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There are many different models of Hoover Windtunnel so I can't be specific to your model, you will need to determine where the cord enters the unit and how to gain access to the internal wiring. Disconnect the old cord and attach the new cord using the proper connectors.
I am not sure of the motor wattage but it is unlikely to exceed 2kw and is probably much less so that sort of load being plugged into a power outlet capable of safely delivering a much larger current is unlikely to cause heating of the plug. That the plug did become hot indicates a poor contact between the supply cables and power outlet, between the power outlet and plug or what seems the most likely, between the plug and the power cord.
Given that the plug has been getting hot and that most breakdowns of portable appliances including vacs are internal breaks of the power cord usually at or somewhere near the plug, so that would be a good place to start testing...
Based on your description, ( first disconnect the plug from the wall recptacle).You will need to open up the Hoover Vacuum Body to gaion access to the internal wiring. In order to better assist you, please provide me with the specific hoover model. In general though, you will need to see where inside the Hoover that wire became detached and then rerun it. Since your cord is already broken, you may be able to strip back more of the outer cord insulation to expose the internal conductors and then route, cut to fit and reinstall them. Hope that helps.. If not, send model details,,,
http://geeksquad.fixya.com/ThreadView.aspx?prdid=618767&thid=632107 Replace interior hose for cleaning attachment for... Posted by castcomm on May 29, 2008 How do you dismantle handle to replace aforementioned hose? Swing arm on unit goes all the way to the floor. Is this normal? Is there a "stop" broken that caused the hose to stretch, and ultimately break? Hello, I would advise you to ALWAYS to FIRST UNPLUG YOUR VACUUM before beginning any service procedure.Hoover SteamVac Carpet / Upholstery Deep Carpet Cleaner. There are handle screws that you can get into the handle and then you can back track the replace the interior hose for the cleaning attachment. There should not be a stop that caused the hose to stretch ad break. The hoses after a while do get old crack and break due from normal use or if the bend @ sharp angles, this is common among all vinyl vacuum cleaner hoses. You should really check with your local factory authorized Hoover vac dealer in your area or , please feel free to contact your local vacuum cleaner dealer in your area or in the yellow pages, or contact the factory phone number or website to further assist you with your questions. http://www.hoover.com Telephone Contact our Customer Service Department at 1.330.499.9499 Monday through Friday 8 a.m. - 7 p.m. EST Thanks, Don the Vac Man Go Ahead. Use Us.
Very likely it's the cord at the nozzle neck. These cords flex when you vacuum and they often break internally where the cord goes into the neck. Turn the vacuum on and wiggle the cord at the powerhead and see if the powerhead comes on and off. If this happens, then you will have to replace the cord.
On some of the early models, the receptacle in the hose, where it plugs into the top of the wands, will break away from the plastic pins it sits in, and the receptacle will slide back into the handle, which means that it will not plug into the powerhead connection when you connect the hose. You can check this by looking at the end of the hose and observing if the receptacle is sitting flush with the opening it sits in. If it is pushed back, it will not make a complete connection with the powerhead cord that is sitting at the top of the wands.