Bose AW 1 Service Manual

The Bose AW 1 is a professional-grade, weather-resistant loudspeaker designed for demanding outdoor and marine audio applications. This service manual provides authorized technicians with detailed technical information, disassembly procedures, parts lists, and troubleshooting guidelines for the repair and maintenance of the Bose AW 1 loudspeaker system. Below are key sections covering safety, specifications, component identification, service procedures, and parts replacement.

Features and Applications

Key design elements: Weather-resistant composite enclosure, UV-stable grille, high-excursion woofer, pivoting tweeter, integrated crossover network.

Safety Precautions

Before servicing, disconnect all power sources. Use appropriate personal protective equipment.

1. Electrical Safety: Ensure amplifier is powered off and disconnected before handling speaker terminals.
2. Mechanical Safety: Use correct tools; avoid damaging seals or enclosure during disassembly.
3. Component Handling: Handle drivers and crossover components with care to avoid damage.
4. Work Area: Perform service in a clean, dry, static-safe environment.

WARNING! This manual is for qualified technicians only. Incorrect repair can cause injury or further damage. Always follow local safety regulations.

Technical Specifications

• Type: 2-way, weather-resistant loudspeaker system.
• Woofer: 6.5" or 8" (model dependent), high-excursion design.
• Tweeter: 1" pivoting dome tweeter.
• Frequency Response: 55 Hz - 20 kHz (±3 dB).
• Nominal Impedance: 8 ohms.
• Power Handling (Continuous/Peak): 150W / 600W.
• Sensitivity: 90 dB (1W @ 1m).
• Crossover Frequency: 2.5 kHz.
• Enclosure: Sealed, non-ported design.
• Dimensions (H x W x D): Approx. 14" x 9" x 10" (model dependent).
• Weight: Approx. 15 lbs.
• Ingress Protection: IP55 (Protected against dust and water jets).

Exploded View and Parts List

Refer to diagram AW1-EXP-001 for component layout and relationship.

Key Components:

1. Front Grille Assembly (Part # AW1-GRL-01)
2. Woofer Driver (Part # AW1-WFR-01)
3. Tweeter Assembly (Part # AW1-TWT-01)
4. Crossover Board (Part # AW1-XVR-01)
5. Enclosure Main Body (Part # AW1-ENC-01)
6. Rear Terminal Plate (Part # AW1-TRM-01)
7. Mounting Bracket(s) (Part # AW1-BRK-01)
8. Sealing Gaskets (Part # AW1-GSK-01)
9. Hardware Kit (Screws, bolts) (Part # AW1-HWK-01)

Note: Always verify part numbers with Bose Parts Department before ordering.

Disassembly Procedure

Tools required: Phillips screwdriver, Torx drivers (as needed), plastic pry tool, hex key set.

1. Remove the front grille: Carefully insert plastic tool between grille and baffle; release clips evenly around perimeter.
2. Remove woofer: Unscrew the mounting screws (typically 8) securing the woofer to the baffle. Gently lift woofer out, noting wire polarity.
3. Disconnect internal wiring: Label or note connections from crossover to woofer and tweeter before disconnecting.
4. Access crossover: Remove screws securing the terminal plate or access panel on the rear of the enclosure.
5. Extract crossover board: Carefully disconnect all wires and remove the board from its mounting points.

CAUTION! Do not force components. Keep all screws and gaskets organized for reassembly.

Driver Replacement

Procedure for replacing woofer or tweeter.

1. Verify replacement driver part number matches original.
2. For woofer: Place new driver into cutout, ensuring the gasket is properly seated. Connect wires observing correct polarity (+/-). Tighten mounting screws in a cross pattern to ensure even pressure and seal.
3. For tweeter: The tweeter assembly may be secured from the front or rear. Disconnect wires, remove mounting hardware, and replace. Reconnect wires, ensuring polarity is maintained.
4. Test driver functionality with a low-level audio signal before final reassembly.

Tip: Apply a thin bead of appropriate sealant (if specified) to the driver gasket for critical weather sealing.

Crossover Network

The passive crossover network divides the audio signal between woofer and tweeter and provides protection.

Testing: Use a multimeter to check for:

1. Continuity on input terminals.
2. Resistance across woofer and tweeter output terminals (should match driver DC resistance approximately).
3. Check capacitors for shorts or opens; check inductors for continuity.

Replacement: If faulty, replace the entire crossover board (Part # AW1-XVR-01). Solder new connections exactly as the original.

Enclosure and Grille

Inspect enclosure for cracks, especially around mounting points. Check grille for corrosion or damage to the fabric.

Grille Replacement: Remove old grille by releasing clips. Align new grille and press firmly until all clips engage.

Enclosure Repair: Minor cracks can be repaired with epoxy formulated for the enclosure material. For major damage, replace the entire enclosure.

Sealing: Integrity of all gaskets and seals is critical for weather resistance. Replace any compromised gaskets (Part # AW1-GSK-01).

Electrical Testing

Use a multimeter and audio tester for verification.

1. Impedance Check: Disconnect speaker from amplifier. Measure resistance across terminals. Should read approximately 5-7 ohms (close to nominal 8 ohms).
2. Driver Test: With crossover disconnected, test woofer and tweeter individually for DC resistance and by applying a very low voltage (1.5V battery) for a "pop" sound.
3. Polarity: Verify all internal connections maintain consistent polarity from input terminals to each driver.
4. Signal Test: Reconnect everything and apply a low-level, full-range audio signal to check for output from both woofer and tweeter.

Reassembly and Sealing

Reverse the disassembly procedure, paying special attention to seals.

1. Ensure all gaskets are clean and properly positioned.
2. Reinstall crossover board and reconnect all wires securely.
3. Reinstall drivers, tightening screws to the specified torque in a star pattern.
4. Reinstall terminal plate/access panel, ensuring its seal is intact.
5. Snap the front grille back into place, ensuring all clips are engaged.
6. Perform a final audio and weather-seal check.

WARNING! An improper seal will void the weather resistance and may lead to speaker failure.

Troubleshooting and Diagnostics

Service Contact: For technical support and genuine Bose parts, contact Bose Professional Services or visit the Bose Professional website.