JBL GT5-A604 User manual

GT5-A604
4 CHANNEL POWER AMPLIFIER
SERVICE MANUAL
JBL Consumer Products
250 Crossways Park Dr.
Woodbury, New York 11797 Rev0 3/2008
Released 2007
Discontinued XXXX

- CONTENTS -
SPECIFICATIONS ………………………………………..1
PACKING……………………………………………..…....2
CONTROL/INSTALLATION DRAWINGS………………3
CONTROL/INSTALLATION INSTRUCTIONS………....4
BASIC TROUBLESHOOTING……………………………5
EXPLODED VIEW/PARTS LIST…….….….…………....6
AMPLIFIER BLOCK DIAGRAM…………………….……7
ELECTRICAL PARTS LIST ..……….……….…….…….8
P.C.B. DRAWINGS….………………………...…….……11
IC/TRANSISTOR PINOUTS..…………………….….…..15
SCHEMATICS……………..……………….………..…...16
GT5-A604 Specifications
Output Power: 60W RMS x 4 channels @ 4 ohms; ≤1% THD + N
(14.4V supply) 80W RMS x 4 channels @ 2 ohms; ≤1% THD + N
160W RMS x 2 channel (bridged) @ 4 ohms; ≤1% THD + N
Signal-to-noise ratio: 85dBA (reference 1W into 4 ohms)
102dBA (reference rated power into 4 ohms)
Total Peak power: 640W
Frequency response: 10Hz – 100kHz (–3dB)
THD+N 1KHz LPF=22KHz ≤0.05% (rated power @ 4 ohms)
Channel Separation ≥50db
Input Impedance 15kΩ
Maximum input signal: 6.0V
Maximum sensitivity: 200mV
Hi-Pass, Low Pass X-over Limits 32Hz – 320Hz ±20% 12dB/oct
Bass Boost @ 50Hz 0-6dB
DC Offset <30mV
Output regulation: 40dB
Idle Current @ 4 ohms 1.1A
Max Current Draw ≤35A
Remote Operating Voltage 5V
Turn-on delay time 3 sec
Circuit Protection Temperature (85±5C), Short circuit, Operating voltage range (8-16V)
Dimensions: 2 1/8 x 9 1/4 x 12" (54 x 235 x 305mm)
Fuse: 2 x 20A
JBL continually strives to update and improve existing products, as well as create new ones. The specifications and details in
this and related JBL publications are therefore subject to change without notice.
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GT5-A604

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GT5-A604

ABCDEF
A
B
C
2-1/8"
54mm
9-1/4"
235mm
12"
305mm
2x
4x 1x
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GT5-A604

Installation Warnings and Tips
•Disconnect the negative (–) lead from your vehicle’s
battery.
•At the installation sites, locate and make a note of
all fuel lines, hydraulic brake lines, vacuum lines
and electrical wiring. Use extreme caution when
cutting or drilling in and around these areas.
•Choose a safe mounting location away from moisture.
•Make sure there is sufficient air circulation at the
mounting location for the amplifier to cool itself.
•Mount the amplifier, using the supplied hardware.
Specifications
•60W RMS x 4 channels @ 4 ohms and ≤1% THD + N*
•80W RMS x 4 channels @ 2 ohms, 14.4V supply and
≤1% THD + N*
•160W RMS x 2 channels @ 4 ohms, 14.4V supply and
≤1% THD + N*
•THD + N: 0.05% (rated power @ 4 ohms)*
•Signal-to-noise ratio: 85dBA
(reference 1W into 4 ohms)*
•Signal-to-noise ratio: 102dBA
(reference rated power into 4 ohms)
•Frequency response: 10Hz – 100kHz (–3dB)*
• Total peak power: 640 watts
*CEA-2006A-compliant
0Speaker Output Connectors
•Connect the speakers to these terminals,
observing proper polarity:
•Four-channel operation: Connect the front
left speaker to the Front L+ and L– terminals,
and the front right speaker to the Front R+ and
R– terminals. Repeat for rear speakers, using
the Rear L+ and L– terminals, and the Rear R+
and R– terminals.
•Three-channel operation: Connect the stereo
speakers to the Front terminals, as above.
Connect the single speaker into which the
amplifier’s rear channels will be bridged to the
Rear R+ and Rear L– terminals.
•Two-channel (bridged) operation: Connect one
speaker to the Front R+ and Front L– termi-
nals. Connect the other speaker to the Rear
R+ and Rear L– terminals.
•Minimum speaker impedance for stereo opera-
tion is 2 ohms. Minimum speaker impedance for
bridged operation is 4 ohms.
1Fuses
•Replace only with the same type and rating.
2Power Input Connectors
•+12V: Connect to the positive terminal of the
vehicle’s battery. 8 AWG wire is recommended.
Install an appropriate fuse holder and fuse (40A
minimum) within 18 inches of the battery. Make
sure the wire is not damaged or pinched during
installation. Install protective grommets when
routing wires through the firewall or other sheet
metal.
•GND: Connect to the vehicle’s chassis. Refer to
the picture below.
•REM: Connect to the “Remote Out” lead from
the source unit or to a source of switched
12V+ (ACC).
3Aux Output Connectors (RCA)
•Summed, nonfiltered pass-through output.
Front right and rear right inputs are combined
and sent to the right AUX output. Front left
and rear left inputs are combined and sent
to the left AUX output. Connect to the input
of an additional subwoofer amplifier.
4Front Input Connectors (RCA)
•Connect to the front RCA outputs from the
source unit or signal processor.
5Front Input-Level Control
•Used to match the front input level of the
amplifier to the output level of the source unit.
•See Ffor the adjustment procedure.
6Front Crossover-Frequency Control
•12dB/octave crossover, variable from
32Hz to 320Hz.
•See Gfor the adjustment procedure.
7Front Crossover-Filter Selector
•LP: Select for subwoofer(s).
•FLAT: Select for full-range speakers when
no subwoofer will be used in the system.
•HP: Select for midrange speakers or
full-range speakers when a subwoofer is
used in the system.
8Power On LED
•Illuminated when the amplifier is on.
9Protect LED
•Illuminated under any of the following fault
conditions: battery over/under voltage, short
circuit in speaker wires, amplifier is too hot,
amplifier’s output circuit has failed (DC voltage
present in the amplifier’s output).
ARear Bass-Boost Control
•Provides up to 6dB of boost at 50Hz. Set
the Bass-Boost control according to your
preference, being careful not to apply enough
boost to damage the speaker(s).
BRear Crossover-Frequency Control
•12dB/octave crossover, variable from
32Hz to 320Hz.
•See adjustment procedure in G.
CRear Crossover-Filter Selector
•LP: Select for subwoofer(s).
•FLAT: Select for full-range speakers when
no subwoofer will be used in the system.
•HP: Select for midrange speakers or
full-range speakers when a subwoofer is
used in the system.
DRear Input-Level Control
•Used to match the rear input level of the
amplifier to the output level of the source unit.
•See Ffor the adjustment procedure.
ERear Input Connectors (RCA)
•Connect to rear RCA outputs from the source
unit or signal processor.
FSetting Input Level
ATurn all Input-Level controls counterclockwise
to 6V (minimum).
BWith a dynamic music track playing, turn head
unit’s volume control to the 3/4 position.
CTurn Front Input-Level control clockwise until
the music is so loud that it no longer sounds
clear (distortion is present in the output).
DTurn Front-Input-Level control counterclock-
wise gradually, just until the music sounds
clear, once again.
EFront-level input is now adjusted correctly.
FAdjust Rear Input-Level control so that the
level of the rear speakers is proportionate to
the level of the front speakers, according to
your preference.
GSetting the Crossover
ACrossover setting for 5" or larger full-range
speakers when no subwoofer is included in
the system.
BCrossover setting for midrange and/or
full-range speakers when a subwoofer
is included in the system.
CCrossover setting for subwoofers.
Note: Acceptable frequency ranges indicated
in gray.
GT5-A604 CAR AUDIO POWER AMPLIFIER OWNER’S MANUAL
Factory Bolt Ring Connector
Ground Wire
Note: Remove any paint
below ring connector.
Star Washer
This product is designed for mobile applications and is not
intended for connection to the mains.
Avalid serial number is required for warranty coverage.
Features, specifications and appearance are subject to change
without notice.
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GT5-A604

Amplifier Troubleshooting Guide
1. Status LED on Amplifier not Lit - Head Unit (Source) Turned ON
Verify: A. Remote turn-on wire from source to amplifier has proper voltage
B. Power (B+) connections at amplifier, terminal blocks, and battery are secure
C. Ground (GND) connections at amplifier and vehicle chassis are secure
D. Battery B+ fuse (if used) is OK
E. Amplifier fuse is OK
F. B+ at battery and B+ at amplifier has proper voltage
2. Status LED’s Lit, No Output from Speakers in Normal Operating Condition
Verify: A. RCA cables from amplifier to source are securely connected
B. Volume adjustment on amplifier is correctly adjusted
C. Source is ON and playing
3. Engine Noise From Speaker(s)
Turn source OFF, Disconnect RCA cables at amplifier. If noise stops, check equipment & cables leading
to amplifier.
Verify: A. RCA cables are of good quality with no breakage to internal shields
B. RCA cables from source to amplifier are not run alongside any power cables
4. Amplifier Output Distorted Music
Verify: A. Source output music to amplifier is not distorted
B. Source output sensitivity is correctly adjusted
5. Amplifier Shuts Down, Green LED’s are Lit - Amplifier is in Thermal Protection Mode
Verify: A. Amplifier is mounted with adequate air circulation around heatsinks or vents
B. Amplifier is not mounted under carpet or sealed enclosure
C. Speakers meet correct impedance for application (mono or stereo hookup)
6. Amplifier Does Not Turn ON, and Red LED is Lit Amplifier (and not Connected to a Shorted Speaker)
Verify: A. Speaker crossover (if used) is not defective
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GT5-A604

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GT5-A604

GT5-A604 Electrical Parts List
Part Number Qty Reference Designator
Semiconductors
TR-KTC1027Y TRANS SMALL SIGNAL NPN "TO-92"KTC1027Y 4 Q134,234,334,434
TR-KTA1023Y TRANS SMALL SIGNAL PNP "TO-92"KTA1023Y 4 Q144,244,344,444
TR-KTA1266GR TRANS SMALL SIGNAL PNP "TO-92"KTA1266GR 16 Q11,12,23,33,133,141,142,233,241,242,Q333,341,
342,433,441,442
TR-KTA1268GR TRANS SMALL SIGNAL PNP "TO-92"KTA1268GR 1 Q22
TR-KTC3198BL TRANS SMALL SIGNAL NPN "TO-92"KTC3198BL 1 Q21
TR-KTC3198GR TRANS SMALL SIGNAL NPN "TO-92"KTC3198GR 16 Q02,55,131,132,143,181,231,232,243,Q281,331,332,
343,431,432,443
TR-KTC3200GR TRANS SMALL SIGNAL NPN "TO-92"KTC3200GR 4 Q151,251,351,451
DIODE-1N4148 DIODE SWITCHING SIGNAL 1N4148 9 D03,04,65,70,151,251,351,451,D80
DIODE-1N4004 DIODE RECTIFIER 1N4004 1 D02
DIODE-FR154 DIODE FAST RECOVERYFR154 4 D51,52,53,54
DIODE-1N4744 DIODE ZENNER 15V 1W1N4744 2 D191,391
IC-TL494CN IC PWM IC,DIP-16TL494CN 1 U01
IC-KIA393P IC COMPARATOR, DIP-8KIA393P 1 U71
FET-50N60P FET N-CH POWER MOS FET,TO-220KEC50N60P 4 Q43,44,53,54
TR-A1220A TRANS SMALL SIGNAL PNP "TO-126"A1220A-Y 1 Q01
TR-KTB688 TRANS AUDIO POWER PNP,TO-3PKTB688 4 Q145,245,345,445
TR-KTB718 TRANS AUDIO POWER NPN,TO-3PKTD718 4 Q135,235,335,435
TR-KTC3200GR1 TRANS SMALL SIGNAL NPN "TO-92"KTC3200GR 4 Q140,240,340,440
DIODE-1N4744 DIODE ZENNER 15V 1W1N4744 2 D291,491
DIODE-1N5404 DIODE RECTIFIER 1N5404 1 D1
DIODE-YG225D2 DIODE FAST RECOVERYYG225D2 2 D41,42
IC-NJM2068M IC DUAL OP AMP NJM2068M 3 U102,105,302
IC-NJM2058M IC OP AMP NJM2058M 7 U101,103,104,301,303,304,305
LED3 LED 3PHI,GREEN & RED(TOP:GREEN,
BOTTOM:RED)L-H322005GB 1 LED01
LED1 LED ACYLE 3.0 AWG#24,RED/BLACK200m/m 1 LOGO BACKLIGHT
Resistors
RES1R01/2-J RESISTOR METAL FILM 1/2WJ1 OHM 1 R03
RES10011/8-F RESISTOR METAL FILM 1/8WF1K OHM 8 R120,172,220,272,320,372,420,472
RES47011/8-F RESISTOR METAL FILM 1/8WF4.7K OHM 1 R62
RES10521/8-F RESISTOR METAL FILM 1/8WF10.5K OHM 2 R11,60
RES22021/8-F RESISTOR METAL FILM 1/8WF22K OHM 4 R121,221,321,421
RES4R71/2-J RESISTOR METAL FILM 1/2WJ4.7 OHM 4 R161,261,361,461
RES2211/2-J RESISTOR METAL FILM 1/2WJ220 OHM 2 R41,51
RES2201/8-J RESISTOR CARBON FILM 1/8WJ22 OHM 16 R133,134,143,144,233,234,243,244,333,334,
R343,344,433,434,443,444
RES4701/8-J RESISTOR CARBON FILM 1/8WJ47 OHM 12 R43,44,53,54,136,146,236,246,336,346,R436,446
RES1211/8-J RESISTOR CARBON FILM 1/8WJ120 OHM 4 R150,250,350,450
RES1021/8-J RESISTOR CARBON FILM 1/8WJ1K OHM 22 R07,31,42,52,56,65,131,135,141,145,R231,235,241,
245,331,335,341,345,431,435,R441,445
RES1521/8-J RESISTOR CARBON FILM 1/8WJ1.5K OHM 4 R151,251,351,451
RES2221/8-J RESISTOR CARBON FILM 1/8WJ2.2K OHM 1 R76
RES2721/8-J RESISTOR CARBON FILM 1/8WJ2.7K OHM 4 R147,247,347,447
RES3321/8-J RESISTOR CARBON FILM 1/8WJ3.3K OHM 1 R74
RES3921/8-J RESISTOR CARBON FILM 1/8WJ3.9K OHM 4 R137,237,337,437
RES4721/8-J RESISTOR CARBON FILM 1/8WJ4.7K OHM 2 R01,02
RES6221/8-J RESISTOR CARBON FILM 1/8WJ6.2K OHM 4 R171,271,371,471
RES5621/8-J RESISTOR CARBON FILM 1/8WJ5.6K OHM 8 R132,142,232,242,332,342,432,442
RES6821/8-J RESISTOR CARBON FILM 1/8WJ6.8K OHM 1 R72
RES8221/8-J RESISTOR CARBON FILM 1/8WJ8.2K OHM 1 R05
RES9121/8-J RESISTOR CARBON FILM 1/8WJ9.1K OHM 1 R71
RES1031/8-J RESISTOR CARBON FILM 1/8WJ10K OHM 3 R12,13,14
RES1531/8-J RESISTOR CARBON FILM 1/8WJ15K OHM 2 R34,35
RES2231/8-J RESISTOR CARBON FILM 1/8WJ22K OHM 3 R32,55,61
RES2431/8-J RESISTOR CARBON FILM 1/8WJ24K OHM 2 R21,22
RES2731/8-J RESISTOR CARBON FILM 1/8WJ27K OHM 4 R152,252,352,452
RES3331/8-J RESISTOR CARBON FILM 1/8WJ33K OHM 1 R33
RES5631/8-J RESISTOR CARBON FILM 1/8WJ56K OHM 5 R04,181,281,381,481
RES1041/8-J RESISTOR CARBON FILM 1/8WJ100K OHM 1 R73
RES4341/8-J RESISTOR CARBON FILM 1/8WJ430K OHM 1 R06
Description
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GT5-A604

Part Number Qty Reference Designator
Description
RES1051/8-J RESISTOR CARBON FILM 1/8WJ1M OHM 2 R75 R80
RES1012-J RESISTOR METAL FILM 2WJ100 OHM 1 R30
RES2212-J RESISTOR METAL FILM 2WJ,Forming=15m/m220 OHM 4 R191,291,391,491
RES6812-J RESISTOR METAL FILM 2WJ,Forming=15m/m680 OHM 4 R162,262,362,462
RESR055-J RESISTOR WIRE WOUND 5WJ,Forming=30m/m0.05 OHM 4 R160,260,360,460
RES-2202-0805-F RESISTOR CHIP"0805"1/8WF22K OHM 4 R100,200,300,400
RES-1002-0805-F RESISTOR CHIP"0805"1/8WF10K OHM 4 R125,126,225,226
RES-4702-0805-F RESISTOR CHIP"0805"1/8WF47K OHM 16 R101,102,103,104,201,202,203,204,301,302,R303,304,4
01,402,403,404
RES-102-0805-J RESISTOR CHIP"0805"1/8WJ1K OHM 14 R127,128,165,166,227,228,265,266,R365,366,391,465,4
66,491
RES-475-1206-J RESISTOR 4.7K OHM 1/4W ±5% 1206 7" 1 R192
RES-332-0805-J RESISTOR CHIP"0805"1/8WJ3.3K OHM 2 R392,492
RES-562-0805-J RESISTOR CHIP"0805"1/8WJ5.6K OHM 8 R113,115,213,215,313,315,413,415
RES-682-0805-J RESISTOR CHIP"0805"1/8WJ6.8K OHM 10 R105,114,205,214,305,314,405,414 R395,495
RES-103-0805-J RESISTOR CHIP"0805"1/8WJ10K OHM 18 R108,109,110,111,112,208,210,211,212,308,R309,310,3
11,312,408,410,411,412
RES-223-0805-J RESISTOR CHIP"0805"1/8WJ22K OHM 4 R116,216,316,416
RES-104-0805-J RESISTOR CHIP"0805"1/8WJ100K OHM 2 R129,229
RES-681-0805-J RESISTOR CHIP"0805"1/8WJ680 OHM 4 R107,207,307,407
RES-472-0805-J RESISTOR CHIP"0805"1/8WJ4.7K OHM 4 R106,206,306,406
RES-512-0805-J RESISTOR CHIP"0805"1/8WJ5.1K OHM 2 R396,496
RES-105-0805-J RESISTOR CHIP"0805"1/8WJ1M OHM 2 R397,497
3B20Kx2 LEVEL,BASS POT RM1221G1PA2-5-B20K±10%-G 3 VR101,301,303
15C50Kx4 FREQ POT RM1241G1PA2-5-C50K-G 2 VR102,302
RET94011/8-F THERMISTOR NTC, 50KOHMFTD5-350 1 TH01
Capacitors - see legend last page
CAP050220-C CAPACITOR CERAMIC DISK 50V "NPO"22pF 4 C172,272,372,472
CAP050101-C CAPACITOR CERAMIC DISK 50V "NPO"100pF 12 C132,142,151,232,242,251,332,342,351,432,C442,451
CAP050473-C CAPACITOR CERAMIC DISK 50V 473pF 5 C33,53,63,200,400
CAP050104-C CAPACITOR CERAMIC DISK 50V 104pF 7 C03,22,60,71,72,74 C31
CAP050102-C CAPACITOR CERAMIC DISK 50V 102pF 4 C121,221,321,421
CAP0502R2-E-1 CAPACITOR ELECTROLYTIC"SHL"2.2㎌/50V 4 C120,220,320,420
CAP025100-E CAPACITOR ELECTROLYTIC"SHL"10㎌/25V 1 C15
CAP016220-E CAPACITOR ELECTROLYTIC"SHL"22㎌/16V 1 C65,
CAP0504R7-E CAPACITOR ELECTROLYTIC"SHL"4.7㎌/50V 8 C131,141,231,241,331,341,431,441
CAP016470-E CAPACITOR ELECTROLYTIC"SHL"47㎌/16V 1 C14
CAP025470-E CAPACITOR ELECTROLYTIC"SHL"47㎌/25V 1 C16
CAP050470-E CAPACITOR ELECTROLYTIC"SHL"47㎌/50V 2 C57,67
CAP016101-E CAPACITOR ELECTROLYTIC"SHL"100㎌/16V 8 C11,12,13,171,181,271,371,471
CAP025101-E CAPACITOR ELECTROLYTIC"SXE"100㎌/25V 1 C02
CAP016331-E CAPACITOR ELECTROLYTIC"SHL"330㎌/16V 4 C191,291,391,491
CAP016100-E CAPACITOR ELECTROLYTIC "SHL"10/16V 1 C06
CAP100102-M CAPACITOR MYLAR 5% 100V102J 1 C21
CAP100222-M CAPACITOR MYLAR 5% 100V222J 1 C08
CAP100473-M CAPACITOR MYLAR 5% 100V473J 4 C140,240,340,440
CAP100104-M CAPACITOR MYLAR 5% 100V104J 5 C01,161,261,361,461
CAP063105-M CAPACITOR MYLAY 5% 63V "TL"105J 1 C32
CAP0035471-E CAPACITOR ELECTROLYTIC"SHL"470㎌/35V (D)10x(L)16m/m 2 C51,61
CAP025332-E CAPACITOR ELECTROLYTIC 3300㎌/25V (D)18x(L)25m/m 2 C04,05
CAP035332-E CAPACITOR ELECTROLYTIC 3300㎌/35V (D)18x(L)25m/m 2 C52,62
CAP050100-0805 CAPACITOR CHIP"0805"10pF 4 C105,205,305,405
CAP050220-0805 CAPACITOR CHIP"0805"22 p F 10 C103,104,126,203,204,226,303,304,403,404
CAP050470-0805 CAPACITOR CHIP"0805"47pF 8 C107,111,207,211,307,311,407,411
CAP050220-0805 CAPACITOR CHIP"0805"100 p F 2 C393,493
CAP050104-0805 CAPACITOR CHIP"0805"104 p F 4 C209,210,409,410
CAP016220-E CAPACITOR ELECTROLYTIC "SHL"22/16V 8 C101,102,201,202,301,302,401,402
CAP016100-E CAPACITOR ELECTROLYTIC "SHL"10/16V 8 C100,125,200,225,300,325,400,425
CAP0504R7-E-1 CAPACITOR ELECTROLYTIC "SHL"4.7/50V 2 C128,228
CAP100823-M CAPACITOR MYLAR 5% 100V823J 8 C113,115,213,215,313,315,413,415
CAP100183-M CAPACITOR MYLAR 5% 100V183 J 2 C392,492
CAP100104-M CAPACITOR MYLAR 5% 100V104 J 2 C391,491
CAP050471-0805 CAPACITOR CHIP"0805"470PF 2 C127,227
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GT5-A604