Repair or Replace?

Whether they operate one mower or a fleet of 20, lawn maintenance contractors will eventually have to answer these questions: Should I buy a replacement mower and, if so, when is the best time to do so? Or, would it make more sense to repair my old one?

The answer depends on many variables, not the least of which is money. The recent economic downturn forced many mowing contractors to postpone upgrading their equipment when other factors such as mower age and operating hours may have otherwise dictated their decision.

Whether to repair or replace a mower hinges on other considerations as well, including how well a machine has been maintained over the years. In this issue, for example, the owners of Cutzgras essentially replace every wear part on their Walker Mowers prior to the start of the mowing season. For Dennis Jontos, being a former helicopter mechanic, and Mark Jontos, a former jet engine mechanic, this discipline, not to mention the accompanying skills, is second nature. Many Walker Mower dealers offer a similar service that can extend mower life and reduce headaches later in the year.

Location, too, can be an issue. Having to trailer a piece of equipment a couple of hours every time it needs repairs becomes an expensive proposition in travel and downtime. In this instance, replacing a mower every few years might be the better choice.

Nuts and Bolts

The costliest repair item on most types of equipment is the engine. For quality mowers such as the Walker Mower, the tractor and deck will far outlast the engine depending on the engine type and overall upkeep of the equipment.

“We don’t replace the mower, we replace the engine,” says George Shrum, senior mechanic at Sposato Landscape Management. He’s referring to a fleet of 63 Walker Mowers (Walker Talk volume 31). The Milton, Delaware, company purchased its first Walker Mower in 1994, and still operates unit No. 5.

Sposato’s Walker Mowers are all powered by Kohler gasoline engines. Shrum notes that on average the company replaces engines between the 2,200- and 2,500-hour mark. They either rebuild the old engines for around $500 or install a new one for around $3,000.

Shrum’s engine replacement schedule shadows the advice given by Ohio Walker Mower dealer/distributor and former landscape contractor Tom Emmett. To determine approximate engine life for air-cooled engines, he simply multiplies the horsepower rating by 100. For liquid-cooled engines, he uses 150 as the multiplier.

Says Emmett, “If your Walker Mower is powered by 23-hp engine, it should go approximately 2,300 hours before the engine needs replacing. This is long before the machine’s lifecycle is up. Liquid-cooled engines may not outlast the lifecycle of a quality mower such as the Walker Mower, but they will bring the engine’s longevity and that of the mower’s closer together.

“Many of our customers rotate their air-cooled equipment every three years. Assuming they mow an average of 600 hours a year means they will be replacing the mower before the first large engine repair bill.”

When Yard Perfect’s owner Harry Stokes, Jr. (Walker Talk volume 35) recently downsized his business, he sold his diesel-powered Walker Mower in favor of keeping an older one with a smaller deck. “I hated to get rid of one of my Walkers, but couldn’t justify keeping both of them,” the Alabama owner/operator recalls. “I kept the smaller one because it would go through backyard gates.

“If I still owned the diesel and the engine needed replacing, I would replace it, just like I’ve replaced the engine on my other Walker Mower,” he adds. Would Stokes rather buy a new mower? “Yes,” he replies, “if I had the money. The key, though, would be to trade the mower while the engine still has life.”

Repair Logic

Using Emmett’s rule of thumb gives operators like Stokes some insight into when it’s time to trade in their mowers or otherwise replace an engine before experiencing performance and downtime issues.

No matter what approach is best for your operation, purchasing quality equipment and keeping it on a preventive maintenance schedule contains repair costs, optimizes equipment longevity, and helps retain trade-in value.

“Every day we grease our Walker Mowers and install a sharp set of blades,” relates Shrum. “Twice a week we blow out the engine compartment. The key for our Walker Mower longevity—and that of our Exmark, Toro and Wright mowers—is preventive maintenance.”

Cal Kearns, owner of Oregon-based C&D Landscape Company (Walker Talk volume 35) agrees, noting that the strategy applies to equipment and vehicles, alike. “A big board in our repair shop displays the maintenance schedule for our vehicles and mowers. Making sure schedules are not missed is the responsibility of both our mechanic and the operator.

“On Hood Monday, for example, our foremen open their truck’s engine compartment and double check all the fluid levels and overall give the engine a good once over. Our nine Walker Mowers receive similar attention, and operators are required to check their fluid levels every morning.”

Kearns says his technician has replaced a few Kohler engines on his Walker Mowers and will continue to do so as long as everything else is functional and in good shape. The owner’s strategy could be described as the “can” approach. As Kearns says, “We keep our machines as long as we can, and rebuild them when we can.”

Not to say he wouldn’t like to rotate his mowers every couple of years. He would, but economics often dictate, and replacing an engine is more cost-effective for him right now than buying a new mower. It is for Harry Stokes, too, who emphasizes how important it is to prepare for the inevitable. “One big mistake I made in business was not putting money aside to help buy a replacement machine. Even the best-maintained mowers will eventually need to be replaced.”

Company owners have options when it comes to replacing or repairing their equipment. One is to replace equipment before the warranty runs out. This saves money on repairs, but would be impractical for operators who log minimal hours on a machine or who just couldn’t afford the expense. Another is to rotate mowers every three or four years. This strategy reduces the likelihood of a big-ticket repair bill, minimizes downtime, and helps ensure top performance in the field.

Then again, the most attractive approach may be to keep a mower for the duration of its lifecycle and replace engines instead. What works best for your operation depends on your business model. No matter what course you take, the balancing act is to maintain top performance while minimizing equipment repair and operating costs.