Milwaukee 4792 Use and care manual

BUL. 54-00-1700
May 1.1973
OPERAl’lNG INSTRUCTIONS
AND PARTS LISTFOR
CATALOG NUMBER
4792
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. 4792
2 The PART NAME 4. The NAME of Item: AC ALTERNATOR
5. STARTING SERIAL NO. 51l-1001
MILWAUKEE ELECTRICTOOL CORPORATION
13135 WEST LISBON ROAD
BROOKFIELD, WISCONSIN 53005 a
Printed in USA-100

54-00-1700
Page 2
MODEL
NO.
0101
0102.1
Olrn
0121
0122.1
014o
0160
0180
0181
0190
0191
0200
0229
0221
0222-l
0800
0850
0870
0890
loo0
1000.1
1100
1100-l
llrn
1mo
1200.1
1600
1600-l
16m-1
16M
1650-l
1675-l
1700
FULL LOAD
WATTS
340
370
340
370
370
340
340
340
370
340
370
340
34o
370
370
400
aoo
400
a00
4oo
400
400
a00
2so
400
400
660
660
660
660
660
750
1250
AMI+
3.0
3.0
3.0
3.25
3.25
3.0
3.0
3.0
3.25
3.0
3.25
3.0
3.0
3.25
3.25
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
15.5
4.0
4.0
6.0
6.0
6.0
6.0
6.0
7.5
11.0
FULL LOAD WATTS
OF
MILWAUKEEELECTRIC TOOLS
MODEL
NO.
1700.1
1750
1750-l
18u)
1850-1
2mo:1
2400-l
3820
3880
3940
4020
4o3o
4o35
4250-l
4260.)
4270.1
4280-l
4290.1
4295-l
5191
5x10
5220
5240
5260
5265
5300
5350
5360
5390
5400
5410
5450
5530
FULLLOAD
WATTS AMPS
1100 10.0
1250 11.0
1100 10.0
1250 11.0
1100 10.0
125o 10.0
1250 10.0
16OO 15.0
MOO 15.0
Moo ,15.0
1600 15.0
Moo 15.0
1600 15.0
400 4.0
1100 11.5
1100 11.5
1100 11.5
1100 11.5
1100 11.5
350 3.3
1000 10.0
1300 11.5
1300 11.5
1300 11.5
460 4.4
1150 10.0
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
5650
6000
6020
6060
6200
6250
6280
6293
6320
6331
6360
6370,
6400
6505
65KI
6541-1
6542-l
6571-1
6581-1
6582-l
6620-l
6640-l
6747-l
6781-1
6798-l
6800
6810
6820
6830
8600
905o
FULLLOAD
WATTS AMPS
105o 10.0
900 8.0
950 10.0
220 2.0
1200 11.5
1200 11.5
1600 13.0
360 2.3
360 4.0
1100 10.5
1400 12.0
1200 10.5
1250 12.0
1300 13.0
14oO 17.0
460 4.0
460 4.0
370 3.25
370 3.25
370 3.25
370 3.25
370 3.25
400 4.0
400 4.0
500 4.5
310 3.25
515 4.5
240 2.1
300 3.0
700 6.4
700 6.4
360 3.2
__I 4.0

RULES FOR SAFE OPERATION
1. Gasoline engines give off deadly carbon mon-
oxide. Never run a gasoline engine in the basement
or other areas in 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 is hot.
6. Check the oil every time you fill the gastank or
every five operating 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
alternatorwith 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 ap-
pliances connected to the alternator.
CAUTION
This product hasbeen engineered and manufactured
to provide- trouble free operation, if proper-
ly cared for and used within its rated specifications.
Always use r;afe 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, OHV, single cylinder, 3%”
bore,
2-7/8” in. stroke, 27.66 cu. in. displace-
ment,
16 horsepower.
COOLING: Pressureair cooled.
GOVERNOR: Mechanical-fixed speed.
IGNITION: Flywheel magneto.
STARTING: Electric
01 L SYSTEM: 50 oz.
FUEL TANK: 2-3/4 gallon.
54-00_1700
Page 3
ALTERNATOR
7000 WATT - Electric Start
TYPE: Revolving field two pole, single phase,
115/230 volt at 66.8/30.4 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 polythermalete wire.insu-
lation. Dacron tie tape, modified fiber wedges,
COOLING: Centrifugal blower directly connected
to the rotor shaft.
COLOR: Metco Red
INSTALLING & OPERATING
1. ( 1‘Uncrate and inspect for shipping damage.
2. ( ) Ventilation: Adequate ventilation must be
provided ror safe, efficient operation.
3. ( 1 Follow the detailed instructions in the fol-
lowing section on filling with oil.
1. ( 1 Fill engine with 50 oz. of oil.
NOTE: Oil weight Recommendations
Summer - SAE 30 M.S.
Winter - SAE 10 M.S.
2. ( 1 Fill fuel tank, with regular
gasoline.
MAINTENANCE
or non-leaded
1. Periodically (approximately every 200 operating
hours) inspect the alternator brushesand clean the
slip rings. To gain accessto these parts, remove tap-
tite screw (item 11, drawing 38852) and brush
cover (item 7). Remove two tapdte screws (item
131, hold down clamp ‘(item lo), two taptite
screws (item 141, and brush holder (item 6). This
will expose the brushes inside the brush.holder and
the slip rings through the opening in the bear
bearing carrier. Brusheswhich are chipped, cracked,
or worn to a length of lessthan 5/16” should be
replaced.
Note: To Order An Exact Replacement Engine, Order From M.E.T.CO. Part No. 43-20-5008

54-00-1700
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 266 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
on the #exploded view illustrations. Each part is
identified with an index number which is keyed 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 part - 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 nameptate.)
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. Pressstart button or usestarter rope.
2. STOPPING &STORAGE OF ALTERNATOR
To stop, pressstarter 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
loads that may be applied. It isvery important that
polarized plugs be used in order to maintain a com-
mon ground between the alternator and its load.
All alternators of 2666 watts or larger are equip-
pedwith automatic reset,thermal overload switches,
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 114
Freezer l/3
10” Table Saw
Centrifugal Pump :,4 to l-1/2
Submersible Pump l/2 to l-1/2
Sump Pump l/3 to l/2
MOTOR STARTING REQUIREMENTS
*Motors of higher horsepcwer shown In this classlficatlon are not
generally used.
ALTERNATOR CAPAbILITY FOR ELECTRIC MOTOR STARTING
TYPE OF MOTOR AND HP RATING
Rc ulrlon
A$earnngor J eavy In$zhtpn Capacitor Split Phru
In Watts Universal :‘,z Start Heavy Lfght Heavy Light
Start Start Start Start
Load Load Load Load Load
1000 v, - -
:f% : i 34 ; 1
f:% l-I*5 c 2 G l/3
1
;;lmg ; 22* :I/: llh ; 9 14
4 3 l
‘*LL1500
l‘LL3000 3 H & ;. ;
“LLSOOO :z 3 2& : ?I4 314
34
*Motors of higher horsepower rating than shown In the classlficatlon
are not eneraliy used.
l*LL-240 RPM units.
8

LEGEND
Frame Ground
Wire Nut (Red)
Wire Nut (Yellow)
Solenoid
Starter Motor
Choke
Battery Charge
Diode
Reactor Thermal
Protector
rh
e
z?
s
C
BCP
A
---Es
I@-
92
STOP
_J4
t
TIRT
4gp g4 L2Y
-zBatt. @ Stetor Thermal
Protector
f3J
LD
~1 THIS BW3i CLOSEST
k TO ROTOR BEARING
I
m SCHEMATIC
LZI
0 ENGINI
CUT OFF
r30 ,’
rloI-L, II
WIRING DIAGRAM
Control No.
38851

tern Part No. Req’d
1 42-20-0445 1
2 43-33-0485
3 06-97-4 100 8
4 06-75-0300 5
5 06-75-0495 2
6 45-76-0210 1
7 06-81-4720 2
8 06-55-l 980 8
9 06-75-0020 4
IO 06-97-3400 4
11 06-57-3000 5
12 23-35-0175 1
13 22-56-0060 2
14 23-04-0060 5
15 22-89-0075 3
16 22-89-0060 2
17 23-04-0070 1
I8 06-81-5630 11
9 42-36-0397 1
!O 23-33-0130 2
!1 23-66-0950 1
!2 23-33-0240 2
‘3 23-33-0265 1
‘4 06-97-0870 12
15 06-81-4212 6
‘6 06-55-l 100 8
‘7 45- 12-0285 1
8 06-81-0275 4
9 43-33-0310 2
0 45-36-0785 2
1 06-97- 1020 2
2 45-56-0150 1
3 06-75-0525 3
Description
Mounting Base
Vibration Dampner
Lock Washer 5/16
Hex Hd. Cpsc. 5/16-18 x 3
Hex Hd. Cpsc. 3I8-16
Fuel Line
Rd.Hd.Mach.Sc. X-20 x 5/8 Lg.
Hex Nut 5/16-18
Hex Hd.Mach.Sc.No.1 O-32
No. 10 Lockwasher
No. lo-32 Lokut Hex Nut
Control Panel
3/8 Straight Connector
Fuse Holder
Fuse 30 Amp EXPLODED VIEW OF
BASE & PANEL
Fuse 15 Amp (Not Shown)
Fuse Holder
PhiLPan Hd.Mach.Sc.No. 8-32 x % Lg.
Rectifier Supt. Assembly
115-V Parallel Blade Outlet
Switch Spst.
125-V 30A Twist-Lok Plug
250-V 30A Twist-Lok Plug
No. 10 External Shakeproof
Phillips Pan Hd.Mach.Sc.No.lO-32 x % Lg.
Hex Nut No. lo-32
Panel Shroud
Whiz Screw
Vibration Dampner
Spacer
5/16 External Shakeproof
Ground Strap
Hex Hd.Cpsc. 3/S-16 x 1% Lg.
Item
34
35
36
37
38
39
40
41
42
43
44
t:
47
::
50
‘;I/
I*
Part No. Req’ Description
42-36-0395 1 Engine Support
22-89-O 100 1 Fuse 30 Amp
43-20-5000 1 Engine HH 160
06-97-4 125 2 3/8 Lock Washer
23-38-2635 1 Rectifier Assembly
23-74-0480 1 Ground Terminal
23-81-0210 1 Reactor Assembly
06-97-5600 2 External Shakeproof K
06-55-l 500 2 Hex Nut X-20
42-68-0355 1 Hose Clamp
45-80-0145 1 Shut Off Valve
45-66-0065 1 Fuel Tank
06-75-0200 2 Hex Hd.Cpsc. X-20 x 1% Lg.
45-56-0140 2 Tank Strap
06-97-3200 10 No. 8 Lock Washer
06-55-0825 10 Hex Nut No. 8-32
23-33-0245 2
23-33-0270 1 125-V 30A Twist-Lok Plug (Not Shown) g
250-V 30A Twist-Lok Plug (Not II)

54-00-1700
Page 7
18
EXPLODED VIEW OF
EXHAUST SYSTEM
l
Engine
Item
1
3’
4
.5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Part No. Req’d
06-57-7480 1
43-33-0295 1
06-57-7500 1
43-33-0475 1
43-33-0305 1
42-68-0330 1
43-3 l-0250 1
42-68-0335 1
06-97-4100 2
06-55-l 980 2
42-68-0340 1
42-36-0945 1
06-97-4125 2
06-55-2400 2
06-75-0100 1
43-44-0310 1
06-75-0075 2
44-l 4-0075 1
42-70-0175 1
45-60-0360 1
06-97-1000 3
06-55-1500 3
l Iterns 12 & 20 mounts to
alternator adapter casting
Description
1” Pipe Lock Nut
90° Reducing St. Eli. 1” x
1%” Pipe Lock Nut
Choke Support Bracket
1%” Half Nipple 2%” Lg.
l-3/4 U-Bolt
Muffler
l-3/4” Saddle
5/16 Lock Washer
5/16-18 Hex Nut
U”Bolt
Muffler Support Bracket
3/8 Lock Washer
3/8-16 Hex Nut
Hex Hd.Cpsc. x-20 x 3/4 Lg.
Automatic Choke
Hex Hd.Cpsc. x-20 x H Lg.
Choke Linkage
Dorman Clip
Choke Support
% Lock Washer
Hex Nut x-20

item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
;:
23
24
Part No. Req’d
42-04-0475 1
22-84-0415 1
02-04- 1545 1
23-58-0485 1
45-60-0345 1
22-20-0220 1
42-92-0345 1
22-l 8-0340 2
22-56-0060 1
42-68-0325 1
06-81-0030 1
06-81-3640 2
06-81-0451 2
06-81-8650 2
45-88-7216 8
06-75-0355 3
06-75-0465 1
06-97-4100 5
06-55- 1980 7
06-97-4125 4
06-75-0495 4
45- 12-0295 1
06-92-l 395 1
23-40-0410 1
EXPLODED VIEW OF
ALTERNATOR
Description
Adapter Casting \ .
Fan
Bearing
Stator Assembly
Rear Bearing Carrier
Brush Holder
Brush Cover
Brush Assembly
3/8 Straight Connector
Hold Down Clamp
Taptite No.1 O-32 x 3/8 Lg.
Taptite No.8-32 x 5/8 Lg.
Taptite No.8-32 x 3/8 Lg.
Sims SC. No. 6-32 x % Lg.
Flat Washer 5/16
Stator Bolt 5/16-18x 10% Lg.
Rotor Bolt 5/16-24 x 8% Lg.-
5/16 Lock Washer
Hex Nut 5/16-18
Lock Washer 3/8
Hex Hd.Cpsc. 3/8-16 x 3/4 Lg.
Heat Shield
Stud 5/16-18 x 12” Lg.
Rotor Assembly
Control No.
rl
38852
I 1