COBHAM SAILOR 1000 XTR Ku 8W Gebrauchs- und Pflegehandbuch

Field Replacement Procedure

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

Thrane & Thrane A/S, Kgs. Lyngby, Denmark

Sea Tel Inc., Concord USA

www.cobham.com/satcom

SAILOR 1000 XTR Ku –BUC 8 W or 16 W

Field replacement procedure

Brief Summary:

Field replacement document for replacing the BUC 8W or 16W.

Spare part:

S-67-178100 BUC, Ku band, 8 W

S-67-178101 BUC, Ku band, 16 W

Location of the BUC

Cobham SATCOM

Global Technical Service dept.

Date: October 2021

Document Number: 97-178196-A

Page 2 of 7

www.cobhamsatcom.com

Field replacement procedure –

Doc. No.: 97-178196-A

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.

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) Cable to Power Detector housing (be careful

as the PCB is fragile),

d) polarisation motor cable.

Page 3 of 7

www.cobhamsatcom.com

Field replacement procedure –

Doc. No.: 97-178196-A

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. 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

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

underneath the waveguide arm.

9. Slide the waveguide to the side.

Page 4 of 7

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Field replacement procedure –

Doc. No.: 97-178196-A

10. Remove the four Hex nuts M6 and the four

washers holding the BUC

11. Remove the faulty BUC, including the power

detector housing (blue circle).

12. Remove the four screws holding the power

detector housing.

13. Remove the power detector housing and O-ring

from the faulty BUC.

14. Mount the O-ring and power detector housing

onto the new replacement BUC.

15. Tighten with 2.5 Nm.

16. Remove the four screws holding the BUC adapter

plate.

17. Remove the BUC adapter plate from the faulty

BUC and mount it on the new replacement BUC.

18. Tighten with 2.5 Nm

19. Mount the replacement BUC on the stays and

mount loosely the four Hexnuts M6 and the four

washers that hold the BUC, tighten later.

Page 5 of 7

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Field replacement procedure –

Doc. No.: 97-178196-A

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

place.

Important: Make sure not to drop the O-

rings into the waveguide.

21. Fasten the waveguide shafts at 2.5 Nm using an

Allen key size 4 mm

22. Tighten the 4 nuts of the BUC to 8 Nm.

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

4 screws.

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 6 of 7

www.cobhamsatcom.com

Field replacement procedure –

Doc. No.: 97-178196-A

25. Connect the cables:

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

b) BUC cable (wrench, 2.0 Nm),

c) Cable to Power Detector housing (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 7 of 7

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Field replacement procedure –

Doc. No.: 97-178196-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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