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Repair Center  How to Replace the Cord Protector on a DeWALT Angle Grinder (Model D28402)

Why Read This Article?

FOLLOW-AND-FIX: Step-by-step instructions and illustrations walk you through the entire repair process. GRINDING DEFINED: Learn to identify and replace related components while performing this repair. ANGLE MANAGEMENT: Restore angle grinder functionality at a fraction of the cost of offsite repair.

Article Breakdown

Removing the Cord Protector 1. Remove the handle. 2. Separate the case. 3. Remove the cord clamp. 4. Remove the power cord. 5. Remove the cord protector. Installing the New Cord Protector 6. Install the cord protector. Reassembling the Unit 7. Connect the cord. 8. Reinstall the switch. 9. Reconnect the handle. 10. Reinstall the lock-on button. 11. Reinstall the paddle. 12. Secure the handle.

Video

Tools & Materials

Fix Factor: Easy Duration: 10 minutes Frequency: As necessary Tools Required: Phillip's screwdriver, small screwdriver

How to Replace the Cord Protector on a DeWALT Angle Grinder (Model D28402)

February 19, 2015
Fixing things makes sense. This article will help you make sense of replacing the cord protector (strain relief) on a DeWALT D28402 angle grinder.
How to replace the cord protector on a DeWalt angle grinder The Facts

If broken parts and faulty starts are grinding on your nerves, it's time to face the fix. Whether you are a grinding pro or seasonal grinder, eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.

The cord protector (aka, "strain relief"), protects the cord wires from pulling out of the grinder. Over time, the cord protector can develop cracks and abrasions. It can also break when severely impacted or bent into extreme positions. The cord protector should be replaced as soon as damage is detected. Replacing the component is easy to do. And this simple repair will protect your grinder's cord (and your wallet) from sustaining further damage.

This article provides step-by-step instructions for replacing the cord protector on a DeWALT D28402 angle grinder. Let's get started.

The Fix   REMOVING THE CORD PROTECTOR [top] 1. Remove the top half of the handle assembly.

Remove the (5) retaining screws.

Remove the screws

 

Remove the top half of the handle assembly.

Remove the top half

 

  2. Separate the handle from the field case.

Remove the paddle assembly.

Remove the paddle

 

Remove the lock-on button assembly.

Remove the lock-on button

 

Separate the rear housing from the front.

Separate housing

 

  3. Remove the cord clamp.

Remove the clamp retaining screws.

Remove the screws

 

Remove the cord clamp.

Remove the clamp

 

  4. Remove the power cord.

Lift the cord and switch assembly out of the handle.

Lift the cord and switch

 

Remove the screws connecting the cord to the switch.

Remove the screws from the cord

 

Remove the power cord from the grinder.

Remove the cord

 

  5. Remove the cord protector.

Slide the cord protector off the power cord.

Remove the cord protector

 

  INSTALLING THE NEW CORD PROTECTOR [top] 6. Install the cord protector.

Slide the new cord protector (strain relief) onto the power cord.

Install the cord protector

 

  REASSEMBLING THE UNIT [top] 7. Connect the power cord to the switch.

Align the eyelets with the mounting holes on the switch.

Align the eyelets

 

Secure the connections with the screws.

Secure the cord

 

  8. Reinstall the cord / switch assembly into the handle.

Reinstall the switch into the handle.

Install the switch

 

Reinstall the cord and cord protector into the handle.

Install the cord

 

Tuck the cord wires into the handle.

Tuck the cord wires

 

Reinstall the cord clamp.

Install the clamp

 

Secure the cord clamp (and switch) with the screws.

Secure the clamp

 

  9. Reconnect the handle assembly to the field case.

Partially connect the lower half of the handle assembly to the field case.

Partially assemble the halves

 

Tuck the wires into the designated slots and channels on the assembly.

Tuck all wires

 

Connect the lower half of the handle to the field case (manipulate the two components until they “snap” into place).

Snap the halves together

 

  10. Reinstall the lock-on button.

One side of the lock-on button contains a small tab. This tab should be installed facing the armature.

Align the tab with the armature

 

Install the lock-on button into the handle.

Install the lock-on button

 

  11. Reinstall the paddle assembly.

Install the paddle assembly into the handle; ensure that the “tail” is positioned above the switch button, and the “fulcrum” is seated within the recess in the handle.

Install the paddle

 

  12. Reinstall the top half of the handle assembly.

Partially install the top half of the handle assembly.

Align the handle cover

 

Align the posts (on the fulcrum and the lock-on button) with the recesses in the top of the handle.

Align the posts

 

Before securing the handle with the screws, test the paddle and the lock-on button for proper functionality.

Test the buttons

 

Secure the handle with the screws.

Secure the cover

  The Finish

You can't place a value on a job well done, unless you did it yourself. (Which you did.) Now you can place that value back into your own pocket. (Or into your business.) Not only did you refine your grinder at a fraction of the cost of replacement; you have expanded your skills far beyond the daily grind.

Find your next fix here.   [top]

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