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