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Ball Intake Valve Manual

INSTRUCTIONS FOR SAFE OPERATION AND MAINTENANCE

WARNING
Read instruction manual before use. Operation of this device without understanding the manual and receiving proper training is a misuse of this equipment. A person who has not read and understood all operating and safety instructions is not qualified to operate the Ball Intake Valve.

This instruction manual is intended to familiarize firefighters and maintenance personnel with the operation, servicing and safety procedures associated with the Ball Intake Valve. This manual should be kept available to all operating and maintenance personnel.

Operating Range:
Pressure Max 250 psi
Pressure Min. Full Vac.
Hydrostatic Proof Test:
900 psi

3.0 General Information

The Ball Intake Valve is intended for use on the intake manifold of a fire engine. The valve is kept closed while the water supply from a hydrant or another pumper to the engine is being established. This prevents the pump from sucking air through the intake manifold and losing its prime. Once the supply hose is filled and under pressure, and the air has been vented from the hose, the valve may be opened to connect the pump to the water supply. An adjustable pressure relief valve mounted on the bottom of the valve opens to relieve any excess pressure that may damage the hose or the pump. The Task Force Tips Ball Inlet Valve has a unique patented half ball, with a acts much like a gate valve. thermo-plastic rubber seat, and acts much like a gate valve.

3.1 Corrosion
Hose couplings are attached using polymer bearing rings which provides electrical insulation to help prevent galvanic corrosion. In the past some valves were made of bare aluminum. Task Force Tips is using a three-step process to fight corrosion. The cast aluminum parts in this valve have been impregnated to fill the microscopic pores in the cast aluminum. The parts are then hard anodized, and finally powder coated, inside and out, to help prevent corrosion. The effects of corrosion can be minimized by good maintenance practice. See section 9.0 for maintenance.

3.2 Use with Salt Water
Use with salt water is permissible provided valve is thoroughly cleaned with fresh water after each use. The service life of the valve may be shortened due to the effects of corrosion and is not covered under warranty.

4.0 Installation

4.1 Mounting on Trucks
Screw the large coupling to the pump inlet manifold. The valve position indicator should be clearly visible, but need not be level.

4.2 Changing Hand Wheel to Left Side
The handwheel is shipped from the factory on the right hand side of the valve. The hand wheel. can be switched to the left hand side for convenience or if it interferes with other equipment on the pump panel. To move the hand wheel to the opposite side, unscrew the jam nuts on the end of the shaft. Pull the shaft out of the gear box. As the shaft is withdrawn, grasp the small key on the shaft so it does not fall and get lost. Remove and switch the two plastic bushings that come out of the sides of the gearbox. The bushing with the large hole is installed on the same side as the handwheel. Look through the gear box and note approximate position of the keyway in the worm inside the gear box. Slide the shaft into the gearbox on the opposite side of the gear box with the key oriented the same as the keyway. A small dab of grease will keep the key place. Rotate the shaft until the key finds the keyway and push the shaft in until it stops. Screw on the nut until it is 1/6 turn past finger tight. Tighten the second nut against the first one. If you over tighten the first nut, the crank will be hard to turn.

5.0 Use

5.1 Intake Elbow
The intake elbow swivels 360 degrees to help prevent hose kinks, and make connection of suction lines easier. The intake can be turned forward or backward to help make connections in tight places if the water supply is in front of or behind the truck. To turn the elbow, pull the shot pin knob on top of the elbow. The elbow will lock into a detent every 45 degrees. There is a 1/4-20 tapped hole in the flange of the elbow to attach the lanyard or chain on a cap. Use a Stainless Steel Screw no longer than 1/2 inch. A longer screw may cause the swivel to be hard to turn or not turn at all. The elbow may be swivelled to any of eight positions by pulling the shot pin knob.

5.2 Valve Position Indicator
To open the valve turn the hand wheel until the valve position says "OPEN". To close the valve turn the hand wheel the opposite way until the valve position indicator says "CLOSED".

6.0 Air Vent and Water Drain

This valve is equipped with an Air Vent/Drain which will allow the air to escape from the valve when the hose is charged. The Air Vent/Drain is opened by turning the knob counter clockwise and closed by turning it clockwise. To drain the water out of the valve after use open the Air Vent/Drain. A 1/2" diameter plastic tube may be used to run the drain behind the pump panel.

7.0 Pressure Relief Valve

Caution: There is a pressure relief valve on the bottom side of the valve. It may be set to any pressure between 50 and 250 psi. Its function is to protect the pump and the supply hose from excess pressure. The relief valve may be mounted with its opening facing the front, back, right or left. A piece of hose or tubing may be mounted on the round spout to direct the water coming out of the relief valve away from the pump panel. To change the orientation of the relief valve, remove the four 7/16 bolts on the corners of the relief valve flange, orient the valve the way you want it, and replace the bolts. Use a drop of thread locking compound on the threads of the bolt to prevent them from coming loose. Loss of prime can interrupt water flow and cause injury or death. Always bleed out air with air valve to prevent possible loss of prime.

7.1 Relief Valve Setting Pressure
To set the relief valve pressure turn the adjusting screw on the relief valve housing until the surface of the screw is even with the desired pressure. Do not cap or plug discharge opening.

7.2 Relief Valve Flow vs Pressure Curve

8.0 Maintenance

This valve should be disconnected, cleaned and visually inspected inside and out at least once per month. Moving parts such as hand wheels, valve ball/seat and couplings should be checked for smooth and free operation and greased as needed. A silicone based grease such as Dow Corning 44 will exclude moisture and retard the effects of corrosion. Any scrapes that expose bare aluminum should be cleaned and touched up with enamel paint such as Rust-Oleum. Replace any missing or damaged parts before returning valve to service.

CAUTION: Dissimilar metals coupled together can cause galvanic corrosion that can result in the inability to unscrew the threads of complete loss of thread engagement over time. Per NFPA 1962 (1998 edition), if dissimilar metals are left coupled together an anti-corrosive lubricant should be applied to the threads. Also the coupling should be disconnected and inspected at least quarterly.

CAUTION: Any alterations to the Ball Intake Valve and its markings could diminish safety and constitutes a misuse of this product.