Starting Motor - To start an engine it is
necessary to make electric current flow to the
Figure 3.34 – Starter motor.
Figure 3.35 – Starter circuit at beginning of
current flow.
Figure 3.36 – Starter circuit immediately after the
motor starts.
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starting motor. Figure 3.34 shows that the motor
consists of a motor, a pinion gear and a magnetic
switch.
The starting motor is actuated by pressing the
start button or by turning the starting switch key
to the START position. Current begins flowing to
the starting motor to bring it to a gradual turn.
See Figure 3.35.
Immediately after the motor starts, a pinion starts
engaging with a ring gear on the engine flywheel
so that the motor can drive the engine.
Current from the starting switch flows through
terminal "C" to the magnetic coil. A magnetic
force generated in coil 2 overcomes spring 4 and
pulls plunger 3 to the right. Notice that the
magnetic switch coil consists of two coils, a
pull-in coil and a holding coil. When the plunger
is pulled, overcoming return spring 4 requires a
large force so current flows to both coils. After
the plunger is pulled, the auxiliary contact cuts
off current to the pull-in coil and a small current
continues to flow through the holding coil to keep
the plunger to the right. These two coils are
used to prevent overheating of the coils and to
reduce consumption of electricity.
Figure 3.37 – Starter circuit during cranking.
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When plunger 3 reaches the end of its stroke,
contacts 1 are closed and terminal "B" is
connected to terminal "M" of the switch. Now a
greater intensity of current can flow to the motor
via terminal "M", thereby increasing motor speed
up to its maximum.

When plunger 3 (Figure 3.39) is pulled to the

right, shift lever 5 (Figure 3.39) pushes shaft ring
6, clutch assembly 7 and pinion 8 to the left, Figure 3.38 – Starter magnetic switch.
where the pinion engages the ring gear to begin
engine cranking.

Safety Relay - Komatsu designed starter circuits

include a safety relay. This item prevents the
flow of current into the starter after the engine is
running. Even if the starter switch is
inadvertently turned on while the engine is
running, no current will pass through the safety
relay so the starter pinion and flywheel ring gear
are protected from damage.

There are two types of safety relays. The Figure 3.39 – Starter motor.
original version consists of coils and contact
points and the newer semi-conductor type.

The original safety relay looks very much like a

remote mounted battery relay. It has a shiny
black color and four marked terminals. These
terminals are labeled "B", "C", "A" and "S".

This type safety relay was remote mounted on

the engine compartment fire wall.

Figure 3.40 – Original safety relay containing coils

and contact points.

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March 2005 Page 3-15
The drawing in Figure 3.41 shows the contents of the original safety relay when the cover is
removed.

Figure 3.42 – Circuit diagram of original safety

relay. Key switch in ON position.

Figure 3.41 – Original safety relay.

The circuit diagram in Figure 3.42 shows the three coils, four contact points, two resistors and
five wiring terminals of the original safety relay.

When the starting motor switch is turned to START, current flows from terminal "C" of the
starting switch to terminal "S" of the safety relay coil "L1" switch "S1" and terminal "E".
When current flows to coil "L1", switches "A" and "B" are pulled down to make a circuit. Then,
current flows to the positive terminal of the battery at the "B" terminal of the safety relay switch
"A" switch "B" terminal "C" of the safety relay terminal "C" of the starting motor to rotate
the engine.

The drawing in Figure 3.43 shows current flow through the battery relay when cranking the
engine. The drawing in Figure 3.44 shows the same current flow using a schematic.

Figure 3.44 – Current through safety relay with

Figure 3.43 – Original safety relay – key in START key switch in START position.
position and current passing from “B” to “C”
terminals.

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If the key switch were held too long in the START position or if the starting motor switch were
inadvertently moved to the START position after the engine is running, current being generated
by the DC generator or by an alternator would cut the electricity to the starter motor to prevent
damage.

Figure 3.45 – Current from the alternator cuts the Figure 3.46 – Current through original safety relay
circuit to the starter. after the engine starts.

While the engine is running, the current generated by the DC generator or alternator flows to
terminal "A".

Alternator current entering terminal "A" flows through coil "L2" resistor "R2" terminal "E"
then to ground on the body. The flow of current through coil "L2" produces a magnetic force
which pulls switch "S1" to open its contacts. Therefore, when the engine is running and the
generator or alternator is generating electricity, the current which would normally flow from
terminal "S" to coil "L1" is cut off by switch "S1" and no magnetic force is produced in coil "L1".
Consequently, switches "A" and "B" do not contact and the starter does not rotate.

Semi-conductor type safety relay - There are

two designs of the semi-conductor type safety
relay, the combination type and the separated
type.

The combination type fits directly onto the starter.

As you can see in Figure 3.47 a bolt and holder
are provided for this purpose. Notice that there
are five wiring terminals. Each terminal is
attached as follows: Figure 3.47 – Combination type safety relay.

Terminal Location
E Ground
B B terminal of starting motor solenoid
C C terminal of starting motor solenoid
S From stating key switch C terminal
R From alternator R terminal

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