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GT5-A402
2 CHANNEL POWER AMPLIFIER
SERVICE MANUAL
JBL Consumer Products
250 Crossways Park Dr.
Woodbury, New York 11797 Rev0 3/2008
Released 2007
Discontinued XXXX
GT5-A402
- 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
P.C.B. DRAWINGS................................................8
ELECTRICAL PARTS LIST ...................................10
IC/TRANSISTOR PINOUTS....................................13
SCHEMATICS......................................................14
GT5-A402 Specifications
Output Power: 40W RMS x 2 channels @ 4 ohms; 1% THD + N
(14.4V supply) 60W RMS x 2 channels @ 2 ohms; 1% THD + N
120W RMS x 1 channel (bridged) @ 4 ohms; 1% THD + N
Signal-to-noise ratio: 85dBA (reference 1W into 4 ohms)
101dBA (reference rated power into 4 ohms)
Total Peak power: 240W
Frequency response: 10Hz 100kHz (3dB)
THD+N 1KHz LPF=22KHz 0.05% (rated power @ 4 ohms)
Channel Separation 50db
Input Impedance 15k
Maximum input signal: 6.0V
Maximum sensitivity: 200mV
Hi-Pass, Low Pass X-over Limits 32Hz 320Hz ±20% 12dB/oct
Bass Boost @ 50Hz 6dB
DC Offset <30mV
Output regulation: 38dB
Idle Current @ 4 ohms 0.46A
Max Current Draw 11A
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 7 1/2 x 9 1/4" (54 x 191 x 235mm)
Fuse: 15A
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-A402
PACKAGING
2
GT5-A402
4x 1x 1x
9-1/4"
235mm
7-1/2"
191mm
2-1/8"
54mm
A B C D E
A
B
C
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GT5-A402
GT5-A402 CAR AUDIO POWER AMPLIFIER OWNER'S MANUAL
Installation Warnings and Tips 0 Speaker Output Connectors 5 Power On LED
· Disconnect the negative () lead from your vehicle's · Connect the speakers to these terminals, · Illuminated when the amplifier is on.
battery. observing proper polarity. 6 Protect LED
· At the installation sites, locate and make a note of · Two-channel operation: Connect the left · Illuminated under any of the following fault
all fuel lines, hydraulic brake lines, vacuum lines speaker to the L+ and L terminals and the conditions: battery over/under voltage, short
and electrical wiring. Use extreme caution when right speaker to the R+ and R terminals. circuit in speaker wires, amplifier is too hot,
cutting or drilling in and around these areas. · One-channel (bridged) operation: Connect the amplifier's output circuit has failed (DC voltage
· Choose a safe mounting location away from moisture. single speaker to the R+ and L terminals. is present in the amplifier's output).
· Make sure there is sufficient air circulation at the · Minimum speaker impedance for 2-channel 7 Crossover-Frequency Control
mounting location for the amplifier to cool itself. operation is 2 ohms. Minimum speaker impedance · 12dB/octave crossover, variable from
· Mount the amplifier, using the supplied hardware. for 1-channel (bridged) operation is 4 ohms. 32Hz to 320Hz.
1 Fuse · See B for the adjustment procedure.
Specifications · Replace only with the same type and rating. 8 Crossover-Filter Selector
· 40W RMS x 2 channels @ 4 ohms and 1% THD + N* 2 Power Input Connectors · LP: Select for subwoofer(s).
· 60W RMS x 2 channels @ 2 ohms, 14.4V supply and · +12V: Connect to the positive terminal of the · FLAT: Select for full-range speakers when
1% THD + N* vehicle's battery. 10 AWG wire is recommended. no subwoofer will be used in the system.
· 120W RMS x 1 channel @ 4 ohms, 14.4V supply and Install an appropriate fuse holder and fuse (15A · HP: Select for midrange speakers or
1% THD + N* minimum) within 18 inches of the battery. Make full-range speakers when a subwoofer is
sure the wire is not damaged or pinched during used in the system.
· THD + N: 0.05% (rated power @ 4 ohms)*
installation. Install protective grommets when 9 Bass-Boost Control
· Signal-to-noise ratio: 85dBA routing wires through the firewall or other sheet
(reference 1W into 4 ohms)* · Provides 6dB of boost at 50Hz. Set the Bass-
metal. Boost control according to your preference,
· Signal-to-noise ratio: 101dBA · GND: Connect to the vehicle's chassis. Refer to being careful not to apply enough boost to
(reference rated power into 4 ohms) the picture below. damage the speaker(s).
· Frequency response: 10Hz 100kHz (3dB)*
Factory Bolt Ring Connector A Setting Input Level
· Total peak power: 240 watts A Turn Input-Level control counterclockwise to
Ground Wire
* CEA-2006A-compliant 6V (minimum).
B With a dynamic music track playing, turn the
head unit's volume control to the 3/4 position.
C Turn Input-Level control clockwise until the
music is so loud that it no longer sounds clear
(distortion is present in the output).
D Turn Input-Level control counterclockwise
Note: Remove any paint Star Washer
gradually, just until the music sounds clear,
below ring connector.
once again.
· REM: Connect to the "Remote Out" lead from E Input level is now adjusted correctly.
the source unit or to a source of switched B Setting the Crossover
12V+ (ACC). A Crossover setting for 5" or larger full-range
3 Input Connectors (RCA) speakers when no subwoofer is included in
· Connect to the RCA outputs from the source unit the system.
or signal processor. B Crossover setting for midrange and/or
4 Input-Level Control full-range speakers when a subwoofer
· Used to match the input level of the amplifier is included in the system.
to the output level of the source unit. C Crossover setting for subwoofers.
· See A for the adjustment procedure. Note: Acceptable frequency ranges are indicated
in gray.
4
GT5-A402
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
5
GT5-A402
EXPLODED VIEW
GT5-A402
7
GT5-A402
8
GT5-A402
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GT5-A402
GT5-A402 Electrical Parts List
Part Number Description Qty Reference Designator
Semiconductors
TR-KTA1266GR TRANS SMALL SIGNAL PNP,TO-92KTA1266GR 10 Q03,04,8,9,102,104,105,202,204,205
TR-KTA1268GR TRANS SMALL SIGNAL PNP,TO-92KTA1268GR 1 Q06
TR-KTC3198BL TRANS SMALL SIGNAL NPN,TO-92KTC3198BL 1 Q05
TR-KTC3198GR TRANS SMALL SIGNAL NPN,TO-92KTC3198GR 10 Q02,07,101,103,113,123,201,203,206, 213
TR-KTC3200GR TRANS SMALL SIGNAL NPN,TO-92KTC3200GR 2 Q112,212
TR-KTA1023Y TRANS SMALL SIGNAL PNP,TO-92KTA1023Y 3 Q01,124,209
TR-KTC1027Y TRANS SMALL SIGNAL NPN,TO-92KTC1027Y 2 Q114,208
DIODE-1N4148 DIODE SWITCHING SIGNAL1SS133 7 D03,04,05,13,14,151,201
DIODE-1N4004 DIODE RECTIFIER 1N4004 1 D02
DIODE-FR154 DIODE FAST RECOVERYFR154/1504 4 D06,07,08,09
DIODE-1N4744 DIODE ZENER, 15V/1W1N4744 2 D102,103
IC-TL494CN IC PWM IC,SO-16TL494CN 1 U01
IC-NJM208LD IC DUAL OP AMP,SSOP-08NJM2068L 8 U101,102,103,104,105,106,107,108
FET-K30AGR TRANS N-CH JFET,TO-92KTK30AGR 3 Q12,100,200
FET-50N60P TRANS N-CH POWER MOSFET,TO-220 KEC50N60P 2 Q10,11
TR-KTC3200GR1 TRANS SMALL SIGNAL NPN,TO-92KTC3200GR 2 Q107,207
TR-KTD718 TRANS AUDIO POWER NPN,TO-3PKTD718 2 Q110,210
TR-KTB688 TRANS AUDIO POWER PNP,TO-3PKTB688 2 Q111,211
DIODE-1N5404 DIODE RECTIFIER1N5404 1 D01
DIODE-YG225D2 DIODE FAST RECOVERY, TO-220YG225D2 2 D11,12
LED3 LED 3PHI,GREEN/RED ARRAY L-H322005GB 1 LED01
LED2 LED ACYLE 3.0 AWG#24,RED/BLACK150m/m 1 LOGO BACKLIGHT
Capacitors - see legend last page
CAP0502R2-E-1 CAPACITOR ELECTROLYTIC"DSA" ,5m/m 2.2uF/50V 2 C122 222
CAP0502R2-E CAPACITOR ELECTROLYTIC"MHA" ,5*11m/m 2.2uF/50V 4 C26,27,121,221
CAP016100-E CAPACITOR ELECTROLYTIC"MHA" ,5*11m/m 10uF/16V 5 C02,101,107,201,207
CAP025100-E CAPACITOR ELECTROLYTIC"MHA" ,5*11m/m 10uF/25V 1 C33
CAP016220-E CAPACITOR ELECTROLYTIC"MHA" ,5*11m/m 22uF/16V 4 C102,103,202,203
CAP016470-E CAPACITOR ELECTROLYTIC"MHA" ,5*11m/m 47uF/16V 2 C06,12
CAP035470-E CAPACITOR ELECTROLYTIC"MHA" ,5*11m/m 47uF/35V 1 C29
CAP016101-E CAPACITOR ELECTROLYTIC"MHA" ,5*11m/m 100uF/16V 6 C05,09,11,125,131,225
CAP025101-E CAPACITOR ELECTROLYTIC"MHA" ,5*11m/m 100uF/25V 2 C133,134
CAP100102-M CAPACITOR MYLAR,100V 5% 102(M) 1 C10
CAP100183-M CAPACITOR MYLAR,100V 5% 183(M) 2 C116,216
CAP100222-M CAPACITOR MYLAR,100V 5% 222(M) 1 C21
CAP100473-M CAPACITOR MYLAR,100V 5% 473(M) 2 C140,224
CAP100823-M CAPACITOR MYLAR,100V 5% 823(M) 4 C112,113,212,213
CAP100104-M CAPACITOR MYLAR,100V 5%,BOX or TL104(M) 4 C115,130,215,230
CAP050100-C CAPACITOR DISK TYPE, CERAMIC, 50V"NPO" 10 pF 2 C104,204
CAP050220-C CAPACITOR DISK TYPE, CERAMIC, 50V"NPO" 22 pF 6 C28,105,106,205,206,209
CAP050330-C CAPACITOR DISK TYPE, CERAMIC, 50V"NPO" 33 pF 2 C128,228
CAP050470-C CAPACITOR DISK TYPE, CERAMIC, 50V"NPO" 47 pF 6 C108,111,114,208,211,214
CAP050680-C CAPACITOR DISK TYPE, CERAMIC, 50V"NPO" 68 pF 2 C123,223
CAP050221-C CAPACITOR DISK TYPE, CERAMIC, 50V"NPO" 220 pF 4 C126,127,226,227
CAP050473-C CAPACITOR DISK TYPE, CERAMIC, 50V 473 pF 5 C13,14,15,23,25
CAP050104-C CAPACITOR DISK TYPE, CERAMIC, 50V 104 pF 8 C01,03,07,17,117,118,151,229
CAP0351022-E-1 CAPACITOR ELECTROLYTIC"WL"1000/35V" 1 C04
CAP0351022-E CAPACITOR ELECTROLYTIC"SHL/SD"1000/35V"SHL" 2 C22,24
Resistors
RES47011/8-F RESISTOR METAL FILM 1/8WF 4.7K 1 R37
RES56011/8-F RESISTOR METAL FILM 1/8WF 5.6K 2 R131,231
RES10521/8-F RESISTOR METAL FILM 1/8WF 10.5K 1 R36
RES22021/8-F RESISTOR METAL FILM 1/8WF 22K 3 R101,201,232
RES47021/8-F RESISTOR METAL FILM 1/8WF 47K 8 R102,103,104,105,202,203,204,205
RES1001/8-J RESISTOR CARBON FILM 1/8W 10 1 R11
RES2201/8-J RESISTOR CARBON FILM 1/8W 22 8 R135,136,137,138,235,236,237,238
RES4701/8-J RESISTOR CARBON FILM 1/8W 47 6 R26,27,141,144,241,244
RES1211/8-J RESISTOR CARBON FILM 1/8W 120 2 R147,247
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GT5-A402
Part Number Description Qty Reference Designator
RES6811/8-J RESISTOR CARBON FILM 1/8W 680 2 R108,208
RES4711/8-J RESISTOR CARBON FILM 1/8W 470 2 R22,23
RES5611/8-J RESISTOR CARBON FILM 1/8W 560 4 R106,146,206,246
RES8211/8-J RESISTOR CARBON FILM 1/8W 820 1 R13
RES1021/8-J RESISTOR CARBON FILM 1/8W 1K 10 R06,17,24,25,118,134,218,234,140,240
RES1521/8-J RESISTOR CARBON FILM 1/8W 1.5K 2 R150,250
RES2721/8-J RESISTOR CARBON FILM 1/8W 2.7K 2 R172,243
RES3921/8-J RESISTOR CARBON FILM 1/8W 3.9K 2 R127,242
RES4721/8-J RESISTOR CARBON FILM 1/8W 4.7K 6 R01,02,07,08,107,207
RES8221/8-J RESISTOR CARBON FILM 1/8W 8.2K 1 R05
RES5121/8-J RESISTOR CARBON FILM 1/8W 5.1K 2 R122,222
RES5621/8-J RESISTOR CARBON FILM 1/8W 5.6K 4 R113,115,215,217
RES6821/8-J RESISTOR CARBON FILM 1/8W 6.8K 6 R114,133,139,216,233,239
R09,10,21,33,34,109,111,112,119,120,130,
RES1031/8-J RESISTOR CARBON FILM 1/8W 10K 19
209,210,211,213,214,219,220,230
RES1121/8-J RESISTOR CARBON FILM 1/8W 1.1K 2 R145,245
RES1531/8-J RESISTOR CARBON FILM 1/8W 15K 4 R20,35,154,251
RES2231/8-J RESISTOR CARBON FILM 1/8W 22K 6 R15,16,18,110,132,212
RES3331/8-J RESISTOR CARBON FILM 1/8W 33K 1 R19
RES2731/8-J RESISTOR CARBON FILM 1/8W 27K 2 R121,221
RES4731/8-J RESISTOR CARBON FILM 1/8W 47K 1 R14
RES5631/8-J RESISTOR CARBON FILM 1/8W 56K 3 R252,152 R04
RES6831/8-J RESISTOR CARBON FILM 1/8W 68K 1 R12
RES4341/8-J RESISTOR CARBON FILM 1/8W 430K 1 R28
RES2241/8-J RESISTOR CARBON FILM 1/8W 220K 1 R32
RES1041/8-J RESISTOR CARBON FILM 1/8W 100K 2 R129 ,R229
RES1051/8-J RESISTOR CARBON FILM 1/8W 1M 2 R123,223
RES2221/1-J RESISTOR METAL FILM 1/4W J 2.2K 1 R163
RES4R71/2-J RESISTOR METAL FILM 1/2WJ4.7/0.5W 2 R153,253
RES1001/2-J RESISTOR METAL FILM 1/2WJ10/0.5W 1 R03
RES1012-J RESISTOR MOR, 2WJ100/2W 1 R31
RES1512-J RESISTOR MOR, 150/2W J 2 R161,162
RES0R15-J RESISTOR MOR, 5WJ0.1/5W 4 R148, 149,248,249
3B20Kx2 LEVEL POT V9M(7x5) G3(PH2R)N 15S-3B20Kx220KB*2 1 VR01
15C50Kx4 FREQ POT V9M(7x5) G(4R)(PH2R)N15S-15C50Kx450KC*4 1 VR02
RET94011/8-F RESISTOR DISK TYPE,NTC 50K50K 1 TH01
Miscellaneous
CORE-GT402 TRANSFORMER 29PHI ,ISU29PHI 6t(0.7x6):11t(0.7x3) 1 T01
CORECL-300 INDUCTOR BAR CORECL-300 1 L01
TER-3P 3P TERMINAL PLATED,3P,POWERJSZ3-02 POWER 1 P01
TER-4P 4P TERMINAL PLATED,4P,SPEAKER JSZ4-03 SPEAKER 1 P02
AV2-8.4-13A RCA JACK PLATED 2P(TOP:RED, BOTTOM:WHITE) 1 RCA1
15PWF-9402 FUSE HOLDER WF-9402PWF-9402P 1 for F01
FUSE-15A FUSE FUSE 15A 1 F01
SW-2PJSS-2219 SWITCH SLIDE SW,2C-2PJSS-2219 BASS BOOST 1 SW02
SW-3PJSS-2319 SWITCH SLIDE SW,2C-3PJSS-2319 HP/LP/FLAT 1 SW01
PLAL0640-02P 2P NEILSBED 2.54m/m pitch, 2PLAL0640-02 1 JA03
PLAL0640-07 7P NEILSBED 2.54m/m pitch, 7PLAL0640-07 1 JA02
W-60MM GROUND 1007,AWG#24,4.5PHI RING LUG60m/m 1 W01
W-7-80MM 7P CONNECT WIRE AWG#24, HOUSING to WAFER80m/m 1 J01
FIBER6-200 SLIP 200.0×6.0×0.5t 0.4
FIBER8-200 SLIP 200.0×8.0×0.5t 0.3
BUSHING0.7 BUSHING 0.7PHI 8m/m*4 3.2cm Q107,207,TH01
HEA-GT402 HEATSINK AL/Die-casting L=170.0mm 1 BLACK SPRAY
END CAP END CAP ABS(XR401) 2 SILVER(8400C) SPRAY END CAP
PAN-RGT402 FRONT PANEL EGI,1.2t 1 BLACK SPRAY / SILVER SILK 1°
PAN-FGT402 REAR PANEL EGI,1.2t 1 BLACK SPRAY / SILVER SILK 1°
BOTC-GT402 BOTTOM COVER SECC,1.0t 1 BLACK SPRAY
LOGO-B-PC LOGO BADGE PC(ORANGE CLEAR) 1 SILVER HOT STAMPING
BSBM-24 CUPRUM BRACKET BSBM H5, L=24.0mm 3 MAIN PCB+SUB PCB
JIG-30-15 TRANS CLAMP SPCC 30x15x3(mm) 2 WITH SLIP 48.152.0280130011
JIG-46-15 TRANS CLAMP SPCC 46x15x3(mm) 2 WITH SLIP 48.152.0450140011
PAD-70-23 SILICON PAD (SP1000)70.0x23.0x0.2t 1
PAD-50-23 SILICON PAD (SP1000)50.0x23.0x0.2t 2
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GT5-A402
Part Number Description Qty Reference Designator
FELT-15-7 WEAVE FELT, 15.0x7.0x0.3t 2
RUB10-10-2 RUBBER RUBBER,10.0x10.0x2.0t 2 for FET
FIBER70-148 SLIP FIBER 148x70x0.5t 1 SUB PCB
SCR-BH3-8BK SCREW STT2 BH 3x8 BK 3 RCA(1),TERMINAL(2)
SCR-BH3-6NI SCREW STT2 BH 3x6 NI 1 for FET
SCR-PH2-10BK SCREW STT1 PH 2x10 BK 1 for FUSE
SCR-MB3-6NI SCREW SMB 3x6 NI-P 10 PCB+HEATSINK(4), PCB SUPPORT(6)
PANEL+HEATSINK(2) TOP HEAT SINK
SCR-MB3-6BK SCREW SMB 3x6 BK 6
+BOTTOM COVER(4)
SCR-FH3-8BK SCREW STT3 FH 3x8 BK 8 PANEL+HEATSINK(8) SIDE
SCR-BH3-5NI SCREW STT2 BH 3X5 NI WASHER 2 BADGE
SCR-MB4-14NI SCREW SMB 4X14NI LOCK HEAD 4 TR BRACKET
General Capacitance Codebreaker Chart
pico-farad nano-farad micro-farad capacitance
(pF) (nF) (mF,uF or mfd) code
1000 1 or 1n 0.001 102
1500 1.5 or 1n5 0.0015 152
2200 2.2 or 2n2 0.0022 222
3300 3.3 or 3n3 0.0033 332
4700 4.7 or 4n7 0.0047 472
6800 6.8 or 6n8 0.0068 682
10000 10 or 10n 0.01 103
15000 15 or 15n 0.015 153
22000 22 or 22n 0.022 223
33000 33 or 33n 0.033 333
47000 47 or 47n 0.047 473
68000 68 or 68n 0.068 683
100000 100 or 100n 0.1 104
150000 150 or 150n 0.15 154
220000 220 or 220n 0.22 224
330000 330 or 330n 0.33 334
470000 470 or 470n 0.47 474
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GT5-A402
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GT5-A402
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