DM300c/DM400c/DM450c/DM475 Digital Mailing Systems DM300c DM30 DM400c/ DM450c DM475 Service Manual US English Edition
NOTICE! 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.
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.
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 device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Responsible party: Pitney Bowes, 1 Elmcroft Rd., Stamford, CT 069260700.
Table of Contents Chapter 1 – Introduction 1.1 1.2 1.3 1.4 Purpose ....................................................................................................... 1-1 Related Publications/Information ................................................................. 1-1 Book Organization ....................................................................................... 1-1 Warning Messages ......................................................................................
Table of Contents 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......................
Table of Contents 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 ......................................................................
Table of Contents Chapter 5 – Removal and Replacement 5.1 Introduction .................................................................................................. 5-1 Printer/Base (use for all models) 5.2 5.3 5.4 5.5 5.6 Back Cover ................................................................................................. 5-3 Control Panel .............................................................................................. 5-3 Front Sub-Panel .......................................
Table of Contents Auto-Feeder (use for DM400c/DM450c/DM475) 5.25 5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 5.36 5.37 Feeder Upper Cover ................................................................................ 5-26 Side Guide ............................................................................................... 5-27 Feed Deck ............................................................................................... 5-28 Feeder Unit .............................................
Table of Contents Chapter 6 – Service Menus 6.1 6.2 6.3 6.4 Service Menu Overview............................................................................... 6-1 Making SBR Setup Display in Service Menu [DM475] ................................ 6-4 SBR Setup [DM475] .................................................................................... 6-5 Diagnostics .................................................................................................. 6-9 PM Diagnostics ......................
1 • Introduction 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 purposes. For reference, the table below shows a quick comparison of the models.
1 • Introduction 1.3 Book Organization 1 • Introduction — Presents vital safety information and an overview of manual. 2 • Specifications — Provides a brief product description and lists the equipment, 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.
Introduction • 1 1.4 Safety Personal Safety (continued) • Don’t underestimate the danger of shock: 1 mA (1/1000 amp) is uncomfortable; 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.
1 • Introduction 1.4 Safety Electrostatic Discharge (ESD) Procedures Follow these guidelines to protect sensitive equipment from static damage: 1-4 • Always use a wrist grounding strap and anti-static mat when working on equipment sensitive to electrostatic discharge. These items are furnished in the ESD Field Service Kit, L-8351. • Ground yourself before reaching into the equipment, or touching any circuit board or other electrical component.
2 • Specifications 2.1 Product Description The DM300c, DM400c, and DM475 (all service installable) are desktop mailing systems designed for the global marketplace. They are fully compliant 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.
2 • Specifications 2.2 Product Features 2-2 Both the DM300c (manual) and DM400c/DM475 (automatic feeder) versions have the same feature set. This includes: • Ease of use — no training necessary for basic user operation. • Customer accessible tape track for jam clearance.
2 • Specifications 2.2 Product Features 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 categorizes and rates each mail piece based on its dimensions in compliance with global Shape Based Pricing regulations. • a combined feeder/WOW module, separate from the printing module.
2 • Specifications 2.3 Material Specifications Material Spectrum The table below shows a range of materials suitable for use in DM300c/ DM400c/DM475 mailing machines. This is a partial listing. 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.
2 • Specifications 2.3 Material Specifications Envelope Size 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 Thickness Minimum 0.20 mm (0.02 inch) Maximum (DM300c) 9.5 mm (3/8 inch) Maximum (DM400c/DM475) 8 mm (5/16 inch) Envelope Weight Minimum 1 gram (0.035 oz.
2 • Specifications 2.3 Material Specifications 2-6 Envelope Flaps For a proper seal, the envelope’s minimum flap angle must meet the following 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. DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
2 • Specifications 2.4 Ink Capacities, Consumption and Cartridge Life Capacities and Print Consumption Ink Cartridge Capacity 45ml (43 grams). See note below. Consumption, DM300c 5,800 imprints at 33 envelopes per day, average Consumption, DM400c/DM475 8,800 imprints at 88 envelopes per day, average Waste Tank 200 grams maximum NOTE: Ink cartridge capacity is calculated using a US indicium with barcode and is subject to change.
2 • Specifications 2.5 Equipment Specifications General Machine Specifications Power Requirements Printhead Tape Strips Longest Duty Cycle Throughput DM300c 100-240 VAC, 50/60Hz. 1.0A DM400c/DM475 100-240 VAC, 50/60Hz. 2.0A Description Bubble jet, 616 nozzles (600 used) Life 500,000 print cycles or 5 calender years Print resolution 300h x 600v dpi Barcode 2D variable Print Image Area 1" (25.
2 • Specifications 2.5 Equipment Specifications User Interface Controller Keyboard Full QWERTY plus numeric keypad and function keys LCD DM300c/DM400c Display 3.5 x 1.7" (88 x 44 mm) 7 lines, 26 characters (monochrome) DM475 3.75 x 2.12" (95 x 54 mm) 8 lines x 26 characters (color) Connectivity Weighing Platforms 2-, 5- and 10-pound integrated; 15-, 30-, and 70 pound USB Interfaced. See note below. Integrated Weighing Platform Interface Serial, TTL level.
2 • Specifications 2.5 Equipment Specifications Postage Meter Maximum Refill Amount $99,999.00 Minimum Refill Amount $1.00 Maximum Stamp $99.999 Low Funds Lockout Amount Runs to 0. Reset Type Postage By Phone® Modem refill Power cord On/Off Switch Required at install and at inspection due Supplied Yes.
2 • Specifications 2.
2 • Specifications 2.7 Weighing Options Weighing Platform MP9G (DM300c-DM450c only) Integrated Weighing Platform, 5- and 10 pound MP4D (DM475 only) Integrated Weighing Platform, 5- and 10 pound Software Features for Weighing Capacity 2 Pound Weighing Option 5 Pound Weighing Option 10 Pound Weighing Option 1 Kilogram Weighing Option 2.
2 • Specifications 2.12 Compatible Pitney Bowes Software Budget Manager Business Manager INVIEW Accounting Barcode Scanning (for USPS Confirmation Services) Data Exchange™ for DM Series Mail Finishing Machines Ascent™ (USB connection only) SendSuite™ 2.
2 • Specifications 2.15 Meter Reports The mailing systems can generate and print the following reports. All reports can be printed on an envelope or tape strip (with the exception of the System Setup report, which requires an optional attached printer, such as a laser printer). Last 5 Refills Report Last 5 Refills This report lists the last five postage refills. It must be printed on an envelope or tape strip.
2 • Specifications Last Five Updates Report This report lists the last five rate downloads to your machine. System will begin using new rates on the date effective. Description Version Effective Meter No.: 3231234 Zip/Zone D .01 DEC 06 08 Page 1 of 1 US Rates G .02 MAY 11 09 Last Rates Update 2.
2 • Specifications 2.15 Meter Reports Confirmation Services Report (if optional USPS Confirmation Services feature is purchased) Confirmation Services This report provides a list of the last 20 mail pieces (by barcode number) that had one of the USPS Confirmation Services applied. Barcode: 1234567890 2345678901 Postage: 001 . 480 001 .
3 • Theory 3.1 Introduction This chapter explains how the DM300c/DM400c/DM475 mailing systems work. It includes descriptions and explanations of the user interface, tape and envelope transport mechanisms, motion control system, print engine and electronics. 3.2 Product Features The products are designed for the small office and home markets with low- to mid-mailing volume applications. See Table 3-1 below for a feature comparison. Refer to the Operating Guide (SV61800) for detailed user instructions.
3 • Theory Of Operation All models are equipped with a fixed (non-user removable) Intellilink™ control center. The user interface includes a seven-line monochrome LCD display (DM300c/DM400c) or an eight-line color LCD display (DM475), an integrated full QWERTY keyboard, a numeric keypad, dedicated function keys and software-defined “soft” keys. 3.3 User Interface Unlike some previous DM models, the user interface PCB does not include any controller functions: it is a keyboard and display only.
3 • Theory Of Operation 3.3 User Interface Modes of Operation Self-Install Mode. In this mode, the user display prompts the user to perform the necessary steps for first-time use of the meter. 1. The self-install mode starts after power up if the system detects that the self-install was not completed. 2. The system automatically starts the following functions: a. Install ink. b. Change language or accept default prompt (if the PCN parameter is set for multi languages). c.
3 • Theory Of Operation 3.3 User Interface Modes of Operation (cont’d) Setup. Users view and customize system settings, as explained in the DM300c/DM400c/DM475 Operating Guide. These system settings include: 1. Date / Ad / Inscriptions Menu 2. Options Menu 3. Reports Menu 4. Presets (Normal and Custom) Menu 5. Accounting Menu 6. Meter Graphics Menu 7. Setup Menu 8. Advanced Functions Menu 9. Funds Menu 10. Account Menu 3.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport DM400c/DM450c/DM475 Autofeeder Transport (cont’d) Feeder Motor. This is a DC motor driven with discrete devices resident on the feeder PCB. The motor is connected to the feeder PCB through J306 (DM400c/DM450c). NOTE: The feeder motor has an added temperature sensor connected to J312 that is not used on the printer or WOW transport motors. Drive System.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport ✍ TIP: The DM475 uses the existing DM400c autofeeder hardware, print engine, modem, USB and serial ports, meter PSD, and tape feeder. ✍ TIP: See section 3.10 for DM475 differences and specific theory. DM400c/DM450c/DM475 Autofeeder Transport (cont’d) When a stack is loaded, it rests on the stack sensor arm, blocking FS1, the Feeder Input (Stack Present) sensor.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport DM400c/DM450c/DM475 Autofeeder Transport (cont’d) Envelope Moistener. The mail piece is driven through the moistener via the two sets of takeaway rollers. The moistener assembly is a variant of the design used in the Pitney Bowes DM500 mailing systems. Figure 3-3H shows the DM400c/DM450c moistener. The moistener used for the DM300c, DM400c, DM450c and DM475 all have similar but not interchangeable parts.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport ✍ TIP: See section 3.10 for DM475 differences and specific theory. Tape Feeder Gear Train The tape feed unit has a capacity of 55 tape strips and can feed up to 65 strips per minute. Tape Motor The unit consists of a tape feed motor and gear train that drives a feed roller equipped with a rubber tire. When the user presses the tape button on the Tape Drive Roller control panel, the printer transport starts.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport Upper Transport The transport drive motor is mounted on the rear plate of the machine. It turns clockwise as seen in Figure 3-5, driving the main shaft that runs from the rear to the front of the printer, through a seMain Drive ries of pulleys and belts (figShaft ure, right.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport ✍ TIP: See section 3.10 for DM475 differences and specific theory. Lower Transport The lower transport assembly is hinged to the right and left side plates by means of two pivot studs. The assembly is equipped with a lock lever that allows the user to lower the transport for jam clearance. Rotating the lock (jam) clockwise moves the lock lever slide to the Figure 3-7 Top View of Lower Transport Releft.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport Sequence of Operation The mailing machine is equipped with a sophisticated motion control system that continuously monitors envelope or tape strip position along the transport and triggers all key operations at the appropriate time in the machine cycle.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport Sequence of Operation (cont’d) Sensor Inputs. The transport is equipped with five sensors in the case of the DM400c, and three in the case of the mailing machine. See Figure 3-10 below for a diagram of the transport layout. Autofeeder. FS1 (Feeder Sensor 1) is the stack present sensor. FS2 is a lead edge/trail edge sensor, the input of which helps the system determine envelope length.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport Sequence of Operation (cont’d) Sensor PS3 is used to report jams or no paper conditions. In the 3C00 only, sensors PS2 and PS3 are used for skew detection. DM400c-DM475 software does not detect skew and do not use PS2. PS3 also triggers the postage debit request; if that request is completed successfully within 110/120msec, the printing process starts. ✍ TIP: See section 3.10 for DM475 differences and specific theory.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport Sequence of Operation (cont’d) NOTE: If sensor PS1 does not detect a lead edge within 15 seconds, the print carriage returns to the home position. 2. When the print carriage is in the print position, the transport motors start and one piece is separated from the stack. ✍ TIP: As noted earlier, DM400c to DM475C software does not report skew conditions; it reports jams or no paper conditions.
DM300c/DM400c/DM475 Service Manual (SV61801 Rev. D) 89 4.48 [IPS] (113.8 [mm/sec]) 100 63.5 16 [IPS] (406.4 [mm/sec]) TIP: See section 3.10 for DM475 differences and specific theory. 89 Stack Sensor FS1 ✍ 23 [IPS] (584.1 [mm/sec]) 113 23.5 [IPS] (596.6 [mm/sec]) Moistener 18 FS2 PS1 33 63 PS1 2 64 PS2 PS3 Start Debit PS2 PS3 24 [IPS] (609.
3 • Theory Of Operation 䇭 䋨 PS2 PS1 Separate Roller Input Roller PS3 Output Roller Carriage print position change completed -> Transport motor feeder motor start Separate Roller 䇭䇭 FS2 PS2 PS1 Input Roller PS3 Output Roller Detect envelope edge with PS3 -> Envelope skew check FS1 䇭䇭 Separate Roller FS2 PS2 PS1 Input Roller PS3 Envelope arrives at print start position -> Print Start FS1 Separate Roller FS2 䇭䇭 Output Roller Head 㽵 FS1 Head 㽴 䋫 PS2 PS1 Input Roller PS3 Ou
3 • Theory Of Operation 3.4 Envelope/ Tape Transport Sequence of Operation (cont’d) Debit Request PS3 110/120 msec (3 inches) Mailpiece Debit Complete Print Head Generate Data, Initiate Printing Figure 3-17 Debit and Print Timing 4. Once the system has confirmed the debit within the allotted time, it issues the print start command and prints the indicium (meter stamp). FS1 senses the following mailpiece which is approaching FS2. ✍ TIP: See section 3.10 for DM475 differences and specific theory.
3 • Theory Of Operation 3.4 Envelope/ Tape Transport Sequence of Operation (cont’d) Operating Sequence—DM300c. For the discussion that follows, refer to the Transport Timing Diagram (Figure 3-18) below and the DM300c Envelope Print Diagram (Figure 3-19) on the following page. The operating sequence for the DM300c is essentially the same as that for the DM400c, with the obvious difference that the autofeeder, and therefore sensors FS1 and FS2 are not present. 1.
3 • Theory Of Operation 䇭 䋨 Detect envelope by PS1 -> Shift carriage print position Purge if necessary PS2 PS1 Input Roller PS3 Output Roller Carriage print position shift complete -> Start transport motor 䇭 Input Roller 䇭 Output Roller Detect front of envelope by PS3 -> Stop transport motor -> Check envelope skew -> Start data generate PS2 PS1 䇭䇭 Input Roller PS3 Output Roller Data generate complete -> Start transport motor PS2 PS1 䇭䇭 PS3 Output Roller Envelope arrives at print st
3 • Theory Of Operation 3.4 Envelope/ Tape Transport ✍ TIP: The DM475 uses the existing DM400c autofeeder hardware, print engine, modem, USB and serial ports, meter PSD, and tape feeder. ✍ TIP: See section 3.10 for DM475 differences and specific theory. Sequence of Operation (cont’d) Operating Sequence—Tape. For the discussion that follows, refer to the Tape Print Sequence diagrams (Figure 3-20) on the following two pages.
3.
3 • Theory Of Operation 3.
3 • Theory Of Operation 3.5 Ink System The ink system is comprised of the: • Ink tank (cartridge) • Print head • Carriage Assembly • Carriage Board • Purge Unit • Waste Tank Ink Cartridge ✍ TIP: The DM475 uses the existing DM400c autofeeder hardware, print engine, modem, USB and serial ports, meter PSD, and tape feeder. The DM300c/DM400c/DM475 use the same, unique ink car- Figure 3-21 Ink Tank (Cartridge) tridge (figure, right).
3 • Theory Of Operation 3.5 Ink System Ink Cartridge (cont’d) Ink Tank Expiration Notice—Ink tank will expire in XX days. This is based on the date of manufacture and the number of days of use. Low Ink. Remaining ink is less than needed to print 500 indicia. No Ink Tank Detected—System failed to detect ink tank. System will run in seal-only mode. Ink Tank Expired—Install new ink tank (based on the date of manufacture). Ink Tank Access Cover Open—Close cover or replace ink cartridge/print head.
3 • Theory Of Operation 3.5 Ink System Print Head and Carriage Board (cont’d) • The communication protocol to the print head is not standard. • The print head functions only with Pitney Bowes-managed equipment. • There is an enciphered link between the PSD (iButton) and the carriage board. The following error messages are associated with the print head: • Print Head Fault—The system detected a print head fault. Power cycle the machine. If the problem persists, install a new print head.
3 • Theory Of Operation 3.5 Ink System Purge Unit Carriage Home Sensor The purge unit is designed to maintain good print quality. It is a totally self-contained unit (no external pumps or other components) that is cantilevered off the right side plate and located midway beneath the print carriage rails. Wiper As shown in the figures, right, the purge unit has a motor, Motor Gear Cam Gears pump, capping station, wiper, print lock and carriage home Figure 3-26 Purge Unit, Right Side sensor. Motor.
3 • Theory Of Operation 3.5 Ink System Purge Unit (cont’d) Wiper. The wiper removes excess ink and debris from the print head as the carriage assembly moves to the print position. A wiper cleaner attached to the back of the print head carriage is designed to keep the wiper free of excess ink and contaminants. Print Head Lock. The print head lock is cam driven up to the locking position as the print head carriage reaches the home.
3 • Theory Of Operation 3.5 Ink System Table 3-2 Purge Cycles Purge A (Power ON Purge) • Suctioned ink: 0.2 - 0.3g • Suction time: 1.25 sec. • Movement: suction, wiping and spits. • When: 72 hours after the last purge A, B, or C, when printing is initiated. Purge B (Ink Cartridge Replacement Purge) ✍ TIP: The machine does not perform purges when it is in the sleep mode. The machine does not perform the 72-hour purge until a print is requested and 72 hours have passed since the last type A, B or C purge.
3 • Theory Of Operation 3.5 Ink System Waste Tank The waste tank consists of an absorbent pad that sits in a drawer located on the right side of the machine. Its purpose is to prevent spillage of ink and ink contamination with the machine in any orientation and under the shock and vibration conditions that normally occur during shipping. Figure 3-29 Waste Tank Drawer The tank, located directly below the purge pump drain, has a capacity of 200 grams.
3 • Theory Of Operation 3.6 Electronics Figure 3-31 below is a block diagram of the system architecture for the DM300c/DM400c/DM450c. Figures 3-32 A and B on the subsequent pages provide a simplified block diagram that shows the printed circuit boards (PCBs) used in the system and the devices that are connected to them. PCBs and system electronic components are described on the following pages.
3 • Theory Of Operation 3.
3 • Theory Of Operation 3.
3 • Theory Of Operation 3.6 Electronics PCBs Control Panel Unit. The control panel includes a multi-line character display, main control keyboard and QWERTY keyboard for data entry. Unlike some previous models in the DM Series, the feature memory, control and PSD do not reside on this board; they reside instead on the main logic board. Figure 3-33 User Interface PCB The keyboard/display unit is connected to the main logic board at J124 and J120. Power Supply PCB.
3 • Theory Of Operation 3.6 Electronics PCBs (cont’d) LEDs 1701, 1702 J127 Print Head J130B Keyboard J130 Keyboard J122 Encoder Sensor J121 Top Cov Intlk J119 Sensor Board J126 PS J107 Serial Port J120 Purge Unit J116 Purge Unit J117 Tape Motor J118 Carriage Motor J103 3C00/4C00/5C00 Controller Main Logic Board.
3 • Theory Of Operation 3.6 Electronics PCBs (cont’d) It also provides the interface to the autofeeder for the DM400c system. In addition, it supports the keypad and display functions through an interface to the control panel PCB. The board supports all USB communications, the serial interface to the integrated scale, the analog modem and the feeder communications channel.
3 • Theory Of Operation 3.6 Electronics PCBs (cont’d) 6C00 Controller Main Logic Board (DM475). The 6C00 Main Logic Board includes all the functions of the 3C00/4C00/5C00 Main Logic Board (see previous section) and adds a USB Feeder/WOW connection. Also added is an Internal LAN and RJ45 connector. The addition of the integrated LAN requires the external attaching screw to be moved inside, to the bottom of the board’s mounting frame.
3 • Theory Of Operation 3.6 Electronics PCBs (cont’d) Carriage Board. This PCB contains the decryption elements used in data communication to the print head as well as connections to the print head. It is sealed in the print head carriage as shown in Figure 3-38. It connects to the main logic board through a 50-pin FFC at J127. It also provides the electrical connections to the NVM in the ink tank (cartridge). See Tank NVM below.
3 • Theory Of Operation 3.6 Electronics PCBs (cont’d) Purge Unit. This PCB provides connections from the carriage home sensor, pump sensor and cap sensor. It serves solely as a junction board and therefore has no active components on it. The purge PCB also routes the 5V required for the sensors from the main logic board. It connects to the main logic board through J120.
3 • Theory Of Operation 3.6 Electronics PCBs (cont’d) Feeder Logic Board (DM400c/DM450c). The feeder logic board is the heart of the feeder subsystem used on the DM400c/DM450c. It has a single chip Hitachi micro controller that provides all the computing and communication power to the feeder subsystem. Also resident on the feeder PCB are the motor driver for the feeder motor as well as the buffers for the feeder sensors.
3 • Theory Of Operation 3.6 Electronics PCBs (cont’d) Feeder/WOW Logic Board (DM475). The feeder/WOW logic board is located in the feeder/WOW module of the DM475 and adds WOW machine motion control (MMC) capability to the existing feeder logic board functionality. The new board is attached to the back of the WOW unit. The feeder/WOW logic board connects directly to the 6C00 main logic board via three cables.
3 • Theory Of Operation 3.6 Electronics Sensor Summary PS1. This is a lead edge sensor that detects the presence of an envelope at the entry point of the transport. On the DM300c, the carriage assembly moves into the print position and the transport starts when PS1 sees a lead edge. PS1 is mounted on the sensor PCB, figure right, below the disc encoder. The sensor board is connected to the main logic board through connector J119. ✍ TIP: See section 3.
3 • Theory Of Operation 3.6 Electronics Sensor Summary (cont’d) Carriage Return Sensor. This sensor is physically mounted on the purge PCB that is housed in the purge unit located below the carriage. The system uses this sensor to detect the position of the print carriage in the Y direction. In this way, the carriage motor drive algorithm has the input necessary to drive the carriage to the printing position and back to the home position at the appropriate times in the machine cycle. Pump Sensor.
3 • Theory Of Operation 3.6 Electronics Motor Summary Tape Motor. The tape motor is an integral part of the tape feed unit. See Figure 3-4A. It feeds tape strips from the feed chute into the tape path of the mail transport. It is a stepper motor driven by discrete switches on the main logic board to which it is connected through J117. A 1.0A non-replaceable fuse protects the motor.
3 • Theory Of Operation 3.7 Scale Controller An optional, integrated platform scale connects to the main logic board through a serial interface using a DB9 connector. This link provides the weight information broadcast from the scale to the logic board’s processor using a 19,200 bit serial stream. The DB9 is connected to the main logic board through connector J107. The DB9 connector provides 5V power to the scale device. 3.
3 • Theory Of Operation 3.10 DM475 Feeder/WOW Theory The DM475 consists of two physical sections which are mated together at install: • ✍ TIP: The DM475c mailing system uses the existing DM400c autofeeder hardware, print engine, modem, USB and serial ports, meter PSD, and tape feeder.
3 • Theory Of Operation 3.10 DM475 Feeder/WOW Theory Figure 3-43 Block Diagram (DM475) 3-46 DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
3 • Theory Of Operation 3.10 DM475 Feeder/WOW Theory Sequence of Operation 1. When the Start key is pressed in WOW Mode or Weigh First Piece Mode, first the feeder/WOW main board’s motion control processor (MCP) downloads the weight breaks from the G900 main board’s Rate Manager. Then the WOW is re-zeroed and the width sensors are recalibrated. The WOW will also pause to be re-zeroed every four minutes during a run. 2.
3 • Theory Of Operation 3.10 DM475 Feeder/WOW Theory Throughput and Estimated Performance The DM475 is marketed with the following throughputs for #10 or shorter envelopes: • • In non-WOW mode, there are two throughput modes for the DM 475: Throughput Mode LPM Default Low 95 Yes High 120 No In WOW mode, the throughput will be defaulted to 80 LPM.
3 • Theory Of Operation 3.10 DM475 Feeder/WOW Theory Sensors Qty Sensor Name Type Function 1 FS1 Deck Digital with Mechanical Flag Detects an empty feeder deck 1 FS2/WS1 Feeder_Exit Mail piece gap creation. Stage mail ahead of WOW module. Used as 1 of 3 sensors to measure mail length 1 WS2 WOW_middle Used to measure envelope length of material less than 9.88 inches. 1 WS3 WOW_Exit Used to measure envelope length greater than 9.88 inches.
3 • Theory Of Operation 3.10 DM475 Feeder/WOW Theory 3-50 Actuators Qty Actuator Name Function Type 1 M1 Feeder Motor and encoder Feed and separate mail Brush DC 1 M2 WOW Motor and encoder Transport mail pieces and stop for weighing when necessary Brush DC 1 M3 Printer Motor and encoder Transport mail at constant speed for printing Brush DC 1 M4 Tape Feed Feed tape at constant speed for printing Stepper DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
4 • Troubleshooting/Diagnostics 4.1 Introduction This chapter explains how to troubleshoot the DM300c/DM400c/DM450c/ DM475. It includes troubleshooting charts, and a list of error codes and their meanings. It also includes instructions for withdrawing the mailing machine from service. General Troubleshooting Chapter 3, Theory of Operation, contains valuable information that can help you analyze a problem and isolate the cause. A good understanding of machine timing is very helpful in this respect.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-1 Power ON and Initialization Faults Errors Checkpoints Possible Causes/Solutions Mailing machine is connected to power, but control panel LED is off, no initialization, no display, no printer sounds. Does the cord show obvious signs of wear? Does another cord work? Replace the power cord. Is the power cord connected to a functioning wall outlet? Check wall outlet.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-2 Keyboard and Display Faults Fault Checkpoints Possible Causes/Solutions Keyboard failure. Does not respond. Wiring from keyboard to J130A. Keyboard PCB. Poor connection at keyboard, wiring and connection at Main Logic Board, J130A. No display. Machine may be in sleep mode. Is front panel LED orange? Press any key to wake unit. Check display contrast. Adjust display contrast as required. Machine not getting power.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-3 Automatic Feeder Faults (DM400c/DM450c/DM475) Fault Checkpoints Possible Causes/Solutions Fails to feed. Is material load properly? Check that operator is loading material correctly. Does material fall within published specifications? Check material specifications. Is hopper overloaded? Stack should not exceed 2.5 pounds or 3 inches in height.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-4 Mailing Machine Transport Faults Fault Checkpoints Possible Causes/Solutions Operator Error. Operator may be feeding piece improperly. Instruct operator to position envelope top edge against rear wall and slide it to right. Interlocks. Are all covers and transports closed? An error message should display if a cover is open. Fails to feed when operator inserts envelope. PS1. Dirty or defective sensor.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-4 Mailing Machine Transport Faults (cont’d) Fault Checkpoints Possible Causes/Solutions Transport fails to drive, PS1 okay (continued). Drive shaft fails to turn. Drive shaft is binding. Check pulleys. Make sure they are securely mounted on shaft. Transport drive belt. Check belt for proper tracking. Check for wear, glazing, cracks, etc. Lower transport problems.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-5 Tape Feeder Faults Fault Checkpoints Possible Causes/Solutions Failure to Feed Tape Strips. Operator may be loading tapes improperly. Check that operator is loading tapes properly and in the correct orientation. See Operator Guide. Also check that operator is not exceeding hopper capacity (50 to 55 tapes). Operator may be using substandard material. Check that tape strips meet PB published specifications.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-6 Printing Faults Errors Checkpoints Possible Cause/Solution No print out of box. • In some cases, the print head may dry out or be cold from shipment. This could result in a no print condition. Allow the system to warm up to room temperature. • Check gold contacts on the print carriage for ink or other deposits and clean if necessary. • Check for capping station ink “kiss mark” on the metal plate of the print head.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-6 Printing Faults (cont’d) Errors Checkpoints Possible Cause/Solution Poor print from used ink cartridge. Follow steps at right. Remove the printhead and check for bent pins. Pins are normally angled downward. Make sure printhead is correctly installed. Check printhead harness and connection at J127. If purges fail to correct the problem, and the ink cartridge is not empty, replace the printhead.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-6 Printing Faults (cont’d) Errors Checkpoints Possible Cause/Solution Customer complains that ink usage is high. Ink yield is based on usage. Factors affecting ink usage are: How many pieces per day does this customer run? • The number of pieces run per day. Do they run one at a time or run them in batches? • Whether the pieces are run in a batch or separately. • Performing manual maintenance.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-6 Printing Faults (cont’d) Errors Checkpoints Possible Cause/Solution Poor print with new ink cartridge. Ink Cartridge 1. How to weigh a print cartridge using an integrated platform scale: Remove cartridge and tap it upside down on a desk two times. 2. Remove print head. Check that tape has been removed from the ink port on the bottom of the ink cartridge. 3. Replace printhead and make sure it is properly seated.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-7 Print Carriage Faults Errors Checkpoints Possible Cause/Solution PS1 fails to sense envelope or tape lead edge. Check for debris in transport path. Check PS1 using service diagnostics. Carriage home sensor. Sensor is blocked when carriage is in the home position. Use service diagnostics to check sensor status. Also check harnesses from Purge Unit to J116 and J120 on Main Logic (Controller) Board.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-8 Moistener Faults Problem Possible Cause Solution Envelopes don’t seal. Incorrect feeding. Check that operator is sliding envelope flap under blue edge of feed deck. If this is not done, moistener can’t wet flap. Low sealant level. Check sight glass on left side of moistener tank. If level is low, add E-Z Seal® until it reaches bottom of fill hole. Dry moistener brush. Try wetting moistener brush.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-10 Modem/Connection Faults Problem Possible Cause Solution Machine fails to connect to Postage By Phone Data Center: No dial tone. System not connected to working analog phone line. 1. Make sure the phone cord is firmly connected to a single line analog phone jack.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-10 Modem/Connection Faults (cont’d) Problem Possible Cause Solution Machine fails to connect tp Postage By Phone Data Center: No dial tone.
4 • Troubleshooting/Diagnostics 4.2 Troubleshooting Tables Table 4-11 Integrated Scale Faults Problem Possible Cause Solution Scale problems at time of install. The scale line is not showing or an error code (e.g., 1103, 11F6) displays Put in for a download. Try steps at right. 1. Try uploads and downloads. Scale problems after install. If the scale has been working and the scale line shows but nothing else, or the scale line shows with LB and OZ, but no zeroes, try steps at right. 2.
4 • Troubleshooting/Diagnostics 4.3 Error Codes About the Codes The mailing systems may display an error code when a fault occurs. These codes are distinct from operator error messages and prompts that routinely display during normal operation. Error codes are defined in the tables on the following pages. Table 4-12 lists and explains some of the more common error codes/messages. Code Listing Tables 4-13 through 4-21 list all codes, arranged by class.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages Error Code (Type) 010E Message Description/Causes Resolution Error occurred while trying to initialize printer. If error occurs during install, check that all shipping tape has been removed from the system. Remove the power cord. Wait three minutes and reconnect power. Make sure the ink cartridge cover is closed. 0112 Ink carriage motor timing area. Usually occurs along with 2443 error when the system is rebooted.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) 200C Message Description/Causes Resolution Real time clock error — out of range. If this error occurs during out-of-box setup, reboot the system. If the error happens again, reboot, press continue to bypass the current clock time and complete the install process. Change clock time after installation is complete.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) 2485 (No paper error) Message Description/Causes Resolution • Piece jammed before printer Verify mail piece and rerun through machine if necessary. • No print, funds not debited • Jam at transport sealer roller • False jam lever open cover message 2494 Ink tank communication error. This error usually occurs when a new ink cartridge is installed.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) Message Description/Causes Resolution 248B (Jam) Mail Jammed Stall/Jam in printer. Clear jam in printer area. Clear Printer Transport. - If stall/jam is before S3, stops with piece in printer. No postage will be printed onto the envelope/tape. - If stall/jam is after S3, system may stop with piece in printer or eject the piece.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) Message Description/Causes Resolution Loose connection of the iButton. Unplug the machine, remove cover, and remove iButton. Use a small screwdriver to bend the inner contact out and the outer contact in so the iButton has full contact on both sides. Replace iButton.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) Message Description/Causes 372D (Jam feeder error) Mail Jammed Stall/Jam before feeder sensor Clear jam. FS2. Timeout occurs with material on feeder deck (at FS1) and material has not made it to FS2/WS1. Operator can press soft key to continue or can press Clear to go the home screen and press start from the home screen. System will allow start up without material being cleared.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) Message 372F (Feeder/ WOW error) Mail Jammed Description/Causes Stall/Jam at WOW exit sensor (WS3). Error occurs when Clear WOW Transport. WS3 has been blocked too long. Resolution Clear jam. - In Non-WOW modes, will allow system to start again if material is not cleared. - In WOW mode, error code 37B6 can occur instead of 372F System may stage a piece at FS2/WS1.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) Message Description/Causes Resolution 37A2 (Feeder Fault) Feeder-WOW Cover Open Piece hanging at printer, no jam, print OK. Stops immediately when system detects cover open in the feeder/ WOW. Clear jam. If in a Non-WOW mode: If operator closes the cover: - If printer is clear of material, allow system to start. - Process material in WOW and feeder modules.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) Message 37B1 (WOW error) WOW Error 37B2 (WOW error) WOW Calibration Error Description/Causes Resolution Clear jam. Clear WOW Transport. Recalibrate WOW. See section Call for Service 37B3 (WOW error) WOW Re-zero Error 37B4 (WOW error) WOW Re-zero Error Clear jam. Clear WOW Transport. Re-zero error in WOW mode Clear jam. 37B6 Error on DM400c.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) DE00 Message Description/Causes Resolution When trying to connect with the Data Center, either PbP is not set up to communicate with the meter or there is some other type of network problem. 1. Confirm the meter is installed at PbP, that the customer has not reached his or her credit limit, and that there are funds available to download. 2.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) Message Description/Causes Link Negotiation Failed Resolution Check that system is connected to an analog line. Try using 1-800-590-4857, 1-866-297-8025 or a local access number. 1. Reboot system. 2. Press CLEAR when display prompts: DO YOU NEED TO ENTER A NUMBER TO REACH AN OUTSIDE LINE? 3. Select QUIT INSTALL and YES/ENTER to confirm. Display prompts: NOT AUTHORIZED. 4. Press OPTIONS. 5.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-12 Common Error Codes/Messages (cont’d) Error Code (Type) Message (SBR Error) SBR Error Mailpiece Too Description/Causes Resolution Clear jam. Run proper size material for WOW modes. ...Wide ...Long ...Short ...Thick ...Thin ...Light Clear WOW Transport. (SBR Error) Mailpiece Too Heavy Stops with piece in WOW transport. Reports WOW piece Clear WOW Transport. too heavy error.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-13 iButton® PSD Error Codes (20xx) These errors are reported by the iButton® UIC when the PSD returns an error. Error Description 2000 IPSD State detected - No problem 2001 IPSD Packet detected - No problem 2002 Unknown Error 2003 Sent invalid message for the IPSD’s state. 2004 Authorization attempted with wrong Public Key Data 2005 PVD mgs received with ascending/descending register values that don’t match the PSD values.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-13 iButton® PSD Error Codes (20xx) (cont’d) Error Description 2022 From Get PSD KeyData, (or from Gen PVD or PVR or Precompute R) 2023 French: KMA Key loaded or createIndicium attempted before KFAB_ma Key. 2024 A PVD refill has been attempted on a PSD configured for Keypad Refill only.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-15 Image Generator Errors (22xx) This class of errors is reported by the UIC when there are image generator errors. Error Description 2201 Font, graphic, barcode, or text ad component had wrong schema version 2202 Too many “indicia” components in the region map OR too many “town circle” components in the region map(s).
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-15 Image Generator Errors (22xx) (cont’d) Error Description 221C The text ad works out to be wider than the ad region 221D The text ad works out to be taller than the ad region 221E The ad area doesn’t have any space except for the required border around the text ad 221F One of the text ad lines has a font ID that isn’t allowed to be used for text ads 2220 Something failed previously in the image generator.
4 • Troubleshooting/Diagnostics 4.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-18 Print Manager Errors (24xx) Error Description 2400 General printer fatal error 2401 Problem with the PSOC chips - could actually be a 2300, 2301, 2302 error. 2441 Purge pump motor or sensor failure 2442 Cap motor or sensor failure 2443 Carriage motor or sensor failure 2444 Inside temperature out of range 2445 Transport motor or encoder failure 2446 ASIC motor drive time limit exceeded 2447 Print carriage not detected.
4 • Troubleshooting/Diagnostics 4.
4 • Troubleshooting/Diagnostics 4.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-19 “BOB” Task Errors (25xx) (cont’d) Error Description 254F Failure to correct shadow log 2550 Error logging postage value refund message to shadow log 2551 Error in fnValidData, probably a missing table entry 2552 Error in fnWriteData, probably a missing table entry 2553 Glob-to-bob conversion references area beyond glob limit. 2554 Bob-to-glob conversion references area beyond glob limit.
4 • Troubleshooting/Diagnostics 4.3 Error Codes Table 4-20 WOW Motion Control Processor (MCP) Error Codes (2Axx) Error Description 2A3E WOW Weighing Error. While weighing a mail piece the WOW MCP reports an error. 2A3F Width sensor calibration error at start of run. 2A8E WOW unable to weigh – weight unstable. 2AAC WOW Error. General-purpose error reported by the WOW MCP. 2AAD Weight Break Download Sequence error.
4 • Troubleshooting/Diagnostics 4.4 Cleaning the Print Head and Related Surfaces You can perform this procedure when you suspect, or have seen: • bad printing, even after changing the ink cartirdge 1. Remove print head and place the print head on its back side on the absorbent pad. Print Head Removed and Placed on its Back Side 2. Locate a bottle of clear ink (PN# 4Y1-9107, it can be ordered as a Service part). Pour a small amount of clear ink in the ink cap.
4 • Troubleshooting/Diagnostics 4.4 Cleaning the Print Head and Related Surfaces 4. Clean the wiper blades with the cleaning swab. Cleaning Swab Wiper Blades 5. Clean the cap of the purge unit with the cleaning swab. Cleaning Swab Clean ink on top surface Purge Unit Cap Ink Pad Clean ink on edges 6. Reinstall print head. From the Service Menu, select Diagnostics>PM Maintenance>Print Test Pattern, and/or run some sample mail pieces through the machine to confirm proper printing.
4 • Troubleshooting/Diagnostics 4.5 Meter Withdrawal Scenarios For a meter withdrawal, the customer or the service representative must transfer the remaining balance of postage from the machine into the customer’s Postage By Phone® (PbP) Account. Normally this is done if the customer is no longer going to use the machine or if the machine fails to operate properly and cannot be repaired in the field. There are two possible scenarios that determine how to return equipment: 1.
4 • Troubleshooting/Diagnostics 4.5 Meter Withdrawal Removal of iButton PSD 1. Transfer funds to Postage By Phone® account: Push Holder Away from Board and Lift Up to Remove a. Press Menu and page down to select Advanced Features. b. Select Meter Withdrawal. c. Select Continue. d. When the transfer is complete select Print Receipt and follow the prompts. e. Confirm the funds “Available in Meter” is equal to $000.000. Figure 4-7 Removing PSD 2. Remove the iButton PSD from the Main Logic board: a.
4 • Troubleshooting/Diagnostics 4.5 Meter Withdrawal Running Meter Withdrawal from Menu NOTES: Contact Pitney Bowes first before withdrawing funds. The machine must be connected to an analog phone line. 1. Press Options. 2. Press Page Down to the third screen. 3. Select "Advanced Features". Page Up OPTIONS ◄Advanced Features Page Down 4. Press Page Down to the second screen. 5. Select "Meter Withdrawal". Page Up ADVANCED FEATURES ◄Meter Withdrawal Page Down 6.
4 • Troubleshooting/Diagnostics 4.5 Meter Withdrawal Withdrawal Process The DM300c/DM400c/DM475 iButton PSD cannot be replaced separately from the machine. If the iButton fails, the complete machine must be replaced. The iButton PSD must never be separated from its machine. The only exception is if a lease customer wants to return their meter and cancel their Postage by Phone® Account, but they want to keep their machine base.
4 • Troubleshooting/Diagnostics 4.5 Meter Withdrawal Completing the 3601C 1. Do not enter any data into section A, Box 10 until you have completed the transaction and the outcome. 2. You must include an accurate explanation/description of the action you have taken in Section A, Box 10. 3. If you cannot perform funds transfer via modem, note the explanation description for withdrawing the ICC/PSC and complete the transaction as a QAR. 4.
5 • Removal & Replacement 5.1 Introduction This chapter contains instructions for removing and installing field-replaceable parts. Adjustments are explained when required. This chapter is divided into three major sections, and each is color-coded: • Printer/Base (use for all models* - DM300c/DM400c/DM450c/DM475) • Auto-Feeder (use for DM400c/DM450c/DM475*) • WOW Section of Feeder/WOW module (use for DM475) *Differences among models, if any, will be noted in the procedure.
5 • Removal & Replacement 5.1 Introduction Auto-Feeder (use for DM400c/DM450c/DM475) (photos show DM400c but procedures apply to all auto-feed models) 5.25 Feeder Upper Cover .............................................................. 5-26 5.26 Side Guide ............................................................................. 5-27 5.27 Feed Deck ............................................................................. 5-28 5.28 Feeder Unit .....................................................
5 • Removal & Replacement Printer/Base (use for all models) 5.2 Back Cover 1. Disconnect power and remove scale if present. 2. DM475 - Separate feeder/WOW module from printer/base (section 5.38). 3. Remove three screws as shown (Figure 5-2). 4. Lift off cover (Figure 5-3). Figure 5-2 Back Cover Mounting Screws Figure 5-1 Back Cover Keyboard Cover Tabs Seen from Underside of Control Panel Figure 5-3 Removing Back Cover Figure 5-4A Pry Off Control Panel Overlay 5.3 Control Panel 1.
5 • Removal & Replacement Printer/Base (use for all models) 5.3 Control Panel Figure 5-6 Control Panel Harness Figure 5-5 Removing Control Panel 5.4 Front Sub-Cover 1. Remove the back cover and control panel (sections 5.2 and 5.3). 2. Remove 4 screws securing front sub-cover (Figure 5-9). 3. Lift cover off base. Figure 5-7 Control Panel Assembly Control panel harnesses Figure 5-8 Control Panel and Display Assembly (for Reference) Figure 5-9 Sub-Cover Mounting Screws 5.
5 • Removal & Replacement Printer/Base (use for all models) 5.6 Bottom Cover (Base Pan) and Side Deck Guide 1. Remove all printer/base covers (sections 5.2, 5.3, and 5.4). 2. Remove five screws located inside base and one screw located on side (Figures 5-11 through 5-13). 3. Lift machine out of base pan and place on work surface protected by paper towels. Purge unit drain can leak ink. Figure 5-11 Base Pan Mounting Screw Figure 5-12 Side Deck Mounting Screw Locations. Chassis Removed for PurLocation.
5 • Removal & Replacement Printer/Base (use for all models) 5.7 Main Transport Feed Belt 1. Unlock and lower the lower transport. 2. Slightly loosen the tension idler, press down on it to relieve belt tension, and tighten in position. 3. Remove old belt. 4. Install new belt so center ridge rides in grooves of pulleys. 5. Loosen belt tensioner slightly and allow spring to normalize belt tension. DO NOT apply additional tension to belt. 6. Tighten belt tensioner. 7. Make sure belt tracks properly. 8.
5 • Removal & Replacement Printer/Base (use for all models) 5.8 Purge Unit 1. Remove all printer/base covers (sections 5.2, 5.3, 5.4, and 5.6). 2. Disconnect two wire harnesses as shown (Figure 5-16). 3. Hold the purge unit from the bottom using a paper towel or rags to protect yourself from ink leakage from the drain. 4. While holding the purge unit, remove two mounting screws as shown (Figure 5-16). 5. Remove the purge unit from the bottom of the machine. 6. Reassemble in reverse order.
5 • Removal & Replacement Printer/Base (use for all models) 5.8 Purge Unit Gear Tab (Opposite Flat) Figure 5-17C Removing Purge Unit Sensor Board Figure 5-17D Purge Unit Sensor Board 5.8.2 Purge Unit Motor and Gears 1. Remove purge unit (section 5.8). 2. Unsnap plastic cover (see Figure 5-17B). 3. Press down outer gear tab opposite flat on shaft (Figure 5-17C) and remove outer and inner gears. 4. Carefully disconnect harness connector. Figure 5-17E Purge Motor Removed 5.
5 • Removal & Replacement Printer/Base (use for all models) 5.9 Transport Drive Motor Figure 5-18 Disconnect Motor Harness Figure 5-19 Open Wire Clamps at Main Logic Board Figure 5-20 Loosen Belt Tensioner Slightly; Tighten in UP position. Figure 5-21 Remove Belt from Drive Pulley Figure 5-22 Remove Two Motor Mount- Figure 5-23 Transport Drive Motor ing Screws DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
5 • Removal & Replacement Printer/Base (use for all models) 5.10 Carriage Drive Motor 1. Remove all printer/base covers (sections 5.2, 5.3, 5.4, and 5.6). 2. Disconnect two harnesses from purge unit as shown (Figure 5-24). This is necessary to provide clearance. 3. Unscrew plastic wire loom (one screw) and let hang as shown (Figures 5-24 and 5-25). 4. Disconnect motor harness. 5. Unscrew motor mounting bracket (two screws). See Figure 5-25. 6. Remove motor and bracket (Figure 5-26). 7.
5 • Removal & Replacement Printer/Base (use for all models) 5.11 Rear Drive Belts 5.11.1 Main Drive Shaft Belt 1. Remove all printer/base covers (sections 5.2, 5.3, 5.4, and 5.6). 2. Loosen belt tensioner slightly. Press on tensioner to relieve tension on belt and tighten tensioner. See Figure 5-28. 3. Walk belt off pulleys. See Figure 5-29. 4. Replace belt. 5. Loosen belt tensioner. Allow spring to normalize tension on belt. DO NOT apply additional tension. 6. Tighten belt tensioner. 7.
5 • Removal & Replacement Printer/Base (use for all models) 5.12 Carriage Drive Belt 1. Remove rear cover (section 5.2), control panel (section 5.3) and subcover (section 5.4). 2. Scribe location of belt tensioner assembly as shown in Figure 5-31. 3. Loosen belt tensioner. 4. Walk belt off pulleys and carefully remove belt from printhead loop. 5. Insert replacement belt in printhead loop as shown in Figure 5-32. 6. Position belt on pulleys. 7. Move tensioner to scribed position and tighten.
5 • Removal & Replacement Printer/Base (use for all models) 5.13 Print Head Carriage Assembly 1. Remove rear cover (section 5.2), control panel (section 5.3) and subcover (section 5.4). 2. Remove ink cartridge (Figures 5-33 and 5-34). 3. Remove the print head (Figure 5-35). 4. Make sure carriage is home. In this position the carriage is located above the purge unit and you should be able to see the printhead cap as shown in Figure 5-36.
5 • Removal & Replacement Printer/Base (use for all models) 5.13 Printhead Carriage Assembly Figure 5-38 Removing Print Head Cable at Main Logic Board Figure 5-39 Removing Cable Keeper Figure 5-40 Installing Cable Keeper NOTE: To reinstall keeper, position rear tabs in cutout first as shown in Figure 5-40, then align the front tab with the corresponding cutout. Pull out the lower rear locking tab slightly and snap the front of the keeper into position. 9. Remove main drive belt (section 5.11.1). 10.
5 • Removal & Replacement Printer/Base (use for all models) 5.13 Printhead Carriage Assembly Figure 5-42 Removing Inner Rail Mount- Figure 5-43 Pushing Rail Forward ing Screw 14. Remove the mounting screw from the outer rail as shown in Figure 5-44, right. 15. Lift the shaft up slightly and pull it toward the front of the machine to remove the carriage assembly. 16. Reassemble in reverse order.
5 • Removal & Replacement Printer/Base (use for all models) 5.14 Drive Shaft 1. Remove all printer/base covers (sections 5.2 through 5.5 and 5.7). 2. Remove main drive and intermediate drive belts (sections 5.11.1 and 5.11.2). 3. Remove drive shaft gear as shown in Figure 5-48 and pull bearing off as shown in Figure 5-49. 4. Unsnap roller from groove in shaft. See Figure 5-51. CAUTION: Tabs on roller flange break easily. 5. Remove pin from shaft and slide out shaft from front. 6.
5 • Removal & Replacement Printer/Base (use for all models) 5.15 Tape Feed Unit 1. Remove rear cover (section 5.2), control panel (section 5.3) and subcover (section 5.4). 2. Remove two screws as shown in Figure 5-52. 3. Carefully lift the tape feeder unit up. Note that a wiring harness is connected to it. See Figure 5-53 below. 4. Disconnect harness as shown. 5. Remove the tape feed assembly. 6. Reassemble in reverse order. Figure 5-52 Tape Feeder Mounting Screws Figure 5-53 Tape Feeder Harness 5.15.
5 • Removal & Replacement Printer/Base (use for all models) 5.16 Postal Security Device (PSD) You must remove the Postal Security Device (PSD) when you swap out Main Logic (Controller) Boards. Reinstall PSD on the new Main Logic Board. Push Holder Away from Board and Lift Up to Remove NOTE: There is a special procedure for handling removal and disposition of a PSD in the event a customer closes their Postage By Phone® account and wishes to retain the mailing machine.
5 • Removal & Replacement Printer/Base (use for all models) 5.17 Main Logic Board 1. Remove back cover (section 5.2). 2. Remove PSD as described above in section 5-16. 3. Remove three mounting screws as shown in figure, right. 4. Remove lower mounting screw at rear of machine as shown in Figure 5-59, right. NOTE: This screw is not used Figure 5-58 Main Logic Board Fastenon DM475, but there is an exers tra screw on the bottom of the board’s base plate attached to the floor of the frame (see Figure 5-59B).
5 • Removal & Replacement Printer/Base (use for all models) 5.18 Modem Board 1. Remove main logic board as described in section 5.17. 2. Remove mounting screws (one plastic) as shown in figure, right. 3. Carefully lift up modem board to unplug it from logic board. NOTE: There is a connector attached to modem board. See Figures 5-61 and 5-62. Figure 5-60 Modem Board 4. Disconnect wiring harness from board to free it. 5. Reassemble in reverse order.
5 • Removal & Replacement Printer/Base (use for all models) 5.19 Power Supply Figure 5-63 Removing Power Supply and Shield Figure 5-64 Removing Power Supply PCB 1. Remove all printer/base covers (sections 5.2 through 5.5 and 5.7). 2. Remove the printer/base from its base pan. Section 5.6, steps 1 through 3. 3. Unlock cable clamps for harnesses as required. 4. Disconnect cable at back cover interlock switch. 5. Disconnect power supply harnesses at Main Logic Board (J125 and J126). 6.
5 • Removal & Replacement Printer/Base (use for all models) 5.20 Encoder Sensor, Encoder Disc and Sensor Board 1. Remove all printer/base covers Encoder Sensor Assembly (sections 5.2 through 5.5 and 5.7). 2. Remove main logic and power supply PCBs (sections 5.17 and 5.19). 3. Remove sensor assembly (one screw). See figure, right. Disc Cover Mounting Screw 4. Remove encoder disc cover (one screw, figure, right). 5. Remove encoder disc. It is secured to shaft by one screw that passes through disk flange.
5 • Removal & Replacement Printer/Base (use for all models) 5.21 Segmented Roller 1. Remove all printer/base covers (sections 5.2 through 5.5 and 5.7). 2. Remove main logic and power supply PCBs (sections 5.17 and 5.19). 3. Remove encoder sensor, encoder disc and cover (section 5-20). 4. Remove input feed deck (three screws). See Figure 5-70. 5. Carefully remove the black plastic apron (four screws). See Figure 5-70. 6. Free segmented roller from frame and belt as shown in Figure 5-71. 7.
5 • Removal & Replacement Printer/Base (use for all models) 5.22 Lower Transport Assembly The lower transport assembly is mounted on two studs that serve as hinges. 1. Remove all printer/base covers (sections 5.2 through 5.5 and 5.7). 2. Remove the printer/base from its base pan. Section 5.6, steps 1 through 3. 3. Remove the right and left stud brackets. Each is held in place by one screw. See Figures 5-73 and 5-74 below. 4. Maneuver the lower transport out of the machine base.
5 • Removal & Replacement Printer/Base (use for all models) 5.23 Lower Transport Cover 1. Remove lower transport assembly from machine (section 5.22). 2. Pull off transport lock lever. 3. Remove two screws that secure cover to transport assembly. See figure, right. 4. Separate cover from lower transport assembly. 5. Reassemble in reverse order. Figure 5-77 Lower Transport Cover Removal 5.24 Waste Pad Replacement 1. Squeeze tray handles and slide out waste pad tray. 2.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.25 Feeder Upper Cover 1. Open feed access door and remove water bottle. Feed Access Door Water Bottle Figure 5-80 Feed Access Door and Water Bottle 2. Remove two mounting screws as shown and close feed access door. Figure 5-81 Mounting Screws 3. Remove four mounting screws and detach feeder upper cover. Feeder Upper Cover 4. Reassemble in reverse order. [DM475 - The left side screw is the ground for nudger deck back plate.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.26 Side Guide 1. Remove feeder upper cover (section 5.25). 2. Remove stepped screw that serves as stop for side guide slide. See figure, right. Screw Figure 5-83 Removing Stepped Screw 3. Slide side guide to front and remove it as shown in figure, right. Side Guide 4. Reassemble in reverse order. Side Guide Slide Figure 5-84 Removing Side Guide DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.27 Feed Deck 1. Remove feeder upper cover (section 5.25) and side guide (section 5.26). 2. Remove screw shown in figure, right, and detach entrance guide. Entrance Guide Screw 3. Remove six screws (located by arrows in Figure 5-86). NOTE: The DM475 feed deck has eight screws. When removing the left rear screw, Figure 5-85 Removing Entrance Guide make sure you leave the ground connection under it Feed Deck intact. 4.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.27 Feed Deck Operating Note: Maximum stack weight is 4.5 pounds. Weights greater than this will cause the belts to skip and consequently erratic or failto-feed conditions. Service Note: You can eliminate or reduce drive component noise by applying a small amount of silicone lubricant to the offending parts. Figure 5-87 Moving the Stack Present Sensor Flag to provide Clearance Figure 5-88 Feed Deck Mounting Tab 5.28 Feeder Unit 1.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.28 Feeder Unit 4. Remove moistener as shown in figure, right. Moistener Assembly Figure 5-90 Removing Moistener 5. Remove moistener tank. Moistener Tank and Wick Figure 5-91 Removing Moistener Tank Figure 5-92 A and B Removing Feed Unit Mounting Screws 5-30 DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.28 Feeder Unit 6. Remove two screws shown in figures below. Feeder Unit 7. Remove two screws shown at right and below, and detach feeder unit. 8. Reassemble in reverse order. Figure 5-93 A, B and C Feeder Unit Removal 5.29 Feeder PCB Assembly (DM400c/ DM450c) 1. Remove feeder upper cover (section 5.25). Mounting Screws 2. Unplug five connectors (arrows in figure, right) and remove four screws to detach feeder PCB. 3.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.30 Retard Roller 1. Remove feeder PCB assembly as described in section 5.29. 2. Remove one screw (figure, right), and detach the entrance guide. Entrance Guide Screw Figure 5-95 Removing Entrance Guide 3. Remove two springs (4S32380) as shown in figure, right. IMPORTANT! The four remaining springs (4S3-2379) used in this assembly have a different spring rate. The springs are not interchangeable.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.30 Retard Roller 4. Remove E-Clip, washer and bushing. 5. Remove retard roller assembly as shown in figure, right. E-Clip, Washer and Bushing Figure 5-97 Removing Shaft Components Retard Roller Assembly 6. Remove screw and cap. Figure 5-98 Retard Roller 7. Reassemble in reverse order. Cap Screw Figure 5-99 Removing Screw and Cap DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.31 Feed Roller Assembly 1. Remove printer/base from base pan (section 5.6). B 2. Remove two springs (4S32380) at location A in figure, right. 3. Remove four springs (4S32379) at location B in figure, right. See IMPORTANT note on next page (step 9). 4. Remove release holder. Push back on seal/no seal lever to provide clearance. B A Figure 5-100 Spring Locations Release Holder Figure 5-101 Release Holder 5.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.31 Feed Roller Assembly 7. Slide feed roller assembly (right side) to front and remove it. See figure, right. Feed Roller Assembly 8. Remove screw shown in fig- Figure 5-104 Feed Roller Assembly (1) ure, right, and slide feed roller Feed Roller Assembly unit (left side) to front and remove it. 9. Reassemble in reverse order.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.32 Feed Belt Assembly 1. Remove feeder unit (section 5.28). Release Lever 2. Release the release lever. Figure 5-108 Release Lever 3. Remove spring and loosen the belt tensioner screw as shown in the figure, right. E-Clips and Pulleys Gear 4. Remove timing belt and gear. 5. Remove two E-Clips, and pulleys as shown at the right. Loosen Screw Spring Timing Belt Figure 5-109 Timing Belt/Gear Removal 6.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.32 Feed Belt Assembly 7. Remove three screws as shown in Figures 5-111 and 5-112, right, and detach roller plate. NOTE: Roller plate is aligned to moistener deck by two studs, one of which is shown in Figure 5-112. Use care when separating the roller plate from moistener deck. Figure 5-111 Screw Removal, Left Stud Figure 5-112 Screw Removal, Right 8.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.32 Feed Belt Assembly 9. Remove spring (A). 10. Remove the E-Clip (B), and detach gear unit (C). 11. Remove screw (D) and detach gear (E) and bushing (F). 12. Remove screw (G) and feed belt assembly (H). F H D E B G C 13. Reassemble in reverse order. A Figure 5-114 Feed Belt Assembly Removal Figure 5-115 Feed Belt Assembly Removed from Roller Plate 5.33 Feed Motor 1. Remove the feeder unit (section 5.28). 2.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.33 Feed Motor 3. Remove spring (A) and loosen belt tensioner screw (B), Figure right. A 4. Walk belt (C) off motor pulley. B 5. Remove two screws (D). 6. Disconnect harness (E), Figure below, right. D 7. Remove motor (F). C 8. Reassemble in reverse order. Figure 5-117 Removing Feed Motor (1) E F Figure 5-118 Removing Feed Motor (2) 5.34 Feed Encoder 1. Remove feeder unit (section 5.28). 2. Unplug connector (A). A B 3.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.35 Feeder Sensor (FS2/ WS1) PCB 1. Remove feeder upper cover (section 5.25) Connector 2. Unplug connector. PCB 3. Remove screw and feeder sensor PCB. 4. Reassemble in reverse order. Screw Figure 5-120 Feeder Sensor PCB 5.36 Seal/No Seal Lever 1. Push cap assembly (figure, right) in. 2. Turn cap assembly one-quarter turn to remove cap and spring. 3. Free lever. 4. Reassemble in reverse order.
5 • Removal & Replacement Auto-Feeder (use for DM400c/DM450c/DM475) 5.37 Sealer Finger 1. Remove feed roller assembly (section 5.32). 2. Release sealer finger pressure spring. Tab 3. Free lever. 4. Squeeze tabs on back wall. See figure, right, for location. Pressure Spring 5. Remove sealer pressure finger. Tab 6. Reassemble in reverse order. Figure 5-122 Sealer Finger Pressure Spring Figure 5-123 Sealer Finger Assembly in Position DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.38 Separation of Feeder/WOW Module from Printer/Base 1. Disconnect power and remove scale if present 2. Lift up the feeder/WOW cover and remove water bottle. 3. Locate the interface cable cover. Open the cable cover by pressing on the plastic latch away from the edge of the cavity and lifting up. Interface Cavity 4. Disconnect the three cables (two purple harnesses and one black USB cable) in the interface cable cavity.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.39 Feeder/ WOW Cover 1. Separate the feeder/WOW module from the printer/base (section 5.38). 2. Remove water bottle. 3. Remove screws (nine in total) holding cover to chassis - five on back, one on each side, and two on top (when cover is open). 4. Lift cover straight up. Cover 5. Reassemble in reverse order.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.41 Feeder/ WOW Control Board (PCB) 1. Remove the feeder/WOW module cover (section 5.39). 2. Disconnect the white flex cable at the feeder/WOW junction board end. This cable is held in just by its placement in the connector - no fastener is used. White Flex Cable (partially obscured) Feeder/WOW Junction Board 3. Undo two plastic clips and remove feeder harness (purple and orange wires).
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.41 Feeder/ WOW Control Board (PCB) 6. Remove board with metal frame from chassis. 7. Disconnect the two harnesses (interface adapters) with white ferrites from board. Harnesses with Ferrites 8. Undo the top plastic clip for the white flex cable on the back of the metal frame. This will allow enough slack to pull up the flex cable from the top and unfasten it from the board.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.42 WOW Thickness and Feed Encoders 1. Remove feeder/WOW Control Board (section 5.41). You only need to do steps 1-6 from that procedure. 2. [Feed encoder only] Unlatch plastic hold-down to allow enough slack to remove harness in step 6. Do this by squeezing in the tab that compresses the pin that fits in the hole. Feed Encoder Thickness Encoder Plastic Hold-Down 3. Unplug purple harness from encoder.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.43 Feeder/ WOW Junction Board 1. Remove Feeder/WOW Control Board (section 5.41). 2. Unplug all connectors (three on top, three ribbon in the middle, and one on bottom right) and remove two screws. 3. Reassemble in reverse order. Screws Top Connectors Middle Connectors Bottom Right Connector 5.44 WOW WS2 (Middle) and WS3 (Exit) Sensors 1. Remove Feeder/WOW Control Board (section 5.41). 2.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.45 WOW Transport Belts (two, behind wall) 1. Remove Feeder/WOW Control Board (section 5.41). 2. Remove WOW thickness encoder (section 5.42). 3. Loosen (but do not remove) belt tensioner screws (one for each belt). Be careful not to over loosen the screw(s). Left Belt Tensioner Screw (Left Belt) Right Belt Tensioner Screw (Right Belt) 4.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.46 WOW Transport Pulleys (three, behind wall) 1. Remove WOW transport belts (section 5.45). 2. For left clutched pulley – Remove the WOW unit chassis (section 5.51). For middle and right pulleys – Remove feeder/WOW Control Board (section 5.41); you only need to do steps 1-6 from that procedure. 3. Remove pulleys (orientation is looking from behind): A.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.47 WOW Upper Transport (as a whole unit) 1. Remove the feeder/WOW module cover (section 5.39). 2. Open WOW jam release lever. 3. Remove thickness encoder (section 5.42). 4. Remove the eight screws that hold the upper transport to metal frame. Eight Screws (Circled), Two Tabs (in dotted boxes) Thickness Encoder (Unmounted from wall) 5. Remove upper transport unit (note two tabs) from metal frame.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.48 WOW Upper Transport Arms Assembly 1. Remove the WOW upper transport (section 5.47). 2. Release spring tension from each roller (eight total). 3. Remove e-clips on each shaft (and bushing on back side of thickness encoder shaft). E-Clip and Bushing 4. Note the position of the “tails” of the arms, then remove arms assembly. 5. Reassemble in reverse order.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.49 WOW Width Sensors (WS4, WS5, WS6) 1. Remove width sensor cover on WOW deck (lift gently from the back). 2. Note location of the two sensors (some models sold outside of US have three sensors) using the scale on opaque cover. Unfasten four screws and remove opaque cover. NOTE: For countries using two sensors only (like the US), a spare cable (for the third sensor) will be left in the cavity.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.49 WOW Width Sensors (WS4, WS5, WS6) 6. Reassemble using this order, keeping in mind the following: A. Install the new sensor(s) on metal bar and reinstall metal bar. B. Reattach opaque lens. C. Reposition the sensor to its original location. Place pencils into holes on either side of the sensor, push down, and move it to its respective setting (see below), using the numbers listed on the opaque cover as your guide.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.50 WOW Deck 1. Separate the feeder/WOW module from the printer/base (section 5.38) 2. Remove five screws from deck (one is embedded in a deep slot on the left, one is in the right back corner under upper transport). Screws for WOW Deck (Circled) Screw Under Upper Transport (Circled) 3. Disconnect width sensor cables from their sensors (section 5.49). 4. Open WOW jam clearance lever. 5.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.51 WOW Unit Chassis (as a whole unit) 1. Locate and lock-down the three WOW load cell shipping screws. The two front screws are accessed via notched holes in the feeder/WOW deck (left photo below), while the back screw is accessed through a hole in the interface cable compartment (right photo below). Notched Access Holes on Deck Access Hole Inside Interface Cable Cavity (interface cables disconnected) 2.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.51 WOW Unit Chassis (as a whole unit) 5. Remove three screws that attach the rear of the load cell assembly to the tub. These are the long, washer head screws in the oval adjustment holes. Three Long Screws in Rear of Load Cell Assembly (Circled) 6. Remove one screw for brass grounding fingers on right side of bottom chassis. Brass Fingers Screw for Brass Fingers 7.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.51 WOW Unit Chassis (as a whole unit) 8. Lift up and out whole WOW unit assembly. WOW Unit Removed from System 9. Reassemble using this order, keeping in mind the following: A. Place unit in bottom chassis (tub). Be careful the rear does not get caught on the feeder unit. B. Fasten the six long washer-head screws, but back off a 1/4 turn from fully tightened. This allows you to adjust the WOW unit. C.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.52 WOW Transport Motor 1. Remove WOW unit chassis (section 5.51). 2. Untension the motor drive belt. Tensioner Motor Drive Belt 3. Disconnect motor harness cable from junction board. Unclip harness from two clips in and under the lower WOW transport assembly. Motor Harness Cable at Feeder/WOW Junction Board Lower WOW Transport Assembly Two Plastic Clips for Motor Harnesses (Circled) WOW Transport Motor 4.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.52 WOW Transport Motor 5. Remove two screws holding motor to wall plate. Note that the motor plate is slightly off angle to the wall plate. This is normal. Screws for Motor (Circled) 6. Slide motor towards printer and remove. 7. Reassemble in reverse order. Keep in mind the following: • Ensure all cable hold-downs are properly closed around cables.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.53 Lower WOW Transport Assembly (as a whole unit) 1. Remove the feeder/WOW module cover (section 5.39). 2. [Optional, but recommended] Remove WOW unit chassis (section 5.51). 3. Remove the WOW deck (section 5.50). 4. Release tension on left belt (looking from behind) and remove e-clip from middle pulley. Encoder and Hardware Over Middle Pulley Left Belt Middle Pulley Tensioner Screw for Left Belt 5.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.53 Lower WOW Transport Assembly (as a whole unit) 7. Remove five screws (circled below) holding lower WOW transport assembly to the load cell upper casting, and remove assembly. Lower WOW Transport Assembly (Removed) Screws (circled) 8. Reassemble in reverse order. Keep in mind the following: • The three width sensor flex cables are not labelled and are attached together – do not try to separate them.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.54 Lower WOW Transport Components 1. Remove lower WOW transport assembly (section 5.53). 2. Remove WOW exit rollers (held on by e-clips and bearing). WOW Exit Rollers WOW Drive Belts 3. Remove WOW drive belts: A. Loosen the tensioner spring on each side. Screws for Tensioner Spring B. Compress spring and retighten screws on each side. C. Remove main drive belt roller (third one when looking from front of unit).
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.54 Lower WOW Transport Components D. Remove right black plastic stiffener (one screw). E. Remove e-clip and slide off middle belt roller. F. Remove left black plastic stiffener (one screw). G. Release tension spring on both sides. H. Remove tension spring assembly on front (one screw) and only loosen the tension spring assembly on the back. “Work out” shaft. I. Remove belts.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.55 WOW Load Cell Assembly 1. Remove WOW unit chassis (section 5.51). 2. Remove feeder/WOW control board on its bracket (section 5.41) 3. Remove WOW upper transport assembly (section 5.47) 4. Remove lower transport WOW assembly (section 5.53). 5. Release tensioner and remove belt on motor drive pulley. 6. Remove the motor drive pulley (consists of pulley, e-clip brass washer and plastic washer).
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.55 WOW Load Cell Assembly 8. Remove wall plate from two position pins on load cell wall (black circles in photo above). Wall Plate Removed 9. Remove load cell assembly. Load Cell Removed 10. Reassemble in reverse order. Keep in mind the following: • When re-installing back wall on load cell base, attach wall to right locking pin first, then left locking pin (when looking from the rear).
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.56 Feeder/ WOW Registration Wall Alignment This procedure aligns the registration wall of the feeder section with the registration wall of the WOW section in the feeder/WOW module. This will prevent mail pieces from hitting the WOW registration wall and ensure a straight path for the mail piece.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.56 Feeder/ WOW Registration Wall Alignment 4. Remove one screw for brass grounding fingers on right side of bottom chassis. Brass Fingers Screw for Brass Fingers 5.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.56 Feeder/ WOW Registration Wall Alignment 6. Check to make sure the WOW unit can be moved forward and backward. Move WOW unit all the way back towards the back of the machine (see bottom right photo). Moving WOW Unit Backward/Forward Screw Indicating WOW Unit In Fully Back Position 7. Remove cover screw mounting “L” bracket on right side of bottom chassis. Cover Screw Mounting “L” Bracket 8.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5.56 Feeder/ WOW Registration Wall Alignment 10. Take ruler (or straight edge) and slide up and down against back wall of feeder/WOW deck and WOW registration wall. Move WOW unit until the two walls are vertically aligned. Unaligned Walls Registration Feeder/ Wall WOW Deck Aligned Walls Straight Edge Touching Wall Note the two walls lining up against side of straight edge 11.
5 • Removal & Replacement WOW Section of Feeder/WOW Module (use for DM475) 5-70 DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
6 • Service Menus 6.1 Service Menu Overview ✍ TIP: Access the Service Menu by typing 6946 and pressing Refill Postage key. This chapter discusses the menu programs available to Service that can help diagnose/troubleshoot problems on the machine. The table below lists the top level selections in the Service Menu. Use the scroll buttons as required to see all available options. Press the appropriate soft key to select a menu option. Press the Back (Clear) key to go to the previous screen.
6 • Service Menus 6.1 Service Menu Overview Service Menu Submenu 1 Submenu 2 SBR Setup [only displays if SBR has not been done out of box or has been reset - see “Reset SBR Status” below] Diagnostics PM Diagnostics Start Normal test Motor Diagnostics Submenu 3 Run Transport Motor Submenu 4 Stop Test Run Encoder Full Rev.
6 • Service Menus 6.1 Service Menu Overview Service Menu Submenu 1 Submenu 2 WOW Options [DM475] WOW Calibration [Calibrates WOW] Static Weight [Performs static weight test] Set WOW Mode Normal Mode Precision Mode Re-zero WOW [Re-zeros WOW] Calibration Report [List dates that WOW was calibrated] Verify WOW [Place 16 oz. weight on WOW. System takes five samples and provides standard deviation and “Pass/Fail” status.
6 • Service Menus 6.2 Making SBR Setup Display in Service Menu [DM475] SBR Setup is only displayed if it has not been completed. If SBR Setup does not display on the Service Menu and you need to rerun this option, follow the procedure below. 1. At the main Service Menu, select Diagnostics. Service Menu 5. The previous screen displays. Press Back/C key.
6 • Service Menus 6.3 SBR Setup [DM475] SBR Setup is run when you first install a DM475 machine or when you have replaced the WOW width sensors (WS4, WS5, WS6) or WOW thickness or feed encoders. 1. At the main Service Menu, select SBR Setup. NOTE 1: If SBR Setup does not display, see Making SBR Setup Display in Service Menu on previous page. ✍ TIP: Access the Service Menu by typing 6946 and pressing Refill Postage key.
6 • Service Menus 6.3 SBR Setup [DM475] 4. The Width Sensor Status screen appears. Use a piece of paper and block/unblock the sensors, one at a time. You are only looking for a transition here from "Clear" to "Blocked", not a specific value. This verifies the width sensor board is functioning. Press Enter to continue. NOTE 1: The width sensor positions are adjustable, but they are factory-preset for US machines. NOTE 2: Sensor 3 is not installed on the DM475 for the US, so the value always shows "Clear".
6 • Service Menus 6.3 SBR Setup [DM475] 5. The WOW Calibration screen appears. Ensure the WOW locking screws are loosened, then press Enter to continue. WOW Calibration Make sure that WOW locking screws (3) are backed out and Transport tray is empty [Enter] to continue B. When instructed, place a 16 oz. weight onto the center of the WOW unit (etched circle on top of the feeder/WOW clearance level assembly). Press Enter to continue. 16 oz. Weight C.
6 • Service Menus 6.3 SBR Setup [DM475] 6. The Length Sensor Calibration screen appears. Place the length calibration gauge on feed deck and adjust the side guide appropriately. Press Start to continue. NOTE 1: Make sure you have closed the feeder/WOW cover; otherwise the transport won't start up when you press the Start key (and no error message displays). Length Sensor Calibration Please run calibration gauge 16 times through system.
6 • Service Menus 6.4 Diagnostics PM Diagnostics Submenu 1 Submenu 2 Submenu 3 PM Diagnostics Motor Diagnostics Run Transport Motor Run Tape Motor Cap/uncap Print Head ✍ Sensor Diagnostics S1 Transport S2 Transport TIP: Access the Service Menu by typing 6946 and pressing Refill Postage key. S3 Transport Jam Lever Top Cover Open Cap Home Pos. Pump Home Pos. Carriage Pos. Print Head Vol. Motor Diagnostics Run Transport Motor. Select this option to test the transport motor.
6 • Service Menus 6.4 Diagnostics PM Diagnostics (cont’d) Sensor Diagnostics The sensor diagnostics option shows you the state of the machine sensors (see table on the previous page for a list). You can test a sensor by manually changing it’s state and confirming the change on the display screen. (P)S1, (P)S2 and (P)S3. These are the mailing machine’s transport sensors as shown in the accompanying PS2 figure.
6 • Service Menus 6.4 Diagnostics PM Maintenance Submenu 1 Submenu 2 PM Maintenance Print Test Pattern Clean Printer Nozzle Replace Ink Tank Replace Print Head Example A: Good Example B: Bad Print Test Pattern. This option prints a test pattern like those shown in figures above. Gaps in the pattern (example B) indicate a purge (cleaning) is required. Clean Printer Nozzle This option allows you to select from four purges: A, B, C or D. These are described in Table 3-2.
6 • Service Menus 6.
6 • Service Menus 6.4 Diagnostics Feeder/WOW Diagnostics (cont’d) Information Provides basic information about the system and counters for different states the machine may undergo. • PCN Information – lists model, SN#, PCN, and Software Maintenance Release (SMR) version on the WOW • Counters – lists total pieces, WOW cycles, WOW jams, power cycles, “watchdog” reboots, and reset counts.
6 • Service Menus 6.4 Diagnostics SBR Diagnostics Submenu 1 Submenu 2 SBR Diagnostics Length Calibration Submenu 3 Re-zero Thickness Last 256 Dimensions Reset SBR Status Rest Status Don’t Reset status Length Calibration This program allows you to calibrate the length sensors (FS2/WS1, WS2, WS3) in the feeder/WOW module. A length calibration gauge is required for this test (PN# White DJ62084 or Black DW62384).
6 • Service Menus 6.4 Diagnostics SBR Diagnostics (cont’d) Last 256 Dimensions Lists the weight (oz.), length (inches), and thickness (inches) of the last 256 mail pieces run through the machine. It also provides what width sensor (if any) was triggered by the mail piece as it went through, and the mail piece sequence number. Last 256 Dimen. Captured No Weight Length W Thick Sequence # (note the order goes from bottom to top) 004 14.060 12.625 1 0.316 003 14.050 12.250 1 0.309 002 3.150 8.609 0 0.
6 • Service Menus 6.5 WOW Options [DM475] Service Menu Submenu 1 Submenu 2 WOW Options [DM475] WOW Calibration [Calibrates WOW] Static Weight [Performs static weight test] Set WOW Mode Normal Mode Precision Mode ✍ TIP: Access the Service Menu by typing 6946 and pressing Refill Postage key. Re-zero WOW [Re-zeros WOW] Calibration Report [List dates that WOW was calibrated] Verify WOW [Place 16 oz. weight on WOW.
6 • Service Menus 6.5 WOW Options Static Weight This procedure should be performed after replacing the load cell assembly and after the load cell has been calibrated (see WOW Calibration on previous page). It can help confirm whether the load cell is properly seated and also helps you check if an obstruction is touching the load cell assembly. 1 Select “Re-zero WOW”. 2. When done, select “Static Weight”. Position a 16 oz.
6 • Service Menus 6.5 WOW Options Re-zero WOW Allows you to re-zero the WOW manually for those instances where the system cannot re-zero itself (e.g., after certain error conditions) or before running the Static Weight procedure (see previous page). Calibration Report This reports lists dates and times on which the WOW was calibrated. Verify WOW This allows you to test the WOW load cell accuracy You place a 16 oz. test weight on the WOW and the system takes five samples.
6 • Service Menus 6.8 System Information Internal Information Lists information about the system, such as the UIC version, PCN, SN#, rates level, software levels, etc. USB Device ✍ TIP: Access the Service Menu by typing 6946 and pressing Refill Postage key. This screen shows if a USB device is connected to the system and the type (“MCP” or “HUB”), basically letting you know USB communications are working. It does not imply that the USB device itself is fully functional.
6 • Service Menus This page was put in as a placeholder so you can print this guide in a duplex (double-sided) mode while keeping the proper page positions. 6-20 DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
Appendix A • Glossary Account. Accumulated information from a set of transactions that have the same account ID number. Ad Slogan. An advertisement image printed to the left of the inscription position. APIN. Alphanumeric Piece Identification Number. Art Card. Smart Card device used to load custom graphics, such as Ad Slogans, into the meter. Ascending Register Amount. The cumulative amount of postage spent. ASIC. Application-Specific Integrated Circuit. Bank.
Appendix A • Glossary Meter Printer. A print head assembly driven by a PB print head controller which prevents the use of the mailing machine printer by other than a Pitney Bowes meter. Multi-Slogan. An inscription printed next to the Ad Slogan. NVM. Non-Volatile Memory PC. Personal Computer PCN. Product Code Number. Each system configuration localized for a particular market and/or equipped with a defined feature set is assigned a unique PCN for identification.
Appendix A • Glossary Secure Print Head. An ink jet print head with integrated PUB ASIC to enhance the security of the indicia data sent between the vault and the print head. Service Mode. This refers to a mode of operation, available to the CSR, in which certain non-user accessible parameters may be entered or modified. This mode corresponds to the Service Mode of previous mailing machine designs, although some operations which, in the past, required access to Service Mode are now available in Setup Mode.
Appendix A • Glossary A-4 DM300c/DM400c/DM475 Service Manual (SV61801 Rev.
Appendix B • Operator Training Checklist The following checklist is intended to be used as a training aid. As you review each topic, check it off and move on to the next until you have completed all sections of the Operator Guide (SV62261 Rev. C or later). 1 - Introduction 1. ___ Getting Help (on page v of Operator Guide) 2. ___ Other Sources of help (Cardex, CD with Operator Guide, PB websites) 3. ___ Important Safety Notes/Telephone Safety Instructions 4.
Appendix B • Operator Training Checklist 4 - Printing Options 1. ___ Manually Changing Printed Date for the Meter Stamp 2. ___ Sealing Envelopes without Printing a Meter Stamp 3. ___ Printing the Date and Time, Ad or Text (no Meter Stamp) 4. ___ Omitting/Restoring Day or Date on the Meter Stamp 5. ___ Adjusting Horizontal Print Position of Indicia 6. ___ Adding/Removing a Postal Inscription to Meter Stamp 7. ___ Adding/Removing an Envelope Ad to the Meter Stamp 5 - Normal and Custom Presets 1.
Appendix B • Operator Training Checklist 8 - Standard Accounting 1. ___ Overview of Accounting Option 2. ___ Activating/Setting Up Standard Accounting 3. ___ Turning On/ Off Accounting 4. ___ Turning On/Off Account Passwords 5. ___ Creating New Accounts 6. ___ Editing Account Names and Passwords 7. ___ Selecting An Account to Track Postage 8. ___ Displaying Account Totals 9. ___ Printing Account Reports 10. ___ Clearing All Account Totals 11. ___ Deleting Accounts 9 - Reports 1.
Appendix B • Operator Training Checklist 12 - Maintenance 1. ___ Replacing the Ink Tank Cartridge 2. ___ Filling/ Maintaining the Moistener 3. ___ Cleaning the Feeder Exit/WOW Entrance Sensor 13 - Troubleshooting 1. ___ Printing Problems 2. ___ Feeding Problems (stalled envelopes) 3. ___ Moistening Problems (envelopes don’t seal) 4. ___ Accidentally Printing the Wrong Postage 14 - Supplies and Options 1.
Appendix C • USPS® First Class Mail® Sizes USPS® First Class Mail® Sizes (Domestic) First-Class Mail Domestic—Retail SHAPE SIZE PRICE Postcards 4-1/4" max. 3-1/2" min. length height thickness Height Length 5" min. minimum maximum 5 inches 3-1/2 inches 0.007 inch 6 inches 4-1/4 inches 0.016 inch minimum maximum 5 inches 3-1/2 inches 0.007 inch 11-1/2 inches 6-1/8 inches 1/4 inch Price $0.28 $x.xx 6" max. Letters 6-1/8" max. length height thickness 3-1/2" min. Heigth Length 5" min.
Appendix C • USPS® First Class Mail® Sizes USPS® First Class Mail® Sizes (International) First-Class Mail International—Retail SHAPE PRICE SIZE * Postcards minimum maximum length 5-1/2 inches 6 inches height 3-1/2 inches 4-1/4 inches thickness 0.007 inch 0.016 inch 4-1/4" max. 3-1/2" min. Prices Canada Mexico All other countries $x.xx $0.75 x.xx 0.79 x.xx 0.98 Height Length 5-1/2" min. 6" max. Letters 6-1/8" max.
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