HANDPUMP REPAIR AND

MAINTENANCE MANUAL
Water For People India
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical
action. Pumps can be classified into three major groups according to the method they use to
move the fluid: direct lift, displacement, and gravity pumps.

Hand pumps are manually operated pumps; they use human power and mechanical
advantage to move fluids or air from one place to another. They are widely used in every
country in the world for a variety of industrial, marine, irrigation and leisure activities. In
developing countries, generally they are used for lifting water from groundwater table for
domestic use purpose.

The pump principle has changed little since its inception, whether for the piston pump invented
in 275 BC by Ctesibius, or the rope pump invented in the 1st century BC in China.

Even 2,200 years ago, the Greek mathematician and physicist Archimedes, invented an
apparatus that could raise water from rivers, so it can be used for irrigation. The apparatus is
called Archimedes' Screw, and it is still used in many places in the world.

New Installation :
For Hand Pump Installation :

➢ After the formal meeting with the community, generally we decide about the need/
requirement (quantity) of water for that area.
➢ After it is mandatory to do a geo-hydrological (widely used study is VES) study to know
about the depth of groundwater table from the “existing ground level”.
➢ Then we should know about the history of drilling of that surroundings to know about the
type of machine to be engaged for drilling
➢ After drilling, if possible we should have do the recuperation test, i.e. the yield of water
from that bore hole
➢ Accordingly, we can design the type of hand pump to be installed in that place.

Rehabilitation of the Existing Hand Pump :

Generally, reviving of the water for lifting is called rehabilitation is called rehabilitation of hand
pump.

➢ After getting the result of geo-hydrological study, the depth of the drilling can be decided.
➢ Then as per the early bore hole internal diameter of the re-drilling should be decided.
➢ Then the same procedure should be followed off as per in the case of new installation.
➢ Accordingly, the depth of the raiser pipe can be decided

Renovation of Existing Hand Pump :

Usually, the meaning of the renovation of hand meant for the hand pump having the yield of
water in it’s bore hole.

➢ If contamination is available in the then required treatment can be done

➢ Required civil renovation can be done according to the requirement of site requirement
➢ The platform height can be raised according to site requirement
➢ The design should be done according to present requirement of the society
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For Environmental Safety or Safe Sanitation (Common to All) :

➢ First, we must have to know about the “High Flood Level” of that area to design the
height of the platform from existing water level
➢ Accordingly, the soak pit and the drainage system for waste water is decided.
➢ Generally, one elevated place is decided by the technocrat for the construction of the
platform.
➢ The drainage system should be below ground lining, so that the area can be keep the
area sanitized.
➢ The minimum distance of soak pit from the center of the bore hole should
➢ Septic tanks of Latrines or for Sewage Line, the boreholes need to be keep at 10.00
meters away.
➢ Strom water drainage canals, ditches or houses of up to 7.00 meters.
➢ Garbage dumps or landfills, as well as gas stations areas should be at least 100.00
meters away.
➢ The soak pit of waste water of the hand pump should be keep at 3.00 to 10.00 meter or
as depending upon the land availability with the required special treatment to avoid
contamination of the bore hole water.
➢ The drainage of the cattle shade should keep at 5.00 to 10.00 meter from the bore hole.

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Introduction :
The surface water from stream, springs are generally contaminated, but the borewell with hand
pump are sealed to protect harmful contaminations practically. The deep borewell with hand
pump is one of the good quality water are used in many places of India. Generally, India Mark II
hand pump with borewell is widely use throughout India because of it’s proven workability. It is
necessary to get good quality of domestic used water, for that the hand pump should be in good
condition. It is also necessary that a well workable hand pump should installed properly with
periodically required maintenance should be done accordingly.

WORKING PRINCIPLE OF INDIA MARK-II HAND PUMP AND THEIR PARTS :

India Mark - II Hand Pump is simply working on the principle of reciprocating pump. Its operation
can be briefed as under: When the plunger is raised (upward stroke), the space in the cylinder
below the plunger fills with air from the suction pipe. On the downward stroke the entrapped air
is compressed between plunger and the bottom of the cylinder. Then air lifts the plunger valve
and escape through the priming water. On the next up stroke, more air will be drawn out of the
pipe and the water will rise higher. On the next downward stroke the plunger and valve pass
through the water. When the plunger reaches the bottom of the cylinder and stops, the plunger
valve closes, thus trapping the water above the plunger. The plunger will have lifted out from the
pump.

The India Mark-Il Pump can be divided

by function into three main parts

1. The Head Assembly at top of the

borewell (Pump head assembly)

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2. The Pump Cylinder Assembly should be in contact with water, it should be below the
water level as per the requirement (cylinder assembly)

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3. The connecting assembly, which the pump stand and cylinder is connected with the help
of riser main pipes and connecting pump rods (raiser rod).

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PRECAUTION TO BE TAKEN BEFORE USING THE INDIA MARK-II HAND
PUMP :
To increase the life and for better performance of the pump, following points should be
remember before using the Hand Pump:
i. Do not use the Hand Pump roughly.
ii. You should operate the pump handle with slow and long stroke.
iii. You should try to keep the area around the platform dry and don't let water collect around
the, platform.
iv. Make the proper arrangement for the disposal of waste water and if it is possible then us&
the waste water for nearby gardening or by constructing soakage pit. It will avoid collection
of waste water around the Hand Pump.
Soakage pit is easy to construct and can be made with locally available materials. It is a simple
rectangular pit in which brick ballast of different size and soil is filled up in pit and now waste
water will fall in soakage pit through open channel: Waste water being absorbed in the soil of
soakage pit. It does not allow to collect water nearby and also helps to make space clean.
General Problems of India Mark-II Hand Pump with Rectification :

Sl.
Trouble Shooting Cause Rectification
No.
1. Easily handle of the hand It may due to no water a) If possible we can go for re-bore
pump is working without at the source and well for more depth
pumping water is dry. b) If water is within 40.00 m.
(practically) the we can be lowered
the cylinder to a certain depth with
increasing the height of raiser pipe
and connecting rod/raiser rod.
‘OR’
Priming is losing in Priming the pump as per the
pump technical requirement
‘OR’
The leather washer of Here we should have to replace the
the cylinder may be cylinder cup washer
worn out/damaged
‘OR”
There may be Tighten all the connecting rod joint
skidding of connecting and repair as per the need
rod
‘OR’
There may be broken Replace the rod
of pump rod
‘OR’
Huge leakages in the Replace the pipe
raiser pipe

Leakage in the bottom Check the bottom gasket and if

of the cylinder required replace the gasket
Cntd.
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Sl.
Trouble Shooting Cause Rectification
No.
1. Easily handle of the hand The outer wall of the Replace the cylinder
pump is working without cylinder may cracked
pumping water ‘OR’
There may be Clear the chock and clean all pipes
chocked in the suction with clear water and cotton clothes
pipe
2. Hand pump is working Plunger leather may Replace the plunger leather
properly, but the delivery be damaged
of water is quite low ‘OR’
Recuperation of the Make arrangement for recharge of
bore well is very less borewell or make required technical
repair
‘OR’
Leakages in valve Repair if repairable of replace the
valve
3. Pump needs too many The vertical/horizontal Realigned the priming of the hand
strokes to deliver water alignment of the pump head assembly
priming is turned out
‘OR’
Cup seals of the Replace the cylinder seal
cylinder may be
damaged
4. Handle of the pump is There may be a chock Remove all parts of inside head
getting up after down in the raiser pipe or assembly, i.e. raiser pipe and
stroke automatically cylinder cylinder clean all and then fix them.
‘OR’
There may be less in Fix raiser pipe as per the requirement
the height of suction and technical specifications
pipe
‘OR’
Water level of the Add some more raiser pipe so that
borewell is below the the cylinder should be at least more
cylinder than 10.00 m. (as per recuperation)
5. More noise created at Handle & other parts Tighten all parts of the head
the time of pumping of head assembly may assembly and if required replace the
be loosened required parts
‘OR’
The connecting rod Check the size of connecting rods
may be not correct in and if required replace or repair
size
‘OR’
Due to loosen of Check properly and tighten the
connecting rods connecting rods
‘OR’
Level alignment of the Check the level of top flange, pump
top flange is incorrect stand and if required realigned them
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Sl.
Trouble Shooting Cause Rectification
No.
5. More noise created at Ground fixing of the Dismantle the bottom concrete seal
the time of pumping hand pump stand is and fix it properly with leveling and
loosened with M10 PCC
‘OR’
Dried up of lubricant in Lubricate all required parts of the
the head assembly head assembly

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INDIA MARK-II HAND PUMP INSTALLATION :
General Comments :

Sustained safe drinking water supply and sanitation facilities are essential to improve the living
conditions of the rural population. The provision of safe water helps to combat water borne
diseases and improves community health in general. Benefits of a safe water supply can reach
far beyond considerations of public health and have a positive influence on the general
wellbeing, economic status and quality of life in a community.

Protection of Water Source :

If a good site is chosen and the well drilled (or dug) into the ground at a site which is elevated
and away from water logged areas during the rainy season, the water which percolates from an
underground aquifer into the well should be pure enough to drink.

However, a water point obviously attracts a great deal of human contact. This is a potential
source of contamination and should be protected against. The safety measures are as follows:

Well Siting :

a) The well should be in an elevated place, so that during the rainy season the water will
run away from it, rather than into it.
b) It should be at least 10.00 meters away from a latrine and should be the site is situated
in the uphill of the latrine.
c) It should be at least 10.00 meters away from a cattle kraal, and uphill of the kraal.
d) It should be well away from any depressed area in the ground, such as hollows used for
rubbish dumping, hollows used for brick making or any other areas where water might
collect.
e) A good quality platform as per technical specifications should be constructed with
required volume of soak pit.

Disinfecting the Borewell :

As soon as the curing time is over and the platform is ready for installation of the handpump, the
well needs to be disinfected with chlorine.

Many of the diseases that are common in the communal lands are carried by water, especially
from unprotected wells, natural water path, stream, rivers and dams.

Dysentery, diarrhea and typhoid can arise because of drinking water that is infected. The
disease carrying organisms found in the water can be effectively killed by disinfecting the water
with chlorine.

Therefore, it is recommended to disinfect the well shortly before the installation of the
handpump takes place. Proceed as follows:

➢ Mix 300 grams of bleaching powder thoroughly in 15 liters of water in a bucket and pour
the solution into the borehole.

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 ➢ The required dosage of bleaching powder is depending of the amount of water stored in
the well.

➢ It is recommended to use between 150 to 200 grams of bleaching powder per cubic
meter water for safe disinfection.

➢ In some places, due to massive fecal contamination the requirement of potassium

permanganate is required. For the application of this chemical, please consult with public
health department.

Cylinder Setting :

Static Water Level (SWL)

One of the important factors for the cylinder setting is the surface of the water in a well, which is
called “Static Water Level” (SWL). The SWL can vary due to seasonal conditions (dry or wet
seasons) and therefore should be checked and recorded over a period of several years. Such
records would be important for the decision at what depth the cylinder should be placed.

Dynamic Water Level (DWL)

Apart from seasonal fluctuations, there are also fluctuations in the well itself because of
pumping water from the well. To check the drop in the water level (draw down) and to find the
DWL, test pumping on a new borehole should be done by the drilling crew.

For handpumps, the test pump should be set for 1,000 liters per hour (maximum) to see where
the DWL is reaching. These tests should be continued for approximately 2 hours, to ensure the
correct DWL. This figure is another important factor for deciding on the best setting depth of the
handpump cylinder. (On marginal holes, pumping rate might be reduced to 800 liters/hour.)

Other Important Factors :

➢ Any pump intake in a borehole must be set above the well screen in fully screened well
or above any rock fissures providing water in an unlined well. A pump intake above the
well screen or rock fissures is minimizing the turbulent flow of water and therefore
reduces the pumping of fines and silts.

➢ Pumping water with a too high content of fines or silt is wearing the surface of the pump
cylinder and the plunger seals in an unacceptable rate.

➢ If a pump cylinder is placed too close to the bottom of a borehole, silt and sand could
build-up and trap the pump in the hole.

Cylinder setting in Boreholes :

➢ Check the depth of the DWL and the depth where the well screen starts (information
must be available from the drilling crew). The start of the well screen should be
considerably lower than the DWL. If there were a large difference, it would be ideal to
place the cylinder approximately 1.00 meter above the well screen.

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 ➢ Check the SWL regularly, especially during the dry season, to avoid that the newly
installed pump is running dry. Should the cylinder setting depth be critical during the dry
season, add one length of riser pipe and one pump rod.

Preparation Work Prior to Installation :

Riser pipes and Pump Rods

➢ Step 1 Check all pipe threads

with socket for good
engagement.
➢ Step 2 Check all pump rod
threads with couplers for good
engagement.
➢ Step 3 Apply hemp fiber with
grease or sealing liquid to one
threaded end of all pipes and
attach one socket.
➢ Step 4 Place several logs or a
pipe stand near the installation
place.
➢ Step 5 Place all prepared pipes
neatly on top of the logs or pipe
stand (above the ground) so that all threads remain clean.
➢ Step 6 Introduce one pump rod to each of the riser pipes and make sure that the long
hexagonal couplers are on the same side as the riser pipe sockets.

Pump Cylinder

➢ Step 1 Assemble all components of the plunger

Attach a Cup seal to

Place Rubber seating
to the Upper valve the lower part of the
Spacer

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Attach another Cup
Introduce the Follower Place the Upper valve
seal at the top of the
into the Spacer on top of the Assembly
Spacer

Attach another Cup

Introduce the Follower Place the Upper valve
seal at the top of the
into the Spacer on top of the Assembly
Spacer

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 ➢ Step 2 Assemble all components of the check valve body.

Assemble Check valve Place Rubber seating and secure with

with Check valve seat Seat retainer

➢ Step 3 Assemble the Pump Cylinder

Prior to assembling check cleanliness of cylinder liner and clean all threads and prepare them
with sealing fluid or hemp fiber with grease (cylinder pipe and Reducer caps).

Place first Sealing ring Introduce Check valve and Attach the cylinder with
into a Reducer cap place second Sealing ring liner to the Reducer cap

Introduce Plunger assembly Place third Sealing ring and Tighten both Reducer caps
into the Cylinder pipe attach Reducer cap with pipe wrenches

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➢ Step 4 Leakage Test Proceed as follows :

✓ Immerse suction part of cylinder into a bucket with clean water

✓ Operate the plunger by pulling and pushing the plunger rod

✓ As soon as the cylinder is filled, place it in a vertical position and check for any leaks

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Preparation of “Above Ground Components” :

➢ Step 1 Assembling of Pump handle

Place first Ball bearing to Introduce Mounting tool Insert Spacer into
Bearing mounting tool into Bearing housing Bearing housing

Place second Ball bearing Introduce Pressure plate

Add the hexagonal nut
on Bearing mounting tool on Bearing mounting tool

Take two spanners (19 mm) and tighten

the nut of the Bearing mounting tool, so
that both all bearings are pushed into their
end position.

If Ball bearings are mounted, remove

Bearing mounting tool.

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➢ Step 2 Assembling of Pump head

Introduce the pre-assembled Pump handle

into the Pump head assembly and place the
Ball bearings near the Axle bushes at the
sides of the Pump head.

Knock the handle axle gently into the end position

(use a plastic hammer if available).

Introduce Axle washer and If the pump handle is moving smoothly (up- & down), take
fasten one nut by hand second nut as a check nut to secure the correct position.

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Sequences of India Mark-II Hand Pump Installation :
“Borewell Components”

➢ Step 1 Take the first riser pipe with

pump rod from the logs. Place it
horizontally on the pump platform
and connect the pump rod to the
plunger rod of the cylinder.

➢ Step 2 If the pump rod is tight, apply

hemp fibers with grease, sealing
liquid or Teflon tape to the pipe
thread and screw the riser pipe into
the reducer cap of the cylinder.

➢ Step 3 Tighten riser pipe with

reducer cap of the cylinder with two
pipe wrenches.

➢ Step 4 Lower the first riser pipe with cylinder into the pump
stand (by hand) until the riser pipe protrudes the top face of
the pump stand by approximately 50 cm.

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➢ Step 5 Introduce the pipe vice and fasten the riser
pipe in this position (ideal working height).

Step 6 Take the second riser pipe with pump rod from the
logs, connect the pump rods first and then the riser pipe
after hemp fibers with grease, sealing liquid or Teflon
tape has been applied.

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➢ Step 7 With the help of the two lifting spanners, the
rising main can be lowered after the pipe vice has
been opened and removed.

➢ Step 8 Proceed in the same manner until the last

pump rod and riser pipe is connected.

Please Note : As soon as the rising main is too heavy for being handled with the lifting
spanners (5 to 10 pipe lengths), attach the pipe clamp and connect it with the hook of the chain
block. Lower the rising main with the help of the chain block on the tripod until the height
required (50 cm) for the next connection is reached!

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➢ Step 9 At the end of the last riser pipe located in
the pipe vice, the water tank will be attached.
Therefore, take off the last socket of the last riser
pipe and re-apply hemp fibers with grease or
sealing liquid to the pipe thread.

➢ Step 10 Then the water tank is screwed onto the

last pipe end and tighten by hand.

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➢ Step 11 (A) (For shallow
installations, when rising main is
not heavy). With the help of a
short piece of riser pipe attached
to the socket in the water tank, the
entire rising main can be held in
place with the help of 2 or 3 lifting
spanners. As soon as the pipe
vice has been removed, the riser
pipe assembly with water tank can
be lowered slowly to the pump
stand flange.

➢ Step 11 (B) (For deep installations with

heavy rising main assemblies). With a short
piece of rope attached to the hook of the
chain block, the water tank can be held
securely in position, so that the pipe vice
can be removed from the pump stand. Then
the water tank with rising main attached can
be slowly lowered to the pump stand flange.

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 ➢ Step 12 Turn the water tank so
that the spout is pointing into the
required direction and tighten it
properly to the pump stand with 4 x
M12 bolts and nuts. Now the
installation of the “above ground
components” can start.

Installation of Components “Above the Ground”

➢ Step 1 The protruding last pump rod needs to be

cut to the exact length, so that the plunger
connected is not knocking the check valve or the
cylinder cap during pump operation.

➢ Step 2 Use a hacksaw for marking the exact

length of the last pump rod (at the top face of the
water tank flange).

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➢ Step 3 Lift marked pump rod for easy cutting
and fasten with connecting rod vice on the top
flange of the water tank. Take a clean piece of
cloth and wrap it around the marked rod, to
prevent metal shavings or oil from falling into the
well (contamination).

➢ Step 4 Cut last pump rod at the mark.

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➢ Step 5 Remove sharp edges and make
a nice chamfer prior to threading.

➢ Step 6 Use little oil for cutting the M12

tread (40 mm long). As soon as thread is
finished, remove cloth carefully and
clean pump rod, vice and pump stand
from remaining oil and shavings. Prevent
shavings from falling into well.

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➢ Step 7 Insert middle flange.

➢ Step 8 Allow middle flange to rest on

top of connecting rod vice and fix the
check nut on the newly threaded top rod.

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➢ Step 9 Screw the chain coupler on the
connecting rod threads by hand.

➢ Step 10 Tighten check nut of connecting

rod with the chain coupler.

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➢ Step 11 Insert chain coupler supporting tool
below the chain coupler. Hold middle flange
and remove connecting rod vice.

➢ Step 12 Carefully lower the middle flange to

the top of water tank and ensure that all four
corners coincide.

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➢ Step 13 Hold head assembly in position and
insert chain through the hole in the bottom/
flange. Lower head on top of middle flange
ensuring all four corners to coincide.

➢ Step 14 Tighten head, middle flange and water

tank with bolts and nuts.

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➢ Step 15 Lift handle up and attach free end of
the chain with high tensile bolt, washer and
“Nyloc” nut.

➢ Step 16 Tighten “Nyloc” nut.

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➢ Step 18 Lift handle up and apply grease on
the chain.

➢ Step 19 Make sure :

➔ that the connecting rod moves up and down freely. If it does not, the rod has been
bent. Check the rod,
➔ that the chain coupler is fully engaged on the connecting rod and that the lock nut is
tight,
➔ that the axle nut and lock nut on the handle are tight,
➔ that the handle axle is firm in place,
➔ that the “Nyloc” nut has been tightened securely with the chain anchor bolt,
➔ that all 8 flange bolts and nuts are tight,
➔ that nothing has been left inside the pump head (tools, cloth etc.).

➢ Step 20 Fit inspection cover.

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➢ Step 21 Tighten the cover bolt.

➢ Step 22 Now the handpump

must be operated for first
filling of the rising main pipe.
Depending on the depth of
the cylinder setting, the
pump handle should have to
be operated for many
strokes (as an example: a
40.00 m. cylinder setting
requires approx. 100 full
handle strokes for filling the
entire rising main).

➢ Step 23 As soon as the

water is flowing from the
spout, operate the pump for
another 100 full strokes.
Check whether the water is
clean (no oil or dirt).If the water is not clean, the pump operation needs to be continued
until the water is acceptable.

➢ Step 24 If the water quality is acceptable (optically), the leakage test and the discharge
test must be made.

➢ Step 25 If the India Mark II Pump is working as expected, the users must be instructed
in “Operation and Maintenance” (O&M) of their pump.

➢ Step 26 Don’t forget to fill the “Installation Card”.

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TOOLS REQUIRED FOR DISMANTELLING/IINSTALLATION OF INDIA
MARK-II HAND PUMP :
Pump dismantling may be required for rectification of previously mentioned trouble. So, for as
repair and dismantling of pump is concerned, it is necessary that one should arrange some
special tools as detailed below :
➢ Self-Locking Clamp/Locking Clamp : It will help at the time of pulling and lowering of
riser pipe. If self-locking clamp (Figure-A) is not available, then arrange/fabricate two
pieces of such type of clamp (Figure-B)

Figure-B
Figure-A

➢ Pipe wrench, Slide Wrench and Spanners : Size as per requirement.

Pipe Wrench Slide Wrench Spanners

➢ Tool for holding the Chain Coupler : It helps to attach the chain with handle and will
be use between chain coupler and head assembly flange (Figure-C)

Figure-C
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➢ Tool for lifting/lowering of the pump rod : As per requirement, pump rod can be lift
out with the help of lifting tool (Figure-D)

Figure-D

➢ Pump rod vice : It is use for holding the pump rod at the time of repairing or thread
cutting (Figure-E)

Figure-E

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➢ Other general tools : Hammer, Screw Drivers, Punch and Pipe wrench etc.

Hammer Screw Driver

Punch

Page 34 of 46
DISMANTLING OF PUMP :
For dismantling of pump for repairing, at first remove the inspection cover from head assembly
refer (Figure-F)

Figure-F

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Fix the tool for holding the chain coupler inside the head assembly, refer (Figure-G).

Figure-G

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Release the chain with handle after loosen up the nut and bolt in the upward position of the
handle, refer (Figure-H)

Figure-H

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➢ Now, carefully release the handle axle by using the punch and hammer. Again, release
the handle and flange bolts from head assembly.

➢ Insert the pipe spanners in the both side holes of the head assembly and lift the head
assembly in upward direction, refer (Figure-I)

Figure-I

➢ Fix the pump rod vice in the flange of water tank after lifting of head assembly in upward
direction and make assure the holding of pump rod with the vice

➢ Rotate the head after loosening the lock nut of head assembly. Remove the chain
assembly and head assembly.

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➢ Remove the pump rod vice after lifting the pump rod in upward direction with the help of
lifter (pump rod clamp). Remove the lifter after lowering of pump rod in downward
direction, refer (Figure-J)

Figure-J

➢ Again, hold the riser main pipe by self-locking clamp/locking clamp and remove the
water tank after loosening of bolts of bottom flange of water tank

Page 39 of 46
 ➢ Collect the riser main pipe and pump rod at a dean place after dismantling. Remove the
self-locking damp/locking clamp at the time of dismantling of last riser pipe and pump
rod.

➢ Dismantle the last riser pipe and pump rod from cylinder by hand after pulling the last
pipe connected with cylinder assembly and to the last pump rod.

➢ Check the all threads of the dismantled pump rod and riser pipe and remove the rust &
dust with help of emery paper. If it is necessary, then make the new thread on the riser
pipe/pump rod. If the pump rod has been damaged/bend, it is advisable to replace the
old (damaged) pump rod by new.

REASSEMBLY OF THE PUMP :

After repairing reassemble the pump properly-As per following Instructions :

➢ At first joint the plunger rod with pump rod (first pump rod) and pump cylinder with riser
pipe (first pipe) and tighten property after applying the sealant on the threads. After
tighten the pump rod and riser pipe if you feel there are excess sealant then remove it
otherwise it will increase the impurities in the tube well.

➢ Now lower the cylinder, first pump rod & first riser pipe in the tube well through the pump
stand assembly.

➢ Properly hold the riser pipe with the self-locking clamp/clamp. Again, joint the first pump
rod with second pump rod and first riser pipe with second pipe and tighten it properly
after applying the sealant on threads.

➢ Lower the pump rod and riser pipe slowly and slowly after loosening of locking clamp.
Repeat the same process up to last pump rod and last riser pipe.

➢ Lock the last riser pipe with locking clamp

➢ Mount and tighten the water tank on the threads of last riser pipe

➢ Hold the riser pipe properly with the help of pipe wrench after tighten a small piece of
pipe in the coupling of water tank. Release the locking clamp from stand (after loosening
the riser pipe).

➢ Lower the water tank carefully in down ward direction and fix it on the flange of pump
stand.

➢ Release the excess piece of pipe which is fitted in the coupling of water tank.

➢ Tighten the all four nut and bolts of the water tank & pump stand flange.

➢ Lowering the last pump rod carefully in down ward direction after fixing of lifter on the
threads of last pump rod and hold it properly in pump rod vice.

➢ Release the lifter from pump rod after properly resting of pump rod vice on water tank.
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➢ Lowering the pump head through pump rod in down ward direction up to pump rod vice
and tighten the chain to pump rod (up to three or four threads only) now.

➢ Tighten the chain coupler by the revolving of pump rod.

➢ Put the chain coupler holding tool inside the pump rod.

➢ Allow the lowering of pump rod (after loosening of pump rod vice) up to resting of chain
coupler on chain coupler holding tool.

➢ Release the pump rod vice after pulling the pump head in upward direction with the help
of pipe spanners.

➢ Rest the properly pump head on water tank after carefully lowering of pump head in
down ward direction.

➢ Put the handle assembly inside the pump head.

➢ Insert the handle axle inside the hole with the help of punch and hammer. Tighten the all
nuts with the help of spanner.

➢ Connect the chain with handle and be sure that handle shall be in upward position at the
time of connection.

➢ Tighten the nuts of chain & handle by spanner and make the proper lubrication on chain
with grease.

➢ Make the handle in down ward direction and release the tool (tool for holding the chain
coupler).

➢ Now, be assure that all nut & bolts are tighten properly and after assuring mount the
inspection cover on head assembly and tighten it.

Finally, start the pumping but it is advisable not to use the water at the first delivery and after
10-15 buckets the water can be used.

As chlorination of tube well is necessary after repairing work therefore pour the chlorine
solution into tube well. Remember that hand pump must not be used at least for six hours
after chlorination.

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 THE STANDARD TOOLS REQUIRED BY A COMMUNITY HAND PUMP
MECHANIC/JALBANDHU

Sl.
Tools Quantity Unit
No.
1. Button Die to Suit M12 x 1.75 Threads 1 No.
2. Die Set for 32/40 mm. Pipe 1 No.
3. 450 mm. Pipe Wrench 2 Nos.
4. M17 x M19 Double Ended/Single Ended Spanners (10 mm. x 12 mm.) 1 No.
5. 600 mm. Pipe Wrench 2 Nos.
6. Screw Driver 300 mm. Long 2 Nos.
7. 10 lb. (ball Point Hammer) 1 No.
8. Hack Saw Frame and Blade (300 mm.) 1 No.
9. Injectable Oil Can (200 ml.) 1 No.
10. Wire Brush 1 No.
11. 250 mm. Half Round File with Handle 1 No.
12. 250 mm. Flat File with Handle 1 No.
13. Graphite and Lithium Grease 200 Ml.
14. Slide Wrench 1 No.
15. Nylon Rope (4 Strung) 75.00 M.

REPAIR AND REHABILITATION PROCEDURES :

For installing or dismantling a borehole, at least two trained people are required to oversee and
guide the unskilled labor force. The technicians should ensure that they have a complete tool
box with all the required tools for installing / dismantling including an extension rod of about
30.00-50.00 cm. length.

THE ROLES OF THE WATER USER COMMITTEE IN ENSURING THE

FUNCTIONALITY OF THE WATER POINT :
➢ Mobilize community members to participate in water source protection for example
Building the fence, and regular cleaning of the surrounding.

➢ Keep an updated list of the water users in the community.

➢ Collect and keep contributions towards the construction cost and the O&M funds

➢ Regularly visit and monitor the condition and performance of the water point

➢ Verification of the purchase of materials needed for the repair or maintenance of the
water source.

➢ Pay for any repairs carried out by a mason or hand pump mechanic.

➢ Supervise and provide support to the water source caretakers.

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THE ROLES OF THE CARETAKERS :
➢ Show people how to use the water point properly

➢ Carry out regular maintenance of the water point for example sweeping and slashing
around the borehole.

➢ Keeping record of all the maintenance work carried out on the source either directly by
the caretaker or by a (HPM) Hand Pump Mechanic (Jalbandhu), plumber or mason.

➢ Mobilize community members to participate in maintenance activities for example

regular cleaning of the surrounding of the water source, advice the community on regular
cleaning of containers both for storage and collection.

GENERAL MAINTENANCE GUIDELINES :

The India Mark II deep borewell with hand pumps are to be properly maintained to ensure safe
potable drinking water to the community, without break down. Proper and regular maintenance
will prevent breakdowns. The moving parts in the India Mark II hand pump above and below the
ground level are few and therefore simplifying the maintenance of the hand pump.

The following schedule of maintenance has been drawn at fixed intervals and has been
explained more elaborately.

I. Once in 30 days :

i. Tighten the handle axle nut and lock nut

ii. Look for loose or missing flange bolts and nuts

iii. Open the front of the head cover and clean inside the pump.

iv. Check the chain anchor bolt for proper fitment. Tighten if necessary.

v. Clean the chain assembly. Apply graphite grease.

vi. Look for rusty patches and clean them.

vii. Check whether the hand pump base is losing in the foundation. In case it is loose an
arrangement should be made to redo the foundation.

II. After 365 days (One year)

a) Examine the pump carefully and check whether :

i. Discharge is satisfactory

ii. Handle shaky and not firm

iii. Guide bush has excessively worn out

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 iv. All bolts, nuts and washers are in position

v. Chain has worn out

vi. Roller chain guide is excessively worn out

b) Overhaul the pump and follow the instructions :

i. If chain, bearing spacer are damaged, replace them

ii. If roller chain is badly worn out, replace the handle assembly

iii. If there are any damaged pipes have them replaced

iv. Open out the cylinder assembly and replace cup washers, sealing rings and other
components found to be faulty

v. Check the condition of the water tank riser holder. If the threads are worn out,
replace water chamber

vi. Check for any other seam line failures or cracks

vii. Re-install the pump as in the training



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 REFERENCES

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