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I couple things can cause that. CMYK mode Too high or too low Latex optimizer settings. Lower passes. Black generation in your profile for CMYKcm mode where black start is at 0 or low percentages. I like to use 30% if I want to avoid graininess.

When you printed the "Latex optimizer check plot" what did the different values look like and did they make any difference. Also what was you ink density set at.

That old of a machine there could be a number of things causing your yellow problem. Hope someone has had similar experiences and can point you in the best direction to look.

If you can barely see the yellow in some areas late would indicate a problem. Probably in just one head though and the heads should be under warranty if you just changed them.

So now you have found the problem. Replace the printhead!

Hopefully you have taken the steps necessary and am acquiring the hardware for proper color management and are confident that you can produce the same color matching a quality that you have been suppling your client.

What spectro are you using? It could be a problem with the measuring instrument.

I that case most likely you have a color management setting wrong. Probably your RGB input profile is not the correct one for the file your printing. Maybe you have AdobeRGB set but the file was create with sRGB working space or vice versa.

The gray samples you posted are just different percentages of grays not a gray to white gradient. The gray percentage samples looked to be off in the midtones. So I think you need to explain why you now say "Printing GRAY is no issue". Are referring to process gray verses black channel only grays?

The real question you need to ask yourself is, do you have the time for the extra work of printing and the finishing involved?

A-Korn Roller did a recoat of a Seal Laminator roller a few months back for me for around $1K.

If you don't want to do basic color maintenance (re-linearazation/calibration) on your printers then I guess you have to live with it or hire someone who does.

Rotate the print and see where it shows up. Same place on the printer or same place on the print will indicated if it is a printer or RIP problem. Have you cleaned the encoder strip. Also how much ink has gone through your lc/lm printhead? Also try if in CMYK mode. Will be a more grainy print...

How often do you do the head alignment? And have you eliminated that it might be from the RIP?

Better check how many nozzle clogs you have before you try anything else. And, replace printheads as needed.

I am sure you already have a linearization. Re-linearization is what you want to do. If creating new output profile then you want to do a new linearization.

Or, you can set in the RIP to print your grays using black only. But, if you choose to print CMYK grays then a proper linearization and profile has to be created, and linearization/calibration has to be maintained. But, Color Monkeys don't seem to be able to grasp this. And, don't forget the...

Are you at least doing a re-linearization?

Are you creating your own profiles?

Not anything like that happening here.