Sony BRAVIA KLV-32EX330 User manual

SERVICE MANUAL
Version Date Subject
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9-888-134-03
HISTORYINFORMATION FOR THE FOLLOWING MANUAL:
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SERVICE MANUAL
LCDTV
9-888-134-03
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MODEL LIST
MODEL COLOR COMMANDER DEST.
MODEL COLORCOMMANDER DEST.
KLV-32EX330 Black RM-GA022SaudiArabia, India,
Singapore, Indonesia,
Philippines, Vietnam, Sogul,
Malaysia,SouthAfrica,
Thailand.
KLV
32
EX
33
A
Black
RM
GA
022
Mala siaSingapore
KLV
-
32
EX
33
A
Black
RM
-
GA
022
Mala
y
sia
,
Singapore
,
Philippines, Vietnam,
Indonesia, Thailand.
KL
V
-
3
2
EX33B Black RM-GA02
2
Mala
y
sia
y
KLV-40EX430 Black RM-GA022SaudiArabia, India,
Singapore, Indonesia,
Philippines, Vietnam, Sogul,
Malaysia,South Africa,
Thailand.
KLV-40EX43A Black RM-GA022 Malaysia, Singapore,
PhilippinesVietnam
Philippines
,
Vietnam
,
Indonesia, Thailand.
KLV-40EX43B Black RM-GA022 Malaysia
3

7$%/(2)&217(176
Section Title Page
4.SERVICEADJUSTMENTS
4-1. Acces s ing ServiceMode ....................................................................
.
54
4
-
1
-
1
Accessing SoftwareVersion
54
Section Title Page
1.SAFETYNOTES
1-1.Caution Handling ofLCD Panel...........…………….......................
.
5
1-2
SafetyCheckOut
5
411
.
Acces s in g
Software
Version
..............................................................
54
4-1-2. Accessing SerialNumber Edit……………………………………
…
55
4-1-3.Accessing ModelNameEdit ………………………………………
…
56
4-1-4. Accessing Self Diagnostic History………………………………… 58
4-2. Accessing Self DiagnosticMenu …………………………………
…
58
4-3. Updating The Software ……………………………………………
…
59
1-2
.
Safety
Check
Out
......................................……………........................
5
1-3. Leakage Test ........................................................................................ 5
1-4. HowtoFind a Good EarthGround…………………………………
…
6
1-5. Warning and Caution .......................................................................... 6
1-6. Lead FreeInformation………………………………………………
…
6
1-7. Handling the Flexible Flat Cable (FFC)……………………………
…
7
1
-
8
How toRemoveStand &Under Cover (32/40)
8
5. DIAGRAMS
5-1. Block Diagram...................................................................................... 60
5-2.Connector Diagram …………………………………………………
…
61
5-2-1. KLV-32EX330,EX33A,EX33B ……………………………………
…
61
5-2-2. KLV-40EX430,EX43A,EX43B ……………………………………
…
62
5-3. CircuitBoardLocation
18
.
How
to
Remove
Stand
&
Under
Cover
(32/40)
…………..………
…
8
1-9.HowtoReplaceB Board (32"/ 40")………………………………
…
9
1-10.Preparation onBezelDisassembly(32"/40")……………………
…
12
1-11.HowtoDisass embleBezel(32"/40")……………………………… 12
1-12.HowtoReplaceLS Board (32"/40")………………………………
…
13
2.SELFDIAGNOSTIC FUNCTION
5-3-1. KLV-32EX330,EX33A,EX33B ……………………………………
…
63
5-3-2. KLV-40EX430,EX43A,EX43B ……………………………………
…
63
5-4. Wire Dressing
5-4-1. KLV-32EX330,EX33A,EX33B ……………………………………
…
64
5-4-2. KLV-40EX430,EX43A,EX43B ……………………………………
…
66
6DISASSEMBLY EXPLODED VIEWS AND OTHER PARTS
2-1. Overviewof ControlButtons............................................................... 16
2-2. LEDDisplay Control..................................................................... 16
2-3.LED Pattern……………….................................................................... 16
2-4. StandbyLED Error Display…………………………………………
…
17
2-5. Triage Chart .......................................................................................... 18
6
.
DISASSEMBLY
,
EXPLODED
VIEWS
AND
OTHER
PARTS
6-1. KLV-32EX330,EX33A,EX33B ……………………………………
…
68
6-2.KLV-40EX430,EX43A,EX43B ……………………………………
…
73
OPERATINGINSTRUCTIONS
3.TROUBLE SHOOTING
3-1. Trouble Shooting Flow ........................................................................ 19
3-2.NoPower……………………………………………………………… 19
3-3.
StandbyLEDBlinking…………………………………………
…
21
3-4.AudioProblem………………………………………........................... 22
3-5.Video Problem………………………………………………………
…
32
3-6.HDMI-Troubleshooting Flow………………………………………
…
40
3-7. Tuner - Troubleshooting Flow……………………………………… 44
3-8. IR-Troubleshooting Flow..................................................................... 45
3-9. RTC Troubleshooting Flow ................................................................ 47
310
TblhiRf
48
3
-
10
.
T
rou
bl
es
h
oot
i
ng
R
e
f
erence ………………………………………
…
48
3-10-1.BWMBoard …………………………………………………………… 48
3-10-2.BFMBoard ……………………………………………………………
…
51
4
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3)Check all control knobs, shields, covers, groundstraps and mounting
hardwarehave beenreplaced.Be absolutely certain you have replacedall
the insulators.
4) Look for unauthorizedreplacementparts, particularly transistors that were
installed during apreviousrepair Point them out to the customerand
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When repairingthe LCD Panel, make sure you are grounded with a wrist band.
When repairingthe LCD Panel on the wall, the panel must be securedusing the 4
mountingholes on the rear cover.
1) Do not press the panelor frame edge to avoid the risk of electric shock.
installed
during
a
previous
repair
.
Point
them
out
to
the
customer
and
recommendtheir replacement.
5)Lookforparts which,though functioning showobvious signsof deterioration.
Point them out to the customerand recommend their replacement.
6) Check the line cords for cracks and abrasion. Recommend the replacement
of any such line cord to the customer.
2) Do not scratch or press on the panel with any sharp objects.
3) Do not leave the module in high temperatureor in areas of high humidity for
an extended period of time.
4) Do not expose the LCD panelto direct sunlight.
5) Avoid contact with water. It may cause short circuit within the module.
6
)Disconnect the AC powerwhen replacing the backlight (CCFL)or
7) Check the antenna terminals, metal trim, "metallized“ knobs, screws and all
other exposedmetal parts for AC leakage.Check leakage test as described
next.
8)Forsafety reasons, repairing the PowerBoard and/orinverterboard is prohibited.
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6
)
Disconnect
the
AC
power
when
replacing
the
backlight
(CCFL)
or
inverter circuit. (High voltageoccurs at the inverter circuit at 650Vrms)
7) Always clean the LCD panelwith a soft cloth material.
8) Use care when handlingthe wires or connectors of the inverter circuit.
Damagingthe wires may cause a short circuit.
9) Protect the panelfrom ESD to avoid damagingthe electronic circuit
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The AC leakage from any exposedmetal part to earth groundand from all exposed
metal parts to any exposedmetal part havinga return to chassis must not exceed
0.5mA (500 microamperes).
Leakage currentcan be measured by any one of the three methods:-
1. A commercial leakagetester such as the SIMPSON 229 or RCA WT-540A.
(C-MOS).
10) During the repair, DO NOT leave the Power On or Burn-in period for more than
1 hour while the TV is face down on a cloth.
Follow the manufacturers instructionsto use those instructions.
2. A battery-operated AC milliampmeter. The DATA PRECISION 245 digital
multimeter is suitable for this job.
3. Measuringthe voltage drop across a resistor by means of a VOM or battery
operated AC voltmeter. The 'limit' indication is 0.75V so analogmeters must
have an accurate low voltage scale The SIMPSON
'
S
250
and SANWA
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 rangeare suitable.
(see Figure 2.)
Figure 1. TVis faced down on a cloth during repair.
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After correctingthe originalservice problem, perform the following safety checks
beforereleasingthe set to the customer:-
1) Check the area of your repair for unsolderedor poorly soldered connections.
Check the entire board surface for solder splashesand bridges.
5
Figure 2. AC voltmeter to check AC leakage
2)Check theinterboardwiringto ensure thatnowiresarepinched orcontact
high-wattage resistors.
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Safety Notes
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1) A cold-water pipe is a guaranteed earth ground; the cover-plateretaining
screw on most AC outlet boxes is also at earth ground.
2) If the retainingscrew is to be used as your earth ground, verify that it is at
db ithitbtitdld
ti ith
4) Be sure to follow these guidelinesto protect your property and avoid causing
serious injury.
• Carry the TV with an adequatenumberof people;larger size TVs require
groun
d
b
y measur
i
ng
th
e res
i
s
t
ance
b
e
t
ween
it
an
d
a co
ld
-wa
t
er p
i
pe w
ith
an
ohmmeter. The readingshould be zero ohms.
3) If a cold-waterpipe is not accessible, connect a 60- to 100-watt trouble-light
(not a neon lamp) between the hot side of the receptacle and the retainingscrew.
Try both slots, if necessary, to locate the hot side on the line; the lamp should
light at normal brilliance if the screw is at ground potential (see Figure 3).
two or more people.
• Correct handplacement while carrying the TV is very importantfor safety
and to avoid damages.
5) Components identifiedby shading and ! mark on the schematic diagrams,
exploded views,and in the parts listare critical for safe operation. Replace
light
at
normal
brilliance
if
the
screw
is
at
ground
potential
(see
Figure
3).
exploded
views,
and
in
the
parts
list
are
critical
for
safe
operation.
Replace
these components with Sony parts whose part numbers appear as shown in
this manual or in supplements published by Sony. Circuit adjustments that
are critical for safe operationare identifiedin this manual. Follow these
procedures whenevercritical components are replacedor improper
operation is suspected.
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The circuit boardsused in these models have been processedusing LeadFree
Solder.The boardsare identifiedby the LF logo locatedclose to the board
Solder.
The
boards
are
identified
by
the
LF
logo
located
close
to
the
board
designation.
Figure 3. Checking for earth ground.
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1)
These
servicing instructionsare for use by qualified service personnel
only.
Figure 4: LF
Logo
1)
These
servicing
instructions
are
for
use
by
qualified
service
personnel
only.
2) To reduce the risk of electric shock, do not perform any servicing other than
that contained in the operating instructionsunless you are qualified to do so.
3) An isolation transformer should be used during any service to avoid possible
shock hazard,becauseof live chassis. The chassis of this receiver is directly
connected to theac
p
ower line.
Figure 5: LF logo on circuit board
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Safety Notes
The servicing of these boardsrequires special precautions. It is strongly
recommended to use LeadFree Solder material in order to guarantee optimal
quality of new solder joints. Lead Free Solder is available underthe following part
numbers:-
FFC can reverse insertionto connector of BAQ board.
If reverse insertion FFC, all pins short-circuit, and board is broken.
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Due to high melting point of Lead Free Solder, the solderingiron tip
temperatureneedsto be set to 370 degreescentigrade. This requires
solderingequipmentcapableof accurate temperaturecontrol coupled
ith d h thtiti
BAQ Board
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When you insert / pull out FFC, please grasp a reinforcement board
and main body of FFC. BAQ Board
7

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Screwsdetail refer to
Section
6
Safety Notes
CAUTION:During this disassemble, the TVset must lie above Soft Cushion sheet/Protection Sheet.
( Confirm all screws & positions before
removing)
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Section
6
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removing)
STEP 1: Remove Stand
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1. Place TVset facing
down on a flat surface.
1.Unscrewall screws.
(Please refer next page)
CAUTION
•
During this disassemblyprocess DO NOT
•
During
this
disassembly
process
,
DO
NOT
disassemble with bare hands. MUST USE hand glove
2
Remove
2
pcs
Stand
2.Hold Bottom of Under Cover with
both Thumb.
3.Flip open the Under
Cover.
2
.
Remove
2
pcs
Stand
Screw from Bottom.
(SCREW, +PSW M5X16)
8
3.Remove Stand.
4.Under Cover is free to be removed.

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Safety Notes
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1. Remove this
VA Tape on
Left Speaker.
12
And finally remove
S

11. Final FFC
condition.
12
.
And
,
finally
remove
B-Board from Main
Bracket.
(For
40
”
model only)
10. Gently hold blue
supporting tape
and pull FFC out.
(For
40
model
only)
2. Remove this VA
Tape on top of
Stand Bracket.
3. Unplug
connector at
B-Board.
9. Unclamp FFC
by lifting down
the bar
4
Disassemble
7.UnscrewB-Board screws.
(
SCREW
,
the
bar
.
4
.
Disassemble
Speaker Left
& Right.
(,
+PSW M3X8)
8. Unplug Connector.
6. After unplug,
insert back
9
5. Take out Speaker Right & Left before
unplugConnector Assy 4P.
insert
back
both speaker.

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Safety Notes
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1. Prepare all
12. Insert speaker wire
into the hole
between rib. 13. Insert speaker wire
behindthe hook.
S

needed parts.
2.Place B-Board onto
14. Insert speaker wire into the hole between rib.
Main Bracket based
on the positioning
hole.11. Plug in connector to B-Board.
(for 32” model only)
3.Ready to insert
FFC. 10. Push speaker back to
Back Light Cover
speaker slot.
(for 40” model only)
4.Hold blue supporting
tape to push FFC to
the connector.
15. Tape at speaker wire &
LS harness.
(for 32” model only)
16. Tape at speaker
wire, position: above
standbracket.
5.Make sure black
marking line
aligned while
clamping
9. Insert connector to speaker before putting
into Back Light Cover.
6.Screw the B-Board to
clamping
.7.Plug Connector Assy 4P to B-Board.
8. Prepare to insert connector to
speaker.
(for 40” model only)
(for 32”/40”model only)
10
Bkt, Main by using
Screw, +PSW M3x8.

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Safety Notes
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STEP 5: Reinstall Under Cover & Stand
S
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1. Initial condition.
8.Hold the stand while screwing.
(SCREW +PSW M
5
X
16
)
2
Insert Under Cover
(SCREW
,
+PSW
M
5
X
16
)
2
.
Insert
Under
Cover
from bottom to top
direction .
7. Insert stand.
3.Encloseand press
downward across
downward
across
the line to ensure
it fits properly. 6.Move and align set bottom to the edgeof table.
4.Press downward,
position:at circled
area in order to
5. Put all screws +BVTP
3x10 Type 2 IT-3.
11
ensure it closed
properly.

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50*$
Safety Notes
3UH
S
DUDWLRQRQ%H]HO'LVDVVHPEO
\
´

´

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
´

´

S
\

Pr
e
-
s
t
ep:
B
e
f
o
r
e
IDENTIFY BEZEL HOOK POSITION


e
sep:eoe
closing Under
Cover
1.Place TV set on a Flat surface.
Front
CAUTION
•BEFORE CLOSING UNDERCOVER,PLEASE
MAKE SURE NO WIRE WILL PINCH.
TOTAL = 17 HOOKS
CAUTION
•
From this step onwardsall
Hold
•AFTER CLOSING UNDERCOVER, FLIP OVER
THE SET FACING UPWARD.
•
From
this
step
onwards
,
all
operation should be done in
CLEAN ROOM ENVIRONTMENT. 2.Remove bottom cornerhook up
(Left & Right symmetric).
Hold
1. Enclose Under
Cover.
4. Set facing
Upward.
6.Done
3.Remove side hook to outside
(Lower-> Upper) (Left & Right symmetric).
DO NOT PUSH CELL OVER THAN 5kg/1cm2 5. Remove bottom
hook with rotation.
3. Next.
2. Flip Over the
set.
12
4.Remove top hook to outside.(Center->Corner)
DO NOT PUSH CELL OVER THAN 5kg/1cm2

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50*$
Safety Notes
+RZ7R5H
S
ODFH/6%RDUG

´

´

5.Push LS Board as
S

STEP 1: Remove Old LS Board
indicated by arrow.
end
1.Zoom in.
6.Push LS Board until both
end alignedto the hook.
2.Identify the 2 hook
condition.
7.Lift LS Board up
11.LS Board had been
removed.
&21&(37725(029(
2) Push Inward
(for 32” model only)
removed.
1) Pull
Upward
3) Gentle Lift
(for 40” model only)
10.Pull connector out.
3. Actual removal situation.
Side View Top View
8.Prepareto unplug
connector at left
end
9.Press the clip.
4.Next Condition.
13
end
.

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50*$
Safety Notes
+RZ7R5H
S
ODFH/6%RDUG

´

´

S

REMINDER
•FOR
OLD LS BOARD WITH SUPPORTER PIN
AFRESH ONE SHOULD BE REPLACE TOTHE
NEW LS
STEP 2: Install new LS Board
&21&(3772,167$// 3) Gently Press Downward
5,*+7326,7,21•
A
FRESH
ONE
SHOULD
BE
REPLACE
TO
THE
NEW
LS
BOARD
1. Insertconnector.
1) Pull Upward
2) Push Inward
2.Insert LS Board properly
to the LS Hook.
5.Adjust LS Board
position to ensure
the dowel fits into
positioninghole.
Supporter Pin Assy
&+(&.$1<0,6),7
&21',7,21
6.Final Condition
3. Confirm lock.
&21',7,21
(for 32” model only)
DO NOT REUSE
(ONCE DISASSEMBLED CHANGE FRESH
Then, push other endFirstly, hook one end
1
)
Insert 2
)
Push In
LEFT POSITION CENTER POSITION
(for 40” model only)
CHECK ANY MISFIT CONDITION
(ONCE
DISASSEMBLED
,
CHANGE
FRESH
ONE)
4.Action 1) & 2) is
done simultaneously.
)
)
RIGHT POSITION
14
RIGHT
POSITION

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50*$
Safety Notes
+RZ7R5H
S
ODFH/6%RDUG

´

´



+75O
LS Type Location
S

(for 32” model only)




+
RZ
7
R
5
HS
O
DFH
/6%RDUG´´
A
A
B
B
A
B
LS Type Location
A
A
B
B
A
(for 40” model only)
A
A
B
A
B
B
B
Toavoid brightness unevenness, please follow below instruction:
-Arrange LS board according to each type location at BLC
-1set BLU must consist of same LED bin number
LED Bin
Number
15

6(&7,21
6(/)',$*1267,&)81&7,21
StatusPicture
Off/
Timer LED
Standby
LED
Power
LED
Remarks
2YHUYLHZRI&RQWURO%XWWRQV /(''LVSOD\&RQWURO
Power Off
( AC Off and *1) OFFOFFOFF*1 power switch off
(by touch button)
Power On OFFOFF Green
Standby
( by remote control
OFF
Red
OFF
( by remote control
off only)
OFF
Red
OFF
Picture Off Green Off Green
Set "Sleep Timer" Orange Off Green
Set "On Timer"
Orange
Off
Green
( Power On)
Orange
Off
Green
Set "On Timer"
( Standby )Orange RedOff
Picture Frame Orange Off Green
Th b f LED
FailureOff Red
BlinkingOff
Th
e
num
b
er
o
f LED
blinkingindicates
cause of failure.
Error of panel ID Orange
BlinkingOff Green
Blinking
Blinking:0.5sec On /
0.5sec Off
Orange
Blinking: 1sec On/
Software Updating
Orange
BlinkingRed Off
Blinking: 1sec On/
1sec Off
When safety shutdown occurs, Standby LED displayreports the cause by using the lightning
patterns as indicated below.
/('3DWWHUQ


3.0sec 3.0sec
0.5sec
0.5sec


16
Example: The figure above shows LED display when SHUTDOWN is caused by Audio
Error. It repeats flashing for a specified number of times in 0.5sec/cycle and has a 3 seconds
interval of lighting off. Please note that a 3 seconds interval of lighting off is fixed regardless of abnormal state types.
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50*$

Self Diagnostic Function
6WDQGE\/('(UURU'LVSOD\
Note: Details refer to Troubleshooting Section.
The Number of DetectionItems Board Error Item
Standby LED
(RED blinking)
2Main Power Error AC adapterError
3Audio Error B* board Error
5
Panel Power Error
B
*
or Source
board Error
5
B
or
Source
board
Error
Panel ID NVM Error
6BacklightError B* board Error

SizeB* Board Type
32” BWM
17
40’’ BFM
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50*$

Self Diagnostic Function
7ULDJH&KDUW
Blinking No Picture No Sound
2 3 5 6 Tuner USB Video1 VIdeo2 Compon
ent HDMI MHL PC Main
S
p
eake
r
HP Video1 Video2 Compone
nt Tuner HDMI USB
p
BWM/BFM Board
HTW/HTF Board
U1 Board
Light Source Board
Open Cell
AC Ad t
AC
Ad
ap
t
o
r
Speaker Unit
LS Harness
Main Harness
Speaker Harness
FFC Cable
Note: Details refer to Troubleshooting Section.
DoubtfulPart Problem
Few possibility

SizeB* Board
Type
HT* Board
Type
18
32” BWM HTW
40’’ BFM HTF
./9(;(;$(;%(;(;$(;%
50*$

./9(;(;$(;%(;(;$(;%
50*$
6(&7,21
7528%/(6+227,1*
7URXEOHVKRRWLQJ)ORZ
START
1R3RZHU
NP
START
Does the Power Led
stay on when the
Open Detail
N
o
P
ower
Check DC voltage at Yes
•
See DDCON
stay
on
when
the
TV is switched on ?-NoPowerJL6016 (BWM) or JL6506 (BFM)
Is it 19.5V?
No
•
See
DDCON
Sheet
Is the StandbyLed
blink ?
Open Detail
-StandbyLED Blink Take out adaptor
and test at adaptor
output is it 19V –19.5V?
B*-board
Yes
Green & Amber
blink?
-Panel ID Error
-Panel Not Supported
Change adaptor
No
A
da
p
tor
OK
Is the Picture and
Sound OK?
Open Detail
-Audio/Video
and test again
A
C source
p
NG
END

SizeB* Board Type
32
”
BWM
19
32
BWM
40’’ BFM

./9(;(;$(;%(;(;$(;%
50*$
Troubleshooting
Start DDCON
'' &RQ
Check voltage at JL6012
(BWM) or JL6503
() ?
OK
Check F6000 (BWM)
or F6500
(
BFM
)
NG
No
Fuse
(
BFM
)
is it 3.3V
?
Yes
Check voltage at JL6010
()
No
Change B
*
-
DDCON
Yes
(BWM) or JL6501
(BFM) is it 1.2V?
Check voltage at CL6001
(BWM and BFM)
Check F6002 (BWM)
No
OK
No
Change
B
-
board
Check voltage at JL6011
(BWM) or JL6502
(BFM) is it 1.5V?
(BWM
and
BFM)
is it 12V?
or F6501(BFM)
No
NG
Change B*-
board
After checking, take note of
NG condition &change
B
*
board
Check voltage at JL6504
(BWM and BFM)
is it 5V?
No
Yes
Change B*-
board
Fuse
NG
condition
&
change
B
board
is
it
5V?
Yes

SizeB* Board Type
32
”
BWM
20
32
BWM
40’’ BFM