Nordco Super Claws LS-2 User manual

Super Claws
Model LS-2
Operation and
Maintenance
Manual
Applies to S/N 350537 and Above
Reorder Part: 49453500
Last Revision: Rev. -
MARCH 2006
Read and fully understand the precautions contained in this manual before operating
or servicing this machine. Refer to Section 1 for important safety information.
Com
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onent Troubleshootin
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can now be found on the blue
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This manual is a guide for the operation and routine maintenance of a NORDCO Railroad Maintenance
Machine. It covers product technical information, basic operating and maintenance procedures, and
safety information and is provided for use by the qualified personnel who will supervise, operate or service
the equipment described herein.
Measurements in this manual are given in both metric and customary U.S. unit equivalents.
Personnel responsible for the operation and maintenance of this equipment should thoroughly study the
manual before commencing operation or maintenance procedures.
This manual should be considered a permanent part of your machine and should
remain with the machine at all times.
Additional copies of this manual are available either as a part (Operation Manual
only) or a whole (operation and parts manual), at a nominal cost, through our Part
Sales Department. Additional service information, parts, and application information
is available through these Nordco product support resources:
NORDCO Sales: Milwaukee, Wisconsin
[phone]
[email protected]
NORDCO Parts: Milwaukee, Wisconsin
1-800-647-1724
[email protected]
Oshawa, Ontario, Canada
[phone], Ext. 224
[email protected]
NORDCO Service: 1-800-445-9258
[email protected]
We ask that if you have any comments or suggestions about this manual, let us hear from you. We are
here to be of service to you, our customers. Direct your comments and inquiries to:
Technical Documentation Department
NORDCO Inc.
245 W. Forest Hill Avenue
Oak Creek, WI 53154

HAZARDOUS MATERIAL DATA
In an effort to provide information necessary for your employee safety training program and to meet the
requirements of OSHA Hazard Communication Standard 1910.1200, we have OSHA Form 20 Safety Data
Sheets available that cover the material contained in this machine.
If you are interested in receiving this information, please refer to the Name, model, and Serial Number of
your machine when calling or writing, and direct your inquiries to:
Vice-President of Operations
NORDCO Inc.
245 W. Forest Hill Avenue
Oak Creek, WI 53154
Fax: [phone]
Phone: [phone]

This manual is a guide for the operation and routine maintenance of a NORDCO Railroad Maintenance
Machine. It covers product technical information, basic operating and maintenance procedures, and
safety information and is provided for use by the qualified personnel who will supervise, operate or service
the equipment described herein.
Measurements in this manual are given in both metric and customary U.S. unit equivalents.
Personnel responsible for the operation and maintenance of this equipment should thoroughly study the
manual before commencing operation or maintenance procedures.
This manual should be considered a permanent part of your machine and should
remain with the machine at all times.
Additional copies of this manual are available, at a nominal cost, through our Part
Sales Department. Additional service information, parts, and application information is
available through these Nordco product support resources:
NORDCO Sales: [phone]
[email protected]
NORDCO Parts: [phone]/4608
1-800-647-1724
[email protected]
NORDCO Service: [phone]
1-800-445-9258
[email protected]
Customer Support: [phone]
[email protected]
We ask that if you have any comments or suggestions about this manual, let us hear from you. We are
here to be of service to you, our customers. Direct your comments and inquiries to:
Manager of Customer Support
NORDCO Inc.
P.O. Box 1562
Milwaukee, WI 53201
Or
[email protected]

HAZARDOUS MATERIAL DATA
In an effort to provide information necessary for your employee safety training program and to meet the
requirements of OSHA Hazard Communication Standard 1910.1200, we have OSHA Form 20 Safety Data
Sheets available that cover the material contained in this machine.
If you are interested in receiving this information, please refer to the Name, model, and Serial Number of
your machine when calling or writing, and direct your inquiries to:
Vice-President of Operations
NORDCO Inc.
P.O. Box 1562
Milwaukee, WI 53201
Fax:[phone]
Tele:[phone]
[email protected]

Super Claws Model LS-2 SAFETY
MAR/2006 (4945-3500) Section 1-1
SAFETY
Please read and comply with all of the
safety precautions in this manual BEFORE
operating this machine.
GENERAL
DO NOT use this machine for machine
operations other than for which it was
intended.
NORDCO is not responsible for any
modifications made without authorization or
written approval. Replace all NORDCO
and OEM parts with genuine NORDCO or
OEM parts. Use of non-OEM parts could
compromise the safety of your machine.
FRA regulations require that a copy of this
Operation Manual be kept on the machine
at all times. Additional copies of the
Operation Manual only can be ordered
from Nordco Parts Sales at 1-800-647-
1724.
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety messages in this
manual. Learn how to operate the
machine and how to use controls properly.
Do not let anyone operate this machine
without instruction. Failure to understand
the contents of this manual could result in
serious personal injury or death.
SAFETY ALERT SYMBOLS!
These are the safety-alert symbols.
These symbols means pay
attention! Your safety is at risk!
DANGER is used to indicate a definite
hazardous situation which, if not avoided,
WILL result in severe bodily harm or even
death.
WARNING indicates a potentially
hazardous situation which, if not avoided,
COULD result in severe bodily harm or
even death.
CAUTION indicates a potentially
hazardous situation which, if not avoided,
MAY result in minor or moderate injury.
CAUTION without the safety “!” means that
failure to follow the alert may result in
machine damage.
SAFETY means that the following points
are instructions for safely operating the
machine or the specific component of the
machine.

SAFETY Super Claws Model LS-2
Section 1-2 MAR/2006 (4945-3500)
GENERAL SAFETY TIPS
Only trained and authorized personnel
should be allowed to operate this machine.
In addition, all personnel at the worksite
(gang) should be aware of the safety
concerns and their individual
responsibilities prior to working this
machine.
1. Handle fuel safely. It is highly
flammable and prolonged
breathing of fumes may cause
bodily harm.
2. Prepare for emergencies. Keep a
first aid kit and fire extinguisher
handy.
3. Wear adequate protective gear:
a. Safety Glasses
b. Good-fitting pants and shirt
c. Safety-toed work boots
d. Leather gloves
e. Hard hat
SAFETY PRIOR TO WORKING
All personnel at the worksite (gang) should
be aware of the safety concerns and their
individual responsibilities prior to working
this machine:
• Review the operating instructions if
you are unsure of anything.
• Use the “pre-operational checklist”
to check the machine for obvious
faults. Repair or replace as
necessary PRIOR to operating the
machine.
• Before climbing onto the machine,
make certain the area around and
under the machine is clear of
obstructions and personnel.
• Use care when climbing onto the
machine. Always use the steps
and handrails provided. (If an area
does not have tread grips,
walkways, or other methods to
access the area, then DO NOT
attempt to access that area.)
• Make seat and control adjustments
PRIOR to starting the machine.
ALWAYS wear a seatbelt.
• Know the weather forecast and
plan your work speeds accordingly.
• There are guards on this machine.
These are to be removed ONLY
when service or maintenance is
being performed on that area of
the machine. Make certain they
have been re-installed PRIOR to
starting the machine.
• Check and service the fire
extinguisher at regular intervals.
Make certain all personnel are
trained in its use. Note - Non-use
of fire extinguisher still requires
that it be recharged at the interval
stated on its last inspection notice.
• Keep the stairs, cab entry platform
and cab interior free and clear of
ice, tools and personal items. Use
the accessories provided on the
machine (tool box, cup holder, coat
hook, etc.) to properly store your
gear.
• Never climb onto the machine
while it is in motion.
• There are lockups on this machine
that are used for both work and
travel. These should be kept clear
and free of debris, grease, etc.
See Lockup section for
instructions on their use.
• Inspect safety decals and replace
when they become unreadable or
are damaged. (See “Safety
Decals”at the end of this Safety
section).

Super Claws Model LS-2 SAFETY
MAR/2006 (4945-3500) Section 1-3
SAFETY WHILE STARTING THE
MACHINE
NORDCO recommends the use of a
Command position. This means that the
machine is never running unless someone
is at or near the main control panel or
remote control boxes. To prevent injury to
personnel or damage to the machine, it is
highly recommended to:
1. Only start and operate the machine
from the operator’s seat.
2. Use the “STARTUP Checklist” to
check the machine controls and
gauges to make certain all systems
are operating correctly.
SAFETY WHILE
OPERATING/TRAVELING
1. Never allow more riders than seats and
seatbelts allow. This machine was
designed to be operated by one
person.
2. The machine is to be operated from
the Operator’s seat only. Do NOT
stand and operate this machine.
3. Press the EMERGENCY STOP
pushbutton on the center control
console in emergencies and potentially
dangerous situations.
4. If personnel or bystanders are near the
machine during operation, give a
warning signal using the air horn. If
they fail to respond to this warning,
stop operation immediately.
5. Slow down the work cycle and use
slower travel speeds in congested or
populated areas.
6. Halt work if visibility is poor. Strong
rains, fog, and extremely dusty
conditions can affect visibility in your
work area. Wait for the weather to
improve before continuining work.
SAFETY WHILE PARKED
When leaving a machine engine running,
make certain that the parking brake is
applied and the electrical interlock button
has been activated.
NEVER stop and park this machine on an
incline unless the machine wheels have
been chocked.
SAFETY DURING MAINTENANCE
The following guidelines are suggested
when performing maintenance:
1. Always chock the wheels
2. Alert others in the area that service
or maintenance is being performed
on this machine.
3. Become familiar with, and use,
your company’s lockout/tagout
procedures when performing
maintenance on this machine. See
LOCKOUT/TAGOUT
REQUIREMENTS later in this
Safety Section for a chart on
energy sources located on this
machine.
4. Do not start the engine if repairs or
work is being performed alone.
You should always have at least
two people working together if the
engine must be run during service.
One person needs to remain in
the command position (at the
controls), ready to stop the
machine and shut off engine if the
need arises.
5. Collect oils and fuels and dispose
of them properly. There is a
danger of scalding when working
with engine oils.
6. Use only Nordco supplied repair
parts for this machine. Use of non-
OEM designed parts could
comprise the integrity of this
machine.
7. There are welding cautions on this
machine. Pay attention to them
PRIOR to welding.
8. Kits supplied by Nordco have
welding instructions included.
Welding of any components NOT
of Nordco’s manufacture or failure
to follow these instructions may
affect the stability of this machine.

SAFETY Super Claws Model LS-2
Section 1-4 MAR/2006 (4945-3500)
MACHINE SAFETY
ALERTS
DANGER ALERTS
Improper use of this machine for any type
of operation can cause serious injury or
death.
To avoid serious injury or death, make
certain that the area around and under the
machine is clear of all personnel and
obstructions BEFORE travelling or working.
Serious injury or death can result from
reaching into working components while
machine is running. Make all observations
from a distance and SHUT OFF machine
while making adjustments.
Shut off engine when checking battery
electrolyte level. Do not check or fill battery
in presence of open flame, sparks, or when
smoking. Battery fumes are flammable
and/or explosive and if ignited will result in
severe bodily injury or death.
Do not ride on tow bar between the
machine and the towing vehicle. Falling
from a moving vehicle may cause serious
injury or death.
MACHINE SAFETY ALERTS
WARNING ALERTS
Failure to engage all lockup devices before
propelling at travel speed can result in
injury to personnel and/or extensive
damage to the machine.
Remove hoses/fittings only when system is
not pressurized. High pressure leaks can
cause personal injury.
Always turn off machine when performing
maintenance, making adjustments, or
whenever unintended movement of
machine could occur; unless directed
otherwise. Failure to comply could result in
personal injury and/or damage to the
machine.
Exhaust emissions caused by the use of
the engine on this machine may cause
cancer, birth defects, or other reproductive
harm if inhaled.
Disconnect the battery before servicing this
machine. Failure to do so could result in
personal injury from accidental engine
startup.
When machine is to be turned using the
turntable, raise machine only high enough
for the wheels to clear the rail.
CAUTION ALERTS
Before starting a new or overhauled engine
that has been in storage, consult the
engine manufacturer’s manual for initial
start instructions. Failure to follow those
instructions can result in serious engine
damage.
Never shut off battery disconnect switch
with the engine running. This could cause
damage to the voltage regulator, alternator,
and/or electrical system

Super Claws Model LS-2 SAFETY
MAR/2006 (4945-3500) Section 1-5
LOCKOUT AND/OR TAGOUT
REQUIREMENTS
The following list suggests lockout
procedures to use on all components
of the machine that require lockout due
to the storage of various forms of
energy. It is your company’s
responsibility to Lockout/Tagout
Procedures based on this list, train
you in their proper and safe use, and to
periodically inspect your work area to
verify that you are complying with the
procedures. Lockout/Tagout
Procedures must be followed!
NORDCO has provided the means to
lockout this machine. NORDCO
cannot be held responsible for injury
caused by failure to comply with your
company’s Lockout/Tagout
Procedures.
LOCKOUT-TAGOUT PROCEDURES
The following procedures are designed to lead the operator through the steps required to shut the
machine down and prepare it for performing mechanical maintenance work. These procedures are
intended to release potentially dangerous stored energy forms and make the machine safe to begin
repairs.
SAFETY PROCEDURES
LOCKOUT/TAGOUT
1. Apply parking brakes by pushing in parking brake button located
on the center (front) control console.
2. Chock wheels to prevent accidental rolling of machine on grade.
3. If you have not already done so, determine which components are
to have maintenance. Place all machine mechanical systems or
workheads in the full up and locked positions.
4. When mechanical locking up of equipment is not feasible for
maintenance lower the component to the ground prior to working on
the equipment.
5. Turn the ignition switch to the OFF position. This turns off the
power to the control circuits on the machine. Place a TAGOUT
card in close proximity to the ignition switch.
6. Turn the battery disconnect switch (BDS) to the OFF position.
Place a lockout/tagout device on the switch.
7. Bleed off hydraulic pressure.
8. Follow all of your company’s lockout/tagout rules before proceeding.
Note: When working on machine components, be aware that
moving components during repairs may create energy (ie., moving a
hydraulic cylinder). Proper precautions should be taken.

SAFETY Super Claws Model LS-2
Section 1-6 MAR/2006 (4945-3500)
SAFETY DECALS ON THIS MACHINE
Safety decals and plaques that have been placed on this machine are to be kept clean and legible.
Replace any decals or plaques that have become illegible or are missing.
When repairing or replacing components that had safety decals on them, it is your responsibility to
replace the safety decals. These can be ordered from the Parts Sales Department.
Safety Decals on this Machine are:
PART NO. DESCRIPTION LOCATION
5642 0001 General Machine Cautions Inside Cab
5642 0002 Caution! Watch Your Step Each stairway
5642 0004 Danger! Pinch Points On workhead
5642 0005 Warning! Hand Hazard On workhead
5642 0006 Danger! Before Servicing... Logic Box Sides
5642 4501 Caution! Before Welding... Logic Box Face
Battery Box
5642 0010 Lockout Area Logic Box Face
5642 0011 Lockout Area Battery Box
5642 0012 Lockup Points All areas requiring
Lockups for travel.
Also need turntable warning.

Super Claws Model LS-2 GENERAL
MAR/2006 (4945-3500) Section 2-1
GENERAL
This manual contains operation and maintenance information for the Super Claws LS-2 with Tier 2 Engine,
manufactured by NORDCO INC., Oak Creek, Wisconsin. Information regarding the operation and
maintenance of this machine can be found behind the appropriate tabs. Information regarding operation
and maintenance of OEM parts not of NORDCO manufacture can be found at the back of this manual,
behind the tab marked Component Data.
Become familiar with all safety instructions, controls and instruments before operating this machine. Follow
all instructions carefully.
ABOUT THIS MANUAL
This manual has been broken down into sections which have been separated by index tabs. Behind each
index tab is a blue colored section for troubleshooting the applicable section.
Mechanical has individual parts breakdown drawings and lists for each assembly
Hydraulic includes adjustment instructions and troubleshooting for the hydraulic system; and all
piping and functional drawings for a standard machine and optional equipment
Electrical, includes all electrical schematics, logic box, control box, and cable drawings for the
machine; and troubleshooting instructions
Component Data includes parts breakdowns and service instructions for components installed on the
machine that are not of NORDCO’s manufacture

GENERAL Super Claws Model LS-2
Section 2-2 MAR/2006 (4945-3500)
SPECIFICATIONS
GENERAL
Machine Name........................................................................................................Super Claws Spike Puller
Model..........................................................................................................................................................LS-2
Gross Weight........................................................................................................................7,250 lbs/3291 kg*
Length.............................................................................................................14 feet (168 inches)/4.25 meters
Width.......................................................................................................7 feet 6 inches (90 inches)/2.3 meters
Height....................................................................................................8 feet 6 inches (102 inches)/2.6 meters
Travel Speed..........................................................................................................24 mph maximum (39 km/h)
Work Speed...............................................................................................................5 mph maximum (8 km/h)
Towing Speed........................................................................................................20 mph maximum (32 km/h)
Rated Draw Bar Pull .............................................................................................................1,650 lbs. (750 kg)
Turntable.........................................................................................................................Hydraulically Operated
Wheel Base...........................................................................................................7 feet (84 inches)/2.1 meters
Pulling Force (maximum)................................................................................................ 30,500 lbs. (135.7 kN)
CAPACITIES
Fuel Tank
Standard Tank .......................................................................................................... 12.8 gallons (48 liters)
Optional Tank............................................................................................................. 28 gallons (106 liters)
Hydraulic Oil Tank
Standard Tank ........................................................................................................ 32.5 gallons (123 liters)
Optional Tank............................................................................................................. 45 gallons (170 liters)
Oil Cooler............................................................................................................................100 gpm (378 L/mn)
ENGINE
ENGINE (OPTION)
Make/Model ..................................................................................................................John Deere 4024D, Tier 2
Type.......................................................................................................................................................4 Cylinder
Oil Capacity................................................................................................................................To be determined
Coolant Capacity……………………………………………………………………………………2.7 Quarts (2.6 liters)
HYDRAULIC SYSTEM
Pressure Settings:
Relief Valve - Main Pump ...........................................................................................................3,000 psi (200 bar)
Compensator - Main Pump........................................................................................................2, 500 psi (172 bar)
Main Pump Make........................................................................................................................... Vickers PVM Series
Control Valves..................................................................................................................................Vickers Manifolded
ELECTRICAL SYSTEM
Battery......................................................................12 Vdc (Dual 12V DC batteries), 1150 Cold Cranking Amps
Ground.....................................................................................................................................................Negative
Alternator (John Deere)…………………………………………………………………………………………...75 Amp
AXLE DRIVE SYSTEM
Drive Type...........................................................................................................................Dual Axle Chain Drive
Propulsion Motor Type............................................................................................................................Hydraulic
Items or capacities may vary according to options on your machine.
* Approximate weight. Actual weight may vary according to options on your machine. Actual weight of
your machine is as stenciled.

Super Claws Model LS-2 GENERAL
MAR/2006 (4945-3500) Section 2-3
DRIVE SYSTEM
Drive Type.....................................................................................................Two wheel with one axle standard
Four wheel/two axle optional
Propulsion Motor Type.........................................................................................................................Hydraulic
WHEELS
Type...................................................................................................................................................Cast Steel
Size.........................................................................................................................16 inch ( 406 mm) diameter
Brake Type...........................................................................Four wheel shoe type, spring actuated (deadman)
All rights reserved. In view of the constant improvements to our equipment, the specification data and
other technical information included in this manual are subject to change. No part of this manual may be
reproduced in any form or by any means without our written permission.
Dimensional Information

GENERAL Super Claws Model LS-2
Section 2-4 MAR/2006 (4945-3500)
--- Page Intentionally Left Blank --

Super Claws Model LS-2 PRE-OPERATION/STARTUP
MAR/2006 (4945-3500) Section 3-1
BEFORE OPERATION
GENERAL
DO NOT use this machine for machine
operations other than for which it was intended.
FRA regulations require that a copy of this
Operation Manual be kept on the machine at all
times. Additional copies of the Operation Manual
only can be ordered from Nordco Parts Sales at
1-800-647-1724.
Carefully read all safety messages in this manual
and on the decals located throughout the
machine. Learn how to operate the machine and
how to use controls properly.
Do not let anyone operate this machine without
instruction. Failure to understand the contents of
this manual could result in serious personal injury
or death.
ABOUT THIS MACHINE
It is always good practice to become familiar with
the components of the machine you are using.
OPERATOR’S STATION
Almost all the controls for running this machine
are located in the Operator’s Station. This
includes but is not limited to those on the logic
box and the main control panel, as well as the
hand controller and the propulsion lever.
Depending on the machine you are on, it is either
a left-hand or right-hand machine.
Under no circumstances are there to be more
riders on this machine than seats available.
Always use your seat belt when sitting in the
operator seat.
For additional information concerning the controls
used in the Operator’s Station including the hand
controllers and Propulsion lever, refer to
Operator Station Controls later in this section.
WORKHEAD
Each workhead assembly consists of the Pulling
Frame (the A-shaped frame shown in Figure 1)
and the Claw Housing (shown in Figure 2). Two
pulling claws straddle the rail and work in unision
to pull line spikes, anchor spikes, and hairpin
spikes (optional equipment required) without
changing pattern.
The Up/Down position of the workhead is
determined by limit switches mounted to the side
of the pulling frame.
There are two lockup pins located on the
workhead. These should be locked during travel.
See lockup requirements in the LOCKUP
section of this manual.
PROPULSION/DRIVE SYSTEM
The machine is dual axle outboard driven,
comprised of a single chain, two drive sprockets
and a hydraulic motor.
BOOM/WINCH (OPTIONAL)
The boom/winch system is in place to allow the
operator to easily lift bags of anchors into the
Anchor Bin. The winch is capable of lifting loads
up to 300 lbs. The boom and winch should be
locked up for travel or when not being used. See
lockup requirements in the Lockup section of this
manual.
Figure 2 - Claw Housing
Figure 1 - Pulling Frame

PRE-OPERATION/STARTUP Super Claws Model LS-2
Section 3-2 MAR/2006 (4945-3500)
HYDRAULIC SYSTEM
The hydraulic system utilizes manifolded
hydraulics and a Vickers PVH Pump.
ELECTRICAL SYSTEM
The hydraulic functions of the machine are
controlled by the electrical system. The relays,
limit switches, micro switches and timing module
that make up the electrical system are shown on
the schematics and wiring diagrams included in
the ELECTRICAL section of this manual.
SEQUENCE CHART
The Functional Sequence Chart located at the
back of the Troubleshooting Section enables the
operator to identify what the machine is doing
and what hydraulic cylinders are activated in
relation to the energized or de-energized
condition of the micro switches or limit switches.
The sequence chart describes each complete
operating cycle, step by step, as it occurs during
actual operation.
CONTROLS AND INSTRUMENTS
Some controls and all of the instruments are
located on the Main Control Panel. Additional
controls are located remotely on the machine.
Become thoroughly familiar with the function and
operation of all controls, as described in this
section, before attempting to operate the
machine. However, the information in this
section is intended to be for descriptive purposes
only. Also read carefully the instructions in the
Operation section of this manual before
attempting to operate the machine.
NOTE:
Your machine may not have all the optional
controls and instruments that are described in
this section.

Super Claws Model LS-2 PRE-OPERATION/STARTUP
MAR/2006 (4945-3500) Section 3-3
MAIN CONTROL PANEL

PRE-OPERATION/STARTUP Super Claws Model LS-2
Section 3-4 MAR/2006 (4945-3500)
MAIN CONTROL PANEL
ENGINE AND PUMP CONTROLS AND GAUGES
GAUGES AND MISC. CONTROLS