INFORMATION FOR THE FOLLOWING MANUAL:

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1 HISTORY INFORMATION FOR THE FOLLOWING MANUAL: SERVICE MANUAL ORIGINAL MANUAL ISSUE DATE: 1/2010 Version Date Subject 1.0 1/2010 No revisions or updates are applicable at this time. AZ1-A CHASSIS Segment: 5-2 LCD Digital Color TV

2 SERVICE MANUAL AZ1-A CHASSIS Segment: 5-2 LCD Digital Color TV

3 MODEL LIST MODEL COLOR COMMANDER DEST. KLV-32BX300 Black RM-SA019 China KLV-40BX400 Black RM-SA019 China MODEL COLOR COMMANDER DEST. KLV-32BX300/40BX400(CH) 3

WARNINGS AND CAUTIONS - ENGLISH CAUTION These servicing instructions are for use by qualified ie service

To reduce the risk of electric shock, do not perform rm any servicing other than that contained in the

! An isolation transformer should be used during any service to avoid possible shock hazard, because of live

CARRYING THE TV Be sure to follow these guidelines to protect your property and avoid causing serious injury.

Correct hand placement while carrying the TV is very important for safety and to avoid damages.

mark on the schematic diagrams, exploded ed views, i and in the parts list are critical for safe operation.

4 WARNINGS AND CAUTIONS - ENGLISH CAUTION These servicing instructions are for use by qualified ie service personnel only. To reduce the risk of electric shock, do not perform rm any servicing other than that contained in the operating instructions unless you are qualified to do so. 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. CARRYING THE TV Be sure to follow these guidelines to protect your property and avoid causing serious injury. Carry the TV with an adequqate 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 damages. SAFETY-RELATED COMPONENT WARNING!! Components identified by shading and! mark on the schematic diagrams, exploded ed views, i and in the parts list are critical for safe operation. Replace these components with Sony parts whose part numbers appear as shown in this manual al or in supplements published by Sony. Circuit adjustments that are critical for safe operation are identified in this manual. Follow these e procedures es whenever critical components are replaced or improper operation is suspected. KLV-32BX300/40BX400(CH) 4

WARNINGS AND CAUTIONS USE CAUTION WHEN HANDLING THE LCD PANEL When

band. When repairing the LCD panel on the wall, the LCD panel must

1) Do not press on the panel or frame edge to avoid the risk of

2) Do not scratch or press on the panel with any sharp objects.

of high humidity for an extended period of time.

6) Disconnect the AC power when replacing the backlight (CCFL) C or

(High voltage occurs at the inverter circuit at 650Vrms.

5 WARNINGS AND CAUTIONS USE CAUTION WHEN HANDLING THE LCD PANEL When repairing the LCD panel, be sure you are grounded by using a wrist band. When repairing the LCD panel on the wall, the LCD panel must be secured using the 4 mounting holes on the rear cover. 1) Do not press on 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 temperatures es or in areas as of high humidity for an extended period of time. 4) Do not expose the LCD panel to direct sunlight. 5) Avoid contact with water. It may cause a short circuit within in the module. 6) Disconnect the AC power when replacing the backlight (CCFL) C 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. cu it. Damaging the wires may cause a short. 9) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS). KLV-32BX300/40BX400(CH) 5

SAFETY CHECK-OUT After correcting the original service problem, perform the following safety

Check the area of your repair for unsoldered or poorly soldered connections.

Check the interboard wiring to ensure that no wires are pinched or touching high-wattage

Check that all control knobs, shields, covers, ground straps, s, and mounting hardware have

Look for unauthorized replacement parts, particularly transistors, to rs that were e

Point them out to the customer and recommend their replacement. 5.

Point them out to the customer and recommend their replacement. 6.

6 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, s, and mounting hardware have been replaced. Be absolutely certain that you have replaced all the insulators. 4. Look for unauthorized replacement parts, particularly transistors, to rs that were e 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. erio rati on. Point them out to the customer and recommend their replacement. 6. Check the line cords for cracks and abrasion. Recommend the replacement ent of any such line cord to the customer. 7. Check the antenna terminals, metal trim, metallized knobs, screws, and all other exposed ed metal parts for AC leakage. Check leakage as described below. 8. For safety reasons, repairing the Power board and/or Inverter board is prohibited. KLV-32BX300/40BX400(CH) 6

SAFETY CHECK-OUT Leakage Test The AC leakage from any exposed metal part to earth ground and from all exposed metal parts to any

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.

The Data Precision i 245 digital multimeter is suitable for this job. 3.

75 V, so analog meters er must have an accurate low voltage scale.

Nearly all battery-operated digital multimeters that have a 2 VAC range are suitable (see Figure A).

7 SAFETY CHECK-OUT 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. io ns. 2. A battery-operated AC milliampmeter. The Data Precision i 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 er 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). KLV-32BX300/40BX400(CH) 7

SELF DIAGNOSIS FUNCTION The units in this manual contain a self-diagnostic function.

The number of times the LED flashes translates at to a probable source of the problem.

If an error symptom cannot be reproduced, the remote commander can be used to review the failure occurrence data stored in

DIAGNOSTIC TEST INDICATORS When an error occurs, the STANDBY LED will flash a set number of times to indicate the possible

Result for all of the following diagnostic items are displayed on screen. If the screen displays a 0, no error has occurred.

measure (Replace either/all according to seguence) Replace either/all 1) Power Supply Board 2) BAA Board Replace 1) BAA Board

8 SELF DIAGNOSIS FUNCTION The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY LED will automatically begin to flash. The number of times the LED flashes translates at to a probable source of the problem. A definition of the STANDBY LED flash indicators t is listed in the instruction manual for the user s knowledge and reference. If an error symptom cannot be reproduced, the remote commander can be used to review the failure occurrence data stored in memory to reveal past problems and how often these problems occur. DIAGNOSTIC TEST INDICATORS When an error occurs, the STANDBY LED will flash a set number of times to indicate the possible cause of the problem. If there is more than one error, the LED will identify the first of the problem areas. Result for all of the following diagnostic items are displayed on screen. If the screen displays a 0, no error has occurred. STBY LED Flash time Service menu Item name (Screeen Dsisplay) 2 Main Power 3 DC_Alert Aud_Prot MotionFlow onflo Counter measure (Replace either/all according to seguence) Replace either/all 1) Power Supply Board 2) BAA Board Replace 1) BAA Board 2) Power Supply Board 3) TCON 4) Speaker 4 Balancer_Error rr 5 T-CON Error Panel ID NVM Error 1) Inverter Board 2) Panel 3) Power Supply Board 4) BAA Board 1) TCON 2) BAA Board 3) LVDS Cable 4) Power Supply Board 6 Backlight Error 7 Temp_Error 1) Inverter Board 2) Power Supply Board 3) BAA Board 1) BAA Board 2) Power Supply Board KLV-32BX300/40BX400(CH) 8

SELF DIAGNOSIS FUNCTION DISPLAY OF STANDBY LED FLASH COUNT 0.5 0.

mes goes out that cannot be confirmed, it is possible to bring up past occurrences of failure for confirmation on the

9 SELF DIAGNOSIS FUNCTION DISPLAY OF STANDBY LED FLASH COUNT SELF-DIAGNOSTIC SCREEN DISPLAY For errors with symptoms such as power sometimes shuts off or screen e sometimes mes goes out that cannot be confirmed, it is possible to bring up past occurrences of failure for confirmation on the screen: [To Bring Up Screen Test] In standby mode, press buttons on the remote commander sequentially in rapid succession ces si as shown below: KLV-32BX300/40BX400(CH) 9

10 SELF DIAGNOSIS FUNCTION [SELF DIAGNOSTIC SCREEN DISPLAY] KLV-32BX300/40BX400(CH) 10

SELF DIAGNOSIS FUNCTION Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screen.

Error history and Error count : Press the Channel ne 8 => Channel 0. 2. Panel operation time : Press the Channel 7 => Channel 0.

11 SELF DIAGNOSIS FUNCTION Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screen. After you have completed the repairs, clear the result display to 0. Clearing the Self Check Diagnostic List 1. Error history and Error count : Press the Channel ne 8 => Channel Panel operation time : Press the Channel 7 => Channel 0. Exiting the Self-diagnostic screen To exit the Self Diagnostic screen, turn off the power to the TV by pressing the POWER button on the remote or the POWER button on the TV. KLV-32BX300/40BX400(CH) 11

12 SEC 1. DISASSEMBLY 1-1. MOVIE LIST KLV-32BX KLV-40BX400 KLV KLV-40BX400 KLV-32BX300/40BX400(CH) 12

13 SEC 2. TROUBLE SHOOTING 2-1. TRIAGE CHART Reference No Video No Video No Video No Tuner Tuner OK No HDMI No Audio BL OK No BL BL OK Video OK Video 1-3 OSD OK No OSD Bad BAA board H2LR board H2LS board 2Blinks 3Blinks 4Blinks 5Blinks Symptom (dead set) Video distored or missing 6Blinks 7Blinks No Power G2LE (32 ) G2HE (40 ) T-con board Speaker unit Panel module FFC cable Joint connector Problem No Power BAA TCON, Balancer board Panel ID Inverter Temperature Power BAA A BAA BAA BAA BAA BAA BAA e No board board board board board board board Doubtful part few possibility KLV-32BX300/40BX400(CH) 13

14 TROUBLE SHOOTING 2-2. NO POWER No Power Vac OK 3.3V_DC CV6200 Pin3 On BAA Board YES 3.3V_DC CV6200 Pin10 On BAA Board YES BAA Board NG NO NO AC Cable Power board No standby 3.3V Power board No REG12V KLV-32BX300/40BX400(CH) 14

15 TROUBLE SHOOTING 2-3. VIDEO PROBLEM Video Problem NO All inputs have problem? HDMI problem? NO RF/Analog input problem? NO NO Digital input problem? BAA Board YES YES YES YES BAA Board BAA Board BAA Board YES Backing ht turn on? BAA Board NO Check LVDS harness connection between BAA board or Panel or Power board KLV-32BX300/40BX400(CH) 15

16 TROUBLE SHOOTING 2-4. AUDIO PROBLEM Audio Problem NO Only Speaker out? HDMI problem? NO RF/Analog input problem? NO NO Digital input problem? BAA Board YES YES YES YES BAA Board BAA Board BAA Board UI of Audio setting correct? Volume, TV speaker YES Check Speaker or BAA Board NO Set correctly by menu KLV-32BX300/40BX400(CH) 16

Comp1/Video3 L/R PC (WXGA) CCFL MT5388 BGA RGB HV DCC LPF

17 SEC 3. DIAGRAMS 3-1. BLOCK DIAGRAM Tuner CVBS Out CVBS In CVBS1/ Mon Tu I2C Video1/Mon L/R Video1/Mon L/R CVBS2 Video2 L/R Video2 L/R PDD0~7 Yuv1/CVBS3 PANEL 8bit In L/R Comp1/Video3 L/R Comp1/Video3 L/R PC (WXGA) CCFL MT5388 BGA RGB HV DCC LPF PWM P TMDS0 HDMI1 PWM P DDC0 LPF HDMI2 TMDS2 DDC2 M_I2C STBY UART0 SIRCS LED D+/D- USB1 KLV-32BX300/40BX400(CH) 17

18 DIAGRAMS 3-2. CIRCUIT BOARDS LOCATION (1) KLV-32BX300 G2LE Board BAA Board Inverter H2LS Board Speaker (L) Speaker (R) H2LR Board KLV-32BX300/40BX400(CH) 18

19 DIAGRAMS (2) KLV-40BX400 T-CON G2HE Board Inverter BAA Board H2LS Board Speaker (L) Speaker (R) H2LR Board KLV-32BX300/40BX400(CH) 19

20 SEC 4. EXPLODED VIEWS Items with no part number and no description are not stocked because they are seldom required for roution service. The construction parts of an assembled part are indicated with a collation number in the remark colum. Items marked " * " are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items. KLV-32BX300/40BX400(CH) 20

KLV-32BX300/40BX400(CH) 6 4-1-1. CHASSIS-1 4-1.

X-2546-236-1 3-283-459-12 4-158-400-01 4-158-354-01 X-2514-986-1 REF. No.

21 KLV-32BX300/40BX400(CH) CHASSIS KLV-32BX PART No. X X REF. No POWER-SUPPLY CORD DESCRIPTION REAR COVER (32) ASSY COVER, ECS COVER, NECK (M3B) NECK (M3B) BASE (M3B) ASSY 21 MARK EXPLODED VIEWS

EXPLODED VIEWS 4-1. KLV-32BX300 4-1-2. CHASSIS-2 52 51 53 54 55 REF. No. PART No.

22 EXPLODED VIEWS 4-1. KLV-32BX CHASSIS REF. No. PART No. DESCRIPTION MARK 51 X BEZEL (32) ASSY 52 A A H2LR MOUNT LCD PANEL (S32TSC) 54 A A BAA COMPLE 55 X BRACKET ASSY, SIDE JACK LOUDSPEAKER (12.5X4.5CM) 57 X SP BRACKET (32L) ASSY 58 X SP BRACKET (32R) ASSY 59 A A G2LE UNIT 60 A A H2LS MOUNT (AZ1A) KLV-32BX300/40BX400(CH) 22

EXPLODED VIEWS 4-1. KLV-32BX300 4-1-3. SCREWS PART No.

+PSW M3X12 7-685-648-79 SCREW +BVTP 3X12 TYPE2 IT-3 2-580-608-01 SCREW,

23 EXPLODED VIEWS 4-1. KLV-32BX SCREWS PART No. DESCRIPTION SCREW, +BVTP 4X16 TYPE2 IT SCREW, +PSW M3X SCREW +BVTP 3X12 TYPE2 IT SCREW, +PSW M5X SCREW, +PSW M3X SCREW, +PSW M4X10 KLV-32BX300/40BX400(CH) 23

24 KLV-32BX300/40BX400(CH) CHASSIS KLV-40BX PART No. X * X REF. No POWER-SUPPLY CORD DESCRIPTION REAR COVER (40) ASSY COVER, ECS COVER, NECK (ML3B) NECK (ML3B) BASE (ML3B) ASSY 24 MARK EXPLODED VIEWS

EXPLODED VIEWS 4-2. KLV-40BX400 4-2-2. CHASSIS-2 152 151 153 REF. No. PART No.

A-1772-464-A BAA COMPL 155 X-2546-243-1 BRACKET ASSY, SIDE JACK 154 155 156 1-858-364-12 LOUDSPEAKER (12.5X4.

25 EXPLODED VIEWS 4-2. KLV-40BX CHASSIS REF. No. PART No. DESCRIPTION MARK 151 X BEZEL (40) ASSY 152 A A H2LR MOUNT LCD PANEL (S40TSP) 154 A A BAA COMPL 155 X BRACKET ASSY, SIDE JACK LOUDSPEAKER (12.5X4.5CM) 157 X SP BRACKET (40L) ASSY 158 X SP BRACKET (40R) ASSY 159 A A G2HE UNIT 160 A A H2LS MOUNT (AZ1A) KLV-32BX300/40BX400(CH) 25

26 EXPLODED VIEWS 4-2. KLV-40BX SCREWS PART No. DESCRIPTION SCREW, +BVTP 4X16 TYPE2 IT SCREW, +PSW M3X SCREW +BVTP 3X12 TYPE2 IT SCREW, +PSW M5X SCREW, +PSW M3X SCREW, +PSW M4X10 KLV-32BX300/40BX400(CH) 26

(RM-SA019) * 1-837-731-11 FFC WITH CONNECTOR

BAG ASSY, FALL LOCK BELT * 1-910-059-62 CONNECTOR

1-910-059-67 CONNECTOR ASSY 14P (KLV-40BX400) 00)

(KLV-32BX300) CN6200(BAA)-CN6401(G2LE)- 0(BA A)

CN4000(BAA)-SP(1) 0( * 1-910-800-08 MAIN HARNESS

27 EXPLODED VIEWS 4-3. OTHER PART MISCELLANEOUS ACCESSORIES PART No. DESCRIPTION MARK PART No. DESCRIPTION MARK * FLEXIBLE FLAT CABLE 30P (KLV-32BX300) 300) 0) CN9701(BAA)-TCON(1) REMOTE COMMANDER (RM-SA019) * FFC WITH CONNECTOR (KLV-40BX400) CN9700(BAA)-TCON(1) 0 X BAG ASSY, FALL LOCK BELT * CONNECTOR ASSY 14P (KLV-32BX300) CN6402(G2LE/G2ME)-INV(1) * CONNECTOR ASSY 14P (KLV-40BX400) 00) CN6402(G2HE)-INV(1) * MAIN HARNESS (KLV-32BX300) CN6200(BAA)-CN6401(G2LE)- 0(BA A) CN5600(BAA)-CN100(H2LR)- C CN1(H2LS); CN4000(BAA)-SP(1) 0( * MAIN HARNESS (KLV-40BX400) CN6200(BAA)-CN6401(G2HE)- 0( A) N640 CN5600(BAA)-CN100(H2LR)- C 0 0( ) CN1(H2LS); CN4000(BAA)-SP(1) 0(BA A) KLV-32BX300/40BX400(CH) 27

28 END Sony EMCS Corporation Inazawa TEC English 2010AL08-Data Made in Japan KLV-32BX300/40BX400(CH) 28

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