Pioneer SX-7 very hot running TO-220s due to poor design or component failure?

@wg_ski thank you for your very helpful and informative posts!


At this point, based on comments from rayma, Bill_P and wg_ski, my plan is to:
---check all relevant voltages before removing anything
---remove, clean, heatsink, and reinstall the D836 Darlington transistor
---install a new B596 ( I have two on hand) with heatsink to replace the B507 (this is the hottest of the three)
---install a new D880 with heatsink (not necessary, but I have 10 of them sitting in a bag)
---possibly drill some holes in the bottom of the chassis near the B507 and D880. this area is far from any air inlets and, oddly, not physically close to the D836
---replace all electrolytics in the regulator
---recheck voltages and temperatures
---report back here that the mission was completed successfully



Another question, likely an easy one for you guys: in a regulator like the one shown in my original post, are the TO-220 series pass transistors driven to saturation, as a transistor would be when driving a protection relay?

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The reason those regulator pass transistors are getting so 🥵 hot is because they are very far from saturation. Lots of volts at even 100 mA is enough watts to sizzle your fingers. If the voltage drop were only six tenths of a volt it would run cold - or at least, cool.
 
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