Merco RT-2AR Service Manual

PARTS & SERVICE MANUAL for RT-2AR

“Adjustable Range” Toaster

The information found in this Manual
will prove very helpful. Although the
instructions are easy to follow, all
repair procedures should be carried
out by a qualified Merco/Savory
Certified Service Representative.

The RT-2AR should be placed in the
most convenient location for ease of
cleaning, maintenance, service and
general operation. Careful consider­ation should be given to avoid drafts,
close proximity to grease or vapor­producing appliances or high ambient
heat equipment. Minimum of ½”
clearance is required for air circula­tion. This is assured by the rounded
“acorn” nuts protuding from the sides
and rear. Overhead clearance from the
top of the toaster should be as much
as possible and sufficient to allow heat
dissipation.

DESCRIPTION Part# Qty

Inf Control 208V 14702 2
Inf Control 240V 12355 2
Knob Inf Control 12919 2
Element upper 890W 208V * 21103 2
Element upper 890W 240V * 21105 2
Element assy lower 208V 12618 1
Element assy lower 240V 12620 1
Element lower 1200W 208V * 12126 2
Element lower 1185W 240V * 21103 1
Element assy upper 208V 12254 1
Element assy upper 240V 12266 1
Motor 208/240V 22743 1
Speed control 208/240V 21842 1
Switch, toggle DPST 20a 68117 1
Knob, speed control 12447 1

05-02kdl 07155

DESCRIPTION Part# Qty

Cordset, 6-30P 21221 1
Light Pilot 208/240V 51070 2
Bearings 22754 4
Wire harness kit(wires only) 12933 1
Jumper 21358 4
Terminal block 21858 1
Drive chain 54 links 12412 1
32T sprocket assy 21319 1
8T sprocket asst 30494 1
Front trim, left side 12219 1
Legs 1” plastic 12668 4
Control panel 12060 1
Control panel decal 12061 1
Savory logo 12523 1
Savory lubricant 21720 1

A Case Removal

1. Remove reflector tray, toast pan and delivery chute.

2. Remove the 2 screws along the front trim panel and
remove.

3. Remove left front panel.

4. Remove the 4 screws holding control panel to unit and
carefully pull panel towards you with all wires intact.
Slide control panel towards center of unit.

5. With hands on each side of case, pull forward to re­move.

B Case Replacement

1. Slide case over unit making sure tabs on the sides and
top of case fit into grooves on back of unit.

2. Carefully replace control panel.

3. Replace left front panel and front trim panel.

4. Replace reflector tray, toast pan and delivery chute.

C On/Off (Main Power) Switch

1. With control panel removed (Section A), remove the 2
slotted screws holding the on/off switch to the control
panel.

2. Disconnect wires and remove switch.

3. Install new switch from rear of panel and reconnect
wires. (Refer to appropriate wiring diagram)

D Conveyor On/Off Switch

1. With control panel removed (Section A), disconnect
wires to switch noting proper orientation.

2. Remove bezel from front of panel, and push switch
through back of panel.

3. Insert new switch from back of panel. NOTE: Be sure

terminals are in correct position.

4. Attach bezel on front of panel and tighten.

5. Re-attach wires to switch. (Refer to appropriate wiring
diagram)

E Infinite Control Switch

1. With control panel removed (Section A), remove the
infinite control knob to gain access to the 2 slotted
screws that hold the control to the unit. Remove those
2 screws.

2. Disconnect wires from infinite switch terminals.

3. Install new switch from back of panel and re-attach
wires. (Refer to appropriate wiring diagram)

NOTE: The two (2) infinite controls on the RT-2AR
model serve as on/off switches to the heating ele­ments. The upper infinite knob controls the upper
elements and the lower infinite knob controls the
lower heating elements.

F Speed Control/P.C. Board As­sembly

NOTE: The speed control and P.C. board are wired
together and must be replaced as an assembly.

1. With control panel removed (Section A), loosen set
screw on speed control knob and remove.

2. Remove retaining nut that holds speed control in place
and remove from back of panel.

3. Disconnect motor lead and on/off lead from P.C.
board terminals.

4. Remove the 2 screws and nuts holding P.C. board to
floor of unit and remove assembly.

5. Reverse this procedure to install new assembly.
(Refer to appropriate wiring diagram)

P.C. Board Adjustment

The P.C. board is factory set and should not require
adjustment. If speed control range appears faulty, the
following procedure should be carried out:

1. Turn speed control knob clockwise until it stops.

2. Connect to power source and turn unit on.

3. Turn trimmer adjustment to right to start conveyor
motor running. Now turn trimmer adjustment screw to
the left to slow conveyor motor. Continue turning
screw until motor just stops. Adjustment is now
completed. All further adjustments can be made by
operating at the speed control knob.

SPECIAL NOTICE: The RT-2AR is no longer built with the
P.C. board installed. To wire or convert units with the old
style assembly, which included a resistor and/or P.C.
board, do the following: The Gearmotor, which has 2
black wires, one is plugged into the white side of the
terminal block, and the other one is spliced togeather with
the black wire off the Conveyor Speed Control POT. Then
the blue wire off the Conveyor Speed Control POT, is
attached to the On/Off Switch.

2

G Gearmotor

1. With outer case removed (Section A), disconnect
motor leads from on/off switch and Conveyor speed
control and cut wire ties at floor panel.

2. Remove the 2 retaining bolts from the underside of the
unit.

3. Remove the drive chain and lift out the motor.

4. Separate motor from motor mounting bracket by
removing the 4 slotted screws on the bracket.

5. Using a 1/16” Allen wrench, remove the drive sprocket
from the motor shaft.

6. Attach new gearmotor to motor mounting bracket.

7. Install drive sprocket on motor shaft making sure the
Allen screw rests on the flat of the shaft. DO NOT
tighten set screw.

8. Install new motor with bracket attached. DO NOT
tighten retaining bolts.

9. Replace drive chain over sprockets.

10. Slide motor to right until drive chain is taut. There
should be approximately ¼” play in the drive chain.
Tighten retaining bolts on underside of unit.

11. Check drive chain alignment. Tighten drive sprocket
set screws.

12. Re-attach motor leads to on/off switch and Conveyor
speed control. (Refer to appropriate wiring diagram)

H Drive Chain

1. With outer case removed (Section A), loosen the 2
motor mounting bracket retaining bolts on underside of
unit, but do NOT remove.

2. Slide motor to the left to loosen drive chain tension.

3. Remove drive chain.

4. Install new chain over sprockets with open looped side
of chain facing out.

5. Slide motor to right to tighten drive chain tension.
There should be approximately ¼” plat in the drive
chain.

6. Check for proper drive chain alignment.
(See Figure 6 & 7)

7. Tighten motor mounting bracket retaining bolts on
underside of unit.

I Drive (Motor) Sprocket
NOTE: RT-2AR model use an
8T sprocket

1. With outer case removed (Section A), and drive
chain removed (Section H) loosen the set screw
on sprocket with a ¼” Allen wrench and removed
sprocket.

2. Install new sprocket on motor shaft making sure
Allen screw rests on the flat of the shaft.

3. Replace drive chain. (Section H)

J Rear (Conveyor) Shaft
Sprocket
NOTE: RT-2AR model use an
32T sprocket

1. With outer case removed (Section A), and drive
chain removed (Section H), loosen the 2 set
screws on sprocket with a 1/16” Allen wrench
and remove sprocket.

2. Install new sprocket on conveyor shaft aligning
the 2 set screws with the holes on the shaft.

3. Replace drive chain. (Section H)

3