Bowers & Wilkins 804 D3 User manual

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 1 of 51 © Bowers & Wilkins 2016
Distributor Service Technical Manual
804 D3 Speakers
Produced by: T. Taylor

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 2 of 51 © Bowers & Wilkins 2016
Revision History
Date
Revision
By
Details
22 MAR 2016
1
TT
Initial Release
800 Series Tool Kit

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 3 of 51 © Bowers & Wilkins 2016
Content
Front Cover Page 1
Revision History & 800 Series Tool Kit Page 2
Content Page 3
Introduction Page 4
Technical Sheet Page 5
1. Tool and Test Equipment Page 6
2. Cosmetic Inspection Page 7
3. First Functional Test Page 8
4. Basic Wire Connections to Speakers Page 8
5. Bi-Wiring Connections to Speakers Page 9
6. Bi-Amplification Connections to Speakers Page 9/11
7. Vertical Bi-Amplification Connection to Speakers Page 11/12
8. 804D3 Mechanical Drawing & Spare Parts List Page 13/15
9. Wiring Diagram for 804D3 Page 16
10. Tweeter Motor Disassembly Page 17/20
11. Tweeter Mechanical Drawing& Parts Page 21
12. Tweeter Unit Removal Page 22/24
13. Mid - Range Removal Page 25/28
14. Draw Bar Assembly Removal Page 28/30
15. 5” MF Cabinet Tube Removal Page 30/31
16. Upper and Lower Base Unit Speaker Removal Page 31/32
17. Upper 6” Cabinet Tube Removal Page 33/34
18. Lower 6” Cabinet Tube Removal Page 34/35
19. Terminal Tray Removal Page 36/37
20. HF Crossover Assembly Removal Page 38/40
21. LF Crossover Assembly Removal Page 40/41
22. HF Crossover Drawing & Circuit Page 42
23. HF Parts List Page 43
24. LF Crossover Drawing & Circuit Page 44
25. LF Parts List Page 45
26. Final Functional Test (Stethoscope Examination) Page 45/46
27. Cleaning Page 47
28. Product Test List Page 48
29. Test Result Sheet Page 49/51

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 4 of 51 © Bowers & Wilkins 2016
Introduction
Please read this manual carefully before commencing servicing!
Only qualified and authorised technicians should attempt to service this product.
Antistatic Precautions (ESD)
Electronic devices and components are extremely sensitive
to electrostatics (ESD). Always observe ESD precautions
when handling electronic modules or PCBs. Never
exchange boards with a different revision number, unless
authorised by B&W
Always use B&W original type replacement parts.
Whenever you see this
warning, always take
electrostatic precautions.
Chemicals and Solvents (COSHH)
Solder’s, fluxes and cleaning agents are used widely in the
servicing of electronic products. Such substances are
hazardous to health; therefore always take precautions to
protect yourself and others when using any hazardous
substance. Protective clothing and equipment if provided
should be worn. If in doubt refer to the COSHH.
Be aware whenever
you see this warning.
Electricity
Electricity is the most common hazard that will be confronted
when building and testing product.
Always take precautions when working on live equipment or
with any test equipment that uses electricity. Note: Do not
wear an ESD wrist strap when working on live electricity.
Be aware whenever
you see this warning.
Personal Protection Equipment (PPE)
PPE is equipment that will protect the user against health or
safety at work. It can include items such as safety helmets
and hard hats, gloves, eye protection, high visibility clothing,
safety footwear and safety harnesses.
Be aware whenever
you see this warning.

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 5 of 51 © Bowers & Wilkins 2016
Technical Sheet
Technical Features: Diamond Tweeter, Continuum Cone FST, Turbine
Head, Aerofoil Cone Bass Units, Flow Port, Optomised
Matrix and Solid Body Tweeter.
Description: 3-way vented-box system
Drive units: 1x ø25mm (1 in) diamond dome high-frequency
1x ø130mm (5 in) Continuum cone FST™ midrange
2x ø165mm (6.5 in) Aerofoil cone bass units
Frequency range: 20Hz to 35kHz
Frequency response: 24Hz to 28kHz (+/-3dB from reference axis)
Sensitivity: 89dB SPL (2.83Vrms at 1m)
Harmonic distortion: 2nd and 3rd harmonics (90dB, 1m on axis)
<1% 70Hz - 20kHz & <0.3% 120Hz - 20kHz
Nominal impedance: 8Ω (minimum 3.0Ω)
Recommended AMP power: 50W - 200W into 8Ω on unclipped programme
Cable Impedance: 0.1Ω cable impedance
Dimensions: Height: 1180mm - Width: 340mm - Depth: 480mm
Net weight: 33Kg (73Ib)
Cabinet & Grille: Rosenut/Black –Gloss Black/Black & Satin White/Grey

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 6 of 51 © Bowers & Wilkins 2016
1. Tools and Test Equipment
The tools listed below in Figure: 1 are required to carry out the initial testing and repair of the
804 D3 Speakers, , the specialized tools are included in the 800 Diamond Tool Kit.
1 x HF Retaining Bolt Tool HH37842, 1 x Grill Removal Tool HH37214, 1 x HF Motor
Removal Tool HH15156, 1 x Terminal Nut Runner HH33782, 1 x Hex/Aln Key 3mm,
1 x Phillips Screwdriver, 1 x Facom Screwdriver 4.0x0.8, 1 x Offset Screwdriver
WIHA 224/1-2, 1 x Tyco tool, 1 x Molex Tool, 1 X Mid Extractor Tool HH15121, MF
Adaptor Cap HH15180, 1 x Tommy Bar HH36994, 1 x 6mm Box Spanner, 1 x Torx
T8, 1 x Amplifier, Spring Hook HH15164, 1 x CD Player, 1 x Stethoscope, 1 x Signal
Generator and Gloves.
Required Tools
Figure: 1
HH37214
HH15156
HH37842
HH33782
Tyco Tool
Hex/Alen Keys
Facom 4.0x0.8
WIHA 224/1-2
HH36994
HH15121
HH15180
HH15164
Torx
Tool - 8
Molex Tool
Phillips Screwdriver
6mm Box

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 7 of 51 © Bowers & Wilkins 2016
2. Cosmetic Inspection
This is visual check and should be done before any work commences to clarify that
there is no external damage to the 804 D3 Speaker see Figure: 2.
Note: It is recommended that PPE gloves are used for this function.
Check the cabinets
Check both tweeters, Mid - Range & Upper/Lower Base Drivers
Check the Trim Rings
Check both Flow Ports
Check both sets of terminals trays
Terminals
Mid - Range
Figure: 2
Flow Port
Tweeter
Magnetic Trim Ring
Lower Base Driver
Dust Cap
Upper Base Driver

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 8 of 51 © Bowers & Wilkins 2016
3. First Functional Test
Confirm the reason for returning the 804 D3 Speakers, carry out a functional test
using the equipment shown below in Figure: 3.
4. Basic-wire Connections to Speakers
B&W 804D3 have speaker wire connections to allow for bi-amplification or bi-wiring.
Connection of a basic audio system where there is only one connection from the
amplifier is very simple and is shown in Figure: 4. Connect the speakers using the
regular left and right speaker wire connections and ignore the second set of terminals.
B&W speakers are shipped with Terminal Links connecting the two sets of terminals
that allow the speaker to be connected as a traditional loudspeaker.
Figure: 3
Terminal Links
Figure: 4
Positive Terminal
Link cable
Input cable from the
amplifier
Negative Terminal
Link cable

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 9 of 51 © Bowers & Wilkins 2016
5. Bi-wiring Connections to Speakers
The Bi-wire connection separates the woofer/midrange from the tweeter section.
These two sets of terminals allow the speakers to be split into two independent
sections. The split connects the mid and high frequency drivers to one set of
terminals and the low frequency driver to the other pair. In the bi-wire connection the
Terminal Links are removed and separate sets of speaker wire are run from the
amplifier to each section as shown in Figure: 5.
Connect speakers in the bi-wire mode:
Ensure that your system is powered OFF.
Remove the Terminal Links from speakers (this separates the LPF & HPF).
Connect each amplifier channel to its respective speaker section as shown.
6. Bi-Amplification Connections to Speakers
Bi-amplification is the use of two amplifiers for both speakers with one amplifier
connected to the woofer section of a loudspeaker while the other is connected to the
tweeter section. With this arrangement each amplifier operates over a restricted
frequency range. This restricted range presents each amplifier with a much simpler
job and each amplifier is less likely to "influence" the sound in some way.
Connect speakers in the bi-amplification mode:
Ensure that your system is powered OFF.
Figure: 5
Terminal Links
Removed

Bowers & Wilkins TECHNICAL SUPPORT
The contents of this document and associated files contain confidential information that is propriety to Bowers & Wilkins, and
are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
with electronic products. No part of the contents should be supplied or published elsewhere.
Page 10 of 51 © Bowers & Wilkins 2016
Remove the Terminal Links from each speaker (this separates LPF & HPF).
Connect each amplifier channel to its respective speaker section as shown in
Figure: 6.
Set the level controls on the amplifiers such that the signal will arrive at all speaker
terminals at the same power-volume level. If your amplifiers are identical, it is usually
sufficient to set all the amplifier level controls the same. The speaker's built-in
crossover is designed to match the efficiency of all the individual drivers (tweeters,
midranges, and woofers). When using the bi-amplifier connection you must directly
deal with some of these issues by adjusting levels according to your listening
preference.
The following advice assumes that you have a pre-amplifier and two power amplifiers.
Ideally, the power amplifiers should be identical models. Here are the steps to
connect speakers in the Bi-Amplification mode.
a. Turn everything OFF and wait at least 30 seconds for the power amplifiers to
shut down.
Figure: 6
Terminal Links
Removed
Amplifier 1
Amplifier 2