ASTRO AstroJet 5000 Service Manual

AstroJet 5000

PRINTER

SERVICE

MANUAL

ASTRO MACHINE CORP.

630 Lively Blvd.

Elk Grove Village, IL 60007

Phone: [phone]

Fax: [phone]

www.astromachine.com

SAFETY PRECAUTIONS

THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN
OPERATING THE ASTROJET 5000 PRINTER.

BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL
CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY
WARNINGS, AND INSTRUCTIONS:

ü Keep hands, hair, and clothing clear of rollers and other moving parts.
ü Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure

machine mechanisms come to a stop.

ü Always turn off the machine before making adjustments, cleaning the machine, or performing any

maintenance covered in this manual.

ü A power cord is supplied with the machine. Plug it into a properly grounded wall outlet located near

the machine and easily accessible. Failure to properly ground the machine can result in sever personal
injury and/or fire.

ü The power cord and wall plug is the primary means of disconnecting the machine for the power

supply.

ü DO NOT use an adapter plug on the line cord or wall outlet.
ü DO NOT remove the ground pin from the line cord.
ü DO NOT route the power cord over sharp edges or trapped between furniture.
ü Avoid using wall outlets that are controlled by wall switches, or shared with other equipment.
ü Make sure there is no strain on the power cord caused by jamming between the equipment, walls or

furniture.

ü DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a qualified

service representative. Report any damage of covers to your service representative.

ü This machine requires periodic maintenance. Contact your authorized service representative for

required service schedules.

ü To prevent overheating, do not cover the vent openings.
ü Use this equipment only for its intended purpose.

In addition, follow any specific occupational safety and health standards for your workplace or area.

This manual is intended solely for the use and information of Astro Machine Corp., its designated agents,
customers, and their employees. The information in this guide was obtained from several different sources
that are deemed reliable by all industry standards. To the best of our knowledge, that information is
accurate in all respects. However, neither Astro Machine Corp. nor any of its agents or employees shall be
responsible for any inaccuracies contained herein.

AstroJetTM is a registered trademark of Astro Machine Corp.
Hewlett-Packard is a registered trademark of Hewlett-Packard Corporation.
Windows 98 and Windows XT are registered trademarks of Microsoft Corporation.
IBM is a registered trademark of International Business Machines.
All other trademarks are the property of their respective holders.

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher

TABLE OF CONTENTS

Table of Contents

SECTION 1 – Installation 1

Contents of Packaging 1
Tools Requires 1
Unpacking and Assembly 1
Connecting the AstroJet 5000 3
Installing the Inkjet Cartridges 4
Installing the Printer Driver 5

SECTION 2 – Trouble Shooting 9

Power Problems 9
Interface Communication Problems 9
Feeding Problems 10
Software Problems 12

SECTION 3 – Functional Operation 13

Sequence of Operation 13
Printer Controls 14
Printer Driver Properties 15

SECTION 4 – Adjustments 21

Drive Belt Tension Adjustment 21

SECTION 5 – Disassembly and Assembly 23

Basic disassembly 23
Replacing Separator Tips 23
Service Disassembly Procedures 23

Right-hand Side Cover 24
Left-hand Side Cover 25
Replacing Motor Drive Belt 26
Replacing Feed Rollers 27
Replacing Main PC Board 30
Removing and Replacing Cleaning Station 31
Removing the Print Engine 33
Replacing Transport Rollers 36

SECTION 6 – Maintenance 39

The Inkjet Cartridge 39
Jams in the AstroJet 5000Printer 40
Replacing the Sheet Separators 41
Cleaning 41

Appendices 43

Appendix A – ASTROJET 5000 Specifications 43
Appendix B – Supplies and Optional Hardware 44
Appendix C – Wiring Diagram 45

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TABLE OF CONTENTS

NOTES

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Section 1 – Installation

Contents of Packaging

1. ASTROJET 5000 Printer

2. AC Power Adapter

3. Parallel Cable and USB

4. Software Driver

5. Paper Guides

6. Operator Manual

7. Driver Software Disk

SECTION 1

INSTALLATION

Tools Required

Tools required Standard #2 Phillips head screwdriver.

Unpacking and Assembly

Remove the Printer and its parts from the carton. Remove all packing tape. The screws that attach the
various parts of the guides to the printer are under the tape in their respective positions.

Begin by installing the Fixed Side Guide. It is held in place by two screws [1]:

1

SECTION 1
INSTALLATION

Next install the Adjustable Side guide using the two screws
[2] provided.

Attach the Rear Paper Support using the two knobs [3]
provided.

NOTE: the large slots fit over the socket head screws.

Install the Back Guide using the thumbscrew and washer
[4] provided. The washer goes between the screw and the
Rear Paper Support.

2

SECTION 1

INSTALLATION

Connecting the AstroJet 5000

Plugging in the Printer

Make sure that the main power switch of the Printer is in the OFF position.

1. Connect the power cord from the power pack to the connector [4] at the rear of the Printer.

2. Plug the power cord into the power pack and then plug the other end into a 115-220 Volt AC, 50/60

Hz. Grounded outlet.

CAUTION

USE THE POWER SUPPLY PACKED WITH THE PRINTER.

DO NOT USE AN ADAPTER PLUG OR EXTENSION CORD TO

CONNECT THE PRINTER TO THE WALL RECEPTACLE.

DO NOT USE OUTLETS CONTROLLED BY WALL SWITCHES.

DO NOT USE AN OUTLET THAT SHARES THE SAME CIRCUIT

WITH LARGE ELECTRICAL MACHINES OR APPLIANCES.

Connecting to the Computer

The Printer has both a USB and a Parallel Port [1]
connection. The two ports are located one above the
other as shown. If you use the parallel printer cable
from your computer plug it in and latch the two
locking clips. If using a USB Port [2] plug that cable
into the connector mounted below the parallel
connecter.

The Main Power Switch [3] should be turned on after
you attach the power cord to the Power Receptacle [4]

3

SECTION 1
INSTALLATION

Install the Inkjet Cartridges

The AstroJet 5000 uses two ink cartridges, the HP57 Color cartridge and the HP56 or HP58 Black
cartridge. Use the HP56 Black cartridge for everyday printing and the HP58 Black Cartridge for photos
and high quality printing.

Install and replacing the cartridge is done in the following manner:

1. Plug in the Printer and turn the main

power switch ON. Open the top cover
and press the soft power button [1], the
button will light... The printhead
carriage will move side to side and the
printhead wiper mechanism will move to
its downward position. Wait until the
mechanism stops moving. Then open
the two printhead latching covers [2] by
lifting them from the front.

2. Inset the cartridge in their appropriate

positions as shown. The color cartridge
goes on the left.

3. Press down on the cartridge latches until

you hear a click, and then close the
machine cover.

4

SECTION 1

INSTALLATION

Installing the Printer Driver

The installation procedure for the AJ5000 driver is different for USB and Parallel Ports. Follow the
instructions below for installing the printer with a USB port. Instructions for installing the printer on a
Parallel Port follow the instructions below.

Install the disk supplied with the printer in your CD drive. If the Window’s Explorer window opens, close
it.

USB Port Installation

1. Connect the printer to the computer via the

USB port and turn the printer ON. In a few
minutes the “Welcome to the Found New
Hardware wizard” will open on the computer
screen. Check the box “No, not this time” as
shown. Then click NEXT>.

2. The next window that opens will show the

name of the printer AMC50 or AMCAMC50.
Click on the “Install the software
automatically (Recommended” box and then
click on NEXT>.

3. After a few moments the window shown

below will appear, and then the “Hardware
Installation” window will appear. Click on
“Continue Anyway” and the driver software
will load from the disk.

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SECTION 1
INSTALLATION

4. Once the driver is loaded the

“Completing the found New Hardware
Wizard” window will appear. Click
FINISH.

5. The installation is complete when the “Found New Hardware” box appears in the lower right-hand
corner of your screen.

Parallel Port Installation

1. Connect the printer to the computer via the Parallel

port (LPT1) and turn the printer ON. If the disk loads
and the “Welcome to the Found New Hardware
wizard” opens; CLOSE it.

2. Click on START and then Printers and Faxes.

When the “Printers and Faxes” window opens click on
Add a printer.

3. The “Welcome to the Add Printer Wizard”

window will open. Click NEXT.

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4. Click on the Local printer attach to the

computer and Automatically detect and install
my Plug and Play printer buttons in the “Local

or Network Printer” window. Then click NEXT.

5. The “Welcome to the Found New Hardware

Wizard” window will then open. Click on No,
not at this time and then click NEXT.

SECTION 1

INSTALLATION

6. In the “Found New Hardware Wizard” window

that appears next, click on Install the software
automatically (Recommended) button and
then click NEXT.

7. The installer will look for the disk. This may take a

few minutes. Then the “Please wait while the wizard
installs the software…” will open as will the “Copying
Files” window.

7

SECTION 1
INSTALLATION

8. After a few moments you will see the “Hardware

Installation” window. Click on the Continue
Anyway button to continue the installation of the
software.

9. When the “Completing the Found New Hardware

Wizard” window opens click FINISH.

10. The “New Printer Detection” window opens. It is

a good idea to print a test page at this point to
confirm that the printer driver and the printer are
communicating. Load a sheet of 8-1/2” X 11”
paper in the printer and click NEXT.

11. Once the test page is printed the “Completing the

Add Printer Wizard” window will display
information about the printer. Click FINISH to
close the window.

12. Restart the computer to complete the installation.

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SECTION 2

TROUBLE SHOOTING

Section 2 – Trouble Shooting

This section is arranged by first the condition that might occur, and then by possible
problems, their cause and recommended solutions.

Power Problems

CONDITION PROBLEM SOLUTION

Power is on, nothing happens. No power to printer Check that the power cord is plugged in.

Check that the power outlet is live.
Replace AC Adapter...

Interface Communication Problems

CONDITION PROBLEM SOLUTION

Printer does not respond to
software.

Printer not responding to
software

Connection problems. Check that port is

communicating with printer by
using another parallel or USB
cable, replace cable.

Check cable connection to see if
any of the pins are bent or
missing. If so replace cable.

If port cannot communicate using
another parallel or USB cable,
check printer.

If port cannot communicate using
another parallel or USB cable
and the printer is OK, check
parallel or USB port on the
computer.

Poor connection between printer
and computer

Turn printer off and on again.

Check connections.

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SECTION 2
TROUBLE SHOOTING

Feeding Problems

CONDITION PROBLEM SOLUTION

Intermittent feeding Feed ramp not used

Side guides set improperly

Dirty feed rollers

Paper stuck together

Uneven mail piece

Multiple feeds Separator gap not set properly.

Media stuck together.

Side guides too close to media

Brake misadjusted.

Failure to feed Side guides too close to media

The feed ramp adds a slope to the stack
and helps feeding.

Loosen the side guides slightly.

Clean the feed roller with distilled water
and a cloth. DO NOT use any solvents or
detergents as they may damage the feed
rollers.

Fan media before placing it in printer

Tap inserts to front of envelopes and retry.

Adjust separators to thickness of media.

Fan the media before loading in printer.

Push side guides away from media.
Adjust brake (see Section 4- Adjustments)

Readjust side guides

No power to printer.

Feed gap too tight.

Feed gap too loose

Material is out of specification.

Motor on, feed rollers not turning.

Clutch not engaging.

Motor failure.

No power

Check the power button is ON and that the
power cord is plugged in.

Adjust separator to thickness of media

Adjust separator to thickness of media.

Maximum thickness is 0.0625”

Check for broken drive belt and replace,
Check for loose set screws on drive pulley
or belt drive roller pulley.

Replace Clutch.

Check that motor is receiving power from
the power supply.

See Power Problems in this Section.

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CONDITION PROBLEM SOLUTION

SECTION 2

TROUBLE SHOOTING

Jams Paper path obstruction

Paper not loaded properly

Feed ramp not used properly

Separators improperly adjusted

Media curled or bent.

The separators are worn.

Printing Problems

CONDITION PROBLEM SOLUTION

Extra lines; losing data

Improper output (address
information out of order, miss­feeding, etc.)

Media jams

No communication

Print too light or missing
character dots
Blurry address

Split line of type

Feeding problems

Paper Light Flashes

Cancel Light Flashes

Database problem Check data in database

Wrong interface settings
Static electricity

Dirty media sensor
Double feeding

Media is curled or bent
Media is too thin

Improper cabling / connector

Unit not receiving power

Clogged or dirty printheads
Running out of ink
Image is not sharp Replace the inkjet cartridge

A line of type does not match
up.

Double sheets.
Miss feeds.
Paper Miss Feed Press the Paper button to

Ink Cartridge Missing Install print cartridge.

Clear jam and remove pieces remaining
under printhead.

Instruct operator in proper loading of
media.

Set feed ramp

Adjust separators to thickness of media.

Uncurl media.

Replace separator tip.

program
Check software or data base
on PC.
Close the software and then
turn Printer of and on.
Clean media sensor.
Adjust Sheet Separators on
feeder.
Uncurl media.
The minimum thickness for
media is 0.006”.
Use Proper cable (see
Operator Manual).
Check plug connections,
on/off switch and fuse on
back.
Replace inkjet cartridges.

or change the printer
resolution setting.
Check media thickness.

Check media thickness. The
minimum thickness for
material is 0.006”.
Increase the resolution of
the print.
Adjust the sheet separator.

feed the paper into position
for printing.

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SECTION 2
TROUBLE SHOOTING

Software Problems

Refer to the manual for the application software being used.

12

FUNCTIONAL OPERATION

Section 3 – Functional Operation

Sequence of Operation

The user prepares the printer

1. Install cartridges in proper location.

2. Uses a single piece of media to set sheet separators.

3. Loads media and adjusts the side guide to within 1/32” of media.

4. Stacks media in feeder and adjusts feed ramp.

5. Turn printer on.

The user prepares the layout and creates a job

1. The user selects the database and opens th e layout software such as Microsoft Word.

2. Creates a layout consisting of the variable data from the database using the merge function.

SECTION 3

3. User then creates a layout using fixed information such as return address and adds graphics as

required.

4. User saves layouts.

5. User initiates the Print function through the File menu in the program.

6. User then selects through the printer driver properties menu paper size and desired print resolution .

7. User then clicks on the print button to print the job.

Printing the Job.

1. As soon as enough of the job is sent from the computer to the printer, the soft power button will begin

to blink. If this is the first job of the day, the printheads will automatically start the cleaning function.
Once this is complete the printer will begin to feed paper.

2. After the media travels to the printer, the paper sensor will detect the lead edge of the paper and will

then stop the feeding and line up the lead edge of the paper with the printheads.

3. The printheads then begin to move across the paper printing the job. After each pass the paper is

advanced by the paper feed clutch to continue the printing.

4. When the first piece is printed it is ejected and the next piece is moved into position and aligned for

printing.

5. When the last piece in the job is printed the printer ejects it and any pieces waiting to be printed.

6. The printheads return to the capping station and remain there until the next job is sent.

Printing

The print engine consists of two printheads mounted on a movable shuttle. One printhead is three color s
(Cyan, Magenta and Yellow) and the other is Black to provide full color CMYK printing. The printing and
operation of the printer is controlled by the single main circuit board.

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