Caroni flail smoking belts

leonz · Dec 7, 2020

Johnston Tilliryy said:
Picked up a new Caroni TM1900 from AgriSupply yesterday and tried it out this afternoon for the 1st time after greasing everything and cutting PTO shaft. Started smoking after the 2nd pass. The outside belt was 1/2 way off the tensioner. Set them back in line, tightened past where it was previously and tried again with the same results. Looks to me like the top pulley is too far out and causing the belt to slide off regardless of tension. What do yall think? Thanks for any help. Sorry if this is in the wrong place.

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Hello JohnstonTilliryy,

I want to welcome you as the newest resident member of the "Flail Mower Nations".

Please fill in the rest of your information so we know where you reside ONLY so that if we
have a fellow Flail Mower Nations resident member near to you that can help you if you have problems.

About your beautiful Caroni Flail Mower I need to know a few things first to help you.

What is the cutting height you are using?? Did the folks at AgriSupply explain to you how to level the flail mower for the proper cutting height??

"with the mower leveled using the top link and a torpedo level resting on the gear box you need adjust the top link in or out to assure it is level at all times to prevent it from falling forward and possibly damaging the flail mower knives and hangers.

With the black rubber coating the snubber pulley as shown in your photo the V belts are too tight.

leonz · Dec 7, 2020

Hello JohnstonTilliryy,

I want to welcome you as the newest resident member of the "Flail Mower Nations".

We can help you and please do not think I/we are trying to get in your way as your new flail mower
will outlast your tractor and easily be mounted on the next larger frame size tractor if you trade up
in the future.

Please fill in the rest of your information so we know where you reside ONLY so that if we
have a fellow Flail Mower Nations resident member near to you that can help you if you have problems.

About your beautiful Caroni Flail Mower I need to know a few things first to help you.

What is the cutting height you are using?? Did the folks at AgriSupply explain to you how to level the flail mower for the proper cutting height??

"With the job of leveling the mower the mower you use the top link and a torpedo level resting on the gear box to adjust the top link in or out to assure it is level at all times to prevent it from falling forward and possibly damaging the flail mower knives and hangers."

With the black rubber coating the snubber pulley as shown in your photo the V belts are too tight and the pulley has slid out binding the pulley and the V belts and in the process causing the rubber to heat up and coat the snubber pulley with the melted rubber dust.

The top V belt pulley has slid outward and needs to be taken care of.

The V belt sheave must be loosened in order to correct this by removing the belts and examining the
Sheave 3 V pulley, The key, and the set screws.

Lets get the upper sheave pulley off and then go from there as there is a specific sequence to properly
install and adjust the sheave pulley and the belt tension.

If you have a steel straight edge you can correctly align the drive and driven pulleys BUT B$ you do this you need to make sure the set screws bite into the key. you do this with a small drill bit to create a dimple in the key so the set screw has more metal to bite into.

Now its important to uses a few drops of blue Loctite on the set screw threads to secure the set screw and hold it in place. The blue loctite will allow you to remove the pulley in the future if needed.

leonz · Dec 7, 2020

Double posts GGGGRRRRRRR

Johnston Tilliryy · Dec 7, 2020

Thanks for everyone's help! A few answers:

- Measured with a straight edge and the top is 5/8" further out. Had to order a spanner wrench small enough for the nut to try and bring it in (since nobody w/in 45min stocks them, but still complain about people shopping online). Supposed to be here by Wed.

- I took the tensioner/idler off to check and it was spinning freely. The black area in the pic was a surface rust spot with rubber on top. It was looser when I picked it up, but I over tightened to try and keep the outside belt on before realizing the top pulley wasn't aligned.

- I didn't run it fast or through thick stuff. There was a shallow groove in the outer most belt from rubbing on the corner of the idler.

- Still not opposed to cutting the spacer down 1/2" if needed but hoping I can bring it in with a wrench.

- The people on site weren't very knowledgeable when I picked it up. I asked if the gear box was full and if not, did it call for anything special. The young guy looked at the spec sheet and said 30-60hp..:duh:. Older guy seemed to know his stuff but was loading other people. It looks to be at the lowest setting and I'll need to adjust once I get it running. Primary reason I got it was for some small fields with kudzu. I had good luck this year on 1 field by mowing low (2.5" with zero turn) and spot spraying but went through 3 sets of blades from rocks and am worried about damaging the mower.

leonz - do you recommend not running it in the slotted top link hole to keep it level?

leonz · Dec 7, 2020

Johnston Tilliryy said:
Thanks for everyone's help! A few answers:

- Measured with a straight edge and the top is 5/8" further out. Had to order a spanner wrench small enough for the nut to try and bring it in (since nobody w/in 45min stocks them, but still complain about people shopping online). Supposed to be here by Wed.

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Did they provide you with an owners manual??????????????????????????????????

(BEFORE you do anything you need to have some blue loctite in hand and just wait a couple of days)

(I will need many more pictures)
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- I took the tensioner/idler off to check and it was spinning freely. The black area in the pic was a surface rust spot with rubber on top. It was looser when I picked it up, but I over tightened to try and keep the outside belt on before realizing the top pulley wasn't aligned.

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Get the rubber off the snubber pulley before you do anything else please AND call agrisupply for new belts as they should provide them at no cost to you as you need new belts since these are damaged due to the loosened pulley.

- I didn't run it fast or through thick stuff. There was a shallow groove in the outer most belt from rubbing on the corner of the idler.

(you need new belts) call agrisupply for a new set of belts as its a warranty issue).

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How fast was your travel speed??? I need to know this.
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- Still not opposed to cutting the spacer down 1/2" if needed but hoping I can bring it in with a wrench.

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Do not do this.

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- The people on site weren't very knowledgeable when I picked it up. I asked if the gear box was full and if not, did it call for anything special. The young guy looked at the spec sheet and said 30-60hp..:duh:. Older guy seemed to know his stuff but was loading other people. It looks to be at the lowest setting and I'll need to adjust once I get it running. Primary reason I got it was for some small fields with kudzu. I had good luck this year on 1 field by mowing low (2.5" with zero turn) and spot spraying but went through 3 sets of blades from rocks and am worried about damaging the mower.

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(90 weight gear oil)

If the rear roller is at the lowest position its at the highest cutting height.

Were you running the engine at the 540 rpm engine speed for the flail mower to operate correctly???

The need to travel at a crawl in kudzu is a must.

Lest get the belt issue fixed with new belts before we go any further.

You may also have kudzu vines wrapped around the bearing housings.

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leonz - do you recommend not running it in the slotted top link hole to keep it level?

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the top hole as you are a new user as you have had problems with it from the beginning.

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grsthegreat · Dec 8, 2020

is it just me, or am i crazy to wonder why you even have to bother trying to repair a brand new $2100 piece of equipment. or is the owner responsible for adjusting it before use? im confused.

Johnston Tilliryy · Dec 8, 2020

Its close to a 4 hr round trip and I work 6 days a week. Guess I could try to get them to ship a new one free and pick up old but I'd still need to be available to take delivery. If I can make some adjustments myself after work it'd save me a lot of headache and cost me less money.

Johnston Tilliryy · Dec 17, 2020

For some closure in case someone has the same issue in the future: AgriSupply shipped me a new one at no cost after I was unable to bring the top pulley in with a spanner wrench. Top pulley on new unit is sitting flush with the bottom pulley and tensioner. Good customer support so far. They are going to send someone else to pick up other unit. 4 13mm nuts to remove the cover over the pulleys to check with straight edge as mentioned previously. Easy 30 second check before buying if in person. Tech I spoke to said he hasn't seen that misalignment before. Greased and ready to try out once I get a few dry days.