Sony Bravia KDL-40EX725 User manual

SERVICE MANUAL
LCD Digital Color TV
AZ2-F Chassis
Segment: 3a-2
9-888-439-02
Version Date Subject
1.0 3/25/2011 Original Manual Release Date
2.0 2/8/2012 Reissue entire manual.
ORIGINAL MANUAL ISSUE DATE: 3/2011
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE MANUAL
LCD Digital Color TV
AZ2-F Chassis
Segment: 3a-2
9-888-439-02
Self Diagnosis
Supported model
KDL-40EX725

MODEL LIST
MODEL COMMANDER DESTINATION MODEL COMMANDER DESTINATION
KDL-32EX725 RM-YD062 BRAZIL
KDL-40EX725 RM-YD062 BRAZIL
KDL-46EX725 RM-YD062 BRAZIL
KDL-55EX725 RM-YD062 BRAZIL
9-888-439-02

KDL-32EX725/40EX725/46EX725/55EX725 i
TABLE OF CONTENTS
Section 1 - Safety and Features.................................................1
Warnings and Cautions ..............................................................1
Handling the LVDS FFC Connector ...........................................3
Disconnecting the LVDS FFC Connector .................................... 3
Connecting the LVDS FFC Connector ........................................ 4
Safety-Related Warnings ...........................................................5
Safety Check-Out.......................................................................6
Self Diagnosis Function .............................................................8
Overview ....................................................................................9
Features .....................................................................................9
See It All in 3D............................................................................. 9
MotionFlow™ XR 240 ................................................................. 9
Navigation Made Easy ................................................................ 9
LightSensor™ Technology .......................................................... 9
X-Reality™ Engine ...................................................................... 9
Presence Sensor....................................................................... 10
USB Photos, Videos & Music .................................................... 10
Edge LED Backlighting.............................................................. 10
Internet Streaming & Connectivity............................................. 10
Faster Start-Up.......................................................................... 10
BRAVIA® Sync™ Compatible ................................................... 10
Specications ........................................................................... 11
Section 2 - Software Requirements.........................................13
Overview ..................................................................................13
Software Updates for Customers .............................................13
Software Updates for Servicers ...............................................14
Software Update Responsibility ................................................ 14
Checking the Software Version ................................................. 15
Examples of Software Correctable Symptoms.......................... 15
Section 3 - Chassis Overview..................................................16
Overview ..................................................................................16
Overall Circuit Description........................................................19
Main Board...............................................................................19
Tuner ......................................................................................... 19
X-Reality Processor................................................................... 19
Audio Amplier .......................................................................... 19
Temperature Sensor.................................................................. 19
Power Supply ...........................................................................20
Power Supply for Backlight System .........................................20
3D IR Emitter............................................................................20
Switch Unit ...............................................................................20
Motion Sensor Board ...............................................................20
IR Board ...................................................................................20
LCD Panel Assembly ...............................................................21
TCON Board.............................................................................. 21
LD Board (LED Drive Board)..................................................... 21

KDL-32EX725/40EX725/46EX725/55EX725 ii
TABLE OF CONTENTS
Diagrams..................................................................................22
Block Diagram ........................................................................... 22
Connector Diagrams ................................................................. 24
Section 4 - Troubleshooting.....................................................30
Overview ..................................................................................30
Updating the Software............................................................... 30
Triage Chart .............................................................................31
Protection Shutdown ................................................................32
Standby LED Flash Count......................................................... 32
Diagnostic Code Descriptions ..................................................36
Viewing the Self Check Diagnostic History ............................... 37
Section 5 - Flow Charts and Diagrams ...................................38
Overview ..................................................................................38
No Power................................................................................... 39
Standby LED Blinking................................................................ 41
No Picture/No Sound................................................................. 47
TV/Remote Commander Buttons Not Working ......................... 50
Network Not Connecting .......................................................... 52
3D Does not Display.................................................................. 54
Skype Accessory Not Working .................................................. 55
Section 6 - Disassembly/Part Number Information ...............57
Table-top Stand Assembly Removal ........................................57
Rear Cover and AC Cover Removal ........................................58
Switch Unit and Speakers Removal.........................................59
LD Board, HEM2 Board, HLR2 Board
and HMS3 Board Removal.................................................60
G10/G4/G5/G6/G8 (Power Supply) Board, and
BATV (Main) Board Removal .............................................61
KDL-32EX725/40EX725/46EX725 Only ................................... 61
KDL-55EX725 Only ................................................................... 62
Panel Brackets and LCD Panel Removal ................................63
Cleaning the LCD Panel............................................................ 63
Screw Legend ..........................................................................64
Connectors...............................................................................64
KDL-32EX725 Only............................................................. 64
KDL-40EX725 Only............................................................. 65
KDL-46EX725 Only............................................................. 65
KDL-55EX725 Only............................................................. 65
Accessories and Packaging .....................................................66
Miscellaneous ..........................................................................66
Optional Accessories................................................................66
Remote Commander................................................................66
Wire Dressing...........................................................................67
KDL-32EX725 Only ................................................................... 67
KDL-40EX725 Only ................................................................... 67
KDL-46EX725 Only ................................................................... 67
KDL-55EX725 Only ................................................................... 67

KDL-32EX725/40EX725/46EX725/55EX725 iii
TABLE OF CONTENTS
Section 7 - Service Adjustments .............................................68
Overview ..................................................................................68
Updating the Software..............................................................68
Accessing Service Adjustments ...............................................68
Viewing or Changing Service Data............................................ 69
Updating Service Adjustment Data
When Replacing the Main Board........................................70
Selecting the Segment Code..................................................... 70
Selecting the Destination........................................................... 71
Selecting the Model Name ........................................................ 73
Selecting the BU Trans.............................................................. 74
Adding the Serial Number ......................................................... 75
Conrming the Model ID and Product ID................................... 77
Updating Service Adjustment Data
When Replacing the LCD Panel.........................................78
Copying the BU Flash Data....................................................... 78
Conrming the Model ID and Product ID................................... 80
Resetting the Panel Operation Time ......................................... 81
Optional Adjustments ...............................................................82
Setting White Balance Adjustments .......................................... 82
Resetting the TV to Factory Condition .....................................83
Resetting the TV to Factory Condition Using Service Mode ..... 83
Appendix A - Removing the Rear Cover ............................... A-1
Removing the Power Cord from the Rear Cover ................... A-2
KDL-32EX725 ..........................................................................A-2
KDL-40EX725 ..........................................................................A-4
KDL-46EX725 ..........................................................................A-6
Appendix B - Attaching the Rear Cover................................ B-1
Reattaching the Rear Cover to the Bezel............................... B-1
KDL-32EX725 ..........................................................................B-1
KDL-40EX725 ..........................................................................B-2
KDL-46EX725 ..........................................................................B-2
Appendix C - Replacing the LCD Panel ................................ C-1
Removing the LCD Panel from the Bezel .............................. C-1
Reattaching the LCD Panel onto the Bezel............................ C-2

KDL-32EX725/40EX725/46EX725/55EX725 1
WARNINGS AND CAUTIONS
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.
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.
•Disconnect all cables when carrying the TV.
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.
!
SAFETY-RELATED COMPONENT WARNING!!
Components identied by shading and
!
mark on the exploded views are critical for safe operation.
Replace all components with Sony parts whose part numbers appear as shown in this manual or in supplements published by Sony. It is essential
that all critical parts be replaced only with the part number specied in this manual to prevent electric shock, re, or other hazard.
Circuit adjustments that are critical for safe operation are identied in this manual.
Follow these procedures whenever critical components are replaced or improper operation is suspected.
NOTE: Do not modify the original design without obtaining written permission from the manufacturer or you will void the original parts and labor
guarantee.
SECTION 1 - SAFETY AND FEATURES

KDL-32EX725/40EX725/46EX725/55EX725 2
SECTION 1 - SAFETY AND FEATURES
CAUTION
WDo 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.
WDo Not use any cleaning product containing alkaline/acid cleaner, scouring powder, or volatile solvent, such as alcohol, ammonia,
benzene, thinner or insecticide. Using any of these harsh cleaners may result in permanent damage to the screen.
WDo Not spray water or detergent directly onto the TV screen . If liquid drips into the bottom of the screen it may cause a failure.
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.
RStubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water.
RIf using a chemically pretreated cloth, please follow the instruction provided on the package.
RNever use strong solvents such as a thinner, alcohol or benzine for cleaning.
RPeriodic vacuuming of the ventilation openings is recommended to ensure to proper ventilation.

KDL-32EX725/40EX725/46EX725/55EX725 3
SECTION 1 - SAFETY AND FEATURES
HANDLING THE LVDS FFC CONNECTOR
Several 2011 Models use a LVDS FFC Connector from the Main Board to the TCON Board. There are three different types of
connectors that are used.
CAUTION:
Refer to the illustration below when disconnecting or
connecting the LVDS FFC Connector.
Correct Incorrect
DISCONNECTING THE LVDS FFC CONNECTOR
Connector Type 1
1. Slightly tilt the Main Board
connector release away from the
LVDS FFC Connector.
DO NOT remove the LVDS FFC
Connector by the reinforcement
tab only.
2. Gently wiggle the LVDS FFC
Connector to detach it from the
Main Board.
䐠
Main Board
Reinforcement
Tab
Tilt away from LVDS
Connector Type 2
1. Gently press down on the
release tab of the Main Board
connector.
DO NOT remove the LVDS
FFC Connector by the
reinforcement tab only.
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.
DO NOT remove the LVDS
FFC Connector by the
reinforcement tab only.
2. Correctly holding onto the
LVDS FFC Connector, pull out
the connector while continuing
to hold down the release tabs
of the Main Board connector.
䐠Reinforcement
Tab
Press down
Main Board

KDL-32EX725/40EX725/46EX725/55EX725 4
SECTION 1 - SAFETY AND FEATURES
CONNECTING THE LVDS FFC CONNECTOR
CAUTION:
The LVDS FFC Connector can be inserted into the Main
Board upside down. If it is inserted upside down, the
pins on the LVDS FFC Connector will short-circuit and
damage the board.
Inserted Correctly Inserted Incorrectly
Connector Type 1
1. While holding onto the LVDS FFC
Connector, gently tilt the Main
Board connector release towards
the Main Board then slide the
LVDS FFC Connector straight in.
Main Board
Reinforcement
Tab
Tilt away from LVDS
Connector Type 2
1. Gently press down on the release
tab of the Main Board connector.
2. Holding onto the entire LVDS FFC
Connector, insert the LVDS FFC
Connector into the Main Board
connector.
Main Board
Reinforcement
Tab
Press down
䐠
Connector Type 3
1. Gently press down on the 2
release tabs of the Main Board
connector.
2. Holding onto the entire LVDS FFC
Connector, insert the LVDS FFC
Connector into the Main Board
connector.
Reinforcement
Tab Press down
Main Board
䐠