COBHAM SAILOR 1000 XTR Ku 8W Operating and safety instructions

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

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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.

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Field replacement procedure –
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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
a)
b)
c)
d)

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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.

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Field replacement procedure –
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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

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Field replacement procedure –
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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.

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Field replacement procedure –
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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).
a)
b)
c)
d)

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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.