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In this video, I will be showing you how to replace a damaged cord on your angle grinder. I will have three different examples using large 7 to 9 inch capacity angle grinders. The disassembly for each of the grinders does vary so this should provide a fairly good understanding of what to expect.
A cord should be replaced whenever you see any deterioration, cuts, cracks, or any other form of damage in the cord which can jeopardize your safety or others around you.
The first one here is a Fein (fine). Handle disassembly procedures will vary and depending on the age of your tools and if someone has disassembled it before, sometimes fasteners can get lost and replaced with things that are a close fit.
For this, four screws are holding the handle onto the main body.
Unfortunately, it can’t be fully disconnected from the main body, therefore the handle needs to be split in half, again more screws are holding it together.
These handles are typically packed with components and everything has a specific location. To be safe, you may want to take photos so you can remember the assembly procedure.
Here you can see the switch, along with where the wires are connected.
The cord will be clamped into the handle and this is to prevent it from pulling out. It also has a strain relief to reduce added stress on the cord when bending. Remove those two screws.
Now the switch can be lifted out.
Here are the contacts, the wire is clamped into place on the switch terminals.
Loosen those screws to remove the wires. Make note of which color of wire is located where. White is on the silver terminal and this is known as neutral. Black goes to the gold terminal and this is known as hot or power. Then there will be the green terminal which is for the green wire and that is ground. Once that wire is out, the strain relief can also be slid off. This grinder only requires a two-conductor wire and that consists of a power and neutral.
You’ll either have a two or three conductor wire, this can depend on your grinder. Next is also the size of the wire, all grinders shown in the video are 15 amp, therefore you’ll need the wire sized accordingly and this is also affected by the length of the cord used too. The cord for the grinder should be anywhere from 3 to 6 feet depending on your preference, it’s also better to be oversized than undersized.
The exterior casing was cut off using a razor knife, be extremely careful not to cut the insulation on the wires inside. If that happens, cut that section off and then start over. There will be a paper or fiber separator inside and then is also cut away flush with the exterior casing.
Using a wire stripper, remove the insulator, about a 1/4” but this can vary depending terminals.
Next to no conductor should be exposed outside of the terminal connection, however, that conductor should be firmly clamped inside without the chance of it pulling out.
Install the wire clamp so the components inside are in their proper places. Too much wire inside the handle can cause assembly issues.
Here’s a close up before everything gets put back together.
Now reassemble the handle. I did screw the one half of the handle in place first, made sure all the components were in place, then installed the other side. If you noticed the inside was clean, I did go all the components with contact cleaner and removed any dirt from the inside. The safety lock was also seized, so that was repaired as well.
For the plug, again these are available in two or three conductors so pick the correct one needed for your grinder. These also have amperage ratings as well and that is typically stamped on the casing. This is a two-conductor plug, as shown by the two prongs and is rated at 15 amps.
Disassembly can vary depending on the design. This model has screws on the face, once removed the face is removed and you can see the contacts inside.
Install the rear cap and make sure the clamp is loose.
Strip the exterior casing to the appropriate length, this casing should still be inside the plug.
Cut out the exposed paper or fiber separator.
Then strip the wires to the length of the terminals inside the plug.
Again match up the black with the gold and white with the silver. Wherever those clamp terminals are, make sure they’re tight. If not tight, they can cause heat due to a poor connection and loosen the connection further causing issues.
Reinstall the outer cap and tighten the screws.
Then tighten the clamp on the plug for the cord.
Once done, as you can see the grinder is functioning correctly and it’s safe to use.
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