Sony XM-4060GTX Operating & Connection User manual

1
SERVICE MANUAL
US Model
Canadian Model
AEP Model
UK Model
E Model
XM-4060GTX
STEREO POWER AMPLIFIER
Other Specifications
Circuit system OTL (output transformerless) circuit
Pulse power supply
Inputs RCA pin jacks
High level input connector
Outputs Speaker terminals
Suitable speaker impedance
2 – 8 Ω(stereo)
4 – 8 Ω(when used as a bridging amplifier)
Maximum outputs Four speakers:
120 W ×4 (at 4 Ω)
150 W ×4 (at 2 Ω)
Three speakers:
120 W ×2 + 300 W ×1 (at 4 Ω)
Rated outputs (supply voltage at 14.4V)
Four speakers:
60 W ×4 (20 Hz – 20 kHz, 0.08% THD, at 4 Ω)
75 W ×4 (20 Hz – 20 kHz, 0.1% THD, at 2 Ω)
Three speakers:
60 W ×2 + 150 W ×1 (20 Hz – 20 kHz,
0.1% THD, at 4 Ω)
Frequency response 5 Hz – 50 kHz ( dB)
Harmonic distortion 0.005% or less (at 1 kHz)
Input level adjustment range
0.3 – 6.0 V (RCA pin jacks)
1.2 – 12 V (High level input)
High-pass filter 50 – 300 Hz, –12 dB/oct
Low-pass filter 50 – 300 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 : 31 A (4 Ω)
Remote input : 1 mA
Dimensions Approx. 400 ×55 ×276 mm
(w/h/d) (15 3/4 ×2 1/4 ×10 7/8 in.) not incl.
projecting parts and controls
Mass Approx. 4.6 kg (10 lb. 3 oz.) not incl. accessories
Supplied accessories Mounting screws (4)
High level input cord (1)
Protection cap (1)
Design and specifications are subject to change without
notice.
SPECIFICATIONS
AUDIO POWER SPECIFICATIONS (US MODEL)
POWER OUTPUT AND TOTAL HARMONIC DISTORTION
60 watts per channel minimum continuous average power into
4 ohms, both channels driven from 20 Hz to 20 kHz with no more
than 0.08% total harmonic distortion per Car Audio Ad Hoc
Committee standards.
+0
–3
Ver. 1.1 2005. 05
Sony Corporation
e Vehicle Group
Published by Sony Engineering Corporation
9-961-369-02
2005E04-1
© 2005. 05

2
TABLE OF CONTENTS
1. GENERAL
Location and Function of Controls.......................................... 3
Connections ............................................................................. 4
2. DISASSEMBLY
2-1. Bottom Plate ........................................................................ 6
2-2. Main Board Section ............................................................. 7
2-3. Main Board, Hi-level Board ................................................ 7
2-4. LED Board ........................................................................... 8
3. ELECTRICAL ADJUSTMENT...................................... 9
4. DIAGRAMS
4-1. IC Block Diagram.............................................................. 10
4-2. Block Diagram................................................................... 11
4-3. Printed Wiring Board –Main Section– .............................. 12
4-4. Schematic Diagram –Main Section (1/2)– ........................ 13
4-5. Schematic Diagram –Main Section (2/2)– ........................ 14
4-6. Printed Wiring Boards –Hi-level, LED Section–............... 15
5. EXPLODED VIEWS
5-1. Heat Sink (Main) Section .................................................. 16
5-2. Main Board Section ........................................................... 17
6. ELECTRICAL PARTS LIST......................................... 18
XM-4060GTX
SAFETY-RELATED COMPONENT WARNING!!
COMPONENTS IDENTIFIED BY MARK 0OR DOTTED LINE
WITH MARK 0ON 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 0SUR LES
DIAGRAMMES SCHÉMATIQUES ET LA LISTE DES PIÈCES
SONT CRITIQUES POUR LA SÉCURITÉ DE FONCTIONNEMENT.
NE REMPLACER CES COMPOSANTS QUE PAR DES PIÈCES
SONY DONT LES NUMÉROS SONT DONNÉS DANS CE MANUEL
OU DANS LES SUPPLÉMENTS PUBLIÉS PAR SONY.
Notes on Chip Component Replacement
•Never reuse a disconnected chip component.
•Notice that the minus side of a tantalum capacitor may be
damaged by heat.

3
XM-4060GTX
SECTION 1
GENERAL This section is extracted
from instruction manual.

4
XM-4060GTX

5
XM-4060GTX

6
XM-4060GTX SECTION 2
DISASSEMBLY
Note : Follow the disassembly procedure in the numerical order given.
2-1. BOTTOM PLATE
Note : This set can be disassemble according to the following sequence.
2-1. BOTTOM PLATE
(Page 6)
2-2. MAIN BOARD SECTION
(Page 7)
2-4. LED BOARD
(Page 8)
SET
2-3. MAIN BOARD,
HI-LEVEL BOARD
(Page 7)
3 bottom plate
4 insulating shee
t
1 three screws
(+ BTP 3 x 6)
2 three screws
(+ BTP 3 x 6)

7
XM-4060GTX
2-3. MAIN BOARD, HI-LEVEL BOARD
2-2. MAIN BOARD SECTION
heat sink (main)
6 CN850
5 MAIN board section
1 three screws
(+ P 3 x 8)
2 three screws
(+ P 3 x 8)
3 screw
(+ P 3 x 8)
4 three screws
(+ P 3 x 8)
7 front panel
5 HI-LEVEL board
4 CNP101
8 MAIN board
claws
6 bracket (HI LEVEL)
A
A
1 two screws
(+ P 3 x 8)
2 three screws
(+ P 3 x 8)
3 two screws
(+ P 3 x 8)

8
XM-4060GTX
2-4. LED BOARD
2 LED board
heat sink (main)
light guide plate
1 screw
(+BT P 3 x 6)

9
XM-4060GTX
Bias Adjustment
Note : The Bias adjustment should be performed only if any of
Q109 and Q110 for RV104, Q209 and Q210 for RV204,
Q309 and Q310 for RV304, and Q409 and Q410 for RV404
are replaced.
Setting :
Procedure:
1. Rotate variable resistors RV104 (FRONT L-CH), RV204
(FRONT R-CH), RV304 (REAR L-CH) and RV404 (REAR
R-CH) full clockwise as seen from the pattern side to minimize
the bias current.
2. The input signal is with no signal.
3. Connect the stabilized power supply between B+ and REM
terminals and gradually increase the voltage to 14.4 V while
checking for any abnormal current.
4. AdjustRV104 (FRONTL-CH), RV204 (FRONTR-CH), RV304
(REAR L-CH) and RV404 (REAR R-CH) so that the digital
voltmeter connected between the respective test points reads
6±1 mV.
5. After this adjustment, verify that the current value of the
stabilized power supply is 1.4 to 1.8A.
SECTION 3
ELECTRICAL ADJUSTMENT
+
_
stabilized
power supply digital voltmeter
B+, REM terminals
set
GND terminal test points
Adjustment Location :
RV Ref. No. Test points
RV104 TP11 and TP12
RV204 TP21 and TP22
RV304 TP31 and TP32
RV404 TP41 and TP42
TP32
TP22
TP21
TP11
TP12
TP31
TP41
TP42
RV404
BIAS ADJUSTMENT
(REAR R-CH) RV104
BIAS ADJUSTMENT
(FRONT L-CH)
RV204
BIAS ADJUSTMENT
(FRONT R-CH)
RV304
BIAS ADJUSTMENT
(REAR L-CH)
– MAIN BOARD (CONDUCTOR SIDE) –

10
XM-4060GTX
4-1. IC BLOCK DIAGRAM
IC901 TL594INSR
16 15 14 13 12 11 10 9
1 2 3 4 5 6 7 8
OSC
REF. REG.
ERROR
ERROR
0.1V
Q201 H-12
Q202 G-10
Q203 F-11
Q204 F-11
Q207 F-11
Q208 F-11
Q209 G-12
Q210 G-12
Q211 F-12
Q212 G-10
Q301 G-6
Q302 D-10
Q303 C-10
Q304 C-10
Q307 C-10
Q308 D-10
Q309 B-10
Q310 B-11
Q311 B-10
Q312 D-11
Q401 H-6
Q402 D-9
Q403 C-9
Q404 C-9
Q407 C-9
Q408 C-9
Q409 B-8
Q410 B-8
Q411 B-9
Q412 D-8
Q801 E-8
Q802 E-8
Q803 A-5
Q804 B-5
Q805 A-4
Q808 F-6
Q809 F-6
Q810 C-7
Q812 B-4
Q813 A-4
Q814 A-3
Q850 B-4
Q901 H-1
Q902 H-2
Q903 H-2
Q904 F-2
Q905 E-2
Q906 E-2
Q907 D-2
Q908 E-2
Q909 E-2
Q910 F-8
Q911 F-8
Q912 E-2
Q913 E-2
D101 D-10
D141 E-12
D201 G-10
D241 F-12
D301 D-10
D341 C-10
D401 D-8
D441 C-9
D801 E-8
D802 E-8
D805 D-8
D824 D-8
D825 D-8
D826 D-8
D827 D-8
D828 C-7
D829 C-7
D901 H-2
D902 H-2
D903 E-6
D904 E-6
D905 D-6
D906 D-6
D907 B-2
D908 C-2
D911 D-6
D912 E-6
D913 F-8
D914 F-8
D917 E-6
D918 E-5
IC801 H-9
IC802 I-10
IC806 H-10
IC807 H-11
IC808 H-8
IC809 H-8
IC811 G-7
IC812 H-7
IC813 G-7
IC814 H-6
IC901 G-1
IC902 E-7
Q101 H-10
Q102 E-11
Q103 E-11
Q104 E-11
Q107 E-11
Q108 E-11
Q109 E-12
Q110 D-12
Q111 E-12
Q112 D-10
•Semiconductor Location (MAIN SECTION)
Ref.No. Location Ref.No. Location
SECTION 4
DIAGRAMS
THIS NOTE IS COMMON FOR PRINTED WIRING BOARDS
AND SCHEMATIC DIAGRAMS.
(In addition to this, the necessary note is
printed in each block.)
for schematic diagram:
Note:
•All capacitors are in µF unless otherwise noted. (p: pF)
50 WV or less are not indicated except for electrolytics
and tantalums.
•All resistors are in Ωand 1/4W or less unless otherwise
specified.
•%: indicates tolerance.
•2: nonflammable resistor.
•C: panel designation.
Note:
The components identi-
fied by mark 0or dotted
linewithmark0arecriti-
cal for safety.
Replace only with part
number specified.
Note:
Lescomposantsidentifiés par
une marque 0sont critiques
pour la sécurité.
Ne les remplacer que par une
piéce portant le numéro
spécifié.
•A: B+ Line.
•B: B– Line.
•H: adjustment for repair.
•Powervoltageisdc14.4Vandfedwithregulateddcpower
supply from +12V and REM terminals.
•Voltage and waveform are dc with respect to ground
under no-signal condition.
•Voltagesare taken with aVOM(Inputimpedance10 MΩ).
Voltage variations may be noted due to normal produc-
tion tolerances.
•Waveforms are taken with a oscilloscope.
Voltage variations may be noted due to normal produc-
tion tolerances.
•Circled numbers refer to waveforms.
•Signal path.
F:AUDIO
for printed wiring boards:
Note:
•X: parts extracted from the component side.
•: Pattern from the side which enables seeing.