Sony FW-43XE8 Series User manual

Version Date Subject
1 10/2016 1st Issue.
2 02/2017 Add 49in and 55in models
LCD TV
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
GN3TRCHASSIS
Segment: KF
SERVICE MANUAL (COMMON)
9-888-720-02
For SM - Unique , please refer:
9-888-720-Ax ( America )
9-888-720-Cx ( China)
9-888-720-Ex ( Europe )
9-888-720-Px ( Pan Asia)

LCD TV
SERVICE MANUAL (COMMON)
GN3TRCHASSIS
Segment: KF

MODEL
FW-43XE8* FW-49XE8* FW-55XE8*
KD-43XE8* FW-49X8*E FW-55X8*E
KD-43X8*E KD-49XE8* KD-55XE8*
KJ-43X8*E KD-49X8*E KD-55X8*E
XBR-43X8*E KJ-49X8*E XBR-55X8*E
XBR-49X8*E
MODEL LIST
THIS SERVICE MANUAL CONTAINS COMMON INFORMATIONFOR BELOW REGIONSAND MODELS:
REGION
ASIA AMERICA EUROPE CHINA JAPAN

SectionTitle Page
1. SAFETY NOTES 5
2. SELF DIAGNOSTICFUNCTION 14
3. TROUBLE SHOOTING 18
4. SERVICE ADJUSTMENTS
124
5. DIAGRAMS
135
4
TABLE OF CONTENTS
Please refer ServiceManual – Unique for below information:
-SafetyWarnings
-WireDressing
-Circuit Board Location
-Disassembly and Exploded View.
Note: Pictures provided in this ServiceManual might have slight differencefrom the
actual sets.
Please refer to ServiceProcedure for Panel , Board and Software Change / Upgrade
Manual , part number 9-888-719-0x in TISS.

5
SECTION 1
SAFETY NOTES
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 holeson 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 temperatureor in areas of high humidity for
an extendedperiod 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.
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 panel from ESD to avoid damagingthe electronic circuit (C-MOS).
10) During the repair, DO NOT leave the Power On or Burn-in period for more
than 1 hour while the TV is face down on a cloth.
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 performany servicing other than
that contained in the operating instructionsunless you are qualified to do so.
3) An isolation transformershould be used during any service to avoid
Possible shock hazard, because of live chassis. The chassis of this receiver is
directly connectedto the ac power line.
4) Be sure to follow these guidelines to protect your 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 forsafe operation.Replace these
componentswith Sony parts whose part numbers appearas shown in this
manualor in supplementspublished by Sony. Circuit adjustmentsthat are
critical forsafe operation are identifiedin this manual. Follow these
procedureswhenevercritical componentsare replaced or improper
operationis suspected.
!
Figure 1. TV is faced down on a cloth during repair.

6
1-4. Safety Check-Out
Aftercorrecting the original service problem, performthe following
safetychecks beforereleasing the set to the customer:-
1) Check the area of your repair forunsoldered 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-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.
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) Outercase broken batteryshould not contact to water.
1-5.Leakage Test
(To protectelectric shock when customertouch the terminal.)
Leakagecurrent can be measured by V: Voltmeteror oscilloscope (r.m.s. or
peakreading)
Stabilized power supply instrument and isolated voltage transformer:
Use too much current capacity and isolated voltage transformerdoes not
need to use stabilized power supply equipment.
Specificationof 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 connectedto protective earth by diode
# Leakage current of measurement instrument is less than 10μArms when
undertest equipmentAC plug is opened
# Set up the following condition and turn on the set. Applied voltage:
Nominal input voltage (Description on Nameplate)
# Measure the leakagecurrent between one phase conductor and neutral
for terminal 1 and terminal
2. 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
measurementmust not exceed AC 283uA peak).
Note: including AC adaptor, AC adaptor/DC operated unit combination
Note: Products which are always used in touch with human body: 141uA
(peak)
Note:As for productsdestined forSoutheastAsia (Rod Antennais
accessory.Or it is packed with a product.),the worst value must not exceed
AC 141uA (peak).
Figure 1 – Measuring network
for Leakage Current

The servicing of theseboards requires special precautions.It is strongly
recommendedto use Lead Free Solder material in order to guaranteeoptimal
quality of new solder joints.
1-8. Handling the FLEXIBLE FLAT CABLE (FFC)
Whenyou insert / pull out FFC, please grasp a reinforcementboard and main
body of FFC.
7
1-7. Lead Free Information
The circuit boards used in these models have beenprocessedusing 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
1-6. How to Find a Good Earth Ground
1) A cold-water pipe is a guaranteedearth ground;the cover-plate retaining
screw on most AC outletboxes 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) between the hot side of the receptacleand 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.

<PULL OUT>
8
Press release buttonat the same
time pull out FFC cable
Insert properly without slanting
<INSERTION>
1-8. Handling the FLEXIBLE FLAT CABLE (FFC) ( continue )

9
1-8. Handling the FLEXIBLE FLAT CABLE (FFC) ( continue )

10
1-8. Handling the FLEXIBLE FLAT CABLE (FFC) ( continue )

11
θ≒20°
①The insertion & extraction angle of the module is permitted to
specified degree for connector
Push down to screw.
Service manual operation (agreed by service member):
Not using insertion jig. Due quantity not many as production.
SC can control by:
1) Issue service manual for WW ASC.
2) Give training/lecture how to assemble tuner. Will be handle by SOEM
service
20°
For removing Tuner Module,
In the case of small type Tuner module.
After un screwed, Automatically the Module
will float to correct degree.
So please extract it with keeping this degree.
Please confirms whether no dust and no bend on
terminal of connecter(CN2800) and card-edge
connecter
Attachment order of screw.
1. Side of antenna terminal (W/BFX board).
2. Rear side of Tuner module.
2
1
1-9. Solder-less tuner replacement procedure

12
1-9. Solder-less tuner replacement procedure (Cont. )

13
1-9. Solder-less tuner replacement procedure ( Cont. )

SECTION 2
SELF DIAGNOSTIC FUNCTION
14
DIAGNOSTIC TEST INDICATORS
When an error occurs, the Smart Core Red LED will flash a set number of times to indicate the possible cause of the problem.
If there is more than one error, the LED will identify the first of the problem areas.
Result for all of the following diagnostic items are displayed on screen.
If the screen displays a “0”, no error has occurred .
The units in this manual contain a self-diagnostic function. If an error occurs, the Smart Core Red 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 Smart Core Red 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.
Smart Core RED
LED blinking count Detection Items
2x <B/G/A/LD> Main 12V over voltage [MAIN_POWER]
3x <B> Main 5.0V failure [DC_ALERT]
<B/S/K> Audio amp. protection [AUD_ERR]
4x
(KP/KPSP/KS
only )
<LD/P> LED driver failure/LED voltage protection [LD_ERR]
<LD/P>Error detection of the I2C communication between the
Main device and the LD IC.[BCM_ERR]
5x <P/T/G/B> Panel ID EEPROM I2C No ACK (Also panel power
failure is a suspect) [P_ID_ERR]
6x <G/P/B/LD> Backlight failure [BACKLIGHT]
7x Over temperature protection [TEMP_ERR]
<B> Temp. sensor I2C No ACK [TEMP_ERR]
8x (KP/KPSP)
8x (KS)
<B> 4KBE Error (4KBE WDT)
<B> 4KPQ Error (4KPQ WDT)
Blue italic: detect at startup sequence only.
<G>: Power supply board,
<B>: Main board,
<T>: T-con board,
<LD>: LD board (if AC adapter model, it would power supply for Set),
<P>: Panel module,
<S>: Speaker,
<A>: Power Adapter,
<Tu>: Tuner board,
<K> : Audio board (KFW/KPSP only)

15
Record Only
Item Detection Items
TU_DEMOD <B/Tu> Tuner & Demodulator I2C communication failure
Tuner board set detect signal monitoring
TCON ERR
(KP/KPSP/KS/KH only ) <T> T-CON device I2C communication failure
FRCTC_I2C
(KS/KH)
(KF/KFW/KFC)
<B> FRC device is not finished Initial sequence
FRC device I2C communication failure
<T/B> FRC device is not finished Initial sequence
FRC device I2C communication failure
AUD_ERR_I2C
(KP/KPSP/KS/KH only ) <B/K> Audio amp I2C communication failure
4KPQ_ERR_I2C
(KS/KH only) <B> 4KPQ device I2C communication failure
Blue italic: detect at startup sequence only.
<G>: Power supply board,
<B>: Main board,
<T>: T-con board,
<LD>: LD board (if AC adapter model, it would power supply for Set),
<P>: Panel module,
<S>: Speaker,
<A>: Power Adapter,
<Tu>: Tuner board,
<K> : Audio board (KFW/KPSP only)
Whensafety shutdown occurs, Standby LED display reports the cause by using the lightning patterns as indicated below.
LED Pattern
3.0sec 3.0sec
0.5sec
0.5sec
Example: The figure above shows LED display when SHUTDOWNis 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.

16
Panel Operation Time clear
<7> -> <0>
Timestamps and Error Count clear
<8> -> <0>
Total Operation Time and Boot Count clear
<9> -> <0>
•Panel Operation Time is recorded every 30 min, but Total
Operation Time is recorded every 1 hr.
Therefore, the panel op. time might become larger than the
total op. time.
Format of error timestamps
YYMMDDhhmmss (in UTC)
Example:
120823132523 -> Aug 23 2012 13:25:23 UTC
* Only when time is set, an error timestamp
is saved.
Entry (Self Diagnosis Display)
- Go to the standby by a remote.
- Push the buttons sequentially:
<Display><5><Vol-><Power>
Exit
-If you want to finish service mode app, do AC OFF/ON
→*Service mode app is disable perfectly
-if you want to move home menu, push <HOME>button
→*Service mode app do background(not disable
perfectly)
SELF CHECK
<<
002 MAIN POWER 000000000000 000000000000 000000000000 000
003 DC ALERT 000000000000 000000000000 000000000000 000
003 AUD ERR 150101000018 150101000018 150101000018 003
003 AUD ERR I2C 150101000123 150101000045 150101000045 003
003 TU DEMOD 150101000218 150101000223 150101000105 003
004 LD ERR 000000000000 000000000000 000000000000 000
004 BCM ERR 000000000000 000000000000 000000000000 000
005 TCON ERR 150101000504 000000000000 000000000000 001
005 P ID ERR 000000000000 000000000000 000000000000 000
006 BACKLIGHT ERR 000000000000 000000000000 000000000000 000
007 TEMP ERR 150101000200 150101000002 000000000000 002
008 4KBE ERR 000000000000 000000000000 000000000000 000
Back
00005 00414 00002
[Home]Exit
Smart
Core Red
LED
blinking
count
Error Item Error count
Total Operation Time [hr] – Boot Count – Panel Operation Time [hr]
Error
timestamp
for last
recorded
error
Error
timestamp
for second
last
recorded
error
Error
timestamp
for 3rd
last
recorded
error

Triage Chart
17
Reference
Symptoms - Shutdown. Power LED
blinking red diagnostics sequences No Power
Video
- missing or
distorted
Remote
Networ
k Audio Smart Core
Bluetooth
(BT)
2 3 4 5 6 7 8 9 10
No White Power
LED & does not
reponse to
remote (Dead
Set)
Station
ary
colored
lines or
dots
No
video
One of
Inputs
No
video
all
Inputs
No
Remote
Wireless
can't
connect
No
Audio
Smart Core
no LED
(Set is still
alive)
Bluetooth /
One Step
Remote
(OSR) can't
connect
B* Board
















G* Board







H* Board



K* Board


Speaker


Wifi & BT
Module



LD* Board


V By One
FFC



Tcon




LCD Panel






Before you make the service call…
1. Confirm the symptom from the customer.
2. Select that symptom from the chart.
3. Bring all the boards and cables listed for that symptom.
4. Follow the troubleshooting charts in the technical guides to isolate the board.
5. Chart
Color Code
RED DOT: Most likely defective part
BLUE TRIANGLE: Secondary possible defective part
ABC BLACK TEXT: Board that may correct the symptom
GN3 KF segment

18
TV Business Division
KF/KFW 55” No Power(GL71 PSU board)
Connector Output
Name
Input/output
Voltage PIN
CN6401 STBY3.3V 3.35~3.55V 5
CN6401 POWER_
ON 2.6~3.55V 9
CN6401 REG12V 12.2~13.2V 13~18
CN6401 BL_ON 2.6~3.55V 7
CN6801 +OUT2/3 85.5~125.3V 2~3
NO POWER
Check
Fuse F6101,
Open?
Check
STBY3.3V
Connector CN6401
PIN 5
Check
POWER_ON
Connector CN6401
PIN 9
Check
REG12V
Connector CN6401
PIN 13to18
PSU broken*
Replace PSU
PSU broken*
Replace PSU
Main Board Problem
PSU broken*
Replace PSU
Yes
no
No Voltage
Okay
No Voltage
Okay
No Voltage
Okay
Main Board Problem
No Voltage
Check +Out2
and +Out3 at
CN6801
PSU broken*
Replace PSU
No Voltage
PSU OK
Check
BL_ON
Connector CN6401
PIN 7
Okay
Okay
AC Off
AC ON
Switch Off plug(AC Off)
OpenTV rear cover to check PSU Board
Waitmore than 5 minutes before start
This is to ensure PSU is not in protection mode
*If PSU board replaced, please proceed with PSU
standalone check
18
SECTION 3
TROUBLESHOOTING

19
TV Business Division
1. Appearance check
2. PSU info checking and confirmation
3. Broken parts checking
Note: PSU board CANNOT be repair(unless requested by design)
Any request to repair will be instruct.
GL71 Broken PSU standalone checking
19

20
TV Business Division
No Operation Tool Remarks
1 Check A-side appearance Glove Visual check
Keep record PC/Pen/Photo
2 Check B-side appearance Glove Visual check
Keep record PC/Pen/Photo
Appearance check
Criteria: No abnormality
Example: PWB crack/Burn mark
Burn mark at AC inlet PIN(L~N)
PWB crack
A-side B-side
1 2
20