My first question is what did the old brushes look like, was the spring burnt, were the contact faces on the brushes not the same. I would make sure that the brushes move freely in the tubes allowing contact with the armature, to ensure this use your volt ohms meter and place one in at a time and check by inserting your probe on the commutator thru the opposite brush tube and the top of the installed brush. I assume you have one if you indicate the cord/switch are OK. If they were not burnt then the next thing I would look for is a loose connection or broken wire from the vibration of this tool. You can get a breakdown and wiring schematic by going to milwaukeetool.com. I strongly recommend doing this before further disassembly. Let me know
sounds like you are mechanically inclined so what I am going to recommend is bypassing the cord and switch and hooking up a jumper direct to the motor, this will let you know for sure. Did you check the continuity thru the field?? There could still be a broken wire in the cord that is intermittent that is why I would bypass all these. If this doesn't work then I would have to assume it is major electrical
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Brushes were evenly worn and were not burned. There is no burned smell in the motor. I have checked all of the wires and they are in tact. I have also checked the continuity in the cord, switch, and wiring to brushes. This is a real puzzler for me as it was working great one moment then I moved the hammer to hit another spot, depressed the switch and I was dead.
Thanks. I did bypass the cord, nothing, so, unfortunately I think you are right it is "major electrical"
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