Zenith DVD5201 Service Manual
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Zenith DVD5201 Service Manual

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See also: Operating Manual
SERVICE MANUAL
Product Type:
Chassis:
Manual Series: VR166
Manual Part #: 923-03461
Model Line:
Product Year:
Made/Printed
in the U.S.A.
DVD Player
DVD2
D
2001
CONTENTS
OVERVIEW ........................................................ 5
DISASSEMBLY .................................................... 8
MECHANISM .................................................... 10
ELECTRICAL ..................................................... 14
PARTS ............................................................ 28
DIAGRAMS ...................................................... 37
SCHEMATICS .................................................... 38
Published by Technical Publications
Zenith Electronics Corporation
P.O. Box 240007
Huntsville, Alabama 35824
Copyright
June 2001 by Zenith Electronics Corporation
Model Series:
DVD5201
DVD5591

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Summary of Contents for Zenith DVD5201

  • Page 1 MECHANISM ............ 10 ELECTRICAL ............. 14 PARTS ............28 DIAGRAMS ............37 SCHEMATICS ............ 38 Published by Technical Publications Zenith Electronics Corporation P.O. Box 240007 Huntsville, Alabama 35824  Copyright June 2001 by Zenith Electronics Corporation Made/Printed in the U.S.A.
  • Page 2 When servicing this product, under no circumstances should the original design be modified or altered without permission from Zenith Electronics Corporation. All components should be replaced only with types identical to those in the original circuit and their physical location, wiring and lead dress must conform to original layout upon completion of repairs.

  • Page 3: Table Of Contents

    DIAGRAMS ............37 DVD5201/5591 EXPLODED VIEW ..... 37 SCHEMATICS ............ 38 DVD5201/5591 POWER SUPPLY CIRCUIT ..38 DVD5201/5591 DVD AND DSP CIRCUIT .... 39 DVD5201/5591 DRIVE AND RF CIRCUIT ... 40 DVD5201/5591 MICRO CIRCUIT ...... 41 DVD5201/5591 MEMORY CIRCUIT ....42 DVD5201/5591 TIMER CIRCUIT ......

  • Page 5: Overview

    OVERVIEW OVERVIEW FEATURES • 5 Disc Changer • MP3 Decoding • DTS®/Dolby Digital® Capable • Component Video Output • Universal Remote Control with Shuttle • Zoom (4X, 16X) • Still Pause and Frame Advance • EZ Search, EZ Scan with Marker •...

  • Page 6: Package Contents

    OVERVIEW PACKAGE CONTENTS 810 CABLE SET ASS'Y BATTERY OWNER'S MANUAL REMOCON PACKING SHEET PACKING PACKING BOX CARTONX OPTIONAL PARTS VR166 - 923-03461 DVD2 - OVERVIEW...

  • Page 7: Servicing Precautions

    SERVICING including Metal pan-els, Input terminals, Earphone jacks, SERVICING PRECAUTIONS etc. Before servicing the DVD covered by this service data ELECTROSTATICALLY SENSITIVE (ES) DEVICES (and its supplements and addendums), read and follow Some semiconductor (solid state) devices can be the safety precautions. If unforeseen circumstances create damaged easily by static electricity.

  • Page 8: Disassembly

    CHASSIS DISASSEMBLY Note: Before removing the main circuit board, be sure to shortcircuit the laserdiode output land. After replacing the main circuit board, open the land after inserting the flexible connecto r. (Refer to Mechanism Disassembly) 1. Disassemble Main circuit board, Jack 2.
  • Page 9 CHASSIS CABINET DISASSEMBLY 3. Front Panel 1. Eject the disc tray. (See Fig. 2-2) 1. T op Case 2. Remove the tray door. (See Fig. 2-2) 1. Release 7 screws (A). (See Fig. 2-1) 3. Pull the front panel toward you while pressing 2.

  • Page 10: Mechanism

    MECHANISM MECHANISM ¥ T op V iew (W ith T ray) 3 Screws 2 Connectors 1 Hook 2 Locking T abs 1 Screw 2 Locking T abs 2 Screws 1 Connector 2 Screws ¥ T op V iew (W ithout T ray) 1 Screw 2 Screws 5 Connectors...
  • Page 11 MECHANISM HOLDER CLAMP PL ATE CLAMP (S1) (S1) (S1) PL ATE CLAMP MAGNE T CLAMP (H1) HOLDER CLAMP UPPER CLAMP BASE TR AY (L1) (C2) (C1) BASE MAIN (L1) BASE ASSEMB LY TR AY Fig. 4-1 Fig. 4-2 2-1. T ray Disc(Fig.4-2) 1 ) Release 3 Screws(S1).
  • Page 12 MECHANISM (L3) GEAR MIDDLE GEAR ASSEMB LY FEED GEAR ASSEMB LY RACK (S7) RUBBER REAR RUBBER DAMPER (S8) RUBBER REAR (S7) (S7) PICK U P ASSEMB LY GENERAL BASE PU(OUTSE R T) (S7) (C7) RUBBER DAMPER PICK U P ASSEMB LY GENERAL MOT OR ASSEMB LY GEAR UP/DOWN (S5)
  • Page 13 MECHANISM (S10) GEAR SLIDER GEAR MAIN (S12) Fig.(B) GEAR UP/DOWN GEAR EXCHANGE (S11) (S13) GEAR LOADING (S15) Fig.(C) MOT OR ASSEMB LY MAIN (S15) GEAR WHEE L MAIN (S14) BASE MAIN MOT OR ASSEMB LY MAIN (L4) (C9) (C8) MODE SWITCH Fig.(A) (S9) PCB ASSEMB LY MAIN MODE...

  • Page 14: Electrical

    ELECTRICAL ELECTRICAL BLOCK DIAGRAMS 5591 Main EE_CS , EE_CLK , EE _OUT DISC DVD: A,B,C,D, DVD: A,B,C,D, IC502 IC3F1 DVD; RF IC304 IC2A1 CD: A,B, E, F FLASH 93C46 MIRR SDRAM TA33P3721 EEPROM RF_XLAT , LDON 16/32BIT IC301 /FLD_CS LADD XC9572VL FLD_CLK [04:19]...
  • Page 15 ELECTRICAL 5591 Audio COMM_DATA U-COM COMM_CLK IC402 DAC_CS IC401 LPF & Buffer PCM1716 NJM4580D LRCK Audio DAC MPEG DA_BCK OP AMP DA_XCK A_0WT3 /SRST IC452 COMM_DATA NJM4580D COMM_CLK µ -COM DAC_CS2 IC451 /SRST IC453 PCM1600 DA_XCK NJM4580D 5.1ch Auto DAC DA_BCK MPEG LR CLK...
  • Page 16 ELECTRICAL MPEG IC304 MIRR RF & SDRAM IC301 LDON MOTOR 16/32BIT IC502 XC9572VL EE_CS 93C46 CPLD EEPROM I/O PORT 72 MCLK2 MA[00:10] MD[00:31] MA12,13 /RAS/ /CS0 /CAS AD[00:15] F_IN /DQM[0:3] IC3F1 FLASH SPINDLE_FG MEMORY LA[0:3] AD[0:7] DVD[0:7] LADD[04:19] LA[0:3] IC302/IC303 SCLK,SDATA LATCH SQCK,SQS0...
  • Page 17 ELECTRICAL Power RECTIFIER(FLD) -27VA 12VA RECTIFIER(14V) -12VA RECTIFIER(9V) REG(8V) 5.2VA 5V_D RECTIFIER(5.2V) 5V_A REG(3.3V) 3.3V,3.3V_M FEED B. 2.5V REG(3.3V) RECTIFIER(3.8V) AC120V PWR ON/OFF VR166 - 923-03461 DVD2 - SERVICING...

  • Page 18: Troubleshooting

    ELECTRICAL TROUBLESHOOTING 1. Power(SMPS) Circuit No 5V_D No Display or 5V_ A . Is 5.2VA section working? Is 5.2VA section working? (Is the POWER CT L at Pin6 High/low?) Is oscillation present at the Are D109, L103 open? Base of Q108? No 5.2VA.
  • Page 19 ELECTRICAL 2. µ-COM Circuit A. No Power POWER ON Does “Hello” appear at FLD? Is P3901 Does “DV 50" Bars appear? connected normally? Reconnect it. Does Logo appear Check power. on the screen? (Refer to power) If power is normal Is P3901 Pin 8, 9, 18 normal? Refer to Front Part The waveform...
  • Page 20 ELECTRICAL B. Audio abnormal C. Video abnormal AUDIO ABNORMAL VIDEO ABNORMAL Check Audio jack. Check Video jack. YES (If OK) YES (If OK) Refer to Audio Circuit Refer to V ideo Circuit. YES (If OK) YES (If OK) Refer to Decoder Circuit Refer to Micro Circuit YES (If OK) YES (If OK)
  • Page 21 ELECTRICAL Servo Circuit Micro Circuit Servo Circuit VR166 - 923-03461 DVD2 - SERVICING...
  • Page 22 ELECTRICAL 4. Front Circuit (Digitron & key) S T AR T Power on. Is oscillation of Check Powe r. LED ON? X901 normal? Check waveform Is Digitron on normally? Replace IC902. of IC901 Pin 6. Do all the Is waveform of IC901 Check waveform buttons work Pin 40 normal?
  • Page 23 ELECTRICAL 3. Micro Circuit Power is on Does Zenith Logo appears Check power & clock. on the screen. Check CD/DVD DSP output Is Micro Circuit Data signal normal signal. Check CD/DVD DSP output Is error signal normal? signal. Is Micro data...
  • Page 24 ELECTRICAL 5. RF/Servo Circuit CHECK POINT(General) Check "2.Micro Circuit Does Does Replace X201 or IC206 TT L pulse output to 33.8688MHz clock input IC201 Pins 140, 142? (30MHz clock defect) to IC201 Pin 63? Replace IC201 (IC206 soldering or IC defect). Is IC201 Check power circuit.
  • Page 25 ELECTRICAL No disc Power on Check loading Part. Push Pick-up to inner track to Does tray open or close? the end by hand. Does DECK assembly is defective. PMD03 Pin 6 change (Limit sw) high to low? check Micro Circuit Replace IC2M1.
  • Page 26 ELECTRICAL DISC IN OPEN/CLOSE Fig.3. FOCUS ERROR waveform Check IC2A1 Pin 11,12,13,14 FOCUS ON? in DVD Mode IC201 no output : Pick-up is defective. Replace IC201. Replace IC501 or IC201. Check IC2M1 Pin 21, PMD03 Does the disc turn? Pin 5 turn when the IC2M1 Check IC201 and IC2M1 when PMD03 Pin 5 is abnormal Pin 21 is less than 2.2V.
  • Page 27 ELECTRICAL CHECK A Fig.5. RF waveform Check RF Eye-Pattern. No signal: Pick-up is defective Check IC2A1 Pins 5, 6, 7, 8. RF : 1.5-1.6V(IC2A1 Pin 57) Does the sawtooth waveform emit See the eye-pattern vivid? Does the 1.6V emit? Replace IC2A1. at IC2A1 Pin 41? YE S YE S...
  • Page 28 COMPONENT PARTS LIST COMPONENT PARTS LIST REFERENCE CHART The following information is for models in and out of warranty. To Order Parts: call 1-888-3-ZENITH fax 1-888-6-ZENITH MODEL INDENTIFIER DVD5201 By Mail: ZENITH NATIONAL PARTS DVD5591 SALES AND DISTRIBUTION CENTER P O Box 240007...
  • Page 29 CAP, FIXED ELEC 330UF 25V 20% 857-10369 PANEL ASSY, FRONT AB C126 822-10841 CAP, FIXED FILM 0.01UF 630V 10% 828-10103 DOOR ASSY TRAY (DM4952N ZENITH AB C127 822-05689 CAP, FIXED ELECTRO 10UF 16V 20% 5 828-10104 DOOR ASSY TRAY (DM4911N ZENITH AB C128 822-10728 CAP, FIXED FILM 0.047UF 50V 5%...
  • Page 30 COMPONENT PARTS LIST DVD 5201/5591 NOTE: This list will enable you to easily determine the parts used on each Model, Chassis, or Assembly. RC REF PART# DESCRIPTION RC REF PART# DESCRIPTION AB C238 822-10957 CAP, FIXED CERAMIC 0.1UF 50V 80%,-20% AB C2C9 822-10968 CAP, FIXED CERAMIC 33PF 50V 5%...

  • Page 31: Parts

    COMPONENT PARTS LIST DVD 5201/5591 NOTE: This list will enable you to easily determine the parts used on each Model, Chassis, or Assembly. RC REF PART# DESCRIPTION RC REF PART# DESCRIPTION AB C408 822-10957 CAP, FIXED CERAMIC 0.1UF 50V 80%,-20% C492 822-10957 CAP, FIXED CERAMIC 0.1UF 50V 80%,-20%...
  • Page 32 COMPONENT PARTS LIST DVD 5201/5591 NOTE: This list will enable you to easily determine the parts used on each Model, Chassis, or Assembly. RC REF PART# DESCRIPTION RC REF PART# DESCRIPTION AB C906 822-06765 CAP, FIXED TUBULAR 33PF D 50V 5% AB IC304 905-10686 IC, HYUNDAI HY57V653220CTC-7 86P AB C907...
  • Page 33 COMPONENT PARTS LIST DVD 5201/5591 NOTE: This list will enable you to easily determine the parts used on each Model, Chassis, or Assembly. RC REF PART# DESCRIPTION RC REF PART# DESCRIPTION AB Q2M3 921-02271 TRANSISTOR, BIPOLAR CHIP KRC103S-T1(NC)22-22 AB R236 863-11156 RESISTOR, METAL GLAZED(CHIP) 100 OHM 1/16W AB Q301...
  • Page 34 COMPONENT PARTS LIST DVD 5201/5591 NOTE: This list will enable you to easily determine the parts used on each Model, Chassis, or Assembly. RC REF PART# DESCRIPTION RC REF PART# DESCRIPTION AB R2E9 863-11175 RESISTOR, METAL GLAZED(CHIP) 5.6K OHM 1/16W AB R329 863-11173 RESISTOR, METAL GLAZED(CHIP) 4.7K OHM 1/16W...
  • Page 35 COMPONENT PARTS LIST DVD 5201/5591 NOTE: This list will enable you to easily determine the parts used on each Model, Chassis, or Assembly. RC REF PART# DESCRIPTION RC REF PART# DESCRIPTION AB R422 863-11158 RESISTOR, METAL GLAZED(CHIP) 10K OHM 1/16W R486 863-11173 RESISTOR, METAL GLAZED(CHIP) 4.7K OHM 1/16W...
  • Page 36 COMPONENT PARTS LIST DVD 5201/5591 NOTE: This list will enable you to easily determine the parts used on each Model, Chassis, or Assembly. RC REF PART# DESCRIPTION RC REF PART# DESCRIPTION AB R590 863-11155 RESISTOR, METAL GLAZED(CHIP) 75 OHM 1/16W AB SW910 885-10071 SWITCH, TACT THVV502GAA POSTECH NON 12V 5A AB R591...

  • Page 39: Diagrams

    Diagrams DVD5201/5591 Exploded View DVD5201/5591 DIAGRAMS DVD5201/5591 DIAGRAMS...

  • Page 40: Schematics

    Schematics DVD5201/5591 Power Supply Circuit Oscillation abnormal PROV 903-10486 Digitron no Power 903-10417 905-10770 903-10417 PROV PROV 903-10517 903-10551 903-10517 SVC681D 8V line dead PROV No Power 3.3V line dead. 811-10036 PROV PROV No Power 5V_A/5V_D, No Power CRITICAL SAFETY COMPONENTS ARE IDENTIFIED BY THE SYMBOL...

  • Page 41: Dvd5201/5591 Dvd And Dsp Circuit

    DVD5201/5591 DVD and DSP Circuit µ -com µ -com CD/DVD picture Interface Data Spindle Servo fail Interface adress audio abnormal MPEG Interface PROV DVD/CD picture Line audio abnormal IC205 Tracking/Focus 903-10691 Servo fail Disc Detect Error IC201 905-10600 Tracking Servo fail...

  • Page 42: Dvd5201/5591 Drive And Rf Circuit

    DVD5201/5591 Drive and RF Circuit CD/DVD picture abnormal PROV µ -com PROV Interface line PROV PROV PROV PROV PROV PROV PROV Focus Servo fail Tray Loading Speed control DVD laser not operate Turntable PROV not operate Tracking Servo fail PROV...

  • Page 43: Dvd5201/5591 Micro Circuit

    DVD5201/5591 Micro Circuit System not operate No Power on System not working or Audio DAC Interface Digitron not display. IC501 905-10688 PROV PROV PROV PROV DSP interface line Spindle Motor Y/Pb/Pr(Component) CVBS unstable WAVEFORM Y.c(S-VHS) Audio L/R OUT OPTICAL/COAXITAL OUT...

  • Page 44: Dvd5201/5591 Memory Circuit

    DVD5201/5591 Memory Circuit Program download fail Digitron abnormal Not power on IC305 905-10766 Not memoried setup Menu PROV Digitron all not display System not working Not used Digitron all not display System not working PROV PROV PROV PROV PROV Disc number...

  • Page 45: Dvd5201/5591 Timer Circuit

    DVD5201/5591 Timer Circuit Digitron abnormal System not operate Remocon not operate Power not control Digitron abnormal CRITICAL SAFETY COMPONENTS ARE IDENTIFIED BY THE SYMBOL NEXT TO VOLTAGES ARE DC MEASURED WITH A DIGITAL DVD5201/5591 SHEET 43 THEIR COMPONENT DESIGNATORS OR ARE SHADED. REPLACE ONLY WITH PART VOLTMETER DURING PLAY MODE.

  • Page 46: Dvd5201 Audio/Video Circuit

    DVD5201 Audio/Video Circuit R446 Q408 KTC3875 R445 R441 R444 Q407 Q401 is defective 2CH. 2.2K KTC3875 R442 Audio out bad. R443 PROV PROV PROV PROV IC401 is defective. 2CH Audio out bad. IC401 is defective. 2CH Audio out bad. PROV IC403, Q404 are defective.

  • Page 47: Dvd5591 Audio/Video Circuit

    PROV PROV PROV PROV CRITICAL SAFETY COMPONENTS ARE IDENTIFIED BY THE SYMBOL NEXT TO VOLTAGES ARE DC MEASURED WITH A DIGITAL DVD5201/5591 SHEET 45 THEIR COMPONENT DESIGNATORS OR ARE SHADED. REPLACE ONLY WITH PART VOLTMETER DURING PLAY MODE. NUMBERS SPECIFIED.

  • Page 48: Dvd5201 Jack Circuit

    DVD5201 Jack Circuit PROV PROV PROV CRITICAL SAFETY COMPONENTS ARE IDENTIFIED BY THE SYMBOL NEXT TO VOLTAGES ARE DC MEASURED WITH A DIGITAL DVD5201/5591 SHEET 46 THEIR COMPONENT DESIGNATORS OR ARE SHADED. REPLACE ONLY WITH PART VOLTMETER DURING PLAY MODE.

  • Page 49: Dvd5591 Jack Circuit

    DVD5591 Jack Circuit PROV PROV PROV CRITICAL SAFETY COMPONENTS ARE IDENTIFIED BY THE SYMBOL NEXT TO VOLTAGES ARE DC MEASURED WITH A DIGITAL DVD5201/5591 SHEET 47 THEIR COMPONENT DESIGNATORS OR ARE SHADED. REPLACE ONLY WITH PART VOLTMETER DURING PLAY MODE. NUMBERS SPECIFIED.

  • Page 50: Dvd5201/5591 Main Pcb Layout

    DVD5201/5591 Main PCB Layout LOCATION GUIDE (BOTTOM SIDE) (TOP SIDE) CRITICAL SAFETY COMPONENTS ARE IDENTIFIED BY THE SYMBOL NEXT TO VOLTAGES ARE DC MEASURED WITH A DIGITAL DVD5201/5591 SHEET 48 THEIR COMPONENT DESIGNATORS OR ARE SHADED. REPLACE ONLY WITH PART VOLTMETER DURING PLAY MODE.

  • Page 51: Dvd5201/5591 Pcb Layouts

    DVD5201/5591 PCB Layouts SMPS LOCATION GUIDE A/V JACK LOCATION GUIDE CONTROL PANEL CRITICAL SAFETY COMPONENTS ARE IDENTIFIED BY THE SYMBOL NEXT TO VOLTAGES ARE DC MEASURED WITH A DIGITAL DVD5201/5591 SHEET 49 THEIR COMPONENT DESIGNATORS OR ARE SHADED. REPLACE ONLY WITH PART VOLTMETER DURING PLAY MODE.

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