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SERVICE MANUAL
ORIGINAL MANUAL ISSUE DATE: 2/2010 AZ1-L CHASSIS
Segment: 3a-0
Version Date Subject
1.0 02/2010 No revisions or updates are applicable at this time.
2.0 03/2010 Add updated Panel Caution Note (P.6) and “Label, Rear Terminal”
Part Number (P.41, 44, 47, 50, 53).
3.0 04/2010 Addition of Note about Sharp Edges on Rear Cover (P.13).
Addition of Appendix about Sharp Edges on Rear Cover (P.60~68).
Amend 32” (P.42) and 40” (P.45) Static Converter Part Numbers.
Add illustration showing location of neck to base screws (P.43, 46, 49, 52, 55).
4.0 07/2010 Add “Lens” Part Number (P.42, 45, 48, 51, 54). LCD Digital Color TV
5.0 08/2010 Add “Frame Bottom” Part Number (P44, 47)
6.0 08/2010 Correct “Lens” Part Number (P.42, 45, 48, 51, 54).
7.0 09/2010 Add “Cover, Hook” Part Number (P.41, 44, 47, 50, 53).
Add “Bracket, Panel” Part Number (P.42, 45, 48, 51, 54).
KDL-32/40/46/52/60EX700 9-888-277-07
Series(AEP/UK)
SERVICE MANUAL
AZ1-L CHASSIS
Segment: 3a-0
KDL-32/40/46/52/60EX700 9-888-277-07
Series(AEP/UK)
MODEL LIST
MODEL COLOR COMMANDER DEST. MODEL COLOR COMMANDER DEST.
KDL-32EX700 Black RM-ED035 AEP KDL-52EX700 Black RM-ED035 AEP
KDL-32EX701 Black RM-ED035 AEP KDL-52EX703 Black RM-ED035 UK
KDL-32EX703 Black RM-ED035 UK KDL-52EX705 Black RM-ED035 AEP
KDL-32EX705 Black RM-ED035 AEP KDL-60EX700 Black RM-ED035 AEP
KDL-32EX706 Black RM-ED035 AEP KDL-60EX703 Black RM-ED035 UK
KDL-32EX707 Black RM-ED033 AEP KDL-60EX705 Black RM-ED035 AEP
KDL-32EX709 Black RM-ED033 AEP
KDL-40EX700 Black RM-ED035 AEP
KDL-40EX701 Black RM-ED035 AEP
KDL-40EX703 Black RM-ED035 UK
KDL-40EX705 Black RM-ED035 AEP
KDL-40EX706 Black RM-ED035 AEP
KDL-40EX707 Black RM-ED033 AEP
KDL-40EX708 Black RM-ED033 AEP
KDL-40EX709 Black RM-ED033 AEP
KDL-46EX700 Black RM-ED035 AEP
KDL-46EX701 Black RM-ED035 AEP
KDL-46EX703 Black RM-ED035 UK
KDL-46EX705 Black RM-ED035 AEP
KDL-46EX706 Black RM-ED035 AEP
KDL-46EX707 Black RM-ED033 AEP
KDL-46EX708 Black RM-ED033 AEP
KDL-46EX709 Black RM-ED033 AEP
KDL-32/40/46/52/60EX700 Series(AEP/UK) 3
WARNINGS AND CAUTIONS - ENGLISH
CAUTION
These servicing instructions are for use by qualified service personnel only.
To reduce the risk of electric shock, do not perform any servicing other than that contained in the operating instructions unless you are qualified to
do so.
WARNING!!
An isolation transformer should be used during any service to avoid possible shock hazard, because of live chassis.
The chassis of this receiver is directly connected to the ac power line.
CARRYING THE TV
Be sure to follow these guidelines to protect your property and avoid causing serious injury.
• Carry the TV with an adequate number of people; larger size TVs require two or more people.
• Correct hand placement while carrying the TV is very important for safety and to avoid damages.
KDL-32/40/46/52/60EX700 Series(AEP/UK) 4
WARNINGS AND CAUTIONS - FRENCH
ATTENTION!!
Ces instructions de service sont à l’usage du personnel de service qualifi é seulement.
Pour prévenir le risque de choc électrique, ne pas faire l’entretien autre que celui contenu dans le Mode d’emploi à moins que vous soyez qualifi é
faire ainsi.
WARNING!!
Afi n d’eviter tout risque d’electrocution provenant d’un chássis sous tension, un transformateur d’isolement doit etre utilisé lors de tout
dépannage. Le chássis de ce récepteur est directement raccordé à l’alimentation du secteur.
ALERTE!!
Afi n d’eviter tout risque d’electrocution provenant d’un chassis sous tension, un transformateur d’isolement doit etre utilise lors de tout
depannage. Le chassis de ce recepteur est directement raccorde a l’alimentation du secteur.
KDL-32/40/46/52/60EX700 Series(AEP/UK) 5
WARNINGS AND CAUTIONS
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 (CCFL) or inverter circuit. (High voltage occurs at the inverter circuit at 650Vrms.)
7) Always clean the LCD panel with a soft cloth material.
8) Use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short.
9) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
10) It is recommended not to exceed 1 hour of Power-On nor Burn-in period with LCD panel face down condition, in repair activity.
KDL-32/40/46/52/60EX700 Series(AEP/UK) 6
SAFETY CHECK-OUT
After correcting the original service problem, perform the following safety checks before
releasing the set to the customer:
1. Check the area of your repair for unsoldered or poorly soldered connections. Check the entire
board surface for solder splashes and bridges.
2. Check the 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 you have replaced all the insulators.
4. Look for unauthorized replacement parts, particularly transistors, that were installed during a
previous repair. Point them out to the customer and recommend their replacement.
5. Look for parts which, though functioning, show obvious signs of deterioration. Point them out
to the customer and recommend their replacement.
6. Check the line cords for cracks and abrasion. Recommend the replacement of any such line
cord to the customer.
7. Check the antenna terminals, metal trim, “metallized” knobs, screws, and all other exposed
metal parts for AC leakage. Check leakage as described below.
8. For safety reasons, repairing the Power board and/or Inverter board is prohibited.
KDL-32/40/46/52/60EX700 Series(AEP/UK) 7
SAFETY CHECK-OUT
Leakage Test
The AC leakage from any exposed metal part to earth ground and from all exposed metal parts to
any exposed metal part having a return to chassis, must not exceed 0.5 mA (500 microamperes).
Leakage current can be measured by any one of three methods.
1. A commercial leakage tester, such as the Simpson 229 or RCA WT-540A. Follow the
manufacturers’ instructions to use these instructions.
2. A battery-operated AC milliampmeter. The Data Precision 245 digital multimeter is suitable
for this job.
3. Measuring the voltage drop across a resistor by means of a VOM or battery-operated AC
voltmeter. The “limit” indication is 0.75 V, so analog meters must have an accurate low
voltage scale.
The Simpson’s 250 and Sanwa SH-63TRD are examples of passive VOMs that are suitable.
Nearly all battery-operated digital multimeters that have a 2 VAC range are suitable (see
Figure A).
KDL-32/40/46/52/60EX700 Series(AEP/UK) 8
SELF DIAGNOSIS FUNCTION
The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY LED will automatically begin to flash.
The number of times the LED flashes translates to a probable source of the problem.
A definition of the STANDBY LED flash indicators is listed in the instruction manual for the user’s knowledge and reference.
If an error symptom cannot be reproduced, the remote commander can be used to review the failure occurrence data stored in memory to reveal past
problems and how often these problems occur.
KDL-32/40/46/52/60EX700 Series(AEP/UK) 9
SELF DIAGNOSIS FUNCTION
0.5
0.5
3
KDL-32/40/46/52/60EX700 Series(AEP/UK) 10
SELF DIAGNOSIS FUNCTION
12345-00333-06789
KDL-32/40/46/52/60EX700 Series(AEP/UK) 11
SELF DIAGNOSIS FUNCTION
Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screen.
After you have completed the repairs, clear the result display to “0”.
KDL-32/40/46/52/60EX700 Series(AEP/UK) 12
SEC 1. DISASSEMBLY
1-1. MOVIE LIST
Note: Metal type Rear Cover is used in these models.
When handle the Rear Cover, please pay special attention to the sharp edges due to no curing finish.
When working, wearing gloves is recommended.
Location of the sharp edges, please refer to “APPENDIX”.
KDL-32EX700
KDL-32EX700 Series
Series
KDL-40EX700
KDL-40EX700 Series
Series
KDL-46EX700
KDL-46EX700 Series
Series
KDL-52EX700
KDL-52EX700 Series
Series
KDL-60EX700
KDL-60EX700 Series
Series
KDL-32/40/46/52/60EX700 Series(AEP/UK) 13
SEC 2. ADJUSTMENT
HOW TO ENTERING SERVICE MODE
1) Turn on the main power switch to place this set in standby mode.
2) Press the buttons on the remote commander as follows, and entering service mode.
Item name
CHASSIS SERVICE
DIGITAL SERVICE Item number 000 CXD2813R
Category name
000 H_DET_NOSIG_CNT 1
001 OP
000 VERS --- Category number
Data
<MAIN> <SUB>
DM1.301J00AA SM1.010W00AA
M2.105C SB1.000W00AA
DD1.016J00AA SD1.010W00AA
(DM1.301J00AA) RF01.05 Press “OPTIONS”
WP00.521J00AA ID1C117081
ID1C117081 LTY320AB01 or “JUMP” button
PID04020000
WF:2.0.0.99 <BEM>
WF:0B BM1.012W00LU
Camera FW BB1.000W00LU
Camera FW BD1.011J46LUX
---.---------
KDL-32/40/46/52/60EX700 Series(AEP/UK) 14
ADJUSTMENT
5) After entering service mode, then turn off the power switch.
KDL-32/40/46/52/60EX700 Series(AEP/UK) 15
ADJUSTMENT
DIGITAL SERVICE
DIGITAL SERVICE WB
006 WB *1 R_DRV 128
000 WHITE_BALANCE ___ 2 G_DRV 128 Gain
0: x 0.5, 128: x 1, 255: x1.5
3 B_DRV 128
4 R_BKG 128
5 G_BKG 128 Offset
6 B_BKG 128 128: offset 0
KDL-32/40/46/52/60EX700 Series(AEP/UK) 16
ADJUSTMENT
CHASSIS WRITE
000 CXD2813R
000 H_DET_NOSIG_CNT 1
KDL-32/40/46/52/60EX700 Series(AEP/UK) 17
ADJUSTMENT
CHANGE DATA
Note: “Digital” service mode don’t have to Save. (except “002 MODEL” category)
1) Change Data of “Digital” service mode. (except “003 DIG_SRV_MODE” category)
DIGITAL SERVICE
a. Press “2 / 5” on remote to select (up / down) category. 004 TUNER
b. Press “1 / 4” on remote to select (up / down) Item. 000 A_NOSIG_DET 001
c. Press “0 / 10” on remote to select item.
DIGITAL(DIG_SRV_MODE) SERVICE
TEST_PATTERN
*1 Video
2 Audio
KDL-32/40/46/52/60EX700 Series(AEP/UK) 18
ADJUSTMENT
KDL-32/40/46/52/60EX700 Series(AEP/UK) 19
ADJUSTMENT
KDL-32/40/46/52/60EX700 Series(AEP/UK) 20
SEC 3. TROUBLE SHOOTING
3-1. TRIAGE CHART
Note: Power board is different in name every inch. Therefore this section displays difference point in "*".
: doubtful part
: Few pos s ibility
KDL-32/40/46/52/60EX700 Series(AEP/UK) 21
TROUBLE SHOOTING
START
Yes Yes
END
Is the Standby Led No See
blink ? Standby LED Blink
Yes
Yes
Do the buttons
No See
on the TV & Remote
TV/ Commander
Commander work
button malfunction
properly?
Yes
KDL-32/40/46/52/60EX700 Series(AEP/UK) 22
TROUBLE SHOOTING
3-3. NO POWER
No Power
SW OFF
Check
Turn on the Switch
Power Saving Switch
SW ON
OK OK
Harness
BAL Board
KDL-32/40/46/52/60EX700 Series(AEP/UK) 23
TROUBLE SHOOTING
2 times Blinkings
12V OK OK
KDL-32/40/46/52/60EX700 Series(AEP/UK) 24
TROUBLE SHOOTING
Check +12.5V NG
DC_ALERT at pin 2 of
G* Board
CN3800 on
Check D+3.3V at NG the BAL Board
F3700,IC3700,etc
JL3715 or JL3716
(BAL Board) OK
on the BAL Board
OK NG
Check +12.5V_AU1
F4200,IC4200,etc
at F4200 on
(BAL Board)
the BAL Board
Check +5V_MAIN NG
F3701,IC3701,etc
at JL3731 or JL3732 on
(BAL Board) OK
the BAL Board
FE/BE Communication
OK
IC9000,etc
(BAL Board)
KDL-32/40/46/52/60EX700 Series(AEP/UK) 25
TROUBLE SHOOTING
4 times Blinkings
BAL Board
KDL-32/40/46/52/60EX700 Series(AEP/UK) 26
TROUBLE SHOOTING
5 times Blinkings
NG NG
Check PANEL_VCC
Panel (T-con)
at JL3806 G* Board BAL Board
change
on the BAL Board
NG Panel (T-con)
Between G* to Panel
Harness
harness check
OK
NG
LVDS Harness
LVDS Harness
check
OK
KDL-32/40/46/52/60EX700 Series(AEP/UK) 27
TROUBLE SHOOTING
Under 2.65V
Check Setting circumstance NO
PANEL_FAIL at is OK? Set to another
BAL Board
JL2565 Temperature, Location, etc.
on the BAL Board Ventilation, etc.
NG
Change BAL Board,
Panel
and Aging a few hours
OK
NG BAL Board
Change G* Board Panel (T-con)
OK
G* Board
KDL-32/40/46/52/60EX700 Series(AEP/UK) 28
TROUBLE SHOOTING
3-5. NO PICTURE
No Picture
NO YES BL_ON:H NG
PANEL_VCC Check
Press HOME Key Replace LCD Panel
At JL3806 on the BL_ON at JL2566
XMB (Menu) displayed? the LVDS Harness (T-con)
BAL Board on the BAL Board
OK
NG
Change BAL Board G* Board
OK
BAL Board
KDL-32/40/46/52/60EX700 Series(AEP/UK) 29
TROUBLE SHOOTING
3-6. NO SOUND
No Sound
“Audio System”
Check the Change to
“Speakers setting” “TV Speaker”
“TV Speakers”
OK OK
Check the Speaker Replace
BAL Board
Harness the BAL Board
NG NG
KDL-32/40/46/52/60EX700 Series(AEP/UK) 30
TROUBLE SHOOTING
Button malfunction
on the TV
OK OK
BAL to Switch Unit
Switch Unit change Switch Unit
harness check
NG NG
KDL-32/40/46/52/60EX700 Series(AEP/UK) 31
TROUBLE SHOOTING
TV isn’t controlled
by remote commander
NG NG
NG
OK
Exchange the Harness Harness
NG
Exchange the OK
HLR Board
HLR Board
NG
BAL Board
KDL-32/40/46/52/60EX700 Series(AEP/UK) 32
TROUBLE SHOOTING
OK NO
OK NO
NG BAL Board
Connection result
Proxy setting
Internet Access
KDL-32/40/46/52/60EX700 Series(AEP/UK) 33
SEC 4. DIAGRAMS
4-1. BLOCK DIAGRAM
KDL-32/40/46/52/60EX700 Series(AEP/UK) 34
DIAGRAMS
T-CON
GE3 Board
BAL Board
Switch Unit
Speaker (L)
Speaker (R)
HLR Board
HMS2 Board
KDL-32/40/46/52/60EX700 Series(AEP/UK) 35
DIAGRAMS
T-CON
GE3 Board
BAL Board
Switch Unit
Speaker (L)
Speaker (R)
HMS2 Board HLR Board
KDL-32/40/46/52/60EX700 Series(AEP/UK) 36
DIAGRAMS
GE2-B Board
T-CON
BAL Board
Switch Unit
Speaker (L)
GE2-B Board
T-CON
BAL Board
Switch Unit
Speaker (L)
GE2-A Board
T-CON
BAL Board
Switch Unit
Speaker (L)
KDL-32/40/46/52/60EX700 Series(AEP/UK) 39
SEC 5. EXPLODED VIEWS
• Items with no part number and no description are not stocked because they are seldom required for roution service.
• The construction parts of an assembled part are indicated with a collation number in the remark colum.
• Items marked " * " are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items.
KDL-32/40/46/52/60EX700 Series(AEP/UK) 40
EXPLODED VIEWS
KDL-32/40/46/52/60EX700 Series(AEP/UK) 41
EXPLODED VIEWS
22
19
18 20
KDL-32/40/46/52/60EX700 Series(AEP/UK) 42
EXPLODED VIEWS
KDL-32/40/46/52/60EX700 Series(AEP/UK) 43
EXPLODED VIEWS
KDL-32/40/46/52/60EX700 Series(AEP/UK) 44
EXPLODED VIEWS
19
20
18
KDL-32/40/46/52/60EX700 Series(AEP/UK) 45
EXPLODED VIEWS
KDL-32/40/46/52/60EX700 Series(AEP/UK) 46
EXPLODED VIEWS
KDL-32/40/46/52/60EX700 Series(AEP/UK) 47
EXPLODED VIEWS
19
18 20
KDL-32/40/46/52/60EX700 Series(AEP/UK) 48
EXPLODED VIEWS
KDL-32/40/46/52/60EX700 Series(AEP/UK) 49
EXPLODED VIEWS
7
4 11
8 9
Note: If ordering item 11 (Rear Cover Assy) please
order the correct “Label, Rear Terminal” as well.
4-164-921-01 - EX700/701/703
10 4-164-921-11 - EX705/706/707/708/709
KDL-32/40/46/52/60EX700 Series(AEP/UK) 50
EXPLODED VIEWS
19
18 20
KDL-32/40/46/52/60EX700 Series(AEP/UK) 51
EXPLODED VIEWS
KDL-32/40/46/52/60EX700 Series(AEP/UK) 52
EXPLODED VIEWS
7
11
4
9
8 Note: If ordering item 11 (Rear Cover Assy) please
order the correct “Label, Rear Terminal” as well.
4-164-921-01 - EX700/701/703
10
4-164-921-11 - EX705/706/707/708/709
KDL-32/40/46/52/60EX700 Series(AEP/UK) 53
EXPLODED VIEWS
19
18 20
KDL-32/40/46/52/60EX700 Series(AEP/UK) 54
EXPLODED VIEWS
KDL-32/40/46/52/60EX700 Series(AEP/UK) 55
5-6. OTHER PARTS
32 INCHES
40 INCHES
46 INCHES
KDL-32/40/46/52/60EX700 Series(AEP/UK) 56
52 INCHES
60 INCHES
KDL-32/40/46/52/60EX700 Series(AEP/UK) 57
5-6-3. REMOTE COMMANDER
5-6-4. MISCELLANEOUS
KDL-32/40/46/52/60EX700 Series(AEP/UK) 58
END
English
Sony Corporation 10IP7100-1
Sony UK Made in U.K.
9-888-277-07 Service Promotions Dept. © 2010. 09
KDL-32/40/46/52/60EX700 Series(AEP/UK) 59
APPENDIX
CAUTION TO SHARP EDGE OF REAR COVER(32)
OK
(Curling area)
NG
(Side Jack hole/Control button hole/Under cover area)
OK to grab
(curling area)
NG to grab
(sharp edge and
easy to deform.)
OK
(Note edge area)
KDL-32/40/46/52/60EX700 Series(AEP/UK) 60
APPENDIX
OK
(Curling area)
NG
(Side Jack hole/Control button hole/Under cover area)
OK to grab
(curling area)
NG to grab
(sharp edge and
easy to deform.)
OK
(Note edge area)
KDL-32/40/46/52/60EX700 Series(AEP/UK) 61
APPENDIX
OK
(Curling area)
NG
(Side Jack hole/Control button hole/Under cover area)
OK to grab
(curling area)
NG to grab
(sharp edge and
easy to deform.)
OK
(Note edge area)
KDL-32/40/46/52/60EX700 Series(AEP/UK) 62
APPENDIX
OK
(Curling area)
NG
(Side Jack hole/Control button hole/Under cover area)
OK to grab
(curling area)
NG to grab
(sharp edge and
easy to deform.)
OK
(Note edge area)
KDL-32/40/46/52/60EX700 Series(AEP/UK) 63
APPENDIX
OK
(Curling area)
NG
(Side Jack hole/Control button hole/Under cover area)
OK to grab
(curling area)
NG to grab
(sharp edge and
easy to deform.)
OK
(Note edge area)
KDL-32/40/46/52/60EX700 Series(AEP/UK) 64
APPENDIX
1. Lift up HOOK COVER a little to make gap between
REAR COVER and SP‐BRACKET.
2. Grab REAR COVER at the bottom area with gap.
Gap
KDL-32/40/46/52/60EX700 Series(AEP/UK) 65
APPENDIX
3. Hold REAR COVER
4. Lift up REAR COVER by both hands until around 20
degrees.
5. Pull REAR COVER downward to release hook at top
edge of BEZEL.
3
20
4
KDL-32/40/46/52/60EX700 Series(AEP/UK) 66
APPENDIX
1. Align the holes of REAR COVER to the hooks of
BEZEL at top edge, and insert.
2. Pushing RC at the middle of top edge (hook
portion) can help insertion completed.
1
20
Hook of BEZEL
Hole of REAR COVER
KDL-32/40/46/52/60EX700 Series(AEP/UK) 67
APPENDIX
3. Align Close while pushing RC on the top.
4. Pushing Confirm screw holes indicated below are
aligned, and screw these holes at first.
(Need to hold RC while screwing, otherwise RC
moves downward due to the gravity.)
3
4
KDL-32/40/46/52/60EX700 Series(AEP/UK) 68