Chapter

Baker Hughes INTEQ

NaviTrak Short Radius

Repair & Maintenance
Manual
P/N 750-500-029 Rev. A
November 1994

Warning!
This guide is for reference only and is subject to change. No work is authorized to be done
on tools nor any service provided by using this guide without first checking with supervi-
sors and consulting the latest Field Maintenance Memos (FMMs).

Confidentiality Statement
Copyright © 1994, by Baker Hughes INTEQ. All rights reserved worldwide. No part of
this publication may be reproduced, transmitted, transcribed, stored in a retrieval system,
or transmitted into human or computer language, in any form or by any means, electronic,
mechanical, magnetic, optical, manual, or otherwise, without the express written permis-
sion of Baker Hughes INTEQ, 2001 Rankin Road, Houston, Texas 77073. Direct all
inquires to the Baker Hughes INTEQ, Marketing Services, Leader/Documentation Depart-
ment.

Confidential
Assembly NaviTrak Actuator

1-2 Baker Hughes INTEQ

Confidential P/N Rev. A/June 1994
 Table of Contents

Chapter 1
Main Valve Servicing
Main Valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Main Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Main Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Main Valve Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Chapter 2
NaviTrak Actuator SR Assembly and Disassembly
Short Radius Actuator Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Piston and Actuator Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Filler Stem Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Actuator Wiring and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
(P1) Bulkhead Connector Wiring . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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P/N 750-500-029 Rev. A / November 1994 Confidential
Table of Contents NaviTrak Short Radius

(P1) Bulkhead to (P101) Connector Wiring . . . . . . . . . . . . . . . . 2-8

(P101) Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Build-up of Bearing Housing and Transmission Shaft . . . . . . . . . . . . . 2-10
Build-up of Ballscrew Assembly to Stepper Motor . . . . . . . . . . . . . . . . 2-11
Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Testing Equipment Required: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Building Assembly into Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Evacuation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Hydrostatic Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Building the Poppet Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Setting the Poppet Valve Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Test Weight Stand Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Test Weight Stand Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Short Radius Actuator Disassembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Actuator Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Testing Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Valve Gap Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Test Weight Stand Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Actuator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Hydrostatic Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Stepper Motor and Associated Parts . . . . . . . . . . . . . . . . . . . . . 2-25
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Chapter 3
Pulser Driver Module
Pulser Driver Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Pulser Driver Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ii Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994
NaviTrak Short Radius Table of Contents

Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Pulser Driver Module Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
PDM Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Pulser Driver Module Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Monitor DMM Setting “A” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Chapter 4
Lithium Batteries
Battery Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Battery Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Reference Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Battery Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Reference Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Battery Harness Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Chapter 5
DAS Servicing
DAS Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
DAS Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Micro Processor Unit (MPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Sensor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
DAS Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Repair & Maintenance Manual iii

P/N 750-500-029 Rev. A / November 1994 Confidential
Table of Contents NaviTrak Short Radius

Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
DAS Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Reference Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Programming the DAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Manually Entered Commands (TALK) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
DAS General Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Chapter 6
Tandems/Bow Springs
Tandem Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tandem Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Disassembly Procedure (Upper DAS Tandem) . . . . . . . . . . . . . . . . . . . . 6-3
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Troubleshooting (All Tandems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Bow Spring Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Chapter 7
Flow Switch Servicing
Flow Switch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

iv Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994
NaviTrak Short Radius Table of Contents

Flow Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Flow Switch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Flow Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Reference Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Vibration Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Test Fixture Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Flow Threshold Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Delay Timer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Chapter 8
Full Tool Functional Test
Test Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Chapter 9
Short Radius Troubleshooting
Troubleshooting Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Tool Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Full Tool Test Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
No Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
No Pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Survey Readings Incorrect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Batteries Not Switching When Depleted . . . . . . . . . . . . . . . . . . . 9-3
Flow Remains On or Is On When No Flow is Present . . . . . . . . 9-3

Chapter 10
Inspection Procedures
Flow Sub Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

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Table of Contents NaviTrak Short Radius

Reference Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Lock Sub Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Reference Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Belleville Spring Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Reference Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Chapter 11
Non Magnetic Compressive Service Drill Pipe (NMCSDP)
Collar Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Appendix A
O-ring Selection and Inspection
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Backup Rings (Seals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Appendix B
Short Radius Forms
Forms Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Battery Pack Test Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Example Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

vi Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994
 Chapter 1

Main Valve Servicing

This chapter contains step-by-step instructions for

assembly, disassembly, and inspection of the NaviTrak
Short Radius Main Valve Assembly.

Main Valve Overview

The Main Valve is a flow restricting component that creates the pressure
pulses. The Actuator drives the pilot valve. The position of the pilot valve
causes the Main Valve to either open or close. Refer to Figure 1-1.

Figure 1-1. Main Valve Assembly. The Main Valve Assembly is the top portion of the Pulser
Module which includes the Fishing Head, Main Valve, Orientation or Nozzle Retaining Block,
Bypass Housing, and Deflector Housing.

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Following are shop procedures for the Main Valve.

Main Valve Assembly

This procedure has step-by-step instructions for assembling the Main
Valve Assembly. Where applicable, parts are identified by a name and
followed by an item number (in brackets), which corresponds to the
reference drawing. You will need to acquire the reference drawing,
materials, and tooling prior to the Main Valve Assembly.
To start this procedure, you will need to gather the following materials:

Reference Drawing
• Main Valve (Dwg. No. 702-500-239)

Materials
• Magnalube (P/N 29265)
• 272 Loctite (P/N 723-500-014)
• Alco Metalube (P/N 714-500-715)

Tools
• 2" Parmelee (P/N 707-500-031)
• Alignment Tool (P/N 702-500-105)
• Valve Extractor Tool (P/N 703-500-110)
• Torque Wrench (P/N 22023)

Assembly Procedure
1. Place the Main Valve (7) in a Bench Vise.
2. Place the Carbide Restrictor (5) on top of the restrictor housing
in the Keyway.
3. Place an O-ring (19) on the OD of the Main Valve Housing (7).
4. Install the Carbide Wear Sleeve (4) over the Main Valve
Housing (7).
5. Now the Apollo head can be installed with Loctite 271. Torque
the Apollo head to 225 ft-lb using the Alignment Tool.
6. Lubricate and install 2 O-rings (13) in the glands of the Fishing
Head.
7. Carefully slide the Inlet Screen using care not to cut the O-rings
or your fingers.

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8. Lubricate and install T-Seals (16) and Backup Rings (15) onto
the Valve Stem.
9. Lubricate and install T-Seals (18) and Backup rings (17) on
Valve Base.

Note: The splits in the Back-up Rings should be placed at a

180o angle to each other.

10. Engage the Valve Extractor Tool on the threads below the
retaining nut on the Main Valve base.
11. Cut both seal areas with Alco Metalube.
12. Insert the stem into the housing while rotating to spread the
lubricant.
13. Check the valve for smooth, free movement.
14. Remove Valve Extractor Tool.

Note: Upper Main Valve Flex Tandem will be used for

replacement of NaviTrak Deflector Housing.

15. Apply Loctite 242 to threads, engage to Main Valve housing,

tighten and torque to 225 ft-lb.
16. The Main Valve is now ready to be attached to the Actuator
Assembly.

Main Valve Disassembly

This procedure discusses disassembling the Main Valve. You will need to
acquire the following reference drawing, materials, and tools before
beginning.

Reference Drawing
• Main Valve (Dwg. No. 702-500-239)

Materials
• None required.

Tools
• 2" Jaw Adapters (P/N 703-500-142)
• Pipe Wrench
• Pin Jaw (P/N 20898)

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• 9/16" Socket
• Valve Extractor Tool (P/N 703-500-110)

Disassembly Procedure
1. Place the 2" Pin Jaw Adapters in a Bench Vise.
2. Grip the tool on the Poppet Valve housing area.
3. Use a Pipe Wrench and a Pin Jaw to break from Actuator
Housing.
4. Remove the Poppet Valve assembly from the Bench Vise and set
aside. The procedure for the actuator is contained in another
chapter.
5. Place the Main Valve Assembly in a Bench Vise by gripping
onto the Bypass Housing.
6. Engage the threads of the Valve Extractor Tool to the threads
below the Hex Nut (9) on the bottom of the Valve Base (8).
7. Pull on the Extractor Tool to remove Valve Base and Valve Stem
(3) from the housing.
8. Remove and discard all O-rings and T-Seals on the base and
stem.
9. Use a Pin Wrench and Breaker Bar to remove the Fishing Head
(1).
10. Remove the Jam Nut in front of the Restrictor Block (6).
11. Slide the Restrictor Block (6) off the Bypass Housing Assembly
(7).
12. Remove Bypass Housing Assembly (7) from the Bench Vise.
13. Clean and inspect all parts for wear and pitting.

Note: Make and record all measurements as requested on the

Inspection Report. On both the Valve Stem and the Valve
Base, measure above and below the T-Seal groove. If the
measurements are within tolerance and there are no
visual defects, then it is not necessary to further
disassemble the stem. Should one of the parts need to be
replaced, proceed as follows.

14. Place Valve Stem (3) in a Bench Vise.

15. Use a 9/16" socket to remove Retaining Nut (9), and Washers
(10) and (11).

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16. Tap Valve Stem (3) through the Valve Base (8).
17. If not replacing Stem, make sure the center orifice has no
obstructions.
18. Inspect all parts for excessive wear, pitting, chips, or cracking.
19. Make the following measurements and record on Inspection
Report:
• Bypass Housing (7) - Measure ID between threads and seat area.
Measure OD between port holes and shoulder.
• Fishing Head (1) - Measure ID at the T-Seal landing area.
Measure port holes at several different locations.
• Inlet Screen (2) - Visually inspect for cracks or abnormal wear.

Note: Maximum tolerances are on the Inspection Report. If any

parts are defective or out of tolerance, note same on
report and replace.

Main Valve Reassembly

The following procedure contains instructions for Main Valve Reassembly.
Obtain all materials and tooling before you begin.

Materials
• Solvent (P/N 65195-001)
• Loctite Primer T (P/N 85952)
• Loctite 242 (P/N 85951)
• Loctite 271 (P/N 86342)
• Alco Metalube (P/N 714-500-001)

Tools
• Torque Wrench (P/N 22023)
• Valve Extractor Tool (P/N 703-500-110)

Procedure
1. Clean all parts, including any new replacement parts, with
solvent, then, if available, in a bead blaster.

Note: If it was necessary to disassemble the Main Valve Stem,

perform Step 2 through 9. Otherwise, proceed to
Operation 10.

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2. Grip Main Valve Stem (3) in a Bench Vise near its center point.
Do not grip on any carbide coated area.
3. Spray the threads and entire seating area with Loctite Primer T.

Note: The Primer T causes accelerated drying of Loctite. Have

all pieces ready for quick assembly once the Loctite is
applied.

4. Slide the Main Valve Base (8) onto the stem, tapered end first.
Before Base is completely seated, wipe off any excess Loctite
271. Do not allow Loctite to get into the area where the tip of the
base seats on the stem.
5. Place the Flat Washer (10) over the threaded Stem.
6. Apply Loctite 242 on the stem threads and to the internal threads
of the 9/16" Nut (9).
7. Engage the Nut on the threads and torque to 10 ft-lb.
8. Remove Valve Stem from the Bench Vise and set aside.
9. Place the Bypass Housing (7) in a Bench Vise.
10. Spray the ID threads of the Fishing Head (1) and the remaining
threads of the Bypass Housing (7) with Loctite Primer T. Allow
to dry for 5 minutes.

Note: The Primer T causes accelerated drying of Loctite. Have

all pieces ready for quick assembly once the Loctite is
applied.

11. Apply Loctite 272 on threads of Fishing Head (1) and threads of
Bypass Housing (7).
12. Engage the threads, tighten and torque to 225 ft-lb.
13. Lubricate and install 2 O-rings (2) in the glands on the Fishing
Head (1).
14. Carefully slide the Inlet Screen (2) using care not to cut O-rings
or fingers.
15. Lubricate and install T-Seal (16) and Back-up Ring (15) on
Valve Stem (3).
16. Lubricate and install T-Seal (18) and Back-up rings (17) on the
Valve Base (8).
17. The splits in the Backup Rings should be placed at a 180o angle
to each other.

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NaviTrak Short Radius Main Valve Servicing

18. Engage the Valve Extractor Tool on the threads below the
retaining nut on the Main Valve Base (8).
19. Coat both seal areas with Alco Metalube.
20. Insert the Stem (3) into Housing (7) while rotating to spread the
lubricant.
21. Check Valve for smooth, free movement.
22. Remove Valve Extractor Tool.
23. Apply Loctite 242, engage to Main Valve housing, tighten and
torque to 225 ft-lb.
24. The Main Valve is now ready to be attached to Actuator
Assembly.

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1-8 Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994
 1
Chapter 2

NaviTrak Actuator SR Assembly and

Disassembly

This chapter contains step-by-step instructions for

assembly, testing, and disassembly of the NaviTrak Short
Radius Actuator Assembly.

Short Radius Actuator Overview

The NaviTrak Actuator Assembly is an electromechanical device for
activation of the Pulser Assembly, which creates the positive pulse that is
detected uphole. Furthermore, the Actuator is a precise device for initiating
the transfer of measurements and data which are computed downhole.
Following are shop procedures for the Actuator.

Actuator Assembly
Before starting any work on the Actuator Assembly, it is important to
inspect all components prior to build-up. Review and practice the
following inspection criteria.
• Carefully check all parts for defects. DO NOT use any parts that are
questionable. Notify a Quality Inspector about any part in question.
• Inspect all O-rings and Seals for cuts and nicks in accordance to
Appendix A: O-ring Selection and Inspection. Discard any that are
defective.
This procedure starts by assembling the Piston and Actuator Housing
Assembly.

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NaviTrak Actuator SR Assembly and Disassembly NaviTrak Short Radius

Piston and Actuator Housing Assembly

In this procedure, the piston and actuator housing are assembled and set
aside, to be used in a later operation. You will need to acquire the reference
drawing, materials, and tooling prior to Actuator assembly.
To start this procedure, you will need to gather the following materials and
tools:

Reference Drawing
• NaviTrak SR Actuator (Dwg. No. 702-500-240)
• Manufacturing Test Procedure (Dwg. No. 708-500-074)

Materials
• Loctite 271 (P/N 86342)
• Dow Corning III Grease (P/N 980000005)

Tools
• Torque Wrench (P/N 22023)
• Adaptor Wrench (P/N 707-500-013)
• Vise Pin Blocks (P/N 703-500-142)
• Hydrostatic Test Adaptor (P/N 702-500-115)
• Pulser Driver Test Box (P/N 702-500-163)
• Modified DMWD Tool (P/N 20898)
• Modified Punch
• Floating Piston Depth Indicator (P/N 703-500-331)
• Mitutoyo Depth Micrometer

Assembly
Begin this the assembly by performing the following operations.
1. Lubricate one O-ring (4) with Dow Corning III Grease and
install into groove on the Piston Housing (25).
Refer to Figure 2-1.
2. Position Pin Blocks into a Bench Vise and then position the
Actuator Housing (29). Tighten the vise to secure the Actuator
Housing in place. It is not necessary to over-tighten the vise.
3. Apply Loctite 271 to threads on Piston Housing (25). Hand
tighten the Piston Housing to the Actuator Housing.

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NaviTrak Short Radius NaviTrak Actuator SR Assembly and Disassembly

Figure 2-1. Piston

and Actuator Pin Adaptor Wrench and
Housing Calibrated Torque Wrench
[Link] (Torque to 225 ft-lb)
piston and actuator
housing are
assembled
together and
torqued in a vise.
Loctite 271
O-Ring

Piston Pin Actuator

Housing Hole Housing

Note: Ensure no Loctite is placed onto the shoulder of Piston

Housing.

4. With a calibrated Torque Wrench and Adaptor Wrench, engage

to the pin block hole. Torque housing connection to 225 ft-lb.
5. After completing the torquing operation, check the housing inner
diameter for any sign of Loctite. No Loctite is allowed, since this
will affect the installation of the motor assembly. If any Loctite is
visible, clean the inner diameter thoroughly.
6. The housing assembly is complete. Set it aside for a later
operation.

Filler Stem Assembly

In this procedure, the Filler Stem is assembled into the Converter Stem.
You will need the following materials and tools before starting.

Materials
• Loctite 680

Tools
• 1/8-inch drill

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NaviTrak Actuator SR Assembly and Disassembly NaviTrak Short Radius

• Oven
Before beginning the next operation, ensure all parts are thoroughly
cleaned.
1. Check the Converter Stem (64) inner bore for metal chips and
burrs. Also, check that the 1/8" hole has been drilled.
2. Apply a liberal amount of Loctite 680 to the Filler Stem (24).

Note: A 100% coverage of Loctite 680 is required around the

smooth diameter of the Filler Stem.

3. Install the Filler Stem (24) into Converter Stem (17). See Figure
2-2.
4. Clean-up any excess Loctite 640.
5. Place the Filler Stem into an oven at 200 degrees F for 15
minutes.

Figure 2-2. Filler

Stem and
Converter Stem
[Link]
filler stem is Converter
assembled to the Stem
converter stem.

Filler Stem
(Loctite 640, 100% Coverage, Outer Diameter)

6. After the Filler Stem has heat cured, drill a 1/8" hole, by using
the hole in the Converter Stem as a guide. Drill this hole through
the Filler Stem.
7. Apply Loctite 680 to the top of the Actuator Ballscrew (28).
8. Install Lead Screw Stop and install over Actuator Ballscrew.

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Note: Do not allow Loctite 680 to run into lead screw.

9. Put Actuator Ballscrew into an oven at 200 degrees F for 15

minutes.
10. Bulkhead-Apply #1838 B/A 3M Epoxy around the pins on the
alignment hole side. Do not cover the solder cup and leave
enough room for the shrink sleeving.

Actuator Wiring and Assembly

Before beginning this procedure, obtain all materials and tooling listed
below. For a wiring schematic for the NaviTrak Actuator, refer to print
702-500-240.

Materials
• Flux
• Hi-Temp Solder (P/N 20529)
• .125" Heat Shrink Tubing (P/N 26321)

Tools
• Ruler
• Diagonal Side Cutters
• Thermal Strippers
• Heat Gun

Stepper Motor
Wiring operations start with wiring the Stepper Motor. Begin wiring steps
with Operation 1.
1. With a ruler, measure and mark the four wires on the Stepper
Motor (40) to 6" in length.

Note: Wires are already marked brn, red, orn, and yel.
However, when sizing the wires, these markings may be
cut off. If this is the case, ensure that you carefully
remark the wires. Also, to note, make sure your hands are
clean and free of solvents, since markings can be
dissolved off the wires.

2. Cut all four wires at the 5" mark using diagonal side cutters. See
Figure 2-3.

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NaviTrak Actuator SR Assembly and Disassembly NaviTrak Short Radius

Figure 2-3.
Stepper Motor
[Link] stepper
motor wiring is
prepared prior to
soldering. Stepper Motor
.125 Heat Shrink
Tubing

Cut Wires to
5-inches

3. Measure and cut a 3" section of .125" Heat Shrink Tubing (P/N
26321). Slip Shrink Tubing over all four Stepper Motor wires.

Note: Do not heat shrink the tubing at this time.

4. Next, take the Thermal Strippers, and remove 5/32" of insulation

off each Stepper Motor wire.
5. Apply flux to each wire and with Hi-temp solder, pre-tin all
wires.
6. Slip Bulkhead Spacer (42) over wires and position flush against
the Stepper Motor housing. The alignment of the spacer notches
is not important, but must be flush against the housing.

Note: The Actuator Spacer stores all wires and prevents wires
from being pinched later on in the assembly.

(P1) Bulkhead Connector Wiring

In the following operations, you will be soldering the (P1) Bulkhead
Connector to the Stepper Motor. Continue assembly with Operation 7.
7. Take the (P1) Bulkhead Connector (45) and with a black marker
put a mark outside the connector for orientation of Pin A. The pin
below the alignment hole is Pin A.

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8. Put the (P1) Bulkhead Connector into a small Bench Vise. You
will now be ready to solder the Stepper Motor wires to the 6-Pin
Connector. Refer to Figure 2-4.

Figure 2-4.
Stepper Motor
Stepper Motor Bulkhead Spacer (P1) Connector
(P1) Bulkhead
Connector. The
stepper motor wires
are soldered to the
(P1) bulkhead
connector.
Orientation Hole
Pin A (no wire)

Pin F (yellow wire)

Pin B (no wire)

Pin E (orange wire) Pin C (brown wire)

Pin D (red wire)

9. Solder the brown wire (Stepper Motor) to pin C (P1 Connector).

Make sure that you apply flux to the connector before soldering.

Note: No wires are soldered to Pins A and B.

10. Next, solder the red wire (Stepper Motor) to pin D (P1
Connector).
11. Solder the orange wire (Stepper Motor) to pin E (P1 Connector).
12. Solder the yellow wire (Stepper Motor) to pin F (P1 Connector).
13. Install an O-ring (46) to P1 Connector (45). Apply oil to the O-
ring.
14. Position the Bulkhead Retainer (44) over the P1 Connector (45).
Align the Retainer to the alignment hole.
15. Apply oil to threads on the Bulkhead Spacer (42) and then screw
the Bulkhead Spacer and Bulkhead Retainer (44) together and
hand tight.
16. With a Heat Gun, heat shrink the already installed Heat Shrink
Tubing (P/N 26321), (P/N 954000901), (P/N 716-000-051) on
both sides of the Bulkhead Connector.

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17. Coil the completed wiring harness inside the Bulkhead Spacer
(42) until the Stepper Motor (40) makes contact.

(P1) Bulkhead to (P101) Connector Wiring

The Actuator wiring continues with wiring the (P1) Bulkhead to the (P101)
Connector. Continue assembly with Operation 18. Refer to Figure 2-5.

Figure 2-5. (P1)

Bulkhead to (P101) (P1) Connector
Connector Wiring. Measure and
Wires are soldered Stepper Motor Bulkhead Spacer Cut Wires to
to the P1 and P101 11-inches
connectors.

Pin A (no wire)

Pin B (no wire) Pin F (yellow wire)

Pin C (brown wire)

Pin E (orange wire)

Pin D (red wire)

18. Select the following color-coded wire from spools: red (65),
yellow (66), brown (67), orange (68). Measure an 11" length for
each wire and mark. Cut wires to length with Diagonal Side
Cutters.
19. With Thermal Strippers, strip 5/32" insulation off from each end.
Follow this by pre-tinning each wire.
20. Position the completed Stepper Motor/Bulkhead Connector into
a vise, positioned so the Bulkhead Connector faces upward.
21. Solder the brown wire to pin C on the Bulkhead Connector.
22. Solder the red wire to pin D on the Bulkhead Connector.
23. Solder the orange wire to pin E on the Bulkhead Connector.
24. Solder the yellow wire to pin F on the Bulkhead Connector.
25. Use Flux Remover Solvent and clean all connections.

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26. Measure and cut four lengths of Heat Shrink Tubing (P/N
954000901), (P/N 716-000-051) and place one piece over each
wire. Heat shrink all pieces into place.
27. Measure and cut a 10-1/2" length of Silicon Tubing (P/N 716-
500-006).
28. Lubricate the wires with oil and slip Silicon Tubing (P/N 716-
500-006) into place.
29. Clean off any residual oil with solvent.
30. Apply an even coating of RTV 3145 into the Bulkhead
Connector. Allow the assembly to cure for 24 hours before
further build-up.

(P101) Connector Assembly

31. After the RTV 3145 has cured for 24 hours, you are now ready to
install the (P1) Connector. Continue assembly with Operation
31. See Figure 2-6.

Figure 2-6. (P101)

Connector
[Link] (P1) Connector (P101) Connector
Stepper Motor
(P101) connector is
also soldered to
wiring in circuit with
the stepper motor.

Brown wire to Pin 6

Red wire to Pin 3
Orange wire to Pin 4
Yellow wire to Pin 5
Jumper wire to Pins 1&2

32. Slide Back-up Seal (49) over end of the previously installed
Silicon Tubing.
33. Install Connector (P101) according to Dwg. No. 702-500-240.
The wires will be crimped as follows:
Wiring for the Stepper Motor assembly is now complete.
Continue with build-up operations.

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Table 1: P101 Connector Wiring

Brown Wire to Pin 6

Red Wire to Pin 3
Orange Wire to Pin 4
Yellow Wire to Pin 5
Jumper Wire to Pins 1 and 2

34. Position Thread Adapter (37) onto other end of the Stepper
Motor (40). Install four Screws (38) with Split Lock Washers
(39) into the Thread Adapter (37). Torque screws to 5 ft-lb using
a Hex Head Socket.

Build-up of Bearing Housing and Transmission Shaft

The following operations cover assembling the Bearing Housing (35) and
Transmission Shaft (36) to the Stepper Motor (40).
35. Install a Needle Roller Bearing (32) over the Bearing Driver
(modified DMWD tool). Position Bearing Driver (with Bearing)
into Bearing Housing (35) until the Bearing makes contact with
the bearing recess. Take a Dead Blow Hammer, then drive the
Roller Bearing until it seats.

Note: After the Roller Bearing is seated, ensure it can spin

freely and there is no binding.

36. Take the Transmission Shaft (36) and install a Thrust Washer
(33), Thrust Bearing (34), Thrust Washer (33) in this order.
Repeat this same sequence on the other end.
37. Lubricate the Thrust Bearings (34) with oil.
38. Install the assembled Transmission Shaft (36) into the Bearing
Housing (35). Ensure that the Transmission Shaft moves freely
inside the Bearing Housing.
39. Take the Actuator Ballscrew (27) which was assembled in an
earlier operation and ensure that the Lead Screw Stop is securely
Loctited in place.
40. Lubricate the Actuator Ballscrew (27) with oil. Check that the
ballscrew moves freely up-and-down.
41. Apply Loctite 242 to threads of Actuator Ballscrew (27).
42. Insert the Actuator Ballscrew (27) into the Bearing Housing (35)
and screw it into the Transmission Shaft (36), until snug.

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43. Insert a Modified Punch (ground off to match the flat in the
Transmission Shaft) into the other end of the Bearing Housing.
Transfer the assembly to a vise and clamp down on the Modified
Punch. With Vise Grips, clamp on the Transmission Shaft (36)
and tighten.
44. Recheck the Actuator Ballscrew for free movement, ensuring
there are no particles or Loctite to cause any interference.
45. Next, the Converter Stem Assembly (with Filler Stem) which
were Loctited and heat cured earlier will be assembled. Mate the
Converter Stem (17) to the Actuator Ballscrew (27).
46. Assemble four Split Lock Washers (30) onto four Cap Screws
(31). Install Screws into Converter Stem (17) using a Hex Head
Driver.
47. Check for any run-out by rotating the Converter Stem (17) and
look for any unbalanced movement.
48. Back-off the Actuator Ballscrew and lubricate the threads with
oil.
49. Install the Poppet Valve Bushing (26) over the Converter Stem
(17) and tighten hand tight.

Note: You can use Pin Wrenches to tighten the Ballscrew

Housing Guide, but DO NOT over tighten.

Build-up of Ballscrew Assembly to Stepper Motor

With the Ballscrew built-up, the next operations will cover assembling it to
the Stepper Motor.
50. Lubricate the threads on the Stepper Motor (40) with oil.
51. Align the “flats” on the Transmission Shaft (36) to the “flat” on
the Stepper Motor (40).
52. Screw the two assemblies together hand tight.
53. Prepare the assembly for electrical testing.

Electrical Testing
You must perform an electrical resistance (ohm) check on the assembly at
this point. Checks are done through the (P101) Connector.

Testing Equipment Required:

• Digital Multimeter (Fluke Model 87 or equivalent)

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• Insulation Tester (Simpson Model 401 or equivalent)

• 24 volt Current Box (P/N 702-500-163)
Following is a table referencing pins of reference (P101 Connector) for
testing.

Table 2: Electrical Resistance Checks (P101 Connector)

Electrical Resistance Check Pins 4 & 6 1.48–1.80 ohms
(using a Digital
Multimeter) Pins 3 & 5 1.48–1.80 ohms

Electrical Resistance Check Pin 6 to Case > 200 megohms

(using an Insulation Tester
@ 500 VDC) Pin 5 to Case > 200 megohms
Pins 5 & 6 > 200 megohms

1. By referencing the Table 2, perform each electrical resistance

check using the Multimeter and the Insulation Tester. Ensure all
electrical checks are within specifications.
2. Now, connect the (P101) Connector to the 24 volt current box.
Turn power ON to the current box and check that the Ballscrew
extends. If this test passes, continue with the next operations.

Building Assembly into Housing

The first operation is to build-up the Floating Piston Assembly. You will
need the following materials and tooling listed below.

Materials
• Dow Corning III (P/N 980000005)

Tools
• Vise Pin Blocks (P/N 703-500-142)
• Special Wrench (Modified DMWD) (P/N 20898)
• 2 Piston Tools (P/N 702-500-108)
• Locknut Tool (P/N 23059)

Assembly Procedure
1. Lubricate O-ring (18) with Dow Corning III and then install into
groove of Floating Piston (23).

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2. Lubricate a T-Seal (20) with Dow Corning III and install into
groove of Floating Piston (23).
3. Install two Back-up Rings (19), one on each side of the T-Seal
(20). Rotate both Back-up Rings 180 degrees. Once in place,
lubricate with Dow Corning III.
4. Lubricate a T-Seal (21) with Dow Corning III and install into
inner groove of Floating Piston (23).
5. Install two Back-up Rings (22), one on each side of T-Seal (21).
Rotate both Back-up Rings 180 degrees. Again, lubricate with
Dow Corning III.
6. Lubricate the Converter Stem outer diameter with Dow Corning
III.
7. Put a small amount of Dow Corning III into the inner diameter of
the Piston and Actuator Housing (assembled earlier).
8. Clamp the Piston and Actuator Housing into a Bench Vise and
use the Vise Pin Blocks.
9. Lubricate a O-ring (47) with Dow Corning III and slide it over
the (P101) Connector until it seats onto the Bulkhead Retainer
(44).
10. Before installing assembly into the Housing, ensure that the
Stepper Motor Wiring Harness is properly coiled inside the
Spacer.
11. Slide the built-up Assembly into the Actuator Housing (29), with
Converter Stem end positioned first. Push until the Assembly is
seated within the Housing.
12. Lubricate the Back-up Nut (50) with Dow Corning III and install
Nut into Actuator Housing (20). Use a Special Wrench
(Modified DMWD Tool) and slip Nut and Wrench over the
(P101) Connector. Tighten hand tight, then back off the Nut 1-
turn.

Note: When installing the Back-up Nut (50), ensure that the
wires are not twisting or pinching.

13. Install the previously built-up Floating Piston (23) into the Piston
Housing (25), other end from where the Back-up Nut was
installed. To install, thread two Piston Tools into the Floating
Piston (23).
14. Carefully install the Floating Piston into the Piston Housing (25),
while checking that the Piston slides freely back-and-forth.

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15. Go to the Actuator Housing (29) end and tighten the Back-up
Nut (50). Torque the Back-up Nut to 60 ft-lb using a Torque
Wrench and Locknut Tool.
16. Again, check that the Floating Piston (23) is free and without any
binds. Remove the Piston Tooling.
17. With the Actuator in a Bench Vise, install the Connector
Housing (51) into the Actuator Housing (29). Do this by sliding
the wiring assembly through the slot on the Housing. Make sure
Connector Housing (51) is flush with Locknut (50).
18. Install O-ring (58) over Connector Housing (51). Make sure O-
ring seats by pushing it back.
19. Place LEMO Connector (P101) into Connector Housing (51).
20. Install Connector Retainer (55) over LEMO Connector.
21. Screw the Tandem Adapter (52) to the Actuator Housing.

Note: Ensure that the Connector Housing does not turn with the
Tandem Adapter.

22. Align the Connector Housing (51) with the Tandem Adapter
Keyway, then install Keyway Retainer (54) into the Connector
Housing.
23. Torque the Tandem Adapter (52) to 225 f-lb.

Note: The Alignment Tool must be installed into the Keyway

before torquing.

The Actuator is now ready for Evacuation and Filling

operations.

Evacuation Procedure
In this procedure, the Actuator is evacuated of air and charged with oil.
1. Move the Actuator to the Evacuation/Fill Stand area.
2. Position Actuator upright, with Piston Housing on top, and
install the Stop Nut for the Floating Piston. Use the Special
Wrench to seat Nut.
3. Screw-in oil fill adaptor into the end of the Converter Stem (17).
4. Start the vacuum pump, set the vacuum system to evacuate for
15-20 minutes.

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5. Set the vacuum system to charge at 90 psi (40.8 kpsi). Allow to

charge for 10 minutes.

Note: The piston should move freely up-and-down upon

evacuation and charging. When evacuating, the piston
should retract and when charging, the piston will extend.

6. Switch to evacuate and evacuate for 15-20 minutes.

7. Repeat operations 5 and 6 at least twice or until no air bubbles
are visible in the oil line. If air bubbles are still present, then a
seal leak may have occurred. It will be necessary to once again
disassemble the unit and check all o-rings and seals.
8. After the last charge cycle, release the pressure, disconnect from
the vacuum system, and place assembly upright in a vise.
9. Remove the temporary Stop Nut, holding the Floating Piston.
10. Turn the Pulser Driver Test Box ON/OFF several times to ensure
the Converter Stem (17) has bottomed out.
11. Use the Floating Piston Depth Indicator set the piston depth (2.0-
inches +/- .010). Check this dimension with a Depth Micrometer.
12. Lubricate O-ring (16) and install the Oil Fill Plug (15) in end of
the Converter Stem (17).
13. The Actuator is now ready for the Hydrostatic Pressure Test.

Hydrostatic Pressure Test

This test pressurizes the Actuator to check for oil leaks and proper
operation.
1. Install the Hydrostatic Test Adaptor to the Actuator.
2. Connect the hose from the Enerpac to the Hydrostatic Test
Adaptor.
3. Hand pump the Enerpac until the Actuator is pressurized to 6,000
psi.
4. Connect the Pulser Driver Test Box to the Actuator (P101)
Connector.
5. Turn-on the Pulser Driver Test Box to allow the Converter Stem
to extend and retract. The amp meter should read according to
the range of the Test Box.
6. Allow operation to continue for 15 minutes.

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7. Check for oil leaks at the interface between the Piston Housing
and Actuator Housing. Also, check for leakage at the bottom in
the area of the Bulkhead Retainer/O-ring is located.

Note: If the hydrostatic pressure remains constant on the

pressure gauge, this an indication of a good fill.

8. After 15 minutes, turn OFF the Pulser Driver Test Box, release
the pressure, disconnect the hose, and remove the Hydrostatic
Test Adaptor.
9. Turn the Pulser Driver Test Box ON/OFF several times to
bottom out the Converter Stem.
10. Recheck the Floating Piston Height with a Depth Micrometer.
This should be 2.0-inches +/- .010. Piston depth should remain at
within specification. If the Floating Piston has moved,
disassemble and replace the defective part.

Building the Poppet Valve Assembly

The last Actuator assembly stage is building the Poppet Valve Assembly.
You will require the following materials and tools listed below before
starting this procedure.

Materials
• Dow Corning 111 Compound (P/N 980000005)
• Alco Metalube (P/N 714-500-001)

Tools
• Poppet Seal Housing Tool (P/N 24739)
• Valve Seat Holder Tool (P/N 702-500-123)
• Seal Cap Tool (P/N 702-500-112)
• Vise Pin Blocks (P/N 703-500-142)
• 7/16" Crowsfoot Wrench
• Dial Indicator
• Mitutoyo Depth Micrometer

Assembly Procedure
1. Lubricate O-ring (11) with Dow Corning 111 Compound and
install into Seal Cap (12).

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2. Lubricate O-ring (10) with Dow Corning 111 Compound and

install into Seal Cap (12).
3. Lubricate O-ring (6) with Dow Corning 111 Compound and
install onto Poppet Seal Housing (13).
4. Lubricate O-ring (6) with Dow Corning 111 Compound and
install onto Poppet Valve Seat Holder (2).
5. Lubricate two O-rings (8) and two O-rings (4) with Dow Corning
III Compound and install onto Poppet Valve Housing (7).
6. Install Screen (9) over Poppet Valve Housing (7) until it snaps in
place.
7. While using a small brush, coat the inner diameter of the Poppet
Valve Housing (7) with Alco Metalube.
8. Apply Alco Metalube to Seal Cap (12) and assemble to Poppet
Seal Housing (13).
9. Clamp Poppet Seal Housing Tool into a vise and position Poppet
Seal Housing (13). Take the Seal Cap Tool along with a Torque
Wrench and torque the Seal Cap (12) to 5 ft-lb.
10. Install Vise Pin Blocks into the vise. Install Poppet Valve
Housing (7) into vise and tighten.
11. Take the Poppet Seal Housing (13) and lubricate the outer and
inner diameters with Alco Metalube.
12. Install the Poppet Seal Housing (13) into the Poppet Valve
Housing (7).
13. With the Poppet Seal Housing Tool and a Torque Wrench, torque
the Poppet Seal Housing (13) to 10 ft-lb.
14. Install the Valve Seat Holder (2) into the Poppet Seal Housing
(13). Using a Valve Seat Holder Tool, tighten nut about halfway
down.

Note: The Valve Seat Holder (2) is used to adjust the Poppet
Valve Assembly.

15. Take the Valve Seat (5) and install a total of four O-rings (3).
Place two O-rings on each side.
16. Apply a light coating of Alco Metalube to O-rings (3).
17. Install the Valve Seat (5) into Poppet Seal Housing (13).
18. Apply Alco Metalube to the Valve Seat Locknut (1) and install
into Poppet Seal Housing (13).

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Note: The Valve Seat Locknut is installed hand tight at this

stage. It will be torqued later when the Poppet Valve is
adjusted.

19. Stand the Actuator Assembly upright (connector facing down) in

a Bench Vise and tighten the Vise handle.
20. Clean the external threads of the Converter Stem (17) and any
residual oil from the Actuator Housing.
21. Apply Loctite 242 to the Poppet Valve (14) threads and install
onto Converter Stem (17). Torque to 5 ft-lb with a Crowsfoot
Wrench and calibrated Dial Indicator.

Note: Ensure that the hole in the Converter Stem is drilled all
the way through.

22. Pack Alco Metalube inside the Piston Housing (25) and to the
bottom of the threads.
23. Lubricate the threads and O-ring on the Poppet Valve Housing
(7) with Alco Metalube.
24. Thread the Poppet Valve Housing (7) to the Piston Housing (25).
25. Reposition the Actuator Assembly into the vise in a horizontal
position. Install the Vise Pin Blocks and position the Actuator in
order to clamp on the Piston Housing.

Note: DO NOT clamp down on the Actuator Housing.

26. Torque the Poppet Valve Housing to 225 ft-lb by using an

Adaptor and calibrated Torque Wrench.

Setting the Poppet Valve Gap

27. Reposition the Actuator Assembly vertically in a Bench Vise.
Snug down on the Vise handle.
28. Plug in the Power Supply to the (P101) Connector. Let the
Poppet Valve (14) extend/retract for a few minutes to allow the
Alco Metalube to work around the Poppet Valve Housing.
To set the Poppet Valve (14), perform the following operations.
29. Turn the Power Supply ON and allow the Converter Stem to
bottom out. Do this 2 or 3 times.
30. Remove the Actuator Locknut (1).

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31. Place your finger over the Actuator Valve Seat (5), and apply
power to the Power Supply until you feel the Poppet Valve (14)
touching the Actuator Seat (5).
You are now ready to adjust the Valve Gap.
32. Tighten the Valve Seat Holder (2), with a Valve Seat Adaptor
and Ratchet Wrench, until it touches the Poppet Valve (14).
33. Reinstall the Actuator Locknut (1).
34. Adjust the valve gap to .128-.132-inches. To do this, insert a
Depth Micrometer into the Actuator Valve Seat (5).
35. Apply power to the Power Supply Box to allow the Converter
Stem to bottom out.

Note: You will hear a grinding noise, indicating that the

Converter Stem has bottomed out.

36. Turn the Depth Micrometer thimble down until it touches the top
of the Poppet Valve (14).
37. Turn the Power Supply Box power to ON. Allow the Converter
Stem to extend and take a measurement.
38. Readjust the gap as necessary to achieve a .128-.132" gap.
Recheck the gap again with the Depth Micrometer.

Note: If it is necessary to change the gap, turn in on the Valve

Seat Holder (2) to close the gap, or back off the Valve
Seat Holder to open the gap.

39. Reinstall the Actuator Locknut (1). Torque to 10 ft-lb using and
Adaptor and calibrated Torque Wrench.
40. Transfer the Actuator Assembly to the Test Weight Stand.

Test Weight Stand Test

The Test Weight Stand Test is used to break-in the Actuator Assembly
over a 24-hour period. The Actuator is powered-up and extends/retracts
against the resistance of weights. Lighter weights (10 lb) are first applied
and then increased with heavier weights (60 lb).
The required materials and tooling that you will need are as follows.

Materials
• None required.

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Tools
• Test Weight Stand (P/N 702-500-110)
• Weights (lb) (P/N 24759)
• Power Supply Test Box (P/N 702-500-163)

Test Weight Stand Procedure

Begin this procedure by performing the following operations.
1. Install the Actuator Assembly into the Weight Stand until it
bottoms, then back off 1 full turn.
2. Connect the Power Supply cable to the Actuator (P101)
connector.
3. Turn on power to the Power Supply Box.

Note: Initially, no weights are put onto the Test Weight Stand
bar. This is because the bar weighs 10 lb and this weight
is applied to the Actuator.

4. Apply weight (10-20 lb) to the Test Weight Stand, enough so the
Actuator does not stall. Once you have established the proper
break-in weight, allow this test to run for 24-hours. At the end of
the test, the Actuator should push 60 lb.
5. Repeat Electrical Resistance checks (Multimeter and Insulation
Tester) on the Actuator Assembly. Refer and repeat instructions
in the Electrical section on page 12.
6. Once the Actuator Assembly has passed the Test Weight Stand
Test and Electrical Resistance checks, it is now ready for Stores.
7. Attach all pertinent paperwork, such as sign-off sheets. This
concludes building and testing the Actuator Assembly.

Short Radius Actuator Disassembly Overview

The purpose for this procedure is to provide instructions for post field
testing and disassembling the NaviTrak Actuator. Furthermore, inspecting
parts and determining the cause of failure is diagnosed by using this
procedure. Results from tests and inspections are documented on post field
paperwork. All parts are inspected and checked against wear specifications.
Before starting any disassembly work on the NaviTrak Actuator Assembly,
acquire all the necessary tooling and paperwork.

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This procedure contains the following sections:

• Actuator tests
• Disassembly instructions

Actuator Tests
Before disassembly can begin, several tests are performed before the
Actuator is disassembled. These tests include an electrical test, a valve gap
check, a weight stand test, and a hydrostatic pressure test.

Electrical Test
You must perform an electrical resistance (ohm) check on the Actuator
Assembly first. Make sure you have acquired the necessary electrical
testing equipment. Try to determine if there is an electrical problem or
short. Electrical checks are done through the 6-pin (P101) connector.

Note: If the problem is confined to an electrical problem, then

the Actuator can be disassembled without performing the
Weight Stand Test.

Testing Equipment Required

• Digital Multimeter (Fluke Model 87 or equivalent)
• Insulation Tester (Simpson Model 401 or equivalent)
• 24 volt Current Box (P/N 702-500-163)

Test Procedure
Table 3 shows the electrical checks and reference (P101 connector) for
electrical testing and specifications.
Table 3: Electrical Resistance Checks (P101 Connector)

Electrical Resistance Pins 4 & 6 1.48–1.80 ohms

Check (using a Digital
Multimeter) Pins 3 & 5 1.48–1.80 ohms

Electrical Resistance Pin 6 to Case > 200 megohms

Check (using an Insulation
Tester) @ 500 VDC Pin 5 to Case > 200 megohms
Pins 5 & 6 > 200 megohms

1. Perform a Hi-Pot test with an Insulation Tester and compare your

results to those in Table 3.

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2. Perform an electrical resistance test with a Multimeter and

compare your results to those in Table 3.
3. Install the Actuator into a Bench Vise and remove the Main
Valve Assembly. The Main Valve can be removed with a Pipe
Wrench.

Valve Gap Check

4. Plug a 13-pin cable from the Power Supply Box to the 6-pin
(P101) Connector.

Note: When performing a valve gap check, the Converter Stem

must be bottomed out.

5. Let the Poppet Valve (14) retract/extend by turning the Power

Supply Box ON/OFF.
6. Check the valve gap between the Poppet Valve bottomed out and
the extended position. To do this, turn the Power Supply Box ON
to retract the Poppet Valve. Insert a Depth Micrometer into the
Actuator Valve Seat (5) and measure this distance. Turn the
Power Supply Box OFF to allow the Poppet Valve to extend.
While the Poppet Valve is extending, back off the depth
micrometer until the Poppet Valve has fully extended. This
measurement should be .128-.132-inches.
7. Record this measurement on the your paperwork.

Test Weight Stand Test

The Actuator Assembly is powered-up and extends/retracts against the
resistance of weights on the Test Weight Stand. Weights are applied to the
Weight Stand bar incrementally until reaching a total of 60 lb minimum.
To perform this test, you will need the following tools.

Tools
• Test Weight Stand (P/N 702-500-110)
• Weights (5 lb & 10 lb) (P/N 24759)
• Power Supply Test Box (P/N 702-500-163)
• Mitutoyo Depth Micrometer
• Adapter Wrench (P/N 703-500-335)
8. Install the Actuator Assembly to the Test Weight Stand until it
bottoms, then back off 1 full turn.

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9. Connect the Power Supply Cable to the Actuator 6-pin (P101)

connector.
10. Turn the power ON (Power Supply Box).
11. Apply two (10 lb) weights to the Test Weight Stand for a total of
30 lb starting weight.

Note: The Test Weight Stand bar weighs 10 lb.

12. Check that the Actuator can push the 30 lb weight.

13. Add another 10 lb weight. Check for Actuator extension.
14. Continue to add 5 lb increments until the total weight is 60 lb.
15. To pass this test, the Actuator should be able to push 60 lb
minimum.

Actuator Disassembly
Continue this procedure by disassembling the SR Actuator.
16. Locate the Pin Blocks into a Bench Vise and then clamp the
Actuator somewhere on the Piston Housing (25). It is not
necessary to over-tighten the vise.

Note: DO NOT clamp on the Actuator Housing since this will

break out the Piston Housing.

17. With the Adaptor Wrench, locate the pin block hole in the Poppet
Valve Housing (7). Break-out the Poppet Valve Housing from
the Piston Housing (25).
18. Clean out the Charging Stem and Poppet Valve Housing of all
Alco Metalube before cleaning in the solvent tank. Use the
solvent tank to remove any residual lubricant. Investigate
Charging Stem area for any problems causing failure.
19. Remove the Poppet Valve (14) from the Converter Stem (17). An
Adjustable Wrench can be used to remove the Poppet Valve and
another wrench is used to hold the Converter Stem.
20. Change the Actuator from a horizontal position to a vertical
position in the bench vise. Secure the Actuator in the bench vise.
21. Next, you must check the depth of the Floating Piston.
Reconnect the (P101) Connector Cable to the Actuator. Make
sure the Converter Stem is bottomed out by activating the Power
Supply Box. The depth of the Floating Piston should be 2.0-
inches +/- .010.

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NaviTrak Actuator SR Assembly and Disassembly NaviTrak Short Radius

22. Fill the Piston Housing (25), to the bottom thread, with Actuator
oil. Insert the Depth Micrometer and then activate the Power
Supply Box to check if the Floating Piston moves down whereas
the Converter Stem will move up. The movement should be
1.900"- 2.100".

Hydrostatic Pressure Test

Continue this disassembly procedure by performing a Hydrostatic Pressure
Test. To perform this test, you will need the following tools:

Tools
• Hydrostatic Test Adaptor (P/N 702-500-115)
• Enerpac (P/N 790-500-072)
• Pulser Driver Test Box (P/N 702-500-163)
• Mitutoyo Depth Micrometer
• 2" Parmelee Wrench (P/N 707-500-031)
23. Install the Hydrostatic Test Adaptor to the Actuator.
24. Connect the hose from the Enerpac to the Hydrostatic Test
Adaptor.
25. Hand pump the Enerpac until the Actuator is pressurized to 6,000
psi.
26. Ensure the (P101) Connector Cable is connected.
27. Turn on the Pulser Driver Test Box to allow the Converter Stem
to extend and retract.
28. Allow this operation to continue for 15 minutes.
29. Check for oil leaks at the interface between the Piston Housing
and Actuator Housing. Also, you must check for leakage at the
bottom area at the Bulkhead Retainer.
30. After 15 minutes, turn OFF the Pulser Driver Test Box, release
the pressure, disconnect the hose, and remove the Hydrostatic
Test Adaptor.
31. Make sure that the Converter Stem is bottomed out and then
recheck the Floating Piston depth with a Depth Micrometer.
Document your results.
32. Carefully remove the Oil Fill Plug (15) from the Converter Stem
(17) and check for any entrapped gas or moisture in the oil.

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NaviTrak Short Radius NaviTrak Actuator SR Assembly and Disassembly

Note: The Oil Fill Plug is only removed for Level 2

maintenance.

33. Pour out the excess oil from the Actuator into an approved
container.
34. Clamp the Actuator into the vise (horizontal position) for
removing the Floating Piston (23).
35. Remove the Floating Piston by using two Threaded Rods. Allow
the oil to drain and record the oil condition on paperwork.
36. Remove the Lower Keyway Retainer (54) Lockring.
37. Carefully unscrew the Connector Adaptor Housing using a Pin
Wrench or 2" Parmelee Wrench. A Breaker Bar may be
necessary to break the torque.

Note: Ensure that the Actuator Housing Connector does not

move inside the Connector Adaptor Housing, to avoid
damage to the wiring.

38. Remove the Retainer (55) with Needle Nose Pliers with Stopper
(P/N 703-500-622).
39. Remove the LEMO and wiring harness through the slot on the
Actuator Housing Connector.
40. Remove the rear Back-up Nut (50) using the Special Adaptor.
Maintain tension on the connector assembly when removing the
Back-up Nut.
41. Remove the Bearing Housing (35), Transmission Shaft (36), and
Stepper Motor (40) parts from the Piston and Actuator Housing.
You may have to carefully tap the assembly for removal.
42. Allow the oil to drain into an oil container.
43. Clean the Piston and Actuator Housing with solvent and check
the inner diameter for any evidence of pitting or other problems.

Stepper Motor and Associated Parts

Continue the disassembly procedure by removing the Stepper Motor and
Associated Parts. Obtain the following tools:

Tools
• Spanner Wrench (P/N 707-500-013)
• Modified Punch

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NaviTrak Actuator SR Assembly and Disassembly NaviTrak Short Radius

• Valve Seat Adaptor Wrench (P/N 24739)

• Vise Pin Blocks (P/N 703-500-142)
44. Repeat the earlier Hi-Pot and Continuity test on the Stepper
Motor and Associated parts.
45. With your hands, disassemble the Stepper Motor (40) from the
Bearing Housing (35).
46. While using two Spanner Wrenches, break-out the Bearing
Housing (38) from the Poppet Valve Bushing (27).
47. At this point, check the Actuator Ballscrew (27) for free
movement, noting any binding or defects.
48. Remove four Cap Screws (31) from the Converter Stem (17),
using a Hex Head Driver.
49. Insert the Modified Punch into the Actuator Ballscrew (27) and
lock the Modified Punch into a Bench Vise. With Vise Grips,
remove the Transmission Shaft (39).
50. Separate the Bearing Housing (38), Actuator Ballscrew (27),
Transmission Shaft (36), Thrust Washers (33), and Thrust
Bearings (34).
51. Remove four Screws (38) from the Thread Adaptor (37) using a
Hex Head Socket. Separate the Thread Adaptor from the Stepper
Motor.
52. Check the Stepper Motor shaft for movement. This shaft should
turn freely.
53. With a Punch, slightly tap the Bulkhead Retainer (44) and
remove it from the Bulkhead Connector (45).
54. Install the Vise Pin Blocks into the vise. Install the Poppet Valve
Housing (7) upright and then tighten the Bench Vise.
55. With the Valve Seat Adaptor Wrench, remove the Valve Seat
Locknut (1).
56. Remove the Valve Seat (5) from the Poppet Seal Housing (13).
57. Remove the Valve Seat Holder (2) with the Valve Seat Adaptor
Wrench.

Note: Use care when removing the Valve Seat Holder. It is

possible to damage the ceramic seat.

58. Reverse the Poppet Valve Housing (7) in the Bench Vise.

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NaviTrak Short Radius NaviTrak Actuator SR Assembly and Disassembly

59. Remove the Poppet Seal Housing (13) using the Valve Seat
Adaptor Wrench.
60. Remove the Seal Cap (12) from the Poppet Valve Seal Housing
(13).
61. Reposition the Poppet Valve Housing (7) horizontally in the
Bench Vise.
62. Use a Punch and Hammer to remove the Screen (9) from the
Poppet Valve Housing (7).
63. All parts are now ready for cleaning. Cleaning includes using
solvent and bead blasting some parts.
64. Perform a visual inspection of all parts for wear. Check wear
limits according to specifications in Table 4. Record your
findings on post field or historical paperwork.

Table 4: NaviTrak Inspection Wear Limits

Part Name Wear Limit
Orientation Block Visual
Wear Sleeve 1.970"
Main Valve Stem 0.491"
Main Valve Base 1.490"
Bypass Housing ID 1.504"
Bypass Housing OD 1.910"
Bypass Housing Seat Visual
Fishing Head ID 0.510"
Inlet Ports 0.300"
Inlet Screen Visual
Deflector Housing Visual
Poppet Valve Seat Visual
Poppet Valve Stem 0.425"
Poppet Valve Screen 0.090"
Floating Piston ID 0.629"
Floating Piston OD 1.431"

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NaviTrak Actuator SR Assembly and Disassembly NaviTrak Short Radius

Table 4: NaviTrak Inspection Wear Limits

Converter Stem 0.620"

Piston Housing ID 1.439"
Transfer Housing ID 1.518"
Motor Housing Visual
Stepper Motor Power Hours
Stepper Motor hi-temp/hi-torque Power Hours
Lead Screw Power Hours
Lead Screw hi-temp/hi-torque Power Hours
Bearing Assembly Power Hours
Connector Power Hours
Connector Pins Power Hours
Bulkhead N/A

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Confidential P/N 750-500-029 Rev. A / November 1994
 Chapter 3

Pulser Driver Module

This chapter contains step-by-step instructions for

assembly, disassembly, and testing the NaviTrak Short
Radius Pulser Driver Module (PDM).

Pulser Driver Overview

The Pulser Driver Module (PDM) is the interface between the Pulser
Module and the Directional Attitude Sensor (DAS). The Pulser Driver
Module receives pulses from the DAS and then powers the Actuator to
open and close the poppet valve with these pulses. The Short Radius PDM
also has a Dual Battery Controller which switches Batteries when one
Battery Pack becomes depleted to achieve longer life from the batteries.
Following are shop procedures for the Pulser Driver Module (PDM).

Pulser Driver Module Assembly

This procedure has step-by-step assembly instructions for the Pulser Driver
Module. Where applicable, parts are identified by a name and followed by
an item number (in brackets), which corresponds to the reference drawing.
You will need to acquire the reference drawing, materials, and tooling
prior to assembly.
To start this procedure, you will need to gather the following materials and
tools:

Reference Drawing
• Pulser Driver (Dwg. No. 702-500-242), (Dwg. No. 702-500-241), and
also (Dwg. No. 702-500-243)

Materials
• Magnalube-G (P/N 29265)

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Pulser Driver Module NaviTrak Short Radius

Tools
• 1-3/4" Parmelee (P/N 702-500-03), 2 required

Assembly Procedure
1. Place the Barrel Housing (P/N 703-500-587) in a Bench Vise.
2. Thoroughly clean the ID of the Barrel Housing.
3. Apply a small coating of Magnalube-G to the O-rings and the
Shock Mount.
4. Install the PDM Module (2) into the Barrel Housing.

Note: Be careful to not damage the O-rings.

5. With your hand, start screwing the Tandem (1) into the Barrel
Housing.

Note: Be sure that the end LEMO turns in the same direction as
your turning, or damage may occur to the wiring.

6. When you can no longer turn the tandem, align the Connector
Housing (3) to the Barrel Housing Key (P/N 703-500-587).
7. Place the Snap Ring (P/N 703-500-606) in place.
8. Using two 1-3/4" Parmelees: one on the Tandem, and the other
on Barrel Housing, torque both together to 150 ft-lb.
9. Install Protective Endcaps (P/N 703-500-696 female, P/N 703-
500-697 male) onto both ends.

Pulser Driver Module Disassembly

Below is the disassembly procedure for taking the Pulser Driver Module
apart. Be sure you obtain all materials and tooling required for
disassembly.

Materials
• None required

Tools
• 1-3/4" Parmelee (P/N 707-500-031), 2 required
• Snap Ring Pliers, PR-21A Blue Point

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NaviTrak Short Radius Pulser Driver Module

• Locknut Wrench (P/N 23059)

PDM Procedure
1. Remove the Snap Ring (P/N 703-500-606) from the end of the
PDM Housing (P/N 703-500-587); i.e., the LEMO Connector
End with Snap Ring Pliers.
2. Place the Pulser Driver Module (2) in a Bench Vise and use two
1-3/4" Parmelees: place one on the Barrel Housing (P/N 703-
500-587) and the other on the Tandem (1).
3. Untorque the Tandem (1).

Note: Make sure that the LEMO end turns in the same
direction as the Tandem while it is turning all the way out
of the housing or damage may occur to the wiring.

4. The PDM Module (2) can now be pulled out.

5. Check and inspect the O-rings, and replace if necessary.
6. Check the Tandem Shock Mount for cracks or worn condition.
7. Check the Beryllium Copper 250-28 Screws (12) to make sure
they are tight.
8. Remove Retaining Sleeve Locknut (3) with the Locknut Wrench.
9. Remove the Retaining Sleeve (2).
10. Replace the O-rings (15).
11. Apply Loctite 242 to Retaining Sleeve Lock Nut (3) and torque
to 50 ft-lb using the Locknut Wrench.
12. Check that there is free play in the Sleeve (2). It should turn with
the Parmelee Wrench attached.
Continue to the Pulser Driver Module Testing. See Drawing No.
702-500-243.

Pulser Driver Module Testing

This is a temporary procedure which will be updated when the required
Test Hardware is completed. You will need the following tools to perform
the Pulser Driver Module test.

Tools
• Dual 30 volt Power Supply (2 Amp)

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Pulser Driver Module NaviTrak Short Radius

• Function Generator
• 2 Digital Multimeters (Fluke 87 or equivalent)
• Actuator Weight Stand (P/N 702-500-110)
• 100 ohm, 25 watt load (P/N 65647-001)
• LEMO Test Cable (P/N 703-500-602, 702-500-323)
Reference Figure 3-1, “PDM Test Setup” for an overall testing setup.

VB1

VB2

Figure 3-1. PDM Test Setup. This electrical diagram illustrates the hardware setup and electrical
connections for testing the Pulser Driver Module.

13. On the Digital Volt Meter set A to read DC voltage and set B to
read current on the 2 Amp range.

Note: On the Fluke 87 meter set the range to 100 msec.

14. Set the Function Generator to .5 Hz, square wave and 0 to 5 Vp-p.
15. Leave the 100 ohm resistor off of the Ve line and power up the
PDM.
16. Set VB1 to 30 volts and VB2 to 28 volts.

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NaviTrak Short Radius Pulser Driver Module

17. The PDM will Self-Test for nine pulses. Make sure the first pulse
is in the down position.
18. After the Self-Test, the Pulser Driver Module will pulse
normally. Monitor the current on the B setting on the DMM. It
should read between 20 mA +/- 3mA.
19. Power-down (Install Load), then Power-up. Verify operations 16
and 17.
The 20 mA current should be seen only between pulses before
Ve equals VB1.

Note: Adjust the frequency to adjust the pulsing speed.

20. Monitor the pulsing current. It should be 775mA +/- 50mA.

21. Lower the voltage of B1 to 18 volts to represent a depleted
battery. The PDM will then pulse for 255 pulses, then the PDM
will begin a test pattern of 13 transitions followed by 2
transitions every minute until the flow line is grounded again.

Monitor DMM Setting “A”

Note: Ensure that the batteries have switched and that the
pulsing continues at the frequency rate once flow is
grounded through a 1k Ohm, 1/4 Watt resistor (P/N
300472).

22. Ground the Test line (line 3) through a 1 k Ohm, 1/4 Watt
resistor. The system should stop pulsing for 10 seconds then go
into a reset pattern as long as the 1k Ohm resistor is grounded.
23. Remove the 1k Ohm resistor.
24. Ensure pulsing occurs according to frequency rate.
25. Turn OFF Power.

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Pulser Driver Module NaviTrak Short Radius

3-6 Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994
 Chapter 4

Lithium Batteries

This chapter contains step-by-step instructions for assembly

and disassembly of the NaviTrak Short Radius Lithium
Batteries.

Battery Overview
The NaviTrak Short Radius tool uses Lithium Batteries as a principle
downhole power source. The Short Radius tool uses a split battery design.
In a vertical toolstring, the Battery Module, with Tandems at both ends,
will be positioned below the Pulser Driver Module and above the
Directional Attitude Sensor.
Before working with Lithium Batteries, you must satisfy Baker Hughes
INTEQ handling and safety requirements.

WARNING!
Lithium Batteries present a potential
hazard. Do not handle the battery assembly
unless you have received proper training.
Before working with these batteries, you
must have completed Lithium Battery
Safety Training, also read and review all
sections on Lithium Batteries in the Baker
Hughes Health, Safety, and Environment
Manual.

Following are shop procedures for Lithium Batteries.

Battery Assembly
This procedure has step-by-step assembly instructions for the Battery
Assembly. Where applicable, parts are identified by a name and followed

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Lithium Batteries NaviTrak Short Radius

by an item number (in brackets), which corresponds to the reference

drawing. You will need to acquire the reference drawing, materials, and
tooling prior to assembly.
To start this procedure, you will need to gather the following materials and
tools:

Reference Drawings
• Lithium Battery (Dwg. No. 702-500-245, 702-500-246, 702-500-247)

Materials
• Loctite 242 (P/N 27953)
• Dow Corning 3145 RTV (P/N 85940)
• Magnalube-G (P/N 29265)

Tools
• Snap Ring Pliers PR-21A, Blue Point
• 1-3/4" Parmelee (P/N 707-500-08), 2 required

Assembly Procedure
You should always inspect the Rubber Shock Mounts and Battery Cable
Harness for cracks, cuts, etc. Refer to either Dwg. No. 702-500-245, 702-
500-246, or 702-500-247.
1. Lay a new Battery Pack (2) on your bench.
2. Clean up the Barrel Housing (2).
3. Take the Battery Harness (26) end and insert it into the positive
insert.

Note: Make sure the Battery Cable Harness is below the top of
the Battery Pack Channel. The end caps (positive and
negative) may have to be hand filed down. Doing this will
make insertion easier.

4. Line up the 9/64" screws (3) to holes and apply Loctite 242 and
install. Torque these screws to 20 in-lb.

Note: Do not exceed the torque on the screws.

5. Apply Loctite 242 to two 3/16" Allen Head Screws and install
into the shock mount tandem end. Torque Screws to 30 in-lb.

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NaviTrak Short Radius Lithium Batteries

6. Apply Dow Corning 3145 RTV to the entire channel of the

Battery Pack Cable Harness.

Note: Make sure no excess Dow Corning 3145 RTV is on the

OD of the Battery Pack or the Battery Cable Harness.

7. Install the LEMO end to a negative.

8. Apply Loctite 242 to four 9/64" Allen Head Screws (4) and
install to Battery Pack (4) holes. Torque Screws to 20 in-lb.

Note: Do not over-tighten the Screws. Torque for the 9/64"

Allen Head Screws should NOT exceed 20 in-lb.

9. Apply Loctite 242 to two 3/16" Allen Head Screws (2) and install
into the Shock Mount. Torque these Screws to 30 in-lb.

Note: Do not over-tighten the screws. Torque for the 3/16"

Allen Head Screws should NOT exceed 30 in-lb.

Note: Press the Battery Harness down onto the Battery Pack
Channel.

10. Place masking tape one inch apart over the Harness onto the
Battery Pack (2), and then let dry for 1 hour.
11. Remove the masking tape and apply Magnalube-G to O-rings
(21), and Shock Mounts (7).
12. Being careful not to damage the Wiring Harness (26), push in the
entire Tandem and Battery Pack into the Barrel Housing (2).
13. With your hand, install the Tandem (1) into the Housing (2).

Note: Make sure the LEMO ends turn in the same direction as
the Tandem or damage to the wiring will occur.

14. When you can no longer turn the Tandem by hand, align the
Connector Housing (3) to the Barrel Housing Key (3).
15. While using the Snap Ring Pliers, place the Snap Ring (3) into
the Barrel (2). Always make sure the LEMO connector is
perfectly aligned to the key way on the Barrel Housing (2) before
and after the Snap Ring (3) is installed.
16. Using two 1-3/4" Parmelee Wrenches: one on the Tandem (1),
and one on the Housing (2), torque to 150 ft-lb.
17. Install Protective Endcaps (6, 7) onto both ends.

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Lithium Batteries NaviTrak Short Radius

Battery Disassembly
This procedure discusses disassembling the NaviTrak Short Radius Battery
module. Be sure you have acquired the following drawings and tools prior
to starting.

Reference Drawings
• Lithium Battery (Dwg. No. 702-500-245, 702-500-246, 702-500-247)

Tools
• Snap Ring Pliers PR 21A, Blue Point
• 1-3/4" Parmelee Wrench (P/N 707-500-03), 2 required
• 3/16" Allen Head Wrench
• Torque Wrench (P/N 790-500-080)

Disassembly Procedure
Always inspect the Rubber Shock Mounts and Battery Cable Harness for
cracks, cuts, etc.

Module Removal
1. Place the Battery Pack Housing in a Bench Vise.
2. With Snap Ring Pliers, remove the Snap Ring (3) from the
LEMO connector end of the Barrel Housing (2).
3. Put one 1-3/4" Parmelee Wrench on the Tandem (1) and the
other 1-3/4" Parmelee Wrench on the Barrel Housing (2).
4. Untorque the Tandem (1) from the Housing.

Note: Make sure that as you untorque the Tandem that the
LEMO ends are turning in the same direction as the
Tandem or damage may occur to the wiring.

5. The Module can now be pulled out.

Battery Harness Removal

1. Place the Battery Pack (2) on your bench.
2. Remove the four Allen Head Screws (3, 4) using a 3/16" Allen
Head Wrench (be careful not to damage any wiring). There are
two Screws at each end of the housing, located on the Shock
Mount.

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NaviTrak Short Radius Lithium Batteries

3. Remove eight 9/64" Allen Head Screws (12) using a 9/64" Allen
Head Wrench. You may want to pull the Shock Mounts out
slightly to better expose the 9/64" Allen head Screws.

Note: When pulling the Shock Mount away from the ends of the
Battery Pack, do not pull them more than 1 inch. and
always be careful not to damage the wiring.

4. Remove the Battery Harness.

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Lithium Batteries NaviTrak Short Radius

4-6 Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994
 Chapter 5

DAS Servicing

This chapter covers step-by-step instructions for assembly,

disassembly, and testing the NaviTrak Short Radius
Directional Attitude Sensor (DAS).

DAS Overview
The Directional Attitude Sensor (DAS) is a highly complex and
sophisticated electronic assembly used in the NaviTrak tool. The DAS is
used to provide the attitude or direction of the drillstring in the wellbore. It
acquires downhole information as a raw data format. This raw data
originates from the six directional sensors: three accelerometers, three
magnetometers, and one temperature sensor. The raw data is processed by
the electronics section, encoded to a transmission format, and sent to the
Pulser Driver Module.
Following are shop procedures for the Directional Attitude Sensor.

DAS Assembly
This procedure covers assembly instructions for the DAS. Where
applicable, parts are identified by a name and followed by an item number
(in brackets), which corresponds to the reference drawing. You will need
to acquire the reference drawing, materials, and tooling prior to assembly.
To start this procedure, you will need to gather the following materials and
tools:

Reference Drawing
• DAS (Dwg. No. 702-500-250, 702-500-251, and 702-500-252)

Materials
• Magnalube (P/N 29265)

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DAS Servicing NaviTrak Short Radius

Tools
• 1-3/4" Parmelee Wrench (P/N 707-500-031), 2 required

Assembly Procedure
Start this procedure by assembling the Micro Processor Unit.

Micro Processor Unit (MPU)

1. Place Micro Processor Unit Housing (1) into a Bench Vise.
2. Take the MPU Module (2) and apply a small coating of
Magnalube- G to the O-rings (8) and Shock Mount (3).

Note: Always use new O-rings. And always inspect prior to

assembly.

3. Being careful not to damage the O-rings or components, push the

MPU Module (2) into the Housing (1).
4. Begin to screw the Tandem (2) into the Module (1, 3) by hand.

Note: Make sure that as you are turning the Tandem that the
end LEMO turns with the module in the same direction
you are turning or damage to the wiring may occur.

5. When you can no longer turn the Tandem (2) by hand, align the
Connector Housing (1, 5) to the Barrel Housing Key (4).
6. Place the Snap Ring (4) in place.
7. Using two 1-3/4" Parmelee Wrenches: place one on the Tandem
(2) and the other on the Housing (1). Torque to 150 ft-lb.

Sensor Module
8. Place the Sensor Module Housing (3) in a Bench Vise.
9. Take the Module (4) and apply a small coating of Magnalube- G
to the O-rings (8) and the Shock Mount (3).
10. Being careful not to damage the O-rings (1) or components, push
the MPU Module (2) into the Housing (3).
11. Begin to screw the Tandem (2) into the Module (4) by hand.

Note: Make sure that as you are turning the Tandem that the
end LEMO turns with the module in the same direction
you are turning or damage to the wiring may occur.

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NaviTrak Short Radius DAS Servicing

12. When you can no longer turn the Tandem by hand, align the
Connector Housing (5) to the Barrel Housing Key (3).
13. Place the Snap Ring (4) in place.
14. Using two 1-3/4" Parmelee Wrenches: place one on the Tandem
(2) and the other on the Housing (3). Torque to 150 ft-lb.
15. Install Protective Endcaps (12, 7) on both ends.

DAS Disassembly
This procedure discusses disassembling the DAS. Acquire the following
tools before disassembly.

Tools
• Snap Ring Pliers PR 21A, Blue Point
• 1-3/4" Parmelee Wrench (P/N 707-500-031), 2 required

Disassembly Procedure
1. Place the Micro Processor Unit (2) into a Bench Vise.
2. With the Snap Ring Pliers, remove the Snap Ring (4) on the
MPU Housing end.
3. From the LEMO end of the Housing (1), use one 1-3/4"
Parmelee Wrench on the middle of the DAS Tandem and one 1-
3/4" Parmelee Wrench on the MPU Housing (1), untorque the
Tandem Module (2).
4. Unscrew the Tandem (2).

Note: Make sure that as you are turning the tandem that the end
LEMO turns with the module in the same direction you
are turning or damage to the wiring may occur.

5. Pull the MPU Module (2) out of the Housing (1).

6. Take the Barrel (1) out of the Bench Vise and put it aside.
7. Turn the Sensor Housing (3) around and put it into a Bench Vise.
8. Using the Snap Ring Pliers, remove the Snap Ring (4) from the
end of the LEMO end of the Sensor Module Housing (3).
9. With two 1-3/4" Parmelee Wrench; place one on the Tandem
(2) and the other on the Sensor Housing (3) and untorque the
Tandem Module (2).

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Note: Make sure that as you are turning the tandem that the end
LEMO turns with the module in the same direction you
are turning or damage to the wiring may occur.

10. Pull the Sensor Module (4) out of the Housing (3) being careful
not to damage module components.

DAS Testing
There are four DAS procedures that are outlined below. These procedures
are as follows:
• Sensor Test
• Programming the DAS
• Manually Entered Commands
• DAS General Function Test
You will need the following documentation and materials to perform the
DAS procedures.

Reference Documentation
• Calibration Document (P/N 708-500-081)
• NaviTrak 2.03 User’s Manual

Materials
• Surface Interface Box (SIB) (P/N 108610-01-01)
• NaviTrak 2.03 Software
• Personnel Computer with RS-232 port
• Mud Box (P/N 702-500-178)
• Interface Language Specification (ILS manual) (refer to this
document when using the direct command mode)
• Adapter Cable (P/N 702-500-323)

Note: Use the NaviTrak 2.03 User’s Manual as a reference

when performing tests with NaviTrak software 2.03.

Testing Procedure
Refer to Figure 5-1 for the setup required for running the DAS tests.

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NaviTrak Short Radius DAS Servicing

Figure 5-1. DAS

Test Setup. The
DAS Module is
connected to the
SIB and the
computer for
verifying
communications.

Sensor Test
In this test, you will check three readings from the DAS: a change in
inclination, a change in Toolface, and reasonable raw directional values.
1. Turn the power ON to the SIB, DAS, Mud Box, and your
computer.
2. Check to make sure that the Mud Box is setup as follows:
• Power- SIB
• Flow- OFF
• Pumps- OFF
• Load- OFF
• Meter Switch- VBS Current (verify current is about 13 mA)
3. Execute “NaviTrak” Software: use “NaviTrak C” for color

Note: Press <Esc> to return to the Main Menu.

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4. In the Main Menu, highlight “Reset DAS/SIB” by using the

<ARROW> keys. Verify that the configuration settings are
correct.
5. In the Main Menu, highlight “Diagnostics Menu” and then
[ENTER].
6. Select “DAS Sensor Test” from the “Diagnostics Menu”.
7. Execute the “DAS Sensor Test” and observe the amp window of
the Mud Box to ensure the current is 100-120 mA when taking a
survey.
8. Place DAS in the Calibration Stand at 70 degrees Inclination
Angle.
9. Starting at 0 degrees Toolface, rotate the Toolface at 45 degrees
increments and record data at each position through full rotation.

Note: Give the DAS a few seconds to settle between each

survey. Refer to Calibration Document 708-500-081 to
ensure specifications.

Programming the DAS

This test programs the DAS. Follow the procedures below.
1. Turn the power ON to the SIB, DAS, Mud Box, and your
computer.
2. Check to make sure that the Mud Box is setup as follows:
• Power- SIB
• Flow- OFF
• Pumps- OFF
• Load- OFF
• Meter Switch- VBS Current (verify current is about 13 mA)
3. Execute the NaviTrak 2.03 software and from the Main Menu
select “Initialize SIB/Tool”.
4. Enter in a preferred SIB/Tool settings with the <ARROW>
keys.
5. Press [F10] when you want to program the SIB/DAS.

Manually Entered Commands (TALK)

NaviTrak software has a TALK program which allows the user to send or
receive commands from a SIB or DAS. The procedure is as follows:

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1. Execute the “TALK” program.

2. Select the desired setting of the first four option screens.
3. Enter “1” for Dialog: TALK.
4. Enter “8” for SIB or “1” for DAS.
5. Refer to the ILS document for proper usage of the DV-485
commands and enter command.

DAS General Function Test

This test uses NaviTrak software to perform a pulse test.
1. Turn the power ON to the SIB, DAS, Mud Box, and the
computer.
2. Check to ensure that the Mud Box has the following settings:
• Power- SIB
• Flow- OFF
• Pumps- ON
• Load- OFF
• Meter Switch- VBS Current
3. Execute the “NaviTrak” Software.
4. Program the DAS. See section on DAS programming.
5. Press [F4] for on-line, then [F2] for Survey.
6. Toggle the Mud Box’s Flow switch to the ON position.
7. Verify that after 30 seconds the Flow LED on the Mud Box turns
ON.
8. The Mud Box’s pulse light should repeatedly blink ON and OFF
signifying pulsing sometime after flow is on, depending on the
synchronization settings you selected.
9. On your computer monitor, verify that the DAS is functioning by
watching values update on your screen.

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 Chapter 6

Tandems/Bow Springs

This chapter contains step-by-step maintenance instructions

for the NaviTrak Short Radius Tandems and Bow Springs.

Tandem Overview
Each assembly in the NaviTrak Short Radius toolstring is connected by a
bow spring Tandem which is different than the earlier 2" NaviTrak design.
The tandems are wired for data bus continuity and are wired pin-for-pin. A
tandem is always installed with the male connector to the uphole end.

Note: The upper Tandem is not interchangeable with other

Tandems in the toolstring.

Following are shop procedures for the Tandem.

Tandem Maintenance
This procedure has step-by-step maintenance instructions for the Short
Radius Tandems. Where applicable, parts are identified by a name and
followed by an item number (in brackets), which corresponds to the
reference drawing. You will need to acquire the reference drawing,
materials, and tooling prior to performing maintenance on the Tandems.
To start this procedure, you will need to gather the following items:

Reference Drawing
• Short Radius Tandems (Dwg. No. 702-500-241, 702-500-243, 702-
500-246, 702-500-249, and 702-500-256)

Tools
• Digital Multimeter (Fluke 87 or equivalent)

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Maintenance Procedure
Check Tandems by performing the following procedure.
1. Replace all O-rings (P/N 728-500-028) and Back-up Rings (P/N
703-500-605) 1.531" bore after every run.

Note: O-rings must be replaced after every run.

2. Inspect and check the condition of the O-ring glands.

3. Use a Digital Multimeter to perform an electrical check between
each pin and to the housing.

Note: Refer to the appropriate drawing for tandem wiring.

4. Inspect the condition of the Tandem for erosion cracks, being

straight, etc.
5. Inspect the condition of the LEMO Connector for bent pins,
cracks, and being straight, etc.

Assembly Procedure
To assemble the Module to a Tandem, use this procedure. Acquire the
drawing and tooling prior to starting.

Reference Drawing
• Tandem (Dwg. No. 702-500-243)

Tools
• 9/64" Allen Ball Driver
• 9/64" Allen Head Wrench
1. Apply Loctite 242 to four Screws (P/N 725-500-325) to be
installed into the Module Chassis (Adaptor End).
2. Carefully mate the Tandem to Module while aligning the MDM
Connector (female-to-male).
3. Install Screws and torque to 30 in-lb with 9/64" Allen Ball Head
Driver.
4. Apply Dow Corning 3145 RTV to Screws and in between
Adaptor slot holes.

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NaviTrak Short Radius Tandems/Bow Springs

Disassembly Procedure
To disassemble the Tandem from a Module, use this procedure. Acquire
the drawing and tooling prior to starting.

Reference Drawing
Tandem (Dwg. No. 702-500-243)

Tools
• 9/64" Allen Ball Driver
• 9/64" Allen Head Wrench
1. Pick out all Dow Corning 3145 RTV from the Adaptor slots, in
order to remove the Screws.
2. Remove four Screws (P/N 725-500-325), using 9/64" Allen Ball
Driver.
3. Separate the Tandem from the Module.

Disassembly Procedure (Upper DAS Tandem)

This procedure is a disassembly for the Upper DAS Tandem only. Acquire
the drawing and tooling prior to starting.

Reference Drawing
Upper Tandem (Dwg. No 702-500-249)

Tools
• Extractor Nut Tool (P/N 707-500-037)
• Retainer Ring Extractor Tool (P/N 703-500-622)
1. Remove Sleeves (2) by using the Extractor Nut Tool. Install
Extractor Nut Tool into Sleeve and unscrew left hand Locknut
(3).
2. Repeat for the other end.
3. Pull off Sleeves.
4. Remove O-rings (7) and Back-up Rings (6).

Note: The Tandem and Tandem glands can be inspected for

erosion, cracks, cuts, and being straight.

5. Remove Retainer Ring (4) using the Retainer Ring Extractor

Tool.

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6. Repeat for the other end.

7. Perform a continuity and Hi-Pot test as per Troubleshooting
section.
8. LEMO Connectors (J101, J102) can be pulled from the Tandem
and the wires can be cut and removed.

Note: If the Tandem wires are cut, then refer to drawing 702-
500-249 and the parts list for wiring assembly.

Troubleshooting (All Tandems)

This short procedure is used to troubleshoot the Upper DAS Tandem.
Acquire drawing and tools prior to starting.

Reference Drawing
• Upper DAS Tandem (Dwg. No. 702-500-249)
• Use (Dwg. No. 705-500-008) as a reference

Tools
• Digital Multimeter (Fluke 87 or equivalent)
• Insulation Tester (Simpson Model 401 or equivalent)
Following is the procedure.
1. Use the Multimeter to perform an electrical check between each
pin and the Tandem Housing. All should read greater than 100
megohms.
2. Use the Multimeter to perform a continuity check from end-to-
end, pin-to-pin, all pins should read 0 Ohms.
3. Use an Insulation Tester and perform a Megohm check for each
pin-to-case. The 100 Megohm scale should read open (no
continuity).
Bow Spring Overview
Bow Springs are used to centralize the modules within the drill collar.
These are wear parts and require a thorough inspection. When necessary
they may be replaced.

Inspection
Before inspecting the Bow Springs, acquire the necessary reference
drawings and equipment.

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NaviTrak Short Radius Tandems/Bow Springs

Reference Drawing
• Bow Spring (Dwg. No. 703-500-725, 703-500-726, and 703-500-727)

Tools
• Vernier Caliper

Procedure
1. With a Vernier Caliper, measure the Bow Spring free height
according to Figures 6-1, 6-2, 6-3, or 6-4. Replace the Bow

FREE HEIGHT

Figure 6-1. Bow Spring 2.812". This is an example of Bow Spring drawing 703-500-725.

Spring if the measured dimension is below the minimum

specified in the Figure.
2. The thickness of the Bow Spring can wear to .060". If the
thickness is less than .060", then replace with another Bow
Spring.

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FREE HEIGHT

Figure 6-2. Bow Spring 2.500". This is an example of Bow Spring drawing 703-500-726.

FREE HEIGHT

Figure 6-3. Bow Spring 2.687". This is an example of Bow Spring drawing 703-500-727.

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NaviTrak Short Radius Tandems/Bow Springs

FREE HEIGHT

Figure 6-4. Bow Spring 2.187". This is an example of Bow Spring drawing 703-500-630.

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 Chapter 7

Flow Switch Servicing

This chapter contains step-by-step instructions for

assembly, disassembly, and testing of the NaviTrak Short
Radius Flow Switch.

Flow Switch Overview

The Flow Switch Assembly is composed of a piezoelectric accelerometer,
a mechanical amplifier assembly, and a PCB. The purpose of the Flow
Switch is to detect the presence of drilling mud flow and produce a logic
high output signal to the Directional Attitude Sensor (DAS).
The flow of drilling mud causes a low level vibration, or noise signal,
which is detected on the pressure housing by the accelerometer mechanical
amplifier assembly. The logic high signal is used by the DAS electronics as
an indicator to commence a survey for transmission to the surface
equipment.
Following are shop procedures for the Flow Switch.

Flow Switch Assembly

This procedure has step-by-step instructions for assembling the Flow
Switch Assembly. Where applicable, parts are identified by a name and
followed by an item number (in brackets), which corresponds to the
reference drawing. You will need to acquire the reference drawing,
materials, and tooling prior to assembly.
You will need to gather the following items:

Reference Drawing
• Flow Switch (Dwg. No. 702-500-243, 702-500-256)

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Materials
• Magnalube-G (P/N 29265)

Tools
• 2" Parmelee, 2 required (P/N 707-500-031)
• Snap Ring Pliers

Assembly Procedure
1. Take the Flow Switch Module (2) and apply a small coating of
Magnalube-G to O-rings (15) and Shock Mount (7).
2. Taking care not to damage the O-rings (15) or the Flow Switch
Bracket, push the Flow Switch Module (2) into the Housing (P/N
703-500-587).

Note: Make sure the end LEMO turns with the Module in the
same direction or damage to the wiring will occur.

3. When you can no longer turn the Tandem by hand, align the
Connector Housing (3) to the Barrel Housing Key.
4. Place the Snap Ring (P/N 703-500-587) in place.
5. Using two 1-3/4" Parmelee Wrenches: one on the Tandem and
one on the Housing, then torque to 150 ft-lb.

Flow Switch Disassembly

Ensure you have acquired all materials and tooling before beginning this
procedure.

Materials
• None required

Tools
• Lock Ring Socket (P/N 703-500-622)
• Snap Ring Pliers
Following is a disassembly procedure for the Flow Switch.
1. Remove the Snap Ring (P/N 703-500-606) from the end of the
Flow Switch Housing (P/N 703-500-587); i.e., the LEMO
Connector End.
2. Place the Flow Switch Module (2) in a Bench Vise.

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3. Using two 1-3/4" Parmelee Wrenches: place one on the Tandem

(1) and the other on the Barrel Housing (P/N 703-500-587).
Untorque the Tandem.

Note: Make sure the end LEMO turns with the Module in the
same direction or damage to the wiring will occur.

4. The Flow Switch Module (2) can now be pulled out.

5. Check and inspect the O-rings (15) and replace if necessary.
6. Check the Tandem Shock Mount (7) for cracks and wear.
7. Check the Screws (4) to make sure they are tight.
8. Check the Retaining Sleeve Lock Nut (3). Torque to 50 ft-lb
using Lock Ring Socket.
9. Check that there is free play in the Sleeve (2). It should turn with
the Parmelee Wrench attached.

Flow Switch Testing

This procedure details testing the NaviTrak Short Radius Flow Switch with
the Flow Switch Test Fixture.
To start this procedure, you will need the following reference drawing and
materials:

Reference Drawing
• ATP (P/N 708-500-138)
• Flow Switch (Dwg. No. 702-500-255)

Materials
• Digital Multimeter (Fluke 87 or equivalent)
• +30 Volt Power Supply
• Flow Switch Vibration Transducer (P/N not available)
• Adapter Cable (P/N 702-500-323)
• Random Vibration Cassette Recording
• Realistic SCD 31 Cassette Player or equivalent
• Realistic MDA 30 Power Amplifier or equivalent
• Short Radius Fixture Clamps (P/N not available)
• Tape Measure

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• Marker Pen

Vibration Transducer Installation

1. Place Test Box Clamps around the Short Radius Barrel, located
5" from the male LEMO end. Refer to Dwg. No 702-500-255.
2. Measure the computed distance from the end of the pressure
housing and to the transducer location on the outside of the
pressure housing and mark the location.
3. Attach the Vibration Transducer at the location previously
marked.

Electrical Connections
1. Connect the Multimeter to the meter binder posts on the
Vibration Transducer. Connect the meter’s positive input to the
red meter binder post. Connect the meter’s negative input to the
black meter binder post.
2. Ensure that the +30 volt power supply is switched OFF. Connect
the power supply to the power binder posts. Connect the power
supply positive output to the red power binder post. Connect the
power supply negative output to the black power binder post.
3. Connect the Short Radius Adapter Cable (J101) on the Flow
Switch to the male circular connector of the Vibration
Transducer.
4. Connect the amplifier (AMP) input to the Vibration Transducer
to the amplifier. Connect the white wire to the 8 ohm amplifier
output. Connect the black wire to GND amplifier terminal.
5. Connect the Cassette Tape Player output to the amplifier’s AUX
input with a RCA type patch cord. Connect the “R” Cassette
Player output to the “R” amplifier input. Connect the “L”
Cassette Player output to the “L” amplifier input.
6. Double check all electrical connections. The test fixture setup
should be as illustrated in Figure 7-1.

Test Fixture Start-up

1. Insert the Random Vibration Cassette Tape into the Cassette
Player.
2. Switch the power to the +30 volt Power Supply. Ensure the Flow
Switch Assembly is not drawing excessive current.
3. Switch on the Multimeter and set it to AC millivolt scale. Select
the average function by pressing the “min/max” button.

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NaviTrak Short Radius Flow Switch Servicing

Figure 7-1. Test

Fixture Setup.
This diagram
shows the
electrical
connections and
hardware for the
Test Fixture.

4. Ensure the amplifier output control is set to a minimum level. Set

the AUX input amplifier control to a maximum level. Switch on
power to the amplifier and Cassette Player.

Flow Threshold Test

1. Start the Cassette Player and increase the amplifier output until
the Multimeter indicates 400 mV rms. Observe the flow indicator
LED on the Vibration Transducer for 30 seconds.
2. If the LED does not light after 30 seconds, increase the amplifier
output by 20 mV and wait 30 seconds. Repeat this step until the
flow indicator LED lights. If the amplifier’s output is increased
to 900 mV and the LED never lights, then the Flow Switch
assembly has failed.
3. After the LED has lit, indicating the Flow Switch has detected
vibration, determine the lower vibration threshold. Decrease the
output of the amplifier until the Multimeter indicates a 20 mV
reduction. Remember the Multimeter output requires 30 seconds
to stabilize. Repeat the reduction process until the LED
extinguishes. Record the voltage indicated by the Multimeter as
the lower threshold. If the amplifier’s output is decreased to 200
mV rms and the LED never turns off, then the flow switch
assembly has failed.
4. Increase the amplifier output voltage by 20 mV and wait for 30
seconds while observing the flow indicator LED. Repeat five
percent voltage increases until the LED lights. Remember, there

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is a 30 second delay from the time the Flow Switch detects flow
to the time the Flow Switch output changes to indicate flow.
When the LED lights, record the voltage indicated by the
Multimeter as the upper threshold.

Delay Timer Test

1. When the Flow Switch indicating the “ON” state, stop the
Cassette Player. Measure the time period from the stop of the
tape player and extinguishing the flow LED on the Transducer
Assembly. The period should be approximately 5 seconds.
Record the result.
2. Start the Cassette Player and measure the time period until the
flow LED lights, indicating flow is “ON”. The period should be
approximately 30 seconds. Record the result.

Note: The location of the Vibration Transducer on the Pressure

Housing has a severe effect on the amplifier voltage level
required to cause the Flow Switch to switch on.

Note: The pressure housing should be supported on supports

with the smallest possible contact area between the
support and the pressure housing. The support should be
setting on a hard surface.

Note: The Vibration Transducer is not high temperature rated

and should not be used in an oven.

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 Chapter 8

Full Tool Functional Test

This chapter contains step-by-step instructions for

performing a Full Tool Functional Test on the NaviTrak
Short Radius tool.

Test Overview
This is a verification test of the NaviTrak Short Radius tool. This test will
include: battery voltage readings, current draw readings, pulse test, flow
switch test, and data acquisition.
Following are testing procedures for the Full Tool Functional Test.

Functional Testing
A computer with NaviTrak 2.03 Software and test equipment is used to
perform the functional test.
To start this procedure, you will need to gather the following equipment:

Equipment
• Computer with RS-232 cable
• Signal Interface Box (SIB) (P/N 108610-01-01)
• Mud Box with Cabling (P/N 702-500-178)
• ILS Document
• NaviTrak 2.03 Software
• Upper Adapter Cable (P/N 702-500-322)
• Lower Adapter Cable (P/N 702-500-323)

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Test Setup
Refer to Figure 8-1 for the Full Tool Test Setup. Then, begin the Test Setup
procedure.
Figure 8-1. Full
Tool Test Setup.
This diagram
shows the cabling
and hardware
connections for
testing the tool.

1. Turn the power ON to the SIB, DAS, Mud Box, and the
computer.

Note: See Chapter 5 section on Programming the DAS.

2. Check to make sure that you have set the Mud Box with the
following settings:
• Power- BATTS
• Flow- OFF
• Pumps- ON
• Load- OFF
• Meter Switch- VBU Current
3. Use NaviTrak 2.03 Software.
4. With the Meter Switch set to Volts current check voltages.

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NaviTrak Short Radius Full Tool Function Test

5. With a Multimeter, switch to VBU, and check VBU current which

should indicate idle current between
40 to 60 mAmps.
6. Do a Flow Switch Tap Test.
• Choose [F4] on-line, then [F2] for Survey.
• Ensure that Pumps ON, Flow OFF, and Power BATTS, and start
tapping on the Flow Switch at the same time.
• Verify that the Flow LED lights after 30 seconds and the tool
pulses shortly there after depending on what synchronization rate
you have selected.
7. Check the Survey Current using the Mud Box. It should read
between 100-160 mA.
8. Verify that your Azimuth, Toolface, and Inclination are correct.
9. Stop tapping on the Flow Switch and the Actuator should stop
pulsing in 5 seconds.

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 Chapter 9

Short Radius Troubleshooting

This chapter is about NaviTrak Short Radius

troubleshooting. A series of tests may be used to identify
areas where failures occurred in the toolstring and also other
related problems.

Troubleshooting Overview
This chapter is about troubleshooting the NaviTrak Short Radius tool. A
computer with NaviTrak 2.03 software, along with testing boxes can be
used to troubleshoot some common failures.

Tool Troubleshooting
For Full Tool troubleshooting there are tests that can be run for checking
the tool. For troubleshooting the tool there are five common failures. These
include:
• No Communication
• No Pulsing
• Survey Readings Incorrect
• Batteries Not Switching When Depleted
• Flow Remains On or Is On When No Flow is Present
To start this procedure, you will need to gather the following materials:

Materials
• Computer with RS-232 Cabling
• Signal Interface Box (P/N 108610-D1-01)
• ILS Document

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• Adapter Cable (P/N 702-500-323)

• Mud Box (P/N 702-500-081)
• NaviTrak Software, Version 2.03)

Full Tool Test Setup

In Figure 9-1, an example of the Full Tool Test Setup is illustrated. The
equipment is to be connected according to this example.
Figure 9-1. Full
Tool Test Setup.
This diagram
illustrates the
equipment for Full
Tool Test Setup
troubleshooting.

No Communication
When you see that there is no communication, you should perform
following:
1. Verify that power is ON to the SIB, Mud Box, and PC.
2. Check to make sure all cabling is correctly run and secure.
3. Check that the battery voltage using the Mud Box is above 25
volts.
4. Verify that the VBU Current on the Mud Box is between 40 and
60 mA.
5. If SIB power is used it should have a VBS Current close to the
VBU Current.

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NaviTrak Short Radius Short Radius Troubleshooting

6. If the Current is incorrect, ensure that the Mud Box is delivering

power.
7. If the current is correct, then do a Sensor Test in the NaviTrak
2.03 Software to verify that the DAS is operating correctly.
(Refer to Chapter 5: DAS Servicing).

No Pulsing
If the poppet valve is not opening and closing, then you should run this test.
1. Separate the tool as shown in Figure 9-1.
2. Perform a tap test (see functional test) and verify that the Flow
LED is illuminated. If it is not illuminated, then check the Flow
Switch.
3. If flow exists, check the functionality of the DAS through
NaviTrak 2.03 (see DAS section), and verify that there are pulses
seen on the pulse LED on the Mud Box. If there are pulses and
the batteries are good, then perform a functional test on the PDM
and the Actuator.

Survey Readings Incorrect

1. Verify that the Survey Current is 100 to 160 mA, if not check the
DAS.
2. Run NaviTrak 2.03 and verify the DAS orientation (refer to the
DAS section).
3. If MAG or Accel Raw values read zero’s at all orientation,
remove the Tandem between the sensor and MPU sections and
reconnect them as if you were running a 2" DAS and then rerun
NaviTrak 2.03.
4. If the problem still exists, replace the DAS, or check pin-to-pin
continuity of the Tandem.

Batteries Not Switching When Depleted

1. Check the PDM Dual Controller on the PDM Module.

Flow Remains On or Is On When No Flow is Present

1. Verify that the FLOWDET parameter is set in the DAS correctly.
2. Use TALK to verify (refer to ILS document and Chapter 5) the
following:
• flowdet=1,10,8000,8000;
• fspsi=20000;

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Short Radius Troubleshooting NaviTrak Short Radius

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Confidential P/N 750-500-029 Rev. A / November 1994
 Chapter 10

Inspection Procedures

This chapter contains inspection procedures for the

NaviTrak Short Radius Flow Sub, Lock Sub, and Belleville
Springs.

Flow Sub Overview

The Flow Sub retains the Main Valve Assembly and is designed to flex in a
similar manner as compressive service drill pipe (CSDP). See Figure 10-1.

Belleville Cartridge Restrictor

P/N 702-500-321 P/N 703-500-710

Thrust Washer
P/N 703-500-722
Taper, Locking Sleeve O-ring
2.795 P/N 703-500-718 P/N 87032-144
Adj. Spacers Flow Sub
2.825
P/N 33016-001thru -007 P/N 33021-001, -002

Figure 10-1. Flow Sub with Main [Link] Flow Sub retains the Main Valve as shown in this
illustration.

The Flow Sub has an internal key that is used as a anti-rotation mechanism
and also the reference for tool face. The Main Valve is compressed in place

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Inspection Procedures NaviTrak Short Radius

by means of Belleville Spring Cartridge and a Lock Sub. The pin length on
the Lock Sub is very critical, and is held to a much tighter tolerance than
the API standard.

Note: The Lock Sub part number is (P/N 3008-001), and see
drawing NAV036.

Following is a procedure for inspecting the Flow Sub. Before getting

started, obtain all reference drawings and equipment.

Reference Drawings
• Flow Sub (Dwg. No. 30021)
• Flow Sub/Main Valve Installation (Dwg. No. NAV036)
• Inspection Procedure CSDP QM11-003
• Liquid Inspection Procedure SPM 100-003

Equipment
• Boreoscope
• Liquid Inspection Kit
• Inspection Mirror(s)
• Inside Micrometer
You are ready to start the inspection procedure.

Inspection
1. Inspect the threads according to standard field procedures
(Magnaflux for -001 (steel) liquid penetrant -002 (non-mag). If a
recut (or recuts) is required, refer to Figure 10-2, for the
minimum length of sub. If the sub is below the minimum length,
remove from service.
2. Measure and record the OD dimensions. Recommended wear
limits will be issued in the next revision of this manual.
3. Inspect the 2.735" bore for wear or corrosion. No wear beyond
the manufacturing tolerances are permissible.
4. Inspect the wear knot areas per QM11-003 (sheet 9 of 9) with
liquid penetrant according to SPM 100-003. If the sub does not
fall within the acceptance level specified in document QM11-
003, then remove the sub from service.
5. Inspect the keyway and landing shoulder for peening and/or
erosion. For the wear limit on the keyway, refer to Figure 10-2.

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NaviTrak Short Radius Inspection Procedures

Minimum 12.90 Minimum 5.50

Flow Sub 33021-001, -002

Minimum Wear Limit 1.015

Figure 10-2. Flow Sub Wear Limits. Established wear limits are shown in this illustration.

6. Inspect the 2.25" bore for erosion and cracks with a Boreoscope.
7. Once the inspection is complete and the sub is ready for service,
install the thread protectors and apply an anti-corrosion coating
on the steel (-001) subs.

Lock Sub Overview

The Lock Sub is used to lock the Main Valve Assembly in place and to
serve as a crossover to the client’s connection. You will need the following
reference drawings and equipment prior to starting work.

Reference Drawings
• Lock Sub (Dwg. No. 30008)
• Inspection Procedure CSDP QM11-003
• Liquid Inspection Procedure SPM 100-003

Equipment
• Boreoscope
• Liquid Inspection Kit

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Inspection Procedures NaviTrak Short Radius

• Inspection Mirror(s)
• Inside Micrometer
You are ready to start the procedure.

Inspection
1. Inspect the threads according to standard field procedures
(Magnaflux for -001 (steel) liquid penetrant -002 (non-mag). If a
recut (or recuts) is required the minimum length of the sub is
6.00".
2. Inspect the 2.25" bore for erosion and cracks using a Boreoscope.
3. Once the inspection is complete and the sub is ready for service,
install thread protectors and apply an anti-corrosion coating on
the steel (-001) subs.

Belleville Spring Overview

The Belleville Spring Cartridge is used to load the Main Valve Assembly
into the Flow Sub by means of being compressed by the Lock Sub. You
will need the following reference drawings and equipment prior to starting
work.

Reference Drawings
• Cartridge Assembly Loading - SR NaviTrak (Dwg. No. 702-500-321)
• Belleville Spring (Dwg. No. 703-500-721)
• Liquid Inspection Procedure (SPM 100-003)

Equipment
• Liquid Inspection Kit

Inspection
1. Completely disassemble the Cartridge after each job at an FMD
or Satellite facility.
2. Thoroughly clean the End Sleeve (2) and the Body (1). See
Figure 10-3.
3. Perform a visual inspection of the End Sleeve (2) and the Body
(1) for cracks.
4. Inspect 100% both the End Sleeve (2) and the Body (1) with
Liquid Penetrant, according to SPM 100-003.

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Confidential P/N 750-500-029 Rev. A / November 1994
NaviTrak Short Radius Inspection Procedures

Figure 10-3. SR NaviTrak Cartridge Assembly. This is a sample drawing of 702-500-321.

5. Inspect the free height of the Belleville Springs. A minimum

height of 0.120" is permissible. See Figure 10-4. Replace any
Belleville Spring that falls below this free height.

Figure 10-4. Belleville Spring Loading. This is a sample drawing of 703-500-721.

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Inspection Procedures NaviTrak Short Radius

6. Reassemble the Cartridge Assembly according to Figure 10-3.

Note: Be sure to note the orientation of the Belleville Springs

when reassembling.

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Confidential P/N 750-500-029 Rev. A / November 1994
 Chapter 11

Non Magnetic Compressive Service

Drill Pipe (NMCSDP)

This chapter contains maintenance and reference

instructions for the NaviTrak Non Magnetic Compressive
Service Drill Pipe (NMCSDP).

Collar Overview
The NaviTrak Short Radius toolstring, which contains magnetic survey
instruments, is installed into an NMCSDP after it is fully assembled and
static tested on the rig’s catwalk. The NMCSDP is installed and fully
torqued to the drill bit.

Inspection
A NMCSDP is inspected for the following:
• Checked that it is straight
• Measured for tool joint wear
• Visual inspection for cracks, corrosion, and pitting
• Inspection of the thread profile
For the revision of this manual, details for the drill collar inspection will
not be covered, but only referenced. To perform a drill collar inspection,
refer to an earlier document produced by Eastman Christensen (Doc. No.
QM11-003). If you need a copy, contact any region Quality Control
Department.

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NMCSDP NaviTrak Short Radius

11-2 Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994
 O
ring
O-
Appendix A

O-ring Selection and Inspection

This appendix provides a primer for selecting, inspecting,

and installing O-rings for the NaviTrak Short Radius tool.

Introduction
The entire NaviTrak Short Radius tool utilizes O-rings for pressure seals. A
single mistake, or oversight, in identifying a defective O-ring can cause a
catastrophic tool failure. Additionally, an improperly or poorly installed O-
ring can also cause a failed pressure seal. O-rings are very fragile, a surface
imperfection or scratch can lead to pressure migration through the scratch
and subsequent damage to internal components.
Over torque can cause extrusion of the O-ring beyond the sealing surface.
Improper lubrication where specified can cause a dry stressed surface that
does not seal adequately. Conversely, lubrication with a non-approved
lubricant can cause a breakdown of the O-ring material composite. Another
potential problem is the substitution of O-rings. Several of the O-rings used
in the tool have the same physical dimensions, yet have a different
hardness coefficient, therefore, it is easy to mistake one for another, unless
properly marked and stored. Even then, it is wise to double check before
installation in the tool. Remember, most O-rings only cost a few pennies
but a defective O-ring can cost thousands of dollars.
In that light, the following information is offered as a primer for selecting,
inspecting, and installing the proper O-ring.

Selection
All O-rings used in assembly of tools must be specified and approved by
the Components Engineer. Only O-rings from specified manufacturers are
to be used.

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NaviTrak Short Radius O-ring Selection and Inspection

Storage
When the O-rings are received, each package should be inspected to ensure
the proper nomenclature is marked. O-rings should be stored in a cool dry
place, free from dirt, oil, or other contaminants.

Inspection
In preparation for each assembly, all the necessary O-rings should be
placed on the O-ring Assembly Aid for the unit that is to be assembled.
Each O-ring should be inspected before being place on the O-ring
Assembly Aid. This inspection should consist of a visual and dimensional
verification of the O-rings.
If there is any doubt from the packaging label as to the type and size of an
O-ring, a Dimensioning Cone should be used to make sure it is the proper
one.

Visual Inspection
1. Remove all dust, dirt, lint and any surface contaminants from the
surface of the O-ring. A damp cloth can be used to perform this
step.
2. Examine the O-ring under magnification for any surface
imperfections or defects. When viewing, minor flexing or
bending of the O-ring can often make visible hidden cuts,
scratches or other imperfections on the O-ring surface. Do not,
however, stretch the O-ring.
3. Following are some examples of specific defects to look for:
Backrind Torn or Gouged- A defect appearing as a recess at the
O-rings mold parting lines. This defect is usually caused by
thermal expansion over the sharp O-ring molds edge or by
premature core hardening. See Figure A-1.
Foreign Material- A defect evidenced by coarse or undisbursed
material within the O-ring. Also evidenced as an irregular
depression, if the material has been removed. See Figure A-2.
Excessive Trimming- A defect appearing as flat spots or nicks
along the outer O-ring edge, caused by excessive over-buffing or
trimming of the O-rings “flash” at the parting line. This defect
causes an out-of-tolerance cross section.
Flash- A defect evidenced as a thin, film like extrusion from the
O-ring parting line, resulting from mold separation or inadequate
trimming. See Figure A-3.

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NaviTrak Short Radius O-ring Selection and Inspection

Figure A-1.
Backrind Torn or
Gouged. This O-
ring defect is
indicated at the
mold parting lines.

Figure A-2.
Foreign
Material. This O-
ring defect is
recognized by
coarse or
undisturbed
material within the
O-ring.

Mold Deposit Defect- A defect appearing as a surface indention

that is irregular in shape with a rough surface texture. This is
caused by a buildup of hardened deposits inside the mold cavity
surface. See Figure A-4.
Flow Marks- A defect evidenced by a knurled surface, flow
lines, contoured depressions or delaminations. This is caused by
poor jointing of the O-ring compound as it is injected into the O-
ring mold. See Figure A-5.

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O-ring Selection and Inspection NaviTrak Short Radius

Figure A-3.
Flash Defect.
This defect is
evidenced as a
thin, film-like
extrusion from the
O-ring parting line.

Figure A-4. Mold

Deposit Defect.
This defect
appears as a
surface indentation
that is irregular in
shape.

Off Register or Mismatch- A defect evidenced by one half of the

O-ring being offset from the other half of the O-ring. This is
caused by nonalignment or shifting of the O-rings mold halves.
See Figure A-6.
Non-Fill - A defect appearing as an irregular flat spot or
ribbonlike strip with a coarse surface texture. It can also appear
as a half moon recessed wedge. This is caused by not enough
injection of the O-ring elastomer into the mold cavity. See Figure
A-7.

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Confidential P/N 750-500-029 Rev. A / November 1994
NaviTrak Short Radius O-ring Selection and Inspection

Figure A-5. Flow

Marks. This
defect is
evidenced by a
knurled surface,
flow lines,
contoured
depressions.

Figure A-6. Off

Register or
Mismatch. This
defect is when
one half of the O-
ring is offset from
the other half.

If the visual inspection reveals any defects the O-ring should not be used.

Replacement
In general, when a tool is disassembled for scheduled or unscheduled
maintenance, the used O-rings should be discarded and replaced with new,
inspected O-rings.

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O-ring Selection and Inspection NaviTrak Short Radius

Figure A-7. Non-

Fill. This defect
appears as an
irregular flat spot
or ribbon-like strip
with a coarse
surface texture.

Installation
O-rings, as specified, will fit very snugly in the intended groove. Care
should be taken during installation not to stretch an O-ring any more than
absolutely necessary to fit over the OD of the shaft or barrel.
In most cases, the shaft or barrel can be lubricated so the O-ring can slide
easily along the surface until it reaches the intended groove. Magnalube
can be used for this purpose.
Where there are two or more O-rings in succession on the same OD, install
the one closest to the end of the shaft or barrel first allowing the next O-
ring to slide over the first and so on.
If it is necessary to move or remove an O-ring after it is seated in the
groove, use a wooden pick that is beveled to a fine edge on one end.
Carefully insert the beveled edge under the O-ring and lift up just enough
to clear the OD of the shaft or barrel. While holding the uplifted section
against the shaft or barrel, slide the wooden pick around the circumference
easing the remainder of the O-ring up to the OD The O-ring can then be
slid along the surface to new location or removed.
In some instances, Backup Rings (installed adjacent to the O-ring) or Cap
Seals (installed over the O-ring) are required. The procedure for
installation is basically the same as for O-rings. Ensure that the backup
Rings are placed on the correct side of the O-ring.

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NaviTrak Short Radius O-ring Selection and Inspection

Lubrication
Improper lubrication can cause a dry, stressed surface that does not seal
adequately. Conversely, lubrication with non-approved lubricant can cause
a breakdown of O-ring material.
In order to facilitate the merging of subassemblies that are sealed with O-
rings, the O-rings should be lubricated with Magnalube or Dow Corning
111. This will also keep the O-rings from extruding due to excess friction
during installation and /or operation.

Backup Rings (Seals)

As stated earlier, high pressures involved in downhole operations can cause
O-ring extrusion leading to major tool damage. Figures A-8, 9, and 10 are
examples showing proper O-ring fit and possible appearances under
pressure.

Figure A-8.
Properly Fitted O-
ring. This diagram
illustrates a
properly fitted O-
ring.

To reduce the possibility of the O-ring becoming extruded, backup rings

are used in all high-pressure connections. Although in most cases, a single
backup ring in the low pressure side of the O-ring would be sufficient,
there are times when a backup ring is installed on both sides of the O-ring.
When replacing O-rings in the tool, make sure that the replacement
configuration matches the drawing. Double check the part numbers to
make sure the proper O-rings and backup seals are being used.

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O-ring Selection and Inspection NaviTrak Short Radius

Figure A-9. O-
ring Under High
Pressure. This
diagram show the
effect of pressure
on the O-ring.

Figure A-10.
Extruded O-ring.
This diagram
shows an O-ring
that becomes
extruded.

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Confidential P/N 750-500-029 Rev. A / November 1994
 Appendix B

Short Radius Forms

This appendix is about the various forms of paperwork for

recording information about the NaviTrak Short Radius
tool.

Forms Overview
The following paperwork are a representation of various forms for testing
and inspection. These include:
• Battery Pack Test Sheet
• Test Data Sheets for Actuator Assembly Inspection
• Actuator Inspection Report
• Pulser Failure Inspection Report- Part A

Note: Be aware that the paperwork contained in this chapter

are examples only and are subject to change. Always
consult the latest Engineering print for the latest forms
and other documentation.

Battery Pack Test Sheet

The following Tables are used to verify that the Batteries are good. Table 1
checks the Unloaded Voltage (ULV), while Table 2 checks the Loaded
Voltage (LV) of both Battery Packs. Also, refer to Figure B-1 for a
simplified diagram of the Battery Pack.
The Unloaded Voltage (Table 1) checks both Battery Packs separately and
in series. If a Battery Pack falls outside the voltages given, the Battery is
not good. Change out the bad Battery Pack and continue testing.

Repair & Maintenance Manual B-1

P/N 750-500-029 Rev. A / November 1994 Confidential
Short Radius Forms NaviTrak Short Radius

Uphole Downhole
+ - + -
VBU 2 5 Cells 2 2 5 Cells 2

GND 4 4 4 4

GND 10 10 10 10

Battery #1 Battery #2
(B1) (B2)

Figure B-1. Battery Pack. This schematic shows the configuration for Battery Pack 1 and 2.

Note: Pins are located on the LEMO Connectors.

Table 1: Unloaded Voltage Check

Uphole Connector (Pin # to Measured Required

Descriptions
Pin #) ULV ULV
2 4 = 36 +/- .5 volt B1 & B2
2 10 = 18 +/- .5 volt B1
10 4 = 18 +/- .5 volt B2

The Loading Voltage (Table 2) checks both Batteries in series. Apply 100
Ohm load between Pin 2 and Pin 4 for 15 minutes. For good Batteries, the
current should be approximately 360 mA. After 15 minutes, if the voltage
is below 32 volts, then the Battery or Batteries are not good. Replace the
bad Battery or Batteries with a new Pack(s).
Apply 100 Ohm load (approximately 360 mA) for 15 minutes.

Table 2: Loading Voltage Check

Uphole Connector (Pin # to Pin #) LV Measured Required LV

(360mA)
2 4 = minimum 32 volt

Example Forms
Following are examples of various forms that may be used.

B-2 Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994
NaviTrak Short Radius Short Radius Forms

LY
N
O
E
PL
M
SA

1.64 +/- 0.16

1.64 +/- 0.16

Figure B-2. Actuator Test Data Sheet. This form is a sample page of the NaviTrak Short
Radius Actuator.

Repair & Maintenance Manual B-3

P/N 750-500-029 Rev. A / November 1994 Confidential
Short Radius Forms NaviTrak Short Radius

LY
N
O
E
PL
M
SA

Figure B-3. Actuator Test Data Sheet. This form is a sample page of the NaviTrak Short
Radius Actuator.

B-4 Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994
NaviTrak Short Radius Short Radius Forms

LY
N
O
E
PL
M
SA

2.00" +/- .010"

50 lbs. min.

.128"-.132"

Figure B-4. NaviTrak Actuator Inspection Report. This form is a sample of the NaviTrak
Actuator Inspection Report.

Repair & Maintenance Manual B-5

P/N 750-500-029 Rev. A / November 1994 Confidential
Short Radius Forms NaviTrak Short Radius

LY
N
O
E
PL
M
SA

Figure B-5. Pulser Inspection Report. This form is a sample Pulser Inspection Report (Part
A).

B-6 Baker Hughes INTEQ

Confidential P/N 750-500-029 Rev. A / November 1994