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Sony KDL-32EX525 Service Manual
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Sony KDL-32EX525 Service Manual

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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL
KDL-32EX525
KDL-40EX525
ORIGINAL MANUAL ISSUE DATE: 5/2011
REVISION DATE
5/19/2011
9-888-445-51
COMMANDER
RM-YD064
RM-YD064
CONFIDENTIAL
ELECTRICAL SERVICE MANUAL
INTERNAL ONLY
SUBJECT
No revisions or updates are applicable at this time.
AZ2-F
DESTINATION
LEVEL
ARGENTINA
CONFIDENTIAL
ARGENTINA
LCD DIGITAL COLOR TV
CHASSIS
3

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  • Page 1 HISTORY INFORMATION FOR THE FOLLOWING MANUAL: AZ2-F SERVICE MANUAL CHASSIS MODEL COMMANDER DESTINATION LEVEL KDL-32EX525 RM-YD064 ARGENTINA CONFIDENTIAL KDL-40EX525 RM-YD064 ARGENTINA CONFIDENTIAL ELECTRICAL SERVICE MANUAL INTERNAL ONLY ORIGINAL MANUAL ISSUE DATE: 5/2011 REVISION DATE SUBJECT 5/19/2011 No revisions or updates are applicable at this time.

  • Page 2: Table Of Contents

    BATV Board Schematic Diagram (11 of 12) ..............................22 BATV Board Schematic Diagram (12 of 12) ..............................23 GE2 Board Schematic Diagram (KDL-32EX525 Only) ............................ 26 GE3 Board Schematic Diagram (KDL-40EX525 Only) ............................ 29 HLR2 Board Schematic Diagram ..................................31 HMS3 Board Schematic Diagram ..................................

  • Page 3: Safety-Related Component Warning

    KDL-32EX525/40EX525 SAFETY-RELATED COMPONENT WARNING There are critical components used in LCD color TVs that are important for safety. These components are identified with shading and mark on the schematic diagrams and the electrical parts list. It is essential that these critical parts be replaced only with the part number specified in the electrical parts list to prevent electric shock, fire, or other hazard.
  • Page 4 KDL-32EX525/40EX525 The circuit boards used in these models have been processed using Lead Free Solder. The boards are identified by the LF logo located close to the board designation e.g. H1 etc [ see example ]. The servicing of these boards requires special precautions to be taken as outlined below.

  • Page 5: Safety Check-Out

    KDL-32EX525/40EX525 SAFETY CHECK-OUT The AC leakage from any exposed metal part to earth ground and After correcting the original service problem, perform the following from all exposed metal parts to any exposed metal part having a safety checks before releasing the set to the customer: return to chassis, must not exceed 0.5 mA (500 microamperes).

  • Page 6: Section 1: Diagrams

    KDL-32EX525/40EX525 SECTION 1: DIAGRAMS 1-1. CIRCUIT BOARDS LOCATION BATV SWITCH UNIT TCON HLR2 HMS3 KDL-32EX525 ONLY BATV SWITCH UNIT TCON HLR2 HMS3 KDL-40EX525 ONLY KDL-32EX525/40EX525...

  • Page 7: Printed Wiring Boards And Schematic Diagrams Information

    KDL-32EX525/40EX525 1-2. PRINTED WIRING BOARDS AND SCHEMATIC DIAGRAMS INFORMATION Readings are taken with a color-bar signal input. All capacitors are in μF unless otherwise noted. pF : μμF 50WV or less are not indicated except for electrolytics and tantalums. Readings are taken with a 10M digital multimeter.
  • Page 8 KDL-32EX525/40EX525 Terminal name of semiconductors in silk screen REFERENCE INFORMATION printed circuit ( RESISTOR CAPACITOR Circuit Device Printed symbol Terminal name : RN METAL FILM : TA TANTALUM Collector : RC SOLID : PS STYROL Transistor Emitter Base : FPRD NONFLAMMABLE CARBON...

  • Page 9: Block Diagrams

    KDL-32EX525/40EX525 1-3. BLOCK DIAGRAMS WIFI Board BATV-Board Switch Unit Wireless LAN Keys Power Key (EX523 Models Only) Function Keys HMS3-Board Motion Sensor HLR2-Board Power/ LEDs SIRCS IR Sensor Optical Digital Audio Output Light Level Headphone/Analog Audio Output X-Reality Processor TV Microprocessor...
  • Page 10 KDL-32EX525/40EX525 USB1 Ether DiSEqC_Out USB2 X’tal 27MHz H Con. TCON DiSEqC_In Silicon [LNBH23] Satellite Zero-IF Tuner Ext Demod IFAGC Cable I2CB [HORUS3] [SEKITO2] DDR3 USB4 Current Current USB3 DMD_CLK_ENABLE2 –1333 Limit Limit DMD_CLK_ENABLE1 Wifi [TPS2553DBV] [TPS2553DBV] DMD_RST Current X’tal Limit One –...

  • Page 11: Connector Diagram

    KDL-32EX525/40EX525 1-4. CONNECTOR DIAGRAM (Only Interface between board and board) BAT- V board T- con Board(60Hz) HMS3 board JAM 3pin Straight To BAT CN6201(40" GE3) CN6704 (32" GE2) - 821- 130- 11 LUT_SEL2 LUT_SEL2 SJM20-28WLB LUT_SEL1 LUT_SEL1 PANEL FFC To B board (100106)

  • Page 12: Schematics And Supporting Information

    KDL-32EX525/40EX525 1-5. SCHEMATICS AND SUPPORTING INFORMATION BATV BOARD SCHEMATIC DIAGRAM (1 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 13: Batv Board Schematic Diagram (2 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (2 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 14: Batv Board Schematic Diagram (3 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (3 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 15: Batv Board Schematic Diagram (4 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (4 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 16: Batv Board Schematic Diagram (5 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (5 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 17: Batv Board Schematic Diagram (6 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (6 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 18: Batv Board Schematic Diagram (7 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (7 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 19: Batv Board Schematic Diagram (8 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (8 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 20: Batv Board Schematic Diagram (9 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (9 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 21: Batv Board Schematic Diagram (10 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (10 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 22: Batv Board Schematic Diagram (11 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (11 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...

  • Page 23: Batv Board Schematic Diagram (12 Of 12)

    KDL-32EX525/40EX525 BATV BOARD SCHEMATIC DIAGRAM (12 OF 12) — — — — — — — — — — — — — — — KDL-32EX525/40EX525...
  • Page 24 KDL-32EX525/40EX525 BATV [SYSTEM/STREAM/DEMOD/CI/BCAS/ONE NAND/DDR3/VIDEO AUDIO IN/OUT/ETHERNET/USB/POWER/GND/HDMI/LVDS/PANEL/A/V CONNECTOR/HDMI EQ/CONNECTOR/AUDIO AMP/TUNER] COMPONENT SIDE cam017 cam021 cam007 cam031 cam001 R2976 RB2900 cam101 C9802 C9714 C9685 C9811 C9690 C9813 C2900 camcn6002 R9072 JL9005 C9707 FB2900 C9803 C9715 C9686 C9682 C9711 C9820 Q6005 C9633 C9812...
  • Page 25 KDL-32EX525/40EX525 BATV [SYSTEM/STREAM/DEMOD/CI/BCAS/ONE NAND/DDR3/VIDEO AUDIO IN/OUT/ETHERNET/USB/POWER/GND/HDMI/LVDS/PANEL/A/V CONNECTOR/HDMI EQ/CONNECTOR/AUDIO AMP/TUNER] CONDUCTOR SIDE R9136 C9017 C9101 Q9003 JL9011 R9067 C9908 Q6004 C9704 C9703 C9702 C6051 C9902 camic9010 R6035 R2903 R2901 R2915 R2966 R2967 R2914 R2918 R9114 C9706 C9705 R9068 Q9007 JL6022 JL9012 R6038 —...

  • Page 26: Ge2 Board Schematic Diagram (Kdl-32Ex525 Only)

    KDL-32EX525/40EX525 GE2 BOARD SCHEMATIC DIAGRAM (KDL-32EX525 ONLY) +OUT1 D6407,D6408 Mount Mecha A6401 409608101 設計手配リストを参照 +OUT2 120V +OUT3 +OUT4 — JL6127 Mount Mecha A6101 409608101 IC6351 R6115 JL6601 Newアルミ中型 C6108 R6606 CN6701 120V-0V swithcing 1/10W 0 . 1 1/10W D6002 RN-CP...
  • Page 27 KDL-32EX525/40EX525 [POWER] COMPONENT SIDE (KDL-32EX525 ONLY) — — — — — — — — — — — — — — — — KDL-32EX525/40EX525...
  • Page 28 KDL-32EX525/40EX525 [POWER] CONDUCTOR SIDE (KDL-32EX525 ONLY) J L 6 1 4 5 — C 6 1 3 1 T 6 3 0 2 J C 6 0 2 3 J C 6 0 2 7 R 6 1 3 6 J L 6 1 0 3 —...

  • Page 29: Ge3 Board Schematic Diagram (Kdl-40Ex525 Only)

    KDL-32EX525/40EX525 GE3 BOARD SCHEMATIC DIAGRAM (KDL-40EX525 ONLY) CN6101 T6301 — R6307 JL6314 D6201 C6303 R6308 1/2W 100k SR206-09 A0 470p JL6201 JL6214 JS6201 630V 3216 JL6202 D6305 ET6101 EY6105 EY6106 1F6G-TA26 C6202 C6210 C6211 JL6315 0.01 6.3V 6.3V JL6203 JL6115...
  • Page 30 KDL-32EX525/40EX525 [POWER] [POWER] COMPONENT SIDE (KDL-40EX525 ONLY) CONDUCTOR SIDE (KDL-40EX525 ONLY) — — — — — — — — — — — — — — — — — — — — — — — — — — — — —...

  • Page 31: Hlr2 Board Schematic Diagram

    KDL-32EX525/40EX525 HLR2 BOARD SCHEMATIC DIAGRAM — — JL105 STBY+3.3V LED_REC LED_STBY — LED_TIMER LED_POWER LED_PIC_MUTE DEVICE_SDA/GND DEVICE_SCL/LED_BDR — OPT_SENS VD+3.3V SIRCS CN100 R136 R137 1 . 5 k R138 — JL100 R102 R103 JL102 JL103 R111 R112 JL104 JL101 1 . 8 k 2 .
  • Page 32 KDL-32EX525/40EX525 HLR2 [IR/LED/SENSOR] COMPONENT SIDE D C B 3 2 1 JL105 JL106 C102 R130 R129 R127 R119 R118 R117 R135 C111 cam25 > E P G W < 6 5 4 R131 R112 VDR100 C N 1 0 0...

  • Page 33: Hms3 Board Schematic Diagram

    KDL-32EX525/40EX525 HMS3 BOARD SCHEMATIC DIAGRAM R136 CHIP 1005 — R130 R132 3 . 3 k R127 1/16W 1/16W C105 RN-CP CHIP 1/16W 6.3V CHIP 2012 RN-CP R125 1/16W 220k 470k 1/16W R128 1/16W R104 CHIP 8.2M RN-CP C108 C107 1005 6.3V...
  • Page 34 KDL-32EX525/40EX525 HMS3 [MOTION SENSOR] COMPONENT SIDE R100 R101 R102 R103 R105 R106 R108 R109 1 - 8 8 3 - 7 5 5 - 2 1 R111 R113 R114 R115 R116 R117 R118 R119 R120 R121 R122 R123 R124 R112...

  • Page 35: Section 2: Electrical Parts List

    KDL-32EX525/40EX525 SECTION 2: ELECTRICAL PARTS LIST BATV Items marked with an asterisk are not stocked since they NOTE: The components identified by shading RESISTORS are seldom required for routine service. Expect some delay mark are critical for safety. Replace only •...
  • Page 36 KDL-32EX525/40EX525 BATV REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C1621 1-100-916-11 CERAMIC CHIP 0.1µF C2014 1-100-916-11 CERAMIC CHIP 0.1µF C1639 1-100-905-11 CERAMIC CHIP 0.001µF 10% C2019 1-114-869-11 CERAMIC CHIP 2.2µF 6.3V C1640 1-100-905-11 CERAMIC CHIP 0.001µF 10%...
  • Page 37 KDL-32EX525/40EX525 BATV REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C4504 1-114-130-11 CERAMIC CHIP 1µF 6.3V C6020 1-114-813-11 CERAMIC CHIP 1µF C4522 1-114-130-11 CERAMIC CHIP 1µF 6.3V C6021 1-114-802-11 CERAMIC CHIP 0.0033µF 10% C4593 1-114-807-11 CERAMIC CHIP 0.015µF 10%...
  • Page 38 KDL-32EX525/40EX525 BATV REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C9042 1-100-905-11 CERAMIC CHIP 0.001µF 10% C7030 1-100-916-11 CERAMIC CHIP 0.1µF C9043 1-100-905-11 CERAMIC CHIP 0.001µF 10% C7033 1-112-780-11 CERAMIC CHIP 0.47µF C9052 1-116-720-11 CERAMIC CHIP 10µF...
  • Page 39 KDL-32EX525/40EX525 BATV REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES CN5502 1-842-681-11 HDMI CONNECTOR C9638 1-100-916-11 CERAMIC CHIP 0.1µF CN5505 1-842-681-11 HDMI CONNECTOR C9639 1-100-916-11 CERAMIC CHIP 0.1µF CN6002 1-819-452-11 HEADER ASSEMBLY FOR PWB C9640 1-100-916-11 CERAMIC CHIP 0.1µF...
  • Page 40 KDL-32EX525/40EX525 BATV REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES IC6002 6-716-852-01 TPS54425PWPR FB4094 1-469-084-21 FERRITE IC6003 6-716-892-01 BD95830MUV-E2 FB4095 1-469-084-21 FERRITE IC6005 6-716-890-01 TPS53114PWR FB4096 1-469-084-21 FERRITE IC8400 6-715-859-01 MM3464A18NRE FB4097 1-469-084-21 FERRITE IC8402 6-716-980-01...
  • Page 41 KDL-32EX525/40EX525 BATV REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES L5511 1-234-400-21 CONDUCTOR, NETWORK (1005X4) R1404 1-218-953-11 METAL CHIP 1/16W L6001 1-457-864-11 INDUCTOR 1µH R1405 1-218-941-81 METAL CHIP 1/16W L6002 1-457-730-11 INDUCTOR 2.2µH R1407 1-218-941-81 METAL CHIP...
  • Page 42 KDL-32EX525/40EX525 BATV REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R2432 1-218-945-11 METAL CHIP 1/16W R5627 1-218-990-81 SHORT CHIP R2533 1-218-990-81 SHORT CHIP R5628 1-218-990-81 SHORT CHIP R2534 1-218-990-81 SHORT CHIP R5631 1-218-929-11 METAL CHIP 1/16W...
  • Page 43 KDL-32EX525/40EX525 BATV REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R8473 1-218-965-11 METAL CHIP 1/16W R9438 1-218-937-11 METAL CHIP 1/16W R9001 1-218-953-11 METAL CHIP 1/16W R9439 1-218-990-81 SHORT CHIP R9003 1-218-990-81 SHORT CHIP R9440 1-218-990-81 SHORT CHIP...
  • Page 44 KDL-32EX525/40EX525 BATV REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES TRANSFORMER RB2705 1-234-381-11 RES, NETWORK 100K (1005X4) RB4002 1-234-381-11 RES, NETWORK 100K (1005X4) T1401 1-445-777-11 TRANSFORMER, RF (SMD) (2010) RB4003 1-234-381-11 RES, NETWORK 100K (1005X4) T5200...
  • Page 45 1-107-908-11 ELECT 33µF C6358 1-100-597-91 CERAMIC CHIP 0.1µF C6359 1-100-927-21 CERAMIC CHIP 0.001µF 10% 630V A-1805-916-A GE2 BOARD, COMPLETE (KDL-32EX525 ONLY) C6360 1-112-481-11 CERAMIC 470pF 4-382-854-01 SCREW (M3X8), P, SW (+) C6362 1-100-927-21 CERAMIC CHIP 0.001µF 10% 630V 1-481-203-11 FERRITE...
  • Page 46 KDL-32EX525/40EX525 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C6618 1-162-970-11 CERAMIC CHIP 0.01µF D6610 8-719-069-34 DIODE S3L60 C6619 1-112-781-11 CERAMIC CHIP 1µF D6611 6-502-767-01 DIODE ST03-240F1 C6620 1-112-781-11 CERAMIC CHIP 1µF D6701 6-502-979-01 DIODE DA4J104K0L...
  • Page 47 KDL-32EX525/40EX525 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES JC6036 1-216-295-91 SHORT CHIP R6101 1-208-814-91 METAL CHIP 0.50% 1/10W JC6037 1-216-296-11 SHORT CHIP R6102 1-215-882-81 METAL OXIDE JC6038 1-216-296-11 SHORT CHIP R6103 1-257-095-21 METAL JC6039 1-216-296-11...
  • Page 48 KDL-32EX525/40EX525 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R6221 1-216-055-00 METAL CHIP 1.8K 1/10W R6510 1-216-849-11 METAL CHIP 220K 1/10W R6301 1-257-099-21 FUSIBLE 1/2W R6511 1-216-304-11 METAL CHIP 1/10W R6308 1-216-819-11 METAL CHIP 1/10W R6512...
  • Page 49 KDL-32EX525/40EX525 GE2 GE3 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R6641 1-215-904-11 METAL OXIDE 100K THERMISTOR R6642 1-216-113-00 METAL CHIP 470K 1/10W TH6101 1-811-343-41 POWER THERMISTOR R6643 1-250-699-11 METAL CHIP 1/10W TH6401 1-811-028-11 THERMISTOR, POSITIVE...
  • Page 50 KDL-32EX525/40EX525 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C6505 1-112-869-41 CERAMIC 470pF 250V C6629 1-162-970-11 CERAMIC CHIP 0.01µF C6506 1-162-970-11 CERAMIC CHIP 0.01µF C6630 1-162-970-11 CERAMIC CHIP 0.01µF C6509 1-125-891-11 CERAMIC CHIP 0.47µF C6631 1-100-591-91 CERAMIC CHIP 1µF...
  • Page 51 KDL-32EX525/40EX525 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES D6610 6-502-976-01 DIODE DZ2J150M0L JR6134 1-216-295-91 SHORT CHIP D6611 6-502-961-01 DIODE DA2J10100L JR6135 1-216-295-91 SHORT CHIP D6612 6-502-979-01 DIODE DA4J104K0L JR6136 1-216-295-91 SHORT CHIP D6616 6-502-979-01 DIODE...
  • Page 52 KDL-32EX525/40EX525 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES Q6723 6-551-678-01 TRANSISTOR 2SA1364-T111-1DE R6506 1-208-842-11 METAL CHIP 330K 0.50% 1/10W Q6724 6-552-408-01 TRANSISTOR DSC500100L R6508 1-250-650-11 METAL CHIP 1/10W Q6725 6-551-714-01 TRANSISTOR INK0001AC1-T112-1 R6509 1-216-081-00 METAL CHIP...
  • Page 53 KDL-32EX525/40EX525 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R6653 1-250-652-11 METAL CHIP 1/10W R6602 1-216-833-11 METAL CHIP 1/10W R6655 1-250-656-11 METAL CHIP 1/10W R6603 1-216-841-11 METAL CHIP 1/10W R6657 1-250-656-11 METAL CHIP 1/10W R6604 1-216-839-11...
  • Page 54 KDL-32EX525/40EX525 HLR2 HMS3 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R6798 1-260-330-11 CARBON 1.5K 1/2W R112 1-218-957-11 METAL CHIP 2.2K 1/16W R6799 1-216-833-11 METAL CHIP 1/10W R115 1-218-941-81 METAL CHIP 1/16W R6800 1-249-385-11 CARBON 1/4W...
  • Page 55 KDL-32EX525/40EX525 HMS3 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES RESISTOR R104 1-250-559-11 METAL CHIP 470K 1/16W R107 1-218-989-11 METAL CHIP 1/16W R110 1-218-973-11 METAL CHIP 1/16W R112 1-248-243-81 METAL CHIP 8.2M 1/16W R125 1-218-981-91 METAL CHIP...

  • Page 56: Appendix A: Encryption Key Components

    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.

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Kdl-40ex525

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