Sony KDF-55-WF-655 Service manual

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE MANUAL

MODEL NAME REMOTE COMMANDER DESTINATION

KDF-55WF655
KDF-60WF655

RM-Y915 US/CND

RM-Y915 US/CND

LA-3

CHASSIS

ORIGINAL MANUAL ISSUE DATE: 9/2004

:UPDATED ITEM

☛

REVISION DATE SUBJECT

9/2004 No revisions or updates are applicable at this time.
10/2004 Updated Block Diagram (Replaced Page 35 with Page 35)
Corrected PN for Cabinet Assembly Bottom, Added missing parts to Exploded View section
(Replaced Page 73 with Page 73, Replaced Page 74 with Page 74)
Added PN for Lamp and Washer (Replaced Page 122 with Page 122)
1/2005 Corrected Section 2-1. Setting the Service Adjustment Mode and
2-2. Service Adjustment Mode Memory (Replaced Page 27 with Page 27)
Corrected Section 2-4. Remote Adjustment Buttons and Indicators (Replaced Page 28 with Page 28)
Updated contact information for Service Data requests (Replaced Page 30 with Page 30)
Updated contact information for Tiled Schematic requests (Replaced Last Page with Last Page)
1/2005 Added Caution statement (Replaced Page 6 with Page 6)
8/2005 Corrected location of LVDS Cables (Replaced Page 75 with Page 75)

9-965-972-05

LCD PROJECTION TELEVISION

Self Diagnosis

Supported model

SERVICE MANUAL

MODEL NAME REMOTE COMMANDER DESTINATION

KDF-55WF655
KDF-60WF655

RM-Y915 US/CND

RM-Y915 US/CND

LA-3

CHASSIS

9-965-972-05

KDF-55WF655 RM-Y915

LCD PROJECTION TELEVISION

KDF-55WF655/60WF655

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. Chassis Assembly and fan Removal ................................... 14

1-4. Service Position ................................................................... 14

1-5. Power Supply Block Removal (Lamp Drive Unit)................. 15

1-6. RF Antenna Switch and P Board Removal.......................... 15

1-7. U Board, H4 Board, and Fan 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. Woofer Removal .................................................................. 18

1-13. Optics Unit Block Assembly and D.C. Fan Removal............ 19

1-14. T Board Removal................................................................. 19

1-15. Front Cover Assembly Removal........................................... 20

1-15-1. Replacing the Lamp................................................. 20

1-16. HM Board and H2 Board Removal....................................... 20

1-17. H1 Board Removal............................................................... 21

1-18. Screen Mirror Block Assembly Removal.............................. 21

1-19. Mirror Cover Assembly, H3 Board, and Speaker Removal.. 22

1-19-1. Diffusion plates (Screens) Tape Method.................. 22

Wire Dressing............................................................................... 23

SECTION 2: CIRCUIT ADJUSTMENTS.............................................. 27

2-1. Setting the Service Adjustment Mode.................................. 27

2-2. Service Adjustment Mode Memory...................................... 27

2-3. Memory Write Confi rmation Method .................................... 28

2-4. Remote Adjustment Buttons and Indicators......................... 28

2-5. H/V Center Confi rmation and Adjustments.......................... 29

2-6. Service Data......................................................................... 30

2-7. ID Map Table........................................................................ 32

SECTION 3: DIAGRAMS..................................................................... 33

3-1. Circuit Boards Location........................................................ 33

3-2. Printed Wiring Boards and

Schematic Diagrams Information......................................... 33

3-3. Block Diagram...................................................................... 35

3-4. Schematics and Supporting Information.............................. 36

A Board Schematic Diagram (1 of 3).................................... 36

A Board Schematic Diagram (2 of 3).................................... 37

A Board Schematic Diagram (3 of 3).................................... 38

B Board Schematic Diagram (1 of 6) ................................... 41

B Board Schematic Diagram (2 of 6) ................................... 42

B Board Schematic Diagram (3 of 6) ................................... 43

B Board Schematic Diagram (4 of 6) ................................... 44

B Board Schematic Diagram (5 of 6) ................................... 45

B Board Schematic Diagram (6 of 6) ................................... 46

G2 Board Schematic Diagram (1 of 2)................................. 49

G2 Board Schematic Diagram (2 of 2)................................. 50

P Board Schematic Diagram ............................................... 53

KD Board Schematic Diagram............................................. 54

G1 Board Schematic Diagram (1 of 2)................................. 56

G1 Board Schematic Diagram (2 of 2)................................. 57

F Board Schematic Diagram................................................ 60

HM Board Schematic Diagram............................................. 62

H1 Board Schematic Diagram.............................................. 64

H2 Board Schematic Diagram.............................................. 66

H3 Board Schematic Diagram.............................................. 68

H4 Board Schematic Diagram.............................................. 69

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 .................................................................... 74

4-3. Chassis ................................................................................ 75

SECTION 5: ELECTRICAL PARTS LIST........................................... 76

KDF-55WF655/60WF655

3

SPECIFICATIONS

p

)

r

KDF-55WF655/60WF655

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-55WF655 KDF-60WF655

S

eaker Output(W

Woofe

Dimensions (W x H x D)

mm 1,456 x 943 x 491 mm 1,574 x 1,005 x 518 mm

1/3

57

in

x 37

Mass

kg 46 kg 50.5 kg

lbs 101 lbs 7 oz 111 lbs 5 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

1/8

x 19

1/3

in 62 x 39

1/2

x 20

1/3

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-55WF655/60WF655

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)

55 inches (KDF-55WF655 Only)
60 inches (KDF-60WF655 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-55WF655/60WF655

Lamp

UHP lamp, 100W XL-2100 or XL2100U

Supplied Accessories

Remote Commander RM-Y915
Two Size AA (R6) Batteries

KDF-55WF655/60WF655

5

KDF-55WF655/60WF655

WARNINGS AND CAUTIONS

CAUTION

These servicing instructions are for use by qualifi ed 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 qualifi ed 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.

! 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!!

Ces instructions de service sont à l’usage du personnel de service qualifi é seulement. Pour prévenir le risque de choc électrique, ne

☛

pas faire l’entretien autre que celui contenu dans le Mode d’emploi à moins que vous soyez qualifi é faire ainsi.

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-55WF655/60WF655

6

SAFETY CHECK-OUT

KDF-55WF655/60WF655

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

Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.

KDF-55WF655/60WF655

Earth Ground

AC
Voltmeter
(0.75V)

Trouble Light

AC Outlet Box

Ohmmeter

Cold-water Pipe

7

KDF-55WF655/60WF655

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 fas t ened 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 t i mes

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 s ecurely

- Fan caught wires or harnesses

- Internal temperature is too high

- IIC-E line connector is not seated properly
(WE:H3 board, WF/XS:H4 board)

- Short-circuit of A udi o power supply l i ne
(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-55WF655/60WF655

8

Display of POWER/STANDBY or LAMP LED Flash Count

For KDF-WE655 series

For KDF-WF655 series

KDF-55WF655/60WF655

POWER

PRO

STD/DUO

LAMP TIMER POWER/STANDBY

Projection lamp

Indicators

Screen

Projection lamp

Indicators

- Oneflashisnotusedfor self-diagnosis.

-Example
Diagnosis

Number of times LED Flash
Lampcover 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-55WF655/60WF655

9

KDF-55WF655/60WF655

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-55WF655/60WF655

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-55WF655/60WF655

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-55WF655/60WF655

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-55WF655/60WF655

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-55WF655/60WF655

12

1-1. REAR COVER REMOVAL

KDF-55WF655/60WF655

SECTION 1: DISASSEMBLY

Rear cover

2

1-2. CENTER PILLAR REMOVAL

Disconnect
three ground wires

3

Center Pillar

1

Eleven screws
(+BVTP 4x16)

Gently lift the Center Pillar up then out

4

from the bottom bracket.

Three screws from the top of the center pillar

1

(+BVTP 4x16)

KDF-55WF655/60WF655

Two screws
(+BVTP 4x16)

2

13

1-3. CHASSIS ASSEMBLY AND FAN REMOV AL

4

5

Disconnect one connector
and one ground wire

KDF-55WF655/60WF655

1

One screw
(+PWH 4x16)

1-4. SERVICE POSITION

2

Chassis assembly

Four screws

6

(+BVTP 3X12)

3

Four screws
(Washer Head +P 4x16)

KDF-55WF655/60WF655

Chassis assembly

Pull back on claw, then gently pull out chassis assembly

1

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-55WF655/60WF655

Unhook the antenna cable

3

Pull forward to remove

5

1

Disconnect two connectors

1-6. RF ANTENNA SWITCH AND P BOARD REMOVAL

2

Two screws (+PWH 4x16)
(to detach the cables from the
Optics Unit Block Assembly)

Power supply block

4

Four screws (+BVTP 3x12)

2

Disconnect one connector
and the ground wire

Two screws

4

3

(+BVTP 3x8)

P board

2

U bracket

RF antenna switch

Six Screws (+BVTP 3x12)

1

KDF-55WF655/60WF655

15

1-7. U BOARD, H4 BOARD, AND FAN REMOVAL

KDF-55WF655/60WF655

Gently pull back on tab to
release U board

One screw

2

(+BVTP 3X12)

Four screws

5

(+BVTP 3X12)

4

Three screws

(Washer Head +P 4x16)

1-8. F BOARD AND G1 BOARD BOARD REMOVAL

Disconnect two connectors (CN1603 & CN1604)

Disconnect two connectors

7

(CN1601 and CN1602)
and one ground wire (CN1607)

6

1

3

Gently pull back on tabs
to release H4 board

G1 board

Remove wires from purse locks

5

U board

Remove one screw
(+BVTP 3X12 TYPE2)

Disconnect two connectors
(CN1908 and CN1909)
and two ground wires
(CN1902 and CN1903)

Disconnect the Power cord
from CN1900 connector.

KDF-55WF655/60WF655

Claw

Pull F Bracket out
and up to remove

3

2

1

9

4

8

Unfasten three Circuit Board Supports

Gently pull back on the three clips
on the pin connection slots
while slowly lifting the G1 Board.

16

1-9. A BOARD AND KD BOARD REMOVAL

Disconnect three connectors
(CN4701, CN4705, and CN4702)

6

KDF-55WF655/60WF655

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
(+BVTP 3X12)

7

Remove two screws

6

(+BVTP 3X12 TYPE2)

Remove cables from purse locks

8

5

Q Box Assembly

Remove two connectors

9

3

(CN3501 and CN3502)

1

Remove cables from purse

B board

Remove two screws

2

(3X12), + BVWHTP

Gently pull back

4

on the two clips
on the Pin Connection slots
while slowly lifting the B board

KDF-55WF655/60WF655

17

1-11. G2 BOARD REMOVAL

y

KDF-55WF655/60WF655

Disconnect 6 connectors
(CN6000, CN6024,
CN6028, CN6021,
CN6023, and CN6022)

Disconnect 2 ground wires
(CN6013 and CN6015)

Gently pull back on the two clips
while slowly lifting the G2 Board.

2

1

G2 board

3

3

1-12. WOOFER REMOVAL

2

Connector

Woofer block assembl

3

1

Four screws

(+TPTWH 4x25)

KDF-55WF655/60WF655

18

1-13. OPTICS UNIT BLOCK ASSEMBLY AND D.C. FAN REMOVAL

4

Three screws
(+BVTP 3x12)

3

Optics Unit block assy

2

Pull forward to remove

1

KDF-55WF655/60WF655

Disconnect two connectors

D.C. Fan

Two screws
Special (+PW4X30)

1-14. T BOARD REMOVAL

Disconnect
one connector

T board

2

One screw (+BVTP 3x12)

1

KDF-55WF655/60WF655

19

1-15. FRONT COVER ASSEMBLY REMOVAL

r

r

Three screws
(+BVTP 3X12 TYPE2)

KDF-55WF655/60WF655

1 Two ornamental screws

Cable Cove

Gently pull the
Front cover assembly forward.
Note the area of the 3 magnets
holding the cover

2

1-15-1.REPLACING THE LAMP

For detailed instructions on replacing the lamp, see
Page 16 of the Operating Instructions manual.

1-16. HM BOARD AND H2 BOARD REMOVAL

3

One screw

(+BVTP 3X12)

Disconnect one connector
(CN4502)

Two screws
(+BVTP 3X12 TYPE2)

KDF-55WF655/60WF655

One screw
(+BVTP 3x12)

2

1

3

H2 board

4

Two screws
(+BVTP 3X12 TYPE2)

6

Disconnect USB cable

6

Disconnect one connecto
(CN7301)

HM board

5

Pull back on the clip
while lifting the HM board up

20

1-17. H1 BOARD REMOVAL

Disconnect one connector

3

Screen mirror block assembly

H1 board

H1 button

H1 board

H1 bracket

Gently pull back on the bottom tab

4

of the H1 bracket then slide out the H1 board

One screw

2

(+BVTP 4x16)

1

Using tweezers gently detach the
H1 Bracket Cap

KDF-55WF655/60WF655

1-18. 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: Be sure to remove the screws that secure
the reinfocement plates (R)/(L).

Screen mirror block assembly

Seven screws
(+BVTP 4x16)

3

1

Disconnect three connectors

KDF-55WF655/60WF655

2

Four screws
(+BVTP 4x16)

21

1-19. MIRROR COVER ASSEMBLY, H3 BOARD, AND SPEAKER REMOVAL

KDF-55WF655/60WF655

Sixteen screws
(+BVTP 4X16)

Eight screws
(+BVTP 4X16)

Four screws
(+BVTP 4X16)

Four screws

2

(+BVTP 4X16)

1

11

Disconnect one connector

10

4

5

4

5

3

Lift bracket out

Two screws
(+BVTP 4x16)

7

6

Lift H3 board up,
then pull back to remove
from bracket

9

Two screws
(+BVTP 4x16)

8

Remove H3
Bracket door

1-19-1.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

Top

1

Diffusion Plate (Fresnel)

Diffusion Plate (Lenticular)

KDF-55WF655/60WF655

22

[F] EMI Shield wire around
2nd post

KDF-55WF655/60WF655

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-55WF655/60WF655

23

KDF-55WF655/60WF655

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-55WF655/60WF655

24

Tape must avoid OP Block Label

KDF-55WF655/60WF655

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-55WF655/60WF655

Left Side Coated Lead Pins details

25

Right Side Coated Lead Pins
details

Twist Coated Lead inward to
avoid contact with fan assembly
after installation

KDF-55WF655/60WF655

KDF-55WF655/60WF655

26

SECTION 2: CIRCUIT ADJUSTMENTS

KDF-55WF655/60WF655

2-1. SETTING THE SERVICE ADJUSTMENT

☛

MODE

To adjust various set features, use the Remote Commander to put the
set into service mode to display the service menus.

1. TV must be in standby mode. (Power off).

2. Press the following buttons on the Remote Commander within a
second of each other:

DISPLAY

The fi rst service menu (TV) displays.

3. To display the service menu that contains the category you want to
adjust, press
(Refer to Service Menus)

Service Menu

PANEL NVM OK 1 5D089T9PN

41RLVL_

Channel 5 Volume +

JUMP

on the Remote Commander.

POWER

Category

H

4590

Ircnmetne

D

i ff1

ste sp

.

TV

VERSION

CXA2209Q

AP

DLBY

BUSSW

CXA2103

CXA2163

2DCOMB

TELETEXT

MSP SIZE

MSPMD

☛

Q BOX

QM

QT

SERVICE MENUS

(CATEGORIES ONLY)

WEM 2

(WEGA ENGINE)

DCP-INT

DCP-OSD

DCP-BLK

DCP-ADJ1

DCP-ADJ2

DCP-USER

DCP-AVP

MID-1-9

SNNR

SNSS

DRCVR

(DISPLAY ENGINE)

PANEL

OP

A7001R

A7001G

A7001B

GB_RGB

FAN_C NT1

FAN_C NT2

TEMP

OSD_E

OPTION_E

S_MAS_M

Item #

Data value

Adjustment

item

Sample Panel (Display Engine) Service Menu

2-2. SERVICE ADJUSTMENT MODE

☛

MEMORY

The screen displays the fi rst category in the selected service menu.

4. To change the category, press 2 or 5 on the Remote Commander.

Note: Pressing 2 or 5 only changes the categories within the

service menu displayed. To change a category on one of the other
service menus, press the
is displayed.

5. To change the adjustment item, press 1 or 4 on the Remote
Commander.

6. To change the data value, press 3 or 6 on the Remote Commander.

Note: To go back to the last saved data value, press 0 then

ENTER

on the Remote Commander to read the memory.

7. To write into memory, press
Commander.

8. To exit service mode, turn the power off.

JUMP

button until the correct service menu

MUTING

then

ENTER

on the Remote

MSPSEL

MSPFNC

MSP3714G

CCPS (1-11)

DELAY (1-2)

OSD

CC M

CC S

CC T

ID

OPB GA

OP GA

OP US

USER-NR

LPFC

CCPM-1 (1-12)

OVSN

OP

S_MAS_S

J_L004

D9809_1

D9809PIC

D9809TPN

D9809CUR

D9809TG1

D9809 OSD

D9809HPF

D9809CSC

D9809CGA

D9809HUE

IMG_SHFT

PROT_CNT

KDF-55WF655/60WF655

27

KDF-55WF655/60WF655

2-3. MEMORY WRITE CONFIRMATION METHOD

☛

1. After completing all adjustments turn the set off with the Remote Commander and WAIT for the fans to turn off before proceeding to the next step.

Note: It may take up to two minutes for the fans to stop.

Caution: To avoid over heating the lamp, do not unplug the set until the fans have stopped.

2. After the fans have stopped, unplug the set from the AC outlet, then plug the set back in the AC outlet.

3. To verify the changes repeat steps 2 through 5 from sections 2-1. Setting the Service Adjustment Mode and 2-2. Service Adjustment Mode Memory.

4. To exit service mode, turn the power off.

Note: To restore the User Controls and Channel Memory settings to the preset factory conditions, put the set into service mode (step 2
from 2-1. Setting the Service Adjustment Mode), then press
initial setup screen.

2-4. REMOTE ADJUSTMENT BUTTONS AND INDICATORS

☛

8

then

on the Remote Commander. The set will restart and display the

ENTER

MUTING

Write into
memory

Adjustment
item up

Category up

Adjustment
item down

Restore User Control
and Channel Memory

1

2

4

8

VOLUME (+)

POWER

DISPLAY

Data value up

3

Data value

6

down

Category down

5

ENTER

0

Read data
from last
saved NVM

JUMP

Displays Service Menus

KDF-55WF655/60WF655

RM-Y915

28

KDF-55WF655/60WF655









MID-X1 9 MDHP + MDH

P

(Don't change the MDVP data)

MID-X1 9 MDHP + MDHP

10 MDVP + MDVP





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 .

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:

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-55WF655/60WF655

29

2-6. SERVICE DATA

A

A

Only the Adjustable registers are shown in this data list.

A complete set of the service data, Fixed and Adjustable, can be downloaded at:

KDF-55WF655/60WF655

Only Sony authorized Service Technician can access this site. To request a complete list of the service data in PDF format please
contact the Service Promotion Department at [e-mail].

☛

http://www-ec.sdp.sel.sony.com/padics/Model_Data_List.htm

TV SERVICE DAT

SERVICE DATA (dec)

CXA2103

ITEMCATEGORY #

4SCON RF 8 8 0 15

5SCOL RF 3 3 0 15

6 SHUE RF 10 10 0 15

DESCRIPTION CONDITION

CV 8 8 0 15
YC 8 8 0 15

CV 3 3 0 15
YC 3 3 0 15

CV 3 3 0 15
YC 3 3 0 15

55WF655

60WF655

MIN

MAX

WEGA ENGINE SERVICE DAT

SERVICE DATA (dec)

CATEGORY #
DCP_OSD 16 RP1H 0 0 0 15

DCP_ADJ1 2 SCON Component-480i 185 185 0 255

ITEM

17 RP1L 251 251 0 255

DESCRIPTION CONDITION

Component-480p 192 192 0 255
Component-1080i 193 193 0 255
Component-720p 194 194 0 255
ATSC-480i 178 178 0 255
ATSC-480p 182 182 0 255
ATSC-1080i 183 183 0 255
ATSC-720p 182 182 0 255
ATSC-TEXT 183 183 0 255
HDMI-480i 185 185 0 255
HDMI-480p 192 192 0 255
HDMI-1080i 193 193 0 255
HDMI-720p 194 194 0 255
HDMI(VGA etc) 192 192 0 255
MemoryStick(MPEG1) 183 183 0 255
MemoryStick(MPEG2) 183 183 0 255
MemoryStick(PHOTO) 183 183 0 255

55WF655

60WF655

MIN

MAX

KDF-55WF655/60WF655

30