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Bose® Lifestyle® Model CD5 Series I Music Center

Note: The first series CD5 can be distinguished from the later CD5V and CD5VII by the serial number label located on the bottom of the unit. The CD5 will not have a V on the serial number label, the CD5V will have a V, and the CD5V2 will have a V with the number 2 above the V.
©

1998 Bose Corporation

Service Manual
Part Number 174798 REV 01

Contents
Safety Information ............................................................................................................................ 2 Electrostatic Discharge Sensitive (ESDS) Device Handling ........................................................ 2 Specifications ................................................................................................................................ 3-4 Figure 1. CD5 Block Diagram Sheet 1 of 2 ...................................................................................... 5 Figure 2. CD5 Block Diagram Sheet 2 of 2 ...................................................................................... 6 CD Terms ..................................................................................................................................... 7-11 Theory of Operation .................................................................................................................. 12-17 Figure 3. Labelled Exploded View .................................................................................................. 18 Disassembly/Assembly Procedures ....................................................................................... 19-21 Figure 4. APC PCB ........................................................................................................................ 19 Figure 5. Back Panel with Tab Locations ....................................................................................... 22 Figure 6. Right Cover Assembly (side view) .................................................................................. 22 Figure 7. Base Assembly (top view with covers removed) ............................................................. 22 RC5 Disassembly/Assembly Procedures .................................................................................... 23 Figure 8. Remote Control Assembly Exploded View...................................................................... 23 Test Procedures ........................................................................................................................ 24-26 Figure 9. AM Test Setup ................................................................................................................. 26 Figure 10. Audio PCB Test Section ................................................................................................ 26 CD Test Procedures .................................................................................................................. 27-31 Figure 11. CD Alignment Fixture and Test Setup ........................................................................... 28 Figure 12. Passive Filter Network and Test Setup ......................................................................... 29 Figure 13. Digital PCB Adjustment Locations ................................................................................ 32 Parts List Notes .............................................................................................................................. 33 Console Assembly Parts List ........................................................................................................ 34 Figure 14. Exploded View .............................................................................................................. 35 Remote Control Assembly Parts List ........................................................................................... 36 Figure 15. RC5 Exploded View ...................................................................................................... 36 Electrical Part List ..................................................................................................................... 37-46 RC5 Electrical Part List ............................................................................................................. 47-49 Packaging Part List ........................................................................................................................ 50 Figure 16. Packaging Exploded View ............................................................................................ 50 Service Bulletin ......................................................................................................................... 51-53 CD5 Troubleshooting Guide .......................................................................................................... 54 CD5 Voltages and Waveforms.................................................................................................. 55-58 Integrated Circuit Diagrams ..................................................................................................... 59-66 Figure 17. RC5 PCB Layout ........................................................................................................... 67 Figure 18. RC5 Schematic ............................................................................................................. 68 CAUTION: THE LIFESTYLE ® MODEL 5 MUSIC CENTER 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. 1

SAFETY INFORMATION
1. Parts that have special safety characteristics are identified by the symbol on schematics or by special notes in the part lists. 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. Use the following checks to perform these measurements: A. Leakage Current Hot Check: With the unit completely assembled, 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's AC switch first in the ON position and then in the OFF position, measure from a known earth ground (metal water pipe, conduit, etc.) to all exposed metal parts of the unit (antennas, handle bracket, metal cabinet, screw-heads, 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's power cord plug in the outlet and repeat the 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 5.2M . 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.

ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) DEVICE HANDLING
This unit contains ESDS devices. We recommend the following precautions when repairing, replacing or transporting ESDS devices: · Perform work at an electrically grounded work station. · Wear wrist straps that connect to the station or heel straps that connect to conductive floor mats. · Avoid touching the leads or contacts of ESDS devices or PC boards even if properly grounded. Handle boards by the edges only. · 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.

2

SPECIFICATIONS
General
Dimensions: Weight: Finish: Power Input: Serial Data Output: Power: Input Impedance (@ 1kHz, max. volume): Output Impedance: Distortion: S/N Ratio: Headphone Output (32): Channel Separation: Muting (A, B outputs): Max. Output Level: 2.5"H x 15"W x 9"D (6 x 38 x 23cm) 3.7lb. (1.7kg) Plastic, in-mold brushed aluminum finish Detachable power pack, 12VAC compatible with each country's power requirements 2-3.5mm stereo jacks, Tip: Serial data output, Ring: +12Vdc turn on output. 14 Watts max. 5k @ aux./video input, 100k @ tape input 600 @ Speaker A, B output, 1k @ tape output 0.02% THD @ 1kHz, 2Vrms 105dB (A-weighted, max. volume) 45mW (max. output) 70dB -80dB 5Vrms (@ 1kHz, THD < .12%)

FM Electrical
Antenna Input: Usable Sensitivity: 50dB quieting sensitivity: S/N ratio (65dBf input): THD (65dBf, 1kHz input): Capture Ratio: AM Rejection (45 dBf input): Alternate Channel Selectivity (45 dBf input): Image Rejection: Frequency Response: Stereo Channel Separation: US: 75 F connector, Europe: 75 PAL US: 12dBf, Europe: 17dBf Mono: US: 15dBf, Europe: 20dBf Stereo: US: 37dBf, Europe: 42dBf Mono: 75dB, Stereo: 70dB Mono: 0.2%, Stereo: 0.3% 1.5dB 60dB US: 70dB, Europe: 75dB 70dB ± 0.5dB (30Hz-15kHz) 40dB @ 1kHz

3

SPECIFICATIONS
(Continued)

AM Electrical
Antenna Input: Usable Sensitivity: Alternate Channel Selectivity: Adjacent Channel Selectivity: Image Rejection Ratio: S/N Ratio: THD: Frequency Response (@ 100dBuV/m): Binding posts 55dBuV/m (IHF standard test loop antenna) 60dB 45dB 40dB 50dB (@ 100dBuV/m) 1.0% (@ 100dBuV/m) 100Hz: -8dB 3kHz: -8dB

CD Electrical
D/A Process: Maximum Output Level: THD+N: S/N Ratio: Channel Separation: Frequency Response: Dynamic Range: Defect Tracking (Void): Defect Tracking (Black Dot): Defect Tracking (Scratch): Defect Tracking (Fingerprint): Defect Tracking (Warped disc): Defect Tracking (Eccentric Disc): 8x over sampling dual 16-bit D/A conversion 4V 0.05% (@ 1kHz, 0dB) 100dB (A-weighted) 50dB (@ 1kHz) ± 0.5dB (20Hz-20kHz) 90dB 1.5mm (Pierre Verany Test Disc #2) 1mm (ABEX Test Disc TCD-725R) 1.6mm (ABEX Test Disc TCD-721R) 75um (ABEX Test Disc TCD-725R) 1mm (ABEX Test Disc TCD-732RA) 280um (ABEX Test Disc TCD-741R)

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Figure 1. CD5 Block Diagram Sheet 1 of 2

5

Figure 2. CD5 Block Diagram Sheet 2 of 2

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CD TERMS
Basic Terms
Access: See track access. Access Time: The length of time required to change tracks. CD Mechanism: The mechanical assembly of components used to read information off of the CD. It contains the optical pickup, sled assembly, disc motor, sled motor, and spindle. Disc Motor: The motor which spins the disc. Focus Actuator: The magnet and coil assembly that moves the optical pickup's lens up and down. Laser: A semiconductor light source similar to an LED that is used to read the data off of a CD. When the laser is turned on it can be seen as a red glow inside the lens. Laser Pickup: The portion of the CD mechanism that contains the laser diode, lens, focus and tracking actuators, and photodetector diodes. Mechanism: see CD Mechanism. Optical Pickup: See Laser Pickup. Playability: The extent to which a player can successfully play less than perfect discs. Playability is measured with special test discs (playability discs) that contain certain types of defects and problems. Playability Disc: A disc which contains a calibrated defect or problem. These include eccentricity, warp, scratch, void, black dot, and fingerprints. Parking: When the sled is moved to the innermost position on the disc. This is done before (if necessary) and after playing a disc. Sled: The portion of the CD mechanism that moves inside to outside to position the optical pickup near the desired track. Sled Motor: The motor which moves the sled back and forth. Spindle: The hub that the disc sits on. Track Access: The process of moving from one track on a disc to a different track. Tracking Actuator: The magnet and coil assembly that moves the optical pickup's lens inside and out.

Playability Terms
Dropout: A momentary loss of the audio signal, usually caused by a large scratch or other optical defect.

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CD TERMS
Eccentricity: The extent to which the hole in the middle of the disc is not located in the geometric center. In other words, the amount that the disc moves in and out as it rotates. Eccentricity is measured as the distance between the center of the hole and the center of the disc (as determined by the spiral tracks). Mistracking: When a CD player fails to play the disc in a continuous manner. This may be caused by a large enough optical defect (scratch, etc.) or by vibration. Optical Defect: A defect on the surface of the disc which adversely affects the reading of information by the laser pickup. There are four basic types of optical defects: voids, black dots, fingerprints, and scratches. Skipping: When a CD mistracks backwards and gets caught in an "endless loop". This is usually caused by a large scratch or other optical defect. Warp: The extent to which the surface of the disc is not parallel to the seating plane of the disc (at the center). In other words, the amount that the disc wobbles up and down. Warp is measured as the vertical deviation between the seating plane and the particular point on the disc.

Alignment Terms
CD Alignment: The process of adjusting a CD player for optimum performance, particularly with respect to its playability. Free Run Frequency: The VCO frequency in the absence of any signal from the disc. Accurate frequency adjustment is required for the player to be able to read data off the disc. VCO misalignment results in poor track access and longer access times. Tracking Offset: The DC offset voltage present at the output of the tracking servo in the absence of any input signal. For best results, the offset should be adjusted near 0 to keep the laser positioned in the center of the track. Negative offset causes the laser to be positioned towards the inside of the track. Misalignment of this parameter can cause the player to skip or mistrack when playing a dirty or "black dot" disc, especially if the disc is also eccentric. Scratches and voids may also cause the problem. Focus Offset: The DC offset voltage present at the output of the focus servo in the absence of any input signal. For best results, the offset should be adjusted near 0 to keep the laser exactly in focus. Misalignment of this parameter usually causes dropouts when playing a dirty or "black dot" disc, especially if the disc is also warped. Scratches may also cause problems. Note that on the CD5, the focus offset is preset and the adjustment pot is not loaded, however, there is a spot on the PCB for it. E-F Balance: The DC offset that results from driving both the E and the F elements of the photodetector with equal signals. For best results, the offset should be adjusted near 0 to keep the laser positioned in the center of the track. As with track offset, negative offset causes the laser to be positioned towards the inside of the track. Misalignment of this parameter can cause any number of problems including: 1. Poor or slow track access even when playing a good disc, and 2. Skipping or mistracking when playing a scratched or void disc, especially if the disc is also eccentric.

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CD TERMS
Tracking Gain: The overall loop gain of the tracking servo. This controls how tightly the laser is held in the center of the track. If the gain is too low, the player will have trouble with vibration and eccentric discs, especially during track access. If the gain is too high the player will have skips or mistracking with voids and scratches. Proper alignment is a compromise between these two performance parameters. Focus Gain: The overall loop gain of the focus servo. This controls how tightly the laser is held in focus. If the gain is too low, the player will have trouble with vibration and warped discs, especially during track access. If the gain is too high the player will have skips or mistracking with black dots and scratches. Proper alignment is a compromise between these two performance parameters.

Technical Terms
RFSM: RF SUM. The amplified A+B+C+D signal from the laser pickup. Eye Pattern: The pattern displayed on an oscilloscope when monitoring the RFSM test point. Jitter: The extent to which the zero crossings of the eye pattern occur at other than their ideal times. Focusing: Before a disc can be played, the player must focus the CD mechanism by changing the distance between the lens and the surface of the disc. This must occur before the disc can start rotating. If the player fails to achieve focus, it will retry. This occurs four times in the CD5 before it "gives up" and indicates "no disc" by lighting up the disc icon in the display. TOC: Table Of Contents. The innermost area on the disc where track and time information is stored. When a new disc is inserted into a player (i.e. when the door switch is opened), it must read the TOC before the first track can be played. CIRC: Cross Interleave Reed-Solomon Coding: The error detection and correction scheme used on CDs to provide immunity to small scratches, etc. CLV: Constant Linear Velocity. CD players rotate the disc at a constant linear velocity of 1.25 M/S. The angular velocity changes from about 500 RPM down to 200 RPM as the disc plays from beginning (inside) to end (outside). EFM: Eight-to-Fourteen-Modulation. The format in which the digital data is recorded on the CD. Photo Diode: The receiving element that translates the modulated light beam into electrical signals. Subcode Q data: The track and time information read off the CD. Three Beam System: The most common system for providing focus and tracking error signals for the respective servos. A three beam system uses a six element photo diode array, with the elements designated A through F. The A, B, C, and D elements are located in the center and read the information as well as supply the focus error signal. The E and F elements are located on either side and provide the tracking error signal.

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CD TERMS
Major Components of the System
ASP: Analog Signal Processor. The component in the CD circuitry that contains the RF amplifier, VCO, and the tracking, focus, and sled servos. DSP: Digital Signal Processor. The component in the CD circuitry that performs slicing, EFM demodulation, CIRC decoding, error correction and concealment, track access, CLV regulation, and drives the D/A. Digital to Analog Converter (D/A, DAC): A device that converts digital information (usually a serial data stream) into an analog signal.

µC: Micro Controller. The component of the CD circuitry that performs track access, sequences all events (such as focus, disc start, stop, etc.), monitors for servo errors, and processes user information (commands, door open, etc.). CLV Servo: The circuit that keeps the disc rotating at a constant linear velocity. Focus Servo: The circuit that keeps the optical pickup's lens the proper distance away from the surface of the disc. Sled Servo: The circuit that keeps the sled positioned within the linear range of the tracking actuator. Tracking Servo: The circuit that keeps the optical pickup's lens positioned within a single track as the disc rotates. VCO: Voltage Controlled Oscillator. Part of the phased locked loop circuit that generates an output frequency dependent on its input voltage.

Signal Names
ATSC: Anti-Shock Circuit. SLEQ: Sled Equalizer FDO: Focus Drive Output FEAO: Focus Error Amplifier Output. HFL: High Frequency Level PDO: Phase Detector Output PH: Peak Hold SLDO: Sled Drive Output. SPDO: Spindle Drive Output.

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CD TERMS
Signal Names
(continued) TAP: Test Access Port. A 3 pin test interface used by automated test to control and observe the board under test. TDO: Tracking Drive Output. TEAO: Tracking Error Amplifier Output. TGL: Tracking Gain Low. THLD: Tracking Hold. TOFF: Tracking Off TPA+: Tracking Pre-Amplifier (+ input). TPA-: Tracking Pre-Amplifier (- input). TPAO: Tracking Pre-Amplifier Output. VCOO: VCO Output Vref1: The reference voltage used by the RF amplifier in the ASP. Vref2: The unbuffered reference voltage used by the servos in the ASP. Vref3: The buffered reference voltage used by servos in the ASP.

List of Abbreviations
ASP CE CIRC CLV D/A DSP EEPROM EFM IC IR kHz MHz PLL RF µC VCO VFD Analog Signal Processor Control ExpanderTM Cross Interleave Reed-Solomon Code Constant Linear Velocity Digital to Analog Digital Signal Processor Electrically Erasable Program Read Only Memory Eight-to-Fourteen Modulation Integrated Circuit Infrared Kilohertz Megahertz Phase Locked Loop Radio Frequency Microcontroller Voltage Controlled Oscillator Vacuum Fluorescent Display

11

THEORY OF OPERATION
Overview
The Lifestyle® Model 5 music center is a self-contained CD player, AM/FM tuner, preamplifier, and control center for use with Bose® powered speaker systems. In addition to the two internal sources (CD and tuner), it also allows for up to three external devices to be connected (i.e. AUX, VIDEO, and TAPE). It uses a Radio Frequency (RF) remote control that allows the unit to be operated from different rooms within a house without the need for a line-of-sight path back to the console. The remote control commands for the external sources are translated and passed to the serial data output jack. With the CE-I accessory device this data can be converted to Infrared (IR) for use with many conventional audio devices.

Power Supply
The unit is powered by an external 12VAC power supply capable of delivering 1.2 amps rms. Dl, C2, D2, and C6 form positive and negative half-wave rectifiers respectively. Q1, Q2, Q3, and their respective components make up a discrete low dropout regulator with a nominal output voltage of 10. 2V. VR1 is the corresponding negative voltage regulator with an output of -12V. These two regulators create the bipolar supply used by all of the audio circuits. The supply is turned on and off with the unit by the control signal on J7-10. R5, D3, C9, and VR2 create an +8V regulated supply that is used by the CD servo circuits and the remote RF receiver. R6, D4, C11, and VR3 create a +5V regulated supply that is used by the main and CD microcontrollers (U402 and U505), and the CD control circuits (U501, U502, etc.). Both supplies are live at all times. R5 and R6 limit the power dissipation of their respective regulators. VR2 and VR3 normally run quite hot to the touch. R8, D6, and C13 form an unregulated supply (M+) that is used by the CD drive electronics. C14, D7, D8, and C15 form a charge pump that creates a negative high voltage. This voltage is regulated down to -24V by R9, D9, and C16. The vacuum fluorescent display (VFD) driver U403 uses this -24V to shut off segments in the display. C19 and C18 reduce the 12VAC to approximately 3Vrms. This voltage powers the display's (VFD401) heater. C16, D10, C17, and R10 provide a DC bias of -15V for the VFD heater (cathode).

Control Electronics
Main microcontroller (µC) U402 controls the audio circuits, tuner, display, and push buttons. The µC runs at a nominal frequency of 4.0MHz that is supplied by ceramic resonator X401. The µC is reset by a rising edge on pin 1 caused by R409 and C404. This occurs automatically on power-up but may be forced manually by depressing S416 (if installed). U402 communicates with U403 over a four wire serial data bus (U403, pins 15, 16, 18 and 19). The bus is updated once per millisecond. U403 latches the serial data into its outputs, driving the VFD. The VFD is a four grid multiplexed display with 16 anodes at each grid. The grids are turned on sequentially, one each millisecond. As each grid is turned on, the corresponding anodes for that grid are also turned on. This lights the desired segments. When the next grid is turned on, the anodes are changed to correspond to the desired segments under this next grid. In this way, the entire display is scanned, 1/4 at a time. The display is blanked for a brief interval in-between when one grid is turned off and the next is turned on. In this blanking interval, the push buttons are scanned to determine what keys are being pressed. This data is read in on U402, pins 12 through 15.

12

THEORY OF OPERATION
There is one main serial data bus that controls source selection IC U101, volume control IC U103, PLL frequency synthesizer U302, and EEPROM U401. The clock and data information for all of these devices is sent out on U402, pins 5 and 7. However, U401, U302, U101 and U103 each have their own chip select line. Data is sent to U302 whenever the tuner frequency is changed. During the serial data transmission, U302, pin 3 is driven high. Data is sent to U101 or U103 whenever a new source is selected or the volume is changed. At the completion of this transmission, the STRB line (J9-5) is driven high briefly. U401 is a nonvolatile EEPROM which is used for storing certain data such as tuner presets and house codes. This data is protected from loss during a power outage. U401 communicates with U402 over the main serial data bus. During communication to this chip, the chip select line (U401, pin 1) is driven high. There is another serial data bus between U402 and U505. These lines are labeled CD_READY, CD_CLK, CD_ CMD, and CD_DATA on the schematic. The bus sends commands (play, stop, etc.) to U505 and also sends track and time information to U402 so that it may be displayed. This bus is constantly in use any time "CD" is selected as the source. RR101 receives and demodulates commands from the RF remote control. R138, C130, C129, R139, and D109 remove noise and shape the pulse. U106 squares up the pulse edges and converts them to 5V logic levels. This signal is then fed to U402, pin 37. C401 prevents any glitches at this pin. In addition to the major functions mentioned above, U402 also performs several miscellaneous tasks. The bipolar power supply for the audio circuits (+1OV/-12V) is turned on and off by U402, pin 19 (power). Both supplies are turned on when this line is high (+5V), and off when it is low. The unregulated supply is monitored by C414, R407, and R408. In the event of a power failure, U402 will shut down the system gracefully. There are three independent muting circuits: Mute A, Mute B, and Power-on Mute. Mute A and Mute B are controllable from the remote, and allows the A and B outputs to be controlled independently. The Power-on Mute is used only during power-up (when the bipolar supply is turned on) to prevent pops and clicks. When an external source is selected (AUX, VIDEO, or TAPE), the transport commands (FF, FR, etc.) are passed through the serial data jack via Q401 and its associated circuitry.

Audio Circuits
There are two internal audio sources (CD and Tuner) and three external sources (AUX, VIDEO, and TAPE). All of the sources are routed to U101. R101-106 and R201-206 provide level matching for the different input sources. D101-106, D201-206, C101-103, and C201-203 provide static protection on the inputs. U101 selects 1 of the 5 input sources, and routes it to its output on pins 5 and 9 (left), and pins 20 and 24 (right). One half of U102 (pins 1-3 and 12-14) provides gain and buffering for the input signal. The buffered output is routed to U103 and to the FIXED output on J103. U103 consists of two sections. The first section attenuates the signal from 0 to 70dB in 10dB steps. The output of the first section is buffered by the other half of U102 (pins 5-7 and 8-10) and is fed to the second section. The second section attenuates the signal in 1dB steps. The two sections together provide smooth attenuation from 0 to 80dB in 1dB steps.

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THEORY OF OPERATION
U103's output signal is buffered by U105, and is fed to the A and B outputs. These outputs are independently mutable through transistors Q103-106 and Q203-206. Each pair of transistors provides approximately 80dB of attenuation when muted. These mute transistors are controlled by the signals on J9-7 and J9-8. U103's output signal is also routed to headphone amplifier U104. This provides gain and buffers the signal in order to drive a low impedance load. When the headphones are inserted into J104, the control signal on J105-3 causes the A speaker output to be muted. The TAPE output jack functions like the FIXED output does. There is one exception. The TAPE output is shut off whenever "TAPE" is selected as the source. This prevents feedback through the TAPE deck if it was placed in "Record" while "TAPE" was selected as the source. This is accomplished by feeding the FIXED level output signal from U102, pins 1 and 14 back into U101. A control signal from U402 allows U101 to pass this signal to its outputs on pins 5 and 17, except when "TAPE" is selected as a source. The FIXED, TAPE, and headphone outputs all have a single mute transistor which is used to prevent pops and clicks during power-up and power-down. These transistors are all controlled by the signal on J9-6. Each transistor provides about 40dB of attenuation when the muting is switched on.

CD Player
The CD circuitry consists of six major sections: Analog signal processor (ASP) U501, digital signal processor (DSP) U502, digital to analog converter (D/A) U506, CD microcontroller (µC) U505, power drivers U503 and U504, and the CD mechanism. U501 contains the RF amplifier and servo control circuits. U502 performs EFM demodulation, CIRC decoding, and outputs the digital audio to U506. It also extracts the subcode Q information (track #, time, etc.) and controls U501 during track access. U505 receives and interprets the subcode Q data from U502 and sends it along to U402. It also issues commands to U502 for track access, and controls all operations of the CD circuitry. U501 receives its input signal (through P501) from the mechanism's photo diode pickup. The A, B, C, and D inputs are added together and amplified. The RF amplifier output appears on RFSM (U501, pin 72 ). This signal is the familiar "eye pattern." This signal is sent to EFMIN on U502, Pin 8 where it is sliced for EFM demodulation. The inverted and non-inverted sliced outputs appear on the EFMO and EFMO~ lines (U502, pins 6 and 7) . These signals are lowpassed and subtracted and the output appears on SLCO (U501, pin 53). This signal supplies the DC bias for the RFSM signal. This signal is then sent to the slicer for slice level control. The RFSM signal is peak-detected and compared to a reference to determine if there is a signal being received back from the disc. The output appears on DRF (U501, pin 40 ). This signal is used by U505 to determine if the lens is in focus. The envelope of the RFSM signal is also used in determining when the laser crosses a track boundary during track access. The HFL signal (U501, pin 48) conveys this information to U502. The A+C signal is subtracted from the B+D signal. This produces the focus error signal FEAO (U501, pin 26 ). The focus gain is adjusted by R527. This signal is amplified and filtered by the focus servo amplifier (inside U501). It then appears as an output at FDO (U501, pin 22). The FDO signal is fed to U503. U503 generates the complementary outputs (pins 11 and 14) that are used to actuate the focus coil (P502, pins 5 and 8).

14

THEORY OF OPERATION
The E and F signals are amplified and subtracted. This produces the tracking error signal TEAO (U501, pin 7 ). The F channel's gain is adjusted by E-F balance potentiometer R506. The TEAO signal is used by the anti-shock circuit, the track jump detection circuit, and the tracking servo. The track jump detection output is sent to U502 on the TES line (U501, pin 47). R510, which is connected to TPA+ (U501, pin 13 ), adjusts the tracking gain. This signal is amplified and filtered. It then appears as an output on TPAO (U501, pin 15). R511 adjusts the tracking offset . The TPAO signal is further amplified and filtered. It then appears as an output on TDO (U501, pin 21). This signal is fed to U503. U503 generates the complementary outputs (U503) that are used to actuate the tracking coil (P502, pins 6 and 7). The TDO signal is also used as the input for the sled servo. This signal is filtered and fed to the sled servo amplifier on SLEQ (U501, pin 20). This signal is amplified and is then added to the FEED signals from U505. The result appears on SLDO (U501, pin 33). This signal is fed to U504. U504 generates the complementary outputs (pins 11 and 14) that are used to drive the sled motor (P503, pins 5 and 6). The Constant Linear Velocity (CLV) servo is regulated by comparing the playback speed to a FIXED reference frequency in U502. The error signal appears at U502, pins 10 and 11 (CLV+ and CLV-). These signals are subtracted and the difference appears on SPD (U501, pin 29). The SPD signal is filtered and amplified. It then appears at the output on SPDO (U501, pin 31). This signal is fed to U504. U504 generates the complementary outputs (pins 3 and 6) that are used to drive the disc motor (P503, pins 1 and 2). U501 regulates the laser power by monitoring the MD input (P502-3). This signal is compared to a reference to generate the proper drive signal on LDD (U501, pin 74). This signal biases Q501. Q501 drives the laser diode output LD (P502-1). U501's main DC reference voltage is Vref3 which appears on pin 9. This voltage is nominally 4V. The VCO is the final function contained in U501. The VCO is used by U502 for EFM demodulation. The PDO output signal (U502, pin 4) is filtered and amplified by U501. In turn, this output appears on VCOC (U501, pin 59) This is the VCO control voltage input. The nominal VCO free-run frequency is 8.64MHz and is set by R558. The VCO also requires a 16.9344MHz clock input from U502. This input appears on CLK (U501, pin 62). The VCO output appears at VCOO (U501, pin 60). This signal is buffered by U502. The buffered output appears on AO (U502, pin 2). The VCO output is divided by 2 in U502. In turn, its output appears on PCK (U502, pin 18), which is 4.32MHz. The DSP clock is derived from a 16.9344MHz crystal oscillator (X501). However, this oscillator is normally turned off by U505. It is only switched on during focusing and when a disc is playing. U502 receives its EFM input from U501 on EFMIN (pin 8). This signal is sliced, EFM demodulated, and CIRC decoded. The digital audio output signal is sent serially to U506 on the LRCLK, DFOUT and DACLK lines (U502, pins 33, 35, and 36). U502 receives servo control commands from U505 on the serial bus (U502, pins 51, 53 and 54). These commands are translated to appropriate control signals for U501 for focusing, disc start, disc stop, disc braking, and track jumps. The focus servo is controlled by the FOCS and FST outputs. The CLV servo is controlled through the CLV+ and CLV- lines. The tracking servo is controlled by the TOFF, TGL, and THLD outputs. Track jumps are created by signals on the JP+ and JP- lines. Track jump detection is based on signals from U501 on the HFL and TES inputs. 15

THEORY OF OPERATION
U505's oscillator is obtained from a 4MHz ceramic resonator (X502). U505 is reset by a rising edge on pin 1 that is caused by R573 and C574. This occurs automatically on power-up, but may be forced manually by depressing S502 (if installed). U505 communicates with U502 on a serial bus (U502, pins 50 through 54). U505 sends servo commands for focusing and track access to U502. U502 sends subcode Q data to U505 which extracts track, time and table of contents information from it. The time and track data is formatted, and is sent to U402 on a serial bus (U505, pins 11-13). During track access, U505 controls the sled motor directly using the FEED+ and FEED- lines (U505, pins 21 and 22). It also directly controls the laser U503 and VCO using the LASER~ line (U505, pin 9). When the laser is turned on, the VCO and U503 are enabled, otherwise they are turned off. U505 can also enable and disable U504 with the MOTOR_EN line (U505, pin 20). U506 (D/A converter) performs 8x oversampling and digital filtering. It then converts the digital audio into left and right stereo outputs. D/A reference voltages are obtained from zener diode D504. U506's analog outputs are buffered by one-half of U507 (pins 5-7 and 8-10). The buffered signal is lowpass filtered by the other half of U507. This removes any residual out-ofband digital noise. The recovered audio is then routed to U101.

Tuner
The FM antenna signal is routed through F connector J301 and enters the FM front end module. This contains a tuned RF amplifier, FM local oscillator, and a mixer. The IF output signal appears on pin 4 (front end) and passes through 10.7MHz ceramic filter CF302. The filter's output is amplified by the IF gain stage. This stage consists of Q307, Q308 and their associated components. The signal is then passed through a second ceramic filter, CF303, a second gain stage (Q309, Q310, etc.) and a third ceramic filter, CF304. CF304's output signal is sent to the main tuner IC, U301. This device contains the FM detector, FM stereo MPX decoder, stop level detection, as well as most of the AM circuitry (see below). U301 further amplifies the IF signal, and then performs FM detection. This detection uses a double tuned quadrature detector formed by T304 and T305. T305 is adjusted for FM center frequency by adjusting it for 0VDC between the AFC terminal (U301, pin 4) and the Vreg terminal (U301, pin 28). T304 is adjusted for minimum distortion (A few iterations may be required because these two adjustments are dependent on one another). The recovered audio appears on U301, pin 8. C313 and its associated components filter the recovered audio and feed it back into U301, pin 9. U301 performs the FM stereo MPX decoding. When you select FM, the decoded L/R channel signals are sent out on pins 14 and 15. The resistance between pin 12 and ground controls the separation. 456kHz ceramic resonator CF301 controls the PLL decoder. The PLL loop filter components are connected to pin 11. Potentiometer R334, which is connected to pin 30, sets the FM stop level to 33dBf (nominal). C304, R304, C307, and R309 perform FM de-emphasis. Q301, Q302 and their associated components buffer the signals. MPX filters T301 and T302 remove any unwanted out-of-band signals before sending them to U101. The AM loop antenna signal enters the unit through J301's screw terminals. The signal is then fed to AM front end module, T303. This device contains an RF tuned section and the AM local 16

THEORY OF OPERATION
oscillator tuned circuit. The tuned output appears on pin 12 and is fed to AM buffer FET Q300. The buffered output is sent to U301, pin 27. U301 contains the AM RF amplifier, mixer, IF amplifier, AM detector and AM stop level detection. Potentiometer R339, which is connected to pin 16, sets the AM stop level to 70dB uV/M (nominal). The IF output signal appears on pin 26 and is filtered by IF filter T307. The signal is then fed back into U301, pin 24 for AM detection. The AM detected output (pin 5) is filtered by C315, R316, and C314. The filtered output is fed back into U301, pin 6. Finally, it is sent to the L/R outputs (pins 14 and 15) when "AM" is selected. U302 controls the AM and FM local oscillators. U402 sets U302 so that it can select the AM or FM band and can tune to a particular frequency. The PLL reference oscillator originates from 7.2MHz crystal X301. This frequency is divided down to 400KHz (U302, pin 7). U302 divides down the local oscillator frequencies and compares them to an internal reference frequency. The error signal resulting from this comparison appears at pin 18. This error signal is integrated and filtered by Q304, Q305, and their associated components. This produces the tuning voltage which appears at Q304's collector. The tuning voltage is further filtered by R323, C326, R322, and C319. This signal is then sent to AM front end module T303, pin 14. It is used to vary the capacitance of two varactor diodes. This first diode varies the frequency of the AM local oscillator. The second tunes the AM RF input section to the desired frequency. Similarly, the tuning voltage is filtered by R330 and C333. Then it is fed to the FM front end module. The front end uses this voltage to vary the local oscillator frequency and to tune the RF input sections.

17

See Figure 6 for a side view of this assembly.

Figure 3. Labelled Exploded View

18

DISASSEMBLY/ ASSEMBLY PROCEDURES
1. Left Cover Assembly Removal Note: Refer to Figures 3 and 5 for Procedures 1 and 2. 1.1 Remove the two screws (18A) that secure the left cover (7) to the base (19). 1.2 Press in the three recessed gray tabs located on the connector panel and lift up on the rear of the cover. 2. Left Cover Assembly Replacement 2.1 Align the five hooks on the left cover (7) with the five catches on the front of the base (19). 2.2 Lower the left cover and snap it into place. The cover should be flush with the closed door assembly (1). 2.3 Replace the two screws (18A) that secure the left cover to the base (19). 3. Door Assembly and Right Cover Removal Note: Refer to Figures 3, 5 and 6 for Procedures 3 and 4. 3.1 Remove the left cover assembly (Procedure 1). 3.2 Remove the two screws (18B) that secure the right cover (6) to the base (19). 3.3 Press in the two recessed black tabs located on the connector panel. Lift up on the rear of the door assembly (1) and right cover assembly (6). 3.4 Remove the console latch (16). 4. Door Assembly and Right Cover Replacement 4.1 Position the console latch (16) in the base (19). 4.2 Align the two hooks on the right cover assembly (6) with the two catches on the front of the base assembly (19). Lower the cover into position. 4.3 There are two black tabs on the bottom of the right cover. Push them in slightly and snap the cover into place. 4.4 Replace the two screws (18B) that secure the right cover to the base. 4.5 Replace the left cover assembly (Procedure 2). 5. CD Mechanism Removal Note: Refer to Figures 3, 4 and 7 for Procedures 5 and 6. 5.1 Remove the left cover assembly (Procedure 1) and the door/right cover assembly (Procedure 3). 5.2 Lift the CD mechanism (11) straight up from the four metal posts in the base (19). Later models have 4 nylon washers (23) mounted on the posts. Do not remove them. 5.3 To prevent electrostatic damage to the mechanism, solder together the two points indicated in Figure 4.

Shorting point

Figure 4. APC PCB 5.4 Disconnect the 6 pin connector from the PCB that is attached to the motors and the 5 pin and 8 pin connectors from the APC PCB. Note: The support grommets (14, 15) and CD cover (12) are not supplied as part of the mechanism. Remove and reuse them if complete replacement of the mechanism is required. 19

DISASSEMBLY/ ASSEMBLY PROCEDURES
5.5 Slide the violet (14) and gray (15) grommets away from the slots in each corner of the mechanism. 5.6 Remove the two screws (13) that secure the cover (12) to the mechanism. Unsnap the cover from the mechanism. 6. CD Mechanism Replacement 6.1 Snap the cover (12) into position. Align the screw holes and replace the two screws (13) that secure the cover to the mechanism (11). 6.2 Slide the violet (14) and gray (15) grommets into their respective slots on each corner of the mechanism. See Figure 3 for their proper locations. 6.3 Connect the 6 pin connector to the PCB that is connected to the motors and the 5 pin (with black cable) and 8 pin connectors to the APC PCB. 6.4 Remove the solder from the shorted points shown in Figure 4. Note: Make sure that four nylon washers (23) are mounted on the posts before installing the mechanism (later models only). Note: The CD mechanism wires must be routed correctly (see Figure 7) for proper CD operation. A sign of improper routing is a clicking noise when playing tracks at the outermost edge of the CD. Perform the CD Final Verification tests on page 31 to ensure proper operation. 6.5 Place the mechanism on the four metal posts located in the base (19). Position as shown in Figure 3. 6.6 Replace the door/right cover assembly (Procedure 4) and left cover assembly (Procedure 2). 7. Digital PCB Removal Note: Refer to Figures 3 and 7 for Procedures 7 and 8. 7.1 Remove the left cover assembly (Procedure 1) and the right cover/door assembly (Procedure 3). 7.2 Lift up the CD mechanism (11) and move it aside. Keep the mechanism connected to the PCB unless removal is required. See Procedure 5 for removal procedure. 7.3 There are four black plastic tabs that hold the PCB (10) in position. See Figure 3. Flex them carefully outward and pull the PCB up and out. 7.4 Remove any connections required to troubleshoot the PCB. 8. Digital PCB Replacement 8.1 Replace any connections that were disconnected during troubleshooting. 8.2 Slide the PCB (10) into position. There are notches in the PCB which mate with notches in the base (19). See Figure 7. 8.3 Snap the PCB carefully down under the four locking tabs. 8.4 Push the CD mechanism (11) down onto the four metal posts. 8.5 Replace the right cover/door assembly (Procedure 4) and the left cover assembly (Procedure 2). 9. Audio PCB Removal Note: Refer to Figures 3 and 7 for Procedures 9 and 10. 9.1 Remove the left cover assembly (Procedure 1), the door/right cover assembly (Procedure 3), and the Digital PCB (Procedure 7). 9.2 There are four locking tabs (three on the PCB edges and one in the middle of the PCB) that secure the PCB (10) to the base (19). Flex the tabs carefully away from the PCB and disengage the PCB. 20

DISASSEMBLY/ASSEMBLY PROCEDURES
9.3 Slide the PCB clear of the connector panel, and pull it away from the base. 9.4 Remove any connections required to troubleshoot the PCB. 10. Audio PCB Replacement Note: Make sure that the connections to the Headphone Jack PCB (10) are routed through the guiding notch on the side of the console (see Figure 7). 10.1 Restore any connections that were disconnected during troubleshooting. 10.2 Slide the PCB's connectors through the holes in the rear of the base (19). 10.3 Snap the PCB (10) carefully down under the four locking tabs. Make sure that the CD mechanism connections are routed properly. See Figure 7 and procedure 6 note. 10.4 Replace the Digital PCB (Procedure 8), the door/right cover assembly (Procedure 4), and the left cover assembly (Procedure 2). 11. Headphone Jack PCB Removal Note: Refer to Figures 3 and 7 for Procedures 11 and 12. 11.1 Remove the left cover assembly (Procedure 1) and door/right cover assembly (Procedure 3). 11.2 There are two black plastic snaps that secure the PCB (10). Flex the snaps outward and carefully pull the PCB away from the unit. 12. Headphone Jack PCB Replacement 12.1 Snap the PCB (10) into place by engaging the two locking tabs. Note: Make sure that the connector wires are routed through the guiding notch on the side of the base (19). 12.2 Replace the door/right cover assembly (Procedure 4) and the left cover assembly (Procedure 2).

21

Figure 5. Back Panel with Tab Locations

Hooks onto front of console.

Tab that fits into cutouts on back panel Figure 6. Right Cover Assembly (side view)

Figure 7. Base Assembly (top view with covers removed)

22

RC5 DISASSEMBLY/ASSEMBLY PROCEDURES
1. Enclosure Disassembly 1.1 Slide off the battery compartment door (5) and remove the batteries. 1.2 While holding the top cover (4) with one hand, place your fingers from your other hand in the battery compartment and grasp the lower part of the bottom cover (3) with your fingers. 1.3 With your finger tips in the battery compartment, first pull parallel to the unit and then pull perpendicular. 1.4 With the catches released at the bottom, work your fingers up the sides to release the rest of the catches. 2. Enclosure Assembly 2.1 Lower the bottom cover (3) onto the top cover (4) so that the bottom cover's lip fits over the top cover. 2.2 Press the top cover and the bottom cover together until they snap into place. 3. PCB Removal 3.1 Lift the PCB (1) straight up. The springs will come up with the PCB. 4. PCB Replacement 4.1 Lower the PCB (1) into the top cover (4) so that the springs are in the battery compartment. 5. Pad Removal 5.1 The pad (2) is not secured. Grasp a corner of the pad and lift it out. 6. Pad Replacement 6.1 Lower the pad (2) into the top cover (4) so that the buttons line up with the holes in the top cover.

5 3

10

1

6

2

7 9

8 4

Figure 8. Remote Control Assembly Exploded View

23

TEST PROCEDURES
GENERAL TEST SETUP
Load the outputs as follows: Headphone output-33, 1% load. Audio (A, B, Fixed) outputs-10k load. Note: The remote control or console buttons can be used to select sources in these procedures. 1. AUX Gain Test 1.1 Select AUX. 1.2 Apply a 500mVrms, 1kHz signal to the left (right) AUX input. Adjust the volume to maximum. Reference a dB meter to the applied signal. 1.3 Ground the TAPE, VIDEO and the right AUX inputs. 1.4 Measure the outputs according to the following table. Output Speaker A (L,R) Speaker B (L,R) Tape (L,R) Fixed (L,R) Headphone (L,R) Min (dB) 4.2 4.2 3.3 4.2 5.4 Max (dB) 5.4 5.4 4.5 5.4 7.4 2.4 Measure the outputs according to the following table. Output Speaker A (L,R) Speaker B (L,R) Tape (L,R) Fixed (L,R) Headphone (L,R) Separation (dB) 50 50 50 50 50

2.5 Repeat this test for the right channel. Note: This test is the same for the VIDEO input. Apply a 500mVrms, 1kHz signal to the left (right) VIDEO input and repeat this test. 3. TAPE Gain Test 3.1 Select TAPE. 3.2 Apply a 500mVrms, 1kHz signal to the left (right) TAPE input. Adjust the volume to maximum. Reference a dB meter to the applied signal. 3.3 Ground the AUX, VIDEO and the right TAPE inputs. 3.4 Measure the FIXED level output. It should be 8.9 to 9.9dB. 3.5 Repeat this test for the right channel. 4. Volume Control Mute 4.1 Select the AUX input. 4.2 Apply a 500mVrms, 1kHz signal to the left (right) AUX input. 4.3 Set the volume to minimum at the speaker A output. 4.4 Measure the gain at the A output (relative to maximum volume). It should be -75dB.

1.5 Repeat this test for the right channel. Note: This test is the same for the VIDEO input. Apply a 500mVrms, 1kHz signal to the left (right) VIDEO input and repeat this test. 2. AUX Separation Test 2.1 Select AUX. 2.2 Apply a 500mVrms, 1kHz signal to the left (right) AUX input. Adjust the volume to maximum. Reference a dB meter to the applied signal. 2.3 Ground the TAPE, VIDEO, and right AUX inputs.

24

TEST PROCEDURES
5. Headphone Mute 5.1 Select the AUX input. 4. Stereo Separation 5.2 Apply a 500mVrms, 1kHz signal to the L/R AUX input. 5.3 Insert a mini-jack into the headphone output. The A output should mute. 4.1 Set the RF generator to 65 dBf, pilot on, left modulation, 1kHz, 100% (75kHz deviation). 4.2 Reference a dB meter to left FIXED output. 4.3 Measure the right FIXED output. It should be -25dB. Note: If the unit fails this test, perform the following procedure. 1. Change R354 to a 560, 5%, 1/10. 2. Remove W302. 3. Add R355 (a 1k, 10%, 1/2 W potentiometer). Adjust R355 for maximum separation. This option is listed on note 9 of the schematic. 5. FM Sensitivity 5.1 Set the RF generator to 42dBf, L= -R modulation, pilot on. 5.2 Reference a dB meter to the left FIXED output. 5.3 Measure the noise (with modulation off and pilot on) at the right FIXED output. The SNR should be > 50dB for the 120V version and > 45dB for the 220V version. Note: If the unit fails this test, the FM front end should be replaced. 3.3 Adjust the generator's output to 35dBf. Verify that U301 pin 21 is < 2.5Vdc.

FM ALIGNMENT TESTS AND ADJUSTMENTS
Unless otherwise noted, set an RF generator to 98.1MHz, 40dBf, 1kHz, mono modulation, pilot off, 100% (75kHz deviation). 1. Front End Mixer Coil Adjustment 1.1 Adjust the FM front end (TUNER) mixer coil until a maximum DC voltage is measured at U301 pin 25. Adjust the coil until the voltage comes within +0, -20mV of the peak voltage. 2. FM Detector Zero Adjust and Distortion Adjustment 2.1 Set the RF generator to 65dBf. 2.2 Adjust T305 until the voltage reads 0Vdc ± 110mVdc across C317+ (AFC test point) and C322+ (VREG test point). 2.3 Adjust T304 for minimum distortion. The distortion should be < 0.4%. 2.4 Repeat this procedure until optimal results are obtained. 3. FM Stop Level Adjustment 3.1 Set the RF generator to 31dBf. 3.2 Rotate R334 counterclockwise until the voltage at U301 pin 21 drops below 2.5Vdc. Then rotate R334 clockwise until the voltage goes above 2.5Vdc. Note: The correct adjustment is at the point just after the voltage switches high.

25

TEST PROCEDURES
AM ALIGNMENT PROCEDURES
Test setup: Connect the generator to a standard radiating loop. Unless otherwise noted, set an RF generator to 70dBu field strength, 400Hz, 30% modulation. See Figure 9.
STANDARD SIGNAL GENERATOR

1.2 Reference a dB meter to the Fixed level output. 1.3 Shut off the modulation and measure the noise. The SNR should be > 30dB. 2. AM Stop Level Adjustment 2.1 Set the RF generator so that the field strength at the unit's antenna is 59dBµ (59dBµ V/M). 2.2 Rotate R339 counterclockwise until the voltage measured at U301 pin 21 goes below 2.5Vdc. Then, rotate R339 clockwise until the voltage goes above 2.5Vdc. Note: The correct adjustment is at the point just after the voltage switches high. 2.3 Adjust the field strength to 64 dBµ (64 dBµ V/M). Verify that the voltage at U301 pin 21 is < 2.5Vdc.

(PLAN VIEW)

60cm TEST LOOP (SIDE VIEW)

STANDARD SIGNAL GENERATOR

Figure 9. AM Test Setup The equivalent field intensity is 26dB less than the generator output level or 1/20th of the output voltage. 1. AM Sensitivity Alignment 1.1 Set the RF generator so that the field strength at the unit's antenna is 70dBµ (70dBµ V/M).

Figure 10. Audio PCB Test Section

26

CD TEST PROCEDURES
CD ALIGNMENT PROCEDURES (WITH FIXTURE)
Note: Some of these procedures require the use of a CD alignment fixture (P/N 176318). Alternate procedures that do not require a fixture begin on page 30. Refer to Figure 11, CD Alignment Fixture Test Setup. The fixture is required unless otherwise specified. Refer to Figure 13 for adjustment locations. button until TO lights up). The meter should read approximately 90mVdc. 2.4 Simulate a closed CD door by placing an object between S501's two black posts (the CD door latch can be used). Select CD (S413). 2.5 After the focusing operation is completed, press ERASE (S403). The meter should change from its previous reading in step 2.3 (it will drop). If not, remove power and repeat the test. 2.6 Adjust R511 until the meter reads between -7 to 17mVdc. 3. E/F Balance (E/F) 3.1 Advance the alignment fixture (ADV button) to the E/F setting and set the voltmeter to read DC voltage. 3.2 Simulate a closed CD door by placing an object between S501's two black posts (the CD door latch can be used). Load the YEDS-18 test disc, select CD (S413), and play track 2. 3.3 Press STORE (S411). This puts the unit in the E/F balance mode. The time display will stop. 3.4 Adjust R506 until the meter reads between - 10 to + 50mVdc. 4. Tracking Gain (TG) 4.1 Shut the unit off. 4.2 Advance the fixture to the TG setting and set the voltmeter to read AC voltage. 4.3 Simulate a closed CD door by placing an object between S501's two black posts (the CD door latch can be used). Load the YEDS-18 test disc, select CD (S413), and play track 2. 4.4 Adjust R510 until the meter reads between 440 to 500mVrms. 27

Test Equipment Needed
Digital Voltmeter Frequency Counter Sony Disc YEDS-18 Bose® CD Alignment Fixture (176318) 1. PLL Free Run Frequency (VCO) Note: This test does not require a test disk or the alignment fixture. 1.1 Connect the frequency counter to PCK and ground. 1.2 Simulate a closed CD door by placing an object between S501's two black posts (the CD door latch can be used). Select CD (S413). 1.3 Adjust R558 until the frequency counter reads 4.320MHz ± 20kHz. (If the adjustment is not done within 4 seconds, then CD must be selected again). 2. Tracking Offset (TO) Note: Remove any previously loaded test disc. This test will not work with a disc loaded. 2.1 Connect the cable from the test fixture to connector P504 on the unit. 2.2 Connect a DC voltmeter to the positive (+) and negative (-) terminals on the test fixture. 2.3 Select TO on the fixture (press the ADV

CD TEST PROCEDURES
5. Focus Gain (FG) 5.1 Advance the fixture to FG and set the voltmeter to read AC voltage. 5.2 Simulate a closed CD door by placing an object between S501's two black posts (the CD door latch can be used). Load the test disc, select CD (S413), and play track 2. 5.3 Adjust R527 until the meter reads between 380 to 420mVrms. 6. Tracking Offset Readjustment 6.1 Refer to procedure 2 and readjust if necessary.

Front Panel

ADV.

TO

E/F

TG

FG

Back Panel
To DVM + Power Pack

P504

T o 12 VAC CD5 IN

This RJ-45 connection only fits one way. The other end plugs directly into P504 on the Digital PCB.

2' cable connects to "12 VAC ~ IN" on CD5 back panel. Both ends of the cable are terminated exactly the same way as the power pack.

Figure 11. CD Alignment Fixture and Test Setup

28

Figure 12. Passive Filter Network and Test Setup 29

CD TEST PROCEDURES
CD ALIGNMENT PROCEDURES
(Without Fixture)
Note: Refer to Figure 12 throughout this procedure. 3. E/F Balance Note: The test disc is required for this test. Construct the filter indicated in Figure 12 and connect it to P504 pin 4 (TEAO). 3.1 Connect a DC voltmeter between the filter output and P504 pin 1 (Vref3). 3.2 Load the test disc, select CD (S413), and play track 2. Skip forward using S408. 3.3 Press STORE (S411). This puts the unit in the E/F balance mode. The time display will stop. 3.4 Adjust R506 until the meter reads between - 10 to + 50mVdc. 4. Tracking Gain Note: Shut the unit off. Construct the filter indicated in Figure 12 and connect it (FLT IN) to P504 pin 6 (TPA+). 4.1 Connect an AC voltmeter between the filter output (FLT OUT) and P504 pin 1 (Vref3). 4.2 Connect a 100k resistor to P504 pin 7 (TPA-). Connect an oscillator to the resistor's other end and apply a .5Vrms, 1.7kHz signal to it. 4.3 Insert the test disc and select CD (S413) and play track 2. 4.4 Adjust R510 until the meter reads between 26.3 ± 1.5mVrms. 5. Focus Gain Note: Construct the filter indicated in Figure 12 and connect it (FLT IN) to P504 pin 5 (FEAO). 5.1 Connect an AC voltmeter between the filter output (FLT OUT) and P504 pin 1 (Vref3). 5.2 Connect a 300k resistor to P504 pin 8 (FSW). Connect an oscillator to the resistor's other end and apply a .5Vrms, 1.7kHz signal to it. 30

Test Equipment Needed
Voltmeter (input impedance > 10M) Frequency Counter Sony Disc YEDS-18 Audio Oscillator 1. PLL Free Run Frequency (VCO) 1.1 Connect the frequency counter to PCK and ground. 1.2 Simulate a closed CD door by placing an object between S501's two black posts (the CD door latch can be used). Select CD (S413). 1.3 Adjust R558 until the frequency counter reads 4.320MHz ± 20kHz. (If the adjustment is not done within four seconds, then CD must be selected again). 2. Tracking Offset Note: Remove any previously loaded test discs. This test will not work with a disc loaded. 2.1 Connect a DC voltmeter between P504 pins 2 (TDO) and 1 (Vref3). The meter should read approximately 90mVdc. 2.2 Simulate a closed CD door by placing an object between S501's two black posts (the CD door latch can be used). Select CD (S413). 2.3 After the focusing operation is completed, press ERASE (S403). The meter should change from its previous reading in step 2.1 (it will drop). If not, remove power and repeat the test. 2.4 Adjust R511 until the meter reads between -7 to +17mVdc.

CD TEST PROCEDURES
5.3 Skip back to the beginning of track 2. 5.4 Adjust R527 until the meter reads between 23.2 ± 1.5mVrms. 6. Tracking Offset Readjustment 6.1 Refer to procedure 2 and readjust if necessary. 3.4 Fingerprint: Play track 15 (75µm). Listen for at least 10 seconds.

Final CD Verification Tests
Note: Audible defects are defined as CD dropouts or skipping during play. All units must be able to pass these tests without any audible defects. 1. Warp 1.1 Insert Abex test disc TCD-732RA (or equivalent). Play track 16 (.7 mm). 1.2 Pause the CD and confirm that there are no mechanical scraping sounds. 1.3 Access track 16 again and confirm that it plays properly. 2. Eccentricity 2.1 Insert Abex test disc TCD-714R (equivalent test disc must be eccentric by 210µm). 2.2 Play track 1 (210µm). Listen for at least 4 seconds. 2.3 Access track 15 ( or furthest track on equivalent disc) and confirm that the unit plays properly. 3. Optical Defects 3.1 Insert Abex test disc TCD-725 (or equivalent). 3.2 Void: Play track 6 (1mm). Listen for at least 6 seconds. 3.3 Black dot: Play track 9 (.8mm). Listen for at least 8 seconds. 31

Figure 13. Digital PCB Adjustment Locations 32

PARTS 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 Parts 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. 4. This PCB is part of a pallet. The pallet contains the Display PCB, Audio PCB, and Headphone PCB. This PCB assembly is manufactured and sold as a pallet.

33

CONSOLE ASSEMBLY PARTS LIST
(Figure 14)
Item Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Description Door Assembly Spring-Torsion, LH Spring-Torsion, RH Pin-Hinge, 5.3" Gear-Damper, Blue Cover Assembly, Right Cover Assembly, Left Nameplate, Flat Black Spring, Ground PCB Assembly, 120V PCB Assembly, 220V PCB Assembly, 120V/220V CD Mechanism, CD90V1, W/APC Cover, CD Mechanism Screw-Tapp, 2 x 6 mm, PAN, XREC Grommet, CD Support, Violet Grommet, CD Support, Gray Latch, Console Spacer, Foam, Rectangular, .25 Screw-Tapp, 6-20 x .375, PAN, XRC/S Base Assembly Cable, 5 conductor, 8" Cable, 8 conductor, 8" Pad, Foam, Adhesive Backed Part Number 187743-001 176083 176082 173210 146816-05 149956 190819 180213 173449 146075-101A 146075-201A 146075-601A 146074 148787 149954-04 146822-02 146822-01 146081 172332-04 172779-06 149955-01 172599 172673 174231 Note

1, 2, 4

34

Figure 14. Exploded View 35

REMOTE CONTROL ASSEMBLY PARTS LIST
(Figure 15)
Item Number 1 2 3 4 5 6 7 8 9 10 Description PCB ASSY RMT CNTRL, RC-5A MAT, SWITCH, CD-5 COVER, BOTTOM, CD-5 COVER, TOP, CD-5 DOOR, BATTERY, CD-5 CONTACT, BATTERY, CONE CONTACT, BATTERY, FLAT CONTACT, BATTERY, CONE/FLAT CONTACT, BATTERY, FLAT/CONE SPACER, PAD, FOAM Part Number 194387 146088 146089 146090 146226 174001 174000 174002-01 174002-02 173605 Note 1, 2

5 3

10

1

6

2

7 9

8 4

Figure 15. RC5 Exploded View 36

ELECTRICAL PART LIST
Resistors
Reference Designator R1, 4, 113, 213, 330, 333, 336, 342, 348, 353, 145, 406, 420-423, 426, 427, 431, 433-442, 502, 503, 553, 572, 598, 600 R2, 315 Description 1k, 5%, 1/10W, 0805 Part Number 133626-1025 Reference
US/Can.

5.11k, 1%, 1/10W, 0805 R3, 109, 111, 209, 4.75k, 1%, 1/10W, 211 0805 R5 2.7, 5%, 1/2W, 52mm, CF R6 10, 5%, 1W, Metallic Oxide R7 1.5k, 5%, 1/4W, 52mm, CF R8 1.5, 5%, 1W, Metallic oxide R9 220, 5%, 1/4W, 52mm, CF R10 75, 5%, 1/4W, 52mm, CF R12 27, 5%, 1/10W, 0805 R101, 102, 201, 202 9.76k, 1%, 1/10W, 0805 R103, 203, 588, 592 1k, 1%, 1/10W, 0805 R104, 105, 204, 205 15.4k, 1%, 1/10W, 0805 R106, 107, 110, 100k, 5%, 1/10W, 114, 139, 206, 207, 0805 210, 214, 407, 415, 424, 425, 545, 566, 568, 575, 577, 589, 593, 595 R108, 208 12.4k, 1%, 1/10W, 0805 R112, 212 22.1k, 1%, 1/10W, 0805 R115, 215 825, 1%, 1/10W, 0805 R116, 117, 119, 4.7k, 5%, 1/10W, 120, 123-125, 127, 0805 130-133, 216, 217, 219, 220, 223-225, 227, 230-233, 318, 331, 337, 323, 327, 335, 356, 357, 410, 414, 509, 524, 560, 580, 603 R118, 218 619, 1%, 1/10W, 0805
37

133625-5111 133625-4751 121243-1512R75 173314-1005 121243-1211525 171259-1R55 121243-1212215 121243-1217505 133626-2705 133625-9761 133625-1001 133625-1542 133626-1045

133625-1242 133625-2212 133625-8250 133626-4725

133625-6190

ELECTRICAL PART LIST
Resistors (Continued)
Reference Description Designator R121, 128, 221, 228 432, 1%, 1/10W, 0805 R122, 129, 222, 229 182, 1%, 1/10W, 0805 R126, 226 150, 1%, 1/10W, 0805 R134-136, 142, 599, 1M, 5%, 1/10W, 601 0805 R138, 304, 309, 10k, 5%, 1/10W, 325, 338, 341, 358 0805 R140, 303, 308, 552 330k, 5%, 1/10W, 0805 R141, 522, 557, 578 33k, 5%, 1/10W, 0805 R143 30k, 5%, 1/10W, 0805 R144, 569 1.8k, 5%, 1/10W, 0805 R145 3.3k, 5%, 1/10W, 0805 R145, 302, 307, 2.2k, 5%, 1/10W, 504, 565 0805 R300, 525, 540 1.2k, 5%, 1/10W, 0805 R301 220, 5%, 1/10W, 0805 R305, 310, 313, 507 2.7k, 5%, 1/10W, 0805 R306, 311, 516 5.6k, 5%, 1/10W, 08