NVE 304 Challenger Series User manual

National Vacuum Equipment
Owner’s Manual
304 Challenger Series Rotary Vane Vacuum Pumps
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]
www.fraserwoods.ca

2| 304 Challenger Series
© 2015 National Vacuum Equipment, Inc.
Revision: 1 (Released) April, 2015
No part of this manual may be reproduced without the written permission of
National Vacuum Equipment, Inc.
304 Challenger
Owner’s Record
Date of Purchase: _________________________
Purchased from: __________________________
Serial Number: ____________________________
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304 Challenger Series | 3
Clockwise
Rotation
Counter - Clockwise
Rotation
IMPORTANT INFORMATION
FOR INSTALLING PUMP
304 CHALLENGER SERIES PUMPS AERIAL VIEW
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4| 304 Challenger Series
Contents
Introduction 5
General Information���������������������������������������������������������5
Limited Warranty 6
Warranty ��������������������������������������������������������������������������6
304 Challenger 9
Application �����������������������������������������������������������������������9
PumpSpecications ��������������������������������������������������������9
System Requirements �����������������������������������������������������9
Pressure and Vacuum Settings �������������������������������������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 21
304 Parts Diagram���������������������������������������������������������21
304 Challenger Series Vacuum Pumps Parts List���������22
Vane Replacement 25
304 Vane Replacement Instructions������������������������������26
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304 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 North America�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
components, 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| 304 Challenger Series
Warranty
National Vacuum Equipment, Inc.
Guarantees that the product it provides is free of manufacturer’s
defects, including materials and workmanship� When properly
installed and maintained this product is warranted for a period of
two (2) 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 two (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 two (2) 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
304 Challenger
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304 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 herein 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�
12� NVE is not responsible for pump coupling tightness or
alignment�Customer needs to inspect periodically to ensure
proper alignment and to check tightness of set screws�
Any items found to be defective after delivery to the end user that
should have been discovered prior to delivery will qualify for
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| 304 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 materials authorization (RMA)
form from NVE before returning product�
• All serial-numbered products must retain the original 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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304 Challenger Series | 9
Application
• Duty cycle will vary depending on several factors, such as altitude,
RPM & ambient temperature�
304 Challenger
Model-Specic
Information
Pump Specications
Air Flow @ Free Air........................................ 210 CFM
Maximum Intermittent Vacuum................... 27-1/2” Hg
Maximum Intermittent Pressure ................. 20 psi
Operating Speed .......................................... 1000 - 1400 RPM
Porting Size................................................... 2” (optional 1-1/2”)
Shaft Size (1/4” Key)................................... 1-1/4”
Approximate Weight ..................................... 179 lbs
System Requirements
Shutoffs
• We recommend a primary shut-off, secondary shut-off, and an oil
catchmuferbeinstalledonthesystem.
Hose
• Use 2” or larger hose to plumb your system� We recommend you
use a hose that can withstand high temperatures such as hot
tar-asphalt hose�
Pressure and Vacuum Relief Valves
• Properly adjusted pressure relief and vacuum relief valves should
also be incorporated in the system between the secondary shutoff
and the pump�
• The relief valves should be set to where the pump operates at a
maximum temperature of 375 degrees Fahrenheit�
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10 | 304 Challenger Series
Via delle Acacie 8 - Z.I. D4 - P.O. Box 64 - 28075 GRIGNASCO (N0) ITALY
Export dept. +39 - 0163 - 415 221 /222 Fax. +39 - 0163 - 411 914
Web www.riv-vg.com www.velattagroup.com E-mail e x p o r t.s a l e s @ r i v- vg.c om
VACUUM RELIEF VALVES - SETTING INSTRUCTION
1) Remove the protection cap “A”
2) Turn the spring-tightener “B”, through a
spanner“C” ,Clockwise to increase the
pressure, Anti-clockwise to reduce the
pressure
3) Once obtained the desired pressure, screw
down the lock nut “D”
4) Screw down the protection cap and fix it
using the rings “E” situated on the valve
bodyand on the cap
AC
B
D
E
1� Remove the protection cap “A”
2� Turn the spring-tighter “B”, through a spanner “C”, clockwise to
increase the pressure, counter-clockwise to reduce the pressure
3� Once obtained the desired pressure, screw down the lock nut “D”
4. Screwdowntheprotectioncapandxitusingtherings“E”
situated on the valve body and on the cap
Picture 1�
1� Unscrew the lock nut “A”
2� Turn the spring-tightener “B”
Picture 2�
1� Once obtained the desired pressure, screw down the lock nut “A”
Picture 3�
1� Fix the setting, using the rings “C” Situated on the body and on the
spring tightener
Pressure and Vacuum Relief Valve Setting Instructions
Vacuum Relief Valve
Pressure Relief Valve
Via delle Acacie 8 - Z.I. D4 - P.O. Box 64 - 28075 GRIGNASCO (N0) ITALY
Export dept. +39 - 0163 - 415 221 /222 Fax. +39 - 0163 - 411 914
Web www.riv-vg.com www.velattagroup.com E-mail e x p o r t.s a l e s @ r i v- vg.c om
PRESSURE RELIEF VALVES - SETTING INSTRUCTION
Picture 1
1) Unscrew the lock nut"A”
2) Turn the spring-tightener“B”,
Clockwise to increase the pressure.
Anti-clockwise toreduce the pressure
Picture 2
Once obtained the desired pressure, screw
down the lock nut “A”
Picture 3
Fix the setting, using the rings “C”
Situated on the bodyandon the spring-
tightener
B
123
A A
C
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304 Challenger Series | 11
Drive System
• The pump should be mounted on a level, horizontal
surface, secured with grade 8 fasteners�
• The drive system should be sized to supply the required
horsepower to the pump plus a reserve to insure long life�
• The power take off (PTO) must be slowly engaged or it will
damage the pump and drive components�
• 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�
Direction of Rotation
• The direction of rotation required by your drive system should
be determined prior to ordering the pump�
Factory Settings
• The automatic lubrication pumps are set at the factory during
pump testing and should require no further adjustment
during pump installation� The oil pump is easily adjustable
from 5-24 ounces per hour�
• It is the responsibility of the installer to ensure proper vacuum
and pressure settings and RPM�
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12 | 304 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)�
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
Jam Nut
Tight Against
Piston
O-ring
Seated in
Groove
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304 Challenger Series | 13
Adjusting Factory Oil Settings Continued
Turns From Boom 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
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14 | 304 Challenger Series
Operating Instructions
304 Challenger
Normal Operation
Oil Reservoir
•Checkoilreservoirdailyandllasrequired.
• Drain and clean periodically depending on use�
Recommended RPM
• 1000 - 1400 RPM�
• 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!
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304 Challenger Series | 15
Recommended Lubricant
Recommended NVE Turbine Oils:
1� *NVE ISO 68 Oil (Winter Blend)
2� *NVE ISO 150 Oil (Summer Blend)
Other Acceptable Turbine Oils:
1� Shell Turbo 68
2� Mobil D�T�E� Heavy - Medium
3� Texaco Regal R & O 68
4� Chevron GST
5� Penzoil Penzabell 68 T�O�
* NVE ISO 68 and NVE ISO 150 Oils are recommended for the
Challenger series vacuum pumps. Challenger Vacuum Pump
Oil is sold by the case, (6) gallons per case.
Although we recommend using a turbine oil for optimum use,
you may use any type of oil you prefer, as long as you monitor
your operating temperatures and keep your pump within the
proper operating range (must not exceed 375 degrees)� Using
a non-turbine oil outside of the recommended range may cause
problems such as overheating, lacquering and excessive wear,
which can lead to severe damage to your equipment�
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16 | 304 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 container with 4-5 ounces of
diesel fuel� Start your pump and run as slow as possible�
3� With the suction valve in the vacuum position, monitor the
dieselowtoyourpump.
4� When the diesel fuel is gone, switch the suction valve to
neutral and run the pump for 2 minutes�
5� Speed the pump up to normal RPM, switch the suction
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 once 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 outside diameter, 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 4 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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304 Challenger Series | 17
Cold Weather Operation
Prior to engaging pump.
•Conrmpumpisnotfrozen.
If pump is frozen, thaw it.
• If the pump is frozen, thaw it out by moving 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�
Maintenance Continued
•Ifequippedwithalter,checklterregularly.
•Cleanlterwithcompressedairoracleaningsolution.
The lter is made of stainless steel, please keep that in
mind when choosing your cleaning solution.
•Beforereinsertingthelterintothehousing,lubethe
insideendofthelterthatwilltoverthelipinthebottom
of the housing�
Properly apply lube here on
the inside lip of the lter...
...before reinserting here.


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18 | 304 Challenger Series
Troubleshooting
NVE 304
Vacuum Pump
Problem: Pump overheats
Causes:
• No oil in pump
• Oil adjustment set too lean
• RPM too fast
• Prolonged operation at excessive vacuum or pressure levels
• Pump is dirty
•Inletlterisclogged(ifequipped)
Problem: Pump uses too much oil
Causes:
• Oil pump set too rich
• Leaving pump under vacuum between jobs
Problem: Pump doesn’t turn
Causes:
• Broken vane or bearing
• Pump is frozen
• Problem in the drive train
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304 Challenger Series | 19
Problem: No vacuum
Causes:
• 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
•Inletlterclogged(ifequipped)
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 mode at its
recommended RPM�
• Check the vacuum level at the pump inlet� The 304
Challenger in new condition will develop 27” Hg�
• If the pump checks out okay, 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.natvac.com or call us at 800-253-5500.
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20 | 304 Challenger Series
Making a vacuum tester
1� Procureaangetomountonyour4-wayvalve,a
short 2” pipe nipple, a 2” pipe cap and a vacuum
gage�
2� Drill and tap a 1/4” NPT 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�
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