Sony kdfe55a20 schematic
HISTORY INFORMATION FOR THE FOLLOWING MANUAL:
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDF-E55A20
KDF-E60A20
RM-YD002 US/CND/MEXICO
RM-YD002 US/CND/MEXICO
LA-3
CHASSIS
ORIGINAL MANUAL ISSUE DATE: 6/2005
:UPDATED ITEM
☛
REVISION DATE SUBJECT
6/2005 No revisions or updates are applicable at this time.
6/2005 Corrected Exploded View section to show only one PN for Power Supply Block and
replaced PN for Lamp with PN for Lamp Block Assembly (Replace Pg. 71 with Pg. 71)
Removed PN for Lamp (Replace Pg. 110 with Pg. 110)
LCD PROJECTION TELEVISION
9-965-984-02
Self Diagnosis
Supported model
SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION
KDF-E55A20
KDF-E60A20
RM-YD002 US/CND/MEXICO
RM-YD002 US/CND/MEXICO
LA-3
CHASSIS
9-965-984-02
KDF-E55A20 RM-YD002
LCD PROJECTION TELEVISION
KDF-E55A20/E60A20
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. OU Bracket Removal ........................................................... 13
1-3. Chassis Assembly and fan Removal ................................... 14
1-4. Service Position ................................................................... 14
1-5. RF Antenna Switch Removal ............................................... 15
1-6. U1 Board and H4 Board Removal ........................................ 15
1-7. GM Board Removal .............................................................. 16
1-8. A1 Board and KD Board Removal ....................................... 16
1-9. DMB Assembly (Q Box) and B1 Board Removal ................. 17
1-10. GI Board Removal ................................................................ 17
1-11. Fan and T Board Removal ................................................... 18
1-12. H1 Board Removal ............................................................... 18
1-13. Front Cover Assembly Removal ........................................... 19
1-13-1. Replacing the Lamp ................................................. 19
1-14. Power Supply Block Removal (Lamp Drive Unit) ................. 19
1-15. Optics Unit Block Assembly Fan Removal .......................... 20
1-16. H2 Board, H3 Board, and H5 Board Removal ..................... 20
1-17. Screen Mirror Block Assembly Removal .............................. 21
1-18. Speaker Removal ................................................................. 21
Wire Dressing ............................................................................... 22
SECTION 2: CIRCUIT ADJUSTMENTS .............................................. 33
2-1. Remote Adjustment Buttons and Indicators ......................... 33
2-2. Accessing the Service Adjustment Mode ............................. 33
2-3. Changing Service Adjustment Mode Memory ...................... 33
2-4. Memory Write Confi rmation Method .................................... 34
2-5. H/V Center Confi rmation and Adjustments .......................... 35
2-6. Adjusting On Screen Display (OSD) Position ...................... 36
2-7. Service Data ......................................................................... 37
SECTION 3: DIAGRAMS ..................................................................... 39
3-1. Circuit Boards Location ........................................................ 39
3-2. Printed Wiring Boards and
Schematic Diagrams Information ......................................... 39
3-3. Signal Flow Block Diagram .................................................. 41
3-3. Schematics and Supporting Information .............................. 42
A1 Board Schematic Diagram (1 of 2) ................................. 42
A1 Board Schematic Diagram (2 of 2) ................................. 43
B1 Board Schematic Diagram (1 of 5) ................................. 45
B1 Board Schematic Diagram (2 of 5) ................................. 46
B1 Board Schematic Diagram (3 of 5) ................................. 47
B1 Board Schematic Diagram (4 of 5) ................................. 48
B1 Board Schematic Diagram (5 of 5) ................................. 49
GM Board Schematic Diagram ............................................ 52
KD Board Schematic Diagram ............................................. 55
GI Board Schematic Diagram (1 of 2) .................................. 57
GI Board Schematic Diagram (2 of 2) .................................. 58
H1 Board Schematic Diagram .............................................. 61
H2 Board Schematic Diagram .............................................. 63
H3 Board Schematic Diagram .............................................. 65
H4 Board Schematic Diagram .............................................. 66
H5 Board Schematic Diagram .............................................. 66
T Board Schematic Diagram ................................................ 67
U1 Board Schematic Diagram .............................................. 67
3-4. Semiconductors ................................................................... 69
SECTION 4: EXPLODED VIEWS ........................................................ 70
4-1. Cover .................................................................................... 70
4-2. Bottom Cabinet .................................................................... 71
4-3. Chassis ................................................................................ 72
SECTION 5: ELECTRICAL PARTS LIST ........................................... 73
KDF-E55A20/E60A20
3
SPECIFICATIONS
y
KDF-E55A20/E60A20
Power Requirements
Power Consumption (W)
In Use (Max)
In Standby
Inputs/Outputs
120V AC, 60Hz
265W
Less than 15W
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)
3 total (1 on front panel)
1Vp-p, 75ohms unbalanced, sync negative
S Video (IN)
3 total (1 on front panel)
Y: 1Vp-p, 75ohms unbalanced, sync negative
C: 0.286Vp-p (Burst signal), 75ohms
Audio (IN)
6 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.
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-E55A20 KDF-E60A20
Speaker Output (W)
Dimensions (W x H x D)
mm 1,456 x 943 x 491 mm 1,574 x 1,005 x 518 mm
3/8
57
in
x 37
Mass
kg 42 kg 46.1 kg
lbs 92 lbs 5 oz 101 lbs 5 oz
Trademark Information
As an ENERGY STAR® Partner, Sony
Corporation has determined that this product
meets the ENERGY STAR
energy efficiency.
®
is a U.S. registered mark.
CableCARD
ENERGY STAR
™
is a trademark of Cable Television
Laboratories, Inc.
TruSurround XT, SRS and the ( )
trademarks of SRS Labs, Inc. TruSurround XT
technology is incorporated under license from SRS Labs,
Inc.
®
guidelines for
®
symbol are
12W (L), 12W (R)
1/4
x 19
3/8
in 62 x 39
5/8
x 20
1/2
in
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.
This TV is manufactured under
license from Dolby Laboratories.
Dolby and the double-D symbol are
trademarks of Dolby Laboratories.
This TV incorporates HighDefinition Multimedia Interface
(HDMI
™
) technology. HDMI, the HDMI logo and HighDefinition Multimedia Interface are trademarks or
registered trademarks of HDMI Licensing LLC.
WEGA, Grand WEGA, WEGA GATE, Steady Sound,
Digital Reality Creation, CineMotion, PlayStation, and
BN Smoother are trademarks of Son
Corporation.
KDF-E55A20/E60A20
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-E55A20 Only)
60 inches (KDF-E60A20 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-E55A20/E60A20
Lamp
132W, XL-2200
Supplied Accessories
Remote Commander RM-YD002
Two Size AA (R6) Batteries
Optional Accessories
HDMI Cable
Component Video Cable
S VIDEO Cable
A/V Cable
Audio Cable
Optical Cable
TV Stand: SU-GW12
Lamp: 132W, XL-2200
KDF-E55A20/E60A20
5
KDF-E55A20/E60A20
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-E55A20/E60A20
6
SAFETY CHECK-OUT
KDF-E55A20/E60A20
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).
0.15 F
Figure A. Using an AC voltmeter to check AC leakage. Figure B. Checking for earth ground.
KDF-E55A20/E60A20
To Exposed Metal
Parts on Set
Earth Ground
AC
Voltmeter
(0.75V)
Trouble Light
AC Outlet Box
Ohmmeter
Cold-water Pipe
7
KDF-E55A20/E60A20
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 fastened 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 (GM board) - No picture/No sound
Audio error 7 times
D-OVP error 8 times
ATSC-OVP error 10 times - No "Q5V " output (GM board, GI board) - No picture/No sound
Lamp error LAMP-LED is ON. - Lamp is dead - No picture/No sound
Number of times
STANDBY or
LAMP LED lam
Probable Cause Detected Symptoms
- Fan1-4 Power is not supplied.
(GI board)
- Fan connector is not seated securely.
- Fan caught wires or harnesses.
- Internal temperature is too high.
- IIC-E line connector(H4 board)
is not seated properly.
- Short-circuit of Audio power supply line
(KD board, GM board)
- Blowout of a fuse
(PS4702,PS4703 on KD board)
- IC failure
(IC4703,IC4708,IC4710 on KD board)
- Overvoltage of +3.3V or +2.5V
(A board, B board)
- No picture/No sound
- No picture/No sound
- No picture/No sound
- No picture/No sound
KDF-E55A20/E60A20
8
Display of POWER/STANDBY or LAMP LED Flash Count
Screen
LAMP TIMER POWER
KDF-E55A20/E60A20
POWER
Projection lamp
Indicators
- Oneflashis notusedfor 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
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-E55A20/E60A20
9
KDF-E55A20/E60A20
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 mode).
2. Press
3. Press Channel 8
DISPLAY
Channel
ENT
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 H4 board detects high temperature, or IIC-E line connector
(CN6022:GI board, CN44:H3board/H4board) is not seated securely, the DE-micro turns off the
lamp.
5 : Lamp driver When the "LAMP-PROT" (pin 95 IC6902) is low, the lamp is not turned on. If the "LAMP-HV-
DET" (pin 96 IC6902) is low at the same time, it is classified as no high voltage of the lamp
6 : Low B error When no "SETIIV " is detected, pin 129 of IC3002 is low and it turns off the main power.
driver.
7 : Audio When DC voltage is detected at the speaker or woofer outputs, pin 128 of IC3002 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 IC3002 is low and it turns off the
10 : DTL-OVP When no "Q 5V" is detected, pin 127 of IC3002 is low and it turns off the main power.
main power.
LAMP : Lamp When the "LAMP-PROT" (pin 95 IC6902) is low, the lamp is not turned on. If the
"LAMP-HV-DET" (pin96 IC6902) is high at the same time, it is classified as no lamp or a dead
lamp.
POWER
KDF-E55A20/E60A20
10
Self-Diagnosis Block Diagram
H4 board
IC41
Te m p
4:Temp
sensor
GI board
IC6902
Display Engine u-com
FAN PROT
IIC-E
LAMP-COVER
LAMP-PROT
LAMP-HV-DET
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
KDF-E55A20/E60A20
Lamp
KD board
Audio
amp
GM board
+3.3V
+2.5V
GM board
SETIIV
Q5V
7:Audio
8:D-OVP
6:LowB
error
CN6029
23
CN1609
A14
CN1609
B14
CN6006
5
IIC-TV
CN6019
A8
A14
B14
CN6017
16
12:DTL
OVP
B1 board
IC3002 TV u-com
IIC-TV
SP_DC_PROT
128
126
D_OVP
LB_ERROR
129
127
ATSC_OVP
KDF-E55A20/E60A20
11
Reading Lamp and Panel time
Use the following to determine the lamp and panel time of a set.
Screen Display Method
To access service mode, press the buttons on the Remote Commander sequentially, in rapid succession, as shown below:
KDF-E55A20/E60A20
1. Press
2. Press
3. To display the Lamp time, press 2 until the OPTION_E category displays.
4. The LampTM is the fi rst item in the OPTION_E category.
(If the LampTM item is not displayed, press 1 until the LampTM item displays.)
DISPLAY
JUMP
Channel
until the PANEL service menu displays.
5
Volume +
POWER
Category
exam
ple
PANEL NVM OK 9 OPTION_E
0 LAMP 0 Diff 1
Item
The screen displays:
“Total lamp time is 14 hours” and “Total lamp ON/OFF cycle is 71 times”
NOTE: If replacing the lamp, reset the lamp time by pressing Channel
WRI-EXE(Character color is Red) is momemtarily displayed and LampTM is reset to “0”.
5. To display the Panel time, press 1 until the PanelTM item displays.
LampTM LampCT14 71
Hours
On/Off Cycle
3
Mute
ENT
.
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-E55A20/E60A20
12
1-1. REAR COVER REMOVAL
KDF-E55A20/E60A20
SECTION 1: DISASSEMBLY
Rear cover
1-2. OU BRACKET REMOVAL
1
Thirteen screws
(+BVTP 4x16)
OU bracket
6
One Screw
4
1
(+BVTP 4x16)
2
Tw o screws
(+BVTP 4x16)
5
Three ground wires
KDF-E55A20/E60A20
3
Two screws
(+BVTP 4x16)
13
1-3. CHASSIS ASSEMBLY AND FAN REMOVAL
3
Chassis assembly
4
1
Screw
(+BVTP 4x16)
Side stay (R)
2
Fan bracket (chassis)
6
with DC fan
5
Three screws
(+PTPWH 4x16)
KDF-E55A20/E60A20
1-4. SERVICE POSITION
Chassis assembly
Pull back on claw, then gently pull out chassis assembly
1
KDF-E55A20/E60A20
14
1-5. RF ANTENNA SWITCH REMOVAL
KDF-E55A20/E60A20
Unplug five connectors
4
Four Screws (+BVTP 3x12)
2
U bracket
Push down on tab to release bracket
3
5
RF antenna switch
Two Washers
1
Three Screws (M3x8) P, SW(+)
2
1-6. U1 BOARD AND H4 BOARD REMOVAL
Gently pull back on tab to
release U1 board
One screw
(+BVTP 3X12)
2
3
Gently pull back on tabs
to release H4 board
1
U1 board
KDF-E55A20/E60A20
15
1-7. GM BOARD REMOVAL
KDF-E55A20/E60A20
Disconnect three connectors
(CN1611, CN1608 & CN1612)
Disconnect three ground wires
(CN1603, CN1604 and CN1605)
2
Claw
6
GM board
1
Disconnect the Power cord
from CN1602 connector.
4
8
9
Gently pull back on the three clips
on the pin connection slots
while slowly lifting the GM board.
5
Remove wires from purse locks
Unfasten two Circuit Board Supports
1-8. A1 BOARD AND KD BOARD REMOVAL
Disconnect two connectors
(CN4705 and CN4702)
Unfasten two Circuit Board Supports
Disconnect two connectors
(CN8003 and CN8008)
and coax cable from tuner
Gently pull back
on the three clips
on the Pin Connection slots
while slowly lifting the A board
Remove cables
from purse locks
4
3
1
6
2
A1 board
KD board
Gently pull back
5
on the two clips
on the Pin Connection slots
while slowly lifting the KD board
KDF-E55A20/E60A20
16
1-9. DMB ASSEMBLY (Q BOX) AND B1 BOARD REMOVAL
KDF-E55A20/E60A20
Disconnect two connectors
and one ground wire
Unplug two coax cables
connected to the antenna switch
Remove four screws
(+BVTP 3X12)
6
Remove two screws
5
(+BVTP 3X12 TYPE2)
7
DMB Box Assembly
Remove one screw
3
9
(3X12), + BVWHTP
Remove two connectors
2
(CN3500 and CN3501)
1
Remove cables from purse locks
B1 board
Gently pull back
4
on the two clips
on the Pin Connection slots
while slowly lifting the B1 board
1-10. GI BOARD REMOVAL
Disconnect 1 ground wire
(CN6018)
Gently pull back on the two clips
while slowly lifting the GI Board.
Disconnect 5 connectors
(CN6000, CN6028,
CN6021, CN6023,
and CN6022)
1
3
2
GI board
4
KDF-E55A20/E60A20
17
1-11. FAN AND T BOARD REMOVAL
2
T board
Screw
3
(+BVTP 3x12)
Duct fan bracket
with DC fan
1
KDF-E55A20/E60A20
Screw
(+BVTP 4x16)
1-12. H1 BOARD REMOVAL
Disconnect one connector
KDF-E55A20/E60A20
3
Screen mirror block assembly
H1 board
H1 button
H1 board
H1 bracket
Gently pull back on the bottom tab
4
of the H1 bracket then slide out the H1 board
One screw
2
(+BVTP 3X12)
1
Using tweezers gently detach the
H1 Bracket Cap
18
1-13. FRONT COVER ASSEMBLY REMOVAL
Be sure the Front Input door is closed before removing the Front Cover Assembly.
Two screws
(+BVTP 3X12 TYPE2)
KDF-E55A20/E60A20
1 Remove the two ornamental screws from back of set
Cable Cover
Gently pull the
Front cover assembly forward.
Note the area of the 2 magnets
holding the cover
2
4
Push towards center of set to unlatch
3
One screw
(+BVTP 3X12)
1-13-1. REPLACING THE LAMP
For detailed instructions on replacing the lamp, see Page 76 of the Operating Instructions manual.
1-14. POWER SUPPLY BLOCK REMOVAL (LAMP DRIVE UNIT)
Use caution when removing the Power Supply Block to not move the Optical Unit Block
NOTE: Do not discard the Plug Holder Assembly
when replacing the Power Supply block.
This part is not included with the
Power Supply assembly.
One screw (+PWH 4x16)
3
(to detach the Plug Holder Assembly from the
Lamp Bracket)
4
Two screws (+PWH 4x16)
(to release the cables from the bracket)
Power supply block
Four screws (+BVTP 3x12)
Pull forward to remove
1
Remove the lamp
Unhook the antenna cable
7
5
6
KDF-E55A20/E60A20
2
Disconnect two connectors
19
1-15. OPTICS UNIT BLOCK ASSEMBLY FAN REMOVAL
Remove three screws
3
(+BVTP 3X12)
2
1
Two screws
Optics Unit block assembly
(with power supply block)
KDF-E55A20/E60A20
NOTE: Do not discard the Plug Holder Assembly
when replacing the Optics Unit block assembly.
This part is not included with the
Optics Unit block assembly.
1-16. H2 BOARD, H3 BOARD, AND H5 BOARD REMOVAL
10
11
One screw
(+BVTP 3x12)
2
1
3
H2 board
disconnect one connector
Two screws
(+BVTP 3X12 TYPE2)
Push H3 Door
open to remove
Two screws
(+BVTP 3X12 TYPE2)
Remove H3 Bracket (R)
Disconnect one connector
(CN4502)
Push H3 Board back
to release and
9
8
Two screws
(+BVTP 3X12 TYPE2)
Remove two screws
5
(+BVTP 3X10)
Disconnect
6
one connector
H5 board
7
(CN7301)
Lift the H5 board up
KDF-E55A20/E60A20
4
Two screws
(+BVTP 3X12 TYPE2)
20
1-17. SCREEN MIRROR BLOCK ASSEMBLY REMOVAL
Caution:
When repairing anything inside the Screen Mirror Block Assembly be sure to clean the mirror and Diffusion Plate(s)
to remove any dust particles.
Remove sixteen screws
5
(+BVTP 4X16)
TIP: The Mirror Cover assembly is securely fasten
to the Screen Frame assembly. To ease removal,
Mirror Cover assembly
Pull left side of
Screen Frame assembly
away from Mirror Cover assembly
Screen Frame assembly
6
leave screws to secure the top right side of the
Screen Frame while pulling the left side of the screen
away from the Mirror Cover. Replace the Screen Frame,
then remove the last two screws, then while securing
the left side of the Screen Frame with your hand,
pull the right side of the Screen Frame away
from the Mirror Cover.
KDF-E55A20/E60A20
4
Four screws
(+BVTP 4x16)
3
Four screws
(+BVTP 4x16)
1-18. SPEAKER REMOVAL
2
Remove four screws
(+BVTP 4X16)
1
Remove chassis and large fan
from the inside the Rear Cover to
disconnect five connectors
7
Pull right side of
Screen Frame assembly
away from
Mirror Cover assembly
Two screws
(WASHER HEAD)
(+P 4X16)
KDF-E55A20/E60A20
1
1
21
[KD] Shield to QU Heat Sink
KDF-E55A20/E60A20
WIRE DRESSING
[C] LVDS Connector
Route LVDS Connector as shown below
[B1] LVDS
231876601
ELECTRIC CONDUCTION TAPE, A
(1 Piece)
191001690 to DMB. Route
wire around Main Harness
Install Faston Terminal of
and LVDS
DMB PP Cable
DMB LVDS AND [B1] LVDS
191001690
WIRE ASSY, FASTON TERMINAL
Secure w/ B1 Shield Screw
KDF-E55A20/E60A20
231876601
ELECTRIC CONDUCTION TAPE, A
(2 Pieces)
Tape Must completely cover connector header and
make good contact with shield
22
231876601
ELECTRIC CONDUCTION TAPE, A
(1 Piece)
KDF-E55A20/E60A20
KDF-E55A20/E60A20
Do Not Crease/Fold FFC cable
After securing the coax cable on DMB ensure that it is in a
horizontal position as shown below
23
191001689
WIRE ASSY, FASTON TERMINAL
KDF-E55A20/E60A20
Dress into B1 Clamp
Install to CN6018 on [GI]
KDF-E55A20/E60A20
Ground from
GM Board
Ground from
GI Board
Dress into 2nd B1 Clamp
24
Single Braided Wire
to OU Bracket
Double Braided Wire
to ANT SWITCH
191001691
WIRE ASSY, FASTON TERMINAL
KDF-E55A20/E60A20
Dress into U-Bracket
Dress Under Ant Switch
KDF-E55A20/E60A20
Install Double
Braided Wire into
Ant Switch
Ground from
GM Board
Ground from
GI Board
25
404928101
PURSE LOCK (DIA.11)
146908911
FILTER, CLAMP (FERRITE CORE)
KDF-E55A20/E60A20
146908911
FILTER, CLAMP (FERRITE CORE)
Install on COAX cable.
Ferrite core MUST be between B1 Shield and DMB Shield
FILTER,CLAMP
(FERRITE CORE)
KDF-E55A20/E60A20
404928101
PURSE LOCK (DIA.11)
150049711
Excess Cable should be
placed inside opening
404928101
PURSE LOCK (DIA.11)
404928101
PURSE LOCK (DIA.11)
150049711
FILTER,CLAMP(FERRITE CORE)
Loop Video 2 around core 1 time
26
PURSE LOCK (DIA.11)
H3 Connector Assy, Speaker/Power
Button/Control Button Connector
Assys Secure with Purse Lock to
Main Harness as shown
KDF-E55A20/E60A20
404928101
150008211
CLAMP, SLEEVE FERRITE
Loop Connector Around Ferrite one
time
KDF-E55A20/E60A20
150008211
CLAMP, SLEEVE FERRITE
27
1. Install 4-662-796-01 CLIP, COACHING to
H4 Board.
2. Then secure using 7-685-648-71 SCREW
+BVTP 3X12 TYPE2 IT-3
1. Install AC Cord to CN1602 on [GM] Board
KDF-E55A20/E60A20
KDF-E55A20/E60A20
28
1. Twist AC Cord as shown and install into
Chassis bracket.
1. Secure AC cord with Clip, Coaching as shown
KDF-E55A20/E60A20
KDF-E55A20/E60A20
29
HM BLOCK WIRE DRESSING
Secure H5 Connector Assy with
Sony P/N 407859001 TAPE
KDF-E55A20/E60A20
KDF-E55A20/E60A20
Tape should not overlap bottom
edge of HM BRACKET
Bottom Edge
30
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