Repair Tool List August, 2009 You will find a lot of hints for repairing.
* Please place an order with Code No. CONTENTS 1 CONTENTS
Name Code No. Page Name Code No. Page
Tapping Bit Holder 70MM 1R001 1 Bearing Setting Pipe 18-10.2 1R027 5
Retaining Ring S Pliers ST-2N 1R003 1 Bearing Setting Pipe 20-12.2 1R028 5
Retaining Ring S Pliers ST-2 1R004 1 Bearing Setting Pipe 23-15.2 1R029 5
Retaining Ring R Pliers RT-2N 1R005 1 Bearing Setting Pipe 25-17.2 1R030 5
Retaining Ring R Pliers RT-2 1R006 1 Bearing Setting Pipe 28-20.2 1R031 5
Tips for Retaining 1R007 1 Bearing Setting Plate 8.2 1R032 5 Ring Pliers (Straight) Tips for Retaining 1R008 1 Bearing Setting Plate 10.2 1R033 5 Ring Pliers (90 °)
T-shaped Hex. Bolt Wrench 9 1R009 2 Bearing Setting Plate 12.2 1R034 5
T-shaped Hex. Bolt Wrench 12 1R010 2 Bearing Setting Plate 15.2 1R035 5
T-shaped Hex. Bolt Wrench 13 1R011 2 Bearing Setting Plate 17.2 1R036 5
Box Wrench 1R012 2 Bearing Setting Plate 20.2 1R037 5 1R013 L-shaped Torx Wrench Available until 2 Armature Holder 32 Set for Vise 1R038 5 ( stock runs out ) 1/4” Hex. Shank Bit M4 1R014 2 Armature Holder 41.5 Set for Vise 1R039 5
1/4” Hex. Shank Bit M5 1R015 2 Armature Holder 50 Set for Vise 1R040 5
1R041 1/4” Hex. Shank Bit M6 1R016 2 Vise Plate 5 (1 pc/ case)
1/4” Hex. Shank Bit M8 1R017 2 Wrench for Bearing Retainer 1R042 6 37-20
Hex. Socket Bit M8 1R018 3 Wrench for Bearing Retainer 1R043 6 32-20 1R044 Hex. Socket Bit M6 1R019 3 Gear Extractor (small) Available until 6 ( stock runs out ) Bearing Extractor (Large) 1R020 3 Gear Extractor (large) 1R045 6 1R021 1R047 Bearing Extractor (Small) Available until 3 Tool for Trigger Valve Case Available until 7 ( stock runs out ) ( stock runs out ) Bearing Plate 1R022 4 Drill Chuck Remover 11 1R048 7 (for arbor press)
Pipe Ring (for arbor press) 1R023 4 Drill Chuck Remover 15 1R049 7
Press Tool (for arbor press) 1R024 4 Drill Chuck Remover 22 1R050 7 1R025 Bearing Extractor Available until 4 Brush Holder Setter Type 72 1R051 7 ( stock runs out ) Bearing Setting Pipe 16-8.2 1R026 5 Brush Holder Setter Type 84 1R052 7 CONTENTS 2
Name Code No. Page Name Code No. Page
Brush Holder Setter Type 94 1R053 7 Hammer Testing Stand 1R083 13 1R055 Chain Saw Repair Stand Available until 8 Hammer Testing Bit (large) 1R084 13 ( stock runs out ) 1R056 Punch A for disassembly Available until 8 Hammer Testing Bit (medium) 1R085 13 ( stock runs out ) 1R057 Punch B for disassembly Available until 8 Hammer Testing Bit (small) 1R086 13 ( stock runs out ) 1R058 Inserting Punch A Available until 8 Hammer Bit Holder 1R087 13 ( stock runs out ) 1R059 1R088 Inserting Punch B Available until 8 Ring Terminal Installer Available until 14 ( stock runs out ) ( stock runs out ) 1R060 Riveting Punch Available until 8 Bearing Extractor 1R089 15 ( stock runs out ) 1R061 Pin Available until 8 Round Bar of Copper 10 - 180 1R090 15 ( stock runs out ) 1R062 Guide Bar M4 for fitting Field 9 Round Bar of Copper 20 - 100 1R091 15 (1 pc/ case) 1R063 Guide Bar M5 for fitting Field 9 Commutator Filing Brush 1R095 16 (1 pc/ case) for CB-76 Commutator Filing Brush 1R098 1R064 9 Wrench Available until 16 for CB-124 ( stock runs out ) Torque Wrench Commutator Filing Brush 1R065 9 1R114 16 for CB-167 (for measuring torque) 1R067 Fuse (for Motor Tester) Clutch Tool Available until 9 1R116 16 ( stock runs out ) 100/115V 1R069 Fuse (for Motor Tester) Piston Holder Tool Available until 9 1R117 16 ( stock runs out ) 220/230/240V 1R070 Tachometer 10 Hammer Testing Bit 370 1R118 16 (w/Manual) 17 Hex. shank Hammer Testing Bit 355 1R119 Leveler 500 1R071 10 Available until 16 17 Hex. shank ( stock runs out ) Leveler 750 1R072 10 Air Density Tester 1R127 17
Leveler 1,000 1R073 10 Nose 10-13 1R130 17
Leveler 1,500 1R074 10 Nose 12-15 1R131 17 1R075 Armature Tester 100V Available until 10 Nose 15-20 1R132 17 (without plug) ( stock runs out ) Tester (Circuit Tester) 1R076 10 Nose 20-25 1R133 17
Insulation Resistance Tester 1R077 10 Drill Chuck Extractor 1R139 18
Motor Tester 100V 1R078 11 Throw-away Tip 1R141 18
Arbor Press 2ton 1R080 12 Throw-away Bite holder 1R142 18
Arbor Press 1ton 1R081 12 Rolling Center 1R143 18
Vise 1R082 12 Main Shaft Center 1R144 18 CONTENTS 3
Name Code No. Page Name Code No. Page
L Type Torx Wrench Set 1R145 Available until 19 Field Test Cable 1R174 22 (5pcs) ( stock runs out ) L Type Torx Wrench M6 1R146 19 Earth Cable 1R175 22
L Type Torx Wrench M8 1R147 19 Line Cable 1R176 22
1R148 Armature Tester 115V 19 Pliers 1R177 23 (w/o Plug) 1R149 Armature Tester 220V 19 Seal Inserting Pipe 1R178 23 (w/o Plug) 1R150 Armature Tester 240V 19 T Type Screwdriver 1R179 23 (w/o Plug) 1R180 Electricity Discharging Cord 1R151 19 Magnet Extractor Available until 24 ( stock runs out ) 1R181 L Type Torx Wrench M3 1R153 19 Ignition Checker 24 (w/Manual)
L Type Torx Wrench M4 1R154 19 Clutch Extractor 1R183 25
Crank Shaft Lock Bolt 1R155 20 Worm Gear Extractor 1R184 25 1R156 Valve Puller Available until 20 Oil Seal Extractor 1R185 26 ( stock runs out ) O-Ring Guide Tool 1R157 20 T Type Torx Wrench 1R186 26
Servo-Press Gun 1R187 1R158 20 Impact Socket 19-17 Available until 27 Disassembling Tool ( stock runs out ) 1R161 1R188 Spring Pin Extractor 2 Available until 21 Hex. Bar 17H-100 Available until 27 ( stock runs out ) ( stock runs out ) 1R162 1R189 Spring Pin Extractor 2.5 Available until 21 Clutch Extractor Available until 28 ( stock runs out ) ( stock runs out ) 1R163 1R190 Spring Pin Extractor 3 Available until 21 Rotor Pulling Tool Available until 28 ( stock runs out ) ( stock runs out ) Ring Spring Setting Tool A 1R164 21 Joint Nut Wrench 1R191 29
1R192 Ring Spring Setting Tool B 1R165 21 Lead Battery Checker MUK 29 (w/Manual) 1R193 Joint Nut Wrench 1R166 22 Lead Battery Checker MA/MC 29 (w/Manual) 1R194 T Type Hex. Wrench 3-70 1R167 22 Lead Battery Checker 230V 29 (w/Manual) 1R195 T Type Hex. Wrench 4-77 1R168 22 Lead Battery Checker 240V 29 (w/Manual)
T Type Hex. Wrench 5-89 1R169 22 Worm Gear Extractor 1R196 29
T Type Hex. Wrench 3-127 1R170 22 Commutator Filing Brush 1R197 30 for CB-251 Commutator Filing Brush T Type Hex. Wrench 4-130 1R171 22 1R198 30 for CB-408 1R199 T Type Hex. Wrench 5-153 1R172 22 Spring Fixing Jig Available until 30 ( stock runs out ) 1R200 Retaining Ring R Pliers 1R173 22 Piston Pin Punch Available until 30 ( stock runs out ) CONTENTS 4
Name Code No. Page Name Code No. Page
Jig for Retaining Ring 1R201 31 Bearing Extractor 1R225 38
Commutator Filing Brush 1R202 31 Commutator Filing Brush 1R226 38 for CB-203 CB-407/ 419
Commutator Filing Brush 1R203 31 Wire Stripper 1R227 38 for CB-303
Jig for Tightening 1R204 31 1/4” Hex. Shank Bit for M4 1R228 39 Nut M15-23 1R205 Taper Sleeve Available until 32 1/4” Hex. Shank Bit for M5 1R229 39 ( stock runs out ) Wrench for Clutch 1R206 32 1/4” Hex. Shank Bit for M6 1R230 39
45-degree Set Square 1R207 32 1/4” Hex. Shank Bit for M8 1R231 39
90-degree Set Square 1R208 32 Pipe 30 1R232 39
Repair Tool Holder 1R209 33 Round Bar for Arbor 4-100 1R233 39
Oil Seal Setter 1R210 33 Round Bar for Arbor 5-100 1R234 39
Pressure Gauge 1R211 33 Round Bar for Arbor 6-100 1R235 39
Tip for Retaining Ring Pliers 1R212 34 Round Bar for Arbor 7-100 1R236 39
Cylinder Extractor 1R213 34 Round Bar for Arbor 8-100 1R237 39
Taper Sleeve 1R214 34 Round Bar for Arbor 9-100 1R238 39
Block A for Crank Shaft 1R215 35 Round Bar for Arbor 10-100 1R239 39
Block B for Crank Shaft 1R216 35 Round Bar for Arbor 11-100 1R240 39
Ring 22 1R217 36 Round Bar for Arbor 12-100 1R241 39
Adjust Sleeve 1R218 36 Round Bar for Arbor 13-100 1R242 39
Torque Wrench Shaft 2-6N.m 1R254 37 Round Bar for Arbor 14-100 1R243 39 (w/Manual)
Torque Wrench Shaft 7-23N.m 1R219 37 Round Bar for Arbor 15-100 1R244 39 (w/Manual)
Torque Wrench Shaft 20-90N.m 1R223 37 Round Bar for Arbor 16-100 1R245 39 (w/Manual)
Ratchet Head 9.5 1R220 37 Round Bar for Arbor 18-100 1R246 39
Ratchet Head 12.7 1R224 37 Round Bar for Arbor 20-100 1R247 39
Spanner Head 15 1R221 37 Round Bar for Arbor 22-100 1R248 39
Spanner Head 12 1R253 37 Round Bar for Arbor 24-100 1R249 39
Socket Adapter 1R222 37 Round Bar for Arbor 26-100 1R250 39 CONTENTS 5
Name Code No. Page Name Code No. Page
Round Bar for Arbor 28-100 1R251 39 Round Bar for Arbor 4-50 1R278 48
Round Bar for Arbor 30-100 1R252 39 Round Bar for Arbor 5-50 1R279 48
Spanner Head 12 1R253 40 Round Bar for Arbor 6-50 1R280 48
Torque Wrench Shaft 2-6N.m 1R254 40 Round Bar for Arbor 7-50 1R281 48
Retaining Ring S-7 Setter 1R255 40 Round Bar for Arbor 8-50 1R282 48
Clutch Extracting Tool 1R257 41 Round Bar for Arbor 9-50 1R283 48
1R258 V Block 41 Round Bar for Arbor 10-50 1R284 48 (1set: 2pcs)
Taper Sleeve 1R259 41 Round Bar for Arbor 11-50 1R285 48
Motor Tester 115V 1R260 42 Round Bar for Arbor 12-50 1R286 48
Motor Tester 220V 1R261 42 Round Bar Storage Board 1R287 48
Motor Tester 240V 1R262 42 Screwdriver Magnetizer 1R288 48
Bearing Extractor 1R263 43 Switch Unit Adjusting Gauge 1R289 49
Torque Wrench 1R264 43 Torx Bit VT-27 1R290 49
Torque Checking Faceplate 1R265 43 Retaining Ring S and R Pliers 1R291 49
Spring Pin Extractor 2 1R266 44 Wrench for Bearing Retainer 1R292 50
Spring Pin Extractor 2.5 1R267 44 Wrench for Clutch 1R293 50
Spring Pin Extractor 3 1R268 44 Commutator Filing Brush 1R294 50 CB-407 Bearing Extractor 1R269 44 Commutator Filing Brush 1R295 50 CB-412
Hammer Testing Bit 1R270 45 Spring Pin 1.5 Remover 1R296 50 SDS-Max
Hammer Testing Bit 1R271 45 Spanner Head 17 1R297 51 SDS-Plus
Ring Spring 26 Setting Tool A 1R272 45 Hex Bar 10 with Square Socket 1R298 51
Ring Spring 26 Setting Tool B 1R273 45 Bearing Extractor (small) 1R299 51
Type 72 Field Insert Jig 1R274 46 Bearing Extractor (large) 1R300 51
Type 94 Field Insert Jig 1R275 46 Commutator Filing Brush 1R301 51 CB-431
Acrylic Dust Box 1R276 47 Commutator Filing Brush 1R302 51 CB-424
Torx Driver T10x75 1R277 47 Commutator Filing Brush 1R303 52 CB-430 CONTENTS 6
Name Code No. Page Name Code No. Page
Commutator Filing Brush 1R304 51 Silicon KE-45N 1R330 56 CB-432
Wrench for Case Joint 1R305 52 Needle Bearing Extractor 43.5 1R331 57
Ring Spring Removing Jig 1R306 52 Needle Bearing Extractor 50.0 1R332 57
ET Holder O-Type 2.5 1R307 52 Needle Pin 4.5 1R333 57
Spring Pin Extractor 4.0 1R308 53 Interchangeable Adapter 1R334 58
Spring Pin Extractor 5.0 1R309 53 Battery Checker 1R335 58
Spring Pin Extractor 6.0 1R310 53 Ring Spring Setting Tool A 1R336 59
Retaining Ring Pliers 1R311 53 Ring Spring Setting Tool B 1R337 59 with long bent nails
Hammer Stand 1R312 53 RS232C Cable 1R338 58
Bit for One-Touch 1R313 53 Software for Battery Checker 1R339 58 Cord Lock Adapter
Torx Bit V-25 1R314 54 Bearing Retainer Wrench 1R340 60
Laser Beam Positioning Jig 1R315 54 Spanner Head 41 1R341 60
Adjustable Bearing 1R316 55 Battery Checker 1R342 61 Retainer Wrench
Hex Wrench 3/16" 1R317 55 Retaining Ring Setting Jig 1R343 61
Hex Wrench 5/32" 1R318 55 Torque Driver 1R344 62
Hex Wrench 3/32" 1R319 55 Hex Bit 1R345 62
Hex Wrench 5/64" 1R320 55 Center Attachment for 1R045 1R346 63
Tool Retainer Pole Hex Wrench Assortment 1R321 55 1R347 63 Removing Tool
Hex Wrench 17 1R322 55 Spring Pin 8 Remover 1R348 63
Impulse Oil 1R323 56 Spacer 15.9 1R349 64
Bumper Removing Tool 1R324 56 Ring 60 1R350 64
Torx Driver T7Hx80 1R325 56 Anvil Holding Jig 1R351 65
Torx Driver T15Hx80 1R326 56 Fastening Nut Holding Jig 1R352 66
Torx Driver T25Hx120 1R327 56 Clutch Case Holding Jig 1R353 66
Torx Driver T27Hx120 1R328 56 Joint Holding Jig 1R354 67
Screw Extractor No.802 1R329 56 Pinion Gear Positioning Jig 1R355 67 CONTENTS 7
Name Code No. Page Name Code No. Page
Bearing Plate 10mm 1R356 68 (for arbor press)
Cam A Setting Jig 1R357 65, 68
Bar for 90 degree Adjustment 1R358 68
Chuck Removing Tool 1R359 69
Clutch Removing Tool 1R360 70
Bearing Retainer Tightening Tool 1R361 70
Retaining Ring Pliers 1R362 71 with Long Bent Nails Ring Spring Removing Tool 1R363 71 for SDS-MAX Tool Holder
Flywheel Puller 1R364 72
Hook Wrench 1R365 72
Feeler Gauge Set 1R366 72
Taper Sleeve 1R367 73
Commutator Filing Brush 1R368 73 for CB-350
(presently unused number) 1R369 73
Ring Terminal Setting Jig 1R370 73 for models using spring-type 1 Model/Size Tool Name/Description Code No. available Tapping Bit Holder 70MM Holds tapping bit for rethreading.
70mm Accepts Ø4.0mm to 110mm 1R001 Ø10mm tapping bits.
Tap-grasping diameter Ø4.0 to Ø10
Retaining Ring S Pliers ST-2N For removing/installing Retaining Ring S (external) L=250mm from/on the shaft. W=120mm 1R003
W (Holds Ø32-58mm L retaining Rings.)
ST-2 L=200mm W= 85mm 1R004 Recommendation: (Holds Ø19-30mm Use Code No.1R212 tips to remove/install retaining Rings.) Ring Spring and Concentric Retaining Ring.
Retaining Ring R Pliers RT-2N For removing/installing Retaining Ring R (internal) from/in the hole. L=250mm W=115mm 1R005 (Holds Ø32-58mm retaining Rings.) L W
RT-2 L=200mm W=100mm 1R006 (Holds Ø19-30mm retaining Rings.)
Tips for Retaining Ring Pliers (Straight) 10mm Replacement 34mm parts for 1R007 1R004 1R006
W/4 screws
Tips for Retaining Ring Pliers 10mm (90 °) 27mm Replacement 10mm parts for Useful to remove/install Retaining 1R008 Ring R in tight space. 1R004 1R006 W/4 screws 2 Model/Size Tool Name/Description Code No. available
A T-shaped Hex. 250mm Bolt Wrench A=9mm 1R009
For removing/installing Hex. Bolts used in hard-to-access places Ø20 150mm A=12mm 1R010
A=13mm 1R011
14mm Box Wrench 127mm Tightens/loosens Hex. Nuts of such a switch as installed on Planer-Jointers. 100mm
25mm
Nut —— 1R012
Switch Protector
L-shaped Torx Wrench 60mm For tightening/loosening Torx screws of the slider section of Jig Saw. 20mm 4300A 1R013 Size T-20 Available until ( stock runs out ) To be replaced ( by 1R154 )
1/4” Hex. Shank Bit Length Between For tightening/loosening Opposite Sides= 3mm 6.35mm(1/4”) Hex. Socket Head Bolts. 130mm
Size M4 1R014
13mm
Size M5 1/4” Hex. Shank Bit Length Between A=4mm 1R015 Tightens/loosens such Opposite Sides= A 6.35mm(1/4”) Hex. Socket Head Bolts L L=160mm as used for fastening Size M6 the Barrel of Demolition Hammers. A=5mm 1R016 13mm L=140mm Size M8 A=6mm 1R017 L=200mm 3 Model/Size Tool Name/Description Code No. available Hex. Socket Bit Tightens/loosens such 6.35mm(1/4”) Hex. Socket Head Bolts 315mm as used for fastening the Barrel of Demolition Ø19 Hammers. Size: M8 1R018
12mm 13mm
Hex. Socket Bit 6.35mm(1/4”) Tightens/loosens such 175mm Hex. Socket Head Bolts as used for fastening the Barrel of Demolition Ø13 Hammers. Size: M6 1R019 9mm 13mm
Bearing Extractor (large)
105mm
1R020 —— (w/Hex. wrench)
8mm 100mm
24 to 55mm (small)
90mm
1R021 —— (w/Hex. wrench) Available until 6mm ( stock runs out ) 50mm To be replaced ( by 1R269 ) 19 to 35mm
Re: You can remove the Bearing installed on Armature efficiently by letting the Vise #1R082 grip this Bearing Extractor after removal of Hex. socket head bolts. 4 Model/Size Tool Name/Description Code No. available Bearing Plate (for Arbor Press) Put two Plates on Pipe Ring to pull out Bearing or Gear. 120mm
Ram of 120mm Arbor Press —— 1R022
When this part is broken, change it with new one. Bearing Plate 1R022 Ø15
Pipe Ring 1R023 Ø60
Pipe Ring Ø114.3 (for Arbor press) Ø97.1 Multi-purpose Ring for extracting bearing or gear. If using it together with 1R218, you can adjust the —— 1R023 height every 50mm. 130mm
Press Tool Ø15 (for Arbor press) Press Tool
Use this tool when the shaft gets flush with the bearing in the operation as illustrated 20mm above. Bearing Plate —— 1R024 (1R022)
15mm
Ø8
Bearing Extractor Useful to extract the Bearing which is installed close to the Armature fan.
120mm 110mm
60mm Ball Bearing 1R025 608/627 Available until ( stock runs out )
[Exclusively for Ball Bearing 608/627] 5 Model/Size Tool Name/Description Code No. available A - B Bearing Setting Pipe 1R026 ø8.2 - ø16 Choose the setting pipe that is A - B the most suitable for the inner B 1R027 race of the bearing, and then A ø10.2 - ø18 insert the bearing into the shaft A - B 1R028 using Arbor Press. ø12.2 - ø20 A - B 1R029 50mm ø15.2 - ø23 A - B 1R030 ø17.2 - ø25 A - B 1R031 Note: Be sure not to hit this pipe with iron hammer. ø20.2 - ø28
Bearing Setting Plate A= ø8.2 1R032 Choose the setting plate that is the most suitable for the inner A= ø10.2 1R033 race of the bearing, and then put the bearing over the U-shaped ø60 A= ø12.2 1R034 opening of Arbor Press. A
A= ø15.2 1R035 15mm A= ø17.2 1R036
A= ø20.2 1R037
Armature Holder Set for Vise (aluminum) For fixing firmly such round parts as Armature, etc. A= ø32 using Vise (1R082). 1R038 55 Type 50mm
A A= ø41.5 1R039 100mm 72 Type
30 mm 40mm 21 50mm mm A= ø50 1R040 84 Type Note: Cannot be used for new 94 type armature.
Vise Plate (copper)
Protects parts from damages. 3mm
1R041 2 pcs are —— required at the 20mm 100mm ( ) same time. 125mm 30mm 6 Model/Size Tool Name/Description Code No. available Wrench for Bearing Retainer *Because the groove on Bearing Retainer is shallow, be sure to push the wrench against Bearing Retainer while turning it. *Does not fit most recent Bearing Retainers; in this case, make the inner width of nails wider by filing them. Note: 6016 1R042 Make sure the screw is right-handed or left-handed 150mm before turning Bearing Retainer. 20mm 37mm
Bearing Retainer
6100 1R043 150mm 20mm 32mm
Gear Extractor (small) *Useful to extract a gear such as installed on the shaft of Circular Saw. *Use arbor press when you find difficulty in extracting. 100mm
—— 1R044 Available until ( stock runs out ) To be replaced by 1R045 Nails open up to 75mm. 40mm
Gear Extractor (large) *Useful to extract a gear such as installed on the shaft of 120mm Circular Saw. *Use arbor press when you find difficulty in extracting.
—— 1R045
160mm 7 Model/Size Tool Name/Description Code No. available Tool for Trigger Valve Case *Useful to replace the O-ring on Trigger Valve Case. *After replacement, put adhesive tapes on screw holes to prevent air leakage. 100mm *Also can be used when inserting Valve Case. 120mm
AN5000 21mm 1R047 AN5010 Available until ( stock runs out ) 6mm
Drill Chuck Remover For removing tapered Spindle; if you find difficulty, use arbor press. 6500 A 1R048 40mm 35mm A=11
Drill Chuck Remover A 6400B 1R049 A=15 10mm Taper
2mm 8mm
Drill 6300B 1R050 A=22 Drill Chuck Drill Chuck Remover
Brush Holder Setter Aim for angle. Brush holder can be set in place at the A= ø15 correct angle without any damage to 72 B= 5mm 1R051 screw threads by using Arbor Press or Plastic Hammer. C= 8mm
A C B A= ø18 84 B= 6mm 1R052 C= 10mm
Brush Holder Setter Brush Holder
A= ø21 94 B= 6mm 1R053 C= 13mm 8 Model/Size Tool Name/Description Code No. available Chain Saw Repair Stand
Holes for holding Pin of Chain teeth
10mm 7100B 1R055 7104 Available until 35mm ( stock runs out )
Ø150
Punch A for Disassembly
1R056 70mm Ø8 7100B 7102 Available until ( stock runs out )
Punch B for Disassembly
60mm Ø13 7100B 1R057 7102 Available until ( stock runs out )
Pin (1R061)
Inserting Punch 7100B 1R058 20mm 7102 40mm 1R059(B) Available until A ( stock runs out )
1R058(A) 8mm 5mm 7100B 1R059 7102 Available until B ( stock runs out ) 1mm Riveting Punch (for caulking Pins)
Ø15 100mm 7100B 1R060 7102 Available until ( stock runs out )
Pin
40mm Ø3 7100B 1R061 7102 Available until ( stock runs out ) 9 Model/Size Tool Name/Description Code No. available Guide Bar for fitting Field Guide Bar Fasten Guide Bars to Motor Housing completely, and then, passing Guide Bars through the holes of Field, insert Field into Motor Housing.
Hint for setting: When it’s hard to let Field fit in Motor 130mm Housing, it’s advisable to hit lightly outside 15mm 1R062 M4 of Motor Housing for smooth fitting. (2 pcs required) Minus grooves
150mm 15mm 1R063 M5 (2 pcs required) Minus grooves
Commutator Filing Brush For CB124 B A=6 B=16 1R064 These brushes make commutator smooth to reduce sparks, letting the brake system work 8500N well. Let the motor run for 10 minutes at half of the rated voltage. A For CB167 A=6.5 B=17 1R065 HR3811
Clutch Tool (for Engine Chain Saw) For replacing Clutch or Crank Shaft of Engine.
Note: 20mm Put Crank Shaft Lock Bolt (1R155) or Rope into Cylinder through Plug hole to fix Crank Shaft. Nails(3 pcs) 35mm 1R067 Hook the nails E2830N Available until ( stock runs out )
Clutch Wrench 19
Piston Holder Tool (for Engine Chain Saw) 100mm 40mm Put this tool under Piston to 60mm hold it.
12mm Products by 1R069 Kyoritsu/ Dolmar Available until ( stock runs out ) All Engine Chain Saw To be replaced ( by 1R155 ) 10 Model/Size Tool Name/Description Code No. available Tachometer The Engine rotation can be digitally displayed simply by putting Tachometer clip on Plug Cord. Engine products 1R070 with plug (w/Manual)
Clip
Leveler L=500mm 1R071 Check whether or not the table of Planer-Jointer or the base of Hand Planer is level. L L=750mm 1R072
L=1,000mm 1R073
L=1,500mm 1R074
Armature Tester 100V Check the short circuit in Armature. Iron plate Turn Armature on the Tester
Normal : Iron plate does not stick to Armature. Plug in 1R075 100V Abnormal : Iron plate is attracted by Armature, (without plug) and vibrates slightly. Available until ( stock runs out )
115V-1R148 For export { 220V-1R149 are also available. 240V-1R150
Tester (Circuit Tester) Measures AC/DC voltage, amperage and resistance.
Use a 3 AA- battery. —— 1R076
Insulation Resistance Tester Measures the insulation state of Press this button products to judge Pass/Failure. for measurement.
Use eight 3 AA- batteries. —— 1R077
*Warning: Stay alert against electric shock because the voltage is DC500V at the terminals of this tester. 11 Model/Size Tool Name/Description Code No. available Motor Tester
Ammeter Voltmeter Megaohmmeter 550mm
200mm
Switch
430mm
Fuse (1R116)
Lamp Receptacle board accepts any Type ( of plugs. ) Test Button
Outlet for Cable for Variable voltage control Field Test from 0 to 130V Outlet for Line Cable Maximum output: 20A Outlet for Earth Cable
Re: Short-circuit Test of Field Connect wires as illustrated below, and then push Test Button (1). If Lamp (2) turns on, there is short-circuit in Field. 100V 1R078 Lamp (2) Test Button (1) * For export use the the followings following Ring terminal are available: 3 tools 115V–1R260 together: 220V–1R261 1R174 1R175 240V–1R262 Green ( 1R176 ) Red
White
Field Test Cable Black Lead Wire (1R174)
Megaohmmeter Re: Measuring Insulation Resistance Velcro tape, etc. First, turn on the switch, and keep it on using velcro tape, etc. Then, connect wires as illustrated below, and If the Megaohmmeter hand swings left to go under 10 Mega, there is Insulation failure.
Test Button (2) Earth Clip
Earth Cable (1R175)
Line Cable (1R176) Plug 12 Model/Size Tool Name/Description Code No. available
Arbor Press Ø202 40mm For press-fitting Bearing, A= 390 Gear, Spindle, etc. Max. load: 60mm 50mm 1R080 20,000N (2 ton) Dimensions 30mm of Base with 34mm Base with U-shaped A U-shaped A= 255 openings Openings Ø152 Note: Max. load: 1R081 Fix it to a work table, 10,000N and then fix the table firmly to the floor. 24mm 44mm (1 ton)
Use 2 pcs of Vise Vise Plates Grips to fix machine, tool, workpiece, etc. (1R041) together. Use Clasp (vise plate) or waste cloth. Max. Opening: 160mm
—— 1R082 125mm
Note: Fix it to a firm table. Ø15 Hole for fixing vise 13 Model/Size Tool Name/Description Code No. available Hammer Testing Stand Use Demolition hammer or Rotary hammer on this test base and check its hammering action, when you are required to; *Know where to repair. *Check whether or not the tool has been correctly repaired.
Put the Hammer vertical against Hammering Test Base.
1R083
Set Hammer Bit Use the Receiver (1R087). Hammer Weight: 73kgs following Testing Bit 6 tools together: 1R087, 1R084, 85, 86, 1R118, 1R119 250mm
250mm
Two hooks for easy transport using ropes, chains, etc.
Note: It’s advisable to put the Hammering Test Base on a rubber tire to avoid making a big noise. 250mm
Hammer Testing Bit 260mm 8600N 1R084 Regarding Ø22 SDS type bits, Ø22 (large) cut off the tip of the bit, and then use it as a testing bit 335mm 17mm Hex. shank testing bits 8900N Ø22 1R085 are also available with part (medium) numbers 1R118 and 1R119. (see page 16.) 360mm 8900S 1R086 Ø21 (small)
Hammer Bit Holder Ø25
25mm
45mm —— 1R087
Ø77 14 Model/Size Tool Name/Description Code No. available Ring Terminal Installer Convenient for installing Ring Terminal on hard-to-access places. Lever
240mm Lever is pushed forward by Spring. Body
Guide Bar
120mm
Jig Hole 1) Put the Body through Filed Core, and set Ring Terminals as illustrated below.
Filed Core
Ring Terminal Guide Bar 9500N 1R088 Available until ( stock runs out )
2) Using Guide bars for fitting Field, insert the unit which you made in (1) into Motor housing Note: Be careful of the position of the Lead wires in order not to pinch them.
Guide Bar for Fitting Field (1R062)
3) Setting Jig holes to Brush holder holes on Motor housing, insert Guide Bar into Brush Holder as illustrated below, and push the Lever toward Motor housing. Then Ring terminals are set in place.
Lever
Guide Bar 15 Model/Size Tool Name/Description Code No. available Bearing Extractor Pulls Bearing out of hard-to-access places.
Note: Use one of Noses 1R130/131/132/133 together.
510mm
Hammer
(1) Nose Slit is Initially closed. 1R130/131/132/133
(2) Insert Nose (1) into the inner race of Bearing (2). Turn Shaft (3) to let it go into 1R089 Bearing. At this time, the slit between inner nails of Nose is 9607 Use one of (3) spread to catch Bearing. the following tools together: 1R130 to 1R133
Grip
Hammer
(1) Hammer Nose
Grip Bearing Bearing can be pulled out by sliding Hammer to hit it strongly against Grip.
Round Bar of Copper Shaft, Metallic item, Bearing, etc. can be A= ø10 inserted without scratches on them. 1R090 L= 180mm
L
A
A= ø20 1R091 L= 100mm 16 Model/Size Tool Name/Description Code No. available Commutator Filing Carbon Brush
These brushes make commutator smooth to reduce 9.5mm sparks and to work the brake system well. Run the motor for 10 minutes at half of the rated CB-76 5mm 1R095 voltage. 9500A
Wrench (for #4040)
1R098 A=36mm available until ( stock runs out ) A
Torque Wrench (for measuring torque) Check whether or not tightening tools tighten bolts at required torque. Mainly used for torque check after Impact Wrench repairing Impact Wrench model 6906. Model 6906
1R114 W/o Socket Max. torque 1,160mm Accepts all measurable: hex. sockets 700N.m for #6906 (7,000kgf.cm) (are available. )
Square Drive 19: Accepts all hex. ( sockets for #6906. )
Fuse (for Motor Tester) 1R116 Externally accessible for replacement 100V/115V For (20A) ( 1R078 ) 1R260
1R117 220V For For 100V 1R078 240V For 115V 1R260 1R261 Motor Tester: (10A) { For 220V 1R261 ( 1R262 ) For 240V 1R262
Hammer Testing Bit 17mm 370mm Use together with Hammer 8500N 1R118 Testing Stand (1R083).
17mm 355mm 1R119 8501 available until ( stock runs out ) 17 Model/Size Tool Name/Description Code No. available Air Density Tester For checking air leakage in Crank Room and Carburetor of Engine.
Air Density Test of Ignition Plug : Engine Crank Room Has to be fixed surely with M19 Socket Wrench. Connect the tube with 1) Stand by as illustrated to right. Pulse Pressure Pipe 2) Give air pressure using a pump. If Pressure Gauge indicates 0.05Mpa (0.5kgf/cm2, for 5 to 10 sec.), there is no problem in Crank Room.
Note: If Pressure Gauge indicates below IR127 0.05Mpa (0.5kgf/cm2), which means E2930 M19 Socket air leakage, check the deterioration E2935 Wrench is of Oil Seal and the exfoliation of ( required. ) adhesive on Crank Shaft of Piston. Stick plastic tape on and around the intake and outlet, and press them with fingers firmly to prevent air-leakage.
Air Density Test of Carburetor Connect the tube with Fuel inhalant pipe 1) Stand by as illustrated to right. 2) Give air pressure over 0.08Mpa (0.8kgf/cm2) to open the slot. The slot Primary pump returns by itself. Next, give air pressure up to 0.05Mpa (0.5kgf/cm2). If the Pressure Gauge does not indicate 0.05Mpa (0.5kgf/cm2) in 10 sec, the Carburetor is good.
Note: If the Pressure Gauge becomes lower, it is probable that Inlet needle valve is not good or Needle Valve Spring is deformed.
Nose (for Bearing Extractor) Inner Nail Pulls Bearing out of hard-to-access places. 1R130 10 to 13mm
Inner Nail 1R131 Inner Nail 12 to 15mm
Inner Nail 1R132 15 to 20mm
Note: Use Bearing Extractor (1R089) together. Inner Nail See page 15 for how to use 1R089. 1R133 20 to 25mm 18 Model/Size Tool Name/Description Code No. available Drill Chuck Extractor Model Names are written near each groove available. (Spindle Fixing Jig) Note: 1) In case Drill has reversible function, first, remove a left-handed chuck screw. 2) If Change Ring of 8419B/6300T is made of plastic, grind down part illustrated to right.
* 6013BR 6300-4 6300T 6300L * 6300LR 1R139 6301 6310 Use Grind down about 0.5 to 0.8 mm deep and 5mm wide 8406 Wrench 43 in case of Note (2) mentioned to left. 8406C (Part No. Use Wrench 43 (Item No. 781024-2) 8419B 781024-2) for turning Drill Chuck. 8420V ( together ) If Drill Chuck cannot be removed with Wrench 43, attach a 400mm connecting DP4700 pipe to Wrench to make the lever longer. HP1030 HP1501 HP2031 UT1301 UT2201 * Reversing model
Drill Chuck Extractor
Throw-away Tip Throw-away Bite Holder Throw-away Tip 12mm (available in 3 faces) 12mm 1R141
Throw-away 80mm Bite Holder 10mm 1R142
Use with Wrench 45mm a small lathe (for changing Throw-away Tip) for rough Rolling Center adjustment of commutator surface 1R143
Main Shaft Center
1R144 19 Model/Size Tool Name/Description Code No. available
L Type Torx Wrench Set Products of ( 5 pcs) KARCHER Tightens/loosens Torx Bolt. #HW56 T-10 (M3) 1R145 T-20 (M4) ( 5 pcs/set ) T-25 (M5) Available until T-30 (M6) ( stock runs out ) T-40 (M8)
L Type Torx 1R146 Wrench M6 T-30 single part (M6) Products ( from 1R145 ) of KARCHER L Type Torx #HW56 1R147 Wrench M8 T-40 single part (M8) ( from 1R145 ) Shape of Torx Bolt
Armature Tester Iron bar Turn Armature on Tester 1R148 115V For checking the short circuit in Armature. (without plug )
Normal : Iron bar does not stick to Armature. 1R149 Plug in 220V Abnormal : Iron bar sticks to Armature, and (without plug ) vibrates slightly. 1R150 #100V Armature Tester is also available 240V (without plug ) with Code No.1R075. Electricity Discharging Cord Clip (Black) For discharging electricity remaining inside Battery before repair of OCR (over current relay) or receptacle of Battery.
Clip (Red)
Connect each Clip to ( Red) (Black) Connect to the same color cord the product Electricity Discharging Cord
Battery 1402 1R151
Models applicable: Battery-powered Pruning Shear 4603D Impact Wrench 6902D • 6931D Tree Pruner 4610D
Run Motor to discharge Warning: electricity inside Battery. Repairing without discharging electricity is very dangerous !
L Type Torx Wrench For repairing the motor in early T-15 (M3) 1R153 Brush Cutters. (#UM250, #UM350)
Torx Wrench M4 is also used for removing/installing Torx screws from/on Slider section. T-20 (M4) 1R154 20 Model/Size Tool Name/Description Code No. available Crank Shaft Lock Bolt Piston needs to be fixed when you remove Clutch/ Clutch Drum in various engine tools. 55mm And Piston can be locked by one of the following two ways: *By screwing Crank Shaft Lock Bolt in the hole for Spark Plug *By putting Recoil Rope into Cylinder.
E2935
Hole for Spark Plug All 2- stroke 1R155 Recoil Rope Crank Shaft Lock Bolt engines
Piston
Valve Puller For removing Packing/V-seal in Cylinder Head of High-Pressure Cleaner without making scratches on them and other parts.
165mm HW56 1R156 Available until ( stock runs out )
O-Ring Guide Tool For inserting O-Ring into Piston Ring used Backing-up Ring for Trigger Gun of High-Pressure Cleaner. O-Ring
HW170 1R157 Ø7
36mm
Servo-Press Gun Disassembling Tool For removing/installing Piston Ring from/on Servo-Press Gun Trigger Gun of High-pressure Cleaner. Disassembling Tool
HW170 1R158 40mm
Ø17 21 Model/Size Tool Name/Description Code No. available Spring Pin Extractor For removing Spring Pin from Trigger/ Trigger Valve Case of Pneumatic Nailers. 1R161 A= ø2.0 150mm Available until ( stock runs out )
A 1R162 Pneumatic Spring Pin A= ø2.5 Nailers Available until ( stock runs out ) Spring Pin Extractor
1R163 A= ø3.0 Available until ( stock runs out )
Ring Spring Setting Used for inserting Ring Spring Tool A 30.5 into Tool Holder of Model HM0810. Ring Spring Ø30 Put Ring Spring 30.5 on Ring Setting Spring Setting Tool A as Tool B illustrated to right, and put (1R165) Ring Spring Setting Tool B on it, and then, using arbor press as illustrated below, insert 1R164 Ring Spring 30.5 into Tool 50mm Holder of Model HM0810.
Ring Tool A (1R164)
Ø34 5mm
Put down Tool HM0810 Ring Spring Setting Retainer to its side. Ring Spring 30.5 Tool B
Ø40
1R165
1R164
1R165
80mm
Barrel
Put Tool Holder on the U-shaped opening of Base. 22 Model/Size Tool Name/Description Code No. available Joint Nut Wrench For removing/installing Joint Nut in front Rotor of Air-Impact Driver in order to exchange fan, etc.
Handle: Inserting type 300mm
Joint Nut is left-handed. AD600 1R166 Ø38
24mm
24mm 70mm
Note: Be careful not to mistake this tool for 1R191 which is for AD601 and AD602 because they are similar to each other. T Type Hex. Wrench ( for Hex. Socket-Head Bolt) W - L (mm) ----
Removes/installs Hex. Socket-Head Bolts 3-70 1R167 of High-Pressure Cleaner or Pneumatic tools. Features T-shaped handle for easy operation.
4-77 1R168
L 5-89 1R169
3-127 1R170
4-130 1R171 W Note: Hex. Shank Bit without handle is Hex. Socket-Head Bolt also available (1R014/ 015/ 016/ 017). 5-153 1R172
Retaining Ring R Pliers For removing/installing Retaining Ring R (internal) from/in the hole. 190mm 85mm
RT-1 (Holds Ø19-30mm 1R173 retaining Rings.)
Optimum for small holes because of thin tips.
Field Test Cable 1R174
See page 11 Earth Cable Accessories for Motor Tester for how to use 1R175 For measuring } 1R078 . } insulation resistance Line Cable 1R176 23 Model/Size Tool Name/Description Code No. available Pliers For removing Piston Guide inside Cylinder Head of High-pressure Cleaner without making scratches on Piston Guide and other parts. 178mm 82mm
1R177
Covered with plastic to protect other parts from scratches.
Seal Inserting Pipe ( plastic) For inserting Oil seal into Pump of High-Pressure Cleaner. 90mm ø28
ø13 ø24 HW70 1R178
T Type Screwdriver For removing Pistons in the upper and lower positions of High-Pressure Cleaner. The illustration below shows removal of the 150mm Piston in the upper position with the Piston in the lower position clamped by vise. 8mm Note: Magnetized tip *Use waste cloth when using vise. *Can be used for other applications. 1R179
vise 24 Model/Size Tool Name/Description Code No. available
Magnet Extractor For adjusting the height of Magnet Note: Make a tool group suitable to Collars ( Extractor. ) Fixing Bolts, 3 pcs. each individual engine chain saw by choosing the followings: Size of Collar Size and Quantity of Fixing bolts Quantity of Nuts
Magnet Extractor
3 Nuts
Screw the Fixing bolts into Magnet (Rotor) and put Collar on the center of Magnet.
E2935 1R180 Available until ( stock runs out )
Magnet Collar
Wrench 13 Set Magnet Extractor as illustrated to right. Tighten Nuts with Wrench 13, and then Magnet will come off.
Note: If Magnet does not come off easily, hit the center of Magnet Extractor to give a shock, and it will come off.
Ignition Checker Low Voltage Terminal Plug Cap For checking troubles in Ignition System of Gasoline engines. Spark Distance Adjusting Knob Set it between Plug Cap and Plug to check the state of ignition. High Voltage Terminal
How to check: - Pull Recoil Starter. 6mm - If spark appears in Spark Window, Spark Window check only Ignition Plug. - If spark doesn’t appear in Spark 6mm position Various 1R181 Window, check all electric parts engine tools (w/Manual) except Ignition Plug. 25 Model/Size Tool Name/Description Code No. available Clutch Extractor Used for replacing Clutch and Crank Shaft.
Note: 11mm 1) First, put a copper bar on Shaft and hit it with iron hammer. If the Clutch cannot be removed, use this tool. 10mm Pin
2) Put Cotton Rope or Crank Shaft Lock Bolt into 8mm Cylinder through Plug Hole to fix Crank Shaft. Because the left-handed screw is used, turn 35 Clutch Extractor clockwise to remove Clutch. ø
Insert the Pin of Clutch Extractor Wrench 19 into the grooves on Clutch. DE3430 1R183
Clutch
There are two kinds of Clutches.
Worm Gear Extractor Removes Worm Gear when replacing Crank Shaft of Engine.
100mm
ø20
Screw in Worm Gear Extractor (left-handed screw) until it hits against Crank Case. And then pull Worm Gear out of Crank Shaft. When assembling, turn the fully screwed DE3430 1R184 Worn Gear until it hits against Crank Case.
Worm Gear Extractor
Worm Gear 26 Model/Size Tool Name/Description Code No. available Oil Seal Extractor Using this tool, Oil Seal can be removed without disassembling Crank Housing of Engine.
Hex. Bolt
62mm
Thread cutting into Oil Seal.
ø20
Screw firmly Oil Seal Extractor into Oil Seal Screw Oil Seal of Crank Shaft. Extractor firmly. 1R185 use Wrench 17 DE3430 and Wrench 13 ( together )
Holding Oil Seal Extractor with wrench 13, turn Hex. Bolt of Oil Seal Extractor using Wrench 17 Wrench 13 wrench 17. Then Oil Seal can be pulled out.
T Type Torx Wrench For removing/installing Torx screws used for Engine Cutter/Trimmer/Chain Saw of DOLMAR.
200mm Size T-27 1R186 27 Model/Size Tool Name/Description Code No. available Impact Socket 19-17 51mm 1R187 ø37 17mm Available until ( stock runs out )
Hex. Bar 17H-100
100mm 1R188 Available until 17mm ( stock runs out )
How to Use: Use Impact Wrench #6906 together with Impact Socket and Hex. Bar for removing/installing such threaded Tool Holder as used Available for Rotary Hammers and Demolition Hammers. for Models using 17-mm Hex. Bull point.
Right handed screw: Use Vise Plate HM0811 together (1R041). HM0821 HM0810 (HM0801)
Left handed Screw: HR3511 HR3520 (HR3501) Use Impact Wrench #6906 HR3811 HR3850 Put the product on Square wood for stability. (HR3801)
When adhesive is applied to Tool Holder, it may be impossible 1m pipe to loosen Tool Holder even with Impact Wrench. Use copper plate In such a case, insert 1m pipe together (1R041) into 17mm Hex. Bar Wrench, and turn it. Burner If still impossible, heat up Tool Holder using Burner.
17mm
Put the product on Square wood steadily 17mm Hex. Bar Wrench
Note: Make sure whether the screw of Tool Holder is right-handed or left-handed before you loosen Tool Holder. 28 Model/Size Tool Name/Description Code No. available Clutch Extractor For replacing Clutch or Crank Shaft. Hex. Bolt
First, put a copper bar on Shaft, and hit it with Iron hammer. If it is impossible to remove Clutch, Clutch Puller Set Bolts use these tools. (plate)
Collar Set Bolts DPC7000 1R189 Clutch Collar Available until Clutch Puller Crank Case ( stock runs out ) (plate)
Hex. Bolt
Shaft
Note: Fix Crank Shaft by putting Cotton Rope or Crank Shaft Lock Bolt (1R155) into Cylinder through Plug Hole. Clutch
Rotor Pulling Tools For replacing Rotor or Engine Crank Shaft.
Put Collar on Rotor
Hex. Bolt
Rotor Puller Set Bolts
Hex. Bolt Collar
Rotor Puller 1R190 Use Wrench Set Bolts DPC7000 17/19 First, apply a copper bar to Shaft, ( ) and hit it with iron hammer. together If it is impossible to remove Rotor, Available until use these tools. ( stock runs out )
Holding Rotor Puller with wrench 19, Wrench 19 turn Hex. bolt using wrench 17. Wrench 17
Note: Fix Crank Shaft by putting Cotton Rope or Crank Shaft Lock Bolt (1R155) into Cylinder through Plug Hole. 29 Model/Size Tool Name/Description Code No. available Joint Nut Wrench Removes/installs Joint Nut in front Rotor of Pneumatic Impact Driver when replacing Fan. Handle inserting type 300mm AD601 Note: Be careful not to mistake this tool for AD602 1R191 Ø32 1R166 which is for AD600 because (left handed screw) they are similar to each other. 23mm
23mm 70mm
Lead Battery Checker (For Battery 120/121/122) (Charger for Over-discharged Batteries) 110V 1R192 For checking troubled batteries or (For MUK) (w/Manual) Battery selecting dial Charging state indicating lamp charging over-discharged batteries quickly. 300mm
Start Switch 110mm 115V 1R193 (For MA/MC) (w/Manual)
200mm How to Use: *Connect Battery to the terminal. *Adjust Battery selecting dial to Terminal for connecting Battery 1R194 the model name of the battery 230V you are checking. (w/Manual) *Turn on the start switch.
1R195 240V (w/Manual)
Lead Battery 120 Lead Battery 121 Lead Battery 122
Worm Gear Extractor
Removes Worm Gear in the process of Hex. Bolt replacing Crank Shaft of Engine.
90mm
Ø17
Collar 6mm 1R196 12mm Use Put Collar on Shaft, and screw in Worm Gear Extractor. Ø30 And then screw Hex. Bolt until it hits against Collar to Wrench 22 Ø45 DE4345 remove Worm Gear. and Wrench 17 Fixing ( ) together
Collar Worm Gear 30 Model/Size Tool Name/Description Code No. available
Commutator Filing Brush For CB-251 These brushes make commutator smooth to B A=7mm, B=17mm 1R197 reduce sparks, letting the brake system work 5605A well. Let the motor run for 10 minutes at half A of the rated voltage. For CB-408 A=6mm, B=12mm 1R198 9520
Spring Fixing Jig Fixes Spring of Kick-back brake of Engine Chain Saw. Hook Spring here.
Spring
DE3430 1R199 200mm Available until ( stock runs out )
Put a waste cloth.
Piston Pin Punch For replacing Piston or Crank Shaft of Engine.
130mm
Ø5
Use Piston Holder (1R069) together.
Remove two Spring Rings from Piston of Engine with pliers. 1R200 DE3430 Use 1R069 ( together ) Available until ( stock runs out )
Piston can be removed by pushing Piston Pin out of Piston. Piston Pin Punch Piston Pin can be pushed out by hitting Piston Pin Punch slightly, or by pushing Piston Pin Punch by hand with a firm grip.
Note: Hold Piston with your hand not to overload Crank Shaft. 31 Model/Size Tool Name/Description Code No. available Jig for Retaining Ring When replacing Retainer of Demolition Hammers, you may find considerable difficulty in removing the Pin from Retainer Ring because of the inter- ference of Spring. In such a case, use this tool together with arbor press. Put M8 Hex. Socket Head Bolt into the screw hole of Tool Holder, and then press the bolt with arbor press to pull Pin out of retainer Ring.
Make this face upward. Jig for Retaining Ring HM1303B 1R201
Ø23
35mm Be sure to keep Retainer upright.
Commutator Filing Brush 3612C 1R202 These brushes make commutator smooth to (for CB- 203) reduce sparks, letting the brake system work well. Let the motor run for 10 minutes at half of the rated voltage. 5606A 5806A 1R203 (for CB-303)
Jig for Tightening Nut M15-23 39mm For replacing Torque Limiter, Bearing, Spindle or Gear of Angle Grinders. 23mm
12.7
25mm Use Torque Wrench (1R223) to tighten this nut at tightening torque of 55-60 N.m Use Ratchet head (1R224). 9040 1R204 (550-600 kgf.cm). Use Jig for Tightening Nut M15-23 9047 series 1R223 9057 series Use Vise Plates 1R224 (1R041). 9059 series ( ) together
Note: See page 38 for how to use Torque Wrench (1R223) and Ratchet Head (1R224). 32 Model/Size Tool Name/Description Code No. available Taper Sleeve Tapered For fitting Fluoride Rings on Impact Bolt of Rotary Hammers. 1R205 HR4500C Available until Re: Insert Impact Bolt stock runs out See page 35 for how to use 1R214. into this side when this tool is replaced ( by 1R214 )
Wrench for Clutch For replacing Clutch or Crank Shaft of Engine. 20mm
180mm
9.5mm
32mm MDE331 1R206
Note: Fix Crank Shaft by putting Cotton Rope or Crank Shaft Lock Bolt (1R155) into Cylinder through plug hole.
45-degree Set Square For adjusting saw blade angle to 45 degree bevel, or checking the accuracy of saw blade angle set at 45 degree bevel.
Note: Raise saw blade cover, and then put Square to 60mm Slide Compound saw blade tightly. Saws and 1R207 Table Saws.
20mm Concavity is the clearance for the set teeth of saw blade.
95mm 25mm
90-degree Set Square For adjusting saw blade angle to 90 degree bevel, or checking the accuracy of saw blade angle set at 90 degree bevel.
Note: Raise saw blade cover, Slide Compound and then put Square to saw blade tightly. Saws and 1R208 70mm Table Saws.
20mm Concavity is the clearance for the set teeth of saw blade. 25mm 75mm 33 Model/Size Tool Name/Description Code No. available Repair Tool Holder Various small tools such as Wrenches/Screw Bits/Drivers/ Spring Pin Pullers can be neatly stored.
150mm
—— 1R209 55mm
300mm
Oil Seal Setter For inserting Oil Seal into Plunger. 110mm Some amount of oil is sealed 23mm in Plunger for lubrication. And if the oil is turbid, replace- ment of Oil Seal and oil is necessary because white turbid oil is caused by a Ø12 water leakage into Plunger. Install Oil Seal on the concave part.
MHW700 1R210
Oil Seal Setter
Plunger
Pressure Gauge Used for measuring water exhausting pressure.
MHW700 is not equipped with pressure gauge. Therefore, using this Pressure Gauge, check whether or not water exhausting pressure is normal. Connect High-pressure Hose here for check of water exhausting pressure.
MHW700 1R211
Note: If the Pressure Gauge indicates around 6.9Mpa (70kgf/cm2,, 69 bar ), water exhausting pressure is normal. 34 Model/Size Tool Name/Description Code No. available Tip for Retaining Ring Pliers M4x8 Countersunk Head Screws By attaching these Tips to Retaining Concave nails prevents (Item No. 912107-9) come with Ring S Pliers (1R003), Ring Spring Rings from slipping out tips. of Pliers. or Concentric Retaining Ring can be easily installed on shaft. For fastening 1R212 on Retaining HR5001C Ring Pliers, use M4x8 Countersunk HR4000C Head Screws which come with Tips. 1R212 HM1100C
1R212 Retaining Ring S Pliers (1R003)
Cylinder Extractor
Use for pulling Cylinder out of 100 Rotary Hammers HR5001C mm and HR4000C. 185mm Cylinder can be pulled out by hooking the pins at each end of Cylinder Extractor's legs on the side holes of Cylinder. Push and open Cylinder Extractor's legs
Left-handed screw Tension Spring (Part No.231791-4) HR5001C 1R213 Turn the handle clockwise HR4000C to pull out Cylinder.
Crank Case Adjust Extractor so that Pins may enter Cylinder holes properly. Cylinder
Taper Sleeve Use for fitting Fluoride Rings on Impact Bolt of Rotary Hammers. Fluoride Ring does not shrink by itself after expanded. Therefore, after replacement of Fluoride Rings, insert Impact Bolt on which Fluoride Rings are installed into Taper Sleeve, #HR5001C keeping it in Taper Sleeve over 15 seconds. #HM1202C Fluoride Ring HR5001C
HR5001C HR4000C 1R214 Push Impact Bolt surely Also can into Taper Sleeve. HR4000C HM1202C For HR3000C be used as ( 1R205. ) ( use 1R259 ) * When it is hard to pull out Impact 120mm Bolt, insert a round bar in the opposite side and hit it slightly. ø ø30 ø45 20 #HR4000C
* Insert Impact Bolt from the side on which its model name is stamped. 35 Model/Size Tool Name/Description Code No. available Block A for Crank Shaft ( for disassembly) Arbor press Put Crank Housing on Block A for removing Crank Shaft from Crank Housing without deforming Round Bar for Arbor the Crank Housing, which is made (1R234) of aluminum and soft enough to be deformed when excessive Crank Housing force is overloaded. Crank Shaft Ø28
wide wall 0.5mm HR2410 1R215 45mm HK0500 narrow wall
1R215
Be sure to place the wide wall of Block A and Crank Housing as illustrated here.
Note: Since a height difference between the wide wall and the narrow one is merely 0.5 mm, Block A is unavailable for other use.
Block B for Crank Shaft Arbor Press (for assembly) A jig to hold Crank Shaft when press-fitting Straight Bevel Gear Gear with arbor press Because Block B is hardened, also can be Apply Makita Grease No.2 used as a simple round bar.
Ø24 } Thrust Needle Bearing 1224
Crank Housing 10mm
14mm 50mm
HR2410 1R216 1R216 Ball Bearing HK0500 689ZZ Note: Do not hit Block B with iron hammer. Flat Washer 9
Ball Bearing 699ZZ 1R216 Crank shaft
1R215
Ref: Compact storage with 1R215 36 Model/Size Tool Name/Description Code No. available Ring 22 Ø110 A large Ring which you put directly on Pipe Ring (Item No.1R023). Ø22.4 Always be sure to use this tool when removing Spindle of Models 9067 and 9069, because Gear is so tightly press-fitted to Spindle that Labyrinth Ring is easily deformed when removing Spindle. 15mm Also can be used for any other use.
9067 1R217 9069
Note: As Ring 22 is heavy, be careful not to let it fall from work table, your hands, etc.
Adjust Sleeve (for 1R023) Ø140 Ø115 A Multi-purpose Ring with which you pull out such a long Ø99 rotor as used for Air Compressor. Concavity Use Bearing Plate (1R022) and Pipe Ring (1R023) together. With the concave top and convex bottom as illustrated to right, Adjust Sleeves fit each other or other tools. 50mm
Use Bearing Plate (1R022) together. Convexity
AC2201 1R218 AC2211 Pipe Ring (1R023) is placed on the concave part.
You can adjust the height every 50 mm by piling up multi pieces. {
Note: As Adjust Sleeve is heavy, be careful not to let it fall from work table, your hands, etc. 37 Model/Size Tool Name/Description Code No. available Torque Wrench Shaft N60LCK L=173mm For tightening, with adequate torque, such important bolts as used for Torque Limiter of Rotary 590g 1R254 Hammers/ Disc Grinders, or the most important section of various Pneumatic Tools/ Engine Tools. ( w/Manual) Accepts Ratchet Heads and Spanner Heads listed below. Torque Range 2 - 6N.m When the tightening torque reaches (20 - 60kgf.cm) preset torque, Torque Wrench bends N230LCK at the junction of attached Wrench L=208mm Head and Wrench Shaft with L 170g 1R219 a "click" sound, informing you ( w/Manual) Torque Range 7 - 23N.m that tightening has completed. (70 - 230kgf.cm) Adjust the numbers of these two scales to required torque. N900LCK L=325mm Note: 200g 1R223 Handle with care because Torque Wrench ( w/Manual) is a measuring instrument. Torque Range 20 - 90N.m (200 - 900kgf.cm) Ratchet Head Accepts 6.35 hex. shank bits. Specially designed for the 3 Torque Wrench Shafts Suitable Torque listed above (Part Nos. Wrenches: 1R219/ 223/ 254). 1R219 Bit Adapter (Part No.134873-0) can be used. 1R254 1R220 Square Drive All Makita 12.7 Square for Drive Sockets can be used. 9.5 12.7 Note: Torque measuring function All Makita 12.7 of each Torque Wrench Socket Square Drive (1R219/ 223/ 254) works Adapter Sockets can only when the wrench is 1R222 be used. turned in the direction indicated by the arrow Suitable Torque on the shaft. Square Square So, when Ratchet Head Drive 9.5 Drive 12.7 Wrenches: (1R220/ 224) is switched 1R223 1R224 for reverse rotation, Square Drive reverse Torque Wrench Shaft at the same time for so that it may bend 12.7 towards the direction of arrow. Ratchet Head Ratchet Head 1R220 1R224 Spanner Head For Joint Elbow 15 mm AC2201/AC2211 1R221 Can be attached to Torque Wrench Shafts (1R219/ 254) A=15mm (custom made) For fixing Tank/ Motor Note: Cannot be used for 1R223. A AC2201/AC2211 1R253 A=12mm (for general use)
Socket Adapter 12.7 For Multi-purpose For changing Square Drive Torque Wrenches, from 9.5 mm to 12.7 mm. 1R219 All Makita Sockets for Square 1R254 1R222 Drive 12.7 can be used for Torque Attached to Wrenches, 1R219 and 1R254. 9.5 Ratchet Head *Useful for attaching 6.35 Hex. Bit Adapter (Item No.134868-3) Note: Cannot be used for 1R223. 1R220 Torque Wrench Shaft (see above) —— 1R223 Ratchet Head for Torque Wrench
Ratchet Head (see above) —— 1R224 38 Model/Size Tool Name/Description Code No. available Bearing Extractor Special tool for removing Armature, Ball Bearing and Oil Seal of HM1100C. 90mm
Ø11.8 Arbor Press 20mm
1) Set Bearing Extractor as illustrated to right, and push out Armature with arbor press; if Ball Bearing and Oil Seal come out together with Armature, you do not have to take the step described below in 2).
#HM1100C 1R225
Arbor Press
Use Adjust Sleeve (1R218) together.
Bearing Extractor
2) When Ball Bearing and Oil seal do not come out, set Bearing Extractor as illustrated to left, and to push them out using arbor press.
Ball Bearing Oil seal
Commutator Filing Brush These brushes make commutator smooth to reduce sparks, letting the brake system work well. Let the motor run for 10 minutes at half For CB-407/ 419 of the rated voltage. 1R226 #HR2410
Wire Stripper (Model No. For stripping off the sheath of 3000A) 170mm lead wire. Applicable to You can remove the sheath the following completely and quickly simply Core wires: by inserting Lead Wire through teeth and grasping handle. mm2 AWG 1R227
0.5 #24 With adjusting stopper for to 1.25 to #16 uniform length of stripped sheath to 1.6 to #14
to 2.0 to #12 39 Model/Size Tool Name/Description Code No. available 1/4” Hex. Shank Bit 6.35mm Multi-purpose (1/4”) Allows you to loosen/tighten M4 1R228 M4 to M8 Hex. Socket Head 110mm Bolts fixing Magazine Case D=3 of Air Nailer or Handle of D 13mm Hammer Drill with a fastening tool slanted. Multi-purpose In spite of inferiority to standard Ball Point Bits in the rotation M5 1R229 smoothness of bit and the 20 degrees D=4 inclination angle to workpiece, these bits excels them in mech- anical strength and durability. Multi-purpose
Note 1: M6 1R230 Suitable for use with cordless D=5 fastening tools such as Cordless Impact Driver (Model 6908D), etc. Inclines up to Note 2: about 20 degrees. Multi-purpose When attaching this bit to Pneumatic Impact Drivers, M8 1R231 cut 13 mm shank to 9.5 mm. D=6
Ø36 Pipe 30 Ø30 Necessary for protecting Crank Housing from deformation when you remove Crank Shaft form Crank Housing of HK0500. Can be used for other applications. Pipe 30 50mm
HK0500 1R232
Use Round Bar for Arbor (1R233) together.
1) Reverse Crank Housing and set Pipe 30 Pipe 30 on Crank Housing as illustrated.
2) Reversing Crank Housing again together with Pipe 10, put them on the turn base of Arbor Press, and then push out Crank Shaft using Arbor Press. ØA(mm) —— Round Bar 100 for Arbor 4 1R233 ØA 5 1R234 *For inserting Shaft, Metallic item, Bearing, etc. 6 1R235 without scratches on them. 7 1R236 *Various sizes are available for efficient 8 1R237 press-fitting jobs. 9 1R238 *Long length of 100mm for a wide range of 10 1R239 press-fitting applications. *Chamfered both ends prevent workpiece from 11 1R240 slanting in press-fitting operation. 12 1R241 13 1R242 100mm 14 1R243 Note: 15 1R244 *Do not hit these bars with iron hammer. 16 1R245 *When you cut a Round Bar 100 in order to 18 1R246 shorten it, be sure to machine and chamfer 20 1R247 the cut plane using lathe. 22 1R248 24 1R249 26 1R250 28 1R251 30 1R252 40 Model/Size Tool Name/Description Code No. available Wrench Head 12
See Page 37. 1R253
Torque Wrench
See Page 37. 1R254
Retaining Ring S-7 Setter Sets Retaining Ring to Spindle 120mm without deforming it. Plier is available. But if not using Plier properly, a small Retaining Ring does not restore to original form. Ø7 Ø18 12mm
Set Retaining Ring (Item No.961023-2) 6702D 1R255 in this hole.
Gear Retaining Ring is put in the depth of Spindle. 41 Model/Size Tool Name/Description Code No. available
Clutch Extracting Tool 35mm Use for exchanging Clutch or Crank Shaft of Engine. Note: Put Crank Shaft Lock Bolt (1R155) 28mm or cotton rope into Cylinder through plug hole to lock Crank Shaft. As the left-handed Screw is used, turn it clockwise to remove Clutch.
3 nails
DE4345 1R257 Hook nails on Clutch.
Clutch Wrench 19
V Block
A multi-purpose repairing tool 25mm 125mm 37mm [ Some examples of a wide range of applications ] Useful for removing Bearing using Arbor Press.
Arbor Press 44mm
63mm 69mm
Multi-purpose 1R258 Keeps DC Motor upright in 4072DW press-fitting of Fan of cordless BO3700 Cleaner. For checking the distortion of round bars (Also can be used as a stable stand for round bars.) Holds parts of sheet metal in modifying of their distortion.
Taper Sleeve
For fitting Fluoride Ring ton Impact Bolt #HR3000C of Rotary Hammer. HR3000C Use 1R214 ømm 1R259 for HR4000C Fluoride Ring ø45 HR5001C ø21 ø20 Note: See 1R214 on page 34 for how to use. 42 Model/Size Tool Name/Description Code No. available Motor Tester
Ammeter Voltmeter Megaohmmeter 550mm
200mm
Switch 430mm Fuse 115V-1R116 220V 230V 1R117 ( 240V } ) Lamp
Receptacle board Test Buttons accepts any type of plugs. Outlet for Cable for Variable voltage cotrol Field Test from 0 to 240V Maximum output: 10A Outlet for Line Cable Outlet for Earth Cable
115V 1R260 Re: Short-circuit Test of Field 220V Connect wires as illustrated below, and then 115V 1R261 push Test Button (1). If Lamp (2) turns on, 220V 240V there is short-circuit in Field. 240V 1R262
Lamp (2) use the Test Button (1) 100V following Ring terminal 1R078 3 tools together: 1R174 ( 1R175 ) Green 1R176 Red
White
Cable for Field Test Black Lead Wire (1R174)
Megaohmmeter Re: Measuring Insulation Resistance Velcro tape banding First, turn on the switch, and keep it on using velcro tape, etc. Then, connect wires as illustrated below, and If the Megaohmmeter hand swings left to go under 10 Mega, there is Insulation failure.
Test Button (2) Earth Clip
Earth Cable (1R175)
Line Cable (1R176) Plug 43 Model/Size Tool Name/Description Code No. available Bearing Extractor Removes Bearing or Gear more easily than slotted screwdriver: A 12mm First, lift up Bearing slightly using A side, and then pull it out completely using B side.
B
1R263 260mm Use 2 Bearing Extractors. 1pc/ case: Various models 2 pcs are required for ( operation. )
Concave tip for safe operation: Surely catches the shaft and Use 2 Vise Plates hardly slips off the shaft. (1R041) together.
Note: Do not use this tool for Bearing on the Fan side of Armature, because Fan may be pushed toward Armature to be out of place.
Torque Wrench ( Torque range measurable: 20-200 N.m) Checks the tightening torque of Impact Drivers.
Multi-purpose 1R264
12.7 square drive 440mm
Torque Checking Faceplate Us to check the tightening torque of Impact Drivers. M12 High-tensile bolt Fix this Plate to Vise, and fasten High-tensile bolt to this Plate. And then measure the M12 High-tensile washer tightening torque using Torque Wrench 30 Hex. Socket listed above (1R264). High-tensile bolts M12 and M16 M12 High can be used. -tensile nut Socket Adapter 140
M12 holes Various 1R265 M16 holes Impact Drivers
185
Pull the switch trigger to the full for 5 seconds to fasten High-tensile bolt, and then check the tightening torque with Torque Wrench (1R264). 44 Model/Size Tool Name/Description Code No. available
Spring Pin Extractor Use to remove/install Spring Pins from/on Trigger or Trigger Valve Case of Pneumatic Nailers. D Air Nailer The head is stepped for positioning as illustrated for ø2.0 Pin 1R266 below. Therefore, it is very easy to remove/install L= 50 L Pins which is difficult to handle using Spring Pin D= ø1.8 Extractors (1R161/ 162/ 163).
Air Nailer for ø2.5 Pin 1R267 L= 60 D= ø2.3
Also can be used as a guide pin.
Air Nailer for ø3.0 Pin 1R268 L= 70 Note: D= ø2.7 Spring pin Extractors 1R161/ 162/ 163/ 296 are also available.
Bearing Extractor Removes Bearings which cannot be pulled out with Bearing Extractor 1R021. Fast operation can be assured because the claws are designed so that they do not 80mm spread out even if thy are not fixed with hex. socket bolts. Convenient when; *Bearings cannot be removed even with arbor press. *Arbor press is not available.
Movable handle
Hanger Nail thickness: 1.0mm 65mm 6mm —— 1R269
Max. 36mm
*Thin nails are optimum for narrow openings. *When the opening is narrow, clamp Bearing Extractor at the backs of claws with vise (see Fig.1). *When the opening is wide, put an adjustable wrench on the hanger of Bearing Extractor as a spindle lock.
Fig.1 Fig.2 45 Model/Size Tool Name/Description Code No. available
Hammer Testing Bit 250mm HM1100C Use these testing bits together with 17mm 1R270 Hammer Testing Stand (1R083). SDS-Max
220mm HR2400 14mm 1R271 SDS-Plus
Use to install Ring Spring 26 on Tool Holder Ring Spring 26 Setting Tool A of Rotary Hammers. How to Use: 1) First, put Ring Spring 26 on Setting Tool A, and then put Setting Tool B on Setting Tool A. (See Fig.1.) 2) Next, using arbor press, press down the unit that you have made in 1), Flat Washer 29 and Compression Spring 29 toward Tool Holder. (See Fig.2.) Fig.1 ø25
Setting Tool B 1R273 1R272 45mm
Ring Spring 26 Setting Tool A ø29 1R272
Note: Be careful not to injure yourself, because the edge of the wider BHR200 end is sharp. Ring Spring 26 Setting Tool B Fig.2
ø29
1R273
1R273 100mm Flat Washer 29 1R272
Compression Spring 29
ø37 Put Tool Holder on the turn base of arbor press. 46
Model/Size Tool Name/Description Code No. available
Type 72 and Type 94 Field Insert Jigs
Use to insert Fields which you may find difficulty in setting in place such as used for Demolition Hammers.
12mm (*19.5mm)
62mm (*83mm)
20mm (*30mm)
70mm (*92mm) *The numbers in parentheses Type 72 are dimensions of 1R275 8500N 1R274 Motors
Steps to Insert Field Fig.1
1. See Fig.1. 1R062 or 1R063 Insert Guide Bar M4 (1R062) or M5 into each of the two holes on Motor Housing by hand till it stops.
2. Insert the holes of Field through Guide Bars, and push Field into Motor Housing by hand and with plastic hammer. Note: Always be sure to take this step 2 because skipping step 2 may result in inclined Field. A
3. See Fig.2 Set Motor Housing on the turn base of arbor press, and set Field Insert Jig on Field as illustrated. And then push the center of the Jig to insert Field. Fig.2
4. When Field is inserted by approximate 10mm, check whether or not Guide Bars rotate lightly. If the holes of Field are not aligned with those of Motor Housing, Guide Bars cannot be rotated by hand. In such a case, therefore, hit the places Type 94 HM1302 indicated by "A" in Fig.1 with plastic 1R275 hammer to turn Field slightly. Motors 8600S Thus, the position of Field is corrected, letting guide Bars turn smoothly.
5. Taking care not to pinch the wires of Ring Terminals, etc., insert Field till it stops.
Note: Always Use Guide Bar 1R062 or 1R063 together with Field Insert Jig. 47
Model/Size Tool Name/Description Code No. available
Acrylic Dust Box Can be used when cleaning the dust of Vacuum Cleaners, etc. Transparent Acrylic Board
Vacuum Cleaners Dust Collectors 1R276 Cutters
Torx Driver T10x75 Use to remove/ install the case cover of Slide Type Batteries
172mm 75mm
28mm
Slide Type Batteries B2417 Torx screws are used for fastening the case cover of Slide Type Batteries. Torks screw has a tamper-proof pin at the center of its star socket as illustrated below. B2430 Therefore, the top of Torx Driver is concaved in order to accept the pin. B9017 B9017A BH9020A Torx Driver 1R277 BH9033A BH1220 BH1220B BH1420 BH1433 BH1233 BH1233B
Torx Screw 48
Model/Size Tool Name/Description Code No. available
Round Bar 50 for Arbor øA øA (mm) Sister tool to Round Bar 100 4 1R278 *For inserting Shaft, Metallic item, Bearing, etc. without scratches 5 1R279 *Various sizes are available for efficient press-fitting. 6 1R280 *Tough against heavy duty press-fit 50mm 7 1R281 *Chamfered both ends prevent workpiece from slanting. 8 1R282 9 1R283 Note: *Do not hit these bars with iron hammer. 10 1R284 Re: The following tools are also available 11 1R285 Round Bars 100 (1R233 - 1R252) Round Bar Storage Board (1R287) 12 1R286
Round Bar Storage Board Can be used to arrange Round Bars and some other tools.
300mm
The following tools 40mm can be stored; Ring Spring Setting Tool B (1R165), 200mm Block A for Crank Shaft (1R215), Pipe 30 (1R232), 1R287 Round Bars 100 (1R233 to 1R252), Ring Spring Setting Round Bar Storage Board is made of wood. Tool B (1R273), So it can be used as a storage stand by Round Bars 50 fastening 2 boards of plywood cut as illustrated to right, reducing less space of job site. (1R278 to 1R286)
Screwdriver Magnetizer *Screwdriver or driver bit can be magnetized. *Convenient for putting screw on screwdriver when fastening hard-to-access screws, or removing steel balls. *Magnetic force can be removed from magnetized screwdrivers. How to Use: There are two ways to use: 1. Insert screwdriver/driver bit into the Magnetizer, Iron and then access screw or steel ball. 2. Insert screwdriver/driver bit into the Magnetizer Screwdrivers, till it reaches the other end of the Magnetizer. Bits, 1R288 Grasp the Magnetizer while pressing screwdriver/ Round Bars driver bit against the side of the Magnetizer. And then pull quickly screwdriver/driver bit out of the Magnetizer to magnetize it. Note: In case of 2, the magnetic force gets week in several days. So, if you find the change, magnetize screwdriver/driver bit again. 49
Model/Size Tool Name/Description Code No. available
Switch Unit Adjusting Gauge For correct work of Auto Stop System of Model 6796D, specially designed to adjust the distance between Torque-up Plate and the switch lever of switch Unit.
1.4mm
Pan Head Screw M2.3x10 w/washer Switch Unit Torque-up Plate 6796D 1R289 Tapping Screw Bind PT3x10 only Adjust Holder Plate
Switch Lever 1.4 0.2mm
Gear Case Complete 1R289 When installing Switch Unit, adjust the distance between Torque-up Plate and the switch lever of Switch Unit so that the distance comes to be 1.4mm 0.2mm. This adjustment can be done by moving up/down the elliptic hole of Holder Plate.
Torx Bit VT-27 *Tightens/loosens the torx socket head bolt used for fastening Tool-less Blade Clamp of Models JR3000VT/ JR3030T. *Also convenient when assembling/disassembling 6.35mm petrol tools of Dolmar. *To use Torx Bit VT-27, attach it to Model 6093D/ 6916D, etc. 12.7mm JR3000VT JR3030T 1R290 Petrol Tools of Dolmar Used for Torx Socket Head Bolt. 110mm
Retaining Ring S and R Pliers Remove/install both internal and external Retaining Rings; applicable to Retaining Rings of 10 to 40mm nominal diameter. Convenient for removal/installment of the Retaining Ring placed deep in the hole on gear head or clutch of Brush Cutter. This compact double-duty tool may be indispensable to engineers on the move.
Brush Cutters and Various Models Nails for 1R291 External Rings of Makita, Dolmar
Nails for Internal Rings 50
Model/Size Tool Name/Description Code No. available Wrench for Bearing Retainer Removes/installs the Bearing Retainer of ø30mm internal diameter and and ø40mm external diameter.
DA4030 152mm 1R292 DA4031
30mm 39.0mm The followings are also available; Wrenches for Bearing Retainer (No. 1R042 and R043)
Wrench for Clutch Use this Wrench when replacing Clutch or Crankshaft of Engine.
Hex. Socket Head Bolt M8x12 DE3435 1R293 DA4031 180mm
25mm Note: 76mm Put Crank Shaft Lock Bolt (1R155) [Back view] or cotton rope into Cylinder through plug hole to lock Crank Shaft. As the left-handed Screw is used, turn it clockwise to remove Clutch.
Commutator Filing Brush For CB-166 These brushes make commutator smooth to 1R294 reduce sparks, letting the brake system work Model 407 well. Let the motor run for 10 minutes at half of the rated voltage.
For CB-412 1R295 Model 420S
Spring Pin 1.5 Remover For disassembling the trigger lever of pneumatic impact wrench.
dia. 1.4mm For Pin 1.5
40mm Model AD601 1R296 Model AD602
Relevant repair tools are: Enlarged view of the tool head No.1R161 to 1R163 No.1R266 to 1R268 51
Model/Size Tool Name/Description Code No. available
Spanner Head 17 Use for tightening Union nut of dia.10mm copper tube to a specified torque. For modular use with Use with Torque wrench shaft (No.1R219 or 1R254)
For 17mm Joint elbow 1R297 AC3000
Relevant repair tools: 1R219, 1R221, 1R253, 1R254 17.0mm
Hex Bar 10 with Square Socket
Use this bar when tightening drill chuck 10mm Hex Bar at indicated torque. Also applicable to tighten M12 hex socket head bolt at indicated torque. 65mm How to Use: 6304R 1R298 Couple Hex Bar 10 with Ratchet Head 12.7 (1R224), and then install them on Torque 100mm Wrench 20-90N.m (1R223) to tighten drill chuck or hex socket bolt. 12.7mm Square Re: Socket See page 37 for how to use 1R224 and 1R223.
Bearing Extractor (small)
Use to remove the ball bearing on the bottom side of model AD601/AD602.
AD601 1R299 AD602
Bearing Extractor (large)
Use to remove the ball bearing on the top side of model AD601/AD602.
AD601 1R300 AD602
Commutator Filing Brush (for DC Motor) For CB-431 BTD150 1R301 These brushes make commutator smooth to reduce sparks, letting the brake system work For CB-424 6503D 1R302 well. Let the motor run for 10 minutes at half of the rated voltage. For CB-430 6343D 1R303
For CB-432 BTD200 1R304 52
Model/Size Tool Name/Description Code No. available
Wrench for Case Joint Use for removal/ installation of Case Joint. How to use: AD603 1R305 Secure the cylinder case in vise. Fit the projections in the pin holes of Case Joint, then turn the handle.
Ring Spring Removing Jig Use this tool when removing Ring Spring 11 from Spindle. Ram of How to Use: Arbor Press *When using this tool, install it on the ram of arbor press. 10mm *Make a countersunk hole on the ram of arbor press as illustrated to right in order to prevent the tool from falling out of the ram. Countersink here. And then fix the tool at the hole with the screw 98.5mm on the tool. *If this tool cannot be installed on the ram, grind down the end of the ram using Angle 6304RT Grinder, etc. and 1R306 Many Other Models
12mm
140mm
26mm
As the ram of arbor press goes down, Ring Spring Removing Jig presses down Compression Spring to remove Ring Spring from Spindle.
ET Holder O-Type 2.5 Use to install E-2.3 Stop Ring (E-Style Retaining Ring). How to Use: 1. First, install Stop Ring on ET Holder using pliers. (See Fig.1 & 2.) 2. An then set Stop Ring in place using ET Holder. (See Fig.3.)
10mm 124mm
AF502 1R307 Fig.1 Fig.3
Fig.2 53
Model/Size Tool Name/Description Code No. available
Spring Pin Extractor For ø4.0 Pin Use to remove Spring Pins used for Planer-Jointers or the base and blade case of L= 70 1R308 old type Circular Saws. D= ø3.7 øD For ø5.0 Pin L L= 100 1R309 D= ø4.7
For Air Nailers, the following Spring Pin Extractors are available: For ø6.0 Pin 1R161, 1R162, 1R163 L= 100 1R310 Enlarged view of the tool head 1R266, 1R267, 1R268 D= ø5.7
Retaining Ring Pliers with Long Bent Nails Removes/installs Internal Retaining Rings; applicable to Retaining Rings of 10 to 34mm nominal diameter. With long nails for easy access to Retaining Rings on hard-to-reach holes.
4340CT and 1R311 Many Other Models
Hammer Stand Can be used as a stable stand on which Demolition Hammer is put vertically for repairing.
HM1100C and 1R312 Many Other Models
Bit for One-Touch Cord Lock Adapter Use to remove/install the tamper-proof screws. 9mm 6.35mm
6825 1R313 50mm
Applicable to recessed screw 75mm 54
Model/Size Tool Name/Description Code No. available Torx Bit VT-25 Use to tighten the torx screw of models of model BFL080F series when fastening the clutch section to the spindle: When tightening the screw, install this bit on a cordless impact driver - 6903VD, 6916D, etc. Installed on a torque wrench, also can be use for torque control. (See below.)
12.7mm 6.35mm (N type) Torque Control: Install this bit on at torque wrench to tighten the screw at required torque.
Models of BFL080F 1R314 series Torque wrench 110mm
Torx bit VT-25
Applicable to type T-25 torx screw
Laser Beam Positioning Jig Use to adjust the position of laser beam of model LS0713FL.
side view top view How to Use: Take the following steps for the correct positioning of the laser beam: 1. Set the both of miter angle (base) and bevel angle (saw head) at 0° . 2. Remove outer flange, saw blade and inner flange. 3. Install this jig on spindle; put the round hole of the jig through the spindle, and then fix the jig to spindle with the hex bolt which is used for fastening saw blade. 4. Turn the jig downwards till it cannot be lowered any more (Fig.1), and then adjust M4x6 screw (designated with A in Fig.3) so that the line of the jig gets closest to that of the laser beam. 5. Turn the jig upward till it cannot be raised any more (Fig.2), and then adjust M4x6 screw (designated with B in Fig.3) so that the line of the jig becomes on or parallel with that of the laser beam. 6. Repeat the adjustment described above in 4 and 5 till the line of the laser beam is on that of the jig. Fig.1 Fig.2 LS0713FL 1R315
Jig
Fig.3
(B) M4x6 Screw (A) M4x6 Screw: Turn this screw to adjust the angle to the Base.
(B) M4x6 screw: Turn this screw to adjust the angle to (A) M4x6 Screw the Guide fence. 55
Model/Size Tool Name/Description Code No. available
Adjustable Bearing Retainer Wrench Can be used for installation/removal of all kinds of bearing retainers employed for angle grinders, circular saws, etc.; of course, can be used as an ordinary adjustable wrench.
Pins
Various How to Use: 1R316 1. Fix the bearing box using a vise. models 2. Adjust the distance between the two pins to the pitch of the bearing retainer. 3. Check whether the bearing retainer is right-handed or left-handed, and then loosen the bearing retainer.
Note: The conventional bearing retainer wrenches - 1R042, 1R043, 1R292 - will be discontinued when they run out of stock.
Hex Wrench (Inch Sized) size: 3/16" 1R317 Use to install/remove the inch sized hex socket head screws employed for Models HB270, TF1100JQ, etc. size: 5/32" 1R318
size: 3/32" 1R319
Size of Hex Socket size: 5/64" 1R320 assortment of 12 different sizes 1R321 :comes with a wrench holder.
Hex Wrench 17 Designed for the Rotary hammers and Demolition hammers which have a screwed tool holder.
Use this tool and a pipe of approximately 1m length, when the tool holder cannot be removed using Impact socket (1R187) and Hex bar 17H-100 (1R188). Rotary (Also refer to page 27.) Hammers and Demolition Use 2 copper vise plates (1R041). Hammers which uses approx. 1m pipe 17mm hex bull point
Burner Screwed 1R322 clockwise: HM0810 Hex=17mm HM0811 HM0821
Screwed counter- Hex wrench 17 clockwise: (1R322) HR3520 Place the machine on a piece of lumber HR3811 so that it can be fixed firmly. HR3850
Note: Use of pipe wrench may damage the tool. Therefore, use this wrench as often as possible. 56
Model/Size Tool Name/Description Code No. available
Impulse Oil Use to lubricate the O ring and piston ring of Model TF1100JQ. (114g in tube)
TF1100JQ 1R323
Bumper Removing Tool Use to remove the bumper of Model TF1100JQ.
dia. 8mm
TF1100JQ 1R324
110mm
25mm
260mm
Torx Driver TF1100JQ,etc Use to screw/unscrew Torx screws. 1R325 size:T7Hx80 180mm (T7, T15) 225mm (T25, T27)
TF1100JQ,etc 28mm (T7, T15) 1R326 32mm (T25, T27) size:T15Hx80 80mm (T7, T15) 120mm (T25, T27)
TF1100JQ,etc 1R327 size:T25Hx120
Also available for tamper-proof Torx screws TF1100JQ,etc with a hole drilled for tamper-resistant pin 1R328 size:T27Hx120
Screw Extractor No.802 For preventing screws from turning 62mm
20mm 5mm TF1100JQ, etc 1R329
5mm Also can be used for removing broken screws and bolts.
Silicon KE-45N For fixing the Spark unit of Model TF1000JQ (100g in tube) TF1100JQ, etc 1R330 57
Model/Size Tool Name/Description Code No. available
Needle Bearing Extractor For removing Needle bearing 4016 or 4516 that is press-fitted on the end (Crank housing side) of Barrel. dia. A: 1R331= 43.5mm 25mm 1R332= 50.0mm HR3520 How to remove Needle bearing 4016/4516 HR3520B 1R331 Place the tools as illustrated below, then push out the Needle bearing. HR3521 Note: Use 1R232 or similar tool because the needle bearing cannot be pushed out with 1R273 alone.
ram of arbor press
1R232 (or the like)
1R273
Barrel
1R232 (or the like)
HR3811 Needle bearing 1R273 HR3850 extractor HR3850B 1R332 HR3850K HR3851
Needle bearing Needle bearing extractor 4016 or 4516
Needle Pin 4.5 For removing Shoulder pin 9-11A that is press-fitted in Tool holder: Use this pin when the shoulder pin cannot dia.4.5mm be removed using Round bar for arbor 4-50 (No.1R278) because it is hard to deform 53mm by reason of; 1. Specially designed to the diameter of the pin installation hole in Tool retainer 2. Harder than Round bar for arbor 4-50
HR3520T 1R333 Cross-section of Tool holder Needle pin 4.5
Set the shoulder pin perpendicular to the ram of arbor press using 1R036 or similar tool.
Shoulder pin 9-11A 58
Model/Size Tool Name/Description Code No. available
Battery Checker (1R335) Designed from Model ADP03 Interchangeable Adapter (1R334) Designed from Model ADP01 for use of cluster-type and stick-type batteries
RS232C Cable (1R338) For connecting Battery checker with PC Software for Battery Checker (1R339) Will be provided on CD, floppy disk or the like.
Cluster-type or Stick-type batteries
Slide-type batteries
[1R334]
[1R335]
[1R338]
1R334 Cordless 1R335 tools 1R338 1R339
[DC24SA/ DC14SA] [PC] [1R339]
Setting up 1) When checking slide-type batteries: Install Battery Checker (1R335) on Charger DC24SA or DC14SA. When checking cluster-type or stick-type batteries: Install Battery Checker (1R335) on Charger DC24SA or DC14SA, then attach Interchangeable Adapter (1R334) to the Battery Checker. 2) Connect Battery Checker (1R335) with a PC on which Software for Battery Checkers (1R339) has been installed. 3) Now battery check can be carried out on the PC monitor.
What Can Be Done *Checking details of failure, usage history (slide-type batteries only), etc *Judgment of memory effect and elimination of memory effect by refreshing charge
What Can Be Viewed on the PC Monitor a) When a slide-type battery is checked: *Detailed information on battery capacity or failures in thermal sensor or battery cells *Result of failure detection letting you know the cause of defect - worn-out failure, initial failure, etc; an accurate result will be given with the display of usage history. b) When a cluster-type or stick-type batteries is checked: *Detailed information on battery capacity or failures in thermal sensor or battery cells *Result of failure detection letting you know the cause of defect - worn-out failure, initial failure, etc; the result, however, will not be very accurate because of obscure usage history. 59
Model/Size Tool Name/Description Code No. available
Ring Spring Setting Tool A (1R336) Ring Spring Setting Tool B (1R337) Use these two tools for setting Ring spring 7 that secures Lock washer and Spiral bevel gear.
Mark
Ring Spring Setting Tool A Ring Spring Setting Tool B (1R336) (1R337)
How to Use
1) Put 1R336 over the top of Spindle, then fit Ring spring 7 on 1R336 as illustrated below.
Ring Spring 7
1R336 9015A 1R337
2) Push down Ring spring 7 half way using the "mark 1" end of 1R337, then push down using the "mark 2" end of 1R337 till Ring spring fits in the groove on Spindle.
"mark 1" end "mark 2" end
Note: Use 1R004 for removing Ring spring 7 from Spindle. Important: Do not use a Spring ring 7 removed from Spindle. Be sure to replace it by new one. 60
Model/Size Tool Name/Description Code No. available
Bearing Retainer Wrench Use for installation/removal of the bearing retainer located deep in a cup-shaped portion. Also can be used for general installation/removal of bearing retainers.
1) Hold a bearing box securely in a vise being careful not to deform the bearing box. 2) Fit the two protrusions on the end of the pipe portion securely in the grooves on the bearing retainer. 3) While pressing the pipe portion straight down, turn the handle in the direction of loosening. At this time, be careful not to tilt the pipe portion. Note: Before turning the handle, make sure Series models whether the bearing retainer is right-handed 3mm of or left-handed. GA9010C, GA7010C, dia.25mm PW5000C, 9560C; 1R340 dia.30mm and models using the bearing retainer of the same size
Relevant tool=1R316
Spanner Head 41 Use for repairing or angle adjustment of the angle head of Angle screwdrivers such as BFL300F, BL400F or the like. Designed for modular use with 41mm Torque Wrench Shaft (1R223). 75mm
85mm
How to Use BFL300F loosen 1R341 As illustrated to right, turn Hex nut M35-41 BFL400F using 1R341 and 1R223 while fixing the angle head with adjustable wrench or the like. tighten 1R223
1R341
Relevant tool=1R223 61
Model/Size Tool Name/Description Code No. available
Battery Checker
TD123D (Japanese 1R342 market only)
Retaining Ring Setting Jig Designed for easy installation of Retaining ring S-12 that secures the spiral bevel gear in the spindle section of Model 9553NB and 9556NB series models. Use this jig instead of general retaining ring pliers because tips of such pliers are interfered by the wave washer (1 or 2 pcs) secured over the spiral bevel gear.
25mm
Caution: Be careful not to cut yourself 12mm on the sharp edge of the bottom.
12 degrees
How to Use Series Models of After installing large spiral bevel gear and wave washer 12 on spindle; 1R343 1) Put retaining ring S-12 on Retaining Ring Setting Jig (No.1R343) from the tapered end of the jig. 9553NB 2) Put the jig onto spindle, then put Bearing Setting Pipe 20-12.2 (No.1R028) over the jig. 9556NB 3) Using arbor press, press down the pipe till the retaining ring is securely fitted in place on the spindle with a snap.
Arbor press
No.1R028
Retaining Retaining ring S-12 ring S-12
Wave washer No.1R343
Relevant tool=1R026 62
Model/Size Tool Name/Description Code No. available
Torque Driver (1R344) Cat. No.= RTD500CN, Manufacturer= Tohnichi For tightening bolts to a uniform torque
Coupler Main graduation
Bit (option) Sub graduation Locker Grip
Hex Bit (1R345) Cat. No.= B-W4, Manufacturer= Tohnichi
22mm
9mm
4mm AN910H 50mm 1R344 (Japanese 1R345 market only)
Application Use for fastening Feed cylinder of AN910H
Be careful not to M4 Hex socket damage O ring. head bolt (2pcs) Feed cylinder: Can be deformed by overtightening because made of plastic, requiring severe torque control.
*Specified torque= 1.8N.m 63
Model/Size Tool Name/Description Code No. available
Center Attachment for 1R045 Use with Gear Extractor, large (No.1R045) for removing gear, etc. 1R045
The threads on the center shaft of 1R045 are rather easily broken because they cannot be tempered. Therefore, if necessary, attach well-tempered No.1R346, the tip of which cannot Multi-purpose be damaged. (for modular Also 1R346 can be used as an adapter when 1R346 the hole in material is so large that the center use with shaft of 1R045 enters in the hole. No.1R045) Important: When removing gear, be sure to securely grasp 1R346 the legs of the Gear Extractor so that its claws dia.15mm cannot be pushed out of position.
[Enlarged view]
Tool Retainer Pole Removing Tool Use for removing Tool retainer pole of HM1800 and HM1810.
How to Use: 1) Put No.1R347 on Tool retainer pole as illustrated below. Then attach No.1R346 securely to No.1R045.
1R045 1R347
35mm 12mm 1R346
10mm HM1800 1R347 HM1810
[Enlarged view]
Compression spring
Relevant tools: No.1R045, 1R346 Retainer ring
2) While grasping the legs of No.1R045 securely so that they cannot be spread, turn the handle clockwise to compress Compression spring. 3) Remove Pin 4 in Retainer ring, and now Tool retainer pole can be removed by turning the handle counterclockwise.
Spring Pin 8 Remover For removing Spring 8 assembled to the tool retainer section of Model HM1800 or the like. Also applicable to the tools using Spring 8.
dia. 7.5mm Models using spring pin 8 100mm such as 1R348 [Enlarged view of the tool head] HM1800 or HM1810
Relevant repair tools are: dia. 5mm No.1R161 to 1R163, 1R266 to 1R268 No.1R296, 1R308 to 1R310 64
Model/Size Tool Name/Description Code No. available
Spacer 15.9
Use with No.1R315 for adjusting the position dia.40mm of laser line as illustrated below. dia.15.9mm Important: 1) Do not confuse Spacer 15.9 with Ring 16 (2pcs) used for the machine; one on the inside of the blade, 2.5mm and the other on the outside of the blade . 2) Do not forget to remove Spacer 15.9 after laser line adjustment.
Ring 16 1R349 Blade case LS1013L 1R349 LS1214L 1R315
Important: Be sure to tighten the Hex flange head bolt by hand, and be careful Relevant repair tool: No.1R315 not to overtighten.
Ring 60 dia.78mm Use together with No.1R213 for removing Cylinder from Crank housing of HR4011C series models. dia.60mm You can obtain enough length to pull off Cylinder by putting two on Crank housing as illustrated below.
Important: 30mm Do not forget to remove Ring spring 30 and Flat washer 33 when removing Cylinder.
Note: This steel ring is hardened, allowing to use for a wide range of repair jobs using arbor press.
HR4011C 1R213 Series Models 1R350 and Many other models
1R350 (2pcs)
Cylinder
Crank housing
Relevant repair tool: No.1R213 65
Model/Size Tool Name/Description Code No. available
Anvil Holding Jig
Use together with No.1R357 for; 12mm 12mm 1. Removing Anvil from Gear case of Model BPT130 2. Press-fitting Cam A in place on Anvil of Model BPT130
1. Removing Anvil from Gear case 5mm 20mm 1) Remove Retaining ring WR-5 using 1R291 or 1R212 and 1R003. Note: Retaining ring WR-5 cannot be removed if it is stuck 100mm under Cam A. If so, put off Cam A from Retaining ring WR-5 by setting Cam A in place as described in "2. Press-fitting Cam A in place on Anvil". 2) Fit the T-shaped end of Anvil in the deep notches of 1R351. 3) Remove Anvil from Gear case by pressing down with arbor press. dia.40mm
Anvil Anvil
1R351
1R351 deep notch (Use together shallow notch 1R351 with 1R357.)
2. Press-fitting Cam A in place on Anvil 1) Fit the T-shaped end of Anvil in the shallow notches of 1R351. BTP130 2) Put 1R357 on Cam A with the face B on the Cam side. Press down Cam A using arbor press all the way until it stops when the face A of 1R357 is flush with the upper end surface of Anvil.
1R357 Anvil
Cam A 1R351 shallow notch Anvil
1R351 deep notch
Cam A Setting Jig dia.25mm face A dia.19.5mm
dia.15.5mm
1R357 (Use together 25.2mm with 1R351.)
face B 66
Model/Size Tool Name/Description Code No. available
Fastening Nut Holding Jig
1R352 is a special tool for removing Fastening nut that fastens dia.36.5mm the motor of Model KDW-6 (pneumatic impact driver of the former 32mm Kanematsu). dia.3mm
How to Use 1) Fix the flat surfaces of Hammer room in vise, and unfasten 15mm by turning clockwise. 2) Remove O Ring from Housing. Burn the threadlocker using gas burner. 15mm 3) Fit the flat surfaces of 1R352 in vise. Fit two 3mm diameter 70mm pins of 1R352 in two of the four holes on Fastening nut. 4) Remove Fastening nut by turning Housing clockwise. Kanematsu Important: Be sure to burn the threadlocker using gas burner KDW-6 because 3mm diameter pins are rather week. (model available 1R352 in Japanese market only) 27mm
Clutch Case Holding Jig
1R353 is a special tool for removing Clutch case of Model KDW-7 dia.80mm (pneumatic impact driver of the former Kanematsu). Made of polycarbonate plastic in order not to damage Clutch case.
How to Use Fix the flat surfaces of 1R353 in vise. 46.4mm Insert Clutch case into the hexagonal socket portion of 1R353. 70mm Remove Clutch case by turning Motor case clockwise using plastic hammer.
Important: Be sure to press Motor case by hand as illustrated below because the insert length of Clutch case is short. Kanematsu KDW-7 (model available 1R353 in Japanese market only)
Relevant repair tool: No.1R354 67
Model/Size Tool Name/Description Code No. available
Joint Holding Jig
1R354 is a special tool for removing Joint of Model KDW-7 dia.37.5mm (pneumatic impact driver of the former Kanematsu). 6mm How to Use 1) Remove Clutch case using 1R353. 2) Fix hexagonal portion of 1R354 in vise. 3) Set the machine on 1R354. Remove Joint by turning Motor case clockwise using plastic hammer.
45mm
Kanematsu KDW-7 24mm Hex. (model available 1R354 in Japanese market only)
Relevant repair tool: No.1R353
Pinion Gear Positioning Jig
1R355 is a special tool for assembling Pinion gear dia.4.5mm (Spiral bevel gear 19) to Armature.
How to Use 1) Put 1R355 through the assembly of Pinion gear and Gear housing cover. 2) Press down Armature until the end of Armature shaft stops 18mm 23mm against the end of 1R355. Important: Armature is apt to tilt when pressed down with arbor press. If you press down tilted Armature, Armature shaft can be deformed in the worst case. In order to press straight down, gradually insert Armature shaft into Pinion gear while turning Armature; press down dia.20mm Armature carefully every quarter turn until Armature shaft stops against 1R355.
BGA452 1R355
Armature
Gear housing cover
Pinion gear (Spiral bevel gear 19)
1R355 Press down Armature until the end of Armature shaft stops against the end of 1R355. 68
Model/Size Tool Name/Description Code No. available
Bearing Plate 10mm (for arbor press)
1R356 is a sister jig to 15mm diameter 1R022.
120mm dia.10mm 1R356
BVR350 series models and 1R356 Many other 120mm dia.60mm 1R023 models
Replace with new Bearing plates if this portion is chipped.
Relevant repair tools: No.1R022, 1R023
Cam A Setting Jig See page 65 for details. BTP130 1R357 (Use together with 1R351.)
Bar for 90 degree Adjustment
Use together with 1R208 for adjusting the angle of Base plate to Cutter to 90 degrees.
How to Use Put the U-shaped notch of 1R358 through Spindle, and fasten 1R358 to Spindle with Outer flange and Hex nut. 133mm
U-shaped notch
15mm
30mm
3005BA 1R358 1R358 (Use together with 1R208.)
1R208
Outer flange
Hex nut
Relevant repair tool: No.1R208 69
Model/Size Tool Name/Description Code No. available
Chuck Removing Tool
Use for removing Drill chuck of the Cordless driver drills listed on the right column if it cannot be removed in the way described in "Technical Information" for the models.
20mm 22mm 29mm
50mm
How to Use Fig. 1 1) Disassemble Gear assembly until Spindle can be seen. (Fig. 1)
2) Assemble Lock cam to Carrier complete, 20mm then attach them to 1R359. (Fig. 2) BDF430 Note: BDF440 See the list on the right column to choose BHP440 which side of 1R359 to use. Spindle BDF442 3) Fix 1R359 securely in vise. BDF450 Fig. 2 BDF452 4) Insert the spline portion of Spindle into BHP450 Lock cam as illustrated to right in Fig. 3. 22mm Lock cam 1R359 5) Remove *Chuck screw by turning clockwise BDF441 using an appropriate Cordless impact driver. BDF451 * (-) Flat head screw (left-handed, Carrier complete threadlocker coated) is used as Chuck screw. BHP441 BHP451 6) Fix one leg of a Hex wrench 10 in the jaws 6319D of Drill chuck. (left in Fig. 3) 6339D 6349D 7) Attach an appropriate steel pipe to the other 1R359 leg of the Hex wrench. 8414D Drill chuck can now be removed by turning 8434D the steel pipe counterclockwise. (left in Fig. 3) 8444D
Fig. 3
Hex wrench 10
Steel pipe Spindle
Vise
Lock cam 1R359 70
Model/Size Tool Name/Description Code No. available
Clutch Removing Tool dia.40mm Use for replacement of the clutch or the crankshaft of engine. dia.19mm Disassembling steps 1) Lock the crankshaft using Crankshaft lock bolt (1R155) or recoil rope; see page 20 for details. 10mm 2) Insert the three pins of Clutch removing tool in the three U-shaped notches of the clutch as shown below. 3) Because the clutch has left-hand threads, the clutch can 11mm be removed by turning Clutch removing tool clockwise with spanner 19. 8mm dia.5mm For DOLMAR models 1R360 DE5045 U-shaped notch DE6450 Spanner 19 Pin
Bearing Retainer Tightening Tool
Use for installation/removal of the bearing retainer located deep in a cup-shaped portion. Also can be used for general installation/removal of bearing retainers.
dia.17mm This tool does not come complete with 3mm a turning handle. Insert a Phillips screwdriver of a proper size or the like through the holes for use 5210L, 5240L, as a turning handle. dia.22mm 5205FX, CS540D, KS520D, KS521D, SS520D, SS540D How to Use 1) Hold the bearing box securely in a vise being careful and not to deform the bearing box. all other models 1R361 using (Or hold the flats of the spindle in a vise; be sure to insert T-Type hex wrench [1R167] or the like through a bearing retainer a screw hole of the bearing box to prevent the bearing of the same size box from rotating together with the bearing retainer.) as used for 2) Fit the two protrusions on the end of the pipe portion the 8 models securely in the grooves on the bearing retainer. shown above 3) While pressing the pipe portion straight down, turn the handle in the direction of loosening. At this time, be careful not to tilt the pipe portion. Note: Before turning the handle, make sure whether the bearing retainer has right-hand or left-handed threads.
Relevant repair tool: No.1R316, 1R340 71
Model/Size Tool Name/Description Code No. available
Retaining Ring Pliers with Long Bent Nails
Removes/installs Internal Retaining Rings; applicable to Retaining Rings of 10 to 20mm nominal diameter. MBC230DW, With long nails for easy access to Retaining Rings MEM263 and on hard-to-reach holes. 1R362 many other models
Relevant repair tool: No.1R311
Ring Spring Removing Tool for SDS-MAX Tool Holder Use together with 1R003 and 1R212 for installation/removal of the ring spring located at the top of the tool holder.
Washer 8 75mm M8 Screw 60mm
Dummy shank of M8 Nut SDS-MAX type
37mm
How to Use HM1214C series 1) Remove the tool holder cap. 2) Insert the dummy shank of 1R363 into the tool holder, HM1213C series and lock it same way as you do for a real bit. HM1317C series 1R363 3) Press down the flat washer under the ring spring by turning the M8 Nut of 1R363 clockwise HR4011C series using a socket wrench 13. (Fig. 1) HR5211C series 4) Remove the ring spring using 1R003 and 1R212. (Fig. 2) 5) When assembling, do the reverse of the disassembling steps described above.
Socket wrench 13
Flat washer 1R212
1R003
Ring spring
Fig. 1 Fig. 2 72
Model/Size Tool Name/Description Code No. available
Flywheel Puller Use for removing the flywheel from the tapered crankshaft of petrol powered products.
Component parts of 1R364 Plate Center bolt Set bolts and nuts Note: 88mm This tool does not come complete with a turning handle. Insert a Phillips screwdriver of a proper size or the like through the holes of Center bolt for use as a MEM427 turning handle. and other 1R364 How to Use petrol powered 1) Lock the flywheel using 1R365 as shown on right. products 2) Set Center bolt and Plate on the flywheel using Set bolts and nuts. Then insert a Phillips screwdriver Phillips screwdriver of a proper size or the of a proper size like through the holes of Center bolt. 3) The flywheel can now be removed by turning Flywheel the screwdriver clockwise. Note: If there is not a center hole on the end of the crankshaft, make a center hole using a power drill. Similar repair tools: 1R180, 189, 190 1R365 Relevant repair tool: No.1R365
Hook Wrench Use for locking the flywheel when: Removing the flywheel from the crankshaft using 1R364 as described above. Removing the clutch from the flywheel as shown below right.
MEM427 and other 1R365 petrol powered 280mm Clutch products 1R365
1R206 Relevant repair tool: No.1R180,189, 190, 206, 364
Feeler Gauge Set Use for: Adjusting the electrode gap of spark plug (Fig. 1) Adjusting the gap between the permanent magnet of flywheel magneto and the laminations of ignition coil (Fig. 2) Adjusting the tappet clearance of 4-stroke engines Note: 1) See Instruction manual or Service manual for proper This set includes 19 leaves of value of each gap/clearance. the following different thicknesses: 2) If desired thicknesses are not included in this set, 0.03, 0.04, 0.05, 0.06, 0.07, you can obtain it by combining two or more leaves of 0.08, 0.09, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, Petrol powered different thickness 1R366 0.50, 0.70, 0.80, 1.00 products 3) Handle the thin leaves of this set very carefully, or you will bend or cut them.
Fig. 1 Fig. 2 73
Model/Size Tool Name/Description Code No. available
Taper Sleeve Use for fitting fluoride rings on the impact bolt of rotary hammers.
130mm
HR3540C series ø45mm ø25mm ø21mm HR3200C series 1R367 HR3000C series * Insert the impact bolt from the side on which its model name is stamped. How to Use See the description of 1R214 in page 34. Relevant repair tool: No.1R214, 1R259* *Note: 1R259 will be discontinued once current stock is exhausted.
Commutator Filing Brush for CB-350 Use for making the surface of commutator smooth 16mm For CB-350 of to reduce sparks, bringing the function of electric brake 1R368 back to normal. 11mm HR4011C series Let the motor run for 10 minutes at half of the rated voltage.
1R369 is presently an unused number. 1R369
Ring Terminal Setting Jig for models using spring-type Use for setting the spring-type ring terminal of the field in place on the brush holder.
Two slotted screwdrivers have been commonly used for the purpose. This conventional way, however, requires to learn the knack, and it is still difficult for a skilled person and almost impossible for an unskilled person to set the ring terminal of type 61 or smaller motor.
On the contrary, you will be able to set the ring terminal in place easily and securely only in 5 to 10 seconds once you get accustomed to using this jig.
130mm
35mm All models using 1R370 spring-type How to Use ring terminal 1) Grip the handle of this jig securely with your dominant hand. Do not hold it with a pencil grip, or sufficient power will not be delivered to its L-shaped end. 2) First, hook the near side of the ring terminal on the brush holder. (Fig. 1) 3) Taking care not to allow the hooked portion of the ring terminal to slip off from the brush holder, slide the L-shaped end of this jig towards the far side of the ring terminal. (Fig. 2) 4) While pressing down the ring terminal firmly, slide the L-shaped end towards the far side of the terminal ring until the ring terminal snaps in place on the brush holder. (Fig. 3)
Hint for Assembling a New Field to Motor Housing After assembling each lead wire of the two ring terminals to a new field, bend each lead wire for easy ring terminal setting on the brush holder before putting the field in the motor housing.
Fig. 1 Fig. 2 Fig. 3