Porter PFM-4000 Instruction manual

Installation, Operations, and
General Maintenance
PFM-4000
Flange Machine
6Z8303
PFM-4000
Flange
Machine

© 2003 by Porter®International, Incorporated. All rights reserved.
Porter is a registered trademark of Porter International, Inc.
The Porter stylized logo is a trademark 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.
Hi-Performance Lucas Oil Products is a registered trademark of Lucas Oil Products, Inc.
Texaco is a registered trademark of Texaco, Inc.
Certain illustrations in this manual are used with the permission of Pegasus®Sewing Machine Manufacturing
Company, Limited.
All other product names are either registered trademarks or trademarks of their respective owners in the United
States and/or other countries. All rights reserved.
U.S. patents pending: 60/472,351
Porter International, Inc.
388 Newburyport Turnpike
Rowley, Massachusetts 01969
1-800-343-8138
1-978-948-8288
www.gsgcompanies.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 6Z8303 (2nd print)

Table of Contents
Part Number 6Z8303i
Section 1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
How This Manual Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Terms and Visual Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How to Get Additional Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How to Give Your Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview of Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warning and Caution Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical and Pneumatic Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Using Personal Safety Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Securing Your Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 3
Installation and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preparing the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unpacking the Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the PFM-4000 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembling the Belt Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Positioning the Synchronizer, the Waste Remover System, and the Flange Rack . . . . . . . . 12
Assembling the Thread Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubricating the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Threading the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grounding the PFM-4000 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connecting the Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checking the Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting the Pneumatic Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Performing an Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Making a Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table of Contents
iiPart Number 6Z8303
Section 4
Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
What Is a PFM-4000 Flange Machine? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overview of the PFM-4000 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sewing Head Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sewing Table Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Optional Equipment: EDS T-100 Air Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Section 5
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How Does a PFM-4000 Flange Machine Work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Quick Start for Experienced Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operating the PFM-4000 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Preparing to Sew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Activating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Setting the Sewing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Flanging a Mattress Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Finishing a Mattress Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Section 6
Sewing Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Checking Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Needles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Loopers and Needle Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Mounting the Needles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mounting the Loopers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Threading the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Setting Stitch Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Making Tension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Adjusting Thread Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Testing Thread Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Adjusting Thread Take-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Adjusting the Needle Thread Take-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Adjusting Looper Thread Take-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Adjusting the Top Feed Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Table of Contents
Part Number 6Z8303iii
Section 7
Timing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Setting the Needle Bar Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Setting the Safety Stitch Looper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Setting the Overedge Looper Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Setting the Overedge Looper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Timing the Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Setting the Spreader and Spreader Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Setting the Needle Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Setting the Safety Stitch Needle Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Setting the Overedge Needle Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Setting the Walking Foot Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjusting the Presser Foot Front or Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Setting the Top Feed and Presser Foot Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Adjusting the High-Speed Spring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Setting the Lower Main Feed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Setting the Synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Section 8
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Safety Procedures for Cleaning and Maintaining the PFM-4000 Flange Machine . . . . . . . . . . . 57
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Lubricating the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Filling the Sewing Head Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Draining the Sewing Head Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Replacing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Working with an Automatic Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Lubricating Other Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Releasing Condensation from the Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Setting the Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Setting the Bottom Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Setting the Top Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Adjusting the Bottom Knife Left or Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Adjusting the Top Knife Left or Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Checking the Setting of the Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Replacing the Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Replacing the Top Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Replacing the Bottom Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Sharpening the Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Sharpening the Rotary Flange Cutter Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Table of Contents
ivPart Number 6Z8303
Section 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Electrical and Control System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Sewing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Mechanical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Other Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Flange Machine
Part Number 6Z8303
About This Manual
1
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 PFM-4000 Flange
Machine. Use it 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-4000 Flange Machine arrives with the following documentation and
tools:
•Installation, Operations, and General Maintenance Manual (part number
6Z8303)
•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 Organized
Section 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 Orientation, introduces the basic components of the flange
machine.
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.
IMPORTANT! Only qualified service personnel should perform installation
and maintenance.

2
PFM-4000
Part Number 6Z8303
About This Manual
Section 6, Sewing Adjustments, gives detailed instructions for the sewing
head.
Section 7, Timing Procedures, gives detailed instructions for synchronizing 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.
This manual also includes an index.
Terms and Visual Aids
Terms 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.
How to Get Additional Help
We recognize there are times when you need additional help. Porter International
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,
WARNING: Indicates a potentially hazardous situation which, if not
avoided, may result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury, loss of
material, or damage to equipment.
IMPORTANT! Indicates specific procedures or important additional
information that contribute to successful machine
operation.

Flange Machine
Part Number 6Z8303
About This Manual
3
and computer questions. You will get answers to your questions more quickly if
you do the following:
•Try to find the answer in this manual.
•Ask a supervisor.
•Look up your Customer ID number.
•Make a note of the machine’s serial number. The model number and serial
number of the flange machine are located on the front of the sewing head.
•Locate a phone that is close to the machine so you can tell the technical staff
what is happening.
There are times when your specific problem requires 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 Service Department manager
at 1-800-343-8138 or 1-978-948-8288 for specific information on fees and services.
How to Give Your Feedback
We’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.
Please address all comments to:
Porter International, Inc.
Technical Documentation/Engineering
388 Newburyport Turnpike
Rowley, MA 01969 USA
or via the Internet at: www.gsgcompanies.com.

4
PFM-4000
Part Number 6Z8303
About This Manual