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****** Page 1 ****** Instruction Manual for 70C, 700 75C and 75D FLEXIDYNE@ Couplings and Drives These instructions must be read thoroughly before installation or operation. This instruction manual was accurate at the time of printing. Please see baldor.com for updated instruction manuals. Note! The manufacturer of these products, Baldor Electric Company, became ABB Motors and Mechanical Inc. on March i, 2018. Nameplates, Declaration of Conformity and other collateral material may contain the company name of Baldor Electric Company and the brand names of Baldor-Dodge and Baldor-Reliance until such time as all materials have been updated to reflect our new corporate identity. WARNING: To ensure the drive is not unexpectedly started, turn off and lock-out or tag power source before proceeding. Failure to observe these precautions could result in bodily injury. WARNING: All products over 25 kg (55 lbs) are noted on the shipping package. Proper lifting practices are required for these products. DESCRIPTION FLEXIDYNE dry fluid couplings and drives are unique concepts to provide soft start and momentary overload protection for all types of driven equipment. Standard EMAB motors with RPM base speeds of 1750, 1160 or 860 are commonly used with a FLEXIDYNE coupling or drive, yet other available power sources may be used with the FLEXIDYNE mechanism. The dry “fluid” in the FLEXIDYNE housing is heat treated steel shot. A measured amount, referred to as flow charge, is added into a housing which has been keyed to the motor shaft. When the motor is started, centrifugal force throws the flow charge to the perimeter of the housing, packs it between the housing and the rotor which in turn transmits power to the load. After the starting period of slippage between housing and rotor the two become locked together and achieve full load speed, operating without slip and with 100% efficiency. Consequently, the motor accelerates instantly to base speed, while the load starts gradually and smoothly. WARNING: Because of the possible danger to person(s) or property from accidents which may result from the improper use of products, it is important that correct procedures be followed. Products must be used in accordance with the engineering information specified in the catalog. Proper installation, maintenance and operation procedures must be observed. The instructions in the instruction manuals must be followed. Inspections should be made as necessary to assure safe operation under prevailing conditions. Proper guards and other suitable safety devices or procedures as may be desirable or as may be specified in safety codes should be provided, and are neither provided by ABB nor are the responsibility of ABB. This unit and its associated equipment must be installed, adjusted and maintained by qualified personnel who are familiar with the construction and operation of all equipment in the system and the potential hazards involved. When risk to persons or property may be involved, a holding device must be an integral part of the driven equipment beyond the speed reducer output shaft. Motor Shaft Housing Flexible Coupling Flow Charge Output Shaft Rotor Coupling Housing Flow Charge Motor Shaft Output Sheave Rotor Drives Figure i – Housing cross section INSTALLATION COUPLINGS: Install coupling flange on motor shaft and drive housing mechanism on driven shaft in accordance with the instruction manual for the Taper-Lock@ bushings. NOTE: The coupling flange must be mounted on motor shaft (not driven shaft) to allow proper operation of the FLEXIDYNE coupling. Shaft ends must not protrude beyond bushing ends. Install coupling disc over pins on drive housing mechanism. Position the motor and the driven unit so that the spacer buttons on the coupling disc slightly contact the coupling flange. Reference Dimension A on Parts Replacement Drawing. (A = 5/8″ on size 70C; A = 3/4″ on size 75C) For longest FLEXIDYNE coupling life, it is always desirable to align coupling as accurately as possible at initial installation. Check alignment by laying a straight edge across the coupling flange and drive housing at several points around the circumference. NOTE: Driven shaft must not touch housing hub. 1

****** Page 2 ****** DRIVES: Install the FLEXIDYNE special bolt-on sheave on the driven hub. Use screws and lock washers provided with the FLEXIDYNE drive. Torque screws to 160 inch-pounds. Stake motor shaft key in place and slide FLEXIDYNE drive onto the motor shaft, with collar as close to the motor as possible. Tighten key set screw securely against motor shaft key. Tighten shaft set screw securely against motor shaft. NOTE: The sheave is the output of the FLEXIDYNE drive, do not input power to the FLEXIDYNE drive through the sheave. In other words, do not mount the FLEXIDYNE drive on the driven shaft. Nameplate Motor 400 300 Current 200 100 In-rush Amps Acceleration Amps Lock-ln Running Amps 2 6 8 4 Seconds from Start 10 1. 2. 3. START-UP Remove the filler plug and install the proper amount of flow charge specified in Table 1. Replace and tighten filler plug, making sure that no flow charge is trapped in threads. Torque filler plug to 35 inch-pounds. Attach AC ammeter (conventional clamp-on or equivalent) to one line of the AC motor. Set range to cover 200% of motor nameplate current. Note the maximum allowable acceleration time as stated in Tables 1 and 2. Note: Table 2 lists starting time capacity for starting cycles occurring more than once every 2 hours. 4. Push start button. Observe motor current during load acceleration and number of seconds required to reach full speed (Fig. 2). Increase amount of flow charge if: A. Acceleration time reaches maximum allowable before load is up to speed. Turn off power immediately if this time is reached. B. Acceleration amperage is below motor nameplate. Decrease amount of flow charge if: A. Acceleration time is less than 1-1/2 seconds. B. Acceleration amperage is above 200% of motor nameplate. Once satisfactory operation has been obtained, record the following for future reference: 1. The amount of flow charge 2. Starting current 3. Acceleration Time WARNING: The rotor must slip during acceleration to allow flow charge to become evenly distributed in the FLEXIDYNE housing. Therefore, DO NOT ALLOW FLEXIDYNE MECHANISM To RUN “FREE” (that is, without a load on the driven end), otherwise an out-of-balance condition may result, damaging mechanism and attached equipment. Figure 2 – Typical Motor Current vs. Time OPERATION The amount of flow charge in the housing determines the acceleration time for a given load. Slower acceleration times will occur when less flow charge is used and faster acceleration, from stop to full speed, will be observed with greater amounts of flow charge. The FLEXIDYNE mechanism should start the load smoothly and without delay, provided the proper amount of flow charge has been used. Should the acceleration time exceed the maximum allowable in Table 1, shut off power to the FLEXIDYNE mechanism immediately. Allow the FLEXIDYNE mechanism to cool, then add small amounts of flow charge until proper acceleration is observed. Vibration is an indication of accelerating too rapidly and not allowing flow charge to become evenly distributed in the FLEXIDYNE housing. This can be corrected by removing small amounts of flow charge until vibration subsides. Other causes of vibration are: undersize shafting, unit not installed far enough on shaft or worn bore in the unit. Slippage — The FLEXIDYNE mechanism can, without slipping, transmit overloads up to 130% of its pre-set starting torque. Should this breakaway torque be exceeded, the FLEXIDYNE mechanism will slip and generate heat (see Overload Protection). Although slippage usually indicates increased loads, it can also be caused by worn flow charge or a worn rotor especially if the FLEXIDYNE mechanism has been in operation for some time. The necessity to replace either a rotor or flow charge will be made evident by a loss in power transmitting capacity of the FLEXIDYNE mechanism. MAINTENANCE For average industrial applications involving 3 or 4 starts a day and of not more than 6 seconds acceleration time each, the flow charge should be changed every 10,000 hours of operation. For more severe conditions, visually inspect flow charge at more frequent intervals; it should be changed when it has deteriorated to a half powder, half granular condition. See page 8 for flow charge analysis. Visual inspections should continue until enough flow charge changes have been made to adequately establish a schedule for renewing FLEXIDYNE flow charge. The FLEXIDYNE mechanism has been lubricated at the factory and no further lubrication is required. Never apply grease, oil or any other foreign material to the flow charge. 2

****** Page 3 ****** THERMAL CAPACITY Since there is slippage within the flow charge during acceleration, heat is generated from friction. The thermal capacity of the FLEXIDYNE mechanism is based on balancing this heat generated during acceleration against the cooling time between accelerations. The amount of heat generated is determined by the amount of horsepower dissipated by slipping and the duration of each acceleration. If the flow charge weight is light, the heat generated will not be as great as that which would be generated with a heavier flow charge, when compared at the same acceleration time. A longer time between starts will dissipate more heat; therefore, higher starting horsepowers may be transmitted, or longer acceleration times may be allowable. (See Starting Cycle) Acceleration times shown in Table 1 are for starting frequencies of one start per hour or less. If starting frequency is more than once per hour, use acceleration time for actual starting cycle shown in Table 2. Acceleration times listed in Tables 1 and 2 are the MAXIMUM permissible for the various starting frequencies listed. The MINIMUM acceleration time required for proper FLEXIDYNE mechanism operation is 1 to 11/2 seconds. This is the time required for the flow charge to be uniformly distributed around the housing cavity before the unit “locks inn. Any acceleration time between the minimum and maximum listed is acceptable, although a shorter acceleration time will generally provide longer wear life. For applications requiring a specific acceleration time (within these limits) flow charge may be added or removed to produce the required results. Stalled — If a jam-up stalls the drive, the motor continues to run and the FLEXIDYNE mechanism slips. This causes heat to be generated at twice the rate of normal acceleration. Therefore, the allowable slipping time, when stalled, is half the allowable acceleration time given in Table 1. Starting Cycle is the time from the beginning of one acceleration to the beginning of the next. Allowable acceleration times in Table 2 are based on the assumption that the FLEXIDYNE mechanism will be running continuously except for a momentary stop before the next start. If the stop is more than momentary, decrease the actual starting cycle by one-half the stopped time before using Table 2; for example, with a 50 minute actual starting cycle of which 20 minutes is stopped time, decrease 50 by half of 20 to give 40 minutes as the starting cycle time to use for Table 2. Grouped Starts For several starts grouped together followed by uninterrupted running, add the acceleration times of all starts and consider it as the time for one start. The starting cycle would be the time from the beginning of one group of starts to the beginning of the next group. 3

****** Page 4 ****** Table 1 – Flow Charge Recommendations Based on 0/0 of Startin Tor ue for 1760 RPM NEMA Desi n B Motors 100% @ 1760 RPM 125% @ 1750 RPM 150% @ 1740 RPM Rated FLEXIDYNE Motor Mechanism Size 70C, 70D 3 70C, 70D 5 7-1/2 75C, 75D 10 75C, 75D Rated FLEXIDYNE Motor Mechanism Size 70C, 70D 3 70C, 70D 5 7-1/2 75C, 75D 75C 75D 10 Rated FLEXIDYNE Motor Mechanism Size 70C, 70D 1 1-1/2 70C, 70D 75C, 75D 2 75C, 75D 3 Rated FLEXIDYNE Motor Mechanism Size 1 70C, 70D 1-1/2 70C, 70D 75C 75D 2 75C 75D 3 Rated FLEXIDYNE Motor Mechanism Size 1/2 70C, 70D 3/4 70C, 70D 75C, 75D 1 1-1/2 75C, 75D Rated FLEXIDYNE Motor Mechanism Size 1/2 70C, 70D 3/4 70C, 70D 75C, 75D 1 1-1/2 75C 75D Flow Chare Max Flow Chare Max Flow Chare Max Starting 3.0 5.0 7.5 10.0 oz. 11 14 11 15 Time in Sec. 150 94 71 58 Starting 3.7 6.2 9.4 12.5 Starting Time in Lbs. 1 1 1 1 Lbs. 1 2 1 2 oz. 13 1 14 3 Sec. 123 79 60 53 4.5 7.5 11.2 14.9 Lbs. 1 2 2 2 oz. 14 4 1 6 Time in Sec. 105 67 54 48 175% @ 1700 RPM Flow Chare Max 175% @ 1700 RPM Flow Chare Max Starting Starting 5.1 8.5 12.7 17.0 Lbs. 2 2 2 2 Oz. O 8 4 9 Time in Sec. 93 60 52 43 5.1 8.5 12.7 17.0 Lbs. 2 2 2 2 Oz. O 8 4 9 Time in Sec. 93 60 52 43 Based on % of Startin Tor ue for 1175 RPM NEMA Desi n B Motors 1000/0 @ 1175 RPM Flow Chare Max 125% @ 1160 RPM Flow Chare Max 1500/0 @ 1150 RPM Flow Chare Max Starting 1.0 1.5 2.0 3.0 Lbs. 1 1 1 1 Time in Sec. 500 300 250 150 Starting Starting Time in Oz. 10 13 10 15 1.2 1.9 2.5 3.7 Lbs. 1 2 1 2 Oz. 12 1 13 3 Sec. 400 260 190 125 1.5 2.2 3.0 4.5 Lbs. 1 2 2 2 Oz. 14 3 o 7 Time in Sec. 33. 210 150 100 175% @ 1130 RPM Flow Chare Max 200% @ 1100 RPM Flow Chare Max Starting Oz. 1 6 2 10 Time in Sec. 290 190 135 89 Starting 1.7 2.5 3.4 5.1 Lbs. 2 2 2 2 1.9 2.8 3.8 5.7 Lbs. 2 2 2 2 Oz. 4 9 6 12 Time in Sec. 260 170 120 82 Based on 0/0 of Startin Tor ue for 875 RPM NEMA Desi n B Motors 100% @ 875 RPM Flow Chare Max 125% @ 870 RPM Flow Chare Max 150% @ 850 RPM Flow Chare Max Starting Starting Time in Starting Time in .50 .75 1.0 1.5 Lbs. 1 2 1 2 Oz. 12 0 13 2 Sec. 900 800 520 330 .62 .94 1.2 1.9 Lbs. 1 2 2 2 Oz. 15 3 o 7 Sec. 850 570 400 300 .75 1.1 1.5 2.2 Lbs. 2 2 2 2 Oz. 1 6 3 10 Time in Sec. 800 500 330 250 175% @ 840 RPM Flow Chare Max 200% @ 820 RPM Flow Chare Max Starting Starting .85 1.3 1.7 2.5 Lbs. 2 2 2 2 oz. 4 8 7 11 Time in Sec. 750 400 320 220 .94 1.4 1.9 2.3 4 Lbs. 2 2 2 2 oz. 6 12 8 12 Time in Sec. 570 350 300 200

****** Page 5 ****** Table 2 – Thermal Capacity Maximum Allowable Acceleration Time in Seconds For Standard Motor S eeds of Various Startin C cles Starting .50 .75 1.0 2.0 2.5 70 3.0 4.0 6.0 8.0 10.0 Starting .50 .75 1.0 2.0 2.5 70 3.0 4.0 6.0 8.0 10.0 Starting 1.0 2.0 3.0 4.0 5.0 75 7.0 8.0 10.0 15.0 20.0 Starting 1.0 2.0 3.0 4.0 5.0 75 7.0 8.0 10.0 15.0 20.0 870 900 800 550 870 500 400 330 870 520 300 200 870 420 210 150 2 Hours 1160 500 260 190 170 130 10 Min 1160 320 190 143 133 90 2 Hours 1160 250 120 110 90 75 10 Min 1160 180 110 82 70 60 1750 210 180 150 110 80 63 53 1750 170 140 120 83 60 41 36 1750 85 73 70 58 48 40 1750 65 57 54 45 34 27 870 900 800 550 1 Hour 1160 500 260 190 170 130 1750 210 180 150 110 80 63 53 870 900 800 550 30 Minutes 1160 500 260 190 170 130 1750 210 180 150 110 80 63 53 Maximum Allowable Acceleration Time in Seconds For Standard Motor S eeds of Various Startin C cles 870 250 230 210 5 Minutes 1160 200 120 88 80 60 1750 105 85 74 54 38 29 23 870 100 100 100 2 Minutes 1160 80 60 45 36 1750 58 45 39 30 21 16 13 Maximum Allowable Acceleration Time in Seconds For Standard Motor S eeds of Various Startin C cles 870 520 300 200 1 Hour 1160 250 150 110 90 75 1750 85 73 70 58 48 40 870 520 300 200 30 Minutes 1160 250 150 110 90 75 1750 85 73 70 58 48 40 Maximum Allowable Acceleration Time in Seconds For Standard Motor S eeds of Various Startin C cles 870 260 130 100 5 Minutes 1160 110 65 50 45 38 2 Minutes 1160 60 40 28 24 21 870 800 700 500 870 50 50 50 870 520 300 200 870 50 40 30 1750 40 35 30 21 17 870 100 80 52 1750 22 20 18 16 11 15 Minutes 1160 450 230 165 155 118 1 Minutes 1160 45 38 33 28 23 15 Minutes 1160 220 130 100 85 70 1 Minutes 1160 40 22 18 16 14 1750 190 160 100 72 56 46 1750 36 29 25 19 13 10 1750 80 68 64 53 43 35 1750 15 13 11 10

****** Page 6 ****** REPLACEMENT OF PARTS COUPLINGS: Disassembly: DRIVES: Disassembly: 1. 2. 3. 4. 5. 6. 7. Remove drive housing mechanism from driven shaft. Remove filler plug and flow charge from FLEXIDYNE housing. Remove housing screws, housing cover and cover seal. Remove screws that attach driven hub to rotor retainer. Remove driven hub and rotor. Remove bronze bushing retainer ring and slip bronze bushing off drive housing. Remove ball bearing snap ring and ball bearing. In removing ball bearing, place 3 equal length pins in the 3 holes thru the end of the drive housing and press against the pins. For sizes 70 and 75 use to 9/64 diameter pins. Remove rotor retainer. Reassembly: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Loosen set screws in collar and remove FLEXIDYNE drive from motor shaft. Remove filler plug and drain flow charge from FLEXIDYNE housing. Remove sheave from FLEXIDYNE mechanism. Remove housing screws and remove housing cover. Remove cover seal. Remove collar. Remove the six rotor screws and slide driven hub off drive hub. Remove rotor. Remove needle bearing snap ring and needle bearing inner race. Remove the six drive hub screws and remove the drive hub housing. Remove housing seal. Remove rotor retainer and seal felt. Remove ball bearing snap ring and remove ball bearing. Remove needle bearing and seal from driven hub by placing a plug in the left hand end (as viewed in the drawing) of driven hub bore and pressing against the plug. 2. 3. 4. 5. 6. 7. 8. Install new seal felt and housing seal in drive housing. Set rotor retainer in place in drive housing. Press ball bearings onto drive housing. Note: Press against inner (not outer) race of bearing. Make sure rotor retainer is not cocked when bearing enters it. Check to see that rotor retainer rotates freely in housing seal. Install ball bearing retaining ring. Install bronze bushing and snap ring. Install rotor and driven hub. Install and tighten screws. Install cover seal in housing cover and place cover in position on drive housing. Install and tighten housing screws. Replace flow charge and filler plug per STARTUP. Reassembly: 1. 2. 3. 4. 5. 6. Press roller bearing into right hand end of driven hub. Make sure left hand end of bearing is % from left hand end of driven hub. Roller bearing should be filled with high temperature roller bearing grease. Tap roller bearing seal into place, flush with left hand end of driven hub. Install housing seal in drive hub housing and attach drive hub housing to drive hub with six screws. Install seal felt on drive hub and rotor retainer in position in drive hub housing, making sure that housing seal is properly seated in drive hub housing. Press ball bearing onto drive hub. Press against inner (not outer) race of bearing. Rotor retainer must not be cocked when bearing enters it. Check, after pressing by making certain rotor retainer rotates freely in seal. Install ball bearing snap ring. Install needle bearing inner race and snap ring on drive hub. Place rotor in position. Slide driven hub over drive hub. Install and tighten the six rotor screws. Install cover seal. Install housing cover on drive hub housing so filler plug hole lines up with relief on the flange of drive hub housing. Install and tighten housing screws. Install motor shaft collar and filler plug. Place bolt-on sheave in position and install and tighten six sheave bolts. Table 3 – Manufacturer’s Part Numbers for Replacement Ball Bearings FLEXIDYNE Mechanism Size 70C & 701) 75C& 751) Dodge Part Number 391200 391200 SKF Part Number 6010 2RS/ME 6010 2RS/ME NEW DEPARTURE Part Number Z4993LlOXlV Z4993LlOXlV 6

****** Page 7 ****** Parts Replacment for 70C, 70D 75C and 75D FLEXIDYNE@ Couplings and Drives 20 28, 29 22 46 30 28, 29 10 50 42 40 DRIVEN END 36 32 Name of Part 14, 15 6 2 (Type H) MOTOR END 4 (Type F) 8 44 34 24, 25, 26 22 30 60,61 18 16 52 48 49 50 70C 008041 008040 1215 1610 008032 409122 305076 305078 415100 419007 305091 305138 411296 419007 407082 305018 419190 305075 305094 305096 415052 391200 421150 308024 426070 421004 20 36 32 14, 15 40 42 44 34 24, 25, 26 Part Number Reference 2 4 5 6 8 10 12 14 15 16 18 0 20 22 24 25 26 28 29 30 32 34 36 40 42 44 46 48 49 50 52 60 61 ype H Coupling Flange ype F Taper-Lock Bushing w/screws (Motor End) Taper-Lock Bushing w/screws (Driven End) POLY-DISC@ Coupling Element Flan e Pin Drive Hub Drive Hub Housing Drive Hub Screw Lockwasher Drive Hub Collar Drive Hub Collar Set Screw Drive Hub Key Housing Cover Housing Seal Housing Screw Lockwasher Hex Nut Filler Plug Lockwasher Driven Hub Rotor Rotor Retainer Rotor Screw Ball Bearing Retaining Ring Duct Seat Bronze Bearing Needle Bearing Needle Bearing Inner Race Retaining Ring Bearing Seal Sheave Screw Lockwasher No. Required 4 6 6 2 6 6 6 1 1 6 1 4 4 75C 008043 008042 1615 1610 008033 409123 305077 305078 415100 419007 305091 305138 411296 419007 407082 305018 419190 305075 305095 305096 415052 391200 421150 308024 426070 421004 70D 305079 417020 419043 305135 305091 305138 411296 419007 407082 305018 419190 305073 305094 305096 415052 391200 421150 308024 426022 426039 421145 305139 417047 419045 75D 305079 417020 419043 305135 443390 305091 305138 411296 419007 407082 305018 419190 305074 305095 305096 415052 391200 421150 308024 426022 426039 421145 305139 417050 419045 400054, 2 required. 0) Not shown on arts drawin @ Size 70D x 7/1- 400062, required; Sizes 70D x 11/8 & 75D x 11/8 – 400054, 1 required & 400058, 1 required; Size 75D x 13/8 – 0 305069 required on Size 70D x 7/8; 305070 required on Size 70D x 1-1/8. @ 305071 required on Size 75D x 1-1/8; 305072 required on Size 75D x 1-3/8. 1 required on Size 75D x 1-3/8 only. @ 1 required on FLEXIDYNE Coupling units; 2 required on FLEXIDYNE Drive units 7

****** Page 8 ****** Flexidyne Mechanism Trouble Analysis Symptom Vibration Erratic Acceleration Flexidyne Mechanism Doesn’t Slip Excessive Slippage Poor or short flow charge life Cause Cure 1. 2. 3. 4. 5. 1. 2. 3. 1. 2. 1. 2. 3. 4. 1. 2. Misalignment Bent shaft Excess flow charge Fused flow charge Improper installation – Output shaft jammed against housing Breakdown of flow charge Caked flow charge Below minimum amount of flow charge Improper installation – Output shaft jammed against housing Flow charge in bearings — causing bearing seizure Not enough flow charge Overload Worn flow charge Worn rotor Excessive slip at start up Excessive inching or jogging of machine 1. 2. 3. 4. 5. 1. 2. 3. 1. 2. 1. 2. 3. 4. 1. 2. Realign drive or coupling. Replace or straighten. Remove small amount of flow charge. Correct the overload. Readjust spacing between shafts and Flexidyne housing. Replace flow charge. Moist environment — use stainless flow charge. Add flow charge. Readjust spacing between shafts and Flexidyne housing. Replace seals, bearings and flow charge or replace Flexidyne mechanism. Add flow charge. Relieve overload Replace flow charge. Replace rotor. Add flow charge to reduce starting time. Install time delay in motor control circuit. Flexidyne Mechanism Flow Charge Analysis 1. 2. 3. 4. 5. Condition Red oxide color, granular consistency Red oxide color, powdery consistency, possibly with powdery flakes Black, powdery Red oxide, powdery and chunky Clumping of flow charge 1. 2. 3. 4. 5. ABB Motors and Mechanical Inc. 5711 R. S. Boreham Jr. Street Fort smith, AR 72901 Ph: 1.479.646.4711 Mechanical Power Transmission Support Ph: 1.864.297.4800 new.abb.com/mechanical-power-transmission baldor.com O ABB Motors and Mechanical Inc. MN4034 (Replaces 499868) Cause Normal after some usage. Worn-out, can cause Flexidyne mechanism damage. Rotor worn, excessive slip and heat. Worn-out and moisture present. Moisture present, use stainless flow charge. All Rights Reserved. Printed in USA. 01/20 Printshop 300


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