Sony Bravia KDL-40W580B User manual

Version Date Subject
1 01/2014 1st Issue.
2 04/2014 Model Addition : Add 60” Models ( Model List , pg 45-46 )
LCD TV
9-888-150-02
For SM - Unique , please refer :
9-888-150-A1 ( America )
9-888-150-C1 ( China)
9-888-150-E1 ( Europe )
9-888-150-P1 ( Pan Asia )
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
RB2G CHASSIS
Segment: HM
SERVICE MANUAL (COMMON)

LCD TV
SERVICE MANUAL (COMMON)
RB2G CHASSIS
Segment: HM

3
MODEL LIST
THIS SERVICE MANUAL CONTAINS COMMON INFORMATION FOR BELOW REGIONS AND MODELS:
REGION
ASIA CHINA AMERICA JAPAN EUROPE
MODEL
KDL-40W580B KDL-48W580B KDL-60W600B
KDL-40W590B KDL-48W585B KDL-60W605B
KDL-40W600B KDL-48W590B KDL-60W607B
KDL-40W605B KDL-48W600B KDL-60W608B
KDL-40W607B KDL-48W605B KDL-60W610B
KDL-40W608B KDL-48W607B KDL-60W630B
KDL-48W608B KDL-60WM15B
KDL-48WM15B

Section Title Page
1. SAFETY NOTES
1-1. Warningsand 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………………………………………… 7
1-7. Lead Free Information….…………………………………………………… 7
1-8. Handling the Flexible Flat Cable (FFC)……………………………………. 7
2. SELF DIAGNOSTICFUNCTION
2-1.
Overview of Control Buttons...................................................................
8
2-2. LED Display Control ………..................................................................... 9
2-3. LED Pattern………………........................................................................ 9
2-4. Standby LED Error Display…………………………………………………. 9
2-5. Triage Chart ............................................................................................ 10
3. TROUBLE SHOOTING
3-1. No Power…….……………………………………………………………….. 11
3-2. LED Blinking……………….………………………………………............... 12
3-3. No Sound……………………………......................................................... 20
3-4. No Picture................................................................................................. 21
3-5. Side Buttons Malfunction……………………………………………………. 23
3-6. IR Remote CommanderMalfunction……………………………………… 23
3-7. Light Sensor Error…………………………………………………………. 23
3-8. Network Malfunction:Ethernet (Wired)……………………………………. 24
3-9. 3D-Glasses(Active) malfunction………………………………………….. 25
3-10. WirelessNetwork Malfunction……………………………………………. 26
3-11. Bluetooth Malfunction……………………………………………………….. 27
4
TABLE OF CONTENTS
Please refer ServiceManual – Unique for below information :
-Safety Warnings
-WireDressing
-Circuit Board Location
-Disassembly and ExplodedView.
Section Title Page
4. SERVICE ADJUSTMENTS
4-1. AccessingService Mode ..................................................................... 28
4-2. Transitionof Each Micro’s Service Mode……….……………………… 28
4-3. Change Data by Service Mode 1…………………………………..……. 28
4-4. Change Data by Service Mode 2………………………………………... 29
4-5. Restore WB/ GammaAdj. Data to B Board.………………………….. 30
4-6. WBAdjustmentby Service Mode……………………………………….. 31
4-7. VCOM Adjustment (NFR-AUO/SDC/FXCPanel) …………………………… 31
4-8. VCOM Adjustment(HFR-AUO /FXC Panel) …………………………………. 32
4-9. REC Setting………………………………………................................... 32
4-10. Reset Panel OperationTime………………………………………......... 33
4-11. Set to Shipping Condition……………………………………….............. 33
4-12. Summaryof Service Control……………………………………….......... 33
4-13. ServiceMenu Tree………………………………………........................ 34
4-14. How to Enter Self Diagnosis Display…………………………………… 35
5. DIAGRAMS
5-1. Circuit Board Location ......................................................................... 38
5-2. Block Diagram...................................................................................... 39
5-3. Connector Diagram ………………………………………...................... 44

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
1-2. Caution Handling of LCD Panel
Whenrepairing the LCD Panel, make sure you are groundedwith a wrist band.
Whenrepairing the LCD Panel on the wall, the panel must be secured using the
4 mounting holes on the rear cover.
1) Do not press the panelor frameedge to avoid the risk of electric shock.
2) Do not scratch or press on the panel with any sharp objects.
3) Do not leavethe module in high temperatureor in areasof high humidity for
an extendedperiod of time.
4) Do not expose the LCD panel to direct sunlight.
5) Avoid contactwith water. It may cause short circuit within the module.
6) Disconnect the AC power when replacing the backlight (CCFL) or
invertercircuit. (High voltage occurs at the invertercircuit at 650Vrms)
7) Always clean the LCD panelwith a soft cloth material.
8) Use care when handling the wires or connectorsof the inverter circuit.
Damaging the wires may cause a short circuit.
9) Protect the panelfromESD to avoid damaging the electronic circuit (C-MOS).
10) During the repair, DO NOT leave the Power On or Burn-in period formore
than 1 hour while the TV is face down on a cloth.
5
SAFETY NOTES
SECTION 1
1-1. Warnings and Caution
1) These servicing instructionsare for use by qualified service personnel only.
2) To reduce the risk of electric shock, do not performany servicing other than
that containedin the operating instructionsunless you are qualified to do so.
3) An isolation transformershould be used during any service to avoid
Possible shock hazard, becauseof live chassis. The chassis of this receiver is
directly connectedto the ac power line.
4) Be sure to follow these guidelinesto protectyour propertyand
avoid causing serious injury :
• Carry the TV with an adequatenumber 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.
5) Componentsidentifiedby shading and mark on the exploded views,
and in the parts list are critical for safe operation.Replace these
componentswith Sony parts whose part numbers appearas shown in this
manualor in supplementspublished by Sony. Circuit adjustmentsthat are
critical for safe operation are identifiedin this manual. Follow these
procedureswhenevercritical componentsare replaced or improper
operation is suspected.
!
Figure 1. TV is faced down on a clothduring repair.

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
6
3) Measuring the voltage drop across a resistor by means of a VOM or battery
operatedAC voltmeter. The 'limit' indication is 0.75V so analog meters must
have an accurate low voltage scale.The SIMPSON'S 250 and SANWA SH-
63TRDare examplesof passive VOMs thatare suitable. Nearly all battery
operateddigital multimeterthat have a 2 VAC range are suitable.
(see Figure 2.)
1-4. Safety Check-Out
Aftercorrecting the original service problem, perform the following
safetychecks beforereleasing the set to the customer:-
1) Check the area of your repair for unsoldered or poorly soldered
connections.Check the entire board surfacefor solder splashes and bridges.
2) Check the inter board wiring to ensure that no wires are pinched or
contact high-wattageresistors.
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 unauthorizedreplacement parts,particularly transistorsthat
were installed during a previous repair. Point them out to the customer and
recommendtheir 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 voltmeterto check AC leakage
Safety Notes
1-3. Caution About the Lithium Battery
1) Danger ofexplosion if batteryis incorrectly replaced. Replaceonly with
the same or equivalent type.
2) Outer case broken battery should not contact to water.
1-5.Leakage Test
The AC leakage fromany exposedmetal part to earth ground and fromall
exposedmetalparts to any exposedmetal part having a return to chassis must
not exceed 0.5mA (500 microamperes).
Leakagecurrent can be measured by any one of the three methods:-
1) A commercial leakage testersuch as the SIMPSON 229 or RCA WT540A.
Follow the manufacturersinstructionsto use those instructions.
2) A battery-operatedAC milliampmeter The DATA PRECISION 245 digital
multimeteris suitable forthis job.
1-6. How to Find a Good Earth Ground
1) A cold-waterpipe is a guaranteedearth 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
groundby measuring the resistance between it and a cold-water pipe with an
ohmmeter.The reading should be zero ohms.
3) If a cold-waterpipe is not accessible, connecta 60- to 100-watt trouble-
light(not a neon lamp) betweenthe 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.

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W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
7
Safety Notes
1-7. Lead Free Information
The circuit boards used in these models have been processed using Lead
Free Solder. The boards are identifiedby the LF logo located close to the
board designation.
Figure 4: LF Logo Figure 5: LF logo on circuit board
The servicing of theseboards requires special precautions.It is strongly
recommendedto useLead Free Solder materialin order to guaranteeoptimal
quality of new solder joints.
1-8. Handling the FLEXIBLE FLAT CABLE (FFC)
When you insert / pull out FFC, please grasp a reinforcementboard and main
body of FFC.
< Insertion> <Pullout>
Main Board Main Board
Please hold reinforcement board and
plunge it to depths. Please pull out FFC while pushing the
button of both ends at the same time.

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
SECTION 2
SELF DIAGNOSTIC FUNCTION
2-1. Overview of Control Buttons
8
Self Diagnostic Function
2-1-1. (EXCEPT CHINA) 2-1-2. (CHINA)
频道 +
频道 -
主菜单
INPUT SELECT /
SELECT/ CONFIRM
Press to select the next or
previous channel.
In TV Home Menu: buttons
willwork as (select/confirm)
+/- (Channel) / / ,
+/- (Volume) / / .
Press to select the next or
previous channel.
Press to adjust the volume.
In TV Home Menu: buttons
will work as , , , .
频道
Power
Turnthe TV on or switch to standby mode
Press to display
the TV Home Menu.
主菜单
FRONT
REAR OF TV
HOME
Press to display
the TV Home Menu.
Power
Turnthe TV on or switch to standby mode
INPUT SELECT /
SELECT/ CONFIRM
Press to select the next or
previous channel.
In TV Home Menu: buttons
willwork as (select/confirm)
FRONT
CH+/- (Channel) / / ,
+/- (Volume) / / .
Press to select the next or
previous channel.
Press to adjust the volume.
In TV Home Menu: buttons
will work as , , , .
REAR OF TV

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
9
Self Diagnostic Function
2-4. Standby LED Error Display
2-2. LED Display Control
Example: The figure above shows LED display when SHUTDOWN is caused by Audio
Error. It repeats flashing for a specified number of times in 0.5sec/cycle 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.
Whensafety shutdown occurs, Standby LED display reports the cause by using the lightning
patterns as indicated below.
2-3. LED Pattern
3.0sec 3.0sec
0.5sec
0.5sec
RED LED
blinking count
DetectionItems Board Error Item
2x Main 12V failure [MAIN_POWE]
* This failure is not saved
G** Board Error
BAX_L Board Error
3x
Main 5.0/3.3/1.8/1.0/ 1.1V failure [DC_ALERT]
* 5.0/1.0V failures are not saved. BAX_L Board Error
Audio amp. protection [AUD_ERR] BAX_L Board Error
Speaker
HDMIequalizer/switch I2C NACK [HDMI_EQ]* There is Temp.
sensor on the same I2C bus. BAX_L Board Error
Tuner or demodulator I2C NACK [TU_DEMOD] BAX_L Board Error
Tuner Board Error
AFEdevice I2C NACK [AFE_I2C] BAX_L Board Error
Tuner Board Error
AFE device error SPI NACK [AFE_SPI] * only for AEP,CH BAX_L Board Error
Tuner Board Error
4x
LED driver failure [LD_ERR] LED Driver (LD) Board Error
Panel module
LED voltage error [VLED]] LED Driver (LD) Board Error
Panel module
5x Panel ID EEPROM I2C NACK (Also panel power failure is a
suspect)[P_ID_ERR]
Panel module
Tcon board
G** Board Error
BAX_L Board Error
6x
Backlight failure [BACKLIGHT] Panel module
G** Board Error
BAX_L Board Error
Backlight converter OVP [BACKLIGHT]
Panel module
Tcon board
G** Board Error
BAX_L Board Error
7x Over temperature protection [TEMP_ERR]
Temp. sensor I2C NACK [TEMP_ERR] * There is HDMI Eq on the
same I2C bus.
BAX_L Board Error
8x Software Error (Also the main board’s memory or CAM module is a
suspect) BAX_L Board Error
9x Tuner Board Error [TU_BOARD] Tuner Board Error
Size
G** Board Type
Tuner Board
America/Pan Asia/China/Europe Japan
40” Not applicable TUS TUW
48” Not applicable TUS TUW
Status
White Center
LED
(applicable for
HSC2 only)
Side RGB LED Side Amber
LED Remarks
Power Off
( by power saving switch off and *1) - Off Off *1 power switch off (by side key)
Power On - Green Lit Off
STBY/i.LINK STBY/PC STBY
( by remote control off only ) - Off Off
Skype Call Receive - White one shot Off
Picture Off - White one shot Off
Device Connection - Cyan one shot Off
Power ON Animation - White one shot Off
Sleep Timer/On
Timer/Reminder/REC Timer/Photo
Frame
( Power On )
- Amber
Lit*2, *6 Off
*2 One Shot is only user action.
*6 The actual data behaviour is
“One Shot->Lit” to solve issue
related to LED priority.
On Timer/Reminder/REC Timer
( Deep Standby ) - Off Amber After 5 minutes, side amber LED On
Failure - Red
Blinking Off
The number of LED blinking
indicates cause of failure
( refer to Led Error / Triage
chart)
Aging mode - Green Blinking Off Blinking:0.5sec On / 0.5sec Off
End of Aging mode - Green Blinking Off Blinking:3sec On / 3sec Off
Software Updating - white blinking off
Software Updating finish - Blue lit off
Test Reset - white blinking Amber
blinking
Error of panel ID - Green Blinking Amber
Blinking Blinking:0.5sec On / 0.5sec Off
REC (SCART REC & HDD
REC/LIVE PAUSE) [AEP/J only] - Red(Pink) Lit*2, *6 Off
*2 One Shot is only user action.
*6 The actual data behaviour is
“One Shot->Lit” to solve issue
related to LED priority.
ePOP/
Shop Illumination - Cyan loop Off One shot Center White when feature change.

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
2-5. Triage Chart
Self Diagnostic Function
10
Secondary possible defectivepart
Most likely defective part
Size G** Board Type
TU Board
America/Pan Asia/China/Europe Japan
40” Not applicable TUS TUW
48” Not applicable TUS TUW
Reference
Symptoms - Shutdown. Power LED
blinking red diagnostics sequences No
Power Video
- missing or distorted Remote Network Audio Skype Smart Core Bluetooth
(BT)
2 3 4 5 6 7 8 9 10
No White Power LED
& doesnot reponse
to remote (Dead Set)
Stationary
colored lines
ordots
No video One
of Inputs No video all
Inputs No Remote Wireless can't connect No Audio Skype Can't Work Smart Core no LED (Set is still alive)
Bluetooth / One
StepRemote
(OSR) can't
connect
B* Board
p
l
p
p
l
l
p
p
l
l
p
p
l
p
p
p
TU board
p
p
l
p
l
l
p
G* Board
l
p
p
l
l
p
H* Board
l
l
Speaker
p
l
Skype Module
l
Camera Module
p
Mic. Module
l
Wifi Module
l
l
p
BT Module
l
LD* Board
l
p
LVDS FFC
p
p
p
p
Tcon
p
l
p
p
p
p
LCD Panel
l
l
l
p
l
p
Problem
Power Power LD Panel (Tcon) Panel (Backlight) TEMP Soft- ware Emitter
Audio FAN (N/A)
Local I2C

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
11
SECTION 3
TROUBLESHOOTING
3-1. NO POWER
Parts Board PWB (BAXL- A side) Detail
(L9107)
Troubleshooting
No Power
Check STBY 3.3V
L9107
Harness
Adapter
Replace
Between LD Board to
B* Board Harness
BAXL Board
NG
OK
NG
OK
Replace
LD- Board
NG
LD Board
OK
For HT, HM, change LD board.
For HE, change Panel.
3-1-1. NO POWERAC ADAPTER
1
L9107
Note :
-B* Board – BAXL Board
3-1-2. NO POWER – AYU2/AYU2L failure
AYU2/L Fail Suspected
Replace BAXL Board
No
eMMC / RawNAND erase
Product SW rewrite
Recover? Product SW
writing issue
Yes

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
12
Troubleshooting
3-2-1. LED Blinking: 3x (DC Alert & Communication Error)
3-2. LED BLINKING
Size
G** Board Type
B* Board
40” Not applicable BAX_L
48” Not applicable BAX_L
Speaker
Check
Speaker Impedance
at SP Connector
Check
Audio +12.5V
at pin 18/20 of CN9101
on the B* Board
(except Adapter model)
G* Board
Check
+12.5V / +19.5V
at Power Amp side
of F4401 / F4601 on
the B* Board
F4401 / F4601,
IC4901 / IC4601
,etc
(B* Board)
IC4901 / IC4601,etc
(B* Board)
AUDIO
NG
OK
NG
OK
NG
OK
TUNER Board
TUNER
NG
3-time blinking
Check D+1.0V at
JL9003 / JL9127 on
the B* Board
F9105,IC9103,
Etc (B* Board)
Check
+3.3V_MAIN_1
at JL9117 on
the B* Board
F9104,IC9104,
etc (B* Board)
DC_ALERT
NG
OK
NG
OK
NG
Check
+1.8V_MAIN on
Pin 2 of IC9201 IC9201,etc
(B* Board)
Check
+5.0V_MAIN
at JL9113 / JL9112 on
the B* Board
NG
OK
IC9102 / IC9101
,etc (B* Board)
OK
Note: For location details, refer to troubleshooting Reference for parts location.
Change TUS/TUW
Board

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13
Troubleshooting
Board / Parts Board PWB (A side) Detail
BAXL
(F9104)
BAXL
(IC9104)
BAXL
(IC9201)
F9104
IC9104
IC9201
3-2-1. LED Blinking: 3x (DC Alert & Communication Error)
TroubleshootingReferences(a)

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
Board / Parts Board PWB (A side) (B side) Detail
BAXL
(IC9101)
BAXL
(JL9112)
TU-S (Others)
(CL2101,
CL2102)
TU-W (Japan)
(CL2318,
CL2319)
14
Troubleshooting
IC9101
JL9112
B-Side
CL2318
CL2319
CL2102
CL2101
3-2-1. LED Blinking: 3x (DC Alert & Communication Error)
TroubleshootingReferences(b)

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
Board /Parts Board PWB (A side) Detail
BAXL
(RB8517)
BAXL
(R8546, R8547)
BAXL
(CL5023, CL5024)
15
Troubleshooting
B-Side RB8517
R8546
R8547
CL5023
CL5024
3-2-1. LED Blinking: 3x (DC Alert & Communication Error)
TroubleshootingReferences(c)

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
Board /Parts Board PWB (A side) Detail
BAXL
(R8546, R8547)
BAXL
(CL5023,
CL5024)
BAXL
(F4601)
BAXL
(IC4601)
BAXL
(CN9101)
16
Troubleshooting
R8546
R8547
CL5023
CL5024
F4601
IC4601
CN9101
3-2-1. LED Blinking: 3x (DC Alert & Communication Error)
TroubleshootingReferences(d)

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
Board /Parts Board PWB (BAX-L – B SIDE)
BAXL
BACKLIGHT_MON
= JL9106
17
Troubleshooting
3-2-3. LED BLINKING 4x (LED Voltage Error)
4-times blinking
Check
BACKLIGHT_MON
on the BAXL
Board
BAXL Board
LED driver
Between 0.49V to 1.32V
For HT, HM, change LD board.
For HE, change Panel. BACKLIGHT_MON
= JL9106

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18
Troubleshooting
3-2-3. LED BLINKING 5x (T-Con Error)
5-times blinking
Check
PANEL_VCC 12.5V at
CN8001 on
on the BAXL Board G* Board / Adaptor
Replace the Harness
Between G* / LD board
and BAXL board
Replace
the LVDS Harness
Change
BAXL Board Change
Panel (T-con)
Harness
LVDS Harness
BAXL Board
About 12.5V
NG
OK
NG
Symptom
improvement
Symptom
improvement
Symptom
improvement
NG
NG
Confirm Tcon 12V.
JL9132
(PANEL_VCC)
BAXL (B-Side)
Size G* Board Type
40” Not applicable
48” Not applicable

RB2G CHASSIS
W580B/W585B/W590B/W600B/W605B/W607B/W608B/WM15B
Parts Board PWB (BAXL- B side)
(JL9106)
19
Troubleshooting
3-2-4. LED BLINKING 6x (Backlight Error)
6-times blinking
Check JL9106* at
(BACKLIGHT_MON)
of CN9101
on the BAXL Board BAXL Board
No
Change
G* board
1.3 -1.8 V Symptom
improvement
HaveG* board?
Change LD Board
G* Board
Yes
LD Board
Symptom
improvement
AYU2
JL9106
Size G* Board Type
40” Not applicable
48” Not applicable

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20
Troubleshooting
3-2-5. LED BLINKING 7x (Temperature Error)
7-times blinking
BAXL
Board
Yes
Panel
NG
Change BAXL Board,
and Aging a few
hours
Setting
circumstance is OK?
Temperature,
Ventilation, etc.
Set to another
location, etc.
No
Symptom
improvement
3-3. No Sound
No Sound
Change
the Speaker
Harness
Speaker
Harness
Replace
the BAXL
Board
Speaker
NG
NG
Check the
“Speakers setting” Change to
“TV Speaker”
“Audio System”
“TV Speakers”
Symptom
improvement
Symptom
improvement No Sound:
Audio
No Sound:
Tuner
No Sound:
HDMI
BAXL Board