Sony DL-55W657D User manual

SERVICE MANUAL
Version Date Subject
1.0 11/2016 Original manual issue.
1.2 11/2016 Updated tuner part number and software version 16,43,45
12/2016 Add LGD panel model power board P/N at slide 16
Add LGD panel P/N at slide 17
Add Select Panel Type at slide 4
LCD Digital Color TV
9-888-721-02
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
ORIGINAL MANUAL ISSUE DATE: 11/2016 Chassis Name :GN2TP
Segment Name : QW

KDL-55W657D 2
MODEL LIST
MODEL COLOR COMMANDER DEST. MODEL COLOR COMMANDER DEST.
KDL-55W657D Black RMT-TX102B CO1

Table of content
3
Description Page
Caution--Two Panel Source Handling…………………………………. 4
Main Board Replacement Caution Guide[KDL-55W657D]………… 5
Power Board Replacement Caution Guide [KDL-55W657D]……….. 6
WARNINGS AND CAUTIONS………………………………………… 7
USE CAUTION WHEN HANDLING THE LCD PANEL…………… 8
SAFETY CHECK-OUT………………………………………………… 9
SELF DIAGNOSIS FUNCTION……………………………………… 10
SERVICE POSITION…………………………………………………… 12
SEC 1. DISASSEMBLY AND PARTS LIST…………………………… 13
1-1. KDL-55W657D …………………………………………………… 14
1-1-1. BASE STAND……………………………………………… 14
1-1-2. REAR COVER ……………………………………………… 15
1-1-3. POWER BOARD, A BOARD AND SPEAKER ………… 16
1-1-4. LCD PANEL, DECO and COVER, BOTTOM ………… 17
1-1-5. MISCELLANEOUS………………………………………… 18
1-2. How to disassemble rear cover [KDL-55W657D]…………….. 19
1-3. How to disassemble Deco………………………………….…… 20
1-3-1. How to disassemble Deco [KDL-55W657D]……………. 20
1-4. How to disassemble LVDS cable [KDL-55W657D]…………… 21
1-4-1. How to disassemble LVDS cable [KDL-55W657D]……… 21
1-5. How to disassemble IR Board[KDL-55W657D ]………………. 22
1-6. How to ass’y the LED lens [KDL-55W657D]…………………. 23
1-7. How to ass’y the KEY Board[KDL-55W657D]………………… 24
Description Page
1-8. How to disassembly the Front bezel[KDL-55W657D]………….. 25
1-9. How to ass’y the Front bezel[KDL-55W657D]………………...… 28
1-10. How to assy the Himeron Countermeasure on panel
[KDL-55W657D]……………………………………………………… 29
SEC 2. ADJUSTMENT…………………………………………………….. 35
SEC 3. DIAGRAMS AND CHASSIS STRUCTURE………………… 37
3-1. BLOCK DIAGRAM……………………………………………… 37
3-2. CONNECTOR DIAGRAM……………………………………… 38
3-3. CIRCUIT BOARDS LOCATION……………………………… 39
3-4. Tape location……………………………………………………… 40
APPENDIX-1 Trouble analysis flow…………………………………… 42
APPENDIX-2 Software data update…………………………………… 43
APPENDIX-3 Panel Operation Time………………………………….. 47
APPENDIX-4 Edit MODEL NAME and Serial Number…………… 48
APPENDIX-5 Assembly parts…………………………………………… 49
KDL-55W657D

Service Mode
Status Information >>
Self diagnosis history >>
Panel Selection <[ 27_LVB550FHB ]>
STATUS 1st Tu Infor >>
LVDS Spectrum(%) <[ 30 ]>
SERIAL NUMBER EDIT 8150003
MODEL NAME EDIT KDL-55W657D
TEST RESET <[ OFF ]>
UART Selection <[ Factory ]>
Tu Data for serv >>
SDB Service Menu >>
White Balance >>
Aging Mode <[ Off ]>
Default date for HDD recording <[ On ]>
Tuner detection >>
LVDS Driver Strength <[ 4 ]>
ATMOS CEC DISABLE <[ 0 ]>
[</>Set[Home]Exit
4
Caution--Two Panel Source Handling
KDL-55W657D
Select: Panel Type
1.Entering Service Mode
2.Select “Panel Selection”
Please check TV set s/n and set the panel selection item correctly
If TV s/n is 6,200,001-6,300,000, please ensure the item set to “27_LVB550FHB”.
If TV s/n is 6,300,001-6,400,000, please ensure the item set to “26_ LVG550DUY”.
3. Use the left and right key on RC to select Panel Type.
KDL-55W657D CO1
First Panel(BOE)
Second Panel(LGD)
Panel Type
27_LVB550FHB
26_LVG550DUY
Panel P/N
A-2123-136-A
A-2178-977-A
PSU P/N
1-895-955-11
1-982-362-11
Panel
Model Name
Product Code
Serial number
BOE
KDL-55W657D CO1
18894200
6,200,001-6,300,000
LGD
KDL-55W657D CO1
18894200
6,300,001-6,400,000
Make sure the panel selection is in right
setting after main board replacement.
Caution 1: This adjustment step for panel selection is mandatory check item after main board replacement.
Caution 2 : Please make sure the power board is matched with the panel brand when panel replacement.

Service Mode
Status Information >>
Self diagnosis history >>
Panel Selection <[ 27_LVB550FHB ]>
STATUS 1st Tu Infor >>
LVDS Spectrum(%) <[ 30 ]>
SERIAL NUMBER EDIT 8150003
MODEL NAME EDIT KDL-55W657D
TEST RESET <[ OFF ]>
UART Selection <[ no log ]>
Tu Data for serv >>
SDB Service Menu >>
White Balance >>
Aging Mode <[ Off ]>
Default date for HDD recording <[ On ]>
Tuner Detection >>
LVDS Driver Strength <[ 4 ]>
ATMOS CEC DISABLE <[ 0 ]>
[</>Set[Home]Exit
5
Caution: This adjustment step for UART is mandatory check item after main board replacement.
Other items should be kept the original setting.
Service mode optional bit check and manual adjustment step [KDL-55W657D]
KDL-55W657D
Main Board Replacement Caution Guide[KDL-55W657D]
1. HOW TO ENTERING SERVICE MODE
1) standby mode
a.Turn on the main power switch to place this set in standby mode.
b.Press the buttons on the remote commander as follows, and entering
service mode.
2) power on mode
a.Turn on the main power switch to place this set in Power on mode.
b.Press the buttons on the remote commander as follows, and entering
service mode.
2. Check UART Selection:
Please check TV set default setting of UART is “No Log”.
Make sure the default setting of
UART is “No Log” after main
board replacement.

6
Caution: Please check the support pin after power board replacement.
Assembly the PSU Support pin [KDL-55W657D]
KDL-55W657D
1. Assembly the two support pins into the power board.And then check whether the support pins is locked well on the back side of
the power board.
Check the support pin is
fixed well after power
board replacement.
Not locked well on the
back side of the power
board.
Locked well on the back
side of the power board.
Power Board Replacement Caution Guide [KDL-55W657D]
Item
Sony PN
Description
Qty
1
4-571-413-01
SUPPORT, PWB
2

7
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-55W657D

8
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) Always clean the LCD panel with a soft cloth material.
7) Use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short.
8) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
9)It is recommended not to exceed 1 hour of Power-On nor Burn-in period with LCD panel face down condition, in repair activity.
10)Disconnect the AC power when replacing the parts.(FFC cable etc.).
KDL-55W657D

9
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-55W657D

10
SAFETY CHECK-OUT
Leakage Test
(To protect electric shock when customer touch the terminal.)
Leakage current can be measured by V: Voltmeter or oscilloscope (r.m.s. or peak reading)
Stabilized power supply instrument and isolated voltage transformer:
Use too much current capacity and isolated voltage transformer does not need to use stabilized power supply equipment
Specification of RMS volt meter: Input resistance > 1 Mohm, Input capacitance < 200 pF,
Frequency range: 15 Hz –1MHz (Refer Figure 1). Isolated type volt -meter (FLUKE 8921A etc *1)
*1 Not use FLUKE 8920A that connected to protective earth by diode
# Leakage current of measurement instrument is less than 10μArms when under test equipment AC plug is
opened
# Set up the following condition and turn on the set.
Applied voltage: Nominal input voltage (Description on Nameplate)
# Measure the leakage current between one phase conductor and neutral for terminal A and terminal B.
Read rms value, and then calculate to peak value PEAK VALUE =√2 RMS VALUE
Comply with the following requirement Class II equipment (2-pin plug): for each terminal, the worst value of measurement must
not exceed AC 350uA peak). Note: including AC adaptor, AC adaptor/DC operated unit combination
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-55W657D

11
SELF DIAGNOSIS FUNCTION
This model support Self Diagnosis Function.
SELF CHECK
BACK <<
002 MAIN_POWER 000
003 AUD_ERR 000
004 PANEL_POWER ERROR 000
005 PANEL_I2C_COMM_ERR 000
006 BACKLIGHT_ERR 000
000 BE_I2C 000
000 TU_DEMOD 001
00000-00003-00000
[Home] Exit
HOW TO ENTERING Self Diagnosis Display
1) standby mode
a.Turn on the main power switch to place this set in standby mode.
b.Press the buttons on the remote commander as follows, and entering service mode.
2) power on mode
a.Turn on the main power switch to place this set in Power on mode.
b.Directly go to Self Diagnosis Display in Service Menu.
Self Diagnosis Display
Display 5 Vol- Power
Items
Error Items
Description
002
MAIN_POWER
Detect and observe main voltage
003
AUD_ERR
Detecting/Observing audio AMP error
004
PANEL_POWER_ERR
Detect and observe for Panel_12V
005
PANEL_I2C_ERR
Detect Panel I2C Communication access error
006
BACKLIGHT_ERR
Detect and observe backlight error
000
BE_I2C
BE device I2C communication error detection.
000
TU_DEMOD
Tuner & Demodulator 2Ccommunication monitoring.
Tuner Detect signal monitoring.
KDL-55W657D

12
SERVICE POSITION
2. Remove all screws on the Rear Cover to
Bezel & Main Board & Bracket (23 screws)
1. Remove all screws on the Stand
to main unit (4 screws)
3. After removing rear cover , lie down the main unit
to a surface for following test/repair.
As for this model, the bottom of rear cover is installed between the stand assy and the panel.
Therefore according to the following procedure when performing adjustment and operation check after the part replacement.
Note: Remove rear cover, then assemble the stand to main unit. This
will cause the stand with main unit fit closely, scratch or deformation
may occurred easily on the stand or bezel deco.
Attention: This photo is based on Sony criteria for appearing standing the
main unit after removing back cover and assembling the stand. But
considering mechanical design of the models and normal service process,
it is not recommended to keep main unit standing by this status for
repairing/testing at repair center. Please pay attention for avoiding
possible scratch/deformation occurred.
<KDL-55W657D>
Pls add SONY P/N
4-592-444-01 SCREW, +PSW M5X12
4-595-220-01 SCREW +BVTP 4X12 TYPE2 N-S, ODM(T)
7-682-903-19 SCREW +PWH 3X6
4-595-222-01 SCREW +PWH 3X8 W7.5, ODM(T)
4-595-219-01 SCREW +BVTP 3X8 TYPE2 N-S, ODM(T)
4-595-213-01 SCREW +K 3X6, ODM(T)
KDL-55W657D

13
• 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.
SEC 1. DISASSEMBLY AND PARTS LIST
KDL-55W657D

1-1-1. BASE STAND
DISASSEMBLY AND PARTS LIST
1
REF. No. PART No. DESCRIPTION MARK
1 A-2123-138-A STAND ASSY
26 4-592-438-01 STAND, NECK
28 4-571-144-01 HANDLE
4-592-444-01 SCREW, +PSW M5X12
4-595-223-01 SCREW +PSW M6X22, ODM(T)
14
1-1. KDL-55W657D
26 28
1
If want to disassemble the stand neck from the stand ASSY,
just remove the six screws.
KDL-55W657D

23 4-689-453-01 LABEL, SIDE I/O
24 4-689-480-01 LABEL, DOWN I/O
25 4-689-452-01 LABEL, BACK I/O
15
DISASSEMBLY AND PARTS LIST
1-1-2. REAR COVER
1-1. KDL-55W657D
2
4-595-220-01 SCREW +BVTP 4X12 TYPE2 N-S, ODM(T)
7-682-903-19 SCREW +PWH 3X6
4-595-222-01 SCREW +PWH 3X8 W7.5, ODM(T)
4-595-219-01 SCREW +BVTP 3X8 TYPE2 N-S, ODM(T)
4-595-213-01 SCREW +K 3X6, ODM(T)
24
25
KDL-55W657D
23

16
DISASSEMBLY AND PARTS LIST
1-1-3. POWER BOARD, A BOARD AND SPEAKER
15
REF. No. PART No. DESCRIPTION MARK
3 1-895-955-11 MOUNTED PWB POWER UNIT for CO1 model BOE panel
1-982-362-11 MOUNTED PWB POWER UNITLGD for CO1 model LGD panel
4 1-897-076-11 MOUNTED PWB A
5 1-895-956-11 MOUNTED PWB H
6 1-910-111-41 CONNECTOR ASSY16P (MB-PSU)
7 1-910-111-44 CONNECTOR ASSY6P (MB-WiFi)
8 1-910-111-43 CONNECTOR ASSY(MB-IR-KEY)
9 1-910-111-42 CONNECTOR ASSY4P (MB-SP)
10 1-910-111-45 LVDS CABLE (MB-Panel)
11 4-592-437-01 SHEET, INSULATION
12 4-592-435-01 BRACKET, SIDE I/O
13 4-593-153-01 BRACKET, DOWN I/O
14 4-571-385-01 BRACKET, PSU
15 1-859-187-11 LOUDSPEAKER (12W)
21 1-895-957-11 MOUNTED PWB KEY
22 1-895-960-11 WI-FI MODULE (WITH ANTENNA)
27 4-592-421-01 HOLDER, WIFI
1-1. KDL-55W657D
5
21
22
13
27
4-595-216-01 SCREW +PSW 3X6 W6.5, ODM(T)
4-595-221-01 TAPPING +PWH 3X8 TYPE2 N-S, ODM(T)
4-595-218-01 SCREW +PSW 4X8, ODM(T)
4-595-217-01 SCREW +PSW 3X8 W6.5, ODM(T)
4-595-214-01 SCREW +PWH 3X5, ODM(T)
4-595-224-01 SCREW +PSW 3X6 W8, ODM(T)
KDL-55W657D
4
15
3
11
6
8
5
7
10
9
14 12
22
13 28
8

17
DISASSEMBLY AND PARTS LIST
1-1-4. LCD PANEL, DECO and COVER, BOTTOM
REF. No. PART No. DESCRIPTION MARK
17 A-2123-136-A LCM ASSY(55) for CO1 model BOE panel
A-2178-977-A LCM ASSY(55) (LGD) for CO1 modelLGD panel
18 4-592-433-01 BRACKET L, STAND
19 4-592-434-01 BRACKET R, STAND
20 4-592-419-01 COVER, BOTTM (55)
4-570-423-01 NUT SCREW
18
17
19 20
1-1. KDL-55W657D
KDL-55W657D

18
PART No. DESCRIPTION MARK
1-492-977-21 REMOTE COMMANDER (RMT-TX102B) for CO1 model
1-846-425-43 CORD SET, POWER-SUPPLY for CO1 model
DISASSEMBLY AND PARTS LIST
1-1-5. MISCELLANEOUS
1-1. KDL-55W657D
KDL-55W657D

19
PROCEDURE TO REMOVAL OF REAR COVER
1. Remove all screws on Rear Cover and AC Cover.
2. Open Rear Cover in order as below.
Hold the panel from the middle of bezel, and lift rear cover in the direction of the arrow.
1-2. How to disassemble rear cover [KDL-55W657D]
KDL-55W657D

20
PROCEDURE TO REMOVAL OF DECO
1-3. How to disassemble Deco
Remove screw from bezel
Remove deco from bezel
1-3-1. How to disassemble Deco[KDL-55W657D]
HOOK HOOK
KDL-55W657D