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Sony XM-7557 Service Manual

Stereo power amplifer
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SERVICE MANUAL
Ver 1.1 2004. 04
Sony Corporation
9-926-590-12
e Vehicle Company
2004D02-1
Published by Sony Engineering Corporation
© 2004.04
XM-7557
SPECIFICATIONS
STEREO POWER AMPLIFER
US Model
Canadian Model
AEP Model
UK Model
E Model
1

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  Summary of Contents for Sony XM-7557

  • Page 1 XM-7557 SERVICE MANUAL US Model Canadian Model Ver 1.1 2004. 04 AEP Model UK Model E Model SPECIFICATIONS STEREO POWER AMPLIFER Sony Corporation 9-926-590-12 e Vehicle Company 2004D02-1 Published by Sony Engineering Corporation © 2004.04...
  • Page 2: Table Of Contents

    TABLE OF CONTENTS Notes on chip component replacement • Never reuse a disconnected chip component. • Notice that the minus side of a tantalum capacitor may be 1. SERVICE MODE ............. 3 damaged by heat. 2. GENERAL ................4 3. DISASSEMBLY 3-1.
  • Page 3: Service Mode

    SECTION 1 SERVICE NOTE Clearing the Protector During Repairs • OVER CURRENT : Detects overcurrent during output. • OFF SET : Detects DC offset at the speaker terminal. 1. Clearing the OVER CURRENT protector • When the position of the MODE switch (S801/power board) is set to HI-CURRENT : Cut the jumper wire JW230 of the amplifier board.
  • Page 4: General

    SECTION 2 This section is extracted from instruction manual. GENERAL...
  • Page 7: Disassembly

    SECTION 4 SECTION 3 DISASSEMBLY ELECTRICAL ADJUSTMENT Note: Follow the disassembly procedure in the numerical order given. IDLING CURRENT ADJUSTMENT 4 Bottom plate 3-1. SIDE PLATE,SUB 1/SUB 2 AND FILTER BOARD • Perform adjustments in the HI-VOLTAGE mode. 1 Three screws 1 Adjustment point (BTP3x8) Semi-fixed resistors VR101, VR201, VR301, VR401, VR501,...
  • Page 8: Diagrams

    XM-7557 SECTION 5 DIAGRAMS 5-1. BLOCK DIAGRAM – AMPLIFIER SECTION – LINE SWITCH DIRECT Q102 SW703 SPEAKER OUT DIFFERENTIAL POWER AMP (VOLTAGE STAGE) CN704 LOWBOOST LINE SWITCH PRE AMP H.P.F H.P.F L.P.F L.P.F CNJ702 IC701 Q104-105 Q108 Q103 LEVEL IC703...
  • Page 9: Block Diagram - Power Section

    XM-7557 5-2. BLOCK DIAGRAM – POWER SECTION – POWER BOARD LED BOARD D803 D804 D805 MODE HI-C HI-V THERMAL OVER CURRENT OFFSET S801 CNB805 CNP804 OFFSET LED OFFSET CONTROL Q809-810 Q804 D801 D802 AMPLIFIER D806 HI-VOLTAGE HI-CURRENT BOAD CNP805 MUTE CONTROL...
  • Page 10: Block Diagram - Sub 1/Sub 2 Section

    XM-7557 5-3. BLOCK DIAGRAM – SUB 1/SUB 2 SECTION – THIS NOTE IS COMMON FOR PRINTED WIRING BOARDS AND SCHEMATIC DIAGRAMS. (In addition to this, the necessary note is printed in each block.) SUB 1 BOARD CNJ711 CNJ709 CNP709 SUB 1 For schematic diagrams.
  • Page 11: Printed Wiring Board -Filter/Sub 1/Sub 2 Section

    XM-7557 5-5. PRINTED WIRING BOARD – FILTER/SUB 1/SUB 2 SECTION – FILTER BOARD JW24 S701 S702 S704 R258 R458 S705 • Semiconductor VR702 VR705 Location R157 R357 C452 C252 C153 Ref. No. Location C353 R257 R457 JW37 IC707 AMPLIFIER BOARD...
  • Page 12: Printed Wiring Board -Amplifier Section

    XM-7557 5-6. PRINTED WIRING BOARD – AMPLIFIER SECTION – AMPLIFIER BOARD POWER BOARD CN705 POWER BOARD CNJ701 CN704 CNJ702 SPEAKER OUT INPUT SPEAKER OUT CNJ703 (Page 11) (Page 11) SUBWOOFER MONO-R MONO-L MONO-R MONO-L CN707 SPEAKER OUT VR706 VR704 S706...
  • Page 13: Schematic Diagram -Amplifier(1/3)/Filter/Sub 1/Sub 2 Section

    XM-7557 5-7. SCHEMATIC DIAGRAM – AMPLIFIER (1/3)/FILTER/SUB 1/SUB 2 SECTION – • See page 10 for IC Block Diagram. • Semiconductor Location Ref. No. Location Ref. No. Location D101 G-12 Q211 G-10 D102 G-11 Q212 AMPLIFIER BOARD D103 Q213 D201...
  • Page 14: Schematic Diagram/Printed Wiring Board -Amplifier (2/3)/Led/Tr Section

    XM-7557 5-8. SCHEMATIC DIAGRAM/PRINTED WIRING BOARD – AMPLIFIER (2/3)/LED/TR SECTION – • See page 10 for IC Block Diagram. R141 42.9 POWER BOARD 0.1X2 AMPLIFIER BOARD CNP804 LED BOARD Q104-107 R119 Q108 (Page 15 ) DIFFERENTIAL 4.7K 42.3 2SA1360JY 26.8 26.8...
  • Page 15: Printed Wiring Board -Power Section

    XM-7557 5-9. PRINTED WIRING BOARD – POWER SECTION – POWER BOARD (SIDE A) • Semiconductor Location Ref. No. Location D903 D905 D906 R820 R835 D910 C921 C902 D902 D912 D807 D913 D901 R837 R903 R904 D808 IC813 Q902 IC901 IC903...
  • Page 16 XM-7557 CN802 CNJ801 REMOTE +12V +12V POWER BOARD (SIDE B) • Semiconductor Location MODE Ref. No. Location HI-C HI-V F901 F902 F903 F904 S801 S802 D806 CNJ801 D807 R838 D808 D901 D902 D904 D907 IC813 LED BOARD AMPLIFIER D908 CNB804...
  • Page 17: Schematic Diagram -Power/Amplifier (3/3)/Tr/Led Section

    XM-7557 5-10. SCHEMATIC DIAGRAM – POWER/AMPLIFIER (3/3)/TR/LED SECTION – • See page 10 for IC Block Diagram. AMPLIFIER AMPLIFIER TO AMPLIFIER BOARD (2/3) BOARD (1/3) BOARD (2/3) L702 AMPLIFIER BOARD µ D708 0.45 +42V C757 C720 D709 L703 0.001 µ...
  • Page 18: Exploded Views

    A-3317-936-A POWER BOARD, COMPLETE 3-039-219-01 HEATSINK (COVER) * 12 1-675-267-11 FILTER BOARD 3-912-431-01 SCREW (P) 3-039-173-01 PLATE (BKT), BOTTOM 3-704-177-11 EMBLEM (No. 7), SONY * 55 A-3317-937-A AMPLIFIER BOARD, COMPLETE * 64 3-039-172-01 HOLDER, VOL 3-039-170-01 LENS(COVER) 3-040-933-01 BOLT, M4 HEXAGON HOLE...
  • Page 19: Electrical Parts List

    SECTION 7 AMPLIFIER ELECTRICAL PARTS LIST Note: • Due to standardization, replacements in the parts list • SEMICONDUCTORS When indicating parts by reference In each case, u: µ , for example: may be different from the parts specified in the number, please include the board uA...: µ...
  • Page 20 AMPLIFIER Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C536 1-126-044-11 ELECT CNP703 1-784-917-11 CONNECTOR, BOARD TO BOARD 9P C537 1-126-044-11 ELECT * CNP708 1-564-704-11 PIN, CONNECTOR (SMALL TYPE) 2P * CNP710 1-564-513-11 PLUG, CONNECTOR 10P C538 1-126-044-11 ELECT * CNP803 1-564-705-11 PIN, CONNECTOR (SMALL TYPE) 3P...
  • Page 21 AMPLIFIER Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark L706 1-410-396-71 INDUCTOR 0.45uH Q413 8-729-216-21 TRANSISTOR 2SA1162-Y < TRANSISTOR > Q414 8-729-202-17 TRANSISTOR 2SC2713L-TE85R Q503 8-729-184-53 TRANSISTOR 2SC1841-FA Q101 8-729-107-43 TRANSISTOR 2SC3624-T1L1718 Q504 8-729-184-53 TRANSISTOR 2SC1841-FA Q102 8-729-203-48 TRANSISTOR 2SC3327-A...
  • Page 22 AMPLIFIER Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R120 1-208-453-61 RES,CHIP 4.7K 1/10W R226 1-249-576-11 CARBON 1/4W R227 1-249-955-11 CARBON 1/4W R121 1-216-238-00 RES,CHIP 1/8W R228 1-249-955-11 CARBON 1/4W R122 1-216-238-00 RES,CHIP 1/8W R229 1-216-635-11 METAL CHIP 0.5% 1/10W R123...
  • Page 23 AMPLIFIER Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R333 1-208-534-61 RES,CHIP 100K 1/10W R440 1-208-449-61 RES,CHIP 3.3K 1/10W R334 1-208-534-61 RES,CHIP 100K 1/10W R335 1-211-960-11 RES,CHIP 1/10W R441 1-205-991-11 METAL 0.1/0.1 R442 1-205-991-11 METAL 0.1/0.1 R336 1-211-960-11 RES,CHIP 1/10W...
  • Page 24 AMPLIFIER FILTER Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark R570 1-208-441-61 RES,CHIP 1.5K 1/10W < VARIABLE RESISTOR > R571 1-208-434-61 RES,CHIP 1/10W R572 1-242-800-11 METAL 0.05/0.05 VR101 1-241-760-11 RES, ADJ, CERMET 470 (IDLING) R573 1-242-800-11 METAL 0.05/0.05 VR201 1-241-760-11 RES, ADJ, CERMET 470 (IDLING)
  • Page 25 FILTER POWER Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark IC708 8-759-711-82 IC NJM4580E(T1) 1-675-268-11 LED (5CH) BOARD IC709 8-759-711-82 IC NJM4580E(T1) ************** IC710 8-759-711-82 IC NJM4580E(T1) IC711 8-759-711-82 IC NJM4580E(T1) < DIODE > IC712 8-759-711-82 IC NJM4580E(T1) D801 8-719-076-62 DIODE GL-5ED60 (HI-VOLTAGE) D802...
  • Page 26 POWER Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C921 1-163-141-00 CERAMIC CHIP 0.001uF F903 1-576-256-11 FUSE (BLADE TYPE) (AUTO FUSE)(25A) C922 1-163-021-11 CERAMIC CHIP 0.01uF F904 1-576-256-11 FUSE (BLADE TYPE) (AUTO FUSE)(25A) C923 1-126-009-81 ELECT 100uF C924 1-126-006-11 ELECT...
  • Page 27 POWER Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark < RESISTOR > R933 1-220-852-11 CARBON 1/4W R934 1-220-852-11 CARBON 1/4W R816 1-216-190-00 RES,CHIP 1/8W R935 1-220-852-11 CARBON 1/4W R817 1-216-190-00 RES,CHIP 1/8W R936 1-208-462-61 RES,CHIP 1/10W R818 1-216-190-00 RES,CHIP 1/8W...
  • Page 28 SUB 2 SUB 1 Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark 1-675-265-11 SUB 1 (5CH) BOARD R512 1-208-518-61 RES,CHIP 1/10W R513 1-216-631-11 METAL CHIP 0.5% 1/10W **************** R514 1-208-453-61 RES,CHIP 4.7K 1/10W < CAPACITOR > R515 1-208-441-61 RES,CHIP 1.5K...
  • Page 29 SUB 2 Ref. No. Part No. Description Remark S710 1-771-802-11 SWITCH (TEST TONE) < VARIABLE RESISTOR > VR707 1-225-922-11 RES, VAR 20K/20K (FILTER/50Hz-200Hz) ************************************************************** 1-675-500-11 TR BOARD ********* < TRANSISTOR > Q703 8-729-141-83 TRANSISTOR 2SB1375 ************************************************************** MISCELLANEOUS ************* F901 1-576-256-11 FUSE (BLADE TYPE) (AUTO FUSE) (25A) F902 1-576-256-11 FUSE (BLADE TYPE) (AUTO FUSE) (25A) F903...
  • Page 30 XM-7557 MEMO...
  • Page 31: Service Manual

    XM-7557 US Model Canadian Model SERVICE MANUAL AEP Mode UK Model E Model Ver 1.0 1999. 10 SUPPLEMENT-1 File this supplement with the service manual. Subject: 1. CHANGE OF DISASSEMBLY 2. CHANGE OF EXPLODED VIEWS 3. CHANGE OF ELECTRICAL PARTS LIST 4.
  • Page 32 1. CHANGE OF DISASSEMBLY : Changed portion Page 3-2. AMPLIFIER/POWER BOARD AND LED BOARD 3 Six screws !™ Six screws 6 Three screws (BVTP3x14) (P3x10) (BTP3x8) 2 Four screws (P4x40) 4 Two Retainers !¶ Three brackets (POWER) !¢ Sub heat sink (Amplifier) !§...
  • Page 33 2. CHANGE OF EXPLODED VIEWS : Changed portion Page New Type Former Type Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark * 66 3-042-419-01 BRACKET (POWER) not supplied #4 #4 (Including Ref No.62 ) (Including Ref No.55 ) (Including Ref No.55 ) (Including...
  • Page 34 3. CHANGE OF ELECTRICAL PARTS LIST : Changed portion Page Former Type New Type Ref. No. Part No. Description Remark Ref. No. Part No. Description Remark C113 1-102-959-61 CERAMIC 22PF C113 1-102-508-11 CERAMIC 10PF 0.5PF C213 1-102-508-11 CERAMIC 10PF 0.5PF C213 1-102-959-61 CERAMIC 22PF...
  • Page 35 XM-7557 4. CHANGE OF DIAGRAMS • BLOCK DIAGRAM – AMPLIFIER SECTION – LINE SWITCH DIRECT Q102 SW703 SPEAKER OUT DIFFERENTIAL POWER AMP CN704 LOWBOOST (VOLTAGE STAGE) LINE SWITCH PRE AMP H.P.F H.P.F L.P.F L.P.F CNJ702 IC701 Q104-105 Q108 Q103 LEVEL...
  • Page 36 XM-7557 • BLOCK DIAGRAM – POWER SECTION – POWER BOARD LED BOARD D803 D804 D805 MODE HI-C HI-V THERMAL OVER CURRENT OFFSET S801 CNB805 CNP804 OFFSET LED OFFSET CONTROL Q809-810 Q804 D801 D802 D806 AMPLIFIER HI-VOLTAGE HI-CURRENT BOAD CNP805 MUTE CONTROL...
  • Page 37 XM-7557 • PRINTED WIRING BOARD – FILTER/SUB 1/SUB 2 SECTION – FILTER BOARD JW24 S701 S702 S704 R258 R458 S705 • Semiconductor VR702 VR705 Location R157 R357 C452 C252 C153 Ref. No. Location C353 R257 R457 JW37 IC707 AMPLIFIER BOARD...
  • Page 38 XM-7557 • PRINTED WIRING BOARD – AMPLIFIER SECTION – FILTER BOARD AMPLIFIER BOARD CN705 FILTER BOARD CNJ701 CN704 CNJ702 SPEAKER OUT CNJ703 INPUT SPEAKER OUT (Page 7) (Page 7) SUBWOOFER MONO-R MONO-L MONO-R MONO-L CN707 SPEAKER OUT VR706 VR704 S706...
  • Page 39: D101 G-12 Q211 G

    XM-7557 • SCHEMATIC DIAGRAM/PRINTED WIRING BOARD – AMPLIFIER (2/3)/ SECTION – • Semiconductor Location Ref. No. Location Ref. No. Location D101 G-12 Q211 G-10 R141 42.9 0.1X2 AMPLIFIER BOARD D102 G-11 Q212 Q104-107 R119 Q108 42.3 26.8 D103 Q213 DIFFERENTIAL 4.7K...
  • Page 40 XM-7557 • SCHEMATIC DIAGRAM – POWER/AMPLIFIER (3/3)/TR/LED SECTION – AMPLIFIER AMPLIFIER (Page 9) (Page 9) BOARD (1/3) BOARD (2/3) TO AMPLIFIER BOARD (2/3) AMPLIFIER BOARD L702 µ D708 0.45 +45V C757 C720 D709 L703 0.001 µ C722 0.45 0.047 Q704...
  • Page 41 XM-7557 • PRINTED WIRING BOARD – POWER/LED/TR SECTION – POWER BOARD (SIDE A) AMPLIFIER BOARD (Page 8) 1-675-241- • Semiconductor Location POWER BOARD CNP804 LED BOARD (Page 12) Ref. No. Location TR BOARD D801 Q703 CNB804 D802 D802 HI-CURRENT D803...
  • Page 42 XM-7557 POWER BOARD (SIDE B) CN802 CNJ801 +12V +12V REMOTE • Semiconductor F904 F903 F902 F901 Location MODE Ref. No. Location HI-CURRENT HI-VOLTAGE D806 S802 S801 C920 CNJ801 D807 C901 R838 D808 D901 D902 R820 R835 D903 C921 C902 D904...
  • Page 43 XM-7557 US Model Canadian Model SERVICE MANUAL AEP Model UK Model E Model Ver 1.1 2004. 04 SUPPLEMENT-2 File this supplement with the service manual. Subject : Change of Amplifier Board 9-926-590-84...
  • Page 44 XM-7557 When performing service and inspection, check the suffix of the part nimber if the amplifier board. 1. DISCRIMINATION – AMPLIFIER BOARD (COMPONENT SIDE) – New type : 1-675-264-14...
  • Page 45 XM-7557 • PRINTED WIRING BOARD – AMPLIFIER SECTION (SIDE A) – AMPLIFIER BOARD (Component Side) 1-675-264-...
  • Page 46 XM-7557 • PRINTED WIRING BOARD – AMPLIFIER SECTION (SIDE B) – AMPLIFIER BOARD (Conductor Side) 1-675-264-...
  • Page 47 XM-7557 • SCHEMATIC DIAGRAM – AMPLIFER SECTION (1/3) – AMPLIFIER BOARD B– B– C702 C701 220/16V 220/16V 9P CNP702 9P CNJ702 R109 IC701 R115 3.3k S701 NJM4580E Q102 FILTER (T1) 2SC3327-A C153 X10) LINE SW 0.15 C156 47/16V R155 10k C152 0.15...
  • Page 48 XM-7557 • SCHEMATIC DIAGRAM – AMPLIFER SECTION (2/3) – R141 42.9 0.1X2 AMPLIFIER BOARD Q104-107 Q108 R119 R161 42.3 26.8 DIFFERENTIAL 2SA1360JY 26.8 -TB5 D104 Q104 Q111 42.9 1SS226 C119 R135 C706 R146 FS70SMJ-2 2SC1841-FA R149 R150 1000P 470K Q105...
  • Page 49 XM-7557 • SCHEMATIC DIAGRAM – AMPLIFER SECTION (3/3) – AMPLIFIER AMPLIFIER TO AMPLIFIER BOARD (2/3) BOARD (1/3) BOARD (2/3) AMPLIFIER BOARD D708 +34V C720 D709 C722 0.047 R742 R743 Q704 C759 D713 0.047 DRIVER-2SC2712-Y C724 DRIVER D712 C726 T701 D715...
  • Page 50 XM-7557 ELECTRICAL PARTS LIST NOTE: Ref. No. Part No. Description Remarks Ref. No. Part No. Description Remarks • Due to standardization, replacements in the • RESISTORS The components identified by mark 0 C534 1-126-008-51 ELECT 47uF < CONNECTOR > parts list may be different from the parts All resistors are in ohms.
  • Page 51 XM-7557 Ref. No. Part No. Description Remarks Ref. No. Part No. Description Remarks Q107 8-729-140-82 TRANSISTOR 2SA988-PAFAEA Q515 8-729-140-82 TRANSISTOR 2SA988-PAFAEA Q108 8-729-209-18 TRANSISTOR 2SA1360-Y Q516 8-729-209-18 TRANSISTOR 2SA1360-Y Q109 8-729-203-45 TRANSISTOR 2SC3423-O Q110 8-729-055-13 TRANSISTOR 2SD1861-TV2 Q517 8-729-203-45 TRANSISTOR...
  • Page 52 XM-7557 Ref. No. Part No. Description Remarks Ref. No. Part No. Description Remarks R134 1-216-699-11 METAL CHIP 100K 0.5% 1/10W R248 1-208-518-61 RES-CHIP 1/10W R135 1-216-615-11 METAL CHIP 0.5% 1/10W R249 1-215-860-11 METAL OXIDE R250 1-215-860-11 METAL OXIDE R136 1-216-615-11 METAL CHIP 0.5%...
  • Page 53 XM-7557 Ref. No. Part No. Description Remarks Ref. No. Ref. No. Part No. Part No. Description Description Remarks Remarks R407 1-216-631-11 METAL CHIP 0.5% 1/10W R540 1-208-437-61 RES-CHIP 1/10W R408 1-208-453-61 RES-CHIP 4.7K 1/10W R409 1-208-449-61 RES-CHIP 3.3K 1/10W R541...
  • Page 54 XM-7557 SUB1 Ref. No. Part No. Description Remarks Ref. No. Part No. Description Remarks R722 1-208-462-61 RES-CHIP 1/10W C502 1-164-222-91 CERAMIC CHIP 0.22uF R723 1-208-462-61 RES-CHIP 1/10W C504 1-126-047-21 ELECT 4.7uF R724 1-208-462-61 RES-CHIP 1/10W C505 1-126-047-21 ELECT 4.7uF R725...
  • Page 55 XM-7557 SUB1 Ref. No. Part No. Description Remarks R518 1-216-661-11 METAL CHIP 2.7K 0.5% 1/10W R519 1-216-665-11 METAL CHIP 3.9K 0.5% 1/10W R520 1-208-789-11 METAL CHIP 0.5% 1/10W R521 1-208-449-61 RES-CHIP 3.3K 1/10W R522 1-208-437-61 RES-CHIP 1/10W R523 1-208-510-61 RES-CHIP...
  • Page 56: Revision History

    XM-7557 REVISION HISTORY Clicking the version allows you to jump to the revised page. Also, clicking the version at the upper right on the revised page allows you to jump to the next revised page. Ver. Date Description of Revision 1999.06...