SONY KDF-E55A20, KDF-E60A20 Service Manual

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)
12/2005 Reissue entire manual to include information for SN ranges 9,100,001 to 9,799,999 and 9,900,001 and up

LCD PROJECTION TELEVISION

9-965-984-03

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

9-965-984-03

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 ............................................................... 14

1-1. Rear Cover Removal ............................................................ 14

1-2. OU Bracket Removal ........................................................... 14

1-3. Chassis Assembly and Fan Removal .................................. 15

1-4. Service Position ................................................................... 15

1-5. RF Antenna Switch Removal ............................................... 16

1-6. U1 Board and H4 Board Removal ........................................ 16

1-7. GM Board Removal .............................................................. 17

1-8. A1 Board (or A2 Board) and KD Board Removal ................. 17

1-9. DMB Assembly (Q Box) and B1 Board Removal ................. 18

1-10. GI Board (or GK Board) Removal ........................................ 18

1-11. Fan and T Board Removal ................................................... 19

1-12. H1 Board Removal ............................................................... 19

1-13. Front Cover Assembly Removal ........................................... 20

1-13-1. Replacing the Lamp ................................................. 20

1-14. Power Supply Block Removal (Lamp Drive Unit) ................. 20

1-15. Optics Unit Block Assembly Fan Removal .......................... 21

1-16. H2 Board, H3 Board, and H5 Board Removal ..................... 21

1-17. Screen Mirror Block Assembly Removal .............................. 22

1-18. Speaker Removal ................................................................. 22

Wire Dressing ............................................................................... 23

SECTION 2: CIRCUIT ADJUSTMENTS .............................................. 43

2-1. Remote Adjustment Buttons and Indicators ......................... 43

2-2. Accessing the Service Adjustment Mode ............................. 43

2-3. Changing Service Adjustment Mode Memory ...................... 43

2-4. Memory Write Confi rmation Method .................................... 44

2-5. H/V Center Confi rmation and Adjustments .......................... 45

2-6. Adjusting On Screen Display (OSD) Position ...................... 46

SECTION 3: DIAGRAMS ..................................................................... 47

3-1. Circuit Boards Location ........................................................ 47

3-2. Printed Wiring Boards and

Schematic Diagrams Information ......................................... 47

3-3. Block Diagrams .................................................................... 49

Signal Flow Block Diagram (SN 9,000,001 to 9,099,999

and 9,800,000 and 9,899,999 Only) ........................ 49

Signal Flow Block Diagram (SN 9,100,001 to 9,799,999

and 9,900,001 Up) ................................................... 50

Audio Block Diagram ....................................................... 51

3-3. Schematics and Supporting Information .............................. 52

A1 Board Schematic Diagram (1 of 2) (SN 9,000,001 to

9,099,999 and 9,800,001 to 9,899,999 Only) .......... 52

A1 Board Schematic Diagram (2 of 2) (SN 9,000,001 to

9,099,999 and 9,800,001 to 9,899,999 Only) .......... 53

A2 Board Schematic Diagram (1 of 2) (SN 9,100,001 to

9,799,999 and 9,900,001 and Up Only) .................. 55

A2 Board Schematic Diagram (2 of 2) (SN 9,100,001 to

9,799,999 and 9,900,001 and Up Only) .................. 56

B1 Board Schematic Diagram (1 of 5) ................................. 58

B1 Board Schematic Diagram (2 of 5) ................................. 59

B1 Board Schematic Diagram (3 of 5) ................................. 60

B1 Board Schematic Diagram (4 of 5) ................................. 61

B1 Board Schematic Diagram (5 of 5) ................................. 62

GI Board Schematic Diagram (1 of 2) (SN 9,000,001 to

9,099,999 and 9,800,001 to 9,899,999 Only) .......... 65

GI Board Schematic Diagram (2 of 2) (SN 9,000,001 to

9,099,999 and 9,800,001 to 9,899,999 Only) .......... 66

GK Board Schematic Diagram (1 of 3) (SN 9,100,001 to

9,799,999 and 9,900,001 and Up Only) .................. 69

GK Board Schematic Diagram (2 of 3) (SN 9,100,001 to

9,799,999 and 9,900,001 and Up Only) .................. 70

GK Board Schematic Diagram (3 of 3) (SN 9,100,001 to

9,799,999 and 9,900,001 and Up Only) .................. 71

GM Board Schematic Diagram ............................................ 74

H1 Board Schematic Diagram .............................................. 77

H2 Board Schematic Diagram .............................................. 79

H3 Board Schematic Diagram .............................................. 81

H4 Board Schematic Diagram (SN 9,000,001 to 9,099,999

and 9,800,001 to 9,899,999 Only) ........................... 82

H5 Board Schematic Diagram .............................................. 83

KD Board Schematic Diagram (SN 9,000,001 to 9,099,999

and 9,800,001 to 9,899,999 Only) ........................... 84

T Board Schematic Diagram ................................................ 86

U1 Board Schematic Diagram .............................................. 87

3-4. Semiconductors ................................................................... 89

SECTION 4: EXPLODED VIEWS ........................................................ 90

4-1. Cover .................................................................................... 90

4-2. Bottom Cabinet .................................................................... 91

4-3. Chassis ................................................................................ 92

SECTION 5: ELECTRICAL PARTS LIST ........................................... 93

KDF-E55A20/E60A20

3

SPECIFICATIONS

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

, PR)

2 (Y, P

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

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

57

in

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.

ENERGY STAR

®

is a U.S. registered mark.

TruSurround XT, SRS and the ( )
trademarks of SRS Labs, Inc. TruSurround XT
technology is incorporated under license from SRS Labs,
Inc.

WEGA, Grand WEGA, WEGA GATE, Steady Sound,
Digital Reality Creation and CineMotion
are registered trademarks of Sony Corporation.

®

guidelines for

®

symbol are

KDF-E55A20 KDF-E60A20

12W (L), 12W (R)

3/8

x 37

1/4

x 19

3/8

in 62 x 39

5/8

x 20

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 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 Sony Corporation.

Macintosh is a trademark licensed to Apple Computer, Inc.,
registered in the U.S.A and other countries.

1/2

in

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 µF

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

DISPLAY

Channel

3. Press Channel 8

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
(SN 9,000,001 to 9,099,999 and 9,800,001 to 9,899,999 Only)

GI board

IC6902

H4 board

IC41

Te m p

4:Temp

Display Engine u-com

FAN PROT

IIC-E

4:Fan

92

sensor

LAMP-COVER

LAMP-PROT

LAMP-HV-DET

94

95

96

CN6000

2

5

8

11

CN6022

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

Self-Diagnosis Block Diagram
(SN 9,100,001 to 9,799,999 and 9,900,001 and Up Only)

GK board

IC6902

Display Engine u-com

92

94

95

96

IC6911

Te m p

sensor

FAN PROT

IIC-E

LAMP-COVER

LAMP-PROT

LAMP-HV-DET

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

GM board

+3.3V
+2.5V

GM board

SETIIV

Q5V

8:D-OVP

6:LowB

error

CN1609

A14

CN1609

B14

CN6006

5

IIC-TV

A14

B14

CN6017

16

12:DTL

OVP

B1 board

IC3002 TV u-com

IIC-TV

126

D_OVP

LB_ERROR

129

127

ATSC_OVP

KDF-E55A20/E60A20

12

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 momentarily 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

13

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

Two screws

(+BVTP 4x16)

5

Three ground wires

KDF-E55A20/E60A20

3

Two screws

(+BVTP 4x16)

14

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

15

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

The H4 Board is only in SN 9,000,001 to 9,099,999 and 9,800,001 to 9,899,999

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

16

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 (OR A2 BOARD) AND KD BOARD REMOVAL

The A1 Board and the KD Board are only in SN 9,000,001 to 9,099,999 and 9,800,001 to 9,899,999
The A2 Board is only in SN 9,100,001 to 9,799,999 and 9,900,001 and up

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

17

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 (OR GK BOARD) REMOVAL

The GI Board is only in SN 9,000,001 to 9,099,999 and 9,800,001 to 9,899,999
The GK Board is only in SN 9,100,001 to 9,799,999 and 9,900,001 and up

Disconnect 5 connectors
(CN6000, CN6028,
CN6021, CN6023,
and CN6022)

Disconnect 1 ground wire
(CN6018)

Gently pull back on the two clips
while slowly lifting the GI Board.

1

3

2

GI board

4

KDF-E55A20/E60A20

18

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

19

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

20

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)

21

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

22

WIRE DRESSING

Use these instructions for SN 9,000,001 to 9,099,999 and 9,800,001 to 9,899,999
for SN 9,100,001 to 9,799,999 and 9,900,001 and up use instructions on Page 34

[KD] Shield to QU Heat Sink

KDF-E55A20/E60A20

[C] LVDS Connector

Route LVDS Connector as shown below

[B1] LVDS

231876601

ELECTRIC CONDUCTION TAPE, A

(1 Piece)

Install Faston Terminal of
191001690 to DMB. Route
wire around Main Harness

and LVDS

DMB PP Cable

DMB LVDS AND [B1] LVDS

191001690

WIRE ASSY, FASTON TERMINAL

Secure w/ B1 Shield Screw

KDF-E55A20/E60A20

ELECTRIC CONDUCTION TAPE, A

231876601

(2 Pieces)

Tape Must completely cover connector header and

make good contact with shield

23

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

24

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

25

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

26

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

27

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

28

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

29

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

30