Sony KE-42XBR900 - 42" Xbr Plasma Wega™ Integrated... User manual

No. DATA CONTENTS
1
2003. 2 Addition of Disassembly,Adjustments, Troubleshooting and Diagrams
(P.1-1, P.2-1, P.3-1, P.4-1)
Revised all pages for Exploded Views (P.5-1)
MODEL NAME : KE-42XBR900
SERVICE MANUAL
PARTSNo.: 9-978-755-02
MODIFICATION
HISTORY
* Blue characters are linking.

SERVICE MANUAL
SPECIFICATIONS
KE-42XBR900
FLAT PANEL COLOR TV
US Model
Canadian Model
Panel System Plasma Display panel
Display resolution Display resolution:
(horizontal) ×768 pixels (vertical)
Antenna 75 ohm external terminal for VHF/UHF
Television System NTSC, American TV Standard
Channel Coverage VHF 2-13
UHF 14-69
CATV 1-125
Power Requirements 120V, 60 Hz
Inputs/Outputs
DVI-HDTV 1 terminal, 3.3V T.M.D.S., 50 ohms
The DVI-HDTV input terminal is compliant with the EIA-861 standard and is not
intended for use with personal computers.
Video (IN) 3 total (1 on front panel) 1 Vp-p, 75 ohms unbalanced, sync negative
S Video (IN) (1 on front panel) Y: 1 Vp-p, 75 ohms unbalanced, sync negative
C: 0.286 Vp-p (Burst signal), 75 ohms
Audio (IN) (1 on front panel) 500 mVrms (100% modulation)
Impedance: 47 kilohm
Component Video Input 2 (Y, P
B , P R ) Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative;
P
B : 0.7 Vp-p, 75 ohms
P
R : 0.7 Vp-p, 75 ohms
CONTROL S (OUT)
Variable/Fixed Audio (OUT) More than 408 m Vrms at the maximum volume
setting (Variable)
More than 408 mVrms (Fixed)
Impedance (output): 2 kilohms
Monitor/Fixed Audio (OUT) ×1
S b f (OUT) 1
1
1
hjk
3 total
6 total
1024 pixels

KE-42XBR900(UC) 2
()
Sub woofer (OUT) 1
2
1
phono jack
RF Input
Converter
Supplied Accessories Remote Control RM-927Y
AAA (LR03) Batteries 2 supp
AC power code (2)
Display interface cable (1)
Antenna cable (1)
Cleaning cloth
lied for remote control
Screen Size (measured diagonally) KE-42XBR900 42 inches
Speaker Output 15W ×2
Dimensions (W ×H ×D) PDM-4200 1352 ×720 ×102 mm
(53 1/4 ×28 3/8 ×4 1/8 in)
(17 ×4 1/4 ×14 1/4 in)
MBT-XBR900 430 ×105 ×360 mm
Design and specifications are subject to change without notice.
Mass Display unit
PDM-4200: 39kg (86 lbs )
Media receiver unit
MBT-XBR900: 7.5kg (16 lbs)
Power Consumption Display unit
PDM-4200: 460 W
Media receiver unit
MBT-XBR900: 36 W
In Standby
In Use
Under 1.5 W

KE-42XBR900(UC) 3
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 instruments.
2. A battery-operated AC milliammeter. 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 250
and Sanwa SH-63Trd are examples of a passive VOMs that are suitable.
Nearly all battery operated digital multimeters that have a 2 V AC range
are suitable. (See Fig. A)
Fig. A. Using an AC voltmeter to check AC leakage.
1.5 k Ω 0.15 µFAC Voltmeter
(0.75 V)
To Exposed Metal
Parts on Set
Earth Ground
SAFETY CHECK-OUT
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
contact 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 connector shell, metal trim, “metallized” knobs, screws, and
all other exposed metal parts for AC Leakage. Check leakage as de-
scribed right.

KE-42XBR900(UC) 4
AVERTISSEMENT!!
ATTENTION AUX COMPOSANTS RELATIFS À LA SÉCURITÉ!!
LES COMPOSANTS IDENTIFIÉS PAR UNE TRAME ET UNE
MARQUE !SONT CRITIQUES POUR LA SÉCURITÉ. NE LES
REMPLACER QUE PAR UNE PIÈCE PORTANT LE NUMÉRO
SPECIFIÉ.LES RÉGLAGESDE CIRCUITDONT L’IMPORTANCEEST
CRITIQUE POUR LA SÉCURITÉ DU FONCTIONNEMENT SONT
IDENTIFIÉS DANS LE PRÉSENT MANUEL. SUIVRE CES
PROCÉDURES LORS DE CHAQUE REMPLACEMENT DE
COMPOSANTS CRITIQUES, OU LORSQU’UN MAUVAIS
FONCTIONNEMENT EST SUSPECTÉ.
WARNING!!
SAFETY-RELATED COMPONENT WARNING!!
COMPONENTS IDENTIFIED 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 ADJUST-
MENTS THAT ARE CRITICAL FOR SAFE OPERATION ARE
IDENTIFIED IN THIS MANUAL. FOLLOW THESE PROCEDURES
WHENEVER CRITICAL COMPONENTS ARE REPLACED OR IM-
PROPER OPERATION IS SUSPECTED.

KE-42XBR900(UC) 5
DIAGNOSIS (Reliability Self Diagnostic Display Specifications for MEDIA RECEIVER)
1) *Operation count is based on WDT.
*For flashes, the Power/Standby LED flashes in red.
*The flash period is based on the reliability standard.
The abnormal conditions are indicated by the following LED flashes.
Flash Count Error Display Name Error Description Oprating Detection Port
4 Fan Error Error detected for Detects Low when fan IC6200 pin #2
fan box function normally.
Detects High when Fan stops
abnormally
8 Digtal OVP OVP for DD Con- Detects High when normal. IC5210 pin #49
verter on DP board Detects Low when abnormal.
9 Panel Error Panel malfunction Detects during communication
detected with panel.
Repair part
•FAN
•FAN CONNECTOR
•SET 11V LINE
•SET 5V LINE
DP board
•Q1612, Q1613, Q1614
Panel Display Unit
*A failure part can be expected by the number of times of blink of LED.
*When two failures occur, the failure item generated previously is detected.
*When failure occurs simultaneously, an item with little number of times of blink is detected.
*In other than “Fan Error”, the unit is in standby state and blink LED at intervals of regulation.
In “Fan Error”, the unit is in a standby state after display for 1 minute about the message of “Fan problem –
Powering down”
every about 0.3s
about 3s
•Timing of LED blink (example of 4 times blink)
ON
OFF

KE-42XBR900(UC) 6
In the following case, POWER LED of Media Receiver Box blinks at a fixed interval in ORANGE
•When the cable which connects between Media Receiver Box and Panel Display has fallen out.
•When the AC code for Panel Display has fallen out.
In the following case, POWER LED of Panel Display blinks at a fixed interval in ORANGE
•When the cable which connects between Media Receiver Box and Panel Display has fallen out.
•When the AC code for Media Receiver Box has fallen out.
2)
The example which judges whether it is failure
• POWER LED of Media Receiver Box: Blink 9 times in RED, and of Panel Display blink,
and No picture or Power circuit does not work →Large possibility that Panel Display is out of order.
•When turn on Media Receiver Box, and NO LED of Box shine
•When NO Blue LED of Box shine →Large possibility that Media Receiver Box is out of order.
Check SET5V or IIC line on H1 board.
•When turn on Media Receiver Box, and Fan does not work
→Large possibility that Media Receiver Box is out of order
3)
→Large possibility that Media Receiver Box is out of order.

KE-42XBR900(UC) 7
SAFETY CHECK-OUT ................................................... 3
DIAGNOSIS ...................................................................... 5
1. DISASSEMBLY
1-1. Display Unit (PDM-4200)
1-1-1.Rear Cover Removal ....................................... 1-1
1-1-2.K and F Boards Removal ................................ 1-2
1-1-3.P Board Removal ............................................ 1-3
1-1-4.G and F2 Boards Removal .............................. 1-4
1-1-5.R1 Board Removal .......................................... 1-5
1-1-6.R2 Board Removal .......................................... 1-6
1-2. Media Receiver Unit (MBT-XBR900)
1-2-1.Panel and Covers Removal.............................. 1-7
1-2-2.H1 Board Removal ......................................... 1-8
1-2-3.H4 Board Removal.......................................... 1-9
1-2-4.H3 Board Removal ......................................... 1-10
1-2-5.MS2 Board Removal....................................... 1-11
1-2-6.H2 Board Removal ......................................... 1-12
1-2-7.A Board Removal............................................ 1-13
1-2-8.B Block Assy Removal .................................. 1-14
1-2-9.M, AD, and AU Boards Removal ................... 1-15
TABLE OF CONTENTS
Section Title Page Section Title Page
1-2-10.A and AU Boards Removal........................... 1-16
1-2-11.M Board Removal ........................................ 1-17
1-2-12.IF Boards Removal........................................ 1-18
1-2-13.U1 Boards Removal ...................................... 1-19
1-2-14.U2 Boards Removal ...................................... 1-20
2. ADJUSTMENTS
2-1. VS, VD Voltage Adjustment (PDM-4200)............... 2-1
2-2. White Balance Adjustment (PDM-4200).................. 2-2
3. TROUBLESHOOTING
3-1. Display Unit (PDM-4200) ........................................ 3-1
3-2. Media Receiver Unit (MBT-XBR900) ..................... 3-2
4. DIAGRAMS
4-1. Block Diagrams
4-1-1.Display Unit(PDM-4200)................................ 4-1
4-1-2.Media Receiver Unit (MBT-XBR900) ........... 4-6
4-2. Frame Diagram ......................................................... 4-15
4-3. Circuit Boards Location
4-3-1.Display Unit(PDM-4200)................................ 4-16

KE-42XBR900(UC) 8
Section Title Page Section Title Page
4-3-2.Media Receiver Unit (MBT-XBR900)............ 4-17
4-4. Schematic Diagrams and Printed WiringBoards....... 4-18
4-4-1.Display Unit(PDM-4200)................................ 4-19
(1)Schematic Diagrams of F Board ......................... 4-19
(2)Schematic Diagram of F2 Board ......................... 4-20
(3)Schematic Diagrams of G Board ......................... 4-21
(4)Schematic Diagram of K Board .......................... 4-25
(5)Schematic Diagrams of P Board ......................... 4-27
(6)Schematic Diagrams of R1 amd R2 Boards ........ 4-32
4-4-2.Media Receiver Unit (MBT-XBR900)................... 4-33
(1)Schematic Diagrams of A Board ......................... 4-33
(2)Schematic Diagram of AD Board ....................... 4-36
(3)Schematic Diagrams of AU Board ...................... 4-41
(4)Schematic Diagram of DP Board ........................ 4-43
(5)Schematic Diagrams of H1 and H5 Boards ......... 4-45
(6)Schematic Diagrams of H2 Board ....................... 4-47
(7)Schematic Diagram of H3 and H4 Board ............ 4-48
(8)Schematic Diagrams of IFA Board ..................... 4-49
(9)Schematic Diagrams of M Board ........................ 4-51
(10)Schematic Diagrams of MS2 Boards ................ 4-57
(11)Schematic Diagrams of U1 Board ..................... 4-59
(12)Schematic Diagram of U2 Board ...................... 4-61
(13)Schematic Diagram of BM1C Board ................ 4-62
(14)Schematic Diagram of DICA Board ................. 4-65
4-5. Semiconductors......................................................... 4-71
5. EXPLODED VIEWS .................................................. 5-1
5-1. Display Unit (PDM-4200) ....................................... 5-2
5-2. Media Receiver Unit-1 (MBT-XBR900) ................. 5-4
5-3. Media Receiver Unit-2 (MBT-XBR900).................. 5-6
5-4.
Packing Materials for Display Unit (PDM-4200) ........ 5-7
5-5. Packing Materials for Media Receiver Unit
(MBT-XBR900) ...................................................... 5-8
6. ELECTRICAL PARTS LIST ................................... 6-1

KE-42XBR900(UC) 1-1
SECTION 1
DISASSEMBLY
1-1. PANEL UNIT (PDM-4200)
1-1-1. REAR COVER REMOVAL
4Rear cover assy
1Eight screws
(+PSW 5X16)
2Three screws
(+PSW 3X8)
3Ten screws
(+BVTP 4X16)
3Ten screws
(+BVTP 4X16)
1

KE-42XBR900(UC) 1-2
1-1-2. K AND F BOARDS REMOVAL
3Four screws
(+PSW 3X8)
1Two screws
(+PSW 3X8)
2F Board
4K Board

KE-42XBR900(UC) 1-3
1-1-3. P BOARD REMOVAL
3Four screws
(+PSW 3X8)
4P Board
1Two Connector screws
2Two screws
(M2.6 S HEAD)

KE-42XBR900(UC) 1-4
1-1-4. G AND F2 BOARDS REMOVAL
1Three screws
(+BVTP 3X12)
2F2 Board
3Seven screws
(+BVTP 3X12)
4G Board

KE-42XBR900(UC) 1-5
1-1-5. R1 BOARD REMOVAL
1Two screws
(+BVTP 4X16)
2Filter bracket (V) assy
3Three screws
(+BVTP 3X10)
Earth plate
4R1 Board

KE-42XBR900(UC) 1-6
1-1-6. R2 BOARD REMOVAL
7R2 Board
1Four screws
(+BVTP 4X16)
1Four screws
(+BVTP 4X16)
2Four screws
(+PSW 5X16)
2Four screws
(+PSW 5X16)
3Panel assy
4Two screws
(+BVTP 4X16)
5Filter bracket (H) assy
6Two screws
(+BVTP 3X10)
Earth plate

KE-42XBR900(UC) 1-7
1-2. MEDIA RECEIVER UNIT (MBT-XBR900)
1-2-1. PANEL AND COVERS REMOVAL
!∞ Rear panel
6Bottom cover assy
9Front panel assy
1Two screws
(+PSW 3X8) 3Two screws
(+PSW 3X8)
!¡ Two screws (HEX)
!™ Two screws (HEX)
!£ Four screws (+PSW 3X8)
!¢ Two screws (+PSW 3X8)
0Two screws GRIP, M2.6 S'HEAD(EG)
3Two screws
(+PSW 3X8)
7Eight screws
(precision)
7Four screws
(precision)
2Screw
(+PSW 3X8)
4Screw
(+PSW 3X8)
5Top cover assy
8Top chassis assy

KE-42XBR900(UC) 1-8
1-2-2. H1 BOARD REMOVAL
1Two screws
(+BVTP 3X12)
2H1 Board
1Two screws
(+BVTP 3X12)
Front panel

KE-42XBR900(UC) 1-9
1-2-3. H4 BOARD REMOVAL
1Two screws
(+BVTP 3X12)
2H4 Board
Front panel

KE-42XBR900(UC) 1-10
1-2-4. H3 BOARD REMOVAL
1Three screws
(+BVTP 3X12)
2H3 Board
Front panel

KE-42XBR900(UC) 1-11
1-2-5. MS2 BOARD REMOVAL
3Two screws
(+BVTP 3X12)
4MS2 Board
Front panel
1Two screws
(+BVTP 3X12)
2MS bracket