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My 802a starts real well in the cold as well, never used the glow plugs. Perhaps if the batteries are low the start relay drops out when the starter engages, then comes back in when the load goes away.

Since the unit cranks well when the dead crank is used I suspect the battery and starter are OK. It sounds like the start signal to the starter is cutting out as soon as the starter is engaged and getting it back when it unloads. I would say that either the control ground (or power) is being...

If the gauge reads F with the float up and E with the float down you could bend the rod going to the float. That's what I did on my 802 along with moving the sensor up on the bracket. Mine was off the other way though.

You are right, the sensor must be wired backwards. The battery voltage would not be 27 if it were discharging. Does the ammeter approach zero if it runs for awhile and the battery voltage increase to 28 or so?

Rustystud's engine looks like a 4 and the OP's is a 6.

Any lost motion or binding in the linkage can cause surging.

Are you testing the rectifiers on the resistance setting? Try using the diode setting on the Fluke.