Sony BRAVIA KDL-55EX500 User manual

SERVICE MANUAL
LCD Digital Color TV
AZ1-K Chassis
9-883-843-05
Version Date Subject
1.0 1/14/2010 Norevisionsorupdates
2.0 4/19/2010 AddedSafetyRelatedWarning.ReplacedPage5.
  CorrectedinstructionsforAccessingFactoryMode.ReplacedPage20.
3.0 7/26/2010 AddedinformationforBusinesstoBusinessKDL-55EX500model.ReplacedPages15&18.
4.0 9/28/2010 UpdatedDisassemblySection1-7-2.Connectors.ReplacedPage17.
5.0 11/1/2010 CorrectedSpecicationinformation.Replacedpage2.
ORIGINAL MANUAL ISSUE DATE: 1/2010
HISTORYINFORMATIONFORTHEFOLLOWINGMANUAL:

SERVICE MANUAL
LCD Digital Color TV
AZ1-K Chassis
9-883-843-05
Self Diagnosis
Supported model

MODELLIST
MODEL COMMANDER DESTINATION MODEL COMMANDER DESTINATION
9-883-843-05
KDL-55EX500 RM-YD034 CND
KDL-55EX500 RM-YD034 MEXICO
KDL-55EX500 RM-YD034 US
KDL-55EX501 RM-YD034 CND
KDL-55EX501 RM-YD034 US
KDL-60EX500 RM-YD034 CND
KDL-60EX500 RM-YD034 MEXICO
KDL-60EX500 RM-YD034 US

KDL-55EX500/55EX501/60EX500 i
TABLE OF CONTENTS
..................................................................................................................................................................................1
..................................................................................................................................................................3
..................................................................................................................................................................5
............................................................................................................................................................................6
...............................................................................................................................................................8
 ..........................................................................................................................12
1-1. Table-Top Stand Assembly Removal .............................................................................................................................. 12
1-2. Rear Cover, Under Cover, and Vesa Brackets Removal ................................................................................................ 13
1-3. Speakers, Speaker Spacers, AC Inlet, and Panel Supports Removal ........................................................................... 14
1-4. Bottom Frame, G5E/G8S (Power) Boards, D1 Board, Switch Unit,
A Board, Side Jack Bracket, LCD Panel, and HRK Board Removal .............................................................................. 15
1-5. Cleaning the LCD Panel ................................................................................................................................................. 16
1-6. Screw Legend................................................................................................................................................................. 16
1-7. Connectors ..................................................................................................................................................................... 17
1-7-1. Connectors (KDL-55EX500/55EX501 Only) ...........................................................................................................................................17
1-7-2. Connectors (KDL-60EX500 Only)............................................................................................................................................................17
1-8. Accessories and Packaging ........................................................................................................................................... 18
1-9. Miscellaneous................................................................................................................................................................. 18
1-10.Remote commander....................................................................................................................................................... 18
 ........................................................................................................................................................19
2-1. Accessing Service Adjustment Mode ............................................................................................................................. 19
2-1-1. Accessing Service Mode..........................................................................................................................................................................19
2-1-2. Accessing Factory Mode..........................................................................................................................................................................20

KDL-55EX500/55EX501/60EX500 ii
TABLE OF CONTENTS
 ...........................................................................................................................................................................21
3-1. Circuit Boards Location .................................................................................................................................................. 21
3-2. Block Diagram ................................................................................................................................................................ 22

KDL-55EX500/55EX501/60EX500  1
SPECIFICATIONS
System
Television system NTSC: American TV standard
ATSC (8VSB terrestrial): ATSC compliant 8VSB
QAM on cable: ANSI/SCTE 07 2000 (Does not include CableCARD functionality)
Channel coverage Analog terrestrial: 2 - 69 / Digital terrestrial: 2 - 69
Analog Cable: 1 - 135 / Digital Cable: 1 - 135
Panel system LCD (Liquid Crystal Display) Panel
Speaker output 10 W + 10 W
Input/Output jacks
CABLE/ANTENNA 75-ohm external terminal for RF inputs
VIDEO IN 1/2 VIDEO: 1 Vp-p, 75 ohms unbalanced, sync negative
AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms
COMPONENT IN 1/2 YPBPR (Component Video): Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative / PB: 0.7 Vp-p, 75 ohms
PR: 0.7 Vp-p, 75 ohms / Signal format: 480i, 480p, 720p, 1080i, 1080p
AUDIO: 500 mVrms (Typical) / Impedance: 47 kilohms
HDMI IN 1/2/3/4 HDMI: Video: 480i, 480p, 720p, 1080i, 1080p, 1080/24p
Audio: Two channel linear PCM 32, 44.1 and 48 kHz, 16, 20 and 24bits, Dolby Digital
AUDIO OUT 500 mVrms (typical)
DIGITAL AUDIO OUT
(OPTICAL)
PCM/Dolby Digital optical signal
PC IN D-sub 15-pin, analog RGB, 0.7 Vp-p, 75 ohms, positive
PC/HDMI IN 1 AUDIO INPUT Stereo mini jack, 500 mVrms, (Typical) / Impedance: 47 kilohms
Licensing Information
Macintosh is a trademark of Apple Inc., registered in the U.S. and
other countries.
HDMI, the HDMI logo and High-Definition Multimedia Interface
are trademarks or registered trademarks of HDMI Licensing, LLC.
Fergason Patent Properties, LLC:
U.S. Patent No. 5,717,422
U.S. Patent No. 6,816,141
Manufactured under license from Dolby Laboratories. Dolby, Pro
Logic, and the double-D symbol are trademarks of Dolby
Laboratories.
Blu-ray Disc is a trademark.
“BRAVIA” and , Motionflow, BRAVIA Sync, and
are trademarks or registered marks of Sony Corporation.
“PlayStation” is a registered trademark and “PS3” is a trademark of
Sony Computer Entertainment Inc.
Your BRAVIA TV is ENERGY STAR® qualified
in the “Home” mode. It meets strict energy
efficiency guidelines set by the U.S.
Environmental Protection Agency and
Department of Energy.
ENERGY STAR is a joint program of these
government agencies, designed to promote energy
efficient products and practices. Changes to certain features,
settings, and functionalities of this TV (i.e. Picture/Sound, Power
Savings) can increase or change the power consumption. Depending
upon such changed settings, the power consumption may exceed the
limits required for the ENERGY STAR qualification in the “Home”
mode.

KDL-55EX500/55EX501/60EX500  2
SPECIFICATIONS
Power Requirement
Power Consumption in use 425 W 315 W
in standby Less than 0.23 W with 120 V AC and
with 240 V AC less that 0.6 W
Less than 0.23 W with 120 V AC and
with 240 V AC less that 0.4 W
60 54.6
(
55 class
)
S
p
eaker/Full Ran
g
e
(
2
)
mm 45 x 120 45 x 200
in (1
13/16
x 4
3/
4)
with speaker box
(113/16 x 77/8)
Dimensions
with stand mm 1,455 x 910 x 386 mm 1,324 x 832 x 350 mm
in 57
3/8
x 357
/8
x 15
1/
4 in 52
1/
4 x 327
/8
x 137
/8
in
without stand mm 1,455 x 873 x 119 mm 1,324 x 795 x 105 mm
in 573/8 x 343/8 x 43/4 in 521/4 x 313/8 x 41/8 in
wall-mount hole pattern (mm)
Mass
with stand
kg 43.0 kg 30.7 kg
lbs 94.8 lbs 67.7 lbs
without stand
kg 36.5 kg 26.7 kg
lbs 80.4 lbs 58.9 lbs
Su
pp
lied Accessories
Common to all Models
Individual Models AC Power Cord(1)
Table-Top Stand(1 set)/
AC Power Cord(1)
Screw(4)
O
p
tional Accessories
* Optional Accessories availablity depends on its stock.
* Design and specifications are subject to change without notice.
400 x 300
Display Resolution 1,920 dots (horizontal) x 1,080 lines (vertical)
Connecting Cables/Support Belt Kit/Wall-Mount Bracket: SU-WL500
Remote Control RM-YD034(1)/Size AAA Batteries(2)/Operating Instructions(1)/Quick Setup
Guide(1)/ Warranty Card(1)/Safety and Regulatory Booklet(1)/ Software License(1)/Stand
Installation Guide(1) (Except KDL-60EX500)
Screen Size
(
inches measured dia
g
onall
y)
wall-mount screw size (mm) M6 x 8-12 mm
Model Name KDL- 60EX500 55EX500
55EX501
Power and others
110-240 V AC, 50/60 Hz (USA/Canada 120 V AC, 60 Hz)

KDL-55EX500/55EX501/60EX500 3
CAUTION
These servicing instructions are for use by qualified 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 qualified to do so.
CARRYING THE TV
• Carry the TV with the adequate number of people; larger size TVs require two or more people.
• Correct hand placement while carrying the TV is very important for safety and to avoid
damage.
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 identified by shading and ! mark on the exploded views are critical for safe operation.
Replace all components with Sony parts whose part numbers appear as shown in this manual or in supplements published by Sony. It is
essential that all critical parts be replaced only with the part number specified in this manual to prevent electric shock, fire, or other hazard.
Circuit adjustments that are critical for safe operation are identified in this manual.
Follow these procedures whenever critical components are replaced or improper operation is suspected.
NOTE: Do not modify the original design without obtaining written permission from the manufacturer or you will void the original parts and
labor guarantee.
WARNINGS AND CAUTIONS

KDL-55EX500/55EX501/60EX500 4
ATTENTION!!
Ces instructions de service sont à l’usage du personnel de service qualifié 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 qualifié faire ainsi.
POUR TRANSPORTER LE TÉLÉVISEUR
• Transportez le téléviseur avec le nombre de personnes approprié ; un téléviseur de grande
taille doit être transporté par au moins deux personnes.
• Lors du transport du téléviseur, l’emplacement des mains est très important pour votre
sécurité, ainsi que pour éviter de causer des dommages.
ALERTE!!
Afin 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 identifies 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 identifies dans le present manuel. Suivre ces procedures lors de chaque remplacement de composants
critiques, ou lorsqu’un mauvais fonctionnement suspecte.
WARNING AND CAUTIONS

KDL-55EX500/55EX501/60EX500 5
SAFETY-RELATED WARNING
USE CAUTION WHEN HANDLING THE LCD PANEL
When repairing the LCD panel, be sure you are grounded by using a wrist band.
When installing the LCD panel on a wall, the LCD panel must be secured using the 4 mounting holes on the rear cover.
1) Do not press on the panel or frame edge to avoid the risk of electric shock.
2) Do not scratch or press on the panel with any sharp objects.
3) Do not leave the module in high temperatures or in areas of high humidity for an extended period of time.
4) Do not expose the LCD panel to direct sunlight.
5) Avoid contact with water. It may cause a short circuit within the module.
6) Disconnect the AC power when replacing the inverter circuit.
(High voltage occurs at the inverter circuit at 650Vrms.)
7) Always clean the LCD panel with a soft cloth material.
8) Use care when handling the wires or connectors of the inverter circuit. Damaging the wires may cause a short.
9) Protect the panel from ESD to avoid damaging the electronic circuit (C-MOS).
10) During the repair, DO NOT leave the Power On for more than 1 hour while the TV is face down on a cloth.

KDL-55EX500/55EX501/60EX500 6
After correcting the original service problem, perform the following safety checks before releasing the set to the customer:
SAFETY CHECK-OUT
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 antenna terminals, metal trim, “metallized” knobs, screws, and
all other exposed metal parts for AC leakage. Check leakage as described
below.
To Exposed Metal
Parts on Set
0.15 µF
Earth Ground
AC
Voltmeter
(0.75V)
Figure A. Using an AC voltmeter to check AC leakage.

KDL-55EX500/55EX501/60EX500 7
SAFETY CHECK-OUT
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).
Trouble Light
AC Outlet Box Ohmmeter
Cold-water Pipe
Figure B. Checking for earth ground.

KDL-55EX500/55EX501/60EX500 8
SELF DIAGNOSIS FUNCTIONS
SELF DIAGNOSIS FUNCTION
The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY LED will automatically begin to flash. The number
of times the LED flashes translates to a probable source of the problem. A definition of the STANDBY LED flash indicators is listed in the
instruction manual for the user’s knowledge and reference. If an error symptom cannot be reproduced, the remote commander can be used to
review the failure occurrence data stored in memory to reveal past problems and how often these problems occur.
DIAGNOSTIC TEST INDICATORS
When an error occurs, the STANDBY LED will flash 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 first of the problem areas.
Result for all of the following diagnostic items are displayed on screen.
If the screen displays a “0”, no error has occurred .
Diagnostic Item
Description
Number of times Standby
LED blinks Possible Location
Main Power Error 2 G5E (Power) Board (KDL-55EX500/55EX501 Only)
G8S (Power) Board (KDL-60EX500 Only)
Audio Error 3 A (Main) Board
Balancer 4 LCD Panel
TCON Error 5 LCD Panel
TCON Control MT Board
HFR Error 5 LCD Panel
Backlight Error 6 LCD Panel
Temperature Error 7 A (Main) Board
Self Diagnosis
Supported model

KDL-55EX500/55EX501/60EX500 9
SELF DIAGNOSIS FUNCTIONS
STANDBY LED FLASH COUNT
Ambient Sensor/
(IR) Infrared Receiver
Picture Off /
Timer LED
Standby LED Power LED
2 times
5 times
LED ON 0.3 sec.
LED OFF 0.3 sec. LED OFF
3 sec.

KDL-55EX500/55EX501/60EX500 10
SELF DIAGNOSIS FUNCTIONS
VIEWING THE SELF CHECK DIAGNOSTIC LIST
For errors with symptoms such as “power sometimes shuts off” or “screen sometimes goes out” that cannot be confirmed, it is possible to
bring up past occurrences of a failure for confirmation on the Self Check 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 Channel 5Volume -POWER .
* NOTE: This differs from accessing Service Adjustments Mode (Volume +)
Back <<
002 MAIN_POWE 001 001 indicates an error was detected
003 AUD_PORT 000 000 indicates no error was detected
003 DC_ALERT 000
004 BALANCE
R
000
005 TCON_ERR 000
005 HFR_ERR 000
005 P_ID_ER
R
000
005 PANEL_POWE 000
006 BACKLITE 000
007 TEMP_ERR 000
00000 00010 00000 [Menu] Exit
Panel Operation Time by Hour (max 99999)
Boot Count (max 99999)
Total Operation Time by Hour (max 99999)
SELF CHECK

KDL-55EX500/55EX501/60EX500 11
CLEARING THE SELF CHECK DIAGNOSTIC LIST
Since the diagnostic results displayed on the screen are not automatically cleared, always check the self-diagnostic screen after you have
completed the repairs to be sure you have cleared the result display to “0”.
1. Error history and Error count :Press the Channel 8Channel 0.
2. Panel operation time :Press the Channel 7Channel 0.
EXITING THE SELF CHECK DIAGNOSTIC SCREEN
1. To exit the Self Diagnostic screen, turn off the power to the TV by pressing the POWER button on the remote or the POWER button on
the TV.
SELF DIAGNOSIS FUNCTIONS

KDL-55EX500/55EX501/60EX500 12
Components not identified by a part number or
description are not stocked because they are seldom
required for routine service.
The component parts of an assembly are indicated by the
reference numbers in the far right column of the parts list
and within the dotted lines of the diagram.
* Items marked with an asterisk are not stocked since
they are seldom required for routine service. Expect
some delay when ordering these components.
NOTE: Les composants identifies per un trame et
une marque
!
sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.
NOTE: The components identified by shading
and
!
mark are critical for safety. Replace only
with part number specified.
NOTE: The components identified by a red outline and a mark contain
confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.
SEC 1. DISASSEMBLY/PART NUMBER INFORMATION
1-1. TABLE-TOP STAND ASSEMBLY REMOVAL
ARemove 4 screws from Table-Top Stand Assembly
BLift up TV set to detach from Table-Top Stand Assembly
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
CGently place the TV set face down onto a soft cloth
B
A
Soft Cloth
C
1 X-2514-983-1 BASE (LL3) ASSEMBLY [2]
(KDL-55EX500/55EX501 ONLY)
1 X-2514-984-1 BASE (LLL3) ASSEMBLY [2]
(KDL-60EX500 ONLY)
2 4-158-387-01 COVER, STAND (LL3)
(KDL-55EX500/55EX501 ONLY)
2 4-158-388-01 COVER, STAND (LLL3)
(KDL-60EX500 ONLY)
3 X-2546-542-1 COVER (LL3) ASSEMBLY [4-5]
(KDL-55EX500/55EX501 ONLY)
4 4-158-397-01 COVER, NECK (LL3 FRONT)
(KDL-55EX500/55EX501 ONLY)
4 4-158-398-01 COVER, NECK (LLL3 FRONT)
(KDL-60EX500 ONLY)
5 4-158-403-01 COVER, NECK (LL3 REAR)
(KDL-55EX500/55EX501 ONLY)
5 4-158-404-01 COVER, NECK (LLL3 REAR)
(KDL-60EX500 ONLY)
6 4-158-351-01 NECK (LL3)
(KDL-55EX500/55EX501 ONLY)
6 4-158-352-01 NECK (LLL3)
(KDL-60EX500 ONLY)
7 2-580-608-01 SCREW, +PSW M5X16
(SCREWS TO ATTACH TABLE-TOP STAND TO LCD TV)
For product protection and safety reasons, Sony strongly recommends
that you use the screws provided with the TV
CAUTION: These screws cannot be used to secure the TV to
the Wall Mount Brackets
2-580-608-01 SCREW, +PSW M5X16
7
6
1
2
4
3
5
(Check the Sony Electronics Service Information website for any additional service related issues for this model.)

KDL-55EX500/55EX501/60EX500 13
DISASSEMBLY/PART NUMBER INFORMATION
NOTE: Les composants identifies per un trame et
une marque
!
sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.
NOTE: The components identified by shading
and
!
mark are critical for safety. Replace only
with part number specified.
NOTE: The components identified by a red outline and a mark contain
confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
1-2. REAR COVER, UNDER COVER, AND VESA BRACKETS REMOVAL
ARemove screws from Rear Cover
13 from KDL-55EX500/55EX501 ONLY
12 from KDL-60EX500 ONLY
BRemove 2 screws from Rear Cover Top-Center
CRemove 2 screws from Rear Cover Bottom-Center
DRemove 1 screw from Side Jack position
ERemove 1 screw from Terminal position
FLift up Rear Cover from bottom to remove from Bezel Assembly
GRemove 1 screw from Under Cover Position and lift up Under Cover to detach from Bottom Frame
HRemove screws to detach Vesa Brackets from Panel
2 from KDL-55EX500/55EX501 ONLY
4 from KDL-60EX500 ONLY
ILift up Vesa Bracket (S) to detach from Rear Cover (KDL-55EX500/55EX501 ONLY)
A
B
C
D
E
G
H
I KDL-55EX500/
55EX501 ONLY
F
KDL-55EX500/
55EX501 ONLY
KDL-60EX500 ONLY
KDL-55EX500/
55EX501 ONLY
KDL-60EX500 ONLY
51 4-166-855-01 REAR COVER (55)
(KDL-55EX500/55EX501 ONLY)
51 4-156-223-01 REAR COVER (60)
(KDL-60EX500 ONLY)
52 4-157-979-02 COVER, UNDER (55)
(KDL-55EX500/55EX501 ONLY)
52 4-157-980-01 COVER, UNDER (60)
(KDL-60EX500 ONLY)
53 4-168-273-01 BRACKET,VESA(XL)
(KDL-55EX500/55EX501 ONLY)
53 4-156-947-01 BRACKET, VESA (XXL)
(KDL-60EX500 ONLY)
54 3-297-324-02 COVER, ECS
55 4-168-272-01 BRACKET,VESA(S)
(KDL-55EX500/55EX501 ONLY)
2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3
7-685-648-79 SCREW, +BVTP 3X12 TYPE2 IT-3
4-159-298-01 SCREW, +PSW M4X10
54
51
52
53
55
(Check the Sony Electronics Service Information website for any additional service related issues for this model.)

KDL-55EX500/55EX501/60EX500 14
DISASSEMBLY/PART NUMBER INFORMATION
NOTE: Les composants identifies per un trame et
une marque
!
sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.
NOTE: The components identified by shading
and
!
mark are critical for safety. Replace only
with part number specified.
NOTE: The components identified by a red outline and a mark contain
confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.
ALift up left-side Loudspeaker to remove from Bezel Assembly (KDL-55EX500/55EX501 ONLY)
Lift up left-side Speaker Box Assembly to remove from Bezel Assembly (KDL-60EX500 ONLY)
BRemove 2 screws from left-side Speaker Spacers to detach from Bezel Assembly
CRemove screws from AC Inlet
1 to detach from AC Inlet Bracket (KDL-55EX500/55EX501 ONLY)
1 to detach from Bottom Frame (KDL-60EX500 ONLY)
DLift up right-side Loudspeaker to remove from Bezel Assembly (KDL-55EX500/55EX501 ONLY)
Lift up right-side Speaker Box Assembly to remove from Bezel Assembly (KDL-60EX500 ONLY)
ERemove 2 screws from right-side Speaker Spacers to detach from Bezel Assembly
FPress down on Panel Support
GSlide out Panel Support to remove from Bezel Assembly
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
1-3. SPEAKERS, SPEAKER SPACERS, AC INLET, AND PANEL SUPPORTS REMOVAL
C
F
A
D
G
AC Inlet
B
E
101 1-858-354-11 LOUDSPEAKER LEFT
(KDL-55EX500/55EX501 ONLY)
101 1-858-355-11 SP BOX ASSEMBLY LEFT
(KDL-60EX500 ONLY)
102 4-166-135-01 SPACER, SPEAKER
(KDL-55EX500/55EX501 ONLY)
102 4-166-135-11 SPACER, SPEAKER
(KDL-60EX500 ONLY)
!103 1-842-009-11 AC INLET FILTER
104 1-858-354-21 LOUDSPEAKER RIGHT
(KDL-55EX500/55EX501 ONLY)
104 1-858-355-21 SP BOX ASSEMBLY RIGHT
(KDL-60EX500 ONLY)
105 NA SUPPORT, PANEL
FOR ALL PANEL SUPPORT PART NUMBER INFORMATION
REFER TO THE LCD PANELS SERVICE MANUAL
2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3
2-580-629-01 SCREW, +BVST 3X8
103
101
104
102
102
105
105
(Check the Sony Electronics Service Information website for any additional service related issues for this model.)

KDL-55EX500/55EX501/60EX500 15
DISASSEMBLY/PART NUMBER INFORMATION
NOTE: Les composants identifies per un trame et
une marque
!
sont critiques pour la securite.
Ne les remplacer que par une piece portant le
numero specifie.
NOTE: The components identified by shading
and
!
mark are critical for safety. Replace only
with part number specified.
NOTE: The components identified by a red outline and a mark contain
confidential information. Specific instructions must be adhered to whenever
these components are repaired and/or replaced.
See Appendix A: Encryption Key Components in the back of this manual.
ARemove 2 screws from Bottom Frame to detach from Bezel Assembly
BRemove screws from Bottom Frame to detach from LCD Panel
2 from KDL-55EX500/55EX501 ONLY
6 from KDL-60EX500 ONLY
CRemove 4 screws from G5E/G8S (Power) Boards
DDisconnect 5 connectors from G5E/G8S (Power) Boards
ERemove 2 screws from D1 Board (KDL-55EX500/55EX501 ONLY)
FDisconnect 5 connectors from D1 Board (KDL-55EX500/55EX501 ONLY)
GRemove 2 Mini Card Spacers to detach D1 Board from LCD Panel (KDL-55EX500/55EX501 ONLY)
HLift up Switch Unit to remove from Bezel
IDisconnect 1 connector from Switch Unit
JDisconnect 6 connectors from A Board
KRemove 4 screws from A Board
LRemove 1 PWB Spacer to detach A Board from LCD Panel
MSlide Side Jack Bracket to right side of A Board
to detach from position
NRemove 2 screws from
Main Bracket to detach
from Bezel Assembly
(KDL-60EX500 ONLY)
ORemove 3 screws from Panel
to detach from Bezel Assembly
(KDL-60EX500 ONLY)
PCarefully Lift up Panel to remove
from Bezel Assembly
QDisconnect 1 connector from
HRK Board
and release from LED Guide
NOTE: The Mini Card Spacers,
PWB Spacer, and PWB Holders
are not included with the Boards
and must be replaced when
replacing the Boards. The G Frame
and Main Frame are not included
with the Panel and must be replaced
when replacing the Panel.
REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES] REF. NO. PART NO. DESCRIPTION [ASSEMBLY INCLUDES]
1-4. BOTTOM FRAME, G5E/G8S (POWER) BOARDS, D1 BOARD, SWITCH UNIT,
A BOARD, SIDE JACK BRACKET, LCD PANEL, AND HRK BOARD REMOVAL
PWB
Holder
PWB
Spacer
Main
Bracket
Q
H
G
E
I
F
P
C
D
B
A
K
JL
M
Mini Card
Spacer
KDL-55EX500/
55EX501 ONLY
KDL-60EX500 ONLY
KDL-55EX500/
55EX501 ONLY
KDL-60EX500 ONLY
O
N
151 X-2546-673-1 BEZEL ASSEMBLY (TR55 GM)
(KDL-55EX500 ONLY)
151 X-2546-681-1 BEZEL ASSEMBLY (TR55 B)
(KDL-55EX501 ONLY)
151 X-2546-674-1 BEZEL ASSEMBLY (TR60 GM)
(KDL-60EX500 ONLY)
152 A-1758-163-A HRK BOARD, MOUNTED
153 NA LCD PANEL
FOR ALL LCD PANEL PART NUMBER INFORMATION
REFER TO THE LCD PANELS SERVICE MANUAL
154 4-166-286-11 BRACKET, SIDE JACK
155 A-1758-161-A A BOARD, COMPLETE
155 A-1787-382-A A BOARD, COMPLETE
156 1-474-203-11 G5E (POWER) BOARD, COMPLETE
(KDL-55EX500/55EX501 ONLY)
156 1-474-207-11 G8S (POWER) BOARD, COMPLETE
(KDL-60EX500 ONLY)
157 1-474-206-11 D1 BOARD, COMPLETE
(KDL-55EX500/55EX501 ONLY)
158 1-487-736-11 SWITCH UNIT
2-580-640-01 SCREW, +BVTP 4X16 TYPE2 IT-3
2-580-592-01 SCREW, +PSW M3X8
4-159-298-01 SCREW, +PSW M4X10
2-580-629-01 SCREW, +BVST 3X8
(KDL-60EX500 ONLY)
152
151
158
157
153
156
155
154
(Check the Sony Electronics Service Information website for any additional service related issues for this model.)
(FOR BUSINESS TO BUSINESS MODELS ONLY)