Bose 3-2-1 Service Manual
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21 Preliminary 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. 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. Bass Module Procedures Equipment required: • Audio signal generator • dB Meter • Distortion meter • Digital multimeter • 2 Ohm, 50 Watt load resistor • 60 Ohm, 10 Watt load resistor • 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 resis- tance 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. 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 mea- suring across the two pins of the woofer harness. It should be 1.55 Ohms + 15%. US/Canada 3.7 Ohms +/- 15% Europe 14.0 Ohms +/- 15% Japan 2.8 Ohms +/- 15% International 3.7 Ohms +/- 15% (115V) 14.0 Ohms +/- 15% (230V)
22 Preliminary 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 rela- tive 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. 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.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 mod- ule 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 bet- ween 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. 6. Air Leak Test 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 sput- tering noise. Repair any air leaks. All repairs must be hidden.
23 Preliminary 7. Frequency Sweep Test 7.1 Apply a 350 mVrms, 10 Hz signal be- tween 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: • Refer to Figure x for the following procedures. • The satellite arrays are non-repairable. The grilles can be replaced using the disassembly/assembly procedures. • 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 cor- rectly. If not, it is wired incorrectly. Repeat steps 2.2 and 2.3 for the other driver in the array.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. 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).
24 Preliminary MAIN PART LIST Console Assembly (see Figure 5) Item NumberDescription Part NumberQty. Note 1 LABEL, TOP COVER, GRAPHITE LABEL, TOP COVER, PLAT WHT256946-001 256946-0021 2 COVER, CONSOLE, DVD, GRAPHITE COVER, CONSOLE, DVD, PLAT WHT264482-001 264482-0021 3 STRAP, DVD, (CLAMP) 260462 1 4 SHIELD, FOIL, DVD, (ATAPI SHIELD) 260471-001 1 5 DRIVE, DVD ROM 256150-001 1 6 SCREW, M3 260463 2 7 CABLE, POWER, DVD, 155 MM 256955-155 1 8 CABLE, RIBBON, ATAPI, 40 POSITION 256954-090 1 9 HEATSINK, MAIN 260281 1 10 CABLE, FLEX, 172 MM, 24 CONDUCTOR 254584-172 1 11 PAD, THERMAL PHASE CHANGE (CONSOLE AMPLIFIER IC)258627 1 12 CLIP, HEATSINK 262080 1 13 SCREW, TF, 8-11X.625", PAN, TORX 256947-10 9 14 HEATSINK, BRACKET, DVD (CASTING) 256949 1 15 GASKET, FOAM, EMI, 25MM 262635-025 5 16 PAD, THERMAL, COMPLIANT, 25 x 25 MM 262078-001 1 17 PAD, THERMAL, COMPLIANT, 9 x 7 MM 262078-002 1 18 GASKET, FOAM, EMI, 3MM 262635-003 3 19 PANEL, I/O, GRAPHITE PANEL, I/O, PLAT WHT262802-001 262802-0021 20 MAIN PCB ASSY, PROGRAMMED 263202-001 1 2, 4 21 BASE, CONSOLE, GRAPHITE BASE, CONSOLE, PLAT WHT254547-001 254547-0021 22 SHIELD, LOWER 263026-001 1 23 INSULATOR, SHIELD 263486-001 1 24 FOOT, RUBBER, .50 DIA X.062 THK 260465 4 25 STRAP, GROUND, FOIL, 25.4MMX105 MM 262634-105 1 26 LCD DISPLAY PCB ASSY, PROGRAMMED 262309-001 1 2, 4 27 BEZEL SUB ASSEMBLY 255127-001 1 28 BEZEL, DRAWER, DVD 256957-001 1 29 NAMEPLATE, 38 MM DIAMOND CUT 256945-001 1 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.
25 Preliminary Figure 5. Console Exploded View 1 2 3 4 5 6 7 8 9 10 11 12 13 14 13 15 16 1718 19 20 21 22 24 25 26 27 28 29 4x 23 3x 5x2x 9x 2x
26 Preliminary MAIN PART LIST Bass Module Assembly (see Figure 6) 1 6 PLACES 2 2 PLACES 3 4 5 6 7 8 9 1011 4 PLACES 4 PLACES 4 PLACES4 PLACES4 PLACES 2 PLACES Figure 6. Bass Module Assembly Exploded View Item NumberDescription Part NumberQty. Note 1 SCREW, TAPP, 8-11X.5, PAN, ASY, SQ 250817-08 6 2 GASKET, FOAM, .32”x12.0”x.125” 255202 2 3 BRACKET-L, COVER, AMP 255179 2 4 INSERT, BARBED, 10-32X20mm 145712-03 4 5 VIBRATION MNT, DBL STUD, 8/10-32 263002-006 4 6 NUT, HEX, 8-32, KEPS 118260-08 4 7 TRANSFORMER, EI, 120V, 60HZ, NTC 258862-001 1 8 ENCLOSURE, REAR, BASS MOD, GRAPHITE 255165-201 1 ENCLOSURE, REAR, BASS MOD, PLAT WHT 255165-202 9 SCREW, TT, 8-32X0.5, PAN, XREC/SQ 255191-08 4 10 BASS BOX PCB/HEATSINK ASSY, US 255139-001 1 2 11 SCREW, TAPP, 8-11x.75, PAN, XRC/SQ 172672-12 8
27 Preliminary MAIN PART LIST Bass Module PCB Assembly (see Figure 7) Figure 7. Bass Module PCB Assembly Exploded View 1 2 3 456 3 PLACES 3 PLACES U1 BR1 Q1 Item Numbe r Description Part NumberQty. Note 1 HEATSINK, BASS MODULE 260093-001 1 2 CLIP, SPRING 142864 1 3 PAD, FOAM, .25”x.75”x.06” 255201 3 4 PC BOARD ASSY, BASS BOX , NO HEATSINK 254575-001 1 2 5 SCREW, M3.5X10MM, THD ROLL 140447-10 3 6 CLIP, HEAT SINK, BASS BOX AMP 255174 1
28 Preliminary ELECTRICAL PART LIST Resistors Console Main PCB Assembly Reference DesignatorDescription Part Number Note R1 33.2K, 0603, 1/10W, 1% 191465-3322 R2 33.2K, 0603, 1/10W, 1% 191465-3322 R3 6.04K, 0603, 1/10W, 1% 191465-6041 R4 9.09K, 0603, 1/10W, 1% 191465-9091 R5 10K, 0603, 1/10W, 1% 191465-1002 R6 19.1K, 0603, 1/10W, 1% 191465-1912 R11 22.1K, 0603, 1/10W, 1% 191465-2212 R12 9.53K, 0603, 1/10W, 1% 191465-9531 R14 1K, 0603, 1/10W, 1% 191465-1001 R15 10K, 0603, 1/10W, 1% 191465-1002 R27 51 OHMS, 0603, 1/10W, 5% 199403-510 R32 4.7K, 0603, 1/10W, 5% 199403-472 R33 4.7K, 0603, 1/10W, 5% 199403-472 R36 4.7K, 0603, 1/10W, 5% 199403-472 R89 33.2K, 0603, 1/10W, 1% 191465-3322 R90 13.3K, 0603, 1/10W, 1% 191465-1332 R91 10.2K, 0603, 1/10W, 1% 191465-1022 R92 4.22K, 0603, 1/10W, 1% 191465-4221 R93 13.3K, 0603, 1/10W, 1% 191465-1332 R95 499 OHMS, 0603, 1/10W, 1% 191465-4990 R96 10K, 0603, 1/10W, 5% 199403-103 R98 1K, 0603, 1/10W, 1% 191465-1001 R99 1K, 0603, 1/10W, 1% 191465-1001 R100 1K, 0603, 1/10W, 1% 191465-1001 R103 JUMPER, 0603 196042 R114 JUMPER, 0603 196042 R115 750 OHMS, 1206, 1/4W, 5% 124895-7515 R116 750 OHMS, 1206, 1/4W, 5% 124895-7515 R117 JUMPER, 0603 196042 R118 100 OHMS, 0805, 1/10W, 5% 133626-1015 R152 470K, 0603, 1/10W, 5% 199403-474 R153 47K, 0603, 1/10W, 5% 199403-473 R154 47K, 0603, 1/10W, 5% 199403-473 R155 19.6K, 0603, 1/10W, 1% 191465-1962 R156 19.6K, 0603, 1/10W, 1% 191465-1962 R157 560 OHMS, 0603, 1/10W, 1% 191465-5600 R158 560 OHMS, 0603, 1/10W, 1% 191465-5600 R159 19.6K, 0603, 1/10W, 1% 191465-1962 R160 19.6K, 0603, 1/10W, 1% 191465-1962 R161 560 OHMS, 0603, 1/10W, 1% 191465-5600 R162 19.6K, 0603, 1/10W, 1% 191465-1962 R163 19.6K, 0603, 1/10W, 1% 191465-1962 R164 560 OHMS, 0603, 1/10W, 1% 191465-5600 R165 19.6K, 0603, 1/10W, 1% 191465-1962 R166 19.6K, 0603, 1/10W, 1% 191465-1962 R167 10K, 0603, 1/10W, 1% 191465-1002
29 Preliminary ELECTRICAL PART LIST Resistors Console Main PCB Assembly Reference DesignatorDescription Part Number Note R168 10K, 0603, 1/10W, 1% 191465-1002 R169 10K, 0603, 1/10W, 1% 191465-1002 R170 10K, 0603, 1/10W, 1% 191465-1002 R171 1K, 0603, 1/10W, 5% 199403-102 R172 1K, 0603, 1/10W, 5% 199403-102 R173 10.0K, 0805, 1/10W, 5% 133626-1035 R175 10.0K, 0805, 1/10W, 5% 133626-1035 R196 19.6K, 0603, 1/10W, 1% 191465-1962 R197 19.6K, 0603, 1/10W, 1% 191465-1962 R198 19.6K, 0603, 1/10W, 1% 191465-1962 R199 19.6K, 0603, 1/10W, 1% 191465-1962 R200 19.6K, 0603, 1/10W, 1% 191465-1962 R201 19.6K, 0603, 1/10W, 1% 191465-1962 R202 19.6K, 0603, 1/10W, 1% 191465-1962 R203 19.6K, 0603, 1/10W, 1% 191465-1962 R204 100 OHMS, 0603, 1/10W, 5% 199403-101 R205 100 OHMS, 0603, 1/10W, 5% 199403-101 R206 JUMPER, 0805 133627 R1000 100K, 0603, 1/10W, 5% 199403-104 R1001 100K, 0603, 1/10W, 5% 199403-104 R1002 100K, 0603, 1/10W, 5% 199403-104 R1004 100K, 0603, 1/10W, 5% 199403-104 R1005 100K, 0603, 1/10W, 5% 199403-104 R1006 100K, 0603, 1/10W, 5% 199403-104 R1008 560 OHMS, 0603, 1/10W, 5% 199403-561 R1009 560 OHMS, 0603, 1/10W, 5% 199403-561 R1010 1.00K, 0805, 1/10W, 5% 133626-1025 R1011 4.7K, 0603, 1/10W, 5% 199403-472 R1012 4.7K, 0603, 1/10W, 5% 199403-472 R1015 100K, 0603, 1/10W, 5% 199403-104 R1016 100K, 0603, 1/10W, 5% 199403-104 R1017 1.00K, 0805, 1/10W, 1% 133625-1001 R1018 1.00K, 0805, 1/10W, 1% 133625-1001 R1019 1.00K, 0805, 1/10W, 5% 133626-1025 R1020 1.00K, 0805, 1/10W, 5% 133626-1025 R1021 1.00K, 0805, 1/10W, 5% 133626-1025 R1023 1.00K, 0805, 1/10W, 5% 133626-1025 R1024 1.00K, 0805, 1/10W, 5% 133626-1025 R1025 1.00K, 0805, 1/10W, 1% 133625-1001 R1026 1.00K, 0805, 1/10W, 1% 133625-1001 R1027 1.00K, 0805, 1/10W, 1% 133625-1001 R1028 1.00K, 0805, 1/10W, 1% 133625-1001 R1029 1.00K, 0805, 1/10W, 1% 133625-1001 R1030 1.00K, 0805, 1/10W, 1% 133625-1001 R2000 3.01K, 0603, 1/10W, 1% 191465-3011
30 Preliminary ELECTRICAL PART LIST Resistors Console Main PCB Assembly Reference DesignatorDescription Part Number Note R2004 1K, 0603, 1/10W, 5% 199403-102 R2005 120 OHMS, 0603, 1/10W, 5% 199403-121 R2006 499 OHMS, 0603, 1/10W, 1% 191465-4990 R2007 2.32K, 0603, 1/10W, 1% 191465-2321 R2008 2.32K, 0603, 1/10W, 1% 191465-2321 R2009 330 OHMS, 0603, 1/10W, 1% 191465-3300 R2010 150 OHMS, 0603, 1/10W, 5% 199403-151 R2011 100 OHMS, 0603, 1/10W, 1% 191465-1000 R2012 4.75K, 0603, 1/10W, 1% 191465-4751 R2013 51 OHMS, 0603, 1/10W, 5% 199403-510 R2014 6.8K, 0603, 1/10W, 5% 199403-682 R2015 17.8K, 0603, 1/10W, 1% 191465-1782 R2016 5.1K, 0603, 1/10W, 5% 199403-512 R2017 5.1K, 0603, 1/10W, 5% 199403-512 R2018 3.01K, 0603, 1/10W, 1% 191465-3011 R2019 51 OHMS, 0603, 1/10W, 5% 199403-510 R2020 3.32K, 0603, 1/10W, 1% 191465-3321 R2021 3.32K, 0603, 1/10W, 1% 191465-3321 R2022 4.32K, 0603, 1/10W, 1% 191465-4321 R2023 4.32K, 0603, 1/10W, 1% 191465-4321 R2024 3.32K, 0603, 1/10W, 1% 191465-3321 R2025 3.32K, 0603, 1/10W, 1% 191465-3321 R2026 17.8K, 0603, 1/10W, 1% 191465-1782 R2028 10K, 0603, 1/10W, 5% 199403-103 R2029 4.75K, 0603, 1/10W, 1% 191465-4751 R2033 6.81K, 0603, 1/10W, 1% 191465-6811 R2034 2.2K, 0603, 1/10W, 5% 199403-222 R2035 100 OHMS, 0603, 1/10W,,5% 199403-101 R2036 3.32K, 0603, 1/10W, 1% 191465-3321 R2037 2.0K, 0603, 1/10W, 5% 199403-202 R2038 1K, 0603, 1/10W, 1% 191465-1001 R2039 1K, 0603, 1/10W, 5% 199403-102 R2040 1K, 0603, 1/10W, 5% 199403-102 R2041 82K, 0603, 1/10W, 5% 199403-823 R2042 82K, 0603, 1/10W, 5% 199403-823 R2043 1K, 0603, 1/10W, 5% 199403-102 R2044 JUMPER, 0603 196042 R2046 2.2K, 0603, 1/10W, 5% 199403-222 R2048 2.2K, 0603, 1/10W, 5% 199403-222 R2049 2.2K, 0603, 1/10W, 5% 199403-222 R2050 JUMPER, 0603 196042 R2051 3.01K, 0603, 1/10W, 1% 191465-3011 R2102 2.2K, 0603, 1/10W, 5% 199403-222 R2103 47K, 0603, 1/10W, 5% 199403-473 R2104 100K, 0603, 1/10W, 5% 199403-104 R2105 22 OHMS, 0603, 1/10W, 5% 199403-220