SoundDock® Portable

Digital Music System

February 16, 2009 - The Apple® Computer security chip (U7042) was added to the DSP board to provide
“Works With iPhone” compatibilty. DOM 9026.

©2007 Bose Corporation Service Manual

Reference Number 300657-SM Rev. 10
Electronic Copy Only
 CONTENTS
Safety Information ............................................................................................................................. 3
Specifications .................................................................................................................................... 4
Part List Notes .................................................................................................................................. 5
Electrostatic Discharge Sensitive (ESDS) Device Handling ....................................................... 5
Warranty .............................................................................................................................................5
Product Description ..................................................................................................................... 6-7
Power Supply Part List .....................................................................................................................8
Packaging Part List ........................................................................................................................... 9
Figure 1. Packaging Exploded View ..................................................................................................9
Speaker Assembly Part List ........................................................................................................... 10
Figure 2. Speaker Assembly Exploded View ...................................................................................10
Baffle Assembly Part List ............................................................................................................... 11
Figure 3. Baffle Assembly Exploded View ....................................................................................... 11
Dock Assembly Part List ................................................................................................................. 12
Figure 4. Dock Assembly Exploded View ........................................................................................ 12
Electrical Part Lists .................................................................................................................. 13-25
Disassembly Procedures ......................................................................................................... 26-28
Test Procedures ............................................................................................................................. 29
iPhone Test Procedures ................................................................................................................ 30
Tap Command Set Up ............................................................................................................... 31-33
Amplifier Gain Procedure .............................................................................................................. 34
Battery Test ............................................................................................................................... 35-36
Block Diagram ................................................................................................................................. 37
Revision History ............................................................................................................................. 38

2
 SAFETY INFORMATION
1. Parts that have special safety characteristics are identified by the symbol on schematics
or by special notes on the parts list. Use only replacement parts that have critical characteristics
recommended by the manufacturer.

2. Make leakage current or resistance measurements to determine that exposed parts are
acceptably insulated from the supply circuit before returning the unit to the customer.
Use the following checks to perform these measurements:

A. Leakage Current Hot Check-With the unit completely reassembled, plug the AC line cord
directly into a 120V AC outlet. (Do not use an isolation transformer during this test.) Use a
leakage current tester or a metering system that complies with American National Standards
Institute (ANSI) C101.1 “Leakage Current for Appliances” and Underwriters Laboratories (UL)
UL6500 / UL60065 / IEC 60065 paragraph 9.1.1. With the unit powered on, 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 cur-
rent measured must not exceed 0.5 milliamp. Reverse the unit power cord plug in the outlet and
repeat test. ANY MEASUREMENTS NOT WITHIN THE LIMITS SPECIFIED HEREIN INDICATE
A POTENTIAL SHOCK HAZARD THAT MUST BE ELIMINATED BEFORE RETURNING THE
UNIT TO THE CUSTOMER.

B. Insulation Resistance Test Cold Check-(1) Unplug the power supply and connect a jumper
wire between the two prongs of the plug. (2) Turn on the power switch of the unit. (3) Measure
the resistance with an ohmmeter between the jumpered AC plug and each exposed metallic
cabinet part on the unit. When testing 3 wire products, the resistance measured to the product
enclosure should be between 2 and infinite MOhms. Also, the resistance measured to exposed
input/output connectors should be between 4 and infinite MOhms. When testing 2 wire prod-
ucts, the resistance measured to exposed input/output connectors should be between 4 and
infinite MOhms. 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.
CAUTION: The SoundDock® Portable Digital Music System con-
tains no user-serviceable parts. To prevent warranty infractions,
refer servicing to warranty service stations or factory service.

WARNING: Danger of explosion if remote battery is incorrectly

replaced. Replace with only Duracell, Eveready, Energizer,
Maxell, Toshiba or Shun Wo CR2032 or DL2032 3-volt lithium
battery.

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.

3
 SPECIFICATIONS

Electrical

Power Supply Input:

Voltage: 100VAC to 240VAC (universal), 50-60Hz

Current Consumption: 1 A (rms) max for 115VAC
.5 A (rms) max for 230VAC

Power Supply Output:

Voltage: 20V +/- 1V DC

Current: 2A (max)

SoundDock® Input:

Voltage: 20V, +/- 1V DC

Current Consumption: 2 Amp (max, continuous)
Power Consumption: 40W (max, continuous)

Acoustic

Drivers: 2 - 2.25” Full Range Twiddler™ speakers

Nominal Impedance: 2.2 Ohms

Port Tuning: 65 HZ

Physical Description

Mechanical Specifications: Battery attached, Dock open

6.59”H x 12.08”W x 5.75”D (16.73 cm x 30.68 cm x 14.60 cm)

Weight: System with Battery attached

4.45 lb (2.0 kg)
Enclosure: Ultrasonically welded PC/ABS plastic

4
 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.

WARRANTY
The SoundDock® Portable Digital Music System electronics are covered by a limited 1-year transfer-
able warranty.

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.

4. This part is referenced for informational purposes only. It is not stocked as a repair part. Refer
to the next higher assembly for a replacement part.

5
 PRODUCT OVERVIEW

PRODUCT DESCRIPTION
The SoundDock® Portable Digital Music System is the next product in the line of Bose® iPod
speaker systems. It offers all of the features of the original SoundDock and adds rechargeable
battery enabled portability, a stow-away dock, an auxiliary input and a fresh appearance.
Features:

• Rotating iPod Dock

• Volume Controls (touch sensors)
• Vibration Isolation Mounting
• Power Input
• AUX input
• Battery Connection
• Infrared Detector
• Indicator LED
• Carrying Handle (Acoustic Port)

POWER SUPPLY
A 20 Volt, 40 Watt switching power supply is provided. The power supply is intended to plug
directly into an AC outlet rather than using an AC line cord. This universal power supply can be
used with any standard power distribution network including 90 volts to 240 volts and 50 Hz to 60
Hz.

There are two version of the power supply, they were developed independently and therefore
have different electrical designs. Outwardly they look very similar. Separate from the power
supply will be one or more sets of clips – also referred to as prongs, plugs, or adapters. The
clips connect to the power supply housing and interface to the local AC power socket conven-
tion.

There are seven different types of clips:

• North America
• EU
• China
• UK
• Australia
• Korea
• Argentina

The two different supplies do not have the same mechanical interface for the clips – clips from
one version of the supply cannot be used on the other. It is easy to tell them apart: one uses a
circular clip design and the other uses a rectangular clip design. The combination of two ver-
sions, two colors and seven regions results in a total of 28 different clips. The power supply is
not serviceable.

REMOTE CONTROL
An infrared remote control is included. It uses the same battery that is used with our credit card
style remote controls: CR2032. The infrared codes used for this remote control do not overlap
with those used for other Bose products. The remote control is not serviceable.

6
 PRODUCT DESCRIPTION CONTINUED

BATTERY
SoundDock® Portable uses a 4-cell lithium-ion rechargeable battery similar to those used for
laptop computers. It comes in black or white to match the console.

The battery comes already attached to the SoundDock Portable console. A spring loaded coin
screw serves as the attachment mechanism. Electrically, connection is made through an 8-pin
blade connector.

The battery contains the cells, protection circuitry, fuel-gauging circuitry and charging circuitry. It
is not serviceable and must be recycled or returned to the vendor if it is not working properly.
Note that the SoundDock Portable battery expected life time is about 3 years or 300 charging
cycles. Additional batteries are available separately.

IPOD INSERTS
All SoundDock Portable systems are shipped with an iPod insert already inserted into the dock. It
is purposely over-sized and allows any iPod with a docking connector to be plugged in. It does
not, however, provide mechanical support to the iPod, and it is highly recommended that the
appropriate insert from Apple be used.

Additionally, SoundDock Portable systems are shipped with an insert that is appropriate for use
with an iPod Nano. This is because it is considered especially important that an insert be used
with a Nano.

7
 POWER SUPPLY PART LIST

301141-001 BLK 306386-101 BLK

301141-002 WHT 306386-102 WHT
or
301141-011 BLK
301141-012 WHT

Note: The power supply part number does not include

the AC clip. See part list below for details.

There are two different power supplies created for the SoundDock® Portable Digital Music
System. Each has a unique mechanical interface. One is circular and the other is rectangular,
they are not interchangable. Use the part list below to identify the part numbers needed for each
version of the supply.

Description Bose® Part Note

Number
PWR PACK, 20V, 2A, BLK (rectangular) 301141-001 3
PWR PACK, 20V, 2A, WHT (rectangular) 301141-002
or or
PWR PACK, 20V, 2A, BLK (rectangular) 301141-011
PWR PACK, 20V, 2A, WHT (rectangular) 301141-012

PWR PACK, 20V, 2A, BLK (circular) 306386-101

PWR PACK, 20V, 2A, WHT (circular) 306386-102

AC CLIP, 120V, US, BLK (rectangular) 304114-001 3

AC CLIP, 120V, US, WHT (rectangular) 304114-002
AC CLIP, 120V, US, BLK (circular) 304158-001
AC CLIP, 120V, US, WHT(circular) 304158-002
*AC CLIP KIT, APAC, BLK (rectangular) 304114-251
*AC CLIP KIT, APAC, WHT (rectangular) 304114-252
*AC CLIP KIT, APAC, BLK (circular) 304158-351
*AC CLIP KIT, APAC, WHT (circular) 304158-352
*AC CLIP KIT, EU/UK, BLK (rectangular) 304114-121
*AC CLIP KIT, EU/UK, WHT (rectangular) 304114-122
*AC CLIP KIT, EU/UK, BLK (circular) 304158-121
*AC CLIP KIT, EU/UK, WHT (circular) 304158-122
*APAC kit includes the AC clips for China, Australia and Korea
*EU/UK kit includes the AC clips for Europe and the United Kingdom

8
 PACKAGING PART LIST
BOSE® SOUNDDOCK PORTABLE DIGITAL MUSIC SYSTEM
Item Description Part Number QTY Note
Number
1 OWNERS GUIDE, MAX, 8L, US/EU/UK 300673 1
OWNERS GUIDE, SD P, 6L, AP 306331
2 SEE POW ER SUPPLY DETAILS ON PAGE 7 - -
3 SEE AC PRONG DETAILS ON PAGE 7 - -
4 INSERT NANO, SD P, BLK 307663-001 1
INSERT NANO, SD P, W HT 307663-002
5 REMOTE CNTRL, IR, 6 FUNC, BLK 301373-001 1
REMOTE CNTRL, IR, 6 FUNC, W HT 301373-002
6 PACKING, TRAY, TOP 14 X 9 X 4 300698 1
7 PACKING, TRAY, BOTTOM 14 X 9 X 4 300699 1
8 CARTON, BLK 14.19 X 9.19 X 8, PRINTED 311574 1
CARTON, BLK 14.19 X 9.19 X 8, BLANK 300697
- INSERT, UNIVERSAL, WHT 303570-002
- INSERT, UNIVERSAL, BLK 303570-001 1
- RECHARGE, LI-ION, BATTERY PACK, BLK 043517 1 3
RECHARGE, LI-ION, BATTERY PACK, W HT 043516

4
5 3
6

Figure 1. Packing Exploded View

9
 SPEAKER ASSEMBLY PART LIST
BOSE® SOUNDDOCK PORTABLE DIGITAL MUSIC SYSTEM
Item
Number Description Part Number QTY Note
1 BAFFLE, FRONT, SHEET METAL - 1 4
2 NUT PLATE, LEFT 300679-001 1
3 RECHARGE, LI-ION, BATTERY PACK, BLK 043517 1 3
RECHARGE, LI-ION, BATTERY PACK, WHT 043516

4 SCREW, 6-13 X .625, PAN, XREC/SQ 288374-010 6 4

5 TWIDDLER ASSY W/HARNESS 302612-001 1
6 NUT PLATE, RIGHT 300680-001 1
7 CABLE, 28AWG, RIBBON, 1.0MM, 220MM 302209-15220 1
8 IO BOARD, PCB ASSY, SVC, ROHS 307957-002 1 3

9 SCREW, 6-13 X .5/8 LG HD XREC/SQ 307354-010 1 4

10 SCREW, 6-13 X .625, PAN, XREC/SQ 288374-010 6 4
11 MODULE ASSY, CRADLE, SVC, MD SLVR, BLK 300660-101 1
MODULE ASSY, CRADLE, SVC, MD SLVR, WHT 300660-102
12 SCREW, 6-13 X 5/8 LG HD XREC/SQ - 4 4
13 FOOT, RUBBER 301750-001 4
14 GRILL, ASSY, MD SLVR, BLK 300684-001 or 1
309981-001
GRILL, ASSY, MD SLVR, WHT 300684-002 or
309981-002
15 GRILL GASKET 304107-018 4
16 GASKET, EMI, RECTANGULAR 307375-050 2
17 CABLE, FLEX, 2POS, 0.5P 310678-001 1
18 ENCLOSURE, REAR, BLK 300676-011 1
ENCLOSURE, REAR, WHT 300676-012
- FASTENER, INTERLOCK, 120mm (velcro) 309014-120 2
- FASTENER, INTERLOCK, 120mm (velcro) 309014-025 2
3

17
5

18
6
4 7

8
9

11

10
12

13
14 15 16

Figure 2. Speaker Assembly Exploded View

10
 BAFFLE ASSEMBLY PART LIST
BOSE® SOUNDDOCK® PORTABLE DIGITAL MUSIC SYSTEM

Item Description Part Number QTY Note

Number
1 FOAM, TOP, PORON 308109-002 1
2 PAD, THERMAL 303561-001 1
3 *AMP BOARD, SVC, ROHS *307960-002 1
4 CABLE, FFC, 25POS, 38MM 301956-038 2
5 SCREW, TAPP, 6-32 x .375, PAN, TORX - 7 4
6 IR, SVC BOARD, ROHS 307961-002 1
7 CABLE, FFC, 5POS, 85MM 301957-085 1
8 SCREW, TAPP, 6-32 x. 375, PAN, TORX - 1 4
9 TAPE, FOAM 307725-012 1
10 BAFFLE, FRONT, SHEET METAL 300696-001 1
11 FOAM, BOTTOM, PORON 308110-002 1
12 *DSP, SVC BOARD, ROHS (Works With iPhone) *319975-001S 1
13 SPS, SVC BOARD, MAX, ROHS 307959-002 1
* See page 33 - Default gain adjustment

1 4 5
3
2

13
6
12

9 11
8
7

10

Figure 3. Baffle Assembly Exploded View

11
 DOCK ASSEMBLY PART LIST
BOSE® SOUNDDOCK® PORTABLE DIGITAL MUSIC SYSTEM
Item Description Part Number QTY Note
Number
1 TOP CRADLE, BLK 300690-001 1
TOP CRADLE, WHT 300690-002
2 DOCK, SVC BOARD 307958-002 1
3 INSERT CLIP 303567-001 1
4 CABLE, FFC, 8POS, 0.5P, 155MM 303564-155 1
5 CABLE, FFC, 10POS, 0.5 MMP, 165MM 303565-165 1
6 CRADLE ASSY, PTD, MED SLVR, BLK 300685-004 1
CRADLE ASSY, PTD, MED SLVR, WHT 300685-003
7 LOGO, NAMEPLATE, CURVED 301757-001 1
8 PLATE, BOTTOM ENCL, BLK 305265-001 1
9 UNIVERSAL INSERT, IPOD, BLK 303570-001 1
UNIVERSAL INSERT, IPOD, BLK 303570-002
10 PLATE, CRADLE STOP 304103-001 1
11 DAMPER, GEAR, LOW PROFILE 305113-001 1
12 SPRING, CRADLE LATCH 309584-002 1
13 DOCK, TRIM, METAL, BLK 301498-001 1
DOCK, TRIM, METAL, WHT 301498-002
14 LATCH 300686-001 1
15 SCREW-6-32-PAN_HD-ROLOK 306601-001 1
16 SPRING, DOCK 301754-001 1
17 SCREW, THD FRM, 2-28 X 1/4, PAN 289396-004 3 3
18 MAGNET, DOCK 304109-001 1
19 ISOLATION GROMMET 305269-001 4

Figure 4. Dock Assembly Exploded View

9
1

10

11
3

12
4
13
5
6

14

7 15

19
16

17

18

12
 ELECTRICAL PART LIST
DSP PCB Assembly
Resistors
Reference Description Part Number Note
Designator
R7000 10K, 0603, .1W, 1% 191465-1002
R7001 10K, 0603, .1W, 1% 191465-1002
R7002 15K, 0805, .1W, 1% 133625-1502
R7003 15K, 0805, .1W, 1% 133625-1502
R7004 10K, 0603, .1W, 1% 191465-1002
R7006 1M, 0603, .1W, 5% 199403-105
R7007 1M, 0603, .1W, 5% 199403-105
R7008 10K, 0603, .1W, 1% 191465-1002
R7009 10K, 0603, .1W, 1% 191465-1002
R7010 1M, 0603, .1W, 5% 199403-105
R7012 1M, 0603, .1W, 5% 199403-105
R7013 1M, 0603, .1W, 5% 199403-105
R7014 1M, 0603, .1W, 5% 199403-105
R7015 1M, 0603, .1W, 5% 199403-105
R7016 1M, 0603, .1W, 5% 199403-105
R7018 10K, 0603, .1W, 1% 191465-1002
R7019 10K, 0603, .1W, 1% 191465-1002
R7020 10K, 0603, .1W, 1% 191465-1002
R7021 18.2K, 0603, .1W, 1% 191465-1822
R7022 18.2K, 0603, .1W, 1% 191465-1822
R7023 10K, 0603, .1W, 1% 191465-1002
R7024 10K, 0603, .1W, 1% 191465-1002
R7025 150 OHM, 0603, .1W, 1% 191465-1500
R7026 150 OHM, 0603, .1W, 1% 191465-1500
R7052 2.0K, 0603, .1W, 5% 199403-202
R7053 100K, 0603, .1W, 1% 191465-1003
R7054 49.9K, 0603, .1W, 1% 191465-4992
R7055 1.82K, 0603, .1W, 1%, 191465-1821
R7056 1K, 0603, .1W, 1% 191465-1001
R7058 1K, 0603, .1W, 1% 191465-1001
R7077 330 OHM, 0603, .1W, 5% 199403-331
R7078 330 OHM, 0603, .1W, 5% 199403-331
R7082 1K, 0603, .1W, 1% 191465-1001
R7092 18.2K, 0603, .1W, 1% 191465-1822
R7094 10K, 0603, .1W, 1% 191465-1002
R7095 10K, 0603, .1W, 1% 191465-1002
R7122 100 OHM, 0603, .1W, 5% 199403-101
R7143 100 OHM, ARRAY, SMT, 4 POS, 5% 186433-1014
R7146 100 OHM, 0805, .1W, 5% 133626-1015
R7147 100 OHM, 0805, .1W, 5% 133626-1015
R7150 330 OHM, 0603, .1W, 5% 199403-331
R7151 10 OHM, 0603, .1W, 5% 199403-100
R7203 10K, 0603, .1W, 1% 191465-1002
R7208 10K, ARRAY, SMT, 4 POS, 5% 186433-1034
R7209 100K, 0603, .1W, 1% 191465-1003
R7210 100 OHM, 0603, .1W, 5% 199403-101
R7213 100K, 0603, .1W, 1% 191465-1003
R7220 15K, 0603, .1W, 1% 191465-1502
13
 ELECTRICAL PART LIST
DSP PCB Assembly
Resistors (continued)

Reference Description Part Number Note

Designator
R7222 10K, 0603, .1W, 1% 191465-1002
R7231 100K, 0603, .1W, 1% 191465-1003
R7232 3.9K, 0603, .1W, 1% 191465-3901
R7233 6.19K, 0603, .1W, 1% 191465-6191
R7238 100 OHM, 0603, .1W, 5% 199403-101
R7241 100 OHM, 0603, .1W, 5% 199403-101
R7246 100 OHM, 0603, .1W, 5% 199403-101
R7248 330 OHM, 0603, .1W, 5% 199403-331
R7249 330 OHM, 0603, .1W, 5% 199403-331
R7250 330 OHM, 0603, .1W, 5% 199403-331
R7251 330 OHM, 0603, .1W, 5% 199403-331
R7255 330 OHM, 0603, .1W, 5% 199403-331
R7256 330 OHM, 0603, .1W, 5% 199403-331
R7257 100 OHM, 0603, .1W, 5% 199403-101
R7258 100 OHM, 0603, .1W, 5% 199403-101
R7260 100 OHM, 0603, .1W, 5% 199403-101
R7262 330 OHM, 0603, .1W, 5% 199403-331
R7263 330 OHM, 0603, .1W, 5% 199403-331
R7264 330 OHM, 0603, .1W, 5% 199403-331
R7267 330 OHM, 0603, .1W, 5% 199403-331
R7269 330 OHM, 0603, .1W, 5% 199403-331
R7271 330 OHM, 0603, .1W, 5% 199403-331
R7273 330 OHM, 0603, .1W, 5% 199403-331
R7275 330 OHM, 0603, .1W, 5% 199403-331
R7276 10K, 0603, .1W, 1% 191465-1002
R7277 330 OHM, 0603, .1W, 5% 199403-331
R7279 3.01K, 0603, .1W, 1% 191465-3011
R7280 100 OHM, 0603, .1W, 5% 199403-101
R7281 200K, 0603, .1W, 1% 191465-2003
R7283 49.9K, 0603, .1W, 1% 191465-4992
R7285 10K, ARRAY, SMT, 4 POS, 5% 186433-1034
R7291 10K, 0603, .1W, 1% 191465-1002
R7292 10K, 0603, .1W, 1% 191465-1002
R7294 1K, 0603, .1W, 1% 191465-1001
R7295 100 OHM, 0603, .1W, 5% 199403-101
R7296 100 OHM, 0603, .1W, 5% 199403-101
R7297 10K, 0603, .1W, 1% 191465-1002
R7300 49.9K, 0603, .1W, 1% 191465-4992
R7306 100 OHM, 0603, .1W, 5% 199403-101
R7307 100 OHM, 0603, .1W, 5% 199403-101
R7308 100 OHM, 0603, .1W, 5% 199403-101
R7309 100 OHM, 0603, .1W, 5% 199403-101
R7310 100 OHM, 0603, .1W, 5% 199403-101
R7311 30K, 0603, .1W, 5% 199403-303
R7312 10K, 0603, .1W, 1% 191465-1002
R7313 1.33K, 0603, 100MW, 1% 191465-1331
R7314 1.33K, 0603, 100MW, 1% 191465-1331
R7315 301K, 0603, .1W, 1% 191465-3013
14
 ELECTRICAL PART LIST
DSP PCB Assembly
Capacitors
Reference Description Part Number Note
Designator
C7000 180pF, 0603, COG, 50V, .1% 188454-181
C7001 180pF, 0603, COG, 50V, .1% 188454-181
C7002 180pF, 0603, COG, 50V, .1% 188454-181
C7003 180pF, 0603, COG, 50V, .1% 188454-181
C7004 180pF, 0603, COG, 50V, .1% 188454-181
C7006 10uF, EL, 85C, 16V, 20% 177902-100C
C7007 10uF, EL, 85C, 16V, 20% 177902-100C
C7008 10uF, EL, 85C, 16V, 20% 177902-100C
C7010 10uF, EL, 85C, 16V, 20% 177902-100C
C7011 10uF, EL, 85C, 16V, 20% 177902-100C
C7012 .033uF, 0603, X7R, 50V, 10% 191470-333
C7013 100uF, EL, 85C, 16V, 20% 177902-101C
C7035 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7036 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7037 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7038 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7039 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7040 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7041 100uF, EL, SMD, 105, 35V, 20% 255071-101V
C7042 8pF, 0603, COG, 50V, .1% 188454-8R0
C7043 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7044 8pF, 0603, COG, 50V, .1% 188454-8R0
C7045 330pF, 0805, COG, 50V, 5% 133622-331
C7048 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7049 100pF, 0805, COG, 50V, 5% 133622-101
C7060 3300pF, 0603, X7R, 50V, .1% 191470-332
C7065 3300pF, 0603, X7R, 50V, .1% 191470-332
C7066 3300pF, 0603, X7R, 50V, .1% 191470-332
C7067 10uF, EL, 85C, 16V, 20% 177902-100C
C7068 10uF, EL, 85C, 16V, 20% 177902-100C
C7077 330pF, 0603, X7R, 50V 191470-331
C7078 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7079 3300pF, 0603, X7R, 50V, .1% 191470-332
C7080 3300pF, 0603, X7R, 50V, .1% 191470-332
C7081 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7082 10uF, EL, 85C, 16V, 20% 177902-100C
C7083 2.2uF, 1411, TANT, 25V, 20% 188588-225
C7084 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7162 10uF, EL, 85C, 16V, 20% 177902-100C
C7163 10uF, EL, 85C, 16V, 20% 177902-100C
C7181 10uF, EL, 85C, 16V, 20% 177902-100C
C7193 3300pF, 0603, X7R, 50V, .1% 191470-332
C7194 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7204 330pF, 0603, X7R, 50V 191470-331
C7205 10uF, EL, 85C, 16V, 20% 177902-100C
C7210 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7211 0.1uF, 0805, X7R, 50V,10% 286499-104
C7216 0.1uF, X7R, 0603, 50V, 10% 191470-104
15
 ELECTRICAL PART LIST
DSP PCB Assembly
Capacitors (continued)
Reference Description Part Number Note
Designator
C7217 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7225 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7226 10uF, EL, 85, 16V, 20% 177902-100C
C7227 10uF, EL, 85, 16V, 20% 177902-100C
C7228 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7229 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7230 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7231 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7236 100pF, 0603, X7R, 50V, .1% 191470-101
C7239 100pF, 0603, X7R, 50V, .1% 191470-101
C7244 100pF, 0603, X7R, 50V, .1% 191470-101
C7246 3300pF, 0603, X7R, 50V, .1% 191470-332
C7247 3300pF, 0603, X7R, 50V, .1% 191470-332
C7248 3300pF, 0603, X7R, 50V, .1% 191470-332
C7249 3300pF, 0603, X7R, 50V, .1% 191470-332
C7250 3300pF, 0603, X7R, 50V, .1% 191470-332
C7251 3300pF, 0603, X7R, 50V, .1% 191470-332
C7253 3300pF, 0603, X7R, 50V, .1% 191470-332
C7254 .01uF, 0603, X7R, 50V 191470-103
C7255 10uF, EL, 85C, 16V, 20% 177902-100C
C7258 .01uF, 0603, X7R, 50V 191470-103
C7259 .01uF, 0603, X7R, 50V 191470-103
C7261 .01uF, 0603, X7R, 50V 191470-103
C7262 3300pF, 0603, X7R, 50V, .1% 191470-332
C7266 3300pF, 0603, X7R, 50V, .1% 191470-332
C7268 3300pF, 0603, X7R, 50V, .1% 191470-332
C7269 3300pF, 0603, X7R, 50V, .1% 191470-332
C7271 10uF, EL, 85, 16V, 20% 177902-100C
C7272 0.47uF, 10V, X5R, 0603 278992-474
C7275 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7276 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7277 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7278 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7279 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7280 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7281 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7282 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7283 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7284 33000pF, X7R SMD, 0603, 25V, .1% 257154-333K25
C7285 330pF, 0603, X7R, 50V 191470-331
C7286 3300pF, 0603, X7R, 50V, .1% 191470-332
C7400 100pF, 0603, X7R, 50V, .1% 191470-101
C7401 3300pF, 0603, X7R, 50V, .1% 191470-332
C7402 3300pF, 0603, X7R, 50V, .1% 191470-332
C7403 100pF, 0603, X7R, 50V, .1% 191470-101
C7404 100pF, 0603, X7R, 50V, .1% 191470-101
C7405 3300pF, 0603, X7R, 50V, .1% 191470-332

16
 ELECTRICAL PART LIST
DSP PCB Assembly
Integrated Circuits
Reference Description Part Number Note
Designator
U7000 IC, OP-AMP, LO-PWR, 1MHz, SC-70 302888-001
U7006 IC, INVERTER, SMD 266582-001
U7008 IC, VOLT REG, SMD, POS, SOT89, +5V 258167-05
U7010 IC, RESET, SOT-23, MAX809, 2.63V 191158-06
U7011 IC, DSP, TMS320DA705, MASKED 289857-7051
U7015 IC, FLASH, SERIAL, 1Mbit, 3.3V 307546-001
U7018 IC, MULTIPLEX/DEMULTIPLEX 2-CH 298096-003
U7019 IC, A/D CONV, 96KHz, 24BIT, AK5381 299343-001
U7020 IC, DAC, 192kHz, 24Bit, 2ch, AK4384 299344-001
U7027 IC, HI-PERFORMANCE, CPLD 298467-001
U7036 TRANSISTOR, MOSFET, P-CH, 30V 298094-001
U7037 IC, VOLT REG, SMD, POS, SOT89, 3.3V 258167-33
U7038 IC, UC, 8-BIT, FLASH BASED, SSOP 299197-677ISS
U7040 IC, DUAL BILAT, ANALOG SWITCH 299221-001
U7041 IC, VOLT REG, ADJ, 500MA, DPAK 258496-001

Miscellaneous

Reference Description Part Number Note

Designator
J200 CONN, SMT, .5MM, 10-POS, FFC 269863-010
J201 CONN, SMT, .5MM, 8-POS, FFC 269863-008
J300 CONN, HEADER, 25-POS, TOP ENTRY, SM 253356-T25
J400 CONN, HEADER, 1mm, SMT, 20POS 301236-T020
J500 CONN, HEADER, 5-POS, TOP ENTRY,SMD 253356-T05
J800 CONN, HEADER, 25-POS, TOP ENTRY, SM 253356-T25
Y7001 CRYSTAL, 16.9344MHz, 4-PIN SMD 291429-004

17
 ELECTRICAL PART LIST
DSP PCB Assembly
Capacitors (continued)

Reference Description Part Number Note

Designator
C7407 3300pF, 0603, X7R, 50V, .1% 191470-332
C7409 100pF, 0603, X7R, 50V, .1% 191470-101
C7410 330pF, 0603, X7R, 50V 191470-331
C7411 330pF, 0603, X7R, 50V 191470-331
C7427 0.1uF, X7R, 0603, 50V, 10% 191470-104
C7428 .033uF, 0603, X7R, 50V, 10% 191470-333
C7429 5pF, 0603, COG, 50V, .1% 188454-5R0
C7430 5pF, 0603, COG, 50V, .1% 188454-5R0
C7431 0.1uF, X7R, 0603, 50V, 10% 191470-104

Inductors

Reference Description Part Number Note

Designator
L7002 330 OHM, FERRITE BD, 0603, 200MA 268373-331
L7019 330 OHM, FERRITE BD, 0603, 200MA 268373-331
L7020 330 OHM, BEAD, FERRITE, 0805, 1.5A 267539-331

Diodes

Reference Description Part Number Note

Designator
D7003 DIODE, SOT-23, BAV 99 147239
D7004 DIODE, SHOTTKY, BAT42W, SOD-123 196984-002
D7005 DIODE, SOT-23, BAV 99 147239
D7006 DIODE, SHOTTKY, BAT42W, SOD-123 196984-002

Transistors

Reference Description Part Number Note

Designator
Q7034 XSISTOR, BPLR, N, 50V, 100mA, SOT23 146817
Q7037 XSISTOR, BPLR, N, 40V, 200mA, SOT23 146819
Q7040 XSISTOR, BPLR, N, 40V, 200mA, SOT23 146819
Q7041 XSISTOR, BPLR, P, 40V, 200mA, SOT23 148596
Q7042 XSISTOR, P, 50V, 2SA1341 146818
Q7043 XSISTOR, P, 50V, 2SA1341 146818

18
 ELECTRICAL PART LIST
Amplifier PCB Assembly
Resistors

Reference Description Part Number Note

Designator
R7116 100K, 0603, .1W, 1% 191465-1003
R7224 10 OHM, 0603, .1W, 5% 199403-101
R7225 121K, 0603, .1W, 1% 191465-1213
R7226 121K, 0603, .1W, 1% 191465-1213
R7227 121K, 0603, .1W, 1% 191465-1213
R7228 121K, 0603, .1W, 1% 191465-1213
R7229 10K, 0603, .1W, 1% 191465-1002
R7230 10K, 0603, .1W, 1% 191465-1002
R7231 10 OHM, 0603, .1W, 5% 199403-101
R7234 10 OHM, 0603, .1W, 5% 199403-101
R7236 10 OHM, 0603, .1W, 5% 199403-101
R7237 10 OHM, 0603, .1W, 5% 199403-100
R7238 10 OHM, 0603, .1W, 5% 199403-101
R7239 10 OHM, 0603, .1W, 5% 199403-101
R7240 10 OHM, 0603, .1W, 5% 199403-101

Capacitors

Reference Description Part Number Note

Designator
C7128 .22uF, 0805, X7R, 25V,10% 181264-224
C7129 .22uF, 0805, X7R, 25V,10% 181264-224
C7130 .01uF, 0805, X7R, 50V, 10% 286499-103
C7131 .01uF, 0805, X7R, 50V, 10% 286499-103
C7134 .1uF, 0805, X7R, 50V, 10% 286499-104
C7135 .1uF, 0805, X7R, 50V, 10% 286499-104
C7136 .1uF, 0805, X7R, 50V, 10% 286499-104
C7137 .1uF, 0805, X7R, 50V, 10% 286499-104
C7138 .1uF, 0805, X7R, 50V, 10% 286499-104
C7139 .1uF, 0805, X7R, 50V, 10% 286499-104
C7140 .1uF, 0805, X7R, 50V, 10% 286499-104
C7141 10uF, EL, SMD, 105C, 35V, 20% 255071-100V
C7146 .01uF, 0805, X7R, 50V, 10% 286499-103
C7147 1uF, EL, SMD, 105C, 50V, 20% 255071-1R0H
C7148 .22uF, 0805, X7R, 25V,10% 181264-224
C7149 .22uF, 0805, X7R, 25V,10% 181264-224
C7150 .1uF, 0805, X7R, 50V, 10% 286499-104
C7151 .1uF, 0805, X7R, 50V, 10% 286499-104
C7152 1uF, EL, SMD, 105C, 50V, 20% 255071-1R0H
C7153 1uF, EL, SMD, 105C, 50V, 20% 255071-1R0H
C7212 1uF, EL, 85C, 50V, 20% 177902-010H
C7213 1uF, EL, 85C, 50V, 20% 177902-010H
C7214 1uF, EL, 85C, 50V, 20% 177902-010H
C7215 1uF, EL, 85C, 50V, 20% 177902-010H
C7218 .1uF, X7R, 0603, 50V, 10% 191470-104

19
 ELECTRICAL PART LIST
Amplifier PCB Assembly
Capacitors (continued)

Reference Description Part Number Note

Designator
C7219 .1uF, X7R, 0603, 50V, 10% 191470-104
C7240 .01uF, EL, 105C, 25V, 20% 269823-103EZ
C7241 100pF, 0603, X7R, 50V, .10% 191470-101
C7242 3300pF, 0603, X7R, 50V, .10% 191470-332
C7243 3300pF, 0603, X7R, 50V, .10% 191470-332
C7244 3300pF, 0603, X7R, 50V, .10% 191470-332
C7245 3300pF, 0603, X7R, 50V, .10% 191470-332
C7246 3300pF, 0603, X7R, 50V, .10% 191470-332
C7247 3300pF, 0603, X7R, 50V, .10% 191470-332
C7248 3300pF, 0603, X7R, 50V, .10% 191470-332
C7250 .1uF, 0805, X7R, 50V, 10% 286499-104
C7251 .1uF, 0805, X7R, 50V, 10% 286499-104
C7252 .1uF, 0805, X7R, 50V, 10% 286499-104
C7253 .1uF, 0805, X7R, 50V, 10% 286499-104

Inductors

Reference Description Part Number Note

Designator
L7015 22uH, INDUCTOR, FIXED, 3.9A 300618-220M
L7016 22uH, INDUCTOR, FIXED, 3.9A 300618-220M
L7017 22uH, INDUCTOR, FIXED, 3.9A 300618-220M
L7018 22uH, INDUCTOR, FIXED, 3.9A 300618-220M

Integrated Circuits

Reference Description Part Number Note

Designator
U7028 IC, PWR-AMP, CLASS D, 20W 298092-001

Miscellaneous

Reference Description Part Number Note

Designator
J7001 CONN, HEADER, 25POS, TOP ENTRY, SM 253356-T25
J7002 CONN, 2.5MM, 2 POS, FORMED 307962-001
J7003 CONN, 2.5MM, 2 POS, FORMED 307962-001

20
 ELECTRICAL PART LIST
SPS (Switching Power Supply) PCB Assembly
Resistors

Reference Description Part Number Note

Designator
R003 10 OHM, 0603, .1W, 5% 199403-100
R004 10 OHM, 0603, .1W, 5% 199403-100
R005 1K, 0603, .1W, 5% 199403-102
R006 1K, 0603, .1W, 5% 199403-102
R007 100K, 0603, .1W, 1% 191465-1003
R013 100 OHM, 0603, .1W, 5% 199403-101
R014 30.1K, 0603, .1W, 1% 191465-3012
R015 60.4K, 0603, .1W, 1% 191465-6042
R017 2K, 0603, .1W, 1% 191465-2001
R018 100K, 0603, .1W, 1% 191465-1003
R019 2K, 0603, .1W, 1% 191465-2001
R020 121K, 0603, .1W, 1% 191465-1213
R021 100K, 0603, .1W, 1% 191465-1003
R022 9.53K, 0603, .1W, 1% 191465-9531
R023 0.10 OHM, 0805, 1/8W, 5% 304926-R10
R024 0.10 OHM, 0805, 1/8W, 5% 304926-R10
R026 1M, 0603, .1W, 5% 199403-105
R027 1M, 0603, .1W, 5% 199403-105
R028 1M, 0603, .1W, 5% 199403-105
R029 1M, 0603, .1W, 5% 199403-105
R030 1M, 0603, .1W, 5% 199403-105
R033 10K, 0603, .1W, 1% 191465-1002
R035 1M, 0603, .1W, 5% 199403-105
R037 10K, 0603, .1W, 1% 191465-1002
R038 2.2K, 0603, .1W, 5% 199403-222
R039 1M, 0603, .1W, 5% 199403-105
R040 1M, 0603, .1W, 5% 199403-105
R041 22K, 0603, .1W, 5% 199403-223
R042 12K, 0603, .1W, 5% 199403-123
R043 100K, 0603, .1W, 1% 191465-1003
R045 10K, 0603, .1W, 1% 191465-1002
R046 2.2K, 0603, .1W, 5% 199403-222

Capacitors

Reference Description Part Number Note

Designator
C001 470pF, 0603, X7R, 50V, 10% 191470-471
C002 470pF, 0603, X7R, 50V, 10% 191470-471
C003 .1uF, 0805, X7R, 50V, 10% 286499-104
C004 .1uF, 0805, X7R, 50V, 10% 286499-104
C005 .1uF, x7r, 0603, 50V, 10% 191470-104
C006 .1uF, x7r, 0603, 50V, 10% 191470-104
C007 .01uF, 0603, X7R, 50V, 10% 191470-103
C008 100pF, 0603, X7R, 50V, 10% 191470-101
C009 220pF, 0603, X7R, 50V, 10% 191470-221

21
 ELECTRICAL PART LIST
SPS (Switching Power Supply) PCB Assembly
Capacitors (continued)

Reference Description Part Number Note

Designator
C010 .01uF, 0603, X7R, 50V, 10% 191470-103
C011 1000pF, 0603, X7R, 50V, 10% 191470-102
C012 1000pF, 0603, X7R, 50V, 10% 191470-102
C013 47uF, 7343, TANT,16V, LO-R, 10% 275411-476
C014 100uF, 7343, TANT, LO-R, 10% 275411-107
C015 .1uF, 0805, X7R, 50V, 10% 286499-104
C016 .1uF, 0805, X7R, 50V, 10% 286499-104
C020 .1uF, 0805, X7R, 50V, 10% 286499-104
C024 .1uF, 0805, X7R, 50V, 10% 286499-104
C025 3300pF, 0805, X7R, 50V, 10% 286499-332
C027 220uF, EL, SMD, 105, 35V, 20% 255071-221V
C028 3300pF, 0603, X7R, 50V, 10% 191470-332
C029 .1uF, X7r, 0603, 50V, 10% 191470-104
C033 3300Pf, 0603, X7R, 50V, 10% 191470-332
C037 .1uF, x7r, 0603, 50V, 10% 191470-104
C040 1uF, EL, SMD, 105, 50V, 20% 255071-1R0H
C041 1uF, EL, SMD, 105, 50V, 20% 255071-1R0H
C042 .1uF, 0805, X7R, 50V, 10% 286499-104
C043 100pF, 0603, X7R, 50V, 10% 191470-101
C049 .0082uF, 0603, X7R, 50V, 10% 191470-822
C053 .1uF, 0805, X7R, 50V, 10% 286499-104
C054 .1uF, 0805, X7R, 50V, 10% 286499-104
C056 1800pF, 0603, X7R, 50V, 10% 191470-182
C058 .1uF, X7r, 0603, 50V, 10% 191470-104
C061 100pF, 0603, X7R, 50V, 10% 191470-101
C062 100pF, 0603, X7R, 50V, 10% 191470-101
C063 220uF, EL, SMD, 105, 35V, 20% 255071-221V

Inductors

Reference Description Part Number Note

Designator
L1 220uH, 1.0A, SMT, 20% 303213-221M
L2 47uH, 1.1A,SMT, 20% 303222-470M

Diodes

Reference Description Part Number Note

Designator
D1 DIODE, SCHOTTKY, 40V, 3A, SMB 193847-001
D2 DIODE, SCHOTTKY, 40V, 3A, SMB 193847-001
D3 DIODE, SWITCHING, 75V, 200mA 148582
D4 DIODE, SWITCHING, 75V, 200mA 148582

22
 ELECTRICAL PART LIST
SPS (Switching Power Supply) PCB Assembly
Transistors

Reference Description Part Number Note

Designator
Q8 XSISTOR, MFET, P, SOT-23, 40V, 3.0A 303215-001
Q9 XSISTOR, MFET, P, SOT-23, 40V, 3.0A 303215-001

Integrated Circuits

Reference Description Part Number Note

Designator
U1 IC, PWM, VOLTAGE CONTROLLER, TPS40200 303218-001
U2 IC, PWM, VOLTAGE CONTROLLER, TPS40200 303218-001
U5 IC, V REG, POS, 3.3V, 0.15A, LDO 299071-033
U8 IC, SENSOR, QT, 5V, QFN 300674-001

Miscellaneous

Reference Description Part Number Note

Designator
J301 CONN, HEADER, 25POS, TOP ENTRY, SM 253356-T25
J303 CONN, HDR, 6POS, VERT, SMT, ZIFF 305369-T06

23
 ELECTRICAL PART LIST
I/O PCB Assembly
Resistors

Reference Description Part Number Note

Designator
R4000 100K, 0603, .1W, 1% 191465-1003
R4001 15K, 0805, .1W, 1% 133625-1502
R4002 39K, 0603, SMD, .1W, 5% 199403-393
R4003 39K, 0603, SMD, .1W, 5% 199403-393

Capacitors

Reference Description Part Number Note

Designator
C4007 100pF, 0603, X7R, 50V 10% 191470-101
C4008 100pF, 0603, X7R, 50V 10% 191470-101
C4010 3300pF, 0603, X7R, 50V, 10% 191470-332
C4001 330pF, 0603, X7R, 50V, 10% 191470-331
C4003 330pF, 0603, X7R, 50V, 10% 191470-331
C4004 330pF, 0603, X7R, 50V, 10% 191470-331
C4006 330pF, 0603, X7R, 50V, 10% 191470-331
C4005 .1uF, 0805, X7R, 50V, 10% 286499-104
C4009 .1uF, 0805, X7R, 50V, 10% 286499-104

Inductors

Reference Description Part Number Note

Designator
L4000 BEAD, FERRITE, CHIP, 1806 256116-181

Diodes
Reference Description Part Number Note
Designator
D4000 DIODE, SCHOTTKY, 40V, 3A, SMB 193847-001
D4002 DIODE, SCHOTTKY, 60V, 3A 307429-60
ZR4000 DIODE, ZENER, 22V 307428-22

Miscellaneous

Reference Description Part Number Note

Designator
J4000 CONN, HEADER, 1mm, SMT, 20 POS 301236-T020
J4001 CONN, BATTERY, 8-PIN, 2.0mm 301572-008
J4002 CONN, DC PWR, JP3.5MM, COMBO 301948-001

24
 ELECTRICAL PART LIST
IR PCB Assembly
Resistors

Reference Description Part Number Note

Designator
R2000 100 OHM, 0603, .1W, 5% 199403-101

Capacitors

Reference Description Part Number Note

Designator
C2000 .1uF, X7R, 0603, 50V, 10% 191470-104

Inductors

Reference Description Part Number Note

Designator
L4000 BEAD, FERRITE, CHIP, 1806 256116-181

Diodes

Reference Description Part Number Note

Designator
DS2000 DIODE, LED, 625nm, 160mA, 5V 307558-001

Miscellaneous

Reference Description Part Number Note

Designator
J2000 CONN. ,SMT, LIF, 5 POS., SIDE 255130-005

25
 DISASSEMBLY PROCEDURES
1. Grill removal

1.1 The grill is removed by pulling from the

top center. The left and right sides of the grill
are molded to fit inside the main assembly.
Pulling from the center allows the left and
right sides to dislodge and be removed. See
Figure 5.

Note: The grill and the baffle assembly have

velcro that may make removal difficult.
Figure 5

2. Removing Baffle Assembly

2.1 Remove the 12 Phillips-head screws that

secure the assembly. See Figure 6.

Figure 6

2.2 Lift the assembly using a flat blade

screwdriver. Once lifted, the baffle assembly
can be easily lifted away from the main
assembly. Be careful not to damage the
gasket that is placed under the assembley.
See figure 7. Be careful not to
damage the gasket

Figure 7

2.3 Disconnect the J200, J201, J303 and

J400. See figure 8.

Figure 8

26
 DISASSEMBLY PROCEDURES

3. Dock Removal

3.1 Once the baffle assembly has been

removed, lift up the four rubber feet. See
Figure 9.

3.2 Remove the four phillips screws.

Figure 9

3.3 Remove the dock assembly being careful

not to damage the two cables that feed into
the main assembly. See Figure 10.

Figure 10

4. Dock Disassembly

4.1 Remove the three Phillips-head screws

that secure the dock. See figure 11.

Figure 11
4.2 Lift the top section of the dock by pulling
up on the dock connector. See figure 12.

4.3 Remove the one screw holding the dock

in place.

4.2 Lift the dock away from the bottom plate.

Note: The dock spring is not secure when

lifting the dock away from the bottom plate.
The spring can be easily lost if not accounted
for.
Figure 12

27
 DOCK RE-ASSEMBLY PROCEDURES

1. Dock Re-assembly

Figure 13

1.1 Place the spring into the slotted groove

on the bottom plate as shown in figure 14.

Figure 14

1.2 Place the other side of the spring into the

slotted groove on the dock as shown in figure
15.

Figure 15

1.3 Turn the dock counter clockwise one full

rotation. See figure 16.

1.4 Use the one screw to tighten down the

dock to the bottom plate.

Figure 16

28
 TEST PROCEDURES
2. Left Right Driver Test
SoundDock® Portable Digital Music
System Functional Tests 2.1 Apply the input signal to SoundDock
Portable left channel only. Set generator as in
Equipment Required step 1.3 and 1.4, except set the frequency to
800Hz and confirm that only the left driver
Digital Multi-meter plays.
Audio Signal Generator
iPod Eliminator PCB, P/N 287089 2.2 Reduce generator output to zero volts
Notes: 2.3 Repeat step 2.1 for the right channel.
1. Begin the test with no power applied.
2. Confirm the Audio Signal Generator out- 2.4 Reduce input signal to zero volts and
put is set to zero volts before connecting. reconnect the right channel.

3. Frequency Sweep Test

1.1 Air Leak Test
3.1 Set audio signal generator to:
1.1 Connect the audio signal generator to the A. Voltage = 100mV +10%
mini jack AUX input on the back of Sound- B. Sweep range = 40 HZ - 5KHz +10%
Dock® Portable.
3.2 Execute the sweep for a minimum of five
1.2 Set the signal generator output to: seconds up and then down the range.
A. Voltage = 0V 3.3 Listen for any extraneous noises such as
B. Frequency = 80Hz +10% buzzes, rattles, ticks, and distortion.
1.3 Apply power to the SoundDock Portable,
the system will default to the AUX input if PASS if no noise can be heard at a distance
there is nothing connected to the dock. of less than 1ft (0.3M).
Press and hold the volume plus button for 15
seconds, this should set the system to max FAIL if any noise can be heard at a distance
less than 1ft (0.3M).
volume.
3.4 Reduce the input signal to zero volts.
1.4 Set the Signal generator output to:
A. Voltage = 100mV +10%
B. Frequency = 65Hz +10%

1.5 Listen for air leaks around all the cabinet

seams, joints, and wire harness through-
holes.

PASS if no audible air leaks can be heard at

a distance of less than 1ft (0.3M) from any
exterior surface of the enclosure.
FAIL if any air leaks can be heard at a dis-
tance less than 1ft (0.3M) from any exterior
surface of the enclosure.

29
 TEST PROCEDURES CONTINUTED
speakers.
SoundDock® Portable iPhone Test
2.2 Place the iPhone on the dock.
Equipment Required

Apple® iPhone.
2.3 Press the play button on the remote,
SoundDock system built after January 26th
adjust the volume to a moderate level.
2009 (DOM 9026) See cover page for de-
Confirm audio is clean and no distortion can
tails.
be heard.

1. Authorization Test

1.1 Apply AC power to the SoundDock

system. Allow the system to power up by
waiting for the boot beep sound from the
speakers.

1.2 Place the iPhone on the dock cradle.

1.3 Confirm the following message does not

appear on the iPhone screen.

Note: If this screen appears on the display,

re-dock the iPhone to determine if the prob-
lem appears again. It is normal to see this
screen on an occasional basis.

2. iPhone Functional Test

2.1 Apply AC power to the SoundDock

system. Allow the system to power up by
waiting for the boot beep sound from the

30
 TAP COMMAND SET UP

SoundDock® Portable Digital Music

System TAP command set up

J1
1
Equipment Required

R2

R1
IBM compatible computer
RS232 to TTL converter
iPod Eliminator PCB, P/N 287089
ETAP Cable, P/N 309866-001

J2
Notes: TAP commands can be sent to the

J3
1

SoundDock Portable system by connecting a

PC to the iPod eliminator board via the 30 pin
dock connector.

An ETAP cable, iPod eliminator PCB and

RS232 to TTL Converter are required for this iPod Eliminator PCB
communication. The ETAP cable and iPod
Eliminator PCB are available from Bose®.
The RS232 to TTL Converter is made by
B+B electronics, model number 232LPTTL.
It can be purchased online at http://www.bb-
elec.com.

The TAP commands will be needed for the

following procedures:

A. Calibration of the DSP board and amplifier

board.

B. Battery test ETAP cable schematic

iPod RS 232 to TTL

Eliminator Converter
PCB

SoundDock Computer
B+B Electronics model 232LPTTL
RS232 to TTL converter
ETAP
Cable

31
 TAP COMMAND SET UP CONTINUED
1. Hyper Terminal set up 1.4 Select 19200 bits per second, 8 data bits,
no parity, one stop bit and no flow control.
Hyper Terminal is standard on IBM compatible Then select OK.
PC’s and is the interface used to send com-
mands to the SoundDock® Portable system. Note: If the flow control has Hardware se-
lected the communication will not work. Flow
1.1 Use the Start menu to select Programs, control should be set to None.
Accessories, Communications then Hyper
Terminal.

1.2 The new connection box will appear, type

in SoundDock Portable as the name. Then
select OK.

2. Configuring the properties and the

ASCII settings

1.3 Confirm the Connect using option is set 2.1 Once the Hyper terminal is running,
to COM1. Then select OK. select file then properties.

32
 TAP COMMAND SET UP CONTINUED

2.2 Change the Emulation to Auto detect,

then select ASCII setup.

2.3 Select Echo typed characters locally,

Append line feeds to incoming line ends
and Wrap lines that exceed terminal
width. Then select OK.

2.4 Once these changes have been made,

select OK. Select File and Save as
SoudDock® Portable.
33
 AMPLIFIER GAIN PROCEDURE
SoundDock® Amplifer gain value
adjustment

Equipment Required

IBM compatible computer

RS232 to TTL converter
iPod Eliminator PCB, P/N 287089
Tap Cable- P/N 309866-001

*Note: This procedure must be run if the

DSP board or the power amplifier board
are replaced.

A default gain value is sent via TAP com-

mands from a PC to the SoundDock Por-
table system.

1. Setting the Default Gain

1.1 Use the TAP command set up procedure

to allow the SoundDock Portable system to
receive TAP commands (see TAP command
setup on page 29).

1.2 Issue TAP command SP 109, 8D87 to

set the gain to 36231.

8D87 is the hex number for 36231.

2. Confirm Gain Value has been changed

2.1 Power cycle the system by disconnect-

ing the AC power supply and the battery for a
minimum of 10 seconds.

2.2 Issue the TAP command SP 109 to

confirm the default value was received by the
SoundDock Portable. The number returned
should be 3623109.

34
 BATTERY TEST

SoundDock® Portable Digital Music 1.4 The results are returned with a Hex num-
Battery test ber with the bytes in reversed order. Convert
this number to decimal and confirm it is less
Equipment Required than 250.

iPod Eliminator PCB, P/N 287089 Example - 0200 is displayed

Tap Cable- part number 309866-001
Number of cycles = 2
Notes: The battery must meet the following
requirements:
2.0 Time Since Production
1. Number of Cycles: < 250
2. Time Since Production: < 30 months 2.1 Use the four digit DOM within the serial
3. V Battery: > 17 volts number to determine the batteries age. If the
4. V Balance: < 70mV battery is more than 30 months old, it should
be replaced.
The battery tests are run by sending TAP
commands from a PC to the SoundDock Serial Number Example -
Portable system. 040274Z62170107AC

All Battery TAP commands must be followed The first 6 characters identify the product
by two commands to see the results: code - 040274
“Check Read Status” Command = SP 506
“Get Result” Command = SP 507 Characters 8 to 11 identify the DOM - 6217
This allows the results to be printed to the 6217 = the 217th day of 2006
screen.

The results are returned in reversed byte 3.0 V Battery - Total Battery Voltage
order. For example, if the returned is Hex
1234, the two bytes need to be reversed to 3.1 Execute the Total Battery Voltage com-
give Hex 3412 before further interpretation is mand SP 50B,09.
performed.
3.2 Execute the “Check Read Status” Com-
1.0 Number of cycles mand SP 506.

1.1 Execute the “Number of Cycle” com- 3.3 Execute the “Get Result” Command
mand. SP 507.

SP 50B,17 3.4 The results are returned with a Hex num-

ber with the bytes in reversed order. Convert
1.2 Execute the “Check Read Status” Com- this number to decimal and confirm it is more
mand. than 16 Volts.

SP 506 Example - 4140 is displayed

1.3 Execute the “Get Result” Command. Total Battery Voltage is 16.449

SP 507 4041 converted to decimal using Microsoft®

Windows scientific calculator = 16449

35
 BATTERY TEST CONTINUED
4.0 V Balance

4.1 To calculate V Balance, all four cell

voltages need to be collected. Perform the
cell commands below and execute the
“Check Read Status” SP 506 and “Get
Results” SP 507 after each command to
read the results.

The results returned will be a Hex number

with the bytes in reversed order. Convert this
number to decimal and write down the
results after each command. The highest
and lowest voltages will be used at the end of
the procedure to calculate the V Balance.

Cell commands needed for V Balance

SP 50B,3F - Cell One

SP 50B,3E - Cell Two
SP 50B,3D - Cell Three
SP 50B,3C - Cell Four

Note: “Read Status” and “Get Results”

commands need to be executed after each
of the Cell command.

Example -

SP 50B, 3F / SP 506 / SP 507

4.2 Determine V Balance using the following

calculation:

V_Balance = Max Cell Voltage - Min Cell Voltage

If V Balance is more than 70mV, the battery

should be replaced.

36
 BLOCK DIAGRAM
VDC
3.3V_MP
SPS Board J400 J4000
J301 J300 1/2 1/2 J4001
Touch Reset D VBP
Touch Reset 6 6 17 14 DSP_ON
5 5 2 VBP
PWR_Switch 6 G S
Detect Out 8 8 19 U7038 U7036 14 14 5 SDA
Sync2 10 10 PIC 13 13 6 SCK
Controller 4 4 1 VRAW
Detect SDA
Dock PCB 8V Out 2 To Battery
3.3V Reset Power_Fail U7040 SCK
Sync2 6 I/O Board 303293
J3001 J3002 J201
viPod U7041 iPod Charge 1/2
VRAW
Charger 8 1 8 3 1 2 37 26 33 34
5V
J3003 J200 iPod Detect XTAL
iPod Detect 30 7 4 5 44 Y7001
U7027
Left 28 3 10
Right 27 1 8 CPLD
Transmit Data 18 10 1
Source
Select
I/O Expander J2000
19 2 1 U7018 11 8 J 500
Receive Data 9 LED 1
13 Input 12 2 4
LED 2
Select 13 1 5
3 42 41 23 22 19 4 2
AUX
Present Stby Mute
4
J 4000 J 400 15 IR Board 303293
Aux Right 14 14 2
Aux Left 15 15 12

DIgital Out
Aux Present 12 12

Digital In
I/O Board 303293 6 2
1/2
U7000
7 1 3.3V
Audio Audio
Right Left
IR_IN
60 115 120
1 2 Digital 122
Audio
U7019
117 U7011

37
9
ADC DSP
Audio Amp Board 303293
TX Data Processor
135
130 J800
RX Data J800 J7001 Left
8 113 1
Mute 20
8 18 45
U7028 21 2
DSP Board 1.2V
Stby
44 Audio Amp
7 19
298019 Digital
5V 5V
Audio
J700
I/O Board 8 14 Right
3 Left 40 1
SPS PCB 10 1 25 3
D4002 U7020 41 2
Right
Power U7036 11
Supply
Invalid VRAW VBP VDC DAC 3 23 5
Voltage
Protection
U5 Q8 Q9
Low Power 3.3 8 Volt 1.2 Volt U7028
Volt Regulator Switcher Switcher Power Amp
Battery Battery
Charging
DSP
On/Off
Battery
U7041 iPod
Output
5 Volt Linear
Q7037 Charge
AMP PCB
3.3V_MP Switch
Control
U7008
Analog
5 Volt Linear
Electronics
U7038
Microcontroller U7037
DSP
3.3 Volt
Linear + Logic
DSP PCB
 SERVICE MANUAL REVISION HISTORY
Date Revision Level Description of Change Change Driven By Pages
Affected
08/17/07 00 Document released at revision 00 Service Manual release All
10/09/07 01 Added universal inserts Part missing from original 8

Part number change

Changed power supply part numbers from 301141- 7
001 and -002 to 301141-011 and -012
12/03/07 02 DSP part number change – Software change 10
From 297427-004 to 307983-001
12/10/07 03 Universal Insert part number change. From 303557- Part numbers where not correct 8
001, --002 to 303570-001, -002.
Cradle Assembly part number change. 300660-001 Packaging change. 10
and 300660-002 to 300660-101 and 300660-102.
Latch Cradle Spring part number changed from New part number (different size spring 11
300687 to 309584-002. needed)
1/19/08 04 Calibration procedure change. It is not longer Calibration procedure change based on 32,33
necessary to calculate the gain value. A default extensive testing.
number can be used on all systems.

Front cover product image change

Cover
3/17/08 05 U7015 and R7055 changed part numbers. 16
U7015 -307546-001
R7055 – 191465-1821

Screw part number added. Referance number 4 and

12 on page 9 9

Flex cable added, part number 310678-001

5/8/08 9
9/23/08 06 Dock board part number change. From 307958-001 Board change to RoHS 12
to 307958-002

Grill part number added – 309981-001 and -002. Improved part 10

New DSP PCB part number –

307983-021S New DSP software 11

10/10/08 07 Changed printed carton part number to 311574 New number created 9

Added blank carton part number

Generic blank carton created to fit all 9
SoundDock products
12/22/08 08 Add rear enclosure part numbers. Scratches to the enclosure are very 10
300676-011 and 300676-012. difficult to remove.

1/27/09 08 New power supply part numbers Cost savings on new supply 8
2/18/09 09 DSP board part number change Board modified and works with iPhone 10
319975-001S chip added.

8/24/09 iPhone test added Repair Group test 30

10/8/09 Added fastener and screw part numbers Missing from original drawing 10

10/20/09 Removed DSP board part numbers 307983-001 and Manufacturing no longer builds the 10
307983-021S. non-iPhone version.
319975-001S is now the only board available.
9/10/10 10 304158-251 replaced by 304158-351 AC Clips for APAC changed 8
304158-252 replaced by 304158-352

38
 SPECIFICATIONS AND FEATURES SUBJECT TO CHANGE WITHOUT NOTICE

Bose Corporation
The Mountain
Framingham Massachusetts USA 01701
P/N: 300657-SM Rev. 10 5/2008 (H)
http://serviceops.bose.com