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2.1 Starter System

DB Electrical 410-52442 Starter

Type: High-Torque Diesel Starter

Model: DB Electrical 410-52442

Manufacturer: DB Electrical

Product Page: DB Electrical 410-52442

Voltage: 12V

Power: 2.7 kW

Rotation: Clockwise (CW)

Teeth: 10-tooth pinion

Mount Type: PLGR (Planetary Gear Reduction)

Weight: 19 lbs

Mounting: Engine block (PLGR mount)

Power Source: START battery+ direct connection (2/0 AWG)

OEM Cross-Reference:

  • Cummins: 4996706
  • Denso: 428000-7090, 438000-3110
  • Isuzu: 5-128000-980

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: The crank signal (60A PURPLE START) comes solely from the PBS-I keyless module, which owns RFID authorization, the brake interlock, ACC/IGN/START sequencing, and the cold-start WAIT-to-Start lamp procedure — see Keyless Ignition. (An automatic crank lockout was evaluated and deferred — see the WAIT-to-Start Lockout Design Note.)

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

Wiring

Circuit Source Destination Wire Gauge Current Notes
Main Power START battery+ Starter solenoid battery post 2/0 AWG 400-600A See START Battery Distribution for wire specs
Solenoid Power Tap START battery post Cole Hersee 24213 input 10 AWG 30-75A ~2 ft
Start Signal PBS-I PURPLE START output Firewall Pin 15 → Cole Hersee coil+ 16 AWG ~0.69A PBS-I output rated 60A but only Cole Hersee coil downstream1
Solenoid Coil Ground Cole Hersee 24213 coil- Engine bay ground bus 16 AWG ~0.69A ~3 ft
Solenoid Output Cole Hersee 24213 output Starter solenoid switch post 10 AWG 30-75A ~2 ft
Ground Return Starter case Engine block → START battery- 2/0 AWG 400-600A Via engine bay ground bus

See Keyless Ignition for PBS-I power and brake input wiring.

Control Flow

PBS-I asserts PURPLE START  (fob auth + brake + sequence: see Keyless Ignition)
            ↓
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 → button released → 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 Firewall Pin 15 (16 AWG, PBS-I PURPLE START)
  • Small Stud 2 (Coil-): #10-32 steel stud; to engine bay ground bus (16-18 AWG)

Outstanding Items

🔴 Critical (2)

High (7)

📋 Medium (3)

  • Horn button → PMU In 1 wiring path through steering column (#152) — PMU In 1 (horn request) lists "steering wheel button" as its source, and the horn page puts the button on the steering-wheel PTT bracket — but no wire path, gauge, or connector is defined for how the button contact reaches PMU In 1 through/around the steering column. Street-legal item with an under-specified signal path.
  • iBooster Wiring Harness Selection (#105) — Select the Bosch iBooster (Gen 2) wiring harness: Tulay's Gen 2 universal (plug-and-play) vs EVcreate Gen 2 connector kit (DIY). Decision pending donor arrival and pigtail condition inspection. Tracked in the purchase tracker but was missing a TBD issue.
  • Axle Brake Flex Hose Length (#86) — DOT (FMVSS 106) braided-stainless extended-length flex at each axle - length blocked on axle + suspension selection (Section 10); size to full droop, do not cut until ride height fixed

🔍 Verify (5)

  • iBooster standby current spec (ignition-off test value) (#151) — The engine-systems testing checklist includes "Verify iBooster standby current within spec (ignition OFF)" but no standby-current spec value is documented anywhere (the brake-booster page does not state one). The test step cannot be completed as written.
  • WAIT-to-start lamp polarity: ECM Pin 35 active-low vs HDX input active-high (#150) — ECM Pin 35 (WAIT lamp, yellow) is active LOW (~0V when WAIT on, ~+12V off); the HDX indicator input is documented as active HIGH. If wired without resolving this, the cold-start indicator reads inverted — and the documented cold-start procedure depends entirely on watching the WAIT lamp.
  • Restomod Air HVAC integration — verify A/C request wiring to PMU In 9 + blower draw (#146) — The factory TJ HVAC is replaced by a custom Restomod Air electronic HVAC kit (ordered, owner-confirmed 2026-06-11) — this resolves the original "no A/C request source post-PCM-delete" gap. Restomod Air kits are fully electronic (servo-driven doors, no vacuum), and the control head generates the A/C request: compressor-engage output (12V) → trinary pressure switch (30/406 psi cutouts) → PMU In 9. PMU logic then drives OUT17 → compressor clutch.
  • AMOT 4261M 2.8″ intake air-path connection OD / reducer coupler to 2.125″ turbo inlet (#129) — The 4261M02 is a wafer butterfly valve that sleeves into a 2.8″ (71 mm) nominal intake duct; the AMOT datasheet (4261M_Air_Shutoff_Valve_0119rev2) publishes only nominal size (71 mm), bore (61 mm / 2.4″), and overall envelope — not the air-path spigot/wafer OD or clamp interface. The NPT thread in part number 4261M02A027-AA (actuator code 27) is the pneumatic control port, not the air path.
  • Grid Heater Current (#42) — Design value 80A - verify via element resistance measurement during installation (~0.15 ohm @ 12V).

  1. Littelfuse (Cole Hersee) 24213 continuous-duty SPST solenoid, product page / DigiKey #6347082. Rated 200A continuous with two 5/16"-24 copper power studs + two #10-32 steel coil studs; coil ~0.69A @ 12V (17.5 Ω). Corrects the earlier unsourced "85A / M8 / 6.3mm-push-on" figures (validated 2026-05-30). 200A is comfortably oversized for the ~10A starter-trigger path. ↩↩↩↩↩