Although the supply is behaving like it's under-loaded, there could be 
another culprit: noise.

I've looked at the schematic, and it's possible that the PCB layout could 
be injecting excess noise into the MAX1771. Is the bypass cap C3 located as 
close to the 1771 as possible ?  I think C4 should be close to the 
inductor. Be sure to check the power supply pins of the 1771 with your 
scope.

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