Milwaukee 4777 Use and care manual

BUL. 64-00-1600
May 1,1973
OPERATlNG INSTRUCTIONS
AND PARTS LIST FOR
CATALOG NUMBER
4777
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. 4777
2 The PART NAME 4. The NAME of Item: AC ALTERNATOR
5. STARTING SERIAL NO. 5 1O-1001
MILWAUKEE ELECTRIC TOOL CORPORATION
13135 WEST LISBON ROAD
BROOKFIELD, WISCONSIN 53005 @
Printed in USA-100
SB-62670401

54-00-1600
Page 2
FULL LOAD WATTS
MILWAUKEE E%TRIC TOOLS
MODEL
NO.
0101
0102-l
0120
0121
0122-l
0140
0164
018o
0181
'Owe
0191
02OO
0220
0221
0222-l
0850
0870
0890
1000
woo-1
1100
1100-l
1120
1m0
1200-l
1600
1600.1
1620-l
1650
1650-l
1675-l
17io
FULLLOAD
WATTS AMPS
340 3.0
370 3.0
340 3.0
370 3.25
370 3.25
340 3.0
340 3.0
340 3.0
370 3.25
340 3.0
370 3.25
340 3.0
340 3.0
370 3.25
370 3.25
4oo 4.9
400 4.0
400 4.0
400 4.0
a00 4.0
400 4.0
400 4.0
400 4.0
250 15.5
400 4.0
400 4.0
660 6.0
660 6.9
660 6.0
660 6.0
660 6.0
750 7.5
1250 11.0
MODEL
NO..
170011
1750
1750.1
185O
1856-l
22oo-1
2400-l
3820
3880
3940
4020
4i30
4035
4250-l
4260-l
4270-l
4280-l
4290-l
4295-l
-5191
5200
52m
5240
5260
5265
5300
5350
5360
5390
5400
5410
5450
5530
FULLLOAD
WATT5
1100
125o
1100
1250
1100
1250
1250
1608
MOO
MOO
1600
1600
MOO
400
1100
1100
1100
1100
1100
350
loo0
1300
1300
1300
460
115O
650
390
515
300
680
1100
1100
AMPS
10.0
11.0
10.0
11.0
10.0
10.0
10.0
15.0
15.0
15.0
15.0
15.0
15.0
4.0
11.5
11.5
11.5
11.5
11.5
3.3
10.0
11.5
11.5
11.5
4.4
10.0
6.0
4.0
4.5
3.0
6.4
10.0
10.0
MODEL
NO.
5500
5610
5650
6020
6060
6200
6250
6280
6293
6320
6331
636O
6370
6400
6505
6510
6541-l
6542-l
6571-l
6581-l
6582-l
4620-i
6640-l
6747-l
6781-l
6798-l
6800
6810
6820
6830
8600
905o.
FULL LOAD
WATT5
105o
900
95o
220
1200
1200
1600
360
360
1100
1400
1200
125o
1300
14OO
460
460
370
370
370
370
370
400
400
500
310
515
240
300
700
700
360
I.._
AMPS
10.0
8.0
10.0
20
11.5
11.5
13.0
2.3
4.0
10.5
12.0
10.5
12.0
13.0
12.0
4.0
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

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 5 hours.
7. Under no condition should the gasoline engine
be hooked up to any pressure fuel pump (auto,
tractor or auxiliary line).
6. 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.
lO.The load should be applied to the alternator
&er it has reached its operating sp&. 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 ap-
pliances connected to the alternator.
CAUTION
This product hasbeen engineered and manufactured
to 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
TARTING: Rope
OIL SYSTEM: Splash Lube 32 Oz
FUEL TANK: 2-314 gallon capacity
54-00-1600
Page 3
ALTERNATOR
5000 WATT - Manual Start
TYPE: Revolving field four pole, single phase,
115/230 volt at 43.4/21.7 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 bearings running
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 poljrthermaleze wire insu-
lation. Dacron tie tape, modified fiber wedges.
CCOLING: 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.
3.1 1 Follow the detailed instructions in the fol-
lowing section on fihing with oil.
1. ( ) Fill engine with 32 oz. of oil.
NOTE: Oil weight Recommendations
Summer - SAE 30 t&S.
Winter - !5W2bM.S.
2. ( ) Fill fuel tank, with regular or non-leaded
gasoline.
MAINTENANCE
1. Periodically (approximately every 200 operating
hours) inspect the alternator brushes and clean the
slip rings.
Note: To Order An Exact Replacement Engine, Order From M.E.T.0; Part No. 43-204400

54-00-1600
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
on the lexploded 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 name and 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. 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.
Page 4
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 isvery 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-
ped with automatic reset,thermal overload switches,
which will open under extreme-overloads, thereby
shutting off the AC to the receptacles. The over-
road 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
SPlll
Phase
Motors
ALTERNATOR CAPABILITY FOR ELECTRIC MOTOR STARTING
1200
1700
1950
26?0
l
.
l
l
l
*Motors of higher horsepower shown in this classlflcatlonare not
generally used.
TYPE OF MOTOR AND HP RATING
Alternator R;petlsp n In$$m Capacitor Split Phase
start Hewy LHht tteavy Light
Rating start Start Start Start
In Watts Universal :?a! Load Load Load Load Load
*Motors of higher horsepower ratlng than shown In the ClaSSiflCatlOn
are not generally used.
l*LL-2400 RPM units.

LEGEND
r+/ FRAME GROUND
& WIRE NUT (RED)
-fB WIRE NUT (YELLOW)
A REACTOR THERMAL
PROTECTOR
@ STATOR THERMAL
PROTECTOR
TO ROTOR BEARING
SC-HEM AT&
roENGINE
CUT OFF
I I ‘WI I
-9 1
I I/‘-‘4
15 Amp
L I
WIRING DIAGRAM
I
Control No.
38652 I

Item
1
2
3
4
6”
7
8
9
Part No. Req’d
42-04-0475 1
23-4@0400 1
02-04-1545 1
23-58-0480 1
45-60-0345 1
22-20-0220 1
42-92-0345 1
22-18-0340 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
45-887216 8
06-75-0355 4
06-75-0465 1
06-97-4100 5
06-55-l 980 4
06-97-4125 4
06-75-0495 4
42-12-0290 1
Description
Adaptor Housing
Rotor and Fan’ Assembly
Bearing
Stator Assembly
Rear Bearing Carrier
Brush Holder
Brush Inspection Cover
Brush Assembly
3/8” Straight Connector
Wire Hold Down
1O-32 x 3/8” Lg. Taptite
8-32 x 5/8” Lg. Taptite
832 x 3/8” Lg. Taptite
6-32 x I$” Lg.Sims.Rd.Hd.Mch.Sc.
5/l 6” Flatwasher
5/16-l 8 x 10%” Lg.Hex.Hd.Cpsc.
Rotor Bolt 5/16-24 x 8%” Lg.
5/l 6” Lockwasher
5/16-18 Hex Nut
3f8” Lockwasher
3/8-16 x 3/4” Lg.Hex.Hd.Cpsc.
Heat Shield
EXPLODED VIEW OF
ALTERNATOR
m

Item Part No. Req’d
:
3
4
5
6
7
B
9
10
11
12
13
14
15
16
17
18
;
21
22
23
43-20-4400 1
45-60-0355 1
45-36-0790 1
22-51-0190 1
42680350 1
45690350 1
06-750345 2
23-94-9565 1
23-16-0345 1
42-70-0170 1
06-57-7480 1
43-33-0295 1
4333-0480 1
433 l-0250 1
42-68-0330 1
42-68-0335 1
06-97-4100 2
06-55-l 980 2
42690340 1
06-97-4125 3
06-55-2400 2
42680345 1
06-75-0495 1
54-00-1600
Page 7
Description
Engine Wisc.TRA 12
Coil Support
Spacer
Ignition Coil
Clamp
Muffler Support
Hex Hd. Cpsc. 5/16-18 x 2-3/4 Lg.
Spark Plug Wire
Coil Nipple
Coil Clip
Pipe Lock Nut 1”
9fl” Red. St.EII. 1 x 1%
Half Nipple 1% x 3
Muffler
U Bolt
Saddle
Lock Washer 5/16
Hex Nut 5/16-18
U Bolt
Lock Washer 3/8
Hex Nut 3/8-16
Clamp
Hex Hd.Cpsc. 3/8-16 x 3/4

54-00-1600
Page 8
27
I
i I I zB3X&23,24i
I-r
22
EXPLODED VIEW OF
f3ASk &PANEL
:em Part No. Req’d
1 42-29-0450 1
2 43-33-0470 1
3 96-974190 10
4 96-75-9340 ‘9
5 45-88-5261 4
6 43-33-0390 4
7 45887290 4
8 06-551980 8
9 06-81-4652 4
10 96-97-3400 4
11 06-57-3000 5
12 23-35-0170 1
13 22-56-0060 2
14 23-04-0060 5
15 22-89-0090 2
16 22-89-0100 1
17 22890060 2
18 06-81-5630 10
19 23-38-2585 1
20 23330130 2
21 23660950 1
22 23-33-0255 2
23 23-33-0265 1
24 06-97-0870 12
25 06-81-4212 6
26 06-551100 6
27 45-12-0285 1
.
Description
Mounting Base
Vibration Dampner
5/16 Lock Washer
Hex Hd.Cpsc. 5/16-l 8 x 1” Lg.
Flat Washer 3/8
Vibration Dampner
Spacer
Hex Nut 5/16-18
Hex Hd. Mch.Sc.No.1932 x % Lg.
No. 10 Lock Washer
No. lo-32 Lokut Hex Nut
Control Panel
3/8 Straight Connector
Fuse Holder
Fuse 29 Amp
Fuse 30 Amp
Fuse 15 Amp (Not Shown)
Item Part No. Req’d Description
28 06-81-0275 4 Whiz Screw
29 43X3-0310 2 Vibration Dampner
30 45-36-9785 2 Spacer
31 96-97-1020 2 5/16 External Shakeproof
32 45569145 1 Ground Strap
33 96-75-0525 2 Hex Hd.Cpsc. 3/8-16 x l-3/4 Lg.
34 42-36-0395 1 Engine Support
35 06-75-0600 2 Hex Hd.Cpsc.3/&16 x l-3/4 Lg.
36Ref. dwg.38622 1 TRA 12-D Engine
37 06-97-4125 2 Lock Washer 318
38 06-55-2400 2 Hex Nut 3/8-l 6
39 23-74-0480 1 Ground Terminal
40 23-81-0200 1 Reactor Assembly
41 06-97-1000 4 ‘/4Lock Washer
42 06-551560 2 %-20 Hex Nut
43 42680280 2 Hose Clamp
44 45800145 1 Shut Off Valve
Phil.Pan Hd.Mach.Sc.No.832 x % Lg. 45
Rectifier Assembly 46
115 V Parallel Blade Cutlet 47
Rocker Switch Spst. 48
125 V 20 A Twist-Lok Outlet 49
250 V 30 A Twist-Lok Outlet 50
No. 10 External Shakeproof 51
Phil.Pan Hd.Mach.Sc,No. 1O-32 x K Lg.‘52
Hex Nut No. 19-32 53
Panel Shroud
45-66-0065 1
06-75-0200 1
45-56-O 140 2
06-81-4720 2
06-55-0825 10
06-97-3200 10
42-36-0397 1
23-33-0260 2
23-33-0270 1
Fuel Tank
Hex Hd.Cpsc. X-20 x 1% Lg.
Tank Strap
Rd.Hd.Mach.Sc, X-20 x 5/8 Lg.
No. 832 Hex Nut
No. 8 Lock Washer
Rectifier Support Assembly
125 V 20 A Twist-Lok Plug (Not Shown)
250 V 30 A Twist-Lok Plug (Not Shown)