MAX Impact power

MAX K95

Service manual
TABLE OF CONTENT

1. Functional testing of the lubricator ............................................................................................. 3

2. Checking of the pneumatic air hose ............................................................................................. 4
3. Main piston. Disassembly, servicing and assembly procedures................................................... 5
4. Steering seal check ....................................................................................................................... 7
5. Steering service procedures ......................................................................................................... 7
6. Schematic drawing and parts list of K95S impact mole ............................................................. 12
7. Schematic drawing and parts list of K65 air hose....................................................................... 13

Page 2 of 13
 1. Functional testing of the lubricator

Move the lever of the steering valve to the REVERSE (R) position. Air supply handle should be in closed position
(Figure 1). Connect the air supply hose to the lubricator.

Figure 1

Move the lever of the steering valve to the FORWARD (F) position (Figure 2).

Steering of the machine

FORWARD position REVERSE position

Figure 2

With the lever moved to FORWARD position compressed air should blast out of the thin hose connector of the
lubricator. Then block the thin hose connector with the lever moved to REVERSE position. Compressed air should
blast out of the silencer.

Check the oil level and fill the tank with EcoMax oil up to the top.

Then connect the lubricator to the source of compressed air, move the air supply handle to the maximum and
move the lever of the steering valve into the FORWARD position. In addition, turn oil regulator into the maximum
position. (Figure 3).

Figure 3

With these settings adjusted, air and oil mixture should blast out of the thick and thin air hose connectors of the
lubricator.
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 2. Checking of the pneumatic air hose

Make sure, that the control tube seal (o-ring) is in the right place and its technical condition is appropriate (Figure
4).

CONTROL TUBE SEAL

Figure 4

In case of any defects, wrinkles or other damages, it should be replaced with a new seal, according to the
specifications indicated in Table 1.

MACHINE Control tube seal size (o-ring) [mm]

MAX K95S Ø 4,3 x 2,4; 80 NBR
Table 1

Set the air supply handle in closed position and lever of pneumatic steering valve to REVERSE position (Figure
1). Connect the air hose to the lubricator and move the lever of pneumatic steering valve to FORVARD position
(Figure 5).

Figure 5
Compressed air should blast out of the inner connector of thin air hose responsible for machine’s steering (Figure
6).

Machine’s steering

Figure 6

Then block the thin hose connector of the air hose with the lever moved to REVERSE position. Compressed air
should blast out of the silencer in the lubricator.
With the air hose connected to the lubricator, the end cap (male) should be screwed in. Then move the air supply
handle to the maximum and move the lever of the steering valve into the FORWARD position (Figure 3). Observe
the air hose for few second. Make sure that there is no leakage in pneumatic air hose. In case of air hiss locate
the leak and eliminate it.

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 3. Main piston. Disassembly, servicing and assembly procedures

The end screw should be dismantled using eye tool and hook tool dedicated for the machine’s diameter. Make
sure that threaded studs of the eye tool and hook tool got into the corresponding sockets of the end screw and
the tail screw. (Figure 7).

Figure 7

Threaded studs should be screwed in by a hex key according to the specifications indicated in TABLE 2.

MACHINE HEX KEY SIZE [mm]

MAX K95S 8

Table 2

Make sure that threaded studs of the eye tool and hook tool got into the corresponding sockets of the end screw
and the tail screw. Only then you could start unscrewing by hitting hook tool handle with a hammer. After that,
the steering could be pulled out.
The tail screw should be dismantled using eye tool and hook tool dedicated for the machine’s diameter. Make
sure that threaded studs of the eye tool and hook tool got into the corresponding sockets of the end screw and
the tail screw (Figure 8). Make sure that threaded studs of the eye tool and hook tool got into the corresponding
sockets of the tail screw and the cylinder. Only then you could start unscrewing by hitting severely the eye tool
handle with a 5 kg hammer. After that, the mail piston could be pulled out.

Figure 8

Measure the thickness of piston sliding rings using vernier calliper. Depending on the diameter of the machine
the residual thickness of the sliding ring should be not less than indicated in Table 3. Measurements should be
made at least for four different parts of each sliding ring.

MACHINE NOMINAL THICKNESS MINIMAL THICKNESS

OF THE SLIDING RING [mm] OF THE SLIDING RING [mm]
MAX K95S 2,5 2,2

Table 3

It is necessary to make a split in sliding rings before its installation onto main piston. Figure 9 shows how to make
such split.
Page 5 of 13
 Figure 9

Cut width and dimension sizes of sliding rings are shown in Table 4.

MACHINE CUT WIDTH A [mm] SLIDING RING SIZES [mm]

MAX K95S 7 - 10 Ø 80 x 2,5
Table 4

Besides, a new set of piston's sealings should be mounted as it shown on Figure 10 according to the specification
indicated in Table 5.

Piston sealing o-rings

Figure 10

MACHINE SEALING RINGS (O-RINGS)

MAX K95S Ø 69 x 2; 60-70 Silicone

Table 5

Teflon sealing ring could be mounted using special set of tools: assembly sleeve and assembly mandrel in sizes
corresponding with machine’s diameter Figure 11.

Back side Assembly sleeve Teflon sealing Assembly

of main piston ring mandrel

Figure 11

A new teflon sealing ring (Figure 12) size is indicated in Table 6.

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 Teflon sealing ring

Figure 12

MACHINE TEFLON SEALING RING SIZE [mm]

MAX K95S Ø 80 x 2,5

Table 6

4. Steering seal check

Set the air supply handle on the lubricator in closed position. The lever of the steering valve should be set to
REVERSE (R) position (Figure 1). Connect the steering to the lubricator with the air supply hose. Than move the
lever of pneumatic steering valve to FORVARD position (Figure 5). As a consequence, the control piston will pull
out (Figure 12).

Control piston in pulled in position

Control piston in pulled out position

Figure 12
With the lever moved to FORWARD and control piston in pulled out position check every connection of steering
for air leakage.

5. Steering service procedures

The steering should be griped in a bench-vice by securing thick air hose connection. A bench-vice should be
equipped with removable or stationary aluminum jaws. Than an exhausted polymeric connection block should
be removed. Unscrew the nut with special service wrench (Figure 13). After that remove the nut and the piston.

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 Figure 13

New sealing elements and the steering piston sliding ring should be installed as it shown on Figure 14.

Control piston sliding ring I

Control piston sealing o-ring

Figure 14

It is necessary to make a split in the steering piston sliding ring before its installation onto the steering piston.
Figure 15 shows how to make such split.

Figure 15

Cut width and dimension sizes of the sliding ring are shown in Table 7.
MACHINE CUT WIDTH B [mm] SLIDING RING SIZE [mm]
MAX K95S 1,5 - 3 Ø38 x 1,5
Table 7
A new steering piston sealing o-ring (Figure 14) size is indicated in Table 8.

MACHINE STEERING PISTON SEALING O-RING I SIZE

MAX K95S 22 x 2; 80 NBR
Table 8

The steering should be griped in a bench-vice by securing thick air hose connection. A bench-vice should be
equipped with removable or stationary aluminum jaws. Than an exhausted polymeric connection block should
be removed. Remove the screw with bilateral wrench. (Figure 16).

Page 8 of 13
 Figure 16

Make sure, that the control tube seal (o-ring) is in the right place and its technical condition is appropriate (Figure
17).
CONTROL TUBE SEAL (O-RING)

CONTROL TUBE SECURITY E-CLIP

CONTROL TUBE GUIDE PIECE

Figure 17

In case of any defects, wrinkles or other damages, it should be replaced with a new seal, according to the
specifications indicated in TABLE 9.
MACHINE Control tube seal size (o-ring) [mm]
MAX K95S Ø 4,3 x 2,4; 80 NBR
Table 9

Control tube security and steering tube guide piece should be dismantled (Figure 17).

The hex key according to the Table 10 should be gripped in a bench-vice.

MACHINE HEX KEY SIZE [mm]

MAX K95S 14
Table 10

The steering should be put on the hex key with steering tube’s socket. The thick air hose connection should be
unscrewed with an open-end wrench with S according to the Table 11 to dismantle the hose

MACHINE OPEN-END WRENCH SIZE S [mm]

MAX K95S 50
Table 11

Dismantle the steering piston (Figure 18) out of the steering cylinder unit. There are sealing and sliding elements
on the steering piston shown on Figure 18.

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 CONTROL PISTON SEALING RINGS II

CONTROL PISTON SLIDING RING II

CONTROL PISTON SEALING RINGS I

CONTROL PISTON SEALING RING

Figure 18

Teflon control piston sealing ring, according to sizes from Table 12 could be mounted using special set of tools:
assembly sleeve and assembly mandrel in sizes corresponding with machine’s diameter (Figure 19).

Control piston Assembly sleeve Teflon sealing ring Assembly mandrel

Figure 19

MACHINE CONTROL PISTON SEALING RING SIZE [mm]

MAX K95S Ø 55 x 3
Table 12

It is necessary to make a split in the steering piston sliding II ring before its installation onto the steering tube.
Figure 20 shows how to make such split.

Figure 20

Cut width and dimension sizes of the sliding ring are shown in Table 13.

MACHINE CUT WIDTH C [mm] SLIDING RING SIZE [mm]

MAX K95S 1,5 - 3 Ø29 x 1,5
Table 13

The new control piston sealing rings sets I and II should be mounted to the control piston as it shown on Figure
18 according to the specification indicated in Table 14.

MACHINE CONTROL PISTON SEALING RINGS I SIZE [mm] CONTROL PISTON SEALING RINGS II SIZE [mm]
MAX K95S 45 x 2,5; 70 Silikon 26 x 2; 80 NBR
TABELA 14

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Pull out the steering cylinder. Then the new steering cylinder seal should be installed onto the steering tube
(Figure 21), according to the table 15.

STEERING CYLINDER SEALING

Figure 21

MACHINE STEERING CYLINDER SEAL SIZE [mm]

MAX K95S Ø 45 x 2,5; 70 Silikon
Table 15

Fix the steering tube using the hexagonal key of a size shown in Table 10 being gripped in a bench-vice. Then
disassemble the control tube connection with the box-end wrench of a size shown in table 16.

MACHINE BOX-END WRENCH SIZE S [mm]

MAX K95S 14
Table 16

An assembly of the steering and a machine should be carried out in a reverse mode to a disassembly.

The new screw seal I and screw seal II should be mounted onto the screw as it shown on Figure 22 according to
the table 17. Then put the screw tightly in with a bilateral wrench.

SCREW SEAL 2

SCREW SEAL 1

Figure 22

MACHINE SCREW SEAL 1 SIZE [mm] SCREW SEAL 2 SIZE [mm]

MAX K75S Ø 32 x 4; 80 NBR Ø 35 x 3,5; 80 NBR
Table 17

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 6. Schematic drawing and parts list of K95S impact mole

Q-ty,
№ Name of the part Article number
pcs
1. Head nut PMNAK-M095-00.09 1
2. Head PMNAS-M095-00.01 1
3. Cylinder PMCYL-M095-00.02 1
4. Chisel PMPRZ-M095-00.08 1
5. Tail screw PMTSR-M095-00.03 1
6. End nut (end screw) PMWKR-M095-00.04 1
7. Main Piston PMBIJ-M095-00.05 1
8. Piston leading(sliding) ring PMPRB-M095-00.06 2
PMUSB-M095-00.07
9. Piston sealing kit (1 x teflon, 2 x O-ring 69x3) 1
MTSORSI0033
10. Nut II PMNKSP-S095-00.10 1
11. Control piston seal (O-ring 22x2) MTSORSI0011 1
12. Piston PMTLOK-S095-00.04 1
13. Control piston shock absorber PMAMOR-S095-00.06 1
14. Control piston sealing PMUTS-S095-00.01-P3 1
15. Control piston PMTLS-S095-00.02 1
16. Control piston sealing rings I (2x O-ring 45x2,5) MTSORSI0016 MTSORSI0016 2
17. Steering tube PMRUS-S095-00.05 1
18. Steering cylinder sealing (O-ring 45x2,5) MTSORSI0016 1
19. Steering cylinder PMCYLSTR-S095-01.01 1
20. Connection block PMLST-S095-00.08 1
21. Control piston sliding ring I PMPT1-S095-00.03 1
22. Control piston sealing rings II (O-ring 26x2) MTSORSI0012 MTSORSI0012 2
23. Control piston sliding ring II PMPT2-S095-00.09 1
24. Control tube connection PMKWC-S095-00.11 1

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 PMTULZW-W095-00.11
25. Control tube injection sleeve 2
PMTULZW-W095-00.11
26. Control tube MTSWG0016 1
27. Control tube seal (O-ring 4.3x2.4) MTSORNB0004 1
28. Control tube guide piece PMWWC-W095-00.08 1
29. Hose connection PMKWG-S095-00.07 1
30. Hose MTSWG0018 1
31. Screw sealing set (O-ring 32x4, O-ring 35x3,5) MTSORIU0005 MTSORIU0006 1
32. Control tube connection nipple (male) PMLWCM-W095-00.07 1
33. Control tube security E-clip MMEMNPZ0004 1
PMTULZW-W095-00.10
34. Hose sleeve 2
PMTULZW-W095-00.10
35. Hose connector PMLWG-W095-00.04 1
36. Screw PMSRB-W095-00.05 1
37. End cap (female) PMZAZ-W095-00.06 1
38. Short control tube set (Pos. 24, 25 x 2, 26, 32, 27) PMWKC095K 1
39. Short hose set (Pos. 29, 30, 34 x 2, 35) WAWZ095 1
40. Seal kit M95 small (Pos. 8,9,14) WAUM095M 1
41. Seal kit M95 (Pos. 8, 9, 11, 14, 16, 18, 21, 22, 23, 27, 31) WAUK095 1

7. Schematic drawing and parts list of K65 air hose

Q-ty,
№ Name of the part Article number
pcs
1. End cap (male) PMZAW-W095-00.01 1
2. End cap seal (O-Ring 34x4) MTSORSI0014 1
3. Connector (female) PMLWZ-W095-00.03 1
4. Connector seal (O-Ring 29x3,5) MTSORNB0030 1
5. Nut PMNAW-W095-00.02 1
6. Control tube guide piece PMWWC-W095-00.08, 2
7. Control tube connector (female) PMWWC-W095-00.08 1
8. Control tube security PMLWCZ-W095-00.09 2
9. Control tube injection sleeve MMEMNPZ0004, 2
10. Hose connector MMEMNPZ0004 2
11. Hose sleeve PMTULZW-W095-00.11, 2
12. Air hose 20m PMTULZW-W095-00.11 1
13. Control tube 20 m PMLWG-W095-00.04, 1
14. Control tube connection nipple PMLWG-W095-00.04 1
15. Control tube seal (O-Ring 4,3x2,4) PMTULZW-W095-00.10, 1
16. Screw seal (O-ring 35x3,5) PMTULZW-W095-00.10 1
17. Screw MTSWG0010 1
18. End cap MTSWG0016 1
19. Screw seal (O-ring 32x4) PMLWCM-W095-00.07 1

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