HAFCO-WOODMASTER K053, W486 Assembly Instructions

1

W486 HAFCO ST254 table saw 3-12-14

Assembly instructions (use in conjunction with factory supplied manual)

Your HAFCO ST254 saw bench comes supplied in 2 cartons
1 of 2 contains main saw bench assembly and 2 off 2 contains parts for rip fence.

Open both boxes and inspect for any damage etc before assembly.

Main Carton # 1
Carefully remove the 2 x cast tables and then loose parts packed inside machine and around it.
Note 2 x small pieces of key steel wrapped in brown paper with the 2 hand wheels. Put these aside so as not to lose
them they will be needed later

Break off all four sides of the main carton and remove out of the way. Hammer over any sharp nails left in the base
of carton.
Find the 4 Legs marked A, B, C, D and the rear panel “E” with the dust extraction cut out.
Locate the dust extraction moulding and fit it to the panel “E” with the bolts and nuts provided.
The orientation of the moulding should leave it fitted with the 30mm port pointing upwards when machine is right
side up later. (Ie pointing towards the long side of the panel. The sides of the panel being those with the holes in)
Below picture may help. Tighten all nuts.

Find 20 x M8x16 long mm Bolts nuts and double washers
Fit the legs to the upside down machine, noting the
corresponding letters A,B,C,D on the legs fit to the
corresponding letters on the machine and that the orientation
of the legs are fitted so the tapped holes in the legs point up
when fitted on the upside down machine
Fit legs using a washered bolt through the legs and secure
with washer and nut (Secure the nuts finger tight only)

Fit the Rear panel “E” with the dust extraction cute fitted to
the rear of the machine on the side marked “E”
Using washered bolts through the sides to the panel/legs and
secure with washer and nut (Secure the nuts finger tight only)

Now is a good time to fit the dust extraction hose
Locate the hose and the two large hose clamps, slip the clamps over the hose and first fit one end to the outlet of
the saw blade box. Slip hose clamp over and ensuring the hose is pushed on correctly tighten the clamp checking to
ensure the hose is on tightly.
Fit the other end to the inside of the dust extractor moulding and slide on clamp and tighten.

Now fit the other 3 side panels using washered bolts through the sides to the panel/legs and secure with washer and
nut (Secure the nuts finger tight only)
While aligning the side panels in the legs tighten all sets of bolt/nuts around the base then tighten the 4 bolt/nut sets
holding the base to the machine.
When all are tight the machine can now be lifted upright. At least two people should be used to do this.
Hint! Tilt it over towards the side of the body with nothing coming out of it (Hand wheel shaft/Switch/Dust Cute)
That way if you come into difficulty and have to lay machine down it will not rest on anything that can get damaged.

2

Fit the Tilt and the Raise and Lower hand wheels onto the
shafts of the machine
ew.
Tighten 2 x Screw tightly onto flats on shafts

Fitting extension Tables to main table..

Note the machine can now be set up in one of two
configurations

SET UP # 1 With an extension table on each side of
the machine.

NB: as above, the tape fitted to the fence rail as
delivered is split in two, having the ability to use the
fence on the left and right of the blade .
If set up like this the Support Leg is not needed but
can be used if you want (Pick a side!)

SET UP #2 With both extension tables on the
Right hand side and the support leg supplied
used to prop it up.
If set up like this, the original measurement
tape gets taken off the front fence rail and the
new one put on.

This set up is also used when fitting optional

sliding table # W487

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Assembly Cast extension tables

Select one of the Extension tables (they are identical)
Find the 4off M8 x 25mm long Bolts and flat washers and 4 x M8 x 30mm long bolts washers and nuts supplied.
Ensure the front edge of the extension table is correctly orientated (The front edge of the Extension tables are
Chamfered. This matches the front edge of the main table that is also chamfered. )
Stand the back end of the table on the floor on the right hand side of the main table, then lift it up and putting one
of the M8 x 25mm washered bolts through the top hole screw the bolt into the front tapped hole in the main table
until almost home.
Carefully lift up the bottom edge of the table and swing up, aligning the tops faces fit another bolt and washer and
then the middle two.
Nip up the front and rear bolts. Now with a soft hammer, line up the front edge and rear edges of the cast table with
the main table. This is needed to ensure Fence rail can be attached easily and accurately
With the soft hammer you can level up the tops of both main table and extension table as needed.
If there is a slight lump or drop in the middle of the joining top edges, this can be reduced by removing two off end
bolts and working from one end to the other, lift or lower table to line up top faces as you go tightening the
attachment bolts ensuring the front and rear ends are still in line with the main table
When done tighten all 4 bolts.

For set up # 1 Repeat the above with the second Cast Extension table on the left side of the main table using the M8
x 30mm long bolts and washers

For set up # 2 Repeat the above with the second Cast Extension table bolted to the side of the first cast extension
with the 4off M8 x 30mm long bolts nuts and double washers supplied to bolt Second table onto the first one,
So both tables are now on the Right hand side of the main table….
Then fit the support leg supplied to the 2 middle taped holes on the outer edge of the second cast extension table.
When the Saw bench is located in its final position the support leg can be adjusted up to the correct height using a
straight edge across the main table over the cast extensions to adjust as needed.

Assembly Rip Fence

Find the 10off M8 SQUARE Head bolts washers and nuts
The best way to fit the rails is to fit the M8 x Square head bolts
in front and back holes (5 each) with the Square head of the
bolt on the outside and the washer and nut in under table lip

Slide on front and back rails, introducing the square head of the
bolt into the Tee slot of the extruded front and rear rails

For Set up # 1 Align each rail approximately central on the
machine then finger tighten up both rails end bolts only (2 of,
each rail)

For set up #2 Align each rail so it is in from the left edge of the main cast
table about 8 to 10mm

Ensuring machine is not plugged in.
Wind blade fully up ## Caution of sharp teeth on blade!! ##

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Fence Locked in

Find the Rip fence assembly complete with the Side extension plate.
Remove the fence extension side plate
off the fence and put it aside.

For set up # 1 Front rail as supplied with 2 tapes on 0-64 on the left
and 0-62 on the right
From the right hand side, slide the fence on to the front and rear rails
Zero the sight line over the “0” of the right hand tape.
While pushing forward to hold the fence square on the front rail, slide
the front rail across with fence held on the Zero mark until the fence
touches the blade,
Checking fence sight line is still over “0”, nip up
the end bolts of the front rail while at the same
time lifting rail up each end while locking the nut.
(To ensure clearance between fence and table
surface)
Recheck the Zero line and that the fence is
touching blade, then tighten the end nuts only of
the front rail..
Line up rear fence rail were needed and while
lifting that up, tighten the end nuts and then the
remaining 3 nuts to fasten the rear rail secure.

For set up # 2 Remove the existing
measurement tapes 0-64 on the left and 0­62 on the right of the front fence rail as
these are only needed for set up #1.
The tape can be carefully lifted with a sharp
blade and peeled off. Residue glue on rail
can be removed with kerosene and a small
scraper.
The new Tape left to Right reading 0-98
now has to be fitted in the correct position.
To do this, From the right hand side, slide
the fence on to the front and rear rails and
then slide the fence all the way across to be
touching the blade lightly. Lock the fence
down.
Feed the tape (with backing paper still on!)
under the fence and “Zero the sight line over the “0” of the tape.
With a black marker put a mark on the tape and front rail as
shown, checking the Zero line is still over the “0” of the tape.
Pull the tape out and remove the Fence. Clean the front rail with a
dry cloth in the slot the tape will be going being carefull not to
remove the black mark just put on.

place, up against

raised blade

Tape with backing paper

fed under fence.

Align Zero lone with “0”

And mark tape and rail.

5

Screw to

Start peeling the backing tape off the new
tape and position the tape on the rail, lining
up the black marker lines as you go, then if
all Ok, peel the rest of the backing paper off
as you put the rest of the tape into the
groove. Press the tape down firmly along its
lengh.

Continue For set up # 1 and # 2

Move the fence in line with the mitre slot in the table and
check it is parallel with the slot.
If needed, loosen the 4 x screws holding the fence to the rail
and square it up, tightening the 4 screws when finished.

Recheck the “0” on the sight line of the fence is correct with
fence touching the blade!
If needed reset front rail to get this correct
Then tighten the other remaining 3 nuts to fasten the front rail
secure.

Lower the blade all the way down under table surface.

Slide the fence assembly off and mount the fence
“Micro-Adjuster” to the rip fence front bracket on the right
hand side (when up the correct way) .

Refit the Fence onto the rails.
The micro –Adjuster is used by pushing in
the spring loaded knob and then turning it.
This engages the gear on the rack running along the
bottom of the fence rail.
It may need adjusting to allow the gear to come better
into mesh with the rack, or it may be too tight.
To adjust this if needed, the shaft of the gear is in an
adjustable black cam bush.
Loosen the screw under the bush with an Allen key and
turn the black bush to move the shaft/gear up or down
as needed. Tighten screw when set as required.
If the gear is still too tight on the rack an extra washer
can be fitted between the mounting bracket and rip
fence to drop the gear down further.

loosen for

adjustment

6

Fit the 4 x plastic end caps with the self-tapping screws
supplied, then check for any protruding plastic and file flush if
needed so it doesn’t catch when the fence is slid to the
further most ends of the rails.
Fit the fence “side extension” back on…

Assembly Riving Knife and blade guard

Ensuring machine is not plugged in.
Wind blade fully up !!Caution of sharp teeth on blade!!
Undo and remove the 5 screws holding table insert in and remove insert
Undo the 2 x bolts on the front of the riving knife holder behind the blade just enough to allow the slot in the riving
knife to go over the center bolts in the assembly push the riving knife towards the blade and tighten the bolts of the
front bracket, Note the mounting plate for the riving knife has been factory set. Do not adjust the 4 bolts
Refit the table insert and lower the blade
checking the knife does not foul the table
insert.

Fit the blade guard onto the riving knife
The attachment bolt in the knife slides down
into the “L” shaped slot when all the way
down slide it back into the “L”

Wind the blade down then fit the 30mm Dust
hose from the blade guard to the rear dust
chute Hole in place with the 2 x 30mm hose
clamps supplied.

# Fit the small mitre fence….

# Connect machine to Suitable Dust Collector

Your Hafco Sawbench is now ready to use.

Further information on setting, maintenance and spare parts
available can be found in the Main Factory manual.