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WaterMax 60 Series Owner’s Manual 11/10/2008 33
Assembly and Parts, Cont.
Bypass Assembly Cont.
90262 Bypass
End Cap—Left;
90263 Bypass
End Cap—Right
Seals the left/right Piston opening on the Housing (90246). The opening is sealed with an O-Ring
used as an axial or “face” seal. The O-Ring sits in a groove in the End Cap. This groove must be free
of defects such as pits or scratches and also free of debris. When assembling the End Cap to the
Housing, care should be taken to make sure that the O-Ring stays in the groove in the End Cap. If
misaligned, the O-Ring can become pinched and leak. On the Left End Cap is the Piston Axle, a 1/4"
square shaft that acts as a guide/slide and anti-turning mechanism for the Bypass Piston. On the
Right End Cap is the guide/bushing for the Bypass Piston Drive Shaft (90218). There is an O-Ring
seal at the opening for the Drive Shaft. This seal area must be free of defects such as pits or
scratches and also free of debris.
90252 Blending
Dial Cap
The Cap should be held in place by the three 1/2" screws and be in the proper orientation.
90222 Blending
Dial
The dial permits the addition of “hard water” into the soft water outlet. It is closed when pointing
toward the Main Valve Body and open when pointing toward the inlet side.
90246 Bypass
Housing
Makes the connection between the plumbing and Main Valve Body. Also, contains the “Hard Water”
Blending Valve and Bypass Piston. The recommended seal for the 1-1/4" male inlet-outlet threads is
the plastic Hook-up Nut (90251), O-Ring (90837), and Copper Adapter (90254). Make sure the O-
Ring is between the Housing and Copper Adapter. The O-Ring seal areas at the Main Valve Body
inlet and outlet must be smooth and free of defects and debris, and lubricated with silicone grease
before assembling. When attaching to the Main Valve Body, put the O-Rings on the male bosses on
the Valve Body and push the Bypass into place; if not, the O-Rings may be “pinched.” If the O-Rings
are pinched, replace with new ones. The Bypass is pre-assembled with the Sensor housing and
turbine axle. These are not field-serviceable and if damaged, must be replaced with a new assembly.
The Bypass Piston bore is to be smooth and, at the recessed areas, have a smooth transition (no
sharp corners) to the seat areas.
90616 Bypass
Piston Assembly
The white Teflon Hydro-slide O-Ring covers should be free of defects such as indentations and cuts.
The Piston should move freely into and out of the Bypass Housing (90246) without damaging the
Hydro-slides. If the Hydro-slides catch, tear or crimp, the Housing should be replaced.
Note: Some compression will occur when the Hydro-slides pass through the seal areas.
90218 Bypass
Piston Drive
Shaft
The Drive Shaft has an acme thread which is used to move the Piston from “bypass” to “service”
position. When operating the Bypass, to achieve either “service” or “bypass,” it is only necessary to
turn the Handle (90221) until the Piston (90616) stops. Additional pressure (torque) will not improve
the seal. Once the Piston reaches the stop at either position, it can be backed off up to one half turn
of the handle and still achieve a seal.
90226 Test Port
Valve
The Test Port Valve is used to draw water samples for testing of treated water.
Note: The Bypass must be in the “service” position to get an accurate sample. There are two types of
seals on the Test Port. One seal is an O-Ring which seals off the threaded area when the Valve is
opened. The other seal is a compression O-Ring seal between the Test Port Valve material and the
Right End Cap material. If this seal is “overtightened,” it can damage the O-Ring and cause a
permanent leak.
93860 Turbine
Sensor Wire
Picks up the magnetic field from the Turbine and relays it to the Controller. Care should be taken
when putting the Sensor Wire into the Sensor Housing. The cap is then put in place and the mounting
screw is installed. A slot is provided in the cap for the wire to exit. The three-wire socket connector
must be properly installed in the controller. Stops on the connector prevent improper (upside down)
assembly. Do not force the connector past the stops.
90522 Turbine
Assembly
The turbine must have a 1/8" diameter Rare Earth magnet pressed into place adjacent to the axle
opening. When assembled to the axle, the Turbine should spin freely. Do not use any lubricants. If the
Turbine should become “jammed,” clean and flush the Turbine and Bypass Valve.