Sony KDL-32EX655 Installation guide

SERVICE / TRAINING MANUAL
LCD Digital Color TV
AZ3G Chassis
Segment: P-2A
9-883-892-01
Self Diagnosis
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:

SERVICE / TRAINING MANUAL
LCD Digital Color TV
AZ3G Chassis
Segment: P-2A
9-883-892-01
Self Diagnosis
Supported model
KDL-32EX655

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

KDL-32EX655/40EX655/46EX655 i
TABLE OF CONTENTS
Cautions and Warnings..................................................................................iii
Section 1 - Features and Overview ................................................................1
Features ........................................................................................................1
Specications ................................................................................................1
Checking the Accessories.........................................................................2
Chassis Overview..........................................................................................3
Overall Circuit Description.............................................................................5
Main Board ...............................................................................................5
Power Supply Board .................................................................................5
IR Board....................................................................................................5
Switch Unit................................................................................................6
LCD Panel Assembly................................................................................6
Section 2 - Troubleshooting ...........................................................................7
Overview .......................................................................................................7
Updating the Software ..............................................................................7
Self Diagnosis Function.................................................................................7
Standby LED Blink Count .........................................................................7
Viewing the Self Check Diagnosis History................................................8
Triage Chart.................................................................................................10
Section 3 - Flow Charts and Diagrams ........................................................ 11
Block Diagram ............................................................................................. 11
No Power ................................................................................................12
Standby LED Blinking .............................................................................14
No Picture ...............................................................................................15
Section 4 - Disassembly/Part Number Information ....................................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..............................................................................................24
Section 5 - Updates and Adjustments .........................................................25
Overview .....................................................................................................25
Software Updates for Customers ................................................................25
Software Updates for Servicers...................................................................25
Software Update Responsibility..............................................................26
Checking the Software Version...............................................................26
Completing Service Requirements
When Replacing the Main Board.................................................................26
Updating the Software ............................................................................26
Updating the Software ............................................................................26
Selecting the Segment Code ..................................................................27
Selecting the Destination ........................................................................29
Selecting the Model Name......................................................................30
Adding the Serial Number.......................................................................30

KDL-32EX655/40EX655/46EX655 ii
TABLE OF CONTENTS
Conrming the Model ID and Product ID ................................................32
Clearing the Self Diagnosis Self Check Information ...............................33
Resolving an 8 Blink Error...........................................................................34
Verifying There is an 8x Error .................................................................35
Resetting the TV to Factory Condition....................................................35
Updating the Software ............................................................................35
Replacing the Main Board ......................................................................35
Completing Service Requirements When
Replacing the LCD Panel or TCON Board .................................................36
Updating the Software ............................................................................36
Conrming 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 the TV to Factory Condition Using Service Mode...................40
Appendix A: Encryption Key Components ............................................... A-1

KDL-32EX655/40EX655/46EX655 iii
CAUTION
These servicing instructions are for use by qualied 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 qualied to do so.
WARNING!!
An isolation transformer should be used during any service to avoid possible
shock hazard, 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 identied 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 specied in the parts list to prevent
electric shock, re, or other hazard.
NOTE: Do not modify the original design without obtaining written permission
from the manufacturer or you will void the original parts and labor warranty.
CAUTIONS AND WARNINGS

KDL-32EX655/40EX655/46EX655 iv
CAUTIONS AND WARNINGS
SETTING UP AND CARRYING THE TV
●Disconnect all cables when carrying the TV.
●Carry the TV with the 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 damage.
USE CAUTION WHEN HANDLING THE LCD PANEL
When repairing the LCD panel, be sure you are grounded by using a wrist band.
When installing the LCD panel on a 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 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. During the repair, DO NOT leave the Power On for more than
1 hour while the TV is face down on a cloth.

KDL-32EX655/40EX655/46EX655 v
CAUTIONS AND WARNINGS
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.
Wipe the LCD screen gently with a soft cloth.
;Stubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water.
;If using a chemically pretreated cloth, please follow the instruction provided on the package.
;Never use strong 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 cleaner, scouring powder, or volatile solvent, such as alcohol, ammonia, benzine, thinner or
insecticide. Using any of these harsh cleaners may result in permanent damage to the screen.
;Do Not spray water or detergent directly onto the TV screen . If liquid drips into the bottom of the screen it may cause a failure.

KDL-32EX655/40EX655/46EX655 vi
CAUTIONS AND WARNINGS
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 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 battery-operated AC milliammeter.
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. Nearly all
battery-operated digital multimeters that have a 2 VAC range are
suitable. (see Figure A)
To Exposed Metal
Parts on Set
0.15 µF
Earth Ground
AC
Voltmete
r
(0.75V)
Figure A. Use an AC voltmeter to check AC leakage.
HOW TO FIND A GOOD EARTH GROUND
The cover-plate retaining screw on most AC outlet boxes is at earth ground.
Verify the AC outlet box retaining screw ground by connecting a 60W to
100W incandescent (not a neon or uorescent 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)
Figure B. Checking for earth ground.
Trouble Light
AC Outlet Box

KDL-32EX655/40EX655/46EX655 1
FEATURES
The AZ3G chassis is one of several designs for the 2012 model line of Sony
Bravia® LCD televisions. This manual covers the following models:
KDL-32EX655
KDL-40EX655
KDL-46EX655
The BRAVIA® EX65x series LED LCD HDTVs have incomparable picture
quality and an ultra-thin design
●Brilliant Full HD (1080p) picture quality
●X-Reality™ Engine that creates crisp detail in each scene
●Bright picture & thin design with Edge LED backlight
●One-touch access to the Sony Entertainment Network™ and apps1
●Skype™ ready1
●PC and tablet content2 on your TV w/ Intelligent Connect
●Media Remote™ app to control your TV with a smartphone2
●Wi-Fi® adaptor included to stream HD entertainment.
SECTION 1 - FEATURES AND OVERVIEW
SPECIFICATIONS
System
Television system Analog: NTSC/PAL-M/PAL-N
Digital: SBTVD
Channel coverage VHF: 2-13
UHF: 14-69
CATV (Analog): 1-135
Panel system LCD (Liquid Crystal Display) Panel
10 W + 10 W (8 ohms, 1 kHz, 10% THD*Speaker output1,127V)
Input/Output jacks
75-ohm external terminal for RF inputsCABLE/ANTENNA
VIDEO IN 1 Video / Audio input (phono jacks)
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 (stereo mini jack) (HDMI IN 2 only, common with PC IN)
ARC (Audio Return Channel) (HDMI IN 1 only)
DIGITAL AUDIO OUT
(OPTICAL)
Digital optical jack (Two channel linear PCM, Dolby Digital)
PC IN
PC/HDMI 2 AUDIO IN
Analog RGB (Mini D-sub 15-pin)
Audio input (stereo mini jack) (common with HDMI IN 2)
krowtenehtnognidnepedreffidyamdeepsnoitcennoC(rotcennocXT-ESAB001/T-ESAB01NAL
environment. 10BASE-T/100BASE-TX communication rate and communication quality are not
guaranteed for this TV.)
.tamrofdetroppusroflaunaM-iehtotrefeRANLD/BSU
1. Broadband speed of at least 2.5 Mbps recommended (10 Mbps for HD). Content subject
to change and may require fees. Skype requires CMU-BR100 camera sold sep. Subject to
Skype’s terms and conditions.
2. Requires devices connected to the same wireless home network.

KDL-32EX655/40EX655/46EX655 2
SECTION 1 - FEATURES AND OVERVIEW
Model name KDL- 46EX65540EX655
Power and others
Power requirement110-220 V AC, 60 Hz
Power
consumptionin standby Less than 0.2 W with 127 V AC and less than 0.3 W with 220 V AC
Screen size*2(cm)
(inches measured diagonally)
Approx. 101.6
40 inches
Approx. 116.8
46 inches
Display resolution 1,920 dots (horizontal) × 1,080 lines (vertical)
Optional Accessories
Supplied Accessories Refer to Checking the Accessories
Camera and Microphone Unit: CMU-BR100
USB Wireless LAN Adapter: UWA-BR100
Dimensions*
2
with stand (mm) 1,074 × 669 ×241
without stand
wall-mount hole
pattern (mm)
300 × 300200 × 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 specications are subject to change without notice.
1,074 × 651 × 60
CHECKING THE ACCESSORIES
Control remoto (1)*1
Pilas de tamaño AAA (2
)
Soporte de sobremesa (1)*
2
Tornillos de fijación para el soporte de
sobremesa (M5 × 16) (3)
Tornillos de montaje para el soporte de
sobremesa (M5 x 16) (2)
Manual de instrucciones (este manual) y
otros documento
s
*
1Consulte el número del modelo impreso en el
control remoto.
*
2Se requiere ensamblar la base de soporte de
sobremesa. Para ensamblar la base de soporte
de sobremesa consulte el folleto suministrado.

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 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

KDL-32EX655/40EX655/46EX655 4
SECTION 1 - FEATURES AND OVERVIEW
SWITCH
UNIT
HL
TCON
GL4
BAPS
BOARD LAYOUT FOR KDL-46EX655 ONLY

KDL-32EX655/40EX655/46EX655 5
SECTION 1 - FEATURES AND OVERVIEW
OVERALL CIRCUIT DESCRIPTION
“Block Diagram” on page 11 provides an overview of the AZ3G chassis.
The following are descriptions of the boards and their functions.
MAIN BOARD
Common to all models the Main Board, designated as the BAPS Board,
contains the TV control, video, and audio processing circuitry. All these
functions are accomplished using the X-Reality Processor IC9000.
TUNER
The tuner is a combination ATSC/NTSC unit. It can receive traditional
analog NTSC signals via cable or terrestrial along with ATSC digital
signals via terrestrial (8VSB) or cable (64 or 256 QAM).
X-REALITY PROCESSOR
IC9000 performs the majority of the necessary audio and video processing
on the Main Board.
TV Microprocessor: The CPU internal to the X-Reality processor
controls all aspects of the television functions. Input from the user along
with monitoring of critical circuits is also performed by this CPU.
Digital Audio and Video Decoder: The MPEG2 and Digital Dolby audio
streams are received from the tuner for decompression. All video sources
which are not native 1920 X 1080p 60HZ are scaled to this resolution.
Digital audio content is output to the class D amplier for processing and
amplication.
HDMI Input and Switching: The customer can select the HDMI1,
HDMI2, HDMI3, HDMI4 input via the HDMI switch IC5500. Each HDMI
input contains a common EDI NVM (internal to IC5500) to provide display
information data to any device connected via the HDMI inputs.
LVDS Transmitter: Integrated 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) conversion.
AUDIO AMPLIFIER
The main speaker audio amplier (IC4601) and sub-woofer amplier
(IC4701) amplies the digital audio output of the X-Reality processor and
sends it to the speakers.
TEMPERATURE SENSOR
The temperature sensor detects over-temperature conditions on the Main
Board, LCD Panel, or ambient room temperature and sends the shutdown
signal to the processor.
POWER SUPPLY BOARD
There are different Power Supply Boards used in the models in this manual.
The type of board depends on the size of LCD panel. They are:
●GL2 Board (for 32” models)
●GL4 Board (for 40” and 46” models)
There are 3 distinct sections on the power supply:
Standby Supply: Continuously operational as long as AC power is applied,
the standby supply generates 3.3V for the circuits requiring power while the
unit is turned off. An unregulated 19V line is present to provide power to the
main relay, PFC and main power supply at turn-on.
Main Supply: Once the power supply receives a power-on command from
the CPU on the Main Board, the main switching supply is turned on to
provide a regulated 12V source and Audio 12V.
Converter: Generates the B+ and B- voltages for the LED backlights.
IR BOARD
Designated as the HL Board, the IR Board contains the power, standby, and
timer LED’s that are located on this board along with the IR remote receiver
and light level sensor.

KDL-32EX655/40EX655/46EX655 6
SECTION 1 - FEATURES AND OVERVIEW
SWITCH UNIT
This board contains the power, channel and volume up/down, and menu
buttons.
LCD PANEL ASSEMBLY
The LCD Panel Assembly includes the LCD Panel, TCON Board, and LED
Backlight system.
The LCD Panel contains the actual liquid crystals, color lters, and
polarizers. The liquid crystals are manipulated by the applied voltage to
pass a specic 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
microprocessor on the Main Board.
NOTE: The TCON Board is not available as a replacement part for all
models. To determine if the TCON Board is available as a replacement
part, refer to the LCD Panels Manual.

KDL-32EX655/40EX655/46EX655 7
OVERVIEW
This chapter provides information regarding the Self Diagnosis feature in
our TVs.
UPDATING THE SOFTWARE
The Self Diagnosis function is designed to provide information regarding
the problem with the TV, however, there are several issues that may be
resolved by updating the TV software to the latest version. Always check
the Sony site for any issues that are software related. Most symptoms that
are correctable by software updates involve communications issues with
other devices or minor glitches in the operation of a specic function. Below
is a list of some of the symptoms that may be corrected with a software
update:
●Fluctuations in picture brightness
●Intermittent picture freezing or noise
●Problems with certain inputs (especially HDMI)
●Intermittent or distorted audio
●Erratic remote control operation
●TV turns on and off by itself
●Loss of color
●Internet connectivity
●Certain features not working correctly
(photo or video le viewing)
SECTION 2 - TROUBLESHOOTING
Self Diagnosis
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 occurred will automatically cause the CPU to blink the Standby LED
in groups of repeating sequences. The number of times the Standby LED
blinks indicates the possible cause of the problem.
Not all of the available protect codes are used in every model. For example,
models that don’t have the local dimming feature do not use the 4X blink
error as this circuit is found in models that are backlit with uorescent lamps.
The information in this section provides guidance in locating the possible
component causing the shutdown.
STANDBY LED BLINK COUNT
Standby LED
2 times
5 times
LED ON 0.3 sec.
LED OFF 0.3 sec. LED OFF
3 sec.
LED DISPLAY & BLINK COUNT

KDL-32EX655/40EX655/46EX655 8
SECTION 2 - TROUBLESHOOTING
VIEWING THE SELF CHECK DIAGNOSIS HISTORY
When an error is detected, the Self Check screen records the date(s) and
the number of times the error occurred. This is helpful in conrming past
occurrences of an error, and for determining if an error is intermittent when
the customer is not sure what is causing the television to shut down. If the
screen displays a 0, no error has occurred.
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 differs from accessing Service Adjustments Mode
(Volume +)
SELF CHECK
000 RESERVED --------------------- ------------------------------------------ 00
000 RESERVED --------------------- ------------------------------------------ 00
002MAIN_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_ERR120123132522 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_WDT --------------------- ------------------------------------------ 00
00345 000333 06789
Total operation time by hour (MAX:65535)
Boot count (MAX:65535)
Panel operation time by hour (MAX:65535)
Total operation time by hour (MAX:65535)
Boot count (MAX:65535)
Panel operation time by hour (MAX:65535)
StandBy LED
Blink Count
Diagnosis
Item
Date and Time Display*
Error Count
(00-99)
*Format of Error History = YYMMDDhhmmss example 120123132522= Jan 23, 2012 13:25:22 (1:25:22PM
)
NOTE: date and time must be set for this to work
SAMPLE SELF CHECK DIAGNOSIS PAGE

KDL-32EX655/40EX655/46EX655 9
SECTION 2 - TROUBLESHOOTING
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 on the secondary supply lines can cause the switching
regulator to stop, or fail again, if a replacement board is installed.
3X Blink- DC Regulator/Audio Error/HDMI/Tuner
Several items are monitored on the main board. Any error detected in the
following circuits will cause the television to shut down and generate a 3X
error:
●Loss of regulated B+ circuits
●Audio amplier failure
●HDMI equalizer IC
●Tuner demodulator circuits
In most cases, replacement of the main board will remedy a 3X error.
4X Blink – Balancer Error
NOT USED IN THIS MODEL SERIES
5X Blink - TCON Error
The 5X blink protection mode indicates a communications error between
the TCON Board and the X-Reality microprocessor on the Main Board. If
the TCON is available for replacement, replace the TCON. If the TCON is
not available, the LCD panel must be replaced since the TCON circuit is
part of the LCD panel assembly. In rare cases a loose or defective LVDS
cable could also be the cause.
6X Blink - Converter System Failure
An open LED in the backlight strings 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 error. Replacement of the Power Supply Board should remedy
this condition.
7X Blink - Temperature Failure
If the temperature inside the television becomes excessive, the temperature
sensor (located on the Main Board) noties the TV to shut down and display
a 7X error. Excessive temperature errors will always occur when the TV
has been running a while and can be caused by excessive ambient heat or
improper ventilation of the television.
If the television shuts down immediately, this can be caused by a defective
temperature sensing IC or failure of the communications bus between the
IC and the microprocessor. Replacement of the Main Board is necessary.
8X Blink – Not listed in Self Check
The 8X blink code is mainly used during TV software development. Look in
TV’s service Self Check for error code history and notice at the bottom of
the list WDT (Watch Dog Timer) error codes, in particular notice 103 HOST_
WDT. If this error code appears, check for any additional documentation on
the Sony ESI site.
10X Blink – IR Sync Transmitter Failure
NOT USED IN THIS MODEL SERIES

KDL-32EX655/40EX655/46EX655 10
SECTION 2 - TROUBLESHOOTING
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.
2. Select that symptom from the chart.
RED DOT: (Primary) Most likely defective part
3. Bring the primary component listed for that symptom.
▲
BLUE Triangle: (Secondary) Possible defective par
t
oiduArewoPNAL
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
VideoProtection Modes
4. Follow the associated flowcharts in the Training Manual to isolate the board.
Board Reference
*Immediate Shutdown After Power ON & 7X
*NOTE: REFER TO LCD PANEL SERVICE MANUAL IN REFERENCE
LIBRARY DATABASE FOR CORRECT REPLACEMENT PARTS
BASED ON SERIAL NUMBER.

KDL-32EX655/40EX655/46EX655 11
SECTION 3 - FLOW CHARTS AND DIAGRAMS
BLOCK DIAGRAM
VIDEO 2 CVBS/COMP
VIDEO 1 CVBS
RF
HDMI 1
PC HD15
SWITCH
UNIT
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