2.1 Starter System¶

System Configuration¶

Control Method: Two-stage relay system

Main Power Source: START battery+ direct connection (see START Battery Distribution for wire specs)

Control Solenoid: Cole Hersee 24213 (200A continuous-duty)¹

Safety Interlock: PBS-I keyless ignition module sources the crank signal (60A PURPLE START output). Brake interlock and RFID authorization are inside the PBS-I. A single external SPST WAIT-gate relay blocks cranking while the Cummins WAIT-to-Start lamp is on (cold-start grid heater preheat). See Keyless Ignition for the full architecture.

Battery Requirement: 800 CCA minimum (Odyssey PC1500 provides 850 CCA)

Wiring¶

See Keyless Ignition for PBS-I power, brake input, and WAIT-gate relay coil wiring.

Control Flow¶

Driver presses brake + holds Start Button (PBS-I-mounted)
            ↓
PBS-I (cabin) authenticates fob → asserts PINK IGN (ECM powers up) and PURPLE START
            ↓
WAIT-gate relay (NC): closed if WAIT lamp off → start signal passes through
                       open  if WAIT lamp on  → wait for grid heater to finish
            ↓
PBS-I PURPLE START → Firewall Pin 15 → Cole Hersee 24213 coil → Ground
            ↓
Cole Hersee main contacts close
            ↓
START battery → Cole Hersee output → Starter switch post → Bendix engages → cranks
            ↓
Engine starts → driver releases button → Cole Hersee de-energizes → Bendix retracts

Starter Motor Terminals¶

Battery Post (M8 x 1.25 thread, qty 2):

• Main power from START battery (2/0 AWG)
• Power tap for control solenoid (10 AWG)

Switch Post (6.3mm flat male push-on):

• Trigger from Cole Hersee 24213 output (10 AWG, 30-75A)

Ground:

• Via starter mounting bolts to engine block

Cole Hersee 24213 Solenoid¶

Specifications:

• Rating: 200A continuous duty¹
• Coil Voltage: 12V DC
• Coil Draw: ~0.69A (17.5 Ω coil @ 12V)¹
• Mounting: Firewall (engine bay side)

Terminals:¹

• Large Stud 1 (Input): 5/16"-24 copper power stud; from START battery post (10 AWG)
• Large Stud 2 (Output): 5/16"-24 copper power stud; to starter switch post (10 AWG; starter post is 6.3mm push-on)
• Small Stud 1 (Coil+): #10-32 steel stud; from WAIT-gate relay NC contact (16 AWG, gated PBS-I PURPLE START)
• Small Stud 2 (Coil-): #10-32 steel stud; to engine bay ground bus (16-18 AWG)

Outstanding Items¶

Starter-circuit-specific items are tracked in the Keyless Ignition doc and the TBD Tracker, since the crank chain is sourced from the keyless ignition design.

See installation checklist for build tasks.

Related Documentation¶

• START battery Distribution - Main power source
• Firewall Ingress - Ignition START wire routing
• Engine Bay Ground Bus - Ground connections
• Power Generation - Battery specifications
• Wire Distance Reference - Starter to battery routing distances
• Keyless Ignition - PBS-I sources PURPLE START; WAIT-gate relay gates on grid heater lamp