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Fixing a Sears Kenmore Water Softener

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By Khalid on 2004/12/15 - 21:01, last updated 2005/11/13 - 16:12

I have been struggling with the Water Softener for a few months now. I got it fixed by Sears for about 165$Cdn two years or so ago. A few months ago, it started having problems again. So I decided to try and fix it myself.

What is a water softener?

First a little background.

In North America city water is locally produced from underground water, not from a river like in Egypt. Deep under the ground there are aquifers, and the city taps into it, treats it and make it available to the inhabitants. If the bedrock has a lot of calcium, .e.g limestone, in it, then the water is often said to be "hard water".

Hard water causes a lot of problems: dishes would look cloudy, the tea kettle will have white residue in it, soap will not rinse from your hand (no squeaky clean feeling), your hair will clump if you use soap in the shower instead of shampoo, and the water heater efficiency will decrease as the calcium from the hot water precipitates on its walls. Soap and detergent use is also increased.

How does a water softener work?

So, there is a market for water softeners in places that have hard water.

A water softener works by having a tank that is filled with salt, and a tanks full of a special resin. The resin can remove the hardness from the water, but requires that it be regenerated by washing it with salt brine during regeneration. Water softener are either demand based (after a certain number of gallons have been processed), or time based (e.g. twice week). Regeneration happens in the early hours of the morning, depending on how you set it. It goes through several cycles, which are basically:

  • Fill: Water is passed to the salt tank
  • Brining: Water is left in the tank to form brine
  • Rinse: The brine is used to rinse the resin, remove the calcium that it has removed in the past, and make it able to remove calcium again
  • Back Wash: The resin tank is flushed for residues and iron deposit
  • Fast Rinse: The resin is rinsed from all the above
  • Service: This means that the water softener is serving soft water for the house

There are many brands of water softeners out there in the market. Many are rebranded. For example, Sears Kenmore, Ecoline and General Electric (GE) are the same. Culligan is also similar.

About my handyman's skills

Before I start, I should say that I am not at all handy with maintaining a house. Part of it is due to the fact that in Egypt most people live in concrete apartments, and not woodframe and drywall houses with lawns. Part of it is that I never got the hang of being mechanically adept, whether it is plumbing, carpentry, car maintenance, and such. So, fixing a water softener, which involves mechanical, electrical and plumbing aspects is quite a challenge.

Symptoms

Many things can go wrong with a water softener. The basic complaint is that "there is no soft water". Another is high water level in the salt tank. Yet another is salt level that does not go down as the weeks pass.

Solutions

The manual for a water softener often has some comprehensive diagnostics that can be done to see

Start with cleaning the nozzle and Venturi. This should not require any tools, and can be disassembled and assembled by hand. Take note on how things fit before you remove them. Wash the components in water. Use some vinegar. Make sure there is no deposits, salt, rust, calcium or debris.

Then check the float in the salt well in the tank. The float should be able to move up and down, and the hose should be able to inject water in the tank and suck it again.

Then shut the water supply, drain the house (open the lowest lying faucet in the house), then disassemble the cam gear and rotor from the valve head. Check all the seals and gaskets and that there is no wear on the smooth side of the rotor.

Run the diagnostics as per the manual, and make sure that the cam gear moves well. If the motor is skipping and making a clicking sound and failing to move the cam gear, then replace it.

Replacing all the gaskets, the rotor, the cam gear and the motor should solve most problems, and only cost me 74$ Cdn. That is provided that the nozzle/venturi are clean, and that there is no obstruction to the float assembly.

Check for the formation of a salt bridge, specially in humid environment. Tap the side of the tank and see if there is a hollow sound at some spot under a solid sound. Use a broom stick to break it.

Once every six months, get a water softener cleaner (basically a sulphite powder that removes iron deposit. You can buy it at Canadian Tire or other hardware stores. It is more expensive at Sears, so avoid buying it there.

Every year or 18 months, try to remove all the salt from the tank and wash it. You can use warm water, and a wet/dry vacuum to remove it.

Conclusion

Fixing a water softener is easier than you think. Save your money and do it yourself. Get the manuals online, go buy the parts, and do it.

The morale of the story is: If I could do it, anyone can do it.

Resources and Links

Here are some useful links with more information:

  • Sears Kenmore Water Softener Manuals (PDF)
  • Sears Kenmore Water Softener Interactive Troubleshooting animations (highly recommended!). There are also some animations on how a water softener works.
  • HowStuffWorks.com: How Water Softeners Work - a shot article.
  • Some symptoms and solutions, from people who did that themselves.
Contents: 
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Comments

Anonymous (not verified)

Kenmore Ultrasoft 200 Leaking

Sun, 2013/07/14 - 19:40

My water softener is leaking from the bottom. It does not leak all the time just when the unit is in operation. If no water is running in the house, the floor is dry. Once you turn on the water, a small flow starts to come out from the bottom of the tank. Anyone know why this would happen or fixes for it?

Thanks,

  • reply

Cal (not verified)

ERR 01

Tue, 2013/07/16 - 12:28

Kenmore water softener not using much salt and water hard. Cleaned ventura assembly. Checked out motor assembly. ERR 01 appears on the screen and it won't come out of 'Generate Now' cycle.

  • reply

Firefly (not verified)

Constant discharging water

Sat, 2013/08/03 - 01:56

The Kenmore softener. an Ultra Soft 275, constantly leaks, in a slow trickle, water down the discharge tube. I tried changing the timer, but there was no change. I also recleaned the venturi. We have used this softener for at least 7 years with no problems. Any suggestions?

  • reply

Edward (not verified)

sears water softener, model Ultra soft 200, 625.388250

Mon, 2013/09/16 - 08:21

Please send me a copy of my comment regarding the Sears water softener, model 200, with model name Ultra soft 625.388250

  • reply

David (not verified)

Sears Water Softener Model 625.348591

Sat, 2015/05/09 - 08:36

I'm not sure why our water softener started overflowing in the of the night, but when I first heard some water dripping, I checked it and found the the little discharge hose near the top on the outside was simply disconnected from the hose barb, so I reconnected it and went back to bed. When I got up this morning, I heard water gushing, so I went back down to the utility room and found the tank was full and overflowing with the full force of the main water line. It seems that the water was coming at the full rate through the system. I quickly switched the bypass valve over to stop the flow. Can you help me?

  • reply

Anonymous (not verified)

water softner

Sun, 2015/11/01 - 18:51

NY water softner says err 3 how do I fix it..

  • reply

Bill Walch (not verified)

Kenmore 625.348591 Water Softener for sale - Never Used

Thu, 2018/10/04 - 02:03

Hello, I have a never used Kenmore 625.348591 Water Softener for sale. I bought it in 2002, but never installed it. Still in the box. I live on Orlando, so I'd prefer a local pickup, but would ship for the right price. I have no idea what to ask for it, other than I paid about $500 back then. I know this forum is more for repairs, but this is essentially a new unit. Thanks!

  • reply

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