SONY kdf 42wf655, kdf 50wf655 Diagram
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDF-42WE655
KDF-50WE655
RM-Y915 US/CND
RM-Y915 US/CND
LA-3
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 9/2004
REVISION DATE REVISION TYPE SUBJECT
9/2004 No revisions or updates are applicable at this time.
LCD PROJECTION TELEVISION
9-965-971-01
Self Diagnosis
Supported model
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDF-42WE655
KDF-50WE655
RM-Y915 US/CND
RM-Y915 US/CND
LA-3
CHASSIS
9-965-971-01
KDF-42WE655 RM-Y915
LCD PROJECTION TELEVISION
KDF-42WE655/50WE655
TABLE OF CONTENTS
SECTION TITLE PAGE SECTION TITLE PAGE
Specifi cations ................................................................................. 4
Warnings and Cautions .................................................................. 6
Safety Check-Out ........................................................................... 7
Self-Diagnostic Function................................................................. 8
SECTION 1: DISASSEMBLY............................................................... 13
1-1. Rear Cover Removal............................................................ 13
1-2. Center Pillar Removal .......................................................... 13
1-3. Service Position .................................................................. 14
1-4. Fan and Chassis Assembly Removal................................... 14
1-5. Power Supply Block Removal (Lamp Drive Unit) ................. 15
1-6. Fan, RF Antenna Switch, and P Board Removal ................. 15
1-7. U Board Removal ................................................................. 16
1-8. F Board and G1 Board Board Removal ............................... 16
1-9. A Board and KD Board Removal.......................................... 17
1-10. Q Box Assembly, and B Board Removal.............................. 17
1-11. G2 Board Removal............................................................... 18
1-12. T Board Removal ................................................................. 18
1-13. Woofer Removal .................................................................. 18
1-14. H3 Board Removal (KDF-42WE655 Only)........................... 19
1-15. Front Cover Assembly Removal........................................... 19
1-15-1. Replacing the Lamp................................................. 19
1-16. HM Board Removal (KDF-42WE655 Only).......................... 20
1-17. H3 Board and HM Board Removal (KDF-50WE655 Only)... 20
1-18. H2 Board Removal............................................................... 21
1-19. H1 Board Removal............................................................... 21
1-20. Screen Mirror Block Assembly Removal.............................. 22
1-21. Mirror Cover Assembly and Speaker Removal .................... 23
1-21-1. Diffusion plates (Screens) Tape Method.................. 23
Wire Dressing ............................................................................... 24
SECTION 2: CIRCUIT ADJUSTMENTS.............................................. 28
2-1. Setting the Service Adjustment Mode .................................. 28
2-2. Service Adjustment Mode Memory ...................................... 28
2-3. Memory Write Confi rmation Method .................................... 29
2-4. Remote Adjustment Buttons and Indicators ......................... 29
2-5. H/V Center Confi rmation and Adjustments .......................... 30
2-6. Service Data......................................................................... 31
2-7. ID Map Table........................................................................ 33
SECTION 3: DIAGRAMS..................................................................... 34
3-1. Circuit Boards Location ........................................................ 34
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 34
3-3. Block Diagrams .................................................................... 36
3-4. Schematics and Supporting Information .............................. 37
A Board Schematic Diagram (1 of 3).................................... 37
A Board Schematic Diagram (2 of 3).................................... 38
A Board Schematic Diagram (3 of 3).................................... 39
B Board Schematic Diagram (1 of 6) ................................... 42
B Board Schematic Diagram (2 of 6) ................................... 43
B Board Schematic Diagram (3 of 6) ................................... 44
B Board Schematic Diagram (4 of 6) ................................... 45
B Board Schematic Diagram (5 of 6) ................................... 46
B Board Schematic Diagram (6 of 6) ................................... 47
G2 Board Schematic Diagram (1 of 2) ................................. 50
G2 Board Schematic Diagram (2 of 2) ................................. 51
P Board Schematic Diagram ............................................... 54
KD Board Schematic Diagram ............................................. 55
G1 Board Schematic Diagram (1 of 2) ................................. 57
G1 Board Schematic Diagram (2 of 2) ................................. 58
F Board Schematic Diagram ................................................ 61
HM Board Schematic Diagram............................................. 63
H1 Board Schematic Diagram.............................................. 65
H2 Board Schematic Diagram.............................................. 67
H3 Board Schematic Diagram.............................................. 68
T Board Schematic Diagram ................................................ 69
U Board Schematic Diagram................................................ 70
3-5. Semiconductors ................................................................... 72
SECTION 4: EXPLODED VIEWS........................................................ 73
4-1. Cover.................................................................................... 73
4-2. Bottom Cabinet (KDF-42WE655 Only) ................................ 74
4-3. Bottom Cabinet (KDF-50WE655 Only) ................................ 75
4-4. Chassis ................................................................................ 76
4-5. Optical Unit Block ................................................................. 77
SECTION 5: ELECTRICAL PARTS LIST........................................... 78
KDF-42WE655/50WE655
3
SPECIFICATIONS
p
)
r
KDF-42WE655/50WE655
Power Requirements
Power Consumption (W)
In Use (Max)
In Standby
Inputs/Outputs
120V AC, 60Hz
230W
Under 20W
HDMI IN
Video - 1080i, 720p, 480p, 480i
Audio - Two channel linear PCM 32, 44.1 and 48 kHz,
16, 20, and 24 bit
Video (IN)
4 total (1 on front panel)
1Vp-p, 75ohms unbalanced, sync negative
S Video (IN)
4 total (1 on front panel)
Y: 1Vp-p, 75ohms unbalanced, sync negative
C: 0.286Vp-p (Burst signal), 75ohms
Audio (IN)
7 total (1 on front panel)
500 mVrms (100% modulation)
Impedance:47 kilo ohms
Audio (VAR/FIX) Out
1 total
500 mVrms at the maximum volume setting (Variable)
500 mVrms (Fixed)
Impedance (Output):2 kilo ohm
Note: Audio Out jacks are operable only when
the TV’s speaker is set to Off.
Control S (IN)
1 total
Minijack
Control S (OUT)
1 total
Minijack
Component Video Input
2 (Y, P
, PR)
B
Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative
:
P
0.7 Vp-p, 75 ohms;
B
PR: 0.7 Vp-p, 75 ohms
RF Inputs
2 total
Digital Audio Optical Output (PCM/Dolby Digital)
1 total
Optical Rectangular (1)
CableCARD Slot
1 total
PCMCIA Type I/II
KDF-42WE655 KDF-50WE655
S
eaker Output(W
Woofe
Dimensions (W x H x D)
mm 1,200 x 818 x 314 mm 1,376 x 927.2 x 379 mm
1/4
47
in
x 32
Mass
kg 32.5 kg 39 kg
lbs 71 lbs 10 oz 85 lbs 14 oz
CableCARD™ is a trademark of Cable Television
Laboratories, Inc.
TruSurround, SRS and the ( )
of SRS Labs, Inc.
TruSurround technology is incorporated under license
from SRS Labs, Inc.
BBE and BBE Symbol are trademarks of BBE Sound,
Inc. and are licensed by BBE Sound, Inc. under U.S.
Patent No. 4,638,258 and 4,482,866.
Manufactured under license from
Dolby Laboratories Licensing
Corporation. Dolby and the double-D
symbol are trademarks of Dolby
Laboratories Licensing Corporation.
®
symbol are trademarks
5W x 2
20W
1/4
x 12
1/3
in 54
1/8
x 36
1/2
x 15 in
This TV incorporates High-Definition
Multimedia Interface (HDMI
technology. HDMI, the HDMI logo
and High-Definition Multimedia
Interface are trademarks or registered
trademarks of HDMI Licensing LLC.
WEGA, Steady Sound, Digital Reality Creation,
CineMotion, Memory Stick, Memory Stick Duo,
Memory Stick PRO, Memory Stick PRO Duo,
MagicGate, MID and Twin View are trademarks of Sony
Corporation.
™
)
KDF-42WE655/50WE655
Design and specifi cations are subject to change without notice.
4
Television system
American TV standard, NTSC
ATSC compliant 8VSB, ATSC (8VSB terrestrial)
ANSI/SCTE 07 2000 QAM on cable
Channel coverage
Terrestrial 2-69/ Cable TV: 1-125 (analog)
Terrestrial: 2-69/ Cable TV: 1-135 (digital)
Screen Size (measured diagonally)
42 inches (KDF-42WE655 Only)
50 inches (KDF-50WE655 Only)
Antenna
75-ohm external antenna terminal for VHF/UHF
Projection System
3 LCD Panels, 1 lens projection system
LCD Panel
0.87 inch TFT LCD panel Approx. 3.28 million dots
(1,042,168 pixels)
Projection Lens
High Performance, large diameter hybrid lens F2.4
KDF-42WE655/50WE655
Lamp
UHP lamp, 100W XL-2100 or XL2100U
Supplied Accessories
Remote Commander RM-Y915
Two Size AA (R6) Batteries
KDF-42WE655/50WE655
5
KDF-42WE655/50WE655
WARNINGS AND CAUTIONS
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.
! SAFETY-RELATED COMPONENT WARNING!!
Components identifi ed 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 identifi ed in this manual. Follow these procedures
whenever critical components are replaced or improper operation is suspected.
ATTENTION!!
Afi n d’eviter tout risque d’electrocution provenant d’un chássis sous tension, un transformateur d’isolement doit etre utilisé lors de tout
dépannage. Le chássis de ce récepteur est directement raccordé à l’alimentation du secteur.
! ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!!
Les composants identifi es par une trame et par une marque ! sur les schemas de principe, les vues explosees et les listes de pieces
sont d’une importance critique pour la securite du fonctionnement. Ne les remplacer que par des composants Sony dont le numero
de piece est indique dans le present manuel ou dans des supplements publies par Sony. Les reglages de circuit dont l’importance
est critique pour la securite du fonctionnement sont identifi es dans le present manuel. Suivre ces procedures lors de chaque
remplacement de composants critiques, ou lorsqu’un mauvais fonctionnement suspecte.
KDF-42WE655/50WE655
6
SAFETY CHECK-OUT
KDF-42WE655/50WE655
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 B+ and HV to see if they are specifi ed values. Make sure
your instruments are accurate; be suspicious of your HV meter if sets
always have low HV.
8. Check the antenna terminals, metal trim, “metallized” knobs, screws,
and all other exposed metal parts for AC leakage. Check leakage as
described below.
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 0.5 mA (500 microamperes).
Leakage current can be measured by any one of three methods.
1. A commercial leakage tester, such as the Simpson 229 or RCA
WT-540A. Follow the manufacturers’ instructions to use these
instructions.
2. A battery-operated AC milliampmeter. The Data Precision 245
digital 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 0.75
V, 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
multimeters that have a 2 VAC range are suitable (see Figure A).
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).
To Exposed Metal
Parts on Set
0.15 F
Earth Ground
Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.
KDF-42WE655/50WE655
1.5 K Ω
AC
Voltmeter
(0.75 V)
Trouble Light
AC Outlet Box
Ohmmeter
Cold-water Pipe
7
KDF-42WE655/50WE655
p
SELF-DIAGNOSTIC FUNCTION
Self Diagnosis
Supported model
The units in this manual contain a self-diagnostic function. If an error occurs, the POWER/STANDBY or LAMP LED will automatically begin to fl ash.
The number of times the LED fl ashes translates to a probable source of the problem. A defi nition of the POWER/STANDBY or LAMP LED fl ash
indicators is listed in the instruction manual for the user’s knowledge and reference. If an error symptom is diffi cult to reproduced use the Remote
Commander to display the record that is stored at the internal NVM to specify the cause of the failure.
Diagnostic Test Indicators
When an error occurs, the POWER/STANDBY or LAMP LED will fl ash 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 fi rst of the problem areas. If the errors occur simultaneously, the one that corresponds to the fewest
fl ashes is identifi ed fi rst.
Results for all of the following diagnostic items are displayed on screen. No error has occurred if the screen displays a “0”.
Diagnostic Item
Description
Lamp cover error 3 times - Lamp cover is not fastened securely - No picture/No sound
Fan error 4 times
Temp error 4 times
Lamp driver error 5 times - Lamp driver defect - No picture/No sound
Low B error 6 times -No "DD 6V " output (G1 board) - No picture/No sound
Audio error 7 times
D-OVP error 8 times
ATSC-OVP error 10 times
Lamp error LAMP-LED is ON. - Lamp is dead - No picture/No sound
Number of times
STANDBY or LAMP LED
lam
flashes
Probable Cause Detected Symptoms
- Fan1-4 Power is not supplied.(G2 board)
- Fan connector is not seated securely
- Fan caught wires or harnesses
- Internal temperature is too high
- IIC-E line connector is not seated properly
(WE:H3 board, W F/XS:H4 board)
- Short-circuit of Audio power supply line
(KD board, G1 board)
- Blowout of a fuse
(F4702,F4703,F4704 on KD board)
- IC failure
(IC4703,IC4708,IC4710 on KD board)
- Overvoltage of +3.3V or +2.5V
(A board, B board)
-No "DTL MODULE 5V " output
(G1 board, G2 board)
- No picture/No sound
- No picture/No sound
- No picture/No sound
- No picture/No sound
- No picture/No sound
KDF-42WE655/50WE655
8
Display of POWER/STANDBY or LAMP LED Flash Count
For K DF-WE655 series
For KDF-WF655 series
KDF-42WE655/50WE655
POWER
PRO
STD/DUO
LAMP TIMER POWER/STANDBY
Proj ecti on l amp
Indi cators
Screen
Proj ection l amp
Indicat ors
- Oneflash is notusedfor self-diagnosis.
-Example
Diagnosis
Number of times LED Flash
Lamp cover 3 times
Fan 4 times
LED ON : 0.3sec
LED OFF : 0.3sec
LED OFF
3.0sec
Releasing the POWER/STANDBY LED Flash
Unplug the power cord from the outlet to temporarily stop the POWER/STANDBY lamp from fl ashing.
Self-Diagnosis Screen Display
For failures that are diffi cult to reproduce, or accompany occasional power off and/or picture mute, the Self-Diagnosis screen display is useful to
specify the cause..
To Bring Up Screen Test
In standby mode, press the buttons on the Remote Commander sequentially, in rapid succession, as shown below:
Display
1.
Self-Diagnostic Screen Display
Channel
5
Sound Volume
Power ON
SELFCHECK
1 : LAMP ERR 0
3:
LAMP COVER 0
FAN-E/TEMP-E 1
4:
5 : LAMP DRIVER
0
"1" is displayed when a failure is detected one or more times
"0" is displayed when no failure has been detected
6 : LowB-ERR 0
7 : Audio-Prot
1
8 : D-OVP 0
10 : ATSC_OVP 0
101 : WDT 0
Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screen during repairs. When you
have completed the repairs, clear the result display to “0”.
Note: The self-diagnostic function will not be able to detect any subsequent faults after completion of the repairs unless the result display is
cleared to “0”.
KDF-42WE655/50WE655
9
KDF-42WE655/50WE655
Clearing the Result Display
To clear the result display to “0”, press the buttons on the Remote Commander sequentially when the diagnostic screen is displayed, as shown below:
1. If the screen is already displayed, proceed to step 3. If not, Power off (Set to Standby model).
2. Press
Display
3. Press Channel
8
Channel
ENTER
5
Sound Volume
Clearing the Self-Diagnostic Screen
The self diagnosis screen display is cleared by turning off the set using the Remote Commander or the power switch.
Self-Diagnostic Circuit
Self-Diagnosis Function Operation
3 : Lamp cover The rib at the back of the lamp cover closes the SW on the T board to ground pin 3 of CN8001.
It is monitored by the DE-micro (pin 94 of IC6902) and turns off the lamp when it is opened.
4 : Fan Fan rotation is detected by "FAN-PROT" and the DE-micro (pin 92 of IC6902) turns off the lamp
when it is "high".
4 : Temp When the temperature sensor on the H3 board (WE models) or H4 board (WF/XS models)
detects high temperature, or IIC-E line connector (CN6022:G2 board, CN44:H3board/H4board)
is not seated securely, the DE-micro turns off the lamp.
5 : Lamp driver When the "LAMP-PROT" (pin 95) is low, the lamp is not turned on. If the "LAMP-HV-DET"
6 : Low B error When no "DD 6V " is detected, pin 129 of TV-micro is low and it turns off the main power.
(pin 96) is low at the same time, it is classified as no high voltage of the lamp driver.
7 : Audio When DC voltage is detected at the speaker or woofer outputs, pin 128 of TV-micro is low and it
turns off the main power.
8 : D-OVP When overvoltage of "+3.3V" or "+2.5V" is detected, pin 126 of TV-micro is low and it turns off
the main power.
10 : ATSC-OVP When no "Digital Module 5V" is detected, pin 127 of TV-micro is low and it turns off the main
power.
LAMP : Lamp When the "LAMP-PROT" (pin 95) is low, the lamp is not turned on. If the
"LAMP-HV-DET" (pin96) is high at the same time, it is classified as no lamp or a dead lamp.
Power ON
KDF-42WE655/50WE655
10
Self-Diagnosis Block Diagram
H3(WE)/H4(WF/XS)
board
IC41
Temp
4:Temp
sensor
G2 board
IC6902
Display Engine u-com
FAN PROT
IIC-E
LAMP-COVER
LAMP-PROT
LAMP-HV-DET
IIC-WE
92
94
95
96
4:Fan
CN6022
CN6000
2
5
8
11
14
8
13
14
FAN1-PRT
FAN2-PRT
FAN3-PRT
FAN4-PRT
3:Lamp cover
5:Lamp
driver
Fan1
Fan2
Fan3
Fan4
T board
S8001
SW
Lamp driver
HV-DET
B
IC3801 WE u-com
IIC-WE
IIC-TV
KDF-42WE655/50WE655
Lamp
KD board
Audio
amp
A board
+3.3V
+2.5V
G1 board
DD6V
DTL5
7:Audio
8:D-OVP
6:LowB
error
CN6029
23
CN6020
C26
CN6029
23
CN6006
CN6019
A8
A14
B14
CN6017
16
CN6023
515
12:ATSC
OVP
IC3604 TV u-com
IIC-TV
SP_DC_PROT
128
126
D_OVP
LB_ERROR
129
127
ATSC_OVP
Digital Box
DTL MDL5V
KDF-42WE655/50WE655
11
Reading Lamp and Panel time
Use the following to determine the lamp and panel time of a set.
Screen Display Method
In standby mode, press the buttons on the Remote Commander sequentially, in rapid succession, as shown below:
KDF-42WE655/50WE655
1. Press
2. To enter the DE-micro service menu, press
3. To display the Lamp time, press Channel
Display
Channel
5
Sound Volume + Power ON
Jump
3 times.
2
9 times.
example
PANEL NVM OK 9 OPTION_E
0 LAMP 0 Diff 1
LampTM 14 LampCT 71
The screen displays:
“Total lamp time is 14 hours” and “Total lamp ON/OFF cycle is 71 times”
1
Mute
7 times
To reset the lamp time press Channel
WRI-EXE(Character color is Red) is momemtarily displayed and LampTM is reset to “0”.
4. To display the Panel time, press Channel
3
Enter
.
example
PANEL NVM OK 9 OPTION_E
7 SH SFT1 10 Diff 1
PanelTM 14h
The screen displays:
“Total Panel time is 14 hours”
NOTE: You cannot reset the Panel time with the Service menu.
Exiting Service Mode
After completing the changes exit service mode by turning off the set using the Remote Commander or the power switch.
KDF-42WE655/50WE655
12
1-1. REAR COVER REMOVAL
SECTION 1: DISASSEMBLY
Rear cover
2
1
Eleven screws
(+BVTP 4x16)
KDF-42WE655/50WE655
1-2. CENTER PILLAR REMOVAL
Disconnect
three ground wires
Two small screws
(+PSW 3x8)
4
2
Two screws
(+BVTP 4x16)
Gently lift the Center Pillar up then out
5
from the bottom bracket.
Three screws from the top of the center pillar
1
(+BVTP 4x16)
Center Pillar
3
KDF-42WE655/50WE655
13
1-3. SERVICE POSITION
r
Chassis assembly
Pull back on claw, then gently pull out chassis assembly
1
KDF-42WE655/50WE655
1-4. FAN AND CHASSIS ASSEMBLY REMOVAL
Chassis assembly
Pull back on claw,
then gently pull out chassis assembly
4
Fan bracket with D. C. fan
Four screws
3
(+PWH 4x35)
2
Disconnect one connecto
D. C. FAN
1
Four screws
(+PWH 4x16)
KDF-42WE655/50WE655
14
1-5. POWER SUPPLY BLOCK REMOVAL (LAMP DRIVE UNIT)
CAUTION: When removing the Power Supply Block be careful not to move the Optical Unit Block
KDF-42WE655/50WE655
Unhook the antenna cable
3
Pull forward to remove
5
4
Four screws (+BVTP 3x12)
1
Disconnect two connectors
1-6. FAN, RF ANTENNA SWITCH, AND P BOARD REMOVAL
6
Disconnect three connectors
and the ground wire
7
P board
2
Two screws (+PWH 4x16)
(to detach the cables from the
Optics Unit Block Assembly)
Power supply block
Disconnect four ground wires
RF antenna switch
KDF-42WE655/50WE655
Two screws
(+BVTP 3x8)
Fan Bracket
8
2
4
Seven Screws (+BVTP 3x12)
1
U bracket
3
Three Screws (Washer Head)
(+P 4X16)
D. C. Fan
Four Screws (Washer Head)
(+P 4X35)
5
15
1-7. U BOARD REMOVAL
KDF-42WE655/50WE655
Gently pull back on tab to
1
release U board
1-8. F BOARD AND G1 BOARD BOARD REMOVAL
Disconnect two connectors
(CN1603 & CN1604)
6
U board
G1 board
Disconnect two connectors
(CN1601 and CN1602)
and one ground wire (CN1607)
Pull F Bracket out
and up to remove
Remove one screw
(+BVTP 3X12 TYPE2 TT(B))
Disconnect two connectors
(CN1908 and CN1909)
and two ground wires
(CN1902 and CN1903)
Disconnect the Power cord
from CN1900 connector.
Remove wires from purse locks
7
9
3
2
5
8
Unfasten three Circuit Board Supports
Gently pull back on the three clips
on the pin connection slots
while slowly lifting the G1 Board.
1
KDF-42WE655/50WE655
16
1-9. A BOARD AND KD BOARD REMOVAL
Disconnect three connectors
(CN4701, CN4705, and CN4702)
6
KDF-42WE655/50WE655
Disconnect three connectors
4
(CN8003, CN8004, and CN8008)
and coax cable from tuner
Unfasten two Circuit Board Supports
Gently pull back
3
2
on the three clips
on the Pin Connection slots
while slowly lifting the A board
A board
Remove cables
1
from purse locks
1-10. Q BOX ASSEMBLY, AND B BOARD REMOVAL
KD board
Gently pull back
5
on the two clips
on the Pin Connection slots
while slowly lifting the KD board
Disconnect six connectors
Unplug two coax cables
connected to the antenna switch
Remove four screws
7
Remove two screws
6
(+BVTP 3X12 TYPE2 TT(B))
Remove cables from purse locks
8
5
Q Box Assembly
9
Remove two connectors
3
1
(CN3501 and CN3502)
B board
Remove two screws
2
Gently pull back
4
on the two clips
on the Pin Connection slots
while slowly lifting the B board
KDF-42WE655/50WE655
17
y
1-11. G2 BOARD REMOVAL
KDF-42WE655/50WE655
Disconnect 2 ground wires
(CN6013 and CN6015)
1-12. T BOARD REMOVAL
Disconnect 6 connectors
(CN6000, CN6024,
CN6028, CN6021,
CN6023, and CN6022)
1
Lift the G2 Board
3
out of the
Main Bracket
2
3
1-13. WOOFER REMOVAL
Disconnect
one connector
T board
2
One screw (+BVTP 3x12)
1
3 Woofer block assembl
KDF-42WE655/50WE655
2 Connector
1 Four screws
(+TPTWH 4x25)
18
1-14. H3 BOARD REMOVAL (KDF-42WE655 ONLY)
H3 board
1
3
H3 bracket
KDF-42WE655/50WE655
Disconnect two connectors
and one ground wire
1
Spring
plate
Two screws
(+BVTP 3x12)
1-15. FRONT COVER ASSEMBLY REMOVAL
Front cover
assembly
2
1 Two ornamental screws
1-15-1.REPLACING THE LAMP
For detailed instructions on replacing the lamp, see
Page 16 of the Operating Instructions manual.
KDF-42WE655/50WE655
2
Four latches
19
1-16. HM BOARD REMOVAL (KDF-42WE655 ONLY)
H2 block assembly
KDF-42WE655/50WE655
Two screws
(+BVTP 4x16)
Disconnect two connectors
MS panel
1
4
2
HM board
3
Two screws
(+BVTP 4x16)
4
1-17. H3 BOARD AND HM BOARD REMOVAL (KDF-50WE655 ONLY)
Note:
To remove the HM Board you need to remove the screws inside the Bottom Cabinet Assembly
H3 board
Spring
plate
One screw
4
H3 bracket
KDF-42WE655/50WE655
Two screws
(+BVTP 3x12)
MS bracket
3
2
1
Disconnect two connectors
and one ground wire.
Disconnect two connectors
3
HM board
Bottom cover assembly
20
1-18. H2 BOARD REMOVAL
r
KDF-42WE655/50WE655
Two screws
(+BVTP 3x12)
H2 board
H2 bracket
1
Four screws
(+BVTP 4x16)
1-19. H1 BOARD REMOVAL
3
Light guide (LED)
2
Disconnect one connecto
Screen mirror block assembly
One screw (3x12)
4
Disconnect one connector
KDF-42WE655/50WE655
H1 button
Two screws
2
(+BVTP 4x16)
1 H1 bracket cap
Using tweezers gently detach two
3
H1 board
H1 bracket
H1 Bracket Caps
21
1-20. SCREEN MIRROR BLOCK ASSEMBLY REMOVAL
Caution:
When repairing anything inside the Screen Mirror Block Assembly be sure to clean the mirror and Diffusion Plate
to remove any dust particles.
Note: For the model 50WE655, remove the screws that secure
the reinfocement plates (R)/(L).
Screen mirror block assembly
KDF-42WE655/50WE655
Seven screws
(+BVTP 4x16)
3
1
Disconnect three connectors
2
Four screws
(+BVTP 4x16)
KDF-42WE655/50WE655
22
1-21. MIRROR COVER ASSEMBLY AND SPEAKER REMOVAL
Two Screws
3
(+BVTP 4X16)
Fourteen Screws
1
(+BVTP 4X16)
1
2
KDF-42WE655/50WE655
Two Screws
3
(+BVTP 4X16)
1-21-1.DIFFUSION PLATES (SCREENS) TAPE METHOD
The following diagram illustrates the taping method when replacing the Diffusion Plates.
For Part Numbers refer to section 6-1. Cover.
Black Acetate (2142) 23X50M
1
To p
1
Diffusion Plate (Fresnel)
Diffusion Plate (Lenticular)
KDF-42WE655/50WE655
23
[F] EMI Shield wire around
2nd post
KDF-42WE655/50WE655
WIRE DRESSING
Make sure purse lock is
completely seated to [G1]
Tie btwn 1st & 2nd posts
Blk/Wht to the right
Use Coated Lead Pin to keep
wires from migrating into
Primary Ckt
Make sure Coated Lead
Pin does not touch
[G1] heat sink
USB cable must stay to right
side of [B]
[KD] wires are secured to free
purse lock, not ATSC Box
Make sure 8 pin connector is
fully seated
KDF-42WE655/50WE655
24
KDF-42WE655/50WE655
LVDS Cables dresses behind
purse lock
Detail of front side ATSC Box
Detail of front side [G1] All wires through purse lock
Detail of front side ATSC Box [C1] LVDS dressing
Emi Tape added to Sub Tuner
cable
Top connector wires must be to
the left of lower wires
Fan wire must be under the
foam gasket material
Detail of USB around ATSC
Box Area
Bend GND tab after wire is
installed
USB Cable must not touch
metal grill for EMI issue
KDF-42WE655/50WE655
25
Tape must avoid OP Block Label
KDF-42WE655/50WE655
Sensor wire should be in left
three purse locks
Purse Lock must be to the right of
the cable tie position
Front side
harnesses
dressed
through bottom
block purse lock
Front side harnesses dressed
behind the 1st [C1] purse lock &
secured with free purse lock
Loop sensor wire at the 2nd purse
lock position
Clip position move to avoid wire
touching Emi Shield
2
Dress Drvr harness
through bottom coated
lead pin then the top
1
KDF-42WE655/50WE655
Left Side Coated Lead Pins details
26
Right Side Coated Lead Pins
details
Twist Coated Lead inward to
avoid contact with fan assembly
after installation
KDF-42WE655/50WE655
KDF-42WE655/50WE655
27
SECTION 2: CIRCUIT ADJUSTMENTS
KDF-42WE655/50WE655
2-1. SETTING THE SERVICE ADJUSTMENT
MODE
1. Standby mode (Power off).
2. Press the following buttons on the remote commander within a
second of each other:
Display
The following screen appears:
Channel
Category Name
3D-COMB 0 0 SERVICE
NRMD TV
WSL: xxx
Item Name Input Signal
F/A FLAG: xxxxxxxx
CBA FLAG: xxxxxxxx
Category Name
Sound Volumne
5
Item No.
Data
+
Mode
Power
2-2. SERVICE ADJUSTMENT MODE
MEMORY
1. The SCREEN displays the item being adjusted.
2. Press 1 or 4 on the Remote Commander to select the item.
3. Press
4. Press
Note: Every time you press
3
or 6 on the Remote Commander to change the data.
2
or 5 on the Remote Commander to change the category.
2
in the order as shown below:
VERSION0
CCPM-1
CCPM-2
CCPM-3
CCPM-4
CCPM-5
CCPM-6
CCPM-7
CCPS-5
CCPS-6
CCPS-7
CCPS-8
CCPS-10
DCP-INT
DCP-OSD
DCP-BLK
(Category Up), Service Mode changes
DLBY
MID1
MID2
MID3
MID4
MID5
MID6
MID7
D9671TPN
D9671CUR
D9671TG1
D9671TG2
D9671CSC
A7001R
A7001G
A7001B
Item No.
L001OUT 0 0 G
OCKPN
Item Name
TEMP 42DEG
LCD PJ ENGINE VER.0.026
9/11
EE2F
<LCD PROJECTOR ENGINE>
Data
CCPM-8
CCPM-9
CCPM-10
CH-SET
CCPS-1
CCPS-2
CCPS-3
CCPS-4
DCP-ADJ1
DCP-ADJ2
DCP-USER
DCP-AVP
USR-NR
CXA2171
AP
AK4524
5. To go back to the most recently saved value
MID8
MID9
SNNR
SNSS
DRCVR
CCD
D9671-1
D9671PIC
0
then
ENTER
the memory.
6. Press
MUTING
then
ENTER
to write into memory.
7. When you want to exit Service Mode, turn the power off.
Note: Press
8
then
ENTER
on the remote commander to set the
shipping conditions or turn set off and on to exit.
SH SET
H POS SHI
TEMP
OSD-E
OPTION-E
FAN-CTL
GB RGB
OPTION-E
ID
to read
KDF-42WE655/50WE655
28
2-3. MEMORY WRITE CONFIRMATION METHOD
1. After adjustment, pull out the plug from the AC outlet, then replace the plug in the AC outlet again.
2. Turn the power switch ON and set to Service Mode.
3. Call the adjusted items again to confi rm they were adjusted.
2-4. REMOTE ADJUSTMENT BUTTONS AND INDICATORS
KDF-42WE655/50WE655
MUTING
(Enter into
memory)
Adjustment
Item up
Adjustment
Category up
Adjustment
Item down
User control goes to the
standard state (Shipping
Conditions)
1
2
4
8
POWER
(Service Mode)
DISPLAY
(Service Mode)
3
Data up
6
Data down
5
Adjustment
category down
ENTER
(Enter into
memory)
0
Read data
from NVM
VOLUME (+)
(Service Mode)
FUNCTION OF KEYS ON COMMANDER
• 1 : Changes adjustment item.
(item No. moves up)
• 4 : Changes adjustment item.
(item No. moves down)
• 2 : Changes adjustment category.
(category moves up)
• 5 : Changes adjustment category.
(category moves down)
• 3 : Changes data value. (up)
• 6 : Changes data value. (down)
RM-Y915
Commander Function
Button Mode Description
MUTING + ENTER WRITE Writes data to NVM.
0 + ENTER READ Reads data from NVM.
8 + ENTER RESET Set the shipping condition.
(Use only to reset to
shipping standards)
KDF-42WE655/50WE655
29
KDF-42WE655/50WE655
M
t
M
2-5. H/V CENTER CONFIRMATION AND ADJUSTMENTS
Please check the picture horizontal/vertical center after the replacement of the Optics Unit Block Assembly or any part of the Top assembly.
1. Check the H/V center with 480i monoscope signal in “Full” mode.
2. If the center is shifted, adjust using the following service items:
NOTE: Please record the steps shifted as
MDHP and MDVP .
MID-X1 9 MDHP (for H center)
10 MDVP (for V center)
MDVP
3. Change the WIDE mode to “Normal” and change the register data as follows:
4. Display the Twin Picture with the “split” button of the remote commander and change the registers data as follows:
5. Press “Favorites” button and change the registers data as follows:
MDHP
MID-X1fififi9fifiMDHPfi+fififififi
(Don'tfichangefithefiMDVPfida
fiMID-X1fififi9fifiMDHPfi+fififififi
fi10fifiMDVPfi+fififififiM
MID-X1 9 MDHP + MDHP
10 MDVP + MDVP
6. OSD horizontal position must be adjusted as follows:
If above sum exceeds 255, set 1 to “16 RP1H” and set the “sum-256” to “17 RP1L”.
Since the registers are different from other cases, be careful to follow complete instructions, and write the data before changing the display/
wide mode .
KDF-42WE655/50WE655
30
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