KDL-32EX500, KDL-40EX500, KDL-40EX501, KDL-46EX500, KDL-46EX501 (serv.man2) — Sony TV Service Manual (repair manual)

Model
KDL-32EX500 KDL-40EX500 KDL-40EX501 KDL-46EX500 KDL-46EX501 (serv.man2)
Pages
37
Size
22.16 MB
Type
PDF
Document
Service Manual
Brand
Device
TV / LEVEL 3
File
kdl-32ex500-kdl-40ex500-kdl-40ex501-kdl-46ex500-kd.pdf
Date

View Sony KDL-32EX500 / KDL-40EX500 / KDL-40EX501 / KDL-46EX500 / KDL-46EX501 (serv.man2) Service Manual online

LCD DIGITAL COLOR TV
 SERVICE MANUAL 
AZ1-K
 
CHASSIS
 
MODEL NAME 
                       REMOTE COMMANDER                                 DESTINATION 
9-883-841-51
KDL-32EX500
 RM-YD034 
US/CND
KDL-40EX500
 RM-YD034 
US/CND
KDL-40EX501
 RM-YD034 
US/CND
KDL-46EX500
 RM-YD034 
US/CND
KDL-46EX501
 RM-YD034 
US/CND
LEVEL 
3
CONFIDENTIAL
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
ORIGINAL MANUAL ISSUE DATE: 1/2010
REVISION 
DATE 
  SUBJECT     
1/2010 
 
 
 
No revisions or updates are applicable at this time.
CONFIDENTIAL
ELECTRICAL SERVICE MANUAL
INTERNAL ONLY
2
KDL-32EX500/40EX500/40EX501/46EX500/46EX501 
KDL-32EX500/40EX500/40EX501/46EX500/46EX501 
TABLE OF CONTENTS
SECTION TITLE   
PAGE
Safety-Related Component Warning .......................................................................................................................................................................... 3
Safety Check-Out ....................................................................................................................................................................................................... 5
SECTION 1:  DIAGRAMS ................................................................................................................................................................................................... 6
1-1.  Circuit Boards Location ...................................................................................................................................................................................... 6
1-2.  Printed Wiring Boards and Schematic Diagrams Information ............................................................................................................................ 6
1-3.  Block Diagrams  ................................................................................................................................................................................................. 8
1-4.  Schematics and Supporting Information ............................................................................................................................................................ 9
A Board Schematic Diagram (1 of 20) ................................................................................................................................................................ 9
A Board Schematic Diagram (2 of 20) .............................................................................................................................................................. 10
A Board Schematic Diagram (3 of 20) .............................................................................................................................................................. 11
A Board Schematic Diagram (4 of 20) .............................................................................................................................................................. 12
A Board Schematic Diagram (5 of 20) .............................................................................................................................................................. 13
A Board Schematic Diagram (6 of 20) .............................................................................................................................................................. 14
A Board Schematic Diagram (7 of 20) .............................................................................................................................................................. 15
A Board Schematic Diagram (8 of 20) .............................................................................................................................................................. 16
A Board Schematic Diagram (9 of 20) .............................................................................................................................................................. 17
A Board Schematic Diagram (10 of 20) ............................................................................................................................................................ 18
A Board Schematic Diagram (11 of 20) ............................................................................................................................................................ 19
A Board Schematic Diagram (12 of 20) ............................................................................................................................................................ 20
A Board Schematic Diagram (13 of 20) ............................................................................................................................................................ 21
A Board Schematic Diagram (14 of 20) ............................................................................................................................................................ 22
A Board Schematic Diagram (15 of 20) ............................................................................................................................................................ 23
A Board Schematic Diagram (16 of 20) ............................................................................................................................................................ 24
A Board Schematic Diagram (17 of 20) ............................................................................................................................................................ 25
A Board Schematic Diagram (18 of 20) ............................................................................................................................................................ 26
A Board Schematic Diagram (19 of 20) ............................................................................................................................................................ 27
A Board Schematic Diagram (20 of 20) ............................................................................................................................................................ 28
G2HE Board Schematic Diagram (KDL-32EX500/40EX500/40EX501 ONLY) ................................................................................................ 31
GD2 Board Schematic Diagram (1 of 2) (KDL-46EX500/46EX501 ONLY) ...................................................................................................... 32
GD2 Board Schematic Diagram (2 of 2) (KDL-46EX500/46EX501 ONLY) ...................................................................................................... 33
H2 Board Schematic Diagram .......................................................................................................................................................................... 36
APPENDIX A:  ENCRYPTION KEY COMPONENTS ..................................................................................................................................................... A-1
3
KDL-32EX500/40EX500/40EX501/46EX500/46EX501 
KDL-32EX500/40EX500/40EX501/46EX500/46EX501 
SAFETY-RELATED COMPONENT WARNING
There are critical components used in LCD color TVs that are important for safety. These components are identifi ed with shading and 
!
 
mark on the schematic diagrams and the electrical parts list. It is essential that these critical parts be replaced only with the part number 
specifi ed in the electrical parts list to prevent electric shock, fi 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 guarantee. 
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. 
To avoid damaging the LCD panel:
do not press on the panel or frame edge to avoid the risk of electric shock.
  do not scratch or press on the panel with any sharp objects.
  do not leave the module in high temperatures or in areas of high humidity for an extended period of time.
  do not expose the LCD panel to direct sunlight.
  avoid contact with water. It may cause a short circuit within the module. 
  disconnect the AC adapter when replacing the backlight (CCFL) or inverter circuit. 
(High voltage occurs at the inverter circuit at 650Vrms.) 
  always clean the LCD panel with a soft cloth material.
  use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short. 
  protect the panel from ESD to avoid damaging the electronic circuit (C-MOS). 
LEAKAGE CURRENT HOT CHECK CIRCUIT
4
KDL-32EX500/40EX500/40EX501/46EX500/46EX501 
KDL-32EX500/40EX500/40EX501/46EX500/46EX501 
The circuit boards used in these models have been processed using 
Lead Free Solder. The boards are identified by the LF logo located 
close to the board designation e.g. H1 etc [ see example ]. The 
servicing of these boards requires special precautions to be taken as 
outlined below. 
example
It is strongly recommended to use Lead Free Solder material in order to guarantee optimal quality of new solder joints.  
Lead Free Solder is available under the following part numbers : 
Due to the higher melting point of Lead Free Solder the soldering iron tip temperature needs to be set to 370 degrees centigrade. 
This requires soldering equipment capable of accurate temperature control coupled with a good heat recovery characteristics. 
For more information on the use of Lead Free Solder, please refer to  
 http://www.sony-training.com
7
0
7
0
7
0
7
0
7
0
7
1
7
1
7
1
5
KDL-32EX500/40EX500/40EX501/46EX500/46EX501 
KDL-32EX500/40EX500/40EX501/46EX500/46EX501 
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.
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).
To Exposed Metal
Parts on Set
0.15 μF
Earth Ground
AC
Voltmeter
(0.75V)
Trouble Light
AC Outlet Box
Ohmmeter
Cold-water Pipe
Figure A. Using an AC voltmeter to check AC leakage.
Figure B. Checking for earth ground.

Download Sony KDL-32EX500 / KDL-40EX500 / KDL-40EX501 / KDL-46EX500 / KDL-46EX501 (serv.man2) Service Manual (Repair Manual)

Here you can view online or download Sony KDL-32EX500 / KDL-40EX500 / KDL-40EX501 / KDL-46EX500 / KDL-46EX501 (serv.man2) Service Manual in pdf. This Service Manual can help you recover, restore, fix, disassemble and repair Sony KDL-32EX500 / KDL-40EX500 / KDL-40EX501 / KDL-46EX500 / KDL-46EX501 (serv.man2) TV. Information contained in Sony KDL-32EX500 / KDL-40EX500 / KDL-40EX501 / KDL-46EX500 / KDL-46EX501 (serv.man2) service manual (repair manual) typically includes:

  • Disassembly, troubleshooting, programming, maintenance, remote, adjustment, installation and setup instructions.
  • Schematics, wiring and block diagrams.
  • Printed wiring boards (PWB) and printed circuit boards (PCB).
  • Parts list (bill of materials).