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Got the cattle fed before the snow began again. Had my brother in law verify the battery cables. All was correct there. I toggled the dead crank switch from NORMAL to OFF and back to NORMAL. Then went to show him how the panel was dead, but it wasn't dead this morning... Turned the master...

Thanks Ray70, I'll run through those checks tomorrow.

Thanks for confirming my thought process. I went through most of that in my first post. Seems like something may have failed before/during the battery change.

Got the TMs. I'll work through the ENGINE FAILS TO CRANK portion of the -24 tomorrow.

Yes, the batteries are in series to make 24v. After charging the lower battery, I'm reading 24.7v at the slave receptacle. No change to the panel after charging.

I tested the voltage of the new batteries. One was 12.25 and the other was 11.77, so I hooked a charger to the one that was low.

A month ago, I noticed that the 803 at my in-law's ranch was slow to turn over when the air temp was below freezing. The batteries were 6 years old, so I decided to replace them next visit. Later that day after temps warmed up a bit, the gen started and ran fine for about an hour. Today, I...

I'll take one.

£24.00 each plus £26.00 shipping. Looks like you could get a pair today shipped to the USA for about $85 based on the current exchange rate.

Here's a possible prefab option. I haven't tried this personally, and it seems expensive, but the dimensions seem fairly close: https://www.auroragenerators.com/product-page/50-gallon-sub-base-fuel-tank

When replacing the small return line, it can be a bit of a struggle to get the hose onto the plastic tees above the injectors. I've found that adding 1 drop of diesel in the end of the hose helps lubricate and makes it easier to push the hose on.

Any chance the starter is hanging up and becomes a load? What happens if you remove the starter and try to pull start it?

Is your 802 sitting on the ground or mounted on a trailer, etc? I had an 802 that shook like crazy when it was on a 803-sized dolly made of 2x6's. The wood had too much flex to it. It got much better when I put it on a concrete floor. Later I mounted it on a small trailer and between the tires...

Assuming you're on a relatively flat surface, I'd jack it up and put it on a couple 2x6's and some caster wheels. Just use a floor jack to pick up 1 end at a time. Make sure you support it with jack stands or cribbing. Then put the wheels under it and let it down. Worst case, it has a skid...

Do you know how far down the pump is? I'm curious if the length of wire down to the pump is causing voltage drop.

Sorry, I'm out of ideas.

I'm not familiar with this genset either. Can you take another picture of the panel, but zoom out a little more so you get the whole thing? Does it have a Battle Short switch that you can use to temporarily bypass this fault? What is the normal starting sequence? Do you have to hold the start...

How's the oil pressure?

If the little black fuel return line hose is leaking or weeping, you should be able to see that when the fuel pump is running, even if the engine is off. You mentioned before that the engine quit while you were away, but the fuel pump was still running when you got back. Perhaps there is a fuel...

Nice score! That ought to extend your runtime quite a bit.