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The hose and wiring assembly on Polyvance's nitrogen plastic welder is subject to wear and damage in daily shop use. The following tutorial will show you how to replace the damaged hose on Polyvance and Urethane Supply "red box" welders where the hose comes out the front panel of the welder, as on the model 6057, 6059, and 6085 models.
Make sure your welder is cool and disconnected from the power before you begin the repair.
Always wear proper safety gear while working!
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This is the replacement hose and wiring assembly for the following welders:
The hose and wiring assembly on Polyvance's nitrogen plastic welder is subject to wear and damage in daily shop use. The following tutorial will show you how to replace the damaged hose on Polyvance and Urethane Supply "red box" welders where the hose comes out the front panel of the welder, as on the model 6057, 6059 and 6085 models.
First, unscrew the hood of the welder and lift it up to gain access to the wires inside. Remove the three wires from the holster switch. Move the hood out of the way. Remove the plumbing so you can easily access the control panel. Remove the two ribbons attached to the control panel. Do not remove them from the display boards. Remove the five wires attached to the control board. Carefully cut the zip ties holding the wires in place.
On the bottom of the welder, unscrew the four screws that connect to the control board bracket. Remove the control board bracket and vent shield. On the backside of the welder, unscrew the nut and remove the washer and green ground wires from the ground stud. Detach the male and female blue wires. Snip the three terminals off the wires. Remove the plumbing going to the brass tee. Using a wrench, unscrew the compression nut, and remove the O-ring with your fingers. Using two wrenches, hold the hose in place and give the brass tee a quarter turn. Remove the ninety-degree fitting from the top of the brass tee. Hold the hose in place and finish removing the brass tee. Hold the hose in place with one wrench while you remove the aluminum nut with another. Remove the hose from the welder. Re-tape the aluminum barb.
Feed the wires from the new hose back into the welder, and secure the aluminum nut. Tighten the aluminum nut while holding the hose in place. Run the wires back through the brass tee and secure until hand-tight. Use two wrenches to tighten the brass tee, but be sure to leave room to for the ninety-degree fitting. Add the ninety-degree fitting back on the brass tee and tighten. Place the O-ring and compression nut back on the wires and tighten securely. On the three new wires, strip off a small portion of the insulation and attach the new terminals. The red flag terminal should go on the brown wire, the blue terminal should go on the blue wire, and the round brass terminal should go on the green wire. Place the two green ground wires and washer back on the ground stud and tighten the nut. Reattach the two male and female blue wires. Slide the shielding vent under the wires, and line up the holes. Place the control board bracket on top of the shielding vent.
Secure the four screws on the bottom of the welder to the control board. Attach the wires back onto their appropriate place on the control board. The wires and control board are both labeled to help with the placement. Secure all of the plumbing back into the appropriate fittings. Place the ribbons back onto the control board. Be very careful not to bend the prongs Place the hood on top of the welder. Attach the three wires to the holster switch. Red should go in front, yellow in the middle, and the yellow and black wires go in the back. Lower the hood down the rest of the way and screw it back on tightly. Now your hose and wiring assembly is good to go!
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