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You know, a 5 hp shaper is a darned big shaper! It would be fun to visit your wood shop sometime. What do you make there?

There's really very little in the way of electrical equipment that would be bothered by the frequency being a few Hz off of 60. Mainly old motor driven clocks. Modern electronic equipment like TVs, DVRs, and computers have power supplies that make DC for all the internals, and those power...

Wiring resistance won't change the AC frequency, so if it read 40 when the frequency was really 60, something is wrong. You're right about starting current. That can easily be 5 times running current. I've actually measured industrial 3 phase motors that draw about ten times their running...

This probably isn't your problem, but... the frequency meter will read very erratically if the engine speed is very far from 1800 rpm, sometimes reading full scale one way and/or the other. Have you verified that the engine is really running 1800 rpm?