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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE / TRAINING MANUAL


ORIGINAL MANUAL ISSUE DATE: 2/2011
Version Date
1.0
2.0

2/11/2011
12/19/2011

AZ2-F Chassis

Segment: 3a-2_No_3D

Subject

Original Manual Release Date


Updated entire manual.

LCD Digital Color TV

9-888-391-02

Self Diagnosis

Supported model

SERVICE / TRAINING MANUAL


AZ2-F Chassis

Segment: 3a-2_No_3D

KDL-40EX620

LCD Digital Color TV

9-888-391-02

MODEL LIST
MODEL

COMMANDER

DESTINATION

MODEL

COMMANDER

DESTINATION

KDL-40EX620

RM-YD063 US/CND

KDL-55EX620

RM-YD063 US/CND

KDL-40EX621

RM-YD063 US/CND

KDL-55EX621

RM-YD063 US/CND

KDL-46EX620

RM-YD063 US/CND

KDL-46EX621

RM-YD063 US/CND

9-888-391-02

TABLE OF CONTENTS
Section 1 - Safety and Features.................................................1

Section 2 - Software Requirements.........................................17

Warnings and Cautions - English................................................1


Handling the LVDS FFC Connector............................................3
Disconnecting the LVDS FFC Connector..................................... 3

Overview...................................................................................17
Software Updates for Customers..............................................17
Software Updates for Servicers................................................18

Connecting the LVDS FFC Connector......................................... 4

Software Update Responsibility................................................. 19

Warnings and Cautions - French.................................................5


Safety-Related Warnings............................................................7
Safety Check-Out........................................................................9
Self Diagnosis Function............................................................12
Overview...................................................................................13
Features....................................................................................13

Checking the Software Version.................................................. 19

Navigation Made Easy............................................................... 13


LightSensor Technology......................................................... 13
X-Reality Engine..................................................................... 13
Presence Sensor........................................................................ 13
USB Photos, Videos & Music..................................................... 13
Edge LED Backlighting............................................................... 14
Internet Streaming & Connectivity.............................................. 14
Faster Start-Up........................................................................... 14
BRAVIA Sync Compatible.................................................... 14

Specifications............................................................................14

Examples of Software Correctable Symptoms........................... 19

Section 3 - Chassis Overview...................................................20


Overview...................................................................................20
Overall Circuit Description.........................................................22
Main Board................................................................................22
Tuner.......................................................................................... 22
X-Reality Processor.................................................................... 22
Audio Amplifier........................................................................... 22
Temperature Sensor................................................................... 22

Power Supply............................................................................23
Power Supply for Backlight System..........................................23
Switch Unit................................................................................23
Motion Sensor Board................................................................23
IR Board....................................................................................23
LCD Panel Assembly................................................................24
TCON Board............................................................................... 24

LD Board (LED Driver Board)...................................................24


Diagrams...................................................................................25
Block Diagram............................................................................ 25
Connector Diagrams.................................................................. 27

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 i

TABLE OF CONTENTS
Section 4 - Troubleshooting......................................................33

Connectors................................................................................61

Overview...................................................................................33

KDL-40EX620/40EX621 Only.................................................... 61

Updating the Software................................................................ 33

KDL-46EX620/46EX621 Only.................................................... 61

Triage Chart..............................................................................34
Protection Shutdown.................................................................35

KDL-55EX620/55EX621 Only.................................................... 61

Standby LED Flash Count.......................................................... 35

Diagnostic Code Descriptions...................................................39


Section 5 - Flow Charts and Diagrams....................................41
Overview...................................................................................41
No Power.................................................................................... 42
Standby LED Blinking................................................................. 44
No Picture/No Sound.................................................................. 50

Section 6 - Disassembly/Part Number Information................53


Table-Top Stand Assembly Removal.........................................53
Rear Cover and AC Cover Removal.........................................54
Switch Unit and Speakers Removal..........................................55
LD Board, HLR2 Board and HMS3 Board Removal.................56
G4/G5/G6/G8 (Power Supply) Board and
BATV (Main) Board Removal..............................................57
KDL-40EX620/40EX621/46EX620/46EX621 Only..................... 57
KDL-55EX620/55EX621 Only.................................................... 58

Panel Brackets and LCD Panel Removal.................................59


Cleaning the LCD Panel............................................................. 59

Screws......................................................................................60

Accessories and Packaging......................................................62


Optional Accessories.................................................................62
Remote Commander.................................................................62
Wire Dressing............................................................................63
KDL-40EX620/40EX621 Only.................................................... 63
KDL-46EX620/46EX621 Only.................................................... 63
KDL-55EX620/55EX621 Only ................................................... 63

Section 7 - Service Adjustments..............................................64


Overview...................................................................................64
Updating the Software...............................................................64
Accessing Service Adjustment Mode........................................64
Viewing or Changing Service Data............................................. 65

Updating Service Adjustment Data When Replacing the Main


Board...................................................................................66
Selecting the Segment Code...................................................... 66
Selecting the Destination............................................................ 67
Selecting the Model Name......................................................... 69
Selecting the BU Trans............................................................... 70
Adding the Serial Number.......................................................... 71
Confirming the Model ID and Product ID.................................... 73

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 ii

TABLE OF CONTENTS
Updating Service Adjustment Data
When Replacing the LCD Panel..........................................74
Copying the BU Flash Data........................................................ 75
Confirming the Model ID and Product ID.................................... 76
Resetting the Panel Operation Time.......................................... 77

Optional Adjustments................................................................78
Setting White Balance Adjustments........................................... 78

Resetting the TV to Factory Condition......................................79


Resetting the TV to Factory Condition Using Service Mode...... 79

Appendix A - Removing the Rear Cover................................ A-1


Removing the Power Cord from the Rear Cover.................... A-1
KDL-40EX620/40EX621 Only...................................................A-1
KDL-46EX620/46EX621 Only...................................................A-3

Appendix B - Attaching the Rear Cover................................. B-1


Reattaching the Rear Cover to the Bezel................................ B-1
KDL-40EX620/40EX621 Only...................................................B-1
KDL-46EX620/46EX621 Only...................................................B-1

Appendix C - Replacing the LCD Panel................................. C-1


Removing the LCD Panel from the Bezel............................... C-1
Reattaching the LCD Panel onto the Bezel............................. C-2
Appendix D - Rear Cover Caution.......................................... D-1
Appendix E - Setup Guide....................................................... E-1

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 iii

SECTION 1 - SAFETY AND FEATURES


WARNINGS AND CAUTIONS - ENGLISH
CAUTION

These servicing instructions are for use by qualified 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 qualified to do so.

CARRYING THE TV

Disconnect all cables when carrying the TV.


Carry the TV with the adequate 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 damage.

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.

SAFETY-RELATED COMPONENT WARNING!!

Components identified by shading and

mark on the exploded views are critical for safe operation.

Replace all components with Sony parts whose part numbers appear as shown in this manual or in supplements published by Sony. It is essential
that all critical parts be replaced only with the part number specified in this manual to prevent electric shock, fire, or other hazard.
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.
NOTE: Do not modify the original design without obtaining written permission from the manufacturer or you will void the original parts and labor
guarantee.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 1

SECTION 1 - SAFETY AND FEATURES


CAUTION

W Do Not use paper towels, any type of abrasive pad, rags, rubber or vinyl materials to clean the screen. Using these materials could easily
scratch the screen which may result in permanent damage.
W Do Not use any cleaning product containing alkaline/acid cleaner, scouring powder, or volatile solvent, such as alcohol, ammonia,
benzene, thinner or insecticide. Using any of these harsh cleaners may result in permanent damage to the screen.
W Do Not spray water or detergent directly onto the TV screen . If liquid drips into the bottom of the screen it may cause a failure.

CLEANING THE LCD PANEL

CAUTION: When cleaning the TV, be sure to unplug the power cord to avoid any chance of electric shock.
Clean the cabinet of the TV with a dry soft cloth.
Wipe the LCD screen gently with a soft cloth.
R Stubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water.
R If using a chemically pretreated cloth, please follow the instruction provided on the package.
R Never use strong solvents such as a thinner, alcohol or benzine for cleaning.
R Periodic vacuuming of the ventilation openings is recommended to ensure to proper ventilation.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 2

SECTION 1 - SAFETY AND FEATURES


HANDLING THE LVDS FFC CONNECTOR

Several 2011 Models use a LVDS FFC Connector from the Main Board to the TCON Board. There are three different types of
connectors that are used.

CAUTION:
Refer to the illustration below when disconnecting or
connecting the LVDS FFC Connector.

Connector Type 2

1. Gently press down on the


release tab of the Main Board
connector.

Press down

DO NOT remove the LVDS FFC


Connector by the reinforcement
tab only.

Reinforcement
Tab

2. Correctly holding onto the LVDS


FFC Connector, pull out the
connector while continuing to
hold down the release tab of the
Main Board connector.
Correct

Incorrect

DISCONNECTING THE LVDS FFC CONNECTOR


Connector Type 1
1. Slightly tilt the Main Board
connector release away from the
LVDS FFC Connector.

DO NOT remove the LVDS FFC


Connector by the reinforcement tab
only.

Main Board

Main Board

Reinforcement
Tab

2. Gently wiggle the LVDS FFC


Connector to detach it from the
Main Board.

Connector Type 3
1. Gently press down on the 2
release tabs of the Main Board
connector.

DO NOT remove the LVDS FFC


Connector by the reinforcement
tab only.

Main Board

Reinforcement
Tab

Press down

2. Correctly holding onto the LVDS


FFC Connector, pull out the
connector while continuing to
hold down the release tabs of
the Main Board connector.

Tilt away from LVDS

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 3

SECTION 1 - SAFETY AND FEATURES


CONNECTING THE LVDS FFC CONNECTOR

Connector Type 1

CAUTION:
The LVDS FFC Connector can be inserted into the Main
Board upside down. If it is inserted upside down, the pins
on the LVDS FFC Connector will short-circuit and damage

the board.

1. While holding onto the LVDS FFC


Connector, gently tilt the Main Board
connector release towards the Main
Board then slide the LVDS FFC
Connector straight in.

Main Board

Reinforcement
Tab

Tilt away from LVDS

Connector Type 2
Inserted Correctly

1. Gently press down on the release


tab of the Main Board connector.

Inserted Incorrectly

2. Holding onto the entire LVDS


FFC Connector, insert the LVDS
FFC Connector into the Main
Board connector.

Press down

Reinforcement
Tab

Main Board

Connector Type 3
1. Gently press down on the 2
release tabs of the Main Board
connector.

2. Holding onto the entire LVDS


FFC Connector, insert the LVDS
FFC Connector into the Main
Board connector.

Main Board

Reinforcement
Tab

Press down

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 4

SECTION 1 - SAFETY AND FEATURES


WARNINGS AND CAUTIONS - FRENCH
ATTENTION!!

Ces instructions de service sont lusage du personnel de service qualifi seulement. Pour prvenir le risque de choc lectrique, ne pas faire
lentretien autre que celui contenu dans le Mode demploi moins que vous soyez qualifi faire ainsi.

POUR TRANSPORTER LE TLVISEUR

T ransportez le tlviseur avec le nombre de personnes appropri ; un tlviseur de grande


taille doit tre transport par au moins deux personnes.
Lors du transport du tlviseur , lemplacement des mains est trs important pour votre
scurit, ainsi que pour viter de causer des dommages.

ALERTE!!

Afin deviter tout risque delectrocution provenant dun chssis sous tension, un transformateur disolement doit etre utilis lors de tout dpannage.
Le chssis de ce rcepteur est directement raccord lalimentation du secteur.
!

ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!!

Les composants identifies par une trame et par une marque ! sur les schemas de principe, les vues explosees et les listes de pieces sont
dune 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 limportance est critique pour la securite
du fonctionnement sont identifies dans le present manuel. Suivre ces procedures lors de chaque remplacement de composants critiques, ou
lorsquun mauvais fonctionnement suspecte.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 5

SECTION 1 - SAFETY AND FEATURES


AVERTISSEMENT

W Nutilisez pas de serviettes en papier, tout type de tampons ou chiffons abrasifs, ou matriaux en caoutchouc ou en vinyle pour nettoyer
lcran. Ces types de matriaux peuvent facilement rayer lcran, entranant ainsi un dommage permanent.
W Nutilisez pas de produit de nettoyage contenant un nettoyant alcalin/acide, poudre abrasive ou solvant volatil, comme de lalcool ou de
lammoniaque, du benzne, un diluant ou un insecticide. Lusage de ces types de nettoyants peut causer des dommages permanents
lcran.
W Ne vaporisez pas deau ou de dtergent directement sur lcran du tlviseur. Si du liquide sinsre dans le bas de lcran, cela peut causer
une panne.

NETTOYER LCRAN ACL

AVERTISSEMENT : Au moment de nettoyer le tlviseur, assurez-vous de dbrancher le cordon dalimentation afin dviter tout risque
de choc lectrique.
Nettoyez le caisson du tlviseur avec un chiffon doux et sec.
Essuyez lcran ACL doucement avec un chiffon doux.
R Les taches tenaces peuvent tre enleves avec un chiffon lgrement humect dune solution de savon doux et deau tide.
R Si vous utilisez un chiffon chimique prtrait, suivez les directives figurant lemballage.
R Nutilisez jamais de solvants puissants comme un diluant, de lalcool ou du benzne pour nettoyer.
R Nous recommandons de passer laspirateur de faon priodique sur les ouvertures de ventilation afin dassurer une ventilation approprie.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 6

SECTION 1 - SAFETY AND FEATURES


SAFETY-RELATED WARNINGS
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.
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 or in areas 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 the module.
6. Disconnect the AC power when replacing the backlight 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. Damaging the wires may cause a short.
9. Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
10. During the repair, DO NOT leave the Power On for more than 1 hour while the TV is face down on a cloth.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 7

SECTION 1 - SAFETY AND FEATURES


AVERTISSEMENTS DE SCURIT
FAITES ATTENTION LORS DE LA MANIPULATION DE LCRAN ACL
Au moment de rparer lcran ACL, assurez-vous dtre mis la terre laide dun bracelet cet effet.
Au moment dinstaller le panneau ACL sur un mur, il doit tre maintenant en place laide des 4 orifices de fixation prsents au
couvercle arrire.
1. Nappuyez par sur le bord du panneau ou du cadre afin dviter le risque de choc lectrique.
2. Ne rayez pas ou nappuyez pas sur le panneau avec des objets pointus.
3. Ne laissez pas le module expos des tempratures leves ou dans des secteurs haut niveau dhumidit pour une
priode prolonge.
4. Nexposez pas le panneau ACL lensoleillement direct.
5. vitez le contact avec leau, car elle peut causer un court-circuit dans le module.
6. Dconnectez lalimentation c.a. au moment de remplacer le rtroclairage ou le circuit inverseur (Un voltage lev se produit
dans le circuit inverseur 650Vrms).
7. Nettoyez toujours le panneau ACL avec un chiffon doux.
8. Faites attention lors de la manipulation des fils ou connecteurs du circuit inverseur. Le fait dendommager les films peut
causer un court-circuit.
9. Protgez le panneau des dcharges lectrostatiques afin dviter dendommager le circuit lectronique (C-MOS).
10. Pendant la rparation, NE LAISSEZ PAS lalimentation en fonction pendant plus de 1 heure pendant que lcran du tlviseur
repose sur un tissu.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 8

SECTION 1 - SAFETY AND FEATURES


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.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 9

SECTION 1 - SAFETY AND FEATURES


VRIFICATION DE SCURIT

1.
2.
3.
4.
5.
6.
7.

Aprs avoir corrig le problme de service original, effectuez les vrifications de scurit suivantes avant de remettre le
tlviseur au client :
Vrifiez le secteur de votre rparation afin de vous assurer quil ne reste aucune connexion non soude ou mal soude.
Vrifiez toute la surface du circuit pour la prsence dclaboussures ou de ponts de soudure.
Vrifiez le filage inter-modules afin de vous assurer quaucun fil nest pinc ou soit en contact avec des rsistances
wattage lev.
Assurez-vous que tous les boutons de contrle, crans, couvercles, courroies de mise la terre et quipement de fixation
ont t remplacs. Soyez absolument certain davoir remplac tous les isolateurs.
Recherchez la prsence de pices de remplacement non autorises, surtout au niveau des transistors, qui auraient t
installs lors dune rparation antrieure. Faites-en la remarque au client et recommandez leur remplacement.
Recherchez toute pice qui, quoique fonctionnelle, fait montre de signez vidents de dtrioration. Faites-en la remarque au
client et recommandez leur remplacement.
Vrifiez la prsence de fissures et dabrasions sur les cordons. Recommandez le remplacement de ces cordons au client.
Vrifiez les terminaux dantenne, les garnitures en mtal, les boutons mtalliss , les vis et autres pices en mtal
exposes pour toute fuite de courant. Vrifiez les fuites de la faon dcrite ci-dessous.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 10

SECTION 1 - SAFETY AND FEATURES


LEAKAGE TEST

To Exposed Metal
Parts on Set

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 Simpsons 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).

AC
Voltmeter
(0.75V)

0.15 F

Earth Ground

Figure A. Using 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 60-to 100-watt troublelight (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).

Trouble Light
AC Outlet Box

Figure B. Checking for earth ground.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 11

Self Diagnosis

Supported model

SECTION 1 - SAFETY AND FEATURES

SELF DIAGNOSIS FUNCTION


The TVs 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 to a probable source of the problem. A definition of the standby LED flash indicator is listed in the Operating
Instruction manual for the users 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.
For complete information, refer to Section 4 - Troubleshooting on page 33.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 12

SECTION 1 - SAFETY AND FEATURES


OVERVIEW
The AZ2-F chassis is one of several designs for the 2011 model line
of Sony Bravia LCD televisions. This manual covers the following
models:
KDL-40EX620
KDL-40EX621
KDL-46EX620
KDL-46EX621
KDL-55EX620
KDL-55EX621

FEATURES
Several new features are introduced in this chassis model lineup
along with some carryovers from the previous year.

NAVIGATION MADE EASY


Enjoy an easy-to-use menu that allows you to navigate additional
content or adjust the picture settings while watching your favorite
program.

LIGHTSENSOR TECHNOLOGY
Enjoy customized picture brightness and save energy without lifting
a finger. The built-in Light Sensor automatically adjusts the picture
brightness based on the amount of light in the room.

X-REALITY ENGINE
Enjoy a vivid, lifelike picture experience. Sonys X-Reality engine
brings out the best by analyzing each scene so you see sharpened
images, and amazing contrast detail.

PRESENCE SENSOR
Save energy when youre not around. The televisions built-in motion
sensor has the ability to scan the room and detect movement. If the
sensor detects no movement it automatically turns off the picture
leaving only sound. After more time and no movement, the TV turns
itself off minimizing any unnecessary power draw.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 13

SECTION 1 - SAFETY AND FEATURES


USB PHOTOS, VIDEOS & MUSIC
Share your photos on the big screen or listen to your favorite music.
Simply connect your digital camera, USB-enabled MP3 player, or
USB storage device directly to your HDTVs USB input.

EDGE LED BACKLIGHTING


Experience the next level of picture quality and contrast with Sonys
Edge LED Backlight technology. This technology sharpens image
contrast giving an amazingly crisp picture you can see. The ultra-thin
backlight system allows for a slimmer, sleeker design.

INTERNET STREAMING & CONNECTIVITY


Internet Streaming: Internet favorites now streaming on your
television. In addition to Qriocity, watch hit movies with Netflix,
popular TV shows on Hulu Plus or user-generated video on
YouTube. You can even listen to personalized music on Pandora.
Enjoy the widest selection of internet content at your fingertips.

Skype Ready:Connect to friends and family all over the globe with
Internet voice and video calls using your TV. Make free video Skypeto-Skype calls and low-cost Skype-to-phone calls with a Sony
compact microphone/camera (required, sold separately).2
Wi-Fi Ready:Going wireless is easy with the UWA-BR100 Wi-Fi
adapter (sold separately). Just plug it in and get ready to stream
movies, photos, music and videos straight to your TV from the Internet
or your home network.
DLNA Streaming:Access and share photos, videos and music on
your TV by streaming them from compatible DLNA device like your
PC or Playstation3 system.

FASTER START-UP
Quick Start & Viewing feature enables this Sony television to go from
OFF to ON 2-3 times faster than previous Sony televisions.

BRAVIA SYNC COMPATIBLE


Conveniently operate and control other BRAVIA Sync compatible
devices - including BRAVIA HDTVs, Blu-ray Disc Players,
surround sound systems, Handycam camcorders and Cyber-shot
digital still cameras, all with one remote control.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 14

SECTION 1 - SAFETY AND FEATURES


SPECIFICATIONS
System
Television system

Channel coverage
Panel system
Speaker output

Input/Output jacks
CABLE/ANTENNA
VIDEO IN 1/2
COMPONENT IN
HDMI IN 1/2/3/4

AUDIO OUT/Headphones
DIGITAL AUDIO OUT
(OPTICAL)
PC IN
PC/HDMI 4 AUDIO IN
LAN

USB/DLNA
REMOTE
(EX729 series only)

NTSC: American TV standard


ATSC (8VSB terrestrial): ATSC compliant 8VSB
QAM on cable: ANSI/SCTE 07 2000 (Does not include CableCARD functionality)
Analog terrestrial: 2 - 69 / Digital terrestrial: 2 - 69
Analog Cable: 1 - 135 / Digital Cable: 1 - 135
LCD (Liquid Crystal Display) Panel
10 W + 10 W
75-ohm external terminal for RF inputs
VIDEO / AUDIO
YPBPR (Component Video) / Signal format: 480i, 480p, 720p, 1080i, 1080p
AUDIO
HDMI: Video: 480i, 480p, 720p, 720/24p/30p, 1080i, 1080p, 1080/24p/30p
HDMI: Audio: Two channel linear PCM 32, 44.1 and 48 kHz, 16, 20 and 24 bits, Dolby Digital
Analog audio input (minijack) (HDMI IN 4 only)
ARC (Audio Return Channel) (HDMI IN 1 only)
500 mVrms (typical)
Stereo mini jack / Impedance: 16 ohms
PCM/Dolby Digital optical signal
D-sub 15-pin , analog RGB
Stereo mini jack
10BASE-T/100BASE-TX connector (Connection speed may differ depending on the
network environment. 10BASE-T/100BASE-TX communication rate and communication
quality are not guaranteed for this TV.)
Refer to the i-Manual for supported format.
RS232C, D-sub 9 pin.
This jack is for receiving the external control signal.

Checking the accessories


Remote control (1)*1
Size AAA batteries (2)
Table-Top Stand (1)*2
Fixing screws for Table-Top Stand (M5 16) (3)
Assembling screws for Table-Top Stand (M6 14) (4)
(for KDL-55/46EX62x)
Assembling screws for Table-Top Stand (M6 14) (3)
(for KDL-40EX62x)
Hexagon wrench (1)
Operating Instructions (this manual)
and other documents

Model name KDL-

55EX62x

46EX62x

40EX62x

Power and others


Power requirement
Power consumption
in use
in DAM*

110-240 V AC, 50/60 Hz (U.S.A./Canada 120 V AC, 60 Hz)


166 W

122 W

110 W

0.02 kWh/Day
(You may hear a clicking noise during the download but this is normal.)

in standby
Less than 0.2 W with 120 V AC and less than 0.3 W with 240 V AC
Screen size
54.6 inches
46 inches
40 inches
(inches measured diagonally)
(55 class)
D i spl ay resol uti on
1, 920 dots ( hori zontal ) 1, 080 l i nes ( verti cal )
Speaker
30 150 (2)
Full range
(mm)
1 3/16 6 (2)
(inches)
1,078 690 260
943 616 250
Dimensions with stand
(mm) 1,269 799 315
42 1/2 27 1/4
37 1/4 24 3/8
(inches)
50 31 1/2
1
1
12 /2
10 /4
9 7/8
without stand
(mm)
1,269 769 41
1,078 660 42
943 586 42
(inches)
50 30 3/8
42 1/2 26
37 1/4 23 1/8
1 5/8
1 11/16
1 11/16
wall-mount hole pattern
300 300
(mm)
wall-mount screw size
M6 (length: refer to the Setup Guide.)
(mm)
Mass
with stand (kg)/(lb.)
25.4 / 56
17.9 / 39.5
14.4 / 31.8
without stand (kg)/(lb.)
20.2 / 44.5
14.3 / 31.5
11.2 / 24.7
Supplied accessories
See Checking the accessories.
Optional accessories

Operating temperature

Connecting cables
Support Belt Kit
Wall-Mount Bracket: SU-WL500
USB Wireless LAN Adapter
32 F - 104 F (0 C - 40 C)

* Download Acquisition Mode (DAM) is used for software updates and/or


collecting data for Rovi On Screen Guide.
Optional accessories availability depends on its stock.
Design and specifications are subject to change without notice.

*1 Please refer to the model name printed on the remote control.


*2 Assembling the Table-Top Stand is required.
Refer to the supplied Table-Top Stand leaflet to assemble the Table-Top Stand.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 15

SECTION 1 - SAFETY AND FEATURES


CAUTION

Licensing Information

To prevent electric shock and blade


exposure, do not use this polarized AC
plug with an extension cord, receptacle
or other outlet unless the blades can be
fully inserted.

Macintosh is a trademark of Apple Inc.,


registered in the U.S. and other
countries.

Some people may experience


discomfort (such as eye strain, fatigue,
or nausea) while watching 3D video
images or playing stereoscopic 3D
games. Sony recommends that all
viewers take regular breaks while
watching 3D video images or playing
stereoscopic 3D games. The length
and frequency of necessary breaks
will vary from person to person. You
must decide what works best. If you
experience any discomfort, you
should stop watching the 3D video
images or playing stereoscopic 3D
games until the discomfort ends;
consult a doctor if you believe
necessary. You should also review (i)
the instruction manual of any other
device or media used with this
television and (ii) our website
(www.sony.com/tvsupport) for the
latest information. The vision of
young children (especially those
under six years old) is still under
development. Consult your doctor
(such as a pediatrician or eye doctor)
before allowing young children to
watch 3D video images or play
stereoscopic 3D games. Adults should
supervise young children to ensure
they follow the recommendations
listed above.
When using the simulated 3D
function, please note that the
displayed image is modified from the
original due to the conversion done by
this television.
Operate the TV only on 110-240 V
AC (U.S.A./Canada 120 V AC)

HDMI, the HDMI Logo, and HighDefinition Multimedia Interface are


trademarks or registered trademarks of
HDMI Licensing LLC in the United
States and other countries.
Fergason Patent Properties, LLC:
U.S. Patent No. 5,717,422
U.S. Patent No. 6,816,141
Manufactured under license from Dolby
Laboratories. Dolby and the double-D
symbol are trademarks of Dolby
Laboratories.
Rovi and Rovi On Screen Guide are
trademarks of Rovi Corporation and/or
its subsidiaries.
The Rovi On Screen Guide system is
manufactured under license from Rovi
Corporation and/or its subsidiaries.
The Rovi On Screen Guide system is
protected by one or more United States
patents of Rovi Corporation and/or its
subsidiaries.

Rovi Corporation and/or its subsidiaries


and related affiliates are not in any way
liable for the accuracy or availability of
the program schedule information or
other data in the Rovi On Screen Guide
system and cannot guarantee service
availability in your area. In no event
shall Rovi Corporation and/or its related
affiliates be liable for any damages in
connection with the accuracy or
availability of the program schedule
information or other data in the Rovi On
Screen Guide system.
Blu-ray Disc is a trademark.
BRAVIA and
, S-Force,
Motionflow, BRAVIA Sync, and
are
trademarks or registered marks of Sony
Corporation.
PlayStation is a registered trademark
and PS3 is a trademark of Sony
Computer Entertainment Inc.
DLNA, the DLNA Logo and DLNA
CERTIFIED are trademarks, service
marks, or certification marks of the
Digital Living Network Alliance.

Music and video recognition technology


and related data are provided by
Gracenote. Gracenote is the industry
standard in music recognition
technology and related content delivery.
For more information, please visit
www.gracenote.com.
CD, DVD, Blu-ray Disc, and music and
video-related data from Gracenote, Inc.,
copyright 2000-present Gracenote.
Gracenote Software, copyright 2000present Gracenote. One or more patents
owned by Gracenote apply to this
product and service. See the Gracenote
website for a nonexhaustive list of
applicable Gracenote patents.
Gracenote, CDDB, MusicID,
MediaVOCS, the Gracenote logo and
logotype, and the Powered by
Gracenote logo are either registered
trademarks or trademarks of Gracenote
in the United States and/or other
countries.

Your BRAVIA TV is
ENERGY STAR
qualified in the Home
mode.
It meets strict energy
efficiency guidelines
set by the U.S.
Environmental Protection Agency and
Department of Energy. ENERGY
STAR is a joint program of these
government agencies, designed to
promote energy efficient products and
practices.
Changes to certain features, settings,
and functionalities of this TV (i.e. Rovi
On Screen Guide, Picture/Sound, Light
Sensor, Power Savings) can increase or
change the power consumption.
Depending upon such changed settings,
the power consumption may exceed the
limits required for the ENERGY STAR
qualification in the Home mode.

FACE DETECTION logo is


trademark of Sony Corporation.
TrackID is a trademark or registered
trademark of Sony Ericsson Mobile
Communications AB.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 16

SECTION 2 - SOFTWARE REQUIREMENTS


OVERVIEW
There are 2 reasons for updating the software on the TVs.
Software updates for customers

These updates are for enhancements or improvements that
have been made to the software after the TV was released.
These updates are accessed by the customer from the Sony
Support Site at http://esupport.sony.com.
Software update for servicers

These updates are specifically for servicers to use during a
service call and are only available on the Sony Authorized
Servicer Portal at http://www.sony.com/asp.

SOFTWARE UPDATES FOR CUSTOMERS


The subject of software updates is very important. The televisions
of today have advanced to the point where they are not simply a
television anymore. They are evolving into devices that are designed
to integrate with numerous other devices found in the home. Some
examples are: Portable audio and video devices, still cameras, home
computer networks and accessing the internet to name a few.
Communications with these varying devices requires that the
television be compatible with varying communications protocols.
Although standards are detailed for each of these protocols, the real
world dictates that occasional errors may occur that could prevent
devices from operating or communicating properly.
Keeping the software in the television up-to-date is a procedure that
is normally handled by the owner of the television. Most customers
who own computers and other digital devices are familiar with and are
accustomed to updating the software in their products. If a customer
contacts the Sony Customer Support Center and it is deemed to
be correctable with a software update, the issue is handled at the
customer level.
Software updates can be performed by:
Customer Manual Downloads: Software updates can be
accessed by the customer from the Sony Support Site at
http://esupport.sony.com where they can be downloaded
and placed on a USB thumb drive to be loaded onto the TV.
The instructions for downloading the software file vary from
chassis to chassis and sometimes from model to model. The
customer is provided with the instructions to properly format
the USB thumb drive, unzip the file, and the procedures for
loading the software into the television.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 17

SECTION 2 - SOFTWARE REQUIREMENTS


Network Downloads: Internet software updates are
becoming more prevalent as more and more models
incorporate home network capabilities. This method is the
most practical since the television will check for the latest
version of software. The models using the AZ2-F chassis
provide the customer with a choice of turning the automatic
software update feature on or off. If set to on, the television
will lookup software information while the unit is in standby.
If a newer version is available, it will be downloaded and
installed without any input from the customer.
Built-in Tuner: OTA or cable sources having the proper
station that is transmitting software update data packets.
Although the ability to transmit software update is possible in
this way, it is the least common and is reserved for particular
situations where a critical update is forced, thereby
updating the unit without any input from the customer.

SOFTWARE UPDATES FOR SERVICERS


The models in this manual utilize a generic type Main Board. In
the past, many different Main Boards needed to be stocked due to
differences in software requirements. The software loaded on the
board was specific to the model and its features along with the type
of LCD panel installed during production.
Replacement Main Boards are now stocked with basic software.
Once the replacement board is installed in the unit, the most current
software needs to be installed using a USB thumb drive containing
the necessary software downloaded.
This new method of supplying Main Boards significantly reduces
the complexity of replacing LCD panels and Main Boards.
Information about the LCD panel is stored on the TCON circuits.
This information is automatically loaded onto the Main Board
when the TV is powered up. With the correct software version the
Main Board and/or the TCON or LCD panel can be replaced more
efficiently. The software update and procedures for the software
installation are located on the Sony Authorized Servicer Portal at
http://www.sony.com/asp.
In addition to software installation, service adjustment information
may need to be modified or verified to complete the service of the
TV. Service adjustment information is covered in Section 7 - Service
Adjustments on page 64.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 18

SECTION 2 - SOFTWARE REQUIREMENTS


SOFTWARE UPDATE RESPONSIBILITY
Software updates are designed to be performed by the customer.
Warranty repairs in which the issue can be resolved by a software
update are not reimbursable. Most issues involving software
updates are handled by the customer service center and should not
be directed to an authorized service center. It is the responsibility
of the servicer to prevent service calls for issues that involve
software updates. Exceptions to this are certain cases whereby the
customer is unable or unwilling to perform the task. In this situation,
the servicer will be notified and receive the proper authorization for
reimbursement.
It is the servicers responsibility, however, to make certain that any
TV requiring a legitimate service is running the latest software
version and to install it if necessary.

CHECKING THE SOFTWARE VERSION


The easiest way to check the version of software that is currently on
the TV is to access the Contact Sony screen by using the customer
menu.

EXAMPLES OF SOFTWARE CORRECTABLE


SYMPTOMS
Always check the Sony Authorized Servicer Portal at http://www.
sony.com/asp site for any known and/or listed issues that are
software related. Most symptoms that are correctable by software
updates involve communications issues with other devices or minor
glitches in the operation of a specific function. Below is a list of some
of the symptoms that may be corrected with a software update:
Fluctuations in picture brightness
Intermittent picture freezing or noise
Problems with certain inputs (especially HDMI)
Intermittent or distorted audio
Erratic remote control operation
Unit turns on and off by itself
Loss of color
Internet connectivity
Certain features not working correctly
(photo or video file viewing)

Figure 2-1. EXAMPLE OF SOFTWARE VERSION


LOCATED ON THE CONTACT SONY SCREEN

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 19

SECTION 3 - CHASSIS OVERVIEW


OVERVIEW
The primary circuits contained in the AZ2-F chassis consists of a Main Board (designated as the BATV Board), Power Supply Board (designated
as the G4 Board for the 40 models, G5 Board for the 46 models, and G6 Board and G8 Board for the 55 models), the Motion Sensor
(HMS3 Board), the IR Board (HLR2 Board), the Switch Unit, and the LCD Panel Assembly which contains the TCON Board.
NOTE: For connector part number information, refer to Connectors on page 61. For Wire Dressing information, refer to Wire Dressing on page 63.

NOTE: The LD Board is not included with the LCD Panel

BATV

G4
LD
SWITCH
UNIT
TCON

HLR2

HMS3

Figure 3-1. BOARD LAYOUT FOR KDL-40EX620/40EX621 ONLY

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 20

SECTION 3 - CHASSIS OVERVIEW


NOTE: The LD Board is not included with the LCD Panel

BATV

G5

LD

SWITCH
UNIT

TCON

HLR2

HMS3

Figure 3-2. BOARD LAYOUT FOR KDL-46EX620/46EX621 ONLY

NOTE: The LD Board is not included with the LCD Panel

G8

G6
SWITCH
UNIT

BATV
LD
TCON

HLR2

HMS3

Figure 3-3. BOARD LAYOUT FOR KDL-55EX620/55EX621 ONLY

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 21

SECTION 3 - CHASSIS OVERVIEW


OVERALL CIRCUIT DESCRIPTION
Figure 3-5. Overall Block Diagram on page 25 provides an overview
of the AZ2-F chassis. The following are descriptions of the boards
and their functions.

MAIN BOARD
Common to all models the Main Board, designated as the BATV
Board, contains the TV control, video, and audio processing circuitry.
All these functions are accomplished using the X-Reality Processor.

Tuner
The tuner is a combination ATSC/NTSC unit. It can receive traditional
analog NTSC signals via cable or terrestrial along with ATSC digital
signals via terrestrial (8VSB) or cable (64 or 256 QAM).

X-Reality Processor
IC9000 performs the majority of the necessary audio and video
processing on the main board.
TV Microprocessor: The CPU internal to the X-Reality processor
controls all aspects of the television functions. Input from the user
along with monitoring of critical circuits is also performed by this
CPU.

HDMI Input and Switching: The customer can select the HDMI1,
HDMI2, HDMI3, HDMI4 input. Each HDMI input contains a common
EDI NVM (not shown) to provide display information data to any
device connected via the HDMI inputs.
LVDS Transmitter: Integrated into IC9000 is a Low Voltage
Differential Signaling (LVDS) transmitter. This circuit converts
the 8-bit parallel RGB video information into a set of high speed
serial lines for noise-free transmission to the TCON circuits located
internally to the LCD panel.
Scan Converter: Signal processing circuit that performs resolution
conversion (aspect ratio) and interlaced to progressive scan (IP)
conversion

Audio Amplifier
The audio amplifier (IC4601) amplifies the digital audio output of the
X-Reality processor and sends it to the speakers.

Temperature Sensor
The temperature sensor detects over-temperature conditions on the
Main Board, LCD Panel, or ambient room temperature and sends
the shutdown signal to the processor.

Digital Audio and Video Decoder: The MPEG2 and Digital Dolby
audio streams are received from the tuner for decompression. All
video sources which are not native 1920 X 1080p 60HZ are scaled to
this resolution. Digital audio content is output to the class D amplifier
for processing and amplification.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 22

SECTION 3 - CHASSIS OVERVIEW


POWER SUPPLY
There are different Power Supply Boards used in the models in this
manual. The type of board depends on the size of LCD panel. They
are:
G4 Board (40)
G5 Board (46)
G6 Board (55)
Note:the G8 Board in the 55 models is the Power Supply
Board for the Panel LED backlight system.
There are 2 distinct sections on the power supply:
Standby Supply: Continuously operational as long as AC power is
applied, the standby supply generates 3.3V for the circuits requiring
power while the unit is turned off. An unregulated 19V line is present
to provide power to the main relay, PFC and main power supply at
turn-on.
Main Supply: Once the power supply receives a power-on command
from the CPU on the Main Board, the main switching supply is turned
on to provide a regulated 12V source and an regulated 24V source
for the LED power supply circuits.

POWER SUPPLY FOR BACKLIGHT


SYSTEM
The G8 Board is the Power Supply Board for the Panel LED
backlighting system (including the LED Driver Board) for the 55
model only. 390V, 19V, and 12V are applied to the board from the
G6 Board to develop the 24V. The 24V is applied to the LD Driver
Board.

SWITCH UNIT
This board contains the power, channel, and volume up/down and
menu buttons.

MOTION SENSOR BOARD


Designated as the HMS3 Board, the Motion Sensor Board contains
the circuits for the Motion Sensor. The Motion Sensor detects when
there is movement in front of the TV. If there is no movement in
front of the TV after a predetermine amount of time the backlight is
turned off (audio present). After an extended period of time the TV is
completely turned off.

IR BOARD
Designated as the HLR2 Board, the IR Board contains the power,
standby, and timer LEDs are located on this board along with the IR
remote receiver and light level sensor.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 23

SECTION 3 - CHASSIS OVERVIEW


LCD PANEL ASSEMBLY
The LCD Panel Assembly includes the LCD Panel, TCON Board,
and LED Backlight system.
NOTE: The LD Board is not included with the LCD Panel.
The LCD Panel contains the actual liquid crystals, color filters, and
polarizers. The liquid crystals are manipulated by the applied voltage
to pass a specific amount of light - from the backlight- depending on
the level of voltage applied.
The TCON performs all the control, timing, charge, and discharge
functions driving the operation of the LCD Panel.
A new LCD Panel assembly from parts will include the following
items.

1. LCD Panel
2. LED Backlighting Components
3. TCON Board

TCON Board
The TCON Board communicates between the LCD Panel and the
microprocessor on the Main Board. (NOTE: The TCON Board is not
available as a replacement part for all models.)

LD BOARD (LED DRIVER BOARD)


The LED Driver Board is controlled by the TCON/HFR Board to
perform overall backlight power-on, backlight level, and local dimming
functions. This board takes the 24V from the Power Supply Board
(or G8A Board for the 55 models) and develops the negative and
positive voltages to directly drive the LEDs in the panel assembly.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 24

SECTION 3 - CHASSIS OVERVIEW

TS2

I2CB
DMD_CLK_ENABLE2
DMD_CLK_ENABLE1
DMD_RST

SW
Xtal

IF1

Ext Demod

IFAGC

[GAIA1a]

TS1

[GL850G]

I2CB

Ether
PHY

[RTL8201E]

Crystal

Xtal

X_SYSTEM1_RST
TMDS1
DDC1

HDMI1
(ARC)

USB
HUB

[MIC2005]

PEL3

1333
2Gb

One
NAND

BACKLIGHT

DDR3
1333
2Gb

Muxed
2Gb

12M

41M

LVDS

DDC_5V_1

HDMI2

HPD1
ARC
CEC1
TMDS2
DDC2
DDC_5V_2
HPD2

HDMI3

CEC2
TMDS3
DDC3
DDC_5V_3
HPD3

HDMI4

CEC3
TMDS4
DDC4
DDC_5V_4
HPD4

LVDS_ODD
LVDS_EVEN

I2CA

EQ SW

TS

[Sil9287B]

SYSTEM1_PWR

SYSTEM2_PWR

Xtal
41M

1.5V

IF1

DDC
Xtal

3.3->1

48M

Xtal

TMDS
DDC
CEC

32.76
8K

SYSTEM2_PWR
Reset

Push
AC_MON

3.3V

DDC

CEC4

3.3V
LDO

2.5V
LDO

3.4V
LDO

GND

CVBS

VIDEO_CV
VIDEO1_LR

COMP

[LM75B]

SIRCS
DIMMER
DMD_CLK_ENABLE2
DIMMER_DC
LOGO

Tuner_LR
VIDEO1_LR

PC_CON_Det
PC_R,PC_G,PC_B,PC_H,PC_V
PC_LR
PC_5V, PC_DDC

DEBUG_LED3
PANEL_PWR
DMD_CLK_ENABLE1
DMD_RST
X_WIFI_RST
HP_DET

Line Out_LR

[NJU72040V]

HP_/ Line Out Det


HP/Line Out LR

Assist
SPEAKER

Atreyu_SPDIF

[D510D]

Main Speaker_Out_LR
Assist Speaker_Out_LR

X_SYSTEM1_RST

PWM
Analog Signal

UART
I2C

SPI

H/L

DC_MON
KEY

Digital Audio
Analog Audio

Light_Sensor_Det
Human_Sensor_Det
PANEL_SEL

X_AUDIO_MUTE1

AUDIO_MON

PANEL_PWR_Det
BACKLIGHT_MON

[D510D]
X_FAULT

STBY_LED
TIMER_LED
PIC_MUTE_LED
MAIN_PWR
SYSTEM1_PWR
SYSTEM2_PWR
MAIN_SS_MON
AC_MON
PFC_MON
POWER_KEY
DEBUG_LED1
X_HOTEL_PWR_CTRL
X_RF_RST

Main Speaker_Out_LR

POWER_LED
REC_LED
X_SYSTEM1_RST
NMI
BACKLIGHT_ON
PFC_PWR
X_AUDIO_MUTE1
X_AUDIO_MUTE2
VIDEOA_DET
VIDEOB_DET
CR_DET
PC_CON_DET

Audio
Power AMP

KEY
UARTE

Light_Sensor_Det

X_TCON_RST
SA_MODE

Digital Video/TS/TMDS
Analog Video

Audio
Power AMP

Power_KEY

Human_Sensor_Det

BINT
TCON_RDY
DATA1

Main
SPEAKER

Assist Speaker_Out
X_SYSTEM1_RST

S1.2V S1.8V
LDO LDO

AUDIO_12V
AUDIO_12V
STBY 3.3V

Temp Sensor
Sircs

KEY

SPDIF_SEL
X_AUDIO_MON
HDMIEQ_INT

Tuner_LR

SPDIF

SYSTEM2_PWR

DEBUG_LED2

COMP2_LR
PC_LR

OPAMP

SPDIF

Temp
Sensor

I2CA

PC_G
PC_B
PC_R
PC_H
PC_V

REG12V
REG12V

REG_12V

PEM_LOG
UARTA(LOG)
UARTD
MODE_PEM
Reset
UARTC(Hotel/ECS)
I2CA(Hotel_Clock)
SIRCS

X_Hotel_PWR_CTRL

COMP_Y
COMP_Pb
COMP_Pr

T-CON_VCC

DIMMER2

UARTA (LOG)
UARTB (RF-Remote)
UARTC (IR Blaster/ECS)

XReality

COMP_Y, Pb, Pr
VideoB_Det
COMP2_LR
ASPECT1
Cr_Det

PC

HP/Line
Out

I2CA (EQSW, Temp Sensor, Hotel Clock)


I2CB (Ext Demod)
I2CC (Panel, RGB Sensor)

VIDEO_CV

REG_12V

TCON-ON
DIMMER_DC
DIMMER
BACKLIGHT_ON
BACKLIGHT_MON
MAIN_PWR
AC_MON
PFC_PWR

COMP_Y

VideoA_Det

DDC

SYSTEM2_PWR
REG_12V DDC
5V

Reset
[PST3629]

1.2V

REG_12V

Power

IF2

[ASCOT2Sip]

LNA

Current
Limit

[TPS2553DBV]

Power_Control

Aerial

Current
Limit

[TPS2553DBV]

P
A
N
E
L

DDR3

Hotel TL-JIG
/ECS

Silicon
Tuner

4M

Current
Limit

USB4 USB3
BD
Wifi

TCON

LUT_SEL1/X_TCON_RST/LR_FLAG
T_PANEL_SEL

[SEKITO2]

MODE_PEM/TCON_RDY

Ext Demod

IFAGC

SA_MODE/LUT_SEL0
PEM_WDT/XBUSY/BINT

Zero-IF

[HORUS3]

Ether

USB1
USB2

I2C_C

LNA

H Con.

X_SYSTEM1_RST

Satellite
Cable

MS

DDC
[LNBH23]

X_SYSTEM1_RST
5V

Silicon
Tuner

27M

5V

BLOCK DIAGRAM

DiSEqC_Out
DiSEqC_In

27MHz

Xtal

5V

DIAGRAMS

POWER_LED
STBY_LED
TIMER_LED
REC_LED
PIC_MUTE_LED

Light Sensor
Human Sensor
LED

Panelless

Figure 3-5. OVERALL BLOCK DIAGRAM

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 25

SECTION 3 - CHASSIS OVERVIEW


Power Key
Function Keys

Keys

Switch Unit
Motion Sensor
LEDs
IR Sensor
Light Level
HLR2

HMS3
Power/
SIRCS

X-Reality Processor
TV Microprocessor
Video Processing
HDMI Processing
HDCP Processing
IP (Image Processor)
Scan Converter (Scalar)
Audio Processing
Video Switcher
HDMI Switcher
ATSC/NTSC Tuner
Temperature Sensor
Audio Output Amplifier

RF Input
Component/Composite
Composite
PC Input
4 HDMI Inputs
2 USB 2.0

Optical Digital Audio Output


Headphone/Analog Audio Output

NOTE: The LD-Board is NOT included


in the LCD Panel Assembly

LCD Panel Assembly

TCON/HFR
(120Hz)

LVDS

RJ45 Ethernet

LCD Panel
Control

LCD PANEL

Power

BATV
Main Power Supply
Standby Power Supply
AC Relay
LED Backlight Power Supply
(32", 40", 46")
AC
Input

G4-Board (40")
G5-Board (46")
G6-Board (55")

55" Models
Power

LED 24V
G8

Power &
Control

LED Power
LD

LED
Backlight System

32", 40", 46" Models


Power &
Control

Power +

LED Power
LD

Power Control

Figure 3-6. OVERALL BLOCK DIAGRAM

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 26

SECTION 3 - CHASSIS OVERVIEW


CONNECTOR DIAGRAMS
HMS3 board

BAT- V board

JAM 3pin Straight

To BAT

GND

40

BD USB GND

Panel_Ct rl1 / NC

51

Panel_Ct rl1 / NC

Mot ion Sensor

MOTION_SENS

38

BD VBUS

Y 2
Panel_Ctrl2 / TCON_RD

50

Panel_Ct rl2 / TCON_RDY

3a- X/ V/ 2

REG+5V

39

BD USB_P

P-1/2

1- 821- 130- 11

SW module

GND

SW module

POWER_INT

35

ALL

KEY1

36

49

Panel_Ctrl4 / X_FRC_RS
T 4

48

Panel_Ct rl3 / T_TD_HSYNC


NC

BD USB_N

(Fo
Panel_Ctrl5 / LR_FLAG

47

Panel_Ct rl5 / LR_FLAG(For Asura)

BD USB SPDIF

Panel_Ct rl6 / SA_MODE

46

Panel_Ct rl6 / SA_MODE

BD EJ ECT/ BDR ON

Panel_Ct rl7 / SETON2(N

45

BD DISC1/ BDR GPIO1

Panel_Ct rl8 / PANEL_SE

44

43

Panel_Ct rl9 / BINT

BD DISC2/ U_DL_STAT

Panel_Ct rl9 / BINT

-OUT1

PANEL FFC
SLCD : 96pin
SHARP : 80pin
AUO : ??pin

-OUT2

-OUT3

NC

-OUT4

NC

40"~55" 80pin

CN1000
JST SM05B-PASS-TBT

BD UART Tx/ BDR KEY1

Panel_Ct rl10 / T_TD_VSY 10

11

BD UART Rx/ BDR KEY2 / HLR DEVICE_SDA

Panel_Ct rl11 / SDA

11

41

Panel_Ct rl11 / SDA

0-844-179-01

12

BDR STBY_+3.3V

Panel_Ct rl12 / SCL

12

40

Panel_Ct rl12 / SCL

KYOCERA ELCO

13

BDR UART_Tx/ RF UART_TX

GND

13

14

BDR UART_Rx/ RF_UART_RX

PANEL_EVEN4_P

14

15

BDR WAKEUP_STBY_MICON/ RF SEL

PANEL_EVEN4_N

Panel_Ct rl10 / T_TD_VSYNC

CN1003

+OUT1

39

GND

CN11 FFC 56pin

38

PANEL_EVEN4_P

1-822-905-11

15

37

PANEL_EVEN4_N

GND

BL_TYPE3

04-6802-656-000-883 +

+OUT2

+OUT3

+OUT4

BDR GPIO0/ RF_RST

PANEL_EVEN3_P

16

36

PANEL_EVEN3_P

1- PWM1

BL_TYPE2

CN1001

STBY+3.3V

33

17

BDR GND

PANEL_EVEN3_N

17

35

PANEL_EVEN3_N

1- PWM2

BL_TYPE1

JST SM04B-PASS-TBT

LED/ IR/ RGB Sensor/ OPT_Sensor

GND

31

18

WIFI GND

GND

18

34

GND

1- PWM3

REF

2b- 3

LED_REC

29

19

WIFI USB_P

PANEL_EVEN_CLK_P

19

33

PANEL_EVEN_CLK_P

1-PWM4

FAIL

3a- V

LED_STBY

27

20

WIFI GND

PANEL_EVEN_CLK_N

20

32

PANEL_EVEN_CLK_N

1- PWM5

3a- 2

LED_TIMER

25

21

WIFI USB_N

GND

21

31

GND

P- 1

LED_POWER

28

NC

22

WIFI GND

PANEL_EVEN2_P

22

P- 2

LED_PIC_MUTE

30

23

WIFI VBUS

PANEL_EVEN2_N

23

51pin FFC

10

NC

11

11

GND

HLR DEVICE_SCL

PANEL_EVEN1P

24

28

PANEL_EVEN1P

25

HLR LED_ON_TIMER

PANEL_EVEN1_N

25

27

PANEL_EVEN1_N

32

12

PANEL_EVEN0_P

2- PWM1

VD+3.3V

11

34

27

HLR LED_STBY

PANEL_EVEN0_N

27

25

PANEL_EVEN0_N

2- PWM2

13

SIRCS

12

26

28

HLR LED_POWER

GND

28

24

GND

2- PWM3

14

15

26

12

56pin FFC

NC

12V

NC

12

NC

13
14

TCON_VCC

29

HLR LED_REC

PANEL_ODD4_P

29

23

PANEL_ODD4_P

2- PWM4

15

15

30

HLR LED_PIC_MUTE

PANEL_ODD4_N

30

22

PANEL_ODD4_N

2- PWM5

16

16

17

17

GND

18

18

4-PWM8

19

4-PWM7

31

HLR GND

PANEL_ODD3_P

31

21

PANEL_ODD3_P

2- PWM6

10

32

HLR OPT_SENS

PANEL_ODD3_N

32

20

PANEL_ODD3_N

2- PWM7

33

HLR STBY_3.3V

GND

2- PWM8

19

34

1
SYNC

LD_STDBY

10

24

1- 821- 139- 11

LED_ON

GND

NC

26

VLED_MPC

NC
NC

PANEL_EVEN0_P

LD - TC Harness
TCON - LD

8
9

HLR SIRCS

1- PWM7
1- PWM8

26

PANEL_EVEN2_P
PANEL_EVEN2_N

DEVICE_SCL/ LED_BDR

10

1- PWM6

30
29

DEVICE_SDA/ GND

OPT_SENS

RFRC module

16

LVDS-FFC
B-PEL3

1
2

NC

CMI :
32"~37" 60 pin

42

BLK Board

NC

10

BV - H Harness
H-B

N 3
Panel_Ctrl3 / T_TD_HSY

BD GND

2
5

37

1- 822- 693- 11

HLR board
HLR2
board

T- con Board

11

33

19

GND

NC
NC

HLR 3.3V

PANEL_ODD_CLK_P

34

18

PANEL_ODD_CLK_P

GND

RESET

16

35

SW POWER_KEY

PANEL_ODD_CLK_N

35

17

PANEL_ODD_CLK_N

LD_TYPE

21

21

4-PWM5

RFRC module

GND

17

36

SW_KEY

GND

36

16

GND

3- PWM1

22

22

4-PWM4

2b- 1/ 2b- 2/ 2b- 3/ 3a- 1/ 3a- 2/ P- 1

RX

13

37

SW GND

PANEL_ODD2_P

37

15

PANEL_ODD2_P

3- PWM2

23

23

4-PWM3

only Japan

TX

14

38

HMS DET / SONY LOGO

PANEL_ODD2_N

38

14

PANEL_ODD2_N

3- PWM3

24

24

4-PWM2

VDD

12

39

HMS 5V / LOGO 5V

PANEL_ODD1P

39

13

PANEL_ODD1P

3- PWM4

25

25

40

HMS GND/ LOGO GND

PANEL_ODD1_N

40

12

PANEL_ODD1_N

3- PWM5

26

26

27

27

GND

JAM SYT10-06-WL-ET
1-821-146-11

Wifi module
(US, EU deri 46 & 32
O l )

R3 or RU board

4-PWM6

4-PWM1
GND

CN9006

PANEL_ODD0_P

41

11

PANEL_ODD0_P

3- PWM6

1- 818- 692- 21

PANEL_ODD0_N

42

10

PANEL_ODD0_N

3- PWM7

28

28

3-PWM8

HEADER ASSENBLY 40P

GND

43

GND

3- PWM8

29

29

3-PWM7

GND

44

GND

Panel_Ct rl13

GND

30

30

3-PWM6

GND

31

31

3-PWM5

GND

46

NC

4- PWM1

32

32

3-PWM4

PANEL_VCC_SW

45

47

GND

PANEL_VCC_SW

4- PWM2

33

33

PANEL_VCC_SW

48

PANEL_VCC_SW

4- PWM3

34

34

3-PWM3
3-PWM2

STBY3.3V

PANEL_VCC_SW

49

PANEL_VCC_SW

4- PWM4

35

35

3-PWM1
LD_TYPE

20

RS232_RXD

PANEL_VCC_SW

50

PANEL_VCC_SW

4- PWM5

36

36

WIFI VCC

23

RS232_TXD

PANEL_VCC_SW

51

PANEL_VCC_SW

4- PWM6

37

37

GND

WIFI USB_P

19

SIRCS_OUT

CN2001

4-PWM7

38

38

2-PWM8

1- 842- 547- 11

4-PWM8

39

39

2-PWM7

GND

40

40

2-PWM6

NC

41

41

2-PWM5

NC

42

42

2-PWM4

TCON_VCC 43

43

WIFI USB_M

21

SIRCS_IN

WIFI GND

18

GND

SM05B-GHS-TB

CN9005

1-819-334-11

6pin connector 182113311

STBY3.3V

RS232_RXD

SIRCS_IN

4
5
6

FFC Direct in Connector


JAE

44

44

NC

45

45

2-PWM1

GND

46

46

VLED_MPC

NC

47

47

GND

12V

48

48

1-PWM8

NC

49

49

1-PWM7

LD_STDBY 50

50

1-PWM6

2
3
4
5
6

G-B Harness
G-B

LED_ON 51

CN101
182018311

L+ (Fasten # 187)

L- (Fasten #110)

R- (Fasten # 110)

R+ (Fasten # 187)

L+

L-

R-

R+

2-PWM3

NC

RS232_TXD

GND

SPEAKER
Front
Rch

20

GND

SIRCS_OUT

SPEAKER
Front
Lch

20

51

2-PWM2

1-PWM5
1-PWM4

FAIL

52

52

REF

53

53

1-PWM3

54

54

1-PWM2

55

55

1-PWM1

56

GND

BL_TYPE1
BL_TYPE2
BL_TYPE3

56

Housing Speaker Connect or


2.0ch:4pin MOLEX 502439-0400 2.0ch:CN4601 4pin 1-821-614-11 MOLE
X 502494-0470

[3a-2 32,46 1/2]


Figure 3-7. CONNECTOR DIAGRAM FOR KDL-46EX620/46EX621 ONLY (1 OF 2)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 27

SECTION 3 - CHASSIS OVERVIEW


HEM2 Board

T- con Board
12V

3D Emit t er

12V

3a- V

GND

Except EX720 Model

GND

1
2
3
4

GLS_CTR

GLS_CTRL2

EMI_FAIL

NC

6
7

NC

12V

NC

12V

NC

GND

NC

GND
SM04B- PASS- TBT(LF)(SN)

1-819-460-11

1-821-135-11

CN6704 (32" G10A)


1

CN6151(46"G5D)SJM20-28WLB

To B board (100106)

T- con

B board

12V
12V

NC

GND

27

NC

GND

T-CON_VCC12V

26

NC

GLS_CTRL

GND

25

NC

GLS_CTRL2

EMI_FAIL

NC

NC

T-CON_VCC_12V To B 24

Option

28

GND

T-CON_Vcc12V

GND

23

BDR_ASU_12V

22

NC

GND

21

NC

BDR_ASU_12V

20

NC

GND

19

NC

REG12V

18

GND

17

REG12V

16

GND

15

AU_12V

14

JST SM08B- GHS- TB


1-819-468-11

BAT- V board

AU_GND

13

AU_12V

12

AU_GND

11

B board

10

10

STBY_+3.3V

12

AUDIO+12.5V

STBY3.3V

10

10

14

AUDIO+12.5V

GND

T-CON_ON

AC_OFF_DET

BL_ERR

9
6

11

AUDIO+12.5V_GND

13

AUDIO+12.5V_GND

15

REG+12.5V_GND

17

REG+12.5V_GND

NC

NC

16

REG+12.5V

NC

NC

18

REG+12.5V

PFC_ON

24

T-CON_VCC

NC

NC

POWER_ON

CN6001
1-842-569-11
HEADER ASSEMBLY FOR PWB 10P

GND

UARTD_TX

UARTD_RX

RESET
STBY_+3.3V

6
7

NC (MD2)
UARTC_RX
UARTC_TX
GND
UARTA_TX
ECS_MATRIX
STBY_+3.3V
MODE_PEM

AC_OFF_DET

POWERON

6
NC

BL_ERR

NC

NC

NC

NC

NC

TCON_ON

PFC_PWR

GND

4
5

MODE_TVM
UARTA_RX

8
9
10
11
12

TL- EX1JIG board

13
14
15

PEM_LOG_RX

16

PEM_LOG_TX

17

GND

18

CN9004
1- 774- 667- 51
TL- EX1 Connect or,FFC/ FPC 18P

CN6002
1- 842- 559- 11

VLED_VCC

VLED_VCC

VLED_VCC

VLED_VCC

NC

NC

VLED_GND

NC

BLK Board
1

VLED_VCC

NC

VLED_VCC

NC

NC

BLK

NC
NC

NC

VLED_GND

VLED_GND

VLED_GND

VLED_GND

10

10

11

LD_ERR

11

NC

10

NC

NC

12

NC

13

11

GL_CTRL

GL_CTRL

13

11

14

12

LED_ON

14

12

VLED_GND
VLED_GND
VLED_GND
VLED_GND

1-822-339-11

LD_ERR

LED_ON
CN1002

CN6705 (32" G10A)

0-844-177-01

JST XA 14P

JST

CN6801(46" G5D)

SM12B-PBVSS-TB(LF)(SN)

AC IN
AC-N

AC-L

CN6001(46" G5D / 32"G10A)


SFP79-02WLB JAM
1-822-908-11

AC pigtail

[3a-2 32,46 2/2]

Figure 3-8. CONNECTOR DIAGRAM FOR KDL-46EX620/46EX621 ONLY (2 OF 2)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 28

SECTION 3 - CHASSIS OVERVIEW


(NOTE: 37 model not available)
HMS3 board

BAT- V board

T- con Board(PEL3)

JAM 3pin Straight


1

40

BD USB GND

Panel_Ct rl1 / NC

51

Panel_Ct rl1 / NC

Mot ion Sensor

MOTION_SENS

38

BD VBUS

Panel_Ct rl2 / TCON_RDY

50

Panel_Ctrl2 / TCON_RDY

3a- X/ V/ 2

REG+5V

39

BD USB_P

P-1/2

1- 821- 130- 11

Panel_Ct rl3 / T_TD_HSYNC

49

Panel_Ct r l3 / T_TD_HSYNC

BD GND

Panel_Ct rl4 / X_FRC_RST

48

NC

BD USB_N

Panel_Ct rl5 / LR_FLAG(For Asura)

47

Panel_Ct rl5 / LR_FLAG(For Asura)

SW module

POWER_INT

35

ALL

KEY1

36

37

BV - H Harness
H-B

1- 822- 693- 11

LED/ IR/ RGB Sensor/ OPT_Sensor


2b- 3

BD USB SPDIF

Panel_Ct rl6 / SA_MODE

46

Panel_Ct rl6 / SA_MODE

BD EJ ECT/ BDR ON

Panel_Ct rl7 / SETON2(NC)

45

NC

8
GND

SW module

HLR board
HLR2
board

STBY+3.3V
GND
LED_REC

BLK Board

To BAT

GND

33

31

BD DISC1/ BDR GPIO1

Panel_Ct rl8 / PANEL_SEL

44

NC

BD DISC2/ U_DL_STAT

Panel_Ct rl9 / BINT

43

Panel_Ct rl9 / BINT

10

BD UART Tx/ BDR KEY1

Panel_Ct rl10 / T_TD_VSYNC

10

42

Panel_Ct rl10 / T_TD_VSYNC

NC

11

BD UART Rx/ BDR KEY2 / HLR DEVICE_SDA

Panel_Ct rl11 / SDA

11

41

Panel_Ct rl11 / SDA

12

BDR STBY_+3.3V

Panel_Ct rl12 / SCL

12

40

Panel_Ct rl12 / SCL

13

BDR UART_Tx/ RF UART_TX

GND

13

14

BDR UART_Rx/ RF_UART_RX

PANEL_EVEN4_P

14

15

BDR WAKEUP_STBY_MICON/ RF SEL

PANEL_EVEN4_N

16

BDR GPIO0/ RF_RST

17

BDR GND

18

WIFI GND

PANEL FFC
SLCD : 96pin
SHARP : 80pin
AUO : ??pin
CMI :
32"~37" 60 pin
40"~55" 80pin

CN11 FFC 56pin


1-822-905-11

15

37

PANEL_EVEN4_N

GND

PANEL_EVEN3_P

16

36

PANEL_EVEN3_P

1- PWM1

PANEL_EVEN3_N

17

35

PANEL_EVEN3_N

1- PWM2

34

GND

CN1000

1- PWM3

KYOCERA ELCO

+OUT1

04-6802-656-000-883 +

+OUT2

+OUT3

BL_TYPE3

+OUT4

BL_TYPE2

CN1001

BL_TYPE1

JST SM04B-PASS-TBT

REF

29

19

WIFI USB_P

PANEL_EVEN_CLK_P

19

33

PANEL_EVEN_CLK_P

1-PWM4

3a- V

LED_STBY

27

20

WIFI GND

PANEL_EVEN_CLK_N

20

32

PANEL_EVEN_CLK_N

1-PWM5

3a- 2

LED_TIMER

25

21

WIFI USB_N

GND

21

31

GND

1- PWM6

P- 1

LED_POWER

22

WIFI GND

PANEL_EVEN2_P

1- PWM7

P- 2

LED_PIC_MUTE

30

23

WIFI VBUS

PANEL_EVEN2_N

23

29

PANEL_EVEN2_N

1- PWM8

DEVICE_SDA/ GND

NC

NC

24

HLR DEVICE_SCL

PANEL_EVEN1P

24

28

PANEL_EVEN1P

DEVICE_SCL/ LED_BDR

NC

25

HLR LED_ON_TIMER

PANEL_EVEN1_N

25

27

PANEL_EVEN1_N

OPT_SENS

10

32

12

26

HLR SIRCS

PANEL_EVEN0_P

26

26

VD+3.3V

11

34

27

HLR LED_STBY

PANEL_EVEN0_N

27

25

SIRCS

12

26

28

HLR LED_POWER

2- PWM3

14

14

29

HLR LED_REC

PANEL_ODD4_P

29

23

PANEL_ODD4_P

2- PWM4

15

15

30

HLR LED_PIC_MUTE

PANEL_ODD4_N

30

22

PANEL_ODD4_N

2- PWM5

16

16

31

HLR GND

PANEL_ODD3_P

31

21

PANEL_ODD3_P

2- PWM6

17

17

GND

10

32

HLR OPT_SENS

PANEL_ODD3_N

32

20

PANEL_ODD3_N

2- PWM7

18

18

4-PWM8

28

NC

1- 821- 139- 11

RFRC module

15

11

33
34

GND

HLR STBY_3.3V

GND

HLR 3.3V

22

28

33

51pin FFC

30

24

19

LD - TC - Harness
TCON - LD

LED_ON
LD_STDBY

FAIL

6
7
9

NC
12V

GND

10

10

NC

VLED_MPC

11

11

GND

PANEL_EVEN0_P

2- PWM1

12

12

NC

PANEL_EVEN0_N

2- PWM2

13

NC

GND

GND

2- PWM8

13

56pin FFC

19

19

TCON_VCC
NC
NC

4-PWM7

PANEL_ODD_CLK_P

34

18

PANEL_ODD_CLK_P

GND

20

20

4-PWM6

RESET

16

35

SW POWER_KEY

PANEL_ODD_CLK_N

35

17

PANEL_ODD_CLK_N

LD_TYPE

21

21

4-PWM5

RFRC module

GND

17

36

SW_KEY

GND

36

16

GND

3- PWM1

22

22

4-PWM4

2b- 1/ 2b- 2/ 2b- 3/ 3a- 1/ 3a- 2/ P- 1

RX

13

37

SW GND

PANEL_ODD2_P

37

15

PANEL_ODD2_P

3- PWM2

23

4-PWM3

only Japan

SYNC

PANEL_EVEN2_P

14

38

HMS DET / SONY LOGO

PANEL_ODD2_N

38

14

PANEL_ODD2_N

24

4-PWM2

12

39

HMS 5V / LOGO 5V

PANEL_ODD1P

39

13

PANEL_ODD1P

3- PWM4

25

25

4-PWM1

40

HMS GND/ LOGO GND

PANEL_ODD1_N

40

12

PANEL_ODD1_N

3- PWM5

26

26

PANEL_ODD0_P

41

11

PANEL_ODD0_P

3- PWM6

27

27

GND

PANEL_ODD0_N

42

10

PANEL_ODD0_N

3- PWM7

28

28

3-PWM8

GND

43

GND

3- PWM8

29

GND

1-821-146-11

CN9006
HEADER ASSENBLY 40P

Wifi module
(US & EU deri 40 Only)

R3 or RU board

GND

29

3-PWM7

44

GND

30

30

3-PWM6

Panel_Ct rl13

45

GND

GND

31

31

3-PWM5

GND

46

NC

4- PWM1

32

32

3-PWM4

STBY3.3V

PANEL_VCC_SW

47

PANEL_VCC_SW

4- PWM2

33

33

3-PWM3

GND

20

RS232_RXD

PANEL_VCC_SW

48

PANEL_VCC_SW

4- PWM3

34

34

3-PWM2

WIFI VCC

23

RS232_TXD

PANEL_VCC_SW

49

PANEL_VCC_SW

4- PWM4

35

35

3-PWM1

WIFI USB_P

19

SIRCS_OUT

PANEL_VCC_SW

50

PANEL_VCC_SW

4- PWM5

LD_TYPE

WIFI USB_M

21

SIRCS_IN

PANEL_VCC_SW

51

PANEL_VCC_SW

WIFI GND

18

GND

SM05B-GHS-TB

CN9005

1-819-334-11

6pin connector 182113311

SPEAKER
Front
Rch

24

GND

36

36

4- PWM6

37

37

GND

CN2001

4-PWM7

38

38

2-PWM8

1- 842- 547- 11

4-PWM8

39

39

2-PWM7

GND

40

40

2-PWM6

NC

41

41

2-PWM5

NC

42

42

2-PWM4

TCON_VCC 43

43

2-PWM3

FFC Direct in Connector


JAE

SPEAKER
Front
Lch

3- PWM3

23

TX
VDD
JAM SYT10-06-WL-ET

L+ (Fasten # 187)

L- (Fasten #110)

R- (Fasten # 110)

R+ (Fasten # 187)

STBY3.3V

RS232_RXD

RS232_TXD

SIRCS_IN

SIRCS_OUT
GND
CN101

5
6

L+

NC

44

44

NC

45

45

GND

46

46

L-

NC

47

47

R-

12V

48

48

R+

Housing Speaker Connect or


2.0ch: 4pin MOLEX 502439-040 2.0ch: CN4601 4pin 1-821-614-11 MOLE X 502494-0470

4
5

0-844-179-01

GND
PANEL_EVEN4_P

18

-OUT3
-OUT4

JST SM05B-PASS-TBT

39

GND

1
2

NC

CN1003

38

LVDS-FFC
B-PEL3

-OUT1
-OUT2

2-PWM2
2-PWM1
VLED_MPC
GND
1-PWM8

NC

49

49

1-PWM7

LD_STDBY

50

50

1- PWM6

LED_ON

51

51

1- PWM5

FAIL

52

52

1- PWM4

REF

53

53

1-PWM3

BL_TYPE1

54

54

1-PWM2

55
56

55
56

1-PWM1

BL_TYPE2
BL_TYPE3

GND

1
2
3
4
5
6

G-B Harness

[3a-2 37,40 1/2]

182018311

Figure 3-9. CONNECTOR DIAGRAM FOR KDL-40EX620/40EX621 ONLY (1 OF 2)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 29

SECTION 3 - CHASSIS OVERVIEW


(NOTE: 37 model not available)
HEM2 Board

12V

3D Emit t er

12V

3a- V

GND

Except EX720 Model

GND

4
5

EMI_FAIL

NC

T- con Board(PEL3)

GLS_CTRL
GLS_CTRL2

1-821-135-11

NC

NC

NC

12V
GND

NC

GND

12V

SM04B-PASS-TBT(LF)(SN)
1- 819- 460- 11
CN6704 (37" G10A)
CN6151 (40" G4B)

SJM20-28WLB

To B board (100106)

T- con
Option

12V

12V

28

NC

GND

27

NC

T-CON_VCC12V

26

NC

GND

25

NC

GLS_CTRL

T-CON_VCC_12V To B

24

GLS_CTRL2

GND

23

NC

EMI_FAIL

BDR_ASU_12V

22

NC

GND

21

NC

BDR_ASU_12V

20

NC

GND

19

NC

REG12V
GND

REG12V
GND

AU_12V

B board

T- con

T-CON_Vcc12V

18
17
16
15

GND
10

14

8
6

AU_12V

12

AU_GND

11

B board

10

STBY_+3.3V

UARTD_TX

1
2

12

AUDIO+12.5V

UARTD_RX

14

AUDIO+12.5V

RESET

11

AUDIO+12.5V_GND

STBY_+3.3V

13

AUDIO+12.5V_GND

MODE_TVM

STBY3.3V

10

10

15

REG+12.5V_GND

UARTA_RX

GND

17

REG+12.5V_GND

NC (MD2)

16

REG+12.5V

UARTC_RX

18

REG+12.5V

UARTC_TX

10

24

T- CON_VCC

GND

11

UARTA_TX

12

T-CON_ON
AC_OFF_DET

8
7

BL_ERR

3
9

NC

NC

NC

NC

PFC_ON

NC

NC

POWER_ON

NC

BAT- V board

13

GND

JST SM08B- GHS- TB


1-819-468-11

AU_GND

GND

CN6001

1- 842- 569- 11

ECS_MATRIX

13

HEADER ASSEMBLY FOR PWB 10P

STBY_+3.3V

14

MODE_PEM

15

PEM_LOG_RX

16

AC_OFF_DET

PEM_LOG_TX

17

POWERON

GND

18

BL_ERR

CN9004

NC

1-774-667-51

NC

TL-EX1 Connector,FFC/FPC 18P

NC
NC

6
5

NC

NC

TCON_ON

PFC_PWR

GND

3
9

TL- EX1JIG board

CN6002
1- 842- 559- 11

VLED_VCC

VLED_VCC

VLED_VCC

NC

VLED_VCC

NC

BLK Board

BLK board

VLED_VCC

VLED_VCC

NC

NC

VLED_GND

NC
NC

NC

NC

VLED_GND

NC

VLED_GND

VLED_GND

VLED_GND

VLED_GND

VLED_GND

10

VLED_GND

VLED_GND

10

11

LD_ERR

11

NC

10

NC

NC

12

NC

13

11

GL_CTRL

GL_CTRL

13

11

14

12

LED_ON

LED_ON

14

CN6801 (40" G4B)

12

LD_ERR

CN1002

0-844-177-01

CN6705 (32" G10A)

1-822-339-11

JST

JST XA 14P

SM12B-PBVSS-TB(LF)(SN)

AC_IN
AC-N

AC-L

CN6001
SFP79-02WLB JAM

AC pigtail

[3a-2 37,40 2/2]

1-822-908-11

Figure 3-10. CONNECTOR DIAGRAM FOR KDL-40EX620/40EX621 ONLY (2 OF 2)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 30

SECTION 3 - CHASSIS OVERVIEW


HMS3 board

BAT- V board

T- con Board(PEL3)

JAM 3pin Straight


1

40

BD USB GND

Panel_Ct rl1 / NC

51

Panel_Ct rl1 / NC

Mot ion Sensor

MOTION_SENS

38

BD VBUS

Panel_Ct rl2 / TCON_RDY

50

Panel_Ct rl2 / TCON_RDY

3a- X/ V/ 2

REG+5V

39

BD USB_P

C 3
Panel_Ctrl3 / T_TD_HSYN

49

Panel_Ct rl3 / T_TD_HSYNC

P-1/2

1- 821- 130- 11

BD GND

Panel_Ct rl4 / X_FRC_RST

48

NC

BD USB_N

Panel_Ctrl5 / LR_FLAG(For

47

Panel_Ct rl5 / LR_FLAG

SW module

GND

37

SW module

POWER_INT

35

ALL

KEY1

36

1- 822- 693- 11

HLR board
HLR2
board

BLK Board

To BAT

GND

BV - H Harness
H-B

STBY+3.3V

33

BD USB SPDIF

BD EJ ECT/ BDR ON

Panel_Ct rl7 / SETON2(NC)

45

NC

BD DISC1/ BDR GPIO1

Panel_Ct rl8 / PANEL_SEL

Panel_Ct rl6 / SA_MODE

44

NC

46

BD DISC2/ U_DL_STAT

10

BD UART Tx/ BDR KEY1

Panel_Ct rl10 / T_TD_VSYN

10

42

Panel_Ct rl10 / T_TD_VSYNC

11

BD UART Rx/ BDR KEY2 / HLR DEVICE_SDA

Panel_Ct rl11 / SDA

11

41

Panel_Ctrl11 / SDA

12

BDR STBY_+3.3V

Panel_Ct rl12 / SCL

12

40

Panel_Ct rl12 / SCL

LVDS-FFC
B-PEL3

GND

CN11 FFC 56pin

BDR UART_Rx/ RF_UART_RX

PANEL_EVEN4_P

14

38

PANEL_EVEN4_P

1-822-905-11

PANEL_EVEN4_N

15

37

PANEL_EVEN4_N

GND

16

BDR GPIO0/ RF_RST

PANEL_EVEN3_P

16

36

PANEL_EVEN3_P

1- PWM1

35

PANEL_EVEN3_N

+OUT1

04-6802-656-000-883 +

1- PWM2

2
3

+OUT2

BL_TYPE3

BL_TYPE2

BL_TYPE1

LED/ IR/ RGB Sensor/ OPT_Sensor

GND

31

18

WIFI GND

GND

18

34

GND

1- PWM3

REF

2b- 3

LED_REC

29

19

WIFI USB_P

PANEL_EVEN_CLK_P

19

33

PANEL_EVEN_CLK_P

1- PWM4

FAIL

3a- V

LED_STBY

27

20

WIFI GND

PANEL_EVEN_CLK_N

20

32

PANEL_EVEN_CLK_N

1- PWM5

3a- 2

LED_TIMER

25

21

WIFI USB_N

GND

21

P- 1

LED_POWER

28

NC

22

WIFI GND

PANEL_EVEN2_P

22

LED_PIC_MUTE

P- 2

DEVICE_SDA/GND

30
8

DEVICE_SCL/LED_BDR
OPT_SENS

NC

NC

10

32

VD+3.3V

11

34

SIRCS

12

26

SYNC
RESET

16

23

1- PWM6

1- PWM7

29

PANEL_EVEN2_N

1- PWM8

LD - TC Harness
TCON - LD

LED_ON

LD_STDBY

8
9

24

28

PANEL_EVEN1P

GND

10

10

NC

PANEL_EVEN1_N

25

27

PANEL_EVEN1_N

VLED_MPC

11

11

GND

12

26

HLR SIRCS

PANEL_EVEN0_P

26

26

PANEL_EVEN0_P

2- PWM1

12

12

NC

28

PANEL_EVEN0_N

HLR LED_STBY
HLR LED_POWER

GND

27
28

25
24

PANEL_EVEN0_N
GND

2- PWM2
2- PWM3

13

56pin FFC

14

13
14

HLR LED_REC

PANEL_ODD4_P

29

23

PANEL_ODD4_P

2- PWM4

15

15

NC

HLR LED_PIC_MUTE

PANEL_ODD4_N

30

22

PANEL_ODD4_N

2- PWM5

16

16

NC

31

HLR GND

PANEL_ODD3_P

31

21

PANEL_ODD3_P

2- PWM6

17

17

GND

32

20

PANEL_ODD3_N

2- PWM7

HLR OPT_SENS

PANEL_ODD3_N

18

18

4-PWM8

33

HLR STBY_3.3V

GND

33

19

GND

2- PWM8

19

19

4-PWM7

11

34

HLR 3.3V

PANEL_ODD_CLK_P

34

18

PANEL_ODD_CLK_P

GND

20

20

35

SW POWER_KEY

PANEL_ODD_CLK_N

35

17

PANEL_ODD_CLK_N

LD_TYPE

21

21

22

22

4-PWM4

4-PWM6
4-PWM5

GND

17

36

SW_KEY

GND

36

16

GND

3- PWM1

2b- 1/ 2b- 2/ 2b- 3/ 3a- 1/ 3a- 2/ P- 1

RX

13

37

SW GND

PANEL_ODD2_P

37

15

PANEL_ODD2_P

3- PWM2

23

23

4-PWM3

only J apan

TX

14

38

HMS DET / SONY LOGO

PANEL_ODD2_N

38

14

PANEL_ODD2_N

3- PWM3

24

24

4-PWM2

VDD

12

39

HMS 5V / LOGO 5V

PANEL_ODD1P

39

13

PANEL_ODD1 P

3- PWM4

40

HMS GND/ LOGO GND

PANEL_ODD1_N

40

12

PANEL_ODD1_N

3- PWM5

1-821-146-11

WIFI VCC

20

3- PWM6

27

27

GND

PANEL_ODD0_N

3- PWM7

28

28

3-PWM8

HEADER ASSENBLY 40P

GND

43

GND

3- PWM8

29

29

3-PWM7

32

3-PWM4

33

33

3-PWM3
3-PWM2

RS232_RXD

PANEL_VCC_SW

49

PANEL_VCC_SW

4- PWM4

35

35

3-PWM1

RS232_TXD

PANEL_VCC_SW

50

PANEL_VCC_SW

4- PWM5

36

36

PANEL_VCC_SW

51

PANEL_VCC_SW

GND

18

37

37

4-PWM7

38

38

2-PWM8

1- 842- 547- 11

4-PWM8

39

39

2-PWM7

CN9005

FFC Direct in Connector

6pin connector 182113311

JAE

L+

LD_TYPE

4- PWM6

CN2001

GND

GND

40

40

2-PWM6

NC

41

41

2-PWM5

NC

42

42

2-PWM4

TCON_VCC 43

43

2-PWM3

NC

44

44

NC

45

45

2-PWM1

GND

46

46

VLED_MPC

NC

47

47

GND

12V

48

48

1-PWM8

NC

49

49

1-PWM7

LD_STDBY 50

50

1-PWM6

51

1- PWM5

LED_ON
1

32

4- PWM2

3-PWM5

4- PWM1

PANEL_VCC_SW

34

21

GND

34

3-PWM6

31

NC

4- PWM3

WIFI USB_M

R+ (Fasten # 187)

GND

PANEL_VCC_SW

SIRCS_IN

R- (Fasten # 110)

30

31

47

SM05B-GHS-TB

SPEAKER
Front
Rch

45

48

SIRCS_OUT

30

46

PANEL_VCC_SW
PANEL_VCC_SW

GND
GND

GND
STBY3.3V

44

Panel_Ct rl13

GND

L- (Fasten #110)

GND

PANEL_ODD0_P

10

19

L+ (Fasten # 187)

4-PWM1

11

42

1-819-334-11

SPEAKER
Front
Lch

26

41

PANEL_ODD0_N

3
5

25

PANEL_ODD0_P

1- 818- 692- 21

WIFI USB_P
WIFI GND

23

26

CN9006

Wifi module (US Only)


GND

25

51

CN1001
JST SM04B-PASS-TBT

NC

29
30

RFRC module

JAM SYT10-06-WL-ET

TCON_VCC

3
7

32

2
3

+OUT4

NC

PANEL_EVEN1P

HLR LED_ON_TIMER

27

+OUT3

12V

24
25

15

PANEL_EVEN2_N

HLR DEVICE_SCL

GND
PANEL_EVEN2_P

10

RFRC module

WIFI VBUS

31
30

NC

1- 821- 139- 11

23

51pin FFC

4
5

JST SM05B-PASS-TBT

BDR WAKEUP_STBY_MICON/ RF SEL

17

39

-OUT3
-OUT4
CN1000

KYOCERA ELCO

14

PANEL_EVEN3_N

13

1
2

CN1003

15

BDR GND

GND

-OUT1
-OUT2
NC

Panel_Ct rl9 / BINT

17

BDR UART_Tx/ RF UART_TX

43

PANEL FFC
SLCD : 96pin
SHARP : 80pin
AUO : ??pin
CMI :
32"~37" 60 pin
40"~55" 80pin

1
3

13

Panel_Ct rl6 / SA_MODE

NC
4

Panel_Ct rl9 / BINT

(For Asura)

2-PWM2

FAIL

52

52

1- PWM4

REF

53

53

1- PWM3

L-

BL_TYPE1

54

54

1-PWM2

R-

BL_TYPE2

55

55

1-PWM1

R+

BL_TYPE3

56

56

GND

Housing Speaker Connect or


2.0ch:4pin MOLEX 502439-0400 2.0ch:CN4601 4pin 1-821-614-11 MOLE X 502494-0470

G-B Harness
G-B

R3 or RU board

STBY3.3V

RS232_RXD

RS232_TXD

SIRCS_IN

SIRCS_OUT

GND

1
2
3

[3a-2 55 1/2]

4
5
6

CN101
182018311

Figure 3-11. CONNECTOR DIAGRAM FOR KDL-55EX620/55EX621 ONLY (1 OF 2)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 31

SECTION 3 - CHASSIS OVERVIEW


HEM2 Board

12V

3D Emit t er

12V

3a- V

GND

Except EX720 Model

GND

GLS_CTRL

GLS_CTRL2

[3a-2 55 2/2]
5

EMI_FAIL

NC

1-821-135-11

CN6101

T- con

To B board (100106)

T- con

Option

28

GND

27

T-CON_VCC12V

26

28

26

27

25

12V
12V
GND
GND

GND

25

T-CON_VCC_12V To B

24

NC

SM04B-PASS-TBT(LF)(SN)

GND

23

NC

1- 819- 460- 11

BDR_ASU_12V

22

NC

GND

21

NC

BDR_ASU_12V

20

NC

GND

19

NC

REG12V
GND

REG12V
GND

AU_12V

B board

T- con Board(PEL3)

SJM20-28WLB

T-CON_Vcc12V

18
17
16
15

14

13

AU_12V

12

AU_GND

11

B board

STBY3.3V

10

10

GND

AC_OFF_DET

8
7

BL_ERR

AU_GND

T-CON_ON

2
4

BAT- V board

NC

NC

NC

PFC_ON

NC

NC

POWER_ON

12V
12V

GND

GND

GLS_CTRL

GLS_CTRL2

EMI_FAIL

NC
J ST SM08B- GHS- TB
1-819-468-11

NC

3
4

10

10

STBY_+3.3V

12

GND

UARTD_TX

UARTD_RX

RESET

AUDIO+12.5V

STBY_+3.3V

14

AUDIO+12.5V

MODE_TVM

11

AUDIO+12.5V_GND

UARTA_RX

13

AUDIO+12.5V_GND

NC (MD2)

15

REG+12.5V_GND

UARTC_RX

17

REG+12.5V_GND

UARTC_TX

16

REG+12.5V

GND

18

REG+12.5V

UARTA_TX

T-CON_VCC

NC

8
9
10
11

ECS_MATRIX

13

CN6001

STBY_+3.3V

14

1-842-569-11

MODE_PEM

15

HEADER ASSEMBLY FOR PWB 10P

PEM_LOG_RX

16

PEM_LOG_TX
GND
7

AC_OFF_DET
POWERON

NC

NC

NC

NC

NC

NC

TL- EX1JIG board

12

17
18

CN9004
1-774-667-51
TL-EX1 Connector,FFC/FPC 18P

BL_ERR

TCON_ON

PFC_PWR

GND

CN6002
1-842-559-11

BLK Board

REG_12V

REG_12V

VLED_VCC

VLED_VCC

GND

GND

VLED_VCC

VLED_VCC

NC

1
3

NC

NC

NC

NC

BL_ERR

NC

NC

NC

VLED_GND

BL_ERR

NC
NC

NC

NC

NC

NC

NC

NC

NC

VLED_GND

AC_OFF_DET

VLED_GND

VLED_GND

6
8

VLED_GND

1-821-888-11

1-821-888-11

VLED_GND

JST L 7p CN6701

VLED_GND

VLED_GND

10

11

LD_ERR

11

NC

10

NC

NC

12

NC

13

11

GL_CTRL

GL_CTRL

13

11

14

12

LED_ON

14

12

PRI_VCC

PRI_VCC

PRI_GND

PRI_GND

1-817-207-11

1-817-207-11

JST

JST

PFC_GND

PFC_OUT

CN6601

PFC_GND

PFC_OUT

SFP79-02WLB JAM

10

LD_ERR

LED_ON
CN1002

0-844-177-01
1-822-339-11
JST XA 14P CN6700

JST

SM12B-PBVSS-TB(LF)(SN)

1-822-908-11 CN6600

SFP79-02WLB JAM
CN6501

BLK board

JST L 7p

CN6502

NC
AC_OFF_DET
CN6102

1-822-908-11
AC_IN
AC-N

AC-L

AC
AC pigtail
pigtail

CN6001
SFP79-02WLB JAM
1-822-908-11

Figure 3-12. CONNECTOR DIAGRAM FOR KDL-55EX620/55EX621 ONLY (2 OF 2)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 32

SECTION 4 - TROUBLESHOOTING

Self Diagnosis

Supported model

OVERVIEW
This chapter provides information regarding the Self Diagnosis
feature in our TVs.

UPDATING THE SOFTWARE


As mentioned in Section 2 - Software Requirements on page 17 there
are several issues that may be resolved by updating the software
to the latest version. For a list of possible correctable issues see
Examples of Software Correctable Symptoms on page 19.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 33

SECTION 4 - TROUBLESHOOTING
TRIAGE CHART
Use the Triage Chart to determine what may possibly be causing the error before going out to the customers location.
Before you make the service call

1. Confirm the symptom from the customer.


2. Select that symptom from the chart.
3. Bring all the boards listed for that symptom.

5. Chart Color Code


RED DOT: (Primary) Most likely defective part
BLUE Triangle: (Secondary) Possible defective part

4. Follow the associated flowcharts in the Training Manual to isolate the board.
Board Reference

MAIN BOARD
POWER SUPPLY BOARD

2X

3X

Power

Audio

4X

Protection Modes

Power

5X

6X**

6X*
BL

Temp

No RED
STBY LED
(Dead Set)

Balancer

TCON/HFR

BL

7X

8X

Video

Audio

No Video
(BL OK)

Distorted
Video
(BL OK)

No Audio
Main Speakers

HLR2
Switch Unit

LD
Service Bulletin
(See Appendix Section)

Software Update
LCD Panel
TCON

LVDS Cable
AC Outlet
Ventilation

*NOTE: REFER TO LCD PANEL SERVICE MANUAL IN REFERENCE LIBRARY


DATABASE FOR CORRECT REPLACEMENT PARTS BASED ON SERIAL NUMBER.

* Sharp Vertical or Horizontal Lines, Missing Pixels

* Immediate Shutdown After Power ON & 7X


6X** No Backlight before Shut OFF
6X* Momentary Backlight before Shut OFF

This Triage document is for general reference purposes. 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-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 34

SECTION 4 - TROUBLESHOOTING
PROTECTION SHUTDOWN

STANDBY LED FLASH COUNT

Self Diagnosis

Supported model

The models 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 to a probable source of
the problem.
A history of the errors is stored on the Self Check diagnostic page
as shown in Figure 4-3. Sample Self Check Diagnosis Page on
page 40. This page can be used to review the failure occurrence
data stored in memory to reveal past problems and how often these
problems occured. If there is more than one error, the standby LED
will identify the first of the problem areas. If the Self Check screen
displays a 0, no error has occurred.

Ambient Sensor/
(IR) Infrared Receiver

Picture Off /
Timer LED

Standby LED

Power LED

Figure 4-1. LED DISPLAY

2 times
5 times
LED ON 0.3 sec.
LED OFF 0.3 sec.

LED OFF
3 sec.

Figure 4-2. BLINK COUNT

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 35

SECTION 4 - TROUBLESHOOTING
2X Blink - Main Power Error
A 2X protection mode blink pattern can be activated due one of the
following defects.
Loss of REG12V (LVP)*
Loss of -125V (Single Line)
Excessive -125V Level (OVP)*
Loss of Power-ON Signal
Excessive PFC Voltage (OVP)
Excessive PFC Temperature (OTP)
*Low Voltage Protection (LVP)
*Over Voltage Protection (OVP)
A loss or excessive condition of the REG12VDC secondary voltage
from the main power supply IC6351 will cause a 2X blink pattern on
the standby LED. The 12Vdc can be checked at CN6704/pin 16.
If the measurement is 0V or rises above 12Vdc (approaches 15V)
before the TV shuts down the Power Supply Board is defective.
If approximately 12Vdc is present and remains below 12Vdc before
shutdown then further troubleshooting is necessary to determine the
defective component.
After confirming proper REG12V levels, check the Negative LED
Backlight supply levels. A loss or excessive condition of the negative
supply will cause a 2X blink failure. The voltage level can be checked
at CN6701/pins 1 & 3 before the TV shuts off. There will be 2 to 4
wires (Red & Blue) depending on the panel size. All individual wires
should be checked for proper voltage level. In normal operation the
voltage level will initially rise to approximately -175V and then should

regulate down to between 89V and 125V depending on the Backlight


adjustment in the User Menu. If one of the negative supplies is 0V
or rises above -175V before shut-off then the Power Supply Board is
defective, replace it to fix the problem.
A defective X-Reality processor on the Main Board or Switch circuit
on the Power Supply Board will cause a loss of the Power-ON signal
(2X). To determine which component is defective check the PowerON voltage level at CN6704/pin 1. In normal operation 3V should be
measured. If the 3V is present before shut-off then the Power Supply
Board is defective. If 0V is measured before shut-off then the Main
Board is defective.
Finally, there are PFC protection circuits on the Power Supply Board
that when activated will cause a 2X blink protection mode. The PFC
circuit is monitored for both over-voltage and over-temperature.
Therefore, if all the previously discussed circuits checkout okay,
there could still be a problem on the Power Supply Board in the PFC
circuit causing the 2X blink. Replacing the Power Supply Board will
fix the TV.
3X Blink- DC Regulator/Audio Error
The Audio error can occur due on of the following error conditions.
Defective DC Regulator on Main Board
Shorted or Damaged Speaker Connections
Defective Audio Amplifier (Main Board)
Loss of AU12V (Open F4200 on Main Board)
Loss of AU12V (Open Fuse on Power Supply Board)
The first thing to check when a 3X blink protection mode occurs is
the physical condition of the speakers and speaker connections. The
speakers should measure 8 ohms. Shorted speakers or connections
can cause a 3X blink protection mode.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 36

SECTION 4 - TROUBLESHOOTING
If the speakers and connections check okay, then the defective
component is on the Main Board. Either an open F4200, defective
DC Regulator, or defective Audio amplifier will cause a 3X blink
protection mode. In any of these cases, replace the Main Board to
fix this condition.

If a 6X blink pattern is activated then a defect has occurred in one of


the following areas.

A defect on the Power Supply Board can cause a 3X blink protection


mode and shut-off. Check the AU12V level at CN6704/pin 14. If 0V is
measure before shut-off the Power Supply Board is defective.

When troubleshooting a 6X backlight system failure it is key to notice


if the backlights illuminate before the TV shuts off. The following
list shows the possible backlight status and blink pattern and the
possible failed components.

4X Blink Balancer Error

Defective Panel LED(s)


Defective Power Supply

The 4X error code is only used on models incorporating local dimming


LED backlighting. If a failure occurs on the LD board the TV will shut
down and display this diagnostic code. Models using conventional
non-local dimming LED backlighting do not utilize this error code.

1)

Momentary Backlight and 6X

a) Defective LED(s) (LCD Panel Assb.)

2)

No Backlight and 6X

5X Blink - TCON Error

a) Replace Power Supply

The 5X blink protection mode indicates a communications error


between the TCON Board and the X-Reality microprocessor on the
Main Board. If the TCON is available for replacement, replace the
TCON. If the TCON is not available, the LCD panel must be replaced
since the TCON circuit is part of the LCD panel assembly. In rare
cases a loose or defective LVDS cable could also be the cause.

In most cases, if the Sony logo (Backlight) momentarily illuminates


and the TV shuts off and a 6X is activated than one or more of the
backlight LEDs are defective. The LCD Panel assembly panel must
be replaced for a defective LED. However, before replacing the LCD
panel assembly check for a complete loss of the Negative Backlight
(-89V to -125V) power supply. The -89V to -125V power supply can
be checked at CN6702/pins 1 & 3.

6X Blink - Backlight System Failure


NOTE: All models will make two attempts to power up before a 6X is
activated. The SONY logo (Backlight) may or may not display on the
screen. However, the splash tones will be heard two times. After the
second attempt the TV will turn off and the standby LED will blink a
6X protection mode. (Note: The splash tone may not be heard if it is
turned off or the volume is set to minimum.)

If there is no backlight before the TV shuts off and activates a 6X,


than check the Backlight ON signal from the TV microprocessor
and the Positive (+145V) Backlight power supply from the Power
Supply Board. The BL-ON signal can be checked at CN6704/pin 5
and the +145V at CN6701/pins 1 & 3.
If the Backlight-ON signal is okay and the Positive Power supply
is missing then the Power Supply Board is defective. However, if
the Backlight-ON is missing then the X-Reality Microprocessor is
defective and the Main Board must be replaced to repair the problem.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 37

SECTION 4 - TROUBLESHOOTING
7X Blink - Temperature Failure
These models do not display a temperature warning OSD dialogue
box before shutting off and going into a 7X standby LED blink pattern.
The main objective when a 7X blink pattern occurs is to determine
which of the following possible defects is causing the excessive
temperature condition indication.
Excessive Ambient Room Temperature
Dust or Debris Blocking the TV Ventilation Apertures
Defective Temperature Sensor or X-Reality Microprocessor
(Main Board)
The first step is to notice how long it takes the TV to shut off and
trigger a 7X blink protection mode.
If the TV has an actual excessive temperature condition it will
take a considerable period of time to shut off and indicate a 7X
blink protection mode. This is because it will take time for the TV
components to heat up and for the temperature sensor to detect the
excessive temperature and shut the TV off.

Check that all vented areas on the TV are clear of all dust
and debris.
If the TV shuts off immediately after Power-ON then one
of the following components has failed (Not an Actual
Excessive Temperature Condition).
X-Reality Microprocessor (Main Board)
Temperature Sensor (Main Board)
In either case the Main Board must be replaced to fix the
problem.
8X Blink Not listed in Self Check
8X blink code is mainly used during TV software
development. Look in TVs service SELF CHECK for error
code history and notice at the bottom of the list WDT (Watch
Dog Timer) error codes, in particular notice 103 HOST_WDT.

If the TV takes a considerable period of time to shut-off check the


following items:
The TV should not be located too close to any heating
devices.
The TV should have at least 4 inches of clearance around
the sides & rear, and 11 inches of clearance over the top to
ensure adequate ventilation.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 38

SECTION 4 - TROUBLESHOOTING
DIAGNOSTIC CODE DESCRIPTIONS
The Diagnostic Table provides an overview of the number of times the standby LED blinks and the possible location. To access the Triage
documents for the models listed in this manual, login into the Sony Authorized Servicer Portal at http://www.sony.com/asp.

Diagnostic item

Diagnostic item
Description

Number of times
Standby LeD blinks

MAIN_POWER

Main Power Error

DC_ALERT

DC Regulator/Audio Error

AUD_PROT

Audio Error Detection

BALANCER

Balancer Error

TCON ERR

TCON Error

P_ID_ERR

Possible Location
G4 Board (40" Models Only)
G5 Board (46" Models Only)
G6 Board (55" Models Only)
BATV Board
BATV Board
G4 Board (40" Models Only)
G5 Board (46" Models Only)
G6 Board (55" Models Only)

LCD Panel
BATV Board

TCON Control MT Board


BATV Board
G4 Board (40" Models Only)
G5 Board (46" Models Only)
G6 Board (55" Models Only)

Panel ID NVM Error

BACKLITE

Backlight Error

TEMP_ERR

Temperature Error

103 HOST_WDT

Watch Dog Timer Notification

LD Board
G8 Board (55" Models Only)
LCD Panel
BATV Board
Ventilation
BATV Board
Software Update
BATV Board

Figure 4-3. DIAGNOSTIC TABLE

NOTE: To provide information to customers regarding how to use their TV features or FAQs, refer the customer to the Sony esupport web site
at http://esupport.sony.com.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 39

SECTION 4 - TROUBLESHOOTING
VIEWING THE SELF CHECK DIAGNOSTIC HISTORY
It is possible to bring up past occurrences of a failure for confirmation
on the Self Check diagnostic history screen. This feature is useful for
failures which are intermittent or when the customer is not sure what
is causing the television to shut down.

1. TV must be in standby mode. (Power off).


2. Press the following buttons on the Remote Commander
within a second of each other:

DISPLAY

Channel 5

Volume -

POWER



* NOTE: This differs from accessing Service Adjustments Mode
(Volume +)
StandBy LED Flash Count
Diagnostic Item

----------------------------------------

-------------- -------------- 00
-------------- -------------- 00
-------------- -------------- 00

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

01
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00

Since the diagnostic results displayed on the screen are not


automatically cleared, always check the self-diagnostic screen after
you have completed the repairs to be sure you have cleared the
result display to 0.

1. To clear the Error history and Error count


0 .
press 8
RESETTING THE LCD PANEL OPERATING HOURS
The 3 sets of numbers displayed on the lower left corner of the screen
indicates the total accumulated operating hours of the television and
the operating hours of the LCD panel. Total operating hours is on the
left, boot count in the center and panel hours in the right group (The
center numbers are not used.)

1. To clear the LCD Panel operating hours of the LCD


0 .
Panel after replacing the panel, press 7

SELF CHECK
000 RGB_SEN
000 RESERVED
000 RESERVED
002 MAIN_POWE
003 DC_ALERT
003 AUD_PROT
004 BALANCER
005 HFR_ERR
005 TCON_ERR
005 P_ID_ERR
006 BACKLITE
006 VLED
007 TEMP_ERR
007 FAN_ERR
010 EMITTER
012 IA
101 VPC_WDT
102 MEPS_WDT
103 HOST_WDT
104 STBY_WDT

CLEARING THE SELF CHECK DIAGNOSTIC LIST

Error Count
(00-99)

EXITING THE SELF CHECK DIAGNOSTIC SCREEN


1. 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.

12345-00333-06789
Panel operation time by hour (MAX:65535)
Boot count (MAX:65535)
Total operation time by hour (MAX:65535)

Figure 4-3. SAMPLE SELF CHECK DIAGNOSIS PAGE

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 40

SECTION 5 - FLOW CHARTS AND DIAGRAMS


OVERVIEW
The following flow charts provide information to determine what repair parts to order based on the TV error.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 41

SECTION 5 - FLOW CHARTS AND DIAGRAMS


NO POWER
These voltage levels will vary slightly due
to panel size (40" Panel Levels shown).

55" Models
CN6102
CN6502
CN6501

1
2
1

12V
19V
400V

18
18

LCD Panel Assembly

CN6701
1

CN6601
CN6700

18

CN6600

14

LED-ON
24V

12
1

CN1001
CN1002

CN1000

G8

+109V
-61V to -82V

LD

LCD
PANEL

40", 46" Models


CN6001
110VAC

CN6801

1
14

24V

LED-ON

12

CN1001
CN1002

CN1000

AC
Input

LCD
Panel

LD
LED-ON &
BL Control
CN6151 (40",46")
CN6101 (55")

1
7
8
10

AC-OFF-Detect 3V
TCON-ON 3V
STBY 3.3V

12

AU12V

16

REG 12V

24

G4(40")
G5(46")
G6(55")

Power-ON 3V

TCON 12V

LED
Backlights

CN2001

8
9

CN6002

49

CN9006
39

10
8
3

CN6001

33

TCON
(120Hz)

TCON 12V
5V

STBY 3.3V

Motion Sensor
HMS3

IR Sensor
HLR2

BATV

Figure 5-1. POWER SUPPLY DIAGRAM

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 42

SECTION 5 - FLOW CHARTS AND DIAGRAMS


Power Error

Is
Standby LED
illuminate steady
RED?

Yes

Press Remote
Power Button

No

Confirm TV is
securely plugged into
an Active AC Outlet

Does the
Power LED
Light Green ?

OK

Is
110VAC Present
at CN6001 ?

No

Repair AC Outlet or
Replace AC-Power Cord

Yes

Initial Power-ON OK
Troubleshoot Video,
Backlight, Panel, or Audio
Problem

Yes
Check Main Fuse
F6101

Is Fuse
Open?

No

Yes

Replace
Power Supply
Board

Is
voltage
3.3V
Present ?
Yes

Does the
Power LED
Light?

Yes

Replace
Remote Batteries or
Remote

No

Replace
Main Board

No
Check STBY 3.3V
(In STBY Mode)

Press TV
Power Button

Check
AC-OFF-Detect
(In STBY Mode)
No

Replace
Power Supply
Board

Is
voltage
3.3V
Present ?

No

Replace
Power Supply
Board

Yes

Replace
Main Board

Figure 5-2. NO POWER

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 43

SECTION 5 - FLOW CHARTS AND DIAGRAMS


STANDBY LED BLINKING
Unit Shuts OFF
RED LED
Blinking

2X Blink Pattern
REG12V Error

Check REG12V
*Before Shutdown

Is voltage
12V
Present?

No

Replace
Power Supply
Board

Yes
Check Power-ON
*Before Shutdown

Is
voltage
3V
Present ?

No

Replace
Main Board

Yes

Replace
Power Supply
Board

Figure 5-3. 2 BLINK ERROR

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 44

SECTION 5 - FLOW CHARTS AND DIAGRAMS


Unit Shuts OFF
RED LED
Blinking

3X Blink Pattern
Audio Error
Check
Speakers &
Connections

Do
Speakers
Measure
8 ohms ?

No

Replace
Speaker(s)

Yes
Check AU12V
*Before Shutdown

Is voltage
12V
Present?

No

Replace
Power Supply
Board

Yes

Replace
Main Board

Figure 5-4. 3 BLINK ERROR

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 45

SECTION 5 - FLOW CHARTS AND DIAGRAMS


Unit Shuts OFF
RED LED
Blinking

4X Blink Pattern
(Balancer Error)
Replace
LCD Panel
Assembly

Is 4X still
occuring ?

Yes

Replace
Main Board

No

Problem
Solved

Figure 5-5. 4 BLINK ERROR

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 46

SECTION 5 - FLOW CHARTS AND DIAGRAMS


Unit Shuts OFF
RED LED
Blinking

5X Blink Pattern
TCON/HFR Error
Check LVDS connection
between
LCD Panel (TCON) & BATV Brds

Is
connection
OK?

No

Repair
Connection

Yes
Check
TCON 12V supply

Is
Yes
12V Present ?

Replace
TCON Board

No
Check TCON ON
Signal

Is
Yes
3V Present?

Replace
Power Supply
Board

No

Replace
Main Board

Figure 5-6. 5 BLINK ERROR

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 47

SECTION 5 - FLOW CHARTS AND DIAGRAMS


Unit Shuts OFF
RED LED
Blinking

Check +109V & -70V


LED Supplies
*Before Shutdown

6X Blink Pattern
(Backlight Error)
Is SONY logo
Displayed and
Tones Heard?

Are
all voltage
Present ?
Is
Backlight ON
Before Shut
Down?

No

Replace
LCD Panel
Assembly

No
Check 24V to LD-Board
*Before Shutdown

Yes

Replace
LCD Panel
Assembly

Is
Issue
Resolved ?

Yes

Is
voltage
24V Before
Shutdown?

Yes

Replace
LD-Board

No
No

Replace
Main Board

Check LED-ON to LD-Board


*Before Shutdown

Yes

Issue
Resolved

Is
voltage
3V Before
Shutdown ?

No

Replace
TCON-Board

Yes
Check Dimmer signal
*Before Shutdown

Is
voltage
1V to 3V Before
Shutdown?
Yes

No

Check for
Short

Replace
Main Board

Replace
Power Supply
Board

Figure 5-7. 6 BLINK ERROR

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 48

SECTION 5 - FLOW CHARTS AND DIAGRAMS


Unit Shuts OFF
RED LED
Blinking

7X Blink Pattern
Temperature Error

Yes

Does
unit Shut-Down
Immediately after
Power ON ?
No

Clear unit ventilation areas


and confirm adequate local
room temperature

Does unit still


shutdown (7X)?

No

Issue
Resolved

Yes

Replace
Main Board
Figure 5-8. 7 BLINK ERROR

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 49

SECTION 5 - FLOW CHARTS AND DIAGRAMS


NO PICTURE/NO SOUND
User Menu (XMB)

RF Input

IC1404
NTSC/ATSC
Tuner IC

NAND FLASH
User Data
White Balance
GAMMA

Video
Audio
Video
Audio

Video 1 (Composite)

Video
Audio

Video 2
(Component / Composite)

Video
Audio

PC Input

CN2001
Digital Video

From SPDIF Output


(Optical)
HDMI IN 1
(ARC)
HDMI IN 2
HDMI IN 3
HDMI IN 4

USB 2.0
USB 2.0
RJ45 (Ethernent)

IC5500
HDMI
Switch
&
EQ
(EDID)

Video
Audio

TCON 12V

IC9000
X-Reality
(HDCP)

Interface

Video
Audio

Interface

Video
Audio

Interface

Video
Audio

Service Mode

14
/
42

LVDS Cable
LCD Panel Assembly
TCON/HFR
(120Hz)

49

LCD Panel

LCD
Panel

LED Backlight
System

To HDMI 1 for
ARC Output
CN2700

SPDIF

Digital Audio
Output (Optical)

LR
IC4502
Audio OPAMP

J2702

Headphone/Analog
Audio Output

CN4602
LR
Audio

IC4601
Output
Amplifier

L
R

F4200
AU12V

BATV

Figure 5-9. VIDEO/AUDIO DIAGRAM

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 50

SECTION 5 - FLOW CHARTS AND DIAGRAMS


Missing or
Distorted Video

Is
Video Missing or
Distorted on All
Inputs?

Check External Device


and Connections
Swap Devices and
connections

No

Is
Yes
External Device
& connection OK?

No

Yes

Is
Video Missing
or Distorted ?

Repair External
Device

Distorted

Is
Distortion
Present in
User Menu
OSD ?

Missing

Can
User Menu be
Displayed ?

Yes

Replace
Main Board

No

Replace
Main Board

Yes

No
Sharp Horizontal
or Vertical Lines

Is
Single Pixels
or Complete Line
of Pixels
missing?

Skew (or Rock) the LVDS


connector from its socket
at the TCON Brd.

Are
Flashes
of color
displayed ?

Replace
Main Board

Yes
Yes

Replace
Main Board

No

Check LVDS cable


for Physical Damage

NG

Replace
LVDS Cable

Cable OK
Perform WIDE Mode Test

Replace
LCD Panel
Does
Distortion follow
picture size
when changing
WIDE mode?

No

Replace
TCON Board

Yes

Replace
Main Board

No

Replace
TCON Board

Figure 5-10. NO VIDEO ERROR

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 51

SECTION 5 - FLOW CHARTS AND DIAGRAMS


Missing or Distorted Audio

Is Audio
Missing or Distorted
on All Inputs?

No

Check External Device


and Connections
Swap Devices and
connections

Is
Yes
External Device
& connection OK?

Yes

No

Repair External
Device

Check
HP Audio Output

Is Audio
Present?

Replace
Main Board

No

Replace
Main Board

Yes

Check
Speaker Resistance at
(across Speakers)
& Connections

Check
AU12V from Power Supply

Is 12V
Present?
Yes

No

Replace
Power Supply
Board

8 ohms
&
Connections
OK?

No

Replace
Speaker(s)

Yes

Replace
Main Board

Figure 5-11. AUDIO ERROR

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 52

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


TABLE-TOP STAND ASSEMBLY REMOVAL
A Remove 3 screws from Table-Top Stand Assembly

Components not identified by a part number or


description are not stocked because they are seldom
required for routine service.
NOTE: The components identified by shading
and ! mark are critical for safety. Replace only
with part number specified.

* Items marked with an asterisk are not stocked since

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.

NOTE: Les composants identifies per un trame et


une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.

they are seldom required for routine service. Expect


some delay when ordering these components.

NOTE: The components identified by a red outline and a mark contain


confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

(Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues.)

A
5

B Lift up TV set to detach from Table-Top Stand Assembly


C Gently place the LCD TV set face down onto a soft cloth

REF. NO.

B
Soft Cloth

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]


1
4-267-497-01

2
4-259-180-02


2
4-259-183-02


2
4-259-186-02

STAND, HEAD(ML9)
NECK (ML9)
(KDL-40EX620/40EX621 ONLY)
NECK (L9)
(KDL-46EX620/46EX621 ONLY)
NECK (LL9)
(KDL-55EX620/55EX621 ONLY)


3
4-267-560-01


3
4-267-564-01


3
4-267-566-01

STAND, BASE(ML2)
(KDL-40EX620/40EX621 ONLY)
STAND, BASE(L2)
(KDL-46EX620/46EX621 ONLY)
STAND, BASE(LL2)
(KDL-55EX620/55EX621 ONLY)

REF. NO.

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]


4


5




4-259-541-01
USER SCREW ST
(SCREWS TO ATTACH HEAD STAND AND BASE STAND TO NECK)
2-580-608-01
SCREW, +PSW M5X16
(SCREWS TO ATTACH TABLE-TOP STAND TO LCD TV)
For product protection and safety reasons, Sony strongly recommends
that you use the screws provided with the TV
CAUTION: These screws cannot be used to secure the TV to
the Wall Mount Brackets

2-580-608-01
SCREW, +PSW M5X16
(SCREWS TO ATTACH TABLE-TOP STAND TO LCD TV)
For product protection and safety reasons, Sony strongly recommends
that you use the screws provided with the TV
CAUTION: These screws cannot be used to secure the TV to
the Wall Mount Brackets

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 53

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


NOTE: The components identified by shading
and ! mark are critical for safety. Replace only
with part number specified.

REAR COVER AND AC COVER REMOVAL


CAUTION: Do not damage the Power Board Connector and Power Supply Cord when removing the
Rear Cover. Refer to Appendix A - Removing the Rear Cover on page A-1 for complete instructions.

NOTE: Les composants identifies per un trame et


une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.

NOTE: The components identified by a red outline and a mark contain


confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

(Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues.)

A Remove screws from Rear Cover



4 from KDL-40EX620/40EX621 Only

6 from KDL-46EX620/46EX621 Only

14 from KDL-55EX620/55EX621 Only
B Remove screws from Rear Cover

2 from all models except KDL-55EX620/55EX621

4 from KDL-55EX620/55E621 Only
C Remove 1 screw and release clips from AC Cover to detach from Rear Cover

(Refer to Removing the Power Cord from the Rear Cover on page A-1 instructions)
D Remove 2 screws from Rear Cover
E Remove 1 screw from Terminal Area position
F Remove screws from Rear Cover

7 from All Models except KDL-46EX620/46EX621

5 from KDL-46EX620/46EX621 Only
G Gently lift up Rear Cover form bottom side to detach from Bezel

51

52
53

B
E

FROM ALL
MODELS
EXCEPT
KDL-55EX620/
55EX621
(KDL-55EX620/
55EX621 ONLY)

REF. NO.

F
G

PART NO.


51
4-275-420-02


51
4-275-413-02


51
4-268-007-02

DESCRIPTION

[ASSEMBLY INCLUDES]

REAR COVER(40)
(KDL-40EX620/40EX621 ONLY)
REAR COVER(46)
(KDL-46EX620/46EX621 ONLY)
REAR COVER (55 CAS) A
(KDL-55EX620/55EX621 ONLY)

REF. NO.

PART NO.

4-256-393-01
7-685-648-79
2-580-639-01
4-257-907-01
4-268-126-02
7-685-646-79

DESCRIPTION

[ASSEMBLY INCLUDES]

SCREW, +PSW M3X6 W12


SCREW +BVTP 3X12 TYPE2 IT-3
SCREW, +BVTP 4X12 TYPE2 IT-3
JOINT, STAND
SCREW, ORNAMENTAL M6X12
SCREW +BVTP 3X8 TYPE2 IT-3


52
4-265-028-01
LABEL(BAT-V REAR) (TERMINAL LABEL)

(KDL-55EX620/55EX621 ONLY)

(ORDER THIS PART WHEN REPLACING THE REAR COVER)

53
4-266-269-01
COVER, AC(M)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 54

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


NOTE: The components identified by shading
and ! mark are critical for safety. Replace only
with part number specified.

SWITCH UNIT AND SPEAKERS REMOVAL


A
B
D
D
E
F

Lift up Switch Unit and disconnect 1 connector to detach from Bezel


Lift up AC Power Cord and disconnect 1 connector to detach from LCD Panel
Remove 1 screw from right side Speaker (KDL-46EX620/46EX621 Only)
Slide-out right side Speaker to detach from Bezel
Remove 1 screw from left side Speaker (KDL-46EX620/46EX621 Only)
Slide-out left side Speaker to detach from Bezel

NOTE: Les composants identifies per un trame et


une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.

NOTE: The components identified by a red outline and a mark contain


confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

(Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues.)

102
103

101

102

F
B

E
REF. NO.

101
102

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]

1-489-582-11
1-858-594-12

SWITCH UNIT
LOUDSPEAKER (3X15CM)

REF. NO.

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]

103

1-838-797-11

POWER-SUPPLY CORD (WITH CONN.)

4-167-964-01

SCREW, +PWTP2 4X16

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 55

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


LD BOARD, HLR2 BOARD AND HMS3 BOARD REMOVAL
A


B
C
D
E
F

Remove screws and lift-up LD Shield to detach from LCD Panel


4 from 40EX620/40EX621 Only
2 from All Models except KDL-40EX620/40EX621
Disconnect 2 connectors and lift-up LD Board to detach from LCD Panel
Release clips and disconnect 1 connector to detach HLR2 Board from LED Guide
Remove 1 screw from HMS3 Board
Release clips and disconnect 1 connector to detach HMS3 Board from LED Guide
Lift up Frenel Lens to detach from HMS3 Board

NOTE: The components identified by shading


and ! mark are critical for safety. Replace only
with part number specified.

NOTE: Les composants identifies per un trame et


une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.

NOTE: The components identified by a red outline and a mark contain


confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

(Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues.)

154

153
152

151

C
REF. NO.

B
A

PART NO.


151
A-1796-818-A


151
A-1804-042-A


152
A-1792-877-A

153
A-1806-495-A
* 154
1-856-184-11

DESCRIPTION

[ASSEMBLY INCLUDES]

LD BOARD, MOUNTED
(KDL-40EX620/40EX621 ONLY)
LD BOARD, MOUNTED
(ALL MODELS EXCEPT KDL-40EX620/40EX621)
HLR2 BOARD, MOUNTED
HMS3 BOARD, MOUNTED
FRENEL LENS

REF. NO.

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]

2-990-421-41
7-685-646-79

SCREW (+PSW) (M3X6)


SCREW +BVTP 3X8 TYPE2 IT-3

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 56

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


G4/G5/G6/G8 (POWER SUPPLY) BOARD AND
BATV (MAIN) BOARD REMOVAL

NOTE: The components identified by shading


and ! mark are critical for safety. Replace only
with part number specified.

NOTE: Les composants identifies per un trame et


une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.

NOTE: The components identified by a red outline and a mark contain


confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

(Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues.)

NOTES:

To disconnect the LVDS Connector, refer to Handling the LVDS FFC Connector on page 3
instructions.

The Insulation Sheet (G10), Insulation Sheet (G4), Insulation Sheet (G7), and Side Jack Label
(Label BAT-V Mold Side) are not included with the LCD Panel and must be replaced when replacing
the LCD Panel.

201

KDL-40EX620/40EX621/46EX620/46EX621 ONLY
A
B
C

D

Remove 5 screws and disconnect 3 connectors from G4/G5 Board


Remove 5 screws from BATV Board
Disconnect 5 connectors from BATV Board
(Refer to Handling the LVDS FFC Connector on page 3 instructions)
Release 2 clips to detach Side Jack Bracket from BATV Board

202

203
204

REF. NO.

205

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]


201
4-256-435-11
LABEL (BAT-V MOLD SIDE) (SIDE JACK LABEL)

(ORDER THIS PART WHEN REPLACING THE LCD PANEL.)

202
4-265-828-01
BRACKET SIDE (BAT-V MOLD)
203
A-1814-572-B
BATV BOARD, COMPLETE

AFTER REPLACING THE MAIN BOARD OR THE LCD PANEL, YOU

MUST UPDATE THE SOFTWARE TO THE LATEST VERSION.

REF. NO.

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]


204
1-474-300-11
G4 BOARD, COMPLETE

(KDL-40EX620/40EX621 ONLY)

204
NA
G5 BOARD, COMPLETE

(KDL-46EX620/46EX621 ONLY)

FOR ALL POWER SUPPLY BOARD PART NUMBER INFORMATION

REFER TO THE LCD PANELS SERVICE MANUAL.

205
4-268-443-01
SHEET, INSULATION (G4)

2-990-421-41

SCREW (+PSW) (M3X6)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 57

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


KDL-55EX620/55EX621 ONLY
A
B
C
D

E

Remove 2 screws and disconnect 4 connectors from G8 Board


Remove 4 screws and disconnect 5 connectors from G6 Board
Remove 5 screws from BATV Board
Disconnect 5 connectors from BATV Board
(Refer to Handling the LVDS FFC Connector on page 3 instructions)
Release 2 clips to detach Side Jack Bracket from BATV Board

NOTE: The components identified by shading


and ! mark are critical for safety. Replace only
with part number specified.

NOTE: Les composants identifies per un trame et


une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.

NOTE: The components identified by a red outline and a mark contain


confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

(Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues.)

251
252

253

254

256

255

C
257

REF. NO.


251

252


253


254

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]

1-474-302-11
G8 BOARD, COMPLETE
4-268-445-01
SHEET, INSULATION (G7)
(ORDER THIS PART WHEN REPLACING THE LCD PANEL.)
4-256-437-01
LABEL (BAT-V METAL SIDE) (SIDE JACK LABEL)
(ORDER THIS PART WHEN REPLACING THE LCD PANEL.)
4-265-834-01
BRACKET SIDE (BAT-V METAL)

REF. NO.

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]

255
A-1814-572-B
BATV BOARD, COMPLETE

AFTER REPLACING THE MAIN BOARD OR THE LCD PANEL, YOU

MUST UPDATE THE SOFTWARE TO THE LATEST VERSION.

256
1-474-303-11
G6 BOARD, COMPLETE

257
4-268-443-01
SHEET, INSULATION (G4)

(ORDER THIS PART WHEN REPLACING THE LCD PANEL.)

2-990-421-41

SCREW (+PSW) (M3X6)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 58

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


NOTE: The components identified by shading
and ! mark are critical for safety. Replace only
with part number specified.

PANEL BRACKETS AND LCD PANEL REMOVAL


NOTES:

The LD Board is NOT included with the replacement LCD Panel.
Remove the LCD Board from the original LCD panel to use on the replacement LCD Panel.

To remove the LCD Panel from the Bezel, refer to Appendix C - Replacing the LCD Panel on page C-1.
instructions.

NOTE: Les composants identifies per un trame et


une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.

NOTE: The components identified by a red outline and a mark contain


confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

(Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues.)

A Remove 3 screws from Top Horizontal Panel Brackets



(KDL-55EX620/55EX621 Only)
B Lift up Top Horizontal Panel Brackets to detach from Bezel

2 from All Models except KDL-55EX620/55EX621

7 from KDL-55EX620/55EX621 Only
C Remove 2 screws from Side Vertical Panel Brackets

(KDL-55EX620/55EX621 Only)
D Lift up Side Vertical Panel Brackets to detach from Bezel

4 from KDL-40EX620/40EX621 Only

6 from KDL-46EX620/46EX621 Only

8 from KDL-55EX620/55EX621 Only
E Gently lift-up LCD Panel to detach from Bezel

305
301
304
305

302
B
A

303

REF. NO.

CLEANING THE LCD PANEL

CAUTION: When cleaning the TV, be sure to unplug the power cord to avoid any chance of electric shock.





Clean the cabinet of the TV with a dry soft cloth.


Wipe the LCD screen gently with a soft cloth.
Stubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water.
If using a chemically pretreated cloth, please follow the instruction provided on the package.
Never use strong solvents such as a thinner, alcohol or benzine for cleaning.
Periodic vacuuming of the ventilation openings is recommended to ensure to proper ventilation.

PART NO.


301
4-275-901-11


301
4-275-901-01


301
4-275-900-11


301
4-275-900-01


301
4-275-899-11


301
4-275-899-01

DESCRIPTION

BEZEL(40 CAS NON EM)


(KDL-40EX620 ONLY)
BEZEL(40 CAS NON EM)
(KDL-40EX621 ONLY)
BEZEL(46 CAS NON EM)
(KDL-46EX620 ONLY)
BEZEL(46 CAS NON EM)
(KDL-46EX621 ONLY)
BEZEL(55 CAS NON EM)
(KDL-55EX620 ONLY)
BEZEL(55 CAS NON EM)
(KDL-55EX621 ONLY)

[ASSEMBLY INCLUDES]

REF. NO.

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]


302
NA
LCD PANEL

NOTE: THE LD BOARD IS NOT INCLUDED WITH THE REPLACEMENT

LCD PANEL.

FOR ALL LCD PANEL AND TCON BOARD PART NUMBER

INFORMATION REFER TO THE LCD PANELS SERVICE MANUAL

303
4-266-012-01
BRACKET, PANEL (C)

(ALL MODELS EXCEPT KDL-55EX620/55EX621)

304
4-266-016-01
BRACKET, PANEL (H)

(ALL MODELS EXCEPT KDL-55EX620/55EX621)

305
4-266-019-01
BRACKET, PANEL (M)

(KDL-55EX620/55EX621 ONLY)

4-256-393-01

SCREW, +PSW M3X6 W12

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 59

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


NOTE: The components identified by shading
and ! mark are critical for safety. Replace only
with part number specified.

SCREWS
KDL-40EX620/40EX621

P/N

DESCRIPTION

REMARKS

2-580-608-01
4-256-393-01
7-685-648-79
2-580-639-01
4-257-907-01
4-268-126-02
2-990-421-41
4-167-964-01
7-685-646-79
4-259-541-01

SCREW, +PSW M5X16


SCREW, +PSW M3X6 W12
SCREW, +BVTP 3X12 TYPE2 IT-3
SCREW, +BVTP 4X12 TYPE2 IT-3
JOINT, STAND
SCREW, ORNAMENTAL M6X12
SCREW, (+PSW) (M3X6)
SCREW, +PWTP2 4X16
SCREW, +BVTP 3X8 TYPE2 IT-3
USER SCREW ST

TABLE-TOP STAND(3)
RC(4), AC COVER(1)
TERMINAL AREA(1)
RC(7)
RC(2)
RC(2)
BATV(5), G4B(5), LD(4)
NOT IN THIS MODEL
HMS3(1)
HEAD STAND to NECK(1), NECK to BASE STAND(2)

TOTAL

NOTE: Les composants identifies per un trame et


une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.

NOTE: The components identified by a red outline and a mark contain


confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

(Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues.)

3
5
1
7
2
2
14
0
1
3

KDL-46EX620/46EX621

P/N

DESCRIPTION

REMARKS

2-580-608-01
4-256-393-01
7-685-648-79
2-580-639-01
4-257-907-01
4-268-126-02
2-990-421-41
4-167-964-01
7-685-646-79
4-259-541-01

SCREW, +PSW M5X16


SCREW, +PSW M3X6 W12
SCREW, +BVTP 3X12 TYPE2 IT-3
SCREW, +BVTP 4X12 TYPE2 IT-3
JOINT, STAND
SCREW, ORNAMENTAL M6X12
SCREW, (+PSW) (M3X6)
SCREW, +PWTP2 4X16
SCREW, +BVTP 3X8 TYPE2 IT-3
USER SCREW ST

TABLE-TOP STAND(3)
RC(6), AC COVER(1)
TERMINAL AREA(1)
RC(5)
RC(2)
RC(2)
BATV(5), G5D(5), LD(2)
SPKR-L(1), SPKR-R(1)
HMS3(1)
HEAD STAND to NECK(1), NECK to BASE STAND(3)

TOTAL

3
7
1
5
2
2
12
2
1
4

KDL-55EX620/55EX621

P/N

DESCRIPTION

REMARKS

2-580-608-01
4-256-393-01
7-685-648-79
2-580-639-01
4-257-907-01
4-268-126-02
2-990-421-41
4-167-964-01
7-685-646-79
4-259-541-01

SCREW, +PSW M5X16


SCREW, +PSW M3X6 W12
SCREW, +BVTP 3X12 TYPE2 IT-3
SCREW, +BVTP 4X12 TYPE2 IT-3
JOINT, STAND
SCREW, ORNAMENTAL M6X12
SCREW, (+PSW) (M3X6)
SCREW, +PWTP2 4X16
SCREW, +BVTP 3X8 TYPE2 IT-3
USER SCREW ST

TABLE-TOP STAND(3)
RC(14), AC COVER(1), PNL BRKT(5)
NOT IN THIS MODEL
RC(7)
RC(2)
RC(4)
BATV(5), G6A(4), G8A(2), LD(2)
NOT IN THIS MODEL
TERMINAL AREA(1), HMS3(1)
HEAD STAND to NECK(1), NECK to BASE STAND(3)

TOTAL

3
20
0
7
2
4
13
0
2
4

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 60

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


NOTE: The components identified by shading
and ! mark are critical for safety. Replace only
with part number specified.

CONNECTORS

NOTE: Les composants identifies per un trame et


une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.

NOTE: The components identified by a red outline and a mark contain


confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.

(Check the Sony Authorized Servicer Portal at http://www.sony.com/asp website for any additional service related issues.)

KDL-40EX620/40EX621 ONLY

KDL-46EX620/46EX621 ONLY

KDL-55EX620/55EX621 ONLY

351
452

401
352

454

451

453

402

353

455

403
354

REF. NO.

*
*
*
*
*

351
352
353
354
355

404

355

PART NO.

DESCRIPTION

1-910-801-12
1-838-865-11
1-910-801-10
1-910-801-41
1-910-801-61

CONNECTOR ASSEMBLY 28P


(LVDS) FLEXIBLE FLAT CABLE N4 40S
CONNECTOR ASSEMBLY 14P
(LVDS) FLEXIBLE FLAT CABLE 56 PIN
HARNESS ASSEMBLY

456

[ASSEMBLY INCLUDES]

REF. NO.

*
*
*
*
*

401
402
403
404
405

405

PART NO.

DESCRIPTION

1-910-801-22
1-838-864-11
1-910-801-19
1-910-801-42
1-910-801-72

CONNECTOR ASSEMBLY 28P


(LVDS) FLEXIBLE FLAT CABLE N4 46S
CONNECTOR ASSEMBLY 14P
(LVDS) FLEXIBLE FLAT CABLE 56 PIN
HARNESS ASSEMBLY

457

[ASSEMBLY INCLUDES]

REF. NO.

458

PART NO.

DESCRIPTION

[ASSEMBLY INCLUDES]

*
*
*
*
*

451
452
453
454
455

1-838-919-11
1-838-920-11
1-910-801-45
1-910-801-30
1-910-801-33

CONNECTOR ASSEMBLY 2P
CONNECTOR ASSEMBLY 2P
CONNECTOR ASSEMBLY 7P
CONNECTOR ASSEMBLY 14P
CONNECTOR ASSEMBLY 28P

*
*
*

456
457
458

1-838-863-11
1-910-801-43
1-910-801-80

(LVDS) FLEXIBLE FLAT CABLE N4 55S


(LVDS) FLEXIBLE FLAT CABLE 56 PIN
HARNESS ASSEMBLY

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 61

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


ACCESSORIES AND PACKAGING




*

3-299-071-05
4-273-074-11
4-275-462-11
4-275-462-21
4-270-904-11

FLYER, SAFETY (ENGLISH VERSION)


FLYER, SAFETY (ENGLISH/FRENCH/SPANISH VERSION)
MANUAL, INSTRUCTION (ENGLISH VERSION)
MANUAL, INSTRUCTION (FRENCH VERSION)
SUPPLEMENT(STAND INSTALLATION)

MISCELLANEOUS

X-2560-379-1


X-2549-819-1


4-262-708-01

BAG, SCREW ASSEMBLY (L)


(ALL MODELS EXCEPT KDL-40EX620/40EX621)
BAG, SCREW ASSEMBLY (M)
(KDL-40EX620/40EX621 ONLY)
CLAMPER, CABLE


4-281-014-01



4-272-200-01

DOUBLE SIDED TAPE (PANEL 10)


(KDL-55EX620/55EX621 ONLY)
(ORDER THIS PART WHEN REPLACING THE LCD PANEL)
DOUBLE SIDED TAPE (PANEL)
(ALL MODELS EXCEPT KDL-55EX620/55EX621)
(ORDER THIS PART WHEN REPLACING THE LCD PANEL)


4-188-302-11

4-291-832-11


4-291-832-31


4-291-832-51

HEX WRENCH
LABEL, ENERGY GUIDE
(KDL-40EX620/40EX621 US ONLY)
LABEL, ENERGY GUIDE
(KDL-46EX620/46EX621 US ONLY)
LABEL, ENERGY GUIDE
(KDL-55EX620/55EX621 US ONLY)


4-100-136-01

4-256-454-02


4-279-121-11


4-256-443-01

SHEET (CORE), C
SPACER (G A)
(KDL-55EX620/55EX621 ONLY)
SPACER (GA) +C
(ALL MODELS EXCEPT KDL-55EX620/55EX621)
SHEET, RADIATION (BAT-L/V)


7-600-031-96


7-632-452-24

TAPE (3M 1350FW-1)15MMX66M WHT


(ALL MODELS EXCEPT KDL-55EX620/55EX621)
TAPE (NO.303) 18MMX35M YEL

OPTIONAL ACCESSORIES


X-2580-498-1
1-838-940-11
SU-WL500

SUPPORT BELT KIT


USB CABLE
WALL MOUNTING BRACKET

REMOTE COMMANDER

1-489-484-11

REMOTE COMMANDER (RM-YD063)

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 62

SECTION 6 - DISASSEMBLY/PART NUMBER INFORMATION


WIRE DRESSING
KDL-40EX620/40EX621 ONLY

Figure 6-1. KDL-40EX620/40EX621 OVERALL WIRE DRESSING

KDL-55EX620/55EX621 ONLY

Figure 6-3. KDL-55EX620/55EX621 OVERALL WIRE DRESSING

KDL-46EX620/46EX621 ONLY

Figure 6-2. KDL-46EX620/46EX621 OVERALL WIRE DRESSING

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 63

SECTION 7 - SERVICE ADJUSTMENTS


OVERVIEW
As mentioned in Section 2 - Software Requirements on page
17, the models in this manual utilize a generic type Main Board,
therefore certain service adjustments settings must be changed or
confirmed when either the Main Board, LCD Panel, or TCON Board
are replaced.

UPDATING THE SOFTWARE

ACCESSING SERVICE ADJUSTMENT


MODE
1. TV must be in standby mode. (Power off).
2. Access Service Mode by pressing the following buttons
on the Remote Commander within a second of each
other:

DISPLAY

Channel 5

Volume +

POWER

POWER

After replacing the Main Board, LCD Panel, or TCON Board, you
MUST UPDATE the SOFTWARE to the latest version. Instructions
for updating the software are included with the software package
on the Sony Authorized Servicer Portal at http://www.sony.com/asp
web site.

DISPLAY

5
VOLUME+

RM-YD063

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 64

SECTION 7 - SERVICE ADJUSTMENTS


3. The DIGITAL Service Menu displays.
NOTE: There are 3 Service Menus for this model,
DIGITAL, CHASSIS, and VPC. If the DIGITAL Service
Menu is not displayed, press JUMP or OPTIONS on the
Remote Commander.
DIGITAL

SERVICE

001 OP
000 VERS

---

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

Within each Service Menu are Categories and data information.

Category Name

Category Number
Item Number

CHASSIS
000
000

SERVICE
WYVERN
S2_NOISE_TH

32

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX
<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

Item Name

press JUMP
or OPTIONS

SERVICE
WYVERN
S2_NOISE_TH

Data Value

Figure 7-3. Service Data Definitions

Figure 7-1. Sample Digital Service Menu

CHASSIS
000
000

VIEWING OR CHANGING SERVICE DATA

32

Figure 7-2. Sample Chassis Service Menu

Use the buttons on the Remote Commander to review or change the


service data.

4. To change the Category, press 2 to move to the


next Category or press 5 to go back to the Previous
Category.
Note: Pressing 2 or 5 only changes the Categories
within the Service Menu displayed.
5. To change the adjustment item, press 1 to move to
the Next Item or 4 to go back to the Previous Item.
6. To change the Data Value, press 3 to increase the
Data Value or 6 to decrease the Data Value.
7. Press MUTING then press 0 to WRITE (Save) the
changes.
8. To exit service mode, press HOME or turn the TV
power off.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 65

SECTION 7 - SERVICE ADJUSTMENTS


UPDATING SERVICE ADJUSTMENT DATA
WHEN REPLACING THE MAIN BOARD
The following procedures must be performed after replacing the
Main Board and updating the software to ensure that the service
adjustment data is accurate.
If the following adjustments are not completed, some of the features
for the television will not be available.
Select the Segment Code
Select the Destination
Select the Model Name
Select the BU Trans
Add the Serial Number
Confirm Model ID and Product ID

SELECTING THE SEGMENT CODE


Before proceeding, update the software to the latest version. After
updating the software, go into Service Mode to select the correct
Segment Code data value.

1. TV must be in standby mode. (Power off).


2. Access Service Mode by pressing the following buttons
on the Remote Commander within a second of each
other:
POWER
DISPLAY
Channel 5
Volume +
DIGITAL

SERVICE

001 OP
000 VERS

---

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX
<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

3. Press 2 to move to the 002 MODEL category.


DIGITAL
002 MODEL
000 SEG

SERVICE
N7

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 66

SECTION 7 - SERVICE ADJUSTMENTS


4. Using the table, press 3 to increase the data value or
6 to decrease the data value, to select the correct
segment code data value.
ModelName

CodeName

KDL40EX620
KDL40EX620
KDL40EX621
KDL40EX621
KDL46EX620
KDL46EX620
KDL46EX621
KDL46EX621
KDL55EX620
KDL55EX620
KDL55EX621
KDL55EX621

3a2_No_3D
3a2_No_3D
3a2_No_3D
3a2_No_3D
3a2_No_3D
3a2_No_3D
3a2_No_3D
3a2_No_3D
3a2_No_3D
3a2_No_3D
3a2_No_3D
3a2_No_3D

Segment
Code
N7
N7
N7
N7
N7
N7
N7
N7
N7
N7
N7
N7

Region
CND
US
CND
US
CND
US
CND
US
CND
US
CND
US

5. Press MUTING then press 0 to WRITE (Save) the


changes.
DIGITAL
002 MODEL
000 SEG

SERVICE

When complete, the screen briefly indicates the


process is Done.
DIGITAL
002 MODEL
000 SEG

SERVICE
N7
DONE

6. Exit service mode by pressing HOME and then turn the


TV power off.
7. Cycle AC Power.
(Unplug and Plug AC Cord from the AC Outlet).
8. Wait a minute while lights flash, and initial setup screen
shows.
9. Proceed to Selecting the Destination.

SELECTING THE DESTINATION


The correct destination needs to be selected after replacing the Main
Board.
CAUTION: Selecting the incorrect destination may require replacing
the Main Board.

N7
WRITE

Verify before proceeding to the next step:


;; Selected the Segment Code

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 67

SECTION 7 - SERVICE ADJUSTMENTS


1. TV must be in standby mode. (Power off).
2. Access Service Mode by pressing the following buttons
on the Remote Commander within a second of each
other:
POWER
DISPLAY
Channel 5
Volume +
DIGITAL

SERVICE

001 OP
000 VERS

---

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX
<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

3. Press 2 to move to the 002 MODEL category.


4. Press 1 to move to the 001 DEST item.
DIGITAL
002 MODEL
001 DEST

SERVICE
U/C

5. Using the table, press 3 to increase the data value or


6 to decrease the data value, to select the correct
destination of the TV
MODEL

DESTINATION

DATA VALUE

CND
US
CND
US
CND
US

U/C
U/C
U/C
U/C
U/C
U/C

KDL-40EX620
KDL-40EX621
KDL-46EX620
KDL-46EX621
KDL-55EX620
KDL-55EX621

CAUTION: Verify the DESTINATION is set correctly


before proceeding to the next step. If another
destination Data Value is selected, it may possibly
corrupt the software which would require a Main Board
replacement.
6. Press MUTING then press 0 to WRITE (Save) the
changes.
DIGITAL
002 MODEL
001 DEST

SERVICE
U/C
WRITE

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 68

SECTION 7 - SERVICE ADJUSTMENTS


When complete, the screen briefly indicates the


process is Done.
DIGITAL
002 MODEL
001 DEST

SERVICE

9. If the correct model does not display, press 3 until the


model displayed matches the model of the TV.
10. Press MUTING then press 0 to WRITE (Save) the
changes.

U/C

DIGITAL
002 MODEL
002 MODELNAME

DONE

The correct model name needs to be selected after updating the


software.
Verify before proceeding to the next step:

When complete, the screen briefly indicates the


process is Done.
DIGITAL
002 MODEL
002 MODELNAME

;; Selected the Segment Code


;; Selected the Destination

KDL-40EX620
WRITE

7. Proceed to Selecting the Model Name.

SELECTING THE MODEL NAME

SERVICE

SERVICE
KDL-40EX620
DONE

8. Press 1 to move to the 002 MODEL item.


DIGITAL
002 MODEL
002 MODELNAME

SERVICE

11. Proceed to Selecting the BU Trans.

KDL-40EX620

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 69

SECTION 7 - SERVICE ADJUSTMENTS


SELECTING THE BU TRANS

This procedure is to copy the White Balance adjustment data from


the TCON Board to the Main Board. The BU Trans service item is
under the VPC service menu.

NOTE: If the message displays DATA TRANSFER NG


the transfer is not complete. If that occurs, repeat step
13 .
VPC
000
000

Verify before proceeding to the next step:


;; Selected the Segment Code
;; Selected the Destination

12. Press JUMP or OPTIONS on the Remote Commander


until the VPC menu displays.
SERVICE
DATA_COPY
BU_TRANS

13. To change the data value of the BU_Trans, press 3 to


increase the data value to 1.
VPC
000
000

SERVICE
DATA_COPY
BU_TRANS

DATA TRANSFER NG

;; Selected the Model Name

VPC
000
000

SERVICE
DATA_COPY
BU_TRANS

If successful, the data value changes to 3.


VPC
000
000

SERVICE
DATA_COPY
BU_TRANS

DATA TRANSFER SUCCESS

14. Verify the Data Transfer Success message displays.


15. Proceed to Adding the Serial Number.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 70

SECTION 7 - SERVICE ADJUSTMENTS


ADDING THE SERIAL NUMBER
The replacement board does not contain a serial number. Use the
following instructions to add the customers serial number.
CAUTION: The serial number can only be entered once. Please
make sure to enter the correct serial number for the customers TV.
Verify before proceeding to the next step:
;; Selected the Segment Code
;; Selected the Destination
;; Selected the Model Name
;; Selected the BU Trans

16. Locate the serial number for the TV on the side of the
Rear Cover of the TV.
MODEL NO
KDL-40EX620

17. Press JUMP or OPTIONS on the Remote Commander


until the DIGITAL menu displays.
DIGITAL

SERVICE

001 OP
000 VERS

---

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX
<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

18. Press 2 to move to the 002 MODEL category.


DIGITAL
002 MODEL
000 SEG

SERVICE
N7

SERIAL NO
3001318

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 71

SECTION 7 - SERVICE ADJUSTMENTS


19. Press 1 until the 003 SERIAL item displays.
DIGITAL
002 MODEL
003 SERIAL

SERVICE
---

CAUTION: The serial number can only be entered


once. Please make sure to enter the correct serial
number for the customers TV.
22. Using the remote commander, enter the serial number
of the TV.
NOTE: If the incorrect serial number is entered, press
to go back to the Serial Number input screen
and re-enter the correct serial number.

20. Press 0 to display the Serial Number Edit option.


DIGITAL (MODEL)
SerialNumberEdit

23. Press the select button


to WRITE (Save) the serial
number to the replacement Main Board.
DIGITAL (MODEL)
SerialNumberEdit

SERVICE

*1 SerialNumber

*1 SerialNumber

Please input serial number


(0000000-9999999)
3001318


21. Press the select button
Number input screen.
DIGITAL (MODEL)
SerialNumberEdit
*1 SerialNumber
Please input serial number
(0000000-9999999)
----------------

SERVICE

to display the Serial

SERVICE

WRITE

When complete, the screen indicates the process is


Done, then the serial number displays.
DIGITAL (MODEL)
SerialNumberEdit

SERVICE

*1 SerialNumber
3001318

DONE

24. Proceed to Confirming the Model ID and Product ID.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 72

SECTION 7 - SERVICE ADJUSTMENTS


CONFIRMING THE MODEL ID AND PRODUCT ID
After completing all of the service adjustment changes, verify that
the correct Model ID and Product ID displays in the Service menu.
Verify before proceeding to the next step:
;; Selected the Segment Code
;; Selected the Destination
;; Selected the Model Name
;; Selected the BU Trans
;; Added the Serial Number

25. Press 4 to move to the 001 OP category.


DIGITAL

SERVICE

001 OP
000 VERS

---

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX

26. Using the information provided in the Segment Code


table below, verify the Model ID and Product ID are
correct.
Model Name

Destination

LCD Panel Code

Model-ID

Product-ID

KDL-40EX620
KDL-40EX620
KDL-40EX620
KDL-40EX620
KDL-40EX620
KDL-40EX620
KDL-40EX621
KDL-40EX621
KDL-40EX621
KDL-40EX621
KDL-40EX621
KDL-40EX621
KDL-46EX620
KDL-46EX620
KDL-46EX620
KDL-46EX620
KDL-46EX621
KDL-46EX621
KDL-46EX621
KDL-46EX621
KDL-55EX620
KDL-55EX620
KDL-55EX621
KDL-55EX621

US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND

LTU400HF0301
T400HW04 V1
LTY400HF0901
T400HW05 V1
V400HK2-LE1
LTY400HF0902
LTU400HF0301
T400HW04 V1
LTY400HF0901
T400HW05 V1
V400HK2-LE1
LTY400HF0902
11SCT2L460
LTY460HJ0501
T460HW08 V2
V460H1-LE5
11SCT2L460
LTY460HJ0501
T460HW08 V2
V460H1-LE5
LTY550HJ0301
T546HW04 V1
LTY550HJ0301
T546HW04 V1

3D65E91F
3D65E920
3D65E91F
3D65E920
3D65E961
3D65E91F
3D65E91F
3D65E920
3D65E91F
3D65E920
3D65E961
3D65E91F
3D65E906
3D65E906
3D65E91E
3D65E952
3D65E906
3D65E906
3D65E91E
3D65E952
3D65E91C
3D65E91D
3D65E91C
3D65E91D

021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000

<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 73

SECTION 7 - SERVICE ADJUSTMENTS


DIGITAL
001 OP
000 VERS

SERVICE
---

Software Version

Model ID
Product ID
Panel ID

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX
<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

UPDATING SERVICE ADJUSTMENT DATA


WHEN REPLACING THE LCD PANEL
Before proceeding, update the software to the latest version. After
updating the software, go into Service Mode to make the appropriate
adjustments to the copy the data onto the panel.
Copy the BU Flash Data
Confirm Model ID and Product ID
Reset the Panel Operation Time

27. Exit service mode by pressing HOME and then turn the
TV power off.
28. Cycle AC Power.
(Unplug and Plug AC Cord from the AC Outlet).
29. Wait a minute while lights flash, and initial setup screen
shows.
30. TV update is complete.
The additional features of the TV now available.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 74

SECTION 7 - SERVICE ADJUSTMENTS


COPYING THE BU FLASH DATA
This procedure is to copy the White Balance adjustment data from
the TCON Board to the Main Board. The BU Flash service item is
under the VPC service menu.

1. TV must be in standby mode. (Power off).


2. Access Service Mode by pressing the following buttons
on the Remote Commander within a second of each
other:
POWER
DISPLAY
Channel 5
Volume +
DIGITAL

SERVICE

001 OP
000 VERS

---

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX

SERVICE
DATA_BAKUP
BU_FLASH

5. To change the data value of the BU_FLASH,


press 3 to increase the data value to 1.

<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

SERVICE
DATA_COPY
BU_TRANS

VPC
001
000

VPC
001
000

3. Press JUMP or OPTIONS on the Remote Commander


until the VPC menu displays.
VPC
000
000

4. Press 2 to move to the 001 DATA_BAKUP category


and the 000 BU_FLASH item.

SERVICE
DATA_BAKUP
BU_FLASH

NOTE: If the message displays DATA TRANSFER NG


the transfer is not complete. If that occurs, repeat step
5.
VPC
001
000

SERVICE
DATA_BAKUP
BU_FLASH

DATA TRANSFER NG
0

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 75

SECTION 7 - SERVICE ADJUSTMENTS


If successful, the data value changes to 3.


VPC
001
000

SERVICE
DATA_BAKUP
BU_FLASH

6. Verify the Data Transfer Success message displays.


7. Proceed to Confirming the Model ID and Product ID.

After completing all of the service adjustment changes, verify that


the correct Model ID and Product ID displays in the Service menu.
Verify before proceeding to the next step:
;; Copied the BU Flash Data

8. Press JUMP or OPTIONS on the Remote Commander


until the DIGITAL menu displays.
9. If necessary, press 4 to move to the 001 OP category.

SERVICE
---

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

DATA TRANSFER SUCCESS

CONFIRMING THE MODEL ID AND PRODUCT ID

DIGITAL
001 OP
000 VERS

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX
<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

10. Using the information provided in the Segment Code


table below, verify the Model ID and Product ID are
correct.
Model Name

Destination

LCD Panel Code

Model-ID

Product-ID

KDL-40EX620
KDL-40EX620
KDL-40EX620
KDL-40EX620
KDL-40EX620
KDL-40EX620
KDL-40EX621
KDL-40EX621
KDL-40EX621
KDL-40EX621
KDL-40EX621
KDL-40EX621
KDL-46EX620
KDL-46EX620
KDL-46EX620
KDL-46EX620
KDL-46EX621
KDL-46EX621
KDL-46EX621
KDL-46EX621
KDL-55EX620
KDL-55EX620
KDL-55EX621
KDL-55EX621

US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND
US/CND

LTU400HF0301
T400HW04 V1
LTY400HF0901
T400HW05 V1
V400HK2-LE1
LTY400HF0902
LTU400HF0301
T400HW04 V1
LTY400HF0901
T400HW05 V1
V400HK2-LE1
LTY400HF0902
11SCT2L460
LTY460HJ0501
T460HW08 V2
V460H1-LE5
11SCT2L460
LTY460HJ0501
T460HW08 V2
V460H1-LE5
LTY550HJ0301
T546HW04 V1
LTY550HJ0301
T546HW04 V1

3D65E91F
3D65E920
3D65E91F
3D65E920
3D65E961
3D65E91F
3D65E91F
3D65E920
3D65E91F
3D65E920
3D65E961
3D65E91F
3D65E906
3D65E906
3D65E91E
3D65E952
3D65E906
3D65E906
3D65E91E
3D65E952
3D65E91C
3D65E91D
3D65E91C
3D65E91D

021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000
021C0000

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 76

SECTION 7 - SERVICE ADJUSTMENTS


DIGITAL
001 OP
000 VERS

SERVICE
---

Software Version

Model ID
Product ID
Panel ID

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX
<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

11. Exit service mode by pressing HOME and then turn the
TV power off.
12. Cycle AC Power.
(Unplug and Plug AC Cord from the AC Outlet).
13. Wait a minute while lights flash, and initial setup screen
shows.
14. Proceed to Resetting the Panel Operation Time.

1. TV must be in standby mode. (Power off).


2. Press the following buttons on the Remote Commander
within a second of each other:
POWER
DISPLAY
Channel 5
Volume

* NOTE: This differs from accessing Service Adjustments Mode
(Volume +)
SELF CHECK
000 RGB_SEN
000 RESERVED
000 RESERVED
002 MAIN_POWE
003 DC_ALERT
003 AUD_PROT
004 BALANCER
005 HFR_ERR
005 TCON_ERR
005 P_ID_ERR
006 BACKLITE
006 VLED
007 TEMP_ERR
007 FAN_ERR
010 EMITTER
012 IA
101 VPC_WDT
102 MEPS_WDT
103 HOST_WDT
104 STBY_WDT

----------------------------------------

-------------- -------------- 00
-------------- -------------- 00
-------------- -------------- 00

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

01
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00

12345-00333-06789
Panel operation time

RESETTING THE PANEL OPERATION TIME


After completing all steps, reset the panel operation time from the
Self Check screen.
Verify before proceeding to the next step:
;; Copied the BU Flash Data
;; Confirmed Model ID and Product ID

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 77

SECTION 7 - SERVICE ADJUSTMENTS


3. To clear the LCD Panel operating hours of the LCD
0 .
Panel after replacing the panel, press 7
SELF CHECK
000 RGB_SEN
000 RESERVED
000 RESERVED
002 MAIN_POWE
003 DC_ALERT
003 AUD_PROT
004 BALANCER
005 HFR_ERR
005 TCON_ERR
005 P_ID_ERR
006 BACKLITE
006 VLED
007 TEMP_ERR
007 FAN_ERR
010 EMITTER
012 IA
101 VPC_WDT
102 MEPS_WDT
103 HOST_WDT
104 STBY_WDT

----------------------------------------

-------------- -------------- 00
-------------- -------------- 00
-------------- -------------- 00

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

01
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00

SETTING WHITE BALANCE ADJUSTMENTS


White Balance adjustment data is located on the Digital Service
Menu.

1. TV must be in standby Mode. (POWER off).


2. Press the following buttons on the Remote Commander
within a second of each other:
POWER
DISPLAY
Channel 5
Volume +

Panel operation time

OPTIONAL ADJUSTMENTS

All Sony TVs are set for optimal viewing performance. Refer to the
following instructions if the customer requests additional adjustments.

SERVICE

001 OP
000 VERS

---

<MAIN>
DM1.301W00AA
WF1.003W00AA
DF1.001W00AA
YM1.010W00AA
DB2.105W00AA
(DM1.301W00A)
DD1.016W00AA
WP0.521W00AA
MID:3D65E91F
PID:021C0000
PNL:LTU400HF0301
POP:X.XXX

12345-00333-00000
12345-00333-06789
-

4. Exit Self Check by pressing HOME and then turn the


TV power off.
5. Cycle AC Power.
(Unplug and Plug AC Cord from the AC Outlet).

DIGITAL

<EXT>
RF:01.05
WF:2.0.0.99
WF:0B
CAN:X.XXX
FDlXXXX
<PEM>
PM1.012W00LU
PB1.000W00LU
PL1.011J46LUX
PD1.011J46LUX

3. Press JUMP or OPTIONS on the Remote Commander


until the VPC menu displays.
VPC
000
000

SERVICE
DATA_COPY
BU_TRANS

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 78

SECTION 7 - SERVICE ADJUSTMENTS


4. Press 2 to move to 006 WB Category.
VPC
006
000

SERVICE
WB
R_DRV

128

5. To change the data value of the R_DRV, press 3 to


increase the value or 6 to decrease the value.
NOTE: The data value must be set between the range
1 to 255.
6. Press 1 to move to the next item (001 G_DRV).
7. To change the data value, press 3 to increase the
value or 6 to decrease the value.
8. Repeat steps 6 and 7 for each of the following items:
002 B_DRV
003 R_BKG
004 G_BKG
005 B_BKG
9. To save the changes, press MUTING then press 0 .
10. To exit service mode, press HOME or turn the TV
power off.

RESETTING THE TV TO FACTORY


CONDITION
Use the following instructions to restore the User Adjustments and
Channel Memory settings to the preset factory conditions.

1. Turn the TV On by pressing POWER .


2. While holding down the on the Remote Commander,
press the POWER button on the side of the TV.

3. The set restarts and displays the Initial Setup screen.


This may take several minutes.

RESETTING THE TV TO FACTORY CONDITION


USING SERVICE MODE
1. TV must be in standby Mode. (POWER off).
2. Press the following buttons on the Remote Commander
within a second of each other:
POWER
DISPLAY
Channel 5
Volume +
3. If necessary, press JUMP or OPTIONS to go to DIGITAL
mode.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 79

SECTION 7 - SERVICE ADJUSTMENTS


4. Press the following buttons on the Remote Commander
within a second of each other:
0 .
Press 8
MUTING
SERVICE changes to green RST.
RST executes the command and displays EXE.
EXE-RST displays green, then red indicating the TV is
writing the data.
5. When the process is complete the green SERVICE text
displays and the LED display as shown below:

TIMER

Standby

POWER

6. Cycle AC Power
(Unplug and Plug AC Cord from the AC Outlet).
The set restarts and displays the Initial Setup screen.
This may take several minutes.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 80

is a trademark of Sony Electronics


Reproduction in whole or part without written permission is prohibited. All rights reserved
Sony Corporation
9-888-391-02

Sony Technology Center


Technical Services
Service Publication Department

English
2011BJ74WEB-1
Printed in USA
2011.2

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 81

APPENDIX A - REMOVING THE REAR COVER


REMOVING THE POWER CORD FROM THE
REAR COVER

4. Gently start to lift the Rear Cover to detach it from the


Bezel.

The AC Power Cord is connected to the Power Supply Board and


then routed out through the Rear Cover. When removing the Rear
Cover use caution to avoid pulling the AC Power Cord which may
damage the cord.

Caution: These instructions should be followed whenever


removing the Rear Cover.

KDL-40EX620/40EX621 ONLY
1. Using the instructions provided in the Rear Cover and
AC Cover Removal on page 54, remove the screws from
the Rear Cover.
2. Remove 1 screw from AC Cover.
3. Using the illustration to locate the clips that secure the
Rear Cover to the Bezel, gently start to lift the Rear
Cover to detach it from the Bezel.

5. Continue pulling the Rear Cover up from the Bezel one


section at a time.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 A-1

APPENDIX A - REMOVING THE REAR COVER


6. Lift up Rear Cover with AC Cover and AC Power Cord
attached.
NOTE: Hold AC Power Cord while lifting up Rear
Cover. Do not pull the AC Power Cord or damage the
connector on the Power Board.

8. Release the clips on the inside of the rear cover to


detach the AC Cover.

7. Disconnect the AC Power Cord to detach from Power


Supply Board.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 A-2

APPENDIX A - REMOVING THE REAR COVER


KDL-46EX620/46EX621 ONLY
1. Using the instructions provided in the Rear Cover and
AC Cover Removal on page 54, remove the screws from
the Rear Cover.
2. Remove 1 screw from AC Cover.
3. Using the illustration to locate the clips that secure the
Rear Cover to the Bezel, gently start to lift the Rear
Cover to detach it from the Bezel.

4. Gently start to lift the Rear Cover to detach it from the


Bezel.

5. Continue pulling the Rear Cover up from the Bezel one


section at a time.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 A-3

APPENDIX A - REMOVING THE REAR COVER


6. Use care when lifting the Rear Cover from the Bezel by
the Terminal Area.
HINT: Support the Rear Cover by placing your hand
above the screw hole on the Rear Cover.

8. Disconnect the AC Power Cord to detach from Power


Supply Board.

9. Release the clips on the inside of the rear cover to


detach the AC Cover.
7. Lift up Rear Cover with AC Cover and AC Power Cord
attached.
NOTE: Hold AC Power Cord while lifting up Rear
Cover. Do not pull the AC Power Cord or damage the
connector on the Power Board.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 A-4

APPENDIX B - ATTACHING THE REAR COVER


REATTACHING THE REAR COVER TO THE
BEZEL
The following instructions provide additional information for
reattaching the Rear Cover to the LCD Panel.

KDL-46EX620/46EX621 ONLY
1. Gently place the LCD Panel face down onto a soft
cloth.
2. Re-attach the Rear Cover.

KDL-40EX620/40EX621 ONLY
1. Gently place the LCD Panel face down onto a soft
cloth.
2. Re-attach the Rear Cover.
3. Using the illustration below, ensure that the Rear Cover
is securely attached by aligning the slots on the Rear
Cover with the clips on the Bezel and then press the
Rear Cover onto the Bezel.

3. Using the illustration below, ensure that the Rear Cover


is securely attached by aligning the slots on the Rear
Cover with the clips on the Bezel and then press the
Rear Cover onto the Bezel.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 B-1

APPENDIX C - REPLACING THE LCD PANEL


REMOVING THE LCD PANEL FROM THE
BEZEL

NOTE: A flat head screw driver can be used to remove


the brackets.

The LCD Panel is adhered to the Bezel using double sided tape.
When replacing the panel, you should also replace the tape.

Caution: These instructions should be followed whenever


separating the LCD Panel from the Bezel.
1. Using the instructions provided in Rear Cover and AC
Cover Removal on page 54 remove the rear cover, all of
the boards, and connectors.
CAUTION: To avoid damaging the panel and bezel,
always lay the TV with the bezel face down on the cloth
to pull the panel off of the bezel. Placing the panel face
down on the cloth and attempting to pull the bezel off of
the panel may cause damage to the panel.
2. Remove the Panel Brackets.

Panel Bracket

3. Remove the HMS3 Board and the HLR2 Board.


NOTE: The LED Bracket is part of the bezel assembly.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 C-1

APPENDIX C - REPLACING THE LCD PANEL


4. Placing one hand between the LCD Panel and the
bezel, gently start to lift the panel away from the bezel.
Lift up by
holding the
portion of
the panel.
DO NOT
hold onto
the LCD cells

REATTACHING THE LCD PANEL ONTO


THE BEZEL
The double-sided tape used to adhere the LCD Panel to the Bezel
should be replace whenever the panel or the bezel is replaced.

1. Place the replacement bezel face down on a soft cloth.


2. Ensure that all of the original tape has been removed
from the LCD panel and the bezel.

5. Continue the process until the panel is removed from


the bezel.
Lift slowly
removing
one section
at a time.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 C-2

APPENDIX C - REPLACING THE LCD PANEL


3. Using the following illustrations, place the double-sided
tape onto the bezel.
40

40 models use 2 pieces

4. Place the top of the LCD Panel onto the bezel.


a. Adjust the right and left side so the panel fits
securely onto the bezel.
b. Slowly place the bottom of the panel within the
bezel.

46

5. Ensure the panel is securely placed inside the bezel.

46 models use 3 pieces

55 models use 3 pieces

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 C-3

APPENDIX D - REAR COVER CAUTION


Refer to the following illustration when handling the Rear Cover for the KDL-55EX620/55EX621 Models.

Handle the
Rear Cover
using these
areas.
Areas with
yellow have
sharp edges.
Use caution
with these
areas.
Areas with red
have sharp
edges and are
not
reinforced .Use
caution with
these areas to
avoid damaging
the Rear Cover.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 D-1

APPENDIX E - SETUP GUIDE


The Setup Guides (Operating Instructions) are the documents that are included with the television. Sonys BRAVIA TVs now come with an
on-screen i-Manual. To learn more about the TVs features access the i-Manual using the customers remote control.

KDL-40EX620/40EX621/46EX620/46EX621/55EX620/55EX621 E-1