After a few years, an electrical cord plug may get worn out from heat, bent out from being pulled out of the wall or it may even get cut in half from a lawnmower, a hedge trimmer or something else. Some people may throw away the item with the damaged cord thinking that there was nothing more to be done with it. However, fixing an electrical cord plug is a very simple, cheap process that takes very little time and patience. (Which is good because I have neither).
Step 1:
Buy a plug of the same amperage. If it was a grounded plug make sure the one you buy is as well.
Step 2:
Using wire cutters cut the cord about an inch from the broken plug. Strip off the casing to expose the 2 or 3 wires.
Step 3 Inspect the old plug, if it had two prongs and they are identical in size, then you may connect either wire to the connectors in the new plug.
If the old plug had different size prongs or a grounding prong, then you must match the hot, neutral and ground (if present) wires from the power cord to the proper connectors in the new plug. While it should still run regardless of how you connect them, the safety of the device may be compromised if you fail to properly match the hot wire to the narrow prong on the new plug. The wide prong is always neutral and so the neutral wire should be connected to it. In the USA the wires are typically color coded, white is usually neutral, black or red is hot and green is ground. If you can't determine which wire is which, refer to the old plug. Match up the power cord with the old plug and follow the wire that leads to the narrow prong. You may also test the device with ohm meter to find which wire connects to the switch (the hot should connect to the switch).
Step 4:
Pull the wires through the back of the plug and pull them through to the front. Once you have the plug semi-assembled, cut off any excess wire that wont be needed. Excess wire may make reassembly difficult or may result in wires that are protruding from the plug.
Step 5:
Using a wire stripper, strip off roughly 1/2 inch of insulation to expose the metal wire.
Step 6:
Connect the hot wire to the narrow blade prong, the neutral wire to the wide blade prong and the ground wire to the rounded blade prong. If there is no ground just do the hot and neutral wire.
Step 7:
Make a little loop with the and place it clockwise under the screw terminal so that when the screw is tightened it will draw the wire in rather than push it out. Now tighten down the screw. Repeat for each wire. Now you're done and if you did it correctly the plug is as good as new.
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