Sony KDF-42WE655, KDF-50WE655, RM-Y915 Service Manual

LCD PROJECTION TELEVISION

SERVICE MANUAL

LA-3

CHASSIS

MODEL NAME REMOTE COMMANDER DESTINATION

9-965-971-04

KDF-42WE655

RM-Y915 US/CND

KDF-50WE655

RM-Y915 US/CND

HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

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 36 with Page 36) Updated PN for Power Supply Block, Added D.C. Fan (Sirocco) to Exploded View section (Replaced Page 77 with Page 77) 1/2005 Corrected Section 2-1. Setting the Service Adjustment Mode and 2-2. Service Adjustment Mode Memory (Replaced Page 28 with Page 28) Corrected Section 2-4. Remote Adjustment Buttons and Indicators (Replaced Page 29 with Page 29) Updated contact information for Service Data requests (Replaced Page 31 with Page 31) Updated contact information for Tiled Schematic requests (Replaced Last Page with Last Page) 1/2005 Added Caution statement (Replaced Page 6 with Page 6)

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LCD PROJECTION TELEVISION

SERVICE MANUAL

LA-3

CHASSIS

MODEL NAME REMOTE COMMANDER DESTINATION

9-965-971-04

KDF-42WE655

RM-Y915 US/CND

KDF-50WE655

RM-Y915 US/CND

Self Diagnosis

Supported model

KDF-42WE655 RM-Y915

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KDF-42WE655/50WE655

TABLE OF CONTENTS

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

SECTION TITLE PAGE SECTION TITLE PAGE

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KDF-42WE655/50WE655

SPECIFICATIONS

Design and speciﬁ cations are subject to change without notice.

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.

Power Requirements

Power Consumption (W) In Use (Max) In Standby

Inputs/Outputs

Control S (IN)

1 total Minijack

Control S (OUT)

1 total Minijack

Component Video Input

2 (Y, P

, PR) Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative P

0.7 Vp-p, 75 ohms;

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

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

x 32

1/4

x 12

1/3

in 54

1/8

x 36

1/2

x 15 in

Mass

kg 32.5 kg 39 kg

lbs 71 lbs 10 oz 85 lbs 14 oz

5W x 2

20W

CableCARD™ is a trademark of Cable Television Laboratories, Inc.

TruSurround, SRS and the ( )

symbol are trademarks

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.

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.

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KDF-42WE655/50WE655

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

Lamp

UHP lamp, 100W XL-2100 or XL2100U

Supplied Accessories

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

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KDF-42WE655/50WE655

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.

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KDF-42WE655/50WE655

SAFETY CHECK-OUT

After correcting the original service problem, perform the following safety checks before releasing the set to the customer:

1. Check the area of your repair for unsoldered or poorly soldered connections. Check the entire board surface for solder splashes and bridges.

2. 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

1.5 K Ω

Voltmeter

(0.75 V)

Earth Ground

Trouble Light

AC Outlet Box

Ohmmeter

Cold-water Pipe

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

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KDF-42WE655/50WE655

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

Number of times

STANDBY or LAMP LED

lam

flashes

Probable Cause Detected Symptoms

Lamp cover error 3 times - Lamp cover is not fas tened securely - No picture/No sound

Fan error 4 times

- Fan1-4 Power is not supplied.(G2 board)

- Fan connector is not seated securely

- Fan caught wires or harnesses

- No picture/No sound

Temp error 4 times

- Internal temperature is too high

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

- No picture/No sound

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

- Short-circuit of A udi o power suppl y 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)

- No picture/No sound

D-OVP error 8 times

- Overvoltage of +3.3V or +2.5V (A board, B board)

- No picture/No sound

ATSC-OVP error 10 times

-No "DTL MODULE 5V " output (G1 board, G2 board)

- No picture/No sound

Lamp error LAMP-LED is ON. - Lamp is dead - No picture/No sound

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KDF-42WE655/50WE655

Display of POWER/STANDBY or LAMP LED Flash Count

POWER

PRO

STD/DUO

LAMP TIMER POWER/STANDBY

Scree n

Projection lamp

Indicators

Projection lamp

Indicators

For KDF-WE655 series

For KDF-WF655 series

- 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

Channel

Sound Volume

Power ON

Self-Diagnostic Screen Display

SELFCHECK

1 : LAMP ERR 0 3: 4:

LAMP COVER 0

FAN-E/TEMP-E 1 5 : LAMP DRIVER 6 : LowB-ERR 0

7 : Audio-Prot 8 : D-OVP 0

101 : WDT 0

10 : ATSC_OVP 0

"1" is displayed when a failure is detected one or more times "0" is displayed when no failure has been detected

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”.

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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

Channel

Sound Volume

Power ON

3. Press Channel

ENTER

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"

(pin 96) is low at the same time, it is classified as no high voltage of the lamp driver. 6 : Low B error When no "DD 6V " is detected, pin 129 of TV-micro is low and it turns off the main power. 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.

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KDF-42WE655/50WE655

Self-Diagnosis Block Diagram

IC41

IIC-E

LAMP-COVER

FAN PROT

4:Temp

IC6902

Display Engine u-com

H3(WE)/H4(WF/XS)

board

3:Lamp cover

5:Lamp

driver

4:Fan

S8001

T board

Fan1 Fan2 Fan3

FAN1-PRT FAN2-PRT FAN3-PRT

CN6000

7:Audio

G2 board

Temp

sensor

Lamp

HV-DET

Lamp driver

Fan4

FAN4-PRT

LAMP-PROT LAMP-HV-DET

CN6022

A14 B14

CN6019

CN6017

IC3604 TV u-com

128

D_OVP

SP_DC_PROT

LB_ERROR

126

129

127

ATSC_OVP

KD board

CN6029

A board

CN6020

C26

8:D-OVP

+3.3V +2.5V

Audio

amp

6:LowB

error

G1 board

CN6029

DD6V

DTL5

12:ATSC

OVP

CN6023

515

CN6006

Digital Box

DTL MDL5V

IIC-TV

IC3801 WE u-com

IIC-WE IIC-TV

IIC-WE

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KDF-42WE655/50WE655

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:

1. Press

Display

Channel

Sound Volume + Power ON

2. To enter the DE-micro service menu, press

Jump

3 times.

3. To display the Lamp time, press Channel

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”

To reset the lamp time press Channel

Mute

Enter

WRI-EXE(Character color is Red) is momemtarily displayed and LampTM is reset to “0”.

4. To display the Panel time, press Channel

7 times

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.

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KDF-42WE655/50WE655

1-1. REAR COVER REMOVAL

SECTION 1: DISASSEMBLY

1-2. CENTER PILLAR REMOVAL

Rear cover

Eleven screws (+BVTP 4x16)

Center Pillar

Gently lift the Center Pillar up then out from the bottom bracket.

Disconnect three ground wires

Two screws (+BVTP 4x16)

Two small screws (+PSW 3x8)

Three screws from the top of the center pillar (+BVTP 4x16)

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KDF-42WE655/50WE655

1-3. SERVICE POSITION

1-4. FAN AND CHASSIS ASSEMBLY REMOVAL

Pull back on claw, then gently pull out chassis assembly

Chassis assembly

Pull back on claw, then gently pull out chassis assembly

Four screws (+PWH 4x35)

Disconnect one connecto

Four screws (+PWH 4x16)

Chassis assembly

D. C. FAN

Fan bracket with D. C. fan

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KDF-42WE655/50WE655

1-5. POWER SUPPLY BLOCK REMOVAL (LAMP DRIVE UNIT)

1-6. FAN, RF ANTENNA SWITCH, AND P BOARD REMOVAL

CAUTION: When removing the Power Supply Block be careful not to move the Optical Unit Block

U bracket

RF antenna switch

Fan Bracket

Three Screws (Washer Head) (+P 4X16)

Four Screws (Washer Head) (+P 4X35)

Seven Screws (+BVTP 3x12)

Disconnect four ground wires

Disconnect three connectors and the ground wire

P board

D. C. Fan

Two screws (+BVTP 3x8)

Power supply block

Four screws (+BVTP 3x12)

Pull forward to remove

Unhook the antenna cable

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

Disconnect two connectors

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KDF-42WE655/50WE655

1-7. U BOARD REMOVAL

1-8. F BOARD AND G1 BOARD BOARD REMOVAL

U board

Gently pull back on tab to release U board

G1 board

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

Disconnect two connectors (CN1601 and CN1602) and one ground wire (CN1607)

Remove one screw (+BVTP 3X12 TYPE2 TT(B))

Pull F Bracket out and up to remove

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

Disconnect two connectors (CN1603 & CN1604)

Unfasten three Circuit Board Supports

Remove wires from purse locks

Disconnect the Power cord from CN1900 connector.

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1-9. A BOARD AND KD BOARD REMOVAL

1-10. Q BOX ASSEMBLY, AND B BOARD REMOVAL

Remove cables from purse locks

Q Box Assembly

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

Remove two screws

Remove two screws (+BVTP 3X12 TYPE2 TT(B))

Remove two connectors (CN3501 and CN3502)

B board

Disconnect six connectors

Unplug two coax cables connected to the antenna switch

Remove four screws

Remove cables from purse locks

Unfasten two Circuit Board Supports

Gently pull back on the three clips on the Pin Connection slots while slowly lifting the A board

Gently pull back on the two clips on the Pin Connection slots while slowly lifting the KD board

A board

KD board

Disconnect three connectors (CN8003, CN8004, and CN8008) and coax cable from tuner

Disconnect three connectors (CN4701, CN4705, and CN4702)

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KDF-42WE655/50WE655

1-12. T BOARD REMOVAL

1 Four screws (+TPTWH 4x25)

2 Connector

3 Woofer block assembl

1-13. WOOFER REMOVAL

T board

Disconnect one connector

One screw (+BVTP 3x12)

1-11. G2 BOARD REMOVAL

Disconnect 2 ground wires (CN6013 and CN6015)

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

Lift the G2 Board out of the Main Bracket

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KDF-42WE655/50WE655

1-14. H3 BOARD REMOVAL (KDF-42WE655 ONLY)

1-15-1.REPLACING THE LAMP

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

1-15. FRONT COVER ASSEMBLY REMOVAL

Spring plate

H3 bracket

H3 board

Disconnect two connectors and one ground wire

Two screws (+BVTP 3x12)

Four latches

1 Two ornamental screws

Front cover assembly

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KDF-42WE655/50WE655

1-16. HM BOARD REMOVAL (KDF-42WE655 ONLY)

1-17. H3 BOARD AND HM BOARD REMOVAL (KDF-50WE655 ONLY)

HM board

H2 block assembly

MS panel

Disconnect two connectors

Two screws (+BVTP 4x16)

Bottom cover assembly

MS bracket

H3 bracket

HM board

H3 board

Spring plate

Disconnect two connectors and one ground wire.

Disconnect two connectors

Two screws (+BVTP 3x12)

One screw

Note: To remove the HM Board you need to remove the screws inside the Bottom Cabinet Assembly

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KDF-42WE655/50WE655

1-18. H2 BOARD REMOVAL

1-19. H1 BOARD REMOVAL

H2 board

H2 bracket

Light guide (LED)

Disconnect one connecto

Two screws (+BVTP 3x12)

Four screws (+BVTP 4x16)

Screen mirror block assembly

1 H1 bracket cap

H1 bracket

H1 board

H1 button

Two screws (+BVTP 4x16)

One screw (3x12)

Disconnect one connector

Using tweezers gently detach two H1 Bracket Caps

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KDF-42WE655/50WE655

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.

Screen mirror block assembly

Note: For the model 50WE655, remove the screws that secure the reinfocement plates (R)/(L).

Seven screws (+BVTP 4x16)

Four screws (+BVTP 4x16)

Disconnect three connectors

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KDF-42WE655/50WE655

Black Acetate (2142) 23X50M

Top

Diffusion Plate (Lenticular)

Diffusion Plate (Fresnel)

1-21-1.DIFFUSION PLATES (SCREENS) TAPE METHOD

1-21. MIRROR COVER ASSEMBLY AND SPEAKER REMOVAL

The following diagram illustrates the taping method when replacing the Diffusion Plates. For Part Numbers refer to section 6-1. Cover.

Two Screws (+BVTP 4X16)

Fourteen Screws (+BVTP 4X16)

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KDF-42WE655/50WE655

WIRE DRESSING

[F] EMI Shield wire around 2nd post

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

Make sure purse lock is completely seated to [G1]

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

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KDF-42WE655/50WE655

Fan wire must be under the foam gasket material

Detail of USB around ATSC Box Area

USB Cable must not touch metal grill for EMI issue

Detail of front side [G1] - All wires through purse lock

Detail of front side ATSC Box

Detail of front side ATSC Box - [C1] LVDS dressing

Top connector wires must be to the left of lower wires

Bend GND tab after wire is installed

Emi Tape added to Sub Tuner cable

LVDS Cables dresses behind purse lock

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KDF-42WE655/50WE655

Tape must avoid OP Block Label

Sensor wire should be in left three purse locks

Loop sensor wire at the 2nd purse lock position

Left Side Coated Lead Pins details

Clip position move to avoid wire touching Emi Shield

Dress Drvr harness through bottom coated lead pin then the top

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

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KDF-42WE655/50WE655

Right Side Coated Lead Pins details

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

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KDF-42WE655/50WE655

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

Channel

Volume

POWER

The ﬁ rst service menu (TV) displays.

3. To display the service menu that contains the category you want to adjust, press

JUMP

on the Remote Commander.

(Refer to Service Menus)

Service Menu

Adjustment

item

Sony KDF-42WE655, KDF-50WE655, RM-Y915 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual