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USER INSTRUCTIONS
Limitorque HBC Series
Installation
Operation
FCD LMENIM3501-01 – 03/14
Maintenance
Experience In Motion

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Summary of Contents for Flowserve Limitorque HBC Series

  • Page 1 USER INSTRUCTIONS Limitorque HBC Series Installation Operation FCD LMENIM3501-01 – 03/14 Maintenance Experience In Motion...
  • Page 2: Table Of Contents

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Contents Introduction Purpose User Safety Inspection, Installation, and Mounting Procedures Initial Inspection and Storage Instructions Inspection and Recording Storage Procedure General Mounting Instructions Setting Position Limit Stops for HBC-0 through -3 Setting Position Limit Stops for HBC-4 through -7...
  • Page 3: Introduction

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Introduction 1.1 Purpose This installation, operation and maintenance manual (IOM) explains how to install and maintain the Flowserve Limitorque HBC gearbox. Information on installation, disassembly, reassembly, lubrication, and spare parts is provided. 1.2 User Safety Safety notices in this manual detail precautions the user must take to reduce the risk of personal injury and damage to the equipment.
  • Page 4: Inspection, Installation, And Mounting Procedures

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Inspection, Installation, and Mounting Procedures Figure 2.1 – HBC-0 through -3 exploded view WARNING: Do not manually operate the HBC gearbox with devices other than the installed handwheel or wrench nut. Using additive force devices (cheater bars, wheel wrenches, pipe wrenches, or other devices of this nature) on...
  • Page 5: Initial Inspection And Storage Instructions

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 2.1 Initial Inspection and Storage Instructions WARNING: Read this installation, operation and maintenance manual carefully and completely before attempting to store the gearbox. If an electric actuator is attached to the HBC gearbox, be aware of the electrical hazards.
  • Page 6: General Mounting Instructions

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 2.4 General Mounting Instructions CAUTION: To avoid disengaging the worm gear segment, ensure that the index mark on the drive sleeve (center- line of gear segment) is oriented to the midpoint of the 90° valve travel. Full stroke rotation of this index mark should not move past the corresponding travel limit index marks on the housing cover.
  • Page 7: Setting Position Limit Stops For Hbc-4 Through -7

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Figure 2.3 – Hex nut type stop (HBC-0 through -3) Two index marks appear Index mark on housing cover on drive sleeve Limit stop housing Hex nut “A” Bolt “C” Bolt “D” Cover plate Hex nut “B”...
  • Page 8: Figure 2.4 - Top Of Drive Sleeve Showing Available Rotation

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Figure 2.4 – Top of drive sleeve showing available rotation Top of drive sleeve with Top of drive sleeve with pointer cap removed pointer cap removed Worm gear Worm gear Index mark at...
  • Page 9: Lubrication

    Alternate lubricants may be used in place of the standard lubricants supplied by Flowserve, provided they are a calcium sulphonate or similar lubricant. CAUTION: Do not add a different lubricant to a Flowserve Limitorque gearbox unless it is of the same soap base as the existing lubricant, or you have received the approval of the lubricant manufacturer.
  • Page 10: Table 3.1 - Lubricant Weights

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Table 3.1 – Lubricant weights Amount of Lubricant Approximate Weight Gearbox Size Approximate Volume (gal.) (lb) (kg) HBC-0 HBC-1 1.32 HBC-2 1.89 HBC-3 1.40 5.30 12.0 HBC-4 3.50 13.2 30.0 13.6 HBC-5 5.20 19.7...
  • Page 11: Dissassembly And Reassembly Instructions

    CAUTION: If a motor actuator is driving the gearbox, do not operate the valve under motor operation without first checking and setting the limit switch setting and checking for correct motor rotation. CAUTION: Do not use replacement parts that are not genuine Flowserve Limitorque parts, as serious personal injury and/or damage to the gearbox and valve may result.
  • Page 12: Safety Practices

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 4.2 Safety Practices The following checkpoints should be performed to maintain safe operation of the HBC gearbox: • Set up a periodic operating schedule on infrequently used valves. • Ensure that the limit and/or torque switches on any electric actuator fitted to the HBC worm gearbox are correctly and appropriately adjusted.
  • Page 13: Hbc-4 Through -7

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Figure 4.1 – HBC-0 through -3 assembly 21 19 10 13 13 10 4 Table 4.1 – HBC-0 through -3 parts list (refer to Figure 4.1) Piece Number Description Housing Housing Cover Through Cap...
  • Page 14: Figure 4.2 - Hbc-4 Through -7 Assembly

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 5. Remove the Pointer Cap (piece #9) and Housing Cover (piece #2). 6. Remove the Worm Shaft (piece #6) by rotating and pulling from Housing (piece #1). It will be necessary to slightly rotate or cock the Drive Sleeve (piece #5) away from the worm in order to allow the Bearing (piece #13) to clear.
  • Page 15: Spur Gear Attachments

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 4.5 Spur Gear Attachments All of the standard Limitorque spur gear attachments are made up of gear sets. The first gear set is the 2.86:1 attachment. When the second gear set is added to the first, the overall attachment ratio increases to between 8.5 and 12:1.
  • Page 16: Figure 4.3 - Spur Gear Attachments

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Figure 4.3 – Spur gear attachments Single reduction ratio – 2.86 to 11 4 15 4 15 Double reduction ratio – 12.00 to 1 2 30 9 21 28 29...
  • Page 17: Table 4.3 - Hbc-1 Through -7 Spur Gear Attachments Parts List

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Figure 4.3 – Spur gear attachments (continued) Triple reduction ratio – 38.90 to 1 26 30 5 Table 4.3 HBC-1 through -7 spur gear attachments parts list (refer to Figure 4.3) Piece Piece...
  • Page 18: Setting Instructions For Awwa Input Shaft Stop

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Setting Instructions for AWWA Input Shaft Stop CAUTION: Following these instructions exactly will prevent jamming or damaging the equipment. Complies fully with AWWA Standard C504, latest revision. Refer to Figures 5.1 and 5.2.
  • Page 19 Limitorque HBC Series FCD LMENIM3501-01 – 03/14 9. Reassemble the Gear Frame Through Cap (piece #11) with two mounting screws to hold the Idler Gear (piece #18) engaged with the Input Pinion (piece #25A) and rotate the Input Shaft (piece #4) counterclockwise to the other extreme valve position.
  • Page 20: Figure 5.1 - Awwa Input Shaft Stop (Back View)

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Figure 5.1 – AWWA input shaft stop (back view) From 0 in. to 1/16 in. CCW rotation CW rotation 25 A 25 B Rack Rack Center punch marks From 0 in. to 1/16 in.
  • Page 21: Figure 5.2 - Awwa Input Shaft Stop (Complete View)

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Figure 5.2 – AWWA input shaft stop (complete view) 17 47, 25 49, 50 38, 42 13 43 22 15 45, 42 37, 41 39, 34 36, 40 flowserve.com...
  • Page 22: Table 5.1 - Awwa Input Shaft Stop Parts List

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 Table 5.1 – AWWA input shaft stop parts list (refer to Figure 5.2) Piece Piece Description Description Number Number Limit Stop Housing Through Cap Gasket Gear Frame Housing Gasket Limit Stop Housing Adapter...
  • Page 23: How To Order Parts

    Limitorque HBC Series FCD LMENIM3501-01 – 03/14 How to Order Parts To order parts or obtain further information about your Flowserve Limitorque HBC gearboxes, contact your local Limitorque distributor sales office, or: Flowserve Limitorque 5114 Woodall Road P.O. Box 11318...
  • Page 24 Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions.

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