Variable speed
It sounds to me that you have used the sander a lot and the vibration has broken a wire or it's about to break on the field windings. The brushes you need to look at to see if worn. But I kind of think wire problem. I had this happen on mine and opened it up to find this is what happened. The sander would be turned on and would not operate until I turn upside down and it would work. This is great if you are sanding upside down but this is just a sign that you are on borrowed time as this will eventually not turn on at all. I was able to fix mine with new wire crimp connection and solder with heat shrink material. If not you can order new field winding if this is what is wrong. Cleaning up the sander won't hurt either. You might want to see what a new sander will cost vs. part. Good Luck!
SOURCE: I have replaced the brushes,
check the comutator (where the brushes contact on the shaft) and make sure it is clean and not shorted
SOURCE: After replacing the brushes in my old Rockwell
Did you dress the brushes to the contour of the commutator?
You wrap the commutator with fine sandpaper and rotate under the brushes till the curve conforms.
If this does not reduce the arcing, then you may have an armature with a bad winding.
Testimonial: "Sounds logical. I'll try it."
power cord stuck in rear wheel of power sander
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