PFM 2002Flange Machine

Installation, Operations, and General Maintenance

Part Number 6Z5816

Copyright © 2001 Porter International, Incorporated. All rights reserved.

Porter and the stylized Porter logo are registered trademarks of Porter International, Inc.

Leggett & Platt and the stylized Leggett & Platt logo are registered trademarks of Leggett & Platt, Inc.

Global Systems Group and the stylized GSG triangle logo are registered trademarks of Gribetz International, Inc.

National Electric Code (NEC), is a registered trademark owned by the National Fire Protection Association, Inc.

Some illustrations used in this manual are provided courtesy of Pegasus® Sewing Machine Manufacturing Company, Limited.

Porter International, Inc.388 Newburyport TurnpikeRowley, Massachusetts 019691-978-948-8288

www.globalsystemsgroup.com

This manual may not, in whole or in part, be copied, photocopied, reproduced, translated, or converted to any electronic or machine readable form without prior written consent of Porter International, Inc.

Details herein are subject to change without notice.

Printed in the United States of America.

Part number 6Z5816, CD-ROM number 6Z5877

Table of Contents

Section 1

About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1How this Manual is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Terms and Visual Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2How to Get Additional Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Before You Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3How to Give Your Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Section 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Overview of Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warning and Caution Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Electrical and Pneumatic Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Using Personal Safety Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Securing Your Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Section 3

Installation and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Preparing the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Preparing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Installing the PFM 2002 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Grounding the PFM 2002 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Connecting the Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Checking the Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Connecting the Pneumatic Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Checking Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Performing an Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Making a Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Turning on Power and Activating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Section 4

Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17What is a PFM 2002 Flange Machine? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Overview of the PFM 2002 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Sewing Head Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Sewing Table Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Optional Equipment: EDS T-100 Air Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Section 5

Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Quick Start for Experienced Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25How Does a PFM 2002 Flange Machine Work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Operating the PFM 2002 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Preparing to Sew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Activating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Flanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Sewing a Thread Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Section 6

Sewing Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29What is a Chainstitch? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29What is a Looper? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Checking Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Looper and Needle Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Mounting the Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Mounting the Looper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Threading the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Making Tension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Adjusting Thread Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Testing Thread Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Adjusting Thread Take-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Adjusting Needle Thread Take-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Adjusting Looper Thread Take-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Adjusting Stitch Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Adjusting the Dead Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adjusting the Top Feed Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Adjusting the Presser Foot Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

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Table of Contents

Section 7

Timing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Setting the Needle Bar Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Setting the Safety Stitch Looper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Setting the Overedge Looper Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Setting the Overedge Looper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Timing the Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Setting the Spreader and Spreader Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Setting the Needle Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Setting the Safety Stitch Needle Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Setting the Overedge Needle Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Setting the Walking Foot Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Adjusting the Presser Foot Front or Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Setting the Top Feed and Presser Foot Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Setting the Lower Main Feed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Section 8

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Safety Procedures for Cleaning and Maintaining the PFM 2002 Flange Machine . . . . . . . . . . . 57Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Lubricating the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Filling the Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Replacing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Replacing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Working with an Automatic Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Lubricating Other Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Releasing Condensation from the Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Setting the Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Setting the Bottom Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Setting the Top Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Adjusting the Bottom Knife Left or Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Adjusting the Top Knife Left or Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Checking the Setting of the Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Replacing Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Replacing the Top Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Replacing the Bottom Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Sharpening Knives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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Section 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Electrical and Control System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Sewing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Mechanical Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Other Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Section 10

Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

ivPFM 2002

How this Manual is Organized About this Manual

1 About this Manual

Flange A strip of fabric sewn to the edge of a mattress cover and secured to the innerspring unit to prevent cover and materials from shifting.

This manual provides detailed information on how to install, operate, adjust, and perform general maintenance on the Porter International, Inc. PFM 2002 Flange Machine. It is designed as a tutorial and as a reference for everyday work.

This manual is intended for operators, maintenance technicians, and supervisory personnel who are familiar with industrial sewing machines and basic sewing principles. Please review this manual periodically.

The PFM 2002 Flange Machine arrives with the following documentation and tools:

� Installation, Operations, and General Maintenance Manual (part number 6Z5816)

� CD-ROM (part number 6Z5877)� Schematic diagrams

Looper A device used for making loops as part of stitch formation.

� Parts kit that includes two loopers, assorted screws, two knives (top and bottom), a spreader, a looper height gauge, and needles.

� Accessories kit that includes various tools to assist with lubrication and adjustments.

How this Manual is OrganizedSection 1. About this Manual, presents an overview of the manual and how to use it.Section 2. Safety, details important safety devices specific to the flange machine along with safe operating practices.Section 3. Installation and Setup, explains how to prepare the site for equipment installation along with step-by-step procedures for installing your flange machine.

Component An essential group of parts of a larger piece of equipment.

Section 4. Machine Overview, introduces the basic components of the flange machine.

NOTE: Installation and maintenance should be performed by qualified service personnel only.

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About this Manual

Section 5. Operating Procedures, offers a quick start for experienced operators and teaches step-by-step instructions on how to operate the flange machine for operators who are new to the flanging process.Section 6. Sewing Adjustments, gives detailed instructions for the sewing head.Section 7. Timing Procedures, gives detailed instructions for how to synchronize the components of the sewing head.Section 8. General Maintenance, discusses routine care and maintenance of the flange machine.Section 9. Troubleshooting, outlines specific troubleshooting situations.Section 10. Review, offers a series of questions in a self test format to help you master the knowledge and skills introduced in this manual.

This manual also includes an index.

Terms and Visual AidsTerms or words that may be unfamiliar to you or may be specific to the sewing industry are located in the sidebar next to the paragraph where they first appear. These terms are also helpful when translating the manual into other languages.

Visual aids in this manual may include photographs, drawings, or tables. Each one provides additional details or information.

Throughout this manual, Warning, Caution, and Note statements have been added to notify you of important information.

WARNING: Informs you of hazardous conditions which can cause serious bodily harm.

CAUTION: Informs you of conditions which can cause loss of material or damage to equipment.

NOTE: Explains additional or helpful information.

2PFM 2002

Terms and Visual Aids About this Manual

How to Get Additional HelpWe recognize that there may be times when you may need additional help. Porter International, Inc. is available to you Monday through Friday, 8:00 a.m. to 5:00 p.m., Eastern Time. Our skilled personnel are able to help you with mechanical, electrical, electronic, and computer questions.

There may be times when your specific problem may require more attention than our staff can deliver through telephone support. In this situation, our technical staff will assess your problem and, if necessary, travel to your site. Please be aware that certain fees apply. Contact the Porter International, Inc. service department manager at 1-978-948-8288 for specific information on fees and services.

Before You Call� Have you read this manual?� Have you referred the question to a supervisor or a qualified technician at

your site?� Do you have your customer identification number?� Do you have the machine�s serial and model numbers?� Is your telephone near the machine?

How to Give Your FeedbackWe�re interested in hearing what you have to say. Please let us know what you like in this manual, as well as what you don�t like. Tell us what you would like to see more or less of, or what you would like to see presented in a different way. We look forward to hearing from you.

FLANGE MACHINE3

How to Give Your FeedbackAbout this Manual

4PFM 2002

Overview of Safety Features Safety

2 SafetyBecause your personal safety is important to us, the PFM 2002 Flange Machine is designed with a full protection package. This package includes warning and caution labels and guards.

Overview of Safety FeaturesSafety features are visible guarding and warning devices which are affixed to, or are part of, a machine. These features are required on machinery that may be hazardous to operate and are designed to protect you from injury. A number of safety features are incorporated in the manufacture of the flange machine and provide the operator with protection against accidents. They are:

� Warning and Caution Decals� Guards� Electrical and Pneumatic Devices

Warning and Caution DecalsThe flange machine is clearly marked with decals as a reminder to observe safe operating procedures. Red decals indicate immediate danger. Special precautions are necessary.

Yellow decals advise of safety risks and good safety procedures, warn against potential hazards, and caution against unsafe practices.

You will find one yellow decal on the PFM 2002 Flange Machine. This decal is found on the control box, which is located beneath the sewing table.

Read and become familiar with the instructions on these decals. Failure to observe decal instructions can result in serious physical injury to workers or damage to property.

NOTE: Read and understand this entire section before you begin operating or maintenancing the PFM 2002 Flange Machine. These instructions contain important safety and operating information.

FLANGE MACHINE5

GuardsSafety

Figure 2.1 Yellow Caution Decal

GuardsSafety guards are barriers that prevent entry to dangerous mechanical parts, providing protection to the operator. The guards typically found on the PFM 2002 Flange Machine are the belt guard and the eye guard. Inspect these guards daily to ensure all hardware is present and securely fastened. Do not operate your machine without these safety guards properly installed. Never remove or defeat guards while the machine is in operation. Doing so may result in serious personal injury.

Figure 2.2 Belt Guard

6PFM 2002

Overview of Safety Features Safety

Figure 2.3 Eye Guard

Electrical and Pneumatic DevicesThe PFM 2002 Flange Machine uses 220VAC ±5%, alternating current, 3-phase or single phase, 15 amps. To ensure your safety during maintenance procedures and when you are away from the machine, always press the red OFF button located on the left side of the machine. Only qualified personnel should perform service to the electrical system.

PSI Pounds per square inch; a measure of air pressure.

Pneumatic power to the flange machine is supplied through a single connection. The main air regulator is located at the bottom of the pneumatic panel, which is mounted to the back right table leg under the sewing table. It is recommended that the main air regulator is set at 80 PSI (5.5 bars). See Section 3. Installation and Setup for more information.

Bars A metric unit of pressure equal to one million dynes (a unit of force) per square centimeter.

In the event that the pneumatic power falls below the recommended PSI, the machine head will operate poorly.

FLANGE MACHINE7

Electrical and Pneumatic DevicesSafety

Figure 2.4 Electrical and Pneumatic Devices

Personal SafetyPersonal safety is the action you take to ensure safe operation and maintenance of the flange machine. Only properly trained and authorized employees should operate or perform maintenance on this machine. The following list describes what you should and should not do while operating or performing maintenance on this machine.

� You should be physically able to operate the flange machine and be able to reach all emergency stops quickly.

� Do not operate the flange machine while under the influence of alcohol or any prescribed or other drug.

� Do not eat, drink, or smoke while operating the flange machine.Horseplay Rough or boisterous play; roughhousing.

� Do not indulge in horseplay.� Keep your hair short or tied back and always wear safety glasses. � It is also important that you are properly dressed. Do not wear loose

clothing, neckties, scarves, headgear, or jewelry.Debris An accumulation of loose material, trash, garbage, litter, or junk.

� Remove debris from the work area. Ensure that the area has proper clearance, and that no unauthorized people are near the machine.

� Do not leave tools or other unnecessary objects on the machine table while operating the machine.

� Do not lean against, climb, sit, stand, or crawl on or under the machine.� Keep hands and other body parts away from all moving parts.

8PFM 2002

Personal Safety Safety

Component An essential group of parts of a larger piece of equipment.

� Do not touch electrical and control components, except where indicated.� Locate and identify fire-fighting equipment, and know how to use it.� When handling needles, always grasp the head of the needle.� Do not place needles under or around the needle bar or on the table.� Do not reuse damaged needles. Dispose of needles in a closeable, puncture

resistant container.� Do not exceed 30 PSI (2 bars) when using compressed air for cleaning

purposes.� Do not use the air hose on any body parts or point it at another person.� Keep all manuals in a convenient, accessible location near the machine.

Figure 2.5 Needle Safety

Using Personal Safety ItemsPersonal safety items are attire specifically designed to protect you from injury while the flange machine is in operation. These items can include safety glasses, footwear, clothing, and particle masks (dust masks).

The following list describes the personal safety items you must use while operating the flange machine.

Metatarsal The top of the foot between the ankle and the toes.

� Sturdy, slip-resistant shoes or boots with adequate toe and metatarsal reinforcement. Do not wear sneakers.

� Impact-resistant safety glasses. Do not use tinted lenses. Do not remove prescription lenses.

� Wear a particle or dust mask when there are particles in the air that could cause the operator discomfort, allergies, or respiratory distress.

� Due to the nature of the sewing industry, static electricity may be present. Wear appropriate anti-static clothing to reduce static discharge. A fiber content of at least 50% cotton is preferred.

FLANGE MACHINE9

Securing Your Work AreaSafety

� Locate and identify fire fighting equipment. Inspect fire protection systems and equipment to ensure that they are in place, charged, and ready for use in the event of fire. Check with local authorities regarding approved fire detection devices for your location.

� Keep all operation and maintenance manuals in a convenient, accessible location near the flange machine.

Securing Your Work AreaThe following list describes what you need to do to secure your work area before operating the flange machine.

� Always keep your work area clean and dry.� Keep work area clear of all bags, containers, bundles, or excess materials.

OSHA Occupational Safety and Health Administration, a U.S. government agency.

� Ensure safe clearances for aisles and passageways. OSHA minimum distance is 3 feet or 1 meter.

� Secure all cables and hoses to avoid tripping and entanglement.� Locate and read all warning and caution decals.� Safely store loose tools, parts, or other foreign objects that can be in, on, or

near the flange machine.� Keep hand tools in a fixed location when the flange machine is in operation.

CAUTION: Never operate the flange machine with unauthorized or unsupervised personnel in the area.

10PFM 2002

Preparing the Site Installation and Setup

3 Installation and SetupThis section is intended for service technicians who have experience and training in electrical and electronic equipment installation.

Preparing the SiteTransformer A device used to convert a current from one voltage to another.

The PFM 2002 Flange Machine does not require extensive site preparation. A work area should be clean, level, structurally sound, and capable of supporting 100 pounds. Air drops and an electrical outlet for 220 VAC single phase must be accessible. (For overseas voltage differences, a transformer is optional.) Ensure that the flange machine has a clear work area of at least 3 feet (1 meter) around the entire machine.

Preparing the MachineThe PFM 2002 Flange Machine consists primarily of the sewing head and the sewing table. These are packed as separate units. Upon receipt of the flange machine, inspect it for any damage. Record any dents, scratches, or other damage. Inspect all parts after opening the containers. Confirm that all parts are shipped and undamaged. Report any damaged parts to the shipping company.

Installing the PFM 2002 Flange MachineThis section explains the procedures needed to assemble the machine. Although some tools, such as a 3mm Allen wrench and a crescent wrench, are necessary, the flange machine requires no special tools or installation procedures upon its arrival. The flange table and the sewing head are shipped together. The sewing head is packed in its own box and placed within the box containing the sewing table. The time needed for assembly is approximately thirty minutes.

Set up the flange machine using the following steps:

1 Place the flange machine in its permanent location allowing enough space for safe movement around it. Loosen the four bolts that attach the table to the skid. Remove the skid.

FLANGE MACHINE11

Installation and Setup

2 Open the shipping carton that contains the sewing table, and remove all packing material found on top of and around the machine.

3 Locate the box containing the sewing head. It is inside the shipping carton with the sewing table. Open the box and remove any packing material from the sewing head. Lift the sewing head from the box, and install it into the sewing table.

Synchronizer The synchronizer is used to position the sewing head needles up or down.

4 Attach the synchronizer to the handwheel and secure into position using a 3mm hex key.

5 Position the waste barrel to the output of the trim waste removal system by fitting the pieces together. Stretch the cover over the top of the container before operating the flange machine.

Flange Rack The flange rack holds the rolls of flange material. For more information, see Section 4. Machine Orientation.

6 Mount the flange rack assembly to the rear table legs using the two bolts provided.

7 Assemble the thread stand and position it into the hole provided. 8 Add oil to the sewing head and to the oil reservoir. For more information

about adding oil, see Section 8. General Maintenance.9 Thread the sewing head. Although the flange machine is pre-threaded at the

factory prior to shipping, you will need to tie the ends of the threads in the machine head with the ends of the threads from the thread cones. Pull the thread through until the new thread from the cones comes to the needle eye. For further detail, color coded threading guides are provided inside the front cover of the sewing head.

Grounding the PFM 2002 Flange MachineNEC® National Electric Code; establishes requirements for electrical wiring and equipment.

Before connecting the power source, you must properly ground the flange machine. To do this, identify the single ground wire leading from the synchronizer which is located on the right side of the sewing head. Attach the ground wire to the sewing head. For more information regarding proper grounding and wiring, refer to NEC® and local codes.

CAUTION: Do not try to pass the thread knots through the eyes of the needles. This could cause the needles to bend.

WARNING: Only qualified electrical personnel should perform grounding procedures. Be careful when installing ground connections. Failure to correctly do so may cause serious injury or even death.

12PFM 2002

Checking the Electrical Connection Installation and Setup

Connecting the Electrical PowerThe power requirement to run the PFM 2002 Flange Machine is 3-phase or single phase, 220 VAC with a minimum current load of 15 amps. To connect, plug the machine receptacle into the electrical outlet. The flange machine does not require any warm-up time.

Checking the Electrical ConnectionAn electrical power check should be performed after the flange machine has been installed.

Use the following steps to perform the electrical power check:

1 Ensure that the flange machine is properly grounded.2 Ensure that the flange machine is completely assembled and that the power

cord is undamaged and free from obstruction.3 Press the red OFF button located on the left side of the machine.4 Plug the machine receptacle into the outlet.5 Press the black ON button located on the left side of the sewing table.

Connecting the Pneumatic Power1 To connect the air lines to the sewing head, match corresponding numbers

printed on air fittings to each air line.

NOTE: Porter International, Inc. assumes no responsibility for damages or injuries related to improper wiring of the electrical source or wiring and grounding performed by unauthorized personnel. Damages to the PFM 2002 Flange Machine caused by improper wiring of the electrical source or wiring performed by unauthorized personnel will not be covered under the warranty.

WARNING: Only trained and authorized personnel may install the flange machine and check electrical connection and grounding. The machine contains high voltages that can cause serious injury or death.

CAUTION: Before activating the machine, be sure no tools or other unnecessary objects are on the sewing table, and that the work area is free of debris.

FLANGE MACHINE13

Installation and Setup

Pneumatic Power Energy for the machine�s parts, which is provided by compressed air.

2 Locate the pneumatic panel. When seated properly at the machine, this panel is located beneath the sewing table on the right side.

3 Attach the main air line to the main air regulator located at the bottom of the pneumatic panel.

4 Verify that the main air regulator is set at 80 PSI (5.5 bars).

Checking LubricationSight glass A window. Check the sight glass located on the front of the machine and fill the sewing head

with oil if needed. Fill the oil reservoir if needed. It is located near the top of theLinkage An assembly of parts linked together to transmit motion.

pneumatic panel, just below the linkage lubricator regulator. To check the oil

filter, the top cover must be removed. For more information on how to add oil and check the oil filter, see Section 8. General Maintenance. Suitable oil is included in the accessories kit shipped with the flange machine.

Performing an Initial CheckoutAfter installing the flange machine for the first time or after moving the machine to a new location, perform the following steps:

1 Remove all packing materials, tools, and other items from the flange machine.

2 Tighten and properly adjust all nuts and bolts. 3 Level all parts of the machine. 4 Verify that the sewing head contains the proper amount of oil.5 Verify that air pressure is available. Connect the air supply.6 Properly ground the machine.7 Connect the receptacle to the outlet.

The flange machine is ready for operation.

NOTE: Verify that the air lines are properly connected. Each air line has a number printed on it. Match the numbers on the air lines with the corresponding numbers printed on the air fittings. The air fittings are found at the top of the sewing head.

CAUTION: The PFM 2002 Flange Machine is not pre-lubricated at the factory. Oil must be added to the machine after it is received.

14PFM 2002

Making a Safety Check Installation and Setup

Making a Safety CheckBefore operating the PFM 2002 Flange Machine, walk around the perimeter and visually check for obstructions. Clear all moving parts and all surfaces of tools, equipment, fabric, and debris. Remove tools and unnecessary objects from the machine table. Ensure no unauthorized people are in the area. Always follow the principles outlined in Section 2. Safety.

Turning on Power and Activating the Machine1 Verify that the air supply source is open. Properly connect the air supply to

the main air regulator located on the pneumatic panel of the machine. 2 Locate the black power ON and red power OFF buttons. When seated

properly at the machine, these square buttons are located on the left side of the sewing table.

3 Press the black ON button.4 The flange machine is activated and ready to operate. It does not require

warm up time. For details on operating the machine, refer to Section 5. Operating Procedures.

FLANGE MACHINE15

Installation and Setup

16PFM 2002

What is a PFM 2002 Flange Machine? Machine Orientation

4 Machine OrientationThis section provides an overview of the PFM 2002 Flange Machine. Study this section to identify the basic components of the flange machine, their purpose, and how they function together.

What is a PFM 2002 Flange Machine?Serging Overedging a single ply of fabric to prevent the fabric from unraveling.

The PFM 2002 Flange Machine is a high speed flanger that is capable of serging and safety stitching edges of panels in addition to attaching the flange material. This flanger features an enhanced linkage design that provides automatic linkage cooling and lubrication. The feature that separates the PFM 2002 Flange Machine

Walking Foot Mechanism A mechanical bit with teeth that assists in the transport of material.

from all others is the unique walking foot mechanism that is patented exclusively by Porter International, Inc. (patent # 4,449,464; #5,309,854). The flange machine sews at a speed of up to 2800 revolutions per minute (RPM) at 3 to 3.5 stitches per inch and is capable of flanging materials from 3/8 inch (.95cm) to 6 inches (15.24cm) thick. This makes the PFM 2002 Flange Machine exceptionally suitable for flanging, serging, and safety stitching thick and heavy materials. These materials include mattress panels, mattress pads, and specialty goods such as automotive upholstery and luggage.

Safety Stitching A stitch formation that combines a row of chainstitch and a row of overedge that are sewn simultaneously.

Table 4.1 PFM 2002 Flange Machine Specifications

Specification Description

length 48� (121.92cm)

width 20� (50.8cm)

height 30� (76.2cm)

sewing speed 2800 rpm (at 100%)

stitch sizes 3 to 10 stitches per inch (SPI); factory setting is typically 3.5 SPI.

FLANGE MACHINE17

Sewing Head ComponentsMachine Orientation

Overview of the PFM 2002 Flange MachineThe primary components of the flange machine are the sewing head and the sewing table. Each of these units include several components, most of which are visible from one side of the machine.

Figure 4.1 Overview of Basic Components

Sewing Head ComponentsThe sewing head is the main component of the sewing machine and does the actual flanging. Needle thread and looper thread join together to stitch the flange material to the panel. The sewing head on this flange machine is a single compact unit, containing a number of features outlined in this section.

power requirements 220V, 3-phase or single phase, 15 amps380V, single phase, 10 amps; transformer is optional.415 - 480V, 15 amps; transformer is required.

air requirements 80 PSI (5.5 bars)

Specification Description

18PFM 2002

Overview of the PFM 2002 Flange Machine Machine Orientation

Figure 4.2 Sewing Head Detail

Walking Foot Mechanism

PFM 2002 Walking Foot This particular design is patented exclusively by Porter International, Inc. (patent # 4,449,464; #5,309,854).

The walking foot mechanism is a mechanical bit with teeth that assists in the transport of material. The motion of the mechanism imitates that of your foot as you walk. The teeth go up, move forward, come down to contact the material, then move in a backward motion to move the fabric as you sew. The presser foot holds the material when the walking foot is raising up and moving forward. When the walking foot moves downward, the presser foot is raised. The walking foot then feeds material through the machine.

Tensioners

The tensioners are the knobs that adjust the upper and lower thread tension. They control how tightly the thread is pulled when stitching. The upper thread tension must be balanced with the lower thread tension to form proper stitches. For locating the tensioners and applying the correct tensions, refer to Section 6. Sewing Adjustments and Section 7. Timing Procedures.

CAUTION: The many small components found within the sewing head are precision parts and should be adjusted by trained service technicians only.

FLANGE MACHINE19

Sewing Table ComponentsMachine Orientation

Thread Guides

There are a number of devices, called thread guides, that guide the movement of thread from the spool to the needle. These guides provide additional thread tension.

Needle Bar

The needle bar is an angled metal rod which holds the needle for sewing. As the machine sews, the needle bar moves up and down, raising and lowering the needle to pierce the panel.

Needles

The needles guide the top sewing thread. The parts kit includes a packet of the recommended 135x7 titanium #23 needles for regular sewing. For more information on needles, see Section 6. Sewing Adjustments.

Throat Plate

Throat Plate This component is commonly referred to as the needle plate.

The throat plate is the flat surface directly below the presser foot which supports the material as it is sewn. It is held in place by two screws. The throat plate has two holes for the needles to pass thread to the looper during stitching. Slots in the throat plate allow the lower feed dogs to pass through without interruption.

Cloth Guide

The cloth guide is the stainless steel frame around the bed or flat part of the sewing head. It allows the panel to move smoothly over the sewing head.

Sewing Table ComponentsThe second section of the flange machine is the table. It is assembled at the factory prior to shipping and has several components, most of which are already attached and require no assembly.

WARNING: Do not place fingers under the needle bar at any time. The needle bar moves at up to 2800 RPM.

WARNING: Do not attempt to replace a needle while the power is turned on; the flange machine might start unexpectedly.

20PFM 2002

Overview of the PFM 2002 Flange Machine Machine Orientation

Thread Stand

The thread stand is on the upper right corner of the sewing tabletop and has four round rods to hold four cones of thread. The thread stand requires assembly and attachment to the table.

Flange Cutter

The flange cutter is located on the tabletop, in front of the sewing head and comes attached to the table. This feature cuts the flange material. It is activated by pressing the small foot pedal to the right of the main sewing pedal.

Plunger

The plunger holds the flange material in place while the operator loads the panel. It is located under the flange guide. The plunger is activated automatically when the main sewing pedal is pressed downward with the heel of the foot.

Waste Remover System

The waste remover system is a vacuum generated by an air supply. It is assembled and connected to the machine at the factory. The sewing trim waste is removed as it travels through the pipe and is deposited into the waste container.

Figure 4.3 Waste Remover System

FLANGE MACHINE21

Sewing Table ComponentsMachine Orientation

Speed Control Dial

The external speed control dial is the small square box on the lower right corner of the tabletop. It allows the operator to control the sewing speed during the initial training period and enhances machine performance.

Flange Rack

The flange rack is located on the lower back side of the table. It is attached by two threaded rods through the back table legs and holds the rolls of flange material.

Control Box

This metal box is located under the tabletop and is mounted on the sewing motor. This box controls all functions of your system. The front of the control box has a yellow caution decal.

Pneumatic Panel

The pneumatic panel arrives attached to the table. It is located under the tabletop and is mounted to the back right table leg. There are two main components found on the pneumatic panel. One is the main air regulator which is located at the bottom of the panel and controls the waste remover and

Linkage Lubricator Regulator Controls cooling and oiling for the top feed.

pressure to the presser foot. The other component is the linkage lubricator regulator.

NOTE: For safe shipping, the flange rack is packaged with the flange machine. After delivery, you must unwrap the rack and attach it to the flange machine table.

WARNING: Opening the control box poses a possible electrical hazard. Only an authorized service technician or a Porter International, Inc. service technician should open the control box.

NOTE: The linkage lubricator regulator is factory set at 5 to 20 PSI (.3 to 1.4 bars), and does not require adjustment.

22PFM 2002

Optional Equipment: EDS T-100 Air Table Machine Orientation

Main Sewing Pedal

The main sewing pedal is the large, square-shaped metal piece attached to the center of the pedal bar under the table. It activates the waste remover, operates the sewing head, controls the sewing speed, and raises the presser foot. The operator presses this pedal forward with the toes, or in a downward motion with the heel depending on the function needed.

Flange Cutter Pedal

The flange cutter pedal is a small, square-shaped metal piece located to the right of the main sewing pedal. The pedal is pressed downward with the foot. This activates the device and the flange material is cut.

Control Buttons

It is important to locate all control buttons before starting the flange machine. The power ON and OFF buttons are located side-by-side on the left side of the sewing table. The ON button is square-shaped and black in color. The OFF button is square-shaped and red in color.

Optional Equipment: EDS T-100 Air TableThe EDS T-100 Air Table provides nearly effortless manipulation of heavy materials during the flanging process. It is designed to work with, and enhance, the flange machine�s capabilities. For more information about this product, contact the Porter International, Inc. Sales Department at 1-978-948-8288.

FLANGE MACHINE23

Sewing Table ComponentsMachine Orientation

24PFM 2002

Quick Start for Experienced Operators Operating Procedures

5 Operating ProceduresThis section contains step-by-step instructions for everyday operation of the flange machine. Studying this section teaches you to flange a panel quickly and accurately. Section 6. Sewing Adjustments and Section 7. Timing Procedures contain additional information for the successful operation of the PFM 2002 Flange Machine.

Quick Start for Experienced OperatorsThe following quick start steps are for experienced operators. For operators new to the flange machine, please read this entire section as it discusses in detail how to operate the machine.

There are only a few simple steps to operating the PFM 2002 Flange Machine. Read and understand the safety features and procedures found in Section 2. Safety before operating the flange machine. Know how to stop the machine in case of an emergency. To do so, press the red OFF button located on the left side of the sewing table, or unplug the machine receptacle from the outlet. The quick start procedures are:

1 Turn the machine on.2 Verify that the main air regulator is set at 80 PSI (5.5 bars).3 Verify that the linkage lubricator regulator is set at 5 to 20 PSI (.3 to 1.4 bars).4 Insert flange material into the flange guide.5 Sew two or three stitches into the flange.

Top Feed Commonly referred to in the industry as the �upper feed.� The top feed is a mechanical component of the walking foot, with teeth designed to assist in the transport of material.

6 With your heel, press the main sewing pedal in a downward motion. This will raise the presser foot and the top feed.

7 Insert the panel.8 With your toes, press the main sewing pedal in a forward motion and begin

sewing.

FLANGE MACHINE25

Operating Procedures

How Does a PFM 2002 Flange Machine Work?The purpose of the PFM 2002 Flange Machine is to sew a strip of fabric to the edge of a mattress panel while simultaneously safety stitching the panel closed. This strip of fabric is then secured to an innerspring unit to prevent the panel and filling materials from shifting. This flange machine is also capable of serging.

While the bulk of the panel rests on a large table, the operator feeds the machine layers of material 3/8� (.95cm) to 6� (15.24cm) thick. The presser foot compresses the layers and the walking foot mechanism automatically pulls them through as they are sewn. This allows the operator more freedom to guide the layered material and ensures even stitching.

Operating the PFM 2002 Flange MachineThis section is for operators who are new to the PFM 2002 Flange Machine. Read and understand the safety features and procedures found in Section 2. Safety before operating the machine. Know how to stop the machine in case of an emergency. To do so, remove your foot from the main sewing pedal, and press the red OFF button located on the left side of the sewing table, or unplug the machine receptacle from the outlet.

Preparing to SewBefore you begin operating the PFM 2002 Flange Machine, always do the following:

Obstruction Something that seriously hinders action or progress.

1 Perform a safety check before activating the machine. Walk around the machine and visually check for obstructions. Remove obstructions from all moving parts. Clear surfaces of tools, equipment, fabric, and debris.

2 Check the oil level in the sewing head by inspecting the sight glass located on the front of the machine. If the oil indicator is below the bottom red indicator line, add more oil. See Section 8. General Maintenance for further details.

3 Check the oil reservoir located just below the linkage lubricator regulator, which is found on the upper part of the pneumatic panel. Add more oil when the reservoir is less than half full. See Section 8. General Maintenance for further details.

4 Check the main air supply. Properly connect the air supply to the main air regulator located at the bottom of the pneumatic panel.

26PFM 2002

Activating the Machine Operating Procedures

Activating the MachineBefore activating the flange machine, plug the machine receptacle into the outlet. Turn on the main air supply and properly attach it to the main air regulator. To activate the flange machine:

1 Press the black ON button located on the left side of the sewing table.2 Verify that the main air regulator is set at 80 PSI (5.5 bars).3 Verify that the linkage lubricator regulator is set at 5 to 20 PSI (.3 to 1.4 bars).

FlangingTo flange a mattress panel:

1 Insert the flange material into the flange guide. Using the opening in the guide, align the material with the needles.

2 Sew two or three stitches by pressing the main sewing pedal in a forward motion with your toes.

3 Press the main sewing pedal in a downward motion with your heel to raise the presser foot and the top feed.

4 From the left, insert the panel. Position the panel by moving it toward the right, making sure that the panel material wraps around the front of the needles.

5 When both panel and flange material are correctly positioned, press the main sewing pedal in a forward motion with your toes, and begin sewing.

CAUTION: Contact authorized maintenance personnel or a Porter International, Inc. service technician if the regulators need adjustment. Do not attempt to adjust them yourself.

NOTE: Adjust panel position from beneath the presser foot.

FLANGE MACHINE27

Operating Procedures

Sewing a Thread ChainBefore you finish a panel, you must sew a thread chain. This is sometimes

Sewing Off To sew on or off the fabric at the beginning or end of a seam without stopping.

referred to as �sewing off.� The PFM 2002 Flange Machine allows you to do this at the regular speed. It is not necessary to slow the machine when sewing off between pieces. To finish sewing a panel, and to begin sewing a new panel:

1 When nearing the end of the panel, stop sewing approximately 3� (7.62cm) in front of the needles.

2 Cut the flange material. To do this, press the flange cutter pedal with your foot. This pedal is located to the right of the main sewing pedal.

Thread Chain Used to prevent stitches from loosening.

3 Continue sewing, making sure to sew over the stitches at the beginning of the panel. This will prevent the stitches from loosening.

4 At the same speed, continue to sew off the panel, leaving behind a thread chain approximately 3� (7.62cm) long.

5 Stop sewing by removing your foot from the main sewing pedal. Pull forward on the panel to extend the threads a few inches (centimeters).

6 Using scissors, cut the threads and remove the panel. 7 Repeat Steps 1-6 for each new panel.

28PFM 2002

What is a Chainstitch? Sewing Adjustments

6 Sewing Adjustments This section provides detailed instructions about how to fine tune certain components of the PFM 2002 Flange Machine sewing head. After you read this section, you should be able to fully understand the relationship between needles and loopers and their functions. This section is intended to serve as a complement to Section 7. Timing Procedures.

What is a Chainstitch?General Services Administration One of the three central management agencies in the Federal Government.

Federal Standard No. 751a Defines the requirements for types of stitches, seams, and stitching formations used in the sewing industry.

According to the General Services Administration, Federal Standard No. 751a, a chain stitch is defined as a Class 400, Type 401 seaming stitch.

During stitch formation, the needle, laced with thread, penetrates the material in an up and down motion. On the downward motion, the needle brings the thread to the underside of the material.

During this period when the needle is on its way back up, the thread creates a loop. As this loop is created, the looper moves forward and catches the loop, bringing the bottom thread into the loop as well. The needle must be correctly set to the needle guard or the looper may break or bend the needle.

Looper A device used for making loops as part of stitch formation.

Once the top and bottom threads are spread, the needle returns to the down position, penetrating the triangle. While the needle is in the down position, the looper moves backward releasing the top and bottom thread and a new stitch is created. The interlooping created by both the top and bottom stitches are then drawn against the underside of the material. This complex interlacing and interlooping is shown in figure 6.1.

WARNING: Press the red OFF button located on the left side of the sewing table before performing any sewing adjustments. Confirm that the machine will not operate when the pedal is pressed. Failure to perform either of these steps may result in serious personal injury.

FLANGE MACHINE29

Sewing Adjustments

Figure 6.1 Stitch Formation

What is a Looper?Safety Stitch Looper This looper is commonly referred to as the left-hand looper.

The looper�s function is to catch the thread loop created by the needle and to bring the bottom thread into the thread triangle. It is very important that the looper and its related parts are in complete alignment with each other. Specific �timing� procedures are discussed in Section 7. Timing Procedures.

Overedge Looper This looper is commonly referred to as the right-hand looper.

There are two loopers on the PFM 2002 Flange Machine, the safety stitch looper and the overedge looper.

Figure 6.2 Safety Stitch and Overedge Loopers

Checking SuppliesYou will receive the following spare parts kit and accessories kit with your machine. Use these parts and accessories for the adjustment and timing procedures discussed in this section and in Section 7. Timing Procedures, and Section 8. General Maintenance.

30PFM 2002

Checking Supplies Sewing Adjustments

Table 6.1 Spare Parts Kit

Parts and Accessories To order additional parts and accessories, contact Porter International, Inc. at 1-978-948-8288.

Table 6.2 Accessories Kit

Part No. Part Description

6Z0386 Bottom (lower) Knife Right

6Z0947 Flat Head Machine Screw, Fillister

6Z1444 Overedge Looper

6Z1532 Safety Stitch Looper

6Z1631 Needle Set Screw

6Z1742 Needle Plate Screw

6Z2869 Spreader 620244

6Z3284 Top (upper) Knife

6Z3538 Screw

6Z3649 Screw, FD. Bar Guide

6Z4061 Needle, Titanium 135 x 7 #23

6Z4219 Looper Height Gauge

6Z5816 Manual, PFM 2002 Flange Machine

Part No. Accessory Description

6Z0187 Allen Wrench

6Z1834 Oil Container

6Z1846 Oil Funnel

6Z3239 Tweezers

6Z3476 Thread Stand, 4 - Spool

730004 Guard, Belt, Ex Series

FLANGE MACHINE31

ThreadSewing Adjustments

ThreadThe PFM 2002 Flange Machine arrives from the factory threaded with a minimal supply of thread. You will need to order additional thread. We recommend using only high quality thread. For proper loop formation, use nylon bonded thread with the specifications of 46-69 Bonded Nylon, or T30-T40 Poly Spun. Some companies find success with cotton thread as well. See figure 6.3 for proper loop formation.

Figure 6.3 Proper Loop Formation

Always keep thread clean and dry. Store thread in consistent environmental conditions.

NeedleUnless otherwise specified when purchased, the spare parts kit includes a packet of 135 x 7 titanium #23 needles (part number 6Z4061). Always use quality needles for flanging.

Always verify the condition of the needle. Look at the point of the needle to test if the end is sharp or broken. You will be unable to see the exact point on a sharp

Burr A rough, metal edge, usually in the eye of a needle.

needle. If the point appears to shine, the needle is probably blunt or damaged. To test for burrs within the needle eyelet:

Eyelet A small thread guide.

1 Thread the needle.2 Slide the thread back and forth along all inside edges of the eyelet. The

thread should move smoothly.3 Select another needle if the thread snags or frays.

See Section 2. Safety, to learn how to properly handle and dispose of needles.

Needle Rising Needle Rising

Improper Loop Formation Proper Loop Formation

32PFM 2002

Checking Supplies Sewing Adjustments

Figure 6.4 details the specific parts of the needle. Become familiar with these parts. Always verify the condition of the needle before sewing.

Figure 6.4 Parts of a Needle

Looper and Needle GuardYou will find two loopers on the flange machine, the safety stitch looper (part number 6Z1532) and the overedge looper (part number 6Z1444). Always verify the condition of the looper before mounting to the looper base. It is important to test for burrs on the top and on the inside of the looper. Should you feel a burr on the top of the looper, use a fine-grit aluminum oxide Emery paper (for metals) and rub very gently to remove the burr. Do not use Emery paper on the looper�s point. To test for burrs on the inside of the looper:

1 Thread the looper. 2 Using a slight tension, slide the looper back and forth. The thread should

move smoothly.3 Select another looper if the thread snags or frays within the eyelet.

In addition to the loopers, three needle guards are found on the PFM 2002 Flange Machine:

� Safety stitch needle guard (part number 6Z1715) � Front overedge needle guard (part number 6Z1048)� Rear overedge needle guard (part number 6Z2156)

The function of the needle guards is to protect the needles from the loopers while a stitch is being formed.

ButtShank

Cone

Bottom

Reinforced blade

Right

LeftTop Blade Scarf Eye Point

FLANGE MACHINE33

Looper and Needle GuardSewing Adjustments

Mounting the NeedleNeedle Bar The upright, mechanical bar that holds the needle in the correct position.

Scarf The curved (or grooved) part of the needle above the eye.

The needle is held in place by a set screw on the needle bar. Loosen this screw prior to mounting the needle. Do not remove this screw from the needle bar. Raise the needle bar to its highest position by manually rotating the wheel clockwise on the end of the sewing head. Insert a needle into the needle bar as far as it will go, making certain that the scarf of the needle is facing the rear of the machine. Hold the needle in place and carefully tighten the needle screw.

Figure 6.5 Mounting and Replacing the Needle

34PFM 2002

Mounting the Looper Sewing Adjustments

Mounting the LooperThe PFM 2002 Flange Machine arrives with the loopers already mounted to the looper base. To replace a looper, remove the 8mm screw located in front of the looper holder. Remove the old looper and set the new looper into the looper holder. Replace the 8mm looper holder screw and tighten it. Whenever you replace a looper, you will need to correctly set the looper height. Refer to Section 7. Timing Procedures for further details.

Threading the Sewing HeadThe flange machine is threaded at the factory. During the initial setup, knot the preset threads to the threads on the thread cones. Carefully pull the thread until the new thread from the cones comes to the needle eye.

Always thread the sewing head after making timing adjustments. For information on timing, see Section 7. Timing Procedures.

Adjustment to the threading, such as lacing the thread through more or fewer eyelets and thread guides, can be made to maintain the correct thread tension and flow. For specific details on threading the sewing head, refer to the color coded guide that is provided inside the front cover of the sewing head.

CAUTION: Do not try to pass the thread knots through the eyes of the needles. This could cause the needles to bend.

FLANGE MACHINE35

Looper and Needle GuardSewing Adjustments

Figure 6.6 Threaded Sewing Head and Guide

36PFM 2002

Making Tension Adjustments Sewing Adjustments

Figure 6.7 Thread Path

Making Tension AdjustmentsTo produce precision stitching, pressure on material should be as light as possible while still sufficient to ensure correct feeding. Tension on thread should also be as light as possible while still sufficient to set the stitch correctly in the material and ensure an even stitch.

Adjusting Thread TensionersTension springs assist in controlling stitch tension. The PFM 2002 Flange Machine

Tension Disc A metal disc specifically designed to apply tension to thread.

uses tension springs and tension discs, similar to a home sewing machine. Each of the three discs located on the front of the sewing head is covered with a knob. The thread tensioner located on the left side of the sewing head is a thumb screw.

To increase thread tension, turn the tension knob or thumb screw clockwise, to the right.

FLANGE MACHINE37

Adjusting Thread TensionersSewing Adjustments

To decrease thread tension, turn the tension knob or thumb screw counterclockwise, to the left.

You may need to adjust thread tension using one or all of the following tensioners:

� Safety stitch looper thread tensioner� Safety stitch needle thread tensioner� Overedge looper thread tensioner � Overedge needle thread tensioner

Adjusting the Safety Stitch Looper Thread Tensioner

After the machine is properly threaded, check all of the thread tensioners. Begin with the safety stitch looper thread tensioner. This tensioner is a thumb screw attached to the casting located on the left side of the machine. To access the tensioner, open the cloth plate. Adjust the tensioner as needed to be sure the thread is pulled through loosely. After this is done, go to the safety stitch needle thread tensioner.

Figure 6.8 Safety Stitch Looper Thread Tensioner

NOTE: It is important to apply tension in the following order:

1 Adjust the safety stitch looper thread tensioner

2 Adjust the safety stitch needle thread tensioner

3 Adjust the overedge looper thread tensioner

4 Adjust the overedge needle thread tensioner

38PFM 2002

Making Tension Adjustments Sewing Adjustments

Adjusting the Safety Stitch Needle Thread Tensioner

Look at the front of the sewing head. You will see three tensioner knobs located on the upper part of the sewing head. The safety stitch needle thread tensioner is the second, or middle, knob. Pull the thread through, making sure tension on the thread is sufficient. Adjust the tensioner as needed, then proceed to the overedge looper thread tensioner.

Adjusting the Overedge Looper Thread Tensioner

This is one of three tensioner knobs located on the front of the sewing head. It is the third (right) knob. After you have threaded this tensioner, check the thread tension. Proper tension is firm, but not too tight. Adjust the tensioner as needed, then go to the overedge needle thread tensioner.

Adjusting the Overedge Needle Thread Tensioner

This tensioner is one of three tensioners located on the front of the sewing head. It is the first (left) knob. Adjust the tensioner as needed so that the thread is pulled through lightly.

Figure 6.9 Tensioners

FLANGE MACHINE39

Testing Thread TensionSewing Adjustments

Testing Thread TensionTo test thread tension, try sewing a short strip of flange. If the seam stitching is puckered on either the top or bottom, then both upper and lower tensions are too tight. If the bottom thread is looped, tighten the upper thread tension and repeat the test. If the top thread lays on top of the fabric, loosen the upper thread tension and repeat the test. Make any adjustments as necessary.

Adjusting Thread Take-UpThread take-up recovers the amount of loose thread created by the loopers and the feeding motion. The PFM 2002 Flange Machine has two types of take-up:

� Needle Thread Take-Up and Thread Guide� Looper Thread Take-Up and Thread Guide

The needle thread take-up and thread guide may be adjusted to increase or decrease the amount of thread drawn at the top of the needle bar stroke.

The looper thread take-up and thread guide may be adjusted for handling more or less thread, according to the thickness of material and the length of the stitch. It may also be adjusted to change the ratio of looper thread in the finished stitch.

Adjusting Needle Thread Take-UpTo increase the amount of thread drawn, loosen the thread take-up set screw and raise the thread take-up or loosen the guide screw and lower the guide.

To decrease the amount of thread drawn, reverse the adjustment by lowering the thread take-up or raising the guide.

For average sewing conditions, the guide should be set with the upper end 5/8 inch above the guide screw. The thread take-up should be set with the lower end 1/2 inch below the bottom of its holder.

Adjusting Looper Thread Take-upTo change the amount of thread handled, loosen the thread guide screw and the looper thread take-up rod screw. Move the thread guide and the take-up rod to the left for more thread or to the right for less thread. Tighten the two screws making certain that the take-up rod passes through the center of the guide yoke.

CAUTION: These measurements are precise and should not be set with metric tools.

40PFM 2002

Adjusting Stitch Length Sewing Adjustments

To change the ratio of the looper thread in the finished stitch, loosen the thread guide screw and lower the yoke or the right end of the thread guide to gain more thread. For less thread, raise the end of the guide. Then, hold in position and tighten the guide screw.

Adjusting Stitch LengthThe factory sets stitch length at 3.5 to 4.5 stitches per inch. To adjust the stitch length, locate the push button indicated in figure 6.10. Press the push button, and at the same time, turn the handwheel. At some point, the push button should move farther inward. When this occurs, continue pressing the push button and turn the handwheel to the desired aligning mark.

Figure 6.10 Stitch Length Adjustment

Adjusting the Dead BandsThe flange machine has two dead band adjustments:

� Top Feed Dead Band� Presser Foot Dead Band

The following sections contain step-by-step instructions for adjusting the dead bands.

NOTE: The factory sets seam width at 1 inch. This is not adjustable.

FLANGE MACHINE41

Adjusting the Top Feed Dead BandSewing Adjustments

Adjusting the Top Feed Dead BandShims Metal spacers used to adjust the top feed dead band and prevent the top feed from placing pressure on the throat plate.

To adjust the top feed dead band:

1 Rotate the handwheel until the presser foot is in its highest position. 2 Insert or remove the two adjustment shims as needed until the teeth of the

lower main feed and the top feed have only a minimum space between them.

3 Test the spacing between the top feed and lower feed by passing a sheet of paper between them. This space should be enough to allow the piece of paper to pass between the teeth of the lower main feed and the top feed.

Figure 6.11 Top Feed Dead Band Adjustment

Adjusting the Presser Foot Dead BandThe presser foot dead band should measure 0.5mm from the throat plate.

To make adjustments on the presser foot dead band:

1 Disconnect the air line leading to the machine. 2 After the air line is disconnected, remove the pressure mechanism tube (see

figure 6.12). Unscrew the tube counterclockwise until you can pull the tube away from the rod end.

NOTE: This measurement is set at the factory; it should require only occasional adjustment.

42PFM 2002

Adjusting the Dead Bands Sewing Adjustments

3 Remove the rod end by grasping it with a pair of tweezers and pulling it straight upward until the rod end clears the spring stop nut. The spring stop nut has two 440 set screws.

4 Using an Allen Key wrench, loosen the two screws by turning them in a counterclockwise direction.

Figure 6.12 Pressure Mechanism

NOTE: Do not remove the two 440 set screws.

FLANGE MACHINE43

Adjusting the Presser Foot Dead BandSewing Adjustments

Figure 6.13 Spring Stop Nut with 440 Set Screws

5 After the two screws are loosened, use the #22 wrench (part number 6Z4045) which is provided with the sewing head, and insert it into the two holes in the spring stop nut.

6 Turn the wrench left to right and adjust the spring stop nut until the presser foot dead band is 0.5mm from the throat plate.

7 After the correct setting is achieved, tighten the two 440 set screws securely and reinsert the rod end into the spring stop nut using the pair of tweezers.

8 Reattach the air mechanism tube. To do this, place it on the rod end and turn the tube in a clockwise direction until it is firmly attached.

9 After the air mechanism tube is correctly in place, reconnect the air line.

Figure 6.14 Presser Foot Dead Band Location

44PFM 2002

Setting the Needle Bar Height Timing Procedures

7 Timing Procedures This section provides detailed instructions for how to synchronize and fine tune the components of the sewing head. After you read this section you should be able to set the proper timing of the primary components of the sewing head and understand their relationship to one another. This section is intended to serve as a complement to Section 6. Sewing Adjustments.

When you adjust or set the timing for a particular component in the sewing head, you may need to adjust other related components as a result. Time the primary sewing head components in the following order:

1 Setting the Needle Bar Height2 Setting the Safety Stitch Looper 3 Setting the Overedge Looper Height4 Setting the Overedge Looper 5 Timing the Spreader6 Setting the Needle Guards7 Setting the Walking Foot Mechanism

Study the procedures in this section to determine whether or not the adjustments you make will affect other components as well. For all adjustments, open the front and side covers of the sewing head to observe movement.

Setting the Needle Bar HeightRotate the Wheel This is commonly referred to in the industry as �turn the machine over.�

The arm drives the needle bars. To set the needle bar height:

1 Manually rotate the wheel located on the right side of the sewing head until the needle bar is in its highest position.

WARNING: Before making timing adjustments, press the red OFF button located on the left side of the sewing table. Confirm that the machine does not operate when the pedal is pressed. Failure to perform either of these steps may result in serious personal injury.

FLANGE MACHINE45

Timing Procedures

2 Loosen the needle bar driver screw and lift the needle bar up until the point of the needle measures 14mm from the throat plate.

3 When the setting is correct, tighten the needle bar driver screw. 4 After setting the needle bar, time the loopers.

Figure 7.1 Needle Bar Height

Setting the Safety Stitch Looper The measurement from the point of the looper to the center of the needle should be 1.5mm. To set the safety stitch looper, do the following:

1 Rotate the handwheel so that the point of the looper is at the center of the needle.

2 Loosen the looper set screw so that you can move the looper up and down. 3 Raise the looper, and set the gap with the spacer (part number 6Z4219) as

shown in Figure 7.2. 4 After the gap is set, tighten the looper set screw. 5 Rotate the handwheel until the looper is in its farthest left position. 6 Set the point of the looper 1.5mm from the center of the needle. 7 Rotate the handwheel and watch the looper as it moves behind the needle.

The looper should pass as closely as possible to the back of the needle, without contacting the needle.

NOTE: These measurements are precise and should not be set using the U.S. system of measurement.

46PFM 2002

Setting the Safety Stitch Looper Timing Procedures

8 If the looper deflects the needle, use the centering screw to move the looper front and back as needed.

9 After this setting is correct, set the looper height.

Figure 7.2 Setting the Safety Stitch Looper Gap

Figure 7.3 Safety Stitch Looper Setting

NOTE: These measurements are precise and should not be set using the U.S. system of measurement.

FLANGE MACHINE47

Timing Procedures

Setting the Overedge Looper HeightChain Finger This component is located above the looper and assists with forming the overedge stitch on the side of the material. When no material is present, the overedge stitch is formed around the chain finger.

To adjust or set the looper height, loosen the 8mm looper holder screw. Rotate the wheel until the looper passes under the chain finger with 0.5mm clearance. Tighten the looper holder screw. After setting the looper height, set the timing for the overedge looper.

Setting the Overedge Looper The measurement from the point of the overedge looper to the center of the needle should be 2.5mm.

To set the overedge looper, do the following:

1 Rotate the wheel until the looper is in its farthest left position. 2 Loosen the looper lever screw just enough so that you can move the lever

manually. 3 After setting the looper at 2.5mm, locate the centering screw.

Centering Screw This screw is found inside the sewing head, on the looper holder.

4 Rotate the wheel and watch the looper as it moves behind the needle. The looper should pass as closely as possible to the back of the needle, without contacting the needle.

5 If the looper deflects the needle, use the centering screw to move the looper front and back.

6 After the looper is correctly set, tighten the looper lever screw.

Figure 7.4 Overedge Looper Setting

48PFM 2002

Timing the Spreader Timing Procedures

Timing the SpreaderSpreader The spreader on this flange machine is a small, forked, metal part used to form the triangle needed for proper stitch formation.

The spreader on the PFM 2002 Flange Machine is located on the right side of the looper, on the spreader rod. Its function is to pick up the thread from the overedge looper and deliver it to the needle with an upward arcing motion. During this process, the spreader forms a triangle with the thread. Then, as the needle moves behind the spreader with a downward motion, it picks up the thread from the spreader and completes the stitch formation. To achieve the proper functioning of the spreader, you will need to set the spreader timing. You will also need to set the spreader height. Study the following paragraphs to ensure that you properly time the spreader.

Setting the Spreader and Spreader HeightTo time the spreader, do the following:

1 Rotate the wheel until the spreader is in its farthest left position. 2 Check the measurement from the bottom point of the spreader to the center

of the needle; it should measure 5mm. The measurement from the top of the throat plate to the bottom point of the spreader should be 14mm.

3 Locate the spreader screw (part number 6Z5611). This screw is located on top of the spreader holder.

4 Loosen the spreader screw to move the spreader up and down and left to right.

5 Manually move the spreader left to right until the measurement from the bottom point of the spreader is 5mm from the center of the needle.

6 Manually move the spreader up and down until the 14mm measurement between the top of the throat plate and the bottom point of the spreader is achieved.

7 After this setting is correct, lightly tighten the spreader screw. 8 Turn the handwheel clockwise, to the right, until the spreader passes behind

the looper just to the left of the looper eye. 9 Verify that the spreader measures approximately 0.5mm from the thinnest

part of the looper. 10 Tighten the spreader screw securely.

FLANGE MACHINE49

Setting the Safety Stitch Needle GuardTiming Procedures

Figure 7.5 Spreader Timing

Setting the Needle GuardsThe function of the needle guard is to protect the needle from the looper while a stitch is being formed. The needle guard holds the needle in the correct position. The PFM 2002 Flange Machine has a safety stitch needle guard and an overedge needle guard. Adjust these guards separately and in the following order:

1 Setting the Safety Stitch Needle Guard2 Setting the Overedge Needle Guards3 Setting the Rear Overedge Needle Guard4 Setting the Front Overedge Needle Guard

Setting the Safety Stitch Needle GuardThe safety stitch needle guard on the PFM 2002 Flange Machine is a one-piece needle guard.

To set the safety stitch needle guard, do the following:

1 Rotate the wheel until the needle is in its down position, inside the needle guard. The needle must be centered left or right inside the needle guard before the guard is adjusted.

2 Loosen the needle holder screw until you can manually move the needle holder left or right.

3 After the needle is centered, loosen the socket head cap screw and manually move the needle guard until it measures.1mm to.2mm from the needle.

4 After the needle and guard are properly centered, tighten the screw.

NOTE: There is no left or right adjustment on this needle guard.

50PFM 2002

Setting the Needle Guards Timing Procedures

Figure 7.6 Safety Stitch Needle Guard Setting

Setting the Overedge Needle GuardsThe overedge needle guard on this machine is a two-piece needle guard. It has a front needle guard and a back needle guard. You will adjust the guards in the following order:

1 Setting the Rear Overedge Needle Guard2 Setting the Front Overedge Needle Guard

Setting the Rear Overedge Needle Guard

To set this guard, do the following:

1 Rotate the wheel until the needle is in its lowest position.2 Loosen the rear needle guard screw so that you can manually move the

needle guard. 3 Set the guard 0.1mm to 0.3mm from the back of the needle making sure they

do not touch one another. 4 After the setting is correct, tighten the rear needle guard screw.

Setting the Front Overedge Needle Guard

To set this guard, do the following:

1 Locate the two screws positioned side-by-side in front of the lower knife. 1 Loosen both screws and manually move the front needle guard to the front

of the needle. 2 Leave 0.1mm to 0.2mm distance between the front of the needle and the

needle guard, then tighten the two screws.

FLANGE MACHINE51

Setting the Overedge Needle GuardsTiming Procedures

Figure 7.7 Overedge Needle Guards

Setting the Walking Foot MechanismPFM 2002 Walking Foot Mechanism This particular design is patented exclusively by Porter International, Inc. (patent # 4,449,464; #5,309,854).

The walking foot on the PFM 2002 Flange Machine is a design that combines the lower main feed and the differential feed into one unit. It has a presser foot and a top feed. The proper timing of these parts is essential to the performance of the sewing head. It is important to time the walking foot mechanism in the following order:

1 Adjusting the Presser Foot Front or Back2 Setting the Top Feed and Presser Foot Height3 Setting the Lower Main Feed Height

NOTE: To ensure correct positioning of the needle guards on this machine, pass a piece of paper between the needle and the needle guard. Rotate the wheel one revolution to ensure that the looper point does not touch the needle.

52PFM 2002

Setting the Walking Foot Mechanism Timing Procedures

Figure 7.8 Presser Foot and Top Feed

Adjusting the Presser Foot Front or BackFor correct spacing of the needles and correct spacing of the spreader when it passes behind the presser foot extension, you may need to adjust the presser foot.

To adjust the presser foot, do the following:

1 Rotate the wheel so that the spreader is positioned as closely behind the presser foot as possible without contacting it.

2 Rotate the wheel so that the needles move in a downward motion through the slots in the presser foot.

3 Watch the needle movement closely and verify that there is clearance from the front of the needle bars to the back of the presser foot extension arm.

4 If you must make an adjustment from front to back, go to the back of the sewing head.

5 Facing the back of the sewing head, locate the screw at the top of the machine, and the screw at the middle of the machine. These screws will allow you to adjust the presser foot from front to back.

6 Loosen the screws. While the two screws are loosened, you can manually move the entire linkage from front to back.

7 After making the necessary adjustments, tighten the two screws.

FLANGE MACHINE53

Setting the Top Feed and Presser Foot HeightTiming Procedures

Setting the Top Feed and Presser Foot HeightThe measurement from the bottom of the presser foot to the top of the throat plate should be 8mm when the presser foot and top feed are in their highest position. To achieve this setting, carefully perform the following steps in the given order. Use figure 7.9 to locate the correct components.

Outer Guide Places pressure on the top feed and the presser beam to hold them against the inner guide.

1 Remove the outer guide by removing the two socket head cap screws from the outer housing.

2 Center the cap screw within the presser foot arm holder slot. Tighten the screw.

3 Adjust the presser foot arm front to back as needed so that the presser foot clears the needle bars in all positions of its travel.

4 Using the eccentric, move the top feed toward the operator as far as possible. Ensure the teeth of the upper feed dog interlock with the teeth of the lower main dog.

5 With the presser foot in its highest position, adjust the connecting link beam so that it measures 1mm from the top feed holder. To do this, loosen the walking foot drive crank screw, and manually move the drive crank up or down until the desired setting is achieved. Then, replace the crank screw and tighten it securely.

6 Tighten all screws. Manually rotate the handwheel clockwise, to the right. Verify that the bottom of the presser foot to the top of the throat plate measures 8mm. Continue rotating the handwheel, making sure parts do not touch each other in all positions of travel, including when the linkage is in its highest position.

7 Replace the outer guide with the two shims provided (part number 802694).

54PFM 2002

Setting the Walking Foot Mechanism Timing Procedures

Figure 7.9 Walking Foot Mechanism Settings

Setting the Lower Main Feed HeightTo set the feed height for this unit:

1 Rotate the wheel until the combined feeds are in their highest position. 2 Loosen the cylinder mount bracket, and manually lift the top feed in the

presser foot. 3 Verify that the teeth of the combined feeds are positioned above the top

surface of the needle plate.4 After the feeds are in the correct position, put the cylinder mount bracket

back into place and turn it clockwise, to the right, to tighten.

FLANGE MACHINE55

Setting the Lower Main Feed HeightTiming Procedures

56PFM 2002

Safety Procedures for Cleaning and Maintaining the PFM 2002 Flange Machine General Maintenance

8 General MaintenanceThe PFM 2002 Flange Machine has many mechanical parts which require cleaning, lubrication, and occasional maintenance. This section is for trained maintenance personnel. It discusses the proper care and maintenance of the machine. For any maintenance procedures not listed in this section, contact Porter International, Inc. for further assistance.

Safety Procedures for Cleaning and Maintaining the PFM 2002 Flange MachineBefore performing any maintenance, review the safety procedures in Chapter 2. Safety.

The following are additional safety precautions when cleaning or performing maintenance on the PFM 2002 Flange Machine.

Precision Parts Components with accurate, calibrated measurements or positions. These parts should only be adjusted by qualified service and maintenance personnel.

� Always wear appropriate personal safety items.� Always turn off the flange machine to clean or lubricate.� Do not touch control system components, except where indicated.� Do not attempt to adjust precision parts.� Always properly store and dispose of cleaning and lubricating materials.

WARNING: Press the red OFF button located on the left side of the sewing table before performing any maintenance. Confirm that the machine does not operate when the pedal is pressed. Failure to perform either of these steps may result in serious personal injury.

WARNING: Only trained and authorized personnel should adjust precision parts. The machine contains high voltages that can cause serious injury or death.

FLANGE MACHINE57

General Maintenance

Cleaning the MachineIt is important to clean the flange machine daily. Use these supplies:

� Lint-free rags or shop towels� Small brush� Mild spray cleaner or soap and water� A vacuum cleaner� Compressed air

Dirt and lint accumulation is the most common cause for a poorly operating machine. Lint build up can destroy certain machine parts. It is not necessary to remove any parts to clean the machine.

To clean the flange machine, do the following:

1 Open the covers and remove the collected lint from around the loopers, feed slots, and under the needle plate.

2 Use a small brush or compressed air to clean these areas daily. 3 After you finish cleaning, close the covers and return the presser foot to the

sewing position.Keep all outside surfaces of the flange machine clean with soap, water, and lint-free rags. Pay particular attention to the table.

Used compressed air to clean the following:

� Feed dog and looper area (daily)� Under tables (daily)� In between tension discs (daily)� Around the needle plate (daily)

With power off to the flange machine, vacuum (monthly) underneath the tables and operator station. Vacuum more frequently if these areas accumulate debris rapidly.

Lubricating the Sewing HeadEvery surface on a sewing machine, which is in a moveable contact with any other point, must be lubricated. A small drop of oil on each point is sufficient. Observe and note every moveable contact point on the machine.

NOTE: The PFM 2002 Flange Machine is not pre-lubricated at the factory. It will be necessary for you to add oil after the machine is installed. For more information on installation procedures, see Section 3. Installation and Setup.

58PFM 2002

Lubricating the Sewing Head General Maintenance

Filling the Oil PanTo fill the oil pan, do the following:

1 Remove the oil cap located on the top of the sewing head. 2 Using the oil container (part number 6Z1834), and the oil funnel (part

number 6Z1846), that are provided in the accessories kit, pour the oil into the sewing head.

3 After the oil pan is filled, check the sight glass on the front of the sewing head. The top of the oil level indicator should be between the two red indicator lines.

4 If the top of the indicator is below the bottom red indicator line, add enough oil to raise it to the proper level.

Figure 8.1 Adding Oil

Replacing the OilTo insure proper functioning of the machine and its components, maintain a consistent lubrication schedule. It is important to replace the oil one month after the first use of the machine. After this, replace the oil approximately every six months.

FLANGE MACHINE59

Replacing the Oil FilterGeneral Maintenance

To drain the oil from the machine, do the following:

1 Have a container ready to collect the used oil.2 Remove the oil drain plug located on the lower left side of the machine, and

collect the oil in the container. 3 When the oil is completely drained, secure the plug. 4 Dispose of the oil according to local or national regulations.

Figure 8.2 Replacing the Oil

Replacing the Oil FilterReplace the oil filter approximately every six months whenever you replace the oil.

To replace the oil filter:

1 Remove the top cover of the sewing head by removing the four screws that secure the cover. Refer to figure 8.3.

60PFM 2002

Lubricating the Sewing Head General Maintenance

Figure 8.3 Replacing the Oil Filter

2 Remove the three screws that secure the oil filter cover (part number 660203).

3 Remove the oil cap and the O-Ring (part number 6Z3622).4 Remove the old filter and replace it with the new one (part number 6Z1843).5 When you finish, replace the O-Ring, the cap, and the top cover of the

sewing head.

Working with an Automatic Lubrication SystemThe PFM 2002 Flange Machine has an automatic lubrication system. Apply two or

Automatic Lubrication A mechanism that works by itself without direct human intervention to provide lubrication as a surface coating to specific moving parts.

three drops to the indicated areas when you install the machine and when the machine has been inoperative for long periods. Use the oil container (part number 6Z1834) provided in the accessories kit to oil all points requiring lubrication.

For regular maintenance, lubricate the sewing head at the points indicated in figure 8.4 and figure 8.5.

FLANGE MACHINE61

Working with an Automatic Lubrication SystemGeneral Maintenance

Figure 8.4 Lubrication Points, Top View

Figure 8.5 Lubricating the Spreader

62PFM 2002

Lubricating the Sewing Head General Maintenance

Wick A cord or strand of loosely woven, twisted, or braided fibers, as on a candle or oil lamp, that draws up fuel to the flame by capillary action.

The flange machine sewing head has a wicking system. Wicks (such as cotton cord) carry the necessary amount of oil directly to an area requiring lubrication. You will be able to see the wicks in the holes that have the wicking system. Check these wicks weekly or more frequently for high production machines. Inject one or two drops of oil into the holes weekly or as needed. Do not over lubricate these wicks.

Remember to oil other moveable parts not reached by wicks.

Do not use sewing machine oil that contains additives. Additives can cause a reduction in the normal flow of oil, which in turn can result in damage to the machine.

Viscosity Flow resistance of a lubricating oil, which occurs with temperature changes.

Table 8.1 Typical Properties for Texaco White Needle Oil 22

CAUTION: For machines in continuous use, all oiling points must be oiled daily, or damage to the machine may result. Use the proper oil, such as Texaco White Needle Oil 22. White needle oil is recommended for its non-staining, water-white properties.

Term Specification

White Oil 22 code number 537

color water-white

viscositycStcSt

SUSSUS

at 40° celsius, 18.2; test method D 445at 100° celsius, 3.7; test method D 445at 100° fahrenheit, 97; test method (calc)at 210° fahrenheit, 39; test method (calc)

pour pointcelsius

fahrenheit

test method D 97-32°-25°

flash pointcelsius

fahrenheit

test method D 92168°335°

viscosity index 75; test method D 2270

gravity, API 31.8; test method D 1298

FLANGE MACHINE63

Working with an Automatic Lubrication SystemGeneral Maintenance

Lubricating Other SectionsLinkage Lubricator Regulator This controls the cooling and lubrication of the linkage system.

Periodically check the oil level in the linkage lubrication regulator located at the top of the pneumatic panel. Add oil when the oil level falls below the indicator line. To add oil, turn the reservoir clockwise to release it and fill the reservoir with oil.

Figure 8.6 Oil Reservoir

NOTE: The information provided above is presented as a guide to Texaco, Inc. lubricant users. This typical product description cannot be guaranteed to be identical to the products produced at any specific time. Check with a local Texaco, Inc. representative for the latest information.

NOTE: The linkage lubricator regulator is factory set at 5 to 20 PSI (.34 to 1.4 bars). Verify this setting each time you fill the oil reservoir. If any adjustments must be made, contact a Porter International, Inc. service technician.

64PFM 2002

Releasing Condensation from the Pneumatic System General Maintenance

Oiling the machine not only lubricates moving parts to prevent wear, it reduces the risk of rust. Rust forms rapidly with any dampness, especially in humid climates. Surface rust can act like loose sand granules in your machine creating excess wear. To protect against rust, wipe all exposed parts with a soft, lint-free brush saturated with white needle oil. Ensure the brush is damp with oil, not dripping. Then, wipe the machine with a clean, dry, lint-free cloth to remove any excess oil.

After lubricating all areas, sew a test strip to check for excess oil.

Releasing Condensation from the Pneumatic SystemTo release condensation from the pneumatic system, ensure the machine is turned off. Locate the orange button on the bottom of the main air regulator. Press the button upward to release any collected moisture. Perform this procedure daily.

Figure 8.7 Releasing Condensation - Pneumatic System

Setting the KnivesThe PFM 2002 Flange Machine has a top knife and a bottom knife. To adjust the knives, you must set them one at a time in the following order:

1 Setting the Bottom Knife2 Setting the Top Knife3 Adjusting the Bottom Knife Left or Right4 Adjusting the Top Knife Left or Right5 Checking the Setting of the Knives

FLANGE MACHINE65

Setting the Bottom KnifeGeneral Maintenance

Setting the Bottom KnifeTo set the bottom knife:

1 Loosen the knife screw.2 Manually move the knife so that it is level with the top of the throat plate. 3 After the bottom knife is level with the throat plate, tighten the knife screw.

Next, set the top knife.

Setting the Top KnifeTo set the top knife:

1 Rotate the wheel until the knife reaches its lowest position. 2 Loosen the knife screw located at the front of the knife. 3 Set the knife 1.5mm below the top of the bottom knife. 4 After the knife setting is correct, tighten the top knife screw.

Figure 8.8 Setting the Knives

Adjusting the Bottom Knife Left or RightTo adjust the bottom knife left or right:

1 Loosen the bottom knife holder screw. The knife holder on this flange machine is spring-loaded and will automatically move to the right until it contacts the top knife.

2 While the knife holder screw is loose, manually place a slight amount of pressure on the bottom knife holder to keep it against the top knife.

3 Maintain pressure against the top knife and tighten the knife holder screw.

66PFM 2002

Replacing Knives General Maintenance

Adjusting the Top Knife Left or RightTo set the top knife left or right:

1 Rotate the wheel until the knife is in its highest position. 2 Loosen the top knife screw and move the top knife holder as far left as

possible without interference with the presser foot. 3 Check for interference by removing the top cylinder mount and manually

moving the presser foot up and down. The motion should not cause interference with the top knife holder.

4 When the setting is correct, tighten the top knife screw.

Checking the Setting of the KnivesAfter you have followed the preceding steps, check the knives to verify that they function together properly. To do this, take a small piece of thread and place it between the two knives. Position the thread so that it rests near the fronts of the knives. Rotate the wheel and verify that the knives cut the thread. If the knives cut the thread, they are properly set.

Replacing KnivesThe PFM 2002 Flange Machine has a top knife and a bottom knife. Read the following paragraphs carefully to ensure that the knives function together properly after replacement.

Replacing the Top KnifeTo replace the top knife, do the following:

1 Loosen the bottom knife holder screw. 2 Push the bottom knife holder as far left as possible, and lightly tighten the

screw. 3 Remove the top knife screw. 4 While wearing cut-resistant gloves, grasp the top knife and remove, pulling

in a downward motion. 5 Rotate the wheel until the top knife clamp is in its lowest position. 6 Insert the new top knife, but do not tighten the top knife screw completely.

WARNING: Use extreme caution when handling knives. The blades are sharp. When handling knives, always wear cut-resistant gloves.

FLANGE MACHINE67

Replacing the Bottom KnifeGeneral Maintenance

7 Set the top knife blade so that its cutting edge overlaps the bottom knife by 0.5mm to 1.0mm.

8 After the knife position is correct, tighten the top knife screw securely. 9 Loosen the bottom knife holder screw. The bottom knife holder is

spring-loaded and will automatically return to the correct position. 10 Tighten the bottom knife holder screw securely.

Replacing the Bottom KnifeTo replace the bottom knife, do the following:

1 Loosen the bottom knife holder screw. 2 Push the bottom knife holder as far left as possible, and lightly tighten the

screw. 3 Loosen the clamp stud nut. 4 While wearing cut-resistant gloves, grasp the bottom knife and remove,

pulling in a downward motion. 5 Insert the new bottom knife into the groove of the bottom knife clamp stud. 6 Set the blade so that the cutting edge is level with the top of the needle plate. 7 When the blade is in place, tighten the clamp stud nut securely. 8 Loosen the bottom knife holder screw. The bottom knife holder is

spring-loaded and will automatically return to the correct position. 9 Tighten the bottom knife holder screw securely.

NOTE: It is very important to fine-tune the knives after any replacement procedures so that they can function properly. Always perform a cutting test after replacing the knives. This procedure is detailed under �Checking the Setting of the Knives.�

68PFM 2002

Adjusting Belt Tension General Maintenance

Sharpening Knives The knives must be kept sharp to ensure proper function. The bottom knife can be sharpened on a grinder. Maintain the correct angles as shown in figure 8.9.

Figure 8.9 Sharpening the Bottom Knife

Adjusting Belt TensionOver time, you may find it necessary to adjust the tension on the motor belt. Tension on the belt should be tight enough to keep the belt from slipping. If the belt is too tight, this will overload and possibly damage the motor.

To adjust the belt tension:

1 Loosen the bottom nut found on the front of the motor.2 Adjust up or down as needed.3 After the adjustment, you will need to tighten both nuts located at the ends

of the motor.

FLANGE MACHINE69

Replacing the Bottom KnifeGeneral Maintenance

70PFM 2002

Troubleshooting

9 TroubleshootingThis section identifies troubleshooting situations that can be handled by the operator. For further information, see Section 1. About this Manual.

If a problem arises with the flange machine, first determine if it is a problem in one of these areas:

� Electrical and Control System� Sewing� Mechanical� Other

Inspect the flange machine�s mechanisms to locate worn or broken parts. Troubleshoot the flange machine�s electronic components and circuitry to determine if there is a fault in the electrical system.

The following tables list the problems, causes and solutions that could occur to the flange machine. Refer to the tables below to determine the solution to a problem.

WARNING: Only trained and authorized personnel should perform service to the electrical system. The machine contains high voltages that can cause serious injury or death.

FLANGE MACHINE71

Troubleshooting

Electrical and Control System ProblemsBefore You Call Have you read this manual?Have you referred the question to a supervisor or qualified technician at your site?Do you have your identification number?Do you have the machine�s serial and model numbers?Is your telephone near the machine?

The following table contains a listing of electrical and control system problems together with possible causes and solutions:

Table 9.1 Electrical and Control System Problems

Problem Cause SolutionMain power does not turn on.

Faulty electrical connection

Notify authorized electrical personnel or Porter International, Inc. Service Department.

Flange machine will not turn on or is not functioning properly.

Fuse blown Replace fuse.

Flange machine does not start.

Call the Service Department at Porter International, Inc.

Flange machine turns off during operation.

Belt is too loose. Look for E8 on the control box, then tighten the belt.

No air pressure Air is not turned on.Pneumatic regulator requires adjustment.Air lines may be damaged.

Turn on air.Adjust air to 80 PSI (5.5 bars).

Check condition of air lines and repair or replace as necessary. Confirm there is no moisture in the lines.

Flange machine is turned on. No power is coming through the machine.

No power Check incoming power connections.Check incoming voltages.

72PFM 2002

Electrical and Control System Problems Troubleshooting

Sewing ProblemsThe following table contains a listing of sewing problems together with possible causes and solutions. See also Section 6. Sewing Adjustments.

Table 9.2 Sewing Problems

Problem Cause SolutionIrregular stitches Incorrect size needle

Improper threadingLoose upper thread tensionPulling materialLight pressure on presser footLoose presser footBottom thread is loopedBottom thread is visible on top of material

Use 135 x 7 titanium #23 needle.Re thread machine.Tighten upper thread tension.

Do not pull material; guide it gently.Increase pressure on presser foot.

Reset presser foot.Tighten upper tension.

Loosen upper tension.

Breaking needles Pulling materialIncorrect size needleLoose presser foot

Do not pull material; guide it gently.Use 135 x 7 titanium #23 needle.Reset presser foot.

Bunching of thread

Feed dog down Raise feed dog.

Puckering Incorrect thread tension Light pressure on presser footUsing two different sizes or types of threadBent or blunt needle

Loose presser foot

Reset thread tension, it may be too tight.

Increase pressure on presser foot.

Upper thread and lower thread should be the same size and type.

Insert new needle.

Reset the presser foot.

FLANGE MACHINE73

Troubleshooting

Skipping stitches Incorrect size needleBent or blunt needleIncorrect position of needleTight upper thread tensionLight pressure on presser footIncorrect timing between needle and looperIncorrect needle height

Damaged thread

Spreader out of alignment

Use 135 x 7 titanium #23 needle.Insert new needle.Reset needle. Set needle with scarf side facing the back of the machine.Loosen upper thread tension.

Increase pressure on presser foot.

Check the timing of the needle and looper. Reset if necessary.

If the thread is making a large loop, raise the needle bar. If the thread is making a small loop, lower the needle bar.Check thread condition. Change thread cone: upper thread must be the same weight as looper thread.Align or replace spreader.

Breaking thread Starting to stitch too fastImproper threadingSharp eye or burr in needleBent or blunt needleIncorrect type or size of needleThread tangled around tension springIncorrect tension

Dust and debris in thread path or in needle and looper areas.

Start to stitch at a medium speed.

Check thread path. Re thread machine.Replace needle.

Replace needle.Use 135 x 7 #23 needle.

Check thread path. Correct as needed.

Loosen or tighten tension as needed.

Clean thread path. Check needle and looper areas.

Problem Cause Solution

74PFM 2002

Other Problems Troubleshooting

Mechanical ProblemsThe following table contains a listing of mechanical problems together with possible causes and solutions:

Table 9.3 Mechanical Problems

Other ProblemsThe following table contains a listing of other problems not covered in the previous tables, together with possible causes and solutions:

Table 9.4 Other Problems

Problem Cause SolutionNeedle bar does not move.

Problem with power connections

Check the motor connection to the electrical supply.

Sluggish or noisy machine

Dirty machineMachine is under lubricated or not lubricated at all

Clean all dust, lint, and debris from machine, especially the feed dogs and in the looper area.Check lubrication points. Use correct oil.

Problem Cause SolutionMaterial becomes soiled when sewing

Sewing head or table is dirty.Sewing head is over lubricated.

Clean flange machine.

Check lubrication. See Section 8. General Maintenance.

Material wrinkles

Too many stitches per inch

Reduce stitches per inch.

FLANGE MACHINE75

Troubleshooting

76PFM 2002

Questions Review

10 ReviewThe activities in this section are a self test to help you master the knowledge and skills introduced in this manual. The answers follow.

QuestionsSection 1

1 True or False. This manual is intended for operators, maintenance technicians, and supervisory personnel who are familiar with industrial sewing machines and basic sewing principles.

2 Before calling Porter International, Inc. for help, you must have:a. customer identification numberb. flange machine�s serial numberc. flange machine�s model numberd. all of the above

3 The _______ symbol informs you of hazardous conditions that can cause serious bodily harm, and the _______ symbol informs you of conditions that can cause loss of material or damage to equipment.

Section 2

1 True or False. Safety features are visible guarding and warning devices which are affixed to, or are part of, a machine.

2 You will find one yellow caution decal on the PFM 2002 Flange Machine. It is located (choose one):a. on the sewing headb. on the sewing tablec. on the control boxd. on the pneumatic panel

3 _______ are barriers that protect the operator from dangerous mechanical parts.

4 Name the two guards typically found on this flange machine. 5 Pneumatic air pressure should be set at _______ .

FLANGE MACHINE77

Review

6 True or False. Never operate the flange machine with unauthorized or unsupervised personnel in the area.

Section 3

1 True or False. The PFM 2002 Flange Machine requires extensive site preparation.

2 Typically, the flange machine requires access to ______ and an electrical outlet for ______ VAC.

3 True or False. Before connecting the power source, you must properly ground the flange machine.

4 True or False. Only trained and authorized personnel may install the flange machine and check electrical connection and grounding.

5 True or False. The PFM 2002 Flange Machine is pre-lubricated at the factory.

Section 4

1 True or False. The PFM 2002 Flange Machine is not capable of serging or safety stitching.

2 The main sections of this flange machine are (choose one):a. The sewing headb. The waste removerc. The pneumatic paneld. The sewing tablee. All of the above

3 The thread guides, the tensioners, and the throat plate are components found on the _______ .

4 True or False. The speed control dial allows the operator to control sewing speed during the initial training period and enhances machine performance.

5 The pneumatic panel controls (choose one):a. the waste removerb. pressure to the presser footc. cooling and oiling of the top feed beamd. all of the above

Section 5

1 True or False. To stop the flange machine, you may press the OFF button located on the left of the sewing table, or unplug the machine receptacle from the outlet.

78PFM 2002

Questions Review

2 When operating the flange machine, the _______ compresses layers of material which are automatically pulled through by the ________.

3 True or False. Check the oil level in the machine by inspecting the sight glass located on the front of the machine.

4 The linkage lubricator regulator should be set at ______ PSI.5 Before you finish a panel, you must (choose one):

a. sew a thread chainb. turn the machine offc. turn the panel overtd. tie a knot in the threads

Section 6

1 True or False. A spreader is a device used for making loops as part of stitch formation.

2 A rough, metal edge, usually in the eye of a needle is called a ______ .3 The two loopers on this flange machine are the ______ looper and the ______

looper.4 True or False. There are three needle guards on the PFM 2002 Flange

Machine.5 The curved (or grooved) part of the needle above the eye is the:

a. needle barb. point of the needlec. scarfd. cone

6 How many thread tensioners are found on the flange machine?7 True or False. The stitch length on the PFM 2002 Flange Machine cannot be

adjusted.

Section 7

1 True or False. When you adjust or set the timing for a particular component in the sewing head, you may need to adjust other related components as a result.

2 The ______ on this flange machine is a small, forked, metal part used to form the triangle needed for proper stitch formation.

3 True or False. The spreader is located on the left side of the looper.4 The ______ protects the needle from the looper while a stitch is being

formed.5 The ______ needle guard is a two-piece needle guard.

FLANGE MACHINE79

Review

6 The ______ is a particular design that is patented exclusively by Porter, International, Inc.:a. overedge looperb. walking foot mechanismc. spreaderd. safety stitch looper

7 True or False. The PFM 2002 Flange Machine combines the lower main feed and the differential feed into one unit.

8 To set the top feed height, rotate the wheel until the top feed is in its ______ position.

Section 8

1 Parts with accurate, calibrated measurements or positions are called ______.2 The proper supplies to use for cleaning the machine are (choose one):

a. lint-free rags or shop towels and a small brushb. mild spray cleaner and compressed airc. a onlyd. b onlye. both a and b

3 True or False. Lint build up can destroy certain machine parts.4 How often should you clean the feed dog and looper areas of the machine?5 True or False. When the proper amount of oil is in the machine, the oil level

indicator will appear below the bottom red indicator line of the sight glass.6 It is important to replace the oil ______ month(s) after the first use of the

machine, and every ______ month(s) afterward.7 True or False. The oil filter should be checked and replaced every six

months.8 The ______ controls the cooling and lubrication of the linkage system.9 True or False. To release condensation from the pneumatic system, you press

the orange button located on the bottom of the main air regulator.

Section 9

1 True or False. The correct needle to use with the PFM 2002 Flange Machine is a 135 x 7 #23 needle.

2 Irregular stitches could be caused by (choose one):a. incorrect needle sizeb. improper threadingc. loose upper thread tension

80PFM 2002

Answers Review

d. all of the above3 True or False. Incorrect timing of the needle and looper could cause skipped

stitches.4 True or False. A sharp eye or a burr in the needle may cause threads to

break.5 True or False. When loops form on top of the material, top tension is too

tight.6 Always hold the needle by the ______ .

a. shankb. buttc. scarfd. point

AnswersSection 1

1 True2 d. all of the above3 warning, caution

Section 2

1 True2 c. on the control box3 safety guards4 belt guard, eye guard5 80 PSI6 True

Section 3

1 False2 air drops, 2203 True4 True5 False

FLANGE MACHINE81

Review

Section 4

1 False2 e. all of the above3 sewing head4 True5 d. all of the above

Section 5

1 True2 presser foot, walking foot mechanism3 True4 5 to 20 PSI5 a. sew a thread chain

Section 6

1 False. The looper is a device used for making loops as part of stitch formation.2 burr3 safety stitch, overedge4 True5 c. scarf6 four7 True

Section 7

1 True2 spreader3 False4 needle guard5 overedge6 b. walking foot mechanism7 False8 highest

82PFM 2002

Answers Review

Section 8

1 precision parts2 e. both a and b3 True4 daily5 False6 one, six7 True8 linkage lubricator regulator9 True

Section 9

1 True2 d. all of the above3 True4 True5 True6 a. shank

FLANGE MACHINE83

Review

84PFM 2002

Index

IndexNumerics220VAC ±5%, power usage, 780 PSI, recommended air pressure setting, 7

Aaccessories

part numbers, 31sewing, description, 30

activating the flange machine, 27adjusting, 40

bottom knife, 66dead bands, 41looper height, 48looper thread take-up, 40motor belt tension, 69needle guards, 50overedge looper thread tensioner, 39overedge needle thread tensioner, 39presser foot dead band, 42safety stitch looper thread tension, 38safety stitch needle guard, 50safety stitch needle thread tensioner, 39stitch length, 41tension, 37timing, 45top feed dead band, 42top knife, 67

air lineconnecting to sewing head, 13disconnecting, 42

air pressureproblem, 72recommended setting, 7used for cleaning purposes, 9what to do if there is none, 72

air regulator, location of, 7allen wrench, part number, 31amount of thread drawn, increasing and decreasing, 40anti-static clothing, personal safety, 9automatic lubrication, description, 61

Bbalancing thread tension, 19before calling for customer assistance, things to do, 3belt guard

part number, 31safety feature, 6

blunt needle, detecting, 32bottom knife

adjusting, 66part number, 31replacing, 68setting, 66

breaking thread, problem, 74broken needles, 73bunching thread, problem, 73burrs

description, 32testing looper for, 33

Ccalling for help, 3caution decals, safety feature, 5chain finger, description, 48chain of thread, sewing, 28chainstitch, description, 29changing the ratio of looper thread, 41checking

knives, setting of the, 67oil filter, 60oil level in sewing head, 26supplies, 30

cleaningflange machine, 58recommended air pressure, 9

cloth guide, description, 20components

definition, 1pneumatic panel, 22sewing table, 20

condensation, releasing from pneumatic system, 65

FLANGE MACHINE85

Index

connecting air lines to sewing head, 13container for oil, part number, 31control box

description, 22location, 22

control buttonsdescription, 23location, 23

controllingspeed of sewing, 22stitch tension, 37tightness of thread, 19

correct position of a needle, determining, 34customer assistance

preparing for, 3times available, 3

Ddaily cleaning of the machine, 58damaged needle, detecting, 32dead bands, adjusting, 41debris, definition of, 8decals, safety features, 5decreasing

amount of thread drawn, 40thread tension, 37

definitionscomponent, 1debris, 8flange, 1horseplay, 8looper, 1, 29metatarsal, 9obstruction, 26OSHA, 10personal safety, description, 8precision parts, 57scarf, 34serging, 17sewing off, 28shims, 42top feed, 25upper feed, 25walking foot mechanism, 17

descriptionsaccessories, 30automatic lubrication, 61burr, 32chain finger, 48chainstitch, 29cloth guide, 20control box, 22control buttons, 23eyelet, 32Federal Standard No. 751a, 29flange cutter, 21flange cutter pedal, 23flange rack, 22General Services Administration, 29guards, 6left-hand looper, 30linkage lubricator regulator, 22main sewing pedal, 23needle bar, 20, 34needle guard, 33, 50needle plate (throat plate), 20needles, 20optional equipment, 23OSHA, 10outer guide, 54overedge looper, 30parts of a needle, 33plunger, 21pneumatic panel, 22right-and looper, 30rotating the wheel, 45safety stitch looper, 30sewing head, 18spare parts, 30speed control dial, 22spreader, 49tension disc, 37thread chain, 28thread guides, 20thread stand, 21thread take-up, 40throat plate, 20

86PFM 2002

Index

descriptions (continued)turning over the machine, 45walking foot mechanism, 19waste remover system, 21yellow decals, 5

disconnecting air line, 42disconnecting air lines, 42documentation, giving feedback about, 3draining oil from the machine, 59drawn thread, increasing/decreasing amount, 40

Eelectrical power information, 7even stitches, adjusting tension, 37experienced operators, instructions for, 25eye guard safety feature, 6eyelet, description, 32

Ffactory settings

linkage lubricator regulator, 22presser foot dead band, 42seam width, 41stitch length, 17, 41

Federal Standard No. 751a, description, 29feedback, about documentation, giving, 3feeding material through the machine, 19filling the oil pan, 59fine-grit aluminum oxide emery paper, removing burrs with, 33finished stitch, change ratio of looper thread in, 41finishing a panel, sewing off, 28flange cutter

description, 21pedal location, 21

flange cutter pedaldescription, 23location, 23

flange machineactivating, 27cleaning, 58does not start, problem, 72draining oil from, 59not functioning properly, 72

flange machine (continued)preparing work area before operating, 10sluggish operation, 75starting, 27too noisy, 75turns off during operation, problem, 72will not turn on, 72

flange machine, feeding material through, 19flange rack, description, 22flange, definition, 1flanging a mattress panel, 27flat head machine screw, fillister, part number, 31forming loops, thread to use, 32frayed thread, testing the needle, 32front of sewing head, thread tensioner locations, 39front overedge needle guard, setting, 51funnel for oil, part number, 31

GGeneral Services Administration, description, 29getting help, 3getting ready for sewing, 26giving feedback about documentation, 3guard

belt part number, 31description, 6

Hheight

flange machine, 17looper, adjusting, 48lower main feed, setting, 55needle bar, adjusting, 45presser foot, setting, 54setting top feed, 54

horseplay, definition of, 8hotline telephone number, customer assistance, 3hours for customer assistance, 3how does the flange machine work?, 26how to give feedback, 3

Iincreasing

amount of drawn thread, 40thread tension, 37

inserting a new needle, 34inspecting the needle, 32installing a new needle, 34

FLANGE MACHINE87

Index

irregular stitches, problem, 73

Kknives

replacing, 67setting, 65

Lleft-hand looper, description, 30length of machine, 17linkage lubricator regulator

checking oil reservoir, 26description, 22

lint-free rags, needed for cleaning, 58location

oil cap, 59oil drain plug, 60oil level sight glass, 26oil reservoir, 26ON button, 27orange release button, air regulator, 65pneumatic power regulator, 7spreader, 49thread tensioner, 37

loop formation, type of thread to use for, 32looper

definition, 1, 29height gauge, part number, 31replacing, 35testing for burrs, 33thread take-up, adjusting, 40thread, changing ratio of in finished stitch, 41

loosened stitches, preventing, 28lower main feed height, setting, 55lubricating sewing head, 58

Mmachine

does not start, problem, 72specifications, 17turns off during operation, problem, 72

main components of flange machine, 18main power does not turn on, problem, 72main sewing pedal

description, 23location, 23

manualorganization of, 1PFM 2002 Flange Machine, part number, 31terms displayed, 2visual aids in, 2

materialcauses for pulling, 73moving, walking foot mechanism, 19soiled, problem, 75types used with flange machine, 17wrinkled, problem, 75

mattress panel, flanging, 27metatarsal, definition of, 9motor belt, adjusting tension, 69mounting the needle, 34moving material, walking foot mechanism, 19moving presser foot to highest position, 42

Nneedle

inserting a new, 34inspecting, 32mounting, 34replacing, 34titanium 135 x 7 #23, part number, 31

needle bardescription, 20, 34does not move, problem, 75height, setting, 45

needle guarddescription, 33, 50setting, 50types of, 33

needle parts, description, 33needle plate

description, 20screw, part number, 31

needle set screw, part number, 31needles

broken, 73causes for breaking, 73description, 20troubleshooting, 74types to use, 20

new thread, inserting, 35no power coming to the machine, 72

88PFM 2002

Index

non-staining oil, recommended type, 63normal sewing settings, thread take-up, 40

Oobstruction, definition, 26oil

checking linkage lubricator regulator, 26draining from machine, 59replacing, 59when to add, 26

oil container, part number, 31oil drain plug, location of, 60oil filter, replacing, 60oil funnel, part number, 31oil level sight glass, location of, 26oil pan, filling, 59oiling the sewing head, 58operating the flange machine

preparing work area, 10quick start steps, 25

optional equipment, description, 23order for adjusting needle guards, 50organization of this manual, 1OSHA, definition, 10outer guide, description, 54overedge looper

description, 30part number, 31thread tensioner, adjusting, 39

overedge needle guard, setting, 51overedge needle thread tensioner, adjusting, 39overview of safety features, 5

Ppanel, sewing off, 28part numbers for accessories, 31parts of a needle, 33pedal

flange cutter, location, 21main sewing, 23

personal safetydefinition, 8items to have, 9

PFM 2002 Flange Machineair pressure requirements, 18documentation shipped with, 1main components, 18manual, part number, 31power requirements, 18tools shipped with, 1types of material to be stitched, 17

phone number for technical assistance, 3plunger, description, 21pneumatic panel

description, 22location, 22main components, 22

pneumatic power information, 7pneumatic system, releasing condensation from, 65power

electrical, information, 7ON and OFF buttons, location, location of, 23

precision parts, definition, 57preparing for

customer assistance, 3operating the flange machine, 10sewing, steps for, 26sewing, work area, 11

presser footdead band, adjusting, 42moving to highest position, 42

problemsbreaking thread, 74broken needles, 73bunching thread, 73flange machine does not start, 72flange machine turns off, 72getting help with, 3Irregular stitches, 73main power does not turn on, 72needle bar does not move, 75no air pressure, 72no power, 72puckered material, 73skipping stitches, 74soiled material, 75wrinkled material, 75

FLANGE MACHINE89

Index

proper loop formation, type of thread to use for, 32puckered seam stitching, adjusting thread tension for, 40puckering, problem, 73purpose of the flange machine, 26

Qquestions, getting answers to, 3quick start steps, operating instructions, 25

Rrags, lint-free, needed for cleaning, 58range of stitch sizes available, 17recommended

air pressure for cleaning, 9needle, titanium, 31setting, air pressure, 7thread to use, 32white needle oil, lubricant, 63

related documentation, 1replacing

bottom knife, 68knives, 67looper, 35needle, 34oil, 59oil filter, 60top knife, 67

right-hand looper, description, 30rotating the wheel, description, 45

Ssafety check before sewing, 26safety features

belt guard, 6caution decals, 5eye guard, 6guards, 6overview, 5warning decals, 5

safety items, personal, 9safety procedures, 57safety stitch looper

description, 30part number, 31thread tensioner, adjusting, 38

safety stitch needle guard, setting, 50safety stitch needle thread tensioner, adjusting, 39

safety, what you should know, 8scarf, definition, 34schedule, lubrication, 59screw, FD. bar guide, part number, 31screw, part number, 31seam width factory setting, 41securing the work area, 10serging, definition of, 17service, calling for customer, 3setting

bottom knife, 66front overedge needle guard, 51knives, 65knives, checking, 67looper height, 48lower main feed height, 55needle bar height, 45needle guards, 50overedge needle guards, 51pressor foot height, 54rear overedge needle guard, 51safety stitch needle guard, 50top feed height, 54top knife, 66walking foot mechanism, 52

sewinggetting ready for, 26safety check before, 26thread chain, 28

sewing headadjusting timing, 45checking oil level, 26description, 18lubricating, 58oiling, 58threading, 35

sewing off, definition, 28sewing speed, 17sewing table components, 20sewing trim waste, how removed, 21sharpness, checking the needle, 32shims, definition, 42shop towels, needed for cleaning, 58site, preparing for the flange machine, 11sizes of stitches, range possible, 17skipping stitches, problem, 74

90PFM 2002

Index

snagging thread, testing the needle, 32spare parts

description, 30part numbers for, 31

speedbreaking thread, problem, 74controlling, 22sewing, 17

spreader620244, part number, 31description, 49

static electricity, personal safety around, 9steps

preparing to sew, 26replacing looper, 35starting the flange machine, 27

stitchadjusting length, 41changing the ratio of looper thread in, 41sizes, 17tension, controlling, 37

stitchesirregular, 73irregular, problem, 73preventing loosened, 28puckering, 73skipping, 74troubleshooting, 74

stitching, types of materials, 17

Ttechnical support, 3telephone number for customer assistance, 3tension disc, description, 37tension, adjusting, 37tensioners, description, 19terms used in this manual, 2testing

cutting after knife replacement, 68looper for burrs, 33needle for burrs, 32needle sharpness, 32sewing after lubricating, 65thread tension, 40

things to do before calling for customer assistance, 3

threadbunching, problem, 73causes for bunching, 73condition of, 74troubleshooting, 74

thread chain, description, 28thread guides, description, 20thread stand

4 - spool, part number, 31description, 21

thread take-up, 40description, 40settings for normal sewing conditions, 40

thread tensionadjusting, 39adjustment knobs, 19from thread guides, 20testing, 40

thread tensioner, location, 37thread, type to use, 32threading the sewing head, 35throat plate, description, 20tightness of thread, how controlled, 19too tight, stitches, adjusting thread tension, 40tools

allen wrench, part number, 31shipped with the PFM 2002 Flange Machine, 1

top feeddead band, adjusting, 42definition, 25

top knifeadjusting, 67part number, 31replacing, 67setting, 66

top thread laying on top of fabric, adjusting thread tension, 40towels, shop, needed for cleaning, 58

FLANGE MACHINE91

Index

troubleshootingbreaking thread, 74broken needles, 73lubrication, 75main power does not turn on, 72needle bar does not move, 75no power, 72

turning the machine over, 45tweezers, part number, 31types of needles to use, 20

Uupper feed (top feed), definition, 25upper knife, part number, 31

Vvisual aids in this manual, 2

Wwalking foot mechanism

definition of, 17description, 19setting, 52

warning decals, safety feature, 5waste remover system, description, 21what does the flange machine do?, 26what you should know about personal safety, 8when to add oil, linkage lubricator regulator, 26white needle oil, recommended lubricant, 63width of machine, 17width of seam, factory setting, 41work area

preparing for the flange machine, 11securing, 10

Yyellow decals, description, 5

92PFM 2002