Shop fox D4902 User manual

OWNER'S MANUAL
(FOR MODELS MANUFACTURED SINCE 11/18)
MODEL D4902
TENONING JIG
Phone: [phone] • Online Technical Support: [email protected]
COPYRIGHT © MARCH, 2019 BY WOODSTOCK INTERNATIONAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT
THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.
#20286KB Printed in Taiwan

This manual provides critical safety instructions on the proper setup,
operation, maintenance, and service of this machine/tool. Save this
document, refer to it often, and use it to instruct other operators.
Failure to read, understand and follow the instructions in this manual
may result in fire or serious personal injury—including amputation,
electrocution, or death.
The owner of this machine/tool is solely responsible for its safe use.
This responsibility includes but is not limited to proper installation in
a safe environment, personnel training and usage authorization,
proper inspection and maintenance, manual availability and compre-
hension, application of safety devices, cutting/sanding/grinding tool
integrity, and the usage of personal protective equipment.
The manufacturer will not be held liable for injury or property
damage from negligence, improper training, machine modifications or
misuse.
Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:
• Lead from lead-based paints.
• Crystalline silica from bricks, cement and other masonry products.
• Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you
do this type of work. To reduce your exposure to these chemicals:
Work in a well ventilated area, and work with approved safety equip-
ment, such as those dust masks that are specially designed to filter
out microscopic particles.

SETUPELECTRICAL MAINTENANCE SERVICE PARTS
OPERATIONS
SAFETYINTRODUCTION
USE THE QUICK GUIDE PAGE LABELS TO SEARCH OUT INFORMATION FAST!
INTRODUCTION ..........................................................................................................2
Woodstock Technical Support ....................................................................................... 2
Functional Overview.................................................................................................. 2
Identification .......................................................................................................... 3
Table Saw Requirements ............................................................................................. 3
SAFETY ....................................................................................................................4
Standard Machinery Safety Instructions ........................................................................... 4
Additional Safety for Tenoning Jigs ................................................................................ 6
SETUP .....................................................................................................................7
Unpacking .............................................................................................................. 7
Inventory ............................................................................................................... 7
Needed for Setup ..................................................................................................... 7
Cleaning Machine...................................................................................................... 8
Preparing Table Saw .................................................................................................. 9
Preparing Tenoning Jig ............................................................................................... 9
Assembly.............................................................................................................. 10
Re-Mounting Guide Bar ............................................................................................. 11
Adjusting Guide Bar ................................................................................................ 13
Adjusting Side Support ............................................................................................. 14
Adjusting Back Support ............................................................................................ 15
Adjusting Blade Clearance......................................................................................... 16
OPERATIONS............................................................................................................ 18
Operation Overview ................................................................................................ 18
Cutting Basic Tenons................................................................................................ 19
ACCESSORIES ........................................................................................................... 25
MAINTENANCE ......................................................................................................... 27
General ............................................................................................................... 27
Cleaning & Protecting .............................................................................................. 27
Lubrication & Storage .............................................................................................. 27
PARTS ................................................................................................................... 28
Main ................................................................................................................... 28
WARRANTY ............................................................................................................. 33
Contents

-2-
Model D4902 (For Machines Mfd. Since 11/18)
INTRODUCTION
INTRODUCTION
Woodstock Technical Support
This machine has been specially designed to provide many years of trouble-free service. Close attention
to detail, ruggedly built parts and a rigid quality control program assure safe and reliable operation.
Woodstock International, Inc. is committed to customer satisfaction. Our intent with this manual is to
include the basic information for safety, setup, operation, maintenance, and service of this product.
We stand behind our machines! In the event that questions arise about your machine, please contact
Woodstock International Technical Support at [phone] Ext. 2 or send e-mail to: techsupport@
woodstockint.com. Our knowledgeable staff will help you troubleshoot problems and process warranty
claims.
If you need the latest edition of this manual, you can download it from http://www.woodstockint.com/
manuals.
If you have comments about this manual, please contact us at:
Woodstock International, Inc.
Attn: Technical Documentation Manager
P.O. Box 2309
Bellingham, WA 98227
Email: [e-mail]
The tenoning jig is designed to work with your table saw
to make a tenon, such as shown at right, which will be
part of a mortise and tenon joint.
With the tenoning jig mounted in the miter slot of the
table saw, the workpiece is clamped upright to the jig in
various configurations so that the tenon cheek cuts can be
made. Then the jig is removed and the workpiece is laid
flat on the table saw to make the shoulder cuts.
Functional Overview
Example of a completed basic tenon.

-3-
Model D4902 (For Machines Mfd. Since 11/18)
INTRODUCTION
The D4902 Tenoning Jig is designed to work with most
table saws. Use the table saw requirements listed below
to verify that your table saw will work with the tenoning
jig.
Table Saw Miter Slot.................. Standard 3⁄4" w/T-Slot
Distance from Miter Slot Center to Blade:
Minimum..................................................... 3
3⁄4"
Maximum .................................................... 6
3⁄4"
Table Saw Requirements
Identification
Become familiar with the names and locations of the controls and features shown below to better
understand the instructions in this manual.
To reduce your risk of serious injury
or damage to the machine, read this
entire manual BEFORE using machine.
Clamp
Handwheel
Side Support
Tilt Lock Lever
Back Support
Lock Lever
Guide Bar
Depth of Cut
Scale & Pointer
Clamp Handle
Slide Plate
Lock Lever
Back SupportClamp
Brace
Clamp
Shoe
Side
Support
Micro-Adjust
Knob
Base
Plate
Slide
Plate
Micro-Adjust
Lock Lever
Slide Plate
Handle

-4-
Model D4902 (For Machines Mfd. Since 11/18)
SAFETY
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury.
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
This symbol is used to alert the user to useful information about
proper operation of the equipment or a situation that may cause
damage to the machinery.
NOTICE
SAFETY
OWNER’S MANUAL.
Read and understand this
owner’s manual BEFORE using machine.
TRAINED OPERATORS ONLY.
Untrained operators
have a higher risk of being hurt or killed. Only
allow trained/supervised people to use this
machine. When machine is not being used,
disconnect power, remove switch keys, or
lock-out machine to prevent unauthorized
use—especially around children. Make
workshop kid proof!
DANGEROUS ENVIRONMENTS.
Do not use
machinery in areas that are wet, cluttered,
or have poor lighting. Operating machinery
in these areas greatly increases the risk of
accidents and injury.
MENTAL ALERTNESS REQUIRED.
Full mental
alertness is required for safe operation of
machinery. Never operate under the influence
of drugs or alcohol, when tired, or when
distracted.
ELECTRICAL EQUIPMENT INJURY RISKS. You can
be shocked, burned, or killed by touching live
electrical components or improperly grounded
machinery. To reduce this risk, only allow an
electrician or qualified service personnel to
do electrical installation or repair work, and
always disconnect power before accessing or
exposing electrical equipment.
DISCONNECT POWER FIRST. Always disconnect
machine from power supply BEFORE making
adjustments, changing tooling, or servicing
machine. This eliminates the risk of injury
from unintended startup or contact with live
electrical components.
EYE PROTECTION. Always wear ANSI-approved
safety glasses or a face shield when operating
or observing machinery to reduce the risk of
eye injury or blindness from flying particles.
Everyday eyeglasses are not approved safety
glasses.
Standard Machinery Safety Instructions
For Your Own Safety,
Read Manual Before Operating Machine
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This
manual uses a series of symbols and signal words intended to convey the level of importance of the
safety messages. The progression of symbols is described below. Remember that safety messages by
themselves do not eliminate danger and are not a substitute for proper accident prevention mea-
sures—this responsibility is ultimately up to the operator!
SAFETY
Standard Machinery Safety Instructions

-5-
Model D4902 (For Machines Mfd. Since 11/18)
SAFETY
WEARING PROPER APPAREL. Do not wear
clothing, apparel,or jewelry that can become
entangled in moving parts. Always tie back
or cover long hair. Wear non-slip footwear to
avoid accidental slips, which could cause loss
of workpiece control.
HAZARDOUS
DUST. Dust created while using
machinery may cause cancer, birth defects,
or long-term respiratory damage. Be aware of
dust hazards associated with each workpiece
material, and always wear a NIOSH-approved
respirator to reduce your risk.
HEARING PROTECTION.
Always wear hearing
protection when operating or observing
loud machinery. Extended exposure to this
noise without hearing protection can cause
permanent hearing loss.
REMOVE ADJUSTING TOOLS.
Tools left on
machinery can become dangerous projectiles
upon startup. Never leave chuck keys,
wrenches, or any other tools on machine.
Always verify removal before starting!
INTENDED USAGE.
Only use machine for its
intended purpose—never make modifications
without prior approval from Woodstock
International. Modifying machine or using
it differently than intended will void the
warranty and may result in malfunction or
mechanical failure that leadsto serious
personal injury or death!
AWKWARD POSITIONS.
Keep proper footing and
balance at all times when operating machine.
Do not overreach! Avoid awkward hand
positions that make workpiece control difficult
or increase the risk of accidental injury.
CHILDREN & BYSTANDERS.
Keep children and
bystanders at a safe distance from the work
area. Stop using machine if they become a
distraction.
GUARDS & COVERS.
Guards and covers reduce
accidental contact with moving parts or flying
debris—make sure they are properly installed,
undamaged, and working correctly.
FORCING MACHINERY. Do not force machine. It
will do the job safer and better at the rate for
which it was designed.
NEVER STAND ON MACHINE. Serious injury may
occur if machine is tipped or if the cutting
tool is unintentionally contacted.
STABLE MACHINE. Unexpected movement during
operation greatly increases risk of injury or
loss of control. Before starting, verify machine
is stable and mobile base (if used) is locked.
USE RECOMMENDED ACCESSORIES. Consult
this owner’s manual or the manufacturer for
recommended accessories. Using improper
accessories will increase risk of serious injury.
UNATTENDED OPERATION. To reduce the risk
of accidental injury, turn machine OFF and
ensure all moving parts completely stop
before walking away. Never leave machine
running while unattended.
MAINTAIN WITH CARE. Follow all maintenance
instructions and lubrication schedules to
keep machine in good working condition. A
machine that is improperly maintained could
malfunction, leading to serious personal injury
or death.
CHECK DAMAGED PARTS. Regularly inspect
machine for any condition that may affect
safe operation. Immediately repair or replace
damaged or mis-adjusted parts before
operating machine.
MAINTAIN POWER CORDS. When disconnecting
cord-connected machines from power, grab
and pull the plug—NOT the cord. Pulling the
cord may damage the wires inside, resulting
in a short. Do not handle cord/plug with wet
hands. Avoid cord damage by keeping it away
from heated surfaces, high traffic areas, harsh
chemicals, and wet/damp locations.
EXPERIENCING DIFFICULTIES. If at any time
you experience difficulties performing the
intended operation, stop using the machine!
Contact Technical Support at [phone].

-6-
Model D4902 (For Machines Mfd. Since 11/18)
SAFETY
Additional Safety for Tenoning Jigs
Serious cuts, amputation, or death can occur from contact with rotating saw blade during
operation. Workpieces, broken blades, or flying particles thrown by blade can blind or strike
operators or bystanders with deadly force. To reduce the risk of these hazards, operator and
bystanders MUST completely heed the hazards and warnings below.
JIG CONTROL. ALWAYS use two hands to firmly
hold both tenoning jig handles when cutting.
NEVER hold jig with just one hand.
ADJUSTING JIG. DISCONNECT SAW FROM POWER
before installing or adjusting jig, saw, or
workpiece.
CUTTING CORRECT MATERIAL. Cutting metal,
glass, stone, tile, etc., increases
risk of operator
injury due to kickback or flying particles. Only
cut natural and man-made wood products, lami-
nate-covered wood products, and some plastics.
Never cut materials not intended for your saw.
SELECTING TENON LOCATION.
Select clean tenon
locations that are low in moisture content, and
are free of knots, staples, nails, and embedded
debris.
CHECKING TABLE SAW ACCESSORIES. Make sure
other accessories used on table saw do not
interfere with operation of tenoning jig.
RE-INSTALLING BLADE GUARD. Always immedi-
ately re-install and correctly adjust blade guard
and any other safety features of table saw after
removing tenoning jig.
OWNER’S MANUALS.
Read and understand this
manual and the manual for your table saw
before using tenoning jig.
HAND & BODY POSITIONING
.Keep hands away
from saw blade and out of blade path during
operation, so they cannot accidentally slip into
blade. Only operate at front of machine and
always stand to side of blade path. Never reach
behind or over blade. If kickback occurs while
reaching over blade, hands, fingers, or arms
could be pulled into spinning blade.
KICKBACK.
Kickback occurs when saw blade ejects
workpiece back toward operator. Know how to
reduce risk of kickback, and learn how to pro-
tect yourself if it does occur.
SECURING WORKPIECE.
ALWAYS securely clamp
workpiece in tenoning jig, and make sure all fas-
teners and lock levers are tight before you start
saw. ALWAYS make sure jig will not make con-
tact with saw blade during operation.
REMOV
ING TOOLS. Remove tools and other items
from jig and table saw before turning saw ON to
avoid risk of these items being thrown toward
operator or bystander at high speed.
READ and understand this
entire manual before using
this machine. Serious per-
sonal injury may occur
if safety and operational
information is not under-
stood and followed. DO
NOT risk your safety by
not reading!
USE this and other machinery with caution
and respect. Always consider safety first,
as it applies to your individual working
conditions. No list of safety guidelines can
be complete—every shop environment is
different. Failure to follow guidelines could
result in serious personal injury, damage to
equipment or poor work results.

-7-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
Unpacking
SETUP
Figure 1. Model D4902 inventory.
AB
C
D
E
Keep machine disconnected from
power until instructed otherwise.
This machine has been carefully packaged for safe
transportation. If you notice the machine has been
damaged during shipping, please contact your authorized
Shop Fox dealer immediately.
Inventory (Figure 1) Qty
A. Tenoning Jig Assembly ....................................1
B. Clamp Handwheel .........................................1
C. Clamp Shoe & Bracket ....................................1
D. Clamp Brace................................................1
E. Handles......................................................2
Hardware & Tools (not shown) Qty
• Lock Washers 10mm.......................................2
• Fender Washer 8mm ......................................1
• Cap Screw M8-1.25 x 50 ..................................1
• Cap Screw M10-1.5 x 25 ..................................1
• Cap Screw M10-1.5 x 20 ..................................1
• Hex Wrenches 2.5, 3, 4, 6, 8mm ................ 1 Each
Inventory
The following is a list of items shipped with your machine.
Before beginning setup, lay these items out and inventory
them.
Note:
If you cannot find an item on this list, carefully
check around/inside the machine and packaging materials.
Often, these items get lost in packaging materials while
unpacking or they are pre-installed at the factory.
Needed for Setup
The following items are needed, but not included, for the
setup/assembly of this machine.
Description Qty
• Square 90°..................................................1
• Shop Rags & Solvent .......................... As Needed
• Phillips Screwdriver #2 ...................................1
• Hex Wrench 3⁄16"...........................................1
• Open-End Wrench 8mm...................................1
• Open-End Wrench 10mm .................................1
• Machinist's Square .........................................1

-8-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
To prevent
corrosion during shipment and storage of your
machine, the factory has coated t
he bare metal surfaces
of your machine
with a heavy-duty rust prevention
compound
.
I
f you are unprepared or impatient, this compound can
be difficult to
remove. To ensure that the removal of this
coating is as easy as possible, please gather the correct
cleaner, lubricant, and tools listed below:
• Cleaner/degreaser
designed to remove storage wax
and grease
• Safety glasses & disposable gloves
•
Solvent brush or paint brush
• Disposable Rags
To
remove rust preventative coating, do these steps:
1.
DISCONNECT MACHINE FROM POWER!
2.
Put on safety glasses and disposable gloves.
3
.Coat the rust preventative with a liberal amount of
cleaner/degreaser, then let it soak for 5–10 minutes.
4
.Wipe off surfaces. If your cleaner/degreaser is
effective, the coating will wipe off easily.
Tip: An easier way to clean off thick coats of rust
preventative from flat surfaces is to use a PLASTIC
paint scraper to scrape off the majority of the
coating before wiping it off with your rag. (Do
not use a metal scraper or you may scratch your
machine.)
5
.Repeat cleaning steps as necessary until all of the
compound is removed.
6
.To prevent rust on freshly cleaned surfaces,
immediately coat with a quality metal protectant.
Gasoline and petroleum
products have low flash
points and can explode
or cause fire if used to
clean machinery. Avoid
using these products
to clean machinery.
Many cleaning solvents
are toxic if inhaled.
Minimize your risk
by only using these
products in a well
ventilated area.
In a pinch, automotive degreasers,
mineral spirits or WD•40 can be used
to remove rust preventative coating.
Before using these products, though,
test them on an inconspicuous area of
your paint to make sure they will not
damage it.
Cleaning Machine

-9-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
Preparing Table Saw
The Model D4902 Tenoning Jig is designed to work with a
table saw that has a 3⁄8" x 3⁄4" miter T-slot on the left side
of the blade. To help ensure safe and accurate tenons,
follow these rules to properly prepare your table saw
before using it with the jig.
• Table Saw Operation: Make sure that you read and
understand your table saw owner's manual, and take
all instructed safety precautions.
• Riving Knife: You must use a riving knife that is
properly installed behind the blade to ensure the
kerf does not close on the blade and cause kickback.
• Saw Blades: Make sure that your saw blades are not
damaged and that the teeth are sharp.
• Saw Adjustments: When using the tenoning jig,
the accuracy of the cuts depend upon the accuracy
of the saw blade. Make sure that your saw blade
is perpendicular to the table and parallel with the
miter slots.
• Miter Slot and Table: Make sure the miter slots
and table are free from burrs or debris that may
interfere with the smooth operation of the jig.
• Lighting: Make sure the top of your table has
adequate lighting so that the tenoning jig and
workpiece are properly illuminated without shadows.
Always disconnect power to the table
saw before performing adjustments,
maintenance, or service to the saw
or tenoning jig. Failure to do this may
result in serious personal injury.
Preparing Tenoning Jig
To properly assemble and adjust your tenoning jig, you
must perform the following procedures before using it to
make tenons:
• Assembly.
• Re-Mounting Guide Bar (Page 11).
• Adjusting Guide Bar (Page 13).
• Adjusting Side Support (Page 14).
• Adjusting Back Support (Page 15).
• Adjusting Blade Clearance (Page 16).

-10-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
Assembly
To assemble tenoning jig, do these steps:
1. Attach clamp brace to back of side support using (1)
M10-1.5 x 20 cap screw with 10mm lock washer, and
(1) M10-1.5 x 25 cap screw with 10mm lock washer,
as shown in Figure 2.
Note: These cap screws are different lengths and
must be installed in the correct holes, as shown in
Figure 2.
Figure 2. Clamp brace installed.
Side
Support
25mm Cap
Screw
20mm Cap
Screw
Clamp
Brace
Figure 3. Handles installed.
Handles
Figure 4. Clamp bracket and handwheel
installed.
Clamp
Brace
Rod
HandwheelClamp
Bracket
Cap Screw &
Fender Washer
2. Install handles into threaded holes on clamp brace
and slide plate, as shown in Figure 3.
3. Slide clamp bracket over clamp brace rod, as shown
in Figure 4, then secure it with (1) M8-1.25 x 50 cap
screw and (1) 8mm fender washer.
4. Align set screw in hub of handwheel (see Figure 4)
with flat of clamp shaft, then slide handwheel onto
shaft and tighten set screw.

-11-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
Re-Mounting Guide Bar
The guide bar can be mounted to the slide plate in two
positions (see Figure 5), depending on the distance
between the left-hand miter slot of the table and the
blade. The jig ships with the guide bar mounted in the
outward position. If the jig needs to be farther from the
blade, you will need to mount the guide bar in the inward
position. Guide Bar
Inward
Mounting
Position
Slide
Plate
Guide Bar
Outward
Mounting
Position
Figure 5. Guide bar mounted to slide
plate.
The jig must be mounted on the table
so that the side support cannot come
in contact with the blade. The jig side
support must stay at least 1⁄2" away
from the blade at all times during
operation. If the side support should
make contact with the blade during
operation, serious personal injury
could result. At best, the blade and jig
will be damaged.
To re-mount guide bar in inward position, do these
steps:
1. Remove slide plate lock lever and flat washer, then
un-thread the M8-1.25 x 55 set screw the lock lever
was attached to (see Figure 6).
Note: The set screw will fall between the slide and
base plates and will be accessible in the following
steps.
2. Loosen micro-adjust lock lever, then rotate micro-
adjust knob counterclockwise to force slide plate to
move and separate from micro-adjust leadscrew, as
shown in Figure 6.
Figure 6. Slide plate and base plates
separated.
Slide Plate Lock
Lever & Parts
Base Plate Slide Plate
Micro-
Adjust
Knob
Micro-Adjust
Lock Lever
Guide
Bar

-12-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
3. Loosen set screw on micro-adjust assembly, then
remove micro-adjust assembly from rod (see
Figure 7).
4. Remove (2) pre-installed M6-1 x 20 button head cap
screws that secure guide bar to base plate, then
re-install bar in inward mounting position, as shown
in Figure 7.
Figure 7. Guide bar mounted in inward
position.
5. Thread M8-1.25 x 55 set screw removed in Step 1
back into middle, inward hole on base plate, then
tighten jam nut to secure it (see Figure 8).
6. Loosen Phillips head screw that secures pointer (see
Figure 8), and swing pointer out of the way.
7. Place slide plate onto base plate over M8-1.25 x 55
set screw, as shown in Figure 8.
Figure 8. Slide plate positioned over base
plate.
Rod
Set Screw
M8-1.25 x 55
Set Screw
Slide Plate
Pointer
8. Slide micro-adjust collar onto rod, align micro-adjust
leadscrew with threaded guide bushing of slide
plate, then rotate knob clockwise until collar is even
with rod, as shown in Figure 9.
9. With one hand pressing slide plate flat against base
plate to properly align micro-adjust assembly, fully
tighten set screw on micro-adjust collar to secure it
to rod.
10. Re-position and secure pointer, then re-install slide
plate lock lever and flat washer. Figure 9. Micro-adjust assembly properly
positioned.
Guide Bar
Inward
Mounting
Position
Slide
Plate
Guide Bar
Outward
Mounting
Position
Figure 10. Guide bar in outward position.
To re-mount guide bar in outward position, do this
step:
1. Perform inward mounting procedure but install guide
bar using right row of mounting holes on base plate
(see Figure 10).
Inward
Mounting
Position
Rod
Knob
Threaded
Guide
Bushing
Leadscrew
Set
Screw
Micro-
Adjust
Collar

-13-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
Adjusting Guide Bar
In this procedure you will adjust the guide bar so that it
slides back and forth in the table saw miter slot without
side-to-side play or tilt that could cause the workpiece to
bind with the blade and create kickback, or produce poor
cutting results.
To adjust guide bar, do these steps:
1. DISCONNECT TABLE SAW FROM POWER!
2. Insert tenoning jig guide bar into table saw miter
slot, then slide it back and forth.
— If guide bar slides freely in miter slot with no
side-to-side play or tilt, then no adjustment is
necessary. Continue with Adjusting Side Support
procedure on Page 14.
— If side-to-side play or tilt exists, continue with
Step 3.
3. Remove tenoning jig from table saw and turn it
upside down, as shown in Figure 11.
4. Evenly adjust set screws shown in Figure 11 the
same amount so that they protrude from guide bar
enough to take up side-to-side play described in
Step 2.
5. Make sure (2) pre-installed 1⁄4-20 x 3⁄8" flat head cap
screws that secure T-slot washers (see Figure 11)
are tight.
6. Repeat Steps 2–5 until you are satisfied with
movement of guide bar in saw miter slot.
DO NOT remove the T-slot washers
from the ends of the tenoning jig guide
bar. Removal of these washers could
allow the jig to come loose from the
table during a cutting operation, which
could cause serious personal injury or
property damage.
Figure 11. Guide bar adjustment
components.
T-Slot Washers
Set Screws
Guide
Bar

-14-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
Adjusting Side Support
In this procedure,you will adjust the side support
perpendicular to the saw table. Then you will set the 90°
positive stop so the support can be quickly returned to
the perpendicular position after an angle cut.
To adjust side support, do these steps:
1. DISCONNECT TABLE SAW FROM POWER!
2. Make sure saw blade is perpendicular to table miter
slot (refer to your table saw owner's manual for
instructions).
3. Completely lower saw blade so it will not interfere
with measurements.
4. Clean away any debris from table or tenoning jig
that could affect measurements, then insert jig all
the way into miter slot.
5. Thread positive stop set screw far enough into side
support (see Figure 12) so that it will not interfere
with the next step.
6. Position machinist's square flat on table and up
against tenoning jig side support, as shown in
Figure 12.
7. Loosen support lock lever, position side support flat
against machinist's square, then, without moving
support, re-tighten lock lever (see Figure 12).
8. Remove square and re-tighten positive stop set screw
until it just meets resistance. The 90° positive stop
is now set for quick perpendicular positioning of side
support.
DO NOT remove the T-slot washers
from the ends of the tenoning jig guide
bar. Removal of these washers could
allow the jig to come loose from the
table during a cutting operation, which
could cause serious personal injury or
property damage.
Figure 12. Adjusting side support
perpendicular to the saw table.
Machinist's
Square
Positive Stop Set Screw
Side Support
Lock Lever
Side Support

-15-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
In this procedure you will adjust the back support
perpendicular to the saw table, then set the 90°
positive stop so the back support can be returned to the
perpendicular position after an angle cut.
To adjust back support, do these steps:
1. DISCONNECT TABLE SAW FROM POWER!
2. Completely lower saw blade so that it will not
interfere with measurements.
3. Clean away any debris from table or tenoning jig
that could affect measurements, then insert jig all
the way into miter slot.
4. Loosen jam nut on positive stop set screw, then back
off set screw to allow adjustment of back support
(see Figure 13).
5. Position machinist's square flat on table and up
against back support, as shown in Figure 13.
6. Loosen back support lock lever (see Figure 13),
position back support flat against machinist's square,
then, without moving back support, re-tighten lock
lever.
7. Remove square and re-tighten positive stop set
screw until it just meets resistance, then re-tighten
jam nut to secure setting. The 90° positive stop is
now set for quick perpendicular positioning of back
support.
Adjusting Back Support
Figure 13. Adjusting back support
perpendicular to saw table.
Machinist's
Square
Back
Support
Back
Support
Lock
Lever
Positive Stop
Set Screw
& Jam Nut

-16-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
Adjusting Blade Clearance
In this procedure you will adjust the side support to be
parallel with the saw blade and 1⁄2" away from it. Then
you will set the safety stop set screw (see Figure 14) so
that the side support cannot come into contact with the
blade when adjusting for different cuts.
To adjust blade clearance, do these steps:
1. DISCONNECT TABLE SAW FROM POWER!
2. Make sure saw blade is perpendicular to table and
parallel with miter slot.
3. Make sure tenoning jig side support is perpendicular
to table (refer to Adjusting Side Support on Page 14
for instructions).
4. Loosen jam nut on safety stop set screw, then back
the set screw out so that it will not interfere with
adjustments (see Figure 14).
5. Fully raise saw blade.
You must ensure side support safety
stop is adjusted so that support cannot
contact blade when jig is mounted
in left-hand table miter slot. Jig
side support must stay at least 1⁄2"
away from blade at all times during
operation. If side support and blade
make contact during operation, serious
personal injury and damage to machine
could result.
Figure 14. Adjusting side support safety
stop.
Safety Stop Set Screw & Jam Nut
Micro-
Adjust
Lock
Lever
Slide Plate Lock Lever
6. Loosen slide plate and micro-adjust lock levers,
shown in Figure 15, then use clamp handwheel to
move clamp leadscrew and shoe out of the way for
the next step (see Figure 15).
Figure 15. Checking for side parallelism
with the saw blade.
Clamp
Leadscrew
Micro-
Adjust
Lock
Lever
Slide Plate
Lock Lever
Clamp
Shoe

-17-
Model D4902 (For Machines Mfd. Since 11/18)
SETUP
7. Use micro-adjust knob to move side support against
saw blade (see Figure 16).
Note: If tenoning jig side support will not reach
the blade, you may need to re-mount guide bar
in the inward or left mounting position (refer to
Re-Mounting Guide Bar on Page 11 for detailed
instructions). If tenoning jig still does not reach the
blade after changing guide bar mounting position,
the difference can be made up when attaching
side support backing board (refer to Step 5 of
Cutting Basic Tenons beginning on Page 19 for
instructions).
— If jig side support is parallel with saw blade, no
adjustments are necessary.
— If side support and blade are not parallel, note the
difference and continue with Step 8.
Note: If side support does not quite reach the
blade, use a precise ruler to compare the distance
between the side support and the front and back of
the blade.
8. Use micro-adjust knob to align slide plate guide
bar access hole (see Figure 16) over guide bar cap
screw, then loosen cap screw.
9. Shift end of tenoning jig assembly with access hole
left or right until side support is parallel with blade,
then tighten guide bar cap screw.
10. Repeat Steps 7–9 until tenoning jig side support is
parallel with saw blade.
11. When side support is parallel with blade, use micro-
adjust knob to move side support at least 1⁄2" away
from saw blade.
12. Tighten safety stop set screw toward slide plate lock
set screw until it just meets resistance, then tighten
jam nut to secure setting (see Figure 14). The
safety stop set screw is now correctly set to prevent
side support from contacting saw blade.
Figure 16. Side parallelism adjustment
components.
Micro-
Adjust
Knob
Guide Bar
Access Hole
Saw
Blade
Side
Support
Guide
Bar

-18-
Model D4902 (For Machines Mfd. Since 11/18)
OPERATIONS
OPERATIONS
To reduce your risk of serious injury
or damage to the machine, read this
entire manual BEFORE using machine.
To reduce the risk of eye injury and
long-term respiratory damage, always
wear safety glasses and a respirator
while operating this machine.
If you are an inexperienced operator,
we strongly recommend that you read
books or trade articles, or seek training
from an experienced operator of this
type of machinery before performing
unfamiliar operations. Above all, safety
must come first!
Operation Overview
The Model D4902 will perform many types of operations
that are beyond the scope of this manual. Many of these
operations can be dangerous or deadly if performed
incorrectly.
The instructions in this section are written with the
understanding that the operator has the necessary
knowledge and skills to operate the table saw with
the tenoning jig. If at any time you are experiencing
difficulties performing any operation, stop using the
machine!
If you are an inexperienced operator, we strongly
recommend that you read books or trade articles, or
seek training from a reliable expert before performing
any unfamiliar operations. Above all, your safety should
come first!
DO NOT investigate problems or adjust
the jig or table saw while the saw is
running. Wait until the saw is turned
OFF, unplugged, and all working parts
have come to a complete stop before
proceeding!