background image

v.8.29.19

Ledra Brands Inc.

www.LedraBrands.com

In a continuing effort to offer the best product possible we reserve the right to change, without notice, specifications or materials that in our opinion will not alter the function of the product.

15774 Gateway Circle    Tustin, CA 92780

P 714.259.9959    F 714.259.9969

EQUIPMENT CHECKLIST

A battery-operated (cordless) drill; 400RPM maximum. 

We recommend using a large battery pack and spares.

In addition to the items supplied in the ZETA 750 SNAP Drill Jig case, other items you will need include:

Remember to wear personal protective equipment (PPE). 

masking tape

- Battery-operated (Cordless) Drill ONLY

- Masking Tape

- Eye Protection (safety goggles)

- Ear Protection (ear muffs or ear plugs)

- Other Personal Protective Gear (PPE) such as gloves, boots etc.

ZETA 750 SNAP DRILL JIG CASE CONTENTS

Your supplied ZETA 750 SNAP Drill Jig case 

contains the following equipment. Please 

note any irregularities with your supplier 

ASAP:

1 x Drill Jig unit pre-installed with 1 x 15 

and 16mm cutters
1 x Flat Face Spacer (for use ONLY with 

Flat face / Square Pipe). Not Shown.
1 x Drilling manual (this guide)
2 x 15mm cutters (spares)
1 x 16mm cutter (spare)
1 x Cutter removal tool (double-sided)
1 x 2mm Allen (hex) key
2 x Hougen

®

 cutting lubricant

1 x AF 10mm nut driver
1 x 10mm wrench
1 x Insertion pliers
1 x File

NOTE!

 Please return all provided  

equipment to the case upon installation 

completion. Kindly notify your distributor 

ASAP with any misplaced items.

  LED PUCK G5 DRILL JIG — MANUAL

G5 DRILL JIG PARTS

ZETA 750 SNAP DRILL JIG PARTS

The ZETA 750 SNAP Drill Jig parts labeled 

in the adjacent image are referred to in the 

following pages. 

Above: the Drill Jig cutter 

assembly

Above: 15mm cutter (left) and 

16mm cutter (right; with inserted 

cutter spacer). Note, the cutters 

may or may not come pre-

installed in the Drill Jig.

angle setter with 

level guide

clamping chain

chain hook

hex drive

tension thumb screw

vice grip handle 

cutter end (shown here 

WITHOUT cutters installed)

clamp body

MINIMUM WALL THICKNESS 

Observe the Drill Jig / LED Puck 

requirements for minimum wall thickness.

COUNTERBORING
To ensure counterboring works as 

intended, make sure that your 15mm and 

16mm cutter installation is correct (step 

3). The result should be the LED Puck 

embedded flush within the rail (below).

RAIL TYPE

Minimum 

Thickness

Curved Face (Tube)

1.5mm

Flat Face (Square)*

2.0mm

  LED PUCK G5 DRILL JIG — MANUAL

HOW THE DRILL JIG WORKS

WHAT IS THE ZETA 750 SNAP DRILL JIG

The ZETA 750 SNAP Drill Jig's purpose is to  

enable consistent and accurate drilling of metal 

pipe, with counterbore, and to significantly 

reduce installation time.
The ZETA 750 SNAP Drill Jig is designed for the 

following: 

- Use with a battery-operated (cordless) 

drill ONLY
- Installing the latest generation LED 

Puck Snap-type modules ONLY: Snap, 

Solo, Zero, RGBW, Wide and IP68
- Use with curved-face metal rail, or flat-

faced rail (spacer fitting required for flat 

faced-rail, see note*) 
- Cutting a hole with a 15mm diameter 

and a 16mm counterbore. See Minimum 

Wall Thickness table.

THE DRILL JIG IN USE 

Operating a drill attached to the ZETA 750 

SNAP Drill Jig will automatically drive its 

cutters into the cutting surface until full depth 

is achieved and the hole fully made. The Drill 

Jig will automatically cut the counterbore 

hole. Once cutting is achieved, reversing 

the drill will withdraw the cutters back 

inside the Drill Jig cutter assembly and 

into a position ready for the next hole.

Above: The ZETA 750 SNAP Drill Jig in use. Proper 

use of the Drill Jig will result in a significantly faster 

and more professional finish.

Curved Face (Tube) Rail Flat Face (Square) Rail

rail types. Contact Planet Lighting or your 

Table 1. Minimum wall thickness for different 

distributor if your specifications are outside 

these minimums. *See Flat Face note below.

TIP!

 Test your first hole on a spare piece 

of pipe and spare LED Puck.

*NOTE!

 Square pipe / flat-faced rail 

applications require a spacer fitted to 

the Drill Jig. Refer to the supplementary 

document: ZETA 750 SNAP Drill Jig Flat 

Face Setup (page 16).

*See flat face rail note 

(right)

1. MARK THE LED POSITIONS

1.1 Measure and mark the LED Puck 

positions on the rail using a short length of 

masking tape (Fig 1.1).
1.2 Check for interference with posts, 

or other obstructions. Adjust positions 

accordingly to avoid all interference.

NOTE! 

Refer to your drawing or 

specifications to measure the correct 

location and positions of the LED Puck.

mark LED positions 

with tape

LED spacing 

Fig 1.1. Measure and mark the LED Puck positions on the rail.

The cutters may or may not be installed 

and ready for use in your Drill Jig. Inspect 

inside the cutter assembly and follow the 

appropriate steps to confirm your setup:

CUTTERS ARE INSTALLED:

2.1 Ensure that the cutter end is fully 

retracted inside the cutter assembly. If not, 

reverse the cutter end into the assembly 

by engaging the drill (reverse) on the Drill 

Jig hex drive (Fig 2.1). The cutters should 

NOT protrude from the cutter assembly.

CUTTERS ARE NOT INSTALLED:

2.2 If cutters are not yet installed (Fig. 2.2), 

proceed to install them as shown in step 3.

NOTE! 

Check if a 

flat face spacer is 

present inside the 

cutter assembly. 

ONLY use the 

spacer if drilling 

square / flat-face 

pipe. Refer to 

ZETA 750 SNAP 

Drill Jig Flat Face 

Setup.

2. INSPECT THE CUTTER 

 

ASSEMBLY

Above: The flat face spacer is 

used with square pipe ONLY

Fig. 2.2 Cutter end of the cutter assembly 

pictured above. The cutters are not yet installed. 

Proceed to cutter installation (step 3).

Fig. 2.1 If cutters are pre-installed, use your 

drill to ensure that both the hex drive and cutter 

end of the cutter assembly are fully retracted.

CORRECT. Cutters are installed and fully 

retracted inside the cutter assembly.

INCORRECT. Installed cutters should NOT 

remain protruding from the cutter assembly. 

Ensure that cutters are fully retracted inside 

the cutter assembly before using the Drill Jig.

flat face spacer

3. INSTALL / REPLACE 

THE CUTTERS

DRILLING CURVED PIPE:

Install BOTH 15mm and 16mm cutters as 

described. Install the 16mm cutter FIRST 

(begin from step 3.1).

DRILLING FLAT FACE / SQUARE PIPE:

Install the flat face spacer FIRST, before 

installing the 16mm and 15mm cutters. 

See  supplementary guide: ZETA 750 SNAP 

Drill Jig Flat Face Setup (page 16).

NOTE! 

Before installing cutters, engage 

your drill on the Drill Jig's hex drive to 

extend the cutter end (below left). The 

Drill Jig is ready for cutter installation 

when the cutter end is FULLY EXTENDED 

from the Drill Jig (below right).

Fig. 3.4 Use the cutter removal tool and wrench provided 

to remove or secure the cutters. Note the cutter removal 

tool's 15mm side (shallow) and 16mm side (deep).

Fig. 3.1 Use your drill to fully extend the cutter 

end (above right) BEFORE cutter installation. 

INSTALLING THE 16MM CUTTER 

(COUNTERBORE CUTTER):

3.1 Extend the Drill Jig's cutter end / 

thread using your drill. Ensure to fully 

extend the cutter end (Fig. 3.1).
3.2 On the 16mm cutter, ensure the cutter 

spacer is carefully inserted into the cutting 

side of the 16mm cutter (see Drill Jig 

Parts).
3.3  Lightly screw the 16mm cutter onto 

the threaded cutter end of the Drill Jig's 

cutter assembly.  
3.4  Secure the 10mm wrench on the hex 

drive and the cutter removal tool's 16mm 

end to the cutter (Fig. 3.4).
3.5  While securing the spanner,  rotate 

the cutter removal tool's lever clockwise 

to tighten the cutter onto the cutter end of 

the Drill Jig until it is firm and secure.

INSTALLING THE 15MM CUTTER:

3.6  Lightly screw the 15mm cutter onto 

the threaded cutter end of the Drill Jig's 

cutter assembly.
3.7  Secure the 10mm wrench on the hex 

drive and the cutter removal tool's 15mm 

end to the cutter.
3.8  While securing the wrench, use the 

cutter removal tool's lever to rotate the 

cutter clockwise onto the cutter end of the 

shaft until it is firmly secure.

REMOVING / REPLACING THE CUTTERS:

Ensure to fully EXTEND the cutter-end 

of the Drill Jig before cutter removal.  

Proceed to reverse the described steps 

for installing the 16mmm and/or 15mm 

cutters. Use a counter-clockwise turn on 

the cutter removal tool.

TIP! 

Place the Drill Jig on a flat surface 

to make cutter installation or removal 

easier.

4. SET THE DRILL ANGLE

The Drill Jig has a level that enables 

drilling holes into the rail at a consistent 

angle.
The drilling angle can be set at 10° 

intervals from the vertical down position. 

Typical installation angles are:

- Standard beam (ST): 30
- Vertical down beams (AS/VA): 0° or 10°

Follow the below instructions to adjust the 

angle setter:
4.1 Loosen the two allen screws on the 

angle setter with the supplied Allen key 

until you can freely turn the angle setter 

(Fig. 4.1).
4.2 Turn the angle setter to the desired 

angle. Note that each indicator mark

represents increments, or an offset, of 10º. 
4.3 Tighten the allen screws to lock the 

angle setter in position.

Fig. 4.1 Loosen the two allen screws with the Allen 

key to adjust the angle setter.

Above: The drill Jig's level bubble should be 

centered before drilling to enable consistent angle 

drilling at your set angle.

5. LUBRICATE THE CUTTERS

The Drill Jig cutters must be lubricated 

Fig 5.1 IMPORTANT! Lubricate the cutters before drilling each hole. A light

twist action will supply a sufficient amount.

before drilling EACH hole. 
5.1 Use the supplied cutting lubricant stick 

to apply a small amount of lubricant onto 

the cutter as shown (Fig. 5.1). 

6.  CLAMP DRILL JIG TO RAIL

6.1 REMINDER! Ensure you have applied 

cutting lubricant to the cutter. 
6.2 Align the Drill Jig's clamp body to the 

tape position and wrap the clamping chain 

around the rail. Engage the chain with the 

Drill Jig's chain hook.

NOTE! 

If rail is painted - protect the 

paintwork from the clamp body / chain 

with a suitable tape or cloth.

TIP! 

Open the vice grip handles fully to 

enable easier engagement of the chain 

and chain hook. 

6.3 Adjust the clamp tension as needed 

using the handle's tension thumb screw.
6.4  Adjust the rotation of the clamp body 

until the angle setter's level indicator is 

centered.
6.5 Squeeze the vice grip handles together 

to lock the Drill Jig in position. Check that 

the clamp body is firmly secure on the rail 

with no lateral movement, and confirm 

that the alignment and level is still correct. 

NOTE!

 Ensure the clamping chain is 

in a central position and that it is not 

touching the cutter assembly or the vice 

grip once the vice grip is engaged. If it 

is touching, tension may be too loose. 

Adjust the tension (see step 6.3)

adjust tension as 

needed

Fig. 6.2 - 6.5 align clamp body with the tape and 

engage the chain hook and clamping chain. Ensure 

the spirit level bubble remains centered.

Adjust tension to ensure the clamp body is secure on the 

Above: The clamping chain is secure, in a central 

position, and is not touching the engaged vice grip or the 

central section of the cutter assembly. 

TIP!

 Once the correct clamp position / tensioning 

has been achieved, mark the chain with 

permanent marker as a reminder of where to 

engage the chain.

TIP! 

The Drill Jig can be rotated / reversed 

180˚ to enable a second clamping orientation. 

Choose the appropriate orientation to prevent 

interference with vertical rail poles. Note, if 

reversing the Drill Jig position, the angle setter 

must be adjusted to the opposite axis / negative 

position (see step 4). 

7. CHECK YOUR DRILL SETUP

The Drill Jig is designed to be used with a 

battery-operated (cordless) drill ONLY. 

BEFORE YOU DRILL:
7.1

 Check that the 10mm driver bit is 

secure in the drill and that the chuck is 

tight.

7.2

 Check that your drill is set to: 

- LOW / SLOW speed / RPM
- the "DRILL" setting 
- clockwise direction.
- the highest torque setting

7.3.

 Put on your eye protection and any 

other appropriate PPE.

NOTE!

 REMINDER! Confirm you have 

applied lubrication to Drill Jig cutter 

(step 5)

NOTE!

 Drill should be set to the LOW 

speed setting. A MAXIMUM 400 RPM 

drill is recommended. Higher speeds 

will reduce cutter life and increase the 

chance of work hardening.

set drill to clockwise

set SLOW / LOW 

speed (RPM)

set to "DRILL" setting or lowest 

RPM setting

set drill to highest torque setting 

(if applicable ) 

Above: Our example drill is set to: "Drill"; 

high torque; and LOW speed (1)

Above: Check the 10mm driver bit 

is secure

DO NOT USE A ROTARY / IMPACT / HAMMER DRILL OR SUCH 

SETTINGS ON YOUR DRILL. DRILL MUST BE SET TO 'DRILL 

SETTING AND A LOW DRILL SPEED (MAXIMUM OF 400RPM).

DRILL JIG  MUST BE USED WITH A BATTERY-POWERED 

(CORDLESS) DRILL ONLY.  DO NOT USE A MAINS POWERED 

DRILL.

READ AND OBSERVE THE SAFETY PRECAUTIONS AND 

OPERATING INSTRUCTIONS ON YOUR CHOSEN DRILL AND 

EQUIPMENT. 

8. DRILL THE HOLE

8.1 Connect the drill's 10mm nut driver

(female) to the matching (male) hex 

drive on the Drill Jig (Fig. 8.1).
8.2 Engage the drill. DO NOT FORCE OR 

PUSH THE DRILL.  Use light pressure to 

keep the socket engaged. STOP DRILLING 

once the hex drive has fully receded into 

the cutter assembly (Fig. 8.2).

NOTE!

 The resistance will vary during 

the cut as the cutters penetrate the 

metal. This is normal. 

8.3 Switch the drill to REVERSE, and 

engage the drill to back out the cutters. 

Ensure the hex drive is fully retracted from 

the cutter assembly (Fig. 8.3).

NOTE! 

When reversing, if the drill spins 

and/or the hex drive does not retract, 

offset the angle of the drill slightly 1-2°

while reversing. The drill and hex drive 

should now reverse.

NOTE! 

Ensure your drill battery is 

charged /changed as needed as this will 

keep drill times efficient and the Drill Jig

operating effectively. 

Fig 8.1 Do NOT force / push the drill.  Use light 

pressure only to keep the socket engaged.

Fig. 8.2 STOP drilling once the hex drive has 

fully receded inside the Drill Jig.

Fig. 8.3 Set drill to reverse and back out the 

cutters / hex drive until it is fully retracted.

hex drive fully  

RETRACTED

hex drive fully 

RECEDED.

9. REMOVE DRILL JIG AND 

CLEAN

9.1 Open the vice grip and disengage the 

clamping chain to remove the Drill Jig 

from the rail.
9.2 Inspect inside the cutter assembly for 

the presence of a slug. If present, REMOVE 

the slug from the cutter with pliers (Fig 

9.2).
9.3 Remove any shavings around the cutters 

with the supplied pliers. Shake out any 

remaining shavings. Do NOT use compressed 

air to clean.
9.4 File the hole with the supplied file to 

remove burrs. Wipe rail clean with a cloth.
9.5 Go to next hole and repeat from step 5.

NOTE! 

Check that you have removed the 

slug after EACH hole drilled. If the slug is 

stuck, use pliers to remove.

NOTE! 

Be sure to collect shavings and 

other waste from the site and dispose 

responsibly. 

TIP!

 A good time to lubricate the cutters 

for the next hole is just AFTER cleaning 

the cutter assembly.

After drilling EACH hole, inspect the cutter assembly. 

Check for a slug and shaving build up (present in the  

above image)

Fig. 9.2 IMPORTANT! REMOVE the slug and shavings

with pliers.

DO NOT CLEAN THE CUTTER ASSEMBLY WITH COMPRESSED 

AIR. THIS MAY CAUSE SWARF TO BE WEDGED BETWEEN 

COMPONENTS, CAUSING ISSUES.

ENSURE TO INSPECT THE CUTTERS AND REMOVE THE SLUG 

AFTER EACH HOLE IS DRILLED. 

SLUG AND SHAVINGS CAN BE HOT ENOUGH TO BURN 

AND INJURE. USE APPROPRIATE PERSONAL PROTECTIVE 

EQUIPMENT (PPE) SUCH AS GOGGLES, GLOVES AND  

SAFETY BOOTS.

ISSUE: 

The drill spins when reversing 

/ the Drill Jig hex drive does not retract 

when reversing and appears stuck.

SOLUTION: 

The hex drive is not 

disengaging from the cutters. To resolve, 

offset the angle of the drill slightly (1-2°) 

while reversing. The hex drive should now 

disengage and retract. 

ISSUE: 

The cutters do not cut / takes a 

long time to cut.

SOLUTION:

 

1. Confirm a slug is not present / stuck 

inside the cutter assembly.
2. The cutters may be blunt. Refer to 

Install / Replace the Cutters (step 3).

ISSUE: 

Shaving colouring appears unusual.

SOLUTION:

 

1. The Drill speed (RPM) is too high. 

Lower the drill speed.
2. There is not enough lubrication on the 

cutters. Lubricate the cutters (step 5).
3. The cutters are blunt / damaged. 

Replace the cutters (step 3).

NOTE!

 If you have an issue that is not 

identified / resolved here, please contact 

your supplier or Ledra Brands for support

Do NOT attempt to modify the Drill Jig or 

operate it outside of the range described 

within this manual. If the Drill Jig is not 

functioning as expected please contact 

Ledra Brands ASAP at (714) 259-9959.

DO NOT ATTEMPT TO MODIFY THE DRILL JIG OR OPERATE IT 

OUTSIDE OF THE RANGE DESCRIBED WITHIN THIS MANUAL. 

CONTACT LEDRABRANDS ASAP IF THE DRILL JIG IS NOT 

OPERATING AS EXPECTED.

THE FLAT FACE SPACER

Square pipe / flat-faced rail applications 

require a spacer fitted inside the Drill Jig. 
The Drill Jig should come pre-fitted with 

the required spacer, however be sure to 

confirm it is installed, and to reinstall it as 

described when removing / replacing the 

cutters. 

INSTALLING THE FLAT FACE SPACER 

1. The Drill Jig cutter assembly is ready 

for installing the spacer when there are 

NO cutters and the cutter end is FULLY 

EXTENDED (see Removing the Cutters in 

step 3). 
2. Simply insert the flat face spacer  

(tapered end first, as pictured) into the 

back of the Drill Jig's cutter assembly.
3. Continue with installing the cutters. 

Refer to Install / Replace the Cutters (step 

3 in this manual).

Flat face (square) rail applications 

require the flat face spacer 

installed in the Drill Jig.

  LED PUCK G5 DRILL JIG — MANUAL (SUPPLEMENTARY GUIDE)

G5 DRILL JIG FLAT FACE SETUP

Above: the flat face spacer.

The flat face spacer is installed FIRST, followed by the cutter installation (see 

step 3). Remember to fully extend the cutter end of the Drill Jig (as shown).

16mm cutter (with 

cutter spacer)

flat face spacer

15mm cutter

1

2

3

ZETA 750 SNAP DRILL JIG CASE CONTENTS

Your supplied ZETA 750 SNAP Drill Jig case 

contains the following equipment. Please 

note any irregularities with your supplier 

ASAP:

1 x Drill Jig unit pre-installed with 1 x 15 

and 16mm cutters
1 x Flat Face Spacer (for use ONLY with 

Flat face / Square Pipe). Not Shown.
1 x Drilling manual (this guide)
2 x 15mm cutters (spares)
1 x 16mm cutter (spare)
1 x Cutter removal tool (double-sided)
1 x 2mm Allen (hex) key
2 x Hougen

®

 cutting lubricant

1 x AF 10mm nut driver
1 x 10mm wrench
1 x Insertion pliers
1 x File

NOTE!

 Please return all provided  

equipment to the case upon installation 

completion. Kindly notify your distributor 

ASAP with any misplaced items.

  LED PUCK G5 DRILL JIG — MANUAL

G5 DRILL JIG PARTS

ZETA 750 SNAP DRILL JIG PARTS

The ZETA 750 SNAP Drill Jig parts labeled 

in the adjacent image are referred to in the 

following pages. 

Above: the Drill Jig cutter 

assembly

Above: 15mm cutter (left) and 

16mm cutter (right; with inserted 

cutter spacer). Note, the cutters 

may or may not come pre-

installed in the Drill Jig.

angle setter with 

level guide

clamping chain

chain hook

hex drive

tension thumb screw

vice grip handle 

cutter end (shown here 

WITHOUT cutters installed)

clamp body

MINIMUM WALL THICKNESS 

Observe the Drill Jig / LED Puck 

requirements for minimum wall thickness.

COUNTERBORING
To ensure counterboring works as 

intended, make sure that your 15mm and 

16mm cutter installation is correct (step 

3). The result should be the LED Puck 

embedded flush within the rail (below).

RAIL TYPE

Minimum 

Thickness

Curved Face (Tube)

1.5mm

Flat Face (Square)*

2.0mm

  LED PUCK G5 DRILL JIG — MANUAL

HOW THE DRILL JIG WORKS

WHAT IS THE ZETA 750 SNAP DRILL JIG

The ZETA 750 SNAP Drill Jig's purpose is to  

enable consistent and accurate drilling of metal 

pipe, with counterbore, and to significantly 

reduce installation time.
The ZETA 750 SNAP Drill Jig is designed for the 

following: 

- Use with a battery-operated (cordless) 

drill ONLY
- Installing the latest generation LED 

Puck Snap-type modules ONLY: Snap, 

Solo, Zero, RGBW, Wide and IP68
- Use with curved-face metal rail, or flat-

faced rail (spacer fitting required for flat 

faced-rail, see note*) 
- Cutting a hole with a 15mm diameter 

and a 16mm counterbore. See Minimum 

Wall Thickness table.

THE DRILL JIG IN USE 

Operating a drill attached to the ZETA 750 

SNAP Drill Jig will automatically drive its 

cutters into the cutting surface until full depth 

is achieved and the hole fully made. The Drill 

Jig will automatically cut the counterbore 

hole. Once cutting is achieved, reversing 

the drill will withdraw the cutters back 

inside the Drill Jig cutter assembly and 

into a position ready for the next hole.

Above: The ZETA 750 SNAP Drill Jig in use. Proper 

use of the Drill Jig will result in a significantly faster 

and more professional finish.

Curved Face (Tube) Rail Flat Face (Square) Rail

rail types. Contact Planet Lighting or your 

Table 1. Minimum wall thickness for different 

distributor if your specifications are outside 

these minimums. *See Flat Face note below.

TIP!

 Test your first hole on a spare piece 

of pipe and spare LED Puck.

*NOTE!

 Square pipe / flat-faced rail 

applications require a spacer fitted to 

the Drill Jig. Refer to the supplementary 

document: ZETA 750 SNAP Drill Jig Flat 

Face Setup (page 16).

*See flat face rail note 

(right)

1. MARK THE LED POSITIONS

1.1 Measure and mark the LED Puck 

positions on the rail using a short length of 

masking tape (Fig 1.1).
1.2 Check for interference with posts, 

or other obstructions. Adjust positions 

accordingly to avoid all interference.

NOTE! 

Refer to your drawing or 

specifications to measure the correct 

location and positions of the LED Puck.

mark LED positions 

with tape

LED spacing 

Fig 1.1. Measure and mark the LED Puck positions on the rail.

The cutters may or may not be installed 

and ready for use in your Drill Jig. Inspect 

inside the cutter assembly and follow the 

appropriate steps to confirm your setup:

CUTTERS ARE INSTALLED:

2.1 Ensure that the cutter end is fully 

retracted inside the cutter assembly. If not, 

reverse the cutter end into the assembly 

by engaging the drill (reverse) on the Drill 

Jig hex drive (Fig 2.1). The cutters should 

NOT protrude from the cutter assembly.

CUTTERS ARE NOT INSTALLED:

2.2 If cutters are not yet installed (Fig. 2.2), 

proceed to install them as shown in step 3.

NOTE! 

Check if a 

flat face spacer is 

present inside the 

cutter assembly. 

ONLY use the 

spacer if drilling 

square / flat-face 

pipe. Refer to 

ZETA 750 SNAP 

Drill Jig Flat Face 

Setup.

2. INSPECT THE CUTTER 

 

ASSEMBLY

Above: The flat face spacer is 

used with square pipe ONLY

Fig. 2.2 Cutter end of the cutter assembly 

pictured above. The cutters are not yet installed. 

Proceed to cutter installation (step 3).

Fig. 2.1 If cutters are pre-installed, use your 

drill to ensure that both the hex drive and cutter 

end of the cutter assembly are fully retracted.

CORRECT. Cutters are installed and fully 

retracted inside the cutter assembly.

INCORRECT. Installed cutters should NOT 

remain protruding from the cutter assembly. 

Ensure that cutters are fully retracted inside 

the cutter assembly before using the Drill Jig.

flat face spacer

3. INSTALL / REPLACE 

THE CUTTERS

DRILLING CURVED PIPE:

Install BOTH 15mm and 16mm cutters as 

described. Install the 16mm cutter FIRST 

(begin from step 3.1).

DRILLING FLAT FACE / SQUARE PIPE:

Install the flat face spacer FIRST, before 

installing the 16mm and 15mm cutters. 

See  supplementary guide: ZETA 750 SNAP 

Drill Jig Flat Face Setup (page 16).

NOTE! 

Before installing cutters, engage 

your drill on the Drill Jig's hex drive to 

extend the cutter end (below left). The 

Drill Jig is ready for cutter installation 

when the cutter end is FULLY EXTENDED 

from the Drill Jig (below right).

Fig. 3.4 Use the cutter removal tool and wrench provided 

to remove or secure the cutters. Note the cutter removal 

tool's 15mm side (shallow) and 16mm side (deep).

Fig. 3.1 Use your drill to fully extend the cutter 

end (above right) BEFORE cutter installation. 

INSTALLING THE 16MM CUTTER 

(COUNTERBORE CUTTER):

3.1 Extend the Drill Jig's cutter end / 

thread using your drill. Ensure to fully 

extend the cutter end (Fig. 3.1).
3.2 On the 16mm cutter, ensure the cutter 

spacer is carefully inserted into the cutting 

side of the 16mm cutter (see Drill Jig 

Parts).
3.3  Lightly screw the 16mm cutter onto 

the threaded cutter end of the Drill Jig's 

cutter assembly.  
3.4  Secure the 10mm wrench on the hex 

drive and the cutter removal tool's 16mm 

end to the cutter (Fig. 3.4).
3.5  While securing the spanner,  rotate 

the cutter removal tool's lever clockwise 

to tighten the cutter onto the cutter end of 

the Drill Jig until it is firm and secure.

INSTALLING THE 15MM CUTTER:

3.6  Lightly screw the 15mm cutter onto 

the threaded cutter end of the Drill Jig's 

cutter assembly.
3.7  Secure the 10mm wrench on the hex 

drive and the cutter removal tool's 15mm 

end to the cutter.
3.8  While securing the wrench, use the 

cutter removal tool's lever to rotate the 

cutter clockwise onto the cutter end of the 

shaft until it is firmly secure.

REMOVING / REPLACING THE CUTTERS:

Ensure to fully EXTEND the cutter-end 

of the Drill Jig before cutter removal.  

Proceed to reverse the described steps 

for installing the 16mmm and/or 15mm 

cutters. Use a counter-clockwise turn on 

the cutter removal tool.

TIP! 

Place the Drill Jig on a flat surface 

to make cutter installation or removal 

easier.

4. SET THE DRILL ANGLE

The Drill Jig has a level that enables 

drilling holes into the rail at a consistent 

angle.
The drilling angle can be set at 10° 

intervals from the vertical down position. 

Typical installation angles are:

- Standard beam (ST): 30
- Vertical down beams (AS/VA): 0° or 10°

Follow the below instructions to adjust the 

angle setter:
4.1 Loosen the two allen screws on the 

angle setter with the supplied Allen key 

until you can freely turn the angle setter 

(Fig. 4.1).
4.2 Turn the angle setter to the desired 

angle. Note that each indicator mark

represents increments, or an offset, of 10º. 
4.3 Tighten the allen screws to lock the 

angle setter in position.

Fig. 4.1 Loosen the two allen screws with the Allen 

key to adjust the angle setter.

Above: The drill Jig's level bubble should be 

centered before drilling to enable consistent angle 

drilling at your set angle.

5. LUBRICATE THE CUTTERS

The Drill Jig cutters must be lubricated 

Fig 5.1 IMPORTANT! Lubricate the cutters before drilling each hole. A light

twist action will supply a sufficient amount.

before drilling EACH hole. 
5.1 Use the supplied cutting lubricant stick 

to apply a small amount of lubricant onto 

the cutter as shown (Fig. 5.1). 

6.  CLAMP DRILL JIG TO RAIL

6.1 REMINDER! Ensure you have applied 

cutting lubricant to the cutter. 
6.2 Align the Drill Jig's clamp body to the 

tape position and wrap the clamping chain 

around the rail. Engage the chain with the 

Drill Jig's chain hook.

NOTE! 

If rail is painted - protect the 

paintwork from the clamp body / chain 

with a suitable tape or cloth.

TIP! 

Open the vice grip handles fully to 

enable easier engagement of the chain 

and chain hook. 

6.3 Adjust the clamp tension as needed 

using the handle's tension thumb screw.
6.4  Adjust the rotation of the clamp body 

until the angle setter's level indicator is 

centered.
6.5 Squeeze the vice grip handles together 

to lock the Drill Jig in position. Check that 

the clamp body is firmly secure on the rail 

with no lateral movement, and confirm 

that the alignment and level is still correct. 

NOTE!

 Ensure the clamping chain is 

in a central position and that it is not 

touching the cutter assembly or the vice 

grip once the vice grip is engaged. If it 

is touching, tension may be too loose. 

Adjust the tension (see step 6.3)

adjust tension as 

needed

Fig. 6.2 - 6.5 align clamp body with the tape and 

engage the chain hook and clamping chain. Ensure 

the spirit level bubble remains centered.

Adjust tension to ensure the clamp body is secure on the 

Above: The clamping chain is secure, in a central 

position, and is not touching the engaged vice grip or the 

central section of the cutter assembly. 

TIP!

 Once the correct clamp position / tensioning 

has been achieved, mark the chain with 

permanent marker as a reminder of where to 

engage the chain.

TIP! 

The Drill Jig can be rotated / reversed 

180˚ to enable a second clamping orientation. 

Choose the appropriate orientation to prevent 

interference with vertical rail poles. Note, if 

reversing the Drill Jig position, the angle setter 

must be adjusted to the opposite axis / negative 

position (see step 4). 

7. CHECK YOUR DRILL SETUP

The Drill Jig is designed to be used with a 

battery-operated (cordless) drill ONLY. 

BEFORE YOU DRILL:
7.1

 Check that the 10mm driver bit is 

secure in the drill and that the chuck is 

tight.

7.2

 Check that your drill is set to: 

- LOW / SLOW speed / RPM
- the "DRILL" setting 
- clockwise direction.
- the highest torque setting

7.3.

 Put on your eye protection and any 

other appropriate PPE.

NOTE!

 REMINDER! Confirm you have 

applied lubrication to Drill Jig cutter 

(step 5)

NOTE!

 Drill should be set to the LOW 

speed setting. A MAXIMUM 400 RPM 

drill is recommended. Higher speeds 

will reduce cutter life and increase the 

chance of work hardening.

set drill to clockwise

set SLOW / LOW 

speed (RPM)

set to "DRILL" setting or lowest 

RPM setting

set drill to highest torque setting 

(if applicable ) 

Above: Our example drill is set to: "Drill"; 

high torque; and LOW speed (1)

Above: Check the 10mm driver bit 

is secure

DO NOT USE A ROTARY / IMPACT / HAMMER DRILL OR SUCH 

SETTINGS ON YOUR DRILL. DRILL MUST BE SET TO 'DRILL 

SETTING AND A LOW DRILL SPEED (MAXIMUM OF 400RPM).

DRILL JIG  MUST BE USED WITH A BATTERY-POWERED 

(CORDLESS) DRILL ONLY.  DO NOT USE A MAINS POWERED 

DRILL.

READ AND OBSERVE THE SAFETY PRECAUTIONS AND 

OPERATING INSTRUCTIONS ON YOUR CHOSEN DRILL AND 

EQUIPMENT. 

8. DRILL THE HOLE

8.1 Connect the drill's 10mm nut driver

(female) to the matching (male) hex 

drive on the Drill Jig (Fig. 8.1).
8.2 Engage the drill. DO NOT FORCE OR 

PUSH THE DRILL.  Use light pressure to 

keep the socket engaged. STOP DRILLING 

once the hex drive has fully receded into 

the cutter assembly (Fig. 8.2).

NOTE!

 The resistance will vary during 

the cut as the cutters penetrate the 

metal. This is normal. 

8.3 Switch the drill to REVERSE, and 

engage the drill to back out the cutters. 

Ensure the hex drive is fully retracted from 

the cutter assembly (Fig. 8.3).

NOTE! 

When reversing, if the drill spins 

and/or the hex drive does not retract, 

offset the angle of the drill slightly 1-2°

while reversing. The drill and hex drive 

should now reverse.

NOTE! 

Ensure your drill battery is 

charged /changed as needed as this will 

keep drill times efficient and the Drill Jig

operating effectively. 

Fig 8.1 Do NOT force / push the drill.  Use light 

pressure only to keep the socket engaged.

Fig. 8.2 STOP drilling once the hex drive has 

fully receded inside the Drill Jig.

Fig. 8.3 Set drill to reverse and back out the 

cutters / hex drive until it is fully retracted.

hex drive fully  

RETRACTED

hex drive fully 

RECEDED.

9. REMOVE DRILL JIG AND 

CLEAN

9.1 Open the vice grip and disengage the 

clamping chain to remove the Drill Jig 

from the rail.
9.2 Inspect inside the cutter assembly for 

the presence of a slug. If present, REMOVE 

the slug from the cutter with pliers (Fig 

9.2).
9.3 Remove any shavings around the cutters 

with the supplied pliers. Shake out any 

remaining shavings. Do NOT use compressed 

air to clean.
9.4 File the hole with the supplied file to 

remove burrs. Wipe rail clean with a cloth.
9.5 Go to next hole and repeat from step 5.

NOTE! 

Check that you have removed the 

slug after EACH hole drilled. If the slug is 

stuck, use pliers to remove.

NOTE! 

Be sure to collect shavings and 

other waste from the site and dispose 

responsibly. 

TIP!

 A good time to lubricate the cutters 

for the next hole is just AFTER cleaning 

the cutter assembly.

After drilling EACH hole, inspect the cutter assembly. 

Check for a slug and shaving build up (present in the  

above image)

Fig. 9.2 IMPORTANT! REMOVE the slug and shavings

with pliers.

DO NOT CLEAN THE CUTTER ASSEMBLY WITH COMPRESSED 

AIR. THIS MAY CAUSE SWARF TO BE WEDGED BETWEEN 

COMPONENTS, CAUSING ISSUES.

ENSURE TO INSPECT THE CUTTERS AND REMOVE THE SLUG 

AFTER EACH HOLE IS DRILLED. 

SLUG AND SHAVINGS CAN BE HOT ENOUGH TO BURN 

AND INJURE. USE APPROPRIATE PERSONAL PROTECTIVE 

EQUIPMENT (PPE) SUCH AS GOGGLES, GLOVES AND  

SAFETY BOOTS.

ISSUE: 

The drill spins when reversing 

/ the Drill Jig hex drive does not retract 

when reversing and appears stuck.

SOLUTION: 

The hex drive is not 

disengaging from the cutters. To resolve, 

offset the angle of the drill slightly (1-2°) 

while reversing. The hex drive should now 

disengage and retract. 

ISSUE: 

The cutters do not cut / takes a 

long time to cut.

SOLUTION:

 

1. Confirm a slug is not present / stuck 

inside the cutter assembly.
2. The cutters may be blunt. Refer to 

Install / Replace the Cutters (step 3).

ISSUE: 

Shaving colouring appears unusual.

SOLUTION:

 

1. The Drill speed (RPM) is too high. 

Lower the drill speed.
2. There is not enough lubrication on the 

cutters. Lubricate the cutters (step 5).
3. The cutters are blunt / damaged. 

Replace the cutters (step 3).

NOTE!

 If you have an issue that is not 

identified / resolved here, please contact 

your supplier or Ledra Brands for support

Do NOT attempt to modify the Drill Jig or 

operate it outside of the range described 

within this manual. If the Drill Jig is not 

functioning as expected please contact 

Ledra Brands ASAP at (714) 259-9959.

DO NOT ATTEMPT TO MODIFY THE DRILL JIG OR OPERATE IT 

OUTSIDE OF THE RANGE DESCRIBED WITHIN THIS MANUAL. 

CONTACT LEDRABRANDS ASAP IF THE DRILL JIG IS NOT 

OPERATING AS EXPECTED.

THE FLAT FACE SPACER

Square pipe / flat-faced rail applications 

require a spacer fitted inside the Drill Jig. 
The Drill Jig should come pre-fitted with 

the required spacer, however be sure to 

confirm it is installed, and to reinstall it as 

described when removing / replacing the 

cutters. 

INSTALLING THE FLAT FACE SPACER 

1. The Drill Jig cutter assembly is ready 

for installing the spacer when there are 

NO cutters and the cutter end is FULLY 

EXTENDED (see Removing the Cutters in 

step 3). 
2. Simply insert the flat face spacer  

(tapered end first, as pictured) into the 

back of the Drill Jig's cutter assembly.
3. Continue with installing the cutters. 

Refer to Install / Replace the Cutters (step 

3 in this manual).

Flat face (square) rail applications 

require the flat face spacer 

installed in the Drill Jig.

  LED PUCK G5 DRILL JIG — MANUAL (SUPPLEMENTARY GUIDE)

G5 DRILL JIG FLAT FACE SETUP

Above: the flat face spacer.

The flat face spacer is installed FIRST, followed by the cutter installation (see 

step 3). Remember to fully extend the cutter end of the Drill Jig (as shown).

16mm cutter (with 

cutter spacer)

flat face spacer

15mm cutter

1

2

3

ZETA 750 SNAP DRILL JIG CASE CONTENTS

Your supplied ZETA 750 SNAP Drill Jig case 

contains the following equipment. Please 

note any irregularities with your supplier 

ASAP:

1 x Drill Jig unit pre-installed with 1 x 15 

and 16mm cutters
1 x Flat Face Spacer (for use ONLY with 

Flat face / Square Pipe). Not Shown.
1 x Drilling manual (this guide)
2 x 15mm cutters (spares)
1 x 16mm cutter (spare)
1 x Cutter removal tool (double-sided)
1 x 2mm Allen (hex) key
2 x Hougen

®

 cutting lubricant

1 x AF 10mm nut driver
1 x 10mm wrench
1 x Insertion pliers
1 x File

NOTE!

 Please return all provided  

equipment to the case upon installation 

completion. Kindly notify your distributor 

ASAP with any misplaced items.

  LED PUCK G5 DRILL JIG — MANUAL

G5 DRILL JIG PARTS

ZETA 750 SNAP DRILL JIG PARTS

The ZETA 750 SNAP Drill Jig parts labeled 

in the adjacent image are referred to in the 

following pages. 

Above: the Drill Jig cutter 

assembly

Above: 15mm cutter (left) and 

16mm cutter (right; with inserted 

cutter spacer). Note, the cutters 

may or may not come pre-

installed in the Drill Jig.

angle setter with 

level guide

clamping chain

chain hook

hex drive

tension thumb screw

vice grip handle 

cutter end (shown here 

WITHOUT cutters installed)

clamp body

MINIMUM WALL THICKNESS 

Observe the Drill Jig / LED Puck 

requirements for minimum wall thickness.

COUNTERBORING
To ensure counterboring works as 

intended, make sure that your 15mm and 

16mm cutter installation is correct (step 

3). The result should be the LED Puck 

embedded flush within the rail (below).

RAIL TYPE

Minimum 

Thickness

Curved Face (Tube)

1.5mm

Flat Face (Square)*

2.0mm

  LED PUCK G5 DRILL JIG — MANUAL

HOW THE DRILL JIG WORKS

WHAT IS THE ZETA 750 SNAP DRILL JIG

The ZETA 750 SNAP Drill Jig's purpose is to  

enable consistent and accurate drilling of metal 

pipe, with counterbore, and to significantly 

reduce installation time.
The ZETA 750 SNAP Drill Jig is designed for the 

following: 

- Use with a battery-operated (cordless) 

drill ONLY
- Installing the latest generation LED 

Puck Snap-type modules ONLY: Snap, 

Solo, Zero, RGBW, Wide and IP68
- Use with curved-face metal rail, or flat-

faced rail (spacer fitting required for flat 

faced-rail, see note*) 
- Cutting a hole with a 15mm diameter 

and a 16mm counterbore. See Minimum 

Wall Thickness table.

THE DRILL JIG IN USE 

Operating a drill attached to the ZETA 750 

SNAP Drill Jig will automatically drive its 

cutters into the cutting surface until full depth 

is achieved and the hole fully made. The Drill 

Jig will automatically cut the counterbore 

hole. Once cutting is achieved, reversing 

the drill will withdraw the cutters back 

inside the Drill Jig cutter assembly and 

into a position ready for the next hole.

Above: The ZETA 750 SNAP Drill Jig in use. Proper 

use of the Drill Jig will result in a significantly faster 

and more professional finish.

Curved Face (Tube) Rail Flat Face (Square) Rail

rail types. Contact Planet Lighting or your 

Table 1. Minimum wall thickness for different 

distributor if your specifications are outside 

these minimums. *See Flat Face note below.

TIP!

 Test your first hole on a spare piece 

of pipe and spare LED Puck.

*NOTE!

 Square pipe / flat-faced rail 

applications require a spacer fitted to 

the Drill Jig. Refer to the supplementary 

document: ZETA 750 SNAP Drill Jig Flat 

Face Setup (page 16).

*See flat face rail note 

(right)

1. MARK THE LED POSITIONS

1.1 Measure and mark the LED Puck 

positions on the rail using a short length of 

masking tape (Fig 1.1).
1.2 Check for interference with posts, 

or other obstructions. Adjust positions 

accordingly to avoid all interference.

NOTE! 

Refer to your drawing or 

specifications to measure the correct 

location and positions of the LED Puck.

mark LED positions 

with tape

LED spacing 

Fig 1.1. Measure and mark the LED Puck positions on the rail.

The cutters may or may not be installed 

and ready for use in your Drill Jig. Inspect 

inside the cutter assembly and follow the 

appropriate steps to confirm your setup:

CUTTERS ARE INSTALLED:

2.1 Ensure that the cutter end is fully 

retracted inside the cutter assembly. If not, 

reverse the cutter end into the assembly 

by engaging the drill (reverse) on the Drill 

Jig hex drive (Fig 2.1). The cutters should 

NOT protrude from the cutter assembly.

CUTTERS ARE NOT INSTALLED:

2.2 If cutters are not yet installed (Fig. 2.2), 

proceed to install them as shown in step 3.

NOTE! 

Check if a 

flat face spacer is 

present inside the 

cutter assembly. 

ONLY use the 

spacer if drilling 

square / flat-face 

pipe. Refer to 

ZETA 750 SNAP 

Drill Jig Flat Face 

Setup.

2. INSPECT THE CUTTER 

 

ASSEMBLY

Above: The flat face spacer is 

used with square pipe ONLY

Fig. 2.2 Cutter end of the cutter assembly 

pictured above. The cutters are not yet installed. 

Proceed to cutter installation (step 3).

Fig. 2.1 If cutters are pre-installed, use your 

drill to ensure that both the hex drive and cutter 

end of the cutter assembly are fully retracted.

CORRECT. Cutters are installed and fully 

retracted inside the cutter assembly.

INCORRECT. Installed cutters should NOT 

remain protruding from the cutter assembly. 

Ensure that cutters are fully retracted inside 

the cutter assembly before using the Drill Jig.

flat face spacer

3. INSTALL / REPLACE 

THE CUTTERS

DRILLING CURVED PIPE:

Install BOTH 15mm and 16mm cutters as 

described. Install the 16mm cutter FIRST 

(begin from step 3.1).

DRILLING FLAT FACE / SQUARE PIPE:

Install the flat face spacer FIRST, before 

installing the 16mm and 15mm cutters. 

See  supplementary guide: ZETA 750 SNAP 

Drill Jig Flat Face Setup (page 16).

NOTE! 

Before installing cutters, engage 

your drill on the Drill Jig's hex drive to 

extend the cutter end (below left). The 

Drill Jig is ready for cutter installation 

when the cutter end is FULLY EXTENDED 

from the Drill Jig (below right).

Fig. 3.4 Use the cutter removal tool and wrench provided 

to remove or secure the cutters. Note the cutter removal 

tool's 15mm side (shallow) and 16mm side (deep).

Fig. 3.1 Use your drill to fully extend the cutter 

end (above right) BEFORE cutter installation. 

INSTALLING THE 16MM CUTTER 

(COUNTERBORE CUTTER):

3.1 Extend the Drill Jig's cutter end / 

thread using your drill. Ensure to fully 

extend the cutter end (Fig. 3.1).
3.2 On the 16mm cutter, ensure the cutter 

spacer is carefully inserted into the cutting 

side of the 16mm cutter (see Drill Jig 

Parts).
3.3  Lightly screw the 16mm cutter onto 

the threaded cutter end of the Drill Jig's 

cutter assembly.  
3.4  Secure the 10mm wrench on the hex 

drive and the cutter removal tool's 16mm 

end to the cutter (Fig. 3.4).
3.5  While securing the spanner,  rotate 

the cutter removal tool's lever clockwise 

to tighten the cutter onto the cutter end of 

the Drill Jig until it is firm and secure.

INSTALLING THE 15MM CUTTER:

3.6  Lightly screw the 15mm cutter onto 

the threaded cutter end of the Drill Jig's 

cutter assembly.
3.7  Secure the 10mm wrench on the hex 

drive and the cutter removal tool's 15mm 

end to the cutter.
3.8  While securing the wrench, use the 

cutter removal tool's lever to rotate the 

cutter clockwise onto the cutter end of the 

shaft until it is firmly secure.

REMOVING / REPLACING THE CUTTERS:

Ensure to fully EXTEND the cutter-end 

of the Drill Jig before cutter removal.  

Proceed to reverse the described steps 

for installing the 16mmm and/or 15mm 

cutters. Use a counter-clockwise turn on 

the cutter removal tool.

TIP! 

Place the Drill Jig on a flat surface 

to make cutter installation or removal 

easier.

4. SET THE DRILL ANGLE

The Drill Jig has a level that enables 

drilling holes into the rail at a consistent 

angle.
The drilling angle can be set at 10° 

intervals from the vertical down position. 

Typical installation angles are:

- Standard beam (ST): 30
- Vertical down beams (AS/VA): 0° or 10°

Follow the below instructions to adjust the 

angle setter:
4.1 Loosen the two allen screws on the 

angle setter with the supplied Allen key 

until you can freely turn the angle setter 

(Fig. 4.1).
4.2 Turn the angle setter to the desired 

angle. Note that each indicator mark

represents increments, or an offset, of 10º. 
4.3 Tighten the allen screws to lock the 

angle setter in position.

Fig. 4.1 Loosen the two allen screws with the Allen 

key to adjust the angle setter.

Above: The drill Jig's level bubble should be 

centered before drilling to enable consistent angle 

drilling at your set angle.

5. LUBRICATE THE CUTTERS

The Drill Jig cutters must be lubricated 

Fig 5.1 IMPORTANT! Lubricate the cutters before drilling each hole. A light

twist action will supply a sufficient amount.

before drilling EACH hole. 
5.1 Use the supplied cutting lubricant stick 

to apply a small amount of lubricant onto 

the cutter as shown (Fig. 5.1). 

6.  CLAMP DRILL JIG TO RAIL

6.1 REMINDER! Ensure you have applied 

cutting lubricant to the cutter. 
6.2 Align the Drill Jig's clamp body to the 

tape position and wrap the clamping chain 

around the rail. Engage the chain with the 

Drill Jig's chain hook.

NOTE! 

If rail is painted - protect the 

paintwork from the clamp body / chain 

with a suitable tape or cloth.

TIP! 

Open the vice grip handles fully to 

enable easier engagement of the chain 

and chain hook. 

6.3 Adjust the clamp tension as needed 

using the handle's tension thumb screw.
6.4  Adjust the rotation of the clamp body 

until the angle setter's level indicator is 

centered.
6.5 Squeeze the vice grip handles together 

to lock the Drill Jig in position. Check that 

the clamp body is firmly secure on the rail 

with no lateral movement, and confirm 

that the alignment and level is still correct. 

NOTE!

 Ensure the clamping chain is 

in a central position and that it is not 

touching the cutter assembly or the vice 

grip once the vice grip is engaged. If it 

is touching, tension may be too loose. 

Adjust the tension (see step 6.3)

adjust tension as 

needed

Fig. 6.2 - 6.5 align clamp body with the tape and 

engage the chain hook and clamping chain. Ensure 

the spirit level bubble remains centered.

Adjust tension to ensure the clamp body is secure on the 

Above: The clamping chain is secure, in a central 

position, and is not touching the engaged vice grip or the 

central section of the cutter assembly. 

TIP!

 Once the correct clamp position / tensioning 

has been achieved, mark the chain with 

permanent marker as a reminder of where to 

engage the chain.

TIP! 

The Drill Jig can be rotated / reversed 

180˚ to enable a second clamping orientation. 

Choose the appropriate orientation to prevent 

interference with vertical rail poles. Note, if 

reversing the Drill Jig position, the angle setter 

must be adjusted to the opposite axis / negative 

position (see step 4). 

7. CHECK YOUR DRILL SETUP

The Drill Jig is designed to be used with a 

battery-operated (cordless) drill ONLY. 

BEFORE YOU DRILL:
7.1

 Check that the 10mm driver bit is 

secure in the drill and that the chuck is 

tight.

7.2

 Check that your drill is set to: 

- LOW / SLOW speed / RPM
- the "DRILL" setting 
- clockwise direction.
- the highest torque setting

7.3.

 Put on your eye protection and any 

other appropriate PPE.

NOTE!

 REMINDER! Confirm you have 

applied lubrication to Drill Jig cutter 

(step 5)

NOTE!

 Drill should be set to the LOW 

speed setting. A MAXIMUM 400 RPM 

drill is recommended. Higher speeds 

will reduce cutter life and increase the 

chance of work hardening.

set drill to clockwise

set SLOW / LOW 

speed (RPM)

set to "DRILL" setting or lowest 

RPM setting

set drill to highest torque setting 

(if applicable ) 

Above: Our example drill is set to: "Drill"; 

high torque; and LOW speed (1)

Above: Check the 10mm driver bit 

is secure

DO NOT USE A ROTARY / IMPACT / HAMMER DRILL OR SUCH 

SETTINGS ON YOUR DRILL. DRILL MUST BE SET TO 'DRILL 

SETTING AND A LOW DRILL SPEED (MAXIMUM OF 400RPM).

DRILL JIG  MUST BE USED WITH A BATTERY-POWERED 

(CORDLESS) DRILL ONLY.  DO NOT USE A MAINS POWERED 

DRILL.

READ AND OBSERVE THE SAFETY PRECAUTIONS AND 

OPERATING INSTRUCTIONS ON YOUR CHOSEN DRILL AND 

EQUIPMENT. 

8. DRILL THE HOLE

8.1 Connect the drill's 10mm nut driver

(female) to the matching (male) hex 

drive on the Drill Jig (Fig. 8.1).
8.2 Engage the drill. DO NOT FORCE OR 

PUSH THE DRILL.  Use light pressure to 

keep the socket engaged. STOP DRILLING 

once the hex drive has fully receded into 

the cutter assembly (Fig. 8.2).

NOTE!

 The resistance will vary during 

the cut as the cutters penetrate the 

metal. This is normal. 

8.3 Switch the drill to REVERSE, and 

engage the drill to back out the cutters. 

Ensure the hex drive is fully retracted from 

the cutter assembly (Fig. 8.3).

NOTE! 

When reversing, if the drill spins 

and/or the hex drive does not retract, 

offset the angle of the drill slightly 1-2°

while reversing. The drill and hex drive 

should now reverse.

NOTE! 

Ensure your drill battery is 

charged /changed as needed as this will 

keep drill times efficient and the Drill Jig

operating effectively. 

Fig 8.1 Do NOT force / push the drill.  Use light 

pressure only to keep the socket engaged.

Fig. 8.2 STOP drilling once the hex drive has 

fully receded inside the Drill Jig.

Fig. 8.3 Set drill to reverse and back out the 

cutters / hex drive until it is fully retracted.

hex drive fully  

RETRACTED

hex drive fully 

RECEDED.

9. REMOVE DRILL JIG AND 

CLEAN

9.1 Open the vice grip and disengage the 

clamping chain to remove the Drill Jig 

from the rail.
9.2 Inspect inside the cutter assembly for 

the presence of a slug. If present, REMOVE 

the slug from the cutter with pliers (Fig 

9.2).
9.3 Remove any shavings around the cutters 

with the supplied pliers. Shake out any 

remaining shavings. Do NOT use compressed 

air to clean.
9.4 File the hole with the supplied file to 

remove burrs. Wipe rail clean with a cloth.
9.5 Go to next hole and repeat from step 5.

NOTE! 

Check that you have removed the 

slug after EACH hole drilled. If the slug is 

stuck, use pliers to remove.

NOTE! 

Be sure to collect shavings and 

other waste from the site and dispose 

responsibly. 

TIP!

 A good time to lubricate the cutters 

for the next hole is just AFTER cleaning 

the cutter assembly.

After drilling EACH hole, inspect the cutter assembly. 

Check for a slug and shaving build up (present in the  

above image)

Fig. 9.2 IMPORTANT! REMOVE the slug and shavings

with pliers.

DO NOT CLEAN THE CUTTER ASSEMBLY WITH COMPRESSED 

AIR. THIS MAY CAUSE SWARF TO BE WEDGED BETWEEN 

COMPONENTS, CAUSING ISSUES.

ENSURE TO INSPECT THE CUTTERS AND REMOVE THE SLUG 

AFTER EACH HOLE IS DRILLED. 

SLUG AND SHAVINGS CAN BE HOT ENOUGH TO BURN 

AND INJURE. USE APPROPRIATE PERSONAL PROTECTIVE 

EQUIPMENT (PPE) SUCH AS GOGGLES, GLOVES AND  

SAFETY BOOTS.

ISSUE: 

The drill spins when reversing 

/ the Drill Jig hex drive does not retract 

when reversing and appears stuck.

SOLUTION: 

The hex drive is not 

disengaging from the cutters. To resolve, 

offset the angle of the drill slightly (1-2°) 

while reversing. The hex drive should now 

disengage and retract. 

ISSUE: 

The cutters do not cut / takes a 

long time to cut.

SOLUTION:

 

1. Confirm a slug is not present / stuck 

inside the cutter assembly.
2. The cutters may be blunt. Refer to 

Install / Replace the Cutters (step 3).

ISSUE: 

Shaving colouring appears unusual.

SOLUTION:

 

1. The Drill speed (RPM) is too high. 

Lower the drill speed.
2. There is not enough lubrication on the 

cutters. Lubricate the cutters (step 5).
3. The cutters are blunt / damaged. 

Replace the cutters (step 3).

NOTE!

 If you have an issue that is not 

identified / resolved here, please contact 

your supplier or Ledra Brands for support

Do NOT attempt to modify the Drill Jig or 

operate it outside of the range described 

within this manual. If the Drill Jig is not 

functioning as expected please contact 

Ledra Brands ASAP at (714) 259-9959.

DO NOT ATTEMPT TO MODIFY THE DRILL JIG OR OPERATE IT 

OUTSIDE OF THE RANGE DESCRIBED WITHIN THIS MANUAL. 

CONTACT LEDRABRANDS ASAP IF THE DRILL JIG IS NOT 

OPERATING AS EXPECTED.

THE FLAT FACE SPACER

Square pipe / flat-faced rail applications 

require a spacer fitted inside the Drill Jig. 
The Drill Jig should come pre-fitted with 

the required spacer, however be sure to 

confirm it is installed, and to reinstall it as 

described when removing / replacing the 

cutters. 

INSTALLING THE FLAT FACE SPACER 

1. The Drill Jig cutter assembly is ready 

for installing the spacer when there are 

NO cutters and the cutter end is FULLY 

EXTENDED (see Removing the Cutters in 

step 3). 
2. Simply insert the flat face spacer  

(tapered end first, as pictured) into the 

back of the Drill Jig's cutter assembly.
3. Continue with installing the cutters. 

Refer to Install / Replace the Cutters (step 

3 in this manual).

Flat face (square) rail applications 

require the flat face spacer 

installed in the Drill Jig.

  LED PUCK G5 DRILL JIG — MANUAL (SUPPLEMENTARY GUIDE)

G5 DRILL JIG FLAT FACE SETUP

Above: the flat face spacer.

The flat face spacer is installed FIRST, followed by the cutter installation (see 

step 3). Remember to fully extend the cutter end of the Drill Jig (as shown).

16mm cutter (with 

cutter spacer)

flat face spacer

15mm cutter

1

2

3

Summary of Contents for ALPHABET ZETA 750 SNAP

Page 1: ...lease contact LedraBrands ASAP at 714 259 9959 CAUTIONS READ ALL SAFETY WARNINGS AND INSTRUCTIONS FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN PERSONAL INJURY LED PUCK HOLE PREPARATION AND DRILLING SH...

Page 2: ...9959 F 714 259 9969 2 EQUIPMENT CHECKLIST A battery operated cordless drill 400RPM maximum We recommend using a large battery pack and spares In addition to the items supplied in the ZETA 750 SNAP Dr...

Page 3: ...Jig case contains the following equipment Please note any irregularities with your supplier ASAP NOTE Please return all provided equipment to the case upon installation completion Kindly notify your...

Page 4: ...59 F 714 259 9969 4 Above 15mm cutter left and 16mm cutter right with inserted cutter spacer Note the cutters may or may not come pre installed in the Drill Jig Above the Drill Jig cutter assembly ang...

Page 5: ...To ensure counterboring works as intended make sure that your 15mm and 16mm cutter installation is correct step 3 The result should be the LED Puck embedded ush within the rail below Table 1 Minimum w...

Page 6: ...714 259 9959 F 714 259 9969 6 1 MARK THE LED POSITIONS 1 1 Measure and mark the LED Puck positions on the rail using a short length of masking tape Fig 1 1 1 2 Check for interference with posts or oth...

Page 7: ...he cutter assembly 2 2 If cutters are not yet installed Fig 2 2 proceed to install them as shown in step 3 NOTE Check if a flat face spacer is present inside the cutter assembly ONLY use the spacer if...

Page 8: ...e described steps for installing the 16mm and or 15mm cutters Use a counter clockwise turn on the cutter removal tool TIP Place the Drill Jig on a flat surface to make cutter installation or removal e...

Page 9: ...al down position Typical installation angles are Standard beam ST 30 Vertical down beam AS VA 0 or 10 Follow the below instructions to adjust the angle setter 4 1 Loosen the two allen screws on the an...

Page 10: ...e function of the product 15774 Gateway Circle Tustin CA 92780 P 714 259 9959 F 714 259 9969 10 5 LUBRICATE THE CUTTERS The Drill Jig cutters must be lubrciated before drilling EACH hole 5 1 Use the s...

Page 11: ...e clamp body is secure on the rail TIP The Drill Jig can be rotated reversed 180 to enable a second clamping orienetation Choose the appropiate orientation to prevent interferance with vertical rail p...

Page 12: ...ease the chance of work hardening BEFORE YOU DRILL 7 1 Check that the 10mm driver bit is secure in the drill and that the chuck is tight 7 2 Check that your drill is set to LOW SLOW speed RPM the DRIL...

Page 13: ...the drill to back out the cutters Ensure the hex drive is fully retracted from the cutter assembly Fig 8 3 NOTE The resistance will vary during the cut as the cutters penetrate the metal This is norm...

Page 14: ...upplied file to remove burrs Wipe rail clean with a cloth 9 5 Go to the next hole and repeat from step 5 After drilling EACH hole inspect the cutter assembly Check for a slug and shaving build up pres...

Page 15: ...OLUTION 1 Confirm a slug is not present stuck inside the cutter assembly 2 The cutters may be blunt Refer to Install Replace the Cutters step 3 ISSUE Shaving coloring appears unusual SOLUTION 1 The Dr...

Page 16: ...nd to reinstall it as described when removing replacing the cutters 1 The Drill Jig cutter assembly is ready for installing the spacer when there are NO cutters and the cutter end is FULLY EXTENDED se...

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