Sony DL-55W657D Service Manual
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Sony DL-55W657D Service Manual

Sony DL-55W657D Service Manual

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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
ORIGINAL MANUAL ISSUE DATE: 11/2016
Version
Date
1.0
11/2016
1.2
11/2016
12/2016
Subject
Original manual issue.
Updated tuner part number and software version 16,43,45
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
Chassis Name :
GN2TP
Segment Name : QW
LCD Digital Color TV
9-888-721-02

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  • Page 1 HISTORY INFORMATION FOR THE FOLLOWING MANUAL: SERVICE MANUAL Chassis Name : GN2TP ORIGINAL MANUAL ISSUE DATE: 11/2016 Segment Name : QW Version Date Subject 11/2016 Original manual issue. 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...
  • Page 2 MODEL LIST MODEL COLOR COMMANDER DEST. MODEL COLOR COMMANDER DEST. KDL-55W657D Black RMT-TX102B KDL-55W657D...

  • Page 3: Table Of Contents

    Table of content Description Page Description Page 1-8. How to disassembly the Front bezel[KDL-55W657D]………….. 25 Caution--Two Panel Source Handling…………………………………. 1-9. How to ass’y the Front bezel[KDL-55W657D]………………...… 28 Main Board Replacement Caution Guide[KDL-55W657D]………… 5 1-10. How to assy the Himeron Countermeasure on panel Power Board Replacement Caution Guide [KDL-55W657D]………..

  • Page 4: Caution--Two Panel Source Handling

    Caution--Two Panel Source Handling 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.

  • Page 5: Main Board Replacement Caution Guide[Kdl-55W657D]

    Main Board Replacement Caution Guide[KDL-55W657D] Service mode optional bit check and manual adjustment step [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 service mode.

  • Page 6: Power Board Replacement Caution Guide [Kdl-55W657D]

    Not locked well on the back side of the power board. Item Sony PN Description 4-571-413-01 SUPPORT, PWB Caution: Please check the support pin after power board replacement. KDL-55W657D...

  • Page 7: Warnings And Cautions

    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.

  • Page 8: Use Caution When Handling The Lcd Panel

    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. Do not press on the panel or frame edge to avoid the risk of electric shock.

  • Page 9: Safety Check-Out

    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.
  • Page 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 >...

  • Page 11: Self Diagnosis Function

    SELF DIAGNOSIS FUNCTION This model support Self Diagnosis Function. 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. Display Vol- Power...

  • Page 12: Service Position

    4-595-213-01 SCREW +K 3X6, ODM(T) 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.

  • Page 13: Sec 1. Disassembly And Parts List

    SEC 1. DISASSEMBLY AND PARTS LIST • 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. •...

  • Page 14: Kdl-55W657D

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

  • Page 15: Rear Cover

    DISASSEMBLY AND PARTS LIST 1-1. KDL-55W657D 1-1-2. REAR COVER 4-689-453-01 LABEL, SIDE I/O 4-689-480-01 LABEL, DOWN I/O 4-689-452-01 LABEL, BACK I/O 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...

  • Page 16: Power Board, A Board And Speaker

    DISASSEMBLY AND PARTS LIST 1-1. KDL-55W657D REF. No. PART No. DESCRIPTION MARK 1-895-955-11 MOUNTED PWB POWER UNIT for CO1 model BOE panel 1-982-362-11 MOUNTED PWB POWER UNIT LGD for CO1 model LGD panel 1-1-3. POWER BOARD, A BOARD AND SPEAKER 1-897-076-11 MOUNTED PWB A 1-895-956-11...

  • Page 17: Lcd Panel, Deco And Cover, Bottom

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

  • Page 18: Miscellaneous

    DISASSEMBLY AND PARTS LIST 1-1. KDL-55W657D 1-1-5. MISCELLANEOUS 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 KDL-55W657D...

  • Page 19: How To Disassemble Rear Cover [Kdl-55W657D]

    1-2. How to disassemble rear cover [KDL-55W657D] 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. KDL-55W657D...

  • Page 20: How To Disassemble Deco

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

  • Page 21: How To Disassemble Lvds Cable[Kdl-55W657D]

    1-4. How to disassemble LVDS Cable 1-4-1. How to disassemble LVDS Cable[KDL-55W657D] 1-4-1-1. PROCEDURE OF REMOVING LVDS CABLE ON KDL-55W657D Remove the PIN KDL-55W657D...

  • Page 22: How To Disassemble Ir Board[Kdl-55W657D ]

    1-5. How to disassemble H Board[KDL-55W657D] PROCEDURE TO REMOVAL OF H Board Release hook from H Board Hook KDL-55W657D...

  • Page 23: How To Ass'y The Led Lens[Kdl-55W657D]

    1-6. How to ass’y the LED lens[KDL-55W657D] The LED lens is installed in the hole. As shown in the picture. 4-592-420-01 LENS, GUIDE KDL-55W657D...

  • Page 24: How To Ass'y The Key Board[Kdl-55W657D]

    1-7. How to ass’y the KEY Board[KDL-55W657D] PROCEDURE TO REMOVAL OF KEY Board Hook Hook Release hook from KEY Board KDL-55W657D...

  • Page 25: How To Disassembly The Front Bezel[Kdl-55W657D]

    1-8. How to disassemble the Front Bezel[KDL-55W657D] PROCEDURE TO REMOVAL OF FRONT BEZEL 1. Remove each parts on LCD-Panel. Ligulate KDL-55W657D...
  • Page 26 1-8. How to disassemble the Front Bezel[KDL-55W657D] PROCEDURE TO REMOVAL OF FRONT BEZEL 2. Reverse the LCD-Panel and remove 14 screws on the side of bezel . Screw ** Remove the bezel KDL-55W657D...
  • Page 27 1-8. How to disassemble the Front Bezel[KDL-55W657D] PROCEDURE TO REMOVAL OF FRONT BEZEL < Caution > * Don’t open O-Cell of Panel ** Don’t lift up O-Cell of Panel *** Don’t touch COF of the panel < Check > * Don't run on the guide of panel KDL-55W657D...

  • Page 28: How To Ass'y The Front Bezel[Kdl-55W657D]

    1-9. How to ass’y the Front Bezel[KDL-55W657D] PROCEDURE TO REMOVAL OF FRONT BEZEL 3. Put the bezel on the panel and ass’y 14’s Screws Put the bezel on the panel Ass’y 14 Screws Reverse Ass’y each parts KDL-55W657D...

  • Page 29: [Kdl-55W657D]

    1-10. How to assemble the Himeron Countermeasure on panel[KDL-55W657D] 3.Stick mylar 2.Stick fabric start at the left end 1.Stick fabric start at the left end of the raised strip, cover the raised of the raised strip, cover the raised strip strip Item Part number...
  • Page 30 1-10. How to assemble the Himeron Countermeasure on panel[KDL-55W657D] 1.Fabric cover this corner angle Item Part number Description(L*W )(mm) Remark 4-595-235-01 CUSHION 490 X 8 Cushion on panel CAUTION: MUST APPLY HIMERON TAPE before assemble Panel if NOT AVAILABLE KDL-55W657D...
  • Page 31 1-10. How to assemble the Himeron Countermeasure on panel[KDL-55W657D] 1.Stick fabric align at the hole , as the red line show Item Part number Description(L*W )(mm) Remark 4-595-242-01 CUSHION 50 X 20 Cushion on panel CAUTION: MUST APPLY HIMERON TAPE before assemble Panel if NOT AVAILABLE KDL-55W657D...
  • Page 32 1-10. How to assemble the Himeron Countermeasure on panel[KDL-55W657D] 1.Stick EVA start at the raised point cover the raised area Item Part number Description(L*W )(mm) Remark 4-595-231-01 CUSHION 720 X 30 Cushion on panel CAUTION: MUST APPLY HIMERON TAPE before assemble Panel if NOT AVAILABLE KDL-55W657D...
  • Page 33 1-10. How to assemble the Himeron Countermeasure on panel[KDL-55W657D] 2.Stick double side tape align at the red 1.Stick double side tape align at the red line show line show Item Part number Description(L*W )(mm) Remark 4-684-835-01 CUSHION 70 X 12 x 1 Cushion on Speaker 4-684-835-01 CUSHION 70 X 12 x 1...
  • Page 34 1-10. How to assemble the Himeron Countermeasure on panel [KDL-55W657D] Stick HIMERON on the of Hex-screws. 1. Make the Himeron roll the vase and the top of the vase could not be covered Item Part number Description(L*W )(mm) Remark 4-596-879-01 CUSHION 77 X 12 Cushion on Hex-screws CAUTION: MUST APPLY HIMERON TAPE before assemble Panel if NOT AVAILABLE...

  • Page 35: Sec 2. Adjustment

    SEC 2. ADJUSTMENT 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.
  • Page 36 ADJUSTMENT 3) How to use the remote commander. Function The flow of control 1)<DISPLAY><5><VOL+><Power> Service mode on 2)<Left><Right><Mute><Ok><Mute><VOL+> Service mode off <RETURN>/<Power off-on> Adjustment Item up / down Data Value up / down 4) After entering service mode, then turn off the power switch. KDL-55W657D...

  • Page 37: Sec 3. Diagrams And Chassis Structure

    SEC 3. DIAGRAMS AND CHASSIS STRUCTURE 3-1. BLOCK DIAGRAM 3-1-1. KDL-55W657D KDL-55W657D...

  • Page 38: Connector Diagram

    DIAGRAMS 3-2. CONNECTOR DIAGRAM 3-2-1. KDL-55W657D Panel WiFi Board CN8601 CN701 CN105 CN408 CN601 Main Board Power Board CN401 CN202 CN 1 IR Board T-Con Board KEY Board CN 01 KDL-55W657D...

  • Page 39: Circuit Boards Location

    DIAGRAMS 3-3. CIRCUIT BOARDS LOCATION 3-3-1. KDL-55W657D WIFI Board POWER UNIT Board A Board Key Board H Board KDL-55W657D...

  • Page 40: Tape Location

    DIAGRAMS 3-4. Tape location 3-4-1. KDL-55W657D TAPE SIZE: KDL-55W657D: 25MM*50MM 20MM*80MM Sony PN of the alternative tape is 7-600-036-11 which approved by TPV design team. The purpose for the tape stick is to make the cables fixed. KDL-55W657D...
  • Page 41 9-888-704-01 Sony Corporation KDL-55W657D...

  • Page 42: Appendix-1 Trouble Analysis Flow

    APPENDIX-1 Trouble analysis flow Return Set Yes or OK Does Backlight turn On? No or NG LED Indicator Does Picture Function check appear? Power On Key V-Line/H-Line Function check Abnormal? Power Cable Panel Cable(FFC) connection Check Connection Check Check IR Cable Reinstall Reinstall Connection...

  • Page 43: Appendix-2 Software Data Update

    APPENDIX-2 Software data update Software data update for Engineering PKG The confirmation of the software version of the TV set. product information of setting menu. [HOME] , [Settings] [Customer Support] Please use the latest software. 1. Model Name 1: KDL-55W657D 2: V5.002 2.
  • Page 44 Software update by USB memory 4. After finish update, TV Set will turn-on automatically. 1. Prepare USB memory with update file. Lights up Green LED . 2. Set TV Master OFF or Standby, Insert USB memory. 3. Press and hold Power Tact Key for 5s while Power ON TV.
  • Page 45 Software data update for OND PKG The confirmation of the software version of the TV set. product information of setting menu. [HOME] , [Settings] [Customer Support] Please use the latest software. 1. Model Name 1: KDL-55W657D 2: V5.002 2. Software Version Software Down load (Applicable USB memory : Format by FAT32, USB2.0 type ) store the software Package to USB memory.
  • Page 46 Software update by USB memory 2) Starting update Orange LED is flushing. (2-3min) 1. Turn on the TV. 2. Connect USB memory. 3) Finish update Lights up Green LED again and TV is turned on. 5. Unplug AC power cord and disconnect USB memory. Update from Menu 6.

  • Page 47: Appendix-3 Panel Operation Time

    APPENDIX-3 Operation Time, Boot Count, Panel Operation Time [To Bring Up Self Diagnostic(SELF CHECK)] In standby mode, press buttons on Or in power on , press buttons on the remote commander sequentially in rapid succession as shown below: [Operation Time, Boot Count, Panel Operation Time Screen] Service Mode Status Information >>...

  • Page 48: Appendix-4 Edit Model Name And Serial Number

    APPENDIX-4 Edit MODEL NAME and Serial Number Edit: MODEL NAME If the user select this menu, the below editing menu is appeared and adjusting it like "Program Labels" editing way. XXX-XXXXXXX, "X" part can change in below way by Remote Commander. Press up/down arrow key to scroll character ("A-Z","0-9","_") and press right arrow key to move the next position. These number should be affected to "Product Information"...

  • Page 49: Appendix-5 Assembly Parts

    APPENDIX-5 Assembly parts 1.Stick HIMERON on the Deco. Step 1: tick HIMERON on the one side of Deco. 2.If the fabric over the deco, flod it to inside of deco 1.If the fabric over the deco, flod it to inside of deco Fabric stick on this two surface Press the fabric, make sure it stick Fabric align at this edge...
  • Page 50 Step 2: Stick HIMERON on the other side of Deco. 1.Stick fabric align the red line. 2.Stick fabric align the red line. Item Sony PN Description Remark Deco 4-592-419-01 DECO Assy CUSHION 490 X 8 CAUTION: MUST APPLY HIMERON TAPE before assemble Panel if NOT AVAILABLE...
  • Page 51 3.Stick HIMERON on the of WIFI board assy. 1.Stick fabric start at this hole, cover the top of board Item Sony PN Description(L*W )(mm) Remark WIFI BOARD 1-895-960-11 WIFI BOARD Assy CUSHION 145 X 5 CAUTION: MUST APPLY HIMERON TAPE before assemble Panel if NOT AVAILABLE...
  • Page 52 4.Stick HIMERON Side IO BKT. 3.Stick fabric align at the bottom side Item Sony PN Description Remark Side IO BKT 4-571-385-01 Side IO BKT Assy CUSHION 150 X 17 x 0.3 CAUTION: MUST APPLY HIMERON TAPE before assemble Panel if NOT AVAILABLE...
  • Page 53 5.Stick EVA on the of Speakers (left and right speaker). 1.Stick EVA at center of magnet at the upside Item Sony PN Description Remark CUSHION 50 X 15 1-859-187-11 Speaker Assy Speakers CAUTION: MUST APPLY HIMERON TAPE before assemble Panel if NOT AVAILABLE...
  • Page 54 Item Part Number Description Remark 6. Stand Assy BASE BASE_LEFT N/A BASE_LEFT N/A BASE_RIGHT N/A BASE_RIGHT N/A FOOT PAD BKT_BASE Stand Assy A-2123-138-A BKT_STAND_R BKT_STAND_L DIE-CASTING_Bracket_R DIE-CASTING_Bracket_L SCREW NON-WOVEN FABRIC PROTECT BAG 850*400 7. Key module Item Part Number Description Remark Key cover 1-895-957-11...

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