TERMA MAX K180S User manual

MAXImpact Power
Operators Instruction
& Parts Manual
MAX K180S
Version 2023
Model: MAX K180S
Registration number:.........................
Purchase date:........................

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Table of contents: Page
1TECHNICAL INFORMATION ....................................................................................................................... 4
1.1 MAX K180S .............................................................................................................................................. 4
1.2 AIR HOSE.................................................................................................................................................... 4
1.3 LUBRICATOR/CONTROL PANEL........................................................................................................................ 4
2ACCESSORIES............................................................................................................................................ 5
3SAFETY INSTRUCTIONS ............................................................................................................................. 7
3.1 WARNING SIGNS:......................................................................................................................................... 7
3.2 PROHIBITORY SIGNS:..................................................................................................................................... 8
3.3 MANDATORY SIGNS:..................................................................................................................................... 8
4USE OF MAX K180S................................................................................................................................... 9
5OPERATION PRINCIPLE ............................................................................................................................. 9
6CONSTRUCTION...................................................................................................................................... 10
6.1 MAX K180S ............................................................................................................................................ 10
6.2 AIR PRESSURE HOSE .................................................................................................................................... 12
6.3 MAX-LUBRICATOR WITH REVERSING MECHANISM........................................................................................... 13
7TRANSPORTATION.................................................................................................................................. 14
8PREPARATIONS BEFORE USE................................................................................................................... 15
8.1 GENERAL INSTRUCTIONS.............................................................................................................................. 15
8.2 STARTING PIT ............................................................................................................................................ 15
8.3 TARGET PIT ............................................................................................................................................... 16
9INSTRUCTIONS........................................................................................................................................ 16
9.1 SAFETY INFORMATION................................................................................................................................. 16
9.2 CONVERT THE MAX K180S......................................................................................................................... 16
9.3 CONNECTING THE AIR HOSE......................................................................................................................... 17
9.4 FUNCTIONS OF THE LUBRICATOR ................................................................................................................... 19
9.5 ALIGNMENT OF THE MAX K180S................................................................................................................. 20
9.6 SOLO-BORING ........................................................................................................................................... 20
9.7 REVERSING MAX K180S ............................................................................................................................ 21
9.8 MANUAL PULLING OF PLASTIC PIPES ............................................................................................................... 22
9.9 DIRECT INSTALLING PE/PVC PIPES................................................................................................................ 22
9.10 STEEL PIPE’S RAMMING ............................................................................................................................... 24
9.11 CLEANING OF STEEL PIPES AFTER RAMMING ..................................................................................................... 25
9.12 EXPANDING THE BOREHOLE .......................................................................................................................... 26
9.13 INSTALLING OF PIPES Ø200 MM WITH EXPANDERS ............................................................................................ 27
9.14 AFTER CARE .............................................................................................................................................. 28
10 MAINTENANCE ................................................................................................................................... 29
10.1 ROUTINE MAINTENANCE.............................................................................................................................. 29
10.2 WHEN MAX HAS NOT BEEN IN USE FOR A WHILE.............................................................................................. 30
10.3 TECHNICAL INSPECTIONS.............................................................................................................................. 30
11 TROUBLESHOOTING............................................................................................................................ 32
12 SPARE PARTS ...................................................................................................................................... 34
12.1 MAX K180S –MOLE SPARE PARTS LIST ......................................................................................................... 34
12.2 PNEUMATIC AIR HOSE 20 M SPARE PARTS LIST ................................................................................................. 36
12.3 LUBRICATOR WITH REVERSING MECHANISM..................................................................................................... 38

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1Technical information
1.1 MAX K180S
Parameter
Unit
Value
Outside diameter
[mm]
180
Length
[mm]
2256
Weight
[kg]
275
Air consumption, min (recommended)
[m3/min]
4,5 (5,0)
Air pressure
[atm]
7
1.2 Air hose
Parameter
Unit
Value
Diameter
[mm]
31,5
Length
[m]
20
Weight
[kg]
30,5
1.3 Lubricator/Control Panel
Parameter
Unit
Value
Length (including caps)
[mm]
665
Width
[mm]
232
Height
[mm]
180
Weight (without oil)
[kg]
15,8
Tank capacity
[l]
3,1
Air pressure
[atm]
7

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2Accessories
With MAX K180S the following accessories can be used:
a) For the alignment of MAX:
-Optical level set
-Starting platform
b) For installing plastic tubes, directly behind the machine:
-Tools for pulling PE/PVC pipes diameter 140, 160, 180, 200 (with rope)
Sleeve ø160 Sleeve ø200
-Tensioner with replaceable sleeves
-Steel pulling rope Ø8 mm with interconnector

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c) For ramming of steel pipes:
-Cones:
S356406 S280340 S230290 S159245
d) To clean the pipes from sand and debris after ramming:
−Pipe plugs: PW 355, PW406, PW 323, PW 273, PW 219, PW 159
PW 159 PW219 PW273 PW323 PW355 PW406
−Locking rods (for the pipe plugs)
−Air pressure hose with valves (for the pipe plugs)
-Foam pipeline pig
e) for increasing bore’s diameter up to Ø219:
-Expanders / Calibrators

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-Tip towing for working with calibrators
-Extending rope for towing tool
f) For lubrication we recommend to use EkoMAX Oil. An environmental friendly product that
consists of bio-degradable components. The EkoMAX Oil is available in 5 and 20 liter
canisters.
3Safety Instructions
Please note specific safety requirements as explained by procedures called out in this manual. Failure
to follow these instructions could result in serious personal injury or death. All tools, materials and
equipment manufactured and supplied by TERMA, are designed to be used by qualified and trained
personnel only. TERMA will not be held liable for any injury or damage to either people or property
resulting from the misuse of TERMA equipment.
3.1 Warning signs:
Danger to people, this symbol is used in conjunction with an inscription that
says danger!
Danger of heavy swinging loads!

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Danger of underground utilities!
Danger of explosion!
Entrapment hazard!
High Air pressure!
Danger of burning!
3.2 Prohibitory Signs:
General prohibition signs; this symbol is used in conjunction with a suffix that
makes statements about the ban.
No unauthorized persons allowed!
3.3 Mandatory Signs:
Wear ear protection!
Wear safety glasses!

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Wear hands protection!
Do not start, operate or service MAX until you have read and understood the
operator’s manual.
Failure to do so may result in serious injury!
4Use of MAX K180S
The MAX K180S can be used to execute tunneling and with the use of appropriate accessories for
pulling of PE, PVC pipes and steel pipes’ ramming.
Using the MAX K180S for other purposes is not permitted. The manufacturer will not be held
responsible for any damage sustained through improper use of the MAX K180S.
5Operation principle
The MAX K180S is a pneumatic earth piercing tool, which is driven through the ground by compressed
air. Like any pneumatic tool, MAX requires a compressor with adequate capacity for optimal operation.
To ensure the longevity of the MAX, over pressure (max 7 bar) should be avoided at all times.
The compressed air is passed through the MAX-oiler with the compressed air hose attached to the
MAX –it is this mechanism that moves the MAX. The exhausted air leaves the MAX via its backside.
The MAX lubricator device is equipped with a pneumatic valve to enable a change of direction by
simply moving the handle from position F to position R

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6Construction
6.1 MAX K180S
Drawing 6.1.1
Nr.
Name
Art.
Q-ty
1
Stepped head nut
PMNAK-M180-00.09
1
2
Stepped head
PMNAS-M180-00.01
1
3
Cylinder
PMCYL-M180-00.02
1
4
Chisel
PMPRZ-M180-00.08-M2
1
5
Control stud housing
PMTSR-M180-00.03
1
6
Reverse cone with pulling eyes
WAHW180
1
7
Impact piston
PMBIJ-M180-00.05
1
8
Piston teflon sliding tapes
PMPRB-M180-00.06
3
9.1.
Piston seal (Teflon)
PMUSB-M180-00.07
1
9.2.
Piston seal (O-ring 136,12x3,53)
MTSORSI0023
2
10.1.
Control rod teflon seal
PMUS1-S180-00.04
1
10.2.
Control rod seal (O-ring 65x5 70Si)
MTSORSI0020
1
11
Control rod sliding tape I
PMPT1-S180-00.13
1
12
Control rod
PMRUS-S180-00.06
1

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13
Elastic damper
PMAMOR-S180-00.14
1
14
Control piston teflon seal
PMUTS-S180-00.02
1
15
Control piston
PMTLS-S180-00.01
1
16
Seal (O-ring 86x3,5)
MTSORSI0022
1
17.1.
Control piston teflon seal II
PMUS2-S180-00.03
1
17.2.
Control piston seal II (O-ring 86x3,5)
MTSORSI0022
1
18
Control cylinder
PMCYLSTR-S180-00.07
1
19
Elastic block
PMLST-S180-00.08
1
20
Splitter seal (O-ring 58x3 70NBR)
MTSORNB0061
1
21
Splitter
PMROS-S180-00.09
1
22
Control rod sliding tape II
PMPT2-S180-00.05
1
23.1.
Control piston teflon seal III
PMUS3-S180-00.15
1
23.2.
Control piston seal III (O-ring 50x3 70Si)
MTSORSI0021
1
24
Retaining ring (E-clip) M130, M160, M180
MMEMNPZ0002
1
25
Control hose seal (O-ring 6x2)
MTSORNB0054
1
26
Coupler seal (O-ring 36x5)
MTSORNB0036
1
27
Coupler seal (O-ring 40,2x3)
MTSORNB0039
1
28
Control hose connector
PMKWC-S130-00.09
1
29
Outer hose crimping ferrule M130, M160, M180
PMTULZW-W130-00.10-
M1
2
30
Control whip hose 0,90 m
MTSWG0006
m
31
Control hose cross spacer M130
PMWWC-W130-00.08
1
32
Control hose barbed coupling (male)
PMLWCM-W130-00.07
1
33
Outer hose barbed connector
PMKWG-S180-00.10
1
34
Exhaust flap M180
MTSORIU0010
1
35
Control stud supporting washer M180
PMPDKS-S180-00.12
1
36
Outer hose nut connector M180S
PMNKKWG-S180-00.16
1
37
Outer whip hose (0,8 m)
MTSWG0013
m
38
Control hose crimping ferrule M130, M160, M180
PMTULZW-W130-00.11-
M1
2
39
Outer hose barbed coupling female M130
PMLWG-W130-00.04
1
40
Outer hose quick coupler (male) M130, M160, M180
PMSRB-W130-00.05-M1
1
41
Dirt cap (female)
PMZAZ-W130-00.06-M1
1
…
Control whip hose, complete (Pos. 30 x 0.9, 28, 38 x 2, 32, 24, 25,
work)
WAWKC180K
1
…
Outer whip hose, complete (Pos. 37 x 0.8, 29 x 2, 39, work)
WAWZ180
1
...
Seal kit M180 basic (Pos. 8 x 3, 9.1., 9.2. x 2, 14, 25)
WAUM180M
1
...
Seal kit M180 complete (Pos. 8 x 3, 9.1., 9.2. x 2, 10.1., 10.2., 11, 14,
16, 17.1., 17.2., 20, 22, 23.1., 23.2., 25, 26, 27)
WAUK180
1

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6.2 Air pressure hose
Drawing 6.2.1
Nr.
Name
Art.
Q-ty
1.
Dirt plug (male)
PMZAW-W130-00.01-M1
1
2.
Coupler seal/Dirt plug seal (O-Ring 36x5)
MTSORNB0036
2
3.
Outer hose quick coupler (female)
PMLWZ-W130-00.03
1
4.
Coupler seal (O-Ring 36x3)
MTSORNB0035
1
5.
Coupler nut
PMNAW-W130-00.02
1
6.
Control hose cross spacer M130
PMWWC-W130-00.08
2
7.
Control hose barbed coupling (female)
PMLWCZ-W130-00.09
1
8.
Retaining ring (E-clip) M130, M160, M180
MMEMNPZ0002
2
9.
Control hose crimping ferrule M130, M160, M180
PMTULZW-W130-00.11-M1
2
10.
Outer hose barbed coupling female M130
PMLWG-W130-00.04
2
11.
Outer hose crimping ferrule M130, M160, M180
PMTULZW-W130-00.10-M1
2
12.
Outer hose 20 m
MTSWG0013
m
13.
Control hose 20 m
MTSWG0006
m
14.
Control hose barbed coupling (male)
PMLWCM-W130-00.07
1
15.
Control hose seal (O-ring 6x2)
MTSORNB0054
1
16.
Coupler seal (O-ring 40,2x3)
MTSORNB0039
1
17.
Outer hose quick coupler (male) M130, M160, M180
PMSRB-W130-00.05-M1
1
18.
Dirt cap (female)
PMZAZ-W130-00.06-M1
1
…
Control hose 20m, complete M130, M160, M180
(Pos. 7, 9 x 2, 13 x 20, 14, 15, work)
WAWW130W
1
…
Air supply/control hose 20 m, complete M130,
М160, М180
WAWZ13020
1

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6.3 MAX-Lubricator with Reversing Mechanism
Drawing 6.3.1
Nr.
Name
Art.
Q-ty
1
GEKA dust cap with chain 42 mm
MMEHYZS0002
1
2
GEKA GZ-Coupling 42 mm 3/4"
MMEHYZL0002
1
3
Splitter II
PMRZG2-OL130-00.01
1
4.1.
XGE 6LR fitting from 1/4" straight connector
MMEHYZL0006
4
4.2.
DPR 6L/S compression ring from 1/4"" straight
connector
MMEMNIN0004
4
4.3.
Nut M12x1.5 M 6L from the straight connector
1/4""
MMEMNNA0006
4
5
Ball valve 3/4"
MMEHYZA0004
1
6
Threaded plug GN 749 1/8"
MMEMNKR0002
1
7
Union fitting 3/4"
MMEHYSR0001
1
8
Oil level sight glass 3/4"
MMEMNIN0008
1
9
Tank container
PMZZM-OL130-01.00-M1
1
10
Splitter I (set)
PMRZG1-OL130-03.00-M1
1
11
Straight standpipe hose tail 130
PMKWO-OL130-00.06
1

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12
Outer hose connector (female) M130
PMLWZ-W130-00.03
1
13
Air hose nut M130
PMNAW-W130-00.02
1
14
End cap M130, M160, M180 (male)
PMZAW-W130-00.01-M1
1
15
O-ring 70NBR PN-90/M-73092
MTSORNB0036
1
16
O-ring 36x3 70NBR PN-90/M-73092
MTSORNB0035
1
17
O-ring 30,2x3 of oil cap, 70NBR
MTSORNB0032
1
18
Oil cap
PMKWO-OL130-04.00
1
19
Needle valve
PMIGL-OL130-02.00
1
20
Gland (stuffing box)
PMDŁ-OL130-02.03
1
21
Clamping plate
PMJAR-OL130-00.04-M2
1
22
Flow control knob
PMPOL-OL130-00.05-M2
1
23
Hydraulic pipe fi6x1
MMERUHY0001
0,39 m
24
Hydraulic pipe fi6x1
MMERUHY0001
0,57 m
25
Needle seat
PMGNIG-OL130-02.01
1
26
Needle seal (O-ring 18x2)
MTSORNB0011
2
27
Needle seal (O-ring 8x2)
MTSORNB0056
2
28
Gland seal (O-ring 10x2)
MTSORNB0001
1
29
Clamping plate screw M4x10 DIN 912
MMEMNSR0058
2
30
Flow control knob screw M4x10 DIN 933
MMEMNSR0059
1
31
Sintered bronze silencer 2931-1/4" Camozzi
MMEHYTL0001
1
32
Three way ball valve with holes 1/4" BSP 500
BAR
MMEHYZAOTW0005
1
33.1.
Valve mounting block 1
PMKMZ-OL130-07.01
1
33.2.
Valve mounting block 2
PMKMZ-OL130-07.02
1
33.3.
Allen screw M4x50 ISO4762 OC 5,8
MMEMNSR0658
2
33.4.
Handle for three-way ball valve 1/4" WKH and
WKH3 (R12)
MMEHYZA00065
1
34
Screw M5x10 Z (WSM)
MMEMNWK0026
7
35
Oiler body
PMOOM-OL130-05.00Z
1
7Transportation
Due to the heavy weight of the machine, the MAX K180S should be handled with extra care and only
be transported and lifted with leads. When carrying MAX by hand, ensure that you always lift the body
of the MAX.
MAX should never be moved, carried, pulled or dragged by the hose!
This is a precaution to avoid any damage to the hose, MAX and yourself!
Drawing 7.1

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The machine should be securely moved and lifted by straps at the front and
back of the cylinder, in such a manner that sliding out is avoided (Drawing
7.1.).
Make sure there are no persons under a lifted device! Persons under the
load are in a danger zone for themselves and others.
Always check the quality and condition of the lifting straps before use!
8Preparations before use
8.1 General Instructions
Before starting the MAX, you need to check for the existence and exact position of the buried pipe and
cables by contacting the respective utilities or owners of networks. The exact location and existence
of the buried cables and pipes should be determined by using trial pits or cable and pipe detection
equipment.
The area where the work is carried out must be marked and locked to prevent
unauthorized entry into the site!
Should you accidently hit an electrical cable, leave the site immediately.
Ensure no-one else enters the site and contact the electrical company to turn
off the electrical supply!
Should you accidently hit a gas pipe, leave the site immediately, ensure no one
else enters the site and contact the gas company to turn off the gas supply!
8.2 Starting pit
The minimum depth specification for operation of the MAX is ten times the tool diameter.
(10 x 180 mm = 1800 mm). Minimum cover = 10 x Diameter of the MAX.
If the minimum depth is not observed, there is a risk of surface damage from soil displacement.
The length of the starting pit depends on the type of hole and the use of accessories (Solo–Boring or
pipe pulling).
The starting pit needs to have enough space for the MAX accessories and pipes. The air pressure hose
must be fully rolled out (avoid kinking).
The starter pit width should allow free access to the MAX, and its accessories precise alignment.
For narrow Start and End pits (especially those with a depth of 1 meter or
more) we recommend that the Start and End pit walls are supported, this is to
avoid undue strain, and potentially, their collapse!
Always ensure that work is carried out in areas marked clearly with signage
stating that work is in progress. No entry to any unauthorized persons!

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8.3 Target pit
The width and depth of the End pit should be able to take the MAX out of the pit without obstruction
- even if the drilling direction has been adjusted.
If for any reason this is not possible, the MAX should be reversed to the Starting pit and removed from
there.
9Instructions
9.1 Safety Information
MAX jacking machine should be used at ambient temperatures not lower than + 5 °C. Working in
smaller temperatures may cause stop the machine during operation.
Operation of MAX K180S only to be carried out by suitably trained, qualified,
and certified personnel only. New operators or operators in training should
only work under the constant supervision of a fully qualified person.
Operating crew should always wear the appropriate safety equipment: ear
protection, safety shoes/boots, hard hat, safety glasses, gloves etc.
All items should be inspected before any work commences.
Faulty or damaged items should be replaced immediately by a trained,
qualified and certified person only.
Any changes or alterations to the MAX or to the accessories will invalidate
the guarantee.
The MAX should only be operated when all parts (lubricator, hoses,
accessories) have been secured and checked.
9.2 Convert the MAX K180S
After each action (Solo-Boring or Pipe pulling) the MAX can be upgraded via (Screwing or unscrewing
the accessories):
Type of work
End screw
Sleeve with rope
connection
Towing tool
Solo-Bore
+
-
+
Direct pipe installing 160
-
+
-
Expanding using Calibrator
+
-
+
Installing 200 with Calibrator
-
+
-
Pipe jacking
+
+
+
+correct use -incorrect use

17 / 39
Drawing 9.2.1
To replace the rear part (Figure 9.2.1.) follow these proceedings:
a) Disconnect the machine from the air compressor.
b) Place MAX (1) spanner wrench (2) on a solid and stable surface. The spanner wrench’ pins
must be placed into the indentations.
c) Mount the eye spanner (3) on a part which should be unscrewed (4). The eye spanner wrench’
pins must be placed into the indentations.
d) Check if the spanners are properly fixed then use a large hammer (5) onto the eye spanner
wrench (3) to loosen a screw.
e) When loose, unscrew a rear part by hand.
It is strictly forbidden to use the MAX without an End part (End cone/Tool for
pulling PE/PVC pipes). The engaging of the machine without a rear part will
result a sudden powerful ejection of control piston out of the cylinder.
f) Teflon tape residues and other dirt on the thread of the component should be cleaned with a
wire brush.
g) The threads of the part to be fitted need to be wrapped the opposite way to the screwing
direction with Teflon tape. We recommended LOCTITE 55, at last two or three threads.
h) Place the taped part into the MAX, then, screw it tight with the eye spanner wrench until you
have some resistance.
i) Tighten with eye spanner wrench and a big hammer
9.3 Connecting the Air Hose
Before connecting, blow air through the air hose to remove dirt or any other
debris or contamination.

18 / 39
To connect the air hose (Figure 9.3.1.) proceed as follows:
a) Place the compressor in a safe and stable location, taking into consideration the length of the
pneumatic hose and the expected bore’s length.
Secure the compressor to avoid unexpected movements.
b) Connect the air hose (1) to the compressor, ensure the hose is securely interlocked and the
safety rings are tightened. Blow some compressed air through the air hose to remove dirt or
other contaminations.
Whilst blowing air through the hose, do not blow compressed air from the
hose at people. The air and dirt can cause injury.
c) Release the lock of GEKA-coupling by turning it anticlockwise. Remove the GEKA locking cap
(2a) from the Lubricator (2) connect the compressor air hose (1) with appropriate GEKA hose
end coupling (¾ "; 42 mm).
Please note that the GEKA coupling must be secured with a nut to prevent
inadvertent decoupling.
d) Unscrew dust cap female (2b) from the Lubricator and end cap male (3a) from the pneumatic
air hose, then connect the pneumatic air hose to the Lubricator. Screw with nut firmly together
until resistance is felt.
e) Unscrew the protective end cap female (3b) from the pneumatic air hose. Clean the air hose
and inner control hose by blowing some air through them. Use pneumatic control valve to
switch the flow of compressed air between hoses.
Figure 9.3.1.

19 / 39
f) Place the MAX in the Starting Pit and remove the end cap female (4a) from the short hose of
the MAX (4). Connect the air hose coming from the lubricator to the short hose of the MAX.
Screw with nut firmly together until resistance is felt.
9.4 Functions of the Lubricator
The lubricator ensures that the necessary amount of lubricant is mixed with air and supplied to MAX.
The compressed air from the compressor blows through the lubricator where it mixes with the
lubricant - this results in a spray effect of oil and air. In this form, it passes through the air hose to the
inside of the MAX device and ensures optimum lubrication for all moving parts. As a lubricant, we
recommend EcoMAX Oil, which is safe to use and bio-degradable.
A valve which is used to change the direction of the machine is located on the lubricator, by turning
this handle an operator of the MAX can change a moving direction of the machine from forward to
backward (reverse) and vice versa.
The lubricator (Figure 9.4.1.) comes with:
-A valve (2) to adjust the air supply.The valve with lever in transverse position closes the supply of
compressed air. Lever in the longitudinal position means full opening of the valve
-Steering valve (1).The possible positions of the control valve lever and the corresponding moving
directions of the MAX (forward-backward) are shown on the Figure 8.4.1
-Oil adjustment knob (3) to adjust the amount of oil with the air. (min-max)
-Oil level indicator (4)
-Oil filler cap (5)
The oil filler cap (5) should never be unscrewed whilst the MAX is in operation!
FORWARD REVERSE
Drawing 9.4.1

20 / 39
9.5 Alignment of the MAX K180S
For accurate aiming of the MAX in the starting pit, we recommend using the Optical Level Set. To
aim the machine precisely follow these steps:
a) Position a surveying stake in the End pit in the place where the end of the borehole should
be located.
b) Place the MAX machine into the Start pit and pre-align it to the End pit, then place the
TERMA telescopic sight onto the machine.
c) With a help of TERMA telescopic sight you have to align the MAX machine to the surveying
stake by changing horizontal and vertical position of the machine.
9.6 Solo-Boring
For this action the machine should be equipped with the End cone
Before starting the machine it must be inspected and checked especially air
hose –machine connections and fittings.
Check pneumatic steering before using the device. This is especially important
if it has not been in use for a long time
To perform a Solo-Boring the next procedures should be followed:
a) Connect the Air hose (see Figure 9.3.1 Connecting the Air Hose).
b) Place the MAX into the starting pit and align precisely to the planned target (see 9.5. Alignment
of the MAX K180S).
c) Move the direction handle in Forward position (F).
d) Abruptly open the air supply valve at the lubricator with a quick movement to the maximum
position, to start-up the MAX.
Ear protection should be worn when performing Solo-Boring at all times.