Your Black & Decker router has been designed
for routing wood and wood products. This tool is
intended for consumer use only.
Safety instructions
General power tool safety warnings
Warning! Read all safety warnings and
all instructions. Failure to follow the
warnings and instructions listed below may
result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future
reference.
The term "power tool" in all of the warnings
listed below refers to your mains operated
(corded) power tool or battery operated
(cordless) power tool.
1. Work area safety
a. Keep work area clean and well lit. Cluttered
or dark areas invite accidents.
b. Avoid body contact with earthed or grounded
surfaces such as pipes, radiators, ranges and
refrigerators. There is an increased risk of
electric shock if your body is earthed or
grounded.
c. Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
d. Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled cords
increase the risk of electric shock.
e. When operating a power tool outdoors, use
an extension cord suitable for outdoor use.
Use of a cord suitable for outdoor use
reduces the risk of electric shock.
f. If operating a power tool in a damp location is
unavoidable, use a residual current device
(RCD) protected supply. Use of an RCD
reduces the risk of electric shock.
b. Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power
tools create sparks which may ignite the dust
or fumes.
c. Keep children and bystanders away while
operating a power tool. Distractions can
cause you to lose control.
2. Electrical safety
a. Power tool plugs must match the outlet.
Never modify the plug in any way. Do not use
any adapter plugs with earthed (grounded)
power tools. Unmodified plugs and matching
outlets will reduce risk of electric shock.
3. Personal safety
a. Stay alert, watch what you are doing and use
common sense when operating a power tool.
Do not use a power tool while you are tired or
under the influence of drugs, alcohol or
medication. A moment of inattention while
operating power tools may result in serious
personal injury.
b. Use personal protective equipment. Always
wear eye protection. Protective equipment
such as dust mask, non-skid safety shoes,
hard hat, or hearing protection used for
appropriate conditions will reduce personal
injuries.
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ENGLISH
c. Prevent unintentional starting. Ensure the
switch is in the off-position before connecting
to power source and/or battery pack, picking
up or carrying the tool. Carrying power tools
with your finger on the switch or energising
power tools that have the switch on invites
accidents.
d. Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key
left attached to a rotating part of the power
tool may result in personal injury.
e. Do not overreach. Keep proper footing and
balance at all times. This enables better
control of the power tool in unexpected
situations.
f. Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
away from moving parts. Loose clothes,
jewellery or long hair can be caught in
moving parts.
g. If devices are provided for the connection of
dust extraction and collection facilities,
ensure these are connected and properly
used. Use of dust collection can reduce
dust-related hazards.
4. Power tool use and care
a. Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at
the rate for which it was designed.
b. Do not use the power tool if the switch does
not turn it on and off. Any power tool that
cannot be controlled with the switch is
dangerous and must be repaired.
c. Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
d. Store idle power tools out of the reach of
children and do not allow persons unfamiliar
with the power tool or these instructions to
operate the power tool. Power tools are
dangerous in the hands of untrained users.
e. Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts
and any other condition that may affect the
power tools operation. If damaged, have the
power tool repaired before use. Many
accidents are caused by poorly maintained
power tools.
f. Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting
edges are less likely to bind and are easier to
control.
g. Use the power tool, accessories and tool bits
etc. in accordance with these instructions,
taking into account the working conditions
and the work to be performed. Use of the
power tool for operations different from those
intended could result in a hazardous situation.
5. Service
a. Have your power tool serviced by a qualified
repair person using only identical
replacement parts. This will ensure that the
safety of the power tool is maintained.
Additional power tool safety
warnings
Warning! Additional safety warnings for
routers
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• Hold the power tool by the insulated gripping
surfaces, because the cutter may contact its
own cord. Cutting a "live" wire may make
exposed metal parts of the power tool "live"
and shock the operator.
• Use clamps or another practical way to
secure and support the workpiece to a stable
platform. Holding the work by hand or
against your body leaves it unstable and may
lead to loss of control.
Warning! Contact with, or inhalation of dusts
arising from routing applications may endanger
the health of the operator and possible
bystanders. Wear a dust mask specifically
designed for protection against dust and fumes
and ensure that persons within or entering the
work area are also protected.
• Thoroughly remove all dust after routing.
• Only use router bits with a shank diameter
equal to the size of the collet installed in the
tool.
• Only use router bits suitable for the no-load
speed of the tool.
• Never use router bits with a diameter
exceeding the maximum diameter specified
in the technical data section.
• Do not use the tool in an inverted position.
• Do not attempt to use the tool in a stationary
mode.
• If the supply cord is damaged, it must be
replaced by the manufacturer or an
authorised Black & Decker Service Centre in
order to avoid hazard.
• Take special care when routing where the
paint is possibly lead based or when routing
some woods which may produce toxic dust:
- Do not let children or pregnant women
enter the work area.
- Do not eat, drink or smoke in the work
area.
- Dispose of dust particles and any other
debris safely.
• The intended use is described in this
instruction manual. The use of any accessory
or attachment or performance of any
operation with this tool other than those
recommended in this instruction manual may
present a risk of personal injury and/or
damage to property.
Safety of others
• This appliance/tool is not intended for use by
persons (including children) with reduced
physical, sensory or mental capabilities, or
lack of experience and knowledge, unless
they have been given supervision or
instruction concerning use of the appliance by
a person responsible for their safety.
• Children should be supervised to ensure that
they do not play with the appliance.
Residual risks
Additional residual risks may arise when using
the tool which may not be included in the
enclosed safety warnings. These risks can arise
from misuse, prolonged use etc.
Even with the application of the relevant safety
regulations and the implementation of safety
devices, certain residual risks can not be
avoided. These include:
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ENGLISH
• Injuries caused by touching any
rotating/moving parts.
• Injuries caused when changing any parts,
blades or accessories.
• Injuries caused by prolonged use of a tool.
When using any tool for prolonged periods
ensure you take regular breaks.
• Impairment of hearing.
• Health hazards caused by breathing dust
developed when using your tool (example:working with wood, especially oak, beech
and MDF.)
Vibration
The declared vibration emission values stated in
the technical data and the declaration of
conformity have been measured in accordance
with a standard test method provided by
EN 60745 and may be used for comparing one
tool with another. The declared vibration
emission value may also be used in a
preliminary assessment of exposure.
Warning! The vibration emission value during
actual use of the power tool can differ from the
declared value depending on the ways in which
the tool is used. The vibration level may
increase above the level stated.
When assessing vibration exposure to
determine safety measures required by
2002/44/EC to protect persons regularly using
power tools in employment, an estimation of
vibration exposure should consider, the actual
conditions of use and the way the tool is used,
including taking account of all parts of the
operating cycle such as the times when the tool
is switched off and when it is running idle in
addition to the trigger time.
Labels on tool
The following pictograms are shown on the tool:
Warning! To reduce the risk of injury,
the user must read the instruction
manual.
Electrical safety
This tool is double insulated; therefore
no earth wire is required. Always
check that the power supply
corresponds to the voltage on the rating plate.
• If the supply cord is damaged, it must be
replaced by the manufacturer or an
authorised Black & Decker Service Centre in
order to avoid a hazard.
Features
1. On/off switch
2. Lock-off button
3. Handle
4. Variable speed control knob
5. Plunge lock lever
6. Spindle lock button
7. Collet
8. Revolver depth stop
9. Depth stop bar
10. Chip deflector
11. Dust extraction adaptor
Assembly
Warning! Before assembly, make sure that the
tool is switched off and unplugged.
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ENGLISH
Fitting a router bit (fig. A)
• Remove the chip deflector (10) by pulling it
straight up from the router base.
Warning! Beware not to bend the chip deflector.
• Keep the spindle lock button (6) depressed
and rotate the spindle until the spindle lock
fully engages.
• Loosen the collet nut (17) using the spanner
provided.
• Insert the shank of the router bit (18) into the
collet (7). Make sure that the shank
protrudes at least 3 mm from the collet as
shown.
• Keep the spindle lock button (6) depressed
and tighten the collet nut (17) using the
spanner provided.
Fitting the edge guide (fig. B)
The edge guide (12) helps to guide the tool
parallel to an edge.
• Insert the bars (19) into the router base as
shown.
Fitting the template guide
(fig. D)
• Fit the template guide (13) to the base of the
router, with the flange to the bottom
(workpiece) side.
• Insert the two long screws (24) from the
bottom side through the template guide and
the holes in the base.
• Place a nut onto each of the screws and
securely tighten the nuts.
Fitting the distance piece (fig. E)
• Fit the distance piece (14) to the base of the
router using the screws provided.
Fitting the centring pin (fig. F)
• Fit the edge guide to the router as shown in
fig. B, but upside down.
• Fit the centring pin (15) to the workpiece side
of the edge guide with the screw (25)
provided.
Fitting the copy follower (fig. G)
• Fit the edge guide to the router as shown in
fig. B.
• Set the edge guide to the required distance.
• Tighten the fixing screws (20).
Fitting the dust extraction
adaptor (fig. C)
The dust extraction adaptor allows you to
connect a vacuum cleaner to the tool.
• Place the dust extraction adaptor (11) onto
the dust extraction outlet as shown.
• Connect the hose (23) of the vacuum cleaner
to the adaptor (11).
• Fit the ‘L' bar (16) to the upper side of the
edge guide using the two screws and nuts
provided.
• Adjust the rotating attachment (26) on the ‘L'
bar with the wing knob (27).
Fitting the additional edge guide
(fig. H)
The additional guide (21) is designed to allow
routing of a thin piece of wood (e.g. the edge of a
door).
• Adjust the edge guide (12) as necessary.
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ENGLISH
• Loosen the fixing screws (28).
• Fit the edge guide (21) to the bars (19)
protruding from the router base.
• Adjust the edge guide so the workpiece
becomes clamped between the two edge
guide.
• Tighten the fixing screws (28).
Use
Warning! Let the tool work at its own pace. Do
not overload.
• Carefully guide the cable in order to avoid
accidentally cutting it.
Adjusting the depth of cut (fig. I,
J & K)
The depth of cut is the distance X between the
depth stop bar (9) and the depth stop (29). The
depth of cut can be set in two different ways as
described below.
Adjusting the depth of cut using
the scale (fig. J)
• Fit the router bit as described above.
• Loosen the locking screw (30).
• Pull the plunge lock lever (5) up.
• Plunge the router down until the router bit
touches the workpiece.
• Push the plunge lock lever (5) down.
• Move the depth stop bar (9) down against
the depth stop using the depth stop adjuster
(31). Reset the scale by aligning the zero
marking (32) with the arrow (33).
• Move the depth stop bar (9) to the calculated
position using the depth stop adjuster (31).
One quarter turn corresponds to approx.
6.25 mm.
12
• Tighten the locking screw (30).
• Fine adjust using the adjusting knob (34).
One full turn corresponds to approx. 1 mm.
• Pull the plunge lock lever (5) up and return
the router to its original position.
• After switching the router on, plunge it down
and make the desired cut.
Adjusting the depth of cut using
a piece of wood (fig. K)
• Fit the router bit and plunge the router down
as described above.
• Loosen the locking screw (30).
• Move the depth stop bar (9) up using the
depth stop adjuster (31).
• Place a piece of wood with a thickness equal
to the desired depth of cut between the depth
stop (29) and the depth stop bar (9).
• Move the depth stop bar (9) down against the
wood using the depth stop adjuster (31).
• Tighten the locking screw (30).
• Fine adjust using the adjusting knob (34).
• Remove the piece of wood.
• Pull the plunge lock lever (5) up and return
the router to its original position.
• After switching the router on, plunge it down
and make the desired cut.
Adjusting the revolver depth
stop (fig. L)
After turning the revolver depth stop to the
desired setting, you can fine-adjust the depth
stop to be used. If you want to make several cuts
with a different depth of cut, adjust each of the
depth stops.
ENGLISH
• Turn the depth stop screw (35) up or down
as required using a screwdriver.
Setting the speed
• Set the speed control knob (4) to the
required speed. Use a high speed for small
diameter router bits. Use a low speed for
large diameter router bits.
Using a batten as a guide
(fig. M)
When it is not possible to use the edge guide,
for example when routing grooves in the back
panel of a bookcase to support shelves, proceed
as follows:
• Select a piece of wood with a straight edge
to use as a batten.
• Place the batten onto the workpiece.
• Move the batten until it is in the correct
position to guide the tool.
• Securely clamp the batten to the workpiece.
Using the template guide (fig. D)
The template guide can be used to make a
cutout shape from a template, for instance a
letter.
• Drill a hole for the point of the centring pin in
the centre of the circle to be cut.
• Place the router on the workpiece with the
point of the centring pin in the drilled hole.
• Adjust the radius of the circle with the bars of
the edge guide.
• The router can now be moved over the
workpiece to cut out the circle.
Using the copy follower (fig. G)
The copy follower helps to maintain an equal
cutting distance along the edge of irregularly
shaped workpieces.
• Place the router on the workpiece at the
desired distance from the edge to be copied.
• Adjust the bars of the edge guide until the
wheel is in contact with the workpiece.
Switching on and off
Switching on
•
Keep the lock-off button (2) depressed and
press the on/off switch (1).
• Release the lock-off button.
• Secure the template over the workpiece with
double-sided tape or ‘G' clamps.
• The router bit must extend below the flange
of the template guide, to cut the workpiece in
the shape of the template.
Using the distance piece (fig. E)
The distance piece can be used for trimming
wooden or laminate vertical projections.
Using the centring pin (fig. F)
The centring pin can be used to cut out circular
patterns.
Switching off
•
Release the on/off switch.
Warning! Always operate the tool with both
hands.
Routing
• Fit the router bit and adjust to the required
depth of cut as described above.
• Holding the tool firmly with both hands by the
handles (3), place the tool on the workpiece
and switch on.
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ENGLISH
• Allow the tool to build up speed before
plunging down into the workpiece. When the
depth stop bar has been contacted, operate
the plunge lock lever (5).
• Carry out the operation by applying a
constant force both downwards and in the
direction of cut. Retain a firm grip on the
handles and be prepared for a possible
reaction force if the router bit suddenly stalls
e.g. following contact with a knot.
• On completion of the operation, release the
plunge lock lever and control the upwards
movement of the tool back to its original
position. When the tool has returned to its
original position, it can be switched off. Be
aware that the base is springloaded and that
the tool will jump upwards if not controlled.
Routing speed
The operating speed of the tool can be varied to
affect the level of finish. The correct speed
selection will depend upon the level of finish
required, the type of material being machined,
the diameter and shape of the router bit.
Hints for optimum use
• When working on outside edges, move the
tool counterclockwise (fig. N). When working
on inside edges, move the tool clockwise.
• Use HSS router bits for softwood.
• Use TCT router bits for hardwood.
• You can use the tool without a guide (fig. O).
This is useful for signwriting and creative
work. Only make shallow cuts.
• Refer to the table below for common types of
router bits.
KW1600EA - Router bits (fig. P)
Description Application
Straight bit (1) Grooves and rebates
Trimming bit (2) Trimming laminates or
hardwood; accurate
profiling using a template
Rebating bit (3) Rebates on straight or
curved workpieces
• Prepare the tool to make a practice cut on a
piece of scrap material. Make a preliminary
adjustment of the speed control selecting a
high speed for small diameter router bits and
a low speed for large diameter router bits.
• When the routing operation is completed,
withdraw the tool from the workpiece, switch
off the tool and inspect the level of finish.
Adjust the speed control knob (4) and repeat
until an optimum level of finish is obtained.
Warning! Do not release the handles to adjust
the speed when the tool is locked down and
operating in the workpiece.
14
V-grooving bit (4) Grooves, engraving and
edge bevelling
Core box bit (5) Fluting, engraving and
decorative edge moulding
Cove bit (6) Decorative edge moulding
Ogee moulding bit (7) Decorative edge moulding
Rounding over bit (8) Rounding over edges
Dovetail bit (9) Dovetail joints
Chamfer bit (10) Chamfer edges
ENGLISH
Maintenance
Your tool has been designed to operate over a
long period of time with a minimum of
maintenance. Continuous satisfactory operation
depends upon proper tool care and regular
cleaning.
Warning! Before performing any maintenance,
switch off and unplug the tool.
• Regularly clean the ventilation slots in your
tool using a soft brush or dry cloth.
• Regularly clean the motor housing using a
damp cloth. Do not use any abrasive or
solvent-based cleaner.
Mains Plug Replacement
If a new mains plug needs to be fitted:
• Safely dispose of the old plug.
• Connect the brown lead to the live terminal of
the new plug.
Technical Data
KW1600E
TYPE1
Input voltage V
Power input W 1,600
No-load speed min-1 11,000 - 28,000
Collet size 1/2" (12.7)/ 1/4" (6.35)/
8 mm / 6 mm
Max. diameter mm 42
of router bit
Max. depth of cut mm 60
Weight kg 5.1
AC 220-240
• Connect the blue lead to the neutral terminal.
• If the product is class l (earthed), connect the
green / yellow lead to the earth terminal.
Warning! If your product is class ll double
insulated (only 2 wires in the cord set), no
connection is to be made to the earth terminal.
Follow the fitting instructions supplied with good
quality plugs.
Any replacement fuse must be of the same
rating as the original fuse supplied with the
product.
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