Troubleshooting poor insert feed in Relay 2500, 3500, and 4500

Learn how to troubleshoot poor insert feed in Relay 2500, 3500, and 4500

Products affected: Relay™ 2500, Relay™ 3500, Relay™ 4500


Poor insert feed.


  • Feeder not selected to feed
  • Insert feeder side guides set incorrectly
  • Inserts loaded incorrectly
  • Insert feeder wedge used incorrectly
  • Inserts out of specification


  • Check job setup
  • Set guides to sheet width and back off 1/4 turn
  • Verify the two insert feeder adjustments (number and letter settings) are set correctly for the type of insert being run
  • Make sure to fan the stack before loading. It may help to change the orientation of the insert stack
  • Let the wedge slide down behind the insert stack for support
  • Check the specifications in this guide

UPDATED: 30 June 2021

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