Ryobi 525H start-up issue

We have been having intermittent issues with our #4 unit on our 525H where it appears that one of the forms does not fully kick on. What happens is that on start up, the print looks washed out on the non-operator side then we stop and restart and everything is fine. On a small run this could cost us too much stock and we end up short. We had a tech in twice, but as I said, it is intermittent. It may not happen for a few days then it occurs 5-6 times in an 8 hour shift. He swapped some solenoids, we installed new forms thinking one or more was long and hanging up. We have greased oiled all without luck. Any thoughts or suggestions?

Thanks!

 

Have you checked form to plate stripes? Better yet, check form to oscillator pressure. There isn't too much room for error on the 500 series presses and if form to oscillator is heavy it will cause the form roller not to drop. Go over your pressures and see what happens.