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Apologies.... somehow I missed this. After running the set with a can of Seafoam and a quart of ATF in the crankcase for about 30 minutes(in addition to a couple quarts of fresh oil) without load, oil came out less than ideal with a lot of gunk. Although it was a lower hour set(reset unit), it...

Is there any surge when it starts happening? or it just drags down to full stall? I had an 803 with a sticky IP rack, but it would surge prior to stalling under load. Also had an 803 with a sticky IP, but it pretty much did the same thing. The 802's since they have half the cylinders may just...

I know it seems kind of stupid, but are you sure that you are on 240v, and not 208v 3 phase? Just because the switch is in the correct position doesn't mean that internally it's not stuck in 3 phase mode. Check the output on the 3rd phase lug with power generation and see if it is showing any...