Sony Bravia KLV-24R402A User manual

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL (COMMON)
SERVICE MANUAL (COMMON)
ITC2CHASSIS
Segment: BA
Version Date Subject
1 6/2013 1st Issue.
LCD TV
9-888-144-01
For SM - Unique , please refer :
9-888-144-P1 ( Pan Asia )
9-888-144-A1 ( America )
9-888-144-E1 ( Europe)

SERVICE MANUAL (COMMON)
SERVICE MANUAL (COMMON)
ITC2CHASSIS
Segment: BA
LCD TV
LCD
TV

MODEL LIST
THIS SERVICE MANUAL CONTAINS COMMON INFORMATION FOR BELOW REGIONS AND MODELS:
REGIO
N
ASIA AMERICA EUROPE
MODEL
KLV
24R402A
KLV
32R402A
KLV
40R452A
KLV
46R452A
KLV
-
24R402A
KLV
-
32R402A
KLV
-
40R452A
KLV
-
46R452A
KLV-24R422A KLV-32R407A KLV-40R457A KLV-46R472A
KLV
-
32R422A
KLV
-
40R472A
KDL
-
46R485A
KLV
32R422A
KLV
40R472A
KDL
46R485A
KDL-32R435A KDL-40R485A
3

TABLE OF CONTENTS
Section Title Page
1. SAFETY NOTES
1-1. Warnings and Caution………………………………………………………. 5
1-2. Caution Handling of LCD Panel ......…………….................................... 5
Section Title Page
4. SERVICE ADJUSTMENTS
4-1.
A
ccessing Service Mode ..................................................................... 56
4-2.
A
ccessing Software Version……….…………………………………….. 56
4
-
3.
Accessing Self Diagnostic History…………………………………..…….
57
1-3. Safety Check Out ........................……………......................................... 6
1-4. Leakage Test .......................................................................................... 6
1-5. How to Find a Good Earth Ground………………………………………… 7
1-6. Lead Free Information….…………………………………………………… 7
1-7. Handling the Flexible Flat Cable (FFC)……………………………………. 7
4
3.
Accessing
Self
Diagnostic
History…………………………………..…….
57
4-4.
A
ccessing Self Diagnostic Menu…………………………………………… 57
4-5.
A
ccessing Serial Number Edit……………………………………….. 58
4-6.
A
ccessing Model Name Edit……………………………………………… 59
4-7. Updating the Software…………………………………………………….. 61
5. DIAGRAMS
2. SELF DIAGNOSTIC FUNCTION
2-1. Overview of Control Buttons ................................................................... 8
2-2. LED Display Control ………..................................................................... 8
2-3. LED Pattern………………........................................................................ 8
5.
DIAGRAMS
5-1. Circuit Board Location ......................................................................... 62
5-2. Block Diagram...................................................................................... 63
5-3. Connector Diagram ………………………………………...................... 65
2-4. Standby LED Error Display…………………………………………………. 8
2-5. Triage Chart ............................................................................................ 9
3. TROUBLE SHOOTING
3-1. Troubleshooting Flow…….…………………………………………………… 10
3
2
NP
11
3
-
2
.
N
o
P
ower……………….………………………………………......................
11
3-3. Standby Led Blinking……………………………........................................ 14
3-4. No Picture................................................................................................ 25
3-5. Audio Problem.......................................................................................... 27
3-6. Troubleshooting Video Problem…………………………………………… 35
3-7. HDMI Troubleshootin
g
Flo
w
……………………………………………… 43
g
3-8. MHL No Picture…………………………………………………………….. 47
3-9. Tuner Troubleshooting Flow………………………………………………… 50
3-10. IR Troubleshooting Flow…………………………………………………….. 53
3-11. Switch Unit Troubleshooting Flow………………………………………… 54
3
-
12.
RTC
Troubleshooting Flow
………………………………………………….
55
Please refer Service Manual – Unique for below information :
-Safety Warnings
-Wire Dressing
Circuit Board Location
3
12.
RTC
Troubleshooting
Flow
………………………………………………….
55
4
-
Circuit
Board
Location
-Disassembly and Exploded View.

SAFETY NOTES
SECTION 1
ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
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.
3) Do not leave the module in high temperature or in areas of high humidity for
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 receiver is
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 to follow these guidelines to protect you
r
property and
avoid causing serious injury :
• Carry the TV with an adequate number of people; larger size TVs require
two or more people.
Ct
hd
lt
hil
i
th
TV
i
itt
f
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
•
C
orrec
t
h
an
d
p
l
acemen
t
w
hil
e carry
i
ng
th
e
TV
i
svery
i
mpor
t
an
t
f
o
r
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
components
with
Sony
parts
whose
part
numbers
appear
as
shown
in
this
!
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 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
.
than 1 hour while the TV is face down on a cloth.
operation
is
suspected
.
Do not leave Power ON > 1 hour
5
Figure 1. TV is faced down on a cloth during repair.

Safety Notes ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
1-4.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)
1-3 Safety Check-Out
After correcting the original service problem, perform the following
safety checks before releasing the set to the customer:-
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) 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
)Ch k
ll
tl
kb
hi ld
d
t
d
ti
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 0.75V 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 multimeter that have a 2 VAC range are suitable
3
)Ch
ec
k
a
ll
con
t
ro
l
k
no
b
s, s
hi
e
ld
s, covers, groun
d
s
t
raps an
d
moun
ti
ng
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
d
th i
lt
operated
digital
multimeter
that
have
a
2
VAC
range
are
suitable
.
(see Figure 2.)
recommen
d
th
e
ir
rep
l
acemen
t
.
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
lt
f
h
li
d
t
th
t
rep
l
acemen
t
o
f
any suc
h
li
ne cor
d
t
o
th
ecus
t
ome
r
.
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
hibit d
pro
hibit
e
d
.Figure 2. AC voltmeter to check AC leakage
6

Safety Notes ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
1-5. 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
1-7. Handling the FLEXIBLE FLAT CABLE (FFC)
When you insert / pull out FFC, please grasp a reinforcement board and main body of
FFC.
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 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;
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).
1-6. Lead Free Information
Figure 3. Checking for earth ground.
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.
Main Board Main Board
Figure 4: LF Logo Figure 5: LF logo on circuit board
Th i i f th b d i i l ti It i t l
7
Th
e serv
i
c
i
ng o
f
th
ese
b
oar
d
s requ
i
res spec
i
a
l
precau
ti
ons.
It
i
s s
t
rong
l
y
recommended to use Lead Free Solder material in order to guarantee optimal
quality of new solder joints. < Insertion> <Pull out>

SECTION 2
SELF DIAGNOSTIC FUNCTION
2
-
1 Overview of Control Buttons
Self Diagnostic Function
2
-
3 LED Pattern
2
-
1
.
Overview
of
Control
Buttons
When safety 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
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.
2-4. Standby LED Error Display
The Number of
Standby LED
Detection Items Board Error Item
2-2. LED Display Control
Status LED Colour Remarks
Power Off
( AC Off and *1) OFF *1 power switch off (by touch button)
Amber = Red + Green
Standby
LED
(RED blinking)
2 Main Power Error AC adapter Error
3 Audio Error BB board Error
Power On Green
Standby
( by remote control off only ) Red
Picture Off Green
4 Panel Power Error BB board Error
5 Panel I2C COMM Error BB or Source board Error
6 Backlight Error BB board Error
Set "Sleep Timer" Amber
Set "On Timer"
( Power On ) Amber
Set "On Timer"
(
Standb
y
)
Amber
(y)
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
8
Blinking
0
.
5sec
Green
Software Updating Amber Blinking Blinking: 1sec On / 1sec Off

Self Diagnostic Function
Rf
Blinking No Picture No Sound
2-5. Triage Chart
R
e
f
erence 23456Tuner USB Video Component HDMI MHL Main
Speaker HP Video Component Tuner HDMI USB
BB Board 
          
Light Source
Board 
Open Cell    
A
C Adapto
r

Speaker Unit 
LS Harness
Main
Harness 
CC







FF
C
C
able







Note: Details refer to Troubleshooting Section.
Secondary possible defective part
Most likely defective part
9

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
SECTION 3
TROUBLESHOOTING
3-1. Troubleshooting Flow
START
Does the Power Led
stay on when the Open Detail
-
No
Power
TV is switched on ?
Is the Standby Led
No
Power
Open Detail
blink ? - Standby LED Blink
Green & Amber
blink?
- Panel ID Error
- Panel Not Supported
Is the Picture and
Sound OK ?
Open Detail
- Picture/Audio/Video
END
10

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
3-2. No Power
No Power
Check DC voltage at
JL6001 Yes •See DDCON
Sheet
Is it 19.5V?
No
Sheet
Tk t d t
T
a
k
e ou
t
a
d
ap
t
or
and test at adaptor
output is it 19V – 19.5V?
(Refer Figure 1)
BB board
Yes
No
Change adaptor
and test again Adaptor
NG
OK
AC source
NG
Figure 1: How to test DC voltage
at adaptor output
11

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
3-2-1. DD Con
Start DDCON
Check voltage at JL6003
is it 3.3V?
OK
Check F6001
& F6002
NGNo Fuse
Yes
Check voltage at JL6000 No
Change BB
is it 1.2V?
Yes OK
Change
BB
board DDCON
Check voltage at JL6002
Is it 1.5V? Check voltage at JL6012.
Is it 12V?
Check F6003.
Is it ok.
No
Yes
NG
No
Change BB
board
Check voltage at JL6005
is it 5V?
No
Yes
NG
Change BB
board
Fuse
Yes After checking, take note of
NG condition & change
BB
board
12
NG
condition
&
change
BB
board

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
Troubleshooting References (BB Board)
JL6002
JL6001
JL6003
JL6000
JL6006
JL6005 JL6006 F6003
13

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
3
3 Standby LED Blinking
3
-
3
.
Standby
LED
Blinking
3-3-1. 2-times Blinking
2 times Blinking
Check DC voltage at
JL6001 Yes Change BB
board
Is it 18V - 19.5V?
No
board
Take out adaptor
and test at adaptor
output is it 18V – 19.5V?
(Refer Figure 1)
Change BB
board
Yes
Change
adaptor
No
Figure 1: How to test DC voltage
at adaptor output
14

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
3
3 Standby LED Blinking
3
-
3
.
Standby
LED
Blinking
3-3-2. 3-times Blinking
Remove
SkC t
No
3x blinking Speaker impedance
≠6~8 Ω
START
3x blinking
S
pea
k
er
C
onnec
t
or
at CN4000 & perform
AC OFF - ON
3x blinking
Check Speaker harness
and Speaker impedance
No connectivity for
speaker harness
Change
Change
Speaker
Change
Speaker
Harness
Connect back
3x blinking
F4000 broken Check connectivity
of F4000.
No connectivity
of F4000
Speaker Connector to CN4000
& perform AC OFF - ON
No 3x blinking
3x blinking
& F4000 OK
Audio IC problem,
IC4000 damage
Change BB
board
15
DONE

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
Troubleshooting References (BB Board)
F4000
IC4000
CN4000
JL6012
16

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
Troubleshooting References
BoardName Board PWB(Aside) Detail
BB
CN4000
F4000
CN4000 CN4000
F4000
F4000
F4000
F4000
F4000
17

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
3
3 Standby LED Blinking
3
-
3
.
Standby
LED
Blinking
3-3-3. 4-times Blinking
No 12V
Check F6003.
Is it ok?
No Fuse
Yes
Check JL6009.
Is it 3.3V? BB board
No
Yes
N
Check JL6012.
Is it 12V? DDCON
N
o
Yes
LVDS
18

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
Troubleshooting References (BB Board)
LVDS FFC
CONNECTOR
JL6012
F6003
JL6009
19
JL6009

ITC2 CHASSIS
R402/ R407/ R422/ R435/ R452/ R457/ R472/ R488
Troubleshooting
3
3 Standby LED Blinking
3
-
3
.
Standby
LED
Blinking
3-3-4. 5-times Blinking
START
Remove and reinsert LVDS Flat
Remove and reinsert LVDS Flat
Flexible Cable (FFC) at
BB Board and
Panel
Replace B-Board BB Board Issue
Incorrect FFC
Insertion
TV Boot Up
Normally
TV Boot Up
Normally
5x Blinking is Still
Observed 5x Blinking is Still Observed
TV Boot Up
TV Boot Up
Replace LVDS Flat
Flexible Cable (FFC) LVDS
Cable Issue
** Replace
O-Cell or Panel Module O-Cell Issue
TV
Boot
Up
Normally
TV
Boot
Up
Normally
END
5x Blinking is Still Observed
** Not recommended at Service Side.
20