JUKI Union Special 36200L220-60 Setup guide

ADJUSTING INSTRUCTIONS / ILLUSTRATED PARTS LIST
MANUAL NO. PT0204-GR
FOR STYLE
36200L220-60
11/22/06

Manual No. PT0204-GR llustrated Parts List for 36200L220-60 Series Machines
First Edition Copyright 2006
By
Union Special Corporation Rights Reserved In All Countries
Printed in U.S.A. Nov 2006
PREFACE
This parts manual has been prepared to assist you in locating individual parts or assemblies on 36200L220-60 Series
machines.
ItisthedesireofUnionSpecialthateachmachinerunatitsoptimumperformance. Partslistedinthismanualaredesigned
specifically for your machine and are manufactured with utmost precision to assure long lasting service.
This manual has been comprised on the basis of available information. Changes in design and/or improvements may
incorporate a slight modification of configuration in illustrations or part numbers.
On the following pages are illustrations and terminology used in describing the parts used on 35600 Series machines.
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CONTENTS
PREFACE .......................................................................................................................................................................................2
TERMS............................................................................................................................................................................................2
IDENTIFICATION OF MACHINES ..................................................................................................................................................3
TORQUE REQUIREMENTS ..............................................................................................................................................................3
DESCRIPTION OF MACHINES.......................................................................................................................................................3
STYLE OF MACHINES ....................................................................................................................................................................3
IDENTIFYING PARTS ......................................................................................................................................................................4
NEEDLES ........................................................................................................................................................................................4
SAFETY RULES:...............................................................................................................................................................................5
THREADING ..................................................................................................................................................................................6
OILING ..........................................................................................................................................................................................7
ADJUSTING INSTRUCTIONS ..........................................................................................................................................................8
SETTING THE NEEDLE BAR HEIGHT & ALIGNMENT .......................................................................................................................8
SETTING THE NEEDLE BAR HEIGHT & ALIGNMENT (CONT) .........................................................................................................9
ALIGNING THE CYLINDER ............................................................................................................................................................9
SETTING THE LOOPER TRAVEL USING GAUGE 21227CN ..........................................................................................................10
SETTING THE LOOPER TRAVEL ....................................................................................................................................................10
TIMING THE NEEDLES TO THE LOOPER .......................................................................................................................................11
INSTRUCTIONS FOR USING SYNCHRONIZING GAUGE 21227CG ...........................................................................................11
TIMING THE NEEDLES TO THE LOOPER (CONT.) ........................................................................................................................11
LOOPER ADJUSTMENTS ..............................................................................................................................................................12
LOOPER ADJUSTMENTS (CONT.) ...............................................................................................................................................13
SETTING THE FRONT NEEDLE GUARD .........................................................................................................................................13
SETTING THE FEED DOGS............................................................................................................................................................13
SETTING THE REAR NEEDLE GUARD ...........................................................................................................................................14
SETTING THE STITCH LENGTH ......................................................................................................................................................14
DIFFERENTIAL FEED CONTROL ...................................................................................................................................................14
TERMS
Prices are net cash and subject to change without notice. All shipments are forwarded F.O.B. shipping point. A charge is made
to cover postage and insurance.

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SETTING THE PRESSER FOOT .......................................................................................................................................................14
SETTING THE PRESSER FOOT (CONT.) ........................................................................................................................................15
SETTING THE PRESSER FOOT (CONT.) ........................................................................................................................................16
SETTING THE KNIFE DRIVE LEVER................................................................................................................................................16
SETTING THE KNIFE DRIVE LEVER (CONT.) .................................................................................................................................17
SETTING THE TRIMMING KNIVES FOR LAP SEAMING ................................................................................................................17
NEEDLE THREAD ADJUSTMENTS .................................................................................................................................................18
LOOPER THREAD ADJUSTMENT..................................................................................................................................................18
COVER THREAD ADJUSTMENT ...................................................................................................................................................18
TENSION RELEASE.......................................................................................................................................................................19
HUNG FOOT ADJUSTMENT.........................................................................................................................................................19
SETTING THE LAP FORMER..........................................................................................................................................................19
OIL SIGHT GAUGES, TOP COVERS & MISCELLANEOUS TAKEUP & EYELET PARTS....................................................................21
MAIN FRAME, BUSHINGS & MISCELLANEOUS EYELET & COVER PARTS ..................................................................................23
MAIN SHAFT & MISCELLANEOUS OILING .................................................................................................................................25
CRANKSHAFT & NEEDLE LEVER PARTS .......................................................................................................................................27
TENSION PARTS ..........................................................................................................................................................................29
DETACHABLE HEAD, HEAD COVERS, NEEDLE BAR & NEEDLE BAR HEAD ................................................................................31
DETACHABLE HEAD, HEAD COVERS, NEEDLE BAR & NEEDLE BAR HEAD ................................................................................33
DIFFERENTIAL & MAIN FEED BARS, FEED DOGS & FEED LIFT ECCENTRIC ASSEMBLY ..............................................................35
FEED DRIVE ASSEMBLY, FEED ROCKER & LOOPER AVOID PARTS .........................................................................................37
KNIFE DRIVING PARTS ................................................................................................................................................................39
LOOPER ROCKER SHAFT & LOOPER ROCKER DRIVE PARTS .....................................................................................................41
LAP FORMER, MISCELLANEOUS CYLINDER COVERS, THROAT PLATE, & CHAIN CUTTING KNIFE ...........................................43
CYLINDER BUSHINGS, DIFFERENTIAL FEED CONTROL ASSEMBLY & MISCELLANEOUS CYLINDER COVERS........................45
PRESSER FOOT ............................................................................................................................................................................47
THREAD STAND ...........................................................................................................................................................................49
MISCELLANEOUS GAUGES & TAPE REEL PARTS ........................................................................................................................51
THREAD LUBRICATOR .................................................................................................................................................................53
NUMERICAL INDEX OF PARTS....................................................................................................................................................54
NUMERICAL INDEX OF PARTS....................................................................................................................................................55
IDENTIFICATION OF MACHINES
Each UNION SPECIAL machine is identified by a style number, which is stamped into the style plate affixed to the middle of the
machine under the tension assembly.
The serial number is stamped in the casting at the right rear base of the machine.
TORQUE REQUIREMENTS
Torque (measured in inch-pounds) is a rotating force (in pounds applied through a distance by a lever (in inches or feet). This is
accomplishedbyawrench,screwdriver,etc. Manyofthesedevicesareavailable,whichwhensetattheproperamountoftorque
will tighten the part to the correct amount and no tighter.
All straps and eccentrics should be tightened to 19-21 inch-pounds (22-24cm/kg) unless otherwise noted.
All other nuts, bolts, screws, etc. should be tightened by hand as tightly as possible, unless otherwise noted.
DESCRIPTION OF MACHINES
Universalstyle,Feed-off-the-arm,highspeed,mediumthrow,fiveorsixthreadmachine. Therearefourneedlesandoneretainer
abreast, one looper and a manually adjusted differential feed control. There is an enclosed automatic lubricating system, filter
type oil return pump, visual sight oil action and supply gauges. The maximum work space in front of the needles is 8 inches
(203.2mm). Recommendedmaximumspeed-3200R.P.M.forallStyles.Machinescanbeusedoneithertableorpedestalmount.
STYLE OF MACHINES
36200L220-60 LAPFLATSEAMER: Forsimultaneously trimmingrightandleft pliesandlapseaming with5needlesfor increased
seam strength on swimsuits, leotards, sports workout wear, etc.
Seam specifications 610-LSa-1. Components produce a .236" (6.0mm) wide seam.
(was 35600JU)

ILLUSTRATIONS
Thismanualhasbeenarrangedtosimplifyorderingrepairparts. Explodedviewsofvarioussectionsofthemechanismareshown
so that the parts may be seen in their actual position in the machine. On the page opposite the illustration will be found a listing
of the parts with their part numbers, description and the number of pieces required in the particular view being shown.
Numbers in the first column are reference numbers only, and merely indicate the position of the part in the illustration. The
reference number should never be used in ordering parts. Always use the part number listed in the second column.
Componentpartsofsub-assemblieswhichcanbefurnishedforrepairsareindicatedbyindenting their descriptions under the
description of the main sub-assembly. As an example refer to the following text.
9. 29126 EC Upper Looper Drive Shaft Assembly ................................................................................. 1
10. 22503 F Screw ....................................................................................................................................... 1
11. 39543 E Cam Follower Locking Clamp ..................................................................................... 1
Itwillbenotedinthepreviousexamplethatthecamfollower, bushingandcamguideandtheupperlooperdriveshaftarenot
listed. The reason is that replacement of these parts individually is not recommended, so the complete upper looper drive shaft
assembly should be ordered.
Whenapartiscommontoallmachinescoveredinthismanual,nospecificusagewillbementionedinthedescription. However,
whenthepartsforthevariousmachinesarenotthesame,thespecificusagewillbementionedinthedescriptionand,ifnecessary,
the difference will be shown in the illustration.
A numerical index of all the parts shown in this manual is located at the back. This will facilitate locating the illustration and
description when only a part number is known.
IDENTIFYING PARTS
Where the construction permits, each part is stamped with its part number. On some of the smaller parts and on those where
construction does not permit, an identification letter is stamped in to distinguish the part from similar ones.
PLEASE NOTE: Partnumbers represent the same part,regardless of which manual theyappear. On all orders please include
part number, name and style of machine for which the part was ordered.
NEEDLES
Eachneedlehasbothatypeandsizenumber. Thetypenumberdenotesthekindofshank,point,length,groove,finishandother
details. Thesizenumber,stampedontheneedleshank,denotesthelargestdiameteroftheblademeasuredbetweentheshank
and the eye. Collectively, the type number and size number represent the complete symbol which is given on the label of all
needles packed and sold by Union Special.
TYPE DESCRIPTION
116GKS Round shank, round point, extra short, double groove, struck groove, spotted, chromium plated needle.
.048 (1.2mm) Diameter Shank. Size 065/025 available only.
When changing the needle, make sure it is fully inserted in the needle driving arm before the clamp screw is tightened.
To have needles promptly and accurately filled, an empty package, a needle sample, or the type and size number should be
forwarded. Usethedescriptiononthe label. Acompleteordershouldreadasfollows: "100 needles,type116GKS,size065/025".
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SAFETY RULES:
1. Before putting the machines described in this manual into service, carefully read the instructions. The
starting of each machine is only permitted after taking notice of the instructions and by qualified
operators.
IMPORTANT! Before putting the machine into service, also read the safety rules and
instructions from the motor supplier.
2. Observe the national safety rules valid for your country.
3. The sewing machines described in this instruction manual are prohibited from being put into service until
it has been ascertained that the sewing units which these sewing machines will be built into, have
conformed with the EC Council Directives (89/392/EEC, Annex II B).
Each machine is only allowed to be used as foreseen. The foreseen use of the particular machine is
described in paragraph “STYLES OF MACHINES” of this instruction manual. Another use, going beyond
the description, is not as foreseen.
4. All safety devices must be in position when the machine is ready for work or in operation. Operation of
the machine without the appertaining safety devices is prohibited.
5. Wear safety glasses.
6. In case of machine conversions and changes all valid safety rules must be considered. Conversions and
changes are made at your own risk.
7. The warning hints in the instructions are marked with one of these two symbols:
8. When doing the following the machine has to be disconnected from the power supply by turning off the
main switch or by pulling out the main plug:
8.1 When threading needle(s), looper, spreader etc.
8.2 When replacing any parts such as needle(s), presser foot, throat plate, looper, spreader, feed dog,
needle guard, folder, fabric guide etc.
8.3 When leaving the workplace and when the workplace is unattended.
8.4 When doing maintenance work.
8.5 When using clutch motors without actuation lock, wait until the motor is stopped totally.
9. Maintenance, repair and conversion work (see item 8) must be done only by trained technicians or
special skilled personnel under consideration of the instructions.
10. Any work on the electrical equipment must be done by an electrician or under direction and supervision
of special skilled personnel.
11. Work on parts and equipment under electrical power is not permitted. Permissible exceptions are
described in the applicable sections of standard sheet DIN VDE 0105.
12. Before doing maintenance and repair work on the pneumatic equipment, the machine has to be
disconnected from the compressed air supply. In case of existing residual air pressure, after discon-
necting from compressed air supply (i.e. pneumatic equipment with air tank), the pressure has to be
removed by bleeding.

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THREADING

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OILING
Referring to Fig. 1, fill the machine at (A) and (B). Oil capacity of class 36200 is 2.5 ounces in the bottom
reservoir and 2.5 ounces in the top reservoir. Use a straight mineral oil, Saybolt viscosity of 90 to 125 seconds
at 100° Fahrenheit. The oil level is checked at gauges (C) and (D). Maintain oil level between the red lines
of these gauges.
This machine is automatically lubricated by a continuously driven rotary pump. Oil flow can be observed
through windows (A) and (B). When installing a new machine or starting a machine that has been idle for
sometime, priming may be necessary. Removeplug screws (E), fill holeswith recommended oil and replace
screws BEFORE operating. If oil does not flow while machine is running, pump is inoperative.
Remove screw 22733B (F, Fig. 1 inset) to drain oil from the top reservoir. To drain oil from bottom reservoir
remove screw 999-196 (G).
Occasionally, it is necessary to oil the linkage of the presser foot, the knife holder shank (36273A), guide
collar (36273K) and the various links and bearings of the presser foot lifting mechanism and thread tension
release.
FIG. 1

ADJUSTING INSTRUCTIONS
Instructions stating direction or location, such as right, left, front or rear of the machine are given relative to
the operator's position at the machine unless otherwise noted. The handwheel rotates clockwise in
operating direction.
SETTING THE NEEDLE BAR HEIGHT & ALIGNMENT
Insert the first (left) and fifth needles into the needle head. The needles for this
Class of machine are made with two flats on the front of the shank This will
enable you to correctly position the needles in the needle head. Make
certain the needle shank is fully inserted and that the screw is seated firmly
on the flat.
To position the needle head square with the throat plate, use the upper knife
or a straight edge to align the needles with the cross grooves in the throat
plate. (See Fig. 2)
Refer to table 1 for the dimension from the fifth (lowest) needle to the surface
of the throat plate and for the number of the needle bar height gauge.
Position the needle bar at its highest
pointoftravel. Loosenneedlebar clamp
screw (A, FIG.3) & use the specified
needle bar height gauge (B) to achieve
the desired height dimension from the
fifth (lowest) needle (C) to the throat
plate surface (D). Tighten clamp screw
(A) and recheck setting. Care must be
taken not to disturb the needle head
alignmentwhilemakingtheadjustment.
Add the remaining needles.
CAUTION: If the needle head has been replaced it must be torqued to 17 in. lbs.
(20cm/kg). Or until torque bar (21227AR), inserted into cross hole in the needle bar,
bends. It will not seat against the bottom of the needle bar. After tightening, check
for expansion of the needle bar by positioning it up into the lower bushing hole. If the
bar has expanded it will bind in the bushing. The bar must be replaced or lapped to
reduce the bell shape. Align and set needle bar height as described above.
FIG. 2
TABLE 1
FIG. 3
ELYTS
HT5MORFNOISNEMID OTELDEEN)TSEWOL( ETALPTAORHT ECAFRUS
ELDEEN RAB THGIEH EGUAG REBMUN ELDEEN THGIEH EGUAG PET
SDEKRAM
06-022L00263)MM7.21("2/1SD72212005.
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SETTING THE NEEDLE BAR HEIGHT & ALIGNMENT (CONT)
Correct spacing of the needles in the throat plate stitch tongue is
imperative to proper sewing conditions. Improper relationship of the
needlestothestitch tongue often results in malformed stitches. When
replacing the stitch tongue make sure needles are aligned properly
(see Fig. 4).
If the stitch tongue and throat plate are properly seated and the
needle position is not correct, the cylinder has probably been forced
out of position. If realignment is necessary, refer to the section
"Centering the Cylinder".
Whentheneedlesare correctly positioned in the throat plate they are
centered in the stitch tongue (see Fig. 4). Actually, the needle bar is
centered to the throat plate and cylinder, however, to provide clear-
ance on the left side of the needle for the needle loops passing
around the looper during the down stroke of the needles, the slots in
the stitch tongue are made off-center to the left. Accurate position-
ing of the needles may be obtained by repositioning the cylinder.
ALIGNING THE CYLINDER
Remove the top front cover and gasket from the main frame. Loosen
cylinder holding screw (A, Fig. 5). Turn eccentric screw (B) clock-
wise to move the cylinder so the needles are closer to the right side
of the stitch tongue. Turn the stud counterclockwise to locate the
needles closer to the left. Tighten screw (A) and recheck settings.
NOTE: Thecylindermaynotmovefreelywhenthe eccentric is turned
because the joint sealant compound has set. Light tapping with a
wooden block at the joint or midpoint of the arm may be necessary.
FIG. 4
FIG. 5

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SETTING THE LOOPER TRAVEL USING GAUGE 21227CN
Attach looper travel gauge plate (A, Fig. 6) to the rear of the cylinder
arm. Set the bottom of the gauge so it is approximately horizontal
and lock lightly in place with screw (B) directly underneath. Attach
looper travel gauge pointer (C) to the looper using the left needle
guardscrewhole. Turnthehandwheel in operating direction until the
looper is positioned to the far right. Set pointer (C) at zero degrees
by rotating gauge plate (A) and lock in place. Continue turning the
handwheel until the pointer stops. If the looper travel is correct the
pointer should indicate 55°40'.
SETTING THE LOOPER TRAVEL
To adjust the looper travel remove the top front cover and the end
cover. Loosen left-handed locknut (A, Fig. 7) and turn screw (B)
clockwise to decrease the looper travel or counterclockwise to
increase the looper travel. Tighten locknut (A) and recheck setting.
NOTE: After setting the looper travel the machine must be checked
for synchronization.
FIG. 7
FIG. 6