OJT Manual India Mark-II Rev-2

The Project of Rural Water Supply in Tabora Region
The United Republic of TANZANIA
<Grant
rant Aid from People of Japan>
Operation and Maintenance Manual

for
India Mark-II
II Extra Deep well Handpump
April, 2016
Earth System Science Co., Ltd.
and
KONOIKE Construction Co., Ltd

Operation and Maintenance Manual (India Mark-II Handpump)

CONTENT
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Pages
1. General
1.1 Outline of the Project -----------------------------------------------------------------------
-------------------------------- 1
1.2 Introduction of Handpump --------------------------------------------------------- --- --- 1
1.3 Reference Documents ---------------------------------------------------------
------------------------------------------------------ ---------- --- 2
1.4 Introduction of Well Construction --------------------------------------------------- --- 3
2. Handpump Assembly
2.1 Structure ----------------------------------------------------------------------------------------
-------------------------------- 4
2.2 Assembly of Above Ground Components ----------------------------------------- --- 6
2.3 Assembly of Below Ground Components ----------------------------------------- --- 7
(1) Cylinder Parts (Stainless Type) ---------------------------------------- -------------- --- 7
(2) Cylinder Parts (Cast Iron Type) ---------------------------------------- ------------- --- 8
(3) Riser Pipe and Pump Rod ---------------------------------------- --------------------- --- 9
2.4 Maintenance Tools and Materials----------------------------------------------------
Materials --- 10
(1) Pipe Handling Instrument ---------------------------------------- -------------------- --- 10
(2) Special Maintenance Tools ---------------------------------------- -------------------- --- 11
(3) Standard Maintenance Tools ---------------------------------------- ----------------- --- 12
(4) Other Materials ----------------------------------------
------------------------------------- ----------------------------------- --- 13
3. Installation of Handpump
3.1 Preparation before Installation --------------------------------------- -------------- --- 14
(1) Preparation of Riser Pipe and Pump Rod ---------------------------------------- --- 14
(2) Checking of Pump Cylinder ---------------------------------------- ------------------- --- 16
(3) Leakage Test of Pump Cylinder ---------------------------------------- ------------- --- 16
(4) How to Assemble Plunger in CylinderC ---------------------------------------- ----- --- 17
(5) How to Assemble Other Parts of Cylinder (Stainless type) --- ------------- --- 18
(6) How to Assemble Other Parts of Cylinder (Cast Iron type) --- ------------- --- 19
(7) Preparation of Pump Head and Handle -------------------------------------- ---- --- 20
3.2 Installation of Below Ground Components ------------------ ------------------- --- 22
(1) Installation of Cylinder and 1st Riser Pipe---------------------------------------- --- 22
(2) Installation of Riser Pipe by Lifting Spanner---------------------------------------- 23
(3) Installation of Riser Pipe by Chain Block ---------------------------------------- --- 24
(4) Installation of Water Tank ------------------------------------------------------------- --- 27
3.2 Installation of Above Ground Components --------------------------------------- --- 28
(1) Adjustment of Pump Rod Length ---------------------------------------- ----------- --- 28
(2) Installation of Chain Assembly ---------------------------------------- -------------- --- 29
(3) Final Works -------------------------------------
-------------------------------------------------------------------------- --- 31
(4) Fixing T-Handle
Handle and Counter Weight ------------------------------------------- -- --- 32
4. Daily Operation and Preventive Check

4.1 Daily Operation -------------------------------------------------------------------------------
-------------------------------- 33
4.2 Preventive Checks------------------------------------------------
------------------------------------------------ ----------------------------- 33
(1) Weekly Checks and Maintenance--------------------------------------
Maintenance -------------- --- 33
(2) Monthly Checks and Maintenance--------------------------------------
Maintenance ------------ --- 33
(3) Leakage Test (Monthly) ----------------------------------------
----------- ------------------------ --- 33
(4) Discharge Test (Monthly) ---------------------------------------- ---------------------- --- 34
(5) Yearly Replacement ----------------------------------------
------------------------------------- ------------------------------ --- 35
4.3 Trouble Shooting ------------------------------------------------------ ------------------------- 36
Operation and Maintenance Manual (India Mark-II

II Handpump)
CONTENT
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Pages
5. Maintenance and Repair

5.1 Maintenance of Above Ground Components------------------------------------------ 37
(1) Check / Maintenance Chain Assembly---------------------------------------- ----- --- 37
(2) Remove
emove out / Replace of Chain Assembly ----------------------------------------- --- 37
(3) Remove out Handle for Maintenance of Bearing ------------------------------- --- 39
(4) Maintenance of Ball Bearing ---------------------------------------- ----------------- --- 39
5.2 Maintenance of Below Ground Components ---------------------------------------- 41
(1) Remove out Water Tank -------------------------------------------
---------------------------- --------------------- --- 41
(2) Remove out Riser Pipe and Cylinder ----------------------------------------------- --- 42
(3) Dismantlement of the Cylinder Assembly ---------------------------------------- --- 43
(4) Supplement of Check Valve ------------------------------------------- ---------------- --- 45
< ANNEX >
Annex-1 Check Sheet of Handpump Maintenance -------------------------------------- -- A-1

Annex-2 Contact Information of Maintenance Service ----------------------------------- A-3
Annex-3 Price List for Handpump Parts ------------------------------------------------------ A-4
Annex-4 Price List for Handpump Repair in the Village --------------------------------- A-6
Annex-5 Contact Information of Region and District ------------------------------------- A-10
Annex-6 Contact Information of Attendants to 2nd Guidance --------------------------- A-11
Operation and Maintenance Manual (India Mark-II Handpump)

Handpump
1. GENERAL
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1. 1 OUTLINE OF THE PROJECT
This project is executed by Grand Aid from the Government of Japan based on the Grant
Agreement between JICA (Japan International Cooperation Agency) and Ministry of Water, the
United Republic of Tanzania,, relating to the improvement of water supply conditions in Tabora
Region. Project name and organization rganization for execution of the project is as follows.
Table 1-1
1 Project Name and Organization
Project Name : The Project of Rural Water Supply in Tabora Region
Client : Ministry of Water, the United Republic of Tanzania
Partner of the Client : Regional Administrative
Administ Secretary Tabora Office
Consultant : Earth System Science Co., Ltd, Japan
Contactor : KONOIKE Construction Co., Ltd, Japan
Community : Community Owned Water Supply Organization (COWSO)
Community-Owned
Maintenance Company : CBRC Community Based Resource Centre Shinyanga
1.2 INTRODUCTION OF HANDPUMP

Selected handpump in this site is INDIA MARK-II EXTRA DEEPWELL HANDPUMP
manufactured by Ajay Industrial Corporation Ltd in India.
India Mark-II
II Deepwell Handpump was designed in the 1970s in India by a joint effort between
the Government of India, UNICEF, and WHO, and it was improved as India Mark-II
Mark Extra
Deepwell Handpump is improved for lifting water from deep well up to 90m.
Table 1-2 Summary of Specification of Selected Handpump

Type India Mark-II
Mark Extra Deepwell Handpump
General
Installation depth Maximum

imum 90m
Discharge rate 12 L per 40 strokes
Pump head, stand, Hot-dip
dip Galvanized Steel complete with handle assembly ( with T bar type
handle handle, 3 counter weights), Water tank, Three legged pedestal
Cylinder Stainless steel assembly of 63.5 inner diameter with plunger and check valve
Specification
Stainless steel 3m length pipe 42mm O.D., 36mm I.D. with welded threaded
Riser pipe
female socket
Inner rod Stainless steel 3m length connecting rod with threaded connector
Plunger Stainless plunger in Cylinder
Check Valve Stainless check valve in Cylinder
Manufacture of handpump is as follows.
Table 1-3
3 Information of Manufacture of Hamdpump
Name : AJAY Industrial Corporation Ltd.
Address : 20/11, Site IV, Sahibabad Industrial Area Ghaziabad, Uttar Pradesh 201010,
India
Tel : +91-(120)-277-0679,
0679, 277-4747
277
E-mail : info@ajayindustrial.com ajaypump@ajaycorp.com
info@ajayindustrial.com,
Website : www.ajayindcorp.com www.ajayind.in
www.ajayindcorp.com,
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1. GENERAL
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1.3 NYARAKA ZA KUMBUKUMBU
This operation and Maintenance Manual is referred following documents,, and we utilize
some of photos or figures, sentence on these documents in this manual. manual We hereby
appreciate to below persons/ organizations.
1) Installation & Maintenance Manual for the India Mark II Handpump, 2008 8, SKAT -
RWSN
* Reference Website: http://rural-water-supply.net/en/resources/details/328
http://rural
*SKAT: An independent Swiss organization working in the field of development and

humanitarian aid since 1978. http://www.skat.ch/
*RWSN: It is stand for Rural Water Supply Network,

Network, and it is a network of individuals and
organizations that are committed to improving water services for the rural water
supply. Former name is HTN (Human Technology Networks).
http://rural-water-supply.net/en/
supply.net/en/
2) India Mark Handpump Specification, Revision

Revis 2 - 2007, SKAT - RWSN
*Reference Website: http://rural-water-supply.net/en/resources/details/327
http://rural
3) Indian Mark 2 Major Maintenance Guideline, Inter Aide Sierra Leone, European Union
*Reference Website: http://rural
ttp://rural-water-supply.net/en/resources/details/630
4) Ajay India Mark-II Handpump Installation

Inst and Maintenance Manual
5) Wikipedia: Lever (https://en.wikipedia.org/wiki/Lever

https://en.wikipedia.org/wiki/Lever)
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1. GENERAL
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1.4 INTRODUCTION OF WELL CONSTRUCTION
It is introduced construction of well from beginning to water supply as follows.
1) Geophysical Survey 2) Drilling Works 3) Pumping Test
4) Water Quality Analysis 5) Concrete Works 6) Pump Installation
Fig. 1-1
1 Working Flows for Well Construction
Table 1-1
1 Introduction of Contractor in this Project
Works Description
KONOIKE Construction Co., Ltd
2-7-5,
5, Minamisuna, Koto-ku,
Koto Tokyo 136-8880, Japan
Tel: +81-3-5617-7862,
7862, Fax: +81-3-5617-7864,
+81 Web: http://www.konoike.co.jp
General
TONE Engineering Corporation (on behalf of KONOIKE)
Yotuya Aneex, 4 Samoncho, Shinjuku-ku,
Shinjuku Tokyo 160-0017, Japan
Tel: +81-3-5312-5214,
5214, Fax: +81-5312-5214,
+81 Web: http://www.tone-eng.co.jp
eng.co.jp
SIAM TONE Co., Ltd
Geological
5/15 Moo 6 Bangna-Trad
Bangna Road, Bangcha-Long
Long Bangplee Samutprakarn 10540,
Survey
Thailand, Tel: +66-2-312-5281
+66
VICTORIA Boreholes Co., LTD
P.O.Box 1352 Dar es Salaam
Drilling Works/ Tel/Fax: +255-732
732-999713, web: http://www.victoriaboreholes.com
Pumping test DDCA (Drilling and Dam Construction Agency)
University of Dar es Salaam Rd, Ubungo, P.O. Box 55658 Dar es Salaam
Tel/Fax: +255-22
22-2410430, Web: http://www.ddca.go.tz
SGS/ African Assay Laboratory Tanzania Ltd
Water Quality
Balewa road, P.O. Box 1826 Mwanza, Tanzania
Analysis
Tel: +255-28-2501091,
2501091, Fax: +255-28-2501093,
+255 Web: http://sgs.com
MAC Contractors Ltd
Concrete Works
P.O.Box 31895 Dar es Salaam, Tel: +255-2202700720
Pump CBRC (Community Based Resource Centre) Shinyanga
Installation Ushirika Area P.O.Box 1200 Shinyanga, Tel/Fax: +250-28-2763279
+250 2763279
TONE Engineering Corporation:
Corp ration: Mr. Katsuhiko ADACHI, Mr. Selestine Shironga
Manual
CBRC: Mr. Ramadhani Chambulilo, Mr. Rajabu Amri Ally
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2. 1 STRUCTURE
The structure of India Mark-II II Extra Deepwell is shown on Fig. 2-1, 2-2.
Fig.2-1 Structure of India Mark-II Extra Deepwell Handpump (General)
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2.. HANDPUMP ASSEMBLY
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Fig.2-2 Structure of India Mark-II

Mark Extra Deepwell Handpump (Detail of Pump head)
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2.2 ASSEMBLY OF ABOVE GROUND COMPONENTS
Assembly of Above Ground Components omponents is shown as bellows.
Pump Stand Water Tank Pump head and Handle
T-Handle Counter weight 100mm Hex.bolt with nut

(for counter weight)
Inside of Pump Head Chain with coupling Handle

(Bearing House)
Handle Axle Bearing Spacer
Fig. 2-3 Assembly of Above Ground Components
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2.3 ASSEMBLY OF BELOW GROUND COMPONENTS
(1) Cylinder Parts (Stainless Type) ype)
Assembly of cylinder parts for stainless type is i shown as bellows. Stainless type is installed
in this project.
Cylinder Assembly Cylinder Assembly Liner Body of Cylinder

(Stainless Type) (Stainless Type)
Check Valve Assembly Check Valve Assembly Top Reducing

Reduc Plug
Plunger Assembly Plunger Assembly Cup Seal / Cup Washer
Rubber Sealing Big Rubber Sealing Small O-Ring

Ring
Fig 2-4 Assembly of Cylinder Parts (Stainless Type)
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(2) Cylinder Parts (Cast Iron Type)
Assembly of cylinder parts for cast iron type is shown as bellows, s, for your reference to
compare with stainless cylinder.
Cylinder Assembly Cylinder Assembly Liner Body of Cylinder

(Cast-Iron Type) (Cast-Iron Type)
Check Valve Assembly Check Valve Assembly Reducer Cap
Plunger Assembly Plunger Assembly Cup Seal / Cup Washer
Big Seating Ring Rubber Seating Small Rubber Sealing

Fig. 2-5 Assembly of Cylinder Parts (Cast Iron Type)
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2. HANDPUMP
HANDPU ASSEMBLY
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(3) Rise pipe and Pump rod
Riser pipe and pump rod is shown as bellows.
Riser pipe (welded socket part) Riser pipe (thread part)
Socket of riser pipe Plug of riser pipe
Pump rod Pump rod Hexagonal Coupler

Fig.2 Riser pipe and Pump rod
Fig.2-6
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2.4 MAINTENANCE TOOLS S AND MATERIALS
(1) Pipe Handling Instrument
Pipe handling instrument are shown as bellows.
bellow
Tripod Tripod Chain Block
Nylon Sling Hoisting Plug with Swivel

Fig.2 Pipe Handling Instrument
Fig.2-7
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(2) Special Maintenance Tools
Special maintenance tools are shown as bellows. bellow
Special Tools Kit Heavy Duty Clamp for Pipe Lifter Pipe for Water Tank
Connecting Rod Clamp Rod Coupling Spanner Connecting Rod Lifter
Handle Axle Punch Crank Spanner Chain Coupler Supporting Tool
Bearing Pressing Tool Tool Box

Fig.
Fig.2-8 Special Maintenance Tools
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HANDPU ASSEMBLY
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(3) Standard Maintenance Tools
Special maintenance tools are shown as bellows. bellow
Standard Tools Kit Bottom Die Thread Tap
Pipe Wrench 600mm Pipe Wrench 450mm Open Jaw Spanner
Screw Driver Adjustable Spanner Ball Pin Hammer
Hacksaw Flat File Wire Brush

Fig.2--9 Standard Maintenance Tools (1)
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HANDPU ASSEMBLY
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Spirit Level 32mm Die with Handle Tool Box

Fig.2-10
10 Standard Maintenance Tools (2)
(4) Other Materials

Other tools and materials are shown as bellow.
Lubricating oil Multipurpose Grease Oil Compound
Sealing Compound Seal Tape Nylon Rope

Fig.2-11 Other Materials
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3. INSTALLATION OF HANDPUMP.
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3.1 PREPARATION BEFORE PUMP UMP INSTALLATION
(1) Preparation of Riser Pipe and Pump Rod
1) Check all pipe threads with socket for good engagement.
* Pipe thread or pipe socket is rarely damaged on transport or at off loading (Fig.3-1). It
shall be rejected these damaged pipe. pipe Installed riser pipes will be not straight in
borehole.
*It is used pipe welded socket at pipe end, in this project.
2) Check all pump rod thread with couplers for good engagement.
*It is used pump rod welded coupler at rod end, in this project.
3) Place all prepared pipes on the logs, pipe stand (Fig.3-2), or Blue Sheet (Fig.3-3)
(Fig.3 so that all
threads keep clean. Do not put materials on ground directly.
Fig.3-1 Check Thread and Fig.3 Prepared Pipe on Pipe

Fig.3-2 Fig.3-3
3 Prepared Pipe on Blue
Socket of Pipe Stand Sheet
4) Clean up thread part of pipe and socket by brush. Toothbrush is useful to clean up female
thread of socket. And then, roll seal tap on threaded end.
Fig.3-4 Clean up male thread of Fig.3-5 Clean up female thread

Fig.3 Fig.3-6
6 Rolling Seal Tape
T on
pipe by brush of socket by toothbrush Threaded End of Pipe
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5) Apply sealing compound (Fig.3-7), (Fig.3 ), sealing liquid or hemp fibers with grease (Fig.3-8) (Fig.3 to
threaded end and socket end in advance or one by one at installation of pipes into borehole.
Hemp fibers are possible to be made with picking hemp rope (Fig.3-9). (Fig.3
Fig.3-7 Apply sealing Fig.3 Apply hem fibers with

Fig.3-8 Fig.3-9 Hemp fibers is made with
compound to thread end grease picking hemp rope
6) Clean up male thread part of rod by brush (Fig.3-10),

(Fig.3 10), and wash up female thread part of
connector in water (Fig.3-11).
7) Insert one pump rod into each of the riser pipes in advance or one by one at installation of
pipe into borehole. Make sure that the long hexagonal couplers are on the same side as the
riser pipe socket. *It is used welded connector at rod end, in this project.
p
8) Apply a little lubricant or grease to thread of rod end in advance or one by one at
installation of rods into borehole together of riser pipe (Fig.3-12).
12). However, do not apply
too much. If it is apply much lubricant or grease, rods will be disconnected
disconnected during
operation later.
Fig.3-10 Clean up male thread Fig.3-11 Wash up female thread

Fig.3 Fig.3-12 Insertion of Pump Rod
of rod by brush of connector in Water into Riser Pipe
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(2) Checking of Pump Cylinder
9) Open both reducer caps by pipe wrenches, and then check any parts of pump cylinder, such
like whether, a) rubber ubber parts are placed correctly, correctly b) rubberubber parts are not damaged such as
score, c) plunger
lunger rod is tighten to plunger assembly.
*It is introduced the particulars how to assemble pump cylinder on chapter chapt of
maintenance.
*In case of stainless cylinder, thread of check valve might be rocked due to prevent that
thread of check valve will be loose during handpump operation. If it will be not found any
problem on check valve visually, it is not necessary to dismantle check valve.
10)) After check inside parts of pump cylinder,, tighten both reducer caps with pipe wrenches.
(3) Leakage Test of the Cylinder

11) Immerse suction part of cylinder into a bucket 11) 12)
with clean water, and operate
perate the plunger by
pulling and pushing the plunger rod.
12) As soon as the cylinder is filled, place it in a

vertical position, and check
heck for any leaks after
waiting some minutes until the cylinder surface
is dry.
13)) Once the cylinder is water tight, the installation

of the down hole components can be start. Fig.3-13 Leakage Test
If there is any leakage, try to tighten both
reducer caps, before finding the reason of the
leakage.
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3. INSTALLATION OF HANDPUMP
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(4) How to Assemble Plunger in Cylinder (for Stainless type, Cast Iron type)
14) Assemble all components of the plunger.
a. Place rubber seating to the upper valve val with minus driver or something.
b. Attach a Cup seal to the lower part of the Spacer. Spacer
a) b)
Fig.3
Fig.3-14 Assembly of the Plunger (1)
c. Attach other Cup seal at middle and top of the spacer.

d. Insert the follower into the spacer.
e. Place the Upper valve on top of the assembly.
c) d) e)
Fig.3
f. Attach Plunger body and tighten securely.

g. Take plunger rod and tighten it to the plunger assembly.
f) g)
Fig.3
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(5) How to Assemble Other Parts of Cylinder (Stainless Type)
15-1) Assemble check valve body.
a. Insert check valve into check valve plug from bottom. bottom
b. Place rubber seating and secure with seat retainer.
c. Hold check valve by stopper or spanner, driver and tight seat retainer by spanner. spanner
*It is mentioned detail for check valve on chapter 5 Maintenance and Repair
a) b) c)
Fig. 3-17 Assembly of Check Valve (Stainless Type)
16-1) Assemble the pump cylinder. Prior to assembling, check cleanliness of cylinder liner
and all threads. And clean it and apply sealing fluid or grease on all of threads.
threads
d. Put O-ring
ring into check valve plug.
e.. Attach the cylinder with liner to the bottom plug (Check valve assembly).
assembly)
f. Insert plunger assembly into the cylinder pipe.
d) e) f)
Fig. 3-18 Assembly of Cylinder (1), Stainless Type
g. Put O-ring into top reducing plug.

h. Attach top reducing plug to cylinder pipe.
pipe
i. Tighten bottom plug and top reducing plug with pipe wrenches.
g) h) i)
Fig. 3-19 Assembly of Cylinder (2), Stainless Type
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(6)) How to Assemble Other Parts of Cylinder (Cast Iron Type)
15-2) Assemble check valve body.
a.. Assemble check valve with check valve seat.
b.. Place rubber seating and secure with seat retainer by spanner.
a) b)
Fig. 3-20 Assembly of Check Valve
16-2) Assemble the pump cylinder.

cylinder Prior to assembling, check cleanliness of cylinder liner
and all threads. And clean it and apply sealing fluid or grease on all of threads.
c.. Place first sealing ring into a lower reducer cap.

d.. Insert check valve into lower reducer cap, and place second sealing ring.
e. Attach thehe cylinder with liner to the lower reducer cup.
c) d) e)
Fig. 3-21 Assembly of Cylinder (1),

(1) Cast Iron Type
f. Insert plunger assembly into the cylinder pipe.

g.. Place third sealing ring and attach top reducer cup.
h. Tighten both reducer caps with pipe wrenches.
f) g) h)
Fig. 3-22 Assembly of Cylinder (2),

(2) Cast Iron Type
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(7) Preparation of Pump Head and Handle
Pump head with handle is already completed in manufacture.. Therefore, it is not necessary
to operate at initial installation.
17) Assemble bearing housing

a. Place first ball bearing to bearing mounting tool.
b. Insert mounting tool into bearing housing.
c. Insert spacer into bearing housing.
a) b) c)
Fig. 3-23
23 Assembly of Bearing Housing (1)
d. Place second ball bearing on bearing mounting tool.

e. Insert pressure plate on bearing mounting tool.
f. Add the hexagonal nut.
d) e) f)
Fig. 3-24
24 Assembly of Bearing Housing (2)
g. Tighten the nut of the bearing mounting tool g)

by two spanners, so that both ball bearing
are pushed into their end position.
If ball bearings are mounted, remove
bearing mounting tool.
Fig. 3-25 Assembly of Bearing Housing
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18) Assemble Pump Handle to Pump ump Head
a. Insert the pre-assembled sembled pump handle into the pump head assembly from front side, side
and place the ball bearings near the Axle bushes at the sides of the pump head.
b.. Knock the handle axle gently into the end position using by hammer with little oil for
smoothly.
c. Insert Axle xle washer and fasten one nut by hand.
a) b) c)
Fig. 3-26 Assembly of Pump Handle to Pump Head (1)
d.. If the pump handle is moving smoothly (up & down), secure the correct position by
second nut as a check nut.
d)
Fig. 3-27 Assembly

Assembl of Pump Handle to Pump Head (2)
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3.2 INSTALLATION OF BELOW GROUND COMPONENTS
(1) Installation of Cylinder and 1st Riser pipe
1) Take the first riser pipe with pump rod from the logs or pump stand, and place it
horizontally on the pump platform, and also pump cylinder.
2) Connect the pump rod to the plunger rod of the cylinder,

cylinder, and tighten it with spanner.
spanner
3)) Connect the riser pipe to the cylinder, and tighten riser pipe with reducer cap of the
cylinder with two pipe wrenches.
2-1) 2-2)
3-1) 3-2)
Fig. 3-28 Connecting 1st Pump Rod and Riser Pipe
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 approx. 50cm.
5) Put the pipe vice on the stand, and fasten the riser pipe in this position.
4) 5)
Fig.3-29 Installation of Cylinder and 1st Riser Pipe
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(2) Installation of Riser Pipe by Lifting Spanner
6) Take the second riser pipe with pump rod from the logs or pipe stand, and connect the
pump rods and tighten it with spanner, spanner at first.
7) Next, connect
onnect the riser pipes after it is applied sealing compound on thread at pipe end and
socket, tighten it with two pipe wrenches
8)) Hold riser pipe by two lifting spanner and then open and remove pipe vice.
6) 7
7) 8)
Fig.3-30
0 Installation of Riser Pipe using with Pipe Wrenches
9) Lower riser pipe into borehole using by two lifting spanner, until the riser pipe protrudes
the top face of the pump stand by approx. 30 to 50cm.
*Be careful to slip out riser pipe from lifting spanner and it will be fall down to borehole.
Lowering using by lifting spanner continue until the riser pipe will be too heavy
for handling by the lifting spanner. It could be 5 to 10 pipes.
However, if you afraid slipping out lowering riser pipe from lifting spanner, it is
recommend to lower it using chain block or pulley from beginning.
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(3) Installation of Riser Pipe by Chain Block or Pulley
10)) As soon as the riser pipe is too heavy for handling by the lifting spanners (5 to 10 pipes),
or from beginning, it will be use the chain block or pulley with tripod for lowering riser
pipes.
Fig.3-31 Installation of Riser Pipe by Chain Block
Fig.3-32 Installation of Riser Pipe by Pulley with Winch
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< Supplement for Setting Tripod ripod >
Supplied tripod in this project is consisted of tripod head and 3 pipes. Tripod head is used
product from TACOM company in Japan, as follows.
Fig.3-33
33 Tripod Head (TACOMAN company)
a) Arrange 3 steel pipes at an angle of 120 degrees each on ground (concrete platform).
b) Joint pipes to tripod head one by one,
one and tighten bolts and nuts.
a) b-1) b-2)
Fig.3-34 Setting Tripod (1)
c) Hold up tripod to personss standing height, and hang chain block on tripod head.
d) Stand tripod pipe up one by one, and arrange position of tripod center on handpump.
c) d--1) d-2)
Fig.3-35 Setting Tripod (2)
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11) Connect hoisting plug for pulling up by the chain block or pulley on tripod.
6) 7)
Fig.3-36 Connection of Hoisting Plug to Riser Pipe
12)) Lower riser pipe into borehole using with chain block or pulley until the riser pipe
protrudes the top face of the pump stand by approx. 30 to 50cm,, and fasten the riser pipe
in this position by pipe vice.
* Pipe vice always stay on pump stand, and it is fasten with stand by bolt and nut.
13) When it is tighten riser pipes using with two pipe wrenches, pipe wrench shall be hold at
part of pipe, not at socket.
14) When it is tighten pump rod by spanner, lower rod shall be hold by spanner or fasten rod
clamp.
12) 14)
Fig.3-37 Fastening of Pipe Vice on Stand Fig.3-38 Fastening of Rod Clamp on

for Tightening of Pipe Pipe for Tightening of Rod
15) Proceed in the same manner until the last pump rod and riser
er pipe is connected.
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(4) Installation of Water Tank
16)) At the end of the last riser pipe located in the 14) 15)
pipe vice, the water tank will be attached.
Therefore, take off the last socket at end of
last riser pipe, and re-apply apply sealing compound
to the pipe thread. In case using welded socket,
it shall be attached plug with both side female
thread.
17)) Screw the water tank onto the last pipe end
and tighten by hand. And hold
old water tank in
position by rope attached to hook of the chain
Fig.3-39 Installation off Water Tank (1)
block, and remove pipe vice from the pump
stand. And then, lower the water
water tank with riser pipe to the pump stand flange slowly.
18)) Turn the water tank so that the spout is positioning to the required direction
19)) Or, it is attached water tank onto the last pipe end in advance before installation of last
pipe, and connect hoisting plug onto water tank.
tank. And then pull up water tank with last
riser pipe, and install it into borehole.
Fig.3
Fig.3-40 Installation of Water Tank (2)
20)) Tighten it to the pump stand with bolts and nuts, and remove out hoisting plug.
Fig.3-41
41 Tightening water tank and stand
27

Mark II Handpump)
HAND
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3.3 INSTALLATION OF ABOVE GROUND COMPONENTS
(1) Adjustment of Pump Rod Length ength
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.
2) Mark the last pump rod by hacksaw at the top face of the water tank flange,
flange or measure
length of extra pump rod.. This position is exact length of pump rod.
1) 2-1) 2-2)
Fig.3-42 Cutting Position of Extra Length of Last Riser Pipe
3) Lift pump rod up at easy cutting position, and fasten with connecting rod vice on the top
flange of the water tank.
4)) Wrap around the marked rod by a clean piece of cloth, in order to prevent meta-shavings
meta or
oil from falling into the well (contamination). And then cut last of pump rod at the mark
position.
5) Remove sharp edge, and make a nice chamfer prior to threading.
3) 4) 5)
Fig.3-43 Cutting Extra Length of Last Riser Pipe
28

Mark II Handpump)
HAND
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6) Make thread (40mm long) on top part of rod by Bottom Die with a little oil. oil As soon as
thread is finished, remove cloth oth carefully and clean pump rod, vice and pump stand from
remaining oil and shavings.
7) Insert a middle flange into pump rod.

rod
8) Allow a middle flange to rest on top of connecting rod vice, and fix the nut on the newly
threaded top rod.
6) 7) 8)
Fig.3-44 Making Thread and Fixing Nut on Top Part of Rod
(2) Installation of Chain Assembly

9)) Screw the chain coupler on the connecting rod threads by hand.
10)) Tighten check nut of connecting rod with the chain coupler.
11) Insert the chain coupler supporting tool below the chain coupler. Hold the middle flange
and remove connecting rod vice.
9) 10) 11)
Fig.3-45 Connecting the Chain Coupler to Pipe rod
29

Mark II Handpump)
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12)) Carefully lower the middle flange to the top of water tank, and ensure that all four holes
coincide.
13) Hold the head assembly in position, and insert the chain through the hole in bottom
flange. Lower head on top of middle flange ensuring all four holes to coincide.
14)) Tighten head, middle flange and water tank with bolts and nuts.
12) 13) 14)
Fig.3-4
46 Installation of the Handle Assembly
15)) Lift handle up, and attach free end of the chain with high tensile bolt, washer and Nyloc
nut.
16) Tighten Nyloc nut.
17)) Lower the handle, and remove chain coupler supporting tool.
15) 16) 17)
Fig.3-47 Connecting the Chain Coupler to the Handle Assembly
30

Mark II Handpump)
H
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(3) Final Works of Pump Head Parts
18)) Lift handle up, and apply grease on the chain.
Make sure as follows.

a. The connecting rod moves up and down freely. If it does not, the rod has been bent.
Check the rod.
b. The chain coupler is fully engaged on the connecting rod, and the lock nut is tight.
c. The axle nut and lock nut on the handle are tight.
d. The handle axle is firm in place.
e. The Nyloc nut has been tightened securely with the chain anchor bolt.
f. All 4 flangess and 8 nuts (dabble nut) are tight.
g. Nothing has been left inside the pump head (tools, cloth etc.).
19) Fit the inspection cover.
20) Tighten the cover bolt.
18) 19) 20)
Fig.3-48 Final Works
21) Operate the handpump for first filling of the 21)

riser pipe. Depending on the cylinder setting
depth, the pump handle has to operate for
many strokes.
22) As soon as the water is flowing from the spout,

operate the pump for another 100 full stroke.
And then, check whether the water is clean
not (no oil or dirt) or not.
Fig.3-49 Completion
31

Mark II Handpump)
HAND
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(4) Fixing Tee-handlehandle and Counter Weight
Tee-handle
handle shall be attached on end of hand with counter weight depending on length of
riser pipes. Counterweight is used for helping of handpump operation of India Mark-II Mark Extra
Deepwell, because cylinder depth is deeper than India Mark-II Mark II and total weight of riser pipe
is heavy.
Tee-handle
handle and counter weight shall tighten by bolts and nuts, nuts, and together with washer at
Tee-handle is shaky.
Fig.3-50 Fixing T-Handle and Counter Weight
< Function of Counter weight >

It is sometimes found India Mark-II
Mark Deepwell handpump without Tee hand and counter
weight, because depth of India Mark-II
Mark is shallower than 45m. It is used India Mark-II
Mark Extra
Deepwell handpump for deeper dynamic water level, and number of steel raiser pipe is much
than India Mark-II.
Tee-handle and counter weight helps pumping to reduce handle operation force by law of
the lever.. A lever is a beam connected to ground by a hinge or pivot called a fulcrum. The
power into the lever equals the power out, and the ratio of output to input force is given by
the ratio of the distances from the fulcrum to the points of application of these forces.
In case handle is upward, it is overbalanced by weight of riser pipe.. In case handle is
downward, it is overbalanced by counterweight. Finally,
Finally, number of counterweight is i decided
by balance of handle and smooth operation by villager.
M1 : Weight of Riser pipe and

pump rod, water in pipe
M2Manpower
+ Tee-handle
Tee +
Counterweight
M1 x a = M2 x b M1: Input force (Resistance, Load) a : Distance between input force and the
t fulcrum
M1/M2 =b/a M2: Output force (Effort) b : Distance between output force and the fulcrum
Fig. 3-51 The Law of the Lever
32

Mark II Handpump)
4. DAILY OPERATION ANDA PREVENTIVE CHECK
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4.1 DAILY OPERATION
a. Keep clean handpump surrounding
b. Move up/down handle smoothly.

Do not move handle down/ up hardly.
Do not jump for moving handle down.
Do
o not shake handle by small stroke.
c. Inform to caretaker, if it will be found unusual thing.
4.2 PREVENTIVE CHECKS

Check sheet is attached on Annex-5.
Annex
(1) Weekly Checks and Maintenance

a. Check that the flange bolts and nuts are tight.
tight. If it is loosen, tight it by spanner.
spanner
b. Check that handle axle nuts. If it is loosen, tight it by spanner.
c.. Check that fastener or parts of handpump are not missing. If it is missing, replace the
parts.
d. Check whether any unusual noise during operation. If any unusual noise is noticed,
check reason and take action.
e. Check any other unusual thing informed from village user.
(2) Monthly Checks and Maintenance

a. Check that chain bolt and Nyloc
Nyloc nut are tight. If it is loosen, tight it by spanner.
b. Grease the chain.
(3) Leakage Test (Monthly)

Leakage test shall be conducted
ed monthly, as follows.
a. Operate the pump handle until water is flowing from the spout.
b. Stop operating the pump handle for approximately 30 minutes.
c. Operate the handle again, and count exactly how many strokes required until the water
is flowing.
If more than 5 full handle strokes are required to make the water flow again, it is
indication of leakage in the riser pipe or cylinder. And if more than 10 full handle strokes
stroke are
required, leakage is beyond an acceptable limit, it may be necessary to check riser pipe and
cylinder and to replace a rubber consumable.
33
Operation and Maintenance Manual (India

( Mark-II
II Handpump)
4. DAILY OPERATION AND PREVENTIVE CHECK
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(4) Discharge Test (Monthly)
Discharge test shall be conducted monthly, as follows.
a. Operate the pump handle until water flow has been continuously.
b. Then, measure water yield at 40 4 full strokes by bucket.
Iff it is difficult to measure water volume in 20 liter bucket, followingng way is easy.
c. Count strokes at filling up 20 0 liter bucket.
d.. Calculate water yield at 40 strokes,
strokes as follows.
(40) strokes for filling up 20 liter: 20L x 40 / (40) = 20L x 1.00 = 20.0 L per 40 strokes
(60) strokes for filling up 20
0 liter:
liter 20L x 40 / (60) = 20L x 0.67 = 13.3 L per 40 strokes
Table 4-1
1 Calculation of Discharge yield at 40 strokes with 20L Bucket
Strokes at 20 L Yield at 40 stroke Strokes at 20 L Yield at 40 stroke
40 20.0 L 72 11.1 L
45 17.8 L 74 10.8 L
50 16.0 L 76 10.5 L
55 14.5 L 78 10.3 L
60 13.3 L 80 10.0 L
62 12.9 L 82 9.8 L
64 12.5 L 84 9.5 L
66 12.1 L 86 9.3 L
68 11.8 L 88 9.1 L
70 11.4 L 90 8.9 L
Remarks: 20L x 40 / ( ) strokes at 20L = ( ) L at 40 strokes
Discharge of India Mark-II II Extra Deepwell Handpump is 12 litters for 40 full strokes. And
in case of less than 10 litters for 40 full strokes, there might be a problem with pump cylinder.
Discharge rate to time is not concerned with pump capacity, but 40 strokes are estimated
as average stroke per 1 minute by human power, although it is depending on operator and
depth of cylinder, dynamic water level. And this is one of record checking well conditions.
Therefore, measure time at filling
ing up 20 liter bucket additionally.
(60) seconds at filling up 20 liter: 20L x 60 / (60) = 20L x 1.00 = 20.0 L/min
(100) seconds at filling up 20 liter: 20L x 60 / (100) = 20L x 0.60 = 12.0 L/min
Table 4-2 Calculation of Discharge Rate with 20L Bucket

Seconds at 20 L Discharge at 1 min.
min Seconds at 20 L Discharge at 1 min.
min
60 20.0 L/min 105 11.4 L/min
65 18.5 L/min 110 10.9 L/min
70 17.1 L/min 115 10.4 L/min
75 16.0 L/min 120 10.0 L/min
80 15.0 L/min 125 9.6 L/min
85 14.1 L/min 130 9.2 L/min
90 13.3 L/min 135 8.9 L/min
95 12.6 L/min 140 8.6 L/min
100 12.0 L/min 145 8.3 L/min
Remarks: 20 L x 60 / ( ) seconds at 20L = ( ) L/min
34

Mark II Handpump)
4. DAILY OPERATION ANDA PREVENTIVE CHECK
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(5) Yearly Replacements
a. Dismantle handle assembly and check ball bearing.
b. Rise up all of riser pipe and cylinder and dismantle cylinder for checking.
c. Replace rubber seating, cup seals, sealing rings and ball bearing.
*If one of the replaced components is still in good shape, spare it for emergency
replacement (in case a new spare part is not immediately available.)
The fast moving spare parts for India Mark II Handpump are bellows.
Table 4-3 Spare Parts List for India Mark-II

Mark Handpump
Parts Item Place to use Qty
Regular Multi-purpose
purpose Grease Chain assembly 1 can
Maintenance Sealing Compound *1 Riser pipe connections 1 pc
Hexagonal bolt (M12 x 40mm) Pump head, Water tank 8 pcs
Head Hexagonal nut ( M12) Pump head, Water tank 16 pcs
Assembly Hexagonal bolt (M12 x 20mm) Pump head cover 1 pc
Washer (to suit M12 bolt) Pump head cover 1 pc
Hexagonal bolt (M10 x 40mm) Chain assembly 1 pc
Hexagonal lock nut (M10, Nyloc) Chain assembly 1 pc
Handle Hexagonal nut ( M12) Handle axle 2 pcs
Assembly Washer (to suit M12 bolt, C2334) Handle axle 1 pc
Spacer (C2332) Bearing house 1 pc
Ball bearing (C1035) Bearing house 2 pcs
Cup seal (C2359) Plunger assembly 3 pcs*2
Rubber seating small Plunger assembly 1 pc
Cylinder
Rubber seating big Check valve assembly 1 pc
parts
O-ring (50mm) *3 Reducer cap, Check valve assembly 2 pcs
Sealing ring *4 Reducer cap,, Check valve assembly 3 pcs
*1 If no sealing compound, it is available hemp fibers with grease.
*2 In case of Extra deepwell type for deeper water level which is installed in this project, cup seals
are 3 pcs. In case of normal type for shallower water level, it are 2 pcs.
*3 In case of stainless cylinder which is installed in this project, O-ring
O ring is used for reducer cap and
check valve assembly.
*4 In case of Cast-Iron
Iron cylinder for normal type, sealing ring is used for both reducer caps and Check
Valve assembly.
35

Mark II Handpump)
4. DAILY OPERATION AND PREVENTIVE CHECK
-----------------------------------------------------------------------------------------------------------------
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-----------------------
4.3 TROUBLE SHOOTING
Trouble shooting is shown as table.
Table 4-4 Trouble Shooting of Hand Pump Function

Problem Operation Cause Measure
Join disconnected rod, or replace
Pumprods are disconnected
broken or corroded rods.
Handle operation is Chain are broken Replace chain
easy Check function of check valve in
Check valve is jammed (not closing) cylinder and make needed
replacements.
No water
Cup seal is defect (worn) Replace cup seal in cylinder
Handle operation is
Water level dropped below cylinder Add more riser pipe and pump rods
normal
Borehole is clocked (silt or sand) Rehabilitation of borehole
Handle operation is
Riser pipe is disconnected Repair/ replace pipes
difficult
Check leakage by leakage test. If
Leaking from check valve leakage, check Check valve and
replace seating rubber
Sealing ring are worn Check sealing ring of cylinder, and
Handle operation is
Delayed flow (In case of Cast-Iron cylinder) replace it
normal
Check cup-seals
seals of plunger, and
of water Cup-seals are worn
replace it
Leakage in pipe joints or rising
Repair/ replace pipes
main pipe is perforated
Handle operation is
Cup seal is too tight Replace with weal of correct size
difficult
Check size of plunger and cylinder,
Folding of Plunger jammed inside cylinder and replace wrong or defective
Handle operation is
chain during components
inconvenient
down-stroke Top rod too long, plunger is sitting Check correct length of pump rod
on top of the check valve assembly, and trace top rod
Straighten or replace bent
Pump rod are touching riser pipes
Abnormal pumprods
Handle operation is
noise during Lack of grease on chain Grease chain
inconvenient
operation
Ball bearings are worn, Check and replace ball bearing
Ball bearings are worn Check and replace ball bearing
Spacer is worn or damaged Check and replace spacer
Handle is shaky
Bearings loose in bearing house Repair or replace handle assembly
when operated
Pump handle Handle axle nuts are loosen Check and tighten nuts fully
shaky
Handle axle is worn or damaged Check and replace handle axle
Pump head is Tighten all bolts and nuts of the
Flanges are loose
shaking flanges
Pumpstand is
Pump platform is cracked Repair pump platform
shaking
36

Mark II Handpump)
5. MAINTENANCE AND REPAIR
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5.1 MAINTENANCE OF ABOVE GROUND COMPORNENTS
(1) Check / Maintenance Chain Assembly
1) Loosen pump head cover bolt,, and remove pump head cover.
2)) Supply grease to the chain by hand, regularly.
1-1) 1
1-2) 2)
Fig. 5-1
1 Open Head Cover and Supply Grease to the Chain
(2) Remove out / Replace of Chain Assembly

3)) Lower pump handle, and put chain supporting tool below the chain assembly.
4) Lift
ft up the pump handle to top position, and then loosen Nyloc nut by two open-ended
open
spanners.
5) Remove the Nyloc nut anchor bolt and pull out chain from the handle.
3) 4) 5)
Fig. 5-2
2 Remove out Chain Assembly from Handle Assembly
37

Mark II Handpump)
REPA
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6) Loosen and remove bolts and nuts connecting pump-head pump and water tank
7)) Lift and remove head assembly. The chain will go through hole in the bottom flange.
6) 7)
Fig. 5-3
5 Remove out Pump Head
8) Turn flange to 90, and lift connecting rod by holding middle flange and insert connecting
rod vice. Place rod vice on top flange of water tank, tighten it.
9) Remove out the chain support tool at first, and then loosen and remove the chain assembly
from top rod.
8) 9)
Fig. 5-4 Remove out the Chain Assembly from Pump rod
10) Leave
eave the middle flange for resting on the rod vice.
vice
11) In case of problem by chain, attach new the chain assembly as spare parts.
38

Mark II Handpump)
REPA
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(3) Remove out Handle for Maintenance of Bearing
It is not necessary to remove out handle for maintenance of riser pipe or cylinder. cylinder In case
of maintenance of ball bearing,, it shall be removed out handle from pump head, head after above
step 5). These works will do without remove out bolts and nuts between pump head and
water tank.
12) Remove out two nuts and washer from handle axle.
13)) Protect thread of handle axle by handle axle punch, and knock the handle axle punch by
hammer for removing handle axle out. It shall be lubricate little oil on handle axle for
smooth removing out.
14)) Pull handle out from front side of pump head.
13-1) 13-2) 14)
Fig. 5-5
5 Remove out Handle Assembly
(4) Maintenance of Ball Bearing

15) After remove out handle, it shall be put on flat place such as on table or platform.
16) In case of supply grease in ball bearing, add grease into space between two bearings from
hole of bearing by finger.
15) 16)
Fig. 5-6
6 Maintenance of Ball Bearing without Removal
39

Mark II Handpump)
REPA
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17)) In case of replacing bearing, move spacer from center to one side in bearing house by
finger.
18) Insert minus drive

ve from hole of one bearing diagonally, and then push out one ball
bearing by tapping with minus driver and hammer,
hammer, gently and changing position.
19) Remove out spacer by finger.
17) 18) 19)
Spacer
Fig. 5-7
7 Remove out a Ball Bearing and Spacer
20)) Push out other ball bearing by tapping with minus drive and hammer.
21)) Before return back used bearing or replace new bearing, apply grease on bearing.
22) The bearings

earings shall be set in bearing house, following process of preparation
20) 21)
Fig. 5-8
8 Remove out another Bearing and Maintenance
40

Mark II Handpump)
REPA
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5.2 MAINTENANCE OF BELOW GROUND COMPORNENTS
(1) Remove out Water Tank
1)) Unscrew check nut, and remove middle flange.
2) Attach the rod lifter (in clockwise direction), and hold the rod lifter firmly. And
A then open
rod vice and remove it.
3)) Gently, lower the pump rod assembly until it sits on top of check valve, and unscrew the
rod lifter.
1) 2) 3)
Fig.
Fig.5-9 Lowering Pipe rod Assembly
4) Remove all bolts and nuts between water tank and pump stand.
5)) Lift the water tank upwards (about 50 cm) by chain block or pulley with tripod,
tripod and insert
and fasten pipe vice.
6)) Unscrew water tank by turning the spout by hand. If riser pipe is hard fixation, it will be
use pipe wrench.
4) 6)
Fig. 5-10 Remove out Water Tank
41

Mark II Handpump)
REPA
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(2) Remove out Riser Pipe ipe and Cylinder
7) Attach socket on the top of riser pipe, and connect hoisting plug. plug
8) Operate
perate chain block until the chain is tight,
tight and
nd open the pipe vice slowly and remove it.
And lift the riser pipes with pump rod and cylinder upward until the next pipe socket is
about 30 to 50cm above the top flange of pump stand.
7) 8)
Fig. 5-11 Remove out Riser Pipe Assembly with Cylinder (1)
9)) Hold riser pipe by pipe vice on the pipe stand, and open the protruding riser pipe by two
wrenches.
10)) Lift up the unscrewed riser pipe by hand,

hand, and unscrew the pumprod connection.
11) Place disconnected riser pipe and pumprod on clean place.
9) 10) 11)
Fig. 5-12
12 Remove out Riser Pipe Assembly with Cylinder (2)
42

Mark II Handpump)
REPA
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12)) Connect hoisting plug to remaining riser pipe, and continue these process, until the whole
riser pipe, pumprod and cylinder are retrieved.
13)) In case riser pipe is no so heavy, it is possible lift it up by the lifting spanner easily.
14)) Remove last riser pipe from the cylinder, and disconnect last pumprod from plunger rod.
12) 13) 14)
Fig. 5-13
13 Remove out Riser Pipe Assembly with Cylinder (3)
(3) Dismantlement of the Cylinder Assembly

15)) Open both caps from the cylinder by two pipe wrench, and remove plunger and check
valve.
Fig. 5-14
5 Open Cylinder Assembly
43

Mark II Handpump)
R
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16) Check and replace rubber consumable parts.
17)
7) Replace each rubber consumable (Cup seals and rubber seatings).
17-1)
Fig. 5-15
15 Cylinder Assembly (Stainless Steel, Extra Deepwell Type)
17-2)
Fig. 5-16
16 Cylinder Assembly (Cast Iron, Extra Deepwell Type)
18) After check / replace rubber consumable, install cylinder and riser pipe following
Installation process mentioned above.
44

Mark II Handpump)
R
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(4) Supplement of Check Valve
The check valve assembly which is consist of check valve and bottom plug (Fig. 5-15), is
attached at bottom of stainless cylinder. And the check valve is moving up and down in
bottom plug, and then water comes enter into the cylinder. The he check valve is consist of upper
part and lower part with seating rubber lain between upper part and lower part (Fig. 5-16).
Check Valve Assembly Check Valve Bottom Plug

Fig. 5-17 Check Valve Assembly of Stailness Cylinder
Upper Part Lower Part Seating Rubber

Fig. 5-18 Check Valve
The check valve is moving up and down in bottom plug during pumping up u water, and if
thread of check valve is loose tighten, check valve of stainless cylinder will be fall down into
borehole, because check valve is supported only upper part on bottom plug and lower part is
hang down from upper part. In case of Cast Iron cylinder, check valve assembly is support on
reducer cup, therefore check valve is not fall down, even if thread will be loose.
Check Valve Assembly on Check Valve Assembly Reducer Cup

Reducer Cup
Fig. 5-19 Check Valve Assembly of Cast Iron Cylinder
45

Mark II Handpump)
REPA
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When stainless cylinder is shipping from manufacture,
thread of check valve might be locked ocked with biting on thread
head (Fig. 5.18).. In case of first installation of stainless
cylinder, do not dismantle check valve.
However, when seating rubber will be replaced to new one,

it shall be dismantle the check valve assembly. The check
valve is free moving from bottom plug, and
a lower part of check
valve is hided in bottom plug, and then it is difficult to hold Fig. 5-20 Locked thread of
lower part by supper or driver to be stick into lower
lo part check valve
(Fig.5-19).
Fig. 5-21
21 Holding lower part of check valve
It is introduced stopper for lower part of check valve as additional tools which hold lower
part of check valve by four fingers from bottom plug.
Fig. 5-22
5 Check Valve Stopper
When it will be assemble check valve again, apply

hemp fibers with grease to thread of check valve, and
then tighten check valve by spanner, holding check valve
with stopper.
Fig. 5-23 Application of hemp

fiver to thread of check valve
46

(Afridev
Afridev Handpump, India Mark-II
Mark Handpumps)
ANNEX
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Annex-1 1 Check Sheet of Handpump Maintenance
Table -1
1 Check Sheet of Handpump Maintenance (1)
(1) General
District : Village :
Borehole No. : Sub-village
Type of handpump : Num. of inner rod : Pcs
(2) Discharge Test

Strokes for 20L bucket Strokes Time for 20L bucket : Second
Discharge at 40 strokes : 20 L x 40 / ( ) strokes = ( ) L per 40 strokes
Discharge at 1 minute 20 L x 60 / ( ) seconds = ( ) L / min
*Measuring water is after water flowing out completely.
*If discharge is less than 10 litters for 40 full strokes, it shall be checked bobbin or U-seal
U of plunger.
(3) Leakage Test

Strokes until Waiting time after
: Strokes : Minutes
water is flowing former operation
*Stop operating handpump after water flowing out from spout, for approximately 30 minutes.
*If more than 5 full handle strokes required water flowing again, it shall be checked bobbin or O-ring
ring of foot valve.
(4) Any Other Conditions

Water condition Clean with slightly color with turbidity with sand
Handle operation Smooth Heavy Light
Noise at operation : Nothing A few noise Noisy
Shaking at operation : Nothing Shaking (Handle, Head, Stand)
Other observation :
(5) Maintenance & Repairing
Confirmation of Caretaker
No Name Signature Date
A-1

(Afridev Handpump, India Mark-II
Mark Handpumps)
ANNEX
----------------------------------------------------------------------------------------------------------------------------------------
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Table -2 2 Check Sheet of Handpump Maintenance (2)
District : Village :
Borehole No. : Type :
Name /
No. Date Item Description
Signature
1 Discharge test 20 L / ( ) strokes /40 = ( ) L per 40 strokes
Leakage test ( ) stroke after ( ) minutes stopping
Water condition Clean Slightly color Turbidity with sand
Handle operation Smooth Not smooth
Noise Nothing Noisy
Shaking Nothing Shaking
Other
observation

Water condition Clean Slightly color turbidity with sand
Noise Nothing Noisy
Other
observation

Noise Nothing Noisy
Other
observation

Noise Nothing Noisy
Other
observation
A-2

Mark Handpumps)
ANNEX
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Annex-2. 2. Contact Information of Maintenance Service
Contact information of maintenance service and parts shop is shown as follows.
Table -3
3 Contact Information of Maintenance Service
1) Contractor (until 1 year after handing over)

Name : KONOIKE Construction Co., Ltd
Address : P.O.Box 31224 Dar es Salaam, Tanzania
Tel : 022-2700308~10
2700308~10
Attention: Contact person in Tabora (Maintenance Staff for Level-1)

Level
Name : Mr. Selestine Shironga
Address : Tabora, Tanzania
Contact : 0757-182222,
182222, 0654-372686
0654 (Mob), sshironga@yahoo.com
2) Maintenance Service and Parts Shop

Name : CBRC Community Based Resource Centre Shinyanga
Address : Ushirika Area P.O. 1200, Shiyanga, Tanzania
Tel : 028-2763279
E-mail : cbrc@africaonline.co.tz
Contact-1 : Mr. Audifas Lyaku Matina (Chairperson)
: 0786-6200048(Mob),
6200048(Mob), audifaslyakumatina@yahoo.com
Contact-2 : Mr. Ramadhani Chambulilo (Operations Manager)
: 0784-711961
711961 (Mob), rchambulilo@yahoo.com
Contact-3 : Mr. Rajabu Amri Ally (Chief Technician)
: 0767-891076
891076 (Mob), rajabamri12@gmail.com
3) Parts Shop
Name : Davis & Shirtliff
Address : P.O.Box 2877 Mwanza, Tanzania
Tel : 028-2541971/2
E-mail : www.davisandshirtliff.com
Contact : Mr. Ellison Malyi (Branch Manger)
: 0754-318827
318827 (Mob), Ellison.Malyi@dayliff.com
A-3

Mark Handpumps)
ANNEX
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Annex-3 Price List for Handpump Parts
(1) Price List for India Mark-II Handpump Parts
Price list for India Mark-II handpump parts is shown on following table.
Table-4 Price List for India Mark-II Handpump Parts

Qty
Unit price
No. Description of Parts Maker (Min. Supplier
(Tshs)
Order)
India Mark-II
II Deepwell Handpump with 1 1/4
1/4 Daivis &
1 AJAY 1 set
GI Pipes & SS rod (60m) and CI cylinder Shirtliff,
India Mark-II
II Deepwell Handpump with 1 1/4
1/4
2 1 set CBRC,
GI Pipes & SS rod (60m), CI cylinder
Shinyanga
3 India Mark-II CI cylinder
4 Cup washer (seal) 1 pc
5 Rubber seating big 1 pc
6 Rubber seating small 1 pc
7 O-ring
ring (50mm) for SS cylinder 1 pc
8 Ball bearing 1 pc
9 Hex bolt, Hex nut 1 set CBRC,
Chain with coupling, High tensile bolt, Shinyanga
10 1 set
Nyloc nut
11 Handle axle, Washer for handle axle 1 set
12 Spacer 1 pc
13 Bolt of front cover 1 pc
14 Hex coupling (rod) 1 pc
15 Standard Spare Parts Kit AJAY 1 set
a) Hex bolts 8pcs, b) Hex nuts 18pcs,
c) High tensile bolt 1pc, d) Nyloc nut 2pcs
e) Handle axle 1pc,
f) Washer for handle axle 1pc
g) Ball bearing 2pcs, h) spacer 1pc Daivis &
i) Chain with coupling 1 pc Shirtliff,
j) Botl for front cover 1pc, k)Cup washers 4pcs,
l) Sealing ring *, m) Rubber seating big 2pcs, Mwanza/
n)Rubber seating small, Dar es
o) Hex coupling (rod) 2pcs Salaam
p) GI Pipe socket 32mm NB*
*It is not used for SS cylinder
*O-ring
ring for SS cylinder is not included
16 India Mark-II II Standard Tools AJAY 1 set
17 India Mark-II Special Tools AJAY 1 set
18 Multi-purpose Grease 1 pc Tabora,
19 Lubricant oil 1 pc Nzega
20 Sealing compound 1 pc Mwanza
A-4

(Afridev Handpump,
Handpump India Mark-II Handpumps)
ANNEX
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
(2) Price List for Afridev Handpump Parts
Price list for Afridev handpump parts is shown on following table.
Table-5 Price List for Afridev Handpump Parts

Qty
Unit price
No. Description of Parts Maker (Min. Supplier
(Tshs)
Order)
Afridev Handpump with 2 PVC pipe, SS rod Daivis &
1 AJAY 1 set 3,015,000
(45m), Plastic Plunger, Plastic foot valve Shirtliff,
Afridev Handpump with 2 PVC pipe, GI rod CBRC,
2 1 set 1,900,000
(45m),, ****Plunger, **** foot valve Shinyanga
3 Afridev Cylinder, **** plunger, **** foot valve 1 pc
4 U seal for plastic planger 1 pc
5 U seal for brass planger 1 pc
6 O ring for plastic foot valve 1 pc
7 Bobbin 1 pc
CBRC,
8 Plastic Bush Bearing 4pcs/set 1 set
Shinyanga
9 Hanger pin assembly 1 no
10 Fulcrum pin 1 pc
11 Rod centralizer 1 pc
12 Pipe centralizer 1 pc
13
14 Standard Spare Parts Kit 1 set 20,000
Daivis &
a) U seal for plastic plunger* 2pcs,
Shirtliff,
b) O ring for plastic foot valve 2pcs,
c) Bobbin 2pcs
Mwanza/
d) Plastic Bush Bearing 4 pcs
Dar es
*It is not used for blas plunger, U seal for AJAY
Salaam
brass plunger is not included
15 Socket spanner 1 pc
16 Open end spanner 1 pc
17 Fishing Tools 1 pc
18 Solvent Cement 1 pc Tabora,
19 Cleaning Fluid 1 pc Mwanza
A-5

(Afridev
Mark Handpumps)
ANNEX
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
Annex-4 4 Price List for Handpump Repair in Village
Price of repair in the village by maintenance service (CBRC Shinyanga) is as follows
Table-6 Price of Miner Maintenance in the Village near Nzega Town

Unit
Amount
No. Description Detail price Qty Unit Remarks
(Tshs)
(Tshs)
person/
Supervisor
Supervisor-I 100,000 1 100,000 Working day
Staff Wage, day
1
allowance person/ No work day
Supervisor
Supervisor-II 80,000 0 0
day (only transport)
2 Consumable 10,000 1 unit 10,000
On above Price
O
3 Spare Parts - - - -
list
Transport of
4 - - - - Actual expense
Material
person/
5 Accommodation 20,000 0 0
day
6 Overhead 40 % 44,000
Moto
2,000 2 way 4,000
(in SHY)
Bus 8,000 16,000
2 way
Transport of (SHY~NZG) ~10,000 ~20,000
7 Actual Expense
person Bus
5,000 2 way 10,000
(NZG~village)
Moto-Taxi
Taxi (in 10,000 person/ 10,000
1
village) ~30,000 day ~30,000
Total 194,000
~218,000
*1 In case of miner works which it is possible 1 supervisor from maintenance service for few
hours.
*2 In case of half day transport from Shinyanga,
Shinyanga, where it is possible daily trip such like villages
near Nzega town. Price of transport will be changed depending actual expense.
*3 Caretaker shall always work for maintenance and repair and assist supervisor from
maintenance service.
*4 Tools and spare parts,, materials shall be provided by COWSO or order to maintenance service
following price list. In case big material is necessary,, it will be charged transport of materials.
Consumable on above list is included miner rubber consumable or lubricant oil or so on.
*5 Overhead is charged to price except transport of person.
*6 Transport fee is actual expense depending on traffic.
*7 Price shall be confirmed maintenance service finally, it will be changed.
*8 It is recommended that Caretaker of COWSO will follow miner maintenance by themselves,
without maintenance service.
A-6

Mark Handpumps)
ANNEX
----------------------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------------------
Table-7
7 Price of Miner Maintenance in the Village other than villages near Nzega Town
Unit
Amount
(Tshs)
(Tshs)
person/
Supervisor
Staff Wage, day
1
allowance person/ No work day
Supervisor
Supervisor-II 80,000 1 80,000
On above Price
O
list
Transport of
Material
person/
5 Accommodation 20,000 1 20,000
day
6 Overhead 40 % 84,000
Moto
2,000 2 way 4,000
(in SHY)
Bus
8,000 16,000
(SHY~NZG
(SHY~NZG, 2 way
Transport of ~10,000 ~20,000
7 TBR) Actual Expense
person
Bus (NZG,, 8,000 16,000
2 way
TBR~village)
~village) ~10,000 ~20,000
Moto-Taxi
1
village) ~30,000 day ~30,000
Total 340,000
~368,000
*1 In case of miner works which it is possible 1 supervisor from maintenance service for few
hours.
*2 In case of whole day transport from Shinyanga and return back with accommodation,
accommodation such like
villages other than villages near ar Nzega town. Price of transport will be changed depending
actual expense.
*4 Tools and spare parts, materials shall be provided by COWSO or order to maintenance service
*6 Transport fee is actual expense depending on traffic.
*7 Price
rice shall be confirmed maintenance service finally, it will be changed.
*8 It is recommended that Caretaker of COWSO will follow miner maintenance by themselves,
without maintenance service.
A-7

Ma Handpumps)
ANNEX
-----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------------------
Table-8 Price of Repairing for Afridev in the Village

Unit
Amount
(Tshs)
(Tshs)
person/
Supervisor
day
person/ No work day
Supervisor
Staff Wage, day (only transport)
1
allowance person/
Facilitator
Facilitator-I 80,000 1 80,000 Working day
day
person/ No work day
Facilitator
Facilitator-II 60,000 2 120,000
On above Price
O
list
Transport of
Material
person/
day
6 Overhead 40 % 224,000
Moto
2,000 4 way 8,000
(in SHY)
Bus
8,000 32,000
(SHY~NZG, 4 way
Transport of ~16,000 ~64,000
person
Bus (NZG, 8,000 32,000
4 way
TBR~village) ~16,000 ~64,000
Moto-Taxi
4
village) ~30,000 day ~120,000
Total 896,000
~1,040,000
*1 In case of repairing works which it is possible 1 supervisor and 1 facilitator from maintenance
service for 1 day.
villages other than villages near Nzega town. Price of transport will be changed depending
actual expense.
*6 Transport fee is actual expense depending on traffic. In case many staff from maintenance
service, hiring car might be cheaper than public transport and it might be reduce educe staff wage
for transport day, and it is easy transport of tools and materials.
*8 It is recommended that Caretaker of COWSO will work well so that it is possible to reduce 1
facilitator and his cost.
A-8

Mark Handpump)
ANNEX
-----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------------------
Table-9
9 Price of Repairing for India Mark-II
Mark in the Village
Unit
Amount
(Tshs)
(Tshs)
person/
Supervisor
day
person/ No work day
Supervisor
Staff Wage, day (only transport)
1
allowance person/
Facilitator
Facilitator-I 80,000 2 160,000 Working day
day
person/ No work day
Facilitator
Facilitator-II 60,000 4 240,000
On above Price
O
list
Transport of
Material
person/
day
6 Overhead 40 % 320,000
Moto
2,000 6 way 12,000
(in SHY)
Bus
8,000 48,000
(SHY~NZG, 6 way
Transport of ~16,000 ~96,000
person
Bus (NZG, 8,000 48,000
6 way
TBR~village) ~16,000 ~96,000
Moto-Taxi
6
village) ~30,000 day ~180,000
Total 1,288,000
~1,504,000
*1 In case of repairing works which it is possible 1 supervisor and 1 facilitator from maintenance
service for 1 day.
villages other than villages near Nzega town. Price of transport will be changed dependingdep
actual expense.
*6 Transport fee is actual expense depending on traffic. In case many staff from maintenance
service, hiring car might be cheaper than public transport and it might be reduce educe staff wage
for transport day, and it is easy transport of tools and materials.
*8 It is required that Caretaker of COWSO will work well so that it is possible to reduce 1
facilitator and his cost.
A-9

Mark Handpumps)
ANNEX
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
Annex-5 Contact Information of Region and District
Contact information of Engineer and staff of water and sanitation department in Regional
office and each districts water office are shown as follows.
Table-3 Contact Information of Region and Municipal / District

Region,
Municipal/ Position Name Tel E-mail
District
Tabora region
Water Engineer
Tabora
Technician
municipal
Water Engineer
Uyui district
Technician
(Tabora Rural)
Water Engineer
Urambo district Technician
Water Engineer
Kaliua district
Technician
(Urambo)
Water Engineer
Sikonge district Technician
Water Engineer
Igunga district Technician
Water Engineer
Nzega district Technician
A-10

Mark Handpumps)
ANNEX
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
Annex-6 Contact Information of Attendants to 2nd guidance
Contact information of attendants to 2nd guidance is as follows.
Table-4 Contact Information of Attendants to 2nd Guidance (1)

Organization Position Name Tel
1) Regional Office
2) Tabora Municipal
Municipal office
Kalumwa village
Misha village
3) Uyui District
District office
Mpumbuli village
Mabama village
Ufuluma village
Lutende village
4) Urambo District
District office
Imalamakoye village
5) Kaliua District
District office
Nsungwa village
Usonga village
6) Sikonge District
District office
Mpombwe village
Kasandalala village
Usunga village
A-11

(Afridev
Mark Handpumps)
ANNEX
-----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------------------
Table-5 Contact Information of Attendants to 2nd Guidance (2)

Organization Position Name Tel
7) Nzega District
District office
Makomelo village
Kitangili village
Wela village
Idala village
Kagongwa village
Shigamba village
Uduka village
Usongwanhala village
Shila village
Isanzu village
Mhembe village
Kilino-A village
Chabutwa village
Wita village
Itima village
8) Igunga District
District Office
Busomeke village
Kalemela village
Chapela village
Tambelale village
A-12

OJT Manual India Mark-II Rev-2

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The Project of Rural Water Supply in Tabora Region

The United Republic of TANZANIA

Operation and Maintenance Manual

Earth System Science Co., Ltd.

KONOIKE Construction Co., Ltd

Operation and Maintenance Manual (India Mark-II Handpump)

4. Daily Operation and Preventive Check

Operation and Maintenance Manual (India Mark-II

5. Maintenance and Repair

< ANNEX >

Annex-1 Check Sheet of Handpump Maintenance -------------------------------------- -- A-1

Operation and Maintenance Manual (India Mark-II Handpump)

1.2 INTRODUCTION OF HANDPUMP

Table 1-2 Summary of Specification of Selected Handpump

Installation depth Maximum

Manufacture of handpump is as follows.

Operation and Maintenance Manual (India Mark-II

*SKAT: An independent Swiss organization working in the field of development and

*RWSN: It is stand for Rural Water Supply Network,

2) India Mark Handpump Specification, Revision

4) Ajay India Mark-II Handpump Installation

5) Wikipedia: Lever (https://en.wikipedia.org/wiki/Lever

Operation and Maintenance Manual (India Mark-II

1) Geophysical Survey 2) Drilling Works 3) Pumping Test

4) Water Quality Analysis 5) Concrete Works 6) Pump Installation

Operation and Maintenance Manual (India Mark-II

Fig.2-1 Structure of India Mark-II Extra Deepwell Handpump (General)

Operation and Maintenance Manual (India Mark-II

Fig.2-2 Structure of India Mark-II

Operation and Maintenance Manual (India Mark-II

Pump Stand Water Tank Pump head and Handle

T-Handle Counter weight 100mm Hex.bolt with nut

Inside of Pump Head Chain with coupling Handle

Handle Axle Bearing Spacer

Fig. 2-3 Assembly of Above Ground Components

Operation and Maintenance Manual (India Mark-II

Cylinder Assembly Cylinder Assembly Liner Body of Cylinder

Check Valve Assembly Check Valve Assembly Top Reducing

Plunger Assembly Plunger Assembly Cup Seal / Cup Washer

Rubber Sealing Big Rubber Sealing Small O-Ring

Operation and Maintenance Manual (India Mark-II

Cylinder Assembly Cylinder Assembly Liner Body of Cylinder

Check Valve Assembly Check Valve Assembly Reducer Cap

Plunger Assembly Plunger Assembly Cup Seal / Cup Washer

Big Seating Ring Rubber Seating Small Rubber Sealing

Operation and Maintenance Manual (India Mark-II

Riser pipe (welded socket part) Riser pipe (thread part)

Socket of riser pipe Plug of riser pipe

Pump rod Pump rod Hexagonal Coupler

Operation and Maintenance Manual (India Mark-II

Tripod Tripod Chain Block

Nylon Sling Hoisting Plug with Swivel

Operation and Maintenance Manual (India Mark-II

Connecting Rod Clamp Rod Coupling Spanner Connecting Rod Lifter

Handle Axle Punch Crank Spanner Chain Coupler Supporting Tool

Bearing Pressing Tool Tool Box

Operation and Maintenance Manual (India Mark-II

Standard Tools Kit Bottom Die Thread Tap

Pipe Wrench 600mm Pipe Wrench 450mm Open Jaw Spanner

Screw Driver Adjustable Spanner Ball Pin Hammer

Hacksaw Flat File Wire Brush

Operation and Maintenance Manual (India Mark-II

Spirit Level 32mm Die with Handle Tool Box