B&W 804 - d3

Bowers & Wilkins TECHNICAL SUPPORT
Distributor Service Technical Manual

804 D3 Speakers
Produced by: T. Taylor
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

Revision History
Date Revision By Details
22 MAR 2016 1 TT Initial Release
800 Series Tool Kit

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

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
Whenever you see this
authorised by B&W
warning, always take
 Always use B&W original type replacement parts.
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
Be aware whenever
wear an ESD wrist strap when working on live electricity. 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.

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

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.
Figure: 1
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
Tyco Tool
HH15156
Hex/Alen Keys
HH37842
Molex Tool
Phillips Screwdriver
HH15180
HH36994 HH15121
Facom 4.0x0.8
HH33782
HH37214
WIHA 224/1-2
Torx
Tool - 8
HH15164
6mm Box

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
Figure: 2 Tweeter
Dust Cap Mid - Range
Upper Base Driver
Magnetic Trim Ring
Lower Base Driver
Flow Port
Terminals

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.
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: 4
Negative Terminal Positive Terminal
Link cable Link cable
Terminal Links
Input cable from the

amplifier

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.
Figure: 5
Terminal Links
Removed
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.

 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.
Figure: 6
Amplifier 1
Terminal Links
Removed
Amplifier 2
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.

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.

Figure: 7
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.

8. 804D3 Mechanical Drawing & Spare Parts

804D3 Spare Parts


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
Molex Plug
Mid - Range
HF Crossover Assembly
Upper Bass Unit
LF Crossover Assembly Lower Bass Unit
Terminal Tray

10. Tweeter & Motor Disassembly
To remove the HF Grille it will need pulling forward from the Tweeter housing as
shown in Figure: 8.
Figure: 8 HF Housing
Gap
HF Grille
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: 9
HF Grille Removal Tool HH 37214
HF Grille Release Slot
HF Grille

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

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.
Figure: 13 HF Motor Removal HF Motor Assy

Tool – HH15156
HF Housing
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.
Figure: 14 Figure: 15
HF Motor
Assembly
HF Motor loose
HF Housing Assembly
secured
HF Housing
It should now be possible to remove the tweeter motor from the HF housing, shown in
Figure: 16.

Figure: 16 HF Housing
Internal View
Tweeter
HF Housing
HF Motor
HF Spade Terminal Assembly
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.
Figure: 17
Thermal Pad
HF Locating
HF Locating lug lug receiver
HF Motor
Assembly
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.

11. Tweeter Mechanical Drawing & Parts

12. Tweeter Unit Removal
With the Mid - Range Unit Speaker removed (as in section 13) the Tweeter Housing
connections can be accessed and disconnected and then removed as shown in Figure: 18.
Figure: 18
HF Retaining Nut/Bolt
HF Molex Socket & Plug
HF Cable Restraint Tie
Cut the HF Cable Restraint Tie and disconnect the Molex Plug as shown in Figure: 19.
Figure: 19
Molex Plug
Molex Socket
The next stage of this process is to use a Molex Removal Tool to extract the Black
and Red cable from the Molex Plug as shown in Figure: 20.

Figure: 20 Figure: 21 HF Cables
HF Retaining
Molex Plug Bolt Tool
Rotate Shaft
Note: The Molex Tool may need the shaft

rotating to help travel the full distance on the
Crimp (take hold of the shaft).
Once the 2 x HF Cables have been removed from the Molex Plug carefully thread both of
the HF Cables into the HF Retaining Bolt Tool as shown in Figure: 21.
Now slide the Removal Bolt Tool up to the Retaining Bolt and proceed to unscrew the
Retaining Bolt. Once the Retaining Bolt is completely unscrewed slide the Removal Bolt Tool
back down the HF cables. This will allow the Retaining Nut and washer to slide down to the
Molex Crimp Pins as shown in Figure: 22.
Figure: 22
HF Retaining Bolt
HF Foam Gasket
HF Washer
HF Retaining Nut
HF Molex Crimp Pins

It will now be possible to carefully feed the Molex Crimp Pins through the HF Retaining Bolt,
the Molex Pins will only go through one at a time. The Tweeter Housing can now be lifted off
the Cabinet.as shown in Figure: 23.
Figure: 23
Tweeter Unit
HF Locating Pin Rear

HF front Locating Pin
HF Isolator
Refit the replacement Tweeter Unit in reverse order and remember to tighten the HF
Retaining Nut with the HF Retaining Bolt Tool HH37842 shown in Figure: 24.
Figure: 24
And remember to refit the Molex Plug with the Black Lead fitted to the pointed side of the
Molex Plug as shown in Figure: 24

13. Mid - Range Removal
To gain access to the Mid - Range Speaker start by putting your fingers against the
Dust Cap, then slowly pull it forwards as shown in Figure: 25. Place the Dust Cap in a
safe place for reinsertion on reassembly.
Figure: 25 Rubber Surround Inner
Mid-Range
Dust Cap
Outer Aluminium Rim
Note: Do not attempt to remove the Outer Aluminium Rim, this is fixed to the Mid -
Range Speaker Rim.
With the Dust Cap completely removed as shown in Figure: 26, it is possible to insert
the Mid Extractor Tool HH15121. Turn the Mid Extractor tool anti-clockwise and
remove the Nut, the Washer will fall away as the Nut is removed.

Figure: 26
Insert Mid Extractor Tool
1 x Nut & Washer
Care should be taken in the form of support when the Nut has ben removed as the
the Mid – Range Speaker will fall forward as shown in Figure: 27, if not reverse the
Mid Extractor Tool HH15121 and remove with the Tool.
The Washer may fall inside the Coil Former Area once the Nut has been removed,
carefully remove this and put to one side along with the Nut for reassembly.

Figure: 27
Mid – Range Falls Forward
Mid-Range removal using the

Mid Extractor Tool HH15121
Coil Former
Washer
The Mid – Range Speaker can now be taken out of its fixing as shown in Figure: 28, take
care not to damage the Bass Unit Speaker below.
Figure: 28
Mid - Range
Wadding
Drawbar Assembly
Turn the Mid – Range Speaker sideways so that the Crimp Connection are accessible
as shown in Figure: 29 and disconnect the 2 x Crimp Connectors.

Figure: 29
Wires
Brown & Blue
Mid - Range Crimp
Connectors
Mid - Range Speaker
Disconnect the 2 x Crimp Connectors and then fit the replacement Mid - Range Speaker in
reverse order...
14. Draw Bar Assembly Removal

With the Mid – Range Speaker removed as per section 10, lift out the wadding and remove
the Sleeve Spring Stop, the Spring and 2 x Washers shown in Figure: 30.
Figure: 30
Draw Bar Assembly
Sleeve Spring Stop 2 x Hex Bolts
1 x Spring
2 x Washers
Sleeve Spring Stop

1 x Spring
2 x Washers

Now remove the 2 x Hex Bolts shown in Figure: 30 and lift the Draw Bar Assembly out of the
Cabinet as shown in Figure: 31.
Figure: 31
Draw Bar Assembly
Once the Sleeve Spring Assembly has been removed from the Cabinet it can be
disassembled further by removing the Circlip as shown in Figure: 32.
Figure: 32 Circlip
Snuber Plate
MF Sleeve Fixing
Lock Sleeve
Draw Bolt fixing
Draw Bar
Rear Isolator

Note: Although it is possible to disassemble the Rear Isolator from the Drawbar it is
recommended that the Rear Isolator remains on the Draw Bar as removing the Draw Bolt
Fixing could damage the Draw Bar.
Once the Drawbar Assembly has been repaired or a replacement sourced refit in reverse
order.
15. 5” MF Cabinet Tube Removal

Start by removing the 8 x Hex Bolts shown in Figure: 33 and put these to one side for
reassembly.
Figure: 33 Note: Take care not to
drop any of the 8 x Hex
Bolts into the Cabinet or
scratch the MF Cabinet
Tube.
8 x Hex Bolts
MF Cabinet Tube
Once all 8 x Hex Bolts have been removed the MF Cabinet Tube will fall forward as shown in
Figure: 34, take care not to damage the Gasket.
Figure: 34 Gasket Note: Take care not to

damage the Cabinet
when lifting the MF
Cabinet Tube away
from the Cabinet.
Also the Gasket may

stick to the MF Cabinet
Tube. Ensure that the
Gasket is in place as
shown in Figure: 35,
before refitting the MF
Cabinet Tube.
MF Cabinet Tube

Figure: 35 Note: Aline the Gasket
before refitting the MF
Cabinet Tube.
Make sure that the

Acoustic Foam is still in
place, if not push it back
Acoustic Foam in place.
Fit a new ty-rap to hold

the Tweeter Cable
Gasket
Replace Ty-Rap
Once the 5” MF Cabinet Tube has been replaced (in reverse order) and following the
instruction in section 13 refit the Mid – Range Speaker in reverse order.
16. Upper & Lower Bass Unit Speakers Removal

To gain access to the Bass Unit Speakers start by putting your fingers against the
Rubber Surround Inner and your thumb on the Outer Aluminium Rim as shown in
Figure: 36. Now apply a small amount of pressure and pull outwardly.
Figure: 36 Outer Aluminium Rim
Bass Unit
Rubber Surround Inner
The Outer Aluminium Rim will come away as shown in Figure: 36, place this in a safe
place in preparation for reassembly. With the Outer Aluminium Rim removed it is
possible to see how it is secured in place as shown in Figure: 37. There are 8 x
Magnets in the Outer Aluminium Rim and 8 x Magents in the Bass Unite Speaker.

Figure: 37
Outer Aluminium Outer Aluminium

Rim securing Rim securing
magnets magnets
With the Outer Aluminium Rim removed now unscrew and remove the 8 x Hex Bolts
as shown in Figure: 38.
Figure: 38 6” Cabinet Tube
8 x Hex Bolts
Bass Unit Speaker
Take care as the Bass Unit Speaker may fall forward or may need pulling forward to
release it from the 6” Cabinet Tube.
Figure: 39 2 x Crimps Handle the Bass Unit Speaker as

shown in Figure: 39.
Now remove the 2 x Crimp Connectors.
This will completely release the Bass

Unit Speaker from the Cabinet.
Note: Follow the same process for

both Bass Unit Speakers.
Refit the new Bass Unit Speaker in

reverse order.

17. Upper 6” Cabinet Tube Removal
reassembly.
scratch the Cabinet
Tube.
8 x Hex Bolts
MF Cabinet Tube
Once all 8 x Hex Bolts have been removed the Cabinet Tube will fall forward as shown in

damage the Cabinet
when lifting the Cabinet
Tube away from the
Cabinet.
Also the Gasket may

stick to the Cabinet
before refitting the
Cabinet Tube.
Cabinet Tube

Cabinet Tube.
Make sure that the

in place.
Acoustic Foam
Gasket
Once the 6” Cabinet Tube has been replaced (in reverse order) and following the instruction
in section 15 refit the Bass Unit Speaker in reverse order.
18. Lower 6” Cabinet Tube Removal

reassembly.
scratch the Cabinet
Tube.
8 x Hex Bolts
MF Cabinet Tube

Once all 8 x Hex Bolts have been removed the Cabinet Tube will fall forward as shown in

damage the Cabinet
when lifting the Cabinet
Tube away from the
Cabinet.
Also the Gasket may

stick to the Cabinet
Cabinet Tube.
Cabinet Tube

Cabinet Tube.
Make sure that the

in place.
Acoustic Foam
Gasket
Once the 6” Cabinet Tube has been replaced (in reverse order) and following the instruction
in section 15 refit the Bass Unit Speaker in reverse order.

19. Terminal Tray Assembly Removal
Start by removing the 2 x Torx Screws using a Torx size 8 key to unscrew the 2 x Torx
screws as shown in Figure: 46.
Figure: 46
Terminal Tray
2 x Torx Screws
With the 2 x Torx Screws removed the Terminal Tray can be pulled forward which is shown
in Figure: 47, this allows access to the Terminal Tray and the crimped wires/ terminals.
Figure: 47
Terminal Isolators
Terminal Tray
After carefully sliding the Terminal Tray out of the Cabinet unscrew the 4 x Terminal Caps to
expose the Terminal Fixings as shown in Figure: 48.

Figure: 48
Exposed Terminal Fixing
Unscrew Terminal Cap
Using the Terminal Nut Runner Tool HH33782 unscrew the Retaining Nuts on each of
the Terminals as shown in Figure: 49.
Figure: 49
Terminal Nut Runner Tool
When the Terminal Nuts have been removed carefully slide each terminal out the back of the
Terminal Tray making sure you retain the 2 x Red and 2 x Black Terminal Isolators as shown
in Figure: 47. Once all of the Terminal Nuts have been removed the 4 x Terminal Posts can
be removed from the Terminal Tray. Now the Terminal Posts and Cables are free from the
Terminal Tray proceed to replace with a new Terminal Tray in reverse order.

20. HF Crossover Assembly Removal
Start by removing the Mid – Range Speaker as in section 12, then remove the
Wadding shown in Figure: 50.
Figure: 50
Molex Connector
Molex Plug
Wadding
Cut Ty - Rap
With the Wadding removed the Molex Connector is visible, pull the Molex Plug out of
the Molex Connector (these Red & Black Cables are for the Tweeter) and cut the Ty-
rap which holds the cable in place as shown in Figure: 51.
Figure: 51
Molex Connector
Molex Plug
Tweeter Cable Ty – Rap cut
Speaker Cable
The Mid – Range Speaker Cable and Tweeter Cable will need to be fed through the
Internal Cabinet and their Rubber Bungs will need pushing down through the holes as
shown in Figure: 51.
Now follow section 15 and remove the Upper Bass Unit Speaker.

With the Upper Bass Unit Speaker removed unscrew the 4 x Phillips Screws holding
the HF Crossover Assembly in place as shown in Figure: 52.
Figure: 52 The Mid – Range Speaker
Cable and the Tweeter Cable
are both connected to the HF
Crossover Assembly.
4 x Screws
These are both shown below
with their Rubber Bungs
HF Crossover Assembly Rubber Bungs
Take extra care when removing the 4 x Phillips Screws not to drop them into the
Cabinet. Now the HF Crossover Assembly can be removed at an angle as shown in
Figure: 53.
Figure: 53
The HF Crossover Assembly can now be replaced in reverse order, see Figure: 54 to
view the complete Upper Crossover Assembly.

Figure: 54
21. LF Crossover Assembly Removal

Start by removing the Upper and Lower Bass Unit Speakers as in section 15. Then
remove the 4 x Phillips Screws holding the LF Crossover Assembly in place shown in
Figure: 55.
Figure: 55
4 x Phillips Screws
LF Crossover Assembly
Take extra care when removing the 4 x Phillips Screws not to drop them into the
Cabinet.
The LF Crossover Assembly can be removed at an angle as shown in Figure: 56.

As the LF Crossover is lifted out the 2 x Crimp connectors from the Upper Bass Unit
Speaker will need disconnecting as shown in Figure: 56.
Figure: 56
2 x Upper Bass Unit

Speaker Crimps
The LF Crossover Assembly can now be replaced in the reverse order, see Figure: 57
to view the complete LF Crossover Assembly.
Figure: 57

22. HF Crossover Drawing & Circuit

23. HF Parts List

24. LF Crossover Drawing & Circuit

25. LF Parts List
26. Final Functional Test (Stethoscope Examination of Speakers)

Aim of the Test
The stethoscope functional test can quickly reveal any air leaks or flaws following a
repair to a loudspeaker. The only sound coming from a loudspeaker enclosure should
be from the driver components themselves, not the surfaces or seams of the speaker
cabinet. We normally hear in stereo as a result of our ears being placed at two
separate points in space separated by several inches. When you use the stethoscope
both of your ears hear from the same single point at the position of the listening piece.
You are now listening not in stereo, but rather in mono mode which allows a greater
accuracy in examining a particular sound source.
Performing a Stethoscope Examination on a Speaker

For the following tests you should remove the chest piece from the end of the
stethoscope and listen via the tube only.
There are two options for carrying out this test:
Option 1
Drive the speaker via an amplifier and signal generator set in the low bass region, say
20 to 60 Hz, to listen for air leaks at the enclosure seams, driver mounting edges, and
jack plates. The smallest air leak will be heard clearly. Follow the same procedure as
in Option 2.
Option 2
Start by playing your choice of music (frequency) through the speaker you wish to
examine and keep the volume moderate.

Next place the earpieces of the stethoscope in your ears and place the listening tube
around the piece on the Speaker Cabinet that you wish to examine.
Place the listening tube several inches in front of each driver in a multi-way speaker
system you can hear each individual driver to a great extent.
Pan between the drivers as shown in Figure: 58, by moving the listening piece
between the woofer and tweeter.
This allows very sensitive panning between drivers to listen for phase effects . . . such
as a notch in the frequency response at crossover. Carefully move the listening tube
about the surface of the enclosure noting the sound level remains consistent.
Figure: 58
Check around
the Tweeter
Check Mid - Range
Upper Base Unit
Lower Base Unit
Check around the Terminal Tray
Flow Port
Once these tests are complete and no leaks are found the Speaker is ready for its
final clean before being returned to the customer.

27. Cleaning
The cabinet surfaces will usually only require dusting. If you wish to use an aerosol or
other cleaner, apply the cleaner onto the cloth, not directly onto the product and test a
small area first, as some cleaning products may damage some of the surfaces.
Avoid products that are abrasive, or contain acid, alkali or antibacterial agents. Marks
on the paint surface may be removed with a dilute perfume-free soap solution.
Remove any remaining streak marks by spraying with a proprietary glass cleaner and
lightly wiping dry with a microfiber cloth. Do not use cleaning agents on the drive units
and avoid touching them as damage may result.

28. Product Test List:
Passive Loudspeakers
 Sweep Frequency Test
20 Hz – 20 kHz (3 volts, all products) check for distortion & balance between left & right
speaker
 Spot Frequency Test
4 volts – Book shelf

5 volts – Floor standing
6 volts – Headed (800 series)
a) Between 20 – 50 Hz, check for air leaks around all joints & fixtures.
b) At 30 Hz, check for internal leaking into midrange cavity (check MR driver is not
moving)
c) Between 20 – 500 Hz, check for rattles, buzzing & any other unwanted noise.
d) Check for correct phase of all drive units.
e) For Dipole, check functionally of dipole switching at 200 Hz
Headphones
 Listen for unwanted noise between 20 Hz – 20 kHz (using hygienic ear cup)
Active devices – Subwoofers & Docking stations etc.
 Set product to half volume & follow procedure as per above instructions, from (a) to
(d)
 Check functionality of the following:
a) Ethernet, Auxiliary, USB, Component & Headphone Output

b) Silent audio track, check for hum at 1 Meter
c) Flash test ALL mains power supply units
d) Soak test for 1 week with audio signal all units returned more than once.
e) Check functionality of GUI as per user manual

29. Test Result Sheet:
Reason for return: □ In Warranty

□ Out of Warranty
□ Chargeable
PAT Testing Required No Date done: N/A
Received packaging re-useable - - Yes / No Serial no.
1. Tools and Equipment Required

Part Number Description
1 x Amp
1 x CD Player
1 x 800 D3 Tool Kit
1 x Other Tools as specified
1 x Stethoscope
1 x Signal Generator
Latex Gloves
Documents Required
Document Number Description
2. Cosmetic Inspection: Tick the box to confirm check done and add comments in notes if required
Check Cabinet for Damage Check Flow Port

Check Tweeter/Grille Check Terminal Tray
Check the Mid-Range
Check the Upper & Lower Bass
Notes:
Date: Operator:
1st Review Before Service/Repair: Commercial / Sales / Technical

Carrier informed of damage Claims form raised
Customer informed of damage Customer quoted
Authorisation: Date:
Repairs performed and replacement parts used (List the quantity, part number and serial numbers):
3. Functional Test: Add initials to the box

Connect 804D3 Speakers to Amp/CD Player and check for Sound Yes/No
Check audio for Tweeter/Mid- Range & Bass Units output is working Yes/No

5. Speaker Bi-Wiring
Check RH/LH speakers are working Bi-wire Yes/No
10. Tweeter & Motor Assembly

Does it need replacing? Yes/No (LH/RH or Both)
Does the Grille need replacing? Yes/No (LH/RH or Both)
12. Tweeter Unit Assembly

13. Mid-Bass Speaker Assembly

R/H Speaker does it need replacing? Yes/No (LH/RH or Both)
L/H Speaker Does it need replacing? Yes/No (LH/RH or Both)
14. Draw Bar Assembly

15. 5”MF Cabinet Tube Assembly

16. Bass Unit Speaker Assembly

R/H Speaker does it need replacing? Yes/No (LH/RH or Both)
L/H Speaker Does it need replacing? Yes/No (LH/RH or Both)
17 & 18. 6”MF Cabinet Tube Assembly

Does one or two need replacing? Yes/No (LH/RH or 1,2,3 or 4)
19. Terminal Tray Assembly

20. HF Crossover Assembly

21. LF Crossover Assembly

11. Final Functional Test

Connect 804D3 Speakers to Amp/CD Player and check for Sound Yes/No
Check audio for Tweeter/Mid- Range & Bass Units output is working Yes/No
Check RH/LH speakers are working Bi-wire Yes/No
Check RH/LH Tweeters/Mid-Range/Bass speakers for leakage using a Stethoscope Yes/No
Check RH/LH Terminal Links are fitted Yes/No

2nd Review During Service and Testing: Commercial / Sales / Technical
Note: Additional parts
Customer informed of damage Customer quoted
Authorisation: Date:
□ Results Recorded Date: Checked by:
□ Clean 804D3 Speakers Date:
Successful completion of repair and all documentation completed Management

Signature:

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Bowers & Wilkins TECHNICAL SUPPORT

Distributor Service Technical Manual

Produced by: T. Taylor

Page 1 of 51 © Bowers & Wilkins 2016

Date Revision By Details

22 MAR 2016 1 TT Initial Release

800 Series Tool Kit

Page 2 of 51 © Bowers & Wilkins 2016

Front Cover Page 1

Page 3 of 51 © Bowers & Wilkins 2016

Antistatic Precautions (ESD)

Chemicals and Solvents (COSHH)

Personal Protection Equipment (PPE)

Page 4 of 51 © Bowers & Wilkins 2016

Technical Features: Diamond Tweeter, Continuum Cone FST, Turbine

Description: 3-way vented-box system

Drive units: 1x ø25mm (1 in) diamond dome high-frequency

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)

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

Page 5 of 51 © Bowers & Wilkins 2016

1 x HF Retaining Bolt Tool HH37842, 1 x Grill Removal Tool HH37214, 1 x HF Motor

1 x Phillips Screwdriver, 1 x Facom Screwdriver 4.0x0.8, 1 x Offset Screwdriver

T8, 1 x Amplifier, Spring Hook HH15164, 1 x CD Player, 1 x Stethoscope, 1 x Signal

Generator and Gloves.

Page 6 of 51 © Bowers & Wilkins 2016

Dust Cap Mid - Range

Upper Base Driver

Magnetic Trim Ring

Lower Base Driver

Page 7 of 51 © Bowers & Wilkins 2016

4. Basic-wire Connections to Speakers

Input cable from the

Page 8 of 51 © Bowers & Wilkins 2016

Connect speakers in the bi-wire mode:

6. Bi-Amplification Connections to Speakers

Connect speakers in the bi-amplification mode:

Page 9 of 51 © Bowers & Wilkins 2016

Page 10 of 51 © Bowers & Wilkins 2016

7. Vertical Bi-Amplification Connections to Speakers

An example is shown below in in Figure: 7.

Page 11 of 51 © Bowers & Wilkins 2016

It does not matter. Just keep it symmetrical.

Page 12 of 51 © Bowers & Wilkins 2016

Page 13 of 51 © Bowers & Wilkins 2016

Page 14 of 51 © Bowers & Wilkins 2016

Page 15 of 51 © Bowers & Wilkins 2016

LF Crossover Assembly Lower Bass Unit

Page 16 of 51 © Bowers & Wilkins 2016

HF Grille Release Slot

Page 17 of 51 © Bowers & Wilkins 2016

Page 18 of 51 © Bowers & Wilkins 2016