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Bose Headset Replacement Plug

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billhuntersemail(at)gmail
Guest

Posted: Tue Apr 21, 2020 9:41 am Post subject: Bose Headset Replacement Plug

Greetings Ya’All,

 

 I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 “GA wire harness”…

 

From the recommendations you gave from my last post on this subject I tried to do a continuity check of the wires to the phone plug so as to determine what color wires went to the jack lugs however the wires were broken inside.  I then tried to dig out the plastic molded on cable end and trace the wire colors to the plug however as the molded on plastic was removed it pulled off the colored insulation from the wires so now I…and my headset…are dead in the water because I do not know what wire is supposed to go where.

 

So I need to know what color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plug’s three lugs (tip/center/ring) and

 

If you can help I would be greatly appreciative since Bose wants 300 bucks for a replacement cable.

 

THANKS!!!!

 

Bill

Eric Page

Joined: 15 Feb 2017
Posts: 242

Posted: Tue Apr 21, 2020 10:36 am Post subject: Bose Headset Replacement Plug

Red (positive) and black (ground) will almost certainly be power to the headset electronics.  White, blue and green are probably left, right and ground for audio.  The correlation of those colors is anyone's guess, but they're easy to figure out.

You may be able to determine audio ground by a continuity check with power ground (black).  Left and right are easily determined by experimentation with a 1.5V AA or AAA battery (do NOT use a 9V!).  Put the headset on, then hold one wire on the "-" pole of the battery and tap another wire on the "+" pole.  You'll hear a scratching noise in the ear that's fed by that wire.

Eric



                  

                                                                    On Tuesday, April 21, 2020, 11:02:28 AM PDT,  <billhuntersemail(at)gmail.com> wrote:                 

                 I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 â€œGA wire harnessâ€â€¦

Eric Page

Joined: 15 Feb 2017
Posts: 242

Posted: Tue Apr 21, 2020 10:38 am Post subject: Bose Headset Replacement Plug

Right after posting that last suggestion, I opened the weekly email from Kitplanes magazine and found this article about repairing the cable on Bose headsets!

https://www.kitplanes.com/crimping-style/



Eric





                  

                                                                    On Tuesday, April 21, 2020, 11:02:28 AM PDT,  <billhuntersemail(at)gmail.com> wrote:                 

                 I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 â€œGA wire harnessâ€â€¦

billhuntersemail(at)gmail
Guest

Posted: Fri Apr 24, 2020 9:57 am Post subject: Bose Headset Replacement Plug

Whilst doing my research on how to replace the phone plug on my Bose A20 headset, I ran across an article by Matt Dralle who modified a Bose A20 headset to make it to automatically turn on.  In the article he took the Bose electronics all apart and did the modification…and he was able to put it all back together again so I figure that he must be pretty smart and he would be the guy to know what color wires to solder to the headphone plug for my replacement Neutrix NP3X plug.

 

Does anyone out there know how to get a hold of Matt and can you please ask him the question:

 

What color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plug’s three lugs (tip/center/ring)?

 

THANKS FOR THE HELP!!!

 

 

 

From: owner-aeroelectric-list-server(at)matronics.com <owner-aeroelectric-list-server(at)matronics.com> On Behalf Of billhuntersemail(at)gmail.com

Sent: Tuesday, April 21, 2020 10:35 AM

To: aeroelectric-list(at)matronics.com

Subject: Bose Headset Replacement Plug

 

Greetings Ya’All,

 

I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 “GA wire harness”…

 

From the recommendations you gave from my last post on this subject I tried to do a continuity check of the wires to the phone plug so as to determine what color wires went to the jack lugs however the wires were broken inside.  I then tried to dig out the plastic molded on cable end and trace the wire colors to the plug however as the molded on plastic was removed it pulled off the colored insulation from the wires so now I…and my headset…are dead in the water because I do not know what wire is supposed to go where.

 

So I need to know what color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plug’s three lugs (tip/center/ring) and

 

If you can help I would be greatly appreciative since Bose wants 300 bucks for a replacement cable.

 

THANKS!!!!

 

Bill

ceengland7(at)gmail.com
Guest

Posted: Fri Apr 24, 2020 10:16 am Post subject: Bose Headset Replacement Plug

Bill,

       

       Did you see my post on how to ID the leads using a 1 1/2 Volt       flashlight battery?

       

       On 4/24/2020 12:52 PM, billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com) wrote:

     

      	  Quote: 	
		                         <![endif]-->   <![endif]-->                

Whilst doing my research on how to replace           the phone plug on my Bose A20 headset, I ran across an article           by Matt Dralle who modified a Bose A20 headset to make it to           automatically turn on.  In the article he took the Bose           electronics all apart and did the modification…and he was able           to put it all back together again so I figure that he must be           pretty smart and he would be the guy to know what color wires           to solder to the headphone plug for my replacement Neutrix           NP3X plug.         

          

Does anyone out there know how to get a           hold of Matt and can you please ask him the question:         

          

What color wires           (red/black/white/blue/green) are supposed to be soldered on to           the replacement Neutrik NP3X plug’s three lugs           (tip/center/ring)?         

          

THANKS FOR THE HELP!!!         

          

          

                                  

From:               owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)               <owner-aeroelectric-list-server(at)matronics.com> (owner-aeroelectric-list-server(at)matronics.com) On                 Behalf Of billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)

               Sent: Tuesday, April 21, 2020 10:35 AM

               To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

               Subject: Bose Headset               Replacement Plug           

         

         

          

Greetings Ya’All,         

          

I am still trying to find out what color           wire connects to the phone jack lugs of the Bose A20 “GA wire           harness”…         

          

From the recommendations you gave from my           last post on this subject I tried to do a continuity check of           the wires to the phone plug so as to determine what color           wires went to the jack lugs however the wires were broken           inside.  I then tried to dig out the plastic molded on cable           end and trace the wire colors to the plug however as the           molded on plastic was removed it pulled off the colored           insulation from the wires so now I…and my headset…are dead in           the water because I do not know what wire is supposed to go           where.         

          

So I need to know what color wires           (red/black/white/blue/green) are supposed to be soldered on to           the replacement Neutrik NP3X plug’s three lugs           (tip/center/ring) and         

          

If you can help I would be greatly           appreciative since Bose wants 300 bucks for a replacement           cable.         

          

THANKS!!!!         

          

Bill         

        

     	
     

     	          		Virus-free. www.avast.com 		 	 [url=#DAB4FAD8-2DD7-40BB-A1B8-4E2AA1F9FDF2] [/url]

billhuntersemail(at)gmail
Guest

Posted: Fri Apr 24, 2020 3:19 pm Post subject: Bose Headset Replacement Plug

 	  Quote: 	
		   Did you see my post on how to ID the leads using a 1 1/2 Volt flashlight battery?

 
	


Sorry not when you initially posted it…just read it now.

 

Would it be safe to assume that the black wire is the ground?  I am so close I do not want try fry anything.

 

I was hoping to find someone on this forum who has done this repair and knew the exact colors to place where.  I was really surprised that the phone plug had 5 wires as I just assumed that it would have only three.

 

From: owner-aeroelectric-list-server(at)matronics.com <owner-aeroelectric-list-server(at)matronics.com> On Behalf Of Charlie England

Sent: Friday, April 24, 2020 11:12 AM

To: aeroelectric-list(at)matronics.com

Subject: Re: Bose Headset Replacement Plug

 

Bill,



Did you see my post on how to ID the leads using a 1 1/2 Volt flashlight battery?



On 4/24/2020 12:52 PM, billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com) wrote:

 	  Quote: 	
		  

Whilst doing my research on how to replace the phone plug on my Bose A20 headset, I ran across an article by Matt Dralle who modified a Bose A20 headset to make it to automatically turn on.  In the article he took the Bose electronics all apart and did the modification…and he was able to put it all back together again so I figure that he must be pretty smart and he would be the guy to know what color wires to solder to the headphone plug for my replacement Neutrix NP3X plug.

 

Does anyone out there know how to get a hold of Matt and can you please ask him the question:

 

What color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plug’s three lugs (tip/center/ring)?

 

THANKS FOR THE HELP!!!

 

 

 

From: owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com) <owner-aeroelectric-list-server(at)matronics.com> (owner-aeroelectric-list-server(at)matronics.com) On Behalf Of billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)

Sent: Tuesday, April 21, 2020 10:35 AM

To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

Subject: Bose Headset Replacement Plug

 

Greetings Ya’All,

 

I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 “GA wire harness”…

 

From the recommendations you gave from my last post on this subject I tried to do a continuity check of the wires to the phone plug so as to determine what color wires went to the jack lugs however the wires were broken inside.  I then tried to dig out the plastic molded on cable end and trace the wire colors to the plug however as the molded on plastic was removed it pulled off the colored insulation from the wires so now I…and my headset…are dead in the water because I do not know what wire is supposed to go where.

 

So I need to know what color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plug’s three lugs (tip/center/ring) and

 

If you can help I would be greatly appreciative since Bose wants 300 bucks for a replacement cable.

 

THANKS!!!!

 

Bill

 	


 

 



Virus-free. www.avast.com

ceengland7(at)gmail.com
Guest

Posted: Fri Apr 24, 2020 4:13 pm Post subject: Bose Headset Replacement Plug

To cover all bases, you can power up       the headset and check all combinations of wire pairs for *voltage*       before doing anything else. Black is *likely* to be ground/common,       but you just need to check for yourself. 

       

       I agree that it's odd to have 5 wires going to a 3 terminal plug,       but maybe they just used the same cable for everything, &       didn't hook up the extra conductors in the cable for the phones       plug. I've seen similar stuff in things like USB and serial       cables.

       

       Does (did...) the headset work in non-noise-cancelling mode if the       batteries are dead or removed? If so, you could do the battery       trick even without it being powered up.

       

       Another option, if you haven't tried it yet, is to take an exacto       knife to the old plug. Cut along the molded housing (not across) a       little depth at a time, trying to peel it away from the conductors       before going a little deeper. You might be able to get past the       broken spot in the wires so you can check wire colors with an ohm       meter. I've had good luck doing this with molded connectors on       other products. 

       

       Charlie

       

       On 4/24/2020 6:15 PM, billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com) wrote:

     

      	  Quote: 	
		                       v\:* {behavior:url(#default#VML);} o\:* {behavior:url(#default#VML);} w\:* {behavior:url(#default#VML);} .shape {behavior:url(#default#VML);} <![endif]-->         <![endif]-->   <![endif]-->                

 	  Quote: 	
		   Did you see my post on how to ID the           leads using a 1 1/2 Volt flashlight battery?         

          
	


Sorry not when you initially posted it…just           read it now.         

          

Would it be safe to assume that the black           wire is the ground?  I am so close I do not want try fry           anything.         

          

I was hoping to find someone on this forum           who has done this repair and knew the exact colors to place           where.  I was really surprised that the phone plug had 5 wires           as I just assumed that it would have only three.         

                                  

From:               owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)               <owner-aeroelectric-list-server(at)matronics.com> (owner-aeroelectric-list-server(at)matronics.com) On                 Behalf Of Charlie England

               Sent: Friday, April 24, 2020 11:12 AM

               To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

               Subject: Re: Bose Headset               Replacement Plug           

         

         

                     

Bill,

             

             Did you see my post on how to ID the leads using a 1 1/2             Volt flashlight battery?

             

             On 4/24/2020 12:52 PM, billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)             wrote:         

          	  Quote: 	
		             

Whilst doing my research on how to             replace the phone plug on my Bose A20 headset, I ran across             an article by Matt Dralle who modified a Bose A20 headset to             make it to automatically turn on.  In the article he took             the Bose electronics all apart and did the modification…and             he was able to put it all back together again so I figure             that he must be pretty smart and he would be the guy to know             what color wires to solder to the headphone plug for my             replacement Neutrix NP3X plug.           

            

Does anyone out there know how to get a             hold of Matt and can you please ask him the question:           

            

What color wires             (red/black/white/blue/green) are supposed to be soldered on             to the replacement Neutrik NP3X plug’s three lugs             (tip/center/ring)?           

            

THANKS FOR THE HELP!!!           

            

            

                                        

From: owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)                 <owner-aeroelectric-list-server(at)matronics.com> (owner-aeroelectric-list-server(at)matronics.com)                 On Behalf Of billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)

                 Sent: Tuesday, April 21, 2020 10:35 AM

                 To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

                 Subject: Bose Headset                 Replacement Plug             

           

           

            

Greetings Ya’All,           

            

I am still trying to find out what color             wire connects to the phone jack lugs of the Bose A20 “GA             wire harness”…           

            

From the recommendations you gave from my             last post on this subject I tried to do a continuity check             of the wires to the phone plug so as to determine what color             wires went to the jack lugs however the wires were broken             inside.  I then tried to dig out the plastic molded on cable             end and trace the wire colors to the plug however as the             molded on plastic was removed it pulled off the colored             insulation from the wires so now I…and my headset…are dead             in the water because I do not know what wire is supposed to             go where.           

            

So I need to know what color wires             (red/black/white/blue/green) are supposed to be soldered on             to the replacement Neutrik NP3X plug’s three lugs             (tip/center/ring) and           

            

If you can help I would be greatly             appreciative since Bose wants 300 bucks for a replacement             cable.           

            

THANKS!!!!           

            

Bill           

          	
         

                     

                                                                            

                                                     

Virus-free.                       www.avast.com

billhuntersemail(at)gmail
Guest

Posted: Fri Apr 24, 2020 4:59 pm Post subject: Bose Headset Replacement Plug

 	  Quote: 	
		   Does (did...) the headset work in non-noise-cancelling mode if the batteries are dead or removed? If so, you could do the battery trick even without it being powered up.

 
	


Yes it did so I will try that first.

 

 

 	  Quote: 	
		  Another option, if you haven't tried it yet, is to take an exacto knife to the old plug. Cut along the molded housing (not across) a little depth at a time, trying to peel it away from the conductors before going a little deeper. You might be able to get past the broken spot in the wires so you can check wire colors with an ohm meter. I've had good luck doing this with molded connectors on other products.

 
	


That is how I screwed it up.  I tried to slowly cut down and peel the plastic back however that plastic was molded on very tight and as I peeled away the wire insulation came off and all I found was three wire conductors connected to the three rings of the plug. 

 

Thanks Charlie  

 

From: owner-aeroelectric-list-server(at)matronics.com <owner-aeroelectric-list-server(at)matronics.com> On Behalf Of Charlie England

Sent: Friday, April 24, 2020 5:09 PM

To: aeroelectric-list(at)matronics.com

Subject: Re: Bose Headset Replacement Plug

 

To cover all bases, you can power up the headset and check all combinations of wire pairs for *voltage* before doing anything else. Black is *likely* to be ground/common, but you just need to check for yourself. 



I agree that it's odd to have 5 wires going to a 3 terminal plug, but maybe they just used the same cable for everything, & didn't hook up the extra conductors in the cable for the phones plug. I've seen similar stuff in things like USB and serial cables.



Does (did...) the headset work in non-noise-cancelling mode if the batteries are dead or removed? If so, you could do the battery trick even without it being powered up.



Another option, if you haven't tried it yet, is to take an exacto knife to the old plug. Cut along the molded housing (not across) a little depth at a time, trying to peel it away from the conductors before going a little deeper. You might be able to get past the broken spot in the wires so you can check wire colors with an ohm meter. I've had good luck doing this with molded connectors on other products. 



Charlie



On 4/24/2020 6:15 PM, billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com) wrote:

 	  Quote: 	
		  

 	  Quote: 	
		   Did you see my post on how to ID the leads using a 1 1/2 Volt flashlight battery?

 
	


Sorry not when you initially posted it…just read it now.

 

Would it be safe to assume that the black wire is the ground?  I am so close I do not want try fry anything.

 

I was hoping to find someone on this forum who has done this repair and knew the exact colors to place where.  I was really surprised that the phone plug had 5 wires as I just assumed that it would have only three.

 

From: owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com) <owner-aeroelectric-list-server(at)matronics.com> (owner-aeroelectric-list-server(at)matronics.com) On Behalf Of Charlie England

Sent: Friday, April 24, 2020 11:12 AM

To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

Subject: Re: Bose Headset Replacement Plug

 

Bill,



Did you see my post on how to ID the leads using a 1 1/2 Volt flashlight battery?



On 4/24/2020 12:52 PM, billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com) wrote:

 	  Quote: 	
		  

Whilst doing my research on how to replace the phone plug on my Bose A20 headset, I ran across an article by Matt Dralle who modified a Bose A20 headset to make it to automatically turn on.  In the article he took the Bose electronics all apart and did the modification…and he was able to put it all back together again so I figure that he must be pretty smart and he would be the guy to know what color wires to solder to the headphone plug for my replacement Neutrix NP3X plug.

 

Does anyone out there know how to get a hold of Matt and can you please ask him the question:

 

What color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plug’s three lugs (tip/center/ring)?

 

THANKS FOR THE HELP!!!

 

 

 

From: owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com) <owner-aeroelectric-list-server(at)matronics.com> (owner-aeroelectric-list-server(at)matronics.com) On Behalf Of billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)

Sent: Tuesday, April 21, 2020 10:35 AM

To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

Subject: Bose Headset Replacement Plug

 

Greetings Ya’All,

 

I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 “GA wire harness”…

 

From the recommendations you gave from my last post on this subject I tried to do a continuity check of the wires to the phone plug so as to determine what color wires went to the jack lugs however the wires were broken inside.  I then tried to dig out the plastic molded on cable end and trace the wire colors to the plug however as the molded on plastic was removed it pulled off the colored insulation from the wires so now I…and my headset…are dead in the water because I do not know what wire is supposed to go where.

 

So I need to know what color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plug’s three lugs (tip/center/ring) and

 

If you can help I would be greatly appreciative since Bose wants 300 bucks for a replacement cable.

 

THANKS!!!!

 

Bill

 	


 

 



Virus-free. www.avast.com

billhuntersemail(at)gmail
Guest

Posted: Sat Apr 25, 2020 9:50 am Post subject: Bose Headset Replacement Plug

Still striking out on my headset plug replacement…cant believe this is so dang complicated…

 

I did as Charlie recommended, I stripped all six wire ends and used a 1.5 volt battery to see if I could hear the headset speakers click hoping to find the mystery three wires. 

 

Instead, only when the black and green wires are touched together will both speakers click.  

 

No matter what other combination of wires are touched together there will be no sound at all out of the speakers.

 

There are six colored wires (ORANGE/GREEN/ BLUE/ YELLOW/ WHITE/ BLACK) and the braided shield…

 

Why would a plug that has only three conductors have six wires routed to it.  When I broke the plastic molded end off there were only three conductors soldered to the plug lugs and sadly the colored wire insulation came off with the plastic.

 

I even tried opening up the plastic electronics housing and I was kinda hoping to find three wires going to one connector and three to a second conductor as a hint however the six wires all go to one 6pin connector.

 

So any suggestions other than paying 300 bucks to buy a new one?

 

 

 

From: owner-aeroelectric-list-server(at)matronics.com <owner-aeroelectric-list-server(at)matronics.com> On Behalf Of billhuntersemail(at)gmail.com

Sent: Tuesday, April 21, 2020 10:35 AM

To: aeroelectric-list(at)matronics.com

Subject: Bose Headset Replacement Plug

 

Greetings Ya’All,

 

I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 “GA wire harness”…

 

From the recommendations you gave from my last post on this subject I tried to do a continuity check of the wires to the phone plug so as to determine what color wires went to the jack lugs however the wires were broken inside.  I then tried to dig out the plastic molded on cable end and trace the wire colors to the plug however as the molded on plastic was removed it pulled off the colored insulation from the wires so now I…and my headset…are dead in the water because I do not know what wire is supposed to go where.

 

So I need to know what color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plug’s three lugs (tip/center/ring) and

 

If you can help I would be greatly appreciative since Bose wants 300 bucks for a replacement cable.

 

THANKS!!!!

 

Bill

Tim Olson

Joined: 25 Jan 2007
Posts: 2871

Posted: Sat Apr 25, 2020 10:13 am Post subject: Bose Headset Replacement Plug

I donâ€™t remember you saying if it was an A20 or X model but if itâ€™s an A20, maybe this:

https://www.ebay.com/itm/Genuine-Dual-Plug-Cable-for-Bose-A20-series-Aviation-Headset-HH/163901594462?pageci=77c40890-b9cb-40d0-975c-a7a7630c5f1b



 	  Quote: 	
		  On Apr 25, 2020, at 12:59 PM, billhuntersemail(at)gmail.com wrote:



ï»¿  <![endif]-->   <![endif]-->

Still striking out on my headset plug replacementâ€¦cant believe this is so dang complicatedâ€¦

 

I did as Charlie recommended, I stripped all six wire ends and used a 1.5 volt battery to see if I could hear the headset speakers click hoping to find the mystery three wires. 

 

Instead, only when the black and green wires are touched together will both speakers click.  

 

No matter what other combination of wires are touched together there will be no sound at all out of the speakers.

 

There are six colored wires (ORANGE/GREEN/ BLUE/ YELLOW/ WHITE/ BLACK) and the braided shieldâ€¦

 

Why would a plug that has only three conductors have six wires routed to it.  When I broke the plastic molded end off there were only three conductors soldered to the plug lugs and sadly the colored wire insulation came off with the plastic.

 

I even tried opening up the plastic electronics housing and I was kinda hoping to find three wires going to one connector and three to a second conductor as a hint however the six wires all go to one 6pin connector.

 

So any suggestions other than paying 300 bucks to buy a new one?

 

 

 

From: owner-aeroelectric-list-server(at)matronics.com <owner-aeroelectric-list-server(at)matronics.com> On Behalf Of billhuntersemail(at)gmail.com

Sent: Tuesday, April 21, 2020 10:35 AM

To: aeroelectric-list(at)matronics.com

Subject: Bose Headset Replacement Plug

 

Greetings Yaâ€™All,

 

I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 â€œGA wire harnessâ€â€¦

 

From the recommendations you gave from my last post on this subject I tried to do a continuity check of the wires to the phone plug so as to determine what color wires went to the jack lugs however the wires were broken inside.  I then tried to dig out the plastic molded on cable end and trace the wire colors to the plug however as the molded on plastic was removed it pulled off the colored insulation from the wires so now Iâ€¦and my headsetâ€¦are dead in the water because I do not know what wire is supposed to go where.

 

So I need to know what color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plugâ€™s three lugs (tip/center/ring) and

 

If you can help I would be greatly appreciative since Bose wants 300 bucks for a replacement cable.

 

THANKS!!!!

 

Bill

billhuntersemail(at)gmail
Guest

Posted: Sun Apr 26, 2020 10:55 am Post subject: Bose Headset Replacement Plug

Tim,

 

Thanks for the link.

 

Great minds think alike as I had found this replacement on eBay and that was the inspiration for me opening up the electronics/battery compartment.

 

There is a super small six conductor plug that connects the wires to the PC board and it seems that the replacement cable does not have the plug so I would have to use the very small telephone cord butt splices to splice it to the electronics/battery box.Â  This might be a cheap option and I could make it less ugly if I staggered the splices and used heavy wall heat shrink tubing to cover the splices.

 

There is a guy on another forum who fixes headsets and I reached out to him to see if he could provide me the three color wires for the plug so I will report back.

 

From: owner-aeroelectric-list-server(at)matronics.com <owner-aeroelectric-list-server(at)matronics.com> On Behalf Of Tim Olson

Sent: Saturday, April 25, 2020 11:11 AM

To: aeroelectric-list(at)matronics.com

Subject: Re: Bose Headset Replacement Plug

 

I donâ€™t remember you saying if it was an A20 or X model but if itâ€™s an A20, maybe this:



 



https://www.ebay.com/itm/Genuine-Dual-Plug-Cable-for-Bose-A20-series-Aviation-Headset-HH/163901594462?pageci=77c40890-b9cb-40d0-975c-a7a7630c5f1b



 



 



 	  Quote: 	
		  

On Apr 25, 2020, at 12:59 PM, billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com) wrote:

ï»¿

Still striking out on my headset plug replacementâ€¦cant believe this is so dang complicatedâ€¦

 

I did as Charlie recommended, I stripped all six wire ends and used a 1.5 volt battery to see if I could hear the headset speakers click hoping to find the mystery three wires. 

 

Instead, only when the black and green wires are touched together will both speakers click.  

 

No matter what other combination of wires are touched together there will be no sound at all out of the speakers.

 

There are six colored wires (ORANGE/GREEN/ BLUE/ YELLOW/ WHITE/ BLACK) and the braided shieldâ€¦

 

Why would a plug that has only three conductors have six wires routed to it.  When I broke the plastic molded end off there were only three conductors soldered to the plug lugs and sadly the colored wire insulation came off with the plastic.

 

I even tried opening up the plastic electronics housing and I was kinda hoping to find three wires going to one connector and three to a second conductor as a hint however the six wires all go to one 6pin connector.

 

So any suggestions other than paying 300 bucks to buy a new one?

 

 

 

From: owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com) <owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)> On Behalf Of billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)

Sent: Tuesday, April 21, 2020 10:35 AM

To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

Subject: Bose Headset Replacement Plug

 

Greetings Yaâ€™All,

 

I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 â€œGA wire harnessâ€â€¦

 

From the recommendations you gave from my last post on this subject I tried to do a continuity check of the wires to the phone plug so as to determine what color wires went to the jack lugs however the wires were broken inside.  I then tried to dig out the plastic molded on cable end and trace the wire colors to the plug however as the molded on plastic was removed it pulled off the colored insulation from the wires so now Iâ€¦and my headsetâ€¦are dead in the water because I do not know what wire is supposed to go where.

 

So I need to know what color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plugâ€™s three lugs (tip/center/ring) and

 

If you can help I would be greatly appreciative since Bose wants 300 bucks for a replacement cable.

 

THANKS!!!!

 

Bill

rnadms(at)gmail.com
Guest

Posted: Sun Apr 26, 2020 11:15 am Post subject: Bose Headset Replacement Plug

might this Google search be of any help?



https://www.google.com/search?safe=active&client=opera&hs=ne&sxsrf=ALeKk02FDjIzcNjwLE9EuLguvkDPXxdNNw%3A1587928058120&ei=-tulXpDjBsW2ggf-kK7ICw&q=bose+headset+wiring+diagram&oq=Bose+Headset+wiring+digram&gs_lcp=CgZwc3ktYWIQARgAMgQIABANMgYIABAWEB4yBggAEBYQHjIGCAAQFhAeMggIABAIEA0QHjIICAAQCBANEB46BAgAEEc6BwgAEBQQhwI6AggAOgQIABBDOgUIABDEAjoECAAQClCgHljjQWC1XGgAcAJ4AIABugGIAaUNkgEEMC4xNJgBAKABAaoBB2d3cy13aXo&sclient=psy-ab



On Sun, Apr 26, 2020 at 7:01 PM <billhuntersemail(at)gmail.com> wrote:



[quote] Tim,



 Thanks for the link.



 Great minds think alike as I had found this replacement on eBay and that

 was the inspiration for me opening up the electronics/battery compartment

billhuntersemail(at)gmail
Guest

Posted: Sun Apr 26, 2020 2:25 pm Post subject: Bose Headset Replacement Plug

 	  Quote: 	
		   might this Google search be of any help?

 
	


Thanks R Adams the Google search link however sadly I was unable to find what I needed.

 

Like when I did the Google search before I posted on AeroElectric I found lots of wire diagrams for aircraft receptacles that accept the Bose headset plugs and these used different wire colors and I also found a number of wire diagrams for other model Bose headsets however the wire colors on those diagrams were also different than the ORANGE/GREEN/ BLUE/ YELLOW/ WHITE/ BLACK wires in my headset plug end.

 

Does somebody know somebody who would knowâ€¦

 

 

From: owner-aeroelectric-list-server(at)matronics.com <owner-aeroelectric-list-server(at)matronics.com> On Behalf Of R Adams

Sent: Sunday, April 26, 2020 12:11 PM

To: aeroelectric-list(at)matronics.com

Subject: Re: Bose Headset Replacement Plug



 

might this Google search be of any help?



 



https://www.google.com/search?safe=active&client=opera&hs=ne&sxsrf=ALeKk02FDjIzcNjwLE9EuLguvkDPXxdNNw%3A1587928058120&ei=-tulXpDjBsW2ggf-kK7ICw&q=bose+headset+wiring+diagram&oq=Bose+Headset+wiring+digram&gs_lcp=CgZwc3ktYWIQARgAMgQIABANMgYIABAWEB4yBggAEBYQHjIGCAAQFhAeMggIABAIEA0QHjIICAAQCBANEB46BAgAEEc6BwgAEBQQhwI6AggAOgQIABBDOgUIABDEAjoECAAQClCgHljjQWC1XGgAcAJ4AIABugGIAaUNkgEEMC4xNJgBAKABAaoBB2d3cy13aXo&sclient=psy-ab



 

On Sun, Apr 26, 2020 at 7:01 PM <billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)> wrote:

 	  Quote: 	
		  

Tim,

 

Thanks for the link.

 

Great minds think alike as I had found this replacement on eBay and that was the inspiration for me opening up the electronics/battery compartment.

 

There is a super small six conductor plug that connects the wires to the PC board and it seems that the replacement cable does not have the plug so I would have to use the very small telephone cord butt splices to splice it to the electronics/battery box.  This might be a cheap option and I could make it less ugly if I staggered the splices and used heavy wall heat shrink tubing to cover the splices.

 

There is a guy on another forum who fixes headsets and I reached out to him to see if he could provide me the three color wires for the plug so I will report back.

 

From: owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com) <owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)> On Behalf Of Tim Olson

Sent: Saturday, April 25, 2020 11:11 AM

To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

Subject: Re: Bose Headset Replacement Plug

 

I donâ€™t remember you saying if it was an A20 or X model but if itâ€™s an A20, maybe this:



 



https://www.ebay.com/itm/Genuine-Dual-Plug-Cable-for-Bose-A20-series-Aviation-Headset-HH/163901594462?pageci=77c40890-b9cb-40d0-975c-a7a7630c5f1b



 



 



  	  Quote: 	
		  

On Apr 25, 2020, at 12:59 PM, billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com) wrote:

ï»¿

Still striking out on my headset plug replacementâ€¦cant believe this is so dang complicatedâ€¦

 

I did as Charlie recommended, I stripped all six wire ends and used a 1.5 volt battery to see if I could hear the headset speakers click hoping to find the mystery three wires. 

 

Instead, only when the black and green wires are touched together will both speakers click.  

 

No matter what other combination of wires are touched together there will be no sound at all out of the speakers.

 

There are six colored wires (ORANGE/GREEN/ BLUE/ YELLOW/ WHITE/ BLACK) and the braided shieldâ€¦

 

Why would a plug that has only three conductors have six wires routed to it.  When I broke the plastic molded end off there were only three conductors soldered to the plug lugs and sadly the colored wire insulation came off with the plastic.

 

I even tried opening up the plastic electronics housing and I was kinda hoping to find three wires going to one connector and three to a second conductor as a hint however the six wires all go to one 6pin connector.

 

So any suggestions other than paying 300 bucks to buy a new one?

 

 

 

From: owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com) <owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)> On Behalf Of billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)

Sent: Tuesday, April 21, 2020 10:35 AM

To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

Subject: Bose Headset Replacement Plug

 

Greetings Yaâ€™All,

 

I am still trying to find out what color wire connects to the phone jack lugs of the Bose A20 â€œGA wire harnessâ€â€¦

 

From the recommendations you gave from my last post on this subject I tried to do a continuity check of the wires to the phone plug so as to determine what color wires went to the jack lugs however the wires were broken inside.  I then tried to dig out the plastic molded on cable end and trace the wire colors to the plug however as the molded on plastic was removed it pulled off the colored insulation from the wires so now Iâ€¦and my headsetâ€¦are dead in the water because I do not know what wire is supposed to go where.

 

So I need to know what color wires (red/black/white/blue/green) are supposed to be soldered on to the replacement Neutrik NP3X plugâ€™s three lugs (tip/center/ring) and

 

If you can help I would be greatly appreciative since Bose wants 300 bucks for a replacement cable.

 

THANKS!!!!

 

Bill

glastar(at)gmx.net
Guest

Posted: Mon Apr 27, 2020 8:11 am Post subject: Bose Headset Replacement Plug

on the manual page 32:

     

     [img]cid:part1.6EC10994.0D8337C8(at)gmx.net[/img]

     

     On 27.04.2020 00:21,       billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com) wrote:

     

      	  Quote: 	
		                         <![endif]-->   <![endif]-->                

 	  Quote: 	
		   might this Google search be of any           help?         

Â          
	


Thanks R Adams the Google search link           however sadly I was unable to find what I needed.         

Â          

Like when I did the Google search before I           posted on AeroElectric I found lots of wire diagrams for           aircraft receptacles that accept the Bose headset plugs and           these used different wire colors and I also found a number of           wire diagrams for other model Bose headsets however the wire           colors on those diagrams were also different than the           ORANGE/GREEN/ BLUE/ YELLOW/ WHITE/ BLACK wires in my headset           plug end.         

Â          

Does somebody know somebody who would knowâ€¦         

Â          

Â                     

From:             owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)             <owner-aeroelectric-list-server(at)matronics.com> (owner-aeroelectric-list-server(at)matronics.com) On               Behalf Of R Adams

             Sent: Sunday, April 26, 2020 12:11 PM

             To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

             Subject: Re: Bose Headset             Replacement Plug         

         

Â                                                 

might                   this Google search be of any help?             

                            

Â              

                            

https://www.google.com/search?safe=active&client=opera&hs=ne&sxsrf=ALeKk02FDjIzcNjwLE9EuLguvkDPXxdNNw%3A1587928058120&ei=-tulXpDjBsW2ggf-kK7ICw&q=bose+headset+wiring+diagram&oq=Bose+Headset+wiring+digram&gs_lcp=CgZwc3ktYWIQARgAMgQIABANMgYIABAWEB4yBggAEBYQHjIGCAAQFhAeMggIABAIEA0QHjIICAAQCBANEB46BAgAEEc6BwgAEBQQhwI6AggAOgQIABBDOgUIABDEAjoECAAQClCgHljjQWC1XGgAcAJ4AIABugGIAaUNkgEEMC4xNJgBAKABAaoBB2d3cy13aXo&sclient=psy-ab             

           

         

         

Â                                  

On Sun, Apr 26, 2020 at 7:01 PM <billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)>               wrote:           

            	  Quote: 	
		                                               

Tim,                 

Â                  

Thanks                   for the link.                 

Â                  

Great                   minds think alike as I had found this replacement on                   eBay and that was the inspiration for me opening up                   the electronics/battery compartment.                 

Â                  

There                   is a super small six conductor plug that connects the                   wires to the PC board and it seems that the                   replacement cable does not have the plug so I would                   have to use the very small telephone cord butt splices                   to splice it to the electronics/battery box.Â  This                   might be a cheap option and I could make it less ugly                   if I staggered the splices and used heavy wall heat                   shrink tubing to cover the splices.                 

Â                  

There                   is a guy on another forum who fixes headsets and I                   reached out to him to see if he could provide me the                   three color wires for the plug so I will report back.                 

Â                                                          

From:                       owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)                       <owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)>                       On Behalf Of Tim Olson

                       Sent: Saturday, April 25, 2020 11:11 AM

                       To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

                       Subject: Re: Bose                       Headset Replacement Plug                   

                 

                 

Â                                     

I                     donâ€™t remember you saying if it was an A20 or X                     model but if itâ€™s an A20, maybe this:                 

                                    

Â                  

                                    

https://www.ebay.com/itm/Genuine-Dual-Plug-Cable-for-Bose-A20-series-Aviation-Headset-HH/163901594462?pageci=77c40890-b9cb-40d0-975c-a7a7630c5f1b                 

                                    

Â                  

                                    

Â                  

                                    

Â                     	  Quote: 	
		                       

On                       Apr 25, 2020, at 12:59 PM, billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)                       wrote:                                                           

ï»¿                     

Still                       striking out on my headset plug replacementâ€¦cant                       believe this is so dang complicatedâ€¦                     

Â                      

I                       did as Charlie recommended, I stripped all six                       wire ends and used a 1.5 volt battery to see if I                       could hear the headset speakers click hoping to                       find the mystery three wires.                      

Â                      

Instead,                       only when the black and green wires are touched                       together will both speakers click.Â                       

Â                      

No                       matter what other combination of wires are touched                       together there will be no sound at all out of the                       speakers.                     

Â                      

There                       are six colored wires (ORANGE/GREEN/ BLUE/ YELLOW/                       WHITE/ BLACK) and the braided shieldâ€¦                     

Â                      

Why                       would a plug that has only three conductors have                       six wires routed to it.Â  When I broke the plastic                       molded end off there were only three conductors                       soldered to the plug lugs and sadly the colored                       wire insulation came off with the plastic.                     

Â                      

I                       even tried opening up the plastic electronics                       housing and I was kinda hoping to find three wires                       going to one connector and three to a second                       conductor as a hint however the six wires all go                       to one 6pin connector.                     

Â                      

So                       any suggestions other than paying 300 bucks to buy                       a new one?                     

Â                      

Â                      

Â                                                                      

From:                           owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)                           <owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)>                           On Behalf Of billhuntersemail(at)gmail.com (billhuntersemail(at)gmail.com)

                           Sent: Tuesday, April 21, 2020 10:35 AM

                           To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)

                           Subject: Bose                           Headset Replacement Plug                       

                     

                     

Â                      

Greetings                       Yaâ€™All,                     

Â                      

I                       am still trying to find out what color wire                       connects to the phone jack lugs of the Bose A20                       â€œGA wire harnessâ€â€¦                     

Â                      

From                       the recommendations you gave from my last post on                       this subject I tried to do a continuity check of                       the wires to the phone plug so as to determine                       what color wires went to the jack lugs however the                       wires were broken inside.Â  I then tried to dig out                       the plastic molded on cable end and trace the wire                       colors to the plug however as the molded on                       plastic was removed it pulled off the colored                       insulation from the wires so now Iâ€¦and my                       headsetâ€¦are dead in the water because I do not                       know what wire is supposed to go where.                     

Â                      

So                       I need to know what color wires                       (red/black/white/blue/green) are supposed to be                       soldered on to the replacement Neutrik NP3X plugâ€™s                       three lugs (tip/center/ring) and                     

Â                      

If                       you can help I would be greatly appreciative since                       Bose wants 300 bucks for a replacement cable.                     

Â                      

THANKS!!!!                     

Â                      

Bill                     

Â

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