SERVICE MANUAL KSH
Contents
1. 1 Remove the bottom lid refer to THERMOSTAT REMOVAL 2 Remove the four screws from the heating plate terminal 3 Remove the screws from the warning thermostat and ground terminal 4 Remove the three screws holding the body and remove the heating plate from the body NOTE Removing and installing the screw holding the heating plate terminal the terminal should be nipped tightly using long nose player Fig C 4 Heating plate terminal Fig C 4 KSH 777DW POWER SUPPLY CORD REMOVAL 1 Remove the three nuts from the terminal of the fixed for power supply cord 2 Remove the cord stopper holder from the body Cord stopper holder Fig C 5 ADJUSTMENT OF SWITCH LEVER AND CONTACTS 1 Turn over the outer pot with inner bowl inside disclose its bottom cover Push Cook switch adjust switch lever and switch contacts PUSH THE COOK SWITCH GAP i H l E _ Fo 8 ae a X NS O lt L S t Fig C 6 A Thermostat rod must not be pressed or drew up by switch lever It should be moving up and down easily 2 As soon as inner bowl is lifted up from outer pot switch lever must spring up Without inner pot switch contacts must touch each other when push switch Cook THERMOSTAT SPRING BACK Fig C 7 SWITCH SPRING BACK 3 Ensure the capability of up down movement of switch lever KSH 777DW SIMPLIFIED TESTING METHOD In case satisfactory cooking of rice is not accompl2. Protection Thermostat Warming Thermostat Micro Switch Action by Cooking Thermostat Warming Thermostat ro Lever of Switch Assembly mai KSH 777DW TROUBLESHOOTING Those marked with black spots are often confused with troubles Give the customers proper operating instructions 1 Trouble during Cooking PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Indicator light will not X Cooking switch kept OFF Cooking switch ON Unable to cook go ON Disconnected plug cap Plugged into the outlet Broken power cord assembly Repair or replace power cord assembly Faulty or loose wiring Repair or replace faulty parts Maladjustment switch assembly Repair or replace it Indicator light will go Burn out of heating plate wire Replace heating plate Faulty wiring Repair or replace faulty parts Poorana cooked Improper quantity of rice or water Advise proper operating instruction rice Local uneven Faulty tightness due to deformed Replace inner bowl or faulty parts Capable of cooking ness of cooked rice is but insufficient excessive Core is left Faulty tightness due to contaminants Remove contaminants or replace parts in rice grain due to etc deposited on heating plate or inner having contaminant deposits early switch OFF bowl bottom heating plate or inner bowl bottom Faulty in setting lid Advise proper operating instruction Faulty thermostat Replace thermostat Malfunction
3. Replace faulty parts body at a touch assembly micro switch assembly power supply cord etc Water soaked cooker body etc Replace faulty parts after drying KSH 777DW COMPONENT REPLACEMENT PROCEDURE PANEL REMOVAL 1 Remove the one screw holding the panel and take off the panel from the body 2 Remove the stop ring holding the lamp assembly and take off the lamp assembly from the panel Fig C 1 4 Remove the panel from the body COOKING THERMOSTAT REMOVAL After removing the thermostat when the thermostat is re moved the inner bowl should be set 3 1 Remove the one screw holding the bottom lid Remove 4 the two screws holding the leg then remove the bottom lid Fig C 2 2 Remove the stop ring from the switch lever to take off the thermostat rod Fig C 3 Stretch the three tabs holding the body holder Now the thermostat is free and at the same time the thermo spring will be free Stop ring switch assembly Fig C 3 SWITCH ASSEMBLY REMOVAL _ 2 Remove the thermostat spring referto THERMOSTAT REMOVAL 3 Remove the two wire leads from the terminal of micro switch Remove the panel refer to PANEL REMOVAL 4 Remove the four screws holding the switch assembly and take off the switch assembly from the body NOTE Installing the switch assembly the switch should be placed so that the switch button is not touched to the panel HEATING PLATE REMOVAL
4. in the inner bowl in step 3 Stir well being careful not to dislodge the silicone sheet Cover with the lid and let rice soak approximately 30 minutes Plug into outlet Press down on the cooking switch The indicator light will come on and cooking will start When cooking is finished the switch pops up and the indicator light goes out After the cooking cycle ends leave the lid closed for at least 15 minutes to steam the rice Then stir well being careful not to dislodge the silicone sheet 10 Serve rice or recover to keep warm See below for keep warm suggestions 11 After using unplug from the outlet KEEP WARM e lf the rice cooker is left plugged in the indicator light will come on occasionally to keep the rice at a serving temperature e Rice quality is optimum at the end of the cooking and 15 minute standing time and should be served as soon as possible e Do not keep warm for more than five hours oN Se COOKING CHART Quantity of Raw Cooking Time Range Kind of Rice Rice Cups Rice Water Ratio Approximately in Minutes Short grain 10 28 cups 1 cup rice to 114 cups water 25 55 10 24 cups 1 cup rice to 1 cups water 30 45 10 24 cups 1 cup rice to 14 cups water 30 45 Converted long grain 10 24 cups 1 cup rice to 1 4 cups water 45 65 10 24 cups 1 cup rice to 1 cups water 45 85 e Always measure accurately e Adding too much water may cause the rice to boil over e If boil over occu
5. of thermostat due to Advise proper operating instruction vibration or impact Faulty interlocking of switch assembly Repair and thermostat Excessively over Insufficient maintenance of inner bowl x Advise proper operating instruction done bottom layer or or washing of rice rice mass Overdone Improper operating temperature of Replace thermostat No adjustment of layer in light brown is thermostat operating temperature is made possible not as ab Maladjustment switch assembly Repair or replace faulty parts normal Cooking will not go OFF Cooking has been carried on by Advise proper operating instruction depressing the switch button forcibly with chopsticks etc 2 Trouble during Warm keeping Capable of cooking PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Unable to keep warm Disconnected plug cap Plug into the outlet Maladjustment switch assembly Repair or replace Faulty or loose wiring Repair or replace faulty parts Faulty warm thermostat assembly Replace warm thermostat assembly 3 Other Trouble Indicator light flickers Faulty receptacles Contact failure Repair receptacles with plugs Nearly broken or contact after Replace power cord supply breakage of cord Loose wiring Repair Faulty indicator light or resistor Replace faulty parts Maladjustment switch assembly Adjustment switch assembly Affected by electric shock from cooker Faulty insulation of heater plate
6. the inner bowl as the cooking results may be affected Replace the inner bowl if it gets damaged The cooking switch should be depressed only once for the entire cook keep warm cycle Never insert any object into the switch Always keep the bottom of the inner bowl the heating plate and the thermostat clean so that no rice or other foreign matter accumulates SPECIFICATIONS Rated voltage 120V 60Hz AC only Power Consumption 1700 W Outside dimensions 19 11 16 W X 17 11 16 D X 13 3 4 Weight Approx 20 Ib 3 Prong Plug 5 15P Receptacle 3 Prong Receptacle 5 15R Knob Inner Bowl Marking PART NAMES Silicone Sheet Inner bowl marking KSH 777DW Inner Bowl SSR l Use for short grain rice Use for other kinds of rice Kg Lb Cups water Handle 12 m Body Heating Plate 4 Indicator Light 8 Power Supply 3 a Thermostat Cord 6 Cooking Switch 2 1o E eS ee HOW TO USE METHOD FOR SHORT GRAIN RICE COOKING To ensure success with short grain rice be sure to 1 2 3 4 o1 CO N O Put the silicone sheet on the bottom of inner bowl to prevent sticking and browning Check that outside of inner bowl is dry and then put into the rice cooker To ensure that the inner bowl is correctly positioned on the heating plate turn the inner bowl left and right Measure desired amount of rice to be cooked
7. Carefully wash rice in separate bowl under running water until the water is clear not cloudy Drain Put rice into inner bowl Add water to appropriate inner bowl level If you use 8 pounds of rice add water to the 8 Ib level Cover with the lid and let rice soak approximately 30 minutes Plug into outlet Press down on the cooking switch The indicator light will come on and cooking will start 0 When cooking is finished the switch pops up and the indicator light goes out After the cooking cycle ends leave the lid closed for at least 15 minutes to steam the rice Then stir well being careful not to dislodge the silicone sheet 11 Serve rice or recover to keep warm See below for keep warm suggestions 12 After using unplug from the outlet METHOD FOR OTHER KINDS OF RICE COOKING To ensure success with other kinds of rice be sure to 1 2 Check that outside of inner bowl is dry and then put into the rice cooker Put the silicone sheet on the bottom of inner bowl to prevent sticking and browning To ensure that the inner bowl is correctly positioned on the heating plate turn the inner bowl left and right 3 KSH 777DW 3 Check chart on page 4 for rice water ratio or follow package or recipe directions to determine the water amount Pour the water until the correct amount is indicated on the Cups Water marking on the inner bowl Measure rice using a standard cup measure and put rice into the water that was measured
8. KSH 777DW SHARP SERVICE MANUAL SY307KSH777DW COMMERCIAL RICE COOKER MODEL KS H 11 DW In the interests of user safety Required by safety regulations in some countries the unit should be restored to its original condition and only parts identical to those specified should be used TABLE OF CONTENTS IMPORTANT SAFEGUARDS PRECAUTIONS SPECIFICATIONS PART NAMES HOW TO USE COOKING CHART CLEANING AND CARE SCHEMATIC DIAGRAM TROUBLE SHOOTING COMPONENT REPLACEMENT PROCEDURE SIMPLIFIED TESTING METHOD INSPECTION AFTER REPAIRING REPLACEMENT PARTS LIST This document has been published to be used for after SHARP CORPORATION sales service only The contents are subject to change without notice KSH 777DW IMPORTANT SAFEGUARDS When using electrical appliances basic safety precautions should always be observed including the following oo Pe NS re 8 9 Read all instructions Do not touch hot surfaces Use handles or knobs To protect against electrical shock do not immerse cord plug and body in water or other liquid Close supervision is necessary when the appliance is used by or near children Unplug from outlet when not in use and before cleaning Allow to cool before putting on or taking off parts Do not operate the appliance with a damaged cord or plug or after the appliance malfunctions or has been damaged in any manner The use of accessory attachments not recommended by SHARP ma
9. ished excessively overdone conduct the temperature test in accordance with the following procedure Simplified Testing Method Simulated Rice Cooking 1 Testing conditions a Power voltage 120V b Fill inner bowl with 500 ml of water Water temperature to be the same as ambient temperature c Ambient temperature to be 20 C to 30 C d RICE COOKER to be sufficiently kept cooled Cooker body temperature to be the same as ambient temperature 2 Testing procedure a Fill the inner bowl with 500 ml of water turn ON the cooking switch for cooking purpose to energize the cooker and measure the time for cooking b When steam comes out open the lid and check the bubbling state on the bottom of inner bowl Check if the inner bowl is allowed to be in close and stable contact with the heating plate Conduct checking within a short period of time so as not to influence be over the operating time c Where the bubbling state is satisfactorily close the lid again and energize the cooker 3 Judgement criteria During the course of the simulated cooking with water conducted under the conditions as above the rice cooker if meeting the following requirements will be considered acceptable a If the bubbling state is such that bubbles occur evenly around the bottom of inner bowl as shown in Fig S 1 A the inner bowl is satisfactorily in contact with the heating plate Where bubbles do not occur more than 1 3 of the bottom periphery as sh
10. justing the switch Upon completion of preparing work inspect the cooker as to the following points without fail Inner bowl to be normally in contact with the heating plate Switch lever Body hole L elie and Inner bowl Switch lever Heating plate Center of body a l Thermo rod Lever to be swing symmetrically Thermo rod Thermostat Fig l 1 Fig l 2 Fig l 3 Center adjustment and confirmation of lever 1 For the center adjustment align not with the thermo rod but with the hole of the body Carry out this work with the greatest care 2 Adjust in such a manner that when the switch lever held by hand as in Fig l 2 is lightly swung to the left and right it moves in a perfect symmetry with respect to the hole of the body 3 This switch button should be at the center of the control panel hole Verification of Work and Function 1 Is there any part left uninstalled or any wrong wiring 2 Is the center adjustment of the switch lever as specified 3 Finally energize for confirmation RICE COOKER should be checked in a horizontal position a Is the state Switch Off achieved when the inner bowl is detached with the cooking switch set to Cook b Does indicator light not flicker when the switch button is gently vibrated with the switch set to Cook c Is there no possibility that the cooking switch is turned ON even when the switch button is depressed without placing the inner bowl d Is the thermostat functioning perfect
11. ly e Does the indicator light come on normally Measurement of Insulation Resistance 1 Insulation resistance should be more than 1MQ upon measurement by a D C 500V merger to be effected before and immediately after the temperature test 2 Dielectric strength should be free from defects at AC 1000V for one min to be carried out after the insulation resistance measurement which is taken immediately after the temperature test Stop to be measured with the cooking switch set to Cook take measurements on the blades of the plug socket and heating plate Temperature Test Based on the testing method explained earlier ensure proper performance for Cook 10 KSH 777DW REPLACEMENT PARTS LIST REF NO PART NO DESCRIPTION Q TY CODE ELECTRICAL PARTS 99Y1K417U Power supply cord 99Y1K251USET Heater plate set 99Y1K2021SET Thermostat Set 99Y1K212UASY Warm thermostat Set 99Y1K491UASY Neon lamp assembly 99Y1K213UASY Protection thermostat assembly 99Y7D2101ASY Micro switch assembly 99Y1R111SET Ground conductor set 99YB13A060GG Heater plate lead wire 1 assembly 99YB13A120GB Heater plate lead wire 2 assembly 99YB13A240GB Micro switch lead wire assembly 99YB13A130GG Warm thermostat lead wire 1 assembly 99YB13A050GG Warm thermostat lead wire 2 assembly MECHANICAL PARTS 99Y1K103UASY Lid assembly 99Y 1K105U Inner bowl 99Y1K401UASY Outer pot set 99Y1K402UASY Handle assembly 99Y1K403UASY Panel asse
12. mbly 99Y1K429U Cord stopper holder 99Y 1B203 Thermostat spring 99Y 1K220 Body holder 99Y1K411UASY Leg assembly 99Y1K415UASY Terminal assembly 5 11 99Y1K391ASET Switch set MISCELLANEOUS ACCESSORIES AND PACKING 99Y 1K507U Operation manual 99Y1K603U Packing case 99Y1K412U Name plate 99Y 1K611U Outer pot caution label 99Y1K615U Lid caution label 1 2 3 4 5 6 7 8 g AE lee eee WMO maQ A7AAN H S NEK wW Ww wW PEHARA D D D U HQ 99Y1K701U Silicone sheet 99Y1K609 Upper pad 99Y1K6051 Bottom pad 99Y1K672U Inner bowl protection sheet WOAIAVARWNPE D D D WMoK gt Hj a ee D D UF HOW TO ORDER REPLACEMENT PARTS To have your order filled promptly and correctly please furnish the following information 1 MODEL NUMBER 2 REF NO 3 PART NO 4 DESCRIPTION Order Parts from the authorized SHARP parts Distributor for your area Defective parts requiring return should be returned as indicated in the Service Policy 11 KSH 777DW 2004SHARP CORP 1S0 20_E 12
13. on how to use See page 3 2 Judgement criteria a Indicator light and switch will turn as follows Cook indicator light goes ON Cooking switch goes OFF after 30 45 minutes Based on cooking chart See page 4 b Check the rice layer on the bowl bottom for the overdone degree Light overdone layer Normal Heavy overdone layer Replace thermostat KSH 777DW INSPECTION AFTER REPAIRING Basic requirement for cooking is to maintain the close contact of inner bowl bottom with heating plate and thermostat As the RICE COOKER is of direct heating type when the temperature of inner bowl bottom reaches 145 C to 155 C the thermostat wick operate to provide change over to warm keeping automatically Therefore the cooker can be put in use in an excellent condition if the bowl bottom is kept contact closely with the heating plate and put in a stable state It is the basic requirement for direct heating type cooking Accordingly if the cooker is used under the unstable state of close contact it will become the causes of early power OFF discoloration and deformation of heating plate or other troubles Also any deformed or contaminant deposited inner bowl and heating plate may lead to early power OFF or other troubles Further to the above this RICE COOKER is so designed that the cooking switch will not be put in Cook position whenever the inner bowl taken off or not set into the cooker before use hence this point must be well noted when ad
14. own in Figure S 1 B contaminant deposits on the heating plate or deformation or damage on the inner bowl may be existing Though such contaminant deposits can be removed by cleaning the inner bowl deformed to the extent hardly rectified should be replaced Good State of Bubbling Poor state of Bubbling with new one A B The same applies to the heating plate deformed Fig S 1 b When the lid is opened immediately after the cooking switch is turned OFF no water should remain in the inner bowl or only a small amount of water approximately 20 cc is to remain in the recess around the outer periphery of the bottom face of the inner bowl c Turn ON the power supply and ensure that the time required for the cooking switch to be turned OFF is approx 20 minutes Bowl Bottom NOTE As this test is nothing but a simplified procedure it should be noted that operating time varies depending on different conditions such as difference between water temperature and ambient temperature variations in the quantity of water etc Where any delicate non conformance such as the operating time being slightly higher than approx 20 minutes is observed as a result of the test It is recommended to conduct practical rice cooking test Practical Rice Cooking Test 1 Testing conditions a Power voltage 120V b Cooking 10 24 cups of rice c Ambient temperature to be 20 C to 30 C d Water to be maintained at standard level on the level gauge Based
15. rs it may be necessary to reduce rice and water quantity in the future e Cooking time will vary depending on the kind and or volume or rice as well as added ingredients room temperature water temperature voltage etc CLEANING AND CARE e Always keep the rice cooker clean e Always unplug from outlet and allow the rice cooker to cool completely before cleaning Body Do not immerse the rice cooker in water Clean the outside with a damp cloth and polish dry with a soft cloth Do not use any harsh cleanser or a scrubbing brush as it could crack the surface and rusting could occur Lid Wash thoroughly with warm soapy water rinse and polish dry with a soft cloth Heating Plate Thermostat Clean with a damp cloth and polish dry with a soft cloth Should there be any remainder use fine sandpaper to polish very lightly Inner Bowl Remove the cooked rice as soon as possible using a utensil that will not scratch or mar Remove the bowl from the body of the cooker Soak the bowl in hot water to loosen any remaining rice Wash in hot soapy water rinse well with clear water and polish dry Do not use an abrasive cleaner or steel wool Silicone Sheet Remove any remaining rice using a rubber plastic spatula Soak in warm soapy water and gently squeeze to be sure that sheet is clean Rinse thoroughly with cool water and lay flat to dry KSH 777DW SCHEMATIC DIAGRAM Cook Lamp Indicator Light
16. y cause injuries Do not use outdoors Do not let cord hang over edge of table or counter or touch hot surfaces 10 Do not place on or near heat sources such as gas or electric ranges or in a heated oven 11 Extreme caution must be used when moving an appliance containing hot food water or other hot liquids 12 Do not use the appliance for other than intended use A B C h ot ea ON A short power supply cord is provided to reduce the risk of becoming entangled in or tripping over a longer cord Extension cords are available and may be used if care is exercised in their use If an extension cord is used 1 The marked electrical rating of the extension cord should be at least as great as the electrical rating of the appliance 2 The cord should be arranged so that it will not drape over the counter top or table top where it can be pulled on by children or tripped over unintentionally PRECAUTIONS Use the rice cooker on a 15 ampere 120 volt 60Hz AC only protected electrical supply Insert the plug firmly to ensure safe operation Do not use the rice cooker on a wet floor an unstable surface or near flammable materials Use the inner bowl only in the rice cooker never on the range top or in the microwave oven Do not turn the rice cooker on without both rice and water in the inner bowl Avoid using the rice cooker to heat just water Never connect the plug or touch the switch or body with wet hands Do not bend or hit
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