PIONEER CDJ-800MK2/WYSXJ5 Service Manual

PIONEER CDJ-800MK2/WYSXJ5 Service Manual
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Service Manual for PIONEER CDJ-800MK2/WYSXJ5, downloadable as a PDF file.

We also have owner's manual to this model.

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Sample pages

ORDER NO.

PIONEER CORPORATION 4-1, Meguro 1-chome, Meguro-ku, Tokyo 153-8654, Japan

PIONEER ELECTRONICS (USA) INC. P.O. Box 1760, Long Beach, CA 90801-1760, U.S.A.

PIONEER EUROPE NV Haven 1087, Keetberglaan 1, 9120 Melsele, Belgium

PIONEER ELECTRONICS ASIACENTRE PTE. LTD. 253 Alexandra Road, #04-01, Singapore 159936

PIONEER CORPORATION 2006

CDJ-800MK2

RRV3364

COMPACT DISC PLAYER

CDJ-800MK2

THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).

Model

Type

Power Requirement

Remarks

CDJ-800MK2

KUCXJ

AC 120 V

CDJ-800MK2

WYXJ5

AC 220 240 V

CDJ-800MK2

RLFXJ

AC 110-120 V / 220-240 V

For details, refer to "Important symbols for good services" .

T-ZZR JUNE 2006 printed in Japan

ORDER NO.

PIONEER CORPORATION 4-1, Meguro 1-chome, Meguro-ku, Tokyo 153-8654, Japan

PIONEER ELECTRONICS (USA) INC. P.O. Box 1760, Long Beach, CA 90801-1760, U.S.A.

PIONEER EUROPE NV Haven 1087, Keetberglaan 1, 9120 Melsele, Belgium

PIONEER ELECTRONICS ASIACENTRE PTE. LTD. 253 Alexandra Road, #04-01, Singapore 159936

PIONEER CORPORATION 2006

CDJ-800MK2

RRV3364

COMPACT DISC PLAYER

CDJ-800MK2

THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).

Model

Type

Power Requirement

Remarks

CDJ-800MK2

KUCXJ

AC 120 V

CDJ-800MK2

WYXJ5

AC 220 240 V

CDJ-800MK2

RLFXJ

AC 110-120 V / 220-240 V

For details, refer to "Important symbols for good services" .

T-ZZR JUNE 2006 printed in Japan

CDJ-800MK2

SAFETY INFORMATION

This service manual is intended for qualified service technicians ; it is not meant for the casual do-it-

yourselfer. Qualified technicians have the necessary test equipment and tools, and have been trained

to properly and safely repair complex products such as those covered by this manual.

Improperly performed repairs can adversely affect the safety and reliability of the product and may

void the warranty. If you are not qualified to perform the repair of this product properly and safely, you

should not risk trying to do so and refer the repair to a qualified service technician.

WARNING

This product contains lead in solder and certain electrical parts contain chemicals which are known to the state of California to

causecancer, birth defects or other reproductive harm.

Health & Safety Code Section 25249.6 Proposition 65

NOTICE

(FOR CANADIAN MODEL ONLY)

Fuse symbols

(fast operating fuse) and/or

(slow operating fuse) on PCB indicate that replacement

parts must be of identical designation.

REMARQUE

(POUR MODÈLE CANADIEN SEULEMENT)

Les symboles de fusible

(fusible de type rapide) et/ou

(fusible de type lent) sur CCI indiquent que

les pièces de remplacement doivent avoir la même désignation.

ANY MEASUREMENTS NOT WITHIN THE LIMITS

OUTLINED ABOVE ARE INDICATIVE OF A POTENTIAL

SHOCK HAZARD AND MUST BE CORRECTED BEFORE

RETURNING THE APPLIANCE TO THE CUSTOMER.

2. PRODUCT SAFETY NOTICE

Many electrical and mechanical parts in the appliance

have special safety related characteristics. These are

often not evident from visual inspection nor the protection

afforded by them necessarily can be obtained by using

replacement components rated for voltage, wattage, etc.

Replacement par ts which have these special safety

characteristics are identified in this Service Manual.

Electrical components having such features are identified

by marking with a

on the schematics and on the parts list

in this Service Manual.

The use of a substitute replacement component which does

not have the same safety characteristics as the PIONEER

recommended replacement one, shown in the parts list in

this Service Manual, may create shock, fire, or other hazards.

Product Safety is continuously under review and new

instructions are issued from time to time. For the latest

information, always consult the current PIONEER Service

Manual. A subscription to, or additional copies of, PIONEER

Service Manual may be obtained at a nominal charge

from PIONEER.

1. SAFETY PRECAUTIONS

The following check should be performed for the

continued protection of the customer and

ser vice technician.

LEAKAGE CURRENT CHECK

Measure leakage current to a known earth ground (waterpipe

, conduit, etc.) by connecting a leakage current tester

such as Simpson Model 229-2 or equivalent between the

earth ground and all exposed metal parts of the appliance

(input/output terminals, screwheads, metal overlays, control

shaft, etc.). Plug the AC line cord of the appliance directly

into a 120V AC 60Hz outlet and turn the AC power switch

on. Any current measured must not exceed 0.5mA.

(FOR USA MODEL ONLY)

Leakage

current

tester

Reading should

not be above

0.5mA

Device

under

test

Test all

exposed metal

surfaces

Also test with

plug reversed

(Using AC adapter

plug as required)

Earth

ground

AC Leakage Test

CDJ-800MK2

IMPORTANT

THIS PIONEER APPARATUS CONTAINS

LASER OF CLASS 1.

SERVICING OPERATION OF THE APPARATUS

SHOULD BE DONE BY A SPECIALLY

INSTRUCTED PERSON.

LASER DIODE CHARACTERISTICS

MAXIMUM OUTPUT POWER: 5 mW

WAVELENGTH: 780 785 nm

WARNING !

The AEL(accessible emission level) of the laser power output is less then CLASS 1

but the laser component is capable of emitting radiation exceeding the limit for

CLASS 1.

A specially instructed person should servicing operation of the apparatus.

Additional Laser Caution

: Refer to page 86.

for RLFXJ

(DRW2308)

(DRW2248)

1. Laser Interlock Mechanism

The position of the switch (S1901) for detecting loading

completion is detected by the system microprocessor,

and the design prevents laser diode oscillation when

the switch is not in LPS1 terminal side (when the

mechanism is not clamped and LPS1 signal is

high level.)

Thus, the interlock will no longer function if the switch is

deliberately set to LPS1 terminal side. ( if LPS1 signal

is low level ).

In the test mode

the interlock mechanism will not

function. Laser diode oscillation will continue, if pin 41

of TC94A15FG (IC101) on the MAIN Assy is

connected to GND, or else the terminals of Q101 are

shorted to each other (fault condition).

2. When the cover is opened, close viewing of the

objective lens with the naked eye will cause exposure

to a Class 1 laser beam.

CDJ-800MK2 WYXJ5 and KUCXJ : Types Only

Printed on the Bottom Plate

Bottom Plate

LABEL CHECK

CDJ-800MK2

[Important Check Points for Good Servicing]

In this manual, procedures that must be performed during repairs are marked with the below symbol.

Please be sure to confirm and follow these procedures.

1. Product safety

Please conform to product regulations (such as safety and radiation regulations), and maintain a safe servicing environment by

following the safety instructions described in this manual.

1 Use specified parts for repair.

Use genuine parts. Be sure to use important parts for safety.

2 Do not perform modifications without proper instructions.

Please follow the specified safety methods when modification(addition/change of parts) is required due to interferences such as

radio/TV interference and foreign noise.

3 Make sure the soldering of repaired locations is properly performed.

When you solder while repairing, please be sure that there are no cold solder and other debris.

Soldering should be finished with the proper quantity. (Refer to the example)

4 Make sure the screws are tightly fastened.

Please be sure that all screws are fastened, and that there are no loose screws.

5 Make sure each connectors are correctly inserted.

Please be sure that all connectors are inserted, and that there are no imperfect insertion.

6 Make sure the wiring cables are set to their original state.

Please replace the wiring and cables to the original state after repairs.

In addition, be sure that there are no pinched wires, etc.

7 Make sure screws and soldering scraps do not remain inside the product.

Please check that neither solder debris nor screws remain inside the product.

8 There should be no semi-broken wires, scratches, melting, etc. on the coating of the power cord.

Damaged power cords may lead to fire accidents, so please be sure that there are no damages.

If you find a damaged power cord, please exchange it with a suitable one.

9 There should be no spark traces or similar marks on the power plug.

When spark traces or similar marks are found on the power supply plug, please check the connection and advise on secure

connections and suitable usage. Please exchange the power cord if necessary.

0 Safe environment should be secured during servicing.

When you perform repairs, please pay attention to static electricity, furniture, household articles, etc. in order to prevent injuries.

Please pay attention to your surroundings and repair safely.

2. Adjustments

To keep the original performance of the products, optimum adjustments and confirmation of characteristics within specification.

Adjustments should be performed in accordance with the procedures/instructions described in this manual.

4. Cleaning

For parts that require cleaning, such as optical pickups, tape deck heads, lenses and mirrors used in projection monitors, proper

cleaning should be performed to restore their performances.

3. Lubricants, Glues, and Replacement parts

Use grease and adhesives that are equal to the specified substance.

Make sure the proper amount is applied.

5. Shipping mode and Shipping screws

To protect products from damages or failures during transit, the shipping mode should be set or the shipping screws should be

installed before shipment. Please be sure to follow this method especially if it is specified in this manual.

CDJ-800MK2

CONTENTS

SAFETY INFORMATION......................................................................................................................................2

1. SPECIFICATIONS .............................................................................................................................................6

2. EXPLODED VIEWS AND PARTS LIST.............................................................................................................8

2.1 PACKING ....................................................................................................................................................8

2.2 EXTERIOR SECTION ..............................................................................................................................10

2.3 CONTROL PANEL SECTION ...................................................................................................................12

2.4 SLOT-IN MECHANISM SECTION ............................................................................................................14

3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM ..........................................................................................16

3.1 BLOCK DIAGRAM ....................................................................................................................................16

3.2 BLOCK DIAGRAM (2) ..............................................................................................................................18

3.3 BLOCK DIAGRAM (Power).......................................................................................................................20

3.4 OVERALL WIRING DIAGRAM .................................................................................................................22

3.5 MAIN (1/3) and RLYB ASSYS ..................................................................................................................24

3.6 MAIN ASSY(2/3).......................................................................................................................................26

3.7 MAIN ASSY(3/3).......................................................................................................................................30

3.8 AC IN, TRNS, SECB and REGB ASSYS..................................................................................................32

3.9 DFLB, JACK and KSWB ASSYS ..............................................................................................................34

3.10 JFLB, SLDB, SLMB and JOGB ASSYS .................................................................................................36

3.11 WAVEFORMS.........................................................................................................................................38

3.12 VOLTAGES..............................................................................................................................................45

4. PCB CONNECTION DIAGRAM ......................................................................................................................49

4.1 MAIN ASSY ..............................................................................................................................................50

4.2 RLYB ASSY ..............................................................................................................................................54

4.3 SECB ASSY .............................................................................................................................................56

4.4 TRNS ASSY..............................................................................................................................................60

4.5 AC IN ASSYS ...........................................................................................................................................62

4.6 DFLB ASSY ..............................................................................................................................................64

4.7 REGB and JACK ASSYS..........................................................................................................................68

4.8 KSWB ASSY.............................................................................................................................................70

4.9 JFLB ASSY...............................................................................................................................................72

4.10 SLDB ASSY............................................................................................................................................76

4.11 SLMB and JOGB ASSYS .......................................................................................................................78

5. PCB PARTS LIST ............................................................................................................................................80

6. ADJUSTMENT ................................................................................................................................................85

7. GENERAL INFORMATION .............................................................................................................................86

7.1 DIAGNOSIS ..............................................................................................................................................86

7.1.1 SERVICE MODE ................................................................................................................................86

7.1.2 RESET and CLOCK MAP ..................................................................................................................92

7.1.3 TROBLE SHOOTING .........................................................................................................................94

7.1.4 POWER ON SEQUENCE ................................................................................................................105

7.1.5 DISASSEMBLY ................................................................................................................................106

7.2 PARTS ....................................................................................................................................................114

7.2.1 IC......................................................................................................................................................114

8. PANEL FACILITIES .......................................................................................................................................140