video): Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative / P B : 0.7 Vp-p,75 ohms
P R : 0.7 Vp-p, 75 ohms / Signal format: 480i, 480p, 720p, 1080i, 1080p
The features of the EX64x series Edge LED backlite LCD HDTV include: AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms
HDMI: Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p

” Brilliant Full HD 1080p picture quality HDMI IN 1/2/3/4 Audio: Two channel linear PCM 32, 44.1 and 48 kHz, 16, 20 and 24bits, Dolby Digital
” /LIHOLNH PRYHPHQW ZLWK 0RWLRQÀRZŒ ;5 AUDIO OUT 500 mVrms (typical)

DIGITAL AUDIO OUT PCM/Dolby Digital optical signal
” Clear Resolution Enhancer for clear detail (OPTICAL)
” Bright picture & thin design with Edge LED backlight P C IN D -s ub 1 5 - p in, a na log R G B , 0 . 7 V p -p , 7 5 ohms , p os itive
PC/HDMI IN 1 AUDIO IN Stereo mini jack, 500 mVrms, (Typical) / Impedance: 47 kilohms
” %5$9,$Š 6\QFŒ $OORZV \RXU 79 WR FRPPXQLFDWH ZLWK RWKHU 6RQ\ US B C omp lia nt with U S B ma s s s tora g e e . g . d ig ita l c a me ra or U S B me mory . A ls o c omp lia nt with
equipment supporting the Control for HDMI function UWA-BR100 as WiFi Dongle
DL N A D L N A C e rtifie d ™ c od e c is the s a me a s U S B ( S ome D L N A C e rtifie d ™ s e rve rs ma y not b e
” '/1$ &HUWL¿HGŒ PHGLD VHUYHUV able to play back)
LAN 1 0 B A S E - T /1 0 0 B A S E - T X c onne c tor ( D e p e nd ing on the op e ra ting e nvironme nt of the
” Movies, music & apps w/ Sony Entertainment Network1 network, connection speed may differ. 10BASE-T/100BASE-TX communication rate and
communication quality are not guaranteed for this TV)
” Wi-Fi® adaptor included to stream HD entertainment1
1. Broadband speed of at least 2.5 Mbps recommended (10 Mbps for HD). Content subject to
change and may require fees. Wireless connectivity requires 802.11 home network (802.11
recommended).
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 1
Model name KDL- 55EX645 50EX645 46EX645/46EX641 40EX645

Power and others
Power requirement 110-240 V AC, 50/60 Hz (U.S.A. / Canada 120 V AC, 60 Hz)
Power consumption
15 2 W 1 46 W 1 17 W 100 W
in use
in standby Less than 0.2 W with 120 V AC and Less than 0.3 W with 120 V AC and Less than 0.2 W with 120 V AC and with 240
with 240 V AC less than 0.25 W with 240 V AC less than 0.35 W V AC less than 0.3 W
Screen size*
(inches measured diagonally) 5 4 . 6 ( 5 5 c la s s ) 50 46 40
D is p la y re s olution 1 , 9 2 0 d ots ( horiz onta l) × 1 , 0 8 0 line s ( ve rtic a l)
Speaker/Full range (2) (mm)
30 × 150 (1 3/16 × 6)
(inches)
Dimensions* with stand (mm) 1,269 × 797 × 311 1,152 × 731 × 251 1,074 × 686 × 251 941 × 612 × 231
(inches) 50 × 31 1/2 × 12 1/4 453/8 × 28 7 /8 × 10 42 3 /8 × 27 1 /8 × 10 37 1/8 × 24 1/8 × 9 1/8
without stand (mm) 1,269 × 760 × 60 1,152 × 693 × 61 1,074 × 649 × 60 941 × 575 × 60
3
(inches) 50 × 30 × 2 3/8 45 /8 × 27 3/8 × 2 1/2 42 3/8 × 25 5/8 × 2 3/8 37 1/8 × 22 3/4 × 2 3/8
wall-mount hole pattern
30 0 × 30 0 3 00 × 4 00 30 0 × 30 0
(mm)
wall-mount screw size
M6 (8-12 mm)
(mm)
Mass* with stand (kg) 23.4 22.8 17.4 14.3
(lb.) 51.6 50.3 38.4 31.5
without stand (kg) 18.9 19.6 14.2 11.7
(lb.) 41.7 43.2 31.3 25.8
Supplied accessories
Remote control RM-YD075 (1) / Size AAA batteries (2) / Operating Instructions (this manual) (1) / Quick Setup Guide (1) / Warranty Card (1)
common to all models Safety and Regulatory Booklet (1) / Software License (1) /Stand installation guide (1) /Table-Top Stand (1 set)
individual models Screws (7)
Optional accessories Connecting cables / Support Belt Kit / Wall-Mount Bracket: SU-WL500
• Optional accessories availability depends on its stock.

• Design and specifications are subject to change without notice.
* Dimensions and mass are approximate values.
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 2
CHASSIS OVERVIEW
The primary circuits in the AZ3FK chassis consist of a Main Board (A Board), Power Supply Board (GL5A for the 40” models, GL5B for the 46” models, GE50
for the 50” models and GE55 for the 55” models), the IR Board (H Board), the Switch Unit, the Wireless LAN Card and the LCD Panel Assembly which includes
the 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 29.
GL5A
A
SWITCH
UNIT
TCON
WIRELESS LAN CARD H

BOARD LAYOUT FOR KDL-40EX645 ONLY
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 3
GL5B
A
SWITCH GE55 A
UNIT SWITCH
UNIT
TCON TCON
WIRELESS LAN CARD H WIRELESS LAN CARD H

BOARD LAYOUT FOR KDL-46EX641/46EX645 ONLY BOARD LAYOUT FOR KDL-55EX645 ONLY
LD BOARD
SWITCH GE50
UNIT
TCON
WIRELESS LAN CARD H

BOARD LAYOUT FOR KDL-50EX645 ONLY
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 4
OVERALL CIRCUIT DESCRIPTION CPU: The CPU internal to the MT5396 processor controls all aspects of
the television functions. Input from the user along with monitoring of critical
The “Block Diagram” on page 10 provides an overview of the AZ3FK circuits is also performed by this CPU.
chassis. The following are descriptions of the boards and their functions. LVDS Transmitter: Integrated into the MT5396 is a Low Voltage Differential
Signaling (LVDS) transmitter. This circuit converts the 8-bit parallel RGB
MAIN BOARD video information into a set of high speed serial lines for noise-free
transmission to the TCON circuits located internally to the LCD panel.
Common to all models utilizing the AZ3FK chassis, the Main Board (A
Board) contains most of the video processing circuitry along with all audio
processing. Control of the television is accomplished via a CPU embedded POWER SUPPLY BOARD
within the MT5396 processor. Below is a list of the key components located There are 4 different Power Supply boards used in the models in this
on the Main Board. manual. The type of board depends on the size of LCD panel. They are:
” GL5A for the 40” models
TUNER
” GL5B for the 46” models
The tuner is a combination ATSC/NTSC unit. It can receive traditional
analog NTSC signals via cable or terrestrial along with ATSC digital signals ” GE50 for the 50” models
via terrestrial (8VSB) or cable (64 or 256 QAM). ” GE55 for the 55” models
There are 3 distinct sections on the power supply:
MT5396 PROCESSOR Standby Supply: Continuously operational as long as AC power is applied,
This IC performs the majority of the necessary audio and video processing the standby supply generates 3.3V for the circuits requiring power while the
on the Main Board. unit is turned off. An unregulated 19V line is present to provide power to the
Analog Video Input Switch: All analog video sources are selected and main relay, PFC and main power supply at turn-on.
A/D converted and scaled (if necessary) to 1920 X 1080p 60HZ resolution. Main Supply: Once the power supply receives a power-on command from
Digital Audio and Video Decoder: The MPEG2 and Digital Dolby audio the CPU on the Main Board, the main switching supply is turned on to
streams are received from the tuner for decompression. All video sources provide a regulated 12V source and Audio 12V.
which are not native 1920 X 1080p 60HZ are scaled to this resolution. Converter: Generates the B+ and B- voltages for the LED backlights.
'LJLWDO DXGLR FRQWHQW LV RXWSXW WR WKH FODVV ' DPSOL¿HU IRU SURFHVVLQJ DQG
DPSOL¿FDWLRQ
IR BOARD
Audio Processing: Analog audio sources are selected and A/D converted
Designated as the H Board, the IR Board contains the power, standby and
directly by the MT5396. The audio information is then processed digitally.
timer LED’s that are located on this board along with the IR remote receiver
Digital audio from the tuner and HDMI sources is also input and processed.
and light level sensor.
&ODVV ' DPSOL¿HU SURYLGHV WKH GULYH IRU WKH VSHDNHUV
HDMI Input and Switching: The customer can select the HDMI1 through
HDMI4 input. Each HDMI input contains a dedicated EDI NVM (not shown) SWITCH UNIT
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 5
WIRELESS LAN CARD

The wireless transmit/receive circuits are located on this board to
communicate with a wireless network.
LCD PANEL ASSEMBLY

The LCD Panel Assembly includes the LCD Panel, TCON Board and LED
Backlight system.
7KH /&' 3DQHO FRQWDLQV WKH DFWXDO OLTXLG FU\VWDOV FRORU ¿OWHUV DQG SRODUL]HUV
7KH OLTXLG FU\VWDOV DUH PDQLSXODWHG E\ WKH DSSOLHG YROWDJH WR SDVV D VSHFL¿F
amount of light - from the backlight - depending on the level of voltage
applied.
The TCON performs all the control, timing, charge and discharge functions
driving the operation of the LCD Panel.
A new LCD Panel assembly from parts will include the following items:
” LCD Panel
” TCON Board
” LED Backlighting Components (varies)
” LD Board (KDL-50EX645 only)
NOTE: The LD Board is not always included with the LCD Panel. Check
with the LCD Panel manual for the most update information regarding this
information.
TCON BOARD
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 6
SECTION 2 - TROUBLESHOOTING Self Diagnosis
Supported model
OVERVIEW SELF DIAGNOSIS FUNCTION

This chapter provides information regarding the Self Diagnosis feature in Critical voltages and circuit operations are monitored by the CPU on the
our TVs. Main Board. If an error is detected the Self Diagnosis function in the TV will
force the TV to shut down by the CPU. The monitored circuit in which the
fault occurred will automatically cause the CPU to blink the Standby LED
UPDATING THE SOFTWARE in groups of repeating sequences. The number of times the Standby LED
The Self Diagnosis function is designed to provide information regarding blinks indicates the possible cause of the problem.
the problem with the TV, however, there are several issues that may be
Not all of the available protect codes are used in every model. For example,
resolved by updating the TV software to the latest version. Always check
models that don’t have the local dimming feature do not use the 4X blink
the Sony Authorized Servicer Portal at http://www.sony.com/asp for any
HUURU DV WKLV FLUFXLW LV IRXQG LQ PRGHOV WKDW DUH EDFNOLW ZLWK ÀXRUHVFHQW ODPSV
issues that are software related. Most symptoms that are correctable by
The information in this section provides guidance in locating the possible
software updates involve communications issues with other devices or
component causing the shutdown.
PLQRU JOLWFKHV LQ WKH RSHUDWLRQ RI D VSHFL¿F IXQFWLRQ %HORZ LV D OLVW RI VRPH
of the symptoms that may be corrected with a software update:
” Fluctuations in picture brightness STANDBY LED BLINK COUNT
” Intermittent picture freezing or noise 2 times
” Problems with certain inputs (especially HDMI)

5 times
” Intermittent or distorted audio
LED ON 0.3 sec.
” Erratic remote control operation LED OFF 0.3 sec. LED OFF
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 7
SECTION 2 - TROUBLESHOOTING
VIEWING THE SELF CHECK DIAGNOSIS HISTORY SELF CHECK

When an error is detected, the Self Check screen records the number of Indicates
WLPHV WKH HUURU RFFXUUHG 7KLV LV KHOSIXO LQ FRQ¿UPLQJ SDVW RFFXUUHQFHV RI Back << an error
an error and for determining if an error is intermittent when the customer is 002 MAIN_ POWER 001 has
not sure what is causing the television to shut down. If the screen displays 003 AUDIO_PROT 000 occurred
a “0”, no error has occurred. 003 DC_ALERT1 000
1. TV must be in Standby mode. 004 BALANCER 000 Indicates
005 TCON_ERR 000 no error
2. Press the following buttons on the Remote Commander within a
005 PANEL_POWE 000 has
second of each other:
006 BACKLITE 000 occurred
DISPLAY Channel 5 Volume + POWER 007 TEMP_ERR 000
3. To access the Self diagnosis history page, press until Self
diagnosis history is highlighted. 00150 00075 00007
Service Mode [Menu] Exit
Sound Adjustment >>
Wide Band Tuning >> SAMPLE SELF CHECK DIAGNOSIS PAGE
Range Scan… >> 2X Blink - Main Power Error
Self diagnosis history >>
Status Information… >> A loss of REG12V from the power supply triggers this protect event. The
LVDS Spectrum(%0) <[ 25 ]> usual cause is a failure of the main switching supply. In some instances,
DPMS <[ Off ]> excessive loading on the secondary supply lines can cause the switching
Low of HPD <[ 5 ]> regulator to stop or fail again, if a replacement board is installed.
TVD_MCDONE_CNT <[ 20 ]>
Demo Special >> 3X Blink- DC Regulator/Audio Error
Bypass AVI Info Detect <[ On ]> The REG 5V and D3.3V source originating on the Main Board is monitored
Panel Selection <[ V500HK1-LS5 ]> for low-voltage conditions by the CPU. A failure causing a 3X shutdown
UART Selection No Log requires replacing the Main Board.
SERIAL NUMBER EDIT 5000004
MODEL NAME EDIT KDL-50EX65 4X Blink – Balancer Error
The 4X error code is only used on models incorporating local dimming LED
[</>]Set [Home] Exit backlighting. If a failure occurs on the LD Board or one of the LED’s fails in
the panel the TV will shut down and display this diagnostic code.
4. Then press to view Self Check screen.
5X Blink - TCON Error/Panel Error
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 8
SECTION 2 - TROUBLESHOOTING
6X Blink - Backlight Converter System Failure 7X Blink - Temperature Failure
If the converter circuits fails to generate high voltage or one or more of A digital thermometer IC located on the Main Board provides a temperature
the backlight fails to light, the television will shut down and display this reading of the chassis and LCD panel. If the temperature exceeds a pre-
diagnostics error. determined point the TV will shut down. If this problem occurs immediately
at turn-on, the temperature sensing IC has failed and replacing the main
board is required. If this occurs after the TV has been running for a while,
check for ventilation issues that could cause the TV to run hotter than
normal.
TRIAGE CHART
Use this general Triage Chart to determine what may possibly be causing the error before going out to the customers location.
1. Confirm the symptom from the customer. RED DOT: (Primary) Most likely defective part.
2. Select that symptom from the chart. BLUE Triangle: (Secondary) Possible defective part.
3. Bring the primary component listed for that symptom.
4. Follow the associated flowcharts in the Training Manual to isolate the board.
5. Chart Color Code.
Protection Modes LAN Power Video Audio
Board Whole Isolated
2X 3X 4X 5X 6X 7X NO WIFI Dead set No Video Screen Area No Audio
Distortion Distortion
Main Board z z* x x x z z
Power Supply z z*** z
LD Board z
LCD Panel z** z
TCON z z x x
WLAN Card z z x x
*NOTE: REFER TO LCD PANEL SERVICE MANUAL IN z* TV Immediate Shuts Off After Power ON & 7X
REFERENCE LIBRARY DATABASE FOR CORRECT z**Backlight Turns ON before TV Shuts Off
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 9
SECTION 3 - FLOW CHARTS AND DIAGRAMS
BLOCK DIAGRAM
ALL MODELS EXCEPT KDL-50EX645

MAIN BOARD
RF TUNER L
CLASS D
AUDIO
AMP
Component/Composite R
Composite ANALOG AUDIO OUT

HDMI 1 OPTICAL AUDIO OUT
HDMI 2 MT5389
HDMI 3 A/V DECODER WIRELESS LAN CARD
A/V PROCESS
HDMI 4
PC HD15
LVDS
USB 1 LCD PANEL, TCON, &
LVDS LED BACKLIGHTS
USB 2
Ethernet
A
Power/Control Power/Control Power/Control
IR BOARD
SWITCH LED
UNIT Power
IR RX
H
POWER SUPPLY Power
AC IN
GL5A (40")
GL5B (46")
GE55 (55")
OVERALL BLOCK DIAGRAM
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 10
KDL-50EX645 ONLY
MAIN BOARD
RF TUNER L
CLASS D
AUDIO
AMP
Component/Composite R
Composite ANALOG AUDIO OUT

HDMI 1 OPTICAL AUDIO OUT
HDMI 2 MT5389
HDMI 3 A/V DECODER WIRELESS LAN CARD
A/V PROCESS
HDMI 4
PC HD15
LVDS
USB 1 LCD PANEL, TCON, &
LVDS LED BACKLIGHTS
USB 2
Ethernet
A
IR BOARD
SWITCH
LED
UNIT
IR RX
H
AC IN POWER SUPPLY
LD
GE50
OVERALL BLOCK DIAGRAM FOR KDL-50EX645
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 11
NO POWER
CN4
1 V+
2 N/C
3 V+
LCD PANEL, TCON
&
LED BACKLIGHTS
CN1 CN3
AC IN (N) 1 1 V+
AC IN (H) 2 2 N/C
3 V+
CN2
1 STBY3.3V CN201
2 AC_OFF_DET REG 12V 8
3 POWER_ON GND 5, 7, 9
4 AUDIO_12V AUDIO_12V 10
5 AUDIO_GND DIMMER 1
6, 7 REG12V_GND BL_ERR 12
8, 9 REG12V BL_ON 13
10 BL_ERR TCON_12V 14
11 BL_ON AC_FF_DET 3
12 DIMMER TCON_ON 15
13 N/C STBY 3.3V 4
14 TCON_12V POWER_ON 2
GL5A (40")
15 TCON_ON
GL5B (46")
GE55 (55") A
POWER AND CONTROL BLOCK DIAGRAM
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 12
KDL-50EX645 ONLY
POWER SUPPLY
CN3
1~5 UNREG 24V
6~10 GND
11 BL_ERR LCD PANEL, TCON

&
12 BL_ON LED BACKLIGHTS
CN1 13 N/C
AC IN (N) 1 14 DIMMER
AC IN (H) 2 LD
MAIN BOARD
CN2 CN201
1 STBY3.3V REG 12V 6, 8
2 AC_OFF_DET 3V GND 5, 7, 9
3 POWER_ON 3V AUDIO_12V 10
4 AUDIO_12V DIMMER 1
5 AUDIO_GND BL_ERR 12
6, 7 REG12V_GND BL_ON 13
8, 9 REG12V TCON_12V 14
10 BL_ERR 0V AC_FF_DET 3
11 BL_ON 3V TCON_ON 15
12 DIMMER STBY 3.3V 4
13 N/C POWER_ON 2
14 TCON_12V
15 TCON_ON 3V
GE50 A
POWER AND CONTROL BLOCK DIAGRAM FOR KDL-50EX645
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 13
1R 3RZHU
3UHVV SRZHU
'RHV UHG VWDQGE\ <HV EXWWRQ ZKLOH <HV
+LJK 9 3RZHU 6XSSO\
/(' RQ IURQW SDQHO PRQLWRULQJ SLQ RI
RQ SLQ " %RDUG
OLJKW" &1 RQ SRZHU
VXSSO\ ERDUG
1R 1R
<HV 6HH
,V VWDQGE\ /(' +LJK 9 <HV
3URWHFWLRQ 6KXWGRZQ 0DLQ %RDUG
EOLQNLQJ" RQ SLQ "
IORZFKDUW
1R 1R
3RZHU 6XSSO\
%RDUG 3RZHU 6XSSO\
%RDUG
NO POWER FLOWCHART
*For Part Number information, Refer to “Section 4 - Disassembly/Part Number Information” on page 18.
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 14
STANDBY LED BLINKING

Protect
Shutdown.
Standby LED
Blinking
Yes Power Supply

2X
Board*
No
Yes
3X Main Board*
Check room
No After a While temperature and
6X 7X
ventilation around
unit
No
Yes Immediately
No
5X
Main Board*
Yes
“SONY” logo No Power Supply

appears before
LCD Panel* Board*
shutdown?
Yes
LCD Panel*
PROTECTION SHUTDOWN FLOWCHART
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 15
NO VIDEO
No Video
Backlights No
LCD Panel*
turned on?
Yes
Any OSD Yes

graphics Main Board*
present?
No
Unplug LVDS
connector at
TCON while unit Any flashes No
is running. This seen on LCD Panel*
may need to be screen?
done more than
once
Yes
Main Board*
NO VIDEO FLOWCHART
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 16
Video Distortion
Is distortion No Lines move

Yes Improper of Vertical lines Yes Yes
across entire when wide-mode Main Board*
missing colors? or bars? changed?
screen?
No Yes No No
LCD Panel*
Main Board*
TCON Board*
Any horizontal Yes

LCD Panel*
lines?
No
Any single or Yes

isolated vertical LCD Panel*
lines?
No
Yes
More than 1 LCD Panel*
vertical band? TCON Board*
VIDEO DISTORTION FLOWCHART
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 17
SECTION 4 - DISASSEMBLY/PART NUMBER INFORMATION
TABLE-TOP STAND REMOVAL &RPSRQHQWV QRW LGHQWL¿HG E\ D SDUW QXPEHU RU 7KH FRPSRQHQW SDUWV RI DQ DVVHPEO\ DUH LQGLFDWHG E\ WKH * ,WHPV PDUNHG ZLWK DQ DVWHULVN DUH QRW VWRFNHG VLQFH
GHVFULSWLRQ DUH QRW VWRFNHG EHFDXVH WKH\ DUH VHOGRP UHIHUHQFH QXPEHUV LQ WKH IDU ULJKW FROXPQ RI WKH SDUWV OLVW WKH\ DUH VHOGRP UHTXLUHG IRU URXWLQH VHUYLFH ([SHFW
A Remove 3 screws from the Table-Top Stand, then lift up the LCD TV and gently place it face down onto a soft cloth. UHTXLUHG IRU URXWLQH VHUYLFH DQG ZLWKLQ WKH GRWWHG OLQHV RI WKH GLDJUDP VRPH GHOD\ ZKHQ RUGHULQJ WKHVH FRPSRQHQWV
127( 7KH FRPSRQHQWV LGHQWL¿HG E\ VKDGLQJ 127( /HV FRPSRVDQWV LGHQWL¿HV SHU XQ WUDPH HW 127( 7KH FRPSRQHQWV LGHQWL¿HG E\ D UHG RXWOLQH DQG D mark contain
and ! mark are critical for safety. Replace only une marque ! sont critiques pour la securite. FRQ¿GHQWLDO LQIRUPDWLRQ 6SHFL¿F LQVWUXFWLRQV PXVW EH DGKHUHG WR ZKHQHYHU
ZLWK SDUW QXPEHU VSHFL¿HG Ne les remplacer que par une piece portant le these components are repaired and/or replaced.
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).
Soft Cloth 2
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
1 4-415-089-01 STAND, HEAD (ML9) x 6&5(: 36: 0 ; /2&.

2 4-298-271-01 NECK TP (M) (SCREWS TO ATTACH HEAD BRACKET AND STAND BASE TO NECK)
(SCREWS TO ATTACH TABLE-TOP STAND TO LCD TV)
3 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.
3 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.
3 4-444-059-01 STAND, BASE TP (50NK2)
(KDL-50EX645 ONLY)
3 4-415-092-01 STAND, BASE TP (LL)
(KDL-55EX645 ONLY)
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 18
REAR COVER REMOVAL and ! mark are critical for safety. Replace only une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
FRQ¿GHQWLDO LQIRUPDWLRQ 6SHFL¿F LQVWUXFWLRQV PXVW EH DGKHUHG WR ZKHQHYHU
ZLWK SDUW QXPEHU VSHFL¿HG these components are repaired and/or replaced.
ALL MODELS EXCEPT KDL-50EX645 (Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues).
CAUTION:
Hold down the Rear Cover as shown in the steps below to avoid deforming or damaging the hooks in the Rear
Cover and Bezel.
The portion of the Rear Cover near the Switch Unit is very fragile. When lifting this section, support the area to avoid
breaking the cover.
Bezel hook
Rear Cover hook
Trying to remove the Rear Cover as shown in this illustration will break the hooks securing it to the Bezel.
A To avoid damaging the AC Power Supply 51

Cord, remove 1 screw from the AC Cover
Hold the 52
and disconnect the 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
53
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.
D Gently hold down the Rear Cover as shown in the steps below, then grasp the inside bottom corner and carefully lift 54
the Rear Cover to release the hooks.

USE CAUTION 51 4-409-316-02 REAR COVER (40NK2) [52] ! 53 1-839-679-11 CORD, POWER (WITH CONNECTOR)
to avoid breaking this
area of the Rear Cover (KDL-40EX645 ONLY) 54 4-299-528-01 AC COVER
51 4-409-325-01 REAR COVER (46NK2) [52]
E Lift the Rear Cover from the bottom and (KDL-46EX641/46EX645 ONLY) ¶ 4-256-393-01 SCREW, +PSW M3X6 W12
push forward to release the top hooks. 51 4-409-328-01 REAR COVER (55NK2) [52] ´ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3
(KDL-55EX645 ONLY) ² 4-159-298-01 SCREW, +PSW M4X10
52 4-409-322-01 BRACKET, VESA (NK2) ° 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 19
KDL-50EX645 ONLY QXPHUR VSHFL¿H See Appendix A: Encryption Key Components in the back of this manual.
CAUTION: (Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues).
Hold down the Rear Cover as shown in the steps below to avoid deforming or damaging the hooks in the Rear
Cover and Bezel.
The portion of the Rear Cover near the Switch Unit is very fragile. When lifting this section, support the area to avoid
breaking the cover.
Bezel hook
Rear Cover hook
Trying to remove the Rear Cover as shown in this illustration will break the hooks securing it to the Bezel.
101
A To avoid damaging the AC Power Supply Disconnect the
Cord, remove 1 screw from the AC Cover Power Supply Cord,
102
and disconnect the AC Power Cord. Hold the then remove Screw
Power Supply Cord
Remove 1 screw from the Rear Cover.
103
B Remove the 22 remaining screws from

the Rear Cover.
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.
D Gently hold down the Rear Cover as shown in the steps below, then grasp the inside bottom corner and carefully lift
the Rear Cover to release the hooks.
104
KDL-50EX645 ONLY
101 4-426-493-01 REAR COVER (50NK2) [102] ý 4-440-924-01 LADDER SCREW, M4X8
USE CAUTION 102 NA BRACKET, VESA (50NK2) 4-268-126-02 SCREW ORNAMENTAL, M6X12
to avoid breaking this
area of the Rear Cover ! 103 1-839-679-11 CORD, POWER (WITH CONNECTOR) ² 4-159-298-01 SCREW, +PSW M4X10
104 4-299-528-01 AC COVER ¶ 4-256-393-01 SCREW, +PSW M3X6 W12
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 20
MAIN BOARD (A) AND POWER SUPPLY BOARD (GL5A/GL5B/GE50/GE55) ZLWK SDUW QXPEHU VSHFL¿HG Ne les remplacer que par une piece portant le these components are repaired and/or replaced.
REMOVAL QXPHUR VSHFL¿H See Appendix A: Encryption Key Components in the back of this manual.

A Detach Side Jack Cover from A Board.
B Remove screws and disconnect connectors from A Board. 151 160
C Remove screws and disconnect connectors from GL5A/GL5B/GE55 Board.
D Disconnect connectors, then slide-out Left and Right Speakers.
E Release clips and disconnect 1 connector from H Board.
F Lift up Switch Unit and disconnect 1 connector.
G Disconnect connectors and remove screws from the Wireless LAN Card and the Wi-Fi Antenna to detach.
159
H Remove Insulation Sheet.
NOTE: The Insulation Sheet is only included in the 40” and 46” models.
152
158
H
157
156
155
154
A 153

E
151 4-409-317-01 SHEET, INSULATION (NK2) 156 1-846-302-21 WIFI ANTENNA CABLE (W)
B
(KDL-40EX645/46EX641/46EX645 ONLY) (KDL-40EX645 ONLY)
C ORDER THIS PART WHEN REPLACING THE LCD PANEL 156 1-846-299-21 WIFI ANTENNA CABLE (W)
G 152 1-895-173-12 GL5A STATIC CONVERTER (TV) (KDL-46EX641/46EX645/55EX645 ONLY)
D
(KDL-40EX645 ONLY) 157 1-458-353-33 WIRELESS LAN CARD
152 1-895-174-11 GL5B STATIC CONVERTER (TV) 158 1-895-176-11 H BOARD, MOUNTED
(KDL-46EX641/46EX645 ONLY)
152 1-895-175-11 GE55 BOARD, MOUNTED 159 1-895-307-11 A BOARD, COMPLETE
(KDL-55EX645 ONLY) AFTER REPLACING THE MAIN BOARD, YOU MUST UPDATE THE
SOFTWARE TO THE LATEST VERSION
F 153 1-489-986-11 SWITCH UNIT 160 4-409-321-01 COVER, SIDE JACK (NK2)
154 1-858-715-11 LOUDSPEAKER (3X15CM)
155 1-846-302-11 WIFI ANTENNA CABLE (W) ³ 2-990-421-41 SCREW, (+PSW) (M3X6)
(KDL-40EX645 ONLY)
155 1-846-299-11 WIFI ANTENNA CABLE (W)
(KDL-46EX641/46EX645/55EX645 ONLY)
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 21
KDL-50EX645 ONLY (Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues).
A Detach Side Jack Cover from A Board.
B Remove screws and disconnect connectors from A Board.
C Remove screws and disconnect connectors from GE50 Board.
D Disconnect connectors, then slide-out Left and Right Speakers.
E Release clips and disconnect 1 connector from H Board. 211
F Lift up Switch Unit and disconnect 1 connector. 201
G Disconnect connectors and remove screws from the Wireless LAN Card and the Wi-Fi Antenna to detach.
H Remove Insulation Sheet.
210
202
209
203
208
207
A 206
205
204
G
D KDL-50EX645 ONLY
C REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
201 4-426-506-01 SHEET, INSULATION (50NK2) 210 1-895-307-11 A BOARD, COMPLETE

ORDER THIS PART WHEN REPLACING THE LCD PANEL AFTER REPLACING THE MAIN BOARD, YOU MUST UPDATE THE
202 1-895-316-11 GE50 BOARD, MOUNTED SOFTWARE TO THE LATEST VERSION
F 203 4-440-965-01 SPACER, PSU (50NK2) 211 4-409-321-01 COVER, SIDE JACK(NK2)
204 1-489-986-11 SWITCH UNIT
205 1-858-715-11 LOUDSPEAKER (3X15CM) ³ 2-990-421-41 SCREW, (+PSW) (M3X6)

208 1-458-353-33 WIRELESS LAN CARD
209 1-895-176-11 H BOARD, MOUNTED
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 22
LCD PANEL REMOVAL ZLWK SDUW QXPEHU VSHFL¿HG Ne les remplacer que par une piece portant le these components are repaired and/or replaced.
ALL MODELS EXCEPT KDL-50EX645 (Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues).
A Remove 2 screws, then press Bezel tabs and lift-up Panel Brackets (H).
B Press Bezel tabs and tilt-up Panel Brackets (V).
C Remove screws and lift up Bottom Frame.
D Gently lift-up LCD Panel.
251
Panel Bracket (H)
A
252
Bezel tab 252
254
D 253
Panel Bracket (V)
Bezel tab
254
255
C
251 4-409-314-01 BEZEL (40NK2) 254 4-299-509-01 BRACKET, PANEL (V)

(KDL-40EX645 ONLY) 255 4-409-323-02 FRAME, BOTTOM (40NK2)
251 4-409-324-01 BEZEL (46NK2) (KDL-40EX645/46EX641/46EX645 ONLY)
(KDL-46EX641/46EX645 ONLY) 255 4-409-326-02 FRAME, BOTTOM (55NK2)
251 4-409-327-01 BEZEL (55NK2) (KDL-55EX645 ONLY)
(KDL-55EX645 ONLY)
252 4-299-512-01 BRACKET, PANEL (H) ¶ 4-256-393-01 SCREW, +PSW M3X6 W12
´ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3
253 NA LCD PANEL ² 4-159-298-01 SCREW, +PSW M4X10
FOR ALL LCD PANEL AND TCON BOARD PART NUMBER
INFORMATION REFER TO THE LCD PANELS SERVICE MANUAL
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 23
KDL-50EX645 ONLY (Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues).
A Remove 2 screws, then press Bezel tabs and lift-up Panel Brackets (H).
B Press Bezel tabs and tilt-up Panel Brackets (50NK2 V).
C Remove screws and tilt-up the Brackets SJ.
D Remove Screws and lift up the WiFi Brackets. 301
E Remove screws and lift up Bottom Frame.
F Gently lift-up LCD Panel.
Panel Bracket (H)
Bezel tab 302
F 302
Panel Bracket (50NK2 V)
304
B 303
Bezel tab
D
E
Bracket, WIFI (NK2)
304
Bracket SJ
307
C 305 306
CLEANING THE LCD PANEL
CAUTION: When cleaning the TV, be sure to unplug the power cord to avoid any chance of electric shock.
Clean the cabinet of the TV with a dry soft clothand wipe the LCD screen gently with a soft cloth. KDL-50EX645 ONLY
; Stubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water.
; If using a chemically pretreated cloth, please follow the instruction provided on the package.
; Never use strong solvents such as a thinner, alcohol or benzine for cleaning. 301 4-426-491-01 BEZEL (50NK2) 304 4-426-495-01 BRACKET, PANEL (50NK2 V)
; Periodic vacuuming of the ventilation openings is recommended to ensure proper ventilation. 302 4-299-512-01 BRACKET, PANEL (H) 305 4-426-504-01 BRACKET, KEY (50NK2)
306 4-426-497-01 FRAME, BOTTOM (50NK2)
; Do Not use paper towels, any type of abrasive pad, rags, rubber or vinyl materials to clean the screen. Using these
303 NA LCD PANEL 307 4-426-498-01 BRACKET, SJ (50NK2)
materials could easily scratch the screen which may result in permanent damage.
FOR ALL LCD PANEL AND TCON BOARD PART NUMBER
; Do Not use any cleaning product containing alkaline/acid cleaner, scouring powder, or volatile solvent, such as alcohol, INFORMATION REFER TO THE LCD PANELS SERVICE MANUAL ý 4-440-924-01 LADDER SCREW, M4X8
ammonia, benzine, thinner or insecticide. 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 24
CONNECTORS QXPHUR VSHFL¿H See Appendix A: Encryption Key Components in the back of this manual.
KDL-40EX645 ONLY KDL-46EX641/46EX645 ONLY
351 401
352 402
353
403
355 405
354
404
404
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
351 1-910-105-22 CONNECTOR ASSEMBLY 40 MB-PSU 15P 354 1-910-105-16 CONNECTOR ASSEMBLY 40 MB-SP-IR-KEY 401 1-910-105-23 CONNECTOR ASSEMBLY 46 MB-PSU 15P 404 1-910-105-17 CONNECTOR ASSEMBLY 46 MB-SP-IR-K
352 1-910-105-31 (LVDS) CONNECTOR ASSEMBLY 40 FFC 51P 355 1-910-107-30 CONNECTOR ASSEMBLY 40 MB-WIFIML 5P 402 1-910-105-29 (LVDS) CONNECTOR ASSEMBLY 46 FFC 51P 405 1-910-107-31 CONNECTOR ASSEMBLY 46 MB-WIFIML 5P
353 1-910-105-30 (LVDS) CONNECTOR ASSEMBLY 40 FFC 41P 403 1-910-105-28 (LVDS) CONNECTOR ASSEMBLY 46 FFC 41P
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 25
KDL-50EX645 ONLY KDL-55EX645 ONLY
451
501
452
453
454 502
456
455 503
504 505
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
451 1-910-107-00 CONNECTOR ASSEMBLY 50 15P MB-PSU 454 1-910-107-01 (LVDS) CONNECTOR ASSEMBLY 50 41P FFC 501 1-910-105-24 CONNECTOR ASSEMBLY 55 MB-PSU 15P 504 1-910-105-18 CONNECTOR ASSEMBLY 55 MB-SP-IR-KEY
&211(&725 $66(0%/< 368í/(' 3 455 1-910-106-99 CONNECTOR ASSEMBLY 50 MB-SP-IR-KEY 502 1-910-103-89 (LVDS) CONNECTOR ASSEMBLY 55 FFC 51P 505 1-910-107-32 CONNECTOR ASSEMBLY 55 MB-WIFIML 5P
453 1-910-107-02 (LVDS) CONNECTOR ASSEMBLY 50 51P FFC 456 1-910-107-29 CONNECTOR ASSEMBLY 50 MB-WIFIML 5P 503 1-910-103-88 (LVDS) CONNECTOR ASSEMBLY 55 FFC 41P
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 26
Ne les remplacer que par une piece portant le
SCREWS ZLWK SDUW QXPEHU VSHFL¿HG
QXPHUR VSHFL¿H
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.
KDL-40EX645 (Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues).
P/N DESCRIPTION REMARKS TOTAL
· 4-421-427-01 SCREW, +PSW M5X16 LOCK TABLE-TOP STAND(3), HEAD to NECK(1), NECK to BASE(3) 7
¶ 4-256-393-01 SCREW, +PSW M3X6 W12 RC(5), AC CVR(1), PNL BRKTS(2) 8
µ 7-685-647-79 SCREW, +BVTP 3X10 TYPE2 IT-3 HEAD(2), BASE(5) 7
´ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3 RC(7), BTM FRM(2) 9
³ 2-990-421-41 SCREW, (+PSW) (M3X6) A BOARD(5), GL5A(5) WF ANT(2), WF CARD(2) 14
² 4-159-298-01 SCREW, +PSW M4X10 RC(2), BTM FRM(6) 8
° 4-400-043-01 JOINT, SCREW RC(2) 2
¯ 7-685-646-79 SCREW, +BVTP 3X8 TYPE2 IT-3 TERMINAL(1), SIDE JACK(1), VESA(2) 4
KDL-46EX641/46EX645

´ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3 RC(7), BTM FRM(2) 9
³ 2-990-421-41 SCREW, (+PSW) (M3X6) A BOARD(5), GL5A(5) WF ANT(2), WF CARD(2) 14
° 4-400-043-01 JOINT, SCREW RC(2) 2
KDL-50EX645

¶ 4-256-393-01 SCREW, +PSW M3X6 W12 AC CVR(1) 1
´ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3 RC(9) 9
³ 2-990-421-41 SCREW, (+PSW) (M3X6) A BOARD(5), GE50(5) WF ANT(2), WF CARD(2), MB BRT(4) 17
² 4-159-298-01 SCREW, +PSW M4X10 BTM FRM(4) WF BRKT(1), AC BRKT(1), K BRKT(1) BTM FRM BRKT (2) 9
° 4-400-043-01 JOINT, SCREW RC(2) 2
ý 4-440-924-01 LADDER SCREW, M4X8 RC(6), PNL BRKTS(2) 8
7-685-646-79 SCREW ORNAMENTAL, M6X12 VESA(2) 2
KDL-55EX645

´ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3 RC(9) 9
³ 2-990-421-41 SCREW, (+PSW) (M3X6) A BOARD(5), GE55(4), WF ANT(2), WF CARD(2) 13
° 4-400-043-01 JOINT, SCREW RC(2) 2
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 27
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)
(KDL-40EX645/50EX645/55EX645 ONLY)
4-415-215-11 SUPPLEMENT (STAND INSTALLATION)
MISCELLANEOUS
4-440-967-01 GASKET, TAPE (50NK2)

(KDL-50EX645 ONLY)
3-299-071-06 FLYER, SAFETY
OPTIONAL ACCESSORIES
4-414-470-01 SUPPORT BELT KIT
REMOTE COMMANDER
1-490-009-11 REMOTE COMMANDER (RM-YD075)
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 28
WIRE DRESSING
OVERALL WIRE DRESSING FOR KDL-40EX645 ONLY OVERALL WIRE DRESSING FOR KDL-50EX645 ONLY
OVERALL WIRE DRESSING FOR KDL-46EX641/46EX645 ONLY OVERALL WIRE DRESSING FOR KDL-55EX645 ONLY
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 29
SECTION 5 - UPDATES AND ADJUSTMENTS
OVERVIEW Customer Support Center and it is deemed to be correctable with a software

update, the issue is handled at the customer level.
The models in this manual utilize a “generic” type of Main Board, therefore a Software updates can be performed by:
software update must be performed and certain service adjustment settings
PXVW EH FKDQJHG RU FRQ¿UPHG ZKHQHYHU WKH 0DLQ %RDUG /&' 3DQHO RU ” Customer Manual Downloads
TCON Board is replaced. Software updates can be accessed by the customer from
There are 2 reasons for updating the software on the TVs. the Sony Support Site at http://esupport.sony.com where
they can be downloaded and placed on a USB thumb drive
” Software updates for customers to be loaded onto the TV. The instructions for downloading
These updates are for enhancements or improvements that WKH VRIWZDUH ¿OH YDU\ IURP FKDVVLV WR FKDVVLV DQG VRPHWLPHV
have been made to the software after the TV was released. from model to model. The customer is provided with the
These updates are accessed by the customer from the Sony instructions to properly format the USB thumb drive, unzip
Support Site at http://esupport.sony.com. WKH ¿OH DQG WKH SURFHGXUHV IRU ORDGLQJ WKH VRIWZDUH LQWR WKH
” Software update for servicers television.
7KHVH XSGDWHV DUH VSHFL¿FDOO\ IRU VHUYLFHUV WR XVH GXULQJ D ” Network Downloads
service call and are only available on the Sony Authorized Internet software updates are becoming more prevalent
Servicer Portal at http://www.sony.com/asp. as more and more models incorporate home network
capabilities. This method is the most practical since the
television will check for the latest version of software. The
SOFTWARE UPDATES FOR CUSTOMERS models with this type of chassis provide the customer with a
choice of turning the automatic software update feature on or
The subject of software updates is very important. The televisions of today off. If set to on, the television will lookup software information
have advanced to the point where they are not simply a television anymore. while the unit is in standby. If a newer version is available, it
They are evolving into devices that are designed to integrate with numerous will be downloaded and installed without any input from the
other devices found in the home. Some examples are: portable audio and customer.
video devices, still cameras, home computer networks and accessing the
internet to name a few. SOFTWARE UPDATES FOR SERVICERS
Communications with these varying devices requires that the television be Replacement Main Boards are now stocked with basic software. Once the
compatible with varying communications protocols. Although standards replacement board is installed in the TV, the most current software needs
are detailed for each of these protocols, the real world dictates that to be installed using a USB thumb drive containing the necessary software.
occasional errors may occur that could prevent devices from operating or
communicating properly. 7KLV QHZ PHWKRG RI VXSSO\LQJ 0DLQ %RDUGV VLJQL¿FDQWO\ UHGXFHV WKH
complexity of replacing the Main Boards. Information about the LCD panel
Keeping the software in the television up-to-date is a procedure that is is stored on the TCON circuits. This information is automatically loaded
normally handled by the owner of the television. Most customers who own onto the Main Board when the TV is powered up. With the correct software
computers and other digital devices are familiar with and are accustomed 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 30
SOFTWARE UPDATE RESPONSIBILITY EXAMPLES OF SOFTWARE CORRECTABLE SYMPTOMS

Software updates are designed to be performed by the customer. Warranty Always check the Sony Authorized Servicer Portal at www.sony.com/asp
repairs in which the issue can be resolved by a software update are not site for any known and/or listed issues that are software related. Most
reimbursable. Most issues involving software updates are handled by the symptoms that are correctable by software updates involve communications
customer service center and should not be directed to an authorized service LVVXHV ZLWK RWKHU GHYLFHV RU PLQRU JOLWFKHV LQ WKH RSHUDWLRQ RI D VSHFL¿F
center. It is the responsibility of the servicer to prevent service calls for function. Below is a list of some of the symptoms that may be corrected with
issues that involve software updates. Exceptions to this are certain cases a software update:
whereby the customer is unable or unwilling to perform the task. In this ” Fluctuations in picture brightness
VLWXDWLRQ WKH VHUYLFHU ZLOO EH QRWL¿HG DQG UHFHLYH WKH SURSHU DXWKRUL]DWLRQ
for reimbursement. ” Intermittent picture freezing or noise
It is the servicer’s responsibility, however, to make certain that any TV ” Problems with certain inputs (especially HDMI)
requiring a legitimate service is running the latest software version ” Intermittent or distorted audio
and to install it if necessary.
” Erratic remote control operation
” Unit turns on and off by itself
CHECKING THE SOFTWARE VERSION
” Loss of color
The easiest way to check the version of software that is currently on the TV
is to access the Contact Sony screen by using the customer menu. ” Internet connectivity
” Certain features not working correctly
Contact Sony SKRWR RU YLGHR ¿OH YLHZLQJ
Please contact Sony directly if you have questions on the use of your television
Website Support: www.sony.com/tvsupport

United States Phone Contact: 1 (800) 222-SONY (7669)
Canada Phone Contact 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
Software Version: v0.006
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 31
OVERVIEW ACCESSING SERVICE ADJUSTMENT MODE

As mentioned on page 30, the models in this manual utilize a “generic” 1. TV must be in Standby mode.
type Main Board, therefore certain service adjustments settings must 2. Press the following buttons on the Remote Commander
EH FKDQJHG RU FRQ¿UPHG ZKHQ HLWKHU WKH 0DLQ %RDUG RU /&' 3DQHO DUH within a second of each other:
replaced.
DISPLAY Channel 5 Volume + POWER
UPDATING THE SOFTWARE
After replacing the Main Board or LCD Panel you MUST UPDATE the POWER
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 32
3. The Service Mode initial screen, will be displayed. COMPLETING SERVICE REQUIREMENTS WHEN
Service Mode
Sound Adjustment >>
REPLACING THE MAIN BOARD
Wide Band Tuning >>
Range Scan… >> The following must be performed after replacing the Main Board to ensure
Self diagnosis history >> that all of the features for the TV will be available.
Status Information… >>
; View the Status Information
LVDS Spectrum(%0) <[ 25 ]>
DPMS <[ Off ]> ; Select the Panel ID Code
Low of HPD <[ 5 ]>
TVD_MCDONE_CNT <[ 20 ]> ; Add the Serial Number
Demo Special >> ; Add the Model Name
Bypass AVI Info Detect <[ On ]>
Panel Selection <[ V500HK1-LS5 ]>
UART Selection No Log VIEWING THE STATUS INFORMATION
SERIAL NUMBER EDIT
MODEL NAME EDIT After replacing the Main Board you MUST UPDATE the SOFTWARE to the
latest version.
[</>]Set [Home] Exit
Whenever the Main Board is replaced, the software must be updated so that
4. Do one of the following: the new board syncs with the LCD Panel. If a message displays indicating
the latest software is already installed, proceed to Resetting the LCD Panel
a. Proceed to Completing Service Requirements when to Update the Software.
Replacing the Main Board. 5. Verify the latest software is installed before proceeding to
the service adjustments.
b. Proceed to Completing Service Requirements when
Replacing the LCD Panel. 6. Press until Status Information is selected.
Service Mode
Sound Adjustment >>
Wide Band Tuning >>
Range Scan… >>
DPMS <[ Off ]>
Low of HPD <[ 5 ]>
Demo Special >>
Panel Selection <[ 9_500HK1 ]>
UART Selection No Log
SERIAL NUMBER EDIT
MODEL NAME EDIT
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 33
7. Then press to view the Status Information screen. SELECTING THE PANEL ID CODE
8. The latest version is displayed as shown: CAUTION: You MUST SELECT THE CORRECT PANEL ID CODE for the
picture to display propertly.
MAIN FW VER: v0.006 Verify before proceeding to the next step:
MAIN NVM VER: 0.001 ; 9HUL¿HG 6WDWXV ,QIRUPDWLRQ
BOOT LOADER VER: 1 10. Press to select Panel Selection.
ANT-SW: Antenna Service Mode
Phy. Ch.: 2 Sound Adjustment >>
Wide Band Tuning >>
Status: Unlock Range Scan… >>
INT VER: 002125_3_001_916 Self diagnosis history >>
S/N: N/A LVDS Spectrum(%0) <[ 25 ]>
Freq. (k Hz): 55250 DPMS <[ Off ]>
Low of HPD <[ 5 ]>
Modulation NTSC TVD_MCDONE_CNT <[ 20 ]>
Offset Freq: N/A Demo Special >>
SERIAL NUMBER EDIT
MODEL NAME EDIT
9. Do one of the following:
a. If the latest software is installed, proceed to Selecting
the Panel ID Code. 11. Using the table below, press the or to select the
correct Panel Code for the Panel ID.
b. If the latest software is not installed, update the software
and then proceed to Selecting the Panel ID Code. Model Name Panel Code Panel Type Panel ID
KDL-40EX645 88_400HF10 SLCD LTY[ Z] 400HF10
KDL-46EX641 91_460HJ07 SLCD LTY[ Z] 460HJ07
KDL-50EX645 9_500HK1 CMI V500HK1-LS5
CAUTION: If you do not select the correct Panel ID Code,

the picture may not display.
12. Verify the Panel ID Code is correct before proceeding to the
next step.
13. Proceed to Adding the Serial Number.
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 34
ADDING THE SERIAL NUMBER Service Mode

Sound Adjustment >>
Verify before proceeding to the next step:
Wide Band Tuning >>
; 9HUL¿HG 6WDWXV ,QIRUPDWLRQ Range Scan… >>
; Selected the Panel ID Code Status Information… >>
14. Locate the Serial Number for the TV on the side of the Rear LVDS Spectrum(%0) <[ 25 ]>
DPMS <[ Off ]>
Cover of the TV.
Low of HPD <[ 5 ]>
MODEL NO TVD_MCDONE_CNT <[ 20 ]>
Demo Special >>
KDL-50EX645 Bypass AVI Info Detect <[ On ]>
SERIAL NO Panel Selection <[ 9_500HK1 ]>
5000004 UART Selection No Log
SERIAL NUMBER EDIT _ _ _ _ _ _ _ _
MODEL NAME EDIT
15. Press until SERIAL NUMBER EDIT is selected.
Service Mode
Sound Adjustment >> 17. Press or XQWLO WKH ¿UVW GLJLW RI WKH 6HULDO 1XPEHU RI
Wide Band Tuning >> the TV displays.
Range Scan… >>
Self diagnosis history >> Service Mode
Status Information… >> Sound Adjustment >>
LVDS Spectrum(%0) <[ 25 ]> Wide Band Tuning >>
DPMS <[ Off ]> Range Scan… >>
Low of HPD <[ 5 ]> Self diagnosis history >>
TVD_MCDONE_CNT <[ 20 ]> Status Information… >>
Demo Special >> LVDS Spectrum(%0) <[ 25 ]>
Bypass AVI Info Detect <[ On ]> DPMS <[ Off ]>
Panel Selection <[ 9_500HK1 ]> Low of HPD <[ 5 ]>
UART Selection No Log TVD_MCDONE_CNT <[ 20 ]>
SERIAL NUMBER EDIT Demo Special >>
MODEL NAME EDIT Bypass AVI Info Detect <[ On ]>
[</>]Set [Home] Exit UART Selection No Log
SERIAL NUMBER EDIT 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 35
18. Continue to use the and or to enter the remaining ADDING THE MODEL NAME
digits of the Serial Number. Verify before proceeding to the next step:
Service Mode
Sound Adjustment >> ; 9HUL¿HG 6WDWXV ,QIRUPDWLRQ
Wide Band Tuning >> ; Selected the Panel ID Code
Range Scan… >>
Self diagnosis history >> ; Added the Serial Number
CAUTION: The Model Name can only be selected once. Be sure to verify
DPMS <[ Off ]>
the information is correct before saving the changes.
Low of HPD <[ 5 ]> 23. Press until MODEL NAME EDIT is selected.
Service Mode
Demo Special >>
Sound Adjustment >>
Wide Band Tuning >>
Panel Selection <[ V500HK1-LS5 ]>
Range Scan… >>
MODEL NAME EDIT
DPMS <[ Off ]>
Low of HPD <[ 5 ]>
19. Verify the Serial Number is correct before proceeding to the
Demo Special >>
next step. Bypass AVI Info Detect <[ On ]>
20. When the complete Serial Number is displayed, press .
21. :KHQ WKH FRQ¿UPDWLRQ VFUHHQ GLVSOD\V SUHVV to select SERIAL NUMBER EDIT 5000004
MODEL NAME EDIT
YES and then press .
22. Proceed to Adding the Model Name.
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 36
24. Press WR EH DEOH WR VHOHFW WKH ¿UVW FKDUDFWHU 26. Continue to use the and or to enter the remaining
Service Mode characters of the Model Name.
Sound Adjustment >> Service Mode
Wide Band Tuning >> Sound Adjustment >>
Range Scan… >> Wide Band Tuning >>
Self diagnosis history >> Range Scan… >>
Status Information… >> Self diagnosis history >>
LVDS Spectrum(%0) <[ 25 ]> Status Information… >>
DPMS <[ Off ]> LVDS Spectrum(%0) <[ 25 ]>
Low of HPD <[ 5 ]> DPMS <[ Off ]>
TVD_MCDONE_CNT <[ 20 ]> Low of HPD <[ 5 ]>
Demo Special >> TVD_MCDONE_CNT <[ 20 ]>
Bypass AVI Info Detect <[ On ]> Demo Special >>
Panel Selection <[ 9_500HK1 ]> Bypass AVI Info Detect <[ On ]>
UART Selection No Log Panel Selection <[ 9_500HK1 ]>
SERIAL NUMBER EDIT 5000004 UART Selection No Log
MODEL NAME EDIT _ _ _ _ _ _ _ _ _ SERIAL NUMBER EDIT 5000004
MODEL NAME EDIT KDL- 50EX645
25. Press or XQWLO WKH ¿UVW FKDUDFWHU RI WKH 0RGHO 1DPH RI
the TV displays. 27. Verify the Model Name is correct before proceeding to the
Service Mode next step.
Sound Adjustment >>
28. When the complete Model Name is displayed, press .
Wide Band Tuning >>
Range Scan… >> 29. :KHQ WKH FRQ¿UPDWLRQ VFUHHQ GLVSOD\V SUHVV to select
Status Information… >> YES and then press .
DPMS <[ Off ]> 30. Press POWER to exit Service Mode.
Low of HPD <[ 5 ]>
Demo Special >>
MODEL NAME EDIT K _ _ _ _ _ _ _ _
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 37
COMPLETING SERVICE REQUIREMENTS WHEN VIEWING THE STATUS INFORMATION

After replacing the LCD Panel you MUST UPDATE the SOFTWARE to the
REPLACING THE LCD PANEL latest version. Verify the latest software is installed before proceeding to the
The following must be performed after replacing the LCD Panel. service adjustments.
; View the Status Information Whenever the LCD Panel is replaced, the software must be updated so that
the new board syncs with the LCD Panel. If a message displays indicating
; Verify the Panel ID Code the latest software is already installed, proceed to Resetting the LCD Panel
; Reset the Panel Operation Time to Update the Software.
1. TV must be in Standby mode. 3. For instructions refer to the section “Viewing the Status
2. Press the following buttons on the Remote Commander Information” on page 33.
within a second of each other: 4. Do one of the following:
DISPLAY Channel 5 Volume + POWER a. If the latest software is installed, proceed to Verifying
the Panel ID Code.
Service Mode
Sound Adjustment >>
b. If the latest software is not installed, update the software
Wide Band Tuning >>
Range Scan… >>
and then proceed to Verifying the Panel ID Code.
VERIFYING THE PANEL ID CODE
DPMS <[ Off ]> 5. Press to select Panel Selection.
Low of HPD <[ 5 ]>
Service Mode
Sound Adjustment >>
Demo Special >>
Wide Band Tuning >>
Range Scan… >>
MODEL NAME EDIT KDL-50EX645
DPMS <[ Off ]>
Low of HPD <[ 5 ]>
Demo Special >>
MODEL NAME EDIT KDL-50EX645
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 38
6. Using the table below, verify the correct Panel Code for the 11. Verify Panel Operation Time has been changed to 00000.
Panel ID. SELF CHECK
Model Name Panel Code Panel Type Panel ID
KDL-40EX645 88_400HF10 SLCD LTY[ Z] 400HF10 Back <<
KDL-46EX641 91_460HJ07 SLCD LTY[ Z] 460HJ07 002 MAIN_ POWER 000
KDL-46EX645 91_460HJ07 SLCD 003 DC_ALERT1 000
LTY[ Z] 460HJ07
003 AUDIO_PROT 000
KDL-50EX645 9_500HK1 CMI V500HK1-LS5
004 BALANCER_ERR 000
005 TCON_ERR 000
7. Proceed to Resetting the Panel Operation Time. 005 PANEL_ID_NVM_ERR 000
006 BACKLIGHT_ERR 000
007 TEMP_ERR 000
RESETTING PANEL OPERATION TIME
8. Press to select Self diagnosis history. 00150 00075 00000
9. On the Self Check screen, identify the Panel Operation [Home] Exit
Time location.
SELF CHECK 12. To exit the Self Check, press HOME .
Back <<
002 MAIN_ POWER 000
003 DC_ALERT1 000
003 AUDIO_PROT 000
004 BALANCER_ERR 000
005 TCON_ERR 000
005 PANEL_ID_NVM_ERR 000
006 BACKLIGHT_ERR 000
007 TEMP_ERR 000
00150 00075 00030
[Home] Exit
TOTAL OPERATION BOOT COUNT PANEL OPERATION

TIME TIME
10. Press 7 0 .
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 39
is a trademark of Sony Electronics
Reproduction in whole or part without written permission is prohibited. All rights reserved
Sony Corporation English
Sony LCSC 2012HJ74WEB-1
Technical Services Printed in USA
9-883-899-02 Service Publication Department © 2012.8
KDL-40EX645/46EX641/46EX645/50EX645/55EX645 40
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:
1. ,Q WKH VHUYLFH PDQXDO WKH &LUFXLW %RDUG V FRQWDLQLQJ HQFU\SWLRQ NH\ FRPSRQHQWV VKDOO EH LGHQWL¿HG ZLWK D UHG RXWOLQH DQG D .
2. Only repair boards or components listed in the service manual shall be utilized for replacement and/or repair.
3. Disassembly, decryption, or reverse-engineering component(s) is strictly prohibited.
4. Any board in which the Servicer replaces an encryption key component must be placed back into the set it orignally came from and the replaced
defective component MUST BE DESTROYED. Boards cannot be swapped.
5. ,I D &LUFXLW %RDUG LGHQWL¿HG ZLWK D UHG RXWOLQH DQG D in the service manual is deemed to be defective:
a. DQG LI D FRUH FKDUJH LV LPSRVHG DQG LV FRYHUHG XQGHU WKH SURGXFW ZDUUDQW\ WKH GHIHFWLYH XQ UHSDLUHG RU PRGL¿HG ERDUG 0867 %( 5(7851('
to Sony.
b. DQG LI WKH FRUH FKDUJH LV 127 FRYHUHG XQGHU WKH SURGXFW ZDUUDQW\ WKH GHIHFWLYH XQ UHSDLUHG RU PRGL¿HG ERDUG 0867 %( '(6752<('
6. ,I D XQLW LV GHVWUR\HG VXFK DV ¿HOG VFUDS WKH &LUFXLW %RDUG LGHQWL¿HG ZLWK D UHG RXWOLQH DQG D in the service manual MUST BE DESTROYED.
KDL-40EX640/46EX640/55EX640 A- 1

Sony Kdl-40ex645 40ex641 46ex645 50ex645 55ex645 Chassis Az3fk

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sony Kdl-40ex645 40ex641 46ex645 50ex645 55ex645 Chassis Az3fk

Uploaded by

Copyright:

Available Formats

Self Diagnosis

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE / TRAINING MANUAL

Version Date Subject

LCD Digital Color TV

SERVICE / TRAINING MANUAL

Cautions and Warnings ..................................................................................iii Section 4 - Disassembly/Part Number Information ....................................18

Chassis Overview ..........................................................................................3 KDL-50EX645 Only ................................................................................20

Section 5 - Updates and Adjustments .........................................................30

Appendix A: Encryption Key Components ............................................... A-1

! SAFETY-RELATED COMPONENT WARNING!!

SETTING UP AND CARRYING THE TV

USE CAUTION WHEN HANDLING THE LCD PANEL

CLEANING THE LCD PANEL

Clean the cabinet of the TV with a dry soft cloth.

2. Check the interboard wiring to ensure that no wires are “pinched” or

KDL-55EX645 VIDEO IN 1/2 VIDEO: 1 Vp-p, 75 ohms unbalanced, sync negative

HDMI: Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p

” /LIHOLNH PRYHPHQW ZLWK 0RWLRQÀRZŒ ;5 AUDIO OUT 500 mVrms (typical)

” Wi-Fi® adaptor included to stream HD entertainment1

Model name KDL- 55EX645 50EX645 46EX645/46EX641 40EX645

• Optional accessories availability depends on its stock.

WIRELESS LAN CARD H

WIRELESS LAN CARD H WIRELESS LAN CARD H

WIRELESS LAN CARD H

WIRELESS LAN CARD

LCD PANEL ASSEMBLY

OVERVIEW SELF DIAGNOSIS FUNCTION

” Problems with certain inputs (especially HDMI)

” TV turns on and off by itself

VIEWING THE SELF CHECK DIAGNOSIS HISTORY SELF CHECK

ALL MODELS EXCEPT KDL-50EX645

Composite ANALOG AUDIO OUT

Power/Control Power/Control Power/Control

OVERALL BLOCK DIAGRAM

Composite ANALOG AUDIO OUT

ALL MODELS EXCEPT KDL-50EX645

POWER AND CONTROL BLOCK DIAGRAM

11 BL_ERR LCD PANEL, TCON

STANDBY LED BLINKING

Yes Power Supply

“SONY” logo No Power Supply

PROTECTION SHUTDOWN FLOWCHART

Any OSD Yes

Is distortion No Lines move

Any horizontal Yes

Any single or Yes

VIDEO DISTORTION FLOWCHART

1 4-415-089-01 STAND, HEAD (ML9) x 6&5(: 36: 0 ; /2&.

A To avoid damaging the AC Power Supply 51

C Gently hold down the Rear Cover from the

ALL MODELS EXCEPT KDL-50EX645

B Remove the 22 remaining screws from

C Gently hold down the Rear Cover from

ALL MODELS EXCEPT KDL-50EX645

ALL MODELS EXCEPT KDL-50EX645

201 4-426-506-01 SHEET, INSULATION (50NK2) 210 1-895-307-11 A BOARD, COMPLETE

206 1-846-300-11 WIFI ANTENNA CABLE (W)

Panel Bracket (H)

Bezel tab 252

251 4-409-314-01 BEZEL (40NK2) 254 4-299-509-01 BRACKET, PANEL (V)

Bezel tab 302

KDL-40EX645 ONLY KDL-46EX641/46EX645 ONLY