Mako 56

Mako 5625
Reference Manual
RETURN
554 Clark Rd.

Tewksbury, MA 01876
Phone (978) 851-0207 Fax - (978) 851-7016
AG12304Rev. 1
Mako 5625
Reference Manual
This manual reflects the Mako 5625 as of May, 1999.
© copyright ECRM Incorporated 1999
Information on ordering additional copies of this manual may be obtained by writing or calling:
ECRM Order Processing

554 Clark Road
Tewksbury, MA 01876
Phone No. (US) - (978) 851-0207 — Fax (US) - (978)-851-7016

Phone No. (UK) - (44) 1923-218255 — Fax (UK) (44) 1923-218256
Phone No. (Hong Kong) - 852-2-564-8989 — Fax (Hong Kong) 852-2-564-8821
Visit our web site: www.ecrm.com
Proprietary Notice
The information contained within this guide is the property of ECRM Incorporated. No transmission, reproduction, tran-
scription, storage in a retrieval system, translation into any language, or other use is permitted in whole or in part in any
form without first obtaining written permission of ECRM Incorporated.
List of Trademarks or Registrations, ECRM® is a registered trademark of ECRM Incorporated, PelBox® is a registered trademark of ECRM Incorporated, KnockOut®
4550 is a registered trademark of ECRM Incorporated, KnockOut®/PRF is a registered trademark of ECRM Incorporated, Marlin™ is a trademark of ECRM Incorpo-
rated.
AG12304 Rev. 1
1 - Specifications .. 7
Introduction .. 7
Warnings .. 8
Media .. 9
Acceptable Media Types .. 9
Roll Specifications .. 9
Acceptable Widths .. 9
Input Cassette .. 9
Output Cassette .. 9
Processing .. 9
Recording Performance .. 10
Image Size .. 10
Image Location .. 10
Linearity .. 10
Repeatability .. 10
Recording Speed .. 10
Resolutions, Video Data Rates, Nominal Throughput Speed .. 11
Fast Media Advance .. 11
Optical Performance .. 11
Source .. 11
Image Width .. 11
Dot Percentage Uniformity .. 11
Line Screen .. 11
Interface Requirements .. 12
Data Interface .. 12
Online Transport .. 12
Environmental Requirements .. 12
Operational Environment .. 12
Storage Environment .. 12
Utility Requirements .. 12
Compliance Requirements .. 12
Optional Requirements .. 12
2 - Installation and Site Requirements .. 13

Introduction .. 13
Warnings .. 14
Pinch Roller Lever Installation on New Machines .. 15
Installation .. 16
Site Preparation .. 16
Recommended Vendor Installation Procedure .. 17
Installation Procedure .. 17
Protective Earth .. 17
Electrical Safety .. 17
Power Cord Types .. 17
Required Information .. 18
AG12304 Rev. 1 3
VERSCHIEDENES .. 18
Schutzerde .. 18
Elektrische Sicherheit .. 18
3 - System Diagrams .. 19
Introduction .. 19
Warnings .. 20
System Block Diagram .. 21
Interlock Description .. 22
Interconnect List .. 23
4 - Remove and Replace .. 25

Introduction .. 25
Warnings .. 26
System Covers .. 27
Opening the Media Door .. 27
Closing the Media Door .. 27
Removing the System Cover .. 27
Replacing the System Cover .. 27
Assembly Location Diagram .. 29
System Power Fuse .. 30
AP24507P4 Main Controller .. 31
AP9992P2 SCSI PelBox Interface .. 33
Remove SCSI Controller Board .. 33
Replace SCSI Controller Board .. 33
AP9996 Control Panel and FA20253 Keypad .. 34
Remove AP9996 or FA20253 .. 35
Replace AP9996 or FA20253 .. 36
AO41042 Lower Optics Assembly .. 37
Remove Lower Optics Assembly .. 37
Replace Lower Optics Assembly .. 39
Image Width Adjustment .. 39
Image Perpendicularity Adjustment .. 39
MO0109 Spinner Motor .. 40
Removing the Spinner Motor .. 40
Replacing the Spinner Motor .. 40
MO0088 Servo DC Motor and Encoder (Drive Motor) .. 42
Belt Replacement .. 43
MA0540 Drive Outside Encoder .. 44
AO41050 Cutter .. 47
AO41050 Cutter Removal .. 47
AO41050 Cutter Replacement .. 48
AO41022 Pinch Roller .. 49
Pinch Roller Removal .. 49
4 AG12304 Rev. 1
Pinch Roller Replacement .. 50
Media Shelf Alignment .. 51
PS0105 System Power Supply .. 52
Power Supply Removal .. 52
Power Supply Replacement .. 53
5 - Calibration and Alignment .. 55

Introduction .. 55
Warnings .. 56
System Calibration Menu Map .. 57
Image Centering .. 58
Pel Correction .. 60
Line Correction .. 61
Ignore System Errors? .. 62
/Beamon Path? .. 62
Laser Bias Level .. 62
Save Setup? .. 63
Perpendicularity Adjustment .. 63
Checking Perpendicularity .. 63
Installing Shims .. 64
System Alignment Menu .. 66
Laser Alignment .. 66
Belt Alignment .. 66
Belt Tension Adjustment .. 67
Black Belt Tension Adjustment .. 68
Kapton Belt Tension Adjustment .. 69
6 - Parts Lists .. 71
Introduction .. 71
Warnings .. 72
AO41000 (Revision 00E) Parts List .. 73
KI41079 (Revision 00A) Spares Kit .. 77
KI18149 Tool Kit .. 78
AG12304 Rev. 1 5
6 AG12304 Rev. 1
1 - Specifications
1.1 Introduction
This is a list of the sections of this Specifications chapter:
Section 1.2, “Warnings” on page 8

Section 1.3, “Media” on page 9
Section 1.4, “Recording Performance” on page 10
Section 1.5, “Optical Performance” on page 11
Section 1.6, “Interface Requirements” on page 12
Section 1.7, “Environmental Requirements” on page 12
Section 1.8, “Utility Requirements” on page 12
Section 1.9, “Compliance Requirements” on page 12
Section 1.10, “Optional Requirements” on page 12
AG12304 Rev. 1 7
1.2 Warnings
WARNING!
Whenever the covers are removed from this equipment, there is danger of
electrical shock.
LEFT REAR OF RECORDER
CAUTION
RECORDER CONTAINS
STATIC SENSITIVE COMPONENTS attach grounding wrist strap here
CAUTION!
Whenever the covers are removed, there is danger of damage to the
equipment from static electricity.
LEAVE THE RECORDER PLUGGED IN, TURNED OFF, AND
WEAR A STATIC GROUNDING WRIST STRAP.
8 AG12304 Rev. 1
1.3 Media
1.3.1 Acceptable Media Types

1. Polyester film.
2. Paper.
3. Polyester Plate material.
4. Visible red sensitive only.
1.3.2 Roll Specifications

1. Emulsion-in, taped to core.
2. 2” core size.
3. Maximum 400’ roll of .004” media, 5.7” max diameter.
1.3.3 Acceptable Widths

1. 22.1” (560 mm)
2. 22.0” (559 mm)
3. 20.5” (521 mm)
4. 20.1” (510 mm)
5. 20.0” (508 mm)
6. 19.6” (498 mm)
7. 18.6” (472 mm)
8. 18.1” (460 mm)
9. 18.0” (457 mm)
10. 17.7” (450 mm)
11. 16.0" (406 mm)
12. 14.0" (355 mm)
1.3.4 Input Cassette

1. Bulk load.
2. Accommodates single 400’ roll of .004” media (5.7” max diameter) at all of the
above widths.
1.3.5 Output Cassette

1. Maximum 25’ capacity of .004” polyester film at all of the above widths.
2. *Maximum 20’ capacity of .004” paper at all of the above widths.
1.3.6 Processing
1. Manual transfer of output cassette to processor is standard.
2. Removable output cassette shelf and standard processor interface allows
optional connection to online processor.
AG12304 Rev. 1 9
1.4 Recording Performance
1.4.1 Image Size

Maximum image width is determined by the width of media used as defined in the following
table. Note that the quality imaging area is 21.7”.
Media Width Image Width (in) Overscan Width (in)

22.1” (560 mm) 22.048 22.2
22.0” (559 mm) 22.048 22.2
20.5” (521 mm) 22.048 22.2
20.1” (510 mm) 20.08 20.24
20.0” (508 mm) 20.08 20.24
19.6” (498 mm) 20.08 20.24
18.6” (472 mm) 20.08 20.24
18.1” (460 mm) 18.0 18.16
18.0” (457 mm) 18.0 18.16
17.7” (450 mm) 18.0 18.16
16.0" (406 mm) 18.0 18.16
14.0" (355 mm) 14.0 14.16
Maximum image length is limited by output cassette capacity.
1.4.2 Image Location

Adjustable to +/- .003” (+/- .01mm) over range of +/- 0.3” (+/- 7.62mm).
1.4.3 Linearity
Fast scan: +/- .11mm absolute position error over 21.7”.
Slow scan: +/- .15mm absolute position error over 28.0”
1.4.4 Repeatability
0.0012” (.03 mm), typical, over four consecutive 20.0” X 28.0” images on 0.004” polyester film.
1.4.5 Recording Speed

267 lines/second (16,000 rpm spinner motor).
10 AG12304 Rev. 1
1.4.6 Resolutions, Video Data Rates, Nominal Throughput Speed
Resolution: Resolution: Approx. Video Throughput

English Metric Rate Speed
(dpi) (dpmm) (MHz) (in/min)
3556 140 116 4.50
3048 120 99 5.25
2540 100 83 6.30
2400 94.5 78 6.67
2032 80 66 7.87
1800 70.9 59 8.89
1524 60 50 10.50
1446 57 47 11.07
1270 50 41 12.60
1200 47.2 39 13.33
1016 40 33 15.75
1000 39.4 33 16.00
1.4.7 Fast Media Advance

35” per minute.
1.5 Optical Performance
1.5.1 Source
Visible red laser.
1.5.2 Image Width

Minimum 21.7” quality image area with overscan to 22.2”.
1.5.3 Dot Percentage Uniformity

Maximum 2.5% deviation from 5% to 95% at 2540 dpi, 150 lpi, on polyester film within the qual-
ity image area.
1.5.4 Line Screen

200 lpi maximum.
AG12304 Rev. 1 11
1.6 Interface Requirements
1.6.1 Data Interface

SCSI interface via AP9992P2. Specifications defined in AG11510.
Pelbox interface port. Maximum resolution 3048 dpi. Specification defined in
AG11273.
1.6.2 Online Transport

Interface to support online processor.
1.7 Environmental Requirements
1.7.1 Operational Environment

1. Temperature range 62°-86°F (17°-30°C).
2. Relative humidity 45%-65%, non-condensing.
1.7.2 Storage Environment

1. Temperature range 0°-130°F (-18°-54°C).
2. Change in temperature not to exceed 25°F (14°C) per hour.
3. Relative humidity not to exceed 65%, non-condensing.
1.8 Utility Requirements

1. 100/115/230 Volts AC, 1.7/1.5/1.0 Amps (+/-10%).
2. 50Hz-60Hz, single phase.
3. 1000 BTU/HR max.
1.9 Compliance Requirements

1. CSA C22.2 No. 950-95
2. TUV EN 60 950:95, EN 60825-1:1994
3. FCC Vol. II, Part 15, Subpart J, Class A.
4. DOC CRC c 1374.
5. EMC EN55022:1994 Class A, EN50082-1:1992
1.10 Optional Requirements

1. 1) Pedestal.
12 AG12304 Rev. 1
2 - Installation and Site Requirements
2.1 Introduction
This chapter contains the following:
Chapter 2.2, “Warnings” on page 14

Chapter 2.3, “Pinch Roller Lever Installation on New Machines” on page 15
Chapter 2.4, “Installation” on page 16
Chapter 2.5, “Recommended Vendor Installation Procedure” on page 17
Chapter 2.6, “Required Information” on page 18
AG12304 Rev. 1 13
2.2 Warnings
WARNING!
electrical shock.
CAUTION
RECORDER CONTAINS
CAUTION!
14 AG12304 Rev. 1
2.3 Pinch Roller Lever Installation on New Machines
New recorders are shipped with the Pinch Roller in the open position and the Pinch Roller Release Lever
removed. Before using the recorder, you must install the Pinch Roller Release Lever.
1. Locate the Pinch Roller Release Lever in the Accessories Bag (which also
contains the power cord).
2. Lift the front door of the recorder to the open position.
3. Locate the slot on the left side of the input cassette compartment. Note the
threaded hole in the shaft behind the slot.
4. Install the Pinch Roller Release Lever into the threaded hole.
5. Move the shaft back and forth several times to verify smooth operation.
install
lever
here
Figure 2 - 1 Installing the Pinch Lever
AG12304 Rev. 1 15
2.4 Installation
2.4.1 Site Preparation

The following section explains the procedures required of the customer when planning for instal-
lation of the Recorder. The customer should follow the procedures to help ensure a trouble-free
installation.
2.4.1.1 Customer Responsibilities

The customer is responsible for the following:
1. Providing the exact location of the Recorder with adequate floor space for
installation and testing.
2. Meeting environmental requirements such as temperature, humidity, and light-
ing.
3. Providing an external power source.
2.4.1.2 Environmental Requirements

Floor Requirements For Recorder: The recorder should be placed on a table and
in an area appropriate for is specific size and weight. An optional pedestal may
also be used. See Chapter , “1 - Specifications” on page 7.
NOTE: The Mako 5625 recorder is a table top design. When choosing a
table to set the recorder on, make sure it is sturdy enough to
support the weight of the recorder.
Floor Requirements For Installation and Testing: Add an additional 2' (61cm)
on each side of the recorder to allow enough space to remove the cover for testing.
Traffic: Locate the recorder in a low traffic area to ensure operator comfort,
machine safety, and cleanliness.
Vibration: The recorder must be located in an area that is free from vibration.
Excessive vibration can cause distortion of the output.
Temperature: Refer to Chapter , “1 - Specifications” on page 7 for operating tem-
perature, relative humidity, and storage temperature.
Heat Dissipation: Refer to Chapter , “1 - Specifications” on page 7
Ambient Light: Normal room lighting is acceptable. Avoid areas of extreme bright-
ness. Such areas may produce fogging on the output media.
Air Quality: The environment should be as dust free as possible. Dust will impair
the optimum operation of the optics.
Recorder Power: Auto Ranging. See Chapter , “1 - Specifications” on page 7
The Recorder may exhibit problems if subject to static electricity. Therefore the
recorder should not be placed in a carpeted area. Use anti-static mats as neces-
sary.
16 AG12304 Rev. 1
2.5 Recommended Vendor Installation Procedure
The following section covers the recommended vendor installation procedure to aid in the set-up of the
Recorder at a customer site. The procedures are suggestions to be added to your own list of installation
procedures.
NOTE: Before operating the recorder, read the Operator Guide.
2.5.1 Installation Procedure

The following procedure is recommended to the vendor for installing a Recorder:
1. Unpack and inventory all items shipped.
2. Set up, clean, and level the recorder at the location designated by the cus-
tomer.
3. Check the recorder off-line using test patterns 3 and 4 to determine sizing,
squareness, focus, and registration.
4. Check the recorder on-line by installing and configuring the RIP.
5. Linearize the recorder to the media and chemistry used.
6. Conduct on-site training of personnel who will operate or supervise the opera-
tion of the Recorder.
7. Provide a check list for the customer to ensure proper installation procedures
have been followed.
CAUTION!
STARTUP TEMPERATURE—If the recorder has been stored in a low tem-
perature environment it must warm up to at least 62°F (17C°) before it is
powered on. Powering up a cold recorder may damage the temperature sensi-
tive components that it contains.
OPERATING TEMPERATURE—The recorder must be used in a normal

operating environment of 62°-86°F (17°-30°C). Failure to operate within this
temperature range may result in degradation of output quality.
2.5.2 Protective Earth

This product is protected by a protective Earth terminal. This protective Earth terminal is the
third conductor in the appliance inlet. This product must be installed near a socket outlet (which
has a protective Earth conductor) and this socket outlet must be easily accessible. The reason
for this is that the plug on the power cord is intended to serve as the disconnect device.
2.5.3 Electrical Safety

There are no user serviceable parts inside this product. Refer all repairs to a properly trained
service technician.
2.5.4 Power Cord Types

Refer to AG11320 for proper cordset selection for your area.
AG12304 Rev. 1 17
2.6 Required Information
The following information in this section is repeated and supplied in German to conform to certain interna-
tional regulatory requirements.
2.6.1 VERSCHIEDENES
Einige Punkte sind nicht leicht einzuordnen, werden aber von der einen oder anderen Behörde
verlangt. Zur Klarstellung werden sie im folgenden aufgeführt.
2.6.2 Schutzerde
Dieses Gerät ist durch einen Schutzleiteranschluß gesichert. Dieser Schutzleiteranschluß ist
der dritte Anschluß der Netzeinführung. Dieses Gerät muß in der Nähe einer frei zugänglichen
Netzsteckdose mit Schutzleiter aufgestellt werden. Der Grund dafür ist, daß der Netzstecker als
Netztrenneinrichtung vorgesehen ist.
2.6.3 Elektrische Sicherheit

Im Inneren des Gerätes gibt es keine vom Anwender zu bedienende Teile. Alle Reparaturen
müssen von einem dafür ausgebildeten Kundendienst-Techniker durchgeführt werden. Ziehen
Sie bitte vor dem Entfernen von Abdeckungen für Kundendienst-Zwecke den Netzstecker an der
Geräte-Rückseite.
18 AG12304 Rev. 1
3 - System Diagrams
3.1 Introduction
This chapter contains:

Section 3.3, “System Block Diagram” on page 21
Section 3.4, “Interlock Description” on page 22
Section 3.5, “Interconnect List” on page 23
The System Block Diagram shows all the major components of the recorder and all interconnections
between the components. Each interconnect is shown with the number of the cable that makes the connec-
tion and the connector numbers, if applicable.
The Interlock description shows the connections between all the components that make up the safety inter-
lock circuit of the recorder.
The Interconnect List identifies all internal cables by part number and by a “from-to” list. The contents of this
list supports the graphic information presented in the System Block Diagram.
AG12304 Rev. 1 19
3.2 Warnings
WARNING!
electrical shock.
CAUTION
RECORDER CONTAINS
CAUTION!
20 AG12304 Rev. 1
3.3 System Block Diagram
Optics Assembly
AP9992P2
SCSI/PelBox Intfc
(AC41107) P2 AP24525
P1 AP24680
PelBox Laser Driver Board P3
Laser Switch Board
P4
(AC41113)
P3
P1 P5
P2 P6 MO0109
Spinner
Motor
(AC41110)
SCSI
(AC41109)
P25
P25
(AC40038)
(AC41111)
(AC41108)
P7 P3 P4 P1 P15
OLP P10
AP24507P4
AC24658 J24
Main Controller
jumper P18 P11
P24
plug
P100 P5 P2 P14 P6 P8 P16

(AC41105)
PS0105
(AC41116)
(AC41102)
Power
Supply
(AC41106)
(AC41115) FAN
cutter motor (AC41114)
(AC41112)
FAN
(AC41103)
EOM
EOM FAN
COV Film Door
(AC41118)
Switch
(AC41104)
CPL CPR
CL
S1-11,
12,
AO40150 EOM Cassette MA0540 MO0088 AC41112 31,
32 Main
Cutter sensor Sensor Outside Drive SOL P2
Encoder Motor sensor Interlock
AP9996
Display
Figure 3 - 1 System Block Diagram
AG12304 Rev. 1 21
3.4 Interlock Description
S1 front interlock
COV
11
1 NO
12
2
3 31
32 NO
NO specified as plunger not depressed

S1 shown with plunger depressed
AC41116
AP24507P4 - P11 PS0105 power supply

1 J24 P24
+5
2 1
GND
3 2
COVER_NOT_CLOSED
4
Figure 3 - 2 Interlock Description
3
2 CL Cassette Present Switch
1
3
2 Cutter Park (Right) sensor
CP(R)
1
12
11
10
9 3
8 2 Cutter Park (Left) sensor
CP(L)
7 1
AP24507P4 - P5 6
5 (AC41118)
4
3 3
2 2
EOM
1 1
AC41115
End--Of-Media sensor
Figure 3 - 3 Sensor Description
22 AG12304 Rev. 1
3.5 Interconnect List
The following interconnect list contains all cables and cable harnesses within the Mako 5625 recorder. The
text in parentheses, such as “12 wire”, refers to the size of the connector, not the number of wires.
Table 3-1
Mako 5625 Interconnections
PS0105 Power Supply
From To Cable ID
PS0105 output harness - “P10” AP24507P4 - P10 p/o power supply output harness
PS0105 output harness - “P24” AC41116 - “J24” p/o power supply output harness
PS0105 output harness - “P25” AP9992P2 - P6 AC41110
AP24507P4 Controller
From To Cable ID
P1 (mini - coax) AP24680 - P5 (p/o Optics assembly ) AC40038
P2 (10 pin ribbon) MA0540 Outside Encoder p/o encoder assembly
P3 (50 pin ribbon) AP9992P2 - P2 AC41109
P4 (26 pin ribbon) AP24680 - P1 (p/o Optics assembly) AC41111
P5 (12 wire) (CPR, CPL, EOM, CASS LOAD) AC41115 (See Figure 3-3 on page 22)
P6 (6 wire) AC41112 SOL sensor assembly p/o AC41112
P7 (10 pin ribbon) On-line Processor (OLP) intfc connector AC41108
P8 (4 wire) FAN AC41105
P10 (10 wire) PS0105 PS0105 output harness
P11 (4 wire) Film Door Switch, Main Interl’k, PS0105 AC41116 (see Figure 3-2 on page 22)
P14 (10 pin ribbon) MO0088 Drive Motor / Encoder AC41106
P15 (6 wire) MO0109 Spinner Motor p/o MO0109
P16 (26 pin ribbon) AP9996 - P2 AC41102, AC41103, AC41104
P18 (4 wire) Jumper (pin 1-3 and pin 2-4) AC24658
P100 (3 wire) Cutter Motor AC41114
AP9992P2 SCSI Controller

From To Cable ID
P1 (50 pin ribbon) PelBox Interface connector AC41107
P2 (50 pin ribbon) AP24507P4 - P3 AC41109
P3 (50 pin ribbon) SCSI Interface Connector AC41113
P6 (3 wire) PS0105 AC41110
AG12304 Rev. 1 23
Table 3-1
Mako 5625 Interconnections
AP9996 Display Board

From To Cable ID
P1 keypad p/o Front Panel Assembly
P2 (26 pin ribbon) AP24507P4 - P16 AC41102, AC41103, AC41104
Optics Assembly
From To Cable ID
AP24680 - P1 AP24507P4 - P4 AC41111
AP24680 - P5 AP24507P4 - P1 AC40038
MO0109 AP24507P4 - P15 p/o MO0109
Cutter
From To Cable ID
Cutter Park Left AP24507P4 - P5 AC41115 (See Figure 3-3 on page 22)
Cutter Park Right AP24507P4 - P5 AC41115 (See Figure 3-3 on page 22)
Cutter Motor AP24507P4 - P100 AC41114
System Ground Connections, Back Panel Connectors, Miscellaneous

From To Cable ID
Casting cover right side Base plate AC18134P1
PS0105 case Optics assembly back plate AC18134P3
Casting left side front Base plate AC18134P7
Casting left side rear Base plate AC18134P1
End-of-Media switch AC41115 - “EOM” AC41118 (See Figure 3-3 on page 22)
Cassette Present Sensor AP24507P4 - P5 AC41115 (See Figure 3-3 on page 22)
MA0540 Outside Encoder AP24507P4 - P2 p/o MA0540
MO0088 Drive Motor / Encoder AP24507P4 - P14 AC41106
AC41112 SOL Sensor Assembly AP24507P4 - P6 p/o AC41112
DC Fan AP24507P4 - P8 AC41105
Main Interlock AP24507P4 - P11 AC41116 (see Figure 3-2 on page 22)
Film Door Switch AP24507P4 - P11 AC41116 (see Figure 3-2 on page 22)
Online Processor (OLP) Connector AP24507P4 - P7 AC41108
SCSI Connector AP9992P2 - P3 AC41113
PelBox Connector AP9992P2 - P1 AC41107
AC24658 Jumper Plug AP24507P4 - P18 AC24658
24 AG12304 Rev. 1
4 - Remove and Replace
4.1 Introduction

Section 4.3, “System Covers” on page 27
Section 4.3.3, “Removing the System Cover” on page 27
Section 4.3.4, “Replacing the System Cover” on page 27
Section 4.4, “Assembly Location Diagram” on page 29
Section 4.5, “System Power Fuse” on page 30
Section 4.6, “AP24507P4 Main Controller” on page 31
Section 4.7, “AP9992P2 SCSI PelBox Interface” on page 33
Section 4.8, “AP9996 Control Panel and FA20253 Keypad” on page 34
Section 4.9, “AO41042 Lower Optics Assembly” on page 37
Section 4.10, “MO0109 Spinner Motor” on page 40
Section 4.11, “MO0088 Servo DC Motor and Encoder (Drive Motor)” on page 42
Section 4.13, “MA0540 Drive Outside Encoder” on page 44
Section 4.14, “AO41050 Cutter” on page 47
Section 4.15, “AO41022 Pinch Roller” on page 49
Section 4.15.3, “Media Shelf Alignment” on page 51
Section 4.16, “PS0105 System Power Supply” on page 52
AG12304 Rev. 1 25
4.2 Warnings
WARNING!
electrical shock.
CAUTION
RECORDER CONTAINS
CAUTION!
26 AG12304 Rev. 1
4.3 System Covers
All procedures in this chapter require the removal of the system covers. See the CAUTION note at the
beginning of this chapter for static grounding wrist strap connection point.
4.3.1 Opening the Media Door

To open the media door, lift it by its handle all the way up and back until it stays up by itself.
4.3.2 Closing the Media Door

To close the media door, pull it forward until it is supported by the gas spring and then release it,
allowing it to close by itself.
CAUTION!
Don’t force the media door to close because it may be damaged. Allow it to
close by itself, supported by its gas spring.
4.3.3 Removing the System Cover

1. Remove the film input cassette and the film output cassette.
2. Remove the two bolts in the back of the system to release the main cover.
See Figure 4-1 on page 28.
3. Pull the main cover back a little, then lift the main cover off the recorder.
4. Unscrew and remove the film release lever. See Figure 4-2 on page 29.
5. Remove the two bolts that secure the rear of the front cover to the base plate.
6. Disconnect the barrier connector located at the inside left rear of the front
cover assembly.
7. Pull the front cover forward until it is supported by its restraint cables.
4.3.4 Replacing the System Cover

1. Lower the front cover until it rests on the base of the recorder.
2. Connect the barrier connector located at the inside left rear of the front cover
assembly.
3. Install the two bolts that secure the rear of the front cover to the base of the
recorder.
4. Install the film release lever. See Figure 4-2 on page 29.
5. Put the main cover in place a short way behind the rear of the front cover.
6. Push the front cover into place against the front cover.
7. Install the two bolts in the back of the system to secure the main cover. See
Figure 4-1 on page 28.
8. Replace the film input cassette and the film output cassette.
AG12304 Rev. 1 27
side view
media door main cover
front cover
barrier connector
left side
rear view
1
to release main cover
remove these bolts 2
pull the main cover back
and off
0
1
front cover hold down bolt

one per side
3
raise the front cover
Figure 4 - 1 System Covers
28 AG12304 Rev. 1
4.4 Assembly Location Diagram
AP9996, display board, not shown - located on front cover
RIGHT as seen from front of recorder LEFT
AO41050 AO41022 (under drive roller)
Film Release Lever
MA0540
MO0088
Media Shelf
AP9992P2
AP24507P4
AO41042 MO0109
PS0105
power entry module SCSI, PelBox, and OLP connectors
Figure 4 - 2 Major Component Locations (base)
AG12304 Rev. 1 29
4.5 System Power Fuse
Locate the power entry module (part of the power supply, PS0105) on the diagram in Figure 4-2 on page
29.
NOTE: Fuse is 4 amp, 250 VAC
fuse door (open)
0 fuse tray
0
pry here with screwdriver
1
Figure 4 - 3 Power Fuse
1. Remove the power cord from the power entry module so the fuse door can
open.
2. With a thin, flat-bladed screwdriver, pry up the fuse door of the power entry
module as shown in Figure 4-3 on page 30.
3. Pull the fuse tray out of the power entry module. The fuse tray has an arrow on
the end.
4. Remove the blown fuse from the fuse tray.
5. Install a new fuse of the proper amperage and voltage, 4A - 250VAC.
6. Install the fuse tray in the power entry module as shown in Figure 4-3 on page
30 and with the arrow on the end of the fuse tray in the up direction.
7. Close the fuse door, snapping it into position.
8. Replace the power cord in the power entry module.
30 AG12304 Rev. 1
4.6 AP24507P4 Main Controller
Locate AP24507P4 board with the diagram in Figure 4-2 on page 29. See the CAUTION note at the begin-
ning of this chapter for static grounding wrist strap connection point.
1. Power down the recorder.
2. Remove system covers as described in Section 4.3.3, “Removing the System
Cover” on page 27.
3. Install laser diode shorting plug. See Figure 4-8 on page 37.
4. Disconnect P1, P100, P6, P5, P11, P16, P2, P7, P3, P4, P14, P10, P15, and
P8. Note that P12, P13, P17, and P9 have no connector installed.
5. Remove nine mounting screws that hold the board in place.
6. Remove the board from the recorder.
7. Remove the jumper plug from P18.
8. Remove U301 and U302 from the board just taken out.
9. Install the jumper plug into P18 of the new AP24507P4.
10. Install U301 and U302 into the new AP24507P4 board.
P7 P3 P4
P14
P2 J2 P10
P1
R17
P12
P16
U301 U302 P13
P11
J1
AP24507P4 P9
P5
main controller
P18
P6 P15
CAUTION
RECORDER CONTAINS
STATIC SENSITIVE COMPONENTS
Wear a static grounding wrist strap! P8

P100
P17
Figure 4 - 4 AP24507P4 Main Controller Board
AG12304 Rev. 1 31
11. Verify that J1 and J2 are in the same configuration as that of the board just
removed.
12. Install the new AP24507P4 board in the recorder.
13. Install and fully tighten the nine mounting screws.
14. Reconnect P1, P100, P6, P5, P11, P16, P2, P7, P3, P4, P14, P10, P15, and
P8. Note that P12, P13, P17, and P9 have no connector installed.
15. Remove laser diode shorting plug. See Figure 4-8 on page 37.
CAUTION!
Do not remove laser diode shorting plug with power on
16. Power up the imagesetter
NOTE: If EPROM error is displayed, press PREV to restart.
17. Observe the control panel display and adjust R17 of the AP24507P4 board for
the best contrast with a minimal amount of black background.
18. Replace system covers as described in Section 4.3.4, “Replacing the System
32 AG12304 Rev. 1
4.7 AP9992P2 SCSI PelBox Interface
Locate the SCSI Controller board, AP9992P2, with Figure 4-2 on page 29. See the CAUTION
note at the beginning of this chapter for static grounding wrist strap connection point.
J2
P2
CAUTION
34 5
RECORDER CONTAINS
01 2
67
S2
89A
EF
B CD
34 5
01 2
67
S1
89A
Wear a static grounding wrist strap!
EF
B CD
P1
P5
J1
P3 J3 P6
Figure 4 - 5 AP9992P2 SCSI Controller Board
4.7.1 Remove SCSI Controller Board

3. Disconnect P1, P2, P3, and P6 of AP9992P2.
4. Remove six mounting screws that hold the board in place.
5. Remove the 9992P2 board from the recorder.
4.7.2 Replace SCSI Controller Board

1. Install the new 9992P2 board in the recorder.
2. Install and fully tighten the six mounting screws.
3. Reconnect P1, P2, P3, and P6 to AP9992P2.
4. Verify that J1, J2, and J3 are in the same configuration as that of the board
just removed.
5. Verify that S1 and S2 are set the same as S1 and S2 of the board removed.
6. Replace system covers as described in Section 4.3.4, “Replacing the System
AG12304 Rev. 1 33
4.8 AP9996 Control Panel and FA20253 Keypad
The keypad (FA20253) and display board (AP9996) assembly is mounted on the media door. The keypad
and the display board may be replaced separately. See the CAUTION note at the beginning of this chapter
for static grounding wrist strap connection point.
assembly shield
CAUTION
RECORDER CONTAINS
display board
AP9996 Wear a static grounding wrist strap!
base plate
keypad
FA20253
Figure 4 - 6 The Keypad and Display Assembly
34 AG12304 Rev. 1
4.8.1 Remove AP9996 or FA20253
2. Open the media door with instructions in Section 4.3.1, “Opening the Media
Door” on page 27.
3. Disconnect system ribbon connector from the AP9996 display board.
4. Remove four screws that hold the assembly shield in place.
5. Remove assembly shield from the system.
6. Unplug the connector from the keypad to the display.
7. Remove four screws that hold the display board in place.
FA20253 keypad
base plate
recorder media door
AP9996 display board
assembly shield
Figure 4 - 7 Keypad and Display Board Assembly
AG12304 Rev. 1 35
8. Remove the display board from the system. Be careful not to damage the two
foam strips on the base plate that form a light shield.
9. If replacing only the display board, AP9996, go to Section 4.8.2, “Replace
AP9996 or FA20253” on page 36, step 4.
10. Remove the four standoffs that hold the base plate in place.
11. Remove the base plate from the system. Be careful not to damage the foam
strips on the media door that form a light shield.
12. Remove the keypad assembly from the system.
4.8.2 Replace AP9996 or FA20253

1. Place the keypad onto the four studs in the display door.
2. Place the base plate onto the four studs in the media door, thus securing the
keypad.
3. Install four standoffs to hold the base plate and keypad in place.
4. Place the display board onto the base plate.
5. Install four screws that hold the display board in place on the base plate.
6. Connect the keypad to the display board.
7. Place the shield in position on the four standoffs.
8. Install four screws to hold the shield in place.
9. Reconnect system ribbon connector from the AP9996 display board.
10. Close media door with instructions in Section 4.3.2, “Closing the Media Door”
on page 27.
36 AG12304 Rev. 1
4.9 AO41042 Lower Optics Assembly
Locate the Lower Optics Assembly, AO41042. See Section 4.4, “Assembly Location Diagram” on page 29.
CAUTION!
THIS ASSEMBLY IS VERY SENSITIVE TO STATIC ELECTRICITY!
WEAR A STATIC GROUNDING WRIST STRAP. SEE THE CAUTION
NOTE AT THE BEGINNING OF THIS CHAPTER FOR STATIC
GROUNDING WRIST STRAP CONNECTION POINT.
4.9.1 Remove Lower Optics Assembly

3. Install laser diode shunt on J1 of AP24525 to protect the laser diode from
static electricity damage. Shunt should be found in “flagged” position, move to
“shunted” position to short, and protect, the laser diode. See Figure 4-8 on
page 37.
(interconnects and PCB components not shown)

AP24525 (bottom view)
AP24680 laser driver board
J1
J1 “flagged” J1 “shunted”
AP24525 laser switch board
CAUTION
RECORDER CONTAINS
Figure 4 - 8 AO40190 Lower Optics Assembly (side view)
AG12304 Rev. 1 37
4. Disconnect P1 and P4 from AP24680 to the recorder.
5. Remove two screws that hold AP24680 to standoffs on the optics. Be sure to
save the two insulating nylon washers.
6. Carefully lay AP24680 down to allow clearance for removing the screws that
hold the optics in place.
7. Remove four mounting screws that secure the Lower Optics assembly to the
bottom of the optics assembly. See Figure 4-9 on page 38.
NOTE: Later versions of the Lower Optics assembly have ten holes in
the lower rails instead of six. ONLY the inner holes of the outer
pairs are the mounting holes. DO NOT remove the outer screws.
8. Carefully remove the Lower Optics assembly from the system.
four mounting holes (dotted holes may not be present)
front mounting surface

this circle aligns the Lower Optics
rear mounting surface
mounting screws (4)
Figure 4 - 9 Lower Optics Assembly Mounting Details
38 AG12304 Rev. 1
4.9.2 Replace Lower Optics Assembly
1. Remove two screws that hold the new AP24680 to standoffs on the new
optics. Be sure to save the two insulating nylon washers.
2. Carefully lay AP24680 down to allow clearance for replacing the screws that
hold the optics in place.
3. Clean the mating surfaces of the Lower Optics and the optics assembly.
4. Install new Lower Optics assembly in the same orientation as that of the
optics assembly just removed. Note that the Lower Optics is self-aligning
when the circular feature of the Lower Optics mates with the casting.
5. Install four screws to secure the new Lower Optics in place.
6. Install AP24680 with two screws and two insulating washers under the screw
heads on the two standoffs on the optics.
7. Reconnect P1 and P5 of AP24680 to the recorder.
8. Unshunt the laser diode by “flagging” J1 of AP24525 .
9. Follow procedures in Section 4.3.4, “Replacing the System Cover” on page 27
to replace the system covers.
4.9.3 Image Width Adjustment

Replacing the Lower Optics Assembly may change the image width. Width can be corrected, if
necessary, by performing Section 5.5, “Pel Correction” on page 60.
4.9.4 Image Perpendicularity Adjustment

Replacing the Lower Optics Assembly may change the image perpendicularity. Perpendicularity
can be corrected, if necessary, by performing Section 5.11, “Perpendicularity Adjustment” on
page 63.
AG12304 Rev. 1 39
4.10 MO0109 Spinner Motor
Locate the Spinner Motor, MO0109. See Section 4.4, “Assembly Location Diagram” on page 29.
4.10.1 Removing the Spinner Motor

1. Wear a static grounding wrist-strap and connect it to the system. See the
CAUTION note at the beginning of this chapter for static grounding wrist strap
connection point.
2. Follow procedures in Section 4.3.3, “Removing the System Cover” on page 27
to remove the system covers.
3. Disconnect Spinner Motor from AP24507P4-P15.
CAUTION
cable exit RECORDER CONTAINS
mirror
alignment scribe (if present)
Figure 4 - 10 MO0109 Spinner Motor
4. Remove 3 mounting screws from around the Spinner Motor. Set the screws
and their washers and spacers aside carefully to replace later.
5. Carefully remove the Spinner Motor by lifting it straight out, being careful to
not let the mirror touch any part of the recorder.
4.10.2 Replacing the Spinner Motor

NOTE: Do not touch the Spinner Motor Mirror for any reason.
1. Carefully guide the new Spinner Motor straight into the housing.
2. If the motor has a scribe mark, align the scribe mark on the edge of the Spin-
ner Motor with the scribe mark on the housing.
40 AG12304 Rev. 1
3. If there is no scribe mark, align the cable exit from the motor in the 10 o’clock
position, with 12 o’clock facing the front of the recorder and 6 o’clock facing
the rear. See Figure 4-11 on page 41. This will align the motor.
Lead cable exit away in

10 o’clock direction
12
11 1
10 2
9 3
8 4
7 5
6
Figure 4 - 11 Spinner Motor Alignment (without scribe mark)
4. Install and torque the three mounting screws with their washers and spacers
to 15 in/lb.
5. Verify that the scribe marks, if present, still line up.
6. Connect the Spinner Motor to AP24507P4-P15.
AG12304 Rev. 1 41
4.11 MO0088 Servo DC Motor and Encoder (Drive Motor)
Locate the Servo DC Motor and Encoder, MO0088. See Section 4.4, “Assembly Location Diagram” on page
29. See the CAUTION note at the beginning of this chapter for static grounding wrist strap connection point.
2. Remove the drive motor (see Section 4.4, “Assembly Location Diagram” on
page 29 for location) and its bracket, by removing two bracket mounting
screws. See Figure 4-12 on page 42.
3. Disconnect the motor’s ribbon cable.
4. Remove the motor from its bracket by removing the four motor mounting
screws.
drive pulley
CAUTION
RECORDER CONTAINS
black belt Wear a static grounding wrist strap!
idler pulley
Kapton belt
motor mounting
screw (typ 4)
screws behind these

two holes hold the
idler pulley in place bracket mounting screw (typ 2)
Figure 4 - 12 Drive Motor, Idler Pulley, and Drive Pulley
5. Hold the Kapton belt clear of the idler pulley and clean the idler pulley with
alcohol (to remove any oil) and allow to dry.
6. Install the new motor onto the motor bracket with the four mounting screws.
7. Install the drive motor and its bracket with the two bracket mounting screws,
but don’t tighten the two screws. See Figure 4-12 on page 42.
8. Adjust the Kapton belt tension as described in Section 5.13.2, “Kapton Belt
Tension Adjustment” on page 69.
42 AG12304 Rev. 1
4.12 Belt Replacement
Locate the Servo DC Motor and Encoder, MO0088. See Section 4.4, “Assembly Location Diagram” on page
29. See the CAUTION note at the beginning of this chapter for static grounding wrist strap connection point.
2. Loosen MO0088 (see Section 4.4, “Assembly Location Diagram” on page 29
for location) and its bracket, by loosening two bracket mounting screws. See
Figure 4-12 on page 42.
3. Horizontally line up the two holes in the idler pulley and loosen the tension on
the idler pulley by loosening the two screws visible through the holes.
4. Remove both belts.
drive pulley
CAUTION
RECORDER CONTAINS
black belt Wear a static grounding wrist strap!
idler pulley
Kapton belt
MO0088
motor mounting
screw (typ 4)
screws behind these

two holes hold the
5. Clean the idler pulley and the drive pulley with alcohol (to remove any oil) and
allow to dry.
6. Install the Kapton belt over the idler pulley and the drive motor shaft.
7. Install the black belt over the drive pulley and the idler pulley shaft and center
the belt on the pulleys.
8. Adjust the tension of both belts as described in Section 5.13.1, “Black Belt
Tension Adjustment” on page 68 and Section 5.13.2, “Kapton Belt Tension
Adjustment” on page 69.
AG12304 Rev. 1 43
4.13 MA0540 Drive Outside Encoder
Locate the Drive Outside Encoder, MA0540. See Section 4.4, “Assembly Location Diagram” on page 29.
See the CAUTION note at the beginning of this chapter for static grounding wrist strap connection point.
2. Unplug encoder ribbon cable from P2 of AP24507P4.
3. Locate drive outside encoder (see Figure 4-2 on page 29).
4. Remove encoder cover.
5. Loosen mounting hardware, but do not remove it.
6. Loosen setscrew in Hub.
7. Pull Centering Slide to Out position.
8. Remove mounting hardware.
9. Remove Encoder.
10. Verify that the new encoder is set up as follows prior to beginning installation.
• With two fingers, front and back, rotate Hub until setscrew aligns with slot
in PC board. This allows the allen wrench to fit into the setscrew without
touching the PC board. (Slide lock mechanism needs to be pushed in
slightly, but not all the way, to allow hub to rotate freely.)
• Pull Slide Lock Mechanism out to fully extended position to lock the Hub in
the correct position. Refer to Figure 4-14 on page 44.
Slide Lock pull out

mechanism
CAUTION
setscrew RECORDER CONTAINS
mounting holes (2)
slot Wear a static grounding wrist strap!
setscrew to slot
alignment
PC board
encoder body
Hub
Figure 4 - 14 The High Accuracy Encoder, Cover Off
11. Verify encoder mount FA21415 is Rev 2 or later (see Figure 4-15 on page
45). Change encoder mount assembly (AO21572) if necessary.
12. Align Hub with Shaft and gently push Hub onto Shaft until Encoder is resting
on mounting surface. Push on Hub only, not on the PC board or the
Encoder Body.
13. Align Encoder with mounting holes and install mounting hardware.
44 AG12304 Rev. 1
14. Maintian pressure on Hub to insure it is seated in centering mechanism and
secure Hub to Shaft by rotating setscrew clockwise, using long leg of allen
wrench, until setscrew makes contact with Shaft. Note that the flat on the
shaft must be lined up with set screw before tightening.
15. Note the position of the short leg of the allen wrench and rotate an additional
1/4 inch clockwise to apply approximately 20 oz-in torque.
16. Push Slide Lock Mechanism in completely.
.65 to .74 Max for Non-thru Shaft

.75 min for Thru Shaft If Encoder Mount looks like this,
install a new Encoder Mount Assembly
3/8
Encoder Mount
(FA21415)
Figure 4 - 15 High Accuracy Encoder Mounts
17. INSPECTION: Verify that a gap exists between the disk and the mask by
inserting a 0.010” shim in the gap on the underside of the PC board (see
Figure 4-16 on page 46). Rotate roller slowly one revolution, gently moving
0.010” shim to verify no binding exists. If a 0.010” minimum gap does not
exist, remove and reinstall the encoder.
CAUTION!
Do not rotate roller without first verifying the gap between mask and disk.
Any disk contact with the mask may result in damage to the disk or to the
mask and require encoder replacement.
18. Install Cover. If Cover has through-hole option, align mylar seal with Shaft and
slide Cover over Encoder body until the tabs on the base engage with the
locking features in the cover. Care must be taken when installing through-hole
cover onto a stepped shaft.
AG12304 Rev. 1 45
Hub
PC board
disk
mask
base
gap
Figure 4 - 16 High Accuracy Encoder, Side View
19. Install encoder ribbon cable in P2 of AP27835.

46 AG12304 Rev. 1
4.14 AO41050 Cutter
Locate the Cutter, AO41050. See Section 4.4, “Assembly Location Diagram” on page 29. See the CAU-
TION note at the beginning of this chapter for static grounding wrist strap connection point.
CAUTION
RECORDER CONTAINS
cutter motor
connectors four mounting screws go here
left cutter park sensor right cutter park sensor
Figure 4 - 17 AO41050 Cutter, Front View
4.14.1 AO41050 Cutter Removal

2. Locate the cutter. See Section 4.4, “Assembly Location Diagram” on page 29.
3. Remove the cutter cover, which is held on by Velcro strips to the front of the
cutter and to a light blocking panel across the lower front of the main casting.
The light blocking panel may come off with the cutter cover.
4. Disconnect the two park sensor cables from the cutter assembly. See
Figure 4-17 on page 47 and Figure 4-18 on page 48.
5. Disconnect the cutter motor connectors from the cutter motor.
6. Loosen four mounting screws, but don’t remove them.
7. Slide the cutter assembly to the left and remove it from the system.
AG12304 Rev. 1 47
4.14.2 AO41050 Cutter Replacement
8. Install the cutter assembly onto its four mounting screws, slide it fully to the
right, and tighten its four mounting screws.
9. Attach the cutter motor connectors.
10. Attach the two park sensor connectors to the cutter.
11. If the light blocking panel came off with the removal of the cutter cover,
replace the panel first.
12. Install the cutter cover under the cutter (velcro attachment), connecting it first
to the light blocking panel and then to the front of the cutter.
cutter motor connectors
right cutter park sensor
left cutter park sensor
Figure 4 - 18 AO40150 Cutter, Rear View
48 AG12304 Rev. 1
4.15 AO41022 Pinch Roller
Locate the Pinch Roller, AO41022. See Section 4.4, “Assembly Location Diagram” on page 29. See the
CAUTION note at the beginning of this chapter for static grounding wrist strap connection point.
4.15.1 Pinch Roller Removal

2. Follow procedures in Section 4.14, “AO41050 Cutter” on page 47 to remove
the cutter assembly.
3. Open the pinch roller with the Film Release Lever.
4. Remove the Film Release Lever.
5. Remove the four mounting screws that hold the media shelf, lift the media
shelf off the recorder casting, disconnect the End-Of-Media sensor and lay
the media shelf carefully back out of the way.
6. Remove the two screws (located at either end of the film guide) that hold the
film guide to the pinch roller assembly (see Figure 4-19 on page 49).
CAUTION
RECORDER CONTAINS
half shaft
film guide
cleat (2 per side)
half shaft
pinch roller assembly
washers
Figure 4 - 19 AO41022 Pinch Roller Assembly
AG12304 Rev. 1 49
7. Remove the film guide from the recorder.
8. Remove the two half shafts, left and right, that hold the pinch roller in place.
Each half shaft is held in by two cleats, four total, which must be removed (see
Figure 4-19 on page 49). Retain the washers that are on each half shaft.
9. Pull the pinch roller assembly forward and out of the recorder.
4.15.2 Pinch Roller Replacement

1. Remove the film guide from the new pinch roller assembly.
2. Place the new pinch roller assembly into the recorder.
3. Install the two half-shafts to hold the pinch roller assembly and install their four
cleats. Be sure to install the washers removed with the half shafts.
4. Install the film guide on the new pinch roller and secure it in place with its two
screws.
5. Reconnect the End-Of-Media sensor.
6. Install the media shelf and install its four mounting screws loosely.
7. Follow instructions in Section 4.15.3, “Media Shelf Alignment” on page 51 to
adjust the media shelf.
8. Replace the Film Release Lever.
9. Follow procedures in Section 4.14, “AO41050 Cutter” on page 47 to replace
the cutter assembly.
50 AG12304 Rev. 1
4.15.3 Media Shelf Alignment
1. Loosen the four mounting screws that hold the media shelf to the casting but
don’t remove them.
2. Install two tools, FX1314, as shown in Figure 4-20 on page 51, over the two
nylon cassette guides at the back of the media shelf and in front of the main
drive roller.
3. Push the media shelf back toward the rear of the recorder until the two tools
come to rest against the main drive roller. Make sure the tools are flat against
the roller and flat down on the media shelf.
4. Tighten the four media shelf mounting screws.
5. Remove the tool FX1314.
main drive roller
FX1314 (2 required)
mounting screw (typ 4)
FX1314
installed
Figure 4 - 20 Media Shelf Alignment
AG12304 Rev. 1 51
4.16 PS0105 System Power Supply
Locate the System Power Supply, PS0105. See Section 4.4, “Assembly Location Diagram” on page 29. See
the CAUTION note at the beginning of this chapter for static grounding wrist strap connection point.
4.16.1 Power Supply Removal

2. Disconnect P25, P24, and P10, all of which are part of the output cable of the
PS0105 power supply.
3. Disconnect the power cord from the back of the recorder.
4. Disconnect the ground strap from the ground lug of the PS0105 power supply.
5. Remove four mounting screws from the base of the PS0105 power supply.
6. Remove the PS0105 power supply from the system.
CAUTION
RECORDER CONTAINS
STATIC SENSITIVE COMPONENTS EMI clips
P10
P24
P25
mounting hole (typ 4) ground lug
Figure 4 - 21 PS0105 Power Supply
52 AG12304 Rev. 1
4.16.2 Power Supply Replacement
1. Install the new PS0105 power supply in the same orientation as the one just
removed.
2. Install and fully tighten the four mounting screws.
3. Verify that the fuse is installed properly. See Section 4.5, “System Power
Fuse” on page 30.
4. Connect the ground strap to the ground lug of the PS0105 power supply
5. Make sure the recorder power switch is in the OFF position, then connect the
power cord.
6. Reconnect P25, P24, and P10.
7. Move the three EMI clips from the old power supply to the new one.
8. Connect the power cord.
AG12304 Rev. 1 53
54 AG12304 Rev. 1
5 - Calibration and Alignment
5.1 Introduction
This is a list of the sections of this Calibration chapter:

Section 5.3, “System Calibration Menu Map” on page 57
Section 5.4, “Image Centering” on page 58
Section 5.5, “Pel Correction” on page 60
Section 5.6, “Line Correction” on page 61
Section 5.7, “Ignore System Errors?” on page 62
Section 5.8, “/Beamon Path?” on page 62
Section 5.9, “Laser Bias Level” on page 62
Section 5.10, “Save Setup?” on page 63
Section 5.11, “Perpendicularity Adjustment” on page 63
Section 5.11.1, “Checking Perpendicularity” on page 63
Section 5.11.2, “Installing Shims” on page 64
Section 5.12, “System Alignment Menu” on page 66
Section 5.13, “Belt Tension Adjustment” on page 67
Section 5.13.1, “Black Belt Tension Adjustment” on page 68
Section 5.13.2, “Kapton Belt Tension Adjustment” on page 69
AG12304 Rev. 1 55
5.2 Warnings
WARNING!
electrical shock.
CAUTION
RECORDER CONTAINS
CAUTION!
56 AG12304 Rev. 1
5.3 System Calibration Menu Map
The Calibration Menu Map is a visual guide to the options available for calibrating the recorder.
ONLINE / OFFLINE
PRESS AND HOLD PREV

THEN PRESS MENU
PREV SELECT IMAGE CENTERING

IMAGE CENTERING
SHIFT RIGHT SHIFT LEFT
NEXT NEXT
IMAGE CENTERING IMAGE CENTERING

VALUE IN 0.01mm VALUE IN 0.01mm
SHIFT RIGHT SHIFT LEFT

BY (0-762):#### BY (0-762):####
NEXT NEXT
PEL CORRECTION
VALUE IN 0.01mm
CALIBRATION DEFAULT VALUES IN METRIC
PREV MENU OPTIONS Mako 5625

EXPECTED VALUE
##### IMAGE CENTERING SHIFT RIGHT 000
IMAGE CENTERING SHIFT LEFT 000
NEXT
PEL CORRECTION VALUE .
PREV
ACTUAL VALUE EXPECTED VALUE 55000
##### ACTUAL VALUE *
LINE CORRECTION VALUE ..
NEXT EXPECTED VALUE 60000
LINE CORRECTION ACTUAL VALUE *
IGNORE SYSTEM ERRORS? YES/NO
VALUE IN 0.01mm
/BEAMON PATH? COAXIAL CABLE P1 (ONLY)
NEXT LASER BIAS LEVEL 100%
PREV SAVE CALIBRATION SETUP? YES/NO
EXPECTED VALUE
#####
*Actual values are calculated from the measured values when running test pat-
NEXT
terns.
ACTUAL VALUE PREV
#####
NEXT
SELECT
IGNORE SYSTEM ERRORS? IGNORE SYSTEM ERRORS?
NO YES
NEXT NEXT
/BEAMON PATH? SELECT /BEAMON PATH?
COAXIAL CABLE P1 RIBBON CABLE P4
NEXT NEXT
LASER BIAS LEVEL
%(0-100):100
NEXT
SAVE CALIBRATION SETUP? SELECT SAVE CALIBRATION SETUP?
NO YES
NEXT NEXT
ONLINE / OFFLINE
Figure 5 - 1 Calibration Menu Map
AG12304 Rev. 1 57
5.4 Image Centering
Refer to the Calibration Menu Map (Figure 5-1 on page 57) for the following procedure. When you enter val-
ues from the keypad, PREV and NEXT move the cursor left and right respectively, and SELECT changes
the value of a selected field.
To set the image centering, output a test pattern and measure the distance from the edge of the test pattern
to the edge of the media.
1. Press the SELECT key to start test pattern #4. The system should display
“Recording Image”.
2. Wait 60 seconds and then press the STOP key.
3. Cut and process the image.
4. If the test pattern is cut off on the left or right side of the output, make an initial
centering adjustment as described below and output the test pattern again
(make all measurements in millimeters):
a. Calculate: X=(Film Width - Expected grid width)*100/2.
b. Measure: Y=existing margin*100.
c. Calculate: Y-X. This is the initial adjustment value.
d. See whether “Image Centering” is “Shift Left” or “Shift Right”.
e. Apply the initial value to the current “Image Centering” value.
For example, if “Shift Left” is selected and the image is too far to the left, sub-
tract from the “Shift Left” value. If “Shift Right” is selected and the image is too
far to the left, add to the “Shift Right” value. See the example in Figure 5-2 on
page 58.
Initial Adjustment Value (all measurements in millimeters):
{ (Film width) - (Expected grid width)

2 }
- (Existing margin) *100 Existing margin
Apply the initial adjustment value to the current Image Centering

Value to move the grid left or right as necessary.
*Example values:
Film width = 310mm
Expected grid width = 300mm
Emulsion Up
Existing margin = 10mm
Trailing Edge
[(310mm-300mm) / 2 - (10mm)] *100 = 500
-Current centering value = “Shift Right” by “1900”.

-This grid must shift right.
-Make “Shift Right” value = “2400”.
(Note: If this example grid was off the film to the right, you Expected grid width
would set “Shift Right” value = “1400”.)
Figure 5 - 2 Example Values for Initial Centering Adjustment
58 AG12304 Rev. 1
This initial adjustment results in an image that appears entirely on the film and
requires a minimal adjustment to become perfectly centered. When the entire
test pattern appears between the left and right sides of the output, complete
the following steps to center the image.
5. Measure the distance between the left edge of the film and the left edge of the
test pattern in millimeters.
6. Measure the distance between the right side of the film and the right side of
the test pattern in millimeters.
7. Calculate the difference between these two values and divide by 2, then multi-
ply by 100. Apply any initial adjustment. This is the image centering value.
8. Use the calibration menu map in Figure 5-1 on page 57 to access the current
“Image Centering” value.
9. Apply the image centering value to the current “Shift Left” or “Shift Right”
value, as required to center the grid on the film.
Smaller distance Greater distance
Trailing edge,
emulsion side up
Image Centering Value (measurements in millimeters)
*100 + initial adjustment value= image centering value
{
(greater distance)-(smaller distance)
2
}
Figure 5 - 3 Adjusting Image Centering
10. Save the calibration setup as described on the menu map in Figure 5-1 on
page 57.
11. Output the test pattern and measure the image centering value again. If the
new image centering value is greater than 1.0mm, repeat this procedure and
add or subtract as needed the correction value to the existing image centering
value.
AG12304 Rev. 1 59
5.5 Pel Correction
Pel correction adjusts the width of the image. Using the centered output from Section 5.4, “Image Center-
ing” on page 58, perform the following:
1. Measure the width of the test pattern #4 grid.
2. Calculate the error by finding the difference between the test pattern width
and the expected width of the test pattern (Figure 5-4 on page 60). The Pel
correction value is the measured error in millimeters, multiplied by 100.
3. Apply the pel correction value to the current “Pel Correction” “ACTUAL
VALUE”.
If the grid is too narrow, subtract the pel correction value from the “ACTUAL
VALUE”. If the grid is too wide, add the pel correction value to the “ACTUAL
VALUE”.
Pel Correction
ACTUAL VALUE
Figure 5 - 4 Pel Correction
60 AG12304 Rev. 1
5.6 Line Correction
Line correction adjusts the length of the image. Make sure the Pel correction is within specification before
adjusting the line correction.
NOTE: There are three independent Line Corrections available. Line

Correction must be made for all media types in use, up to three,
as selected in the System Setup Menu. As each media type is
selected for use, its specific Line Correction is used when
exposing images.
1. Press the SELECT key to run test pattern #4. Wait until the test pattern is
complete and the display no longer indicates “RECORDING IMAGE”.
2. Calculate the error by finding the difference between the test pattern length
and the expected length of the test pattern (Figure 5-5 on page 61). The line
correction value is the measured error in millimeters, multiplied by 100.
3. Apply the line correction value to the current “Line Correction” “ACTUAL
VALUE”.
If the grid is shorter than the expected value, subtract the line correction value
from the “ACTUAL VALUE”. If the grid is longer than the expected value, add
the line correction value to the “ACTUAL VALUE”.
Line Correction
ACTUAL VALUE
Figure 5 - 5 Line Correction
AG12304 Rev. 1 61
5.7 Ignore System Errors?
The occurrence of system errors causes the recorder to display the appropriate error code and cease oper-
ation. To prevent the display of the error code and to cause the recorder to continue operation in the pres-
ence of system errors, the service technician may set Ignore System Errors? to Yes.
For normal operation, set Ignore System Errors? to No.
1. Press and hold PREV and press MENU to access the Calibration menu.
2. Press NEXT until the Ignore System Errors? window appears.
3. Press SELECT to choose either No or Yes.
5.8 /Beamon Path?

The /BEAMON Path? window allows the selection of the correct /BEAMON path for the cable being used.
Most recorders will be set to Coaxial Cable P1 and should not be changed.
NOTE: The factory setting needs to be changed only if the optics are
changed. Only qualified service technicians should change this
default. An incorrect setting results in all black output.
1. Press and hold PREV and press MENU to access the Calibration menu.
2. Press NEXT until the /BEAMON Path? window appears.
3. Press SELECT to choose the correct /BEAMON cable selection for the sys-
tem. Most recorders are set at the factory to Coaxial Cable P1 and should not
be changed.
5.9 Laser Bias Level

This Calibration menu item controls the percent of maximum Laser Bias Level applied when imaging. The
default value is 100%. The percent value can be lowered to reduce background fog on sensitive media.
Refer to the calibration menu in Figure 5-1 on page 57.
1. Output an exposure sweep from the RIP.
2. Cut and process the image and check it for background fog. Background fog
is a change in density between the white area on the header before the expo-
sure sweep and the area to the left of the exposure sweep.
3. If background fog is present, reduce the bias percent as follows:
a. Hold down PREV and press MENU to access the Calibration menu.
b. Press PREV. The Laser Bias Level window appears.
c. Lower the Laser Bias Level % setting. The amount of adjustment neces-
sary depends on the media type being used.
4. Repeat these steps until the exposure sweep appears without background
fog.
NOTE: Reduce the bias only enough to eliminate the background fog.
Overadjusting the bias may result in the loss of vertical line
width.
5. Linearize the imagesetter as described in the RIP Operator Guide.
62 AG12304 Rev. 1
5.10 Save Setup?
Answer YES or NO to this question. Answer YES if the changes to the Calibration Menu are to be saved and
used, even after a power off, until explicitly changed. Answer NO if the changes to the Calibration Menu are
to be maintained only until changed again or until power is turned off, at which time the last values saved
are used.
5.11 Perpendicularity Adjustment

Optics shims are used to adjust the perpendicularity of the recorder.
5.11.1 Checking Perpendicularity

1. Run test pattern #4. Wait until the test pattern is complete and the display no
longer indicates “RECORDING IMAGE”.
2. Cut and process the film.
Emulsion up Emulsion up
trailer trailer
put shim on power supply side put shim on interface connector side
Figure 5 - 6 Adjusting Perpendicularity
3. Measure diagonally in both directions across the image as shown in Figure 5-

6 on page 63.
4. Find the difference between the two measurements (long-short).
5. If the measurement is greater than 0.008 inch, use shims to raise the correct
side of the optics (see Figure 5-6 on page 63), as described in Section 5.11.2,
“Installing Shims” on page 64.
AG12304 Rev. 1 63
5.11.2 Installing Shims
If the perpendicularity measurement is greater than 0.008 inch, install the required shims on the
proper side of the optics (see Figure 5-6 on page 63). Use a shim whose thickness equals the
perpendicularity measurement difference, or use multiple shims whose total thickness equals
the perpendicularity measurement difference. Shims should only be required on one side of the
optics.
1. See Section 4.3, “System Covers” on page 27 for instructions on removing the
recorder cover.
2. Loosen the three mounting screws on the optical bed plate, which secure the
optics assembly to the casting of the recorder. Do not remove the screws.
mounting screws (3)
Figure 5 - 7 Mounting Screw Location
64 AG12304 Rev. 1
3. Place the shim(s) between the pin of the optics assembly and the recorder
casting.
4. Tighten the three mounting screws on the optical bed plate.
5. Replace the cover on the imagesetter as described in Section 4.3, “System
Covers” on page 27.
6. Output test pattern #4 again and recalculate the perpendicularity value. If the
new perpendicularity value is greater than 0.008 inch, repeat this procedure.
shims go here under pins
Figure 5 - 8 Shim Locations (top view of optics area)
AG12304 Rev. 1 65
5.12 System Alignment Menu
The LASER ALIGNMENT option is used to test the exposure values (0-255) for the laser. The BELT ALIGN-
MENT option is used to keep the motor running while adjusting the belt. See Figure 5-9 on page 66.
ONLINE / OFFLINE
press and hold PREV

press and hold NEXT
press MENU
SYSTEM ALIGNMENT SELECT SYSTEM ALIGNMENT

LASER ALIGNMENT BELT ALIGNMENT
STOP
NEXT NEXT
EXPOSURE HIT ADVANCE TO ADVANCE ADVANCING MEDIA
VALUE (0-255):000 START FILM FILM COUNT:000
STOP STOP
ONLINE / OFFLINE
Figure 5 - 9 System Alignment Menu Map
5.12.1 Laser Alignment

The following procedure allows the service technician to look at a test point on the Laser Driver
to verify that the laser diode is functional. This procedure must be performed by a qualified tech-
nician.
1. From ONLINE/OFFLINE, press and hold PREV, press and hold NEXT, then
press MENU. SYSTEM ALIGNMENT appears.
2. Press NEXT. EXPOSURE VALUE (0-255):000 appears. Set the exposure
value to 255. You must press NEXT until the cursor wraps around under the
left most position to set the exposure.
3. With a Digital Volt Meter, measure TP5 on the Laser Driver board. If the volt-
age is above 10V, the diode needs to be replaced.
4. Press STOP. ONLINE/OFFLINE appears.
5.12.2 Belt Alignment

1. From ONLINE/OFFLINE, press and hold PREV, press and hold NEXT, then
press MENU. SYSTEM ALIGNMENT / LASER ALIGNMENT appears.
2. Press SELECT. SYSTEM ALIGNMENT / BELT ALIGNMENT appears. Press
NEXT. HIT ADVANCE TO / START FILM appears. Press ADVANCE to start
the motor. Adjust the belt.
3. When the adjustment is complete. Press STOP twice. The motor shuts off.
ONLINE / OFFLINE appears.
66 AG12304 Rev. 1
5.13 Belt Tension Adjustment
This section may be performed in its entirety for a complete belt tension adjustment, or sections of it may be
performed to adjust the tension of the black belt or the Kapton belt.
2. Loosen the drive motor (see Section 4.4, “Assembly Location Diagram” on
page 29 for location) and its bracket, by loosening two bracket mounting
screws. See Figure 5-10 on page 67.
3. Horizontally line up the two holes in the idler pulley and loosen the tension on
the idler pulley by loosening the two screws visible through the holes.
4. Remove the black belt and the Kapton belt.
drive pulley
CAUTION
RECORDER CONTAINS
black belt
idler pulley
Kapton belt
motor mounting
screw (typ 4)
screws behind these

two holes hold the
5. Clean the idler pulley and the drive pulley with alcohol (to remove any oil) and
allow to dry.
6. Install the Kapton belt over the idler pulley and let it hang there. See Figure 5-
11 on page 68.
7. Install the black belt over the drive pulley and the idler pulley shaft and center
the belt on the pulleys.
AG12304 Rev. 1 67
5.13.1 Black Belt Tension Adjustment
1. Install tool AX0073 as shown and push the idler pulley away from the drive
pulley until the tool shows tension as shown in Figure 5-11 on page 68.
2. Tighten the two mounting screws of the idler pulley through the two holes in
the idler pulley.
3. Check the tension of the black belt with tool AX0073 after tightening the two
screws. Make sure that the full indent is visible but that the spring is not fully
compressed (bottomed out). Repeat the adjustment if necessary.
drive pulley AX0073

Assy, 15.5” Belt Gauge
indent
full indent appears when Kapton belt

tension is correct, but spring
is not fully compressed
black belt
idler pulley
Figure 5 - 11 Adjusting Black Belt Tension
68 AG12304 Rev. 1
5.13.2 Kapton Belt Tension Adjustment
1. Install tool AX0065 as shown in Figure 5-12 on page 69.
2. While lightly pressing the motor bracket against the casting, tighten the two
bracket mounting screws. See Figure 5-12 on page 69.
3. Remove tool AX0065.
idler pulley
AX0065
2 bracket mounting screws

Kapton belt
Figure 5 - 12 Adjusting Kapton Belt Tension
4. Defeat the system interlock and turn on the system.

5. See Section 5.12, “System Alignment Menu” on page 66 to make the motor
turn and allow belt alignment checking.
6. Verify that both belts, especially the Kapton belt, run in or near the center of
the pulleys. See Figure 5-13 on page 69.
very good marginally acceptable not acceptable
pulley
belt
Figure 5 - 13 Belt Alignment

AG12304 Rev. 1 69
70 AG12304 Rev. 1
6 - Parts Lists
6.14 Introduction
Section 6.16, “AO41000 (Revision 00E) Parts List” on page 73
Section 6.17, “KI41079 (Revision 00A) Spares Kit” on page 77
Section 6.18, “KI18149 Tool Kit” on page 78
AG12304 Rev. 1 71
6.15 Warnings
WARNING!
electrical shock.
CAUTION
RECORDER CONTAINS
CAUTION!
72 AG12304 Rev. 1
6.16 AO41000 (Revision 00E) Parts List
23 APR 1999 Master Parts List
11:36:15
Parent : AO41000 Description: ASSY, FINAL MAKO 5625 Um: EA

Mfg Rev: 00E Effective: 04/21/99 Supercedes: N
Qty Comp
Oper Part Number Description UM Quantity Type Type
001 AC41102 ASSY.,CABLE,DISPLAY; BRD.TO EA 1.000000 1 1
002 AC41105 ASSY., CABLE; JUMPER, DC EA 1.000000 1 1
003 AC41103 ASSY.,CABLE,DISPLAY; DOORTO EA 1.000000 1 1
004 AC41104 ASSY.,CABLE, DISPLAY;DOORTO EA 1.000000 1 1
005 AC41106 ASSY., CABLE; JUMPER, DRI EA 1.000000 1 1
006 AC41107 ASSY., CABLE; I/O INTER- FAC EA 1.000000 1 1
007 AC41116 ASSY., CABLE; INTERLOCK SWI EA 1.000000 1 1
008 AC41111 ASSY., CABLE; INTERFACE, LAS EA 1.000000 1 1
009 AC41108 ASSY., CABLE; ON-LINE PRO EA 1.000000 1 1
010 AC41113 ASSY., CABLE; SCANNER INT EA 1.000000 1 1
011 AC41109 ASSY., CABLE; SCSI TO CON EA 1.000000 1 1
012 AC41110 ASSY., CABLE; SCSI/PEL, MAK EA 1.000000 1 1
013 AC41115 ASSY.,CABLE;SENSOR STATUS MA EA 1.000000 1 1
014 AC41112 ASSY.,CABLE; S.O.L. WITH DIO EA 1.000000 1 1
015 AC41114 ASSY.,CABLE; CUTTER MOTOR MA EA 1.000000 1 1
016 AO41042 ASSY, OPTICS, CIR EA 1.000000 1 1
017 AO41020 ASSY, INPUT CASSETTE, MAK EA 1.000000 1 1
018 AO41022 ASSEMBLY, PINCH ROLLER EA 1.000000 1 1
019 AO41030 ASSY, OUTPUT CASSETTE, MAK EA 1.000000 1 1
020 AO41040 ASSY, OPTICS, HOUSING ANDLEN EA 1.000000 1 1
021 AO41050 ASSY, CUTTER, MAKO, 22 EA 1.000000 1 1
022 AP24507P4 ASSY, CONTROLLER BOARD, MAK EA 1.000000 1 1
023 AP9992P2 ASSY, 16MB SCSI/PELBOX INT EA 1.000000 1 1
024 AP9996 ASSY CONTROL PANEL BOA EA 1.000000 1 1
025 CH0025 EMI SUPPRESOR FERRITE RIN EA 3.000000 1 1
026 CO0544 COVER, 9P D-TYPE (SO EA 1.000000 1 1
027 CO0546 COVER, 50P D-TYPE (SO EA 1.000000 1 1
028 CO0548 JACK SCREW KIT, #4-40 FEM EA 2.000000 1 1
029 CO0630 CONN DUST COVER 50 PIN RIB EA 1.000000 1 1
030 CO0799 JACK,BANANA,UNINSULATED STA EA 1.000000 1 1
031 DA0090 OPTO SENSOR W/ 3P CONN SLI EA 2.000000 1 1
032 DA0117 OPTO SENSOR W/3 PIN CON EA 1.000000 1 1
033 FA41074 DEFLECTOR, AIR; PLENUM MAK EA 1.000000 1 1
034 FA41101 PLENUM, AIR; MAKO 5625 EA 1.000000 1 1
035 FA41077 WEAR STRIP, SHELF; OUTPUTCAS EA 1.000000 1 1
036 FA40027 STRIP, WEAR 25" EA 2.000000 1 1
038 FA41075 FILTER, AIR; PLENUM MAK EA 1.000000 1 1
039 FA41076 GASKET, OUTPUT SLOT; MAK EA 1.000000 1 1
040 FA41098 PANEL, I/O; MAKO 5625 EA 1.000000 1 1
045 FA12026 LABEL LASER RADIATION FOR EA 1.000000 1 1
046 FA12028 LABEL DANGER WHEN SAFETY SWI EA 2.000000 1 1
047 FA12583 NUT PLATE EA 1.000000 1 1
048 FA18039 SPRING EOM ACTUATOR EA 1.000000 1 1
049 FA18040 BRACKET EOM SENSOR EA 1.000000 1 1
050 FA18061 CAPSTAN-SHAFT EA 1.000000 1 1
051 FA18062 PULLEY-DRIVE-ROLLER EA 1.000000 1 1
052 FA18063 PULLEY-DRIVE MOTOR EA 1.000000 1 1
AG12304 Rev. 1 73
053 FA18097 WHEEL, MEDIA SENSOR EA 1.000000 1 1
054 FA18098 SPACER EA 1.000000 1 1
055 FA18100 STEM,HANDLE ROLLER REL EA 1.000000 1 1
056 FA18142 BAFFLE,BEAM EA 1.000000 1 1
057 FA18150 LABEL FOR SYSTEM SETTINGS EA 1.000000 1 1
058 FA18152 LABEL, STATIC SENSITIVE EA 2.000000 1 1
059 FA18258 MEDIA SENSITIVITY LABEL (63 EA 1.000000 1 1
060 FA20252 PLATE,MOUNTING,CONTROL PAN EA 1.000000 1 1
061 FA20253 KEYPAD,LCP EA 1.000000 1 1
062 FA21420 BEARING HOUSING,PULLEY EA 1.000000 1 1
063 FA21495 CABLE ASSY,FRONT ENC EA 2.000000 1 1
064 FA21529 LABEL, ATTENTION SYMBOL UL/ EA 1.000000 1 1
065 FA24529 SUPPORT, VR SHOCK MOUNT EA 4.000000 1 1
066 FA27560 LOWER LINK ARM VR4 EA 1.000000 1 1
067 FA27225 PIN MOUNT VR45/HS EA 2.000000 1 1
068 FA27238 MOTOR MOUNT VR4 EA 1.000000 1 1
069 FA27559 PINCH ROLLER CAM VR4 EA 2.000000 1 1
070 FA27561 LOAD LEVER MOUNT VR4 EA 1.000000 1 1
071 FA27656 NUTPLATE, 4550 HINGE EA 1.000000 1 1
072 FA27915 COVER, CONTROL PANEL EA 1.000000 1 1
073 FA27948 LOWER COVER BRACKET PRF EA 2.000000 1 1
074 FA27988 LOWER LEVER AR; VE PRE EA 1.000000 1 1
075 FA27421 DOOR SENSOR MOUNT 455 EA 1.000000 1 1
078 FA27422 DOOR SENSOR FLAG, 455 EA 1.000000 1 1
079 FA28229 BALL STUD, DAMPER, MAKO EA 2.000000 1 1
080 FA28230 HANDLE DOOR MAKO ECRM EA 1.000000 1 1
081 FA28294 HANGER, CASSETTE SHELF; MAK EA 4.000000 1 1
082 FA40307 MOUNT, ENCODER EA 1.000000 1 1
083 FA41011 ROLLER, CAPSTAN, 22 IN EA 1.000000 1 1
084 FA41021 SHAFT, CAM EA 1.000000 1 1
085 FA41024 COVER, CASTING, 22" EA 1.000000 1 1
086 FA41025 CASTING, MAIN, MAKO 22 INC EA 1.000000 1 1
087 FA41029 STOP, CASSETTE EA 3.000000 1 1
088 FA41033 SUPPORT, SOL SENSOR EA 1.000000 1 1
089 FA41049 RETAINER, SPRING, INPUT CAS EA 3.000000 1 1
090 FA41067 CAPSTAN MOUNT, 3/8 SHAFT EA 1.000000 1 1
091 FA41068 GUIDE, CASSETTE SPRING EA 3.000000 1 1
092 FA41082 ENCLOSURE, REAR, MAKO 22 INC EA 1.000000 1 1
093 FA41083 ENCLOSURE, BASE, MAKO, 22 EA 1.000000 1 1
094 FA41084 ENCLOSURE FRONT MAKO 22 EA 1.000000 1 1
095 FA41085 ENCLOSURE, DOOR, MAKO, 22 EA 1.000000 1 1
096 FA41086 SHELF, OUTPUT CASSETTE, MAK EA 1.000000 1 1
097 FA41087 SHELF, INPUT CASSETTE, MAK EA 1.000000 1 1
098 FA9762P2 LABEL,DANGEROUS VOLTAGE PER EA 1.000000 1 1
099 HA0009 SCR PAN HD SLT 4-40 X 3/8 SS EA 2.000000 1 1
100 HA0081 WASHER FLAT 6 5/32 ID X 5/1 EA 4.000000 1 1
102 HA0096 WASHER FLAT 3/8 .406 I.D.X . EA 4.000000 1 1
104 HA0108 WASHER LOCK 1/4 EXT TOOTHSST EA 1.000000 1 1
105 HA0110 SCR SET CUP PT SOC 6-32 X1/4 EA 6.000000 1 1
106 HA0180 SCR SOC HD CAP 8-32 X 3/4SST EA 4.000000 1 1
107 HA0231 WASHER LOCK 8 EXT TOOTH SST EA 3.000000 1 1
108 HA0199 WASHER LOCK SPT 8 .168 IDX . EA 21.000000 1 1
109 HA0254 WASHER LOCK SPT 6 .141 IDX . EA 4.000000 1 1
110 HA0255 WASHER LOCK SPT 10 .194 ID EA 3.000000 1 1
111 HA0269 WASHER #4 SPLIT LOCK .12 EA 10.000000 1 1
74 AG12304 Rev. 1
112 HA0273 SCR SOC HD CAP 4-40 X 1/2BLK EA 4.000000 1 1
113 HA0275 SCR FLAT HD 82 DEG SLT 6-3 EA 10.000000 1 1
118 HA0367 SCR SET CUP PT SOC 8-32 X1/4 EA 2.000000 1 1
119 HA0408 WASHER FLAT 8 .169 ID X .30 EA 2.000000 1 1
121 HA0471 SCR FLAT HD 82 DEG UND EA 2.000000 1 1
122 HA0472 WASHER FLAT NYLON FOR 3/1 EA 2.000000 1 1
124 HA0497 SCR SOC HD CAP #10-32 X 1/4 EA 4.000000 1 1
125 HA0519 WASHER LOCK SPLIT 3/8" SST EA 4.000000 1 1
126 HA0578 NUT(KEP)8-32,W/EXT TOO EA 9.000000 1 1
130 HA0584 SCREW(SEMS)SLT .25 WIDE HEX EA 10.000000 1 1
137 HA0769 SCREW, CAP, SOCKET HD #4- EA 4.000000 1 1
138 HA0822 WASHER,LOCK,#6 COUNTER- SUN EA 8.000000 1 1
139 HA0855 SCR SOC HD CAP 3/8-16X1" SST EA 4.000000 1 1
140 HA0972 SCREW, HEX WASHER HD, SEL EA 6.000000 1 1
141 HB0010 CABLE TIE SELF LOCK 1/16-5/8 EA 0.000000 3 1
142 HB0749 ADHESIVE TYRAP MOUNT EA 0.000000 3 1
143 HB0750 THREADLOCKER, PURPLE #22210M EA 0.000000 3 1
144 HB1245 CABLE CLIP ADHESIVE BACK FLA EA 10.000000 1 1
145 HB1249 STANDOFF, 1/4" FEMALE HEX EA 4.000000 1 1
146 HB1280 SCR SHOULDER SLT HO 8-32 X 3 EA 2.000000 1 1
147 HB1337 BALL KNOB 3/4" DIA BLACK WIT EA 1.000000 1 1
148 HB1391 SCR SHOULDER 1/4" BODY DIA EA 1.000000 1 1
149 HB1560 CABLE CLAMP SPLIT,FLAT (WI EA 0.000000 3 1
150 HB1600 RETAINING RING EA 1.000000 1 1
151 HB1619 CLAMP, SYNCRO MOUNT EA 4.000000 1 1
152 HB1625 FOAM STRIP,SELF STICK POL FT 3.000000 1 1
153 HB1629 VINYL CAP EA 1.000000 1 1
154 HB1635 STANDOFF, MALE/FEMALE #8- EA 2.000000 1 1
155 HB1645 WASHER,WAVE SPRING;.386 X.4 EA 2.000000 1 1
156 HB1742 WASHER, CURVED, .265 ID, .49 EA 2.000000 1 1
157 HB1840 GREASE, ROBOTICS POL EA 0.000000 3 1
158 HB1909 TAPE FOAM ADHESIVE BACKED3/8 FT 3.000000 1 1
159 HB1932 WASHER,FLAT,ST.ST.,09" ID, EA 1.000000 1 1
159 HB1858 FOAM TAPE 11/16" WIDE X 1/2 FT 2.500000 1 1
160 HB2004 ISOLATION MOUNT, VR EA 4.000000 1 1
161 HB2063 HINGE & MTG PLATE;SELF- CLO EA 2.000000 1 1
162 HB2066 BELT, 4550 KAPTON DRIVE EA 1.000000 1 1
163 HB2084 GASKET, CONDUCTIVE EMI FLA FT 10.000000 1 1
164 HB2094 SPACER, BEARING .498OD X .37 EA 2.000000 1 1
165 HB2249 SPACER, SHAFT .25 ID X .37 EA 3.000000 1 1
166 HB2380 COLLAR ONE-PIECE CLAMP 3/8 EA 2.000000 1 1
167 HB2422 BUMPER, RECESSED, 2-1 EA 4.000000 1 1
168 AO41073 ASSY.,24V, DC FAN ASS EA 1.000000 1 1
169 HB2429 FINGER GUARD, 3.52" 90M EA 1.000000 1 1
AG12304 Rev. 1 75
170 HC0236 BEARING EA 2.000000 1 1
171 HC0237 BEARING BALL RADIAL FLA EA 5.000000 1 1
172 HC0410 DAMPER,OIL;5.84"STROKE, DAM EA 1.000000 1 1
173 HC0523 BELT, FLAT, 15.50" LG X .5" EA 1.000000 1 1
175 JA1053 EPROM TABLE 16K/32K MAKO 362 EA 1.000000 1 1
176 JA1087 EPROM, SYSTEM PROGRAM, MAK EA 1.000000 1 1
177 MA0540 ENCODER,MODULAR,1000 CPR 10 EA 1.000000 1 1
178 MO0088 SERVO DC MOTOR & ENCODER 455 EA 1.000000 1 1
179 MO0109 SPINNER MOTOR HYSTERSYNCHAIR EA 1.000000 1 1
180 SW0211 SWITCH, INTERLOCK N.O. SNA EA 1.000000 1 1
181 AC18134P1 GND STRAP BRAID 1/2 EA 2.000000 1 1
182 AC18134P3 GND STRAP BRAID 1/2 EA 1.000000 1 1
183 AC18134P7 GROUND STRAP BRAID 1/2 EA 1.000000 1 1
184 HA0938 WASHER,FLAT 9/32IDx1.0 ODx1/ EA 4.000000 1 1
185 FA41071 BRACKET, DAMPER; UPPER RIG EA 1.000000 1 1
186 FA41072 BRACKET, MOUNTING; SCSI BOA EA 1.000000 1 1
188 HB2077 GASKET, CONDUCTIVE EMI KNI FT 15.000000 1 1
189 FA21511P1 WEAR STRIP,CASSETTE SHE EA 2.000000 1 1
190 AC41118 ASSY, CABLE; EOM JUMPER, MAK EA 1.000000 1 1
191 HA0435 SCR SOC HD CAP 6-32 X 1 3 EA 4.000000 1 1
192 AC40038 ASSEMBLY, 25' IMAGESETTERBEA EA 1.000000 1 1
193 AC24658 JUMPER, MOTOR DRIVE POW EA 1.000000 1 1
194 HA0917 SCREW, SOC. HD CAP 1/4-20X 1 EA 2.000000 1 1
195 FA41078 BRACKET, INTERLOCK EA 1.000000 1 1
196 HB2290 LUG, SOLDER #6 THRU HOLE EA 2.000000 1 1
197 HB2433 SPRING,EXTENSION; .188"ODX 1 EA 2.000000 1 1
198 HB2434 RIVET,POP; 3/16"DIA STEEL.06 EA 5.000000 1 1
199 HB2435 RIVET,POP;3/16"DIA. STEEL.12 EA 2.000000 1 1
200 PS0105 POWER SUPPLY SWITCHING +5V EA 1.000000 1 1
201 HA0842 SCREW,SEMS HEX HEAD W/EXTOR EA 2.000000 1 1
202 HB2448 RIVET,NYLON SNAP; .160"D.X . EA 8.000000 1 1
203 HA0505 WASHER FLAT NYLON FOR 1/4SCR EA 4.000000 1 1
204 HB0211 TAPE FOAM ADHESIVE BACKED3/8 FT 4.000000 1 1
205 HB0795 ADHESIVE,BLACK EA 0.000000 3 1
206 HC0463 EMI GASKET WIRE MESH ON FOA EA 1.000000 1 1
207 HA0863 SCREW,CAP, SOCKET HEAD 5/1 EA 3.000000 1 1
208 HA0227 WASHER LOCK SPT 5/16 .319ID EA 3.000000 1 1
209 HA0482 WASHER FLAT SST FOR 5/16 SCR EA 3.000000 1 1
210 HA0551 SCREW SOC HD 1/4-20 X 1.1 EA 4.000000 1 1
211 FA41132 VELVET PAD, W/ADHESIVE BAC EA 2.000000 1 1
212 FA41133 COVER, CUTTER; MAKO 5625 EA 1.000000 1 1
213 HC0437 FINGER STRIP RADIUS TYP FT 1.330000 1 1
214 HB1848 SPRING PLUNGER 8-32 .437 LG FT 0.400000 1 1
215 FA18041 BRACKET CASSETTE SENSOR EA 1.000000 1 1
216 FA18048 ACTUATOR,CASSETTE SENSOR EA 1.000000 1 1
217 HA0624 NUT ACORN 4-40 SST EA 2.000000 1 1
218 HB2132 STANDOFF F/F HEX .188 AF 4-4 EA 1.000000 1 1
219 FA20491 LABEL CERTIFICATION FOR LAS EA 0.000000 1 1
220 FA41135 LABEL, PATENT, MAKO 5625 EA 0.000000 1 1
221 FA41134 BAFFLE, AIR; MAKO 5625 EA 1.000000 1 1
222 HB1971 VELCRO HOOK WITH HIGH TAC FT 2.000000 1 1
223 HB1972 VELCRO LOOP WITH HIGH TAC FT 2.000000 1 1
224 FA28283 LABEL,FILM LOADING INS EA 1.000000 1 1
76 AG12304 Rev. 1
6.17 KI41079 (Revision 00A) Spares Kit
23 APR 1999 Master Parts List Page: 1
15:17:15
Parent : KI41079 Description: MAKO 5625 SPARES KIT Um: EA

Mfg Rev: 00A Effective: 04/23/99 Supercedes: N
Qty Comp
001 AC41112 ASSY.,CABLE; S.O.L. WITH DIO EA 1.000000 1 1

002 TAO41042 (TESTED) ASSY, OPTICS;CIR EA 1.000000 1 1
003 DA0117 OPTO SENSOR W/3 PIN CON EA 1.000000 1 1
004 FA20253 KEYPAD,LCP EA 1.000000 1 1
005 MO0088 SERVO DC MOTOR & ENCODER 455 EA 1.000000 1 1
006 PS0105 POWER SUPPLY SWITCHING +5V EA 1.000000 1 1
007 TAP9996 SYSTEM TESTED DISPLAY BD EA 1.000000 1 1
008 KI21573 HIGH ACCURACY ENCODER KIT EA 1.000000 1 1
009 DA0090 OPTO SENSOR W/ 3P CONN SLI EA 2.000000 1 1
010 TAP24507P4 TESTED CONTROLLER BOARD, MAK EA 1.000000 1 1
011 TAP9992P2 SYSTEM TESTED SCSI BOARD 16M EA 1.000000 1 1
012 HC0523 BELT, FLAT, 15.50" LG X .5" EA 1.000000 1 1
013 HB2066 BELT, 4550 KAPTON DRIVE EA 1.000000 1 1
014 TMO0109 TESTED SPINNER MOTOR HYS EA 1.000000 1 1
AG12304 Rev. 1 77
6.18 KI18149 Tool Kit
23 APR 1999 Master Parts List Page: 1
15:24:08
Parent : KI18149 Description: PELBOX VR30,VR36,VR45 Um: EA

Mfg Rev: 15 Effective: 02/26/99 Supercedes: N
Qty Comp
001 HB0957 FLASHLIGHT (PENLIGHT) POC EA 1.000000 1 1

002 HB1243 COTTON SWABS 6.0 LG EA 100.00000 1 1
003 HB1247 LENS TISSUE LOW LINT EA 1.000000 1 1
005 HB1420 MEDIUM SIZE PHILLIPS SCR EA 1.000000 1 1
006 HB1467 ALLEN WRENCH SET,12 PC EA 1.000000 1 1
007 HB1471 T-HANDLE HEX KEY SET,8 PC. EA 1.000000 1 1
008 HC0302 LIGHT SCOPE 30X EA 1.000000 1 1
009 PH0046P1 ROLLER CLEANER AND RES EA 1.000000 1 1
010 HB1627 7 PIECE NUT DRIVER SET EA 1.000000 1 1
011 HB1628 STRAP, WRIST, STATIC CON EA 1.000000 1 1
012 AO18167 ASSY TENSION GAUGE #3 EA 1.000000 1 1
13 HB2050 WRENCH, OPEN END 3/8 X 7 EA 1.000000 1 1
014 SW0212 DEFEAT KEY, INTERLOCK SWI EA 2.000000 1 1
015 AX0065 KAPTON BELT TENSION ASS EA 1.000000 1 1
016 AX0073 ASSY, 15.5 IN. BELT GAGE EA 1.000000 1 1
017 HC0576 TORQUE DRIVER, 15 IN LB, PRE EA 1.000000 1 1
018 HB2264 BIT, 5/32, 1/4 HEX POWER DRI EA 1.000000 1 1
019 AG11778 TORQUE DRIVER CAL EA 1.000000 1 1
020 FX0772 ADAPTER,KAPTON BELT TEN EA 1.000000 1 1
021 AX0094 SHELF ALIGNMENT FIXTURE VR3 EA 2.000000 1 1
022 FX0919 FIXTURE SOL ALIGNMENT MAK EA 1.000000 1 1
023 FX0197 SOL SENSOR FIXTURE EA 1.000000 1 1
024 FX1314 SHELF ALIGNMENT FIXTURE MAK EA 2.000000 1 1
78 AG12304 Rev. 1
A E
AO41022 Pinch Roller Assembly .. 49 EMI clips .. 53
AO41042 Lower Optics Assembly .. 37 environmental requirements .. 16
AO41050 Cutter Assembly .. 47 air quality .. 16
AP24507P4 Main Controller .. 31 ambient light .. 16
AP9992P2 Interface Board .. 33 floor requirements .. 16
AP9996 Display Board .. 34 operational .. 12
assembly location diagram .. 29 storage .. 12
AX0065, tension tool .. 69 traffic .. 16
AX0073, tension tool .. 68 vibration .. 16
B F
beamon path selection .. 62 FA20253 Keypad .. 34
belt alignment .. 66 film processing methods .. 9
block diagram fuse, system power .. 30
interlock circuit .. 22 FX1314 Media Shelf Alignment Tool .. 51
recorder .. 21
sensor harness .. 22 G
C German, required information translated .. 18
ground, protective, recorder .. 17
Calibration
menu map .. 57
calibration
I
beamon path selection .. 62 image centering .. 58
image centering .. 58 input cassette specification .. 9
laser bias level adjustment .. 62 installation
line correction .. 61 customer requirements .. 16
pel correction .. 60 environmental requirements .. 16
save setup selection .. 63 installing shims .. 64
system error enable .. 62 Interface Board AP9992P2 .. 33
CAUTION interfaces
static electricity .. 8, 14, 20, 26, 37, 56, 72 online transport .. 12
cautions PelBox interface .. 12
operating temperature .. 17 SCSI data interface .. 12
startup temperature .. 17
correcting Pel .. 60 K
cover removal .. 27
Keypad FA20253 .. 34
Cutter Assembly AO41050 .. 47
D L
laser alignment .. 66
Display Board AP9996 .. 34
laser bias level adjust .. 62
Drive Outside Encoder MA0540 .. 44
layout diagram, major system components .. 29
line correction .. 61
Lower Optics Assembly AO41042 .. 37
AG12304 Rev. 1 79
M linearity .. 10
recording speed .. 10
MA0540 Drive Outside Encoder .. 44 repeatability .. 10
Main Controller AP24507P4 .. 31 resolutions .. 11
media throughput speed .. 11
media types .. 9 video data rates .. 11
roll specifications .. 9 regulatory compliance information .. 12
widths .. 9 required information .. 18
Media Shelf Alignment Tool FX1314 .. 51
menu map, calibration .. 57
MO0088 Servo DC Motor and Encoder .. 42
S
MO0109 Spinner Motor .. 40 safety information, electrical .. 17
save setup selection .. 63
O Servo DC Motor and Encoder MO0088 .. 42
shim placement .. 64
optical performance shims .. 63
dot percent uniformity .. 11 Spinner Motor MO0109 .. 40
image width .. 11 system covers .. 27
line screen .. 11 system errors enable .. 62
source .. 11
output cassette specification .. 9 T
P tension tool AX0065 .. 69
tension tool AX0073 .. 68
parts list
AO41000, Mako 5625 assembly .. 73
KI18149 Tool Kit .. 78
U
KI41079 Spares Kit .. 77 utility requiremens .. 12
pedestal, recorder .. 12
Pel correction .. 60 V
pel correction .. 60
vendor installation procedure .. 17
perpendicularity adjustment .. 63
Pinch Roller Assembly AO41022 .. 49
pinch roller release lever W
installation in new machines .. 15 WARNING
power cord types .. 17 shock hazard .. 8, 14, 20, 26, 56, 72
Power Supply PS0105 .. 52 wiring list .. 23
protective earth terminal .. 17
PS0105 Power Supply .. 52
R
recording
fast media advance .. 11
image location .. 10
image size .. 10
80 AG12304 Rev. 1

Mako 56

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Mako 56

Transféré par

Droits d'auteur :

Formats disponibles

Mako 5625

554 Clark Rd.

© copyright ECRM Incorporated 1999

ECRM Order Processing

Phone No. (US) - (978) 851-0207 — Fax (US) - (978)-851-7016

Visit our web site: www.ecrm.com

2 - Installation and Site Requirements .. 13

4 - Remove and Replace .. 25

5 - Calibration and Alignment .. 55

Section 1.2, “Warnings” on page 8

LEFT REAR OF RECORDER

1.3.1 Acceptable Media Types

1.3.2 Roll Specifications

1.3.3 Acceptable Widths

1.3.4 Input Cassette

1.3.5 Output Cassette

1.4.1 Image Size

Media Width Image Width (in) Overscan Width (in)

22.0” (559 mm) 22.048 22.2

20.5” (521 mm) 22.048 22.2

20.1” (510 mm) 20.08 20.24

20.0” (508 mm) 20.08 20.24

19.6” (498 mm) 20.08 20.24

18.6” (472 mm) 20.08 20.24

18.1” (460 mm) 18.0 18.16

18.0” (457 mm) 18.0 18.16

17.7” (450 mm) 18.0 18.16

16.0" (406 mm) 18.0 18.16

14.0" (355 mm) 14.0 14.16

Maximum image length is limited by output cassette capacity.

1.4.2 Image Location

1.4.5 Recording Speed

Resolution: Resolution: Approx. Video Throughput

3048 120 99 5.25

2540 100 83 6.30

2400 94.5 78 6.67

1800 70.9 59 8.89

1200 47.2 39 13.33

1000 39.4 33 16.00

1.4.7 Fast Media Advance

1.5 Optical Performance

1.5.2 Image Width

1.5.3 Dot Percentage Uniformity

1.5.4 Line Screen

1.6.1 Data Interface

1.6.2 Online Transport

1.7 Environmental Requirements

1.7.1 Operational Environment

1.7.2 Storage Environment

1.8 Utility Requirements

1.9 Compliance Requirements

1.10 Optional Requirements

Chapter 2.2, “Warnings” on page 14

LEFT REAR OF RECORDER

Figure 2 - 1 Installing the Pinch Lever

2.4.1 Site Preparation

2.4.1.1 Customer Responsibilities

2.4.1.2 Environmental Requirements

NOTE: Before operating the recorder, read the Operator Guide.

2.5.1 Installation Procedure

OPERATING TEMPERATURE—The recorder must be used in a normal

2.5.2 Protective Earth

2.5.3 Electrical Safety