SONY KDF-55XS955, KDF-60XS955 Service Manual

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDF-55XS955 KDF-60XS955
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) 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 76 with Page 76)
LCD PROJECTION TELEVISION
9-965-974-05
Self Diagnosis
Supported model
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDF-55XS955 KDF-60XS955
LA-3
CHASSIS
9-965-974-05
KDF-55XS955 RM-Y915
LCD PROJECTION TELEVISION
KDF-55XS955/60XS955

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 and H1 Board Removal................... 20
1-15-1. Replacing the Lamp................................................. 20
1-16. HM Board and H2 Board Removal....................................... 20
1-17. H3 Board and Speaker Removal ......................................... 21
1-18. Screen Mirror Block Assembly Removal.............................. 21
1-19. Mirror Cover Assembly 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 Diagrams.................................................................... 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.............................................. 70
T Board Schematic Diagram................................................ 70
U Board Schematic Diagram................................................ 71
3-5. Semiconductors ................................................................... 73
SECTION 4: EXPLODED VIEWS........................................................ 74
4-1. Cover.................................................................................... 74
4-2. Bottom Cabinet .................................................................... 75
4-3. Chassis ................................................................................ 76
SECTION 5: ELECTRICAL PARTS LIST........................................... 77
KDF-55XS955/60XS955
3

SPECIFICATIONS

p
)
r
KDF-55XS955/60XS955
Power Requirements
Power Consumption (W) In Use (Max) In Standby
Inputs/Outputs
120V AC, 60Hz
265W Under 20W
HDMI IN
2 total 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-55XS955 KDF-60XS955
S
eaker Output(W
Woofe
Dimensions (W x H x D)
mm 1,574 x 952 x 484 mm 1,685 x 1,007 x 514 mm
in
62 x 37
Mass
kg 48 kg 51.5 kg
lbs 105 lbs 29 oz 113 lbs 19 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
1/2
x 19 in 66
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.
3/8
x 39
5/8
x 20
1/4
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.
)
KDF-55XS955/60XS955
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-55XS955 Only) 60 inches (KDF-60XS955 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-55XS955/60XS955
Lamp
UHP lamp, 132W XL-2100
Supplied Accessories
Remote Commander RM-Y915 Two Size AA (R6) Batteries
KDF-55XS955/60XS955
5
KDF-55XS955/60XS955

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-55XS955/60XS955
6

SAFETY CHECK-OUT

KDF-55XS955/60XS955
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-55XS955/60XS955
Earth Ground
AC Voltmeter (0.75V)
Trouble Light
AC Outlet Box
Ohmmeter
Cold-water Pipe
7
KDF-55XS955/60XS955
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 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 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-55XS955/60XS955
8
Display of POWER/STANDBY or LAMP LED Flash Count
For KDF-XS955 series
KDF-55XS955/60XS955
Screen
POWER/STANDBY
POWER
LAMP TIMER
STD/DUO
Projection lamp under the panel
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-55XS955/60XS955
9
KDF-55XS955/60XS955
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-55XS955/60XS955
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-55XS955/60XS955
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-55XS955/60XS955
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-55XS955/60XS955
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-55XS955/60XS955
12

1-1. REAR COVER REMOVAL

KDF-55XS955/60XS955

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-55XS955/60XS955
Two screws (+BVTP 4x16)
2
13

1-3. CHASSIS ASSEMBLY AND FAN REMOV AL

4
5
Disconnect one connector and one ground wire
KDF-55XS955/60XS955
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-55XS955/60XS955
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-55XS955/60XS955
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)
3
Disconnect one connector and the ground wire
Two screws
5
4
(+BVTP 3x8)
P board
2
U bracket
RF antenna switch
Six Screws (+BVTP 3x12)
1
KDF-55XS955/60XS955
15

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

KDF-55XS955/60XS955
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-55XS955/60XS955
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-55XS955/60XS955
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-55XS955/60XS955
17

1-11. G2 BOARD REMOVAL

y
KDF-55XS955/60XS955
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

3
2
Disconnect one connector
Woofer block assembl
1
Four screws
(+TPTWH 4x25)
KDF-55XS955/60XS955
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-55XS955/60XS955
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-55XS955/60XS955
19

1-15. FRONT COVER ASSEMBLY AND H1 BOARD REMOVAL

One Ornamental screw
2
KDF-55XS955/60XS955
Disconnect one connector (CN171)
4
H1 Board
H1 Button
3
H1 Bracket
Two screws (+BVTP 4X16 TYPE2 IT-3)
5
One screw (+BVTP 3X12 TYPE2 IT-3)
Pull forward on the Front Cover Assembly
1

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

Disconnect USB cable
One screw +BVTP 3X12 TYPE2 TT(B)
Pull out HM Bracket and lift out HM Board
H2 Bracket
7
6
5
HM Board
4
Disconnect one connector (CN4502)
3
Two screws +BVTP 3X12 TYPE2 TT(B)
H2 Board
Two screws (+BVTP 3X12 TYPE2 TT(B))
2
1
Two screws (+BVTP 4x16)
KDF-55XS955/60XS955
20

1-17. H3 BOARD AND SPEAKER REMOVAL

Disconnect one connector (CN43)
2
H3 Board
Speaker Box (R)
KDF-55XS955/60XS955
1
Seventeen screws (+BVTP 4X16 TYPE2 TT(B))
2
Four screws (+BVTP 4X16 TYPE2 IT-3)
3
Four screws (+BVTP 4X16 TYPE2 IT-3)
Loudspeakers
Two screws (+BVTP 4x16)
1
Two screws
3
(+BVTP 3X12 TYPE2)
4
Gently pull back on the two clips while slowly lifting the H3 Board.

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)
KDF-55XS955/60XS955
3
1
Disconnect three connectors
2
Four screws (+BVTP 4x16)
21
1-19. MIRROR COVER ASSEMBLY REMOVAL
KDF-55XS955/60XS955
Sixteen screws (+BVTP 4X16)
Four screws
2
(+BVTP 4X16)
1
3

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-55XS955/60XS955
22
[F] EMI Shield wire around 2nd post
KDF-55XS955/60XS955

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-55XS955/60XS955
23
KDF-55XS955/60XS955
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-55XS955/60XS955
24
Tape must avoid OP Block Label
KDF-55XS955/60XS955
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-55XS955/60XS955
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-55XS955/60XS955
KDF-55XS955/60XS955
26

SECTION 2: CIRCUIT ADJUSTMENTS

KDF-55XS955/60XS955
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
SERVICE MENUS
(CATEGORIES ONLY)
TV
VERSION
.
CXA2209Q
AP
DLBY
BUSSW
CXA2103
CXA2163
2DCOMB
TELETEXT
MSP SIZE
MSPMD
Q BOX
(WEGA ENGINE)
QM
QT
DCP-INT
DCP-OSD
DCP-BLK
DCP-ADJ1
DCP-ADJ2
DCP-USER
DCP-AVP
MID-1-9
SNNR
SNSS
DRCVR
WEM 2
PANEL
(DISPLAY ENGINE)
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-55XS955/60XS955
27
KDF-55XS955/60XS955

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-55XS955/60XS955
RM-Y915
28
KDF-55XS955/60XS955




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-55XS955/60XS955
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-55XS955/60XS955
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 Service_Promotion@am.sony.com.
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
55XS955
60XS955
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
55XS955
60XS955
MIN
MAX
KDF-55XS955/60XS955
30
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