ASTRO astrojet 5000 User 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:
üKeep hands, hair, and clothing clear of rollers and other moving parts.
üAvoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure
machine mechanisms come to a stop.
üAlways turn off the machine before making adjustments, cleaning the machine, or performing any
maintenance covered in this manual.
üApower 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.
üThe power cord and wall plug is the primary means of disconnecting the machine for the power
supply.
üDO NOT use an adapter plug on the line cord or wall outlet.
üDO NOT remove the ground pin from the line cord.
üDO NOT route the power cord over sharp edges or trapped between furniture.
üAvoid using wall outlets that are controlled by wall switches, or shared with other equipment.
üMake sure there is no strain on the power cord caused by jamming between the equipment, walls or
furniture.
üDO 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.
üThis machine requires periodic maintenance. Contact your authorized service representative for
required service schedules.
üTo prevent overheating, do not cover the vent openings.
üUse 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
i
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

TABLE OF CONTENTS
ii
NOTES

SECTION 1
INSTALLATION
1
Section 1 –Installation
Contents of Packaging
1. ASTROJET 5000 Printer
2. AC Power Adapter
3. Parallel Cable and USB
4. SoftwareDriver
5. Paper Guides
6. Operator Manual
7. Driver Software Disk
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]:

SECTION 1
INSTALLATION
2
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.

SECTION 1
INSTALLATION
3
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]

SECTION 1
INSTALLATION
4
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.

SECTION 1
INSTALLATION
5
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.

SECTION 1
INSTALLATION
6
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.

SECTION 1
INSTALLATION
7
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.
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.

SECTION 1
INSTALLATION
8
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.

SECTION 2
TROUBLE SHOOTING
9
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. 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.
Printer not responding to
software Poor connection between printer and computer Turn printer off and on again.
Check connections.

SECTION 2
TROUBLE SHOOTING
10
Feeding Problems
CONDITION PROBLEM SOLUTION
Intermittent feeding Feed ramp not used
Side guides set improperly
Dirty feed rollers
Paper stuck together
Uneven mail piece
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.
Multiple feeds Separator gap not set properly.
Media stuck together.
Side guides too close to media
Brake misadjusted.
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)
Failure to feed Side guides too close to media
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
Readjust side guides
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.

SECTION 2
TROUBLE SHOOTING
11
CONDITION PROBLEM SOLUTION
Jams Paper path obstruction
Paper not loaded properly
Feed ramp not used properly
Separators improperly adjusted
Media curled or bent.
The separatorsare worn.
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.
Printing Problems
CONDITION PROBLEM SOLUTION
Extra lines; losing data Database problem Check data in database
program
Improper output (address
information out of order, miss-
feeding, etc.)
Wrong interface settings
Static electricity
Dirty media sensor
Check software or data base
on PC.
Close the software and then
turn Printer of 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.
The 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. The
minimum thickness for
material is 0.006”.
Increase the resolution of
the print.
Feeding problems Double sheets.
Miss feeds. Adjust the sheet separator.
Paper Light Flashes Paper Miss Feed Press the Paper button to
feed the paper into position
for printing.
Cancel Light Flashes Ink Cartridge Missing Install print cartridge.

SECTION 2
TROUBLE SHOOTING
12
Software Problems
Refer to the manual for the application software being used.

SECTION 3
FUNCTIONAL OPERATION
13
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 the layout software such as Microsoft Word.
2. Creates a layout consisting of the variable data from the database using the merge function.
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 colors
(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.

SECTION 3
FUNCTIONAL OPERATION
14
Printer Functional Description
1. A photosensor located on the printhead carriage sees the lead edge of the paper, sends a signal to the
driver motor to reverse and align the paper with the printhead carriage, and sends a signal to the print
engine on the main board that the mailing piece is ready for printing. The feed clutch remains
disengaged as long as a mailing piece is in view of the photosensor.
2. When the mailing piece uncovers the sensor the clutch engages the feed rollers and the next piece of
media starts moving toward the printer section.
3. This cycle repeats itself as long as there is media in the feeder.
4. Either the cycle stops when the feeder runs out of media, the operator stops the process, or there are no
records remain to be printed.
5. When there are no records to be printed, the printer ejects any paper that is in line for printing. The
feed clutch is off at this point.
Cartridge Cleaning
The cartridges are cleaned at the beginning of each startup of a job by the cleaning station and attimes
during a run that is determined by the printer software. A separate motor operates the cleaning station.
Printer Controls
The printer controls and their functions are as follows:
Main Power Connection and ON/OFF Switch
The AC Power Adapter provides the proper voltage to the printer.
The Main Power Switch powers up the printer when it is turned ON.
CAUTION
USE THE AC POWER ADAPTER PACKED
WITH THE PRINTER.
DO NOT USE AN ADAPTER PLUG OR
EXTENSION CORD TO CONNECT THE
ADAPTER 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.
Clear Machine Button
This button operates the main drive motor to help clear paper from the
printer.

SECTION 3
FUNCTIONAL OPERATION
15
Soft Power Button
Pressing and holding this button will reset the printer’s
software. This button glows a steady green when the
printer is ready and blinks when the job is sent to the
printer and it is printing.
Paper Switch and Cancel Switch
The Paper Switch light blinks if the next piece does not
feed into position properly. Press the switch to resume
feeding.
The Cancel Switch when pressed will cancel the job. If the
light on this switch blinks it means that the printer is out of
ink or a cartridge is missing. You must have both the color
and black cartridge in the printer even if you are not
printing in color.
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
addressed quickly and efficiently.
Once the job is set up Click on File, and then on
Print. The widow on the right will open.

SECTION 3
FUNCTIONAL OPERATION
16
Paper/Quality Tab
If you then click on the Properties button, the
“Properties” window will open. 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.
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.