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)

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

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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.

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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.

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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
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!

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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
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.

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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

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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
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