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CONTENTS
Contents and Cautions…………2 The Figure of the Finished The World of Karakuri Mechanical Dolls
The World of Karakuri Mechanical Doll… … … … … 20 The history of Karakuri ("Karakuri" means the mechanism that drives a
Mechanical Dolls… … … … … 3 Let’s Do the Test Run! … … … 21 machine.) automatic dolls in Japan began in the early Edo period(1603~1867).
Parts in this Kit……………………4 Make Fine Adjustment to Each Part…22 The tea-serving doll is the most typical one and it appears in the book
Let’s Assemble the Cart!………6 Check the Move of the Doll……23 written by Ihara Saikaku, a very popular novelist in the Edo period. This
Let’s Install the Escapement!…9 Make the Final Adjustment Karakuri doll kit is produced according to the “Karakuri Zui”, the only
Let’s Assemble the Chest Unit! …11 before your Performance… … … 24 existing manual of Karakuri mechanical dolls written in 1796 by
Let’s Assemble the Motive How to Dress the Doll in Kimono…25 Hosokawa Hanzo, popularly
Power Unit! … … … … … … … 14 Mechanism of the Karakuri known as Karakuri Hanzo
Let’s Install the Other Parts!…19 Mechanical Doll… … … … … 26 who was an engineer of
Tosa domain. Karakuri
dolls can be said to be one
of the original foams of
CAUTION! ★Please read the following instructions before using this kit. modern robots.
Please enjoy
● Be careful of handling thin and pointed metal bars contained in this kit. the beauty of
Improper use may cause injury to persons.
Japanese
● Be careful of handling some metallic parts that are made thin and sharp
craftsmanship
functionally. Improper use may cause injury to persons.
of those days
● Be careful not to swallow small parts to avoid suffocation.
by assembling
● Be careful not to point your hands and eyes with the screwdriver in this kit to avoid
this kit.
injury.
● Be careful that your fingers are not caught in a machine while operation.
● Do not operate the doll on a road to avoid the risk of traffic accidents.
● Do not break up the mainspring. An inner spring may cause injury to persons.
★ Please read the assembly instructions and cautions in this booklet carefully before use.
Do not use the parts that are broken or deformed.
★ Please handle the doll with good care. The doll may be broken if it is treated roughly.
For example, do not shake it with its head down.
★ Be careful not to be scalded when the doll serves hot drinks.
★ The colors may fade out of Kimonos when it is exposed to the sun. Keep the doll with care.
★ Do not wash the Kimonos with whites. The colors may be washed off and stain whites.
driving wheel
arm shaft
driving wheel
*If the driving wheel cover is auto-adjustment
auxiliary stuck in the auxiliary wheel,
rubber
wheel pin
bottom panel please separate each other.
head both sides
adhesive tape front chest
reversal
mainspring shaft stopper A left foot
lower A Variety of Screws
guard
rubber
A: 8 pieces of 3-by-8 mm
band screws
right foot
right body
mainspring B: 3 pieces of 2.6-by-5 mm
screws with a collar
adjuster reversal stopper B
upper C: 5 pieces of 2-by-5 mm
rotary wheel A chanchanko vest screws with a collar
guard
rotary wheel B
D: 4 pieces of 2-by-10 mm
tray screws
Fit the front wheel rubber Fasten the front wheel bearing
Let’s Assemble the Cart! 4 around the front wheel. Put the
wheel into the front wheel
5 to the bottom panel with a screw
C.
●Parts to be used bottom panel driving wheel
looped string
bearing. front wheel bearing
screw C (2-by-5
(large, middle, small)
mm with a collar)
Put it in until it snaps.
driving wheel bottom panel
cover driving
tension spring wheel
(large, middle, small) front wheel
rubber rubber
front wheel ※At this point the front
front wheel bridge
connector front wheel wheel connector comes
auxiliary wheel right foot bearing off easily. Pay attention
front wheel left foot
3 pieces of screw not to lose the connector.
Screws to C’s 2-by-5 mm a piece of screw E front wheel
be used with a collar 2-by-6 mm
front wheel front wheel
Connect the front wheel bearing Hang the string attached to the
6
bearing
7
rubber ※ Select correct screws since all screws resemble in shape.
and the front wheel connector tension spring (small) on the
Insert each looped string into each tension spring. Note: In this “Let’s make the
Put the driving wheel cover on Fit the driving wheel rubber in
10 the driving wheel. 11 the groove between driving
wheel and driving wheel cover.
Let’s Install the Escapement!
●Parts to be used
driving wheel driving wheel escapement
cover rubber
driving wheel
sheet weight
driving wheel
escape wheel
2 piece of screw
Screws to 3 pieces of screw
C’s, 2-by-5 mm
◆Fit the projection of the driving wheel to the be used E’s, 2-by-6 mm
with a collar
holes of the driving wheel cover and snap in. left body
※ Select right screws since all screws resemble in shape.
Set the escape wheel in the Push the escapement bridge into
12 Attach the auxiliary wheel to
the shaft of the driving wheel. 13
Install feet inside the driving
wheel and auxiliary wheel. 1 socket of the left body. 2 the left body.
◆Push the projections at the top and the bottom of
(Be careful not to install right foot and left
auxiliary driving wheel escape wheel the escapement bridge into the holes of the left body.
wheel foot inversely.) At the same time, push the shaft of the escape wheel
◆Insert the point into the center hole of the escapement.
of the shaft in the
right foot left foot left body
◆The direction of hole at the bottom
the auxiliary wheel of the socket.
is like the figure. escape
wheel
left body
bottom panel
use it at p.18.
screw E (2-by-6 mm) ◆This sheet weight
is soft enough to be
left body cut with scissors.
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front chest
neck bridge
neck joint (upper) lower chest neck joint (lower)
sheet weight sheet weight 2 pieces of screw
Screws to 1 piece of screw 4 pieces of screw
B’s, 2.6-by-5 mm
be used with a collar D, 2-by-10 mm E’s, 2-by-6 mm
Put the escapement
neck joint
escapement bridge
(upper) screw E
left body projection
left body (2-by-6 mm)
Check if the neck and the neck Put tension springs (large and Put the hole of the neck bridge Hold the bridge softly and fit the
4 joint (upper) move back and
forth smoothly.
5 middle) into frames on the
chest (lower) to the end as
10 on the projection of the neck
joint (upper).
11 front chest in the groove of the
lower chest.Turn the screw D for
shown in the figure. adjustment just a couple of times.
※Put in the upper
tension spring neck joint (upper)
Side View part of the front chest
(middle) first, then, fit the
Clatter! lower part in the
chest (lower) groove below.
<front side> screw D (2-by-
neck bridge 10 mm)
◆Be careful not to
take the large sheet groove
spring for middle, front chest
because both springs
◆See p.22 for the
tension have the same width, lower adjustment of the
spring although their chest screw D.
(large) lengths are different. neck bridge
Turn over the lower chest and Fasten the upper chest and Hang the string of the tension spring (large) on
6 put the neck joint (lower) on the
projection of the lower chest.
7 the lower chest with screw E’s
paying attention to the
12 the hook at the side of the neck with tweezers.
Put the neck bridge in the hole Keep the neck bridge down.
Now the Chest Unit is Completed!
8 of the neck joint (lower). 9 You’ve finished the
Side View
chest unit. Look at
neck bridge
the figure to make
sure if it is correctly
neck bridge assembled.
Attach the reversal stopper B and the rotary wheel B to the large wheel.
Let’s Assemble the Motive Power Unit! 3
●Parts to be used
①Put the reversal stopper ②Fit the rotary wheel B
mainspring shaft
arm shaft B on the projection of the in the center hole of the ③Make sure that the
adjuster large wheel. large wheel. rotary wheel B turns in
the only one direction
reversal rotary
reversal stopper B stopper B clattering.
rotary wheel B wheel B Clatt
er!
rotary plate
rubber band
※ Select right screws since all screws resemble in shape. Put the mainspring shaft through the rotary plate first, then though the
Attach the adjuster to the rotary plate. Put the The adjuster can move left 4 large wheel in the direction as shown in the figure.
1 adjuster on the projection and fasten with a screw B. and right to some extent
by loosening the screw B.
adjuster
rotary plate
2
Turn over the rotary plate and attach the reversal stopper A and rotary
wheel A in the right direction. ③Make sure that the rotary
5 mainspring shaft to the end so
that the parts don’t come apart. rotary wheel A
wheel A turns to only one rotary wheel B
①Place the rotary plate with its ②Fit the rotary wheel A in rotary plate
backside (without a screw) up the center hole of the rotary direction clattering. (The
rubber band
and put the reversal stopper A on plate. mechanism a wheel can turn
the projection. rotary only in one direction like
reversal stopper A
※Put it on to
wheel A this, is called “ratchet
the end. mechanism”.) Cl
rotary plate atter!
◆ Side view is
rubber band mainspring shaft
like this figure.
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Attach the mainspring to the Fasten the mainspring to the Insert the mainspring shaft into the center hole of the mainspring, while
6 right body in the direction like
the figure below.
7 right body with screw A’s. 10 holding up the neck joint (lower) so that it isn’t in the way.
◆ Fit the two small ◆ These two ◆ Put your finger through
projections of mainspring screw A’s have to the front chest and push the
in the holes of the right be fastened neck bridge to raise the neck
body. firmly, not push joint (lower).
small
mainspring temporarily.
projection mainspring
mainspring
large
screw A
projection mainspring shaft
(3-by-8 mm)
right body right body
small projection
Attach the chest unit finished Fasten the chest unit to the
8 at p.13 to the right body. 9 right body with screw A’s.
11
Fasten a screw D for adjustment to the arm shaft loose. Then, put the arm
shaft through the front chest till the tip comes out from the hole of the right
body.
screw D
chest unit ※ Screw just four or five times (2-by-10 mm)
to fasten loose.
screw A
(3-by-8 mm)
arm shaft
◆ See p.22 for the
screw A adjustment of the
(3-by-8 mm) screw.
◆ Put four projections
of the chest unit in the ◆ Fasten these ◆ After the mainspring shaft was put in, the neck
holes of the right body. two screw A’s a joint (lower) goes between the rotary plate and the
little bit loose
and leave a room large wheel as shown in the figure.
to screw firmly
as a finishing.
right body
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left arm
screw A
(3-by-8 mm) 2 pieces of
screw D ’s
tray 2-by-10 mm
auto-adjustment pin
screw A
(3-by-8 mm) Hang the string of the tension Attach the right and the left
1 spring (middle) on the hook of
the arm shaft.
2 arms to the arm shaft and fasten
with screw D’s.
hook
◆ Bend the tension
spring (middle) with screw D screw D (2-by-10 mm)
your fingers until (2-by-10 mm)
◆ Thrust the tips the string reaches
of the arm shaft
the hook, then hang
and the mainspring left body the string on the
shaft out of the holes
hook with
of the left body.
tweezers.
Sn
ap!
bottom panel
<backside>
screw A screw A
(3-by-8 mm) (3-by-8 mm)
◆ Fasten these two screw A’s a little bit loose at tray
this point. Make sure that there is no distortion
all over, then fasten screw A’s (not only the two
screw A’s fastened now but also screw A’s
fastened loose at 9 and 12) again firmly. auto-adjustment pin
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◆CHECK!◆
Check the action of each part
before you dress the doll.
1 wind up the mainspring with the
winding knob.
2 the tray, the doll starts
moving. First, it goes straight.
tension spring
※Do not fill the cup with
tea during the test so that
◆CHECK!◆ the tea might not be spilt.
escape wheel&
auto-adjustment pin
◆CHECK!◆
driving wheel&
large wheel
(backside)
After the doll goes straight for a Return the teacup on the tray
3 while, it makes a bow. Then, take
the teacup and the doll stops.
4 and the doll starts moving
again. Then, it makes a turn.
(backside)
◆CHECK!◆
front wheel connector&
◆CHECK!◆ front wheel bridge
bottom panel front wheel bridge
(backside)
screw C
(2-by-5
mm with
a collar)
After the turn, it goes straight. When the doll gets back to
5 6
projection
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Make Fine Adjustments to each part Check the Move of the Doll
Before your performance in front of guests, test a couple of times and grasp how each part works, how
long the doll moves and how it turns. Then make fine adjustments to each action as follows if necessary. If the doll moves as follows, you’ve made good adjustments. Check it now!
Make the Final Adjustment Before your Performance ●How to Dress the Doll
When you finish the adjustments on
Wind up the mainspring. ★Before you start dressing ★
p.22, make the final adjustment before
you show the doll to your guest.(This
1 Put on guards (upper and
lower) beforehand so that
guard (upper)
guard (lower)
adjustment is possible after the doll is the dress is not caught in ◆ Pay attention
dressed. In that case, pull the hakama wheels. to the direction.
up.) ● Adjust the distance between the
starting point and where the doll bows 1 Dress the kimono tops. Parts to be used
in front of your guest. 1. Cut a both side adhesive 2. Put each arm through sleeves of the hakama
tape into 10cm. Put it on the kimono top 1 and the 2. Peel the thin skirt
inside of the back margin of paper from the adhesive tape and paste
the kimono top 1 (the left the both sides of kimono tops together at
side when you face it). the back. kimono
Align the kimono top 2
top 1 chanchanko
collars of
both tops. vest
When you wind up the mainspring, the adjuster at the rotary plate comes to
2 the position shown in the figure below. Turn the rotary plate clockwise and
change the position to suite the distance between you and the guest. (The
both side
adhesive tape
2 Dress the hakama skirt. 2. Bring the back laces to the front and tie them at
more you turn, the less the distance becomes. Take a look at the figure
1. Unfold the hakama skirt and put the front. (Cover the back knot with the hakama skirt.
below and adjust the distance.)
through the doll from the bottom. Bring Make the back part higher and the front part lower.)
※ Be sure to turn the rotary When the adjuster is at this ※ Check the collar, the nape, the neckline and the position
the front laces back and tie them at the
plate always clockwise. position, the doll goes straight of the hakama skirt. If they are all right, cut the rest of the
back.(Tie the laces at the height as shown
about 45 cm. adhesive tape and fasten the front with it.
in the figure below. Adjust the skirt so
When the mainspring is wound, that the insteps come out a little bit.) Note: If the front is
the adjuster comes to this position. ◆Note: Keep the screw of the crossed too tight,
The doll goes straight about 90 cm adjuster as it is. (Do not loosen it the doll can’t bow.
(the longest) if you set the doll in and change the position of the Check if the neck
motion in this condition. can move back and
adjuster itself.) the back
part forth before you
higher fasten the front
●If the doll doesn’t move successfully after all adjustments, check the following points.● with a tape.
the front part lower
★The doll starts right after you wind up the ★The doll bows from the beginning. →The
mainspring without putting the teacup on tension spring (large) might not be working 3 Dress the chanchanko vest. Finished!
the tray. →The tension spring (middle) well. Knot the string twice and make the Take off the head. Turn the
might not be working well. Knot the string loop smaller or change the tension spring vest upside down and put the
twice and make the loop smaller or change (large) with a spare. both arms through sleeve
the tension spring (middle) with a spare. ★The doll doesn’t make a bow at all.→If the holes as shown in the figure.
★The doll doesn’t go straight after the turn. doll is dressed already and if it is too tight Dress the vest as it covers the
→The tension spring (small) might not be around the neck, the doll can’t bow. In this neck. Tie the laces. (If the
working well. Knot the string twice and case, loosen the Kimono a little so that the front knot comes out forward,
doll can move the neck. fasten with an adhesive tape.) ↑Take off the head
make the loop smaller or change the tension
and dress the ↑Attach the tray. Be
spring (small) with a spare. Put the head on again. Now ↑Tie the
chanchanko vest. careful that the front laces
you’ve finished! front laces.
24 do not touch the tray. 25
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26 References:Tachikawa, Shoji, Yomigaeru Karakuri (The Revival of the Karakuri Mechanism): NTT Publishing Company. 27
Tachikawa, Shoji and coauthors, Zusetu Karakuri (The Illustrated Karakuri Mechanism): Kawade Syobo Shinsha Publishing Company.