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Power Tool Repair Made Easy

Step 6New Power Cord

New Power Cord
Old tools and drills in particular tend to die from power cords. Here's how I put one on a Bosch jigsaw.

Power cords can be tricky to diagnose. Which is a good thing, because you'll get tools for free and they're easy to fix with random power cords.

I used to do a continuity test by shoving needles into the cable and hooking my meter's clips to those. That way I could find out just where the break was without messing up the insulation.
If it's just the plug at the end you'll want to replace that.
It's also easy to cut the cord and splice a new one on halfway.

Vincent gave me this one with no cord at all so the decision was already made.
I had a scavenged power cord, probably from a computer with the computer end cut off.
I wired it in. This tool had a clamp for keeping the cord from pulling out. If there isn't one of those you can improvise with wire ties or tying a knot in the cord.

Once I looked inside I saw it was an insulated case with no place for a ground attachment. So I cut the green ground wire off my cord. Then I broke off the ground pin from the connector so no one would get confused.

Older tools sometimes have a metal case that is grounded through the third pin. The theory there is that if any wires get loose and short inside, they'll short to the case and blow a fuse instead of electrocuting you.
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5 comments
May 18, 2010. 1:00 PMflamesami says:
What make is the knife in the 1st picture? or is it a custom one? I would appreciate it very much if you could tell me.
P.S. Is it good? It looks really nice, but I'm an ignoramus compared to many people on here.
Mar 27, 2008. 5:15 PMStonefeather says:
I am putting a new power cord on an old bench grinder I bought at auction, since the old one looks unsafe. I know the green wire on the new cord is the ground and I see how to attach it, but the old cord isn't color coded, so I don't know which wire is equivalent to the black and which to the white. How do I figure it out, or doesn't it actually matter? BTW, the new cord is a 14 gauge/15 amp cord, which the fellow at the store told me would be good. Is he right?
Jun 21, 2009. 11:33 PMpfred2 says:
Induction motors typically consider both hot and neutral L1 and L2 and it doesn't matter which is which. Now if you transpose the starter windings then it can matter. Then the motor would run the other way.
May 4, 2008. 9:12 PMchutamarque says:
Hi Mate, This is bloody easy, for a 240v or 110v supply blue ,black is negative (-) and postive is brown or red (+) earth are green or a greenyellow combo. Any other colours could mean a control circut -refer to maker -.thanks -
Apr 26, 2008. 8:45 PMicanryme2002 says:
well make a simple circuit with a battery and a led and test each wire
Feb 29, 2008. 3:30 PMredneck54601 says:
I have a possibly very stupid power cord question...what are the small holes on the end of the two prongs on a regular power cord (the part that plugs into the wall)?? My husband and I can't seem to find the answer. They don't exist on older power cords only newer ones.
Jun 21, 2009. 11:17 PMpfred2 says:
You can lock out the device by putting a lock or a wire through the holes.
Dec 9, 2008. 9:52 PMTheGreatNico says:
I was wondering that exact same thing a few months back, the holes are for the old-style sockets. The new sockets hold the plugs in by means of friction, the old style ones used two ball bearings that held the prongs in place.
Dec 24, 2008. 7:33 PMevanwehrer says:
I thoght it was because hospital electronics are made so that you cant unplug them and the outlet latches onto it.
Jun 21, 2009. 11:20 PMpfred2 says:
Only difference I've ever seen in spec grade outlets is the ground is isolated. That way faults to ground don't make patients end up looking up like Buckwheat if a fault to ground occurs on an unrelated piece of remote electrical equipment.

http://blogs.qc.cuny.edu/blogs/0209N0277/001/buckwheat.jpg
May 22, 2008. 12:03 AMRishnai says:
Seeing as, in my experience, both styles are interchangeable on old and new tools, in both old and new outlets, I'm assuming that's just a maddening quirk of the manufacturing process. Perhaps to save metal.
May 9, 2008. 9:08 AMDerin says:
maby because it holds on like that
May 6, 2008. 7:19 AMDerin says:
can you post me a pic of the plug?maybe i can help you
May 8, 2008. 12:45 PMFlatCat says:
If you look at the picture of the power cord in the instructable, in the "New Power Cord" segment for the Bosch jigsaw, it has the holes she is talking about...I don't know what they are for, either...
Jun 21, 2009. 11:22 PMpfred2 says:
I do. Posted why too to someone else in thread.
Jan 18, 2008. 9:09 PMpharmer1 says:
Great instructable. Thanks for sharing your knowledge :)

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Author:TimAnderson
Tim Anderson is the author of the "Heirloom Technology" column in Make Magazine. He is co-founder of www.zcorp.com, manufacturers of "3D Printer" output devices. His detailed drawings of traditional ...
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