- 1). Examine the new plug. If screws hold it together, unscrew them using an electrician's screwdriver. Put them safely to one side for use later. Other plugs may clip together. Open them by following the manufacturer's instructions.
- 2). Feed the cord through the cord hole in the housing of the new plug. Pull through a foot or two of cord so you can work without the plug housing being in your way. Cut away a couple of inches of the outer insulating sleeve covering the cord, taking care not to damage the insulation covering the three wires housed within it.
- 3). Slide each plug to the appropriate end of the cord so the end of the insulated cord cover rests on the cable clamp. Run the black hot wire to the brass terminal, the bare grounding (sometimes green) wire to the GND terminal, and the neutral white wire to the silver terminal. Cut the wires to length so each reaches the appropriate terminal.
- 4). Cut the colored insulation from the ends of the wires, using a knife. Leave about a quarter of an inch of bare metal at the end of each. If the wire is the braided type, twist it to wrap the fine strands together.
- 5). Wrap the bare wire ends around the terminals, or insert them through the holes, depending on the type of terminal. The grounding wire connects to the GND terminal, black to the brass terminal and white to the silver terminal. Tighten each terminal to firmly grip the wire. Remove any wire left protruding from the terminals.
- 6). Tighten the cord clamp around the cord, making sure it is over an insulated part of the cord, not the exposed wires. Adjust any trapped or stretched wires, as these can short and start a fire. Assemble the plug housing, and the plug is ready for use.
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