DISASSEMBLY / ASSEMBLY PROCEDURES
Chapter 6
6.1 KURZWEIL 1000 SERIES RACKS 6- 2
6.2 KURZWEIL K1000 6- 6
6.3 KURZWEIL ENSEMBLE GRANDE PIANO 6 -1 1
6.4 KURZWEIL MARK III 6 -17
Kurzweil1000 Series Service Manual, Chapter 6 6- 1
6.1 -Kurzweil 1000 Series Rack (PX, PX PLUS, HX, SX, GX,
EX)
6.1.1 Opening the Unit
1. Turn power off .
2. Remove 4 phillips head screws from each side of the unit.
3. Slide top cover back away from Front Panel to release top cover and remove it.
6.1 .2 Removing the CPU Board
1. Remove the 5 phillips head screws on the bottom of the Front Panel. There are 9 phillips head screws on the bottom of the Front Panel Assembly. Remove only the 5 screws that attach the Front Panel Assembly to the chassis. These screws are located where the chassis sheet metal meets the Front Panel Assembly.
2. Next remove the 2 phillips head screws at the right and left end on the top of the Front Panel Assembly.
3. Remove all cables coming from the Front Panel Assembly to the CPU board. You can now set the Front Panel Assembly aside.
4. Remove the cable coming from the power supply to the CPU board.
5. Remove the hardware from the rear panel securing the MIDI and output jacks. Caution: use care when removing the screws from the MIDI jacks, as they are very small and somewhat fragile.
6. Remove the screws that secure the CPU board to the chassis.
7. You will now be able to remove the CPU board.
Kurzweil1000 Series Service Manual, Chapter 6 6- 2
6.1.3 Removing the Front Panel Assembly
1. Remove the 2 phillips head screws at the right and left end at the top of the Front Panel Assembly.
2. Remove the following cables coming from the Front Panel Assembly to the CPU board:
1 flat ribbon cable going to J2 on the CPU
1 flat ribbon cable going to J3 on the CPU
1 stranded ribbon cable to J1 on the CPU, you must remove a
phillips head screw which secures a retaining strap for the
cable. This screw is on the CPU board at the right of the cable.
1 stranded cable going to J8 on the CPU, this does not exist on
the PX Plus unit.*
3. Remove 5 phillips head screws from the bot ton of the Front
Panel Assembly. You will notice that there are 9 phillips head
screws on the bottom of the assembly. Only remove the 5 screws that attach through the chassis brackets that extend from the main portion of the chassis connecting the Front Panel Assembly to the main portion of the chassis.
4. You can now set the Front Panel Assembly aside.*
*The PX Plus does not have a cable coming from the Front Panel Assembly to J8 on the CPU board. In all other Kurzweil rack units, this cable is used for the LCD backlight circuit. You will notice in the PX Plus units that there is a stranded cable coming from the Front Panel Assembly and is soldered onto the transformer. This is for the backlight circuit in the PX Plus. You do not have
unsolder this cable. However, when servicing the unit, you will not be able to completely remove the Front Panel Assembly for this reason.
Kurzweil1000 Series Service Manual, Chapter 6 6- 3
6.1.4 Removing the Front Panel Board
1. Remove the remaining screws on the top and the bottom of Front Panel Assembly to remove the Front Panel board.
2. Remove the volume potentiometer knob off of the unit. You will need a 1/16" hex allen wrench.
3. Remove the 6 phillips head screws to remove the Front Panel board from the assembly.
6.1.5 Removing the Volume Potentiometer
1. Follow the instructions for removing the Front Panel Assembly and Front Panel board.
2. Simply remove the nut and washer securing it to the Front Panel sheet metal.
6.1.6 Removing the LCD
1. Follow the instructions for removing the Front Panel Assembly and Front Panel board.
2. Remove the 4 phillips head screws securing it to the Front Panel sheet metal.
3. Unsolder the wires connecting the backlight circuit.
4. Unplug the grey flat cable.
5. The LCD can now be removed.
Kurzweil1000 Series Service Manual, Chapter 6 6- 4
6.1.7 Removing the Power Supply Assembly
1. Follow the instructions for removing the Front Panel Assembly and Front Panel board.
2. Remove the straded cable going to J4 on the CPU board.* *Warning: removing this cable, removes the battery voltage from RAM. Therefore, all user programs
stored in RAM will be lost. Please save all user programs prior to doing this or inform the user for approval.
3. Remove the 6 phillips head screws securing the Power Supply Assembly to the chassis.
4. The Power Supply Assembly can now be removed.
6.1.8 Removing Power Supply Board
1. Remove the 4 phillips head screws securing the Power Supply board to the Power Supply Assembly.
2. Disconnect the connector P1 from the board.
3. Remove the 4 phillips head screws coming through the outside of the Power Supply Assembly and the 4 nuts inside the assembly securing the 4 voltage regulators to the heat sink.
4. If you would like to completely remove the board, you will have to cut the tie wrap that secures the stranded cable coming from the transformer to the AC receptacle.
Kurzweil1000 Series Service Manual, Chapter 6 6- 5
6.2 -K1000
6.2.1 Opening the Unit
1. Turn off power .
2. Remove 5 phillips head screws from the endblocks. Two at the left and 3 at the right endblock.
3. Remove 1 phillips head screw from the bottom of the unit located at the rear left hand side, next to the rubber foot (your left while standing at the keyboard).
4. Remove 1 phillips head screw from the rear panel located on the left hand side closest to the bottom (your left while standing at the keyboard).
5. Hold unit by endblocks and hinge top back into its service position .
Once the top cover is in its service position, the following boards are mounted on the bottom pan of the unit: CPU board, left; Keyboard Scan board, middle; Power Supply board, right. The transformer is also mounted in the bottom pan of the unit.
6.2.2 Removing the Keyboard
1. Remove the 8 phillips head screws underneath the unit which
secure the keyboard to the chassis.
2. Disconnect the flat grey ribbon cable coming from the keyboard
to the Keyboard Scan board.
3. Once the cable is disconnected, the keyboard is free and may be
removed and set safely aside.
4. Should you need to remove or change a key, you must follow
these instructions and remove the keyboard first.
Kurzweil1000 Series Service Manual, Chapter 6 6- 6
6.2.3 Removing the CPU Board
1. Disconnect the two flat grey ribbon cables coming from the Front Panel Assembly.
2. Disconnect the cable coming from the Power Supply board.
3. Disconnect the cable coming from the Volume Slider board.
4. Disconnect the 3 pin cable coming from the Keyboard Scan board.
5. Remove the 4 phillips head screws securing the board to the bottom pan .
6. Remove the 6 phillips head screws from the rear panel which secure the MIDI jacks.
7. Remove the 2 phillips head screws from the bottom pan (external) which secure the output jacks. These screws are located directly below the output jacks on the bottom pan.
8. The CPU board can now be removed from the unit.
6.2.4 Removing the Keyboard Scan Board
1. Disconnect the 3 cables going to the Keyboard Scan board.
2. Remove the 6 phillips head screws securing the board to the bottom pan .
3. Remove the 2 phillips head screws from the bottom pan (external) which secure the pedal jacks. These screws are located directly below the pedal jacks on the bottom pan.
4. The Keyboard Scan board can now be removed from the unit.
Kurzweil1000 Series Service Manual, Chapter 6 6- 7
6.2.5 Removing the Power Supply
1. Disconnect the 3 cables going to the Power Supply board.
2. Remove the 4 phillips head screws from bottom pan (external)
which secure the Power Supply heatsink plate.
3. The Power Supply board can now be removed from the unit.
6.2.6 Removing the Front Panel Board
1. Disconnect the flat grey ribbon cable from the right hand side of the board.
2. Remove 4 phillips head screws from the bottom edge of the Front Panel board (bottom edge as viewed with the Front Panel Assembly hinged up in its service position). When you remove the 4 phillips head screws, realize that there are standoffs on the other side of the board and may fallout. Be sure to keep these safely aside.
3. The Front Panel board is secured by the 4 phillips head screws on the bot ton and sits in a channel on the top. Once the screws are removed, you must pull the board gently towards you while exerting downward pressure to remove the board.
4. Disconnect the flat grey ribbon cable from the left hand side of the board.
5. Disconnect the violet cable from the junction connector leading to the transformer. *Caution: This cable is for the backlight circuit. Be sure that the AC power cable is disconnected as there is 160 volts coming from the circuit.
6. The Front Panel board can now be removed from the unit.
Kurzweil1000 Series Service Manual, Chapter 6 6- 8
6.2.7 Installing the Front Panel Board
1. Connect the flat grey ribbon cable into the left hand side of the board.
2. Align the front panel switches with chassis hole positions.
3. Press board in. At this point you should move the board up slightly into its channel.
4. Be sure that the violet cable is not pinched and that it moves freely coming from the left hand side of the board.
5. Take 1 screw and 1 standoff. Put the screw through the standoff. Take your screwdriver and match it to the head of the screw. Then slide the standoff up under the board, while sliding the screw through the mounting slot. Tighten screw enough to hold not fully secured.
6. Follow Step 4 for the remaining 3 screws. Once all 4 screws are in, tighten all 4. Be sure not to over tighten.
7. Located at the bottom of the board you will notice another channel in the chassis. This channel acts as a holder for the violet cable. Push the cable into the channel. Be sure the clear plastic covering for this cable is in the channel. *Caution: This cable is for the backlight circuit. Be sure that the AC power cable is disconnected as there is 160 volts coming from the circuit.
8. Then reconnect all cables previously removed.
6.2.8 Removing the LCD Board
1. After you have followed the steps described in Section 6.2.6 to remove the Front Panel board, the LCD board can be removed.
2. Remove the 4 phillips head screws securing the LCD board to the Front Panel board.
3. The LCD board can now be removed.
Kurzweil1000 Series Service Manual, Chapter 6 6- 9
6.2.9 Removing the Volume Slider Board
1. Remove the 2 phillips head screws securing the Volume Slider board.
2. Disconnect the two cables going to the Volume Slider board.
3. Remove the slidepot knob.
6.2.1 O Removing the Data Slider Board
1. Remove the 2 phillips head screws securing the Data Slider board.
2. Disconnect the cable going to the Data Slider board.
3. Remove the slidepot knob.
6.2.11 Removing the Mod Lever Assembly
1. Remove the 4 phillips head screws (external) securing the Mod Lever Assembly to the bottom pan.
2. You can now turn the assembly over to repair.
3. If you need to remove the entire assembly, you should remove the 2 phillips head screws located inside the assembly. These screws hold the headphone mounting plate in place.
4. Disconnect the cable going to the junction connector.
6.2.12 Removing the AC Receptacle Board
1. Disconnect the cable going to the AC Receptacle board.
2. Remove the 2 phillips head screws securing the board.
3. Remove the 2 phillips head screws (external) and nuts (internal) securing the board. This hardware secures the AC receptacle.
Kurzweil 1000 Series Service Manual, Chapter 6 6-10
6.3 -ENSEMBLE GRANDE PIANO (EGP)
6.3.1 Opening the Unit
1. Turn off power .
2. Remove 5 phillips head screws from the endblocks. Two at the left and 3 at the right endblock.
3. Remove 1 phillips head screw from the bottom of the unit located at the rear left hand side, next to the rubber foot (your left while standing at the keyboard).
4. Remove 1 phillips head screw from the rear panel located on the left hand side closest to the bottom (your left while standing at the keyboard).
5. Hold unit by endblocks and hinge top back into its service position. Once the top cover is in its service position, the following boards are mounted on the bottom pan of the unit: CPU board, left; Keyboard Scan board, middle. The transformer is also mounted in the bottom pan of the unit.
6.3.2 Removing the Keyboard
1. Remove the 8 phillips head screws underneath the unit which secure the keyboard to the chassis.
2. Disconnect the flat grey ribbon cable coming from the keyboard to the Keyboard Scan board.
3. Once the cable is disconnected, the keyboard is free and may be removed and set safely aside.
4. Should you need to remove or change a key, you must follow these instructions and remove the keyboard first.
Kurzweil1000 Series Service Manual, Chapter 6 6-11
6.3.3 Removing the CPU Board
1. Disconnect the 2 flat grey ribbon cables coming from the Front Panel Assembly.
2. Disconnect the cable coming from the Power Supply board.
3. Disconnect the cable coming from the Volume Slider board.
4. Disconnect the 3 pin cable coming from the Keyboard Scan board.
5. Disconnect the cable coming from the Power Amp/Power Supply board.
5. Remove the 4 phillips head screws securing the board to the bottom pan.
6. Remove the 6 phillips head screws from the rear panel which secure the MIDI jacks.
7. Remove the 2 phillips head screws from the bottom pan (external) which secure the output jacks. These screws are located directly below the output jacks on the bottom pan.
8. The CPU board can now be removed from the unit.
6.3.4 Removing the Keyboard Scan Board
1. Disconnect the 4 cables going to the Keyboard Scan board.
2. Remove the 6 phillips head screws securing the board to the bottom pan .
3. Remove the 2 phillips head screws from the bottom pan (external) which secure the pedal jacks. These screws are located directly below the pedal jacks on the bottom pan.
4. The Keyboard Scan board can now be removed from the unit.
Kurzweil1000 Series Service Manual, Chapter 6 6-12
6.3.5 Removing the Power Amp/Power Supply
1. Disconnect the 8 cables going to the board.
2. Remove the 2 phillips head screws (internal) securing the board to the top cover .
3. Remove the 4 phillips head screws (external, rear panel) securing the board.
4. The Power Supply board can now be removed from the unit.
6.3.6 Removing the Front Panel Board
1. Disconnect the flat grey ribbon cable from the right hand side of the board.
2. Remove 4 phillips head screws from the bottom edge of the Front Panel board (bottom edge as viewed with the Front Panel Assembly hinged up in its service position). When you remove the 4 phillips head screws, realize that there are standoffs on the other side of the board and may fallout. Be sure to keep these safely aside.
3. The Front Panel board is secured by the 4 phillips head screws on the bot ton and sits in a channel on the top. Once the screws are removed, you must pull the board gently towards you while exerting downward pressure to remove the board.
4. Disconnect the flat grey ribbon cable from the left hand side of the board.
5. Disconnect the violet cable from its connection to the transformer. *Caution: This cable is for the backlight circuit. Be sure that the AC power cable is disconnected as there is 160 volts coming from the circuit.
Kurzweil1000 Series Service Manual, Chapter 6 6-13
6.3.7 Installing the Front Panel Board
1. Connect the flat grey ribbon cable into the left hand side of the board.
2. Align the front panel switches with chassis hole positions.
3. Press board in. At this point you should move the board up slightly into its channel.
4. Be sure that the violet cable is not pinched and that it moves freely coming from the left hand side of the board.
5. Take 1 screw and 1 standoff. Put the screw through the standoff. Take your screwdriver and match it to the head of the screw. Then slide the standoff up under the board, while sliding the screw through the mounting slot. Tighten screw enough to hold, but not fully secured.
6. Follow Step 4 for the remaining 3 screws. Once all 4 screws are in, tighten all 4. Be sure not to over tighten.
7. Located at the bottom of the board you will notice another channel in the chassis. This channel acts as a holder for the violet cable. Push the cable into the channel. Be sure the clear plastic covering for this cable is in the channel. *Caution: This cable is for the backlight circuit. Be sure that the AC power cable is disconnected as there is 160 volts coming from the circuit.
8. Then reconnect all cables previously removed.
6.3.8 Removing the LCD Board
1. After you have followed the steps described above to remove
the Front Panel board, the LCD board can be removed.
2. Remove the 4 phillips head screws securing the LCD board to
the Front Panel board.
Kurzweil1000 Series Service Manual,
Chapter 6 6-14
6.3.9 Removing the Volume Slider Board
1. Remove the 2 phillips head screws securing the Volume Slider board.
2. Disconnect the cable going to the Volume Slider board.
3. Remove the slidepot knob.
6.3.1 O Removing the Transpose Slider Board
1. Remove the 2 phillips head screws securing the Data Slider board.
2. Disconnect the cable going to the Data Slider board.
3. Remove the slidepot knob.
6.3.11 Removing a Speaker
1. You mayor may not have to remove the insulating material which covers the speaker. Should you wish to do so, realize that this material is stapled in place and will need to be
re-stapled when reinstalling it. However, you can remove a speaker without removing the insulating material by moving the material up or down, depending on the mounting hardware you are removing at the time.
2. A speaker is held in place by 4 wood screws, remove these to change a speaker.
3. Disconnect the cable going to the speaker.
Kurzweil1000 Series Service Manual, Chapter 6 6-15
6.3.12 Removing the Mod Lever Assembly
1. Remove the 4 phillips head screws (external) securing the Mod Lever Assembly to the bottom pan.
2. You can now turn the assembly over to execute repairs.
3. If you need to remove the entire assembly, you should remove the 2 phillips head screws located inside the assembly. These screws hold the headphone mounting plate in place.
4. Disconnect the cable going to the junction connector.
6.3.13 Removing the AC Receptacle Board
1. Disconnect the cable going to the AC Receptacle board.
2. Remove the 2 phillips head screws securing the board.
3. Remove the 2 phillips head screws (external) and nuts (internal) securing the board. This hardware secures the AC receptacle.
Kurzweil1000 Series Service Manual, Chapter 6 6-1 6
6.4 -MARK III
The Mark III has three sections: 1) main electronics section, located directly below the top cover; 2) keyboard bed and front panel assembly and 3) lower speaker section . The following describes the necessary steps to remove the main printed circujt boards and components of the Mark III. You will also notice small interconnection boards used to channel cables from one section to another, the removal of the interconnection boards is not covered.
6.4.1 Removing the Top Cover
1. Remove the 7 phillips head screws from top edge of the rear panel that -secure the top cover .
2. Slide the top cover towards the front of the unit approximately one inch.
3. Lift it up slightly, approximately 6 inches.
4. Disconnect the cables coming from the tweeters (mounted on top cover) to the Power Amp/Power Supply board.
5. The top cover can now be set safely aside.
6.4.2 Removing the CPU Board
1. The CPU board is enclosed in a metal shield.
2. Disconnect the cables going to the CPU board. There are 6 cables that need to be disconnected.
3. Remove the 6 phillips head screws (internal) that hold the metal shield in place.
4. Remove the 3 phillips head screws (external, through rear panel) that hold the metal shield in place.
Kurzweil1000 Series Service Manual, Chapter 6 6-17
continued
5. The shield can then be set aside.
6. Remove the 4 phillips head screws securing the board to the bottom pan.
7. Remove the 6 phillips head screws from the rear panel which secure the MIDI jacks.
8. Remove the 2 phillips head screws from the rear panel which secure the output jacks.
9. The CPU board can now be removed from the unit.
6.4.3 Removing the Keyboard Scan Board
1. Disconnect the 6 cables going to the Keyboard Scan board.
2. Remove the 6 phillips head screws securing the board to the bottom pan.
3. The Keyboard Scan board can now be removed from the unit.
6.4.4 Removing the Power Amp/Power Supply
1. Disconnect the 10 cables going to the board.
2. Remove the 7 phillips head screws (internal) securing the board to the bottom pan.
3. The Power Supply board can now be removed from the unit.
6.4.5 Removing the AC Receptacle Board
1. Disconnect the 2 cables going to the AC Receptacle board.
2. Remove the 3 phillips head screws (internal) securing the board .
3. Remove the 2 phillips head screws (external) and nuts (internal) securing the board. This hardware secures the AC receptacle.
Kurzweil1000 Series Service Manual, Chapter 6 6-18
6.4.6 Opening the Front Panel Assembly
1. Follow the instructions described in Section 6.4.1 to remove the Top Cover.
2. Once the top cover has been removed, you will find 16 phillips head screws placed along the top inner edge of the unit going through the inner portion of the unit to the Front Panel Assembly.
3. Loosen the 16 screws two turns. Do not remove the screws as it will be much easier when reinstalling.
4. Remove the 2 phillips head screws from the Front Panel Assembly. These are located above the right and left check blocks, 1 screw per side.
5. You can now lift the Front Panel Assembly slightly and rest on the top portion of the end blocks. You should put foam between the Front Panel Assembly and the end blocks to avoid scratches.
6. If you need to remove any board from the Front Panel Assembly, disconnect the cable coming from the Volume Slider board and the Transpose Slider board. This will allow you to prop the Front Panel Assembly up into a service position.
6.4.7 Removing the Front Panel Board
1. Disconnect the flat grey ribbon cable from the right hand side of the board.
2. Remove 8 phillips head screws form the Front Panel board.
4. Disconnect the flat grey ribbon cable from the left hand side of the board.
5. If you are replacing the Front Panel board, remove the LCD board and install it on the new board.
Kurzweil1000 Series Service Manual, Chapter 6 6-19
6.4.8 Removing the LCD Board
1. After you have followed the steps described above to remove the Front Panel board, the LCD board can be removed.
2. Remove the 4 phillips head screws securing the LCD board to the Front Panel board.
3. If you are replacing the LCD board, unsolder the violet cable at the LCD board. *Caution: This cable is for the backlight circuit. Be sure that the AC power cable is disconnected as there is 160 volts coming from the circuit.
6.4.9 Removing the Volume Slider Board
1. Remove the 2 phillips head screws securing the Volume Slider board .
2. Disconnect the cable coming from the Volume Slider board.
3. Remove the slide pot knob.
6.4.1 O Removing the Transpose Slider Board
1. Remove the 2 phillips head screws securing the Transpose Slider board.
2. Disconnect the cable coming from the Transpose Slider board.
3. Remove the slide pot knob.
6.4.11 Removing the Tune Slider Board
1. Remove the 2 phillips head screws securing the Tune Slider board .
2. Disconnect the cable coming from the Tune Slider board.
3. Remove the slide pot knob.
Kurzweil1000 Series Service Manual, Chapter 6 6-20
6.4.12 Removing the Mod Lever Assembly
1. Remove the 3 phillips head screws (external) securing the Mod Lever Assembly. These come up through the keyboard bed.
2. Lift the front portion of the Mod Lever Assembly up slightly and slide it towards you.
3. With the assembly held towards you lift the rear portion of the assembly straight up.
3. If you need to remove the entire assembly, you should remove the 2 phillips head screws located inside the assembly. These screws hold the headphone mounting plate in place.
4. There are 2 cables coming from the Mod Lever Assembly, 1 is
connected to the headphone jack and other goes through the
cable feed through hole into the main electronics portion of the
unit. Disconnect this cable at the junction connector in the
main electronics section of the unit.
6.4.13 Removing the Keyboard
1. Follow the instructions described in Section 6.4.12 to remove the Mod Lever Assembly.
2. Remove the 4 phillips head screws (external) underneath the keyboard bed.
3. Remove the 6 phillips head screws (internal) placed along the back edge of the keyboard.
4. Slide the keyboard to the left to clear the right cheek block.
5. Lift the keyboard up from the front.
6. Disconnect the flat grey ribbon cable at the right hand side to completely remove the keyboard.
7. Should you need to remove or change a key, you must follow these instructions and remove the keyboard first.
Kurzweil1000 Series Service Manual, Chapter 6 6-21
6.4.14 Removing/Replacing a speaker
1. There are 4 speakers enclosed in the lower portion of the unit. Two on each side of the unit.
2. Remove the grill cloth from the front of the unit.
3. Remove the hardware securing the speaker.
4. Disconnect the terminal cable for the speaker.
Kurzweil1000 Series Service Manual, Chapter 6 6-22