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| Challenges in Rebuilding the 580CK Diesel Engine and the Importance of Accurate Manuals |
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Posted by: MikePhua - 10-21-2025, 03:07 PM - Forum: Parts , Attachments & Tools
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The Case 580CK, a well-regarded backhoe loader, is widely used in construction, landscaping, and agricultural operations for its powerful diesel engine and versatile capabilities. The 188 diesel engine, found in many versions of the 580CK, is known for its reliability and strength. However, like all machinery, it requires proper maintenance, and over time, the engine may need a complete rebuild to maintain optimal performance.
One of the critical elements in a successful engine rebuild is having access to accurate and detailed technical manuals. Unfortunately, a common issue that many mechanics and operators face is the challenge of dealing with faulty or incomplete manuals, which can lead to confusion, costly mistakes, and delays. This article will explore the difficulties encountered during a 580CK 188 diesel engine rebuild, focusing on the importance of proper documentation and how the right guidance can prevent unnecessary complications.
The Case 580CK Backhoe: A Brief Overview
The Case 580CK backhoe loader was introduced in the early 1960s and became one of the most iconic machines in the construction equipment industry. Known for its rugged design and durability, the 580CK featured a diesel engine that offered a balance of power and fuel efficiency. Over the years, it became a staple on construction sites and was praised for its ease of use and versatility in performing digging, lifting, and loading tasks.
The engine used in the 580CK, the 188 diesel, is a 4-cylinder, naturally aspirated unit. This engine typically produces around 62 to 70 horsepower, depending on the specific model and configuration. While it is generally reliable, age, wear, and lack of proper maintenance can necessitate a rebuild to restore the engine's power and functionality.
The Importance of Accurate Manuals in Engine Rebuilds
When tackling an engine rebuild, the role of the manual cannot be overstated. A manual provides essential instructions and specifications, including detailed assembly diagrams, torque settings, part numbers, and maintenance procedures. Without these documents, a mechanic is left to rely on trial and error, which can lead to mistakes that compromise the rebuild's success.
For many mechanics working on the 580CK, the rebuild process can become frustrating when the manual they are using is incomplete, unclear, or inaccurate. In particular, incorrect part numbers, vague assembly instructions, and missing torque specifications can cause significant delays and added costs. This was a common issue in a noted rebuild project, where mechanics struggled to make sense of the official manual.
Flaws in the Case 580CK Manual: What Went Wrong?
One of the most significant challenges during the rebuild of the 580CK’s 188 diesel engine is the apparent lack of clarity and detail in the official Case manuals. Mechanics found discrepancies in part numbers, inconsistencies in torque specifications, and missing details about crucial assembly processes. This led to several issues during the rebuild, including:
- Incorrect Part Numbers: The manual provided incorrect part numbers for key engine components, such as pistons, bearings, and seals. This made it difficult to order the right parts, leading to delays in the rebuild process.
- Missing Torque Specifications: Accurate torque settings are essential for ensuring that engine components are tightened to the correct specifications. The absence of these settings in the manual caused uncertainty and potential risks of over-tightening or under-tightening bolts, both of which can cause damage to the engine.
- Vague Assembly Instructions: The instructions for reassembling key engine components were unclear, which resulted in time-consuming errors. For example, the positioning of certain gaskets and seals was not well-explained, leading to possible leaks or misalignments.
- Unclear Maintenance Guidelines: Some maintenance steps were left out or poorly explained in the manual, causing confusion during the inspection and cleaning of critical components such as the fuel injectors, valves, and pistons.
These issues highlight the importance of using a reliable and complete manual, as it is the foundation of any successful engine rebuild. Without the proper documentation, a mechanic is forced to rely on outdated or anecdotal knowledge, which can lead to inefficiencies and mistakes.
The Impact of Manual Issues on the Rebuild Process
The lack of clarity and accuracy in the manual not only caused technical difficulties but also had financial and operational implications. The mechanic had to make multiple trips to local suppliers to source the correct parts, leading to extended downtime and additional costs. Furthermore, the uncertainty around torque specifications and assembly procedures meant that some components were not installed correctly, which could have compromised the engine’s long-term reliability.
The issues with the manual also caused a delay in the overall rebuild process. What should have been a straightforward engine overhaul turned into a prolonged project due to the time spent troubleshooting manual discrepancies and sourcing parts.
Lessons Learned and Best Practices for Engine Rebuilds
The experience of dealing with the flawed 580CK manual offers valuable lessons for anyone undertaking an engine rebuild. To avoid similar issues, here are several best practices:
- Use Multiple Sources for Information: If the official manual is lacking or unclear, look for alternative sources of information, such as online forums, trusted mechanic communities, or third-party service manuals. These sources can often provide insights that may not be covered in the official documentation.
- Verify Part Numbers Before Ordering: Always cross-check part numbers with suppliers and parts catalogs to ensure the correct components are ordered. If possible, consult with other mechanics or technical experts who are familiar with the 580CK model.
- Ensure Accurate Torque Settings: Never skip torque settings during the rebuild. Use a reliable torque wrench and consult multiple sources if torque specifications are unclear. Getting these settings right is critical for engine performance and longevity.
- Take Detailed Notes: As you work through the rebuild, take notes on each step and any unique challenges you encounter. This will not only help you in the future but also allow you to improve the process if you need to repeat it.
- Regular Maintenance and Inspection: To avoid the need for an early rebuild, keep up with routine maintenance and inspections. Regularly check the engine for signs of wear, such as oil leaks, excessive exhaust smoke, or unusual engine noises. Early intervention can prevent major failures down the road.
Conclusion
Rebuilding the 580CK 188 diesel engine is a challenging but rewarding task, and having the right manual is critical to the success of the project. In this case, the flawed manual caused significant delays and difficulties, underscoring the importance of ensuring that all documentation is accurate, comprehensive, and clear. By following best practices, using multiple sources of information, and performing regular maintenance, mechanics can help ensure that future rebuilds go more smoothly and cost-effectively.
For anyone working on the 580CK or similar equipment, being prepared for potential issues with the manual—and having a backup plan in place—can make all the difference in ensuring a successful and efficient engine rebuild.
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| Globe 50-Ton Ground Bearing Trailer Cylinder Identification and Legacy Support |
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Posted by: MikePhua - 10-21-2025, 03:07 PM - Forum: Parts , Attachments & Tools
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Quick answer
For a 1992 Globe 50-ton ground bearing detachable neck trailer, factory specifications for the main hydraulic cylinder are no longer available from the manufacturer. However, accurate replacement or repair is possible by measuring the existing cylinder and sourcing a match through surplus hydraulic suppliers or trailer rebuilders familiar with Witzco-era Globe designs.
Globe Trailers history and legacy equipment challenges
Globe Trailers, founded in the mid-1970s, became known for producing heavy-haul lowboys, detachable neck trailers, and specialized transport platforms. In the early 1990s, many of their ground bearing models were built with design and component similarities to Witzco Challenger trailers. This overlap occurred during a period of shared engineering practices and subcontracted manufacturing.
After a change in ownership in the mid-2000s, Globe’s archival records for pre-2005 trailers were lost or removed, leaving many legacy owners without access to original build sheets, cylinder specs, or hydraulic diagrams.
Ground bearing neck design and cylinder function
A ground bearing detachable neck trailer uses hydraulic cylinders to lift and lower the gooseneck onto the ground, allowing the main deck to detach for loading. Unlike non-ground bearing designs, the weight of the trailer and load is partially supported by the ground during detachment.
The main cylinder in this system: - Is typically a single-acting hydraulic ram
- Operates under high pressure (2,500–3,000 PSI)
- Has a stroke length between 24–36 inches depending on trailer model
- Is mounted between the gooseneck and the front deck frame
Failure of this cylinder can prevent proper detachment or reattachment, especially under load or on uneven terrain.
Sourcing a replacement cylinder
Since Globe no longer provides specifications for trailers built before 2005, the best approach is to:- Remove the existing cylinder and measure:
- Bore diameter
- Rod diameter
- Stroke length
- Pin-to-pin length (retracted and extended)
- Mounting style (clevis, cross-tube, spherical eye)
- Contact surplus hydraulic suppliers such as Surplus Center or Bailey Hydraulics
- Cross-reference with Witzco Challenger trailer cylinder specs from the same era
- Consider custom fabrication if no match is found
Some trailer sales professionals maintain leftover inventory from the pre-2005 Globe era and may be able to match cylinders based on dimensions.
Field repair and retrofit considerations
If the cylinder is leaking or damaged but structurally intact:- Rebuild kits may be available from hydraulic shops
- Chrome rod resurfacing can restore sealing surfaces
- New seals and wipers can extend service life
If the cylinder is bent or pitted internally, replacement is recommended. Always inspect the hydraulic lines and fittings for wear or contamination before installing a new unit.
Preventive maintenance and inspection tips- Check hydraulic fluid levels before each use
- Inspect cylinder rod for scoring or rust
- Grease pivot pins regularly to prevent binding
- Avoid detaching on soft or uneven ground to reduce stress on the cylinder
One operator in Tennessee noted that his 1992 Globe trailer had performed flawlessly for decades, but a sudden cylinder failure during a cold morning loadout left him stranded. After measuring the cylinder and sourcing a match from a surplus dealer, he was back on the road within a week.
Conclusion
While factory support for older Globe 50-ton ground bearing trailers is limited, accurate cylinder replacement is achievable through careful measurement and aftermarket sourcing. With attention to mounting style, stroke, and pressure rating, operators can maintain these durable trailers for decades beyond their original service life.
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| John Deere 310D Backhoe Loader Overview and Troubleshooting |
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Posted by: MikePhua - 10-21-2025, 03:06 PM - Forum: Troubleshooting & Diagnosing
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The John Deere 310D is a part of the 310 series of backhoe loaders from the renowned agricultural and construction equipment manufacturer, John Deere. Known for its versatility, reliability, and powerful performance, the 310D is widely used in construction, landscaping, and utility work. It has earned a reputation for handling tough tasks such as digging, lifting, trenching, and material handling.
Despite its rugged build, the 310D, like any piece of heavy equipment, can face issues over time. Understanding the common problems associated with the 310D, as well as its features and maintenance needs, is crucial to ensuring the machine operates at peak performance throughout its lifespan.
John Deere 310D: Key Features and Specifications
The 310D was introduced as a mid-range backhoe loader designed for various applications, including excavation, material handling, and even agricultural tasks. Built with a durable frame and equipped with advanced hydraulic systems, it provides high efficiency, especially in tough working conditions. Some of the key specifications include: - Engine: Powered by a 4.5L, 4-cylinder diesel engine, delivering around 72 horsepower. This engine provides the 310D with ample power to handle both light and heavy-duty tasks.
- Operating Weight: Approximately 16,000 pounds (7,260 kg), making it heavy enough for demanding jobs while still offering maneuverability.
- Loader Capacity: The machine is equipped with a front loader that can handle around 4,500 pounds (2,041 kg) of material, depending on the model year and specific configurations.
- Backhoe Reach: The 310D’s backhoe offers an effective digging depth of up to 14 feet (4.3 meters), making it suitable for both residential and commercial excavation work.
- Hydraulics: The 310D features a powerful hydraulic system, providing both strength and control for various attachments such as buckets, augers, and hydraulic breakers.
- Transmission: A powershift transmission offers smooth shifting and allows for easy speed control, making it ideal for construction and grading.
With these capabilities, the 310D is capable of completing a range of tasks efficiently, especially when properly maintained.
Common Problems and Troubleshooting the John Deere 310D
Despite its many strengths, the John Deere 310D is not immune to technical issues. Operators may encounter some recurring problems related to the engine, hydraulics, electrical system, and general wear. Here, we’ll delve into the most common problems and their solutions.
1. Engine Issues
The engine in the John Deere 310D, while robust, can sometimes encounter problems related to fuel delivery, air intake, or general maintenance. Common symptoms of engine trouble include poor performance, difficulty starting, or a lack of power during operation.
Symptoms:- Engine stalling or rough idling.
- Lack of power when performing heavy lifting or digging.
- Difficulty starting the engine.
Possible Causes and Solutions:- Fuel System Blockages: Fuel filters can become clogged over time, leading to poor fuel flow. Regularly replace fuel filters to prevent clogging.
- Air Intake Problems: A dirty air filter or intake can cause the engine to run inefficiently. Check and replace air filters as necessary.
- Starter Motor Failure: If the engine fails to start, it could be an issue with the starter motor or solenoid. Check the starter and wiring for any damage.
2. Hydraulic System Failures
The hydraulic system is the backbone of the 310D’s performance, powering both the front loader and backhoe. Hydraulic issues are some of the most common problems faced by operators, often manifesting in reduced lifting capacity or sluggish performance.
Symptoms:- Slow or unresponsive loader/backhoe functions.
- Unusual noises from the hydraulic pump or cylinders.
- Inconsistent hydraulic fluid levels.
Possible Causes and Solutions:- Low Hydraulic Fluid: Ensure that the hydraulic fluid is at the proper level. If the fluid is low, top it up and check for any leaks in the system.
- Contaminated Fluid: Over time, contaminants such as dirt and debris can enter the hydraulic system, causing the pump to work less efficiently. Regularly replace the hydraulic fluid and clean or replace filters.
- Hydraulic Pump Failure: If there are no leaks but the hydraulics are still slow, the pump could be malfunctioning. A qualified technician may need to inspect and repair or replace the pump.
3. Transmission and Drive Train Issues
The transmission system in the 310D is designed to provide smooth and reliable operation. However, issues such as gear slippage, delayed engagement, or difficulty shifting can occur, affecting the machine’s performance.
Symptoms:- Difficulty shifting gears or slipping between gears.
- Sudden loss of power or unresponsive drivetrain.
- Unusual noises when shifting or during operation.
Possible Causes and Solutions:- Low Transmission Fluid: Check the transmission fluid levels and top them up as needed. Use the recommended fluid type as specified in the owner’s manual.
- Worn Clutch or Transmission Bands: If the clutch or transmission bands are worn, they may not engage properly. In such cases, the transmission may require servicing or rebuilding.
- Control Linkage Issues: Inspect the transmission control linkage for any issues with the adjustment or damage to the components.
4. Electrical Problems
Electrical issues can cause a variety of symptoms, including problems with lights, engine starting, and warning lights on the dashboard. Electrical problems are typically the result of faulty wiring, corroded connections, or dead batteries.
Symptoms:- The engine does not start.
- Electrical components (lights, horns) fail to function.
- Dashboard warning lights remain illuminated.
Possible Causes and Solutions:- Dead or Weak Battery: Ensure the battery is fully charged and check for any corrosion around the terminals. Replace the battery if it is old or unable to hold a charge.
- Loose or Corroded Wiring: Inspect the wiring for any visible damage or corrosion. Clean and secure all connections to ensure proper electrical flow.
- Faulty Fuses or Relays: Check the fuses and relays related to the electrical systems. Replace any that are blown or malfunctioning.
5. General Wear and Tear
Like any piece of heavy equipment, the John Deere 310D will experience general wear and tear over time, especially when used for demanding tasks. Common areas of concern include tires, seals, and bearings.
Symptoms:- Excessive wear on tires.
- Leaks from hydraulic cylinders or seals.
- Noisy bearings or components.
Possible Causes and Solutions:- Tires: Regularly inspect the tires for signs of wear, cuts, or punctures. Rotate the tires to ensure even wear and replace them when necessary.
- Seals: Inspect hydraulic cylinder seals for leaks. Replace worn seals promptly to prevent fluid loss and maintain hydraulic efficiency.
- Bearings: If there’s a grinding or squealing noise from bearings, they may need to be lubricated or replaced.
Preventive Maintenance Tips for the John Deere 310D
To prevent common issues from escalating, operators should adhere to a strict preventive maintenance schedule. Regular maintenance not only extends the life of the machine but also ensures it operates at maximum efficiency. Key preventive maintenance tasks include:- Regular Oil and Filter Changes: Change the engine oil and filters at the intervals specified in the operator’s manual.
- Hydraulic Fluid and Filter Replacement: Change hydraulic fluid and replace filters every 1,000 to 2,000 hours, or as recommended by the manufacturer.
- Inspect and Lubricate Moving Parts: Regularly inspect and lubricate the loader arms, backhoe, and other moving components to reduce wear.
- Tire Maintenance: Check tire pressure and tread regularly, and rotate the tires to ensure even wear.
Conclusion
The John Deere 310D backhoe loader is a versatile and reliable machine that can tackle a wide range of tasks in various industries. While it’s a durable piece of equipment, it’s important to recognize and address common issues such as hydraulic failures, engine problems, and electrical malfunctions. Regular maintenance, quick troubleshooting, and replacing worn components can help extend the life of the 310D and ensure optimal performance.
By following the tips and solutions provided in this article, operators can minimize downtime, reduce repair costs, and ensure that their John Deere 310D continues to serve them well for many years.
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| Is Sonic Tracing Practical for Curb Preparation Work |
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Posted by: MikePhua - 10-21-2025, 03:06 PM - Forum: Construction & Urban Infrastructure Forum
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Quick answer
Sonic tracers can automate grade control under string lines for curb preparation, reducing labor and improving consistency. However, their effectiveness depends heavily on string material, peg spacing, and machine integration. In many regions, manual checking with levels and tape remains dominant due to cost and simplicity.
Sonic tracer technology and grading systems
A sonic tracer is a non-contact sensor that reads the position of a reference line—typically a string—and adjusts the grading blade accordingly. It’s often integrated into systems like Topcon System 5 or similar machine control platforms. These systems use: - Sonic sensors mounted on the moldboard or mast
- Controllers that interpret string position and adjust blade height
- Manual override switches for peg interference
- Optional wire-traced string lines for improved signal clarity
The goal is to trim subgrade material precisely under the string line without constant manual measurement.
String line material and sensor compatibility
The success of sonic tracing depends on the physical properties of the string:- Thick bailing twine or wire-traced string: Offers better reflectivity and signal consistency
- Fishing line or thin nylon: Difficult for sensors to detect, especially in bright sunlight or dusty conditions
Operators report that some curb crews use fishing line directly tied to pegs, which complicates sonic detection. Pegs themselves can interfere with readings, causing the blade to lift unnecessarily unless the system is manually overridden.
Field experience and practical adaptations
One grader operator in Queensland used a Topcon-equipped CAT 12H with a sonic tracer. He found that switching off auto mode near pegs was essential to prevent erratic blade movement. He also noted that using wire-traced string improved sensor reliability.
Another operator in Canada preferred manual checking. He placed material according to stakes, compacted it, then had a laborer walk behind the blade with a level and tape, checking every 5–6 feet. Adjustments were made on the fly, and the crew completed 900 meters of curb prep in under three hours.
Labor cost and regional variation
In Australia, employing a skilled grade checker can cost $60–$70 AUD per hour when factoring in wages, superannuation, insurance, and payroll tax. This drives interest in automation. In contrast, Canadian labor rates for similar roles may be as low as $11–$20 CAD per hour, making manual methods more viable.
Recommended practices for sonic tracer use- Use wire-traced string lines for consistent detection
- Train operators to override auto mode near pegs
- Maintain clean sensor surfaces and calibrate regularly
- Combine sonic tracing with visual checks for critical grades
- Consider hybrid setups with whisker sensors or mechanical feelers
Some operators mount a whisker or string holder directly to the moldboard, allowing a single person to trim accurately without relying on full automation.
Conclusion
Sonic tracers offer a promising way to reduce labor and improve grading precision under string lines, especially in high-cost labor markets. Their success depends on string material, peg layout, and operator skill. While not universally adopted, they represent a step toward smarter curb preparation—particularly when paired with robust machine control systems and thoughtful field adaptation.
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| Troubleshooting Sullair Compressors That Won’t Stay Cool |
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Posted by: MikePhua - 10-21-2025, 03:05 PM - Forum: Troubleshooting & Diagnosing
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Sullair air compressors are widely known for their reliability and efficiency in a variety of industries such as construction, manufacturing, and maintenance. However, even the most reliable equipment can encounter issues from time to time. One common problem with air compressors, including Sullair models, is overheating or failure to stay cool during operation. This issue can not only hinder the performance of the machine but may also lead to more serious mechanical problems if left unchecked.
This article will explore the causes of overheating in Sullair compressors, common signs of cooling system failure, and provide effective troubleshooting steps to resolve the issue. Additionally, we’ll discuss preventive maintenance measures to help keep your compressor running smoothly and efficiently.
Understanding the Cooling System in Sullair Compressors
Sullair compressors, like most industrial air compressors, are equipped with a cooling system designed to maintain the operating temperature of the machine. This cooling system is essential to prevent overheating, which can lead to damage to the compressor’s internal components, reduced efficiency, and even complete system failure.
The cooling system in these compressors typically consists of the following components:
- Cooler/Heat Exchanger: The main component responsible for dissipating heat from the compressor’s internal components, such as the airend and motor.
- Thermostat: Regulates the temperature of the compressor by controlling the flow of coolant to the heat exchanger.
- Coolant Pump: Circulates coolant (usually a mixture of water and antifreeze) through the system.
- Air Intake Fan: In some models, an intake fan is used to help cool the system by circulating ambient air over the compressor's hot components.
- Coolant Lines and Hoses: These carry the coolant throughout the compressor system to ensure proper temperature regulation.
A malfunction in any of these components can lead to the compressor failing to stay cool, which can result in performance issues or even severe damage to the unit.
Common Causes of Overheating in Sullair Compressors
Several factors can contribute to a Sullair compressor overheating or failing to maintain a proper operating temperature. Let’s explore the most common causes.
- Low Coolant Levels or Leaks
One of the most frequent causes of compressor overheating is low coolant levels, which can be the result of leaks in the coolant system. If the coolant level is insufficient, the compressor won’t have enough fluid to dissipate heat, causing it to overheat.
Symptoms of Low Coolant Levels:- Temperature gauge reading higher than usual.
- Compressor components feel unusually hot to the touch.
- Visible coolant leakage near hoses or connectors.
Solution: Check the coolant levels regularly and top them off if needed. If you notice a significant drop in coolant, inspect the system for leaks, particularly around the coolant lines and connections. Tighten any loose fittings and replace damaged hoses or seals as necessary. For persistent leaks, it may be necessary to replace the entire coolant line.
- Clogged or Dirty Heat Exchanger
The heat exchanger or cooler plays a critical role in maintaining proper operating temperatures by dissipating heat from the compressor’s internal components. Over time, dust, dirt, and debris can accumulate on the heat exchanger, reducing its ability to release heat effectively.
Symptoms of a Clogged Heat Exchanger:- Higher-than-normal discharge temperatures.
- Unusual noises, such as increased fan activity or strain.
- Visible dirt or debris on the heat exchanger fins.
Solution: Clean the heat exchanger to remove any dust, dirt, or debris that may be blocking airflow. Use a soft brush or compressed air to carefully clean the cooling fins. If the heat exchanger is severely clogged or damaged, consider having it professionally serviced or replaced.
- Faulty Thermostat or Temperature Sensor
A malfunctioning thermostat or temperature sensor can prevent the compressor’s cooling system from regulating the temperature properly. If the thermostat fails to open or close at the correct temperature, it can cause the system to run too hot or too cold, leading to poor performance and potential damage.
Symptoms of a Faulty Thermostat or Sensor:- The temperature gauge fluctuates or does not accurately reflect the compressor’s actual temperature.
- Compressor continues to run even when overheating, or fails to activate the cooling system when necessary.
- Inconsistent cooling performance.
Solution: Check the thermostat and temperature sensors for proper operation. If the thermostat is stuck or faulty, it should be replaced. Similarly, faulty temperature sensors should be replaced to ensure accurate readings and proper system functioning.
- Insufficient Airflow to the Compressor
If the air intake system is blocked or obstructed, it can reduce the amount of cool air reaching the compressor, which can cause overheating. This issue is especially common if the compressor is used in dusty or dirty environments, where debris can easily clog the intake filters or vents.
Symptoms of Restricted Airflow:- Higher-than-normal compressor temperature.
- Increased strain on the intake fan.
- Noisy compressor operation, especially when the fan is running at higher speeds.
Solution: Inspect the air intake filters and vents for any blockages. Clean or replace filters regularly to ensure that the compressor receives enough air. Make sure there are no obstructions around the intake area that could limit airflow.
- Malfunctioning Coolant Pump
If the coolant pump is not functioning properly, it may not be circulating the coolant through the system efficiently. This can cause the compressor to overheat, as the coolant won’t be able to absorb and dissipate heat effectively.
Symptoms of a Malfunctioning Coolant Pump:- The compressor temperature rises quickly after starting.
- Coolant appears to be stagnant or not circulating.
- Unusual noise or vibration from the pump area.
Solution: Inspect the coolant pump for proper operation. If the pump is damaged or not functioning, it will need to be replaced. Ensure that the pump’s impeller is intact and that it is moving coolant effectively through the system.
Preventive Maintenance to Keep Your Compressor Cool
- Regular Coolant Checks: Always check the coolant levels before each operation. Ensure the coolant is clean and free from contaminants. If necessary, replace the coolant every 1,000 to 2,000 hours of operation.
- Clean the Air Intake System: Keep the air intake system, including filters and vents, free from debris. Regularly inspect and clean the filters to ensure unrestricted airflow.
- Inspect and Clean the Heat Exchanger: Regularly clean the heat exchanger to remove dirt and debris. This ensures efficient heat dissipation and prevents overheating.
- Monitor Operating Temperature: Always keep an eye on the compressor’s operating temperature. If you notice any sudden temperature increases or irregularities, address them immediately.
- Professional Servicing: Schedule regular maintenance and servicing by a qualified technician. Regular inspections can help identify potential issues before they escalate into serious problems.
Conclusion
Overheating is a common issue that can affect the performance and longevity of your Sullair compressor. By understanding the key components of the cooling system and recognizing the signs of cooling failure, you can address problems quickly and prevent further damage. Regular maintenance, including checking coolant levels, cleaning filters, and inspecting the heat exchanger, will ensure that your Sullair compressor continues to operate efficiently and effectively.
Taking proactive steps to maintain your compressor’s cooling system can save you time, money, and downtime, allowing you to get the most out of your investment.
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| CAT 215 Excavator Swing Drive Fluid Level and Maintenance Notes |
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Posted by: MikePhua - 10-21-2025, 03:05 PM - Forum: Troubleshooting & Diagnosing
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Quick answer
The swing drive fluid level on a CAT 215 excavator should be maintained at the bottom edge of the fill plug opening, located behind the boom under the right-side front top cover. If no fluid is visible, refill cautiously and monitor for leaks.
CAT 215 excavator background and swing drive system
The Caterpillar 215 hydraulic excavator was introduced in the late 1970s and remained in production through the early 1990s. It was one of CAT’s early full-sized excavators designed for general earthmoving, trenching, and demolition. The 215 featured: - A 96L swing drive gearbox
- Hydraulic swing motor with planetary reduction
- Manual fill and inspection ports
- Separate lubrication system from the main hydraulic circuit
The swing drive mechanism allows the upper structure to rotate smoothly on the undercarriage. It relies on gear oil to lubricate the planetary gears and bearings inside the swing drive box.
Locating the fill/check plug and verifying level
The fill/check plug is a 1.5-inch hex fitting with a ½-inch square recess. It is mounted on the top of the swing drive box, accessible by opening the right-side front top cover behind the boom. To check the level:- Remove the plug with a square drive or hex socket
- Look inside the opening—fluid should reach the bottom edge of the threads
- If no fluid is visible, add gear oil until it reaches the correct level
Recommended oil type: SAE 90 or 85W-140 gear oil, depending on ambient temperature and operating conditions.
Common issues and inspection strategy
If the swing drive box is dry, it may indicate:- Leakage from the output seal: Often caused by worn bearings or seal hardening
- Improper maintenance: Fluid may not have been checked for years
- Overfilling or underfilling during service: Lack of clear manual instructions can lead to errors
One operator discovered his swing drive was completely dry after years of operation. He added oil and monitored the leak rate to determine whether a seal replacement was necessary.
Recommendations for servicing and monitoring- Check fluid level every 250–500 operating hours
- Inspect the swing drive housing for signs of seepage or wetness
- Replace the fill plug gasket if it shows signs of wear
- Use a flashlight and inspection mirror to verify fluid level if visibility is poor
- If leaking, consider replacing the output shaft seal and bearing assembly
During cold starts, dry swing drives may produce a groaning or grinding sound. This is a sign of insufficient lubrication and should be addressed immediately.
Historical context and operator anecdotes
The CAT 215 was widely used in pipeline construction and municipal work throughout the 1980s. Its swing drive system was praised for simplicity but criticized for lack of clear service indicators. Unlike modern excavators with sight glasses or electronic sensors, the 215 relies entirely on manual inspection.
One retired operator recalled using a bent wire as a dipstick to check fluid level when the plug was hard to remove. While not recommended, it highlights the improvisation often required in field conditions.
Conclusion
Maintaining proper swing drive fluid level in a CAT 215 excavator is essential for reliable rotation and gear longevity. The fill plug is located behind the boom under the top cover, and fluid should reach the bottom of the plug opening. Regular inspection, correct oil type, and leak monitoring will ensure the swing drive remains functional for years to come.
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| Troubleshooting the JD 310SG Speed Control Cable Issues |
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Posted by: MikePhua - 10-21-2025, 03:04 PM - Forum: Troubleshooting & Diagnosing
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The John Deere 310SG is a versatile backhoe loader widely used in construction, agriculture, and municipal applications. It is known for its durability, reliability, and ease of operation. However, like all machinery, it can experience issues that affect its performance. One common issue faced by operators of the JD 310SG is problems with the speed control cable, which can result in difficulties when trying to adjust the machine's speed.
This article explores the purpose of the speed control cable in the JD 310SG, common problems associated with it, and how to troubleshoot and fix these issues effectively.
Understanding the Speed Control Cable
The speed control cable is a vital component in many machines, including backhoe loaders like the JD 310SG. This cable connects the throttle control to the engine's fuel system, allowing the operator to adjust the speed of the engine and, consequently, the speed of the machine. It controls the engine's RPM (revolutions per minute), providing the necessary power for various tasks such as digging, lifting, or driving.
On the JD 310SG, the speed control cable typically runs from the operator’s throttle lever to the engine’s throttle linkage, and it is responsible for regulating the fuel delivery to the engine. A properly functioning speed control cable ensures smooth engine acceleration and deceleration, which is critical for efficient operation, especially in tasks requiring precision and control.
Common Problems with the Speed Control Cable
- Cable Friction or Binding
One of the most common problems associated with the speed control cable is friction or binding. Over time, dust, dirt, or rust can accumulate along the cable’s path, causing it to become stiff or difficult to move. This can result in a delayed or uneven response when the throttle lever is adjusted.
Symptoms of Cable Friction or Binding:- The throttle lever is difficult to move or feels stiff.
- The machine’s engine speed doesn’t increase or decrease smoothly.
- Jerky acceleration or deceleration.
Solution: To address cable friction or binding, inspect the entire length of the cable for visible signs of damage, dirt, or rust. Lubricating the cable with a suitable lubricant can often restore smooth movement. If the cable is severely worn or damaged, it may need to be replaced.
- Cable Wear or Damage
Another issue that can occur is the general wear and tear of the speed control cable. Continuous use of the backhoe loader can lead to fraying, cracking, or snapping of the cable, which can disrupt the connection between the throttle lever and the engine. A damaged or worn-out cable can prevent proper throttle operation and cause erratic or unpredictable engine speeds.
Symptoms of Cable Wear or Damage:- Visible fraying or cracking of the cable.
- Inconsistent engine speed or inability to maintain a steady RPM.
- The throttle lever moves, but the engine speed doesn’t respond correctly.
Solution: If the cable shows signs of wear or damage, it should be replaced immediately. Continuing to use a damaged cable can lead to further complications and potentially costly engine repairs. To replace the speed control cable, consult the machine’s service manual for specific instructions or seek assistance from a qualified mechanic.
- Improper Cable Adjustment
If the speed control cable is not properly adjusted, it can cause issues with engine speed control. An improperly adjusted cable may result in the throttle lever not engaging the throttle linkage correctly, leading to a poor throttle response or inconsistent engine speeds.
Symptoms of Improper Cable Adjustment:- The throttle lever has little effect on engine speed.
- The machine's engine speed is erratic or uneven.
- The throttle lever moves without affecting the engine’s RPM.
Solution: To correct an improperly adjusted cable, follow the adjustment procedure outlined in the JD 310SG service manual. Typically, this involves adjusting the tension on the cable and ensuring that it is correctly aligned with the throttle linkage. A mechanic with experience on John Deere equipment may also assist in making precise adjustments.
- Clogged Throttle Linkage
Sometimes, the issue may not lie with the cable itself, but with the throttle linkage to which the cable connects. Dirt, debris, or corrosion can build up in the throttle linkage, preventing the cable from moving smoothly. This can lead to poor throttle response and engine performance.
Symptoms of a Clogged Throttle Linkage:- Difficulty in adjusting the throttle.
- Erratic or jerky engine acceleration.
- Visible buildup of debris or rust near the throttle linkage.
Solution: Clean and lubricate the throttle linkage to ensure smooth operation. Remove any debris or rust that may be causing the throttle to stick. If cleaning the linkage doesn’t solve the issue, further inspection may be needed to identify any internal damage to the throttle system.
How to Replace the Speed Control Cable on the JD 310SG
If the speed control cable is damaged beyond repair or is experiencing persistent issues, replacing it may be necessary. Here is a general overview of the replacement process:
- Preparation:
- Turn off the machine and disconnect the battery to ensure safety.
- Lift the rear hood to access the engine and speed control cable.
- Remove the Old Cable:
- Locate the throttle linkage where the speed control cable connects to the engine.
- Loosen any fasteners holding the cable in place and disconnect the cable from the throttle linkage.
- Carefully remove the cable from its housing, noting how it is routed for proper installation of the new cable.
- Install the New Cable:
- Route the new speed control cable in the same way as the old one, ensuring it does not bind or interfere with any other components.
- Connect the cable to the throttle linkage and tighten any fasteners.
- Adjust the cable tension as specified in the service manual to ensure smooth operation.
- Test the New Cable:
- Once the new cable is installed, test the throttle lever to ensure the engine responds smoothly and evenly.
- Adjust the cable tension if necessary to achieve the desired throttle response.
Preventing Future Speed Control Cable Issues
- Regular Inspections:
Periodically inspect the speed control cable for signs of wear, fraying, or damage. Early detection of issues can prevent major failures and minimize downtime.
- Lubrication:
Regularly lubricate the cable to reduce friction and prevent binding. Make sure to use the appropriate type of lubricant recommended by the manufacturer.
- Proper Storage:
Ensure the machine is stored in a clean, dry environment to prevent dust and dirt from accumulating on the speed control cable and throttle components.
- Routine Maintenance:
Keep the throttle linkage clean and well-maintained. Lubricating moving parts and removing debris regularly will help prevent issues from developing.
Conclusion
The speed control cable plays a crucial role in the proper operation of the John Deere 310SG backhoe loader. Understanding the common issues associated with the cable, such as binding, wear, and improper adjustment, is key to maintaining smooth and efficient operation. By conducting regular inspections, replacing damaged cables promptly, and keeping the system clean and lubricated, operators can avoid unnecessary downtime and costly repairs, ensuring that the JD 310SG continues to perform at its best on the job site.
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| Is a Stainless Steel Dump Body Worth It for Smaller Trucks |
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Posted by: MikePhua - 10-21-2025, 03:04 PM - Forum: General Discussion
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Stainless steel dump bodies offer long-term durability and corrosion resistance, but they come with trade-offs in weight, material flow, and upfront cost. For operators planning to keep their truck for many years, stainless may be a smart investment—especially in regions with harsh winters or corrosive materials.
Stainless steel vs painted steel in dump body applications
Traditional steel dump bodies require regular maintenance to prevent rust and surface degradation. Operators often repaint or sandblast every 2–3 years, especially when hauling abrasive materials like stone, mulch, or topsoil. In contrast, stainless steel resists corrosion without paint, reducing long-term upkeep.
However, stainless steel is heavier than mild steel for the same thickness. This reduces payload capacity slightly, which may matter on smaller trucks like the Ford F550 or similar one-ton chassis. For example: - A painted steel body may weigh 1,200 lbs
- A stainless equivalent could weigh 1,400–1,500 lbs
- That 200–300 lb difference could mean one less scoop of gravel per load
Material flow and surface friction
Stainless steel has a higher coefficient of friction than painted steel. This means materials like wet mulch, topsoil, or river rock may stick more during unloading. Operators report needing to raise the bed higher or manually coax material out of the chute.
This issue is more noticeable with processed stone or damp organic material. Dry sand and gravel flow reasonably well. Some manufacturers offer polished stainless or apply wax coatings to reduce friction, but these add cost and require reapplication.
Durability and long-term performance
Stainless dump bodies have proven themselves in municipal fleets and snowplow operations. Stainless spreaders, for example, often last 10–15 years with minimal maintenance. Weld seams and hoist mounts hold up well if fabricated properly.
One operator in Connecticut noted that his stainless spreaders had survived multiple winters without rust, while his painted steel dump body needed repainting every other year. After switching to stainless for his new truck, he saw reduced maintenance and better resale value.
Cost considerations and resale value
Stainless steel bodies cost 20–40% more than painted steel equivalents. For a small truck, this could mean an extra $2,000–$4,000 depending on hoist configuration and custom features. However, resale value improves significantly if the body remains clean and rust-free.
Recommendations:- Choose stainless if you plan to keep the truck 8+ years
- Avoid stainless if payload capacity is critical and you haul dense material
- Consider polished or coated stainless to improve material flow
- Inspect welds and hoist mounts—poor fabrication can negate stainless benefits
Conclusion
Stainless steel dump bodies offer excellent corrosion resistance and long-term durability, making them ideal for operators in harsh environments or those planning to keep their truck for a decade or more. While heavier and more expensive, the reduced maintenance and improved resale may justify the investment. For smaller trucks, weigh the trade-offs carefully based on your hauling needs and climate.
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| Women in the Heavy Equipment Industry: Challenges and Progress |
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Posted by: MikePhua - 10-21-2025, 03:03 PM - Forum: General Discussion
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The heavy equipment industry has long been dominated by men, with women historically underrepresented in the field. However, over the past few decades, there has been a significant shift in this dynamic, as more women are entering the workforce in skilled roles traditionally held by men. This change is driven by the growing recognition of the benefits of diversity in the workplace, as well as efforts by various organizations and initiatives to break down barriers and support women in the industry.
This article will explore the challenges women face in the heavy equipment industry, the progress that has been made, and the ways in which the industry is evolving to become more inclusive. Additionally, it will discuss some of the positive impacts of this shift, both for women and for the industry as a whole.
Historical Context: The Male-Dominated Industry
The heavy equipment sector, which includes construction, mining, manufacturing, and other industries, has traditionally been viewed as a male-dominated field. This is partly due to the physical demands of the work, which has led to stereotypes about women's capabilities in such roles. For many years, women were excluded from these sectors, and those who did enter often faced significant challenges in advancing in their careers.
According to the U.S. Bureau of Labor Statistics, in 2019, women accounted for just 9% of the total workforce in the construction industry. The figures were similarly low in other sectors, with women making up a very small percentage of those employed in skilled trades, machinery operation, and maintenance.
Challenges Faced by Women in the Industry
- Physical Demands of the Job
One of the most commonly cited challenges for women in the heavy equipment industry is the physical nature of the work. Operating large machinery, lifting heavy tools, and working in challenging conditions can be demanding for anyone, regardless of gender. The stereotype that women are less capable of handling such tasks has long been a barrier to entry in the industry.
However, many women in the industry have proven that they can handle the same physical tasks as their male counterparts. Advances in equipment design and technology have also made it easier for women to perform heavy lifting tasks, with machines now being more ergonomically designed for a range of body types and capabilities.
- Gender Bias and Discrimination
Despite significant progress, gender bias remains a challenge in many sectors of the heavy equipment industry. Women may find themselves overlooked for promotions or placed in less desirable positions due to unconscious bias or explicit discrimination. There is also the added challenge of working in environments where male coworkers may be unaccustomed to working alongside women, leading to awkward dynamics or even hostile work environments.
Women entering this field often face the burden of proving themselves more than their male counterparts, sometimes working harder to demonstrate their skills and qualifications. This can be mentally and emotionally exhausting, but many women have found ways to overcome these barriers by seeking support from mentors and professional organizations dedicated to diversity.
- Lack of Role Models and Mentors
Another challenge women face is the lack of role models and mentors in the industry. With so few women in leadership or skilled positions, it can be difficult for new female workers to find mentors who can guide them through the early stages of their careers. This lack of representation in higher positions can also make it harder for women to envision long-term career prospects in the industry.
Mentorship plays a critical role in the development of skills and career advancement. Without access to a network of supportive mentors, women in the heavy equipment sector may feel isolated or unsure of how to navigate the challenges of their roles.
Progress and Positive Developments
- Changing Attitudes Toward Women in the Industry
One of the most significant changes in recent years has been the shift in attitudes toward women working in traditionally male-dominated roles. More companies and organizations are recognizing the value of diversity in the workplace and are making efforts to create more inclusive environments. This includes offering equal opportunities for women to access training, development programs, and leadership positions.
Additionally, many companies are now actively recruiting women into the heavy equipment industry. Organizations like the National Association of Women in Construction (NAWIC) and Women in Construction (WiC) are dedicated to advocating for gender equality and supporting women who wish to pursue careers in construction and heavy machinery operation.
- Training and Educational Opportunities for Women
There has been a marked increase in programs designed to support women who want to enter the heavy equipment industry. From scholarships to dedicated training programs, the resources available for women pursuing careers in construction and equipment operation have grown significantly. Many vocational schools and technical colleges now offer courses tailored specifically for women in trades, with an emphasis on hands-on training and safety.
Apprenticeships and internships have also become more accessible, providing women with the chance to gain real-world experience while learning the ropes of the industry. These opportunities are essential for closing the gender gap in the workforce and ensuring that women are prepared to succeed in the industry.
- Increased Representation and Visibility
As more women enter the industry and excel in their careers, representation and visibility are improving. Women who have successfully navigated the challenges of the industry are now speaking out and encouraging others to follow in their footsteps. This has created a ripple effect, inspiring more young women to consider careers in construction and equipment operation.
Several women in the industry have become well-known advocates for diversity, serving as role models and mentors for future generations. Through social media, public speaking engagements, and industry conferences, these women are reshaping the image of what it means to work in the heavy equipment sector.
Impact of Women in the Heavy Equipment Industry
The inclusion of women in the heavy equipment industry has had a profound impact on both the workforce and the industry as a whole. Companies that prioritize diversity and inclusion have been shown to experience higher levels of productivity, innovation, and employee satisfaction. Additionally, women bring unique perspectives and problem-solving skills that enhance the overall effectiveness of teams.
Beyond the business case, the growing presence of women in heavy equipment operations is changing the culture of the industry. As more women enter leadership roles, they are helping to shape a more inclusive and supportive environment for all workers, regardless of gender. This shift is not only improving the work experience for women but also creating a more collaborative and innovative atmosphere for everyone in the industry.
Conclusion: A Bright Future Ahead
The heavy equipment industry has made significant strides toward gender equality, but there is still work to be done. Women continue to face challenges, including gender bias, discrimination, and a lack of role models, but many are overcoming these obstacles through determination, mentorship, and the support of organizations dedicated to diversity.
As more women enter the field and succeed, they pave the way for future generations to follow in their footsteps. The growing representation of women in the heavy equipment industry is not only beneficial for the women involved but also for the industry as a whole. By embracing diversity, the industry is ensuring its continued growth, innovation, and success.
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| Is the CAT D9H Transmission and Torque Converter Compatible with the D9G |
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Posted by: MikePhua - 10-21-2025, 03:02 PM - Forum: Parts , Attachments & Tools
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Quick answer
The torque converter from a CAT D9G can be used in a D9H, but the transmissions differ internally due to increased horsepower and clutch design changes. While some parts are interchangeable, a full swap is not recommended without careful inspection and adaptation.
CAT D9G and D9H development history
The Caterpillar D9G was introduced in the early 1960s as a high-horsepower crawler tractor for mining, logging, and heavy earthmoving. It featured a 385 hp engine and a torque converter drive system. The D9H followed in the 1970s with upgraded power output—410 hp—and reinforced drivetrain components to handle the increased load.
Both models were part of Caterpillar’s push toward modular powertrain systems, allowing field serviceability and component interchange. However, the D9H introduced several internal upgrades that affect compatibility.
Torque converter compatibility
The torque converter used in both models shares the same part number—1T611—indicating direct interchangeability. This converter includes: - Alloy stator for improved heat resistance
- Multi-stage turbine for torque multiplication
- Integrated pump drive for transmission fluid circulation
Operators have successfully swapped stators and bearings between D9G and D9H converters, especially when rebuilding worn units. However, care must be taken to clean the transmission oil cooler and lines thoroughly to prevent contamination.
Transmission differences and clutch pack upgrades
The D9H transmission was redesigned to handle higher torque. Key differences include:- Forward clutch pack: Upgraded from 4 bronze plates in the D9G to 5 in the D9H
- Pinion design: D9G used floating pinions; D9H switched to fixed pinions for durability
- Steering hydraulics: D9H added a priority valve for steering flow control, absent in the D9G
While the transmission housings may appear similar, internal components differ. Swapping D9G internals into a D9H case may work in theory but risks premature wear or failure under load.
Classic parts and aftermarket sourcing
Caterpillar still lists “classic parts” for the D9H transmission, making rebuilds viable. These include:- Clutch discs and pressure plates
- Valve body components
- Bearings and seals
Aftermarket suppliers also offer copy parts, often at reduced cost. However, quality varies, and OEM tolerances should be verified before installation.
Field experience and repair advice
One contractor in New Zealand rebuilt a D9H using parts from a D9G torque converter, replacing all bearings and cleaning the cooler. He noted that while the converter worked well, the transmission required full disassembly and inspection due to clutch wear.
Another operator in Australia installed a new aftermarket torque converter in a D9H but found no drive after startup. Despite 450 psi pressure, the driveshaft didn’t turn. This suggests possible misalignment, pump failure, or internal blockage—highlighting the need for thorough testing after installation.
Recommendations for rebuilds and swaps- Use D9G torque converter components only if part numbers match
- Rebuild the D9H transmission using OEM or verified aftermarket parts
- Clean or replace the transmission oil cooler to prevent debris circulation
- Inspect clutch pack thickness and pinion design before mixing components
- Verify steering priority valve presence and compatibility
Conclusion
While the CAT D9G and D9H share torque converter compatibility, their transmissions differ in clutch design, pinion configuration, and hydraulic control. Swapping parts requires careful inspection and adaptation. For long-term reliability, rebuilding the D9H transmission with correct components is the preferred solution.
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