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Sony KDL-22EX357 Service And Training Manual Download Page 1

SERVICE / TRAINING MANUAL

LCD Digital Color TV

AZ3FK 

Chassis

Segment: P-2L

9-883-894-02

Self Diagnosis

Supported model

Version Date 

Subject

1.0  

6/20/2012 

Original Manual Release Date.

2.0 

7/18/2012  

New Caution added on page ii.

 

 

  Updated Service Adjustments section. Replaced pages 17 - 21.

ORIGINAL MANUAL ISSUE DATE: 6/2012

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

Summary of Contents for KDL-22EX357

Page 1: ... 894 02 SelfDiagnosis Supported model Version Date Subject 1 0 6 20 2012 Original Manual Release Date 2 0 7 18 2012 New Caution added on page ii Updated ServiceAdjustments section Replaced pages 17 21 ORIGINAL MANUAL ISSUE DATE 6 2012 HISTORY INFORMATION FOR THE FOLLOWING MANUAL ...

Page 2: ...SERVICE TRAINING MANUAL LCD Digital Color TV AZ3FK Chassis Segment P 2L 9 883 894 02 SelfDiagnosis Supported model KDL 32EX357 ...

Page 3: ...EL COMMANDER DESTINATION MODEL COMMANDER DESTINATION 9 883 894 02 KDL 22EX357 RM YD081 COLOMBIA KDL 32EX357 RM YD081 COLOMBIA KDL 32EX358 RM YD081 COLOMBIA KDL 40EX457 RM YD081 COLOMBIA KDL 40EX458 RM YD081 COLOMBIA ...

Page 4: ... 40EX458 Only 17 LCD Panel Removal 18 KDL 22EX357 Only 18 KDL 32EX357 32EX358 40EX457 40EX458 Only 19 Reattaching the Bezel to the LCD Panel 20 Cleaning the LCD Panel 20 Connectors 21 Screws 21 Accessories and Packaging 22 Optional Accessories 22 Wire Dressing 23 Section 5 Updates and Adjustments 24 Overview 24 Software Updates for Customers 24 Software Updates for Servicers 24 Software Update Res...

Page 5: ...ARNING There are critical components used in LCD color TVs that are important for safety These components are identified with shading and mark on the schematic diagrams and the parts list It is essential that these critical parts be replaced only with the part number specified in the parts list to prevent electric shock fire or other hazard NOTE Do not modify the original design without obtaining ...

Page 6: ...el 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 ...

Page 7: ... 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 c...

Page 8: ...leakage Check leakage as described in Leakage Test 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 Follow the manufacturers instructions provided with the teste...

Page 9: ...2EX357 5 W 5 W Tomas de entrada salida CABLE ANTENNA Terminal externo de 75 ohm para entrada de señal de radiofrecuencia VIDEO IN 1 2 VIDEO 1 Vp p 75 ohm no equilibrado sincronización negativa AUDIO 500 mVrms Típico Impedancia 47 kiloohmios COMPONENT IN YPBPR video componente Y 1 0 Vp p 75 ohm no equilibrado sincronización negativa PB 0 7 Vp p 75 ohm PR 0 7 Vp p 75 ohm Formato de señal 480i 480p 7...

Page 10: ...tos horizontales 1080 líneas verticales 1366 puntos horizontales 768 líneas verticales Bocina Gama completa 2 mm 0 0 1 5 3 0 0 1 0 4 Dimensiones consoporte mm 941 617 233 753 509 213 534 376 147 sinsoporte mm 941 577 72 753 471 71 534 348 64 patrón de los orificios de montaje mural mm 300 300 200 100 100 100 tamaño de tornillos de montaje mural mm M6 8 12 mm M4 6 5 10 mm 7 4 8 7 9 1 1 g k e t r o ...

Page 11: ...upply Board GE22 Board for the 22 models GL8 Board for the 32 models and GL5 Board for the 40 models the IR Board H Board the Switch Unit and the LCD Panel Assembly which includes the TCON Board NOTE For connector part number information refer to Connectors on page 21 For Wire Dressing information refer to Wire Dressing on page 23 SWITCH UNIT H G A BOARD LAYOUT FOR ALL MODELS ...

Page 12: ...board contains the power channel and volume up down and menu buttons OVERALL CIRCUIT DESCRIPTION The Block Diagram on page 9 provides an overview of the AZ3FK chassis The following are descriptions of the boards and their functions MAIN BOARD 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 Contr...

Page 13: ...rom 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 Backlight system TCON BOARD The TCON Board communicates between the LCD Panel and the microprocessor on the Main Board NOTE The TCON Bo...

Page 14: ...ternet connectivity Certain features not working correctly photo or video file viewing SECTION 2 TROUBLESHOOTING SelfDiagnosis Supported model SELF DIAGNOSIS FUNCTION Critical voltages and circuit operations are monitored by the CPU on the 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 occu...

Page 15: ...0 003 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 00001 00036 00001 Home Exit SELF CHECK SAMPLE SELF CHECK DIAGNOSIS PAGE 2X Blink Main Power Error A loss of REG12V from the power supply triggers this protect event The usual cause is a failure of the main switching supply In some instances excessive loading ...

Page 16: ...at 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 ...

Page 17: ...site RF Composite HDMI 1 PC HD15 POWER SUPPLY SWITCH UNIT LED IR RX LCD PANEL TCON LED BACKLIGHTS A H L R ANALOG AUDIO OUT OPTICAL AUDIO OUT MT5367 A V DECODER A V PROCESS TUNER USB 1 HDMI 2 LVDS AC IN CLASS D AUDIO AMP GE22 22 GL8 32 HDMI 3 HDMI 4 Ethernet USB 2 GL5 40 MAIN BOARD IR BOARD OVERALL BLOCK DIAGRAM ...

Page 18: ...DIO_GND BL_ERR REG12V_GND REG12V 5 6 7 8 9 10 BL_ON TCON_12V DIMMER N C 11 12 13 14 TCON_ON 15 AC IN N AC IN H 1 2 CN6401 A N C DIMMER 13 14 CN6402 REG 12V GND AUDIO_12V 8 5 7 9 10 DIMMER BL_ERR 1 12 CN201 TCON_12V 14 AC_FF_DET TCON_ON 3 15 BL_ON 13 STBY 3 3V 4 POWER_ON 2 CN6101 LCD PANEL LED BACKLIGHTS GE22 22 GL8 32 GL5 40 POWER SUPPLY MAIN BOARD POWER AND CONTROL BLOCK DIAGRAM ...

Page 19: ...formation on page 15 No Power Is standby LED blinking No Yes No See Protection Shutdown flowchart Yes Does red standby LED on front panel light Press power button while monitoring pin 3 of CN6401 on power supply board High 3 3V on pin 3 Yes No Main Board Power Supply Board High 3 3V on pin 2 Yes No Power Supply Board Power Supply Board NO POWER FLOWCHART ...

Page 20: ...es 2X 3X 5X No Yes LCD Panel 6X Yes 7X No Immediately After a While Check room temperature and ventilation around unit Power Supply Board Main Board SONY logo appears before shutdown Yes No LCD Panel Power Supply Board Main Board PROTECTION SHUTDOWN FLOWCHART For Part Number information Refer to Section 4 Disassembly Part Number Information on page 15 ...

Page 21: ...n Unplug LVDS connector at TCON while unit is running This may need to be done more than once Any flashes seen on screen Yes No Any OSD graphics present No Main Board No LCD Panel Yes Yes Main Board LCD Panel NO VIDEO FLOWCHART For Part Number information Refer to Section 4 Disassembly Part Number Information on page 15 ...

Page 22: ...Video Distortion Is distortion across entire screen Any horizontal lines No No Yes Yes Improper of missing colors Yes Main Board No Vertical lines or bars No Yes Lines move when wide mode changed Yes No LCD Panel TCON Board Main Board LCD Panel Any single or isolated vertical lines Yes LCD Panel More than 1 vertical band No Yes LCD Panel TCON Board VIDEO DISTORTION FLOWCHART ...

Page 23: ...maging the AC Power Supply Cord remove the screw from the AC Cover and disconnect the AC Power Cord REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES 1 4 420 103 11 REAR COVER 22IRSF 2 KDL 22EX357 ONLY 1 4 420 104 11 REAR COVER 32IRSF 2 KDL 32EX357 32EX358 ONLY 1 4 420 105 11 REAR COVER 40IRSF 2 KDL 40EX457 40EX458 ONLY 2 4 421 636 01 BRACKET VESA 22IRSF KDL...

Page 24: ...x A Encryption Key Components in the back of this manual KDL 22EX357 ONLY A Remove screws and disconnect connectors from A Board Detach the Side Bracket from A Board B Detach the Side Bracket from A Board C Remove screws and disconnect connectors from GE22 Board D Slide out Left and Right Speakers then disconnect connectors E Release clips and disconnect connector from H Board F Lift up Switch Uni...

Page 25: ...E KDL 32EX357 ONLY AFTER REPLACING THE MAIN BOARD YOU MUST UPDATE THE SOFTWARE TO THE LATEST VERSION 102 1 895 264 71 A BOARD COMPLETE KDL 32EX358 ONLY AFTER REPLACING THE MAIN BOARD YOU MUST UPDATE THE SOFTWARE TO THE LATEST VERSION 102 1 895 264 51 A BOARD COMPLETE KDL 40EX457 ONLY AFTER REPLACING THE MAIN BOARD YOU MUST UPDATE THE SOFTWARE TO THE LATEST VERSION 102 1 895 264 91 A BOARD COMPLETE...

Page 26: ...Key Components in the back of this manual LCD PANEL REMOVAL KDL 22EX357 ONLY A Remove screws from LCD Bracket then release Bezel clips and gently lift up LCD Panel to detach from Bezel B Remove screws from LCD Bracket and lift up to detach from LCD Panel Screws Use CAUTION to avoid breaking the Bezel clips Bezel clips Screws REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES REF NO PART NO DESCRIPTION A...

Page 27: ...ket H Bezel tab A D Gently lift up LCD Panel CAUTION Refer to Figure 1 when pulling the Bezel away from the LCD Panel and then be sure to remove all of the double sided tape before reattaching the LCD Panel to the Bezel refer to Figure 2 FIGURE 1 FIGURE 2 201 4 420 101 01 BEZEL 32IRSF KDL 32EX357 ONLY 201 4 420 101 11 BEZEL 32IRSF KDL 32EX358 ONLY 201 4 420 102 01 BEZEL 40IRSF KDL 40EX457 ONLY 201...

Page 28: ...ter securing the double sided tape PN 4 435 135 01 to the new Bezel be sure to remove the paper protecting the tape before replacing the LCD Panel 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 and wipe the LCD screen gently with a soft cloth Stubborn stains may be removed ...

Page 29: ...51 1 910 106 19 CONNECTOR ASSEMBLY22MB H KEY SP14P KDL 22EX357 ONLY 251 1 910 106 24 CONNECTOR ASSEMBLY32MB H KEY SP14P KDL 32EX357 32EX358 ONLY 251 1 910 106 28 CONNECTOR ASSEMBLY40MB H KEY SP14P KDL 40EX457 40EX458 ONLY 252 1 910 106 22 LVDS CONNECTOR ASSEMBLY 22 FFC 30P KDL 22EX357 ONLY 252 1 910 106 26 LVDS CONNECTOR ASSEMBLY 32 FFC 30P KDL 32EX357 32EX358 ONLY 252 1 910 106 97 LVDS CONNECTOR ...

Page 30: ... 299 071 06 FLYER SAFETY 4 437 132 01 GEAR SCREW M3X5 4 428 003 31 GUIDE QUICK SET UP 4 427 844 31 MANUAL INSTRUCTION 4 416 690 11 SUPPLEMENT STAND INSTALLATION A 1890 428 A ACCESSORYASSEMBLY CO1 OPTIONAL ACCESSORIES PART NO DESCRIPTION 4 414 470 01 SUPPORT BELT KIT REMOTE COMMANDER PART NO DESCRIPTION 1 489 991 11 REMOTE COMMANDER RM YD081 ...

Page 31: ...KDL 22EX357 32EX357 32EX358 40EX457 40EX458 23 SECTION 4 DISASSEMBLY PART NUMBER INFORMATION WIRE DRESSING BOARD LAYOUT FOR ALL MODELS ...

Page 32: ...ng the software in their products If a customer contacts the Sony Customer Support Center and it is deemed to be correctable with a software update the issue is handled at the customer level Software updates can be performed by Customer Manual Downloads Software updates can be downloaded and placed on a USB thumb drive to be loaded onto the TV The instructions for downloading the software file var...

Page 33: ...software that is currently on the TV is to access the Contact Sony screen by using the customer menu Contact Sony Please contact Sony directly if you have questions on the use of your television con Website Support United States Phone Contact Model Name Serial Number Software Version Canada Phone Contact Other Countries Contact www sony com tvsupport 1 800 222 SONY 7669 1 877 899 SONY 7669 Consult...

Page 34: ...onfirmed when either the Main Board LCD Panel or TCON Board are replaced UPDATING THE SOFTWARE After replacing the Main Board LCD Panel or TCON Board you MUST UPDATE the SOFTWARE to the latest version ACCESSING SERVICE ADJUSTMENT MODE 1 TV must be in Standby mode 2 Press the following buttons on the Remote Commander within a second of each other DISPLAY Channel 5 Volume POWER DISPLAY POWER SELECT ...

Page 35: ...WHEN REPLACING THE MAIN BOARD The following must be performed after replacing the Main Board to ensure that all of the features for the TV will be available View the Status Information Select the Panel ID Code Add the Serial Number Add the Model Name VIEWING THE STATUS INFORMATION After replacing the Main Board you MUST UPDATE the SOFTWARE to the latest version 5 Verify the latest software is inst...

Page 36: ...ORRECT PANEL ID CODE for the picture to display propertly Verify before proceeding to the next step Verified the Status Information 10 Press to select Panel Selection Sound Adjust Wide Band Tuning Range Scan Self diagnosis history Status Information LVDS Spectrum 0 25 Panel Selection LTY320AN03 SERIAL NUMBER EDIT MODEL NAME EDIT Set Home Exit Service Mode 11 Using the table below press the or to s...

Page 37: ...ER EDIT MODEL NAME EDIT Set Home Exit Service Mode 16 Press to be able to select the first digit CAUTION The Serial Number can only be selected once Be sure to verify the information is correct before saving the changes Sound Adjust Wide Band Tuning Range Scan Self diagnosis history Status Information LVDS Spectrum 0 25 Panel Selection LTY320AN03 SERIAL NUMBER EDIT _ _ _ _ _ _ _ _ MODEL NAME EDIT ...

Page 38: ...g the Model Name ADDING THE MODEL NAME Verify before proceeding to the next step Verified Status Information Selected the Panel ID Code Added the Serial Number CAUTION The Model Name can only be selected once Be sure to verify the information is correct before saving the changes 23 Press until MODEL NAME EDIT is selected Sound Adjust Wide Band Tuning Range Scan Self diagnosis history Status Inform...

Page 39: ...2EX357 Set Home Exit Service Mode 27 Verify the Model Name is correct before proceeding to the next step 28 When the complete model name is displayed press 29 When the confirmation screen displays press to select YES and then press 30 Press POWER to exit Service Mode COMPLETING SERVICE REQUIREMENTS WHEN REPLACING THE LCD PANEL The following must be performed after replacing the LCD Panel View the ...

Page 40: ...agnosis history Status Information LVDS Spectrum 0 25 Panel Selection LTY320AN03 SERIAL NUMBER EDIT 5001692 MODEL NAME EDIT KDL 32EX357 Set Home Exit Service Mode 6 Using the table below verify the correct panel code for the Panel ID Model Name Panel Code Panel Type Panel ID KDL 32EX357 KDL 32EX358 KDL 40EX457 KDL 40EX458 15_LED_WXGA_CMI_22 KDL 22EX357 CMO V216B1LE3 16_LED_WXGA_SLCD_32 SLCD LTY320...

Page 41: ...s the following buttons on the Remote Commander within a second of each other MUTING MUTING HOME NOTE The instructions to access Factory Mode are NOT THE SAME as the Service Mode procedure Input Source TV White Balance Off Internal Pattern Off Color Temp Aging Mode Off ADC Calibration TVD ADC Calibration Auto Phase Off Factory Reset default Off Recall Data Off Data Backup Off Site Air Channels Off...

Page 42: ...000 Panel Info LTY320AN03 EDID Version HDMI 1 3 VGA 1 3 Factory Version v2 500 Set EXIT Exit Factory Mode 4 Press to access Color Temp adjustments Back Color Temp Neutral R Gain 538 G Gain 512 B Gain 452 R Offset 512 G Offset 512 B Offset 512 Recall Data Off Data Backup Off Set EXIT Exit Factory Mode Color Temperature 5 Press the or buttons to select the Color Temp type Cool Neutral Warm1 or Warm2...

Page 43: ...olor Temp Neutral R Gain 538 G Gain 512 B Gain 452 R Offset 512 G Offset 512 B Offset 512 Recall Data Off Data Backup Off Set EXIT Exit Factory Mode Color Temperature 10 Press to select the option W B and press 11 Do one of the following a To make changes to one of the other Temperature types repeat steps 5 through 10 b To exit Factory mode press HOME ...

Page 44: ...Corporation Sony LCSC Technical Services Service Publication Department 9 883 894 02 English 2012FJ74WEB 1 Printed in USA 2012 6 is a trademark of Sony Electronics Reproduction in whole or part without written permission is prohibited All rights reserved ...

Page 45: ... 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 If a Circuit Board identified with a red out...

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