Caroni 72" belt replacement how to?

[presta24]

My old man is getting old and tells me this job is a PITA. I'm gonna go out on a limb and assume it isn't that bad, he just doesn't want to mess with it. Looking for a simple how to so I can get an idea of what it entails before I dive into it for him.

On this topic, he also replaced the main gearbox seal several years ago but it continued to leak after. Hes been pouring STP into it to keep it lubed and allow him to mow with it. Any info on the replacement as well would be appreciated.

Its a side discharge, unsure of model

 

[5030]

Email ASC for a manual. They have parts as well. They are the American distributors for Caroni.

 

[Rebeldad1]

did you try utube? If its not simple most manufactures have a video. being its only a mower it cant be too hard.

 

[Rebeldad1]

Have your dad fill the gearbox with John Deere Corn Head grease. turns liquidish when warm, works great. Dont overfill, is usually why most leak especially with out a vented plug.

 

[chim]

I really like the Caroni finish mowers, and may be able to help. I rebuilt a 91" about 2 years ago and am in the process of refurbing a 5 footer for our little Ford. Way too busy with things so the 5 footer is went on the back burner following the welding. Make sure the shaft is really clean and smooth without any sort of burrs when you replace the seal, lube the shaft. I think I hit it with some silicone grease. Access to the seal is time-consuming but not terribly difficult. First of all, here's the parts manual:

https://www.caroni.it/wp-content/uploads/2017/07/1_CARONI_SPARE_PARTS_TOSAERBA.pdf

If the oil is coming from the bottom of the gear box, the manual says the seals for the gear boxes on the models shown are all the same. See the first item on Page 8. The 91" deck I did wouldn't even hold the oil because of a damaged seal. The seal on the 5 footer looked bad, so that'll get replaced. There was no evidence of leakage at the input shaft on either deck.

Here are a few pictures:

The box with the seal in it has the 40x80x10 seal that matches the factory and it was available at a real hardware store nearby.

Center shows how I removed the old seal. A couple self-drilling screw and some gentle prying did the trick.

Third photo is the old seal before removal.

 

[Kernopelli]

I have a Kioti rear discharge RFM that Im pretty sure is a rebranded Caroni. As best as I remember, you have to loosen the gearbox mount to allow the belts enough clearance to slip onto the main pulley. It's not an ideal set up but it's only 4 bolts.

 

[Rancilio]

Hello,

Can you tell me how to remove the gearbox? Or point me in the direction of a Caroni maintenance/procedure manual?

I really like the Caroni finish mowers, and may be able to help. I rebuilt a 91" about 2 years ago and am in the process of refurbing a 5 footer for our little Ford. Way too busy with things so the 5 footer is went on the back burner following the welding. Make sure the shaft is really clean and smooth without any sort of burrs when you replace the seal, lube the shaft. I think I hit it with some silicone grease. Access to the seal is time-consuming but not terribly difficult. First of all, here's the parts manual:

https://www.caroni.it/wp-content/uploads/2017/07/1_CARONI_SPARE_PARTS_TOSAERBA.pdf

If the oil is coming from the bottom of the gear box, the manual says the seals for the gear boxes on the models shown are all the same. See the first item on Page 8. The 91" deck I did wouldn't even hold the oil because of a damaged seal. The seal on the 5 footer looked bad, so that'll get replaced. There was no evidence of leakage at the input shaft on either deck.

Here are a few pictures:

The box with the seal in it has the 40x80x10 seal that matches the factory and it was available at a real hardware store nearby.

Center shows how I removed the old seal. A couple self-drilling screw and some gentle prying did the trick.

Third photo is the old seal before removal.

 

[chim]

Welcome aboard! Removing the gear box isn't necessary for belt replacement. There are various things that need loosened for belt replacement though. Refer to the parts diagram in the link in my earlier post.

To remove the gear box the easiest approach is probably loosening things up and removing the gear box support. Then there's a bolt holding the pulley on the bottom shaft of the gear box that has to come out to remove the pulley. The gear box is bolted to a plate that in turn is bolted to the support via studs up through slotted holes. Hope this makes helps.

EDIT TO ADD: Owner's Manual:

https://tractortoolsdirect.com/content/Other_Attachments/CaroniFinishMowerDeckOwnersManual.pdf

 

[Rancilio]

Thank you. I should have clarified that I am replacing the gearbox oil seal. I realize now that I needed to remove the gearbox support in order to pull the pulleys and to get to the oil seal.

 

[chim]

Looks like you have it under control

A good flushing / refill and it'll run for a long time.