Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough)

   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #11  
Thanks for the complement! I appreciate that.:)
Brad, it seems you're on the right track with the KSB, especially since you've already done a lot of what I was suggesting- checking wires, grounds, etc.
So, I think you definitely want to locate the sensor that is connected into the KSB circuit so it can be eliminated as a possible cause of your troubles.
The service manual page said it is located in the intake manifold. The sensor is in effect until the intake manifold has 40degrees C= 104degrees F. So it is NOT a coolant temp the KSB responds to; it IS an AIR temp it is reading, SO if your thermostat is delaying the engine coming up to temperature it could affect the intake temperature too. Find that intake sensor and remove it for inspection. It should have a range of temp it works at and you could test it to see if it is within specs. OR your dealer could give you another one and a thermostat to exchange and note what changes. If you do both, do one at a time to see which has what effect. As far as running near hot when having worked the tractor I would suggest changing out the t-stat and see if anything changes. Have you ever changed the coolant in the radiator? If not, it may be time to do so. Coolant naturally breaks down over time and should be changed every couple of years. It can turn to almost sludge like consistency and does not provide adequate cooling and corrosion protection after a lot of hours of use. This could also dull/delay the sensor readings the KSB unit is looking for to tell it how much fuel to deliver when coming up to temp in colder weather.It is hard to read the wiring diagram, and when I blow it up to readable size it is too blurred to see clearly. But I think I get the jist of it. There is a 15amp fuse in the circuit, so verify it is good, and clean. Keep taking notes, especially of ambient temp and such like you did today- it will help you keep focused and narrow down exactly when the machine does what.
And it sounds like you have a good tractor that has some nasty bugs that need to be worked out so you can get it to being what it should be- reliable for your use.
I would keep on your dealer about a list of ALL the issues you just mentioned to get them to remedy them under warranty. This is their job.
The temperature thing I believe is tied into the situation. You say it tends to run hot when working it hard. This is not what I would call normal. And your persistent slew of wiring issues is not good, nor normal either. For the wiring I would take a serious look at your battery negative cable and where it attaches to the frame and clean it by removing the bolt at the frame, removing any and all corrosion, grease, dirt etc. Then shine up the ground lug at the frame, coat it's bolt with copper anti-seize and then spray the frame/lug/bolt with battery protection spray after tightening the bolt real tight. Do the same to both the pos and neg at the battery, in addition to using the felt washers available in any auto/tractor store. Then have someone grab the negative cable and move it around while you crank the engine to see if there is any effect on gauges/lights/ etc. If there is any fluctuation, replace the entire cable with new lug and battery post end. Cables do corrode internally, especially with intermittent issues like you have in your system.
 
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   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #12  
If you get this figured out let us know. I've been dealing with this same issue for 6 years now.
 
   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #13  
Has any one tried disconnecting the 12 volt wire to the ksb from the relay that is switched on by the thermosenser switch

after reading the description and the schematic it would seem the easiest thing to try would be to disable power to the ksb

since the description says

(No sooner the temperature reaches above 40*C and engine achieves stable condition the sensor STOPS electric supply to relay AND KSB solenoid. thus normal timing is restored.)

it would seem that disconnecting the relay wire to the KSb should disable the solenoid , thereby stopping the pressure increase and timing advance and the tractor should act like every other mechanically injected diesel without any cold start timing or pressure changes and it would act as if the outside temp had not ever dropped below 40*C

thinking it might be worth a try... and that If the Ksb is staying on and powered up when it shouldn't be -that the overly advanced injection timing- may be hard on a fully warmed up engine...
 
   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #14  
If you get this figured out let us know. I've been dealing with this same issue for 6 years now.
Have you tried advancing the injector timing by rotating the injector pump about 1/16 inch? Cured mine completely. I now have 1300Hrs.
larry
 
   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #15  
No I haven't tried that. I'll have to research that.

Not trying to hijack the thread, but how is everyone elses tractor on fuel? Mine drinks it like crazy:eek:
 
   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #16  
1 to 3 GPH depending on load. ... seems worse because its a small tank. ?What yr is your tractor? The rubber filler hose leading to my tank cracked and started leaking at about 6yrs.
larry
 
   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #17  
I bought mine in sept. 2007. My tank is under the floor board,no filler hose on this one.
 
   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #18  
So is mine. Where do you put the fuel in?
 
   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #19  
My tank is molded so the cap sticks out just past the floor board. I'll try to get a pic for ya
 
   / Mahindra 7520 - Possible KSB issue - (bluish-white smoke / running rough) #20  
Oh. Mine, 2006, comes up behind the seat. I didnt know they had changed it.
 

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