BOSE 203 Service Manual

MODEL 203™ LOUDSPEAKER

®

®

©2010 Bose Corporation

Service Manual

Reference Number 193625-SM Rev. 02

CONTENTS

Specifications......................................................................................................................2

Disassembly/Assembly procedures...............................................................................3-4

Test Procedures .................................................................................................................. 5

Figure 1. Model 203™ Loudspeaker test setup diagram ................................................................ 5

Figure 2. Model 203 Loudspeaker Crossover Assembly topside and etch layout diagram............. 6

Figure 3. Model 203 Loudspeaker Driver wiring diagram ............................................................... 6

Figure 4. Model 203 Loudspeaker Crossover Assembly schematic diagram ................................. 7

Model 203 Loudspeaker Crossover Assembly part list (per figure 5)............................ 8

Figure 5. Model 203 Loudspeaker Crossover Assembly layout diagram ........................................ 8

Model 203 Loudspeaker part list (per figure 6) ................................................................ 9

Figure 6. Model 203 Loudspeaker exploded view........................................................................... 9

Model 203 Loudspeaker packing list (per figure 7)........................................................10

Figure 7. Model 203 Loudspeaker packing diagram ..................................................................... 10

Optional 70/100V Transformer Accessory part list and installation............................. 11

CAUTION: THE MODEL 203 LOUDSPEAKER 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.

SPECIFICATIONS

Model 203™ Loudspeaker Versions: 6 Ohm, 100 Watt, (no transformer)70/100V,

80Watt,(transformer accessory)

Impedance: 6 Ohms Nominal, 4.8 minimum from

20Hz to 20kHz.

Frequency Range: 60Hz to 16kHz, 3dB
Beamwidth: Vertical: 132°Horizont al: 185°
Port (each side): Flared slot port tuned to 60 Hz.
Shading Network Assembly: 10uF capacitor with 0.065 mH

series inductor

Internal Cabinet Volume: 5.7 Liters (347 cu.in.) net
External Dimensions: 12.83"L x 8.43"D x 7.25"H

(32.6cm x 21.4cm x 18.42cm)

Sensitivity (1W, 1m): 83.8dB SPL (calculated), freefield, per

IEC-268-5 (for octave-band centered at 400Hz).

Power Handling: 100W (24.5 Vrms) continuous
Weight: 1 1.5 lb (5.2 kg) each
Shipping Weight: 25.5 lb (1 1.6 kg) per packed p air

2

DISASSEMBLY/ASSEMBLY PROCEDURES

Note: Refer to Figure 6 for the following

procedures.

1. Grille removal

1.1 Using your fingers, grasp the grille (1)

edge nearest the port slot and gently pull
the grille away from the cabinet until it
comes free.

1.2 Grasp the opposite edge of the grille
and gently pull it away from the cabinet
until it comes free as well.

2. Grille replacement

2.1 Orient the grille (1) so that the Bose

logo (14) is aligned with the print on the
rear of the cabinet.

2.2 Align the two grille posts on the curved
grille edge with the cabinet post holes and
press the grille edge in place.

2.3 Align the two grille posts at the
opposite grille edge with the grille socket
grommets (4) and press the grille in place.
The grille should be neat and flush with the
cabinet.

4. Driver replacement

4.1 Observing polarity, solder the wires

from the crossover assembly (5) to the
driver (3) terminals.

4.2 Orient the driver correctly into the
cabinet and secure it using the screws (2)
removed in procedure 3.2.

4.3 Replace the grille (1) using
procedure 2.

5. Crossover Assembly removal

®

5.1 Remove the grille (1) and angled
driver (3) using procedure 3.

5.2 Remove the batting material and retain
it for replacement later.

5.3 Using a long shaft phillips-head
screwdriver, remove the four screws that
secure the crossover assembly (5) to the
interior of the speaker cabinet.

5.4 Unsolder the driver and barrier
connector (10) wires from the crossover
assembly.

3. Driver removal

3.1 Remove the grille (1) using

procedure 1.

3.2 Using a phillips-head screwdriver,
remove the three screws (2) that secure the
driver (3) to the speaker cabinet.

3.3 Using your fingers, grasp the plastic
basket of the driver and pull gently. The
driver should come free.

3.4 Note the driver wiring color code, and
cut the wires as close to the terminals as
possible.

Note: Refer to Figure 3. Model 203™
Loudspeaker driver wiring diagram, for
the following procedure.

6. Crossover Assembly replacement

6.1 Solder the driver (3) and barrier

connector (10) wires to the appropriate
locations on the crossover assembly (5).

6.2 Secure the crossover assembly to the
interior of the speaker cabinet in the
previous location using the four screws
removed in procedure 5.3.

6.3 Replace the batting material removed
in procedure 5.2.

6.4 Replace the driver and grille (1) using
procedure 4.

3

DISASSEMBLY/ASSEMBLY PROCEDURES (CONT.)

7. Barrier connector removal

7.1 On the rear of the loudspeaker,

remove the two (11) screws that secure the
barrier connector to the plate (9).

7.2 Grasp the barrier connector and pull it
straight out away from the loudspeaker.
It should come free.

7.3 Cut the wires as close to the terminals
as possible.

7.4 Retain the barrier strip gasket (12) for
replacement later.

8. Barrier connector replacement

8.1 Observing polarity, solder the

loudspeaker wires to the barrier connector
(10) leads.

8.2 Slide the barrier connector into the
speaker cabinet. Be sure it is oriented
properly.

8.3 Secure the barrier connector to the
speaker cabinet using the two (11) screws
removed in procedure 7.1.

4

TEST PROCEDURES

Frequency
Generator

+ -

Power Amplifier

+-

+-

+

-

DMM

Loudspeaker

+

-

Figure 1. Model 203™ Loudspeaker test

setup diagram

Note: Refer to Figure 3. Model 203 driver

wiring diagram for the following procedure.

1. Phase test

1.1 Remove the speaker grille using

procedure 1.

1.2 Observing polarity, apply a +6Vdc level
to the input terminals on the rear of the
loudspeaker. The speaker drivers should
both move outward.

1.3 Replace the grille using procedure 2.

2.4 Replace the grille using procedure 2.

3. Air leak test

3.1 Remove the grille using procedure 1.

3.2 Apply a 6Vrms, 60Hz signal to the

input terminals on the rear of the speaker
cabinet. Leave the speaker port open.

3.3 Test duration should be 5 seconds
minimum.

3.4 Listen carefully for air leaks along all
glue joints, at the binding post connector,
and at both transducer mounting locations.
Air leaks will be heard as a hissing or
sputtering sound. All repairs must be
hidden.

3.5 Replace the grille using procedure 2.

4. Power sweep test

4.1 Apply a 6Vrms, 10Hz signal to the

input terminals on the rear of the speaker
cabinet. Leave the speaker port open.

Note: Refer to Figure 1. Model 203
Loudspeaker test setup diagram, for the
following tests.

2. Rub and tick test

2.1 Remove the grille using procedure 1.

2.2 Apply a 6 Vrms, 10 Hz signal to the

input terminals on the rear of the speaker
cabinet.

2.3 Listen carefully for any buzzes, rattles,
or other extraneous noises from the drivers
or trim parts.

Note: There is a normal suspension noise.
To distinguish between a rub or a tick and
suspension noise, displace the driver cone
slightly with a finger. If the noise stays the
same, it is suspension noise.

4.2 Sweep the input frequency from 10Hz
to 3 kHz.

4.3 Reduce the input voltage level to
4Vrms and sweep the oscillator from 3kHz
to 5kHz.

Note: The whooshing noise from the port
at approximately 60Hz is acceptable.

4.4 Replace any transducer that has a
buzzing noise. There shall not be any
buzzes or rattles from the internal
connecting wires or components.
Redress any buzzing wires.

5

Figure 2. Model 203™ Loudspeaker Crossover Assembly topside and etch layout diagram

PCB

BLACK

YELLOW

GREEN

_

RED

DRIVER

Figure 3. Model 203 Loudspeaker Driver wiring diagram

+

BLUE

-

6

BARRIER
STRIP

+

DRIVER

-

+

TO

ANGLE

DRIVER

IN

-

1

W6

W5

(BLACK)

1

-

W4

(BLUE)

1

+

W3

(BLUE)

1

-

L1

65uH

TO

FRONT

DRIVER

PTC2

RXE040

(0.4A,1.3 OHM)

C1

10/50V

W2

(RED)

1

+

DS2DS1

Figure 4. Model 203™ Loudspeaker Crossover Assembly schematic diagram

PTC1

RXE 090

(0.90A,0.5 OHM)

W1

1

IN

+

(YELLOW) (GREEN)

7

Model 203™ Loudspeaker Crossover Assembly part list (per figure 5)

Item

Number

1 C1 Cap, El, BP, 85, 50V, 20%, 10 uF 290391-100 1
2 PTC2 Polyswitch, 60V, 4mm 190348-040 1
3 PTC1 Polyswitch, 50V, 4mm 190348-090 1
4 Tape, Foil, w/liner 134636 1
5 DS1, DS2 Lamp. 2.5, 24Vdc, Mini 132111 2
6 PCB, Bare Board, 203 Crossover 291226-001 1
7 L1 Inductor, 65 uH, 11 Ohm Ferrite 189799 1
8 Screw, Machine, 4-40x1, Pan , Xrec 103146-16 1

9 Washer, Flat, .141,#5 108258-05 1
10 Nut, Hex, 4-40 103234-440 1
11 Screw, Tapp, .8-11x.625, Pan, X RC/S 289388-010 4
12 Foot, .25X.50, Black 174402-01 4

Reference

Designator

Description Part Number Qty

1

2

3

4

FOIL
TAPE

YELLOW

BLUE

BLUE

GREEN

BLACK

RED

C1

PTC2

L1

M

11 12

PTC1

(4X)

5

M

(2X)

DS1,
DS2

6

7 8 9 10

Figure 5. Model 203 Loudspeaker Crossover Assembly layout diagram

8

Model 203™ Loudspeaker part list (per figure 6)

Item

Description Part Number Qty

Number

1 Grill e, Lef t, Model 203, Pro Gray

Grill e, Lef t, Model 203, Arc tic Whi t e
Grill e, Right , Model 203, Pro Gr ay
Grill e, Right , Model 203, Arct i c White

187223-011
187223-021
187223-012

187223-022
2 Screw, T app, 8-1 1x75, Pan, Xrc/S q 289388 -012 10
3 Drive r Assembl y, 4.5”, Model 203 187233 -002 2
4 Grommet, Grille Socket 176068 4
5 Crossover, Assembly, 203 291034-001 1
6 Insert , Threaded, Ext, Intl 121690 4
7 Nut, Lock, Flange, M8 121691 4
8 Washer, Lock, 326,5/16, Intl T 121692-31 4
9 Plate, Arctic White

Plate, Pro Gray

190649-001

190649-003

10 Connector, Barrier, 2 position 124484-02 1
11 Sc rew, Tapp, 6-32x75, PAN, TO RX 1 22994-12 2
12 Gasket, barrier strip, 102 128410 1
13 Gasket, Plate 290310-001 1
14 Namepl ate, Logo , clear/ bl ack 14670 1-1 1

6 7 8

(2X)

6

REF

1

1

(3X)

(2X)

2

(3X)

DETAIL A

8

7

REF

5

DETAIL A

TYPICAL INSERT ASSEMBLY

10

6 7 8

(2X)

(4X)

4

2

3

9

REF

11

(2X)

12

2

(4X)

13

1

14

Figure 6. Model 203™ Loudspeaker exploded view

9

Model 203™ Loudspeaker packing list (per figure 7)

Item

Description Part Number Qty

Number

1 Manual, Owner’s, Model 203 191913 1
2 Bracket, 203, Arctic White

Bracket, 203, Pro Grey

190650-001

190650-003
3 Packing, End Cap, Model 203 187243-001 2
4 Bag, Poly, 13.5x33.5x13x3 mil 114522 2
5 Carton, RSC, 300PM 291034-001 1

- Hardware Kit, Bracket 290316-001 1

1

(2X)

2

2
2

3

(2X)

4

(2X)

3

(2X)

5

Figure 7. Model 203™ Loudspeaker packaging diagram

10

Optional 70/100V transformer accessory part list and installation

Notes: 1. To be used with Model 203® pro gray variation only.

2. To be used with Model 203 artic white variation only.

Transformer accessory installation

Note: Refer to Figure 6 for the following

procedure.

1.1 Remove the CVT-2 transformer and
gasket from the packing carton.

1.2 On the back of the Model 203 loud­speaker, remove the plate (9) with the barrier
connector (10) by removing the four retaining
screws (2).

1.3 Gently lift the plate away from the
speaker cabinet.

1.4 Cut the wires as close to the barrier
connector as possible.

1.5 Strip the wires exposing about
1/2” (1.7 cm) of bare wire.

1.6 On the CVT-2 transformer, locate the
three positive output leads. The white wire is
the 19W lead, the green is the 38W lead and
the blue is the 75W lead.

Choose the positive output lead that best
matches your system’s power requirements.

1.7 Cut off the other two positive output
leads as they will not be required.

1.8 Place the transformer gasket on the
back of the transformer housing.

1.9 Observing polarity, solder the two
speaker leads to the two transformer leads.
Be sure to insulate the connections with
electrical tape.

1.10 After deciding which way you want the
transformer housing to face, align the trans­former housing with the back of the speaker
cabinet.

1.11 Secure the transformer housing to the
speaker cabinet using the four screws
removed in step 1.2.

1.12 Connect the leads to the 203 loud­speaker to the appropriate connections on
the barrier strip.

11

SERVICE MANUAL REVISION HISTORY

Date Revision

Level

8/97 00 Docum ent rel ease rev isi on 00 Service manual rel ease Al l
3/02 00 P a rt numb ers fo r PTC1 and

04/06 01 Added RoHS part number s

05/10 02 Ne w driver part number Part num ber change 9

Des cription of Change Cha nge Driven By Pages

Affected

Part num ber change

PT C2 chang ed.
Part numb er for t he CTV-2

transformer accessory changed

Supplement 193625-S1 and
193 625-S 2 informati on add ed.

Part num ber change

This product is now

built with RoHS

compliant parts.

PTC 1 , PT C 2 , C VT - 2

par t numbers updated.

8,9,10,11

8,11

8

11

12

SPECIFICATIONS AND FEATURES SUBJECT TO CHANGE WITHOUT NOTICE

®
®

Bose Corporation
The Mountain
Framingham, Massachusetts, USA 01701

P/N 193625-SM REV. 02; 05/10 FOR TECHNICAL ASSISTANCE OR PART ORDERS, CALL 1-800-367-4008