In late 2018 R1 / 2018 R2 versions we have identified a bug whereby manual bulk bill claims will fail to print properly.
This may show as an error "Printer driver escape sequence 5 [PASSTHROUGH] failed".
We are currently working on a fix for this bug.
A workaround is to leave the 'Online' tick on in the Medicare Bulk Billing screen. This will still print out a DB4 form which can be submitted via Manual Batch. It's just that you will have to untick 'Online' when you're in the batching screen. See screenshots further below.