Introduction

Follow this guide to remove the handle and axle of the India Mark II. You can then replace or repair either or both.

Tools

No tools required.

Parts

No parts required.

Before performing any repairs, perform a water test on the pump by raising and lowering the handle a full 40 strokes. A properly performing pump will yield greater than 10 liters. Remove the hex head bolt from the top of the access door on the pump head.
  • Before performing any repairs, perform a water test on the pump by raising and lowering the handle a full 40 strokes. A properly performing pump will yield greater than 10 liters.

  • Remove the hex head bolt from the top of the access door on the pump head.

  • On reassembly, this bolt should be hand-tight.

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Pull the access door straight up off the pump head. Store the access door in a sanitary place to prevent contamination. Store the access door in a sanitary place to prevent contamination.
  • Pull the access door straight up off the pump head.

  • Store the access door in a sanitary place to prevent contamination.

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The access door has a tongue that fits into the base of the pump head. The access door makes a convenient tray to hold nuts and bolts during the disassembly.
  • The access door has a tongue that fits into the base of the pump head.

  • The access door makes a convenient tray to hold nuts and bolts during the disassembly.

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Place the spacer collar around the pump rod below the raised chain, with the beveled side down, and the flat side facing up. Place the spacer collar around the pump rod below the raised chain, with the beveled side down, and the flat side facing up. Place the spacer collar around the pump rod below the raised chain, with the beveled side down, and the flat side facing up.
  • Place the spacer collar around the pump rod below the raised chain, with the beveled side down, and the flat side facing up.

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The following procedure requires two people. If you attempt to do this alone, you risk injuring yourself and damaging the pump. Lift the pump handle until the base of the chain comes to rest on the spacer collar, and the chain is slack. Hold the handle in this position while the chain is being detached. Lift the pump handle until the base of the chain comes to rest on the spacer collar, and the chain is slack. Hold the handle in this position while the chain is being detached.
  • The following procedure requires two people. If you attempt to do this alone, you risk injuring yourself and damaging the pump.

  • Lift the pump handle until the base of the chain comes to rest on the spacer collar, and the chain is slack. Hold the handle in this position while the chain is being detached.

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Using the two access holes, place an angled socket wrench on the bolt and nut attaching the chain to the pump handle. Using the two access holes, place an angled socket wrench on the bolt and nut attaching the chain to the pump handle. Using the two access holes, place an angled socket wrench on the bolt and nut attaching the chain to the pump handle.
  • Using the two access holes, place an angled socket wrench on the bolt and nut attaching the chain to the pump handle.

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Hold the wrench on the bolt stationary. Loosen the nut. Loosen the nut.
  • Hold the wrench on the bolt stationary.

  • Loosen the nut.

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Remove the nut from the chain bolt. Remove the nut from the chain bolt. Remove the nut from the chain bolt.
  • Remove the nut from the chain bolt.

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Remove the washer from the chain bolt. Remove the washer from the chain bolt.
  • Remove the washer from the chain bolt.

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Remove the chain bolt. Remove the chain bolt.
  • Remove the chain bolt.

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Pull the top of the chain straight off of the pump handle. Pull the top of the chain straight off of the pump handle. Pull the top of the chain straight off of the pump handle.
  • Pull the top of the chain straight off of the pump handle.

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Use a wrench to loosen the nut on the end of the handle axle. Remove the nut and washer from the end of the axle. Remove the nut and washer from the end of the axle.
  • Use a wrench to loosen the nut on the end of the handle axle.

  • Remove the nut and washer from the end of the axle.

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Set the axle punch over the exposed threaded section of the axle. Set the axle punch over the exposed threaded section of the axle.
  • Set the axle punch over the exposed threaded section of the axle.

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The following procedure requires two people. If you attempt to do this alone, you risk injuring yourself and damaging the pump. The first person will use a hammer to gently tap on the axle punch, to push the axle through the handle bearings and out of the pump head. At the same time, a second person will hold up the handle, supporting its weight, while twisting the axle with a wrench, to loosen it in the bearings and make it easier to dislodge.
  • The following procedure requires two people. If you attempt to do this alone, you risk injuring yourself and damaging the pump.

  • The first person will use a hammer to gently tap on the axle punch, to push the axle through the handle bearings and out of the pump head.

  • At the same time, a second person will hold up the handle, supporting its weight, while twisting the axle with a wrench, to loosen it in the bearings and make it easier to dislodge.

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Gently tap the axle punch to push the axle out of the pump head. Gently tap the axle punch to push the axle out of the pump head.
  • Gently tap the axle punch to push the axle out of the pump head.

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Once the axle is loose, push it through the pump head. Once the axle is loose, push it through the pump head. Once the axle is loose, push it through the pump head.
  • Once the axle is loose, push it through the pump head.

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While supporting the pump handle, remove the axle. While supporting the pump handle, remove the axle. While supporting the pump handle, remove the axle.
  • While supporting the pump handle, remove the axle.

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Slide the pump handle out of the pump head. Slide the pump handle out of the pump head. Slide the pump handle out of the pump head.
  • Slide the pump handle out of the pump head.

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At this point you can inspect the pump handle bearing for damage or excessive wear.
  • At this point you can inspect the pump handle bearing for damage or excessive wear.

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The following steps demonstrate reassembly. After sliding the pump handle back into the pump head, line up the pump handle bearing with the holes in the side of the pump head.
  • The following steps demonstrate reassembly.

  • After sliding the pump handle back into the pump head, line up the pump handle bearing with the holes in the side of the pump head.

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Insert the axle back into the pump head. Be sure to support the weight of the handle and line up the holes in the sides of the pump head with the pump handle bearing. Be sure to support the weight of the handle and line up the holes in the sides of the pump head with the pump handle bearing.
  • Insert the axle back into the pump head.

  • Be sure to support the weight of the handle and line up the holes in the sides of the pump head with the pump handle bearing.

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Use a block of wood and hammer to gently tap the axle back into place. Do not hit the axle directly with a hammer, as you may damage it.
  • Use a block of wood and hammer to gently tap the axle back into place.

  • Do not hit the axle directly with a hammer, as you may damage it.

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Replace the washer and nut on the axle. Tighten the nut with a wrench. Tighten the nut with a wrench.
  • Replace the washer and nut on the axle.

  • Tighten the nut with a wrench.

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Conclusion

To reassemble your device, follow these instructions in reverse order.

One other person completed this guide.

Andrew Optimus Goldberg

Member since: 10/17/2009

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