India Mark II Axle and Handle Replacement

Written By: Andrew Optimus Goldheart
  • Comments: 0
India Mark II Axle and Handle Replacement

Difficulty

Moderate

Steps

23

Time Required

No estimate

Introduction

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

  1. knxaBegnqXhMVOJP
    knxaBegnqXhMVOJP
    6FLXjZRrK3VCdh52

    • 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.

  2. kc2lU4ebqKFBw1qN
    kc2lU4ebqKFBw1qN
    RnQHnIhOOpsDGOxf
    xOfQglAwmagVWqOA

    • Pull the access door straight up off the pump head.

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

  3. JoFFylEdtWmtoaVd
    JoFFylEdtWmtoaVd
    EWeXySTTDWTlrIdC

    • 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.

  4. ZLyVQlSriGIPKxlb
    ZLyVQlSriGIPKxlb
    cE4kCkHEeyGF2Z33
    dFnMSifarrKBA2Py

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

  5. jmjPoMTClufyYHRg
    jmjPoMTClufyYHRg
    ilaDGuKR5gNU4oXh
    otydbJoQoRkXb2Eb

    • 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.

  6. nganIEDqQwYTW1bG
    nganIEDqQwYTW1bG
    fDEoPsAF4IGJN1hN
    UOEYfclHQGql4MKv

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

  7. wMxHBO5NN4iLT6W2
    wMxHBO5NN4iLT6W2
    yt3EcteQG1QO5x6M
    yWTHPjfWm1A5blFC

    • Hold the wrench on the bolt stationary.

    • Loosen the nut.

  8. BbMrLL1NYZ1Py1OV
    BbMrLL1NYZ1Py1OV
    rGRfQYBIxUvRieBY
    CL2VfUlxpEkiFZ4a

    • Remove the nut from the chain bolt.

  9. L2PxN3LCJESbIObN
    L2PxN3LCJESbIObN
    xsjVCgKRRRdTMRDR

    • Remove the washer from the chain bolt.

  10. NqcotAWFnyxiFXwx
    NqcotAWFnyxiFXwx
    h24eMFUR4mQ5JwnC

    • Remove the chain bolt.

  11. tXEBpJUxjYvmSfIq
    tXEBpJUxjYvmSfIq
    eYRLASOYRcjpDlvp
    udcSSChydYn2GRbd

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

  12. EHlbsYDxKuvpxgtE
    EHlbsYDxKuvpxgtE
    PJLPAryjsoO1qPXx
    Xu5kRwYHV1XlQUfx

    • 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.

  13. Xq6KhFJfxK42Nncd
    Xq6KhFJfxK42Nncd
    ehKZLYJFbZBNDOqZ

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

  14. 6lTAyHRnwA4VhdTA
    6lTAyHRnwA4VhdTA
    TRUVtsEsisCtAVFg
    TBJNrkXNEBOL1Zc2

    • 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.

  15. OJaSAwtKwWJhSgXc
    OJaSAwtKwWJhSgXc
    mwaE3ArDmdswTKVw

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

  16. Yw4hloiVFMDs4rqW
    Yw4hloiVFMDs4rqW
    Yo1TDUxxlieH5JCF
    rNJfFkMASbeCTWm2

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

  17. 4EdpH4WtfQUAr3Nl
    4EdpH4WtfQUAr3Nl
    JgbHFeTQaTZHetVu
    rvYbObmpiJvGOVTP

    • While supporting the pump handle, remove the axle.

  18. VmSnTfwUcPIDF2ih
    VmSnTfwUcPIDF2ih
    gADZGysDu5lCN3hF
    5uV31C25ypMASKDx

    • Slide the pump handle out of the pump head.

  19. i6vQFhb2dKakklCw

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

  20. wwpkAEeiNijXVyZQ
    wwpkAEeiNijXVyZQ
    mo1IABriR3HItwK2

    • 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.

  21. aWxJRMeHBEndnLGu
    aWxJRMeHBEndnLGu
    F6MGuDcMCL2Fy3TV
    CgKVl6J46GNQXfG2

    • 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.

  22. LdJJZolFVWlNLVEa
    LdJJZolFVWlNLVEa
    d4f2qfKeNY3auJhW

    • 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.

  23. 3eDHUp56WPlEqqfZ
    3eDHUp56WPlEqqfZ
    VZIN6EhhZ5uWVbEr
    jc64S4PK2oeGSbZG

    • Replace the washer and nut on the axle.

    • Tighten the nut with a wrench.

Conclusion

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

Author

Andrew Optimus Goldheart

Member since: 17/10/09

505446 Reputation

0 comments