Sony MINIDISC ZS-M35 User manual

– 1 –
ZS-M35
SERVICE MANUAL
PERSONAL MINIDISC SYSTEM
US Model
Canadian Model
Taiwan Model
CD
Model Name Using Similar Mechanism PMC-20
Section CD Mechanism Type KSM-213CDM
Optical Pick-up Name KSS-213C
MD
Model Name Using Similar Mechanism PMC-MD55
Section
MD Mechanism Type MDM-5GA
Base Unit Name MBU-5A
Optical Pick-up Name KMS-260B
U.S. and foreign patents licensed from Dolby Laboratories
Licensing Corporation.
CD player section
System
Compact disc digital audio system
Laser diode properties
Material: GaAlAs
Wave length: 785 nm
Emission duration: Continuous
Laser output: Less than 44.6 µW
(This output is the value measured at a distance of
about 200 mm from the objective lens surface on
the optical pick-up block with 7 mm aperture.)
Spindle speed
200 r/min (rpm) to 500 r/min (rpm) (CLV)
Number of programme positions
2
Frequency response
20 - 20,000 Hz +1/–2 dB
Wow and flutter
Below measurable limit
Radio section
Frequency range
FM: 87.5 - 108 MHz
AM: 530 - 1,710 kHz
Antennas
FM: Telescopic antenna
AM: AM loop antenna
SPECIFICATIONS
MD player section
System
Minidisc digital audio system
Disc
MiniDisc
Laser diode properties
Material: GaAlAs
Wave length: 785 nm
Emission duration: Continuous
Laser output: Less than 44.6 µW
(This output is the value measured at a distance of
about 200 mm from the objective lens surface on
the optical pick-up block with 7 mm aperture.)
Recording/playback time
Stereo recording:
Maximum 80 minutes (with MDW-80)
Monaural recording:
Maximum 160 minutes (with MDW-80)
Revolutions
400 rpm to 900 rpm (CLV)
Error correction
Advanced Cross Interleave Reed Solomon Code
(ACIRC)
Sampling frequency
44.1 kHz
–Continued on next page –
AUDIO POWER SPECIFICATIONS (US model)
POWER OUTPUT AND TOTAL
HARMONIC DISTORTION
With 4-ohm loads, both channels driven from
150 - 10,000 Hz; rated 4 W per channel-
minimum RMS power, with no more than 10%
total harmonic distortion in AC operation.
Ver 1.2 2001.07
Sony Corporation
Personal Audio Company
Shinagawa Tec Service Manual Production Group
9-927-183-33
2001G0400-1
© 2001.7

–2 –
Coding
Adaptive TRansform Acoustic Coding (ATRAC)
Modulation system
EFM (Eight-to-Fourteen Modulation)
Number of programme positions
2 stereo programme positions
Frequency response
20 - 20,000 Hz +1/–2 dB
Signal-to-noise ratio
Over 80 dB (during playback)
Wow and flutter
Below measurable limit
General
Speaker
Full-range: 8 cm (3 in.) dia., 4 ohms, cone type (2)
Inputs
LINE IN (stereo minijack): Sensitivity 436 mV/
870 mV
Outputs
Headphones jack (stereo minijack) (1):
For 32 ohms impedance headphones
Power output (excluding US model)
5 W + 5 W (at 4 ohms, 10 % harmonic distortion
in AC operation)
Power requirements
For personal minidisc system:
120 V AC, 60 Hz
For back-up memory:
4.5 V DC, 3 size AA (R6) batteries
For remote control:
3 V DC, 2 size AA (R6) batteries
Power consumption
24 W
Dimensions (incl. projecting parts)
Approx. 498.5 ×173.5 ×227 mm (w/h/d)
(17 3/4×6 1/2×9 1/2inches)
Mass
Approx. 5.2 kg (13 lb. 4 oz)
Supplied accessories
AC power cord (1)
Remote control (RMT-CM35A) (1)
AM loop antenna (1)
Design and specifications are subject to change
without notice.
To Exposed Metal
Parts on Set
0.15µF 1.5k
Ω
AC
voltmeter
(0.75V)
Earth Ground
Fig. A. Using an AC voltmeter to check AC leakage.
SAFETY CHECK-OUT
After correcting the original service problem, perform the following
safety check before releasing the set to the customer:
Check the antenna terminals, metal trim, “metallized”knobs,
screws, and all other exposed metal parts for AC leakage. Check
leakage as described below.
LEAKAGE TEST
The AC leakage from any exposed metal part to earth ground and
from all exposed metal parts to any exposed metal part having a
return to chassis, must not exceed 0.5 mA (500 microamperes).
Leakage current can be measured by any one of three methods.
1. A commercial leakage tester, such as the Simpson 229 or RCA
WT-540A. Follow the manufacturers’instructions to use these
instruments.
2. A battery-operated AC milliammeter. The Data Precision 245
digital multimeter is suitable for this job.
3. Measuring the voltage drop across a resistor by means of a VOM
or battery-operated AC voltmeter. The “limit”indication is 0.75
V, so analog meters must have an accurate low-voltage scale.
The Simpson 250 and Sanwa SH-63Trd are examples of a passive
VOM that is suitable. Nearly all battery operated digital
multimeters that have a 2V AC range are suitable. (See Fig. A)
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.

–3 –
1. SERVICING NOTES
1-1. Notes on Handling the Optical Pick-up Block or Base Unit .. 4
1-2. Notes on Laser Diode Emission Check............................... 4
1-3. Notes on Chip Component Replacement ............................ 4
1-4. Flexible Circuit Board Repairing ........................................ 4
1-5. Chuck Plate Jig on Repairing .............................................. 4
1-6. Demonstration ..................................................................... 4
1-7. Checking the Laser Diode and Focus Search Operation..... 4
1-8. Jig for Checking BD Board Waveform ............................... 5
1-9. Checks Prior to Parts Replacement and Adjustments ......... 6
1-10. Change of Pulley .................................................................6
2. GENERAL
Playing a CD ....................................................................... 7
Recording a whole CD ........................................................ 7
Playing an MD..................................................................... 8
Listening to the radio........................................................... 8
3. DISASSEMBLY
3-1. Cabinet (Rear) Assy ............................................................ 9
3-2. Power Board ........................................................................ 9
3-3. Cabinet (Upper) Assy ........................................................ 10
3-4. MD Block Assy ................................................................. 10
3-5. Tuner Board ....................................................................... 11
3-6. Jack Board ......................................................................... 11
3-7. LED Board ........................................................................ 12
3-8. Key Board ......................................................................... 12
3-9. Top Board .......................................................................... 13
3-10. FL Board ........................................................................... 13
3-11. Main board ........................................................................ 14
3-12. CD Board .......................................................................... 14
3-13. CD Mechanism Block .......................................................15
3-14. DG Board .......................................................................... 15
3-15. Plate (Front), Shield .......................................................... 16
3-16. MD Mechanism Block-1 (MDM-5GA) ............................16
3-17. MD Mechanism Block-2 (Slider (Cam) Assy) ................. 17
3-18. MD Mechanism Block-3 (BD Board)............................... 18
3-19. MD Mechanism Black-4 (SW Board)...............................18
4. TEST MODE
4-1. MD section ........................................................................ 19
5. ELECTRICAL ADJUSTMENTS
5-1. Tuner section ..................................................................... 22
5-2. MD section ........................................................................ 24
5-3. CD section ......................................................................... 31
TABLE OF CONTENTS
6. DIAGRAMS
6-1. IC Pin Function Descriptions ............................................33
6-2. Circuit Boards Location .................................................... 42
6-3. Block Diagram –Tuner Section– ....................................... 43
6-4. Block Diagram –MD Section–..........................................46
6-5. Block Diagram –CD Section–........................................... 49
6-6. Block Diagram –Audio Section– ......................................51
6-7. Schematic Diagram –CD Section (1/2)–...........................53
6-8. Schematic Diagram –CD Section (2/2)–...........................55
6-9. Printed Wiring Boards –CD Section– ...............................57
6-10. Printed Wiring Boards –Tuner Section– ........................... 59
6-11. Schematic Diagrams –Tuner Section– .............................. 61
6-12. Printed Wiring Boards –BD Section– ............................... 63
6-13. Schematic Diagram –BD Section (1/2)–...........................65
6-14. Schematic Diagrams –BD Section (2/2)– ......................... 67
6-15. Schematic Diagram –DG Section– ................................... 69
6-16. Schematic Diagram –DG Section– ................................... 71
6-17. Printed Wiring Board –DG Section–.................................73
6-18. Printed Wiring Board –Main Section– .............................. 75
6-19. Schematic Diagram –Main Section (1/3)– ........................ 77
6-20. Schematic Diagram –Main Section (2/3)– ........................ 79
6-21. Schematic Diagram –Main Section (3/3)– ........................ 81
6-22. Printed Wiring Boards –Panel Section– ............................83
6-23. Schematic Diagrams –Panel Section–............................... 85
6-24. Printed Wiring Boards –Switch Section–.......................... 87
6-25. Schematic Diagrams –Switch Section– ............................89
6-26. Printed Wiring Boards –Power Supply Section– .............. 91
6-27. Schematic Diagrams –Power Supply Section– .................93
6-28. IC Block Diagrams............................................................ 95
7. EXPLODED VIEWS
7-1. Cabinet (Rear) Section .................................................... 101
7-2. Cabinet (Front) Section ...................................................102
7-3. Cabinet (Upper) Section.................................................. 103
7-4. MD Block Section........................................................... 104
7-5. MD Mechanism Section (MDM-5GA) .......................... 105
7-6. MD Base unit Section (MBU-5A) ................................. 106
7-7. Optical Pick-up Section (KSM-213CDM)...................... 107
8. ELECTRICAL PARTS LIST.................................... 108

–4 –
SECTION 1
SERVICING NOTES
This Compact Disc player
is classified as a CLASS 1
LASER product.
The CLASS 1 LASER
PRODUCT label is located
on the bottom exterior.
1-1. NOTES ON HANDLINGTHE OPTICAL PICK-UP
BLOCK OR BASE UNIT
The laser diode in the optical pick-up block may suffer electro-
static break-down because of the potential difference generated
by the charged electrostatic load, etc. on clothing and the human
body.
During repair, pay attention to electrostatic break-down and also
use the procedure in the printed matter which is included in the
repair parts.
The flexible board is easily damaged and should be handled with
care.
1-2. NOTES ON LASER DIODE EMISSION CHECK
The laser beam on this model is concentrated so as to be focused
on the disc reflective surface by the objective lens in the optical
pick-up block. Therefore, when checking the laser diode emis-
sion, observe from more than 30 cm away from the objective lens.
1-3.NOTES ON CHIP COMPONENT REPLACEMENT
•Never reuse a disconnected chip component.
•Notice that the minus side of a tantalum capacitor may be dam-
aged by heat.
1-4. FLEXIBLE CIRCUIT BOARD REPAIRING
•Keep the temperature of the soldering iron around 270 ˚C dur-
ing repairing.
•Do not touch the soldering iron on the same conductor of the
circuit board (within 3 times).
•Be careful not to apply force on the conductor when soldering
or unsoldering.
1-5. CHUCK PLATE JIG ON REPAIRING
On repairing CD section, playing a disc without the CD lid, use
Chuck Plate Jig.
•Code number of Chuck Plate Jig: X-4918-255-1
1-6. DEMONSTRATION
This set enters the demonstration mode about 10 seconds after the
power cord is connected. The demonstration displays such as
“DEMONSTRATION MODE”and “CREATEYOUR ORIGINAL
MD”then appears.
When no operation is entered for one minute after the [POWER]
button is turned on, the demonstration mode is also entered.
To release the demonstration mode, set the timer in this set or press
and hold down the [NO/CANCEL] button for about 2 seconds.
1-7. CHECKINGTHE LASER DIODE AND FOCUS
SEARCH OPERATION
1. Turn on the POWER and open the CD cover.
2. As shown below, push S402 (CD DOOR) with a screwdriver or
other tool.
3. Press the CD button.
4. Check the objective lens to make sure that the laser diode is
emitting light. If not so, the auto power control circuit or optical
pickup would be damaged.
Verify that the objective lens moves vertically three times for
focus search.
S402
CAUTION
Use of controls or adjustments or performance of proce-
dures other than those specified herein may result in haz-
ardous radiation exposure.

–5 –
1-8. JIG FOR CHECKING BD BOARDWAVEFORM
The special jig (J-2501-149-A) is useful for checking the waveform of the BD board. The names of terminals and the checking items to
be performed are shown as follows.
GND: Ground
I+3V : For measuring IOP (Check the deterioration of the optical pick-up laser)
IOP : For measuring IOP (Check the deterioration of the optical pick-up laser)
TEO : TRK error signal (Traverse adjustment)
VC : Reference level for checking the signal
RF : RF signal (Check jitter)
CN110
RF
5P connector
6P connecto
r
VCTEO
IOP
I+3V
GND
Mechanism deck
RF
VC
TEO for MDM-
3
for MDM-
5
IOP
I+3V
VC
RF
TEO
IOP
I+3V
GND
VC
RF
TEO
IOP
I+3V
GND
1
5
1
6

–6 –
1-9. CHECKS PRIORTO PARTS REPLACEMENT AND ADJUSTMENTS (FOR MD SECTION)
Before performing repairs, perform the following checks to determine the faulty locations up to a certain extent.
Details of the procedures are described in “5 Electrical Adjustments”.
•0.9 mW power
Specified value : 0.84 to 0.92 mW
•7.0 mW power
Specified value : 6.8 to 7.2 mW
lop (at 7mW)
•Labeled on the optical pickup
Iop value ± 10mA
•Error rate check
Specified value : For points a, b, and c
C1 error : About 200
ADER : Below 2
•Error rate check
Specified value:
a. When using test disc (MDW-74/AU-1)
C1 error : Below 80
ADER : Below 2
b. When using check disc (TDYS-1)
C1 error : Below 50
•CPLAY error rate check
Specified value:
C1 error : Below 80
ADER : Below 2
Laser power check
(6-1 : See page 26)
Focus bias check
(6-2 : See page 26)
C PLAY check
(6-3 : See page 26)
Self-recording/playback
check
(6-4 : See page 26)
Criteria for Determination
(Unsatisfactory if specified value is not satisfied)
•Clean the optical pick-up
•Adjust again
•Replace the optical pick-up
•Replace the optical pick-up
•Replace the optical pick-up
•Replace the optical pick-up
If always unsatisfactory:
•Replace the overwrite head
•Check for disconnection of the circuits around the
overwrite head
If occasionally unsatisfactory:
•Check if the overwrite head is distorted
•Check the mechanism around the sled
Measure if unsatisfactory:
Note:
The criteria for determination above is intended merely to determine if satisfactory or not, and does not serve as the specified value for
adjustments.
When performing adjustments, use the specified values for adjustments.
1-10. CHANGE OF PULLEY
pulley
M102, 103 2.5 m
m
Install the pulley to the motor.

–7 –
SECTION 2
GENERAL This section is extracted
from instruction manual.
Basic Operations
4
Playing a CD
Basic Operations
For hookup instructions, see pages 57 - 59.
1Press ZPUSH OPEN/CLOSE
down to open the CD
compartment and place the CD
on the CD compartment.
2Close the lid of the CD
compartment.
3Press CD u(CD Non the
remote).
The player turns on (direct
power-on) and the player plays
all the tracks once.
With the label side up
Display
Playing
time
Track
number
1, 23
Basic Operations
Basic Operations
5
Use these buttons for additional operations
To Press
adjust the volume VOLUME +, –
(VOL +, – on the remote)
stop playback CD x
pause playback CD u(CD Xon the
remote)
Press the button again to
resume play after pause.
go to the next track >
go back to the previous track .
remove the CD ZPUSH OPEN/CLOSE
turn on/off the player POWER
Tip
Next time you want to
listen to a CD, just press
CD u. The player
turns on automatically
and starts playing the
CD.
VOLUME –, +
CD u. , >
ZPUSH
OPEN/CLOSE
CD x
POWER
Basic Operations
6
Recording a whole CD
(Synchronized recording)
Display
34 21
For hookup instructions, see pages 57 - 59.
1Insert a recordable MD (direct
power-on).
2Press ZPUSH OPEN/CLOSE
and place the CD on the CD
compartment.
Press ZPUSH OPEN/CLOSE
again to close the CD
compartment.
3Press CD x.
With the label side up
With the label
side up
After “TOC Reading”is
displayed, the disc name
will be displayed if it is
labeled.
Insert in the direction of
the arrow
5
Basic Operations
Basic Operations
7
To Press
stop recording MD xor CD x
turn on/off the player POWER
If “CD>MD OK?”alternates with time display
There is not enough space on the MD to record the whole
CD.
If it is all right to record as much as possible and cancel
recording of some tracks, press YES•ENTER. To stop
recording, press NO•CANCEL.
If any other messages are displayed, see page 72.
MD x
Track number
of MD
YES
ENTER
NO
CANCEL
4To record at high speed, press
HIGH SPEED.
The indicator lights up.
To record at normal speed, skip this step.
5Press SYNCHRO REC CD N
MD.
The player starts recording
automatically.
If the MD has any previous
recording, recording will be
made from the last recorded
position.
Remaining
recording
time of MD
Use these buttons for additional operations
CD x
Notes
•After you
stop recording, do not
disconnect the AC
power cord or move
the player while “TOC
EDIT”is flashing in the
display. If you do so,
recording may not be
done properly.
•When you record a
whole CD, you cannot
pause recording.
Tips
•Adjusting the volume or
the audio emphasis
(page 49) will not affect
the recording level.
Keep the volume at a
moderate level so as to
prevent the sound from
skipping.
•To record over the
previous recording, see
page 33.
•Once the clock is set, the
recording date and time
are stamped
automatically (page 50).
•You can label an MD or a
track during recording
(page 44).
POWER

–8 –
Basic Operations
8
Playing an MD
For hookup instructions, see pages 57 - 59.
1Insert the MD (direct power-on).
2Press MD u(MD Non the
remote).
The player plays all the tracks
once.
With the label
side up
Display
Playing time
Track number
12
Insert in the direction of
the arrow
After “TOC Reading”is
displayed, the disc name
will be displayed if it is
labeled.
Track name is displayed
if it is labeled.
m
Basic Operations
Basic Operations
9
Use these buttons for additional operations
To Press
adjust the volume VOLUME +, –
(VOL +, –on the remote)
stop playback MD x
pause playback MD u(MD Xon the
remote)
Press the button again to
resume play after pause.
go to the next track >
go back to the previous track .
remove the MD Z
turn on/off the player POWER
Tip
Next time you want to
listen to a MD, just press
MD u. The player
turns on automatically
and starts playing the
MD.
VOLUME –, +
Z
MD x
POWER
MD u
., >
Basic Operations
10
Listening to the radio
For hookup instructions, see pages 57- 59.
1Press RADIO BAND until the
band you want appears in the
display (direct power-on).
2Hold down TUNE + or TUNE –
until the frequency digits begin to
change in the display.
The player automatically scans
the radio frequencies and stops
when it finds a clear station.
If you can’t tune in a station,
press TUNE + or TUNE –
repeatedly to change the
frequency step by step.
1
2
Display
“FM”or “AM”appears
Indicates an FM stereo
broadcast
Basic Operations
Basic Operations
11
Use these buttons for additional operations
Tips
•If the FM broadcast is
noisy, press MONO/
ST•REPEAT (MODE on
the remote) until
“Mono”appears in the
display and radio will
play in monaural.
•Next time you want to
listen to the radio, just
press RADIO BAND.
The player turns on
automatically and starts
playing the previous
station.
To Press
adjust the volume VOLUME +, –
(VOL +, –on the remote)
turn on/off the radio POWER
To improve broadcast reception
FM:
Reorient the antenna for FM.
AM:
Keep the AM loop antenna as far as possible from the
player and reorient it.
VOLUME –, +
MONO/ST
REPEAT
POWER

–9 –
SECTION 3
DISASSEMBLY
Note : This set can be disassemble according to the following sequence.
Note : Follow the disassembly procedure in the numerical order given.
3-1. CABINET (REAR) ASSY
Set Cabinet (Rear)
Assy FL Board Main Board CD
Board CD Mechanism
Block
Cabinet (Upper) Assy
Power Board
DG Board
LED Board
Plate (Front), Shield
Tuner Board
Top Board
MD Block Assy
Jack Board
Key Board
MD Mechanism
Block - 1
(MDM-5GA)
MD Mechanism
Block - 2
(Slider (Cam) Assy)
MD Mechanism
Block - 3
(BD Board)
MD Mechanism
Block - 4
(SW board)
3-2. POWER BOARD
1BVTP 3x12
6CN402
7CN401
handle
2BVTP 3x1
4
3BVTP 3x14
5BVTP 3x14
8cabinet (rear) assy
4BVTP 3x12
1BVTP 3x12
3BVTP 4x12
4BVTP 3x12
6POWER board
cabinet (rear) assy
chassis, transformer
5
2CN903

–10 –
3-3. CABINET (UPPER) ASSY
3-4. MD BLOCK ASSY
1BVTP 3x10
3CN404
5CN301
6CN408
7CN303
8CN407
q; CN409
9CN406
4connector
2CN705
qacabinet (upper) assy
2BVTP 3x1
4
3MD block assy
1CN2