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Service Manual
Service Manual
SERVICE MANUAL
AZ1-K Chassis
ORIGINAL MANUAL ISSUE DATE: 1/2010
9-883-842-02
SERVICE MANUAL
AZ1-K Chassis
9-883-842-02
9-883-842-02
KDL-46EX400/46EX401 i
KDL-46EX400/46EX401 1
Supplied accessories Remote control RM-YD035 (1)/Size AAA batteries (2)/Operating Instructions (1)/Quick Setup Guide
common to all models (1)/Warranty Card (1)/Safety and Regulatory Booklet (1)/Software License (1)/Stand installation
guide (1)/Table-Top Stand (1 set)
individual models Screw (4)
Optional accessories Connecting cables / Support Belt Kit / Wall-Mount Bracket: SU-WL500
KDL-46EX400/46EX401 2
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.
KDL-46EX400/46EX401 3
ALERTE!!
Afin d’eviter tout risque d’electrocution provenant d’un chássis sous tension, un transformateur d’isolement doit etre utilisé lors de tout
dépannage. Le chássis de ce récepteur est directement raccordé à l’alimentation du secteur.
KDL-46EX400/46EX401 4
KDL-46EX400/46EX401 5
1. Check the area of your repair for unsoldered or poorly soldered connections.
Check the entire board surface for solder splashes and bridges.
To Exposed Metal
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 you have replaced
all the insulators. AC
0.15 μF Voltmeter
(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 deterioration. Earth Ground
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. Figure A. Using an AC voltmeter to check AC leakage.
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-46EX400/46EX401 6
The Simpson’s 250 and Sanwa SH-63TRD are examples of passive VOMs Cold-water Pipe
that are suitable. Nearly all battery-operated digital multimeters that have a
2 VAC range are suitable (see Figure A).
HOW TO FIND A GOOD EARTH GROUND
A cold-water pipe is a guaranteed earth ground; the cover-plate retaining screw
on most AC outlet boxes is also at earth ground. Figure B. Checking for earth ground.
KDL-46EX400/46EX401 7
KDL-46EX400/46EX401 8
2 times
5 times
KDL-46EX400/46EX401 9
2. Press the following buttons on the Remote Commander within a second of each other:
SELF CHECK
Back <<
002 MAIN_POWE 001 001 indicates an error was detected
003 AUD_PORT 000 000 indicates no error was detected
003 DC_ALERT 000
004 BALANCER 000
005 TCON_ERR 000
005 HFR_ERR 000
005 P_ID_ERR 000
005 PANEL_POWE 000
006 BACKLITE 000
007 TEMP_ERR 000
KDL-46EX400/46EX401 10
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.
KDL-46EX400/46EX401 11
(Check the Sony Electronics Service Information website for any additional service related issues for this model.)
5
A
3
C B
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
1 X-2546-641-1 TABLE-TOP STAND ASSEMBLY (L3B) [2-4] 5 2-580-608-01 SCREW, +PSW M5X16
2 4-167-479-01 COVER, STAND (L3B) For product protection and safety reasons, Sony strongly recommends
3 4-166-871-01 COVER,NECK(ML3B) that you use the screws provided with the TV
4 4-166-868-01 NECK(ML3B) CAUTION: These screws cannot be used to secure the TV to
the Wall Mount Brackets
2-580-608-01 SCREW, +PSW M5X16
Soft Cloth
KDL-46EX400/46EX401 12
53
52
B
51
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
C F 51 X-2546-685-1 REAR COVER (46) ASSEMBLY 2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3
52 4-163-784-11 COVER, UNDER (40) 7-685-648-79 SCREW +BVTP 3X12 TYPE2 IT-3
53 4-163-809-01 COVER, ECS 4-159-298-01 SCREW, +PSW M4X10
KDL-46EX400/46EX401 13
E Remove 2 screws from Loudspeaker and lift up to detach from Speaker Bracket Right
F Press down on Panel Support
G Slide out Panel Support to remove from Bezel Assembly
101
104
AC Inlet
Bracket
103 101
E
102
AC Inlet
Bracket
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
D AC Inlet
101 1-858-371-11 LOUDSPEAKER (4.5X20CM) 4-167-964-01 SCREW, +PWTP2 4X16
B 102 4-166-129-01 BRACKET, SP (46L) 2-580-629-01 SCREW, +BVST 3X8
! 103 1-842-008-11 AC INLET FILTER
C 104 4-166-130-01 BRACKET, SP (46R)
105 4-163-795-01 PANEL SUPPORT (A)
KDL-46EX400/46EX401 14
B Remove 2 screws from Bottom Frame to detach from LCD Panel (Check the Sony Electronics Service Information website for any additional service related issues for this model.)
C Lift up Switch Unit to remove from Bezel
D Disconnect 1 connector from Switch Unit
E Disconnect 6 connectors from GD2 (Power) Board
F Remove 4 screws from GD2 (Power) Board 151
152
156
153
Mini Card
Spacer
D 154
155
C
F REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
PWB L
Holder 151 X-2546-671-1 BEZEL (CY46) ASSEMBLY 154 4-163-796-01 BRACKET, SIDE JACK
K (KDL-46EX400 US MODELS ONLY) 155 1-857-593-21 A BOARD, COMPLETE
B
G 151 X-2547-683-1 BEZEL (CY46)F ASSEMBLY 156 1-474-205-11 GD2 (POWER) BOARD, COMPLETE
I (KDL-46EX400 CND & MX MODELS ONLY) 157 1-487-889-11 SWITCH UNIT
151 X-2546-679-1 BEZEL (CY46)DF ASSEMBLY
H (KDL-46EX401 ONLY) 2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3
A 2-580-592-01 SCREW, +PSW M3X8
J
152 1-857-594-11 H2 BOARD, COMPLETE 4-159-298-01 SCREW, +PSW M4X10
153 NA LCD PANEL
FOR ALL LCD PANEL PART NUMBER INFORMATION
REFER TO THE LCD PANELS SERVICE MANUAL
KDL-46EX400/46EX401 15
SP SP
H2
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
201 1-910-060-89 LVDS CONNECTOR ASSY LVDS 46-I 203 1-910-060-97 CONNECTOR ASSY HV CABLE-I
202 1-910-060-96 CONNECTOR ASSY FOR PANEL 204 1-910-060-98 CONNECTOR ASSY HV CABLE-II
KDL-46EX400/46EX401 16
KDL-46EX400/46EX401 17
VOLUME+
RM-YD035
KDL-46EX400/46EX401 18
System FW 1
Arrow buttons Model Name KDL-40EX400
Serial number See rear or side of TV
MENU
Picture Quality PQ0.5000
Audio Quality AQ1.000
MCU Version SM1.00W00AA
Pahel Info MT001.0000.0000?LT
MUTING EDID Version 79
[</>]Set [Menu] Exit
RM-YD035
KDL-46EX400/46EX401 19
GD2
H2
SWITCH UNIT
KDL-46EX400/46EX401 20
KDL-46EX400/46EX401 21
KDL-46EX400/46EX401 22