NVE 866 Challenger Series Owner'S Manual Download Page 18

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| 866 Challenger Series

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Ballast Valve Rebuilding

Ballast Valve Rebuilding_____________________________________________________________

If, from the troubleshooting guide shown previously, a ballast valve is determined to require

rebuild, a rebuilding kit can be obtained from NVE. This kit will include all the components

necessary to rebuild the ballast valve. The ballast valves have been designed to be field rebuild-

able. The procedure is shown below:

1. Remove the ballast valve vacuum line from the ballast valve cover (1/2” Wrench)

2. Remove the six socket head bolts from the

ballast valve cover

Caution: The cover will be under slight spring

tension

3. Remove cover carefully (spring should stay in

cover)

4. Remove plunger assembly from ballast valve

5. Remove nut from

plunger

assembly and

disassemble

6. Replace ballast valve diaphragm and the ballast valve

protective

gasket and reassemble plunger assembly

7. Place a small amount of Loctite on threads and an mating face

of nut and tighten

8. Ensure plunger sealing face and internal housing sealing face

are free of burrs

9. Insert plunger assembly back into ballast valve housing

10. Place spring in the cover pilot, align JIC fitting downward and close to the pump, and

replace cover

Note: Spring tension will have to be overcome to start bolts

Important: The shorter bolt goes in the 6 o’clock position

11. Tighten bolts evenly

12. Remove and replace the boss plug in the ballast valve cover

*Since adjustment wasn’t altered, ballast valve should retain previous opening level

REMOVE COVER &

SPRING

BALLAST VALVE

DIAPHRAGM

(120-097-004)

BALLAST VALVE

PROTECTIVE GASKET

(120-095-012)

Ballast Valve Rebuilding_____________________________________________________________

If, from the troubleshooting guide shown previously, a ballast valve is determined to require

rebuild, a rebuilding kit can be obtained from NVE. This kit will include all the components

necessary to rebuild the ballast valve. The ballast valves have been designed to be field rebuild-

able. The procedure is shown below:

1. Remove the ballast valve vacuum line from the ballast valve cover (1/2” Wrench)

2. Remove the six socket head bolts from the

ballast valve cover

Caution: The cover will be under slight spring

tension

3. Remove cover carefully (spring should stay in

cover)

4. Remove plunger assembly from ballast valve

5. Remove nut from

plunger

assembly and

disassemble

6. Replace ballast valve diaphragm and the ballast valve

protective

gasket and reassemble plunger assembly

7. Place a small amount of Loctite on threads and an mating face

of nut and tighten

8. Ensure plunger sealing face and internal housing sealing face

are free of burrs

9. Insert plunger assembly back into ballast valve housing

10. Place spring in the cover pilot, align JIC fitting downward and close to the pump, and

replace cover

Note: Spring tension will have to be overcome to start bolts

Important: The shorter bolt goes in the 6 o’clock position

11. Tighten bolts evenly

12. Remove and replace the boss plug in the ballast valve cover

*Since adjustment wasn’t altered, ballast valve should retain previous opening level

REMOVE COVER &

SPRING

BALLAST VALVE

DIAPHRAGM

(120-097-004)

BALLAST VALVE

PROTECTIVE GASKET

(120-095-012)

Ballast Valve Rebuilding_____________________________________________________________

If, from the troubleshooting guide shown previously, a ballast valve is determined to require

rebuild, a rebuilding kit can be obtained from NVE. This kit will include all the components

necessary to rebuild the ballast valve. The ballast valves have been designed to be field rebuild-

able. The procedure is shown below:

1. Remove the ballast valve vacuum line from the ballast valve cover (1/2” Wrench)

2. Remove the six socket head bolts from the

ballast valve cover

Caution: The cover will be under slight spring

tension

3. Remove cover carefully (spring should stay in

cover)

4. Remove plunger assembly from ballast valve

5. Remove nut from

plunger

assembly and

disassemble

6. Replace ballast valve diaphragm and the ballast valve

protective

gasket and reassemble plunger assembly

7. Place a small amount of Loctite on threads and an mating face

of nut and tighten

8. Ensure plunger sealing face and internal housing sealing face

are free of burrs

9. Insert plunger assembly back into ballast valve housing

10. Place spring in the cover pilot, align JIC fitting downward and close to the pump, and

replace cover

Note: Spring tension will have to be overcome to start bolts

Important: The shorter bolt goes in the 6 o’clock position

11. Tighten bolts evenly

12. Remove and replace the boss plug in the ballast valve cover

*Since adjustment wasn’t altered, ballast valve should retain previous opening level

REMOVE COVER &

SPRING

BALLAST VALVE

DIAPHRAGM

(120-097-004)

BALLAST VALVE

PROTECTIVE GASKET

(120-095-012)

*Since adjustment wasn’t altered, ballast valve should retain

previous opening level

Summary of Contents for 866 Challenger Series

Page 1: ...National Vacuum Equipment National Vacuum Equipment National Vacuum Equipment 800 253 5500 natvac com Owner s Manual 866 Challenger Rotary Vane Pump ...

Page 2: ... without the written permission of National Vacuum Equipment Inc 866 CHALLENGER Owner s Record Date of Purchase _________________________ Purchased from __________________________ Serial Number ____________________________ If your pump was manufactured after June 1 2014 it contains a NVE manufactured 4 port oil pump See pages 12 13 for additional information ...

Page 3: ...ries 3 www natvac com 800 253 5500 Counter Clockwise Rotation Clockwise Rotation IMPORTANT INFORMATION FOR INSTALLING PUMP 866 CHALLENGER SERIES PUMPS AERIAL VIEW SHADED AREA MUST BE KEPT CLEAR FOR SERVICING THE FILTER ...

Page 4: ...actory Oil Settings 12 Operating Instructions 14 Normal Operation 14 Recommended Lubricant 15 Ballast Valve System 16 Ballast Valve Troubleshooting 16 Adjusting Ballast Valve Opening Level 17 Ballast Valve Rebuilding 18 Maintenance 20 Cold Weather Operation 21 Troubleshooting 22 Pump overheats 22 Pump uses too much oil 22 Pump doesn t turn 22 No vacuum 23 System Troubleshooting 23 Making a Vacuum ...

Page 5: ...n a timely basis We are a one stop shop for manufacturers and distributors of vacuum equipment Our History National Vacuum Equipment Inc was founded in 1980 by Bruce Luoma The Company started as a retailer of vacuum pumps Soon after it started the Company secured the rights to exclusive distribution of the Battioni vacuum pumps in North America This helped the Company to evolve into its current st...

Page 6: ...rrantable All pumps received for warranty consideration must retain the original NVE serial number tag 2 The one 2 year period shall begin the day the product is shipped from our warehouse unless we are provided with an authentic copy of the original resale invoice in which case the one 2 year period shall begin at such invoice date 3 The covered product must be used in an application for which it...

Page 7: ...idental and consequential damage is hereby excluded to the full extent permitted by law 9 Manufacturer s liability as stated herein cannot be altered except in writing signed by an officer of National Vacuum Equipment Inc The maximum allowable operating vacuum will vary depending on R P M ambient temperature altitude and time running The basic principle to keep in mind is faster R P M higher air t...

Page 8: ...ed operation is desired Proven applications are Oil field Septic Restaurant Grease Industrial Waste Pump Specifications 866 Calculated Flow Data 866 CHALLENGER Model Specific Information RPM Pressure PSI Free Flow Vacuum in Hg 20 15 10 5 0 6 12 15 18 21 27 1150 Hp 44 36 30 23 19 18 22 23 25 26 29 CFM 461 1000 Hp 37 30 24 18 10 14 18 20 22 23 26 CFM 410 900 Hp 33 25 22 16 8 12 15 17 18 20 23 CFM 35...

Page 9: ...vacuum relief valve 1 5 or larger should also be incorporated into the system between the vacuum pump and moisture trap Your vacuum pump will potentially produce more pressure than is safely allowed for you vacuum tank Consult with your tank manufacturer to determine the appropriate pressure rating The vacuum relief valve will vary due to factors such as vacuum pump RPM ambient temperature altitud...

Page 10: ...the responsibility of the installer and user to ensure the vacuum pump or blower is not being over torqued at start up The pump should be set up to engage slowly to avoid initial torque damage Direction of Rotation The direction of rotation and RPM are marked on the front of the pump The direction of rotation required by your drive system should be determined prior to ordering the pump If during a...

Page 11: ... 4 Tighten adjustment screw CW until it seats on the cam Do not force Seated Against Flat of Cam 5 Back the screw off the desired amount of turns CCW 5 turns if running at 900 RPM Tip More turns out equals less oil flow Fewer turns out equals more oil flow 6 Retighten jam nut while holding adjustment screw 7 Repeat process for other adjustment screw 8 Reassemble cover onto pump assuring o ring doe...

Page 12: ...natvac com 800 253 5500 Adjusting Factory Oil Settings Continued Turns From Bottom Ounces Per Hour 7 5 6 7 25 7 7 8 6 75 9 6 5 10 6 11 5 5 12 5 13 4 75 14 4 5 15 4 25 16 NVE 4 Port Oil Pump Adjustment Rate Chart Tested at 1100 RPM ...

Page 13: ...s working vacuum 23 Hg at 1150 RPM RPM should be set to meet the needs and expectations of the operator Vacuum relief valves should be adjusted for a maximum working exhaust temperature of 375 degrees Fahrenheit Pressure relief valves should be adjusted to meet the tank manufacturer specifications Too low of an RPM can cause the vanes to clatter inconsistent contact with the housing causing wear S...

Page 14: ...turbine oil be used in our pumps Turbine oil is much more resistant to breakdown due to heat than normal motor oil thereby avoiding the problems associated with motor oil such as lacquering and excessive wear NVE ISO 150 Oil is our recommended pump oil for the Challenger series vacuum pumps Challenger Vacuum Pump Oil is sold by the case six 1 gallon containers of oil per case ...

Page 15: ...termined vacuum level has been reached usually at 12 Hg Inclusion of the ballast system greatly enhances the 866 s duty cycle The 866 should never be run for extended periods above 12 Hg without the allowance of ballast air Ballast Valve Troubleshooting Ballast valve not opening Ballast valve adjustment screw set to open too high see next section Clogged ballast air filter Loose vacuum line fittin...

Page 16: ...Run pump to desired ballast opening vacuum level recommend 12 Hg If ballast is not open and should be turn adjustment screw CCW slowly with flat head screwdriver until air just begins to flow If ballast opens before desired vacuum has been reached turn adjustment screw CW slowly with flat head screwdriver until air is just flowing Place thumb over adjustment hole and ensure opening level is accura...

Page 17: ...on 3 Remove cover carefully spring should stay in cover 4 Remove plunger assembly from ballast valve 5 Remove nut from plunger assembly and disassemble 6 Replace ballast valve diaphragm and the ballast valve protective gasket and reassemble plunger assembly 7 Place a small amount of Loc tite on threads and an mating face of nut and tighten 8 Ensure plunger sealing face and internal housing sealing...

Page 18: ... from plunger assembly and disassemble 6 Replace ballast valve diaphragm and the protective gasket and reassemble plunger a 7 Place a small amount of Loctite on threads and an mating face of nut and tighten 8 Ensure plunger sealing face and internal housing sealing face are free of burrs 9 Insert plunger assembly back into ballast valve housing 10 Place spring in the cover pilot align JIC fitting ...

Page 19: ...n the diesel fuel is gone switch the 4 way valve to neutral and run the pump for 2 minutes 5 Speed the pump up to normal RPM switch the 4 way valve to vacuum 6 Close the valve and remove the hose 7 Drain oil catch muffler and properly dispose of used oil and flushing fluid Checking Vane Wear We recommend checking vane wear at a minimum every 12 months A new vane is flush with the outside diameter ...

Page 20: ...pump turn by hand to confirm it is not frozen If pump is frozen thaw it If the pump is frozen move the truck into a heated building Avoid freezing problems You can avoid freezing problems by putting a small amount of diesel fuel into the pump at the end of the day VANE ANALYSIS TRACKING SHEET DATE WEAR IN REPLACEMENT COMMENTS ...

Page 21: ...tment set too lean RPM too fast Prolonged operation at excessive vacuum or pressure levels Pump is dirty Ballast filter is clogged or dirty Pump Uses Too Much Oil Oil pump set too rich Leaving pump under vacuum between jobs Product running through pump Pump Doesn t Turn Broken vane or bearing Pump is frozen Problem in the drive train ...

Page 22: ...uble If you notice a decrease in pump performance start troubleshooting at the pump Remove the suction and discharge hoses at the pump Start the pump and run it in vacuum only at its normal rpm Check the vacuum level at the pump inlet The 866 Challenger in new condition will develop 27 28 5 Hg If the pump checks out ok check the vacuum level at the secondary then the primary shutoff Keep working y...

Page 23: ... a 1 4 NPT thread in the pipe cap 3 Assemble the flange nipple pipe cap and vacuum gauge 4 Remove a flange from the four way valve on your pump 5 Start the pump and confirm the location you have chosen to test from is at vacuum 6 Using the existing O ring fasten the testing flange to your pump 7 Start your pump and read the vacuum level on the gauge Making a Vacuum Tester ...

Page 24: ...6 19 18 10 20 2 8 75 322 15 16 12 13 312 316 60 59 316 24 57 58 23 306 304 17 25 311 316 30 79 80 319 306 315 314 316 20 10 9 8 308 315 3 4 56 310 316 313 46 42 14 47 1 22 4 5 7 9 316 314 11 309 50 35 77 64 77 40 69 61 72 70 71 63 305 81 68 44 43 45 314 316 27 49 307 315 314 316 41 66 74 71 72 70 201 204 206 207 205 203 202 64 63 62 63 32 26 318 54 55 39 38 303 307 317 303 ...

Page 25: ...Y FTR VALVE 18 2 120 053 506 SEAL 45 X 62 X 8 VITON 19 1 120 054 506 BEARING COVER 20 2 120 055 506 GASKET BEARING COVER 21 2 120 058 PLUG BRASS HEX HEAD 1 8 NPT 22 3 120 059 PLUG BRASS HEX HEAD 1 4 NPT 23 1 120 060 001 HANDLE 367 GEN 2 24 1 120 060 002 GRIP HANDLE W LOGO 25 1 120 062 006 PLUG 866 26 2 120 063 506 FLANGE 4 NPT 27 2 120 064 002 O RING 2 214 VITON 28 1 120 064 004 O RING 2 265 VITON...

Page 26: ... 120 107 001 SERIAL TAG SS 56 1 120 220 THERMOMETER 50 400 DEG 2 FACE 57 1 120 310 001 COVER FILTER 607 866 58 4 120 312 002 KNOB 5 16 18UNC 59 1 120 314 001 FILTER ELEMENT 607 866 60 1 120 320 002 MANIFOLD 866 MACHINED 61 1 123 000 004 OIL PUMP 4 PORT BIDIRECTIONAL 62 1 123 408 017 BANJO ADAPTER TO 0 250 HB 63 10 123 013 001 WASHER 3 8 SEALING NBR 64 5 123 408 014 BANJO BOLT 1 8 BSPP 66 1 280 355...

Page 27: ... 150 TAR 0950 HOSE 1 5 HOT TAR AND ASPHALT 9 5 82 2 426 150 TBC CLAMP T BOLT 2 DIA 200 1 OWNERS MANUAL 866 OWNERS MANUAL 866 201 1 320 082 001 OIL TANK 5QT W LOGO 202 1 320 083 009 OIL TANK FILTER 100 MESH 203 1 320 083 010 FILTER FITTING OIL TANK 1 4 NPT 204 5 FT 320 407 003 OIL LINE BLK 1 4 ID 30R7 205 2 416 025 1WC CLAMP WORM 1 4 DIA 206 6 IN 320 R102 OIL LINE 3 8 X 1 4 ID X 6 LG 207 1 310 LP5 ...

Page 28: ...13 311 313 65 84 42 44 311 313 66 79 81 83 47 43 45 305 312 64 63 61 67 41 68 59 2 62 70 74 308 313 15 13 33 2 25 4 8 36 311 313 22 21 34 304 303 55 56 313 55 35 57 29 58 313 310 18 19 17 20 16 316 312 304 77 78 311 313 10 11 27 49 53 3 46 313 307 9 80 9 82 301 12 14 23 29 1 4 7 37 313 309 5 6 8 303 306 10 11 27 26 313 311 32 70 71 68 69 ...

Page 29: ...4 WAY FTR VALVE 22 1 120 047 DRAIN PLUG 3 4 NPT 23 1 120 047 1 DRAIN PLUG 3 4 NPT MAGNETIC 24 1 120 049 BUSHING 3 4 NPT X 1 8 FNPT 25 2 120 053 506 SEAL 45 X 62 X 8 VITON 26 1 120 054 506 BEARING COVER 27 2 120 055 506 GASKET BEARING COVER 28 1 120 058 PLUG BRASS HEX HEAD 1 8 NPT 29 3 120 059 PLUG BRASS HEX HEAD 1 4 NPT 30 1 120 060 001 HANDLE 367 GEN 2 31 1 120 060 002 GRIP HANDLE W LOGO 32 1 120...

Page 30: ...5 70 1 320 407 009 OIL LINE 3 SST 90 DEG JIC TO BANJO 30 71 1 320 407 010 OIL LINE 3 SST FEMALE JIC TO BANJO 37 50 72 1 320 407 034 OIL LINE 3 SST 90 DEG JIC TO STR 3 FEMALE JIC 14 75 73 2 320 408 016 FITTING STR 3 MJIC X 1 8 MNPT 74 3 320 408 017 FITTING ELBOW 3 MJIC X 1 8 MNPT 75 1 320 408 034 ADAPTER STRAIGHT 1 8 MNPT X 1 8 FNPT BRASS 76 6 320 409 003 P CLIP OIL LINE 1 4 X 5 16 77 2 320 LF8 DRI...

Page 31: ...SCRIPTION 201 1 320 082 001 OIL TANK 5QT W LOGO 202 1 320 083 009 OIL TANK FILTER 100 MESH 203 1 320 083 010 W HB FILTER FITTING OIL TANK 1 4 NPT 204 5 FT 320 407 003 OIL LINE BLK 1 4 ID 30R7 205 2 416 025 1WC CLAMP WORM 1 4 DIA 206 6 IN 320 R102 OIL LINE 3 8 X 1 4 ID X 6 LG 207 1 310 LPS HOSE BARB 1 4 X 1 8 NPT STRAIGHT ...

Page 32: ...P O Box 685 Traverse City MI 49685 USA 231 941 0215 Phone 231 941 2354 Fax sales natvac com www natvac com 800 253 5500 National Vacuum Equipment National Vacuum Equipment ...

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NVE 866 Challenger Series, Owner'S Manual

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