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ASTRO AstroJet 5000 Service Manual

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AstroJet 5000
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 AstroJet 5000 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

    Removing the Print Engine Replacing Transport Rollers SECTION 6 – Maintenance The Inkjet Cartridge Jams in the AstroJet 5000Printer Replacing the Sheet Separators Cleaning Appendices Appendix A – ASTROJET 5000 Specifications Appendix B – Supplies and Optional Hardware Appendix C – Wiring Diagram...
  • Page 4 TABLE OF CONTENTS NOTES...

  • Page 5: Section 1 - Installation

    SECTION 1 INSTALLATION Section 1 – Installation Contents of Packaging ASTROJET 5000 Printer AC Power Adapter Parallel Cable and USB Software Driver Paper Guides Operator Manual Driver Software Disk Tools Required Tools required Standard #2 Phillips head screwdriver. Unpacking and Assembly Remove the Printer and its parts from the carton.
  • Page 6 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.

  • Page 7: Connecting The Astrojet 5000

    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.

  • Page 8: Installing The Inkjet Cartridges

    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.

  • Page 9: Installing The Printer Driver

    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.
  • Page 10 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.
  • Page 11 SECTION 1 INSTALLATION 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”...
  • Page 12 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.

  • Page 13: Section 2 - Trouble Shooting

    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.

  • Page 14: Feeding Problems

    SECTION 2 TROUBLE SHOOTING Feeding Problems CONDITION PROBLEM SOLUTION Intermittent feeding Feed ramp not used The feed ramp adds a slope to the stack and helps feeding. Side guides set improperly Loosen the side guides slightly. Dirty feed rollers Clean the feed roller with distilled water and a cloth.
  • Page 15 SECTION 2 TROUBLE SHOOTING 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 16: Software Problems

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

  • Page 17: Section 3 - Functional Operation

    SECTION 3 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.

  • Page 18: Printer Controls

    SECTION 3 FUNCTIONAL OPERATION 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.

  • Page 19: Printer Driver Properties

    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.
  • Page 20 SECTION 3 FUNCTIONAL OPERATION 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.

  • Page 21: 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 the least amount of ink, has the lowest resolution and prints the fastest. It is equivalent to 300 dpi (dots per inch).

  • Page 22: Effects Tab

    SECTION 3 FUNCTIONAL OPERATION Effects Tab The 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.

  • Page 23: Color Tab

    SECTION 3 FUNCTIONAL OPERATION Color Tab The 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 that are available. The second option Print in sepia will print a sepia colored color image.
  • Page 24 SECTION 3 FUNCTIONAL OPERATION Clicking on the Print a Test Page button will print a sample page on the printer as shown. Clicking on the Print a Diagnostic button will print the pattern shown. When the Clean the Print Cartridge button is pressed the “Clean the Print Cartridge(s)”...
  • Page 25 SECTION 3 FUNCTIONAL OPERATION on 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.
  • Page 26 SECTION 3 FUNCTIONAL OPERATION To cancel out of the Tap 13 sequence press and hold the Soft key on the front of the printer, press the Cancel key one time and then the Paper key three times. Then release the Soft key. The Paper key light will blink twice indicating that the Tap 13 sequence is off.

  • Page 27: Section 4 - Adjustments

    SECTION 4 ADJUSTMENTS SECTION 4 – Adjustment ASTROJET 5000 Drive Belt Tension Adjustment REQUIREMENT: To ensure the drive belt has the proper tension. ADJUSTMENT: 1. Unplug the machine and remove the Left-hand side cover. (6 screws) 2. Unplug the wires to the Switch PC Board and set the cover aside.
  • Page 28 SECTION 4 ADJUSTMENTS Notes...

  • Page 29: Basic Disassembly

    SECTION 5 DISASSEMBLY – ASSEMBLY Section 5 – Disassembly – Assembly Procedures Basic Disassembly Turn off Power Disconnect Power Cord Disconnect Interface Cable Replacing the Separator Tips 1. Before replacing the separator tips, unplug the Printer. 2. Loosen the separator locking knob and raise the separator to its maximum up position.

  • Page 30: Right-Hand Side Cover

    SECTION 5 DISASSEMBLY – ASSEMBLY Right-hand Side Covers 1. Remove two screws at the top of the rear right-hand side cover. Then remove the two screws from the bottom of the cover. Then remove the cover. 2. Disconnect the Fan Power connector. Remove the two screws at the top of the front right-hand side cover.

  • Page 31: Left-Hand Side Cover

    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 the three screws at the top non-operator side cover.

  • Page 32: Replacing Motor Drive Belt

    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 Feed Rollers

    SECTION 5 DISASSEMBLY – ASSEMBLY Replacing Clutch 1. Remove rear right-hand side cover. 2. Disconnect the clutch from the wiring harness. 3. While pushing the clutch toward the pulley remove the mounting pin. 4. Remove the clutch from the feed roller shaft. 5.
  • Page 34 SECTION 5 DISASSEMBLY – ASSEMBLY 4. Remove the side paper guides and the rear paper support. 5. Put the Sheet Separators in the up position and remove the two screws from each side of the separator guide assembly and remove it from the machine. 6.
  • Page 35 SECTION 5 DISASSEMBLY – ASSEMBLY 9. Remove the screw holding the Clutch Support Bracket and remove the bracket. 10. Remove the Feed Roller Drive pulley. 11. Next remove the washer and spring from the 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. The two sets of forwarding rollers and shafts can be removed in the same manner as the feed rollers and shaft. Remove the bearing cap on the side frame, slide the roller and shaft toward you and lift out of the machine.

  • 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 SECTION 5 DISASSEMBLY – ASSEMBLY 4. Remove the screw that attaches the Cleaning Station to the Print Engine. 5. Then remove the screw that attaches the Cleaning Station to the Side Frame. 6. Lift and pull the Cleaning Station away from the machine.

  • Page 39: Removing The Print Engine

    SECTION 5 DISASSEMBLY – ASSEMBLY Removing the Print Engine 1. See the instruction above and remove the side covers and the top cover. 2. Then, remove the Main PC Board and Cleaning Station. 3. Remove the four screws holding the cover over the print engine. 4.
  • Page 40 SECTION 5 DISASSEMBLY – ASSEMBLY 8. Unplug the connector on the encoder sensor assembly [4]. 9. Release the printhead encoder from the right- hand side by pulling the end in the direction of the arrow and slip it over the notch, then releasing it from the left-hand side.
  • Page 41 SECTION 5 DISASSEMBLY – ASSEMBLY 11. Remove the torque screw on the other end of the printhead carriage shaft. NOTE: Do not remove the shaft from the print engine assembly. When the screw is removed the support/nut can be removed from the frame.

  • Page 42: Replacing Transport Rollers

    SECTION 5 DISASSEMBLY – ASSEMBLY Replacing Transport Rollers 1. To replace the transport rollers first remove the covers, main pc board, cleaning station, and print engine. NOTE: This is to prevent damage to these parts and to give access to the transport rollers. 2.
  • Page 43 SECTION 5 DISASSEMBLY – ASSEMBLY 6. Then remove Allen screw and the pulley from the roller shaft and the bearing on the right- hand side. 7. Remove the roller. 8. Removing the forwarding roller requires removal of the pulley on the left-hand side of the machine.
  • Page 44 SECTION 5 DISASSEMBLY – ASSEMBLY Notes...

  • Page 45: Section 6 - Maintenance

    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 has not helped the image quality. The Approximate life of the Black number 56 inkjet cartridges based on three lines of 20 characters at 10- point size per address is 20,000 addresses in the Fast Draft mode.

  • Page 46: Jams In The Astrojet 5000Printer

    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.

  • Page 47: Replacing The Sheet Separators

    Replacement of the sheet separators is not difficult. Just 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.
  • Page 48 SECTION 6 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.

  • Page 49: 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 Up to 4,000 #10 envelopes per hour ADDRESS SPEED High Quality 1200 dpi PRINT QUALITY (Dots Per Inch)

  • Page 50: 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 51: Appendix C - Wiring Diagram

    APPENDIX Appendix C – Wiring Diagram...
  • Page 52 APPENDIX NOTES ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 54 Copyright © 2008 ASTRO MACHINE CORP. Elk Grove Villa/e, IL 60007 04/24/2008 Part Number: 300-AJ5000 Rev. C...

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