How To Replace A Damaged Power Tool Cord

When you have a construction job to do, nothing is worse that downtime caused by malfunctioning tools. We have all been there, right? You are on location, and you are about ready to start work, when you see a frayed cord with exposed wires. Whether it is a saw, a router, a drill, a sander, or any other type of tool, the question is the same: Do you chance still using to tool and risking possible danger? Power tool cords take a lot of abuse, and often need to be replaced. The constant twisting, rubbing, dragging, pinching and pulling take their toll and eventually crack or wear away the outer lining of the cord. This can damage the wires inside, and expose the tool operator to severe danger. The good news is that the repair work for a power tool cord is not difficult with the right tools and the right knowledge. This article is dedicated to the replacement of power tool electrical cords. *Disclaimer: Power tool maintenance should only be performed by properly trained individuals. If some maintenance procedures are performed by non-authorized individuals, it may void the manufacturer's warranty. This article is to be used only as a guideline, please check with your local authorized service centers if you have any questions. The entire replacement process should take less that one hour. The tools that are needed: Screwdriver Utility Knife Wire Strippers Lineman's Pliers Multitester The materials that are needed: The correct replacement power cord Masking tape Safety Tips: Always unplug the tool before you begin any work Start with a clean, uncluttered work bench area (When working on the inside of power tools, you do not want to get dirt or any other foreign objects into the inside of the tool) Step By Step Procedure Uncover the wire terminals: The cord for most power tools connects directly to the tool switch through a wire terminal. Most switches are located in the handle of the tool. First remove the plate to the tool to expose the inside of the tool. You may have to remove more than one plate (for example on many tools, you may also have to remove the handle) Disconnect the wires from the terminals: Loosen the wire terminal screws with a small screwdriver and pull the wires out of the terminal. At this point, it is very important to note the route that the wires follow out of the terminal to connect to the plug. You need to route the new wires back in the same way or you may pinch the wires when you replace the handle. Once the wire terminals are loose, mark each wire with masking tape to ensure that the correct wires will be connected with the new cord. Cords with three pronged plugs usually have three wires and cords with two prongs usually have two wires. *Note that if you are also replacing the tool switch, many new switches require a different wiring pattern from the old one. See the manufacturers wiring diagrams for help with this. Taking out the old cord: Most tools have a retaining bracket that keeps the power cord secure and fastened in place. Remove the retaining bracket (most need to be unscrewed) and remove the old cord. The old cord will have the wires market with masking tape, so keep it nearby to help with positioning the new wires. Installing the new cord: Power cords are different for many types of models, based on the amperage and the voltage or the model (even the length of the cord is important). Make sure to buy the right replacement cord for the right tool. Click here for Ma kita Replacement Parts Click here for Bo sch Replacement Tool Parts Click here for DeWalt Replacement Tool Parts. If the new cord already has the wires stripped, you are ready to install it in directly. Stripping the Wires: If not you must strip the wires first. First, take a knife and cut the power cord jacket six inches, but be careful not to cut or damage the wires inside the jacket. The jacket is the flexible protective covering that surrounds the inner wires in the cord. Measure the new cord against the old one to make sure that the wire length is the same for the new cord. Use a pair of wire strippers to strip