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If your unit is under warranty, contact the manufacturer first to have the cord replaced by professionals.
Read through these instructions carefully. If you are not completely happy about tackling this yourself, find a repair shop and spend the extra money to have it done correctly. Be sure to have removed the electrical cord from the outlet before you start the work.
Check the availability of videos on popular sites with respect to opening the casing of a Dremel.
You will likely need a special screwdriver - My Dremels use splined screws. Your local hardware store or electronics supplier should have what you need.
Obtain a replacement electrical cord for your model.
Loosen the casing screws carefully and put them somewhere safe - use an empty yoghurt pot or an empty matchbox.
Remove the end cap near the chuck.
Carefully prise apart the two halves of the Dremel. Watch out for the locking pin and spring metal band that you push to lock the spindle when you loosen the chuck - they will fall out.
If there is resistance or the two halves are not coming apart easily, check to make sure you have removed all of the screws properly.
With the two pieces apart, look carefully at where the locking pin and spring metal band fit before proceeding. Take a photo with a camera or your cellphone - make sure it's in focus. Check the shots you take before continuing.
Look at the arrangement of wires that connect from the electrical cord. Make sure you double check the colours.
Match up your replacement cord.
Carefully loosen (but don't remove) the screws holding the cord on to the circuit board.
Carefully loosen (and remove) the screws holding the cord grip to the casing.
Carefully withdraw the old cord.
If the new cord does not have a strain relief fitted, you will need to remove the existing strain relief and fit it to the new cord.
Offer up the new cord following your photos from earlier to get the correct connections.
Carefully tighten the screws holding the cord to the circuit board.
Adjust the cord in the cord grip. Fit the strain relief into the casing.
Replace the other half of the cord grip and insert the cord grip screws. Tighten these screws.
Fit the locking pin and spring metal band back into the casing and carefully align the two halves. There should be very little resistance. Make slight adjustments to ensure the internal parts match up with the corresponding parts of the casing.
With the casing closed and no gaps around the casing, grip it tightly closed with one hand and turn the chuck with your other hand. It should run easily. If not, something is jammed. Re-open the casing and locate the part that is jamming and try again.
When the two halves are together and the chuck and spindle run free, replace the end cap to keep the two halves together.
Replace the screws in the casing to keep it together.
Try the spindle one last time to make sure that it spins freely.
Plug the unit into the mains outlet and try it.
Hope this helps.
These instructions are not meant as a complete guide for the replacing of power cords for Dremels. You should undertake to research how your device is disassembled before attempting this procedure. Following safety advice and knowing how your power tools operate can reduce the likelihood of personal injury.
I have successfully replaced power cords, speed controllers and armatures in Dremels based on my qualifications in Electronic and Communications Engineering. I have been repairing electrical and electronic equipment since 1982.
Open the case, locate the two AC wires and detach. Get new cord and replace as per the previous wire attachments.
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