Sony KDL-32R435A / KDL-40R485A / KDL-46R485A / KLV-24R402A / KLV-24R422A / KLV-32R402A / KLV-32R407A / KLV-32R422A / KLV-40R452A / KLV-40R457A / KLV-40R472A / KLV-46R452A / KLV-46R472A Service Manual ▷ View online
SAFETY NOTES
SECTION 1
ITC2
CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
1-2. Caution Handling of LCD Panel
When repairing the LCD Panel, make sure you are grounded with a wrist band.
When repairing the LCD Panel on the wall, the panel must be secured using the
When repairing the LCD Panel on the wall, the panel must be secured using the
1-1. Warnings and Caution
1) These servicing instructions are for use by qualified service personnel only.
2) To reduce the risk of electric shock, do not perform any servicing other than
4 mounting holes on the rear cover.
1) Do not press 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 temperature or in areas of high humidity for
that contained in the operating instructions unless you are qualified to do so.
3)
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.
3) Do not leave the module in high temperature or in areas of high humidity for
an extended period of time.
an extended period of time.
4) Do not expose the LCD panel to direct sunlight.
5) Avoid contact with water. It may cause short circuit within the module.
4) Be sure to follow these guidelines to protect your property and
avoid causing serious injury :
• Carry the TV with an adequate number of people; larger size TVs require
two or more people.
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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
• Correct hand placement while carrying the TV is very important for
safety and to avoid damages.
5) Components identified by shading and
mark on the 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
!
8) Use care when handling the wires or connectors of the inverter circuit.
Damaging the wires may cause a short circuit.
9) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
10) During the repair, DO NOT leave the Power On or Burn-in period for more
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.
than 1 hour while the TV is face down on a cloth.
operation is suspected.
Do not leave Power ON > 1 hour
5
Figure 1. TV is faced down on a cloth during repair.
Safety Notes
ITC2
CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
1-4.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 5mA (500 microamperes)
exposed metal parts to any exposed metal part having a return to chassis must
not exceed 0 5mA (500 microamperes)
1-3 Safety Check-Out
After correcting the original service problem, perform the following
safety checks before releasing the set to the customer:-
not exceed 0.5mA (500 microamperes).
Leakage current can be measured by any one of the three methods:-
1) A commercial leakage tester such as the SIMPSON 229 or RCA WT540A.
Follow the manufacturers instructions to use those instructions.
2) A battery-operated AC milliampmeter The DATA PRECISION 245 digital
multimeter is suitable for this job
Leakage current can be measured by any one of the three methods:-
1) A commercial leakage tester such as the SIMPSON 229 or RCA WT540A.
Follow the manufacturers instructions to use those instructions.
2) A battery-operated AC milliampmeter The DATA PRECISION 245 digital
multimeter is suitable for this job
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 inter board wiring to ensure that no wires are pinched or
contact high-wattage resistors.
3)Ch
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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 0.75V 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 multimeter that have a 2 VAC range are suitable
3) Measuring the voltage drop across a resistor by means of a VOM or battery
operated AC voltmeter. The 'limit' indication is 0.75V 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 multimeter that have a 2 VAC range are suitable
3)Check all control knobs, shields, covers, ground straps and mounting
hardware have been replaced. Be absolutely certain 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
hardware have been replaced. Be absolutely certain 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
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operated digital multimeter that have a 2 VAC range are suitable.
(see Figure 2.)
(see Figure 2.)
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
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
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replacement of any such line cord to the customer.
7) Check the antenna terminals, metal trim, metalized knobs, screws and all
other exposed metal parts for AC leakage. Check leakage test as described
next.
8. For safety reasons, repairing the Power board and/or Inverter board is
7) Check the antenna terminals, metal trim, metalized knobs, screws and all
other exposed metal parts for AC leakage. Check leakage test as described
next.
8. For safety reasons, repairing the Power board and/or Inverter board is
hibit d
prohibited.
Figure 2. AC voltmeter to check AC leakage
6
Safety Notes
ITC2
CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
1-5. How to Find a Good Earth Ground
1) A cold-water pipe is a guaranteed earth ground; the cover-plate retaining
screw on most AC outlet boxes is also at earth ground.
2) If the retaining screw is to be used as your earth ground verify that it is at
screw on most AC outlet boxes is also at earth ground.
2) If the retaining screw is to be used as your earth ground verify that it is at
1-7. Handling the FLEXIBLE FLAT CABLE (FFC)
When you insert / pull out FFC, please grasp a reinforcement board and main body of
FFC.
2) 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.
3) 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;
ground by measuring the resistance between it and a cold-water pipe with an
ohmmeter. The reading should be zero ohms.
3) 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;
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 3).
the lamp should light at normal brilliance if the screw is at ground potential
(see Figure 3).
1-6. Lead Free Information
Figure 3. Checking for earth ground.
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.
Free Solder. The boards are identified by the LF logo located close to the
board designation.
Main Board
Main Board
Figure 4: LF Logo
Figure 5: LF logo on circuit board
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The servicing of these boards requires special precautions. It is strongly
recommended to use Lead Free Solder material in order to guarantee optimal
quality of new solder joints.
recommended to use Lead Free Solder material in order to guarantee optimal
quality of new solder joints.
< Insertion>
<Pull out>
SECTION 2
SELF DIAGNOSTIC FUNCTION
2-1 Overview of Control Buttons
Self Diagnostic Function
2-3 LED Pattern
2-1. Overview of Control Buttons
When safety shutdown occurs, Standby LED display reports the cause by using the lightning
patterns as indicated below
patterns as indicated below
.
2 3. LED Pattern
3.0sec
3.0sec
0.5sec
0.
5sec
Example: The figure above shows LED display when SHUTDOWN is caused by Audio
Error. It repeats flashing for a specified number of times in 0.5sec/cycle and has a 3 seconds
interval of lighting off. Please note that a 3 seconds interval of lighting off is fixed regardless of abnormal state types.
interval of lighting off. Please note that a 3 seconds interval of lighting off is fixed regardless of abnormal state types.
2-4. Standby LED Error Display
The Number of
Standby LED
Standby LED
Detection Items
Board Error Item
2-2. LED Display Control
Status
LED Colour
Remarks
Power Off
( AC Off and *1)
( AC Off and *1)
OFF
*1 power switch off (by
touch button)
touch button)
Amber
=
Red
+
Green
Standby LED
(RED blinking)
(RED blinking)
2
Main Power Error
AC adapter Error
3
Audio Error
BB board Error
Power On
Green
Standby
( by remote control off only )
( by remote control off only )
Red
Picture Off
Green
4
Panel Power Error
BB board Error
5
Panel I2C COMM Error
BB or Source board Error
6
Backlight Error
BB board Error
Set "Sleep Timer"
Amber
Set "On Timer"
( Power On )
( Power On )
Amber
Set "On Timer"
( Standby )
( Standby )
Amber
(
y )
Picture Frame
Amber
Failure
Red Blinking
The number of LED blinking
indicates cause of failure.
indicates cause of failure.
Error of panel ID
Amber/Green
Blinking
Blinking:0.5sec Amber/
0 5sec Green
0 5sec Green
8
Blinking
0.5sec Green
Software Updating
Amber Blinking
Blinking: 1sec On / 1sec Off
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