Bose 3-2-1 Service Manual
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11 Preliminary 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 assem- bly 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 straight- ened 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.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: • 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. • 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. • 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.
12 Preliminary 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 re- lease the clip (12) that secures the amplifier output IC to the heatsink (9). Use a small flat- tip screwdriver to carefully pry the output IC slightly away from the heatsink. Lift the casting and heatsink assembly out of the chassis.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. 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.
13 Preliminary 6.5 Align the I/O panel (19) with the connec- tors 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 re- leased, 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 coat- ing that wears off after just a few removals and insertions, ruining the cable.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. 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 se- curely 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.
14 Preliminary 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 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. 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. 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. Coaxial Digital Audio Test 3.1 Connect the audio signal generator to the input of the analog to SPDIF converter. 3.2 Connect the output of the SPDIF con- verter 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 4.1 Connect the audio signal generator to the input of the analog to SPDIF converter. 4.2 Connect the output of the SPDIF con- verter to the input of the SPDIF to optical conver ter. 4.3 Connect the output of the optical con- verter to the VIDEO 1 optical input.
15 Preliminary 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 COM- POSITE VIDEO OUTPUT. 5.3 Set the video generator to display a test pattern. 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 S- VIDEO input only. 5.7 Connect the video monitor to the S- VIDEO 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 S- VIDEO output of the console.6.3 On the 3-2-1 system remote control, press the CD/DVD button to star t 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. 7.2 If necessary, connect the Twiddler TM arrays to the 9-pin D-sub connector. 7.3 On the 3-2-1 system remote control, press the CD/DVD button to star t playback of the DVD disc. 7.4 Verify that the audio plays. 8. CD Playability Tests 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. • Play the defect tracking (interruption) track. Verify that the track plays properly. The nominal is a 1.0 mm defect, 0.8 mm limit. • 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. • 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.
16 Preliminary Figure 2. Laser voltage test points Figure 3. Laser current rating label 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 me- dium, 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).9.7 The measured laser current value should be + 20% of the printed current rating on the pickup head (PU). PU-.20PU
17 Preliminary 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. 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.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 maxi- mum level. Verify that the level is greater than 30 mVrms. 10.6 Repeat steps 10.2 to 10.5 until maxi- mum 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 mea- sure 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 match- ing 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. Unit under test External AM loop antenna AM test loop antenna RF signal generator 24 inches (60cm) 24 inches (60cm)
18 Preliminary 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 conver- sions given below. 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 distor- tion is less than 0.55%. 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 J2000.14.2 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 instruc- tions in the appendix for proper connection to an IBM compatible computer. Refer to Figure 4, AM antenna setup dia- gram, 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 measure- ments/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 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. 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. Using a resistive network (5.7dB loss)Subtract 1.3dB. eg: 65dBf => set generator to 63.7 dBuV emf Using a “lossless” transformerSubtract 6.5dB eg: 65dBf => set generator to 59.5 dBuV emf
19 Preliminary Note: If you receive an error response on the computer screen, enter the TUAM com- mand 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 maxi- mum 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. 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 adjust- ment. 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.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 Enter the command TUFM to switch source to FM. 17. FM IF Centering Adjustment 17.1 Inject a 98.1MHz, 1 kHz mono modula- tion, 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 com- mand 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)
20 Preliminary 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 ac- count 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 modula- tion, 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 distor- tion is less than 0.55%. 19. FM Sensitivity 19.1 Inject a 98.1MHz, 1 kHz mono modula- tion, 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 modula- tion, 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.