I am not expert. But I am wondering why you use KCl rather than NaCl. I presume you are looking for less sodium in the water. KCl costs more, and I wonder if it is as soluble.
"I am getting tired of bailing water out the tank to get around the salt level and it seems to regenerate fine. "
I don't think this is compatible with regenerating fine. You are having to remove brine to keep the brine tank from overflowing? Clearly there is a problem. A clog? I don't know.
Anyway, I suggest you post one or more photos including the controller, so that when the knowledgeable guys get here, they will have info to give you better suggestions. Also, if they suggest replacement, they will want to know the number of people, bathrooms, water use, etc.