So, I just want to bring some information from my experience analyzing the SCEx checks, OPUs and trying to understand their spindle motor lubrication.
In the 5501 videos, the OPUs are clearly reading poorly just by hearing the sound they produce. The FMVs play well but that doesn't mean the OPUs work as intended since there is no seeking or change in disc speed while playing them.
With a perfect OPU, the 1x-2x speed changes and seeking should be smooth (no lens hissing noise when spinning up), there shouldn't be any loud ticks (lens loosing tracking/focus and resetting itself) or the disc suddenly increasing or decreasing a little bit its speed for no reason then going back to normal speed.
This "sector count", as you call it, is simply a seeking in a slow way. The only time it should happen in the normal boot sequence is when the OPU reads a game exe that is located at the middle or end of the disc and then the ReadTOC command (CdControl() 0x1E command) is issued to the CD controller.
This command will slow down the disc to 1x and do this slow seeking until it finds the leadin to read the TOC and do a SCEx check at the same time which will take a few seconds for these games. I guess the fact that some of them have their exe not at the beginning means that the people mastering them didn't know or didn't care to adjust the disc layout (see CDGen doc in PsyQ SDK) for a faster boot and they shipped the master discs to Sony like that which is a shame, unless there is a good reason I'm not aware of.
Another thing, in the videos, just before this "sector count", we can see/hear that the sled starts to move but goes back to home.
What happens is that the PS1 first tried to do a fast seeking to reach the exe but the focus/tracking was too bad while doing it that it resetted and it went back to home position, then it did this slow seeking to reach it probably as a fallback way.
Also, while doing some OPU swapping tests, I noticed that the 550x motherboard was driving the sled more quickly and "aggressively" than the 100x to get less seek latency and that increases the probability of seeking failures.
This explains why the 5501 does the "sector count" but not the DTL no matter the OPU as you say in the 1st DTL video.
To me, that looks like a poor lubrication of the spindle motors, I don't think the high ESR caps have a significant role in these specific seeking issues.
I'm still a noob at mechanics and their maintenance, oiling and stuff but I did some experiments and I think I finally correctly oiled 2 spindle motors from OPUs that had similar issues as yours.
Months ago, I tried spreading WD-40 at the back of the motor and that worked for a bit of time but the WD-40 evaporated and the reading issues appeared again.
Then, I tried fine oil but I put way too much of it and sure, the motor was completely silent but the OPU was reading even worse than before.
Then I learnt that we're supposed to put a tiny bit of oil in the right holes at the back and at the front of the motor like the guy says in this video (which is a motor from an old sewing machine but I guess the advices also work for the OPU motors?):
https://www.youtube.com/watch?v=MvdFrL3GlAU
So I cleaned the motor with isopropyl alcohol (no idea if this is harmful for the motor but that worked, it was rattling again) then I did put one drop in the proper hole at the back of the spindle motor.
I didn't see any improvements, the motor was still rattling even after adding one more drop at that same location. I was then thinking that I should try to add oil at the front.
I've seen this video where the guy puts the oil directly at the base of the shaft output:
https://www.youtube.com/watch?v=L_0SKz8aHRk
I did like him and that actually worked (not really easy to do because I didn't want to remove the fragile ceramic spindle hub to access the area to oil).
My two OPUs are now reading the discs way better and really smoothly even if that's still not perfect. No idea how long that will last though.
The following videos show the KSM-440ACM OPU from SCPH-1002 on SCPH-5502 before and after proper lubrication.
The game exe is located at the end (LBA 232216) and you will see that the OPU also does the "sector count" in the 1st video to reach it but that doesn't happen anymore in the 2nd video. Btw, this disc has almost no scratches.
Poorly lubricated (too much oil in windings):
Properly lubricated:
I should also mention that the caps on both my 1002 and 5502 motherboards are probably bad because the RF signal is lower than my 7502 and 102 with the same audio CD-ROM and OPUs (about 1Vpp on 7502 and 102 but only 900mVpp on 1002 and 5502).
Now, about the debug DTL, I knew they could boot any disc but I never took a closer look until now.
The boot sequence is quicker on those because the ReadTOC commands are simply not sent to trigger the SCEx checks again and these steps take some time to do depending on where the lens is.
Also, I noticed that the DTL has almost the same boot process as a Stealth Unlocker equipped PS1. Even though this ROM allows the normal boot sequence to play, the secret unlock procedure changes the behaviour.
To better understand, this may not be completely exact but I listed the boot steps on a normal 550x with/without Stealth Unlocker and on the DTL based on my own experience and by checking on no$psx with the debug TTY enabled to see the CD commands sent.
Normal 550x boot sequence with legit disc inserted:
1. Start spinning the disc at 1x speed, do automatic servo adjustments, quick sled movement then go back to home position in leadin
2. Read the TOC and do the first SCEx check at the same time (equivalent of ReadTOC command but done automatically, the main CPU is not involved), when success, the OPU goes in program area and pause mode is set
3. Wait end of Sony logo animation stuff
4. Send the ReadTOC command to seek in leadin, read the TOC and do the second SCEx check at the same time, when success, the OPU goes in program area and pause mode is set
5. Speed up to 2x
6. Read the license text and PS logo from disc
7. Display the PS logo screen
8. Slow down to 1x (no idea why, seems useless) then instantly speed up to 2x
9. Read the ISO 9660 filesystem stuff and then fast seek to read the exe
10. Send the ReadTOC command to slow down to 1x, do the slow seeking until reaching the leadin (will last a few seconds if the exe is at the end of the disc), read the TOC and do the third SCEx check at the same time, when success, the OPU goes in program area and pause mode is set
11. Launch the game (which usually triggers the 2x speed)
Stealth Unlocker (version 220814c from Unirom 8.0.K) equipped 550x boot sequence with CD-R inserted:
1. Start spinning the disc at 1x speed, do automatic servo adjustments, quick sled movement then go back to home position in leadin
2. Read the TOC and do the first SCEx check at the same time (equivalent of ReadTOC command but done automatically, the main CPU is not involved), the CPU waits until SCEx check timeout since no SCEx in leadin (usually takes 5-6s), then the OPU goes in program area and pause mode is set
3. Speed up to 2x
4. Read the license text and PS logo from disc
5. Display the PS logo screen (SCEx appears if correct SCEx region on the disc, otherwise no SCEx appears)
6. Slow down to 1x (no idea why, seems useless) then instantly speed up to 2x
7. Read the ISO 9660 filesystem stuff and then fast seek to read the exe
8. Launch the game (which usually triggers the 2x speed but here it is already enabled)
Debug DTL-H1001H boot sequence with CD-R inserted:
1. Start spinning the disc at 1x speed (no servo adjustments like above since they are manual on the board, current position is in leadin)
2. Read the TOC and do the first SCEx check at the same time (equivalent of ReadTOC command but done automatically, the main CPU is not involved), seems to success instantly then the OPU goes in program area and pause mode is set (infered from the multiple ticks in the 1st DTL video at 00:13, otherwise no ticks and waiting 5-6s for the SCEx signal like in retail 1001)
3. Wait end of Sony logo animation stuff
4. Speed up to 2x
5. Read the license text and PS logo from disc
6. Display the PS logo screen (SCEx appears if correct SCEx region on the disc, otherwise no SCEx appears)
7. Slow down to 1x (no idea why, seems useless) then instantly speed up to 2x
8. Read the ISO 9660 filesystem stuff and then fast seek to read the exe
9. Launch the game (which usually triggers the 2x speed but here it is already enabled)