Black & Decker KW800 User manual

KW800
KW800E
KW800_E UK p01-12 16-01-2001, 13:111

Congratulations!
Onthepurchaseofyour
Black&Deckerrouter.
Toensurethebestresultsfromyourrouter
pleasereadthesesafetyandusage
instructionscarefully.
Ifyouhaveanyquestionsorqueriesafter
readingthisusermanualpleasedonot
hesitatetocallourServiceandInformation
Centre,whosenumberyouwillfindtowards
thebackofthisusermanual,or oneofour
AuthorisedRepairAgents.Alistofthese
Agentsandfurtherinformationisavailableon
theInternetatwww.2helpU.com.
KW800_E UK p01-12 16-01-2001, 13:112

Contents
Page4 Safetyinstructions
Doubleinsulation
Page5 Electricalsafety
Mainsplugreplacement
Extensioncables
Unwantedtoolsandtheenvironment
TheBlack&Deckerguarantee
AftersalesserviceforyourBlack&Deckerproduct
Page6 Ouraftersalesservicepolicy
Accessories
Technicaldata
Features
Operatingyourrouter
Page7 Fittingtherouterbit
Adjustingthedepthofcut
Usingapieceofwood
Usingthescale
Page8 Fineadjustmentwiththetripledepthstop
Fittingtheedgeguide
Alternativeguidemethod
Fittingthevacuumadaptor
Fittingthetemplateguide
Electronicspeedregulation
Usingthedistancepiece
Page9 Usingthecentringpin
Usingthecopyfollower
Routerbits
Handyhints
Toolcare
ECdeclarationofconformity
Black&Deckerphonenumbersandaddresses
Guaranteecard
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4
SAFETYINSTRUCTIONS
Warning!Whenusingelectrictools,thefollowing
basicsafetyprecautionsshouldalwaysbetakento
reducetheriskoffire,electric shock andpersonal
injury.Readalltheseinstructionsbeforeattemptingto
operatethe productandsavethisbooklet.
Forsafeoperation:
•Keeptheworkareaclean.Cluttered areasand
benchesinviteinjuries.
•Considertheworkareaenvironment.Donotexpose
the power tool to rain and do not use in damp or wet
locations.Keep thework areawell lit.Do notuse
thepower tool where thereis a riskto cause fire
orexplosion.
•Guardagainstelectricshock.Avoidbodycontact,
wherepossible,withearthedorgroundedsurfaces
(e.g.pipes,radiators,rangesandrefrigerators).
•Keepchildrenaway.Do notletvisitors touchthe
toolorextensioncord.All visitorsshouldbekept
awayfrom the workarea.
•Storeidletools.When notin use,tools should be
storedin a dry,high or lockedplace, out ofreach
ofchildren.
•Donotforcethetool.It will do the job better and
moresafely atthe ratefor whichit wasintended.
•Usetherighttool.Do notforce small toolsor
attachmentsto do thejob ofa heavy dutytool.
Donot usethe toolfor purposesnot intended;for
example,do not usea circular sawto cut tree
limbsorlogs.
•Dressproperly.Do not wear looseclothing or
jewelleryasthey canbecaught inmovingparts.
Rubberglovesandnon-skidfootwearare
recommendedwhenworkingoutdoors.Wear
protectivehaircoveringtocontainlonghair.
•Usesafetyglasses.Usea faceor dust maskas well,
if the operation is dusty or if the tool is being used in
enclosedspaces.
•Connectingdustextractionequipment.Ifdevices
areprovidedfortheconnectionofdustextraction
andcollectionensuretheseareconnectedand
properlyused,especiallyinconfinedareas.
•Donotabusethecord.Never carry the tool by its
cordor yankit todisconnect it from the socket.Keep
thecordawayfrom heat,oilandsharp edges.
•Securethework.Use clamps or a vice to hold the
work. It is safer than using a hand and it frees both
handstooperatethetool.
•Donotoverreach.Keepproperfootingandbalanceat
alltimes.
•Maintainthetoolwithcare.Keep a cuttingtool
sharpand cleanforbetterandsaferperformance.
Followtheinstructionsforlubricatingandchanging
accessories.Inspectthetoolscordperiodicallyand,
ifdamaged,haverepairedbyanauthorisedservice
facility.Inspecttheextensioncordperiodicallyand
replaceifdamaged.Keepthehandlesdry,cleanand
freefromoilandgrease.
•Disconnectthetoolwhennotinuse, before
servicingandwhenchangingaccessoriessuchas
blades,bitsandcutters.
•Removeadjustingkeysandwrenches.Formthe
habitofchecking toseethat keysandadjusting
wrenchesareremovedfrom thetoolandreplaced in
thestorageareabeforeswitchingon.
•Avoidunintentionalstarting.Donotcarrya
plugged-intoolwitha fingerontheswitch.
Ensuretheswitch isoffwhen pluggingin.
•Useanoutdoorextensioncord.Whena toolis used
outdoors,onlyuseanextensioncordintendedfor
outdooruseandsomarked.
•Stayalert.Watchwhatyouaredoing, usecommon
senseand donot operatethe tool whentired.
•Checkdamagedparts.Beforefurtheruseof the tool,
aguard or otherpart thatis damaged shouldbe
carefullycheckedtodeterminewhetheritwill
operateproperlyandperformitsintendedfunction.
Checkforalignmentofmovingparts, free runningof
movingparts,breakageofparts,mountingandany
otherconditionsthatmayaffectitsoperation.
Aguard or otherpart thatis damaged shouldbe
properlyrepairedorreplacedbyanauthorised
servicecentreunlessotherwiseindicatedinthe
productbooklet.Havedefectiveswitchesreplaced
byan authorisedservice agent.Do not use the toolif
the switch does not turn it on and off.
•Warning!Theuseofanyaccessoryorattachment,
otherthanrecommendedintheproductbooklet,
maypresentariskof personal injury.
•Havethetoolrepairedbyaqualifiedperson.The
electricaltoolisinaccordancewiththerelevant
safetyrequirements.Repairsshouldonlybecarried
outbyqualifiedpersonsusingoriginalspareparts,
otherwise,thismayresultinconsiderabledangerto
theuser.
Savetheseinstructions!
DOUBLEINSULATION
Thetoolis double insulated.Thismeans thatall
theexternalmetalpartsareelectricallyinsulated
fromthe mainspower supply.This isdone by
Router user manual
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5
placinginsulationbarriersbetweenthe
electricalandmechanicalcomponentsmakingit
unnecessaryforthetoolto be earthed.
Note:Doubleinsulationdoesnottaketheplace
ofnormalsafetyprecautionswhenoperatingthe
tool.Theinsulationsystemisforaddedprotection
againstinjuryresultingfromapossibleelectrical
insulationfailurewithinthetool.
ELECTRICALSAFETY
Be sure the supply is the same as the voltage given on
therating plate. Thetool isfitted with atwo-core cable
andplug.
MAINSPLUGREPLACEMENT(UKONLY)
Shouldthemains plugneedreplacing andyouare
competenttodothis,proceedasinstructedbelow.
Ifyou are in doubt, contacta Black& Decker service
agentoraqualifiedelectrician.
• Disconnectthe plugfromthepowersupply.
• Cutoff the plugand dispose ofsafely.A plug with
baredcopperconductorsisverydangerousif
engagedinalive socket outlet.
• OnlyfitBS1363Aapprovedplugsfittedwiththe
correctlyratedfuse.
Note:Fusesdonotgivepersonalprotectionagainst
electricshock.
• Thecable wirecolours, ora letter,willbe marked at
theconnectionpointofmostgoodqualityplugs.Attach
thewiresto theirrespectivepoints inthe plug (see
diagram).Brown is L(live) andblue is N(neutral).
Fit a 5 amp fuse
approved
to BS1362
N
L
E
230 volts AC only
Never use a light
socket
Make sure that the
outer sheath of the
cable is held firmly
by the clamp
Fit a BS1363A
approved
resilient plug
Connect
blue to
N (neutral)
Connect
brown to
L (live)
• Beforereplacingthe top coverofthe plugensure
thatthecable restraint isholdingthe outersheathof
thecablefirmly andthatthe twoleads are correctly
fixedat theterminal screws.If thefuse coveris
missingor damageddo notuse theplug.
ENGLISH
Forreplacementordetachablefusecovers,
contactaBlack&Deckerservice agent.
Warning!Neverconnect live orneutralwiresto the
earth pin marked E or .
REPLACEMENT OF THE SUPPLY CORD
(AUSTRALIAANDNEWZEALANDONLY)
Ifthe supply cord is damaged,it mustbe replaced by
themanufactureroritsserviceagentorsimilarly
qualifiedpersoninorder to avoidahazard.
EXTENSIONCABLES
Upto 30m(100ft) of3-core extensioncable canbe used
withoutunduelossofpower.Note:Anextension cable
shouldnotbeusedunlessabsolutelynecessary.Useof
animproperextension cablecouldresult ina risk of
fireandelectric shock.Ifan extensioncable must be
used,makesureit isproperlywired,contains the
correctratedfuse as recommended initsliteratureand
isingoodelectricalcondition.
UNWANTEDTOOLSANDTHEENVIRONMENT
Shouldyou findone day thatthe toolneeds
replacementor isof nofurther use, think of the
protectionoftheenvironment.Black&Decker
serviceagentswillacceptold toolsandwill
disposeoftheminanenvironmentallysafeway.
THEBLACK&DECKERGUARANTEE
(UK,AUSTRALIAANDNEWZEALANDONLY)
IftheBlack&Decker productbecomesdefectivedue
tofaultymaterialsandworkmanship,within24months
fromthedate of purchase,weguarantee toeither
replacealldefectivepartsoratourdiscretion,replace
theunitfreeof chargeprovidedthat:
• Theproduct is returnedto usorour authorised
repairerswithevidenceofdateofpurchase.
• Theproduct hasnot been usedfor trade,
professionalorhirepurposes.
• Theproducthasnot beensubjectedtomisuse
orneglect.
• Theproducthasnotsustainedanydamagethrough
foreignobjects,substancesoraccidents.
• Repairshavenotbeenattemptedbyanyoneother
thanourownservicestafforauthorisedrepair
distributors.
Thisguarantee is offeredas anextra benefit andis
additionaltothecustomersstatutoryrights.
AFTERSALESSERVICEFORYOURBLACK&DECKER
PRODUCT(UK,AUSTRALIAANDNEWZEALANDONLY)
Black&Deckeroffersa nationwide networkof
authorised service agents.
230/240VAConly
KW800_E UK p01-12 16-01-2001, 13:115

6
ENGLISH
The use of other than genuine Black & Decker
accessories and parts may damage or reduce the
performance of your Black & Decker product and
may also endanger the user. The terms and
conditions of the warranty may also be effected.
OUR AFTER SALES SERVICE POLICY
(UK, AUSTRALIA AND NEW ZEALAND ONLY)
It is our aim that all Black & Decker customers should
be totally satisfied with their Black & Decker product
and after sales service, but if help or advice is needed
please contact your local Black & Decker authorised
repair agent who will be happy to help. Full details of
our after sales service and a list of these agents can be
foundon theInternet atwww.2helpU.com.Alternatively,
call our Service and Information Centre whose number
you will find towards the back of this manual.
ACCESSORIES
The performance of any power tool is dependant upon
the accessory used. Black & Decker accessories are
engineered to high quality standards and are designed
to enhance the performance of your tool. Buying a
Black & Decker accessory will ensure that you get the
very best from your Black & Decker tool.
For full details of accessories available, please
consult your nearest stockist or service agent.
TECHNICAL DATA
The level of sound pressure of the tool is in accordance
with EEC legislation. It is recommended that you take
appropriatemeasures forthe protectionof yourhearing
if the sound level seems uncomfortable.
KW800 KW800E
Volts (V) ~ 230 230
Input power (W) 710 800
No load speed/min 30,000 8,000-30,000
The Black & Decker policy is one of continuous improve-
ment to our product and as such we reserve the right
tochange theproduct specificationwithout priornotice.
Note: This user manual may also cover more than one
catalogue number within this product group. Refer to
your rating plate for details of your product. Your
product includes some or all of these features.
FEATURES
1. On/offswitch
2. Electronicspeed switch (KW800E)
3. Spindlelock
4. Colletnut
5. Plunge lock lever
6. Triple depth stop
7. Depth stop bar
8. Allen wrench (for removing motor pack from frame)
9. Wing screw
10. Vacuum adaptor
11. Templateguide
12. Edgeguide
13. Centringpin
14. Copyfollower
15. Distance plate
OPERATING YOUR ROUTER
• Insert the desired cutter into the collet.
• Set the required depth of cut.
• Set the guide fence for the position of cut.
• Set the on/off switch to ‘I’.
• Plunge your router down and lock.
• Route the workpiece.
• Release the plunge lock.
• Set the on/off switch to ‘O’.
10
15
12
13
•
•
•
•
•
•
2
5
3
1
7
•
•
•
•
•
•
•
8
•6
•
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7
ENGLISH
FITTING THE ROUTER BIT
Disconnect the plug from the electricity supply.
If a router bit is
alreadyfitted,
pressthespindle
lockbuttonand
releasethecollet
clampnut,using
the spanner
provided.
Insert the router
bit. Make sure it
protrudes at least
3mm from the
end of the shank.
Press the spindle
lock button and
tighten the collet
clamp nut using the spanner provided.
ADJUSTING THE DEPTH OF CUT The depth of cut
is the distance (x)
between the
triple depth stop
and the depth
stop bar. Each
router bit varies
in length and the
triple depth stop
provides three different positions. Use one of the
following methods to set the depth of cut.
USING A PIECE OF WOOD
The most common method is to use a piece of wood
as a gauge as follows:
• Fit the router bit.
• Loosen the wing screw.
• Pull the plunge lock lever up.
• Plunge your router down until the cutter is in
contact with the workpiece.
• Push the plunge lock lever down to hold your
router in this position. Pull up the depth
stop bar.
Put a piece of
wood of the same
thickness as the
desired depth of
cut, between the
depth stop bar
and the triple
depth stop.
• Tighten the wing screw.
• Removethepiece of wood.
• Pullthe plungelock leverup to move your router
backtoitsoriginalposition.
• Moveyour router toits workingposition and setthe
on/offswitchto‘I’.
• Plungeyourrouterdown totheworkpieceand
pushthe plungelock leverto holdyour routerat
thisdepth.
• Makethedesiredcut.
USING THE SCALE
Proceedasfollows:
• Fittherouter bit.
• Loosenthewingscrew.
• Pulltheplunge lockleverup.
• Plungeyourrouter downuntilthe cutteris in contact
withtheworkpiece.
• Pushthe plungelock lever downto holdyour router
inthis position. The scale onthe depthstop bar now
showsthestartingposition.Thisstartingposition
willvary,dependingonthecutterused.
• Addthedesired depthofcut tothestarting position;
for example, if the scale shows 23mm and the
desired depth of cut is 10mm, the correct adjustment
on the scale is 23 +10 = 33mm. If the scale shows
46mm and the desired depth of cut is 5mm, the
correct adjustment on the scale is 46 + 5 = 51mm.
• Move the depth stop bar to the calculated number.
• Clampthe depthstop barwith the wingscrew.
• Pull the plunge lock lever up to move your router
to its original position.
• Moveyour router toits workingposition and setthe
on/offswitchto‘I’.
• Plungeyourrouterdown totheworkpieceand
pushthe plungelock leverto holdyour routerat
thisdepth.
• Makethedesiredcut.
• Forbetterquality cutsanda longer cutterlife,make
aseries of cuts,instead ofa single cut.
x
3mm
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8
FINE ADJUSTMENT WITH THE TRIPLE DEPTH STOP
After turning the
tripledepthstop,
fineadjustmentis
madewith a
screwdriveron
theappropriate
screw.Whenyou
wishto make
severalcutsat
differentdepthsin the same material,adjustthethree
screwsonthetripledepthstopaccordingly.
FITTING THE EDGE GUIDE
Theedge guideis used whenmaking parallelcuts or
whenmakingdecorativeedges.
Inserttwoscrews
providedinthe
endholes in the
edgeguideand
screwtheminto
thethreadedends
ofthe two bars.
Insertthetwo
barsinthegrooves
inthe base ofyour router. Adjust the guide to give the
desireddistanceandtightenthetwowingscrews.
ALTERNATIVEGUIDEMETHOD When it is not
possibleto usean
edgeguide,(such
aswhenrouting
groovesto
supportshelvesin
abookcaseend),
useastraight
pieceofwood
clampedacrosstheworkpiecetoactasaguidingedge.
FITTINGTHEVACUUMADAPTOR
Thevacuumadaptorenablestheconnectionofavacuum
cleanertoyourrouterto keeptheworkplaceclean.
Locatethe
vacuumadaptor
on the base of
yourrouter.Insert
thetwo long
screwsprovided,
fromthe bottomof
the holes; place
two nuts on top of the adaptor and tighten the screws.
FITTING THE TEMPLATE GUIDE Use this guide to
makeacutout
shapefrom a
template.The
templateis
securedoverthe
workpiece using
double-sided tape
or ‘G’ clamps. The
router bit extends below the template guide, to cut
the workpiece in the shape of the template. In this
way, a number of workpieces are made accurately to
the same shape.
To fit the template
guide, secure it to
the base of your
router using the
two long screws
provided.
ELECTRONIC SPEED REGULATION (KW800E)
The electronic
speedswitch
permitsthe
settingofthe
optimum speed to
suit the router bit
diameter and the
material of the
workpiece. This
reduces the risk
of burning the workpiece, especially when crosscutting.
USING THE DISTANCE PIECE The distance
pieceisused
whentrimming
woodenor
laminatevertical
projections.
Attach the
distance piece to
the base using
the screws
provided.
ENGLISH
56
4
3
2
1
7
8
9
10
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9
USING THE CENTRING PIN
The centring pin
enables you to use
your router as a
compass to cut out,
scribe or produce
circular patterns.
Attach the
centring pin to the edge guide with the screw provided.
USING THE COPY FOLLOWER
The copy follower helps maintain an equal cutting
distance along the edge of irregularly shaped workpieces.
To fit the copy follower, proceed as follows:
Attach the ‘L’ bar
(a) to the edge
guide (b) using
the two screws
and nuts
provided. Attach
the rotating
attachment (c) to
the ‘L’ bar with
the wing screw
provided. Adjust the edge guide in the base of your
router until the wheel is in contact with the workpiece.
ROUTER BITS
• Only use cutters with a shank size of 6mm, 8mm or
1/4” with the equivalent collet size provided.
Rounding, rebating and laminate bits have either a
ball bearing or a pilot pin for use at the edge of the
workpiece. Most of the following router bits are
available in two different grades:
• HSS cutters for use on softwood.
• TCT cutters for use on hardwood, chipboard
plastics and aluminium.
No Description Purpose
1 Straight bit Channelling
2 V-Grooving bit Chamfers, grooves and letter work
3 Core box bit Grooves, edge profiles and drop-
leaf joints
4 Dovetail bit Dovetail grooves
5 Rounding bit Profiles and drop-leaf joints
6 Roman ogee bit Profiles
7 Rebating bit Easy rebates
8 Laminate bit Trimming wooden or laminate
horizontal projections
HANDY HINTS
You can use your
router without
using a guide.
This is useful for
signwriting and
creative work.
Use only
shallow cuts.
The cutter of your
router rotates
clockwise. For
more efficient
cutting, move
your router from
left to right as you stand facing the workpiece.
• When cutting outside edges, move your router anti-
clockwise and clockwise when cutting inside edges.
TOOL CARE
Do not apply excessive pressure when you use your
router. This can cause your router to overheat. If your
router becomes too hot, operate it off-load for
2 minutes. Keep the air cooling vents on the motor clear.
ECDECLARATIONOF CONFORMITY
We declare that units: KW800, KW800E conform to
98/37/EC,89/336/EEC, EN55014, 73/23/EEC,EN50144,
EN61000. A weighted sound pressure 85.5dB (A),
A weighted sound power 98.5dB (A), Hand/arm
weightedvibration 2.7m/s2
Brian Cooke, Director of Engineering
Black & Decker, Spennymoor, Co Durham DL16 6JG, UK
ENGLISH
1234
5678
ca
b
KW800_E UK p01-12 16-01-2001, 13:149

01/01
Australia DeWaltIndustrialPowerToolCompany Tel: [phone]
(DistributorsofBlack&Deckerproducts) Fax: [phone]
7ClariceRoad,BoxHill, Victoria3128
NewZealand Black & Decker Tel: [phone]
483GreatSouthRoad Fax: [phone]
Penrose,Auckland
SouthAfrica Black &DeckerSouthAfrica (Pty)Ltd Tel: [phone]
Suiteno107, PostNet X65 Fax: [phone]
HalfwayHouse1685
UnitedKingdom Black& Decker Tel: [phone]
210BathRoad, Slough Tlx: 848317 BANDMH
BerkshireSL13YD Fax: [phone]
KW800_E UK p01-12 16-01-2001, 13:1210

Address of the dealer where your router was purchased: Date of your purchase:
Was your router a gift? Was your router your first purchase? Was your router bought as a replacement? What was the price of your router? Address of the dealer where your router was purchased:
Name: House number or name and street:
Town: County or state: Postcode:
Country: Product catalogue number: KW800/_
Data protection act: Tick this box if you prefer not to receive information from Black & Decker or other companies.
Yes No
KW800_E UK p01-12 16-01-2001, 13:1211

01/01
GUARANTEECARDFORTHEUK,IRELANDANDSOUTHAFRICA
SouthAfrica:Black&DeckerSouthAfrica(Pty)Ltd,Suiteno107,PostNetX65,HalfwayHouse1685
UnitedKingdom&Ireland:POBox821,Slough,Berkshire,SL13AR
Pleasecompletethissectionimmediatelyafterthepurchaseofyourrouter
andpostittotheBlack&Deckeraddressinyourcountry(above).
IfyouliveinAustraliaorNewZealand,pleaseregisteryourpurchasebyusing
thealternativeguaranteecardsupplied.
KW800_E UK p01-12 16-01-2001, 13:1212