Sony KLV-32W6*D, KLV-48W6*D, KDL-32W6*D, KLV-40W6*D, KDL-48W6*D Service Manual

Version Date Subject

1 01/2016 1st Issue.

LCD TV

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

GN2S CHASSIS

Segment: QW

SERVICE MANUAL (COMMON)

9-888-190-01

For SM - Unique , please refer :

9-888-190-Ax ( America )

9-888-190-Cx ( China)

9-888-190-Ex ( Europe )

9-888-190-Px ( Pan Asia)

LCD TV

SERVICE MANUAL (COMMON)

GN2S CHASSIS

Segment: QW

MODEL

KLV-32W6*D KLV-40W6*D KLV-48W6*D
KDL-32W6*D KDL-40W6*D KDL-48W6*D KDL-55W6*D

MODEL LIST

THIS SERVICE MANUAL CONTAINS COMMON INFORMATION FOR BELOW REGIONS AND MODELS:

REGION
ASIA AMERICA EUROPE

CHINA

Section Title

Page

1. SAFETY NOTES

1

-1. Warnings and Caution………………………………………………………. 5

1

-2. Caution Handling of LCD Panel ......…………….................................... 5

1

-3. Caution About the Lithium Battery……………......................................... 6

1

-4. Safety Check Out ........................……………......................................... 6

1

-5. Leakage Test .......................................................................................... 6

1

-6. How to Find a Good Earth Ground………………………………………… 6

1

-7. Lead Free Information….…………………………………………………… 7

1

-8. Handling the Flexible Flat Cable (FFC

)…………………………………….

7

2. SELF DIAGNOSTIC FUNCTION

2

-1.

Overview of Control Buttons ...................................................................

8

2

-2. LED Display Control

……….....................................................................

8

2

-3. LED Pattern

………………........................................................................

8

2

-4. Standby LED Error Display…………………………………………………. 8

2

-5. Triage Chart

............................................................................................

9

3. TROUBLE SHOOTING

3

-1. LED Blinking

.............................................................................................

12

3

-2. No Power…….……………………………………………………………….. 28

3

-3.

No Picture.............................................................................. .............. .... .

54

3

-4. No Sound.............................………………………………………….......... 107

4

TABLE OF CONTENTS

Please refer Service Manual – Unique for below information :

-Safety Warnings

-Wire Dressing

-Circuit Board Location

-Disassembly and Exploded View.

Section Title

Page

4. SERVICE ADJUSTMENTS

4

-1.

Accessing Service Mode .....................................................................

129

4

-2.

Accessing Software Version....................……….………………………

129

4

-3.

Accessing Self Diagnostic History………………………………..……..

130

4

-4.

Accessing Self Diagnostic Menu………………………………………...

130

4

-5.

Accessing Serial Number Edit……………….…………………………..

132

4

-6.

Accessing Model Number Setting........................................................

133

4

-7.

White Balance.................................................................... ............. .....

135

4

-8.

Aging Mode........................................................................ .............. ....

139

4

-9.

Tuner Detection....................................................................... .............

140

5. DIAGRAMS
5

-1.

Circuit Board Location .........................................................................

143

5

-2.

Block Diagram......................................................................................

144

5

-3.

Connector Diagram

………………………………………...................... 147

Note: Pictures provided in this Serv ice Manual might have slight difference from the
actual sets.

Please refer to Service Procedure for Panel , Board and Software Change / Upgrade
Manual , part number 9-888-196-0x in TISS .

SAFETY NOTES

SECTION 1

1-2. Caution Handling of LCD Panel

When repairing the LCD Panel, make sure you are grounded with a wrist band.
When repairing the LCD Panel on the wall, the panel must be secured using the

1-1. Warnings and Caution

1) These servicing instructions are for use by qualified service personnel only.

2) To reduce the risk of electric shock, do not perform any servicing other than

4

mounting holes on the rear cover.

1) Do not press 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.

that contained in the operating instructions unless you are qualified to do so.

3) An isolation transformer should be used during any service to avoid
Possible shock hazard, because of live chassis. The chassis of this receiveris
directly connected to the ac power line.

3) Do not leave the module in high temperature 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 short circuit within the module.

4)Be sure tofollow these guidelines to protect yourproperty and
avoid causing serious injury :

• Carry the TV with an adequate number of people;larger size TVs require
two or more people.

6) Di

sconnect the AC power when replacing the bac

klight (CCFL)

or

inverter circuit. (High voltage occurs at the inverter circuit at 650Vrms)

7) Always clean the LCD panel with a soft cloth material.

•

Correct

hand

placement

while

carrying

theTVis

very

important

for

safety and to avoid damages.

5) Components identified by shading and mark on the exploded views,

and in the parts list are critical for safe operation. Replace these

!

8) Use care when handling the wires or connectors of the inverter circuit.

Damaging the wires may cause a short circuit.

9) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).

10) During the repair, DO NOT leave the Power On or Burn-in period for more

components

with

Sony

parts

whose

part

numbers

appear

as

shown

in

this

manual or in supplements published by Sony. Circuit adjustmentsthatare
critical for safe operation are identified in this manual. Follow these
procedures whenever critical components are replaced or improper
o

p

eration is suspected.

th

an 1 hour w

hile the TV is f

ace down on a cloth.

p

p

5

Figure 1. TV is faced down on a cloth during repair.

6

3) Measuring the voltage drop across a resistor by means of a VOM or battery
operated AC voltmeter. The 'limit' indication is 0.75V so analog meters must
have an accurate low voltage scale. The SIMPSON'S 250 and SANWA SH­63TRD are examples of passive VOMs that are suitable. Nearly all battery
operated digital multimeter that have a 2 VAC range are suitable.
(see Figure 2.)

1-4. 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 inter board wiring to ensure that no wires are pinched or
contact high-wattage resistors.

3)Check all control knobs, shields, covers, ground straps and mounting
hardware have been replaced. Be absolutely certain 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, metalized knobs, screws and all
other exposed metal parts for AC leakage. Check leakage test as described
next.

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

Figure 2. AC voltmeter to check AC leaka ge

1-3. Caution About the Lithium Battery

1) Danger of explosion if battery is incorrectly replaced. Replace only with
the same or equivalent type.

2) Outer case broken battery should not contact to water.

1-5.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 0.5mA (500 microamperes).
Leakage current can be measured by any one of the three methods:-

1) A commercial leakage tester such as the SIMPSON 229 or RCA WT540A.
Follow the manufacturers instructions to use those instructions.

2) A battery-operated AC milliampmeter The DATA PRECISION 245 digital
multimeter is suitable for this job.

1-6. How to Find a Good Earth Ground

1) A cold-water pipe is a guaranteed earth ground; the cover-plate retaining
screw on most AC outlet boxes is also at earth ground.

2) 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.

3) If a cold-water pipe is not accessible, connect a 60- to 100-watt trouble­light (not a neon lamp) between the hot side of the receptacle and the
retaining screw. Try both slots, if necessary, to locate the hot side on the line;
the lamp should light at normal brilliance if the screw is at ground potential
(see Figure 3).

Figure 3. Checking for earth
ground.

1-7. Lead Free Information

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.

Figure 4: LF Logo

Figure 5: LF logo on circuit board

The servicing of these boards requires special precautions. It is strongly
recommended to use Lead Free Solder material in order to guarantee optimal
quality of new solder joints.

1-8. Handling the FLEXIBLE FLAT CABLE (FFC)

 When you insert / pull out FFC, please grasp a reinforcement board and main

body of FFC.

7

Insert properly without slanting

1-8. Handling the FLEXIBLE FLAT CABLE (FFC)

Press release button at the same
time pull out FFC cable

<INSERTION>

<PULL OUT>

8

9

1-9. Assemble and Dissemble Tuner Module

20°

20°

1. The insertion & extraction angle of the module is permitted to
specified degree for connector

Push down to screw.

Tuner Module treatment way

Reference paper for 20 degree
(If need please use for fit by cutting this paper)

For removing Tuner Module,
After un screwed, Automatically t he M odule
will float to correct degree.
So please extract it with keeping this degree.

Status LED Colour Remarks
Power Off ( AC Off and *1) OFF *1 power switch off (by touch button)
Power On Green
Standby(by remote control off

and Side Key off)

OFF

Picture Off Green
Set "Sleep Timer" Amber
Set "On Timer” ( Power On ) Amber
Set "On Timer”( Standby ) Amber
Picture Frame Amber

Failure Red Blinking

The number of LED blinking indicates
cause of failure.

Error of panel ID

Amber/Green

Blinking

Blinking:0.5sec Amber/ 0.5sec Green

Software Updating

Amber

Blinking

Blinking: 1sec On / 1sec Off

SECTION 2

SELF DIAGNOSTIC FUNCTION

2-1. Overview of Control Buttons

6

10

2-2. LED Display Control

When safety shutdown occurs, Standby LED display report s the cause by using the lightning
patterns as indicated below

.

2-3. LED Pattern

3.0sec 3.0sec

0.5sec

0.5sec

Example: The figure above shows LED display when SHUTDOWN is caused by Audio
Error. It repeats flashing for a specified number of ti mes i n 0.5sec/c ycle and has a 3 seconds interval of lighting
off. Please note that a 3 seconds interval of lighting off is fixed regardless of abnormal state types.

Amber = Red + Green

2-4. Standby LED Error Display

The Number of Standby LED
(RED blinking)

Error Detection Error Location

2 Main Power Error AC adapter Error
3 Audio Error B* board Error
4 Panel Power Error B* board Error
5 Panel I2C COMM Error B* or Source board Error
6 Backlight Error B* board Error

Size

B* Board Type

PAN ASIA,AMERICA,

CHINA

EUROPE

32” BBA BBE
40” BBA BBE
48” BBA BBE

LED Indicator

• Lights up in green when you select “Picture Off”.

• Lights up in amber when you set the timer or
“Photo Frame Mode”.

• Lights up in green when the TV is turned on.

• Flashes while the remote is being operated.

2-5. Triage Chart

11

Secondary possible defective part

Most likely defective part

Reference

Segment

Symptoms - Shutdown. Power LED
blinking red diagnostics sequences

No Power

(No Pic, No

Sound, No BL)

Video

(missing/distorted)

Remote

Network
*QT,QW,

SE3N

Audio

(missing/
distorted)

front LED Tact-Key

QT QW QW-L SE3N SE3 2 3 4 5 6

No Power LED

&

No Reponse to

remote

(Dead Set)

Stationary

colored
lines or

dots

No Video
in 1(one)
of Inputs

No

Video

in

All

Inputs

RF

Cannot

Tune

No Reponse

when press
remote key

(Tact-Key OK)

Wireless

can't

connect

No Audio

No LED

(Set is still

alive)

No

Response

when

press
Tact-Key
(Remote

OK)

B* Board Y Y Y Y Y



    







    



AC Adaptor Y Y Y Y Y







H* Board Y Y Y Y Y





Stereo

Speaker

Y Y Y Y Y





Assist

Speaker

Y Y





Wi-Fi

module

Y Y Y



LVDS FFC Y Y Y Y Y









LED Panel Y Y Y Y

   



Tuner

module

Y Y Y Y Y



Switch Unit Y Y Y Y Y



Problem

Power Audio

Panel

(Power)

Panel

(Communication)

Panel

(Backlight)

Size

B* Board Type

PAN ASIA,AMERICA,

CHINA

EUROPE

32” BBA BBE
40” BBA BBE
48” BBA BBE

12

SECTION 3

TROUBLESHOOTING

3-1. LED BLINKING

3-1-1. 2x Blinking (Main power Error)

BBE, BBA board (QW, QWL) only

2 times
Blinking

Change
adaptor

B-Board

Check DC voltage at

JL6001

18V – 22.5V?

*Typical: 19.5V

No

Yes

Change B-board Change B-board

Yes

Adaptor

Take out adaptor

and check the output voltage.

18V – 22.5V?

(Refer Figure 1)

*Typical: 19.5V

No

Figure 1: How to check adaptor’s output
voltage.

+ve

-ve

Ensure that
+ve probe is
touching the

needle.

Size

B* Board Type

PAN ASIA,AMERICA,

CHINA

EUROPE

32” BBA BBE
40” BBA BBE
48” BBA BBE

13

Board Name Board PWB (A side) Detail

BBA
(Q6020)

BBE
(Q6020)

Q6020

Q6020

2 x Blinking (Checking Point)

14

3-1. LED BLINKING
3-1-2. 3x Blinking (Audio Error)

F4000 broken,

Replace F4000

Remove

Speaker Connector

at CN4001 & perform

AC OFF - ON

Check connectivity

of F4000

3x blinking

Check Speaker harness
And Speaker impedance

Speaker Impedance
≠ 6~8 Ω

3x blinking &
F4000 OK

Audio IC problem,

IC4001 damage

Change Speaker

Harness

Change Speaker

START

Connect back

Speaker Connector

to CN4001

& perform AC OFF - ON

DONE

3x blinking

No 3x blinking

Change BB* board

No connectivity of F4000

No connectivity for
speaker harness

3x blinking

No 3x blinking

3x blinking

No 3x blinking

 TV must be power OFF condition

before unplug any of the
FFC/FPC/wire/cable from the board.

-> This is to prevent possibility
circuit damage happen.

15

Board

Name

Board PWB (A side) Details

BBA
(QW, QT)

IC4001
F4000
CN4001

F4000

IC4001

CN4001

Details

3x Blinking (Checking Point)- BBA

16

3x Blinking (Checking Point)- BBE

Board Name Board PWB (A side) Details

BBE
(QW, QWL,
QT)

IC4001
F4000
CN4001

F4000

IC4001

CN4001

Details

17

3-1. LED BLINKING

3-1-3. 4 x Blinking (Panel Power Error)- BBA

Yes

No

Start

Check voltage at

JL6030(BBA)

11.52V-12.82V?

End

IC6019 Checking

Procedure

3-1-4. 4 x Blinking (Panel Power Error)- BBE

Yes

No

Start

Check voltage at

JL6034(BBE)

11.52V-12.82V?

End

No

Check PANEL_PWR

3.00V-3.33V?

MTK Problem

or TV in stand-

by mode.

Yes

No

Yes

Check JL6034 (BBE)

11.52V-12.82V?

Replace

Q6023

Refer IC6019

Checking

Procedure

18

POWER1

3.3V_STBY

1.5V

1.2V

PANEL_PWR

EN_V

F6003

Q6020

19.5V

19.5V_ADP

Q6023

4 x Blinking (Checking Point) QW/QT-BBE [1/2]

19.5V & Q6020

STBY_5V

F6002

19

POWER1

3.3V_STBY

19.5V & Q6020

STBY_5V

F6002

F6003

1.2V

EN_V

PANEL_PWR

1.5V

F6002

Q6020

19.5V

19.5V_ADP

4 x Blinking (Checking Point) QW/QT –BBA [2/2]

3-1-5. 5 x Blinking (Panel I2C Error - General Checking)

START

TV set is OK now

NG Symptom:

B-Board Issue NG

TV Boots Up Normally

* O-Cell or Panel
Module
replacement
depends on
service
capabilities

END

Reinsert LVDS Flat

Flexible Cable (FFC) at B-Board

and Panel Side. Make sure FFC is

taped properly.

5 Times Blinking happen?

YES

No

Replace LVDS Flat Flexible

Cable (FFC)

TV set is OK now

NG Symptom:

Incorrect FFC Insertion

5 Times Blinking happen?

YES

No

TV set is OK now

NG Symptom:

LVDS Cable NG

Replace B-Board

5 Times Blinking happen?

YES

No

Replace

O-Cell* or Panel Module*

Check voltage PANEL_SDA &

PANEL_SCL.

Is 3V available?

Is 3V -3.33V available?

YES

NO

Refer to Panel I2C

Manual Checking

3-1. LED BLINKING

20

3-1-6. 5x Blinking (Panel I2C Checking Manual)

START

Replace CN8600/CN8601

NG Symptom:

CN8600/CN8601 Mount

or Part Issue

END

Is Connector OK?

YES

NO

Check CN8600 (32”F/40”/43”/ 48”/49”)

or CN8601 (32”W) condition.

Check Impedance at PANEL_SDA &

PANEL_SCL.

Is High Impedance?

Yes

No

Check voltage 3.3V at

Q8601 (Source).

3V available?

Is 3V-3.33V available?

YES

NO

Replace Q8600?

Replace Q8601

5 Times

Blinking happen?

Yes

No

DDCON checking procedure
(IC6009)

5 Times

Blinking happen?

Yes

No

Suspect IC5000/IC5001/IC9000 NG

IC9000 – Refer to 6X Blinking

IC5001 – Refer to No Picture

Troubleshooting

IC5000 – Replace Board

21

3-1. LED BLINKING

BBA
FHD

BBA
WXGA

22

Q860
0

Q860
1

PANEL_SD
A (Top)

PANEL_SC
L (Bottom)

PANEL_SDA
(Top)

PANEL_SCL
(Bottom)

5 x Blinking (checking Point [1/2])

Q8601
(Source

)

BBE
FHD

BBE
WXGA

23

Q8600

Q8601

PANEL_SDA
(Top)

PANEL_SCL
(Bottom)

PANEL_SDA
(Top)

PANEL_SCL
(Bottom)

5 x Blinking (Panel I2C Checking Manual [2/2])

Q8601
(Source)

24

3-1-7. 6x Blinking (Backlight Error)- QW

6x Blinking

Check if LED harness (CN9000)

is connected properly?

Replace LS bar*

Yes

No

Change B Board.

AC ON 6x Blinking?

B Board broken**

Change Harness.

AC ON 6x Blinking?

Check F9000 Fuse.

Impedance fuse > 1Ω?

Yes

No

Able to repair

Panel Module?

Yes

Change Panel Module

No

Change F9000 Fuse.

AC ON 6x Blinking?

Fuse F9000 broken

No

Yes

Yes

Harness broken

*To avoid changing all LS bar, please follow steps below

(1) Turn off AC
(2) Unplug DC adaptor from DC jack
(3) Plug in DC adaptor to DC jack
(4) Turn on AC
(5) LS bar will turn on for ~4s before 6x blinking
(6) Observe which LS bar cannot turn on during power on
(7) Replace LS bar that failed to turn on

**For 6x blinking B Board Troubleshooting please refer
next page.

No

Yes

No

Yes

Connect LED harness

AC ON 6x Blinking?

LED harness loose

No

3-1. LED BLINKING

25

B-Board Broken

Check L9001 (AC OFF)

L9001 impedance < 1Ω?

Yes

No

Check D9001 (AC OFF)
VF > 0.1V and < 0.8V?

No

Check Q9000 (AC OFF)

Impedance RDS > 100 ohm

No

Yes

Change Q9000

AC ON 6x Blinking?

Q9000 broken

Yes

L9001 broken

Change L9001

AC ON 6x Blinking?

Change D9001.

AC ON 6x Blinking?

D9001 broken

Check LED_VCC (AC OFF)

LED_VCC short to ground?

Impedance > 1kΩ?

Yes

C9026 & C9027 broken

Change C9026 & C9027

AC ON 6x Blinking?

Check D9002 (AC OFF)

VF > 0.5V and < 1V?

Yes

D9002, Q9001, and RB9001 broken

Change D9002, Q9001, and RB9001

AC ON 6x Blinking?

No

Yes

Suspect : Other Part damage

Change the board

No

Yes

No

Yes

No

No

No

Yes

Yes

No

3-1-8. 6x Blinking (Backlight Error - B Board Troubleshooting)-QW

3-1. LED BLINKING

26

L9001

Q9000

D9001

F9000

F9000, L9001, D9001, Q9000

C9026, C9027, CN9000, IC9000, LED_VCC

C9026

C9027

LED_VCC

IC9000

CN9000

R9021

D9002

Q9001

RB9001

RB9001, Q9001, D9002, R9021

D

S

Multimeter

Q9000 RDS Measurement

-ve

+ve

6x Blinking (Checking Point) QW-BBA [1/2]

27

L9001

Q9000

D9001

F9000

F9000, L9001, D9001, Q9000

C9026, C9027, CN9000, IC9000, LED_VCC

C9026

C9027

LED_VCC

IC9000

CN9000

R9021

D9002

Q9001

RB9001

RB9001, Q9001, D9002, R9021

D

S

Multimeter

Q9000 RDS Measurement

-ve

+ve

6x Blinking (Checking Point) QW-BBE [2/2]

28

3-2-1.H-board troubleshooting flow (for QW, QWL)

TV cannot be controlled

by remote commander

No

Yes

Check Green LED

at Power LED indicator.

Is it lighted up?

Check voltage at

Pin1 of H board connector

(refer next page)

Is it 5V?

No

Place remote commander (RC)

near to window and press RC key.

Is the LED blinking?

Yes

No

Main IC SIRCS line broken.

Change B-board

Check SIRCS voltage

using multimeter

at R5038 on B board.

Then press and hold RC key and

observe voltage drop.

Does it drop

from 3.9V to (<2.9V)?

Change Mechanical part

(ex. Ornamental panel,

or guide light)

Yes

Yes

Condition: TV is plugged to AC power supply,
and AC power supply is turned ON.

Check voltage at resistor of

5V source of B board.

Is it 5V?

Yes

No

STBY5V NG. Refer toIC6014

troubleshooting section

No

IR sensor broken.

Change H board.

Check H board to B board

harness condition.

Is it connected properly?

Yes

No

Connect harness properly

3-2. NO POWER

Board name Board picture

HCY

B board

Pin 1 of
H board connector

BBA

BBE

R5038

R5038

H-board troubleshooting flow (Checking Point)

29

30

3-2-2 : Switch unit troubleshooting flow (for QW, QWL)

Switch Unit NOT FUNCTIONING

Yes

Change Switch Unit

Yes

No

NG

No

Yes

Change Wire Harness

And connect properly

Yes

Change B-board

No

*VOLTAGE LEVEL FOR EACH PRESSED BUTTON (for QW, QWL, QT
switch unit only)

KEY Voltage

(average)

Voltage

range

-

0.000

0.00 – 0.2

+

1.05

1.00 – 1.13

No Input

2.420

2.26 – 2.58

**see next page for probing point of B board

** Check 3.3V

in Pin2, CN1

(Switch Unit).

Is it 3.3V?

Check if Wire Harness

And Connector is

connected properly?

*Check Pin 1

Voltage Level in CN1

(switch unit). Is

voltage level

according to key

pressed?

**Check 3.3V in (Pin

8, CN9702 on

B board . Is it 3.3V?

3-2. NO POWER