TEST PROCEDURES

Disassembly/Assembly Procedures 2. Analog Audio Test

(continued)
2.1 Apply a 1 Vrms, 1 kHz signal to the left
Array Procedures (continued): and right VIDEO 1 audio analog inputs.

1.2 Place the array on its back on a bench. 2.2 On the console, select the VIDEO 1
Use your thumb to press down on the array input.
grille just where at the top of the curve. At
the same time, use the screwdriver to pry 2.3 Measure the output level at the line
the end of the grille off of the array housing. outputs on the console rear panel. It should
It should come free of the housing. Repeat be 1 Vrms + 10%.
this step at the other end of the grille. Lift the
grille off the housing. 2.4 Repeat steps 2.1 to 2.3 for the VIDEO 2
audio analog inputs.
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 3.1 Connect the audio signal generator to the

Preliminary
the front of the array housing. input of the analog to SPDIF converter.

2.2 Press the grille in place. It should latch 3.2 Connect the output of the SPDIF con-
at each end of the grille to the housing. verter to the VIDEO 1 coaxial digital input.

Test Procedures 3.3 Apply a 500 mV, 1 kHz signal to the

analog input of the SPDIF converter.
Console Procedures
3.4 On the console, select the VIDEO 1
Equipment required: source.

Audio signal generator 3.5 Measure the output level at the line
Digital multimeter outputs on the console rear panel. It should
Analog to SPDIF converter be 500 mVrms + 10%.
SPDIF to optical converter
AM/FM signal generator 3.6 Repeat steps 3.1 to 3.5 for the video 2
Abex test DVD (TDV-540A) digital coaxial input.
Video monitor
DC power supply 3.7 Repeat steps 3.1 to 3.5 for the AUX
Video cable digital coaxial input.
Optical cable
4. Optical Digital Audio Test
Test Setup
4.1 Connect the audio signal generator to
Set up the unit under test as shown in the input of the analog to SPDIF converter.
Figure x for the following tests.
4.2 Connect the output of the SPDIF con-
1. Button Test verter to the input of the SPDIF to optical
converter.
1.1 Turn on the unit under test (UUT) using
the ON/OFF button on the console. Observe 4.3 Connect the output of the optical con-
that the display lights up. verter to the VIDEO 1 optical input.

14
 TEST PROCEDURES
4.4 Apply a 250 mV, 1 kHz signal to the 6.3 On the 3-2-1 system remote control,
analog input of the SPDIF converter. press the CD/DVD button to start playback
of the DVD disc.
4.5 On the console, select the VIDEO 1
source. 6.4 Verify that video appears on the video
monitor.
4.6 Measure the output level at the line
outputs on the console rear panel. It should 7. DVD Audio Test
be 250 mVrms + 10%.
7.1 Load the test DVD into the console.
5. Video Tests
7.2 If necessary, connect the TwiddlerTM
5.1 Connect the video generator to the arrays to the 9-pin D-sub connector.
COMPOSITE VIDEO INPUT only.
7.3 On the 3-2-1 system remote control,
5.2 Connect the video monitor to the COM- press the CD/DVD button to start playback
POSITE VIDEO OUTPUT. of the DVD disc.
Preliminary

5.3 Set the video generator to display a test 7.4 Verify that the audio plays.
pattern.
8. CD Playability Tests
5.4 On the console, select the VIDEO 1
source. Test discs required:
ABEX TCD-714R
5.5 Confirm that the test pattern appears on ABEX TCD-721R
the video monitor. ABEX TCD-725R
ABEX TCD-732R
5.6 Connect the video generator to the S- Philips TS4
VIDEO input only.
8.1 Insert the ABEX TCD-725R test disc
5.7 Connect the video monitor to the S- into the console CD/DVD tray.
VIDEO output.
• Play the defect tracking (interruption)
5.8 Set the video generator to display a test track. Verify that the track plays properly.
pattern. The nominal is a 1.0 mm defect, 0.8 mm
limit.
5.9 On the console, select the VIDEO 1
source. • Play the defect tracking (black dot) track.
Verify that the track plays properly. The
5.10 Confirm that the test pattern appears on nominal is a 1.0 mm defect, 0.8 mm limit.
the video monitor.
• Play the defect tracking (fingerprint)
6. Internal DVD Video Test track. Verfiy that the track plays properly.
The nominal is a 75 um defect, 65 um
6.1 Load the test DVD into the console. limit.

6.2 Connect the video monitor to the S- 8.2 Insert the ABEX TCD-721R test disc
VIDEO output of the console. 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
 TEST PROCEDURES
8.3 Insert the ABEX TCD-714R test disc 9.7 The measured laser current value should
into the console CD/DVD tray. Play the be + 20% of the printed current rating on the
defect tracking (eccentric disc) track. Verify pickup head (PU). PU-.20PU<LC<PU+.20.
that the disc plays properly. The nominal is a See Figure 3.
280 um defect, 210 um limit.
9.8 Repeat steps 3 to 6 for the DVD laser
8.4 Insert the ABEX TCD-732R test disc assembly.
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.

Preliminary
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.
Figure 2. Laser voltage test points
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. Figure 3. Laser current rating label
9.6 Subtract L5V from 5V (5V-L5V) and
record the laser voltage (LmV).

16
 TEST PROCEDURES
3-2-1 Console Tuner Adjustments/ 10.3 Tune the console to 1500 kHz and
Measurements adjust the red slug (T2004) for maximum
audio level at the left or right audio output.
The following tests can be performed without Verify that the level is greater than 30
the use Of An IBM compatible PC mVrms.

Set up the device under test (console) as 10.4 Change the RF frequency to 600kHz
shown in the diagram below. and re-tune the console to 600kHz.

Unit under test 10.5 Adjust the black slug (T2004) for maxi-
mum level. Verify that the level is greater
than 30 mVrms.
24 inches (60cm)
10.6 Repeat steps 10.2 to 10.5 until maxi-
mum audio output is obtained without the
External AM
loop antenna need for further adjustment.

24 inches (60cm) 11. AM Sensitivity

Preliminary

AM test 11.1 Inject a 1080kHz RF signal at a level of

loop antenna 74 dBuV emf, 30% modulation, 400 Hz
modulation frequency.

RF signal generator 11.2 Tune the console to 1080 kHz.

11.3 Connect a dB meter to the tape output

Figure 4. AM Loop Antenna Test Setup jacks and reference it (set to 0dB) to the
current audio output.
AM Adjustments
11.4 Remove the AM modulation and mea-
For all AM alignments and tests plug the AM sure the tape output. The reading should be
antenna, part number 199824-002, into the less than -20dB.
console and position it at least 2 feet away
from the unit. Configure the AM antenna, a FM Adjustments
standard test loop and RF generator as
shown below to create the specified field Note: Unless otherwise noted, set the RF
strength for each test. Set the AM modulation generator for 1 kHz, mono modulation, pilot
to 30% with a 1kHz signal. Refer to the AM off and 75 kHz deviation.
Setup procedure below
Power levels for FM testing are given in dBf
10. AM RF Tracking at the antenna input to the unit.

10.1 Connect an AC meter to the AUX OUT Typically a test setup will consist of an RF
jacks. generator with a 50 ohm output impedance
and a 50 ohm to 75 ohm impedance match-
10.2 Inject an 1500kHz RF signal at a level ing element. The two most commonly used
of 90 dBuV emf, 30% modulation, 1 kHz impedance matching element are a resistive
modulation frequency. network which has a 5.7dB insertion loss
and a “lossless” transformer which has a
0.5dB insertion loss.

17
 TEST PROCEDURES
To find the required setting in dBuV emf from 14.2 Reference a dB meter to the left tape
a given dBf value for an RF generator with a output.
50 ohm output impedance use the conver-
sions given below. 14.3 Switch the RF signal modulation to right
only channel.
Using a resistive Subtract 1.3dB. eg:
network 65dBf => set generator 14.4 Measure the left tape output. It should
(5.7dB loss) to 63.7 dBuV emf read -25dB or less.
Using a Subtract 6.5dB eg:
“lossless” 65dBf => set generator Computer Assisted Tuner Test Procedures
transformer to 59.5 dBuV emf
Note: Refer to the computer set up instruc-
Note: For generators with RF level resolution tions in the appendix for proper connection
of only 1dB round up. to an IBM compatible computer.

12. FM Distortion Measurement/Adjustment Refer to Figure 4, AM antenna setup dia-

gram, to achieve the proper field strength
12.1 Inject a 98.1MHz RF signal at a level of for the given RF generator setting.

Preliminary
65dBf into J2000.
Some of the commands will automatically
12.2 Tune the console to 98.1MHz. set the calibration, requiring only an external
RF signal at the input of the tuner. Other
12.3 Measure the distortion plus noise commands require the technician to make
(THD+N) at the tape output. If it is less measurements and adjustments.
than or equal to 0.50%, verify that the audio
level is greater than 190 mV. If these are not Before commencing with the tuner measure-
the measurements you have, proceed to ments/alignments enter the command LXOF
step 12.4. to disable communication between the
display microprocessor and the system
12.4 If the THD+N is greater than 0.55%, or microprocessor You should receive an ACK
the audio level is less than 190 mV, adjust (acknowledge) response on the computer’s
T2001 for minimum distortion. Verify that the screen. If not then re-try until successful. To
level is greater than 190 mV and the distor- re-enable communication enter LXON.
tion is less than 0.55%.
AM Adjustments
13. FM Sensitivity
Enter the command TUAM to switch source
13.1 Inject a 98.1MHz RF signal at a level of to AM.
19 dBf into J2000.
15. AM Alignment
13.2 Measure the THD+N at the tape output.
It should be less than or equal to 3%. 15.1 Inject an 1500 kHz RF signal at a level
of 90 dBuV emf.
14. FM Stereo Separation
15.2 Enter the command TUSF15000 into
14.1 Inject a 98.1MHz RF signal set to 1kHz the computer. This will tune the unit to 1500
left only modulation with 10% pilot modulation kHz.
and 75kHz total deviation at a level 65dBf
into J2000. 15.3 You should receive the response
“ACK>” (acknowledge) on the computer’s
screen.
18
 TEST PROCEDURES
Note: If you receive an error response on 16.5 Enter the command TURA to see the
the computer screen, enter the TUAM com- stored level; the response on the computer
mand to ensure the correct mode is selected should be as follows: XX (where XX is the
and re-enter the command in 15.2. stored level in hexadecimal form).

To verify the AM tuning frequency enter the The current AM S-meter voltage level =
TUGF command to get the presently tuned 5 x (stored level in decimal) / 256
frequency. The response on the computer
screen should be “1500“ followed by an FM Tuner Tests
“ACK>”
For all FM measurements and adjustments,
15.4 Adjust the red slug of T2004 for maxi- the RF signal is to be connected from the
mum audio output. Verify that the level is signal generator to J2000 via a 50 to 75
greater than 40 mVrms. Ohm impedance matching network.
The input levels are to be as read at the
15.5 Inject a 600kHz RF signal at a level of input of J2000.
90 dBuV emf.
FM Adjustments
Preliminary

15.6 Enter the command TUSF06000 into the

computer. This will tune the unit to 600 kHz. Enter the command TUFM to switch source
to FM.
15.7 You should receive an ACK response
on the computer screen. 17. FM IF Centering Adjustment

15.8 Adjust the black slug of T2004 for 17.1 Inject a 98.1MHz, 1 kHz mono modula-
maximum audio output. Verify that the level is tion, pilot OFF, 75 kHz deviation RF signal
greater than 40 mVrms. (83.0 MHz for Japan) at a level of 50dBf into
J2000.
15.9 Repeat steps 15.1 through 15.8 until the
audio level is at a maximum without adjust- 17.2 Enter the command TUSF09810
ment. (TUSF08300 for Japan) into the computer.
This will tune the unit to the appropriate
16. AM Stop Level frequency.

16.1 Inject a 1080 kHz RF signal at a level of 17.3 You should receive an ACK response
78 dBuV emf, 30% modulation at 1 kHz. on the computer screen.

16.2 Enter the command TUSF10800 into the Note: If you receive an error response on
computer. This will tune the unit to 1080 kHz. the computer screen, enter the TUFM com-
mand to ensure the correct mode is selected
16.3 You should receive an “ACK>” response and re-enter the command in 17.2.
on the computer screen.
To verify the FM tuning frequency enter the
16.4 Enter the command TUAR. The unit will TUGF command to get the presently tuned
then sample the AM S-meter level, and store frequency. The response on the computer
it in the EEPROM as the stop level and screen should be the “98.1” (“83.0” for
return an “ACK>” response. Japan)

19
 TEST PROCEDURES
17.4 Enter the command TUIF into the 20. FM Stereo Separation
computer. The unit will then go through an
algorithm that determines the optimum offset 20.1 Inject a 98.1MHz (83.0 MHz for Japan)
for the local oscillator (L.O.) setting to ac- RF signal set to 1kHz left only modulation
count for filter variances in the IF strip. This with 10% pilot modulation and 75kHz total
offset is then stored in the EEPROM. deviation at a level 65dBf into J2000.

Enter the command TUGI to see the stored 20.2 Enter the command TUSF09810
offset; the response on the computer should (TUSF08300 for Japan) into the computer.
be as follows: “TUGI X >” followed by an This will tune the unit to the appropriate
“ACK>” (where X is the stored offset). The frequency.
actual frequency offset of the L.O. is this
offset multiplied by 25kHz. Valid offsets are 20.3 Reference a dB meter to the left tape
–1, 0 or 1 output.

18. FM Distortion Measurement/Adjustment 20.4 Switch the RF signal modulation to right

only channel.
18.1 Inject a 98.1 MHz, 1 kHz mono modula-

Preliminary
tion, pilot OFF, 75 kHz deviation (83.0 MHz 20.5 Measure the left tape output. It should
for Japan) RF signal at a level of 65dBf into read -25dB or less.
J2000.
21. FM Stop Level
18.2 Enter the command TUSF09810
(TUSF08300 for Japan) into the computer. 21.1 Inject a 98.1MHz, 1 kHz mono modula-
This will tune the unit to the appropriate tion, pilot OFF, 75 kHz deviation (83.0MHz
frequency. for Japan) RF signal at a level of 30 dBf into
J2000.
18.3 Measure the distortion plus noise
(THD+N) at the tape output. If it is less 21.2 Enter the command TUSF09810
than or equal to 0.50%, verify that the audio (TUSF08300 for Japan) into the computer.
level is greater than 190 mV. If these are not This will tune the unit to the appropriate
the measurements you have, proceed to frequency.
step 18.4.
21.3 You should receive an ACK response
18.4 If the THD+N is greater than 0.55%, or on the computer screen.
the audio level is less than 190 mV, adjust
T2001 for minimum distortion. Verify that the 21.4 Enter the command TUFR. The unit will
level is greater than 190 mV and the distor- then sample the AM S-meter level, and store
tion is less than 0.55%. it in the EEPROM as the stop level.

19. FM Sensitivity 21.5 Enter the command TURF to see the

stored level; the response on the computer
19.1 Inject a 98.1MHz, 1 kHz mono modula- should be as follows: XX (where XX is the
tion, pilot OFF, 75 kHz deviation (83.0 MHz stored level in hexadecimal form).
for Japan) RF signal at a level of 19 dBf
(21dBf for Japan) into J2000. The current FM S-meter voltage level =
5 x (stored level in decimal) / 256.
19.2 Measure the THD+N at the tape output.
It should be less than or equal to 3%.

20
 TEST PROCEDURES
22. FM Stereo & Force Mono Threshold Bass Module Procedures

22.1 Inject a 98.1MHz RF (83.0 MHz for Equipment required:

Japan) signal set to 1kHz stereo L=-R
modulation with 10% pilot modulation and • Audio signal generator
75 kHz total deviation at a level of 42 dBf • dB Meter
into J2000. • Distortion meter
• Digital multimeter
22.2 Enter the command TUSF09810 • 2 Ohm, 50 Watt load resistor
(TUSF08300 for Japan) into the computer. • 60 Ohm, 10 Watt load resistor
This will tune the unit to the appropriate • Bass module test cable (see instructions
frequency. in the appendix)

22.3 Enter the command TUSR. The unit will Test Setup
then sample the FM S-meter level, and store
it in the EEPROM as the stereo level. Refer to Figure x for the following tests.

Enter the command TURS to see the stored 1. Unpowered Transformer Impedance Test
Preliminary

level; the response on the computer should

be as follows: XX (where XX is the stored 1.1 On the bass module, set the AC mains
level in hexadecimal form). switch to the ON position (if applicable). For
the International variation, set the voltage
22.4 Reduce the RF signal level by 2dB. select switch to 120V.

22.5 Enter the command TUSM. The unit will 1.2 Using a DMM, measure the DC resis-
then sample the FM S-meter level, and store tance of the transformer primary through the
it in the EEPROM as the force-mono level. AC connector J1. For the international
version, first measure with the voltage select
Enter the command TUMS to see the stored switch set to 115V, then move the switch to
level; the response on the computer should 230V and measure again. Verify that the
be as follows: XX (where XX is the stored readings are in accordance with the following
level in hexadecimal form). table.

FM S-meter voltage levels for each of these US/Canada 3.7 Ohms +/- 15%
settings can be calculated as per the stops Europe 14.0 Ohms +/- 15%
level. Japan 2.8 Ohms +/- 15%
International 3.7 Ohms +/- 15% (115V)
23. FM Signal to Noise Ratio 14.0 Ohms +/- 15% (230V)

23.1 Set the RF signal generator to 98.1 2. Woofer DC Resistance Test

MHz, 1 kHz modulation, pilot off, 75 kHz
deviation and at the level that corresponds to 2.1 Remove the bass module rear enclosure
65 dBf into J2000. using bass module disassembly/assembly
procedure 1.
23.2 Measure the output level at the left or
right audio output. Reference a dB meter to 2.2 Remove the woofer harness from J7 on
this level. the bass module PCB. Measure the DC
resistance of the woofer voice coil by mea-
23.3 Turn off the RF modulation and verify suring across the two pins of the woofer
that the level drops by > 70 dB. harness. It should be 1.55 Ohms + 15%.

21
 TEST PROCEDURES
3. Power Up Test 5. Clipping Detect Test

3.1 Apply a short across BASS-EQ (J6 pin 5.1 Remove the bass module rear enclosure
6) and AGND (J6 pin 5). Apply 0 V to MUTE using bass module disassembly/assembly
(J6 pin 13). procedure 1.

3.2 Apply AC mains voltage to the bass 5.2 Unplug the woofer harness connector at
module. J7 on the bass module PCB. Connect a
60 Ohm, 10 Watt load resistor to J7 on the
3.3 Measure the transformer quiescent bass module PCB.
primary current. It should be < 250 mArms.
5.3 Apply a +5 VDC level to the bass mod-
3.4 Measure the V supply voltage at J6 pins ule MUTE input at J6 pin 13. This DC level
7, 8, 14 and 15. It should be +16.5 + 1.0 will unmute the bass module amplifier.
VDC. Remove the short applied in step 3.1.
5.4 Apply a 1.0 Vrms, 100 Hz signal bet-
3.5 Measure the J7 speaker output DC ween BASS-EQ (J6 pin 6) and AGND
potential on each pin of the connector rela- (J6 pin 5).

Preliminary
tive to PGND at J6 pin 2 or 3. It should be
+ 8.2 + 1.0 Vdc. 5.5 Using a DMM, measure the average
voltage of the digital clipping detect signal
4. Gain, Distortion and Mute Tests COMP (J6 pin 12). It should be +1.7 + 1.0
Vdc.
4.1 Connect a 2 Ohm, 50 Watt load resistor
to the bass channel output to J7 on the bass 5.6 Remove the + 5.0 Vdc level applied to
module PCB. MUTE at J6 pin 13.

4.2 Apply a +5 Vdc level to MUTE at J6 pin 5.7 Using a DMM, measure the average
13. This DC level will unmute the bass voltage of the digital clipping detect signal
module amplifier. COMP (J6 pin 12). It should be +5.0 + 0.5
Vdc.
4.3 Apply a 100 mV, 100 Hz signal between
BASS-EQ (J6 pin 6) and AGND (J6 pin 5). 5.8 Re-connect the woofer harness to J7 on
the bass module PCB.
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. 6.1 Apply a 200 mVrms, 45 Hz signal
between BASS-EQ (J6 pin 6) and AGND
4.6 Measure the distortion level at J7. (J6 pin 5).
It should be < 0.1%.
6.2 Listen for air leaks around all cabinet
4.7 Apply a 0 Vdc level to MUTE at J6 pin 13. seams, joints and wire harness thru-holes.
This DC level will mute the bass module Air leaks will be heard as a hissing or sput-
amplifier. tering noise. Repair any air leaks. All repairs
must be hidden.
4.8 Measure the mute attenuation level at J7
relative to the input level. It should be > 40
dB.

22
 TEST PROCEDURES
7. Frequency Sweep Test 3. Air Leak Test

7.1 Apply a 350 mVrms, 10 Hz signal be- 3.1 Apply a 180 Hz, 3 Vrms signal to one of
tween BASS-EQ (J6 pin 6) and AGND the drivers in the satellite array for 5 seconds
(J6 pin 5). minimum.

7.2 Sweep the input frequency from 10 Hz 3.2 Listen for air leaks around all enclosure
to 500 Hz. Listen for any extraneous noises seams, joints and the input connector. Air
such as buzzes, rattles, ticks, port noise or leaks will be heard as a hissing or sputtering
distortion. noise. Repair any air leaks. All repairs must
be hidden.
Satellite Array Procedures
3.3 Listen for any rubbing or ticking noise
Notes: from the driver. Replace any driver that is
• Refer to Figure x for the following defective.
procedures.
• The satellite arrays are non-repairable. Note: There is a normal suspension noise.
The grilles can be replaced using the To distinguish between a rub or tick and
Preliminary

disassembly/assembly procedures. suspension noise, displace the cone slightly

• Each satellite array contains two identical with your finger.
drivers that are wired independently. If the rubbing can be made to go away or get
You must test each of them separately worse, then it is a rub or tick. If the noise
unless otherwise specified. stays the same, it is suspension noise.

1. DC Resistance Test 3.4 Repeat steps 3.1 to 3.3 for the other
driver in the array.
1.1 Using a digital multi-meter, measure the
DC resistance of each of the array drivers. 4. Frequency Sweep Test
Each should measure 3.2 Ohms + 10%.
4.1 Jumper both of the drivers in a single
2. Phase Test array together. Both center pins of the array
connector are negative (-). The two outer
2.1 Remove the array grille using Array pins are the positive (+) pins.
disassembly/assembly procedure 1.
4.2 Apply a 100 Hz, 3.0 Vrms signal to both
2.2 Observing polarity, apply a +6 Vdc level of the array drivers.
to one driver on the array input connector.
4.3 Slowly sweep the signal generator from
2.3 Observe the driver under test. When the 100 Hz to 2.0 kHz. Listen for any extraneous
DC level is applied, the driver should move noises such as buzzes, rattles, ticks, port
outward. If it does, the driver is wired cor- noise or distortion. Replace any array with
rectly. If not, it is wired incorrectly. Repeat an extraneous noise that can be heard at a
steps 2.2 and 2.3 for the other driver in the distance greater than 1 foot (0.3m).
array.

23