Bose 402 Series Bedienungsanleitung

Service Manual

402®Series II Loudspeaker

Reference Number 260431-SM Rev. 02

Electronic copy only

SPECIFICATIONS

WARRANTY

5 year limited warranty

PROPRIETARY INFORMATION

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION

OF BOSE®CORPORATION WHICH IS BEING FURNISHED

ONLY FOR THE PURPOSE OF SERVICING THE IDENTIFIED

BOSE PRODUCT BY AN AUTHORIZED BOSE SERVICE CEN-

TER OR OWNER OF THE BOSE PRODUCT, AND SHALL NOT

BE REPRODUCED OR USED FOR ANY OTHER PURPOSE.

Specifications ....................................................................................................................................1

Disassembly/Assembly Procedures ........................................................................................... 2-3

Figure 1. Schematic Diagram ..............................................................................................................3

Test Procedures ................................................................................................................................4

Main Part List.....................................................................................................................................5

Figure 2. Exploded View ......................................................................................................................5

Crossover PCB Part List ..................................................................................................................6

Figure 3. Crossover PCB Layout ........................................................................................................6

Packaging Part List ...........................................................................................................................6

Figure 4. Packaging View ....................................................................................................................6

External dimensions:

Single speaker: 23.3" H x 8.2" W x 7.8" D (59.2 x 20.8 x 19.8)cm

Packed system: 27.0" H x 12.0" W x 11.0" D (68.6 x 30.5 x 27.9)cm

Weight:

Single speaker: 17.5 lbs (7.94 kg)

Packed system: 21.3 lbs (9.66 kg)

Transducer: Four 4.5" environmental drivers per enclosure

Internal cabinet volume: 1067.9 cu. In. (17.5 liters)

Port:

Type: Two rectangular ports located at the top and bottom.

Total port area: 8.84 sq. in. (57 sq. cm)

Port length: 3.23" (8.2cm)

Resonance frequency: 90 Hz

Impedance: 8 ± 2 Ohm

Power handling: 120W continuous per IEC-268-5

Sensitivity: 90 dB SPL, 1W, 1m

CONTENTS

Figure 1. Exploded View

MAIN PART LIST

12x

2x 2x

12x

Item

Number Description Part Number Qty Note

1 GRILLE, BLACK

GRILLE, ARCTIC WHITE

GRILLE, PRO GRAY

252380-001

252380-002

252380-004

2 SCREW, TAPP, 8-15, HEXW, SLOT 290290-12 14

3 DRIVER ASSEMBLY, 4.5" 291020-001 4 1

4 GASKET, DRIVER, 4.5" 128407 4

5 FOAM, ACOUSTIC, 19.75"x7"x1 120357 1

6 CLIP, TINNERMAN 187943 2

7 CROSSOVER ASSEMBLY 291042-001 1

8 CONN, SPEAKON, PANEL MOUNT 258213-002 2

9 SCREW, THUMB, M8x1.25x25mm 137050 2

10 CONN, FUSE CLIP, 1 POS, FEMALE 121112 2

11 SCREW, TAPP, 6-20x.5, PAN, XR 290296-08 2

12 TAPE, FOAM 257555 1

13 NUT, J-TYPE, 8-32 109481 12

14 INSERT, KNURLED 290293-01 4

15 DEFLECTOR 126973-1 1

16 SCREW, TAPP, 6-13x.625, PAN 290294-10 4

17 NAME PLATE, LOGO, BLACK

NAME PLATE, LOGO, WHITE 254458-001

254458-002 1

Note: When ordering a driver, also order a driver gasket.

PACKAGING PART LIST

Figure 3 Packaging View

Item

Number

Description Part

Number

Qty

1 LAMP, AXIAL LEAD 114462 2

2 20uF, CAP, FILM, 75V, 10% 119026 1

CROSSOVER PCB PART LIST

Figure 2. Crossover PCB Layout

Item

Number

Description

Part Number

Qty

Note

1 PACKING, FOAM, BOTTOM, EPS 258908 1

2 PACKING, FOAM, P/U, RIGHT 258927 2

3 PACKING, FOAM, P/U, LEFT 258928 2

4 MANUAL, OWNERS 256597 1

5 BAG, POLY, 13.5x35x9.5x1 MIL 114522 1

6 CARTON, RSC, 402 II 256591 1

3.4 Cut the wires as close as possible to the

driver’s wire terminal.

4. Driver Replacement

4.1 Referring to the schematic below, attach

the wires to the driver (1).

4.2 Line up the driver (1) to the cabinet and

secure it with three screws (7).

4.3 Line up the deflector (8) with the cabinet

and secure it with four screws (12).

5. Crossover Removal

5.1 Remove the three screws (7) securing the

top driver (1) to the cabinet. Lift out the driver.

5.2 Remove the two screws (7) securing the

crossover PCB to the cabinet.

5.3 Pull the crossover PCB through the driver

opening in the cabinet.

Deflector

Crossover PCB

DISASSEMBLY/ASSEMBLY PROCEDURES

Note: Numbers in parenthesis correspond to

call-outs in figure 1.

1. Grille Removal

1.1 Rotate the Bose® logo (9) 450to release

the grille (6).

1.2 Grasp the edge of the grill and pull it off.

2. Grille Replacement

2.1 Rotate the Bose logo (9) 450so the

locking tabs on the logo line up with the slot

on the deflector (8). Press the grille into place.

2.2 Rotate the Bose logo horizontally, locking

the grille into place.

3. Driver Removal

3.1 Perform procedure 1.

3.2 Remove the four screws (12) securing the

deflector (8) to the cabinet. Lift off the deflector.

3.3 Remove the three screws (7) securing the

driver (1) to the cabinet. Lift out the driver.

7.3 Pull out the Speakon connector and

remove the wires.

8. Speakon Connector Replacement

8.1 Referring to figure 1, attach the wires to

the Speakon connector (4).

8.2 Align the Speakon connector in the

cabinet.

8.3 Reshape the tinnerman clip (5) or use a

new one. Place an appropriate size wood

block between the Speakon connector (rear

of speaker) and a hard surface. Using a flat-

blade screwdriver (or similar tool) and a

hammer, secure the tinnerman clip into place.

Make sure the Speakon connector is securely

fastened.

6. Crossover Replacement

6.1 Replace the two screws (7) securing the

crossover PCB (3) to the cabinet.

6.2 Perform procedure 4 and 2.

7. Speakon Connector Removal

7.1 Perform procedure 3.1-3.3 to remove the

two center drivers.

7.2 Using a flat-blade screwdriver, pry out the

tinnerman clip (5) securing the Speakon

connector (4) to the cabinet.

DISASSEMBLY/ASSEMBLY PROCEDURES

Speakon

Connector

Tinnerman Clip

Figure 4. Schematic Diagram

1. Phase Test

1.1 Observing polarity, apply 9 VDC to the

input connector. Refer to the figure below.

1.2 All driver cones should move outward.

Referring to figure 4, rewire any driver that

moves inward.

2. Crossover Test

2.1 Connect a 0.5 Ohm resistor and amplifier

to the speaker input connector as shown in

the diagram below.

2.2 Apply a 2 Vrms, 8 kHz signal to the

speaker input connector.

2.3 Measure the voltage across the 0.5 Ohm

resistor. It should be 68-90 mVrms. If the

voltage is out of range, check the crossover

components and wiring.

3. Rub and Tick Test

3.1 Apply a 9 Vrms, 10 Hz signal to the

speaker input connector.

3.2 No extraneous noises such as rubbing,

scraping or ticking should be heard.

Note: To distinguish between normal suspen-

sion noise and rubs or ticks, slightly displace

the cone of the driver with your fingers. If the

Amplifier

0.5 Ohm

Speaker

Volt meter

Speaker output

TEST PROCEDURES

noise can be made to go away or get worse, it

is a rub or tick and the driver should be

replaced. If the noise stays the same, it is

normal suspension noise and the driver is

fine. Suspension noises will not be heard with

program material.

4. Air Leak Test

4.1 Apply a 15 Vrms, 65 Hz signal to the

speaker input connector.

4.2 Listen for air leaks around the drivers and

cabinet seam. Reposition or replace any

gasket that is found to leak. Repairs made to

the cabinet seam should not be visible from

the exterior of the speaker.

5. Sweep Test

5.1 Apply a 9 Vrms, 10 Hz signal to the

speaker input connector.

5.2 Sweep the signal generator from 10 Hz to

500 Hz.

5.3 Apply a 500 Hz, 2 Vrms signal to the

speaker input connector.

5.4 Sweep the signal generator from 500 Hz

to 5 kHz.

5.5 Listen for buzzes, rattles or other noises.

Redress any wire that buzzes; replace any

driver that is found to be defective.

Note: A whooshing noise from the port at its

resonance frequency of approximately 90 Hz

is acceptable.

Positive input

Negative input

SERVICE MANUAL REVISION HISTORY

Date Revision

Level

Description of Change Change Driven By Pages

Affected

02/01 00 Document release revision 00

Service manual release All

02/06 01 Added RoHS part numbers This product is now built

with RoHS compliant parts. 3

1/07 No change Corrected part number, Driver

Assembly, 4.5” Correct part number is

254451 3

5/09 02 - New part numbers for

speaker parts and packaging

- Layout changed to reflect

current manuals

Part changes

Service manual layout

change

3, 4

All

Specifications and Features Subject to Change Without Notice

Bose Corporation

The Mountain

Framingham Massachusetts USA 01701

P/N 260431-SM Rev. 02 05/2009 (P) For Technical Assistance or Part Orders, Call 1-800-233-4408

http://serviceops.bose.com

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