Matweld 06500 User manual

632South3rdStreet
P.O.Box2816•Paducah,KY42002
270-444-0085
Fax:[phone]
Website:www.matweld.com
Email:[email protected]
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
By boosting low-pressure oil (2000
psi/140 bar) to high pressure (10,000
psi/700 bar) the intensifier powers
cylinders, jacks crimpers, nut splitters
torque wrenches and similar hydraulic
devices. The Matweld intensifier is a
complete self contained, safe, com-
pact unit. The intensifier is designed
to operate off of a 2000 psi 5 gpm
power source.All Intensifiers have a
relief pressure adjustable up to
10,000 psi. This ensures a safe
operation, not allowing the cylinders to
receive excessive pressures.
06500
HYDRAULIC INTENSIFIER
02/09
FLOW PRESSURE DIMENSIONS WEIGHT
5 gpm
(19 lpm) INPUT: 2000 psi 140 bar)
OUPUT: adjustable up
to 10,000 psi
A - 15 1/2”
B - 8”
C - 11”
33 lbs.
(15 kg)

2
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
02/09

3
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
02/09
GENERAL SAFETY PRECAUTIONS:
TOOLOPERATORSANDMAINTENANCE PERSONNELMUSTALWAYSCOMPLYWITHTHESAFETYPRE-
CAUTIONSGIVENINTHISMANUAL,ANDWITHALLSTICKERSANDTAGSATTACHEDTOTHETOOLAND
HOSE. ALL SAFETY PRECAUTIONS ARE GIVEN FOR YOUR SAFETY. READ TO UNDERSTAND AND
FOLLOWALLSAFETY,MAINTENANCEAND OPERATIONINSTRUCTIONS BEFOREYOUUSE ORMAIN-
TAINTHETOOL.REVIEWTHE MANUALDAILYBEFORE USINGTHETOOL. INADDITION, FOLLOWALL
SAFETYGUIDELINES GIVENYOU BYYOURSUPERVISOR. DONOTUSETHETOOLIFYOU HAVEANY
QUESTIONSABOUTTHE OPERATION, SAFETYOR MAINTENANCE OF THISTOOL. FAILURE TO FOL-
LOW THESE INSTRUCTIONS CAN RESULTIN PERSONAL INJURY OR EQUIPMENT DAMAGE.
MATWELD HAS NO CONTROL OVER TOOL USE OR OPERATION ONCE IT LEAVES THE MATWELD
PLANT. MATWELD HAS NO CONTROL OVER OPERATOR OR MAINTAINER SELECTION. THE CUS-
TOMER MUSTASSUME RESPONSIBILITY FOR THE TOOL’S SUITABILITY FORA PARTICULAR FUNC-
TION. DURING USE OF TOOL, GOOD JUDGEMENT MUST BE USED TO WORK SAFELY AND EFFI-
CIENTLY WITHOUTENDANGERING THEMSELVES OR BYSTANDERS. UNDERSTANDING OF THE OP-
ERATIONANDMAINTENANCEMANUALISESSENTIALFORANYONEUSINGORMAINTAININGTHETOOL.
• DO NOT OPERATE THE TOOL UNTIL YOU HAVE BEEN THOROUGHLY AND PROPERLY TRAINED
OR UNDER THE SUPERVISION OFAN INSTRUCTOR.
• CHECK POWER SOURCE DAILYTO DETERMINE IF CORRECTFLOWAND PRESSUREAREAVAIL-
ABLE. NEVER EXCEED FLOWS OR PRESSURES FOR THE TOOL BEING USED. PERSONAL IN-
JURY OR DAMAGE TO THE TOOL CAN RESULT.
• OPERATORS MUST CLEAR THE WORKAREA OF NONESSENTIAL PERSONNEL. FLYING DEBRIS
CANCAUSE SERIOUSINJURY.
• THE OPERATOR MUST BE FAMILIAR WITH ALL PROHIBITED WORK AREAS SUCH AS UNSAFE
GRADES, POOR FOOTINGAREASAND OVERHEAD HAZARDS.
• MAINTAINBALANCEANDPROPER FOOTINGATALLTIMES. NEVEROVERREACHTOTHE EXTENT
THATABROKEN PART OR SUDDEN MOVEMENT OF THE TOOL CAN CAUSE YOU TO LOSE YOUR
BALANCEAND FALL, OR CAUSE INJURYTO YOUR SELF OR SOMEONE ELSE.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
02/09
• WHENWORKING NEARELECTRICALCONDUCTORS,ALWAYSASSUMETHATTHECONDUCTORS
AREENERGIZEDANDTHATHOSESAND CLOTHINGCANCONDUCTHARMFULELECTRICITY. USE
HOSES LABELEDAND CERTIFIEDAS NONCONDUCTIVE.
• DO NOT OPERATE THE TOOLAT EXCESSIVE FLUID TEMPERATURES OPERATOR DISCOMFORT
ANDPOTENTIALBURNS CANRESULTATHIGH OILTEMPERATURES.
• NEVER WEAR LOOSE CLOTHING THAT CAN GET ENTANGLED IN THE WORKING PARTS OF THE
TOOLS OR BE CARELESS WITH HANDS, FEETOR OTHER BODY PARTSAROUND THE WORKING
PARTS OF THETOOLS. HYDRAULICTOOLS EXERT HIGH TORQUEAND FORCEAND CAN CAUSE
SERIOUS INJURYOR DEATH IF IMPROPERLY USED.
• TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE, ALL TOOL REPAIR, MAINTENANCE OR
SERVICE MUSTONLY BE PERFORMED BYAUTHORIZEDAND PROPERLYTRAINED PERSONNEL.
• ALWAYSWEAR SAFETYEQUIPMENTSUCHASOILINJECTIONRESISTANTWORKGLOVES,SAFETY
GLASSES,SAFETYBOOTS, EARPROTECTIONAND OTHERSAFETYAPPARELDICTATEDBYYOUR
SUPERVISORAPPLICABLE FORTHE JOB YOU ARE DOINGAND THE TOOLYOUARE USING.
• DO NOT CLEAN INSPECT OR REPAIR THE TOOL WHILE CONNECTED TO THE POWER SOURCE.
ACCIDENTALENGAGEMENTOF THETOOLCANCAUSE SERIOUS PERSONALINJURY.
• OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS A CONDITION WHERE HY-
DRAULIC OIL IS INJECTED UNDER THE SKIN FROM PRESSURE IN THE LINE. ALWAYS WEAR
GLOVESAND REPAIRANY LEAKS IMMEDIATELY. NEVER CARRYATOOLBYTHE HOSES.
• DO NOTUSE DAMAGEDEQUIPMENT. IMMEDIATELYREPLACEANY DAMAGEDHOSES, FITTINGS,
OROTHER COMPONENTSSHOWING WIRE BRAID,NICKS, CUTS,DAMAGEORABRASIONS. FAIL-
URE TO DO SO MAY RESULT IN EQUIPMENT DAMAGEAND / OR PERSONAL INJURY OR DEATH.
• CLEANUPANYOILOR FLUIDSPILLSIMMEDIATELY.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
02/09
HAVE SUPERVISORADDADDITIONALPRECAUTIONS RELATINGTOTHESPECIFICWORKAREAANDLOCAL
SAFETYREGULATIONS BELOW:
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*

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
02/09
06500 HYDRAULIC INTENSIFIER
SAFETY PRECAUTIONS:
1. ALWAYS WEAR PROTECTIVE EQUIPMENT SUCHAS GLOVES, SAFETYGLASSES, EAR PROTEC-
TIONAND SAFETYSHOES.
2. DO NOT WEAR CLOTHING WHICH MAY BECOME ENTANGLED IN THE TOOL.
3. ALWAYS KEEP WORKAREA FREE OF TOOLS ORANY OTHER OBJECTS WHICH MAY
IMPAIR SOUND FOOTING.
4. CAUTION OILINJECTION HAZARDEXISTS WITHTHIS TOOL.OILINJECTION
ISACONDITION WHERE THE HYDRAULIC OILIS FORCED UNDER THE SKIN THROUGH
PRESSURE IN THE LINE.ALWAYS WEAR GLOVESAND REPAIR LEAKS IMMEDIATELY.
5. NEVERATTEMPTTO CARRYTHE INTENSIFIER WITH THE POWER SOURCE VALVE IN
THE “ON” POSITION, TURN THE POWER SOURCE “OFF”.
6. MOST HYDRAULIC OILS HAVEAFLASH POINT OF 500 DEGREES (F). MAKE SURE HOSES
ARE COMPLETELY CLEAR OF SPARKS AND HOT DEBRIS. HAVE ANOTHER PERSON
STAND CLOSE TO HYDRAULIC POWER SOURCE CONTROLS TO OBSERVE.
7. NEVERATTEMPTTO PERFORM MAINTENANCE ON THE INTENSIFIER WHILE UNDER
PRESSURE.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
02/09
06500 HYDRAULIC INTENSIFIER
FLOW: 5 GPM (19 LPM) OR 10 GPM (38 LPM)
PRESSURE: 2000 PSI (140 BAR) INPUT
10000 PSI (700 BAR) OUTPUT MAXIMUM
APPLICATIONS:
By boosting low pressure oil (2000 psi/140 bar) to high pressure (10,000 psi/700 bar), the Matweld intensi-
fier powers cylinders, jacks, crimpers, nut splitters and similar hydraulic actuated devices.
OPERATION:
1. WITH THE POWER SOURCE IN THE “OFF” POSITION, CONNECT THE POWER TRANSMISSION
HOSES TO THE QUICK DISCONNECT FITTINGS ON THE LOW PRESSURE END OF THE INTENSI-
FIER WHERE LABELED
“INLET P&T”.
2. CONNECTA HIGH PRESSURE TOOL TO THE INTENSIFIER ON THE END LABELED “HIGH PRES-
SURE”.
WARNING!ANYHOSEAND FITTINGASSEMBLESATTACHED MUST BE RATED FOR 10,000 PSI
WORKING PRESSURE.
3. TURN THE POWER SOURCE “ON” TO SUPPLY 5 GPM HYDRAULIC FLUID @ 2000 PSI TO THE
INTENSIFIERINLET.
4. TO OPERATE THE HIGH PRESSURE TOOL BEING USED MOVE THE CONTROL LEVER WITH
BLACK KNOB (LOCATED ON TOP OF THE INTENSIFIER) FORWARD TOWARD THE HIGH PRESSURE
END. YOU SHOULD SEETHE INTENSIFIER PRESSURE GAGE READING STARTTO INCREASE.
5. THE FLUID LOCK VALVE IS SUPPLIED TO HOLDATOOL INAFIXED POSITION SUCHASAJACK
THAT IS HOLDING AN ELEVATED LOAD. ONCE THE TOOL IS IN THIS POSITION LET GO OF THE
INTENSIFIER LEVERAND LOCK THE LOAD BYTURNING THE FLUID LOCK VALVE KNOB CLOCK-
WISE. IT IS NOTNECESSARY TO CONTINUE TO RUN THE POWER UNIT WHILEATOOLIS IN THIS
LOCKED POSITION. TO RELEASE THE LOCKED FLUID PRESSURE ROTATE THE FLUID LOCK
VALVE KNOB COUNTER CLOCKWISE .
6. TO RETRACT OR LOWER A TOOL, WITH THE POWER UNIT SUPPLYING 5 GPM, PULL BACK ON
THE CONTROL LEVER; THE TOOL SHOULD BEGIN
TO REPOSITIONAND THE INTENSIFIER PRESSURE GAGE READING SHOULD DECREASE.
WARNING! MAKE SURE THE PRESSURE GAGE IS READING ZERO BEFOREATTEMPTING TO DIS-
CONNECT HIGH PRESSURE HOSES.
7. TURN THE POWER SOURCE “OFF” BEFORE DISCONNECTING TOOL.
SERVICE NOTE: SPRAY DOWN QUICK DISCONNECTS WITHA LUBRICANT
AND WIPE WITHA CLEAN CLOTH BEFORE COUPLING HOSES.
DO NOT DRAG THE SERVICE HOSES BY PULLING WITH THE TOOL. LAY HOSES OUT INAN OR-
DERLY FASHION WHILE WORKINGAND BEAWARE OFTHEIR LOCATIONATALLTIMES.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
02/09
06500 HYDRAULIC INTENSIFIER
MAINTENANCE:
1. CHECK TOOL DAILY FOR PROPER OPERATION, LEAKS, OR DAMAGE.
2. INSPECT HOSES DAILY. REPLACE CUT, BURNED, OR OTHERWISE DAMAGED HOSES.
3. KEEP QUICK DISCONNECT COUPLERS CLEAN AND LUBRICATED.
4. USE HYDRAULIC FLUIDS THAT COMPLY WITH HTMASPECIFICATION 5.7, THE HYDRAULIC FLUID
SHOULDHAVEAVISCOSITYBETWEEN 100AND 400SSU (20-82CENTISTOKES)ATTHEMAXIMUM
AND MINIMUM EXPECTED OPERATING TEMPERATURES. PETROLEUM BASED HYDRAULIC FLU-
IDS WITH ANTI-WEAR PROPERTIES AND A VISCOSITY INDEX OF OVER 140 WORK FOR A WIDE
RANGEOF OPERATINGCONDITIONS.
THE FOLLOWING OILS MEET HTMA SPECIFICATION 5.7:
AMOCORYKON MV CITGOA/WALLTEMP
SUNVIS706 MOBILD.T.E.13
CHEVRONEP-MV TEXACO “RANDO”HDAZ
OTHER FLUIDS THAT MEET OR EXCEED THIS SPECIFICATION CAN BE USED.
*SEE COLD WEATHER OPERATION HYDRAULIC OIL NOTE.
5. HAVETOOLINSPECTED,ATLEASTANNUALLY,BYMATWELDORAMATWELD QUALIFIEDSERVICE
REPRESENTATIVE TO DETERMINE IF TOOL IS IN NEED OF SAFETY CHANGES OR WORN PART
REPLACEMENT.
6. CONTACT MATWELD ON A PERIODIC BASIS, AT LEAST ANNUALLY, FOR SERVICE BULLETINS,
SAFETY NOTICES, OR OTHER IMPORTANT INFORMATION PERTAINING TO THISTOOL.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
02/09
06500 HYDRAULIC INTENSIFIER RAIL PULLER MOUNTING KIT
CYLINDER CONNECTION
12
11
10
9
9
10 8
10
9
13
10
13
12
11
5
8
9
7
6
3
4
2
1
ITEM
NO.
65/16 SAE WASHERA2191 3
3
1
2
6
6
INTENSIFIER06500
J-BOLT
U-BOLTA6850
06329
1
2
2
4
5
5
4
2
7
INTENSIFIER CONNECTION
2
3/8 STREET EL704008 3' HOSE ASSEMBLY
5/16 NYLOCKNUT
BATTERY STRAP
FRAME704013
A2048
00123
704010
1
6
1
4
3/8 SERVICE TEE
3/8 COUPLING704007
704006
Q.D. SET704011
3
2
3
1
DESCRIPTIONPART
NO. QTY.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
02/09
06500
HYDRAULIC INTENSIFIER
REVISED 02/26/09