KDL 40ex657

Self Diagnosis
Supported model
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE / TRAINING MANUAL

AZ3F Chassis
ORIGINAL MANUAL ISSUE DATE: 4/2012
Version Date
1.0
04/5/2012
Segment: P-2A
Subject
Original Manual Release Date
LCD Digital Color TV
9-883-886-01
Self Diagnosis
Supported model
SERVICE / TRAINING MANUAL

AZ3F Chassis
Segment: P-2A
KDL-32EX657
LCD Digital Color TV
9-883-886-01
MODEL LIST
MODEL
COMMANDER
DESTINATION
KDL-32EX657
RM-YD079
COLUMBIA
KDL-40EX657
RM-YD079
COLUMBIA
KDL-46EX657
RM-YD079
COLUMBIA
MODEL
COMMANDER
DESTINATION
9-883-886-01
TABLE OF CONTENTS
Cautions and Warnings ..................................................................................iii
Section 1 - Features and Overview ................................................................1
Features ........................................................................................................1
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Chassis Overview ..........................................................................................3
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0DLQ %RDUG ...............................................................................................4
3RZHU 6XSSO\ %RDUG .................................................................................4
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Switch Unit ................................................................................................5
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Section 4 - Disassembly/Part Number Information ....................................16

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5HPRYDO ...........19
3DQHO %UDFNHWV DQG /&' 3DQHO 5HPRYDO ....................................................20

Cleaning the LCD Panel .........................................................................20
&RQQHFWRUV ..................................................................................................21
Screws .........................................................................................................21
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Section 2 - Troubleshooting ...........................................................................6
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Overview .......................................................................................................6
Wire Dressing ..............................................................................................23
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Triage Chart...................................................................................................9
Section 5 - Updates and Adjustments .........................................................24

Overview .....................................................................................................24
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6RIWZDUH 8SGDWHV IRU 6HUYLFHUV ...................................................................24
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Section 3 - Flow Charts and Diagrams ........................................................10
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KDL-32EX657/40EX657/46EX657
TABLE OF CONTENTS
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APPENDIX A: ENCRYPTION KEY COMPONENTS .................................... A-1
KDL-32EX657/40EX657/46EX657
ii
CAUTIONS AND WARNINGS

CAUTION
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KDL-32EX657/40EX657/46EX657
iii

SETTING UP AND CARRYING THE TV
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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.
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CLEANING THE LCD PANEL
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Clean the cabinet of the TV with a dry soft cloth.
Wipe the LCD screen gently with a soft cloth.
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KDL-32EX657/40EX657/46EX657

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KDL-32EX657/40EX657/46EX657
To Exposed Metal
Parts on Set
AC
Voltmeter
(0.75V)
0.15 F
Earth Ground
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HOW TO FIND A GOOD EARTH GROUND

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SECTION 1 - FEATURES AND OVERVIEW

FEATURES
SPECIFICATIONS
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Sistema
Sistema de TV
Anlogo: NTSC 3.58 / PAL-M / PAL-N

Digital: DVB-T2/T
VHF: 2-13, UHF: 14-69
CATV (Anlogo): 1-135
Panel LCD (pantalla de cristal lquido)
10 W + 10 W
.'/
(;
Cobertura de canales
.'/
(;
Sistema del panel

Salida de bocinas
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Tomas de entrada/salida
CABLE/ANTENNA
(Cable/Antena)
VIDEO IN 1
(Entrada de video 1)
COMPONENT IN
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(Entrada HDMI 1/2/3/4)
AUDIO OUT (Salida de

audio)/Auriculares
DIGITAL AUDIO OUT
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PC IN (Entrada de PC)
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KDL-32EX657/40EX657/46EX657
Terminal externa de 75 ohms para entrada de seal de radiofrecuencia

Entrada de video/audio (izquierda-derecha)
YP B P R (video componente): 1080p (50, 60 Hz), 1 080i (50, 60 Hz), 720p (50, 60 Hz),
576p, 576i, 480p, 480i
Entrada de audio (izquierda-derecha)
Entrada de video (contacto comn de componente)
Video: 1080p (30, 50, 60 Hz), 1 080/24p, 1 080i (50, 60 Hz), 720p (30, 50, 60 Hz),
720/24p, 576p, 576i, 480p, 480i, Formatos de PC
Audio: PCM lineal de dos canales 32; 44,1y 48 kHz, 16, 20 y 24 bits, Dolby Digital
Entrada de audio analgico (minitoma estreo) (slo HDMI IN 2, comn con PC IN
(entrada de PC))
ARC (slo HDMI IN 1)
Minitoma estreo
Toma ptica digital (PCM lineal de dos canales, Dolby Digital)
RGB analgico (Conector D-sub de 15 pines)
Entrada de audio (minitoma estreo) (comn con HDMI IN 2)
C one c tor 1 0 B A S E -T /1 0 0 B A S E -T X ( L a ve loc id a d d e la c one x in p od ra va ria r e n

funcin del entorno de red. No se garantizan la tasa de comunicacin ni la calidad de
comunicacin 10BASE-T/100BASE-TX para este TV.)
C ons ulte e l i-M a nua l p a ra e l forma to c omp a tib le .

Nombre del modelo KDLAlimentacin y otras especificaciones
32EX65x
46EX65x
40EX65x
Requisitos de alimentacin
Consumo de en uso
potencia
en espera
Tamao de pantalla*
(cm)
(medido diagonalmente) (pulgadas)
110-240 V ca, 50/60 Hz

111 W
Menos de 0,3 W
104 W
74 W
101,6
40
80,1
31,5
(32 clase)
Resolucin del monitor

Dimensiones* con soporte (mm)
1 920 puntos (horizontal) 1 080 lneas (vertical)
sin soporte
(mm)
patrn de orificios
de montaje mural
(mm)
tamao de
tornillos de
montaje mural
(mm)
Peso*
con soporte (kg)
sin soporte (kg)
Accesorios suministrados
Accesorios opcionales
Temperatura de funcionamiento
CHECKING THE ACCESSORIES

Control remoto (1)*1
Pilas de tamao AAA (2)
116,8
46
1 074 669 241
941 595 241
753 490 226
1 074 651 60
941 576 60
753 472 60
300 300
200 200
Soporte de sobremesa (1)*2

Tornillos de fijacin 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 documentos
M6 (8-12mm)
16,4
13,6
14,1
11,3
Consulte la verificacin de los accesorios.
Soporte de montaje mural: SU-WL500
Unidad de cmara y micrfono: CMU-BR100
Adaptador de LAN inalmbrica USB: UWA-BR100
0 C 40 C
9, 7
7, 8
*1 Consulte el nmero del modelo impreso en el

control remoto.
*2 Se requiere ensamblar la base de soporte de
sobremesa. Para ensamblar la base de soporte
de sobremesa consulte el folleto suministrado.
* El tamao, las dimensiones y el peso de la pantalla son valores aproximados.
La disponibilidad de los accesorios opcionales depender de los pases, regiones, modelo del TV
y de las existencias.
El diseo y las especificaciones estn sujetos a cambios sin previo aviso.
KDL-32EX657/40EX657/46EX657

CHASSIS OVERVIEW
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KDL-32EX657/40EX657/46EX657
BOARD LAYOUT FOR KDL-40EX657/46EX657ONLY

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HDMI Input and Switching: 7KH FXVWRPHU FDQ VHOHFW WKH +'0,
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LCD Panel.
KDL-32EX657/40EX657/46EX657
7KHUH DUH GLIIHUHQW 3RZHU 6XSSO\ %RDUGV XVHG LQ WKH PRGHOV LQ WKLV
PDQXDO 7KH W\SH RI ERDUG GHSHQGV RQ WKH VL]H RI /&' SDQHO 7KH\ DUH
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Standby Supply: &RQWLQXRXVO\ RSHUDWLRQDO DV ORQJ DV $& SRZHU LV

DSSOLHG WKH VWDQGE\ VXSSO\ JHQHUDWHV
9 IRU WKH FLUFXLWV UHTXLULQJ SRZHU
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SRZHU WR WKH PDLQ UHOD\ 3)& DQG PDLQ SRZHU VXSSO\ DW WXUQ RQ
Main Supply: 2QFH WKH SRZHU VXSSO\ UHFHLYHV D SRZHU RQ FRPPDQG
IURP WKH &38 RQ WKH 0DLQ %RDUG WKH PDLQ VZLWFKLQJ VXSSO\ LV WXUQHG RQ
WR SURYLGH D UHJXODWHG 9 VRXUFH DQG $XGLR 9
Converter: *HQHUDWHV WKH % DQG % YROWDJHV IRU WKH /(' EDFNOLJKWV
IR BOARD
'HVLJQDWHG DV WKH +/ %RDUG WKH ,5 %RDUG FRQWDLQV WKH SRZHU VWDQGE\
DQG WLPHU /('V WKDW DUH ORFDWHG RQ WKLV ERDUG DORQJ ZLWK WKH ,5 UHPRWH
UHFHLYHU DQG OLJKW OHYHO VHQVRU

SWITCH UNIT
7KLV ERDUG FRQWDLQV WKH SRZHU FKDQQHO DQG YROXPH XS GRZQ DQG PHQX
EXWWRQV
LCD PANEL ASSEMBLY

7KH /&' 3DQHO $VVHPEO\ LQFOXGHV WKH /&' 3DQHO 7&21 %RDUG DQG /('
%DFNOLJKW V\VWHP
7KH /&' 3DQHO FRQWDLQV WKH DFWXDO OLTXLG FU\VWDOV FRORU OWHUV DQG
SRODUL]HUV 7KH OLTXLG FU\VWDOV DUH PDQLSXODWHG E\ WKH DSSOLHG YROWDJH WR
SDVV D VSHFLF DPRXQW RI OLJKW IURP WKH EDFNOLWH GHSHQGLQJ RQ WKH OHYHO
RI YROWDJH DSSOLHG
7KH 7&21 SHUIRUPV DOO WKH FRQWURO WLPLQJ FKDUJH DQG GLVFKDUJH IXQFWLRQV
GULYLQJ WKH RSHUDWLRQ RI WKH /&' 3DQHO
$ QHZ /&' 3DQHO DVVHPEO\ IURP SDUWV ZLOO LQFOXGH WKH IROORZLQJ LWHPV
LCD Panel
7&21 %RDUG
/(' %DFNOLJKWLQJ &RPSRQHQWV YDULHV
TCON BOARD
7KH 7&21 %RDUG FRPPXQLFDWHV EHWZHHQ WKH /&' 3DQHO DQG WKH
PLFURSURFHVVRU RQ WKH 0DLQ %RDUG
127( 7KH 7&21 %RDUG LV QRW DYDLODEOH DV D UHSODFHPHQW SDUW IRU DOO
PRGHOV 7R GHWHUPLQH LI WKH 7&21 %RDUG LV DYDLODEOH DV D UHSODFHPHQW
SDUW UHIHU WR WKH /&' 3DQHOV 0DQXDO
KDL-32EX657/40EX657/46EX657
SECTION 2 - TROUBLESHOOTING
OVERVIEW
7KLV FKDSWHU SURYLGHV LQIRUPDWLRQ UHJDUGLQJ WKH 6HOI 'LDJQRVLV IHDWXUH LQ
RXU 79V
UPDATING THE SOFTWARE

7KH 6HOI 'LDJQRVLV IXQFWLRQ LV GHVLJQHG WR SURYLGH LQIRUPDWLRQ UHJDUGLQJ
WKH SUREOHP ZLWK WKH 79 KRZHYHU WKHUH DUH VHYHUDO LVVXHV WKDW PD\ EH
UHVROYHG E\ XSGDWLQJ WKH 79 VRIWZDUH WR WKH ODWHVW YHUVLRQ $OZD\V FKHFN
WKH 6RQ\ VLWH IRU DQ\ LVVXHV WKDW DUH VRIWZDUH UHODWHG 0RVW V\PSWRPV WKDW
DUH FRUUHFWDEOH E\ VRIWZDUH XSGDWHV LQYROYH FRPPXQLFDWLRQV LVVXHV ZLWK
RWKHU GHYLFHV RU PLQRU JOLWFKHV LQ WKH RSHUDWLRQ RI D VSHFLF IXQFWLRQ %HORZ
LV D OLVW RI VRPH RI WKH V\PSWRPV WKDW PD\ EH FRUUHFWHG ZLWK D VRIWZDUH
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3UREOHPV ZLWK FHUWDLQ LQSXWV HVSHFLDOO\ +'0,
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79 WXUQV RQ DQG RII E\ LWVHOI
/RVV RI FRORU
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SKRWR RU YLGHR OH YLHZLQJ
Self Diagnosis
Supported model
SELF DIAGNOSIS FUNCTION

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0DLQ %RDUG ,I DQ HUURU LV GHWHFWHG WKH 6HOI 'LDJQRVLV IXQFWLRQ LQ WKH 79 ZLOO
IRUFH WKH 79 WR VKXW GRZQ E\ WKH &38 7KH PRQLWRUHG FLUFXLW LQ ZKLFK WKH
IDXOW RFFXUUHG ZLOO DXWRPDWLFDOO\ FDXVH WKH &38 WR EOLQN WKH 6WDQGE\ /('
LQ JURXSV RI UHSHDWLQJ VHTXHQFHV 7KH QXPEHU RI WLPHV WKH 6WDQGE\ /('
EOLQNV LQGLFDWHV WKH SRVVLEOH FDXVH RI WKH SUREOHP
1RW DOO RI WKH DYDLODEOH SURWHFW FRGHV DUH XVHG LQ HYHU\ PRGHO )RU H[DPSOH
PRGHOV WKDW GRQW KDYH WKH ORFDO GLPPLQJ IHDWXUH GR QRW XVH WKH ; EOLQN
HUURU DV WKLV FLUFXLW LV IRXQG LQ PRGHOV WKDW DUH EDFNOLW ZLWK XRUHVFHQW ODPSV
7KH LQIRUPDWLRQ LQ WKLV VHFWLRQ SURYLGHV JXLGDQFH LQ ORFDWLQJ WKH SRVVLEOH
FRPSRQHQW FDXVLQJ WKH VKXWGRZQ
STANDBY LED BLINK COUNT

2 times
5 times
LED ON 0.3 sec.
KDL-32EX657/40EX657/46EX657
LED OFF 0.3 sec.
LED OFF
3 sec.
Standby LED
LED DISPLAY & BLINK COUNT
VIEWING THE SELF CHECK DIAGNOSIS HISTORY
:KHQ DQ HUURU LV GHWHFWHG WKH 6HOI &KHFN VFUHHQ UHFRUGV WKH GDWH V DQG
WKH QXPEHU RI WLPHV WKH HUURU RFFXUUHG 7KLV LV KHOSIXO LQ FRQUPLQJ SDVW
RFFXUUHQFHV RI DQ HUURU DQG IRU GHWHUPLQLQJ LI DQ HUURU LV LQWHUPLWWHQW ZKHQ
WKH FXVWRPHU LV QRW VXUH ZKDW LV FDXVLQJ WKH WHOHYLVLRQ WR VKXW GRZQ ,I WKH
VFUHHQ GLVSOD\V D QR HUURU KDV RFFXUUHG
1.
7DNH WKH 79 RXW RI GHHS 6WDQGE\ PRGH E\ SUHVVLQJ POWER WR

WXUQ RQ WKH 79
2.
Press POWER WR WXUQ WKH 79 EDFN RII
3.
3UHVV WKH IROORZLQJ EXWWRQV RQ WKH 5HPRWH &RPPDQGHU ZLWKLQ D

VHFRQG RI HDFK RWKHU
DISPLAY
Channel 5
9ROXPH -
POWER
127( 7KLV GLIIHUV IURP DFFHVVLQJ 6HUYLFH $GMXVWPHQWV 0RGH

9ROXPH
StandBy LED
Blink Count
Date and Time Display*
Diagnosis
Item
SELF CHECK
000
000
002
003
003
003
003
004
004
005
005
005
006
007
007
010
101
102
103
104
RESERVED
RESERVED
MAIN_POWE
DC_ALERT
AUD_PROT
HDMI_EQ
TU_DEMOD
VLED
LD_ERR
HFR_ERR
TCON_ERR
P_ID-ERR
BACKLITE
TEMP_ERR
FAN_ERR
EMITTER
VPC_WDT
MEPS_WDT
HOST_WDT
STBY_WDT
--------------------- --------------------- --------------------- 00

--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
120123132522 120123113645 --------------------- 02
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
--------------------- --------------------- --------------------- 00
Error Count
(00-99)
00345 000333 06789

Panel operation time by hour (MAX:65535)
Boot count (MAX:65535)
Total operation time by hour (MAX:65535)
*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-32EX657/40EX657/46EX657
2X Blink - Main Power Error
$ ORVV RI 5(* 9 IURP WKH SRZHU VXSSO\ WULJJHUV WKLV SURWHFW HYHQW 7KH
XVXDO FDXVH LV D IDLOXUH RI WKH PDLQ VZLWFKLQJ VXSSO\ ,Q VRPH LQVWDQFHV
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UHJXODWRU WR VWRS RU IDLO DJDLQ LI D UHSODFHPHQW ERDUG LV LQVWDOOHG
3X Blink- DC Regulator/Audio Error/HDMI/Tuner
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IROORZLQJ FLUFXLWV ZLOO FDXVH WKH WHOHYLVLRQ WR VKXW GRZQ DQG JHQHUDWH D ;
HUURU
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4X Blink Balancer Error
127 86(' ,1 7+,6 02'(/ 6(5,(6
7X Blink - Temperature Failure

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VHQVRU ORFDWHG RQ WKH 0DLQ %RDUG QRWLHV WKH 79 WR VKXW GRZQ DQG GLVSOD\
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8X Blink Not listed in Self Check
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79V VHUYLFH 6HOI &KHFN IRU HUURU FRGH KLVWRU\ DQG QRWLFH DW WKH ERWWRP RI
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10X Blink IR Sync Transmitter Failure
127 86(' ,1 7+,6 02'(/ 6(5,(6
5X Blink - TCON Error

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WKH 7&21 %RDUG DQG WKH ; 5HDOLW\ PLFURSURFHVVRU RQ WKH 0DLQ %RDUG ,I
WKH 7&21 LV DYDLODEOH IRU UHSODFHPHQW UHSODFH WKH 7&21 ,I WKH 7&21 LV
QRW DYDLODEOH WKH /&' SDQHO PXVW EH UHSODFHG VLQFH WKH 7&21 FLUFXLW LV
SDUW RI WKH /&' SDQHO DVVHPEO\ ,Q UDUH FDVHV D ORRVH RU GHIHFWLYH /9'6
FDEOH FRXOG DOVR EH WKH FDXVH
6X Blink - Converter System Failure
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LQ WKH FRQYHUWHU FLUFXLWV 7KH V\PSWRP ZLOO EH D PRPHQWDU\ DSSHDUDQFH
RI WKH EDFNOLJKWV 6RQ\ ORJR PD\ DSSHDU IROORZHG E\ D ; VKXWGRZQ
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,I WKH FRQYHUWHU IDLOV WR JHQHUDWH YROWDJH IRU WKH /(' EDFNOLJKWV WKH ORZ
YROWDJH SURWHFWLRQ FLUFXLWV DUH DFWLYDWHG DQG WKH WHOHYLVLRQ ZLOO VKXW GRZQ
ZLWK D ; HUURU 5HSODFHPHQW RI WKH 3RZHU 6XSSO\ %RDUG VKRXOG UHPHG\
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KDL-32EX657/40EX657/46EX657
TRIAGE CHART
8VH WKLV JHQHUDO 7ULDJH &KDUW WR GHWHUPLQH ZKDW PD\ SRVVLEO\ EH FDXVLQJ WKH HUURU EHIRUH JRLQJ RXW WR WKH FXVWRPHUV ORFDWLRQ
1.
2.
3.
4.
5. Chart Color Code

Confirm the symptom from the customer.
z RED DOT: (Primary) Most likely defective part
Select that symptom from the chart.
x BLUE Triangle: (Secondary) Possible defective part
Bring the primary component listed for that symptom.
Follow the associated flowcharts in the Training Manual to isolate the board.
Symptoms - Shutdown. Power LED
blinking red diagnostics sequences
Power
Video
Reference
2X
4X
5X
6X
Main Board
Power Supply
3X
Whole
Screen
Distortion
7X
8X
Dead Set
No Video
z*
x
z
Audio
Isolated
Area
Distortion
No Audio
IR Board
LCD Panel
TCON
SERVICE BULLETIN
z
z
SOFTWARE UPDATE
Problem
POWER
POWER
AUDIO
POWER
z
x
PANEL
PANEL
(TCON)
(INVERTER)
TEMP
SOFTWARE
*NOTE: REFER TO LCD PANEL SERVICE MANUAL IN REFERENCE

z* Immediate Shutdown After Power ON & 7X
LIBRARY DATABASE FOR CORRECT REPLACEMENT PARTS BASED ON
SERIAL NUMBER.
KDL-32EX657/40EX657/46EX657
SECTION 3 - FLOW CHARTS AND DIAGRAMS

BLOCK DIAGRAM
L
IC4701
SUBWOOFER
AMP
R
L
IC4601
AMP
R
RF
OPTICAL
AUDIO OUT
TUNER
VIDEO 1 CVBS
ANALOG AUDIO
OUT
VIDEO 2 CVBS/COMP
HDMI 1
HDMI 2
HDMI 3
IC5500
HDMI
SWITCH
EQ
IC9000
A/V
DECODER
VIDEO
PROCESS
USB
ADAPTER
HDMI 4
PC HD15
EITHERNET
LVDS
USB2.0
USB HUB
HFR
TCON
BAPS
USB2.0
LCD PANEL
SWITCH
UNIT
LED BACKLIGHTS
LED
IR RX
LIGHT SENSE
HL
AC IN
POWER SUPPLY/
CONVERTER
GL2 (32")
GL4 (40" & 46")
OVERALL BLOCK DIAGRAM
KDL-32EX657/40EX657/46EX657
10

NO POWER
CN6601
1
+OUT1
NC
NC
+OUT2
CN6602
1
-OUT1
NC
TO LED
BACKLIGHTS
NC
-OUT2
CN6205
CN6001
DC_DIMMER
TCON_VCC
PWM_DIMMER
AU_12V
2, 4
BL_ERR
REG12V
3, 5
BLINKING
AUDIO_GND
12, 8
BL_ON
AUDIO_12V
7, 9
DIGITAL_STBY
STBY3.3V
10
7, 8
AU_GND
BLINKING
12
9~12
GND
POWER_ON
13
13,14
REG12V
PWM_DIMMER
14
17, 18
AU_12V
DIGITAL_STBY
15
19
TCON_VCC
DC_DIMMER
16
23
STBY3.3V
BL_ON
17
26
TCON_ON
BL_ERR
18
27
AC_OFF_DET
AC_OFF_DET
19
28
POWER_ON
TCON_ON
20
GL2 (32 model)

GL4 (40/46 models)
BAPS
POWER AND CONTROL BLOCK DIAGRAM
KDL-32EX657/40EX657/46EX657
11

No Power
Does red standby

LED on front panel
light?
Yes
Press power
button while
monitoring pin 3 of
CN6205 on power
supply board
High (3.3V)
on pin 3?
No
Is standby LED
blinking?
Yes
Power Supply
Board*
No
Yes
See
Protection Shutdown
flowchart
High (3.3V)
on CN6205/pin 2?
No
Yes
Main Board*
No
Power Supply
Board*
Power Supply
Board*
NO POWER FLOWCHART
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'LVDVVHPEO\ 3DUW 1XPEHU ,QIRUPDWLRQ RQ SDJH 16.
KDL-32EX657/40EX657/46EX657
12

STANDBY LED BLINKING
Protect
Shutdown.
Standby LED
Blinking
Yes
2X
Power Supply
Board*
No
See Resolving an
8x Error
8X
Yes
3X
Main Board*
No
No
5X
Yes
TCON
(LCD Panel)*
6X
No
Yes
Power Supply
Board*
After a while
7X
Check ventilation
Imediately
Main Board*
PROTECTION SHUTDOWN FLOWCHART
KDL-32EX657/40EX657/46EX657
13

NO PICTURE
No Video
Backlights
turned on?
No
Power Supply
Board*
Yes
Any OSD
graphics
present?
Yes
Main Board*
No
Unplug LVDS
connector at
TCON while unit
is running. This
may need to be
done more than
once
Any flashes
seen on
screen?
No
LCD Panel*
TCON Board*
Yes
Main Board*
NO VIDEO FLOWCHART
KDL-32EX657/40EX657/46EX657
14

Video Distortion
Is distortion
across entire
screen?
Yes
No
Improper of
missing colors?
Yes
No
Vertical lines
or bars?
No
Yes
Lines move
when wide-mode
changed?
Yes
Main Board*
No
LCD Panel
TCON Board*
Main Board*
Any horizontal
lines?
Yes
LCD Panel*
No
Any single or
isolated vertical
lines?
Yes
LCD Panel*
No
More than 1
vertical band?
Yes
LCD Panel
TCON Board*
VIDEO DISTORTION
KDL-32EX657/40EX657/46EX657
15
SECTION 4 - DISASSEMBLY/PART NUMBER INFORMATION

TABLE-TOP STAND REMOVAL
A 5HPRYH
VFUHZV IURP WKH 7DEOH 7RS 6WDQG WKHQ OLIW XS WKH /&' 79 DQG JHQWO\ SODFH LW IDFH GRZQ RQWR D VRIW FORWK
&RPSRQHQWV QRW LGHQWLHG E\ D SDUW QXPEHU RU

description are not stocked because they are seldom
required for routine service.
The component parts of an assembly are indicated by the

reference numbers in the far right column of the parts list
and within the dotted lines of the diagram.
* Items marked with an asterisk are not stocked since

they are seldom required for routine service. Expect
some delay when ordering these components.
127( 7KH FRPSRQHQWV LGHQWLHG E\ D UHG RXWOLQH DQG D mark contain

FRQGHQWLDO LQIRUPDWLRQ 6SHFLF LQVWUXFWLRQV PXVW EH DGKHUHG WR ZKHQHYHU
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.
127( 7KH FRPSRQHQWV LGHQWLHG E\ VKDGLQJ

and ! mark are critical for safety. Replace only
ZLWK SDUW QXPEHU VSHFLHG
2
A
Soft Cloth
REF. NO.
PART NO.
DESCRIPTION
67$1' +($' 3 0
.'/ (; 21/<
67$1' +($' 3 0/
.'/ (;
(;
67$1' 3,3( 0
.'/ (; 21/<
67$1' 3,3( 0/
.'/ (;
(;
KDL-32EX657/40EX657/46EX657
[ASSEMBLY INCLUDES]
REF. NO.
21/<
PART NO.
DESCRIPTION
[ASSEMBLY INCLUDES]
6&5(: 36: 0 ;
6&5(:6 72 $77$&+ 67$1' +($' 72 67$1' 3,3(
6&5(:6 72 $77$&+ 7$%/( 723 67$1' 72 /&' 79
)RU SURGXFW SURWHFWLRQ DQG VDIHW\ UHDVRQV 6RQ\ VWURQJO\ UHFRPPHQGV
WKDW \RX XVH WKH VFUHZV SURYLGHG ZLWK WKH 79
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:DOO 0RXQW %UDFNHWV
21/<
16


REAR COVER REMOVAL

CAUTIONS:
+ROG GRZQ WKH 5HDU &RYHU DV VKRZQ LQ WKH VWHSV EHORZ WR DYRLG GHIRUPLQJ RU GDPDJLQJ WKH KRRNV LQ WKH 5HDU
&RYHU DQG %H]HO
7KH SRUWLRQ RI WKH 5HDU &RYHU QHDU WKH 6ZLWFK 8QLW LV YHU\ IUDJLOH :KHQ OLIWLQJ WKLV VHFWLRQ VXSSRUW WKH DUHD WR DYRLG
EUHDNLQJ WKH FRYHU
Bezel hook
Rear Cover hook
Trying to remove the Rear Cover as shown in this illustration will break the hooks securing it to the Bezel.
A 7R DYRLG GDPDJLQJ WKH $& 3RZHU 6XSSO\ &RUG

UHPRYH WKH VFUHZ IURP WKH $& &RYHU DQG
GLVFRQQHFW WKH $& 3RZHU &RUG
52
Hold the
Power Supply Cord
51
56
5HPRYH WKH UHPDLQLQJ VFUHZV IURP WKH 5HDU

&RYHU
IURP WKH .'/ (;
2QO\
IURP WKH .'/ (;
2QO\
IURP WKH .'/ (;
2QO\
C *HQWO\ KROG GRZQ WKH 5HDU &RYHU IURP WKH
FHQWHU WKHQ FDUHIXOO\ VWDUW WR OLIW WKH 5HDU &RYHU
IURP WKH ERWWRP WR FUHDWH FOHDUDQFH EHWZHHQ
WKH %H]HO DQG 5HDU &RYHU
54
55
D *HQWO\ KROG GRZQ WKH 5HDU &RYHU DV VKRZQ LQ WKH VWHSV EHORZ WKHQ JUDVS WKH LQVLGH ERWWRP FRUQHU DQG FDUHIXOO\ OLIW
WKH 5HDU &RYHU WR UHOHDVH WKH KRRNV
USE CAUTION
to avoid breaking this
area of the Rear Cover
/LIW WKH 5HDU &RYHU IURP WKH ERWWRP DQG SXVK

IRUZDUG WR UHOHDVH WKH WRS KRRNV
KDL-32EX657/40EX657/46EX657
53
REF. NO.
PART NO.
DESCRIPTION
[ASSEMBLY INCLUDES]
5($5 &29(5 =(8 $

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5($5 &29(5 =(8 $
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REF. NO.
> @
PART NO.
DESCRIPTION
[ASSEMBLY INCLUDES]
/$%(/ 81'(5 7(50,1$/

25'(5 7+,6 3$57 :+(1 5(3/$&,1* 7+( 5($5 &29(5
$& &29(5
&25' 32:(5 :,7+ &211(&725
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/$%(/ 6,'( 7(50,1$/ =(8

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/$%(/ 6,'( 7(50,1$/
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6&5(: 36: 0 ;
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6&5(: %973 ; 7<3( ,7
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6&5(:6 86(' :+(1 67$1' ,6 $77$&+(' 127 86(' :,7+
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6&5(: 36: 0 ; :
17

HANDLING THE LVDS FFC CONNECTOR
6HYHUDO PRGHOV XVH D /9'6 ))& &RQQHFWRU IURP WKH 0DLQ %RDUG WR WKH
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DUH XVHG
CAUTION:
DISCONNECTING THE LVDS FFC CONNECTOR

5HJDUGOHVV RI WKH FRQQHFWRU W\SH '2 127 UHPRYH WKH /9'6 ))&
&RQQHFWRU E\ WKH UHLQIRUFHPHQW WDE RQO\
CONNECTOR TYPE 1
5HIHU WR WKH LOOXVWUDWLRQ EHORZ ZKHQ GLVFRQQHFWLQJ RU FRQQHFWLQJ WKH

/9'6 ))& &RQQHFWRU 5HJDUGOHVV RI WKH FRQQHFWRU W\SH '2 127
UHPRYH WKH /9'6 ))& &RQQHFWRU E\ WKH UHLQIRUFHPHQW WDE RQO\
CONNECTING THE LVDS FFC CONNECTOR

CAUTION:
CAUTION:
'2 127 LQVHUW WKH /9'6 ))& &RQQHFWRU LQWR WKH 0DLQ %RDUG XSVLGH
GRZQ
CONNECTOR TYPE 1
6OLJKWO\ WLOW WKH 0DLQ %RDUG FRQQHFWRU UHOHDVH DZD\ IURP WKH /9'6 ))&
&RQQHFWRU
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%RDUG
:KLOH KROGLQJ RQWR WKH /9'6 ))& &RQQHFWRU JHQWO\ WLOW WKH 0DLQ %RDUG
FRQQHFWRU UHOHDVH WRZDUGV WKH 0DLQ %RDUG WKHQ VOLGH WKH /9'6 ))&
&RQQHFWRU VWUDLJKW LQ
Main Board
Main Board
Reinforcement
Tab
Reinforcement
Tab
Correct
Tilt away from LVDS
Incorrect
Tilt away from LVDS
CAUTION:
7KH /9'6 ))& &RQQHFWRU FDQ EH LQVHUWHG LQWR WKH 0DLQ %RDUG XSVLGH
GRZQ ,I LW LV LQVHUWHG XSVLGH GRZQ WKH SLQV RQ WKH /9'6 ))& &RQQHFWRU
ZLOO VKRUW FLUFXLW DQG GDPDJH WKH ERDUG
CONNECTOR TYPE 2
CONNECTOR TYPE 2
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&RUUHFWO\ KROGLQJ RQWR WKH /9'6 ))& &RQQHFWRU SXOO RXW WKH FRQQHFWRU
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FRQQHFWRU
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Press down
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Reinforcement
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Inserted Correctly
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Main Board
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CONNECTOR TYPE 3
CONNECTOR TYPE 3
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KDL-32EX657/40EX657/46EX657
Press down
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18

MAIN BOARD (BAPS) AND POWER SUPPLY BOARD (GL2/GL4) REMOVAL


&$87,21 'R QRW UHDWWDFK WKH */ */ %RDUG ZLWKRXW WKH 6SDFHUV %

127(6
5HIHU WR+DQGOLQJ WKH /9'6 ))& &RQQHFWRU RQ SDJH 18 WR GLVFRQQHFW WKH /9'6 ))& &RQQHFWRU
7KH 6SDFHUV % DUH QRW LQFOXGHG ZLWK WKH */ */ %RDUG DQG PXVW EH UHDWWDFKHG WR WKH UHSODFHPHQW 3RZHU %RDUG
7KH &XVKLRQ 3:% * ,QVXODWLRQ 6KHHW */ DQG ,QVXODWLRQ 6KHHW */ DUH QRW LQFOXGHG ZLWK WKH 3RZHU %RDUG DQG
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A 'HWDFK WKH 6LGH %UDFNHW DQG %RWWRP %UDFNHW IURP %$36 %RDUG
B 5HPRYH VFUHZV DQG GLVFRQQHFW FRQQHFWRUV IURP %$36 %RDUG
5HIHU WR+DQGOLQJ WKH /9'6 ))& &RQQHFWRU RQ SDJH 18 LQVWUXFWLRQV
C 5HPRYH VFUHZV DQG GLVFRQQHFW FRQQHFWRUV IURP */ */ %RDUG
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D 6OLGH RXW /HIW DQG 5LJKW 6SHDNHUV WKHQ GLVFRQQHFW FRQQHFWRUV
( 5HOHDVH FOLSV DQG GLVFRQQHFW FRQQHFWRU IURP +/ %RDUG
F /LIW XS 6ZLWFK 8QLW DQG GLVFRQQHFW FRQQHFWRU
110
109
101
108
107
104
102
103
105
106
REF. NO.
E
B
C
D
Cushion
(PWB G)
Spacer(B)
F
PART NO.
DESCRIPTION
[ASSEMBLY INCLUDES]
REF. NO.
%5$&.(7 6,'( 02/'

$
$
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$)7(5 5(3/$&,1* 7+( 0$,1 %2$5' <28 0867 83'$7( 7+(
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/28'63($.(5 ; &0
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PART NO.
DESCRIPTION
[ASSEMBLY INCLUDES]
&86+,21 3:% *
25'(5 7+,6 3$57 :+(1 5(3/$&,1* 7+( */ %2$5'
6+((7 ,168/$7,21 */
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6+((7 ,168/$7,21 */
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6&5(: 36: 0 ;
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63$&(5 %
*/ %2$5' &203/(7(
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KDL-32EX657/40EX657/46EX657
19


PANEL BRACKETS AND LCD PANEL REMOVAL

127(6
7KH 7KHUPDO 6KHHW $WUH\X LV QRW LQFOXGHG ZLWK WKH /&' 3DQHO DQG PXVW EH UHDWWDFKHG WR WKH
replacement LCD Panel.
A 5HPRYH VFUHZV WKHQ SUHVV %H]HO WDEV DQG OLIW XS 3DQHO %UDFNHWV +
B 3UHVV %H]HO WDEV DQG WLOW XS 3DQHO %UDFNHWV 9
C 5HPRYH VFUHZV DQG OLIW XS %RWWRP )UDPH
D *HQWO\ OLIW XS /&' 3DQHO
151
Panel Bracket (H)

A
153
Bezel Tab
153
154
152
Panel Bracket (V)

B
155
Bezel tab
154
C
156
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Clean the cabinet of the TV with a dry soft cloth, and wipe the LCD screen gently with a soft cloth.
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DPPRQLD EHQ]LQH WKLQQHU RU LQVHFWLFLGH 8VLQJ DQ\ RI WKHVH KDUVK FOHDQHUV PD\ UHVXOW LQ SHUPDQHQW GDPDJH WR WKH
screen.
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IDLOXUH
KDL-32EX657/40EX657/46EX657
REF. NO.
PART NO.
DESCRIPTION
[ASSEMBLY INCLUDES]
REF. NO.
1$
/&' 3$1(/
)25 $// /&' 3$1(/ $1' 7&21 %2$5' 3$57 180%(5
,1)250$7,21 5()(5 72 7+( /&' 3$1(/6 6(59,&( 0$18$/
%5$&.(7 3$1(/ +
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PART NO.
DESCRIPTION
[ASSEMBLY INCLUDES]
6+((7 7+(50$/ $75(<8

25'(5 7+,6 3$57 :+(1 5(3/$&,1* 7+( /&' 3$1(/
)5$0( %27720 0
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6&5(: 36: 0 ;
6&5(: %973 ; 7<3( ,7
6&5(: 36: 0 ; :
20


CONNECTORS
SCREWS
KDL-32EX657
P/N
DESCRIPTION
REMARKS
6&5(: 36: 0 ;
6&5(: 36: 0 ;
6&5(: %973 ; 7<3( ,7
6&5(: %973 ; 7<3( ,7
-2,17 6&5(:
6&5(: 36: 0 ; :
6&5(: 36: 0 ;
7$%/( 723 67$1' WR 79

67$1' +($' WR 67$1' 3,3(
5&
%70 )50 WR 31/
5& 6,'(-$&.
5& 81'(5-$&.
5& 7(50,1$/
9(6$ WR 5& 2
5&
%70 )50 WR %=/
5&
5&
$&
31/ %5.76
%$36
*/
DESCRIPTION
REMARKS
6&5(: 36: 0 ;
6&5(: 36: 0 ;
6&5(: %973 ; 7<3( ,7
6&5(: %973 ; 7<3( ,7
-2,17 6&5(:
6&5(: 36: 0 ; :
6&5(: 36: 0 ;
7$%/( 723 67$1' WR 79

67$1' +($' WR 67$1' 3,3(
5&
%70 )50 WR 31/
5& 6,'(-$&.
5& 81'(5-$&.
5& 7(50,1$/
9(6$ WR 5& 2
5&
%70 )50 WR %=/
5&
5&
$&
31/ %5.76
%$36
*/
DESCRIPTION
REMARKS
6&5(: 36: 0 ;
6&5(: 36: 0 ;
6&5(: %973 ; 7<3( ,7
6&5(: %973 ; 7<3( ,7
-2,17 6&5(:
6&5(: 36: 0 ; :
6&5(: 36: 0 ;
7$%/( 723 67$1' WR 79

67$1' +($' WR 67$1' 3,3(
5&
%70 )50 WR 31/
5& 6,'(-$&.
5& 81'(5-$&.
5& 7(50,1$/
9(6$ WR 5& 2
5&
%70 )50 WR %=/
5&
5&
$&
31/ %5.76
%$36
*/
TOTAL
KDL-40EX657
P/N
201
202
TOTAL
KDL-46EX657
P/N
REF. NO.
PART NO.
DESCRIPTION
/9'6
.'/
/9'6
.'/
/9'6
.'/
[ASSEMBLY INCLUDES]
))& :,7+ &211(&725

(; 21/<
3 $ ) )/(;,%/()/$7&$%/(
(; 21/<
3 $ ) )/(;,%/()/$7&$%/(
(; 21/<
KDL-32EX657/40EX657/46EX657
3
3
REF. NO.
PART NO.
DESCRIPTION
[ASSEMBLY INCLUDES]
TOTAL
3 $ ) +$51(66 $66(0%/<
.'/ (; 21/<
3 $ ) +$51(66 $66(0%/<
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3 $ ) +$51(66 $66(0%/<
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21

ACCESSORIES AND PACKAGING
PART NO.
DESCRIPTION
%$* 6&5(: $ 3 0
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6&5(: 36: 0 ;
6&5(:6 72 $77$&+ 67$1' +($' 72 67$1' 3,3(
6&5(:6 72 $77$&+ 7$%/( 723 67$1' 72 /&' 79
)RU SURGXFW SURWHFWLRQ DQG VDIHW\ UHDVRQV 6RQ\ VWURQJO\ UHFRPPHQGV
WKDW \RX XVH WKH VFUHZV SURYLGHG ZLWK WKH 79
&$87,21 7KHVH VFUHZV FDQQRW EH XVHG WR VHFXUH WKH 79 WR WKH :DOO 0RXQW %UDFNHWV
)/<(5 6$)(7<
)/<(5 6$)(7<
0$18$/ ,16758&7,21
6833/(0(17 67$1' ,167$//$7,21
MISCELLANEOUS
PART NO.
DESCRIPTION
&/$03(5 &$%/(
&86+,21 )50 %8
-2,17 6&5(:
6&5(:6 86(' :+(1 67$1' ,6 $77$&+(' 127 86(' :,7+ :$// 028176
7$3( 0
):
00; 0 :+7
OPTIONAL ACCESSORIES
PART NO.
DESCRIPTION
6833257 %(/7 .,7
REMOTE COMMANDER
PART NO.
DESCRIPTION
5(027( &200$1'(5 50 <'
KDL-32EX657/40EX657/46EX657
22

WIRE DRESSING
OVERALL WIRE DRESSING FOR KDL-32EX657 ONLY
OVERALL WIRE DRESSING FOR KDL-46EX657ONLY
OVERALL WIRE DRESSING FOR KDL-40EX657 ONLY
KDL-32EX657/40EX657/46EX657
23
SECTION 5 - UPDATES AND ADJUSTMENTS

OVERVIEW
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PXVW EH FKDQJHG RU FRQUPHG ZKHQHYHU WKH 0DLQ %RDUG /&' 3DQHO RU
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call.
SOFTWARE UPDATES FOR CUSTOMERS

7KH VXEMHFW RI VRIWZDUH XSGDWHV LV YHU\ LPSRUWDQW 7KH WHOHYLVLRQV RI WRGD\
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SOFTWARE UPDATES FOR SERVICERS

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24

SOFTWARE UPDATE RESPONSIBILITY
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UHSDLUV LQ ZKLFK WKH LVVXH FDQ EH UHVROYHG E\ D VRIWZDUH XSGDWH are not
reimbursable 0RVW LVVXHV LQYROYLQJ VRIWZDUH XSGDWHV DUH KDQGOHG E\ WKH
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SETTING WHITE BALANCE ADJUSTMENTS
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Sony Corporation
9-883-886-01
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Sony Technology Center

Technical Services
Service Publication Department
English
2012DJ74WEB-1
Printed in USA
2012.4
41
APPENDIX A: ENCRYPTION KEY COMPONENTS

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KDL-32EX657/40EX657/46EX657
A-1

KDL 40ex657

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KDL 40ex657

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Self Diagnosis

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE / TRAINING MANUAL

LCD Digital Color TV

SERVICE / TRAINING MANUAL

LCD Digital Color TV

Section 4 - Disassembly/Part Number Information ....................................16

3DQHO %UDFNHWV DQG /&' 3DQHO 5HPRYDO ....................................................20

Section 2 - Troubleshooting ...........................................................................6

2SWLRQDO $FFHVVRULHV ...................................................................................22

Wire Dressing ..............................................................................................23

8SGDWLQJ WKH 6RIWZDUH ..............................................................................6

Section 5 - Updates and Adjustments .........................................................24

Section 3 - Flow Charts and Diagrams ........................................................10

&KHFNLQJ WKH 6RIWZDUH 9HUVLRQ...............................................................25

%ORFN 'LDJUDP .............................................................................................10

&RPSOHWLQJ 6HUYLFH 5HTXLUHPHQWV

6WDQGE\ /(' %OLQNLQJ .............................................................................13

8SGDWLQJ WKH 6RIWZDUH ............................................................................25

6HOHFWLQJ WKH 6HJPHQW &RGH ..................................................................26

%OLQN (UURU ...........................................................................33

9HULI\LQJ 7KHUH LV DQ [ (UURU .................................................................34

CAUTIONS AND WARNINGS

SAFETY-RELATED COMPONENT WARNING!!

CAUTIONS AND WARNINGS

'LVFRQQHFW DOO FDEOHV ZKHQ FDUU\LQJ WKH 79

USE CAUTION WHEN HANDLING THE LCD PANEL

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CAUTIONS AND WARNINGS

CAUTIONS AND WARNINGS

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HOW TO FIND A GOOD EARTH GROUND

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SECTION 1 - FEATURES AND OVERVIEW

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Anlogo: NTSC 3.58 / PAL-M / PAL-N

Sistema del panel

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C one c tor 1 0 B A S E -T /1 0 0 B A S E -T X ( L a ve loc id a d d e la c one x in p od ra va ria r e n

SECTION 1 - FEATURES AND OVERVIEW

110-240 V ca, 50/60 Hz