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Owner’s Manual
&
Operating Instructions
607 Challenger Series Rotary Vane Vacuum Pumps
607 Challenger
Owner’s Record
Date of Purchase: _________________________
Purchased from: __________________________
Serial Number: ____________________________
Limited Warranty 6
. Warranty��������������������������������������������������������������������������6
607 Challenger 10
. Application���������������������������������������������������������������������10
. Pump Specifications������������������������������������������������������10
. System Requirements��������������������������������������������������� 11
. Drive System ����������������������������������������������������������������12
. Factory Settings�������������������������������������������������������������12
. Adjusting Factory Oil Settings���������������������������������������13
Operating Instructions 14
. Normal Operation ���������������������������������������������������������14
. Recommended Lubricant����������������������������������������������15
. Maintenance������������������������������������������������������������������16
. Cold Weather Operation������������������������������������������������17
Troubleshooting18
. 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
Pump Rebuilding 21
. Vane Replacement��������������������������������������������������������21
. Complete Rebuild����������������������������������������������������������25
Parts Breakdown 37
. Fan Parts List����������������������������������������������������������������37
. Liquid Parts List�������������������������������������������������������������41
Our Mission
We are dedicated to the manufacture 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 equip-
ment.
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.
607 Challenger
Warranty
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.
Any items found to be defective after delivery to the end user that
should have been discovered prior to deliver will qualify replace-
ment 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 responsi-
bility of the assembler.
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607 Challenger
Model-Specific
Information
Application
Pump Specifications
Shutoffs
• We recommend an 8” cage and a 6” S.S. ball which is
standard in all of our primary and secondary shutoffs.
Hose
• Use 3” or larger hose to plumb your system. We
recommend you use a hose that can withstand high
temperatures such as hot tar-asphalt hose.
Direction of Rotation
• The direction of rotation and RPM are marked on the front
of the pump.
Factory Settings
• The automatic lubrication pumps are set at the factory
during pump testing and should require no further adjust-
ment during pump installation. The pump should consume
12oz - 15oz of oil per hour. Please contact us if oil usage is
outside of these parameters.
2. Fill the oil tank to the top at night. Check the oil level
before service the next day to ensure no internal leak-
ing.
3. To adjust the oil rate, remove cap [P16]. Under this cap
you will find a jam nut [P15] and adjusting screw [P11]
607 Challenger
Normal Operation
Oil Reservoir
• Check oil reservoir daily and fill as required.
Temperature
• Check exhaust temperature. It must not exceed 375
degrees Fahrenheit at any time.
Recommended RPM
• Do not operate the pump faster than the recommended rpm of
1250. 1500 RPM is for intermittent use only.
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!
3. Shell Turbo 68
Flushing
We recommend periodic flushing of your pump. To do this:
• 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
7 vane slots, it’s time to replace the vanes.
NVE 607
Vacuum Pump
Pump overheats
• No oil in pump
• Pump is dirty
• Pump is frozen
System Troubleshooting
Locating the source of the trouble
• Start the pump and run it in vacuum only at its normal rpm
• If the pump checks out ok, check the vacuum level at the
secondary, then the primary shutoff. Keep working your
way back until you find the problem.
ITEM DESCRIPTION
300 SHCS - 1/4-20 UNC X 0.50
301 SHCS - 5/16-18 UNC X 1
302 HHCS - 5/16-18 UNC x 0.75
303 HHCS - 5_16-18 UNC x 1
304 HHCS - 5/16-18 UNC X 2 FULL THREAD
305 SHCS - 5_16-24 UNF X 1.25
306 HHCS - 3/8-16 UNC X 0.50
307 HHCS - 3/8-16 UNC x 0.75
308 HHCS - 3_8-16 UNC X 1.50
309 HHCS - 3/8-16 UNC X 2.25
310 HHCS - 1/2-13 UNC X 1.00
311 BHCS - 1/4-20 UNC X 0.38
312 HEX SOCKET SET SCREW 1_4-20 UNC X 0.75
313 HEX HEAD SELF TAPPING SCREW 1/4-14
314 BLIND RIVET, 1/8 DIA X 1/8 GRIP, ALUM
315 LOCK WASHER, 5/16
316 LOCK WASHER, 1/2
317 Flat Washer, 3/8”
318 FLAT WASHER - 3/8 USS
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14. PERFORMANCE TEST PUMP ACCORDING THE PROCEDURE OUTLINED IN THE DOCUMENT: 39 1 EAC
SPREADSHEET1(R:)\PUMP TEST PROCEDURES.XLS UNDER TAB PUMP TEST NEW. USE STANDARDS 31 33 13 201 57
40 1 EAC
SHOWN UNDER TAB "STANDARDS". NO BLANKS SPACES ARE ALLOWED ON THE TEST FORM. THE
FOLLOWING PERFORMANCE REQUIREMENTS MUST BE MET. 5 304 41 1 EAC
49 204 42 4 EAC
17 311
MINIMUM VACUUM: 27.2 IN HG 46 43 1 EAC
MAXIMUM EXHAUST TEMP: 380°F 300
6 203 19
OIL USAGE: 12-15 OZ/HR (10.7 TO 8.5 HRS/GAL) 4
60 44 1 EAC
PRESSURE TEST: NO LEAKS AT 20 PSI 312
VACUUM RUN TEST: 60 MINUTES @ 23 IN HG 45 3 EAC
PRESSURE RUN TEST: 5 MINUTES AT 5 PSI BACK PRESSURE D 46 6 EAC
45
48 2 EAC
15. EACH PUMP TO BE SUPPLIED WITH THE COMPONENTS LISTED IN THE ACCESSORIES LIST (200 SERIES 24
49 1 EAC
PARTS).
43 50 1 EAC
16. FIRMLY ATTACH KEY TO SHAFT USING MASKING TAPE.
51 2 EAC
45 52 4 EAC
SERIAL NUMBER TRACKING
EFFECTIVE S/N 53 1 EAC
REVISION
- 31015 & 31016 310 54 1 EAC
B 51 316
A 31172 59 55 5.771 FT
31782 (APPROX.) 48 42
B 6.104
46 42
C-F 31845 12 20 56 5.083 FT
G TBD 51 25
16 10 5.417
309 57 1 EAC
317
7 58 1 EAC
14
18 59 1 EAC
60 1 EAC
313
11 1 61 1 EAC
3 62 1 EAC
16 2
14 PARTS LIST
7
ITEM QTY PART NUMBER DESCRIPTION TORQUE ADD'L INFO
12
300 2 SHCS - 1/4-20 UNC X 0.50 SHCS - 1/4-20 UNC X 0.50 9 FT-LBS SEE NOTE 3
15
10 301 8 SHCS - 5/16-18 UNC X 1 SHCS - 5/16-18 UNC X 1 18 FT-LBS
8
315 302 4 HHCS - 5/16-18 UNC x 0.75 HHCS - 5/16-18 UNC x 0.75 18 FT-LBS
303
303 16 HHCS - 5_16-18 UNC x 1 HHCS - 5_16-18 UNC x 1 18 FT-LBS
23
317 304 4 HHCS - 5_16-18 UNC X 2 FT HHCS - 5/16-18 UNC X 2 FULL THREAD 18 FT-LBS TOLE
308
21 305 1 SHCS - 5_16-24 UNF X 1.25 SHCS - 5_16-24 UNF X 1.25 18 FT-LBS O
305
6 5 4 3 2
C) BORE - REAR D) BORE - FRONT A) REAR BEARING
(11.032) REV DATE
D) BORE - FRONT UP
(11.500) D 3/24/2010
(4.000) C) BORE - REAR E 4/28/2010 U
(5.516) 9/8/2010
F
)B
10/25/201 UP
G
0
(8.152)
TOLERANCES UNLESS OTHER
B) FRONT BEARING
One place (.X)
B) FRONT BEARING Two places (.XX)
G Three places (.XXX)
NOTE P-CLIP ON Angles
D) BORE - FRONT C) BORE - REAR BEARING COVER
All machined surfaces 125 R
B Remove all burrs and sharp e
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OIL LINE ROUTING: 100-607-FD C) BORE - REAR CAD drawing - NO manual ch
(6.549) DESIGNATION DESCRIPTION TYPE (8.893)
PART NUMBER LENGTH (IN
(14.925) (13.500) All dimensions in inches unle
320-407-001-607FD1 7.25
A R. BEARING OIL LINE
320-409-002-607FD1 5.25 This document may contain co
OIL LINE 320-407-001-607FD2 28.25 secret information which is t
B F. BEARING
PROTECTOR 320-409-002-607FD2 26.00 property of National Vacuum E
OIL LINE 320-407-001-607FD3 11.00 information on this drawing
C BORE - REAR disclosed to anyone not havi
Notes
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www.natvac.com | 800.253.5500 607 Challenger Series | 25
Notes
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26 | 607 Challenger Series www.natvac.com | 800.253.5500
Parts Breakdown
ITEM DESCRIPTION
300 SHCS - 1/4-20 UNC X 0.50
301 HHCS - 5/16-18 UNC x 0.75
302 HHCS - 5_16-18 UNC x 1
303 HHCS - 5/16-18 UNC X 2 FULL THREAD
304 SHCS - 5/16-18 UNC X 1
305 HHCS - 3/8-16 UNC x 0.75
306 HHCS - 3/8-16 UNC X 1.75
307 HHCS - 1/2-13 UNC X 1.00
308 LOCK WASHER, 5/16
309 LOCK WASHER, 3/8”
310 LOCK WASHER, 1/2
311 Flat Washer, 3/8”
NOTES:
301
1. ALL FASTENERS ARE GRADE 8 UNLESS OTHERWISE SPECIFIED.
305
2. BRASS COMPRESSION FITTING ASSEMBLY INSTRUCTIONS: FIRST TIME-FINGER TIGHT PLUS ONE WRENCH 47 308
TURN. REMAKE INSTRUCTIONS: FINGER TIGHT PLUS 1/16 TURN. APPROX. 8 REMAKES ARE POSSIBLE WITH THIS 309
SETUP.
311
3. WRAP ALL PIPE THREAD FITTINGS AND OTHER THREADS REQUIRING SEALING WITH TEFLON TAPE, 3 WRAPS 6 ITEM QTY UO
D
MINIMUM. 18
607 Challenger - Liquid Cooled Parts Diagram 1 1 EACH
4. PRESET OIL PUMP FLOW BY BACKING OFF ADJUSTING SCREWS FULLY CCW (FULL FLOW) AND TURNING EACH 2 1 EACH
19 56 3 2 EACH
SCREW 5 1/2 TURNS CW TO REDUCE FLOW (APPROXIMATELY 1 DROP/7 SECONDS/PORT). SEAT LOCKING NUTS.
VERIFY REASONABLE FLOW THROUGH OIL LINES DURING ONE HOUR TEST. 4 2 EACH
301 43 35
55 5 2 EACH
52 59
5. APPLY SEALANT TO BOTH SIDES OF OIL PUMP GASKET BEFORE ASSEMBLY. USE EITHER LOCTITE AVIATION 308 6 2 EACH
53
GASKET SEALANT #30517, PERMATEX AVIATION FORM A GASKET #80019 OR EQUIVALANT. 47 7 1 EACH
13 308 8 1 EACH
6. ASSEMBLY ROTOR TO HOUSING WHILE HOUSING IS UPSIDE DOWN USING A .007" SHIM FOR THE SEAL GAP.
9 1 EACH
7. BRUSH A LIBERAL AMOUNT OF ISO 68 TURBINE OIL TO THE VANES BEFORE INSERTING INTO ROTOR SLOTS. 12 16 10 1 EACH
11 1 EACH
8. BEARING INNER RACE AND SEAL SLEEVE ASSEMBLY: HEAT INNER RACE AND SEAL SLEEVE TO 260 F 15 12 1 EACH
THROUGHOUT ON BEARING HOT PLATE. DO NOT EXCEED 260°F AS BEARING DAMAGE MAY OCCUR. BE SURE 22 21 13 1 EACH
ROTOR IS COOLED TO ROOM TEMPERATURE BEFORE ATTEMPTING ASSEMBLE OF RACE OR SLEEVE. 20
48 14 2 EACH
11 304 15 1 EACH
9. APPLY HEAVY GREASE TO O-RING GROOVE TO ASSIST IN RETAINING THE O-RING DURING ASSEMBLY TO THE
VALVE BODY. 58 16 1 EACH
17 1 EACH
20 201
10. VERIFY ASSEMBLY OF PLUG INTO MANIFOLD IN THE ORIENTATION AS SHOWN. 18 1 EACH
19 2 EACH
11. ORIENT VALVE HANDLE IN LINE WITH FILTER LID WHEN THE PLUG IS IN NEUTRAL.
20 2 EACH
31 21 1 EACH
12. APPLY LOCTITE SUPERFLEX RED HIGH TEMPERATURE RTV SILICONE #59630 OR EQUIV. TO ENDPLATE SCREWS 308
14 22 1 EACH
THAT THREAD INTO WATER JACKET AND WATER JACKET PLATE SCREWS BEFORE ASSEMBLY. 17
10 DETAIL A 23 2 EACH
204
C 13. DO NOT SLIDE HANDLE GRIP OVER HANDLE. FIRMLY ATTACH TO THE HANDLE USING MASKING TAPE OR ZIP 24 7 EACH
TIE. THIS ALLOWS OEM TO ORIENT THE GRIP ACCORDING TO END USE. 302
SCALE 2/5
205 25 4 EACH
206 26 2 EACH
14. PAINT PUMP GLOSS BLACK AFTER ALLOWING TO COOL AND AFTER CLEANING OFF ALL OILS/DIRT. USE PPG 202
26 308 27 2 EACH
ACR-100 ACRYLIC LACQUER OR EQUIVALENT AND PROCESS PER MANUFACTURERS REQUIREMENTS WITH THE
37 28 2 EACH
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EXCEPTION OF PRIMING METAL. EXCEPTION TO PRIMING IS VENDOR APPROVED. MASK OFF 2-3 INCHES OF OIL 14 203
308
LINE AT THE OIL PUMP END OF PUMP BEFORE PAINTING. ALSO PLACE MASKING PLUGS IN INLET AND OUTLET 304 57 29 2 EACH
9 300 48
FLANGES, MASK OFF SHAFT, OIL PUMP INLET, DIESEL FLUSH INLET, AND THERMOMETER FACES. 30 1 EACH
303
33 31 2 EACH
15. PERFORMANCE TEST PUMP ACCORDING TO THE PROCEDURE OUTLINED IN THE DOCUMENT: 7
32 1 EACH
SPREADSHEET1(R:)\PUMP TEST PROCEDURES.XLS UNDER TAB PUMP TEST NEW. USE STANDARDS SHOWN UNDER 34
46 30 33 1 EACH
TAB "STANDARDS". NO BLANKS SPACES ARE ALLOWED ON THE TEST FORM. THE FOLLOWING PERFORMANCE 8
REQUIREMENTS MUST BE MET. 47
A 38 34 1 EACH
MINIMUM VACUUM: 27.2 IN HG 311 306 35 2 EACH
41
MAXIMUM EXHAUST TEMP: 380°F 40 36 1 EACH
OIL USAGE: 12-15 OZ/HR (10.7 TO 8.5 HRS/GAL) 35 37 1 EACH
PRESSURE TEST: NO LEAKS AT 20 PSI (WATER JACKET & PUMP) 6 38 1 EACH
VACUUM RUN TEST: 60 MINUTES @ 23 IN HG
PRESSURE RUN TEST: 5 MINUTES AT 5 PSI BACK PRESSURE 39 1 EACH
40 1 EACH
307
16. EACH PUMP TO BE SUPPLIED WITH THE 200 SERIES COMPONENTS, 41 1 EACH
PACKAGED SEPERATELY IN BAG & ATTACHED TO HANDLE. 301 42 1 EACH
310 43 1 EACH
17. FIRMLY ATTACH KEY TO SHAFT USING MASKING TAPE. 308 45 44 44 1 EACH
45 45 4 EACH
36 48
302 46 1 EACH
SERIAL NUMBER TRACKING 32
B 308 47 3 EACH
REVISION EFFECTIVE S/N 51
23 4
- 31015 & 31016 5
A 31172 29 48 6 EACH
25
B 31782 (APPROX.) 306 51 1 EACH
C-F 31845 311 52 1 EACH
4
G TBD 27
3
31 53 4 EACH
54 2 EACH
55 6.167 FT
54 6.583
56 5.500 FT
39
1 5.917
24
3 57 1 EACH
2
58 1 EACH
27
4 59 1 EACH
311
306
25
29
FASTENER PARTS LIST (GRADE 8)
28
23 ITEM QTY PART NUMBER DESCRIPTION TORQUE ADD'L INFO
5
300 2 SHCS - 1/4-20 UNC X 0.50 SHCS - 1/4-20 UNC X 0.50 9 FT-LBS SEE NOTE 3
www.natvac.com | 800.253.5500
D) BORE - FRONT C) BORE -
C) BORE - REAR BEARING COVER REAR FAll machined surfaces 125 RMS max.
(8.985) (13.375) Remove all burrs and sharp edges.
OIL LINE ROUTING: 100-607-LD CAD drawing - NO manual changes.
DESIGNATION DESCRIPTION TYPE PART NUMBER LENGTH (IN) All dimensions in inches unless spec
OIL LINE 320-407-001-607LD1 7.25
A R. BEARING
PROTECTOR 320-409-002-607LD1 5.25 This document may contain confidenti
B OIL LINE 320-407-001-607LD2 30.25 secret information which is the excl
Pump Rebuilding
13. Inspect the housing for wear or damage. If the housing needs to
be bored or honed, remove only as much material as is neces-
sary to give a smooth clean bore.
320
SeeDiagram
Parts PartsonDiagram
page 45 Opposite.
Part # Description
* CW Worm
CCW Worm 2 Port 1 Port
Side Side
2 Port 1 Port
Side Side
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Part # Description
* CW Worm
CCW Worm 2 Port
Gear
2 Port
Gear
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Business Name:_____________________________________________________________________________________________
Address:________________________________________________________________ Telephone:_________________________
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Date Purchased:_____________________________________ Tank Size:________________________________________________
Purchased From:____________________________________________________________________________________________
__________________________________________________________________________________________________________
Comments:_________________________________________________________________________________________________
__________________________________________________________________________________________________________