Waterax MARK-3 Owner's Manual
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Waterax MARK-3 Owner's Manual

Portable high-pressure fire pump
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MARK-3
Owner's Manual
Publication Date: 03/2016
Publication Number: 701247, Rev. 5
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Summary of Contents for Waterax MARK-3

  • Page 1 ® MARK-3 Owner's Manual Publication Date: 03/2016 Publication Number: 701247, Rev. 5...
  • Page 2 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.

  • Page 3: Table Of Contents

    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 03/2016 – Page 3 of 52...
  • Page 4 WATERAX MARK-3 Owner's Manual 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 ............................

  • Page 5: Important Safety Instructions

    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.

  • Page 6: Preventing Damage To Equipment

    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.

  • Page 7: Parts Identification

     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.

  • Page 8: 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.
  • Page 9 WATERAX MARK-3 Owner's Manual 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.

  • Page 10: Pump Connections And Priming

    WATERAX MARK-3 Owner's Manual 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.

  • Page 11: Engine Startup

    2 minutes before using full throttle. Note: The MARK-3 engine is broken-in at the factory. Full throttle operation can be used provided the engine is given a thorough warm-up period beforehand. Failure to allow engine to warm up may lead to piston scoring and possibly more serious engine damage.

  • Page 12: Discharge

    WATERAX MARK-3 Owner's Manual Discharge Once the pump is primed, and with the engine running, you can begin to discharge water. a) If pressure does not build in the discharge hose, the pump has not been fully primed. Prime the pump again b) The engine works best at wide open throttle.

  • Page 13: Removing Or Attaching The Pump End

    WATERAX MARK-3 Owner's Manual Removing or Attaching the Pump End The MARK-3 pump has a quick release pump clamp and detachable pump end which facilitates the servicing of pump units and minimizes down-time in the field by allowing the quick replacement of pump ends.
  • Page 14 WATERAX MARK-3 Owner's Manual Regular maintenance Regular maintenance is a schedule of continuous systematic maintenance, designed to prevent frequent or major breakdowns before they occur. WARNING: Maintenance on a fire pump should not be done on the fire line. Always check your pump unit immediately after use.

  • Page 15: Troubleshooting

    WATERAX MARK-3 Owner's Manual Troubleshooting This section provides brief troubleshooting instructions for verifying the set-up and operation of the pump. Each section describes a condition and lists possible causes along with a list of items to check to identify the source of the problem and resolve it.
  • Page 16 WATERAX MARK-3 Owner's Manual Engine Does Not Start, Runs Irregularly or Misses Refill fuel tank. Carburetor Loose Tighten nuts and/or Fuel Supply Tank studs. Empty Fuel Supply Valve Open supply valve. Defective Carburetor Repair or replace. Closed See “Carburetor” Air Vent on Fuel Tank...

  • Page 17: Service

    SERVICE This section includes instructions for overhaul and maintenance requiring disassembly of the 185cc engine and 4-stage pump end model 12-16S. Note: It is recommended that all fasteners be replaced with genuine WATERAX parts. Carburetor Parts breakdown ID ITEM NO...
  • Page 18 WATERAX MARK-3 Owner's Manual Maintenance The carburetor can be cleaned with a minimum of tools. Before disassembling the carburetor, it is imperative to flush it clean of dirt by using proper carburetor cleaner. 1. Remove strainer cover retaining screw and plastic cover.
  • Page 19 WATERAX MARK-3 Owner's Manual Before reassembling the carburetor (in reverse order as outlined previously), wash all component parts in carburetor cleaner and blow off with compressed air. The channels in the metering body should be cleaned by blowing through the low and high speed adjusting orifices. All fuel passages in the three castings should be cleaned with compressed air.
  • Page 20 It will be necessary to readjust the carburetor when operating the pump at different altitudes. A special offset screwdriver is available. It allows for an easy adjustment of the low speed jet on the MARK-3 carburetor. Item number is 801147. 03/2016 – Page 20 of 52...

  • Page 21: Troubleshooting

    WATERAX MARK-3 Owner's Manual Troubleshooting Carburetor Flooding Dirt or Foreign Remove, clean and/or Diaphragm Lever Remove lever and Particles Preventing replace. Spring Not Seated on reinstall. Inlet Needle From Lever Dimple Seating Diaphragm Improperly Replace diaphragm or Improper Use of Choke Disengage/Open choke.

  • Page 22: Air Filter

    2 800489 R-791 LOCKWASHER #10 SPLIT ZINC 3 600177 R-1044 LOCK PLATE FOR MARK-3 4 600169 R-794 AIR FILTER COVER FOR MARK-3 5 701286** EMBER SEPARATOR FOR MARK-3 6 700810 R-955 AIR FILTER 7 600519 R-790 CARBURETOR SHROUD, WITH DECAL...

  • Page 23: Fan Cowl (Housing)

    WATERAX MARK-3 Owner's Manual Parts breakdown (USFS) ID ITEM NO DESCRIPTION 1 600136* R-1206A-GSA 5' FUEL LINE PRIMING BULB 2 700715** O-RING-10 O-RING 9/16"ODX3/8"IDX3/32"THK 3 700660** A-7505 MALE PLUG 4 800814 R-732 CONNECTOR 1/4"TUBE X 1/8"NPT 5 700017 12-65 COUPLING SWIVEL...

  • Page 24: Pump Clamp

    WATERAX MARK-3 Owner's Manual Pump Clamp Parts breakdown ITEM NO DESCRIPTION 700581 A-4460 LEVER, ZINC PLATED 600122 A-4452 SIDE LINK FOR LEVER, ZINC PLATED 800426 C-4462-5 COTTER PIN DIN 94 2.5MM X 16MM 800263 A-4455 CLEVIS PIN FOR LEVER SIDE...

  • Page 25: Rewind Starter

    WATERAX MARK-3 Owner's Manual Rewind Starter Parts breakdown ID ITEM NO DESCRIPTION - 800131 R-529 REWIND STARTER COMPLETE 1 800083 R-518 CIRCLIP 5MM, DIN 6799.5, BLACK 2 800101 R-517 FLAT WASHER 3 800086 R-516 SPRING - FRICTION 4 800100 R-526 WASHER - FRICTION...
  • Page 26 WATERAX MARK-3 Owner's Manual Disassembly 1. Remove the rewind starter from the fan cowl. Warning: Wear safety goggles during the disassembly and assembly of the rewind starter. Special attention must be paid to the rewind spring. 2. Remove the circlip #1 and flat washer #2.
  • Page 27 WATERAX MARK-3 Owner's Manual 3. Slide in the rope guide, rubber buffer and starter handle on the rope. 4. Tie a knot to secure the starter handle in place. 5. Apply a small amount of Molykote G-N grease on the starter housing shaft.

  • Page 28: Muffler

    C-5200N MOUNTING FRAME WITH HARDWARE 600082 C-5200N-15 HARWARE KIT FOR C-5200N FRAME (INCL. ALL PARTS EXCEPT C-5201 FRAME) 1 600037 A-6149P MARK-3 MOUNTING LEG, PLATED 2 600108 A-4005 MOUNTING PAD, PLATED 3 700021 A-6179 RING, RUBBER 4 700652 C-5200-5 WASHER,13/16"ODX1/2"IDX1/8"THK...

  • Page 29: Digital Overspeed Switch (Dos)

    MARK-3 is in operation or by using the DTM DOS Testing Module (700773). Below is the normal behavior of the DOS when running on a MARK-3: Start the engine. The DOS LED shall flash 4 times at engine start up and DOS LED shall flash continuously to indicate that the DOS is powered up.

  • Page 30: Ignition System

    WATERAX MARK-3 Owner's Manual Ignition System Spark plug Operating with a defective or incorrect spark plug will affect the engine's performance and can cause hard starting, fouling, missing, overheating, pre ignition and/or lack of power. To service and inspect the spark plug, the following steps must be performed.
  • Page 31 WATERAX MARK-3 Owner's Manual CDI module diagnostic GROUND A.T. “STOP” “VERDE” (red wire) (high voltage) “STOP” ≤ 0.1 Ω ≥ 50 MΩ ≥ 50 MΩ “VERDE” ≤ 0.1 Ω ≥ 50 MΩ ≥ 50 MΩ GROUND ≥ 50 MΩ ≥ 50 MΩ...
  • Page 32 WATERAX MARK-3 Owner's Manual Ignition timing The stator must be positioned adequately in order to have the appropriate ignition timing. An ignition timing tool (801146) is available. 1. To position the stator, remove labyrinth ring and install ignition timing adjustment tool. Turn stator clockwise until coil rests on adjustment tool.

  • Page 33: Engine Overhaul Procedures

    WATERAX MARK-3 Owner's Manual ENGINE OVERHAUL PROCEDURES The following outlines how to conduct major overhaul service on the MARK-3 engine. It lists all instructions to replace or service the following components: • Cylinder; • Crankshaft-connecting rod assembly; • Crankshaft ball bearings;...

  • Page 34: Crankcase

    ZINC DIN912 17 800062 R-117 STUD M8 X 1.25 X 32 MM LG 5 801107 LOCKWASHER M6 SPLIT BOWED ZINC 18 700124 R-136 PUMP MOUNTING FLANGE FOR MARK-3, DICHROMATE DIN128A 6 800041 R-236 STUD M8 X 1.25 X 151 MM LG...

  • Page 35: Crankshaft Assembly, Pistons And Shims

    R-331-O-1 OVERSIZED L-TYPE PISTON RING 800031 R-331-O OVERSIZED PISTON RING 0.078" Engine Tool Kit ID ITEM NO DESCRIPTION 250286 R-952N TOOL KIT FOR MARK-3 ENGINE 1 600157 R-938 PULLER, CRANKSHAFT BEARING 1-PIECE 2 600164 R-953 CRANKSHAFT JACK 3 701352 CIRCLIP REMOVAL TOOL FOR 185CC...

  • Page 36: Piston/Cylinder Matching

    WATERAX MARK-3 Owner's Manual Piston/Cylinder Matching During engine top end repair, it is highly recommended to match the piston with the cylinder in order to obtain the correct piston/cylinder clearance. To facilitate the matching process, a color scheme is used: red piston matches with red cylinder;...

  • Page 37: Decarbonising

    WATERAX MARK-3 Owner's Manual Decarbonising After several hours of normal operation, carbon deposits will form on the piston crown, cylinder head, in the cylinder exhaust port and around piston rings and in the ring grooves, causing erratic and faulty operation. The piston skirt may also show signs of gum and varnish deposits.
  • Page 38 WATERAX MARK-3 Owner's Manual excessive engine temperature. The issue resides with the abnormally high friction that is created when these “high” spots are “rubbed/worn down”. Friction generates heat; heat creates material expansion; expansion reduces running clearances which in turn increases friction.

  • Page 39: Disassembly Of The Engine From The Mark-3

    WATERAX MARK-3 Owner's Manual Disassembly of the Engine From the MARK-3 1. Remove pump end and coupling buffer. 2. Disconnect all wiring from engine. 3. Remove spark plug cable clamp. 4. Remove bracket R-799, which fastens to side of carburetor shroud to engine crankcase.
  • Page 40 WATERAX MARK-3 Owner's Manual 7. Measure the thickness of ball bearing R-343. Call this dimension (E) (see image). 8. Measure the thickness of crankshaft spacer R-334. Call this dimension (F) (see image). 9. Measure the width of the crankshaft between both bearing thrust surfaces. Call this dimension (G) (see image).
  • Page 41 WATERAX MARK-3 Owner's Manual 29. Carefully cut off the crankcase gasket protruding from the cylinder base gasket surface with a sharp knife. 30. Oil the crankshaft needle bearing and bearing oil holes in the crankcase. 31. If piston was removed, reinstall it in proper position (arrow on top of piston pointing towards muffler side).

  • Page 42: Pump End Overhaul Procedures

    Important: It is recommended to discard all O-rings, lockwashers and nylon lock screws. Kit containing replacements O-rings, lockwashers and nylon lock screws is available from WATERAX (item no 250228). 03/2016 – Page 42 of 52...

  • Page 43: Assembly Procedure For Pump End 12-16S

    WATERAX MARK-3 Owner's Manual Assembly Procedure for Pump End 12-16S ID ITEM NO DESCRIPTION 16 700006 12-17 COUPLING BUFFER 17 700037* 12-2C PUMP SHAFT FOR 12-16 18 800364 12-25 SCREW #8-32X7/16 PHILLIPS FLAT NYLON LOCK SS 19 700032* 12-3 RETAINING RING FOR BEARING, ALU.

  • Page 44: Pump Test

    17.6-17.9 bar Note: Performance can vary depending on test conditions Pump Tool Kit ID ITEM NO DESCRIPTION 250158 R-900 TOOL KIT FOR MARK-3 PUMP 1 800081 R-908 WRENCH - OPEN END 5 & 8 MM 2 700541 A-3023 CARBURETTOR ADJUSTING TOOL 3 800492 R-902 SCREWDRIVER 1/8"...

  • Page 45: Technical Data

    WATERAX MARK-3 Owner's Manual TECHNICAL DATA Pump End Threads 1-1/2” [38 mm] NPSH male Discharge port 2” [51 mm] NPSH male Suction (intake) port 1-1/2” [38 mm] NPSH male Priming port Torque Values Retaining ring screw 22-25 in-lbs 2.5-2.8 Nm...
  • Page 46 WATERAX MARK-3 Owner's Manual Clearance Data and Limits Spark plug gap 0.020-0.024 in 0.5-0.6 mm Ignition timing – contact breaker (point) 0.147 - 0.020 in 3.75 - 0.5 mm Ignition timing – CDI 0.147 +/- 0.020 in 3.75 +/- 0.5 mm Magneto air gap 0.010-0.013 in...

  • Page 47: Parts Index

    20 700118 R-505 LOCK PIN 5.5MM DIA X 6MM LG, STEEL 600160 R-906M WRENCH, BOX & OPEN END 10 MM 42 700124 R-136 PUMP MOUNTING FLANGE FOR MARK-3 600161 R-933 OIL SEAL - PRESSING TOOL 33 700531 A-4329 PRESSING SLEEVE ROTARY SEAL...
  • Page 48 WATERAX MARK-3 Owner's Manual ITEM NO DESCRIPTION PAGES ITEM NO DESCRIPTION PAGES 700552 A-2391B ADP, FEM NPT - SWIVEL FEM 42 800039 R-274 IGNITION CABLE 500MM 700555 A-2389 TOOL AND ACCESSORY BOX 42 800040 R-120 HEX NUT M8 X 1.25...
  • Page 49 WATERAX MARK-3 Owner's Manual ITEM NO DESCRIPTION PAGES ITEM NO DESCRIPTION PAGES 800164 R-1012 FUEL PUMP DIAPHRAGM 15 800544 R-150 NUT M6X1.0 HEX FUJI LOCK ZINC 21,26,28,31 800263 A-4455 CLEVIS PIN FOR LEVER SIDE 22 800545 R-149 LOCKWASHER M6 SPRING ZINC...
  • Page 50 WATERAX MARK-3 Owner's Manual Notes 03/2016 – Page 50 of 52...

  • Page 51: Warranty

    WHEREAS subject to the following general and specific terms and conditions, WATERAX Inc. (the “Seller”) hereby warrants to the original purchaser of the products from WATERAX, (the “Purchaser”) that its products, including any pump parts products manufactured by WATERAX (the “Products”) sold under Seller’s brands will be free of defects in material and workmanship for the applicable Warranty Period (as set out in full at www.waterax.com/eng/warranty).
  • Page 52 All information contained in this document including drawings is proprietary to WATERAX and may not be copied, reproduced or used in whole or in part without our prior written permission. The information in this document is subject to change without notice. Model displayed with multiple options.

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