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My dw423 variable sander quit while still new and was told to bypass some wiring anyone know what to do

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  • 35 Answers

Look for thermal cut out device in one of the lead wires to the motor

Posted on Apr 25, 2017

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Posted on Jan 02, 2017

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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!

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Motor runs, but the belt doesn't turn. Is this an easy fix or is it time to get a new sander?


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Checked the net for answers and got a couple of maybe's. 1.) Brushes, 2.) variable speed control, which some were direct wiring.
I tried the brushes firs and that has solved the problem for now. I guess the brushes stuck or somehow lost contact.
I got a parts diagram and found the brushes (will be covered with dust). Took the springs out and stretched them a little, replaced and the sander turned on. You will need to remove the top cover to do this. Verdit is still out as to long term performance. Not a great start.

My particular sander was lightly used (second project) and it has not been abused.

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1 Answer

Sander will operate only at a very low level of power.


It is either a bearing or bearings that are failing and causing the sander to slow down or the variable speed switch is failing.

Mar 17, 2009 | Tools & Hardware - Others

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