Sony KDL-32EX400 - Bravia Ex Series Lcd... User manual

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
AZ1-L CHASSIS
Segment: 3a-2
ORIGINAL MANUAL ISSUE DATE: 12/2009
Version
Date
Subject
Version
Date
Subject
1.0 12/2009 No revisions or updates are applicable at this time.
2.0 01/2010 Change Destination of General Area and replace Block Diagram.
3.0 04/2010 Add Base, Cover, Neck Information for KDL-40EX400 (Page 46)
4.0 08/2010 Add Support, Panel information (Page 38), (Page 41)
5.0 09/2010 Change Link of Disassembly Movie (Page 13)
6.0 10/2010 Add Note for Disassembly Movie download ( Page 13 )
7.0 11/2010 Add Troubleshooting Reference information ( Page 48 )
8.0 08/2011 Part Information Charge:
i) Delete Power Supply Cord (Pg 39), (Pg 42).
ii) Revised Old Power Supply Cord destinations ((Pg 53) (Pg 55).
iii) Add
New
Power Supply Cord and destinations
(Pg
54
)(Pg
55
)
iii)
Add
New
Power
Supply
Cord
and
destinations
(Pg
54
)
,
(Pg
55
)
iv) Plug Conversion Adaptor destination correction (Pg 44), (Pg 46).
v) Instruction Manual P/N Suffix Change and Destination Correction
(Pg 45), (Pg 47).
LCD Digital Color TV

SERVICE MANUAL
LCD Digital Color TV
AZ1-L CHASSIS
Segment: 3a-2

KDL-32/40EX400(HK/WB/GA)3
MODEL LIST
MODEL COLOR COMMANDER DEST.MODEL COLOR COMMANDER DEST.
KDL-32EX400 Black RM-GD015 Hong Kong
KDL-32EX400 Blue RM-GD015 Hong Kong
KDL-32EX400 Red RM-GD015 Hong Kong
KDL-32EX400 Black RM-CD009 Taiwan
KDL-32EX400 Blue RM-CD009 Taiwan
KDL-32EX400 Red RM-CD009 Taiwan
KDL-32EX400 Black RM-GD015 Australia, New
Zealand, Singapore ,
South Africa , GAA
KDL-32EX400 Blue RM-GD015 Australia, New
Zealand, Singapore ,
South Africa , GAA
KDL-32EX400 Red RM-GD015 Australia, New
Zealand, Singapore ,
South Africa , GAA
KDL-40EX400 Black RM-GD015 Hong Kong
KDL-40EX400 Black RM-CD009 Taiwan
KDL-40EX400 Black RM-GD015 New Zealand ,
Singapore , South
Africa

KDL-32/40EX400(HK/WB/GA)4
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 adequqate 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.
SAFETY-RELATED COMPONENT WARNING!!
Components identified by shading and ! mark on the schematic diagrams, 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 operation are identified in this manual. Follow these procedures whenever critical components are replaced or
improper operation is suspected.

KDL-32/40EX400(HK/WB/GA)5
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.
POUR TRANSPORTER LE TÉLÉVISEUR
Tenez compte de ce qui suit pendant l’installation du téléviseur :
• Débranchez tous les câbles avant de transporter le téléviseur.
• Transportez le téléviseur avec le nombre de personnes approprié ; un téléviseur de grande taille doit être transporté par au moins deux personnes.
• Lors du transport du téléviseur, l’emplacement des mains est très important pour votre sécurité, ainsi que pour éviter de causer des dommages.
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.
ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!!
Les composants identifi es par une trame et par une marque ! sur les schemas de principe, les vues explosees et les listes de pieces sont d’une
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 de circuit dont l’importance est critique pour la securite du
fonctionnement sont identifi es dans le present manuel. Suivre ces procedures lors de chaque remplacement de composants critiques, ou lorsqu’un
mauvais fonctionnement suspecte.

KDL-32/40EX400(HK/WB/GA)6
WARNINGS AND CAUTIONS
USE CAUTION WHEN HANDLING THE LCD PANEL
When repairing the LCD panel, be sure you are grounded by using a wrist band.
When repairing the LCD panel on the 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 (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).

KDL-32/40EX400(HK/WB/GA)7
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-32/40EX400(HK/WB/GA)8
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).
How to Find a Good Earth Ground
A cold-water pipe is a guaranteed earth ground; the cover-plate retaining screw on most AC outlet
boxes is also at earth ground.
If the retaining screw is to be used as your earth ground, verify that it is at ground by measuring the
resistance between it and a cold-water pipe with an ohmmeter. The reading should be zero ohms.
If a cold-water pipe is not accessible, connect a 60- to 100-watt trouble- light (not a neon lamp)
between the hot side of 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 is at ground
potential (see Figure B).

KDL-32/40EX400(HK/WB/GA)9
SELF DIAGNOSIS FUNCTION
DIAGNOSTIC TEST INDICATORS
When an error occurs, the STANDBY LED will flash a set number
of times to indicate the possible cause of the problem.
If there is more than one error, the LED will identify the first of the
problem areas.
Result for all of the following diagnostic items are displayed on
screen.
If the screen displays a “0”, no error has occurred .
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.
STBY LED
Flash time
Service menu Item name
(Screeen Dsisplay) Diagnostic Item Description
2 MAIN_POWE Main Power Over Voltage Protection
DC_ALERT DC_ALERT
DTT_WDT DTT Error
AUD_PROT Audio Abnormal Detection
4 BALANCER_ Panel Balancer Error
TCON_ERR T-CON Error
HFR_ERR HFR Error
P_ID_ERR Panel ID NVM Error
6 BACKLITE_ Back Light Error (Panel Inverter)
TEMP_ERR Thermal Error
FAN_ERR FAN Error (Not Detected. Display Only)
8-Not used
9-Not used
10 - Not used
11 - Not used
12 - Not used
- RGB_SEN RGB Sensor ACK Error
3
5
7

KDL-32/40EX400(HK/WB/GA)10
SELF DIAGNOSIS FUNCTION
DISPLAY OF STANDBY LED FLASH COUNT
SELF-DIAGNOSTIC SCREEN DISPLAY
For errors with symptoms such as “power sometimes shuts off” or “screen sometimes goes out” that cannot be confirmed, it is possible to bring up
past occurrences of failure for confirmation on the screen:
[To Bring Up Screen Test]
In standby mode, press buttons on the remote commander sequentially in rapid succession as shown below:
0.5
0.5 3

KDL-32/40EX400(HK/WB/GA)11
SELF DIAGNOSIS FUNCTION
0501210811 0412311234 0311111825 00
0000000000 0000000000 0000000000 00
0000000000 0000000000 0000000000 00
0000000000 0000000000 0000000000 00
0000000000 0000000000 0000000000 00
0000000000 0000000000 0000000000 00
SELF CHECK(1)
002 MAIN P
003 DC_ALERT1
004 DC_ALERT2
006 BL
007 TEMP
009 FAN
12345-00333-06789
<1> NEXT PAGE->
Error count (00-99)
Error history (Last failure time beforehand)
Error history (Failure time before last)
Error history (The last failure time)
Item name
STBY LED flash time
Total operation time by hour (MAX:65535)
Boot count (MAX:65535)
Panel operation time by hour (MAX:65535)
[SELF DIAGNOSTIC SCREEN DISPLAY]

KDL-32/40EX400(HK/WB/GA)12
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”.
Clearing the Self Check Diagnostic List
1. Error history and Error count : Press the Channel 8 => Channel 0 .
2. Panel operation time : Press the Channel 7 => Channel 0 .
Exiting the Self-diagnostic screen
To exit the Self Diagnostic screen, turn off the power to the TV by pressing the POWER button on the remote or the POWER button on
the TV.

KDL-32/40EX400(HK/WB/GA)13
SEC 1. DISASSEMBLY
KDL-32EX400
KDL
KDL- -32EX400 32EX400
1-1. MOVIE LIST
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



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Note:
1. This link does not work from outside Sony network.
2. The Disassembly movie can be downloaded from ORISS Service Manuals site.

KDL-40EX400
KDL
KDL- -40EX400 40EX400

KDL-32/40EX400(HK/WB/GA)14
CHASSIS SERVICE
000 CXD2813R
000 H_DET_NOSIG_CNT 1
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.
3) Service mode display.
Note: First of all, when you enter Service Mode, you can see “Digital” service mode.
Whenever you press “OPTIONS” or “JUMP” on remote, each service mode is changed.
“Digital” -> “Chassis” -> “Sub”
DIGITAL SERVICE
001 OP
000 VERS ---
<MAIN> <SUB>
DM1.301J00AA SM1.010W00AA
M2.105C SB1.000W00AA
DD1.016J00AA SD1.010W00AA
(DM1.301J00AA) RF01.05
WP00.521J00AA ID1C117081
ID1C117081 LTY320AB01
PID04020000
WF:2.0.0.99 <BEM>
WF:0B BM1.012W00LU
Camera FW BB1.000W00LU
Camera FW BD1.011J46LUX
---.---------
Item number
Category number
Item name
Category name
Data
Press “OPTIONS”
or “JUMP” button

KDL-32/40EX400(HK/WB/GA)15
ADJUSTMENT
4) How to use the remote commander.
5) After entering service mode, then turn off the power switch.
Function The flow of control
Service mode on <Test>+<TV>/<Display><5><Vol Up><Power>
Service mode off <Other> / <Power off + on>
Item up / down <1>/<4>
Category up / down <2>/<5>
Data up / down <3>/<6>
Test reset <8> + <Mute> + <0>
Read data <9> + <0>
Execute <10 or 0>
Write data <Mute> + <0>
Change module <Jump> / <Option>

KDL-32/40EX400(HK/WB/GA)16
ADJUSTMENT
WHITE BALANCE ADJUSTMENT
Change Data of “Digital” service mode. (“006 WB” category)
a. Press “0” or “10” on remote to enter WB adjustment mode.
b. Press number key “1”~”6” directly. “*” stamp move.
c. Press “12 / enter / select” to decide and advance next step.
When returning on the previous page, press “return”.
d. Change data by number key “0”~”9” directly. (0-255)
e. Press “12 / enter / select” to save data.
It shows red “WRITE”. It indicate writing is processing.
f. Writing process is done at this point.
DIGITAL SERVICE
006 WB
000 WHITE_BALANCE ___
DIGITAL SERVICE
WB
*1 R_DRV 128
2 G_DRV 128
3 B_DRV 128
4 R_BKG 128
5 G_BKG 128
6 B_BKG 128
Please input WB items
(0-255)
---
Gain
0: x 0.5, 128: x 1, 255: x1.5
Offset
128: offset 0

KDL-32/40EX400(HK/WB/GA)17
SAVE CHANGING DATA
1) Change Data of “Chassis” or “Sub” service mode
2) Write data for “Chassis” or “Sub” service mode
a. Press “Mute” on remote.
It shows green “SERVICE” changes to green “WRITE”.
b. Press “0” or “enter” on remote. Green “WRITE” changes to red “WRITE”. It indicate writing is processing.
c. After a while, red “WRITE” changes to green “SERVICE”. Writing process is done at this point.
3) TV reboot is necessary for applying data change.
CHASSIS WRITE
000 CXD2813R
000 H_DET_NOSIG_CNT 1
ADJUSTMENT

KDL-32/40EX400(HK/WB/GA)18
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)
a. Press “2 / 5” on remote to select (up / down) category.
b. Press “1 / 4” on remote to select (up / down) Item.
c. Press “0 / 10” on remote to select item.
DIGITAL SERVICE
004 TUNER
000 A_NOSIG_DET 001
DIGITAL SERVICE
003 DIG_SRV_MODE
000 TEST_PATTERN ---
DIGITAL(DIG_SRV_MODE) SERVICE
TEST_PATTERN
*1 Video
2 Audio
2) Change Data of “Digital” service mode. ( “003 DIG_SRV_MODE” category)
“003 DIG_SRV_MODE” is one category of “Digital” service mode.
Please note because this operation is special.
a. Press “2 / 5” on remote to select “003 DIG_SRV_MODE”.
b. Press “1 / 4” on remote to select (up / down) Item.
c. Press “0 / 10” on remote to select item.
d. Press number key “1”~”9” directly. “*” stamp move.
e. Press “12 / enter / select” to decide and advance next step. Press “return”,
when returning on the previous page.

KDL-32/40EX400(HK/WB/GA)19
ADJUSTMENT
3) Write data for “Digital” service mode. ( “002 MODEL” category)
Note: This procedure operation, when replaced the B board.
Note: Do not write a wrong segment or destination information in Product ID.
When the wrong setting is written, TV may not operate.
000 SEG ・・・Product ID - segment information
001 DEST・・・Product ID – destination information
a. Change data for each model.
b. Press “0” or “enter” on remote.
It shows red “WRITE”. It indicate writing is processing.
c. Writing process is done at this point.
DIGITAL SERVICE
002 MODEL
000 SEG 01 : 2a-3
Write

KDL-32/40EX400(HK/WB/GA)20
ADJUSTMENT
SET TO SHIPPING CONDITION
How to do shipping condition.
a. Move to “Digital” service mode.
Press “8” on remote.
It shows green “SERVICE” changes to green “RST-”.
Press “mute” on remote.
Added green “EXE” after green “RST-”.
d. Press “0” or “enter” on remote. Green “EXE-RST” changes to red “EXE-RST”. It indicate writing is processing.
After a while, red “EXE-RST” changes to green “SERVICE”.
And all LED lights.
Writing process is done at this point.
<Another way>
You can set to shipping condition w/o entering Service Mode.
-> “Cursor Up” on remote + “Power Key” on Front panel.
TIMER Standby POWER