It’s that time again, you walked outside to your RV, generator, Ect. and noticed that your power cord has burned up, or you need a special adapter. Save some cash by installing your own assembly plugs and connectors, and make the cord you need for cheaper than a molded unit.
You do not have to be an experienced electrician to be able to make a power cord or adapter. In fact, you only need a few small hand tools and a little elbow grease to make it happen. Install your own plug or connector onto a new or existing cord by following our short instructions with pictures!
What you need
• Flat-Head Screwdriver
• Phillips-Head Screwdriver
• Razor Blade
• Wire Strippers
• Measuring Tape
• Proper wire for the job
• Assembly Plug / Connector (We used a Conntek ASTT-30P, found here for under $20)
(If you don’t know what connection you have try our RV Connection Infographic to find the name)
1. Remove the Wire Jackets
The outer insulation is very thick, but must be cut very delicately, as this jacket protects the inner 3 wires! Depending on your assembly part you will need to remove a certain length of this jacket. It just so happens our instructions say to cut about 2.5″ off.
Carefully measure, and score a line through the jacket just enough to break he surface. Then take the cord and bend it at the cut you just made to force the jacket to tear away from the other wires. Remove by hand.
After you remove the jacket you should end up with something like this. Looking good!
So you have your wire with the outer jacket removed like the picture above. Now you need to remove the inner wire jackets that protect the copper strands. Once again go by what the manufacturer suggests. Our was about 0.5″ (long enough to fit into the terminals of the assembly end but not expose any extra copper)
Give the copper strands a light twist to keep them together, and your wire is ready to be installed into the assembly part.
2. Disassemble your Wiring Device
It is time to start taking apart your wiring device. Most of them will have screws that will hold the terminal housing in place, and must be removed to wire your cord. Start by removing these screws, and pull the terminal housing out.
Our model has a cable clamp at the other end and might need to be loosened a bit to feed the cord. Other models might come with a “screw-off,” rear clamp with small washers that clamp onto the cable as you tighten it (Like this model). If you have this model just make sure to set these parts off to the side and remember the orientation of how they came out for later on!
Now your wiring device should be taken apart so you can start the wire it!
3. Feed Wires Through the Housing
Once you have the terminal housing out of the way, you can feed your newly stripped wires into the empty assembly housing, you may need to give it a little push as the wires can be a little stiff. Make sure to pay close attention to the orientation of the wires, and the terminals they are going to be wired to.
4. Wiring the terminals
Follow the instructions by your manufacturer and wire each terminal based on the color of its jacket. The terminals should be labeled individually by the color of the inner jacket wires. G, B, W Ect.
Simply slide each stripped copper end into the correct terminal, and hand tighten (Hand tighten!) the terminal screws with the correct screwdriver to secure the wires in place.
Once every wire is in the correct place you can now proceed to re-assembling your plug / connector.
6. Re-Assemble your Wiring Device
You are on the home stretch. Reassemble the wiring device by gently pulling the cord back away from the assembly housing, while guiding the terminal housing back into the proper orientation as you received it.
Line up the screws on the terminal housing and hand tighten them to secure the device back in place. You do not have to crank them down, hand tight is good enough!
And your last step will be to tighten the cable clamp to hold it in place for good! Some models will have a “screw-on,” style mentioned above like this model. Just make sure to get it nice and tight, and you are all done! Pat yourself on the back.
Need to find Assembly parts for your RV or generator? Find it at: www.conntek.com , or send us an inquiry and we can help you find it!!