NVE 866 Challenger Series User manual

National Vacuum Equipment
Owner’s Manual
866 Challenger Series Rotary Vane Vacuum Pumps
www.fraserwoods.ca
Authorized NVE Distributor, Service & Repair Facility
120 –10293 276 ST, Acheson, Alberta, Canada T7X 6A5
T: 780.962.1827 F: 780.962.1830 E: [email protected]

2| 866 Challenger Series
© 2014 National Vacuum Equipment, Inc.
Revision: 3 (Release) June 2014
No part of this manual may be reproduced 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
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866 Challenger Series | 3
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
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4| 866 Challenger Series
CONTENTS
Introduction ...................................................................... 5
General Information....................................................................5
Limited Warranty ............................................................. 6
Warranty.....................................................................................6
866 Challenger ................................................................. 9
Application..................................................................................9
PumpSpecications...................................................................9
System Requirements..............................................................10
Drive System ...........................................................................11
Factory Settings .......................................................................11
Adjusting Factory Oil Settings..................................................12
Operating Instructions .................................................. 14
Normal Operation ....................................................................14
Recommended Lubricant.........................................................15
Maintenance.............................................................................16
Cold Weather Operation...........................................................17
Troubleshooting ............................................................ 18
Pump overheats.......................................................................18
Pump uses too much oil...........................................................18
Pump doesn’t turn....................................................................18
No vacuum...............................................................................19
System Troubleshooting...........................................................19
Making a Vacuum Tester..........................................................20
Parts Breakdown ........................................................... 22
Fan Parts List..........................................................................22
Liquid Parts List.......................................................................26
Oil Pump Parts List .................................................................29
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866 Challenger Series | 5
Introduction
General Information
About National Vacuum Equipment
Congratulations! You now own a quality vacuum/pressure pump proudly
manufactured in the U.S.A. by National Vacuum Equipment, Inc. You
havenotonlyacquiredasuperiorpieceofequipmentfromaqualied
dealer, you have hired a team of vacuum experts. We stand ready to
work with your dealer to answer your questions and provide you with the
information necessary to keep your equipment in peak working condition.
Thank you for putting your trust in National Vacuum Equipment.
Our Mission
We are dedicated to the production and wholesale distribution of quality
vacuum system products at a reasonable price, on 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 NorthAmerica. This helped the Company to
evolve into its current status as a wholesale supplier.
To reach the goal of becoming a full service supplier of vacuum system
components, the Company began fabrication of its own line of
componentry, purchased and developed its own line of vacuum pumps,
and began purchasing for resale, various valves and accessories.
Today, NVE has full service machine, fabrication and powder-coating
shops complete with CNC-controlled production equipment designed for
close tolerance work. The company has a highly trained staff, all of whom
are dedicated to quality.
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6| 866 Challenger Series
Warranty
National Vacuum Equipment, Inc.
Guarantees that the product it provides is free of manufacturer’s
defects, including materials and workmanship. Properly installed and
maintained product is warranted for a period of one (1) year subject to
the following conditions:
1. A properly completed warranty registration card must be
received by us within 30 days of sale to end user for pump sales
to be considered warrantable. All pumps received for warranty
consideration must retain the original NVE serial number tag.
2. The one (1) 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 (1) year period shall begin at such invoice date.
3. The covered product must be used in an application for which it
was intended. We do not recommend our product for particular
uses or applications.
4. Vane breakage, or damage caused by vane breakage, is not
warrantable.
5. Damage caused by improper use or lack of proper maintenance
is not warrantable.
6. Manufacturer’s liability under this or any other warranty, whether
express or implied, is limited to repair of or, at the manufacturer’s
option, replacement of parts which are shown to have been
defective when shipped.
LIMITED WARRANTY
866 Challenger
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866 Challenger Series | 7
7. Manufacturer’s liability shall not be enforceable for any product
until National Vacuum Equipment, Inc. has been paid in full for
such product.
8. Except to the extent expressly stated herein, manufacturer’s
liability for incidental and consequential damage is hereby
excluded to the full extent permitted by law.
9. Manufacturer’s liability as stated herin cannot be altered except
inwritingsignedbyanofcerofNationalVacuumEquipment,
Inc.
10. Certain products provided by National Vacuum Equipment, Inc.
are covered by their respective manufacturer’s warranties (e.g.,
engines used in the NVE engine drive packages). These
products are not covered by the National Vacuum Equipment,
Inc. Manufacturer’s Warranty.
11. Final assemblers responsibility. NVE goes to great lengths to
insure the quality and proper functionality of the products it
supplies. Many products we supply are purchased for resale or
are impossible or impractical to test prior to the installation of the
item in a vacuum system. It is therefore the responsibility of the
nalassemblertothoroughlytestthevacuumsystemand
components supplied to the assembler by NVE prior to the
deliveryofthenalproducttotheenduser.
Any items found to be defective after delivery to the end user that
should have been discovered prior to deliver will qualify replacement
of the defective part only with absolutely no compensation for outside
labor or travel expenses. Any subsequent damage to other
components caused by the defective part will be the sole responsibility
of the assembler.
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8| 866 Challenger Series
WARRANTY PROCEDURES
Should a potential warranty situation arise, the following
procedures must be followed:
•Contact your dealer or NVE immediately upon the occurrence of the
event and within the warranty period.
•Customer must receive a return goods authorization (RGA) before
returning product.
•All serial-numbered products must retain the NVE serial number tag
tobequaliedforwarranty.
•Product must be returned to NVE intact for inspection before
warranty will be honored.
•Product must be returned to NVE freight prepaid in the most
economical way.
•Credit will be issued for material found to be defective upon our
inspection, based upon prices at the time of purchase.
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866 Challenger Series | 9
Application _______________________________________________________
Designed for extended operation
•Duty cycle will vary depending on several factors, such as
altitude, RPM & ambient temperature.
•The 866 Challenger is a severe duty vacuum pump, designed
to be used in liquid waste pumping systems where extended
operation is desired.
•Proven applications are:
-Oileld -Septic
- Restaurant Grease - Industrial Waste
Pump Specifications _____________________________________________
866 Calculated Flow Data
866 Challenger
Model-Specic
Information
RPM
Pressure (PSI) Free Flow Vacuum (in Hg)
20 15 10 5 0 6 12 15 18 21 27
1150 Hp 43 36 27 25 18 21 23 24 25 25 29
CFM 431 438 447 457 519 470 453 440 438 425 351
1000 Hp 38 32 24 20 15 18 20 21 22 23 25
CFM 375 381 389 398 452 409 394 390 381 370 306
800 Hp 32 25 19 15 13 14 16 17 18 19 21
CFM 319 324 331 342 385 348 333 331 324 315 242
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10 | 866 Challenger Series
System Requirements _______________________________________________
High Quality Components
•The 866 Challenger is a high performance vacuum pump and
requires compatible, high quality components as manufactured
by NVE.
Shutoffs
•We recommend the use of our Parts F-802C portal/portal
shutoff, and our Part #F-901-C, 12 gallon scrubber/secondary
shutoff.
Final lter
• Wealsorequiretheuseofanallter.Youcanuseour
remotemountedlter.(Part#F-1001C)
Hose
•Use 4” or larger hose to pump your system. We recommend
you use a hose that can withstand high temperatures such as
hot tar-asphalt hose.
Pressure relief and vacuum relief valves
•A pressure relief valve and vacuum relief valve should also be
incorporated in the system.
•The pressure relief valve should be set for a maximum of
25 p.s.i. or as allowed by the tank manufacturer if lower.
•The vacuum relief valve should be set for 20” Hg.
•The relief valves should be set to where the pump operates as
a maximum temperature of 350 degrees F.
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866 Challenger Series | 11
Drive System _________________________________________________________
•The pump should be mounted on a level, horizontal surface,
secured with grade 5 or better fasteners.
•The drive system should be sized to supply the required horse-
power to the pump plus a reserve to insure long life.
•Make certain that all shafts, pulleys or turning parts are properly
guarded.
•Check the ratio of the drive system prior to installation to verify
that the pump will be turning at the proper speed and direction.
•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assemblyofyourunityoundyouneedtheopposite
rotation, call the factory for instructions.
Factory Settings __________________________________________________
•The automatic lubrication pumps are set at the factory during
pump testing and should require no further adjustment during
pump installation. The pump should consume 12 o.z.-15 o.z. of
oil per hour. Please contact us if oil usage is outside of these
parameters.
•It is the responsibility of the installer to ensure proper vacuum
and pressure settings and RPM.
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12 | 866 Challenger Series
Oil Pump Flow Rate Adjustment Procedures
1. Remove oil pump cap (3/32 hex).
Ensure o-ring stays intact.
3/32 Hex
2. Move cam so adjustment screws
arerestingonlowerats
Upper Flat
Lower Flat
3. Holdadjustmentscrew(9/64hexorat
head screw) while loosening jam nut
1/4” wrench). Spin jam nut all the way
up to the head. Adjustment
Screw 9/64
Hex or Flat
Head Screw
Depending
on Unit
Jam Nut
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):
a. 607 PRO = 7 turns
b. 866 = 4.75 turns
Tip:Moreturnsoutequalslessoilow.
Fewerturnsoutequalsmoreoilow.
6. Retighten jam nut while holding
adjustment screw.
7. Repeat process for other
adjustment screw.
8. Reassemble cover onto pump
assuring o-ring does not fall out of
groove, and springs are located over
adjustment screws
Springs
Located Over
Screws
If oil pump requires further adjustment, the
ruleis1/2turnCCW=1oz/ hrhigheroilow.
Jam Nut
Tight Against
Piston
O-ring
Seated in
Groove
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866 Challenger Series | 13
Chart #1
Pump RPM
Turns From
Boom 800 900 1000 1100 1250 1500
9.75 4 4 4 4 4 4
9.5 4 4 4 5 5 5
9.25 5 5 5 5 5 6
9 5 6 6 6 6 7
8.75 6 6 6 7 7 7
8.5 6 7 7 7 8 8
8.25 7 7 7 8 8 9
8 7 8 8 8 9 10
7.75 8 8 9 9 10 11
7.5 8 9 9 10 11 12
7.25 9 9 10 10 11 13
7 9 10 10 11 12 14
6.75 10 10 11 12 13 15
6.5 10 11 12 12 14 15
6.25 11 11 12 13 14 16
6 11 12 13 14 15 17
5.75 11 12 13 14 16 18
5.5 12 13 14 15 16 19
5.25 12 14 15 16 17 20
5 13 14 15 16 18 21
4.75 13 15 16 17 19 22
4.5 14 15 16 18 19 23
4.25 14 16 17 18 20 23
4 15 16 18 19 21 24
3.75 15 17 18 20 22 25
3.5 16 17 19 20 22 26
3.25 16 18 19 21 23 27
3 17 18 20 22 24 28
2.75 17 19 20 22 25 29
2.5 18 19 21 23 25 30
2.25 18 20 22 23 26 31
2 19 20 22 24 27 31
1.75 19 21 23 25 28 32
1.5 20 22 23 25 28 33
1.25 20 22 24 26 29 34
NVE Oil Pump Flow Rate Chart
Adjusting Factory Oil Settings Continued
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14 | 866 Challenger Series
866 Challenger
Normal Operation _______________________________________________
Oil Reservoir
• Checkoilreservoirdailyandllasrequired.
•Drain and clean periodically depending on service.
• Cleantheballastairlterwithdieselfuelregularly
Recommended RPM
•Do not operate the pump faster than the recommended rpm of
1000. 1150 RPM is for intermittent use only.
•Too low of an RPM can cause the vanes to clatter (inconsistent
contact with the housing) causing wear.
Suction Valve
•To operate the suction valve, move the handle in the
appropriate direction for either vacuum or pressure;
center is neutral.
Vacuum Levels
•Do not operate your pump for extended periods of time at
vacuum levels which cause the pump to exceed 375 degrees
Fahrenheit exhaust gas temperature.
Guards
Make certain all guards are in place prior to running your pump.
Think Safety!
OPERATING INSTRUCTIONS
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866 Challenger Series | 15
Recommended Lubricant ______________________________________
•We recommend that 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.
Acceptable oils include:
1. * NVE ISO 68 Oil
2. Penzoil Penzabell 68 T.O.
3. Shell Turbo 68
4. Mobil D.T.E. Heavy - Medium
5. Texaco Regal R & O 68
* NVE ISO 68 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.
Ballast Cooling __________________________________________________
•Ballast cooling of a vacuum pump is accomplished by
introducing atmospheric air into the exhaust side of the pump
housing. The ballast inlet is located at a point where the
affected pump cell is no longer in contact with the intake port.
•The result is cooling of the housing and rotor with no
appreciable drop in vacuum level.
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16 | 866 Challenger Series
Maintenance _____________________________________________________
Washing
•Periodically wash the mud and dirt off of your pump as it must
be clean to allow heat to radiate from it.
Flushing
Werecommendperiodicushingofyourpump.Todothis:
1. Connectthehosetotheushvalvelocatedonthesideofthe
inlet port.
2. Put the end of the hose in a one pint container of diesel fuel.
Start your pump and run as slow as possible.
3. Withthe4-wayvalveinthevacuumposition,opentheush
valveandmonitorthedieselowtoyourpump.
4. When 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. Remove the hose and close the valve.
7. Properlydisposeofusedoilandushinguid.
Checking Vane Wear
We recommend checking vane wear at least every 12 months.
• Anewvaneisushwiththeoutsidediameteroftherotor.
•Remove the plug from the vane check port, insert a rod to rotor
O.D., rotate rotor until the rod falls into one of the vane slots. If
the rod falls more than a 1/4” into any of the 6 vane slots, it’s
time to replace the vanes.
•Vanes should be replaced in sets and it is always a good idea
to have an extra set of vanes on hand for emergencies.
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866 Challenger Series | 17
Cold Weather Operation ________________________________________
Conrm pump is not frozen
• Priortoengagingthepump,turnbyhandtoconrm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.
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18 | 866 Challenger Series
TROUBLESHOOTING
NVE 866
Vacuum Pump
Pump overheats ________________________________________________
•No oil in pump
•Oil adjustment set too lean
•RPM too fast
•Prolonged operation at excessive vacuum or pressure levels,
•Pump is dirty
•Ballastlter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
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866 Challenger Series | 19
No vacuum _______________________________________________________
•Suction valve is in neutral
•Worn seals or vanes
•Pump is not turning fast enough
•Check valve or suction valve is clogged
• Leakinthetankorttings
•Collapsed hose between the pump and shutoffs
• Ballastlterclogged
System Troubleshooting _______________________________________
Locating the source of the trouble
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 your way
backuntilyoundtheproblem.
For rebuild instructions please visit our website at
www.nvepump.com or call us at 800-253-5500.
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20 | 866 Challenger Series
1. Procureaangetomountonyourfour-wayvalve,ashort4”
pipe nipple, a 4” pipe cap and a vacuum gage.
2. Drill and tap a 1/4” N.P.T. thread in the pipe cap.
3. Assembletheange,nipple,pipecapandvacuumgage.
4. Removeaangefromthefour-wayvalveonyourpump.
5. Startthepumpandconrmthelocationyouhavechosentotest
from is at vacuum.
6. UsingtheexistingO-ring,fastenthetestingangetoyourpump.
7. Start your pump and read the vacuum level on the gauge.
Making a Vacuum Tester _______________________________________
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