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Sony XM-ZR604 Service Manual

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SERVICE MANUAL

Ver. 1.1 2007. 08
Sony Corporation
9-887-768-02
2007H04-1
eVehicle Division
© 2007. 08
Published by Sony Techno Create Corporation
Photo: Red Logo
SPECIFICATIONS
Circuit system
OTL (output transformerless) circuit
Pulse power supply
Inputs
RCA pin jacks
High level input connector
Input level adjustment range
0.3 – 6 V (RCA pin jacks),
2.8 – 12 V (High level input)
Outputs
Speaker terminals
Speaker impedance
2 – 8 Ω (stereo)
4 – 8 Ω (when used as a bridging amplifier)
4 speakers: 110 W × 4 (at 4 Ω)
Maximum output
3 speakers: 150 W × 2 (at 2 Ω) + 300 W × 1 (BTL, at 4 Ω)
Rated output (supply voltage at 14.4 V)
4 speakers:
60 W × 4 (20 Hz – 20 kHz, 1% THD, at 4 Ω)
65 W × 4 (20 Hz – 20 kHz, 0.1% THD, at 2 Ω)
Frequency response
5 Hz – 50 kHz (
0.005% or less (at 1 kHz, 4 Ω)
Harmonic distortion
Low-pass filter
80 Hz, –18 dB/oct
High-pass filter
80 Hz, –12 dB/oct
Power requirements
12 V DC marine battery (negative ground)
Power supply voltage
10.5 – 16 V
at rated output : 33 A (4 Ω, 60 W × 4)
Current drain
Remote input : 1 mA
Dimensions
Approx. 396 × 55 × 256 mm (w/h/d)
not incl. projecting parts and controls
Mass
Approx. 3.1 kg not incl. accessories
Supplied accessories
Mounting screws (4)
High level input cord (1)
Protection cap (1)
Design and specifications are subject to change without
notice.
XM-ZR604
+0
dB)
–3
STEREO POWER AMPLIFIER
AEP Model
UK Model
E Model
1

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  Summary of Contents for Sony XM-ZR604

  • Page 1: Service Manual

    Supplied accessories Mounting screws (4) High level input cord (1) Protection cap (1) Design and specifications are subject to change without notice. STEREO POWER AMPLIFIER Sony Corporation 9-887-768-02 2007H04-1 eVehicle Division © 2007. 08 Published by Sony Techno Create Corporation...
  • Page 2: Table Of Contents

    WITH MARK 0 ON THE SCHEMATIC DIAGRAMS AND IN THE PARTS LIST ARE CRITICAL TO SAFE OPERATION. REPLACE THESE COMPONENTS WITH SONY PARTS WHOSE PART NUMBERS APPEAR AS SHOWN IN THIS MANUAL OR IN SUPPLEMENTS PUBLISHED BY SONY.
  • Page 3: General

    El representante autorizado para la aplicación de la LEVEL LEVEL manipulación en el momento de deshacerse de este directiva EMC y la seguridad de los productos es Sony producto. El reciclaje de materiales ayuda a conservar FRONT REAR Deutschland GmbH, Hedelfinger Strasse 61, 70327 los recursos naturales.
  • Page 4: Installation

    XM-ZR604 Connections/Conexiones/Conexões Make the terminal connections as illustrated below. Realice las conexiones de terminal como se ilustra a continuación. Installation Ligue os terminais conforme exibido na figura abaixo. Before Installation First, place the unit where you plan to install it, and mark the positions of the 4 screw holes on •...
  • Page 5: Speaker Connections

    XM-ZR604 Speaker Connections Turn on or off the LPF and HPF switch at the unit rear as illustrated below. Conexiones de los altavoces Encienda o apague los interruptores LPF y HPF situados en la parte posterior de la unidad, como se muestra a continuación.
  • Page 6 XM-ZR604 Dimensions/Dimensiones/Dimensões Input Connections/Conexiones de entrada/Conexões de entrada Unit: mm (in) 396 (15 Unidad: mm 339 (13 Line Input Connection Unidade: mm Conexión de entrada de línea Conexão de entrada de linha Car audio unit Sistema de audio para automóvil Rádio automotivo...
  • Page 7: Disassembly

    XM-ZR604 SECTION 2 DISASSEMBLY Note : This set can be disassemble according to the following sequence. 2-1. BOTTOM PLATE (Page 7) 2-2. MAIN BOARD SECTION (Page 8) 2-3. MAIN BOARD (Page 8) Note : Follow the disassembly procedure in the numerical order given.
  • Page 8 XM-ZR604 2-2. MAIN BOARD SECTION 1 screw (+BTP 3 × 6) 2 three screws 3 three screws (+P 3 × 8) (+P 3 × 8) 4 three screws (+P 3 × 8) 5 MAIN board section main heat sink 2-3. MAIN BOARD...
  • Page 9: Diagrams

    XM-ZR604 SECTION 3 DIAGRAMS 3-1. BLOCK DIAGRAM (FRONT) PRE AMP IC801 (1/2) CN903 OVERLOAD GAIN CONTROL AMP MUTE FRONT CNJ101 (1/2) IC805 (1/2) SWITCH SPEAKER Q112 Q101 VR801-1 IC803 (1/2) DIFFERENTIAL DRIVE DRIVE POWER Q103 Q104 Q108 Q110 MUTE BIAS...
  • Page 10 XM-ZR604 • Note for Replacement of the Transistors • Waveform THIS NOTE IS COMMON FOR PRINTED WIRING The transistors Q110, 111, 210, 211, 310, 311, 410 and 411 have BOARDS AND SCHEMATIC DIAGRAMS. two different ranks: P rank and Y rank.
  • Page 11: Printed Wiring Board

    XM-ZR604 3-2. PRINTED WIRING BOARD : Uses unleaded solder. MAIN BOARD • Semiconductor Location Ref. No. Location Ref. No. Location D101 Q210 D102 Q211 D201 Q212 D202 Q301 D301 Q302 D302 Q303 D401 Q304 D402 Q305 D801 Q306 D802 Q307...
  • Page 12: Schematic Diagram -Main Section (1/2)

    XM-ZR604 3-3. SCHEMATIC DIAGRAM — MAIN SECTION (1/2) — R159 R158 R175 D101 R155 Q108 R170 Q104 Q103 C152 Q110 R165 Q112 R167 R177 R163 R112 C151 C153 Q101 VR801 R113 JC726 R153 R161 Q107 CNJ101 IC801(1/2) TP15 R108 C111...
  • Page 13: Schematic Diagram -Main Section (2/2)

    XM-ZR604 3-4. SCHEMATIC DIAGRAM — MAIN SECTION (2/2) — • Refer to page 10 for Waveform and page 14 for IC Block Diagram. (Page 12) R805 C805 Q807 TP22 TP28 Q812 Q811 Q809 Q810 R926 Q911 T901 C819 D803 TP26...
  • Page 14 XM-ZR604 • IC Block Diagram IC903 TL594INSR (MAIN BOARD (2/2)) ERROR REF 5V ERROR 0.1V XM-ZR604...
  • Page 15: Exploded Views

    XM-ZR604 SECTION 4 EXPLODED VIEWS NOTE: • The mechanical parts with no reference • Color Indication of Appearance Parts The components identified by mark 0 or dotted line with mark number in the exploded views are not supplied. Example : 0 are critical for safety.
  • Page 16: Main Board Section

    XM-ZR604 4-2. MAIN BOARD SECTION not supplied not supplied Q111,Q110, Q310,Q311,Q411,Q410 Q211,Q210 not supplied D804,D803 Q911,Q910,Q912,Q913 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark A-1219-711-B MAIN BOARD, COMPLETE Q211 8-729-024-77 TRANSISTOR 2SA1908-Y 3-225-184-12 SCREW (+PS.TT.3XL) Q310...
  • Page 17: Electrical Parts List

    XM-ZR604 SECTION 5 MAIN ELECTRICAL PARTS LIST NOTE: • Due to standardization, replacements in • SEMICONDUCTORS The components identified by mark 0 or dotted line with mark the parts list may be different from the In each case, u : µ, for example: 0 are critical for safety.
  • Page 18 XM-ZR604 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C818 1-162-974-11 CERAMIC CHIP 0.01uF D807 8-719-914-43 DIODE DAN202K C819 1-165-949-41 ELECT 1500uF D901 8-719-914-43 DIODE DAN202K C820 1-165-949-41 ELECT 1500uF D902 8-719-914-43 DIODE DAN202K C821...
  • Page 19 XM-ZR604 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < COIL > Q411 8-729-024-76 TRANSISTOR 2SA1908-P Q411 8-729-024-77 TRANSISTOR 2SA1908-Y L901 1-411-756-21 COIL, CHOKE 50uH Q412 8-729-120-28 TRANSISTOR 2SC1623-L5L6 Q802 8-729-120-28 TRANSISTOR 2SC1623-L5L6 < TRANSISTOR >...
  • Page 20 XM-ZR604 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R166 1-216-182-00 RES-CHIP 1/8W R309 1-218-871-11 METAL CHIP 0.5% 1/10W R167 1-216-134-00 RES-CHIP 1/8W R310 1-218-871-11 METAL CHIP 0.5% 1/10W R168 1-216-134-00 RES-CHIP 1/8W R311 1-218-853-11 METAL CHIP 1.8K...
  • Page 21 XM-ZR604 MAIN Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R465 1-216-837-11 METAL CHIP 1/10W R931 1-216-789-11 METAL CHIP 1/10W R466 1-216-182-00 RES-CHIP 1/8W R932 1-216-150-11 RES-CHIP 1/8W R467 1-216-134-00 RES-CHIP 1/8W R933 1-216-150-11 RES-CHIP 1/8W...
  • Page 22 XM-ZR604 Ref. No. Part No. Description Remark PARTS FOR INSTALLATION AND CONNECTIONS ************************************** X-2108-372-1 SCREW SUB ASSY (MOUNTING SCREW) 1-823-952-11 CORD (WITH CONNECTOR) (HIGH LEVEL INPUT) (0.2m) 2-695-957-01 COVER (POWER) φ 5 × 15 mm ( × 4) 0.2 m...
  • Page 23 XM-ZR604 MEMO...
  • Page 24 XM-ZR604 REVISION HISTORY Clicking the version allows you to jump to the revised page. Also, clicking the version at the top of the revised page allows you to jump to the next revised page. Ver. Date Description of Revision 2007. 07 2007.