CyScan MK4 Engineers & Service Guide Guidance Marine Ltd,

Issue Date: 07/04/2016 5 Tiber Way

Meridian Business Park
Document No: 94-0357-4
Leicester
LE19 1QP
UK

Tel: +44 116 229 2600

Tel (Customer Services): +44 116 229 2665
Email: customerservices@guidance.eu.com
Web: www.guidance.eu.com/customer-support

Copyright 2016 Guidance Marine Limited. All Rights Reserved.

Copyright in the whole and every part of this document belongs to Guidance Marine
Limited (the Owner) and may not be used, sold, transferred, copied or reproduced in
whole or in part in any manner or form or in or on any media to any person other than in
accordance with the terms of the Owners Agreement or otherwise without the prior
written consent of the Owner. CyScan is a registered trademark of Guidance Marine
Ltd. All other brand or product names are trademarks or registered trademarks of their
respective companies or organisations.

94-0357-4 CyScan MK4 Engineers and Service Guide Page 1

Contents

Basic System Overview ................................................................................................................................................................. 3

Rotor Assembly Removal ............................................................................................................................................................... 4
Rotor Assembly Replacement .......................................................................................................................................................... 5
Access Cover ............................................................................................................................................................................. 5
Removal and Replacement of the I/O & Controller Tray ........................................................................................................................... 7
Remove the I/O Module from the Controller Tray ................................................................................................................................... 8
Removal and Replacement of the PSU ............................................................................................................................................... 9
Removal of the Base Plate ............................................................................................................................................................ 10
Removal of the Rotor Drive Belt ...................................................................................................................................................... 11
Replacement of the Rotor Drive Belt (Spring Tensioned, 2011 onwards) ..................................................................................................... 12
Replacement of the Rotor Drive Belt (Non Spring Tensioned, 2010 - 2011) .................................................................................................. 13
Slip Ring Replacement ................................................................................................................................................................. 14
Removal and Replacement of the Rotor Cover .................................................................................................................................... 15
Replacement of the Rotor Optics Tilt Drive Belt .................................................................................................................................... 16
Appendix A: CyScan MK4 Sensor Maintenance Requirements and Recommended Storage Conditions ................................................................ 17
Appendix B: List of Replacement Parts .............................................................................................................................................. 18

WARNING: Ensure unit is isolated from power before carrying out any of the procedures contained in this document

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Basic System Overview

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Rotor Assembly Removal
1. Using a hex driver, remove the 6 x M5 screws located in
the base of the rotor, access to the screws is via the
semicircular recess shown in the image to the left.

2. You will need to turn the rotor by hand after each screw
to access the next one.

3. The rotor can then be lifted from the rotor drive plate

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Rotor Assembly Replacement

1. Apply DC4 to the white foam seal on the rotor drive.

2. Place the rotor onto the rotor drive plate making 3. Replace the 6 x M5 hex head screws; tighten the
sure to locate the rotor correctly on the locating pin screws via the semicircular recess as previously
(as indicated by the red arrows). done during the removal.

SERVICE TIP: Ensure the circular foam seal on the rotor drive plate is not damaged before replacement.

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Access Cover

Removal
Warning: The retaining screws are not captive. Also the
access cover is not secured with a lanyard therefore must
be supported during removal.
1. Using an M4 hex driver remove the 4 x M5 screws
located in the four corners of the access cover.
Replacement
1. Inspect the foam seal on the access cover for damage.
2. Apply DC4 to the seal.
3. Replace the 4 x M5 hex head screws and tighten - ensure
that the seal is compressed to provide watertight integrity.

SERVICE TIP: Ensure the display window is clean both externally and internally prior to replacement

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Removal and Replacement of the I/O & Controller Tray
Warning: Isolate all power to unit otherwise damage will
occur to the Controller Module.
Removal
1. Remove the Access Cover
2. Disconnect all plugs (power / serial / ethernet).
3. Remove the gland plate if necessary and withdraw the
cables completely.
4. Using a hex driver remove the 4 x M5 screws as
marked in the photo (top). Note: Access holes are
provided to locate tool correctly.
5. Gently separate the I/O & Controller Tray from the main
body and withdraw as per the lower photo.

Replacement
1. Replacement is the reversal of the above procedure.
2. Prior to replacement the foam seal should be inspected
for damage and DC4 applied to its surface.
3. When replacing the 4 x M5 head screws, ensure they
are tightened sufficiently to compress the seal so as to
maintain watertight integrity.

SERVICE TIP: When inserting the I/O & Controller Tray make sure the complete assembly is firmly pressed home before
tightening the M5 screws.

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Remove the I/O Module from the Controller Tray
Removal Replacement
1. Follow the procedure for the removal of the I/O and 1. Replacement is a reversal of the removal procedure,
Controller Tray. 2. Care should be taken to route the power cable underneath
2. Disconnect the ribbon cable and the power supply cable the PSU correctly so it is not pinch or trapped before
from the Controller PCB as shown below (left). tightening the M5 screws up.
3. Remove the 3 x M5 screws on each side of the Controller
Tray (6 total) that secure it to the I/O Module as shown
below (center).
4. Turn the I/O on its front and remove the two M5 screws
on the underside of the Controller Tray as below (right).
5. The I/O Module and Controller Tray should now come
apart.

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Removal and Replacement of the PSU

Removal
1. Follow the procedure for removing the I/O and Controller
Tray.
2. This procedure is easier if you also follow the procedure for
separating the I/O from the Controller.
3. On the rear of the I/O module, disconnect the orange power
connector and the lower of the two white connectors as
shown opposite (top).
4. Using a Torx driver, and whilst supporting the Quint PSU,
remove the 4 small Torx screws securing the PSU to the
I/O module as shown opposite (bottom).
5. Lift and remove the PSU, then disconnect and retain the
two power cables.

Replacement
1. Reconnect the two power supply cables to the PSU..
2. Locate the PSU in order to replace and tighten the 4 x Torx
screws in the left hand side of the PSU.
3. Reconnect the two power supply cables to the back of the
I/O module.

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Removal of the Base Plate

Removal
1. Remove the I/O & Controller Tray.
2. Carefully lay the Cyscan on its
side allowing access the
underside.
3. Using a hex driver, remove the 13
x M5 screws as shown in the
photo opposite.
4. From inside, push the plate to
separate it from the base.

Replacement
1. Prior to replacement, ensure the
foam seal on the base plate is
covered with a layer of DC4.
2. Replacement is then simply the
reversal of the removal procedure.

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Removal of the Rotor Drive Belt

1. Follow the procedure for removing the I/O and Controller Tray.
2. Follow the procedure for removal of the Base Plate.
3. Disconnect the Slipring plug from the Back Plane (below, left).
4. If your Cyscan has a black plastic catch mould* over the gears and belt, remove it by using unscrewing the 3 x M5 screws
shown below (right).
5. Loosen (do not remove) the 5 x M5 screws securing the motor drive plate as shown below (center).
6. You should now be able to slide the motor drive plate slightly**, giving you some slack in the belt which in turn allows you to
remove it as below (right).

* Some older units (2010-2011) may not have this cover fitted.
** Units manufactured 2011 onwards have a spring tensioner fitted so extra force may be required to slide the motor drive plate.

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Replacement of the Rotor Drive Belt (Spring Tensioned, 2011 onwards)

1. Place a new belt (455mm) over the large pulley, see below (left)
2. With the 5 x M5 hex head screws still loose from the removal stage, slide the motor drive plate allowing you to fit the belt
over the smaller pulley, see below (center).
3. Let go of the motor drive plate and the spring will set the correct tension - no further adjustment is required.
4. Fully tighten down the 5 x M5 hex head screws shown below (center).
5. Replace the black plastic catch mould if originally fitted, secure it with the 3 x M5 hex head bolts as shown below (right).
6. Reconnect the Slipring plug into the backplane, ensuring the cable is secured and out of the way. It may be necessary to
apply a small amount of silicone sealant to the plug to hold it in place.
7. Follow the steps for the replacement of the Base Plate.
8. Follow the steps for the replacement of the I/O Module and Controller Tray.

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Replacement of the Rotor Drive Belt (Non Spring Tensioned, 2010 - 2011)
1. Place a new belt (450mm) over the large pulley.
2. With the 5 x M5 hex head screws still loose from the removal stage, slide the motor drive plate allowing you to fit the belt
over the smaller pulley, see below (centre).
3. Pull the motor drive plate in order to tighten the belt, only hand force is required. Whilst maintaining force on the belt, insert a
2mm hex key into the adjustment hole furthest away from the drive pulley (see below, left), this should hold tension.
4. With the 2mm hex key in place, tighten down the 2 x M5 screws either side of the small drive pulley.
5. Remove the 2mm hex key and fully tighten down the 5 x M5 hex head screws shown below (centre).
6. Check the tension with a steel rule pressed flat against the belt by measuring the following, see below (centre & right):
a. The distance to the centre of the nearest adjustment screw (no force applied to belt), should be 28mm +/- 1.5mm
b. Push the drive belt in with the rule, the distance now should be 33mm to 36mm.
7. Reconnect the Slipring plug into the backplane, ensuring the cable is secured and out of the way. It may be necessary to
apply a small amount of silicone sealant to the plug to hold it in place.
8. Follow the steps for the replacement of the Base Plate.
9. Follow the steps for the replacement of the I/O Module and Controller Tray.

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Slip Ring Replacement
Removal
1. Remove the Rotor.
2. Remove the I/O & Controller Tray.
3. Remove the Base Plate.
4. Remove the 2 x M3 hex head nuts
securing the round Cyscan Shaft
Connector PCB (top right photo).
5. Carefully lift the Cyscan Shaft Connector
PCB and disconnect the Slipring plug (top
left photo) pull the plug not the wires!
6. Inside the Base Chassis, remove the 3 x
flat head screws securing the Slipring
(lower right photo).
7. Carefully withdraw the Slipring,
disconnecting the cable from the Back
Plane Board (lower left photo).

Replacement
1. Replacement is the reversal of the removal
procedure.

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Removal and Replacement of the Rotor Cover
Removal Replacement
1. Remove the Rotor. 1. Apply DC4 to the seal in the white outer cover.
2. Place the Rotor upside down on a flat 2. Very carefully lower the outer cover over the internals, ensuring the
surface giving you access to the underside. optics line up with the glass window on the cover.
3. Using a hex driver, remove the 6 x M5 3. Whilst supporting the internals (silver part) and the outer white cover,
screws. turn it back over and place on a flat surface.
4. Carefully, whilst supporting the internals 4. Insert the 6 x M5 screws and tighten down.
(silver part) and the outer white cover, turn it
over and place on a flat surface.
5. Slowly lift up over the optics and remove the
white outer cover.

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Replacement of the Rotor Optics Tilt Drive Belt

Removal
1. Remove the Rotor.
2. Remove the Rotor Cover
3. With the drive belt facing you, rotate the tilt
assembly clockwise until the tilt assembly stops
rotating.
4. Simply slide the drive belt off the upper (large)
pulley and then remove it from the lower (small)
pulley.

Replacement
1. With the drive belt facing you, rotate the tilt
assembly clockwise until the tilt assembly stops
rotating.
2. Locate the new belt on the lower pulley.
3. Keeping the belt taught on the lower pulley, slide
the belt onto the upper pulley.
4. If required gently turn the large pulley which will
help locate the belt onto the pulley.
5. Ensure the belt sits completely on the large pulley,
and that it sits centered.
6. Replace the Rotor Cover,
7. Replace the Rotor.

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Appendix A: CyScan MK4 Sensor Maintenance Requirements and Recommended Storage Conditions
Full maintenance requirements for the complete range of Guidance products can be found in document 94-0502-4 Sensor Maintenance Requirements
and Recommended Storage Conditions available from Customer Services. All part numbers for spares can be found in Appendix B.

FREQUENCY PROCEDURE NOTES

Weekly Clean rotor window
Clean prisms / reflectors

3 - Yearly Replace silica gel bags There are four silica gel bags (part#: 98-0001-4) within the CyScan MK4:
Two are located inside the Rotor, for access follow the instructions for Removal
and Replacement of the Rotor Cover
Two further silica gel bags are located at the rear inside the base chassis, for
access follow the instructions for Removal and Replacement of the I/O &
Controller Tray.
Replace Slip Ring For replacement follow the instructions for Slip Ring Replacement

5 - Yearly Replace rotor and base drive belts. For replacement follow the instructions for:
Rotor Optics Tilt Drive Belt

Replacement of the Rotor Drive Belt (Spring Tensioned)

or
Replacement of the Rotor Drive Belt (Non Spring Tensioned)

All maintenance items should be carried out in accordance with the instructions contained within the relevant product guide. If in doubt contact Guidance
Marine.
The storage guidelines and recommendations for position reference sensors manufactured by Guidance Marine are:
Temperature -25C to +70C
Humidity less than 90% RH, non-condensing

Note: Prolonged storage may affect service items and post storage service may be required. If you have any queries please do not hesitate to contact
Customer Services or your local sales representative. Details of which can be found on our website.

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Appendix B: List of Replacement Parts
Replacement parts can be ordered by contacting Guidance Marine either via email or at http://marine.direct/.

PART NAME GUIDANCE PART NUMBER

Rotor Assembly T-21-0205-1
Labyrinth Base Chassis T-21-0256-0
CyScan MK4 I/O + Controller Tray (Yatagan) T-21-0438-1
I/O Module T-21-0312-2
Controller Tray Module (Yatagan) T-21-0451-2
PSU (5A) 38-0029-2
Slipring (Moog) 39-0042-2
Rotor Drive Belt (Spring Tensioned) 455mm 50-0019-3
Rotor Drive Belt (Non Spring Tensioned 450mm 50-0018-3
Rotor Optics Tilt Belt 50-0017-3
DC4 100g Tube 98-0025-4

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