as rojec said the firmware installed on unit is correct and do not update/change it ,,as to unable to replace it for now .
have you tried running it in Cross demo to see if it behaves same ,,
you are trying to eliminate the problem ,,which is you ask ,,mechanical or electrical .. mechanical will be caused from overuse/extensive use ,, led/lights you probably can live with ,, elimiate the electrical before you go tearing the controller apart for lights,, this unit is years old and even thought it fit a great niche,,parts and repair of mechanical are non existent ,,gonna re read you post and see if anything is in common with known issues ,