Milwaukee 4612 Datasheet

BUL. 54-00-1400
October 1, 1973
OPERAllNG INSTRUCTIONS
AND PARTS LIST FOR
CATALOG NUMBER
4612
I7 AC ALTERNATOR
MILWAUKEE ELECTRIC TOOL CORP.
DEPENDABLE POWER
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING
INFORMATION AS SHOWN IN THIS LIST:
1. M.E.T.CO. PART NUMBER’ 3. M.E.T.CO.. CAT. NO. 4612
2 The PART NAME 4. The NAME of Item: AC ALTERNATOR
5. STARTING SERIAL NO. 508 - 1104
MILWAUKEE ELECTRIC TOOL CORPORATION
13135 WEST LISBON ROAD
BROOKFIELD, WISCONSIN 53005 a
.
Printedin USA-100
Put No. 39639
SB-62651-101

54-00-1400
Page 2
MODEL
NO.
0101
0102-l
0120
0121
0122-l
0140
0160
0180
0181
0190
0191
02OO
0220
0221
0222-l
0800
0850
.0870
0890
1000
1000-l
1100
1100-l
1120
lmo
1200-l
1600
c 1600-l
1620-l
1650
165Q-1
1675-1
1700
FULLLOAD
WATTS AMPS
340 3.0
370 3.0
340 3.0
370 3.25
33th 3.25
340 3.0
340 3.0
340 3.0
370 3.25
340 3.0
370 3.25
320 34
340 3.0
370 3.25
370 3.25
400 4.0
4oo 4.0
4al 4.0
400 4.0
400 4.0
a00 4.0.
400 4.0
400 4.0
250 15.5
400 4.0
400 4.0
660 6.0
660 6.0
660 6.0
660 6.0
660 6.0
750 7.5
1250 11.0
FULL LOAD WATTS
OF
MILWAUKEE ELECTRIC TOOLS
MODEL
NO.
1700-l
175o
1750-l
1850
185Q,l
2200-l
2400-l
3820
3880
3940
4om
4o3o
4035
4250-l
4260.1
427u.l
4280-l
4290-l
4295-l
5191
52ho
5220
5240
5260
5265
53uo
535o
5360
5390
5400
5410
5450
5530
FULLLOAD
*WATTS AMPS
1100 10.0
125o 11.0
1100 10.0
1250 11.0
1100 10.0
1250 10.0
1250 10.0
1600 15P
1600 15.0
1600 is.0
1600 15.0
l&O w
16a+ lrp
400 4.0
1100 11.5
1100 11.5
1100 11.5
1100 11.5
1100 11.5
350 3.3
loo0 10.0
1300 11.5
1300 11.5
1300 11.5
460 4.4
1150 1O.b
650 6.0
390 4.0
515 4.5
300 3.0
680 6.4
1100 10.0
1100 10.0
MODEL
NO.
5590
5610
565o
6000
6020
6oM)
6200
625O'
6280
6293
6320
6331
637U
6400
6505
6510
6541-1
6542-l
6571-1
6581.1
6582-l
66x)-1
6640-l
6747-l
6?81-1
6798-l
#BOO
6810
6820
6830
8600
9050
FULLLOAD
WATTS
1050
900
950
220
1200
lmo
1600
360
360
1100
1400
12OO
1250
MO
Moo
460
460
370
370
370
370
370
400
400
MO
310
515
24Q
300
700
700
360
-_-s
-AMPS
10.0
8.0
10.0
2.0
11.5
11.5
13.0
2.3
4.0
10.5
12.0
10.5
12.0
13.0
12.0
4a
4.0
3.25
3.25
3.25
,3.25
3.25
4.0
4.0
4.5
3.25
4.5
2.1
3.0
6.4
6.4
3.2
4.0

54-00-1400
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RULES FOR SAFE OPERATION
1. Gasoline engines give off deadly carbon mon-
oxide. Never run a gasoline engine in the basement
or other areasin a building.
2. This alternator has an air cooled engine which
must have good circulation of air.
3. Gasoline enginesshould not be stored or operated
in holds of boats or ships.
4. Check the local code as to the laws governing
storing gasoline in confined areas.
5. Never fill a gasoline engine in the dark or when
the engine ishot.
6. Check the oil every time you fill the gastank or
every 5 hours.
7. Under no condition should the gasoline engine
be hooked up to any pressure fuel pump (auto,
tractor or auxiliary line).
8. Always check wattage requirements on labeled
motors and appliances before attempting to oper-
ate.
9. If an extension cord is necessary, always use as
short a length as possilbe. The longer the cord the
greater the voltage drop resulting in less power
applied to the tube.
10. The load should be applied to the alternator
after it has reached its operating speed. Never start
alternator with load.
11. Engine speed is preset at the factory. If this
speed is incorrectly readjusted by the customer,
serious damage may be incurred in the tools or W
pliancesconnected to the alternator.
CAUTION
This product hasbeen engineered and manufactured.
W_ provide trouble free operation, if proper-
ly caredfor and used within its rated specifications.
Always use care when operating or repairing this
alternator, lethal voltages are present and the same
caution should be exercised as is used with’ the
electrical wiring in your home. Follow a regular
maintenance and service schedule to provide ef-
ficient and safe operation.
ENGINE SPECIFICATIONS
TYPE: 4 cycle, L head, single cylinder, 3% ” bore,
2-7/8” stroke, 27.66 cu. in. displacement, 12 H.P.
COOLING: PressureAir Cooled
GOVERNOR: Mechanical Type Preset
IGNITION: Flywheel Magneto
STARTING: Rope
3lL SYSTEM: Splash Lube 32 Oz.
FUEL TANK: 1 gallon capacity
ALTERNATOR
3099 WATT - Manual Start
TYPE: Revolving field four pole, single phase,
115/230 volt at 26/13 amps. 60 cycle, drip
proof design.
ROTOR: Laminated electrical steel, pressed on
shaft, sintered brasscollection rings. Windings are
precision semi-automatic wound.
STATOR: Laminated electrical steel pressed into
steel stator band. Precision wound, automatic tied
coils, pressedend returns.
BEARINGS: Life Time sealed ball bearingsrunning
in a steel bearing insert.
VARNISH: Class “H” Westinghouse double dip
7 hr. cure cycle.
INSULATION: Modified class “H” insulating sys-
tem, DMD liners, heavy polythermaleze wire insu-
lation. Dacron tie tape, modified fiber wedges.
COOLING: Centrifugal blower directly connected
to the rotor shaft.
COLOR: Metco Red
INSTALLING & OPERATING
1. ( ) Uncrate and inspect for shipping damage.
2. ( ) Ventilation: Adequate ventilation must be
provided ror safe, efficient operation.
3. ( ) Fill engine with 32 oz. of oil.
NOTE: Oil weight Recommendations
Summer -SAE 30 M.S.
Winter - cNv20 M.S.
4, ( ) Fill fuel tank, with regular or low-leaded
gasoline.
1. Periodically
hours) inspect
slip rings.
MAINTENANCE
(approximately every 290 operating
the alternator brushesand clean the
Note: To Order An Exact Replacement Engine, Order From M.E.T.O. Part No. 43-20-4010

54-00-1400
Page 4
2. To clean slip rings,’polish with a piece of fine
sandpaper while rotor is turning. DO. NOT USE
EMERY PAPER. Disconnect spark plug wire and
turn engine with starter to polish slip rings.
3. The alternator should be kept clean and reason-
ably dry.
4. Maximum engine life can be obtained if oil is
changed every 200 operating hours or 30 days,
whichever occurs first. After engine is drained,
repeat “Filling Engine”.
ILLUSTRATED PARTS LIST
All replacement parts for the alternator are shown
ort the *exploded view illustrations. Each part is
identified with an index number which iskeyed to
the parts list. The index numbers are used solely
for identification - not for ordering parts.
To save time - to make sure’that you get the cor-
rect pat-t - be sure to include the following infor-
mation with your parts order;
1. Part nameand part number (NOT the index num-
ber shown on the exploded view.)
2,The alternator model and serial number (found
on the nameplate.)
3. Quantity of each part ordered.
1. STARTING PROCEDURE
a. Fill gastank with gasoline.
b. Check Oil.
C. Open fuel line valve (if applicable).
d. Press start button or use starter rope.
2. STOPPING &STORAGE OF ALTERNATOR
To stop, press starter button to off position.
.If alternator is placed in storage for any period of
time, the fuel tank should be drained.Then run the
engine to burn up the gasoline in the carburetor.
Remove the spark plug and place a teaspoon of oil
in the head. Turn the engine over a few times then
replace the spark plug.
The engine should be run in by operating at loads
not in excess of % the name plate rating for the
first two full tanks of gasoline. This will greatly ex-
tend the useful life of your engine.
Loads may be applied to the alternator by plugging
into one or more of the receptacles on the panel.
Check the individual wiring diagram for specific
loadsthat may be applied. It isven/ important that
polarized plugs be used in order to maintain a com-
mon ground between the alternator and its load.
All alternators of 2000 watts or larger are equip-
pedwith automatic reset,thermal overload swirches,
which will open under extreme overloads,‘thereby
shutting off the AC to the receptacles. The over-
load device will close, when the operating tempera-
ture drops to a safe level. Smaller units are
inherently protected by oversize windings which
cannot overheat.
TYPICAL HORSEPOWER RATINGS
Item Horsepower
Furnace - Stoker l/4
Furnace - Oil Burner l/6
Furnace - Blower l/4
Freezer l/3
10” Table Saw 1
Centrifugal Pump l/4 to l-1/2
Submersible Pump l/2 to l-1/2
Sump Pump l/3 to l/2
MOTOR STARTING REQUIREMENTS (NO LOAD)
ALTERNATOR CAPABILITT FOR ELECTRIC MOTOR STARTING (NO LOAD)

54-00-1400
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.

Item Part No. Req’d Description
+
:
3
4
:
7
8
9
42-04-0475
23-40-039 1
02-04-l 545
23-58-047 1
45-60-0345
22-20-0226
42-92-0345
22-l 8-0340
1
1
1
1
1
1
:
1
1
:
2
2
8
:
1
:
4
4
Adaptor Housing
Rotor and Fan Assembly
Bearing
Stator Assembly
Rear Bearing Carrier
Brush Holder
Brush lnspeotion Cover
Brush Assembly
318” Straight Connector@’ JJ-S~-*~~”
Wire Hold Down
fO-32 x 3/8” Lg. Taptite
8-32 x 5/8” Lg. Taptite
832 x 3/8’ Lg. Taptite
632 x X” Lg. Sims.Rd.Hd.Mach.Sc.
5/l 6” Flatwasher
5/16 - 18 x 8” Lg. Hex.Hd. Cpsc.sc.
5/16”-18 x 7%” Lg.Hex.Hd.Cpsc.
5/16-24 x 7-5/8” Lg.Rotor Bolt
5/l 6” Lockwasher
5/16 - 18 Hex Nut
318” Lockwashers
3/8 - 16 x 3/4” Lg.Hex.Hd.Cpsc.
10
11
21 12
:3
15
16
17
18
19
20
42-68-0325
06-81-0030
06-8i-3640
06-81-0451.
06-81-8650
45-88-7216
06-75-0339
06-75-0337
06-75-0450
06-97-4 100
06-55-l 980
06-97-4125
m-75-0495
18
FxPLODED VIEW OF
ALTERNATOR

54-00-1400
Page 7
Item
:
3
4
6”
;
9
10
11
12
13
Part No.
43-20-4010
06-75-0343
44-66-4200
06-75-0340
06-97-4100
06-55-l 980
45-56-0135
43-3 l-0260
42-68-0315
42-68-0320
43-33-0255
06-57-7480
43-33-0260
Req’d
1
2
1
1
1
1
1
1
1
1
:
2
Description
Wise.Tra. 12 D Engine
Stressproof Bolt
Muffler Bracket
506 - 18 x 1” Hex.Hd.Bolt
506” Lockwasher
5/16 - 18 Hex Nut
Muffler Strap
Muffler
“U” Bolt
Saddle
1” NPT x 3” Lg.Nipple
1” Locknut, Pipe
1” NPT x 45O Street Elbow
EXPLODED VIEW OF ENGINE ACCESSORIES

54-00-1400
Page 8
\
, EXPLODED VIEW OF
BASE & PANEL
Item Part No.
1
2
3
4
5
6
7
8
9
10 -
11
12
13
14
15
16
17
18
19
20
Req’d Description
45-600340 1
42-36-0905 1
40-50-6900 4
06-75-0495 1
06-75-0340 6
06-97-4100 8
06-55-l 980 8
06-97-4125 3
06-81-4652 4
06-97-3400 4
06-57-3000 5
23-8 l-0200 1
23-7410480 1
06-75-0625 2
42-36-0910 1
45-36-0775 4
40-50-7725 6
06-55-2400 2
06-75-0600 2
23-38-2560 1
Mounting Base
Alternator Support
Springs
3/8 - 16 x 3/4” Hex.Hd.Cpsc.
5/16 - 18 x 1” Hex.Hd.Cpsc.
5/l 6” Lockwasher
5/l 6 - 18 Hex. Nut
3/8 Lockwasher
10 - 32 x %” Rd.Hd.Mach.Sc.
No. 10 Lockwasher
No. 10 Lokut Nut
Reactor Assembly
Ground Lug
3/8 - 16 x 2” Lg.Hex.Hd.Mach.Sc.
Engine Support
Spacer
Spring
3/8 - 16 Hex Nut
3/8 - 16 x l-3/4” Lg.Hex.Hd.Cpsc. 38 42-36-0912 1
Rectifier 23-33-0250 1 20 Amp-250 volt Twist Lock Plug (not showr
23-33-0245 1 20 Amp-l 15 volt Twist Lock Plug (not showr
Item Part Na. Req’d Description I
21
22
23
24
25
26
27
26
29
30
31
32
33
34
35
36
37
45-l Z-0280
23-35-0165
23-33-0240
23-33-0235
23-66-0950
23-33-0130
23-66-0945
23-64-0060
22-89-0065
06-81-5630
06-97-3200
06-55-0825
22-56-0060
06-81-4212
06-97-0870
06-55-l 100
06-81-0275
1
1
1
1
1
2
1
2
2
4
4
4
2
4
8
4
4
Panel Shroud
Control Panel
125 Volt Twist Lik Outlet
250 Volt Twist Lik Outlet
S.P.S.T. Switch
115 Volt Parallel Blade Outlet
3 P.D.T. Switch
Fuse Holder
Fuse 15A
6-32 Pan Hd. Mach.!%.
No. 8 Lock Washer
‘8-32 Hex Nut
3/S Straight Connector
1032 x 1/2”Lg.Pan Hd.Mach.Sc.
No. 10 Lockwasher
10-32 Hex Nut
Whiz SC. 10-32 x (/2” Lg.
Rectifier Support