How to Replace the Cord Protector on a DeWALT Circular Saw

The power cord passes through the cord protector as it goes into the saw's handle. The cord protector gives extra support to the cord, preventing it from kinking and rubbing against the handle. The cord protector is made of rubber and will eventually harden and crack. Once it does, the cord can tend to kink near the handle. This can lead to broken wires. Left unprotected, the cord can also rub against the handle housings, eventually rubbing through the insulation, leaving bare wires.

Let's get started.

REMOVING THE CORD PROTECTOR   1. Remove the top half of the handle.

a. Remove the screws securing the top half of the handle assembly to the lower half.

b. Lift the top half of the handle away from the assembly.

  2. Remove the cord clamp.

a. Remove the two screws securing the cord clamp to the lower handle.

b. Remove the cord clamp.

  3. Remove the power cord.

a. Lift the cord assembly and cord protector out of the lower handle.

b. Remove the wire nut connecting the white cord wires.

c. Loosen the screw securing the black cord wire to the switch and disconnect the black cord wire from the switch.

d. Remove the cord assembly and cord protector from the lower handle.

  4. Remove the cord protector.

a. Slide the cord protector off the power cord.

INSTALLING THE NEW CORD PROTECTOR

  5. Install the cord protector.

a. Slide the new cord protector onto the power cord.

REASSEMBLING THE UNIT

  6. Reinstall the power cord.

a. Connect the black cord wire to the switch.

b. Secure the black cord wire to the switch with the screw.

c. Connect the white cord wires and secure them with the wire nut.

d. Align the power cord with the slot on the lower handle.

e. Align the cord protector with the pocket on the lower handle.

f. Install the cord clamp.

g. Secure the cord clamp with the two screws.

  7. Reinstall the top half of the handle.

a. Tuck all exposed wiring into the lower handle.

b. Install the top half of the handle.

c. Secure the top half of the handle with the screws.