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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 ½ inch of the insulation away from the wire. If you do not
have wire strippers, be sure to buy some, or borrow them from a
friend. Avoid the temptation to just strip the wires with a
knife, because that will often damage the wires and lessen the
power that goes to the motor. Twist the wires carefully with
lineman's pliers to make the best connection to the wire
terminals Put in the New Replacement Cord: Check the masking
tape labels on the old cord, to make sure that the wires are
connected correctly. Place the wires in the correct path to
avoid pinching the wires when the tool case in put back in
place. Secure the power cord back in place with the retaining
bracket. Replace the safety cover: You are just about finished!
Replace the safety cover of the tool. Again, be sure that all of
the wires are routed in the same path as they were originally.
Failure to do so may result in a pinched wire, which could
decrease the life of the tool, and even cause harm. Check the
Tool for Safety: The last step is to make sure that the tool is
safe to use. A bad electrical connection can pass electrical
current through the metal housing of the tool - this is a
serious danger for operation. A multitester is the best way to
ensure that the tool is safe. (A multitester measures the
resistance and current in electrical circuits. With the
multitester set to RX1 put one end to the plug and the other end
to the outside housing of the tool. There should be no
connection between the two.
Summary Proper tool maintenance may not seem that important when
tools are new. Today's power tools are built tougher than ever
before, and it seems that they are almost even designed for
abuse. However, no matter how tough a tool is, regular wear and
tear will take its toll. If you learn simple maintenance steps,
you can save a
About the author:
David Fairbanks is with eReplacementparts.com -
Power Tool Repair Parts - an online reseller of power tool
parts and accessories. They specialize in selling Ma
kita Repair Parts and Bo
sch Tool Parts.
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