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India Mark II Axle and Handle Replacement

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

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  1. India Mark II Axle and Handle Replacement, Access Door: crwdns2935265:01crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 India Mark II Axle and Handle Replacement, Access Door: crwdns2935265:01crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Before performing any repairs, perform a water test on the pump by raising and lowering the handle a full 40 strokes. A properly performing pump will yield greater than 10 liters.

    • Remove the hex head bolt from the top of the access door on the pump head.

    • On reassembly, this bolt should be hand-tight.

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  2. India Mark II Axle and Handle Replacement: crwdns2935265:02crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:02crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:02crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

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

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

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  3. India Mark II Axle and Handle Replacement: crwdns2935265:03crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:03crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • The access door has a tongue that fits into the base of the pump head.

    • The access door makes a convenient tray to hold nuts and bolts during the disassembly.

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  4. India Mark II Axle and Handle Replacement, Chain: crwdns2935265:04crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement, Chain: crwdns2935265:04crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement, Chain: crwdns2935265:04crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

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

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  5. India Mark II Axle and Handle Replacement: crwdns2935265:05crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:05crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:05crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • The following procedure requires two people. If you attempt to do this alone, you risk injuring yourself and damaging the pump.

    • Lift the pump handle until the base of the chain comes to rest on the spacer collar, and the chain is slack. Hold the handle in this position while the chain is being detached.

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  6. India Mark II Axle and Handle Replacement: crwdns2935265:06crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:06crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:06crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

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

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  7. India Mark II Axle and Handle Replacement: crwdns2935265:07crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:07crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:07crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Hold the wrench on the bolt stationary.

    • Loosen the nut.

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  8. India Mark II Axle and Handle Replacement: crwdns2935265:08crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:08crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:08crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Remove the nut from the chain bolt.

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  10. India Mark II Axle and Handle Replacement: crwdns2935265:09crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:09crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove the washer from the chain bolt.

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  11. India Mark II Axle and Handle Replacement: crwdns2935265:010crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:010crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove the chain bolt.

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  12. India Mark II Axle and Handle Replacement: crwdns2935265:011crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:011crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:011crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

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

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  13. India Mark II Axle and Handle Replacement, Axle and Handle: crwdns2935265:012crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement, Axle and Handle: crwdns2935265:012crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement, Axle and Handle: crwdns2935265:012crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • 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.

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  14. India Mark II Axle and Handle Replacement: crwdns2935265:013crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:013crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

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

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  15. India Mark II Axle and Handle Replacement: crwdns2935265:014crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:014crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:014crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • 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.

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  16. India Mark II Axle and Handle Replacement: crwdns2935265:015crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:015crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

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

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  17. India Mark II Axle and Handle Replacement: crwdns2935265:016crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:016crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:016crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

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

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  18. India Mark II Axle and Handle Replacement: crwdns2935265:017crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:017crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:017crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • While supporting the pump handle, remove the axle.

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  19. India Mark II Axle and Handle Replacement: crwdns2935265:018crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:018crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:018crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Slide the pump handle out of the pump head.

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  20. India Mark II Axle and Handle Replacement: crwdns2935265:019crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

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

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  21. India Mark II Axle and Handle Replacement: crwdns2935265:020crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:020crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • 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.

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  22. India Mark II Axle and Handle Replacement: crwdns2935265:021crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:021crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:021crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • 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.

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  23. India Mark II Axle and Handle Replacement: crwdns2935265:022crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:022crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • 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.

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  24. India Mark II Axle and Handle Replacement: crwdns2935265:023crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:023crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 India Mark II Axle and Handle Replacement: crwdns2935265:023crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Replace the washer and nut on the axle.

    • Tighten the nut with a wrench.

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

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