How to Replace the Power Cord on a Porter-Cable Router

Can’t turn your router on? You might need a new power cord. The cord set is a two-wire power cord that has connectors already attached to it (for connecting the wires to the switch). Power cords tend to receive lots of abuse. The cord can be cut, nicked, internally damaged, or have the prongs broken off. A damaged power cord should be immediately replaced to avoid electrical shock and to safely operate the router.

Let's get started.

REMOVING THE POWER CORD   1. Remove the top cap.

a. Remove the (4) screws securing the top cap.

b. Remove the top cap.

  2. Remove the power cord.

a. Lift the rocker switch assembly out of the motor housing.

b. Remove the two screws securing the cord clamp to the power cord.

c. Remove the cord clamp from the power cord.

d. Disconnect the cord wires from the rocker switch. (Note the position of the wires for reassembly.)

e. Remove the cord protector from the power cord.

INSTALLING THE NEW POWER CORD 3. Install the power cord.

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

b. Install the cord clamp over the cord protector.

c. Secure the cord clamp with the two screws.

d. Connect the new power cord wires to the terminals on the rocker switch.

REASSEMBLING THE UNIT

  4. Reinstall the rocker switch.

a. Align the power cord with the opening on the side of the motor housing.

b. Tuck the wire connectors and wires into the motor housing (before installing the rocker switch).

c. Install the rocker switch into the motor housing.

d. Align the power cord and clamp assembly with the opening on the motor housing.

  5. Reinstall the speed control lever.

a. Install the speed control lever onto the motor housing (the notch on the lever fits over the tab on the speed control module).

  6. Reinstall the top cap.

a. Install the top cap.

b. Secure the top cap with the (4) screws.