321 Service Manual_Part1.pdf part of Bose 321 321 Service Manual_Part1.pdf, Service Manual text manual preview

Text preview for : 321 Service Manual_Part1.pdf part of Bose 321 Service Manual

Back to : 321 Service Manual_Part1. | Home

CONTENTS
Accessories ....................................................................................................................................... 2 Safety Information ............................................................................................................................3 Electrostatic Discharge Sensitive (ESDS) Device Handling .........................................................3 Warranty .............................................................................................................................................3 Specifications ................................................................................................................................ 4-7 Figure 1. 3-2-1 Console Block Diagram ............................................................................................ 8 Disassembly/Assembly Procedures ......................................................................................... 9-13 Test Procedures ........................................................................................................................ 14-23 Figure 2. Laser voltage test points .................................................................................................. 16 Figure 3. Laser current rating label ................................................................................................. 16 Figure 4. AM Loop Antenna Test Setup ........................................................................................... 17 Part List Notes ................................................................................................................................. 24 Main Part List, Console Assembly (see Figure 5) ........................................................................ 24 Figure 5. Console Exploded View ................................................................................................... 25 Main Part List, Bass Module Assembly (see Figure 6) ................................................................ 26 Figure 6. Bass Module Assembly Exploded View ........................................................................... 26 Main Part List, Bass Module PCB Assembly (see Figure 7) ........................................................ 27 Figure 7. Bass Module PCB Assembly Exploded View .................................................................. 27 Electrical Part Lists ................................................................................................................... 28-46 Console Main PCB Assembly .................................................................................................. 28-43 Console LCD Display PCB Assembly ..................................................................................... 43-44 Bass Module PCB Assembly ................................................................................................... 45-46 Packaging Part List, 3-2-1 Home Theater System System (see Figure 8) .................................. 46 Figure 8. 3-2-1 Home Theater System Packaging View ................................................................. 47 Accessory Kit Part List, 3-2-1 Home Theater System Accessory Kit (see Figure 9) ................ 48 Figure 9. Accessory Kit Exploded View .......................................................................................... 48 Integrated Circuit Diagrams ..................................................................................................... 49-62 Appendix .................................................................................................................................... 63-85 Figure 10. 3-2-1 Console Test Setup Diagram ................................................................................ 63 Figure 11. 3-2-1 Bass Module Test Setup Diagram ......................................................................... 64 Figure 12. 3-2-1 Speaker Array Wiring Diagram ............................................................................. 64 Figure 13. DVD Mechanism Rear Panel ......................................................................................... 65 Figure 14. Bass Module Test Cable Wiring ...................................................................................... 66 Figure 15. Tap Interface cable wiring diagram ................................................................................. 67 Bass Module Troubleshooting Information .................................................................................. 85 Parental Control Information ......................................................................................................... 85 Table 1. 3-2-1 Console DVD Parental Control Rating Codes .......................................................... 85 Table 2. Region Codes and Covered Areas .................................................................................... 85 Figure 17. LCD Display PCB Component and Bottom Etch Rev. 00 Diagram ................................ 86 Figure 16. LCD Display PCB Component and Topside Etch Rev. 00 Diagram ............................... 86 Figure 19. LCD Display PCB Component and Bottom Etch Rev. 01 Diagram ................................ 87 Figure 18. LCD Display PCB Component and Topside Etch Rev. 01 Diagram ............................... 87 Figure 20. Bass Amplifier PCB Rev. 00 Component and Etch Layout Diagram ............................. 88 Figure 21. Bass Amplifier PCB Rev. 01 Component and Etch Layout Diagram ............................. 89 Glossary of Terms ........................................................................................................................... 90

Preliminary

1

CAUTION: The BoseŽ 3-2-1 Home Entertainment System contains no user-serviceable parts. To prevent warranty infractions, refer servicing to warranty service stations or factory service.

PROPRIETARY INFORMATION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF BOSE CORPORATION WHICH IS BEING FURNISHED ONLY FOR THE PURPOSE OF SERVICING THE IDENTIFIED BOSE PRODUCT BY AN AUTHORIZED BOSE SERVICE CENTER OR OWNER OF THE BOSE PRODUCT, AND SHALL NOT BE REPRODUCED OR USED FOR ANY OTHER PURPOSE.

Accessories The BoseŽ Model 3-2-1 home entertainment system shelf speakers are compatible with Bose mounting accessories, including the UB-20 wall brackets, UFS-20 floor stands and UTS-20 table stands. 2

Preliminary

SAFETY INFORMATION
1. Parts that have special safety characteristics are identified by the symbol on schematics or by special notes on the parts list. Use only replacement parts that have critical characteristics recommended by the manufacturer. 2. Make leakage current or resistance measurements to determine that exposed parts are acceptably insulated from the supply circuit before returning the unit to the customer. Refer to Paragraph 84 of UL1270. Use the following checks to perform these measurements: A. Leakage Current Hot Check-With the unit completely reassembled, plug the AC line cord directly into a 120V AC outlet. (Do not use an isolation transformer during this test.) Use a leakage current tester or a metering system that complies with American National Standards Institute (ANSI) C101.1 "Leakage Current for Appliances" and Underwriters Laboratories (UL) 1492 (71). With the unit AC switch first in the ON position and then in OFF position, measure from a known earth ground (metal waterpipe, conduit, etc.) to all exposed metal parts of the unit (antennas, handle bracket, metal cabinet, screwheads, metallic overlays, control shafts, etc.), especially any exposed metal parts that offer an electrical return path to the chassis. Any current measured must not exceed 0.5 milliamp. Reverse the unit power cord plug in the outlet and repeat test. ANY MEASUREMENTS NOT WITHIN THE LIMITS SPECIFIED HEREIN INDICATE A POTENTIAL SHOCK HAZARD THAT MUST BE ELIMINATED BEFORE RETURNING THE UNIT TO THE CUSTOMER. B. Insulation Resistance Test Cold Check-(1) Unplug the power supply and connect a jumper wire between the two prongs of the plug. (2) Turn on the power switch of the unit. (3) Measure the resistance with an ohmmeter between the jumpered AC plug and each exposed metallic cabinet part on the unit. When the exposed metallic part has a return path to the chassis, the reading should be between 1 and 5.2 Megohms. When there is no return path to the chassis, the reading must be "infinite". If it is not within the limits specified, there is the possibility of a shock hazard, and the unit must be repaired and rechecked before it is returned to the customer.

Preliminary

ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) DEVICE HANDLING
This unit contains ESDS devices. We recommend the following precautions when repairing, replacing or transporting ESDS devices: ˇ Perform work at an electrically grounded work station. ˇ Wear wrist straps that connect to the station or heel straps that connect to conductive floor mats. ˇ Avoid touching the leads or contacts of ESDS devices or PC boards even if properly grounded. Handle boards by the edges only. ˇ Transport or store ESDS devices in ESD protective bags, bins, or totes. Do not insert unprotected devices into materials such as plastic, polystyrene foam, clear plastic bags, bubble wrap or plastic trays.

WARRANTY
The Bose 3-2-1 Home Entertainment System is covered by a limited 1-year transferable warranty
Ž

3

SPECIFICATIONS
System Specifications: Power Rating: Console Inputs: Console Outputs: USA/Canada: 120VAC, 50/60 Hz, 300W AUX, Video 1, Video 2 1 Audio Output (AUX), 1 Composite Video Output and 1 S-Video Output External Antennas: FM, 75 Ohm, 3.5 mm mono connector AM Loop, 2.5 mm mono connector 40 degrees C 47 Watts

Maximum Ambient Temperature: Maximum Product Power Dissipation: Low Frequency Cut-off (-3dB nearfield):

Maximum SPL:

105 dB SPL acoustic output at 400 Hz at 1 meter Packed System: 35.5 lb (16.1 kg) Console: 7.0 lb (2.7 kg) Bass Module: 26.5 lb (12.0 kg) Arrays (each): 3.0 lb (1.4 kg) IR Remote: 0.26 lb (0.1 kg) Console: 9.8 x 12.8 x 3.9 inches (250 mm x 326 mm x 99.5 mm) Bass Module: 14 x 7.5 x 20.1 inches (35.6 cm x 18.4 cm x 51.1 cm) Bass Module internal volume: 1205 cubic inches (19.7 liters) Arrays: 7.9 x 5.3 x 3.4 inches ( 200 mm x 134 mm x 86 mm) IR Remote: (65 mm x 204 mm x 30 mm)

Weight:

Dimensions:

Console Specifications: Compression Formats Supported for discs inserted into the DVD/CD drive: Compression Formats NOT Supported for discs inserted into the DVD/CD drive: 4

AC-3, MP3, CD-RW, MLP, DTS, MPEG-2

SACD Format (Sony), DVD-ROM

Preliminary

Array Cube: 200 Hz Bass Module: 50 Hz

SPECIFICATIONS
Console Specifications (continued): Compression Formats Supported for sources connected to the digital inputs: CD/DVD Drive Performance: Interface: Data Transfer Rate: ATAPI Sustained Mode (DVD): 2704-6536 kbs Sustained Mode (CD-ROM mode 1) 2069-4800 max kbs DVD-ROM CD-ROM (32x) Average Random Seek 105ms-95ms Average Random Access 135ms-95ms Average Full Stroke Access 230ms-160ms

AAC, AC-3, DTS, MPEG-2

Access Time:

Preliminary

CD Playability Requirements:

Parameter Defect tracking (interruption) Defect tracking (black dot) Defect tracking (scratch) Defect tracking (finger print) Defect tracking (warped disc) Defect tracking (eccentric disc) Cueing time
Physical Characteristics:

Nominal 1.0 mm 1.0 mm 1.6 mm 75 ľm 1.0 mm 280 ľm 2 sec

Limit 0.8 mm 0.8 mm 1.0 mm 65 ľm 0.7 mm 210 ľm 3 sec

Conditions ABEX test disc TCD-725R ABEX test disc TCD-725R ABEX test disc TCD-721R ABEX test disc TCD-725R ABEX test disc TCD-732R ABEX test disc TCD-714R Phillips TS4, tracks 1-15

Weight: 2.2 lbs (0.98 kg) Dimensions: 1.6" H x 5.7" W x 7.6" D (41.5 mm x 146 mm x 193 mm) +12 Vdc, +5 Vdc -78 dBFS THD+N, unweighted, 22-22kHz for a 1 kHz signal at FS -1 dB -90 dBFS THD+N, unweighted, 22-22kHz for a 1 kHz signal at FS -10 dB

Power Requirements: Distortion and Noise:

Dynamic Range:

-90 dBFS THD+N, unweighted, 22-22kHz for a 1 kHz signal at FS -60 dB < 0.1% @ 0.5 W < 400 mVrms, A-weighted < 1 mVrms, band limited 400 Hz to 300 kHz < 400 uVrms, A-weighted 5

Distortion: Output Noise: Out of Band Noise (greater than 20 kHz): Noise when Muted:

SPECIFICATIONS
Console Specifications (continued): DC Offset: Channel Balance: Channel Separation: < 50 mVdc, all channels +/- 1.5 dB for all volume settings > 40 dB @ 1 kHz, > 30 dB @ 10 kHz, stereo mode

Analog Input Characteristics: Maximum source signal for ADC full scale: Minimum source signal for ADC full scale: Input Impedance: Input Coupling: Analog Output (Aux) Characteristics: Output level from 0 dBFS: Gain from CODEC 0 dBFS: Output level from FM (mono, 75 kHz dev): Output level from AM (30% mod, 100 dBuV): Source Impedance at 1 kHz: Output Coupling: S/PDIF Coaxial Input Characteristics: Sampling Rates Accommodated: Number of bits recognized: Input Impedance: Error Checking and Handling: 44.1 kHz, 48 kHz 16, 20 and 24 75 Ohms +/- 10% Implements full error checking and handling, considering CRC, validity bit, loss of lock, parity error, and bi-phase error. AC 1 Vrms at less than 0.05% THD 2 Vrms (-6 dB +/- 1 dB) 0.3 Vrms nominal 0.2 Vrms nominal 1560 Ohms nominal, +/- 10% AC 2 Vrms 200 mVrms 100k Ohms nominal +/- 10% AC coupled to remove source DC offset

Input Coupling: Optical S/PDIF Input Characteristics: Sampling Rates Accommodated: Number of bits recognized: Error Checking and Handling:

Input Connector: LFE Channel Volume Control:

44.1 kHz and 48 kHz 16, 20 and 24 Implements full error checking and handling, considering CRC, validity bit, loss of lock, parity error, and bi-phase error. TOSLINK +6 dB to -12 dB gain range from the bass tone control Selectable on or off Treble Control: Range of -2 to +2 dB in 11 steps Bass Control: Range of -12 to +6 dB in 18 steps 6

Film EQ: Tone Controls:

Preliminary

SPECIFICATIONS
Console Specifications (continued): FM Tuner Performance (per IHF-T-200): Channel Spacing: Band Limits: De-emphasis: 50 dB Quieting Sensitivity: Mono: Stereo: Signal to Noise Ratio @ 65 dBf: Harmonic Distortion @ 65 dBf: Capture Ratio @ 45 dBf: AM Rejection @ 45 dBf: Adjacent Channel Selectivity (200 kHz): Alternate Channel Selectivity (400 kHz): Image Rejection: RF Intermodulation: Sub-carrier Product Rejection: Frequency Response: Stereo Channel Separation @ 1 kHz: Auto Stop Level (seek): Mono / Stereo Threshold: AM Tuner Performance (per IHF-T-100): Channel Spacing: Band Limits: Usable Sensitivity (mono): Adjacent Channel Selectivity: Alternate Channel Selectivity: Image Rejection: Auto Stop Level: Signal to Noise Ratio: Distortion: Frequency Response: 10 kHz 530 kHz - 1710 kHz 46 dB nominal / 56 dB limit 23 dB nominal / 18 dB limit 30 dB nominal / 25 dB limit 40 dB nominal / 35 dB limit 54 dBuV/m +/- 3 dB 50 dB nominal / 45 dB limit 0.6% nominal / 1.4% limit 220 Hz: -3 dB nominal / -6 dB limit 2.0 kHz: -3 dB nominal / -6 dB limit 200 kHz 87.5 MHz - 107.9 MHz 75 usec 13 dBf nominal / 17 dBf limit 38 dBf / limit 42 dBf 74 / limit 69 dB mono, 70 / limit 65 dB stereo Mono 0.3% / limit 0.6%, stereo 0.4% / limit 0.8% 2.0 dB nominal / limit 3.0 dB 60 dB nominal / 50 dB limit 13 dB nominal / 10 dB limit @ 45 dBf 70 dB nominal / 65 dB limit @ 45 dBf 45 dB nominal / 40 dB limit 65 dB nominal / 55 dB limit 55 dB nominal / 45 dB limit 30 Hz to 15 kHz +/- 1.0 dB nominal, +/- 2.0 dB limit 35 dB nominal / 25 dB limit 30 dBf +/-5 40 dBf +/-5

Preliminary

Bass Module Characteristics: Woofer Impedance: Bass Amplifier Distortion Level: Bass Amplifier Output Noise: Bass Amplifier DC Offset: Single woofer at 1.55 Ohms < 0.4% THD @ 0.5W < 2 mVrms, unweighted < 50 mVdc

7

INPUTS
VIDEO
COMPOSITE S-VIDEO AUDIO/ VIDEO MUX CODEC TUNER POWER AMP

COMPOSITE

S-VIDEO

LC

AM FM VIDEO 1 VIDEO 2 AUX INPUT VIDEO 1 VIDEO 2 AUX INPUT DIGITAL AUDIO RECEIVER

LS

RC

RS VIDEO ENCODER

Figure 1. 3-2-1 Console Block Diagram
DVD PROCESSOR DSP DAC DVD-ROM

BASS

AUX OUT L

AUX OUT R

8

Preliminary
ANTENNA ANALOG AUDIO DIGITAL AUDIO

OUTPUTS

VIDEO

TWIDDLER

BASS MODULE

ANALOG AUDIO

DISASSEMBLY/ASSEMBLY PROCEDURES
Bass Module Procedures Refer to Figure x for the following procedures. 1. Rear Enclosure Removal 1.1 Place the bass module on its side. Using a Phillips-head screwdriver, remove the four screws (9) that secure the rear enclosure (8) to the bass module. 1.2 Slide the rear enclosure off of the bass module. 2. Rear Enclosure Replacement 4.2 Secure the transformer in place using the four nuts (6) removed in steps 3.3. 4.3 Plug the transformer cables onto J3 and J5 of the bass module PCB. Plug the woofer harness cable onto J7. 4.4 Perform procedure 2. 5. Bass Module PCB/Heatsink Assembly Removal 5.1 Perform procedure 1. 5.2 On the bass module PCB/heatsink assembly, unplug the cables at J3 and J5 that run to the power transformer. Unplug the woofer harness jack at J7. 5.3 Using a Phillips-head screwdriver, remove the four screws (11) that secure the bass module PCB/heatsink assembly to the bass module enclosure. Carefully lift it out of the enclosure. 6. Bass Module PCB/Heatsink Assembly Replacement 6.1 Align the bass module PCB/heatsink assembly (10) with the four screw locations on the bass module enclosure baffle. 6.2 Secure the bass module PCB/heatsink assembly to the bass module enclosure using the four screws (11) removed in step 5.3. 6.3 Plug the cables from the power transformer (7) onto the connectors at J3 and J5 of the bass module PCB/heatsink assembly. Plug the woofer cable onto the board at J7. 6.4 Perform procedure 2.

Preliminary

2.1 Align the rear enclosure (9) with the bass module so that the bass module PCB/ heatsink assembly (10) connecters are aligned with the openings in the rear enclosure. Slide the rear enclosure onto the bass module. 2.2 Using a Phillips-head screwdriver, replace the four screws (9) removed in step 1.2. 3. Power Transformer Removal 3.1 Perform procedure 1. 3.2 On the bass module PCB/heatsink assembly, unplug the cables at J3 and J5 that run to the power transformer. Unplug the woofer harness jack at J7. 3.3 Using an 8/32" nut driver, remove the four nuts (6) that secure the power transformer (7) to the bass module enclosure. 3.4 Lift the power transformer off of the mounting studs (5) and out of the enclosure. 4. Power Transformer Replacement 4.1 Align the power transformer (7) with the mounting studs (5) on the baffle of the bass module enclosure. Slide the transformer onto the studs. 9

DISASSEMBLY/ASSEMBLY PROCEDURES
Console Procedures Note: Refer to Figure x for the following procedures. 1. Top Cover Removal 1.1 Place the console on the bench with the front facing toward you. On the rear of the console and using finger pressure only, press inward in the center of the rear panel just below the edge of the top cover (2). When you have pressed the rear panel in approximately 1/4", lift upward on the top cover and release the pressure on the rear panel of the console. The finger in the center of the top cover should be sitting on top of the corresponding latch hole in the rear panel. Once the center finger has cleared, lift upward on the rear edge of the top cover until the four tabs to the sides clear the console rear panel. 1.2 Slide the top cover to the rear of the console approximately 1/2". Lift the top cover off of the console. 2. Top Cover Replacement 2.1 Align the top cover (2) with the console base (21) so that the concave edge faces the front of the unit and place it on the top of the console base with the front edge approximately 1/2" back from the bezel sub assembly (27). 2.2 Slide the top cover forward, making sure that the front lip slides under the bezel sub assembly. 2.3 On the rear panel of the console base, make sure that the four tabs of the top cover are inside the rear panel. Using finger pressure only, press inward on the rear panel of the console base until the top cover finger snaps into place. The top cover should be seated evenly across the rear of the console. 3. DVD ROM Drive Removal 3.1 Perform procedure 1. 3.2 On top of the DVD drive (5), you will see a large spring clamp (3) holding the DVD drive in place. Using two large flat-tip screwdrivers, press down and pry the tabs on one side of the spring clamp away from the casting (14) at the corners. Lift the spring clamp off of the DVD drive. 3.3 At the rear of the DVD drive you will see a shield (4) over the ATAPI (8) and power (7) cables. There were two types of shields used in production of the media center, an adhesive folded metal foil type and a formed metal shield. If your unit has the folded foil type, peel the foil back from the rear of the DVD mechanism until you can access the cables. If you have the formed metal shield, lift up the rear of the DVD mechanism and slide the shield off. Unplug the ATAPI and power cables from the rear of the DVD mechanism. 3.4 Lift up on the back of the DVD drive until the DVD drawer bezel (28) pops off the front of the DVD drive drawer. You need to lift the drive up quite a bit to get this to work. Once the drawer extension is off, slide the DVD drive to the rear until it is out from under the edge of the bezel. 3.5 On the underside of the DVD drive, remove and retain the two small silver colored Phillips-head screws (6) located near the front of the drive. These screws are the ones that protrude from the bottom of the drive. You will need to install these screws in the same location on your replacement DVD mechanism. They are used to physically align the DVD mechanism in the console casting (14).

10

Preliminary

DISASSEMBLY/ASSEMBLY PROCEDURES
4. DVD Drive Replacement 4.1 Install the two Phillips-head screws (6) that were removed in step 3.5. These screws should be installed into the two threaded holes located on the underside of the drive (5) near the front. These screws will protrude from the chassis of the drive and are used to help align the drive with the console casting (14). 4.2 On the rear of the DVD drive, plug in the ATAPI (8) cable and power (7) cables. Be sure that the strain relief on the ATAPI cable is on the end of the cable that plugs into the main PCB (20). Also verify that the mode select jumper is in place in the MASTER location. Refer to the diagram on the top of the DVD drive. 4.3 In order to make installing the DVD drive easier, you should remove the bezel sub assembly (27). Place the console on the bench so that the front panel is facing toward you. Using a small flat-tip screwdriver, press in the tabs that secure the bezel sub assembly to the console base (21). There are two tabs located at the top of the base behind the front panel near the LCD display PCB (26) ribbon cable and the heatsink (9). There are two more inside the opening for the DVD drawer. Once you get these released, turn the console on its side and release the four tabs on the bottom of the console base directly behind the bezel sub assembly. Place the console back on its feet and place the bezel sub assembly face down on a soft surface to avoid scratching the lens. Do not disconnect the ribbon cable to the LCD display PCB. 4.4 On the DVD mechanism, use a straightened paper clip or a small probe in the emergency drawer release hole of the DVD mechanism to release the DVD drawer latch. This hole is located on the right front of the mechanism. Slowly slide the DVD drawer partially out of the mechanism. ˇ With the shield as shown, bend the bottom section of the shield 90 degrees away from you. Peel off the plastic on this section. You should have a rectangular section with the adhesive facing down. ˇ Align the exposed adhesive section with the rear of the casting (14) near the input and output jacks. You will place this section of the shield on the casting just past the lip at the back of the casting. If you place the shield on top of this lip the drive will not sit flat in the console. One of the tabs of the casting should protrude through the small rectangular knock-out section of the foil shield. Remove the knock-out section and discard it. ˇ Press the adhesive foil shield section in place on the casting, leaving the rest of it standing up along the rear of the console base (21). 4.6 Plug the DVD drive cables into their corresponding jacks located at the rear of the main PCB assembly (20). Route the power cable (7) behind the ATAPI cable (8), but not under the DVD drive. 4.7 Place the DVD drive down onto the casting inside the console. Make sure that it is sitting flat on the casting. 4.5 Before you can install the DVD drive (5), you must replace the ATAPI shield (4) on the back of it. If you have the formed metal type shield, simply slide it in place over the back of the drive. If your drive used the folded foil type shield, you will need to use a new shield, part number 260471-001. To install the folded foil shield, perform the following steps:

Preliminary

11

DISASSEMBLY/ASSEMBLY PROCEDURES
Note: To assure correct clamping, you should use a new DVD clamp when installing the DVD drive into the console. 4.8 Align the clamp (3) over the DVD drive (5) and with the ears of the casting (14). Press down firmly on the clamp until it snaps into place on the casting. 4.9 Place the drawer opening in the bezel sub assembly (27) over the DVD drive drawer, allowing the drawer to extend through the opening. Align the slots in the DVD drawer bezel (28) with the DVD drawer. Slide the DVD drawer bezel down until it snaps in place. Be careful to not damage the DVD drawer. Snap the bezel sub assembly in place on the front of the console base (21). 4.10 At the rear of the DVD drive, peel the protective plastic off of the side and top sections of the foil shield. Press the adhesive side sections in place, and then press the top section in place. 4.11 Perform procedure 2. 5. Main PCB Removal 5.1 Perform procedure 3. 5.2 Unplug the ribbon cable at J6500 on the main PCB (20). This cable runs to the display PCB (26). 5.3 Using a size T-15 Torx head driver, remove the nine screws (13) that secure the casting (14) and main PCB (20) to the console base (21). 5.4 Use a small flat-tip screwdriver to release the clip (12) that secures the amplifier output IC to the heatsink (9). Use a small flattip screwdriver to carefully pry the output IC slightly away from the heatsink. Lift the casting and heatsink assembly out of the chassis. 6.3 On the main PCB, check to make sure that the large thermal pad (16) is in place on top of the DVD decoder IC (U3000) and the small thermal pad (17) is in place on top of the CODEC IC (U4000). Align the casting (14) with the console base (21) and slide it down over the main PCB. It will slide down onto the main PCB slightly away from the output IC. Slide the casting over against the output IC. Replace the output IC clip (12). Make sure to place the clip near the top of the output IC. 6.4 Secure the main PCB and casting to the chassis using the nine Torx-head screws (13) removed in step 5.3, starting with the hole nearest the heatsink, then across to the hole near the ribbon cable and then the rest. Do not overtighten these screws. 5.5 On the rear of the console base (21), unclip the four tabs that secure the I/O panel (19) to the base. Pull away and down on the top of the I/O panel until it unclips from the base. It should come off completely. 5.6 Carefully lift the front edge of the main PCB (20) out of the base. Slide the main PCB forward slightly until it clears the jacks on the back of the board. Lift the main PCB and casting (14) out of the base. 6. Main PCB Replacement 6.1 Align the main PCB (20) with the console base (21). Angle the main PCB so that the jacks will protrude through the opening in the rear of the base and set it in place. 6.2 On the heatsink (9), use a straight-edge razor blade to scrape off any thermal phase change pad (11) material. Take care to not scratch the coating on the heatsink. Clean off any residue with alcohol. On the main PCB, clean any thermal phase change pad residue off of the output IC. apply a small amount of thermal compound to the back of the output IC.

12

Preliminary

DISASSEMBLY/ASSEMBLY PROCEDURES
6.5 Align the I/O panel (19) with the connectors on the main PCB. Press the I/O panel in place on the console base (21). It should snap in place and be flush with the base all around its perimeter. 6.6 Perform procedure 4. 7. LCD Display PCB Removal 7.1 Perform procedure 3. 7.2 On the main PCB (20), unplug the ribbon cable at connector J6500. This cable runs to the LCD display PCB (26). Peel off the foil ground strap (25) located directly under the ribbon cable. This foil strap provides a common ground between the main PCB and the LCD display PCB. 7.3 Place the console on the bench with the front panel facing toward you. Using a small flat-tip screwdriver, press in the tabs that secure the bezel sub assembly (27) to the console base (21). There are two located at the top of the base behind the front panel near the ribbon cable and the heatsink (9). There are two more inside the opening for the DVD drawer. Once you get these released, turn the console on its side and release the four tabs on the bottom of the base directly behind the bezel sub assembly. Take care not to drop the LCD display PCB. It is not secured in the bezel sub assembly. 7.4 Place the bezel sub assembly face down on a soft surface. Take care to not scratch the soft plastic lens. Lift the LCD display PCB out of the bezel sub assembly. Using a small flat-tip screwdriver, flip up the edge of the ZIF connector at J2. Unplug the ribbon cable. Take care to not plug and unplug this cable too many times. It has a carbon coating that wears off after just a few removals and insertions, ruining the cable. 8.2 Align the LCD display PCB with the bezel sub assembly so that the LCD display is located behind the lens of the bezel sub assembly. 8.3 Align the bezel sub assembly and LCD display PCB assembly with the front of the console base (21). Feed the LCD display PCB ribbon cable and the foil ground strap (25) through the small rectangular opening at the front of the base. Snap the bezel sub assembly and the LCD display PCB in place on the front of the base. 8.4 Secure the foil ground strap to the corner of the casting (14) nearest the point it enters the chassis. Be sure to press the foil securely in place. Plug the LCD display PCB ribbon cable into the main PCB (20) at J6500. The ribbon cable should feed straight into the connector with no twist. 8.5 Perform procedure 2. Array Procedures 1. Grille Removal 1.1 Wrap some masking tape around the shaft of a flat-tip screwdriver approximately 1/2" back from the end. This is needed to protect the plastic housing of the array. 8. Display PCB replacement 8.1 Using a small flat-tip screwdriver, flip up the edge of the J2 ZIF connector on the LCD display PCB (26). Slide the bezel sub assembly (27) ribbon cable into the J2 ZIF connector on the LCD display PCB. The carbon traces on the cable should face down toward the board. Snap the J2 ZIF connector down into place.

Preliminary

13

TEST PROCEDURES
Disassembly/Assembly Procedures (continued) Array Procedures (continued): 1.2 Place the array on its back on a bench. Use your thumb to press down on the array grille just where at the top of the curve. At the same time, use the screwdriver to pry the end of the grille off of the array housing. It should come free of the housing. Repeat this step at the other end of the grille. Lift the grille off the housing. 2. Grille Replacement 3. Coaxial Digital Audio Test 2.1 Align the grille so that the Bose logo is facing the same direction as the arrows on the front of the array housing. 2.2 Press the grille in place. It should latch at each end of the grille to the housing.
Ž

2. Analog Audio Test 2.1 Apply a 1 Vrms, 1 kHz signal to the left and right VIDEO 1 audio analog inputs. 2.2 On the console, select the VIDEO 1 input. 2.3 Measure the output level at the line outputs on the console rear panel. It should be 1 Vrms + 10%. 2.4 Repeat steps 2.1 to 2.3 for the VIDEO 2 audio analog inputs.

3.2 Connect the output of the SPDIF converter to the VIDEO 1 coaxial digital input. 3.3 Apply a 500 mV, 1 kHz signal to the analog input of the SPDIF converter. 3.4 On the console, select the VIDEO 1 source. 3.5 Measure the output level at the line outputs on the console rear panel. It should be 500 mVrms + 10%. 3.6 Repeat steps 3.1 to 3.5 for the video 2 digital coaxial input. 3.7 Repeat steps 3.1 to 3.5 for the AUX digital coaxial input. 4. Optical Digital Audio Test

Test Procedures
Console Procedures Equipment required: Audio signal generator Digital multimeter Analog to SPDIF converter SPDIF to optical converter AM/FM signal generator Abex test DVD (TDV-540A) Video monitor DC power supply Video cable Optical cable Test Setup Set up the unit under test as shown in Figure x for the following tests. 1. Button Test 1.1 Turn on the unit under test (UUT) using the ON/OFF button on the console. Observe that the display lights up. 14

4.1 Connect the audio signal generator to the input of the analog to SPDIF converter. 4.2 Connect the output of the SPDIF converter to the input of the SPDIF to optical converter. 4.3 Connect the output of the optical converter to the VIDEO 1 optical input.

Preliminary

3.1 Connect the audio signal generator to the input of the analog to SPDIF converter.

TEST PROCEDURES
4.4 Apply a 250 mV, 1 kHz signal to the analog input of the SPDIF converter. 4.5 On the console, select the VIDEO 1 source. 4.6 Measure the output level at the line outputs on the console rear panel. It should be 250 mVrms + 10%. 5. Video Tests 5.1 Connect the video generator to the COMPOSITE VIDEO INPUT only. 5.2 Connect the video monitor to the COMPOSITE VIDEO OUTPUT. 7.2 If necessary, connect the TwiddlerTM arrays to the 9-pin D-sub connector. 7.3 On the 3-2-1 system remote control, press the CD/DVD button to start playback of the DVD disc. 7.4 Verify that the audio plays. 8. CD Playability Tests 5.4 On the console, select the VIDEO 1 source. 5.5 Confirm that the test pattern appears on the video monitor. 5.6 Connect the video generator to the SVIDEO input only. 5.7 Connect the video monitor to the SVIDEO output. 5.8 Set the video generator to display a test pattern. 5.9 On the console, select the VIDEO 1 source. 5.10 Confirm that the test pattern appears on the video monitor. 6. Internal DVD Video Test 6.1 Load the test DVD into the console. 6.2 Connect the video monitor to the SVIDEO output of the console. Test discs required: ABEX TCD-714R ABEX TCD-721R ABEX TCD-725R ABEX TCD-732R Philips TS4 8.1 Insert the ABEX TCD-725R test disc into the console CD/DVD tray. ˇ Play the defect tracking (interruption) track. Verify that the track plays properly. The nominal is a 1.0 mm defect, 0.8 mm limit. ˇ Play the defect tracking (black dot) track. Verify that the track plays properly. The nominal is a 1.0 mm defect, 0.8 mm limit. ˇ Play the defect tracking (fingerprint) track. Verfiy that the track plays properly. The nominal is a 75 um defect, 65 um limit. 8.2 Insert the ABEX TCD-721R test disc into the console CD/DVD tray. Play the defect tracking (scratch) track. Verify that the disc plays properly. The nominal is a 1.6 mm defect, 1.0 mm limit. 15 6.3 On the 3-2-1 system remote control, press the CD/DVD button to start playback of the DVD disc. 6.4 Verify that video appears on the video monitor. 7. DVD Audio Test 7.1 Load the test DVD into the console.

Preliminary

5.3 Set the video generator to display a test pattern.

TEST PROCEDURES
8.3 Insert the ABEX TCD-714R test disc into the console CD/DVD tray. Play the defect tracking (eccentric disc) track. Verify that the disc plays properly. The nominal is a 280 um defect, 210 um limit. 8.4 Insert the ABEX TCD-732R test disc into the console CD/DVD tray. Play the defect tracking (warped disc) track. Verify that the disc plays properly. The nominal is a 1.0 mm defect, 0.7 mm limit. 8.5 Insert the Philips TS4 test disc into the console CD/DVD tray. Play tracks 1 through 15, verifying that each track cues up within the test limits. Nominal is 2 seconds or less, limit 3 seconds. 9. Laser Current Measurement Procedure Note: The 3-2-1 system console CD/DVD drive uses a separate laser for each medium, CD or DVD. You will need to perform these tests using a CD disc to measure the CD laser current and a DVD disc to measure the DVD laser current. 9.1 Remove the console top cover using Disassembly/Assembly procedure 1. 9.2 Remove the bottom cover of the CD/ DVD mechanism to allow access to the board. 9.3 Connect the DVD drive to the console using the ATAPI and DVD power extender cables. This will allow better access to the test points while playing the DVD or CD disc. 9.4 Insert a CD disc into the mechanism tray. Start the disc playing so that the timer on the display is counting. 9.5 Measure and record the voltage at the point 5V and L5V. Be sure to use the GND pad near the 5V and L5V points. See Figure 2. 9.6 Subtract L5V from 5V (5V-L5V) and record the laser voltage (LmV). 16 Figure 2. Laser voltage test points 9.7 The measured laser current value should be + 20% of the printed current rating on the pickup head (PU). PU-.20PU
Figure 3. Laser current rating label

Preliminary

TEST PROCEDURES
3-2-1 Console Tuner Adjustments/ Measurements The following tests can be performed without the use Of An IBM compatible PC Set up the device under test (console) as shown in the diagram below.
Unit under test

10.3 Tune the console to 1500 kHz and adjust the red slug (T2004) for maximum audio level at the left or right audio output. Verify that the level is greater than 30 mVrms. 10.4 Change the RF frequency to 600kHz and re-tune the console to 600kHz. 10.5 Adjust the black slug (T2004) for maximum level. Verify that the level is greater than 30 mVrms. 10.6 Repeat steps 10.2 to 10.5 until maximum audio output is obtained without the need for further adjustment. 11. AM Sensitivity 11.1 Inject a 1080kHz RF signal at a level of 74 dBuV emf, 30% modulation, 400 Hz modulation frequency. 11.2 Tune the console to 1080 kHz. 11.3 Connect a dB meter to the tape output jacks and reference it (set to 0dB) to the current audio output. 11.4 Remove the AM modulation and measure the tape output. The reading should be less than -20dB. FM Adjustments Note: Unless otherwise noted, set the RF generator for 1 kHz, mono modulation, pilot off and 75 kHz deviation. Power levels for FM testing are given in dBf at the antenna input to the unit. Typically a test setup will consist of an RF generator with a 50 ohm output impedance and a 50 ohm to 75 ohm impedance matching element. The two most commonly used impedance matching element are a resistive network which has a 5.7dB insertion loss and a "lossless" transformer which has a 0.5dB insertion loss. 17

24 inches (60cm)

External AM loop antenna

Preliminary

24 inches (60cm) AM test loop antenna

RF signal generator

Figure 4. AM Loop Antenna Test Setup AM Adjustments For all AM alignments and tests plug the AM antenna, part number 199824-002, into the console and position it at least 2 feet away from the unit. Configure the AM antenna, a standard test loop and RF generator as shown below to create the specified field strength for each test. Set the AM modulation to 30% with a 1kHz signal. Refer to the AM Setup procedure below 10. AM RF Tracking 10.1 Connect an AC meter to the AUX OUT jacks. 10.2 Inject an 1500kHz RF signal at a level of 90 dBuV emf, 30% modulation, 1 kHz modulation frequency.

TEST PROCEDURES
To find the required setting in dBuV emf from a given dBf value for an RF generator with a 50 ohm output impedance use the conversions given below. 14.2 Reference a dB meter to the left tape output. 14.3 Switch the RF signal modulation to right only channel. 14.4 Measure the left tape output. It should read -25dB or less. Computer Assisted Tuner Test Procedures Note: Refer to the computer set up instructions in the appendix for proper connection to an IBM compatible computer. Refer to Figure 4, AM antenna setup diagram, to achieve the proper field strength for the given RF generator setting. Some of the commands will automatically set the calibration, requiring only an external RF signal at the input of the tuner. Other commands require the technician to make measurements and adjustments. Before commencing with the tuner measurements/alignments enter the command LXOF to disable communication between the display microprocessor and the system microprocessor You should receive an ACK (acknowledge) response on the computer's screen. If not then re-try until successful. To re-enable communication enter LXON. AM Adjustments 13. FM Sensitivity 13.1 Inject a 98.1MHz RF signal at a level of 19 dBf into J2000. 13.2 Measure the THD+N at the tape output. It should be less than or equal to 3%. 14. FM Stereo Separation 14.1 Inject a 98.1MHz RF signal set to 1kHz left only modulation with 10% pilot modulation and 75kHz total deviation at a level 65dBf into J2000. 15.2 Enter the command TUSF15000 into the computer. This will tune the unit to 1500 kHz. 15.3 You should receive the response "ACK>" (acknowledge) on the computer's screen. 18 Enter the command TUAM to switch source to AM. 15. AM Alignment 15.1 Inject an 1500 kHz RF signal at a level of 90 dBuV emf.

Using a resistive network (5.7dB loss) Using a "lossless" transformer

Subtract 1.3dB. eg: 65dBf => set generator to 63.7 dBuV emf Subtract 6.5dB eg: 65dBf => set generator to 59.5 dBuV emf

Note: For generators with RF level resolution of only 1dB round up. 12. FM Distortion Measurement/Adjustment 12.1 Inject a 98.1MHz RF signal at a level of 65dBf into J2000. 12.2 Tune the console to 98.1MHz. 12.3 Measure the distortion plus noise (THD+N) at the tape output. If it is less than or equal to 0.50%, verify that the audio level is greater than 190 mV. If these are not the measurements you have, proceed to step 12.4. 12.4 If the THD+N is greater than 0.55%, or the audio level is less than 190 mV, adjust T2001 for minimum distortion. Verify that the level is greater than 190 mV and the distortion is less than 0.55%.

Preliminary

TEST PROCEDURES
Note: If you receive an error response on the computer screen, enter the TUAM command to ensure the correct mode is selected and re-enter the command in 15.2. To verify the AM tuning frequency enter the TUGF command to get the presently tuned frequency. The response on the computer screen should be "1500" followed by an "ACK>" 15.4 Adjust the red slug of T2004 for maximum audio output. Verify that the level is greater than 40 mVrms. 15.5 Inject a 600kHz RF signal at a level of 90 dBuV emf. 16.5 Enter the command TURA to see the stored level; the response on the computer should be as follows: XX (where XX is the stored level in hexadecimal form). The current AM S-meter voltage level = 5 x (stored level in decimal) / 256 FM Tuner Tests For all FM measurements and adjustments, the RF signal is to be connected from the signal generator to J2000 via a 50 to 75 Ohm impedance matching network. The input levels are to be as read at the input of J2000. FM Adjustments 15.6 Enter the command TUSF06000 into the computer. This will tune the unit to 600 kHz. 15.7 You should receive an ACK response on the computer screen. 15.8 Adjust the black slug of T2004 for maximum audio output. Verify that the level is greater than 40 mVrms. 15.9 Repeat steps 15.1 through 15.8 until the audio level is at a maximum without adjustment. 16. AM Stop Level 16.1 Inject a 1080 kHz RF signal at a level of 78 dBuV emf, 30% modulation at 1 kHz. 16.2 Enter the command TUSF10800 into the computer. This will tune the unit to 1080 kHz. 16.3 You should receive an "ACK>" response on the computer screen. 16.4 Enter the command TUAR. The unit will then sample the AM S-meter level, and store it in the EEPROM as the stop level and return an "ACK>" response. Enter the command TUFM to switch source to FM. 17. FM IF Centering Adjustment 17.1 Inject a 98.1MHz, 1 kHz mono modulation, pilot OFF, 75 kHz deviation RF signal (83.0 MHz for Japan) at a level of 50dBf into J2000. 17.2 Enter the command TUSF09810 (TUSF08300 for Japan) into the computer. This will tune the unit to the appropriate frequency. 17.3 You should receive an ACK response on the computer screen. Note: If you receive an error response on the computer screen, enter the TUFM command to ensure the correct mode is selected and re-enter the command in 17.2. To verify the FM tuning frequency enter the TUGF command to get the presently tuned frequency. The response on the computer screen should be the "98.1" ("83.0" for Japan)

Preliminary

19

TEST PROCEDURES
17.4 Enter the command TUIF into the computer. The unit will then go through an algorithm that determines the optimum offset for the local oscillator (L.O.) setting to account for filter variances in the IF strip. This offset is then stored in the EEPROM. Enter the command TUGI to see the stored offset; the response on the computer should be as follows: "TUGI X >" followed by an "ACK>" (where X is the stored offset). The actual frequency offset of the L.O. is this offset multiplied by 25kHz. Valid offsets are 1, 0 or 1 18. FM Distortion Measurement/Adjustment 18.1 Inject a 98.1 MHz, 1 kHz mono modulation, pilot OFF, 75 kHz deviation (83.0 MHz for Japan) RF signal at a level of 65dBf into J2000. 18.2 Enter the command TUSF09810 (TUSF08300 for Japan) into the computer. This will tune the unit to the appropriate frequency. 18.3 Measure the distortion plus noise (THD+N) at the tape output. If it is less than or equal to 0.50%, verify that the audio level is greater than 190 mV. If these are not the measurements you have, proceed to step 18.4. 18.4 If the THD+N is greater than 0.55%, or the audio level is less than 190 mV, adjust T2001 for minimum distortion. Verify that the level is greater than 190 mV and the distortion is less than 0.55%. 19. FM Sensitivity 19.1 Inject a 98.1MHz, 1 kHz mono modulation, pilot OFF, 75 kHz deviation (83.0 MHz for Japan) RF signal at a level of 19 dBf (21dBf for Japan) into J2000. 19.2 Measure the THD+N at the tape output. It should be less than or equal to 3%. 20. FM Stereo Separation 20.1 Inject a 98.1MHz (83.0 MHz for Japan) RF signal set to 1kHz left only modulation with 10% pilot modulation and 75kHz total deviation at a level 65dBf into J2000. 20.2 Enter the command TUSF09810 (TUSF08300 for Japan) into the computer. This will tune the unit to the appropriate frequency. 20.3 Reference a dB meter to the left tape output. 20.4 Switch the RF signal modulation to right only channel. 20.5 Measure the left tape output. It should read -25dB or less. 21. FM Stop Level 21.1 Inject a 98.1MHz, 1 kHz mono modulation, pilot OFF, 75 kHz deviation (83.0MHz for Japan) RF signal at a level of 30 dBf into J2000. 21.2 Enter the command TUSF09810 (TUSF08300 for Japan) into the computer. This will tune the unit to the appropriate frequency. 21.3 You should receive an ACK response on the computer screen. 21.4 Enter the command TUFR. The unit will then sample the AM S-meter level, and store it in the EEPROM as the stop level. 21.5 Enter the command TURF to see the stored level; the response on the computer should be as follows: XX (where XX is the stored level in hexadecimal form). The current FM S-meter voltage level = 5 x (stored level in decimal) / 256.

20

Preliminary

TEST PROCEDURES
22. FM Stereo & Force Mono Threshold 22.1 Inject a 98.1MHz RF (83.0 MHz for Japan) signal set to 1kHz stereo L=-R modulation with 10% pilot modulation and 75 kHz total deviation at a level of 42 dBf into J2000. 22.2 Enter the command TUSF09810 (TUSF08300 for Japan) into the computer. This will tune the unit to the appropriate frequency. 22.3 Enter the command TUSR. The unit will then sample the FM S-meter level, and store it in the EEPROM as the stereo level. Bass Module Procedures Equipment required: ˇ Audio signal generator ˇ dB Meter ˇ Distortion meter ˇ Digital multimeter ˇ 2 Ohm, 50 Watt load resistor ˇ 60 Ohm, 10 Watt load resistor ˇ Bass module test cable (see instructions in the appendix) Test Setup Refer to Figure x for the following tests. 1. Unpowered Transformer Impedance Test 1.1 On the bass module, set the AC mains switch to the ON position (if applicable). For the International variation, set the voltage select switch to 120V. 1.2 Using a DMM, measure the DC resistance of the transformer primary through the AC connector J1. For the international version, first measure with the voltage select switch set to 115V, then move the switch to 230V and measure again. Verify that the readings are in accordance with the following table.

Preliminary

Enter the command TURS to see the stored level; the response on the computer should be as follows: XX (where XX is the stored level in hexadecimal form). 22.4 Reduce the RF signal level by 2dB. 22.5 Enter the command TUSM. The unit will then sample the FM S-meter level, and store it in the EEPROM as the force-mono level. Enter the command TUMS to see the stored level; the response on the computer should be as follows: XX (where XX is the stored level in hexadecimal form). FM S-meter voltage levels for each of these settings can be calculated as per the stops level. 23. FM Signal to Noise Ratio 23.1 Set the RF signal generator to 98.1 MHz, 1 kHz modulation, pilot off, 75 kHz deviation and at the level that corresponds to 65 dBf into J2000. 23.2 Measure the output level at the left or right audio output. Reference a dB meter to this level. 23.3 Turn off the RF modulation and verify that the level drops by > 70 dB. 21

US/Canada Europe Japan International

3.7 Ohms +/- 15% 14.0 Ohms +/- 15% 2.8 Ohms +/- 15% 3.7 Ohms +/- 15% (115V) 14.0 Ohms +/- 15% (230V)

2. Woofer DC Resistance Test 2.1 Remove the bass module rear enclosure using bass module disassembly/assembly procedure 1. 2.2 Remove the woofer harness from J7 on the bass module PCB. Measure the DC resistance of the woofer voice coil by measuring across the two pins of the woofer harness. It should be 1.55 Ohms + 15%.

TEST PROCEDURES
3. Power Up Test 3.1 Apply a short across BASS-EQ (J6 pin 6) and AGND (J6 pin 5). Apply 0 V to MUTE (J6 pin 13). 3.2 Apply AC mains voltage to the bass module. 3.3 Measure the transformer quiescent primary current. It should be < 250 mArms. 3.4 Measure the V supply voltage at J6 pins 7, 8, 14 and 15. It should be +16.5 + 1.0 VDC. Remove the short applied in step 3.1. 3.5 Measure the J7 speaker output DC potential on each pin of the connector relative to PGND at J6 pin 2 or 3. It should be + 8.2 + 1.0 Vdc. 4. Gain, Distortion and Mute Tests 4.1 Connect a 2 Ohm, 50 Watt load resistor to the bass channel output to J7 on the bass module PCB. 4.2 Apply a +5 Vdc level to MUTE at J6 pin 13. This DC level will unmute the bass module amplifier. 4.3 Apply a 100 mV, 100 Hz signal between BASS-EQ (J6 pin 6) and AGND (J6 pin 5). 4.4 Reference a dB meter to the input level. 6. Air Leak Test 4.5 Measure the output gain level at J7. It should be +26.0 dB + 2.0 dB. 4.6 Measure the distortion level at J7. It should be < 0.1%. 4.7 Apply a 0 Vdc level to MUTE at J6 pin 13. This DC level will mute the bass module amplifier. 4.8 Measure the mute attenuation level at J7 relative to the input level. It should be > 40 dB. 6.1 Apply a 200 mVrms, 45 Hz signal between BASS-EQ (J6 pin 6) and AGND (J6 pin 5). 6.2 Listen for air leaks around all cabinet seams, joints and wire harness thru-holes. Air leaks will be heard as a hissing or sputtering noise. Repair any air leaks. All repairs must be hidden. 5. Clipping Detect Test 5.1 Remove the bass module rear enclosure using bass module disassembly/assembly procedure 1. 5.2 Unplug the woofer harness connector at J7 on the bass module PCB. Connect a 60 Ohm, 10 Watt load resistor to J7 on the bass module PCB. 5.3 Apply a +5 VDC level to the bass module MUTE input at J6 pin 13. This DC level will unmute the bass module amplifier. 5.4 Apply a 1.0 Vrms, 100 Hz signal between BASS-EQ (J6 pin 6) and AGND (J6 pin 5). 5.5 Using a DMM, measure the average voltage of the digital clipping detect signal COMP (J6 pin 12). It should be +1.7 + 1.0 Vdc. 5.6 Remove the + 5.0 Vdc level applied to MUTE at J6 pin 13. 5.7 Using a DMM, measure the average voltage of the digital clipping detect signal COMP (J6 pin 12). It should be +5.0 + 0.5 Vdc. 5.8 Re-connect the woofer harness to J7 on the bass module PCB.

22

Preliminary

TEST PROCEDURES
7. Frequency Sweep Test 7.1 Apply a 350 mVrms, 10 Hz signal between BASS-EQ (J6 pin 6) and AGND (J6 pin 5). 7.2 Sweep the input frequency from 10 Hz to 500 Hz. Listen for any extraneous noises such as buzzes, rattles, ticks, port noise or distortion. Satellite Array Procedures Notes: ˇ Refer to Figure x for the following procedures. ˇ The satellite arrays are non-repairable. The grilles can be replaced using the disassembly/assembly procedures. ˇ Each satellite array contains two identical drivers that are wired independently. You must test each of them separately unless otherwise specified. 1. DC Resistance Test 1.1 Using a digital multi-meter, measure the DC resistance of each of the array drivers. Each should measure 3.2 Ohms + 10%. 2. Phase Test 2.1 Remove the array grille using Array disassembly/assembly procedure 1. 2.2 Observing polarity, apply a +6 Vdc level to one driver on the array input connector. 2.3 Observe the driver under test. When the DC level is applied, the driver should move outward. If it does, the driver is wired correctly. If not, it is wired incorrectly. Repeat steps 2.2 and 2.3 for the other driver in the array. 3.3 Listen for any rubbing or ticking noise from the driver. Replace any driver that is defective. Note: There is a normal suspension noise. To distinguish between a rub or tick and suspension noise, displace the cone slightly with your finger. If the rubbing can be made to go away or get worse, then it is a rub or tick. If the noise stays the same, it is suspension noise. 3.4 Repeat steps 3.1 to 3.3 for the other driver in the array. 4. Frequency Sweep Test 4.1 Jumper both of the drivers in a single array together. Both center pins of the array connector are negative (-). The two outer pins are the positive (+) pins. 4.2 Apply a 100 Hz, 3.0 Vrms signal to both of the array drivers. 4.3 Slowly sweep the signal generator from 100 Hz to 2.0 kHz. Listen for any extraneous noises such as buzzes, rattles, ticks, port noise or distortion. Replace any array with an extraneous noise that can be heard at a distance greater than 1 foot (0.3m). 3. Air Leak Test 3.1 Apply a 180 Hz, 3 Vrms signal to one of the drivers in the satellite array for 5 seconds minimum. 3.2 Listen for air leaks around all enclosure seams, joints and the input connector. Air leaks will be heard as a hissing or sputtering noise. Repair any air leaks. All repairs must be hidden.

Preliminary

23

PART LIST NOTES
1. This part is not normally available from Customer Service. Approval from the Field Service Manager is required before ordering. 2. The individual parts located on the PCBs are listed in the Electrical Part List. 3. This part is critical for safety purposes. Failure to use a substitute replacement with the same safety characteristics as the recommended replacement part might create shock, fire and/or other hazards.

MAIN PART LIST
Console Assembly (see Figure 5)

Item Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Description LABEL, TOP COVER, GRAPHITE LABEL, TOP COVER, PLAT WHT COVER, CONSOLE, DVD, GRAPHITE COVER, CONSOLE, DVD, PLAT WHT STRAP, DVD, (CLAMP) SHIELD, FOIL, DVD, (ATAPI SHIELD) DRIVE, DVD ROM SCREW, M3 CABLE, POWER, DVD, 155 MM CABLE, RIBBON, ATAPI, 40 POSITION HEATSINK, MAIN CABLE, FLEX, 172 MM, 24 CONDUCTOR PAD, THERMAL PHASE CHANGE (CONSOLE AMPLIFIER IC) CLIP, HEATSINK SCREW, TF, 8-11X.625", PAN, TORX HEATSINK, BRACKET, DVD (CASTING) GASKET, FOAM, EMI, 25MM PAD, THERMAL, COMPLIANT, 25 x 25 MM PAD, THERMAL, COMPLIANT, 9 x 7 MM GASKET, FOAM, EMI, 3MM PANEL, I/O, GRAPHITE PANEL, I/O, PLAT WHT MAIN PCB ASSY, PROGRAMMED BASE, CONSOLE, GRAPHITE BASE, CONSOLE, PLAT WHT SHIELD, LOWER INSULATOR, SHIELD FOOT, RUBBER, .50 DIA X.062 THK STRAP, GROUND, FOIL, 25.4MMX105 MM LCD DISPLAY PCB ASSY, PROGRAMMED BEZEL SUB ASSEMBLY BEZEL, DRAWER, DVD NAMEPLATE, 38 MM DIAMOND CUT
24

1 1 1 2 1 1 1 1 1 1 9 1 5 1 1 3 1 1 1 1 1 4 1 1 1 1 1 2, 4

262080 256947-10 256949 262635-025 262078-001 262078-002 262635-003 262802-001 262802-002 263202-001 254547-001 254547-002 263026-001 263486-001 260465 262634-105 262309-001 255127-001 256957-001 256945-001

2, 4

Preliminary

Part Number 256946-001 256946-002 264482-001 264482-002 260462 260471-001 256150-001 260463 256955-155 256954-090 260281 254584-172 258627

Qty. 1 1

Note

1

2

3 4

5

6 2x 7

Preliminary

9 11 12

8

10 13 9x

14

2x 13 15 5x 16 17 18 3x 19 20 21

22 27 26 25

23

24 4x

28 29

Figure 5. Console Exploded View 25

MAIN PART LIST
Bass Module Assembly (see Figure 6)

Item Number 1 2 3 4 5 6 7 8 9 10 11

Description SCREW, TAPP, 8-11X.5, PAN, ASY, SQ GASKET, FOAM, .32"x12.0"x.125" BRACKET-L, COVER, AMP INSERT, BARBED, 10-32X20mm VIBRATION MNT, DBL STUD, 8/10-32 NUT, HEX, 8-32, KEPS TRANSFORMER, EI, 120V, 60HZ, NTC ENCLOSURE, REAR, BASS MOD, GRAPHITE ENCLOSURE, REAR, BASS MOD, PLAT WHT SCREW, TT, 8-32X0.5, PAN, XREC/SQ BASS BOX PCB/HEATSINK ASSY, US SCREW, TAPP, 8-11x.75, PAN, XRC/SQ

Part Number 250817-08 255202 255179 145712-03 263002-006 118260-08 258862-001 255165-201 255165-202 255191-08 255139-001 172672-12

Qty. 6 2 2 4 4 4 1 1 4 1 8

Note

2

1

6 PLACES

2

2 PLACES

3 2 PLACES 4 4 PLACES 5 6 4 PLACES 8 7 4 PLACES

9

4 PLACES

11 4 PLACES 10

Figure 6. Bass Module Assembly Exploded View 26

Preliminary

MAIN PART LIST
Bass Module PCB Assembly (see Figure 7)

Item Number 1 2 3 4 5 6

Description HEATSINK, BASS MODULE CLIP, SPRING PAD, FOAM, .25"x.75"x.06" PC BOARD ASSY, BASS BOX , NO HEATSINK SCREW, M3.5X10MM, THD ROLL CLIP, HEAT SINK, BASS BOX AMP

Part Number 260093-001 142864 255201 254575-001 140447-10 255174

Qty. 1 1 3 1 3 1

Note

2

Preliminary

1

2

U1

6

BR1 Q1

5 3

3 PLACES

3 PLACES
4

Figure 7. Bass Module PCB Assembly Exploded View 27

ELECTRICAL PART LIST
Console Main PCB Assembly Resistors

Reference Designator R1 R2 R3 R4 R5 R6 R11 R12 R14 R15 R27 R32 R33 R36 R89 R90 R91 R92 R93 R95 R96 R98 R99 R100 R103 R114 R115 R116 R117 R118 R152 R153 R154 R155 R156 R157 R158 R159 R160 R161 R162 R163 R164 R165 R166 R167

Description 33.2K, 0603, 1/10W, 1% 33.2K, 0603, 1/10W, 1% 6.04K, 0603, 1/10W, 1% 9.09K, 0603, 1/10W, 1% 10K, 0603, 1/10W, 1% 19.1K, 0603, 1/10W, 1% 22.1K, 0603, 1/10W, 1% 9.53K, 0603, 1/10W, 1% 1K, 0603, 1/10W, 1% 10K, 0603, 1/10W, 1% 51 OHMS, 0603, 1/10W, 5% 4.7K, 0603, 1/10W, 5% 4.7K, 0603, 1/10W, 5% 4.7K, 0603, 1/10W, 5% 33.2K, 0603, 1/10W, 1% 13.3K, 0603, 1/10W, 1% 10.2K, 0603, 1/10W, 1% 4.22K, 0603, 1/10W, 1% 13.3K, 0603, 1/10W, 1% 499 OHMS, 0603, 1/10W, 1% 10K, 0603, 1/10W, 5% 1K, 0603, 1/10W, 1% 1K, 0603, 1/10W, 1% 1K, 0603, 1/10W, 1% JUMPER, 0603 JUMPER, 0603 750 OHMS, 1206, 1/4W, 5% 750 OHMS, 1206, 1/4W, 5% JUMPER, 0603 100 OHMS, 0805, 1/10W, 5% 470K, 0603, 1/10W, 5% 47K, 0603, 1/10W, 5% 47K, 0603, 1/10W, 5% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 560 OHMS, 0603, 1/10W, 1% 560 OHMS, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 560 OHMS, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 560 OHMS, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 10K, 0603, 1/10W, 1%
28

Part Number 191465-3322 191465-3322 191465-6041 191465-9091 191465-1002 191465-1912 191465-2212 191465-9531 191465-1001 191465-1002 199403-510 199403-472 199403-472 199403-472 191465-3322 191465-1332 191465-1022 191465-4221 191465-1332 191465-4990 199403-103 191465-1001 191465-1001 191465-1001 196042 196042 124895-7515 124895-7515 196042 133626-1015 199403-474 199403-473 199403-473 191465-1962 191465-1962 191465-5600 191465-5600 191465-1962 191465-1962 191465-5600 191465-1962 191465-1962 191465-5600 191465-1962 191465-1962 191465-1002

Note

Preliminary

ELECTRICAL PART LIST
Console Main PCB Assembly Resistors

Reference Designator R168 R169 R170 R171 R172 R173 R175 R196 R197 R198 R199 R200 R201 R202 R203 R204 R205 R206 R1000 R1001 R1002 R1004 R1005 R1006 R1008 R1009 R1010 R1011 R1012 R1015 R1016 R1017 R1018 R1019 R1020 R1021 R1023 R1024 R1025 R1026 R1027 R1028 R1029 R1030 R2000

Description 10K, 0603, 1/10W, 1% 10K, 0603, 1/10W, 1% 10K, 0603, 1/10W, 1% 1K, 0603, 1/10W, 5% 1K, 0603, 1/10W, 5% 10.0K, 0805, 1/10W, 5% 10.0K, 0805, 1/10W, 5% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 19.6K, 0603, 1/10W, 1% 100 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% JUMPER, 0805 100K, 0603, 1/10W, 5% 100K, 0603, 1/10W, 5% 100K, 0603, 1/10W, 5% 100K, 0603, 1/10W, 5% 100K, 0603, 1/10W, 5% 100K, 0603, 1/10W, 5% 560 OHMS, 0603, 1/10W, 5% 560 OHMS, 0603, 1/10W, 5% 1.00K, 0805, 1/10W, 5% 4.7K, 0603, 1/10W, 5% 4.7K, 0603, 1/10W, 5% 100K, 0603, 1/10W, 5% 100K, 0603, 1/10W, 5% 1.00K, 0805, 1/10W, 1% 1.00K, 0805, 1/10W, 1% 1.00K, 0805, 1/10W, 5% 1.00K, 0805, 1/10W, 5% 1.00K, 0805, 1/10W, 5% 1.00K, 0805, 1/10W, 5% 1.00K, 0805, 1/10W, 5% 1.00K, 0805, 1/10W, 1% 1.00K, 0805, 1/10W, 1% 1.00K, 0805, 1/10W, 1% 1.00K, 0805, 1/10W, 1% 1.00K, 0805, 1/10W, 1% 1.00K, 0805, 1/10W, 1% 3.01K, 0603, 1/10W, 1%

Part Number 191465-1002 191465-1002 191465-1002 199403-102 199403-102 133626-1035 133626-1035 191465-1962 191465-1962 191465-1962 191465-1962 191465-1962 191465-1962 191465-1962 191465-1962 199403-101 199403-101 133627 199403-104 199403-104 199403-104 199403-104 199403-104 199403-104 199403-561 199403-561 133626-1025 199403-472 199403-472 199403-104 199403-104 133625-1001 133625-1001 133626-1025 133626-1025 133626-1025 133626-1025 133626-1025 133625-1001 133625-1001 133625-1001 133625-1001 133625-1001 133625-1001 191465-3011

Note

Preliminary

29

ELECTRICAL PART LIST
Console Main PCB Assembly Resistors

Reference Designator R2004 R2005 R2006 R2007 R2008 R2009 R2010 R2011 R2012 R2013 R2014 R2015 R2016 R2017 R2018 R2019 R2020 R2021 R2022 R2023 R2024 R2025 R2026 R2028 R2029 R2033 R2034 R2035 R2036 R2037 R2038 R2039 R2040 R2041 R2042 R2043 R2044 R2046 R2048 R2049 R2050 R2051 R2102 R2103 R2104 R2105

Description 1K, 0603, 1/10W, 5% 120 OHMS, 0603, 1/10W, 5% 499 OHMS, 0603, 1/10W, 1% 2.32K, 0603, 1/10W, 1% 2.32K, 0603, 1/10W, 1% 330 OHMS, 0603, 1/10W, 1% 150 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 1% 4.75K, 0603, 1/10W, 1% 51 OHMS, 0603, 1/10W, 5% 6.8K, 0603, 1/10W, 5% 17.8K, 0603, 1/10W, 1% 5.1K, 0603, 1/10W, 5% 5.1K, 0603, 1/10W, 5% 3.01K, 0603, 1/10W, 1% 51 OHMS, 0603, 1/10W, 5% 3.32K, 0603, 1/10W, 1% 3.32K, 0603, 1/10W, 1% 4.32K, 0603, 1/10W, 1% 4.32K, 0603, 1/10W, 1% 3.32K, 0603, 1/10W, 1% 3.32K, 0603, 1/10W, 1% 17.8K, 0603, 1/10W, 1% 10K, 0603, 1/10W, 5% 4.75K, 0603, 1/10W, 1% 6.81K, 0603, 1/10W, 1% 2.2K, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W,,5% 3.32K, 0603, 1/10W, 1% 2.0K, 0603, 1/10W, 5% 1K, 0603, 1/10W, 1% 1K, 0603, 1/10W, 5% 1K, 0603, 1/10W, 5% 82K, 0603, 1/10W, 5% 82K, 0603, 1/10W, 5% 1K, 0603, 1/10W, 5% JUMPER, 0603 2.2K, 0603, 1/10W, 5% 2.2K, 0603, 1/10W, 5% 2.2K, 0603, 1/10W, 5% JUMPER, 0603 3.01K, 0603, 1/10W, 1% 2.2K, 0603, 1/10W, 5% 47K, 0603, 1/10W, 5% 100K, 0603, 1/10W, 5% 22 OHMS, 0603, 1/10W, 5%
30

Part Number 199403-102 199403-121 191465-4990 191465-2321 191465-2321 191465-3300 199403-151 191465-1000 191465-4751 199403-510 199403-682 191465-1782 199403-512 199403-512 191465-3011 199403-510 191465-3321 191465-3321 191465-4321 191465-4321 191465-3321 191465-3321 191465-1782 199403-103 191465-4751 191465-6811 199403-222 199403-101 191465-3321 199403-202 191465-1001 199403-102 199403-102 199403-823 199403-823 199403-102 196042 199403-222 199403-222 199403-222 196042 191465-3011 199403-222 199403-473 199403-104 199403-220

Note

Preliminary

ELECTRICAL PART LIST
Console Main PCB Assembly Resistors

Reference Designator R2106 R3001 R3002 R3003 R3004 R3005 R3006 R3007 R3008 R3009 R3049 R3050 R3051 R3052 R3053 R3054 R3055 R3056 R3058 R3059 R3060 R3062 R3063 R3064 R3065 R3066 R3067 R3068 R3105 R3106 R3107 R3109 R3110 R3111 R3112 R3113 R3124 R3125 R3129 R3131 R3132 R3133 R3135 R3140 R3141 R3142

Description 1.18K, 0603, 1/10W, 1% 33 OHMS, 0603,,1/10W,,5% 33 OHMS, 0603,,1/10W,,5% 33 OHMS, 0603, 1/10W, 5% 33 OHMS, 0603, 1/10W, 5% 33 OHMS, 0603, 1/10W, 5% 33 OHMS, 0603, 1/10W, 5% 33 OHMS, 0603, 1/10W, 5% 10K, 0603,1/10W, 5% 1K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 5.6K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 5.6K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 2.2K, 0603, 1/10W, 5% 10K, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 51 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 100 OHMS, 0603, 1/10W, 5% 1.5K, 0603, 1/10W, 5% 5.6K, 0603, 1/10W, 5% 1.5K, 0603, , 1/10W, 5% 10