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C-Com iNetVu 755A Service Manual

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New Generation Service Manual
755A/981A/985A and 1201A
The iNetVu™ brand and logo are registered trademarks of C-COM Satellite Systems, Inc. ©
Copyright 2006 C-COM Satellite Systems, Inc.
1-877-iNetVu6
www.c-comsat.com
Revision 003
May 25, 2014

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Summary of Contents for C-Com iNetVu 755A

  • Page 1 New Generation Service Manual 755A/981A/985A and 1201A The iNetVu™ brand and logo are registered trademarks of C-COM Satellite Systems, Inc. © Copyright 2006 C-COM Satellite Systems, Inc. 1-877-iNetVu6 www.c-comsat.com Revision 003 May 25, 2014...
  • Page 2 This document contains information, which is protected by copyright. All rights reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as followed under the copyright laws. Both the iNetVu™ and C-COM names and logos are registered trademarks of C-COM Satellite Systems Inc. ®...
  • Page 3 RV dealer/installer mount the system on your vehicle. These conditions are also required by C-COM for all other installed locations. All iNetVu™ Mobile earth station installers must be C-COM Certified, and must have specifically acknowledged the requirements for iNetVu™ Mobile installations, which are as follows: “Installation”...
  • Page 4 Including but not limited to, any modification of any part of the hardware, software, specific operational frequencies, the authorized satellite, or the size or other characteristics of the earth station supplied to them by C-COM or C- COM’s authorized representatives.
  • Page 5 New Generation Service Manual Page 5 of 53  C-Com Satellite Systems Global Headquarters 2574 Sheffield Road Ottawa, Ontario, Canada K1B 3V7 Phone: +1-613-745-4110 Fax: +1-613-745-7144 General Inquiries: info@c-comsat.com Dealer Information: dealer@c-comsat.com Support Services: support@c-comsat.com Phone: +1-613-745-4110 OPT2 Toll Free: 1-877-463-8886 OPT2 Monday –...
  • Page 6 New Generation Service Manual Page 6 of 53 This page is left Blank intentionally C-COM Satellite Systems Inc.

  • Page 7: Table Of Contents

    3.9.3. Platform Model Ka 755/985 ................. 38 3.10. Replacing Base Bearing Assembly – 981 Series Platforms ......... 39 ® 3.11. Stow Adjustment on iNetVu Ka-75V/981-Ku/Ka-98(H/G/V) ......... 50 3.12. Emergency Stow Procedure ................... 52 3.13. APPENDIX 1: TORQUE/THREAD LOCKING TABLE ..........53 C-COM Satellite Systems Inc.

  • Page 8: Introduction

    1.1. About This Manual This service manual explains how to fully maintain the iNetVu™ Drive-Away System(s), and repair/replace certain product components. An electronic version of this manual is included on the iNetVu™ USB Drive that came with your system. C-COM Satellite Systems Inc.

  • Page 9: Maintenance

    (1) month when subjected to snow and ice, dirt, grime, road spray, sand, salt spray, or extreme heat or cold. Immediately perform maintenance after exposure to known chemicals, corrosives, contaminants, or before the system is prepared for storage. C-COM Satellite Systems Inc.

  • Page 10: Maintenance Items

    2.1.5. Preparation for Storage Specifically before storage in a transportable case or sealing into a storage container, the system should be cleaned, thoroughly dried, and then lubricated as per maintenance procedures before covering. C-COM Satellite Systems Inc.

  • Page 11: Cleaning Inetvu™ Mobile Platform Connectors

    Motor Control, Sensor, and Coaxial Ports. Use a can of compressed air if necessary. Fig. 1: iNetVu™ Drive-Away Platform Connector Location Military Style Connectors and Coax cables 981A Ku Drive-Away 1201A Ku Drive-Away 985A Ka Drive-Away 755A Ka Drive-Away C-COM Satellite Systems Inc.

  • Page 12: Spray On Corrosion Inhibitor - Application To Az/El Assembly

     If no Hex Sockets are installed on the EL/AZ Motor Reducer Shafts, please clean and apply Corrosion inhibitor to the exposed metal. If your system did not ship with the Hex Sockets installed on the Motor Reducer Shafts contact C-COM Satellite Systems Inc. C-COM Satellite Systems Inc.
  • Page 13 New Generation Service Manual Page 13 of 53 Keyless Bushing 1201 Torque 1201 Belleville Limiter Nut Washers C-COM Satellite Systems Inc.

  • Page 14: Repairs And Replacements

    New Generation Service Manual Page 14 of 53 3. REPAIRS AND REPLACEMENTS C-COM Satellite Systems Inc.

  • Page 15: Replacing The Azimuth Motor

    2. Locate and remove (2) mounting screws securing the azimuth encoder in place. Remove (2) Screws 3. Loosen the (2) set screws from the encoder. Disconnect the cable and you should be able to lift away the encoder at this point. Loosen (2) Set Screws C-COM Satellite Systems Inc.
  • Page 16 5. Remove (4) reducer mounting screws. The azimuth motor should be free and you will be able to remove it from the azimuth chassis. Remove (4) Screws NOTE: Please keep track of all parts and their original location C-COM Satellite Systems Inc.

  • Page 17: Installing The Azimuth Motor

    NOTE: Adjustment must be completed within 5 minutes of applying Loctite to threads. 9. Measure the tension on the AZ belt using a Belt Tension Device/Meter. 755/981/985 should be 285Hz ± 15 and 1201 should be 375Hz ± 19. DO NOT OVER TENSION THIS BELT. C-COM Satellite Systems Inc.
  • Page 18 13. Install and tighten the (2) mounting screws securing the azimuth encoder in place. 14. Connect the Azimuth Encoder and Azimuth Motor to the internal wiring harness. 15. Congratulations you have successfully replaced the Azimuth Motor. C-COM Satellite Systems Inc.

  • Page 19: Replacing The Elevation Motor

    Move Tension Wedge in this direction to release tension 2. There should be enough slack to slid the belt out. Once the belt is free, we can lift the motor freely and remove the tension wedge C-COM Satellite Systems Inc.

  • Page 20: Installing The Elevation Motor

    5. If the motor you receive does not have the Mounting Plates installed they must be transferred from the failed motor. 6. Assemble the EL Motor mounting plates. Install one plate on each side of the motor. Fasten the (4) screws on each side. C-COM Satellite Systems Inc.
  • Page 21 Slide the Belt onto the EL Reducer out-put shaft. Slide the belt onto lower Pulley, making sure the belt teeth are aligned in the grooves. The tension wedge can be moved further to the rear providing additional slack for the belt. 10. Proceed to tension the belt. C-COM Satellite Systems Inc.

  • Page 22: Elevation Belt Tension

    1201 set to 550 ±28 Hz 981, 985, 755 set to 380 ±20 Hz Tension Wedge NOTE: Adjustment must be completed within 5 minutes of applying Loctite to threads. 14. Congratulations you have successfully replaced the Elevation Motor. C-COM Satellite Systems Inc.

  • Page 23: Elevation Pulley Belt Removal & Installation

    3. Remove the top (4) screws from the EL Pulley Clamp and remove the top plates. 4. Loosen the remaining (4) screws from the EL Pulley Clamp farthest from the elevation motor. Remove (4) Screws Loosen (4) Screws from top plates 5. Remove the belt to be replaced. C-COM Satellite Systems Inc.
  • Page 24 3. Ensure last belt tooth is placed on the last groove, place top clamp and tighten into place. 4. Tighten the (4) bottom clamp screws on the clamp that is furthest away from the EL motor. Last Groove C-COM Satellite Systems Inc.
  • Page 25 7. Set the belt tension by adjusting the tensioning screw. Set the tension on the Pulley belt to 485 ±24 Hz for the 1201, and 330 ±10 Hz for the 755/981/985 Platforms. Tension Screw 8. To complete the replacement tighten the (4) bottom screws closest to the elevation motor. C-COM Satellite Systems Inc.

  • Page 26: Replacing The Polarization Assembly For A 1201 Platform

    Feed Horn. Tighten specified screws. Feed Horn Feed Rotator Arm 3. Install POL cage assembly onto Feed Arm. Insert side with Rotator Arm first into top Feed Boom Pivot and ensure its pointing away from reflector. C-COM Satellite Systems Inc.
  • Page 27 Washer 5. Insert same amount of spring washers on the other end of the POL Cage shaft and install retaining ring. (3) Washers on Rotator Side C-COM Satellite Systems Inc.
  • Page 28 8. Insert shoulder screw into piston end of gas spring, using small plastic bushing as a spacer and applying loctite 242. 9. Apply jam nut on the other end of the screw and tighten into place. C-COM Satellite Systems Inc.

  • Page 29: Replacing The Polarization Assembly For A 981 Platform

    2. Insert mounting screws into place and tighten to specified torque. Mounting Screws 3. Remove cover and connect cables in POL Cage, Tilt Sensor, Motor, Compass etc. 4. You have successfully installed the 981 Polarization Assembly. C-COM Satellite Systems Inc.

  • Page 30: Replacing And/Or Adjusting The Azimuth Sensor's

    5. Connect all cables. Power up the 7024 controller and attempt to stow the platform. If you are able to stow the platform you may now continue as normal. 6. Congratulations you have successfully replaced the azimuth encoder. C-COM Satellite Systems Inc.

  • Page 31: Azimuth Home Or Away Sensor

    From the iNetVu Software Controls screen the Azimuth ST should be active. Attempt to auto-stow the platform. d. To test the Away Sensor, move the platform to roughly 180 or -180 degrees. If the Away Sensor is properly aligned with the target the LED should be ON. C-COM Satellite Systems Inc.

  • Page 32: For The 981/755 Home And Away Sensors

    To test the Away Sensor, move the platform to roughly 180 or -180 degrees. If the Away Sensor is properly aligned with the target the LED should be ON. 6. Congratulations you have successfully replaced the AZ ST/AW sensor. C-COM Satellite Systems Inc.

  • Page 33: Replacing And/Or Adjusting The Elevation Sensor's

    Note: To perform these steps you will be required to move the antenna on Elevation 1. Lower or raise the antenna so that the sensor target lines up with the sensor. 2. Disconnect it from the internal harness. Loosen the nut and unscrew the sensor out. Sensor Target C-COM Satellite Systems Inc.

  • Page 34: Elevation Down Sensor

    4. Congratulation you have successfully replaced the EL ST/UP limit sensor. 3.7.3. Elevation Down Sensor 1. Raise the antenna so that the EL Down Limit Sensor lines up with a solid part of the EL Down flag. C-COM Satellite Systems Inc.

  • Page 35: Replacing And/Or Adjusting The Polarization Sensor's (981, 1201 Only)

    4. Screw the replacement sensor in until it touches a solid part of PL flag. Roll back half a turn and tighten the bolt in place. Use .01 inch feeler gauge. 5. Move PL to the center position and verify the LED on the switch is active. C-COM Satellite Systems Inc.
  • Page 36 New Generation Service Manual Page 36 of 53 Target is a blank space Polarization Home Switch LED 6. Congratulations you have successful replaced the polarization limit sensor. C-COM Satellite Systems Inc.

  • Page 37: Compass Replacement

    Compass cable tail end should face away from reflector. 3. Push grommets into place. 4. Install compass on BUC mounting plate. Ensure logo on compass is facing out so it’s viewable. 5. Connect compass cable to internal harness connector exiting the Feedboom. C-COM Satellite Systems Inc.

  • Page 38: Platform Model Ku 981

    2. Install the new compass label facing out on the feed horn protection bracket. Ensure cable end is opposite to metal ear. Connect the compass cable to external cable coming out the feed arm. C-COM Satellite Systems Inc.

  • Page 39: Replacing Base Bearing Assembly - 981 Series Platforms

    Thread Locker - High Procedure: Warning: It is recommended (2) people perform this procedure to avoid serious damage or harm to both operator and equipment. 1. Remove AZ/EL cowling and set aside. 2. Remove Cable Clip. C-COM Satellite Systems Inc.
  • Page 40 4. Tip/Lay mount on its side supporting the elevation arms. You may want to consider removing the reflector to avoid damaging it. 5. Snip cable ties and disconnect sensor connections. AZ Away Sensor EL Stow Sensor Cable AZ Home Sensor 6. Pull coax cables out through the center AZ/EL base assembly. C-COM Satellite Systems Inc.
  • Page 41 7. Pull the remaining harness cables also through center of AZ/EL base assembly. 8. Tip mount back on its base, make sure sensor cables are tucked up and away to avoid getting pinched by the AZ/EL machined base edge. C-COM Satellite Systems Inc.
  • Page 42 11. Loosen outer Bearing Slewing Ring screws. Caution as this step will leave the EL Arm and Feed Arm unsupported causing it to tip forward. Second person must support mount top level as screws are being removed. C-COM Satellite Systems Inc.
  • Page 43 13. Lift top level assembly off base assembly leaving Pulley and Bearing assembly. 14. Remove faulty/old AZ Base Bearing assembly and place new AZ Base Bearing (replacement part) assembly on parent base assembly. C-COM Satellite Systems Inc.
  • Page 44 Location of Cable Exit Opening 16. Place 2 screws to (one at the front and the other at the back) temporarily hold down Base Bearing to parent base assembly. 17. Place belt over Base Bearing assembly. C-COM Satellite Systems Inc.
  • Page 45 20. Slide belt onto AZ Reducer Shaft. Belt at the back end should be above Pulley for easy installation. Reducer Belt Shaft Pulley 21. Slide belt onto Pulley, ensure belt teeth align in grooves on the Pulley. C-COM Satellite Systems Inc.
  • Page 46 23. Remove 2 screws that were temporarily holding chassis to base. 24. Tip antenna on its side. 25. Feed motor and sensor cables through center. C-COM Satellite Systems Inc.
  • Page 47 Note: Ensure pins of sensor line up with connector holes to avoid bending pins. 28. Connect AZ Home (also referred to as AZ Stow), from the bottom view it’s the sensor on the left. Away Home C-COM Satellite Systems Inc.
  • Page 48 New Generation Service Manual Page 48 of 53 29. Connect AZ Away sensor. EL Stow Home Away 30. Clean up cables by applying cable ties so they are tucked away. 31. Feed 2 coax cables through center of chassis. C-COM Satellite Systems Inc.
  • Page 49 32. Set system in the upright position, holding the cables underneath chassis opening. 33. Align mount holes on base and chassis. 34. Apply thread locker and insert fasteners, hand tighten leaving them loose until all have been inserted and Feed Arm aligned for proper stowing. C-COM Satellite Systems Inc.

  • Page 50: Stow Adjustment On Inetvu Ka-75V/981-Ku/Ka-98(H/G/V)

    Feed Arm is too far off the center or does not touch down on stow plate. Note: Antenna is not required to be completely stowed to make the required centering adjustments. Feed Arm should be at minimum touching the base plate. C-COM Satellite Systems Inc.
  • Page 51 Note: Manually moving the elevation up a few degrees may be required in order to shift and center the azimuth axis. 5. Tighten base hold-down bolts. 6. Deploy and verify system stows with proper centering. 7. Install cable clip. C-COM Satellite Systems Inc.

  • Page 52: Emergency Stow Procedure

    Hex Socket  If your system did not ship with the Hex Sockets installed on the motor reducer shafts contact C-COM Satellite Systems Inc. Fig. 38: Using a Hex Socket Wrench to operate AZ & EL motors Note: A drill is NOT recommended as this may cause damage to the gear reducer.

  • Page 53: Appendix 1: Torque/Thread Locking Table

    Hex Head (ISO 4014/4017, DIN 931/933) Socket Low Head (DIN 7984) Thread Threadlocker Threadlocker Threadlocker Torque (Nm) Torque (Nm) Torque (Nm) diameter strength strength strength medium medium medium medium medium medium medium medium medium medium medium medium C-COM Satellite Systems Inc.

This manual is also suitable for:

Inetvu 981aInetvu 985aInetvu 1201a

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