Zenith dvd 5201 service manual

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zenith

SERVICE MANUAL Model Series:

DVD5201
Product Type: DVD Player DVD5591

Chassis: DVD2
Manual Series: VR166
Manual Part #: 923-03461
Model Line: D

Product Year: 2001

CONTENTS
OVERVIEW ........................................................ 5
DISASSEMBLY .....
MECHANISM
ELECTRICAL.
PARTS .....
DIAGRAMS ..
SCHEMATICS .......................

Published by Technical Publications
Zenith Electronics Corporation
P.0. Box 240007
Huntsville, Alabama 35824

Copyright © June 2001 by Zenith Electronics Corporation

Made/Printed
in the U.S.A.

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PRODUCT SAFETY GUIDELINES

IMPORTANT SAFETV NOTICE
This manual was prepared for use only by properly trained audio-visual service
technicians.

When servicing this product, under no circumstances should the original
design be modified or altered without permission from Zenith Electronics
Corporationt 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

Special components are also used to prevent x-radiation. shock and fire hazard.
These components are indicated by the letter x" included in their component
designators and are required to maintain safe performance. No deviations are
allowed without prior approval by Zenith Electronics Corporation.

Circuit diagrams may occasionally differ from the actual circuit used. This way,
implementation of the latest safety and performance improvement changes into
the set is not delayed until the new service literature is printed.

CAUTION: Do not attempt to modify this product in any way. Never perform
customized installations without manufacturer's approvalt Unauthorized
modifications will not only void the warranty. but may lead to property damage
or user injury.

Senrice work should be performed only after you are thoroughly familiar with
these safety checks and servicing guidelines.

GRAPHIC SVMBOLS

The exclamation point within an equilateral triangle is intended
to alert the service personnel to important safety information in
the service literature.

The lightning flash with arrowhead symbol within an equilateral
triangle is intended to alert the service personnelto the presence
of noninsulated "dangerous voltage" that may be of sufficient
magnitude to constitute a risk of electric shock.

The pictorial representation of a fuse and its rating within an
equilateraltriangle is intended to convey to the service personnel
the following fuse replacement caution notice:

A v CAUTION: FOR CONTINUED PROTECTION AGAINST RISK OF FIRE,

REPLACE ALL FUSES WITH THE SAME TYPE AND RATING AS MARKED
NEAR EACH FUSEt

SERVICE INFORMATION

While servicing, use an isolation transformer for protection from AC line shock.
After the original service problem has been corrected, make a check of the
following:

FIRE AND SHOCK HAZARD

1. Be sure that all components are positioned to avoid a possibility of
adjacent component shorts. This is especially important on items trans-
ported to and from the repair shop.

2. Verify that all protective devices such as insulators, barriers, covers,
shields, strain reliefs, power supply cords, and other hardware have been
reinstalled per the original design. Be sure that the safety purpose of the
polarized line plug has not been defeated.

3. Soldering must be inspected to discover possible cold solder joints, solder
splashes, or sharp solder points. Be certain to remove all loose foreign
particles

4. Check for physicalevidence of damage or deterioration to parts and compo-
nents, for frayed leads or damaged insulation (including the AC cord), and
replace if necessary.

5. No lead or component should touch a receiving tube or a resistor rated at
1 watt or more. Lead tension around protruding metal surfaces must be
avoided

6. After reassembly of the set, always perform an AC leakage test on all exposed
metallic parts ofthe cabinet (the channelselector knobs, antenna terminals,
handle and screws) to be sure that set is safe to operate without danger of
electrical shock. DO NOT USE A LINE ISOLATION TRANSFORMER DURING THIS
TESTt Use an AC voltmeter having 5000 ohms per volt or more sensitivity in
the following manner: Connect a 1500 ohm, 10 watt resistor, paralleled by
a 15 mfd 150V AC type capacitor between a known good earth ground
water pipe, conduit, etc.) and the exposed metallic parts, one at a time.
Measure the AC voltage across the combination of 1500 ohm resistor and
JS mfd capacitor. Reverse the AC plug by using a non-polarized adaptor
and repeat AC voltage measurements for each exposed metallic part. Voltage
measured must not exceed 0.75 volts RMS. This corresponds to 0.5 milliamp
AC. Any value exceeding this limit constitutes a potential shock hazard and
must be corrected immediately.

A.C. Vollmeler

[ 0'15}: J Fl m' in
Good Earth Ground , . _ ace Is pro e
such as the Water On each exposed
Pipe, Conduit, etc. 1500 OHM metal part.
10 WATT

X-RADIATION

it Be sure procedures and instructions to all service personnel cover the
subject of x-radiation. The only potential source of x-rays in current TV
receivers is the picture tube. However. this tube does not emit x-rays when
the HV is at the factory-specified level. The proper value is given in the
applicable schematic. Operation at higher voltages may cause a failure of
the picture tube or high-voltage supply and, under certain circumstances
may produce radiation in excess of desirable levels.

2t Only factory-specified CRT anode connectors must be used

3t It is essential that the service personnel have available an accurate and
reliable high-voltage metert

4. When the high-voltage circuitry is operating properly, there is no possibility
of an x-radiation problemt Every time a color chassis is serviced. the
brightness should be run up and down while monitoring the high voltage
with a meter. to be certain that the high voltage does not exceed the
specified value and that it is regulating correctly.

5. When troubleshooting and making test measurements in a product with a
problem of excessively high voltage. avoid being unnecessarily close to
the picture tube and the high voltage power supply. Do not operate the
product longer than necessary to locate the cause of excessive voltage.

fit Refer to HV, B+. and shutdown adjustment procedures described in the
appropriate schematics and diagrams (where used)

IMPLOSION
it All direct view picture tubes are equipped with an integral implosion
protection system: take care to avoid damage during installation

2t Use only the recommended factory replacement tubes.

TIPS 0N PROPER INSTALLATION

it Never install any receiver in a closed-in recess, cubbyhole, or closely
fitting shelf space over. or close to, a heat duct, or in the path of heated
air flow.

at Avoid conditions of high humidity such as: outdoor patio installations
where dew is a factor. near steam radiators where steam leakage is a factor,
etc.

3. Avoid placement where draperies may obstruct venting. The customer
should also avoid the use of decorative scarves or other coverings that
might obstruct ventilation.

A Wall- and shelf-mounted installations using a commercial mounting kit
must follow the factory-approved mounfing instructions. A product mounted
to a shelf or platform must retain its original feet (or the equivalent
thickness in spacers) to provide adequate air flow across the bottom. Bolts
or screws used for fasteners must not touch any parts or wiring. Perform
leakage tests on customized installations.

5. Caution customers against mounting a product on a sloping shelf or in a
tilted position. unless the receiver is properly secured.

fit A product on a roll-about cart should be stable in its mounting to the cart.
Caution the customer on the hazards of trying to roll a cart with small
casters across thresholds or deep pile carpets.

7. Caution customers against using a cart or stand that has not been listed
by Underwriters Laboratories, Inc for use with its specific model of
television receiver or generically approved for use with TVs of the same or
larger screen size.

at Caution customers against using extension cords. Explain that a forest of
extensions, sprouting from a single outlet. can lead to disastrous
consequences to home and family.

VR166 » 923-03461

DVDZ - SAFETY