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Repair Center  How to Replace the Power Cord on a Porter Cable Sander

Why Read This Article?

Finish Nailer Repair - Replacing the Driver Guide (Ridgid Part # 79004001022)

Article Breakdown

Finish Nailer Repair - Replacing the Driver Guide (Ridgid Part # 79004001022)

Video

Tools & Materials

Fix Factor: Easy Duration: About 30-40 minutes Frequency: As necessary Tools Required: Phillip's screwdriver, Torx drivers, large flat-blade screwdriver, hex wrenches, small screwdriver, long-nosed pliers, wire cutters, crimping tool, soldering gun, solder, paste flux, wire strippers, flag terminal Part #: 330072-98

Safety Guidelines

Wear safety glasses when using solderSafety glasses are recommended when working with solder.

How to Replace the Power Cord on a Porter Cable Sander

Finish Nailer Repair - Replacing the Driver Guide (Ridgid Part # 79004001022)
Replacing the power cord on a porter cable sander The Facts

Power cord cracked? It's time to face the fix. Whether you are a master carpenter or a seasonal sander, eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.

The cord on your sander takes a lot of abuse. As soon as damage is noticed, the cord should be replaced. Most forms of damage (such as nicks and cuts along the insulation) can by identified by visually inspecting the power cord each time the sander is used. The plug should also be inspected for missing or damaged prongs.

If you're planning to "pull the plug" on your Porter Cable random orbit sander, this article will show you how to complete the repair quickly and easily.

Let's get started.

The Fix REMOVING THE POWER CORD [top] 1. Remove the sanding pad.

Remove the (3) screws from the sander pad.

Remove the screws

 

 

Remove the sanding pad from the sander.

Remove the sander pad

 

 

  2. Remove the clutch belt.

Remove the clutch belt from the fixed pulley and the pad support pulley.

Remove the belt

 

 

  3. Remove the pad housing.

Remove the (2) screws from the pad housing.

Remove the two screws

 

 

Separate the two halves of the pad housing.

Separate the two housing halves

 

 

Separate the sander from the pad housing.

Separate the sander from the housings

 

 

  4. Remove the housing O-ring.

Use a screwdriver to pry the O-ring out of the groove in the housing.

Pry the o-ring

 

 

Work around the edges of the O-ring; stretching it around the pad support assembly as you move.

Remove the O-ring

 

 

Remove the O-ring from the sander.

Remove the O-ring

 

 

  5. Remove the pad support.

Grasp the fan to prevent the pad support from rotating.

Hold the fan

 

 

Remove the (1) screw from the pad support.

Remove the screw

 

 

Remove the pad support (and washer) from the sander.

Remove the pad support

 

 

  6. Remove the fan.

Slide the fan assembly off the spindle and away from the sander.

Remove the fan

 

 

  7. Split the motor housing.

Remove the (4) screws from the motor housing.

Remove the screws

 

 

Remove the top half of the motor housing.

Remove the housing top

 

 

  8. Remove the power cord.

Disconnect the white wire (containing the flag terminal) from the motor brush.

Disconnect the white wire

 

 

Lift the switch (and the black wire) out of the motor housing.

Lift the switch out

 

 

Loosen the screw that secures the black wire to the switch.

Loosen the switch screw

 

 

Disconnect the black wire from the switch.

Disconnect the black wire

 

 

Remove the power cord from the sander.

Remove the cord

 

 

Remove the cord protector from the old power cord.

Remove the cord protector

 

 

  PREPARING THE NEW POWER CORD [top] 9. Cut the wires to length.

Place the new power cord beside the old cord to compare the wires.

Compare the cords

 

 

Use wire cutters to cut the wires to match the length of the original wires.

Cut the wires

 

 

  10. Install the cord protector.

Slide the cord protector onto the new power cord.

Install the cord protector

 

 

  11. Prepare the wires and hardware.

Use wire strippers to strip approximately one-quarter of an inch of insulation from each of the two wires.

Strip the wires

 

 

Twist the ends of the exposed wires to prepare them for installation of the terminals.

Twist the wires

 

 

Use wire cutters to remove the extra tab from the flag terminal. (The tab is used during the manufacturing process and is not required for installation of the terminal).

Cut the tab

 

 

Install the flag terminal onto the WHITE wire.

Install the flag terminal

 

 

Use crimpers to secure the flag terminal to the white wire. (Flag terminals are usually installed by a machine at the factory. Because of this, they can be difficult to install by hand. However, we will be using solder to secure the flag terminal, so it is only necessary to crimp the connection sufficiently to hold it in place until the solder is applied.)

Crimp the connector

 

 

  12. Solder (and tin) the wires.

Apply paste flux to both sets of wires (and to the base of the flag terminal).

Apply flux to wires

 

 

Use a soldering gun (and solder) to secure the flag terminal to the white wire.

Solder the white wire

 

 

Use a soldering gun (and solder) to tin the end of the black wire.

Tin the black wire

 

 

  INSTALLING THE NEW POWER CORD [top] 13. Install the power cord.

Install the black wire into the switch.

Install the black wire

 

 

Secure the black wire to the switch with the screw.

Secure the black wire

 

 

Connect the white wire (the flag terminal) to the motor brush.

Connect the white wire

 

 

  REASSEMBLING THE UNIT [top] 14. Tuck the wires.

Install the switch assembly into the recess in the motor housing.

Install the switch

 

 

Tuck the black wire into the channel along the top of the motor housing.

Tuck the black wire

 

 

Install the cord protector into the recess in the motor housing.

Install the cord protector

 

 

Tuck the insulated portion of the power cord (containing both sets of wires) into the channel in the motor housing.

Tuck the power wire

 

 

Tuck the white wire into the channel in the motor housing.

Tuck the white wire

 

 

  15. Reinstall the top half of the motor housing.

Install the rubber bumper into the recess on the motor housing.

Install the rubber bumper

 

 

Visually inspect the wires for potential pinch-points; adjust the wires as necessary.

Inspect the wires

 

 

Install the top half of the motor housing.

Install the top housing

 

 

Secure the motor housing with the (4) screws.

Secure the housing

 

 

  16. Reinstall the fan.

Slide the fan onto the spindle.

Install the fan

 

 

  17. Reinstall the pad support.

Install the pad support onto the sander.

Install the pad support

 

 

Install the washer onto the pad support. (The side with the recess should be facing away from the bearing).

Install the washer

 

 

Secure the pad support with the (1) screw.

Secure the pad support

 

 

  18. Reinstall the housing O-ring.

Install the housing O-ring into the groove on the motor housing.

Install the housing O-ring

 

 

  19. Reinstall the pad housing.

Install one half of the pad housing onto the sander (the seam should align with the seam on the motor housing).

Install the pad housing

 

 

Install the second half of the pad housing onto the sander.

Install the second pad housing

 

 

Secure the pad housing with the (2) screws.

Secure the sides

 

 

  20. Reinstall the clutch belt.

Install the clutch belt onto the fixed (small) pulley.

Install the clutch belt

 

 

Stretch the clutch belt onto one side of the pad support.

Stretch the belt into position

 

 

Rotate the pad support to seat the clutch belt.

Rotate the pad

 

 

  21. Reinstall the sanding pad.

For easy alignment: Pass a small screwdriver through one of the screw holes on the sander pad; then insert the end of the screwdriver into one of the holes on the pad support.

The easy way

 

 

Install the sanding pad.

Install the sanding pad

 

 

Secure the sander pad with the (3) screws.

Secure the pad The Finish

Sanding can be a demanding task. But you don't have to rough-up your accountant to smooth-out your countertops. As you just learned, repairing your own power tools is simple when you follow our step-by-step guides. Not only did you expand sander functionality at a fraction of the cost of replacement; you have taken the edge off all future repairs.

Find your next fix here.   [top]

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