How to Replace the Power Cord on a DeWALT Polisher

The power cord is a two-wire, sixteen-gauge cord. Power cords tend to receive lots of abuse. The cord can be cut, nicked, internally damaged, or have the prongs broken. A damaged cord should be immediately replaced to avoid electrical shock.

Let's get started.

REMOVING THE POWER CORD   1. Remove the top half of the handle.

a. Remove the screws securing the top half of the handle to the lower half.

b. Lift the top half of the handle away from the lower half.

  2. Remove the power cord.

a. Remove the two screws securing the cord clamp to the lower handle.

b. Remove the cord clamp.

c. Remove the screw securing the switch to the lower handle.

d. Lift the switch assembly out of the lower handle.

e. Disconnect the two cord wires from the switch. (The wires are secured by 'trap door' connectors. To disengage the connectors, insert a small pick into the openings on the switch and pull the wires out of the switch.)

f. Remove the cord assembly from the unit.

g. Remove the cord protector from the power cord.

INSTALLING THE NEW POWER CORD

  3. Prepare the new power cord (tin the wires).

a. Using wire cutters, cut the wires on the new power cord to the length of the original cord wires (use the old cord as a template).

b. Use wire strippers to strip approximately 1/4-inch of insulation from the new cord wires.

c. Using a soldering iron, apply solder to the exposed ends of the new cord wires. (Tinning allows the wires to more easily engage the trap-door connectors on the switch.)

d. Install the cord protector onto the new power cord.

  4. Install the power cord.

a. Connect the two cord wires to the switch.

b. Install the switch assembly into the lower handle.

c. Secure the switch with the screw.

d. Align the cord protector with the slot on the lower handle.

e. Install the cord clamp.

f. Secure the cord clamp with the two screws.

REASSEMBLING THE UNIT

  5. Reinstall the top of the handle.

a. Tuck any exposed wires into the lower handle.

b. Install the top half of the handle.

c. Secure the top half of the handle with the screws.