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Unplug the iron: Make sure the iron is unplugged and cooled down before attempting to replace the cord.
Remove the cord from the iron: Depending on the model of your iron, you may need to remove a cover or panel to access the cord. Look for any screws or clips that hold the cover in place and remove them using a screwdriver. Once the cover is removed, you should be able to see the cord and the connections to the iron.
Disconnect the cord: Use a pair of pliers or a wire stripper to carefully remove the wire connectors from the cord. Be sure to hold onto the wire connectors so you do not lose them.
Attach the new cord: Follow the steps above in reverse to attach the new cord to the iron. Strip the ends of the wires on the new cord and attach them to the wire connectors. Be sure to connect the wires according to the correct polarity (i.e., positive to positive, negative to negative).
Replace the cover: Once the new cord is attached, replace the cover and secure it with the screws or clips you removed earlier.
Test the iron: Plug in the iron and test it to make sure it is functioning properly.
If you are not comfortable or experienced in electrical repairs, it is recommended to have a professional perform the cord replacement. Tampering with the electrical components of an appliance can be dangerous and can cause damage to the appliance or injury to the user.
You can buy replacement cords and ends at any decent hardware store to make your own cord. However you need to disassemble your iron to make the change. I would only recommend trying this if you are familiar with doing such a task, you wouldn't want to risk a misfire and causing a fire.
Terminal block is fastened/secured with body by a screw but before removing the terminal block from body, make sure that the iron element terminals are also disconnected. this can be done by opening the screws on other side of the cord terminals-3 in number as also in the cord. Otherwise the terminal block would not come out fully.In any case you normally do not need to remove the terminal block.
If you've had this iron for a while it sounds like the cord may be frayed. switch it off at the wall and unplug it, check the cord for wear, if the insulation is frayed, torn or broken and there are black burn marks on the cord where you saw sparks then the cord needs to be replaced. DONT plug the iron back in until the cord is replaced.
Otherwise If there are no breaks or black burn marks on the cord, then your power point may be faulty and needs to be replaced!
Thank you for using FixYa. Is the cord cut near the iron end or the outlet end? could the cord be shortened? A new cord can be purchased at most reasonable hardware stores and with a little care and attention can be replaced yourself.
In replacing the cord, you have to remove the screw that holds the back cover and unscrew the damaged cord from the heater terminal. Insert the new cord on the rubber insulator and screw it to the heater terminal.
If you can use a screwdriver you can probably do it yourself. Take all the screws out of the handle which should allow you to get to the cord. Determine how they have it attached to your unit. If it is spade lugs there could be a problem. If it is soldered there could be a problem. If they are screwed on we can proceed. Remove the wires and hookup your new cord which could be an old extension cord which is no longer any good. Put your unit back together and you should be good to go.
The back comes straight off. All you need to do is take a small screwdriver and pry against the bottom metal piece, then it should start to come off. Make sure you take it off carefully so as not to break anything. Pry evenly all around the plastic end cap until it comes off.
After that, you can replace the cord. It's connected via two crimp caps. Easy to replace. Just make SURE you purchase a cord rated for an iron.. DO NOT clip the plug end from an extension cord or similar and use it. The iron uses 16 gauge HEATER CORD. Easy to find, but you could melt your power cord and possibly cause a fire if you don't replace it with the correct type.
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