R&D has fixed this in future versions of 6.2, AR 16821 (Provide shared library for zlib on AIX). For now you can use the attached tar file of zlib libraries. Just untar into $HCIROOT/lib. Backup the existing files if you like.
To route a reply to a different thread in 6.1 or greater you need to uncheck the “Route Replies to original source only” box in the process. It’s a common gotcha when doing reply routes in newer versions.
If this is on windows, I’ve found that the Adobe Acrobat solution has to have a logged in user to the windows desktop, so it isn’t feasible within Cloverleaf.