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National Vacuum Equipment, Inc.

Owner’s Manual
&
Operating Instructions
607 Challenger Series Rotary Vane Vacuum Pumps
607 Challenger

Owner’s Record

Date of Purchase: _________________________

Purchased from: __________________________

Serial Number: ____________________________

© 2011 National Vacuum Equipment, Inc.


Revision: 3 (Release) March 2011

No part of this manual may be reproduced without the written permission of


National Vacuum Equipment, Inc.

2 | 607 Challenger Series www.natvac.com | 800.253.5500


IMPORTANT INFORMATION
FOR INSTALLING PUMP

607 CHALLENGER SERIES PUMPS AERIAL VIEW

SHADED AREA MUST BE KEPT CLEAR


FOR SERVICING THE FILTER

Clockwise Counter Clockwise


Rotation Rotation

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Contents
Introduction5
. General Information���������������������������������������������������������5

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

4 | 607 Challenger Series www.natvac.com | 800.253.5500


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 qualified
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 using National Vacuum Equipment.

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.

To reach the goal of becoming a full service supplier of vacuum system


components, the Company began fabrication its own line of componen-
try, 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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Limited Warranty

607 Challenger

Warranty

National Vacuum Equipment, Inc.

Guarantees that the product it provides is free of manufactur-


er’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
6 | 607 Challenger Series www.natvac.com | 800.253.5500
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 officer of National Vacuum
Equipment, Inc.

10. Certain products provided by National Vacuum Equipment,


Inc. are covered by their respective manufacturer’s warran-
ties (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 in-
stallation of the item in a vacuum system. It is therefore the
responsibility of the final assembler to thoroughly test the
vacuum system and components supplied to the assembler
by NVE prior to the delivery of the final product to the end
user.

12. 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 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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____________________________________________________
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 qualified 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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Notes

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607 Challenger

Model-Specific
Information

Application

Designed for extended operation

• Duty cycle will vary depending on several factors, such as


altitude, RPM & ambient temperature.

• The 607 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 field - Septic


- Restaurant Grease - Industrial Waste

Pump Specifications

607 Calculated Flow Data

Pressure (PSI) Free Flow Vacuum (in Hg)


RPM 20 15 10 5 0 5 10 15 20 25 27
Hp 34 32 29 27 23 23 22 21 20 19 19
1500
CFM 282 291 301 331 357 348 338 331 310 282 244
Hp 29 27 24 23 20 20 19 16 15 14 14
1250
CFM 229 237 244 269 290 282 275 269 252 229 198
Hp 26 23 20 18 15 15 14 14 13 12 12
1000
CFM 178 184 190 209 226 220 214 209 196 178 155

10 | 607 Challenger Series www.natvac.com | 800.253.5500


System Requirements
High Quality Components
• The 607 Challenger is a high performance vacuum
pump and requires compatible, high quality components
as manufactured by NVE.

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.

Pressure and Vacuum Relief Valves


• A properly adjusted pressure relief and vacuum relief valve
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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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 P.T.O. 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 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. Please
pay special attention to the orientation of the final filter,
which varies with rotation.

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.

• It is the responsibility of the installer to ensure proper


vacuum and pressure settings and RPM.

12 | 607 Challenger Series www.natvac.com | 800.253.5500


Adjusting Factory Oil Settings
The automatic oil pump is a metered piston-type pump. Before
adjusting the oilers, please follow these basic trouble shooting steps.
1. Make sure the pump (tank) is not under vacuum
between jobs.

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. Monitor the period of use and measure the oil required


to replenish the tank (this should be 12oz - 15oz per
hour). Compare this with the oil collected from the oil
catch muffler.
If after following these steps it is determined that an oil adjustment is
needed, then please follow the basic steps below.
1. Disconnect the hose running from your remote oil
reservoir to the pump intake.

2. Oil flow is changed by adjusting the length of the stroke


of the piston.

3. To adjust the oil rate, remove cap [P16]. Under this cap
you will find a jam nut [P15] and adjusting screw [P11]

4. Loosen the jam nut and turn adjusting screw clockwise


to reduce oil flow or counterclockwise to increase oil
flow.

5. When making adjustments do so one turn of the screw


at a time and test before making further adjustments.

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Operating Instructions

607 Challenger

Normal Operation
Oil Reservoir
• Check oil reservoir daily and fill as required.

• Drain and clean periodically depending on service.

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.

• 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!

14 | 607 Challenger Series www.natvac.com | 800.253.5500


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 prob-
lems 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.

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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 flushing of your pump. To do this:

1. Connect the hose to the flush 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 suction valve in the vacuum position, monitor the


diesel flow 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 flushing fluid.

Checking Vane Wear


• We recommend checking vane wear at least every 12
months.

• A new vane is flush 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
7 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 emergen-
cies.

16 | 607 Challenger Series www.natvac.com | 800.253.5500


Cold Weather Operation
Confirm pump is not frozen.
• Prior to engaging the pump, turn by hand to confirm it is
not frozen.

In pump is frozen, thaw it.


• If the pump is frozen, thaw it out by heating the bottom
of the pump with a torch or 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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Troubleshooting

NVE 607
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

• Inlet filter is clogged.

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

18 | 607 Challenger Series www.natvac.com | 800.253.5500


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 fittings

• Collapsed hose between the pump and shutoffs

• Inlet filter 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 607


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 find the problem.

For rebuild instructions please visit our website at


www.natvac.com or call us at 800-253-5500

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Making a vacuum tester
1. Procure a flange to mount on your 4-way valve, a
short 3” pipe nipple, a 3” pipe cap and a vacuum
gage.

2. Drill and tap a 1/4” N.P.T. thread in the pipe cap.

3. Assemble the flange, nipple, pipe cap and


vacuum gage.

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.

20 | 607 Challenger Series www.natvac.com | 800.253.5500


Parts Breakdown
Fan Parts List

ITEM PART NUMBER DESCRIPTION


1 120-001-367 Housing, 367 Pinned Endplate
2 120-005-367 Rotor, Hvy Dty 360 Slotting
3 120-009-367 Seal Sleeve, 360HD, 367, 607
4 120-041-367 Poppet, 3” Check Valve
5 120-042-367 Retainer Ring, 3” (360, 367 & 607)
6 120-077-367 Shroud Support, 360, 367 & 607
7 120-003-001 ENDPLATE, 607
8 120-054-001 Bearing Cover, 607
9 120-073 Fan Guard, 367, 460, 466, 506 & 607
10 120-055-367 Gasket, Front Bearing Cover
11 120-007-367 Vane: 350, 360, 367 & 607
12 120-018-367 Seal, 60x72x8 Viton Sgl Lip
13 120-039-367 Gasket, Flange Int/Exh
14 120-004-367 Gasket, 367/607 End Plate
15 120-053 Seal, 40x52x7 Viton
16 120-019-367 Bearing, NJ 308 L1308B
17 120-046-367 SPRING, CHECK VALVE 367/607
18 120-058 Plug, Brass 1/8” NPT, Hex Hd.
19 Serial number 31845 and above
320-LW32-bD OIL PUMP, 4 PORT (CW PUMP)
320-LW32-bS OIL PUMP, 4 PORT (CCW PUMP)
serial number 31844 and below
320-lw32-ad oil pump, 3 port (cw )
320-lw32-as oil pump, 3 port (ccw)
20 320-R31 Gasket, Oil Pump
21 120-083-002 FAN ASSY, CW 607
120-083-001 FAN ASSY, CCW 607
22 120-105 TAG, LARGE, NVE SERIAL NUMBER
23 120-074-001 FAN SHROUD, 607
24 120-076 KEY, 3/8” X 3/8” X 1”
25 120-054-002 BEARING COVER, 607
26 120-079-001 GUARD, OIL PUMP 607
27 120-060-002 GRIP, HANDLE W/ LOGO
28 120-062-001 PLUG, 4-WAY, 607
29 120-065-002 TOWER, 3” 607
30 120-060-001 HANDLE, 367 607
31 120-063-367 Flange, 3” NPT
32 120-064-002 O-RING, 2-214 VITON
33 120-059 Plug, Brass 1/4” NPT, Hex Hd.
34 120-064-001 O-RING, 2-154 VITON
35 120-045 4-Way FV Spring (Compressed)

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ITEM PART NUMBER DESCRIPTION
36 120-310-001 COVER, FILTER 607
37 120-314-001 FILTER ELEMENT, 60 MESH
38 120-220 THERMOMETER, 50- 400 DEG,
39 120-064-004 O-RING, 2-265 VITON
40 120-064-003 O-RING, 2-240 VITON
41 120-320-001 HOUSING, FILTER-INTEGRAL
42 445-408-001 ADAPTER, ELBOW 1/8 BSPTM-NTPF
43 120-071-367-D SHROUD, 367/607 TOP CW
120-071-367-S SHROUD, 367/607 TOP CCW
44 120-070-367 SHROUD, LOWER, 367/607
45 320-409-003 P-CLIP, OIL LINE 1/4” X 5/16
46 320-408-004 FITTING, STRT 1/8 NPT-TUBE
47 310-LP5 Hose Barb to Male Pipe
48 320-408-005 FITTING, ELBOW 1/8 NPT-TUBE
49 120-100-001 DECAL, 607 CHALLENGER HD
50 120-101-367-D DECAL, RPM-CW 607
120-101-367-S DECAL, RPM-CCW 607
51 120-045-001 SPRING, WAVE WIRE 3.50”
52 120-312-002 KNOB, 5/16-18UNC
53 120-006 KEY, 3/8” X3/8” X 2
54 120-102 Valve, Drain 1/8” NPT
55 320-407-001 TUBE, 1/8” OD PFA
56 320-409-002 OIL LINE PROTECTOR, 1/4” F-GLASS

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

22 | 607 Challenger Series www.natvac.com | 800.253.5500


NOTES: ITEM QTY UOM PART NUMBER DESCRIPTION NOTES ITEM QTY UO
1. ALL FASTENERS ARE GRADE 8 UNLESS OTHERWISE SPECIFIED. F607 CW 1 1 EACH 120-001-367 Housing, 367 Pinned Endplate 6 1 EAC
OR 2 1 EACH 120-005-367 Rotor, Hvy Dty 360 Slotting SEE NOTE 6 7 2 EAC
2. BRASS COMPRESSION FITTING ASSEMBLY INSTRUCTIONS: FIRST TIME-FINGER TIGHT PLUS ONE F607 CCW SERIAL NUMBER FROM
THE LOG AT FRONT DESK. 3 2 EACH 120-009-367 Seal Sleeve, 360HD & 367 SEE NOTE 8 8 1 EAC
WRENCH TURN. REMAKE INSTRUCTIONS: FINGER TIGHT PLUS 1/16 TURN. APPROX. 8 REMAKES ARE
POSSIBLE WITH THIS SETUP. 4 1 EACH 120-041-367 Poppet, 3" Check Valve 9 1 EAC
1500
5 1 EACH 120-042-367 Retainer Ring, 3" (360 & 367) 10 2 EAC
D 3. WRAP ALL PIPE THREAD FITTINGS AND THREADS REQUIRING SEALING WITH TEFLON TAPE, 3 WRAPS DATE PUMP 11 7 EAC
MINIMUM. ASSEMBLED MM/DD/YY 12 4 EAC
13 2 EAC
4. PRESET OIL PUMP FLOW BY LOOSENING ADJUSTING SCREWS FULLY CCW (FULL FLOW) AND TURNING
EACH SCREW 5 1/2 TURNS CW TO REDUCE FLOW (APPROXIMATELY 1 DROP/7 SECONDS/PORT). SEAT 56 14 2 EAC
LOCKING NUTS. VERIFY REASONABLE FLOW THROUGH OIL LINES DURING ONE HOUR TEST. 54 15 2 EAC
607 Challenger - Fan Cooled Parts Diagram 16 2 EAC
5. APPLY SEALANT TO BOTH SIDES OF OIL PUMP GASKET BEFORE ASSEMBLY. USE EITHER LOCTITE 307 50 30 17 1 EAC
AVIATION GASKET SEALANT #30517, PERMATEX AVIATION FORM A GASKET #80019 OR EQUIVALANT. FRONT BEARING
62 18 2 EAC
318
6. ASSEMBLE UPSIDE DOWN USING 0.007" SHIM TO SET AIR GAP. 19 1 EAC
27
302
7. BRUSH A LIBERAL AMOUNT OF ISO 68 TURBINE OIL TO THE VANES BEFORE INSERTING INTO ROTOR 20 1 EAC
SLOTS. 315 55 21 1 EAC
52
8. BEARING INNER RACE AND SEAL SLEEVE ASSEMBLY: HEAT INNER RACE AND SEAL SLEEVE TO 260 F 32 315
THROUGHOUT ON BEARING HOT PLATE. DO NOT EXCEED 260°F AS BEARING DAMAGE MAY OCCUR. BE 22 1 EAC
46
SURE ROTOR IS COOLED TO ROOM TEMPERATURE BEFORE ATTEMPTING ASSEMBLY OF RACE OR SLEEVE. 29 36 23 1 EAC
BORE - FRONT 24 1 EAC
9. APPLY HEAVY GREASE TO O-RING GROOVE TO ASSIST IN RETAINING THE O-RING DURING ASSEMBLY 40 39 46 25 1 EAC
TO THE VALVE BODY.
58 27 1 EAC
35 37
10. VERIFY ASSEMBLY OF PLUG INTO MANIFOLD IN THE ORIENTATION AS SHOWN. 28 1 EAC
BORE - REAR
28 34 18 29 1 EAC
11. ORIENT VALVE HANDLE IN LINE WITH FILTER LID WHEN THE PLUG IS IN NEUTRAL. 30 1 EAC
301 315 34 31 2 EAC
12. DO NOT SLIDE HANDLE GRIP OVER HANDLE. FIRMLY ATTACH TO THE HANDLE USING MASKING TAPE
OR ZIP TIE. THIS ALLOWS OEM TO ORIENT THE GRIP ACCORDING TO END USE. 205 DETAIL D 32 2 EAC
C 206 SCALE 1 / 3 33 1 EAC
13. PAINT PUMP GLOSS BLACK AFTER ALLOWING TO COOL AND AFTER CLEANING OFF ALL OILS/DIRT. 34 2 EAC
USE PPG ACR-100 ACRYLIC LACQUER OR EQUIVALENT AND PROCESS PER MANUFACTURERS 314 206 35 1 EAC
REQUIREMENTS WITH THE EXCEPTION OF PRIMING METAL. EXCEPTION TO PRIMING IS VENDOR 314 41 38 31 315 301
36 1 EAC
APPROVED. MASK OFF 2-3 INCHES OF OIL LINE AT THE OIL PUMP END OF PUMP BEFORE PAINTING.
ALSO PLACE MASKING PLUGS IN INLET AND OUTLET FLANGES, MASK OFF SHAFT, OIL PUMP INLET, 303 37 1 EAC
DIESEL FLUSH INLET, AND THERMOMETER FACES. 38 1 EAC
22 315
61

www.natvac.com | 800.253.5500
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

607 Challenger Series | 23


9 306 8 HHCS - 3_8-16 UNC X 0.50 HHCS - 3/8-16 UNC X 0.50 33 FT-LBS T
317 T
306 307 1 HHCS - 3/8-16 UNC x 0.75 HHCS - 3/8-16 UNC x 0.75 33 FT-LBS
44 A
308 6 HHCS - 3_8-16 UNC X 1.50 HHCS - 3_8-16 UNC X 1.50 33 FT-LBS
309 8 HHCS - 3_8-16 UNC X 2.25 HHCS - 3/8-16 UNC X 2.25 33 FT-LBS All
Re
ACCESSORIES LIST (PACKAGE SEPARATELY, SEE NOTE 15) 310 4 HHCS - 1_2-13 UNC X 1.00 HHCS - 1/2-13 UNC X 1.00 80 FT-LBS C
A ITEM QTY UOM PART NUMBER DESCRIPTION 311 1 BHCS - 1_4-20 UNC X 0.38 BHCS - 1/4-20 UNC X 0.38 9 FT-LBS All
201 1 EA 320-083-002 CAP, OIL TANK, BLACK 2 1/4" 312 1 HSSS - 1_4-20 UNC X 0.75 HEX SOCKET SET SCREW 1_4-20 UNC X 0.75 ADD LOCTITE 268
Thi
REVISION HISTORY 202 1 EA 320-082-001 OIL TANK, 5QT, W/LOGO 313 11 TAPSCR - 1_4-14 X 0.75 HEX HEAD SELF TAPPING SCREW 1/4-14
(13.500)

607 Challenger - Fan Cooled - Oil Line Routing


(5.750)

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

24 | 607 Challenger Series


Counter
3" FEMALE NPT Clockwise
.688
(8.956) (13.375)
B) FRONT BEARING B) FRONT BEARING
MOUNTING HOLE LOCATIONS
ON
NOTE P-CLIPVIEW G-G
BEARING COVER
SCALE 1 / 4
OIL LINE ROUTING: 100-607-FS
DESIGNATION DESCRIPTION TYPE PART NUMBER LENGTH (IN)
OIL LINE 320-407-001-607FS1 7.25 A) REAR BEARING
A R. BEARING
(23.669) PROTECTOR 320-409-002-607FS1 5.25
OIL LINE 320-407-001-607FS2 28.25
B F. BEARING
PROTECTOR 320-409-002-607FS2 26.00 D) BORE - FRONT
OIL LINE 320-407-001-607FS3 15.00
(18.609) C BORE-REAR
PROTECTOR 320-409-002-607FS3 13.00
OIL LINE 320-407-001-607FS4 22.75
D BORE-FRONT
PROTECTOR 320-409-002-607FS4 20.75 Clockwise

(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

Liquid Parts List

ITEM PART NUMBER DESCRIPTION


1 120-001-367-L Housing, 367 Water Cooled
2 120-005-367 Rotor, Hvy Dty 360 Slotting
3 120-009-367 Seal Sleeve, 360HD, 367, 607
4 120-003-001 ENDPLATE, 607
5 120-045-001 SPRING, WAVE WIRE 3.50”
6 120-021-367 COVER PLATE, 367/607 WATER JACKET
7 120-046-367 SPRING, CHECK VALVE 367/607
8 120-041-367 Poppet, 3” Check Valve
9 120-042-367 Retainer Ring, 3” (360, 367, 607)
10 120-320-001 HOUSING, FILTER-INTEGRAL
11 120-062-001 PLUG, 4-WAY, 607
12 120-064-003 O-RING, 2-240 VITON
13 120-065-002 TOWER, 3” 607
14 120-063-367 Flange, 3” NPT
15 120-064-004 O-RING, 2-265 VITON
16 120-310-001 COVER, FILTER 607
17 120-220 THERMOMETER, 50- 400 DEG
18 120-060-001 HANDLE, 607
19 120-064-002 O-RING, 2-214 VITON
20 120-064-001 O-RING, 2-154 VITON
21 120-314-001 FILTER ELEMENT, 60 MESH
22 120-045 4-Way FV Spring
23 120-055-367 Gasket, Front Bearing Cover
24 120-007-367 Vane: 350, 360, 367 & 607
25 120-018-367 Seal, 60x72x8 Viton Sgl Lip
26 120-039-367 Gasket, Flange Int/Exh
27 120-004-367 Gasket, 367 End PlatE
28 120-053 Seal, 40x52x7 Viton
29 120-019-367 Bearing, NJ 308 L1308B
30 120-102 Valve, Drain 1/8” NPT
31 120-058 Plug, Brass 1/8” NPT, Hex Hd.
32 320-LF8 Drive Tab
33 serial number 31845 and above
320-LW32-BD OIL PUMP, 4 PORT (CW)
320-LW32-BS OIL PUMP, 4 PORT (CCW)
serial number 31844 and below
320-lw32-ad oil pump, 3 port (cw )
320-lw32-AS Oil pump, 3 port (ccw)
34 320-R31 Gasket, Oil Pump

www.natvac.com | 800.253.5500 607 Challenger Series | 27


ITEM PART NUMBER DESCRIPTION
35 120-022-367 GASKET, 367/506/607 COVER PLATE
36 120-006 KEY, 3/8” X3/8” X 2
37 120-059 Plug, Brass 1/4” NPT, Hex Hd.
38 120-220-1 1/8” NPT Thermometer 220 F
39 120-047-1 DRAIN PLUG, 3/4” NPT MAGNETIC
40 120-047 DRAIN PLUG, 3/4” NPT
41 120-107 TAG, SERIAL NUMBER, BRASS
42 120-054-001 Bearing Cover, 607
43 120-060-002 GRIP, HANDLE W/ LOGO
44 120-079-001 GUARD, OIL PUMP 607
45 320-408-001 ADAPTER, ELBOW 1/8 BSPTM-NTPF
46 120-049 Bushing, 3/4”NPTx1/8”NPT
47 320-409-003 P-CLIP, OIL LINE 1/4” X 5/16
48 320-408-004 FITTING, STRT 1/8 NPT-TUBE
49 310-LP5 Hose Barb to Male Pipe
51 120-054-002 BEARING COVER, 607
52 120-101-367-D DECAL, RPM-CW 607
120-101-367-S DECAL, RPM-CCW 607
53 120-312-002 KNOB, 5/16-18UNC
54 320-408-005 FITTING, ELBOW 1/8 NPT-TUBE
55 320-407-001 TUBE, 1/8” OD PFA
56 320-409-002 OIL LINE PROTECTOR, 1/4” F-GLASS

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”

28 | 607 Challenger Series www.natvac.com | 800.253.5500


8 7 6 5 4 3

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

607 Challenger Series | 29


42
308 301 20 HHCS - 5/16-18 UNC x 0.75 HHCS - 5/16-18 UNC x 0.75 18 FT-LBS
302
302 16 HHCS - 5_16-18 UNC x 1 HHCS - 5_16-18 UNC x 1 18 FT-LBS
303 4 HHCS - 5_16-18 UNC X 2 FT HHCS - 5/16-18 UNC X 2 18 FT-LBS
ACCESSORIES LIST (SEE NOTE 15) FULL THREAD
A ITEM QTY UOM PART NUMBER DESCRIPTION 304 8 SHCS - 5/16-18 UNC X 1 SHCS - 5/16-18 UNC X 1 18 FT-LBS
201 1 EA 320-083-002 CAP, OIL TANK, BLACK 2 1/4" 305 1 HHCS - 3/8-16 UNC x 0.75 HHCS - 3/8-16 UNC x 0.75 33 FT-LBS
202 1 EA 320-082-001 OIL TANK, 5QT, W/LOGO 306 16 HHCS - 3_8-16 UNC X 1.75 HHCS - 3/8-16 UNC X 1.75 33 FT-LBS
203 1 EA 320-083-001 FILTER, OIL TANK PLASTIC 307 4 HHCS - 1_2-13 UNC X 1.00 HHCS - 1/2-13 UNC X 1.00 80 FT-LBS
607 Challenger - Liquid Cooled - Oil Line
(5.516)
Routing
5 4 3 2
(11.500)
A) REAR BEARING
(11.032) C) BORE - REAR
C) BORE - REAR
E) D) BORE - FRONT
NOTE EXTRA P-CLIP
(5.750)

30 | 607 Challenger Series


.688
Counter
(8.922) (13.500)
Clockwise
MOUNTING HOLE LOCATIONS
B) FRONT BEARING VIEW F-F
B) FRONT
BEARING
SCALE 1/4
NOTE P-CLIP ON BEARING COVER
OIL LINE ROUTING: 100-607-LS
DESIGNATION DESCRIPTION TYPE LENGTH
PART NUMBERA) REAR (IN)
BEARING
OIL LINE 320-407-001-607LS1 7.25
A R. BEARING
PROTECTOR 320-409-002-607LS1 5.25
OIL LINE 320-407-001-607LS2 D) BORE - FRONT
31.25
B F. BEARING
PROTECTOR 320-409-002-607LS2 29.25
B) FRONT BEARING OIL LINE 320-407-001-607LS3 15.00
C BORE - REAR
PROTECTOR 320-409-002-607LS3 13.00
OIL LINE 320-407-001-607LS4 25.50
D BORE - FRONT
PROTECTOR 320-409-002-607LS4 23.50 Clockwise
CAD FILE LOCATION: P:\Data
7.250 B.C.
TOLERANCES UNLESS OTHER WISE S

One place (.X) ±.1


1/2-13 UNC - 2B B) FRONT BEARING Two places (.XX) ±.03
1.000 DEEP Three places (.XXX) ±.015
NOTE P-CLIP ON Angles ±1°

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

607 Fan & Liquid


Vane Replacement

1. Clean off the exterior of the pump

2. Remove the oil line guard.


Disconnect all oil lines feeding
from the oil pump

Uninstall the oil pump from the


rear bearing cover.

3. Remove the four (4) bolts that


hold the rear bearing cover to
the rear endplate, and remove
the rear bearing cover.

www.natvac.com | 800.253.5500 607 Challenger Series | 31


4. Remove the oil pump
drive key from the end of
the rotor.

5. (Fan Cooled Only)


Remove the eleven (11)
self-tapping screws that
fasten the fan shroud “tin”
to the pump. Remove the
fan shroud support con-
necting the fan shroud
“tin” to the rear endplate.

6. Remove the top two


bolts that hold the rear
endplate to the pump
housing and replace with
two (2) 3/8-16 threaded
dowels. Once in place,
remove the lower six (6)
3/8 hex bolts.

7. Remove the rear end-


plate, vanes and gasket.

32 | 607 Challenger Series www.natvac.com | 800.253.5500


8. Inspect the original vanes for
any delamination, chipping or
other damage.

A new vane is flush with the


outside diameter of the rotor.

If any of the vanes are worn


more than 1/4”, are chipped
or delaminated they should be
replaced.

We highly recommend replac-


ing vanes in sets. Apply a liberal
amount of lubricant to the vanes
before installing in the rotor
slots.

It is always a good idea to have


a spare set of replacement
vanes on hand to reduce pump
downtime.

9. Install two (2) 3/8-16 hex bolts


with their heads removed so that
they can support the weight of
the endplate for installation.

Install one (1) new endplate gas-


ket between the housing and the
endplate, do not use any gasket
sealer.

Carefully guide the endplate


onto the rotor and threaded
dowel pins

(Fan Cooled Only) Reinstall the


eleven (11) self-tapping screws
and holding the fan shroud to the
rear end-plate. Fasten the upper
fan shroud tin to the fan shroud
support on the rear endplate.

www.natvac.com | 800.253.5500 607 Challenger Series | 33


10. Insert the two (2) “T-handle”
dowel-pins provided in your
rebuild kit into the dowel pin
holes on the endplate through
into the housing.

Snug the endplate close to the


housing.

(Liquid Cooled Only) The


3/8 hex bolts located on the
waterjacket side of the pump
housing need to have high
temperature (Red) RTV Sili-
cone re-applied.

Install the hex head bolts.

Tighten the endplate bolts to


35-40 ft-lbs of torque.

At this point you should be able


to turn the rotor by hand.

11. Reinstall the oil pump drive key in


the rotor.

Reseat the outer bearing in the


endplate pilot.

Reinstall the oil pump / rear bear-


ing cover. Ensure the oil pump
shaft is aligned with the drive key.

Reconnect the oil lines to the oil


pump, and front bearing. Do not
overtighten fittings.

Reconnect the pump to its oil res-


ervoir and start at a slow R.P.M.

Run the pump for a few minutes


to allow oil to fill the lines. Inspect
the translucent oil lines to check
that oil is flowing.
34 | 607 Challenger Series www.natvac.com | 800.253.5500
Pump Rebuilding

607 Fan & Liquid


Complete Rebuild

1. Clean off the exterior of the pump

2. Remove the oil line guard.


Disconnect all oil lines feeding
from the oil pump

Uninstall the oil pump from the


rear bearing cover.

3. Remove the four (4) bolts that


hold the rear bearing cover to
the rear endplate and remove
the rear bearing cover.

www.natvac.com | 800.253.5500 607 Challenger Series | 35


4. Remove the oil pump drive
key from the end of the rotor.

5. (Fan Cooled Only) Remove


the eleven (11) self-tapping
screws that fasten the fan
shroud “tin” to the pump. Re-
move the fan shroud support
connecting the fan shroud “tin”
to the rear endplate.

6. Remove the top two (2) bolts


that hold the rear endplate
to the pump housing and
replace with two (2) 3/8-16
threaded dowels. Once in
place, remove the lower six
(6) 3/8 hex bolts.

7. Remove the rear endplate,


gasket, and vanes.

36 | 607 Challenger Series www.natvac.com | 800.253.5500


8. Place a cushion beneath the
rotor to prevent damage when
the front endplate is unbolted
(cardboard, rag, etc.).

9. (Fan Cooled Only) Remove the


fan guard on the drive end side
of the pump. Remove the fan
and key from the rotor drive end
by first loosening the fan hub
screw. You may find it neces-
sary to drive the hub apart with
a screw driver in order to slide
the fan assembly off of the rotor.

10. Repeat step 6 to drop the rear


end of the rotor down onto the
cushion.

(Fan Cooled Only) Remove


the six (6) hex bolts holding
the aluminum fan shroud to the
front endplate and remove the
shroud.

11. Gently guide the front end-


plate off of the (2) 3/8-16
threaded rod segments to
fully settle the rotor body on
the base of the housing bore.

Remove the rotor with care


from the housing. Place a Tag
on the housing side that corre-
sponds to your drive end side!

www.natvac.com | 800.253.5500 607 Challenger Series | 37


12. Remove the four-way
assembly, gaskets, and check
valve assembly. Carefully turn
the housing upside down so
that the pump feet are facing
the ceiling.

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.

The maximum overbore we recommend is 0.060 inches. A new hous-


ing has a bore of 7.875 inches.

If you bore or hone the housing, remove all connected accessories,


including the fan shroud, 4-way valve, gaskets, etc.

14. Clean the housing of any


debris and apply a liberal
amount of lubrication to the
housing bore.

15. (Optional) If there is damage


evident to the bearings, they
will need to be replaced. Once
the rotor is removed, start
by cutting off the old bearing
inner race on both ends of the
rotor. Be sure to line up the
cutting wheel with one of the
vane slots so as not to dam-
age the rotor or seal sleeve.

38 | 607 Challenger Series www.natvac.com | 800.253.5500


16. Clean the rotor and rotor slots
and inspect the rotor for wear
or damage.

Place the clean rotor inside the


housing with the drive end in the
same orientation it originally was.
This will be the side you tagged in
step 11 of this procedure.

17. (Continuation of Step 15)


Remove the two (2) inner
races from the replacement
bearings provided in your
repair kit.

Place the inner races onto a hot


plate and get them hot. Do not
leave them on the plate so long
that they become discolored.

Use a welding glove to take the


hot inner race from the hot plate
and slide it onto the rotor shaft.

The bearing race shoulder


should be tight against the seal
sleeve.

Install on both sides of the rotor.

Allow ample time for the inner


races to cool and set onto the
rotor before continuing.

www.natvac.com | 800.253.5500 607 Challenger Series | 39


18. Inspect the original vanes for
any delamination, chipping
or other damage.

A new vane is flush with the


outside diameter of the rotor.

If any of the vanes are worn


more than 1/4”, chipped or
delaminated they should be
replaced.

We highly recommend replac-


ing vanes in sets. Apply a liberal
amount of lubricant to the vanes
before installing in the rotor slots.

It is always a good idea to have


a spare set of replacement
vanes on hand to reduce pump
downtime.

19. Shift the housing so that


the intake (Square port) is
hanging slightly off of the
rebuild work surface.

Place one of the 0.007” shims


between the rotor and rotor
bore so that the shim is within
the housing and will not inter-
fere with the endplate when
they are reinstalled.

Divert the pull wire into the


housing cavity and out through
the intake port.

Repeat for both ends of the


rotor.

40 | 607 Challenger Series www.natvac.com | 800.253.5500


20. Remove the seals from the
endplates. Inspect for dam-
age, the seals should be soft
and pliable.

Clean the endplate as needed.


Apply new lubricant along the
seal pilot in each of the end-
plates.

The seals need to be installed


back to back. The faces without
the oil groove should be touching.

We recommend using a seal


driver tool to properly seat the
seals in the endplate. Drive the
seals into the endplate.

Repeat for both endplates.

21. Lubricate the roller bearing


pilot in the endplate. Using a
bearing driver, seat the roller
bearing into the endplate.

Repeat for both endplates.

22. Install two (2) 3/8-16 threaded


dowels so that they can sup-
port the weight of the end-
plate for installation.

Install one (1) new endplate gas-


ket between the housing and the
endplate, do not use any gasket
sealer.

Carefully guide the endplate onto


the rotor and threaded rod seg-
ments

www.natvac.com | 800.253.5500 607 Challenger Series | 41


23. Insert one (1) of the dowel pin
“T-handles” into either of the
dowel pin holes on the end-
plate through into the housing.

Snug the endplate close to the


housing and install the 3/8 hex
head bolts.

(Liquid Cooled Only) The 3/8 hex


bolts located on the waterjacket
side of the pump housing need to
have high temperature (Red) RTV
Silicone re-applied.

Tighten the endplate bolts to 35-40


ft-lbs of torque.

Repeat the process for the op-


posite endplate, but make sure
to install the “T-handle” dowel pin
on the same side of the hous-
ing as the other endplate, so as
to prevent the rotor from twisting
when the endplates are fully bolted
into place

Rotate the housing rightside up


again, so the pump feet are on the
work station.

24. Grasp the shim pull wires


hanging out of the inlet, and
gently pull to remove the
0.007” shims.

You may need to rotate your pump


and pull the wires simultaneously
to get them to release.

25. Reinstall the bearing cover


gaskets, lubricate along the
rotorbearing cover interface, re-
install the bearing covers (with
wave washers installed)
42 | 607 Challenger Series www.natvac.com | 800.253.5500
26. Reinstall the oil pump drive
key in the non-drive end of
the rotor.

Use hardening gasket sealer on


both sides of the oil pump gas-
ket. Apply teflon tape to oil pump
bolts.

Install oil pump to the rear bear-


ing cover. Ensure the oil pump
shaft is aligned with the drive key.

Reconnect the oil lines to the oil


pump, and front bearing.

Do not overtighten fittings to the


plastic oil line, or oil flow may be
restricted.

27. (Fan Cooled Only) Reinstall


the fan assembly, the key
should be pushed all the way
to the end of the key slot on
the drive end.

Make sure there is sufficient


clearance to mount the fan cover
when positioning the fan assem-
bly. Tighten the fan hub screw.

Refer to step 9 for additional


information.

www.natvac.com | 800.253.5500 607 Challenger Series | 43


28. Install two (2) four-way
gaskets to the housing
interface.

Reinstall the four way mani-


fold, making sure to line up the
square port on the housing with
the square port on the four way
manifold.

Replace any gaskets / O-rings


as needed.

29. We highly recommend pres-


sure testing your pump for
leaks before putting it to
work. We test our pumps at
20 psi of pressure.

Put a 3” Male NPT plug in the


exhaust port and a similar
adapter that can connect to a
controlled pressurized air supply
in the inlet.

Spraying your pump with soapy


water while pressurized will
expose any bubbling air leaks in
your vacuum pump.

30. Reconnect the pump to its


oil reservoir and start at a
slow R.P.M.

Run the pump for a few min-


utes to allow oil to fill the lines.
Inspect the translucent oil lines
to check that oil is flowing.

The pump is now ready to go


to work!

44 | 607 Challenger Series www.natvac.com | 800.253.5500


Pa
Detail - Key # 26
Automatic Oil Pump See
Three Outlet Type
Part
Part # 320 - LW32AD Clockwise
320
Part # 320 - LW32AS Counterclockwise
320
320
320
320
320
320
320
320
320
320
320
320
320
320
* 320
*

320

Parts list on page 46

National Vacuum Equipment | 800.253.5500 | www.natvac.com

www.natvac.com | 800.253.5500 607 Challenger Series | 45


Parts List – Automatic Oil Pump

SeeDiagram
Parts PartsonDiagram
page 45 Opposite.

Part # Description

320-P3CW Pump Body (Clockwise)


320-P3CCW Pump Body (Counterclockwise)
320-P5 Driven Gear (Clockwise)
320-PA5 Driven Gear (Counterclockwise)
320-P6 Spring
320-P7 Driving Gear (Clockwise)
320-P7CCW Driving Gear (Counterclockwise)
320-P8 Seal
320-P9 Plug
320-P10 Retainer
320-P11 Adjusting Screw
320-P12 Gasket
320-P13 Lid
320-P14 Screw
320-P15 Jam Nut
320-P16 Cap

320-P5 and 320-PA5 Details


L on 3 Port CW R on 3 Port CW

* CW Worm
CCW Worm 2 Port 1 Port
Side Side

L on 3 Port CCW R on 3 Port CCW

2 Port 1 Port
Side Side

w.natvac.com

46 | 607 Challenger Series www.natvac.com | 800.253.5500


P
Detail - Key # 26
Se
Automatic Oil Pump Th
Four Outlet Type
Pa
Part # 320 - LW32BD Clockwise
32
Part # 320 - LW32BS Counterclockwise
32
32
32
32
32
32
32
32
32
32
32
32
32
32
* 32
*

Parts list on page 48

National Vacuum Equipment | 800.253.5500 | www.natvac.co

www.natvac.com | 800.253.5500 607 Challenger Series | 47


Parts List – Automatic Oil Pump
See Parts on
Parts Diagram Diagram
page 47 Opposite.
This oil pump is in all pumps with a Serial # that is 31845 or above.

Part # Description

320-P4CW Pump Body (Clockwise)


320-P4CCW Pump Body (Counterclockwise)
320-P5 Driven Gear (Clockwise)
320-PA5 Driven Gear (Counterclockwise)
320-P6 Spring
320-P7 Driving Gear (Clockwise)
320-P7CCW Driving Gear (Counterclockwise)
320-P8 Seal
320-P9 Plug
320-P10 Retainer
320-P11 Adjusting Screw
320-P12 Gasket
320-P13 Lid
320-P14 Screw
320-P15 Jam Nut
320-P16 Cap

320-P5 and 320-PA5 Details


L and R on 4 Port CW

* CW Worm
CCW Worm 2 Port
Gear

L and R Gear on 4 Port CCW

2 Port
Gear

www.natvac.com

48 | 607 Challenger Series www.natvac.com | 800.253.5500


Warranty Registration

Model #:__________________________________________________ Serial #:__________________________________________

Business Name:_____________________________________________________________________________________________

Address:________________________________________________________________ Telephone:_________________________

City:_____________________________________________________________ State:__________ Zip:________________________

www.natvac.com | 800.253.5500
Date Purchased:_____________________________________ Tank Size:________________________________________________

Purchased From:____________________________________________________________________________________________

__________________________________________________________________________________________________________

Is this your first National Vacuum Equipment pump purchase?_ o YES_ o NO

Previous pump used?________________________________________________________________________________________

Intended use:_ o Agricultural_ o Septic_ o Commercial o Industrial o Other _________________________________

Comments:_________________________________________________________________________________________________

__________________________________________________________________________________________________________

607 Challenger Series | 49


www.natvac.com | 800.253.5500
no postage
necessary if
mailed in the
united states
Business Reply Mail
First Class Permit No. 146 Traverse City, MI
Postage will be paid by Addressee
National Vacuum Equipment, Inc.
P.O. Box 685
Traverse City, MI 49685-0685

50 | 607 Challenger Series


www.natvac.com | 800.253.5500 607 Challenger Series | 51
National Vacuum Equipment, Inc.

2670 Aero Park Drive


Traverse City, MI 49686 USA
231.941.0215 Phone
231.941.2354 Fax

sales@natvac.com | www.natvac.com | 800.253.5500


52 | 607 Challenger Series www.natvac.com | 800.253.5500