Knowledge Base:  
440i Sticking in Backwash or Brine Refill
Last Updated: 08/10/2011

PROBLEM - Customer Writes,
If I manually regerate the dial and turn it to start it will start and then it seems like it gets stuck on backwash, I left it on there for over a hour and it did not advance. I advanced it to brine/slow rinse and it ran through all the way to the conditioned water spot and I thought it was ok. This morning I went to check it and the salt tank was filled up to the top again with water. What parts do you think I need to fix this, or should I just call the repair man? The timer and motor do seem to be working and advancing the skipper wheel ok.
-Thanks for any help

**** Here are the gears that would effect or cause the type of failure ( not moving out of Backwash ) that you are describing,

  1. Red Knob Gear # 106H ( 1001582 ) * now "Black" .
    Closely examine the "over hang" teeth of the OUT PUT GEAR as they sometimes snap off ( should be 2 1/2 teeth hanging over gap ).

  2. # 8 Black Gear # 420A44 ( 1030844 ) * Drives the Out Put Gear and if Stripped you can easily see this is the problem.

Slight chance it's a problem with the motor ( available in 120 volt and 12 volt versions ), so see this item, and for help OPENING the 440i case, see the video here,
Motor 12 volt for 440i

And complete replacement is an option.

See: 440 Replacement Timer Assembly 440iHV w/Cord

The newest replacement timer is the 460TC ( runs on 12 volts ),
see:The 460TC replaces all previous 440 Timer Assemblies.

And now available for Models 255,263 and 268 is the Logix 740 upgrade timer kit ( does NOT work with the older 155, 163, or 168 valves... sorry ).

See for 255 valves: Upgrade Kit 255/740 Logix Electronic Replacing 440 Series Timer Upgrade Kit 255/740 Logix Electronic Replacing 440 Series Timer

and for Performa 263 or 268: Upgrade Kit Perfoma 740 Logix Electronic Replacing 440i Series Timer Upgrade Kit Perfoma 740 Logix Electronic Replacing 440i Series Timer

A complete replacement is also prudent if the unit is over 10 years old.

Getting INSIDE:

Removing the Tripper Arm screw, the Skipper Wheel screw and the three cover plate screws will gain you complete access to all components for careful examination. It is easier to work on your timer housing if you remove it from the valve body. Pull out the timer retaining pin ( 5F ), slide power cord out of it's retaining slot, unscrew Cam Shaft Bearing at rear of Cam Shaft, and then pull housing straight up. Other Common Gears that fail

Also the "Out Put Connector" # 21E ( 1031496 ) which which attaches to and drives the Cam Shaft can crack or break. On rare occasions the Camshaft # 21F-3 ( 1031950 ) will break at one end.
And last, but not least, you can have a gear post break in the housing body it's self. But only the back plates for the 440i version is available and not the "box" used with the older 440 version. It is simpler and prudent to replace the Complete Timer Assembly at this point.

our Recommendation is the Newest Option
Which replaced the 440i and 440iHV in early 2011:

Complete 460TC ( timer clock ... NOT metered ) with 12 volt transformer

for use with 120 volt 60 hz installations
Uses Electronic 7 Day programmed timer ( will regenerate on the DAYS you SET )
The 460TC replaces all previous 440 Timer Assemblies.

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