Sony KDL-24R400A Bravia Operating instructions

REPAIR MANUAL
Self Diagnosis
Supported model
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
LCD Digital Color TV
9-883-498-02
RB1FK Chassis
Segment: BA
Version Date Subject
1.0 01/27/2013 Original Manual Release Date.
2.0 02/08/2013 Updated Section 3 - Repair Information. Replaced pages 13 - 21.
MODEL COMMANDER DESTINATION
KDL-24R400A RM-YD092 LA/MX
KDL-32R400A RM-YD092 US/CND/LA/MX
KDL-32R400A

KDL-24R400A/32R400A i
TABLE OF CONTENTS
Cautions and Warnings...................................................................................ii
Section 1 - Specications and Layouts .........................................................1
Specications ................................................................................................1
Board Layout .................................................................................................2
KDL-24R400A........................................................................................................2
KDL-32R400A........................................................................................................2
Wire Dressing................................................................................................3
KDL-24R400A........................................................................................................3
KDL-32R400A........................................................................................................3
Section 2 - Troubleshooting ...........................................................................4
Diagnosing the Error .....................................................................................4
Viewing the Self Check Diagnosis History.............................................................4
Triage Chart...................................................................................................5
Flowcharts and Diagrams..............................................................................6
Overall Block Diagram...........................................................................................6
Power and Control Block Diagram.........................................................................7
KDL-24R400A...................................................................................................7
KDL-32R400A...................................................................................................8
No Power Flowchart ..............................................................................................9
Standby LED Blinking Flowchart .........................................................................10
No Video Flowchart ............................................................................................. 11
Video Distortion Flowchart...................................................................................12
Section 3 - Repair Information......................................................................13
Repairing the TV..........................................................................................13
Removing the Table-Top Stand............................................................................13
Removing the Rear Cover/Lower Cover..............................................................13
KDL-24R400A.................................................................................................13
KDL-32R400A.................................................................................................14
Replacing the Main Board ...........................................................................15
Replacing the Power Supply Board.............................................................19
KDL-24R400A......................................................................................................19
KDL-32R400A......................................................................................................19
Removing the Switch Unit ...........................................................................20
Removing the Speakers ..............................................................................20
Removing the Bezel and H Board Assembly...............................................20
KDL-24R400A......................................................................................................20
KDL-32R400A......................................................................................................21
Section 4 - Exploded View/Part Number Information.................................22
KDL-24R400A .............................................................................................22
KDL-32R400A .............................................................................................23
Connectors ..................................................................................................24
KDL-24R400A......................................................................................................24
KDL-32R400A......................................................................................................24
Screws.........................................................................................................25
Section 5 - Accesories Part Number Information .......................................26
Accessories and Packaging ........................................................................26
Miscellaneous..............................................................................................26
Optional Accessories...................................................................................26
Remote Commander ...................................................................................26
Appendix A: Encryption Key Components ............................................... A-1

KDL-24R400A/32R400A ii
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.
ATTENTION!!
For safety reasons, component level repair of the Power Supply Boards
and/or the Inverter Boards is prohibited.
CAUTIONS AND WARNINGS
ATTENTION!!
Ces instructions de service sont à l’usage du personnel de service quali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
qualié faire ainsi.
ALERTE!!
An d’eviter tout risque d’electrocution provenant d’un chássis sous tension,
un transformateur d’isolement doit etre utilisé lors de tout dépannage.
!
ATTENTION AUX COMPOSANTS
RELATIFS A LA SECURITE!!
Les composants identi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 identies dans le present manuel. Suivre ces procedures lors de
chaque remplacement de composants critiques, ou lorsqu’un mauvais
fonctionnement suspecte.
ATTENTION!!
Pour des raisons de sécurité, Interdire de réparer ou remplacer les
composantes dans les blocs d’alimentation et/ou sur les modules d’inverseur.

KDL-24R400A/32R400A iii
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-24R400A/32R400A 1
SPECIFICATIONS
KDL-32R400A: 8 W + 8 W
KDL-24R400A: 5 W + 5 W
CABLE/ANTENNA
COMPONENT IN
HDMI IN 1(ARC)
HDMI IN 2/MHL
AUDIO OUT
DIGITAL AUDIO OUT
(OPTICAL)
System
Television systemATSC (8VSB terrestrial): ATSC compliant 8VSB
QAM on cable: ANSI/SCTE 07 2000 (Does not include CableCARD functionality)
NTSC: American TV standard
Channel coverage
Analog Cable: 1 - 135 / Digital Cable: 1 - 135
Analog terrestrial: 2 - 69 / Digital terrestrial: 2 - 69
Panel system LCD (Liquid Crystal Display) Panel, LED Backlight
Speaker output
Input/Output jacks
75-ohm external terminal for RF inp
VIDEO IN VIDEO: 1 Vp-p, 75 ohms unbalanced, sync negative
AUDIO: 500 mVrms (Typical) / Impedance:47 kilohms
YPB PR (Component Video): Y:1.0 Vp-p, 75 ohms unbalanced, sync negative
PR: 0.7 Vp-p, 75 ohms / Signal format: 480i, 480p, 720p, 1080i, 1080p
PB: 0.7 Vp-p, 75 ohms
AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms
HDMI: Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p
MHL: Video: 480i, 480p, 720p, 720/30p, 1080i, 1080/30p, 1080/24p
Audio: Two channel linear PCM 32, 44.1 and 48 kHz, 16, 20 and 24bits, Dolby Digital, PC Input
500 mVrms (typical)
PCM/Dolby Digital optical signal
USB Photo, Music and Video
SECTION 1 - SPECIFICATIONS AND LAYOUTS
KDL-32R400A KDL-24R400A
W 04W 06
23,6 (24 class)31,5 (32 class)
8,950,08
(mm) 001 × 53 001 × 04
with stand (mm)731 × 461 × 163
46 × 343 × 85567 × 144 × 137
100 × 100
8,310,5
8,218,4
Model name
Power and others
Power requirement110-240 V AC, 50/60 Hz (USA, Canada, Mexico 120 V AC, 60 Hz)
Power consumption
in use
in standby Less than 0.3 W with 120 V AC and less Less than 0.3 W with 120 V AC
and 240 V AC
Screen size*
(measured diagonally)
(inches)
Display resolution 1,366 dots (horizontal) × 768 lines (vertical)
Speaker/Full range (2)
558 × 363 × 140
Dimensions*
without stand (mm)
wall-mount hole pattern
(mm)
wall-mount screw size
(mm) M4 (6.5~10 mm)
Mass* with stand (kg)
without stand (kg)
Supplied accessoriesRemote control RM-YD092 (1) / Size AAA batteries (2) / Operating Instructions (1) / Quick Setup
Guide (1) / Warranty Card (1) / Safety and Regulatory Booklet (1) / Software License (1) /
Stand Installation Guide (1) / Table-Top Stand (1 set) / Screws (2)
Optional accessoriesConnecting Cables / Support Belt Kit
•O
ptional accessories availability depends on its stock.
•D
esign and specications are subject to change without notice.
*Dimensions and mass are approximate values.
than 0.4 W with 240 V AC
(cm)

KDL-24R400A/32R400A 2
SECTION 1 - SPECIFICATIONS AND LAYOUTS
BOARD LAYOUT
KDL-24R400A
TCON
H BOARD
POWER SUPPLY
BOARD (GE24)
SWITCH
UNIT
MAIN BOARD
(A BOARD)
KDL-32R400A
TCON
SWITCH
UNIT
H BOARD
MAIN BOARD
(A BOARD)
POWER SUPPLY
BOARD (GL3)

KDL-24R400A/32R400A 3
SECTION 1 - SPECIFICATIONS AND LAYOUTS
WIRE DRESSING
KDL-24R400A KDL-32R400A

KDL-24R400A/32R400A 4
DIAGNOSING THE ERROR
Before servicing the Television:
1. Verify the TV has the symptom the customer indicated.
2. Check to see if the latest Software is installed.
a. If not, install the latest version.
3. Determine the replacement part required.
VIEWING THE SELF CHECK DIAGNOSIS HISTORY
When an error is detected, the Self Check screen records 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. Press
POWER
to turn on the TV and then turn it off again.
2. Press the following buttons on the Remote Commander within 1
second of each other:
DISPLAY
Channel 5Volume
-
POWER
NOTE: This differs from accessing Service Adjustments Mode
(Volume +).
SECTION 2 - TROUBLESHOOTING
Self Diagnosis
Supported model
Back <<
002 MAIN_ POWER 001
003 DC_ALERT1 000
003 AUDIO_PROT
000R_ERRECNALAB400
000
000
000RRE_NOCT500
005 PANEL_ID_NVM_ERR
000TILKCAB600
000RRE_PMET700
[Home] Exit
SELF CHEC
K
Indicates
an error
has occurred
Indicates
no error
has occurred
00116 00024 00115
SAMPLE SELF CHECK DIAGNOSIS PAGE

KDL-24R400A/32R400A 5
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. RED Dot: (Primary) Most likely defective part.
2. Select that symptom from the chart. BLUE Triangle: (Secondary) Possible defective part.
3. Bring the primary component listed for that symptom.
5. Chart Color Code.
Power Audio
2X 3X 5X 6X Dead setNo
Video
Whole
Screen
Distortion
Isolated
Area
Distortion
No Audio
MAIN BOARD
▲ ▲  
POWER SUPPLY   
LCD PANEL 
TCON
  ▲ ▲
Video
Protection Modes
4. Follow the associated flowcharts in the Training Manual to isolate the board.
Board
*NOTE: REFER TO LCD PANEL SERVICE MANUAL IN REFERENCE LIBRARY DATABASE
FOR CORRECT REPLACEMENT PARTS BASED ON SERIAL NUMBER.
To access the most recent version of the Triage documents for the models listed in this manual, login into the Sony Authorized Servicer Portal at
http://www.sony.com/asp.

KDL-24R400A/32R400A 6
SECTION 2 - TROUBLESHOOTING
FLOWCHARTS AND DIAGRAMS
OVERALL BLOCK DIAGRAM
COMPONENT/
COMPOSITE
RF
COMPOSITE
HDMI 1
PC HD15
POWER SUPPLY
SWITCH
UNIT
LED
IR RX
LCD PANEL, TCON
LED BACKLIGHTS
A
H
L
R
ANALOG AUDIO OUT
OPTICAL AUDIO OUT
MT5389
A/V DECODER
A/V PROCESS
TUNER
USB 1
HDMI 2
LVDS
AC IN
CLASS D
AUDIO
AMP
GL3 (32")
HEADPHONE AUDIO OUT
GE24 (24")
MAIN BOARD
&

KDL-24R400A/32R400A 7
SECTION 2 - TROUBLESHOOTING
POWER AND CONTROL BLOCK DIAGRAM
KDL-24R400A
STBY 3.3V
GND
AC_OFF_DET
POWER_ON
1
2
3
4~7
REG_12V
PWM
BL_ERR
BL_ON
8~11
12
13
14
NC
15
AC IN (N)
AC IN (H)
1
2
CN2
A
STBY 3.3V
GND
VCC-12V
1
2, 7, 11
3, 8
BL PWM
AC_DET
4
5
CN201
TCON_VCC
10
AUDIO_12V
12
POWER_ON
6
BL_ERR
13
BL_EN
14
CN1
LCD PANEL, TCON
&
LED BACKLIGHTS
LED 1
1
LED 2
2
CN3
GE24 (24")
3
4
LED 3
LED 4
NC
5
6, 7
VLED (28.8V)
8
9
NC
LED 5
10
11
12
LED 6
LED 7
LED 8
POWER SUPPLY
MAIN BOARD

KDL-24R400A/32R400A 8
SECTION 2 - TROUBLESHOOTING
KDL-32R400A
GND
VCC_12V
STBY 3.3V
POWER_ON
1, 3
2
4
5, 7
AC_OFF_DET
BL_CNTRL
BLKT_EN
AUDIO_12V
6
8
9, 11
10
AUDIO_12V
NC
BKL_ERR
VCC_12V
11
12
13, 15
14
NC
16
AC IN (N)
AC IN (H)
1
2
CN6401
A
STBY 3.3V
GND
VCC-12V
1
2, 7, 11
3, 8
BL PWM
AC_DET
4
5
CN201
TCON_VCC 10
AUDIO_12V 12
POWER_ON 6
BL_ERR 13
BL_EN 14
GL3 (32")
CN6101
LCD PANEL, TCON
&
LED BACKLIGHTS
LED +
1
LED -
2
CN6801
POWER SUPPLY
MAIN BOARD

KDL-24R400A/32R400A 9
SECTION 2 - TROUBLESHOOTING
. *For Part Number information, refer to “Section 4 - Exploded View/Part Number Information” on page 22.
NO POWER FLOWCHART
No Power
Is standby LED
blinking?
No
Yes
No
See Standby
LED Blinking
flowchart
Yes
Does red standby
LED on front panel
light steady?
Press power
button while
monitoring pin 4 of
CN6401 on Power
Supply Board
High (3.3V)
on pin 4?
Yes
No
Main Board
High (3.3V)
on pin 6?
Yes
No
Unplug TV from
AC power. Wait at
least 20 seconds
and re-apply AC
power
24"?
Press power
button while
monitoring pin 3 of
CN2 on Power
Supply Board
High (3.3V) on
pin 3?
High (3.3V) on
pin 2?
Yes
No
Power Supply
Board
Power Supply
Board
Yes
Power Supply
Board
Power Supply
Board
Main Board
Power Supply
Board
No
Yes
No

KDL-24R400A/32R400A 10
SECTION 2 - TROUBLESHOOTING
. *For Part Number information, refer to “Section 4 - Exploded View/Part Number Information” on page 22.
STANDBY LED BLINKING FLOWCHART
Protect
Shutdown.
Standby LED
Blinking
No
Yes
No
Yes
2X
Main Board
3X
5X
No
Yes
LCD Panel
6X
Yes
Power Supply Board
“SONY” logo
appears before
shutdown?
Yes
No
LCD Panel
Power Supply Board

KDL-24R400A/32R400A 11
SECTION 2 - TROUBLESHOOTING
. *For Part Number information, refer to “Section 4 - Exploded View/Part Number Information” on page 22.
NO VIDEO FLOWCHART
No Video
Backlights
turned on?
Unplug LVDS
connector 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
LCD Panel
Yes
Yes
Main Board
LCD Panel

KDL-24R400A/32R400A 12
SECTION 2 - TROUBLESHOOTING
. *For Part Number information, refer to “Section 4 - Exploded View/Part Number Information” on page 22.
VIDEO DISTORTION FLOWCHART
Video Distortion
Is distortion
across entire
screen?
Any horizontal
lines?
No
No
Yes
Yes
Improper of
missing colors?
Yes
Main Board
No
Vertical lines
or bars?
No
Yes
Lines move
when wide-mode
changed?
Yes
No
LCD Panel
Main Board
LCD Panel
Any single or
isolated vertical
lines?
Yes
LCD Panel
More than 1
vertical band?
No
Yes
LCD Panel
Uneven
brightness? LCD Panel
Yes
No

KDL-24R400A/32R400A 13
SECTION 3 - REPAIR INFORMATION
REPAIRING THE TV
If the latest Software does not correct the issue, complete the following:
1. Verify the television has the symptom the customer indicated.
2. Replace part causing the error.
3. Install the latest version of Software (Required for ALL repairs).
4. Perform the required service adjustments and checks.
5. Verify the repair resolved the issue.
REMOVING THE TABLE-TOP STAND
1. Place TV face down on a soft and at surface.
2. Remove 2 screws from Table-Top Stand and carefully detach from
Rear Cover.
REMOVING THE REAR COVER/LOWER COVER
KDL-24R400A
1. Remove 6 screws from the Rear Cover and 1 screw from AC Cover.
2. After removing the screw from the AC Cover, slide Power Cord to the
left and release the AC Cover.
3. Press upwards on the areas shown to separate the Rear Cover. Slide
the Power Cord through the AC Cover opening.

KDL-24R400A/32R400A 14
SECTION 3 - REPAIR INFORMATION
KDL-32R400A
1. Remove 11 screws from the Lower Cover.
2. Hold the bottom of the Lower Cover as shown, then lift to detach.
3. Pull out to remove.

KDL-24R400A/32R400A 15
SECTION 3 - REPAIR INFORMATION
4. Remove 5 screws and lift to detach board from Rear Cover.
5. Install the new Main Board and 5 screws.
6. Reconnect the LVDS cable and all other connectors:
CAUTION: Make sure the black line is aligned to the connector before
locking.
For KDL-24R400A
a. Insert LVDS cable in the connector and close black locking bar to
secure position.
For KDL-32R400A
b. Press both sides to clamp connector and insert back.
7. Holding the FFC cables, insert into the connector and secure position.
REPLACING THE MAIN BOARD
The Main Board used in these models is available for repair. For Part
Number information refer to Section 4 - Exploded View/Part Number
Information on page 22.
1. Disconnect LVDS cable according to the TV model:
For KDL-24R400A
a. Lift the black locking bar and pull LVDS cable to release.
For KDL-32R400A
b. Press both sides to unclamp connector and pull to release.
2. To disconnect FFC cables lift the black locking bar and pull to release.
3. Disconnect all the remaining connectors.

KDL-24R400A/32R400A 16
SECTION 3 - REPAIR INFORMATION
8. Update the Software.
After ALL repairs UPDATE the SOFTWARE to the latest version.
Instructions are included with the Software package on the Sony
Authorized Service Portal website.
a. Insert the USB device with the latest Software into the TV.
b. Press
POWER
to turn on the TV.
c. Wait until the Software update is complete.
9. After update is complete, press
POWER
to turn off the TV.
10. Access Service Mode by pressing the following buttons within 1
second of each other:
DISPLAY
Channel 5Volume +
POWER
Sound Adjustment >>
Wide Band Tuning >>
Range Scan… >>
Self diagnosis history >>
Status Information… >>
LVDS Spectrum(%0) <[ 30 ]>
Low of HPD <[ 5]>
TVD_MCDONE_CNT <[ 20 ]>
Demo Special >>
Bypass AVI Info Detect <[ On ]>
Panel Selection <[
21_LSY320AN02
]>
UART Selection No Log
SERIAL NUMBER EDIT
MODEL NAME EDIT
[</>]Set [Home] Exit
Service Mode
11. Press until Panel Selection is selected.
Sound Adjustment >>
Wide Band Tuning >>
Range Scan… >>
Self diagnosis history >>
Status Information… >>
LVDS Spectrum(%0) <[ 30 ]>
Low of HPD <[ 5]>
TVD_MCDONE_CNT <[ 20 ]>
Demo Special >>
Bypass AVI Info Detect <[ On ]>
Panel Selection <[
21_LSY320AN02
]>
UART Selection No Log
SERIAL NUMBER EDIT
MODEL NAME EDIT
[</>]Set [Home] Exit
Service Mode
12. Press or to select the correct Panel Code for theTV model.
(Use the table below for reference).
Model Name Panel Code
KDL-24R400A
21_LYS320AN02
23_V236BJ1
KDL-32R400A
CAUTION: Select ONLY the correct Panel Code.
13. Locate the Serial Number for the TV on the side of the Rear Cover.
MODEL NO
KDL-32R400A
SERIAL NO
6000001