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DD-4030
Service manual
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Table of contents
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Mitsubishi DD-4030 Service manual

0 (0)
2002
Service Manual
DVD PLAYER
MODEL
DD-4030
TABLE OF CONTENTS
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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