Molly Ayala
Extension cords can be damaged in several ways, from pulling out the plug by the cord to running them over with vehicles. If you have a damaged extension cord, you don't have to throw it out. You can replace the electrical cord end by cutting off the old plug and attaching a new one. This involves using wire strippers to strip insulation from the cord, twisting the exposed wires, attaching them to the new plug, and securing them with screws. It's important to ensure that the wires are connected correctly and safely, as incorrect wiring can damage electronic devices or increase the risk of electrical shock.
| Characteristics | Values |
|---|---|
| When to replace | When the plug wears out or gets damaged |
| What to replace | Power cord plugs, power cords |
| Tools | Phillips-head screwdriver, flat-head screwdriver, wire cutters, wire strippers, utility knife, pliers, electrical tape, PVC shrink tube, duct tape |
| Preparation | Unplug the device, turn off the power at the breaker if the plug is damaged |
| Steps | Expose wires, twist strands together, bend into hooks, attach to prongs, thread cord through cover, align cord with wiring channel, insert cord through assembly clip, cut through outer jacket, split jacket, slide new plug over cord, attach wires to terminals, wrap wires around screws, close plug housing, wrap with electrical tape |
| Safety | Ensure wires don't touch, check for loose connections, test for correct wiring, monitor for overheating or unusual smells |
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What You'll Learn
Preparing the cord
Before you begin, make sure the cord is unplugged from any power source. If the plug is damaged but still plugged into an outlet, turn off the power at the breaker before unplugging.
If your cord is damaged, cut off the old plug and any damaged portions at the end of the cord using wire cutters. If your cord is in good condition, simply cut off the old plug.
Now, cut partially through the outer jacket of the cord with a utility knife, being careful not to cut through the insulation on the cord wires. The cut should be about 3 inches from the end of the cord. Then, split the jacket with your fingernails and peel the two sides apart.
Using wire strippers, strip about 3/4 inch of insulation from the end of each wire, exposing the copper wires. Be careful not to remove more of the insulated casing than necessary. If you don't have wire strippers, you can use a utility knife or another sharp tool, but be very cautious not to damage the electrical wires.
Finally, bend the copper portion of each wire into a U-shape or a small hook. This will make it easier and more secure to attach them to the new plug.
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Removing the old plug
Before attempting to replace an electrical cord end, it is important to ensure that the cord is unplugged from any power source. If the plug is damaged but still plugged into an outlet, turn off the power at the breaker before unplugging.
Once the power source is removed, you can proceed to cut off the old plug from the cord. Use wire cutters or a utility knife to carefully remove the old plug without damaging the cord. Cut through the insulation and wiring in one attempt, and then do the same on the other side of the plug to completely remove it.
After removing the old plug, you will need to strip the insulation from the end of the cord to expose the wires. Use wire strippers to remove about 3/4 inch of insulation, being careful not to damage the wires underneath. If you don't have wire strippers, you can use a utility knife or another sharp tool, but be extremely cautious to avoid cutting the wires.
Now that the wires are exposed, you will need to prepare them for connection to the new plug. Bend the copper portion of each wire into a U-shape or a small hook, which will make it easier and more secure to attach them to the new plug. At this point, you should also ensure that the wires are long enough to reach the terminals in the new plug. If they are too short, you may need to cut off more of the insulation to expose more of the wires.
By following these steps, you will have successfully removed the old plug and prepared the cord for the installation of the new plug. It is important to work carefully and pay attention to safety precautions when working with electrical cords to avoid any potential hazards.
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Attaching the new plug
Firstly, open the new plug housing. This usually involves using a screwdriver to unscrew the plug cover. Set the screws aside safely so they are not lost. The screws are typically located near the prongs or on the side of the plastic plug cover. Once unscrewed, gently pull and wiggle the plug open. You should now have two parts.
Now, carefully slide the new plug over the cut end of the cord. Ensure that the replacement plug has the same amperage and voltage ratings as the original cord, as indicated by the printed ratings on the plug. If your plug has two parts, only slide the outer shell onto the cord for now.
Next, attach the wires to the new plug. The wires must be plugged into the proper spots, as incorrect placement can be dangerous. The wire colours indicate their function and where they should be placed. For example, the ground wire is typically green, the neutral wire is white or blue, and the hot wire is black. Bend the copper portion of each wire into a U-shape or a small hook to make attaching them to the new plug easier and more secure.
Finally, close the plug housing and tighten any screws to secure it in place. Use electrical tape to wrap the area where the cord enters the plug for added protection and to reinforce the connection.
Once the new plug is attached, it is important to test the cord to ensure it is functioning correctly and safely. Inspect the plug to make sure all connections are tight and no bare wires are exposed. Plug the cord into a receptacle and use a circuit tester to check if the wires are hooked up correctly. If you do not have a circuit tester, carefully plug in a small appliance to test the cord. Monitor the plug for any signs of overheating or unusual smells during the initial test run.
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Connecting the wires
Before connecting the wires, ensure the cord is unplugged from any power source. If the plug is damaged but still plugged into an outlet, turn off the power at the breaker before unplugging. You can then cut off the old plug from the cord using wire cutters.
Now, it's time to connect the wires. Using wire strippers, strip about 1/2 to 3/4 of an inch of insulation from the end of each wire. This will expose the copper wires. Twist the exposed copper strands of each wire to prevent fraying when you attach them to the plug. You can also bend the copper portion of each wire into a U-shape or a hook, which will make attaching them to the new plug easier and more secure.
Next, open the replacement plug to access the terminal screws inside. The replacement plug must have the same amperage and voltage ratings as the original cord. These ratings are printed on the plug. Loosen each screw to open up enough room for a wire in each terminal. On some models, it may be easier to remove the screws completely. If you do remove them, set them aside so you don't lose them.
Finally, attach each exposed wire to the appropriate terminal screw. The wires must be plugged into the proper spots for the cord to work correctly and to avoid damage to electronic devices or an increased risk of electrical shock. Tuck the ends of the exposed wires clockwise under the screws, ensuring they don't touch each other. Work on the wires one at a time, connecting them to the proper cap terminals. Wrap each wire clockwise around its respective terminal and tighten the screws securely.
Once all the wires are attached, carefully tuck them into the plug housing, ensuring they remain separate and do not touch. Close the plug housing and tighten any screws that hold it together. You can use electrical tape to wrap the area where the cord enters the plug for added protection and to reinforce the connection point.
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Testing the new plug
Testing a new plug is essential to ensure your safety and that the appliance works correctly. The most important test is to check the voltage. This can be done using a multimeter, which is a handy and affordable tool that can be purchased by anyone.
To test the voltage, first, set your multimeter to measure voltage. Then, insert a probe into each slot, ensuring you hold the probes by the insulated parts only and do not touch any metal parts. The black lead goes on the left, and the red lead on the right. A properly functioning outlet will give a reading of 110 to 120 volts. If there is no reading, check the wiring and the outlet.
You can also check if your outlet is grounded by inserting the red lead into the smaller slot on the right of your outlet, and the black lead into the ground or rounded slot. If the reading varies, your outlet is not properly grounded.
To check for reversed wiring, insert the red lead into the larger slot on the left, and the black lead into the right slot. If you get a reading, your wiring is reversed. While this won't affect simple appliances, it can damage more advanced equipment.
Always remember to exercise caution when working with electricity. When conducting these tests, the power will usually be on, so be careful and follow the instructions that came with your multimeter.
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Frequently asked questions
If your cord has damaged sheathing, exposed wires, or other damage, it may be time for a replacement.
You will need wire cutters, wire strippers, a utility knife, a screwdriver, and electrical tape.
First, make sure the cord is unplugged from any power source. Then, cut off the old plug from the cord using wire cutters.
Strip about 3/4 inch of insulation from the end of each wire inside the cord. Twist the exposed strands of wire together and bend them into a hook. Loosen the screws on the new plug and attach each wire to the appropriate terminal screw. Tighten the screws and close the plug housing.
