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DRIVE CAP ASSEMBLY, MAIN PISTON AND REGENERANT PISTON:
The drive assembly must be removed to access the drive cap assembly. The drive cap assembly must be removed to
access the piston(s). The drive cap assembly is threaded into the control valve body and seals the o-ring. To remove the
drive cap assembly use the optional maintenance wrench or insert a ¼” to ½” flat bladed screwdriver into one 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 4). 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 spline, 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 and, a regenerant piston.
The regenerant piston (the small diameter one behind the main piston) is removed from the main piston by unsnapping it
from its latch. Chemically clean in dilute sodium bisulfite or vinegar or replace the regenerant piston if needed. To remove
the main 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 diluted sodium bisulfite 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 red or clear lip 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 using the maintenance wrench or 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 the main drive gear still turns freely. The exact position of the piston is not important as long as the main
drive gear turns freely.
Reattach the drive assembly to the control valve and connect all plugs. After completing any valve maintenance, press and
hold NEXT and REGEN buttons for 5 seconds or unplug power source jack (black wire) from the circuit board and plug back
in. This resets the electronics and establishes the home position for softening. Reset the time of day.
SPACER STACK ASSEMBLY:
To access the spacer stack assembly remove the drive assembly, drive cap assembly and piston. The spacer stack
assembly can be removed easily without tools by using your thumb and forefinger. Inspect the black o-rings and red or clear
lip seals for wear or damage. Replace the entire stack if necessary. The spacer stack assembly has been 100% tested at
the factory to insure proper orientation of one way seals. Do not disassemble stack.
The spacer stack assembly may be chemically cleaned (dilute sodium bisulfite or vinegar) or wipe with a soft cloth.
The spacer stack assembly can be pushed into the control valve body bore by hand. Since the spacer stack assembly can
be compressed it is easier to use a blunt object (⅝” to 1⅛” in diameter) to push the center of the assembly into the control
valve body. The assembly is properly seated when at least four threads are exposed (approximately ⅝”) Do not force the
spacer stack assembly in. The control valve body bore interior can be lubricated with silicone to allow for easy insertion of
the entire stack. Do not use silicone or any other type of lubricant on the red or clear lips seals or the piston.
Reattach the drive cap assembly and piston(s) and the drive assembly.
After completing any valve maintenance, press and hold NEXT and REGEN buttons for 5 seconds or unplug power source
jack (black wire) from the circuit board and plug back in. This resets the electronics and establishes the home position for
softening. Reset the time of day.
