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

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MARK-3
Owner's Manual
Publication Date: 06/2023
Publication Number: 702135, Rev.1
®
Watson Edition

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Summary of Contents for Waterax MARK-3 Watson Edition

  • Page 1 ® MARK-3 Watson Edition Owner's Manual Publication Date: 06/2023 Publication Number: 702135, Rev.1...
  • 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

    Warnings..............................4 Preventing Damage to Equipment ......................5 Introduction ..............................6 About this Manual ............................6 About the MARK-3 Watson Edition ......................6 Parts Identification ............................. 7 Pump Operation ............................8 Pre-Operation Checklist ..........................8 User Interface (UI) ............................. 8 Fuel Supply ..............................

  • Page 4: Important Safety Instructions

    Please read this entire manual before using your WATERAX pump and follow all Personal Safety Advisories. This pump must only be operated by trained personnel.

  • Page 5: Preventing Damage To Equipment

     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 parts be replaced with genuine WATERAX parts. 06/2023 – Page 5 of 62...

  • Page 6: Introduction

    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 for any additional safeguards, operating, or maintenance considerations that may be required.

  • Page 7: Parts Identification

    WATERAX MARK-3 Watson Edition Owner's Manual Parts Identification A. Engine B. Pump Intake (suction) C. Pump Discharge D. Quick Release Pump Clamp E. Fuel Connection F. Engine Drain Plug (not shown) G. Air Filter H. Choke I. Carburetor Purge Bulb J.

  • Page 8: Pump Operation

    WATERAX MARK-3 Watson Edition Owner's Manual PUMP OPERATION Pre-Operation Checklist Before using your pump, follow this verification procedure: 1. Visually inspect product. When you first receive your pump, inspect the product and check for any damage. Notify the supplier if any damage is found.

  • Page 9: Fuel Supply

    Do not use two-cycle mixing oil made for water cooled engines (TCW). 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.
  • Page 10 In the spring and summer when ambient temperatures are warm, a lower-RVP gasoline prevents vapor lock, when too much vapor may prevent an engine from starting or running properly. Thus, WATERAX strongly recommends using summer- grade gasoline with the MARK-3, especially when ambient temperatures are hot, to ensure optimal startability, operation and performance.

  • Page 11: Pump Connection And Priming

    WATERAX MARK-3 Watson Edition Owner's Manual 3. With both choke and throttle in fully open position, pull starter rope several times until excess fuel is exhausted. 4. Before reinstalling spark plug, clean and dry the electrode and insulator tip. 5. If engine is severely flooded, remove the engine drain plug and drain engine.

  • Page 12: Engine Startup

    WATERAX MARK-3 Watson Edition Owner's Manual Engine Startup 1. Close/engage choke (H), if engine is cold. (CLOSED/ 2. Move throttle lever to “START/WARM UP” (3 ENGAGED increments from “IDLE”). POSITION) 3. Slowly crank engine until resistance (past compression). 4. Pull the rope until recoil pawl engages the pulley, then give starter cord a quick and steady pull.

  • Page 13: Discharge

    WATERAX MARK-3 Watson Edition 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 is not fully primed. Verify that there is no leak between the suction hose and the pump end.

  • Page 14: Removing Or Attaching The Pump End

    WATERAX MARK-3 Watson Edition Owner's Manual Removing or Attaching the Pump End The MARK-3 Watson Edition 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 15 WATERAX MARK-3 Watson Edition Owner's Manual 15. Make sure UIM is free of dirt and debris. Verify condition of wiring and connectors. 16. Note and report any performance irregularities or any abnormal mechanical sounds. 17. Make sure all necessary tools, spares, and accessories are with the pump.

  • Page 16: Troubleshooting

    WATERAX MARK-3 Watson Edition 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 17 WATERAX MARK-3 Watson Edition Owner's Manual Pump Cavitating  Restrictive or malfunctioning foot valve. Replace. Lift Too High  Clogged strainer. Clean.  Move pump closer to water source.  Decrease pump’s intake hose length.  Increase pump’s intake hose size.
  • Page 18 WATERAX MARK-3 Watson Edition Owner's Manual Engine Does Not Develop Normal Power And/Or Overheats See “Fuel Supply.” Wrong Oil Air Filter Dirty Clean or replace. See “Fuel Supply.” Replace muffler and/or Wrong Gasoline Muffler Blocked spark arrestor. See “Fuel Supply.”...

  • Page 19: Maintenance

    WATERAX MARK-3 Watson Edition Owner's Manual MAINTENANCE Regular maintenance Regular maintenance is a schedule of continuous systematic maintenance, designed to prevent frequent or major breakdowns before they occur. Warning: Before doing any maintenance to the pump, always ensure that the equipment cannot be accidentally started.

  • Page 20: Service

    WATERAX MARK-3 Watson Edition Owner's Manual SERVICE This section includes instructions for the complete overhaul of the unit. Servicing should be completed by a trained and experienced mechanic/technician. For any question regarding servicing, contact WATERAX technical support. Warning: ® It is important to respect the specified torque and application of Loctite where specified.
  • Page 21 WATERAX MARK-3 Watson Edition Owner's Manual  Pully not engaged on the spring. Re-assemble and engage pulley with spring.  Spring housing screws too tight. Torque at 5 lb-in (0.6 Nm). Disassembly Warning: Wear safety goggles during the disassembly and assembly of the rewind starter.
  • Page 22 WATERAX MARK-3 Watson Edition Owner's Manual 3. Align the spring retaining loop with the post in the housing and install the spring in the housing. 4. Apply Loctite 222 and tighten three screws #4 to a torque of 5 lb-in (0.6 Nm) to secure the spring in the housing.
  • Page 23 WATERAX MARK-3 Watson Edition Owner's Manual 12. Apply a small amount MOLYKOTE 1122 on the shaft. Be careful not to apply grease on the circlip groove. Clean the groove if necessary. 13. Align the opening in the pulley with the spring end and install the pulley.

  • Page 24: Fan Cowl Assembly

    WATERAX MARK-3 Watson Edition Owner's Manual Fan Cowl Assembly In the event of a physical shock, inspect the fan cowl, fan cowl bracket, and carry handle for cracks. Replace if necessary. Parts breakdown ITEM NO DESCRIPTION 701773 SHIELD FAN WATSON...

  • Page 25: Flywheel & Ignition

    WATERAX MARK-3 Watson Edition Owner's Manual Flywheel & Ignition The flywheel and stator provide AC power to the batteryless module, which in turn, regulates and rectifies it into DC power to feed the User Interface Module (UIM). Parts breakdown ITEM NO...
  • Page 26 WATERAX MARK-3 Watson Edition Owner's Manual 1. Disconnect the spark plug cable and remove the spark plug. 2. Clean the spark plug and inspect carefully. If tip of insulator core is rough, cracked, broken, or blistered, or if electrodes are burned away, replace with new plug.
  • Page 27 WATERAX MARK-3 Watson Edition Owner's Manual Assembly 1. Install the grommet in the crankcase. Be careful not to use a sharp tool to prevent damaging the grommet. 2. Install the stator with the cable facing the intake. Apply Loctite 222 and tighten the three M4 screws with the flat washers to 16.2 lb-in (1.8 Nm).

  • Page 28: Electronics

    WATERAX MARK-3 Watson Edition Owner's Manual Electronics Parts breakdown ITEM NO DESCRIPTION 701881 BUTTON AND LED USER INTERFACE WATSON 701797 HARNESS START BUTTON 6 WIRES WATSON 701979 USER INTERFACE MODULE UIM 701980 UIM DUST COVER BATTERY CR2032 701981 UIM BATTERY COVER...
  • Page 29 WATERAX MARK-3 Watson Edition Owner's Manual 5. Using finger pressure, bend the side walls of the Button and LED cover assembly and pull it (upwards) off the carburetor bracket. 6. Remove the three screws holding the electronics housing to the unit.
  • Page 30 WATERAX MARK-3 Watson Edition Owner's Manual 3. Apply Loctite 243 and install the rubber dampener screw and flat washer to 35.4 Lb- in (4 Nm). 4. When installing the temperature sensor: apply a small amount of thermal paste (e.g., DOWSIL™...

  • Page 31: Air Filter & Throttle

    WATERAX MARK-3 Watson Edition Owner's Manual Air Filter & Throttle Parts breakdown ITEM NO DESCRIPTION 701847 THROTTLE ASSEMBLY WATSON 701987 SCREW M5X0.8X12 HEX SOCKET BUTTON SS BLACK OXYDE 701892 COVER UIM BUTTON WATSON 702033 WASHER M4 FLAT 4.3MM X 9MM SS DIN125 701988 SCREW M4X0.7X10 HEX SOCKET CAP SS DIN...

  • Page 32: Carburetor

    WATERAX MARK-3 Watson Edition Owner's Manual Carburetor Parts breakdown ITEM NO DESCRIPTION 701904 CARBURETOR WITH PURGE PORT WATSON 800544 R-150 NUT M6X1.0 HEX FUJI LOCK ZINC 800545 R-149 LOCKWASHER M6 SPRING ZINC 701766 GASKET INTAKE CARBURETOR SIDE WATSON 701905 ISOLATING FLANGE INTAKE WATSON...
  • Page 33 WATERAX MARK-3 Watson Edition Owner's Manual Important: Do not soak the gaskets and diaphragms to avoid swelling. A gentle cleaning is recommended before reinstallation. Important: It is not recommended to blow compressed air inside the carburetor as this can damage the various check valves, further worsening the problem.
  • Page 34 WATERAX MARK-3 Watson Edition Owner's Manual 1. Before starting the pump unit, close both high and low speed adjustment screws by turning CW until they just touch the seat. Note: carburetors supplied as spare parts come pre-adjusted. 2. The entry settings are as follows: •...

  • Page 35: Fuel Connector & Purge Bulb

    WATERAX MARK-3 Watson Edition Owner's Manual Fuel Connector & Purge Bulb Parts breakdown ITEM NO DESCRIPTION 701957 SCREW M5X0.8X35 HEX SOCKET CAP SS DIN912 701927 WASHER M5 FLAT 5.3MM X 10MM SS DIN125 702058 BODY FUEL BLOCK ALU WATSON 702044...

  • Page 36: Muffler Assembly

    WATERAX MARK-3 Watson Edition Owner's Manual Muffler Assembly Parts breakdown ITEM NO DESCRIPTION 701729 GASKET EXHAUST FLANGE W140 701735* SCREW SPARK ARRESTOR 701734* SPARK ARRESTOR W140 701960* MUFFLER W140 701800 SCREW M8X1.25X50 HEX SOCKET CAP ZINC CL12.9 DIN912 701961* HEAT SHIELD MUFFLER W140 701927* WASHER M5 FLAT ID 5.3MM OD 10MM SS...

  • Page 37: Pump Hub

    WATERAX MARK-3 Watson Edition Owner's Manual Pump Hub Parts breakdown ITEM NO DESCRIPTION 701816 MOUNTING FLANGE PUMP WATSON 701814 WASHER M8 FLAT 8.4MM X 15MM SS 701815 SCREW M8X1.25X25 HEX SOCKET CAP SS DIN912 701818 COUPLING DRIVE 12 TEETH M16X1.5 ENGINE...

  • Page 38: Frame Assembly

    WATERAX MARK-3 Watson Edition Owner's Manual Frame Assembly Parts breakdown ITEM NO DESCRIPTION 600629 FRAME ASSEMBLY WITH CROSS-MEMBER WATSON 702025 NUT FLANGE CUSTOM M8 SS ISOLATOR MOUNT WATSON 702066 ISOLATOR MOUNT 30 DURO 1.313X.402 FRAME WATSON 702026 CROSS-MEMBER FRAME WATSON...

  • Page 39: Engine

    WASHER 5MM X 9MM COPPER 702096 SCREW M5X12MM SCHS The following section outlines how to conduct major overhaul service on the MARK-3 Watson Edition engine. Refer to the Engine Tool Kit for specialised disassembly and assembly tools. Piston It is recommended to replace the piston, piston pin, needle bearing and circlips at 125 hours. This servicing step is recommended to ensure optimal durability and performance of the engine.
  • Page 40 WATERAX MARK-3 Watson Edition Owner's Manual on several factors such as the fuel mix ratio, the carburetor adjustments, and the throttle position during operation. If a loss of power is observed, the engine should be decarbonised. To decarbonise the engine, proceed as follows: 1.
  • Page 41 WATERAX MARK-3 Watson Edition Owner's Manual 1. Adjust the carburetor as per the Carburetor adjustments section. 2. Once carburetor adjustments are completed, run at WOT for 15 minutes. 3. After the first 5 minutes, validate high speed adjustment. 4. At the end of the 15 minutes, verify carburetor adjustments. Adjust low speed, high speed, and idle speed if necessary.
  • Page 42 WATERAX MARK-3 Watson Edition Owner's Manual 9. Using an oven, heat both case halves to 350 °F (177 °C) for 30 minutes. Place the halves with the bearings facing down. The use of an oven is recommended for a controlled and uniform temperature.
  • Page 43 WATERAX MARK-3 Watson Edition Owner's Manual 8. Lightly oil the crankcase seal and bearing bores with 10W40 motor oil. 9. Press the seal (25 mm ID) using pressing tool. The seal spring must face inward. 10. Install MAG side protective sleeve 702128.
  • Page 44 WATERAX MARK-3 Watson Edition Owner's Manual 22. Using the crankshaft puller 702132, tighten the nut to pull the crankshaft into the inner race of the PTO bearing. Ensure that the center gasket stays in place. Tighten the nut just enough to ensure that the cases are together and tight.
  • Page 45 WATERAX MARK-3 Watson Edition Owner's Manual 29. Apply 10W40 motor oil to the wrist pin bearing and connecting rod small end and install in the connecting rod. 30. Using double angle hook pick install a wrist pin circlip into the PTO side of the piston.
  • Page 46 WATERAX MARK-3 Watson Edition Owner's Manual 43. Apply Copper gasket seal (e.g., Permatex Copper Spray-A-Gasket High-Temperature Sealant) to both sides of the head gasket and install it over the studs. 44. Orient the cylinder head over the cylinder head studs, observing that the outer most shape will only align with the cylinder fins in one orientation.

  • Page 47: Pump End

    WATERAX MARK-3 Watson Edition Owner's Manual Pump End The pump end does not require any special maintenance. The frequency of the part replacement will largely depend on the fluid that is pumped through. Pumping water with high concentrations of abrasive material (e.g.: sand, pebbles) and corrosive agents (e.g.: brackish water, salt water, chlorinated water) will eventually...
  • Page 48 WATERAX MARK-3 Watson Edition Owner's Manual Important: Do not use flat screwdrivers to remove the suction cover: this could cause the bronze bearing bushing to be misaligned. 6. Remove the first impeller. 7. Place the pump end upside down on the shaft assembly fixture 701859, aligning the shaft key with the keyway.
  • Page 49 WATERAX MARK-3 Watson Edition Owner's Manual Important: The mechanical rotary seal requires careful inspection. The seal should be discarded if there are signs of cracks or chipping. Warning: ® It is important to respect the specified torque and application of Loctite where specified.
  • Page 50 WATERAX MARK-3 Watson Edition Owner's Manual 3. Carefully slide the volute on to the seal. 4. Position the bearing on the shaft and the volute bearing bore. 5. Align the bearing pressing tool 701862 with the bearing inner race and press the bearing all the way down.

  • Page 51: Pump Test Kit

    WATERAX MARK-3 Watson Edition Owner's Manual 16. Install washer and shaft nut. Center the washer as much as possible on the impeller to avoid impeding the incoming water flow. Apply Loctite 243 and tighten to 18.4 lb-ft (25 Nm). 17. Align suction cover holes with corresponding threaded holes in the volute.

  • Page 52: Fuel Line

    WATERAX MARK-3 Watson Edition Owner's Manual Fuel Line Parts breakdown (Mercury) ITEM NO DESCRIPTION 600605* 12-401B-NSC COMPLETE FUEL LINE, STANDARD STYLE 800864 FA-451 FEM QUICK-CONNECT 600389 12-405-1 FUEL LINE PRIMING BULB 700017 12-65 COUPLING SWIVEL 800814 R-732 CONNECTOR 1/4"TUBE X 1/8"NPT...

  • Page 53: Tools

    WATERAX MARK-3 Watson Edition Owner's Manual Tools Parts breakdown – Engine tool kit ITEM NO DESCRIPTION 702108 TOOL KIT ENGINE W140 702105 TOOL FLYWHEEL PULLER W140 600157 R-938 TOOL BEARING 52MM PULLER CRANKSHAFT 702134 TOOL PISTON SUPPORT W140 702119 FIXTURE ASSEMBLY CRANKCASE W140...
  • Page 54 WATERAX MARK-3 Watson Edition Owner's Manual Parts breakdown – Pump end tool kit ITEM NO DESCRIPTION 702114 TOOL KIT PUMP END WATSON 701865 WATSON DISTRIBUTOR PRESSING TOOL 600079 A-1888 TOOL SUCTION COVER PULLER 702111 TOOL SEAL SEAT REMOVAL PUMP END...

  • Page 55: Technical Data

    WATERAX MARK-3 Watson Edition Owner's Manual TECHNICAL DATA Specifications – Pump Unit Dimensions (L x W x H) 21.6 x 12 x 14.6 in 549 x 305 x 371 mm Weight (dry) 44 lbs 20 kg Sound level Maximum 107 dBA...
  • Page 56 WATERAX MARK-3 Watson Edition Owner's Manual Torque Values Torque ® Component Fastener Thread Size Loctite Lb-in Lb-ft Frame Channel Support Screw M6-Button 35.4 Frame Handle Screw Cross-Member to Frame Screw 26.5 Cross-Member to Engine Screw 19.9 Fuel Block Screw 35.4...
  • Page 57 WATERAX MARK-3 Watson Edition Owner's Manual Clearance Data and Limits – Engine Spark plug gap .020-.024 in 0.5-0.6 mm CDIM to flywheel air gap .020-.024 in 0.5-0.6 mm Crankcase Main bearing diameter (new) 2.0453-2.0457 in 51.95-51.96 mm Main bearing diameter wear limit 2.0469 in...

  • Page 58: Trademark

    WATERAX MARK-3 Watson Edition Owner's Manual Wiring diagram TRADEMARK ® The Bluetooth word mark and logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by WATERAX is under license. 06/2023 – Page 58 of 62...

  • Page 59: Notes

    WATERAX MARK-3 Watson Edition Owner's Manual NOTES 06/2023 – Page 59 of 62...
  • Page 60 WATERAX MARK-3 Watson Edition Owner's Manual 06/2023 – Page 60 of 62...

  • Page 61: 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 62 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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