You can either patch the cord with insulating electrical tape (if the cord is not badly severed) or you can replace the cord entirely. The later choice is preferable for a more permanent repair.
To access the cord where it hooks up to the innards of your machine, you will need to crack open the vacuum cleaner's housing. Depending on how the manufacturer of you vaccum assembled the unit, you will need to disconnect the existing power cord from the main switch and motor. If you're fortunate, you will be dealing with solderless connectors inside your vacuum when you see where the power enters the unit. These are removed as simply as they are installed - just remove the terminals from their respective connectors. On the other hand, you may be dealing with a combination of terminals and *soldered* connnections inside your unit. For soldered connections, you will need to desolder them (an pencil type soldering iron will do). If you don't feel comfortable using a soldering iron, find someone nearby who is.
When replacing the cord on your unit, make doubly sure that you find a replacement cord that exactly matches the old cord. The gauge of the wires inside the cord must be the same, as well as the insulation type. Keep your old cord and take it with you to a hardware/vacuum repair center for a perfect match. *Never* replace an old power cord with a substitute cord that has a *lower amperage rating* than the original. This rating will be printed on the cord itself or on a back panel of your vacuum cleaner.
Once you have replaced the cord, and everything looks okay, reaassemble the unit as it was taken apart and power up the vacuum cleaner. Make note of any unusual smells or sounds if they occur. If they do, immediately turn off the vacuum and check over your work looking for any possible shorts inside the housing. On the other hand, if everything checks out okay and the vacuum cleaner is working as normal, congratulate yourself on a job well done.
Bruce Gilliz, May 2004
