Bose 802 E Service Manual

							11
DISASSEMBLY/ASSEMBLY  PROCEDURES
402® and 802® 

 Second Variation
1. Top Cover Removal
1.1 Remove the 5 screws (1) that secure
the top cover (2) to the chassis.
1.2 Lift off the top cover .
2. Top Cover Replacement
2.1 Place the top cover (2) onto the chassis.
2.2 Secure the top cover to the chassis
using the 5 screws (1) that were remove in
procedure 1.1.
NOTE: The front panel is not removable.
3. PCB Removal
3.1 Perform procedure 1.
3.2 Disconnect the two power transformer
connectors and the two wires (12) going to
the  power switch (9).
NOTE: If the opti-Voice
® PCB is used,
disconnect the harness at the opti-Voice
PCB.
3.3 Remove the 6 screws (6) that secure
the connectors (4) to the rear panel.
3.4 Remove the 7 screws (3) that secure
the PCB assembly (5) to the chassis.
3.5 Slide the PCB assembly towards the
front of the unit and lift up the rear of the
PCB  to remove it from the chassis.
4. PCB Replacement
4.1 Place the PCB assembly into the
chassis aligning the connectors (4) with the
rear panel.4.4 Connect the connectors for the line
cord and power transformer. If the
opti-Voice PCB was used, connect the
harness to the PCB.
4.5 Perform procedure 2.
5. Transformer Removal
5.1 Perform procedure 1.
5.2 Disconnect the two wire harnesses
from the transformer (11) to the PCB
assembly (5).
5.3 Remove the two 11/32” hex nuts (10)
that secure the transformer to the chassis.
5.4 Lift the transformer up and away from
the chassis.
6. Transformer Replacement
6.1 Place the transformer (11) into the
chassis aligning it to the studs.
Note: Proper orientation is required for the
transformer wire harnesses.
6.2 Secure the transformer to the chassis
using the two 11/32” hex nuts (10) that
were removed in procedure 7.3.
6.3 Connect the two wire harnesses from
the transformer to the PCB.
6.4 Perform procedure 2. Note: Refer to Figure 3 for the following
procedures.
4.3 Secure the connectors (4) to the rear
panel using the 6 screws (6) removed in
procedure 3.3. 4.2 Secure the PCB assembly (5) to the
chassis using the 7 screws (3) removed in
procedure 3.4. 
						

							12
TEST SETUP PROCEDURE
The controls on the back panel should be set as follows (unless otherwise specified):
1. Set the input switches to the -10 dB position.
2. Set the Mode switch to the number 2 (BA) position.
3. Set the Low Frequency Level control to the +3 dB position.
4. Set the Output Mode switch to the NORM position
input
switch
Input connections: connect pin 1 (-) and pin 3 (shield) together at the signal generator and
audio analyzer (oscilloscope and dB meter).
Input and Output connection DiagramBack Panel View
The following test procedures refer to the 402
®, 402 series 

 802® series 


and the 802 series 


. These references are to the PCB assembly changes that were made
recently to accommodate the new series of 402 and 802 speakers.
The new PCB assembly can be identified by the label on the top side of the PCB near the
BOSE
® logo. The following are the new PCB assembly par t numbers:
259148 for the 402
259145 for the 802input
switchmode
switch
output
mode
switchlow freq.
switch 
						

							13
402® TEST PROCEDURES
1. High Frequency Gain Test
1.1 Apply a 100 mVrms, 850 Hz signal to
the controller’s input terminals.
1.2 Reference a dB meter to the input of the
controller.
1.3 Measure the gain at the high frequency
output terminals. The gain should be +9.8
 
+ 1.0 dB.
1.4 Change the input switches to +4 dB.
1.5 The gain should be -3.4 
+ 1.0 dB.
2. Low Frequency Gain Test
Note: Set the input switches to the -10 dB
position.
2.1 Apply a 100 mVrms, 80 Hz signal to the
controller’s input terminals.
2.2 Reference a dB meter to the input.
2.3 Measure the gain at the low frequency
outputs. The gain should be +22.5 dB 
+ 2.0
dB.
2.4 Change the Output Mode switch to the
SUM position and measure the output at
channel 1. The gain should be +28.1 dB
+ 1.5 dB.
3. Frequency Response Test Full Range
Mode
Note: Set the Mode switch to the number 1
position (FR), the input switch to the -10 dB
position and the Output Mode switch to the
NORM position.
3.1 Apply a 100 mVrms, 850 Hz signal to
the controller’s input terminals. Note: Perform the following tests on both
channels.
Frequency Output Tolerance
60 Hz -3.7 dB
±1.5 dB
105 Hz +8.5 dB
±1.5 dB
220 Hz +3.5 dB
±1.5 dB
850 Hz 0.0 dB reference
4 kHz +5.8 dB
±1.5 dB
14.5 kHz +13.3 dB
±1.5 dB
402 Frequency Response Table
Full Range Mode
Frequency Output Tolerance
60 Hz +3.2 dB
±1.5 dB
90 Hz +10.0 dB
±1.5 dB
220 Hz +7.3 dB
±1.5 dB
600 Hz -2.4 dB
±1.5 dB
850 Hz 0.0 dB reference
4 kHz +5.6 dB
±1.5 dB
13.5 kHz +15.5 dB
±1.5 dB
402 Series 

 Frequency Response Table
Full Range Mode
4. Frequency Response Test Bi-Amp Mode
Note: Set the Mode switch to the number 2
position (BA).
4.1 Apply a 100mVrms, 850 Hz signal to
the controller’s input terminals.
4.2 Reference a dB meter to the input
signal.
4.3 Measure the output at the high fre-
quency output terminals. Refer to the
frequency response table for the series of
402 you are testing. 3.2 Reference a dB meter to the input
signal.
3.3 Measure the response at the high
frequency output terminals. Refer to the
frequency response table for the series of
402 you are testing. 
						

							14
402® TEST PROCEDURES
402 Series 

 Frequency Response Table
Bi-Amp Mode Full Range Output
Frequency Output Tolerance
60 Hz -13.0 dB
±1.5 dB
90 Hz -5.6 dB
±1.5 dB
220 Hz +6.8 dB
±1.5 dB
600 Hz -2.4 dB
±1.5 dB
850 Hz 0.0 dB reference
4 kHz +5.8 dB
±1.5 dB
13.5 kHz +15.5 dB
±1.5 dB
5. Low Frequency Response Bi-Amp Mode
5.1 Apply a 100mVrms, 80 Hz signal to the
controller’s input terminals.
5.2 Reference a dB meter to the input.
5.3 Measure the output at the low fre-
quency output terminals. Refer to the
frequency response table for the series
of 402 you are testing.
Frequency Output Tolerance
40 Hz -6.2 dB
±2 dB
80 Hz 0.0 dB reference
100 Hz +1.3 dB
±1 dB
300 Hz -17.5 dB
±2 dB
402 Low Frequency Response Table Bi-Amp
Mode Low Frequency output402 Series 

 Low Frequency Response Table
Bi-Amp Mode Low Frequency Output
Frequency Output Tolerance
40 Hz -6.2 dB
±2 dB
80 Hz 0.0 dB reference
100 Hz +1.3 dB
±1 dB
300 Hz -17.5 dB
±2 dB
6. Midrange Distortion Test
Note: Set the Input Mode switch to the +4
dB position for the following test proce-
dures.
6.1 Set the mode switch to the number 1
(FR) position.
6.2 Apply a 7.5 Vrms, 850 Hz signal to the
controller’s input.
6.3 Measure the distortion at the high
frequency output terminals. The measure-
ment should be 
< .1%.
7. High Frequency Distortion Test
7.1 Apply a 2.25 Vrms, 6 kHz signal to the
controller’s input terminals.
7.2 Measure the distortion at the high
frequency output terminals. The measure-
ment should be 
< .2%.
8. Low Frequency Distortion Test Bi-Amp
Mode
8.1 Set the mode switch to the 2 (BA)
position.
8.2 Apply a 1.6 Vrms, 80 Hz signal to the
controller’s input terminals.
8.3 Measure the distortion at the low fre-
quency output terminals. The measurement
should be 
< .1%.
Frequency Output Tolerance
60 Hz -16.4 dB
±1.5 dB
105 Hz -4.8 dB
±1.5 dB
220 Hz +2.8 dB
±1.5 dB
850 Hz 0.0 dB reference
4 kHz +5.8 dB
±1.5 dB
14.5 kHz +13.3 dB
±1.5 dB
402 Frequency Response Table Bi-Amp Mode
Full Range Output 
						

							15
402® TEST PROCEDURES
9. Midrange Frequency Distortion Test
Bi-Amp Mode
9.1 Apply a 7.5 Vrms, 850 Hz signal to the
controller’s input terminals.
9.2 Measure the distortion at the high
frequency output terminals. The measure-
ment should be 
< .1%.
10. High Frequency Distortion Test Bi-Amp
Mode
10.1 Apply a 2.25 Vrms, 6 kHz signal to the
controller’s input terminals.
10.2 Measure the distortion at the high
frequency output terminals. The measure-
ment should be 
< .2%.
11. Clipping Headroom Test
11.1 Apply a 6.9 Vrms, 850 Hz signal to the
controller’s input terminals.
11.2 Measure the distortion (at an output
of 4.6 
+ .5 Vrms) at the high frequency
output terminals. The measurement should
be 
< 1%.
12. Channel Separation Test Bi-Amp Mode
12.1 Apply a 7.5 Vrms, 850 Hz signal to the
controller’s input terminals.
12.2 Reference a dB meter to the left
channel output.
12.3 Measure the right channel output. It
should be 
> 40 dB.
13. Hum
13.1 Measure the hum and noise at the low
frequency outputs with no input signal
applied. The reading should be 
< 40 uV. 
						

							16
802® TEST PROCEDURES
1. High Frequency Gain Test
1.1 Apply a 100 mVrms, 700 Hz signal to
the controller’s input terminals.
1.2 Reference a dB meter to the input of the
controller.
1.3 Measure the gain at the high frequency
output terminals. The gain should be +15.1
+ 1.0 dB.
1.4 Change the input switches to +4 dB.
1.5 The gain should be 2.0 
+ 1.0 dB.
2. Low Frequency Gain Test
Note: Set the input switches to the -10 dB
position.
2.1 Apply a 100 mVrms, 80 Hz signal to the
controller’s input terminals.
2.2 Reference a dB meter to the input.
2.3 Measure the output at the low fre-
quency outputs. The gain should be +23.5
dB 
+ 2.0 dB.
2.4 Change the Output Mode switch to the
SUM position and measure the output at
channel 1. The gain should be +28.1 dB
+ 1.5 dB. Note: Perform the following tests on both
channels.
802 Series 

 Frequency Response Table
Full Range Mode
802 Series 


 Frequency Response Table
Full Range Mode
4. Frequency Response Test Bi-Amp Mode
Note: Set the Mode switch to the number 2
position (BA).
4.1 Apply a 100mVrms, 700 Hz signal to
the controller’s input terminals.
4.2 Reference a dB meter to the input
signal.
4.3 Measure the output at the high fre-
quency output terminals. Refer to the
frequency response table for the series of
802 you are testing.
Frequency Output Tolerance
40 Hz +8.0 dB
±1.5 dB
55 Hz +13.5 dB
±1.5 dB
140 Hz +6.6 dB
±1.5 dB
700 Hz 0.0 dB reference
2.5 kHz +2.1 dB
±1.5 dB
6 kHz +9.6 dB
±1.5 dB
15 kHz +16.7 dB
±1.5 dB
Frequency Output Tolerance
40 Hz +1.9 dB
±1.5 dB
70 Hz +13.5 dB
±1.5 dB
140 Hz +7.5 dB
±1.5 dB
700 Hz 0.0 dB reference
2.5 kHz +1.8 dB
±1.5 dB
6 kHz +6.9 dB
±1.5 dB
15 kHz +13.8 dB
±1.5 dB
3. Frequency Response Test Full Range
Mode
Note: Set the Mode switch to the number 1
position (FR), the input switch to the -10 dB
position and the Output Mode switch to the
NORM position.3.1 Apply a 100 mVrms, 700 Hz signal to
the controller’s input terminals.
3.2 Reference a dB meter to the input
signal.
3.3 Measure the response at the high
frequency output terminals. Refer to the
frequency response table for the series of
802 you are testing. 
						

							17
802® TEST PROCEDURES
802 Series 

 Frequency Response Table
Bi-Amp Mode Full Range Output
Frequency Output Tolerance
40 Hz -21.0 dB
±1.5 dB
60 Hz -11.5 dB
±1.5 dB
700 Hz 0.0 dB reference
2.5 kHz +2.1 dB
±1.5 dB
6 kHz +9.6 dB
±1.5 dB
15 kHz +16.7 dB
±1.5 dB
802 Series 


 Frequency Response Table
Bi-Amp Mode Full Range Output
5. Low Frequency Response Bi-Amp Mode
5.1 Apply a 100mVrms, 80 Hz signal to the
controller’s input terminals.
5.2 Reference a dB meter to the input.
5.3 Measure the output at the low fre-
quency output terminals. Refer to the
frequency response table for the series
802 you are testing.
802 Series 

 Low Frequency Response Table
Bi-Amp Mode Low Frequency output802 Series 


 Low Frequency Response Table
Bi-Amp Mode Low Frequency output
Note: Set the Input Mode switch to the +4
dB position for the following test proce-
dures.
6. Midrange Distortion Test
6.1 Set the mode switch to the number 1
(FR) position.
6.2 Apply a 5.8 Vrms, 700 Hz signal to the
controller’s input.
6.3 Measure the distortion at the high
frequency output terminals. The measure-
ment should be 
< .2%.
7. High Frequency Distortion Test
7.1 Apply a 1.30 Vrms, 6 kHz signal to the
controller’s input terminals.
7.2 Measure the distortion at the high
frequency output terminals. The measure-
ment should be 
< .2%.
8. Low Frequency Distortion Test Bi-Amp
Mode
8.1 Set the mode switch to the number 2
(BA) position.
8.2 Apply a 1.6 Vrms, 80 Hz signal to the
controller’s input terminals.
8.3 Measure the distortion at the low fre-
quency output terminals. The measurement
should be 
< .1%.
Frequency Output Tolerance
40 Hz -24.9 dB
±1.5 dB
70 Hz -10.6 dB
±1.5 dB
140 Hz +5.2 dB
±1.5 dB
700 Hz 0.0 dB reference
2.5 kHz +1.9 dB
±1.5 dB
6 kHz +7.0 dB
±1.5 dB
13 kHz +13.9 dB
±1.5 dB
Frequency Output Tolerance
40 Hz -6.2 dB
±2 dB
80 Hz 0.0 dB reference
100 Hz +1.3 dB
±1.5 dB
300 Hz -17.5 dB
±2 dB
Frequency Output Tolerance
40 Hz -6.2 dB
±2 dB
80 Hz 0.0 dB reference
100 Hz +1.3 dB
±1.5 dB
300 Hz -17.5 dB
±2 dB 
						

							18
11. Clipping Headroom Test
11.1 Apply a 5.8 Vrms, 700 Hz signal to the
controller’s input terminals.
11.2 Measure the distortion (at an output of
7.35 
+ .5 Vrms) at the high frequency
output terminals. The measurement should
be 
< .1%.
12. Channel Separation Test Bi-Amp Mode
12.1 Apply a 4.0 Vrms, 700 Hz signal to the
controller’s input terminals.
12.2 Measure the channel separation
across the high frequency output terminals.
It should be 
> 40 dB.
13. Hum
13.1 Measure the hum and noise at the low
frequency outputs with no input signal
applied. The reading should be 
< 40 uV.
802® TEST PROCEDURES
9. Midrange Frequency Distortion Test
Bi-Amp Mode
9.1 Apply a 5.8 Vrms, 700 Hz signal to the
controller’s input terminals.
9.2 Measure the distortion at the high
frequency output terminals. The measure-
ment should be 
< .1%.
10. High Frequency Distortion Test Bi-Amp
Mode
10.1 Apply a 1.30Vrms, 6 kHz signal to the
controller’s input terminals.
10.2 Measure the distortion at the high
frequency output terminals. The measure-
ment should be 
< .2%. 
						

							19
PART LIST NOTES
1. This part is not normally available from customer service. Approval from the Field Service
Manager is required before ordering.
2. The individual parts located on the PCBs are listed in the Electrical Part List.
3.         This part is critical for safety purposes. Failure to use a substitute replacement with the
same safety characteristics as the recommended replacement part might create shock, fire
and/or other hazards.
4. This part is not shown. 
						

							20
12
11
1
2
6X 2x
3
(5x)
3
4
5
6
7 8
9 10
2x
7x
6
2
(6x)
(2x)
8
(2x)
7
3
511
(2x)1
4
9 10
1213
3
(6x)14
(2x)
15
Figure 2. 402®, 802® 

 Original
 Version Exploded View
Figure 3. 402, 802 

 Current Version
Exploded View
16