ISO 12345:2002
(Main)Diesel engines — Cleanliness assessment of fuel injection equipment
Diesel engines — Cleanliness assessment of fuel injection equipment
ISO 12345 specifies cleanliness assessment procedures for evaluating the amount of debris found within the constituent parts of a diesel fuel injection system that could lead to a reduction in the system's operational effectiveness. It is mainly concerned with new equipment not yet fitted to an engine, and is therefore aimed primarily at engine and fuel injection equipment manufacturers.
Moteurs diesels — Évaluation de la propreté de l'équipement d'injection
General Information
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Standards Content (Sample)
INTERNATIONAL ISO
STANDARD 12345
First edition
2002-11-15
Diesel engines — Cleanliness assessment
of fuel injection equipment
Moteurs diesels — Évaluation de la propreté de l'équipement d'injection
Reference number
ISO 12345:2002(E)
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ISO 12345:2002(E)
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ISO 12345:2002(E)
Contents Page
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Test apparatus . 3
5 Procedure . 6
6 Sample analysis . 13
7 Reporting results . 15
8 Designation . 17
Annexes
A Typical test equipment for measuring fuel injection equipment cleanliness . 19
B Procedure for verifying test equipment initial cleanliness . 22
C Automatic particle contamination measurement devices. 23
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ISO 12345:2002(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO
member bodies). The work of preparing International Standards is normally carried out through ISO technical
committees. Each member body interested in a subject for which a technical committee has been established has
the right to be represented on that committee. International organizations, governmental and non-governmental, in
liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical
Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 3.
Draft International Standards adopted by the technical committees are circulated to the member bodies for voting.
Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote.
Attention is drawn to the possibility that some of the elements of this International Standard may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights.
International Standard ISO 12345 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee
SC 7, Injection equipment and filters for use on road vehicles.
Annex B forms a normative part of this International Standard. Annexes A and C are for information only.
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ISO 12345:2002(E)
Introduction
Modern fuel injection systems contain many closely controlled clearances and rely on the fuel-flowing characteristics
of small orifices; thus they require the close control of sources of contamination in order to maintain the operational
performance demanded of them throughout their design life. To this end, such systems are designed with integral
fuel-filtration equipment, which reduces the amount of potentially damaging debris that could enter the system from
external sources.
However, contamination of the fuel injection system can also occur internally, from system use or wear, from
equipment servicing, or as a result of the original supplier's manufacturing and assembly processes. The focus of this
International Standard is on the latter source of contamination, and is thus concerned with the assessment of the
cleanliness of the fuel injection equipment as originally supplied to the engine manufacturer.
Fuel injection systems comprise a number of components. Traditional systems contain low-pressure elements (fuel
tank, pipe-work, filters, lift pump, etc.), a fuel injection pump, high-pressure pipes and fuel injectors, located within the
engine cylinder head.
During the preparation of this International Standard, the importance of care in the handling and measurement of
contamination samples was clearly recognized. Moreover, the low levels of contaminant experienced with fuel
injection equipment makes this a particularly difficult task. For this International Standard to be used meaningfully —
as an indicator of component cleanliness and a driver towards higher quality standards — extreme attention to detail
is required of the user. Verification requirements for the test equipment used are therefore emphasized, in detail.
It is not always clear what level and type of cleanliness would be beneficial for improved performance and life on a
cost-effective basis. The actual quantitative levels can only be set in relation to other parameters, agreed between
manufacturer, supplier and user. This International Standard provides a set of procedures for evaluating the
cleanliness of diesel fuel injection equipment and a framework for common measurement and reporting.
Work on cleanliness assessment continues within ISO/TC 22/SC 7 and among other groups of experts, and could
result in an amendment of this International Standard in the near future. Items under consideration are
— cleanliness procedures specifically applicable to common rail systems, and
— improvement of the reporting scheme of the cleanliness level.
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INTERNATIONAL STANDARD ISO 12345:2002(E)
Diesel engines — Cleanliness assessment of fuel injection
equipment
1 Scope
This International Standard specifies cleanliness assessment procedures for evaluating the amount of debris found
within the constituent parts of a fuel injection system for diesel engines that could lead to a reduction in the system's
operational effectiveness. It is mainly concerned with new equipment not yet fitted to a diesel engine, and is therefore
aimed primarily at engine and fuel injection equipment manufacturers.
2 Normative references
The following normative documents contain provisions which, through reference in this text, constitute provisions of
this International Standard. For dated references, subsequent amendments to, or revisions of, any of these
publications do not apply. However, parties to agreements based on this International Standard are encouraged to
investigate the possibility of applying the most recent editions of the normative documents indicated below. For
undated references, the latest edition of the normative document referred to applies. Members of ISO and IEC
maintain registers of currently valid International Standards.
ISO 3722:1976, Hydraulic fluid power — Fluid sample containers — Qualifying and controlling cleaning methods
ISO 4006:1991, Measurement of fluid flow in closed conduits — Vocabulary and symbols
ISO 4008-1, Road vehicles — Fuel injection pump testing — Part 1: Dynamic conditions
ISO 4020:2001, Road vehicles — Fuel filters for diesel engines — Test methods
ISO 4405:1991, Hydraulic fluid power — Fluid contamination — Determination of particulate contamination by the
gravimetric method
ISO 4407:2002, Hydraulic fluid power — Fluid contamination — Determination of particulate contamination by the
counting method using an optical microscope
ISO 4113, Road vehicles — Calibration fluid for diesel injection equipment
ISO 4788:1980, Laboratory glassware — Graduated measuring cylinders
ISO 7440-1, Road vehicles — Fuel injection equipment testing — Part 1: Calibrating nozzle and holder assemblies
ISO 7876-1, Fuel injection equipment — Vocabulary — Part 1: Fuel injection pumps
ISO 7876-2, Fuel injection equipment — Vocabulary — Part 2: Fuel injectors
ISO 7876-3, Fuel injection equipment — Vocabulary — Part 3: Unit injectors
ISO 7876-4, Fuel injection equipment — Vocabulary — Part 4: High-pressure pipes and end-connections
ISO 7967-7:1998, Reciprocating internal combustion engines — Vocabulary of components and systems — Part 7:
Governing systems
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ISO 12345:2002(E)
ISO 8535-1, Compression-ignition engines — Steel tubes for high-pressure fuel injection pipes — Part1:
Requirements for seamless cold-drawn single-wall tubes
ISO 8535-2, Compression-ignition engines — Steel tubes for high-pressure fuel injection pipes — Part2:
Requirements for composite tubes
ISO 8984-1, Diesel engines — Testing of fuel injectors — Part 1: Hand-lever-operated testing and setting apparatus
ISO 11171:1999, Hydraulic fluid power — Calibration of automatic particle counters for liquids
ISO 11500:1997, Hydraulic fluid power — Determination of particulate contamination by automatic counting using
the light extinction principle
ISO 11943:1999, Hydraulic fluid power — On-line automatic particle-counting systems for liquids — Methods of
calibration and validation
1)
ISO 18413:— , Hydraulic fluid power — Cleanliness of parts and components — Inspection document and
principles related to contaminant collection, analysis and data reporting
SAE J1549:1988, Diesel fuel injection pump — Validation of calibrating nozzle holder assemblies
3 Terms and definitions
For the purposes of this International Standard, the terms and definitions given in ISO 4006, ISO 7876-1 to
ISO 7876-4, ISO 7967-7 and the following apply.
3.1
fuel injection equipment cleanliness code
FIECC
three-figure code representing the distribution of particles by size found during cleanliness testing of fuel-injection
equipment
3.2
average cleanliness level
ACL
average level for cleanliness measured in gravimetric or particle count terms over at least five consecutive readings
3.3
required cleanliness level
RCL
required level for cleanliness of components or products under test, measured in terms of gravimetric or particle
count
1) To be published.
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ISO 12345:2002(E)
3.4
Reynolds number
Re
dimensionless parameter expressing the ratio between the inertia and viscous forces in a flowing fluid, given by the
formula
U×l
Re=
ν
where
U is the mean axial fluid velocity across the defined area, expressed in millimetres per second
l is the characteristic dimension of the system over which the flow occurs, expressed in millimetres [for
pipes l=d (pipe bore diameter)]
is the kinematic viscosity of the fluid, expressed in square millimetres per second [centistokes]
ν
3.5
scale number
number used to represent the range of particle numbers greater than a specific size measured on a component or
assembly
4 Test apparatus
A typical test equipment set-up recommended for measuring fuel-injection equipment cleanliness is described in
annex A. What follows are details of specific apparatus that may be used.
4.1 Pressure source, taking different forms for different tests, as follows.
4.1.1 Fuel injection pump test bench, a single cylinder inline pump as specified in SAE J1549 and a test bench
as specified in ISO 4008-1.
4.1.2 Hand-lever-operated testing and setting apparatus, a testing apparatus as specified in ISO 8984-1.
4.1.3 High-pressure pulsating flow rig, a pressure source capable of achieving
a) a flow rate that will generate a turbulent flow in the pipes (Re> 4 000) for a period of 30 s±1s, while pulsating
the flow between zero and this value at a frequency of 0,2 Hz to 1 Hz, followed by
b) a flush at 1,4 MPa± 0,1 MPa constant pressure for 15 s±1s.
4.1.4 Verification low-pressure pump, a plunger or diaphragm-type pump having a flow rate of approximately
twice the rated value for the component under test at a pressure of at least 2 MPa.
The verification low-pressure pump shall be cleaned to an ACL in accordance with annex B and carefully stored with
proper cover in a clean environment.
4.1.5 Verification high-pressure pipe assembly, for testing of high-pressure pipes with open ends, having a flow
rate capable of generating a Reynolds number in the pipes of Re> 4 000. A pressure capability of
3 MPa± 0,1 MPa is considered suitable.
The verification high-pressure delivery pump shall be cleaned to an ACL in accordance with annex B and carefully
stored with proper cover in a clean environment.
4.2 Verification high-pressure pipe assembly, 600 mm long, of either
— tube ISO 8535-1 S-2-6-2 1 P 0 (see ISO 8535-1), or
— tube ISO 8535-2 CA-2-6-2 1 P 0 (see ISO 8535-2),
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ISO 12345:2002(E)
and having a M12× 1,5 threaded end connection at one end and a M14× 1,5 threaded end connection at the other.
Stainless steel tubing should be used because of its resistance to rust and corrosion contamination. The verification
high-pressure pipe assembly shall be cleaned to the ACL in accordance with annex B and carefully stored with
proper cover in a clean environment.
4.3 Verification test injector, in accordance with ISO 7440-1, fitted with an orifice plate of orifice diameter 2,5 mm.
The inlet edge filter shall be removed, while the pintle end may be removed to improve particle passage. The nozzle
+0,3
opening pressure shall be set to 20,7 MPa.
−0
4.4 Collecting vessel, which may be necessary for collecting test fluid downstream from the tested equipment at
a flow rate different from that passing through the particle counter, the contamination monitor or the membrane filter.
The collecting vessel may be used for storing test fluid before transfer of fluid samples to the laboratory for analysis.
A cylindrical stainless steel or glass reservoir with conical bottom should be used for facilitating further particle
collection.
4.5 Equipment for contamination measurement, involving the application of three specific techniques for
evaluating the level of contamination:
— gravimetric analysis;
— microscopic examination;
— automatic measurement using either an automatic particle counter (APC) or field contamination monitor (see
annex C).
Each requires the following specific laboratory apparatus.
4.5.1 Gravimetric analysis apparatus, consisting of the following.
◦ ◦
4.5.1.1 Non-ventilated drying oven, capable of maintaining a temperature of 80 C± 2 C.
4.5.1.2 Filter holder, comprising
— funnel of 300 ml capacity with suitably calibrated volumetric graduations (e.g. 25 ml±2ml),
— suitable cover for the funnel (e.g. petri dish),
— clamping device,
— suitable base to support the membrane filter, and
— a means of dissipating any static electricity generated during the filtering process.
4.5.1.3 Vacuum flask, suitable for the filter holder and of capacity enabling it to hold the entire volume of sample
liquid without refilling.
4.5.1.4 Vacuum device able to generate a vacuum of 86,6 kPa (gauge).
4.5.1.5 Solvent dispenser (syringe), a pressurized vessel that discharges solvent through an in-line filter
membrane with a pore size of not greater than µm.
1
4.5.1.6 Tweezers, flat-bladed (non-serrated, blunt tips), and of stainless steel.
4.5.1.7 Graduated cylinders, for measuring out the volume of test liquid, to an accuracy that should be in
accordance with ISO 4788. Alternatively, a sample bottle calibrated with suitable volumetric graduations may be
used, in which case the accuracy of graduation should be ±2%.
4.5.1.8 Sample bottles, of 250 ml nominal capacity, preferably flat-bottomed and wide-mouthed, with a screw cap
containing a suitable internal polymeric seal.
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4.5.1.9 Plastic film, 0,05 mm thick × 50 mm× 50 mm, placed between the sample bottle cap and neck if the cap
does not have an internal seal. The film shall be compatible with both the cleaning and sample liquids.
4.5.1.10 Filter membranes, 47 mm in diameter, white, without grids, and compatible with the fluid to be analysed
and with the rinsing chemicals. Reference membranes shall have a 0,8µm pore size. Any other pore size used shall
be stated.
4.5.1.11 Petri dishes, of glass and 150 mm diameter.
4.5.1.12 Analytical balance, of 0,05 mg accuracy.
4.5.1.13 Alpha-ray ioniser, to be used to prevent collection of dust during the weighing operation, placed under the
balance scale incorporating the filter and projecting from beneath it.
4.5.1.14 Air dryer.
4.5.2 Microscopic analysis apparatus, consisting of the following.
4.5.2.1 Membrane preparation equipment, as specified in 4.5.1.1 to 4.5.1.9.
4.5.2.2 Filter membrane, compatible with the sample liquid and any solvents or chemicals used in the processes.
Normally, the membrane shall be of diameter, white, with grids (each grid square width side
47 mm
3,08 mm± 0,05 mm and equal to 1 % of the effective filtration area), and with a pore size < 1,5µm, used for manual
2µm47mm < 1,5µm
counting down to . A diameter white, membrane without grids and with a pore size of should
be used for image analysis. Membranes of different diameters may be used.
4.5.2.3 Microscope glass base slides and microscope glass cover slips, for transmitted-light method only, of a
dimension greater than the diameter of the membrane filter. The thickness of the cover slip should be approximately
0,25 mm.
4.5.2.4 Membrane holder, made of plastic or equivalent, with lid, for retaining membrane (incident-light method
only).
4.5.2.5 Microscope, manual and with a range of objective lenses which, in combination with the ocular lenses, are
able to resolve particles down to 2µm, and which is fitted with
— fine and coarse focus control,
— through-the-lens lighting for the incident light method or a bottom-lighting source for the transmitted light method,
or both,
— a mechanical stage so that the effective filtration area of the membrane can be scanned,
— provision on the mechanical stage for securely holding the membrane holder or glass slide, and
— an ocular micrometer of which the smallest division shall not subtend a distance larger than the smallest particle
to be counted at a particular magnification, with suitable graduations.
For counting with transmitted light, the projector microscope with suitable screen, over-eyepiece mirror and rotating
super-stage is preferred.
For image analysis, it is preferable to have a stabilized lighting source controlled by the imaging software, so that
illumination fluctuations are eliminated and automatic correction is made for any intensity drift in the light source.
For accurate characterization of particles using the incident light method, combination light as provided by an
additional oblique lighting source could be required (see 5.4).
See Table 1 for nominal magnification and optical combinations.
4.5.2.6 External lamp, of variable intensity, for when oblique illumination of the specimen stage is required.
4.5.2.7 Stage micrometer, graduated in 0,1 m and 0,01 m divisions, calibrated to national standards.
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ISO 12345:2002(E)
Table 1 — Nominal magnifications and optical combinations
Magnification Suggested minimum particle size
× µm
Nominal Ocular lens Objective lens
50 10 5 20
100 10 10 10
200 10 20 5
500 10 50 2
4.5.2.8 Tally counter, with sufficient sections to accumulate numbers of particles and fields counted.
4.5.3 Automatic measurement apparatus, which should be capable of reporting analyses in accordance with the
fuel injection equipment cleanliness code (FIECC) (see clause 7) (see annex C for recommended instruments),
comprising the following.
4.5.3.1 APC, operating on the light extinction principle in accordance with ISO 11500, calibrated in accordance with
ISO 11171. The sensor shall be chosen and set such that it can count the particle at least greater than 15µm,
100µm and 200µm.
4.5.3.2 APC, operating on the filter blockage technique.
4.6 Test fluid, as follows, depending on the test being conducted (see 5.3.2, 5.4.2, 5.5.2.2, 5.5.3.2, 5.6.2, 5.7.2).
4.6.1 Calibration fluid, test oil in accordance with ISO 4113, pre-filtered on a 0,8µm cartridge filter.
4.6.2 Solvent, aliphatic hydrocarbon, pre-filtered using a 0,8µm, single-membrane nylon filter, which
shall
— not leave any residue when vaporized, as residuals can influence the weighing results,
◦
— shall have a minimum flash point of 38 C, in order to fulfil normal working environment safety aspects,
— shall not have any aromatic components that could enter the atmosphere when vaporized, and
◦
— shall have a boiling point not higher than 200 C.
4.7 Clean-up filter, cartridge filter with a filtration rating suited to the cleanliness level required for the test (see
annex B).
4.8 Pressure gauge, capable of measuring the system operating pressure, which is dependent on the system
under test (see 5.3, 5.4, 5.5, 5.6 and 5.7).
◦ ◦
4.9 Thermometer, for measurement of test fluid temperatures between 20C8 and 0 C with an accuracy of
◦
± 1 C.
5 Procedure
5.1 General
This International Standard covers the following components of the fuel injection equipment:
— fuel injection pumps (see 5.3);
— fuel injectors (see 5.4);
— high-pressure fuel injection pipes (see 5.5);
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— low-pressure systems (see 5.6);
— unit injectors (see 5.7).
Each of these, in turn, is treated with respect to three procedural areas:
— equipment set-up and verification;
— test procedure;
— measurement.
Optional test procedures are also specified for some components.
5.2 Contaminant removal validation procedure
As the cleanliness of a component is the total amount of contaminants deposited in or on it, and because these are
extremely difficult to remove, every contaminant removal procedure shall be validated using the following procedure.
a) Repeat several times on the same component the rinsing protocol to be validated, using a separate clean
container for each sample collected.
b) At each rinsing, carefully measure the rinsing fluid volume and precisely measure the parameter of interest (e.g.
gravimetric, number of particles).
c) Divide the result for the last sample by the sum of the results for the previous samples.
d) If the calculated value is � 0,10, sample collection is complete. For particle counting, this criterion applies to the
total number of particles greater than the particle size to be controlled.
e) If the calculated value is > 0,10, additional rinsing is required. Repeat the rinsing protocol as many times as
necessary until the last sample gives a result � 0,10 of the total results of previous samples.
The particle collection process efficiency may be illustrated by drawing the cleaning curve, i.e. the cleanliness level
of the component (expressed in the terms given in clause 7), as a function of the cleaning number (or volume or
time). The cleaning curve should reach an asymptote (less than 10 % of the sum of the previous measurements, see
Figure 1), thus validating the cleaning process.
Figure 1 — Typical cleaning process validation curve
5.3 Fuel injection pumps
5.3.1 General
The procedures are similar for rotary, distributor and inline diesel fuel injection pumps. The tests to be conducted are
dynamic, i.e. with the test pump running under conditions close to normal operation.
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5.3.2 Equipment set-up and verification of cleanliness
a) Set up the equipment for verifying the system, described in annex A, using a pressure source as specified in
4.1.1.
NOTE This pressure source is replaced by the verification pump during testing.
b) For multi-cylinder test pumps, use either a pressure source as specified in 4.1.1 to validate every line or choose
a suitable, clean, multi-cylinder pressure source to validate all lines simultaneously. If the pressure source has
not been previously verified as “clean”, it may be necessary to run the pump for a period prior to verifying the
system in order to ensure a high base level of cleanliness.
c) Use verification high-pressure pipe assemblies in accordance with 4.2 and a verification injector in accordance
with 4.3.
d) Use a test fluid in accordance with 4.6.1, pre-filtered using a filter in accordance with 4.7, permanently fixed in the
system and replaced regularly.
◦ ◦
e) Maintain the test fluid temperature at 40 C± 1 C at the pump inlet.
f) Use a clean pump that is the same as the pumps to be verified, and set it to operate the system. Verify its
cleanliness in accordance with clause 6.
g) See annex B for the procedure for verifying the cleanliness of the equipment.
h) If the cleanliness criterion is not attained, repeat g) or check the clean-up filter efficiency.
5.3.3 Test procedure
a) Ensure the pump return outlet is unrestricted by valves or orifices. If not unrestricted, remove and replace it with
a plain outlet.
−1
10 min 200 min
b) Run the pump on test for a period of on full fuel delivery and at a pump speed of below the
maximum quoted full load speed; collect/count the contaminant output from all high-pressure lines.
c) Separately and similarly collect/count the contaminant output from the pump return (see annex A).
d) Measure and record the results (see 5.3.4).
e) Repeat a) to d) for the number of test samples required, as agreed between supplier and customer.
5.3.4 Measurement
a) For the high-pressure output from the pump, the number of particles at stated sizes should be recorded as well
as the total weight.
b) For pump return flow, measure total weight and the longest dimension of the largest particles. This should be
collected together with the high-pressure output.
c) Divide the result by the number of test samples to determine the average contamination per part.
d) Report the results (see clause 7).
5.4 Fuel injectors
5.4.1 General
The following test simulates operating conditions by use of a pressure source which equates to a fuel injection pump
and which operates the injectors.
5.4.2 Equipment set-up and verification of cleanliness
a) Set up the equipment for verifying the system, described in annex A.
b) Use a pressure source in accordance with 4.1.2, and the high-pressure pipe assembly specified in 4.2.
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c) Fit an injector for verification purposes (see 4.3), to be replaced by the test injectors during testing.
d) Use a test fluid specified in 4.6.2.
◦ ◦
e) Conduct the tests using a fluid temperature of 23 C± 10 C (room temperature).
f) Set up the remainder of the system such that it is as described in annex A, common across all products.
g) Operate the system in the same condition as scheduled for the test, and measure its cleanliness in accordance
with clause 6.
h) Verify the cleanliness of the equipment in accordance with annex B.
i) If the cleanliness criterion is not achieved, repeat a) to g) or check the test equipment and clean-up filter.
5.4.3 Test procedure
a) Remove the system verification injector and cap the nozzle end and inlet port with clean caps.
b) Carefully fit the first injector under test in place of the calibration injector while avoiding any possible source of
contamination.
c) Operate the hand-lever-operated apparatus (see 4.1.2) 50 times using a swift action to ensure injector operation
on all strokes.
d) Collect the output in a suitably cleaned container (see 4.4 and ISO 3722).
e) Repeat the procedure for the number of sample tests required, as agreed
...
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