Manual Izadora Custom Pipe

HERCULES
HYDRAULIC CATWALK – OVERVIEW
Nicholas Morelli
CUSTOM PIPE GLOBAL CONSULTING INC.
Revision 2
CONFIDENTIAL AND PROPRIETY INFORMATION MAY BE CONTAINED HEREIN,
NOT TO BE RELEASED WITHOUT WRITTEN PERMISSION OF
HYDRAULIC CATWALK
OVERVIEW MANUAL
TABLE OF CONTENTS
GENERAL NOTICES .....................................................................................................2

COMPONENT DESCRIPTION .......................................................................................2
INTRODUCTION .................................................................................................................................... 2
FRAME .......................................................................................................................4
DESCRIPTION ........................................................................................................................................ 4
MAIN COMPONENTS............................................................................................................................ 4
LIFT CARRIAGE ASSEMBLY..........................................................................................5
DESCRIPTION ........................................................................................................................................ 5
MAIN COMPONENTS............................................................................................................................ 6
SKATE AND KICKERS...................................................................................................8
DESCRIPTION ........................................................................................................................................ 8
MAIN COMPENENTS (SKATE) ............................................................................................................... 8
MAIN COMPONENTS (KICKERS) ........................................................................................................... 9
GULLWING INDEXERS .............................................................................................. 11
DECRIPTION........................................................................................................................................ 11
MAIN COMPONENTS (INDEXERS) ...................................................................................................... 11
GULLWINGS ............................................................................................................. 12
DESCIPTION ........................................................................................................................................ 12
CONTROL PANEL ...................................................................................................... 13
DESCRIPTION ...................................................................................................................................... 13
MAIN PANEL ....................................................................................................................................... 13
PLC PANEL .......................................................................................................................................... 13
FLASHES.............................................................................................................................................. 13
CONTROL PANEL ................................................................................................................................ 14
[Revision 2]
CONFIDENTIAL AND PROPRIETY INFORMATION MAY BE CONTAINED HEREIN, Page 1 of 15
NOT TO BE RELEASED WITHOUT WRITTEN PERMISSION OF CUSTOM PIPE GLOBAL CONSULTING INC.
HYDRAULIC CATWALK
OVERVIEW MANUAL
GENERAL NOTICES
 Custom Pipe makes every reasonable effort to ensure the accuracy of the information provided in this
Manual. However, as information, components, and procedures are continually improving, Custom Pipe
reserves the right to change at any time without notice, information contained in this Manual and makes
no warranties or representations as to its accuracy
 Unauthorized duplication of this Manual, in whole or in part, is prohibited

 This Manual is by no means a replacement for proper training or experience
 Service on the Catwalk is only to be performed by Qualified Personnel. This is to maintain the high level
of safety integral to the Catwalk and its systems
 Confidential and Proprietary information may be contained herein

 Any unauthorized service changes will VOID the warranty
COMPONENT DESCRIPTION
INTRODUCTION
This section outlines all the major components of the Custom Pipe Catwalk and its main purpose is to familiarize
you with the items and terms that will be used in the following sections. On the next page is a top-down view
of the Catwalk with labels showing the location of major components, as well as a legend for describing smaller
assemblies. After the main view pages, there are descriptions of all the items listed. For any information on
operating instructions or maintenance procedures, refer to the “Operations,” or “Maintenance,” sections of the
Manual, respectively.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
1) Hydraulic Tank 8) Leveling Jacks (4) 15) Strobe

2) Hydraulic Cooler 9) Front Arm Assembly 16) Toolbox
3) Electric Motor & Pump 10) Back Arm Assembly
4) Main Valve 11) Kickers (3 per side)
5) Aux Valve 12) Skate
6) Rack Indexers 13) Gullwing
7) Gullwing Levelers 14) Keeper Pins
*ESD Switches are located on the C as well as the Wireless Remote
E-Stop location Ground pin location
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HYDRAULIC CATWALK
OVERVIEW MANUAL
FRAME
DESCRIPTION
The frame is mainly composed of Wide Flange and HSS Tubing and is the main structural member of the Catwalk.
It holds all of the running components, and is the location of the valve banks.
MAIN COMPONENTS
 Leveling Jacks: These are to assist in leveling the Catwalk for proper operations. The front leveling jacks
have their own separate control valve, just above the main valve. The rear jacks are manually operated
to assist in detaching the trailer from the truck if power is unavailable
 Main Feed Cable Storage: Located under the operators platform to provide protection for the main feed
power cable and plug
 E-Stops: One ESD switch is located on the control panel of the Catwalk, and the other is located on the
wireless Remote
 Toolbox: A lockable place to store smaller Catwalk items such as deck pins, Skate attachments and the
Wireless Remote. Can also be used to hold spare parts
 Stairs w/Handrails (optional): This hinge on the Catwalk to provide a proper and safe way to access the
deck
 Strobe Light: Provides a visual confirmation the Catwalk is running. Also folds down to reduce height for
transport
 Stow Locations: Used to store the Gullwing center supports, center jack stand supports and foot pads for
jacks
WARNING: The Catwalk frame needs to be completely supported for proper and safe operation.
Also ensure that all pins and guards are in place and properly secured to prevent damages/injury.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
LIFT CARRIAGE ASSEMBLY

DESCRIPTION
The Lift Carriage Assembly (or LCA) of the Catwalk could accurately be described as the “Heart” of the Catwalk
since it performs all of the lifting and handling of the pipe up to the rig floor.
There are three section that constitute the LCA, Stage 1, Stage 2, and the Main Lift Arms. Stage 2 contains the
Trough, Kickers and Skate System. Stage 1 contains the Extension Cylinder and is the connection point for the
Main Lifting Arms.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
MAIN COMPONENTS
 Main Lift Arms: Are used to lift the carriage to a user programmable set point.
 Main Extend Cylinder: Is located in between Stage 1 and Stage 2 it is used to pull Stage 2 up to the rig
floor. All the main cylinders have counter-balance valves installed on both ends as a safety measure, to
prevent any motion in the event of a hose failure.
 Cam Followers: These rollers are installed in Stage 1; they provide a low-friction method of extending
and retracting the sections together. Greasing is not necessary as the bearings are sealed and pre—
lubricated from the factory for the life of the roller.
 Kicker Safety Valve: They are mounted on Section 1 and prevent the Kickers from being actuated once
the LCA has been extended from inside the deck. Even if the function is accidentally activated, these
valves will physically prevent hydraulic pressure from reaching the Kicker Cylinders.
 Hose Carrier: Used to protect and organize the hydraulic hoses that run between Stage 1 and Stage 2. It
is a vital part of the Catwalk and needs regular inspection for damage or worn links and cover plates
 PLC: Is used to preset height and extension points for repetitive and safe operation.
*NOTE: Kickers and Skate are detailed in their own individual sections further on.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
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HYDRAULIC CATWALK
OVERVIEW MANUAL
SKATE AND KICKERS

DESCRIPTION
The Skate System and Kickers are located in Stage 2 or top section of the LCA. The purpose of the Skate is to
push the pipe up the trough to the position that is useful for picking up the pipe. This can be done with a winch
or elevator system. If necessary, the Skate can also pull the pipe back with an adapter (when equipped). Each
Kicker consists of cylinders on either side of the trough, and as a set of 3 works together to “Kick” the pipe out
of the trough, usually when lying down. There are two sets; one for each side of the Catwalk will need to be
used.
MAIN COMPENENTS (SKATE)
 Skate Assembly: A two piece Skate runs down the middle of Stage 2. There are different attachments to
assist in the task at hand. The Skate travels almost the entire length of the trough to accommodate even
the shortest lengths of pipe
 Skate Motor/CB Valve: The Skate System is driven by a hydraulic motor with a counter balance valve.
The motor is of a case drain type design and requires no vent. The brake is pressure-released and
automatically applies as soon as the Skate stops moving. There is a dual counterbalance valve installed
to add redundancy to the braking system
 Chain: The main drive chains are two continuous loops that run almost the entire length of Stage 2. They
ride in UHMW guides to help reduce friction and wear. It is very important to keep the guides free of
debris, as well as regularly inspect the chains and components for wear or damage. There is also a shorter
loop of chain in the front of Stage 2 that transfer’s power from the Skate Motor to the Main Drive Chains
 Tensioning System: The chain tensioner consists of non-adjustable idler and a shaft that is mounted in
two adjustable spherical bearings. These are located in the very back of Stage 2. The tension bolts have
jam nuts on them to help ensure that tension is maintained
WARNING: The Skate MUST be in contact with the Tubular as much as possible. Shock loading of
the drive chains is unsafe and will severely reduce their service life.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
MAIN COMPONENTS (KICKERS)
Kicker Safety System: as a standard feature the Kickers will by default automatically return. This is in
combination with valves that close whenever the LCA lifted out of the frame. This is to ensure that a Tubular
cannot be kicked out accidentally above the deck, and to keep the Kickers fully retracted and out of the way of
the Skate.
WARNING: The Kickers must NEVER be actuated when the Skate is directly on top of them. Severe
damage to the Skate assembly WILL result.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
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HYDRAULIC CATWALK
OVERVIEW MANUAL
GULLWING INDEXERS
DECRIPTION
The Gullwing Indexers are used to load pipe to the carriage from the Gullwings. They are used with alignment
pins to assure one pipe is loaded at a time.
MAIN COMPONENTS (INDEXERS)

 Cylinders: Equipped with counterbalance valves to ensure smooth, even operation under load.
 Indexer Arm: Used to initiate the rolling of the pipe also can be used as a stopper.
 Long Stopper Pins: Are used with only sucker rod, this is to insure the sucker rod is elevated enough to
roll into the carriage.*
 Short Stopper Pins: Are used with all other pipe.
 Pin Storage: A toolbox is located on either side of the Catwalk to store pins. Helps prevent loss.
 On Deck Ramps: Used to carry the pipe from Indexer to carriage or from the Kickers to the Gullwings
without getting hung up on the deck due to collars and such.
*NOTE: The extra lift of the long

stopper pins will create too much roll
speed when used with pipe other
than sucker rod.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
GULLWINGS
DESCIPTION
 The Gullwings are an integrated set of pipe racks that are mounted to the Catwalk, and are most often
used in conjunction with the Indexers. They are hydraulically adjustable to either feed Tubulars in to the
Catwalk, or collect Tubulars when lying down. The end pin can be removed to easily work in conjunction
with existing pipe racks. Since they are mounted to the frame, they swing in to stow for easy transport.
 Hinge Assembly: Used to Pivot the Gullwings in and out for transport when pin is in.
WARNING: The Gullwing Legs MUST maintain contact with solid ground when loaded with pipe.
The hinges are designed to support ONLY the weight of the Gullwings when free-standing.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
CONTROL PANEL
DESCRIPTION
The Main Control Panel is located on the Driller Side. The purpose of the panel is to provide a place to control
the HPU, as well as indicating any ESD conditions that may exist. The main disconnect switch is a circuit breaker
style, and the handle has the means to be locked out with a standard pad lock.
MAIN PANEL
 Main Disconnect: Can be locked in the “OFF” position, as well as indicating if the breaker has been
tripped.
 Hand-Off-Auto Switch: Is used to either start the motor manually (Hand), or to start with the Wireless
Remote (auto).
 Start Button: Is used to start the motor when H-O-A Switch is in Hand.
 Run Indicator: Shows when the Catwalk motor is running.
 E-Stop Indicator: Shows when an ESD switch has been pushed, the safety barrier has been tripped, the
Catwalk is low on oil, or the oil temperature is too high.
 High Temp Indicator: The oil in the reservoir is too hot to run (limit set at 80° C).
 Low Oil Indicator: The oil level in the reservoir is too low to run.
PLC PANEL
There is a PLC error indictor located on the door of the panel, if there is an error a series of flashes will occur.
FLASHES
1. Main Lift Sensor Error
2. Extend Cylinder Sensor Error
3. Main Lift Past Set Point
4. Extend Cylinder Past Set Point 5- Radio Error/Off
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HYDRAULIC CATWALK
OVERVIEW MANUAL
CONTROL PANEL
WARNING: High Voltages are present in all of these panels. Work to be performed by Qualified
Personnel only.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
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HERCULES
HYDRAULIC CATWALK – OPERATION & MAINTENANCE MANUAL
Nicholas Morelli
Revision 2
HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
TABLE OF CONTENTS
MANUAL INTRODUCTION...........................................................................................3
OPERATOR REQUIREMENTS AND RESPONSIBILITIES ................................................... 3
CATWALK GENERAL SAFETY .......................................................................................4
SPECIFIC COMPONENT AND EQUIPMENT OVERVIEW................................................. 5
BASIC HERCULES FRAME ....................................................................................................................... 5
HERCULES MAJOR COMPONENTS........................................................................................................ 6
HYDRAULIC LEVELING JACKS................................................................................................................. 7
FRONT ARMS ........................................................................................................................................ 8
TROUGH CARRIAGE .............................................................................................................................. 9
MAIN TROUGH ................................................................................................................................... 10
TROUGH KICKERS................................................................................................................................ 11
HYDRAULIC GULLWINGS ..................................................................................................................... 12
TUBULAR PIPE RUNS ........................................................................................................................... 13
PIPE RACK INDEXERS ........................................................................................................................... 14
SKATE SYSTEM .................................................................................................................................... 15
REAR ARMS ......................................................................................................................................... 16
“LED” WORK LIGHTS ........................................................................................................................... 17
HYDRAULIC TANK ............................................................................................................................... 18
CATWALK CONTROL SYSTEMS ........................................................................................................... 19
PLC CONTROL BOX & SENSORS .......................................................................................................... 20
MAIN VALVE BANK ............................................................................................................................. 21
AUXILIARY VALVE BANK ..................................................................................................................... 22
EMERGENCY STOPS ............................................................................................................................ 23
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HYDRAULIC CATWALK
SPOTTING AND INITIAL POWER UP OF THE CATWALK & LEVELING SYSTEM ............. 24
SPOTTING THE CATWALK ................................................................................................................... 24
ENERGIZING THE CATWALK ............................................................................................................... 24
INITIAL INSPECTION ............................................................................................................................ 25
FILLING THE HYDRAULIC TANK ........................................................................................................... 26
INITIAL CATWALK START UP ............................................................................................................... 27
MOTOR ROTATION ............................................................................................................................. 27
MANUAL CATWALK START UP ............................................................................................................ 28
LEVELING OUT THE CATWALK ............................................................................................................ 29
SETTING UP THE CATWALK FOR OPERATION ........................................................... 30
PIPE RACK INDEXERS .......................................................................................................................... 30
PIPE RACK CASING RUNS .................................................................................................................... 31
HYDRAULIC GULLWINGS .................................................................................................................... 32
SKATE SYSTEM .................................................................................................................................... 33
OPERATING THE CATWALK WITH THE WIRELESS REMOTE SYSTEM .......................... 34
REMOTE OVERVIEW ........................................................................................................................... 34
REMOTE CONTROL CATWALK START UP ............................................................................................ 35
PROGRAMMING NEW HEIGHTS USING THE REMOTE CONTROL ....................................................... 36
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HYDRAULIC CATWALK
MANUAL INTRODUCTION
This Manual was created and should be used to obtain knowledge and assistance for the upkeep and safe
operation of the Hercules Hydraulic Catwalk. If any further instruction and or assistance is required please
contact a “Custom Pipe Handlers Representative”.
WARNING: This Catwalk must always be operated by a Certified Catwalk Operator with a Card of
Certification issued by a Custom Pipe Handler Representative.
OPERATOR REQUIREMENTS AND RESPONSIBILITIES
 Understand fully all Catwalk operations and functions

 Understand the speed of each moving component
 NEVER leave the Catwalk unattended while it is running
 Only a Certified Operator is to operate the Catwalk
 Understand and execute all maintenance programs
 Understand the entire Operation Manual
 Ensure visual checks are completed prior to the Catwalk start-up.
 The Operator shall not operate the Catwalk if the Operator(s) are under the influence of drugs or alcohol
 Stand clear of Catwalk when it is operating
 Report any damages or deficiencies to Site Supervisor; and working with the Catwalk should not continue
until an assessment and or repairs are completed
 Ensure there are no obstructions above the Catwalk that may interfere with safe lifting
WARNING: Any personnel who may negligently misuse this Catwalk in any unsafe manner or form could
result in serious injury or death.
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HYDRAULIC CATWALK
CATWALK GENERAL SAFETY
 The Catwalk must be level before any operations commence

 The correct power should be supplied to the Catwalk before operations to prevent severe damages
to control panel and the electronic components
 NEVER leave Catwalk unattended when Catwalk is running
 NEVER inspect, repair, or attempt maintenance to the Catwalk if it is running and not properly locked
out
 DO NOT use handles on Valve Bank and or Remote for anything else other than the operation of
the Catwalk
 Any damages or deficiencies should be documented and repaired before work with the Catwalk starts
or continues
 DO NOT store tools or other materials against, on, or below Catwalk
 While lowering or raising the Catwalk, the Operator must be in constant communication with the rig
floor, either by hand signals or by radio communication
 Always watch and listen for abnormal movement or noises during the Catwalk operation. If anything is
noticed the Catwalk must be brought back to its “Home” position and safely locked out before any
inspection can be made
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HYDRAULIC CATWALK
SPECIFIC COMPONENT AND EQUIPMENT OVERVIEW

BASIC HERCULES FRAME
D
OFF DRILLER SIDE
C
DRILLER SIDE
A. Front Arm Frame Lug

B. Rear Arm Frame Lug
C. Rear Arm Cylinder Frame Lug
D. Catwalk HPU Control Level
E. Leveling Jacks
F. Gullwing Frame Connection
A G. Indexer Frame Connection
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HYDRAULIC CATWALK
HERCULES MAJOR COMPONENTS
F
OFF DRILLER SIDE
D
E
G
B
H
A
DRILLER SIDE
A. Front Arms
B. Rear Arms
C. Main Trough
D. Trough Carriage
E. Skate
F. HPU & Valve Bank
G. Gullwings
H. Indexers
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HYDRAULIC CATWALK
HYDRAULIC LEVELING JACKS
CAUTION: Before moving the Catwalk always make sure that all 4 Leveling Jacks have been retracted to their
“Home” position.
WARNING: NEVER operate Catwalk with only Leveling Jacks as support for Catwalk, serious injury and
equipment failure may result.
• Located on all 4 corners of the Catwalk

• Are used to assist in the leveling of the Catwalk
• Operated separately by the Auxiliary Valve Bank on the
rear of the Catwalk
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HYDRAULIC CATWALK
FRONT ARMS
CAUTION: Front Arms are a major pinch point, while operating stay back to ensure safety.
• The arms move perpendicular to each

other while ascending and descending
• The arms house two cylinders and one

PLC sensor
• The arms must be greased daily to ensure

C
smooth operation
• The Front Arms are used to advance trough

and Tubular product towards rig floor A
B
• The front arms should be visually checked
daily for any unusual wear and damage
A. PLC Sensor
B. Main Lift Cylinder
C. Spherical Bearings
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HYDRAULIC CATWALK
TROUGH CARRIAGE
• This is a ridged structure that connects the Front and Rear Arms
• The Carriage is lined with Cam Followers in which the Trough moves backwards and forwards
• The Carriage is “Home” for the Trough Extension Motor and the Dual 100R Chain that connects the trough
to the Hydraulic Gear Motor
• The Trough Carriage is also “Home” for the Cable Encoder for the Trough Extension function when using
the PLC
Front Arm Connection 100R Dual Chain Rear Arm Connection
Cam Followers
Hydraulic Drive Motor
FRONT REAR
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HYDRAULIC CATWALK
MAIN TROUGH
• Another rigid structure of the Catwalk that is designed to control and contain all Tubulars and Tubular
products to and from the rig floor
• Equipped with 3 sets of Kickers that eject the Tubulars from the Trough to either DS or ODS of the Catwalk
• The Trough houses the Skate and the Skate Drive System along with the Tubular Kickers built into the
Trough
Tubular Trough Kickers

FRONT REAR
Dual 80R Skate Drive Chain Chain Tensioner
Skate Drive Motor

Trough Connection to Base Carriage Chain Drive
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HYDRAULIC CATWALK
TROUGH KICKERS
CAUTION: Test Plunger Valves before operating Catwalk to ensure the Kickers will activate properly.
• Designed to eject Tubulars from the Trough to either DS or ODS of Catwalk
• They will only activate when Trough and Trough Carriage is in the “Home” position and the Plunger Valves
have been compressed
Plungers must be fully

compressed against base
frame in order to activate
the Trough Kickers.
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HYDRAULIC CATWALK
HYDRAULIC GULLWINGS
WARNING: DO NOT over load Gullwings with Pipe. Doing so may cause failure, collapse and cause serious
injury or death.
• The Hydraulic Gullwings generally were designed to hold Drill Pipe, Drill Collar, Tubing or Casing on
the ODS of the Catwalk
• There is a built-in Indexer in the Gullwing that dispenses Tubulars one at a time when
commanded either from the Valve Bank or from the Remote Control
• All Tubulars are held back by the Gullwing Stopper Pin, which can be adjusted for different sizes of
Tubulars
Built in Indexer
Gullwing Leveling Jack
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HYDRAULIC CATWALK
TUBULAR PIPE RUNS
• Designed to create a bridge between the Casing Pipe Racks and the Catwalk so that the
Operator is further away from the critical area
• They can be adjusted to suite multiple different heights of Pipe Racks and can be extended to reach
further away
CAUTION: Ensure all pins have Safety Pins in

place before Pipe Runs are moved. Not doing
so may cause the pins to slip out and cause
equipment damage or injury. Extendable Reach
Height Adjustment
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HYDRAULIC CATWALK
PIPE RACK INDEXERS
CAUTION: Ensure all connecting pins have Safety Pins in place so the Indexer Arm(s) DO NOT slide out during
operation.
• The Indexers are generally located on the DS of the Catwalk and are used to pick up Tubulars from the
existing Pipe Racks next to the Catwalk
• The longer Indexer Arms (A) can pick up Tubulars on racks as low as 18” and work with the Tubular Pipe
Runs
• The shorter Indexer Arms (B) can be used if the Pipe Racks are set up close to the Catwalk and, like the
longer Indexer Arms they will only pick up one Tubular at a time
WARNING: Always have Deck Pins in the opposite side of where you are picking up Tubulars.
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HYDRAULIC CATWALK
SKATE SYSTEM
• The driven Skate System Chain Devise is designed to push and retrieve to and from the rig floor
• It is driven by a Hydraulic Motor located at the front of the Main Trough
• It is connected to the Motor by 80R Chain that runs down both sides of the Main Trough giving the Skate
two connection points
Instead of relying on gravity to bring the Tubulars

back from the fig floor, the CPH Skate System has
a Grappler Arm on it that grabs the Tubular and
pulls it back to the required position
Dual 80R Drive Chain
WARNING: Always visually check the chain for tightness before operating the Skate, not doing so could result
in the chain to snap or jump links.
The Skate Hood is typically used when running

Casing/Tubing. The Skate Hood prevents the Tubulars
from jumping out of the Trough when the
Elevators are latched onto the Pipe. The Catwalk
comes with two different sizes for a multiple range
of Pipe.
CAUTION: Always use correct size of Hood for the Pipe the Catwalk is running. Using the wrong Head may
allow the Tubulars to slip out of the Trough when latched by the Elevators.
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HYDRAULIC CATWALK
REAR ARMS
• The Rear Arms are always activated after the Front Arms have reached their programmed height
• They push the Main Trough & Trough Carriage towards the rig floor reducing the overall angle of
presentation of the Main Trough on the rig floor
• They house one Cylinder each; However only one arm houses the PLC Sensor
A. Trough to Arm Pin Lugs

C B. Cylinder to Arm Bushing
C. Arm to Frame Pin Lugs
D. Spherical Bearings
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HYDRAULIC CATWALK
“LED” WORK LIGHTS
• Each Catwalk is equipped with two LED Work Lights
• These Work Lights are Atex Zone 1 Div. 1

• They can be turned on by the Switch located on the Main Panel on the Catwalk
Antenna for the Wireless

Remote System
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HYDRAULIC CATWALK
HYDRAULIC TANK
CAUTION: For proper Catwalk Operation ensure the Hydraulic Tank is filled when needed and always fill to
the top of the Sight Glass. Failing to do so may result in severe damage to the Catwalks Hydraulic System.
• The 190 Gallon Hydraulic Tank supplies Hydraulic Oil to the Valve Bank as well as the entire Catwalk
Hydraulic System
• The Hydraulic Tank is equipped with two (2) Sight Glasses
A. Top Sight Glass
• Always keep this Sight Glass filled with Hydraulic Oil

• This Sight Glass also detects oil temperature, when the A
temperature rises over 80ºC the Catwalk will shut down Fillcap
B. Bottom Site Glass
• NEVER let Hydraulic Oil get to the Bottom Sight Glass, it may B
cause the Main Pump to run dry
• This Sight Glass is equipped with a Low Oil Sensor and is triggered
when Hydraulic Oil is reaching dangerously low levels
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HYDRAULIC CATWALK
CATWALK CONTROL SYSTEMS
MAIN CONTROL PANEL

H
• The Main Control Panel supplies power to all of the G
A
Catwalk’s Electrical Components
F
• This panel should always remain closed
• Only qualified personnel should open the Main Control Panel E D
• Before initially starting the Catwalk after it has sat dormant for C B
any period of time, always ensure adequate power is being
supplied as per the Power
DESCRIPTIONS
A. Main Power Switch & Lock Out: This allows power to the Catwalk, always make sure that the handle is
turned to the OFF position when hooking up power to the Catwalk
B. Catwalk Running Indicator & Button: When the Main Power Handle is turned ON and the selector switch
is turned to the HAND position the Catwalk can be started by pressing the top button, the GREEN Indicator
will illuminate once Catwalk is running
C. Catwalk Stop Indicator & Button: This button will shut the Catwalk down. When the Catwalk is shut down
the RED Indicator will illuminate
D. PLC & Manual Selector Switch: This switch allows the Operator to switch between running the Catwalk
manually and the PLC Remote System; the Catwalk will only start manually if the switch is turned to the
HAND position, if it is turned to the AUTO position the Catwalk can only be started from the Remote Control
E. Low Oil Indicator: The Low Oil Sensor Light will illuminate when triggered. At this time the Catwalk should
be shut down, checked for leaks and then the Oil Tank properly filled before work continues
F. High Temperature Indicator: Will illuminate when the Hydraulic Oil has exceeded 80 °C, in this case turn
the Catwalk off to prevent damage to the Hydraulic System. Ensure the Hydraulic Cooling Fan is operating
properly
G. Hour Meter: This will inform the Operator how many hours the Catwalk has been operating
H. LED Light Switch: This switch controls the LED Lights on the rear of the Catwalk, always turn OFF the Lights
when not in use
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HYDRAULIC CATWALK
PLC CONTROL BOX & SENSORS
A. PLC Control Box

• This panel is the Control Center for all the PLC Sensors and the Catwalks
Motion Control
A
• This panel should NEVER be opened unless a CPH Representative is
present
• RED Indicator will flash when there is a PLC Error (A) please see Error
Codes below
B. Balluff Sensor & Temposonic Cylinder

B
• These Sensors must be check daily for damages
• Before operating the Catwalk ensure the Connection Cable (B) is
securely fastened
• If Catwalk is not operating properly with the Remote Control, check all
Sensors to ensure the GREEN light (C) is illuminated, showing the Sensor
is ON and signaling
WARNING: Tampering with the PLC Panel may cause PLC System Failure which may damage equipment
and cause injury.
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HYDRAULIC CATWALK
MAIN VALVE BANK
• The Main Valve Bank controls all the main functions of the Catwalk
• Valve Handles should only be used to operate the Catwalk and should NEVER be used as a hanger
A B C D E F G H
A. Driller Side Indexer: This handle controls the DS Pipe Rack Indexer and is used to pick Tubulars off of the
Pipe Racks and transfer them to the Main Trough, then back to the Pipe Racks when pulling the Tubulars
out of the hole
B. Driller Side Trough Kicker: This handle controls the DS Trough Kicker and kicks the Tubulars out towards
the DS of the Catwalk
C. Off Driller Side Trough Kicker: This handle controls the ODS Trough Kicker and Kicks the Tubular out
towards the ODS of the Catwalk
D. Off Driller Side Indexer: This controls the Indexer inside of the Hydraulic Gullwing and will pick up one
Tubular at a time off the Gullwing and transfer it to the Main Trough
E. Skate Control: This handle controls the Skate on the Main Trough, holding it up will move the Skate
forward and holding it down will pull the Skate back
F. Main Trough Extension: This handle controls the Main Trough Extension, holding the handle up will
extend the Trough and holding the handle down will retract the Trough to its “Home” position
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HYDRAULIC CATWALK
G. Rear Arm Control: This handle controls the Rear Arms on the Catwalk, both handles need to be lifted
equally to activate the Rear Arms, NEVER lift Rear Arms if the Front Arms are not lifted
H. Front Arm Control: These handles control the Front Arms on the Catwalk, again both handles need to be
lifted to activate the Front Arms equally
I. Main Valve Bank Pressure Gauge: Indicates what the pressure is when any of the Main Valve controls are
activated, pressure should NEVER exceed 3000 PSI
WARNING: Lifting the Rear Arms before the Front Arms will cause severe damage to the Catwalk.
AUXILIARY VALVE BANK
• This Valve Bank controls all Auxiliary Components on the Catwalk

• These handles should only be used to control Auxiliary Components. NEVER use as hangers
A. Front Driller Side Leveling Jack: Controls the Leveling Jack on the Front Driller Side of the Catwalk
B. Rear Driller Side Leveling Jack: Controls the Leveling Jack on the Rear Driller Side of the Catwalk
C. Front Of Driller Side Leveling Jack: Controls the Leveling Jack on the Front Of Driller Side of the Catwalk
D. Rear Of Driller Side Leveling Jack: Controls the Leveling Jack on the Rear Of The Driller Side of the Catwalk
E. Front Driller Side Gullwing Leveling Jack (if equipped): Controls the Front Driller Side Leveling Jack on the
Gullwing
F. Rear Driller Side Gullwing Leveling Jack (if equipped): Controls the Rear Driller Side Leveling Jack on the
Gullwing
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HYDRAULIC CATWALK
G. Front Of Driller Side Gullwing Leveling Jack (on conventional units): Controls the Front Of Driller Side
H. Rear Of Driller Side Gullwing Leveling Jack (on conventional units): Controls the Rear Of Driller Side
I. Winch Control: Controls the Hydraulic Winch attached to the rear of the Catwalk; Pulling the handle up
will let out cable and pulling the handle down will retract the cable if installed
EMERGENCY STOPS
There are three (3) Emergency Stops for the Catwalk located on the rear (A) and the front of the Catwalk (B).
There is also an Emergency Stop on the Remote Control System (C).
The E-Stop can be triggered by pressing the RED button firmly.
CAUTION: Only use Emergency Stops in an emergency situation. Using the Stops as a conventional way to
kill power to the Catwalk may cause damage to the system.
NOTE: Before starting the

Catwalk manually or by
Remote, ensure all E-Stops
have been pulled out.
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HYDRAULIC CATWALK
SPOTTING AND INITIAL POWER UP OF THE CATWALK & LEVELING SYSTEM

SPOTTING THE CATWALK
When spotting the Catwalk visually check the area where the Catwalk will be placed and ensure it is free of
debris, that may cause damage to the Catwalk.
V-DOOR SET UP (IF EQUIPPED)
Before folding over the V-Door into position check to ensure the bolts on the Trunion Mounts are tight and in
place.
• Once all visual checks have been completed the V- Door

can now be hoisted to the rig floor by using the rigs winch
system
• The V-Door should sit flush with the rig floor to avoid any
tripping hazards (A)
A
ENERGIZING THE CATWALK
After hooking up the Catwalk to the rigs power source, a Qualified Electrician, should first ensure that the proper
voltage is being supplied to the Catwalks Main Panel (A).
CAUTION: Before hooking up Catwalk to rig power, have all

handles on Catwalks Main Panel turned to the OFF position; A
not doing so may cause damage to the Catwalks Control
Systems.
WARNING: High voltages are present at this time, any misuse of

tools or removal of cables may result in electrocution and cause
severe injury or death.
• Once power has been correctly supplied to the Catwalk the

Main Panel should be closed and locked
• Before starting the Catwalk all initial inspections must be done and documented
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HYDRAULIC CATWALK
INITIAL INSPECTION
• Check entire Catwalk for any fluid leaks
• Check tightness of all Drive Chains, if loose refer to “Tightening Chains” in the Manuals Contents page
• Ensure all grease points have been properly lubricated as per the “Greasing” portion of this Manual
• Ensure all pins are in place and all Safety Pins are present
• Check all PLC Sensors to ensure cable is securely fastened
WARNING: Anything found during the Inspection should be properly fixed and documented before Catwalk
is operated. Not doing so could result in damage to the equipment and or injury to rig personnel.
• Check the Remote Control Antenna for any damage after a rig move and make sure it is securely fastened
• Check Hydraulic Tank and make sure it is filled, see filling Hydraulic Tank (Page 26)
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HYDRAULIC CATWALK
FILLING THE HYDRAULIC TANK
• Before starting the Catwalk the Hydraulic Tank must be filled with the proper Hydraulic Oil depending on
the climate the Catwalk is operating at
• Filling the Catwalk with the incorrect oil may result in slow operation and damage to the Main Pump
• Fill fluid from the Main Fluid Cap located on the top of the DS of the Hydraulic Tank (A)
• Fill the tank until the oil has filled the top Sight Glass on the side of the Hydraulic Tank
Fill to Here
CAUTION: Only use clean Hydraulic Fluid to fill the Hydraulic Tank. Using contaminated oil will cause
Hydraulic System Failure and cause severe damage to the Catwalk.
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HYDRAULIC CATWALK
INITIAL CATWALK START UP
1. Turn Main Power switch to ON position

2. Have all E-Stops pulled out
3. Make sure no handles are pulled up or down on the Main or Auxiliary Valve Bank
4. Proper rotation of Catwalks motor needs to be confirmed, see check Motor Rotation below
OFF ON H
MOTOR ROTATION
• To check Motor Rotation follow steps above and then press the GREEN power button (1) on the panel and
quickly press the RED button (2) to kill the power
• Motor should be turning towards the Operator, if not wiring will need to be adjusted at the rigs power
source
1 2
CAUTION: If Catwalk is left ON with the motor rotating in the wrong direction, severe damage will be caused
to the Catwalk.
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HYDRAULIC CATWALK
MANUAL CATWALK START UP
• Turn Main Power handle to ON (A)
• Turn HAND and AUTO selector to HAND (B)
• Press the GREEN START button (C)
• Motor will turn on
• Allow the Hydraulic Pressure to rise to 1500 psi, this is the Catwalks stationary pressure
A B C
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HYDRAULIC CATWALK
LEVELING OUT THE CATWALK
• The Leveling Jacks are located on all 4 corners of the Catwalk

• All 4 Leveling Jacks are controlled by the Auxiliary Valve Bank
• Each Leveling Jack can be controlled individually by lifting in a synchronized manner
A. Controls the Driller

Side Leveling Jacks
front & rear
B. Controls the Off
Driller Side Leveling
Jacks front & rear
A B
• Once Catwalk is lifted by the Leveling Jacks use wood or rig matting to support the Catwalk
NOTE: It is critical to support the entire length of the Catwalk.
CAUTION: It is critical that the Catwalk is very level both side to side and length ways. If Catwalk is not level
damages may occur during operation. Components that may be damaged include Front Arms, Rear Arms,
Skate System and Trough.
WARNING: Leveling Jacks MUST be fully retracted before the Catwalk can be moved. Failing to do so will
cause severe damage to the Leveling Jacks.
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HYDRAULIC CATWALK
SETTING UP THE CATWALK FOR OPERATION

PIPE RACK INDEXERS
• The height of Pipe Racks that the Indexers will be picking the Tubulars from will determine which type of
Indexer Arms to use
• If the Indexer Arms are picking up Tubulars off of 18” Pipe Racks then the long Hockey Stick Style Indexer
Arms should be used; if the Pipe Racks are 48” tall and close to the Catwalk then the shorter Indexer Arms
may work better
• Once the Operator has chosen what Indexer Arm to use, he then must remove them from their transport
positions into the Indexer Arm Receivers located on the Driller Side of the Catwalk
• Remove the bottom pin on the Receiver and slide the Indexer Arm into place; once the arm is in place slide
the pin back through the Receiver and through the Indexer Arm locking it into position
• This is a two person job… always have help
A. The transport storage for the long Hockey Stick Style Indexer Arms
B. The long Indexer Arm once properly set up
C. Short Indexer Arm once properly set up
CAUTION: Not properly pinning the Indexer Arms may cause them to slip out causing damage to the Catwalk
and/or injury to the Operator and/or Tubulars. Always ensure the “Safety Pins” are in place.
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HYDRAULIC CATWALK
PIPE RACK CASING RUNS
• The Pipe Rack Casing Runs are generally located on the Driller Side of the Catwalk
• Depending on what height the Pipe Racks are the Operator may need to adjust the pin location of the arm
• The arms swing out and can extend towards the Pipe Rack
• The arms should be placed below the first row of Tubulars so that the Tubulars do not drop onto the arms
but gently roll towards the awaiting Indexer Arms
HOME POSITION WORKING POSITION
Reach Adjustment
Height Adjustment Pins
CAUTION: Casing Runs must be securely positioned in between rows of Tubulars so that they do not fall out
when Pipe is being rolled across them causing damage to the equipment and or injury to personnel.
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HYDRAULIC CATWALK
HYDRAULIC GULLWINGS
• The Hydraulic Gullwings are typically found on the Off Driller Side of the Catwalk
• Once un-pinned in the center they will swing out until they create a 90º angle between the Catwalk and
the Gullwings Arm (A)
• Once in that position the Gullwing Stopper Bars must be installed so that the Gullwing cannot swing back
towards the Catwalk (B)
• From the Auxiliary Valve Bank the Gullwing Leveling Jacks can be lowered, only lower the Leveling Jacks
until they touch the ground
• Before the Leveling Jacks are used to raise the Transport

Gullwings, the Transport Pin needs to be changed
to the Operation Position
• The Operation Position allows the Gullwing to
rotate upwards and downwards depending on if Operation
you are loading or unloading Tubulars from the
Catwalk
• Now that the Gullwings are properly set up the Gullwing Stopper Pins must be installed as well as the End
Stopper Pins before any Tubulars are loaded
End Stopper
Gullwing Stopper Pin
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HYDRAULIC CATWALK
SKATE SYSTEM
There are two ways to configure the Skate System:
1. Attaching the Pull Back Arm; this is used when pulling back Tubulars from the rig and laying them down
2. Attaching the Casing Hood; this is used when the Catwalk is picking up Tubulars so that the Tail End of
the Tubular does not jump out of the Trough when the Elevators are latched
When setting up the Retrieval Head, the Operator must check the following things:
A. Ensure that the Gripper Dies’ are pointed in the proper

direction with the teeth pointed towards the Skate D
B. This piece clamps the Skate to the Trough; If this is loose the
Pull Back Head will not engage, (DO NOT over tighten) snug
only
C. Adjust the pin to the size of the Tubular the Skate will be pulling
back C
A B
D. This should be adjusted so that the Gripper Head grips the
Tubular below the upset
E. The Casing Hood should be securely pinned in place E
F. Ensure the proper sized Casing Hood is used for the size of
Tubular the Catwalk is running
CAUTION: Before operating the Skate ensure both chains and

all bolts are tight. F
NOTE: Once all components have been properly set up, the Operator should test the Catwalk to ensure all
functions are working properly. If issues are found the Catwalk should be shut down, locked-out and
evaluated before operating any further.
CAUTION: When operating the Catwalk for the first time, move all functions slowly until the Operator
knows where each function starts and stops and how it reacts to the movement from the Valve Bank.
Operating at full speed for the first time may result in equipment damage and or injury to the worker.
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HYDRAULIC CATWALK
OPERATING THE CATWALK WITH THE WIRELESS REMOTE SYSTEM

REMOTE OVERVIEW
H
I G
A B C D E F
A. Main Lift Toggle: This controls the Front Arms, Rear Arms, and the Trough Extension. Moving it upwards will
command the Front and Rear Arms to lift. Once they have reached their programed height, the Trough will
extend from the base carriage
B. Skate Toggle: Controls the movement of the Skate inside the Trough
C. Driller Side Pipe Rack Indexer Toggle: Pick up Tubulars on the DS of the Catwalk
D. Driller Side Trough Kicker Toggle: Remove/Kickout Tubulars from the Trough to the Driller Side of the
Catwalk
E. Off Driller Side Trough Kicker Toggle: Remove/Kickout Tubulars from the Trough to the Off Driller Side of
the Catwalk
F. Off Driller Side Indexer Toggle: This controls the indexer inside of the Gullwing to load one Tubular at a time
G. Emergency Stop: This should only be used in an Emergency situation
H. Remote ON Indicator Light: When this light is illuminated it means the Remote Control is turned ON. When
this light blinks vigorously it may mean that the battery is getting low and needs to be changed
I. These two switches are used when the Operator chooses to program a new height for the Catwalk to ascend
to or adjust the trough presentation on the rig floor
J. The GREEN button is used to arm the Remote,
turn the Catwalk on, and also save the desired
programmed height into the Catwalks PLC J
System
L
K. Key to turn the Remote Control ON
K
L. These two buttons are used to turn the Catwalk
ON from the Remote
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HYDRAULIC CATWALK
REMOTE CONTROL CATWALK START UP
Before starting the Catwalk always make sure that the Catwalk is being supplied with the proper amount of
power.
NOTE: Remote System will only work when Selector Switch is turned to AUTO.
STEPS:
1. Turn Main Power Handle to ON position

1
2. Turn HAND & AUTO Selector to AUTO
3. Turn the Remote ON by turning the key on the Remote 90 °
The Remote should buzz two times; when you see the GREEN light indicator illuminated and blinking
the Remote is now ON.
4. Press the GREEN button on the side of the Remote Control to connect the
Remote to the System 2
5. Press either the + or – buttons on the side of the Remote Control

6. The Catwalk should be started at this point
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HYDRAULIC CATWALK
PROGRAMMING NEW HEIGHTS USING THE REMOTE CONTROL
When programing the Catwalk to reach a new height or a rig floor presentation, the Operator must always use
the RED key. The Catwalk re-programing will not work with the BLACK key.
• The Operator will start the Catwalk with the RED key
only turning it 90º
• Once the Catwalk is started the Operator must “HOME” Program
the Catwalks PLC System Key
• To do this the Operator will hold the Trough Lift Toggle

downwards until the Operator sees the Front Lift, Rear
Lift and Trough Extend Valve Bank Handles pull down
equally and simultaneously. The Operator will hold the
paddle down for a count of 10 (ten) seconds Regular
Operation Key
• The Catwalk now knows where “HOME” is
Now that the Catwalk has been “HOMED” the Operator can now start the process of programming a new height
for the Catwalk.
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HYDRAULIC CATWALK
WRITTEN STEPS
1. With the Remote on, turn the RED key from 90º to 180º (the Remote will now be in program mode)
2. Press and hold the Front Lift & Rear Lift Selector to the Front Lift (1)
3. While holding the Selector to Front Lift use your other hand and push the Trough Lift Toggle upwards to
raise the Trough until it is at your desired height then release both the Front & Rear Selector and Trough
Lift Toggle Together
4. Press and hold the Front Lift & Rear Lift selector to the Rear Lift (2)
5. While holding the selector over to Rear Lift use your other hand and push the Trough Lift Toggle upwards
to raise the Rear Arms until they are at the desired height; then let go of both the Front & Rear Selector
and Trough Lift Toggle together
6. Press and hold the Extend Selector over to the Extend (3)
7. While holding the selector over to the extend, use your other hand to push the Trough Lift Toggle upwards
until the Trough has been extended to the desired distance. Once the distance has been achieved let go of
both the Extend Selector and the Trough Lift Toggle together (6)
8. The Catwalk should now be in the Operators newly set desired position
9. To save the position press and hold the GREEN button on the side of the Remote Control and move either
the Front Lift/Rear Lift or the Extend Selectors back and forth three times. The Catwalk should now be
programed to the desired height. (4)
10.Turn the RED key back to the 90º position and run the Catwalk down to the “Home” position. The Operator
should run a full cycle up and down with the Catwalk to ensure the program was set properly (5)
11.Once the Operator is satisfied with the program, he then must turn the Remote OFF and insert the BLACK
Operating Key
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HYDRAULIC CATWALK
VISUAL STEPS
1 2
• Press and hold Front Lift Selector (1)
• While holding the selector press Trough Lift

Upwards until Front Arms are at desired
height (2)
• When at desired height let go of both selectors
Raising Rear Arms
1 2
• Press and hold the Rear Lift Selector (1)
• While holding the selector press Trough
Lift Upwards until the Rear Arms are at
desired height (2)
• Once at the desired height let go of both
selectors together
Extending Trough
1 2
• Press and hold the Rear Lift Selector (1)

• While holding the selector press Trough
Lift Upwards until the Rear Arms are at
desired height (2)
• Once at the desired height let go of both
selectors together
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HYDRAULIC CATWALK
Save Program
• Turn RED key back to the 90 º position
• Press the Trough Lift Toggle downwards to run the Catwalk back to its “Home” position
• Once in the “Home” position run the Catwalk back up to ensure the Catwalk is set to where the Operator
has programed it to
Operation
Program
• If the Operator is satisfied with the program of the new position, he must turn the Catwalk OFF, remove
the RED key and replace it with the BLACK Operating Key
• The Catwalk is now ready to run in regular operations
WARNING: When programing the Catwalk no one should be near the Catwalk and proper hand signals
should be visual while the Catwalk is ascending to the rig floor. If Operator cannot see hand signals then
radio contact should be present. Not doing so can result in damage to the rig and the Catwalk and may
cause severe injury or death.
CAUTION: When programing the Catwalk always move slowly to ensure Catwalk is at correct height so it
does not make contact with the rig floor. DO NOT program Catwalk if it is loaded with a Tubular or Tubular
product.
[Revision 2]
CATWALK – INSPECTION & MAINTENANCE GUIDE
Nicholas Morelli
Revision 1
CATWALK
INSPECTION & MAINTENANCE GUIDE
[Revision 1]
CATWALK
[Revision 1]
CATWALK
[Revision 1]
CATWALK
[Revision 1]
HERCULES
HYDRAULIC CATWALK – PLC/HMI Troubleshooting Instructions
Nicholas Morelli
Revision 1
HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
TABLE OF CONTENTS
HOME SCREEN ...........................................................................................................2

REMOTE CONTROLLER ...............................................................................................3
POSITION SETTINGS ...................................................................................................4
ADMINISTRATOR SETTINGS START SCREEN................................................................5
SET TIME ....................................................................................................................6
FIRST COMMISSION SCREEN ......................................................................................7
AUTORANGE SETTINGS ..............................................................................................8
SPEED RANGES ..........................................................................................................9
SPEED SETTINGS ...................................................................................................... 10
ALARMS ................................................................................................................... 11
OUTPUT TREND (BETA) ............................................................................................ 12
GENERAL REVIEW .................................................................................................... 13
BASIC CUSTOMER SETUP .......................................................................................................................... 13
ADMINISTRATOR SETUP ............................................................................................................................ 13
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HYDRAULIC CATWALK
HOME SCREEN
The Home Screen is the first screen one sees on the HMI. The current reading of the Position for each sensor is
displayed, as well as the commanded Speed. The position percentage is based on a full range of 4-20 mA, and
therefore not necessarily the fully in to fully out span.
There in an indicator on the right showing if the Emergency Stop is active, as well as error indicators showing if
an axis has gone too fast or too slow (FF = Front Scissor Fast, RS = Rear Scissor Slow, etc.). If one or more of
these are lit up, they need to be pushed to reset.
The “Auto_Man” switch controls how the catwalk will respond to the Remote Control “Main”. When switched
to “ON”, the “MAIN LIFT” paddle on the remote will control all configured axis (Front Scissor, Rear Scissor, and
Extend). Holding up on the paddle will first ramp the Front Scissor up to the High position, then ramp the Rear
Scissor, then the Extend. Holding down on the paddle will reverse the operation back to Home (Extend, then
Rear, then Front). With this switch “ON”, the paddle can be held at full.
ENSURE THAT THE CATWALK IS CONFIGURED TO PROPER HOME AND HIGH POSITIONS BEFORE USING AUTO
“ON”.
The buttons at the top of the screen will switch screens to a visual of the remote control, or the Position Settings
screen.
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HYDRAULIC CATWALK
REMOTE CONTROLLER
The Remote Controller screen is a visual display of the remote. When a toggle or button is engaged on the
remote, the corresponding visual will go brighter. The value shown on the MAIN LIFT paddle is the voltage
output, showing the proportional control from that paddle. This is configured in the ranges of 1.5-4.5 V down,
and 5.5-8.5 V up. 1.5V is max down, and 8.5 is max up.
The proportional control from the remote is combined with the set speed for a particular zone to give the final
output speed.
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HYDRAULIC CATWALK
POSITION SETTINGS
The Position Settings screen is where the Home and High values are generally set in the field. Move the catwalk
manually to the Home position, then press “Set Current Position as HOME”. Similarly, move the catwalk
manually to the desired final position, then press “Set Current Position as HIGH”.
The values displayed are based on a full range of 4-20 mA. They show the Home and High position settings, as
well as the current reading from the sensors.
The buttons at the top of the screen switch to the “Home Screen” or “Administrator Settings Start Screen”. The
Commissioning Settings button is Username and Password protected.
Some displays have a limit for incorrect entries. Ensure the username and password are correct.
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HYDRAULIC CATWALK
ADMINISTRATOR SETTINGS START SCREEN
The Administrator Settings Start Screen is an access point for further configurations.
The “Auto_Man” switch is the same switch as on the Home Screen.
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HYDRAULIC CATWALK
SET TIME
The Set Time screen is where the PLC Date and Time is set. Enter the Date and Time in the format shown, then
press “Set” to send to the PLC.
The “Background Graphic” switch allows the background picture to be turned off on this screen and the Home
Screen.
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HYDRAULIC CATWALK
FIRST COMMISSION SCREEN
The First Commission Screen allows initial testing of speed and direction for each axis. Enter a speed in to the
left of “Speed Setting %” text. Select which axis to move on the lower buttons, and then press UP or DOWN.
Start slow (eg. 15 -20) and move up from there. There is a minimum value typically in this range that will move
the axis, due to the value controller. Do not enter more than 100.
The current positions and actual commanded speed outputs are shown.
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HYDRAULIC CATWALK
AUTORANGE SETTINGS
The AutoRange Setting screen sets the values for the Speed Zones based on the set Home and High values.
The calculated ranges are shown on the Speed Range Setting screens.
Always confirm the ranges on the individual Speed Ranges Settings screens to double check the adjustments
are appropriate.
Note the negative and positive values for the proper progression of ranges.
The values on this page can be entered manually by pressing on the I/O box showing the current value.
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HYDRAULIC CATWALK
SPEED RANGES
The individual Speed Ranges are used with the settings on the Speed Settings screen for each Range. When an
axis is a range shown on this screen, it will use the corresponding speed setting to allow smooth transitions.
Several options are available for populating these values. Currently the lower left button shows “Disable Auto
Calculation”, which denotes that it is currently auto – calculating the values using the values set for Home and
High, and adding the values in the AutoRanging Screen. (i.e. The Home value was set to 2.34, either on this
screen or the Position Settings screen, and the High value was set to 56.52. The Low Limit is then auto calculated
as 2.34 + (-2.00) = 0.34. The Very Slow To High value is auto calculated to 56.52 + (-7.00) = 49.52. Other values
calculated accordingly.)
If the “Disable Auto Calculation” is selected it disables the auto calculation for all axes and will change the
button text to “Enable Auto Calculation”.
The ranges can be set in sequence by selecting “Initialize Setting Procedure”. The text box will request to move
axis to Low Limit. Move axis as requested, then select “Set Current Selection”; or enter a value next to “Manual
Entry” if current position is not as desired, then select “Manual Entry”. The value for the specific set point will
change and the text box will request the next range point. Continue until all ranges are complete, or select “Exit
Setup” at any point.
Each value can be entered manually as well. If auto calculation is enabled, only changes to Home or High will
be accepted.
[Revision 1]
HYDRAULIC CATWALK
SPEED SETTINGS
The Speed Settings screen allows adjustments for UP and DOWN speeds, separately for each range. The speeds
entered above are for the corresponding range in text between the UP and DOWN values.
Also on this screen is an entry for “Max Measured Speed Limit”, which reads if there is a runaway. It is a
representation of the Percentage Change in Axis per Second. This should be set high enough to avoid any
nuisance errors.
In the bottom right of the screen, the “Ramp” value allows adjustments to the rate of change in speed when
entering a new zone. A higher value changes quicker, a lower value changes slower. If the ramp is too slow, the
axis may not reach the set speed by the end of the current zone. This would be most important to watch for at
the Home and High positions.
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HYDRAULIC CATWALK
ALARMS
The Alarm screen will pop up when any alarm appears, with a time stamp based off the HMI time (set in the
Control Panel of the HMI before the program runs). It shows a description of the alarm, as well as the Status.
The Status will show an “I” for Incoming alarms when an alarm occurs. If the alarm condition is removed the
Status will add an “O” for the Outgoing indication, showing “IO”. If the alarm is then acknowledged by the
selecting the Green Check Mark icon at the bottom right of the pop up, the alarm will disappear from the list.
If an alarm is acknowledged while the condition is still active the Status will show “IA” for Incoming
Acknowledged, and will disappear when the condition is removed.
A small icon appears showing a warning sign and the number of currently active unacknowledged alarm
conditions. It can be moved with drag ‘n’ drop to anywhere on the screen, and will disappear when all alarms
are outgoing and acknowledged.
The main alarm pop up can be moved on the screen, or closed with X in the top right corner. To reopen the pop
up, select the alarm indication warning icon. If the icon is not present, there are no alarms to acknowledge.
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HYDRAULIC CATWALK
OUTPUT TREND (BETA)
The Output Trend screen shows a 100 second snap shot of the current PLC output command of each axis, and
was used in testing.
[Revision 1]
HYDRAULIC CATWALK
GENERAL REVIEW
BASIC CUSTOMER SETUP
When setting to a new height: Set the Auto_Man to off go to the Position Setting screen, move all axes manually
to desired Home then “Set Current Position as Home”, then move all axes manually to High position and “Set
Current Position as High”. Return all axes to Home manually before switching to auto.
The High position can also be set by holding the ARM/SET button on the Remote for 10 seconds.
ADMINISTRATOR SETUP
The Administrator Setup will initially be done at the factory during commissioning.
Test the Remote ESD and HPU Stop Start.
Ensure the “Auto_Man” switch on the HMI is “OFF” for manual control.
Use the manual hydraulics to move the catwalk into a middle range area. Go to the First Commission screen
and test all axes for direction and speed control.
Move the catwalk manually to a temporary Home position above the hard limit down, to give room for
overshoot while configuring speeds. Set position to Home.
Move catwalk manually to a temporary High position below the hard limit up, to give room for overshoot while
configuring speeds. Set position to High.
Ensure there is a wide enough range between Home and High so that all Speed Ranges can be used.
Check all Speed Ranges and Speeds for proper values. The ranges should not overlap and the speeds should be
lowest near the limits and highest in “Fast” range, similar to the example shown on the Speed Settings
screenshot.
Manually move all axes to the temporary Home.
Enable the Front toggle on the Remote and push the MAIN LIFT paddle all the way up. The Front Scissor should
ramp up and down through the speeds and ranges, and stop just past the temporary High position. Be ready to
let go of paddle and stop the hydraulic paddles or E-Stop. Adjust speeds and/or ranges as necessary. Push the
MAIN LIFT paddle all the way down and watch the ramping on the way down. The Front Scissor should stop just
past the temporary Home position.
Start with ranges large enough so that the speed visibly finishes ramping to the new speed, and the overshoot
of Home and High is as small as possible (~0.5%). The ranges and speeds can then be fine-tuned for smooth
motion.
[Revision 1]
HYDRAULIC CATWALK
The axes will have a minimum value for the Speed Setting that will move the axes. This value will be higher
when moving from a standstill.
Repeat the above individual testing for the Rear Scissor, then the Extend, as was done with the Front Scissor.
When finished, manually return the axes to the temporary Home.
Change the “Auto_Man” switch on the HMI to “ON” to enable Auto.
Hold the MAIN LIFT paddle on the Remote all the way up and watch the Front Scissor ramp to High position.
Keep holding the paddle all the way up and the as the Front Scissor enters its Very Slow to High range the Rear
Scissor will start to ramp up. When the Rear Scissor enters its Very Slow to High range, the Extend will start to
ramp up and proceed to its High Position.
Hold the MAIN LIFT paddle all the way down and the catwalk will return to home with ramping and overlapping.
Adjust Speed Ranges and Speeds as necessary for smooth operation.
Once operation is satisfactory, set the actual Home and High positions desired and test the speeds into the hard
stops.
Return to the Home Screen to exit commissioning. The login will last 1 hour from the time the Username and
Password are entered, but will only need to be re-entered if entering the Administrator Settings screen from
the Position Settings screen after the time expires.
[Revision 1]

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HERCULES

HYDRAULIC CATWALK – OVERVIEW

GENERAL NOTICES .....................................................................................................2

 Unauthorized duplication of this Manual, in whole or in part, is prohibited

 Confidential and Proprietary information may be contained herein

1) Hydraulic Tank 8) Leveling Jacks (4) 15) Strobe

*ESD Switches are located on the C as well as the Wireless Remote

E-Stop location Ground pin location

LIFT CARRIAGE ASSEMBLY

SKATE AND KICKERS

MAIN COMPENENTS (SKATE)

MAIN COMPONENTS (KICKERS)

MAIN COMPONENTS (INDEXERS)

*NOTE: The extra lift of the long

OPERATOR REQUIREMENTS AND RESPONSIBILITIES

 Understand fully all Catwalk operations and functions

CATWALK GENERAL SAFETY

 The Catwalk must be level before any operations commence

SPECIFIC COMPONENT AND EQUIPMENT OVERVIEW

A. Front Arm Frame Lug

HERCULES MAJOR COMPONENTS

HYDRAULIC LEVELING JACKS

• Located on all 4 corners of the Catwalk

• The arms move perpendicular to each

• The arms house two cylinders and one

• The arms must be greased daily to ensure

• The Front Arms are used to advance trough

Front Arm Connection 100R Dual Chain Rear Arm Connection

Tubular Trough Kickers

Dual 80R Skate Drive Chain Chain Tensioner

Skate Drive Motor

• Designed to eject Tubulars from the Trough to either DS or ODS of Catwalk

Plungers must be fully

TUBULAR PIPE RUNS

CAUTION: Ensure all pins have Safety Pins in

PIPE RACK INDEXERS

• It is driven by a Hydraulic Motor located at the front of the Main Trough

Instead of relying on gravity to bring the Tubulars

Dual 80R Drive Chain

The Skate Hood is typically used when running

A. Trough to Arm Pin Lugs

“LED” WORK LIGHTS

• Each Catwalk is equipped with two LED Work Lights

• These Work Lights are Atex Zone 1 Div. 1

Antenna for the Wireless

• The Hydraulic Tank is equipped with two (2) Sight Glasses

A. Top Sight Glass

• Always keep this Sight Glass filled with Hydraulic Oil

B. Bottom Site Glass

CATWALK CONTROL SYSTEMS

MAIN CONTROL PANEL

PLC CONTROL BOX & SENSORS

A. PLC Control Box

B. Balluff Sensor & Temposonic Cylinder

MAIN VALVE BANK

AUXILIARY VALVE BANK

• This Valve Bank controls all Auxiliary Components on the Catwalk

NOTE: Before starting the

SPOTTING AND INITIAL POWER UP OF THE CATWALK & LEVELING SYSTEM

V-DOOR SET UP (IF EQUIPPED)

• Once all visual checks have been completed the V- Door

ENERGIZING THE CATWALK

CAUTION: Before hooking up Catwalk to rig power, have all

WARNING: High voltages are present at this time, any misuse of