COBHAM SAILOR XTR GX-R2 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 XTR GX-R2 and generic Ka 4.5W and 9W transceiver unit

Field replacement procedure

Brief Summary:

Field replacement document for replacing the 4.5W and 9W transceiver unit for GX-R2 and

generic Ka antennas.

Spare part:

•S-67-175992 SAILOR XTR GX-R2 4.5W transceiver unit

•S-67-175993 SAILOR XTR GX-R2 9.0W transceiver unit

Location of the part:

Cobham SATCOM

Global Technical Service dept.

Date: November 20222

Document Number: 97-178838-C

Page 2 of 9

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Field replacement procedure –SAILOR 1000 XTR Ka/GX-R2 RF pack

Doc. No.: 97-178838-C

Replacing the part:

SAILOR 1000 XTR Ka/GX-R2

1. Power off the GMU

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

Do not use a power tool!

Access the pedestal through the hatch.

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

switch at the antenna control module).

4. 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 and gets

broken.

5. Disconnect the cable from the RF pack to the

plug marked BUC M&C (a).

6. Remove the cable tie (b).

(a)

(b)

Page 3 of 9

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Field replacement procedure –SAILOR 1000 XTR Ka/GX-R2 RF pack

Doc. No.: 97-178838-C

7. Remove the TX coax cable connector.

8. Disconnect the X-pol cable.

9. Remove the cable tie.

10. Remove the co-pol cable from the RF pack.

11. Take off the RF Package by turning it anti-

clockwise and lift it off.

12. If the complete RF packet is available go to 20.

Else continue

13. Remove the counterweight. 7 screws.

Page 4 of 9

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Field replacement procedure –SAILOR 1000 XTR Ka/GX-R2 RF pack

Doc. No.: 97-178838-C

14. Remove the four screws holding the transceiver

unit

15. Gently slight out the transceiver unit.

16. Remove the polarizer from old unit.

Mount the polarizer on the new unit. Make sure

to keep the O-ring in place. 1 Nm

17. Gently slight the transceiver unit back in.

Press it all in.

Install the four screws.

18. Install the feed horn. Tighten by hand.

Push back the transceiver unit 1 mm. (That’s to

make sure, that once installed again, the feed

horn doesn’t push on the polarizer)

Tighten the four screws. 4.5 Nm.

Remove the feed horn

19. Install the counterweight. 7 screws. 4.5 Nm

Page 5 of 9

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Field replacement procedure –SAILOR 1000 XTR Ka/GX-R2 RF pack

Doc. No.: 97-178838-C

20. Install RF Package by turning it clockwise.

Tighten screws. 4.5 Nm

21. Attach the co-pol cable to the RF pack.

Add the cable tie.

22. Connect the X-pol cable. Tighten to 1 Nm.

23. Connect the TX coax cable N-connector. Tighten

to 2.5 Nm.

24. Connect the cable from the RF pack to the plug

marked BUC M&C (a).

Add the cable tie (b).

(a)

(b)

Page 6 of 9

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Field replacement procedure –SAILOR 1000 XTR Ka/GX-R2 RF pack

Doc. No.: 97-178838-C

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

26. 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).

27. Close the hatch.

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

Grease type: Rocol 250, Nulon 90, or Abcon

790.

29. 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!

30. Tighten the eight screws. 6 Nm

31. Run a new cable calibration and OTC

See Cable calibration and OTC

SAILOR 600 Ka/GX-R2

1. Power off the BDU. (Complete system)

Power off the GMU.

2. Remove the twelve M6 hex screws and washers.

Lift off the radome. Be careful not the damage

the feedhorn.

Page 7 of 9

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Field replacement procedure –SAILOR 1000 XTR Ka/GX-R2 RF pack

Doc. No.: 97-178838-C

3. Remove the BUC control cable, the BUC coax

cable, and the LNB coax cable

4. Remove the four screws. Remove the transceiver

unit. Gently slight if out

5. Remove the polarizer from old unit.

6. Mount the polarizer on the new unit. Make sure

to keep the O-ring in place. 1 Nm

7. Gently slight the transceiver unit back in. Press it

all in, and pull it back out 1 mm. (That’s to make

sure that the feed horn doesn’t push on the

polarizer)

Page 8 of 9

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Field replacement procedure –SAILOR 1000 XTR Ka/GX-R2 RF pack

Doc. No.: 97-178838-C

8. Install the four screws. 4.5 Nm

9. Reinstall the control cable, the BUC coax cable,

and the LNB coax cable. 2.5 Nm

10. Put the radome back on. Be careful not to

damage the feedhorn. Place the warning label

above the draintube. Install the twelve M6

screws and washers. 6 Nm

11. Run cable calibration and OTC

Cable calibration and OTC

1. Enter the ACU WEB MMI and run a cable

calibration

Page 9 of 9

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Field replacement procedure –SAILOR 1000 XTR Ka/GX-R2 RF pack

Doc. No.: 97-178838-C

2. Power ON the GMU / VSAT modem

The GMU / VSAT modem will normally

automatically enter the OTC.

If not: Enter the Modem WEB MMI, Log in using

admin

–

Password

. Go to the commissioning page,

and start the OTC manually.

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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