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How Dirt and Dust Can Damage Your Small Engine

Why replace your small engine air filter? Why is it important to clean small engines? The short answer is, because it will noticeably extend the life of your engine. Debris, dust, and grass clippings are one of the leading causes of premature small engine failure. These culprits build up slowly over time and shorten the lifespan of the engine, which ends up increasing your maintenance and overall equipment costs. The air filter is a primary line of defense in the war against engine damage.

For mower engines, grass clippings stuck to the housing and muffler area may seem like they come with the territory. Once accumulated between engine parts, grass clippings, dirt, and other grime can cause:

– Engine overheating. Clippings, dust, and dirt limit airflow, causing engines to burn too hot.
– Problems regulating engine speed. Debris can cause binding in governor linkages. In pneumatic governors, debris can block air from reaching the governor blade.
– Long-term engine damage. When exposed to dirt and debris, the pistons, cylinders, and carburetor are harmed.

Dirty Air Filters

Air filters prevent damaging refuse from running through engines. Clean air is necessary for engine operation; combustion depends on air mixing with fuel. It is important to regularly check the air filter, as a dirty filter will strangle the engine. A clogged air filter has several damaging effects, including:

– Decreased power output. Air circulation is limited when the air filter is congested. This makes it harder for the engine to run at full power.
– Diminished fuel efficiency. When the air filter is blocked up, the engine will burn more fuel as it attempts to maintain power output.
– Difficulty starting. To start an engine, a spark, air, and fuel are required. When the air filter is clogged, air availability is limited. Sputtering and stalling is the result.

Replacing the air filter earlier rather than later will protect your engine in the long term. It is far less expensive to replace an air filter than to replace an entire engine.

Preventive Maintenance

You can limit the amount of materials clogging your air filter through preventative measures. After every use, examine the blower housing and muffler area and remove debris. Do a more thorough cleaning after every 25 hours of use, and at the end of the mowing season, prior to winter storage. To systematically inspect and clean a small engine, follow the guidelines in your manual, which will generally provide the following steps:

1. Disconnect the spark plug lead.
2. Remove the plastic blower housing.
3. Use a small bristle brush to clean the cooling fins, inside of the blower housing, and the flywheel fins.
4. Clean the flywheel cutting screen. You may need to apply a light solvent to your brush to remove stubbornly stuck debris.
5. Be sure to clean by hand, not compressed air, which can force debris deeper into the engine.
6. Check the governor linkages, and check that the linkages are able to move freely.
7. Look for debris near the break assembly, and see that the linkage and break cable move easily.
8. Once the engine is as clean as possible, replace the blower housing.
9. Reattach the spark plug.

Review the air filter at the same time, and replace if necessary.

If you work in tall and/or wet grass, plan for more frequent deep cleanings. Inspect the engine again at the beginning of each season. Rodents have been known to build nests within engines. Before firing up your small engine, check that the engine does not show signs of animal infestation.

With regular inspection and maintenance, you can keep your small engine debris-free and running smoothly for years to come.

Critical Maintenance for Your Riding Lawn Mower

What is the best way to keep any engine running smoothly for as many years as possible? Maintenance. Proper maintenance is critical for engine longevity and reliability.

Before performing riding lawn mower maintenance, start by disconnecting the battery. Your work area should be well-ventilated, with the mower parked on a flat, hard surface. For all maintenance tasks, consult the manual for specifics.

Establishing a Lawn Mower Maintenance Schedule

First, establish a riding lawn mower maintenance schedule. This will be the basis of your maintenance plan, and ensure that you know how often to complete important tasks.

Additionally, this maintenance schedule will help you track the maintenance you perform throughout the year and help you remember when it is time to perform the task again. Separate tasks into several time categories, such as Every Use, Seasonally, Monthly, and Yearly. Organize these however works most efficiently for you.

Here are some maintenance categories to consider when building your maintenance schedule.

Repairing or Replacing Parts

There are many parts that comprise a riding lawn mower, and each needs to be functioning at its best to extend the life of the mower. Make a list of the parts that will need to be routinely checked for repairs or replacement.

Some of the important parts that wear out over time include the bag and chutes, drive belts, blades, muffler, and spark plugs. These should be checked at least a couple of times per season to assess the wear and tear. Not only will this prevent unexpected damage to your mower, but it will enable you to more effectively plan for upcoming part replacements.

Additionally, there are smaller parts like deflectors, shields, and fasteners that can come loose or pop off entirely. If you notice that any of these are missing, replace them or arrange for repairs through an authorized service provider.

Cleaning the Engine & Equipment

Dust and debris can cause serious problems for the engine. You can keep ahead of these cleaning needs by dealing with clippings after every use. However, a deep cleaning is necessary on a regular basis. Deep cleaning means cleaning the engine cooling fins, motor deck, and underneath the motor deck. You will need to remove the deck to properly address these areas.

A dirty air filter is the main result of failure to properly clean the riding lawn mower. When your air filter is dirty, you may notice a decrease in engine performance. This could manifest as a problem with inconsistent power, increased fuel intake, starting problems, or smoke. To prevent these issues, check the air filter after every 25 hours of use.

Fluid Levels

Effectively managing fluid levels and lubrication will keep your riding lawn mower functioning at its best. First and foremost, check the oil level after every use. Perform oil changes as soon as you notice one is needed to prevent serious engine damage. In general, the oil should be change every 50 hours according to riding lawn mower engine experts.

While checking fluid levels, do not forget to also check the tire pressure on your riding lawn mower. Keeping the recommended tire pressure will help your equipment perform better overall and play a noticeable role in the performance of the riding lawn mower.

Consistent maintenance will bring peace of mind. You can tackle the mowing season head-on, knowing that your mower is in excellent condition. Extend the life of your mower while optimizing its output – perform regular maintenance.

Why Choose a Kohler Engine for Agricultural Equipment?

Farming is vital to our economy, and small engines are vital to farms. Small engines are the power behind tractors, skid steers, and other agricultural equipment. When working in farming applications, small engines face certain challenges. Dusty environments, combined with long operation hours and variable terrain require engines to be powerful, reliable, and tough.

Kohler engines are exceptionally well suited for farm equipment. With decades of engineering expertise, the Kohler brand stands for quality and dependability. Here are a few ways that Kohler engine lines are built to thrive in agricultural settings.

Kohler Engines for Farm Equipment

1. Aegis Line
The Kohler Aegis line includes horizontal, V-twin, liquid cooled engines producing 24 or 30 HP. Aegis engines are liquid cooled for peak power and steady running temperatures. Maintenance is simplified with user-friendly features like dual oil drains, low-oil protection, and easy-access oil fills. A low-profile heat exchanger minimizes engine wear while providing exceptional cooling. Finally, a hardwearing air filter provides twice the filtration area of competition filters, protecting the engine in dusty agricultural settings.

Aegis Kohler engines are ideal for powering grain augers, conveyors, bale choppers, utility tractors, and other farming utility vehicles.

2. Command PRO Line
The Kohler Command PRO line includes V-twin, air-cooled, vertical and horizontal engines in power ranges from 19 to 37 HP. Built-in oil coolers lengthen maintenance intervals and ensure low operating temperatures regardless of power range. Overhead valve technology within Command PRO engines provides further cooling, while boosting fuel efficiency. Large capacity, in-line fuel filters protect against dust-ridden agricultural operation. Command PRO engines are tough enough for agricultural settings; they have multiple durability features, including cast iron cylinder liners, full-pressure lubrication, and dual-element air filters.

The Kohler Command PRO engine line is perfect for agricultural machinery, including two-wheel tractors, feeders, utility vehicles, and more.

3. Kohler Diesel Line
Diesel engines power over two thirds of all farm equipment. The Kohler Diesel line is exceptional for agricultural work. Full pressure lubrication with a full flow filter extends engine life in harsh operating conditions. Moreover, direct injection delivers more complete combustion, for maximum power and minimum fuel use. An aluminum crank case with re-borable cast iron cylinder liners curtails weight while lengthening engine lifespan. Finally, Kohler achieves lower vibrations in its diesel engines, through fewer moving parts, exceptional balance, and decreased cylinder volume. Kohler diesel engines are available with one, two, three, or four cylinders, air or liquid cooling, and horsepower ranging from 6.1 to 134. They are backed by three-year, full manufacturer warranties.

Kohler has designed their diesel engines to run cleanly. In October of 2011, the company announced that it had added fuel injection and cooling exhaust gas recirculation technologies to its small diesel engines. As a result, Kohler diesel engines now produce 10 times fewer carbon particulate emissions (commonly known as soot). This redesign ensured that Kohler diesel engines would meet new environmental regulations in the U.S. and around the world.

For specific advice on how to select an engine from these lines for specific farm equipment, get in touch. Here at Repower Specialists, we are proud of providing the best customer service in the replacement engine industry. We answer all inquiries within one business day, and our engine replacement kits come complete with everything needed for installation. We would be happy to advise you on the best engine for your farming needs.

[Photo from Lee Cannon via CC License 2.0]

Understanding Kohler Homeowner vs. Professional Engines

Having built generators and engines for almost a century, Kohler understands the need for different engines in different settings. The company produces a wide range of engines for various applications, both residential and commercial. From low-horsepower walk mowers to construction equipment, Kohler has a small engine to power all industrial, commercial, and residential machinery. Today we are taking a look at the main differences between Kohler professional engines and Kohler homeowner engines by reviewing which category of Kohler engines best serve different residential and commercial needs.

Kohler Homeowner Engines

Kohler has dozens of homeowner engines available, from the starter-level XT to the Command PRO and Aegis lines, among others. We will examine how different Kohler lines work in different pieces of residential outdoor equipment.

Walking, Riding and Zero Turn Mowers: XT, Courage, and 7000 Series
The Kohler XT series is perfect for walk behind mowers. This line is designed for quick starts and low temperature operation. If your horsepower requirements will be limited, an XT engine will be a low-maintenance, safe choice.

The Courage and 7000 series of Kohler engines are better suited to riding mowers, which demand more power. In both single and twin cylinder Courage engines, larger engine displacement translates to better handling. The 7000 series takes it one step further, with V-twin designs, even greater displacement, and air cooling to minimize maintenance. Zero-turn mowers are slightly heavier than riding mowers, so they also demand more powerful engines, such as those in the Courage or 7000 series.

Utility Equipment: 2000, 3000, Command PRO, and XT Series
Large residential properties may require utility vehicles for hauling, snow plowing, pulling stumps, and more. Kohler recommends picking from the 2000, 3000, Command PRO, or XT Series for utility vehicles.

Again, stronger engines are needed because utility vehicles are heavier and require greater power output. These lines are also considered best for commercial use.

Kohler Professional Engines

Landscapers, agriculture workers, golf course managers and other professionals around the world rely on Kohler engines. Commercial equipment runs for long hours, often in harsh conditions. As such, compared to residential engines, commercial engines must be more powerful, with more sophisticated cooling mechanisms, and more defenses against clogging substances, such as dust. Here is a rundown of which Kohler engines best serve different industries.

Lawn Service and Landscaping: Aegis, Confidant, Command PRO, and Kohler Diesel
The lawn tractors and heavy mowers used in landscaping and lawn service require long-running engines. Kohler Diesel, Confidant, Command PRO, and Aegis engines are strong enough to stand up to the beating of non-stop lawn and landscaping work.

Golf Course Maintenance: Aegis, Command Pro, and Kohler Diesel
The larger the maintenance area, the more powerful an engine must be. Golf course maintenance requires especially robust engines, as acres of maintenance are involved. The Command PRO, Kohler Diesel, and Aegis lines best serve the course maintenance industry.

Power Generation: Courage, Aegis, Command PRO, and Kohler Diesel
Power generation engines should not take up too much room, yet they must be powerful enough to run lights and operate some commercial equipment. Fuel efficiency is another top consideration. The Kohler Diesel, Command PRO, Aegis, and Courage lines fit the bill.

Construction and Agriculture: Kohler Diesel, Command PRO, and Aegis
Both agriculture and construction require powerful engines that must be reliable in dirty environments. The Kohler Diesel line is the most popular among construction and agriculture companies, but Command PRO engines are also strong enough for this kind of work. Finally, the Aegis line is highly fuel efficient, and air cooled to power ongoing farm and construction work.

How to Choose Between Kohler Homeowner and Professional Engines

How will you be using the engine? That is the first question to ask. In general, commercial purposes and utility equipment will require professional-grade engines, such as those in the Command PRO and Kohler Diesel lines. Property size also figures large. Obviously, you will not need a riding mower to take care of a city lot; a small, light engine such as those in the XT line will be enough to power a walking mower. On the other hand, if you maintain acres, a heavy mower will be needed, as will higher horsepower.

We recommend comparing the above information with the work you plan to do. Then, research within the suggested Kohler engine lines. Start to parse out maximum horsepower, maintenance features, and filter innovations. If you will be running the engine in tough conditions, such as dusty, dry heat, extra cooling mechanisms and vigorous filtration will prevent problems. The Kohler Product Matrix includes both big-picture stats (such as horsepower) and design details (such as fuel filter devices). And, of course, if you are repowering an engine you will need to check that the new engine will fit and operate properly.

Do not hesitate to call us for assistance. We are Kohler engine experts, having sold and repowered them for years. We can help you find the best engine for your needs. Call us today.

[Photo from dumbonyc via CC License 2.0]

5 Important Features of Kohler Command PRO Engines

Kohler Command PRO Engines are specifically designed for heavy-duty agricultural and industrial use. The small engine marketplace demands reliable heavy-duty operation, fuel efficiency, and low emissions. As one of the longest established manufacture ring firms in America, Kohler continues to lead the industry in innovative small engine design.

Kohler was founded in 1873, when Austrian immigrant John Kohler purchased the foundry from his father-in-law. In those early days, Kohler manufactured agricultural tools, including steel and cast iron plows. In 1883, Kohler decided to add feet to an animal watering trough, creating a bathtub. This represented their entry into plumbing fixtures; by 1926 the company was a full-line plumbing manufacturer. The company produced its first power product, an electric-driven electric generator, in 1920. By 1963, Kohler-built engines powered nearly half of all lawn and garden tractors in the U.S. The company continued to push the envelope in engine design. In the mid 1980s, Kohler engineers created the first overhead camshaft small engine, delivering a quieter, more fuel-efficient alternative to conventional side-valve engines. The year 2000 brought the next major innovation: Liquid-cooled products modeled after off-road equipment.

Today, Kohler Engines are known for their durability, dependability, efficiency, and high-power performance. Vice President of Kohler Engines Americas Brian Melka calls consistent power the defining characteristic of all Kohler engines, which are proven to go from zero to full load with only a market-leading 10% drop in RPM.

Kohler Command Pro Engines are designed to shine in all conditions. Even if cutting wet, thick grass, Kohler engines thrive, thanks to specialized features such as a specialized governor system. Kohler has also designed their Command PRO engines to minimize emissions while maximizing service intervals. Here are some of the important features that make the Command PRO ideal for commercial use.

Kohler Command PRO Engines: Top 5 Commercial Features

Cast Iron Cylinder Bores
Cast iron resists piston ring wear, retaining a tight seal over time. Moreover, extra large sleeve bearings allow for heavy loads in commercial and industrial environments.

Overhead Valve Technology
Valve placement greatly impacts engine performance. In general, overhead valve engines are more compact than overhead camshaft engines. Overhead valves deliver multiple advantages, most notably the greater volumetric efficiency to a higher compression ratio. Overhead valve placement also results in increased power, improved fuel economy, increased cooling, and reduced oil consumption. Experienced engine technicians would point out that overhead valves also virtually eliminate carbon buildup, slashing overall maintenance costs. Finally, with overhead valve technology, the valve train requires no adjustment; it is practically maintenance-free.

High Performance Spark Plugs
The Command PRO electronic ignition system creates a stronger spark at a low cranking speed. The Specialized Automatic Compression Release allows compression to escape during cranking, reducing pull force.

Advanced Lubrication Features

Agricultural and industrial applications can be rife with dust and debris. Kohler pushes back service intervals while protecting their Command PRO Engines with heavy-duty, high-efficiency air filters. Integrated oil coolers are another pioneering lubrication feature in Command Pro Engines; they help maintain low temperatures during the entire power range, while further extending service intervals. Thanks to full-pressure lubrication, lube is distributes lube continuously to critical engine components, even at a 25-degree angle of operation

Eco-Friendly Technology
Commercial and industrial contractors must meet stringent emissions requirements. Kohler has responded with inventive design features. For instance, the Kohler Command PRO EFI engine features electronic fuel injection where an oxygen sensor in the muffler analyzes the air to fuel ratio. If oxygen levels vary from the perfect air-fuel mixture, the sensor triggers changes to how much fuel is injected into the system.

Kohler Command Pro Engines are ideally suited to commercial and industrial applications. These engines combine reliable power with clean operation and extended service periods. Plus, Kohler includes a two year limited manufacturer warranty to protect your investment. Call us today to learn more about Kohler engines, and how they can support your team.

What Do I Do if My Kohler Engine is Discontinued?

When searching for a replacement for your Kohler engine, you find that your old engine has been discontinued. What to do? Discontinued Kohler engines may be replaced with compatible new models. Here are the important specs to consider when switching out a discontinued Kohler model.

Given the long Kohler company history, it is no surprise that some of their products have been discontinued. After more than a century of cast iron part and bath fixture manufacturing, Kohler produced its first electrical generator in 1920. In 1939, the company began work on its first liquid-cooled diesel engines. Their first small engines factory opened in 1948; it produced single-cylinder cast iron engines. Kohler small engines sales were strong in Thailand and Vietnam throughout the 1950s. At that time, nearly all air-cooled engines in Southeast Asia carried the Kohler brand. It was not until the 1960s that sales of Kohler small engines grew in the U.S. Today, garden tractors, construction equipment, lawnmowers, and snowmobiles are powered with Kohler engines. Over the years, generations of Kohler small engines have come and gone.

Fortunately, the company has retained enough common design features to allow replacement of older Kohler models. Here is what you should know about repowering discontinued Kohler engines.

Replacing Discontinued Kohler Engines: Key Specs

Engine Identification Numbers. When speaking with your Kohler engine dealer, you will need to know the old engine model, specification, and serial number. This information is displayed on a silver decal which is typically located on the blower housing.

Torque and Horsepower. Kohler generally rates the power of its engines with horsepower. If you only have the torque rating on hand, you can convert it to horsepower by multiplying the RPMs by its torque rating, and then dividing the result by 5,250.

As you figure out what horsepower rating you need, be aware that the rating system has changed over time. Prior to 1972, manufacturers advertised gross horsepower (SAE J1995), which describes the engine power with no accessories, mufflers, ignition timing, and under ideal operating conditions. In contrast, net horsepower (SAE J1349) includes accessory draws on an engine, such as ignition timing, exhaust systems, fuel injection, and so forth. As it describes a bare engine with no lost power, gross horsepower is always higher than net horsepower. When checking the horsepower of your original engine against replacement Kohler models, work with net horsepower, according to SAE J1940 specifications.

The Kohler Product Matrix webpage displays specifications for old and new engines. At that site, you can see SAE J1940 horsepower ratings for current models. Specs for discontinued models are also stated in owners manuals.

Work Cycle. The replacement engine should have the same number of cylinders and the same cylinder orientation as the old engine. So, if the old engine was a V-twin, the replacement model must also be a V-twin.

Engine Dimensions. The physical dimensions of old and new engines must match. Check that crankshaft orientation, mounting specs, and engine size will be compatible.

Fuel and Lubrication Type. Your new engine must match the lubrication and fuel of the old engine. A discontinued gasoline-powered engine must be replaced with a new gasoline-powered counterpart. The same rule of thumb applies to oil; the same type of oil must be used in the old and new engines.

Cooling System Type. Kohler manufactures both air-cooled and liquid-cooled engines. Make sure your replacement engine has the same type of cooling system as the discontinued engine.

Uses. How will you use the new engine? For lawn and garden work? Industrial construction? Beyond these categories, Kohler designs engines specifically for agriculture, golf course maintenance, power generation/welders, professional landscaping, and recreation. Each Kohler engine has specialized parts for its intended purpose. For instance, agricultural engines have more robust air filters, as dusty working conditions would otherwise cause clogs. Check that the replacement engine fits into the same application category as its predecessor.

If you need assistance in selecting a replacement for your discontinued Kohler engine, give us a call. Here at Repower Specialists, our staff has decades of experience in replacing engines. We can recommend a replacement Kohler engine that will fit and perform at its best. Call us today, we are here to help!

What's in Your Repower Kit? [Checklist]

When you purchase an engine kit from Repower Specialists, it is important to understand what you will receive. We work hard to ensure that every kit we send is ready for installation in your equipment and fit for your application. In addition to the standard kit, you will receive important parts and pieces like drive line adapters, mounting plates, and new exhaust.

If your new engine from Repower Specialists is missing a part, just give us a call. We will send you the part you need free of charge as part of our satisfaction guarantee. Call Repower Specialists for help in selecting the best small engine for your needs.

3 Important Skid Loader Applications & How They Affect Your Engine

Skid loaders can take on nearly any industrial role with ease. From moving snow to trenching to preparing sod to demolishing interiors, skid steers can do it, thanks to their agile, compact design. When using a skid steer for different jobs, it is important to consider how the task at hand will impact engine performance. The skid steer manager must appreciate how to protect the engine so it will enjoy a long life. We will take a look at three different skid steer loader applications, and how each affects engine performance.

Engine Outcomes for Three Common Skid Loader Tasks

1. Bucket Loading
This was the original reason why the skid steer came into existence. The lift arms, along with a tight turning radius, allow it to handily move materials, even in compact spaces. From snow to dirt to manure, the bucket loading power from a skid steer is helpful on construction sites, farms, golf courses, and more.

Engine impact: If you are moving heavy materials, bucket loading will require plenty of torque, meaning the ability of the engine to turn the crank. Torque is the best description of engine power. Horsepower actually describes how quickly the engine can get work done. Still, horsepower is a good quick reference point to approximate machine strength. In general, smaller skid steer frames correspond to less power:

Small Skid Steer: 1,750 pounds or less, under 50 HP

Medium Skid Steer: 1,750 – 2,200 pounds, 50 – 70 HP

Large Skid Steer: More than 2,200 pounds, over 70 HP

So, if you will be moving heavy loads, look for larger skid steers that can handle more torque. Also consider how you will be handling the materials. If you will be loading them into a dump truck, for instance, a larger skid steer with longer arms may perform best.

2. Landscaping/Farming Work
Skid steer loaders are top performers in the turf and landscaping world. Their attachments can be quickly switched out to transition between multiple outdoor applications:

– Brush cutting
– Rototilling
– Moving hay bales
– Dispensing seed
– Leveling earth
– Splitting logs
– Mulching
– Driving posts
– Pulling trees
– Laying down sod
– Cutting grass

Engine Impact: Outdoor applications send more gunk into the engine. For instance, dust can build up until it blows a head gasket, a costly repair to make. Therefore, it is crucial to perform regular oil changes, filter changes, and other basic engine maintenance tasks when using a skid steer in landscaping and farming tasks. The best approach is to create a written maintenance schedule, and then follow it religiously. Doing so will extend the life of your skid steer engine. Do not ignore daily engine checks, either. Over time, those five minutes of daily maintenance checks can save you thousands of dollars in equipment replacement and repair costs.

3. Grading and Road Building
When equipped with augers, drill bits, and heavy-duty bucket attachments, skid steers can complete tough excavating and road construction tasks. Wheel saws and planers are additional attachments for road preparation. Road site preparation may also require forestry cutters and tree pullers, for readying the landscape.

Engine Impact: Such harsh work requires a terrific amount of torque, so large frame machines are required. Otherwise you risk overwhelming the engine. As with landscaping work, skid steers used for road preparation are exposed to dust, so they demand consistent maintenance. Finally, these high-impact applications require advanced hydraulics. While small- and medium-frame skid steers are often equipped with standard hydraulic systems, larger machines typically boast auxiliary hydraulics. These advanced systems ensure that enough oil is flowing through the system, and at high enough pressure, to maintain healthy engine performance. An auxiliary hydraulic system allows you to use bigger, stronger attachments.

With proper maintenance and load consideration, your skid steer loader will perform magnificently for many years. For any questions about selecting the right engine for your skid steer, contact Repower Specialists and our representatives will be glad to assist you.

[Photo from Arvell Dorsey Jr. via CC License 2.0]