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
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 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