Mitsubishi DD-4021 Service manual

2001
Service Manual
DVD PLAYER
MODEL
DD-4021
TABLE OF CONTENTS
LASER BEAM SAFETY PRECAUTIONS........................................................................................................ 1-2-1
IMPORTANT SAFETY PRECAUTIONS .......................................................................................................... 1-3-1
STANDARD NOTES FOR SERVICING .......................................................................................................... 1-4-1
CABINET DISASSEMBLY INSTRUCTIONS................................................................................................... 1-5-1
BLOCK DIAGRAMS ........................................................................................................................................ 1-6-1
SCHEMATIC DIAGRAMS / CBA’S AND TEST POINTS ................................................................................. 1-7-1
WAVEFORMS.................................................................................................................................................. 1-8-1
WIRING DIAGRAM.......................................................................................................................................... 1-9-1
SYSTEM CONTROL TIMING CHARTS ........................................................................................................ 1-10-1
IC PIN FUNCTION DESCRIPTIONS..............................................................................................................1-11-1
LEAD IDENTIFICATIONS.............................................................................................................................. 1-12-1
EXPLODED VIEWS....................................................................................................................................... 1-13-1
MECHANICAL PARTS LIST .......................................................................................................................... 1-14-1
ELECTRICAL PARTS LIST ........................................................................................................................... 1-15-1
MITSUBISHI ELECTRIC
MITSUBISHI DIGITAL ELECTRONICS AMERICA, INC.
9351 Jeronimo Road, Irvine, CA 92618-1904
Copyright © 2001 Mitsubishi Digital Electronics America, Inc.
All Rights Reserved
HOW TO INITIALIZE THE SETUP MENU
After turning the power ON, without a disc in the tray, press the "1," "2," "3," "4," "DISPLAY" and "ENTER" buttons on the remote control unit in this order. Then, after turning the power OFF temporarily, turn the power ON again to intialize the Setup Menu.
HOW TO CLEAR THE PASSWORD PROTECTION (In case the Parental Lock password is forgotten)
To release parental lock, initialize the setup menu using the procedure above.
HOW TO SET OR CLEAR THE TRAY LOCK
To set the tray lock mode to on, follow the procedures below:
1. With loading a disc, set the DVD player to the stop mode.
2. Press the "SETUP" button to display the SETUP menu.
3. Press the "TITLE" button.
4. Press the "3" button.
5. Press the "AUDIO" button.
6. Press the "0" button.
7. Press the SETUP" button. Tray Lock mode is set to ON and "Tray Lock On" is displayed on the top right of the screen.
While the Tray Lock mode is on, the tray cannot be opened or closed. Other operations are available.
To release the Tray Lock mode, perform the above procedures again. Tray Lock mode is set to OFF and "Tray Lock Off" is displayed on the top right of the screen.
HOW TO MANUAL EJECT
1. Remove the Top Case.
2. Insert the eject-bar (length = approximately 3 mm, diameter = approximately 8 mm) into the manual eject hole on the PCB Holder. Then, press it until the tray is ejected.
3. Pull out the tray.
Tray
Top Case
PCB Holder
Manual Eject Hole
Eject-Bar (Length = approximately 80 mm, Diameter = approximately 3 mm)
Manufatured under license from Dolby Laboratories. "Dolby" and the double-D symbol are trademarks of Dolby Laboratories. Confidential Unpublished Works. (©1992-1997 Dolby Laboratories, Inc. All rights reserved.)
"DTS" and "DTS Digital Out" are trademarks of Digital Theater Systems Inc.

SPECIFICATIONS

ITEM CONDITIONS UNIT NOMINAL LIMIT 1 Video Output 75 ohm load Vpp 1.0 2 Optical Digital Out dBm -18 3 Audio(PCM)
3-1. Output Level 1kHz 0dB Vrms 2.0 3-2. S/N dB 110 3-3. Freq. Response DVD fs=48kHz 20~22kHz dB ± 2 CD fs=44.1kHz 20~20 kHz dB ± 2 3-4. THD+N 1 kHz 0dB % 0.005
NOTES:
1. All Items are measured without pre-emphasis unless otherwise specified.
2. Power supply : AC120 V 60 Hz
3. Load imp. : 100 K ohm
4. Room ambient : +25 °C
1-1-1 E5500SP

LASER BEAM SAFETY PRECAUTIONS

This DVD player uses a pickup that emits a laser beam.
Do not look directly at the laser beam coming from the pickup or allow it to strike against your skin.
The laser beam is emitted from the location shown in the figure. When checking the laser diode, be sure to keep your eyes at least 30cm away from the pickup lens when the diode is turned on. Do not look directly at the laser beam.
Caution: Use of controls and adjustments, or doing procedures other than those specified herein, may result in hazardous radiation exposure.
CAUTION
LASER RADIATION
WHEN OPEN. DO NOT
STARE INTO BEAM.
Location: Inside Top of DVD mechanism.
1-2-1 DVD_LASER

IMPORTANT SAFETY PRECAUTIONS

Product Safety Notice
Some electrical and mechanical parts have special safety-related characteristics which are often not evi­dent from visual inspection, nor can the protection they give necessarily be obtained by replacing them with components rated for higher voltage, wattage, etc. Parts that have special safety characteristics are identified by a # on schematics and in parts lists. Use of a substi­tute replacement that does not have the same safety characteristics as the recommended replacement part might create shock, fire, and/or other hazards. The Product’s Safety is under review continuously and new instructions are issued whenever appropriate. Prior to shipment from the factory, our products are carefully inspected to confirm with the recognized product safety and electrical codes of the countries in which they are to be sold. However, in order to maintain such compli­ance, it is equally important to implement the following precautions when a set is being serviced.
Precautions during Servicing
A.Parts identified by the # symbol are critical for
safety. Replace only with part number specified.
B.In addition to safety, other parts and assemblies are
specified for conformance with regulations applying to spurious radiation. These must also be replaced only with specified replacements.
Examples: RF converters, RF cables, noise block­ing capacitors, and noise blocking filters, etc.
C.Use specified internal wiring. Note especially:
1) Wires covered with PVC tubing
2) Double insulated wires
3) High voltage leads
D.Use specified insulating materials for hazardous live
parts. Note especially:
1) Insulation tape
2) PVC tubing
3) Spacers
4) Insulators for transistors
E.When replacing AC primary side components
(transformers, power cord, etc.), wrap ends of wires securely about the terminals before soldering.
F. Observe that the wires do not contact heat produc-
ing parts (heatsinks, oxide metal film resistors, fus­ible resistors, etc.).
G.Check that replaced wires do not contact sharp
edges or pointed parts.
H.When a power cord has been replaced, check that
5 - 6 kg of force in any direction will not loosen it.
I.Also check areas surrounding repaired locations.
J.Use care that foreign objects (screws, solder drop-
lets, etc.) do not remain inside the set.
K.Crimp type wire connector
The power transformer uses crimp type connectors which connect the power cord and the primary side of the transformer. When replacing the transformer, follow these steps carefully and precisely to prevent shock hazards.
Replacement procedure
1)Remove the old connector by cutting the wires at a point close to the connector.
Important: Do not re-use a connector. (Discard it.)
2)Strip about 15 mm of the insulation from the ends of the wires. If the wires are stranded, twist the strands to avoid frayed conductors.
3)Align the lengths of the wires to be connected. Insert the wires fully into the connector.
4)Use a crimping tool to crimp the metal sleeve at its center. Be sure to crimp fully to the complete closure of the tool.
L.When connecting or disconnecting the internal con-
nectors, first, disconnect the AC plug from the AC outlet.
1-3-1 DVD_SFN1
Safety Check after Servicing
Examine the area surrounding the repaired location for damage or deterioration. Observe that screws, parts, and wires have been returned to their original positions. Afterwards, do the following tests and confirm the speci­fied values to verify compliance with safety standards.
1. Clearance Distance
When replacing primary circuit components, confirm specified clearance distance (d) and (d’) between sol­dered terminals, and between terminals and surround­ing metallic parts. (See Fig. 1)
Table 1 : Ratings for selected area
AC Line Voltage Clearance Distance (d) (d’)
120 V 3.2 mm (0.126 inches)
Note: This table is unofficial and for reference only. Be sure to confirm the precise values.
2. Leakage Current Test
Confirm the specified (or lower) leakage current be­tween B (earth ground, power cord plug prongs) and externally exposed accessible parts (RF terminals, an­tenna terminals, video and audio input and output ter­minals, microphone jacks, earphone jacks, etc.) is lower than or equal to the specified value in the table below.
Measuring Method (Power ON) :
Insert load Z between B (earth ground, power cord plug prongs) and exposed accessible parts. Use an AC voltmeter to measure across the terminals of load Z. See Fig. 2 and the following table.
Z
1.5k
Chassis or Secondary Conductor
Primary Circuit Terminals
dd'
Exposed Accessible Part
AC Voltmeter
0.15µF
Earth Ground
B
Power Cord Plug Prongs
(High Impedance)
Fig. 1
Fig. 2
Table 2 : Leakage current ratings for selected areas
AC Line Voltage Load Z Leakage Current (i) Earth Ground (B) to:
120 V
Note: This table is unofficial and for reference only. Be sure to confirm the precise values.
0.15µF CAP. & 1.5kΩ RES.
Connected in parallel
i 0.5mA Peak Exposed accessible parts
1-3-2 DVD_SFN1

STANDARD NOTES FOR SERVICING

Circuit Board Indications
a.The output pin of the 3 pin Regulator ICs is indicated
as shown.
Top View
Out
b.For other ICs, pin 1 and every fifth pin are indicated
as shown.
Input
In
Pin 1
c.The 1st pin of every male connector is indicated as
shown.
Bottom View
5
10
How to Remove / Install Flat Pack-IC
1. Removal
With Hot-Air Flat Pack-IC Desoldering Machine:
(1)Prepare the hot-air flat pack-IC desoldering ma-
chine, then apply hot air to the Flat Pack-IC (about 5 to 6 seconds). (Fig. S-1-1)
Fig. S-1-1
(2)Remove the flat pack-IC with tweezers while apply-
ing the hot air.
(3)Bottom of the flat pack-IC is fixed with glue to the
CBA; when removing entire flat pack-IC, first apply soldering iron to center of the flat pack-IC and heat up. Then remove (glue will be melted). (Fig. S-1-6)
(4)Release the flat pack-IC from the CBA using tweez-
ers. (Fig. S-1-6)
Pin 1
Instructions for Connectors
1.When you connect or disconnect the FFC (Flexible Foil Connector) cable, be sure to first disconnect the AC cord.
2.FFC (Flexible Foil Connector) cable should be in­serted parallel into the connector, not at an angle.
FFC Cable
Connector
CBA
Caution:
1.Do not supply hot air to the chip parts around the flat pack-IC for over 6 seconds because damage to the chip parts may occur. Put masking tape around the flat pack-IC to protect other parts from damage. (Fig. S-1-2)
2.The flat pack-IC on the CBA is affixed with glue, so be careful not to break or damage the foil of each pin or the solder lands under the IC when removing it.
Hot-air Flat Pack-IC Desoldering Machine
CBA
Masking Tape
Flat Pack-IC
* Be careful to avoid a short circuit.
Tweezers
Fig. S-1-2
1-4-1 DVD_NOTE
With Soldering Iron:
(1)Using desoldering braid, remove the solder from all
pins of the flat pack-IC. When you use solder flux which is applied to all pins of the flat pack-IC, you can remove it easily. (Fig. S-1-3)
Desoldering Braid
Flat Pack-IC
Soldering Iron
Fig. S-1-3
soldering iron to center of the flat pack-IC and heat up. Then remove (glue will be melted). (Fig. S-1-6)
(5)Release the flat pack-IC from the CBA using tweez-
ers. (Fig. S-1-6)
Note:
When using a soldering iron, care must be taken to ensure that the flat pack-IC is not being held by glue. When the flat pack-IC is removed from the CBA, handle it gently because it may be damaged if force is applied.
Hot Air Blower
(2)Lift each lead of the flat pack-IC upward one by one,
using a sharp pin or wire to which solder will not adhere (iron wire). When heating the pins, use a fine tip soldering iron or a hot air desoldering machine. (Fig. S-1-4)
Sharp Pin
Fine Tip Soldering Iron
Fig. S-1-4
(3)Bottom of the flat pack-IC is fixed with glue to the
CBA; when removing entire flat pack-IC, first apply soldering iron to center of the flat pack-IC and heat up. Then remove (glue will be melted). (Fig. S-1-6)
(4)Release the flat pack-IC from the CBA using tweez-
ers. (Fig. S-1-6)
To Solid Mounting Point
CBA
Tweezers
Iron Wire
or
Soldering Iron
Fig. S-1-5
Fine Tip Soldering Iron
Flat Pack-IC
With Iron Wire:
(1)Using desoldering braid, remove the solder from all
pins of the flat pack-IC. When you use solder flux which is applied to all pins of the flat pack-IC, you can remove it easily. (Fig. S-1-3)
(2) Affix the wire to a workbench or solid mounting point,
as shown in Fig. S-1-5.
(3)While heating the pins using a fine tip soldering iron
or hot air blower, pull up the wire as the solder melts so as to lift the IC leads from the CBA contact pads as shown in Fig. S-1-5.
(4)Bottom of the flat pack-IC is fixed with glue to the
CBA; when removing entire flat pack-IC, first apply
Fig. S-1-6
1-4-2 DVD_NOTE
2. Installation
(1)Using desoldering braid, remove the solder from the
foil of each pin of the flat pack-IC on the CBA so you can install a replacement flat pack-IC more easily.
(2)The " ● " mark on the flat pack-IC indicates pin 1.
(See Fig. S-1-7.) Be sure this mark matches the 1 on the PCB when positioning for installation. Then pre- solder the four corners of the flat pack-IC. (See Fig. S-1-8.)
(3)Solder all pins of the flat pack-IC. Be sure that none
of the pins have solder bridges.
Example :
Pin 1 of the Flat Pack-IC is indicated by a " " mark.
Fig. S-1-7
Instructions for Handling Semiconductors
Electrostatic breakdown of the semiconductors may occur due to a potential difference caused by electro­static charge during unpacking or repair work.
1. Ground for Human Body
Be sure to wear a grounding band (1M) that is properly grounded to remove any static electricity that may be charged on the body.
2. Ground for Workbench
Be sure to place a conductive sheet or copper plate with proper grounding (1MΩ) on the workbench or other surface, where the semiconductors are to be placed. Because the static electricity charge on clothing will not escape through the body grounding band, be careful to avoid contacting semiconductors with your clothing.
< Incorrect >
Soldering Iron
CBA
Presolder
CBA
< Correct >
Grounding Band
Flat Pack-IC
Fig. S-1-8
1M
CBA
1M
Conductive Sheet or Copper Plate
1-4-3 DVD_NOTE

CABINET DISASSEMBLY INSTRUCTIONS

1. Disassembly Flowchart
This flowchart indicates the disassembly steps to gain access to item(s) to be serviced. When reassembling, follow the steps in reverse order. Bend, route, and dress the cables as they were originally.
2. Disassembly Method
[1] Top Case
[2] Front Assembly
[3] Function CBA
[4] PCB Holder
[5] DVD Mecha
[7] DVD Main CBA Unit[6] AV CBA
[8] Rear Panel
REMOVAL
ID/
LOC.
No.
[1] Top Case 1 5(S-1) -
[2]
[3]
[4]
[5]
[6] AV CBA 6
[7]
[8]
PART
Front Assembly
Function CBA
PCB Holder
DVD Mecha
DVD Mecha CBA Unit
Rear Panel
REMOVE/
Fig.
*UNHOOK/UNLOCK/
No.
RELEASE/UNPLUG/ DESOLDER
*2(L-1), Tray Panel,
2
*2(L-2), *5(L-3)
3 *3(L-4), *(CN2001) -
42(S-2) -
*(CN001, CN201),
4,5
2(S-3)
4(S-4), 4(S-5), *2(L-5), *(CN701, CN501)
64(S-6) -
73(S-7) -
Note
1-1 1-2
2-1 2-2 2-3
3
-
1 : Identification (location) No. of parts in the figures 2 : Name of the part 3 : Figure Number for reference 4 : Identification of parts to be removed, unhooked, un-
locked, released, unplugged, unclamped, or desoldered. P=Spring, L=Locking Tab, S=Screw, CN=Connector *=Unhook, Unlock, Release, Unplug, or Desolder e.g. 2(S-2) = two Screws (S-2), 2(L-2) = two Locking Tabs (L-2)
5 :Refer to "Reference Notes."
Reference Notes
CAUTION 1: Locking Tabs (L-1) are fragile. Be careful not to break them.
1-1.Connect the wall plug to an AC outlet and press the
OPEN/CLOSE button to open the Tray.
1-2.First, remove the Tray Panel by releasing two Lock-
ing Tabs (L-1). Second, release two Locking Tabs (L-2). Then, release five Locking Tabs (L-3) (to do this, first release three Locking Tabs (A) at the bottom, and then two Locking Tabs (B) at the side.) (Fig. 2)
CAUTION 2: Electrostatic breakdown of the laser diode in the optical system block may occur as a potential difference caused by electrostatic charge accumulated on cloth, human body etc, during unpacking or repair work.
To avoid damage of pickup follow next procedures. 2-1.Slide out the pickup unit as shown in Fig. 5. 2-2.Short the copper pattern (half-moon shape) of FPC
cable with solder before removing the FFC cable (CN001) from it. If you disconnect the FFC cable (CN001), the laser diode of pickup will be destroyed. (Fig. 5)
2-3.Disconnect Connector (CN201). Remove two
Screws (S-3) and lift the DVD Mecha. (Fig. 4)
CAUTION 3: When reassembling, confirm the FFC cable (CN001) is connected completely. Then remove the solder from copper pattern (half-moon shape) of FPC cable. (Fig. 5)
1-5-1 E5540DC
(S-1)
[1] Top Cover
(S-1)
(S-1)
(S-3)
[5] DVD Mecha
(S-3)
(S-2)
[4] PCB Holder
(L-1)
(B)
(A)
(L-1)
Tray Panel
(L-3)
(L-2)
[2] Front Assembly
(B)
Fig. 1
Fig. 2
CN201
CN001
Pickup Unit
DVD Mecha Bottom View
Slide
A
Fig. 4
Short the copper pattern by soldering
View for A
Fig. 5
[3] Function CBA
(L-4)
CN2001
(L-4)
Fig. 3
1-5-2 E5540DC
[6] AV CBA
(S-5)
(S-6)
(S-6)
(L-5)
[7] DVD Main CBA Unit
[8] Rear Panel
CN501
CN701
(S-6)
(S-5)
(S-5)
(S-4)
(S-4)
Fig. 6
(S-7)
Fig. 7
1-5-3 E5540DC
System Control Block Diagram

BLOCK DIAGRAMS

FROM/TO RF SIGNAL PROCESS /SERVO BLOCK DIAGRAM
FROM/TO DVD SIGNAL PROCESS BLOCK DIAGRAM
TFW TREV TIN TOUT
SCLKH SDATA
CSL MUTE PS RS HINT HCS HWR HRD HA0 HA1
HRD HWR JITTER MRDY MCS MALE FG
HD0-HD7
IC400
(FRONT END PROCESSOR)
TIN
60 61
TOUT
3 SCLKH 4 SDATA
5 CSL
99 MUTE 100
PS 1 RS
51 HINT 95 HCS
HWR
10
HRD
8
HA0
92
HA1
93
HD0
83
~
~
HD7
90
37 JITTER 14 MRDY 94 MCS
7 MALE
52 FG
IC002
(OP AMP)
RDY-HIF
/FERS
XOUT8180
SDA SCL
XIN
IC603
(MEMORY)
25 26 30 50
SCL
6 5
SDA
X401
16MHz
IC608
(INVERTER)
2 4
X601 27MHz
IC601
(DVD HOST PROCESSOR)
TFW
200
TREV
201 187
TIN TOUT
188
SDA
196
SCL
195
RDY-HIF
208 186
/FERS
CLOCK
120
VFD-DOUT
VFD-CLK REMOTE
3VFD-STB 1VFD-DIN
2 204 125
CN501 CN1001
FP-STB 19
19
FP-DIN 20
20
FP-DOUT 21
21
FP-CLK 22
22
REMOTE 24
24
RM2001
REMOTE SENSOR
IC2003
(FRONT PANEL CONTROL)
1G
~
11G
a/KEY-1 b/KEY-2
9
FP-STB
7
FP-DIN
6
FP-DOUT FP-CLK
8
c/KEY-3 d/KEY-4
e
f g h
i
j
K2 K1
42
32
14 15 16 17 18 19 20 21 22 23
11 10
FL2002
~
GRID FIP
SEGMENT
CN2001
KEY-4 1
1
KEY-3 2
2
KEY-2 3
3
KEY-1 4
4
K2 5
5
K1 6
6
CN2003
FG SENSOR
CN3004 CN3003
FG-IN 6
6
INNER CBA
1 3
FG-IN 10
1-6-1
CN201
MAIN CBA UNIT
POWER SW
SWITCH CBAFG CBA MECHA CBA
AV CBA
KEY-2 1
1
K2 2
2
JP1003JP1004
1-6-2
KEY MATRIX
FUNCTION CBA
E5542BLS
RF Signal Process/Servo Block Diagram
PICK-UP UNIT
DETECTOR
A 3 D 4 C 1 B 2 F 7 E 8
LD 11
MON 12
GND 9 GND 10
RF(VIDEO/AUDIO) SIGNAL FOCUS SERVO SIGNAL TRACKING SERVO SIGNAL
IC001
(RF SIGNAL PROCESS)
17 18
FOCUS ON
GATE SIGNAL
CN001
CN001
Q001 AMP
29 30
28 25 26 27 40 39
60 58
RF
AMP
INPUT
MATRIX
TRACKING
ERROR DET
FOCUS
ERROR DET
PB-ALPC
SLIDE SERVO SIGNAL DISK SERVO SIGNAL
16 15
AGC AMP
PROGRAMMABLE EQ
MONREF MONREP
TP001 TP002
WF1 WF2
DATA SLICER ASYMMETRY
CONTROL
MIRROR DET
DEFECT DET
CONTROL
REGISTERS
5 6
MCU
I/F
76 77
69
74
73
51
52 53
66 67 68
MAIN CBA UNIT
NRZN NRZP
DEFECT
TC
SRV33M
SCLKH
SDATA
CSL
TO DVD SIGNAL PROCESS BLOCK DIAGRAM
FROM SYSTEM CONTROL BLOCK DIAGRAM
LOADING MOTOR
M
CN3004 CN3003
M M
SPINDLE MOTOR
SPL(-) 11
FSTS
SL(-) 33
SPL(+) 22
SLIDE MOTOR
SL(+) 44
INNER
FS(+) 17
FS(-) 16
TS(+) 15
TS(-) 18
SPL(-) 6
SPL(+) 7
CBA
MECHA CBA
CN001
LD(+) 1
LD(-) 2
SL(+) 9
SL(-) 8
CN201
TRAY-IN
TRAY-OUT
IC200 (SERVO DRIVE)
12 6 11
14 13
10
9
18 17
16 15
TRAY-IN 3 GND 5 TRAY-OUT 4
FOCUS
DRIVE
TRACKING
DRIVE
MUTE
LOADING
MOTOR DRIVE
SPINDLE
MOTOR DRIVE
SLIDE
MOTOR DRIVE
POWER
SAVE
CN201
TP202
FS
TP201
TS
5
TP203
PWM
21
1 2
24
+
-
23 22 27
+
-
26 25
TP205
4
SL
TP104
VREF165
IC002
(OP AMP)
14 12
8 10
7 5
PWM1
PWM2
MUTE
TREV
TRAY-IN
TRAY-OUT
70
FROM DVD SIGNAL PROCESS BLOCK
TFW
FROM/TO SYSTEM CONTROL BLOCK
PS
IC100 (SERVO DSP)
41
PDM2
3 52
PDM0
7
1
PDM3
19
ADC4
PDM1
5
CLKINFSGATE
TC
MIRROR
TZC
DEFECT
ADC1
ADC0
ADC2
RS
HINT
HCS
HWR
HRD
HA0 HA1
HD0
~
HA7
95
27 26
34
FE
IC102
(OP AMP)
TP103
22 10
23
21 14 12
68 76 77 78 79 81 80
90
86 84
82
8
TE
TP102
1 3
ASO
TP101
~
~
HD0-HD7
RS
HINT
HCS
HWR
HRD HAO
HA1
FROM/TO SYSTEM CONTROL BLOCK DIAGRAM
1-6-4
E5542BLRF1-6-3
Loading...
+ 32 hidden pages