COBHAM SAILOR 1000 XTR Ku 8W Bedienungs- und Sicherheitshinweise

Field Replacement Procedure

Following legal entities are trading as / doing business as Cobham SATCOM

Thrane & Thr

ane A/S, Kgs. Lyngby, Denmark

Sea Tel

Inc., Concord USA

www.cobham.com/satcom

SAILOR 1000 XTR Ku – Polarization motor & drive belt replacement

Brief Summary:

Field replacement document for replacing the polarization motor and drive belt.

Tools needed

•Large wrench (40 Nm)

•Socket wrench 8 mm

•Torque wrench (1.0 – 6.0 Nm)

•5mm Hex bit M6 for the radome

•4mm Hex bit, M5. for the motor

•Torx T25 screwdriver

•Optibelt Freq measuring device

Spare part:

•S-67-176324 Polarization motor

•S-41-207851-000 Belt for polarization drive

Cobham SATCOM

Global Technical

Service dept.

Date:

September 2021

Document Number:

97-177616-A

Page 2 of 8

www.cobhamsatcom.com

Field replacement procedure –

Doc. No.:

97-177616-A

Location of the polarization motor and belt

Replacing the part:

1. Open the service hatch, loosen the 8 screws.

Do not use a power tool!

Access the pedestal through the hatch.

2. Power off the ADU (at the ADU power on/off

switch at the antenna control module).

3. Remove the feed horn with a suitably sized

wrench. Apply the wrench close to the dish, see

the flattened area. Turn anti-clockwise.

Important: Handle the feed horn carefully

and make sure that it does falls down and

gets broken.

Page 3 of 8

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Field replacement procedure –

Doc. No.:

97-177616-A

4. Disconnect the cables connected to parts on the

RF pack.

a) 2x LNB cables (using socket wrench 8mm),

b) BUC cable (using a wrench),

c) OMT cable (be careful as the PCB is fragile)

d) polarisation motor cable.

5. With a Torx25 screw driver loosen the four

screws (do not remove them entirely) to remove

the RF pack.

6. Turn the RF pack anti-clockwise and lift it off

using the two handles.

Continue the replacemnt below deck.

7. Loosen the adjustment screw for the motor belt.

8. Remove the four screws of the bracket holding

the motor assembly to remove the motor.

9. Take the belt (green in the image) off the motor

pulley.

Adjustment

screw

Page 4 of 8

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Field replacement procedure –

Doc. No.:

97-177616-A

10. Remove the 2 shafts to loosen the waveguide

arm using an Allen key 4 mm.

Important: DO NOT slide the waveguide

arm away yet in order not to drop the O-

rings into the waveguide accidentally.

11. With a small tool, remove the two O-rings

underneath the waveguide arm.

12. Slide the waveguide to the side and exchange

the belt.

Page 5 of 8

www.cobhamsatcom.com

Field replacement procedure –

Doc. No.:

97-177616-A

13. Slide the waveguide with the O-rings back in

place.

Important: Make sure not to drop the O-

rings into the waveguide.

14. Fasten the waveguide shafts at 2.5 Nm using an

Allen key size 4 mm

15. When attaching the belt verify that the marking

on the motor pulley points towards the

adjustment screw.

16. Mount the polarization motor over the threaded

stays. Mount the washers and loosely tighten the

4 nuts.

- 4 pcs. of 53-200167-006 washers.

- 4 pcs. of 52-203751-006 Nut Hex M6

Page 6 of 8

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Field replacement procedure –

Doc. No.:

97-177616-A

17. Tighten the motor adjustment screw.

18. Make 3 measurements using an Optibelt

frequency measuring device , turning the OMT all

the way to the end stop clockwise, counter

clockwise and midway.

19. Verify that all 3 measurements are in the range

of 110 to 160 Hz. Keep adjusting until

measurements are within the range.

20. After the adjustment tighten the nuts to 8 Nm.

Verify again that the measurements are within

the range of 110 to 160 Hz.

21. Apply Loctite 243 to the thread and tigten the

adjustment screw against the bracket.

22. Attach the RF pack to the antenna dish using the

4 screws.

23. Important! Turn the RF Package as far as

possible clockwise, and keep it there until the

screws are tightened.

24. Tighten the four screws at 4.5 Nm using a Torx

25 screwdriver.

Page 7 of 8

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Field replacement procedure –

Doc. No.:

97-177616-A

25. Connect the cables:

a) 2x LNB cables (socket wrench 8mm, 1.0 Nm),

b) BUC cable (wrench, 2.0 Nm),

c) OMT cable (insert carefully as the PCB is very

fragile)

d) polarisation motor cable.

26. Mount the feed horn, tighten to 40 Nm.

27. Switch on the antenna at the ADU power on/off

switch at the antenna control module and check

that the antenna goes through the POST

(antenna can move freely).

Page 8 of 8

www.cobhamsatcom.com

Field replacement procedure –

Doc. No.:

97-177616-A

28. Close the hatch.

29. Apply copper grease to thread of the 8 screws.

Grease type: Rocol 250, Nulon 90, or Abcon

790.

30. After closing the hatch, make sure to mount all

eight screws before tightening. This is to avoid

that the last screws will misalign.

Do not use a power tool!

31. Tighten the eight screws. 6 Nm

Verify the initialization of the SAILOR XTR ADU:

After replacing the defective component re-initialize the pedestal and verify its operation.

1. Switch on the BDU.

2. Power up the VSAT modem.

3. Perform an Extended POST. Verify that it is completed without any errors or warnings.

4. Verify that the system is online and fully functional.

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