Nibco PC-100 User manual

INSTRUCTION MANUAL
52025251 © 2006 NIBCO Inc. 12/06
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
PC-100
Battery-powered
Pressing Tool
NIBCO Inc. – World Headquarters
1516 Middlebury Street
Elkhart, IN 46516
USA
Technical Services
Phone: [phone]
Fax: [phone]

NIBCO, Inc. 21516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
KEEP THIS MANUAL
Table of Contents
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose of this Manual .................................................. 2
Warranty ......................................................................... 2
Important Safety Information ......................................3-4
Identication................................................................... 5
Specications................................................................. 6
Operation...................................................................7-11
Maintenance................................................................. 12
Troubleshooting............................................................ 13
Description
The PC-100 Battery-powered Pressing Tool is a
hand-held, self-contained tool intended to press 1/2"
through 4" copper and brass NIBCO press ttings and
valves onto type K, L, and M hard-drawn copper tubing.
Safety
Safety is essential in the use and maintenance of NIBCO
tools and equipment. This manual and any markings on
the tool provide information for avoiding hazards and
unsafe practices related to the use of this tool. Observe
all of the safety information provided.
Purpose of this Manual
This manual is intended to familiarize all users with
the safe operation and maintenance procedures for the
tool:
PC-100 Battery-powered Pressing Tool
with 120 volt charger,
and (2) 3.0 Ah batteries
Keep this manual available to all users.
For additional copies of the manual, visit the NIBCO
website: www.nibco.com.
Warranty
For warranty information on the NIBCO pressing tools,
contact NIBCO technical services at 1-888-446-4226, or
visit the NIBCO website: www.nibco.com.
Do not discard this product or throw away!
For recycling information, go to www.nibco.com.
All specications are nominal and may change as design improve-
ments occur. NIBCO, Inc. shall not be liable for damages resulting
from misapplication or misuse of its product.
Tellus is a registered trademark of Shell Oil Company.

NIBCO, Inc. 31516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
IMPORTANT SAFETY INFORMATION
This symbol is used to call your attention to
hazards or unsafe practices which could result in
an injury or property damage. The signal word,
dened below, indicates the severity of the hazard.
The message after the signal word provides infor-
mation for preventing or avoiding the hazard.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in
severe injury or death.
Immediate hazards which, if not avoided, WILL
result in severe injury or death.
SAFETY
ALERT
SYMBOL
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning
could result in severe injury or death.
Electric shock hazard:
This tool is not insulated. When
using this unit on or near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning could
result in severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Do not use solvents or ammable
liquids to clean the pressing tool.
Solvents or ammable liquids could
ignite and cause serious injury or
property damage.
Keep hands away from the pressing
tool head when pressing.
Failure to observe this warning could
result in severe injury or death.
Skin injection hazard:
Oil under pressure easily punctures
skin causing serious injury,
gangrene, or death. If you are injured
by escaping oil, seek medical atten-
tion immediately.
• Do not use hands to check for
leaks.
• Depressurize the hydraulic system
before servicing.

NIBCO, Inc. 41516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
IMPORTANT SAFETY INFORMATION
Note: Keep all decals clean and legible, and replace
when necessary.
Inspect tool before use. Replace any worn or
damaged parts. A damaged or improperly
assembled tool can break and strike bystanders.
Failure to observe this warning could result in severe
injury or death.
Do not dispose of batteries in a re. They will vent
fumes and may explode.
Failure to observe this warning could result in severe
injury from harmful fumes or burns from ying d ebris.
• Do not operate the tool without a tting in place.
Damage to the pressing head can result.
• Do not use this tool for continuous use. After
50 press cycles, allow the tool to cool for 15
minutes.
• Do not secure this tool in a vise. This tool is
designed for hand-held operation.
• This tool may be used in damp or wet environ-
ments; however, air-drying is recommended
before use if the tool becomes soaked. Damage
may result when the tool is operated prior to
thorough drying when electrical components are
soaked.
• Use this tool for the manufacturer’s intended
purpose only.
Failure to observe these precautions may result in
injury or property damage.
Do not allow anything to contact the battery
terminals.
• Do not immerse the batteries in liquid. Liquid
may create a short circuit and damage the
battery. If batteries are immersed, contact your
service center for proper handling.
• Do not place the battery into a pocket, tool
pouch, or tool box with conductive objects.
Conductive objects may create a short circuit
and damage the battery.
• Do not place a battery on moist ground or
grass. Moisture may create a short circuit and
damage the battery.
Failure to observe these precautions may result in
injury or property damage.
• Do not store the battery at more than 60 °C
(140 °F). Damage to the battery can result.
• Do not use another manufacturer’s charger.
Other manufacturers’ chargers may overcharge
and damage the battery.
• Do not attempt to open the battery. It contains
no user-serviceable parts.
Failure to observe these precautions may result in
injury or property damage.
Do not perform any service or maintenance other
than as described in this manual. Injury or damage
to the tool may result.
Failure to observe this precaution may result in
injury and property damage.
An incomplete press can cause a leak.
• Use proper tting and tubing combinations.
Improper combinations can result in an incom-
plete press.
• The relief valve will sound and the drive rollers
automatically retract when a complete press
has been achieved. If you do not hear a “pop”
and the drive rollers do not automatically
retract, the press is not complete.
Failure to observe these precautions may result in
injury or property damage.

NIBCO, Inc. 51516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
Identification
1. Trigger
2. Retract Button
3. Lock Pin
4. Pressing Head
5. Housing
6. Battery load display / Service Indicator
7. Battery
8. Protection sleeve
9. Hand guard
1
2
345
6
7
9
8

NIBCO, Inc. 61516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
Specifications
Pressing Tool (without Pressing Jaws):
Length ........................................................................................... 17.36" (441 mm)
Width.................................................................................................. 3.78" (96 mm)
Height (with battery)....................................................................... 11.65" (296 mm)
Mass/Weight (with battery)..................................................................9.9 lb (4.5 kg)
Sound Level .............................................................................. 75 dB (A) at 1 meter
Vibration .................................................................................................... < 2.5 m/s2
Motor Type .......................................................................DC permanent eld motor
Motor Voltage................................................................................................ 12 VDC
Hydraulic Oil........................................................ 65 ml (2.2 oz) of Shell Tellus®T 15
Recommended Operating Temperature Range...........–20 °C to 40 °C (–4 °F to 104 °F)
Operation Force ............................................................................... 32 kN (7200 lb)
Pressing Cycle Time .......................Approx. 4 to 35 sec (depending on tubing size)
Battery
Charging Voltage........................................................................................... 12 VDC
Charging Time..........................................................................................20 minutes
Battery Capacity ........................................................... 3 Ah (2.6 Ah also available)
17.36"
(441 mm)
11.65"
(296 mm)
3.78"
(96 mm)
3.03"
(77 mm)

NIBCO, Inc. 71516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
Operation
Electric shock hazard:
This tool is not insulated. When
using this unit on or near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning could
result in severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Inspect tool before use. Replace any worn or
damaged parts. A damaged or improperly assem-
bled tool can break and strike nearby personnel.
Failure to observe this warning could result in severe
injury or death.
• Do not use this tool for continuous use. After
50 cycles, allow the tool to cool for 15 minutes.
• Do not secure this tool in a vise. This tool is
designed for hand-held operation.
• This tool may be used in damp or wet environ-
ments; however, air-drying is recommended before
use if the tool becomes soaked. Damage may
result when the tool is operated prior to thorough
drying when electrical components are soaked.
• Use this tool for the manufacturer’s intended
purpose only.
Failure to observe these precautions may result in
injury or property damage.
Charging the Battery
Read the instructions supplied with the battery charger.
Important Features of the Unit
• The hydraulic unit incorporates an automatic retraction
which returns the drive rollers into their starting position
when the maximum operating pressure is reached.
• The unit is equipped with a special brake which stops
the forward motion of the drive rollers when the trigger
is released.
• The unit is equipped with a double-piston pump which
is characterized by a rapid approach of the drive rollers
towards the jaws and a slow pressing motion.
• The pressing head can be smoothly turned by 350°
around the longitudinal axis in order to gain better
access to tight corners and other difcult working areas.
• The PC-100 is equipped with a microprocessor which
indicates service intervals, internal checks and low
battery charges. It also shuts off the motor automati-
cally after the pressing cycle is completed.
The battery load display/service indicator
This tool is equipped with a special circuit board incorpo-
rating several important features to inform the user about
the current status of the unit. The battery load display
signals in the following cases:
An incomplete press can cause leaks.
• Use proper tting and copper tubing combina-
tions. Improper combinations can result in an
incomplete press.
• The relief valve will sound and the drive rollers
automatically retracts when a complete press
has been achieved. If you do not hear a “pop”
and the drive rollers do not automatically retract,
the press is not complete.
Failure to observe these precautions may result in
injury or property damage.
Pinch points:
Keep hands away from the pressing
tool head when pressing.
Failure to observe this warning could
result in severe injury or death.
Signal Duration When it occurs What it means
a few seconds of battery insertion self check - O.K.
flashing
glowing for after press low battery charge
20 seconds
flashing for after press return for service
20 seconds (2Hz)
flashing for during high unit too hot
20 seconds (5Hz) temperature
20 sec. glowing after press service required
and flashing and battery flat
intermittently

NIBCO, Inc. 81516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
Operation (cont’d)
For 1/2" through 2" copper tubing sizes:
1. Select the proper pressing jaw for the intended
application. Examine the jaw for wear, damage, dirt
or copper buildup. Clean the compression area if
dirty and replace if worn or damaged.
2. Check that the red protective sleeve is in the forward
position and the jaws 1/2" to 2" marking is visible
on the PC-100 tool. If not, depress the button on the
protective sleeve and move the sleeve to the forward
position (see view below). Release the button to
secure the protective sleeve.
3. Depress lock pin 3 (see views below) and rotate
counterclockwise to disengage the pin on the
pressing tool.
Before changing the pressing jaws,
remove battery to avoid unintentional
operation.
Failure to observe this warning could
result in severe injury or property
damage.
3
2
1
Note: Rollers must be in the forward position to allow
the sleeve to be moved to the corrrect position.

NIBCO, Inc. 91516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
4. Install the jaw into the pressing tool and align
mounting hole in jaw with lock pin. Depress the lock
pin to secure the jaw (see views below).
5. Compress the ends of the jaw together to open the
jaws and locate the jaws around the tting to be
pressed (see view below).
6. Reinstall the battery and depress the tool trigger
to press the tting. Continue to depress the trigger
until the relief valve actuates and the drive rollers
automatically retract.
Notes:
If the drive rollers do not automatically retract, the
press is incomplete.
The pressing cycle can be interrupted at any
moment by releasing the trigger.
It is normal for the battery load display to light at
both the beginning and near the end of the pressing
cycle.
7. Release the trigger until the drive rollers retract
completely.
8. Compress the jaw ends together to open the jaws
and remove the jaws from the pressed tting.
Notes:
The pressing jaws must close completely to ensure
a leak-free connection. Always check that jaws
close completely during a pressing cycle and no
foreign objects are between the pressing jaws and
mechanism.
The pressing cycle can be interrupted at any
moment by releasing the trigger.
If it is necessary to remove the jaws before a press
cycle is complete, push the retract button (part #2,
page #5). Pushing the retract button will cause the
drive rollers to retract completely.
If the pressing cycle must be stopped before the
crimp is complete, and the jaws or chain have to
be removed from the fitting, the fitting should be
replaced or pressed a second time.
This tool is intended to press NIBCO press fittings
onto type K, L, and M hard-drawn copper tubing.
Operation (cont’d)

NIBCO, Inc. 10 1516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
Operation (cont’d)
For 2-1/2" through 4" copper tubing sizes:
1. Select the proper size pressing chain for the
intended application. Examine the chain for wear,
damage, dirt or copper buildup. Replace if worn or
damaged and remove any dirt or copper buildup
with a brush or soft cloth with light lubricating oil.
2. Disengage the release pin on the pressing chain
(see view below) and open the chain. Install the
pressing chain around the tting to be pressed and
re-engage the pin on the pressing chain.
3. Check that the red protective sleeve is in the rear
position and the chains 2-1/2" to 4" marking is
visible on the PC-100 tool. If not, depress the button
on the protective sleeve and move the sleeve to the
rear position (see view below). Release the button to
secure the protective sleeve.
Release pin
(pull to release)
Swing to open
chain unit
4. Depress retract button (part #2, page 5) to retract
rollers to the back position or complete a trigger
cycle to achieve same result.
5. Depress lock pin 3 (see views below) and rotate
counterclockwise to disengage the lock pin on the
pressing tool.
Before installing the pressing jaws,
remove battery to avoid unintentional
operation.
Failure to observe this warning could
result in severe injury or property
damage.
3
2
1
Part #2
(retract button)

NIBCO, Inc. 11 1516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
Operation (cont’d)
6. Install the adapter jaw into the pressing tool and
align mounting hole in jaw with pin. Depress the pin
to secure the adapter jaw (see views below).
7. Compress the ends of the adapter jaw together to
open the jaws and install the adapter jaw into the
pressing chain (see view below).
8. Reinstall the battery on the tool.
9. Depress the tool trigger to press the tting.
Continue to depress the trigger until the relief valve
actuates and the drive rollers automatically retract.
Notes:
If the drive rollers do not automatically retract, the
press is incomplete.
The pressing cycle can be interrupted at any
moment by releasing the trigger.
It is normal for the battery load display to light at both
the beginning and near the end of the pressing cycle.
10. Release the trigger until the drive rollers retract
completely.
11. Compress the adapter jaw ends together to open
the jaws and remove the adapter jaw from the
pressing chain (below).
12. Disengage the release pin on the pressing chain and
remove the pressing chain from the pressed tting.
Notes:
The pressing jaws must close completely to ensure
a leak-free connection. Always check that jaws
close completely during a pressing cycle and no
foreign objects are between the pressing jaws and
mechanism.
The pressing cycle can be interrupted at any
moment by releasing the trigger.
If the pressing cycle must be stopped before the
crimp is complete, and the jaws or chains have to
be removed from the fitting, or the adapter jaw has
to be removed from the chain, the fitting should be
replaced or pressed a second time.
This tool is intended to press NIBCO press fittings
onto type K, L, and M hard drawn copper tubing.

NIBCO, Inc. 12 1516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
Each Operating Day
Before use:
1. Inspect jaws or chains for wear or damage, such as
cracks, gouges, or chips.
2. Inspect the pressing tool for damage or leaks.
After use:
1. Use a damp cloth and mild detergent to clean the
housing. Allow the housing to dry.
2. Fully retract the drive rollers. Place the pressing tool
in the carrying case and store in a cool, dry place.
3. If necessary, recharge the batteries. Refer to the
instructions supplied with the battery charger.
Monthly
Thoroughly clean all surfaces.
Annually or After 10,000 Pressings
Send the tool to an authorized NIBCO service center for
inspection.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Do not use solvents or ammable
liquids to clean the pressing tool.
Solvents or ammable liquids could
ignite and cause serious injury or
property damage.
Keep hands away from the pressing
tool head when pressing.
Failure to observe this warning could
result in severe injury or death.
Skin injection hazard:
Oil under pressure easily punctures
skin causing serious injury,
gangrene, or death. If you are injured
by escaping oil, seek medical atten-
tion immediately.
• Do not use hands to check for
leaks.
• Depressurize the hydraulic system
before servicing.
Relief valve adjustments must be done by an
authorized service center.
Maintenance

NIBCO, Inc. 13 1516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
Troubleshooting
Before You Begin
1. Make sure that the battery is charged. Recheck
the battery after several minutes to make sure the
battery is holding its charge.
2. Use a nonflammable contact cleaner or pencil
eraser to clean the electrical contacts on the battery
and tool.
3. Reinstall the battery and check the tool again.
Problem Probable Cause Probable Remedy
Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.
of tool.
Pressing tool battery contacts damaged. Reform contacts.
Tool components worn or damaged. Return tool to an authorized
NIBCO service center.
Jaw does not close completely. Air in the hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approximately
10 seconds.
Return tool to an authorized NIBCO
service center.
Battery load display ashes Battery charge low. Charge or replace battery.
constantly.
Tool loses oil. Damaged internal seal. Return tool to an authorized NIBCO
service center.
Oil plug not installed properly. Return tool to an authorized NIBCO
service center.

NIBCO, Inc. 14 1516 Middlebury Street • Elkhart, IN 46516 USA • 888-446-4226
PC-100 Battery-powered Pressing Tool
NIBCO Inc. - World Headquarters
1516 Middlebury Street
Elkhart, IN 46516
USA
Technical Services
Phone: [phone]
Fax: [phone]