KW800 - Milling machine BLACK & DECKER - Free user manual and instructions

Product Type	Milling machine (Router)
Brand	Black & Decker
Model	KW800 / KW800E
Rated Voltage	230 V ~
Input Power	710 W (KW800) / 800 W (KW800E)
No-Load Speed	30,000 min⁻¹ (KW800) / 8,000-30,000 min⁻¹ (KW800E)
Speed Control	Electronic speed regulation (KW800E only)
Collet Size	6 mm, 8 mm, 1/4"
Depth Adjustment	Plunge lock, triple depth stop with fine adjustment
Plunge Lock	Yes, plunge lock lever
Spindle Lock	Yes, for bit changes
Edge Guide	Yes, included
Template Guide	Yes, included
Centring Pin	Yes, for circular cuts
Copy Follower	Yes, for irregular edges
Vacuum Adaptor	Yes, included
Distance Piece	Yes, for trimming vertical projections
Double Insulation	Yes
Weight (approx)	3.5 kg
Dimensions (approx)	250 x 200 x 250 mm
Sound Pressure Level	85.5 dB(A)
Sound Power Level	98.5 dB(A)
Vibration Level	2.7 m/s²

Frequently Asked Questions - KW800 BLACK & DECKER

How do I change the router bit on the Black & Decker KW800?

Disconnect the router from the power supply. Press the spindle lock button to lock the shaft, then use the provided spanner to loosen and remove the collet nut. Insert the new bit (shank size: 6mm, 8mm, or 1/4") ensuring at least 3mm protrudes from the collet. Tighten the collet nut while pressing the spindle lock.

How do I adjust the depth of cut?

First, fit the router bit. Loosen the wing screw, pull up the plunge lock lever, and plunge the router until the cutter contacts the workpiece. Lock the plunge. Then adjust the depth stop bar: either use a piece of wood as a gauge between the bar and triple stop, or use the scale on the bar to calculate the desired depth. Tighten the wing screw and release the plunge before routing.

What is the electronic speed regulation for KW800E?

The KW800E model features an electronic speed switch that allows you to set the optimal speed (8,000-30,000 min⁻¹) for different router bit diameters and workpiece materials. This reduces burning and improves cut quality.

How do I use the edge guide?

Insert the two bars into the grooves on the router base. Attach the edge guide to the bars using the provided screws. Adjust the guide to the desired distance from the bit, then tighten the wing screws. This helps make parallel cuts or decorative edges.

Can I connect a vacuum cleaner to the router?

Yes, use the included vacuum adaptor. Locate it on the base of the router, insert the two long screws from the bottom, place nuts on top, and tighten. This connects to a vacuum for dust extraction.

How do I use the template guide?

Secure the template guide to the router base using the two long screws provided. Then attach a template to the workpiece with double-sided tape or clamps. The router bit extends below the guide, allowing you to cut precisely to the template shape.

What safety precautions should I take?

Always wear safety glasses and hearing protection. Keep work area clean and well-lit. Avoid loose clothing. Ensure the router is unplugged when changing bits. Use an outdoor extension cord if used outside. Do not force the tool, and disconnect when not in use.

How do I achieve finer depth adjustments?

Use the triple depth stop. After turning the stop to the desired position, fine-tune each of the three screws with a screwdriver. This is useful when making multiple cuts of different depths on the same workpiece.

How do I cut circles with the router?

Attach the centring pin to the edge guide with the provided screw. Then mount the edge guide to the router base. Place the centring pin at the center of the desired circle, and pivot the router around it to cut circular patterns.

What maintenance does the router require?

Keep the cooling vents clean and free of dust. Do not apply excessive pressure during use. If the router overheats, run it off-load for 2 minutes. Periodically check the cord for damage and have repairs done by an authorized service agent. Store in a dry place.

USER MANUAL KW800 BLACK & DECKER

On the purchase of your Black & Deckerrouter.

To ensure the best results from your router please read these safety and usage instructions carefully.

If you have any questions or queries after reading this user manual please do not hesitate to call our Service and Information Centre, whose number you will find towards the back of this user manual, or one of our Authorised Repair Agents. A list of these Agents and further information is available on the Internet at www.2helpU.com.

Contents

Page4 Safety instructions

Double insulation

Page5 Electrical safety

Mains plug replacement

Extension cables

Unwanted tools and the environment

The Black & Decker guarantee

After sales service for your Black & Decker product

Page6 Our after sales service policy

Accessories

Technical data

Features

Operating your router

Page 7 Fitting the router bit

Adjusting the depth of cut

Using a piece of wood

Using the scale

Page 8 Fine adjustment with the triple depth stop

Fitting the edge guide

Alternative guide method

Fitting the vacuum adaptor

Fitting the template guide

Electronic speed regulation

Using the distance piece

Page9 Using the centring pin

Using the copyfollower

Router bits

Handy hints

Tool care

EC declaration of conformity

Black & Decker phone numbers and addresses

Guarantee card

Router user manual

SAFETY INSTRUCTIONS

Warning! When using electric tools, the following basic safety precautions should always be taken to reduce the risk of fire, electric shock and personal injury. Read all these instructions before attempting to operate the product and save this booklet.

For safe operation:

• Keep the work area clean. Cluttered areas and benches invite injuries.
• Consider the work area environment. Do not expose the power tool to rain and do not use in damp or wet locations. Keep the work area well lit. Do not use the power tool where there is a risk to cause fire or explosion.
• Guard against electric shock. Avoid body contact, where possible, with earthed or grounded surfaces (e.g. pipes, radiators, ranges and refrigerators).
• Keep children away. Do not let visitors touch the tool or extension cord. All visitors should be kept away from the work area.
• Store idle tools. When not in use, tools should be stored in a dry, high or locked place, out of reach of children.
• Do not force the tool. It will do the job better and more safely at the rate for which it was intended.
• Use the right tool. Do not force small tools or attachments to do the job of a heavy duty tool. Do not use the tool for purposes not intended; for example, do not use a circular saw to cut tree limbs or logs.
• Dress properly. Do not wear loose clothing or jewellery as they can be caught in moving parts. Rubber gloves and non-skid footwear are recommended when working outdoors. Wear protective hair covering to contain long hair.
• Use safety glasses. Use a face or dust mask as well, if the operation is dusty or if the tool is being used in enclosed spaces.
• Connecting dust extraction equipment. If devices are provided for the connection of dust extraction and collection ensure these are connected and properly used, especially in confined areas.
• Do not abuse the cord. Never carry the tool by its cord or yank it to disconnect it from the socket. Keep the cord away from heat, oil and sharp edges.
• Secure the work. Use clamps or a vice to hold the work. It is safer than using a hand and it frees both hands to operate the tool.

• Do not overreach. Keep proper footing and balance at all times.

• Maintain the tool with care. Keep a cutting tool sharp and clean for better and safer performance. Follow the instructions for lubricating and changing accessories. Inspect the tools cord periodically and, if damaged, have repaired by an authorised service facility. Inspect the extension cord periodically and replace if damaged. Keep the handles dry, clean and free from oil and grease.

• Disconnect the tool when not in use, before servicing and when changing accessories such as blades, bits and cutters.
• Remove adjusting keys and wrenches. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool and replaced in the storage area before switching on.
• Avoid unintentional starting. Do not carry a plugged-in tool with a finger on the switch. Ensure the switch is off when plugging in.
• Use an outdoor extension cord. When a tool is used outdoors, only use an extension cord intended for outdoor use and so marked.
• Stay alert. Watch what you are doing, use common sense and do not operate the tool when tired.
• Check damaged parts. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine whether it will operate properly and perform its intended function. Check for alignment of moving parts, free running of moving parts, breakage of parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced by an authorised service centre unless otherwise indicated in the product booklet. Have defective switches replaced by an authorised service agent. Do not use the tool if the switch does not turn it on and off.
• Warning! The use of any accessory or attachment, other than recommended in the product booklet, may present a risk of personal injury.
• Have the tool repaired by a qualified person. The electrical tool is in accordance with the relevant safety requirements. Repairs should only be carried out by qualified persons using original spare parts, otherwise, this may result in considerable danger to the user.

Save these instructions!

DOUBLE INSULATION

The tool is double insulated. This means that all the external metal parts are electrically insulated from the mains power supply. This is done by

ENGLISH

placing insulation barriers between the electrical and mechanical components making it unnecessary for the tool to be earthed.

Note: Double insulation does not take the place of normal safety precautions when operating the tool. The insulation system is for added protection against injury resulting from a possible electrical insulation failure within the tool.

ELECTRICAL SAFETY

Be sure the supply is the same as the voltage given on the rating plate. The tool is fitted with a two-core cable and plug.

MAINS PLUG REPLACEMENT (UK ONLY)

Should the mains plug need replacing and you are competent to do this, proceed as instructed below. If you are in doubt, contact a Black & Decker service agent or a qualified electrician.

• Disconnect the plug from the power supply.
• Cut off the plug and dispose of safely. A plug with bared copper conductors is very dangerous if engaged in a live socket outlet.
• Only fit BS1363A approved plugs fitted with the correctly rated fuse.

Note: Fuses do not give personal protection against electric shock.

- The cable wire colours, or a letter, will be marked at the connection point of most good quality plugs. Attach the wires to their respective points in the plug (see diagram). Brown is L (live) and blue is N (neutral).

Fit a BS1363A
approved resilient plug
Connect blue to N (neutral)

Fit a 5 amp fuse
approved to BS1362
Connect brown to L (live)

Make sure that the outer sheath of the cable is held firmly by the clamp

230/240V AC only Never use a light socket

- Before replacing the top cover of the plug ensure that the cable restraint is holding the outer sheath of the cable firmly and that the two leads are correctly fixed at the terminal screws. If the fuse cover is missing or damaged do not use the plug.

For replacement or detachable fuse covers, contact a Black & Decker service agent.

Warning! Never connect live or neutral wires to the earth pin marked E or 12

REPLACEMENT OF THE SUPPLY CORD (AUSTRALIA AND NEW ZEALAND ONLY)

If the supply cord is damaged, it must be replaced by the manufacturer or its service agent or similarly qualified person in order to avoid a hazard.

EXTENSION CABLES

Up to 30m (100ft) of 3-core extension cable can be used without undue loss of power. Note: An extension cable should not be used unless absolutely necessary. Use of an improper extension cable could result in a risk of fire and electric shock. If an extension cable must be used, make sure it is properly wired, contains the correct rated fuse as recommended in its literature and is in good electrical condition.

UNWANTED TOOLS AND THE ENVIRONMENT

Should you find one day that the tool needs replacement or is of no further use, think of the protection of the environment. Black & Decker service agents will accept old tools and will dispose of them in an environmentally safe way.

THE BLACK & DECKER GUARANTEE (UK, AUSTRALIA AND NEW ZEALAND ONLY)

If the Black & Decker product becomes defective due to faulty materials and workmanship, within 24 months from the date of purchase, we guarantee to either replace all defective parts or at our discretion, replace the unit free of charge provided that:

• The product is returned to us or our authorised repairers with evidence of date of purchase.
• The product has not been used for trade, professional or hire purposes.
• The product has not been subjected to misuse or neglect.
• The product has not sustained any damage through foreign objects, substances or accidents.
• Repairs have not been attempted by anyone other than our own service staff or authorised repair distributors.
This guarantee is offered as an extra benefit and is additional to the customers statutory rights.

AFTER SALES SERVICE FOR YOUR BLACK & DECKER PRODUCT (UK, AUSTRALIA AND NEW ZEALAND ONLY)

Black & Decker offers a nationwide network of authorised service agents.

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 found on the Internet at www.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 appropriate measures for the protection of your hearing if the sound level seems uncomfortable.

KW800 KW800E

Volts (V) \~ 230 230

Input power (W) 710800

No load speed/min 30,000 8,000-30,000

The Black & Decker policy is one of continuous improvement to our product and as such we reserve the right to change the product specification without prior notice.

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/off switch
2. Electronic speed switch (KW800E)
3. Spindle lock
4. Collet nut

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. Template guide
12. Edge guide
13. Centring pin
14. Copy follower
15. Distance plate

• 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 '0'.

ENGLISH

FITTING THE ROUTER BIT

Disconnect the plug from the electricity supply.

Mechanical assembly diagram showing hands operating a component with arrows indicating motion (no text or symbols)

If a router bit is already fitted, press the spindle lock button and release the collet clamp nut, 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.

Illustration of hands using a mechanical tool to adjust or install a component (no text or symbols visible)

Pull up the depth stop bar.

Technical line drawing of a mechanical assembly with no visible text or symbols

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.
• Remove the piece of wood.
• Pull the plunge lock lever up to move your router back to its original position.
• Move your router to its working position and set the on/off switch to 'I'.
• Plunge your router down to the workpiece and push the plunge lock lever to hold your router at this depth.
• Make the desired cut.

USING THE SCALE

Proceed 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. The scale on the depth stop bar now shows the starting position. This starting position will vary, depending on the cutter used.
- Add the desired depth of cut to the starting 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.
- Clamp the depth stop bar with the wing screw.
- Pull the plunge lock lever up to move your router to its original position.
- Move your router to its working position and set the on/off switch to 'I'.
- Plunge your router down to the workpiece and push the plunge lock lever to hold your router at this depth.
• Make the desired cut.
- For better quality cuts and a longer cutter life, make a series of cuts, instead of a single cut.

ENGLISH

FINE ADJUSTMENT WITH THE TRIPLE DEPTH STOP

Technical line drawing of a mechanical assembly with bolts and springs (no text or symbols)

After turning the triple depth stop, fine adjustment is made with a screwdriver on the appropriate screw. When you wish to make several cuts at

different depths in the same material, adjust the three screws on the triple depth stop accordingly.

FITTING THE EDGE GUIDE

The edge guide is used when making parallel cuts or when making decorative edges.

Technical line drawing of a mechanical assembly with no visible text or symbols

Insert two screws provided in the end holes in the edge guide and screw them into the threaded ends of the two bars. Insert the two bars in the grooves

in the base of your router. Adjust the guide to give the desired distance and tighten the two wing screws.

ALTERNATIVE GUIDE METHOD

Technical line drawing of a mechanical assembly with no visible text or symbols

When it is not possible to use an edge guide, (such as when routing grooves to support shelves in a bookcase end), use a straight piece of wood

clamped across the workpiece to act as a guiding edge.

FITTING THE VACUUM ADAPTOR

The vacuum adaptor enables the connection of a vacuum cleaner to your router to keep the workplace clean.

Technical line drawing of a mechanical assembly with hands operating a component (no text or symbols visible)

Locate the vacuum adaptor on the base of your router. Insert the two long screws provided, from the bottom of the holes; place

two nuts on top of the adaptor and tighten the screws.

FITTING THE TEMPLATE GUIDE

Pure technical line drawing of a T-shaped component without any text, numbers, or symbols

Use this guide to make a cutout shape from a template. The template is secured over the 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.

Technical line drawing of a mechanical component with a central pin and mounting holes (no text or symbols)

To fit the template guide, secure it to the base of your router using the two long screws provided.

ELECTRONIC SPEED REGULATION (KW800E)

Technical line drawing of a mechanical knob or dial (no text or symbols)

The electronic speed switch permits the setting of the 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

Technical line drawing of a mechanical assembly with springs and housing (no text or symbols)

The distance piece is used when trimming wooden or laminate vertical projections. Attach the distance piece to the base using the screws provided.

ENGLISH

USING THE CENTRING PIN

Technical line drawing of a mechanical assembly with no visible text or symbols

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.

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

Technical line drawing of a mechanical device with springs and a curved base (no text or symbols)

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.

EC DECLARATION OF 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 weighted vibration 2.7m / s^2

Brian Cooke, Director of Engineering

Black & Decker, Spennymoor, Co Durham DL16 6JG, UK

Australia DeWalt Industrial Power Tool Company Tel: [phone]

(Distributors of Black & Decker products) Fax:[phone]

7 Clarice Road, Box Hill, Victoria 3128

New Zealand Black & Decker Tel: [phone]

483 Great South Road Fax: [phone]

Penrose, Auckland

South Africa Black & Decker South Africa (Pty) Ltd Tel: [phone]

Suite no 107, PostNet X65 Fax: [phone]

Halfway House 1685

United Kingdom Black & Decker Tel: [phone]

210 Bath Road, Slough Tlx: 848317 BAND MH

Berkshire SL1 3YD Fax: [phone]

01/01

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?

Postcode:

Country:

Addresses of the dealer where your router was purchased:

Product catalogue number: KW800/-

Data protection act: Tick this box if you prefer not to receive information from Black & Decker or other companies.
Data protection act: Tik this box if you prefer not to receive
information from Black & Decker or other companies.
Data protection act: Tick this box if you prefer not to receive information from Black & Decker or other companies.

If you live in Australia or New Zealand, please register your purchase by using the alternative guarantee card supplied.

Please complete this section immediately after the purchase of your router and post it to the Black & Decker address in your country (above).

GUARANTEE CARD FOR THE UK, IRELAND AND SOUTH AFRICA South Africa: Black & Decker South Africa (Pty) Ltd, Suite no 107, PostNet X65, Halfway House 1685 United Kingdom & Ireland: PO Box 821, Slough, Berkshire, SL13AR