COBHAM SAILOR 1000 XTR Ku 8W Use and care manual

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.
a)
b)
c)
d)

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
www.cobhamsatcom.com
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
www.cobhamsatcom.com
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).
a)
b)
c)
d)

Page 7 of 7
www.cobhamsatcom.com
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.