Tv is on top of cabinet, not closed in. I have had 2 optical blocks replaced within last 3 weeks. The second time, the repair station took tv in to their shop. They also replaced optical block ribbon cable at Sony's instruction while at their shop. I had a few "words" with repair shop over their procedures while my tv was there. The day that I got the tv back, I had the "high temp warning" appear within first 30 minutes of operation. Never had this problem before. Coincidence? Have had the tv since 2006. I can hear and feel fan operating at lower left back of cabinet.
There are 3 fans in this unit, and 2 are on the rear of the unit. The one that may be a concern for you however is directly over the Optical Block it is inside the unit. That may be the reason for having 2 replacements in such a short time.
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According to the manual you are not getting enough airflow which would explain the optic block failure. Make sure the TV has lots of space for air around it and is not inside a cabinet that would overheat it.
I had the same problem with my 4 yr old Sony KDF60WF655 rear projection set, and I was fortunate to buy a 4 year extended warranty - because it was the "Optic Block", ($1300. -not incl labor), that was replaced to fix the problem. That part contains all new LCDs, & multiple Lens & some electronics. I had already got a new bulb (under warranty) a few weeks earlier, that I had not yet installed so the service guy did replace that as well. (This happened 3 weeks before my warranty ended).
He told me that he replaces hundreds of Sony Optic Blocks every year and that many Sony Rear Projection sets have automatic FACTORY extended warranties (up to 10 years), because of some known problems with the blue LCD panels. You might want to contact a SONY office & see if your set is covered.
ALSO - The tech checked my Service Codes & showed me the TV had been running for 10051 hours in about 4 years - on the Original bulb! He was quite surprised because he said the bulbs usually last about 5000 - 7000 hours. He also said it's good to replace them BEFORE they go bad, because they can sometimes burn out the amplifier that powers the bulb, (which is a seperate piece that attaches to the outside of the Optic Block). My TV is like new now.
My first question is did you have this problem before your set was repaired the first time or did it occur after a tech took it apart?
The switch could be flakey evidenced by it working after the door is removed and reinstalled, but I would think you would have seen that symptom before the TV was repaired. BTW- what problem did you call them out for service on?
The door switches are very delicate and Sony warns techs in their training videos to watch for this when they do an optical block swap.
If I was repairing the set, I would meter the switch for voltage at the time it fails and if I saw voltage the switch is defective or the position of the switch board or optics is changing. If no voltage was measured at the time the set shuts off and the red light still blinks 3 times, then the board the switch goes to could be bad.
I hesitate to tell you this for fear of a bad rating from you, but it is likely the optical block is the source of your problem. Sony was covering replacement of the optical block for this unit until June of 2008, but that warranty extension has expired. I would suggest you contact Sony customer support at 800-222-SONY to see if they will allow for some type of accommodation to cover either the parts, the labor or some portion thereof. Sorry!
Understand I risk getting a bad rating from you, but I thought you should know. You have a bad optical block. Sony was supplying the optical block and covering the labor for replacement until June of this year, but that extension has expired. Your best bet is to contact Sony Customer support at 800-222-SONY. They will probably want an authorized tech to come out and evaluate the set. You may be able to get them to cover the part under warranty, but it may take a letter to the customer service executive committee to get that to happen. I am sorry I could not help more.
Hey joseph, actually replacing the optical Block is not necessary at all, all you need to do is get into the "Service Mode" of the Tv and change a few setting around, did it a few weeks ago and now my TV looks perfect, no reason to waster $1200 as sony is trying to get over on all us consumers.
Check the thermal sensor fuse part# 1-910-023-93 or possibly one of the four fans.
If the unit goes into Fan/Thermal Protect shutdown (4 blinks) it can be difficult to determine the cause since the unit turns off too quickly to troubleshoot.
Solution: Ground the data line by inserting a jumper between pins 3 and 6 of CN44 on the H4 board. This overrides the protection circuits for troubleshooting. Do this right after turning the unit on and as soon as the lamp is seen lighting. Check pins 2, 5, 8, and 11 of CN6000 on the G2 board for less than 1VDC. Any voltage higher than that indicates a faulty fan. If all voltages are within specs, the H4 board must be replaced. If a fan is found defective, the optical block will need to be replaced if it is located inside the assembly.
H4 Board Part Number: A1054674A
Replace the following part based on which pin of CN6000 is out of specs:
Pin 2: Fan 1 (part of optical block)
Pin 5: Fan 2 178723211
Pin 8: Fan 3 178706511
Pin 11: Fan 4 178708111
Optical block Part Number: