Boss 332 545 551 Use - Maintenance Manual

AUTOMATIC BAR FEEDER WITH
HYDRAULIC SUSPENSION
ATTACHMENTS LIST
MANUAL FOR USE AND MAINTENANCE
KEYBOARD INSTRUCTION MANUAL
SPARE PARTS BOOK
SCHEMATICS
EC CONFORMITY DECLARATION FOR MACHINE
BOSS 332-545-551 E
BOSS 332r-545r-551r E
GB MANUAL FOR USE AND MAINTENANCE
Rel. 1 Date 24/06/03 Cod. 346005400
S/N
COMPILER: Ragazzini Gian Luca
ON APPROVAL: Bevini Claudio

MANUFACTURER: IEMCA division of IGMI S.p.A.
ADDRESS: Via Granarolo, 167 - 48018 Faenza (RA) - ITALY
Tel. 0546/698000 - Fax. 0546/46338 - 0546/46224
TLX 550879
TYPE OF DOCUMENT: MANUAL FOR USE AND MAINTENANCE
PRODUCT: AUTOMATIC BAR FEEDER WITH HYDRAULIC SUSPENSION
MODEL: BOSS 332-545-551 E
BOSS 332r-545r-551r E
IEMCA S.p.A.
Via Granarolo, 167
Tel. 0546/698000 - Fax. 0546/46224
TLX 550879
1 GENERAL INFORMATION ..........................................BOSS 332/545/551 E-volution
2 TECHNICAL INFORMATION.......................................BOSS 332/545/551 E-volution
3 SAFETY PROCEDURES - GENERAL INFORMATION....BOSS 332/545/551 E-volution
4 HANDLING AND INSTALLATION ................................BOSS332/545/551 E-volution
5 ADJUSTMENTS AND SETTING-UP .............................BOSS 332/545/551 E-volution
6 USE AND OPERATION................................................BOSS 332/545/551 E-volution
7 BAR FEEDER MAINTENANCE .....................................BOSS 332/545/551 E-volution
8 TROUBLES - CAUSES - CURES ...................................BOSS 332/545/551 E-volution
9 PART REPLACEMENT ..................................................BOSS332/545/551 E-volution
10 LIST OF AFTER-SALES CENTERS
1 - GENERAL INFORMATION BOSS 332/545/551 E-volution GB
INDEX
1.1 TERMS OF WARRANTY.............................................................................................2
1.2 MANUAL PURPOSE...................................................................................................3
1.3 MANUFACTURER AND BAR FEEDER IDENTIFICATION................................................4
1.4 TECHNICAL ASSISTANCE .........................................................................................4
1.5 ANNEXES ENCLOSED ...............................................................................................4
1 - Pag. 1 / 4
GB 1 - GENERAL INFORMATION BOSS 332/545/551 E-volution
Operations described in paragraphs showing this symbol, must be performed by qualified

and skilled personnel only.
Any other operation can be performed either by qualified personnel or by professional
bar feeder operators.
Before carrying out any servicing whatsoever on the bar feeder, it is of the
utmost importance to read this manual carefully.
1.1 TERMS OF WARRANTY
The warranty validity is subordinated to a correct assembly and coupling of the bar feeder to
lathe. In particular, before the first start-up, carry out an accurate check to make sure the bar
feeder is correctly aligned with the lathe and fastened with the expansion plugs as shown in
section 4.
The product warranty is valid only if the bar loader is

installed by an authorized technician with Original
Installation Certificate. Please ask the technician, who will
make the installation, to show the certificate, in order to
ascertain the quality of the technical works being carried
out.
The warranty shall begin from the date on the Installation
Certificate duly filled in and signed.
The document must be sent per mail to:
CUSTOMER SERVICE
IEMCA division of IGMI spa
48018 Faenza (Ra) ITALY - Via Granarolo,167
1 - Pag. 2 / 4
1 - GENERAL INFORMATION BOSS 332/545/551 E-volution GB
1.2 MANUAL PURPOSE
This manual has been written and supplied by the manufacturer, the information herewith
contained has been written in Italian (manufacturer's language) to be translated to other
languages, in order to comply with legal and/or commercial requirements. This manual is
integral part of the bar feeder and of its equipment.
The compliance with the instructions contained herein ensures the operator and bar feeder
safety as well as a running economy and a longer life of the bar feeder itself.
In order to allow a quick search of contents, consult the descriptive index.

Particularly important parts of this manual have been highlighted in bold type and preceded by
the following symbols:
DANGER - WARNING:
shows impending danger which might cause serious injuries, exert the
maximum caution.
CAUTION - PRECAUTION
indicates measures to be adopted to avoid accidents or damages to property.
INFORMATION
technical instructions of particular importance.
For a quick search of topics see the table of contents.

In addition to this manual, which contains all the instructions for the bar feeder use and
maintenance, one more is supplied: the "Push-button panel instruction manual".
The "Push-button panel instruction manual" contains all the instructions on how to use the
installed software.
1 - Pag. 3 / 4
GB 1 - GENERAL INFORMATION BOSS 332/545/551 E-volution
1.3 MANUFACTURER AND BAR FEEDER IDENTIFICATION
A Manufacturer's identification
B CE conformity marking
C Year of manufacture
D Bar feeder model
E Serial number
G Mains frequency
H Absorption power
M Feeding voltage
N Direct driving voltage
P Air pressure
Q Bar feeder and pusher length
R Breaking capacity
S Number of base wiring diagram
T Number of interface wiring diagram
INFORMATION:
Always provide the Manufacturer with the above mentioned specifications when
requesting information or ordering spare parts, etc.
1.4 TECHNICAL ASSISTANCE
Whenever necessary, please apply to one of the Technical Assistance Centres shown in the
attached list.
INFORMATION
when requesting technical assistance for the bar feeder, always specify the
information shown on the machine dataplate.
1.5 ANNEXES ENCLOSED
• Push-button panel instruction manual.

• GUIDES - BAR PUSHER - REVOLVING TIPS - COLLETS. Manual for choice.
• Wiring diagram.
• Pneumatic diagram.
1 - Pag. 4 / 4
2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution GB
INDEX
2.1 GENERAL BAR FEEDER DESCRIPTION.......................................................................2
2.2 OPERATING CYCLE ..................................................................................................4
2.3 SAFETY DEVICES .....................................................................................................7
2.4 SAFETY PLATES - LOCATION AND DESCRIPTION ......................................................9
2.5 VERSION DESCRIPTION .........................................................................................10
2.6 TECHNICAL SPECIFICATIONS .................................................................................11
2.6.1 Noise levels ...........................................................................................................20
2.7 FITTINGS - FOREWORD .........................................................................................21
2.7.1 Bush-holder device - Description .............................................................................21
2.7.2 Axial displacement device - Description ...................................................................22
2.8 DEVICE FOR SLIDING HEADSTOCK LATHES - FOREWORD .......................................23
2.8.1 Bar/headstock synchronizing device - Description.....................................................23
2.8.2 Telescopic nose - Description..................................................................................24
2.9 DEVICES FOR CAM LATHES - FOREWORD ...............................................................25
2.9.1 Headstock return device - Description .....................................................................25
2.9.2 Cam box - Description ............................................................................................25
2.9.3 Camshaft release device - Description .....................................................................26
2 - Pag. 1 / 26
GB 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution
2.1 GENERAL BAR FEEDER DESCRIPTION
The BOSS automatic bar feeder is used in the machine-tool industry and in particular, for
automatic lathe feeding. It is particularly suitable for feeding fixed or sliding headstock lathes,
numerical control or cam lathes.
The working cycle is controlled by a control panel with built-in PLC, which is able to dialogue
with the lathe control.
The digital hand-held keyboard makes programming easier and allows the bar-feeder functions
to be controlled without leaving the lathe.
The bar feeder can be used to feed bars, pipes and metallic as well as polymeric materials of
different sections. Avoid flammable materials.
The guide channel is fully closed during machining; a pump is provided to maintain a
continuous oil flow inside the channel, creating a hydrodynamic support effect; these
characteristics allow the bar to rotate at a high r.p.m. number, with no vibrations and no
surface damaging.
Thanks to the use of a "BRUSHLESS" and electronically controlled motor, the bar speed, thrust
value and feeding position may be determined at any time during the working cycle.
Bar remnant ejection can be caused by bar-pusher feeding or next bar feeding.
Bar feeder series BOSS are produced in the following models:
BOSS 332 (standard version)
BOSS 332r (reversed version)
The texts, tables and illustrations contained in this manual concern, unless otherwise stated,
the standard version (BOSS 332, BOSS 545 and BOSS 551) with the lathe on the operator's
right.
As for the reverse version (BOSS 332r, BOSS 545r and BOSS551r), with the lathe on the
operator's left, do not forget that the main parts are located on the opposite side, as mentioned
below.
2 - Pag. 2 / 26
• MAIN PARTS
A Magazine; where bars are stored.

B Bar selection device; it allows the
first bar to be lowered into the
guides and holds back the remaining
bars in the magazine.
C Guides; they guide the bars during
machining.
D Bar-pusher; it pushes the bar during
machining.
E Feed chain; it transmits motion from
the drive system to the bar-pusher.
F Drive system; it drives the bar-
pusher.
G Insertion/extraction drive; it drives
the bar feeder parts controlling bar
insertion into the collet and
subsequent bar remnant extraction.
It also drives the bar feeder parts
controlling guide opening/closing and
bar selection.
H Clamps; they hold the bar during bar
introduction in and extraction from
the bar-pusher collet.
L Facing device; it sends a signal at
bar passage.
M Remnant collection box; bar
remnants are dropped into this box
after extraction from the bar-pusher
collet.
N Lubricating pump; it delivers oil to
the guides.
P Oil recovery device; it collects oil
flowing out of the guides.
Q Hand-held keyboard; it allows bar
feeder programming and function actuation.
R Electric cabinet; it contains the electric switchboard.
S Lathe
T GUIDE CHANNELS OPENING SHAFT
V ENCODER
2 - Pag. 3 / 26
2.2 OPERATING CYCLE
In the automatic operation mode, bar feeder

movements are controlled in the sequence
described below:
The bar-pusher "A" feeds bar "B" in the lathe by
following lathe impulses until bar end.
The bar-pusher A and remnant C are in their

forwards limit stop position.
The bar-pusher A and remnant C reach their

backwards limit stop position.
The clamps D close and the bar-pusher moves
back; the remnant is extracted from the collet.
The clamps open and the remnant is dropped into
the box E.
2 - Pag. 4 / 26
Clamps "D" close again to perform remnant "C"

extraction check.
If the remnant is still inserted in the bar-pusher
collet, the feeder stops; otherwise, it continues its
cycle.
Upper guides "H" open together with bar pusher

"A"; the bar selection device "F" moves upwards
thereby raising the first bar and withholding the
remaining bars. Bar "G" drips into the guide
channel.
Bar selection device "F" is lowered.
The small pusher truck "M" starts its stroke.
2 - Pag. 5 / 26
When the small pusher truck "M" completes its

stroke, the required space has been created for bar-
pusher insertion.
The small pusher truck executes its return stroke.
The upper guides H are closed; the bar-pusher A

is positioned along the spindle axis.
The clamps "D" close, the bar-pusher "A" moves

forwards; the bar "G" is inserted into the bar-
pusher collet.
The bar-pusher "A" and bar "G" execute their facing

stroke. A new automatic work cycle is started.
2 - Pag. 6 / 26
2.3 SAFETY DEVICES
A Emergency button; by working it, all feeder and lathe functions are stopped in an emergency
situation.
B Emergency button; by working it, all feeder and lathe functions are stopped in an emergency
situation.
C Interlocked mobile guard: associated with microswitch C1.
According to the cycle setting, its functions are:
manual cycle;
- when the guard is opened the feeder will be stopped if the guides are not closed.
- when the guard is opened, if the guide channels are closed the feeder functions are not
disabled because no operator risks are present.
automatic cycle;
- during the bar feeding phase guard opening may be necessary for the purpose of
restocking the magazine. Even if the feeder functions are not disabled there are no
operator hazards present inside the area.
- during the bar change procedure the feeder will stop when the guard is opened. Closing
the guard allows the user to restart the feeder.
2 - Pag. 7 / 26
D Fixed guard: it is made from transparent material to allow visual inspection of the bar
magazine area.
E Fixed guard: it prevents accidental access to the bar selection area.
F Fixed guard: it prevents accidental access to the drive area.
G Fixed guard: it prevents accidental access to the drive belt area.
H Remnant collection tank: it also acts as a fixed guard to prevent accidental access to moving
parts.
L Fixed guard: it prevents accidental access to the bush-holder device.
M Main switch: cuts out the electric energy source during interventions in the electric
switchboard and during the bar feeder periods of inactivity.
2 - Pag. 8 / 26
2.4 SAFETY PLATES - LOCATION AND DESCRIPTION
A Danger of upper limb crushing.

B Caution! Moving parts.
C Do not remove the safety barriers.
D Wear safety gloves and shoes.
E Caution! Danger of electric contact.
F Warning: fix the bar feeder to the ground.
2 - Pag. 9 / 26
2.5 VERSION DESCRIPTION
Table 1. Maximum bar length
Model Version Max. length mm (ft)

21 2080 (6,8)
BOSS 332 32 3200 (10,5)
BOSS 545
BOSS 551 37 3740 (12,2)
44 4400 (14,4)
Table 2. Max. bar-pusher extension
Model Version A – Max extension (mm)

BOSS 332 N 937
BOSS 545 L 1267
BOSS 551
LL 1597
2 - Pag. 10 / 26
2.6 TECHNICAL SPECIFICATIONS
(*) Without axial displacement device, the minimum dimension can be reduced to 850 mm.
Table 3. Overall dimensions

Model Version A (mm) B (mm)
21 2603 /
BOSS 332 – BOSS 332r
32 3802 1220
BOSS 545 - BOSS 545r
BOSS 551 - BOSS 551r 37 4342 1760
44 5002 2420
2 - Pag. 11 / 26
Table 4. General technical specifications
BOSS 432 BOSS 545/551

Ø max 545
Ø min 4 mm Ø max 32 mm Ø min 5 mm 45 mm(1"
Round bar size (5/32") (1" 1/4) (3/16") 3/4)
Ø max 551
51mm(2")(***)
min 4 mm max 27 mm min 5 mm max 36 mm(*)
Hex bar size (key socket)
(3/16") (1" 1/16) (3/16") (1" 7/16)
Mod. 32 – 3200 mm (10,5 ft) Mod. 21 – 2080 mm (6,9 ft)
Mod. 37 – 3740 mm (12,2 ft) Mod. 32 – 3200 mm (10,5 ft)
Max bar length
Mod. 44 – 4400 mm (14,4 ft) Mod. 37 – 3740 mm (12,2 ft)
Mod. 44 – 4400 mm (14,4 ft)
Magazine capacity (working width) n. 28 barre ø 10 mm (3/8") n. 28 barre ø 10 mm (3/8")
(Adjustable) feeding speed Max 1000 mm/sec Max 750 mm/sec
(Adjustable) return speed Max 1800 mm/sec Max 1200 mm/sec
Remnant length (standard version) 400 mm Mod. 21 – 295 mm
400 mm
Remnant length (oversize version *) 700 mm 700 mm
Bar change-over time (with 3000 mm bar) 30 sec 30 sec
Version 32
Input voltage 230/400 Volt 230/400 Volt
Mains frequency 50 Hz / 60 Hz 50 Hz / 60 Hz
Control voltage 24 Volt D.C. 24 Volt D.C.
Installed power 2 kW 2 kW
Oil quantity 57 l 57 l
Air max. pressure. 8 bar 8 bar
Pneumatic energy average consumption (**) 20 NL/min 20 NL/min
Mod. 32 – 835 kg. Mod. 21 – 620 kg.
Mod. 37 – 900 kg. Mod. 32 – 835 kg.
Dry weight
Mod. 44 – 980 kg. Mod. 37 – 900 kg.
Mod. 44 – 980 kg.
(*) excluded version 32 LL and 21

(**) Approximate value depending on the number of activation cycles.
(***) valid also for prepared bars or normal bars machined with front remnant ejection.
2 - Pag. 12 / 26
Table 5. Working axis height
Model Upper screws X (mm) Y (mm)

position Working axis height Max. loading height Y
1 900÷940 1090
2 935÷975 1125
3 970÷1010 1160
BOSS 332 4 1005÷1045 1195
BOSS 545 5 1040÷1080 1230
BOSS 551
6 1075÷1115 1265
7 1110÷1150 1300
8 1145÷1185 1335
9 1180÷1220 1370
10 1215÷1255 1405
2 - Pag. 13 / 26
Table 6. BOSS 332 guide, bar pusher, bar and tube diameters
Model Guide Bar-pusher Bar diameter (mm) Largest tube

diameter diameter diameter (mm)
Min. Max.
(mm) (mm) (*)
10 3 8 10
13
12 4 10 12
15 5 13 15
17
16 5 14 16
18 5 16 18
21 19 5 17 19
20 5 18 20
BOSS 23 8 21 23
26
332 25 8 23 25
25 8 23 25
28
27 8 25 27
30 8 27 30
33 31 8 28 31
32 8 29 32
32 8 29 32
36
35 8 32 32
(*) valid also for prepared bars or normal bars machined with front remnant ejection.
CAUTION:
Barstock diameters for any guide channel are only given as an example. A
barstock diameter approximately 10 mm smaller than the guide channel
diameter may cause vibration and failure to the bar feeder. Therefore, it may be
necessary to slow down the bar rotation speed or to change the guide channel
diameter in order to obtain the best performance for a specific application.
CAUTION:
the collet outside diameter should be at least 0.5 mm smaller than the bar-
pusher outside diameter.
INFORMATION:
The bar feeder is normally provided with a bar pusher with a diameter equal to
the maximum barstock guide channel offered by the lathe. Sometimes, in order
to ensure the best working conditions, it can be necessary to use a bar pusher
with a smaller diameter.
2 - Pag. 14 / 26

diameter (mm) diameter (mm) diameter (mm)
Min. Max.
(*)
10 5 8 10
13
12 5 10 12
15 5 13 15
17
16 5 14 16
18 5 16 18
21 19 5 17 19
20 5 18 20
23 8 21 23
26
25 8 23 25
25 8 23 25
28
BOSS 27 8 25 27
545 30 8 27 30
33 31 8 28 31
32 8 29 32
32 8 29 32
36
35 8 32 35
38 37 8 34 37
40 10 37 40
43
42 10 39 42
42 10 39 42
46
45 10 42 45
52 51 12 45 45
2 - Pag. 15 / 26
CAUTION:
CAUTION:
INFORMATION:
2 - Pag. 16 / 26

Min. Max.
(*)
10 5 8 10
13
12 5 10 12
15 5 13 15
17
16 5 14 16
18 5 16 18
21 19 5 17 19
20 5 18 20
23 8 21 23
26
25 8 23 25
25 8 23 25
28
BOSS 27 8 25 27
551 30 8 27 30
33 31 8 28 31
32 8 29 32
32 8 29 32
36
35 8 32 35
38 37 8 34 37
40 10 37 40
43
42 10 39 42
42 10 39 42
46
45 10 42 45
52 51 12 47 51
2 - Pag. 17 / 26
CAUTION:
CAUTION:
INFORMATION:
2 - Pag. 18 / 26
Table 9. BOSS 332 guides lubricating oils Tab.10. BOSS 545/551 guides lubricating oils
ISO/UNI Make Name ISO/UNI Make Name

rating rating
Agip Acer 100 Agip Acer 150
Api Api Cis 100 Api Api Cis 150
BP Energol CS 100 BP Energol CS 150
Castrol Magna 100 Castrol Magna 150
Circulating Oil Circulating Oil
Chevron Chevron
100 150
Elf Movixa 100 Elf Movixa 150
Esso Nuto 100 Esso Nuto 150
Fina Solna 100 Fina Solna 150
IP IP Hermea 100 IP IP Hermea 150
C class C class
Klüber Crucolan 100 Klüber Crucolan 150
CKB 100 CKB 150
Mobil Vectra Oil Heavy Mobil Vectra Oil Heavy
Olio FIAT Daphne LPN 100 Olio FIAT Daphne LPN 150
Roloil Arm V 100 Roloil Arm V 150
Vitrea 100 Vitrea 150
Shell Shell
Tellus C 100 Tellus C 150
Tamoil Industrial Oil 100 Tamoil Industrial Oil 150
Texaco Omnis 100 Texaco Omnis 150
Cortis 100 Cortis 150
Total Total
Azolla ZS 100 Azolla ZS 150
Q8 Verdi 100 Q8 Verdi 150
Oil quantity: 57 l.
Tabella 11. Air lubricator oils
ISO/UNI BRAND DENOMINATION

DESIGNATION
BP Energol HP 10
Esso Spinesso 10
ISO VG10
Mobil DTE 21
Shell Tellus C 10
2 - Pag. 19 / 26
2.6.1 Noise levels
Bar feeder does not cause acoustic noise.

Noise occurs when lathe, connected to the bar feeder, is working and the bar is rotating into
bar feeder guides.
In such a case, noise level emitted depends on the following conditions:
• perfect alignment and levelling of the lathe-bar feeder unit;
• proper fastening to the floor both of lathe and bar feeder;
• suitable bar gripping device fitted on lathe;
• dimensions of guide channel and bar-pusher suited to the bar stock;
• front guide bush of suitable diameter (if supplied);
• bar with a straightness within prescribed limits (max. arrows equal to 0.5 ‰ mm of the bar
length);
• spindle liner having the same diameter as the bar feeder guide channel diameter;
• spindle rotation speed suitable for the material to be machined;
• as to the bar feeder, use of oil having features suitable for the diameter of the bar to be
machined;
• all bar feeder panels must be closed.
Should the above mentioned conditions be met, the noise level emitted during bar rotation into
the guide channel, measured in compliance with the international standards, will be within the
following limits:
• brass and steel round bars within 80 *) dB(A);
• hexagonal steel bars within 83 dB(A);
• brass hexagonal bars within 85 dB(A);
The noise lever depends on the lathe working condition as well as on the bar type being
machined.
Whenever necessary, operators must wear PPE (personal protective equipment)provided for by
the accident prevention regulations in force in the country in which the machine is installed.
• *) Measurements taken on round bar Ø35mm, guide channel Ø36mm , bar straightness <
5%, 3750 Rpm, on a Biglia B501 lathe, serial number.
2 - Pag. 20 / 26
2.7 FITTINGS - FOREWORD
To improve the feeder performance and increase its versatility, a few optional devices are
available which are listed and then described below.
2.7.1 Bush-holder device - Description

2.7.2 Axial displacement device - Description
2.7.1 Bush-holder device - Description
It is attached to the front part of the bar feeder.

Its function its to reduce bar vibrations to a
minimum, by keeping the bar centered during
rotation through two half bushes A, which are
coupled to form a round channel with a diameter
just slightly larger than that of the bar being
machined.
In many cases, this device can be used (by only
changing the diameter of the half bushes) to
greatly extend the range of diameters which can
be machined without having to replace the guide
channel.
Operation
• When the bar is dropped into the guide channel, the two half bushes are open.
• Closure is controlled by a pneumatic cylinder after the feeder has completed the bar feeding
cycle. Closure also controls lubricating oil flow for lubrication and machined bar support
purposes.
• When the bar-pusher approaches the device, the half bushes open up to allow its passage;
oil flow is then discontinued.
2 - Pag. 21 / 26
2.7.2 Axial displacement device - Description
It allows the feeder to be moved away from the

lathe to allow maintenance, cleaning or any other
servicing of the lathe.
Model Version A (mm) B (mm)

21 1880 800
BOSS 332 – BOSS 332r
32 3170 900
BOSS 545 - BOSS 545r
BOSS 551 - BOSS 551r 37 3770 900
44 4370 900
2 - Pag. 22 / 26
2.8 DEVICE FOR SLIDING HEADSTOCK LATHES - FOREWORD
This feeder has been designed and manufactured to be coupled to sliding headstock lathes too.
To do this, special devices are available which are listed and then described below:
2.8.1 Bar/headstock synchronizing device - Description
2.8.2 Telescopic nose - Description
2.8.1 Bar/headstock synchronizing device - Description
It is used to connect the bar-pusher (and

consequently, the bar) to the lathe headstock, to
obtain their synchronized forwards/backwards
movement.
2 - Pag. 23 / 26
2.8.2 Telescopic nose - Description
It is used to optimize bar guiding between the

bush-holder device and the lathe spindle.
Table 13. Max stroke and overall dimensions
Model Max stroke Overall dimensions

A (mm) B (mm)
200 270
BOSS 332 210 270

BOSS 545 230 300
BOSS 551 280 430
330 480
2 - Pag. 24 / 26
2.9 DEVICES FOR CAM LATHES - FOREWORD
This feeder has been designed and manufactured to be coupled to cam lathes too.
To do this, special devices are available which are listed and then described below:
2.9.1 Headstock return device - Description
2.9.2 Cam box - Description
2.9.3 Camshaft release device - Description
2.9.1 Headstock return device - Description
Necessary when the lathe headstock return spring

size hinders feeder installation.
The original lathe spring A is then installed inside
the feeder.
2.9.2 Cam box - Description
Used to synchronize the feeder and cam lathe

movements. The cams located in the box A are
connected to the lathe camshaft B.
2 - Pag. 25 / 26
2.9.3 Camshaft release device - Description
Used to release and engage the camshaft during bar changeover. A radial version and an axial
version of this device are available.
A Axial version
B Radial version
2 - Pag. 26 / 26
3 - SAFETY PROCEDURES - GENERAL INFORMATIONBOSS 332/545/551 E-volution GB
INDEX
3.1 GENERAL SAFETY PRESCRIPTIONS...........................................................................2
3.2 HANDLING AND INSTALLATION - Safety ...................................................................3
3.3 ADJUSTMENTS AND SETTING UP - Safety .................................................................3
3.4 USE AND OPERATION - Safety..................................................................................4
3.5 BAR FEEDER MAINTENANCE - Safety ........................................................................4
3 - Pag. 1 / 4
GB 3 - SAFETY PROCEDURES - GENERAL INFORMATIONBOSS 332/545/551 E-volution
3.1 GENERAL SAFETY PRESCRIPTIONS
It is of the utmost importance to read this manual carefully before

installing, using or servicing the bar feeder or performing any other work .
Constant compliance with the instructions in this manual is a guarantee of
protection against injury.
• The operator and skilled engineer must perform only their specified duties.
• Do not tamper with the safety devices for any reason whatsoever.
• Comply strictly with the work health and safety regulations issued by the relevant authorities
in the country of installation of the machine.
• IEMCA declines any liability whatsoever for injury to persons or damage to property if the
relevant safety prescriptions are disregarded.
3 - Pag. 2 / 4
3 - SAFETY PROCEDURES - GENERAL INFORMATIONBOSS 332/545/551 E-volution GB
3.2 HANDLING AND INSTALLATION - Safety
• The bar feeder must be handled using suitable means and methods.
• Persons must not stand or transit underneath a suspended load, or within the range of
action of the crane, lift truck or other suitable means of lifting and transportation.
• The working area and bar loading area must be cordoned off to prevent collisions between
the operator and machines used to transport or handle the barstock or other materials.
• Correct positioning of the bar feeder, adequate lighting and a clean working environment are
of the utmost importance as far as personal safety is concerned.
• The electric system connection must be made exclusively by skilled electricians.
• Make sure the electrical system is connected to an efficient earth circuit by means of a
dedicated wire.
3.3 ADJUSTMENTS AND SETTING UP - Safety
• Carry out the adjustments as described in the user manual.
• Do not change working parameters to obtain performances other than those envisaged in the
design and testing phases.
• Do not adjust the bar feeder when it is running unless expressly requested to do so in the
manual.
• Do not feed the machine with bars having dimensions different from those recommended by
the manufacturer.
• Do not use hoses as handholds.
3 - Pag. 3 / 4
GB 3 - SAFETY PROCEDURES - GENERAL INFORMATIONBOSS 332/545/551 E-volution
3.4 USE AND OPERATION - Safety
• The working area around the bar feeder must always be kept clean and uncluttered and its
surface must be slip resistant in order to allow immediate access to the emergency devices
and bar loading to be performed without creating obstructions or danger.
• Perform the cycle starting sequence as prescribed.
• Keep hands and other parts of the body well clear of moving parts or live electrical parts.
• Remove bracelets, watches, rings and neckties.
• Whenever necessary, use strong work gloves with 5 fingers, which do not reduce the
sensitivity or power of your grip.
• Wear working shoes as well as personal protection devices provided for by the accident
prevention regulations in force in the country in which the machine is installed.
• Inform maintenance personnel of all operating anomalies that come to your attention.
• Before starting the bar feeder, make sure that there are no personnel engaged in servicing
or cleaning the machine.
3.5 BAR FEEDER MAINTENANCE - Safety
• Do not allow unauthorized persons to carry out maintenance.
• Read this manual carefully before carrying out maintenance.
• Do not lubricate, repair or adjust the bar feeder while it is running, unless expressly
indicated to do so in the manual.
• Stop the bar feeder in accordance with the prescribed methods before carrying out
lubrication or other work.
• Do use matches, lighters or torches when servicing the machine in the presence of
inflammable fluids.
• Keep spent oil in suitable containers and consign it to companies specialized in the storage
and disposal of polluting waste products.
• Do not pollute the environment.
• Use original IEMCA spare parts only.
3 - Pag. 4 / 4
4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution GB
INDEX
4.1 PACKAGING ......................................................................................................3
4.2 LIFTING ...........................................................................................................3
4.3 INSTALLATION AREA - CHARACTERISTICS .........................................................5
4.4 FEEDER WITHOUT AXIAL DISPLACEMENT DEVICE - INSTALLATION ....................6
4.4.1 Support plates and feet - Installation........................................................................6
4.4.2 Height - Adjustment .................................................................................................7
4.4.3 Preliminary positioning .............................................................................................9
4.4.4 Sleeve - Installation ...............................................................................................10
4.4.5 Levelling and alignment..........................................................................................12
4.4.6 Feeder fastening ....................................................................................................16
4.4.7 Installation If the feeder.........................................................................................17
4.5 FEEDER WITH AXIAL DISPLACEMENT DEVICE - INSTALLATION ........................18
4.5.1 Preliminary operations............................................................................................18
4.5.2 Height - Adjustment ...............................................................................................18
4.5.3 Preliminary positioning ...........................................................................................19
4.5.4 Sleeve - Installation ...............................................................................................19
4.5.5 Levelling and alignment..........................................................................................20
4.5.6 Feeder fastening ....................................................................................................22
4.5.7 Telescopic nose - Installation ..................................................................................22
4.6 DEVICE FOR SLIDING HEADSTOCK LATHES - INSTALLATION ............................23
4.6.1 Bar/headstock synchronizing device ........................................................................23
4.7 DEVICES FOR CAM LATHES - INSTALLATION ....................................................24
4.7.1 Headstock return device .........................................................................................24
4 - Pag. 1 / 32
GB 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution
4.7.2 Cam box ................................................................................................................25
4.7.3 Camshaft release device .........................................................................................26
4.8 LUBRICATING OIL - FILLING ............................................................................28
4.9 ELECTRIC CONNECTION ..................................................................................29
4.9.1 THREE-PHASE POWER SUPPLY ...............................................................................29
4.9.2 SAFETY SIGNALS ...................................................................................................29
4.9.2.1 EMERGENCY STOP .................................................................................................30
4.9.2.2 COVER SAFETY STOP (WHEN PROVIDED) ...............................................................30
4.9.3 FUNCTION SIGNALS...............................................................................................30
4.10 PNEUMATIC CONNECTION ...............................................................................32
4.11 SOFTWARE PARAMETRING ..............................................................................32
4 - Pag. 2 / 32
4.1 PACKAGING
There are three possible bar feeder packagings:

A WITH NO PACKAGING
B WITH PALLET: the feeder is placed on a pallet and wrapped in protective film.
C WITH CRATE: the feeder is placed in a crate wrapped in protective film.
4.2 LIFTING
DANGER - WARNING:
handling and lifting operations should be carried out with suitable equipment
(see weight table in paragraph 2.6.) by specially trained and experienced
personnel.
According to the packaging choice, lifting is carried out as shown in the next page.
4 - Pag. 3 / 32
LIFTING WITH NO PACKAGING

• Insert the two eyebolts with threaded shanks
"A" (type 1 UNI - ISO3266 M20).
• Use a hook type lifting device of suitable
capacity.
LIFTING WITH PALLET

• Use a hook (or fork) type lifting device or of
suitable capacity (see information on
packaging).
LIFTING WITH CRATE

• Use a hook (or fork)type lifting device of
suitable capacity (see information on
packaging).
ATTENTION:
never use any different lifting system
or device from the ones above.
4 - Pag. 4 / 32
4.3 INSTALLATION AREA - CHARACTERISTICS
The floor should be stable and levelled to guarantee good fastening to the ground.
Provide an area of suitable dimensions according to the type of feeder use.
The areas: "D" (work area), "E" (bar feeding area) and "F" (remnant discharge area) should be
properly delimited to prevent collisions between the operator and any handling equipment or
transport vehicles travelling near the bar feeder.
The selected bar feeder setting should be suitably lit and provided with an electric power and
air outlets.
During operation, the feeder will release small amount of oil vapors. Make sure that the
premises where the feeder is installed are suitably ventilated.
The feeder has not been designed and built for use in an explosive atmosphere.
1-2 Without axial displacement

3-4 With axial displacement
Model Version A (mm) B (mm) C (mm)

21 2603
BOSS 332/332r
32 3802
BOSS 545/545r 605 640
BOSS 551/551r 37 4342
44 5002
4 - Pag. 5 / 32
4.4 FEEDER WITHOUT AXIAL DISPLACEMENT DEVICE - INSTALLATION
Before carrying out feeder installation, check lathe stability; make sure that it is firmly fastened
to the ground and with a horizontal spindle axis.
4.4.1 Support plates and feet - Installation
• Position the feeder next to the lathe.

• Keep it lifted and install the plates "A" and feet
"B" in the positions shown in the figure.
4 - Pag. 6 / 32
4.4.2 Height - Adjustment
The feeder is normally factory-preset to have a

working axis height adjusted to lathe height.
However, if feeder height needs adjustment,
proceed as follows:
• tighten the lifting chains and remove the 16
screws "A".
• lift the feeder according to the required
dimension "X" (see table).
4 - Pag. 7 / 32
Table 2. Working axis height
Model Upper screws X (mm) Y (mm)

position Working axis height Max. loading height Y
1 900÷940 1090
2 935÷975 1125
3 970÷1010 1160
BOSS 332 4 1005÷1045 1195
BOSS 545 5 1040÷1080 1230
BOSS 551
6 1075÷1115 1265
7 1110÷1150 1300
8 1145÷1185 1335
9 1180÷1220 1370
10 1215÷1255 1405
• Tighten the "A" screws and remove the "B" eyebolts.
4 - Pag. 8 / 32
4.4.3 Preliminary positioning
• Position the feeder behind the lathe, by

taking into account the overall
dimensions and side plays of both
machines. The coupling distance "B"
should not exceed the bar-pusher max.
extension "A".
1 Fixed headstock or steady rest lathe
2 Sliding headstock N.C. lathe
3 Sliding headstock cam lathe
INFORMATION:
it is not always necessary to
control the bar-pusher all the way
out. In fixed headstock lathes, its
stroke can be reduced to 100 mm
to allow the feeder to be brought
as close as possible to the lathe;
contact IEMCA After-sales Service
for more information.
Table 3. Max. bar-pusher extension
Model Version A – Max extension (mm)

BOSS 332 N 937
BOSS 545 L 1267
BOSS 551
LL 1597
4 - Pag. 9 / 32
• Roughly adjust the working axis height to obtain

alignment with the lathe by turning the feet
screws.
4.4.4 Sleeve - Installation
BOSS 332
• Install the sleeve "A" in the bush holder
device.
• Install the oil recovery device "B".
• Connect the drain pipe to the tank.
4 - Pag. 10 / 32
BOSS 545 - BOSS 551

• Install the sleeve "A" in the bush holder
device.
• Install the oil recovery device "B".
• Connect the drain pipe to the tank.
4 - Pag. 11 / 32
4.4.5 Levelling and alignment
FOREWORD
Alignment between the feeder and lathe is the
most critical installation phase; therefore, this
operation should be carried out by experienced
personnel with the greatest accuracy.
CAUTION:
bad alignment can be the main cause of
feeder malfunction and resulting
damage.
PRELIMINARY PROCEDURE
• Open the upper guard.
• Open rear guard "A".
4 - Pag. 12 / 32
LEVELLING
• Insert the templates in the specially provided
holes in the beam.
• Check levelling by positioning the level crosswise
and lengthwise.
• Carry out the required connections by turning

the feet screws.
4 - Pag. 13 / 32
ALIGNMENT
• Insert the (supplied) crank in the intermediate

drive shaft and move the bar-pusher to its
backwards limit stop.
• Move the crank to the guide opening screw shaft

and open the upper guides.
To obtain alignment lead a (ø 1 mm) nylon

thread between the lathe collet and the feeder
rear plate, then proceed as follows:
• place a drilled bush "A" in the lathe collet;
• stretch out the wire to the hole in the rear
plate;
4 - Pag. 14 / 32
• use a sliding calliper to check alignment near

the sleeve "C" and the spindle "D"; adopt a
tolerance of 0.15 mm in all four directions.
• prepare a perfectly straight ground bar,

having an outside diameter equal to the max.
spindle bar passage and a length equal to
twice the coupling distance (see item "B"
paragraph 4.4.3);
• place the bar in the guide and cause it to slide
forwards and backwards in the spindle, until
almost reaching the lathe collet area.
POSITIONING ADJUSTMENTS
After checking alignment of the feeder with either
the thread or the bar, any required corrections
should be carried out.
Adjust height by turning the screws in the support
feet; carry out lateral adjustment with calibrated
mallet blows on the sides of plates "E".
During this phase, any adjustment carried out
during levelling should be preserved; therefore, in
most cases, feeder positioning will be the result of
a good adjustment compromise.
4 - Pag. 15 / 32
4.4.6 Feeder fastening
GROUND FASTENING
• Drill the floor and fix the backing plates with
expansion plugs.
• Fix the feeder to the plates through the tie-
rods "A" and lock with nuts "B".
• Perform another levelling and alignment
check.
• Remove all the equipment used for levelling
and alignment and restore initial feeder
conditions.
FASTENING TO THE LATHE

Wherever possible, the feeder should be fastened to
the lathe through the suitable coupling unit
according to lathe make and type. The figure shows
a general example of fastening; contact IEMCA
service department for more information.
4 - Pag. 16 / 32
4.4.7 Installation If the feeder
If the feeder is equipped with a telescopic nose,

proceed as described below:
• Remove the fixed sleeve that had been installed
to obtain alignment between the feeder and the
lathe.
• Fix the flange "A" (a general example is shown
in the figure).
INFORMATION:
the lathe spindle nose "B" should not
turn. If it does, a bearing or another
similar device should be mounted to
prevent telescopic nose turning after it
has been installed.
• Move the headstock to its "all the way back"

position and measure the dimension "L". Take
out the grub screw "C", compress the telescopic
nose to its limit stop minus 5 mm and cut the
pipe "D" to the measured dimension.
• Move the headstock to its "all the way forwards"
position. Remove the cover "E", install the
sleeve in the flange "F" and place back the
cover "E".
• Check smooth sliding of the telescopic nose by moving the headstock forwards and
backwards.
4 - Pag. 17 / 32
4.5 FEEDER WITH AXIAL DISPLACEMENT DEVICE - INSTALLATION
Before carrying out feeder installation, check lathe stability; make sure that it is firmly fastened
to the ground and with a perfectly horizontal spindle axis.
4.5.1 Preliminary operations
• Roughly position the feeder behind the lathe.

• Screw out nuts "A" and screws "B".
4.5.2 Height - Adjustment
See paragraph 4.4.2; remember that the mentioned dimension "X" will not change when the
feeder is equipped with an axial displacement device.
4 - Pag. 18 / 32
4.5.3 Preliminary positioning
• Position the feeder behind the lathe, by taking

into account the overall dimensions and side
plays of both machines and the coupling
distance (see item "B" paragraph 4.4.3)
• Roughly adjust the working axis height to obtain
alignment with the lathe by turning the feet
screws.
• Place four plates under the axial sliding frame in

the positions shown in the figure, and screw
down the cone end grub screws "A".
• Check frame levelling crosswise and lengthwise;
adjust if required through the screws "A".
• Roughly restore working axis height and
alignment with the lathe if required.
4.5.4 Sleeve - Installation
See paragraph 4.4.4
4 - Pag. 19 / 32
4.5.5 Levelling and alignment
FOREWORD
Alignment between the feeder and lathe is the most critical installation phase; therefore, this
operation should be carried out by experienced personnel with the greatest accuracy.
CAUTION:
bad alignment can be the main cause of feeder malfunction and resulting
damage.
Preliminary procedure
See paragraph 4.4.5
Levelling
See paragraph 4.4.5
Alignment
See paragraph 4.4.5
Positioning adjustment
After checking alignment of the feeder with either
the thread, any required corrections should be
carried out.
Adjust height by turning the screws in the support
feet; carry out lateral adjustment with calibrated
mallet blows on the sides of frame "A".
During this phase, any adjustment carried out
during levelling should be preserved; therefore, in
most cases, feeder positioning will be the result of
a good adjustment compromise
4 - Pag. 20 / 32
• Position the remaining eight plates under the

axial sliding frame in the positions indicated in
the figure, then tighten the cone end grub
screws "B".
4 - Pag. 21 / 32
4.5.6 Feeder fastening
Ground fastening
• Drill the floor and fix the (axial sliding) frame
with expansion plugs.
• Perform a levelling and alignment check.
• Tighten nuts "A" and screws "B".

• Perform another levelling and alignment check.
• Remove all the equipment used for levelling and
alignment and restore initial feeder conditions.
Fastening to the lathe

See paragraph 4.4.6
4.5.7 Telescopic nose - Installation
See paragraph 4.4.7
4 - Pag. 22 / 32
4.6 DEVICE FOR SLIDING HEADSTOCK LATHES - INSTALLATION
4.6.1 Bar/headstock synchronizing device
INFORMATION:
the figure shows a general example of
installation; contact IEMCA service
department for more information.
• Screw out the screw "A".

• Install the bar "B" and tie-rod "C" and make sure
that the headstock "D" can run freely throughout its
stroke together with shaft "E".
• Position the support "F" in such a way as not to
hinder the headstock stroke and tighten the screw
"A".
4 - Pag. 23 / 32
4.7 DEVICES FOR CAM LATHES - INSTALLATION
4.7.1 Headstock return device
INFORMATION:
• Remove the original headstock return unit from the

lathe.
• Loosen the screw "A".
• Install the bar "B" and tie-rod "C" and make sure
that the headstock D can run freely throughout its
stroke together with shaft "E".
• Position the support "F" in such a way as not to
hinder the headstock stroke and tighten the screw
"A".
4 - Pag. 24 / 32
• Install the (original lathe) spring "G" and adjust

its tension through the ring nut "H".
4.7.2 Cam box
INFORMATION:
• Install the sleeve "A" on the lathe camshaft "B".

• Connect the shaft "C" to the sleeve through the
pin "D".
4 - Pag. 25 / 32
4.7.3 Camshaft release device
INFORMATION:
the figures show a general example
of installation; contact IEMCA service
Radial version
• Mount the articulation "A" in the flange "B".
• Mount the joint "C" in the articulation "D"
and in the lathe control "E".
4 - Pag. 26 / 32
Axial version
• Cut a hole and thread in the lathe casing to
fix the transmission unit "F" and mount the
disk "G" in the control "H".
• Insert the shaft "L" in the joint "M" and lock
with a pin; insert the other end of shaft "L"
in joint "N" and lock with a pin.
4 - Pag. 27 / 32
After completing the above-described operations,

the actuator rotation stroke should be adjusted
(this operation is necessary for both the radial
version and the axial version).
• Loosen the screws, move the slides "Q",

retighten the screws "P".
4.8 LUBRICATING OIL - FILLING
CAUTION:
wear personal protections according to the regulations in force.
• Open the rear base door and pour oil into the machine.
• Check the level by means of the "A" indicator.
Table 4. Guide lubricating oil characteristics
Model Oil type Quantity (l)

BOSS 332 Classe C – CKB 100 57
BOSS 545/551 Classe C – CKB 150 57
See paragraph 2.6. for the comparative table.
4 - Pag. 28 / 32
4.9 ELECTRIC CONNECTION
DANGER - WARNING:
this type of operation should only be entrusted to skilled technical staff to
comply with the applicable standards and statutory regulations in force.
DANGER - WARNING:
the feeder must be electrically connected to the lathe, which in turn, must be
connected to the plant wiring system in compliance with the applicable
regulations in force.
With the following instructions we would like to underline the importance of the connection of
the electrical interface.
The bar feeder is normally provided with one ore more multiple plugs to plug into the special
lathe outlets. The interface signals are wired to these outlets and can be classified into three
types:
• Three-phase power supply

• Safety signals
• Function signals
4.9.1 THREE-PHASE POWER SUPPLY
The bar feeder must be provided with three-phase voltage and with a suitable earthing
connection.
The three-phase supply line should also be protected by means of a suitable temperature switch
(check the installed capacity: see the plate on the door of the electric cabinet).
4.9.2 SAFETY SIGNALS
The above mentioned signals can be used by the hardware only and in agreement wiht the
current electrical safety norms (see current machine directives).
INFORMATION:
As far as the safety class 3 is concerned (see the following points), please refer
to the current safety norms.
4 - Pag. 29 / 32
4.9.2.1 EMERGENCY STOP
4 emergency channels are available, 2 from bar feeder towards to lathe and 2 from lathe to bar
feeder.
· Emergency signal from bar feeder to lathe (2 channels, open contacts=Emergency

activated).
It is used to transmit the active emergency from the bar feeder to the lathe.
These signals should be integrated with the lathe emergency signals, so that in case of an
emergency stop, the whole unit (bar feeder/lathe) is stopped.
· Emergency signal from lathe to bar feeder (2 channles, open contacts =
Emergency activated).
It is used to transmit the active emergency from the lathe to the bar feeder.
As soon as the bar feeder receives these signals, an emergency stop (safety class 3 compliant)
is activated.
4.9.2.2 COVER SAFETY STOP (WHEN PROVIDED)
4 cover safety channels are available, 2 from bar feeder to lathe and 2 from lathe fo bar feeder.
· Cover safety signal from bar feeder to lathe (2 channels, open contacts= open
covers).
Whenever the above mentioned signals are closed, the bar feeder informs the lahte that the
covers are closed: all lathe operations as well as indexing are now allowed.
Whenever one of bar feeder covers is open, the signals are stopped: in this case, all dangerous
operations on the lathe (i.e., on multispindle machines, spindle drum indexing) must be stopped
immediately ,in agreement with safety class 3.
As soon as the contacts are closed, the lathe operation can be recovered.
· Cover safety signal from lathe to bar feeder (2 channles, open contacts= open
covers).
Whenever the above mentioned signals are closed, the lathe informs the bar feeder that the
covers are closed: the bar pusher can be pushed forward.
As soon as one the covers on the lathe is open, the bar pusher is stopped immediately, in
agreement with safety class 3, to avoid injury to the operator.
Any jumper on the safety signals, which had been set for bar feeder final test, should be
removed in order to restore the safety signals.
ATTENTION-DANGER !!!
Bar feeder safety depends on these connections, therefore IEMCA is not responsible for any
enventual damage to persons or structures, caused by improper use of the above mentioned
signals.
4.9.3 FUNCTION SIGNALS
The bar feeder can send and receive all the signals which are necessary to its correct operation.
4 - Pag. 30 / 32
These signals are driven by a PLC, and can be grouped into: inputs (signals from lathe to bar
feeder) and outputs (signals from bar feeder to lathe).
The signals that have been implemented are the result of our long experience and allow the
application of the bar feeder on every lathe type: it is therefore possible that some of them are
not used.
IMPORTANT:
for any other information you may need, please refer to the interface wiring plan or
contact us: our Customer Service and Engineering Department are always at
your disposal.
4 - Pag. 31 / 32
4.10 PNEUMATIC CONNECTION
• Fill the tank of lubricator "A" removing plug

"B" or cup "C"; the oil level must reach the
MAX. reference.
For the oil comparison table, see section 2.6.
• Connect pipe "D" (1/4"Gas)to the compressed
air ductwork system as shown in the figure,
after connecting a three-way valve to adjust
and release pressure. With knob "E", adjust
the pressure at 6 bar.
• Check air lubrication (1-12 drops per 1000 l.
of air); adjust by turning the screw "F".
IMPORTANT:
Air must be filtered.
4.11 SOFTWARE PARAMETRING
There should be an adequate parametring of the bar feeder software according to the working
needs and to the type of lathe.
To obtain any information about how to carry out this operation, check the "Push-button panel
instruction manual".
4 - Pag. 32 / 32
5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution GB
INDEX
5.1 ADJUSTMENT AND SETTING-UP - FOREWORD ...................................................2
5.2 GENERAL ADJUSTMENTS - FOREWORD ..............................................................3
5.2.1 Feeding chain - Adjustment ......................................................................................3
5.2.2 Setting the pressure switch.......................................................................................3
5.3 SET-UP ACCORDING TO THE BAR TO BE MACHINED .................................................4
5.3.1 Guides, half bushes, bar-pusher and collet - Replacement ........................................11
5.3.2 Clamps - Replacement............................................................................................25
5.3.3 Bar guide plates and bar selectors - Adjustment.......................................................27
5.4 CAM BOX - TIMING ................................................................................................30
5 - Pag. 1 / 33
GB 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution
5.1 ADJUSTMENT AND SETTING-UP - FOREWORD
DANGER - WARNING:
do not perform any adjustment while the feeder is in motion unless explicitly
requested in the manual.
In addition to normal adjustments throughout its service life, this bar feeder also needs set-up
according to the type of operation. According to bar size and type of machining, setting up may
also include replacement of a few components.
These operations are listed and then described below:
5.2. General adjustments - Foreword
5.3. Set-up according to the bar to be machined
5.4. Cam box - Timing
5 - Pag. 2 / 33
5.2 GENERAL ADJUSTMENTS - FOREWORD
Including all the necessary adjustments for good feeder operation. They may become necessary
after maintenance, trouble fixing or component replacement.
5.2.1 Feeding chain - Adjustment
5.2.2 Drive belt - Adjustment
5.2.3 Pressure switch - Adjustment
5.2.1 Feeding chain - Adjustment
For the chain that moves stock pusher , an adjusting

screw A on the back plate of bar feeder is provided.
After some hours of operation of bar feeder. chain
tension has to be checked.
• If bush B of chain tension is still fast against rear

plate then no chain extension took place.
• If on the contrary bush B moved away of 1- 2 mm
from rear plate, then a chain extension took place,
which is harmful for a trouble-free operation of
bar feeder. So it is necessary to tighten screw A as
long as bush B is clamped fast to end plate.
5.2.2 Setting the pressure switch
After unscrewing the glass protection, the pressure

switch can be properly adjusted by turning the
relevant adjusting screw (G). Proper setting is 4.5
bars (0.45 MPa).
CAUTION:
Do not further turn anti-clockwise when
the green pointer is found on 0, as this
may cause damage to the pressure
switch.
5 - Pag. 3 / 33
5.3 SET-UP ACCORDING TO THE BAR TO BE MACHINED
According to the "new" bar diameter, a few or several operations must be carried out based on
the diameter of the previously machined bar.
The table shows the available guide diameters with the corresponding range of bar-pushers to
be mounted and the range of diameters of the bars to be machined.
5 - Pag. 4 / 33

diameter diameter diameter (mm)
Min. Max.
(mm) (mm) (*)
10 3 8 10
13
12 4 10 12
15 5 13 15
17
16 5 14 16
18 5 16 18
21 19 5 17 19
20 5 18 20
BOSS 23 8 21 23
26
332 25 8 23 25
25 8 23 25
28
27 8 25 27
30 8 27 30
33 31 8 28 31
32 8 29 32
32 8 29 32
36
35 8 32 32
CAUTION:
CAUTION:
INFORMATION:
5 - Pag. 5 / 33

Min. Max.
(*)
10 5 8 10
13
12 5 10 12
15 5 13 15
17
16 5 14 16
18 5 16 18
21 19 5 17 19
20 5 18 20
23 8 21 23
26
25 8 23 25
25 8 23 25
28
BOSS 27 8 25 27
545 30 8 27 30
33 31 8 28 31
32 8 29 32
32 8 29 32
36
35 8 32 35
38 37 8 34 37
40 10 37 40
43
42 10 39 42
42 10 39 42
46
45 10 42 45
52 51 12 45 45
5 - Pag. 6 / 33
CAUTION:
CAUTION:
INFORMATION:
5 - Pag. 7 / 33

Min. Max.
(*)
10 5 8 10
13
12 5 10 12
15 5 13 15
17
16 5 14 16
18 5 16 18
21 19 5 17 19
20 5 18 20
23 8 21 23
26
25 8 23 25
25 8 23 25
28
BOSS 27 8 25 27
551 30 8 27 30
33 31 8 28 31
32 8 29 32
32 8 29 32
36
35 8 32 35
38 37 8 34 37
40 10 37 40
43
42 10 39 42
42 10 39 42
46
45 10 42 45
52 51 12 47 51
5 - Pag. 8 / 33
CAUTION:
CAUTION:
INFORMATION:
5 - Pag. 9 / 33
Example 1
The previous machining cycle had been carried out under these conditions:
Guide Bar-pusher Bar

diameter (mm) diameter diameter (mm)
(mm)
17 15 8
The new machining cycle requires feeding of 10 mm bars.

In this case, the half bushes and bar-pusher collet must be replaced and the magazine must be
adjusted.
Example 2

(mm)
17 15 8

In this case, the half bushes, bar-pusher and bar-pusher collet must be replaced and the
magazine and clamps must be adjusted.
Example 3

(mm)
17 15 8

In this case, the guides, half bushes, bar pusher and bar-pusher collet must be replaced and
the magazine must be adjusted.
The information contained in this paragraph refers to Example 3, i.e. to the cases where it is
necessary to carry out all adjustment operations and feeder set-up.
These operations are listed and then described below.
5.3.1 Guides, half bushes, bar-pusher and collet - Replacement

5.3.2 Clamps - Replacement
5.3.3 Bar guide plates and bar selectors - Adjustment
5.3.4 Clamps - Adjustment
5 - Pag. 10 / 33
5.3.1 Guides, half bushes, bar-pusher and collet - Replacement
• When the magazine is empty (no bars) set the

feeder to manual mode.
• Use the keyboard to move the bar pusher

forwards beyond the area of the bar
extraction/introduction clamps unit.
• (you can move the bar pusher from the
keyboard in manual mode with the guard open
and the guides closed).
• Close the upper guard.
• On the keyboard press the blue buttons and

the guides opening button simultaneously:
now open the feeder guides.
• Remove the feeding motor protection so that

you can fit the crank.
• Use the crank to bring the bar pusher to its

backwards limit stop and then remove it from
its seat. Bar pushers in the Ø=42...51 range
must be removed from the bars magazine.
5 - Pag. 11 / 33
• Move the small pusher truck forwards until the

flag reaches the opening, then remove the
truck from its seat.
• Disassemble the lower guides

• Proceed disassembling the upper guides.
1 - Fastening screw version

2 - Quick fastening version
5 - Pag. 12 / 33
• Remove the bar pusher support.
A Guides with Ø=13÷46

B Guide with Ø=52
1 Support
2 Spacer
5 - Pag. 13 / 33
Remove the nose in the following way:
Fixed nose
• Remove the oil recovery device "A" and nose
"B".
Telescopic nose
• Remove the nose "C".
Remove the front half bushes in the following

way:
BOSS 332
• Remove the cover and manually extract the two
half bushes.
5 - Pag. 14 / 33
BOSS 545/551
• Remove the cover, fully open the two half
bushes by manually turning the shaft "A" and
extract the lower bush
• Close the remaining half bush by working the
shaft "A" again and extract it.
For BOSS 332 only

• Remove the internal sleeve.
• If necessary, remove the lathe spindle liner and

install another one suitable for the diameter of
the guides.
5 - Pag. 15 / 33
Install front half-bushings suitable for the bar in

the following way:
BOSS 332
• Insert the two half bushes and place the cover.
BOSS 545/551
• Insert the upper half bush, turn the shaft "A"
and insert the lower half bush.
• Fully close the half bushes and place the cover.
For BOSS 332 only

• Install a nose suitable for the guide channel.
5 - Pag. 16 / 33
Place the nose back as follows:
Fixed nose
• Install the nose "B" suitable for diameter of the
guides and the oil recovery device "A".
Telescopic nose
It is not necessary to change the whole telescopic nose assembly: only a few components
supplied as a spare part kit need to be changed.
• Compress the intermediate stage to the end of its stroke and remove the ring "C".
Extract the bush "D", the spring "E", the bush "F", the spring "G" and the sleeve "H".
• Remove the ring "L", replace the bushing M with another one suitable for the bar and
replace the ring "L".
• Replace the nose "H", the spring "G", the bushing "F", the spring "E" and the bushing "D".
The nose H and bushings "F" and "D" must be suitable for the bar.
• Replace the ring "C".
5 - Pag. 17 / 33
• Place the sleeve back into its seat.
For BOSS 332 only

If the "new" guide diameter is 13 mm, the
intermediate flag should be changed as follows.
• Remove the two rings "A", the spring "B" and
the flag
• Mount the 13 mm guide flag then replace the
spring and two rings.
5 - Pag. 18 / 33
• Install top guides first, and then lower guides, suitable

for the bar.
1 Fastening screw version

2 Quick fastening version
INFORMATION:
make sure that the lower guide screws have an
oil inlet hole.
• Choose the right collet for the bar; refer to the

manual "GUIDE CHANNELS - BAR PUSHERS -
REVOLVING TIPS - COLLETS- Selection manual".
INFORMATION:
contact IEMCA After-Sales service for
more information.
Legend:
1 "IEMCA" collet for pipes
2 "IEMCA" collet for bars
3 "IEMCA" collet for machined bars with remnant
front ejection
4 "SCHLENKER" collet for bars
5 Ring
6 Collet connection
5 - Pag. 19 / 33
CAUTION-PRECAUTION :
At every collet change (modell 381p, 381p..011,
381p..021 e 386p) it is necessary to install the
grub screw H and the counter screw L.
5 - Pag. 20 / 33
CAUTION:
the collet outside diameter should be at
least 0.5 mm smaller than the bar-pusher
outside diameter.
• Install the collet in the bar-pusher and make

sure that the rings are riveted in their special
recesses to prevent accidental collet unscrewing
from its connection.
INFORMATION:
The picture shows a generic example of
collet assembly.
• Install a suitable bar pusher support in relation

to the diameter of the bar pusher.
A Guides with Ø=13÷46

B Guide with Ø=52
1 Support
2 Spacer
5 - Pag. 21 / 33
• Install the 1st feeding carriage into its seat.
• Bring the 1st feeding carriage to its backward

stroke limit and fit the bar pusher.
• Move the bar-pusher forwards past the clamps

area.
5 - Pag. 22 / 33
• Close the guard.

• On the keyboard press the two blue buttons
and the guides closing button simultaneously:
now close the guides.
• Bring the bar pusher to its backward limit stop

by means of the keyboard.
The upper surface of the intermediate flag must

be flush with the lower guides; proceed as follows
to obtain adjustment:
• Open the guides by means of the keypad,
pressing the two blue buttons and the guides
opening button simultaneously.
5 - Pag. 23 / 33
Open the guard and proceed as follows:

• Loose the screw, adjust the flag position and
tighten the screw.
• Close the upper guides.
• Move the bar-pusher forwards and backwards

in the flag area to make sure that its stroke is
not hindered.
5 - Pag. 24 / 33
5.3.2 Clamps - Replacement
Clamp replacement becomes necessary when the

new bars to be machined have a different profile
from the previously machined bars (e.g. when
changing over from round bars to square or
hexagonal bars). Contact IEMCA after-sales
service for more information.
Proceed as follows to replace the clamps:
• With the feeder powered off and the
compressed air supply disconnected, close the
clamps manually.
• Open the upper guides.
• Manually lift the lower lever and replace the

clamp. Remove the intermediate flag if
necessary (see paragraph 5.3.1).
5 - Pag. 25 / 33
• Unscrew screws "A" and change the clamp.

• Restore the initial conditions of the bar feeder.
5 - Pag. 26 / 33
5.3.3 Bar guide plates and bar selectors - Adjustment
Preliminary procedure
• Close the upper guides (sensor "A" must be

energized)
• Make sure that the bar selectors are lower than

the magazine surface.
• Prepare two bar remnants having a length of
1200 mm.
5 - Pag. 27 / 33
Adjustment of the bar guide plates

• Loosen the handle "A", lift the plate and
tighten the handle "A"; repeat this operation on
all the plates.
• Feed two bars to the magazine, loosen the
handle "A" and drop the plates which will stop
against the bars.
• If the bars are round or hexagonal, make sure

that a little clearance is left between the plate
and the bars. The clearance must be 3÷8 mm
for square bars.
• Tighten the screws "A" on all plates.
5 - Pag. 28 / 33
Adjusting the bar selectors
Make the adjustment as follows.
• Use screw "B" to adjust the transverse position

of bar stop "A" so that selectors "C" lift just
one bar.
• Open the upper guides; the first bar must be

dropped into the guides, while the second bar
should be retained in the magazine until the
next bar closure.
5 - Pag. 29 / 33
5.4 CAM BOX - TIMING
If the feeder is equipped with a cam box, each cam should be timed to its own microswitch. The
timing procedure is as follows.
MICROSWITCH FUNCTION
S90 - Bar feed enabling

It controls the bar feeding motor start/stop. It must be operated at each collet opening. In
addition, it also controls operation of the bar/headstock synchronizing device.
S91 - Bar change-over enabling

It signals lathe collet opening/closing to the feeder.
It determines the camshaft stop position at bar end.
S92 - Feed stop enabling

Only used in sliding headstock lathes. It disables the feeding thrust during any operations
requiring headstock return with a closed collet.
S99 - Camshaft stop

It determines the camshaft stop position when there is no thread (connected in series with a
microswitch or relay located on the lathe).
5 - Pag. 30 / 33
CAM SETTING
LATHE CAM COMPLETE CYCLE
PHASE HEADSTOCK
PHASE COLLET LATHE
FEEDER CAM COMPLETE CYCLE
PHASE MICROSWITCH
S90
PHASE MICROSWITCH
S91
PHASE MICROSWITCH
S92
A STROKE G CLOSED
B FEED H OPEN
C FORWARD STOP L CLOSED
D RETURN M DISABLED
E BACKWARD STOP N ENABLED
F HEADSTOCK RETURN WITH CLOSED COLLET IF REQUIRED FOR SPECIAL OPERATIONS
5 - Pag. 31 / 33
Microswitches S90 and S91

• Rotate manually shaft "A" up to a distance of 10° approx. from the collet opening, then
"S90" microswitch cam until wheel "B" is released.
• Turn shaft "A" until the collet opens.
• Turn "S91" microswitch cam to release the wheel.
• Rotate shaft "A" until the collet closes.
• Turn the cam to lift "S91" microswitch cam.
• Rotate shaft "A" of 10° approx., then lift "S90" microswitch wheel.
INFORMATION:
"S90" and "S91" microswitch wheels
must lower when the headstock is in a
forward position and lift when the
headstock is backwards, in any case
before the following feeding.
5 - Pag. 32 / 33
Microswitch S92
• Rotate manually shaft "A" until the headstock
starts its return stroke with closed collet.
• Release "S92" microswitch wheel.
• Continue rotation until the headstock has
completed its return stroke.
• Lift wheel "S92".
Microswitch S99
When the threading tool starts its return stroke,
lower "S99" microswitch wheel and lift it before the
stroke is over.
Should microswitch "S99" be fitted on lathe, setting
adjustments are to be performed on lathe cam.
GENERAL REMARKS
• Microswitch activation can be either delayed or
advanced through screw "C".
• Whenever servicing the camshaft, disconnect the cam box, according to the following
procedure:
- loosen clamp "D" and unscrew sleeve "E";
- service the lathe camshaft;
- screw sleeve "E" and tighten clamp "D";
- should shaft "F" be out of phase, loosen sleeve "G" screws, rotate it and tighten the
screws.
5 - Pag. 33 / 33
6 - USE AND OPERATION BOSS 332/545/551 E-volution GB
INDEX
6.1 DESCRIPTION OF THE CONTROLS ............................................................................2
6.2 DESCRIPTION OF KEYBOARD CONTROLS..................................................................4
6.3 LUMINOUS INDICATOR - SIGNAL DESCRIPTION .......................................................6
6.4 BARS TO BE MACHINED - CHARACTERISTICS AND PREPARATION .............................7
6.4.1 BAR STRAIGTHNESS - Measuration ...........................................................................9
6.5 FEEDER SET-UP AND AUTOMATIC CYCLE START.....................................................11
6.5.1 Bar magazine - Filling.............................................................................................12
6.5.2 Lubrication oil - Flow adjustment ............................................................................13
6.5.3 Automatic cycle start..............................................................................................14
6.5.4 Guide channel opening/closing procedure................................................................15
6.5.5 Cycle actuation mode in the STEP BY STEP function.................................................16
6.6 FEEDER STOP........................................................................................................16
6.7 AUTOMATIC CYCLE START AFTER MANUAL CYCLE OPERATIONS .............................17
6.8 AUTOMATIC CYCLE START - RESUMING WORK AFTER POWER-OFF .........................17
6.9 MACHINING CHANGE - QUICK GUIDE ..............................................................18
6.9.1 Machining type change with guide change-over .......................................................18
6.9.2 Machining type change without guide change-over ..................................................19
6 - Pag. 1 / 19
GB 6 - USE AND OPERATION BOSS 332/545/551 E-volution
6.1 DESCRIPTION OF THE CONTROLS
INFORMATION:
from the hand-held keyboard it is possible to start automatically the bar feeder,
even when lathe 'MAN/AUT' signal is in Manual mode.
INFORMATION:
When Automatic mode is on, the bar feeding is possible only when lathe
'MAN/AUT' signal is in Automatic mode.
INFORMATION:
Pressing Manual mode button it is possible to prevent the bar feeder automatic
start by the lathe.
6 - Pag. 2 / 19
The illustration shows the positions of both the electrical controls and hand-held keyboard "1".
2 MAIN SWITCH: turns the power supply on and off.

- Position 0 (OFF) the machine has no power supply.
- Position I (ON) the machine has power supply.
3 HALF-BUSHING OPENING AND CLOSING BUTTON (white light)
- During the "Manual" mode, when the bar feeder is in the required position, the half-
bushings will close when this button is pushed. If pushed again, the half-bushing will
open.
- During the "Automatic" mode, if pushed, the half-bushings will open and close, according
to the selected sequence. If pressed again, the half-bushings will remain open during the
entire operating cycle.
4 BAR FEEDER STOP BUTTON (red): to stop the bar feeder and to reset "Errors".
5 EMERGENCY STOP BUTTON: this button stops the bar feeder in an emergency situation. To
restart, first you must manually unlock the button
6 BAR FEEDER START BUTTON (green light): to start the bar feeder, hold down the button
until the button itself lights up.
7 REMNANT DETECTION DISABLING BUTTON (green light)
Press the button to feed a "new " bar without the detection of bar remnant in the bar pusher
collet.
6 - Pag. 3 / 19
6.2 DESCRIPTION OF KEYBOARD CONTROLS
1 Start buttons: opposite buttons that when

pushed together will start some procedures.
Press the two buttons, and at the same time, the
key corresponding to the required function.
2 Selects the automatic mode.
3 Stops the bar feeder: to restart you must
manually un-lock the button.
4 Selects the keyboard modes:
- in the position; the "messages display"
mode is selected.
- in the position the "parameters display"
mode is selected.
5 Multifunction
- Allows you to scroll the page upwards.
- Moves the cursor upwards.
- Increases the preset data programming of
date and time, by one unit.
6 Selects the manual mode.
7 Selects the semi-automatic mode.
Push to select, press again to unselect.
8 Multifunction
- Selects the previous parameter.
- Moves the cursor towards the left.
9 Starts "step-by-step" movement of an operation
cycle: every push of the key initiates a step in
the cycle.
10 Multifunction
- Sets the font.
- Starts and turns off the oil pump.
Push to start the pump and push again to turn it off.
11 Multifunction
- Number setting.
- Loads the programme from the PLC (entering default settings in the parameters).
12 Multifunction
- Number setting.
- Moves the bar pusher to a high speed.
13 Multifunction
- Allows the downwards scrolling of the page.
- Moves the cursor downwards.
- Decreases the programming mode of date and time by one unit
14 Multifunction
- Selects the next parameter
- Moves the cursor towards the right.
15 Lifts and lowers the bar selectors (LED illuminated when selectors are at their "down"
position).
6 - Pag. 4 / 19
16 Multifunction
- Number setting.
- Opens the guide channels.
Hold down the two start buttons and then the
key; release the two buttons and the key only
when the movement has terminated.
17 Multifunction
- Number setting.
- Moves the bar pusher to a high speed.
18 Multifunction
- Number setting.
- Sets the carriage movement motor.
During the daily use of the bar feeder this
function must never be used.
19 Multifunction
- Number setting.
- Moves the bar pusher to a low speed.
20 Multifunction
- Number setting.
- Resets the "BAR FEEDER ZERO SETTING" of
the carriage.
Hold down the two start buttons and then the
* key; release the two buttons and the key
when the carriage starts moving towards the
"BAR FEEDER ZERO SETTING".
21 Multifunction
- Number setting.
- Closes the guide channels.
Push the two start buttons and then the * key; release the two buttons and the key only
when the movement has terminated.
22 Goes to the MAIN MENU.
23 Multifunction
- Number setting.
- Recalls the cursor.
24 Multifunction
- Interrupts the selection mode.
- Resets the values held before the modifications, which were not confirmed.
25 Confirms the data entered.
26 Sets the 'point'
6 - Pag. 5 / 19
6.3 LUMINOUS INDICATOR - SIGNAL DESCRIPTION
BLINKIGN ORANGE LIGHT; the bar feeder magazine cover is

open.
BLINKING GREEN LIGHT; it indicates that the bar feeder is

in the automatic mode.
BLINKING RED LIGHT; signals that the bar feeder is not

operating, or that it is in the manual mode. (OPTIONAL)
BLINKING BLUE LIGHT; signals that the bar feeder is

carrying out the bar change.
FIXED BLUE LIGHT; signals that the PLC battery is
exhausted. (OPTIONAL)
6 - Pag. 6 / 19
6.4 BARS TO BE MACHINED - CHARACTERISTICS AND PREPARATION
CAUTION:
do not feed bars having different sizes than the manufacturer's prescribed sizes.
clean the bar surface before loading bars.
Table 1. Maximum bar length
Model Version Max. length mm (ft)

21 2080 (6,8)
BOSS 332 32 3200 (10,5)
BOSS 545
BOSS 551 37 3740 (12,2)
44 4400 (14,4)
INFORMATION:
Bar must not present a straightness defect above 0.5 per 1000.
6 - Pag. 7 / 19
Please find herewith some advice to optimise the bar feeder performances.
Usually barstocks do not need any preliminary operations to be carried out on ends,
nevertheless to obtain the best results when loading them, it is advisable to chamfer them.
SOLID BARS
Check that there is not too much rag on bar head,
which might hinder insertion in the lathe collet.
Check that there is not too much rag on bar rear
end, which might hinder insertion in the bar-pusher
collet. In any case, to improve operation during this
phase, we advise to chamfer the bar as shown in
the figure.
If bars with front remnant ejection have to be

machined, we advise to chamfer the bar rear end as
shown in the figure.
If bars have to be machined having a diameter

equal to or only slightly smaller than the bar-pusher
diameter, bar rear ends should be machine-turned;
diameter "D" should be suitable for the collet size
installed in the bar-pusher.
PIPES
If pipes have to be machined, their rear ends
should be chamfered as shown in the figure.
6 - Pag. 8 / 19
6.4.1 BAR STRAIGTHNESS - Measuration
The bar vibrations are partially caused by the condition of the bar itself: in case the bar is not
perfectly straight, this can cause vibrations.
Round bars
As stated also in the UNI-10233/2 regulation, the
bar straightness can be measured by positioning
the bar on two V-supports and control its
straightness. In that case, the measurement can
be carried out as shown in the figure.
It is necessary to rotate the bar on itself and
measure the three indicated sections. In this
case the S-max value (difference between
maximum and minimum reading on the
comparator) should be interpreted as follows:
S max Quality
< 0,25 mm Good
0,25 < S max < 0,5 mm Mediocre
> 0,5 mm Problematic
In order to obtain a reliable value it is necessary to repeat measurements on the whole bar
length by positioning it on a series of supports at a distance of 500 mm from each other and
comparing the different values between prisms.
INFORMATION:
Obviously, bar straightness is proportional to the rigidity of the material and to
the number of revolutions (RPM) the lathe is operated at. highly The lack of bar
straightness highly influences the maximum number of revolutions reachable:
the bigger the diameter the greater the influence. The data concerning bar
straightness do not absolutely refer to local inflection and/or deformation that
the bar shall not absolutely show. Instead, they refer to the bar uniform
curvature.
INFORMATION:
For efficient operation of the feeder the use of rolled bar stock is not
recommended.
6 - Pag. 9 / 19
Hexagonal, square and section bars
For non-round bars, insert some bushings on the

bar to be controlled.
Position 2 bushings on the 2 V-supports.
In that case, the measurement can be carried out
as shown in the figure.
Rotate the bar on itself and carry out the
measurement on a bushing external to the two V-
supports.
6 - Pag. 10 / 19
6.5 FEEDER SET-UP AND AUTOMATIC CYCLE START
The following list is a sequence of feeder set-up and automatic cycle start operations required if
the feeder has to be started up for the first time.
• Perform the software parametering (refer to the "Push-button panel instruction manual")
• Carry out feeder set-up according to the bar to be machined (paragraph 5.3.)
• Prepare the bars to be machined (paragraph 6.4.).
• Feed bars to the magazine (paragraph 6.5.1).
• Adjust lube oil flow (paragraph 6.5.2).
• Start the automatic cycle (paragraph 6.5.3).
6 - Pag. 11 / 19
6.5.1 Bar magazine - Filling
CAUTION:
do not manually lift loads with weights
exceeding those prescribed by the
applicable regulations in force; ask for
another worker's help if necessary.
CAUTION:
wear personal protections according to
the regulations in force.
Follow these instructions to load bars:

• open the upper guard;
• place bars against the guard "A" and close the

upper guard.
6 - Pag. 12 / 19
6.5.2 Lubrication oil - Flow adjustment
Oil flow in the guides and bush-holder device is

automatically controlled during the feeder automatic
cycle.
The pump is started after the feeder has completed
bar change-over; it is stopped when the bar-pusher
approaches the bush-holder device.
Oil flow should be adjusted according to bar
diameter and profile through the valve located
upstream from the installation.
• Adjust oil flow in the bushing holder device as

well.
6 - Pag. 13 / 19
6.5.3 Automatic cycle start
• Power the lathe on.

• Turn the main power switch to the position I (ON).
• Press to start the bar feeder.
• Press to select the manual mode.
• Carry out a "BAR FEEDER ZERO SETTING" in the
following way:
press the start buttons plus , if the top guides
are not closed, the bar feeder will not complete a
"ZERO SETTING"; messages are displayed
describing the operations to carry out in order to
bring the top guides to the required position.
After carrying out the required operations, press
the start buttons plus .
• Enter the parameter values (refer to the "Push-
button panel instruction manual" ).
• Press to move the bar fore end closer to the cutting tool.
To start machining, press , when the lathe collet is closed. In this way, you will obtain
automatic bar feeding until bar running out or according to the selected program.
• Empty the remnant collection box during machining. Lift the remnant box over the tank and
pull it off.
CAUTION:
do not manually lift loads with weights exceeding those prescribed by the
applicable regulations in force.
ATTENTION:
Keep hands out of remnant drop area after the remnant box has been pulled off.
CAUTION:
Place the box back under the remnant outlet.
6 - Pag. 14 / 19
6.5.4 Guide channel opening/closing procedure
The following instructions concern guide

channel opening and closing in the
manual function.
OPENING PROCEDURE
Open the guide channels by pressing the
start buttons plus ; if the carriage
"A" is located in the area beyond the
clamps (area "B"), the guide channels
will open immediately. If the carriage is
located in the area before the clamps
(area "C"), the guide channels will only
open after the carriage has
automatically moved to the "BAR
FEEDER ZERO SETTING" position.
CLOSING PROCEDURE
If the carriage "A" is located in the area
beyond the clamps (area "B"), close the
guide channels by pressing the start
buttons plus .
If the carriage is located in the area before the clamps (area "C"), move it to the "BAR FEEDER
ZERO SETTING" position by pressing any one of the following keys: .
When the carriage reaches this position, the displayed message

will be: "Carriage to back limit stop"
Close the guide channels by pressing the start buttons plus

.
6 - Pag. 15 / 19
6.5.5 Cycle actuation mode in the STEP BY STEP function
Introduction
This mode can be used for many reasons, as for instance:
• to check a complete bar change cycle;
• to check the bar feeder mechanics;
• to load a single bar with the intent of checking the facing;
• eccetera.
Procedure
• Press to start the bar feeder.
• Check that the bar feeder is under closed guide channel conditions.
• Press plus to select the semiautomatic function.
• Press , the bar feeder performs the first step.
• Press , the bar feeder performs the second step, and so on.
6.6 FEEDER STOP
FEEDER EMERGENCY STOP
CAUTION:
if the emergency stop is used during lathe machining, before resuming work
make sure that the sudden stop has not created any hazardous condition (e.g., if
the tool was cutting chips, move the tool away from the workpiece before
restarting the lathe).
• To stop the feeder in an emergency, press an emergency push-button, either that of the
lathe or that of the feeder.
FEEDER STOP AT WORK END
CAUTION:
do not use emergency buttons for normal machine stop.
• Complete the operations in your work schedule.

• Stop the feeder by pressing the button .
• Stop the lathe.
• Turn the main power switch to the position O (OFF).
6 - Pag. 16 / 19
6.7 AUTOMATIC CYCLE START AFTER MANUAL CYCLE OPERATIONS
• If the bar-pusher has been moved while electric power was disconnected, a "BAR FEEDER
ZERO SETTING" should be performed in the following way:
press the start buttons plus if the upper guides are not closed, the feeder will not
perform "BAR FEEDER ZERO SETTING"; messages are displayed concerning the operations to
carry out in order to bring the guides to the required position.
After carrying out the required operations;
• press the start buttons plus .

• Check that the bar is in the required position in the lathe collet and that the collet is closed.
• Press to select the automatic mode; the feeder will wait for an "OPEN COLLET" signal
from the lathe.
6.8 AUTOMATIC CYCLE START - RESUMING WORK AFTER POWER-OFF
IF THE BAR-PUSHER HAS BEEN MOVED WHILE ELECTRIC POWER WAS DISCONNECTED
• Press to start the bar feeder
• Press to select the manual mode.
• Press the start buttons plus to perform "BAR FEEDER ZERO SETTING".
• Move the bar in the lathe collet to the required position and make sure that the collet is
closed.
• Press .
IF THE BAR-PUSHER HAS NOT BEEN MOVED WHILE ELECTRIC POWER WAS
DISCONNECTED
• Press to start the feeder
• Make sure that the lathe collet is closed.
• Press .
6 - Pag. 17 / 19
6.9 MACHINING CHANGE - QUICK GUIDE
The purpose of this paragraph is to provide the operator with a quick guide to the operations
required for machining type change (either with or without guide change-over). The relevant
information is contained in the paragraphs listed below and then described.
6.9.1 Machining type change with guide change-over

6.9.2 Machining type change without guide change-over
6.9.1 Machining type change with guide change-over
• Choose a guide diameter suitable for the bar diameter to be machined (paragraph 5.3.).
• Replace the guides, the half bushes, the bar-pusher and the collet (paragraph 5.3.1);
- remove the bar-pusher and the small pusher truck ;

- remove the lower guides first and then the upper guides;
- remove the bar-pusher support;
- remove the front nose;
- remove the half bushes;
- remove the lathe spindle liner if necessary;
- install a new set of parts by reversing the order of the above operations;
- mount a collet suitable for the "new" bar in the bar-pusher;
- insert the bar-pusher in the guides;
- adjust the intermediate flag position.
• Change the clamps if necessary (paragraph 5.3.2).

• Adjust the bar guide plates and bar selectors (paragraph 5.3.3).
• Place the bar in the guides and adjust the clamps (paragraph 5.3.4).
• Check all the working parameters in the keyboard.
• Prepare the lathe for the new type of machining
• Start the automatic work cycle (paragraph 6.5.3).
6 - Pag. 18 / 19
6.9.2 Machining type change without guide change-over
• Replace the half bushes and collet (paragraph 5.3.1)

- remove the bar-pusher;
- remove the half bushes;
- mount the new half bushes;
- mount a collet suitable for the "new" bar in the bar-pusher;
- insert the bar-pusher in the guides;
• Change the clamps if necessary (paragraph 5.3.2).

• Adjust the bar guide plates and bar selectors (paragraph 5.3.3).
• Place the bar in the guides and adjust the clamps (paragraph 5.3.4).
• Check all the working parameters in the keyboard.
• Prepare the lathe for the new type of machining
• Start the automatic work cycle (paragraph 6.5.3).
6 - Pag. 19 / 19
7 - BAR FEEDER MAINTENANCE BOSS 332/545/551 E-volution GB
INDEX
7.1 MAINTENANCE - GENERAL RULES ......................................................................2
7.2 SCHEDULED MAINTENANCE ..............................................................................3
7.2.1 Revolving tip and collet - Check ................................................................................3
7.2.2 Lubricating oil - Level check......................................................................................4
7.2.3 Lubricating oil - Change............................................................................................5
7.2.4 Guide opening screw - Greasing................................................................................6
7.2.5 Air filter unit - Check ................................................................................................6
7.3 AXIAL DISPLACEMENT DEVICE - USE .................................................................7
7 - Pag. 1 / 7
GB 7 - BAR FEEDER MAINTENANCE BOSS 332/545/551 E-volution
7.1 MAINTENANCE - GENERAL RULES
DANGER - WARNING:
carry out machine maintenance and cleaning while the machine is off.
Regular cleaning and maintenance are critical to ensure smooth operation and longer machine
service life.
It is recommended to regularly and effectively clean the machine, its accessories and work area,
which also increases operator's safety.
Do not use petrol or solvents which would damage the painted and transparent parts, the cable
sheaths etc.
INFORMATION:
oxidation can damage metal parts and electric equipment.
To protect the bar feeder when you expect not to use it for long periods of time, disconnect it
from mains voltage and from compressed air supply and cover it with a suitable protective
sheet.
Any protection used should not be fully closed or sealed at the base; it should have ventilation
holes to make sure that air within the envelope cannot condense due to lack of circulation.
7 - Pag. 2 / 7
7.2 SCHEDULED MAINTENANCE
Table 1. Scheduled maintenance
Frequency
Operation to carry Hours
Bar feeder part Every
out Regularly Cycles
200 1250 2500 year
Revolving tip and collet Wear check •

Half-bushing Wear check •
Oil level check •
Lubrication system
Oil change •
Guides Repair and cleanness •
check
Guide opening screw Greasing •
Oil recovery device Wear check •
brushes
Wear control •
Drive belt
Tension check •
Guide opening belt Wear check •
Bar/headstock
Wear check 5000
synchronizing device (*)
Air filter Check •
PLC battery Replacement •
Safety devices Check operatio (see •
“safety devices”)
(*) Only if installed.
7.2.1 Revolving tip and collet - Check
• Remove the bar-pusher as described under

paragraph 5.3.1
• Check that the revolving tip "A" can turn freely
without too much backlash.
Also check the good state of repair of collet "B".
7 - Pag. 3 / 7
7.2.2 Lubricating oil - Level check
CAUTION:
wear personal protections according to the
regulations in force.
• Wait until the bar feeder has been off for at least 6
hours.
• Check the level by means of the "A" indicator.
For any topping up, pour the oil directly into the base
Model Oil type

BOSS 332 Classe C – CKB 100
BOSS 545/551 Classe C – CKB 150
7 - Pag. 4 / 7
7.2.3 Lubricating oil - Change
CAUTION:
INFORMATION:
store spent oil in special containers to be delivered to companies specialized in
pollutant disposal and storage. Do not pollute the environment.
• Drain the tank using an auxiliary pump. Clean the tank bottom and pump suction system.
• For loading, pour the oil directly into the tank and check its level by means of the "A"
indicator.
Model Oil type Quantity (l)

BOSS 332 Classe C – CKB 100 57
BOSS 545/551 Classe C – CKB 150 57
7 - Pag. 5 / 7
7.2.4 Guide opening screw - Greasing
• Open the upper guard and carry out greasing.
7.2.5 Air filter unit - Check
FILTER A
• Make sure that cup "B" is not full of condensate.
If need be, bleed the condensate by valve "C".
• Check the pressure switch adjustment, see
paragraph 5.2.2.
7 - Pag. 6 / 7
7.3 AXIAL DISPLACEMENT DEVICE - USE
• If the feeder is fixed to the bar, release it.

Disconnect any installed devices (e.g. the
bar/headstock synchronizing device, the cam
box, the camshaft release device etc.).
• Remove the eight screws "A".
• Insert the (supplied) rod "B" in its special hole,

turn the shaft "C" and insert the (supplied) pin
"D".
• Cause the bar feeder to slide backwards. Be
careful not to damage any connection wires
(e.g. the lathe interface power lead, the
camshaft disengagement device lead, the hand-
held keyboard lead, the pneumatic connection
cable, etc).
• Carry out all lathe maintenance operations.
• Cause the bar feeder to slide forwards and
restore its initial conditions.
7 - Pag. 7 / 7
8 - TROUBLES - CAUSES - CURES BOSS 332/545/551 E-volution GB
INDEX
8.1 GENERAL FAULTS .............................................................................................2
8.2 BAR MAGAZINE - Faults ....................................................................................2
8.3 INSERTION IN THE COLLET - Faults ...................................................................3
8.4 BAR FEEDING - Faults .......................................................................................3
8 - Pag. 1 / 3
GB 8 - TROUBLES - CAUSES - CURES BOSS 332/545/551 E-volution
8.1 GENERAL FAULTS
TROUBLE CAUSES CURES

No power Check the electric connections
Open guard Close the guard
The bar feeder will not start Emergency systems on Disconnect the emergency devices
Motor thermal switch tripped Reset the motor overload cut-out
with the special push-buttons.
The bar feeder has been reset No lathe signal Check electric connection to the
but the automatic cycle will not lathe
start
The pneumatic devices will not No air Check the air system
respond to controls
The pre-feed and feed suddenly Motor thermal switch tripped Reset the motor overload cut-out
stop with the special push-buttons
8.2 BAR MAGAZINE - Faults
PROBLEMS CAUSES REMEDIES

During the loading operation The bar contrast strips are Adjust the position of the contrast
the bar cannot be inserted into too low strips
the magazine
The first bar in the magazine The bar contrast strips are Adjust the bar contrast strips (see
fails to drop into the guides incorrectly adjusted chapter 5.3.3).
8 - Pag. 2 / 3
8 - TROUBLES - CAUSES - CURES BOSS 332/545/551 E-volution GB
8.3 INSERTION IN THE COLLET - Faults
PROBLEMS CAUSES CORRECTIVE ACTION

Collet diameter not suitable Change collet.
Bar fails to enter collet. for bar diameter.
Excessive rag on bar rear Trim rag before feeding.
end.
8.4 BAR FEEDING - Faults
PROBLEMS CAUSES CORRECTIVE ACTION

Difficult bar introduction into Bar feeder not aligned with lathe. Check and correct alignment.
lathe spindle
Difficult bar introduction into Excessive rag on bar rear end. Trim rag before feeding.
lathe collet
8 - Pag. 3 / 3
9 - PART REPLACEMENT BOSS332/545/551 E-volution GB
INDEX
9.1 FEED CHAIN - REPLACEMENT ............................................................................2
9.2 GUIDE OPENING BELT - REPLACEMENT .............................................................2
9.3 KEYBOARD BATTERY - REPLACEMENT ...............................................................3
9.4 PLC BATTERY - REPLACEMENT ..........................................................................4
9.5 RECOMMENDED SPARE PARTS ..........................................................................5
9.6 Machine Dismantling [qualification] ..........................................................................5
9 - Pag. 1 / 5
GB 9 - PART REPLACEMENT BOSS332/545/551 E-volution
9.1 FEED CHAIN - REPLACEMENT
Replacement of the feed chain is a highly complex operation; call IEMCA after-sales service.
9.2 GUIDE OPENING BELT - REPLACEMENT
• Open the guard by unscrewing the fastening

screws.
• Manually turn the pulley "B" and simultaneously

pull the belt all the way out.
• Place a new belt in the pulley "C", lead it into
the pulley "B" and turn the belt until it is fully
inserted.
• Re-close the previously opened guard.
9 - Pag. 2 / 5
9.3 KEYBOARD BATTERY - REPLACEMENT
Replace the battery at least every year, and when the following
message is displayed "KEYBOARD BATTERY EXHAUSTED":
INFORMATION:
failure to replace the battery can cause the calendar
- clock memory to be deleted.
• Disconnect power.
• Screw out the six screws and remove the two
half-shells.
• Remove battery A from its housing.

• Insert the new battery (type DURACELL DL2430).
DANGER - WARNING:
danger of battery explosion if the battery is
mounted with inverted polarity.
• Reassemble the two half-shells and screw down the six

screws.
• Reconnect mains supply.
INFORMATION:
Discard used batteries in appropriate waste containers. Avoid environment
pollution.
9 - Pag. 3 / 5
GB 9 - PART REPLACEMENT BOSS332/545/551 E-volution
9.4 PLC BATTERY - REPLACEMENT
Replace the battery at least every year, and when the following
message is displayed: "PLC battery exhausted"
INFORMATION:
when this message is displayed, the battery should
be replaced within one day, otherwise, the "PLC/NC
Software" data will be deleted.
• Unscrew cap "A"and pull out battery "B";

• Insert a new battery (AA 3.6 volts lithium-type
battery) and make sure that it is introduced
correctly, then tighten the cap "A".
9 - Pag. 4 / 5
9.5 RECOMMENDED SPARE PARTS
The heavy-wear parts or easily broken parts are listed below (this list refers to bar feeder
requirements for a two year's period of normal use).
Table 1. Original spares table
Model Code Name Characteristics Notes Qty

Tav.06 n.13 Feed chain 1
Spare Parts Book
Tav.06 n.12 Connection link 1
Spare Parts Book
32210401 Limit switch BERO 3RG4012- 1
0AG33 SIEMENS
32210004 Limit switch BERO 3RG4012- 3
0AG07 SIEMENS
BOSS 332 Tav.101-201 Bar-pusher Specify diameter 1
BOSS 545 Spare Parts Book and length
BOSS 551 Tav.100-200 Revolving tip Specify diameter 1
Spare Parts Book
Collet Specify inside and 1
outside diameter
38130001 Battery Battery 3 Volt Hand held and fixed 1
VARTA CR2032 kieyboards
38130009 Battery Battery 3,6 Volt Plc Arteco

1
9.6 Machine Dismantling [qualification]
This operation is to be carried out by specialized workers, according to the workplace safety
laws in force.
Do not disperse non-biodegradable items, lubricant oils and non-ferrous components (rubber,
PVC, resins etc.) in the environment.
Dispose of them according to the laws in force.
9 - Pag. 5 / 5
10 - LIST OF AFTER-SALES CENTERS GB
INDEX
10.1 LIST OF AFTER-SALES CENTERS...............................................................................2
10 - Pag. 1 / 3
GB 10 - LIST OF AFTER-SALES CENTERS
10.1 LIST OF AFTER-SALES CENTERS
Kitagawa Europe 7 Dolphin Industrial Phone ++44 1722 439721

UK : Fax ++44 1722 421071
Ltd. Estate, Southampton www.kitagawaeurope.com
Road
SP12NB Salisbury
IEMCA France Z.I. Des Grands Pres Tel +33 450 896960
FRANCE: Telefax +33 450 896135
145, Email :
rue Louis Armand
74300 Cluses
Hoßfeld GmbH Königsberger Straße 10 Tel. ++49 02351 / 80521
GERMANY: Fax ++49 02351 / 860442
(West - Nord-
Email :
Deutschl.)
D-58511 Lüdenscheid
Heyde Maschinen Albin-Trommler-Str. 3 Tel. ++49 037754 / 5090
GERMANY: Telefax ++49 037754 / 50920 - Email
(Neue Länder) Service D-08297 Zwönitz
:
Reimo Lobers Elektro-Mechanischer Tel. ++49 07621 / 69551

GERMANY: Fax ++49 07621 / 69491
(Süd-Deutschl) Betrieb Email :
Rebgartenweg 5/1
D-79576 Weil am Rhein
IEMCA S.p.A. Via Granarolo, 167 Tel. 0546 / 698208
ITALY: Fax 0546 / 698290
I-48018 Faenza (RA) Email :
SWITZERLAND: IEMCA S.p.A. Via Granarolo, 167 Tel. 0546 / 698208
(Canton Ticino ) Telefax 0546 / 698290
I-48018 Faenza (RA) Email :
Kenson Component Box,114 Phone ++46 322 637890

SWEDEN Fax ++46 322 633367
AB 44139 Alingsaes E-mail: - www.kenson.se
SWITZERLAND: BARSPEED Zone industrielle Tel. ++41 032 / 4892726

(Suisse Française) Telefax ++41 032 / 4892729
CH- 2607 Cortébert
TAIWAN GIMCO No9, 19th Road Taichung Tel. ++886-4-23596980
Telefax ++886-4-23586838
(ROC): Industrial Park - Email :
Taichung - Taiwan
R.O.C
IGM Nippon K.K. Tokio-To,Edogawa-Ku, Tel ++81 356058016
JAPAN: Telefax ++81 356058066
Nakakasai 7-31-15 E-mail:
Shimisu Bld 1th floor.
Zip code 134-0083
IGM DO BRASIL rua Melo Palheta 165 Phone +55 11 3801 3763
BRASIL: Fax +55 11 3801 3563
LTDA. CEP 05002030 Sao E-mail:
Paulo
Brasil
HYDROMAT INC. 11600 Adie Road Tel. ++314 6928388
U.S.A. Telefax ++314 6925179
CANADA : St. Louis, MO 63043 Email:
10 - Pag. 2 / 3
10 - LIST OF AFTER-SALES CENTERS GB
Tel 0086 21 64686020

CHINA (PRC): IGM of China Room 28F, Shanghai Fax 0086 21 64877987
Shiye Apartment No.38, E-mail:
North Cao Xi Road,Xu
Hui District, Shanghai
200030 China
10 - Pag. 3 / 3

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AUTOMATIC BAR FEEDER WITH

Rel. 1 Date 24/06/03 Cod. 346005400

COMPILER: Ragazzini Gian Luca

ON APPROVAL: Bevini Claudio

ADDRESS: Via Granarolo, 167 - 48018 Faenza (RA) - ITALY

Tel. 0546/698000 - Fax. 0546/46338 - 0546/46224

TYPE OF DOCUMENT: MANUAL FOR USE AND MAINTENANCE

PRODUCT: AUTOMATIC BAR FEEDER WITH HYDRAULIC SUSPENSION

MODEL: BOSS 332-545-551 E

1.1 TERMS OF WARRANTY.............................................................................................2

1.2 MANUAL PURPOSE...................................................................................................3

1.3 MANUFACTURER AND BAR FEEDER IDENTIFICATION................................................4

1.4 TECHNICAL ASSISTANCE .........................................................................................4

1.5 ANNEXES ENCLOSED ...............................................................................................4

Operations described in paragraphs showing this symbol, must be performed by qualified

1.1 TERMS OF WARRANTY

The product warranty is valid only if the bar loader is

1.2 MANUAL PURPOSE

In order to allow a quick search of contents, consult the descriptive index.

For a quick search of topics see the table of contents.

1.3 MANUFACTURER AND BAR FEEDER IDENTIFICATION

1.4 TECHNICAL ASSISTANCE

1.5 ANNEXES ENCLOSED

• Push-button panel instruction manual.

2.1 GENERAL BAR FEEDER DESCRIPTION.......................................................................2

2.2 OPERATING CYCLE ..................................................................................................4

2.3 SAFETY DEVICES .....................................................................................................7

2.4 SAFETY PLATES - LOCATION AND DESCRIPTION ......................................................9

2.5 VERSION DESCRIPTION .........................................................................................10

2.6 TECHNICAL SPECIFICATIONS .................................................................................11

2.6.1 Noise levels ...........................................................................................................20

2.7 FITTINGS - FOREWORD .........................................................................................21

2.7.1 Bush-holder device - Description .............................................................................21

2.7.2 Axial displacement device - Description ...................................................................22

2.8 DEVICE FOR SLIDING HEADSTOCK LATHES - FOREWORD .......................................23

2.8.1 Bar/headstock synchronizing device - Description.....................................................23

2.8.2 Telescopic nose - Description..................................................................................24

2.9 DEVICES FOR CAM LATHES - FOREWORD ...............................................................25

2.9.1 Headstock return device - Description .....................................................................25

2.9.2 Cam box - Description ............................................................................................25

2.9.3 Camshaft release device - Description .....................................................................26

2.1 GENERAL BAR FEEDER DESCRIPTION

A Magazine; where bars are stored.

2.2 OPERATING CYCLE

In the automatic operation mode, bar feeder

The bar-pusher A and remnant C are in their

The bar-pusher A and remnant C reach their

Clamps "D" close again to perform remnant "C"

Upper guides "H" open together with bar pusher

The small pusher truck "M" starts its stroke.

When the small pusher truck "M" completes its

The upper guides H are closed; the bar-pusher A

The clamps "D" close, the bar-pusher "A" moves

The bar-pusher "A" and bar "G" execute their facing

2.3 SAFETY DEVICES

2.4 SAFETY PLATES - LOCATION AND DESCRIPTION

A Danger of upper limb crushing.

2.5 VERSION DESCRIPTION