There this is the problem with rental decks, one they are hard to learn the ins and outs in a short amount of time you have them and the manuals are not that straight forward, took me a while to figure out how to set the SD out to 16:9.
The Kona outs were dead on, deck meters were -20 with tone coming in. the problem when the audio people were monitoring audio out from the deck to their pro tools systems, there was always a 1.3/1.5dB boost in the levels. On deck playback the meters did seem to be going over -3dB (where the program peak was set.
We sent a QC tape off in the beginning and it passed so this may have to much to-do about nothing. So the deck is going back to the rental house without much chance of finding if or where the problem was. Thanks for you help.
When you go through these things it makes that $300/hr charge for HD layoffs worth every penny of it. Give a hard drive to service bureau and let them do there thing.