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This is the pickup list I put together from member's input found earlier threads before my first recovery. Let me know if you want the MS Word version so you can edit it.
If you can take a wire off the rear battery directly to the starter solenoid and start the vehicle then trace that wire that during a normal start would feed 24v to the starter solenoid all the way to it's source of 24 power. Clean and tighten all connections you find.
Did you replace the...
I am not a diesel mechanic, I don't play one on TV and I did not sleep in a Holiday Inn last night but based on this statement and the photographs "the truck stops, engine knocks, no power, black smoke and goes out," I think it is over fuel in that cylinder.
You said the IP had issues including...
I put a 35A SPST switch in the 24V line from the starter relay to the starter solenoid to use as an emergency disconnect if the relay sticks closed. I have tested it while cranking the motor and it does indeed stop the starter motor. I have not measured the actual current flow through the 24V...
Good news indeed.
I installed a 35A SPST switch in line with the 24V power coming from the starter relay. If my starter relay sticks I can flip that switch off and cut the power going to the starter solenoid on the starter (I have tested it and it does indeed cut off the starter while cranking...
Congratulations.
Those guys who live close to the sites that auction 50 trucks a week don't understand what its like not to live close to one of those sites.