Part Number 6Z5816

Installation, Operations, and

General Maintenance

PFM 2002
Flange Machine
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 Turnpike
Rowley, Massachusetts 01969
1-978-948-8288
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How this Manual is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Terms and Visual Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How to Get Additional Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Before You Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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
Preparing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the PFM 2002 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Grounding the PFM 2002 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connecting the Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Checking the Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connecting the Pneumatic Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Checking Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Performing an Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Making a Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Turning on Power and Activating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

i FLANGE MACHINE
 Table of Contents
Section 4
Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
What is a PFM 2002 Flange Machine? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Overview of the PFM 2002 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Sewing Head Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Sewing Table Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Optional Equipment: EDS T-100 Air Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Section 5
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Quick Start for Experienced Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How Does a PFM 2002 Flange Machine Work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating the PFM 2002 Flange Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Preparing to Sew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Activating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Flanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sewing a Thread Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Section 6
Sewing Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
What is a Chainstitch? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
What is a Looper? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Checking Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Looper and Needle Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Mounting the Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mounting the Looper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Threading the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Making Tension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Adjusting Thread Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Testing Thread Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Adjusting Thread Take-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Adjusting Needle Thread Take-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Adjusting Looper Thread Take-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Adjusting Stitch Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Adjusting the Dead Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Adjusting the Top Feed Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Adjusting the Presser Foot Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

PFM 2002 ii
 Table of Contents
Section 7
Timing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Setting the Needle Bar Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Setting the Safety Stitch Looper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Setting the Overedge Looper Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Setting the Overedge Looper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Timing the Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Setting the Top Feed and Presser Foot Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Setting the Lower Main Feed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Section 8
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Safety Procedures for Cleaning and Maintaining the PFM 2002 Flange Machine . . . . . . . . . . . 57
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Lubricating the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Filling the Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Replacing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Replacing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Working with an Automatic Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Lubricating Other Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Releasing Condensation from the Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Setting the Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Setting the Bottom Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Setting the Top Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Adjusting the Bottom Knife Left or Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Adjusting the Top Knife Left or Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Checking the Setting of the Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Replacing Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Replacing the Top Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Replacing the Bottom Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Sharpening Knives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

iii FLANGE MACHINE

 Table of Contents
Section 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Electrical and Control System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Sewing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Mechanical Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Other Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Section 10
Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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

PFM 2002 iv
 How this Manual is Organized About this Manual

About this Manual

1
This manual provides detailed information on how to install, operate, adjust, and Flange A strip of fabric
sewn to the edge of a
perform general maintenance on the Porter International, Inc. PFM 2002 Flange
mattress cover and secured
Machine. It is designed as a tutorial and as a reference for everyday work. to the innerspring unit to
prevent cover and
materials from shifting.

NOTE: Installation and maintenance should be performed by

qualified service personnel only.

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
• Parts kit that includes two loopers, assorted screws, two knives (top and Looper A device used for
bottom), a spreader, a looper height gauge, and needles. making loops as part of
stitch formation.
• 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.
Section 4. Machine Overview, introduces the basic components of the flange Component An essential
machine. group of parts of a larger
piece of equipment.

1 FLANGE MACHINE
 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 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.

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.

PFM 2002 2
 Terms and Visual Aids About this Manual

How to Get Additional Help

We 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 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.

3 FLANGE MACHINE
 About this Manual How to Give Your Feedback

PFM 2002 4
 Overview of Safety Features Safety

Safety
2
Because 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.

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.

Overview of Safety Features

Safety 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 Decals

The 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.

5 FLANGE MACHINE
 Safety Guards

Figure 2.1 Yellow Caution Decal

Guards
Safety 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

PFM 2002 6
 Overview of Safety Features Safety

Figure 2.3 Eye Guard

Electrical and Pneumatic Devices

The 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.
Pneumatic power to the flange machine is supplied through a single connection. PSI Pounds per square
inch; a measure of air
The main air regulator is located at the bottom of the pneumatic panel, which is
pressure.
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.
In the event that the pneumatic power falls below the recommended PSI, the Bars A metric unit of
pressure equal to one
machine head will operate poorly.
million dynes (a unit of
force) per square
centimeter.

7 FLANGE MACHINE
 Safety Electrical and Pneumatic Devices

Figure 2.4 Electrical and Pneumatic Devices

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. 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 • Do not indulge in horseplay.
boisterous play;
• Keep your hair short or tied back and always wear safety glasses.
roughhousing.
• It is also important that you are properly dressed. Do not wear loose
clothing, neckties, scarves, headgear, or jewelry.
Debris An accumulation • Remove debris from the work area. Ensure that the area has proper
of loose material, trash, clearance, and that no unauthorized people are near the machine.
garbage, litter, or junk.
• 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.

PFM 2002 8
 Personal Safety Safety

• Do not touch electrical and control components, except where indicated. Component An essential
group of parts of a larger
• Locate and identify fire-fighting equipment, and know how to use it.
piece of equipment.
• 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 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.
• Sturdy, slip-resistant shoes or boots with adequate toe and metatarsal Metatarsal The top of the
reinforcement. Do not wear sneakers. foot between the ankle and
the toes.
• 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.

9 FLANGE MACHINE
 Safety Securing Your Work Area

• 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 Area

The following list describes what you need to do to secure your work area before
operating the flange machine.

CAUTION: Never operate the flange machine with unauthorized or

unsupervised personnel in the area.

• Always keep your work area clean and dry.

• Keep work area clear of all bags, containers, bundles, or excess materials.
OSHA Occupational • Ensure safe clearances for aisles and passageways. OSHA minimum
Safety and Health distance is 3 feet or 1 meter.
Administration, a U.S.
• Secure all cables and hoses to avoid tripping and entanglement.
government agency.
• 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.

PFM 2002 10
 Preparing the Site Installation and Setup

Installation and Setup

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

Preparing the Site

The PFM 2002 Flange Machine does not require extensive site preparation. A Transformer A device
used to convert a current
work area should be clean, level, structurally sound, and capable of supporting
from one voltage to
100 pounds. Air drops and an electrical outlet for 220 VAC single phase must be another.
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 Machine

The 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 Machine

This 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.

11 FLANGE MACHINE
 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 4 Attach the synchronizer to the handwheel and secure into position using a
synchronizer is used to 3mm hex key.
position the sewing head
needles up or down. 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 6 Mount the flange rack assembly to the rear table legs using the two bolts
rack holds the rolls of provided.
flange material. For more
information, see Section 4. 7 Assemble the thread stand and position it into the hole provided.
Machine Orientation.
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.

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

Grounding the PFM 2002 Flange Machine

NEC® National Electric Before connecting the power source, you must properly ground the flange
Code; establishes
machine. To do this, identify the single ground wire leading from the
requirements for electrical
wiring and equipment. 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.

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.

PFM 2002 12
 Checking the Electrical Connection Installation and Setup

Connecting the Electrical Power

The 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.

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.

Checking the Electrical Connection

An electrical power check should be performed after the flange machine has been
installed.

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.

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.

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.

Connecting the Pneumatic Power

1 To connect the air lines to the sewing head, match corresponding numbers
printed on air fittings to each air line.

13 FLANGE MACHINE
 Installation and Setup

Pneumatic Power 2 Locate the pneumatic panel. When seated properly at the machine, this
Energy for the machine’s panel is located beneath the sewing table on the right side.
parts, which is provided
by compressed air. 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).

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.

Checking Lubrication
Sight 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 the
Linkage An assembly of pneumatic panel, just below the linkage lubricator regulator. To check the oil
parts linked together to
transmit motion. 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.

CAUTION: The PFM 2002 Flange Machine is not pre-lubricated at the

factory. Oil must be added to the machine after it is received.

Performing an Initial Checkout

After 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.

PFM 2002 14
 Making a Safety Check Installation and Setup

Making a Safety Check

Before 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 Machine

1 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.

15 FLANGE MACHINE
 Installation and Setup

PFM 2002 16
 What is a PFM 2002 Flange Machine? Machine Orientation

Machine Orientation
4
This 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?

The PFM 2002 Flange Machine is a high speed flanger that is capable of serging Serging Overedging a
single ply of fabric to
and safety stitching edges of panels in addition to attaching the flange material.
prevent the fabric from
This flanger features an enhanced linkage design that provides automatic linkage unraveling.
cooling and lubrication. The feature that separates the PFM 2002 Flange Machine
from all others is the unique walking foot mechanism that is patented exclusively Walking Foot
Mechanism A
by Porter International, Inc. (patent # 4,449,464; #5,309,854). The flange machine
mechanical bit with teeth
sews at a speed of up to 2800 revolutions per minute (RPM) at 3 to 3.5 stitches per that assists in the transport
inch and is capable of flanging materials from 3/8 inch (.95cm) to 6 inches of material.

(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
Table 4.1 PFM 2002 Flange Machine Specifications combines a row of
chainstitch and a row of
overedge that are sewn
Specification Description simultaneously.

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.

17 FLANGE MACHINE
 Machine Orientation Sewing Head Components

Specification Description
power requirements 220V, 3-phase or single phase, 15 amps
380V, single phase, 10 amps; transformer is optional.
415 - 480V, 15 amps; transformer is required.

air requirements 80 PSI (5.5 bars)

Overview of the PFM 2002 Flange Machine

The 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 Components

The 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.

PFM 2002 18
 Overview of the PFM 2002 Flange Machine Machine Orientation

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

Figure 4.2 Sewing Head Detail

Walking Foot Mechanism

The walking foot mechanism is a mechanical bit with teeth that assists in the PFM 2002 Walking
transport of material. The motion of the mechanism imitates that of your foot as Foot This particular
design is patented
you walk. The teeth go up, move forward, come down to contact the material, exclusively by Porter
then move in a backward motion to move the fabric as you sew. The presser International, Inc. (patent
foot holds the material when the walking foot is raising up and moving # 4,449,464; #5,309,854).
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.

19 FLANGE MACHINE
 Machine Orientation Sewing Table Components

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.

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

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.

WARNING: Do not attempt to replace a needle while the power is turned

on; the flange machine might start unexpectedly.

Throat Plate
Throat Plate This The throat plate is the flat surface directly below the presser foot which
component is commonly supports the material as it is sewn. It is held in place by two screws. The throat
referred to as the needle
plate.
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 Components

The 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.

PFM 2002 20
 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

21 FLANGE MACHINE
 Machine Orientation Sewing Table Components

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.

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.

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.

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.

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 pressure to the presser foot. The other component is the linkage lubricator
Regulator Controls regulator.
cooling and oiling for the
top feed.

NOTE: The linkage lubricator regulator is factory set at 5 to 20 PSI

(.3 to 1.4 bars), and does not require adjustment.

PFM 2002 22
 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 Table

The 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.

23 FLANGE MACHINE
 Machine Orientation Sewing Table Components

PFM 2002 24
 Quick Start for Experienced Operators Operating Procedures

Operating Procedures
5
This 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 Operators

The 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.
6 With your heel, press the main sewing pedal in a downward motion. This Top Feed Commonly
will raise the presser foot and the top feed. referred to in the industry
as the “upper feed.” The
7 Insert the panel. top feed is a mechanical
component of the walking
8 With your toes, press the main sewing pedal in a forward motion and begin
foot, with teeth designed
sewing. to assist in the transport of
material.

25 FLANGE MACHINE
 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 Machine

This 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 Sew
Before you begin operating the PFM 2002 Flange Machine, always do the
following:
Obstruction Something 1 Perform a safety check before activating the machine. Walk around the
that seriously hinders machine and visually check for obstructions. Remove obstructions from all
action or progress. 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.

PFM 2002 26
 Activating the Machine Operating Procedures

Activating the Machine

Before 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).

CAUTION: Contact authorized maintenance personnel or a Porter

International, Inc. service technician if the regulators need
adjustment. Do not attempt to adjust them yourself.

Flanging
To 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.

NOTE: Adjust panel position from beneath the presser foot.

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.

27 FLANGE MACHINE
 Operating Procedures

Sewing a Thread Chain

Before you finish a panel, you must sew a thread chain. This is sometimes
Sewing Off To sew on or referred to as “sewing off.” The PFM 2002 Flange Machine allows you to do this at
off the fabric at the
the regular speed. It is not necessary to slow the machine when sewing off
beginning or end of a seam
without stopping. 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 3 Continue sewing, making sure to sew over the stitches at the beginning of
prevent stitches from the panel. This will prevent the stitches from loosening.
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.

PFM 2002 28
 What is a Chainstitch? Sewing Adjustments

Sewing Adjustments
6
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.

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.

What is a Chainstitch?
According to the General Services Administration, Federal Standard No. 751a, a chain General Services
Administration One of
stitch is defined as a Class 400, Type 401 seaming stitch.
the three central
During stitch formation, the needle, laced with thread, penetrates the material in management agencies in
the Federal Government.
an up and down motion. On the downward motion, the needle brings the thread
to the underside of the material. Federal Standard No.
751a Defines the
During this period when the needle is on its way back up, the thread creates a requirements for types of
stitches, seams, and
loop. As this loop is created, the looper moves forward and catches the loop, stitching formations used
bringing the bottom thread into the loop as well. The needle must be correctly set in the sewing industry.
to the needle guard or the looper may break or bend the needle.
Once the top and bottom threads are spread, the needle returns to the down Looper A device used for
making loops as part of
position, penetrating the triangle. While the needle is in the down position, the
stitch formation.
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.

29 FLANGE MACHINE
 Sewing Adjustments

Figure 6.1 Stitch Formation

What is a Looper?
Safety Stitch Looper The looper’s function is to catch the thread loop created by the needle and to
This looper is commonly
bring the bottom thread into the thread triangle. It is very important that the
referred to as the left-hand
looper. 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 There are two loopers on the PFM 2002 Flange Machine, the safety stitch looper
looper is commonly
and the overedge looper.
referred to as the right-
hand looper.

Figure 6.2 Safety Stitch and Overedge Loopers

Checking Supplies
You 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.

PFM 2002 30
 Checking Supplies Sewing Adjustments

Table 6.1 Spare Parts 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

Parts and Accessories

To order additional parts
Table 6.2 Accessories Kit and accessories, contact
Porter International, Inc. at
1-978-948-8288.
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

31 FLANGE MACHINE
 Sewing Adjustments Thread

Thread
The 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.

Needle Rising Needle Rising

Improper Loop Formation Proper Loop Formation

Figure 6.3 Proper Loop Formation

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

Needle
Unless 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, needle. If the point appears to shine, the needle is probably blunt or damaged. To
usually in the eye of a
test for burrs within the needle eyelet:
needle.

Eyelet A small thread 1 Thread the needle.

guide.
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.

PFM 2002 32
 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.

Blade Scarf Eye Point

Top
Left

Right
Butt Bottom
Shank Reinforced blade
Cone

Figure 6.4 Parts of a Needle

Looper and Needle Guard

You 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.

33 FLANGE MACHINE
 Sewing Adjustments Looper and Needle Guard

Mounting the Needle

Needle Bar The upright, The needle is held in place by a set screw on the needle bar. Loosen this screw
mechanical bar that holds
prior to mounting the needle. Do not remove this screw from the needle bar. Raise
the needle in the correct
position. 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,
Scarf The curved (or
grooved) part of the needle making certain that the scarf of the needle is facing the rear of the machine. Hold
above the eye. the needle in place and carefully tighten the needle screw.

Figure 6.5 Mounting and Replacing the Needle

PFM 2002 34
 Mounting the Looper Sewing Adjustments

Mounting the Looper

The 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 Head

The 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.

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

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.

35 FLANGE MACHINE
 Sewing Adjustments Looper and Needle Guard

Figure 6.6 Threaded Sewing Head and Guide

PFM 2002 36
 Making Tension Adjustments Sewing Adjustments

Figure 6.7 Thread Path

Making Tension Adjustments

To 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 Tensioners

Tension springs assist in controlling stitch tension. The PFM 2002 Flange Machine
uses tension springs and tension discs, similar to a home sewing machine. Each of Tension Disc A metal
disc specifically designed
the three discs located on the front of the sewing head is covered with a knob. The
to apply tension to thread.
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.

37 FLANGE MACHINE
 Sewing Adjustments Adjusting Thread Tensioners

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

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

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

PFM 2002 38
 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

39 FLANGE MACHINE
 Sewing Adjustments Testing Thread Tension

Testing Thread Tension

To 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-Up

Thread 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-Up

To 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.

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

Adjusting Looper Thread Take-up

To 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.

PFM 2002 40
 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 Length

The 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.

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

Figure 6.10 Stitch Length Adjustment

Adjusting the Dead Bands

The 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.

41 FLANGE MACHINE
 Sewing Adjustments Adjusting the Top Feed Dead Band

Adjusting the Top Feed Dead Band

Shims Metal spacers used To adjust the top feed dead band:
to adjust the top feed dead
band and prevent the top 1 Rotate the handwheel until the presser foot is in its highest position.
feed from placing pressure
on the throat plate.
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 Band

The presser foot dead band should measure 0.5mm from the throat plate.

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

occasional adjustment.

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.

PFM 2002 42
 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.

NOTE: Do not remove the two 440 set screws.

Figure 6.12 Pressure Mechanism

43 FLANGE MACHINE
 Sewing Adjustments Adjusting the Presser Foot Dead Band

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

PFM 2002 44
 Setting the Needle Bar Height Timing Procedures

Timing Procedures
7
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 Height
2 Setting the Safety Stitch Looper
3 Setting the Overedge Looper Height
4 Setting the Overedge Looper
5 Timing the Spreader
6 Setting the Needle Guards
7 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.

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.

Setting the Needle Bar Height

The arm drives the needle bars. To set the needle bar height: Rotate the Wheel This
is commonly referred to in
1 Manually rotate the wheel located on the right side of the sewing head until the industry as “turn the
the needle bar is in its highest position. machine over.”

45 FLANGE MACHINE
 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.

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

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.

PFM 2002 46
 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.

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

Figure 7.2 Setting the Safety Stitch Looper Gap

Figure 7.3 Safety Stitch Looper Setting

47 FLANGE MACHINE
 Timing Procedures

Setting the Overedge Looper Height

Chain Finger This To adjust or set the looper height, loosen the 8mm looper holder screw. Rotate the
component is located
wheel until the looper passes under the chain finger with 0.5mm clearance.
above the looper and
assists with forming the Tighten the looper holder screw. After setting the looper height, set the timing for
overedge stitch on the side the overedge looper.
of the material. When no
material is present, the
overedge stitch is formed
around the chain finger.
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 4 Rotate the wheel and watch the looper as it moves behind the needle. The
screw is found inside the looper should pass as closely as possible to the back of the needle, without
sewing head, on the looper contacting the needle.
holder.
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

PFM 2002 48
 Timing the Spreader Timing Procedures

Timing the Spreader

The spreader on the PFM 2002 Flange Machine is located on the right side of the Spreader The spreader
on this flange machine is a
looper, on the spreader rod. Its function is to pick up the thread from the
small, forked, metal part
overedge looper and deliver it to the needle with an upward arcing motion. used to form the triangle
During this process, the spreader forms a triangle with the thread. Then, as the needed for proper stitch
formation.
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 Height

To 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.

49 FLANGE MACHINE
 Timing Procedures Setting the Safety Stitch Needle Guard

Figure 7.5 Spreader Timing

Setting the Needle Guards

The 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 Guard
2 Setting the Overedge Needle Guards
3 Setting the Rear Overedge Needle Guard
4 Setting the Front Overedge Needle Guard

Setting the Safety Stitch Needle Guard

The 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.

PFM 2002 50
 Setting the Needle Guards Timing Procedures

Figure 7.6 Safety Stitch Needle Guard Setting

Setting the Overedge Needle Guards

The 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 Guard
2 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.

51 FLANGE MACHINE
 Timing Procedures Setting the Overedge Needle Guards

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.

Figure 7.7 Overedge Needle Guards

Setting the Walking Foot Mechanism

PFM 2002 Walking The walking foot on the PFM 2002 Flange Machine is a design that combines the
Foot Mechanism This
lower main feed and the differential feed into one unit. It has a presser foot and a
particular design is
patented exclusively by top feed. The proper timing of these parts is essential to the performance of the
Porter International, Inc. sewing head. It is important to time the walking foot mechanism in the following
(patent # 4,449,464;
#5,309,854). order:
1 Adjusting the Presser Foot Front or Back
2 Setting the Top Feed and Presser Foot Height
3 Setting the Lower Main Feed Height

PFM 2002 52
 Setting the Walking Foot Mechanism Timing Procedures

Figure 7.8 Presser Foot and Top Feed

Adjusting the Presser Foot Front or Back

For 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.

53 FLANGE MACHINE
 Timing Procedures Setting the Top Feed and Presser Foot Height

Setting the Top Feed and Presser Foot Height

The 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 1 Remove the outer guide by removing the two socket head cap screws from
pressure on the top feed the outer housing.
and the presser beam to
hold them against the 2 Center the cap screw within the presser foot arm holder slot. Tighten the
inner guide. 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).

PFM 2002 54
 Setting the Walking Foot Mechanism Timing Procedures

Figure 7.9 Walking Foot Mechanism Settings

Setting the Lower Main Feed Height

To 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.

55 FLANGE MACHINE
 Timing Procedures Setting the Lower Main Feed Height

PFM 2002 56
 Safety Procedures for Cleaning and Maintaining the PFM 2002 Flange Machine General Maintenance

General Maintenance
8
The 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.

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.

Safety Procedures for Cleaning and

Maintaining the PFM 2002 Flange Machine
Before 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.
• Always wear appropriate personal safety items. Precision Parts
Components with
• Always turn off the flange machine to clean or lubricate.
accurate, calibrated
• Do not touch control system components, except where indicated. measurements or
• Do not attempt to adjust precision parts. positions. These parts
should only be adjusted by
• Always properly store and dispose of cleaning and lubricating materials. qualified service and
maintenance personnel.

WARNING: Only trained and authorized personnel should adjust

precision parts. The machine contains high voltages that can
cause serious injury or death.

57 FLANGE MACHINE
 General Maintenance

Cleaning the Machine

It 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 Head

Every 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.

PFM 2002 58
 Lubricating the Sewing Head General Maintenance

Filling the Oil Pan

To 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 Oil

To 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.

59 FLANGE MACHINE
 General Maintenance Replacing the Oil Filter

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 Filter

Replace 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.

PFM 2002 60
 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 System

The PFM 2002 Flange Machine has an automatic lubrication system. Apply two or
three drops to the indicated areas when you install the machine and when the Automatic Lubrication
A mechanism that works
machine has been inoperative for long periods. Use the oil container (part number
by itself without direct
6Z1834) provided in the accessories kit to oil all points requiring lubrication. human intervention to
provide lubrication as a
For regular maintenance, lubricate the sewing head at the points indicated in surface coating to specific
figure 8.4 and figure 8.5. moving parts.

61 FLANGE MACHINE
 General Maintenance Working with an Automatic Lubrication System

Figure 8.4 Lubrication Points, Top View

Figure 8.5 Lubricating the Spreader

PFM 2002 62
 Lubricating the Sewing Head General Maintenance

The flange machine sewing head has a wicking system. Wicks (such as cotton cord) Wick A cord or strand of
loosely woven, twisted, or
carry the necessary amount of oil directly to an area requiring lubrication. You
braided fibers, as on a
will be able to see the wicks in the holes that have the wicking system. Check candle or oil lamp, that
these wicks weekly or more frequently for high production machines. Inject one draws up fuel to the flame
by capillary action.
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.

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.

Viscosity Flow resistance

of a lubricating oil, which
Table 8.1 Typical Properties for Texaco White Needle Oil 22 occurs with temperature
changes.

Term Specification
White Oil 22 code number 537

color water-white

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

pour point test method D 97

celsius -32°
fahrenheit -25°

flash point test method D 92

celsius 168°
fahrenheit 335°

viscosity index 75; test method D 2270

gravity, API 31.8; test method D 1298

63 FLANGE MACHINE
 General Maintenance Working with an Automatic Lubrication System

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.

Lubricating Other Sections

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

Figure 8.6 Oil Reservoir

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.

PFM 2002 64
 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

System
To 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 Knives

The 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 Knife
2 Setting the Top Knife
3 Adjusting the Bottom Knife Left or Right
4 Adjusting the Top Knife Left or Right
5 Checking the Setting of the Knives

65 FLANGE MACHINE
 General Maintenance Setting the Bottom Knife

Setting the Bottom Knife

To 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 Knife

To 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 Right

To 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.

PFM 2002 66
 Replacing Knives General Maintenance

Adjusting the Top Knife Left or Right

To 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 Knives

After 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 Knives
The 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.

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

Replacing the Top Knife

To 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.

67 FLANGE MACHINE
 General Maintenance Replacing the Bottom Knife

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 Knife

To 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.”

PFM 2002 68
 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 Tension

Over 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.

69 FLANGE MACHINE
 General Maintenance Replacing the Bottom Knife

PFM 2002 70
 Troubleshooting

Troubleshooting
9
This 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.

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.

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.

71 FLANGE MACHINE
 Troubleshooting

Electrical and Control System Problems

Before You Call The following table contains a listing of electrical and control system problems
Have you read this
together with possible causes and solutions:
manual?
Have you referred the Table 9.1 Electrical and Control System Problems
question to a supervisor or
qualified technician at
your site?
Do you have your Problem Cause Solution
identification number?
Do you have the machine’s Main power does Faulty electrical Notify authorized electrical personnel or
serial and model numbers? not turn on. connection Porter International, Inc. Service
Is your telephone near the Department.
machine?
Flange machine Fuse blown Replace fuse.
will not turn on
or is not
functioning
properly.

Flange machine Call the Service Department at Porter

does not start. International, Inc.

Flange machine Belt is too loose. Look for E8 on the control box, then
turns off during tighten the belt.
operation.

No air pressure Air is not turned on. Turn on air.

Pneumatic regulator Adjust air to 80 PSI (5.5 bars).
requires adjustment.
Air lines may be Check condition of air lines and repair or
damaged. replace as necessary. Confirm there is no
moisture in the lines.

Flange machine No power Check incoming power connections.

is turned on. No Check incoming voltages.
power is coming
through the
machine.

PFM 2002 72
 Electrical and Control System Problems Troubleshooting

Sewing Problems
The 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 Solution

Irregular stitches Incorrect size needle Use 135 x 7 titanium #23 needle.
Improper threading Re thread machine.
Loose upper thread Tighten upper thread tension.
tension
Pulling material Do not pull material; guide it gently.
Light pressure on Increase pressure on presser foot.
presser foot
Loose presser foot Reset presser foot.
Bottom thread is Tighten upper tension.
looped
Bottom thread is Loosen upper tension.
visible on top of
material

Breaking needles Pulling material Do not pull material; guide it gently.

Incorrect size needle Use 135 x 7 titanium #23 needle.
Loose presser foot Reset presser foot.

Bunching of Feed dog down Raise feed dog.

thread

Puckering Incorrect thread Reset thread tension, it may be too tight.

tension
Light pressure on Increase pressure on presser foot.
presser foot
Using two different Upper thread and lower thread should be
sizes or types of the same size and type.
thread
Bent or blunt needle Insert new needle.

Loose presser foot Reset the presser foot.

73 FLANGE MACHINE
 Troubleshooting

Problem Cause Solution

Skipping stitches Incorrect size needle Use 135 x 7 titanium #23 needle.
Bent or blunt needle Insert new needle.
Incorrect position of Reset needle. Set needle with scarf side
needle facing the back of the machine.
Tight upper thread Loosen upper thread tension.
tension
Light pressure on Increase pressure on presser foot.
presser foot
Incorrect timing Check the timing of the needle and
between needle and looper. Reset if necessary.
looper
Incorrect needle If the thread is making a large loop, raise
height the needle bar. If the thread is making a
small loop, lower the needle bar.
Damaged thread Check thread condition. Change thread
cone: upper thread must be the same
weight as looper thread.
Spreader out of Align or replace spreader.
alignment

Breaking thread Starting to stitch too Start to stitch at a medium speed.

fast
Improper threading Check thread path. Re thread machine.
Sharp eye or burr in Replace needle.
needle
Bent or blunt needle Replace needle.
Incorrect type or size Use 135 x 7 #23 needle.
of needle
Thread tangled Check thread path. Correct as needed.
around tension
spring
Incorrect tension Loosen or tighten tension as needed.

Dust and debris in Clean thread path. Check needle and

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

PFM 2002 74
 Other Problems Troubleshooting

Mechanical Problems
The following table contains a listing of mechanical problems together with
possible causes and solutions:
Table 9.3 Mechanical Problems

Problem Cause Solution

Needle bar does Problem with power Check the motor connection to the
not move. connections electrical supply.

Sluggish or noisy Dirty machine Clean all dust, lint, and debris from
machine Machine is under machine, especially the feed dogs and in
lubricated or not the looper area.
lubricated at all Check lubrication points. Use correct oil.

Other Problems
The 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 Solution

Material becomes Sewing head or table Clean flange machine.
soiled when is dirty.
sewing Sewing head is over Check lubrication. See Section 8. General
lubricated. Maintenance.

Material Too many stitches Reduce stitches per inch.

wrinkles per inch

75 FLANGE MACHINE
 Troubleshooting

PFM 2002 76
 Questions Review

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

Questions
Section 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 number
b. flange machine’s serial number
c. flange machine’s model number
d. 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 head
b. on the sewing table
c. on the control box
d. 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 _______ .

77 FLANGE MACHINE
 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 head
b. The waste remover
c. The pneumatic panel
d. The sewing table
e. 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 remover
b. pressure to the presser foot
c. cooling and oiling of the top feed beam
d. 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.

PFM 2002 78
 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 chain
b. turn the machine off
c. turn the panel overt
d. 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 bar
b. point of the needle
c. scarf
d. 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.

79 FLANGE MACHINE
 Review

6 The ______ is a particular design that is patented exclusively by Porter,

International, Inc.:
a. overedge looper
b. walking foot mechanism
c. spreader
d. 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 brush
b. mild spray cleaner and compressed air
c. a only
d. b only
e. 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 size
b. improper threading
c. loose upper thread tension

PFM 2002 80
 Answers Review

d. all of the above

3 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. shank
b. butt
c. scarf
d. point

Answers
Section 1
1 True
2 d. all of the above
3 warning, caution

Section 2
1 True
2 c. on the control box
3 safety guards
4 belt guard, eye guard
5 80 PSI
6 True

Section 3
1 False
2 air drops, 220
3 True
4 True
5 False

81 FLANGE MACHINE
 Review

Section 4
1 False
2 e. all of the above
3 sewing head
4 True
5 d. all of the above

Section 5
1 True
2 presser foot, walking foot mechanism
3 True
4 5 to 20 PSI
5 a. sew a thread chain

Section 6
1 False. The looper is a device used for making loops as part of stitch formation.
2 burr
3 safety stitch, overedge
4 True
5 c. scarf
6 four
7 True

Section 7
1 True
2 spreader
3 False
4 needle guard
5 overedge
6 b. walking foot mechanism
7 False
8 highest

PFM 2002 82
 Answers Review

Section 8
1 precision parts
2 e. both a and b
3 True
4 daily
5 False
6 one, six
7 True
8 linkage lubricator regulator
9 True

Section 9
1 True
2 d. all of the above
3 True
4 True
5 True
6 a. shank

83 FLANGE MACHINE
 Review

PFM 2002 84
 Index

Index
Numerics B
220VAC ±5%, power usage, 7 balancing thread tension, 19
80 PSI, recommended air pressure setting, 7 before calling for customer assistance, things to do, 3
belt guard
A
part number, 31
accessories
safety feature, 6
part numbers, 31
blunt needle, detecting, 32
sewing, description, 30
bottom knife
activating the flange machine, 27
adjusting, 66
adjusting, 40
part number, 31
bottom knife, 66
replacing, 68
dead bands, 41
setting, 66
looper height, 48
breaking thread, problem, 74
looper thread take-up, 40
broken needles, 73
motor belt tension, 69
bunching thread, problem, 73
needle guards, 50
burrs
overedge looper thread tensioner, 39
description, 32
overedge needle thread tensioner, 39
testing looper for, 33
presser foot dead band, 42
safety stitch looper thread tension, 38 C
safety stitch needle guard, 50 calling for help, 3
safety stitch needle thread tensioner, 39 caution decals, safety feature, 5
stitch length, 41 chain finger, description, 48
tension, 37 chain of thread, sewing, 28
timing, 45 chainstitch, description, 29
top feed dead band, 42 changing the ratio of looper thread, 41
top knife, 67 checking
air line knives, setting of the, 67
connecting to sewing head, 13 oil filter, 60
disconnecting, 42 oil level in sewing head, 26
air pressure supplies, 30
problem, 72 cleaning
recommended setting, 7 flange machine, 58
used for cleaning purposes, 9 recommended air pressure, 9
what to do if there is none, 72 cloth guide, description, 20
air regulator, location of, 7 components
allen wrench, part number, 31 definition, 1
amount of thread drawn, increasing and pneumatic panel, 22
decreasing, 40 sewing table, 20
anti-static clothing, personal safety, 9 condensation, releasing from pneumatic system, 65
automatic lubrication, description, 61

85 FLANGE MACHINE
 Index

connecting air lines to sewing head, 13 descriptions

container for oil, part number, 31 accessories, 30
control box automatic lubrication, 61
description, 22 burr, 32
location, 22 chain finger, 48
control buttons chainstitch, 29
description, 23 cloth guide, 20
location, 23 control box, 22
controlling control buttons, 23
speed of sewing, 22 eyelet, 32
stitch tension, 37 Federal Standard No. 751a, 29
tightness of thread, 19 flange cutter, 21
correct position of a needle, determining, 34 flange cutter pedal, 23
customer assistance flange rack, 22
preparing for, 3 General Services Administration, 29
times available, 3 guards, 6
left-hand looper, 30
D
linkage lubricator regulator, 22
daily cleaning of the machine, 58
main sewing pedal, 23
damaged needle, detecting, 32
needle bar, 20, 34
dead bands, adjusting, 41
needle guard, 33, 50
debris, definition of, 8
needle plate (throat plate), 20
decals, safety features, 5
needles, 20
decreasing
optional equipment, 23
amount of thread drawn, 40
OSHA, 10
thread tension, 37
outer guide, 54
definitions
overedge looper, 30
component, 1
parts of a needle, 33
debris, 8
plunger, 21
flange, 1
pneumatic panel, 22
horseplay, 8
right-and looper, 30
looper, 1, 29
rotating the wheel, 45
metatarsal, 9
safety stitch looper, 30
obstruction, 26
sewing head, 18
OSHA, 10
spare parts, 30
personal safety, description, 8
speed control dial, 22
precision parts, 57
spreader, 49
scarf, 34
tension disc, 37
serging, 17
thread chain, 28
sewing off, 28
thread guides, 20
shims, 42
thread stand, 21
top feed, 25
thread take-up, 40
upper feed, 25
throat plate, 20
walking foot mechanism, 17

PFM 2002 86
 Index

descriptions (continued) flange machine (continued)

turning over the machine, 45 preparing work area before operating, 10
walking foot mechanism, 19 sluggish operation, 75
waste remover system, 21 starting, 27
yellow decals, 5 too noisy, 75
disconnecting air line, 42 turns off during operation, problem, 72
disconnecting air lines, 42 will not turn on, 72
documentation, giving feedback about, 3 flange machine, feeding material through, 19
draining oil from the machine, 59 flange rack, description, 22
drawn thread, increasing/decreasing amount, 40 flange, definition, 1
flanging a mattress panel, 27
E
flat head machine screw, fillister, part number, 31
electrical power information, 7
forming loops, thread to use, 32
even stitches, adjusting tension, 37
frayed thread, testing the needle, 32
experienced operators, instructions for, 25
front of sewing head, thread tensioner locations, 39
eye guard safety feature, 6
front overedge needle guard, setting, 51
eyelet, description, 32
funnel for oil, part number, 31
F
G
factory settings
General Services Administration, description, 29
linkage lubricator regulator, 22
getting help, 3
presser foot dead band, 42
getting ready for sewing, 26
seam width, 41
giving feedback about documentation, 3
stitch length, 17, 41
guard
Federal Standard No. 751a, description, 29
belt part number, 31
feedback, about documentation, giving, 3
description, 6
feeding material through the machine, 19
filling the oil pan, 59 H
fine-grit aluminum oxide emery paper, removing height
burrs with, 33 flange machine, 17
finished stitch, change ratio of looper thread in, 41 looper, adjusting, 48
finishing a panel, sewing off, 28 lower main feed, setting, 55
flange cutter needle bar, adjusting, 45
description, 21 presser foot, setting, 54
pedal location, 21 setting top feed, 54
flange cutter pedal horseplay, definition of, 8
description, 23 hotline telephone number, customer assistance, 3
location, 23 hours for customer assistance, 3
flange machine how does the flange machine work?, 26
activating, 27 how to give feedback, 3
cleaning, 58 I
does not start, problem, 72 increasing
draining oil from, 59 amount of drawn thread, 40
not functioning properly, 72 thread tension, 37
inserting a new needle, 34
inspecting the needle, 32
installing a new needle, 34
87 FLANGE MACHINE
 Index

irregular stitches, problem, 73 manual

organization of, 1
K
PFM 2002 Flange Machine, part number, 31
knives
terms displayed, 2
replacing, 67
visual aids in, 2
setting, 65
material
L causes for pulling, 73
left-hand looper, description, 30 moving, walking foot mechanism, 19
length of machine, 17 soiled, problem, 75
linkage lubricator regulator types used with flange machine, 17
checking oil reservoir, 26 wrinkled, problem, 75
description, 22 mattress panel, flanging, 27
lint-free rags, needed for cleaning, 58 metatarsal, definition of, 9
location motor belt, adjusting tension, 69
oil cap, 59 mounting the needle, 34
oil drain plug, 60 moving material, walking foot mechanism, 19
oil level sight glass, 26 moving presser foot to highest position, 42
oil reservoir, 26
N
ON button, 27
needle
orange release button, air regulator, 65
inserting a new, 34
pneumatic power regulator, 7
inspecting, 32
spreader, 49
mounting, 34
thread tensioner, 37
replacing, 34
loop formation, type of thread to use for, 32
titanium 135 x 7 #23, part number, 31
looper
needle bar
definition, 1, 29
description, 20, 34
height gauge, part number, 31
does not move, problem, 75
replacing, 35
height, setting, 45
testing for burrs, 33
needle guard
thread take-up, adjusting, 40
description, 33, 50
thread, changing ratio of in finished stitch, 41
setting, 50
loosened stitches, preventing, 28
types of, 33
lower main feed height, setting, 55
needle parts, description, 33
lubricating sewing head, 58
needle plate
M description, 20
machine screw, part number, 31
does not start, problem, 72 needle set screw, part number, 31
specifications, 17 needles
turns off during operation, problem, 72 broken, 73
main components of flange machine, 18 causes for breaking, 73
main power does not turn on, problem, 72 description, 20
main sewing pedal troubleshooting, 74
description, 23 types to use, 20
location, 23 new thread, inserting, 35
no power coming to the machine, 72

PFM 2002 88
 Index

non-staining oil, recommended type, 63 PFM 2002 Flange Machine

normal sewing settings, thread take-up, 40 air pressure requirements, 18
documentation shipped with, 1
O
main components, 18
obstruction, definition, 26
manual, part number, 31
oil
power requirements, 18
checking linkage lubricator regulator, 26
tools shipped with, 1
draining from machine, 59
types of material to be stitched, 17
replacing, 59
phone number for technical assistance, 3
when to add, 26
plunger, description, 21
oil container, part number, 31
pneumatic panel
oil drain plug, location of, 60
description, 22
oil filter, replacing, 60
location, 22
oil funnel, part number, 31
main components, 22
oil level sight glass, location of, 26
pneumatic power information, 7
oil pan, filling, 59
pneumatic system, releasing condensation from, 65
oiling the sewing head, 58
power
operating the flange machine
electrical, information, 7
preparing work area, 10
ON and OFF buttons, location, location of, 23
quick start steps, 25
precision parts, definition, 57
optional equipment, description, 23
preparing for
order for adjusting needle guards, 50
customer assistance, 3
organization of this manual, 1
operating the flange machine, 10
OSHA, definition, 10
sewing, steps for, 26
outer guide, description, 54
sewing, work area, 11
overedge looper
presser foot
description, 30
dead band, adjusting, 42
part number, 31
moving to highest position, 42
thread tensioner, adjusting, 39
problems
overedge needle guard, setting, 51
breaking thread, 74
overedge needle thread tensioner, adjusting, 39
broken needles, 73
overview of safety features, 5
bunching thread, 73
P flange machine does not start, 72
panel, sewing off, 28 flange machine turns off, 72
part numbers for accessories, 31 getting help with, 3
parts of a needle, 33 Irregular stitches, 73
pedal main power does not turn on, 72
flange cutter, location, 21 needle bar does not move, 75
main sewing, 23 no air pressure, 72
personal safety no power, 72
definition, 8 puckered material, 73
items to have, 9 skipping stitches, 74
soiled material, 75
wrinkled material, 75

89 FLANGE MACHINE
 Index

proper loop formation, type of thread to use for, 32 safety, what you should know, 8
puckered seam stitching, adjusting thread tension scarf, definition, 34
for, 40 schedule, lubrication, 59
puckering, problem, 73 screw, FD. bar guide, part number, 31
purpose of the flange machine, 26 screw, part number, 31
seam width factory setting, 41
Q
securing the work area, 10
questions, getting answers to, 3
serging, definition of, 17
quick start steps, operating instructions, 25
service, calling for customer, 3
R setting
rags, lint-free, needed for cleaning, 58 bottom knife, 66
range of stitch sizes available, 17 front overedge needle guard, 51
recommended knives, 65
air pressure for cleaning, 9 knives, checking, 67
needle, titanium, 31 looper height, 48
setting, air pressure, 7 lower main feed height, 55
thread to use, 32 needle bar height, 45
white needle oil, lubricant, 63 needle guards, 50
related documentation, 1 overedge needle guards, 51
replacing pressor foot height, 54
bottom knife, 68 rear overedge needle guard, 51
knives, 67 safety stitch needle guard, 50
looper, 35 top feed height, 54
needle, 34 top knife, 66
oil, 59 walking foot mechanism, 52
oil filter, 60 sewing
top knife, 67 getting ready for, 26
right-hand looper, description, 30 safety check before, 26
rotating the wheel, description, 45 thread chain, 28
S sewing head
safety check before sewing, 26 adjusting timing, 45
safety features checking oil level, 26
belt guard, 6 description, 18
caution decals, 5 lubricating, 58
eye guard, 6 oiling, 58
guards, 6 threading, 35
overview, 5 sewing off, definition, 28
warning decals, 5 sewing speed, 17
safety items, personal, 9 sewing table components, 20
safety procedures, 57 sewing trim waste, how removed, 21
safety stitch looper sharpness, checking the needle, 32
description, 30 shims, definition, 42
part number, 31 shop towels, needed for cleaning, 58
thread tensioner, adjusting, 38 site, preparing for the flange machine, 11
safety stitch needle guard, setting, 50 sizes of stitches, range possible, 17
safety stitch needle thread tensioner, adjusting, 39 skipping stitches, problem, 74

PFM 2002 90
 Index

snagging thread, testing the needle, 32 thread

spare parts bunching, problem, 73
description, 30 causes for bunching, 73
part numbers for, 31 condition of, 74
speed troubleshooting, 74
breaking thread, problem, 74 thread chain, description, 28
controlling, 22 thread guides, description, 20
sewing, 17 thread stand
spreader 4 - spool, part number, 31
620244, part number, 31 description, 21
description, 49 thread take-up, 40
static electricity, personal safety around, 9 description, 40
steps settings for normal sewing conditions, 40
preparing to sew, 26 thread tension
replacing looper, 35 adjusting, 39
starting the flange machine, 27 adjustment knobs, 19
stitch from thread guides, 20
adjusting length, 41 testing, 40
changing the ratio of looper thread in, 41 thread tensioner, location, 37
sizes, 17 thread, type to use, 32
tension, controlling, 37 threading the sewing head, 35
stitches throat plate, description, 20
irregular, 73 tightness of thread, how controlled, 19
irregular, problem, 73 too tight, stitches, adjusting thread tension, 40
preventing loosened, 28 tools
puckering, 73 allen wrench, part number, 31
skipping, 74 shipped with the PFM 2002 Flange Machine, 1
troubleshooting, 74 top feed
stitching, types of materials, 17 dead band, adjusting, 42
definition, 25
T
top knife
technical support, 3
adjusting, 67
telephone number for customer assistance, 3
part number, 31
tension disc, description, 37
replacing, 67
tension, adjusting, 37
setting, 66
tensioners, description, 19
top thread laying on top of fabric, adjusting thread
terms used in this manual, 2
tension, 40
testing
towels, shop, needed for cleaning, 58
cutting after knife replacement, 68
looper for burrs, 33
needle for burrs, 32
needle sharpness, 32
sewing after lubricating, 65
thread tension, 40
things to do before calling for customer assistance, 3

91 FLANGE MACHINE
 Index

troubleshooting W
breaking thread, 74 walking foot mechanism
broken needles, 73 definition of, 17
lubrication, 75 description, 19
main power does not turn on, 72 setting, 52
needle bar does not move, 75 warning decals, safety feature, 5
no power, 72 waste remover system, description, 21
turning the machine over, 45 what does the flange machine do?, 26
tweezers, part number, 31 what you should know about personal safety, 8
types of needles to use, 20 when to add oil, linkage lubricator regulator, 26
white needle oil, recommended lubricant, 63
U
width of machine, 17
upper feed (top feed), definition, 25
width of seam, factory setting, 41
upper knife, part number, 31
work area
V preparing for the flange machine, 11
visual aids in this manual, 2 securing, 10
Y
yellow decals, description, 5

PFM 2002 92