Toshiba HD-XA1KN User manual

HD DVD PLAYER
SERVICE MANUAL
Mar., 2006 GREEN
FILE NO. 810-200631GR
HD-XA1KN
HD-A1SN
HD-D1KN
The above models are classified as green products (*1), as indicated by the underlined serial numbers.
This Service Manual describes replacement parts for the green products. When repairing these green
product(s), use the part(s) described in this manual and lead-free solder (*2).
For (*1) and (*2), see the next page.
(HD-XA1KN)
DOCUMENT CREATED IN JAPAN, MARCH, 2006
Revision 1

(*1) GREEN PRODUCT PROCUREMENT
The EC is actively promoting the WEEE & RoHS Directives that define standards for recycling
and reuse of Waste Electrical and Electronic Equipment and for the Restriction of the use of
certain Hazardous Substances. From July 1, 2006, the RoHS Directive will prohibit any marketing
of new products containing the restricted substances.
Increasing attention is given to issues related to the global environmental.Toshiba Corporation
recognizes environmental protection as a key management tasks, and is doing its utmost to
enhance and improve the quality and scope of its environmental activities. In line with this,
Toshiba proactively promotes Green Procurement, and seeks to purchase and use products,
parts and materials that have low environmental impacts.
Green procurement of parts is not only confined to manufacture.The same green parts used in
manufacture must also be used as replacement parts.
(*2) LEAD-FREE SOLDER
This product is manufactured using lead-free solder as a part of a movement within the consumer
products industry at large to be environmentally responsible. Lead-free solder must be used in the
servicing and repair of this product.
WARNING
This product is manufactured using lead free solder.
DO NOT USE LEAD BASED SOLDER TO REPAIR THIS PRODUCT !
The melting temperature of lead-free solder is higher than that of leaded solder by 86°F to 104°F
(30°C to 40°C). Use of a soldering iron designed for lead-based solders to repair product made
with lead-free solder may result in damage to the component and or PCB being soldered. Great
care should be made to ensure high-quality soldering when servicing this product especially when
soldering large components, through-hole pins, and on PCBs as the level of heat required to melt
lead-free solder is high.

PREPARATION OF SERVICING
Pickup Head consists of a laser diode that is very susceptible to external static electricity.
Although it operates properly after replacement, if it was subject to electrostatic discharge during replacement, its
life might be shortened. When replacing, use a conductive mat, soldering iron with ground wire, etc. to protect the
laser diode from damage by static electricity.
And also, the LSI and IC are same as above.
LASER BEAM CAUTION LABEL
When the power supply is being turned on, you may not remove this laser cautions label. If it removes, radiation of a laser
may be received.
·Manufactured under license from Dolby Laboratories. “Dolby” and the double-D symbol are trademarks of Dolby Laboratories.
·Manufactured under license from Digital Theater Systems, Inc. U.S. Pat. No’s. 5,451,942; 5,956,674; 5,974,380; 5,978,762; 6,226,616;
6,487,535 and other U.S. and world-wide patents issued and pendling.
“DTS” and “DTS Digital Surround” are registered trademarks of Digital Theater Systems, Inc.
Copyright 1996, 2003 Digital Theater Systems, Inc. All Rights Reserved.
·HDMI, the HDMI logo and High-Definition Multimedia Interface are trademarks or registered trademarks of HDMI Licensing LLC.
·SHARC is a registered trademark and Melody is a trademark of Analog Devices, Inc.
·All other brand and product names mentioned in this manual are trademarks and/or registered trademarks of their respective holders.

SAFETY NOTICE
SAFETY PRECAUTIONS
LEAKAGE CURRENT CHECK
Plug the AC line cord directly into a 120V AC outlet (do
not use an isolation transformer for this check). Use an
AC voltmeter, having 5000 Ωper volt or more sensitivity.
Connect a 1500 Ω10 W resistor, paralleled by a 0.15 μF
150V AC capacitor between a known good earth ground
(water pipe, conduit, etc.) and all exposed metal parts of
cabinet (antennas, handle bracket, metal cabinet
screwheads, metal overlays, control shafts, etc.).
Measure the AC voltage across the 1500 Ωresistor.
The test must be conducted with the AC switch on and
then repeated with the AC switch off. The AC voltage
indicated by the meter may not exceed 0.3 V. A reading
exceeding 0.3 V indicates that a dangerous potential
exists, the fault must be located and corrected.
Repeat the above test with the DVD PLAYER power plug
reversed.
NEVER RETURN A DVD PLAYER TO THE CUSTOMER
WITHOUT TAKING NECESSARY CORRECTIVE AC-
TION.
READING SHOULD NOT EXCEED 0.3V
The lightning flash with arrowhead symbol, within an
equilateral triangle, is intended to alert the user to the
presence of uninsulated “dangerous voltage” within the
product’s enclosure that may be of sufficient magnitude to
constitute a risk of electric shock to persons.
The exclamation point within an equilateral triangle is
intended to alert the user to the presence of important
operating and maintenance (servicing) instructions in the
literature accompanying the appliance.
DVD PLAYER
AC VOLTMETER
(5000 Ωper volt
or more sensitivity)
Good earth ground
such as a water pipe,
conduit, etc.
1500 Ω
10 W
0.15 μF 150V AC
AC OUTLET
Test all exposed metal.
Voltmeter Hook-up for Leakage Current Check

SECTION 2
PART REPLACEMENT AND ADJUSTMENT PROCEDURES
SECTION 3
SERVICING DIAGRAMS
1. CIRCUIT SYMBOLS AND
SUPPLEMENTARY EXPLANATION
1-1. Precautions for Part Replacement
1-2. Solid Resistor Indication
1-3. Capacitance Indication
1-4. Inductor Indication
1-5. Waveform and Voltage Measurement
1-6. Others
2. PRINTED WIRING BOARD AND
SCHEMATIC DIAGRAM
3. BLOCK DIAGRAMS
3-1. Overall Block Diagram
4. CIRCUIT DIAGRAMS
4-1. Power Supply Circuit Diagram
4-2. Front Circuit Diagram
4-2-1. PWR-SW Circuit Diagram
4-2-2. USB Circuit Diagram
4-2-3. Front-MAIN Circuit Diagram
4-2-4. Door-Detect Circuit Diagram (HD-XA1)
4-2-5. Motor Circuit Diagram (HD-XA1)
4-3. AV Circuit Diagram
4-3-1. Audio Circuit Diagram
4-3-2. Video Circuit Diagram
4-3-3. HDMI Circuit Diagram
5. PC BOARDS
5-1. Front Main PC Board
5-2. PWR-SW PC Board
5-3. Door-Detect PC Board (HD-XA1)
5-4. USB PC Board
5-5. Motor PC Board (HD-XA1)
5-6. AV PC Board
CONTENTS
SECTION 1
GENERAL DESCRIPTIONS
1. REPLACEMENT OF MECHANICAL PARTS
1-1. Cabinet Replacement
1-1-1. Top Panel and Top Cover
1-1-2. Front Panel and Motor
1-1-3. Sub-chassis
1-1-4. HD-DVD Drive
1-1-5. Rear Panel
1-1-6. Fan
1-2. PC Board Replacement
1-2-1. Digital PC Board
1-2-2. CPU
1-2-3. SO-DIMM
1-2-4. Power PC Board
1-2-5. AV PC Board
1-2-6. Front PC Boards
2. WIRING CONNECTION DIAGRAM
2-1. Wiring Connection Diagram
2-2. Supplementary Instructions for Reassembling
3. TROUBLESHOOTING
3-1. Standby LED (red) does not lisht.
3-2. LED (green) does not light at power on.
3-3. CPU FAN does not work.
3-4. Indicator does not light. (“WELCOME” does not
light at startup.)
3-5. System does not run. (“WELCOME” displayed and
key operation disabled)
3-6. No picture appears.
3-7. No audio is played back.
3-8. Buzzer does not sound.
3-9. Extension port does not work.
3-10. Front panel key/remote control are disabled.
3-11. Other Symptoms
3-12. Power Circuit Troubleshooting
MEASURING POINTS
SECTION 4
PARTS LIST
SAFETY PRECAUTION
NOTICE
ABBREVIATIONS
1. EXPLODED VIEWS
1-1. Packing Assembly
1-2. Cabinet Assembly 1 (HD-XA1)
1-3. Cabinet Assembly 2 (HD-A1/HD-D1)
1-4. Chassis Assembly
2. PARTS LIST
1. OPERATING INSTRUCTIONS
2. LOCATION OF MAIN PARTS
2-1. Location of Main Parts
2-2. Location of PC Boards
SUPPLEMENT
SUPPLEMENT1. Firmware Version Update
SUPPLEMENT2. Error display

SECTION 1
GENERAL DESCRIPTIONS
1. OPERATING INSTRUCTIONS
Please refer to the owner's manual about the contents.
SECTION 1
GENERAL DESCRIPTIONS

2. LOCATION OF MAIN PARTS
This section describes the location of main parts and PC boards of HD-XA1 as a representative.
2-1. Location of Main Parts
Fig. 1-2-1
2-2. Location of PC Boards
Fig. 1-2-2
HD-DVD DRIVE
CPU FAN FAN
Power PC board
SO-DIMM
DOOR-DETECT PC board
PWR-SW PC board
USB PC board
AV PC board
Front Main PC board
Dgital PC board
CPU
FLASH ROM MODULE


3. TROUBLESHOOTING
3-1. Standby LED (red) does not light.



3-2. LED (green) does not light at power on.










START (1)㩷
VCC+6V supplied to pin
16 of PJ11 from power
unit?㩷
Replace power unit.㩷
START (2)㩷
LEDOUT1 on pin 6 of PJ7
is “H”?
Replace FFC cable.㩷 Failure of digital unit
PJ7 FFC cable inserted
correctly? Replace front unit.㩷
Yes
No
Yes㩷
No㩷
Yes
No㩷
LEDOUT1 on pin 6 of
PJ7 is “L”?
Yes㩷
No
Replace front unit.㩷
Failure of digital unit㩷


3-3. CPU FAN does not work.


3-4. Indicator does not light. (“WELCOME” does not light at startup.)










START (3)㩷
Pin 1 of PJ8770
develope 5V±5%? Replace CPU FAN unit.㩷
Power circuit
troubleshooting㩷
Yes
No㩷
START (4)㩷
Pin 4 of PJ7 reset and
VFD driver IF bus
working at startup?
1: CS#
2: CLK
3: RESET#
4: DOUT
Replace FFC cable.㩷
Failure of digital unit㩷
PJ7 FFC cable inserted
correctly?
Replace front unit or
power unit.
Yes
No
Yes㩷
No㩷
㩷


3-5. System does not run. (“WELCOME” displayed and key operation disabled)

START (5)㩷
LED on FLASH ROM
module (PJ15) flashing
about 10 seconds after
power on?
Power circuit troubleshooting㩷
Failure of digital unit
Yes㩷
No TP105(P5V) voltage
output correctly?
No
Yes
LED of FLASH ROM
module (PJ15) lights up after
replacement?
Upgrade firm
w
are
again.㩷
Yes
No
SO-DIMM module
(PJ1420) inserted
correctly?
Insert again or
replace SO-
DIMM?㩷
No
To (A)
Connecto
r
(PJ9) of
DVD drive and
power connector
connected
tl ?
Check PJ9 connection
and replace FFC cable.
No㩷
System is
r
estored
after firmware
upgrade?
Yes㩷
Upgrade firmware again.㩷
No㩷
(A)㩷
END㩷
Yes㩷Failure of digital unit
Yes
To (5)
Replace
DVD drive.
Not
restored Restored


3-6. No picture appears.


START (6)㩷
PJ730 and cable
normal? Check and replace PJ730 cable.
Yes㩷
No
PJ731 and FFC cable
normal?
Check and replace PJ731 FFC cable.
No
Both components and
HDMI do not output
picture?
Yes㩷
Check and replace PJ731 FFC cable.
Replace AV unit.㩷
No
Yes㩷
Replace AV unit
or
failure of di
g
ital unit.㩷
Yes㩷
PJ732 and FFC cable
normal? Check and replace PJ732 FFC cable.
No
xBefore repair, confirm the connection with a TV
and the settings of XA1/A1/D1.


3-7. No audio is played back.
3-8. Buzzer does not sound.


START (7)㩷
All analog, digital, and
HDMI audio are not
played back?
Yes㩷
Check and replace PJ732 㪝FC cable.
Check and replace PJ733 㪝FC cable.
Replace AV unit.
No
Replace AV unit
or
failure of digital unit.㩷
START (8)㩷
[Remote Controller Sound] in
Setup menu selected?
Yes㩷
Select [Remote Controller Sound] in
application’s Setup menu.㩷
Not selected
Failure of digital unit㩷
PJ7 and FFC cable normal? Check and replace PJ7㩷㪝FC cable.
Replace front unit.㩷
No
Selected㩷
xBefore repair, confirm the connection with a TV
and the settings of XA1/A1/D1.


3-9. Extension port does not work.
START (9)㩷
Neithe
r
right port nor
left port works?
Check and replace PJ14 cable o
r
replace front USB unit.㩷
Eithe
r
one port
does not work.
Failure of digital unit㩷
Yes㩷
Device to be connected is
supported?
Check with the device supported by
HD-XA1/A1/D1.㩷
No
Yes㩷
No


3-10. Front panel keys/remote control are disabled.
3-11. Other Symptoms
xImproper LAN connection
LAN depends on the quality of the environment and lines to which LAN is connected. Check the main unit as well as
network settings, cables, and connected devices.
xImproper CONTROL pin connection
Use a serial cross cable to connect the unit to a PC.

Check the above. However, if the problem still remains, the digital unit may be faulty.
START (10)㩷
PJ7 connected correctly?
Yes㩷
Check and replace PJ7㩷㪝FC cable.
Replace front unit.㩷
No
Failure of digit unit㩷
Front LED lighting?
Yes㩷
Change power unit.㩷
No


3-12. Power Circuit Troubleshooting
RTC backup voltage


PowerMeasuring
point
Output voltage
range
(AC OFF)
Output voltage
range
(AC ON)
R3V TP113 2.0-3.0V3.4-3.0V

EVER system voltage
Powerunitoutput
PowerMeasuring
point
Output voltage
range
PS5VSB TP159 5.5-6.5V
EVER system voltage
M/B REG output, etc.
PowerMeasuring
point
Output voltage
range
M5V TP115 4.75-5.25V
M3V TP114 3.13-3.47V
MM5V TP135 4.5-5.0V
MS5V C842-2PIN 4.75-5.25V
Power system voltage
Power unit output
PowerMeasuring
points
Output voltage
range
PS12VDC TP160 11.4-12.6V
PS5VDC TP165 4.75-5.25V
PS3VDC TP164 3.13-3.47V
Yes㩷
Batter
y
(BT1)
erro
r
Incorrect voltage at
AC OFF㩷
Incorrect voltage
at AC ON
Yes㩷
Yes㩷
No
Power unit ON/OFF control signal check
PS_ON(Pin 1 of PJ12)㩷
“L”㩷
“H”
Yes㩷
To (B)㩷To (C)㩷Failure of harness
and/o
r
power unit㩷
No
NoNo
No


Power system voltage
Power unit output
PowerMeasuring
points
Output
voltage range
2R6-P2V TP109 2.5–2.7V
1R2-P1V TP112 1.19–1.26V
2R5-P2V TP108 2.40–2.60V
P5V TP105 4.75–5.25V
1R25-P1V TP162 1.19–1.30V
1R5-P1V TP110 1.45–1.57V
P3V TP107 3.13–3.47V
VID1R2-P1V TP166 1.19–1.26V
1R8-P1V C121-2PIN 1.71–1.89V
VPL3R3-P1V IC560-2/3PIN 3.13–3.47V
APL3R3-P3V C577-2PIN 3.13–3.47V
PCOREV TP111 1.2–1.3V
No
To (B)㩷To (C)㩷
Failure of digital unitEND
Yes㩷


MEASURING POINTS

TP16
TP16
TP16
TP15
PJ1 PJ1
TP10 TP11
TP11
TP11
TP10
TP11
BT1
TP11
TP16
PJ877
TP10
TP10
PJ14 PJ9 PJ7
TP13
C577
IC560
PJ15 C842
TP16
PJ1420
PJ730 PJ731 PJ732 PJ733
Fi
g
. 1-4-1 Di
g
ital Unit (Top Side)



C121
Fi
g
. 1-4-2 Di
g
ital Unit (Bottom Side)

SECTION 2
PART REPLACEMENT AND
ADJUSTMENT PROCEDURES
SECTION 2
PART REPLACEMENT AND
ADJUSTMENT PROCEDURES
CAUTIONS BEFORE STARTING PART REPLACEMENT
Electronic parts are susceptible to static electricity and may be easily damaged, so do not forget to ground as required.
Many screws are used inside the unit. To prevent the screws from missing or dropping, etc. always use magnetized
screwdriver in servicing. Several kinds of screws are used and some of them need special cautions. That is, take care of
the tapping screws securing molded parts and fine pitch screws used to secure metal parts. If they are used improperly,
the screw holes will be easily damaged and the parts can not be fixed.
This section describes how to replace the parts of HD-XA1 as a representative.
1. REPLACEMENT OF MECHANICAL PARTS
1-1. Cabinet Replacement
1-1-1. Top Panel and Top Cover
1. Remove two screws (1), then remove the side panel L (2) and side panel R (3).
2. Remove three screws (4), then remove the top panel (5).
3. Remove four screws (6), then remove the top cover (7).
Fig. 2-1-1
Screws (1)
Screws (1)
Side panel L (2)
Screws (6)
Screws (6)
Top cover (7)
Side panel R (3)
Gasket
Gasket
Screws (4)
Top panel (5)

1-1-2. Front Panel and Motor
1. Remove the top panel and top cover. (Refer to item 1-1-1.)
2. Remove the screw (1), two screws (2), three screws (3), and the screw (4).
3. Remove six claws, then draw the front panel (5).
4. Remove the screw (6), then remove the front panel (5).
5. Disconnect the connectors (7) and (8) and the flexible cable (9).
6. Disconnect the connector (10).
7. Remove the belt (11).
8. Remove two screws (12), then remove the motor (13) in the arrow direction.
Fig. 2-1-2
Connector (8)
Flexible cable (9)
Screw (4)
Screw (6)
Connector (7)
Screws
(2)
Connector (10)
Motor (13)
Screw (1)
Claws
Claws
Claws
Screws (12)
Gasket
Gasket
Gasket
Screws (3) Belt (11)
Gear assy
Front panel (5)