How To Wire A Plug?

By January 7, 2015News

250Rio plug

Lets go through the stages in a simplified way of how to wire a plug.

  1. Unscrew the philips screw in the centre of the plug using a philips head screwdriver and remove the cap off the plug.
  2. Unscrew the the two mini screws to release the clamp. Remember to not unscrew these fully.
  3. Remove one of the bottom screws and put in a safe place. Keep the other screw attached to the clamp and move the clamp to one side.
  4. Inside the plug you will notice there will be three terminals with the earth (Green & Yellow wire) Live (Brown wire) and Neutral (Blue Wire)
  5. Unscrew all the mini screws on each of the terminals using a flathead screwdriver preferably with a small flathead.
  6. Use the small flathead to unhook the wires from each of the terminals. Now you can repair the cable.
  7. If the internal cables are frayed and need repairing use wire strippers to repair the internal cables and insert the internal cables back into the plug. However if this is not the case then cut the sheaf and start again.
  8. Using a pair of pliers cut the outer sheaf of the cable, making sure the internal wires are not damaged whilst you are cutting. Indenting might be a good idea when you need to release the outer sheaf to reveal the internal wires. I would suggest you make sure there is at least 2 inches of Earth (yellow and green) Blue ( Neutral) and Live (brown) internal wires, this will give you a chance to cut the internal wires down to size.
  9. Using a wire stripper cut the top of each of the coloured inner cables to expose 1 cm of copper wiring.
  10. Twist the copper wire to fit in a much smoother way in each of the terminals which is located inside the plug.
  11. Open a plug by following steps 1 – 3 and place the new repaired cable in the plug. The coloured wires should always be past the clamp area. Now sometimes you can forget where each of the internal cables go. Well in most UK plugs if you look very closely the writing for each internal cable is located at the side of each terminal.
  12. When inserting each of the internal wires you can raise the terminal heads, this will make it much easier for you to place them inside. I suggest you work from right to left. Here is another tip – Some people like to screw the clamp over the outer cable this stops any movement.
  13. Start with the brown cable then screw this into the terminal making sure you can’t see any copper. Use a small flathead screw driver.
  14. Repeat this process for green and yellow cable which is located at the top of the plug. Use a small flathead screw driver.
  15. Repeat this process again for the Blue cable which is located on the bottom left of the plug. Use a small flathead screw driver.
  16. Move the clamp over the white or black outer cable and screw the clamp tightly shut and this keep the wire in place. Use a philips screw driver.
  17. Screw the cap of the plug very tight with a philips screw driver and you now have repaired, wired and fitted a new plug.