I saw the other post but I've isolated my problem down to a specific part / Relay and I need to replace either the Speaker PWB or the relay itself. I can force the clicking by taping on the one of the two relays. The other seems to be ok.
Do you know where I can find or order the PWB Part #1-861-284-11 or the offending relay OSA-SS-212DM3?
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Wow. This is funny. I have the same receiver in my garage I've had for several years I got from a friend. Same problem. I only looked at it for a few minutes and got tired of it. Maybe two years ago. I used to repair audio equipment professionally (20 yrs).
Almost always, this happens when there is a failure in one of the audio output circuits. It can be brought on by a bad speaker, or too low impedance of a speaker being used, etc. This thing is packed with boards, if I remember right. It could be any of the main channels, or one of the surround channels that's doing this. If you're not sure what you're doing, you could blow one of the channels out irreparably.
To see which channel is doing it, you'll need to find the speaker relays. Might even have to take an Exacto knife and pop the "cap" off the relays to gain access to the contacts. To make a long troubleshooting story short, you check for DC voltage on each pin of each speaker relay right after turning it on, to see which channel is bad. That's really as deep as I can explain it. From here, you need bench experience with component and voltage testing. Your bad channel is probably sending 50-80 volts DC to your speaker relay, and the unit is quickly shutting down to prevent the relay(s) from closing, which would burn out a speaker if one were attached. Good luck!
I've tried using the balance for left and right speakers, and when the receiver is acting up with the right speaker having a low volume, I tried moving the balance all the way over to the right speaker. The right speaker volume will not increase in volume but the left speaker will decrease in volume.
Just to clarify, the center and the rear speakers are balanced. The issue only happens sometimes when I first power on the receiver I will have no center channel. If I leave everything alone for a few mins, the center channel will come on.
So it seems to me that something one the receiver is going. The question is, can anyone suggest a physical repair for the receiver for these symptoms?
THe clicking you are hearing is the relay that is being activated byt he protection circuit. See the link below for an explanation of protect mode.
In your specific case, I'd be looking for a potential heat problem or for frayed wires to the speakers that may be shorting out the speaker lines. This can show up as "low impedance" to the amp and make it work extra hard, generating extra heat etc...
The relay or relays that click disconnect the receiver from the speaker terminals so that no dc voltage can burn out the speakers. More than likely the power output transistor(s) are faulty. Look at the relay(s), determine the input and output connections. The inputs come from the output power transistor and emitter resistors area, the output of the relay(s) connect to the speaker terminals. Check for dc voltage on the input contacts in the range of 30-60 volts possibly. If dc voltage is found there then you have bad outputs, caps or emitter resistors. A word of caution -troubleshooting at this level requires advance knowlege of electronics, do not attempt this with out onsite help from a experience tech.
Chances are really good that you need to replace the speaker relay for that side. I recommend replacing all speaker relays. The contacts are dirty. You can get parts from Sony. You will need the relay part number off the top of the relay to order from Digikey or similar parts places. You can try cleaning the relay contacts with a contact cleaner. Sometimes it works.
One or more output channels has dc voltage present or the protection circuit itself is at fault. Protection ckt keeps speaker destroying DC from reaching the speakers. Connect a dc meter before the speaker relay(s) to isolate which channel if any, is bad. The protection ckt has a small value electrolytic cap connected to the power supply that needs to be checked. Small so that as soon as power is turned off the relay(s) release. This cap will fail causing this error. Measure the AC ripple across this cap, over a couple volts, replace. Also this error could be caused by a missing supply. Inspect all heat sinked parts and other parts for bad connections.
Unplug all the speaker wires first, then unplug the unit from the wall for at least 24 hours, The plug back in without the speaker wires or anything else plugged in. Then see if it goes to the protection mode. If it does not, plug in each speaker at a time, and see if any speaker, when hooked up, makes the receiver shut down. If it does shut down, My friend, I'm afraid you will need to take this unit into a repair shop, OR get a new unit. Good Luck