Ultratec G3000 Service Manual page 2

Heat Exchanger Replacement
• Make sure the main power cord is disconnected from power
• Make sure unit has cooled sufficiently to perform the operation
1. Make sure the machine is unplugged.
2. Using a #2 Phillips Screw Driver remove the 12 screws on the lid.
Carefully lift the case off and carefully detach the grounding wire
screwed to the lid.
3. Disconnect the copper tubes from the pumps by loosening the 7/16"
brass nut on the pump. This line may be under high pressure if the tube
was plugged. Slowly loosen the pump that connects to the copper 1/4
tube inlet fitting to release any pressure.
4. Remove the two slot screws (or ¼" hex) from the front edge of the block
cover. Slide the cover backward to release the two back tangs from the
lower cover. Lift the cover off.
5. Remove the insulation on top.
6. Using a ½" socket, loosen the five nuts. Remove all 5 nuts and washers
(these will not be reused). Be careful not to damage any exposed
wiring. Remove the upper steel plate by gently lifting the plate up out of
the way.
7. Remove the ¼" aluminum plate cautiously to avoid damage to the
thermocouple. Examine the thermocouple wires for moisture as this may
cause failures.
8. Remove the aluminum wear plate that is positioned above the coil (this
will not be reused).
Remove the used copper tube from the block (this part will not be
9.
reused).
10. Remove the second thin wear plate (this part will not be reused).
11. Lift the thick aluminum plate up cautiously to avoid damage to the
heaters.
12. Remove the third thin wear plate (this part will not be reused).
13. Remove the second coil from the block (this part will not be reused).
14. Remove the forth thin wear plate (this part will not be reused).
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before attempting to remove the outer cover