I have replaced the brushes, switch and tested the cord yet the sander will not operate, Any suggestions.

Try and test the motor coil if you can to see the motor is intact. If you notice a small circuit board inside, you might as well test its electronic components, e.g. capacitors. You may also test the power cord and the pins to prove they are OK. If these options are exhausted, you can refer to an experienced service tech.

Unplug the the sander open the plate to the power cord check for broken wires. Use a Digital Multimeter on the cord to find hidden broken wires in the insulation, if the power cord checks out fine it is in the motor or the switch check the switch and wires with the Digital Multimeter if the switch is fine it is in the motor replace whatever you find that is bad.

Sometimes Harbor freight tools will give away 7 Function Digital Millimeters just for visiting their store check the ad in the link below.

Harbor Freight Tools Quality Tools at Discount Prices Since 1977

Cheers
Billy from Hayward.

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!

that is possible, but was the tool operating properly first?? unplug tool and check the cord for any breaks, then what I would do is clean the tool as good as possible with compressed air and if you can remove the brush caps do so and check the condition of the spring and clean the area. DO NOT sand the brushes but look across the face to see if both look worn evenly. If you have a volt ohms meter check from the plug to the brush holder with the switch on brushes removed to see if you have continuity and if not then I would have to think the switch

The local hardware store has brushes in all different sizes in a box, next to the switches, fuses, plugs, cords, tool type stuff. They are standard sizes, should be able to find them no problem. Hope this helps.

Milwaukee tools have a 5yr warranty, best thing to do is to take it to a service center. It could be anything from the cord to switch, brushes, field coil etc. If it is newer than 5 yrs, thats the best route.

check brushes or maybe the armiture is bad.

Take the brushes out, inspect them, and blow out the whole tool with compressed air.

Hi, Unfortunately there is no external test, It has to be opened and troubleshot with a multimeter. Especially something with a variable speed controller, power cord, brushes, switches, ect. It could be several things. If you are technical enough to take it apart let us know we will try to help. Good Luck to you!

It's usually not the brushes but the commutator that needs cleaned. The commutator is the surface the brushes ride on. Go to Walgreens and buy a multi-surface nail file, one of the soft ones that are about 3/4" square with different colors for different grits. Don't start at the coarse grit!! Start at the medium grit and lightly drag it over each section in a smooth arcing motion, when the commutator surface is shiny it's clean, then replace the brushes with new ones.