OJT Manual Afridev 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
AFRIDEV
FRIDEV Deepwell Handpump
April, 2016
Earth System Science Co., Ltd.
and
KONOIKE Construction Co., Ltd

Operation and Maintenance Manual (AFRIDEV Handpump)

CONTENT
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Pages
1. General ----------------------------------------------------------------------------------------------------
-------------------------------- 1
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 ---------------------------------------------------------------------------------

-------------------------------- 4
2.1 Structure ----------------------------------------------------------------------------------------
-------------------------------- 4
2.2 Above Ground Components --------------------------------------------------------- -- --- 5
2.3 Downhole Components ---------------------------------------------------------
------------------------------------------------------ -------- --- 6
2.4 Maintenance Tools and Materials----------------------------------------------------
Materials --- 6
(1) Special Maintenance Tools ---------------------------------------- -------------------- --- 7
(2) Other Tools and Materials ---------------------------------------- --------------------- --- 7
3. Installation of Handpump -------------------------------------------------------------------------

-------------------------------- 8
3.1 Installation of Downhole Components -------------------------------------------- --- 8
(1) Preparation of Materials ---------------------------------------- ----------------------- --- 8
(2) Preparation of Cylinder Parts ---------------------------------------- ---------------- --- 8
(3) Installation of Cylinder ----------------------------------------
------------------------------------- ------------------------- --- 9
(4) Installation of Riser Pipe --------------------------------------------------------------- --- 9
3.2 Installation of Above Ground Components --------------------------------------- --- 12
(1) Preparation ----------------------------------------
------------------------------------- ----------------------------------------- --- 12
(2) Installation of Pumprod ----------------------------------------
------------------------------------- ------------------------ --- 12
(3) Adjustment of Pumprod ----------------------------------------
------------------------------------- ------------------------ --- 13
(4) Connecting of Rod Hanger ------------------------------------------------------------- --- 14
(5) Installation of Handle with Pump Head ---------------------------------------- -- --- 14
(6) Connecting of Handle with Pumprod Assembly -------------------------------- --- 15
(7) Final Works--------------------------------
----------------------------------- ---------------------------------------------- --- 15
(8) Introduction of Different Type of Handpump Parts----------------------------
Parts --- 16
4. Daily Operation and Preventive Check ------------------------------------------------------- 18

4.1 Daily Operation -------------------------------------------------------------------------------
-------------------------------- 18
4.2 Preventive Check ------------------------------------------------------ ------------------------ 18
(1) Weekly Checks -----------------------------------------------------------------------------
------------------------------------- --- 18
(2) Leakage Test ----------------------------------------
------------------------------------- --------------------------------------- --- 18
(3) Discharge Test ----------------------------------------
------------------------------------- ------------------------------------- --- 18
4.3 Trouble Shooting ------------------------------------------------------ ------------------------- 20
5. Maintenance and Repair ---------------------------------------------------------------------------

-------------------------------- 21
5.1 Maintenance of Plunger and Footvalve ------------------------------------------------ 21
(1) Remove out Handle ----------------------------------------
------------------------------------- ------------------------------ --- 21
(2) Raising up Pumprod ----------------------------------------
------------------------------------- ----------------------------- --- 21
(3) Catching up Footvalve ----------------------------------------
------------------------------------- -------------------------- --- 22
(4) Replace Consumable Rubber Parts ------------------------------------------------- --- 22
(5) Re-Installation of Pumprod and Handle --------------------------------------- --- --- 22
Operation and Maintenance Manual (Afridev Handpump)

CONTENT
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Pages
5.2 Repair of Riser Pipe ---------------------------------------------------------------------------

-------------------------------- 23
(1) Remove out Pumprod Assembly ---------------------------------------- ------------- --- 23
(2) Pulling out Whole Riser Pipe ---------------------------------------- ----------------- --- 23
(3) Pulling out Riser Pipe with Cutting ---------------------------------------- -------- --- 24
(4) Repair of Riser Pipe ----------------------------------------
------------------------------------- ------------------------------ --- 24
(5) Re-Installation of Riser Pipe --------------------------------------- ------------------- --- 25
(6) PVC Solvent Cement ---------------------------------------
------------------------------------ ----------------------------- --- 26
< 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 (Afidev 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
Contractor : 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 AFRIDEV DEEPWELL HANDPUMP manufactured by AJAY A
Industrial Corporation Ltd in India.
India
Afridev Deepwell Handpump is one of most famous VOMP (Village Level Operation and
Maintenance) pump, Afridev was designed in 1980s
1980 s by SKAT and RWSN (former HIT) for easy
maintenance by villager, and it is manufactured by many factories
factor in many countries.
Table 1-2 Summary of Specification

S of Selected Handpump
Type AFRIDEV
FRIDEV Deepwell Handpump
General
Installation depth Maximum

imum 45m
Discharge rate 16.5 L per 40 strokes
Pump head, stand, Hot-dip
dip Galvanized Steel complete with adjustable handle, Pump head with
handle short spout, Three legged pump stand
Specification
Cylinder uPVC pipe 63mm O.D. with seamless brass liner 50mm I.D
Riser pipe uPVC pipe 63mm O.D. with socket-spigot
Inner rod Stainless Steel Hook & Eye connecting rod,
Plunger Brass plunger
Foot Valve Plastic foot valve with eye.
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,
1

1. GENERAL
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1.3 REFERENCE DOCUMENTS
This operation and Maintenance Manual is referred following documents,, and we utilize u
some of photos or figures, sentence on these documents in this manual. manual We hereby
appreciate to below persons/ organizations.
1) Installation and Maintenance Manual for the AFRIDEV Handpump, Revision 2 - 2007,
SKAT - RWSN
*This
This manual was published with SKAT - HTN as first edition in 1995. You can download
this manual from website: http://rural-water-supply.net/en/resources/details/286
http://rural supply.net/en/resources/details/286
*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
services for the rural
water supply. Former name is HTN (Human Technology Networks).
http://rural-water-supply.net/en/
supply.net/en/
2) AFREDEV Deep-well
well Handpump Specification, Revision 5 - 2007, SKAT - RWSN
*This manual was published with SKAT - HTN as first edition in 1989. You can download
this manual from website: http://rural-water-supply.net/en/resources/details/318
http://rural supply.net/en/resources/details/318
3) AJAY AFRIDEV Deep Well Handpump Installation

Installation and Maintenance Manual
4) ASTM D2564-12:
12: Standard Specification for Solvent Cements for Poly (Vinyl Chloride)
(PVC) Plastic Piping System
2

1. GENERAL
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1.4 INTRODUCTION OF WELL CONSTRUCTION
It is introduced construction of well from begging 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 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,
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,
Ubungo, P.O. Box 55658 Dar es Salaam
Tel/Fax: +255-2222-2410430, Web: http://www.ddca.go.tz
SGS/ African Assay Laboratory Tanzania Ltd
Water Quality
Balewa road, P.O. Box 1826 Mwanza,
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
+255
Pump CBRC (Community Based Resource Centre) Shinyanga
Installation Ushirika Area P.O.Box 1200 Shinyanga,
Shinyanga Tel/Fax: +250-28-2763279
2763279
TONE Engineering Corporation:
Corp ration: Mr. Katsuhiko ADACHI, Mr. Selestine Shironga
Manual
CBRC: Mr. Ramadhani Chambulilo, Mr. Rajabu Amri Ally
3

2.. HANDPUMP ASSEMBLY
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2. 1 STRUCTURE
The structure of AFRIDEV Handpump is shown on Fig. 2-1.
Fig.2-1
1 Structure of AFRIDEV Handpump
4

2. HANDPUMP ASSEMBLY
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2.2 ABOVE GROUND COMPONENTS COMPONE
Assembly above ground components is shown as bellow.
Pump Stand Pump Head Head Cover
Handle Corn Plate Rubber Compression Corn
Fulcrum Pin Rod Hanger Pin Bush Bearing
Rod Hanger Assembly Rubber Flapper Top Sleeve
Fig. 2-2 Assembly above Ground Components
5

2. HANDPUMP ASSEMBLY
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2.3 DOWNHOLE COMPONENTS
Assembly of downhole components is shown as bellow.
uPVC Cylinder uPVC Suction Pipe uPVC Riser Main Pipe
Plastic Foot Valve Brass Plunger Assembly Stainless Riser Rod
Pipe Centralize Nylon Rope Rod Centralize
Foot Valve O-ring U-seal Valve Bobbin
Fig. 2-3 Assembly above Ground Components
6

2. HANDPUMMP ASSEMBLY
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2.4 MAINTENANCE TOOLS AND MATERIALS
(1) Special Maintenance Tools
Special maintenance tools are shown as bellow.
Fishing Tools Open Ended Spanner Socket Spanner

Fig.
Fig.2-4 Special Maintenance Tools
(2) Other Tools and Materials

Other tools and materials are shown as bellow.
Tool Box Hacksaw for SS rod Steel File
Screw Driver Sand Paper Brush
Nylon Rope Solvent Cement Cleaning Fluid

Fig.
Fig.2-5 Other Tools and Materials
7

3. INSTALLATION OF HANDPUMP
HAND
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3.1 INSTALLATION OF DOWNHOLE DOWNHOLE COMPONENTS COMPONENTS
(1) Preparation of Materials
1) Mark each pipe end at 115mm with a permanent marker (Fig.3-1).
2) Place riser pipe centralizers on each pipe at 3meters

3meter intervals (Fig.3-2).
Fig.3-1 Making at end of pipe Fig.3-2 Placing Riser Main Centralizer
3) Roughen slightly on outside of pipe end and inside of bell-end

bell with sand paper (Fig.3-3).
4) Clean outside of plain pipe end and the inside of the bell socket (Fig.3-4).
Fig.3-3
3 Roughening Pipe End Fig.3-4
4 Cleaning Pipe End
(2) Preparation of Cylinder Parts

5) Cut the nylon rope for proper length.
Total length rope is twice of cylinder setting depth
plus an additional 4 meters.
6)) Pass the nylon rope through the hole of o the suction
pipe until it reaches the center of the rope (Fig.3-5).
7)) Make a knot on the rope at both side

sid of the suction
pipe to prevent the rope slipping past the centre Fig.3-5
5 Passing Rope in Cylinder
position (Fig.3-5).
8

HAND
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8) Apply
pply uPVC solvent cement on inside of bell socket of suction pipe and outside of cylinder
bottom end, using the brush.
9)) Push the suction pipe socket into the cylinder bottom end until it is fully engaged, and
wipe out any surplus solvent cement with cotton waste. Allow five minutes for the joint to
set.
< Note >

a. The brush strokes should always be in an axial
ax direction.
b. Ensure that both jointing surfaces are completely covered with a smooth an even
layer of cement.
c. Application time should never exceed 30 seconds for each surface.
d. Wipe out any surplus solvent cement with cotton waste. Adhesive solvent cement
on uPVC pipe cause solvent crack.
e. A curing time is 5 minutes at least
(3) Installation of Cylinder

10) Fix two bolts in two opposite holes of the pump stand
flange (Fig.3-6).
11) Insert
nsert the suction pipe with cylinder into the pump
stand (Fig.3-6),, and lower it so that the cylinder top
is protruding by about 0.5m.
12)) Pass nylon rope through the slots of the centralizer

on the cylinder, and then tighten the ropes on the
two bolts on the pump stand flange.
(4) Installation of Riser Pipe

13)) Apply solvent cement to inside of the bell-end
bell of riser Fig.3-6
6 Installation of Cylinder
pipe (Upper pipe) and outside of cylinder / riser pipe
(Downside pipe) at same time using the brush.
14) Support downside pipe (cylinder or riser pipe) by

hand with 2 persons at least, and push bell-end
bell of
upper riser pipe into downside pipe until its end
position immediately (Fig.3-7)
7).
Dontt twist the newly inserted pipes anymore.
15) Wipe out any surplus of solvent cement immediately.
Fig.3-7
7 Installation of Riser Pipe
9

HAND
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16) Wait 5 minutes for curing before loosening the rope for
lowering the pipe into the position for the next joint.
17) Pass rope through the slots of the centralizer on the

riser pipe (Fig.3-8), and lower the pipes
pipe into the
borehole using the rope.. Never support or hold the pipe
by hand. Fig.3-8
8 Centralizer
18)) As soon as the riser pipe reach to next position, fix the
ropes on the bolts on the pump stand flange to support
the riser pipe (Fig.3-9).
19)) Continue this process of jointing pipe (13 to 17), and

keep on lowering with help of rope till the topmost pipe
end.
Fig.3-9
9 Fixing Rope on Bolt
20) When the last riser pipe is install,

install pass the steel cone thorough pipe, and lay
la it on the top
flange of the pump stand (Fig.3-10
(Fig.3 a). After that, slid the rubber cone over the pipe, then
hold it at about 100mm depth from pipe end (Fig.3-10 a).
21)) Clean the pipe end with cleaning fluid, and as soon as it will be dry, apply solvent cement
on the pipe end (80mm depth) and on the inside of the top sleeve (Fig.3-10 0 b).
b
22) Join top sleeve on end riser pipe, wait for at least 20 minutes for curing. After setting
time, adjust rubber cone and the steel cone (Fig.3-10 c).
23) Two persons shall lift complete riser main assembly up by the steel cone, then third
person shall connect both rope ends to the eyes of the steel cone (Fig.3-10
0 c).
c
a) b) c)
Fig.3-10
10 Top Part of Riser Main Assembly
10

HAND
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24) Cut the rope ends, but leave at least 2m excess length for each rope end, and insert the
rope ends into the pump stand. and.
25) Remove out the bolts and nuts from the pump
stand flange,, and lower riser main assembly
carefully holding corners of the steel cone
(Fig.3-11).
<Attention>
Be careful to be not catch finger between the
steel cone and flange of stand pipe. Fig.3-11 Matching Steel Cone and
Pump Stand Flange
26) Move the steel cone due to all four holes of the
cone plate and the pump stand flange are
matching (Fig.3-11).
27) Cover the hole of the newly installed riser pipe to prevent playing
playing children from dropping
dirt or stones into the well, and let the joints cure for at
a least 12 to 16 hours to obtain full
strength of the joints.
Required lap shear strength of PVC solvent cement is as follows, and shear strength at
curing 16 hours is double of curing 2 hours. It is recommend to be abstained from
handpump operation within 3day after installation of riser pipe.
Table 3-1 Lap Shear Strength and Curing Hours (ASTM-D2564)

Minimum Average Lap
Curing Hours
Shear Strength
2 hours 250 psi (1.7 MPa)
16 hours 500 psi (3.4MPa))
72 hours 900 psi (6.2 MPa)
11

H
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3.2 INSTALLATION OF ABOVE ABOVE GROUND COMPONENTS COMPONE
(1) Preparation
28) Install pump head on the stand assembly and tighten bolts fully (Fig.3-12) 12).
29) Ready Above

Above Ground Components
Components such as plunger rod and pumprod, and check that
the bobbin, O-ring
ring and the U-seal
U are in the correct position.
30) Hold the foot valve from pick up hock, and drop it into the riser
ris pipe (Fig.3-13).
(Fig.3
Fig.3-12
12 Installation of Pump Head Fig.3-13 Drop Foot valve into Reser Pipe
(2) Installation of Pumprod
31) Lower plunger and rod into the riser pipe holding by
hand of 2 or 3 person.
32) Connect between pumprod as follows (Fig.3-14).

(Fig.3
a. Keeping grip downside pumprod by hand of 2 or 3
persons.
b. Insert hook of upper pumprod horizontally into the
eyes of downside pumprod.
c. Turn the rod upwards so that the connection is tight
and the rods are exactly in line.
d. Push centralizer down and fix connection of hook
and eye.
33) Connect and lower all of pumprods until the plunger is

Fig.3-14
14 Connecting Pumprod
sitting on top of the foot valve.
12

HAND
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(3) Adjustment of Pumprod
34) Determine cutting point as follows.
a. Let the pumprod assembly rest fully, so that the
plunger is sitting on top of the foot valve.
b. Insert one hand into the pump head, and grab the
protruding pumprod at the top end of the riser pipe
(Fig.3-15),
15), and keep the exact cutting point by
thumb (Fig.3-16).
c. Lift pumprod assembly by approximately one meter.

* Dontt lose the grip of the pumprod, with helping of Fig.3-15
15 Cutting Point of
Pumprod
two or three other person.
35) As soon as the hand is outside the pump head, mark the
exact point of the thumb with a hacksaw blade.
36) After marking, lift the pumprod assembly as far as to

the next connection, and turn the upper rod
downwards and rest pumprod on slots of pump head.
37) Cut the top rod at the mark.

Fig.3-16
16 Keep Cutting Point by
Thumb
38) Make rough surface of top rod at parts connecting
rod hanger by file or hacksaw, specially in case of
stainless rod (Fig.3-17).
*Stainless is smooth surface and top rod might be
slipped from rod hanger.
Fig.3-17
17 Making Rough
Surface on Rod
13

H
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(4) Connecting of Rod Hanger
39) Slip rubber flapper to the pumprod at first (Fig.3-18),, and then fix the rod hanger
assembly. Tighten hexagonal bolt of rod hanger assembly securely (Fig.3-1 (Fig.3 19).
39) Turn pumprod with hanger upwards, and lower it into pump head.
Insert the spanner handle into rod hanger bush (Fig.3-20),
(Fig.3 ), and lower rodhanger with
spanner handle onto the two slots of pump head for resting pumprod assembly.
Fig.3-18 Slipping rubber Fig.3-19 Connecting Fig.3-20 Insert Spanner Handle

slapper to the pumprod Rod hanger
(5) Installation of Handle with Pump Head

40) Insert fulcrum pin with one bearing into the fulcrum housing of the handle front, and
attach second bearing at other side (Fig.3-21).
(Fig.3
41) Adjust position of the lock-pin

pin of the fulcrum assembly and lug of the bearings into the
slots of the fulcrum bracket (Fig.3-22).
(Fig.3
42) Insert the handle front carefully into slots of the fulcrum
ulcrum bracket, and tighten special
nuts of the fulcrum pin by hand (Fig.3-23).
Fig.3-21 Insert Fulcrum Pin Fig.3-22 Adjustment of Fig.3-23 Insert of Handle

with Bearing into Handle Fulcrum Assembly Front
14

HAND
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(6) Connecting Handle with Pumprod Assembly
43) Insert rod hanger pin with one bearing into the rod hanger, and attach second bearing
at other side (Fig.3-24).
44) Adjust position of the lock-pin

pin of the rod hanger pin and lug of the bearings for sitting it
into slots of handle front.
45) And then, push down handle rear to its lowest position to let handle front upwards, and
catch rod hanger pin assembly up by handle front. Tighten the special nuts of the
fulcrum pin by hand (Fig.3-2
25).
46) Remove out the spanner handle from the rod hanger assembly (Fig.3-2
26), and release
handle slowly to sit rod hanger down.
down
Fig.3-24 Insert Rodhanger Fig.3-25 Adjustment of Rod Fig.3-26 Connecting Handle

Pin into Rodhanger hanger pin Assembly completely
(7) Final Works

47) Adjust length of handle rear to balance of handle by adjustment bolt using with socket
spanner (Fig.3-27).
48)) Fix the cover and tighten the cover bolt using with socket spanner (Fig.3-28
28).
Fig.3-27 Adjusting Balance of Handle Fig.3-28 Adjustment of Rod hanger

pin Assembly
15

HAND
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(8) Introduction of Differentt Type of Handpump Parts
Afridve handpump has options for 1) pump head type, 2) pump stand type, 3) Riser pipe type, 4)
Cylinder (Plunger / Foot valve) type and a 5) pump rod type. Itt is introduced difference cylinder
arrangement and pump rod arrangement.
1) Pump Rod Connection

Pump rod has two type of connection, eye & hook type and thread type. Thread type
connects between male thread of lower rod and female thread of upper rod,
rod, on resting tool.
Left: Thread type (Thread connection) (Eye & Hook connection)

Right: Eye & Hook tye
Fig.3-29
29 Pump rod connecdtion Fig.3-30
30 How to connect pump rod
2) Cylinder Assembly
Cylinder assembly is consisted of plunger and foot valve. Plunger has brass plunger and
plastic plunger, and also foot valve has brass foot valve and plastic foot valve. Brass plunger
is available to connect to brass foot valve at fishing up, but other combination
combination is not available
to connect plunger and foot valve.
Table 3-2 Combination of plunger and foot valve type

Plunger Foot Valve
Type Pump Rod Brass Foot valve Plastic Foot valve
Available, fishing
f foot valve up Available, fishing
ishing foot
Thread type
by thread plunger connection valve up by fishing tool
Brass
Possible, but not recommend.*1
Plunger Eye & Hook Available, fishing foot
Fishing foot valve up by thread
type valve up by fishing tool
plunger connection
Plastic Thread / Available, fishing foot
Eye & Hook Not available
Plunger valve up by fishing tool
*1 Please contact to manufacture or agent.
16

HAND
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Fig.3-31 Combination of plunger and foot valve type
3) Fishing Foot Valve (Please refer to Chapter 5. Maintenance and Repair)

Plastic foot valve with eye is fished up using with fishing tool replaced plunger assembly.
Brass foot valve is fished up connected with brass plunger directly,
directly, and fishing (connecting)
and sitting (remove
move out) of foot valve by connecting tool.
Left: Fishing of foot valve, clockwise turning

Plastic Foot Valve Brass Foot Valve
Right: Sitting foot valve, anti-clockwise
anti turning
Fig.3-32
32 Difference of fishihing of foot valve Fig.3-33 How to fish up brass foot valve
4) O-rings
There are 3 different size of O-ring
ring as follows.
Table 3-3
3 Different size of O-ring
O
Size Place
50mm Top and Bottom plug of S.S. Cylinder
40mm Brass foot valve
28mm Plastic foot valve
50mm 40mm 28mm
Fig.3-34
34 Different size of O-rings
O
17

4. DAILY OPERATION AND 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

(1) Weekly Checks
a. Check that the flange bolts and nuts are tight.
tight If it is loosen, tight it by spanner.
spanner
b. Check that Fulcrum pin nuts and Hanger pin nuts are tight. If it is loosen, tight it by
hand.
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) Leakage Test (Monthly)

Leakage test shall be conducted
ed monthly, as follows.
a. Operate the pump handle until
til 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 must be a
leakage in the riser pipe or the footvalve. Check bobbin or O-ring
ring of footvalve first.
(3) 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 20 liters bucket.
18

4. DAILY OPERATION ANDA PREVENTIVE CHECK
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Iff it is difficult to measure water volume in 20 liter bucket, following way is easy.
c. Count strokes at filling up p 20 liter bucket.
d. Calculate water yield at 40 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 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 Afridev Handpump is 16.5 litters for 40 full strokes. And in case of less than 10
litters for 40 full strokes, there might be a problem with the bobbin or U-seal
U seal of plunger, or
bobbin of footvalve.
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
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

alculation of Discharge Rate with 20L Bucket
Seconds at 20 L Discharge at 1 min. Seconds at 20 L Discharge at 1 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
19

4. DAILY OPERATION AND PREVENTIVE CHECK
---------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------------------
4.3 TROUBLE SHOOTING
Trouble shooting is shown as table.
Table 4-3 Trouble Shooting of Hand Pump Function

Problem Operation Cause Measure
Handle operation is Pumprods are disconnected Replace broken and corroded rods
easy
Handle operation is Riser pipe is disconnected Repair/ replace pipes
difficult
No water
Cup seal (U-Seal, Sealing rings) is Replace seal
Handle operation is defect
normal Borehole is clocked (silt or sand) Rehabilitation of borehole
Water level dropped below cylinder Add riser pipe and pumprods
Leaking of valve bobbins Check and replace bobbins

Leaking of Foot valve O-ring/ Cup Replace O-ring/Cup
ring/Cup washers
Delayed flow Handle operation is
washers
of water normal
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
Reduced Full stroke is not possible Check and adjust length of top rod
discharge Handle operation is Cup seal is worn Replace seal
normal Leaking of valve bobbins Check and replace bobbins
Leaking of the cylinder (cracked) Repair/ replace cylinder
Pumprods rubbing on riser pipes Check and replace worn pumprod
Handle operation is
centralizers
normal
Pumprod centralizers worn replace worn pumprod centralizers
Abnormal
Pumprods are touching riser pipes Straighten or replace bent
noise during
pumprods, replace worn pumprod
operation Handle operation is
centralizers
inconvenient
Bearings are worn, Handle fork Check and replace bearing sets
touching the sides of pump head
Bearings are worn Check and replace bearing sets
Fulcrum pin is loose Check fulcrum pin (and bearing
Handle is shaky
sets) and tighten both nuts fully
when operated
Hanger pin is loose Check hanger pin (and bearing
Pump handle
sets) and tighten both nuts fully
shaky
Pump head is Flanges are loose Tighten all bolts and nuts of the
shaking flanges
Pumpstand is Pump platform is cracked Repair pump platform
shaking
20

5. MAINTENANCE AND REPAIR
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
5.1 MAINTENANCE OF PLUNGER LUNGER AND FOOTVALVE
(1) Remove out Handle
1) Loosen pump cover bolt and remove the cover out (Fig.5-1).
2) Loosen hanger pin nuts and fulcrum pin nuts fully.
3) Push down hand to be up handle front, and hold handle by the spanner handle.
4) Move handle slowly upwards to be down handle front, and pull out the handle horizontally
(Fig.5-2).
Fig.5-1 Open Cover Fig.5-2 Remove out Hadle
5) Remove the fulcrum pin and bearing bush set from the handle (Fig.5-3)
(Fig.
6) Remove hanger pin and bearing bush sets from the rod hanger (Fig.5-4).
(Fig.
7) Place all small components inside the pump head cover.
Fig.5-3 Remove out Fulcrum Pin Fig.5-4 Remove out Hanger Pin
(2) Raising up Pumprod

8) Raise pumprod up by hand of 2 or 3 person.
9) Slip rod connecter as follows (Fig.5-5).
(Fig.
a. Keeping grip downside pumprod by hand of 2 or 3
persons.
b. Move centralizer up and loosen connection of hook
and eye.
c.. Turn the pumprod downwards, and remove out hook
(upper rod) from eye (downside rod) horizontally.
10) Continue to remove all pumprod one by one until

un the
plunger rod is released.
Fig.5-5 Disconnectting Rod
21

R
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
(3) Catching up Footvalve
11) Remove plunger rod from last pumprod, and replace them with the fishing tool (Fig.5-6). (Fig.5
12) Re-install
install all pumprods one by one until the fishing tool is resting on top of the footvalve.
13) Turn round the pumprod assembly slightly to connect hook of fishing tool with eye of
footvalve.
14) Remove all pumprods one by one again until the rod with finish tool and footvalve are
released (Fig.5-7).
Fig.5-6 Installation of Fishing Tool Fig.5-7 Catching Footvaove by Fishing tool
(4) Replace Consumable Rubber Parts

15) Check consumable rubber parts such as bobbin, 28mm O-ring, U-seal,
seal, rod centralizer
(Fig.5-8), and replace it.
Bobbin U-Seal
U O-ring (28mm) Centralizer
Fig.5 Consumable Rubber Parts
Fig.5-8
(5) Re-Installation
ation of Pumprod Assembly and Handle
16) Re-install
install pumprod assembly following process described on 3.2 Installation of Above
Ground Components. On top of pumprod assembly, connect and install pumprod with
rodhanger whichch made it at first installation, with spanner for resting onto slots of pump
head.
22

R
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
5.2 REPARE OF RISER PIPE
The replacement of the riser pipe will need to be carried out by skilled mechanic.
(1) Remove e out Pumprod Assembly

This may not be possible to remove riser pipe, if there are components stuck inside the
riser pipe. Therefore, it shall remove out pumprod assembly and footvalve following above
section 5.1
5.1 Maintenance of Plunger and Footvalve.
Footvalve
(2) Pulling out Whole Riser Pipe

1) Remove the pumphead.
2) Tie the guide rope to the cone plate. The guide rope is used to control the free end of the
pipe.
3) Start to pull the riser pipe out of the borehole by pulling the two ends of the support rope
and pipe.
4) As the riser pipe come out of the borehole, start to bend it in the direction chosen for it to be
laid down.
5) Use the shorter forked poles to take weight of the pipe with keeping the radius of the bend
as long as possible (Fig.5-9).
6) As the pipe continues to be pulled out, use the longer forked poles to support the free end of
the pipe so that pulled pipes at end and middle will be keep horizontal (Fig.5-10).
(Fig.5
Fig.5-9 Pulling out Riser Pipe (1) Fig.5-10 Pulling out Riser Pipe (2)
7) If a joint could be weak, cut at the suspect joint carefully, at any time.
Do not try to bend a weak joint.
8) When the cylinder and suction pipe are reached, withdraw pipes carefully and lay down all
of pipes on the ground.
23
Operation
eration and Maintenance Manual (Afidev Handpump)
REPA
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
(3) Pulling out Riser Pipe with Cutting utting
If it is difficult to remove out whole riser pipes, it
is possible to raise pipes up by cutting into
manageable lengths of 2 to 3 pipe length or 6 to 9
meters. In case pumprods are stuck inside the riser
pipe by broken connectors or fall down, it is better
to use this way. When it will be re-installed re riser
pipe into borehole, it will be connected by short
double sockets.
Fig.5-11 Pulling Out Riser Pipe (3)
(4) Repair of the Riser Pipe

It is most important thatat the overall length of the riser pipe must not be changed. Any
change in the length of the riser pipe would affect the exact position of the plunger in the
pump cylinder.
< Case using Longer Double Socket>

Socket
9)) Find damaged part and choose where to
cut for 300mm.
10)) Mark at both section for cutting out for

300mm with a permanent marker.
11) Cut pipe at marked point.
12) Roughen slightly by sand paper and

clean by cleaning fluid on connected
parts between pipes and sockets.
14) Apply uPVC solvent cement on inside of Fig.5-12 Repairing with Longer Double Socket
bell socket and outside of riser pipe,
using the brush.
15)) Push the double socket into the riser pipe end until it is fully engaged, and wipe out any
surplus solvent cement with cotton waste. Allow five minutes for the joint to set.
Please refer note on 3.1 Installation of DownHole Components for connection with
uPVC solvent cement.
24

REPA
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
< Case using Short Double Socket>
16) Find damaged part and measure length
of replaced section.
17)) Mark at both section for cutting out with

a permanent marker.
18) Prepare
repare pipe with same diameter and
same length of replaced section, and
check it length together.
19) Cut pipe at marked point.
20) Roughen slightly by sand paper and

clean by cleaning fluid on connected Fig.5-13 Repairing with Short Double Socket
parts between pipes and sockets.
21) Apply uPVC solvent cement on connected parts of pips and sockets, and push
p the double
socket into the riser pipe end until it is fully engaged.
engaged
(5) Re-installation of Riser Pipe

22) After necessary repairs have been carried out, clean and disinfect all of riser pipes before
re-installing
installing riser pipe into the borehole.
23) Re-install
install riser pipe on the process of the
reversal of removal.
24) In case of whole pulled out riser

r pipe, it could
be difficult to insert the cylinder and suction
pipe into the borehole to be forced at bending
riser pipe.
25) In case of pulled out riser pipe separately with

cutting, it shall be used short double socket to
connect cutting parts (Fig.5-14),
(Fig.5 following
above instruction using short double socket.
Fig.5-14
14 Connected Cutting Pipe with
Short Double Socket
Major Repairing should be contact with Maintenance Company
25

REPA
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
(6) PVC Solvent Cement
PVC (Poly Vinyl Chloride) solvent cement is a solution of the base PVC resin which content
shall be 10% minimum,, used in jointing PVC piping systems. It shall be free-flowing flowing and
shall not contain lumps, macroscopic un-dissolved un dissolved particles, or any foreign matter.
PVC solvent cements are classified as Regular-, Regular Medium-, or Heaviy-bodied bodied types, based on
their minimum viscosity as follows. follows
Table 5-1
1 Type of PVC Solvent Cement (ASTM-D2564)
Wet Film
Pipe size Minimum
Cement type Minimum
range (inch) Viscosity
Thickness
Regular-bodied
1/8 to 2 90 mPa/s 0.15mm
(Regular duty clear)
Medium-bodied
2-1/2 to 6 500 mPa/s 0.30mm
(Medium duty clear)
Heavy-bodied
8 to 12 1600 mPa/s 0.60mm
(Heavy duty clear)
Diameter of PVC pipe of Afridev handpump is 50mm I.D. (Inside diameter) and 63mm O.D.
(Outside diameter). It shall be regular-bodied
regular or medium-bodied
bodied for PVC piping of Afridev
handpump. Heavy-bodied
bodied is higher viscosity and it could be difficult heavy-bodied
bodied cement to
be applied with a smooth an even layer of cement in small diameter.
It is always available heavy-bodied

bodied (heavy duty-clear)
duty clear) cement at towns in Tabora region,
but it could be difficult to find medium-bodied
medium or regular-bodied
bodied even in Mwanza. It could be
available in Dar es Salaam. If it will be find only heavy-bodied
heavy bodied cement, it will be used it
carefully to apply with smooth an even layer.
26

REPA
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----------------------------------------------------------------------------------------------------------------------------------------
It is introduced PVC solvent cement found at retail shops in Tabora, Mwanza, Dar es
Salaam, as follows. It will be found other production at other shop or other time. time On the other
hand, it could be not always got same product from same shop.
Table 5-2
2 Example of PVC Solvent Cement found in Tanzania Market
Brand A-Z WELD PVC Cement BEST WELD PVC Cement FAST WELD PVC Cement
Type 700-57 Medium duty-clear
clear 777-23 Heavy duty-clear 700-21
21 Heavy duty-clear
duty
Standard ASTM D2564 ASTM D2564 ASTM D2564
Company Hunan Techpower Imp. & Hunan Techpower Imp. & Hunan Techpower Imp. &
Exp. Co., Ltd Exp. Co., Ltd Exp. Co., Ltd
Origin China China China
Photo
Brand WATER WORKS

ERA PVC Cement Clear YIXIANG PVC Cement
PVC Cement
Type 717-21 Heavy duty-clear
clear (Medium or Regular bodied?) 700-24
24 Medium Duty-clear
Duty
Standard ASTM D2564 ASTM D2564 -
Company Hunan Techpower Imp. & Zibo Linzi Yixiang
Yonggao Co., Ltd
Exp. Co., Ltd Chemical Co., Ltd.
Origin China China China
Photo
Brand Tangit PVC-U Glue Tangit PVC-U Glue

Ajay Solvent Cement
All pressure
Type (Heavy bodied?) (Heavy bodied?) (Regular or Medium bondied?)
Standard DIN DIN -
Company Henkel Germany Ltd Henkel Kenya Ltd Ajay Industrial Co. Ltd
Origin Germany Kenya India
Photo
27

REPA
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
Manufacture of PVC solvent cement introduced above are follows.
Table 5-3
3 Information of Manufacture of PVC solvent cement
cement introduced above
Company name Hunan Techpower Imp. & Exp. Co., Ltd.
Ltd
Address Furong road, Changsha city, Huan Province, China
Contact Tel +86-0731-82021316
82021316, Fax +86-0731-2024316
Website http://www.ecvv.com/company/lovely0416/catalog/163256.html
Company name Yonggao Co., Ltd.
Ltd
Address Daixi Road, Huangyan Economic Development Zone, Taizhou, Zhejiang, China
Contact Tel: +86-576-84162728
84162728, Fax: +86-576-84277171
Website http://cnyonggao.en.made
http://cnyonggao.en.made-in-china.com/
Company name Zibo Linzi Yixiang Chemical Co., Ltd.
Address Bianhe, Linzi District, Zibo, Shandong, China
Contact Tel: +86-533-7525879,
7525879, Fax: +86-533-7456686
+86
Website https://www.gmdu.net/corp
https://www.gmdu.net/corp-844675.html
Company name Henel Kenya Ltd.
Address Outer Ring Road, Ruaraka, P.O.Box 40050-00100,
40050 Nairobi
Contact Tel +254-20-2451639
2451639
Website http://en.henkel
http://en.henkel-mea.com/about-henkel/kenya-6057.htm
Company name Ajay Industrial company
Address Sahibabad Industrial Area, Ghaziabad 201010, Uttar Pradesh, India
Contact Tel: +91-120-277
277-0679, Fax: +91-120-277-0729
Website http://www.ajayind.in
www.ajayind.in
Company name Davis & Shirtliff (Mwanza branch) *Shop for Ajay production
Address P.O.Box 2877 Mwanza, Tanzania
Contact Tel: +255-28-2541971/2,
2541971/2, Mob:+255-754-318827,e-mail: Ellison.Malyi@dayliff.com
.Malyi@dayliff.com
Website http://www.davisandshirtliff.com
28

(Afridev
Afridev Handpump, India Mark-II
Mark Handpumps)
ANNEX
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
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
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
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
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
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
----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------
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

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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 (AFRIDEV Handpump)

2. Handpump Assembly ---------------------------------------------------------------------------------

3. Installation of Handpump -------------------------------------------------------------------------

4. Daily Operation and Preventive Check ------------------------------------------------------- 18

5. Maintenance and Repair ---------------------------------------------------------------------------

Operation and Maintenance Manual (Afridev Handpump)

5.2 Repair of Riser Pipe ---------------------------------------------------------------------------

< ANNEX >

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

Operation and Maintenance Manual (Afidev Handpump)

1.2 INTRODUCTION OF HANDPUMP

Table 1-2 Summary of Specification

Installation depth Maximum

Manufacture of handpump is as follows.

Operation and Maintenance Manual (Afidev Handpump)

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

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

3) AJAY AFRIDEV Deep Well Handpump Installation

Operation and Maintenance Manual (Afidev Handpump)

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

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

Table 1-1 Introduction of Contractor in this Project

Operation and Maintenance Manual (Afidev Handpump)

Operation and Maintenance Manual (Afidev Handpump)

Pump Stand Pump Head Head Cover

Handle Corn Plate Rubber Compression Corn

Fulcrum Pin Rod Hanger Pin Bush Bearing

Rod Hanger Assembly Rubber Flapper Top Sleeve

Fig. 2-2 Assembly above Ground Components

Operation and Maintenance Manual (Afidev Handpump)

uPVC Cylinder uPVC Suction Pipe uPVC Riser Main Pipe

Plastic Foot Valve Brass Plunger Assembly Stainless Riser Rod

Pipe Centralize Nylon Rope Rod Centralize

Foot Valve O-ring U-seal Valve Bobbin

Fig. 2-3 Assembly above Ground Components

Operation and Maintenance Manual (Afidev Handpump)

Fishing Tools Open Ended Spanner Socket Spanner

(2) Other Tools and Materials

Tool Box Hacksaw for SS rod Steel File

Screw Driver Sand Paper Brush

Nylon Rope Solvent Cement Cleaning Fluid

Operation and Maintenance Manual (Afidev Handpump)

2) Place riser pipe centralizers on each pipe at 3meters

Fig.3-1 Making at end of pipe Fig.3-2 Placing Riser Main Centralizer

3) Roughen slightly on outside of pipe end and inside of bell-end

(2) Preparation of Cylinder Parts

7)) Make a knot on the rope at both side

Operation and Maintenance Manual (Afidev Handpump)

< Note >

(3) Installation of Cylinder

12)) Pass nylon rope through the slots of the centralizer

(4) Installation of Riser Pipe

14) Support downside pipe (cylinder or riser pipe) by

15) Wipe out any surplus of solvent cement immediately.

Operation and Maintenance Manual (Afidev Handpump)

17) Pass rope through the slots of the centralizer on the

19)) Continue this process of jointing pipe (13 to 17), and

20) When the last riser pipe is install,

Operation and Maintenance Manual (Afidev Handpump)