TOP CAT 56APC Series Instructions for use

General Operators Instructions
and
Maintenance Manual
56APC Series
Vertical Grinders
Top Cat ® Air Tools, Manufactured by T.C. Service Co.
38285 Pelton Road, Willoughby, OH 44094 U.S.A.
Ph: [phone] or [phone] ● Fax: [phone] or [phone]
E-Mail: [email protected] ● Web Site: www.tcservice.com
Read Safety Recommendations Before Operating Tool
Model
Number
Throttle
Type
Power
Output
Rated
Speed Weight Height Over Spindle
Working Air
Consumption
Wheel
Capacity
56APCL Lever
3 H.P.
(2.25 KW)
4500-
9000
R.P.M.
15.7 Lb.
(7.1 Kg)
7.1 Inches
(180 mm)
45 cfm
(21.2 L/S)
8 Inch
(200 mm)
56APCK Safety Lever
56APCM Thumb Switch
56APCBM Machine Mount Thumb Switch
56APC

This is meant to highlight sections of safety standards published by the American National Standards
Institute and the Occupational Safety and Health Administration. This is not meant to replace those
standards but only highlight certain areas.
When care is taken to ensure that the right tool is operated properly, and safety and maintenance
procedures are followed, accidents can be avoided. Read and follow all instructions and directions.
Comply with all rules governing the use of power tools, personal protective equipment and equipment
guards.
Remember - machines, attachments and accessories must be used only for the purpose for which
they were designed. Safety reasons and product liability prohibit any modifications to tools. Any
attachments or accessories must be agreed to in advance with an authorized technical representative
of T.C. Service Co.
Operators Instructions and Safety Precautions
The grinding equipment must be approved
for the rated speed of the machine. The rated
speed, marked on the machine, should not be
exceeded. Be sure to learn the proper handling
and storage of abrasive wheels and inserted
tooling.
Inspect the wheel guard for any signs of wear
and that it is properly mounted to the tool. Any
guard showing signs of wear such as bends,
chips, nicks, or cracks should be replaced.
Always wear eye and hearing protection, and
when necessary, other personal protective
equipment such as gloves, an apron, and
helmet.
Check hose size and air pressure. The air pressure at the tool shall
not exceed 90 psi (6.2 bar). All hoses should be inspected regularly
and kept away from heat, oil and sharp edges. Be sure the tool is
secured to the air hose.
Measure the speed of grinders every 20 hours of actual use or once
per week, whichever comes first.
Tachometers must be checked and calibrated on a regular basis
according to the manufacturers recommendations
Measure speed of all types of grinders after maintenance or repair,
whenever a grinder is issued from the tool crib and at each wheel
change. Several readings should be taken.
This form of inspection should be made with the grinding wheel or
tooling removed.
Airborne particulate resulting
from the grinding process can
cause hazards. Wear appropri-
ate protective equipment.

Proper mounting of grinding wheels
and inserted tooling is crucial to
safe operation and efficient working
conditions. Ensure the exhaust air is
directed away from bystanders.
Disconnect the tool from the air supply before
doing any service. This prevents accidental
start-ups. Do not disassemble or adjust the
governor. The governor is guaranteed for the
life of the tool, if not abused.
The safety procedures for operating air tools are everyone’s responsibility. The following lists several
aspects of air tool safety that should be considered during operation. Please be aware of the these
aspects and report any unsafe practice you see to a supervisor or safety officer immediately.
1) Start any new wheel under a bench and away from bystanders. (Run for a minimum of one
minute.)
2) When starting a cold/new wheel, apply to the work slowly, allowing the wheel to warm gradually.
3) Support the work piece properly.
4) When cutting off, support the work piece so that a jamming of the wheel does not occur. (A Slot
shall remain constant or become wider during operation.)
5) If a jamming of the wheel does occur during a cutting off operation, shut the air supply off to the
tool and ease the wheel free. (Inspect the wheel for damage before continuing operation.)
6) Ensure that sparks from the process do not create a hazard to the eyes or will ignite the
environment.
7) Grinders shall not be used in potentially explosive atmospheres.
8) Pneumatically driven tools are not generally insulated from coming in contact with electrical
sources. Be sure to avoid contact with wires or other possible current carrying sources.
9) The operator must check that no bystanders are in the vicinity.
10) Remember that there is a running on after the throttle has been released.
11) If a grinder fitted with an abrasive wheel is dropped, the wheel must be thoroughly examined
before re-use.
12) Disconnect the tool from the air source before servicing and changing wheels.
13) Release the control device in case of interruption of air supply.
14) Always keep the tool in a clean, dry place when not in use.
15) Beware of loose hair and clothing so as not to become tangled or trapped during operation.
16) Unexpected tool movement or breakage of blade or wheel may cause injury.
17) Unsuitable postures may not allow counteracting of normal or unexpected movement of a power
tool. (A working position shall be adopted which remains stable in the event of a break up of inserted
tooling.)
18) Do not hold the tool near the body when operating.
19) Keep a firm grip on the tool body during operation.
20) Immediately shut off the tool if unusual vibration or sound is detected. Remove and inspect the
wheel and check the tool speed (RPM) with an accurate tachometer. Use of over-speeding grinder or
unbalanced wheels may result in serious injury.
Safety in Operation

Disassemble
1. Disconnect tool from air supply and remove all wheels and accessories.
2. Secure tool in a vise with motor axis in horizontal position. Clap onto the dead handle (550-1C) of grinder.
3. Remove four screws (700-47A), four lock washers (700-46) and wheel guard (650-155).
4. Grasp motor output and pull complete motor assembly from case. The motor assembly must be kept straight to pull from case easily.
Try to maintain alignment as best as possible. Remove case from vise.
5. Secure motor assembly into vise vertically with governor upward. Clamp onto flats of wheel flange (550-12B).
6. Remove governor (AA-550-XX) with use of governor wrench (1100-825). (Left-hand thread.)
7. Remove lock ring (1000-5) with use of snap ring pliers. Remove from vise.
8. Hold motor assembly by the cylinder in one hand. Place a punch in the hole left by the removal of governor. Tap lightly onto the
punch with small hammer. This will drive the spindle (550-8) through the rear bearing (700-9) and rear endplate (550-3). (Take care not
to damage threads inside spindle, or to drop the spindle assembly when it becomes free.)
9. Use a small screwdriver to push the rear bearing out of the rear endplate.
10. Remove the cylinder (550-2), the rotor blades (550-6) and the rotor (550-5). Leave the key (550-10) in the key slot for now.
11. Clamp spindle holder (1100-650) into vise vertically. Align key slot in holder with key of spindle and slide spindle assembly through.
12. Remove wheel flange (550-12B). Remove from vise.
13. Remove key (550-10) and lift off front end plate (550-7).
14. Support front bearing assembly on a suitable drill block. Press spindle (550-8) through front bearing (700-7) with arbor press.
15. Remove snap ring (550-21) with use of snap ring pliers.
16. Lift out bearing cover (550-25).
17. Press out front bearing (700-7) from front bearing support (550-1-BTB).
18. To check throttle valve, unscrew throttle valve cap (700-S-26). Lift out valve spring (600-51) and throttle valve (560-13). Replace
o-ring (200-9) if cracked of torn.
Maintenance

Assembly
1. Be sure all parts are clean and free of any abrasive.
2. Press front bearing (700-7) into front bearing support (550-1-BTB).
3. Slip bearing cover (550-25) into front bearing support and onto front bearing.
4. Install snap ring (550-21) into groove of front bearing support with use of snap ring pliers.
5. Support front bearing assembly on a suitable drill block. Press the spindle (550-8) through the bearing up to the shoulder with an
arbor press.
6. Slide front endplate (550-7) over spindle and up to front bearing support.
7. Place key (550-10) into key slot of spindle.
8. Clamp spindle holder (1100-650) in vise vertically. Align key slot in holder with key of spindle and slide spindle assembly through.
9. Thread wheel flange (550-12B) onto spindle threads and tighten. Remove from vise.
10. Secure motor assembly into vise vertically with rear of motor toward upward direction. Clamp onto flats of wheel flange (550-12B).
11. Align the cylinder pin hole in bearing support (550-1-BTB) and front endplate (550-7).
12. Slide rotor (550-5) over spindle and key.
13. Insert five blades (550-6).
14. Place cylinder (550-2) over rotor with long dowel pin toward downward direction. Dowel pin goes through hole in front endplate and
front bearing support.
15. Place rear endplate (550-3) over cylinder. Locate the short dowel pin of the cylinder in the small hole of rear endplate.
16. Press bearing (700-9) into rear endplate with bearing driver (1100-808).
17. Install lock ring (1000-5) onto spindle with use of snap ring pliers. (There is no groove.)
18. Prior to reassemble inspect governor for gouges, nicks or dents. Oil the governor and inside of motor. Screw governor (AA-550-XX)
into end of spindle and tighten with governor wrench (1100-825). (left hand thread.)
19. Assemble live handle if this was inspected or repaired.
20. Install live and dead handles to case (560-1).
21. Secure tool in a vise with motor axis in horizontal position. Clap onto the dead handle (550-1C) of grinder.
22. Place gasket (550-13) in rear face of case.
23. Slide the motor assembly into case. The motor assembly must be kept straight to install into the case easily. Try to maintain align-
ment as best as possible.
24. Line up guard (650-155) with motor holes. Install as shown on page 8 of this booklet. Install 4 bolts (700-47A) and lock washers
(700-46). Tighten bolts down until snug then back off 1/2 turn.
25. Connect tool to air supply and apply air in several short bursts.
26. Now run tool and tighten down bolts evenly. (Alternating from corner to corner.)
27. Check RPM with a reliable tachometer. Tool must run at or below speed stamped on the tool.
Governors
The governors
are warranted for
the life of the tool.
(Except in cases
of abuse.)
Please return the
governor to the
manufacturer for
warranty repair or
replacement.

Tool Parts Listing
PART NUMBER DESCRIPTION GUARDS
400-44 CYLINDER PIN PART NUMBER DESCRIPTION
550-1-BTB BEARING SUPPORT 650-155 8” TUCK POINT GUARD
550-1-C DEAD HANDLE
550-1-C-H HOLLOWED DEAD HANDLE TOOLS
550-1-C-KN KNURLED DEAD HANDLE PART NUMBER DESCRIPTION
550-1-C-KN-W DEAD HANDLE WRAP 1100-094 15/16” WRENCH
550-2 CYLINDER 1100-200 2” WRENCH
550-2C CHROME CYLINDER 1100-650 SPINDLE HOLDER
550-2R REVERSE ROTATION CYLINDER 1100-808 700-9 BEARING DRIVER
550-2RC REV. ROTATION CHROME CYL. 1100-825 GOVERNOR WRENCH
550-3 REAR ENDPLATE 1100-834 700-7 BEARING DRIVER
550-3C CHROME REAR ENDPLATE
550-5 ROTOR ASSEMBLIES
550-5A ALUMINUM ROTOR PART NUMBER DESCRIPTION
550-6 BLADE (5 REQ) 510071 REPAIR KIT
550-7 FRONT ENDPLATE AA-650-1A BUTTON HANDLE ASSY.
550-8 SPINDLE AA-650-1-AM MACHINE MOUNT HANDLE ASSY.
550-8A 3/8 EXTENDED SPINDLE AA-650-1-BL LEVER HANDLE ASSY.
550-8C CHROME SPINDLE AA-650-1-BLS SAFETY HANDLE ASSY.
550-8-LH LEFT HAND SPINDLE AA-650-1 BL-KN KNURLED LEVER HANDLE ASSY.
550-10 KEY AA-650-1-BL-KN-W KNURLED LEVER HANDLE ASSY. W/ WRAP
550-12B WHEEL FLANGE AA-650-1-UK PINNED/SAFETY LEVER HANDLE ASSY
550-12B-LH L.H. ROTATION WHEEL FLANGE AA-650-1-UL PINNED LEVER HANDLE ASSY
550-13 GASKET AA-560-1 CASE ASSY. (SPECIFY SPEED)
550-21 SNAP RING AA-560-1-PA PIPED AWAY EX. CASE ASSY.
550-25 BEARING COVER (SPECIFY SPEED)
550-48 SCREW (4 REQ) GOVERNORS
550-54 WASHER (4 REQ) PART NUMBER DESCRIPTION
600-48 GOV. PIN RETAINER AA-550-30 GOV.ASSY. (3000 RPM)
700-4 OUTER FLANGE AA-550-45 GOV.ASSY. (4500 RPM)
700-7 BEARING AA-550-60 GOV.ASSY. (6000 RPM)
700-9 BEARING AA-550-80 GOV.ASSY. (8000 RPM)
700-34 SPINDLE NUT AA-550-60-LH L.H. GOV. ASSY. (6000 RPM)
700-34-LH LH SPINDLE NUT OTHER SPEEDS AVAILABLE. ALWAYS USE
700-37 CYLINDER PIN SAME OR LOWER SPEED GOVERNOR AS
700-46 WASHER (4 REQ) IS STAMPED ON CASE.
700-47A SCREW (4 REQ)
Note: Use of any parts other then genuine Top Cat® parts voids
any and all warranties, and may result in a hazardous situation
and a decrease in operating efficiency.

Handle Parts Listing
PART NUMBER DESCRIPTION
200-9 THROTTLE VALVE O-RING
400-33P OILER PLUG
400-37 SET SCREW
550-30 OPERATING BUTTON
550-30M MACHINE MOUNT BUTTON
550-33 ADAPTER CAP
550-33M METRIC ADAPTER CAP
550-38 LEVER
550-50 LEVER PIN
560-13 THROTTLE VALVE ASSY (INCLUDES 200-9)
600-51 THROTTLE VALVE SPRING
650-1A BARE BUTTON HANDLE
650-1AT BARE TURNED DOWN BUTTON HANDLE
650-1B-KN BARE KNURLED BUTTON HANDLE
650-1-BLS BARE LEVER HANDLE
650-1-BLS-KN BARE KNURLED SAFETY HANDLE
650-1-U BARE PINNED LEVER HANDLE
650-35 SCREEN BASKET
650-55 SAFETY LOCKOUT SPRING
650-56 LOCKOUT
650-61 O-RING
650-62 SAFETY LEVER LOCKOUT PIN
700-22 SPACER FOR BUTTON HANDLES
700-23 OILER PLUG SCREW
700-30 O-RING
700-35 BUTTON HANDLE SCREW
700-48 SCREW (2 REQ.)
700-54 LOCK WASHER (2 REQ.)
700-S-26 THROTTLE VALVE CAP
832636 GASKET
HANDLE ASSEMBLIES
PART NUMBER DESCRIPTION
AA-650-1A BUTTON HANDLE ASSY.
AA-650-1-AM MACHINE MOUNT HANDLE ASSY.
AA-650-1-BL LEVER HANDLE ASSY.
AA-650-1-BLS SAFETY HANDLE ASSY.
AA-650-1 BL-KN KNURLED LEVER HANDLE ASSY.
AA-650-1-BL-KN-W KNURLED LEVER HANDLE ASSY. W/ WRAP

The following suggestions will help reduce or moderate the effects of repetitive work motion and/or
extended vibration exposure:
1) Do not over-grip the machine/tool. Use only the force required to maintain control.
2) Keep hands and body dry and warm. (Blood flow is important - exercise hands and arms as often
as necessary.)
3) Keep wrists as straight as possible. (Avoid hand positions that require the wrist to be flexed, hyper
extended or turned side-to-side.)
4) Avoid anything that may inhibit blood circulation such as smoking tobacco or cold temperatures.
5) Do not support body-weight on the tool during operation.
6) Maintain a stress-free posture for the entire body.
Prolonged exposure to vibrations created by vibrating sources may cause health hazards. There are
gloves, handle wraps and other forms of protective measures available to help reduce the hazard.
The fit and condition of any vibration abatement measure must be monitored.
Ergonomics - Work Healthy
Guarding
Always make sure the wheel guard is positioned between the operator and the wheel. Flying debris
from the work piece and/or the wheel can cause a hazard. The guard should be positioned so to
deflect debris from the grinding surface away from the operator. The diagram below details the proper
positioning of the guard to protect any handles the operator might grip and the area where the opera-
tor stands.
Area of
Protection

Following the guidelines will help you to ensure the pneumatic tools your company uses are operating
and are maintained in the very best of condition.
Initial Inspection of a New Tool
When a new tool is delivered to your facility, it is important to inspect the tool for any signs of damage
that may have occurred during shipping. Here is a list of things to inspect:
● With the tool disconnected from the air supply, depress the throttle lever or trigger. The device
should move freely and not become caught.
● Inspect the guard of the tool, if so equipped. The guard should be free of any chips, nicks or dents.
● Inspect the spindle of the tool. The threads should show no signs of bends or chips. Grasp the
spindle by hand and spin. The spindle should turn freely with no resistance.
Plumbing Installation
The tool must have fittings and connectors installed into the air inlet in order to connect with your
companies air system. Your choice of fittings can greatly affect the performance of the tool.
Fitting Size
The size of the air inlet of the tool is the minimum size of fitting that will allow for proper airflow into
the tool. Should a smaller fitting size be used such as reducers or adapters, this will constrict the
airflow into the tool and reduce the overall performance.
Coupling Size and Installation
The coupling size should be equal to or larger than the inlet size of the tool. If a smaller size coupling
is used then the air supply volume may be reduced which may lead to reduced performance from the
tool.
The coupling should be installed near to the tool. It is important that the tool receive internal
lubrication on a regular basis. Having the connection closer to the tool will promote regular lubrication,
as the connection is easily accessible. Hose whips are often used between the tool and the coupling.
Use thread sealant on all pipe threads and ensure a tight fit.
Operating Speed Test
After your initial inspection and installation of the plumbing connections, it is important to test for
the operating speed of the tool. This test should be performed before you install any abrasive or
tooling. Each tool is stamped with a maximum operating speed. This speed determines the highest
rotational speed in R.P.M.’s that the tool will turn when it is functioning properly. This speed was set
from the factory and is closely related to the operating speed of the abrasive used with the tool. This
relationship will be discussed in the “mounting abrasives” section.
Find the maximum operating speed stamped onto the tool. Connect the tool to an air supply that
provides 90 psi and secure the tool in a vise. A lower or higher air pressure will result in a false speed
test and may create a hazardous situation. Depress the throttle lever or trigger and run the tool. Use
a properly calibrated tachometer to determine the actual operating speed of the tool. The actual
operating speed on the tachometer should be 90-95% of the maximum free speed stamped on the
tool. If this is not the case then contact the distributor or tool manufacturer immediately. The tool must
not be put into service if the actual speed is over 95% of the stamped maximum speed.
Installation and Maintenance Tips

Example: Tool rated at 6000 R.P.M.
90% of 6000 (.90 x 6000) = 5400
95% of 6000 (.95 x 6000) = 5700
The tool should run between 5400 and 5700 when tested with a tachometer. Tachometers must be
checked and calibrated on a regular basis according to the manufacturers recommendations
Mounting Abrasives
The mounting of the abrasive used with the tool is very important to ensure safety for the operator
and proper functioning of the tool. There are strict rules for mounting wheels that are outlined in ANSI
B7.1-2000. The following diagrams briefly describe the methods and equipment for mounting most
abrasives.
700-
700-
TOOL FOR USE WITH
8 INCH DIAMOND TIP
CUT-OFF WHEEL
Diamond Tip Cut-
TOOL FOR USE WITH
10 INCH DIAMOND TIP
CUT-OFF WHEEL
NRA42

Each wheel is labeled with a maximum operating speed. It is extremely important to compare this
rating with the maximum operating speed of the tool. Never mount a wheel on a tool where the
maximum operating speed of the tool is higher than the maximum operating speed of the wheel. This
can cause an over speed situation and can result in injury.
The following list details specific items one should inspect and be aware of when mounting abrasives.
● The maximum operating speed marked on the wheel must be equal to or higher than the rated
spindle speed (free speed) of the tool.
● Check the wheel dimensions so that it fits within the guard properly.
● Do not use any wheel that shows cracks, chips or evidence it has been soaked in fluids.
● Wheel flanges should have flat contact surfaces and be without cracks or burrs.
● Immediately shut off the tool if unusual sound or vibration is detected. Remove and inspect the
wheel and check the tool speed (RPM). Use of over-speeding grinder or unbalanced wheels may
result in serious injury.
Testing and Mounted Wheel
Start any new grinder with a new wheel under a bench and away from any bystanders. Run at full
speed for one minute.
Ensure Proper Pressure, Filtration & Lubrication
Properly lubricated pneumatic tools work better, last longer between maintenance intervals and are
safer in general use. The maintenance costs are reduced dramatically when a little time is taken to
regularly lubricate the tools. There are several ways to ensure proper lubrication.
1) Filters, Regulators & Lubricators
These devices should be installed in the air system at each grinding station and inspected regularly
to ensure proper operation. Each device in this set performs a vital task that greatly affects the
performance of the tool and overall longevity of the component parts.
Filters
A filter is a device used to trap/contain particulate and liquid contaminants in the compressed air
system. They generally have a cartridge or screen that requires cleaning or replacement regularly.
Without this maintenance, the filtering device can become clogged and reduce the flow of air to the
tool. A loss in performance can result.
Regulators
A regulator adjusts the operating pressure supplied to the tool. This device generally is used with
a pressure gauge that will indicate the current pressure setting. All Top Cat ® pneumatic tools are
designed to operate at 90 PSI (6.2 bar) while the tool is running. The tool should never be run if the
pressure should exceed 90 PSI (6.2 bar).
Lubricators
Lubricators are devices that induce a controlled amount of oil into the air supply for pneumatically
driven tools. They generally contain a reservoir that one must keep filled with oil. A light grade oil such
as Mobil DTE light or equivalent is recommended. There is a variable setting on the lubricator that will
determine the amount of oil induced into the air supply. It is important to inspect both the setting and
amount of oil in the lubricator regularly to determine proper functioning of the device. The lack of oil in
the air system will greatly reduce the performance and longevity of the pneumatically driven tool.

2) Direct injection of oil into the tool
A simple and easy way to ensure proper lubrication is to inject the oil directly into the tool air inlet.
This should be performed prior to storage of the tool. To perform this task one must have a small
container of the proper lubricating oil.
● Disconnect the tool from the air supply at the air coupling.
● Place a few drops of oil from the container into the air inlet of the tool directly.
● Reconnect the tool to the air supply.
● Direct the exhaust of the tool away from any bystanders or cover the exhaust with a shop rag.
● Run the tool until the oil has completely passed through the unit.
The best lubrication techniques include both methods.
What Conditions Indicate the Need for Maintenance?.
Pneumatic tools will exhibit several distinct signs that maintenance is required. Higher costs can
be avoided if maintenance is performed when the first signs are evident. The following list details
conditions that may indicate the necessity for service.
1) With the tool disconnected from the air supply, grasp the spindle and spin in the direction of
operation. The spindle should spin freely with no resistance.
2) With the tool disconnected from the air supply, grasp the spindle by hand. Attempt to move the
spindle from side to side and back and forth. Excess play can be a sign that service is required.
3) A reduction in power may indicate the necessity for maintenance.
4) Should the tool not maintain a uniform operating speed, servicing may be required.
For More Information
1) General Industry Safety & Health Regulations 29 CFR, Part 1910 and where applicable
Construction Industry Safety & Health Regulations 29 CFR, Part 1926 available from Superintendent
of Documents, Gov’t. Printing Office, Washington, D.C. 20402.
2) Safety Code For Portable Air Tools, ANSI B186.1, B7.1 and Z87.1, available from American
National Standards Institute, Inc. 1430 Broadway, New York, NY 10018
© Copyright 2004
All Rights Reserved
• Vertical Grinders
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Percussion Tools
T.C. Service Co.
38285 Pelton Rd.
Willoughby, OH 44094
U.S.A.
Ph: 440-954-7500
Fax: [phone]
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