D U T C H E S S
Model JN
Semi-Automatic Dough Divider/Rounder
Fixed Pocket Design
General Safety, Installation,
Instruction & Parts Manual
NSF, USDA, UL Listed
4 Machines in 1 Capability
36, 18, 9, & 6 Part Divisions 1-ounce up to 26-ounces each piece
"Dutchess . . . Proven Leadership through Research & Development”
"DUTCHESS ALL-AMERICAN"
MODEL JN
Semi-Automatic Dough Divider/Rounder
NSF, USDA, UL Listed
- Patented -
TABLE OF |
CONTENTS |
|
Page No. |
General Rules |
3-5 |
Machine Specifications |
5 |
Uncrating |
6 |
Installation |
6-7 |
Operating Instructions |
7-8 |
Adjustments |
9-10 |
Head Removal |
11-12 |
Head Replacement |
12-14 |
Head Cleaning |
14-15 |
Machine Cleaning |
15-16 |
Maintenance |
17 |
Lubrication |
18 |
Troubleshooting |
19-20 |
Dough Scaling Charts (English & Metric) |
20-21 |
Assemblies |
22-30 |
Head Assemblies |
31-34 |
Electrical Schematics |
35-36 |
Safety Labels |
37 |
© 2002 Dutchess Bakers' Machinery Company, Inc.
302 Grand Avenue, Superior, WI 54880-0039
DUTCHESS TOLL FREE CUSTOMER SERVICE HOTLINE: 1 - 800 - 777 - 4498
Catalog: A4-441-0001F
General Rules
GENERAL SAFETY RULES:
1.Equipment should not be operated with safety devices or guards removed.
2.Only qualified personnel should operate this machine.
3.Machines should not be started until all personnel are clear.
4.Service and maintenance procedures should never be performed on a machine in motion.
5.To avoid shock or serious injury, only qualified personnel should perform maintenance on the electrical system.
6.The electric power MUST be OFF before servicing the machine.
GENERAL OPERATING RULES:
1.DO NOT operate this machine until you read and understand the operating instructions and become familiar with the machine and its controls.
2.Never operate the machine with safety devices or guards removed or disconnected.
3.DO NOT start the machine until all other personnel have been warned and have moved clear of the machine.
4.Remove any tools and other foreign objects from the area around the machine.
5.DO NOT have loose clothing or unrestrained long hair near operating machinery.
6.Never sit or stand on anything that might cause you to fall against the machine.
7.Horseplay around the machine is prohibited and could cause serious injury.
8.Know the emergency stop procedure for the machine, see Pg. 9, "Emergency Stop".
9.Electrical power MUST be OFF when the machine is not in use.
10.The power switch is to be in the OFF position, and the machine disconnected from the power source, BEFORE servicing the machine.
11.DO NOT operate faulty or damaged equipment.
12.Avoid placing fingers, hands, or any part of your body into the machine, or near moving parts, while operating machine.
SERVICE & MAINTENANCE:
1.DO NOT service a machine until you are thoroughly qualified, trained and familiar with the tasks to be performed.
2.Never operate any controls while other persons are performing maintenance on the machine.
3.DO NOT bypass a safety device.
4.Always use the proper tool for the job.
5.Never open covers with power on.
6.Electrical power switch is to be turned off, and machine disconnected from the power source, unless absolutely required for a specific service being performed.
ELECTRICAL:
1.All electrical maintenance and service should be performed only by trained and authorized electricians.
2.Always assume that the power in ON.
3.To remove load (power) from circuit, open disconnect or breaker, and lock in open position.
4.Make certain that the circuit is open by using the proper test equipment. Test equipment MUST be checked at regular intervals.
5.There may be circumstances where "Trouble Shooting" on live equipment may be required. Under such conditions special precautions must be taken such as, but not limited to:
a.Your body and tools must be clear of the ground.
b.Take extra safety measures in damp areas.
c.Be alert and avoid any outside distractions.
6.Before applying power to any equipment, make certain that all personnel are clear of the machine.
7.Electrical panel doors, where applicable make certain the disconnect handle mechanism for electrical panel doors are operating properly.
8.Close all covers on junction panels before leaving any job.
CLEANING:
1. Turn off electrical power prior to cleaning machine.
2.DO NOT use toxic and/or flammable solvents to clean machine. Use only mild soap and water.
3.Keep panel covers closed and power off when washing a machine.
4.Always clean up spills around machine as they occur and after operating and/or cleaning.
5.Never attempt to clean a machine while it is ON or operating.
"DUTCHESS ALL-AMERICAN"
MODEL JN
Semi-Automatic Dough Divider/Rounder
Machine Specifications
Machine: |
|
Weight (with 36-part head) |
450 lb. (168 Kg.) |
Size (without handle) |
Width: 26-1/2" (673 mm) |
|
Depth: 22" (558.8 mm) |
|
Height: 60" (1524 mm) |
Divider Head w/2 same division Dough Pallets:
Head |
Part Number |
|
Weight Lb. |
Weight Kg. |
|
36-Part |
C4-436-0066 |
|
|
42 lb. |
15.68 kg. |
18-Part |
C4-436-0067 |
|
|
39 lb. |
14.56 kg. |
9-Part |
C4-436-0068 |
|
|
34 lb. |
12.7 kg. |
6-Part |
C4-436-0069 |
|
|
32 lb. |
11.94 kg. |
Dough Pallets: |
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|
|
|
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Pallet |
Part Number |
|
Pallet |
Part Number |
|
36-Part |
C4-150-0003 |
|
|
9-Part |
C4-150-0001 |
18-Part |
C4-150-0002 |
|
|
6-Part |
C4-150-0004 |
Electrical: |
|
|
|
|
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Standard: |
|
208-240v 60hz 3phase (10 amp.) UL Listed |
|
||
Available Options: |
120v |
60hz |
1phase (15 amp.) UL Listed |
|
|
|
|
240v |
60hz |
1phase (10 amp.) UL Listed |
|
|
|
120v |
50hz |
1phase (15 amp.) |
|
|
|
240v |
50hz |
1phase (10 amp.) |
|
|
|
208v |
50hz |
3phase (10 amp.) |
|
|
|
230v |
50hz |
3phase (10 amp.) |
|
UNCRATING
This unit weighs 450 pounds, and proper equipment must be used to lift and move.
1. Set the total carton, with machine, on a flat, level surface.
CAUTION!
Carton staples are sharp - use proper tools to remove staples. Do not pull flaps by hand before removing staples!
2.Cut carton at dotted line at bottom. Lift carton over machine, and remove plastic bag.
3.The rear and side covers on the machine must be removed. Turn the two latches ¼ turn and top edge will move outward. Lift cover upward off retainers.
IMPORTANT
The covers must be reinstalled on the machine after installation!
4.The handle, pallets, and miscellaneous components are located inside the lower base of the machine. Remove through the rear opening.
5.Remove the (4) lag bolts, one in each corner.
6.Using proper equipment, lift machine from packing skid. Do not push or lift on the spring covers!
OPTIONAL HEAD ASSEMBLIES
1.Optional head assemblies are shipped in a separate carton. Remove staples from smaller carton top flaps.
2.Lift inner carton from carton. Remove head assembly from carton and packing materials. There are two dough pallets in the bottom of the outer carton. Remove the protective paper from the pallets.
3.Dispose of all cartons and packing properly.
INSTALLATION
1.Locate the (4) foundation holes inside the base in all four corners. The machine is designed to be secured to the floor, See Fig. 1. Arrange on 18 inch square pattern, (4) 3/8"diameter bolts or studs. (Bolts or studs supplied by others.)
Figure 1
2.Set machine in place with bolts and/or studs properly set and tightened. Seal around the base with an approved silicone sealant, GE RTV 102 or equal.
3.Each machine must be direct wired. See proper wiring diagrams on pages 35 - 36.
CAUTION!
All electrical connections should be installed by an electrician. All state, local and national electrical codes MUST be complied with.
4.Reinstall side covers.
5.Install handle, with hole topside, fully into socket on ram lever. Tighten supplied set-screw, through hole in handle, with hex key wrench.
6.Apply a thin coat of sealant (RTV 102 ) at top edge of plastic plug supplied in package of com ponents. Tap plug into hole over the set-screw. See Fig. 2.
7.Seal around handle at lever arm with sealant (RTV 102).
P L U G A 4 - 1 3 9 - 0 0 2 6
S E T S C R E W 2 9 - E - 0 8 1 2
S E A L 
H A N D L E
Figure 2
8. To change or install head and pallet, see instructions on pages 11 - 14.
OPERATING INSTRUCTIONS
CAUTION!
Machine must be fully assembled before starting or operating. Please refer to Fig. 3, Page 9 for operation:
1. Refer to dough weight charts for required dough piece size. See chart on pages 20 - 21
CAUTION!
Use only pallets supplied! Never use two pallets or shim the pallet, as damage will occur, voiding your warranty.
2. Place a pallet (No. 2) on a worktable. Knead or roll out the weighed dough within the inscribed circle on the pallet. (Do not use flour on pallet, as this will affect the quality of rounding)
IMPORTANT
a.If the dough is sticky, lightly dust the top surface only with flour to prevent the dough from sticking to the head assembly (No. 3). Never flour the pallet. Do not flour the top, unless necessary.
b.Do not use grease or oil on the dough or pallet.
c.The dough to be divided/rounded must not have a crust.
d.All levers and handle must be in the starting, normal position.
3.Flip the power switch to ON, and leave the motor running until the day's dividing/rounding is complete.
4.Place pallet (No. 2) with weighed dough onto the crankplate (No 4).
CAUTION!
The pallet must fit snugly and flat on the crankplate with the handle in the forward position. Damage will occur to pallet, divider, and/or crank plate, if pallet is not in proper position.
5.Pull handle (No. 1) down, lowering ring (No. 5) until head assembly (No. 3) comes in contact with the dough. Now it is important for you to exert firm, even pressure on the dough for 3-4 seconds, by pulling or pushing down on the handle, forcing the dough to level, and become equal in thickness within the confines of the ring.
6.Relax the down pressure on the handle, but continue holding handle down with your right hand. With the other hand, release the trip lever (No. 6) which will release the divider. You can now push the handle to its furthest down position, dividing the dough.
7.While still holding the handle down, pull forward on the rounding lever (No. 7). This will rotate the crankplate (No. 4) and round the divided dough pieces into dough balls, (approximate rounding time required: 5-15 seconds).
8.When sufficient rotations have taken place, return the rounding lever (No. 7) to its idle position. Raise the handle (No. 1) to its uppermost position.
NOTICE
Too many, or too few revolutions during rounding will affect the final results of your dough balls. Experiments should be made to determine the correct number of revolutions necessary for your dough, and product requirements.
IMPORTANT
The further forward you pull the rounding lever, the wider, and faster the rounding motion becomes.
IMPORTANT
Pocket size may be adjusted higher or lower to accommodate various dough sizes and rounding consistency. This will require experimenting to obtain the correct pocket height for various products and doughs. See adjustments on Page 9, Item 1.
9.Remove the pallet (No. 2) with the finished dough balls from the machine. Remove these pieces from the pallet. Repeat the above procedure for additional dividing and rounding.
NOTICE
Achieving the best results with your dough will require some experimenting with the pocket settings and rounding action. See Adjustments Pg. 9 Item 1.
WARNING!
Do not operate this machine without covers and canopies on and in a secured position.
Figure 3
WARNING!
Keep hands and clothing clear of all moving parts.
EMERGENCY STOP
In case of emergency, release rounding lever, flip power switch to OFF, and raise handle.
ADJUSTMENTS
All adjustments have been made at the factory, however, readjusting may be required upon installation, and periodically during use.
1. Your new Dutchess Divider/Rounder comes equipped with a "fixed pocket" design.
Experimentation will be required to determine the correct pocket height for each size dough ball. To
increase the pocket height, loosen the locking nut by turning counter clockwise. Turn the stop rod clockwise to decrease pocket height (for smaller rolls) and counter clockwise to increase pocket height (for larger rolls). Retighten locking nut before rounding by turning clockwise. See Fig. 4
IN C R E A S E |
D E C R E A S E |
L O C K IN G N U T |
S T O P R O D |
Figure 4 Figure 5
2. Motor Belt tension will require tightening as belts wear and stretch.
WARNING!
Before removing cover, place power switch in the OFF position and disconnect the machine from the power source.
To adjust, see Fig. 5. Remove cover from side of base. With a wrench, loosen locking nut, turn knob clockwise by hand to tighten belts. The belts should have approximately 1/16 inch deflection.
Retighten the lock nut and replace the cover. This adjustment must be tested after being made.
3.Drive Slide adjustment is to stop the crank plate in the center, when releasing the rounding lever, See Fig.6. The crank plate must be removed to make this adjustment. (To remove crankplate, see instructions on page 18, Item 7) Loosen lock nut and turn set screw counter clockwise, to allow drive slide to come back to center. Tighten lock nut. If drive slide is coming back beyond center, loosen lock nut, turn set screw clockwise, pushing drive slide to center, tighten lock nut.
Figure 6
HEAD REMOVAL
To remove the head assembly for cleaning, or for interchanging with one of the optional head assemblies of other divisions.
CAUTION!
A pallet must be in place on the crank plate when removing and installing the head assembly.
1.Remove front and rear canopies (Fig. 7, No. 5 & No. 6) by lifting up, and out.
2.Pull handle (Fig. 7, No. 1), down until ring (No. 2) is resting on pallet (No. 3).
RAM PIN
SPINDLES
Figure 7 |
Figure 8 |
WARNING!
Do not release the handle from your hand, until the handle is returned to its uppermost position.
3.Hold handle in this position, grasp outer edges of the ring (Fig. 8, No. 1) keep fingers out of the divider/plug area. Rotate ring ¼ turn until slots are in line with the arms (Fig. 8, No. 2).
4.Slowly raise the handle and watch arms (No.2) for interference. If interference occurs, lower handle and reposition the ring (No. 1). Raise handle, with no interference, to its uppermost position.
5.Remove ring (Fig. 8, No. 1) from machine, set ring aside on work bench. Do not drop or bump ring, as this can cause nicks or other damage to ring.
6.Loosen the two hand knobs (Fig. 10, No. 3) fully.
7.Set pocket height on the stop rod, Fig. 9, at least 1" off the trip plate. Release the trip lever (Fig 10, No. 1).
IN C R E A S E |
D E C R E A S E |
L O C K IN G N U T |
S T O P R O D |
Figure 9 |
Figure 10 |
WARNING!
Do not release the handle from your hand, until the handle is raised to its uppermost position.
8.Pull handle down until head rests on pallet (Fig. 10).
9.Rotate head assembly (Fig. 10, No 2) ¼ turn clockwise.
10.Raise handle slowly, watch ram (Fig. 11) making sure it causes no interference. Continue to raise handle to uppermost position. Head assembly should be resting on the pallet.
Figure 11 |
Figure 12 |
11. Remove head assembly (Fig 12, No. 1). This head can now be cleaned. (See pages 14 - 15).
HEAD REPLACEMENT
1.With pallet in place, position head assembly (Fig. 13, No. 1) in center of pallet with handle in front.
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