Pioneer DJM-500 User manual

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 2005
RRV3107
T – ZZY FEB. 2005 Printed in Japan
¶This service manual should be used together with the following manual(s):
Model No. Order No. Remarks
DJM-500/RELM RRV1405
THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).
Model
DJM-500
Type Power Requirement The voltage can be converted by the
following method.
RELM4
DJM-500
‡AC110-120V/220-240V
DJ MIXER
With the voltage selector

2
A
B
C
D
1234
1234
DJM-500
1. CONTRAST OF MISCELLANEOUS PARTS
Parts marked by "NSP" are generally unavailable because they are not in our Master Spare Parts List.
The mark found on some component parts indicates the importance of the safety factor of the part.
Therefore, when replacing, be sure to use parts of identical designation.
Screws adjacent to mark on product are used for disassembly.
Reference Nos. indicate the pages and Nos. in the service manual for the base model.
NOTES:
When ordering resistors, first convert resistance values into code form as shown in the following examples.
Ex.1 When there are 2 effective digits (any digit apart from 0), such as 560 ohm and 47k ohm (tolerance is shown by J=5%,
and K=10%).
Ex.2 When there are 3 effective digits (such as in high precision metal film resistors).
561
473
R50
1R0
5621
560
47k
0.5
1
RD1/4PU J
RD1/4PU J
RN2H K
RS1P K
56 x 10
1
47 x10
3
R50
1R0
561
473
5.62k RN1/4PC F562 x 10
1
5621
DJM-500/RELM4 and DJM-500/RELM are constructed the same except for the following :
PCB ASSEMBLIES
NSP DSP ASSY DWX1786 DWX2464
P 4 - 8 TERMINAL ASSY DWZ1076 DWZ1148
NSP VR Assy DWM2057 DWM2210
P4 - 10 NSP PHONE JACK ASSY DWZ1057 DWZ1144
P4 - 11 NSP MIC JACK ASSY DWZ1066 DWZ1145
NSP SUB Assy DWM2058 DWM2211
P4 - 20 NSP BAL.OUT ASSY DWZ1059 DWZ1147
P4 - 21 PHONE ASSY DWZ1077 DWZ1146
PACKING
P3 - 8 Polyethylene Bag (0.03 x 230 x 340) Z21-038 Not used
P3 - 8 Polyethylene Bag (0.06 x 230 x 340) Not used AHG7117
IEC 65-6 Caution Not used ARM7067 For Accessories
EXTERIOR
P4 - 35 Label DRW1739 DRW2268
P4 - 57 Display Panel A DAH2095 DAH2177
P4 - 59 Display Panel B DAH2096 DAH2178
P4 - 116 NSP Cord Clamper RNE-513 Not used
CONTRAST TABLE
Part No.
DJM-500/
RELM
Ref. No. Symbol and Description Remarks
Mark DJM-500/
RELM4
• For PCB ASSEMBLIES, Refer to “ CONTRAST OF PCB ASSEMBLIES ”.

3
A
B
C
D
5678
5678
DJM-500
CONTRAST OF PCB ASSEMBLIES
• MIC JACK Assy
DWZ1066 and DWZ1145 are constructed the same except for the following :
Mark Symbol and Description Part No.
DWZ1066 DWZ1145 Remarks
C1005 Not used CCSRCH221J50 *3
*3 : Refer to “ 2. SCHEMATIC DIAGRAM and 3. PCB CONNECTION DIAGRAM”.
• PHONE JACK Assy
DWZ1057 and DWZ1144 are constructed the same except for the following :
Mark Symbol and Description Part No. Remarks
DWZ1057 DWZ1144
C1003, C1004 Not used CKSRYB104K25 *2
• PHONE Assy
DWZ1077 and DWZ1146 are constructed the same except for the following :
Mark Symbol and Description Part No. Remarks
DWZ1077 DWZ1146
C602, C621, C622, C646 CCCSL101J50 CQMA102J50
C1101 - C1104 Not used CCPUSL470J50 *4
C1105 - C1110 Not used CCPUSL560J50 *4
• TERMINAL Assy
DWZ1076 and DWZ1148 are constructed the same except for the following :
Mark Symbol and Description Part No. Remarks
DWZ1076 DWZ1148
R878 - R883 RD1/4PU101J RD1/4PU332J
C867, C869, C875, C877, C879, C881 CCCSL101J50 Not used
C868, C870, C876, C878, C880, C882 CCCSL101J50 CQMA221J50
L901 - L906 Not used LAU221J *1
*1 : Refer to “ 2. SCHEMATIC DIAGRAM and 3. PCB CONNECTION DIAGRAM”.
*4 : Refer to “ 2. SCHEMATIC DIAGRAM and 3. PCB CONNECTION DIAGRAM”.
• BAL.OUT Assy
Although DWZ1059 and DWZ1147 are different in part number, they consist of the same components.
*2 : Refer to “ 2. SCHEMATIC DIAGRAM and 3. PCB CONNECTION DIAGRAM”.

4
A
B
C
D
1234
1234
DJM-500
2. SCHEMATIC DIAGRAM
2.1 TERMINAL ASSY
To INPUT ASSY (J101)To INPUT ASSY (J102)
: AUDIO SIGNAL
: RETURN SIGNAL
: PHONO1 (CH2) SIGNAL
: PHONO2 (CH3) SIGNAL
: PHONO3 (CH4) SIGNAL
: CD (CH1) SIGNAL
: CD (CH2) SIGNAL
: LINE1 (CH1) SIGNAL
: LINE2 (CH3) SIGNAL
(R)
(P1)
(P2)
(P3)
(P1)
0.1V/div 0.2ms/div
-14dB,1KHz
0.56Vp-p
GND
10mVp-p
20mV/div 0.2ms/div
-54dB,1KHz
(P1) (P1)
(P2)
(P2)
(P2) (P2)
(P3) (P3)
(P3)
(P3)
(P2)
(P1)
(P1)
50mV/div 0.2ms/div
1KHz
260mVp-p
8.04
-7.95
106.3mV
247.3mV
106.7mV
104.7mV -252.3mV
104.9mV
TERMINAL ASSY (DWZ1148)

5
A
B
C
D
5678
5678
DJM-500
To VR ASSY (J103)
To PHONE ASSY (J151)
To PHONE ASSY (CN107)
To DSP ASSY (J106)
PLAYER
CONTROL
(R) (R)
GND
5Vp-p
2V/div
3.6mV 15.19
14.1mV
-15.33
3.9mV
3.9mV
15.8mV
14.4mV
-563mV 0
0.5V/div 20ms/div
1KHz
2.6Vp-p
0.5V/div 0.2ms/div
1KHz
1.6Vp-p

6
A
B
C
D
1234
1234
DJM-500
2.2 PHONE ASSY
To TERMINAL ASSY (CN151)
GND
6mVp-p
20mV/div 0.2ms
1KHz
50mV/div 0.2ms
1KHz
280mVp-p
0.1V/div 0.2ms
1KHz
0.54Vp-p
0.1V/div 0.2ms
1KHz
0.56Vp-p
0.5V/div 0.2ms
1KHz
2.4Vp-p
0.5V/div 0.2ms
1KHz
1.6Vp-p
(R)
SIGNAL ROUTE
: RETURN SIGNAL
: AUDIO SIGNAL
(R)
(R)
(R)
(R)
(R)
0
18.7mV
-3.2mV
0.64 15.2
0.64 0.64
0.64
-15.3
0.64
0
0
0
0
-15.3
15.2
0
15.2
-15.3
18.8mV
0
15.2
-40mV
-257mV
0
-15.3
-44mV
-1.6mV
0
8.0 8.0
-8.0
-45mV
0
PHONE ASSY (DWZ1146)
BAL. OUT ASSY
(DWZ1147)

7
A
B
C
D
5678
5678
DJM-500
To TERMINAL ASSY (CN107)
0.5V/div 0.2ms
1KHz 2.7Vp-p
15.2
0
0
-15.3
0
0
15.2
0
0
0
-15.3
0
-0.69
0

8
A
B
C
D
1234
1234
DJM-500
To VR ASSY (2/2)
(J109)
To VR ASSY (2/2)
(J120)
MIC JACK ASSY (DWG1145)
PONE JACK ASSY (DWZ1144)
2.3 PHONE JACK and MIC JACK ASSYS

9
A
B
C
D
5678
5678
DJM-500
3. PCB CONNECTION DIAGRAM
(DNP1726-H) (DNP1726-H)
(DNP1726-H) (DNP1726-H)
MIC JACK ASSY
PHONE JACK ASSY
To VR ASSY
(J120)
SIDE A SIDE B
SIDE A SIDE B
To VR ASSY
(J109)
NOTE FOR PCB DIAGRAMS :
1. Part numbers in PCB diagrams match those in the schematic
diagrams.
2. A comparison between the main parts of PCB and schematic
diagrams is shown below.
3. The parts mounted on this PCB include all necessary parts for
several destinations.
For further information for respective destinations, be sure to
check with the schematic diagram.
4. View point of PCB diagrams.
Symbol In PCB
Diagrams
Symbol In Schematic
Diagrams Part Name
BCE
D
D
G
G
S
S
BCE
BCE
DGS
BCEBCE
BCE
Transistor
Transistor
with resistor
Field effect
transistor
Resistor array
3-terminal
regulator
Capacitor
Connector
P.C.Board Chip Part
SIDE A
SIDE B
3.1 PHONE JACK and MIC JACK ASSYS

10
A
B
C
D
1234
1234
DJM-500
3.2 TERMINAL ASSY
85
41
2
1
15
142
1
15
142
1
12
13
2
1
1
W315
C801
C802
C803 C804
C805
C806
C807 C808
C809
C810
C
8
C
8
C
C837
C838
C839
C840
C841
C842
IC801
CN801 CN802
JA805 JA806
R801 R802
R803 R804
R805 R806
R807 R808
R809 R810
R811 R812 R817
R818
R819
R820
R821
R822
R823 R824
R825
R826
R827
R828
R
8
R
R
8
R853
R854
R855
R856
W326
C855
C856
C857
C858
C859
C860
C861
C862
C863
C864
C865
C866
R878
R879C867
C868
C869
C870
CN102
CN101
CN151
W317
W324
W321
W338
CN106
C885 C886 C883 C884
C887 C888
C
W342
W347 W346
W349
W348
W320
W325
W339
C891
W334
W333
W314
W316
CN107
KN101
W350
C811 C834
R691
R692
R693
IC801
DWZ1076-
1
DNX2227-C
MPL
15.CD2R 14.GNDA 13.CD2L 11.PH1L
6.GNDA 4.GNDA 2.GNDA 9.PH1R 3.CD1R 1.CD1L 5.L1L 7.L1R
GND
V+B
1
15
1.GNDC 2.CH2CT2 3.CH2CT1 4.CH1CT2 5.CH1CT1 6.RETURNL 13.MUTE
12.SENDR 11.GND 10.SENDL 9.GND 8.RETURNR
7.GND
CN106
GND GND
GND
L2R
PH2L
PH2R
L2L
CN151
7.SEND L
8.GND 9.RETURN R 10.GND 11.RETURN R 12.GND 13.SUB L6.GND
5.SEND R 4.V-8A 3.V+8A 2.V-BB 1.V+BB
14.GND 15.SUB R
V-B V+8
V-8
V-B
GND
10.GNDA
8.GNDA
12.GNDA
CN101
TERMINAL ASSY
SIDE A
To PHONE ASSY
(J151)
To DSP ASSY
(J106)
To VR ASSY
(
J101
)
To PHONE ASS
Y
(
J107
)
L9
0L902
(SID
E(SIDE B)
L901
(SIDE B)
L903
(SIDE B)
L906
(SIDE B)
L905
(SIDE B)
L9
0
(SID
E
L901
(SIDE B)

11
A
B
C
D
5678
5678
DJM-500
41
85
41
85
41
85
41
15
142
1
6
7
2
1
1
13
C802
C804
C806
C808
C810
C812
C813
C814 C815
C816
C818
C820
C821
C823 C824
C825
C826
C827 C828
C829 C830
C831
C832
C833
C843 C844
C845
C846
C847 C848
C850
IC802
IC803
IC804
CN803 JA804 CN807
Q801 Q802
Q803
Q804
R813
R814
R815
R816
7
R818
1
9
R820
R822
R824
R826
R828
R829 R830
R831 R832
R833
R834
R835
R836
R837
R838
R839
R840
R841 R842
R843 R844
R845 R846
R847
R848
R849 R850
R851 R852
R857
R858
R859
R860 R861
R862
R863
R864
R867 R868
R869
R870
R871
R872
R873
R874
R875
R876
VR801
W318
C817
C819
W328
W331
W332
W312
C851C852C853
C854 W313
W329
W319
W311 W310
7
8
R879
6
7
6
8
C869
C870
C871
C872
C873
C874
R880 R881
C875
C876
C877
C878
R882 R883
C879
C880
C881
C882
W335
02
W327
W341
W340
W353
W352
W323
D802
D801
D804
D803
C889 C890
W351
W344 W345
W330
CN103
W336
W343
CN107
C836
C835
W322
W337
C849
C822
R693
R694
R695
R696
CN161
Q801 Q802 Q803 Q804
IC802 IC803 IC804
1
7.BOOST L 6.GND 1.MASTER R 3.MASTER L 2.GND 4.GND 5.BOOST R
MUTE MPR GNDA MPL
GND
E E E
E
GND
GND
GND GND
GND GND
GND
L2R
PH2L
PH2R PH3L
PH3R
SUBL
SUBR
L2L
CN103
1.MASTER L 2.GND 3.MASTER R
(DNP1725-E)
SIDE A
L904
(SIDE B)
To VR ASSY
(
J102
)
o
PHONE ASSY
(
J107
)
To VR ASSY
(J103)
L902
(SIDE B)
(SIDE B)
L901
(SIDE B)
L903
(SIDE B)
(SIDE B)
L906
(SIDE B)
(SIDE B)
L905
(SIDE B)
(SIDE B)
L902
(SIDE B)
L903
(SIDE B)
L906
(SIDE B)
L905
(SIDE B)

12
A
B
C
D
1234
1234
DJM-500
3.3 PHONE ASSY
W242
C253
C254
C602
C603
C604
C605
C606
C607 C608
C609
C610
C611
C612
C613
C614
C617
C618
C619
C620
C623
C624
C625
C626
C627
C628
C629
C630
C631
C632
C633
C634
C635
C636
C637
C638
C639
C640
C641
IC17
IC231
IC601
IC602
IC603
IC604
IC605
J108
JA601
JA602
JA603
JA604
JA605
JA606
JA607
Q231
Q232
Q233
Q234
Q601
Q602
Q603 Q604
Q605
R231R232
R233
R234
R235
R236
R237
R238
R239
R240
R241
R242
R243
R244
R245
R246
R247
R248
R249
R250
R251
R252
R253
R254
R255
R256
R257
R258
R259
R260
R261
R262
R263
R264
R265
R266
R267
R268
R601
R602
R603 R604
R605
R606
R607
R608
R609
R610
R611
R612
R613
R614
R615
R616
R617
R618
R619
R620
R621
R622
R623
R624 R625 R626
R627
R628
R629
R630
R631
R632
R633
R634
R635
R636 R637
R638
R639
R640
R641
R642
R643
R644
R645
R646
R647
R648
R649
R951
R952
C642
C643
R650
R953
C644
C645
W142
W133
IC233
IC232
C646
C648
C647
C649
C650
C651
C652
R954
R955
R956
C243
C246
C244
W122
W121
W125
W124
W134
W148
W130
W139
W137
W152
W136
W138
W149
W193
W185
W154
W151
W132
W128
CN121
W120
W215
W209
W140
C601
C622
C621
C957
W145
KN601
C233
C234
C235
C236
C237
C238
C239
C240
C958
R957
W190
J151
W216
W199
J107
D607
D608 D605
D606
D602
D601
D604
D603
W186
R958
R959
W191
W184
C247
C245
C241
C231
C232
R697
W147
W182
W131
W135
R698
W301
E
E
E
E
EE
E
E
DWZ1077- DNX2237-D
E
DWZ1077 DWZ1146
/KUC /RELM
CP1 V0
1
1
1
V+8
V-8
V+15
J151
1.V+BB
2.V-BB
3.V+8A
4.V-8A
5.SEND R
6.GNDA
7.SEND L
8.GNDA
9.RETURN R
10.GNDA
11.RETURN L
12.GNDA
13.SUBMIC L
14.GNDA
15.SUBMIC R
CN121
1.V-8A
2.V+8A
3.V-BB
4.GNDA
5.V+BB
GNDA
R+ R-
L+ L-
GNDA
14
58
14
58
14
58
14
58
14
58
17
8
14
14
58
16
18
18
1
1
14
(DNP1727-E)
To POWER SUP. ASSY
(J121)
To TERMINAL ASSY
(CN107)
To TERMINAL ASSY
(CN151)
Q603 Q231–Q234 Q602 Q605 Q604 Q601
IC17 IC233 IC232 IC603 IC231 IC604 IC602 IC605 IC601
PHONE ASSY
BAL.OUT ASSY
SIDE A
C1105 (SIDE B)
C1106 (SIDE B)
C1109 (SIDE B)
C1110 (SIDE B)
C1107 (SIDE B)
C1103
(SIDE B)
C1104
(SIDE B)
C1108 (SIDE B)
C1102
(SIDE B) C1101
(SIDE B)
C249
C251
C252
C250
JA232 JA231
W247
1
CP1 V0
J108
J250 J251
GNDA
L+
L-
GNDA
R-
R+
DWZ1147- DNX2236-B
6