Sony KDF-46E3000, KDF-50E3000 Service Manual
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDF-46E3000
KDF-50E3000
RM-YD016 US/CND
RM-YD016 US/CND
LA-5
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 6/2007
: UPDATED ITEM
☛
REVISION DATE SUBJECT
6/2007 No revisions or updates are applicable at this time.
8/2007 Updated Disassembly Section 1-6. Replaced Page 14.
LCD PROJECTION TELEVISION
9-883-754-02
Self Diagnosis
Supported model
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDF-46E3000
KDF-50E3000
RM-YD016 US/CND
RM-YD016 US/CND
LA-5
CHASSIS
9-883-754-02
KDF-50E3000 RM-YD016
LCD PROJECTION TELEVISION
KDF-46E3000/50E3000
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 ............................................................... 10
1-1. Overview .............................................................................. 10
1-2. Lamp Removal ......................................................................11
1-3. Power Supply (Ballast Unit) Removal .................................. 12
1-4. HAE Board Removal ............................................................ 13
1-5. HCE Board Removal ............................................................ 13
1-6. Ornamental Cover, Screen Frame,
and Light Guide Removal ..................................................... 14
1-7. Diffusion Plates and Screen Frame Removal ...................... 15
1-7-1. Diffusion Plates (Screens) Tape Method ................. 15
1-8. Separator, Speaker, and HBE Board Removal .................... 16
1-9. Lamp Duct Removal ............................................................. 17
1-10. Optical Unit Block Removal .................................................. 18
1-11. Chassis Removal ................................................................. 19
1-12. Mirror Replacement .............................................................. 20
Wire Dressing ....................................................................... 21
SECTION 2: CIRCUIT ADJUSTMENTS .............................................. 32
2-1. Using the Remote Commander for Electrical Adjustments .. 32
2-2. Accessing Service Adjustment Mode ................................... 32
2-3. Viewing the Service Menus .................................................. 32
2-4. Using the Remote Commander to View Service Data ......... 33
2-4-1. Changing Service Data ............................................ 33
2-4-2. Exiting Service Mode ............................................... 33
2-5. Updating the Model Information when
Replacing the BE Board ....................................................... 33
2-5-1. Verifying Model Information ..................................... 34
2-6. Adjusting the Horizontal and vertical Settings ...................... 34
2-7. Resetting the Lamp .............................................................. 34
2-8. Verifying Service Data Changes .......................................... 34
2-9. Resetting to Factory Defaults ............................................... 35
SECTION 3: DIAGRAMS ..................................................................... 36
3-1. Circuit Boards Location ........................................................ 36
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 36
3-3. Block Diagrams .................................................................... 38
Signal Flow Block Diagram .................................................. 38
Connection Diagram ............................................................ 39
3-4. Schematics and Supporting Information .............................. 40
BE Board Schematic Diagram (1 of 12) ............................... 40
BE Board Schematic Diagram (2 of 12) ............................... 41
BE Board Schematic Diagram (3 of 12) ............................... 42
BE Board Schematic Diagram (4 of 12) ............................... 43
BE Board Schematic Diagram (5 of 12) ............................... 44
BE Board Schematic Diagram (6 of 12) ............................... 45
BE Board Schematic Diagram (7 of 12) ............................... 46
BE Board Schematic Diagram (8 of 12) ............................... 47
BE Board Schematic Diagram (9 of 12) ............................... 48
BE Board Schematic Diagram (10 of 12) ............................. 49
BE Board Schematic Diagram (11 of 12) ............................. 50
BE Board Schematic Diagram (12 of 12) ............................. 51
G Board Schematic Diagram (1 of 2) ................................... 53
G Board Schematic Diagram (2 of 2) ................................... 54
HAE Board Schematic Diagram ........................................... 57
HBE Board Schematic Diagram ........................................... 59
HCE Board Schematic Diagram ........................................... 62
SE Board Schematic Diagram ............................................. 64
TE Board Schematic Diagram .............................................. 67
U Board Schematic Diagram ................................................ 70
3-5. Semiconductors ................................................................... 73
SECTION 4: EXPLODED VIEWS ........................................................ 74
4-1. Screen Frame and Mirror Assemblies .................................. 74
4-2. Chassis and Optical Block Assembly ................................... 75
4-3. Connectors ........................................................................... 76
SECTION 5: ELECTRICAL PARTS LIST ............................................ 77
KDF-46E3000/50E3000
APPENDIX A: ENCRYPTION KEY COMPONENTS ..........................A-1
APPENDIX B: REPLACING THE LAMP ............................................B-1
3
SPECIFICATIONS
p
)
b
a
KDF-46E3000/50E3000
Power Requirements
Power Consumption (W)
In Use (Max)
In Standby
Inputs/Outputs
120V, 60Hz
200W
Less than 0.8W
HDMI IN 1/2
Video - 480i, 480p, 720p, 1080i, 1080p, PC timing
Audio - Two channel linear PCM 32, 44.1 and 48 kHz,
16, 20, and 24 bit
Audio - (HDMI IN 2 only) 500 mVrms
(100% modulation) Impedance:47 kilo ohms
Video (IN) 1/2/3
Video
1 total Y: 1.0 Vp-p, 75ohms unbalanced,
sync negative
S Video (IN)
1 total (4-pin mini DIN)
Y: 1Vp-p, 75ohms unbalanced, sync negative
C: 0.286Vp-p (Burst signal), 75ohms
Audio (IN)
500 mVrms (100% modulation)
Impedance:47 kilo ohms
Component In 1/2/3
) (Component Video)
(Y, P
B/CB
Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative
:
0.7 Vp-p, 75 ohms;
P
B
PR: 0.7 Vp-p, 75 ohms
Signal format: 480i, 480p, 720p, 1080i
Audio (IN)
500 mVrms (100% modulation)
Impedance:47 kilo ohms
Audio Out
500 mVrms (100% modulation) Up to 2 Vrms at the
maximum volume setting (Varies with input level)
Digital Audio Optical Output (PCM/Dolby Digital)
Optical Rectangular
eaker Output(W
S
Speaker Dimension
Dimensions (W x H x D)
Mass
Trademark Information
As an ENERGY STAR® Partner, Sony
Corporation has determined that this product
meets the ENERGY STAR
®
guidelines for
energy efficiency.
ENERGY STAR
®
is a U.S. registered mark.
Blu-ray Disc is a trademark.
“BRAVIA” and , BRAVIA ENGINE EX, “XMB”
and “XrossMediaBar”, S-Force, BRAVIA Theatre Sync, , DM
BRAVIA Internet Video Link Ready and “PS3” are trademarks
or registered marks of Sony Corporation and/or
Sony Computer Entertainment Inc.
KDF-46E3000/50E3000
KDF-46E3000 KDF-50E3000
12W + 12W
mm
in
65 x 130 mm
2
9/16
x 5
1/8
in
mm 1099 x 795 x 301 mm 1187 x 847 x 320 mm
in
43
5/16
x 31
5/16
x 11
7/8
in 46
3/4
x 33
3/8
x 12
5/8
kg 27 kg 30 kg
lbs 59.9 lbs 66.3 lbs
All measurements are approximations
This TV is manufactured under license from Dol
Laboratories. “Dolby” and the double-D symbol
trademarks of Dolby Laboratories.
This TV incorporates High-
™
(HDMI
) technology. HDMI, the HDMI logo and HighDefinition Multimedia Interface are trademarks or
registered trademarks of HDMI Licensing LLC.
x
,
Macintosh is a trademark licensed to Apple Computer, Inc.,
registered in the U.S.A and other countries.
Definition Multimedia Interface
Design and specifi cations are subject to change without notice.
in
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)
KDF-46E300 - approximately 46 inches
KDF-50E300 - approximately 50 inches
Antenna
75-ohm external antenna terminal for VHF/UHF
Projection System
3 LCD Panels, 1 lens projection system
LCD Panel System
LCD (Liquid Crystal Display) Panel
KDF-46E3000/50E3000
LCD Panel
0.73 inch TFT LCD panel (1,280 x 720 pixels)
Projection Lens
High Performance, large diameter hybrid lens F2.4
Lamp
100W, XL-2500 Ultra High Pressure Lamp
Supplied Accessories
Remote Commander RM-YD016
Two Size AA (R6) Batteries
Operating Instructions
Quick Setup Guide
Warranty Card
Online Registration Card
Optional Accessories
Connecting Cables
Lamp
XL-2500 Ultra High Pressure Lamp
TV Stand
SU-RG13M (for both models)
KDF-46E3000/50E3000
5
KDF-46E3000/50E3000
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.
CARRYING THE TV
Carrying the TV requires at least two people. Do not hold
by the pedestal or the front panel of the TV. Doing so may
cause these parts to break off.
When moving the TV, place one hand in the hole on the
lower portion of the TV while grasping the top with the other
hand, as shown in the illustration below.
Do not grasp the
pedestal or the front
panel of the TV.
If you have connected cables and cords, be sure to
unplug them before moving the TV.
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.
TRANSPORTER LE TÉLÉVISEUR
Le transport du téléviseur doit être effectué par au
moins deux personnes. Ne tenez pas le téléviseur
par son socle ni par le panneau avant. Ces pièces
risqueraient de se détacher.
Lorsque vous déplacez le téléviseur, placez une
main dans l’orifice de la partie inférieure du
téléviseur tout en tenant la partie supérieure de
l’autre main, comme illustré ci-dessous.
Ne tenez pas le
téléviseur pa r son soc le
ni par le panneau avant.
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.
Si vous avez branché les câbles et les cordons
d’alimentation, veillez à les débrancher avant de
déplacer le téléviseur.
! 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-46E3000/50E3000
6
SAFETY CHECK-OUT
KDF-46E3000/50E3000
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 μF
Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.
KDF-46E3000/50E3000
Earth Ground
AC
Voltmeter
(0.75V)
Trouble Light
AC Outlet Box
Ohmmeter
Cold-water Pipe
7
KDF-46E3000/50E3000
SELF-DIAGNOSTIC FUNCTION
The units in this manual contain a self-diagnostic function. If an error occurs, the POWER/STANDBY 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 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 will fl ash a set number of times to indicate the possible cause of the problem. If there is more than
one error, the POWER/STANDBY 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”.)
Self Diagnosis
Supported model
Number of times
LED indicator
flashes Diagnosis Item Probable Cause
Lamp not seated properly
1 Lamp Error
(Note: The lamp LED will flash red when
this error occurs, not the Power LED)
2 OVP 10.5V is high on B Board
3 LowB Error 10.5V is low on B Board
4 Not Used in this model
5 HV Detect Ballast is not working
6 Lamp Cover/ Lamp Position The Lamp cover is not closed securely.
7 Temp Error High Temperature or sensor connection
8 Audio Error DC error on U Board
9 Fan Error Fan is not working properly
DISPLAY OF POWER/STANDBY OR LAMP LED FLASH COUNT
Screen
TIMER LAMP POWER
Flashes red for Lamp error
TIMER LAMP POWER
Flashes red for all except Lamp error
- 4 Flash is not used for self-diagnosis
-Example
Diagnosis
LowB Error
Number of times LED Flashes
LED OFF
3.0sec
3 times
Lamp Cover 6 times
KDF-46E3000/50E3000
LED ON : 0.3sec
LED OFF : 0.3sec
LED OFF
3.0sec
8
KDF-46E3000/50E3000
RELEASING THE POWER/STANDBY LED FLASH
Unplug the power cord from the outlet to temporarily stop the POWER/STANDBY lamp from fl ashing.
Self-Diagnostic Screen Display
For failures that are diffi cult to reproduce, or accompany occasional power off and/or picture mute, the Self-Diagnostic screen display is useful to
specify the cause.
VIEWING THE SELF-DIAGNOSTIC SCREEN
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
NOTE: This differs from the method of accessing service mode which is Volume
Sample Self-Diagnostic Screen Display
Channel
1 : LAMP_ERR 0
2 : OVP 0
3 : LowB-ERROR 0
5:
6:
7 : TEMP-ERROR
8 : AUDIO-ERROR 0
9 : FAN-ERROR 0
5
Volume -
SELF CHECK
HV DETECT
LAMP_COVER 1
0
0
POWER
+
"1" is displayed when an error is detected one or more times
"0" is displayed when no error has been detected
Name: KDF-37H1000
Serial: XXXXXXXXXX
NOTE: To refresh the Self Check menu when all the items are not displayed, press
3. Proceed to Viewing the Self-Diagnostic Errors.
JUMP
on the Remote Commander.
CLEARING THE SELF-DIAGNOSTIC SCREEN
The self-diagnostic results displayed on the screen are not cleared automatically, therefore you should always check the self-diagnostic screen during
repairs. When you have completed the repairs, clear the self-diagnostic screen to reset the results to “0”.
Note: The self-diagnostic function will not be able to detect any subsequent faults after completion of the repairs unless the Self-Diagnostic
result display is cleared to reset the results to “0”.
1. If the Self-Diagnostic screen is already displayed, proceed to step 3. If not, Power off (Set to Standby mode).
2. Press
3. Press Channel 8
The status resets to 0.
4. To exit the Self-Diagnostic screen, turn the power off.
DISPLAY
Channel
0
5
Volume -
POWER
KDF-46E3000/50E3000
9
1-1. OVERVIEW
TOOLS NEEDED
Long Phillips Screwdriver
Needle Nose Pliers
Small Flathead Screwdriver or Jewelers Screwdriver
The connectors in this chassis have been redesigned to ensure they are securely fasten to the boards. Please review the illustrations below.
Use caution not to rock the Type 2 or Type 3 connectors when removing or reinstalling to avoid breaking the solder leads off the
Printed Circuit Boards.
KDF-46E3000/50E3000
SECTION 1: DISASSEMBLY
TYPE 1
LIFT ONE SIDE AT A TIME
BY PUSHING TAB IN WITH
SMALL SCREWDRIVER
TYPE 2
SQUEEZE DOWN ON
TAB TO RELEASE
TYPE 3
SQUEEZE LOCKING TAB
TOWARDS CONNECTO R
BEFORE PULLING FREE
CAUTION! IF THE TYPE 2 FEMALE
CONNECTOR HAS A SLOT (AS SHOWN)
MAKE SURE THE LOCK TAB SEATS INSIDE
THIS SLOT.
KDF-46E3000/50E3000
10
1-2. LAMP REMOVAL
For detailed instructions, refer to “Replacing the Lamp” in the Appendix section of this manual
1
Remove the Lamp Door and the Lamp Cover.
2
Disconnect the Lamp Block Assembly by pulling
it out of the Power Supply.
KDF-46E3000/50E3000
Lamp Door
Lamp Block Assembly
XL-2500
2
Lamp Cover
1
KDF-46E3000/50E3000
11
KDF-46E3000/50E3000
1-3. POWER SUPPLY (BALLAST UNIT) REMOVAL
1
Remove 1 screw (+BVTP2 4x16) from the Power Supply (Ballast Unit Lead Cover)
2
Slide out the Ballast Bracket.
3
Release the connector wire from the Bracket
4
Rotate the Bracket.
5
Disconnect 2 connectors
6
Remove 1 screw (+BVTP 3x12 TYPE2 IT-3) from the Power Supply (Ballast Unit)
Ballast Bracket (E)
Ballast Lead Cover
3
1
Power Supply
(Ballast Unit)
2
4
5
6
KDF-46E3000/50E3000
12
1-4. HAE BOARD REMOVAL
1
Remove 2 screws for 46” model, 3 screws for 50” model, +BVTP2 4x16
2
Disconnect a connector from HAE board
3
Remove 2 screws for HAE board removal, +BVTP 3x12 TYPE2
Side Control Bracket
KDF-46E3000/50E3000
HAE Board
2
1-5. HCE BOARD REMOVAL
1
Remove 2 screws for 46” model, 3 screws for 50” model, +BVTP2 4x16
2
Disconnect a connector from HCE board
3
Remove 2 screws for HCE board removal, +BVTP 3x12 TYPE2
3
1
3
2
Side Terminal Bracket
KDF-46E3000/50E3000
HCE Board
1
13
1-6. ORNAMENTAL COVER, SCREEN FRAME, AND LIGHT GUIDE REMOVAL
☛
All of the components of this model can be reached by removing the Screen Frame Assembly from the Rear Cover.
Remove the Side Control Bracket and the Side Terminal Bracket before proceeding. (See 1-4. HAE Board Removal and
1-5. HCE Board Removal.
Caution:
When removing the Rear Cover or the Screen Frame
to remove any dust particles.
1
Remove 20 screws from the Rear Cabinet to release the Screen Frame, +BVTP2 4x16
2
Slide Ornamental Cover to right and pop off from Screen Frame.
3
Remove 3 screws from Screen Frame, +BVTP2 4x16
A
The Light Guide is not included with the Ornamental Cover. When replacing the Ornamental Cover remove 1 screw from
Light Guide, +BVTP 3x12 TYPE2 IT-.
Assembly
, be sure to clean the mirror and Diffusion Plate(s)
KDF-46E3000/50E3000
Rear Cabinet
Screen Frame
3
2
A
Light Guide
1
Ornamental Cover
1
Screen Frame
KDF-46E3000/50E3000
Rear Cabinet
14
1-7. DIFFUSION PLATES AND SCREEN FRAME REMOVAL
Caution:
When replacing the Diffusion Plates be sure to remove any dust particles.
1
Remove 5 screws(Top Holder), 6 screws(Bottom Holder) and 3 screws from each side holders, total 17 screws, +BVTP2 4x16
Screen Frame
KDF-46E3000/50E3000
1
Diffusion Plates
1-7-1. DIFFUSION PLATES (SCREENS) TAPE METHOD
Note:
The following diaglam illustrate the taping method when replacing the diffusion Plates.
For Part Numbers refer to the Explode view section of this manual.
Black Acetate Tape
Diffusion Plate
(Lenticular - Front side)
Screen Holder
Diffusion Plate
(Frensnel - Rear side)
KDF-46E3000/50E3000
15
1-8. SEPARATOR, SPEAKER, AND HBE BOARD REMOVAL
1
Remove 9 screws from Separator, +BVTP2 4x16
2
Release connector wires from hook
3
Disconnect joint connectors from HB board
4
Disconnect joint connectors from Speakers
5
Lift tabs and slide out Separator unit.
6
Remove 4 screws from speakers, +BWTP2 4x16
7
Remove 2 screws for HB board removal, +BVTP 3x12 TYPE2 IT-3
KDF-46E3000/50E3000
Rear Cabinet
1
3
4
Separator
2
7
HBE Board
5
5
Speaker
6
KDF-46E3000/50E3000
16
1-9. LAMP DUCT REMOVAL
1
Remove 3 screws, +BVTP 3x10 TYPE2 IT-3, connecting the Lamp Duct to the Rear Cover (from the bottom of the Lamp Duct)
2
Disconnect 4 connector joints (not shown)
3
Remove Duct unit from rear cabinet.
4
Slide out Fuse unit from Lamp Duct, locating it inside of the duct.
5
Remove one screw, +BVTP 3x12 TYPE2 IT-3
6
Remove fan from Lamp Duct and take Fan cushions off from fan
7
Remove one screw, +BVTP 3x12 TYPE2 IT-3
Note: To remove each duct, lift tabs gently and release from hooks.
KDF-46E3000/50E3000
4
Lamp Duct (EA)
2
1
Fuse Holder
SE Board
Fuse Sheet
4
Fuse Plate
2P Connector
(Thermal Fuse)
5
6
Fan Cushion
Fan
7
TE Board
3
Rear Cabinet
KDF-46E3000/50E3000
Lamp Duct (EB)
Lamp Duct (EC)
17
1-10. OPTICAL UNIT BLOCK REMOVAL
Caution:
When replacing the Optics Unit Block Assembly be sure to remove any dust particles.
1
Remove 2 screws, +PSW M4x12
Note: The connectors are not included with the optical block assembly.
Optical Unit Block
KDF-46E3000/50E3000
1
Optical Unit
Bracket
Main Plate Holder
Main Plate
KDF-46E3000/50E3000
18
1-11. CHASSIS REMOVAL
Caution: When replacing any part of the chassis be sure to remove any dust particles and clean the mirror.
1
Disconnect 9 connectors from G board
2
Disconnect a lead wire connector from B board
3
Disconnect 2 connectors from B board
4
Remove 1 screw, +BVTP 3x12 TYPE2 IT-3, from Fan Bracket
5
Remove 2 screws, +BVTP2 4x16
6
Remove one screw, +BVTP 3x12 TYPE2 IT-3
7
Remove 3 screws, +PSW M3X8
8
Remove 6 screws, +BVTP 3x12 TYPE2 IT-3
9
Disconnect 4 connectors from U board
10
Remove 2 screws, SPECIAL (+PW 4X30)
11
Remove 2 screws, +PSW M3X8
12
Remove 2 screws, +BVTP 3x12 TYPE2 IT-3
13
Remove 1 nut from tuner
1
KDF-46E3000/50E3000
G Board
8
G Bracket
7
2
6
B-Shield
10
9
B Board
11
12
13
Terminal
Bracket
U Board
4
3
5
KDF-46E3000/50E3000
Rear Cabinet
Main Base
19
1-12. MIRROR REPLACEMENT
CAUTION
1
Replace mirror by laying fl at and face-up position.
2
Holder screws should be tighten from center to outer screw positions.
KDF-46E3000/50E3000
KDF-46E3000/50E3000
20
WIRE DRESSING
COMPLETE INTERNAL WIRE DRESSING
KDF-46E3000/50E3000
KDF-46E3000/50E3000
21
r
r
A
OVERALL ASSEMBLY
KDF-46E3000/50E3000
fter installing Optical Block route
HARNESS ASSY into clips behind TOP
BRACKET, OPT (E)
Install 8P connector
from [CE] to [BE]
Install 3P Fan Connector
from Optical Block to
HARNESS ASSY
Install 15P connecto
Install 15P connecto
from [CE] to [G]
from [CE] to [G]
Dress 15P Connector
Dress 15P Connector
to wire pin on [G]
to wire pin on [G]
Dress 3P Fan Connector to
clips on TOP BRACKET,
OPT(E) as shown
Install 20P and 9P connector
from Duct Block Assy to [G]
Dress LVDS connector to
on Main Brkt
Install LVDS connector
from [CE] to [BE]
KDF-46E3000/50E3000
clips
22
OVERALL ASSEMBLY (CONTINUED)
Dress 8P connector from [BE] to clips on Main Brkt.
RED Tape should line up with clips. This connector
should be on top of LVDS Connector
Dress 8P connector to clip
under LVDS connector
KDF-46E3000/50E3000
Install Ferrite Clamp
(146908911) to HARNESS
ASSY as shown.
CRITICAL FOR EMI
Secure HARNESS ASSY
with 20 X 40 HIMELON tape
Secure Ballast Power with 20 X 40
HIMELON tape as shown
Route Ballast Power as shown and
install to wire holders
Route 4P Speaker and 9P HAE connector
as shown before installing Seperator Blk
Install Ballast Power to [G], install Ferrite Clamp
(146908911) and dress to wire pin on [G] as shown.
Ferrite Clamp must be vertical and
as close to Connector as possible
After installing Separator Blk Assy ensure
4P and 9P Connetor are not pinched
between Rear cover and Separator
CRITICAL FOR EMI
KDF-46E3000/50E3000
23
SPEAKER ASSEMBLY
Connect 4P Speaker and 9P HAE
connector as shown .
KDF-46E3000/50E3000
Dress 4P Speaker and 9P HAE connector
to wire holders on Separator Blk Assy
KDF-46E3000/50E3000
24
OPTICAL BLOCK ASSEMBLY
191003656
Harness Assy
KDF-46E3000/50E3000
Dress 191003656 to (3) Wire
Holders on CE Block
183411811 LVDS
Connector Assy
191003666
CONN ASSY, 8P 200
8P connector should be
below LVDS
Dress to (2) wire
holders as shown
Dress to (3) Wire
Holders on CE Block
Place wire into channel in Optical Blk.
Line up edge with tape on 8P Connector
Secure 8P Connector with 20 X 40 Himelon Tape 265206401
KDF-46E3000/50E3000
25
A
DUCT BLOCK ASSEMBLY
KDF-46E3000/50E3000
191002827
CONNECTOR ASSY 2P
fter installing 7P
Conn assy Secure to
Ballast Bracket with
20 X 40 Himelon
Tape 265206401 as
Shown. This is to
avoid it from hitting
Capacitor on ballast
5P Connector should be
under 2P Connector
191003664
CONN ASSY, 5P SMR 60
191003658
CONN ASSY, 7P 455
[T] Board
191003517
CONN ASSY 3P, SMR
191003659
CONN ASSY, 3P VH1120
Route Duct Blk Fan
toward [T] as shown
Use Caution when installing Duct block that 5P
and 2P Connectors are not pinched
191003658
CONN ASSY, 7P 455
Connector should be
routed outside of post
Secure Both Connectors to hooks on Ballast bracket and
ensure Ferrite core is placed in rib as shown
Rib
Hooks
KDF-46E3000/50E3000
After Installing Ballast Bracket route wires through
openings in Duct Block as shown.
26
DUCT BLOCK ASSEMBLY (CONTINUED)
KDF-46E3000/50E3000
Install Ballast Power in Clip on bottom of Duct Block.
Wire should be routed with RED tape in this position
191003657
HARNESS ASSY
Install Ballast Power to Clip and secure with Himelon
Tape 20 X 40. Tape should be centered between clips
Himelon Tape
Clips
191003657
HARNESS ASSY
Connect 9P Ballast Control Connector and
2P Thermal Fuse Connector from
HARNESS ASSY 191003657
Route 3P Fan and 3P
[S] connector to clip on
top of Duct Blk.
Route 2P Thermal fuse
and wire holder.
to clip
Secure Harness Assy, 2P Thermal fuse,4P [HAE], and 9P
Ballast control connector to wire holders as shown.
NOTE: Ensure 9P Connector is routed as shown
Wire Holders
KDF-46E3000/50E3000
Route HARNESS ASSY
191003657 to Clip on
Duct Block.
Route 4P [HAE]
Connector through
Opening in Rear Cover
27
A
r
b
CHASSIS ASSEMBLY
KDF-46E3000/50E3000
fter installing Fan Secure wire with 20 X
40 Himelon Tape as shown.
Lighting ground should be behind AC cord. UL Tube should be
located on [G] board side of connection as shown below
WIRE ASSY, FASTON TERMINAL
191003511
191003507
Dress 3P Chassis Fan Connector to WIRE PIN on [G] as shown
Before Installing [G] Board it may be necessa
bend tab slightly in order to properly install [G]
191003667
CONN ASSY, 4P
SPEAKER SMR
Dress 4P Speaker
Connector to (2) Clips
on Main Bracket
191003508
CONN ASSY, 3P VH 130
KDF-46E3000/50E3000
28
CHASSIS ASSEMBLY (CONTINUED)
KDF-46E3000/50E3000
191003507
CONN ASSY, 40P
Dress 40P Connector to WIRE PIN on [G]
191003660
CONN ASSY, 9P
ZMR 500
KDF-46E3000/50E3000
29
HCE BLOCK ASSEMBLY
KDF-46E3000/50E3000
HARNESS ASSY MUST BE INSTALLED BEFORE
PUTTING INTO HC BRACKET
191003665
HARNESS ASSY
Route HARNESS ASSY THROUGH
OPENING IN THE REAR COVER
Dress to wire holder installed on HCE Board.
Ensure connector is routed so that it does not go
above red line shown above.
Install on [U] board as shown. Connector
should be above 3P Connector
Dress to wire holder
on FAN BRACKET
Dress to Wire Holder on Terminal Bracket.
46" Models must be looped to take up excess slack
50" Models DO NOT need to be looped
KDF-46E3000/50E3000
Correct Routing
of HC wire
30
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