Mitsubishi DD-4030 Service manual
2002
Service
Manual
DVD PLAYER
MODEL
DD-4030
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1-1
LASER BEAM SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2-1
IMPORTANT SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-1
STANDARD NOTES FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4-1
OPERATING CONTROLS AND FUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5-1
CABINET DISASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6-1
BLOCK DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7-1
SCHEMATIC DIAGRAMS / CBA'S AND TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8-1
WAVEFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9-1
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10-1
FIRMWARE RENEWAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11-1
SYSTEM CONTROL TIMING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12-1
IC PIN FUNCTION DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13-1
LEAD IDENTIFICATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14-1
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15-1
MECHANICAL PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16-1
ELECTRICAL PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17-1
MITSUBISHI ELECTRIC
MITSUBISHI DIGITAL ELECTRONICS AMERICA, INC.
9351 Jeronimo Road, Irvine, CA 92618-1904
Copyright © 2002 Mitsubishi Digital Electronics America, Inc.
All Rights Reserved
Manufactured under license from Dolby Laboratories. "Dolby"
and the double-D symbol are trademarks of Dolby Laboratories.
"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. Coaxial Digital Out mVpp 500
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
C
4. Room ambient : +25
°
1-1-1 DVDSP
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.
Drive Mecha Assembly
Laser Beam Radiation
Laser Pickup
Turntable
LASER RADIATION
WHEN OPEN. DO NOT
STARE INTO BEAM.
CAUTION
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. Be careful that foreign objects (screws, solder
droplets, 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’)
Chassis or Secondary Conductor
Primary Circuit Terminals
dd'
120 V
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.
Table 2: Leakage current ratings for selected areas
AC Line Voltage Load Z Leakage Current (i) Earth Ground (B) to:
120 V
≥ 3.2mm (0.126 inches)
0.15µF CAP. & 1.5kΩ RES.
Connected in parallel
Exposed Accessible Part
Z
1.5k
i≤0.5mA Peak Exposed accessible parts
0.15 F
Earth Ground
B
Power Cord Plug Prongs
AC Voltmeter
(High Impedance)
Fig. 1
Fig. 2
Note: This table is unofficial and for reference only. Be sure to confirm the precise values.
1-3-2 DVD_SFN1
STANDARD NOTES FOR SERVICING
Circuit Board Indications
a. The output pin of the 3 pin Regulator ICs is indi-
cated 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.
Pin 1
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
machine, 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)
(1) Release the flat pack-IC from the CBA using twee-
zers. (Fig. S-1-6)
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
* Be careful to avoid a short circuit.
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
CBA
Masking
Tape
Tweezers
Machine
Flat Pack-IC
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)
Flat Pack-IC
Desoldering Braid
(4) 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)
(5) Release the flat pack-IC from the CBA using twee-
zers. (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.
Soldering Iron
Fig. S-1-3
(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 twee-
zers. (Fig. S-1-6)
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
To Solid
Mounting Point
CBA
Tweezers
Hot Air Blower
or
Iron Wire
Soldering Iron
Fig. S-1-5
Fine Tip
Soldering Iron
Flat Pack-IC
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 “I” 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
presolder 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
Semi-conductors
Electrostatic breakdown of the semi-conductors 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 (1MΩ) that is properly grounded to remove any static electricity that may
be charged on the body.
2. Ground for Workbench
(4) Be sure to place a conductive sheet or copper plate
with proper grounding (1MΩ) on the workbench or
other surface, where the semi-conductors are to be
placed. Because the static electricity charge on
clothing will not escape through the body grounding band, be careful to avoid contacting semi-conductors with your clothing.
< Incorrect >
CBA
Presolder
Flat Pack-IC
Fig. S-1-8
CBA
< Correct >
Grounding Band
1MΩ
CBA
1MΩ
Conductive Sheet or
Copper Plate
1-4-3 DVD_NOTE
OPERATING CONTROLS AND FUNCTIONS
FRONT PANEL
REMOTE CONTROL
RM-D#
1
9
10
11
12
13
14
15
16
17
18
1. POWER Button
Press to turn the power on and off.
2. Display, Remote Sensor Window
3. SKIP Buttons
G: Plays back from the beginning of the next
chapter or track.
j: Plays back from the beginning of the current
chapter or track.
4. STOP Button
Stops operation of the disc.
5. PLAY Button
Starts playback of the disc contents.
6. PAUSE Button (main unit)
Pauses the current disc operation.
PAUSE/STEP Button (remote control)
Pauses the current disc operation. View the still
picture frame by frame.
7. OPEN/CLOSE Button
Press to insert or remove discs from the tray.
8. Disc loading tray
28
7
27
26
25
24
23
3
6
5
22
4
21
20
19
78
21
9. Numeric Buttons
10. CLEAR Button
Resets a setting.
11. TITLE Button Displays the title menu.
12. Arrow Buttons
Use when making settings while watching the
display on a TV screen.
13. ENTER Button
Press to accept a setting.
14. ZOOM Button
Enlarges part of a DVD-reproduced image.
15. REV Button
Fast reverse playback to a desired point.
16. SEARCH MODE Button
Press to locate a desired point.
17. REPEAT Button
Repeats playback of the current disc, title, chapter or
track.
18. MODE Button
Activates program playback or random playback mode
when playing CDs or MP3. Also Sets Black level.
19. DIMMER Button
Select the display panel brightness.
20. A-B REPEAT Button
Repeats playback of a selected section.
21. DISPLAY Button
Displays the current status on the TV screen for
checking purposes.
22. FWD Button
Fast forwards playback to a desired point.
23. RETURN Button
Returns to the previous operation.
MENU Button
24.
Displays the disc menus.
25. ANGLE Button
Press to change the camera angle to see the sequence
being played back from a different angle.
26. SUBTITLE Button
Press to select a desired subtitle language.
27. AUDIO Button
Press to select a desired audio language or sound mode.
28. SETUP Button
Press to enter the setup mode or to change setup items.
4 5 63
1-5-1 E5640IB
REAR VIEW
DIGITAL AUDIO OUT
(PCM/BITSTREAM)
AUDIO OUT
VIDEO OUT
YCr
OPTICAL COAXIAL
29 34 363532 3330 31
29. Power Cord
30. OPTICAL DIGITAL AUDIO OUT Jack
31. COAXIAL DIGITAL AUDIO OUT Jack
32. Right AUDIO OUT Jack
DISPLAY
Lights-up when the
multi-angle scene is taken
Lights-up when the A-B repeat
mode is set
Lights-up when the repeat mode
is set
Lit when a DVD is inserted
Lit when a CD is inserted
R L VIDEO
Cb S
33. Left AUDIO OUT Jack
34. VIDEO OUT Jack
35. Component Video Out Jacks
36. S-VIDEO OUT Jack
DISPLAYS DURING
OPERATION
(“ON” is lit.)
(“Disc icon” blinks.)
(“Disc icon” rotates.)
(“Disc icon” rotates.)
(A segment on
“Disc icon” blinks.)
(Two segments on
“Disc icon” blink.)
Power on
Tray open and closed
LOAD
During playback
During pause
Stop (Resume ON)
Displays the time lapse of the
current title or track
Displays a chapter or track number
Displays a title number
Displays the disc status
(“Disc icon” is lit.)
(“OFF” is lit.)
(“ERROR” is lit.)
Stop (Resume OFF)
Power off
No disc or error
ERROR
LOADING THE BATTERIES
1. Open the battery compartment cover.
2. Insert two AA batteries, with each one
oriented correctly.
3. Close the cover.
Notes
Do not mix alkaline and manganese batteries.
Do not mix old and new batteries.
1-5-2 E5640IB
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.
[1] Top Cover
[2] Front Assembly
[3] Function CBA
[4] PCB Holder
[5] DVD Mecha
[7] DVD Main CBA Unit[6] AV CBA
[8] Rear Panel
2. Disassembly Method
ID/
LOC.
No.
[1] Top Cover 1 5(S-1) -
[2]
[3]
[4]
[5]
[6] AV CBA 5
[7]
[8]
PART
Front
Assembly
Function
CBA
PCB
Holder
DVD
Mecha
DVD Main
CBA Unit
Rear
Panel
Fig.
No.
2
3 *3(L-4), *CN2001 -
32(S-2) -
3,4
53(S-7) -
63(S-8) -
REMOVAL
REMOVE/*UNHOOK/
UNLOCK/RELEASE/
UNPLUG/DESOLDER
*2(L-1), Tray Panel,
*2(L-2), *5(L-3)
2(S-3), *CN101,
*CN401
(S-4), 5(S-5), 3(S-6),
*CN1001, *CN1601,
*2(L-5)
Note
1-1
1-2
1-3
1-4
1-5
1-6
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,
unlocked, 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), (L-2) and (L-3) 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. Remove the Tray Panel by releasing two Locking
Tabs (L-1).
1-3. Press the OPEN/CLOSE button again to close
the Tray.
1-4. Press the POWER button to turn the power off.
1-5. Unplug an AC cord.
1-6. Release two Locking Tabs (L-2). Then, release
five Locking Tabs (L-3) (to do this, first release
two Locking Tabs (A) at the side, and then three
Locking Tabs (B) at the bottom.)
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. D4.
2-2. Short the three short lands of FPC cable with sol-
der before removing the FFC cable (CN101) from
it. If you disconnect the FFC cable (CN101), the
laser diode of pickup will be destroyed. (Fig. D4)
2-3. Disconnect Connector (CN401). Remove two
Screws (S-3) and lift the DVD Mecha. (Fig. D3)
CAUTION 3: When reassembling, confirm the FFC
cable (CN101) is connected completely. Then remove
the solder from the three short lands of FPC cable.
(Fig. D4)
↓
(1)
↓
(2)
↓
(3)
↓
(4)
↓
(5)
1-6-1 E5640DC
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