Installation Guide for Particulate Trap Exhaust Filters{1091} Caterpillar


Installation Guide for Particulate Trap Exhaust Filters{1091}

Usage:

769C 01X
Generator Set: 3114 3116 3208 All 3304 All 3306 All 3406 3408 3412 C-12
Industrial Engine: 3114 3116 3126 3126B 3176
3196 (S/N: 1DW1-UP) 3204 3208 3304 Diesel 3306 Diesel 3406 Diesel 3408 Diesel 3412 C-9 C-10 C-12 C-15 C-16
Machine Engines: 3114 3116 3126 3126B 3176 3196 3204 3208 3304 3306 3406 3408 3412 C-9 C-12 C-15 C-16
Truck Engines:
3176 (S/N: 2YG1-UP)
3126E (S/N: DPF1-UP)
C13 (S/N: KCB1-UP)
C9 (S/N: MTB1-UP)

Introduction


NOTICE

Diesel Particulate Filters (DPF) are not applicable to all engines. A Diesel Particulate Filter should typically not be applied to engines that are not regulated. Diesel Particulate Filters are meant for usage on only diesel engines. This technology does not apply to gas engines. Consult with Caterpillar in order to determine if a Diesel Particulate Filter can be used on your engine.


This publication provides a system overview of a Particulate Trap Exhaust Filter. This publication also provides installation and maintenance information for a DPF.

General Information

A Particulate Trap Exhaust Filter is a filtration system for the exhaust that can be added to diesel engines in order to reduce emissions. The DPF is composed of the following subsystems: Particulate Trap Exhaust Filter and Diagnostic Module. The following guidelines must be met before considering the use of a Particulate Trap Exhaust Filter:

  • Ultra-Low Sulfur Diesel Fuel must be used. Ultra-Low Sulfur Diesel Fuel must have an average sulfur content of 15 ppm. The maximum sulfur content of the fuel must not exceed 30 parts per million (ppm).

  • The Exhaust Temperature of the engine must be greater than 260 °C (500 °F) for at least 40% of the time.

  • The ratio of emissions of Oxides of Nitrogen (NOx) to Particulate Matter must be a minimum of 20. This ratio may be higher for applications that involve a lower temperature. This technology is currently applicable to 1991 and newer engines.

  • The engine should have an oil consumption rate of less than 1 quart per 1,000 miles.

Refer to Illustration 1 for the typical operating range of a DPF.




Illustration 1g01035610

Typical Operating Range for a DPF

Particulate Trap Exhaust Filter

The Particulate Trap Exhaust Filter is a device that is used to reduce emissions of particulate matter. The DPF generally replaces the muffler. The filter assembly is a modular design that is composed of four replaceable sections. Illustration 2 shows the correct order of assembly and direction of flow for the DPF. The modular design allows access to the filter section (3) and the catalyst section (2) without removing the entire DPF.




Illustration 2g01032735

Particulate Trap Exhaust Filter

(1) Inlet section

(2) Catalyst section

(3) Filter section

(4) Outlet section

Each section of the DPF is secured to the previous section with a clamp (6) and a gasket (5). Refer to Illustration 3.




Illustration 3g01032780

Particulate Trap Exhaust Filter

(1) Inlet section

(2) Catalyst section

(3) Filter section

(5) Gasket

(6) Clamp

The order of assembly of the DPF is very important. Use the following order of assembly in the direction of flow: inlet section (1), catalyst section (2), filter section (3) and outlet section (4) .

Diagnostic Module

The diagnostic module monitors exhaust temperature and back pressure of the DPF. Exhaust temperature is monitored with a thermocouple probe that is installed in the DPF. Exhaust back pressure is measured with a pressure sensor that is located within the diagnostic module. The pressure sensor is connected to the DPF by an extension tube. The temperature and pressure are monitored by the diagnostic module in order to detect conditions that might exceed recommended limits. The diagnostic module also contains alarm outputs that will warn the operator of potential problems.




Illustration 4g01032825

(7) Status Light

(8) Alarm for High Pressure

(9) Alarm for High Temperature

(10) System Problem

(11) Alarm Reset Button

(12) Pressure Sensor Connector

(13) Connector for Alarm Output

(14) Connector for the Thermocouple

(15) Communications Port

Remote Display Module

The diagnostic module provides two alarm outputs that are used to illuminate warning lamps. The lamps must be mounted in clear view of the operator. One possibility is through the use of a Remote Display Module (RDM). If an acceptable RDM can not be found, an RDM can be fabricated. Alarm 1 should be connected to an amber lamp. This lamp is not required to flash and the lamp should be marked "Service Exhaust Filter Soon". Alarm output 2 should be connected to a flashing red lamp. The lamp should flash at a rate of 60 to 95 flashes per minute. This lamp should be marked "Service Exhaust Filter Immediately".

Installation of Particulate Trap Exhaust Filter

The following general procedure can be followed in order to install a Particulate Trap Exhaust Filter. Rain protection for the exhaust pipe is required if the DPF is mounted vertically. A rain cap or an exhaust pipe that is curved can be used for vertical installations. Choose a mounting location for the DPF that will minimize the heat loss in the exhaust. This can be achieved by minimizing the length of the inlet pipe or by insulating the exhaust pipes.

  1. Inspect the engine in order to ensure that the engine meets the manufacturer's specifications. Correct the engine if the engine does not meet the manufacturer's specifications.

  1. Remove the outlet pipe from the existing muffler.

  1. Remove the inlet pipe from the existing muffler.

  1. Remove the existing mounting brackets and bands. If the existing hardware will be reused, inspect the components. Ensure that the components are not fatigued or cracked. Replace the existing components, as needed.

  1. Remove the existing muffler.

  1. Install the DPF in the location of the previous muffler. Use new clamps and brackets, when possible. The existing brackets from the muffler can be reused, if the brackets are suitable. All mounting brackets must be properly adjusted so that the inlet and the outlet of the DPF line up properly with the existing inlet and outlet pipes of the vehicle.

    Note: A DPF can be significantly heavier than a standard muffler. If existing supports and brackets are reused, these supports should be examined. Ensure that the supports can carry the load of the DPF. Consult Caterpillar for verifying the strength of existing mounts.

    Note: A section of flexible piping may be required between the exhaust outlet on the engine and the inlet of the DPF. All exhaust piping should be aluminum coated steel. Exhaust piping can also be 409 stainless steel or higher grade.

  1. The clamps on the DPF may be loosened in order to align the inlet section or the outlet section with the existing pipes. The clamps may also be adjusted in order to allow easier access. The clamps must be tightened before the piping is installed.

    Torque for clamp ... 20 N·m (15 lb ft)




    Illustration 5g01032735

    Correct orientation for Particulate Trap Exhaust Filter

    (1) Inlet section

    (2) Catalyst section

    (3) Filter section

    (4) Outlet section

  1. The DPF must be installed with the correct orientation of flow. Verify the correct direction of flow through the DPF. This can be done by locating the tag that is marked "INLET". The tag is located on the end of the inlet section.

    Note: The order of assembly of the DPF is very important. At all times during operation, the catalyst section must remain in front of the filter section in the direction of flow. Use the following order of assembly in the direction of flow: inlet section (1), catalyst section (2), filter section (3) and outlet section (4) .

  1. Reinstall the inlet and outlet pipes.

  1. When the installation is complete, check the system for leaks by running the engine at high idle with no load.

  1. Take an initial back pressure reading. Refer to ""Testing the Particulate Trap Exhaust Filter" " for the correct testing procedure. To accurately assess the performance of the DPF, a back pressure reading should at least be taken at the following intervals:

    • Every 25,000 miles

    • Every 6 months

    Note: A diagnostic module must be installed and operated with the DPF in order to validate the warranty of the DPF.

    Note: Only use Ultra-Low Sulfur Diesel Fuel with the DPF. Also, only use the electronic program that is specified for your engine. Using incorrect fuel or using an incorrect program will cause excessive generation of soot. This will void the warranty of the DPF.

    Note: Blending lube oil with the fuel is not allowed. This will void the warranty of the DPF.

    Note: To protect against contamination of the catalyst section and the filter section, ensure that the engine is not consuming more than 1 quart of oil per 1,000 miles.

Installation of Diagnostic Module

The following conditions must be met before installing the diagnostic module:

  • The diagnostic module must be mounted in a space that has an ambient temperature below 85 °C (185 °F) during normal vehicle operation. The diagnostic module must be located away from the following direct sources of heat: the engine, the exhaust manifolds and the radiator.

  • The diagnostic module must be mounted in a location that is not directly exposed to the following items: the elements, splashing water and electrical discharge.

  • The diagnostic module must be connected to a 12 to 24 volt power supply.

  • The diagnostic module must not be exposed to power surges that are greater than 24 volts.

  • Use the thermocouple that was supplied with the diagnostic module. Also, use the wire that was supplied.




Illustration 6g01039403

Wiring Schematic for Diagnostic Module and Remote Display Module

(1) Red Wire

(2) White Wire

(3) Green Wire

(4) Black Wire

(5) Battery

(6) Switched Power Connection

(7) Unswitched Power Connection

(8) Connection from the Thermocouple Probe

(9) Connector for the Thermocouple

(10) Alarm Connector

(11) Wiring Loom

(12) Remote Display Module

(13) Amber Lamp

(14) Red Lamp

(15) Relay

(16) Diagnostic Module

(17) Control

(18) Ground

(19) ECM

(20) 3 Amp Fuse Holder


Note: Standard Caterpillar electrical connectors and pins can be substituted for the electrical connectors that are supplied with the standard installation kit.

Unswitched Power Connection

  1. Locate a source of unswitched power. Unswitched power is simply power that is always on. Machines typically need a 12 volt source of power, and trucks and buses typically need a 24 volt source of power. The most likely location is usually in the battery compartment.

  1. Cut a length of red wire that is long enough to reach from the diagnostic module (16) to the Positive "(+)" power location (5) .

  1. Cut a length of white wire that is long enough to reach from the diagnostic module to a Negative "(-)" power location (5), or chassis ground.

  1. Slide a green silicon seal over the end of the power and ground wires at the location of the diagnostic module. Strip 6.35 mm (0.25 inch) of insulation from the wires. Slide the silicon seal to the edge of the stripped insulation.

  1. Crimp the male terminals onto the power and ground wires. Use a Weather-Pack crimping tool.

  1. Insert the power wire into location "A" of the Shroud Weather-Pack connector for the unswitched power connection (7). Insert the ground wire into location "B" of the Shroud Weather-Pack connector for the unswitched power connection (7) .

  1. Insert a 3 Amp fuse holder (20) between the red power wire and the diagnostic module.

  1. Connect the other end of the red wire to the positive power location (5). This can be done by utilizing the necessary ring terminal.

  1. Connect the other end of the white wire to the negative power location (5), or chassis ground. This can be done by utilizing the necessary ring terminal.

  1. Do not connect the power to the diagnostic module at this time.

  1. Cover the wires with a piece of wiring loom.

Connection for the Thermocouple and the Pressure Sensor

  1. Install the thermocouple and the copper tubing in the inlet section of the Particulate Trap Exhaust Filter.

    1. Apply a thin coat of anti-seize compound to the threads on the Tee fitting. Thread the fitting into the boss on the inlet section.

    1. Insert the reducer fitting into the Tee fitting that is in line with the boss. Tighten the fitting that is on the Tee until the fitting is finger tight. Continue tightening the fitting for 1.25 turns with an appropriate wrench.

    1. Insert the thermocouple into the reducer as far as the thermocouple will go. If the end of the thermocouple contacts the other side of the pipe, slide the thermocouple out of the fitting 5 cm (2 inch). Tighten the fitting on the reducer until the fitting is finger tight. Continue tightening the fitting for 1.25 turns with an appropriate wrench. If necessary, the thermocouple can be bent one time after the thermocouple has been installed in order to eliminate interference. Do not bend the thermocouple more than one time.. Do not exceed a 90 degree bend. Run the thermocouple wire to the location of the diagnostic module.

    1. Insert one end of the copper tubing into the fitting on the Tee that is at a 90 degree angle to the boss. Tighten the fitting on the Tee until the fitting is finger tight. Continue tightening the fitting for 1.25 turns with an appropriate wrench.

    1. All 6.1 m (20 ft) of tubing must be used. If the distance between the DPF and the diagnostic module is less than 6.1 m (20 ft), the excess tubing should be wrapped and mounted in an appropriate location.

    1. Attach the female connector to the threads on the pressure sensor with an appropriate wrench. Insert the copper tube into the fitting. Tighten the fitting on the connector until the fitting is finger tight. Continue tightening the connector for 1.25 turns with an appropriate wrench.

  1. Slide the boot for the thermocouple over the end of the thermocouple wire (8). Strip 12.7 mm (0.5 inch) of the brown coating and foil from the thermocouple wire. The red, yellow, and uninsulated leads will now be exposed. Trim the uninsulated wire back to the edge of the brown jacket.

  1. Strip 6.35 mm (0.25 inch) of insulation from the red and the yellow wires. Open the connector for the thermocouple (9) and remove the red seal. Slide the seal over the wires to the edge of the brown jacket. Insert the yellow wire into the positive "(+)" side of the connector (9). Insert the red wire into the negative "(-)" side of the connector (9). Reassemble the connector and slide the boot over the connector.

  1. Roll back the boot in order to expose the metal prongs on the connector. Plug the cable into the connector on the diagnostic module (16). Roll the boot forward so that the boot covers the connection.

  1. Cover the thermocouple wire (8) with a piece of wiring loom.

Connection for the Alarm

The connections for the alarm outputs are specific to individual applications. The following procedure is one possible way to connect the alarms to the circuit by using a Remote Display Module (RDM) (12) .

  1. Cut the male connector from the end of the wire harness for the RDM.

  1. Cut back the insulation on the harness for the RDM in order to expose the green and the black wires.

  1. Cut a length of green wire that reaches from the diagnostic module (16) to the location of the relay.

  1. Place a green silicon seal over the ends of the two green wires. Place a green silicon seal on the end of the black wire. Strip 6.35 mm (0.25 inch) of insulation from each wire. Slide the silicon seals to the edge of the stripped insulation. Twist the exposed ends of the green wires together.

  1. Crimp the female terminals on the black and green wires. Use a Weather-Pack crimping tool to crimp the wires.

  1. Insert the green wires into location "A" of the male Weather-Pack connector for the alarm (10). Insert the black wire into location "B" of the male Weather-Pack connector for the alarm (10) .

  1. Plug the male connector for the RDM (12) into the female connector on the diagnostic module (16) .

  1. Attach a terminal connector on the end of the green wire that is located at the relay (15). Plug the green wire into pin 85 on the relay (15) .

Switched Power Connection

  1. Cut a length of red wire that reaches from the diagnostic module to a switched power source (6). Machines typically need a 12 volt source of power, and trucks and buses typically need a 24 volt source of power. Also cut a length of red wire that reaches from the diagnostic module (16) to the engine shutdown relay.

  1. Cut a length of white wire that reaches from the diagnostic module (16) to a chassis ground.

  1. Place a green silicon seal over the ends of the two red wires. Place a green silicon seal on the end of the white wire. Strip 6.35 mm (0.25 inch) of insulation from each wire. Slide the silicon seals to the edge of the stripped insulation. Twist the exposed ends of the red wires together.

  1. Crimp the female terminals on the red and white wires. Use a Weather-Pack crimping tool to crimp the wires.

  1. Insert the red wires into location "A" on the male Weather-Pack connector. Insert the white wire into location "B" on the male Weather-Pack connector.

  1. Attach the other end of the white wire to the chassis ground. Use the proper ring terminal. Attach one of the red wires to the positive switched power source by using the proper connector.

  1. Connect the other red wire to pin 86 on the relay (15) .

  1. Connect the male plug into the female plug on the wire harness for the RDM (12) in order to complete the switched power connection.

ECM Connections

  1. Connect pin 87 on the relay (15) to the appropriate pin on the ECM (19) with a piece of green wire. Consult Caterpillar for information regarding the appropriate pin for your application.

  1. Use a piece of white wire to connect pin 30 on the relay (15) to the appropriate pin on the ECM (19). Pin 30 could also connect to an equivalent negative "(-)" chassis ground on the engine or on the machine. Consult Caterpillar for information regarding the appropriate pin for your application.

  1. The ECM must be flashed with a special flash file in order to enable the engine derate when the alarm for high pressure is activated.

  1. Cover all of the exposed wiring with some wiring loom.

  1. Connect the unswitched power plug that was previously assembled to the male connector on the diagnostic module. Verify that the green light on the diagnostic module begins to blink.

General Maintenance

The only required maintenance for the Particulate Trap Exhaust Filter is periodic cleaning of the filter section. Refer to ""Cleaning the Particulate Trap Exhaust Filter" " for the correct cleaning procedure. All Particulate Trap Exhaust Filters collect ash from lube oil during operation. This ash is not combustible. The buildup of ash will eventually cause an increase in back pressure. Perform a back pressure test in order to determine if the DPF needs to be cleaned. Refer to ""Testing the Particulate Trap Exhaust Filter" " for the correct procedure for testing the back pressure. Maintenance intervals will vary depending on the application. The following items are factors that will affect the required maintenance interval:

  • Idle time

  • Composition of the fuel

  • Exhaust temperature

  • Emissions level of the engine

------ WARNING! ------

The muffler and converter will become extremly hot during engine operation. A hot muffler and converter can cause serious burns. Allow adaquate cooling time before working on or near the muffler and converter.

----------------------

------ WARNING! ------

Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts.

When working on an engine that is running, avoid contact with hot parts and rotating parts.

----------------------

Testing the Particulate Trap Exhaust Filter

The Particulate Trap Exhaust Filter will become restricted with soot that is unburned and ash from normal engine operation. The restriction will cause the exhaust back pressure to increase. Testing the back pressure of the exhaust system will determine when the filter section needs to be cleaned.

Testing Back Pressure

Table 1
Required Tools    
Part Number     Part Name     Quantity    
198-4240
or
1U-5470    
Digital Pressure Indicator
or
Engine Pressure Group    
1    

The back pressure can be measured with 198-4240 Digital Pressure Indicator . Refer to Special Instruction, NEHS0818, "Using the 198-4240 Digital Pressure Indicator " for the instructions that are needed to use the tool.

The 1U-5470 Engine Pressure Group can also be used to measure the back pressure. Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Group " for the instructions that are needed to use the tool.

Back pressure measurements are required at the following intervals:

  • Amber dash light turns on.

  • Every 6 months

  • 40234 kilometers (25000 miles)

  • An engine derate occurs.




Illustration 7g01032982

(1) Inlet section

(2) Catalyst section

(3) Filter section

(4) Outlet section

(5) Test location

(6) Tee fitting

(7) Copper tubing

(8) Thermocouple

Do not test the exhaust back pressure if the alarm for high pressure has been activated. Clean the DPF. Refer to ""Cleaning the Particulate Trap Exhaust Filter" " for the proper procedure.

  1. Remove the Tee fitting (6) from the Test port (5) .

  1. Connect the pressure port of the differential pressure gauge to the test port.

  1. Leave the vacuum port of the differential pressure gauge open to the atmosphere.

    Note: Watch the back pressure reading as the engine begins to warm up. Stop the test immediately if the back pressure goes above 25 kPa (100 inch of H2O). The filter section needs to be cleaned. Refer to ""Cleaning the Particulate Trap Exhaust Filter" " for the proper procedure.

  1. Start the engine and run the engine in the no-load condition at high idle until the engine reaches normal operating temperature.

  1. Record the value while the engine is operating at high idle.

  1. Multiply the value from Step 5 by 1.8.

  1. If the results from Step 6 are greater than 25 kPa (100 inch of H2O) the DPF needs to be cleaned. Refer to ""Cleaning the Particulate Trap Exhaust Filter" ".

Cleaning the Particulate Trap Exhaust Filter

Because the sections of the DPF are replaceable, a small stock of filter sections can be maintained. Filter sections from this small stock can be used to replace filters in service at the next scheduled cleaning. The removed filters can be cleaned and returned for installation in the next vehicle. This process of maintaining a stock of filter sections can significantly reduce the amount of down time that will occur.

The following equipment is required to clean the DPF: dry pressurized air supply with 690 kPa (100 psi), high pressure sprayer with a short rubber hose on the tip and a way to collect the dust.

------ WARNING! ------

Wear goggles, gloves, protective clothing and a dust respirator certified by the National Institute for Occupational Safety and Health (NIOSH) and by the Mine Safety and Health Administration (MSHA) when cleaning the diesel particulate filter. Failure to do so could result in personal injury.

----------------------

Note: If the red warning light has been activated do not perform a back pressure test. The catalyst section could begin to regenerate. This will damage the DPF.

Caterpillar recommends recording when the DPF is cleaned. Refer to Table 3 in order to record the important information at each interval of cleaning. Perform a back pressure test prior to cleaning the DPF and record the results. After cleaning the DPF, run the engine at high idle for 5 to 15 minutes. Perform another back pressure test and record the results.

Collection of Dust

A filter bag is required to collect the ash from the DPF. The filter bags are available from your Caterpillar dealer. The filter bag will trap particles as small as 5 microns. A filter bag can be used 5 to 10 times.


NOTICE

Disposal of filter bags must be in accordance with all applicable federal, state and local laws and regulations.


Cleaning Procedure

Follow the recommended procedure for cleaning the DPF.

  1. Mark the inlet side of the catalyst section with a marker. Mark the outlet side of the catalyst section with a marker. Also mark the inlet and the outlet for the filter section. This is important because the sections need to be reinstalled in the correct direction.

  1. Loosen the clamps that hold the filter section. Remove the filter section from the DPF. Inspect the outlet side of the filter section. The outlet side should be white in color. Replace the filter if there are black deposits on the outlet side. Also, inspect the sections for internal damage and external damage. If there is damage to a section, the section should be replaced.

  1. Place a filter bag on the inlet side (dirty side) of the filter section. Secure the bag to the filter section by using one of the clamps from the DPF. Position the filter section in a vertical position. A holding fixture can be fabricated from the fabricated part number FT2931 . Positioning the filter section in this manner will allow the ash to fall into the bag. Refer to Illustration 8 in order to see the proper orientation.



    Illustration 8g01032990

    Typical example

    (9) Outlet side

    (10) Rubber hose

    (3) Filter section

    (11) Inlet side

    (12) Filter bag

  1. Use compressed air at 690 kPa (100 psi) to clean the filter. The air should be dry and free from oil. Place the air nozzle approximately 12.70 mm (0.5 inch) away from the filter section. By using slow circular motions, direct the compressed air through the filter section. Work from the center of the filter section toward the outside. Refer to table 2 for approximate times for cleaning.

    Table 2
    Diameter of Filter     Cleaning Duration    

    143.764 mm (5.66 inch)    
    10 Minutes    

    190.500 mm (7.5 inch)    
    15 Minutes    

    228.600 mm (9.0 inch)    
    20 Minutes    

    241.300 mm (9.5 inch)    
    25 Minutes    

    266.700 mm (10.5 inch)    
    30 Minutes    

    285.750 mm (11.25 inch)    
    35 Minutes    

    304.800 mm (12.0 inch)    
    40 Minutes    

  1. When you install the filter section and the catalyst section, new 216-7993 Gaskets should be used.

    Torque for the clamps ... 20 N·m (15 lb ft)

  1. Reset the diagnostic module if any alarms have been activated.

Perform a back pressure test after cleaning the DPF. The engine should be at operating temperature. Refer to ""Testing the Particulate Trap Exhaust Filter" " for the testing procedure.

Excessive accumulation of soot on the filter section is not a normal occurrence. The excessive accumulation of soot can be the result of many different problems. The following items should be checked if an excessive amount of soot is found on the filter section of the DPF.

  • Check the engine in order to make sure that an abnormal condition has not occurred.

  • Verify that the operating temperature is not too low.

  • Verify that the ratio of NOx to particulate matter is not too low.

  • Verify that the emission levels are not higher than the certification of the engine.

  • Verify that the correct fuel type is being used.

  • Verify that the fuel has the correct sulfur concentration.

  • Verify that the fuel injectors are not damaged and verify that the fuel injectors are functioning properly.

  • Verify that the turbocharger has not failed.

  • Verify that the turbocharger does not have any oil leaks.

  • Verify that the piston rings are not damaged or broken.

  • Verify that there are no leaks at the valve stems.

Excessive buildup of soot will cause the filter section of the DPF to plug. Plugging of the DPF will cause damage to the system.

Table 3
Record of Cleaning    
Model Number of DPF     Serial Number of Filter     Vehicle Identification Number     Back Pressure before Cleaning     Back Pressure after Cleaning     Mileage at Cleaning     Name    
                           
                           
                           
                           
                           
                           
                           
                           
                           
                           
                           
                           
                           
                           
                           
                           
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