COBHAM SAILOR XTR GX-R2 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 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.