Flowserve Limitorque HBC Series User Instructions

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USER INSTRUCTIONS

Limitorque HBC Series

FCD LMENIM3501-01 – 03/14

Installation

Operation

Maintenance

Experience In Motion

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

Contents

1 Introduction 3

1.1 Purpose 3

1.2 User Safety 3

2 Inspection, Installation, and Mounting Procedures 4

2.1 Initial Inspection and Storage Instructions 5

2.2 Inspection and Recording 5

2.3 Storage Procedure 5

2.4 General Mounting Instructions 6

2.5 Setting Position Limit Stops for HBC-0 through -3 6

2.6 Setting Position Limit Stops for HBC-4 through -7 7

2.7 HBC Angular Displacement Tolerances 7

3 Lubrication 9 4 Dissassembly and Reassembly Instructions 11

4.1 Safety Precautions 11

4.2 Safety Practices 12

4.3 HBC-0 through -3 12

4.4 HBC-4 through -7 13

4.5 Spur Gear Attachments 15

5 Setting Instructions for AWWA Input Shaft Stop 18 6 How to Order Parts 23

Figures

Figure 2.1 – HBC-0 through -3 exploded view 4 Figure 2.2 – HBC nameplate 5 Figure 2.3 – Hex nut type stop (HBC-0 through -3) 7 Figure 2.4 – Top of drive sleeve showing available rotation 8 Figure 4.1 – HBC-0 through -3 assembly 13 Figure 4.2 – HBC-4 through -7 assembly 14 Figure 4.3 – Spur gear attachments 16–17 Figure 5.1 – AWWA input shaft stop (back view) 20 Figure 5.2 – AWWA input shaft stop (complete view) 21

Tables

Table 2.1 – HBC angular displacement tolerance 7 Table 3.1 – Lubricant weights 10 Table 4.1 – HBC-0 through -3 parts list 13

Table 4.2 – HBC-4 through -7 parts list 14 Table 4.3 – HBC-1 through -7 spur gear attachments parts list 17 Table 5.1 – AWWA input shaft stop parts list 22

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. The user must read and be familiar with these instructions before attempting installation, operation, or maintenance. Failure to observe these precautions could result in serious bodily injury, damage to the equipment, voiding of the warranty, or operational difﬁculty.

Safety notices are presented in this manual in three forms:

WARNING: Refers to personal safety. Alerts the user to potential danger. Failure to follow warning notices could

result in personal injury or death.

a CAUTION: Directs the user’s attention to general precautions that, if not followed, could result in personal injury

and/or equipment damage.

NOTE: Highlights information critical to the user’s understanding of the HBC gearbox’s installation and operation.

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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 the gearbox handwheel or wrench nut may cause serious personal injury and/or damage to the gearbox or valve.

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. Consult the actuator installation, operation and maintenance manual for guidance.

2.2 Inspection and Recording

Upon receipt of the gearbox, inspect the condition of the equipment, and record nameplate information.

1. Carefully remove the gearbox from shipping carton or skid. Thoroughly examine the equipment for any physical damage that may have occurred during shipment. If damaged, immediately report the damage to the transport company.

2. A nameplate is attached to each gearbox with the following information:

• Gearbox size

• Order number

• Customer tagging

• Gearbox serial number

• Lubricant type

Record this information for future reference, i.e., ordering parts, or obtaining further information.

Figure 2.2 – HBC nameplate

2.3 Storage Procedure

NOTE: The following is the recommended storage procedure to retain maximum product integrity during storage. Failure to comply with recommended procedure will void the warranty.

Storage (Less Than One Year)

Store gearboxes on wooden skids to protect the machined mounting ﬂange. Place the wooden skids containing the gearboxes in a clean, dry, protected warehouse. If the gearboxes must be stored outside, they must be covered in polyethylene protection with silica gel crystals to absorb moisture. If an electric actuator is attached to the HBC, refer to the storage procedures in its respective manual for appropriate storage procedures. Rotate input shafts every three months to mix the lubricant.

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Limitorque HBC Series FCD LMENIM3501-01 – 03/14

2.4 General Mounting Instructions

a 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. Should the housing cover index marks not be visible, the two housing cover bolts (“C” and “D”) can be used for this alignment. Refer to Figure 2.3.

1. Place the valve in full closed position.

2. Press the splined adapter on valve shaft and insert key (should be a press ﬁt to avoid splined adapter movement in HBC drive sleeve), or utilize a set screw to eliminate movement of splined adapter on the valve shaft.

3. Remove the pointer cap from HBC gearbox.

4. Turn the HBC gearbox input shaft to full closed position. The stops are preset for 90° travel. Be certain of correct direction of rotation.

5. Mount the gearbox on the valve and bolt securely. Be sure of gearbox stop alignment before engaging splines. (See angular displacement tolerances in Table 2.1.)

6. For standard stop setting instructions, see Section 2.5, Setting Position Limit Stops for HBC-0 through 3.

7. For gearboxes with AWWA input shaft stop, see Section 5, Setting Instructions for AWWA Input Shaft Stop.

2.5 Setting Position Limit Stops for HBC-0 through -3

Refer to Figure 2.3.

1. With the valve in full closed position, remove limit stop cover plate.

2. You will note two traveling hex nuts, “A” and “B.”

a. If hex nut “B” is near the position shown, run the hex nut hand-tight against the housing so that one of the

ﬂats of the hex nut is on top, facing the cover plate. (If hex nut “A” is near the opposite end of the limit stop housing, proceed with Step 4 ﬁrst.)

b. If hex nut “A” or “B” hits the housing before the valve was tightly closed, back off the hex nut until the valve

is tight and proceed as in Step 2a.

3. Replace the limit stop cover plate and turn the input shaft of the HBC gearbox to fully open the valve.

4. Remove the limit stop cover plate and check the position of hex nut “A.” This nut should be turned until it is ﬂush up against the end of the limit stop housing and one of the ﬂats of the nut is on top facing the limit stop housing cover plate.

5. Bolt the limit stop cover plate into position.

Figure 2.3 – Hex nut type stop (HBC-0 through -3)

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

Bolt “D”

Two index marks appear

on housing cover

Limit stop

housing

Cover plate

Hex nut “A”

Hex nut “B”

Index mark

on drive sleeve

Bolt “C”

2.6 Setting Position Limit Stops for HBC-4 through -7

Refer to Figure 4.2.

1. With the valve in the full closed position, remove Stop Screw Cover (piece #16).

2. Remove the Lockscrew (piece #17).

3. Adjust the appropriate Stop Screw (piece #17) based on rotation of the drive sleeve — inward if valve is closed and stop has not yet been reached, or outward if stop has been reached and valve is not yet fully closed.

4. Once the stop screw is set, lock securely with lockscrew.

5. Operate the valve to fully open position and set open stop in the same manner.

2.7 HBC Angular Displacement Tolerances

Table 2.1 – HBC angular displacement tolerance

Angular Displacement Splined Tooth

Gearbox Size Stop Gear Space in Degrees

HBC-0 105° HBC-1 114° HBC-2 114° HBC-3 114° HBC-4 ±7° HBC-5 ±6.75° HBC-6 ±9° HBC-7 ±9°

Note 1: Stops used on HBC-0 through HBC-3 incorporate standard hex nuts. The tolerance listed is ±0.31 from basic size on the thickness. The data shown above is based on maximum thickness of both nuts.

Note 2: Displacement is based on 45° travel on either side of gear centerline. Note 3: Gearboxes with serial numbers less than S/N 365365 have 110° gear segments.

170° Gear Segment 9.00° 170° Gear Segment 6.42° 170° Gear Segment 4.50° 170° Gear Segment

3.46°

±7° 3.00°

±6.75° 2.14°

±9° 1.80°

±9 N/A

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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

Plus

Plus tolerance

tolerance

Minus

Minus tolerance

tolerance

45ϒ

Index mark at

Index mark at midpoint of

midpoint of available

available rotation

rotation

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

Lubrication

Flowserve Limitorque HBC gearboxes are factory-lubricated with an NLGI grade 0 calcium sulphonate grease suitable for a temperature range of -20°F to +150°F (-29°C to +60°C). Other lubricants approved by Flowserve Limitorque may be used based on customer requirements. See the nameplate for lubricant type.

Quantity

Limitorque gearboxes are built to operate on the partial immersion principle. The primary concern regarding the amount of lubricant is whether the “worm” is totally immersed in grease. This can be veriﬁed by the use of one or more of the many “ﬁll” and “drain” plugs provided on the gearbox housing.

Quality

When removing a “ﬁll” or “drain” plug to inspect the lubricant level, remove a small amount and ensure that it is clean and free of any contaminant, including water. Should dirt, water, or other foreign matter be found, the lubricant must be replaced and will require some partial disassembly. Contact Flowserve Limitorque with the gearbox order number or serial number for replacement parts.

Consistency

The main gearbox lubricant should be slightly ﬂuid, approximating a standard NLGI-0 grade consistency.

Alternate lubricants may be used in place of the standard lubricants supplied by Flowserve, provided they are a calcium sulphonate or similar lubricant.

a 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.

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Table 3.1 – Lubricant weights

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

Amount of Lubricant

Gearbox Size

HBC-0 .20 .76 1.5 0.7 HBC-1 .35 1.32 3.0 1.4 HBC-2 .50 1.89 4.0 1.8 HBC-3 1.40 5.30 12.0 5.4 HBC-4 3.50 13.2 30.0 13.6 HBC-5 5.20 19.7 45.0 20.4 HBC-6 9.25 35.0 80.0 36.3 HBC-7 14.50 54.9 125.0 56.7

Note: Lubricant weepage is normal in cases of infrequent operation, does not affect the form, ﬁt or function of the gearbox, and is not covered by the warranty.

Approximate Volume

(gal.) (L) (lb) (kg)

Approximate Weight

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

Dissassembly and

Reassembly Instructions

4.1 Safety Precautions

WARNING: Read this Installation, Operation and Maintenance Manual carefully and completely before attempting

to install, operate, or troubleshoot the Limitorque gearbox.

WARNING: Potential HIGH-PRESSURE vessel — be aware of high-pressure hazards associated with the attached

valve or other actuated device when installing or performing maintenance on the gearbox. Do not remove the gearbox mounting bolts from the valve or actuated device unless the valve or device stem is secured or there is no pressure in the line.

WARNING: For maintenance and/or disassembly of the gearbox while installed on the valve, ensure that the

gearbox is not under thrust or torque load. If the valve must be left in service, the valve stem must be locked in such a way as to prevent any movement of the valve stem.

WARNING: Do not manually operate the gearbox with devices other than the installed handwheel. Using force

beyond the ratings of the gearbox and/or using additive force devices such as cheater bars, wheel wrenches, pipe wrenches, or other devices on the gearbox handwheel may cause serious personal injury and/or damage to the gearbox and valve.

WARNING: Do not exceed any design limitations or make modiﬁcations to this equipment without ﬁrst consulting

Limitorque.

WARNING: Use of the product must be suspended any time it fails to operate properly.

a 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.

a 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.

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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.

4.3 HBC-0 through -3

Refer to Figure 4.1.

1. Remove the Limit Stop Housing Cap (piece #20) and Gasket (piece #21).

2. Rotate the Worm Shaft (piece #6) clockwise until Pointer Cap (piece #9) stops rotating.

3. Remove the Pointer Cap (piece #9) and Housing Cover (piece #2).

4. Remove both Stop Nuts (piece #18) and Limit Stop Housing (piece #19).

5. Remove the Through Cap (piece #4).

6. Remove the Worm Shaft (piece #6) by rotating and pulling from Housing (piece #1). It may be necessary to

maneuver the Bearing (piece #13) around the Drive Sleeve (piece #5), by rotating the drive sleeve slightly in the direction it was turning in Step 2. It is not necessary to remove the Bearing (piece #13) from Worm Shaft (piece #6).

7. Remove the Drive Sleeve and Worm Gear (piece #5).

NOTE: In reassembling the gearbox, follow all of the above steps in the reverse order. Be sure you have located the center line of the Worm Gear (piece #5) before reinstalling the Housing Cover (piece #2).

NOTE: For reassembly of the worm shaft (step 6 of the disassembly procedure), be sure that end play does not exceed 0.015 in. This is accomplished by the proper combination of 0.015 in. and 0.030 in. gaskets on the stop housing side and input side of the gear housing.

Figure 4.1 – HBC-0 through -3 assembly

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

21 19 18 10 13 13 10 4

Table 4.1 – HBC-0 through -3 parts list (refer to Figure 4.1)

Piece Number

1 2 4 5 6 7 8

9 10 11 13 14 15 18 19 20 21

Description

Housing Housing Cover Through Cap Drive Sleeve and Worm Gear Worm Shaft Spline Adapter Pointer Pointer Cap End and Through Cap Gasket Housing Cover Gasket Worm Shaft Bearing Drive Sleeve O-ring Worm Shaft O-ring Hex Nut Stop Limit Stop Housing Limit Stop Housing Cap Limit Stop Housing Gasket

11 5141

4.4 HBC-4 through -7

Refer to Figure 4.2.

1. Remove the Stop Screw Cover (piece #16).

2. Remove the Lock Screw and Stop Screw (total 2 each, piece #17).

3. Rotate the Worm Shaft (piece #6) full clockwise until Pointer Cap (piece # 9) stops rotating or until the Worm Shaft (piece #6) can no longer be turned.

4. Remove the End Cap (piece #3) and Through Cap (piece #4).

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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. It is not necessary to remove the Bearing (piece #13) from the Worm Shaft (piece #6).

7. Remove the Drive Sleeve and Worm Gear (piece #5).

NOTE: To reassemble the gearbox, proceed in the reverse order listed above. In order to ensure good stop nut engagement at the end of travel, it is recommended that the stops be preset for 90° of rotation by establishing 45° rotation on either side of the worm gear center line while installing the stop screws. It will then be necessary to readjust the stops once the gearbox is on the valve; however, this will minimize the risk of disorienting the worm gear sector.

Figure 4.2 – HBC-4 through -7 assembly

103

Table 4.2 – HBC-4 through -7 parts list (refer to Figure 4.2)

Piece Number Description

1 Housing 2 Housing Cover 3 End Cap 4 Through Cap 5 Drive Sleeve and Worm Gear 6 Worm Shaft 7 Spline Adapter 8 Pointer

9 Pointer Cap 10 End and Through Cap Gasket 11 Housing Cover Gasket 12 Drive Sleeve Bushing 13 Worm Shaft Bearing 14 Drive Sleeve O-ring 15 Worm Shaft O-ring 16 Stop Screw Cover 17 Stop Screw and Lock Screw

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. When both the ﬁrst and second attachment are added to the third, the overall gear ratio is between 19 and 38.9. The disassembly instructions described below will disassemble the 38.9:1 attachment. Steps 1 through 5 describe the 2.86:1 disassembly, steps 1 through 10 describe the 8.5 to 12:1 attachment disassembly, and the full instruction describes the 19 to 38.9:1 attachment disassembly.

Refer to Figure 4.3.

1. Remove the First Set Housing (piece #2).

2. Remove Input Shaft and Pinion (piece #3).

3. Remove Idler Gear (piece #4) and Idler Gear Spacer (piece #8).

4. Remove First Set Output Gear (piece #5).

5. If only 2.86:1 spur attachment is used you must next remove the Housing Adapter (piece #1) and Output Gear Spacer (piece #7).

6. Remove Second Set Housing Adapter (piece #20).

7. Remove Intermediate Shaft and Pinion (piece #22) carefully. Thrust Bearings (pieces #27 and 28) are not captive on the shaft.

8. Remove Output Gear Collar (piece #25).

9. Remove Second Set Output Gear (piece #23) and Second Set Output Gear Spacer (piece #24).

10. If the spur attachment gear ratio is 8.5 to 12:1, remove Second Set Housing (piece #19).

11. If the spur attachment ratio is 19 to 38.9:1, remove Third Set Housing Adapter (piece #32).

12. Remove Intermediate Shaft and Output Pinion (piece #33) carefully. Thrust Bearings (pieces #37 and 38) are not captive on the shaft.

13. Remove Third Set Output Gear Collar (piece #35).

14. Remove Third Set Output Gear (piece #34) and Spacer (piece #36).

15. Remove Third Set Housing (piece #31).

NOTE: In reassembling the spur gear attachments, follow all of the instructions in the reverse order, ensuring that all of the bearings indicated in the assembly drawings are intact and in good condition.

NOTE: When replacing gaskets, use gasket thickness of 1⁄32 in.

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Figure 4.3 – Spur gear attachments

Single reduction ratio – 2.86 to 11

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

Double reduction ratio – 12.00 to 1

20 23

5222829921230

20 23

Figure 4.3 – Spur gear attachments (continued)

Triple reduction ratio – 38.90 to 1

30 5

22 16

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

Table 4.3 HBC-1 through -7 spur gear attachments parts list (refer to Figure 4.3)

Piece

Number

Description

1 First Set Housing Adapter 2 First Set Housing 3 First Set Input Shaft and Pinion 4 Idler Gear 5 First Set Output Gear 6 First Set Collar 7 First Set Output Gear Spacer 8 Idler Gear Spacer

9 First Set Housing Gasket 10 Input Shaft Thrust Bearing 11 Input Shaft Thrust Bearing 12 Idler Gear Thrust Bearing 13 First Set Housing Bearing 14 First Set Housing Adapter Bearing 15 Idler Gear Bearing 16 Input Shaft Quad Ring 17 Input Shaft Retaining Ring 18 Idler Gear Shaft 19 Second Set Housing 20 Second Set Housing Adapter

Piece

Number

Description

21 Second Set Housing Gasket 22 Intermediate Shaft and Pinion 23 Second Set Output Gear 24 Second Set Output Shaft Spacer 25 Second Set Output Gear Collar 26 Intermediate Shaft Bearing 27 Intermediate Shaft Thrust Bearing 28 Intermediate Shaft Thrust Bearing 29 Second Set Housing Bearing 30 Intermediate Shaft Retaining Ring 31 Third Set Housing 32 Third Set Housing Adapter 33 Intermediate Shaft and Output Pinion 34 Third Set Output Gear 35 Third Set Collar Output Gear 36 Third Set Output Shaft Spacer 37 Output Pinion and Shaft Thrust Bearing 38 Output Pinion and Shaft Thrust Bearing 39 Third Set Housing Bearing 40 Third Set Housing Adapter Bearing 41 Third Set Housing Gasket

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Limitorque HBC Series FCD LMENIM3501-01 – 03/14

Setting Instructions

for AWWA

Input Shaft Stop

a 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.

1. Remove the Limit Stop Housing Cover (piece #9), Gear Frame Housing Cover (piece #10), and Gear Frame Through Cap (piece #11). Do not remove Gear Frame Retaining Plate (piece #48).

2. Note the position of the Racks (piece #19). The racks should be in the up position, as shown in Figure 5.1A.

3. Note the position of the three (3) center punch marks on the end of the Input Shaft (piece #4). These center punch marks show the position of the lug on the Lug Sleeve (piece #5).

4. With the input shaft as shown in Figure 5.1B, pull the Idler Gear (piece #18) and hold it out of engagement with the Input Pinion (piece #47).

5. Rotate the handwheel on the Input Shaft (piece #4) clockwise until the valve reaches the extreme position of travel. Normally with clockwise handwheel rotation closing the valve, the valve will go to the fully closed position. If the valve is set up for clockwise handwheel rotation to open, the valve will go to the fully open position.

6. Place the Input Shaft (piece #4) in position, as shown in Figure 5.1C.

7. Using a screwdriver, rotate the Input Pinion (piece #25A), as shown in Figure 5.1B clockwise until the Rack (piece #19A) moves downward, as shown in Figure 5.1C. Do not rotate the pinion any further.

8. Push Idler Gear (piece #18) into engagement and rotate Input Shaft (piece #4) clockwise to check the setting. The lug should hit the Rack (piece #19) and prevent further handwheel rotation.

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. If the Rack (piece #19B) should trip to the down position as shown in Figure 5.1D before the valve reaches the end of travel, use the following procedure:

a. Turn the Input Shaft (piece #4) back one turn. b. Pull Idler Gear (piece #18) out of engagement. c. Place a screwdriver on the Input Pinion (piece #25B). d. Rotate clockwise approximately 50 turns. e. Push Idler Gear (piece #18) into engagement again and rotate handwheel counterclockwise until the valve

goes to the extreme position of travel. Repeat as necessary until the valve reaches the point where the stop should be set.

10. With the valve in the position to be set, position the Input Shaft (piece #4) as shown in Figure 5.1D, hold the Idler Gear (piece #18) out of engagement, and with the screwdriver on the Input Pinion (piece #25B), rotate it counterclockwise until the Rack (piece #19B) moves, as shown in Figure 5.1D. Do not rotate the pinion any further.

11. Push the Idler Gear (piece #18) into engagement and rotate Input Shaft (piece #4) counterclockwise to check setting. The lug should hit the Rack (piece #19B).

12. Reassemble Limit Stop Housing Cover (piece #9), Gear Frame Housing Cover (piece #10), and Gear Frame Through Cap (piece #11).

13. Open and close the valve fully to verify that position limit stops are set at the desired valve position.

NOTE: When the AWWA input shaft stop is supplied, the standard limit stops in the housing are also furnished. The housing limit stops should be adjusted to function as secondary stops by ensuring that the AWWA input stops engage ﬁrst. Section 2 – Inspection, Installation, and Mounting Procedures in this manual provides instruction for setting the standard housing limit stops.

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Figure 5.1 – AWWA input shaft stop (back view)

From 0 in. to 1/16 in.

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

CCW rotation

CW rotation

Rack

Center punch marks

From 0 in. to 1/16 in.

19 B

(A)

19 A

Rack

25 B

19 B

25 A

(B)

19 A

Clockwise rotation

(C)

Counterclockwise

rotation

(D)

Figure 5.2 – AWWA input shaft stop (complete view)

47, 25

Limitorque HBC Series FCD LMENIM3501-01 – 03/14

49, 50

129

432215 101651 27

3238, 42

53 31

48 45, 42

37, 41

36, 40

39, 34

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Limitorque HBC Series FCD LMENIM3501-01 – 03/14

Table 5.1 – AWWA input shaft stop parts list (refer to Figure 5.2)

Piece

Number

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

17 18 19 20 21 22 23 24 25 26 27

Description

Limit Stop Housing Gear Frame Limit Stop Housing Adapter Input Shaft Splined Lug Sleeve Intermittent Gear Shaft Intermittent Pinion Shaft Intermittent Drive Shaft Limit Stop Housing Cover Gear Frame Housing Cover Gear Frame Through Cap Rack Pinion Pinion Input Gear Intermittent Stem Pinion

Intermittent Pinion

Intermittent Gear Idler Gear Rack Flanged Bushing Input Shaft Bushing Intermittent Stem Pinion Bearing Rack Pinion Bearing Bushing Input Pinion Housing Cover Gasket Gear Frame Cover Gasket

Piece

Number

Note: When the AWWA input shaft stop is used, the standard limit stop is also furnished.

Description

Through Cap Gasket

Housing Gasket

Adapter Gasket

O-ring

Bushing

Cap Screw Round Head #10 — 32 in x ½ in long

Roll Pin 3⁄32 in Diameter x ¾ in Long — Not Shown

Cap Screw Hex Head 5⁄16 in — 18 in x 1 in Long

Cap Screw Socket Head 3⁄8 in — 16 x 1½ in Long

Cap Screw Socket Head ¼ in — 20 in x ¾ in Long

Lockwasher #10

Lockwasher 5⁄16 in

Lockwasher 3⁄8 in

Lockwasher ¼ in

Roll Pin 1⁄8 in Diameter x 5⁄8 in Long

1 in — 20 Drain Plug

Cap Screw Round Head ¼ in — 20 x ½ in Long

Dowel Pin ¼ in Diameter x 5⁄8 in Long

Input Pinion — Gear Assembly

Gear Frame Retaining Plate

¼ in — 20 x 7⁄16 in Long Socket Head Cap Screw

¼ in Lockwasher Hi-Collar

Pinion Spacer

Through Cap Gasket

Idler Gear Spacer

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 Lynchburg, VA 24506-1318

Telephone (434) 528-4400 Fax (434) 845-9736

All inquiries or orders must be accompanied by the following information:

1. Gearbox size

2. Order number

3. Serial number

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To find your local Flowserve Limitorque representative, visit www.limitorque.com or call USA 1 800 528 4400.

Flowserve Corporation Flow Control

United States

Flowserve Limitorque 5114 Woodall Road P.O. Box 11318 Lynchburg, VA 24506-1318 Phone: 434-528-4400 Fax: 434-845-9736

England

Flowserve Limitorque Euro House Abex Road Newbury Berkshire, RG14 5EY United Kingdom Phone: 44-1-635-46999 Fax: 44-1-635-36034

Japan

Limitorque – Nippon Gear Co., Ltd. Asahi-Seimei Bldg. 4th Floor 1-11-11 Kita-Saiwai, Nishi-Ku Yokohama-Shi, (220-0004) Japan Phone: 81-45-326-2065 Fax: 81-45-320-5962

Canada

Flowserve Limitorque 120 Vinyl Court Woodbridge, Ontario L4L 4A3 Canada Phone: 905-856-4565 Fax: 905-856-7905

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. Although Flowserve can (and often does) provide general guidelines, it cannot provide speciﬁc data and warnings for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation and maintenance of Flowserve products. The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the speciﬁc application.

While the information and speciﬁcations contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certiﬁed or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the speciﬁcations, dimensions and information contained herein are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or ofﬁces.

Singapore

Limitorque Asia, Pte., Ltd. 12, Tuas Avenue 20 Singapore 638824 Phone: 65-6868-4628 Fax: 65-6862-4940

China

Limitorque Beijing, Pte., Ltd. RM A1/A2 22/F, East Area, Hanwei Plaza No. 7 Guanghua Road, Chaoyang District Beijing 100004, Peoples Republic of China Phone: 86-10-5921-0606 Fax: 86-10-6561-2702

India

Flowserve Limitorque No. 10-12, THE OVAL, Third floor Venkatnarayana Road T. Nagar, Chennai 600 017 Phone: 91-44-2432-8755 and 91-44-2432-4801 Fax: 91-44-2432-8754

ﬂowserve.com

Flowserve Limitorque HBC Series User Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual