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And that overload came out of a machine that I swapped overloads on, only to not solve the problem (similar to what you are fighting, but different). So it should be solid... if its not I stand behind it. But I believe it won't be that part.

How about the burden resistors, have you tested them?

I wonder if you cleaned out something that was preventing the burn up prior (so the current again flowed properly after cleaning) or if the burn up was present, but its time was just up to be discovered.

The switch might be bad too... but its more likely a corrosion/contamination issue.

Soak, cycle dozens of times, soak, cycle a dozen times, soak, drink a beer, cycle, soak... that Deoxit is great stuff. Clean until you get tired of cleaning. If it were me, I would also be cleaning all of the terminal board connections in that same rear control area at the same time!