Header problem with photosmart 8180 when printing with company letterhead

I print many letters through MS Word 2003.  When I print a letter on plain paper, it looks fine and is the correct distance (1 1/2") from the top of the page(s).  Our letterhead consists of a 1" dark band with our logo included and our address across the bottom of the page.  I then insert our letterhead to print a final, the printer moves the letter (date, name, address and body) down another 1", meaning the printer is using the bottom of the band to measure the top margin.  It also ignores the bottom margin of 1" and just prints into the address, instead of going to the next page.  Both types of paper are the same 8 1/2 X 11.
We have Konica network printer and I previously had a HP 930 printer and never have seen this before.  I have uninstalled the printer and reinstalled and the only change I have made since is to change the the paper type, under "Print", "Properties", "Features", "Paper Type", from Automatic to Plain Paper.  Neither helps. 
I have an extended email list with HP Customer Care, telling me everything from installing a 990C driver (or virtual printer?) to have me check to make sure I knew how to load paper. 
I then spent over an hour on the phone with an HP rep and even gave him control of my computer, to no avail.  He thinks he fixed the problem by having me reduce the top margin, to say 1/2" and basically trick the printer into printing at the correct place below the band, but the second page is now too far up because of that.
I hope someone can help.  I found it hard to believe that this has only happened to me. 
Thanks for any help.
Dean

Hello,
at first, what kind of intemec priter do you use? Is it host or stored ipl mode?
value for intermec pm4i in host mode:
my suggestions is the labelsoftware for this printer and the addon tool for r3.
Best regards,
Nino

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