Pitney Bowes Relay 5000 folding issues

[Bobk]

We run a job every quarter on our 5000 that is 4 sheets of 60lb offset half folded into a 6x9 env. We have an issue with the folding unit. It will fold the sheets down to 5.5 and then fold in half again. PB mechanics have thrown every mechanical part they could at the problem and no luck. Letter fold and Z fold work fine. Has anyone encountered this problem? We have been running this same job on the same stock for 4 years and just recently had this issue.

 

[TJPrinter]

Could it be that the 5000 isn’t calculating the size of the sheet or the size of the envelope correctly and folding again to make it fit. What if you tried entering custom sizes instead of letting the 5000 determine sheet and envelope size.