Pitney Bowes DM300c series User manual

DM300c/DM400c/DM450c/DM475
Digital Mailing Systems
Service Manual
US English Edition
DM400c/
DM450c
DM300c
DM30
DM475

The use of this information by the recipient or others for purposes other than the repair, adjustment or operation of
Pitney Bowes equipment may constitute an infringement of patent and/or other intellectual property rights of Pitney
Bowes or others. Pitney Bowes assumes no responsibility for any such use of the information.
Except as provided in writing, duly signed by an officer of Pitney Bowes, no license, either express or implied,
under any Pitney Bowes or any third party’s patent, copyright, or other intellectual property rights is granted by
providing this information.
NOTICE!
April, 2010
©2007, 2010 Pitney Bowes Inc.
Due to publication lead times and continuing product development, this manual may not reflect final product release configurations
and recommended service procedures. Equipment and material specifications as well as performance features are subject to change
without notice. Available product features may vary, depending on machine model, system software level and system setup. Some
product features may be country specific.
Postage By Phone and E-Z Seal are trademarks or registered trademarks of Pitney Bowes Inc. ENERGY STAR is a registered
trademark of the United States Environmental Protection Agency. Other company names, products or services mentioned herein may
be protected by trademarks, registered trademarks or service marks and are the property of their respective owners.
All rights reserved. This book may not be reproduced in whole or in part in any fashion or stored in a retrieval system of any type or
transmitted by any means, electronically or mechanically, without the express written permission of Pitney Bowes.

FCC Part 68 Compliance of the Modem
This equipment complies with Part 68 of the FCC rules and the requirements adopted by the ACTA. On the
bottom of this equipment is a label that contains, among other information, a product identifier in the format
US:AAAEQ##TXXXX. If requested, this number must be provided to the telephone company.
This equipment is designed to be connected to a Facility Interface Code 02LS2 network with RJ11C network
interface.
A plug and jack used to connect this equipment to the premises wiring and telephone network must comply
with the applicable FCC Part 68 rules and requirements adopted by the ACTA. A compliant telephone cord and
modular plug is provided with this product. It is designed to be connected to a compatible modular jack that is
also compliant. See installation instructions for details.
The ringer equivalence number (REN) is used to determine the number of devices that may be connected to a
telephone line. Excessive RENs on a telephone line may result in the devices not ringing in response to an incoming
call. In most but not all areas, the sum of RENs should not exceed five (5.0). To be certain of the number of devices
that may be connected to a line, as determined by the total RENs, contact the local telephone company. The REN
for this product is part of the product identifier that has the format US:AAAEQ##TXXXX. The digits represented by
## are the REN without a decimal point (for example, these models are 10 which is a REN of 1.0).
If this equipment causes harm to the telephone network, the telephone company will notify you in advance that tem-
porary discontinuance of service may be required. But if advance notice isn’t practical, the telephone company will
notify you as soon as possible.Also, you will be advised of your right to file a complaint with the FCC if you believe it
is necessary.
The telephone company may make changes in its facilities, equipment, operations, or procedures that could af-
fect the operation of the equipment. If this happens the telephone company will provide advance notice in order
for you to make necessary modifications to maintain uninterrupted service.
If trouble is experienced with this equipment, please contact Pitney Bowes, 1 Elmcroft Rd., Stamford, CT
06926-0700, for repair or warranty information (also see Servicing section above). If the equipment is causing
harm to the telephone network, the telephone company may request that you disconnect the equipment until
the problem is resolved. This equipment is not intended to be repaired by the customer (user).
Connection to party-line service is subject to state tariffs. Contact the state public utility commission, public
service commission, or corporation commission for information.
If the installation site has specially wired alarm equipment connected to the telephone line, ensure the instal-
lation of this mailing machine does not disable the alarm equipment. If you have questions about what will dis-
able alarm equipment, consult your telephone company or a qualified installer.

Declaration of Conformity According to FCC Rules Part 2 , Paragraph 2.1077
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this de-
vice may not cause harmful interference, and (2) this device must accept any interference received, including interfer-
ence that may cause undesired operation. Responsible party: Pitney Bowes, 1 Elmcroft Rd., Stamford, CT 06926-
0700.
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the
FCC Rules. These limits are designed to provide reasonable protection against interference when the equipment is oper-
ated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause interference to radio communications. Operation
of this equipment in a residential area is likely to cause interference in which case the user will be required to correct the
interference at his own expense.
CAUTION: Changes or modifications to this equipment not expressly approved by the party
responsible for compliance could void the user’s authority to operate the equipment.
Shielded I/O and USB cables must be used with this equipment to ensure compliance with the limits. Use of unshielded
cables is prohibited.
Note for California Customers Only
The battery in this product contains perchlorate material. California requires perchlorate-containing products to be accom-
panied by the following notice: Percholrate Material - special handling may apply.
See: http://www.dtsc.ca.gov/hazardouswaste/perchlorate/

Table of Contents
DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D) i
Chapter 1 – Introduction
1.1 Purpose.......................................................................................................1-1
1.2 Related Publications/Information.................................................................1-1
1.3 Book Organization.......................................................................................1-1
1.4 Warning Messages......................................................................................1-1
Personal Safety...........................................................................................1-2
Electrostatic Discharge (ESD) Procedures .................................................1-4
Chapter 2 – Specifications
2.1 Product Description.....................................................................................2-1
2.2 Product Features.........................................................................................2-2
2.3 Material Specifications.................................................................................2-3
Material Spectrum.......................................................................................2-4
Envelope Size .............................................................................................2-5
Envelope Thickness....................................................................................2-5
Envelope Weight.........................................................................................2-5
Tape Strip Dimensions ................................................................................2-5
Tape Strip Thickness...................................................................................2-5
Tape Strip Capacity.....................................................................................2-5
Stack Height and Weight.............................................................................2-5
Envelope Flaps............................................................................................2-6
2.4 Ink Capacities, Consumption and Cartridge Life.........................................2-7
Capacities and Print Consumption..............................................................2-7
Maintenance Consumption..........................................................................2-7
2.5 Equipment Specifications............................................................................2-7
Size and Weight..........................................................................................2-7
Acoustic Noise Level...................................................................................2-7
General Machine Specifications..................................................................2-8
User Interface Controller.............................................................................2-9
Connectivity.................................................................................................2-9
Postage Meter...........................................................................................2.10
Environmental Limits.................................................................................2-10
2.6 Regulatory.................................................................................................2-11
Electromagnetic.........................................................................................2-11
Safety........................................................................................................2-11
Compliance ...............................................................................................2-11

Table of Contents
ii DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
2.7 Weighing Options......................................................................................2-12
2.8 External Printer Option..............................................................................2-12
2.9 Special Services Options...........................................................................2-12
2.10 Graphics (Slogans, Permits and Inscriptions) .........................................2-12
2.11 Internal Ad and Inscription Storage..........................................................2-12
2.12 Compatible Pitney Bowes Software ........................................................2-13
2.13 Consumables (US)..................................................................................2-13
2.14 User-Replaceable Parts ..........................................................................2-13
2.15 Meter Reports..........................................................................................2-14
Chapter 3 – Theory of Operation
3.1 Introduction..................................................................................................3-1
3.2 Product Features.........................................................................................3-1
3.3 User Interface..............................................................................................3-2
LED States..................................................................................................3-2
Modes of Operation.....................................................................................3-3
3.4 Envelope Tape Transport.............................................................................3-4
DM400c /DM450c/DM475 Autofeeder Transport ........................................3-4
Tape Feeder................................................................................................3-8
Upper Transport ..........................................................................................3-9
Lower Transport ........................................................................................3-10
Sequence of Operation .............................................................................3-11
3.5 Ink System.................................................................................................3-23
Ink Cartridge..............................................................................................3-23
Print Head and Carriage Board.................................................................3-24
Carriage Assembly....................................................................................3-25
Purge Unit .................................................................................................3-26
Waste Tank................................................................................................3-29
User Maintenance.....................................................................................3-29
3.6 Electronics.................................................................................................3-30
PCBs.........................................................................................................3-33
Sensor Summary.......................................................................................3-41
Motor Summary.........................................................................................3-43
3.7 Scale Controller.........................................................................................3-44
3.8 USB...........................................................................................................3-44
3.9 LEDs..........................................................................................................3-44
3.10 DM475 Feeder/WOW Theory..................................................................3-45

Table of Contents
DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D) iii
Chapter 4 – Troubleshooting
4.1 Introduction..................................................................................................4-1
4.2 Troubleshooting Tables................................................................................4-2
Power ON and Initialization Faults..............................................................4-2
Keyboard and Display Faults ......................................................................4-3
Automatic Feeder Faults (DM400c/DM450c/DM475) .................................4-4
Mailing Machine Transport Faults ...............................................................4-5
Tape Feeder Faults .....................................................................................4-7
Printing Faults .............................................................................................4-8
Print Carriage Faults .................................................................................4-12
Moistener Faults........................................................................................4-13
Miscellaneous Faults.................................................................................4-13
Modem/Connection Faults ........................................................................4-14
Integrated Scale Faults .............................................................................4-16
4.3 Error Codes...............................................................................................4-17
Common Error Codes/Messages..............................................................4-18
iButton® PSD Error Codes (20xx) ............................................................4-30
iButton® PSD Error Codes (21xx) ............................................................4-31
Image Generator Errors (22xx) .................................................................4-32
Barcode Generator Errors (22xx)..............................................................4-33
Print Head Security Errors (23xx)..............................................................4-34
Print Manager Errors (24xx)......................................................................4-35
“BOB” Task Errors (25xx)..........................................................................4-36
WOW Motion Control Processor (MCP) Error Codes (2Axx)....................4-39
Motion Control Processor (MCP) and Feeder Errors (37xx).....................4-39
4.4 Cleaning the Print Head and Related Surfaces.........................................4-40
4.5 Meter Withdrawal.......................................................................................4-42
Scenarios ..................................................................................................4-42
Removal of iButton PSD............................................................................4-43
Running Meter Withdrawal from Menu......................................................4-44
Withdrawal Process...................................................................................4-45
Preparing the System for Shipment ..........................................................4-45
Packing the System...................................................................................4-45
Preparing the Box for Shipping .................................................................4-45
Completing the 3601C...............................................................................4-46

Table of Contents
iv DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
Chapter 5 – Removal and Replacement
5.1 Introduction..................................................................................................5-1
Printer/Base (use for all models)
5.2 Back Cover .................................................................................................5-3
5.3 Control Panel ..............................................................................................5-3
5.4 Front Sub-Panel ..........................................................................................5-4
5.5 Control Panel Ribbon Cables..................................................................... 5-4
5.6 Bottom Cover (Base Pan) and Side Deck Guide.........................................5-5
5.6.1 Side Deck Removal...........................................................................5-5
5.7 Main Transport Feed Belt............................................................................5-6
5.8 Purge Unit....................................................................................................5-7
5.8.1 Purge Unit Sensor Board ..................................................................5-7
5.8.2 Purge Unit Motor and Gears .............................................................5-8
5.9 Transport Drive Motor..................................................................................5-8
5.10 Carriage Drive Motor...............................................................................5-10
5.11 Rear Drive Belts.......................................................................................5-11
5.11.1 Main Drive Shaft Belt.....................................................................5-11
5.11.2 Intermediate Drive Belt..................................................................5-11
5.12 Carriage Drive Belt..................................................................................5-12
5.13 Print Head Carriage Assembly ................................................................5-13
5.14 Drive Shaft...............................................................................................5-16
5.15 Tape Feed Unit........................................................................................5-17
5.15.1 Tape Motor ....................................................................................5-17
5.15.2 Tape Feed Roller Assembly...........................................................5-17
5.16 Postal Security Device (PSD)..................................................................5-18
5.17 Main Logic Board.....................................................................................5-19
5.18 Modem Board..........................................................................................5-20
5.19 Power Supply ..........................................................................................5-21
5.20 Encoder Sensor, Encoder Disc and Sensor Board .................................5-22
5.21 Segmented Roller....................................................................................5-23
5.22 Lower Transport Assembly......................................................................5-24
5.23 Lower Transport Cover............................................................................5-25
5.24 Waste Pad Replacement.........................................................................5-25

Table of Contents
DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D) v
Auto-Feeder (use for DM400c/DM450c/DM475)
5.25 Feeder Upper Cover................................................................................5-26
5.26 Side Guide...............................................................................................5-27
5.27 Feed Deck...............................................................................................5-28
5.28 Feeder Unit..............................................................................................5-29
5.29 Feeder PCB Assembly ............................................................................5-31
5.30 Retard Roller ...........................................................................................5-32
5.31 Feed Roller Assembly..............................................................................5-34
5.32 Feed Belt Assembly.................................................................................5-36
5.33 Feed Motor..............................................................................................5-38
5.34 Feed Encoder..........................................................................................5-39
5.35 Feeder Sensor (FS2/WS1) PCB..............................................................5-40
5.36 Seal/No Seal Lever..................................................................................5-40
5.37 Sealer Finger...........................................................................................5-41
WOW Section of Feeder/WOW Module (use for DM475)
5.38 Separation of Feeder/WOW Module from Printer/Base ..........................5-42
5.39 Feeder/WOW Cover................................................................................5-43
5.40 Feeder Unit of Feeder/WOW Module......................................................5-43
5.41 Feeder/WOW Control Board (PCB).........................................................5-44
5.42 WOW Thickness and Feed Encoders .....................................................5-46
5.43 Feeder/WOW Junction Board .................................................................5-47
5.44 WOW WS2 (Middle) and WS3 (Exit) Sensors ........................................5-47
5.45 WOW Transport Belts (two, behind wall).................................................5-48
5.46 WOW Transport Pulleys (three, behind wall)...........................................5-49
5.47 WOW Upper Transport (as a whole unit).................................................5-50
5.48 WOW Upper Transport Arms Assembly..................................................5-51
5.49 WOW Width Sensors (WS4, WS5, WS6)................................................5-52
5.50 WOW Deck..............................................................................................5-54
5.51 WOW Unit Chassis (as a whole unit) ......................................................5-55
5.52 WOW Transport Motor.............................................................................5-58
5.53 Lower WOW Transport Assembly (as a whole unit)................................5-60
5.54 Lower WOW Transport Components.......................................................5-62
5.55 WOW Load Cell Assembly ......................................................................5-64
5.56 Feeder/WOW Registration Wall Alignment..............................................5-66

Table of Contents
vi DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
Chapter 6 – Service Menus
6.1 Service Menu Overview...............................................................................6-1
6.2 Making SBR Setup Display in Service Menu [DM475]................................6-4
6.3 SBR Setup [DM475]....................................................................................6-5
6.4 Diagnostics..................................................................................................6-9
PM Diagnostics ...........................................................................................6-9
PM Maintenance .......................................................................................6-11
Feeder/WOW Diagnostics.........................................................................6-12
SBR Diagnostics .......................................................................................6-14
6.5 WOW Options [DM475].............................................................................6-16
WOW Calibration.......................................................................................6-16
Static Weight.............................................................................................6-17
Set WOW Mode ........................................................................................6-17
Re-zero WOW...........................................................................................6-18
Calibration Report .....................................................................................6-18
Verify WOW...............................................................................................6-18
Last 10 Weights.........................................................................................6-18
6.6 Platform Options........................................................................................6-18
6.7 Time Functions..........................................................................................6-18
6.8 System Information....................................................................................6-19
Internal Information ...................................................................................6-19
USB Device...............................................................................................6-19
Flash File Info............................................................................................6-19
6.9 Enable Features........................................................................................6-19
6.10 Meter Withdrawal.....................................................................................6-19
6.11 Mail Simulation ........................................................................................6-19
Appendix A — Glossary of Terms
Appendix B — Operator Checklist
Appendix C –– Appendix C • USPS® First Class Mail® Sizes

1-1
1 • Introduction
DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
1.1 Purpose This book contains instructions for troubleshooting and site repair of
DM300c, DM400c, DM450C, and DM475 Digital Mailing Systems. It also
includes complete product specifications and a section on theory for training pur-
poses. For reference, the table below shows a quick comparison of the models.
DM300c/DM400c/DM475 Operator Guide SV62261 (Rev. C or later)
DM300c Quick Reference Guide AW19541
DM400c Quick Reference Guide AW19542
DM475 Quick Reference Guide AW22340
Customer Install Instructions—DM300c AW19645
Customer Install Instructions—DM400c AW19646
Service Install Instructions—DM475 SV62308
DM300c/DM400cDM450c//DM475 Parts List SV61924
Other sources of information:
• PC Meter Connect (if installed on the customer’s PC connected to their
mailing machine) - a link to a PDF of their Operator Guide is provided
• Training - see DM475 Self-Directed Course (MSM-MC-01210) at My Port-
folio on the Pitney Bowes intranet.
1.2 Related
Publications/
Information
Marketing
Model Meter PCN Base PCN Features Throughput Connectivity Options to Data Center
DM300c G900 3C00 Semi-auto
feed up to 65 letters per minute • PC Meter Connect • LAN (via USB adapter)
• Analog phone line
DM400c G900 4C00 Auto feed up to 95 letters
per minute • PC Meter Connect • LAN (via USB adapter)
• Analog phone line
DM450c* G900 5C00 Auto feed up to 120 let-
ters per minute • PC Meter Connect** • Analog phone line
• LAN (via USB adapter)
DM475 G900 6C00 • Auto feed
• WOW
• SBR
- up to 120 let-
ters per minute
- up to 80 let-
ters per minute
in WOW mode
• PC Meter Connect
• LAN (via its own port)
• Analog phone line
*No longer sold as a new product in US but still serviced (and included in this manual).
**Must choose “DM400c” as the model when installing this software

1-2 DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
1 • Introduction
Personal Safety
Follow these precautions for your own safety:
• Treat every circuit like a gun that may be loaded. It may not be “live,”
but be sure. Check with a neon tester or voltmeter, or simply unplug the
machine.
• Know how to turn off the power in the work area and get help in an
emergency.
• Don’t work on equipment under power unless it’s absolutely necessary.
If you must, use extreme caution. Don’t grasp two sides of a live circuit
at the same time—use one hand when reaching into a circuit, touching
a grounded case or chassis with that wrist or elbow if possible. This pre-
vents current from passing through vital organs. Observe this rule when
connecting or disconnecting plugs or leads, or making any adjustments
on a live circuit.
Familiarize yourself with proper procedures and methods before you install,
operate or repair the equipment to avoid personal injury or damage to the
equipment. If you train service people or equipment operators, it is important to
explain safety precautions to your students and encourage safety awareness.
1.4 Safety Warning messages appear throughout this manual to alert you to potentially
hazardous conditions. Two designations indicate their relative seriousness:
WARNING! Calls attention to improper practices that
could result in a potentially serious, even lethal injury to you
or the customer.
CAUTION! Calls attention to practices that could cause
minor injury to you or a customer or that could damage
equipment or material.
1.3 Book
Organization 1• Introduction — Presents vital safety information and an overview of manu-
al.
2 • Specifications — Provides a brief product description and lists the equip-
ment, material specifications and PCNs for the models.
3•Theory of Operation — lists the differences between the DM300c,
DM400c, and DM475 machines; and explains how the machine works.
4 •Troubleshooting — Provides troubleshooting/diagnostic procedures.
5 •Removal and Replacement — Describes procedures for part removal,
replacement and adjustment.
6 •Service Menu — explains on-board diagnostic programs used to trouble-
shoot.
Appendix A: Glossary of Terms — Defines some terms used in this man-
ual with which you may not be familiar.
Appendix B: Operator Training Checklist — Provides a handy checklist of

DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D) 1-3
Introduction • 1
Personal Safety (continued)
• Don’t underestimate the danger of shock: 1 mA (1/1000 amp) is uncom-
fortable; 5 mA is dangerous —you may jump back and be injured; 12
mA causes hand muscles to contract, so you cannot free yourself; 24
mA has proven fatal; and 100 mA (1/10 amp) is likely to be fatal.
• Use the right tools for the job. A tool which slips can cause a short—or a
shock. Don’t reach into a circuit with metal tools, or while wearing rings
or a watch. Even in low voltage circuits, a metal object can short circuit
two terminals. When working on live circuits, use tools with insulated
handles and try to keep your tool hand grounded.
• Don’t bypass safety devices, particularly fuses. Three-wire outlets (120
VAC) are designed to ground equipment to make it safe. If a hot wire
shorts to a grounded frame, the only result is an open fuse. If a hot wire
shorts to an ungrounded frame, the frame itself becomes hot and po-
tentially dangerous. A fuse is a weak link in a circuit, designed to break
down before anything else does. The maximum safe current in a circuit
is determined by the designers. Too large a fuse can pass excessive
current, damaging expensive equipment.
• For electrical fires, use Type C, BC or ABC extinguishers only. Don’t use
soda acid or other liquid stream extinguishers. They will damage electri-
cal equipment and present a shock hazard to the user.
• Digital equipment can be easily damaged or destroyed by static charg-
es. Microprocessors and other integrated circuits contain tiny transistors
not much more than a millionth of an inch across, which operate at 5 to
12 volts.
• Be extremely careful when lifting heavy equipment. Follow the guide-
lines below:
a. Squat to lift and lower. DO NOT bend at the waist.
b. Keep your low back bowed in while bending over.
c. Keep the weight as close to you as possible.
d. Bow your back in and raise up with your head first.
e. If you must turn, turn with your feet, not your body.
f. Never jerk or twist!
g. Put the weight down by keeping your low back bowed in.
h. Keep your feet apart, staggered if possible.
i. Wear shoes with non-slip soles.
j. Get help if you need it.
1.4 Safety

1-4 DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
1 • Introduction
Electrostatic Discharge (ESD) Procedures
Follow these guidelines to protect sensitive equipment from static damage:
• Always use a wrist grounding strap and anti-static mat when working
on equipment sensitive to electrostatic discharge. These items are fur-
nished in the ESD Field Service Kit, L-8351.
• Ground yourself before reaching into the equipment, or touching any
circuit board or other electrical component. Just touching a doorknob or
metal workbench may be enough, but the best guarantee is to turn the
machine off but leave it plugged in, and ground yourself on the chassis,
which is grounded through the three-wire power cord.
• Be careful of rugs—even a few steps can recharge you. Re-ground
yourself whenever you’ve walked away and returned to the machine.
Rugs are a major source of static buildup in the body.
• Take greater precautions as the objects you handle get smaller. A board
in the machine is better protected than one that is not plugged in; a chip
on a board is better protected than one in your hand.
• Stay away from metal conductors. The plastic and resin that chips and
boards are made of are much better insulators than metal. It’s most
important to keep your hands away from any metal which contacts the
data. In particular, this means the long connector along the bottom of
each board, and the pins coming out of the chips. These signal and
data lines are directly connected to the fragile inner circuits of the chips.
When handling a board, try not to touch the connector; when handling a
chip, try not to touch the pins.
1.4 Safety

2-1
2 • Specifications
DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
2.1 Product
Description
The DM300c, DM400c, and DM475 (all service installable) are desktop
mailing systems designed for the global marketplace. They are fully com-
pliant with all current postal standards for digital meters worldwide. These
systems replace the following Pitney Bowes models: E510, E520, DP200,
DP390, DM300, DM400, DM300i, DM400i, DM230L, DM300L, DM330L,
DM350L, DM400L, Mega DM400, and DM450c.
The products are designed for the small office and home markets. They are
targeted at new customers with low- to mid-mailing volume applications,
and at existing customers who wish to upgrade from an entry level ma-
chine. See Table 2-1 below for typical usage patterns.
They will also be placed with customers who need to replace their existing
postage meters with a model that complies with new digital postal stan-
dards, as posts worldwide mandate migration to new standards.
Table 2-1 Typical Usage Patterns
Feed Type Average Daily Usage Maximum Usage Mail Mix
DM300c Manual 33 Letters 96 Letters Business letters
DM400c Automatic 88 Letters 295 Letters Business letters
DM475 Automatic
with WOW 88 Letters 295 Letters Mixed thickness mail of the same
envelope size
Figure 2-1 Digital Mailing Systems
DM300c DM400cDM450c
DM475

2 • Specifications
2-2 DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
Both the DM300c (manual) and DM400c/DM475 (automatic feeder) ver-
sions have the same feature set. This includes:
• Ease of use — no training necessary for basic user operation.
• Customer accessible tape track for jam clearance.
• User-friendly, fully integrated QWERTY keyboard with seven or eight-
line LCD display
• Simple, intuitive user interface, which requires minimal training
• Ink jet printing (300 horizontal x 600 vertical dpi print resolution)
• Easily replaceable waste ink tank
• Customer-replaceable ink cartridge and print head
• Common print engine
• Provision for an optional, fully integrated scale (2, 5 and 10 pound ver-
sions) and interfaced 30 and 70 pound scales
• Weights and measures compatible (30 and 70 pound scales)
• Optional differential weighing
• PB232 communication port for integrated scale platform
• USB (slave and host functionality) communication ports for printer,
scale, PC connectivity, scanners and USB LAN adaptor
• RJ-11 jack for telecommunications
• Standard customer-removable moistening unit
• Internal socket modem
• Easily accessible, drop-down envelope transport
• Optional postal funds accounting (number of accounts is based on the
accounting package purchasd)
• Remote meter inspection
• Manual (DM300c) or automatic (DM400c/DM475) envelope feeding,
moistening, and automatic eject
• Error handling and service diagnostics
• Multiple language support
• USPS Services options
• Data capture
• Indicia-based Information (IBI) Compliant
• IntelliLink™ support
• Features, graphics and rates downloading capability
• Internal rating feature
• Custom messaging (based on subscription level)
• Barcode scanning
2.2 Product
Features

2 • Specifications
DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D) 2-3
In addition, the DM475 provides:
• Weigh on the Way (WOW) capability with a maximum 500 g capacity.
• Dimensional Rating (also called Shape Based Rating) – accurately cat-
egorizes and rates each mail piece based on its dimensions in compli-
ance with global Shape Based Pricing regulations.
• a combined feeder/WOW module, separate from the printing module.
• a color graphics display
• a Internal LAN
NOTE: Features and specifications are subject to change without notice. Some fea-
tures may not be available in certain markets or immediately at the time of product
launch.
2.2 Product
Features

2 • Specifications
2-4 DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
2.3 Material
Specifications
Type Source
Regular white wove, 24 lb.,
low ink absorbing Dependable, 24 # White Wove, No.10
Regular white wove, 24 lb.,
high ink absorbing Printmaster, envelopes by Old Colony No. 10 Regular ; Sub. 24 ; White Wove; Diagonal Seam
Bond, 24 lb., smooth finish Strathmore envelopes by Old Colony No. 10, Sub. 24 ,
Strathmore Bond, White Wove
Bond 24 lb., classic laid
finish Neenah Paper, Envelopes by Old Colony No. 10, Sub. 24, Classic Laid Writing, Baronial Ivory
Kraft paper envelopes Cameo, Quality Park Products, No. 11, Sub. 28, Cameo
4-1/2 x 10-3/8, No.13 Booklet Brown Kraft, Single
Clay-filled paper stock Mohawk Paper Mills, Inc., Converted by Williamhouse, No.
10, Sub. 80, Innovation Text, Premium White
Calendared paper stock Neenah Paper, Converted by Williamhouse, No. 10, Sub. 24,
Classic Crest Text, Avon Brilliant White
Air mail envelopes, calen-
dared material, No. 10
Recycled paper stock P604-10, Recycled envelopes, 25% cotton fiber, Southworth
Company, West Springfield, MA
Tyvek envelope stock, No.
10
Common envelope used in
European Market DLAutofil, Item No. 1927, A.S. 90 White Wove, 114 x 229 mm, Wiggins Teape, DL White Woven single, C5 White Wo-
ven (3.2mm), C4 White Woven (6.4mm)
Xerographic grade paper
sheet PB Supply order number 451-1
Dark envelope Eaton Fox River
Recycled Westvaco
Pitney Bowes Meter Tape
Strips PB Supply order number 625-0
Postacrds 75# return Single
Material Spectrum
The table below shows a range of materials suitable for use in DM300c/
DM400c/DM475 mailing machines. This is a partial listing.
NOTE: Mention of a manufacturer should not be construed as an endorsement by
Pitney Bowes.

2 • Specifications
DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D) 2-5
Minimum 0.20 mm (0.02 inch)
Maximum (DM300c) 9.5 mm (3/8 inch)
Maximum (DM400c/DM475) 8 mm (5/16 inch)
Envelope Thickness
Minimum 1 gram (0.035 oz.)
Maximum 450 grams (16 oz.)
Envelope Weight
Minimum 44.2 x 100 mm (1.75 x 4 inches)
Maximum 44.7 x 200 mm (1.76 x 8 inches)
Tape Strip Dimensions
Minimum 0.17 mm (0.007 inch)
Maximum 0.20 mm (0.008 inch)
Tape Strip Thickness
Stack Height 19 mm (0.75 inch) flat mail, 76.2 mm (3 inches) letter mail
Stack Weight 907.8 grams (2 lbs.)
Stack Height and Weight
Capacity: 55 Tape Strips (PB branded)
Throughput: 65 tapes/minute. At least 50 consecutive tapes without interruption.
Tape Strip Capacity
Minimum 89 x 127 mm (3.5 x 5 inches)
Typical 104.8 x 241.3 mm (4 x 9.5 inches)
Maximum All Models (non-WOW mode): 330 x 381 mm (13 x 15 inches),
DM475 in WOW mode: 330 x 355 mm (13 x 14 inches)
Flap Depth 25 mm (7/8 inch) minimum; 72.2 mm (3 inches) maximum
Envelope Size
2.3 Material
Specifications

2 • Specifications
2-6 DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D)
Envelope Flaps
For a proper seal, the envelope’s minimum flap angle must meet the follow-
ing criteria:
• For envelopes with a flap length from 25 to 60mm (1 to 2.36 inches), the
minimum flap angle is 18 degrees.
• For envelopes with a flap length greater than 60mm to the maximum
flap length for the particular model, the minimum flap angle is 21 degrees.
2.3 Material
Specifications