India Mark Ii Tank Replacement Repair Guide

Difficulty

Moderate

Steps

Time Required

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Sections

Access Door
3 steps
Chain
8 steps
Head
4 steps
Chain
6 steps
Head Flange
4 steps
Tank
13 steps

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Introduction

What you need

Step 1

              Access Door

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.

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.

1024

Step 2

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

Step 3

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.

Step 4

              Chain

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.

Step 5

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.

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.

Step 6

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.

Step 7

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

Hold the wrench on the bolt stationary.

Loosen the nut.

Step 8

Remove the nut from the chain bolt.

Remove the nut from the chain bolt.

Step 9

Remove the washer from the chain bolt.

Remove the washer from the chain bolt.

Step 10

Remove the chain bolt.

Remove the chain bolt.

Step 11

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

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

Step 12

              Head

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.

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.

Step 13

Remove the two bolts and nuts from the handle side.

Remove the two bolts and nuts from the handle side.

Step 14

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.

Step 15

Lift and remove the pump head from the pump.
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.

Step 16

              Chain

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.

Step 17

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

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

Step 18

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.

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.

Step 19

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.

Step 20

Lower the head flange.

Lower the head flange.

Step 21

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.

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.

Step 22

              Head Flange

Remove the chain support from around the pump rod.

Remove the chain support from around the pump rod.

Step 23

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

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

Step 24

Remove the head flange.

Remove the head flange.

Step 25

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

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

Step 26

              Tank

Screw a T-handle onto the top of the pump rod. Tighten the T-handle up against the jam nut.

Screw a T-handle onto the top of the pump rod. Tighten the T-handle up against the jam nut.

Step 27

Loosen the rod vise.

Loosen the rod vise.

Step 28

Remove the rod vise from the tank.

Remove the rod vise from the tank.

Step 29

Remove the four bolts connecting the tank to the top flange.
Use one wrench on the bolt and a second wrench on the nut beneath. Hold the bolt still and loosen the nut.

Remove the four bolts connecting the tank to the top flange.

Use one wrench on the bolt and a second wrench on the nut beneath. Hold the bolt still and loosen the nut.

Step 30

Twist the tank 45 degrees in order to get a better grasp on it.

Twist the tank 45 degrees in order to get a better grasp on it.

Step 31

Lift the tank straight up, about one foot.
The tank is attached to the riser main, and the two must be lifted as a unit. Be careful and get help, as this can be very heavy.

Lift the tank straight up, about one foot.

The tank is attached to the riser main, and the two must be lifted as a unit. Be careful and get help, as this can be very heavy.

Step 32

Have a third person place the pipe vise around the riser main, on top of the top flange.
Tighten the pipe vise securely around the riser main.

Have a third person place the pipe vise around the riser main, on top of the top flange.

Tighten the pipe vise securely around the riser main.

Step 33

Secure the pipe vise to the top flange with two bolts and nuts to hold the pipe vise in place.

Secure the pipe vise to the top flange with two bolts and nuts to hold the pipe vise in place.

Step 34

Unscrew the tank from the riser main.

Unscrew the tank from the riser main.

Step 35

Lift the tank up a few inches above the top of the riser main.

Lift the tank up a few inches above the top of the riser main.

Step 36

Insert the rod vise between the riser main and the tank, around the pump rod.
Tighten the rod vise onto the pump rod.

Insert the rod vise between the riser main and the tank, around the pump rod.

Tighten the rod vise onto the pump rod.

Step 37

Unscrew the T-handle from the pump rod and remove it.
Keep the T-handle ready to reattach to the pump rod after the tank is removed.

Unscrew the T-handle from the pump rod and remove it.

Keep the T-handle ready to reattach to the pump rod after the tank is removed.

Step 38

Remove the tank.

Remove the tank.

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

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                    Andrew Optimus Goldheart

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