The psfonts.map distributed with TeX Live 4, which I guess came from the dvips 5.85 distribution but don't know for sure, lacks entries for pbkl8r among others :( :(. Thus a document which uses pbkl will end up causing dvips to run maketexpk :(. The one with tex live 3 was perhaps correct, or else I fixed it by hand then too and have forgotten. Thanks, K