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OP might have been measuring the AC frequency out of the MPU to see the RPM drift up.

All 3 PCB designs in production. Should be getting bare PCBs back in about a week. I also submitted the design for a 002A 003A Voltage Regulator for fab.

When you move S1 to PREHEAT a contactor (relay) closes sending power to the glow plugs. That's the click/clunk you hear.

I suspect the switch is missing this jumper... Here is the OP's switch. I don't see the jumper on it..

Ah, so your switch needs a jumper or two. Terminals 2 & 4 should also have 24 volts on then in STOP. S1 terminals 2,4,6,8 need to all be jumpered together. Add jumpers as needed so you have 24 volts on 2,4,6, & 8 with S1 in STOP.

With S1 in STOP be sure S1 terminals 2,4,6 & 8 have ~24 volts DC on them.

It's worth a shot to dry the main circuit board and seal the 12 or so potentiometers on it. The rest of the board is well potted. It's just the potentiometers that aren't potted or sealed. The main board is on the engine side of the inverter. As I recall you have to take the top panel and...

My money is on the diode CR5 is reversed on S1. The striped end of CR5 should be connected to terminal 1 of S1. The non striped end of CR5 should be connected to terminal 7 of S1.

edit: Kits in stock ready to ship.

Post #57 updated with contact info at Mecc Alte for purchasing the gen head.

Excellent, thank you!

When you put S1 in START does the Fuel Shutoff Solenoid fully retract? Like this.... This is the extended fuel solenoid when set is stopped

I've never seen an 803A like that. Besides the EasyGen the front panel switch and gauge layout is different from "normal" 803A's. Following...

Genius! :)

edit: Kits in stock ready to ship.

Ray, Yes, that's the box it's in. I posted up in case someone had theirs open or someone had an A5 laying around and to save you the trouble of tearing into yours for it.

OK, now I only need 1 measurement on the 004A A5 card. It's the hole center to hole center between either the right 2 mounting screws or the left two screws. Could someone take an accurate measurement of it for me? This...

Ray, Thank you for those measurements! Another step closer to finishing the 3 designs.

Can someone measure one of the 002A or 003A A4 cards and let me know the mounting screw locations? Horizontal distance between mounting screws. Vertical distance between mounting screws. I assume the layout of the 4 screws is symetrical. Distances need to be accurate, not approximate.

I'll look into those too.