We have a KM_5530 that is creating a small void at the lead edge side about a quarter of the way down the page only when pulled from th first cassette. The customer is using either legal or ledger paper and it does it every 3 to 5 copies. We have changed all the clutches including the registration, all feed clutches up and down the side feed as well as new feed unit and guides.

Any suggestions

Unless the image is also shifted 1/4 of the way down the page, I say you have been barking up the wrong tree.

Go to basics, replace the transfer/separation charger housings.

EDIT: Reread the post, and now understand this to be a blank area on the copy 1/4 of the way down, possibly with print ahead of this.

I still recommend the housings first in case there is shorting going on with the transfer. How about a duplex copy?

Clean the suction deck bushings.

I'd agree with Mark B. as well. I have seen those bushings cause this numerous times. They gum up and the belts stop turning smoothly and the paper buckles.

Still having the problem, nothing seems to work, gonna refer to the manufacturer

I had a similar problem as you describe. About 2 or 3 in 20 would be good the rest had Z-fold type voids of varying intesity. About 1 in 20 wouldn't make it through the machine. Reg didn't vary much. Never fixed it...machine was due for replacement, but before that we did throw cluthes, switches, labor and guides at it. We looked at T/S and main ch...like I said we never fixed it, but reading about TroyL's experience makes me wonder about this problem. My machine had its engine PCB replace a week or 2 prior to this symptom appearing, maybe this could be a fix like his, check his post out.

http://dnet-km.com/eve/forums/a/tpc/f/9126013712/m/7041026372

I'd be interested with what you find