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® 



SERVICE MANUAL 

R SERIES GAS 
TOP BURNER UNITS 

MODELS 
RTR644 & RTR645 

WITH 

AUTOMATIC PILOTLESS 



IGNITION 



87632 



^^ yV I f^ Q I ^^® CALORIC CORPORATION 



TOPTON, PENNSYLVANIA 19562 CONSUMER RELATIONS DEPARTMENT 



A Raytheon Company 



IMPORTANT INFORMATION 



The information contained in this manual is intended for use by a qualified service technician 
who is familiar with the application of all safety procedures required in the repair of any gas 
or electrical appliance, and who is equipped with the proper tools and testing instruments. 

Repairs covered in this manual and made by unqualified persons can result in hazards develop- 
ing due to improper assembly or adjustments. 

Inexperienced persons making such repairs subject themselves to the risk of injury or electrical 
shock which can be serious or even fatal. 

IMPORTANT NOTE TO CONSUMER 

If you perform service on your own Caloric product, you must assume responsibility of personal 
injury or property damage which may result. 

Caloric Corp. will not be responsible for injury or property damage arising from service per- 
formed by other than Caloric Factory Authorized Service Agencies! To locate the nearest fac- 
tory authorized service agency please contact your dealer or write to: 

Caloric Corporation 

Consumer Relations Department 

Washington and Heffner Sts. 

Topton, PA 19562 

Telephone: Area Code 215-682-4211 



TABLE OF CONTENTS 

PAGE 

PART I — General Information 

General Information 1 

Limited Appliance Warranty 2 

Product Specifications and Features 3-4 

PART II — Adjustment and Service 6 

PART III — Disassembly Procedures 7 

PART IV — Schematic and Wiring Diagrams 11 

PART V — Parts Distributor Information 12 



r^ 



PART I — GENERAL INFORMATION 



GENERAL INFORMATION 



The following manual provides you with complete instruc- 
tions and suggestions for handling, installing and servicing 
Caloric Gas Built-in Top Burner Units. 

This manual is based on information gained through ex- 
perience and careful testing. This information, if followed 
carefully, will assure your customer of proper gas unit opera- 
tion with a minimum of servicing requirements, thus in- 
suring the maximum benefits of clean, modern cooking. 
Unless the unit is properly installed and carefully explain- 
ed, the customer will not receive the utmost advantages that 
gas cooking provides. 

Feel free at all times, to call Caloric to discuss any problems 
which you may not fully understand. 



Refer to the Parts Catalog when replacement parts are 
needed. 

MODEL IDENTIFICATION 

The model number, manufacturing number (MN) and serial 
number can be found on the rating label. The correct model 
and serial number should be known prior to ordering parts 
so that incorrect shipments and delays can be avoided. An 
example of the rating label is shown below. 

The rating label is located under the maintop. It can be 
observed by lifting the maintop to expose the rating label 
on the burner box. 



CALORIC CDRRDRWCION imtm fa. 1956? usa. 



ImOOEL f^KIt 39* CoD6(/A/ M^OO 

IsERlAL Ii3*5fc7 nru/HH INPUT: OVEN l<1^000 

|eQUIPP£D FOR ''/^r-Z.P ToP MAT. '.0,OOo/l P 9^O0 

IwAWIFOLO PRESS NAT. S LP lO IN.WC. ELEV. OVEN 
l-ANS. Z 2/. 1- (9 75 H5Ehi:>.C0OK. APPL . '"i^,'?''"' 



MINI.MUM CLE-\RA.NCES TO ADJACllNT COMliUSTIBLH VtRl ICAL 

.^..t r-m-yTunrrnD- A" QTHPt; ABOVE 

U.STKRTOl 
;. U" 
ES WITH 



SURF.A.CES:0" ' 

'.rTo'IoT RATING LABEL EXAMPLE 

H-VK. DEPTH OF C\B1M:1; i:hv, ou ii-.i rn, iu.-i. >,>ji-.. ,„ 

21 CPR SUBOIXPTER J; , , , 

KC rtTE .\PPR0VA1. ".''IE |1H12 | MANUF.XCTURED | 



3 



CALORIC MODEL DESCRIPTION BREAKDOWN 



RTR645-U5 



R 


T 


R 


6 


4 


5 


U 


5 


PRODUCT 


PRODUCT 




WIDTH 










LINE 


TYPE 


SERIES 


ON TOP 


BACKGUARD 


FEATURE 


FUEL 


COLOR 


E - Electric 


C ■ Convertible 


R 


• No Width 


- No Backguard 


Variable 


N - Natural 


- No Color 


Range 


D - Down Draft 




Required 


1 - Plain Rail/ 




Gas 


1 ■ White 


R - Gas Range 


E - Electric 




1 ■ 15" - 18" 


Laminated 




L - Bottled 


2 ■ Antique 


T - Trash 


H - High Broil 




2-20"- 18" 


Top 




Gas 


Copper 


Compactor 


J - Hi-Broil w/ 




3 ■ 30" - 35" 


2 - Plain Rail/ 




U - Universal 


3 - Avocado 


H • Vent Hood 


Cont. Clean 




4 - 40" - 42" 


Cutting board 




X - Export 


4 - Autumn 


M • Microwave 


K - Upper Oven 




6 - 36" 


3-4" Backguard 




*Z - Zero 


5 - Satin/Stain- 


D - Dishwasher 


Microwave 






w/Auto-Timer 




Clearance 


less Steel 


K- Kit 


L • Low Broil 






4 - Special Desig- 




1 - 115 Volts 


6 - Black 




M - Low Broil w/ 






nation 




2 - 230 Volts 


9 - Color Pack 




Cont. Cleaning 






5 ■ Standard 




8 - 208 Volts 


C - Dark Copper 




P ■ Portable 






6 - Deluxe Back- 






D - Gold 




R ■ Microwave/ 






guard 






N - Almond 




Electric 






7 - Special Desig- 






V - Avocado 




S - Self-Clean 






nation 






W - White 




T - Cook Top 






8 ■ Deluxe Back- 






F - Snow White 




U - Undercounter 






guard 










V ■ Variable 






9 - Double Decker 










Power 
















V\/ - Wall Oven 
















X - Wall Oven w/ 
















Cont. Cleaning 
















Y - Self-Cleaning 
















Wall Oven 















'Special natural gas models, without elevated ovens, which may be installed flush against one vertical side wall extending above the cooking 
surface. 



PART I — GENERAL INFORMATION 



LIMITED APPLIANCE PARTS WARRANTY 

^^ PARTS WARRANTY 

Caloric warrants all PARTS of this Caloric appliance against detects in material and workmanship for a period of one (1) year from 
the date of its delivery. Any replacement parts furnished at no cost to the purchaser in fulfillment of this warranty, are warranted 
only for the unexpired portion of the original warranty. Caloric's appliance parts warranty pertains only to the PARTS of the ap- 
pliance, not the labor required for repair or replacement, which is the responsibility of the source from whom this appliance was 
purchased. 

WARRANTY SERVICE 

The selling dealer, builder, or utility from whom this appliance was purchased is responsible for advising the purchaser of the period 
of no charge warranty service labor coverage, and how and from whom warranty service is available. Replacement parts under the 
terms of this warranty must be furnished by a franchised Caloric dealer or authorized Caloric service agency. 

OWNERSHIP 

This appliance PARTS warranty remains in force for one year from the initial delivery of the appliance, and continues in force for 
one year from initial delivery, even if relocated by the first or subsequent purchaser(s). 

WARRANTY CONDITIONS 

Caloric's appliance PARTS warranty DOES NOT apply to any appliance which has been subjected to alteration, misuse, abuse, acci- 
dent, improper installation, delivery damage, or other than household use and service. THERMAL AND MECHANICAL FRACTURES 
OF GLASS SMOOTHTOPS WILL BE PRESUMED TO BE CAUSED BY APPLIANCE MISUSE AND/OR ABUSE. Caloric's PARTS warran- 
ty is LIMITED STRICTLY to the terms indicated herein, and no other expressed warranties or remedies thereunder shall be binding 
on us. TO THE EXTENT CONSISTENT WITH STATE AND FEDERAL LAWS: (1) ANY IMPLIED WARRANTIES SHALL BE LIMITED TO 
THE SAME TIME PERIODS STATED HEREIN FOR CALORIC'S EXPRESSED WARRANTIES, AND (2) CALORIC SHALL NOT BE LIABLE 
FOR CONSEQUENTIAL DAMAGES UNDER ANY EXPRESSED OR IMPLIED WARRANTIES RELATING TO THE CALORIC APPLIANCE. 
Caloric's warranty obligation on appliances located outside the contiguous 48 U.S. states and the District of Columbia shall be 
LIMITED STRICTLY to furnishing replacement parts and shall EXCLUDE service labor. 

FEDERAL REGULATORY PROVISIONS 

Some states do not allow limitations on how long an implied warranty lasts nor limitations or exclusions of incidental or conse- 
quential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and 
^^ you may also have other rights which vary from state to state, as well as rights under Federal Laws. 

PURCHASER'S RESPONSIBILITIES 

The purchaser will be responsible for the costs of any service calls requested to demonstrate or confirm the proper operation of 
the appliance, to correct an improper installation that the purchaser may have performed, or to correct malfunctions in the appliance 
created by operation of the appliance in a manner not prescribed by, or cautioned against, In the Caloric Use and Care Instructions. 

PURCHASE REGISTRATION CARD 

The purchaser should fill out and mail to Caloric the purchase registration card included with the appliance. This will help Caloric 
expedite any future communications regarding the appliance. Your warranty rights are not conditioned upon the return of the Pur- 
chase Registration Card. 

MODEL AND SERIAL NUMBERS 

The appliance model number and serial number can be found on a nameplate attached to the appliance. The purchaser should always 
use the model number and serial number when talking to or writing to the dealer, builder, or utility from whom this appliance was 
purchased, the local authorized service agency, or Caloric. 

FACTORY ASSISTANCE 

If the purchaser is unable to locate an authorized service agency, or if the purchaser does not receive satisfaction from the source 
from whom the appliance was purchased, or from the local servicing dealer or agency, write to: Caloric Corporation, Consumer 
Relations Department, Topton, Pennsylvania 19562, or call AC 215-682-4211. 



PART I — GENERAL INFORMATION 



FEATURES AND SPECIFICATIONS 



RTR 645 BUILT-IN 36" 
GAS COOKTOP WITH GRIDDLE 




RTR644 BUILT-IN 36" GAS COOKTOP 





RTR645 FEATURES 

• Four Surface Burners 

• Built-in Griddle and Cover 

• Automatic Pilotless Ignition 

• Raised Outer Edges 

• Push-To-Turn, Hi-Lo-Simmer Controls 

• Hinged Maintop with Support Rod 

• Equipped for use with either Natural 
or LP. Gas (Shipped from the Factory 
Adjusted for Natural Gas) 

• Available in White, Dark Copper, 
Avocado, Almond, Gold and Brushed 
Chrome 



RTR644 FEATURES 

• Four Surface Burners 

• Automatic Pilotless Ignition 

• Raised Outer Edges 

• Push-To-Turn, Hi-Lo-Simmer Controls 

• Hinged Maintop with Support Rod 

• Equipped for use with either Natural 
or L.P. Gas (Shipped from the Factory 
Adjusted for Natural Gas) 

• Available in White, Dark Copper, 
Avocado, Almond, Gold and Brushed 
Chrome 



CUT OUT SPECIFICATIONS AND DIMENSIONS 



SPECIFICATIONS • RTR644 and 645 



Top Burner Rating (Each) 
(RTR645) Grill Burner Rating 
Electrical Requirements 



8,000 BTU's Natural Gas 
7,000 BTU's L.P. Gas 

12,500 BTU's Natural Gas 
12,500 BTU's LP. Gas 

115 Volts AC, 60 Hz, 

15 Amps., Grounded Outlet 




PART I — GENERAL INFORMATION 




INSTALLATION INFORMATION 



25 total counter 
top drptli. 
20" depth 



2-1/4" Min. 
to nearest 
combustible 
wall 



3 minimum distance 
to nearest combustible side wall 
above counter lop. 



Pressure reRulator 
3-13/16" 




15" 



xof 112" female pipe thread 

on regulator. * | 3" 
Below counter lop. 



f^ 



35" 



-RIGHT 5IDE 
OF UNIT 
CUTOUT 



110/120 

FRONT VltW OF UNIT VOIT 60 H/. 

Grounded Outlet 



Street ell fitlinfi for 

Ras connection beneath 

range in base cabinet. 

(Not supplied with unit) 



2" includes counter top 
overhang 



Tr-pf^ 



FRONT OF UNIT*- 



12-13/16" * 



Front of regulator 
(or gas connection 

RIGHT SIDE VIEW OF UNIT 



WARNING 

Electrical Grounding Instructions 

This appliance is equipped with a three- 
prong (grounding) plug for your protec- 
tion against shock hazard and should be 
plugged directly into a properly ground- 
ed three-prong receptacle. Do not cut or 
remove the grounding prong from the 
plug. 



STEP 2. PROVIDE ELECTRICAL CONNECTION: 

The electrical connection of this range is 110/120 volt 15 
AMP* 60 Hertz AC. This range is provided with a 
grounded type range cord. A grounded type outlet should 
be provided in the area directly behind range. Be sure 
to comply with local electrical codes for grounding. 

This unit must be electrically grounded in accordance 
with the National Electrical Code. ANSI/NFPA No. 
70-1981. 

STEP 3. INSTALLING BURNER BOX 

(a) Before installing burner box, install a gas shut-off 
valve before the gas line connects to range top 
manifold. 

(b) Insert unit Into cabinet top opening. Remove grates, 
swing top open and screw or nail the burner box 
to cabinet top through holes in flange. 

STEP 4. MAKE GAS SUPPLY CONNECTION 



n 



STEP 1. PREPARE COUNTERTOP CUT OUT OPENINGS 
CAREFULLY 

Counter top openings and wall clearances should be 
carefully prepared in accordance with the drawing as 
shown. 

NOTE: This range top requires a 5" clearance beneath 
top of counter surface. 



Gas connection is made to the gas pressure regulator 
which accepts 1/2" male pipe thread. This connection 
may be made directly below the burner box by the use 
of a 1/2" street ell fitting or may be made directly through 
the rear of the burner box. See drawing at left for loca- 
tion of the gas connection fittings on the unit. An ap- 
proved pipe compound resistant to the action of L.P. gas 
must be used in making gas connections. Test all points 
for leaks, with a soap solution or other acceptable 
means, but never with an open flame. 

Installation must conform to local codes. In the absence 
of local codes, installation must conform with the Na- 
tional Fuel Gas Code. ANSI Z223 1-1980. 



PART I — GENERAL INFORMATION 



Installation in a mobile home must conform with the 
federal standard for mobile home construction and safe- 
ty, Title 24, HUD (Part 280) or, when such standard is not 
applicable, with local codes. 

This range is equipped with a class 2 convertible gas 
pressure regulator. The maximum gas supply pressure 
for this regulator is 14" WCP. The test pressure for check- 
ing this regulator must be at least 7" WCP for natural 
gas or 11" WCP for LP Gas. It is shipped from the fac- 
tory adjusted for natural gas at 6" WCP. The regulator 
supplied must be used with this range. 

CONVERSION TO LP. (BOTTLED) GAS 

If LP (Bottle or Tank) gas is to be used, the pressure 
regulator must be converted to LPG 10" WCP. Conver- 
sion is done by removing retaining screw in top center 
of regulator, inverting the pressure pin and replacing re- 
taining screw. Orifice hood must be screwed snug for use 
with LP Gas on all Top Burners. 

STEP 5. ADJUSTMENT OF BURNERS 

All units are carefully lighted and checked at the factory, 
however, if your area should have different gas charac- 
teristics or if adjustments have been changed during or 
before installation the following adjustments should be 
checked when gas has been connected. 

(a) Burners: this unit is equipped with a pressure 
regulator which is pre-set at 6" WCP. This should 
eliminate any need for gas adjustment to the main 
burners. However, the air to the burner should be 
adjusted properly with the air shutter. The correct 
air shutter adjustment will usually amount to 1/8" 
to 3/16" open at corner. Proper adjustment will 
result in a sharp blue bead. 

Low burner flame may be adjusted by turning adjustment 
screw in center of valve stem. Normally, the low flame 
should be adjusted to the minimum steady blue flame. 
Check this adjustment by turning from high to low several 
times to see that the burner does not go out. 



Griddle 
Burner 

( IF EQUIPPED ) 



When valve is turned to the "LITE" position this will 
energize spark igniter. When igniters are working you will 
hear a sharp popping sound. 

After burner ignites turn valve knob back slightly until 
popping stops. 

Griddle Burner Flame May Be Observed By Sighting 
Through Left Rear Slot In Main Top (Located In The Con- 
trols Section). 

Adjust air to burners by means of movable air shutter at 
front end of burner casing. Closing the air shutter causes 
the flame to be soft and yellow tipped. Flames will lift 
or blow from the burner when air shutter is wide open. 
Adjust air shutter for medium soft flame. Tighten air shut- 
ter after adjustment so air shutter will remain in place. 

The appliance and its individual shutoff valve must be 
disconnected from the gas supply piping system during 
any pressure testing of that system at test pressures in 
excess of 1/2 psig. 

The appliance must be isolated from the gas supply pip- 
ing system by closing its individual manual shutoff valve 
during any pressure testing of the gas supply piping 
system at test pressures equal or less than 1/2 psig. 



OVIRHtAD CAIINIT 
SHOULD NOT tXCUD 
A MAXIMUM OtPTH 
OF 13 INCHtS. 




rtOM THI 
tOGCOF 
THt REAR 

TRIM STRIP 



Rear Surface 
Burner 



FROM THE 
FRONT EDGE 
OF COOKTOP 





Front Surface 
Burner 



Pressure Regulator 



PART II — ADJUSTMENTS AND SERVICE 



^ 



NATURAL TO LP. GAS CONVERSION 

The cooktop as shipped from the factory is adjusted for 
operation on natural gas. It contains all the components 
necessary to convert from natural to liquid propane (bot- 
tled gas). The components to be converted are the regu- 
lator and the burner gas valve orifice assemblies (4 on 
RTR644, 5 on RTR645). 

1. Regulator 

To convert the regulator to L.P. gas remove the 
regulator screw in the top center of the regulator, 
removing the pressure pin, inverting it and replacing 
it. Replace the retaining screw. 

2. Gas Valve Orifices 

The gas valves each contain a coaxial orifice as- 
sembly containing an orifice hood inside of which is 
located a hollow pin. The opening or orifice in the hood 
is sized for natural gas. The opening in the hollow pin 
is sized for L.P. gas. To adjust the assembly for L.P. 
gas, the orifice hood must be screwed down (clock- 
wise) until the tip of the pin just fills the opening in 
the hood. This takes approximately two complete 
turns clockwise of the hood. Do not overtighten or the 
pin may be damaged. This adjustment must be made 
for all 4 or 5 gas valves. 



LI 



N 



SPARK SWITCHES 



1^ L--. U; L-- L-1 



SURFACE 

BURNER 

ELECTRODES 



I 



GRILLE 
ELECTRODE 



1 
i, I 

LI 1 
I 



• I 
.J 



L___ 

P C B 

SPARK 
MODULE 



1. Switch Testing 

All of the normally open switches, mounted on the 
control valve shafts or stems, are in parallel in the cir- 
cuit. One terminal of each switch connects to the 120 
V.A.C. line while the other terminal of each switch con- 
nects to L1 of the module. Terminal N of the module 
connects to common or neutral side of the AC line. 



ELECTRIC SPARK IGNITORS 

A spark ignitor is located between each pair of left and 
right burners (and one for the griddle burner of RTR645). 

When any of the burner valves is turned on to the "LITE" 
position, the switch on the valve closes and completes 
the 120 V.A.C. circuit to the spark module (see circuit 
diagram). This activates the module to produce the spark 
at the igniters or electrodes to ignite the burner. 



A volt/ohmmeter test of the switches can be made with 
power removed. The meter set to low ohms range should 
be connected across the switch to be tested with lead 
connections removed. When the control is turned to the 
"LITE" position, the meter should indicate zero ohms 
showing the switch closed. 

An AC voltmeter test of the module can be made. With 
the voltmeter connected to LI and neutral, turning any 
of the controls to "LITE" position should give a meter 
reading of 120 V.A.C. If no sparking is observed at the 
electrodes, the module should be replaced. 



PART III — DISASSEMBLY PROCEDURES 




MAINTOP COMPONENTS 

1. Griddle Cover (RTR645) 

2. Maintop 

3. Control Tower 

4. Knob, Valve 

5. Grates 

6. Griddle Burner Baffle (RTR645) 



DISASSEMBLY PROCEDURES 

MAINTOP COMPONENTS 

Those components nnounted on or to the maintop are 
shown in the above illustration, with the exception of the 
griddle. The griddle (item 39) is shown in the following 
illustration. 

The griddle cover, control tower, knobs and grates are 
"lift-off" items. The control tower has mounting studs 
which go through openings in the maintop for position- 
ing purposes. It is not secured to the maintop so that it 
may be removed easily for cleaning purposes. The grid- 
dle burner baffle (item 6) is screw mounted to the cut- 
out lip of the maintop on Model RTR645. 

MAINTOP REMOVAL 

1. Disconnect electric power. 

2. Remove grates, control tower, knobs and griddle 
burner baffle (see burner baffle removal). 



3. The maintop is hinge mounted to the burner box at 
the rear. Removing the hinge screws frees the main- 
top for removal. 

GRIDDLE BURNER BAFFLE REMOVAL (RTR645) 

1. The griddle burner baffle and front and rear griddle 
supports (not shown In the illustration) are screw 
mounted to the maintop. 

2. To remove the griddle baffle, remove one screw at the 
front and one at each side. 

3. To remove the front and rear griddle supports, remove 
the two bolts and nuts securing each support to the 
cut-out lip of maintop. 

NOTE: The supports mount between the cut-out lip of the 
maintop and the griddle burner baffle on Model RTR645. 
Model RTR644 does not feature a griddle. 



PART III — DISASSEMBLY PROCEDURES 




I @ 



BURNER BOX AND OUTSIDE BOX COMPONENTS 



7 


Griddle Burner 


18 


Screw 


30 


Surface Valves 


8 


Griddle Valve 


19 


Screw 




Switch, Spark Ignitor 




Switch, Sparl< Ignitor 


20 


Module Mounting Plate 


31 


Support Rod Clamp 




Griddle Valve Extension 


21 


Spark Module 


32 


Screw 


9 


Burner, Right Rear 


22 


Screw 


33 


Burner Box 


10 


Screw 


23 


Manifold Pipe 


34 


Switch Cover 


11 


Hinge 




Pipe Plug 


35 


Screw 


12 


Flash Tube Assembly 


24 


Pressure Regulator 


36 


Burner, Left Rear 


13 


Electrode Cap Bkt. Assy. 


25 


Burner, Right Front 


37 


Access Cover 


14 


Screw 


26 


Screw 


38 


Outside Box Baffle 


15 


Supply Cord 


27 


Screw, Shipping 


39 


Griddle 




Strain Relief, Heyco Bushing 


28 


Burner, Left Front 


40 


Screw 


16 


Outside Box 


29 


Support Rod 






17 


Access Cover 




Rubber Tip, Support Rod 







PART III - DISASSEMBLY PROCEDURES 



BURNER BOX AND OUTSIDE BOX COMPONENTS 

The preceding illustration shows the various components 
of the burner box and outside box. 



SWITCH COVER REMOVAL 

The switch cover or control cover is screw mounted to 
the edge of the burner box and covers the wiring con- 
nections to the control valve switches. Removing these 
screws permits the cover to be lifted up off the controls. 

NOTE: The screws that secure the cover can be mistaken 
for pop rivets since they have a square opening instead 
of the usual slotted or phillips head. A special tool or bit 
to fit a y4-inch nut driver or socket wrench is available 
through Caloric Parts Distributors under Part No. 44512. 



CONTROL VALVE SWITCH REMOVAL 

1. Remove electric power and lift maintop sufficiently to 
provide easy access to the control area. 

2. Remove the switch cover (see procedure above). 

3. The rotor of each switch is keyed to fit on the half 
round control shaft. Note how switch is positioned on 
the control and slide it up and off the shaft. Discon- 
nect the lead wires. 

4. When installing replacement switch be sure it is 
pushed down on the shaft so that the raised bosses 
on the bottom straddle the valve to secure it. 

5. The switch used on the griddle valve of RTR645 con- 
tains a spring clip over the shaft to hold the switch 
in proper position. The switch also contains three legs 
which down over the control to prevent movement with 
shaft rotation. 



TOP BURNER REMOVAL 

1. The top burners are mounted on the burner box by 
means of a mounting screw at the burner head. 
Although the screw is intended for shipping purposes 
it may be left in since it positions the burner head 
correctly. 

2. To remove a burner, remove the screw and move the 
burner up and to the rear, moving the venturi off of 
the valve orifice. When installing the burner be sure 
the burner venturi is placed over the valve orifice, then 



lower the head into position so that the mounting stud 
on the bottom of the head drops Into the mounting 
hole in the burner box. Install the mounting screw if 
desired. 

3. The griddle burner on Model RTR645 mounts in a 
similar fashion, however it is recommended that the 
mounting screw be installed at the burner head dur- 
ing replacement to assure proper burner position. This 
is important for correct automatic spark ignitor igni- 
tion of the burner. 



BURNER BOX REMOVAL 

1. Disconnect the electric power and shut off gas sup- 
ply to cooktop. 

2. Remove maintop with hinges. 

3. Remove control switch cover. 

4. Remove all top burners. 

5. On RTR645, remove the outside box baffle on the bot- 
tom for access to the high voltage lead to the griddle 
burner spark ignitor. Also remove the griddle burner 
baffle (under the griddle burner) by lifting it out. 

6. Remove the two screws which secure the bottom of 
the burner box to the bottom of the outside box. 

NOTE: At this point the burner box is free of the outside 
box except for the spark ignitor wires thereby providing 
limited upward movement for access under the burner 
box. Complete removal requires removal of the spark ig- 
nitor and lead assemblies. 



SPARK IGNITOR AND LEAD REMOVAL 

The spark ignitors are located between the flash tubes 
of each set of burners and to the rear of the griddle burner 
on the RTR645. 

By removing the screws securing the ignitor mounting 
brackets to the burner box and disconnecting the ignitor 
leads from the spark module, the ignitor and lead 
assembly can be withdrawn from the top of the burner 
box. 

On IVIodel RTR645, the griddle burner ignitor wire runs 
down through the opening in the burner box and the out- 
side box and runs up to the spark module. It is covered 
by the outside box baffle underneath the outside box. 



PART III - DISASSEMBLY PROCEDURES 



GAS VALVE REMOVAL 

The gas control valves for the surface burners can be 
removed from the top of the burner box and do not re- 
quire burner box removal. 

1. Remove electrical pow/er and shut off gas supply to 
the cooktop. 

2. Remove the ignitor switch from the valve being ser- 
viced and move aside. 

3. Note the position of the valve orifice in respect to the 
burner venturi. Remove the burner. 

4. Unscrew the valve from the manifold and mount the 
replacement valve being sure to position it so that the 
orifice hood is in the same direction as that of the 
original valve. This is important with respect to gas 
flow from the orifice into the burner venturi and prop- 
er ignition of the burner. 

5. The gas control valve for the griddle burner on the 
RTR645 has an orifice extension (see illustration page 
8, item no. 8). Turn the valve so that the extension is 
pointing directly to the rear. This provides clearance 
so that the extension can be unscrewed from the 
valve. 

6. With the extension removed, the valve can then be 
unscrewed from the manifold. When mounting the 
replacement valve and extension be sure the unit is 
positioned exactly the same as the original. 

NOTE: A suitable pipe joint compound rated for use with 
L.P. gas should be applied to all threaded connections 
being careful not to get any of the compound inside the 
fittings. 



MANIFOLD REMOVAL 

The manifold, to which the gas control valves are 
mounted, is mounted to the front underside of the burner 
box by two screws on the right and one screw on the left. 

1. Remove electric power and gas supply line to the 
regulator. 



2. Follow Steps 1 through 6 of "Burner Box Removal". 

3. Remove all gas valves. 

4. Lift burner box at front and hold manifold while remov- 
ing the three mounting screws for the manifold. 
Remove manifold and regulator. 

5. Remove regulator from manifold and install on 
replacement unit. 

6. Reverse above procedure to install replacement 
manifold and regulator. Apply pipe joint compound to 
the threaded connections to prevent a potential gas 
leak. 



AUTOMATIC IGNITION SPARK MODULE REMOVAL 

The spark module is mounted to a plate which in turn 
is mounted to the underside of the outer box at the front. 

1. Remove electrical power and shut off gas to the unit. 

2. Access must be obtained to the bottom front of the 
cooktop to the mounting plate on the outer box. If, due 
to the installation, this is difficult then the corner 
mounting screws securing the unit to the counter top 
may have to be removed and the gas line disconnected 
at the regulator. This would permit the assembly to 
be raised at the front. 

3. Remove the screws securing the module mounting 
plate and drop the assembly down. 

4. Remove the screws securing the module to the mount- 
ing plate, with leads connected move the module 
aside. 

5. Mount the replacement module on the mounting plate, 
transfer the lead connections, one-by-one to the same 
terminals on the replacement. 

6. Mount the module and mounting plate to the bottom 
of the outer box. Restore the unit in the cabinet, apply 
electrical power and test operate the module. 



10 



PART IV - SCHEMATIC AND WIRING DIAGRAMS 




11 



,® 



CALORIC 

AUTHORIZED PARTS DISTRIBUTORS 



^••-•**' 




EFFECTIVE - JUNE 1, 1982 



• DISTRIBUTOR LOCATION 
^^ DISTRIBUTOR AREA 



/O 



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I 



South Gate. C A 90280 



Stamford, CT 06902 



CALIFORNIA 

R & B Appliance Parts 
13300 Paramount Blvd 
AC 213-634-8405 

CONNECTICUT 
All Appliance Parts. Inc. 
42 Elm St., Danbury. CT 06810 
AC 203-797-0400 

All Appliance Parts. Inc 
194 Richmond Hill Ave. 
AC 203-324-5701 

All Appliance Parts, Inc. 

223 Brainard Road. Hartford. CT 061 14 

AC 203-247-4212 

GEORGIA 

D & L Appliance Parts Co . Inc. 

5864 New Peachtree Rd., Atlanta, GA 30340 

AC 404-458-8191 

ILLINOIS 
Automatic Appliance Parts Corp. 
1506 E.Algonquin. Arlington Hts.. IL 60005 
AC 312-439-4095 

Automatic Appliance Parts Corp. 

7757 W Lawrence Ave., Norridge. IL 60656 

AC 312-453-8384 

Automatic Appliance Parts Corp. 
16334 S Kilbourn, Oak Forest, IL 60452 
AC 312-687-7300 

MASSACHUSETTS 
MGMS Associates, Inc 
22 Water St.. Cambridge. MA 02141 
AC 617-868-8360 

NEW JERSEY 
All Appliance Parts, Inc. 
470 US Highway 46. Teterboro. NJ 07608 
AC 201 -641 -3444 

NEW YORK 
All Appliance Parts. Inc. 
2580 Sunrise Hwy., Bellmore. NY 11710 
AC 516-221 -6660 

All Appliance Parts. Inc 

1985 NY Ave . Huntington Station, NY 1 1 746 

AC 516-427-2341 

All Appliance Parts, Inc. 

113-02 Atlantic. Richmond Hill. NY 11419 

AC 212-441 -4300 



© 
© 

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All Appliance Parts. Inc. 

600 Jericho Tpk . . Selden . NY 1 1 784 

AC 516-698-5000 

All Appliance Parts. Inc, 

1034 Yonkers Ave.. Yonkers, NY 10704 

AC 914-237 -0500 

NORTH CAROLINA 

D & L Appliance Parts Co., Inc. 

2100 Freedom Dr.. Charlotte. NC 28201 

AC 704-374-0400 

D & L Appliance Parts Co. Inc. 

247 Wellons Village. Durham. NC 27703 

AC 919-682-8640 

D & L Appliance Parts Co.. Inc. 

281 1 Firestone Dr.. Greensboro. NC 27406 

AC 919-274-7627 

D & L Appliance Parts Co.. Inc. 

923 19th St. S.W.. Hickory. NC 28601 

AC 704-322-4503 

DSL Appliance Parts Co.. Inc. 

2324 Atlantic Ave.. Raleigh. NC 27601 

AC 919-828-0975 

D & L Appliance Parts Co.. Inc. 

1090 Burke St.. Winston-Salem. NC 27101 

AC 919-723-3068 

OHIO 

American Electric Washer Co. 

988 E. IVIarket St.. Akron. OH 44305 

AC 216-535-2648 

Pearsol Appliance Parts Co. 

2319 Gilbert Ave.. Cincinnati. OH 45206 

AC 513-221 -1195 

American Electric Washer Co. 

1834 E, 55th St.. Cleveland, OH 44103 

AC 216-431 -4400 

American Electric Washer Co 

2801 Detroit Ave.. Cleveland. OH 441 13 

AC 216-781 -4523 

American Electric Washer Co. 
5817 Pearl Rd.. Parma. OH 44130 
AC 216-888-3300 

12 



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American Electric Washer Co. 

264 E 305th St , Willowick. OH 44094 

AC 216-585-1400 

PENNSYLVANIA 

All Appliance Parts, Inc. 

7735 Castor Ave., Philadelphia, Pa. 19152 

AC 215-722-6100 

All Appliance Parts, Inc. 

312 N, Easton Rd. Willow Grove. Pa, 19090 

AC 215-657-3777 

Collins Appliance Parts. Inc, 

1533 Ivletropolitan. Pittsburgh. Pa. 15233 

AC 412-321 -3700 

SOUTH CAROLINA 

D & L Appliance Parts Co . Inc. 

901 S Cashua Dr . Florence, SC 29501 

AC 803-662-3261 

TEXAS 

Pearsol Appliance Co. 

3127 Main St,, Dallas. TX 75226 

AC 214-741 -4638 

Central Supply 

2612 McKinney, Houston, TX 77003 

AC 713-224-8491 

Central Supply 

5365 College, Beaumont. TX 77707 

AC 713-842-4132 

Central Supply 

7417 Hillcroft #18. Houston. TX 77081 

AC 713-776-9016 

Central Supply 

1604 South Shaver. Pasadena. TX 77502 

AC 713-477-6831 

CANADA 
Mossman s AppI Parts. Ltd. 
1465 Gerrard St E 
Toronto. Ontario M4L2A2 
(416)461-1147 

Reliable Parts Ltd. 
860 Kingsway 
Vancouver. B.C V5V 3C3 
(604172-1291 



Printed in U.S.A. OPC 87632