XM-222MK2

SERVICE MANUAL

Ver 1.1 2002. 03

Canadian Model AEP Model UK Model E Model

SPECIFICATIONS

OTL (output transformerless) circuit Pulse power supply Inputs RCA pin jacks High level input connector Input level adjustment range 0.V (RCA pin jacks), 0.V (High level input) Outputs Speaker terminals Speaker impedance (stereo) (when used as a bridging amplifier) Maximum outputs 100 W 2 (at 4 ) 222 W (BTL, at 4 ) Rated outputs (supply voltage at 14.4 V) 35 W 2 (20 Hz 20 kHz, 0.04% THD, at 4 ) 40 W 2 (20 Hz 20 kHz, 0.1% THD, at 2 ) 80 W (Monaural) (20 Hz 20 kHz, 0.1% THD, at 4 ) Frequency response 5 Hz 80 kHz ( +0 dB) 3 Harmonic distortion 0.005% or less (at 1 kHz, 4 , 10 W) Low-pass filter 80 Hz, 18 dB/oct Power requirements 12 V DC car battery (negative ground) Power supply voltage 10.V Current drain at rated output : 12 A (4 , 35 W 2) Remote input : 1.5 mA Dimensions Approx. 158 mm (w/h/d) not incl. projecting parts and controls Mass Approx. 1.6 kg 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. Circuit system

STEREO POWER AMPLIFIER

9-873-557-02

2002C0400-1 2002. 03

Sony Corporation
e Vehicle Company Published by Sony Engineering Corporation
XM-222MK2 SECTION 3 DIAGRAMS

3-1. BLOCK DIAGRAM

-1 -1 L (BTL) 6

PRE AMP IC801 (1/2) 5

LPF IC802 (1/2) 6 S801-1 LPF (80Hz) ON OFF
GAIN CONTROL AMP IC803 (1/2) 7 SWITCH Q101 DIFFERENTIAL AMP Q102 DRIVE AMP Q104 DRIVE AMP Q108 POWER AMP Q110

CN802 SPEAKER OUT

L VR801-1 LEVEL BIAS Q106,107

CNJ801 INPUT

DIFFERENTIAL AMP Q103

DRIVE AMP Q105

DRIVE AMP Q109

POWER AMP Q111

OVERLOAD DET Q112
PRE AMP IC801 (2/2) -2 -2 R 2 3

LPF IC802 (2/2) 1

GAIN CONTROL AMP IC803 (2/2) S801-2 LPF (80Hz) 1 SWITCH Q201 DIFFERENTIAL AMP Q202 DRIVE AMP Q204 DRIVE AMP Q208 POWER AMP Q210

OFFSET DET Q852,853

R VR801-2 LEVEL MUTE Q851 BIAS Q206,207

CNJ802 HI LEVEL

ON L R OFF

DIFFERENTIAL AMP Q203

DRIVE AMP Q205

DRIVE AMP Q209

POWER AMP Q211

OVERLOAD DET Q212

B+ (14.6V)
15V REG Q951,952, D953 DC DET 4 ICPROTECTOR Q802

B(-14.6V)

-15V REG Q953,954, D954 RECT D951,952 DC-DC CONVERTER TRANSFORMER T901

INVERTER Q903

ERROR LED DRIVE Q803 LD801 POWER/ PROTECTOR

B+ SWITCH Q902

F901 20A

CN801 +12V

B+ (26.2V) INVERTER Q904 10
POWER ON/OFF Q901 REM GND

B(-26.2V)

THERMAL Q801

Signal path

DC-DC CONVERTER IC901

: AUDIO

TH801 TH802
3-3. SCHEMATIC DIAGRAM Refer to page 10 for IC Block Diagram and Common Note on Schematic Diagrams.
R118 Q104 Q108 R124 Q107 Q110 R133 Q112 R126 R129 R130 R125 R120 R123 R128
C113 C119 R138 R137 CNJ802 C220 R239 R237 C219 R238 C120 R139 Q103 R119 C114 R122

C115 Q106

C116 R135 R127 Q111

C117 C118 C218 C217

C104 C857 C112 R131 R132 CN802 C107 Q101 R105 IC802 (1/2) C106 S801 C108 C208 C110 C210 C206 R206 R207 IC802 (2/2) R205 C209 IC803 (2/2) C211 Q201 R108 R208 R109 R209 R110 R210 VR801 R111 R211 C109 C111 IC803 (1/2) R112 R113 Q204 C213 R224 Q207 Q210 R213 Q203 Q202 R219 C214 R220 Q205 R212 R227 R215 R217 D202 R221 Q209 Q211 R236 R136 R223 R222 Q206 R225 R228 C215 R226 R229 C216 R230 R235 R214 R216 D201 R218 Q208 R233 Q212

C101 R101 C102 R102 C103

R106 R107 IC801 (1/2) R104

C858 CNJ801

C201 R201

R204 IC801 (2/2)

C203 C202 R202 R203 C207
D903 Q851 R851 R917 R852 R915 R853 IC851 D851 C851 D852 R918 R854 R920 R919 Q904 C908 R916 Q903 C907

T901 D951

R951 R952 L951 C951 C952 C953 C954 R956 R957 D952 C955 C956

R953 D953 D954 R958

C852 C958 R856

R857 Q853

IC B/D
Q902 R961 R914 C801 R905 Q901 CN801 F901 C901 R901 C902 L901 D901 R902 R903 R904 R803 Q801 D902 C904 C802 R814 R913 C909 R909 R912 R911 PL801 C805 R804

R910 C906

R859 C804 TH801 TH802

R809 R810

R812 R811
R862 R907 R802 D803 IC901 D802

R813 R806 R807 C803 Q803

R805 R808

Waveform

1V/DIV, 5sec/DIV 3.4Vp-p 15sec

Ver 1.1

SECTION 4 EXPLODED VIEW
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: All capacitors are in F unless otherwise noted. pF: F 50 WV or less are not indicated except for electrolytics and tantalums. All resistors are in and 1/4 W or less unless otherwise specified. 2 : nonflammable resistor. Note: The components identified by mark 0 or dotted line with mark 0 are critical for safety. Replace only with part number specified. Note: Les composants identifis par une marque 0 sont critiques pour la scurit. Ne les remplacer que par une pice por tant le numro spcifi. NOTE: The mechanical parts with no reference number in the exploded views are not supplied. Items marked * are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items. Color Indication of Appearance Parts Example : KNOB, BALANCE (WHITE). (RED) R R Parts Color Cabinets Color Accessories are given in the last of this parts list. The components identified by mark 0 or dotted line with mark. 0 are critical for safety. Replace only with part number specified. Les composants identifis par une marque 0 sont critiques pour la scurit. Ne les remplacer que par une pice portant le numro spcifi.

Semiconductor Location Ref. No. D101 D102 D201 D202 D801 D802 D803 D851 D852 D901 D902 D903 D904 D951 D952 D953 D954 IC801 IC802 IC803 IC851 IC901 LD801 Q101 Q102 Q103 Q104 Q105 Q106 Q107 Q108 Q109 Q110 Q111 Q112 Q201 Q202 Q203 Q204 Q205 Q206 Q207 Q208 Q209 Q210 Q211 Q212 Q801 Q802 Q803 Q851 Q852 Q853 Q901 Q902 Q903 Q904 Q951 Q952 Q953 Q954 Location G-10 G-9 G-7 G-6 F-11 E-11 F-11 E-10 F-5 D-10 D-11 D-9 D-8 B-7 B-6 D-4 D-3 E-3 F-3 H-3 E-10 D-8 F-14 F-6 G-10 G-9 G-10 G-9 I-10 H-9 H-10 H-9 J-10 J-9 G-9 G-5 G-6 G-6 G-7 G-6 I-6 H-6 H-7 H-6 J-7 J-6 G-5 E-11 E-12 F-13 E-10 E-12 E-12 D-10 D-10 B-9 B-10 C-4 C-4 C-4 C-4
A : B+ Line. B : B Line. Power voltage is dc 14.4V and fed with regulated dc power supply from +12V and REM terminals. Voltage is dc with respect to ground under no-signal condition. Voltages are taken with a VOM (Input impedance 10 M). Voltage variations may be noted due to normal production tolerances. Waveforms are taken with a oscilloscope. Voltage variations may be noted due to normal production tolerances. Circled numbers refer to waveforms. Signal path. F : AUDIO for printed wiring boards: X : parts extracted from the component side. : Pattern from the side which enables seeing.
IC Block Diagram IC901 PC494GS-T1

REF. REG. 10 9

0.1V ERROR 5 OSC

Ref. No. 6

Part No. 3-240-641-01 3-238-672-01 3-238-671-01 3-238-671-11 3-238-673-01
Description PLATE, BOTTOM PANEL, FRONT HEAT SINK (CHINESE MADE) HEAT SINK (JAPAN MADE) PANEL, REAR

Remark

Ref. No. F901
Part No. 7-685-545-14 3-240-642-01 3-225-183-01 3-225-184-01 3-912-432-01
Description SCREW +BTP 3X6 TYPE2 N-S HEAT SINK (SUB 2CH) SCREW (+PSW.TT.3XL) SCREW (+PS.TT.3X6) SCREW (+B)
A-3274-223-A AMP BOARD, COMPLETE 7-685-646-79 SCREW +BVTP 3X8 TYPE2 IT-3
1-532-732-11 FUSE (BLADE TYPE) (AUTO FUSE) 20A

XM-1002HX

SERVICE MANUAL

CORRECTION - 1

Correct your Service Manual as shown below.
US Model Canadian Model AEP Model UK Model E Model
!: Indicates corrected portion

INCORRECT

D908 D909 D907

CORRECT

JW71 JW72 JW77

(SPM-99018)

Sony Corporation

9-925-785-91

Mobile Electronics Company
99G0277-1 Printed in Japan 1999.7 Published by Quality Assurance Dept.

Ver 1.1 2001. 08

SPECIFICATIONS AUDIO POWER SPECIFICATIONS (US model) POWER OUTPUT AND TOTAL HARMONIC DISTORTION 100/50 watts per channel minimum continuous average power into 4 ohms, both channels driven from 20 Hz to 20 kHZ with no more than 0.04% total harmonic distortion per Car Audio Ad Hoc Committee standards.
Other Specifications Circuit system OTL (output transformerless) circuit Pulse power supply Inputs RCA pin jacks High level input connector Outputs Speaker terminals Through out pin jacks Speaker impedance 1* 8 (stereo) 2* 8 (when used as a bridging amplifier) Maximum outputs (HI-CURRENT/HI-VOLTAGE) 120/230 W x 2 (at 4 ) 380/580 W (monaural) at 4 Rated outputs (HI-CURRENT/HI-VOLTAGE) (supply voltage at 14.4 V) 50/100 W x 2 (20 Hz 20 kHz, 0.04% THD, at 4 ) 70/140 W x 2 (20 Hz 20 kHz, 0.1% THD, at 2 ) 140/280 W (monaural) (20 Hz 20 kHz, 0.1% THD, at 4 ) Frequency response 5 Hz 50 kHz ( +0.5 dB) 3 Harmonic distortion 0.005% or less (at lkHz, 4 ) Input level adjustment range 0.2 4.0 V (RCA pin jacks) 0.4 8.0 V (High level input)
High-pass filter Hz, 12 dB/oct Low-pass filter Hz, 12 dB/oct Low boost dB (40 Hz) Power requirements 12 V DC car battery (negative ground) Power supply voltage 10.V Current drain at rated output : 26 A (4 HI-VOL TAGE mode) Remote input : 2 mA Dimensions Approx. 258 x 50 x 320 mm (10 l/4 x 2 x 12 5/8 in.) (1/h/p) not incl. projecting parts and controls Mass Approx. 3.3 kg (7 lb, 4 oz.) not incl. accessories Supplied accessories Mounting screws (4), Terminal cap (1) Design and specifications are subject to change without notice. * HI-CURRENT only

STEREO POWER AMPLIFIER

9-925-785-12

2001H0400-1 2001. 8

e Vehicle Company Shinagawa Tec Service Manual Production Group

TABLE OF CONTENTS

Specifications.... 1
1. SERVICING NOTE.. 2 2. GENERAL... 3 3. DISASSEMBLY
3-1. Bottom Plate, Panel (Front), Panel (Rear) Removal. 5 3-2. Amplifier Board Removal.. 5
4. ELECTRICAL ADJUSTMENT.. 6 5. DIAGRAMS
5-1. Block Diagram.. 7 5-2. Printed Wiring Boards.. 9 5-3. Schematic Diagram... 13
6. EXPLODED VIEW.. 15 7. ELECTRICAL PARTS LIST. 16

SECTION 1 SERVICING NOTE

CANCELLING THE PROTECTOR DURING SERVICING
Cut JW219 on the amplifier board to cancel the protector. After servicing always be sure to return JW219 to its original state.

T901 C801

IC902 JW219

PROTECTOR OFF

SECTION 5 DIAGRAMS

5-1. BLOCK DIAGRAM

Signal path. F

5-3. SCHEMATIC DIAGRAM

Refer to page 9 for Waveforms.
Refer to page 9 for IC Block Diagrams.

AMPLIFIER

NOTE : Due to standardization, replacements in the parts list may be different from the parts specified in the diagrams or the components used on the set. -XX, -X mean standardized parts, so they may have some difference from the original one. RESISTORS All resistors are in ohms METAL : Metal-film resistor METAL OXIDE :Metal oxide-film resistor F : nonflammable Items marked * are not stocked since they are seldom required for routine service. Some delay should be anticipated when ordering these items. Ref. No. * Part No. Description
SECTION 7 ELECTRICAL PARTS LIST
SEMICONDUCTORS In each case, u : , for example : uA. : A. , uPA. : PA. uPB. : PB. , uPC. : PC. uPD. : PD. CAPACITORS uF : F COILS uH : H Abbreviation G : German When indicating parts by reference number, please include the board.

Remark

Ref. No. C214 C215 C217 C218 C219 C220 C221 C222 C223 C224 C226 C227 C228 C230 C801 C802 C803 C804 C805 C806 C807 C808 C809 C901 C902 C903 C904 C909 C910 C911 C912 C913 C914 C915 C916 C917 C918 C919 C920 C921 C922 C923

1-208-506-11 RES,CHIP

< VARIABLE RESISTOR > RV104 RV204 RV801 RV802 RV803 1-241-761-11 1-241-761-11 1-225-647-11 1-225-648-11 1-225-648-11 RES, ADJ, CARBON 1K (BIAS) RES, ADJ, CARBON 1K (BIAS) RES, VAR 20K/20K/20K/20K (FILTER) RES, VAR 5K/5K (LOW BOOST) RES, VAR 5K/5K (LEVEL) < SWITCH > S801 S901 1-572-185-11 SWITCH, SLIDE (FILTER) 1-771-387-11 SWITCH, TOGGLE (HI-CURRENT/HI-VOLTAGE) < TRANSFORMER > T901 1-431-882-11 TRANSFORMER, DC-DC CONVERTER < TRANSFORMER > TH801 1-808-877-11 THERMISTOR THP802 1-809-664-51 THERMISTOR, POSITIVE THP803 1-809-664-51 THERMISTOR, POSITIVE ************************************************************ MISCELLANEOUS ************** CN804 CN805 D907 D908 D909 D910 F901 Q109 Q110 Q209 Q210 Q904 Q905 Q906 Q907 1-537-479-11 1-537-479-11 8-719-210-30 8-719-210-30 8-719-210-30 8-719-210-30 1-532-947-11 8-729-038-52 8-729-038-01 8-729-038-52 8-729-038-01 8-729-030-73 8-729-030-73 8-729-030-73 8-729-030-73 TERMINAL TERMINAL DIODE F10P20F(R) DIODE F10P20F(R) DIODE F10P20F(R) DIODE F10P20F(R) FUSE (BLADE TYPE) (AUTO FUSE) (30A) TRANSISTOR IRF540(H) TRANSISTOR IRF9540(H) TRANSISTOR IRF540(H) TRANSISTOR IRF9540(H) TRANSISTOR MTAJ30N06HD TRANSISTOR MTAJ30N06HD TRANSISTOR MTAJ30N06HD TRANSISTOR MTAJ30N06HD
1-216-210-00 RES,CHIP 1-216-202-00 RES,CHIP

Ref. No. THP802 THP803

Part No. 1-809-664-51 1-809-664-51
Description THERMISTOR, POSITIVE THERMISTOR, POSITIVE
************************************************************ ACCESSORIES & PACKING MATERIALS ******************************** 3-013-264-01 3-367-410-01 3-701-639-00 3-862-334-11 3-862-334-21 COVER, 3P TERMINAL TABLE SCREW (DIA. 5X15), TAPPING BAG, POLYETHYLENE MANUAL, INSTRUCTION (ENGLISH, FRENCH) (AEP,UK,E) MANUAL, INSTRUCTION (GERMAN, ITALIAN) (AEP,UK,G,E) MANUAL, INSTRUCTION (SPANISH, PORTUGUESE) (AEP,UK,E) MANUAL, INSTRUCTION (DUTCH, SWEDISH) (AEP,UK,E) MANUAL, INSTRUCTION (RUSSIAN,GREEK) (AEP,UK,E) MANUAL, INSTRUCTION (ENGLISH,FRENCH) (US,Canadian)
3-862-334-31 3-862-334-41 3-862-334-51 3-862-334-61
************************************************************ ************** HARDWARE LIST ************** SCREW +BTP 3X5 TYPE2 N-S SCREW +BTP 3X8 TYPE2 N-S SCREW +P 3X8 TYPE2 N-S SCREW +P 3X14 TYPE2 N-S SCREW +P 3X5 TYPE2 N-S SCREW +PSW 3X10 SCREW +P 4X10 TYPE2 N-S SCREW +P 3X6 TYPE2 N-S SCREW M 4X8 (P)
#1 #2 #3 #4 #5 #6 #7 #8 #9
7-685-544-14 7-685-546-19 7-685-646-79 7-685-649-79 7-685-144-11 7-682-949-01 7-685-660-79 7-685-645-79 3-912-431-11