Hummer H1 (2002+). Manual - part 200

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 Electrical System  12-27

®

05745159

Alternator Assembly

1.

Install bearing on rotor shaft. Seat bearing against shoul-
der (Figure 12-38).

2.

Assemble springs and brushes in brush holder and retain
with fabricated pin. Pin holds brushes compressed in brush
holder and will be removed after assembly.

3.

Install rectifier bridge in slip ring end frame and install
screw, output stud insulator, and nut.

4.

Assemble and install brush holder and regulator. Solder
connection between brush holder and regulator if either
part was replaced.

5.

Slide regulator connector strap into regulator contact and
solder together.

6.

Slip capacitor strap under connector strap and position on
rectifier bridge and regulator. Secure capacitor strap with
screw and two insulated screws (Figure 12-51).

Figure 12-51:   Rectifier Bridge and Capacitor Strap 

Location

7.

Attach stator leads to rectifier bridge and secure leads with
nuts.

8.

Install thick collar on rotor shaft (Figure 12-38).

9.

Insert rotor shaft through drive end frame and seat bearing
against thick collar.

10. Install thin collar, fan, and pulley on rotor shaft and secure

with washer and nut. Tighten nut to 40-80 lb-ft (54-109
N•m).

11. Carefully insert rotor through stator and seat ball bearing

in slip ring end frame. Be sure drive end frame and stator
are aligned and seated.

12. Install through-bolts. Tighten through-bolts evenly to

remove any slack.

13. Verify that rotor turns smoothly.

14. Remove brush retaining pin from brush holder. Be sure

brushes extend out brush holder and contact slip rings.

STUD

NUT

SCREWS

INSULATED

SCREWS

SCREW

AND WASHER

RECTIFIER

BRIDGE

CAPACITOR

STRAP

SOLDERED

CONNECTION

4-1-00

12-28

Electrical System

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 Alternator Inoperative (No Charge)

Step

Action

Value(s)

Yes

No

1

Perform visual inspection on belt, pulleys and  
battery cables. Is everything in normal operating 
condition

Go to step 2.

Repair and 
recheck system.

2

Using a battery load tester, place amp pickup on 
the alternator fusable link wire. Start and run 
vehicle at 1500 rpm, load the vehicle batteries 
with 100 amps for 15 seconds. Does charging sys-
tem produce equivalent amperage.

>100 amps

Go to step 7.

go to step 3.

3

Perform battery check, refer to “battery checking 
procedure” in this section. Are batteries in good 
condition

Go to step 4.

Replace batter-
ies and recheck 
charging sys-
tem.

4

Using a DVOM set to measure voltage, place the 
negative lead on a good engine ground. Probe the 
Batt. terminal on the back of the alternator. Is 
voltage present?

12v

Go to step 8.

Go to step 5.

5

Using a DVOM set to measure resistance, mea-
sure resistance between the alternator case and a 
negative battery connection. Is resistance below 
specification.

<.2

Ω

Go to step 6.

Locate and 
repair bad 
ground connec-
tion.

6

Disconnect the positive battery cables, using a 
DVOM set to measure resistance, measure resis-
tance between the positive battery connection and 
the Batt. terminal. Is resistance below specification.?

<.2

Ω

Go to step 8.

Inspect/repair 
fusible link at 
alternator Batt 
terminal.

7

Does voltage gauge indicate a low charge condi-
tion?

Replace gauge 
and check oper-
ation.

No problem 
found at this 
time.

8

Using a DVOM set to measure voltage, and the 
pink ignition lead disconnected from the alterna-
tor, place the negative lead on a good engine 
ground and the positive lead on the pink ignition 
lead. Turn the ignition key to on, is voltage 
present?

12v

Go to step 9.

Locate and 
repair open or 
short to ground 
in engine igni-
tion feed circuit.                                                                

9

Check for expanded female terminal in engine 
harness connector in the alternator ignition feed 
connector. Is a faulty connection found?

Replace female 
terminal

Replace the 
alternator

4-1-00 

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 Electrical System  12-29

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05745159

Figure 12-52:   Alternator Schematic

9-S12-089

ALTERNATOR

FUSE

3B EXTERIOR

20 AMP

C4-3

PNK

EXTERIOR

POWER BUS

TO POSITIVE
BATTERY CABLE

TO EXTERIOR

FUSE BOX

TO INTERIOR

FUSE BOX

FUSIBLE
LINK

FUSIBLE
LINK

ORG

RED

TO

LOW COOLANT

SENSOR

HOT IN RUN AND START

BATTERY TERMINAL

IGN FEED

291

4-1-00

12-30

Electrical System

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STARTER 

Removal 

1.

Disconnect battery negative cable(s) and winch negative 
cable, if equipped.

2.

Remove converter housing cover.

3.

Remove cap and/or adhesive sealant from starter terminal
(Figure 12-53).

4.

Disconnect starter cable or cables from starter terminals
(Figures 12-53 and 12-54).

5.

Disconnect solenoid wire from solenoid.

6.

Remove starter cable clamp.

7.

Loosen locknut and washer securing stud at front of starter
to bracket.

8.

Have helper support starter and remove starter bolts. Then
lower and remove starter and shim (if used).

Installation

1.

Position shim pack on starter.

2.

Position starter in converter housing.

3.

Slide starter stud into chassis bracket. Be sure stud nut and
washer are behind bracket.

4.

Install and tighten starter bolts to 40 lb-ft (54 N•m).

5.

Tighten stud nut to 24 lb-ft (33 N•m).

6.

Attach starter cable clamp to chassis.

7.

Connect solenoid wire to solenoid terminal with clip and
screw. Tighten screw to 22 lb-in. (2 N•m).

8.

Connect starter cable to starter terminal. Tighten nut to 25-
31 lb-ft (34-42 N•m).

9.

Cover starter terminal and solenoid terminal with silicone
sealer.

10. Install converter housing covers.

11. Connect battery negative cable.

Figure 12-53:   Starter Mounting 

STARTER

STARTER

SOLENOID

TERMINAL

CLAMP

STARTER BOLT

CABLE

SOLENOID WIRE

CLIP

SHIM PACK

STARTER STUD

CHASSIS

BRACKET

4-1-00