Training LCD Sony AZ3FK PDF

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

AZ3FK Chassis
ORIGINAL MANUAL ISSUE DATE: 6/2012 Segment: P-2
Version Date Subject

1.0 2/27/2012 Original Manual Release Date
2.0 6/11/2012 New parts included for LA use only
LCD Digital Color TV
9-883-874-02
Self Diagnosis
Supported model
SERVICE / TRAINING MANUAL

AZ3FK Chassis
Segment: P-2
KDL-40EX640
LCD Digital Color TV
9-883-874-02
MODEL LIST
MODEL COMMANDER DESTINATION MODEL COMMANDER DESTINATION
KDL-40EX640 RM-YD075 US/CND KDL-55EX640 RM-YD075 US/CND
KDL-46EX640 RM-YD075 US/CND KDL-55EX640 RM-YD083 MX
9-883-874-02
TABLE OF CONTENTS
Cautions and Warnings....................................................................................ii Section 4 - Disassembly/Part Number Information.....................................16
Table-Top Stand Removal............................................................................16
Section 1 - Features and Overview.................................................................1
Rear Cover Removal....................................................................................17
Features.........................................................................................................1
Handling the LVDS FFC Connector..............................................................18
Specifications.................................................................................................1
Disconnecting the LVDS FFC Connector................................................18
Chassis Overview...........................................................................................3
Connecting the LVDS FFC Connector.....................................................18
Overall Circuit Description..............................................................................5
Main Board (A) and Power Supply Board (GL5A/GL5B/GE55) Removal....19
Main Board................................................................................................5
Panel Brackets and LCD Panel Removal.....................................................20
Power Supply Board..................................................................................5
Cleaning the LCD Panel..........................................................................20
IR Board.....................................................................................................5
Connectors...................................................................................................21
Switch Unit.................................................................................................5
Screws..........................................................................................................21
LCD Panel Assembly.................................................................................6
Accessories and Packaging.........................................................................22
Section 2 - Troubleshooting............................................................................7 Miscellaneous...............................................................................................22
Overview........................................................................................................7 Wire Dressing...............................................................................................23
Updating the Software...............................................................................7
Section 5 - Updates and Adjustments..........................................................24
Self Diagnosis Function..................................................................................7
Overview......................................................................................................24
Standby LED Blink Count..........................................................................7
Software Updates for Customers.................................................................24
Viewing the Self Check Diagnosis History.................................................8
Software Updates for Servicers....................................................................24
Triage Chart....................................................................................................9
Software Update Responsibility...............................................................25
Section 3 - Flow Charts and Diagrams.........................................................10 Checking the Software Version................................................................25
Block Diagram..............................................................................................10 Examples of Software Correctable Symptoms........................................25
No Power................................................................................................. 11 Overview......................................................................................................26
Standby LED Blinking..............................................................................13 Updating the Software..................................................................................26
No Video..................................................................................................14 Accessing Service Adjustment Mode...........................................................26
Selecting the Panel ID Code........................................................................27
Accessing Factory Adjustment Mode...........................................................28
Adjusting the Color Temperature.............................................................28
Appendix A: Encryption Key Components................................................ A-1
KDL-40EX640/46EX640/55EX640 i
CAUTIONS AND WARNINGS
CAUTION ATTENTION!!
These servicing instructions are for use by qualified service personnel only. Ces instructions de service sont à l’usage du personnel de service qualifié
To reduce the risk of electric shock, do not perform any servicing other than seulement. Pour prévenir le risque de choc électrique, ne pas faire l’entretien
that contained in the operating instructions unless you are qualified to do so. autre que celui contenu dans le Mode d’emploi à moins que vous soyez
qualifié faire ainsi.
WARNING!!
ALERTE!!
An isolation transformer should be used during any service to avoid possible
shock hazard, in case of live chassis. Afin d’eviter tout risque d’electrocution provenant d’un chássis sous tension,
un transformateur d’isolement doit etre utilisé lors de tout dépannage.
! SAFETY-RELATED COMPONENT WARNING!!

! ATTENTION AUX COMPOSANTS
There are critical components used in LCD color TVs that are important for
safety. These components are identified with shading and ! mark on the
RELATIFS A LA SECURITE!!
schematic diagrams and the parts list. It is essential that these critical parts Les composants identifies par une trame et par une marque ! sur les
be replaced only with the part number specified in the parts list to prevent schemas de principe, les vues explosees et les listes de pieces sont d’une
electric shock, fire, or other hazard. 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
NOTE: Do not modify the original design without obtaining written permission
de circuit dont l’importance est critique pour la securite du fonctionnement
from the manufacturer or you will void the original parts and labor warranty.
sont identifies dans le present manuel. Suivre ces procedures lors de
chaque remplacement de composants critiques, ou lorsqu’un mauvais
fonctionnement suspecte.
KDL-40EX640/46EX640/55EX640 ii
SETTING UP AND 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.
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-40EX640/46EX640/55EX640 iii
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 proper ventilation.
;; 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.
;; Do Not use any cleaning product containing alkaline/acid cleaner, scouring powder, or volatile solvent, such as alcohol, ammonia, benzine, thinner or
insecticide. Using any of these harsh cleaners may result in permanent damage to the screen.
;; 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.
KDL-40EX640/46EX640/55EX640 iv
SAFETY CHECK-OUT 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
After correcting the original service problem, perform the following safety analog meters must have an accurate low voltage scale. Nearly all
checks before releasing the set to the customer: battery-operated digital multimeters that have a 2 VAC range are
suitable. (see Figure A)
1. Check the area of your repair for unsoldered or poorly soldered
connections. Check the entire board surface for solder splashes To Exposed Metal
and bridges. Parts on Set
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 AC
0.15 µF Voltmeter
you have replaced all the insulators. (0.75V)
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 Earth Ground
deterioration. Point them out to the customer and recommend their
Figure A. Use an AC voltmeter to check AC leakage.
replacement.
6. Check the line cords for cracks and abrasion. Recommend the
replacement of any such line cord to the customer. HOW TO FIND A GOOD EARTH GROUND
7. Check the antenna terminals, metal trim, “metallized” knobs, The cover-plate retaining screw on most AC outlet boxes is at earth ground.
screws, and all other exposed metal parts for AC leakage. Check Verify the AC outlet box retaining screw ground by connecting a 60W to
leakage as described in “Leakage Test”. 100W incandescent (not a neon or fluorescent 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
LEAKAGE TEST is at ground potential. (see Figure B)
The AC leakage from any exposed metal part to earth ground and from all Trouble Light
exposed metal parts to any exposed metal part having a return to chassis, AC Outlet Box
must not exceed 0.5 mA (500 microamperes). Leakage current can be
measured by any one of three methods.
1. A commercial leakage tester.
Follow the manufacturers’ instructions provided with the tester.
2. A battery-operated AC milliammeter.
Figure B. Checking for earth ground.
KDL-40EX640/46EX640/55EX640 v
SECTION 1 - FEATURES AND OVERVIEW
FEATURES SPECIFICATIONS
The AZ3FK chassis is one of several designs for the 2012 model line of System
Sony Bravia® LCD televisions. This manual covers the following models: Television system NTSC: American TV standard
ATSC (8VSB terrestrial): ATSC compliant 8VSB
KDL-40EX640 QAM on cable: ANSI/SCTE 07 2000 (Does not include CableCARD functionality)
Channel coverage Analog terrestrial: 2 - 69 / Digital terrestrial: 2 - 69
KDL-46EX640 Analog Cable: 1 - 135 / Digital Cable: 1 - 135
Panel system LCD (Liquid Crystal Display) Panel LED backlight
KDL-55EX640
Speaker output 10 W + 10 W (KDL-55EX640) 8 W + 8 W (KDL-46EX640, KDL-40EX640)
Input/Output jacks
CABLE/ANTENNA 75-ohm external terminal for RF inputs
The features of the EX640 series Edge LED backlite LCD HDTV include:
VIDEO IN 1/2 VIDEO: 1 Vp-p, 75 ohms unbalanced, sync negative
●● Brilliant Full HD 1080p picture quality AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms
COMPONENT IN YPBPR (Component Video): Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative /
●● Lifelike movement with Motionflow™ XR 240 P:B 0.7 Vp-p, 75 ohms
P R : 0.7 Vp-p, 75 ohms / Signal format: 480i, 480p, 720p, 1080i, 1080p
●● Clear Resolution Enhancer for clear detail AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms
HDMI IN 1/2/3/4 HDMI: Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p
●● Bright picture & thin design with Edge LED backlight Audio: Two channel linear PCM 32, 44.1 and
48 kHz, 16, 20 and 24bits, Dolby Digital
●● Movies, music & apps w/ Sony Entertainment Network1 PC Input (see Operating Instructions manual)
●● Wi-Fi® adaptor included to stream HD entertainment1 AUDIO OUT 500 mVrms (typical)
DIGITAL AUDIO OUT PCM/Dolby Digital optical signal
(OPTICAL)
P C IN D -s ub 1 5 - p in, a na log R G B , 0 . 7 V p -p , 7 5 ohms , p os itive
See the PC Input Signal Reference Chart for PC
and HDMI IN in Operating Instructions manual.
PC/HDMI IN 1 AUDIO IN Stereo mini jack, 500 mVrms, (Typical) / Impedance: 47 kilohms
US B C omp lia nt with U S B ma s s s tora g e e . g . d ig ita l c a me ra or U S B me mory .
Also compliant with UWA-BR100 as WiFi Dongle.
DL N A D L N A C e rtifie d ™ c od e c is the s a me a s U S B . ( S ome D L N A C e rtifie d ™
servers may not be able to play back.)
L AN 1 0 B A S E - T /1 0 0 B A S E - T X c onne c tor ( D e p e nd ing on the op e ra ting
environment of the network, connection speed may differ.
10BASE-T/100BASE-TX communication rate and communication quality
are not guaranteed for this TV.)
1. Broadband speed of at least 2.5 Mbps recommended (10 Mbps for HD). Content subject to
change and may require fees. Wireless connectivity requires 802.11 home network (802.11
recommended).
KDL-40EX640/46EX640/55EX640 1
Model name KDL- 55EX640 46EX640 40EX640

Power and others
Power requirement 110-240 V AC, 50/60 Hz (U.S.A./Canada 120 V AC, 60 Hz)
Power consumption
1 50 W 115 W 97 W
in use
in standby Less than 0.25 W with 120 V AC and with 240 V AC less than 0.35 W
Screen size*
5 4 . 6 ( 5 5 c la s s ) 46 40
(inches measured diagonally)
D is p la y re s olution 1 , 9 2 0 d ots ( horiz onta l) × 1 , 0 8 0 line s ( ve rtic a l)
Speaker/Full range (2) (mm) 30 × 150
(inches) (1 3/16 × 6)
Dimensions* with stand (mm) 1,269 × 797 × 311 1,074 × 686 × 251 941 × 612 × 231
(inches) 50 × 31 1/2 × 12 1 /4 42 3/8 × 27 1/8 × 10 37 1/8 × 24 1 /8 × 9 1 /8
without stand (mm) 1,269 × 760 × 60 1,074 × 649 × 60 941 × 575 × 60
(inches) 50 × 30 × 2 3/8 42 3/8 × 25 5/8 × 2 3/8 37 1/8 × 22 3 /4 × 2 3 /8
wall-mount hole pattern
300 × 300
(mm)
wall-mount screw size
M6 (length: refer to Operating Instructions)
(mm)
Mass* with stand (kg) 23.1 17.2 14.1
(lb.) 50.9 37.9 31.1
without stand (kg) 18.7 14.0 11.5
(lb.) 41.2 30.9 25.4
Supplied accessories Remote control RM-YD075 (1)/Size AAA batteries (2)/Operating Instructions (this manual)
common to all models (1)/Quick Setup Guide (1)/Warranty Card (1)/Safety and Regulatory Booklet (1)/Software
License (1)/Stand installation guide (1)/Table-Top Stand (1 set)/Operating Instructions of
USB Wireless LAN Adapter (1)/USB Wireless LAN Adapter: UWA-BR100 (1)/Unique 1.5 m
extension cable (1)
individual models Screw (7)
Optional accessories Connecting cables / Support Belt Kit / Wall-Mount Bracket: SU-WL500
• Optional accessories availability depends on its stock.

• Design and specifications are subject to change without notice.
* Dimensions and mass are approximate values.
KDL-40EX640/46EX640/55EX640 2
CHASSIS OVERVIEW
The primary circuits in the AZ3FK chassis consist of a Main Board (A Board), Power Supply Board (GL5A for the 40” models, GL5B for the 46’ models, and
GE55 for the 55” models), the IR Board (H Board), the Switch Unit, and the LCD Panel Assembly which includes the TCON Board.
NOTE: For connector part number information, refer to “Connectors” on page 21. For Wire Dressing information, refer to “Wire Dressing” on page 23.
GL5A
A
SWITCH
UNIT
TCON
BOARD LAYOUT FOR KDL-40EX640 ONLY
KDL-40EX640/46EX640/55EX640 3
GL5B
A
SWITCH
UNIT
TCON
GE55 A
SWITCH
UNIT
TCON
KDL-40EX640/46EX640/55EX640 4
OVERALL CIRCUIT DESCRIPTION CPU: The CPU internal to the MT5396 processor controls all aspects of
the television functions. Input from the user along with monitoring of critical
The “Block Diagram” on page 10 provides an overview of the AZ3FK circuits is also performed by this CPU.
chassis. The following are descriptions of the boards and their functions. LVDS Transmitter: Integrated into the MT5396 is a Low Voltage Differential
Signaling (LVDS) transmitter. This circuit converts the 8-bit parallel RGB
MAIN BOARD video information into a set of high speed serial lines for noise-free
transmission to the TCON circuits located internally to the LCD panel.
Common to all models utilizing the AZ3FK chassis, the Main Board contains
most of the video processing circuitry along with all audio processing.
Control of the television is accomplished via a CPU embedded within the POWER SUPPLY BOARD
MT5396 processor. Below is a list of the key components located on the There are 3 different Power Supply boards used in the models in this
Main Board. manual. The type of board depends on the size of LCD panel. They are:
●● GL5A for the 40” models
TUNER
●● GL5B for the 46’ models
The tuner is a combination ATSC/NTSC unit. It can receive traditional
analog NTSC signals via cable or terrestrial along with ATSC digital signals ●● GE55 for the 55” models
via terrestrial (8VSB) or cable (64 or 256 QAM). There are 3 distinct sections on the power supply:
Standby Supply: Continuously operational as long as AC power is applied,
MT5396 PROCESSOR the standby supply generates 3.3V for the circuits requiring power while the
This IC performs the majority of the necessary audio and video processing unit is turned off. An unregulated 19V line is present to provide power to the
on the Main Board. main relay, PFC and main power supply at turn-on.
Analog Video Input Switch: All analog video sources are selected and Main Supply: Once the power supply receives a power-on command from
A/D converted and scaled (if necessary) to 1920 X 1080p 60HZ resolution. the CPU on the Main Board, the main switching supply is turned on to
provide a regulated 12V source and Audio 12V.
Digital Audio and Video Decoder: The MPEG2 and Digital Dolby audio
streams are received from the tuner for decompression. All video sources Converter: Generates the B+ and B- voltages for the LED backlights.
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 IR BOARD
amplification.
Designated as the H Board, the IR Board contains the power, standby, and
Audio Processing: Analog audio sources are selected and A/D converted timer LED’s that are located on this board along with the IR remote receiver
directly by the MT5396. The audio information is then processed digitally. and light level sensor.
Digital audio from the tuner and HDMI sources is also input and processed.
Class D amplifier provides the drive for the speakers.
SWITCH UNIT
HDMI Input and Switching: The customer can select the HDMI1 through
HDMI4 input. Each HDMI input contains a dedicated EDI NVM (not shown) This board contains the power, channel and volume up/down, and menu
to provide display information data to any device connected via the HDMI buttons.
inputs.
KDL-40EX640/46EX640/55EX640 5
LCD PANEL ASSEMBLY

The LCD Panel Assembly includes the LCD Panel, TCON Board, and LED
Backlight system.
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 backlite - 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.
●● LCD Panel
●● TCON Board
●● LED Backlighting Components (varies)
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. To determine if the TCON Board is available as a replacement
part, refer to the LCD Panels Manual.
KDL-40EX640/46EX640/55EX640 6
SECTION 2 - TROUBLESHOOTING Self Diagnosis
Supported model
OVERVIEW SELF DIAGNOSIS FUNCTION

This chapter provides information regarding the Self Diagnosis feature in Critical voltages and circuit operations are monitored by the CPU on the
our TVs. Main Board. If an error is detected the Self Diagnosis function in the TV will
force the TV to shut down by the CPU. The monitored circuit in which the
fault occurred will automatically cause the CPU to blink the Standby LED
UPDATING THE SOFTWARE in groups of repeating sequences. The number of times the Standby LED
The Self Diagnosis function is designed to provide information regarding blinks indicates the possible cause of the problem.
the problem with the TV, however, there are several issues that may be
Not all of the available protect codes are used in every model. For example,
resolved by updating the TV software to the latest version. Always check
models that don’t have the local dimming feature do not use the 4X blink
the Sony Authorized Servicer Portal at http://www.sony.com/asp for any
error as this circuit is found in models that are backlit with fluorescent lamps.
issues that are software related. Most symptoms that are correctable by
The information in this section provides guidance in locating the possible
software updates involve communications issues with other devices or
component causing the shutdown.
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 STANDBY LED BLINK COUNT
●● Intermittent picture freezing or noise 2 times
●● Problems with certain inputs (especially HDMI)

5 times
●● Intermittent or distorted audio
LED ON 0.3 sec.
●● Erratic remote control operation LED OFF 0.3 sec. LED OFF
3 sec.
●● TV turns on and off by itself

●● Loss of color
●● Internet connectivity
Standby LED
●● Certain features not working correctly
LED DISPLAY & BLINK COUNT
(photo or video file viewing)
KDL-40EX640/46EX640/55EX640 7
SECTION 2 - TROUBLESHOOTING
VIEWING THE SELF CHECK DIAGNOSIS HISTORY SELF CHECK

When an error is detected, the Self Check screen records the date(s) and
the number of times the error occurred. This is helpful in confirming past Back <<
occurrences of an error, and for determining if an error is intermittent when 002 MAIN_ POWER 000
the customer is not sure what is causing the television to shut down. If the 003 DC_ALERT1 000
screen displays a “0”, no error has occurred.
003 AUDIO_PROT 000
1. Take the TV out of deep Standby mode by pressing POWER to 004 BALANCER_ERR 000
turn on the TV. 005 TCON_ERR 000
2. Press POWER to turn the TV back off. 005 PANEL_ID_NVM_ERR 000
006 BACKLIGHT_ERR 000
3. Press the following buttons on the Remote Commander within a
007 TEMP_ERR 000
second of each other:
DISPLAY Channel 5 Volume + POWER 00001 00036 00001
[Home] Exit
Service Mode
Sound Adjustment >> SAMPLE SELF CHECK DIAGNOSIS PAGE
Wide Band Tuning >> 2X Blink - Main Power Error
Range Scan… >>
Self diagnosis history >> A loss of REG12V from the power supply triggers this protect event. The
Status Information… >> usual cause is a failure of the main switching supply. In some instances,
LVDS Spectrum(%0) <[ 20 ]> excessive loading on the secondary supply lines can cause the switching
DPMS <[ Off ]> regulator to stop, or fail again, if a replacement board is installed.
Low of HPD <[ 5 ]>
TVD_MCDONE_CNT <[ 20 ]> 3X Blink- DC Regulator/Audio Error
Demo Special >> The REG 5V and D3.3V source originating on the Main Board is monitored
Bypass AVI Info Detect <[ On ]>
for low-voltage conditions by the CPU. A failure causing a 3X shutdown
Panel Selection <[ 13_FHD_SLCD_40 ]>
UART Selection No Log
requires replacing the Main Board.
SERIAL NUMBER EDIT 5000027
4X Blink – Balancer Error
MODEL NAME EDIT KDL-46EX640
NOT USED IN THIS MODEL SERIES
[</>]Set [Home] Exit
5X Blink - TCON Error/Panel Error
The 5X blink protection mode indicates a communications error with the
4. To access the Self diagnosis history page, press until Self
timing control circuits (TCON Board) has occurred. If the TCON Board is
diagnosis history is highlighted, and then press . available for replacement, replace it, if not, replace the LCD Panel Assembly.
In rare cases a loose or defective LVDS cable could also be the cause.
KDL-40EX640/46EX640/55EX640 8
SECTION 2 - TROUBLESHOOTING
6X Blink - Backlight Converter System Failure 7X Blink - Temperature Failure
If the inverter circuits fails to generate high voltage or one or more of the A digital thermometer IC located on the Main Board provides a temperature
backlight lamps fails to light, the television will shut down and display this reading of the chassis and LCD panel. If the temperature exceeds a pre-
diagnostics error. Observing for the presence of backlighting is crucial in determined point the TV will shut down. If this problem occurs immediately
determining which component is likely at fault. at turn-on, the temperature sensing IC has failed and replacing the main
If the backlights turn on before the 6X shutdown occurs, it is safe to assume board is required. If this occurs after the TV has been running for a while,
that the inverter circuits are functioning and one of the lamps failed to ignite. check for ventilation issues that could cause the TV to run hotter than
Replacing the LCD Panel assembly is necessary. If the backlights never normal.
turn on before the 6X shutdown, the Inverter MT Board has failed. If this
board is available for replacement, replace it, if not, replace the LCD Panel
Assembly.
TRIAGE CHART
Use this general Triage Chart to determine what may possibly be causing the error before going out to the customers location.
1. Confirm the symptom from the customer. 5. Chart Color Code
2. Select that symptom from the chart. RED DOT: (Primary) Most likely defective part
3. Bring the primary component listed for that symptom. BLUE Triangle: (Secondary) Possible defective part
4. Follow the associated flowcharts in the Training Manual to isolate the board.
Protection Modes Power Video Audio
Board Whole Isolated
No
2X 3X 5X 6X 7X Dead set
Video
Screen Area No Audio
Distortion Distortion
Main Board  * ▲ ▲   
Power Supply  *** 
H Board
Inverter ▲*
LCD Panel ** 
TCON   ▲ ▲
*NOTE: REFER TO LCD PANEL SERVICE * TV Immediate Shuts Off After Power ON & 7X
MANUAL IN REFERENCE LIBRARY DATABASE ***Backlight Does NOT Turn ON before TV Shuts
FOR CORRECT REPLACEMENT PARTS BASED **Backlight Turns ON before TV Shuts Off
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-40EX640/46EX640/55EX640 9
SECTION 3 - FLOW CHARTS AND DIAGRAMS
BLOCK DIAGRAM
RF TUNER L
CLASS D
AUDIO
AMP
Component/Composite R
Composite ANALOG AUDIO OUT

HDMI 1 OPTICAL AUDIO OUT
HDMI 2 MT5396
HDMI 3 A/V DECODER
A/V PROCESS
HDMI 4
PC HD15
LVDS LCD PANEL, TCON, &
USB 1 LED BACKLIGHTS
USB 2
Ethernet
A
SWITCH LED
UNIT IR RX
H
POWER SUPPLY
AC IN
GL5A (40")
GL5B (46")
GE55 (55")
OVERALL BLOCK DIAGRAM
KDL-40EX640/46EX640/55EX640 10
NO POWER
CN6402
1~5 UNREG24V
6~10 GND
11 BL_ERR
LCD PANEL &
CN6101 12 BL-ON
CCFL BACKLIGHTS
AC IN (N) 1 13 N/C
AC IN (H) 2 14 DIMMER
CN6401 CN201
1 STBY3.3V REG 12V 8
2 AC_OFF_DET GND 5, 7, 9
3 POWER_ON AUDIO_12V 10
4 AUDIO_12V DIMMER 1
5 AUDIO_GND BL_ERR 12
6, 7 REG12V_GND BL_ON 13
8, 9 REG12V TCON_12V 14
10 BL_ERR AC_FF_DET 3
11 BL_ON TCON_ON 15
12 DIMMER STBY 3.3V 4
13 N/C POWER_ON 2
14 TCON_12V
GL5A (40")
15 TCON_ON
GL5B (46")
GE55 (55") A
POWER AND CONTROL BLOCK DIAGRAM
KDL-40EX640/46EX640/55EX640 11
No Power
Press power
Does red standby Yes button while Yes
High (3.3V) Power Supply
LED on front panel monitoring pin 3 of
on pin 3? Board*
light? CN6401 on power
supply board
No No
Yes See
Is standby LED High (3.3V) Yes
Protection Shutdown Main Board*
blinking? on pin 2?
flowchart
No No
Power Supply
Board* Power Supply
Board*
NO POWER FLOWCHART
*For Part Number information, Refer to “Section 4 - Disassembly/Part Number Information” on page 16.
KDL-40EX640/46EX640/55EX640 12
STANDBY LED BLINKING

Protect
Shutdown.
Standby LED
Blinking
Yes Power Supply

2X
Board*
No
Yes
3X Main Board*
Check room
No After a While temperature and
6X 7X
ventilation around
unit
No
Yes Immediately
No
5X
Main Board*
Yes
“SONY” logo No Power Supply

appears before
LCD Panel* Board*
shutdown?
Yes
LCD Panel*
PROTECTION SHUTDOWN FLOWCHART

KDL-40EX640/46EX640/55EX640 13
NO VIDEO
No Video
Backlights No
LCD Panel*
turned on?
Yes
Any OSD Yes

graphics Main Board*
present?
No
Unplug LVDS
connector at
TCON while unit Any flashes No
is running. This seen on LCD Panel*
may need to be screen?
done more than
once
Yes
Main Board*
NO VIDEO FLOWCHART
KDL-40EX640/46EX640/55EX640 14
Video Distortion
Is distortion No Lines move

Yes Improper of Vertical lines Yes Yes
across entire when wide-mode Main Board*
missing colors? or bars? changed?
screen?
No Yes No No
LCD Panel*
Main Board*
TCON Board*
Any horizontal Yes

LCD Panel*
lines?
No
Any single or Yes

isolated vertical LCD Panel*
lines?
No
Yes
More than 1 LCD Panel*
vertical band? TCON Board*
VIDEO DISTORTION FLOWCHART
KDL-40EX640/46EX640/55EX640 15
SECTION 4 - DISASSEMBLY/PART NUMBER INFORMATION
TABLE-TOP STAND REMOVAL Components not identified by a part number or The component parts of an assembly are indicated by the * Items marked with an asterisk are not stocked since
description are not stocked because they are seldom reference numbers in the far right column of the parts list they are seldom required for routine service. Expect
A Remove 3 screws from the Table-Top Stand, then lift up the LCD TV and gently place it face down onto a soft cloth. required for routine service. and within the dotted lines of the diagram. some delay when ordering these components.
NOTE: The components identified by shading NOTE: Les composants identifies per un trame et NOTE: The components identified by a red outline and a mark contain
and ! mark are critical for safety. Replace only une marque ! sont critiques pour la securite. confidential information. Specific instructions must be adhered to whenever
with part number specified. Ne les remplacer que par une piece portant le these components are repaired and/or replaced.
numero specifie. 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 3
Soft Cloth
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
1 4-415-089-01 STAND, HEAD (ML9) 3 4-415-102-01 STAND, BASE TP (ML)

2 4-298-271-01 NECK TP (M) (KDL-40EX640 ONLY)
3 4-415-097-01 STAND, BASE TP (L)
(KDL-46EX640 ONLY)
3 4-415-092-01 STAND, BASE TP (LL)
(KDL-55EX640 ONLY)
▲ 4-421-427-01 SCREW, +PSW M5X16 LOCK

(SCREWS TO ATTACH HEAD BRACKET AND STAND BASE TO NECK)
(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-40EX640/46EX640/55EX640 16
REAR COVER REMOVAL and ! mark are critical for safety. Replace only une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
confidential information. Specific instructions must be adhered to whenever
with part number specified. these components are repaired and/or replaced.
CAUTION:
Hold down the Rear Cover as shown in the steps below to avoid deforming or damaging the hooks in the Rear
Cover and Bezel.
The portion of the Rear Cover near the Switch Unit is very fragile. When lifting this section, support the area to avoid
breaking the cover.
Bezel hook
Rear Cover hook
Trying to remove the Rear Cover as shown in this illustration will break the hooks securing it to the Bezel.
A To avoid damaging the AC Power Supply Cord, 51
remove the screw from the AC Cover and
disconnect the AC Power Cord. Hold the 52
Power Supply Cord
B Remove the remaining screws from the
Rear Cover.
18 from KDL-40EX640 Only
20 from KDL-46EX640 Only
22 from KDL-55EX640 Only 53
C Gently hold down the Rear Cover from the

center, then carefully start to lift the Rear Cover
from the bottom to create clearance between
the Bezel and the Rear Cover.
D Gently hold down the Rear Cover as shown in the steps below, then grasp the inside bottom corner and carefully lift 54
the Rear Cover to release the hooks.
USE CAUTION 51 4-409-316-01 REAR COVER(40NK2) [52] ! 53 1-839-679-11 CORD, POWER (WITH CONNECTOR)
to avoid breaking this
area of the Rear Cover
(KDL-40EX640 ONLY) 54 4-299-528-01 AC COVER
51 4-409-325-01 REAR COVER(46NK2) [52]
(KDL-46EX640 ONLY) △ 4-256-393-01 SCREW, +PSW M3X6 W12
E Lift the Rear Cover from the bottom and push 51 4-409-328-01 REAR COVER(55NK2) [52] □ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3
forward to release the top hooks. (KDL-55EX640 ONLY) ◇ 4-159-298-01 SCREW, +PSW M4X10
52 4-409-322-01 BRACKET, VESA(NK2) 4-400-043-01 JOINT, SCREW
(SCREWS USED WHEN STAND IS ATTACHED - NOT USED WITH
WALL MOUNTS)
7-685-646-79 SCREW, +BVTP 3X8 TYPE2 IT-3
KDL-40EX640/46EX640/55EX640 17
HANDLING THE LVDS FFC CONNECTOR DISCONNECTING THE LVDS FFC CONNECTOR CONNECTING THE LVDS FFC CONNECTOR
CAUTION: CAUTION:
Several models use a LVDS FFC Connector from the Main Board to the
TCON Board. Currently there are three different types of connectors that Regardless of the connector type, DO NOT remove the LVDS FFC DO NOT insert the LVDS FFC Connector into the Main Board upside
are used. Connector by the reinforcement tab only. down.
CAUTION: CONNECTOR TYPE 1 CONNECTOR TYPE 1
Refer to the illustration below when disconnecting or connecting the 1. Slightly tilt the Main Board connector release away from the LVDS FFC
LVDS FFC Connector. Regardless of the connector type, DO NOT 1. While holding onto the LVDS FFC Connector, gently tilt the Main Board
Connector. connector release towards the Main Board then slide the LVDS FFC
remove the LVDS FFC Connector by the reinforcement tab only. 2. Gently wiggle the LVDS FFC Connector to detach it from the Main Connector straight in.
Board.
Main Board
Main Board
Reinforcement
Tab
Reinforcement
䐠 Tab
Correct Incorrect Tilt away from LVDS
CAUTION: Tilt away from LVDS
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 CONNECTOR TYPE 2 CONNECTOR TYPE 2
will short-circuit and damage the board. 1. Gently press down on the release tab of the Main Board connector.
1. Gently press down on the release tab of the Main Board connector.
2. Correctly holding onto the LVDS FFC Connector, pull out the connector 2. Holding onto the entire LVDS FFC Connector, insert the LVDS FFC
while continuing to hold down the release tab of the Main Board Connector into the Main Board connector.
connector. Press down
Press down
Reinforcement
䐠 Tab
䐠 Reinforcement
Tab
Inserted Correctly Inserted Incorrectly Main Board

Main Board
CONNECTOR TYPE 3 CONNECTOR TYPE 3
1. Gently press down on the 2 release tabs of the Main Board connector. 1. Gently press down on the 2 release tabs of the Main Board connector.
2. Correctly holding onto the LVDS FFC Connector, pull out the connector 2. Holding onto the entire LVDS FFC Connector, insert the LVDS FFC
while continuing to hold down the release tabs of the Main Board Connector into the Main Board connector.
connector.
Main Board
Main Board
Reinforcement
䐠 Tab Press down
䐠 Reinforcement Press down

Tab
KDL-40EX640/46EX640/55EX640 18
une marque ! sont critiques pour la securite. confidential information. Specific instructions must be adhered to whenever
MAIN BOARD (A) AND POWER SUPPLY BOARD (GL5A/GL5B/GE55) REMOVAL and ! mark are critical for safety. Replace only
NOTE: Refer to “Handling the LVDS FFC Connector” on page 18 to disconnect the LVDS Connector.
A Detach Side Jack Cover from A Board.
B Remove screws and disconnect connectors from A Board.
(Refer to “Handling the LVDS FFC Connector” on page 18 instructions)
C Remove screws and disconnect connectors from GL5A/GL5B/GE55 Board. 107
D Disconnect connectors, then slide-out Left and Right Speakers.
E Release clips and disconnect 1 connector from H Board.
F Lift up Switch Unit and disconnect 1 connector.
106
101
103
A
104 102
105
E
B REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
C 101 4-409-321-01 COVER, SIDE JACK(NK2) 106 1-895-173-11 GL5A BOARD, COMPLETE
D 102 1-895-172-11 A BOARD, COMPLETE (KDL-40EX640 ONLY)
AFTER REPLACING THE MAIN BOARD, YOU MUST UPDATE 106 1-895-174-11 GL5B BOARD, COMPLETE
THE SOFTWARE TO THE LATEST VERSION (KDL-46EX640 ONLY)
102 1-895-172-21 A BOARD, COMPLETE(LA1) 106 1-895-175-11 GE55 BOARD, COMPLETE
(KDL-55EX640 ONLY) (KDL-55EX640 ONLY)
AFTER REPLACING THE MAIN BOARD, YOU MUST UPDATE 107 4-409-317-01 SHEET, INSULATION (NK2)
THE SOFTWARE TO THE LATEST VERSION (KDL-40EX640/46EX640 ONLY)
F
103 1-895-176-11 H BOARD, MOUNTED ORDER THIS PART WHEN REPLACING THE LCD PANEL
104 1-858-715-11 LOUDSPEAKER (3X15CM)
105 1-489-986-11 SWITCH UNIT ◆ 2-990-421-41 SCREW, (+PSW) (M3X6)
KDL-40EX640/46EX640/55EX640 19
une marque ! sont critiques pour la securite. confidential information. Specific instructions must be adhered to whenever
PANEL BRACKETS AND LCD PANEL REMOVAL and ! mark are critical for safety. Replace only
NOTE: The insulation sheet is not included with the LCD Panel. See part number information on the previous page.
A Remove 2 screws, then press Bezel tabs and lift-up Panel Brackets (H).
B Press Bezel tabs and tilt-up Panel Brackets (V).
C Remove screws and lift up Bottom Frame.
D Gently lift-up LCD Panel.
Panel Bracket (H) 151
A
Bezel tab
153
D
Panel Bracket (V)

153
B
154
152
Bezel tab
154
C
155
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, and wipe the LCD screen gently with a soft cloth. 151 4-409-314-01 BEZEL(40NK2) 153 4-299-512-01 BRACKET, PANEL (H)
;; Stubborn stains may be removed with a cloth slightly moistened with a solution of mild soap and warm water. (KDL-40EX640 ONLY) 154 4-299-509-01 BRACKET, PANEL (V)
;; If using a chemically pretreated cloth, please follow the instruction provided on the package. 151 4-409-324-01 BEZEL(46NK2) 155 4-409-323-01 FRAME, BOTTOM(40NK2)
;; Never use strong solvents such as a thinner, alcohol or benzine for cleaning.
151 4-409-327-01 BEZEL(55NK2) 155 4-409-326-01 FRAME, BOTTOM(46NK2)
;; Periodic vacuuming of the ventilation openings is recommended to ensure proper ventilation. (KDL-55EX640 ONLY) (KDL-46EX640/55EX640 ONLY)
;; Do Not use paper towels, any type of abrasive pad, rags, rubber or vinyl materials to clean the screen. Using these 151 4-409-327-11 BEZEL(55NK2)(LA1)
materials could easily scratch the screen which may result in permanent damage. (KDL-55EX640 ONLY) △ 4-256-393-01 SCREW, +PSW M3X6 W12
;; Do Not use any cleaning product containing alkaline/acid cleaner, scouring powder, or volatile solvent, such as alcohol, 152 NA LCD PANEL □ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3
ammonia, benzine, thinner or insecticide. Using any of these harsh cleaners may result in permanent damage to the FOR ALL LCD PANEL AND TCON BOARD PART NUMBER ◇ 4-159-298-01 SCREW, +PSW M4X10
screen. INFORMATION REFER TO THE LCD PANELS SERVICE MANUAL
;; 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.
KDL-40EX640/46EX640/55EX640 20
CONNECTORS and ! mark are critical for safety. Replace only une marque ! sont critiques pour la securite.
Ne les remplacer que par une piece portant le
confidential information. Specific instructions must be adhered to whenever
with part number specified. these components are repaired and/or replaced.
SCREWS
KDL-40EX640
P/N DESCRIPTION REMARKS TOTAL

▲ 4-421-427-01 SCREW, +PSW M5X16 LOCK TABLE-TOP STAND(3), HEAD to NECK(1), NECK to BASE(3) 7
△ 4-256-393-01 SCREW, +PSW M3X6 W12 RC(5), AC CVR(1), PNL BRKTS(2) 8
■ 7-685-647-79 SCREW, +BVTP 3X10 TYPE2 IT-3 HEAD(2), BASE(5) 7
□ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3 RC(7), BTM FRM(2) 9
◆ 2-990-421-41 SCREW, (+PSW) (M3X6) A BOARD(5), GL5A(5) 10
205
◇ 4-159-298-01 SCREW, +PSW M4X10 RC(2), BTM FRM(6) 8
● 4-400-043-01 JOINT, SCREW RC(2) 2
○ 7-685-646-79 SCREW, +BVTP 3X8 TYPE2 IT-3 TERMINAL(1), SIDE JACK(1), VESA(2) 4
204
KDL-46EX640
203 202
P/N DESCRIPTION REMARKS TOTAL
201 ▲ 4-421-427-01 SCREW, +PSW M5X16 LOCK TABLE-TOP STAND(3), HEAD to NECK(1), NECK to BASE(3) 7
□ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3 RC(7), BTM FRM(2) 9
◆ 2-990-421-41 SCREW, (+PSW) (M3X6) A BOARD(5), GL5B(5) 10
● 4-400-043-01 JOINT, SCREW RC(2) 2
KDL-55EX640
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] P/N DESCRIPTION REMARKS TOTAL
▲ 4-421-427-01 SCREW, +PSW M5X16 LOCK TABLE-TOP STAND(3), HEAD to NECK(1), NECK to BASE(3) 7
201 1-910-105-16 CONNECTOR ASSEMBLY 40 4P SP-MB 204 1-910-105-31 (LVDS FFC) CONNECTOR ASSEMBLY40 51P (FFC)
□ 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3 RC(9) 9
◆ 2-990-421-41 SCREW, (+PSW) (M3X6) A BOARD(5), GE55(4) 9
● 4-400-043-01 JOINT, SCREW RC(2) 2
202 1-910-105-19 CONNECTOR ASSEMBLY 40 14P 205 1-910-105-22 CONNECTOR ASSEMBLY 40 15P
203 1-910-105-30 (LVDS FFC) CONNECTOR ASSEMBLY40 41P (FFC)

(KDL-40EX640 ONLY)
(KDL-46EX640 ONLY)
(KDL-55EX640 ONLY)
KDL-40EX640/46EX640/55EX640 21
ACCESSORIES AND PACKAGING OPTIONAL ACCESSORIES

PART NO. DESCRIPTION PART NO. DESCRIPTION
4-408-779-01 BAG, SCREW A (M) THE WIFI ADAPTER AND EXTENTION CABLE LISTED BELOW
(CONTAINS THE FOLLOWING SCREWS) ARE AVAILABLE THROUGH THE SONY STORE WEBSITE.
4-421-427-01 SCREW, +PSW M5X16 LOCK USE THE DESCRIPTION TO LOCATE THE PART AND PRICING INFORMATION
(SCREWS TO ATTACH HEAD BRACKET AND STAND BASE TO NECK) 1-487-779-21 UWA-BR100U UNIT (WIFI ADAPTER)(FOR ALL MODELS EXCEPT LA1)
(SCREWS TO ATTACH TABLE-TOP STAND TO LCD TV) 1-837-549-12 UWA-BR100 EXTENTION CABLE (FOR ALL MODELS EXCEPT LA1)
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 REMOTE COMMANDER
PART NO. DESCRIPTION
3-299-071-05 FLYER, SAFETY
4-418-731-11 GUIDE, QUICK SET UP (ENGLISH VERSION) 1-490-009-11 REMOTE COMMANDER (RM-YD075)
4-418-731-21 GUIDE, QUICK SET UP (FRENCH VERSION) 1-490-489-11 REMOTE COMMANDER (RM-YD073)(LA1 ONLY)
4-171-791-12 MANUAL, INSTRUCTION

4-418-730-11 MANUAL, INSTRUCTION (ENGLISH VERSION)
4-418-730-21 MANUAL, INSTRUCTION (FRENCH VERSION)
4-415-215-11 SUPPLEMENT(STAND INSTALLATION
MISCELLANEOUS
PART NO. DESCRIPTION
4-400-043-01 JOINT, SCREW

(SCREWS USED WHEN STAND IS ATTACHED - NOT USED WITH WALL MOUNTS)
4-420-093-01 LABEL, ENERGY GUIDE(NK2)

(KDL-40EX640 ONLY)
(KDL-46EX640 ONLY)
(KDL-55EX640 ONLY)
2-186-827-41 LABEL, ENERGY STAR
KDL-40EX640/46EX640/55EX640 22
WIRE DRESSING
OVERALL WIRE DRESSING FOR KDL-40EX640/46EX640 ONLY
OVERALL WIRE DRESSING FOR KDL-55EX640 ONLY
KDL-40EX640/46EX640/55EX640 23
SECTION 5 - UPDATES AND ADJUSTMENTS
OVERVIEW Customer Support Center and it is deemed to be correctable with a software

update, the issue is handled at the customer level.
The models in this manual utilize a “generic” type of Main Board, therefore a Software updates can be performed by:
software update must be performed and certain service adjustment settings
must be changed or confirmed whenever the Main Board, LCD Panel, or ●● Customer Manual Downloads: Software updates can be accessed
TCON Board is replaced. by the customer from the Sony Support Site at http://esupport.
sony.com where they can be downloaded and placed on a
There are 2 reasons for updating the software on the TVs. USB thumb drive to be loaded onto the TV. The instructions for
●● Software updates for customers downloading the software file vary from chassis to chassis and
These updates are for enhancements or improvements that have sometimes from model to model. The customer is provided with
been made to the software after the TV was released. These the instructions to properly format the USB thumb drive, unzip the
updates are accessed by the customer from the Sony Support Site file, and the procedures for loading the software into the television.
at http://esupport.sony.com. ●● Network Downloads: Internet software updates are becoming
●● Software update for servicers more prevalent as more and more models incorporate home
network capabilities. This method is the most practical since the
These updates are specifically for servicers to use during a service television will check for the latest version of software. The models
call and are only available on the Sony Authorized Servicer Portal with this type of chassis provide the customer with a choice of
at http://www.sony.com/asp. 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
SOFTWARE UPDATES FOR CUSTOMERS installed without any input from the customer.
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
SOFTWARE UPDATES FOR SERVICERS
other devices found in the home. Some examples are: portable audio and Replacement Main Boards are now stocked with basic software. Once the
video devices, still cameras, home computer networks and accessing the replacement board is installed in the TV, the most current software needs
internet to name a few. to be installed using a USB thumb drive containing the necessary software.
Communications with these varying devices requires that the television be This new method of supplying Main Boards significantly reduces the
compatible with varying communications protocols. Although standards complexity of replacing the Main Boards. Information about the LCD
are detailed for each of these protocols, the real world dictates that panel is stored on the TCON circuits. This information is automatically
occasional errors may occur that could prevent devices from operating or loaded onto the Main Board when the TV is powered up. With the correct
communicating properly. software version the Main Board and/or the TCON can be replaced
Keeping the software in the television up-to-date is a procedure that is more efficiently. The software update and procedures for the software
normally handled by the owner of the television. Most customers who own installation are located on the Sony Authorized Servicer Portal at
computers and other digital devices are familiar with and are accustomed http://www.sony.com/asp.
to updating the software in their products. If a customer contacts the Sony
KDL-40EX640/46EX640/55EX640 24
SOFTWARE UPDATE RESPONSIBILITY EXAMPLES OF SOFTWARE CORRECTABLE SYMPTOMS

Software updates are designed to be performed by the customer. Warranty Always check the Sony Authorized Servicer Portal at www.sony.com/asp
repairs in which the issue can be resolved by a software update are not site for any known and/or listed issues that are software related. Most
reimbursable. Most issues involving software updates are handled by the symptoms that are correctable by software updates involve communications
customer service center and should not be directed to an authorized service issues with other devices or minor glitches in the operation of a specific
center. It is the responsibility of the servicer to prevent service calls for function. Below is a list of some of the symptoms that may be corrected with
issues that involve software updates. Exceptions to this are certain cases a software update:
whereby the customer is unable or unwilling to perform the task. In this ●● Fluctuations in picture brightness
situation, the servicer will be notified and receive the proper authorization
for reimbursement. ●● Intermittent picture freezing or noise
It is the servicer’s responsibility, however, to make certain that any TV ●● Problems with certain inputs (especially HDMI)
requiring a legitimate service is running the latest software version ●● Intermittent or distorted audio
and to install it if necessary.
●● Erratic remote control operation
●● Unit turns on and off by itself
CHECKING THE SOFTWARE VERSION
●● Loss of color
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. ●● Internet connectivity
●● Certain features not working correctly
Contact Sony (photo or video file viewing)
Please contact Sony directly if you have questions on the use of your television con:
Website Support: www.sony.com/tvsupport

United States Phone Contact: 1 (800) 222-SONY (7669)
Canada Phone Contact 1 (877) 899-SONY (7669)
Other Countries Contact Consult the Warranty Card
Please have the following information available:

Model Name: KDL-46EX640
Serial Number: 5000027
Software Version: v1.008
Device ID: b0.00:00:bb:05:4a
Netflix ESN: SONYKDLEX61386-2B0E2-44F0D20D366
EXAMPLE OF SOFTWARE VERSION

LOCATED ON THE CONTACT SONY SCREEN
KDL-40EX640/46EX640/55EX640 25
OVERVIEW ACCESSING SERVICE ADJUSTMENT MODE

As mentioned in “Section 5 - Updates and Adjustments” on page 24, the This set does not use Service Mode for adjustments. To make adjustments,
models in this manual utilize a “generic” type main board, therefore certain refer to “Accessing Factory Adjustment Mode” on page 28. However, you
service adjustments settings must be changed or confirmed when either can access the Self diagnosis history page from Service Mode.
the main Board, LCD Panel, or TCON Board are replaced. 1. TV must be in Standby mode. (Power On).
UPDATING THE SOFTWARE 2. Press the following buttons on the Remote Commander within a
second of each other:
After replacing the main Board, LCD Panel, or TCON Board, you MUST
UPDATE the SOFTWARE to the latest version. Instructions for updating the DISPLAY Channel 5 Volume + POWER
software are included with the software package on the Sony Authorized
Service Portal website.
POWER
DISPLAY
Onscreen cursor
and select button
VOLUME+
RM-YD075
KDL-40EX640/46EX640/55EX640 26
Service Mode SELECTING THE PANEL ID CODE

Sound Adjustment >>
Wide Band Tuning >> After replacing the Main Board or the LCD Panel, you must update the
Range Scan… >> software to the latest version and then select the Panel ID from Factory
Self diagnosis history >> Mode. Instructions for updating the software are included with the software
Status Information… >> package on the Sony Authorized Service Portal site.
LVDS Spectrum(%0) <[ 20 ]>
1. TV must be in Standby mode. (Power On).
DPMS <[ Off ]>
Low of HPD <[ 5 ]> 2. Press the following buttons on the Remote Commander within a
TVD_MCDONE_CNT <[ 20 ]> second of each other:
Demo Special >>
Bypass AVI Info Detect <[ On ]> DISPLAY Channel 5 Volume + POWER
Panel Selection <[ 13_FHD_SLCD_40 ]> Service Mode
UART Selection No Log Sound Adjustment >>
SERIAL NUMBER EDIT 5000027 Wide Band Tuning >>
MODEL NAME EDIT KDL-46EX640 Range Scan… >>
Self diagnosis history >>
[</>]Set [Home] Exit Status Information… >>
3. To access the Self diagnosis history page, press until Self LVDS Spectrum(%0) <[ 20 ]>
DPMS <[ Off ]>
diagnosis history is highlighted, and then press . Low of HPD <[ 5 ]>
TVD_MCDONE_CNT <[ 20 ]>
SELF CHECK Demo Special >>
Bypass AVI Info Detect <[ On ]>
Back << Panel Selection <[ 13_FHD_SLCD_40 ]>
002 MAIN_ POWER 000 UART Selection No Log
003 DC_ALERT1 000 MODEL NAME EDIT KDL-46EX640
003 AUDIO_PROT 000
004 BALANCER_ERR 000 [</>]Set [Home] Exit
005 TCON_ERR 000
005 PANEL_ID_NVM_ERR 000
006 BACKLIGHT_ERR 000
007 TEMP_ERR 000
00001 00036 00001
[Home] Exit
4. To exit service mode, turn the POWER off.
KDL-40EX640/46EX640/55EX640 27
3. Press to select Panel Selection. ACCESSING FACTORY ADJUSTMENT MODE

Service Mode For these models, adjusment data is changed in Factory Mode.
Sound Adjust… >>
Wide Band Tuning >>
Range Scan… >> ADJUSTING THE COLOR TEMPERATURE
Self diagnosis history >>
The default White Balance data values are set for optimal viewing. The
Status Information… >>
LVDS Spectrum(%0) <[ 20 ]>
following instructions are for technicians who have been requested to
DPMS <[ Off ]> customize calibrations for their customers.
Low of HPD <[ 5 ]> 1. TV must be ON.
TVD_MCDONE_CNT <[ 20 ]>
Demo Special >> 2. Press the following buttons on the Remote Commander within a
Bypass AVI Info Detect <[ On ]> second of each other:
Panel Selection <[ 91_460HJ07 ]>
UART Selection No Log
MUTING MUTING HOME
Factory Mode
MODEL NAME EDIT KDL-46EX640
Input Source <[ TV ]>
[</>]Set [Home] Exit
White Balance <[ Off ]>
Internal Pattern <[ Off ]>
4. Using the table below, press the or Onscreen cursor buttons Color Temp >>
to select the correct panel code for the Panel ID. Aging Mode <[ Off ]>
ADC Calibration >>
Modle Name Panel Code Panel Type Panel ID TVD ADC Calibration >>
KDL-40EX640 88_400HF10 SLCD LTY[Z]400HF10 Auto Phase <[ Off ]>
KDL-46EX640 91_460HJ07 SLCD LTY[Z]460HJ07 Factory Reset (default) Off
Recall Data <[ Off ]>
KDL-55EX640 92_550HJ04 SLCD LTY[Z]550HJ04 Data Backup <[ Off ]>
Site Air Channels <[ Off ]>
5. To save the changes, press and POWER to turn off the Site Cable Channels <[ Off ]>
TV.
System FW v1.001
Model Name KDL-46EX640
Serial Number 5000027
Picture Quality v1.0000
Audio Quality AQ1.0000
Panel Info SLCDP246
EDID Version HDMI: 1.3 / VGA: 1.3
Factory Version v1.00
[</>]Set [EXIT] Exit
KDL-40EX640/46EX640/55EX640 28
3. Using the button, scroll down to select Color Temp. 6. After the correct Color Temperature is selected, press the to
Factory Mode select the Temperature type that needs to be modified.
7. After the correct Temperature type is selected, press the to
Input Source <[ TV ]> increase the data value, or press to decrease the data value.
White Balance <[ Off ]>
Internal Pattern <[ Off ]> 8. Complete the data value adjustments to the remaining temperature
Color Temp >> items within the selected temperature type.
Aging Mode <[ Off ]> NOTE: Changes to the data value must be saved within the
ADC Calibration >> Temperature type selected before making changes to one of the
TVD ADC Calibration >>
other Temperature types.
Auto Phase <[ Off ]>
Factory Reset (default) Off 9. To save the changes, press the to select Data Backup, then
Recall Data <[ Off ]> press .
Data Backup <[ Off ]>
Site Air Channels <[ Off ]> 10. Do one of the following:
Site Cable Channels <[ Off ]>
a. To make changes to one of the other Temperature types,
[</>]Set [EXIT] Exit repeat steps 5 through 9.
4. Press to access Color Temp adjustments. b. To exit Factory mode, press POWER .
Factory Mode
Color Temperature
Back <<
Color Temp <[ Neutral ]>
R Gain <[ 538 ]>
G Gain <[ 512 ]>
B Gain <[ 452 ]>
R Offset <[ 512 ]>
G Offset <[ 512 ]>
B Offset <[ 512 ]>
Recall Data <[ Off ]>
Data Backup <[ Off ]>
[</>]Set [EXIT] Exit
5. Press he or buttons to select the Color Temp type.

(Cool, Neutral, Warm1, or Warm2.)
KDL-40EX640/46EX640/55EX640 29
is a trademark of Sony Electronics
Reproduction in whole or part without written permission is prohibited. All rights reserved
Sony Corporation English
Sony Technology Center 2012BJ74WEB-1
Technical Services Printed in USA
9-883-874-02 Service Publication Department © 2012.2
KDL-40EX640/46EX640/55EX640 30
APPENDIX A: ENCRYPTION KEY COMPONENTS
Encryption key components developed by Sony Corporation contain confidential information, and shall be handled under the non-disclosure obligations
provided in the applicable agreement with Sony Corporation (and/or its subsidiary).
As part of this agreement specific instructions must be adhered to whenever a Circuit Board containing encryption key components is repaired and/or replaced
pursuant to the following:
1. In the service manual the Circuit Board(s) containing encryption key components shall be identified with a red outline and a .
2. Only repair boards or components listed in the service manual shall be utilized for replacement and/or repair.
3. Disassembly, decryption, or reverse-engineering component(s) is strictly prohibited.
4. Any board in which the Servicer replaces an encryption key component must be placed back into the set it orignally came from and the replaced
defective component MUST BE DESTROYED. Boards cannot be swapped.
5. If a Circuit Board identified with a red outline and a in the service manual is deemed to be defective:
a. and if a core charge is imposed and is covered under the product warranty, the defective un-repaired or modified board MUST BE RETURNED
to Sony.
b. and if the core charge is NOT covered under the product warranty, the defective un-repaired or modified board MUST BE DESTROYED.
6. If a unit is destroyed (such as field scrap), the Circuit Board identified with a red outline and a in the service manual MUST BE DESTROYED.
KDL-40EX640/46EX640/55EX640 A-1

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Self Diagnosis

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE / TRAINING MANUAL

Version Date Subject

LCD Digital Color TV

SERVICE / TRAINING MANUAL

Appendix A: Encryption Key Components................................................ A-1

! SAFETY-RELATED COMPONENT WARNING!!

SETTING UP AND CARRYING THE TV

USE CAUTION WHEN HANDLING THE LCD PANEL

CLEANING THE LCD PANEL

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

2. Check the interboard wiring to ensure that no wires are “pinched” or

Model name KDL- 55EX640 46EX640 40EX640

• Optional accessories availability depends on its stock.

BOARD LAYOUT FOR KDL-40EX640 ONLY

BOARD LAYOUT FOR KDL-46EX640 ONLY

BOARD LAYOUT FOR KDL-55EX640 ONLY

LCD PANEL ASSEMBLY

OVERVIEW SELF DIAGNOSIS FUNCTION

●● Problems with certain inputs (especially HDMI)

●● TV turns on and off by itself

VIEWING THE SELF CHECK DIAGNOSIS HISTORY SELF CHECK

Composite ANALOG AUDIO OUT

OVERALL BLOCK DIAGRAM

STANDBY LED BLINKING

Yes Power Supply

“SONY” logo No Power Supply

PROTECTION SHUTDOWN FLOWCHART

Any OSD Yes

Is distortion No Lines move

Any horizontal Yes

Any single or Yes

VIDEO DISTORTION FLOWCHART

1 4-415-089-01 STAND, HEAD (ML9) 3 4-415-102-01 STAND, BASE TP (ML)

▲ 4-421-427-01 SCREW, +PSW M5X16 LOCK

C Gently hold down the Rear Cover from the

Correct Incorrect Tilt away from LVDS

CAUTION: Tilt away from LVDS

Inserted Correctly Inserted Incorrectly Main Board

CONNECTOR TYPE 3 CONNECTOR TYPE 3

䐠 Tab Press down

䐠 Reinforcement Press down

Panel Bracket (V)

CLEANING THE LCD PANEL

P/N DESCRIPTION REMARKS TOTAL

203 1-910-105-30 (LVDS FFC) CONNECTOR ASSEMBLY40 41P (FFC)

ACCESSORIES AND PACKAGING OPTIONAL ACCESSORIES

4-171-791-12 MANUAL, INSTRUCTION

4-400-043-01 JOINT, SCREW

4-420-093-01 LABEL, ENERGY GUIDE(NK2)

OVERALL WIRE DRESSING FOR KDL-40EX640/46EX640 ONLY

OVERALL WIRE DRESSING FOR KDL-55EX640 ONLY

OVERVIEW Customer Support Center and it is deemed to be correctable with a software

SOFTWARE UPDATE RESPONSIBILITY EXAMPLES OF SOFTWARE CORRECTABLE SYMPTOMS

Website Support: www.sony.com/tvsupport

Please have the following information available:

EXAMPLE OF SOFTWARE VERSION

OVERVIEW ACCESSING SERVICE ADJUSTMENT MODE

Service Mode SELECTING THE PANEL ID CODE

00001 00036 00001

3. Press to select Panel Selection. ACCESSING FACTORY ADJUSTMENT MODE

[</>]Set [EXIT] Exit