Institute of Engineering and Rural Technology, Centre for Development of Rural Technology

Mishra, M.

International Development Research Centre: IDRC Digital Library

Do-it-yourself Maintenance of India Mark-I! Hand Pump ARCHIV 102224 Hun F— 0 MAINTENANCE OF INDIA MARK -II HAND PUMP Mahesh Mishra Water from stream and open well usually carries disease, but the tube wells are sealed to protect harmful germs. The deep well Hand Pump is one of the safest source of clean water. Generally it seems that in comparision to other Hand Pumps India Mark-il Hand Pumps are used frequentely. To get fresh water from the pump it is necessary that the hand pump should always work properly and effectively. For good service it is also necessary that the Hand Pump is installed properly and the maintenance has been done periodically. 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. On the next up stroke 2 the plunger will lifted out from the pump. The India Mark-Il Pump can be divided by function into three main parts 1) The Pump stand assembly at top of the well (Pump head assembly see fig. 1). FIg. 1 Cover bolt washer Chain bolt & Connecting Chain Head assembly Water tank assembly Bolt, nut, washer & che:k nut Piateform' Leg Casing pipe 3 2) The Pump cylinder assembly in contact with water (cylinder assembly See fig. 2). Yoke body Rubber seating Specer Follower Cylinder body Rubber Seat retainer Check valve guide Sealing ring Rubber Seating Check valve sheet Reducer cap. Plunger rod Reducer cap upper valve sheet Sealing ring Pump bucket Pump bucket' Brass 4 3) The connecting assembly which the pump stand and cy!inder with the help of riser main pipes and connecting pump rods. 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 (See fig. 3). (Ag. 3) 5 HAND PUMPS TROUBLE AND REMEDIES S. Trouble Likely Cause Remedy No. 1. Pump a. It is due to no water at Development of the Handle the source and well is boring should be done works easily dry. properly. If possible but rio water then cylinder may be delivered, lowered below water level in boring by increasing the riser pipe and pump rod. OR b. Pump has lost its Prime the pump. Priming. OR c. The cylinder cup Replace the cylinder washer (leather) may cup washer by new. be worn out. OR d. Pump rod joints may Check the all joints be opened. of the pump rods and tightned it. OR e. Due to broken of Pump Broken pump rod Rod. must be renewed and this usually means pulling the drop pipe and cylinder out of the bore well. 6 S. Trouble Likely cause Remedy No. f. Hole in Suction Pipe. Renew suction pipe. Cylinder may be lowered below water table in bore well. OR g. Leakage at base Check the cylinder of cylinder, gasket. If require then renew cylinder' gasket. OR h. The Pump Cylinder Replace the Pump may be cracked. cylinder by new. OR 1. The suction pipe may Dismantle the be plugged. suction pipe and clear it. 2. Pump runs a. Plunger leathers badly Renew Leathers.' but delivers warn out. only a small quantity of water. b. Refilling capacity of Make the proper bore well is not development of the enough. bore well. OR a. Valve leaking. Repair/renew valve. 7 S. Trouble Likely cause Remedy No. 3. Pump needs a. Pump has lost its Prime the pump. too many priming. strokes to start Pumping. OR b. The cylinder cup seals Renew the cylinder may be worn out. cup seals. 4. Pump's a. Suction pipe plugged. Remove the pump handle up below pump and clean out suction springs up cylinder, pipe. If well has filled after down with dirt upto suction stroke. pipe, then the pipe should be cut off. OR b. Suction pipe is too Replace it with larger small. suction pipe. OR c. Water table is too far Place the cylinder below from pump nearer to water. cylinder assembly. 5. Pump is a. Pump handle or other Tighten the loose noisy working parts of the parts. pump are loose. OR 8 S. Trouble Likely cause Remedy No. b. Pump rod is not check the pump rod correct in size. size. OR c. Pump rod is being Check and tighten loose, the loose pump rod. OR d. Top flange of the pump Check the level of stand assembly is not the top flange of in level. pump stand assembly and levels it. OR e. Hand Pump stand Check and if stand assembly is loose on assembly is not ground. grouted properly then grout it again with cement, sand and coarse aggregate and allow concrete (repaired portion) to set for a week. OR f. Hand Pump stand Make proper assembly requires lubrication. lubrication. 9 TOOLS REQUIRED FOR DISMANTELLING OF THE HAND PUMP: Pump dismantelling may be required for rectification of previ- ously mentioned trouble. So for as repair and dismantelling of pump is concerned, it is necessary that one should arrange some special tools as detailed below: It will help at the time of pulling and lowering of riser pipe (see fig. 4). If self locking clamp is not available then arrange/fabricate two pieces of such type of clamp (see fig. 4A). IFIg. 4A) 1. Self Locking Clamp/Locking Clamp (Fig. 4) It helps to attach the chain with handle and will be use between chain coupler and head assembly flange (See Fig-5). As per requirement, pumprod can be lift out with the help of lifting tool (see fig 6). (Fig. 6) 10 Size as per requirement. 2. Pipe wrench, Slide Wrench and Spanners. 3. Tool for holding the chain coupler (Fig. 5) 4.Toolfor lifting/lowering of the pump rod. 11 5. Pump rod vice: It is use for holding the pump rod at the time of repairing or thread cutting (See fig 7). (Fig. 7) 6. Other general : Hammer, Screw Drivers, Punch and Pipe tools wrench etc. D!SMANTEWNG OF PUMP 12 • For dismaritelling of pump for repairing, at first remove the inspection cover from head assembly (See fig 8). (Fig. 8) 13 • Fix the tool for holding the chain coupler inside the head assembly. (See fig - 9) (Fig. 9) 14 • Release the chain with handle after loosing the nut and bolt in the upward position of the handle (see fig- 10). (Fig. 10) 15 • 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 assembly and lift the head assembly in upward direction (see fig- (Fig. 11) • Fix the pump rod vice inthe 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 loosing the lock nut of head assembly.Remove the chain assembly and head assembly. 16 • 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 (see fig 12). • Again hold the riser main pipe by self locking clamp/locking clamp and remove the water tank after loosing of bolts of bottom flange of water tank. (Fig. 12) 17 • Collect the riser main pipe and pump rodat a dean place after dismantelling. Remove the self locking damp/locking clamp at the time of dismantelling 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 dismantelled 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. ASSEMBLY 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 pro perty applying the safeda on the threads. After tighten the pump rod and riser pipe if you feel their are excess safeda 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 safeda on threads. • Lower the pump rod and riser pipe slowly and slowly after loosing of locking clamp. Repeat the same process upto last pump rod and last riser pipe. 18 • 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 ther coupling of water tank. Release the locking clamp from stand (after loosing 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. • 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 ) at this time. • 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 loosing 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 up ward direction with the help of pipe spanners. 19 • Rest the properly pump head on water tank after carefully lowering of pump head in down ward direction. • Put the handle assembly in side 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 coulper). • 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 this time. 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. IERT-CDRT-ISD-flIys -39 This work was carried out with the aid of a grant from International Development Research Centre, Ottawa, Canada. INFORMATION SERVICE DIVISION Centre for Development of Rural Technology Institute of Engg. & Rural Technology 26, Chatham Lines, Allahabad - 211 Printed by :- Saraswati Offset Printers: 640888 

Do it yourself : maintenance of India Mark-II hand pump

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Do it yourself : maintenance of India Mark-II hand pump

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