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Commercial Airplanes 727 Service Bulletin ALERT Number: 727-28A0133 Original Issue: October 05, 2011 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Wing and Center Tank Fuel Boost Pump Wire Bundle Replacement and Convoluted Liner Installation Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2011 727-28A0133 1 of 300
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2011 727-28A0133 2 of 300 BOEING SERVICE BULLETIN 727-28A0133
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Table of Contents
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 6 D. Description .............................................. 1 7 E. Compliance .............................................. 1 7 F. Approval ............................................... 1 7 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 2 1 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 1
1. Existing Data .......................................... 2 1
2. Data supplied with this Service Bulletin ............................ 2 1
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 1 K. Publications Affected ........................................ 2 2 L. Interchangeability and Intermixability of Parts ........................... 2 2
2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 4 C. Parts Necessary For Each Airplane ................................. 2 4
1. Kits/Parts ............................................ 2 4
2. Parts and Materials Supplied by the Operator ........................ 3 5
3. Parts Modified and Reidentified ................................ 3 5
4. Parts Removed and Not Replaced .............................. 3 5 D. Parts Necessary to Change Spares ................................. 3 5 E. Special Tooling - Price and Availability ............................... 3 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 6
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 8 FIGURE 1: STATION 720F UPPER LEFT GROUND BRACKET - INSTALLATION ........... 5 5 FIGURE 2: STATION 720F LOWER LEFT GROUND BRACKET - INSTALLATION .......... 5 8 FIGURE 3: STATION 720F RIGHT GROUND BRACKET - INSTALLATION .............. 6 1 FIGURE 4: STATION 740 BULKHEAD STIFFENER GROUND BRACKET - INSTALLATION ..... 6 4 FIGURE 5: LEFT WING - NO. 1 TANK AND NO. 2 TANK FUEL BOOST PUMP REMOVAL, AND RIGHT WING NO. 2 TANK AND NO. 3 TANK FUEL BOOST PUMP - REMOVAL ......... 6 6 FIGURE 6: LEFT WING - NO. 1 TANK AFT FUEL BOOST PUMP WIRE BUNDLE W488 AND NO. 2 TANK LEFT AFT FUEL BOOST PUMP WIRE BUNDLE W492 - REMOVAL ............ 6 8 FIGURE 7: LEFT WING - NO. 1 TANK AFT FUEL BOOST PUMP WIRE BUNDLE W488 - REMOVAL . 72 FIGURE 8: LEFT WING - NO. 2 TANK LEFT AFT FUEL BOOST PUMP WIRE BUNDLE W492 - REMOVAL .................................................. 7 3 FIGURE 9: LEFT WING - NO. 1 TANK FORWARD FUEL BOOST PUMP WIRE BUNDLE W486 AND NO.
2 TANK LEFT FORWARD FUEL BOOST PUMP WIRE BUNDLE W490 - REMOVAL . . . 74
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FIGURE 10: LEFT WING - NO. 1 TANK FORWARD FUEL BOOST PUMP WIRE BUNDLE W486 - REMOVAL .................................................. 7 8 FIGURE 11: LEFT WING - NO. 2 TANK LEFT FORWARD FUEL BOOST PUMP WIRE BUNDLE W490 - REMOVAL ........................................... 7 9 FIGURE 12: LEFT WING - NO. 1 TANK AFT FUEL TANK CONDUIT - REPLACEMENT ........ 8 0 FIGURE 13: LEFT WING - NO. 2 TANK LEFT AFT FUEL TANK CONDUIT - REPLACEMENT ..... 8 3 FIGURE 14: LEFT WING - NO. 1 TANK FORWARD FUEL TANK CONDUIT - REPLACEMENT .... 8 6 FIGURE 15: LEFT WING - NO. 2 TANK LEFT FORWARD FUEL TANK CONDUIT - REPLACEMENT . 89 FIGURE 16: LEFT WING FRONT SPAR WIRE BUNDLE W488 AND WIRE BUNDLE W492 - ROUTING .................................................. 9 2 FIGURE 17: NO. 1 TANK AFT FUEL BOOST PUMP WIRE BUNDLE W488 - REMOVAL OR STOWAGE .................................................. 9 6 FIGURE 18: NO. 2 TANK LEFT AFT FUEL BOOST PUMP WIRE BUNDLE W492 - REMOVAL OR STOWAGE ................................................. 1 0 0 FIGURE 19: LEFT WING FRONT SPAR CONVOLUTED LINERS, WIRE BUNDLE W488, AND WIRE BUNDLE W492 - INSTALLATION ................................... 1 0 4 FIGURE 20: LEFT WING FRONT SPAR WIRE BUNDLE W488 AND WIRE BUNDLE W492 - ROUTING ................................................. 1 1 1 FIGURE 21: LEFT WING - NO. 1 TANK AFT FUEL BOOST PUMP - INSTALLATION ......... 1 1 7 FIGURE 22: LEFT WING - NO. 1 TANK AFT FUEL BOOST PUMP WIRE BUNDLE W488 - WIRING CHANGE ................................................. 1 2 1 FIGURE 23: LEFT WING - NO. 2 TANK LEFT AFT FUEL BOOST PUMP - INSTALLATION ...... 1 2 6 FIGURE 24: LEFT WING - NO. 2 TANK LEFT AFT FUEL BOOST PUMP WIRE BUNDLE W492 - WIRING CHANGE ........................................... 1 3 0 FIGURE 25: STATION 720F UPPER LEFT GROUND STUD ASSEMBLY - WIRE BUNDLE W488 AND WIRE BUNDLE W492 ........................................ 1 3 5 FIGURE 26: LEFT WING REAR SPAR WIRE BUNDLE W486 AND WIRE BUNDLE W490 - ROUTING . 138 FIGURE 27: NO. 1 TANK FORWARD FUEL BOOST PUMP WIRE BUNDLE W486 - REMOVAL OR STOWAGE .......................................... 1 4 2 FIGURE 28: NO. 2 TANK LEFT FORWARD FUEL BOOST PUMP WIRE BUNDLE W490 - REMOVAL OR STOWAGE .......................................... 1 4 6 FIGURE 29: LEFT WING REAR SPAR CONVOLUTED LINER, WIRE BUNDLE W486, AND WIRE BUNDLE W490 - INSTALLATION ................................... 1 5 0 FIGURE 30: LEFT WING REAR SPAR FUEL BOOST PUMP WIRE BUNDLE W486 AND WIRE BUNDLE W490 - ROUTING ....................................... 1 5 7 FIGURE 31: LEFT WING - NO. 1 TANK FORWARD FUEL BOOST PUMP - INSTALLATION ..... 1 6 3 FIGURE 32: LEFT WING - NO. 1 TANK FORWARD FUEL BOOST PUMP WIRE BUNDLE W486 - WIRING CHANGE ........................................... 1 6 7 FIGURE 33: LEFT WING - NO. 2 TANK LEFT FORWARD FUEL BOOST PUMP - INSTALLATION . 172 FIGURE 34: LEFT WING - NO. 2 TANK LEFT FORWARD FUEL BOOST PUMP WIRE BUNDLE W490 - WIRING CHANGE ...................................... 1 7 6 FIGURE 35: STATION 720F LOWER LEFT GROUND STUD ASSEMBLY - WIRE BUNDLE W486 AND WIRE BUNDLE W490 .................................... 1 8 1 FIGURE 36: RIGHT WING - NO. 2 TANK RIGHT AFT FUEL BOOST PUMP WIRE BUNDLE W496 AND NO.
3 TANK AFT FUEL BOOST PUMP WIRE BUNDLE W500 - REMOVAL .......... 1 8 4 FIGURE 37: RIGHT WING - NO. 2 TANK RIGHT AFT FUEL BOOST PUMP WIRE BUNDLE W496 - REMOVAL ........................................... 1 8 8 FIGURE 38: RIGHT WING - NO. 3 TANK AFT FUEL BOOST PUMP WIRE BUNDLE W500 - REMOVAL ................................................. 1 8 9
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FIGURE 39: RIGHT WING - NO. 2 TANK RIGHT FORWARD FUEL BOOST PUMP WIRE BUNDLE W494 AND NO. 3 TANK FORWARD FUEL BOOST PUMP WIRE BUNDLE W498 - REMOVAL . 190 FIGURE 40: RIGHT WING - NO. 2 TANK RIGHT FORWARD FUEL BOOST PUMP WIRE BUNDLE W494
- REMOVAL .......................................... 1 9 4 FIGURE 41: RIGHT WING - NO. 3 TANK FORWARD FUEL BOOST PUMP WIRE BUNDLE W498 - REMOVAL ................................................. 1 9 5 FIGURE 42: RIGHT WING - NO. 2 TANK RIGHT AFT FUEL TANK CONDUIT - REPLACEMENT . . 196 FIGURE 43: RIGHT WING - NO. 3 TANK AFT FUEL TANK CONDUIT - REPLACEMENT ....... 1 9 9 FIGURE 44: RIGHT WING - NO. 2 TANK RIGHT FORWARD FUEL TANK CONDUIT - REPLACEMENT ................................................. 2 0 2 FIGURE 45: RIGHT WING - NO. 3 TANK FORWARD FUEL TANK CONDUIT - REPLACEMENT . . 205 FIGURE 46: RIGHT WING FRONT SPAR FUEL BOOST PUMP WIRE BUNDLE W496 AND WIRE BUNDLE W500 - ROUTING ....................................... 2 0 8 FIGURE 47: NO. 2 TANK RIGHT AFT FUEL BOOST PUMP WIRE BUNDLE W496 - REMOVAL OR STOWAGE .......................................... 2 1 2 FIGURE 48: NO. 3 TANK AFT FUEL BOOST PUMP WIRE BUNDLE W500 - REMOVAL OR STOWAGE ................................................. 2 1 6 FIGURE 49: RIGHT WING FRONT SPAR CONVOLUTED LINERS, WIRE BUNDLE W496, AND WIRE BUNDLE W500 - INSTALLATION .............................. 2 2 0 FIGURE 50: RIGHT WING FRONT SPAR FUEL BOOST PUMP WIRE BUNDLE W496 AND WIRE BUNDLE W500 - ROUTING ....................................... 2 2 7 FIGURE 51: RIGHT WING - NO. 2 TANK RIGHT AFT FUEL BOOST PUMP - INSTALLATION .... 2 3 3 FIGURE 52: NO. 2 TANK RIGHT AFT FUEL BOOST PUMP WIRE BUNDLE W496 - WIRING CHANGE . 237 FIGURE 53: RIGHT WING - NO. 3 TANK AFT FUEL BOOST PUMP - INSTALLATION ........ 2 4 2 FIGURE 54: NO. 3 TANK AFT FUEL BOOST PUMP WIRE BUNDLE W500 - WIRING CHANGE . . . 246 FIGURE 55: STATION 720F RIGHT GROUND STUD ASSEMBLY - WIRE BUNDLE W496 AND WIRE BUNDLE W500 ........................................ 2 5 1 FIGURE 56: RIGHT WING FRONT SPAR FUEL BOOST PUMP WIRE BUNDLE W494 AND WIRE BUNDLE W498 - ROUTING ....................................... 2 5 4 FIGURE 57: NO. 2 TANK RIGHT FORWARD FUEL BOOST PUMP WIRE BUNDLE W494 - REMOVAL OR STOWAGE .......................................... 2 5 8 FIGURE 58: NO. 3 TANK FORWARD FUEL BOOST PUMP WIRE BUNDLE W498 - REMOVAL OR STOWAGE .......................................... 2 6 2 FIGURE 59: RIGHT WING REAR SPAR CONVOLUTED LINERS, WIRE BUNDLE W494, AND WIRE BUNDLE W498 - INSTALLATION ................................... 2 6 6 FIGURE 60: RIGHT WING REAR SPAR FUEL BOOST PUMP WIRE BUNDLE W494 AND WIRE BUNDLE W498 - ROUTING ....................................... 2 7 3 FIGURE 61: RIGHT WING - NO. 2 TANK RIGHT FORWARD FUEL BOOST PUMP - INSTALLATION . 279 FIGURE 62: NO. 2 TANK RIGHT FORWARD FUEL BOOST PUMP WIRE BUNDLE W494 - WIRING CHANGE ................................................. 2 8 3 FIGURE 63: RIGHT WING - NO. 3 TANK FORWARD FUEL BOOST PUMP - INSTALLATION .... 2 8 8 FIGURE 64: NO. 3 TANK FORWARD FUEL BOOST PUMP WIRE BUNDLE W498 - WIRING CHANGE . 292 FIGURE 65: STATION 740 BULKHEAD STIFFENER GROUND STUD ASSEMBLY - WIRE BUNDLE W494 AND WIRE BUNDLE W498 ................................. 2 9 7 APPENDIX A: SHIELDED WIRE INSTALLATION - GENERAL SCOPE OF WORK ........... 3 0 0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 727 Service Bulletin ALERT SummaryNumber: 727-28A0133Original Issue: October 05, 2011 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Wing and Center Tank Fuel Boost Pump Wire Bundle Replacement and Convoluted Liner Installation
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND This service bulletin installs new fuel boost pump wire bundles in the wing and center fuel tanks. New shielded wire bundles in convoluted liners are installed in the fuel tank conduits with wire shield grounding at the fuel boost pump housing and pressure seal. Boeing has issued this service bulletin so that the wiring and sleeve no longer need to be removed and inspected every 15,000 hours in accordance with Boeing Service Bulletin 727-28A0132 and the subject of Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-11-08.
Boeing Service Bulletin 727-28A0132 was issued because damage was found during the repetitive inspection in accordance with Boeing Service Bulletin 737-28A1120 and mandated by Federal Aviation Administration (FAA) Airworthiness Directive AD 99-21-15. The damage was found to the sleeve, jacket, and insulation on the electrical wire. The sleeve was worn through at three locations. At two of the locations the damage was also through the jacket of the electrical wire and exposed the insulation on the electrical wire inside the jacket. The wear did not expose the conductor of the electrical wire. The damage was found approximately 21,000 hours after installation of the sleeve. The 21,000 hours is less than the 30,000 repeat inspection interval hours specified in Federal Aviation Administration (FAA) Airworthiness Directive AD 99-21-15.
Boeing has issued this service bulletin as a final solution to this condition and to replace Boeing Service Bulletin 727-28A0132. Accomplishment of this service bulletin installs new shielded wire bundles in convoluted liners in the wing and center fuel tank conduits. The convoluted liner will decrease the chance of wire bundle damage.
The new shielded wiring will provide a ground path for the Ground Fault Interrupter (GFI) to trip if there is shorting in the wiring. This installation will help prevent potential ignition sources that can cause consequent fire or explosion. The GFI is installed by Boeing Service Bulletin 727-28A0128.
This change affects Airworthiness Limitations document D6-8766-AWL. The new Airworthiness Limitations (AWL) that follow are added: 28-AWL-20 and 28-AWL-21. These AWLs provide maintenance instructions and replace the requirements of Airworthiness Limitation 28-AWL-14.
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Original Issue: October 05, 2011 727-28A0133 7 of 300
Accomplishment of the work in accordance with this service bulletin gives terminating action to the repeat inspections in accordance with service bulletin 727-28A0132.
Boeing Service Related Problem (SRP) 727-SRP-28-0113 is related to this service bulletin.
ACTION (PRR 24852-RS) Get access to the left wing and right wing front spar and rear spar, tank No. 1 forward and aft fuel boost pumps, tank No. 2 left forward, left aft, right forward, and right aft fuel boost pumps, tank No. 3 forward and aft fuel boost pumps, center fuselage splice areas, and air conditioning distribution bay splice area, as necessary. Remove or stow fuel boost pump wire bundles from between each fuel boost pump and center fuselage splice areas or air conditioning bay splice area, as applicable. Do a test of the fuel boost pump conduits for leaks and repair or replace the conduit if any leak is found. Install new wire bundles and convoluted liners in the tank No. 1, tank No. 2, and tank No. 3 fuel boost pump conduits and connect wire bundles to each fuel boost pump, as applicable.
Route new wire bundles along the left wing and right wing front spar or rear spar, as applicable, to the center fuselage splice area or air conditioning bay splice area, as applicable, and connect. Do a test of the fuel boost pumps. Install the tank No. 1, tank No. 2, and tank No. 3 fuel boost pump access panels, as necessary.
EFFECTIVITY 727, 727-100, -100C, -200, -200F, 727C airplanes. Refer to Paragraph 1.A., Effectivity for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Boeing recommends that the change given in this service bulletin be done within 60 months after the original issue date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits.
Operator Supplied Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 727-28A0133
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INSTALL NEW GROUND BRACKETS AS APPLICABLE.
DISCONNECT ELECTRICAL CONNECTORS FROM THE FUEL BOOST PUMPS.
REMOVE FUEL BOOST PUMPS AS NECESSARY.
NSTALL NEW WIRE BUNDLES TO FUEL BOOST PUMPS INSTALL AND TEST FUEL BOOST PUMPS AS NECESSARY.
0000 000000000 00000
PULL WIRE BUNDLES AND TEFLON SLEEVES OUT OF THE FUEL TANK CONDUITS.
REMOVE OR STOW WIRE BUNDLES AS APPLICABLE.
CLEAN FUEL TANK CONDUITS AND INSPECT FOR LEAKS AS NECESSARY.
INSTALL NEW WIRE BUNDLES AND NEW CONVOLUTED LINERS INTO FUEL TANK CONDUITS.
ROUTE WIRE BUNDLES TO SPLICE AREA AND GROUND BRACKETS IN FUSELAGE AND CONNECT.
1898814 Original Issue: October 05, 2011 727-28A0133
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 727 Service Bulletin ALERT Number: 727-28A0133 Original Issue: October 05, 2011 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Wing and Center Tank Fuel Boost Pump Wire Bundle Replacement and Convoluted Liner Installation
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-9825 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. Refer to PRR 24852-RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 727, 727-100, -100C, -200, -200F, 727C Airplanes.-1 Airplane Models:
727, 727-100, 727-100C, 727-200, 727-200F, 727C GroupVariable Number 1E0001 - E0042 1E0101 - E0140 1E0201 - E0216 1E0301 - E0351 1E0401 - E0423 1E3001 - E3006
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GroupVariable Number 1E3011 - E3014 1E3021 - E3040 1E3059 1E3061 - E3077 1E3101 - E3103 1E3111 - E3118 1E3141 - E3152 1E3171 - E3177 1E3201 - E3206 1E3221 - E3224 1E3241 - E3290 1E3341 - E3350 1E3401 - E3421 1E3451 - E3452 1E3471 - E3474 1E3501 - E3513 1E3516 - E3523 1E3551 - E3553 1E3571 - E3578 1E3601 - E3604 1E3621 - E3622 1E3651 - E3655 1E3677 1E3681 - E3684 1E3701 - E3704 1E3751 - E3755 1E3781 - E3784 1E5001 - E5011 1E5031 - E5068 1E5101 - E5116 1E5141 - E5143 1E5161 - E5164 1E5201 - E5203
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