OPERATION MANUAL

for
Model ZB-300
Benchmaster Positioner

Revised June 2009

Effective with Serial Number

ZB-300A - 060418
ZB-300B - 060428

IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web Site: www.jetline.com • E-mail: sales@jetline.com
ZB-300 Benchmaster Positioner

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 ZB-300 Benchmaster Positioner

LIMITED WARRANTY

Jetline Engineering, of Irvine, California, U.S.A., warrants all new equipment to be free from defects
in material and workmanship for the period of one (1) year, provided that the equipment is installed
and operated according to instructions.
Jetline Engineering’s obligation under this warranty is expressly limited to replacing or repairing
any defective part or correcting any manufacturing defect without charge during the warranty period,
if Jetline’s inspection confirms the existence of such defects. Jetline’s option of repair or replacement
will be F.O.B. factory at Irvine, California, and therefore no compensation for transportation costs of
any kind will be allowed.
The warranty period begins on the date of sale to the original-purchase user of the equipment.
Jetline Engineering will not be liable for any loss or consequential damage or expense accruing
directly or indirectly from the use of equipment covered by this warranty.
This warranty supersedes all previous Jetline warranties and is exclusive with no other guaran-
tees or warranties expressed or implied.

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ZB-300 Benchmaster Positioner

NOTICE

The installation, operation and maintenance guidelines set out in this manual will enable you to
maintain the equipment in peak condition and achieve maximum efficiency with your welding opera-
tion. Please read these instructions carefully to become aware of every advantage.

CAUTION

Only experienced personnel familiar with

the operation and safe practice of welding
equipment should install and/or use
this equipment.

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 ZB-300 Benchmaster Positioner

Table of Contents

Section I ........................................................................................................................................1
Safety Precautions.................................................................................................................1
A. Arc Welding ....................................................................................................................1
B. Electric Shock .................................................................................................................1
C. Arc Rays .........................................................................................................................2
D. Fumes and Gases ............................................................................................................2
E. Cylinders.........................................................................................................................2
F. Welding ...........................................................................................................................3
G. Moving Parts...................................................................................................................3
H. EMF Information ............................................................................................................3
I. Principal Safety Standards ..............................................................................................4
Section II ........................................................................................................................................5
Introduction ...........................................................................................................................5
Section III ........................................................................................................................................9
Specifications ........................................................................................................................9
Section IV ...................................................................................................................................... 11
Operation............................................................................................................................. 11
Section V ......................................................................................................................................13
Maintenance ........................................................................................................................13
Section VI ......................................................................................................................................15
Parts List .............................................................................................................................15

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ZB-300 Benchmaster Positioner

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Section I
Safety Precautions
WARNING
A. Arc Welding
Arc Welding can be hazardous. Protect your-
self and others from possible serious injury or
death. Keep children away. Pacemaker wear-
ers keep away until consulting your doctor.
In welding, as in most jobs, exposure to certain
hazards occurs. Welding is safe when precau-
tions are taken. The safety information given
below is only a summary of the more complete
safety information that will be found in the
Safety Standards listed at the end of this section.
Read and follow all Safety Standards.
Have all installation, operation, maintenance
and repair work performed only by qualified
people.
B. Electric Shock
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is
on. The input power circuit and machine internal
circuits are also live when power is on. When
using mechanized wire feed, the wire, wire reel,
drive roll housing and all metal parts touching
the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is
a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and
appropriate body protection.
3. Disconnect input power before installing
or servicing this equipment. Lockout/ta-
gout input power according to OSHA 29
CFR 1910.147 (see Safety Standards).
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ZB-300 Benchmaster Positioner
4. Properly install and ground this equip-
ment according to the operation manual
and national, state and local codes.
5. Always verify the supply ground-check
and be sure that input power cord ground
wire is properly connected to ground
terminal in disconnect box or that cord
plug is connected to a properly grounded
receptacle outlet.
6. When making input connections, at-
tach proper grounding conductor first
- double-check connections.
7. Frequently inspect input power cord for
damage or bare wiring. Replace cord im-
mediately if damaged - bare wiring can
kill.
8. Turn off all equipment when not in use.
9. If earth grounding of the workpiece is re-
quired, ground it directly with a separate
cable - do not use work clamp or work
cable.
10. Do not touch electrode if you are in con-
tact with the work, ground, or another
electrode from a different machine.
11. Use only well-maintained equipment.
Repair or replace damaged parts at once.
Maintain unit according to manual.
12. Wear a safety harness if working above
floor level.
13. Keep all panels and covers securely in
place.
14. Clamp work cable with good metal-to-
metal contact to workpiece or worktable
as near the weld as practical.
ZB-300 Benchmaster Positioner
C. Arc Rays
Arc rays can burn eyes and skin; noise can
damage hearing; flying slag or sparks can injure
eyes.
Arc rays from the welding process produce
intense visible and invisible (ultraviolet and
infrared) rays that can burn eyes and skin. Noise
from some processes can damage hearing. Chip-
ping, grinding and weld cooling throw off pieces
of metal or slag.
1. Use approved ear plugs or ear muffs if
noise level is high.
2. Use a welding helmet fitted with a proper
shade of filter to protect your face and
eyes when welding or watching.
3. Wear approved safety glasses with side
shields.
4. Use protective screens or barriers protect
others from flash and glare; warn others
not to watch the arc.
5. Wear protective clothing made from
durable, flame-resistant material (wool
and leather) and foot protection where
necessary.
D. Fumes and Gases
Fumes and gases can be hazardous to your
health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not
breathe the fumes.
2. If inside, ventilate the area and/or use
exhaust at the arc to remove welding
fumes and gases.
3. If ventilation is poor, use an approved
air-supplied respirator.
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4. Read the Material Safety Data Sheets
(MSDS) and the manufacturer’s instruc-
tion for metals, consumables, coatings,
cleaners, and degreasers.
5. Work in a confined space only if it is well
ventilated, or while wearing an air-sup-
plied respirator. Always have a trained
watch person nearby.
6. Do not weld in locations near degreasing,
cleaning, or spraying operations. The
heat and rays of the arc can react with
vapors to form highly toxic and irritating
gases.
7. Do not weld on coated metals, such as
galvanized, lead or cadmium plated steel,
unless the coating is removed from the
weld area, the area is well ventilated,
and if necessary, while wearing an air-
supplied respirator. The coatings and any
metals containing these elements can give
off toxic fumes if welded.
E. Cylinders
Cylinders can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the
welding process, be sure to treat them care-
fully.
1. Protect compressed gas cylinders from
excessive heat, mechanical shocks, slag,
open flames, sparks, and arcs.
2. Install cylinders in an upright position by
securing to a stationary support or cylin-
der rack to prevent falling or tipping.
3. Keep cylinders away from any welding
or other electrical circuits.
4. Never weld on a pressurized cylinder
- explosion will result.

5. Use only correct shielding gas cylinders,
regulators, hoses and fittings designed for
the specific application; maintain them
and associated parts in good condition.
6. Turn face away from valve outlet when
opening cylinder valve.
7. Keep protective cap in place over valve
except when cylinder is in use or con-
nected for use.
8. Read and follow instructions on com-
pressed gas cylinders, associated equip-
ment, and CGA publication P-1 listed in
Safety Standards.
F. Welding
Welding can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up.
Sparks can fly off from the welding arc. The
flying sparks, hot workpiece, and hot equipment
can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, ex-
plosion, overheating, or fire. Check and be sure
the area is safe before doing any welding.
1. Protect yourself and others from flying
sparks and hot metal.
2. Do not weld where flying sparks can
strike flammable material.
3. Remove all flammables within 35 ft. (10.7
m) of the welding arc. If this is not pos-
sible, tightly cover them with approved
covers.
4. Be alert that welding sparks and hot mate-
rials from welding can easily go through
small cracks and openings to adjacent
areas.
5. Watch for fire, and keep a fire extin-
guisher nearby.
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ZB-300 Benchmaster Positioner
6. Do not weld on closed containers such
as tanks, drums, or pipes, unless they are
properly prepared according to AWSF4.1
(see safety Standards).
7. Connect work cable to the work as close
to the welding area as practical to prevent
welding current traveling long, possibly
unknown paths and causing electric
shock and fire hazards.
8. Wear oil-free protective garments such
as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
G. Moving Parts
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Have only qualified people remove
guards or covers for maintenance and
troubleshooting as necessary.
H. EMF Information
Considerations About Welding and the Ef-
fects of Low Frequency Electric and Magnetic
Fields
The following is a quotation from the General
Conclusions Section of the U.S. Congress, Of-
fice of Technology Assessment, Biological
Effects of Power Frequency Electric & Mag-
netic Fields - Background Paper, OTA-BP-E-53
(Washington, DC: U.S. Government Printing
Office, May 1989):
ZB-300 Benchmaster Positioner
“.... there is now a very large volume of scientific
findings based on experiments at the cellular
level and from studies with animals and people
which clearly establish that low frequency
magnetic fields can interact with, and produce
changes in, biological systems. While most of
this work is of very high quality, the results are
complex. Current scientific understanding does
not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrat-
ing, it does not yet allow us to draw definite
conclusions abut questions of possible risk or to
offer clear science-based advice on strategies to
minimize or avoid potential risks.”
To reduce magnetic fields in the work place, use
the following procedures:
1. Keep cables close together by twisting or
taping them.
2. Arrange cables to one side and away from
the operator.
3. Do not coil or drape cables around the
body.
4. Keep welding power source and cables
as far away as practical.
5. Connect work clamp to workpiece as
close to the weld as possible.
About Pacemakers:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
-4-
I. Principal Safety Standards
Reference as applicable
Safety in Welding and Cutting, ANSI Standard
Z49.1, from American Welding Society, 550
N.W. LeJeune Rd, Miami, FL 33126
Safety and Health Standards, OSHA 29 CFR
1910, from Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C.
20402
National Electric Code, NFPA Standard 70 from
National Fire Protection Association, Battery-
march Park, Quincy, MA 02269
Recommended Safe Practices for the Prepara-
tion for Welding and Cutting of Containers That
Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from
American Welding Society, 550 N.W. LeJeune
Rd, Miami, FL 33126
Safe Handling of Compressed Gases in Cylin-
ders, CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202
Code for Safety in Welding and Cutting, CSA
Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3
Sales Practices for Occupation and Educational
Eye and Face Protection, ANSI Standard Z87.1,
from American National Standards Institute,
1430 Broadway, New York, NY 10018
Cutting and Welding Processes, NFPA Standard
51B, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
 ZB-300 Benchmaster Positioner

Section II

Introduction

Congratulations on your purchase of the Jetline The housing is supported by a frame. See Figure
ZB-300 Benchmaster Positioner. Its quality 1. The frame is made from steel plates bolted
workmanship will bring many years of depend- together. Two friction locks are provided (see
able service. Figure 1) which allow the plane of rotation of
the faceplate to be adjusted a full 90° of tilt.
The ZB-300 Benchmaster positioner (Figure 1)
is designed to be used with any welding head A ground connection is provided for use in weld-
locator device or with a cantilever system when ing applications. See Figure 1.
welding cylindrical parts, whether in the hori-
zontal or vertical position.
CAUTION
The Benchmaster positioner provides a rotat-
ing faceplate that is twelve inches (305 mm) in
It is important that a tight connection to the
diameter and contains four slots for mounting
welding power supply ground is maintained.
the part. See Figure 2. The faceplate is mounted
Otherwise, serious damage to the positioner
on a spindle that extends out from a truncated
bearings can occur.
tubular housing. See Figure 1. On each side of
the housing is a series of holes which will allow
for adjustment. A DC gear motor is contained
inside of the housing.

The control box is located on the side of the

housing. This control box houses the fuse, re-
mote socket, potentiometer knob, forward-off-
reverse switch and manual-remote switch.

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ZB-300 Benchmaster Positioner

Figure 1
ZB-300 Benchmaster Positioner

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 ZB-300 Benchmaster Positioner

Figure 2
ZB-300 Faceplate

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ZB-300 Benchmaster Positioner

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 ZB-300 Benchmaster Positioner

Section III

Specifications

Weight Capacity Service Requirements

Faceplate Vertical 300 lb (136 kg) with Electrical: 115 volts, 1 phase, 50/60 Hz
center of gravity 4”
(100 mm) from face- Ground Conduction: 500 amps
plate
Table Tilt
Faceplate Horizontal 450 lb (204 kg) with
center of gravity 4” Tilt of 90°
(100 mm) from face-
plate Tilt lock is positive, cannot slip under load

Physical Characteristics Faceplate

Length 14.5” (409 mm) 12” (305 mm) diameter, aluminum with 4
Height 15.88” (403 mm) tooling slots
Width 13.63” (346 mm)
Weight 75 lb (34 kg) 0.625” (15.8 mm) diameter through-hole

Speed Range 1.625” (41 mm) and 3” (76 mm) optional

through-hole sizes
ZB-300A 0.2 to 11 RPM
ZB-300B 0.07 to 3.6 RPM
ZB-300C 0.4 to 24 RPM
ZB-300D 0.6 to 30 RPM

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ZB-300 Benchmaster Positioner

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 ZB-300 Benchmaster Positioner

Section IV

Operation

The positioner is designed to be powered by

115 volts AC, 50/60 Hz. We do not recommend
using the 115 VAC receptacle which is provided
with some TIG power supplies to power the
positioner.
The controls on the positioner are the Forward-
Off-Reverse switch, the Foot Control On-Off
switch, and the one-turn speed potentiometer.
Remote Foot Switch
When the positioner is supplied with an On/Off
foot switch cable, the connector is plugged into
the remote socket. The remote socket is located
on the control panel assembly.

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ZB-300 Benchmaster Positioner

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 ZB-300 Benchmaster Positioner

Section V

Maintenance
The Jetline Benchmaster Positioner has been
designed to give trouble free operation under
normal working conditions and requires little
maintenance. The following items should be
checked periodically for optimum perfor-
mance.
1. Check interior of box for foreign mat-
ter which could interfere with efficient
operation.
2. Apply grease (Fiske Lubriplate #105) to
spur gears.
3. Check ground strap for wear and replace
if necessary.
4. Apply an electrical lube to the shaft
where the ground strap contacts the
shaft.
5. Fuses: Check that the proper overload
protection is being used: 3 amp Fast-
Blow.
6. Check connection to ground lug. Tighten
as necessary.

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ZB-300 Benchmaster Positioner

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 ZB-300 Benchmaster Positioner

Section VI

Parts List

The following pages provide a detailed parts list The following parts lists are included in this
of the ZB-300 Benchmaster Positioner. They are manual, their page numbers are:
arranged so that the assembly illustrated on the
left hand page is for the parts list on the adjacent ZB-300 Positioner ................................... 16/17
right hand page. ZB-300-RGA........................................... 18/19
Item numbers shown in the parts list refer to MCM-10 motor Control Module ............ 20/21
those items referenced by the balloon in the
drawing. Each parts list shows the main assem- MCM-10-FC5A (Optional) ..................... 22/23
bly as item 1, all the quantities shown are the
quantities used to make the main assembly.
Two columns are included in the list to show
the spare parts which it is recommended should
be stocked by the user. The two levels can be
defined as follows:
Level 1
These are the spares recommended for US do-
mestic users whose use of the product does not
exceed 2000 hours per year.
Level 2
These are the spares recommended for Interna-
tional users of the product or for US domestic
users who will use the product in excess of 2000
hours per year.

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ZB-300 Benchmaster Positioner

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 ZB-300 Benchmaster Positioner

ZB-300 POSITIONER

Recommended
Item Part Level Level
No. No. Description Qty I II

2 ZB300-2 Pivot Plate Detail .....................................................1

3 ZB300-3 Leg Detail.................................................................2
4 Not shown
5 ZB300-5 Spindle Detail...........................................................1
6 ZB300-6 Tie Detail..................................................................1
7 ZB300-RGA Rotary Ground Assembly.........................................1
8 ZB200-200C Face Plate Detail ......................................................1
9 MCM-10 Motor Control Assembly..........................................1
10 ZB300-10B Worm Gear Reducer.................................................1
11 ZB300-11 Bearing .....................................................................2 1
12 6085K13 Knob.........................................................................2 1 1
13 M1130329 Motor, 90 VDC, 1/9 hp ............................................1 1
14 98870A260 Key (not shown).......................................................1 1 1

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ZB-300 Benchmaster Positioner

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 ZB-300 Benchmaster Positioner

ZB-300-RGA ROTARY GROUND ASSEMBLY

Recommended
Item Part Level Level
No. No. Description Qty I II

2 ZB300-RGA-2 .........................................Hub Detail 1

3 ZB300-RGA-3 Ground Strap Detail .................................................1 1
4 ZB300-RGA-4 Washer Detail ...........................................................1
5 97063A520 Shim .........................................................................1
6 ZB300-RGA-5 Clamp on collar ........................................................1
7 Spring .......................................................................1 1
8 Set Screw .................................................................2
9 Hex Head Set Screw ................................................1
10 Hex Lock Nut...........................................................2

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 OFF

CR1
CR1

R1 CR1

R2 5KΩ
REMOTE 1-TURN
SOCKET

SW2

CR1 SW1 F1
REMOTE / MAN
SWITCH
C1 .025μf
ZB-300 Benchmaster Positioner

120
VAC
C2 .025μf

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POWER
OFF
40 50 60
REV FWD
30 70

3 AMP 20 80
NOTES:
10 90
0 100
REMOTE
MANUAL

REMOTE
MODEL MCM-10
 ZB-300 Benchmaster Positioner

MCM-10 MOTOR CONTROL MODULE

Recommended
Item Part Level Level
No. No. Description Qty I II

1 91F642 Control Enclosure ....................................................1

2 GSM-1-9 Enclosure Bracket ....................................................2
3 MCM-10-100 Face Plate .................................................................1
4 KBIC-120-1/4 Motor Control, with 9839 resistor (not shown) .......1 1 1
5 10F466 Potentiometer, 5K, 1-turn.........................................1 1 1
6 M1432 Knob.........................................................................1 1 1
7 RH2B-U-120VAC Relay (not shown) ....................................................1 1 1
8 M-1901 Connector, 3-pin socket ...........................................1
9 41F494 Switch, 4-pole, DT ...................................................1 1 1
10 23F230 Switch, SPST ...........................................................1 1 1
11 V130LA20B Varistor (not shown).................................................1 1 1
12 13F340 Brake Resistor (not shown)......................................1 1 1
13 18F2730 Capacitor (not shown) ..............................................2 2 2
14 AGC-3 3 Amp Fuse ..............................................................1 5 5
15 28F027 Fuse Holder ..............................................................1
16 6-32x1/4 Screw, round head (not shown) ................................1
17 C-1318-006-BL Cable, 3-prong, 115VAC plug (not shown) .............1
18 Rubber Grommet (not shown) .................................1
19 SRB-7K-2-1 Cord Grip .................................................................1

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 OFF
NOTES:

CR1
CR1

R1 CR1

D C
FOOT
SWITCH R2
E B

I H F A

REMOTE / MAN
SWITCH

CR1 SW1 F1
SW2

C1

C2
ZB-300 Benchmaster Positioner

FOOT CONTROL CIRCUIT

FOOT CONTROL P1 REMOTE SHORTING PLUG P2

PEDAL MATING SIDE SHOWN REQUIRED FOR OPERATION WO/FOOT CONTROL
FC-5A MATING SIDE SHOWN
POWER
OFF
40 50 60
J A J A REV FWD
I K B 30 70
I K B
H N L C H N L C 3 AMP 20 80
G M D G M D 10 90

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F E F E 0 100
REMOTE
MANUAL
A J
B K I
C L N H
D M G
E F

REMOTE
MODEL MCM-10

FOOT CONTROL CIRCUIT

WITH PROPORTIONAL
SPEED CONTROL
FOOT CONTROL P1
PEDAL MATING SIDE SHOWN
FC-5A

J A
I K B
H N L C
G M D
F E
 ZB-300 Benchmaster Positioner

MCM-10-FC5A OPTIONAL
VARIABLE SPEED FOOT CONTROL

Recommended
Item Part Level Level
No. No. Description Qty I II

1 91F642 Control Enclosure ....................................................1

2 GSM-1-9 Enclosure Bracket ....................................................2
3 MCM-10-100 Face Plate .................................................................1
4 KBIC-120-1/4 Motor Control, with 9839 resistor (not shown) .......1 1 1
5 10F466 Potentiometer, 5K, 1-turn.........................................1 1 1
6 M1432 Knob.........................................................................1 1 1
7 RH2B-U-120VAC Relay (not shown) ....................................................1 1 1
8 3102A-20-27S Connector, 14-pin socket .........................................1
9 41F494 Switch, 4-pole, DT ...................................................1 1 1
10 23F230 Switch, SPST ...........................................................1 1 1
11 V130LA20B Varistor (not shown).................................................1 1 1
12 13F340 Brake Resistor (not shown)......................................1 1 1
13 18F2730 Capacitor (not shown) ..............................................2 2 2
14 AGC-3 3 Amp Fuse ..............................................................1 5 5
15 27F794 Fuse Holder ..............................................................1
16 6-32x1/4 Screw, round head (not shown) ................................1
17 C-1318-006-BL Cable, 3-prong, 115VAC plug (not shown) .............1
18 Rubber Grommet (not shown) .................................1
19 SRB-7K-2-1 Cord Grip .................................................................1
20 3106A-20-27P Amphenol Connector, Shorting Plug (not shown) ...1
21 AN-3055-22-10 Amphenol Adapter, cap to plug (not shown) ...........1
22 9160-16 Amphenol Dust Cap (not shown) ............................1
23 FC-5A Variable Foot Control (not shown) ..........................1

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