The Bose Aviation Headset Repair Manual provides comprehensive guidance for diagnosing, maintaining, and repairing Bose aviation headsets. This manual covers safety procedures, component identification, common issues, step-by-step repair instructions, and testing procedures to ensure optimal performance and user safety. Below are key sections for safety, features, disassembly, repair procedures, testing, and troubleshooting.
Key components: Active Noise Reduction (ANR) module, microphone boom, ear cushions, headband, audio cable, battery compartment, control module.
| Feature | Description |
|---|---|
| Active Noise Reduction (ANR) | Electronically reduces ambient cockpit noise |
| Microphone Boom | Flexible boom with noise-canceling microphone |
| Ear Cushions | Replaceable foam/leatherette cushions for comfort and seal |
| Headband | Adjustable padded headband with tension control |
| Audio Cable | Detachable cable with aircraft plug (GA, Helicopter, etc.) |
| Battery Compartment | Houses batteries for ANR system; typically uses AA cells |
| Control Module | Volume control, mute switch, ANR on/off |
| LED Indicators | Battery status, ANR activation |
| Compliance | Meets TSO C139a, C57a standards for aviation use |
| Connector Type | Standard GA plug (dual or single plug configurations) |
Before performing any repair, ensure proper safety measures are followed.
WARNING! Do not attempt repairs while connected to aircraft power. Incorrect repair may compromise safety and void warranty.
Required tools for repair and maintenance.
CAUTION! Using incorrect tools may strip screws or damage plastic components.
Identify key components for repair reference.
External: Headband, ear cups, microphone boom, control module, cable connector, battery door.
Internal: ANR circuit board, speaker drivers, microphone element, wiring harness, battery contacts, volume potentiometer.
Refer to exploded diagram (if available) for part numbers and assembly order.
Step-by-step disassembly for access to internal components.
Tip: Take photos during disassembly to aid reassembly. Keep screws organized.
Detailed procedures for frequent repair scenarios.
WARNING! Ensure all solder joints are clean and secure. Test continuity after repair.
Reassembly in reverse order of disassembly. Testing procedures post-repair.
CAUTION! Do not force components during reassembly. Verify operation before returning to service.
Regular maintenance to prolong headset life.
Clean ear cushions and headband with mild soap and water; air dry. Wipe microphone windscreen with dry cloth. Inspect cable for wear; replace if damaged. Store in protective case when not in use.
CAUTION! Do not immerse headset in liquids. Avoid harsh chemicals on cushions.
Bose aviation headsets comply with FAA TSO standards (C139a, C57a). Copyright © Bose Corporation. For support, visit www.bose.com/aviation or contact Bose Aviation Headset Division. Unauthorized modifications may void warranty and compliance.
| Symptom | Possible Cause | Corrective Action |
|---|---|---|
| No audio in one/both ears | Cable fault, driver failure | Check cable continuity; replace driver if open circuit. |
| Microphone not transmitting | Boom connection, mic element | Inspect boom wiring; replace microphone element. |
| ANR not working | Dead batteries, module fault | Replace batteries; test ANR module voltage; replace module. |
| Intermittent audio | Loose connection, worn cable | Check internal connectors; replace audio cable. |
| Excessive noise/hiss | ANR circuit, grounding issue | Inspect ANR board for damage; ensure proper grounding. |
| Headband loose | Tension spring worn | Adjust or replace headband tension mechanism. |
| Battery drain fast | Faulty ANR, old batteries | Test ANR current draw; use fresh alkaline batteries. |
Reset: Remove batteries for 30 seconds to reset ANR circuit if applicable.
Service: For professional repair, contact Bose Aviation Support: 1-800-999-2673; www.bose.com/aviation