Its only a thought but most of the problems seem to stem from what is present in the way of live feeds to and from the ignition switch. Has the ignition switch/barrel ever been dismantled? We had a situation a while ago on a machine where the plastic bit on the back of the switch had been tugged out and one of our guys just shoved it back on and bent the tags over again. This in effect had wrongly indexed the barrel to the switch and had the starter engaged all the time.<cost me a starter> but a lot more in time finding the fault.
Just thoughts.
Bob
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