Bowers & Wilkins 804 D3 User manual

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Distributor Service Technical Manual
804 D3 Speakers
Produced by: T. Taylor

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are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
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Revision History
Date
Revision
By
Details
22 MAR 2016
1
TT
Initial Release
800 Series Tool Kit

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are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
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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

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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
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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.

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are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
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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

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are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
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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

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are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
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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

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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
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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

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are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
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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

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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

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are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
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b. If present, remove the bi-wire links from each speaker. The Bi-Wire links
normally connect the woofer/midrange and tweeter sections.
c. Connect each power amplifier channel to its respective speaker section. The
amplifier used for bass frequencies would connect to the bass (woofer or low
frequency) terminals of each speaker. Similarly, the power amplifier used for
treble (high frequency) connects to the HF (high frequency or tweeter)
terminals. Ensure that you observe proper phasing of the speaker cables –
that is red to red, black to black.
d. Connect the output of the preamplifier to the appropriate inputs of each power
amplifier. You may need ‘Y’ cables or connectors.
Above, we have shown our suggested setup using two stereo power amplifiers; one
power amplifier for bass, the other for treble. This arrangement allows minimum
confusion regarding connections as the method falls in line with the labelling of the
input and output terminals and sockets.
If your amplifiers are not identical, use the more powerful amplifier for the low sections
and the cleaner (better sounding) amplifier for the high sections.
7. Vertical Bi-Amplification Connections to Speakers
Another method known as ‘Vertical Bi-Amplification’ exists where identical power
amplifiers are used for each Speaker.
This is setup by using one channel in the amplifier for bass signals, the other channel
for treble signals.
In this situation the LH output from the preamplifier is sent to one power amplifier
connected to the LH speaker; the RH output is sent to the power amplifier connected
to the RH speaker.
An example is shown below in in Figure: 7.

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Note: In this diagram the Left Channels of each Amplifier are wired to the Top binding
posts of the corresponding Speakers and the Right Channels to the Bottom binding
posts.
You can have it opposite with the Right Channels of each Amplifier wired to the Top
binding posts of the corresponding Speakers and the Left Channel to the Bottom
binding posts.
It does not matter. Just keep it symmetrical.
Figure: 7

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8. 804D3 Mechanical Drawing & Spare Parts

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804D3 Spare Parts

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Page 15 of 51 © Bowers & Wilkins 2016

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are intended solely for the purpose of servicing the product. The information is intended for use by service technicians familiar
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9. Wiring Diagram for 804D3
The drawing below shows the wiring for each of the Speakers to the HF & LF Crossovers
and the Terminal Tray.
Tweeter
Mid - Range
Upper Bass Unit
Lower Bass Unit
LF Crossover Assembly
HF Crossover Assembly
Terminal Tray
Molex Plug

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10.Tweeter & Motor Disassembly
To remove the HF Grille it will need pulling forward from the Tweeter housing as
shown in Figure: 8.
Once the gap appears around the HF Grille insert the HF Grille Removal Tool HH37214 into
the grille release slot as shown in Figure: 9. Make sure the tool is in the correct orientation
and then rotate the Grille in a clockwise motion to release the HF Grille.
Figure: 8
HF Grille
HF Housing
HF Grille Removal Tool HH 37214
HF Grille Release Slot
Figure: 9
Gap
HF Grille

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Now use a 4mm Alen/Hex to unscrew the rear HF Cap as shown in Figures: 10.
Once the Rear HF Cap is removed the HF Tube is visible shown in Figure: 11.
Use a small Spring Hook, carefully pull the HF tube out of the HF Housing, Figure: 12.
HF Tube
HF Rear Cap
HF Rear HF Cap
4mm Hex/Alen key
HF Tube
Figure: 10
Figure: 11
Figure: 12
HF Housing
HF Housing

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Now insert the HF Motor removal tool HH15156 in to the rear of the tweeter, shown in
Figure: 13 and then slowly rotate the tool until it locks in to the HF motor.
With the HF Motor Removal Tool in the correct position rotate in an anti-clockwise motion
while supporting the HF Motor. This will release the HF Motor so it can be removed from the
front of the HF Housing, see Figures: 14 & 15.
It should now be possible to remove the tweeter motor from the HF housing, shown in
Figure: 16.
HF Motor Removal
Tool –HH15156
Figure: 14
HF Motor
Assembly
loose
HF Housing
HF Motor
Assembly
secured
HF Housing
Figure: 13
HF Housing
HF Motor Assy
Figure: 15

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To refit the replacement motor make sure the locating lug is in the correct orientation
and aligned with the receiver socket as shown in figure 17.
Now carefully insert the replacement HF Motor back in to the HF Housing observing
the correction orientation. Using the HF Removal Tool rotate in a clockwise motion to
secure the motor in the HF Housing. Now replace the HF Tube and HF Rear Cap.
HF Housing
HF Motor
Assembly
Figure: 16
HF Housing
Internal View
HF Spade Terminal
Figure: 17
HF Locating lug
HF Locating
lug receiver
Thermal Pad
Tweeter
HF Motor
Assembly