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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 (85A continuous-duty)

Safety Interlock: PMU24 state machine (OUT24) supplies a hardware crank chain — push button + brake pedal switch + Turbolamik P/N relay + engine-running lockout (all four gates required). See Keyless Ignition for the full architecture.

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
Crank Chain Supply PMU OUT24 Dash push-button supply (cabin) 18 AWG ~1.6A Asserted by PMU state machine; routed through firewall to cabin
Push Button Output Dash push-button Brake switch (start tap) 18 AWG ~1.6A Cabin
Brake-gated Start Brake switch (start tap) Firewall Pin 15 → P/N relay contact 18 AWG ~1.6A Via Deutsch HDP24-24-21 Pin 15
P/N Relay Coil Turbolamik P/N aux output P/N interlock relay coil 18 AWG ~0.1A Engine bay; energized when shifter in P or N
P/N Relay Output P/N interlock relay (NO) Engine-running lockout relay 18 AWG ~1.6A Engine bay
Engine-Run Relay Coil Alternator B+ (filtered) Engine-running relay coil 18 AWG ~0.1A Diode + zener filter; >13V threshold = engine running
Lockout-gated Drive Engine-running relay NC Cole Hersee 24213 coil+ 16 AWG ~1.6A NC contacts: closed when engine off, opens once running
Solenoid Coil Ground Cole Hersee 24213 coil- Engine bay ground bus 16 AWG ~1.6A ~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

Control Flow

PMU OUT24 (Ignition Authorize) → Push Button (cabin) → Brake Switch → Pin 15 (firewall) →
                                                          P/N Relay (coil = Turbolamik P/N) →
                                                          Engine-Running Lockout Relay (NC, coil = alternator) →
                                                              ↓
                                                          Cole Hersee 24213 Coil → Ground
                                                              ↓
                                                          Solenoid Closes (all four gates asserted)
                                                              ↓
                              START battery Post → Cole Hersee Output → Starter Switch Post
                                                              ↓
                                                          Main Solenoid Engages
                                                              ↓
                                                              Starter Cranks
                                                              ↓
                                                  Engine starts → alternator output rises →
                                                  Engine-Running Relay opens → Cole Hersee de-energized

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: 85A continuous duty
  • Coil Voltage: 12V DC
  • Coil Draw: ~1.6A
  • Mounting: Firewall (engine bay side)

Terminals:

  • Large Stud 1 (Input): From START battery post (M8 terminal, 10 AWG)
  • Large Stud 2 (Output): To starter switch post (6.3mm female push-on, 10 AWG)
  • Small Terminal 1 (Coil+): From engine-running lockout relay NC output (16-18 AWG)
  • Small Terminal 2 (Coil-): 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 new crank chain is part of the keyless ignition design.

See installation checklist for build tasks.