ASTRO MACHINE CORP.
630 Lively Blvd.
Elk Grove Village, IL 60007
Phone: (847) 364-6363
Fax: (847) 364-9898
www.astromachine.com
TM
AstroJet
5000
SHUTTLE HEAD
PRINTER
OPERATOR MANUAL
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:
Keep hands, hair, and clothing clear of rollers and other moving parts.
Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be
sure machine mechanisms come to a stop.
Always turn off the machine before making adjustments, cleaning the machine, or performing any
maintenance covered in this manual.
The power cord and power supply supplied with the machine should be plugged it into a properly
grounded, easily accessible wall outlet located near the machine. Failure to properly ground the
machine can result in severe personal injury and/or fire.
The power cord and wall plug is the primary means of disconnecting the machine from the power
supply.
DO NOT use an adapter plug on the line cord or wall outlet.
DO NOT remove the ground pin from the line cord.
DO NOT route the power cord over sharp edges or trap it between furniture.
Avoid using wall outlets that are controlled by wall switches, or shared with other equipment.
Make sure there is no strain on the power cord caused by jamming between equipment, walls or
furniture.
DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a
qualified service representative. Report any cover damage to your service representative.
This machine requires periodic maintenance. Contact your authorized service representative for
required service schedules.
To prevent overheating, do not cover the vent openings.
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, 2000, NT and XP 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
Section 1 – Getting Acquainted
1
Front View
Rear View
1
2
Section 2 – Installing the Printer
3
Choosing a Location
Unpacking and Setup
Connecting the AstroJet 5000
Connecting the Computer
Installing the Inkjet Cartridges
Setting up the Feed
Feeding Envelopes
Installing the Printer Driver
3
3
5
5
6
7
8
9
Section 3 – Operating the AstroJet 5000
13
Setting Up a Job in MS Word
Printer Driver Properties
Paper/Quality Tab
Finishing Tab
Effects Tab
Basics Tab
Color Tab
Service Tab
Tap 13
13
15
15
17
17
17
18
19
22
Section 4 – Maintenance
23
The Inkjet Cartridge
Jams in the Printer
Replacing the Sheet Separators
Cleaning
23
24
25
25
Section 5 –Troubleshooting
27
HP Inkjet Print Cartridges
The Printer
27
28
Appendices
29
Appendix A – Specifications
Appendix B – Supplies and Optional Hardware
29
30
Index
31
TABLE OF CONTENTS
Table of Contents
i
TABLE OF CONTENTS
NOTES
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ii
1.
Paper Switch – When light blinks indicates that the next piece did not feed into
position. Press it to continue printing.
2.
Cancel Switch – Press to cancel the job being printed. When the light is flashing
the Printer is out of ink or a cartridge is missing.
3.
Adjustable Media Guide – Holds the paper against the Fixed Register Guide.
4.
Fixed Media Guide – All printing is registered against this Guide.
5.
Soft Power Button – Press and hold to reset the Printer’s software. Light comes
on when the job is sent to the Printer.
Section 1 – Getting Acquainted
SECTION 1
GETTING ACQUAINTED
Front View
1
SECTION 1
1.
Parallel Port Connection – Attach the Centronics Parallel cable here.
2.
USB Port Connection – USB cable attaches to the printer here.
3.
Main Power Switch – Powers up the printer when turned ON.
4.
Power Connection – Connect the Printer’s Power Pack here. Use only the
Power Supply shipped with the Printer.
5.
Clear Machine Button – Operates the motor to help clear media from the
machine.
6.
Rear Guide Support – Supports the media.
7.
Adjustable Media Guide – Holds the media against the Fixed Register Guide.
8.
Rear Guide – Holds the media against the Front Plate.
9.
Fixed Media Guide – All printing is registered against this Guide.
GETTING ACQUAINTED
Rear View
2
SECTION 2
INSTALLING THE PRINTER
Section 2 – Installing the Printer
Before using the AstroJet 5000 Printer the following must be done:
Choose a location for the Printer
Unpack and assemble the Printer.
Plug in the Printer and connect it to the computer
Install the Inkjet Cartridges
Set up the feed on the Printer
Install the Printer Driver
Choose a Location
The AstroJet 5000 should be placed on a sturdy worktable or cabinet at least 9 inches from any walls.
Protect the AstroJet 5000 from excessive heat, dust, and moisture – avoid placing it in direct sunlight.
Unpacking and Setup
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]:
3
SECTION 2
INSTALLING THE PRINTER
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.
4
INSTALLING THE PRINTER
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 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.
SECTION 2
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].
5
SECTION 2
INSTALLING THE PRINTER
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 every day printing and the HP58 Black Cartridge for photos
and high quality printing.
To install and replace the Cartridge:
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. Insert the Cartridges 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. Refer to Section 3 – Operating the
AstroJet 5000 for information on how to
align the Printheads when you install
new Cartridges.
6
SECTION 2
INSTALLING THE PRINTER
Setting up the Feed
The AstroJet Printer is equipped with four Sheet Separators, two Side Guides (one fixed and the other
adjustable), and a Back Media Guide. The Sheet Separators are adjusted individually as follows:
1. Move the Adjustable Side Guide so that the locking screws on the Sheet Separator Assembly are
accessible.
2. Loosen the locking screw and raise the Separator, then tighten the locking screw to hold the
Separator in the up position.
3. Place the media under the Separators. The
media is always placed against the Fixed
Paper Guide. Loosen the Separator locking
screw. Place the Separator on the media and
tighten the locking screw.
4. Adjust the Movable Side g\Guide so that it
is about 1/32-inch from the sides of the
media. Tighten the locking screws on the
Side Guide. Place some media in the
machine.
5. The Rear Support Guide adjusts by
loosening the two Locking Knobs and
raising it up or down. The starting position
for the Guide is with the slots centered on
the Knobs. If you experience feeding
problems, you can raise or lower the Rear
Support Guide to help improve the angle of
the media to the Feed Roller / Sheet
Separators.
7
SECTION 2
INSTALLING THE PRINTER
6. Adjust the Rear Guide by loosening the
locking screw and place it so that the
media is raised approximately 1/2-inch
above the Feed Table.
7. The same procedure is used for other media sizes and types.
NOTE: The amount of media that can be stacked on the Printer is determined by the weight of
the material. The Feeder may not feed larger and heavier media when the stack is full. If this is
the case, reduce the amount of media in the stack until the Feeder functions properly.
Feeding Envelopes
1. Insert one envelope under the Sheet
Separators and adjust the two outer ones to
the envelope. Do not use the Center
Separator. Then place a small stack of
envelopes in the Printer and adjust the
Adjustable Side Guide to within 1/32" of
the envelopes. Then adjust the large Rear
Envelope Support to that it is centered on
the stack of envelopes and the first
envelope is at the bend in the Rear Guide
as shown.
NOTE: The position of the Rear Guide is a
starting point. Some envelopes may require that
the Guide be slightly further back. Also, the Rear
Support should be in the middle position to start.
2. Load envelopes to the top of the Side
Guides and then place the weight on top of
the pile. There are two weights, one for # 9
and one for # 10 envelopes. These weights
keep pressure on the pile and help feeding.
They are designed to permit feeding of the
last envelope in the stack without the
weight feeding into the Printer.
8
SECTION 2
INSTALLING THE PRINTER
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 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.
9
SECTION 2
INSTALLING THE PRINTER
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>.
10
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 2
INSTALLING THE PRINTER
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.
11
SECTION 2
INSTALLING THE PRINTER
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.
12
SECTION 3
OPERATING THE ASTROJET 5000
Section 3 – Operating the AstroJet 5000
Once the Printer Driver is installed on your computer, you are ready to start printing. Turn the Printer on
from the Main Power Switch. Set up your job and send it to the Printer. The Printer will start and print.
This rest of this section is divided into two parts. The first part describes how to set up a job to print from
Microsoft Word. The second part describes the driver properties and the various options available when
you run a job.
The Printer Driver that you installed on your computer in Section 2 should be set as the default driver. It
will then be accessible through your applications such as Microsoft Word. Other types of applications and
database management software will work in a similar manner when using this Driver.
This Section further assumes that you have set up the Feed and the Printer is connected to your computer.
Setting-Up a Job in MS Word
The first thing that you have to take into account when
setting up a job to print in MS Word or any other
application is the print area of the Printer and the
paper sizes it can handle. The maximum print area for
the AstroJet 5000 Printer is 8.5 inches wide by 17
inches long. The maximum paper size that the Printer
can feed is 11 inches wide by 17 inches long. The
diagram on the right illustrates this difference.
When setting up for the maximum print area for an 11
inch by 17 inch document, always set the paper size as
9.5 inches wide by 17 inches long in the custom paper
setting. Set the top and bottom margin to 0.24 inches
and the left-hand margin to 0 inches. The right-hand
margin should be set to 1 inch. You will now be able
to layout the job and print the maximum printing area.
For other page sizes such as 8.5 inches by 11 inches
(standard letter) or 8.5 inches by 14 inches (legal size)
set the paper size to their exact sizes and choose the
margins you want.
NOTE: the top and bottom margin default is 0.24 inches, but you can make them larger.
A #10 envelope can be chosen from the Page
Setup in MS Word. The envelope should be run
the 9.5 inch wide way. This is the fastest way to
run the envelope, especially if you are addressing
them with a mail merge. Setting up for this is as
simple as selecting the #10 envelope from the
Page Setup Menu and setting the top and bottom
margin at 0.24 inches and the right-hand margin
at 1 inch as shown.
13
SECTION 3
OPERATING THE ASTROJET 5000
Printing the Entire 9.5 inches on a #10 Envelope
If it is necessary to be able to print the entire 9.5 inch length of the #10 envelope it can be done, however
the printing speed will be greatly reduced because you will be running the envelope in the long direction.
1. Set up your layout page by going
to the Page Setup option in MS
Word. Select the margins as
shown below. Set the margins that
you want to use for the layout.
The minimum left and right
margins that can be set are 0.13
inches. Select Landscape for
paper orientation and then select
the Paper tab.
2. When you select the Paper Tab,
select Paper Size “Custom 1” and
then set the paper Width to 9.5
inches and the paper Height to
4.13 inches. Then click on the OK
button.
NOTE: You must use a custom size
to get the correct orientation of the
envelope. Do not use the standard
#10 envelope selection.
3. The last step is to go to print from
the File menu and select
Properties from the Print window.
In the AMC50 Properties window
select “Custom 1” and set the
Width at 4.13 inches and the
Length at 9.5 inches under the
Page size. Click OK in the
“Custom paper size” window and
then click OK in the “AMC50
Properties” window to return to
the “Print” window.
4. Select the number of copies you
want to print, and then click OK.
For more information about changes that can be made in the Driver please see the section on the
Printer Driver below.
14
SECTION 3
OPERATING THE ASTROJET 5000
Printer Driver Properties
The Printer Driver for the AstroJet 5000 works the same as any other Printer Driver for Windows. It does,
however, have some enhancements to help you maximize the ability of the Printer to print variable
addresses quickly and efficiently.
Once the job is set up click on File, and then on
Print. The window at right will open.
Paper/Quality Tab
If you then click on the Properties button, the
“Properties” window opens. Click on "Size is" box to
select the size of the material to be printed. You can
enter up to five custom sizes if the paper size you are
printing on is not listed.
The next step is to click on the "Paper Length" box to
select either Automatic Detection or "Select from
above". Automatic Detection will cause the Printer to
feed one sheet of paper and measure its length. The
Printer will then use this information for each
succeeding sheet. The first sheet is not printed. "Select
from above" allows you to pick the paper size from
the "Size is" box and the first sheet will be printed.
15
SECTION 3
OPERATING THE ASTROJET 5000
The "Type is" box allows you to select the type of
paper you are going to print. Some settings such
as Photo Paper, Glossy will adjust the printing
mode in the software to account for the quality of
the paper.
Print Quality refers to the amount of ink and the
resolution of the image the Printer will print. Fast
Draft uses the least amount of ink, has the lowest
resolution and prints the fastest. It is equivalent to
300 dpi (dots per inch). Fast Normal and Normal
are approximately 600 dpi and print slower, but at
a higher quality. The Best setting is
approximately 1200 dpi and is used where high
quality images are required. Finally, there is the
Maximum DPI setting. This setting is used when
printing photos and has a correction routine
available under the "Real Life Digital
Photography" button to help improve the quality
of photos you print.
On this and subsequent pages in the Properties
window you will notice at the top the Print Task
Quick Sets menu. This menu contains some
standard setups for printing different types of
jobs. You may also add job setups to this menu by
typing in a description or name for a job and
clicking on the Save button. This is particularly
useful if you have some standard jobs you run all
the time. Highlighting the job and clicking the
Delete button will cancel any of the jobs in the
menu.
16
Finishing Tab
Gives you the option of printing more than one page
on a single page or printing a large single page over
several sheets of paper to make a sign or poster. To
print more than one page on a single page, click on
the "Pages per sheet" menu and select the number of
pages you wish to print. This option works with
multiple page documents. The default is one. The
"Poster printing" option works just the opposite
way. If you wish to make a document larger use this
option to select the size of the printed document.
The default for this option is OFF.
Effects Tab
Gives you additional options for print size. You can
use the "Print document on" option to specify a
particular size of paper that you want to print on
regardless of the size of the original document. The
printer will reduce or enlarge the output to match
the document. If you select "% of normal size" the
Printer will print the document in the size you
selected regardless of the size of the paper. The
"Watermarks" option prints a light background
watermark in the paper while printing the original
document. When this option is selected the "First
page only" option will let you print the watermark
on the first page, but not subsequent pages.
SECTION 3
OPERATING THE ASTROJET 5000
The Edit button takes you to a second window that
allows customization of the watermark, including
font selection, color, density and you can also create
you own watermark.
Basics Tab
Two important facts about the Basics tab window:
[1] Orientation should always be set to Portrait,
never Landscape. [2] Under "Page order", if you are
printing a merged database, "Front to back" prints
the last record first and "Back to front" prints the
first record first. The "Back to front" is the fastest
way to print database records.
Copies default is 1, but you can select as many
copies per document as you require. Collate will
keep each set separate as it is printed.
If you check the "Show print preview" box a
window will open before printing starts so that you
can see the document as it will be printed. This box
has options to view the pages, start printing or
cancel the job.
17
SECTION 3
OPERATING THE ASTROJET 5000
The Advanced features option on the right gives
you control over Ink volume which can be used to
put less ink on the paper to help drying on less
porous stock. The "Dry time" option will hold the
printout until the dry time has elapsed and then
print the next record.
The last option in this window is the Low memory
mode. Checking this box will manage the memory
in your computer to print a large job if you do not
have enough computer memory. This box should
be left unchecked unless you really need it.
Color Tab
Helps you control the Printer’s color output. If you
wish to print in black only click on the "Print in
grayscale" and select one of the three options.
"Print in sepia" will print a sepia-colored color
image. You cannot click on both the "Print in
grayscale" and the "Print in sepia" boxes together.
The default setting for "Color space" is
sRGB/sYCC. The other choices are "AdobeRGB"
and "Managed by application". Unless you are
familiar with or have an application that can
manage the color, use the default.
"Advanced color settings" gives you control of
the color and how it is printed. You can adjust
Saturation, Brightness and Color tone. You can
also adjust the individual colors with this window.
This is very useful when printing color photos.
IMPORTANT! When making changes to the
standard settings in the Driver, if it cannot be
done you will get an error message.
18
Service Tab
Allows you to perform maintenance and check
functions on the Printer.
Clicking on the "Print a Test Page" button will print a sample
page on the Printer as shown.
SECTION 3
OPERATING THE ASTROJET 5000
Clicking on the "Print a Diagnostic" button will print the
pattern shown.
19
SECTION 3
OPERATING THE ASTROJET 5000
When the "Clean the Print Cartridge" button is pressed the
“Clean the Print Cartridge(s)” window appears and prints the
page below.
Clicking on the Intermediate Clean button opens the screen at
right. Clicking on the Prime button will take you to the next
level of cleaning if necessary. When the cartridges are clean
click the Done button to exit this routine.
The Display Ink Level button will show you an
approximation of the amount of ink remaining in the
Cartridges. This only works if you start with a new
Cartridge and do not remove it during its use. Click
OK to exit this function.
The Calibrate the Device button is used to calibrate
the relationship between the Black and Color
Cartridges to make
sure they line up
with each other. This
function is usually
performed whenever
a new Ink Cartridge
is installed in the
Printer. Click Done
when the alignment
is completed or on
Align to repeat this
function. A copy of
the print that the
calibration routine prints is shown here.
20
SECTION 3
OPERATING THE ASTROJET 5000
The Calibrate Color button has no function. Pressing it
will return the window at right.
Tap 13
Tap 13 is a routine built into the Printer to change the way it operates. When using Tap 13, the Printer will
print only the number of pieces chosen. It will not eject a blank piece at the end of the run. This eliminates
the last sheet being blank, but it does slow down the operation of the Printer. Tap 13 feeds and prints one
sheet at a time. If you choose more than one sheet they will be printed, but each sheet is fed, printed and
ejected before the next sheet is fed.
To initiate the Tap 13 sequence press and hold the Soft Power key on the front of the Printer, press the
Cancel key one time and then the Paper key three times. Then release the Soft Power key. The Cancel
key light will blink twice indicating that the Tap 13 sequence is initiated.
To print with this feature, select the paper size you are printing on in the Driver under Properties and then
select the “Select from Above” option. If your paper size is not listed, create a custom page size.
To cancel out of Tap 13, press and hold the Soft Power key on the front of the Printer, press the Cancel
key one time and then the Paper key three times. Then release the Soft Power key. The Paper key light
will blink twice indicating that the Tap 13 sequence is OFF.
Turning off the Printer will also cancel the Tap 13 mode.
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SECTION 3
OPERATING THE ASTROJET 5000
NOTES
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SECTION 4
CAUTION
NEVER SHAKE, DROP, OR HIT THE CARTRIDGE AGAINST THE PALM OF YOUR
HAND OR ANY OTHER HARD SURFACE. SHAKING THE PRINT CARTRIDGE DOES
NOT “MIX” THE INK AND HITTING THE CARTRIDGE AGAINST A HARD SURFACE
DOES NOT CLEAR THE NOZZLES. BOTH OF THESE ACTIONS ACTUALLY HURT THE
PRINT QUALITY BECAUSE THEY ALLOW BUBBLES TO FORM NEAR THE INK FIRING
CHAMBERS. THESE BUBBLES PREVENT THE NOZZLES FROM FIRING, CAUSING
WHITE STREAKS IN THE PRINT IMAGE.
MAINTENANCE
Section 4 - Maintenance
This section covers how to care for the Ink Cartridges, clear paper jams, replace the Sheet Separators, and
perform routine maintenance on the Printer.
The Inkjet Cartridge
The AstroJet 5000 Inkjet Cartridges must be replaced when out of ink, when print quality is poor, or when
the built in cleaning process has not helped the image quality.
The Approximate life of the Black number 56 Inkjet Cartridges, based on three lines of 20 characters at 10point size per address, is 20,000 addresses in the Fast Draft mode.
NOTE: These figures can vary depending on the font selected.
To Replace the Inkjet Cartridge:
Turn the Printer on, open the Top Cover and press the soft key. Wait until the Cartridge Heads stop
moving, then lift the Latch Lever to release the Cartridge, pull the Cartridge toward you and lift it
away from the Holder.
Remove the new Inkjet Cartridge from its packaging, taking care not to touch the copper contacts,
the metal plate, or the gold printhead. Remove the protective tape from the Printhead.
Slide the new Cartridge into its Holder and latch the Locking Lever.
Do not force the Lever into place.
Storage
New Cartridges should be stored in their original packaging and kept away from heat.
Once opened, the Cartridge should remain in the Printer.
Disposal
The Cartridge may be disposed of in a normal manner.
For ink spills, use soap and water to clean up any problem areas. Abrasive soap works well in getting
ink off of hands.
23
SECTION 4
MAINTENANCE
Cleaning the Printhead
The Printheads in the AstroJet 5000 Printer are cleaned automatically each time the machine is turned on or
when the Printer software decides they need cleaning. No operator intervention is required.
Jams in the AstroJet 5000 Printer
If a jam occurs, STOP the Printer. You can do this by lifting up the Front Cover.
Some possible reasons for jamming are:
1. Feeding more than one piece of media.
2. Damaged media, such as dog-eared (turned down corners).
3. Media that is not stiff enough may not be usable. Media that meets Postal stiffness requirements for
automated feeding is acceptable in the AstroJet 5000.
4. Envelopes that are caught under the flap of another envelope or stuck to one another may cause
jamming.
Failure to Feed Paper Stoppages
If a sheet feeds, but does not get into the proper position to feed, you can clear it from the machine by
pressing the Green "Clear Machine" Button. This switch will operate the Drive Motor and Rollers, but not
feed any additional paper.
Removing Jammed Media
It may be necessary to remove one or more of the
Paper Guides to gain access to the jammed media.
The Forwarding Roller Guide Plate can be removed
by pressing down on the Plate and sliding it toward
the feeder end of the Printer. Lift the Plate out of the
machine.
NOTE: It is important that when this Guide is
removed and reinstalled it does not have any
side-to-side play. If after installing the Guide you
can move it from side to side, remove and
reinstall it.
The Front Media Guide can be removed by opening
the Front Cover, lifting the Guide vertically, then
lifting it out of its Guide on the Printhead side of the
machine.
24
SECTION 4
WARNING
THE PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED
REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING
ANY MAINTENANCE DISCONNECT THE MACHINE FROM ITS POWER SOURCE!
CAUTION
NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE PRINTER.
EXCESS LIQUID COULD HARM ELECTRONIC PARTS. ALWAYS DAMPEN A RAG
WITH THE CLEANER AND APPLY IT TO THE PARTS TO BE CLEANED.
MAINTENANCE
Misfeeds
Misfeeds cause the Printer to stop and the Red light on the Paper Feed Switch to blink. Press this switch to
restart the Printer and feed the sheet. If the sheets continue to fail to feed, readjust the Sheet Separators to
the media or replace them.
Replacing the Sheet Separators
The Sheet Separators insure separation of the pieces as they are being fed. They do wear and must be
replaced from time to time. If you experience double sheet feeding and cannot adjust the Separators to
prevent it, they should be replaced. Replacement of the Sheet Separators is not difficult, simply follow the
steps below:
1. Turn off the AstroJet 5000 and unplug it from the power source.
2. Release the Separator-by loosening Knob [A]
and move the Paper Side Guides to their
maximum open position.
3. Lower the Separators so that they touch the
Feed Roller.
4. Remove the screw [B] and the Separator
Support [C]. Then remove the Separator [D]
by prying it out of the Holder.
5. Install a new Separator in place and replace
the Separator Support and screw.
Cleaning
The Printer must be cleaned regularly of accumulated paper dust and ink. Depending on the types of media
that are run, paper dust may accumulate within the Printer and on the Transport. Unplug the Printer from
the power receptacle and remove the covers.
Internal areas: Best cleaned with a vacuum that has a soft brush attachment to help loosen the
dust particles. Take care not to damage the PC Boards or electrical wiring.
Exterior areas: May be cleaned with any standard non-abrasive household cleaner that does not
contain plastic-harming solvents.
25
SECTION 4
MAINTENANCE
Feed Rollers and Forwarding Rollers
The Feed and Forwarding Rollers can become glazed with paper lint and ink from the media. They should
be regularly cleaned with a mild abrasive household cleaner on a damp cloth.
Avoid using solvents on the Rubber Rollers.
26
SECTION 5
CONDITION
PROBLEM
SOLUTION
Black streaks in text
Lint or paper dust on Printhead.
Replace the Ink Cartridge
Cartridge will not print
Sheet is blank even after it has gone
underneath Cartridge(s).
Check to make sure the tape
is off the Printhead.
Remove and reinsert the
Cartridge into the Carriage
Holder.
Install a new Print Cartridge.
White streaks in text or
graphics
Poor contact between Printhead and
Printhead Holder.
Lint or dust blocking Printhead
holes.
Clean Interconnects in the
Cartridge Holder.
Remove and reinsert the
Cartridge into the Holder.
Insert a new Print Cartridge.
WARNING
DO NOT REMOVE THE SIDE COVERS OF THE PRINTER!
THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS!
TROUBLESHOOTING
Section 5 – Troubleshooting Guide
The following Troubleshooting Guides are provided to assist you in solving any problems that might occur
with the AstroJet 5000 Printer. We have tried to make them as complete as possible. The best advice we
can offer is to make sure that the system is setup properly, plugged in, that it has an adequate supply of ink
before attempting to troubleshoot any problem.
HP Inkjet Print Cartridges
27
SECTION 5
CONDITION
PROBLEM
SOLUTION
Extra lines; losing data
Database problem.
Check data in database
program.
Improper output (address
information out of order, missfeeding, etc.)
Wrong Interface settings.
Static electricity.
Dirty Media Sensor.
Check software or database
on PC.
Close the software and then
turn Printer OFF and ON.
Clean Media Sensor.
Media jams
Double feeding.
Media is curled or bent.
Media is too thin.
Adjust Sheet Separators on
Feeder.
Uncurl media.
Minimum thickness for
media is 0.006".
No communication
Improper cabling / connector.
Unit not receiving power.
Use proper cable (see
Operator Manual).
Check plug connections,
ON/OFF Switch and Fuse
on back.
Print too light or missing
character dots
Clogged or dirty Printheads.
Running out of ink.
Replace Inkjet Cartridges.
Blurry address
Image is not sharp.
Replace the Inkjet Cartridge
or change the Printer
resolution setting.
Check media thickness.
Split line of type
A line of type does not match
up.
Check media thickness.
Minimum thickness for
material is 0.006”.
Increase the resolution of
the print.
Feeding problems
Double-sheets.
Misfeeds.
Adjust the Sheet Separator.
Paper Light Flashes
Paper Misfeed
Press the Paper button to
feed the paper into position
for printing.
Cancel Light Flashes
Ink Cartridge missing
Install Print Cartridge.
Job is sent to print but does not
print.
Printer not turned on.
Printer not connected to
computer.
Turn Printer Power Switch
ON.
Connect Printer cable to
computer and resend job.
TROUBLESHOOTING
The Printer
28
PRINT TECHNOLOGY
Inkjet, one HP 57 Color and one HP 56 or HP 58 Black Cartridge
ADDRESS SPEED
Up to 4,000 #10 envelopes per hour
PRINT QUALITY
(Dots Per Inch)
High Quality 1200 dpi
Standard Quality 600 dpi
Draft Quality 300 dpi
IMAGE AREA
8.5 inches x 16 inches (215.9 mm x 406.4 mm)
PRINT ORIENTATION
Portrait and Landscape
FONTS
All TrueType fonts available on PC
GRAPHICS, LOGOS, AND
BARCODES
Allows printing of graphics, logos, and barcodes
MATERIAL SIZE
Minimum: 3" x 5" (76 mm x 127 mm)
Maximum: 11" x 17" (279.4 mm x 431.8 mm)
MATERIAL THICKNESS
Minimum: 0.006" (0.2 mm)
Maximum: 0.0625" (1.5 mm)
FEEDER CAPACITY
Up to 300 #10 envelopes
PRINT COLORS
HP 57 Full Color, HP 56 and 58 Black only
INK
Water-based may require drying assistance for coated stock
SOFTWARE
WindowsTM Printer Drivers for WindowsTM 98, 2000, NT, ME, and XP
FIRMWARE UPDATE
Via PC Interface in flash proms.
PC INTERFACE
Parallel and USB (1.1)
DIMENSIONS
19.5" W x 22" L x 17.125" H (49.5 cm W x 55.9 cm L x 43.5 cm H)
WEIGHT
40 lbs. (18.2 kg.)
ELECTRICAL
115VAC or 240VAC 50/60 Hz
OPTIONS
HP Versatile fast dry Black, and Red, Blue, Green, or Yellow,
Conveyor/Stacker, Drop Tray
Appendix A – AstroJet 5000 Specifications
APPENDIX A
All Specifications Subject To Change Without Notice
29
Black Inkjet Cartridge
HP 56
Photo Black Ink Cartridge
HP 58
Color Cartridge
HP 57
Conveyor /Stacker
Drop Tray
APPENDIX B
Appendix B – Supplies and Optional Hardware
The following supply items and optional hardware are available from your Astro
Machine Distributor:
Supplies
Optional Hardware
30
11 x 17 Setup
13
A
Accessories
30
Adjustable Media Guide
1, 2, 4
Adjusting Sheet Separators
7
Automatic Detection
15
B
Back Guide
4
Basics Tab
17
Blurry Printing
28
Broken Print
27
C
Calibrate Color
20
Calibrate Printer
20
Cancel Switch
1
Cartridge Problem
27
Check Ink Levels
20
Clean Print Cartridge
20
Cleaning Feed Rollers
26
Cleaning Inkjet Cartridge
23
Cleaning Printer
25
Clear Machine Button
2
Color Advanced Setting
18
Color Tab
18
Computer Connection
5
Connecting Printer
5
Connecting to Computer
5
D
Diagnostic Check
19
Dirty Print
27
Disposing Inkjet Cartridge
23
E
Effects Tab
17
Envelopes #10
8, 13
Extra Lines
28
F
Failure to Feed
24
Feed Roller Cleaning
26
Feed Setup
7
Feeding Problems
28
Finishing Tab
17
Fixed Media Guide
1
Fixed Media Guide
2
I
Ink Level check
20
Inkjet Cartridge Cleaning
24
Inkjet Cartridge Disposal
23
Inkjet Cartridge Replacing
23
Inkjet Cartridge Storage
23
Inkjet Cartridges
5, 30
Installing Inkjet Cartridges
6
Installing Printer
3
Installing Printer Driver
8
J
Jams in Printer
24
Job Saving
16
L
Losing Data
28
M
Main Power Switch
2
Maintenance
23
Media Jams
28
Misfeeds
25
MS Word
13
O
Operating
13
Options
30
P
Paper Switch
1
Parallel Port
9
Parallel Port Connection
2
Power Connection
2
Print Quality Settings
16
Print Test Page
19
Print/Quality Tab
15
Printer Driver Installation
8
Printer Driver Properties
15
Printer Location
3
R
Rear Guide
2, 4
Rear Guide Support
2
Removing Jams
24
Replacing Inkjet Cartridge
23
Replacing Sheet Separators
25
S
Saving Jobs
16
Select from Above
15
Service Tab
19
Setting up #10 Envelopes
13
Setting up Feed
7
Setting up MS Word
13
Setting up Print Quality
16
Setup
3
Setup 11 x 17
13
Sheet Separators
7
Sheet Separators Replacement
25
INDEX
31
Soft Power Button
1
Specifications
29
Storing Inkjet Cartridge
23
T
Tap 13
22
Troubleshooting
27
U
Unpacking
3
USB Port
8
USB Port Connection
2
INDEX
32
Copyright © 2012 ASTRO MACHINE CORP.
Elk Grove Village, IL 60007
08/29/2012
Part Number: 200-AJ5000 Rev. D
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