Pioneer Audio System Power Amplifier User manual

ORDER NO.
CRT2889
PUB. NO. CRT2889
AUDIO SYSTEM
POWER AMPLIFIER
Manufactured for TOYOTA
by PIONEER CORPORATION
VEHICLE DESTINATION PRODUCED AFTER TOYOTA PART No. ID No. PIONEER MODEL No.
LAND CRUISER PRADO UK, Ireland September 2002 86280-60280 GM-8027ZT/WL
LEXUS GX470 U.S.A., Canada November 2002 86280-60290 GM-8027ZT/E
LAND CRUISER PRADO Europe September 2002 86280-60310 GM-8127ZT/EW
LAND CRUISER PRADO UK, Ireland September 2002 86280-60300 GM-8127ZT/WL
GX470
Service
Manual
LAND CRUISER PRADO

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For details, refer to "Important symbols for good services".

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[ Important symbols for good services ]
In this manual, the symbols shown-below indicate that adjustments, settings or cleaning should be made securely.
When you find the procedures bearing any of the symbols, be sure to fulfill them:
2. Adjustments
To keep the original performances of the product, optimum adjustments or specification confirmation is indispensable.
In accordance with the procedures or instructions described in this manual, adjustments should be performed.
3. Cleaning
For optical pickups, tape-deck heads, lenses and mirrors used in projection monitors, and other parts requiring cleaning,
proper cleaning should be performed to restore their performances.
5. Lubricants, glues, and replacement parts
Appropriately applying grease or glue can maintain the product performances. But improper lubrication or applying
glue may lead to failures or troubles in the product. By following the instructions in this manual, be sure to apply the
prescribed grease or glue to proper portions by the appropriate amount.For replacement parts or tools, the prescribed
ones should be used.
4. Shipping mode and shipping screws
To protect the product from damages or failures that may be caused during transit, the shipping mode should be set or
the shipping screws should be installed before shipping out in accordance with this manual, if necessary.
1. Product safety
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.
SAFETY INFORMATION
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 safely 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 safely, you should not risk trying to do so
and refer the repair to a qualified service technician.
NOTE:
-When diagnosing a product, take care of its heated portion.
Power IC (IC801,802,803)
Power Supply IC (IC901,902)
DSP IC (IC201,251)
Heat Sink
IC Holder

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CONTENTS
SAFETY INFORMATION............................................3
1. SPECIFICATIONS.......................................................4
2. EXPLODED VIEWS AND PARTS LIST ......................6
3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM ....8
4. PCB CONNECTION DIAGRAM................................16
5. ELECTRICAL PARTS LIST........................................25
6. ADJUSTMENT.........................................................31
7. GENERAL INFORMATION.......................................41
7.1 DIAGNOSIS .......................................................41
7.1.1 DISASSEMBLY.........................................41
7.1.2 CONNECTOR FUNCTION DESCRIPTION ......44
7.2 IC ........................................................................45
7.3 EXPLANATION...................................................46
7.3.1 SYSTEM BLOCK DIAGRAM.....................46
7.3.2 OPERATIONAL FLOW CHART .................49
8. OPERATIONS...........................................................51
1. SPECIFICATIONS
Power source . . . . . . . . . . . . .13.2±0.1V(10.5-16.0V)
Grounding . . . . . . . . . . . . . . . .Negative type
Backup current . . . . . . . . . . . .1.0mA or less
Dimensions(No Bracket) . . . .261.6mm(W)x73mm(H)x183.8mm(D)
Weight . . . . . . . . . . . . . . . . . . .2.465kg
Maximum output power . . . .22W or more(Front)
22W or more(Squawker-Front)
22W or more(Rear)
22W or more(Woofer)

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2. EXPLODED VIEWS AND PARTS LIST
2.1 EXTERIOR

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1 Screw BMZ30P200FMC
2 Screw BMZ40P060FZK
3 Screw BMZ50P060FMC
4 Screw BPZ26P080FMC
5 Screw BSZ26P060FMC
6 Screw BSZ30P060FMC
7 Screw BSZ30P100FMC
8 Chassis CNA2142
9 Case CNB2563
10 Shield Case CNC8185
11 Shield Case CNC8186
12 Bracket CNC9778
13 Bracket CNC9779
14 86287-60020 CND1013
15 Insulator CNM6145
16 Seal CNM6686
17 Seal CNM7170
18 Seal CNM7305
19 Seal CNM7745
20 Tape CNM7882
21 Heat Sink CNR1566
22 Cover CNV7037
23 Cover CNV7605
24 DSP Unit(GM-8027ZT/WL) CWM8076
DSP Unit(GM-8027ZT/E) CWM8074
DSP Unit(GM-8127ZT/WL) CWM8356
DSP Unit(GM-8127ZT/EW) CWM8353
25 Cord Assy CDE6990
26 Connector(CN401) CKS2191
27 Socket(CN102) CKS3632
28 Socket(CN101) CKS4241
29 Amp Unit(GM-8076ZT/WL) CWM8077
Amp Unit(GM-8076ZT/E) CWM8075
Amp Unit(GM-8176ZT/WL) CWM8355
Amp Unit(GM-8176ZT/EW) CWM8352
30 Screw BPZ30P060FSN
31 Screw BSZ26P080FMC
32 Connector(CN902) CKM1308
33 Connector(CN901) CKM1310
34 Plug(CN906) CKS4240
35 Plug(CN905) CKS4242
36 Holder CNC8187
37 Bracket CND1012
38 Sheet CNM7015
39 Microphone Unit CWM8205
40 Connector(CN402) CKS2191
41 Screw ISS26P060FMC
42 IC(IC902) BA178M05T
43 IC(IC801) PAL006A
44 IC(IC802) PAL006A
45 IC(IC803) PAL006A
46 Cushion CNM7756
NOTE:
-Parts marked by “*” are generally unavailable because they are not in our Master Spare Parts List.
-Screws 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.)
-EXTERIOR SECTION PARTS LIST
Mark No. Description Part No. Mark No. Description Part No.

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3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM
3.1 BLOCK DIAGRAM
13
11
9
6
13
11
9
6
3
6
9
8
13
7
16
13
10
11
12
6
7
12
IC251
PD2061A
IC181
AK5351VF
IC261
AK4321VF
IC351
PM0017AM
IC101
IC131
S-80730ANDT
IC902
BA178M05T
IC901
NJM2930F08K
Q904
Q906
Q912
Q909
Q903
5V REGULATOR
8V REGULATOR
SYSTEM
POWER SWITCH
5V REGULATOR
AUDIO INPUT
BUFFER
INPUT
CONNECTOR
OUTPUT
CONNECTOR
IC501
NJM2068MD
IC903
M51957BFP
IC703
NJM2068MD IC803
PAL006A
SUB WOOFER
POWER AMP
SUB WOOFER
PRE AMP
REAR
POWER AMP
FRONT
POWER AMP
FRONT-L
PRE AMP
REAR-L
PRE AMP
IC701
NJM2068MD
IC702
NJM2068MD
P
PEE
31
11 9
7
7
9
4
11
1
3
31
11 7
9
2
7
6
1
7
2
6
13
13
SYS4
BU
BU1
BU1
BU
L901
B.U
WFL- WFL+
IC802
PAL006A
IC801
PAL006A
RL- RL+
FL+
FL-
CN901
L- L+
TMUT
MUTE
(H/U MUT)
ACC
Q915
6
718
A/D CONVERTER
ACC1
ACC1
BU1
ASENS
BSENS
Q155
Q151
17
16
N-MU
NMUT
Q171
NAVMUTE 79
RESET
1
RESET 92
SYSTEM CONTROLLER
SYSPW1
SYSPW1
SYS5SYSD5 1
18
17 2
SYSA5
AVDD
DVDD
16 3SYS8
SYS8
Q161
SYSPW1
66
Q910
Q911
24
STBY1
4
25
25
25
Q801
Q802
Q803
PMUT
MUTEO
MUTO
1
MUTE
MUTIN
MUTI
Q175
31
SMUTEIN
Q913
PWSENS 65
MUTE
/STBY
MUTE
VDD5VDD5
VDD
P
PEE
11 8
PEE 21
NMUT1
NAVI/MUTE
ACC SENSE
BACK UP SENSE
SYSTEM MUTE
PEE
SYSP1
CN906
CN101
CN905
CN102
FS
FS 514
A
A
B
B
CN902
ELECTRONIC
VOLUME
IC401
NJM2068MD
Q401
MIC MIC401
VR401
3
ASLIN2
76
1
ASLIN1
74
IC402
NJM2068MD
5
7
ASL
8
8
IC141
HA12187FP
BUS DRIVER
AVCIN
AVCOUT
AVCPW
22
23
20
2
1
8
715 4
DSP
DSP
10 12
XOUT
XIN
21
IC281
AK4321VF
IC291
AK4321VF
IC311
NJM2068MD
IC331
NJM2068MD
IC341
NJM2068MD
FRONT DAC
IC231
TC7WU04F
IC241
TC7W74FU
1
7
CRYSTAL
OSCILLATOR
REAR DAC
WOOFER DAC
FRONT LPF
REAR LPF
WOOFER LPF
16
83
18
15
17 15
19 18 16 15
8
8
3
18
3
18
3
1
17
20
RLO RLIN
22
FLO FLIN
18
WFO WFIN
ML- ML+
17
19
(TWLP)
(TWLP)
(TWLM) (TWLM)
(RLM)
(RLP)
(FLM)
(FLP)
AINL+
AINL- SDATA SDI1
SDO1
SDO0
SDO2
SDI0
SDI1
SDO1
SDO2
(FDATA)
(WDATA )
(RDATA)
VCC
8
VCC
8
3
1
22
35
5
5
(256FS)
CK D
q
XTI
SDATA AOUTL
XTI
SDATA AOUTL
XTI
SDATA AOUTL
IN1
IN3
IN5
OUT3
OUT1
OUT5
(FSW)
(FSW)
Q833
Q832
Q831
10
10
16
Q950
B
ADSP UNIT AMP UNIT
55
19 SDI0
Q291
68
DSPERR
17
AOUTR
6
SYS4
6
SYS4
6
SYS4
22
PMUT
STBY1
STBY1
22
PMUT
22
PMUT
Q101
(ASL1)
(ASL2)
SPD
(SPD)
C
(SPD)
C
Q907
10 9SPD1SPD1
SPEED SENSOR PULSE
15
SPEED
VDD
IC201
PD2061A
6 TXH TXP1
TX+
OFFSET SENSE
2
2
C
MICROPHONE UNIT
GM-8027ZT/E
GM-8027ZT/WL
GM-8127ZT/EW
GM-8127ZT/WL
: PD5726A
: PD5792A
IC271
AK4321VF
IC321
NJM2068MD
SQUAWKER DAC SQUAWKER LPF
83
18
1
5XTI
SDATA AOUTL
(TDATA )
SDO0 17
IC371
SN761029DL
2
ELECTRONIC
VOLUME
19 88
15
TWLINTWLO
1
1
4

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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". A-a
AB C
POWER AMP
ADSP UNIT
BAMP UNIT
C
MICROPHONE UNIT
A/D CONVERTER
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3.2 SCHEMATIC DIAGRAM (GUIDE PAGE)

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A-b
A-a A-b
A-a A-b
A-b
A-a
A B
Decimal points for resistor
and capacitor fixed values
are expressed as :
2.2 2R2
0.022 R022
←
←
Symbol indicates a resistor.
No differentiation is made between chip resistors and
discrete resistors.
NOTE :
Symbol indicates a capacitor.
No differentiation is made between chip capacitors and
discrete capacitors.

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A-a A-b A-a
A-a
A-b 12
A/D CONVERTER
ADSP UNIT
C
MICROPHONE UNIT

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A-a A-b A-a
A-a
A-b
34
POWER AMP
BAMP UNIT
C
MICROPHONE UNIT

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A-a A-b
A-b 12

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A-a A-b
A-b
34
Decimal points for resistor and capacitor fixed values are expressed as : 2.2 2R2 0.022 R022
←
←
Symbol indicates a resistor. No differentiation is made between chip resistors and discrete resistors.
NOTE :
Symbol indicates a capacitor. No differentiation is made between chip capacitors and discrete capacitors.

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4. PCB CONNECTION DIAGRAM
4.1 DSP UNIT
Capacitor
Connector
P.C.Board Chip Part
A
ADSP UNIT
SIDE B
SIDE A
NOTE FOR PCB DIAGRAMS
1.The parts mounted on this PCB
include all necessary parts for
several destination.
For further information for
respective destinations, be sure
to check with the schematic dia-
gram.
2.Viewpoint of PCB diagrams
BCN906
CCN402

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A
SIDE A
FRONT
BCN905

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A
ADSP UNIT

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A
SIDE B

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4.2 AMP UNIT
B
BAMP UNIT ACN101