Waterax MARK-3 User manual

MARK-3®
Owner's Manual
Publication Date: 03/2016
Publication Number: 701247, Rev. 5

03/2016 –Page 2 of 52
This document provides information proprietary to WATERAX Inc. and cannot be used
or disclosed without WATERAX’s written authorization.
WATERAX Inc. reserves the right to make changes without notice in its products or components as
research and development or marketing conditions warrant. Changes affecting the operation of any
component in this manual will be reflected in a subsequent revision. WATERAX Inc. assumes no
responsibility for any omissions or errors that may appear in this document or for any damages that may
result from the use of information contained herein.
The following are trademarks or brand names of WATERAX Inc.: WATERAX, ‘WE MOVE WATER’.
All other trademarks used in this manual are the exclusive property of their owner.
MARK-3®Owner's Manual
Publication No.: 701247, Rev. 5
Publication Date: 03/2016
First Edition: March 2015
Published by:
WATERAX Inc.
6635 Henri-Bourassa W.
Montreal, Quebec H4R 1E1
CANADA
© 2015 WATERAX Inc.
All rights reserved
Printed in Canada

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Contents
Important Safety Instructions.....................................................................................................................5
Personal Safety Advisory...........................................................................................................................5
Warnings ....................................................................................................................................................5
Preventing Damage to Equipment .............................................................................................................6
Introduction..................................................................................................................................................6
About this Manual.......................................................................................................................................6
About the MARK-3 .....................................................................................................................................6
Parts Identification......................................................................................................................................7
Operating MARK-3 Series Pumps..............................................................................................................8
Pre-Operation Checklist.............................................................................................................................8
Fuel Supply.................................................................................................................................................8
Pump Connections and Priming...............................................................................................................10
Engine Startup..........................................................................................................................................11
Discharge .................................................................................................................................................12
Shutdown..................................................................................................................................................12
Operating the Digital Overspeed Switch (DOS).......................................................................................12
Cold Weather Operation...........................................................................................................................12
Removing or Attaching the Pump End.....................................................................................................13
Basic Care and Storage...........................................................................................................................13
Troubleshooting........................................................................................................................................15
Service ........................................................................................................................................................17
Carburetor ................................................................................................................................................17
Troubleshooting........................................................................................................................................21
Air Filter....................................................................................................................................................22
Fuel Line...................................................................................................................................................22
Fan Cowl (Housing)..................................................................................................................................23
Pump Clamp.............................................................................................................................................24
Rewind Starter..........................................................................................................................................25
Muffler.......................................................................................................................................................28
Frame.......................................................................................................................................................28
Digital Overspeed Switch (DOS)..............................................................................................................29
Ignition System.........................................................................................................................................30
Engine Overhaul Procedures ...................................................................................................................33
Cylinder ....................................................................................................................................................33
Cylinder Head With Decompression Switch ............................................................................................33
Crankcase ................................................................................................................................................34
Crankshaft Assembly, Pistons and Shims ...............................................................................................35
Engine Tool Kit.........................................................................................................................................35
Piston/Cylinder Matching..........................................................................................................................36
Decarbonising ..........................................................................................................................................37
Deglazing..................................................................................................................................................37
Break-in....................................................................................................................................................37
Disassembly of the Engine From the MARK-3 ........................................................................................39
Disassembly of the Engine.......................................................................................................................39
Reassembly of the Engine .......................................................................................................................39

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Pump End Overhaul Procedures..............................................................................................................42
Pump Tool Kit...........................................................................................................................................42
Disassembly Procedure for Pump End 12-16S .......................................................................................42
Assembly Procedure for Pump End 12-16S ............................................................................................43
Pump Test................................................................................................................................................44
Pump Tool Kit...........................................................................................................................................44
Technical Data............................................................................................................................................45
Pump End.................................................................................................................................................45
Engine ......................................................................................................................................................45
Parts Index..................................................................................................................................................47
Warranty......................................................................................................................................................51

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IMPORTANT SAFETY INSTRUCTIONS
It is recommended that all information provided in this manual be carefully read and
understood before performing any operation of or maintenance to the pump.
The procedures listed in this manual are general operating and maintenance procedures.
They should be taken in addition to any procedures, policies and guidelines established by
the authority having jurisdiction or the apparatus manufacturer. Where conflicts arise, all
parties (authority having jurisdiction, the apparatus manufacturer, and WATERAX Inc.) will
need to be contacted to determine the best resolution. The solution will need to address the
safety of the operator along with the proper performance and life expectancy of the unit.
Personal Safety Advisory
READ THIS MANUAL BEFORE OPERATING YOUR PUMP!
The improper use of the WATERAX pump could result in serious injuries as well as
damage to the pump. This manual contains very important safety information that MUST be
read, understood and followed to safeguard you and your equipment from harm, as well as
specific information on the proper use and care of your engine. Any operator should
familiarize himself with the apparatus and its capabilities before trying to operate the
equipment in an emergency situation. Please read this entire manual before using your
WATERAX pump and follow all Personal Safety Advisories.
Warnings
 Always wear eye and ear protection when operating the pump unit.
 Do not operate if mentally or physically fatigued.
 Always inspect hoses and piping to avoid burst injuries.
 Use only pipe, hose, and fittings that are rated at or above the maximum pressure rating
of the pump shown below, or according to what maximum pressure the system was
designed for, whichever is lower.
▪ Maximum Allowable Pressure: 600 PSI (41 bar)
▪ Maximum Allow Pump Intake Pressure: 200 PSI (13.8 bar)
 No modifications and/or alterations may be made to the pump. Any such modifications
not only void the pump warranty but can make the unit dangerous to anyone operating
the pump.
 Do not operate the pump higher than the maximum rated pressure. Always run the unit
at the lowest pressure required for the application to enhance operator and equipment
safety.
 Slowly close valves and use slow close valves wherever possible to prevent danger to
other line operators and to prevent water hammer which could damage the pump and its
piping components.
 Relieve all system pressure before doing any service work on the pump.
 Never run the pump in a closed or confined area. Exhaust gas contains carbon
monoxide which is poisonous to humans. Avoid inhalation of exhaust gas.
 Refuel engine with care. Gasoline is extremely flammable, and gasoline vapor can
explode. Refuel in a well-ventilated area, with the engine stopped.
 Be alert and never touch any part of the engine exhaust system while the engine is
running. Always allow enough time, after stopping the unit, for proper cooling of the
muffler and surrounding parts.
 Careful not to pinch your fingers around the cooling fan and engine output shaft.

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PREVENTING DAMAGE TO EQUIPMENT
The following recommendations will help avoid damage to your equipment:
 Always use the proper fuel mixture.
 Do not run the engine at full speed until thoroughly warmed up.
 Do not lift strainer out of the water while pump is operating.
 Do not run engine with pump disconnected.
 Do not run the pump when dry.
 Always draft water using a footvalve suction hose strainer.
 Check strainer frequently to make sure that it is not clogged with moss, leaves, etc.
 Flush the pump with fresh water if the pump has been used to pump salty, brackish,
high mineral content water, water containing debris, or foam injected water. Check that
debris is cleared before using pump again.
 Drain pump after final use.
 During freezing weather, drain the pump and lines of all water. You can also pour some
antifreeze into the pump and circulate it through the pump and plumbing system.
 Pumps should not be operated without water for any extended period of time or without
discharging water. Operating the pump in such a manner can overheat the pump
causing damage to seals, or pump internals.
 It is recommended that all fasteners be replaced with genuine WATERAX parts.
INTRODUCTION
About this Manual
This manual contains general operation, care and servicing procedures for the WATERAX
MARK-3 high pressure 4-stage centrifugal pump.
These instructions cover most wildland pump applications. If the application the pump is
being used for does not fall into these general guidelines, consult WATERAX Inc. for any
additional safeguards, operating, or maintenance considerations that may be required.
For full service and maintenance instructions regarding the engine and the pump, please
refer to the Service section.
Please see www.waterax.com additional documentation related to this product such as the
WATERAX product guide, technical notes, news and other updates about WATERAX and
its goods and services.
About the MARK-3
Features
For full specifications and performance curves, see the Product Data Sheet for your pump
end model.
Applications of the WATERAX MARK-3 series include:
 Attack line firefighting
 Long hose lay for remote watering during firefighting operations
 High elevation firefighting in mountainous areas
 Accuracy in flow trajectory when structure firefighting
 Tandem pumping over long distances
 Parallel pumping for higher volumes

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Features and Benefits of the WATERAX MARK-3 series include:
 Quick release clamp and swappable pump ends for minimal equipment downtime and
inventory
 Sealed bearing to eliminate pump end greasing in the field
 Aluminum alloy pump components and anodized parts for lighter weight and greater
resistance to corrosion
 Compatible with foam applications
 Blister resistant mechanical rotary seal
 Comprehensive manuals
The MARK-3 unit has been designed to meet all the requirements of advanced techniques
in forest fire control, including USDA Forest Service Specifications No. 5100-274C.
Considered an emergency rescue equipment, the MARK-3 is exempt from EPA emission
standards under 40 CFR 1054.660.
Parts Identification
A. Priming cap
B. Pump intake (suction)
C. Pump discharge
D. Quick release pump clamp
E. Fuel connection*
F. Engine drain plug
G. Air filter
H. Choke (not shown)
I. Throttle
J. Rewind starter
K. Digital Overspeed Switch (DOS)
L. Spark plug
M. Decompression switch –optional
(not shown)
N. Muffler
* Mercury fuel fitting shown

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OPERATING MARK-3 SERIES PUMPS
Pre-Operation Checklist
Before using your pump, follow this verification procedure:
1. Visually inspect product. When you first receive your MARK-3 pump, inspect the
product and check for any damage. Notify the supplier if any damage is found.
2. Check that all suction and discharge hoses are structurally sound and do not leak.
3. Inspect all safety features and verify that they are in good order before using the pump.
4. Each time you plan to use the pump, check for damage that may have occurred during
previous use. Notify your manager that the equipment requires repair. Remember that
damaged equipment can expose you to safety hazards.
Fuel Supply
Fuel mixture
The MARK-3 is powered by a 185cc two-cycle (two-stroke) engine.
For lubrication, the engine requires a premixed fuel mixture of
gasoline and oil.
GASOLINE: 87 octane unleaded automotive gasoline
(maximum 10% ethanol)
OIL: High quality two-cycle mixing oil with API-TC,
JASO-FD and ISO-L-EGD certification (e.g.,
Amsoil Saber®Professional Synthetic)
FUEL MIX RATIO: 50:1 (gas to oil)
Note:
Not enough emphasis can be placed on the use of correct gasoline and oil mixture. Using
less than the recommended portion of oil will cause overheating and possible engine
damage. Using more than the recommended proportion of oil will cause spark plug
fouling, erratic carburetion, excessive exhaust smoke and rapid carbon deposits.
Note:
This fuel mixture is compatible with both Nikasil and cast iron sleeve cylinder engines. For
engine break-in fuel mixture, refer to the Service section.
Gasoline, octane and ethanol
WATERAX recommends using high quality automotive grade gasoline with a minimum
octane rating of 87 (AKI) and a maximum ethanol concentration of 10% in its fuel mix for
the MARK-3.
It is important to note that gasoline has a shelf life. Depending on storage conditions,
gasoline can go stale in a matter of weeks. Gasoline will deteriorate in three ways:
1. The more volatile components of the gasoline evaporate, leaving behind a heavier
gasoline which can lead to inferior engine performance and a more difficult engine to
start.
2. Certain hydrocarbons in the gas react with oxygen (oxidation) producing new and
harmful compounds. The stale gasoline will smell sour, its color will go dark, and
gummy particles can appear in the gas. This can lead to poor engine performance and
reliability issues with the carburetor.
3. Water contamination, which is normally caused by condensation, can be catastrophic
to the engine. Gasoline containing ethanol is more susceptible to that problem. Ethanol

WATERAX MARK-3 Owner's Manual
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is hydrophilic, which means that it tends to draw in moisture. If the water contamination
is severe enough, the ethanol will separate from the gasoline and drop to the bottom of
the fuel tank. Since water and oil do not mix well, this ethanol and water blend can
cause severe engine problems due to the lack of lubrication.
To prevent any damage to the engine, it is highly recommended to only use fresh gasoline.
Gas stabilizers can be used to increase the gasoline’s shelf life; however, it will not restore
back bad gasoline.
Supply recommended fuel to engine
1. Carefully mix the fuel as recommended in
the Fuel Mixture section.
2. Connect fuel supply line to fuel tank.
3. Prime fuel supply line to evacuate air
bubbles.
4. Connect fuel supply line to engine fuel
connection.
5. Pump fuel up to carburetor.
Note:
Careful not to flood the engine when pumping fuel up to the carburetor; gently squeeze
the priming bulb.
Warning:
Ensure that the fuel tank is positioned away and at a safe distance of the muffler to avoid
any potential accident. Always refuel with care.
Flooded engine
Flooding an engine refers to an accumulation of excess fuel in the cylinder and crankcase
due to excessive fuel priming or use of choke. This condition makes the engine nearly
impossible to start without clearing the engine of the excess fuel.
Clearing a flooded engine:
a) Disconnect the spark plug cable and remove the spark plug.
b) Re-connect the spark plug cable to the spark plug. Place the spark plug in contact with
the cylinder head in order to ground the spark plug.
Note:
Failure to ground the spark plug can lead to damage of the CDI ignition coil when cranking
the engine.
c) With both choke and throttle in fully open position, pull starter rope several times until
excess fuel is exhausted.
d) Before reinstalling spark plug, clean and dry electrode and insulator tip.
e) If engine is severely flooded, remove the engine drain plug and drain engine.

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Pump Connections and Priming
1. Connect footvalve strainer to male end of suction hose, then fill suction hose with
water. Connect hose to the pump intake. Use universal hose coupling wrench to tighten
coupling firmly.
Manual Priming:
a) Open the priming cap and fill pump with
water manually.
b) Firmly tighten priming cap.
c) Pump can also be primed by “jerking”
the suction hose until water flows from
the pump’s discharge port.
WATERAX Hand Primer: Connect hand
primer to discharge port or priming port and
pump until water is drawn into the pump.
Firmly tighten priming cap.
2. Connect discharge hose, nozzles, etc. to
pump using universal hose coupling wrench to tighten coupling firmly.
Note:
To provide proper operation of the pump, the suction hose/strainer should be submerged
a minimum of 4 to 6 times the hose diameter into the water source.
DO NOT run pump when dry.
DO NOT allow footvalve strainer to rest on bottom of lake or riverbed. Check strainer
frequently to make sure that it is not clogged with moss, leaves, etc.
DO NOT lift strainer from water while the pump is operating. Use a rope or other means to
keep strainer at proper height, approximately 1 foot (30 cm) below water surface. If
strainer is too close to the water surface, it will draw air and pump may lose prime.
To maintain optimum performance from your pump, follow these recommendations for
selecting and installing your suction hose:
▪ Use the shortest length possible, i.e., place the pump as close to the water as
possible.
▪ Select reinforced crush resistant (non-collapsible) hose.
▪ To avoid air locks, flexible hose should rise gently from the water source to the
suction/inlet port without excessive dips, bumps, sharp angles or rise in its lay.
▪ Footvalve suction strainers should be fitted to prevent foreign matter from entering
the pump.
▪ Where practicable, the installation and use of a suction float will aid in the
performance of your pump, by keeping suction away from the debris on the bottom of
the dam or river.
▪ Ensure that the suction hose is completely submersed.