KURZWEIL PC3X Schematic

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.

Part Number: 910515-001 Ver. 1.0

The lightning flash with the arrowhead symbol,

CAUTION

RISK OF ELECTRIC SHOCK

DO NOT OPEN

within an equilateral triangle, is intended to alert
the user to the presence of uninsulated
"dangerous voltage" within the product's
enclosure that may be of sufficient magnitude
to constitute a risk of electric shock to persons.

CAUTION: TO REDUCE THE RISK OF ELECTRIC SHOCK,

DO NOT REMOVE THE COVER

NO USER SERVICEABLE PARTS INSIDE

REFER SERVICING TO QUALIFIED SERVICE PERSONNEL

The exclamation point within an equilateral
triangle is intended to alert the user to the
presence of important operating and
maintenance (servicing) instructions in the
literature accompanying the product.

IMPORTANT SAFETY & INSTALLATION INSTRUCTIONS

INSTRUCTIONS PERTAINING TO THE RISK OF FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS

WARNING: When using electric products, basic precautions should

always be followed, including the following:

1. Read all of the Safety and Installation Instructions and Explanation
of Graphic Symbols before using the product.

2. This product must be grounded. If it should malfunction or break
down, grounding provides a path of least resistance for electric
current to reduce the risk of electric shock. This product is equipped
with a power supply cord having an equipment-grounding
conductor and a grounding plug. The plug must be plugged into an
appropriate outlet which is properly installed and grounded in
accordance with all local codes and ordinances.

DANGER: Improper connection of the equipment-grounding

conductor can result in a risk of electric shock. Do not modify the
plug provided with the product - if it will not fit the outlet, have a
proper outlet installed by a qualified electrician. Do not use an
adaptor which defeats the function of the equipment-grounding
conductor. If you are in doubt as to whether the product is properly
grounded, check with a qualified serviceman or electrician.

3. WARNING: This product is equipped with an AC input voltage
selector. The voltage selector has been factory set for the mains
supply voltage in the country where this unit was sold. Changing
the voltage selector may require the use of a different power supply
cord or attachment plug, or both. To reduce the risk of fire or electric
shock, refer servicing to qualified maintenance personnel.

4. Do not use this product near water - for example, near a bathtub,
washbowl, kitchen sink, in a wet basement, or near a swimming
pool, or the like.

5. This product should be used only with a stand or cart that is
recommended by the manufacturer.

6. This product, either alone or in combination with an amplifier and
speakers or headphones, may be capable of producing sound
levels that could cause permanent hearing loss. Do not operate for
a long period of time at a high volume level or at a level that is
uncomfortable. If you experience any hearing loss or ringing in the
ears, you should consult an audiologist.

7. The product should be located so that its location or position does
not interfere with its proper ventilation.

8. The product should be located away from heat sources such as
radiators, heat registers, or other products that produce heat.

9. The product should be connected to a power supply only of the type
described in the operating instructions or as marked on the product.

10. This product may be equipped with a polarized line plug (one blade
wider than the other). This is a safety feature. If you are unable to
insert the plug into the outlet, contact an electrician to replace your
obsolete outlet. Do not defeat the safety purpose of the plug.

11. The power supply cord of the product should be unplugged from the
outlet when left unused for a long period of time. When unplugging
the power supply cord, do not pull on the cord, but grasp it by the
plug.

12. Care should be taken so that objects do not fall and liquids are not
spilled into the enclosure through openings.

13. The product should be serviced by qualified service personnel
when:

A. The power supply cord or the plug has been damaged;
B. Objects have fallen onto, or liquid has been spilled into the

product;
C. The product has been exposed to rain;
D. The product does not appear to be operating normally or

exhibits a marked change in performance;
E. The product has been dropped, or the enclosure damaged.

14. Do not attempt to service the product beyond that described in the
user maintenance instructions. All other servicing should be
referred to qualified service personnel.

WARNING: Do not place objects on the product’s power supply

15.
cord, or place the product in a position where anyone could trip
over, walk on, or roll anything over cords of any type. Do not allow
the product to rest on or be installed over cords of any type.
Improper installations of this type create the possibility of a fire
hazard and/or personal injury.

RADIO AND TELEVISION INTERFERENCE

WARNING: Changes or modifications to this instrument not expressly

approved by Young Chang could void your authority to operate the
instrument.

IMPORTANT: When connecting this product to accessories and/or other

equipment use only high quality shielded cables.

NOTE: This instrument has been tested and found to comply with the

limits for a Class B digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This instrument
generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause
harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If
this instrument does cause harmful interference to radio or television
reception, which can be determined by turning the instrument off and on,
the user is encouraged to try to correct the interference by one or more
of the following measures:

SAVE THESE INSTRUCTIONS

ii

• Reorient or relocate the receiving antenna.

• Increase the separation between the instrument and the receiver.

• Connect the instrument into an outlet on a circuit other than the one

to which the receiver is connected.

• If necessary consult your dealer or an experienced radio/television

technician for additional suggestions.

NOTICE

This apparatus does not exceed the Class B limits for radio noise
emissions from digital apparatus set out in the Radio Interference
Regulations of the Canadian Department of Communications.

AVIS

Le present appareil numerique n’emet pas de bruits radioelectriques
depassant les limites applicables aux appareils numeriques de la
class B prescrites dans le Reglement sur le brouillage radioelectrique
edicte par le ministere des Communications du Canada.

Important Safety Instructions

1. Read these instructions.

2. Keep these instructions.

3. Heed all warnings.

4. Follow all instructions.

5. Do not use this apparatus near water.

6. Clean only with dry cloth.

7. Do not block any of the ventilation openings. Install in accordance with the manufacturer’s
instructions.

8. Do not install near any heat sources such as radiators, heat registers, stoves, or other apparatus
(including amplifiers) that produce heat.

9. Do not defeat the safety purpose of the polarized or grounding-type plug. A polarized plug has
two blades with one wider than the other. A grounding type plug has two blades and a third
grounding prong. The wide blade or the third prong are provided for your safety. If the
provided plug does not fit into your outlet, consult an electrician for replacement of the obsolete
outlet.

10. Protect the power cord from being walked on or pinched, particularly at plugs, convenience
receptacles, and the point where they exit from the apparatus.

11. Only use attachments/accessories specified by the manufacturer.

12. Use only with a cart, stand, tripod, bracket, or table specified by the
manufacturer, or sold with the apparatus. When a cart is used, use
caution when moving the cart/apparatus combination to avoid
injury from tip-over.

13. Unplug this apparatus during lightning storms or when unused for
long periods of time.

14. CAUTION: Danger of explosion if battery is incorrectly replaced. Replace only with the same or
equivalent type (CR2032).

15. Refer all servicing to qualified service personnel. Servicing is required when the apparatus has
been damaged in any way, such as power supply cord or plug is damaged, liquid has been
spilled or objects have fallen into the apparatus, the apparatus has been exposed to rain or
moisture, does not operate normally, or has been dropped.

Warning - To reduce the risk of fire or electric shock, do not expose this apparatus to rain or moisture.

Do not expose this equipment to dripping or splashing and ensure that no objects filled with liquids,
such as vases, are placed on the equipment.

To completely disconnect this equipment from the AC Mains, disconnect the power supply cord plug
from the AC receptacle.

iii

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: [phone]
Fax: [phone]

http://www.kurzweilmusicsystems.com

Kurzweil Co., LTD

iPark Building #102, Floor 9
Jeongja-Dong 9, Bundang-Gu
Soungnam-Shi, Gyeonggi-Do 463-859
South Korea

http://www.ycpiano.co.kr
http://www.youngchang.com

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 ................................................................................................................................ 2-2

Test Results................................................................................................................................................................ 2-2

Diagnostic Test Modes.................................................................................................................................................... 2-3

Run ............................................................................................................................................................................. 2-3

Loop ........................................................................................................................................................................... 2-3

Continuous................................................................................................................................................................ 2-3

Burn-in loop.............................................................................................................................................................. 2-3

Description of Tests......................................................................................................................................................... 2-4

SDRAM Refresh ....................................................................................................................................................... 2-4

Flash Memory........................................................................................................................................................... 2-4

MARA Validity Check ............................................................................................................................................. 2-4

MARA Communications......................................................................................................................................... 2-4

Expansion DIMM Check......................................................................................................................................... 2-5

MIDI UART............................................................................................................................................................... 2-5

External Card............................................................................................................................................................ 2-6

MARA Delay RAM.................................................................................................................................................. 2-6

MARA Sound ROM................................................................................................................................................. 2-6

Audio Output ........................................................................................................................................................... 2-7

Diagnostic Version 0.20 or earlier................................................................................................................... 2-7

Sine Wave Test................................................................................................................................................... 2-8

Chapter 3 Disassembly/Assembly

Introduction ..................................................................................................................................................................... 3-1

Notes, Cautions, Warnings ..................................................................................................................................... 3-1

Cables, Connectors................................................................................................................................................... 3-1

Cables ................................................................................................................................................................. 3-1

Cable Routing.................................................................................................................................................... 3-1

Required Tools and Materials................................................................................................................................. 3-1

Opening the PC3x ........................................................................................................................................................... 3-2

PC3x Bottom ............................................................................................................................................................. 3-2

Removing the Top Enclosure.................................................................................................................................. 3-3

Replacing the Top Enclosure .................................................................................................................................. 3-5

Closing the PC3x ...................................................................................................................................................... 3-6

Top Enclosure................................................................................................................................................................... 3-7

Removing the Enclosure Support Wall................................................................................................................. 3-8

Replacing the Enclosure Support Wall.................................................................................................................. 3-8

Removing the Connector Board............................................................................................................................. 3-9

Replacing the Connector Board ........................................................................................................................... 3-10

Removing the Slider Board....................................................................................................................................3-11

Replacing the Slider Board ................................................................................................................................... 3-12

i

Kurzweil PC3x Service Manual

Removing the LCD Board..................................................................................................................................... 3-13

Replacing the LCD Board ..................................................................................................................................... 3-14

Removing the Front Panel Board......................................................................................................................... 3-14

Replacing the Front Panel Board ......................................................................................................................... 3-16

Removing the Engine Board................................................................................................................................. 3-17

Replacing the Engine Board ................................................................................................................................. 3-18

Removing the USB/xD Daughtercard................................................................................................................ 3-18

Replacing the USB/xD Daughtercard................................................................................................................. 3-18

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 ............................................................................................................................... 3-23

Replacing a Sharp Key .......................................................................................................................................... 3-23

Replacing a Natural/White Key.......................................................................................................................... 3-24

Servicing the Keyboard Contact Boards............................................................................................................. 3-24

Removing the Treble Contact Board ............................................................................................................ 3-24

Replacing the Treble Contact Board............................................................................................................. 3-24

Removing the Bass Contact Board ............................................................................................................... 3-24

Replacing the Bass Contact Board................................................................................................................ 3-25

Connecting the Keyboard Contact Boards ......................................................................................................... 3-25

Removing the Keyboard Contact Strips ............................................................................................................. 3-25

Replacing the Keyboard Contact Strips.............................................................................................................. 3-25

Chapter 4 Troubleshooting & Maintenance

Introduction ..................................................................................................................................................................... 4-1

Cables, Connectors................................................................................................................................................... 4-1

Cables ................................................................................................................................................................. 4-1

Cable Routing.................................................................................................................................................... 4-1

Surface-Mount Devices ........................................................................................................................................... 4-1

Required Tools and Materials................................................................................................................................. 4-1

Boot Loader...................................................................................................................................................................... 4-2

Entering the Boot Loader........................................................................................................................................ 4-2

Resets................................................................................................................................................................................. 4-2

Hard Reset................................................................................................................................................................. 4-2

Soft Reset ................................................................................................................................................................... 4-2

Saving User Data............................................................................................................................................................. 4-3

Saving to an xD Card............................................................................................................................................... 4-3

Saving to a Computer.............................................................................................................................................. 4-3

Software Updates ............................................................................................................................................................ 4-4

Updating with an xD Card ..................................................................................................................................... 4-4

Updating via Computer.......................................................................................................................................... 4-5

Rebuilding the Internal NAND Flash Memory.......................................................................................................... 4-6

Rebuilding with an xD Card .................................................................................................................................. 4-6

Rebuilding via a Computer .................................................................................................................................... 4-7

Boot EPROM .................................................................................................................................................................... 4-9

Removing the EPROM ............................................................................................................................................ 4-9

ii

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................................................................................................................................................. 4-12

Switch Pedals 1, 2, and 3 ....................................................................................................................................... 4-12

Continuous Control Pedal 1 and 2 ...................................................................................................................... 4-12

Wheels ..................................................................................................................................................................... 4-13

Adjusting the Pitch Wheel Center................................................................................................................ 4-13

Keyboard ................................................................................................................................................................. 4-13

Adjusting Key Pressure Sensitivity.............................................................................................................. 4-13

Power Problems............................................................................................................................................................. 4-14

Dead: LEDs, LCD backlight, and xD Card socket not lit ................................................................................. 4-14

Audio Problems............................................................................................................................................................. 4-14

No Audio................................................................................................................................................................. 4-14

Front Panel Problems.................................................................................................................................................... 4-15

LCD not lit............................................................................................................................................................... 4-15

LCD lit, no characters ............................................................................................................................................ 4-15

Buttons, Sliders or Controllers not working ...................................................................................................... 4-15

Keyboard Problems....................................................................................................................................................... 4-16

Dead Keyboard....................................................................................................................................................... 4-16

Dead Note(s) or no velocity sensitivity .............................................................................................................. 4-16

One or More in a Section................................................................................................................................ 4-16

PC3x Interconnect Diagram......................................................................................................................................... 4-17

Converting the Voltage................................................................................................................................................. 4-18

Accessing the Fuses ............................................................................................................................................... 4-18

The Fuse Holder..................................................................................................................................................... 4-19

Using 5 mm X 20 mm Fuses .......................................................................................................................... 4-21

Replacing the Fuse Holder ................................................................................................................................... 4-21

Chapter 5 Parts Lists

PCB & Sub Assemblies............................................................................................................................................ 5-1

Engine Board............................................................................................................................................................. 5-1

Connector Board ...................................................................................................................................................... 5-4

Front Panel Board..................................................................................................................................................... 5-6

Slider Board............................................................................................................................................................... 5-7

Engine Board–USB/xD Daughtercard.................................................................................................................. 5-7

Button Board............................................................................................................................................................. 5-8

Wheels Assembly..................................................................................................................................................... 5-8

Keyboard Assembly................................................................................................................................................. 5-8

Miscellaneous ........................................................................................................................................................... 5-9

Chapter 6 Schematics

Engine Board Assembly–SH7705 CPU and Memory (1 of 9) ................................................................................... 6-3

Engine Board Assembly–MARA 2 (2 of 9)................................................................................................................... 6-4

iii

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) .................................................................................................... 6-9

Engine Board Assembly–Aux and Headphone Outs (8 of 9) ................................................................................. 6-10

Engine Board Assembly–Mictors, CPLD, Power (9 of 9) .........................................................................................6-11

Connector Board–M38869 Scanner (1 of 4)................................................................................................................ 6-12

Connector Board–MIDI, Pedals, Ribbon, LCD Contrast (2 of 4)............................................................................ 6-13

Connector Board–Power Supply, Audio (3 of 4)....................................................................................................... 6-14

Connector Board–Sample Rate Converter (4 of 4).................................................................................................... 6-15

Front Panel Board–Front Panel Misc. Buttons And LEDs (1 of 2).......................................................................... 6-16

Front Panel Board–Front Panel Bank & Program Buttons & LEDs (2 of 2) .......................................................... 6-17

Slider Board.................................................................................................................................................................... 6-18

Wheels Board–Wheels & AT........................................................................................................................................ 6-19

Engine Board–USB/xD Daughtercard....................................................................................................................... 6-20

i

v

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 .

Notes, Cautions, Warnings

Please pay special attention to all Notes, Cautions, and Warnings used throughout this manual
as they not only point out specific instructions, but also alert you to variations between
manufactured units.

A brief description of these symbols follows:

Note : Provides additional information, indicates differences between models, and emphasizes

specific instructions.

Caution : Highlights areas to instruct you to proceed cautiously so that damage does not occur

to the unit or individual components.

Warning : Alerts you so that damage does not occur to yourself, others, or external equipment

and devices.

Rear Panel Features

Storage —Use this slot to insert an xD memory card to update software, back up, and share files.

USB Port —Use the USB Port to send and receive MIDI or to connect to a computer for file

transfer.

Storage

Figure 1-1 PC3x rear panel, left end

USB Port

1-1

Introduction

Rear Panel Features

MIDI Select Switch —Slide switch to select the operation of the MIDI Thru/Out port. This

switch is recessed into the rear panel so that it cannot be accidentally changed.

MIDI Ports —In, Thru/Out, and Out ports to connect the PC3x to other MIDI devices to receive,

pass, and send MIDI data.

Display —Rotary potentiometers to adjust the brightness and contrast of the LCD for the best

visibility.

MIDI
Select
Switch

MIDI

Ports

Display
Bright,

Contrast

Sync In

Digital Out

Breath

Input

Switch
Pedals

Continuous

Control Pedals

Ribbon
Input

Balanced

Analog Outputs

Headphones

Power Entry

Module

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.

Switch Pedals —Three 1/4” jacks to connect switch pedals that can be assigned to control

operations such as sustain, sostenuto, etc. (use 1/4” tip/sleeve).

1-2

Continuous Control Pedals —Two 1/4” jacks to connect pedals that can be assigned to control

operations such as volume, expression, etc. (use 10K ! linear taper potentiometer, 1/4”
tip/ring/sleeve, wiper to tip).

Breath Input —A 3.5mm jack to connect a standard breath controller to send standard MIDI

Breath messages.

Ribbon Input —Modular jack to connect the Kurzweil Ribbon Controller option.

Balanced Analog Outputs —Four 1/4” balanced audio output jacks. Use the Main outputs, left

(mono) and right, to connect to an amplifier, mixer or sound system. Use the Aux outputs for
monitoring or other operations. They duplicate the Main outputs, but are always in stereo.

Headphones —Standard 1/4” jack to connect headphones.

Power Entry Module —includes the power switch, AC receptacle, and the fuse holder/voltage

select compartment. (See Chapter 4, page 4-18 for instructions to change the voltage setting.)

PC3x Front Panel

V

y

p

Front Panel Features

Introduction

PC3x Front Panel

MASTER

OLUME

BANKS

StringsOrchestraClassic KeysBase 1 Base 2 Exp 1 UserExp 2

Rotary

16' 5 1/3' 8' 4' 2 2/3' 2' 1 3/5' 1 1/3' 1'

A B IEC G HFD

Data MIDI 1 3 MIDI 22 MI DI 23 MIDI 24

Vibrato

DepthOn/Off Chor/VibFast/Slow

Loud/Soft Decay F/S Pitch H/L

On /Off

Percussion Enable

MIDI 25 MIDI 26 MIDI 27 MIDI 28

KB3

On /Off

Figure 1-3 Master Volume, Bank buttons, Sliders

Master Volume —Slider to adjust the overall volume.

Bank buttons—Use these buttons to select different banks of programs, then select an individual

program using the Category and Program buttons. The labeling above the button indicates the
program. In KB3 mode, these buttons have different functions. Their labeling is below the Bank
buttons.

Sliders —The operation of the sliders depends on which mode is active. In KB3 mode, these

sliders emulate the drawbars of an organ. They are labeled as follows: above each slider for KB3
mode, and below when used for data and MIDI controllers.

MODE

MIDIProgram

Mute 1

Setup Master

Q Access Song

Solo Mute Active

Effect Storage

FX Bypass Compare

Record Pla

Mute 2

Mute 4Mute 3

/ Pause Sto

Chan / Layer

Edit

Figure 1-4 Mode, Edit, Chan/Layer and record function buttons

Mode buttons—use these buttons to select one of the eight available operating modes. The

additional labeling of these buttons indicate that they function differently depending on the
current mode or editor.

1-3

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.

ExitExit

Figure 1-5 LCD and Soft, Cursor, and Exit buttons

Display —Angled 240 x 64, backlit graphic LCD.

Soft buttons — use these buttons to select an action or item shown directly above the button in

the bottom line of the display.

Cursor buttons — use these buttons navigate the cursor in the display.

Exit button—press this button to leave the current editor.

PROGRAM

1 432

CATEGORY

E Piano 1Piano 2Piano 1 E Piano 2

8765

BrassOrganClavierPop Keys

PadsSynthsVoicesStrings

PercussionDrumsBassGuitar

Jump

Storage
Active

1 2 3

4 5 6

STU YZVWX

-

/

+

Shift 0-9

Cancel Enter

GHIDEFABC

PQRMNOJKL

8 97

0 Clear

Space

PANIC

1-4

Figure 1-6 Program, Category, Alpha wheel and Alphanumeric buttons

Category and Program buttons—use these buttons to first select a Category , then select one of

the eight

Program buttons.

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.

Alphanumeric Keypad—use these buttons to enter characters (both uppercase and lowercase),
numbers, and spaces. Pressing these buttons simultaneously, selects the Panic button. Select the
Panic button to send an All Notes/All Controllers Off message on all 16 channels.

Storage Active LED—this blue LED is lit when an xD daughter card is installed and there is

activity. (Do not remove the xD card when the blue LED is lit.)

Wheels Assembly (not shown)

Pitch and Mod Wheels—use these wheels to vary modulation and pitch. In some programs, the
Mod Wheel can be used for other functions.

Introduction

ARP button—use this button to active the Arpeggiator.

SW button—this button can be programmed for a variety of functions.

1-5

Introduction

PC3x Front Panel

1-6

Chapter 2
Diagnostics

Diagnostic Tests

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.

• SDRAM Refresh

• Flash Memory

• MARA Validity Check

• MARA Communications

• Exp DIMM Check

• MIDI UART

• External Card

• MARA Delay RAM

• MARA Sound ROM

• Audio Output

Warning: If possible, save all user programs and setups before entering diagnostics or
performing maintenance or repair. For instructions, refer to Saving User Data in Chapter 4,
page 4-2.

Entering Diagnostics

1. Apply power to the unit. When the ****Welcome to the Kurzweil PC3**** message appears in
the LCD, quickly press and release the Exit button. The LCD should display the following:

PC3 Boot Loader Version X.XX

RUN UPDATE RUN SYSTEM FILE
PC3 IMAGE DIAGS RESET UTILITIES

Figure 2-1 LCD example, Boot Loader

2. Press the soft button below RUN DIAGS in the LCD.

2-1

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

OK

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.

LCD and Front Panel Buttons

The LCD displays the list of tests, test modes, actions, and test results.

Press the Left, Right, Up, or Down cursor buttons or turn the Alpha Wheel to navigate through
the available tests.

Use the soft buttons located below the LCD to select different test modes or actions.

Press the Exit button to return to the Boot Loader.

Test Results

At the completion of an individual test, the LCD displays the results of the test. Figure 2-3 shows
an example of the display for the SDRAM refresh test.

Figure 2-3 LCD example, SDRAM refresh test

Running SDRAM refresh test

RAM Test Passed

OK

2-2

Diagnostic Test Modes

Run

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. Press the soft button below RUN to select the test.

At the completion of a test, whether pass or fail, press the OK soft button to exit the test and
return to the test menu.

To exit diagnostics, press the Exit button to return to the Boot Loader.

Loop

Loop continuously runs an individual test. The number of tests performed and the result is
displayed continuously in the LCD. The test continues to run until you press the Exit button.

Continuous

Continuous is the same as Loop, but stops if a failure is detected.

Diagnostics

Diagnostic Test Modes

Burn-in loop

Burn-in continuously runs the following sequence of tests.

• SDRAM Refresh

• Flash Memory

• MARA Validity Check

• MARA Delay RAM

• MARA Communications

• MARA Sound ROM

If a failure is detected, the test stops and displays the result.

To exit Run Burn-in and return to the Boot Loader, press and hold the Exit button.

2-3

Diagnostics

Description of Tests

Description of Tests

SDRAM Refresh

This test verifies the write/read functionality and accuracy of the SDRAM chip (U3) attached to
the microprocessor, SH7705 (U1).

A failure of this test indicates a problem with the SDRAM chip or associated circuitry on the
Engine Board.

Flash Memory

This test verifies the manufacturer ID and the size of the NAND Flash installed. The test then
writes and reads back one or more blocks not occupied by the file system. This test also indicates
if the NAND Flash is formatted or unformatted.

A failure of this test may indicate a problem with the with the microprocessor (U1), NAND
Flash (U2), Fin CPLD (U45), or related circuitry on the Engine Board.

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. It also writes and reads back the various register
blocks in both MARAs that are implemented as RAM cells.

A failure of this test may indicate a problem with the with the microprocessor (U1), MARA 1
(U11) or MARA 2 (U10), or related circuitry on the Engine Board.

MARA Communications

This test transfers data from one MARA to the other via the SMOOCH interface and checks the
accuracy of the data received. All four SMOOCH inputs and outputs are exercised.

This test will likely fail if the MARA Validity Test fails. However if the MARA Validity Test
passes and this test fails, it may indicate a bad solder joint underneath one or both MARAs.

2-4

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
the other with only two out of the four chips populated. The J10 DIMM socket on the Engine
Board can only support the half-populated DIMM version.

Each DIMM module has an upper and lower bank. The half-populated DIMM module has Flash
chips installed in the upper bank only. Therefore, this diagnostic will only report results for
DIMM 0, High Bank; but will report results for both the High and Low Bank of DIMM 1.

Diagnostics

Description of Tests

A failure of this test may indicate a problem with the DIMM(s), their installation, soldering of
the socket(s), or related circuitry on the Engine Board.

MIDI UART

The MIDI test performs a loop-back of the serial port by sending a 23-byte pattern over the
external MIDI link. This test requires a MIDI loop (a MIDI cable that connects two MIDI jacks).
The test will fail if a MIDI cable is not connected between two MIDI jacks. Be sure to run this test
with MIDI cables connected as follows:

1. Connect a MIDI cable to the MIDI In and MIDI Out jacks and run the test.

2. Connect a MIDI cable to the MIDI In and MIDI Out/Thru jacks and set the MIDI select

A failure of this test could be caused by failure of the serial port, other MIDI circuitry, or a
problem on the Engine Board.

On the Engine Board check the signal paths from U1, pins 172, 174, 177, and 179 to connector J5.

switch on the rear panel to Out. Run the test.

2-5

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.

MARA Delay RAM

This is a write/read test to check the Delay RAM connected to MARA 1. The Delay RAM test
first checks address and databus connectivity and then reports which bits are not functioning to
aid troubleshooting.

Error reporting for this test identifies whether the error is likely to have occurred during writing
or during reading. Data value mismatch errors are reported in hexadecimal values starting with
“0x” followed by 8 hex digits. If the data value that was ReadBack differs greatly from the value
Wrote, it could mean there was an address bit error, or one or more of the control signals are bad.

A failure of this test would indicate a problem with the DDR SDRAM (U13), MARA 1 (U11), or
the Engine Board.

MARA Sound ROM

This test calculates and verifies the checksum for each 16 MB section of the on-board Sound
(Sample) ROM. It also tests the data and address lines from both MARAs to the Sound ROMs.
This test may also report errors when the MARA Validity Test fails. If MARA Validity Test only
fails on one of the MARAs, then the other MARA may still pass this test.

Running MARA sound ROM test

MARA 1 Sound ROM checksums are correct
MARA 1 Sound ROM data lines are correct
MARA 1 Sound ROM addr lines are correct
MARA 2 Sound ROM checksums are correct
MARA 2 Sound ROM data lines are correct
OK

Figure 2-5 LCD example, MARA Sound ROM test

A failure of this test may indicate a problem with a Sound ROMs (U20, U21, U22, or U23), or the
Engine Board.

Use the Down cursor button
or the Alpha wheel to scroll
down to the next line of the
test result.

2-6

Audio Output

This is not a test that fails. It is an interactive test for the entire audio chain. However for this test
to pass reliably, the MARA Validity and MARA Delay RAM tests should pass. The software
creates waveforms (sine and sawtooth) and stores them in the Delay RAM. Therefore, MARA 1
and its Delay RAM need to be functioning for this test to produce a clean audio waveform.

When you select this test, the LCD displays the following:

Figure 2-6 LCD example, Audio output test

Note: If the diagnostic version is earlier than 0.20, this test is only useful to check the polarity of
the Main Output audio signals. Use the Sine Wave Test on page 2-8 for audio level and distortion
tests. If the diagnostic version is 0.20 or later, follow the on-screen instructions for use.

Diagnostics

Description of Tests

Running Audio output test

Frequency = 220 Hz
Output = Main outputs

PLAY PLAY SAMPLE
SINE SAWTOOTH LOOP EXIT

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
flatness; an oscilloscope is needed.

1. Move the Volume slider to maximum, then press the Play Sawtooth soft button.

2. A 275 Hz sawthooth with a peak amplitude of +/-0.30V will appear on the Main Left and
Main Right Outputs.

If the polarity is correct, the sawtooth ramp will be positive-going at the Tip contact of
each jack and negative-going at the Ring contact.

If the frequency response is flat, the ramp will be perfectly straight except for three tiny
ripples just before and after the flyback part of the signal.

The volume slider does not act normally during the test so leave it set to maximum. Only the
Main outputs will be driven. When finished checking the Main Output signals, press the Exit
soft button to exit the diagnostic.

The Play Sine soft button will produce a sine wave, also 0.30V peak amplitude, but it is not
pure and thus unsuitable for distortion measurements. Use the Sine Wave Test that follows.

Do not press the Sample Loop soft button. It will hang and require a power cycle to recover.

2-7

Diagnostics

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.

Warning: This test can produce a very high level (20-30dB higher than normal which can be
damaging), and must be activated in order to play. Follow Steps 1–5 to activate and run the test.

1. Position the volume slider and sliders 1-9 to minimum.

2. Use the numeric keypad and select program 1000, Sine Wave.

3. Press the SW1 button located directly above the Mod Wheel.

4. Play C4 (Middle C) to produce a 261 Hz sine wave at all of the outputs.

5. Move the volume slider up slowly.

Note: Do not touch Slider 1 or the amplitude may change.

\

FREQUENCY

NOTE Hz Vrms Vp-p dBm

D2
F#2
C3
F#3
C4
F#4
C5
F#5
C6
F#6
C7
D7

20.6

32.7

65.4

130.8

261.6

523.2

1046.5

2092.8

4186.0

8371.2

16744.0

21096.1

3.08

3.21

2.80

2.80

2.80

2.80

2.77

2.80

2.80

2.81

3.00

2.77

Table 2-1 Frequency and Amplitude Values

AMPLITUDE

(Tip or Ring to Sleeve)

4.35

4.54

3.95

3.95

3.95

3.95

3.92

3.95

3.95

3.97

4.24

3.92

+12.0
+12.3
+11.2
+11.2
+11.2
+11.2
+11.1
+11.2
+11.2
+11.2
+11.8
+11.1

2-8

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.

3. The Headphones Output level is twice that of the Line Outputs. Clipping is
approximately 7.0 Vrms or 20.0Vp-p.

4. The keys are not velocity sensitive.

5. Keys not in the table produce other frequencies from a minimum of 6.49 Hz (E1) to a
maximum of 21096 Hz (D7).

6. The frequency ratio from one key to the next is 1.122462.

2-9

Diagnostics

Description of Tests

2-10

Chapter 3
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.

Notes, Cautions, Warnings

Please pay special attention to all Notes, Cautions, and Warnings as they not only point out
specific instructions, but also alert you to variations between manufactured units.

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
page 3-14 and page 3-16 for further information.

Cable Routing

In some cases, tape fastens cables to printed circuit boards or the top and bottom enclosures.
When disconnecting cables, always peel back the tape from one side so that the tape remains
properly positioned.

Required Tools and Materials

• No. 1 Phillips head screwdriver

• No. 2 Phillips head screwdriver

• Small flat screwdriver

• Dowel (3mm diameter)

• Needle-nose pliers

• Small blunt-end tool (Q-Tip, toothpick, etc.)

• USB cable

• xD Card

• Foam blocks

3-1

Disassembly/Assembly

Opening the PC3x

Opening the PC3x

PC3x Bottom

Refer to Figure 3-1. Arrows indicate the locations of the enclosure support wall, endcap and rear
panel screws.

Keyboard

Endcap screws

Enclosure support wall screws

Access panel

*

Rear panel screws

Rear panel

*Endcap locking bracket screws

Endcap screws

*

Figure 3-1 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.

3. Move the unit so that the rear panel portion of the unit hangs over the edge of your work
surface. This gives you access to the eight screws that secure the rear panel portion of the
top enclosure to the bottom enclosure. Remove the eight screws.

Note: Two of these screws also secure the rear panel portion of the access panel. It is not
necessary to remove the five remaining access panel screws.

3-2

4. Slide the unit back onto the work surface.

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.

Endcap

Endcap Side Bracket

Endcap Locking Bracket

Figure 3-2 Endcap assembly

Disassembly/Assembly

Opening the PC3x

1. Refer to Figure 3-3.

2. Remove the four screws that secure the endcaps to the rear panel.

Endcap screws

Endcap screws

Figure 3-3 PC3x rear panel

3. Refer to Figure 3-1. Move the unit so that one end hangs over the edge of your work
surface.

4. Remove the endcap locking bracket screw from the bottom enclosure.

Caution: When you remove the endcap locking bracket screw, the endcap locking bracket may
remain loosely in the endcap. However, it can come out of the endcap. When you remove the
screw securing the endcap locking bracket, hold it in position so that it does not fall out of the
endcap and become lost or damaged.

5. Remove the remaining three screws and set the endcap safely aside.

6. Repeat for the other endcap.

3-3

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

Rear panel screw locations

Enclosure
Support Wall

Lip

Figure 3-4 Top and bottom enclosures

Warning: Be sure to have your work surface prepared. This includes
placing foam blocks behind the unit. When the top enclosure is removed,
place it on the foam blocks to avoid damaging the Alpha Wheel, control
panel buttons, and sliders. The following procedure requires enough room
behind the rear of the unit to place the top enclosure face down on your
work surface.

8. Grip each end of the top enclosure and rotate it back approximately two inches. This
separates the bottom edges of the top enclosure and bottom enclosure.

9. Lift the top enclosure straight up.

10. Turn the top enclosure over and place it face down onto your work surface.

Caution: Table 3-1 lists the cables, by board location, from the top enclosure to the assembly
they connect to on the bottom enclosure. You do not need to disconnect these cables.

3-4

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. Position the top enclosure behind the bottom enclosure.

2. Move the top enclosure so that the bottom edge of the rear panel is positioned under the
bottom enclosure edge. See Figure 3-4 on page 3-4.

Note: Verify that the cables listed in Table 3-1 are lying flat on the bottom enclosure. Be sure that
all other cables are tucked between the top enclosure and the enclosure support wall.

Disassembly/Assembly

Opening the PC3x

3. Hold the top enclosure safely in place and move the unit so that one end of the rear panel
edge hangs over the edge of your work surface and install the rear panel screw at that end.
Slide the unit back onto your work surface. Repeat for other end.

Warning: Perform Steps 3 and 4 separately. Combining these steps could cause the top
enclosure to flip away from the bottom enclosure or drop off of your work surface.

4. Move the unit so that the rear panel edge of the unit hangs over the edge of your work
surface and install the remaining screws.

3-5

Disassembly/Assembly

s

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.

Note: In addition to the rear panel screws, the endcap locking bracket secures the endcap to the
top enclosure. When the endcap locking bracket is in position, it rests against the endcap
clamping bracket located on the underside of the top enclosure. See Figure 3-5.

Endcap Clamping Bracket

Endcap Locking Bracket

Endcap Screw

Figure 3-5 Top enclosure, endcap locking and clamping brackets

2. Slide one side of the unit off of your work surface and hold the appropriate endcap and
endcap locking bracket in position.

3. Install the endcap locking bracket screw in the bottom enclosure.

4. Install the three remaining endcap screws in the bottom enclosure.

5. Repeat for the other endcap.

6. Refer to Figure 3-3. Install the four endcap screws in the rear panel.

3-6