HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE MANUAL
ORIGINAL MANUAL ISSUE DATE: 2/2011
AZ2W CHASSIS
Segment: P-1
Version Date Subject
1.0 2/2011 Original manual issue.
2.0 3/2011 Added Model KDL-32EX421.
3.0 4/2011 Updated Self Diagnostic and Adjustment Information.
4.0 5/2011 Added Models KDL-37EX521 and KDL-46EX520,521.
Addition of Appendix-1.
5.0 6/2011 Added Models KDL-32EX425,523,524,525, KDL-37EX524,525,
KDL-40EX523,524,525 and KDL-46EX524,525.
LCD Digital Color TV

9-883-491-05
KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK)
S/N range 1,000,001-1,999,999 (BCN)
SERVICE MANUAL
AZ2W CHASSIS
Segment: P-1

LCD Digital Color TV

9-883-491-05
MODEL LIST

MODEL COLOR COMMANDER DEST. MODEL COLOR COMMANDER DEST.

KDL-32EX421 Black RM-ED045 AEP
KDL-32EX425 Black RM-ED045 AEP
KDL-32EX520 Black RM-ED045 AEP
KDL-32EX521 Black RM-ED045 AEP
KDL-32EX523 Black RM-ED045 UK
KDL-32EX524 Black RM-ED045 AEP
KDL-32EX525 Black RM-ED045 AEP
KDL-37EX521 Black RM-ED045 AEP
KDL-37EX524 Black RM-ED045 AEP
KDL-37EX525 Black RM-ED045 AEP
KDL-40EX520 Black RM-ED045 AEP
KDL-40EX521 Black RM-ED045 AEP
KDL-40EX523 Black RM-ED045 UK
KDL-40EX524 Black RM-ED045 AEP
KDL-40EX525 Black RM-ED045 AEP
KDL-46EX520 Black RM-ED045 AEP
KDL-46EX521 Black RM-ED045 AEP
KDL-46EX524 Black RM-ED045 AEP
KDL-46EX525 Black RM-ED045 AEP

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 3
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.

WARNING!!
An isolation transformer should be used during any service to avoid possible shock hazard, because of live chassis.
The chassis of this receiver is directly connected to the ac power line.

CARRYING THE TV
Be sure to follow these guidelines to protect your property and avoid causing serious injury.
• Carry the TV with an 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 damages.

SAFETY-RELATED COMPONENT WARNING!!

Components identified by shading and ! mark on the schematic diagrams, exploded views, and in the parts list are critical for safe operation. Replace these components with Sony
parts whose part numbers appear as shown in this manual or in supplements published by Sony. 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.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 4
WARNINGS AND CAUTIONS - FRENCH

ATTENTION!!
Ces instructions de service sont à l’usage du personnel de service qualifi é seulement.
Pour prévenir le risque de choc électrique, ne pas faire l’entretien autre que celui contenu dans le Mode d’emploi à moins que vous soyez qualifi é faire ainsi.

WARNING!!
Afi n 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.

POUR TRANSPORTER LE TÉLÉVISEUR

Tenez compte de ce qui suit pendant l’installation du téléviseur :
• Débranchez tous les câbles avant de transporter le téléviseur.
• Transportez le téléviseur avec le nombre de personnes approprié ; un téléviseur de grande taille doit être transporté par au moins deux personnes.
• Lors du transport du téléviseur, l’emplacement des mains est très important pour votre sécurité, ainsi que pour éviter de causer des dommages.

ALERTE!!
Afi n d’eviter tout risque d’electrocution provenant d’un chassis sous tension, un transformateur d’isolement doit etre utilise lors de tout depannage. Le chassis de ce recepteur est
directement raccorde a l’alimentation du secteur.

ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!!

Les composants identifi es par une trame et par une marque ! sur les schemas de principe, les vues explosees et les listes de pieces sont d’une 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 l’importance est critique pour la securite du fonctionnement sont identifi es dans le present manuel. Suivre ces procedures lors de chaque remplacement de
composants critiques, ou lorsqu’un mauvais fonctionnement suspecte.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 5
 WARNINGS AND CAUTIONS

USE CAUTION WHEN HANDLING THE LCD PANEL

When repairing the LCD panel, be sure you are grounded by using a wrist band.
When repairing the LCD panel on the wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.

1) Do not press on the panel or frame edge to avoid the risk of electric shock.
2) Do not scratch or press on the panel with any sharp objects.
3) Do not leave the module in high temperatures 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 (CCFL) 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) It is recommended not to exceed 1 hour of Power-On nor Burn-in period with LCD panel face down condition, in repair activity.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 6
 WARNINGS AND CAUTIONS

HANDLING THE FFC

When you insert / pull out FFC, please grasp a reinforcement board and main body of FFC. < Insertion >
Please hold reinforcement board and plunge it to the depths.

Reinforce
plate

B board

<GOOD> <NG>

<Pull out>
FFC can reverse insertion to connector of B board.
If reverse insertion FFC, all pins short-circuit, and board is broken. Please pull out FFC while pushing the upper button
at the same time.

Upper side is GND shield Push!!

Upper side is terminal
1
Reinforce
plate
2

B board
<GOOD> <NG>

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 7
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.

8. For safety reasons, repairing the Power board and/or Inverter board is prohibited.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 8
 SAFETY CHECK-OUT

Leakage Test
The AC leakage from any exposed metal part to earth ground and from all exposed metal parts to any exposed
metal part having a return to chassis, must not exceed 0.5 mA (500 microamperes).
Leakage current can be measured by any one of three methods.

1. A commercial leakage tester, such as the Simpson 229 or RCA WT-540A. Follow the manufacturers’
instructions to use these instructions.
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 Simpson’s 250 and Sanwa SH-63TRD are examples of passive VOMs that are suitable. Nearly all
battery-operated digital multimeters that have a 2 VAC range are suitable (see Figure A).

How to Find a Good Earth Ground

A cold-water pipe is a guaranteed earth ground; the cover-plate retaining screw on most AC outlet boxes is also
at earth ground.
If the retaining screw is to be used as your earth ground, verify that it is at ground by measuring the resistance
between it and a cold-water pipe with an ohmmeter. The reading should be zero ohms.
If a cold-water pipe is not accessible, connect a 60- to 100-watt trouble- light (not a neon lamp) between the hot
side of the receptacle and the retaining screw. Try both slots, if necessary, to locate the hot side on the line; the
lamp should light at normal brilliance if the screw is at ground potential (see Figure B).

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 9
SELF DIAGNOSIS FUNCTION
The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY LED will automatically begin to flash.
The number of times the LED flashes translates to a probable source of the problem.
A definition of the STANDBY LED flash indicators is listed in the instruction manual for the user’s knowledge and reference.
If an error symptom cannot be reproduced, the remote commander can be used to review the failure occurrence data stored in memory to reveal past problems and how often these
problems occur.

DIAGNOSTIC TEST INDICATORS

When an error occurs, the STANDBY LED will flash a set number of times to Service menu Item
STBY LED
indicate the possible cause of the problem. name Diagnostic Item Description
Flash time
If there is more than one error, the LED will identify the first of the problem areas. (Screen Display)
2 MAIN_POWE Main Power Over Voltage Protection
Result for all of the following diagnostic items are displayed on screen.
3 DC_ALERT DC_ALERT
If the screen displays a “0”, no error has occurred .
AUD_PROT Audio Abnorm al Detection
4 BALANCER Not us ed
5 TCON_ERR Not us ed
DISPLAY OF STANDBY LED FLASH COUNT
HFR_ERR Not us ed
P_ID_ERR Panel ID NVM Error
6 BACKLITE Back Light Error (Panel Inverter) or Power Board Error
7 TEMP_ERR Therm al Error
FAN_ERR Fan Error
8 - Software Error
0.5 9 - Not us ed
0.5 10 EMITTER Not us ed
3
11 - Not us ed
12 - Not us ed

SELF-DIAGNOSTIC SCREEN DISPLAY

For errors with symptoms such as “power sometimes shuts off” or “screen sometimes goes out” that cannot be confirmed, it is possible to bring up past occurrences of failure for
confirmation on the screen:

[To Bring Up Screen Test]

In standby mode, press buttons on the remote commander sequentially in rapid succession as shown below:
*
DISPLAY Channel 5 Volume TV POWER
* : Note that this differs from entering the service mode (volume +)

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 10
 SELF DIAGNOSIS FUNCTION

[SELF DIAGNOSTIC SAMPLE SCREEN DISPLAY]

SELF CHECH <1> NEXT PAGE‐>

Item name
000 RGB_SEN ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
002 MAIN_POWE ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
003 DC_ALERT ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
003 AUD_PROT ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
003 DTT_WDT ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
004 VLED ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
004 BALANCER ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
STBY LED flash time 005 HFR_ERR ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00 Error count (00-99)
005 TCON_ERR ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
005 P_ID_ERR ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
006 BACKLITE ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
007 TEMP_ERR ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
007 FAN_ERR ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
010 EMITTER ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00
011 IA ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐ 00 Error history (Last failure time beforehand)
Error history (Failure time before last)
12345‐67891‐23456 Error history (The last failure time)
Panel operation time by hour (MAX:65535)
Boot count (MAX:65535)
Total operation time by hour (MAX:65535)

Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screen.
After you have completed the repairs, clear the result display to “0”.

Clearing the Self Check Diagnostic List

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

Exiting the Self-diagnostic screen

To exit the Self Diagnostic screen, turn off the power to the TV by pressing the POWER button on the remote or the POWER button on the TV.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 11
SEC 1. DISASSEMBLY AND PARTS LIST
• Items with no part number and no description are not stocked because they are seldom required for roution service.
• The construction parts of an assembled part are indicated with a collation number in the remark colum.
• Items marked " * " are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items.
• There is a clutch in the yellow frame[ ]. Therefore please be careful during the disassembly or assembly of parts.

IMPORTANT: When replacing LCD Panel or Circuit Boards ensure that all Radiation Sheets and Insulation Sheets are in their
correct positions in the TV set.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 12
 DISASSEMBLY AND PARTS LIST

1-1. KDL-32EX421/425/520/521/523/524/525
1-1-1. STAND BLOCK REF. No. PART No. DESCRIPTION REMARK

1 4-267-488-11 STAND, HEAD(M9)

2 4-259-177-01 NECK(M9)
3 4-269-900-01 STAND, BASE(M2)

2-580-608-01 SCREW, +PSW M5X16

4-259-541-01 USER SCREW ST

1-1-2. HEAD STAND, NECK AND BASE STAND

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 13
 DISASSEMBLY AND PARTS LIST

1-1. KDL-32EX421/425/520/521/523/524/525
1-1-3. REAR COVER, AC COVER REF. No. PART No. DESCRIPTION REMARK

10 4-275-433-01 REAR COVER(32)

11 4-259-168-11 COVER, AC(M)
12 1-474-277-12 STATIC CONVERTER (TV)-GE2A
10 13 4-258-700-21 BRACKET SIDE (BAT-V32) MOLD
14 4-265-046-21 LABEL(BAT-V MOLD SIDE)
4-265-046-31 LABEL(BAT-V MOLD SIDE) EX520,523
15 1-489-443-21 SWITCH UNIT
11
16 1-858-590-12 LOUDSPEAKER
17 1-838-271-11 POWER-SUPPLY CORD (WITH CONN.)
1-838-334-12 POWER-SUPPLY CORD (WITH CONN.) EX523

4-256-393-01 SCREW, +PSW M3X6 W12

4-268-126-01 SCREW, ORNAMENTAL M6X12
7-685-648-79 SCREW +BVTP 3X12 TYPE2 IT-3
1-1-4. GE2A BOARD, SWITCH UNIT, SPEAKER 4-257-907-01 JOINT STAND
2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3

12
13

14

15

16 17 16

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 14
 DISASSEMBLY AND PARTS LIST

1-1. KDL-32EX421/425/520/521/523/524/525
1-1-5. BAT-V BOARD, HLR2 BOARD, HMS3 BOARD
REF. No. PART No. DESCRIPTION REMARK

20 4-268-446-01 SHEET, INSULATION (G10)

21 * 1-910-801-03 CONNECTOR ASSY 28P
22 A-1807-676-A BAT-V COMPL (SERVICE) EX520,521(AEP)
22 A-1815-928-A BAT-V COMPL (SERVICE) EX521(IT)
21
A-1819-991-A BAT-V COMPL (SERVICE) EX421(AEP)
20 A-1821-544-A BAT-V COMPL (SERVICE) EX421(IT)
A-1839-278-A BAT-V COMPL (SERVICE) EX523(UK),524(AEP)
23 A-1839-746-A BAT-V COMPL (SERVICE) EX525(AEP)
A-1840-513-A BAT-V COMPL (SERVICE) EX425(AEP)
23 * 1-838-833-11 FFC WITH CONNECTOR l1 32S EX421
* 1-838-883-11 FFC WITH CONNECTOR l1 32S EX520,521,523,524,525
24 * 1-910-801-07 HARNESS ASSY EX421,425,521,524,525
24
* 1-910-801-93 HARNESS ASSY EX520,523
25 A-1792-878-A HLR2 MOUNT(B-O-AEP)
26 * 1-856-184-11 FRENEL LENS EX421,425,521,524,525
27 A-1792-511-A HMS3 MOUNT
28 4-256-392-01 BRACKET, PANEL (H)
25
29 4-256-391-01 BRACKET, PANEL (C)
1-1-6. LCD PANEL, BEZEL 30 1-811-323-11 LCD PANEL (S32ESB) EX421,425
1-811-324-11 LCD PANEL (32ESL) EX520,521,523,524,525
28
31 4-266-725-01 BEZEL(32 SYR) EX421,425,521,524,525
29 4-266-725-51 BEZEL(32 SYR) EX520,523

2-990-421-41 SCREW (+PSW) (M3X6)

29

26

27 Note:
The Bezel and LCD panel use double sided tape during installation.
Please refer to APPENDIX-2 for the correct procedure for disassembly
30 and assembly methods.
31

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 15
 DISASSEMBLY AND PARTS LIST

1-2. KDL-37EX521/524/525
1-2-1. STAND BLOCK REF. No. PART No. DESCRIPTION REMARK

1 4-267-495-11 STAND, HEAD(ML9)

2 4-259-180-02 NECK(ML9)
3 4-269-901-02 STAND, BASE(ML2)

2-580-608-01 SCREW, +PSW M5X16

4-259-541-01 USER SCREW ST

1-2-2. HEAD STAND, NECK AND BASE STAND

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 16
 DISASSEMBLY AND PARTS LIST

1-2. KDL-37EX521/524/525
1-2-3. REAR COVER, AC COVER REF. No. PART No. DESCRIPTION REMARK

10 4-287-401-01 REAR COVER(37)

11 4-259-168-11 COVER, AC(M)
12 1-474-277-12 STATIC CONVERTER (TV)-GE2A
10
13 4-258-700-23 BRACKET SIDE (BAT-V32) MOLD
14 4-265-046-21 LABEL(BAT-V MOLD SIDE)
15 1-489-443-21 SWITCH UNIT
16 1-858-592-11 LOUDSPEAKER
11 17 1-838-271-11 POWER-SUPPLY CORD (WITH CONN.)

4-256-393-01 SCREW, +PSW M3X6 W12

4-268-126-01 SCREW, ORNAMENTAL M6X12
7-685-648-79 SCREW +BVTP 3X12 TYPE2 IT-3
4-257-907-01 JOINT STAND
2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3
1-2-4. GE2A BOARD, SWITCH UNIT, SPEAKER

12

13

14

15

16 16
17

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 17
 DISASSEMBLY AND PARTS LIST

1-2. KDL-37EX521/524/525
1-2-5. BAT-V BOARD, HLR2 BOARD, HMS3 BOARD REF. No. PART No. DESCRIPTION REMARK

20 4-268-446-01 SHEET, INSULATION (G10)

21 1-910-801-51 CONNECTOR ASSY 28P
22 A-1815-928-A BAT-V COMPL (SERVICE) EX521(AEP)
22
21 A-1807-676-A BAT-V COMPL (SERVICE) EX521(IT)
A-1839-278-A BAT-V COMPL (SERVICE) EX524(AEP)
20
A-1839-746-A BAT-V COMPL (SERVICE) EX525(AEP)
23 1-838-882-11 FLEXIBLE FLAT CABLE I1 37S
23 24 1-910-801-53 HARNESS ASSY
25 A-1792-878-A HLR2 MOUNT(B-O-AEP)
26 * 1-856-184-11 FRENEL LENS
27 A-1792-511-A HMS3 MOUNT
24
28 4-256-392-01 BRACKET, PANEL (H)
29 4-256-391-01 BRACKET, PANEL (C)
30 1-811-318-11 LCD PANEL (A37V0)
31 4-287-397-01 BEZEL(37 SYR)

25
2-990-421-41 SCREW (+PSW) (M3X6)
7-685-646-79 SCREW +BVTP 3X8 TYPE 2 IT-3
1-2-6. LCD PANEL, BEZEL 28

29

29

26

Note:
The Bezel and LCD panel use double sided tape during installation.
27 Please refer to APPENDIX-2 for the correct procedure for disassembly
and assembly methods.
30
31

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 18
 DISASSEMBLY AND PARTS LIST

1-3. KDL-40EX520/521/523/524/525
1-3-1. STAND BLOCK REF. No. PART No. DESCRIPTION REMARK

1 4-267-495-11 STAND, HEAD(ML9)

2 4-259-180-01 NECK(ML9)
3 4-269-901-01 STAND, BASE(ML2)

2-580-608-01 SCREW, +PSW M5X16

4-259-541-01 USER SCREW ST

1-3-2. HEAD STAND, NECK AND BASE STAND

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 19
 DISASSEMBLY AND PARTS LIST

1-3. KDL-40EX520/521/523/524/525
1-3-3. REAR COVER, AC COVER REF. No. PART No. DESCRIPTION REMARK

10 4-275-424-01 REAR COVER(40)

11 4-259-168-11 COVER, AC(M)
12 1-474-287-21 STATIC CONVERTER (TV)-GE3A
10 13 4-256-424-21 BRACKET SIDE (BAT-V) MOLD
14 4-265-045-21 LABEL,SHEET(BAT-V MOLD SIDE) EX521,524,525
4-265-045-31 LABEL,SHEET(BAT-V MOLD SIDE) EX520,523
15 1-489-443-21 SWITCH UNIT
11 16 1-858-592-11 LOUDSPEAKER
17 1-838-271-11 POWER-SUPPLY CORD (WITH CONN.)
1-838-334-12 POWER-SUPPLY CORD (WITH CONN.) EX523

4-256-393-01 SCREW, +PSW M3X6 W12

4-268-126-01 SCREW, ORNAMENTAL M6X12
7-685-648-79 SCREW +BVTP 3X12 TYPE2 IT-3
1-3-4. GE3A BOARD, SWITCH UNIT, SPEAKER 4-257-907-01 JOINT STAND
2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3

12

13

14

15

16 17 16

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 20
 DISASSEMBLY AND PARTS LIST

1-3. KDL-40EX520/521/523/524/525
1-3-5. BAT-V BOARD, HLR2 BOARD, HMS3 BOARD REF. No. PART No. DESCRIPTION REMARK

20 4-268-443-01 SHEET, INSULATION (G4)

21 * 1-910-801-57 CONNECTOR ASSY 28P
22 A-1807-676-A BAT-V COMPLETE EX520,521(AEP)
A-1815-928-A BAT-V COMPLETE EX520,521(IT)
22 A-1839-278-A BAT-V COMPLETE EX523(UK),524(AEP)
20 21 A-1839-746-A BAT-V COMPLETE EX525(AEP)
23 * 1-838-881-11 FFCWITH CONNECTOR l1 40S
24 * 1-910-801-62 HARNESS ASSY EX521,524,525
23
* 1-910-801-94 HARNESS ASSY EX520,523
25 A-1792-878-A HLR2 MOUNT(B-O-AEP)
26 * 1-856-184-11 FRENEL LENS EX521,524,525
24
27 A-1792-511-A HMS3 MOUNT
28 4-256-392-01 BRACKET, PANEL (H)
29 4-256-391-01 BRACKET, PANEL (C)
30 1-811-325-11 LCD PANEL (S40ESL)
25 31 4-266-704-01 BEZEL(40 SYR) EX521,524,525
4-266-704-31 BEZEL(40 SYR) EX520,523

1-3-6. LCD PANEL, BEZEL

28
2-990-421-41 SCREW (+PSW) (M3X6)

29 29

26

27
Note:
The Bezel and LCD panel use double sided tape during installation.
30
Please refer to APPENDIX-2 for the correct procedure for disassembly
31 and assembly methods.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 21
 DISASSEMBLY AND PARTS LIST

1-4. KDL-46EX520/521/524/525
1-4-1. STAND BLOCK REF. No. PART No. DESCRIPTION REMARK

1 4-267-495-11 STAND, HEAD(ML9)

2 4-259-183-02 NECK(L9)
3 4-269-902-01 STAND, BASE(L2)

2-580-608-01 SCREW, +PSW M5X16

4-259-541-01 USER SCREW ST

1-4-2. HEAD STAND, NECK AND BASE STAND

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 22
 DISASSEMBLY AND PARTS LIST

1-4. KDL-46EX520/521/524/525
1-4-3. REAR COVER, AC COVER REF. No. PART No. DESCRIPTION REMARK

10 4-275-418-01 REAR COVER(46)

11 4-259-168-11 COVER, AC(M)
12 1-474-287-21 STATIC CONVERTER (TV)-GE3A
10 13 4-256-424-21 BRACKET SIDE (BAT-V) MOLD
14 4-265-045-21 LABEL,SHEET(BAT-V MOLD SIDE) EX521,524,525
4-265-045-31 LABEL,SHEET(BAT-V MOLD SIDE) EX520
15 1-489-443-21 SWITCH UNIT
11 16 1-858-592-11 LOUDSPEAKER
17 1-838-271-11 POWER-SUPPLY CORD (WITH CONN.)

4-256-393-01 SCREW, +PSW M3X6 W12

4-268-126-01 SCREW, ORNAMENTAL M6X12
7-685-648-79 SCREW +BVTP 3X12 TYPE2 IT-3
4-257-907-01 JOINT STAND
1-4-4. GE3A BOARD, SWITCH UNIT, SPEAKER 2-580-639-01 SCREW, +BVTP 4X12 TYPE2 IT-3

12

13

14

15

16 17 16

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 23
 DISASSEMBLY AND PARTS LIST

1-4. KDL-46EX520/521/524/525
1-4-5. BAT-V BOARD, HLR2 BOARD, HMS3 BOARD REF. No. PART No. DESCRIPTION REMARK

20 4-268-443-01 SHEET, INSULATION (G4)

21 * 1-910-801-67 CONNECTOR ASSY 28P
22 A-1807-676-A BAT-V COMPLETE EX520,521(AEP)
A-1815-928-A BAT-V COMPLETE EX520,521(IT)
22 A-1839-278-A BAT-V COMPLETE EX524(AEP)
20 A-1839-746-A BAT-V COMPLETE EX525(AEP)
23 1-838-880-11 FFCWITH CONNECTOR l1 46S
21 24 * 1-910-801-73 HARNESS ASSY EX521,524,525
23 * 1-910-801-95 HARNESS ASSY EX520
25 A-1792-878-A HLR2 MOUNT(B-O-AEP)
26 * 1-856-184-11 FRENEL LENS EX521,524,525
24
27 A-1792-511-A HMS3 MOUNT
28 4-256-392-01 BRACKET, PANEL (H)
29 4-256-391-01 BRACKET, PANEL (C)
30 1-811-326-11 LCD PANEL (S46ESL)
25 31 4-266-700-31 BEZEL(46 SYR) EX520
4-266-700-01 BEZEL(46 SYR) EX521,524,525

1-4-6. LCD PANEL, BEZEL

28
2-990-421-41 SCREW (+PSW) (M3X6)
7-685-646-79 SCREW +BVTP 3X8 TYPE 2 IT-3

29 29

26

27 Note:
The Bezel and LCD panel use double sided tape during installation.
Please refer to APPENDIX-2 for the correct procedure for disassembly
30
31 and assembly methods.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 24
 DISASSEMBLY AND PARTS LIST

1-5. OTHER PARTS

1-5-1. MISCELLANEOUS

X-2549-819-1 BAG, SCREW ASSY (M) - See note below.

X-2560-379-1 BAG, SCREW ASSY (L) - See note below. (46 inches)
4-262-708-01 CLAMPER, CABLE
4-256-443-01 SHEET, RADIATION (BAT-L/V) - Not shown.
4-100-136-01 SHEET (CORE), C - Not shown. (46inches)

1-5-2. ACCESSORIES

*4-269-995-14 MANUAL, INSTRUCTION - 32EX523(UK),32EX524(AEP),37EX524(AEP),40EX523(UK),40EX524(AEP),46EX524(AEP)

*4-269-995-23 MANUAL, INSTRUCTION - 32EX421,32/40/46EX520,521,524,37EX521,524(AEP)
*4-269-995-33 MANUAL, INSTRUCTION - 32EX421(AEP),37EX521(AEP),32/40/46EX520,521(AEP/IT)
*4-269-995-43 MANUAL, INSTRUCTION - 32EX421,32/37/40/46EX521(AEP)
*4-269-995-52 MANUAL, INSTRUCTION - 32EX421(IT)
*4-269-995-53 MANUAL, INSTRUCTION - 37EX521,46EX521(IT)
*4-269-996-75 MANUAL, INSTRUCTION - 32EX425,32/37/40/46EX525(AEP)
*4-269-996-84 MANUAL, INSTRUCTION - 32/40EX525(AEP)
1-489-455-11 REMOTE COMMANDER (RM-ED045)

Note
The "Bag , Screw Assy" contains the following:-
2-580-608-01 Screw, +PSW M5x19
4-188-302-11 Hex Wrench
4-259-541-01 User Screw ST

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 25
SEC 2. ADJUSTMENT

HOW TO ENTERING SERVICE MODE

1) Turn on the main power switch to place this set in standby mode.
2) Press the buttons on the remote commander as follows, and entering service mode.

DISPLAY Channel 5 Volume TV POWER

3) Service mode display.

Note: First of all, when you enter Service Mode, you can see “Digital” service mode.
Whenever you press “OPTIONS” or “JUMP” on remote, each service mode is changed.
“Digital” -> “Chassis” -> “VPC”

DIGITAL SERVICE

001 OP CHASSIS SERVICE

000 VERS ‐‐‐ Item number 000 WYVERN Item name
Category number 000 S2_NOISE_TH 32

<MAIN> <EXT>
DM1.301W00AA RF:01.05
WF1.003W00AA WF:2.0.0.99
DF1.001W00AA WF:0B Press “OPTIONS”
YM1.010W00AA CAM:X.XXX or “JUMP” button
DB2.105W00AA FD:XXXX
(DM1.301W00AA) Category name Data
DD1.016W00AA
WP0.521W00AA <PEM>
MID:1C117081 PM1.012W00LU
PID:04020000 PB1.000W00LU
PNL:LTY320AB01 PL1.011J46LUX
POP:X.XXX PD1.011J46LUX

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 26
 ADJUSTMENT

4) How to use the remote commander.

Function The flow of control

Service mode on <Test>+<TV>/<Display><5><Vol Up><Power>

Service mode off <Other> / <Power off + on>
Item up / down <1>/<4>
Category up / down <2>/<5>
Data up / down <3>/<6>

Test reset <8> + <Mute> + <0>

Read data <9> + <0>
Execute <10 or 0>
Write data <Mute> + <0>

Change module <Jump> / <Option>

5) After entering service mode, then turn off the power switch.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 27
 ADJUSTMENT

WHITE BALANCE ADJUSTMENT

Note: Please execute this adjustment if necessary.
Change Data of “VPC” service mode. (“006 WB” category)
a. Press “1” or “4” on remote to select WB adjustment menu.
b. Change data by pressing “3” or “6”. Each range of these items is 0~255.
c. Press “mute” ＋”0” on remote to save the data.
“SERVICE” comment is changed to “WRITE”, indicating writing process.
d. After a while, “WRITE” comment returns to “SERVICE”, which means writing process is done..

VPC SERVICE VPC SERVICE

006 WB 006 WB
000 R_DRV 128 003 R_BKG 128

VPC SERVICE VPC SERVICE

006 WB 006 WB
001 G_DRV 128 004 G_BKG 128

VPC SERVICE VPC SERVICE

006 WB 006 WB
002 B_DRV 128 005 B_BKG 128

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 28
 ADJUSTMENT

VCOM ADJUSTMENT (IMPORTANT - Only for S-LCD 60Hz Panels)

Note: Please execute this adjustment if necessary.
1) Change Data of “Digital” service mode.
a. Select “003 DIG_SRV_MODE” category by pressing “2 / 5” on remote.
b. Press “0” to go to “TEST PATTERN” Mode.
c. Press “Enter” or “12” to go into Video TEST PATTERN.
d. Press “7” or “8” to select the test pattern.
e. Press “Enter” or “12” twice to show the VCOM TEST PATTERN.

DIGITAL (DIG_SRV_MODE) SERVICE

TEST PATTERN
‐‐> 1 Video

*1 White
2 Ramp
3 R Raster
4 G Raster
5 B Raster
6 Color Bar
7 VCOM Pattern1
8 VCOM Pattern2
9 Oｆｆ

Please input a white level.

(00‐10)

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 29
 ADJUSTMENT

2) Change Data of “VPC” service mode.

a. Select “002 VCOM” category by pressing “2 / 5” on remote.
VPC SERVICE
b. Select “000 ENABLE” item by pressing “1 / 4” on remote. 002 VCOM
c. Change ENABLE from “0” to “1” to enable VCOM adjustment. 000 ENABLE 0

d. Select “001 ADJUST” item by pressing “1 / 4” on remote...

e. Change data by pressing “3 / 6” on remote.
VPC SERVICE
002 VCOM
f. Finish the adjustment when the picture seems OK.
001 ADJUST 64

3) Change Data of “Digital” service mode.

a. Select “007 VCOM” category by pressing “2 / 5” on remote.
b. Change data from “1” to “0” by pressing “3 ” on remote. VPC SERVICE
c. Confirm the final result of the VCOM adjustment. 010 VCOM
000 SRV_OSD_EN 1
d. If OK, Finish the VCOM adjustment.
If NG, pressing “6” to show the OSD again and go back to VCOM adjustment 2)-d.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 30
 ADJUSTMENT

SAVE CHANGING DATA

1) Change Data of “Chassis” or “VPC” service mode
2) Write data for “Chassis” or “VPC” service mode
a. Press “Mute” on remote.
It shows green “SERVICE” changes to green “WRITE”.
b. Press “0” or “enter” on remote. Green “WRITE” changes to red “WRITE”. It indicate writing is processing.
c. After a while, red “WRITE” changes to green “SERVICE”. Writing process is done at this point.
3) TV reboot is necessary for applying data change.

CHASSIS WRITE
000 WYVERN
000 S2_NOISE_TH 32

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 31
 ADJUSTMENT

CHANGE DATA
Note: “Digital” service mode don’t have to Save. (except “002 MODEL” and “005 CHAPRESET” category)
1) Change Data of “Digital” service mode. (except “003 DIG_SRV_MODE” category) DIGITAL SERVICE
a. Press “2 / 5” on remote to select (up / down) category.
004 TUNER
000 !A_NOSIG_DET 001
b. Press “1 / 4” on remote to select (up / down) Item.
c. Press “0 / 10” on remote to select item.

2) Change Data of “Digital” service mode. ( “003 DIG_SRV_MODE” category)

“003 DIG_SRV_MODE” is one category of “Digital” service mode. DIGITAL SERVICE
Please note because this operation is special. 003 DIG_SRV_MODE
000 TEST_PATTERN ‐‐‐
a. Press “2 / 5” on remote to select “003 DIG_SRV_MODE”.
b. Press “1 / 4” on remote to select (up / down) Item.
c. Press “0 / 10” on remote to select item.
d. Press number key “1”~”9” directly. “*” stamp move.
e. Press “12 / enter / select” to decide and advance next step. Press “return”, when returning on the
previous page.

DIGITAL(DIG_SRV_MODE) SERVICE

TEST_PATTERN

*1 Video
2 Audio

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 32
 ADJUSTMENT

3) Write data for “Digital” service mode. ( “002 MODEL” category)

Note: This procedure operation, when replaced the B board.
Note: Do not write a wrong segment or destination information in Product ID.
When the wrong setting is written, TV may not operate.

000 SEG -----------------Select JDM code information

001 DEST ---------------Select destination information
002 MODELNAME ---Select model name
004 SERIAL ------------ Can be set only once for the new board

a. Change data for each model.

b. Press “Mute”, “0” on remote sequentially.
It shows red “WRITE”. It indicate writing is processing.
c. After a while. Red “WRITE” disappears. Writing process is done after a while.

DIGITAL SERVICE
002 MODEL
000 SEG I‐1
Write

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 33
 ADJUSTMENT

SET TO SHIPPING CONDITION

How to do shipping condition.
a. Move to “Digital” service mode.
Press “8” on remote.
It shows green “SERVICE” changes to green “RST-”.
Press “mute” on remote.
Added green “EXE” after green “RST-” .
d. Press “0” on remote. Green “EXE-RST” changes to red “EXE-RST”. It indicate writing is processing.
After a while, red “EXE-RST” changes to green “SERVICE”.
And all LED lights.
Writing process is done at this point.

TIMER Standby POWER

<Another way>
You can set to shipping condition w/o entering Service Mode.
-> “Cursor Up” on remote + “Power Key” on Front panel.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 34
 ADJUSTMENT

HDD REC SETTING

HDD Re-Register
a. Press “2” to select “HDD Re-Register” Item.
DIGITAL (REC_SETTING) SERVICE
b.. Press “Enter” or “12” twice to execute the command.
c. If OK, xx= x+1 REC_SETTING
If NG, xx=x
1 Key Copy
*2 HDD Re‐Register

(x) HDDs OK ( xx )

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 35
SEC 3. TROUBLE SHOOTING
3-1. TRIAGE CHART
Note: Main board and Power board is different in name every inch. Therefore this section displays difference point in "*".

Symptoms - Shutdown. Power LED No

Video - missing or distorted Remote Network Audio Skype
blinking red diagnostics sequences Power
Reference Stationary Wireless
No Green Power No video No video No Skype
2 3 5 6 7 8 colored lines can't No Audio
LED (Dead Set) one of Inputs all Inputs Remote Can't Work
or dots connect
B* BOARD
G* BOARD
HLR2 BOARD
SPEAKER
Skype MODULE
WIFI MODULE
LVDS CABLE
T-CON
LCD PANEL
POWER PANEL PANEL
Problem POWER TEMP Software
AUDIO (TCON) (INVERTER)

: doubtful part
: Few possibility

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 36
 TROUBLE SHOOTING

3-2. FLOW CHART

START

Does the Power Led No No

See Is the network See
stay on when the
No Power connection OK? Can’t connect network
TV is switched on ?
Yes
Yes
Yes
Is the Standby Led See
blink ? Standby LED Blink

No

Is the Picture and No See Is the Skype No See

Sound OK ? No Picture / No Sound function OK? Skype malfunction

Yes Yes

Do the buttons
No See No
on the TV & Remote Is the HDD Rec See
TV/ Commander
Commander work function OK? HDD Rec malfunction
button malfunction
properly?
Yes
Yes

END

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 37
 TROUBLE SHOOTING

3-3. NO POWER

No Power

NG NG
Check STBY 3.3V Replace
at pin 10 of CN6001 Between G* Board to G* Board
on the B* Board B* Board Harness

OK OK

B* Board Harness

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 38
 TROUBLE SHOOTING

3-4. STANDBY LED BLINK

1) 2 times blinking (Main Power Error)

2 times blinking

Check REG12V at 12V NG NG

Replace
pins 2/3 of
Between G* Board to G* Board
CN6001 on
B* Board Harness
the B* Board

12V OK OK

B* Board Harness

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 39
 TROUBLE SHOOTING

2) 3 times blinking (DC Alert, Audio Error and Communication Error)

AUDIO
3 times blinking

Check AUDIO+12.5V NG
DC_ALERT at pins 8/9 of
G* Board
CN6001 on
NG the B* Board
Check D+1.2V at
F6001,IC6005,etc
pin 14 of IC6005
(B* Board) OK
on the B* Board

OK NG
Check +12.5V
F4601,IC4601,etc
at F4601 on
(B* Board)
the B* Board
Check +3.3V_MAIN NG
F6003,IC6003,etc
at pins 9/10 of CN9003
(B* Board) OK
on the B* Board

OK

AUDIO
FE/BE Communication
IC4601,etc
Check NG (B* Board)
Speaker Impedance Speaker
at SP Connector

OK

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 40
 TROUBLE SHOOTING

3) 5 times blinking (T-con Error)

5-time blinking

Symptom
NG improvement
Check PANEL_VCC
at pin 1 of
G* Board RGB sensor Change RGB Sensor
CN6001 on
on the B* Board
(b) Only for Y* Models
about 5V : 22” Model OK
about 12V : ex. 22” Model

Symptom
improvement NG
Replace the Harness
Panel (T-con)
Between G* and Panel Harness B* Board
change
(a)
(a) exclude 60Hz Panel Model

NG Symptom
improvement

Symptom
improvement
Replace
LVDS Harness Panel (T-con)
the LVDS Harness

NG

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 41
 TROUBLE SHOOTING

4) 6 times blinking (Backlight Error)

6-time blinking

Check Under 2.65V

BL_ERR at
B* Board
pin 7 of CN6002
on the B* Board

Over 2.65V

Symptom
improvement
Change G* Board G* board

NG

Panel

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 42
 TROUBLE SHOOTING

5) 7 times blinking (Temperature Error) 6) 8 times blinking (Software Error)

7 times blinking 8 times blinking

Setting circumstance NO NO
If the Symptom
is OK? Set to another
Improved by changing B* Board
Temperature, Location, etc.
the WIFI module
Ventilation, etc.

YES YES

WIFI Module
Change B* Board,
Panel
and Aging a few hours

OK

B* Board

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 43
 TROUBLE SHOOTING

3-5. NO PICTURE

No Picture

about 5V : 22”/26” Model

about 12V : ex. 22”/26” Model

NO YES BL_ON:H NG
Check PANEL_VCC Check BL_ON
Press HOME Key Replace LCD Panel
at pin 1 of CN6001 at pin 6 of CN6002
XMB (Menu) displayed? the LVDS Harness (T-con)
on the B* Board on the B* Board

YES NO BL_ON: L OK

NG
Replace Harness
Harness Harness
B* Board G* Board (Between G* Board
(G* to B*) (LVDS)
to B* Board)

OK

NG
Change B* Board G* Board

OK

B* Board

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 44
 TROUBLE SHOOTING

3-6. NO SOUND

No Sound

“Audio System”
Check the Change to
“Speakers setting” “TV Speaker”

“TV Speakers”

NG OK
Check the Speaker Replace
B* Board
Harness the B* Board

OK NG

Speaker Harness Speaker

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 45
 TROUBLE SHOOTING

3-7. TV COMMANDER BUTTONS MALFUNCTION

1) TV button malfunction

Button malfunction
on the TV

OK OK
Replace the Harness
between B* to Switch Unit change Switch Unit
Switch Unit

NG NG

Harness B* Board

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 46
 TROUBLE SHOOTING

2) IR remote commander malfunction

TV isn’t controlled
by remote commander

OK Green LED blinks OK

Green LED light at power indicator Mechanical
at power indicator when using commander (ex. bezel)
near sensor’s window

NG NG

Check the Harness OK

between the B* Board Sensor is broken
and the HLR Board

NG
OK
Exchange the Harness Harness

NG

OK
Exchange the
HLR Board
HLR Board

NG

B* Board

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 47
 TROUBLE SHOOTING

3-8. NETWORK MALFUNCTION

1) Wired Network malfunction

Wired Network
on the TV

NG NG
Connection result
Check the Ethernet Cable Ethernet Cable
Cable Connection

OK OK

B* Board

Auto
Connection result NG Wired Set-up
Check Local router DHCP server
Local Access IP address setting

Manual
OK

Check IP address
and Local router setting

NG
Connection result
Proxy setting
Internet Access

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 48
 TROUBLE SHOOTING

2) USB Wireless Network malfunction 3) Internal Wireless Network malfunction

Wireless Network Wireless Network

on the TV on the TV

Error Message appear YES Error Message appear YES

when the Wireless USB Dongle when the Wireless Wireless Module, Harness
Network is selected? Network is selected?

NO NO

Is the radio field YES Is the radio field YES

Strength too weak Access Point Strength too weak Access Point
or even No signal? or even No signal?

NO NO

B* Board B* Board

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 49
 TROUBLE SHOOTING

3-9. HDD-Rec MALFUNCTION

HDD Rec
Malfunction

HDD is connected No Connect to the

to the appropriate
appropriate port
USB port?

Yes

USB Hub is inserted No Is the drive size larger No Only 32GB~2TB

in between the than 32GB and
is supported
USB port and HDD? Smaller than 2TB??

Yes Yes

USB Hub is
not supported All the setups and No
restrictions listed in Check the iManual
iManual are cleared?

Yes

B board

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 50
SEC 4. DIAGRAMS
4-1. BLOCK DIAGRAM

4-1-1. KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525
USB1 Ether
X’tal 27MHz DiSEqC_Out
DDC
CI/CI+ MS H Con. USB2
27M
Silicon DiSEqC_In
[LNBH23] TCON
Satellite LNA Tuner
Zero-IF
Ext Demod P

X_SYSTEM1_RST
X_SYSTEM1_RST
IFAGC

5V
TS2

5V
I2CB
Cable [HORUS3] [SEKITO2]
A

Power_KEY
KEY
BD_DISC1,2
BD_EJECT
UARTE
DDR3
Current Current
DMD_CLK_ENABLE2 USB4 USB3 Limit Limit –1333

5V
SW

X’tal
DMD_CLK_ENABLE1
DMD_RST
Current
BD Wifi [TPS2553DBV] [TPS2553DBV]
2Gb N
4M
Silicon Limit
USB Ether
One–
DDR3 BACKLIGHT E

X_PEM_RST/LUT_SEL2/X_FRC_RST
IF2
Terrestrial NAND

LUT_SEL1/X_TCON_RST/LR_FLAG
LNA Tuner Ext Demod 0
HUB PHY
[ASCOT2Sip] IF1
IFAGC
[ZHUI]
TS1
I2CB
0
[GL850G]

Crystal
[RTL8201E] Muxed
2Gb
–1333
2Gb
L

PEM_WDT/XBUSY/BINT
X’tal 12M

MODE_PEM/TCON_RDY
SA_MODE/LUT_SEL0
X_SYSTEM1_RST 41M

TMDS1
DDC1
HDMI1

T_PANEL_SEL
DDC_5V_1
HPD1 LVDS_ODD
(ARC) ARC LVDS_EVEN

I2C_C
CEC1 I2CA
TMDS2
DDC2 EQ SW
DDC_5V_2
HDMI2 HPD2 [Sil9287B]
TS
CEC2 X’tal SYSTEM2_PWR SYSTEM1_PWR
TMDS3 41M
1.5V
DDC3 IF1 1.2V
DDC REG_12V DDC REG_12V
DDC_5V_3
HDMI3 HPD3
X’tal SYSTEM2_PWR SYSTEM2_PWR T-CON_VCC
3.3->1
CEC3 Reset

Power
48M
Push 3.3V
TMDS4 TMDS X’tal REG12V
32.76 AC_MON DDC REG_12V DDC REG_12V
DDC4 DDC 8K 5V REG12V
DDC_5V_4 CEC
HDMI4 HPD4 Reset
SYSTEM2_PWR
AUDIO_12V
AUDIO_12V
[PST3629] 2.5V 3.3V 3.4V S1.2V S1.8V
CEC4 LDO LDO LDO LDO STBY 3.3V
LDO
75Ω GND

Power_Control
Drv TCON-ON
[NJM2561] TV_Out DIMMER_DC
DIMMER
BACKLIGHT_ON
BACKLIGHT_MON
MAIN_PWR
AC_MON
S_Det I2CA (EQSW, Temp Sensor, Hotel Clock) PFC_PWR
VideoA_Det I2CB (Ext Demod) DIMMER2
TV_Out Scart_CV I2CC (Panel, RGB Sensor)
TV_Out_LR Scart_G PEM_LOG

Hotel TL-JIG
SCART Scart_CV,R,G,B,FB
Scart_LR
Scart_B
Scart_R UARTA (LOG)
UARTA(LOG)
UARTD
ASPECT1 Scart_FB UARTB (RF-Remote) MODE_PEM

Atreyu UARTC (IR Blaster/ECS) Reset

UARTC(Hotel/ECS)
I2CA(Hotel_Clock)

/ECS
X_Hotel_PWR_CTRL SIRCS

COMP_Y
COMP_Pb I2CA Temp
COMP_Pr Sensor
VideoB_Det [LM75B] Temp Sensor
COMP COMP_LR PC_G
ASPECT1 PC_B
PC_R SIRCS
PC_H
PC_V DIMMER
Sircs
DMD_CLK_ENABLE2
DIMMER_DC
Tuner_LR LOGO
Scart1_LR
PC_CON_Det DEBUG_LED2
PC_R,PC_G,PC_B,PC_H,PC_V AV3_LR
PC PC_LR COMP_LR DEBUG_LED3
PC_5V, PC_DDC PC_LR PANEL_PWR Power_KEY
DMD_CLK_ENABLE1
Line Out_LR DMD_RST
KEY
KEY
OPAMP X_WIFI_RST UARTE
[NJU72040V] HP_DET
HP/Line HP_/ Line Out Det
HP/Line Out LR TV_Out_LR SPDIF_SEL
Out Tuner_LR X_AUDIO_MON
HDMIEQ_INT

Atreyu_SPDIF Light_Sensor_Det
SPDIF SPDIF
Light Sensor
Human_Sensor_Det
Main Speaker_Out_LR
POWER_LED
Human Sensor
STBY_LED
[D–510D] TIMER_LED
REC_LED LED
DATA1
TCON_RDY
BINT

LUT_SEL0
LUT_SEL1
LUT_SEL2

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

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

BACKLIGHT_MON
PANEL_PWR_Det

ASPECT1
PANEL_SEL
Human_Sensor_Det
Light_Sensor_Det

KEY
DC_MON
0 UART_E PIC_MUTE_LED
OPAMP 0

[NJU72011RB]
Audio
Power AMP
Main Main Speaker_Out_LR
SYSTEM1_PWR

[D–510D]
BTV_PINT
NAND_WP

X_RF_RST
BTV_GPIOx6

SPEAKER
BTV_SPDIF
BTV_FID

X_FAULT AUDIO_MON
BTV_SEL
I2S_D0

UARTB

X_AUDIO_MUTE2
I2CA

X_SYSTEM1_RST
X_AUDIO_MUTE1
Digital Video/TS/TMDS Digital Audio PWM UART SPI H/L
Analog Video Analog Audio Analog Signal I2C
Panelless
ASURA ASURA

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 51
 DIAGRAMS

4-2. CONNECTOR DIAGRAM

4-2-1. KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525
NC and No HMS3 Board for the
(Only Interface between board and board)
followingEurope models only.
- KDL-32EX520
- KDL-32EX523 BAT- V board T- con Board(60Hz)
HMS3 board JAM 3pin Straight - KDL-40EX520 To BAT
GND 1 40 NC - KDL-40EX523 6 1 BD USB GND Panel_Ct rl1 / NC 1 51 Panel_Ct rl1 / NC
- KDL-46EX520
Mot ion Sensor MOTION_SENS 2 38 NC 1 2 BD VBUS Panel_Ct rl2 / TCON_RDY 2 50 Panel_Ct rl2 / TCON_RDY
CN6201(40",46" GE3)
3a- X/ V/ 2 REG+5V 3 39 NC 3 3 BD USB_P Panel_Ct rl3 / NC 3 49 Panel_Ct rl3 / NC
CN6704 (37"32" GE2A)
P-1/2 1- 821- 130- 11 4 4 BD GND Panel_Ct rl4 / LUT_SEL2 4 48 Panel_Ct rl4 / LUT_SEL2
SJM20-28WLB
2 5 BD USB_N Panel_Ct rl5 / LUT_SEL1 5 47 Panel_Ct rl5 / LUT_SEL1 PANEL FFC
To B board (100106)
5 6 BD USB SPDIF Panel_Ct rl6 / LUT_SEL0 6 46 Panel_Ct rl6 / LUT_SEL0 96pin
T-CON_Vcc12V 28 NC
7 BD EJ ECT/ BDR ON Panel_Ct rl7 / NC 7 45 Panel_Ct rl7 / NC
GND 27 NC
26 NC SW module 8 BD DISC1/ BDR GPIO1 Panel_Ct rl8 / PANEL_SEL 8 44 Panel_Ct rl8 / PANEL_SEL
T- con T-CON_VCC12V
GND 25 NC
SW module
GND
POWER_INT 2
1 37
35
9
10
BD DISC2/ U_DL_STAT
BD UART Tx/ BDR KEY1
Panel_Ct rl9 / BINT
Panel_Ct rl10 / NC
9
10
43
42
Panel_Ct rl9 / BINT
Panel_Ct rl10 / NC
T-CON_VCC_12V To B 24 1
ALL KEY1 3 36 NC 11 BD UART Rx/ BDR KEY2 / HLR DEVICE_SDA Panel_Ct rl11 / SDA 11 41 Panel_Ct rl11 / SDA
GND 23 NC
1- 822- 693- 11 12 BDR STBY_+3.3V Panel_Ct rl12 / SCL 12 40 Panel_Ct rl12 / SCL
BDR_ASU_12V 22 NC
13 BDR UART_Tx/ RF UART_TX GND 13 LVDS-FFC 39 GND
GND 21 NC BV - H Harness
Option BDR_ASU_12V 20 NC H-B 14
15
BDR UART_Rx/ RF_UART_RX
BDR WAKEUP_STBY_MICON/ RF SEL
PANEL_EVEN4_P
PANEL_EVEN4_N
14
15
B-PEL3 38
37
PANEL_EVEN4_P
PANEL_EVEN4_N
GND 19 NC
16 BDR GPIO0/ RF_RST PANEL_EVEN3_P 16 36 PANEL_EVEN3_P
REG12V 18 2
HLR board
HLR2 board STBY+3.3V 1 33 17 BDR GND PANEL_EVEN3_N 17 35 PANEL_EVEN3_N
GND 17 4
LED/IR/RGB Sensor/OPT_Sensor GND 2 31 5 18 WIFI GND GND 18 34 GND
REG12V 16 3
2b- 3 LED_REC 3 29 3 19 WIFI USB_P PANEL_EVEN_CLK_P 19 33 PANEL_EVEN_CLK_P
GND 15 5
3a- V LED_STBY 4 27 1 20 WIFI GND PANEL_EVEN_CLK_N 20 32 PANEL_EVEN_CLK_N
AU_12V 14 8
3a- 2 LED_TIMER 5 25 4 21 WIFI USB_N GND 21 31 GND
AU_GND 13 6 51pin FFC
AU_12V 12 9 B board P- 1
P- 2
LED_POWER
LED_PIC_MUTE
6
7
28
30
NC
2
22
23
WIFI GND
WIFI VBUS
PANEL_EVEN2_P
PANEL_EVEN2_N
22
23
30
29
PANEL_EVEN2_P
PANEL_EVEN2_N
AU_GND 11 7
DEVICE_SDA/ GND 8 NC NC 24 HLR DEVICE_SCL PANEL_EVEN1P 24 28 PANEL_EVEN1P
STBY3.3V 10 10
B board GND 9 1
DEVICE_SCL/ LED_BDR
OPT_SENS
9
10
NC
32
5
12
25
26
HLR LED_ON_TIMER
HLR SIRCS
PANEL_EVEN1_N
PANEL_EVEN0_P
25
26
27
26
PANEL_EVEN1_N
PANEL_EVEN0_P
T-CON_ON 8 3
VD+3.3V 11 34 4 27 HLR LED_STBY PANEL_EVEN0_N 27 25 PANEL_EVEN0_N
AC_OFF_DET 7 9
SIRCS 12 26 6 28 HLR LED_POWER GND 28 24 GND
BL_ERR 6 7
1- 821- 139- 11 3 29 HLR LED_REC PANEL_ODD4_P 29 23 PANEL_ODD4_P
BL ON 5 6
7 30 HLR LED_PIC_MUTE PANEL_ODD4_N 30 22 PANEL_ODD4_N
DC_DIMMER 4 4
2 31 HLR GND PANEL_ODD3_P 31 21 PANEL_ODD3_P
PFC_ON 3 2
10 32 HLR OPT_SENS PANEL_ODD3_N 32 20 PANEL_ODD3_N
PWM_DIMMER
POWER_ON
2 5
Wifi module 1 33 HLR STBY_3.3V GND 33 19 GND
1 8
(US 32” , 40” & 46” Only) 11 34 HLR 3.3V PANEL_ODD_CLK_P 34 18 PANEL_ODD_CLK_P
2 35 SW POWER_KEY PANEL_ODD_CLK_N 35 17 PANEL_ODD_CLK_N
To LS
GND 1 20 3 36 SW_KEY GND 36 16 GND
CN6601(40",46" GE3) +OUT1 1
WIFI VCC 2 23 1 37 SW GND PANEL_ODD2_P 37 15 PANEL_ODD2_P
CN6701 (37"32" GE2A) NON 2 NC for the followingEurope models only.
WIFI USB_P 3 19 NC 2 38 HMS DET / SONY LOGO PANEL_ODD2_N 38 14 PANEL_ODD2_N
+OUT3 3 - KDL-32EX520
WIFI USB_M 4 21 - KDL-32EX523 NC 3 39 HMS 5V / LOGO 5V PANEL_ODD1P 39 13 PANEL_ODD1P
NON 4
WIFI GND 5 18 - KDL-40EX520 NC 1 40 HMS GND/ LOGO GND PANEL_ODD1_N 40 12 PANEL_ODD1_N
MOLEX L 4P - KDL-40EX523
SM05B-GHS-TB CN9006 PANEL_ODD0_P 41 11 PANEL_ODD0_P
1-822-359-11 - KDL-46EX520
1-819-334-11 1- 818- 692- 21
1 (JST) PANEL_ODD0_N 42 10 PANEL_ODD0_N
LS HEADER ASSENBLY 40P GND 43 9 GND
GND 44 8 GND
To LS
Panel_Ct rl13 45 7 Panel_Ct rl13
CN6602(40",46" GE3) -OUT1 1
GND 46 6 GND
CN6702 (37"32" GE2A) NON 2
-OUT3 3
SPEAKER L+ (Fasten # 187) 1 1 PANEL_VCC_SW 47 5 PANEL_VCC_SW

NON 4
Front L- (Fasten #110) 2 2 PANEL_VCC_SW 48 4 PANEL_VCC_SW

NC 5
Lch 1 1 L+ PANEL_VCC_SW 49 3 PANEL_VCC_SW
2 2 L- PANEL_VCC_SW 50 2 PANEL_VCC_SW
2 3 R- PANEL_VCC_SW 51 1 PANEL_VCC_SW
MOLEX L 5P
1 4 R+ CN2001
1-822-360-11
SPEAKER R- (Fasten # 110) 2 3 Housing Speaker Connect or 1- 842- 548- 11
Front R+ (Fasten # 187) 1 4 FFC Direct in Connector

AC_IN
Rch Yamaichi
1 1 STBY3.3V
AC-N 1 1
AC-L 2 2 AC pigtail 2
3
2
3
RS232_RXD
RS232_TXD TL- EX1JIG board
CN6001
4 4 SIRCS_OUT
SFP79-02WLB JAM
5 5 SIRCS_IN
1-822-908-11
6 6 GND
CN9005
6pin connector 182113311

10 10 STBY_+3.3V
12 9 AUDIO+12.5V
14 8 AUDIO+12.5V
11 7 AUDIO+12.5V_GND
13 6 AUDIO+12.5V_GND GND 1
15 5 REG+12.5V_GND UARTD_TX 2
17 4 REG+12.5V_GND UARTD_RX 3
16 3 REG+12.5V RESET 4
18 2 REG+12.5V STBY_+3.3V 5
24 1 T- CON_VCC MODE_TVM 6
CN6001 UARTA_RX 7
G-B Harness
1-842-569-11 NC (MD2) 8
G-B
HEADER ASSEMBLY FOR PWB 10P UARTC_RX 9
R3 or RU board STBY3.3V
RS232_RXD
1
2
1
2
UARTC_TX 10
7 9 AC_OFF_DET GND 11
RS232_TXD 3 3
1 8 POWERON UARTA_TX 12
SIRCS_IN 4 4
6 7 BL_ERR ECS_MATRIX 13
SIRCS_OUT 5 5
5 6 BL_ON STBY_+3.3V 14
GND 6 6
2 5 DIMMER MODE_PEM 15
CN101
4 4 HSYNC/ DIMMER_DC PEM_LOG_RX 16
182018311
8 3 TCON_ON PEM_LOG_TX 17
3 2 PFC_PWR GND 18
9 1 GND CN9004
CN6002 1-774-667-51
1- 819- 452- 11 TL-EX1 Connector,FFC/FPC 18P [P-1 BAT-V 32/37/40/46]

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 52
 DIAGRAMS

4-3. CIRCUIT BOARDS LOCATION

KDL-32EX421/425/520/521/523/524/525 KDL-37EX521/524/525

BATV Board BATV Board

GE2A Board GE2A Board

Switch Unit T-CON Switch Unit T-CON

HLR2 Board HMS3 Board HLR2 Board HMS3 Board

KDL-40EX520/521/523/524/525 KDL-46EX520/521/524/525

GE3A Board BATV Board GE3A Board BATV

BATV Board
Board

Switch Unit Switch

Switch Unit
Unit
T-CON T-CON

HLR2 Board HMS3 Board HLR2

HLR2 Board
Board HMS3
HMS3 Board
Board
KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 53
END

English
Sony Corporation 11FP7100-1
Sony UK Made in U.K.
9-883-491-05 Service Promotions Dept. © 2011. 06
KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 54
APPENDIX-1
PROCEDURE TO REMOVE THE REAR COVER (32)
1. Remove all the screws on the Rear Cover and the AC Cover.
2. Open the Rear Cover in the order as shown below.

6 6
Notice:
5
3
2
4 1
3
2
1
Insert plastic part (less than 15mm)
*Do not use metal one.
*Take care not to scratch parts.
Please lift Up
the minimum.

Push

3
2 2
1
3

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 55
 APPENDIX-1

PROCEDURE TO REMOVE THE REAR COVER (32)

3. Open the Rear Cover with the “COVER AC” and the AC cable attached.
Note: Make sure to hold the cable not to give any tension to the connector and scratch damage for the cable.
4. Release the AC cable connector.
5. Release the hooks of the “COVER AC” and remove it.
Note:
Confirm the hooks are not broken before re-using COVER AC.
If the hooks are broken please replace with a new one.

3 4 5 AC Cover
AC Cable

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 56
 APPENDIX-1

PROCEDURE TO REMOVE THE REAR COVER (37)

1. Remove all the screws on the Rear Cover and the AC Cover.
2. Open the Rear Cover in the order as shown below.
Note: Do not open quickly when hooks 1~6 are locked.

Notice:
6 6 6 6 6 6
1st and 2nd

5 3

These hooks are automatically

released . 2 2
4 1

1 Insert your hand in the place shown in the picture.

3rd

Insert your hand below the screw hole as shown in the picture.
Open the Rear Cover slowly with care.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 57
 APPENDIX-1

PROCEDURE TO REMOVE THE REAR COVER (37)

3. Open the Rear Cover with the “COVER AC” and the AC cable attached.
Note: Make sure to hold the cable not to give any tension to the connector and scratch damage for the cable.
4. Release the AC cable connector.
5. Release the hooks of the “COVER AC” and remove it.
Note:
Confirm the hooks are not broken before re-using the COVER AC.
If the hooks are broken please replace with a new one.

3 4 5 AC Cover
AC Cable

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 58
 APPENDIX-1

PROCEDURE TO REMOVE THE REAR COVER (40)

1. Remove all the screws on the Rear Cover and the AC Cover.
2. Open the Rear Cover in the order as shown below.
Note: Do not open quickly when hooks 1~5 are locked.

Notice:
5 5 5 5 5 5

4 This hook is automatically 2

released .

1
3
1 Insert your hand in the place shown in the picture.

Insert your hand below the screw hole as shown in the picture.
Open the Rear Cover slowly with care.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 59
 APPENDIX-1

PROCEDURE TO REMOVE THE REAR COVER (40)

3. Open the Rear Cover with the “COVER AC” and the AC cable attached.
Note: Make sure to hold the cable not to give any tension to the connector and scratch damage for the cable.
4. Release the AC cable connector.
5. Release the hooks of the “COVER AC” and remove it.
Note:
Confirm the hooks are not broken before re-using the COVER AC.
If the hooks are broken please replace with a new one.

3 4 5 AC Cover
AC Cable

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 60
 APPENDIX-1

PROCEDURE TO REMOVE THE REAR COVER (46)

1. Remove all the screws on the Rear Cover and the AC Cover.
2. Open the Rear Cover in the order as shown below.
Note: Do not open quickly when hooks 1~6 are locked.

6 6 6 6 6 6 Notice:

1
5 2 Insert plastic part (less than 15mm)
This hook is automatically *Do not use metal one.
released . *Take care not to scratch parts.
4

3 1
Please lift Up
the minimum.

1
2
2.Move

1.Push

Insert your hand above the screw

hole as shown in the picture.
Open the Rear Cover slowly with
KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) care. 61
 APPENDIX-1

PROCEDURE TO REMOVE THE REAR COVER (46)

3. Open the Rear Cover with the “COVER AC” and the AC cable attached.
Note: Make sure to hold the cable not to give any tension to the connector and scratch damage for the cable.
4. Release the AC cable connector.
5. Release the hooks of the “COVER AC” and remove it.
Note:
Confirm the hooks are not broken before reusing the COVER AC.
If the hooks are broken please replace with a new one.

3 4 5 AC Cover
AC Cable

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 62
 APPENDIX-1

PROCEDURE TO ASSEMBLE THE REAR COVER (32)

1. Put the Rear Cover from top side.

Notice:

4
2. Push and confirm the locks in the order as shown below.

1 1

2
4
5
3
6 5
6

3. Confirm all the locks are fitting.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 63
 APPENDIX-1

PROCEDURE TO ASSEMBLE THE REAR COVER (37/40/46)

1. Put the Rear Cover from top side.

2. Push and confirm the locks in the order as shown below.

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2 7 2 6
4
2 5
5 4 3
8 5
3 6 3
4 7
6
9

<37 Inch> <40 Inch> <46 Inch>

3. Confirm all the locks are fitting.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 64
APPENDIX-2
1. PROCEDURE TO REMOVE LCD PANEL FROM BEZEL ASSY
Peel off the double sided tape between the bezel assembly and the LCD panel when exchanging the LCD panel, etc, follow the instructions below.

<32~46 inch>

1.Take off “Bracket, Panel” 2.Peel off double sided tape

(1)Take off LED board to assist with tape peel off. (2)Put hand between the bezel and panel, pull panel up
and push bezel down as shown in the picture.

Should pull up
metal area, and
not cell area.

Put off
(3)Move hands along, peeling off tape, pull up and push down near the tape as you go along.

Pushing hook Moving hands

step by step

Take off “Bracket, Panel” by pushing bezel hook.

The positions are shown on the following pages.

To peel off the double sided tape between the bezel assembly and the panel, push bezel down and pull panel up.
To prevent breaking the panel it is prohibited to push the panel from front.

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 65
 APPENDIX-2

2. EXCHANGE DOUBLE SIDED TAPE

Because the double sided tape’s strength weakens when peeled off, peel off all the tape from bezel assembly, and stick on new ones (P/N: 4-272-200-01).

<32/37/40/46 inch>

1.Peel off double sided tapes from Panel. 2.Stick double sided tapes
(Possibly remain on Bezel side) Peel off separate papers before panel puts on.

32” 37”
2position 2position
5x290mm t=0.4 5x350mm t=0.4

40” 46”
2position 3position
5x380mm t=0.4 5x290mm t=0.4

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 66
 APPENDIX-2

3. PUTTING PANEL ON TO BEZEL

Pay attention to the double sided tape, put the panel on to the bezel assembly as shown below.

1.Putting Panel on to bezel 2.Lock with hooks of Bezel / Putting on “Bracket, panel”
(1) Put from upper side adjusting position to L/R side.
Please lock Panel with hooks of Bezel.
(2) Down panel on to bottom caring about fitting bezel position
ribs and panel cutout area. Put brackets and confirm fixed by hook.

(1)Put on upper side

(2)Put down

Care about positioning rib (L&R) <32~46 inch>

<32~46 inch>

KDL-32EX421,425/37EX521,524,525/32/40/46EX520,521,523,524,525(AEP/UK) 67