Pioneer GM5400T - Bridgeable Amplifier User manual

ORDER NO.
PIONEER CORPORATION 4-1, Meguro 1-chome, Meguro-ku, Tokyo 153-8654, Japan
PIONEER ELECTRONICS (USA) INC. P.O. Box 1760, Long Beach, CA 90801-1760, U.S.A.
PIONEER EUROPE NV Haven 1087, Keetberglaan 1, 9120 Melsele, Belgium
PIONEER ELECTRONICS ASIACENTRE PTE. LTD. 253 Alexandra Road, #04-01, Singapore 159936
PIONEER CORPORATION 2008
GM-5400T/XJ/UC
CRT4251
BRIDGEABLE TWO-CHANNEL POWER AMPLIFIER
GM-5400T /XJ/UC
GM-5400T /XJ/EW5
GM-5400T /XJ/ES
For details, refer to "Important Check Points for Good Servicing".
K-ZZZ. NOV. 2008 Printed in Japan

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SAFETY INFORMATION
CAUTION
WARNING
Where in a manufacturer’s service documentation, for example in circuit diagrams or lists
of components, a symbol is used to indicate that a specific component shall be replaced only
by the component specified in that documentation for safety reasons, the following symbol shall
be used:
This product contains certain electrical parts contain chemicals which are known to the State of
California to cause cancer, birth defects or other reproductive harm.
Health & Safety Code Section 25249.6 - Proposition 65
This service manual is intended for qualified service technicians; it is not meant for the casual do-it-yourselfer.
Qualified technicians have the necessary test equipment and tools, and have been trained to properly and safety repair
complex products such as those covered by this manual.
Improperly performed repairs can adversely affect the safety and reliability of the product and may void the warranty.
If you are not qualified to perform the repair of this product properly and safety, you should not risk trying to do so
and refer the repair to a qualified service technician.

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[Important Check Points for Good Servicing]
In this manual, procedures that must be performed during repairs are marked with the below symbol.
Please be sure to confirm and follow these procedures.
1. Product safety
Please conform to product regulations (such as safety and radiation regulations), and maintain a safe servicing environment by
following the safety instructions described in this manual.
1Use specified parts for repair.
Use genuine parts. Be sure to use important parts for safety.
2Do not perform modifications without proper instructions.
Please follow the specified safety methods when modification(addition/change of parts) is required due to interferences such as
radio/TV interference and foreign noise.
3Make sure the soldering of repaired locations is properly performed.
When you solder while repairing, please be sure that there are no cold solder and other debris.
Soldering should be finished with the proper quantity. (Refer to the example)
4Make sure the screws are tightly fastened.
Please be sure that all screws are fastened, and that there are no loose screws.
5Make sure each connectors are correctly inserted.
Please be sure that all connectors are inserted, and that there are no imperfect insertion.
6Make sure the wiring cables are set to their original state.
Please replace the wiring and cables to the original state after repairs.
In addition, be sure that there are no pinched wires, etc.
7Make sure screws and soldering scraps do not remain inside the product.
Please check that neither solder debris nor screws remain inside the product.
8There should be no semi-broken wires, scratches, melting, etc. on the coating of the power cord.
Damaged power cords may lead to fire accidents, so please be sure that there are no damages.
If you find a damaged power cord, please exchange it with a suitable one.
9There should be no spark traces or similar marks on the power plug.
When spark traces or similar marks are found on the power supply plug, please check the connection and advise on secure
connections and suitable usage. Please exchange the power cord if necessary.
aSafe environment should be secured during servicing.
When you perform repairs, please pay attention to static electricity, furniture, household articles, etc. in order to prevent injuries.
Please pay attention to your surroundings and repair safely.
2. Adjustments
To keep the original performance of the products, optimum adjustments and confirmation of characteristics within specification.
Adjustments should be performed in accordance with the procedures/instructions described in this manual.
4. Cleaning
For parts that require cleaning, such as optical pickups, tape deck heads, lenses and mirrors used in projection monitors, proper
cleaning should be performed to restore their performances.
3. Lubricants, Glues, and Replacement parts
Use grease and adhesives that are equal to the specified substance.
Make sure the proper amount is applied.
5. Shipping mode and Shipping screws
To protect products from damages or failures during transit, the shipping mode should be set or the shipping screws should be
installed before shipment. Please be sure to follow this method especially if it is specified in this manual.

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CONTENTS
SAFETY INFORMATION..................................................................................................................................... 2
1. SERVICE PRECAUTIONS ............................................................................................................................... 5
1.1 SERVICE PRECAUTIONS ........................................................................................................................ 5
1.2 NOTES ON SOLDERING .......................................................................................................................... 5
2. SPECIFICATIONS............................................................................................................................................ 6
2.1 SPECIFICATIONS ..................................................................................................................................... 6
2.2 PANEL FACILITIES.................................................................................................................................... 8
2.3 CONNECTION DIAGRAM ......................................................................................................................... 9
3. BASIC ITEMS FOR SERVICE........................................................................................................................ 10
3.1 CHECK POINTS AFTER SERVICING..................................................................................................... 10
4. BLOCK DIAGRAM.......................................................................................................................................... 10
5. DIAGNOSIS.................................................................................................................................................... 10
5.1 CONNECTOR FUNCTION DESCRIPTION............................................................................................. 10
6. SERVICE MODE ............................................................................................................................................ 10
7. DISASSEMBLY ...............................................................................................................................................11
8. EACH SETTING AND ADJUSTMENT ............................................................................................................11
9. EXPLODED VIEWS AND PARTS LIST.......................................................................................................... 12
9.1 PACKING ................................................................................................................................................. 12
9.2 EXTERIOR............................................................................................................................................... 14
10. SCHEMATIC DIAGRAM............................................................................................................................... 16
10.1 AMP UNIT(GUIDE PAGE) ..................................................................................................................... 16
11. PCB CONNECTION DIAGRAM.................................................................................................................... 22
11.1 AMP UNIT .............................................................................................................................................. 22
12. ELECTRICAL PARTS LIST .......................................................................................................................... 26

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1. SERVICE PRECAUTIONS
1.1 SERVICE PRECAUTIONS
1.2 NOTES ON SOLDERING
1. You should conform to the regulations governing the product (safety, radio and noise, and other
regulations), and should keep the safety during servicing by following the safety instructions
described in this manual.
2. Be careful in handling ICs. Some ICs such as MOS type are so fragile that they can be damaged by
electrostatic induction.
For environmental protection, lead-free solder is used on the printed circuit boards mounted in this unit.
Be sure to use lead-free solder and a soldering iron that can meet specifications for use with lead-free solders for repairs
accompanied by reworking of soldering.
Compared with conventional eutectic solders, lead-free solders have higher melting points, by approximately 40 C.
Therefore, for lead-free soldering, the tip temperature of a soldering iron must be set to around 373 C in general, although
the temperature depends on the heat capacity of the PC board on which reworking is required and the weight of the tip of
the soldering iron.
Compared with eutectic solders, lead-free solders have higher bond strengths but slower wetting times and higher melting
temperatures (hard to melt/easy to harden).
The following lead-free solders are available as service parts:
Parts numbers of lead-free solder:
GYP1006 1.0 in dia.
GYP1007 0.6 in dia.
GYP1008 0.3 in dia.

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2. SPECIFICATIONS
2.1 SPECIFICATIONS
Power source..........................14.4 V DC (10.8 V to 15.1 V
allowable)
Grounding system................ Negative type
Current consumption .......... 30 A (at continuous power,
4?)
Average current drawn....... 10 A (4 for two channels)
19 A (4 for one channel)
Fuse ......................................... 30 A × 2
Dimensions (W × H × D) ... 265 mm × 62 mm × 346
mm
(10-3/8 in. ×2-1/2 in. × 1 ft.
2 in.)
Weight ..................................... 3.8 kg (Leads for wiring not
included)
Maximum power output ...... 250 W × 2 (4 )/760W×1
(4 )
Continuous power output .. 125 W × 2 (at 14.4 V, 4 ,20
Hz to 20 kHz 0.2% THD)
380 W × 1 (at 14.4 V, 4 ,20
Hz to 20 kHz 0.8% THD)
190 W × 2 (at 14.4 V, 2 ,20
Hz to 20 kHz 0.8% THD)
Load impedance ................... 4 (2 to 8 allowable)
(Bridge connection: 4 to 8
allowable)
Frequency response............ 10 Hz to 50 kHz (+0 dB, –1
dB)
Signal-to-noise ratio............. 95 dB (IHF-A network)
Distortion .................................0.03 % (10 W, 1 kHz)
Separation .............................. 70 dB (1 kHz)
Low pass filter:
Cut off frequency .......... 80 Hz
Cut off slope ...................–12 dB/oct
Bass boost:
Frequency....................... 50 Hz
Level................................. 0 dB/6 dB/12 dB
Gain control:
RCA ................................. 200 mV to 6.5 V
Speaker ........................... 0.8 V to 26 V
Maximum input level / impedance:
RCA ................................. 6.5 V / 22 k
Speaker ........................... 26 V / 90 k
CEA2006 Specifications
Power output ......................... 125 W RMS × 2 Channels
(at 14.4 V, 4 and 1%
THD+N)
380 W RMS × 1 Channels
(at 14.4 V, 4 BRIDGE and
1 % THD+N)
190 W RMS × 2 Channels
(at 14.4 V, 2 and 1%
THD+N)
S/N ratio .................................. 75 dBA (reference: 1 W into
4)
Notes
• Specifications and the design are subject to
modifications without notice due to improve-
ments.
• The average current drawn is nearly the maxi-
mum current drawn by this unit when an
audio signal is input. Use this value when
working out total current drawn by multiple
power amplifiers.
GM-5400T/XJ/UC
Backup current ..................... 0.03 mA or less

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GM-5400T/XJ/EW5, GM-5400T/XJ/ES
Power source..........................14.4 V DC (10.8 V to 15.1 V
allowable)
Grounding system................. Negative type
Current consumption .......... 30 A (at continuous power,
4)
Average current drawn....... 10 A (4 for two channels)
19 A (4 for one channel)
Fuse ........................................ 30 A × 2
Dimensions (W × H × D) ... 265 mm × 62 mm × 346
mm
Weight ..................................... 3.8 kg(Leads for wiring not
included)
Maximum power output ...... 250 W × 2 (4 ) / 760 W × 1
(4 )
Continuous power output .. 125 W × 2 (at 14.4 V, 4 ,20
Hz to 20 kHz 0.2% THD)
380 W × 1 (at 14.4 V, 4 ,20
Hz to 20 kHz 0.8% THD)
190 W × 2 (at 14.4 V, 2 ,20
Hz to 20 kHz 0.8% THD)
Load impedance ................... 4 (2 to 8 allowable)
(Bridge connection: 4 to 8
allowable)
Frequency response............ 10 Hz to 50 kHz (+0 dB, –1
dB)
Signal-to-noise ratio............. 95 dB (IEC-A network)
Distortion .................................0.03 % (10 W, 1 kHz)
Separation .............................. 70 dB (1 kHz)
Low pass filter:
Cut off frequency .......... 80 Hz
Cut off slope ...................–12 dB/oct
Bass boost:
Frequency...................... 50 Hz
Level................................ 0 dB/6 dB/12 dB
Gain control:
RCA ................................. 200 mV to 6.5 V
Speaker ........................... 0.8 V to 26 V
Maximum input level / impedance:
RCA ................................. 6.5 V / 22 k
Speaker ........................... 26 V / 90 k
Notes
• Specifications and the design are subject to
modifications without notice due to improve-
ments.
• The average current drawn is nearly the maxi-
mum current drawn by this unit when an
audio signal is input. Use this value when
working out total current drawn by multiple
power amplifiers.
Backup current ..................... 0.03 mA or less

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2.2 PANEL FACILITIES
What ’s what
Front side
Rear side
To adjust the switch, use a flathead screwdri-
ver if needed.
1Power indicator
The power indicator lights up to indicate
power ON.
2BFC (beat frequency control) switch
Located front side the unit. If beats are audi-
ble while listening to MW/LW broadcasts via
car stereo, change theBFC switch using a
small flathead screwdriver.
3BASS BOOST (bass boost level control)
switch
You can select a bass boost level from 0 dB,
6 dB and 12 dB.
4GAIN (gain) control
If output remains low, even when the car
stereo volume is turned up, turn controls to
lower level. If distortion occurs when the car
stereo volume is turned up, turn these con-
trols to higher level.
• For use with an RCA equipped car stereo
(standard output of 500 mV), set to the
NORMAL position. For use with an RCA
equipped Pioneer car stereo, with max.
output of 4 V or more, adjust level to
match that of the car stereo output.
• If you hear too much noise when using
the speaker input terminals, turn the
gain control to higher level.
5LPF (low-pass filter) switch
Switch the settings based on the connected
speaker.
• When the Subwoofer is connected:
Select ON . This eliminates high range
frequency and outputs low range fre-
quency.
• When the full range speaker is con-
nected:
Select OFF.OFF outputs the entire fre-
quency range.
(EW5, ES)
(EW5, ES)

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2.3 CONNECTION DIAGRAM
1Special red battery wire
RD-223 (sold separately)
After completing all other amplifier connec-
tions, finally connect the battery wire terminal
of the amplifier to the positive ( ) battery
terminal.
2Ground wire (Black)
RD-223 (sold separately)
Connect to metal body or chassis.
3Car stereo with RCA output jacks (sold sepa-
rately)
4External output
If only one input plug is used, do not connect
anything to RCA input jack B.
5Connecting wire with RCA pin plugs (sold se-
parately)
6Speaker input terminal
7RCA input jack
8System remote control wire (sold separately)
Connect male terminal of this wire to the sys-
tem remote control terminal of the car stereo
(SYSTEM REMOTE CONTROL ). The female
terminal can be connected to the auto-anten-
na relay control terminal. If the car stereo
lacks a system remote control terminal, con-
nect the male terminal to the power terminal
via the ignition switch.
9Speaker output terminals
aFuse (30 A) × 2
bFuse (30 A) × 2
cGrommet
dRear side
eFront side
(ES)

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3. BASIC ITEMS FOR SERVICE
3.1 CHECK POINTS AFTER SERVICING
4. BLOCK DIAGRAM
There is not information to be shown in this chapter.
5. DIAGNOSIS
5.1 CONNECTOR FUNCTION DESCRIPTION
6. SERVICE MODE
There is not information to be shown in this chapter.
To keep the product quality after servicing, please confirm following check points.
demrifnocebotmetIserudecorP.oN
1 Confirm whether the customer complain has
been solved.
The customer complain must not be
reappeared.
Audio and operations must be normal.
2 Check the output sound. Audio and operations must be normal.
retfaecnaraeppastinotridrosehctarcsoNkcehcecnaraeppA3
receiving it for service.
See the table below for the items to be checked regarding video and audio:
Item to be checked regarding audio
Distortion
Noise
Volume too low
Volume too high
Volume fluctuating
Sound interrupted

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7. DISASSEMBLY
8. EACH SETTING AND ADJUSTMENT
There is not information to be shown in this chapter.
1
1
2
-
Removing
the
Chassis
(Fig
.
1)
Fig.1
Remove the two screws.
Remove the six screws
and then remove the Chassis.
-Removing the Amp Unit (Fig.2)
Remove the twenty four screws
and then remove the Chassis.
Fig.2
11
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
1
11
1
1
1
Chassis
Amp Unit
Bonding Position
GYL1006

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9. EXPLODED VIEWS AND PARTS LIST
9.1 PACKING
N
OTES : Parts marked by " * " are generally unavailable because they are not in our Master Spare Parts List.
The >mark found on some component parts indicates the importance of the safety factor of the part.
Therefore, when replacing, be sure to use parts of identical designation.
Screw adjacent to mark on the product are used for disassembly.
For the applying amount of lubricants or glue, follow the instructions in this manual.
(In the case of no amount instructions,apply as you think it appropriate.)
""

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(1) PACKING SECTION PARTS LIST
(2) CONTRAST TABLE
GM-5400T/XJ/UC, GM-5400T/XJ/EW5 and GM-5400T/XJ/ES are constructed the same except for the following:
Owner's Manual,Installation Manual
Mark No. Description Part No.
* 1-1 Caution Card See Contrast table (2)
* 1-2 Warranty Card See Contrast table (2)
1-3 Owner's Manual See Contrast table (2)
2 Cord Assy CZD5517
3 Polyethylene Bag CZE2962
4 Polyethylene Bag See Contrast table (2)
5 Unit Box See Contrast table (2)
6 Contain Box See Contrast table (2)
7 Cushion CZH6698
8 Screw Assy CEA5330
9 Screw BYC40P180FTB
* 10 Polyethylene Sheet CNM4338
Mark No. Description Part No.
Mark No. Description GM-5400T/XJ/UC GM-5400T/XJ/EW5 GM-5400T/XJ/ES
* 1-1 Caution Card CZR5560 Not used Not used
* 1-2 Warranty Card CRY1276 CRY1279 Not used
1-3 Owner's Manual CZR5552 CZR5551 CZR5553
4 Polyethylene Bag CEG1351 *CZE2987 *CZE2987
5 Unit Box CZH6684 CZH6682 CZH6686
6 Contain Box CZH6685 CZH6683 CZH6687
Part No. Language
CZR5552 English, French, Spanish(Espanol)
CZR5551 English, Spanish(Espanol), German, French, Italian, Dutch, Russian
CZR5553 English, Spanish(Espanol), Portuguese(B), Arabic

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9.2 EXTERIOR
B
A
B
A

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(1) EXTERIOR SECTION PARTS LIST
(2) CONTRAST TABLE
GM-5400T/XJ/UC, GM-5400T/XJ/EW5 and GM-5400T/XJ/ES are constructed the same except for the following:
Mark No. Description Part No.
1 Screw BBZ30P100FTC
2 Screw BBZ30P120FTC
* 3 Screw See Contrast table (2)
4 Screw BSZ26P060FTB
5 Screw BSZ30P060FTB
6 Holder See Contrast table (2)
7 Plate CZN8435
8 Plate CZN8438
9 Spacer CZN8440
10 Chassis CZN8441
11 Amp Unit See Contrast table (2)
12 Screw BBZ30P080FTB
13 Screw BBZ30P100FTC
>14 Fuse(30 A) CEK1330
15 Pin Jack(JA101) CKB1068
16 Terminal(JA801) CKE1055
17 Terminal(JA501) CKE1057
18 Terminal(JA502) CKE1057
19 Terminal(JA802) CND2458
20 Terminal(JA803) CND2458
21 Terminal(JA804) CND2458
22 Terminal(JA805) CND2458
* 23 Bas Bar(1) CZN8425
* 24 Bas Bar(5) CZN8429
* 25 Bas Bar(3) CZN8427
26 Holder CZN8430
* 27 Heat Sink CZN8432
* 28 Heat Sink CZN8433
29 Sheet CZN8443
30 Screw PPZ30P100FNN
31 Case Unit See Contrast table (2)
32 Screw BBZ30H060FTB
* 33 Heat Sink See Contrast table (2)
34 Plate Assy See Contrast table (2)
35 Nut See Contrast table (2)
36 Screw PPZ30P100FTB
* 37 Washer See Contrast table (2)
38 Transistor(Q515,516) KTC3114
39 Transistor(Q523,524,525,526) 2SC5358
40 Transistor(Q527,528,529,530) 2SA1986
41 Transistor(Q805,806,807,808,809,810) FKV550N
42 Transistor(Q811) KTC2026
43 Transistor(Q812) KTA1046
44 Thermistor(TH701,702) CCX1057
45 Diode(D801) FML22S
46 Diode(D802) FML22R
47 Socket(J1) CKM1463
* 48 Seal CAN3984
49 Screw BBZ30P080FTB
50 Screw PPZ30P100FTB
51 Plate CZN8417
52 Earth Terminal(KN801) CZK2969
53 Screw PBZ30P120FTB
Mark No. Description Part No.
Mark No. Description GM-5400T/XJ/UC GM-5400T/XJ/EW5 GM-5400T/XJ/ES
* 3 Screw BMZ40P250FTB Not used Not used
6 Holder CNV8522 Not used Not used
7 Plate CZN8435 CZN8435 CZN8435
11 Amp Unit CZW5578 CZW5577 CZW5577
31 Case Unit CZX6645 CZX6644 CZX6646
* 33 Heat Sink CZN8444 CZN8416 CZN8416
34 Plate Assy CZX6639 CZX6638 CZX6639
35 Nut NB40FTB Not used Not used
* 37 Washer WB45FTB Not used Not used

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10. SCHEMATIC DIAGRAM
10.1 AMP UNIT(GUIDE PAGE)
A
A-a
A-a A-b
A-a A-b
A-b
A-a
Large size
SCH diagram
Guide page
Detailed page
Note: When ordering service parts, be sure to refer to " EXPLODED VIEWS AND PARTS LIST" or
"ELECTRICAL PARTS LIST".
For resistors and capacitors in the circuit diagrams, their resistance values or
capacitance values are expressed in codes:
Ex. *Resistors
Code Practical value
123 12 k ohms
103 10 k ohms
*Capacitors
Code Practical value
103 0.01 uF
101/10 100 uF/10 V
D-D converter output voltage (VH)-1 + 36.5 + 3 V Sp out : 1 kHz, 1 W
- 36.5 + 3 V
D-D converter output voltage (VD)-1 + 44.5 + 3 V Sp out : 1 kHz, 1 W
- 44.5 + 3 V
D-D converter output voltage (VH)-2 + 36.5 + 5 V Rg=1 kohm Referred value
- 39.5 + 5 V
D-D converter output voltage (VD)-2 + 34.5 + 5 V Rg=1 kohm Referred value
- 36.5 + 5 V
NOTE :

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A
A-b
BFC
EW5,ES
AAMP UNIT
The >mark found on some component parts indicates
the importance of the safety factor of the part.
Therefore, when replacing, be sure to use parts of
identical designation.
NM : No Mount
>
>

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A-a A-b
A-b
A
AMP UNIT
The >mark found on some component parts indicates the importance of the safety factor of the part. Therefore, when replacing, be sure to use parts of identical designation.
NM : No Mount

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A-a A-b
A-b
BFC
EW5,ES
>
>

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A-bA-a
A-a
A-b
For resistors and capacitors in the circuit diagrams, their resistance values or capacitance values are expressed in codes: Ex. *Resistors Code Practical value 123 12 k ohms 103 10 k ohms
*Capacitors Code Practical value 103 0.01 uF 101/10 100 uF/10 V
NOTE :