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ASTRO astrojet 5000 Service Manual

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TM
AstroJet
5000
SHUTTLE HEAD
PRINTER

SERVICE MANUAL

ASTRO MACHINE CORP.
630 Lively Blvd.
Elk Grove Village, IL 60007
Phone: (847) 364-6363
Fax: (847) 364-9898
www.astromachine.com

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  • Page 1: Service Manual

    AstroJet 5000 SHUTTLE HEAD PRINTER SERVICE MANUAL ASTRO MACHINE CORP. 630 Lively Blvd. Elk Grove Village, IL 60007 Phone: (847) 364-6363 Fax: (847) 364-9898 www.astromachine.com...

  • Page 2: Safety Precautions

    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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents Table of Contents SECTION 1 – Installation Contents of Packaging Tools Required: Unpacking and Assembly Connecting the Printer Plugging in Printer Connecting to Computer Install the Inkjet Cartridges Installing the Printer Driver USB Port Installation Parallel Port Installation SECTION 2 –...
  • Page 4 Cleaning the Printhead Jams in the Printer Failure to Feed Paper Stoppages Removing Jammed Media Misfeeds Replacing the Sheet Separators Cleaning APPENDIX A – AstroJet 5000 Specifications APPENDIX B – Supplies and Optional Hardware APPENDIX C – Wiring Diagram INDEX...
  • Page 5 TABLE OF CONTENTS NOTES...

  • Page 7: Section 1 - Installation

    SECTION 1 INSTALLATION SECTION 1 – Installation Contents of Packaging ASTROJET 5000 Printer AC Power Adapter Parallel Cable and USB Software Driver Media Guides Operator Manual Driver Software Disk Tools Required: Standard #2 Phillips head screwdriver. Unpacking and Assembly Remove Printer and its parts from carton. Remove all packing tape. Screws that attach the various parts of the Guides to the Printer are under the tape in their respective positions.
  • Page 8 SECTION 1 INSTALLATION 2. Next, install Adjustable Side Guide using two screws [2] provided. 3. Attach Rear Media Support using two Knobs [3] provided. NOTE: Large slots fit over socket head screws. 4. Install Rear Media Guide using thumbscrew and washer [4] provided.

  • Page 9: Connecting The Printer

    SECTION 1 INSTALLATION Connecting the Printer Plugging in Printer Make sure Printer’s Main Power Switch is turned OFF. 1. Connect power cord from power pack to connector [4] at rear of Printer. 2. Plug power cord into power pack and then plug other end into a 115-220 Volt AC, 50/60 Hz. grounded outlet.

  • Page 10: Install The Inkjet Cartridges

    SECTION 1 INSTALLATION Install the Inkjet Cartridges Printer uses two Ink Cartridges (HP57 Color Cartridge and HP56 or HP58 Black Cartridge). Use HP56 Black Cartridge for everyday printing and HP58 Black Cartridge for photos and high quality printing. Install and/or replace Inkjet Cartridge: 1.

  • Page 11: Installing The Printer Driver

    SECTION 1 INSTALLATION Installing the Printer Driver Installation procedure for the Printer Driver is different for USB and Parallel Ports. Follow instructions below for installing the Driver with a USB Port. Instructions for installing the Driver with the Parallel Port follows instructions below.

  • Page 12: Parallel Port Installation

    SECTION 1 INSTALLATION 4. Once Driver is loaded, “Completing the Found New Hardware Wizard” window appears. Click Finish. 5. Installation is complete when “Found New Hardware” box appears in the lower right-hand corner of the screen. Parallel Port Installation 1. Connect Printer to computer via Parallel Port (LPT1).
  • Page 13 SECTION 1 INSTALLATION 4. Click “Local printer attached to the computer” and “Automatically detect and install my Plug and Play printer” buttons in the “Local or Network Printer” window. Click Next>. 5. “Welcome to the Found New Hardware Wizard” window opens. Click “No, not at this time”.
  • Page 14 SECTION 1 INSTALLATION 8. After a few moments, “Hardware Installation” window opens. Click “Continue Anyway” to continue the installation. 9. When the “Completing the Found New Hardware Wizard” window opens, click Finish. 10. “New Printer Detection” window opens. Print a Test Page at this point to confirm that the Printer Driver and the Printer are communicating.

  • Page 15: Section 2 - Troubleshooting

    SECTION 2 TROUBLESHOOTING SECTION 2 – Troubleshooting 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 power cord is plugged in.

  • Page 16: Feeding Problems

    SECTION 2 TROUBLESHOOTING Feeding Problems CONDITION PROBLEM SOLUTION Intermittent feeding Feed Ramp not used Feed Ramp adds a slope to media stack and helps feeding. Side Guides set improperly Loosen Side Guides slightly. Dirty Feed Rollers Clean Feed Roller with distilled water and a cloth.

  • Page 17: Printing Problems

    SECTION 2 TROUBLESHOOTING CONDITION PROBLEM SOLUTION Jams Paper path obstruction Clear jam and remove pieces remaining under Printhead. Paper not loaded properly Instruct operator in proper loading of media. Feed Ramp not used properly Set Feed Ramp. Separators improperly adjusted Adjust Separators to thickness of media.

  • Page 18: Section 3 - Functional Operation

    SECTION 3 FUNCTIONAL OPERATION SECTION 3 – Functional Operation Sequence of Operation User Prepares the Printer 1. Installs Inkjet Cartridges in proper location. 2. Uses a single piece of media to set Sheet Separators. 3. Loads media and adjusts Side Guide to within 1/32" of media. 4.

  • Page 19: Printer Controls

    SECTION 3 FUNCTIONAL OPERATION Printer Functional Description 1. A Photosensor located on the Printhead Carriage sees the lead edge of the media, signals the Driver Motor to reverse and aligns the media with the Printhead Carriage, and signals the Print Engine on the Main Board that the mailing piece is ready for printing.

  • Page 20: Printer Driver Properties

    Printer even if you are not printing in color. Printer Driver Properties 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.

  • Page 21: Paper/Quality Tab

    SECTION 3 FUNCTIONAL OPERATION Paper/Quality Tab If you then click the Properties button, the “Properties” window opens. Click the Size is box to select the size of the media to be printed. Enter up to five custom sizes if media size you are printing on is not listed.

  • Page 22: Finishing Tab

    SECTION 3 FUNCTIONAL OPERATION “Print Quality” refers to the amount of ink and the resolution of the image the Printer will print. Fast Draft uses least amount of ink, has lowest resolution and prints fastest. Equivalent to 300 dpi (dots per inch). Fast Normal and Normal are approximately 600 dpi and print slower, but at a higher quality.

  • Page 23: Effects Tab

    SECTION 3 FUNCTIONAL OPERATION Effects Tab “Effects” tab provides additional options for print size. You can use the Print document on option to specify a particular size of media to print on regardless of the size of the original document. The Printer reduces or enlarges the output to match the document.

  • Page 24: Color Tab

    SECTION 3 FUNCTIONAL OPERATION Color Tab “Color” tab helps control the Printer’s color output. To print in Black only, click Print in grayscale and select one of the three options available. Print in sepia, prints a sepia-colored color image. NOTE: You cannot click both Print in grayscale and Print in sepia boxes together.
  • Page 25 SECTION 3 FUNCTIONAL OPERATION Clicking the Print a Test Page button prints a sample page on the Printer as shown at right. Clicking the Print a Diagnostic button prints the pattern as shown at right. When “Clean the Print Cartridge” button is pressed, “Clean the Print Cartridge(s)”...

  • Page 26: Tap 13

    SECTION 3 FUNCTIONAL OPERATION Clicking “Intermediate Clean” opens screen shown above. Clicking Prime button takes you to next level of cleaning if necessary. Once cartridges are clean, click Done button to exit this routine. Display Ink Level button shows you an approximation of the amount of ink remaining in Cartridges.

  • Page 27: Section 4 - Adjustment

    SECTION 4 ADJUSTMENTS SECTION 4 – Adjustment Printer Drive Belt Tension Adjustment REQUIREMENT: To ensure Drive Belt has proper tension. ADJUSTMENT: 1. Unplug Printer and remove Left-hand Side Cover. (6 screws) 2. Unplug wires to the Switch PC Board. Set Cover aside. 3.
  • Page 28 SECTION 4 ADJUSTMENTS NOTES...

  • Page 29: Section 5 - Disassembly - Assembly Procedures

    SECTION 5 DISASSEMBLY – ASSEMBLY SECTION 5 – Disassembly – Assembly Procedures Basic Disassembly 1. Turn off Power 2. Disconnect Power Cord 3. Disconnect Interface Cable Replacing the Separator Tips 1. Before replacing Separator Tips, unplug Printer. 2. Loosen Separator Locking Knob and raise Separator to its maximum "Up"...

  • Page 30: Right-Hand Side Covers

    SECTION 5 DISASSEMBLY – ASSEMBLY Right-hand Side Covers 1. Remove two screws at the top of the Rear Right-hand Side Cover. Then remove two screws from the bottom of the Cover. Remove Cover. 2. Disconnect Fan Power connector. Remove two screws at the top of the Front Right-hand Side Cover.

  • Page 31: Components Under Right-Hand Side Covers

    SECTION 5 DISASSEMBLY – ASSEMBLY Components under Right-Hand Side Covers 1. Main PC Board 2. Pen Service Station 3. Forwarding Rollers 4. Main Power Inlet PC Board 5. Feed Clutch and Feed Roller Assembly Left-hand Side Cover 1. Remove three screws at the top Non-operator Side Cover.

  • Page 32: Major Components Under Left-Hand Side Cover

    SECTION 5 DISASSEMBLY – ASSEMBLY Major Components under Left-Hand Side Cover 1. Clear Machine Switch 2. Drive Motor 3. Roller Drive Pulley 4. Drive Belt 5. Encoder Wheel 6. Encoder Sensor Replacing Motor Drive Belt or Motor 1. Remove Left-hand Side Cover. 2.

  • Page 33: Replacing Clutch

    SECTION 5 DISASSEMBLY – ASSEMBLY Replacing Clutch 1. Remove Rear Right-hand Side Cover. 2. Disconnect Clutch from wiring harness. 3. While pushing the Clutch toward the Pulley, remove the mounting pin. 4. Remove Clutch from Feed Roller Shaft. 5. Reassemble in reverse order. Replacing Feed Rollers 1.
  • Page 34 SECTION 5 DISASSEMBLY – ASSEMBLY 4. Remove Side Media Guides and the Rear Media Support. 5. Raise Sheet Separators to the "Up" position, remove two screws from each side of Separator Guide Assembly and remove it from Printer. 6. Remove three screws on each side of Printer that hold Rear Deck in place.
  • Page 35 SECTION 5 DISASSEMBLY – ASSEMBLY 9. Remove screw holding Clutch Support Bracket and remove Bracket. 10. Remove Feed Roller Drive Pulley. 11. Remove washer and spring from Feed Roller Shaft. NOTE: This spring and washer keep tension on the Clutch so that the pin holding the Clutch remains in place.

  • Page 36: Replacing Main Pc Board

    SECTION 5 DISASSEMBLY – ASSEMBLY 13. Two sets of Forwarding Rollers and Shafts can be removed in the same manner as Feed Rollers and Shaft. Remove Bearing Cap on Side Frame, slide Roller and shaft toward you and lift out of Printer. 14.

  • Page 37: Removing And Replacing Cleaning Station

    SECTION 5 DISASSEMBLY – ASSEMBLY 5. When replacing the Main PC Board, make sure that the Soft Power Button actuator is positioned properly (as shown in the photo). The actuator goes around the switch on the PC Board. 6. Reassemble in reverse order. Removing and Replacing Cleaning Station 1.

  • Page 38: Removing The Paper Length Sensor

    SECTION 5 DISASSEMBLY – ASSEMBLY 4. Remove screw that attaches Cleaning Station to Print Engine. 5. Remove screw that attaches Cleaning Station to Side Frame. 6. Lift and pull Cleaning Station away from Printer. 7. Reassemble in reverse order. Removing the Paper Length Sensor 1.

  • Page 39: Removing The Print Engine

    SECTION 5 DISASSEMBLY – ASSEMBLY Removing the Print Engine 1. See instructions above and remove Side Covers and Top Cover. 2. Then, remove Main PC Board and Cleaning Station. 3. Remove four screws holding Cover over the Print Engine. 4. Remove Guide Plate by pressing down on the Plate to free it from the Guide Plate Shaft. Then slide it toward feed end of Printer and remove it.
  • Page 40 SECTION 5 DISASSEMBLY – ASSEMBLY 8. Unplug connector on Encoder Assembly [4]. 9. Release Printhead Encoder from right-hand side by pulling the end in the direction of the arrow, slipping it over the notch, then releasing it from the left-hand side. CAUTION DO NOT REMOVE THE ENCODER FROM THE PRINT ENGINE ASSEMBLY.
  • Page 41 SECTION 5 DISASSEMBLY – ASSEMBLY 11. Remove torque screw on other end of the Printhead Carriage Shaft. NOTE: DO NOT remove Shaft from Print Engine Assembly. When screw is removed Support/nut can be removed from Frame. Set it aside. 12. Remove two screws that attach Print Engine to Frame on left-hand side and one screw securing Print Engine to Right-hand Frame.

  • Page 42: Replacing Transport Rollers

    SECTION 5 DISASSEMBLY – ASSEMBLY Replacing Transport Rollers 1. Remove Covers, Main PC Board, Cleaning Station, and Print Engine. NOTE: This is to prevent damage to these parts and to give access to Transport Rollers. 2. Remove Front Cover by removing two screws in Front Cover and one screw on each side of Front Cover on Side Frames.
  • Page 43 SECTION 5 DISASSEMBLY – ASSEMBLY 6. Remove Allen screw and Pulley from Roller Shaft and the Bearing on right-hand side. 7. Remove Roller. 8. Removing Forwarding Roller requires removal of Pulley on left-hand side of Printer. Remove Bearing on right-hand side. Remove Roller. 9.
  • Page 44 SECTION 5 DISASSEMBLY – ASSEMBLY NOTES...

  • Page 45: Section 6 - Maintenance

    SECTION 6 MAINTENANCE SECTION 6 - 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 Inkjet Cartridges must be replaced when out of ink, when print quality is poor, or when built-in cleaning has not helped image quality.

  • Page 46: Cleaning The Printhead

    SECTION 6 MAINTENANCE Cleaning the Printhead Printheads are cleaned automatically each time Printer is turned ON or when Printer software decides they need cleaning. No operator intervention is required. Jams in the Printer If a jam occurs, STOP the Printer. Do this by lifting up the Front Cover. Some possible reasons for jamming are: 1.

  • Page 47: Misfeeds

    SECTION 6 MAINTENANCE Misfeeds Misfeeds cause the Printer to stop and the red light in the Paper Feed Switch to blink. Press the 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.

  • Page 48: Appendix A - Astrojet 5000 Specifications

    APPENDIX APPENDIX A – AstroJet 5000 Specifications 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 High Quality 1200 DPI PRINT QUALITY Standard Quality...

  • Page 49: Appendix B - Supplies And Optional Hardware

    APPENDIX APPENDIX B – Supplies and Optional Hardware The following supply items and optional hardware are available from your Astro Machine Distributor: Supplies Black Inkjet Cartridge HP 56 Photo Black Ink Cartridge HP 58 Color Cartridge HP 57 Optional Hardware...

  • Page 50: Appendix C - Wiring Diagram

    APPENDIX APPENDIX C – Wiring Diagram...
  • Page 51 APPENDIX NOTES ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...

  • Page 52: Index

    INDEX Adjustment Operation, Printer Drive Belt Tension Parallel Port Install, Printer Driver Print Engine Cleaning Feed Rollers Printer Forwarding Rollers Adjustment Inkjet Cartridges Cleaning Printer Connecting Printhead Controls Cleaning Station Disassembly/Assembly Procedures Clutch Drive Belt Tension Feed Rollers Components Left-hand Side Cover Feed Stops Right-hand Side Covers Feeding Problems...
  • Page 53 INDEX Motor Paper Length Sensor PC Board, Main Print Engine Right-hand Side Covers Separator Tips Sheet Separators Transport Rollers Sensor, Paper Length Sheet Separators 23, 41 Software Problems Specifications, Printer Storage, Inkjet Cartridge Supplies & Optional Hardware Tap 13 Tools Required Transport Rollers Troubleshooting Feeding Problems...
  • Page 55 Copyright © 2014 ASTRO MACHINE CORP. Elk Grove Village, IL 60007 12/16/2014 Part Number: 300-AJ5000 Rev. D...

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