down) before gently pulling on the wire connectors to
remove the motor. Pulling directly on the wires without
rotating the motor may break the wires off the motor.
Replace the motor if necessary. Do not lubricate the
motor or the gears. To reinstall the motor, move the
spring clip loop to the right and hold. Gently turn the
motor while inserting so that the gear on the motor
meshes with the gears under the drive gear cover.
Release the spring clip loop and continue to rotate the
motor until the wires are horizontal and the motor
housing engages the small plastic bulge inside the drive
bracket motor retainer. Reconnect the motor plug to
the two-pronged jack on the lower left side of the PC
board. If the motor will not easily engage with the drive
gears when reinstalling, lift and slightly rotate the motor
before reinserting. Reconnect the power plug.
Replace the valve cover. After completing any valve
maintenance, press and hold NEXT and REGEN buttons
for 3 seconds or unplug power source jack (black wire)
plug back in. This resets the electronics and establishes
the service piston position. The display should flash all
wording, then flash the software version and then reset
the valve to the service position.
Drive Cap Assembly, Regenerant and Main Piston
The drive assembly must be removed to access the drive
cap assembly pistons. The drive cap assembly is
threaded into the control valve body and seals with an o-
ring. To remove the drive cap assembly use the special
plastic wrench or insert a ¼” to ½” flat blade screwdriver
into one of the slots around the top 2” of the drive cap
assembly so it engages the notches molded into the
drive back plate around the top 2” of the piston cavity.
See Figure 5. The notches are visible through the holes.
Lever the screwdriver so the drive cap assembly turns
counter clockwise. Once loosened unscrew the drive
cap assembly by hand and pull straight out.
The drive cap assembly contains the drive cap, the main
drive gear, drive cap, piston rod and various other parts
that should not be dissembled in the field. The only
replaceable part on the drive cap assembly is the o-ring.
Attached to the drive cap assembly is the main piston
(downflow or upflow) and if a regenerant is used, a
regenerant piston.
The Regenerant piston (the small diameter one behind
the main piston) is removed from the main piston by
pressing sideways and unsnapping it from its latch.
Chemically clean to dilute sodium bisulfate or vinegar, or
replace the Regenerant piston if needed. To remove the
main downflow or upflow piston fully extend the piston
rod and then unsnap the main piston from its latch by
pressing on the side with the number. Chemically clean
in dilute sodium bisulfate or vinegar, or replace the main
piston.
Reattach the main piston to the drive cap assembly.
Reattach the Regenerant piston (if needed) to the main
piston. Do not lubricate the piston rod, main piston or
regenerant piston. Lubricant will adversely affect the
piston seals. Reinsert the drive cap assembly and piston
into the spacer stack assembly and hand tighten the
drive cap assembly. Continue to tighten the drive cap
assembly and piston into the spacer stack assembly and
hand tighten the drive cap assembly. Continue to
tighten the drive cap assembly using a screwdriver as a
ratchet until the black o-ring on the spacer stack
assembly is no longer visible through the drain port.
Excessive force can break the notches molded into the
drive back plate. Make certain that the main drive gear
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