Introduction

This guide will lead you through removing the traveling valve from the pump cylinder. It can then be replaced as a unit, or disassembled further to replace an individual internal component.

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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Remove the two bolts from the handle side of the pump head. Use one wrench on the bolt and another on the nut beneath. Hold the bolt stationary and loosen the nut. Use one wrench on the bolt and another on the nut beneath. Hold the bolt stationary and loosen the nut.
  • Remove the two bolts from the handle side of the pump head.

  • Use one wrench on the bolt and another on the nut beneath. Hold the bolt stationary and loosen the nut.

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Remove the two bolts and nuts from the handle side. Remove the two bolts and nuts from the handle side. Remove the two bolts and nuts from the handle side.
  • Remove the two bolts and nuts from the handle side.

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After removing the two handle side bolts, have your partner support the weight of the handle. Remove the two remaining bolts in the same fashion.
  • After removing the two handle side bolts, have your partner support the weight of the handle.

  • Remove the two remaining bolts in the same fashion.

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Lift and remove the pump head from the pump. Store the pump head in a sanitary place, preferably above ground, to prevent contamination. Store the pump head in a sanitary place, preferably above ground, to prevent contamination.
  • Lift and remove the pump head from the pump.

  • Store the pump head in a sanitary place, preferably above ground, to prevent contamination.

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Slightly twist the head flange, until the corners overhang the top of the tank far enough to grab. Slightly twist the head flange, until the corners overhang the top of the tank far enough to grab.
  • Slightly twist the head flange, until the corners overhang the top of the tank far enough to grab.

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Lift the head flange up about one foot above the tank. Lift the head flange up about one foot above the tank. Lift the head flange up about one foot above the tank.
  • Lift the head flange up about one foot above the tank.

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Slide the rod clamp around the pump rod, and support it on the tank base. Make sure the pegs in the base of the rod clamp fit into the appropriate holes in the top of the tank. Make sure the pegs in the base of the rod clamp fit into the appropriate holes in the top of the tank.
  • Slide the rod clamp around the pump rod, and support it on the tank base.

  • Make sure the pegs in the base of the rod clamp fit into the appropriate holes in the top of the tank.

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Tighten the rod clamp against the pump rod. Be sure the pump rod is centered within the jaws of the clamp and held securely.
  • Tighten the rod clamp against the pump rod.

  • Be sure the pump rod is centered within the jaws of the clamp and held securely.

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Deck the Halls
With tools and Fix Kits
Lower the head flange. Lower the head flange.
  • Lower the head flange.

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Unscrew the chain from the top of the pump rod. Remove the chain. Check the chain for signs of wear or damage.
  • Unscrew the chain from the top of the pump rod.

  • Remove the chain.

  • Check the chain for signs of wear or damage.

  • Set the chain in a sanitary place, such as the access door that was previously removed.

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Remove the chain support from around the pump rod. Remove the chain support from around the pump rod. Remove the chain support from around the pump rod.
  • Remove the chain support from around the pump rod.

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Remove the jam nut from the top of the pump rod.
  • Remove the jam nut from the top of the pump rod.

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Remove the head flange. Remove the head flange. Remove the head flange.
  • Remove the head flange.

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Screw the jam nut back onto the top of the pump rod.
  • Screw the jam nut back onto the top of the pump rod.

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Place a coupling over the pump rod, on top of the rod vise. Place a coupling over the pump rod, on top of the rod vise.
  • Place a coupling over the pump rod, on top of the rod vise.

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Reattach the T-handle to the top of the pump rod. Reattach the T-handle to the top of the pump rod. Reattach the T-handle to the top of the pump rod.
  • Reattach the T-handle to the top of the pump rod.

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Loosen and remove the rod vise from the pump rod. The coupling will drop down onto the riser main. The coupling will drop down onto the riser main.
  • Loosen and remove the rod vise from the pump rod.

  • The coupling will drop down onto the riser main.

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Screw the coupling onto the end of the riser main. Use a pipe wrench to tighten the coupling onto the riser main.
  • Screw the coupling onto the end of the riser main.

  • Use a pipe wrench to tighten the coupling onto the riser main.

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When using the lifting arms, it is essential that each arm have a gap above and below it, and that the openings alternate direction up the pipe.
  • When using the lifting arms, it is essential that each arm have a gap above and below it, and that the openings alternate direction up the pipe.

  • Set the first lifting arm just above (but not touching) the pipe vise.

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Add the other two lifting arms. Ensure three things about the arms: They must be equally spaced around the riser main (120° apart).
  • Add the other two lifting arms.

  • Ensure three things about the arms:

    • They must be equally spaced around the riser main (120° apart).

    • The arms must not touch each other, the coupling at the top, or the pipe vise at the bottom.

    • The openings should alternate, to keep the riser main secure.

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Communication is very important throughout this procedure. As each person lifts up on their lifting spanner, they announce "got it" to let everyone else know they're holding.
  • Communication is very important throughout this procedure.

  • As each person lifts up on their lifting spanner, they announce "got it" to let everyone else know they're holding.

  • Once all three lifters have announced that they've "got it," loosen the vise.

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With the vise loosened, lift up the riser main 1-2 feet. Lift only as high as everyone is comfortable.
  • With the vise loosened, lift up the riser main 1-2 feet.

  • Lift only as high as everyone is comfortable.

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Tighten the pipe vise, with the following procedure: Announce "tightening."
  • Tighten the pipe vise, with the following procedure:

    • Announce "tightening."

    • Tighten the vise.

    • Announce "Tight."

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Slide the three lifting spanners down on the riser main, into new lifting positions. Again, make sure he lifting spanners don't touch anything above or below, and that they are evenly spaced about the pipe. Again, make sure he lifting spanners don't touch anything above or below, and that they are evenly spaced about the pipe.
  • Slide the three lifting spanners down on the riser main, into new lifting positions.

  • Again, make sure he lifting spanners don't touch anything above or below, and that they are evenly spaced about the pipe.

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Once all of the lifters have said "got it," loosen the pipe vise. Once all of the lifters have said "got it," loosen the pipe vise.
  • Once all of the lifters have said "got it," loosen the pipe vise.

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Lift the riser main another 1-2 feet. Lift the riser main another 1-2 feet. Lift the riser main another 1-2 feet.
  • Lift the riser main another 1-2 feet.

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Tighten the pipe vise, following the same verbal procedure. Repeat the procedure several times:
  • Tighten the pipe vise, following the same verbal procedure.

  • Repeat the procedure several times:

    • Once everyone is securely holding the pipe, loosen the pipe vise.

    • Lift the pipe.

    • Tighten the pipe vise.

    • Slide the lifting spanners down to a new position.

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At ten feet, you will reach the first coupling in the riser main. While the three lifters are holding the riser main, the vise operator must open the vise wide enough to let the coupling pass through the jaws.
  • At ten feet, you will reach the first coupling in the riser main.

  • While the three lifters are holding the riser main, the vise operator must open the vise wide enough to let the coupling pass through the jaws.

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Lift the riser main up through the pipe vise, until the coupling clears the jaws. Tighten the pipe vise and move the lifting spanners down to a new position. Tighten the pipe vise and move the lifting spanners down to a new position.
  • Lift the riser main up through the pipe vise, until the coupling clears the jaws.

  • Tighten the pipe vise and move the lifting spanners down to a new position.

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Lift the riser main high enough that there is room beneath the coupling for the three lifting spanners. Tighten the pipe vise. Tighten the pipe vise.
  • Lift the riser main high enough that there is room beneath the coupling for the three lifting spanners.

  • Tighten the pipe vise.

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Use a pipe vise to unscrew the first section of riser main from the coupling. Be careful not to remove the coupling from the lower section of riser main. You may need to use two pipe wrenches to hold the coupling still while you loosen the top section of riser main.
  • Use a pipe vise to unscrew the first section of riser main from the coupling.

  • Be careful not to remove the coupling from the lower section of riser main. You may need to use two pipe wrenches to hold the coupling still while you loosen the top section of riser main.

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Unscrew the upper section of riser main from the coupling. Be careful—the pipe will likely be full of water, that will leak out above the coupling as you unscrew the pipe.
  • Unscrew the upper section of riser main from the coupling.

  • Be careful—the pipe will likely be full of water, that will leak out above the coupling as you unscrew the pipe.

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Lift the section of pipe straight up from the coupling. Be very careful to hold the pipe as straight up as possible. If it bends or falls over, it may damage the pump rod, or injure someone. Always have at least two people holding the pipe.
  • Lift the section of pipe straight up from the coupling.

  • Be very careful to hold the pipe as straight up as possible. If it bends or falls over, it may damage the pump rod, or injure someone. Always have at least two people holding the pipe.

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Place the rod vise on the pump rod between the section of riser main. Tighten the rod vise on the pump rod. Tighten the rod vise on the pump rod.
  • Place the rod vise on the pump rod between the section of riser main.

  • Tighten the rod vise on the pump rod.

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Use two wrenches to disconnect the upper section of pump rod from the lower section. Hold the lower section stationary and rotate the upper section. Once detached, lift and remove the upper sections of riser main and pump rod together, and set them down.
  • Use two wrenches to disconnect the upper section of pump rod from the lower section.

  • Hold the lower section stationary and rotate the upper section.

  • Once detached, lift and remove the upper sections of riser main and pump rod together, and set them down.

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Remove the T-handle from the top of the pump rod. Remove the T-handle from the top of the pump rod. Remove the T-handle from the top of the pump rod.
  • Remove the T-handle from the top of the pump rod.

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Screw the T-handle onto the newly exposed top of the pump rod. Screw the T-handle onto the newly exposed top of the pump rod.
  • Screw the T-handle onto the newly exposed top of the pump rod.

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Loosen and remove the rod vise. Repeat the lifting procedure for the remaining sections of riser main and pump rod. Repeat the lifting procedure for the remaining sections of riser main and pump rod.
  • Loosen and remove the rod vise.

  • Repeat the lifting procedure for the remaining sections of riser main and pump rod.

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The last section of riser main pipe will have the pump cylinder attached to the bottom.
  • The last section of riser main pipe will have the pump cylinder attached to the bottom.

  • Pull the assembly of riser main pipe and cylinder out of the well and set the assembly on a block of wood to keep the cylinder off the ground.

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Using two pipe wrenches, unscrew the cylinder from the riser main. Using two pipe wrenches, unscrew the cylinder from the riser main. Using two pipe wrenches, unscrew the cylinder from the riser main.
  • Using two pipe wrenches, unscrew the cylinder from the riser main.

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Slowly pull the cylinder off of the pump rod, exposing the traveling valve and foot valve. Slowly pull the cylinder off of the pump rod, exposing the traveling valve and foot valve.
  • Slowly pull the cylinder off of the pump rod, exposing the traveling valve and foot valve.

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Insert a wrench into the slots located at the bottom of the traveling valve. Using another wrench for leverage, unscrew the valve off the pump rod. Using another wrench for leverage, unscrew the valve off the pump rod.
  • Insert a wrench into the slots located at the bottom of the traveling valve.

  • Using another wrench for leverage, unscrew the valve off the pump rod.

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Unscrew the valve from the pump rod. Unscrew the valve from the pump rod.
  • Unscrew the valve from the pump rod.

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Be careful to keep the valve parts off the ground. Check the valve components for signs of wear and tear. Check the valve components for signs of wear and tear.
  • Be careful to keep the valve parts off the ground.

  • Check the valve components for signs of wear and tear.

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Remove the poppet from the valve to check for signs of wear. Be sure to take note of the order and direction of the components for reassembly. This is essential, as the pump will not work if the valve is not reinstalled correctly.
  • Remove the poppet from the valve to check for signs of wear.

  • Be sure to take note of the order and direction of the components for reassembly. This is essential, as the pump will not work if the valve is not reinstalled correctly.

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Conclusion

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

Andrew Optimus Goldberg

Member since: 10/17/2009

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