HOW-TO: Replace the power cord on your DD40 with a plug-it
Sept 14, 2013 8:02:09 GMT -5
alvychippy likes this
Post by jonathan on Sept 14, 2013 8:02:09 GMT -5
As promised, I wrote an easy to follow 17 step-by-step tutorial on how to replace the power cord of your Mafell DD40 Duo Doweler with a Festool plug-it connector.
I estimate the time needed to complete this tutorial to be around 40 minutes.
By the way, I can guarantee the method described here, is more or less identical for the DD40P, P1cc and MT55cc, as this is the way I've done it to all 3 of mine.
The tools and components used/needed:
Step 1: Mark the end of the protective insulation coming out the back of the machine.
You can use painter's tape like I did, a pencil, permanent marker, it doesn't matter, just mark it somehow.
Step 2: Unscrew the back cover and carefully slide it back to reveal the electronics.
Step 3: Unscrew both wires from the green wire terminal connector and free the power cord.
Step 4: Pull the cord through the protective insulation at the back of the cover.
Step 5: Now let's prepare our plug-it connector. Start by taking it out of the box.
Step 6: Disassemble the plug-it connector.
Step 7: Referencing off the original power cord, mark the overall length of the plug-it and where you will need to strip the green insulation.
Again you can use painter's tape, a pencil, a permanent marker, whatever works for you.
Step 8: Cut your plug-it connector to length.
Step 9: Using your box cutter carefully cut the green insulation and pull it off, exposing the brown & blue wires.
Then using your wire stripper, strip the end of the brown & blue wire.
Be careful not to damage the insulation of either the brown or blue wire!
Step 10: Reassemble your plug-it connector.
Your plug-it connector now has the right length and ready to be attached to the DD40.
Step 11: Insert the plug-it connector through the protective insulation on the back of the cover.
Step 12: Roll the copper wires at the end with your fingers so the tiny individual wires don't fray.
For those that want to be really thorough, you can of course always put some solder on the ends.
Step 13: Screw the wires of the plug-it connector back into the green wire terminal connector of the DD40.
Step 14: We'll need some room to work, so disassemble the Plug-It connector.
This will provide us with the space needed to securely clamp the plug-it connector in place.
Step 15: Loop the wires and clamp the green insulation in the red bracket. Screw it securely in place.
If by the end of the tutorial you notice your plug-it connector does not mate up nicely with the plug-it, adjust where you clamp the green insulation by clamping it further down. You'll see soon enough when you finish step 17 wether or not you need to revisit this step.
Step 16: Carefully slide the back cover over the electronics and securely tighten the screw on the back.
Step 17: Re-assemble the plug-it connector.
If you notice your Plug-It connector doesn't nicely mate up with the protective insulator, go back to step 15 and adjust the position where you clamp the green insulation of the Plug-It.
Congratulations!
You've now successfully modified your DD40 to work with a Festool Plug-It power cord without damaging your tool or voiding your warranty. If for whatever reason you ever need to send your DD40 in for maintenance or repairs, you can simply unscrew the plug-it and re-attach your original power cord.
I know it might look complicated with all the pictures, but it's really just 3 simple steps. I just tried to take a picture of every operation.
I hope this guide is useful and easy enough to follow. If there are any questions, please feel free to ask and I'll do my best to answer.
Enjoy!
I estimate the time needed to complete this tutorial to be around 40 minutes.
By the way, I can guarantee the method described here, is more or less identical for the DD40P, P1cc and MT55cc, as this is the way I've done it to all 3 of mine.
The tools and components used/needed:
- Mafell DD40 Duo Doweler
- Festool plug-it connector
- Painters tape, pencil or permanent marker
- Philips 1 or pozidrive 1 bit/screwdriver
- Torx 15 bit/screwdriver
- Torx 20 bit/screwdriver
- Small flat electrical screwdriver
- Box cutter
- Wire cutters
- Wire strippers
Step 1: Mark the end of the protective insulation coming out the back of the machine.
You can use painter's tape like I did, a pencil, permanent marker, it doesn't matter, just mark it somehow.
Step 2: Unscrew the back cover and carefully slide it back to reveal the electronics.
Step 3: Unscrew both wires from the green wire terminal connector and free the power cord.
Step 4: Pull the cord through the protective insulation at the back of the cover.
Step 5: Now let's prepare our plug-it connector. Start by taking it out of the box.
Step 6: Disassemble the plug-it connector.
Step 7: Referencing off the original power cord, mark the overall length of the plug-it and where you will need to strip the green insulation.
Again you can use painter's tape, a pencil, a permanent marker, whatever works for you.
Step 8: Cut your plug-it connector to length.
Step 9: Using your box cutter carefully cut the green insulation and pull it off, exposing the brown & blue wires.
Then using your wire stripper, strip the end of the brown & blue wire.
Be careful not to damage the insulation of either the brown or blue wire!
Step 10: Reassemble your plug-it connector.
Your plug-it connector now has the right length and ready to be attached to the DD40.
Step 11: Insert the plug-it connector through the protective insulation on the back of the cover.
Step 12: Roll the copper wires at the end with your fingers so the tiny individual wires don't fray.
For those that want to be really thorough, you can of course always put some solder on the ends.
Step 13: Screw the wires of the plug-it connector back into the green wire terminal connector of the DD40.
Step 14: We'll need some room to work, so disassemble the Plug-It connector.
This will provide us with the space needed to securely clamp the plug-it connector in place.
Step 15: Loop the wires and clamp the green insulation in the red bracket. Screw it securely in place.
If by the end of the tutorial you notice your plug-it connector does not mate up nicely with the plug-it, adjust where you clamp the green insulation by clamping it further down. You'll see soon enough when you finish step 17 wether or not you need to revisit this step.
Step 16: Carefully slide the back cover over the electronics and securely tighten the screw on the back.
Step 17: Re-assemble the plug-it connector.
If you notice your Plug-It connector doesn't nicely mate up with the protective insulator, go back to step 15 and adjust the position where you clamp the green insulation of the Plug-It.
Congratulations!
You've now successfully modified your DD40 to work with a Festool Plug-It power cord without damaging your tool or voiding your warranty. If for whatever reason you ever need to send your DD40 in for maintenance or repairs, you can simply unscrew the plug-it and re-attach your original power cord.
I know it might look complicated with all the pictures, but it's really just 3 simple steps. I just tried to take a picture of every operation.
I hope this guide is useful and easy enough to follow. If there are any questions, please feel free to ask and I'll do my best to answer.
Enjoy!
