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I'd suggest performing the AC Voltage Regulator Test per the -24 TM.
Be sure to use the correct test procedure. The 804's were built with two different AC Voltage Regulator systems.
Libby & TRC. Different test procedures depending on which VR is in the set.
You'll also want to verify someone...
If no mouse issues or chaffed wires then I'd highly suspect one or more of the contacts in the Phase/Voltage switch are welded closed. Each switch contact relies on a tiny spring to open the contacts.
You need to close the circuit interruptor using the toggle switch on the front panel to get power to the lugs.
Wait 5 seconds after starting the 831 before lifting and releasing the switch.
There are three relays behind the drop down meter panel. They all have a tiny LED in them.
After your start the 831 which relay(s) have their LEDs illuminated?
Also, after you start it are there any fault lamps illuminated on the Fault Monitor?
TM indicates: Four-gallon fuel tank (allowing 8 hours of continuous operation at full load)
You'll want to mouse proof it to keep those Bastids out.
Running for days on end will require an auxiliary fuel tank for it to draw diesel from.
Oil is supposed to be changed every 100 hours of...
The circuit interrupter switch is pretty reliable.
The outlet is hardwired so it only has 120 volts on it all the time. The little red switch only changes the power at the lugs.
You'll need to connect L0 to you electrical systems neutral. If you don't the two 120 volt branches voltages will...
Did you lift and then release the Contactor toggle switch to close the contactor after it's started and running for 10 seconds?
Opening the door to access the lugs does not cut power to them.
Here are where the items are tested in the -24 TM
Fuel Level Gauge Testing Para 2-39
Fuel Level Sender Testing Para 2-76
Temp Gauge Testing Para 2-40
Temp Sender Testing Para 2-92
The control box (DCS) do go bad. One issue is they are supposed to be sealed to keep moisture out. Unfortunately sometimes moist air works its way in, condenses and causes corrosion.
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