Sony KDL-32W6 E Series User manual

Version Date Subject
1 02/2017 1st Issue.
2 02/2017 1. Add Segments KML, KMLW , KL , KLW .
2. Add Block and Connector Diagram for all segments
3. Add Note for Section 5 Circuit Board Location.
LCD TV
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
GN3UNCHASSIS
Segment: KM, KMW
KML, KMLW
KL, KLW.
SERVICE MANUAL (COMMON)
9-888-723-02
For SM - Unique , please refer:
9-888-723-Ax ( America )
9-888-723-Cx ( China)
9-888-723-Ex ( Europe )
9-888-723-Px ( Pan Asia)

LCD TV
SERVICE MANUAL (COMMON)
GN3UNCHASSIS
Segment: KM

SEGMENT MODEL
KM
KDL
-32W6*E
KDL
-40W6*E
KDL
-49W6*E
KDL
-32WE6*
KDL
-40WE6*
KDL
-49WE6*
KMW
KLV
-32W6*E
KLV
-40W6*E
KLV
-49W6*E
KML
KMLW
KLV
-32R4*E
KLV
-40R4*E
KL
KLW
MODEL LIST
THIS SERVICE MANUAL CONTAINS COMMON INFORMATIONFOR BELOW REGIONSAND MODELS:
REGION
ASIA AMERICA EUROPE CHINA

SectionTitle Page
1. SAFETY NOTES 5
2. SELF DIAGNOSTICFUNCTION 14
3. TROUBLE SHOOTING 17
4. SERVICE ADJUSTMENTS
123
5. DIAGRAMS
151
4
TABLE OF CONTENTS
Please refer ServiceManual – Unique for below information:
-SafetyWarnings
-WireDressing
-Circuit Board Location
-Disassembly and ExplodedView.
Note: Pictures provided in this Service Manual might have slight differencefrom the
actual sets.
Please refer to GN3UN ServiceProcedure for Panel , Board and Software Change /
Upgrade Manual , part number 9-888-724-0x 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 holes on the rear cover.
1) Do not press the panel or frameedge 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 exposethe 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
inverter circuit. (High voltageoccurs 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 connectorsof the inverter circuit.
Damaging the wires may cause a short circuit.
9) Protect the panel fromESD 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 facedown on a cloth.
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 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
procedureswhenever critical componentsare replaced or improper
operation is 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 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 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.
1-3. Caution About the Lithium Battery
1) Danger of explosion if batteryis incorrectly replaced. Replaceonly with
the same or equivalent type.
2) Outercase brokenbatteryshould not contact to water.
1-5.LeakageTest
(To protectelectric shockwhen 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 currentcapacity and isolated voltage transformerdoes not
need to use stabilized powersupply 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 conditionand turn on the set. Applied voltage:
Nominal input voltage (Description on Nameplate)
# Measure the leakagecurrent betweenone phaseconductorand 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:Productswhich are always used in touch with human body:141uA
(peak)
Note:As for productsdestinedfor SoutheastAsia (Rod Antennais
accessory.Or it is packedwith 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
qualityof new solder joints.
7
1-7. Lead Free Information
The circuit boardsused in thesemodels have been processedusing 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 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-water pipe 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.

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

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

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

11
1-9. Solder-less tuner replacement procedure
θ≒20°
20°
①The insertion & extractionangle of the module is permittedto
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 the Module
will float to correct degree.
So please extract it with keeping this degree.
20°

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

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

SECTION 2
SELF DIAGNOSTIC FUNCTION
14
LED Indicator
• Lights up in white when you select “Picture Off”.
• Lights up in amber when you set the timer or
“Photo Frame Mode”.
• Lights up in white when the TV is turnedon.
• Flashes while the remote is being operated.
Amber = Red + Green
Status LED Colour Remarks
Power Off
( AC Off and *1) OFF *1 power switch off (by Side
Key)
Power On White
Standby
( by remote control off
and Side Key off) OFF
Picture Off White
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
Software Updating
failure Amber / Red Blinking Blinking:1 sec Amber/ 1sec Red

15
Whensafety shutdown occurs, Standby LED display reports the cause by using the lightning patternsas indicatedbelow.
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.
The Number of Standby LED
(RED blinking) Error Detection Error Location
2 Main Power Error AC Adaptor
3 Audio Error Main Board or Sub Board (LK)
4 Panel Power Error Main Board
5 Panel I2C Comm Error Main Board or Source Board
6 Backlight Error Main Board or Sub Board (LK)
Tuner Demod Error, BE_I2C Error and PMIC_I2C do not go to Safety Shutdown and
do not have RED blinking.
Error Detection Symptoms Error Location
Tuner Demod Error Cannot tune Digital RF/ Analog RF Main Board/Tuner Module
BE I2C Error No picture display Main Board
PMIC I2C error No power Main Board

Triage Chart
16
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
GN3UN Chassis
Reference
Symptoms - Shutdown. Power LED
blinking red diagnostics sequences No Power Video - missing or distorted
Remote
Network Audio
Smart Core
(KL) / LED
(KM)
Bluetooth
(BT)
2 3 4 5 6 7 8 9 10
No White Power
LED & does not
reponse to remote
(Dead Set)
Stationary
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










LK* Board





H* Board



K* Board


Speaker &
Subwoofer


Wifi Module

Adaptor


Tcon




LCD Panel






Section
Problem/Issue
Title
32x blinking –
Main Power Error 3a.1 2x blinking – Main Power Error
3a Trouble Shooting Flow 2x blinking – Main Power Error
SECTION 3
Trouble Shooting Flow
17

18
LK Board
2 times
Blinking
Change LK-
Board
LK-Board
Check DC voltage at
Q6020/*Q6022
18V – 22.5V?
*Typical:19.5V
Yes
No
Change LK-
board
Change
Adaptor
No
Adaptor
Take out adaptor
and check the output voltage.
18V – 22.5V?
(Refer Figure 1)
*Typical:19.5V
Yes
Figure 1: How to check adaptor’s output
voltage.
+ve
-ve
Ensure that
+ve probe is
touching the
needle.
*For LK2
3a.1. 2x Blinking – Main Power Error

19
Board Name Board PWB (A side) Detail
LK1
(Q6020)
LK2
(Q6020 &
Q6022)
3a.1 : 2x Blinking – Main Power Error
LK Board (Checking point)
Q6020 &
Q6022
Q6020
19.5
V
19.5
V

Section
Problem/Issue
Title
33x blinking –
Audio Error 3b.1 3x blinking – Audio Error
3b Trouble Shooting Flow 3x blinking – Audio Error
20