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

Flange Machine
Part Number 6Z8303
Safety
5
2
Safety
Because your personal safety is important to us, the PFM-4000 Flange Machine is
designed with a full protection package. This package includes warning and
caution labels and guards.
Overview of Safety Features
Safety features are visible guarding and warning devices that are affixed to, or are
part of, a machine. These features are required on machinery that can 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 Decals
The flange machine is clearly marked with decals as a reminder to observe safe
operating procedures. Red decals indicate an immediately dangerous situation
which, if not avoided, will result in serious personal injury or death. One red
danger decal is located under the tabletop, near the rotary flange cutter. Special
precautions are necessary.
Yellow decals advise of safety risks and good safety procedures, warn against
potential hazards, and caution against unsafe practices. These indicate a
potentially hazardous situation which, if not avoided, may result in minor or
moderate injury, loss of material, or damage to equipment.
You will find one yellow decal on the PFM-4000 Flange Machine. It is found on
the control box, which is located beneath the sewing table.
IMPORTANT! Read and understand this entire section before you begin
operating or maintaining the PFM-4000 Flange Machine.
These instructions contain important safety and operating
information.

6
PFM-4000
Part Number 6Z8303
Safety
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.
Guards
Safety guards are barriers that prevent entry to dangerous mechanical parts,
providing protection to the operator. The guards typically found on the PFM-4000
Flange Machine are the belt guard and the eye guard. Inspect these guards daily
to ensure all hardware is present and securely fastened.
Figure 2.3 Eye guard
Figure 2.1 Yellow caution decal Figure 2.2 Red danger decal
WARNING: Do not operate your machine without these safety guards
properly installed. Never remove or defeat guards while
the machine is in operation. Doing so can result in serious
personal injury.

Flange Machine
Part Number 6Z8303
Safety
7
Figure 2.4 Belt guard
Electrical and Pneumatic Devices
The PFM-4000 Flange Machine uses 220 VAC ±5%, alternating current, 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. This panel
is located under the tabletop and is mounted to the legs on the right side of the
table. The proper setting for the main air regulator is 80 psi (5.5 bars). See Section
3, Installation and Setup for more information.
Bar 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.
Figure 2.5 Main air regulator

8
PFM-4000
Part Number 6Z8303
Safety
Personal Safety
Personal 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.
DO NOT:
•operate the flange machine while under the influence of alcohol or any
prescribed or other drug.
•eat, drink, or smoke while operating the flange machine.
Horseplay Rough or
boisterous play;
roughhousing.
•indulge in horseplay.
•wear loose clothing, neckties, scarves, headgear, or jewelry. Such
clothing can become entangled in moving parts and cause serious injury
or death.
•leave tools or other unnecessary objects on the machine table while
operating the machine.
•lean against, climb, sit, stand, or crawl on or under the machine.
•touch electrical and control components, except where indicated.
•place spare needles under or around the needle bar or on the table.
•reuse damaged needles. Dispose of needles in a closeable, puncture-
resistant container.
•exceed 30 psi (2 bars) when using compressed air for cleaning purposes.
•use the air hose on any body parts or point it at another person.
DO:
•make sure you are physically able to operate the flange machine and are
able to reach all emergency stops quickly.
•keep your hair short or tied back and always wear safety glasses.
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.
•keep hands and other body parts away from all moving parts.
•locate and identify fire-fighting equipment, and know how to use it.
•when handling needles, always grasp the head of the needle.
•keep all manuals in a convenient, accessible location near the machine.
WARNING: The following lists describe what you should and should
not do while operating or performing maintenance on this
machine. Failing to observe these guidelines could cause
hazardous situations which, if not avoided, may result in
death or serious injury.

Flange Machine
Part Number 6Z8303
Safety
9
Figure 2.6 Needle safety
Using Personal Safety Items
Personal 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 you 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.
•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.
needle point

10
PFM-4000
Part Number 6Z8303
Safety
Securing Your Work Area
The 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.
WARNING: Never operate the flange machine with unauthorized or
unsupervised personnel in the area.

Flange Machine
Part Number 6Z8303
Installation and Setup
11
3
Installation and Setup
This section provides information for service technicians who have experience
and training in electrical and electronic equipment installation. This section
explains the procedures needed to assemble the machine. Although some tools,
such as a 3 mm Allen wrench and a crescent wrench, are necessary, the flange
machine requires no special tools or installation procedures upon its arrival.
Assembly time is approximately thirty minutes.
Preparing the Site
Transformer A device
used to convert a current
from one voltage to
another.
The PFM-4000 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.
Unpacking the Flange Machine
The PFM-4000 Flange Machine consists primarily of the sewing head and the
sewing table. These are packed as separate units and are found within the same
shipping carton. 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.
To unpack the machine:
1Open the shipping carton that contains the sewing table, and remove all
packing material found on top of and around the machine.
IMPORTANT! Porter insures all parcel post packages. If a parcel post
shipment reaches you in damaged condition, contact us
immediately for instructions on filing a claim.

12
PFM-4000
Part Number 6Z8303
Installation and Setup
2Place 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.
3Remove the skid.
4Locate the box containing the sewing head. Open the box and remove any
packing material from the sewing head.
5Remove the sewing head from the box.
Installing the PFM-4000 Flange Machine
Install the flange machine in the following order:
Synchronizer The
synchronizer positions the
sewing head needles up or
down.
Flange Rack The flange
rack holds the rolls of
flange material.
1Assemble the belt guard.
2Position the synchronizer, the waste remover system, and the flange rack.
3Assemble the thread stand.
4Lubricate the sewing head.
5Thread the sewing head.
Assembling the Belt Guard
Assemble the belt guard during the setup and installation of the machine. Do this
before attaching the synchronizer to the handwheel. To assemble the belt guard:
1Place the sewing head in its designated operating position on the sewing
table.
2Connect the V-belt to the sewing head and the motor pulley.
3Attach the belt guard to the fixing screws using the belt guard locking
screws.
Positioning the Synchronizer, the Waste Remover
System, and the Flange Rack
Position the synchronizer, the waste remover system, and the flange rack after
assembling the belt guard. To ensure proper installation:
1Attach the synchronizer to the handwheel and secure into position using a
3 mm hex key.
2Position the waste pipe to the output of the trim waste remover system by
fitting the pieces together.
3Stretch the cover over the top of the waste container.
4Mount the flange rack assembly to the rear table legs using the two bolts
provided.

Flange Machine
Part Number 6Z8303
Installation and Setup
13
Figure 3.1 Flange rack
Assembling the Thread Stand
Assemble the thread stand to complete the attachment of machine components.
To assemble the thread stand:
1Loosen the screws indicated in Figure 3.2.
2Set the thread guide bar 80 mm (3.15 inches) above the top of the machine.
3Position the thread guide bar above and slightly in front of the oil sight
window.
4After the setting is correct, tighten the screws securely.
Figure 3.2 Assembling the thread stand
Lubricating the Sewing Head
The factory drains the oil prior to shipping. You must add oil to the machine
during the installation and setup process. Refer to Section 8, General Maintenance
for more details regarding lubrication. To properly lubricate the sewing head:
Screws
Screws
Thread guide
bar
80 mm Oil sight window

14
PFM-4000
Part Number 6Z8303
Installation and Setup
1Remove the oil plug located on the top of the sewing head.
2Using the oil container and the oil funnel, pour fresh oil into the reservoir.
The oil container and the oil funnel are provided in the accessories kit.
3Fill the reservoir.
Sight Gauge A window
for viewing the level of
fluid, such as oil.
4Check the sight gauge on the front of the sewing head. This gauge is in the
lower right corner. The top of the oil level indicator should be between the
two indicator lines. If the top of the indicator is below the bottom indicator
line, add enough oil to raise it to the proper level.
5After achieving the proper level, replace the oil plug.
6Fill the linkage oil reservoir if the oil level is below the indicator line. This
reservoir is located on the back of the pneumatic panel, between the table
legs (Figure 3.4).
7To add oil, turn the reservoir clockwise to release it and fill the reservoir
with oil.
8After the proper oil level is achieved, replace the reservoir.
Figure 3.3 Adding oil
IMPORTANT! 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
linkage oil reservoir. If any adjustments must be made,
contact a Porter International service technician.
oil cap
sight gauge
proper level
oil jet sight window