UnionSpecial Juki 36200 Series Quick start guide

40040898
No.E373-00
ENGINEER’S MANUAL
Feed-off-the-arm, 4-needle “Flatseamer” for
Top and Bottom Coverstitch
36200 Series
®
Minute-quantity
lubrication

Introduction
This Engineer’s Manual is written for the technical personnel who are responsible for the service and mainte-
nance of the machine.
The maintenance services to be done on this sewing machine should be based on this manual.
This manual gives the "Standard Adjustment" on the former section under which the most basic adjustment
value is described and on the latter section the "Results of Improper Adjustment" under which stitching errors
and troubles arising from mechanical failures and "How To Adjust" are described.
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CONTENTS
1. Specifications ........................................................................................................ 1
2. List of models ........................................................................................................ 2
3. Model numbering system............................................................................ 3
4. Configuration.................................................................................................4
(1) Head names .............................................................................................................................. 4
(2) Names of presser body ........................................................................................................... 5
5. Needles ......................................................................................................... 6
(1) Needle types ............................................................................................................................. 6
(2) Features of needles ................................................................................................................. 6
(3) Needle applications ................................................................................................................. 6
6. How to conduct threading........................................................................... 7
7. Standard adjustment .............................................................................................. 8
(1) Presser removal work ...................................................................................................... 8
(2) Adjusting the height of the needle bar......................................................................... 10
(3) Adjustment of needle array ........................................................................................... 12
(4) Right and left needle entry position adjustments ....................................................... 14
(5) Looper adjustment ......................................................................................................... 16
1) Returning amount of the looper .........................................................................................................16
2) Adjustment of a clearance between looper and needle.....................................................................16
(6) Adjustment of looper and needle bar timing ..................................................................... 18
(7) Adjustment of looper movement......................................................................................... 20
(8) Adjustment of looper movement locus .............................................................................. 22
(9) Adjustment of the feed dog ................................................................................................. 24
(10)Adjustment of needle holder ............................................................................................... 26
1) Adjustment of rear needle holder.......................................................................................................26
2) Adjustment of forward movement needle holder ...............................................................................26
(11) Adjustment of feed mechanisms ........................................................................................ 28
1) Stitch length adjustment ....................................................................................................................28
2) Adjustment of differential feed amount ..............................................................................................28
(12)Adjustment of presser main body mounting ..................................................................... 30
(13)Adjustment of the presser main body proper.................................................................... 32
1) Adjustment of presser lifter connecting lever.....................................................................................32
2) Adjustment of presser lifting strap plunger ........................................................................................32
3) Adjustment of minute presser lifting...................................................................................................32
(14)Adjustment of top fancy looper and fancy thread carrier................................................. 34
1) Stroke position adjustment of drive sleeve ........................................................................................34
2) Amount of fancy thread carrier injection ............................................................................................34
3) Leftmost point of top fancy looper......................................................................................................36
4) Clearance developed at the time of crossing between the fancy thread carrier and
the tip of the top fancy looper ............................................................................................................36
5) Rightmost point of top fancy looper ...................................................................................................36
6) Height of top fancy looper..................................................................................................................36
(15)Adjustment of top fancy cam and bobbin thread cam...................................................... 38
1) Adjustment of top fancy cam .............................................................................................................38
2) Adjustment of bobbin thread cam ......................................................................................................38
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(16) Knife adjustment .................................................................................................................. 40
1) Lower knife adjustment......................................................................................................................40
2) Upper knife adjustment......................................................................................................................40
3) Pressure adjustment of upper knife ...................................................................................................40
(17) Adjustment of upper knife drive lever................................................................................ 42
(18) Adjustment of needle thread path ...................................................................................... 44
1) Adjustment of needle thread guide bar..............................................................................................44
2) Adjustment of needle holder adjusting pin.........................................................................................44
3) Adjustment of needle thread presser spring ......................................................................................44
(19) Adjustment of tension disk rise and protection cover ..................................................... 46
1) Adjustment of tension disk rise ..........................................................................................................46
2) Adjustment of protection cover ..........................................................................................................46
(20) Adjustment of lapformer...................................................................................................... 48
8. Lubrication ........................................................................................................... 50
9. List of rear spring ................................................................................................ 51
(1) One side trim......................................................................................................................... 51
(2) Both side trim........................................................................................................................ 52
(3) Taping .................................................................................................................................... 53
(4) Step gauge ............................................................................................................................ 53
(5) Butted seam .......................................................................................................................... 53
10. Types of feed dogs.............................................................................................. 54
11. Maintenance......................................................................................................... 55
(1) Spare parts ............................................................................................................................. 55
12.Troubles and corrective measures............................................................56
13.Table drawing ..............................................................................................68
(1) Auxiliary drive table.............................................................................................................. 68
(2) Auxiliary drive sub-table ...................................................................................................... 69
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No. Application
36200L/36200U 36200T 36200L220
1Application Intended for taping
2Sewing type
3 Max. sewing speed (normal) 4,200rpm (normal sewing speed: 3,200rpm) 4,200rpm (normal: 2,500rpm)
4 Stitch length 1.6 to 2.5mm (Standard 2.1mm) 1.6 to 1.8mm (standard 1.6mm)
5Needle gauge 5.2mm, 6.0mm 6.0mm
6Needle bar stroke 30mm
UY118GKS065 to 080 (#9 to #12) UY116GKS065
* (Standard 70/ #10) (Standard 80/ #12) (Standard 65/ #9)
36211-060 to 075
* (Standard 65/ #9) (Standard 75/ #11)
9No. of threads used 6 pcs. 5 pcs. 7 pcs.
Main feed ----- Slide type stitch pitch control system
Differential feed ------------Lever control system
11 Lubrication Rotary pump type auto lubrication (minute-quantity lubrication to needle bar and looper sections)
Front oil storage: 70ml to 80ml
Rear oil storage: 60ml to 70ml
Union Special Specification 175 (equivalent to ISO VG22) or
JUKI Oil SUP2000 – 1L
Table and Aux. Drive mounting system
Pedestal mounting system
15 Lifting amount of presser One side trim type 8.0mm, both side trim type 6.0mm
16 Minute presser lifting Provided as standard
17 Needle thread silicone tank Provided as standard
18 External dimensions Height 31.5mm x Width 25.5mm x Depth 42.5mm
19 Weight of head 22kg
20 Working temperature/humidity Temperature : 5°C to 35°C, Humidity : 35% to 85% (no condensation)
21 Supply voltage/frequency Rated voltage ±10% 50 / 60Hz
1. Specifications
Model name
Item
Needles to be used
(Standard needle count)
8
10 Feed control system
12 Quantity of oil storage
13 Lubricating oil
14 Installation system
* For standard usage in Japan, the needle count is [Standard 65/#9]. The needle count for retainer needles is [Standard 60/
#8].
7
Retainer needles to be used
(Standard needle count)
General light-weight -
medium-weight materials For light-weight (swimsuits)
materials
4-needle both side trim
fancy sewing 4-needle one side trim
fancy sewing 5-needle both side trim
fancy sewing
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2. List of models
The standard models are the lapseamers with 4 needles and 6 threads for vertical fancy stitch.
According to the model names, they are classified into specifications for the specific gauges, step gauges, taping,
and multi-purpose.
Model name Application Top fancy Knife Lapformer
General knit goods
36200L100-52 4 1 6 With
One side trim Without
36200L100-60 General knit goods 4 1 6 With
One side trim Without
General knit goods
36200L200-52 4 1 6 With
Both side trim With
General knit goods 1
36200L200-60 4 6 With
Both side trim With
Swimsuits 0
Specific gauges
(Thigh patch-up for
36200L202-52 boxer's briefs, etc.) 4 1 6 With
Both side trim With
Medium-weight materials
Specific gauges
(Thigh patch-up for
36200L202-60 boxer's briefs, etc.) 4 1 6 With Both side trim With
Medium-weight materials
1.27mm step gauges
36200L210-52 4 1 6 With
Both side trim With
1.27mm step gauges
36200L210-60 4 1 6 With Both side trim With
36200T300-52 Fly taping 4 1 5 Without
One side trim Without
36200T300-60 Fly taping 4 1 5 Without One side trim Without
Multi-purpose
36200U300-52 4 1 6 With Combined use Combined use
Multi-purpose
36200U300-60 4 1 6 With Combined use Combined use
(Caution) The list shows the models exclusive for 4 needles. It does not include the models for 5 needles.
Number of
needle Retainer
needle Number of threads
Light- and medium-weight
materials
Light- and medium-weight
materials
Light- and medium-weight
materials
Medium- and heavy-
weight materials
Medium- and heavy-
weight materials
Light- and medium-weight
materials
Light- and medium-weight
materials
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3. Model numbering system
Name: Feed-off-the-arm 4-needle “Flatseamer” for Top and Bottom Coverstitch
123456789101112131415
36200 —AA
6 to 9 Head specifications
Code Specifications Cloth cutting Applications
L100 Lapseam One side trim With edge guide spreader
L200 Lapseam Both side trim With lapformer spreader
L202 Lapseam Both side trim Specific both side trim gauge lapformer
With spreader
L210 Lapseam Both side trim Both side trim 1.27mm, step presser, throat plate, feed dog
With lapformer spreader
L220 Lapseam Both side trim Specific 5-needle presser, lapformer
With spreader (for swimsuits)
T300 Taping Combined use for one side Without spreader, tape reel
and both side trim With tape folder
U300 Multi-purpose Multi-purpose specifications
10 to 11 Needle gauge
52 5.2mm
60 6.0mm
14 Place pf destonation
AStandard
15 Accessories type
AStandard
*Head spec. L220 applicable to 60 (6.0mm) only
12 Region
JJapan
NNorth America, Europe
SAsia
* Head spec. L100 only, Impossible to select J
J (for Japan) of L100 covered by S
Combined use for one side
and both side trim
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4. Configuration
(1) Head names
Presser pressure stroke adjusting screw Frame needle thread path Looper cover
Needle bar guard Needle thread guide bar Presser
Rear top cover Thread path frame Face cover
Lift lever Looper thread guide Minute presser lifting
Oil circulator check window (rear) Stitch length control window screw Swing guard
Oil gauge (rear) Oil gauge (front) Protection cover
Needle thread silicone unit Oil drain screw (front) Lapformer
Thread tension knob Cylinder side cover Oil drain screw (rear)
Thread guide Differential adjusting lever Pulley
Oil circulator check window (front) Scale plate feed Needle thread rocking guide
Threading guard (Assy) Feed dog eccentric pin Needlethread holder adjusting pin
Front top cover
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(2) Names of presser body
Presser bar Fancy thread carrier Drive lever link
Drive link Top fancy looper Drive sleeve
Link pin Lower knife clamp setscrew Minor presser (Minor presser
Link pin setscrew Lower knife clamp for stepped materials)
Drive lever shaft (carrier) Rear spring, left Rear spring, right
Rear spring setscrew Lower knife
Fancy thread carrier setscrew Rear spring hanger wire
Thread chips guard setscrew Fancy looper setscrew
Spring Presser main body
Thread chips guard Drive lever shaft (looper)
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5. Needles
(1) Needle types
UNION standard accessory needle GROZ-BECKERT/UY118GKS 070/#10
No. Needle symbol Thread groove Scoop Strength Thread available for sewing
Presence of front Spun thread, wooly thread,
and rea Tetoron thread, cotton thread
2 UY118GAS Without Strong Spun thread
3 UY118GBS Front only With Weak Wooly thread
4 36211
(2) Features of needles
(3) Needle applications
No. Features
The front and rear sides of a needle have thread grooves. It is somewhat more difficult to obtain an
adequate tension for the needle thread, compared with the 118GAS.
Since there is a scoop behind the needle, the effect of prevention against stitch skipping can be
expected even for a thread that is inefficient in making loops.
There are thread grooves provided to both the front and rear sides of a needle. The needle thread
tension tends to be increased.
Since no scoop is provided to rear side of the needle, needle bend is minimum at the time of
needle entry into the materials. This type of needle is suitable for the products of heavy-weight
materials or those that involve thick sections in materials. (General knit goods, etc.)
Since no scoop is provided, it is not suitable for applications to wooly or Tetoron threads.
Since no thread grooves are provided to the rear side of a needle, the needle thread tension tends to
be decreased. Since there is no thread groove and a scoop is provided to the rear side of the needle,
the needle thread can produce loops easily and therefore this type of needle is suitable for applica-
tions to wooly threads or the like.
4 If a retainer needle (sacrifice needle) is used, softer switches can be obtained.
No. Applications
1 Used for the products of knit goods and swimsuits.
2 Used for general knit products.
3 Used for ladies’ shorts, girdles, etc., made of stretchy textiles.
4 Used for general products of knit products.
(Caution) Standard needles used in Japan are of UY118GKS•GAS, 065 (#9).
1 UY118GKS With Weak
1
2
3
Presence of front
and rear
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6. How to conduct threading
How to make threading for the needle threads and the top and bottom fancy threads
Threading illustration and threading guard setup
1. When you want to use the flatseamer machine head, you have to mount the threading guard (Assy) .
It can be mounted by means of two setscrews (2 pcs.).
2. 1 to 4 correspond to the needle thread, 5 to the top fancy thread, and 6 to the bottom fancy thread.
Make threading according to the threading illustration.
43
2
1
5
432156
56
6
12 3 45
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7. Standard adjustment
(1) Presser removal work
1. To make the standard adjustments of the flatseamer, remove the presser main body first of all.
Main body assembly diagram
Rear side of the presser main body
State of the presser removed
State of the face cover removed
Procedures of assembling
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Procedures of assembling
Disassembly procedures for the presser main body
1. Loosen the setscrews (4 pcs.) and take out the face cover .
2. Open the protection cover and take out the needles (5 pcs.) with the needle bars positioned at
the upper dead point.
3. Loosen the upper knife fixing screw (key wrench of 3/8) and remove the upper knife .
4. Loosen the setscrews (2 pcs.) and take out the upper knife fixing block and the upper knife auxiliary
plate .
5. Loosen the presser bar setscrew .
6. Loosen the presser guide left setscrews (key wrench of 5/32) (2 pcs.) and remove the presser guide
left setscrews on the operator side. Make the presser guide left free.
7. Remove the presser pressure adjusting screw and the pressing screw.
8. Loosen the presser bar guide setscrew and remove the presser bar guide and the presser bar
while the presser bar is pulled out upwards.
9. Remove the presser main body .
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(2) Adjusting the height of the needle bar
12.7mm
13.5mm
Standard Adjustment
o For a needle gauge of 5.2mm
Mount the right needle on the needle clamp with the needle bar positioned at the upper dead point and
put the needle bar height gauge on the upper face of the throat plate . Check this condition in the
position of 531. The standard needle bar height is 13.5mm.
Use the needle bar height gauge (21227BU).
o For a needle gauge of 6.0mm
Mount the right needle on the needle clamp with the needle bar positioned at the upper dead point and
put the needle bar height gauge on the upper face of the throat plate . Check this condition in the
position of 500. The standard needle bar height is 12.7mm.
Use the needle bar height gauge (21227DS).
Needle gauge : 5.2mm Needle gauge : 6.0mm
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Adjustment Procedures Results of Improper Adjustment
1. Remove the face cover and loosen the needle bar connecting bracket
setscrew to adjust the needle bar height by the means of the needle
bar height gauge or .
(Caution) When checking the needle bar height, change the needles
and , enter the needles and in the needle
clamps and to their uppermost ends, and stop them
in the correct positions. The needle shank has a flat sec-
tion. Stop the needle with the flat section positioned in
front.
2. After the adjustment of the needle bar height, adjustment of the needle
array is carried out subsequently. Temporarily fasten the setscrew
of the needle bar connecting bracket .
(Caution) 1. When the needle bar connecting bracket setscrew
is fastened temporarily, the needle bar is required not
to come down even when it is rotated.
2. If the needle bar height is changed for a certain rea-
son, readjustment is needed from the beginning, us-
ing the needle bar height gauge or .
When the needle bar height is
greatly different
oThis will be a cause of stitch skip-
ping, needle breakage, or thread
breakage.
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(3) Adjustment of needle array
A line
B line
B line
,
C line
A line C line
Right and left revolving
Standard Adjustment
1. Needle array
Use the left needle and the retainer needle , and check the needle array based on Line A of the upper
knife .
Apply LineAof the upper knife to the left needle and the retainer needle on both sides. In this state,
the standard angle is that Line B of the upper knife is observed in parallel to Line C of the throat plate
groove.
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Adjustment Procedures Results of Improper Adjustment
Method of needle array check
1. Checks on the needle array parallelism are carried out after the
completion of needle bar height adjustments.
2. When checking the needle array parallelism, the needle bar is
lowered to the midpoint under the condition that no looper is attached.
3. Make LineAof the upper knife come in contact with the left needle
and the retainer needle on both sides. In this state, check the
parallelism between Line B of the upper knife and Line C of the
throat plate groove.
4. If no parallelism is secured, insert a spanner (7mm/9/32) in the needle
clamp and try to secure the needle array parallelism by turning
the needle bar to the right and left.
(Caution) If checking is intended without the dislodgment of the
looper, do it in the position where the left needle and
the retainer needle do not come in contact with the
rear side of the looper.
5. After the confirmation of parallelism, check the needle bar height
again and fix the needle bar connecting bracket setscrew .
When the needle parallelism is not
secured
oThis will be a cause of stitch skip-
ping, needle breakage, thread
breakage, or destruction of throat
plate claws.
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(4) Right and left needle entry position adjustments
Left space wider by
0.15mm Right space
Left direction Right direction
Right and left revolving directions
Left middle needle
regarded as the basis Throat
plate
Standard Adjustment
1. Needle entry
Attach the needles (4 pcs.) and the retainer needle , and check the right and left needle entry spaces
in regard to the throat plate claws .
Examine the position where the left space becomes wider by 0.15mm than the right space. In this state, the
standard position is that the needles (4 pcs.) and the retainer needle (1 pc.), five needles in all, do not
touch the right and left throat plate claws .
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Adjustment Procedures Results of Improper Adjustment
Needle entry adjusting positions
1. When adjusting the right and left needle entry, remove the front top
cover and the oil receiver.
2. Loosen the collar setscrew and move the collar toward the
front.
3. Loosen the hexagon coupling bolt and insert a screwdriver in the
eccentric pin . When the screwdriver is turned to the right and left,
the cylinder arm moves to the right and left.
4. Confirm the result of needle entry position adjustments.
5. After adjustments, tighten the hexagon coupling bolt to return the
collar to its initial position. Since then, tighten the collar setscrew
.
Method of confirmation
oTurning the eccentric pin to the right causes the cylinder arm
to move to the left.
oTurning the eccentric pin to the left causes the cylinder arm to
move to the right.
When the needle parallelism is not
secured
oThis will be a cause of stitch skip-
ping, needle breakage, thread
breakage, or destruction of throat
plate claws as a result of get-
ting flaws.
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(5) Looper adjustment
Center
Clearance between the looper
and the left needle
4mm (5/32)
Tip
Right and left directions
Right and left directions
Forward and back-
ward directions
0.0mm
(Light contact)
Standard Adjustment
1) Returning amount of the looper
When the looper is positioned at the leftmost point, adjust the distance to 4mm from the tip of the looper
to the center of the left needle .
The amount of standard looper return is 4mm. However, the amount of return of the looper may somewhat
change according to the type of thread.
The final amount of return of the looper should be determined by making fine adjustments of the amount
of looper return while making threading and observing the stitches of trial sewing.
4mm shall be regarded as the amount of return of the looper during adjustments.
2) Adjustment of a clearance between looper and needle
The standard clearance is 0.0mm (light contact) when the tip of the looper reaches the center of the left
needle .
After rear needle holder adjustments, check the clearance again between the looper and the left needle
. For the final adjustment, this check should be carried out after making threading.
(Caution) 1. If no rear needle holder is provided, the above-mentioned checks should be carried out
in the state that the tip of the looper slightly touches the left needle .
2. The needles to be used come in two types; with a scoop (118GKS) and without a scoop
(118GAS).
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