Martin MAC 2000 Wash XB User manual

MAC 2000 Wash
service manual

1
MAC 2000 Wash Service Manual
PROCEDURES
Head procedures
CMYC belts and flags, replace . . . . 12
CMYC module, install . . . . . . . . . . . . 5
CMYC module, remove . . . . . . . . . . . 5
CMYC module, separate . . . . . . . . . 11
CMYC motors, replace . . . . . . . . . . 13
Color wheel 1 belt, replace . . . . . . . . 6
Color wheel 1 motor, replace . . . . . . . 6
Color wheel 2 belt, replace . . . . . . . . 6
Color wheel 2 motor, replace . . . . . . . 6
Color wheel module, install . . . . . . . . 7
Color wheel module, remove . . . . . . . 5
Color wheels, adjust . . . . . . . . . . . . . 7
Dimmer blades, replace & adjust . . . 10
Dimmer motor, replace . . . . . . . . . . 11
Effect fans, replace . . . . . . . . . . . . . . 7
Head side covers, remove and install 7
Heat filter assembly, remove & install 8
Heat filter, replace . . . . . . . . . . . . . . . 9
Left lamp fan, replace . . . . . . . . . . . . 7
Reflector, replace . . . . . . . . . . . . . . . . 9
Right lamp fan, replace . . . . . . . . . . . 8
Starter, replace . . . . . . . . . . . . . . . . . 9
Zoom belt, replace . . . . . . . . . . . . . . . 4
Zoom lens assembly, replace . . . . . . 5
Zoom module, install . . . . . . . . . . . . . 3
Zoom module, remove . . . . . . . . . . . . 3
Zoom motor, replace . . . . . . . . . . . . . 4
Zoom rail, replace . . . . . . . . . . . . . . . 5
Yoke procedures
Tilt belt, left, replace . . . . . . . . . . . . .14
Tilt belt, right, replace . . . . . . . . . . . .15
Tilt motors, replace . . . . . . . . . . . . . .16
Tilt motors, synchronize . . . . . . . . . .16
Yoke covers, remove . . . . . . . . . . . .14
Base procedures
Ballast fan, replace . . . . . . . . . . . . . 19
Base fans, replace . . . . . . . . . . . . . . 19
Electronic ballast, replace . . . . . . . . 19
Left pan motor, replace . . . . . . . . . . 20
Main PCB, replace . . . . . . . . . . . . . 18
Pan belt, replace . . . . . . . . . . . . . . . 17
Pan motors, synchronize . . . . . . . . . 21
Power supply, replace . . . . . . . . . . . 18
Right pan motor, replace . . . . . . . . . 20

© 2002 Martin Professional A/S, Denmark. Updated December 23, 2002 2
INTRODUCTION
Risk of electrical shock
Removal of any cover exposes connectors
that carry lethal electric currents. While
working on a fixture under power:
• Make sure the fixture is electrically
grounded.
• Use a supply with ground-fault-inter-
rupt protection.
• Never touch any connector that carries
voltage.
• Be careful with tools that conduct elec-
tricity.
Risk of UV radiation and
lamp explosion
Discharge lamps emit harmful ultraviolet
(UV) light that can cause eye and skin burns
through direct exposure. They also work
under high pressure that occasionally causes
them to explode. To eliminate the risk of
injury from the discharge lamp,
• Never operate the lamp with covers or
lenses removed.
• Do not look directly into the light.
Electrostatic discharge
Printed circuit boards (PCBs), individual
ICs, and Hall sensors can be damaged by
electrostatic discharge (ESD). To avoid
damaging these ESD sensitive parts:
• Ensure that you and your tools have the
same potential (ground) as the fixture
before and when handling any of the
above components.
• Store PCBs in antistatic (electrically
conducting) bags and store ICs in anti-
static foam.
• Power off the fixture and allow capaci-
tors do discharge before removing or
inserting components on the PCB.
Inductive loads
Power off the MAC 2000 Wash before
connecting or disconnecting step motors.
Failure to do so can damage the motor
drivers.
Threadlock
Threadlock is highly recommended on all
machine screws except self-tapping
(Taptite) screws to prevent loosening.
Threadlock should be reapplied if the
screws are removed.
Two types of threadlock are available from
Martin. For set screws, use Loctite 290, P/N
37020002. For all other screws, use Loctite
243, P/N 37021002. Both come in 10 ml
tubes.
Be careful to avoid getting any material on
shafts or axles. A needle and syringe makes
an idea application tool.
Long set screws: Start the screw and turn it
until it contacts the shaft. Back the screw 2
turns, apply a small drop or 2 of Loctite 290
to the threads, and then tighten the screw as
you normally would.
Short set screws: Back the set screw out of
the adaptor until 2 threads stick out of the
shaft. Apply a small drop or 2 of Loctite 290
to the threads, and then tighten the screw
within 60 minutes.
Other metric screws: Apply a drop of
Loctite 243 (blue) to 3 or 4 threads, or
spread a thin stripe with a syringe, before
starting the screw.
Self-tapping screws
The reuse of self-tapping “Taptite” screws
is not recommended as these screws are
designed to cut threads and can strip
existing threads when reinserted. Change to
metric hardware of the same size when
reinstalling parts originally held with
Taptites.
If installing a new part without threads, use
new self-tapping screws. Do not use old
taptites to cut new threads!
Lubrication
Silicone grease, P/N 37302002, “Silicon
grease, clear, 100g”, is used, for example, to
lubricate brass bushings inside of pulleys
and between moving metal plates such as
the motor bracket for color wheel 1 on the
MAC 2000 Wash.
Slides are generally lubricated with the high
viscosity silicone oil, P/N 37302005, “High
viscosity silicone oil, 200 ml, in applicator
bottle.”
Bearings are lubricated with P/N 37302004,
“Silicone oil, 200 ml, in applicator bottle”.
Comments
Your feedback is appreciated. Please send
your comments and suggestions for
improvements to:
Martin Professional
Olof Palmes Allé 18
DK 8200 Aarhus N, Denmark
Attn: Service
E-mail: servic[email protected].
Always disconnect the fixture
from AC power before and while
servicing.

© 2002 Martin Professional A/S, Denmark. Updated December 23, 2002 3
HEAD PROCEDURES
Zoom module, remove
1Remove the top and bottom head
covers and the front lens. Fully back out
the thumbscrew for the lens retaining
wire.
2Unplug cables from the outside row
of the left-side zoom module junction
print. Unplug the unlabeled 2-pin con-
nector from socket 38.
3Unplug the wires from the outside
row of the right-side zoom module junc-
tion print. Unplug connectors 42, 23,
and the unlabeled 2-pin fan plug from
the inside row.
4Unplug the wires from the back row
of the CMYC module junction print and
the thermo-sensor, which is in front of
the junction print.
5Unplug connector 16 from the dim-
mer junction print.
6Remove the 4 zoom module fasten-
ing screws.
7Pull the zoom module (and attached
color wheel module) up, out of the
head.
Zoom module, install
1Lock the head in the horizontal, top
up position.
2Place the ends of the wire bundles
outside of the head, forward of the
yoke.
3Lower the module into the chassis,
working it past each “sticking point” in
turn. Fasten.
4Reconnect the wires to the left and
right junction prints.
5Plug connector 16 into the dimmer
junction print. (Fig. 4)
6Insert the CMYC wire bundle into
the slot in the zoom module. Connect
The color wheel module remains
attached to the zoom module in
this procedure.
Fig. 1 Unplug left junction print
Fig. 2 Unplug right junction print
Fig. 3 CMYC thermo-sensor PCB
Fig. 4 Dimmer junction PCB
Fig. 5 Zoom module screws
Fig. 6 Place wires forward of yoke
Fig. 7 “Sticking points”
Fig. 8 Right junction connections

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MAC 2000 Wash Service Manual
the wires to the junction print. Secure
the bundle under the flexible tie.
Zoom belt, replace
1Remove the zoom module. (p. 3)
2Remove the belt clamp screws.
3Loosen the set screws and remove
the belt clamp from the belt.
4Flip the module over and loosen the
zoom motor screws. Push the motor in
to loosen and remove the old belt.
5Pull the belt tension pulley forward
and loop the new belt over it as shown
in Fig. 12.
6Lead the belt to the motor and loop
it over the gear. Loop the other end of
the belt over the front pulley.
7Tighten the belt by moving the zoom
motor back until the tension pulley
starts to move. Tighten the motor
screws.
8Place the belt clamp on the belt with
the set screws inside the loop and the
small bar between the belt and the
screws. Tighten the set screws.
9Fasten the belt clamp to the lens
car.
10 Install the zoom module. (p. 3)
Zoom motor, replace
1Remove the zoom module. (p. 3)
2Unplug the motor wires and remove
the motor screws. Loosen the bracket
enough to remove the motor.
3Transfer the gear to the new motor
with 0.6 mm (0.025 in.) clearance
between the motor and the gear.
Tighten the set screw.
4Position the motor in the bracket
with the socket facing out. Tighten the
bracket screws. Start the motor screws
but do not tighten.
5Place the belt over the gear. Push
the motor out to tighten the belt until the
tension pulley just begins to move.
Tighten the motor screws.
6Plug in the motor wires.
7Install the zoom module. (p. 3)
Fig. 9 CMYC wire bundle path
Fig. 10 Belt clamp screws
Fig. 11 Loosen the belt
Fig. 12 Loop belt over tensioner
Fig. 13 Zoom belt
Fig. 14 Belt clamp
Fig. 15 Loosen bracket to remove motor
Fig. 16 0.6 mm (0.025 in.)

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MAC 2000 Wash Service Manual
Zoom lens assembly, replace
1Remove the zoom module. (p. 3)
2Remove the belt clamp screws.
(Fig. 10)
3Remove the 4 screws that fasten
the zoom car to the zoom slide. Do not
remove the slide from the rail.
4Fasten the replacement zoom lens
assembly to the slide.
5Fasten the belt clamp.
6Install the zoom module. (p. 3)
Zoom rail, replace
1Remove the zoom lens assembly.
(p. 5)
2Separate the color wheel module
from the zoom module. (p. 5)
3Remove the white plastic plate at
the back of the module.
4Unscrew and remove the zoom rail.
5Starting with the third hole from the
front, fasten the new zoom rail to the
zoom module with 5 M3x6 panhead
Torx screws, P/N 08050702.
6Place the stand-off on the M3x12
panhead Torx screw and insert the
screw through the first hole in the rail.
Fasten with an M3 nut.
7Install the zoom lens car stop. (Fig.
18)
8Install the color wheel module. (p. 7)
9Install the zoom lens assembly. (p.
5)
10 Install the zoom module. (p. 3)
CMYC module, remove
1Remove the zoom module. (p. 3)
2Remove the module fastening
screws: there are two on the top and
two on the bottom.
3Slide the module forward as far as it
will go, then lift it out of the top of the
head.
CMYC module, install
1Lock the head in the horizontal, top
up position.
2Move the wire bundles forward and
out of the way.
3Orient the module with the junction
print up and to the right. Lower the
module into the chassis at an angle.
Square the module with the flaps over
the chassis and slide it back as far as it
will go. Align the screw holes and fasten
at the top and bottom.
4Install the zoom module. (p. 3)
Color wheel module, remove
1Remove the top head shell.
2Disconnect plugs 28/29, 9, and 10
from the inside row of the left-side zoom
module junction print. (Fig. 1)
When removing the zoom car, do
not remove the slide from the rail.
Fig. 17 Do not remove slide from rail
Fig. 18 Zoom lens car stop
Fig. 19 Zoom slide stop
Fig. 20 1 of 4 CMYC module screws
Fig. 21 Insert module at an angle
Fig. 22 Color wheels 1 & 2
2
1

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MAC 2000 Wash Service Manual
3Remove the color module attach-
ment screws and separate the color
wheel module from the zoom module.
Color wheel 1 belt, replace
1Remove the top head shell.
2Press the motor down to release
belt tension. Remove the old belt and
install a new one.
Color wheel 1 motor, replace
1Remove the color wheel module. (p.
5)
2Release belt tension and slip the
belt off the motor gear. (Fig. 24)
3Remove the sensor print to access
the screw underneath. Remove the
screws that fasten the motor bracket to
the module plate.
4Unhook the spring from the motor
bracket. (Fig. 28)
5Transfer the gear (or install a new
one) to the shaft of the replacement
motor with 10 mm clearance between
the bottom of the gear and the face of
the motor. Tighten the set-screw. (No
further adjustment is required.)
6Transfer the mounting bracket to the
new motor. Do not open the new motor!
7Apply a drop or two of silicone
grease (P/N 37302002) to the motor
bracket. Attach the bracket to the plate
with metric screws and bushings.
8Hook the tension spring onto the
motor bracket and connect the motor
wires.
9Reinstall and connect the Hall sen-
sor circuit board.
10 Reinstall the drive belt.
11 Install the color wheel module. (p. 7)
Color wheel 2 belt, replace
1Remove the color wheel module. (p.
5)
2Unscrew and remove the wheel.
3Remove the old belt. Place the new
belt over the motor gear and the axle.
4Reinstall the color wheel and loop
the belt onto the color wheel gear.
5Place the open position over the
tension pulley, pull the pulley in, and
loop the belt over the pulley.
6Install the color wheel module.
Color wheel 2 motor, replace
1Remove the color wheel module.
2Remove the belt from the tension
pulley and motor gear.
3Unscrew and unplug the old motor.
4Transfer the standoffs to the
replacement motor. Do not open the
new motor!
5Transfer the gear (or install a new
one) to the shaft of the replacement
motor with 1.1 mm clearance between
the bottom of the gear and the face of
the motor and tighten the set-screw.
(No further adjustment is required.)
6Place the motor on the plate with
the socket towards the other motor.
Fig. 23 Color module screws
Fig. 24 Release belt tension
Fig. 25 Motor bracket screws
Fig. 26 10 mm clearance
Fig. 27 Motor and bracket
Fig. 28 Color wheel 1 motor
Fig. 29 Color wheel 2 belt

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MAC 2000 Wash Service Manual
Fasten with 4 M3x6 mm countersunk
screws. Plug in the wires.
7Loop the belt over the motor gear
and tension pulley. Verify that the wheel
turns smoothly without binding.
8Install the color wheel module. (p. 7)
Color wheels, adjust
The color wheels are magnetically indexed
using a routine that does not require
mechanical adjustment.
If the wheels are not centered in the optical
path, the Hall sensor IC is probably bent out
of position. The problem can be solved by
entering a position offset in the calibration
menu. In extreme cases it may be necessary
to move the sensor IC.
Color wheel module, install
1Insert the module in the head, mak-
ing sure that the bottom flaps straddle
the chassis plate. Fasten.
2Connect plugs 28/29, 9, and 10 to
the inside row of the left-side zoom
module junction print. (Fig. 1)
Head side covers, remove
and install
1Remove the screws that fasten the
cover: each cover has two screws.
2Pull front covers straight out to
remove. The rear covers must be pulled
out 1 cm at the back before pulling
back.
3When reinstalling the front covers,
verify that the air filter lies flat.
4When reinstalling the rear covers, it
helps to tilt the head down.
Effect fans, replace
1Remove the zoom module. (p. 3)
2Unplug, unscrew, and remove the
defective fan.
3Install the replacement fan with the
air-flow arrow pointing in. To avoid strip-
ping the threads, use M4x30 metric
screws (P/N 008070410) instead of the
original taptites.
4If replacing the left fan, connect the
plug to the front 2 pins of socket 38.
(Fig. 1)
5If replacing the right fan, connect
the plug to the rear 2 pins of socket 37.
(Fig. 8)
6Install the zoom module. (p. 3)
Left lamp fan, replace
1Remove the zoom module (p. 3)
and CMYC module (p. 5). Remove the
left-rear side cover. (p. 7)
2Cut the cable tie if required to
access the lower fan screw. Remove
the fan attachment screws.
3Work the fan assembly free of the
reflector housing.
4Remove the metal heat shield and
the ceramic insulation from the old fan.
5Cut cable ties as required and free
the fan cable. Remove the fan.
6Prepare the new fan. Cut a piece of
foil backing (P/N 33002002) to fit and
apply it to the back of the fan. Place a
40 cm (16 in.) length of sleeve over the
leads, cut the leads to length, and
install a 2-pole plug.
7Install the insulation and heat shield
on the foil-backed side of the prepared
fan.
8Work the fan assembly back into
place and fasten.
9Lead the fan cable forward, through
the holes in the side chassis. Slide the
cable insulation fully back to the fan and
then retie the bundle above the starter.
10 Replace the cable tie at the bottom
fan screw.Keep the wires and thermo-
Fig. 30 Color wheel motors
Fig. 31 Bottom flaps straddle plate
Fig. 32 Apply foil to fan
Fig. 33 Fan heat shield and insulation
Fig. 34 Cable path

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MAC 2000 Wash Service Manual
switch clear of the fan to maintain maxi-
mum airflow.
Right lamp fan, replace
1Remove the zoom module (p. 3)
and CMYC module (p. 5). Remove the
front and rear covers from the right side
of the head. (p. 7)
2Remove the fan attachment screws.
3Work the fan assembly free of the
reflector housing. Though the fit is tight,
it should not be necessary to loosen or
remove the reflector housing.
4Unplug the thermo-switch.
5Cut cable ties as required and
remove the old fan cable. Remove the
fan assembly from the head.
6Prepare the new fan. Cut a piece of
foil backing (P/N 33002002) to fit and
apply it to the back of the fan. (Fig. 32)
Place a 40 cm (16 in.) length of sleeve
over the leads, cut the leads to length,
and install a 2-pole plug.
7Remove the old fan from the heat
shield and install the new fan.
8Lead the fan cable out through hole
1, in through hole 2, under the wire bun-
dle, and out through hole 3 as shown in
Fig. 38.
9Connect the thermo-switch leads.
10 Work the fan assembly into position,
align the screw holes, and fasten.
11 Pull slack in the fan cable towards
the front. Gather the fan cable together
with the cables labeled ‘42’ and ‘23’ and
tie at point 4 in Fig. 38 Wrap the black
wires around the fan cable a few times
to hold them together. Replace any
other cable ties that you removed.
12 Verify that the openings in the plate
around the fan are sealed with high-
temperature polyester electrical tape.
13 Reassemble the head.
Heat filter assembly, remove
& install
1Remove the zoom module (p. 3)
and CMYC module (p. 5).
2Bend open the cable retention tabs
and move the cables out of the way.
3Remove the four heat filter module
screws and remove the module.
4Installation is the reverse.
Fig. 35 Tie bundle at bottom screw
Fig. 36 Thermo-switch connections
Fig. 37 Right lamp fan assembly
Fig. 38 Right fan cable path
1
2
3
4
Fig. 39 Move wires out of way
Fig. 40 Module attachment screws

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MAC 2000 Wash Service Manual
Heat filter, replace
1Remove the heat filter assembly. (p.
8)
2Remove the damaged filter(s).
Clean and degrease the metal plates
with an alcohol cleaner.
3Apply a dab of red, high tempera-
ture silicone adhesive about the size of
a 1 mm ball on each corner of the heat
filter holder. Place the middle frame on
the holder and align the screw holes.
4Place the heat filter glass inside the
middle frame with the coated side down
(towards the lamp) and with the long
edge parallel to the bent sides of the fil-
ter holder. (To find the coated side, hold
the filter up to a source of light. When
the coated side is up, the edges of the
glass have a reddish tint. When the
coated side is down, the edges have a
more gray or black appearance.
5Place the top frame over the glass
and fasten with four screws (4.2x13
self-tap, Torx, black).
6Remove any excess glue that
extends beyond the metal corners and
clean the glass.
7Reinstall the heat filter assembly.
Allow the glue to harden for at least 12
hours before use.
Reflector, replace
1Remove the heat filter assembly. (p.
8)
2Remove the outer screws from the
reflector spring clips, loosen the inner
screws, and turn the clips away from
the rim.
3Remove the reflector and install the
the replacement, carefully aligning the
opening with the lamp.
4Secure the reflector with the spring
clips. Tighten all 8 screws and verify
that the reflector cannot turn.
5Reassemble.
Starter, replace
1Remove the zoom module (p. 3),
CMYC module (p. 5), and the front and
rear left-side head covers (p. 7).
2Remove the lamp.
3Turn the lamp in/out adjustment
screw fully counterclockwise.
4Pry the lamp socket assembly off
the lamp access plate.
5Remove the starter wires from the
lamp socket terminals.
6Loosen the wire clamp at the base
of the lamp access plate by removing
one of the push-on fasteners.
7Pull the wires back to the starter,
cutting cable ties as you go.
Fig. 41 Apply adhesive
Fig. 42 Insert glass filters
Fig. 43 Install top frame
Fig. 44 Turn clips to free reflector
Fig. 45 Turn fully CCW
Fig. 46 Pry out the adjustment plate
Fig. 47 Loosen the cable clamp

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MAC 2000 Wash Service Manual
8Unscrew, unplug, and remove the
starter.
9Plug in the replacement starter and
fasten it to the bracket with the lamp
wires towards the front and bottom.
Lead the wires up, through the hole in
the top of the chassis, and towards the
back as shown in Fig. 48.
10 Place a 30 cm (12 in.) length of 6
mm sleeve (P/N 15802007) on each
lamp wire. Insert the lamp wires through
the hole under the thermo-switch and
pull them out at the back. Adjust the
sleeve as shown in Fig. 49.
11 Lead the wires up through the hole
in the lamp access plate and then to
either side. The lamp wires are not
polarized.
12 Connect the lamp wires to the lamp
socket terminals. Make sure the con-
nections are secure.
13 Snap the lamp socket and adjust-
ment assembly back into place.
14 Gather the white lamp wires
together with the black and blue starter
wires and tie them to the chassis at
point 1 in Fig. 51 Tie the wires that lead
to the back at point 2.
15 Tie the wires under the left fan as
shown in Fig. 52. Keep the wires and
thermo-switch clear of the fan to main-
tain maximum airflow.
16 Adjust the wires for a neat lead at
the lamp socket.
17 Place the cable clamp over both
screws and secure with a push-on fas-
tener. (Fig. 47)
18 Reassemble the fixture and install
the lamp.
19 Adjust the lamp as described in the
user manual
Dimmer blades, replace &
adjust
1Remove the CMYC module. (p. 5)
2Remove the heat shield on the back
(lamp side) of the module.
3Remove the V-shaped plate over
the top dimmer.
4Loosen the shaft adaptor set screws
and remove the dimmer blades.
Remove any nicks or burrs from the
motor shaft with fine sandpaper.
5Install a dimmer blade on the top
motor with a 1.5 mm gap between the
module plate and the inside (black) face
of the blade (Fig. 56). Slightly tighten a
set screw.
6Install a dimmer blade on the bot-
tom motor with a distance of 7 mm from
the module plate to the outside face of
the shaft adaptor (Fig. 57). Slightly
tighten a set screw to hold the position.
Fig. 48 Starter screws
Fig. 49 Lamp wires with sleeve
Fig. 50 Lamp wires at access plate
Fig. 51 Tie starter wires
1
2
Fig. 52 Cable ties at left fan
Fig. 53 Heat shield
Fig. 54 V-plate over top dimmer
Fig. 55 Remove burrs

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MAC 2000 Wash Service Manual
7Connect a 4-pole motor extension
cable to dimmer junction PCB, and
cable 16 in the head or the dimmer out-
put on the PCB. Apply power and can-
cel pan/tilt reset from the control panel.
8When the reset is complete, select
UTIL>AdJ>HEAd>dIM>AdJ (dimmer
adjustment position) from the menu.
Press each blade against its stop and
tighten the set screws.
9Select STRO (strobe) from the
menu and check dimmer movement.
10 Switch off the fixture and discon-
nect the motor extension cable.
11 Reinstall the V-shaped plate and the
heat shield.
12 Reassemble.
Dimmer motor, replace
1Remove the dimmer blade as
described under “Dimmer blades,
replace & adjust” on page 10.
2Unplug and remove the motor.
3Place the spacer on the face of the
replacement motor and install with the
plug oriented as shown. Connect.
4Install and adjust the dimmer blade.
(p. 10)
CMYC module, separate
1Remove the CMYC module. (p. 5)
2Remove the heat shield (Fig. 53)
and the V-plate over the top dimmer
blade (Fig. 54).
3From the dimmer side of the mod-
ule, remove the 8 screws that fasten the
module plate to the stand-offs.
4Unplug the dimmer motors, the light
sensor (41), the cyan and magenta
motors, and the microswitches on the
dimmer half of the module.
5Separate the module into 2 parts.
6Assembly is the reverse.
Fig. 56 Top blade spacing: 1.5 mm
Fig. 57 Bottom blade spacing: 7 mm
Fig. 58 Press blade against stop
Fig. 59 Dimmer motor orientation
Fig. 60 Stand-off screws
Fig. 61 Unplug light sensor
Fig. 62 Unplug microswitches
Fig. 63 Separate into 2 parts

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MAC 2000 Wash Service Manual
CMYC belts and flags,
replace
1Remove and separate the CMYC
module. (p. 11)
2Place the module half that needs
servicing on a clean surface with the fil-
ters up.
3Starting with the top set of filters
(cyan or yellow), release tension and lift
the belt off the pulleys.
4Gently pry the drive rail out of its clip
on one end. Pull the rail lengthwise out
of the other clip.
5Lift the drive rail, filters, and belt out
of the assembly.
6If you need to remove the bottom
set of filters (magenta or CTC), first
remove the idle rail for the top filters.
Then repeat steps 3, 4, and 5 to
remove the bottom filters.
7If replacing the belt or filters, unlock
and remove the belt clamp from each
slide. Remove the belt.
8Clean the rails and lubricate with a
drop of high viscosity silicone oil.
9Slide the flags onto the rail with the
coated (text true) sides facing each
other.
10 Magenta and CTC only: Clamp
the belt to the inside slot of the Yslide.
Lay the flag pair one the rails with the Y
filter on top. Skip to step 12.
11 Cyan and yellow only: Clamp
the belt to the inside slot of the X
slide. Position the flag pair in the mod-
ule with the X filter on top. Skip to step
13.
12 Install the idle rail for the top flag
set.
13 Arrange the belt and make sure the
ends are outside the rail clips. Center
the rail on the clips and snap it into the
clips on each end. Work the belt onto
the pulleys.
14 Set the filters an equal distance
from the clip using any convenient
spacer.
Fig. 64 Color flag order
Fig. 65 Gently pry out drive rail
Fig. 66 Remove flags, rail, & belt
Fig. 67 Remove clamp from slide
Fig. 68 Clamp belt to inside of Y slide
Fig. 69 Y filter on top
Y
X
Fig. 70 Clamp to inside of X slide
Fig. 71 X filter on top
XY
Fig. 72 Equal distance

13
MAC 2000 Wash Service Manual
15 Clamp the belt in the outside slot
of the slide for the bottom filter.
16 Verify that the flags slide smoothly
in opposite directions and that the bot-
tom flag engages the microswitch. If the
flag does not fully engage the switch,
remove the clamp from the bottom
slide, move the filter 1 tooth closer to
the microswitch, and re-clamp.
17 Reassemble and install the module.
CMYC motors, replace
1Remove and separate the CMYC
module. (p. 11)
2Unplug and remove the old motor.
3Measure the position of the gear
along the motor shaft. Transfer the gear
to the replacement motor or install a
new one.
4If replacing the cyan or magenta
motors, place the motor heat shield
under the module plate.
5Orient the motor as shown with 3
springs between the motor and the
plate. Fasten.
6Reassemble the fixture.
Fig. 73 Clamp belt in outside slot
Fig. 74 Flag must engage microswitch
Fig. 75 Magenta motor
Fig. 76 Cyan motor
Fig. 77 Yellow motor
Fig. 78 CTC motor
Fig. 79 Flag motor suspension

© 2002 Martin Professional A/S, Denmark. Updated December 23, 2002 14
YOKE PROCEDURES
Yoke covers, remove
Remove yoke covers in the following order:
1outer arm covers
2inner arm covers
3front and back base covers
4top base cover
Installation is the reverse.
Tilt belt, left, replace
On the left side, the wiring is easiest to
disconnect at the head.
1Disconnect the fixture from AC
power.
2Remove the zoom module. (p. 3)
Remove the inside and outside covers
from the left side of the yoke.
3Cut the cable ties that bind the bun-
dle of black motor and sensor wires to
the lamp and ground wires. Pull the
bundle of black wires out of the head.
4Disconnect the black and blue lamp
wires from top of the connection block
and pull them into the head.
5Disconnect the ground wires and
pull the shorter wire into the head.
6Unhook the motor springs and
loosen the hex-socket motor screws.
Push the motor up and remove the belt
from the motor gear.
7Unlock the head and support it
under the left side.
8Remove the circlip from the tilt bear-
ing.
9Remove 3 screws from each side of
the left tilt arm.
10 Work the arm off of the tilt bearing,
pulling straight, and place a new belt on
the large gear.
11 Work the arm back into position and
align the screw holes. Fasten.
12 Install the tilt axle circlip.
13 Place the belt on the motor gear.
Install the tension springs. Tighten the
hex-socket motor screws.
14 Pull the lamp and ground wires
through the yoke bearing. Connect the
lamp wires to the connection block.
Fasten both ground wires to the top of
the arm with a locknut.
15 Feed the black wire bundle into the
head. Tie the wires neatly together,
leaving some slack, with 3 or 4 cable
Fig. 80 Remove arm covers first
Fig. 81 Disconnect lamp wires
Fig. 82 Disconnect ground wires
Fig. 83 Loosen motor screws
Fig. 84 Support the head
Fig. 85 Remove circlip
Fig. 86 Remove arm screws
Fig. 87 Pull arm off bearing

15
MAC 2000 Wash Service Manual
ties. Tie the bundle to the arm above
the motor.
16 Install and connect the zoom mod-
ule. (p. 3)
17 Synchronize the tilt motors. (p. 16)
Tilt belt, right, replace
On the right side, the wiring is easiest to
disconnect at the yoke.
1Remove the inside and outside cov-
ers from the right arm of the yoke.
2Remove the yoke base covers.
3Unplug all wires that lead down from
the head from the connection print at
the base of the yoke.
4Remove the tilt timing wheel.
5Unhook the belt tension springs,
loosen the hex head motor screws, and
take the belt off the motor gear. (Fig.
83)
6Unlock and support the head under
the right side. (Fig. 84)
7Remove the circlip from the tilt axle.
(Fig. 85)
8Remove the 6 yoke arm screws.
(Fig. 86) Pull the arm straight back off
the axle. Remove the old belt and place
the new one over the large gear.
9Work the arm back into position and
align the screw holes. Fasten.
10 Install the tilt axle circlip.
11 Place the belt on the motor gear and
install the tension springs. (Fig. 88)
Tighten the hex-socket motor screws.
12 Install the timing wheel.
13 Plug the wires back into the sockets
on the connection print shown in Fig. 92
14 Synchronize the tilt motors.
Fig. 88 Attach springs
Fig. 89 Tie bundle to arm
Fig. 90 Unplug bundle at yoke
Fig. 91 Remove arm
38 16
32 42 10 9
87
28/29
65
43
21
PL
42
PL
38
PL
37 PL 36 PL 35
PL 29 PL 28PL 41PL 30
PL 23 PL 22PL 24
PL 17 PL 16PL 18
PL 11 PL 10PL 12
PL 5 PL 4PL 6
PL
40
PL
34
PL
33 PL 32 PL 31
PL 26 PL 25PL 39PL 27
PL 20 PL 19PL 21
PL 14 PL 13PL 15
PL 8 PL 7PL 9
PL 2 PL 1PL 3
33160020-A
38 16
32 42 10 9
87
28/29
65
43
21
23 36 30 37 22
32 41 21 20
31 19 18
26/27 17 15
34 14 13
24 12 11
Pan Lock Side
PL
42
PL
38
PL
37 PL 36 PL 35
PL 29 PL 28PL 41PL 30
PL 23 PL 22PL 24
PL 17 PL 16PL 18
PL 11 PL 10PL 12
PL 5 PL 4PL 6
23 36 30 37 22
32 41 21 20
31 19 18
26/27 17 15
34 14 13
24 12 11
PL
40
PL
34
PL
33 PL 32 PL 31
PL 26 PL 25PL 39PL 27
PL 20 PL 19PL 21
PL 14 PL 13PL 15
PL 8 PL 7PL 9
PL 2 PL 1PL 3
33160020-A
Fig. 92 Yoke base connections

16
MAC 2000 Wash Service Manual
Tilt motors, synchronize
1Remove the outer arm cover from
the left or right side of the yoke.
2With the power off, loosen both
motor gear set screws.
3Apply power and allow the fixture to
reset.
4From the control panel (MAN >
TILT), move the head the minimum
required to access and tighten one of
the set screws.
5Move the head again and tighten
the second set screw.
6Replace the yoke cover.
Tilt motors, replace
Steps in parenthesis are for the right, tilt
sensor, side only.
1Remove the outside and inside arm
covers from the side of the yoke to be
serviced.
2(Remove the timing wheel.)
3Unhook the motor springs and
loosen the hex-socket motor screws.
(Fig. 83) Push the motor up and remove
the belt from the motor gear.
4Remove the hex-socket motor
screws and remove the motor and
bracket. Unplug the motor. (Unplug the
tilt sensor).
5Remove the bracket from the old
motor.
6Transfer the gear to the new motor
or install a new one with a distance of
7.5 mm (0.3 in.) face of the motor to the
inside face of the shaft adaptor. Tighten
a set screw slightly to fix the position.
7Fasten the motor bracket to the new
motor as shown using 3 new M5 x 16
mm hex head taptite screws, P/N
08091005. (Used taptites are not suited
for cutting new threads.)
8Position the motor assembly on the
arm without pinching any wires and
start the hex-socket screws.
9Plug in the motor wires. (Connect
the tilt sensor.)
10 Place the belt on the motor gear and
install the tension springs. (Fig. 88)
Tighten the hex-socket motor screws.
Move the head through its tilt range a
couple of times and verify that the belt
does not rub against the yoke.
11 (Install the timing wheel and verify
that it turns freely.)
12 Synchronize the tilt motors. (p. 16)
13 Replace the yoke covers.
Synchronize the tilt motors with a
front lens installed (for balance)
and with the head as close to verti-
cal as possible.
Fig. 93 Remove motor and bracket
Fig. 94 Tilt motor orientation

© 2002 Martin Professional A/S, Denmark. Updated December 23, 2002 17
BASE PROCEDURES
Pan belt, replace
1Remove the covers from the top of
the base.
2Remove all yoke covers. (p. 14)
3Unplug all wires from the connection
PCB that lead up through the pan shaft.
Disconnect the lamp power and ground
wires from the yoke and cut cable ties
as required to free them.
4Cut the cable ties around the wire
bundle at the top of the pan shaft.
5Remove the pan gear screws with a
short or angled Pozidriv 2 screwdriver.
6Remove the yoke attachment
screws with a 4 mm hex key. Before
removing the last screw, turn the yoke
to the center of the pan range, with the
bottom of the yoke parallel to the main
PCB.
7Note how the pan stop screw aligns
with the edge of the power supply PCB.
The pan gear must be in the same posi-
tion when you reinstall the yoke.
8Lift the yoke off the base and have a
helper feed the wires through the yoke
opening. Set the yoke and head aside.
9Remove the pan timing wheel.
Unhook the springs and loosen the
motor bracket screws.
10 Remove the belt.
11 To ensure that the new belt will be
properly tensioned, remove the springs
and loosen the opposite pan motor.
12 Install the replacement belt on both
motors and the pan gear. Hook the
springs onto both motors and verify that
the belt tension is the same on each
side before tightening the motors.
13 Install the timing wheel.
14 Turn the pan gear to the center of
the pan range. (Fig. 96)
15 Lock the head horizontally with the
top up. Have a helper feed the wires
into the yoke as you place the yoke on
the pan shaft. The front of the head
must face the front of the base
16 Align the holes in the yoke and pan
shaft. Install the hex socket yoke
attachment screws in the holes at the 2,
6, and 10 o’clock positions. (Fig. 95)
17 Install the pan gear screws in the
holes at the 12, 4, and 8 o’clock posi-
tions. (Fig. 95) Apply Loctite 480 to
these screws and be very careful to
avoid stripping the plastic threads.
18 Reconnect the lamp and ground
wires. Connect the other wires as
shown on the label. (Fig. 92) The unla-
beled 2-pin connector in the pan-lock-
side bundle is plug 30.
19 Install cable ties as required to man-
age the wires.
20 Form a collar around the wire bun-
dle at the top of the pan shaft with 2
cable ties (P/N 13104003, “Strap, black,
3.6x140mm”). Position the collar so that
the slack is about the same at the top
and bottom of the shaft. (Fig. 95)
21 Synchronize the pan motors. (p. 21)
22 Install yoke and base covers.
Fig. 95 Pan shaft detail
2
4
10
12
6
8
Fig. 96 Stop aligns with power supply
Warning! To prevent the head
from working loose, always use
threadlock on the yoke attachment
screws.
Fig. 97 Motor bracket screws
Fig. 98 Check belt tension
Fig. 99 Plug 30

18
MAC 2000 Wash Service Manual
Main PCB, replace
See the electrostatic discharge precautions
on page 2.
1Remove the front top base cover.
2Remove the top screws from the
front side cover and swing the cover
down to expose the main PCB.
3Disconnect all wires from the PCB.
4Remove the nuts along the top edge
with a 5.5 mm socket wrench. Lift the
top edge of the PCB over the screws
and then lift the bottom edge out of the
track.
5Check the jumper caps on the
replacement board. The normal posi-
tions are as follows:
6Connect the blue, brown, and black
high voltage wires to the PCB as shown
on the connection label.
7Install the PCB on the front cover.
8Connect the 2-wire electronic ballast
dimmer cable to PL215. (The ballast
end is shown in Fig. 104.)
9Connect the large unlabeled 4-pin
plug at the bottom of the PCB. Follow
the lead from the right base fan (next to
the control panel) and connect it to
PL57. Connect the left base fan to
PL55. Connect the 4-pin lead from the
control panel to PL33.
10 Connect the rectangular 8-pin plug
from the power supply to the socket at
the top of the PCB.
11 Connect the remaining wires as
shown on the connection label.
12 Upload software if required and
reinstall the covers.
Power supply, replace
1Verify that the fixture is discon-
nected from AC power.
2Remove the front top base cover.
3Disconnect the blue and brown
wires at the top of the power supply
PCB and unplug the 8-pin connector on
the right.
4Remove the front side cover and
disconnect the blue, black, and brown
wires so you can get to the nuts at the
bottom of the power supply.
5Remove 2 nuts from the top and 3
nuts from the bottom of the circuit board
with a 5.5 mm socket wrench and
extension. You may also need a 5.5 mm
open-end wrench to hold the stand-offs.
Remove the power module.
6Install and fasten the replacement.
7Connect the brown wire to PL101
and the blue wire to PL102. These
wires are slightly heavier than the
brown and blue wires going to the relay.
8Plug in the 8-pin connector.
9Reconnect the brown, black, and
blue lamp power wires to the main PCB
as shown on the connection label.
10 Reinstall the covers.
Jumper Default position
write enable
boot normal
data receive/send
Fig. 100 DMX, control panel, and fan
connection
Fig. 101 PCB connections
Fig. 102 AC input
brown
blue

19
MAC 2000 Wash Service Manual
Electronic ballast, replace
1Verify that the fixture is discon-
nected from AC power.
2Remove the ballast bracket screws
from the bottom.
3Remove the top cover from the bal-
last side of the base. Remove the top
screws from the rear side cover and tilt
the cover down.
4Disconnect the blue and black wires
from ballast terminals X300 and X301.
5Disconnect the ballast dimmer wire.
6Remove 6 small screws that fasten
the ballast on top and bottom.
7Disconnect the brown and blue
mains wires from terminals X1 and X2.
8Connect the brown mains wire to
the live terminal (X1) and the blue
mains wire to the neutral terminal (X2)
on the replacement ballast.
9Fasten the ballast to the bracket.
10 Connect the brown starter wire to
the “+” terminal (X300) and the blue
starter wire to the “-” terminal (X301).
11 Connect the dimmer wire. (Fig. 104)
12 Fasten the ballast bracket to the
base.
13 Check the ballast fan connection.
Install the covers.
Ballast fan, replace
1Remove the ballast as described in
the previous procedure.
2Disconnect the ballast fan cable
from PL59 on the main PCB. Cut ties as
required to free the cable.
3Remove the fan from the ballast
bracket.
4Transfer the grill to the replacement
fan. Install the fan on the ballast bracket
with the air flow arrow pointing towards
the ballast and the fan lead on the side
of the fan closest to the PCB.
5Lead the fan wires across the base
and connect to PL59. Replace the cable
ties.
6Reinstall the ballast as described in
the replacement procedure.
Base fans, replace
1Remove the top base covers.
Remove the left or right side cover and
handle. Remove the top screw from the
other end of the front cover and tilt the
cover down to access the main PCB.
2Unplug the fan from the main PCB
and cut ties as required to free the
cable.
3Unscrew the fan and remove the
grill. Lift the fan up and pull the fan bot-
tom-first out of the opening.
4 The air flow arrow for both fans
points into the base. If replacing the
right fan (closest to the control panel)
orient it so the wires enter at 9 o’clock,
seen from the outside. If replacing the
left fan (closest to the power switch),
turn it so the wires are on top. Insert the
fan top-first into the base.
5Connect and tie the fan cable.
6Place the grill over the fan. Check
that the fan wires are not pinched and
then fasten.
7Install all covers.
Fig. 103 Ballast bracket screws
Fig. 104 Ballast dimmer connection
Fig. 105 Ballast screws
Fig. 106 Ballast AC connection
Fig. 107 Ballast fan orientation
Fig. 108 Remove fan bottom first
Fig. 109 Fan grill installation