Matweld 05500 User manual

632South3rdStreet
P.O.Box2816• Paducah, KY 42002
270-444-0085
Fax: [phone]
Website:www.matweld.com
Email:[email protected]
TheMatweld Twin Power Unit isdesignedto
deliver2-5gpmcircuitsor 1-10gpmcircuitat2000
psiforhydraulictooloperations.Withtheadditional
5000wattgenerator,ACpoweredequipmentmay
beoperatedsimultaneously.Quietandefficient,this
unitgivesmaintenance-of-waycrewstheversatilityto
operatesafelyandcosteffectiveinadversecondi-
tionswithavarietyofequipment.
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
ACCESSORIES:
06300 - The Mobility Cart is equipped with insulated wheels for on track mobility or wheelbarrow type
operation off track.
02326 - Hose reel equipped with 50’ transmission hose and mounting bracket.
05500 (WITH GENERATOR)
05550 (WITHOUT GENERATOR)
ENGINE
22 hp Kohler
Fuel: gasoline
Start: electric
12 volt
HYDRAULICS
2-5 gpm (19 lpm)
or 1-10 gpm (38 lpm)
Fluid: hydraulic
5 us gal (18.9) liters
GENERATOR
5000W 120/240 V
single phase @ 60hz
120 v - 41.6 amp rating
240 v- 20.8 amp rating
DIMENSIONS
A - 36"
B - 25"
C - 32"
Weight
365 lbs.
(165.5 kg)

2
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01

3
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
GENERAL SAFETY PRECAUTIONS:
TOOL OPERATORS AND MAINTENANCE PERSONNEL MUST ALWAYS COMPLY WITH THE
SAFETY PRECAUTIONS GIVEN IN THIS MANUAL, AND WITH ALL STICKERS AND TAGS AT-
TACHED TO THE TOOL AND HOSE. ALL SAFETY PRECAUTIONS ARE GIVEN FOR YOUR
SAFETY. READ TO UNDERSTAND AND FOLLOW ALL SAFETY, MAINTENANCE AND OPERA-
TION INSTRUCTIONS BEFORE YOU USE OR MAINTAIN THE TOOL. REVIEW THE MANUAL
DAILY BEFORE USING THE TOOL. IN ADDITION, FOLLOW ALL SAFETY GUIDELINES GIVEN
YOU BY YOUR SUPERVISOR. DO NOT USE THE TOOL IF YOU HAVE ANY QUESTIONS ABOUT
THE OPERATION, SAFETY OR MAINTENANCE OF THIS TOOL. FAILURE TO FOLLOW THESE
INSTRUCTIONS CAN RESULT IN 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 SE-
LECTION. THE CUSTOMER MUST ASSUME RESPONSIBILITY FOR THE TOOL’S SUITABIL-
ITY FOR A PARTICULAR FUNCTION, FOR ANYONE USING THE TOOL OR MAINTAINING
THE TOOL REGARDING THEIR FITNESS TO USE THE TOOL OR REPAIR THE TOOL, UN-
DERSTANDING OF THE OPERATION AND SAFETY AND MAINTENANCE MANUAL, INTELLI-
GENCE TO USE GOOD JUDGMENT NECESSARY TO WORK SAFELY AND EFFICIENTLY WITH-
OUT ENDANGERING THEMSELVES OR BYSTANDERS IN THE WORK AREA.
•DO NOT OPERATE THE TOOL UNTIL YOU HAVE BEEN THOROUGHLY AND PROPERLY
TRAINED OR UNDER THE SUPERVISION OF AN INSTRUCTOR.
•CHECK POWER SOURCE DAILY TO DETERMINE IF CORRECT FLOW AND PRESSURE
ARE AVAILABLE. NEVER EXCEED FLOWS OR PRESSURES FOR THE TOOL BEING USED.
PERSONAL INJURY OR DAMAGE TO THE TOOL CAN RESULT.
•OPERATORS MUST CLEAR THE WORK AREA OF NON-ESSENTIAL PERSONNEL. FLY-
ING DEBRIS CAN CAUSE SERIOUS INJURY.
•THE OPERATOR MUST BE FAMILIAR WITH ALL PROHIBITED WORK AREAS SUCH AS
UNSAFE GRADES, POOR FOOTING AREAS AND OVERHEAD HAZARDS.
•MAINTAIN BALANCE AND PROPER FOOTING AT ALL TIMES. NEVER OVERREACH TO
THE EXTENT THAT A BROKEN PART OR SUDDEN MOVEMENT OF THE TOOL CAN CAUSE
YOU TO LOSE YOUR BALANCE AND FALL, OR CAUSE INJURY TO YOUR SELF OR SOME-
ONE ELSE.

4
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
•WHEN WORKING NEAR ELECTRICAL CONDUCTORS, ALWAYS ASSUME THAT THE CONDUC-
TORS ARE ENERGIZED AND THAT HOSES AND CLOTHING CAN CONDUCT HARMFUL ELEC-
TRICITY. USE HOSES LABELED AND CERTIFIED AS NON-CONDUCTIVE.
•DO NOT OPERATE THE TOOL AT EXCESSIVE FLUID TEMPERATURES OPERATOR DISCOM-
FORT AND POTENTIAL BURNS CAN RESULT AT HIGH OIL TEMPERATURES.
•NEVER WEAR LOOSE CLOTHING THAT CAN GET ENTANGLED IN THE WORKING PARTS OF
THE TOOLS OR BE CARELESS WITH HANDS, FEET OR OTHER BODY PARTS AROUND THE
WORKING PARTS OF THE TOOLS. HYDRAULIC TOOLS EXERT HIGH TORQUE AND FORCE
AND CAN CAUSE SERIOUS INJURY OR DEATH IF IMPROPERLY USED.
•TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE, ALL TOOL REPAIR, MAINTENANCE
OR SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED PER-
SONNEL.
•ALWAYS WEAR SAFETY EQUIPMENT SUCH AS OIL INJECTION RESISTANT WORK GLOVES,
SAFETY GLASSES, SAFETY BOOTS, EAR PROTECTION AND OTHER SAFETY APPAREL DIC-
TATED BY YOUR SUPERVISOR APPLICABLE FOR THE JOB YOU ARE DOING AND THE TOOL
YOU ARE USING.
•DONOTCLEAN INSPECTORREPAIRTHETOOLWHILE CONNECTEDTOTHE POWERSOURCE.
ACCIDENTAL ENGAGEMENT OF THE TOOL CAN CAUSE SERIOUS PERSONAL INJURY.
•OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS A CONDITION WHERE
HYDRAULICOIL ISINJECTEDUNDER THESKINFROM PRESSUREINTHE LINE.ALWAYS WEAR
GLOVES AND REPAIR ANY LEAKS IMMEDIATELY. NEVER CARRY A TOOL BY THE HOSES.
•DO NOT USE DAMAGED EQUIPMENT. IMMEDIATELY REPLACE ANY DAMAGED HOSES, FIT-
TINGS, OR OTHER COMPONENTS SHOWING WIRE BRAID, NICKS, CUTS, DAMAGE OR ABRA-
SIONS. FAILURE TO DO SO MAY RESULT IN EQUIPMENT DAMAGE AND / OR PERSONAL IN-
JURY OR DEATH.
•CLEAN UP ANY OIL OR FLUID SPILLS IMMEDIATELY.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
•HAVE SUPERVISOR ADD ADDTIONAL PRECAUTIONS RELATING TO THE SPECIFIC WORK
AREA AND LOCAL SAFETY REGULATIONS BELOW.
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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
05500 TWIN POWER UNIT
SAFETY PRECAUTIONS:
1. ALWAYS WEARPROTECTIVEEQUIPMENT SUCHAS GLOVES,SAFETY GLASSES, EAR
PROTECTION, SAFETY SHOES AND OTHER REQUIRED SAFETY EQUIPMENT.
2. DO NOT WEAR CLOTHING WHICH MAY BECOME ENTANGLED IN THE MOVING PARTS
OF THE UNIT.
3. ALWAYS KEEP WORK AREA FREE OF TOOLS OR ANY OTHER OBJECTS WHICH MAY
IMPAIR SOUND FOOTING.
4. CAUTION OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS A
CONDITION WHERE THE HYDRAULIC OIL IS FORCED UNDER THE SKIN THROUGH
PRESSURE IN THE LINE. ALWAYS WEAR GLOVES AND REPAIR LEAKS IMMEDIATELY.
5. DO NOT OPERATE THE POWER UNIT UNTIL YOU HAVE BEEN PROPERLY TRAINED OR
UNDER THE SUPERVISION OF A QUALIFIED INSTRUCTOR.
6. NEVER STORE ENGINE OIL OR HYDRAULIC OIL NEAR OXYGEN TANKS OR LINES.
7. NEVER ADD ENGINE OIL OR HYDRAULIC OIL WHEN A SPILL MIGHT COME IN CON-
TACT WITH YOUR OXYGEN LINES, TORCH OR FITTINGS.
8. CLEAN UP ANY SPILLS IMMEDIATELY.
9. NEVER PERFORM GRINDING OR SAWING OPERATIONS THAT DIRECT SPARKS INTO
THE CLOSE PROXIMITY OF THE POWER UNIT OR FLAMMABLE MATERIALS.
10.NEVER OPERATE THE POWER UNIT WITH ANY PART OF THE EXHAUST SYSTEM OR
THE HEAT DEFLECTOR REMOVED.
11. PERIODICALLY, INSPECTTHE FUELTANK, FUEL LINEAND FITTINGSFOR CRACKSOR
LEAKS AND REPAIR OR REPLACE AS REQUIRED.
12. AVOIDOVER FILLINGTHE FUELTANK;WIPE UPANYSPILLS IMMEDIATELYAND PROP-
ERLY DISPOSE OF THE CLEANING RAGS.
13. ALWAYS TURN POWER UNIT “OFF” AND DISCONNECT HOSES BEFORE PERFORMING
ANY MAINTENANCE.

7
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
05500 TWIN POWER UNIT
FLOW:(2) 5 GPM PORTS (19LPM) OR (1) 10 GPM PORT (38LPM)
PRESSURE: 2000 PSI (140 BAR)
OPERATION:
•BEFORE STARTING ENGINE, CHECK ALL FLUID LEVELS, AND ADD FUEL, MOTOR OIL, AND/OR
HYDRAULIC OIL AS REQUIRED.
1. TO START THE POWER UNIT, CHECK TO MAKE SURE THAT THE CONTROL VALVE IS IN THE
“OFF” POSITION.
2. SET THE SYSTEM SWITCH TO THE “ON” POSITION.
3. PULL THE CHOKE ALL THE WAY “OUT”.
4. PUSH THE STARTER BUTTON.
5. ALLOW THE ENGINE TO WARM UP UNTIL IT WILL RUN SMOOTHLY WITH THE CHOKE ALL THE
WAY“IN”.
6. CONNECT THE POWER TRANSMISSION HOSE TO EITHER THE 5 OR 10 GPM PORTS, DE-
PENDING ON THE FLOW REQUIRED FOR THE TOOL YOU WILL BE USING.
7. CONNECT THE TOOL(S) TO THE POWER TRANSMISSION HOSE(S) BEFORE TURNING THE
VALVE ON THE POWER UNIT.
8. IN COLD WEATHER START THE POWER UNIT AND ALLOW THE OIL TO CIRCULATE BEFORE
USINGTHETOOLS.IN EXTREMELY COLDWEATHER REFERTOCOLD WEATHEROPERATION
SECTION OF THIS MANUAL.
9. DURING THE WARM WEATHER, THE HYDRAULIC OIL COOLER FAN SHOULD BE TURNED ON
FOR ADDITIONAL COOLING CAPACITY. THE FAN CONTROL SWITCH IS LOCATED ON THE EN-
GINE CONTROL PANEL.
10. TO SHUT DOWN THE POWER UNIT OR TO CHANGE TOOLS, TURN THE CONTROL VALVE TO
THE “OFF” POSITION AND TURN SYSTEM SWITCH “OFF”.
GENERATOR OPERATION
•THE POWER UNIT PROVIDES TWO DIFFERENT POWER SOURCES; 120 VOLT SINGLE PHASE
AND 240 VOLT SINGLE PHASE.
•PLUG ACCESSORY INTO THE PROPER RECEPTACLE AND OPERATE AS DESIRED.
•PUSH BREAKERS “IN” TO RESET IN CASE OF A TRIPPED CIRCUIT.
CAUTION HIGH VOLTAGE: WHEN THE ENGINE IS RUNNING THE RECEPTACLES ARE HOT AT
ALL TIMES!

8
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
05500 TWIN POWER UNIT
VALVE POSITIONING:
THE 05500 TWIN POWER UNIT IS DESIGNED TO OPERATE EITHER ONE TOOL AT 10 GPM
(38LPM) OR TWO TOOLS, SIMULTANEOUSLY AT 5 GPM (19 LPM) EACH. REFER TO THE
OPERATING INSTRUCTIONS FOR EACH TOOL TO DETERMINE FLOW REQUIREMENTS.
NOTE: WHENOPERATINGA10GPMTOOL,YOU CANNOTHAVE ANYOTHERTOOLCONNECTED
TO THE 5 GPM PORTS, EVEN IF THE TOOL IS NOT BEING USED.
5 GPM TOOLS:
TO OPERATE TWO - 5 GPM (19 LPM) TOOLS, CONNECT BOTH TOOLS TO THE PORTS
MARKED 5 GPM AND TURN THE VALVE TO THE “TWO 5 GPM” POSITION.
10 GPM TOOLS:
TO OPERATE A 10 GPM (38 LPM) TOOL, CONNECT IT TO THE PORT MARKED 10 GPM AND
TURN THE VALVE TO THE “ONE 10 GPM” POSITION.
CHANGING TOOLS:
1. ALWAYS TURN THE CONTROL VALVE TO THE “OFF” POSITION BEFORE DISCONNECTING
HOSES.
2. ONCE THE TOOL HAS BEEN CHANGED, TURN THE VALVE TO THE DESIRED POSITION
DEPENDING ON FLOW AND PRESSURE REQUIREMENTS OF THE TOOL BEING USED.

9
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
COLD WEATHER OPERATION:
THE POWER UNIT AND TOOLS WILL PERFORM WELL IN EXTREME COLD WEATHER IF
THE WARM-UP PROCEDURES ARE FOLLOWED. THESE PRECEDURES SHOULD BE USED
ANYTIME THE TEMPERATURE IS BELOW 40 DEGREES FAHRENHEIT (4.4C).
INEXTREMELYCOLDCLIMATES,CHANGINGTOANAIRCRAFTQUALITYHYDRAULICOIL(MIL.SPEC.
H-5606) WILL REDUCE THE WARM UP TIME REQUIRED. WHEN WARM WEATHER RETURNS, BE
SURE TO CHANGE BACK TO A HIGHER VISCOSITY HYDRAULIC OIL.
1. STARTTHE POWERUNIT ANDLETITRUNUNTIL ITIS RUNNINGSMOOTHLYWITH THECHOKE
ALL THE WAY “IN”.
2. CONNECT THE POWER TRANSMISSION HOSES TO THE POWER UNIT AND COUPLE THE
POWER TRANSMISSION HOSE TOOL ENDS TOGETHER FORMING A “LOOP”.
3. TURN CONTROL VALVE “ON” TO CIRCULATE OIL THROUGH THE HOSE.
4. WHEN THE OIL REACHES 50 DEGREES FAHRENHEIT (10 C) YOU MAY BEGIN TO OPERATE
THE TOOLS.
MAINTENANCE:
1. CHECK POWER UNIT FOR OVERALL WORKING CONDITION DAILY.
2. INSPECT HOSES DAILY. ATTHE FIRSTSIGN OFANY ABRASIONOR CUT TO THECOVER, THE
HOSES MUST BE CHANGED.
3. KEEP QUICK DISCONNECT COUPLERS CLEAN & LUBRICATED.
4. USE ONLY RECOMMENDED HYDRAULIC OILS. NEVER USE ATF OR MOTOR
OIL.
SUGGESTED HYDRAULIC OILS:
AMOCO RYKON MV CITGO A\W ALL TEMP
SUN 2105 MOBIL D.T.E. 15
CHEVRON EP-MV TEXACO “RANDO” HD-AZ
IF YOUR LOCAL DISTRIBUTOR DOES NOT CARRY ANY OF THE ABOVE SUGGESTED
HYDRAULIC OILS USE THE FOLLOWING GUIDELINES:
VISCOSITY @ 100°F……………………………………………100-190SUS
VISCOSITY INDEX………………………………………………MIN.150
EACHAPPLICATION ISDIFFERENT, IFTHERE AREANYQUESTIONSCONCERNINGTHE RIGHT
CHOICE FOR YOUR PARTICULAR APPLICATION CALL MATWELD FOR ASSISTANCE.
05500 TWIN POWER UNIT

10
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
05500 TWIN POWER UNIT
5. HAVE POWER UNIT INSPECTED, AT LEAST ANNUALLY, BY A MATWELD OR MATWELD QUALI-
FIED SERVICE REPRESENTATIVE TO DETERMINE IF POWER UNIT IS IN NEED OF SAFETY
CHANGES OR WORN PART REPLACEMENT.
ENGINE MAINTENANCE
MAINTENANCE SCHEDULE
FOLLOWTHE HOURLY ORCALENDARINTERVALS, WHICHEVEROCCURFIRST.MOREFREQUENT
SERVICE IS REQUIRED WHEN OPERATING IN ADVERSE CONDITIONS NOTED BELOW.
* PERFORM THESE MAINTENANCE PROCEDURES MORE FREQUENTLY UNDER
EXTREMELY DUSTY, DIRTY CONDITIONS
#HAVE KOHLER ENGINE SERVICE DEALER PERFORM THIS SERVICE.
FREQUENCY
MAINTENANCE REQUIRED
DAILY OR BEFORE
STARTING ENGINE
FILL FUEL TANK
CHECK OIL LEVEL
* CHECK AIR CLEANER FOR DIRT, LOOSE, OR DAMAGED PARTS.
* CHECK AIR INTAKE AND COOLING AREAS, CLEAN AS NECESSARY.
EVERY 25 HOURS * SERVICE PRECLEANER ELEMENT
EVERY 100 HOURS * REPLACE AIR CLEANER ELEMENT.
CHANGE OIL ( MORE FREQUENTLY UNDER SEVER CONDITIONS).
*,# REMOVE COOLING SHROUDS AND CLEAN COOLING AREAS.
EVERY 200 HOURS CHECK SPARK PLUG CONDITION AND GAP.
CHANGE OIL FILTER.
ANNUALLY OR EVERY
500 HOURS
HAVE BENDIX STARTER DRIVE SERVICED.
HAVE SOLENOID SHIFT STARTER DISASSEMBLED AND CLEANED.
REMOVE HYDRAULIC PUMP FROM MOUNT FLANGE AND APPLY
GREASE TO SPLINE AND REASSEMBLE.
EVERY 1500 HOURS * REPLACE FUEL FILTER

11
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
05500 TWIN POWER UNIT
TROUBLESHOOTING GUIDE
A. BEFORE ANY TROUBLESHOOTING, CHECK ALL FLUID LEVELS, AND ADD FUEL, MOTOR OIL
AND OR HYDRAULIC OIL AS REQUIRED.
B. REPAIR ANY LEAKS OR OBVIOUS DAMAGE TO POWER UNIT.
C. MAINTENANCE TO BE PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLY. READ
OPERATION MANUALTOUNDERSTAND OPERATIONAL CHARACTERISTICSBEFORE MAKING
ANY ADJUSTMENTS.
PROBLEM: POWER UNIT RUNS, BUT ENGINE QUITS WHEN UNDER LOAD.
1. CHECKSYSTEMRELIEF PRESSURE- SYSTEMRELIEF VALVE (PART#05502-01) SHOULD
BE SET AT 2250 PSI
2. IF FLOW AND PRESSURE OK, BUT ENGINE STILL QUITS UNDER LOAD:
-DRAIN GAS AND CHECK FOR WATER
-TUNE ENGINE (IF MUFFLER HAS HOLES VALVES MAY BE BURNED)
PROBLEM: HYDRAULIC OIL OVERHEATS.
1. CHECKTEMPERATUREWITHTHERMALMEASUREMENTDEVICE. IFOVER140DEGREES
F. (50 DEGREES CELSIUS), CHECK THE FOLLOWING:
-HYDRAULIC OIL TO FULL MARK IN TANK
-ADEQUATE CLEARANCEFORGOODAIRCIRCULATIONAROUNDPOWERUNIT. POWER
UNITSHOULD BEMOVEDSOUNRESTRICTEDAIR MOVEMENTISAVAILABLE INFRONT,
REAR AND SIDES OF UNIT. REMEMBER, THE COOLER DRAWS AIR FROM AROUND
THE POWER UNIT. IF THE COOLER CAN ONLY DRAW HOT EXHAUST, CAPTURED AIR
NEXT TO BULKHEAD, OR SUPERHEATED AIR IN TRUCK BODY HOT HYDRAULIC OIL
WILL BE THE RESULT.
2. CHECK TOOL FLOW RATE. OPERATE 5 GPM TOOLS ONLY ON 5 GPM. EXCESS FLOW
AT 10 GPM CAN CAUSE OVERSPEEDING OF THE TOOL OR HEAT BUILDUP DEPEND-
ING ON THE TOOL DESIGN.
IMPORTANT:MAKE CERTAIN THAT THE CONTROL VALVE IS POSITIONED FOR THE TOOL BEING
USED.HAVING BOTHKNOBSTURNED ONAND ONLYUSINGONE5 GPMTOOLWILL ALLOWFLUID
TO BE FORCED OVER THE RELIEF VALVE CAUSING EXTREME HEATING.

12
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
56
2856
45
144616
13
2
44
43
28
27
36
56
1215
38
39
37
36
19
23
184222
29
24
2521
32
56
20
3
32
26
1
34
35
48
47
28
47
56
325
56
57
8
4917
51
41
52
9
48
51
10
40
33
34
51
48
46
2930
31
11
5453
55
56
7
05500 TWIN POWER UNIT
FIG. 1 ENGINE ASSEMBLY
08/14/01
REV 0

13
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
1
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55
56
57
58
59
05502
05503
05503-01
05501
05512
05517
05524
A2062
05510
05513
05504
05505
05506
05509
05507
05508
05527
05526
05516
05502-01
05502-02
00145
6400-10-12
05502-03
249-08-08
231P-04
05531
A1002
6400-12-12
6802-10-10
4604-16-12
A2046
05515
00147
SVM-16
6801-12-16
00123
00122
00121-02-01
4404-16-16
00165
00146
A1026
A3810
A1003
A3809
A2048
A2191
A1027
A1452
A1022
A2162
A1042
A2192
A1500
A2190
05512-07
A1045
A2050
MANIFOLD
COOLER
FAN
ENGINE
BASEASSEMBLY
RETURN FILTER ASSEMBLY
HEAT DEFECTOR SHIELD
1/4" NUT INSERT
GENERATOR
HYDRAULICRESERVOIR
PUMP
DRIVESPROCKET-ENGINE
DRIVESPROCKET-GENERATOR
HELICAL TOOTH DRIVE BELT
BUSHING-ENGINE SPROCKET
BUSHING-GENERATORSPROCKET
HOSE-COOLER/FILTER
HOSE- MANIFOLD/COOLER
HOSE- PRESSURE
VALVE-RELIEF
VALVE-FLOW DIVIDER
QUICK DISCONNECT COUPLER
#10 MJIC X #12 MOR
CONTROLVALVE
#8 X 1/2 MP NIPPLE
#4 O-RING PLUG
COOLER SUPPORT BRACE
1/4"-20 X 1 GR. 5 ZP
# 12 MJIC X # 12 MOR
#10 MOR X #10 MJIC 45
#12 SAE X 1” HOSE BARB
1/4-20 NYLOCK NUT
HOSE-SUCTION
HOSE CLAMP
SIGHT GLASS
#16 MORB X #12 MJIC 90
BATTERYSTRAP
BATTERY
BATTERY POST COVER
1” MPT X 1” BEADED BARB
ENGINE SHAFT KEY
QUICK DISCONNECT NIPPLE
5/16-18 X 2” GR 5 ZP.
5/16” LOCK WASHER
1/4-20 X 1-1/4 GR. 5 ZP
1/4" LOCK WASHER
5/16-18 NYLOCK NUT
5/16 SAE FLAT WASHER
5/16-18 X 2-1/4 GR. 5 ZP
5/16-18 JAM NUT
5/16-18 X 1” GR 5 ZP
5/16 USS FLAT WASHER
3/8 X 1 GR. 5 ZP
3/8 SAE FLAT WASHER
6 X 12 HEX HEAD METRIC BOLT
1/4 SAE FLAT WASHER
COOLERMOUNT-BOTTOM
3/8-16 X 1-3/4 GR. 5 ZP
3/8 NYLOCK NUT
1
1
1
1
1
1
1
26
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
5
1
1
5
2
1
1
5
1
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2
1
1
1
1
1
3
3
3
3
3
10
15
2
2
8
4
2
10
7
19
1
4
7
QTY.ITEM NO. PART NO. DESCRIPTION
05500 TWIN POWER UNIT
PARTS LIST FIG. 1
NOTE: ITEMS 58 & 59 (ENGINE MOUNT HARDWARE) OMITTED FROM DRAWING FOR CLARITY

14
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
7
9
31
32
24
23
6
8
10
5
10
26
29
28
27
30
25
10
35
33
34
36
11
3
38
15
14
21
22
12
1
13
4
37
2
16
18
20
19
17
05500 TWIN POWER UNIT
FIG. 2 ENCLOSURE ASSEMBLY

15
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
05500 TWIN POWER UNIT
ENCLOSURE ASSEMBLY FIG. 2
05514-10
05518
05514-07
05514-08
05514-05
05514-02
05514-03
05514-04
05514-04
01031
05514-06
00128A
00180
00129
00154
00127
00131-01
03804
A1022
A2191
A2046
A2190
A1056
A2192
A0999
A2062
705003
705005
705009
00157
A1001
A1000
692303
01032
00193
02903
05525
QTY.
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
4
4
4
12
3
6
70
51
1
1
2
1
4
4
1
1
1
1
1
ITEM NO.
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PART NO. DESCRIPTION
TOP PANEL
LIFTING FRAME
REAR PANEL
LEFT REAR CORNER PANEL
LEFT/RIGHT SIDE PANEL
CONTROL PANEL
COOLER PANEL
LEFT FRONT CORNER PANEL
RIGHT FRONT CORNER PANEL
FUEL LINE CLAMP
RIGHT REAR CORNER PANEL
FUEL TANK
FUEL TANK INSULATION
FUEL VALVE
FUEL TANK STRAP
FUEL CAP
HYDRAULIC OIL CAP
LIFTING EYE
5/16 X 1 GR 5 ZP
5/16 SAE FLAT WASHER
1/4-20 NYLOCK NUT
1/4" SAE FLAT WASHER
3/8 X 5 GR 5 ZP
3/8 SAE WASHER
1/4 X 5/8 FLANGE HEAD BOLT
1/4" NUT INSERT
240 VOLT RECPTECALE
110 VOLT GFCI RECEPTACLE
20 AMP BREAKER
CHOKE CABLE
1/4" X 3/4 GR. 5 ZP
1/4-20 X 1/2 GR. 5 ZP
START SWITCH
SYSTEM SWITCH
FAN SWITCH
HOUR METER
FUEL LINE

16
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
WIRE COLOR LEGEND
GREEN WHITE BLACK WHITE BLACK
ORANGE GREEN
12-5 SO CORD
WHITE BLACK RED
2
2
1
1
3
5
4
3
4
5
GENERATOR WIRING
Y
G
X
RECEPTACLE
240V
20A
20A
RECEPTACLE
110V GFCI
PANEL CONNECTION
12-5 SO CORD
2
3
1
1
3
2
4
5
5
4
GENERATOR
SWITCH
OFF ON
SYSTEM POWER
SWITCH
BLACK
YELLOW
SWITCH
START
HOUR METER
FAN
M
ENGINE
RED-LARGE RED-SMALL WHITE PURPLE BLUE
22 HP KOHLER
OEM SUPPLIED CONNECTIONS
BATTERY
FAN
YELLOW
05500 TWIN POWER UNIT
DC POWER SCHEMATIC
08/24/01
REV 0
05500 TWIN POWER UNIT
AC POWER SCHEMATIC
08/24/01
REV 0

17
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
REVIEW OF HYDRAULIC PRINCIPLES
A. TOOL CIRCUIT
1. HYDRAULIC FORMULAS:
CID X RPM GPM X PSI
GPM = 231 HP = 1714 (.85)
1456.9
Example: HP required to deliver 10 GPM at 1500 PSI.
10 GPM X 1500 PSI = 15000 = 10.3 HP
1456.9 1456.9
(subtract back pressure for tool HP)
Estimated HP delivered by pump or used by tool.
PSI
GPM 500 1,000 1,500 2,000 2,500 3,000
3 1.03 2.06 3.09 4.12 5.15 6.18
5 1.72 3.43 5.15 6.86 8.58 10.30
10 3.43 6.86 10.3 13.70 17.20 20.60
15 5.15 10.30 15.40 20.60 25.70 30.90
2. BACK PRESSURE
BACK PRESSURE MEASURED AT THE TOOL RETURN PORT MUST NOT EXCEED THE MANUFAC-
TURERS BACK PRESSURE RATING. MOST MANUFACTURERS LIST THE MAXIMUM BACK PRES-
SURE FOR THEIR HYDRAULIC TOOLS AT 250 PSI. BACK PRESSURE MEASURED ON THE RE-
TURN SIDE OF THE TOOL IS THE FORCE REQUIRED TO GET THE OIL BACK TO THE TANK. IN
ALMOSTALL CASESTHELOWER THEBACKPRESSURE THEBETTERTHE TOOLPERFORMANCE.
FIRST, THE BACK PRESSURE IS SUBTRACTED FROM THE MAXIMUM TOOL PRESSURE TO AR-
RIVE AT A MAXIMUM TOOL OPERATING PRESSURE. FOR EXAMPLE, TOOLS WITH 2000 PSI OP-
ERATING PRESSUREARE INSTALLEDONA SYSTEMWITH 250PSI BACKPRESSURE. THIS LEAVES
1750PSIAS AMAXIMUM TOOLPRESSURE. IMAGINE ASYSTEM WITH500 PSI BACKPRESSURE.
2000 MINUS 500 PSI BACK PRESSURE LEAVES ONLY 1500 PSI FOR THE TOOL. SECOND, TOOLS
ARE DESIGNED FOR PRESSURE TO BUILD ON THE PRESSURE SIDE OF THE TOOL. IF TOO
MUCH PRESSURE BUILDS ON THE RETURN SIDE, NOT ONLY IS PERFORMANCE EFFECTED,
BUT SEALS MAY BLOW. THIS IS WHY IT IS VERY IMPORTANT TO DIRECT THE FLOW INTO THE
TOOL CORRECTLY. REVERSING THE HOSES TO TEST MAY RESULT IN BLOWN SEALS, DAMAGE
TO THE TOOL, AND PERSONAL INJURY.

18
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
05500 TWIN POWER UNIT
DECAL LEGEND:

19
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01
LIMITED WARRANTY
MATWELD, INC., PADUCAH, KY., WARRANTS TO THE ORIGINAL PURCHASE OF THIS PROD-
UCT THAT THE PRODUCT WILL BE FREE FROM DEFECTS IN MATERIAL AND WORKMAN-
SHIP FOR THE PERIOD OF ONE (1) YEAR AFTER THE DELIVERY OF SUCH PRODUCT TO
THE CUSTOMER. OTHER EQUIPMENT AND PARTS USED, BUT NOT MANUFACTURED BY
MATWELD INC. ARE COVERED DIRECTLY BY THE WARRANTY OF THE MANUFACTURER
OF THOSE PRODUCTS. PROOF OF PURCHASE MUST BE DOCUMENTED INCLUDING REF-
ERENCE TO A SERIAL NUMBER LOCATED ON EACH TOOL. THE PURCHASER’S ONLY REM-
EDIES UNDER THIS LIMITED WARRANTY SHALL BE LIMITED AT MATWELD’S SOLE OP-
TION TO THE FOLLOWING: REPAIR, REPLACEMENT OR REFUND OF THE PURCHASE PRICE
OF THE DEFECTIVE PRODUCTS. EACH OF THESE REMEDIES REQUIRES TIMELY NOTIFI-
CATION OF THE DEFECT IN THE PRODUCT AND SUBSTANTIATION THAT THE PRODUCT
HAS BEEN PROPERLY STORED, MAINTAINED AND USED. MATWELD’S OBLIGATIONS HERE-
UNDER EXTEND ONLY TO THE PURCHASER OF THE PRODUCT AND NOT TO ANY THIRD
PARTY.
AS A CONDITION PRECEDENT TO MATWELD’S OBLIGATION HEREUNDER, THE DEFEC-
TIVE PRODUCT MUST NOT HAVE BEEN ALTERED OR MODIFIED WITHOUT THE EXPRESS
WRITTEN APPROVAL OF MATWELD, INC. THE PRODUCT MUST NOT HAVE BEEN SUB-
JECTED TO DELIBERATE DAMAGE, SHIPPING DAMAGE, NEGLECT, TAMPERING BY UNAU-
THORIZED PERSONNEL OR DAMAGE BY IMPROPER USE, STORAGE OR MAINTENANCE.
SERIAL NUMBERS MUST NOT HAVE BEEN ALTERED, DEFACED OR REMOVED. SUCH AC-
TION VOIDS LIMITED WARRANTY.
EXCLUSIONS TO LIMITED WARRANTY
THIS LIMITED WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRIT-
TEN OR ORAL, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED
WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITED WARRANTY DOES NOT COVER NORMAL WEAR AND TEAR ITEMS SUCH AS FIL-
TERS, HOSES, COUPLERS, BITS, SOCKETS, AUGERS, AND BATTERIES.
LIMITATION OF LIABILITY
EXCEPT AS PROVIDED ABOVE, MATWELD SHALL IN NO EVENT BE LIABLE OR RESPON-
SIBLE FOR ANY INJURY, LOSS OR DAMAGE, DIRECT, INCIDENTAL OR CONSEQUENTIAL,
ARISING OUT OF THE USE OR MISUSE OR INABILITY TO USE THE PRODUCT, HOWEVER
CAUSED AND ON ANY THEORY OF LIABILITY INCLUDING, WITHOUT LIMITATIONS, BREACH
OF CONTRACT, TORT, (INCLUDING NEGLIGENCE OR STREET LIABILITY) AND NOT WITH-
STANDING ANY FAILURE OF ANY REMEDY HEREIN OF ITS ESSENTIAL PURPOSE, EVEN
IF MATWELD WAS AWARE OF THIS POSSIBILITY OF SUCH DAMAGE. MATWELD’S LIMITED
WARRANTY AS SET FORTH ABOVE SHALL NOT BE ENLARGED, DIMINISHED OR AFFECTED
BY, AND NO OBLIGATION OR LIABILITY SHALL ARISE OR GO OUT OF THE RENDERING OF
TECHNICAL ADVICE OR SERVICE BY MATWELD OR ITS AGENTS. THE FOREGOING MAY
NOT BE CHANGED EXCEPT BY WRITTEN AGREEMENT SIGNED BY AN AUTHORIZED OF-
FICER OF MATWELD, THE REMEDIES SET FORTH HEREIN ARE EXCLUSIVE.

CUSTOMER INFORMATION:
Name _____________________________________________________
Company___________________________________________________
Serial # of your Matweld tool___________________________________
( Upon receiving your Matweld tool, make sure to list serial number above so that a good record is kept for order
information.) MATWELD HYDRAULIC TOOL LIST
All Matweld Hydraulic Tools operate at
5 or 10 GPM @ 2000 PSI
POWER UNITS:
07000 – HYDRA POWERED MODULAR SYSTEM
02900 – DIESEL 1-10 GPM OR 2-5 GPM
(OPTIONAL CATALYTIC EXHAUST AND/OR MSHA CERTIFIED)
00100 – GASOLINE 1-10 GPM OR 2-5 GPM
02050 – GASOLINE 1-5 GPM
05500 – TWIN POWER DUAL CIRCUIT UNIT 1-10 GPM OR 2-5 GPM & 5000 WATT GENERATOR
TRACKTOOLS:
01600A – 1” IMPACT WRENCH
04500D – ½” IMPACT DRILL
00800A – 16” RAIL SAW
03900A – REVERSING RAIL SAW
01100 – SPIKE PULLER
01300A – TIE TAMPER
01400 – SPIKE DRIVER
01500 – RAIL DRILL
01000 – CHAIN SAW
03500 – SELF FEED RAIL DRILL
GRINDERS:
04600 & 04650– STRAIGHT STONE CW & TRIGGER VERSION
04700 & 04750 – STRAIGHT STONE CCW & TRIGGER VERSION
04800 & 04850 – CUPSTONE & TRIGGER VERSION
00700 – RAIL SURFACING GUIDE
02400 – 10” OR 14” FROG AND SWITCH GRINDER
05900 – FROG/PROFILE GRINDER - ON/OFF FLOW CONTROL
05950 – FROG/PROFILE GRINDER - SAFETY TRIGGER
06000 – PROFILE GRINDER
05400 – ANGLE GRINDER
OTHER PRODUCTS:
HYDRAULIC MANIFOLDS
HYDRAULIC TEST GAUGES
HOSE REELS
HYDRAULIC HOSES
ACCESSORIES
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
09/01