Dink,
This is deja vue of the problem I had with mine before Mike replaced the receiver (after 3 trips back to Mike to try to fix the problem).
Gun would work 100 % in semi.
In FA mode it would stop with a round chambered but hammer forward, round had slight firing pin dimple in it. This would happen 7 or 8 times in a hundred round belt.
My sear pack worked 100% in FA mode in MP5, MP5K-PDW, HK21, C-93.
Before the problem, gun worked with TULA and Wolf very well.
Gun would not work properly either with XM193, Wolf or Tula after the problem, all brands had the failure in FA mode.
The conclusion I came to was that the gun somehow was tripping the FA sear too early, the hammer would then follow the bolt home resulting in a no fire situation. Manually checking the action sequence by slowly allowing the bolt to move forward within the receiver under control with the cocking lever showed everything working as it should. Timing seemed spot on, hammer would release in FA mode when it was supposed to. But in live FA mode fire - repeated failures.
Mike tried moving the trip point on the bottom of the bolt back slighly by cutting it with a mill. Didn't change the problem. He put a much stronger spring on the sear, so much so that it was hard to uninstall and reinstall the sear into the trigger pack. Didn't change the problem. Each time the gun was returned to me Mike would say it was fixed. Within a few hundred rounds the problem was back.
I had sent the sear pack along with the gun a few times.
Mike would say "It works in my testing, it is fixed" "Yours was one of the first 5 guns made, the early guns did have some problems"
"you are the only one having this issue" "Had some heat treat problems with early components"
But on the last trip back when he tested it, he got the same problem. Would only fire one round in FA mode. That is when he said he would replace the receiver under warranty. I got the "new" gun back and it worked for about 300 rounds and then the hammer broke in two (just like the picture in the thread).
Put a new retimed hammer (from HK Parts) in and the gun was back to works in semi mode only. Took the buffer out of the stock and it was cracked 3/4 of the way around. Sent buffer and broken hammer in to Mike. Just got the replacements a week ago and so far the gun is back to working in FA mode.
Sorry to be so long winded about this but our situations sound very similar, thought the detail might help.