Cassese CS 960 User manual

CS 960
Cassese Communication
Z15768
Manual Operated Double-Mitre Saw 45°
Instructions for Use &
Technical Data
VERSION 2 - 09-2005

CS 960 DESCRIPTION
Left vertical clamp
handle
Left vertical
clamp (option)
Main case
Main case handle
Left table
Right table
Moulding guide
Extraction nozzles
Offcut outlet
Blade carriage arms
Left horizontal
clamp
Left horizontal
clamp handle
Machine identity
plate
LEFT SIDE OF MACHINE
Electrical
contactor
RIGHT SIDE OF MACHINE
Air supply
Right vertical clamp handle
Right vertical clamp (option)
Electrical cabinet door
Left table support
bracket
Right table support
bracket
Levelling foot (x4)
Foot locking nut
(x4) Clamp control pedal
Cover safety screw
A
Isolation valve
Removable panel

PRODUCT NAME CS 960
Year of creation 2005
Cutting capacity:
maximum width 160 mm
maximum moulding height 110 mm
Blade dimensions Ø350 mm
Bore Ø30 mm
Maximium cutting length: 1500 mm
Rotation speed: 2800 rpm (50-60Hz) 3400 rpm (60Hz)
Electrical power supply
Power cable, standard, section
2 power motors (compliant with standard EN 60204 ) 1.5 kW
Extraction nozzle, ext. dia. 2x100 mm
Extraction compliant with standards: 28 m3/s at 4 m for Ø100
Air supply: 4 bar min. / 4 to 6 bar
Max. consumption: 2,3l / cycle
Weight 950 kg (# < 58) / 710 Kg (# > 57)
Noise ( compulsory ear protection) 85 dB
TECHNICAL DATA
B
CUTTING CAPACITY (OVERALL)
Options: - Right extension arm:
- Z15732 : 2 metres - Z15731 : 1,00 metres
- Digital measuring stop* (on request / Factor Adaptation):
- Z15736 : Smart Stop - Z15735 : Quick Stop
Dimensions in mm
230v Mono/ 30A 230vTRI/ 16A - 400vTRI/ 10A
3x 2.5 H07 RNF 3G2.5 4x 1.5 H07 RNF 4G1.5
for max. width = 160

C

CS 960 DESCRIPTION A
TECHNICAL DATA B
CS 960 OVERALL DIMENSIONS C
I - INTRODUCTION 1
II - UNPACKING & HANDLING 2, 3
III - SETTING UP THE MACHINE
- Installing the right and left tables 4,5
- Electrical connections 6
- Air connections 6
- Dust extraction 6
IV - START-UP
- Control panel 6, 7
V - SAWING
- Horizontal clamp setting 7
- Vertical clamp setting 8
- First cut on the left 8
- Measuring the first piece 9
- Cutting the first piece 10
VI - PREVENTIVE AND CORRECTIVE MAINTENANCE
- Opening the main case 11
- Removing / refitting the blades 11
- Replacing the martyr cube 12
- Preventive maintenance / Troubleshooting 12
LIST OF WEARING PARTS
TECHNICAL DRAWINGS AND PARTS LISTS
Contents

I- INTRODUCTION
The CS 960 saw is used to produce 45° mitre cuts on all mouldings made
from solid or reconstituted wood, with or without coating (paint, varnish,
plastic, paper, metal leaf such as gold, bronze, aluminium, etc.).
It cannot be used for:
·Moulding profiles that do not have a 90° heel at least 5 mm high,
· Any metal profiles,
· Thin extruded plastic profiles:
(plastic cords, trimming, etc.).
Its two circular blades are driven by two electric motors.
The moulding is clamped automatically by vertical (option) and horizontal
(standard) pneumatic cylinders.
A control, actuating the release of the blade carriage ensures operator safety
by keeping hands out of range of the blades.
The electrical control equipment is installed in a cabinet at the front of the
machine.
The pneumatic equipment is installed in the base and on the right-hand side
of the machine.
This machine was built to meet safety and hygiene requirements. It is
forbidden to modify the electrical and pneumatic equipment, remove
protective equipment installed on delivery or modify the machine safety
devices.
Saw CS 960 cannot be used by more than one operator at a time.
1
Residual Risks
Hands must never be inserted inside the main case as this contains the
clamping cylinders and rotating saw blades in their rest position.
For any other work inside the machine:
See the «Maintenance» section of this manual (page 11).

This machine is packed in a crate containing:
· 1 right table extension with Slot base measuring system + Fixed stop
· 1 left table extension
· 1 box containing:
- 1 Allen key, 10 mm (blade removal) - 1 Allen key, 4 mm (table assembly)
- 1 Allen key, 2,5 mm + 1 Allen key, 5 mm+1Allenkey, 6 mm
- 1 quick-fit connector (fitted on machine)/1barbedconnector / 1 USA connector / 1
quick-fit coupling (see page 6)/1bladesteadying handle
II - UNPACKING AND HANDLING
Using a screwdriver, open the crate fasteners then remove the lid and 4 sides.
Leaving the protection in place , remove :
1) the accessories box, the left and right blade carriage
arms and the left table extension located below the ma-
chine,
2) the right table extension located behind the machine.
Leave the pedal in place on the cutting table as it is wired
to the cabinet.
Using a cross-head screwdriver, remove the blocks from
the 4 feet of the machine.
For handling, a lift truck with forks at least 115 cm long must be used. The forks must be
positioned correctly below the frame: See below. Gross weight of the machine: 950 kg
BLOCK
2

Manutención por la cara anterior
Manutención por el costadoManutención por el costado
2 cales de bois 120 x 150 x 850
2 cuñas de madera 120 x 150 x 850
2 wooden blocks 120 x 150 x 850
Fourches du matériel de levage
Horquillas del equipo de elevación
Forks of the lifting equipment
Manutention par la face avant / Handling from the front
Manutention par le côté / Handling from the side
2 cales de bois 120 x 150 x 850
2 cuñas de madera 120 x 150 x 850
2 wooden blocks 120 x 150 x 850
Fourches du matériel de levage
Horquillas del equipo de elevación
Forks of the lifting equipment
Once the machine is installed, removed the protection. Open the removable panel at the rear of
the machine after removing the 4 screws (5-mm Allen key). Release the two pieces of wood
blocking the blade carriages (safety measure during transport). Refit the removable panel and
the 4 screws.
CAUTION: NEVER USE THE MACHINE WITHOUT REFITTING AND THE REAR
PANEL AND ITS SCREWS.
CAUTION:
SAFETY DIS-
TANCE =
50 MM
3
CAUTION: SETTING THE FORK SPACING
MOVING THE PALLET TO THE FLOOR: FRONT PANEL = 670 MM - SIDE: 530 MM
THEN SET THE FORK SPACING FOR THE REMAINING MOVEMENT (SEE DRAWING BELOW).
POSITION OF THE FORKS: EQUIDISTANT FROM THE FRAME AXIS.

III - SETTING UP THE MACHINE
There must be sufficient clearance around the machine to allow free
movement and access for maintenance (see page C).
The CS 960 must be installed on a stable, flat floor capable of
supporting its weight (950 kg). Before making any electrical and
pneumatic connections, level the machine by means of the adjustable
feet.
Use a 24-mm open-end spanner on lock nut CE and a 12-mm open-
end spanner for base B. Tighten lock nut CE firmly after adjustment
and levelling.
As the work surface is 900 mm from the floor it may be necessary to
have a platform available for operator of short stature.
B
CE
Assembling the left and right tables
Open the main case by fully
loosening safety screw VS
and releasing left and right
spring clips SG / SD.
SG
SD
VS
Remove screws A, B and C, D (on the right and left sides of the
machine frame) and screws E, F of the cylindrical suppports (on
the extension support brackets) with a 5-mm Allen key.
A B
C D
E F
The cutting table has 2 series of 3 screws and 2 rule supports R, which secure the right and left stops BD and
BG.
BG BD
BMI
BMI
BD
BG RR
VV
4
1 2 3
3 2 1

BG BD
BMI
D’ C’ B’ A’
Using a 4-mm Allen key, slightly loosen the locking screws on stops BD and BG located beolw each table
extension. This allows stops BD and BG to slide along them.
Position the left extension support bracket
below the left table.
Slide stop BG of the left extension into
screws 1-2-3 and the 2 rule supports R of the
left table.
Screw the extension to the frame (at C’ and
D’) using screws C and D. Secure the
cylindrical support of the bracket using
screw E.
Set the extension level with the cutting table.
Position the right table support
bracket below the right extension.
Slide right extension stop BD into
screws 1-2-3 of the right table and
the screws of the 2 rule supports
until it is stopped by screws R and
B’.
Screw the extension to the frame
(at A’ and B’) using screws A and
B. Secure the cylindrical support
of the bracket using screw F.
Tighten screws 1,2,3 and the rule
support screws. Set level.
Slide stop BG fully home through screws 1,2,3
and the screws of the 2 rule supports, until it is
stopped by screw B.
R
Measure the distance (1) between stops BD and BMI
and (2) set the same distance at the middle of the exten-
sion, by adjusting BD. Tighten the screw on the
underside. (3) Repeat the operation at the end of BD.
Once the stop spacing is
set, retighten the remaining
screws below the table.
12
3
BG
Retighten the locking screws below the table
extension.
B
BD
BD
BMI
Do not loosen the screws of the internal measuring stop BMI (factory setting).
Using the 4-mm Allen key, tighten screws 1,2,3
and the screws of the 2 rule supports.
B’
5

IV - STARTING UP
MAIN ISOLATING SWITCH
- Open the compressed air source (4 bar: factory setting).
- Switch on the machine: main isolating switch at top right of
the machine (see CS 960 description page A).
Indicator lamp 3 (see Control panel, page 7) lights.
This indicator only lights when the CS 960 is energised.
PRESSURE
REGULATING
VAVLE
Unlock button 5 then press button 4 (see Control panel, page 7).
Check the direction of rotation of the two blades, i.e.:
- clockwise for the left blade,
- anti-clockwise for the right blade.
If the direction is not correct, press button 5 (see Control panel, page 7), disconnect the machine and reverse the
two phases of the power supply cable.
1
2
Use a supply hose of inner dia. 8 mm withstanding the maximum pressure of the source, which
must not be less than 4 bar. Source characteristics: dry, non lubricated air.
Electrical connection
The user must connect the power supply cable to a source complying with the regulations in
force and protect the machine by fitting fuses: 25 Amp aM for 220 Volt single-phase and 16
Amp aM for 380/220 Volt 3-phase.
To conform to hygiene standards, the machine must be connected to an
extraction system producing a maximum flow rate of 28 m3/second over
a diameter of 100 mm. The circuit comprises 2 nozzles 100 mm in
diameter at the rear of the machine. This installation guarantees effective
extraction and must never be dismantled or modified.
Pneumatic connection
Dust extraction
USA FITTING
COMPRESSOR
SAW PRESSURE
REGULATING
VALVE
FEMALE QUICK-FIT
CONNECTOR
Z 675 Z 749
Z 701
Z 556
STANDARD
BARBED
FITTING
Pedal connection
Connect the pedal as follows:
-BLUE TRANSPARENT tube in
position 1
-RED tube in position 4
-BLUE or CLEAR TRANSPARENT
tube in position 2
2
35
4
1BLEU
RED
TRANSPARENT
OFF
ON
2
BLUE
MD
6

CONTROL PANEL
MACHINE
POWER ON
STOP
BLADES
UNLOCK RIGHT
BLADE
UNLOCK LEFT
BLADE
START
BLADES
When the air supply is switched on, the clamps move to CLAMPING posi-
tion. When the pedal is pressed the clamps are released.
PEDAL FUNCTION
12
3
4
5
SETTING THE HORIZONTAL CLAMPS
SWITCH ON THE MACHINE. Place the bead on the work table presenting it from the left of the
machine (slot side facing the saw blades and pressing against stops BD - BG).
Press the pedal: the clamps move to UNCLAMPING position.
Keep the pedal pressed with your foot throughout setting.
Release the left clamp handle (M) and move the pressor to roughly 1 cm from the profile edge,
then retighten handle M. Repeat the operation for the right horizontal pressor (for preparatory
cut see next page 8 - 1st CUT ).
CLAMPING
UNCLAMPING
PEDAL PRESSED PEDAL RAISED
M
1 CM
7
V - SAWING
FITTING THE LEFT AND RIGHT
ARMS OF THE CARRIAGE
Open the removable panel at the rear of the machine, after
unscrewing the 4 screws (5-mm Allen key). Fix the left arm to
the blade carriage using screws V1 and V2 (6-mm Allen key).
Repeat the operation for the right arm. Close the rear panel
(compulsory).
V1
V2

SETTING THE VERTICAL CLAMPS
(OPTION)
After releasing the handle (M2), position the vertical clamp positioning arms (BP) according to
the profile and the width of the moulding.
Apply the clamps by lifting your foot from the pedal, checking that the clamp pressor does not tilt
the moulding. The back of the moulding must be flat against the stops and its base on the work
table. To guarantee high quality cutting and safe operating conditions the moulding must be
immobilised throughout the operation.
Repeat the test under the same conditions for the right clamp. The measurement obtained
after setting the left vertical clamp can be set on the rule of the right vertical clamp.
M2
BP
MEASURE
MEASURE
LEFT VERTICAL CLAMP RIGHT VERTICAL CLAMP
1 st CUT ( preparing the moulding )
The moulding must have a fresh mitre cut before starting the measuring operations.
IMPORTANT: When the cut is made, the right clamp must always be in contact with the
bottom of the slot and never press against the cut part of the moulding. If the latter is the
case, loosen the handle of the right horizontal clamp and move it back. Only the left hori-
zontal clamp will be used for clamping.
Once setting of the horizontal and vertical (option) clamps is complete:
- Unlock button 5.
- Lift your foot from the pedal.
- Press button 4 on the control panel (to start the blades).
- Press button 2 continuously with a finger of your right hand. This releases the left blade.
- Grip the arm of the left blade carriage with your left hand and pull the blade slowly
towards the clamped profile. Make the cut through to the front stop.
- Release button 2 and the blade carriage arm (which will return automatically to the back
position).
- Press button 5 to stop the machine.
- Press the pedal: the clamps move to unclamped position.
- Slide the moulding, pushing it from the left table to the right table.
12
3
4
5
8

9
Lift your foot from the pedal
to activate the clamps. Move
the MOBILE STOP into con-
tact with the moulding and
lock it.
Remove the cursor from
below the moulding.
Measurement of the moulding
slot base is complete.
MEASURING THE SLOT BASE (INSIDE MEASUREMENT)
Slide the CURSOR along the rule and lock it at the required dimension by tightening its locking
screw. Press the pedal to release the clamps. Move the moulding to the cursor aligning the edge
of the slot base with the 45° angle.
MEASURING THE OUTSIDE DIMENSION
CURSOR
RULE LOCKING SCREW
READING
POINT
CURSOR
MOBILE STOP LOCKING
HANDLE
READING
POINT STUD
Slide the stop along the rule to
the required measurement.
Be sure to use the outside rule
for your measurement, with
respect to the stud on the mo-
bile stop block. Lock the stop.
The measurement has been set.
MEASURING THE FIRST PIECE (MOBILE STOP)
Loosen the locking handle of the MOBILE STOP.
45°

10
CUTTING THE FIRST PIECE
The moulding is in contact with the mobile stop.
- Unlock button 5.
- Lift your foot from the pedal (clamping position).
- Press button 4 on the control panel (to start the blade).
- Press button 1 continuously with a finger of the left hand. This releases the right blade.
- Grip the arm of the right blade carriage with your right hand and pull it slowly towards
the clamped profile. Make the cut through to the front stop.
- Release button 1 and the blade carriage arm (the carriage returns automatically to back
position).
- Press button 2 continuously with a finger of the right hand. This releases the left blade.
- Grip the arm of the left blade carriage with your left hand and pull it slowly towards the
clamped profile. Make the cut through to the front stop.
- Release button 2 and the blade carriage arm (the carriage returns automatically to back
position).
- Press button 5 to stop the machine.
- Press the pedal: the clamps move to unclamped position.
- Release the piece of cut moulding from the right-hand side.
- Slide the moulding, pushing it from the left table towards the right table.
END OF MOULDING
- Clamping and cutting are visible to the operator. He must therefore check that the hori-
zontal clamp is correctly engaged in the moulding slot and does not create pressure on the end
of the moulding.
If it does, the operator must only use right clamping and cancel the left clamp (loosen the
handle of the left horizontal clamp and release it towards the back).
- After cutting, if the off-cut or remaining piece of moulding do not drop under gravity
and cannot be retrieved outside the cover, it must be removed by pushing with the next
moulding or a stick.
The operator must never put his
hands inside the case
!
- It is strictly forbidden to cut several lengths of moulding at the same time by stacking
them or placing them one in front of the other.
- When the machine is in use, the workstation must not be occupied by more than one
person. This person is responsible for the controls.
- When cutting a moulding into thin sections, check that no off-cuts get jammed and
prevent the saw from operating correctly.
12
3
4
5

Opening the main case: Fully loosen safety screw VS and open the 2 spring clips S1 and S2.
Open the main case. Remove the blade protection case after unscrewing the two screws C1 and
C2 with a 4-mm Allen key.
11
Clean blades and flanges.
Install the blade (teeth in cutting direction). Check the rotation direction indicated on the sup-
port.
Refit the flange and screw, tightening it while immobilising the shaft with the steadying handle.
Close the main case. Hook up the 2 spring clips and close their levers, then switch on the main
isolating switch.
Lock the main case by screwing the cover safety screw fully home.
REFITTING THE BLADES
IMPORTANT
REMOVING THE BLADES
Disconnect the air supply.
Switch off the machine at the main isolating switch on the right of the machine and lock
it by installing a padlock on the tab.
10-mm Allen key
Blade steadying
handle
USING THE BLADE
STEADYING HANDLE
VI - MAINTENANCE
During this operation, gloves should be worn to handle the
blades and avoid getting your hands caught.
Use the blade steadying handle
provided to immobilise the shaft, loosen
the nut (as a general rule, to loosen the
nuts securing the blade turn the Allen
key in the blade rotation direction), then
remove the flange and the blade.
C1
C2
S1 S2
VS

Open the main case (see page 11). Unscrew screw V1 using a 2-mm Allen key and remove the
worn martyr block by pulling it upwards. Turn the martyr cube over through 180°, refit it in its
housing and secure it by retightening screw V1.
REPLACING THE MARTYR CUBE
INSIDE THE MACHINE
V1
Close the main case: Close the locking levers of the 2 spring clips and screw the cover safety
screw fully home. Switch on the main isolating switch and open the air supply. Unlock button
5, then start up the blades by pressing button 4 on the control panel (Control panel, page 7).
Make a right and left cut to wear in the martyr cube.
- Check the electrical power supply.
- Main isolating switch not engaged.
- Fuses need to be changed.
According to frequency of use. On the basis of 8 working hours a day:
Cleaning : Clean the plexiglass screen with a soft cloth
Clean the offcut outlet hopper.
Belt inspection : Every 3 months
Blade sharpening : Cutting quality depends on the sharpness of the blade.
We recommend contacting your retailer for this service.
PREVENTIVE MAINTENANCE
FAULT POSSIBLE CAUSES
Indicator 3 of the control
panel does not light.
Indicator 3 lights but the
blades do not rotate.
Type of blade recommended for multi-use cutting
Teeth Number of teeth Body thickness Standard
Dia. 350 3° positive LR 108 2.7 mm EN 847-1: 1997
- Unlock button 5 on the control panel
(see Control pane, page 7)
- Check the air pressure.
- Main case not correctly closed (safety screw).
- Thermal circuit breaker in OFF position. Open the door of the
electrical cabinet (page a) . See Z7774 or Z10569 (Electrical
panel) and reset.
12
MARTYR
Poor quality cutting. - Blades rotating in wrong direction.
- Blades need to be sharpened.
- Moulding in unstable position and moves during the cut