How to Replace the Cord Guard on a DeWALT Chop Saw (Model D28715)

Saw chopping into your budget? It's time to face the fix. Whether you are a commercial contractor or a weekend welder, eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.

The cord guard protects the power cord where it enters the saw's handle. Without the cord guard, the cord could be easily kinked, cut or otherwise damaged. Over time, the cord guard will harden and become brittle. Eventually, it will crack or break off. Once this happens, cord damage is just around the corner (unless you replace the cord guard).

This article provides step-by-step instructions for removing and installing the cord guard on a DeWALT chop saw (model D28715).

Let's talk chop.   REMOVING THE CORD GUARD [top] 1. Unplug the saw.

Disconnect power to the saw.

      2. Remove the handle.

Remove the screws securing the top half of the handle.

Lift the top half of the handle away from the lower half.

  3. Disconnect the switch.

Remove the screw securing the switch to the lower handle.

Lift the switch assembly (and wires) away from the lower handle.

Remove the screws securing the two power (cord) wires to the switch assembly.

Disconnect the cord wires from the switch.

  4. Remove the cord guard.

Remove the (2) screws securing the metal cord clamp to the lower handle.

Remove the cord clamp.

Pull the cord wires out of the holders in the lower handle.

Remove the power cord from the saw.

Remove the cord guard from the cord.

    INSTALLING THE NEW CORD GUARD [top]  5. Install the cord guard.

Install the new cord guard onto the power cord.

  REASSEMBLING THE UNIT [top] 6. Reinstall the power cord.

Align and install the cord protector into the slot on the lower handle housing.

Rotate the cord (within the cord protector) to align the white and the black wire pairs.

Adjust the cord (within the cord protector) until the cord insulation extends approximately three-quarters of an inch beyond the cord clamp.

Install the cord clamp.

Secure the cord clamp with the (2) screws.

  7. Reconnect the switch.

Secure the black wire to the switch (with the screw).

Secure the white wire to the switch (with the screw).

  8. Install the switch into the handle.

Install the switch assembly into the lower handle.

Secure the switch to the lower handle with the screw (using the hole closest to the body of the switch).

Tuck the switch wires and the cord wires into the channels on the lower handle.

      9. Reinstall the top half of the handle.

Install the top half of the handle.

Secure the handle with the screws.

Do-it-yourself repairs like these are easier than you might think: From lawn machines to cordless drills, kitchen mixers to outdoor grills. Our "how-to" articles walk you through each repair from start to finish.

So, doing-it-yourself means never having to do it alone.

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