XM-ZR704 - Sony Car Audio Service Manual (repair manual)

xm-zr704 service manual
Model
XM-ZR704
Pages
26
Size
8.96 MB
Type
PDF
Document
Service Manual
Brand
Device
Car Audio
File
xm-zr704.pdf
Date

Read Sony XM-ZR704 Service Manual online

SERVICE MANUAL
Sony Corporation
Audio&Video Business Group
Published by Sony Techno Create Corporation
XM-ZR704
SPECIFICATIONS
STEREO POWER AMPLIFIER
9-889-266-01
2008I04-1
© 
2008.09
US Model
Canadian Model
AEP Model
UK Model
E Model
Ver. 1.0  2008.09
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),
 
3 – 12 V (High level input)
Outputs Speaker 
terminals
Speaker impedance 
2 – 8 
Ω (stereo)
 
4 – 8 
Ω (when used as a bridging amplifi er)
Maximum outputs 
2 Speakers: 350 W × 2 (at 4 
Ω)
 4 
Speakers: 
150 
× 4 (at 4 Ω)
Rated outputs (supply voltage at 14.4 V, 20 Hz – 20 kHz, 1% THD)
 2 
Speakers: 
160 
× 2 (at 4 Ω)
 4 
Speakers: 
80 
× 4 (at 2 Ω)
  
70 
× 4 (at 4 Ω)
Frequency response 
10 Hz – 100 kHz (      dB)
Harmonic distortion 
0.05% or less (at 1 kHz, 4 
Ω)
Low-pass fi lter 
50 – 300 Hz, 12 dB/oct
High-pass fi lter 
50 – 300 Hz, 12 dB/oct
Subsonic fi lter 
6 – 70 Hz, 12 dB/oct
Low boost 
0 – 10 dB (40 Hz)
Power requirements 
12 V DC car battery (negative ground)
Power supply voltage 
10.5 – 16 V
Current drain 
at rated output : 45 A (4 
Ω, 70 W × 4)
 
Remote input : 1 mA
Dimensions Approx. 
424 
× 55 × 248 mm
 (16
 3/4
 
× 2
 1/4
 
× 9
 7/8
 in) (w/h/d)
 
not incl. projecting parts and controls
Mass 
Approx. 3.1 kg (6 lb 14 oz) not incl. accessories
Supplied accessories 
Mounting screws (4)
 
High level input cord (1)
 
Protection cap (1)
Design and specifi cations are subject to change without notice.
+0.5
–3.0
XM-ZR704
2
1. GENERAL
 
Location and Function of Controls .................................   3
 Connections 
....................................................................  
4
2. DISASSEMBLY
2-1. Bottom 
Plate 
...................................................................   7
2-2.  MAIN Board Section ......................................................   8
2-3.  LED ILLUMI (R) Board, LED ILLUMI (L) Board .......   8
2-4. MAIN 
Board 
...................................................................   9
3. DIAGRAMS
3-1. Block 
Diagram 
................................................................  11
3-2.  Printed Wiring Board –Main Section– ............................   12
3-3.  Printed Wiring Boards –LED Section– ...........................   13
3-4.  Schematic Diagram –Main Section (1/3)– ......................   14
3-5.  Schematic Diagram –Main Section (2/3)– ......................   15
3-6.  Schematic Diagram –Main Section (3/3)– ......................   16
4. 
EXPLODED  VIEWS
4-1.  Heat Sink (Main) Section ...............................................   17
4-2.  MAIN Board Section ......................................................   18
5. 
ELECTRICAL  PARTS  LIST
  ..............................   19
TABLE  OF  CONTENTS
SAFETY-RELATED  COMPONET  WARNING!
COMPONENTS  IDENTIFIED  BY  MARK  
0  OR  DOTTED  LINE  
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.
ATTENTION  AU  COMPOSANT  AYANT  RAPPORT  
À  LA  SÉCURITÉ!
LES  COMPOSANTS  IDENTIFIÉS  PAR  UNE  MARQUE  
0  SUR  
LES  DIAGRAMMES  SCHÉMATIQUES  ET  LA  LISTE  DES  
PIÈCES  SONT  CRITIQUES  POUR  LA  SÉCURITÉ  DE  FONC-
TIONNEMENT.  NE  REMPLACER  CES  COMPOSANTS  QUE  
PAR  DES  PIÈCES  SONY  DONT  LES  NUMÉROS  SONT  DON-
NÉS  DANS  CE  MANUEL  OU  DANS  LES  SUPPLÉMENTS  
PUBLIÉS  PAR  SONY.
PROTECTOR  OPERATION  CHECK
Thermal Protect
1.  Short across TH901 with the power on.
2.  Verify that the protector is operated and D943 illuminates 
green. When input the signal and verify that there is no output 
on the SP-OUT even when the volume is increased.
3.  Verify that the protector is released and there is an output on 
the SP-OUT when the short is removed.
4.  Likewise, perform items 1 to 3 for TH902 and TH903.
Over Current Protect
1.  Short between the positive and negative sides of the speaker 
output terminal CN904 (1/2) with the power on.
2.  Verify that the protector is operated and D943 illuminates red.
3.  Verify that the protector is not released and D943 remains red 
even when the short is removed.
4.  Verify that the protector is released and D943 illuminates green 
when the power is turned off and then on again.
Offset Protect
1.  Short between the +12V terminal of CN904 (2/2) and the 
(L+R) + or (L+R) – of the speaker output terminal CN904 
(1/2).
 
(Short between +12V terminal and (L+R) + and between +12V 
terminal and (L+R) –.)
2.  Verify that the protector is operated and D943 illuminates red.
3.  Verify that the protector is not released and D943 remains red 
even when the short is removed.
4.  Verify that the protector is released and D943 illuminates green 
when the power is turned off and then on again.
UNLEADED  SOLDER
Boards requiring use of unleaded solder are printed with the lead-
free mark (LF) indicating the solder contains no lead.
(Caution:  Some printed circuit boards may not come printed with 
the lead free mark due to their particular size)
 : LEAD  FREE  MARK
Unleaded solder has the following characteristics.
•  Unleaded solder melts at a temperature about 40 °C higher 
than ordinary solder.
 
Ordinary soldering irons can be used but the iron tip has to be 
applied to the solder joint for a slightly longer time.
 
Soldering irons using a temperature regulator should be set to 
about 350 °C.
Caution: The printed pattern (copper foil) may peel away if 
the heated tip is applied for too long, so be careful!
• Strong 
viscosity
 
Unleaded solder is more viscous (sticky, less prone to fl ow) 
than ordinary solder so use caution not to let solder bridges 
occur such as on IC pins, etc.
• 
Usable with ordinary solder
 
It is best to use only unleaded solder but unleaded solder may 
also be added to ordinary solder.
NOTES  ON  CHIP  COMPONENT  REPLACEMENT
• 
Never reuse a disconnected chip component.
• 
Notice that the minus side of a tantalum capacitor may be dam-
aged by heat.
XM-ZR704
3
SECTION  1
GENERAL
This section is extracted 
from instruction manual.
Location and Function of Controls
 POWER/PROTECTOR indicator
Lights up in green during operation.
When the PROTECTOR is activated the indicator
will change from green to red.
When the PROTECTOR is activated refer to the
Troubleshooting Guide.
 SUBSONIC FILTER cut-off frequency
adjustment control
Set the cut-off frequency (6 - 70 Hz) for the
subsonic filter.
 LEVEL adjustment control
The input level can be adjusted with this control.
Turn it in the clockwise direction when the output
level of the car audio unit seems low.
 Cut-off frequency adjustment control
Set the cut-off frequency (50 - 300 Hz) for the low-
pass or high-pass filter.
 FILTER selector switch
When the switch is in the LP position,the filter is set
to low-pass. When the switch is in the HP position,
the filter is set to high-pass.
 LOW BOOST level control
Turn this control to boost the frequencies around
40 Hz to a maximum of 10 dB.
Precautions
[
This unit is designed for negative ground 12 V DC
operation only.
[
Use speakers with an impedance of 2 to 8 Ω 
(4 to 8 Ω when used as a bridging amplifier).
[
Do not connect any active speakers (with built-in
amplifiers) to the speaker terminals of the unit.
Doing so may damage the active speakers.
[
Avoid installing the unit in areas subject to:
— high temperatures such as from direct sunlight
or hot air from the heater
— rain or moisture
— dust or dirt.
[
If your car is parked in direct sunlight and there is a 
considerable rise in temperature inside the car,
allow the unit to cool down before use.
[
When installing the unit horizontally, be sure not to
cover the fins with the floor carpet etc.
[
If this unit is placed too close to the car audio unit
or antenna, interference may occur. In this case,
relocate the amplifier away from the car audio unit
or antenna.
[
If no power is being supplied to the car audio unit,
check the connections.
[
This power amplifier employs a protection circuit*
to protect the transistors and speakers if the
amplifier malfunctions. Do not attempt to test the
protection circuits by covering the heat sink or
connecting improper loads.
[
Do not use the unit on a weak battery as its
optimum performance depends on a good power
supply.
[
For safety reasons, keep your car audio unit volume
moderate so that you can still hear sounds outside
your car.
Fuse Replacement
If the fuse blows, check the power connection and
replace both the fuses. If the fuse blows again after
replacement, there may be an internal malfunction. In
such a case, consult your nearest Sony dealer.
Warning
When replacing the fuse, be sure to use one matching
the amperage stated above the fuse holder. Never use
a fuse with an amperage rating exceeding the one
supplied with the unit as this could damage the unit.
Protection circuit
This amplifier is provided with a protection circuit that 
operates in the following cases:
— when the unit is overheated
— when a DC current is generated
— when the speaker terminals are short-circuited.
The color of the POWER/PROTECTOR indicator will change 
from green to red, and the unit will shut down.
If this happens, turn off the connected equipment, take out 
the cassette tape or disc, and determine the cause of the 
malfunction. If the amplifier has overheated, wait until the 
unit cools down before use.
If you have any questions or problems concerning
your unit that are not covered in this manual, please
consult your nearest Sony dealer.
XM-ZR704
4
Connections /
/
Installation
Before Installation
[
Mount the unit either inside the trunk or under a 
seat.
[
Choose the mounting location carefully so the unit
will not interfere with the normal movements of the
driver and it will not be exposed to direct sunlight
or hot air from the heater.
[
Do not install the unit under the floor carpet, where
the heat dissipation from the unit will be
considerably impaired.
First, place the unit where you plan to install it, and
mark the positions of the 4 screw holes on the
mounting board (not supplied). Then drill a 3 mm 
(
1
/
8
 in) pilot hole at each mark and mount the unit
onto the board with the supplied mounting screws.
The mounting screws are all 15 mm (
19
/
32
 in) long, so
make sure that the mounting board is thicker than
15 mm (
19
/
32
 in).
Mount the unit as illustrated.
Cautions
[
Before making any connections, disconnect the
ground terminal of the car battery to avoid short
circuits.
[
Be sure to use speakers with an adequate power
rating. If you use small capacity speakers, they may
be damaged.
[
This is a Phase-Inverted Amplifier.
[
Do not connect the
 terminal of the speaker
system to the car chassis, and do not connect the
terminal of the right speaker with that of the  left
speaker.
[
Install the input and output cords away from the
power supply wire as running them close together
can generate some interference noise.
[
This unit is a high powered amplifier. Therefore, it
may not perform to its full potential if used with the
speaker cords supplied with the car.
[
If your car is equipped with a computer system for
navigation or some other purpose, do not remove
the ground wire from the car battery. If you
disconnect the wire, the computer memory may be
erased. To avoid short circuits when making
connections, disconnect the +12 V power supply
wire  until all the other wires have been  connected.
Power Connection Wires (not supplied)
to a metal point of 
the car
Fuse (50 A)
+12 V car battery
Car audio unit
Remote output*
1
less than 450 mm (18 in)
*
2
*
1
If you have the factory original or some other car audio unit without a remote output for the amplifier, connect the 
remote input terminal (REMOTE) to the accessory power supply.
In High level input connection, car audio unit can also be activated without need for REMOTE connection. However, this 
function is not guaranteed for all car audio units.
Make the terminal connections as illustrated below.
D
Pass the wires through the cap, connect the wires, then cover the terminals with the cap.
Note
When you tighten the screw, be careful not to apply too much torque* as doing so may damage the screw.
* The torque value should be less than 1 N•m.
Notes on the power supply
[
Connect the +12 V power supply wire only after all the other 
wires have been connected.
[
Be sure to connect the ground wire of the unit securely to
a metal point of the car. A loose connection may cause a
malfunction of the amplifier.
[
Be sure to connect the remote control wire of the car audio 
unit to the remote terminal.
[
When using a car audio unit without a remote output on the 
amplifier, connect the remote input terminal (REMOTE) to
the accessory power supply.
[
Use a power supply wire with a fuse attached (50 A).
[
All power wires connected to the positive battery post
should be fused within 450 mm (18 in) of the battery post,
and before they pass through any metal.
[
Make sure that the vehicle’s battery wires connected to the 
vehicle (ground to chassis)*
2
 are of a wire gauge at least 
equal to that of the main power wire connected from the 
battery to the amplifier.
[
During full-power operation, a current of more than 50 A 
will run through the system. Therefore, make sure that the 
wires to be connected to the 
+12 V and GND terminals of 
this unit are at least 10-Gauge (AWG-10) or have a sectional
area of more than 5 mm
2
 (
7
/
32
 in
2
).
Page of 26
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