Sony KDL-32EX655 Page 12 Service Training Manual Download | Manualshive

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KDL-32EX655/40EX655/46EX655 3

SECTION 1 - FEATURES AND OVERVIEW

CHASSIS OVERVIEW

The primary circuits in the AZ3G chassis consist of a Main Board (BAPS Board), Power Supply Board (GL2 Board for 32“ models, and GL4 Board for 40” &

46” models), the IR Board (HL 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

. For Wire Dressing information, refer to

“Wire Dressing” on page

SWITCH

UNIT

HL

TCON

GL2

BAPS

BOARD LAYOUT FOR KDL-32EX655 ONLY

SWITCH

UNIT

HL

TCON

GL4

BAPS

BOARD LAYOUT FOR KDL-40EX655 ONLY

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Summary of Contents for KDL-32EX655

Page 1: ...Digital Color TV AZ3G Chassis Segment P 2A 9 883 892 01 SelfDiagnosis Supported model Version Date Subject 1 0 06 05 2012 Original Manual Release Date ORIGINAL MANUAL ISSUE DATE 6 2012 HISTORY INFORMATION FOR THE FOLLOWING MANUAL ...

Page 2: ...SERVICE TRAINING MANUAL LCD Digital Color TV AZ3G Chassis Segment P 2A 9 883 892 01 SelfDiagnosis Supported model KDL 32EX655 ...

Page 3: ...MODEL LIST MODEL COMMANDER DESTINATION MODEL COMMANDER DESTINATION 9 883 892 01 KDL 32EX655 RM YD079 BRAZIL KDL 40EX655 RM YD079 BRAZIL KDL 46EX655 RM YD079 BRAZIL ...

Page 4: ...on 17 Table Top Stand Removal 17 Rear Cover Removal 18 Handling the LVDS FFC Connector 19 Disconnecting the LVDS FFC Connector 19 Connecting the LVDS FFC Connector 19 Main Board BAPS and Power Supply Board GL2 GL4 Removal 20 Panel Brackets and LCD Panel Removal 21 Cleaning the LCD Panel 21 Connectors 22 Screws 22 Accessories and Packaging 23 Miscellaneous 23 Optional Accessories 23 Wire Dressing 2...

Page 5: ...ain Board 35 Completing Service Requirements When Replacing the LCD Panel or TCON Board 36 Updating the Software 36 Confirming the Model ID and Product ID 36 Resetting the Panel Operation Time 37 Clearing the Self Diagnosis Self Check Information 38 Optional Adjustments 39 Enabling VCOM to Adjust the Picture 39 Setting White Balance Adjustments 40 Resetting the TV to Factory Condition 40 Resetting...

Page 6: ...rd in case of live chassis SAFETY RELATED COMPONENT WARNING 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...

Page 7: ...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 v...

Page 8: ... 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 sc...

Page 9: ... 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 tester 2 A b...

Page 10: ...COMPONENT IN VIDEO IN 2 YP BPR Component Video 1080p 50 60 Hz 1080i 50 60 Hz 720p 50 60 Hz 576p 576i 480p 480i Audio input phono jacks Video input common phono pin with Y input HDMI IN 1 2 3 4 Video 1080p 30 50 60 Hz 1080 24p 1080i 50 60 Hz 720p 30 50 60 Hz 720 24p 576p 576i 480p 480i PC Formats Audio Two channel linear PCM 32 44 1 and 48 kHz 16 20 and 24 bits Dolby Digital Analog audio input ster...

Page 11: ...00 200 wall mount screw size mm M6 8 12 mm Mass 2 Operating humidity 10 80 RH non condensing 32EX655 Approx 80 1 31 5 inches 32 class 1 Total Harmonic Distortion 2 Screen size dimensions and mass are approximate values Optional accessories availability depends on countries region TV model stock Design and specifications are subject to change without notice 1 074 651 60 CHECKING THE ACCESSORIES Con...

Page 12: ...dels and GL4 Board for 40 46 models the IR Board HL 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 22 For Wire Dressing information refer to Wire Dressing on page 24 SWITCH UNIT HL TCON GL2 BAPS BOARD LAYOUT FOR KDL 32EX655 ONLY SWITCH UNIT HL TCON GL4 BAPS BOARD LAYOUT FOR KDL 40EX655 ONLY ...

Page 13: ...KDL 32EX655 40EX655 46EX655 4 SECTION 1 FEATURES AND OVERVIEW SWITCH UNIT HL TCON GL4 BAPS BOARD LAYOUT FOR KDL 46EX655 ONLY ...

Page 14: ...ed into IC9000 is a Low Voltage Differential Signaling LVDS transmitter This circuit converts the 8 bit parallel RGB video information into a set of high speed serial lines for noise free transmission to the TCON Board circuits located internally to the LCD Panel Scan Converter Signal processing circuit that performs resolution conversion aspect ratio and interlaced to progressive scan IP conversi...

Page 15: ... a specific amount of light from the backlite 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 TCON BOARD The TCON Board communicates between the LCD Panel and the micropr...

Page 16: ...by itself Loss of color Internet 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 circu...

Page 17: ...This differs from accessing Service Adjustments Mode Volume SELF CHECK 000 RESERVED 00 000 RESERVED 00 002 MAIN_POWE 00 003 DC_ALERT 00 003 AUD_PROT 00 003 HDMI_EQ 00 003 TU_DEMOD 00 004 VLED 00 004 LD_ERR 00 005 HFR_ERR 00 005 TCON_ERR 120123132522 120123113645 02 005 P_ID ERR 00 006 BACKLITE 00 007 TEMP_ERR 00 007 FAN_ERR 00 010 EMITTER 00 101 VPC_WDT 00 102 MEPS_WDT 00 103 HOST_WDT 00 104 STBY_...

Page 18: ...will cause an over voltage condition in the converter circuits The symptom will be a momentary appearance of the backlights Sony logo may appear followed by a 6X shutdown Replacement of the LCD panel is required to remedy this condition If the converter fails to generate voltage for the LED backlights the low voltage protection circuits are activated and the television will shut down with a 6X err...

Page 19: ...symptom BLUE Triangle Secondary Possible defective part o i d u A r e w o P N A L 2X 3X 4X 5X 6X 7X 8X No WIFI Dead set No Video Whole Screen Distortion Isolated Area Distortion No Audio Main Board Power Supply HL LCD Panel TCON SERVICE BULLETIN SOFTWARE UPDATE WLAN 5 Chart Color Code Video Protection Modes 4 Follow the associated flowcharts in the Training Manual to isolate the board Board Refere...

Page 20: ...LED IR RX LIGHT SENSE LCD PANEL HFR TCON BAPS HL L R ANALOG AUDIO OUT OPTICAL AUDIO OUT HDMI 3 IC4601 AMP IC5500 HDMI SWITCH EQ TUNER ETHERNET USB2 0 HDMI 2 HDMI 4 LVDS AC IN WIRELESS LAN CARD IC9000 A V DECODER VIDEO PROCESS USB2 0 USB HUB LED BACKLIGHTS POWER SUPPLY CONVERTER GL2 32 GL4 40 46 L R IC4701 SUB WOOFER AMP OVERALL BLOCK DIAGRAM ...

Page 21: ...12V TCON_ON AU_12V STBY3 3V 13 14 17 18 19 CN6601 TCON_VCC AUDIO_GND AU_12V REG12V 1 2 4 3 5 12 8 AUDIO_12V STBY3 3V 7 9 10 BLINKING DIGITAL_STBY POWER_ON PWM_DIMMER DC_DIMMER CN6001 TO LED BACKLIGHTS BAPS OUT1 OUT2 NC NC 1 2 3 4 CN6602 AC_OFF_DET POWER_ON 26 27 28 23 TCON_VCC 12 13 14 15 16 17 18 19 20 BL_ON BL_ERR AC_OFF_DET TCON_ON CN6205 GL2 32 GL4 40 46 POWER AND CONTROL BLOCK DIAGRAM ...

Page 22: ... on pin 27 of CN6205 on power supply Yes No Main Board Press power button while monitoring pin 28 of CN6205 on power supply board High 3 3V appears momentarily Yes No Power Supply Board Power Supply Board Power Supply Board Remove AC power and wait at least 30 seconds before reapplying NO POWER FLOWCHART For Part Number information Refer to Section 4 Disassembly Part Number Information on page 17 ...

Page 23: ...inking No Yes Power Supply Board Yes 2X Main Board 3X No 5X Yes 6X No 7X Imediately TCON LCD Panel Yes No After a while Main Board Check ventilation Power Supply Board 8X See Resolving an 8x Error PROTECTION SHUTDOWN FLOWCHART For Part Number information Refer to Section 4 Disassembly Part Number Information on page 17 ...

Page 24: ...nector 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 Power Supply Board Yes Yes Main Board LCD Panel TCON Board NO VIDEO FLOWCHART For Part Number information Refer to Section 4 Disassembly Part Number Information on page 17 ...

Page 25: ...oper or missing colors Yes Main Board No Vertical lines or bars No Yes Lines move when wide mode changed Yes No TCON LCD Panel Main Board LCD Panel Any single or isolated vertical lines Yes LCD Panel More than 1 vertical band No Yes TCON LCD Panel VIDEO DISTORTION For Part Number information Refer to Section 4 Disassembly Part Number Information on page 17 ...

Page 26: ... from the Table Top Stand then lift up the LCD TV and gently place it face down onto a soft cloth REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES REF NO PART NO DESCRIPTION ASSEMBLY INCLUDES 1 A 1882 098 A STAND HEAD P M BLACK KDL 32EX655 MODELS ONLY 1 A 1875 985 A STAND HEAD P M WHITE KDL 32EX655 MODELS ONLY 1 A 1880 666 A STAND HEAD P ML KDL 40EX655 46EX655 ONLY 2 A 1875 984 A STAND PIPE M KDL 32EX...

Page 27: ...NLY ORDER THIS PART WHEN REPLACING THE REAR COVER 53 4 400 427 01 LABEL SIDE TERMINAL KDL 40EX655 46EX655 ONLY ORDER THIS PART WHEN REPLACING THE REAR COVER 54 4 400 432 11 LABEL UNDER TERMINAL ORDER THIS PART WHEN REPLACING THE REAR COVER 54 4 400 432 41 LABEL UNDER TERMINAL WHITE KDL 32EX655 MODELS ONLY ORDER THIS PART WHEN REPLACING THE REAR COVER 55 4 297 989 01 AC COVER FOR ALL EXCEPT KDL 32E...

Page 28: ...he release tab of the Main Board connector 2 Correctly holding onto the LVDS FFC Connector pull out the connector while continuing to hold down the release tab of the Main Board connector 䐠 Press down Main Board Reinforcement Tab CONNECTOR TYPE 3 1 Gently press down on the 2 release tabs of the Main Board connector 2 Correctly holding onto the LVDS FFC Connector pull out the connector while contin...

Page 29: ...rs E Release clips and disconnect connector from HL Board F Lift up Switch Unit and disconnect connector 101 4 299 504 01 BRACKET SIDE MOLD FOR ALL EXCEPT KDL 32EX655 WHITE MODEL 101 4 299 504 51 BRACKET SIDE MOLD WHITE KDL 32EX655 MODELS ONLY 102 A 1878 459 A BAPS BOARD COMPLETE AFTER REPLACING THE MAIN BOARD YOU MUST UPDATE THE SOFTWARE TO THE LATEST VERSION 103 4 299 503 21 BRACKET UNDER MOLD 1...

Page 30: ...28 11 BEZEL 32 NK1 A WHITE KDL 32EX655 MODELS ONLY 151 4 414 815 21 BEZEL 40 NK1 A KDL 40EX655 ONLY 151 4 414 798 22 BEZEL 46 NK1 A KDL 46EX655 ONLY 152 NA LCD PANEL FOR ALL LCD PANELAND TCON BOARD PART NUMBER INFORMATION REFER TO THE LCD PANELS SERVICE MANUAL 153 4 297 525 11 BRACKET PANEL H 154 4 297 524 01 BRACKET PANEL V 155 4 300 810 01 SHEET THERMAL ATREYU 156 4 297 475 01 FRAME BOTTOM M KDL...

Page 31: ...SCREW BVTP 4X12 TYPE2 IT 3 RC 7 BTM FRM to BZL 2 9 7 685 661 71 WHITE SCREW BVTP 4X12 TYPE2 IT 3 RC 7 BTM FRM to BZL 2 9 4 400 043 01 JOINT SCREW RC 2 2 4 256 393 01 BLACK SCREW PSW M3X6 W12 RC 5 AC 1 PNL BRKTS 2 8 4 256 393 11 WHITE SCREW PSW M3X6 W12 RC 5 AC 1 PNL BRKTS 2 8 2 990 421 41 SCREW PSW M3X6 BAPS 6 GL2 4 10 P N DESCRIPTION REMARKS TOTAL 2 580 608 01 SCREW PSW M5X16 TABLE TOP STAND to T...

Page 32: ...roduct protection and safety reasons Sony strongly recommends that you use the screws provided with the TV CAUTION These screws cannot be used to secure the TV to the Wall Mount Brackets 4 411 914 12 MANUAL INSTRUCTION MISCELLANEOUS PART NO DESCRIPTION 4 262 708 03 CLAMPER CABLE 4 421 301 01 CUSHION FRM BU 4 400 043 01 JOINT SCREW OPTIONAL ACCESSORIES PART NO DESCRIPTION 4 414 470 01 SUPPORT BELT ...

Page 33: ...55 40EX655 46EX655 24 SECTION 4 DISASSEMBLY PART NUMBER INFORMATION WIRE DRESSING OVERALL WIRE DRESSING FOR KDL 32EX655 ONLY OVERALL WIRE DRESSING FOR KDL 40EX655 ONLY OVERALL WIRE DRESSING FOR KDL 46EX655 ONLY ...

Page 34: ...he customer level Software updates can be performed by Customer Manual Downloads Software updates can be downloaded and placed on a USB device to be loaded onto the TV The instructions for downloading the software file vary from chassis to chassis and sometimes from model to model The customer is provided with the instructions to properly format the USB device unzip the file and the procedures for...

Page 35: ...fono de contacto en Argentina 011 6770 7669 4003 SONY 7669 0800 880 SONY 7669 Tengo la siguiente información a mano Please refer to the rear of this TV SONY_Tarte_SA_1 06 Nombre del modelo KDL 32EX655 Póngase en contacto directament con Sony si tiene algún problems con el TV EXAMPLE OF SOFTWARE VERSION LOCATED ON THE CONTACT SONY SCREEN COMPLETING SERVICE REQUIREMENTS WHEN REPLACING THE MAIN BOARD...

Page 36: ...he data value to 1 CHASSIS SERVICE 007 000 DL PID_DATA_MISMAT 1 8 Press MUTING then press 0 to WRITE Save the changes When complete the screen briefly indicates WRITE CHASSIS SERVICE WRITE 007 000 DL PID_DATA_MISMAT 1 9 Exit service mode by turning the TV power off 10 Return to Updating the Software on page 26 SELECTING THE SEGMENT CODE Before proceeding update the software to the latest version A...

Page 37: ...next category until the 002 MODEL category displays DIGITAL SERVICE 002 MODEL 000 SEG P 2A_BASE 6 Using the table press 3 to increase the data value or 6 to decrease the data value to select the correct segment code data value Model Name Code Name Data Value Model Name KDL 2A_BASE KDL 32EX655 KDL 2A_BASE KDL 40EX655 KDL 2A_BASE KDL 46EX655 7 Press MUTING then press 0 to WRITE Save the changes DIGI...

Page 38: ...ess 1 to move to the next item until 001 DEST item displays DIGITAL SERVICE 002 MODEL 001 DEST ISDB LTN_BASE 6 Using the table press 3 to increase the data value or 6 to decrease the data value to select the correct destination of the 7 TV Model Name Code Name Data Value Model Name Destination Data Value KDL 2A_BASE KDL 32EX655 BRZ ISDB LTN_BASE KDL 2A_BASE KDL 40EX655 BRZ ISDB LTN_BASE KDL 2A_BAS...

Page 39: ...ges DIGITAL SERVICE 002 MODEL 002 MODELNAME KDL 32EX655 WRITE When complete the screen briefly indicates the process is Done DIGITAL SERVICE 002 MODEL 002 MODELNAME KDL 32EX655 DONE 13 Proceed to Adding the Serial Number ADDING THE SERIAL NUMBER The replacement board does not contain a serial number Use the following instructions to add the customer s serial number CAUTION The serial number can on...

Page 40: ...ress 1 until the 003 SERIAL item displays DIGITAL SERVICE 002 MODEL 003 SERIAL 18 Press 0 to display the Serial Number Edit option DIGITAL MODEL SERVICE SerialNumberEdit 1 SerialNumber 19 Press the select button to display the Serial Number input screen DIGITAL MODEL SERVICE SerialNumberEdit 1 SerialNumber Please input serial number 0000000 9999999 CAUTION The serial number can only be entered onc...

Page 41: ... that the correct Model ID and Product ID displays in the Service menu Verify before proceeding to the next step Updated the Software Selected the Segment Code Selected the Destination Selected the Model Name Added the Serial Number 23 Press 4 to move to the 001 OP category DIGITAL SERVICE 001 OP 000 VERS MAIN EXT DM1 027AAA AA RF 0000 WF1 002W00AA WF 9 2 1 12 4 DF3 130W00AA WF 0A YM1 409W00AA FD ...

Page 42: ...n after you have completed the repairs to be sure you reset the result display to 0 Verify before proceeding to the next step Updated the Software Selected the Segment Code Selected the Destination Selected the Model Name Added the Serial Number 1 Take the TV out of deep Standby mode by pressing POWER to turn on the TV 2 Press POWER to turn the TV back off 3 Press the following buttons on the Remo...

Page 43: ...used during TV software development To verify that there is an actual 8X error view the TV s Self Diagnosis Self Check list history specifically at the bottom of the list WDT Watch Dog Timer error codes The 8X error code could be the result of Software Issue Network Issue Skype Login Issue Incompatible USB Device Plugged Inserted Defective Main Board Every time 3 errors are registered in the Self ...

Page 44: ...HE SOFTWARE Verify before proceeding to the next step Verified the error is an 8X error Reset the TV to Factory Condition 1 Check for latest Software Version through Network Connection or Reference Library 2 Connect and Configure TV Network Connection 3 Display the menu by pressing HOME 4 Using the and the on the on the Remote Control select the following Settings Product Support Software Update N...

Page 45: ... 2 If the picture displays you will need to reset the LCD Panel ID to force update the software Proceed to Resetting the LCD Panel to Update the Software 2 After the update is complete proceed to Confirming the Model ID and Product ID CONFIRMING THE MODEL ID AND PRODUCT ID After completing all of the service adjustment changes verify that the correct Model ID and Product ID displays in the Service...

Page 46: ... reset the panel operation time from the Self Check screen Verify before proceeding to the next step Updated the Software Confirmed Model ID and Product ID 1 Take the TV out of deep Standby mode by pressing POWER to turn on the TV 2 Press POWER to turn the TV back off 3 Press the following buttons on the Remote Commander within a second of each other DISPLAY Channel 5 Volume POWER NOTE This differ...

Page 47: ...e Panel operation time 5 Proceed to Clearing the Self Diagnosis Self Check Information CLEARING THE SELF DIAGNOSIS SELF CHECK INFORMATION After resetting the panel operation time clear the Self Check screen 6 To clear the error history and error count press 8 0 SELF CHECK 000 RESERVED 00 000 RESERVED 00 002 MAIN_POWE 00 003 DC_ALERT 00 003 AUD_PROT 00 003 HDMI_EQ 00 003 TU_DEMOD 00 004 VLED 00 004...

Page 48: ...009W00AA PEM MID 1C23A225 PID 04047040 PNL LTY320HN0301 TUNER ENABLE 4 Press JUMP or OPTIONS on the Remote Commander until the VPC menu displays 5 Press 2 to move to the 002 VCOM category VPC SERVICE 002 000 VCOM ENABLE 0 6 Enable the VCOM by pressing 3 to increase the data value to 1 7 Press 1 to move to the 001 ADJUST item VPC SERVICE 002 001 VCOM ADJUST 64 8 Change the value of the 001 ADJUST i...

Page 49: ... the following instructions to restore the User Adjustments and Channel Memory settings to the preset factory conditions 1 Turn the TV On by pressing POWER then wait approximately 40 to 60 seconds 2 While holding down the on the Remote Commander press the POWER button on the side of the TV 3 The set restarts and displays the Initial Setup screen This may take several minutes RESETTING THE TV TO FA...

Page 50: ...S 6 When the process is complete the green SERVICE text displays and the LED display as shown below TIMER Standby POWER 7 Cycle AC Power Unplug and Plug AC Cord from the AC Outlet The set restarts and displays the Initial Setup screen This may take several minutes ...

Page 51: ... Sony LCSC LCSC Technical Services Service Publication Department 9 883 892 01 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 52: ... 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 outline and...

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