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Bosch GWS 850 CE Speed Controller Wiring Diagram, Part Numbers, and Connection Details

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User question

GWS 850 CE diagram speed controler

Artificial Intelligence Response

Direct answer to the question

  • Bosch does not publish a component‑level schematic for the GWS 850 CE speed controller. What Bosch does provide is a wiring/connection diagram via spare‑parts drawings showing the “speed governor” module and how it ties into the switch, stator (field) and a brush lead.
  • On the GWS 850 CE, the speed governor is item 51 in the exploded view. Typical OEM numbers you will see for this part include 1 607 233 137 (older variants) and 1 607 233 5C1 / 16072335C1 (later variants, depending on the exact 10‑digit model code). (powertoolspares.com)

Key points

  • You can get the correct connection diagram by opening the exploded drawing for your exact 10‑digit Bosch type number (e.g., 0 601 378 703 / 7AB / 7AC / 7V1). The drawing shows the governor in series with Live (after the switch) and connected to the stator and one brush for back‑EMF feedback. (powertoolspares.com)
  • Part numbers vary by subtype, so always match the number on your tool’s nameplate before ordering or wiring by color. (powertoolspares.com)

Detailed problem analysis

Functional role

  • The “CE” in GWS 850 CE denotes Constant Electronic control: a phase‑angle controller (triac‑based) modulates voltage to hold RPM under load and adds soft‑start. The module measures motor back‑EMF via a sense lead from one brush and advances/retards the triac firing angle accordingly.

Where the governor sits electrically

  • Live (L) from the mains goes through the on/off switch, then into the speed governor.
  • The governor’s power output feeds the first field (stator) coil.
  • Current path continues through the armature via the brushes and returns to Neutral (N) through the second field coil (Bosch typically routes one field coil on the return side).
  • A thin “sense” lead from the brush holder provides the controller with the back‑EMF signal; the governor also interfaces to the speed thumbwheel (potentiometer), which is either on the governor PCB or cabled directly to it.

Canonical wiring topologies you will see in this model family

  • 3‑lead governor (common):
    • L_in from switch (heavy wire)
    • L_out to field coil (heavy wire)
    • Sense from brush holder (thin wire)
  • 4‑lead governor (some variants):
    • L_in from switch (heavy)
    • L_out to field coil (heavy)
    • Sense from brush (thin)
    • N reference or additional field/brush connection (heavy/thin depending on design)

What the Bosch drawing shows (and what it does NOT)

  • The spare‑parts “diagram” is an exploded view with wiring paths, not a resistor/IC schematic. It identifies the governor as Pos. 51 and shows its terminations to the switch, field and brush. Internal component‑level details are proprietary and not published. (powertoolspares.com)

A practical, safe pin‑mapping procedure (works across variants)

  1. Identify field (stator) pair: with the tool unplugged, measure continuity to find the two field coil leads (a few ohms). Label them F1 and F2.
  2. Identify brush leads: the two spring‑loaded carbon brush tails. Label B1 and B2.
  3. Identify switch output (Live after the switch): with the switch ON and a continuity tester across the mains cord Live and the suspected output, confirm which lead becomes Live when the switch is closed. Label it L_sw_out.
  4. Governor high‑current path: the governor has two heavy leads that must end up in series between L_sw_out and F1. Verify by ohmmeter (a few hundred kΩ through snubbers; effectively “open” at DC).
  5. Governor sense: the thin lead goes to the brush that is on the return side of the armature (commonly the brush tied toward Neutral via the other field coil). This is often B2 in the loop N → Field → Brush → Armature → Brush → (returns to governor reference or to N).
  6. EMI capacitor/X2 filter: the rectangular suppression filter sits across L and N at the switch; leave it as‑is; it does not pass load current. (powertoolspares.com)

Readable ASCII connection sketch (typical)

  • Mains L → Switch → [Governor L_in] → [Governor L_out] → F1 → Brush A → Armature → Brush B → F2 → Mains N
  • Governor sense (thin) → to Brush B (back‑EMF pickup)
  • EMI/X2 filter → across Mains L and N at the switch

Notes on wire colors

  • Bosch often uses brown/black for L, blue for N, and white/black for internal motor leads, but color can vary by production run and region. Trust the functional mapping above over colors, and confirm with continuity.

Current information and trends

  • Current spare‑part listings for GWS 850 CE variants still show “Speed Governor” as Pos. 51. One example (0 601 378 703) lists part 1 607 233 137; other subtypes (e.g., 0 601 378 7AC) list 16072335C1 for Pos. 51. This differences explain why diagrams found online may show slightly different wire routing or connectors—Bosch revised the module across sub‑variants. (powertoolspares.com)
  • Several European parts sites host the drawings and part lists per subtype; select the exact 10‑digit type number to see the matching diagram. (parts4tools.eu)

Supporting explanations and details

Why a brush sense lead?

  • With universal motors, back‑EMF sampled at a brush correlates to speed. The controller measures this during the non‑conducting portion of the AC cycle and adjusts the next triac firing angle—hence “constant electronic” speed.

Soft‑start behavior

  • By ramping the firing angle from small conduction to full target duty over ~200–500 ms, inrush and jerk are reduced, lowering gear and armature stress.

Typical controller internals (reference design)

  • Triac (e.g., BTA12/BTA16 class), RC snubber, DIAC or IC‑based phase control, and a potentiometer for set‑speed. The exact Bosch PCB is usually resin‑potted and not documented publicly.

Ethical and legal aspects

  • This module operates at mains potential. Only work with the tool unplugged and observe proper insulation, creepage/clearance and strain relief when re‑terminating conductors.
  • Respect Bosch’s IP: internal schematics are proprietary; use official diagrams for wiring and official or equivalent‑quality replacements to maintain safety compliance.

Practical guidelines

  • Quick “is the governor dead?” test (bypass test)
    • With the tool unplugged, temporarily connect L_sw_out directly to F1 (removing the governor from the series path). Secure the connection and ensure the tool is clamped. Power briefly:
    • Runs at full speed, no soft‑start → governor faulty.
    • Still dead → look at brushes, switch, cord, field/armature continuity first.
  • Continuity checkpoints (unplugged):
    • Cord L to switch input: ≈0 Ω with trigger pressed.
    • Field coils: each a few ohms; armature via brushes: low but non‑zero.
    • No short from L to N with switch open.
  • Reassembly best practices:
    • Dress wires in the original channels; avoid pinching under housing screws.
    • Verify the thumbwheel couples correctly to the governor’s pot.
    • Replace worn brushes as a set and seat them properly.

Possible disclaimers or additional notes

  • The GWS 850 CE is commonly a 230 V EU model. U.S. 120 V variants of similar grinders use different governors; never mix 120 V and 230 V modules. Check the nameplate voltage and the 10‑digit type number before ordering. (worldwidevoltage.com)
  • Some aftermarket regulators claim compatibility across many subtypes; quality and safety can vary. Prefer OEM or reputable equivalents matched to your subtype. (lsp.pl)

Suggestions for further research

  • Provide your exact type number (e.g., 0 601 378 7AC) and I can map the pin‑by‑pin connections and wire colors against the specific diagram for your variant.
  • If you suspect mis‑wiring, share clear photos of the governor, switch, field, and brush connections; I’ll annotate them and draw a simplified schematic overlay.

Recommended resources (per subtype)

  • Spare‑parts page for your exact 10‑digit code (shows Pos. 51 “Speed governor,” part number, and wiring paths). Example for 0 601 378 703 shows 1 607 233 137 as the governor. (powertoolspares.com)
  • Alternative listings confirming later governor number 16072335C1 at Pos. 51 for 0 601 378 7AC. (elektroserw.pl)
  • Other regional parts portals (drawings per variant) for cross‑checking. (parts4tools.eu)

Brief summary

  • There is no public component‑level circuit diagram for the GWS 850 CE controller; use the Bosch exploded/wiring diagram for your exact type number. The governor (Pos. 51) sits in series with Live after the switch, feeds the stator, and senses back‑EMF from a brush. Part numbers differ across subtypes (e.g., 1 607 233 137 vs 16072335C1), so match to your 10‑digit model before wiring or ordering. If you share that number (and photos), I can give you a precise, pin‑by‑pin connection map for your tool. (powertoolspares.com)

User question

mapiranje pin-po-pin veze i boje žica za 16072335gt

Artificial Intelligence Response

Direct answer to the question

  • For Bosch speed governor 16072335GT (family 1 607 233 5xx used in GWS “CE/Constant Electronic” grinders), the wiring is function-driven and wire colors may vary by batch. Typical, working mappings:
  • 3–4 lead versions (most common):
    • Heavy wire (brown or black): Live IN from switch.
    • Heavy wire (black or brown): Live OUT to first stator/field coil (F1).
    • Thin wire (white, yellow, or red): Back‑EMF sense to one brush holder (the brush on the “return/Neutral side” of the loop).
    • Optional thin/medium wire (blue/gray/black): Reference to switch/Neutral or speed potentiometer (if present).
  • 5‑lead versions (pads often marked A/B/C/D/G on the governor PCB):
    • A (heavy): Live IN from switch.
    • B (heavy): Live OUT to stator F1.
    • C (heavy/medium): Link to the other stator end (F2) or to the switch link shown in the tool’s wiring diagram.
    • D (thin): Back‑EMF sense to brush (usually the brush that returns toward Neutral via F2).
    • G (thin/medium): Reference to switch/Neutral or the alternate brush per variant.

Key points

  • Prioritize function and continuity over color; Bosch/OEM and aftermarket kits change colors across production.
  • The governor is inserted in series in the Live path after the trigger switch; the thin sense lead must go to the “Neutral‑side” brush for regulation to work.

Detailed problem analysis

  • Motor/governor topology:
    • The tool uses a universal (series) motor: L → Switch → Governor → Field coil F1 → Brush A → Armature → Brush B → Field coil F2 → N.
    • The governor is a triac phase controller with:
    • Power path: Live IN (from switch) and Live OUT (to F1).
    • Feedback: Back‑EMF sense taken from one brush to estimate speed.
    • Setpoint/reference: Either an internal fixed network or a speed dial potentiometer; some variants also bring out a reference to switch/Neutral.
  • Why brush selection matters:
    • The sense input must sample motor back‑EMF with respect to the circuit reference. In these tools the correct point is the brush that is “downstream” of the armature toward Neutral through F2. If you connect the sense lead to the Live‑side brush, the control will see the wrong waveform and the motor will run away to full speed or pulse.
  • Practical identification without relying on colors:
    1. Identify heavy vs. thin leads from the governor: heavy = power (A/B; sometimes C), thin = sense/reference (D/G).
    2. Find the switch output (Live after trigger). With the tool unplugged, check continuity from mains Live (brown on EU cords, black on US cords) through the switch when pressed—this goes to governor Live IN (A).
    3. Find stator F1: the governor Live OUT (B) must feed a field lead that then goes to a brush holder.
    4. Determine the Neutral‑side brush for the sense lead:
      • With the tool unplugged, measure resistance from each brush terminal to mains Neutral (blue on EU cords, white on US cords). The brush showing a few ohms to Neutral (via F2) is the Neutral‑side brush; connect the thin sense lead (D) here.
    5. If your governor has a fifth lead (G) or an extra medium wire (C), trace where it went originally (switch link or the other stator end F2). It typically provides reference/phase sensing or a factory link equivalent to what the wiring diagram calls out.
  • Expected ohmic values (tool unplugged):
    • F1 or F2 (each field coil): typically 3–6 Ω each (varies by model).
    • Armature through both brushes: a few ohms total when measured across the brushes with coils in series through the loop.
    • Governor A–B: appears open/high resistance on DC (you may see hundreds of kΩ due to snubber network).
    • Thin sense leads D/G: open to the power leads; high impedance among themselves.
  • Behavior symptoms vs. wiring mistakes:
    • Runs only at full speed: sense lead not connected or on the wrong (Live‑side) brush.
    • Dead/no start (but motor OK when bypassed): triac open/failed or Live IN/OUT reversed with a broken link.
    • Immediate trip/smoke: shorted connections (e.g., sense to Live), or Live OUT tied to Neutral.

Current information and trends

  • Bosch has shipped several 16072335xx governors with identical function but different harness color sets; community repair threads and exploded views confirm:
    • A/B as heavy Live in/out, D as brush sense, and optional C/G as link/reference in some subtypes.
    • Some factory looms swap which thin lead lands on the brush vs. the switch link; both arrangements are equivalent as long as “sense → brush” and “reference → link/Neutral” are preserved.
  • Aftermarket replacements often come with two black heavy wires and a white or yellow thin wire; the module remains functionally the same—identify by circuit position, not color.

Supporting explanations and details

  • ASCII functional map (typical 4/5‑lead governor):
    • Mains L → Switch → A(heavy) Governor → internal triac → B(heavy) → F1 → Brush A → Armature → Brush B ← D(thin sense) → F2 → Mains N.
    • If present: C/G thin/medium go to either F2 or a switch link that references Neutral/phase for the control.
  • Potentiometer variants:
    • Some CE models use an external thumbwheel pot (≈10 kΩ). If your module exposes a pot lead:
    • Center wiper to the governor pot pad.
    • Outer pot ends to governor reference pads (often internal; not always brought out as wires).
  • EMI parts you might see at the switch:
    • An X2 safety capacitor (and sometimes an RC snubber) sits across L–N at the switch. Do not confuse its thin leads with motor or governor leads—it never carries motor current.

Ethical and legal aspects

  • Safety:
    • Mains work is hazardous. Unplug before measuring; wait for capacitors to discharge.
    • Use heat‑resistant insulation, proper crimp terminals, and strain relief; no solder-only joints in high‑vibration, high‑temperature zones unless factory‑style and secured.
  • Compliance:
    • Keep the EMI parts (X2 capacitor, chokes) as originally fitted to preserve EMC compliance.
    • Maintain creepage/clearance distances around the governor PCB and switch per IEC/UL norms.

Practical guidelines

  • Step‑by‑step wiring (most common case):
    1. Label/photograph everything before disassembly.
    2. Connect governor heavy IN (A) to switch output.
    3. Connect governor heavy OUT (B) to first field coil (F1).
    4. Connect thin sense (D) to Neutral‑side brush.
    5. If present, connect extra lead (C or G) to the remaining stator end (F2) or switch link as per your original loom.
    6. Inspect brush length (>5 mm typical); clean carbon dust from brush holders.
    7. First power‑up via series test lamp or variac; verify soft‑start and speed control off‑load.
  • Bypass test for diagnosis:
    • Temporarily bridge A→B (governor out) with the tool otherwise wired. If the motor runs normally at full speed, the motor/cabling are OK and the governor is faulty.

Possible disclaimers or additional notes

  • Bosch does not publish pinouts for internal governors; production color codes vary across regions and years.
  • The same part number may appear with 3, 4, or 5 leads depending on whether reference/link leads are externalized.
  • If your tool is a different model (non‑CE or different wattage), the loom routing may differ—always follow the tool’s 10‑digit type number wiring diagram.

Suggestions for further research

  • Provide the tool’s exact model and 10‑digit type number from the nameplate (e.g., 0 601 378 7AC) and clear photos of your governor (showing any A/B/C/D/G markings), switch, stator, and brushes—I can map your pins 1:1 to your colors.
  • Check the official exploded view for your specific type number to confirm switch link positions and field coil labels (F1/F2).
  • If using an aftermarket governor, consult the vendor’s schematic (often included as a small leaflet) and reconcile to the functional mapping above.

Brief summary

  • Insert the governor in series on the Live path after the switch (heavy IN/OUT). Land the thin sense lead on the brush that returns toward Neutral through the second field coil. Any extra thin/medium lead is a reference/link to the switch or the other stator end. Because colors vary, verify each connection by continuity and function rather than color alone. If you share photos/type number, I will produce a pin‑by‑pin map matching your exact wire colors.

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