Kurzweil PC3x Service Manual

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Page 1 PC3x Service Manual ©2008 All rights reserved. Kurzweil® is a product line of Young Chang Co., Ltd. Young Chang®, Kurzweil®, and PC3® are trademarks of Young Chang Co., Ltd. All other products and brand names are trademarks or registered trademarks of their respective companies. Product features and speciﬁcations are subject to change without notice.
Page 2 The lightning flash with the arrowhead symbol, within an equilateral triangle, is intended to alert CAUTION the user to the presence of uninsulated "dangerous voltage" within the product's RISK OF ELECTRIC SHOCK enclosure that may be of sufficient magnitude DO NOT OPEN to constitute a risk of electric shock to persons.
Page 3: Important Safety Instructions
Important Safety Instructions Read these instructions. Keep these instructions. Heed all warnings. Follow all instructions. Do not use this apparatus near water. Clean only with dry cloth. Do not block any of the ventilation openings. Install in accordance with the manufacturer’s instructions.
Page 4 Kurzweil International Contacts Contact the Kurzweil ofﬁce listed below to locate your local Kurzweil representative. Kurzweil Music Systems 19060 S. Dominies Hills Drive Rancho Dominguez California 90220 USA Telephone: (310) 637-2000 Fax: (310) 637-2025 http://www.kurzweilmusicsystems.com Kurzweil Co., LTD iPark Building #102, Floor 9...
Page 5: Table Of Contents
Kurzweil PC3x Service Manual Chapter 1 Introduction Notes, Cautions, Warnings ............................1-1 Rear Panel Features................................. 1-1 PC3x Front Panel ................................1-3 Front Panel Features ..............................1-3 Wheels Assembly (not shown)........................1-5 Chapter 2 Diagnostics Diagnostic Tests ................................2-1 Entering Diagnostics............................... 2-1 LCD and Front Panel Buttons ..........................
Page 6 Removing the Wheels Assembly ......................... 3-19 Replacing the Wheels Assembly.......................... 3-19 PC3x Keyboard Assembly............................3-20 Removing the PC3x Keyboard Assembly......................3-20 Replacing the PC3x Keyboard Assembly ......................3-21 Removing Keys ..............................3-22 Natural/White Key ............................3-22 Removing Natural/White Keys........................... 3-23 Removing Sharp/Black Keys ..........................
Page 7 Kurzweil PC3x Service Manual Replacing the EPROM............................. 4-9 Replacing the Battery..............................4-10 Accessing the Battery............................. 4-10 Removing the Battery ............................4-10 Installing the Battery ............................. 4-10 Scanner Tests ...................................4-11 Front Panel Buttons ..............................4-11 Alpha Wheel ................................4-12 Front Panel Sliders ..............................4-12 Right Main Output..............................
Page 8 Kurzweil PC3x Service Manual Engine Board Assembly–MARA 1 (3 of 9)........................6-5 Engine Board Assembly–MARA Clocks, Delay Memory Interface (4 of 9)............6-6 Engine Board Assembly–Sound ROM (5 of 9) ......................6-7 Engine Board Assembly–ROM DIMMs, SmartMedia Interface, LCD, etc. (6 of 9) ..........6-8 Engine Board Assembly–DAC, Main Outs (7 of 9) ....................
Page 9: Chapter 1 Introduction
This chapter provides the service technician with a layout of the front and rear panel features, as well as a brief explanation of their functions. For in-depth descriptions of the many features the PC3x includes, consult the Getting Started Guide. Warning: If possible, save all user programs and setups before disassembly. For instructions, refer to the Boot Loader in Chapter 4, page 4-2.
Page 10 Figure 1-2 PC3x rear panel, right end Sync In—This RCA jack allows the PC3x to receive digital clock signals when it is slaved to another device. Digital Out—RCA jack to connect to another device with an AES or S/PDIF input via a 75! coaxial cable.
Page 11: Pc3X Front Panel
Introduction PC3x Front Panel PC3x Front Panel Front Panel Features BANKS Base 1 Base 2 Classic Keys Orchestra Strings Exp 1 Exp 2 User Fast/Slow On/Off Chor/Vib Depth On/Off Loud/Soft Decay F/S Pitch H/L On/Off Rotary Vibrato Percussion Enable MASTER...
Page 12 Introduction PC3x Front Panel Chan/Layer buttons—depending on the current editor, use these buttons to scroll through layers, presets, values, and zones. Record, Play/Pause, and Stop buttons—use these buttons to activate the sequencer to record and playback songs. Edit button—use this button to enter the editor or the current mode to modify a selected object or parameter.
Page 13: Wheels Assembly (Not Shown)
Introduction PC3x Front Panel Alpha Wheel—use the Alpha Wheel to increase or decrease a value by one or several increments. Plus (+) and Minus (–) buttons—these buttons operate similar to the Alpha Wheel. Pressing the Plus (+) or Minus (-) button allows you to increase or decrease a value by one. Pressing these buttons simultaneously, selects the Jump function.
Page 14 Introduction PC3x Front Panel...
Page 15: Chapter 2 Diagnostics
The following lists the diagnostic tests available for the PC3x. Note: Throughout this manual many references are made to the MARA 1 and MARA 2 ICs. For service personnel unfamiliar with the PC3x, MARA is the name given to the two Kurzweil Custom Sound ICs.
Page 16: Lcd And Front Panel Buttons
Diagnostics Entering Diagnostics 3. The LCD ﬂashes the message: Running ROM-based diagnostics 4. The LCD displays the following: Running SDRAM refresh test RAM Test Passed Figure 2-2 LCD example, diagnostic main menu 5. The bottom line in the display shows the four test modes. Press the soft button below the test mode to run the tests.
Page 17: Diagnostic Test Modes
Diagnostics Diagnostic Test Modes Diagnostic Test Modes The run test mode allows you to select an individual test, or to step through and run each available test. To step through the different tests, use the Left, Right, Up, or Down cursor buttons or turn the Alpha Wheel.
Page 18: Description Of Tests
MARA Validity Check Note: Throughout this manual many references are made to the MARA 1 and MARA 2 ICs. For service personnel unfamiliar with the PC3x, MARA is the name given to the two Kurzweil Custom Sound ICs. This tests veriﬁes the proper content of certain read-only registers and the read/write accuracy of certain read/write registers on both MARAs.
Page 19: Expansion Dimm Check
Diagnostics Description of Tests Expansion DIMM Check This test checks to see if a DIMM module is installed in J10 or J11 and conﬁrms the type. Running Exp DIMM check test CHECK READ WRITE PLAY DIMMS DIMMS DIMMS DIMMS EXIT Figure 2-4 LCD example, Exp DIMM check test Note: There are two types of DIMM modules—one with all four NOR Flash chips present and...
Page 20: External Card
Diagnostics Description of Tests External Card This test checks the hardware interface for the xD Card. The test ﬁrst checks to see if a card is installed; and if so, reads and reports the identifying data. Note: This test is safe to run on an xD Card that has data on it. A failure of this test indicates a problem with USB/xD Daughtercard, related circuitry or the Engine Board.
Page 21: Audio Output
If the diagnostic version is 0.20 or later, follow the on-screen instructions for use. Warning: This test produces loud sine waves. Before beginning this test, turn the volume slider on the PC3x and your sound system down to minimum. Diagnostic Version 0.20 or earlier To use diagnostic Version 0.19 or earlier to check amplitude, polarity, and frequency response...
Page 22: Sine Wave Test
Description of Tests Sine Wave Test For a pure sine wave that exercises the full dynamic range of the PC3x, press the Run PC3 soft button to exit diagnostics and return to normal operation. In Program mode, use the numeric keypad and select program 1000, Sine Wave.
Page 23 Diagnostics Description of Tests Notes 1. Slider 1 is a ﬁne amplitude adjustment. It has a range from 63% of the values listed in Table 2-1 to beyond clipping. 2. Clipping level is speciﬁed to be 4.25 Vrms, 6.00Vp-p, +14.8 dBm unbalanced, +20.8 dBm balanced at the Main and Aux Outputs.
Page 24 Diagnostics Description of Tests 2-10...
Page 25: Disassembly/Assembly
Disassembly/Assembly Introduction This chapter contains all the procedures for the disassembly and reassembly of the PC3x. There are three main sections: Opening the PC3x, Top Enclosure, and the PC3x Keyboard Assembly. Warning: If possible, save all user programs and setups before disassembly. For instructions, refer to Boot Loader in Chapter 4, page 4-2.
Page 26: Opening The Pc3X
PC3x bottom enclosure Caution: Do not remove the endcap or rear panel screws at this point of the procedure. 1. Tilt the PC3x up and remove the four enclosure support wall screws. 2. Place the unit ﬂat on your work surface.
Page 27: Removing The Top Enclosure
Opening the PC3x Removing the Top Enclosure The following procedure assumes that you have completed Steps 1–4 in PC3x Bottom. Removing the top enclosure requires removing the left and right endcaps. Each endcap includes the endcap, endcap side bracket and endcap locking bracket.
Page 28 Disassembly/Assembly Opening the PC3x 7. Refer to Figure 3-4. The bottom edge of the rear panel and back edge of the bottom enclosure connect to form a lip. The rear panel screws secure the lip. Transformer Enclosure Support Wall Figure 3-4 Top and bottom enclosures Warning: Be sure to have your work surface prepared.
Page 29: Replacing The Top Enclosure
Disassembly/Assembly Opening the PC3x Top cover Assembly Bottom Enclosure Connector Board, Bass Keyboard Assembly, Bass Connector Board, Treble Keyboard Assembly, Treble Slider Board Button Board/Wheels Assembly Connector Board Wheels Assembly Table 3-1 Top and bottom enclosure cables Replacing the Top Enclosure 1.
Page 30: Closing The Pc3X
Disassembly/Assembly Opening the PC3x Closing the PC3x Warning: The following procedure assumes that you have completed Steps 3 and 4 in Replacing the Top Enclosure. If you have not completed these steps, do so before continuing. 1. Refer to Figure 3-1. Tilt the unit up and install the four enclosure support wall screws.
Page 31: Top Enclosure
Disassembly/Assembly Top Enclosure Top Enclosure The top enclosure includes six boards: Connector, Front Panel, LCD, Slider, Engine, and USB/xD Daughtercard. The enclosure support wall, transformer and AC recptacle are also included on the top enclosure. Figure 3-6 shows the placement of the enclosure support wall on the top enclosure.
Page 32: Removing The Enclosure Support Wall
Disassembly/Assembly Top Enclosure Removing the Enclosure Support Wall The shielded cable bundle connecting J302 on the Connector Board to J18 on the Engine Board is routed and taped along the front of the enclosure support wall. Tape also secures the cable bundle to the Slider and Front Panel Boards.
Page 33: Removing The Connector Board
3. Disconnect the stranded wire cables from J301, J303, and J325 on the Connector Board. Note: The cables used throughout the PC3x are bundled and routed so that their locations and destinations seem obvious. However, to avoid reversing the Bass and Treble cables when reconnecting, mark one or both cables designating B for Bass and T for Treble.
Page 34: Replacing The Connector Board
Disassembly/Assembly Top Enclosure longer screws with spacers Figure 3-9 Rear panel hardware locations 6. Remove the eight screws that secure the Connector Board to the rear panel. Two screws are longer than the others and have spacers located between the screw and the rear panel. See Figure 3-9 for the locations of the screws and spacers.
Page 35: Removing The Slider Board
Disassembly/Assembly Top Enclosure 3. Connect the stranded wire cable from the Slider Board to J305 on the Connector Board. 4. Connect the stranded wire cable from the Transformer to J324 on the Connector Board. 5. Connect the stranded wire cable from the Wheels Assembly to J308. 6.
Page 36: Replacing The Slider Board
Disassembly/Assembly Top Enclosure J303 FP Bridge Slider Board J304 J302 Figure 3-11 Slider Board, screw locations 8. Remove the four screws that secure the two PC board clamps (two screws per clamp). These screws also secure the rear panel edge of the Board. 9.
Page 37: Removing The Lcd Board
Disassembly/Assembly Top Enclosure Removing the LCD Board 1. Follow the procedure described on page 3-8 to remove the enclosure support wall. 2. Follow the procedure described on page 3-9 to remove the Connector Board. 3. Disconnect the ﬂat ribbon cable from J15 on the Engine Board. This cable is bundled with other cables routed along the rear panel portion of the top enclosure.
Page 38: Replacing The Lcd Board
Disassembly/Assembly Top Enclosure Replacing the LCD Board 1. Place the LCD Board in position face down onto the front panel bezel. 2. Install the four screws that secure it to the front panel bezel. 3. Connect the ﬂat ribbon cable to J15 on the Engine Board. Be sure that you bundle the LCD cable with the other cables positioned along the rear panel and tie wrap them to the cable mounts.
Page 39 Disassembly/Assembly Top Enclosure Note: If the service you are performing only requires that you have access to the Front Panel Board for component testing or component replacement, it is not necessary to separate the LCD Board from Front Panel Board. 5.
Page 40: Replacing The Front Panel Board
Disassembly/Assembly Top Enclosure Replacing the Front Panel Board Note: If you are replacing the Front Panel Board with another board, be sure to remove the four screws that secure the LCD bezel to the board and install it on the new board. 1.
Page 41: Removing The Engine Board
Disassembly/Assembly Top Enclosure Removing the Engine Board The USB/xD Daughtercard is mounted on the Engine Board. The following procedure describes removing the Engine Board with the USB/xD Daughtercard attached. 1. Following Steps 2–4, disconnect the cables listed in Table 3-5. Ref.
Page 42: Replacing The Engine Board
Disassembly/Assembly Top Enclosure Replacing the Engine Board 1. Place the Engine Board in position on the top enclosure. Note: Be sure the blue xD Daughtercard bezel is seated in the rear panel cutout properly. 2. Align the center screw hole on the front panel edge with the thread marks in the extrusion and install the three screws that secure the front panel edge.
Page 43: Removing The Wheels Assembly
Disassembly/Assembly Top Enclosure Removing the Wheels Assembly 1. Refer to Figure 3-15 on page 3-20. Slide the left side of the unit forward off of your work surface so that you can access the four screws and washers securing the assembly to the bottom enclosure.
Page 44: Pc3X Keyboard Assembly
1. The keyboard is secured to the bottom enclosure using twelve screws. Refer to Figure 3-15 for the position of the screws. Arrows identify the locations of the twelve screws. 2. Tilt the PC3x up and remove the six keyboard rear screws, then lay the PC3x ﬂat on your work surface.
Page 45: Replacing The Pc3X Keyboard Assembly
Wheels Assembly to the bottom enclosure. 6. Move the PC3x back onto your work surface. 7. Slide the PC3x forward so that you can install the six keyboard front screws. 8. Move the PC3x back onto your work surface. 9. Tilt the PC3x up and install the six keyboard rear screws.
Page 46: Removing Keys
Note: If you are merely replacing one or more keys, it is not necessary to entirely remove the keyboard from the PC3x. Once you have followed the procedure to remove the keyboard, you can slide it toward the rear panel to give you enough access to remove and replace keys.
Page 47: Removing Natural/White Keys
Disassembly/Assembly PC3x Keyboard Assembly Removing Natural/White Keys 1. Unlock the key from the pivot anchoring the key to the keyboard chassis. To do this, insert a small ﬂat screwdriver at the back end of the pivot and press toward the front edge of the keyboard.
Page 48: Replacing A Natural/White Key
Disassembly/Assembly PC3x Keyboard Assembly Replacing a Natural/White Key 1. Verify the placement of the key spring. 2. Hook the front end of the key under the keyboard chassis. 3. Lower the key into position. Align the pivot with the hole at the rear of the key.
Page 49: Replacing The Bass Contact Board
Disassembly/Assembly PC3x Keyboard Assembly Replacing the Bass Contact Board 1. Position the Bass Contact Board on the keyboard chassis. Be sure that the rubber key contacts line up properly through the holes in the keyboard chassis. 2. Install the 18 screws that secure the board to the keyboard chassis.
Page 50 Disassembly/Assembly PC3x Keyboard Assembly 3-26...
Page 51: Troubleshooting & Maintenance
Chapter 4 Troubleshooting & Maintenance Introduction Cables, Connectors Cables All cables with connectors are keyed, and therefore cannot be reversed. Warning: Some units may have a small PC board installed on the ﬂat ribbon cable connected to J202 on the Front Panel Board. Neither the socket nor the pins on this board are keyed. See Removing the Front Panel Board in Chapter 3, page 3-14 and page 3-16 for further information.
Page 52: Boot Loader
Troubleshooting & Maintenance Boot Loader Boot Loader Use the PC3x’s Boot Loader to enter Diagnostics or perform a Hard Reset to the unit. You can also install operating system updates and objects into Flash memory. Entering the Boot Loader Apply power to the unit. When the ****Welcome to the Kurzweil PC3**** message appears in the LCD, quickly press and release the Exit button.
Page 53: Saving User Data
Saving User Data Saving User Data To save user data, ﬁrst apply power to the PC3x. Once the unit is on and ready for normal operation, follow the procedure to save user data to an xD card or a computer.
Page 54: Software Updates
Windows or MacOS formatted xD card up to 256 Mb. If you format an xD card, use DOS format, FAT 16. You can format xD cards on the PC3x, enter the Boot Loader and select the FILE UTILITIES soft button. However, the maximum size for xD cards formatted on the PC3x is 128Mb.
Page 55: Updating Via Computer
4-3. 1. Connect a USB cable from a computer to the USB port on the PC3x. 2. Apply power to the unit. When the ****Welcome to the Kurzweil PC3**** message appears in the LCD, quickly press and release the Exit button.
Page 56: Rebuilding The Internal Nand Flash Memory
PC3 Diagnostics ﬁle, PC3DG018 or higher • PC3 Objects ﬁle, PC3OB111.PC3 or higher 2. Turn on the PC3x and enter the Boot Loader. Then insert the xD card into the slot on the PC3x. 3. Press the File Utilities soft button.
Page 57: Rebuilding Via A Computer
Card or the USB port via computer. 1. Connect a USB cable from a computer to the USB port on the PC3x. 2. Apply power to the unit. When the ****Welcome to the Kurzweil PC3**** message appears in the LCD, quickly press and release the Exit button.
Page 58 System objects installed. displays brieﬂy then the root menu will display. 13. Press the Quit soft button then press the <back> soft button on the next menu. The normal Boot Loader menu should now be displayed. 14. Press the RUN PC3 soft button. The PC3x should boot up normally.
Page 59: Boot Eprom
Troubleshooting & Maintenance Boot EPROM Boot EPROM The PC3x uses a 32 pin EPROM located at U4 to store the boot up information for the CPU. Removing the EPROM 1. Place the PC3x upside down on a ﬂat protected surface.
Page 60: Replacing The Battery
2. Remove the seven screws that secure the access panel and set it safely aside. Removing the Battery The battery (CR2032) in the PC3x keyboard is mounted into a holder on the Engine Board and is accessible when the access panel is removed.
Page 61: Scanner Tests
RIGHT JACK message in the display. To enter the Scanner Tests, ﬁrst turn on the PC3x. Once the PC3x is on and ready to play, simultaneously hold down the 4, 5 and 6 buttons. All front panel LEDs will ﬂash and the LCD will slowly display the following: PC3 Scan V1.5 DIAG B=3.2 W=122 OPT=-3--...
Page 62: Alpha Wheel
Troubleshooting & Maintenance Scanner Tests Alpha Wheel To test the Alpha Wheel, turn it to increase or decrease the value by one. Turning clockwise should increase the numbers in order 0-1-2-3-0-1-2... and decrease the numbers in order 3-2-1-0- 3-2-1... turning counterclockwise. The expected test result when the Alpha Wheel is turned is one of four values–0, 1, 2, or 3: SPINKNOB = 3 Front Panel Sliders...
Page 63: Wheels
Troubleshooting & Maintenance Scanner Tests Wheels To test the pitch and mod wheels, move the wheel up and down. An example of the expected test results for the pitch wheel follows (your results may vary slightly): At bottom: PITCH WHEEL At center: PITCH WHEEL At top: PITCH WHEEL Adjusting the Pitch Wheel Center...
Page 64: Power Problems
If a unit set for 120V is plugged into 240V, the fuses will blow immediately but no damage should occur to the unit. 4. Place the PC3x upside down on a ﬂat protected surface. 5. Remove the seven screws that secure the access panel and set it safely aside.
Page 65: Front Panel Problems
4. Refer to the Front Panel Board schematics and check the signal path. LCD lit, no characters 1. Place the PC3x upside down on a ﬂat protected surface. 2. Remove the seven screws that secure the access panel and set it safely aside.
Page 66: Keyboard Problems
Troubleshooting & Maintenance Keyboard Problems Keyboard Problems Dead Keyboard 1. Run the Scanner Tests. If the tests pass, the problem is likely the result of a setting in the Control Setup. Perform a Hard Reset to the unit or refer to the Control Setup sections in the Getting Started Guide.
Page 67: Pc3X Interconnect Diagram
Troubleshooting & Maintenance PC3x Interconnect Diagram PC3x Interconnect Diagram *The routing of this cable is important! See Chapter 3, Page 3-8. USB/xD Daughter Card Graphic LCD PC3 Power MIDI & CPU Bank 1 Expansion Sound ROM Bank 0 Expansion Sound ROM USB/SM Card Dig.
Page 68: Converting The Voltage
Troubleshooting & Maintenance Converting the Voltage Converting the Voltage Accessing the Fuses 1. Turn the power off and remove the power cord. 2. The fuse holder is located on the rear panel and is part of the power entry module. 3.
Page 69: The Fuse Holder
Converting the Voltage The Fuse Holder The fuse holder used in the PC3x can accommodate different fuse conﬁgurations. In general, two fuses are required in EU countries and for all units conﬁgured for 230V regardless of location. Only one fuse is required in the USA. Check local regulations for requirements in other locations.
Page 70 Troubleshooting & Maintenance Converting the Voltage 3. Lift off the clip. 4. Be sure to save the conversion clip so that it can be installed if the fuse holder is once again conﬁgured for a single fuse. 4-20...
Page 71: Using 5 Mm X 20 Mm Fuses
Troubleshooting & Maintenance Converting the Voltage Using 5 mm X 20 mm Fuses 1. If you use 5 mm X 20 mm fuses, install them toward the inside end of the fuse holder near the metal pins. 2. The photo below shows the correct position for a 5 mm X 20 mm fuse. Replacing the Fuse Holder 1.
Page 72 Troubleshooting & Maintenance Converting the Voltage 4-22...

Kurzweil PC3x Service Manual

Chapter 1 Introduction

Chapter 2 Diagnostics

Chapter 3 Disassembly/Assembly

Chapter 4 Troubleshooting & Maintenance

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