Bench Test Procedure For A TA22-M4WD Agricultural Transmission {3030, 3073} Caterpillar


Bench Test Procedure For A TA22-M4WD Agricultural Transmission {3030, 3073}

Usage:

TA22-M4WD T4W
Transmission
TA22 (S/N: X4B1-UP; XAB1-UP; X4G1-UP; XAG1-UP; T4W1-UP)

Introduction

Table 1
Revision  Summary of Changes in REHS3283 
06  Updated Introduction. 
Updated TA3 Navigation.
Added Note.
Updated Captions for Graphics 48 and 49.
05  Standardized. 
04  Added new serial numbers. 
03  Changed Title to reflect TA22-M4WD sales model per Engineers request. Added tool statement. 
02  Added Serial Number Prefix and new introduction. 

© 2016 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This special instruction contains the necessary information that is required to bench a specific transmission arrangement. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. Every effort has been made to provide the most current information that is known to Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Table 2
Machine Model  Transmission Arrangement 
TA22-M4WD  265-5693, 267-6624, 267-6625, 267-6628, 375-4305, 375-4306 

Canceled Part Numbers and Replaced Part Numbers

This document may include Canceled part numbers and replaced part numbers. Use NPR on SIS for information about Canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information



Illustration 1g02139237

Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel must be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING, or” “CAUTION”. The “WARNING” Safety Alert Symbol is shown in illustration below.



Illustration 2g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your Safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Collecting The Test Data

Since conditions vary for the test bench, use data that is collected from your test bench. The collected data is used to compare test results. The data should be collected and maintained by the operator.

Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are used to compare values on portions of this transmission test. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.

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

Personal injury or death can result from escaping fluid under pressure.

Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.


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

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.


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

Personal injury or death can result from not following the proper procedures.

To avoid the possibility of injury or death, follow the established procedure.


Tools Needed

Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure.

Table 3
Required Tools 
Tool  Part Number  Part Description  Qty 
1U-9584  Rail As 
439-3939 Link Bracket As 
8T-4193 Bolt 
9X-8257 Washer 
275-5213  Mounting Plate 
1U-9722  Load Binder Assembly 
D(1)  8T-0271  Bolt 
8T-4121 Washer 
- Fabricated Spacer 
E(1)  273-4082  Yoke Assembly 
4C-4627  Input Adapter 
136-3647  Adapter Assembly 
1U-9131  Adapter Assembly 
1U-9359  Adapter Assembly 
7M-8485  O-Ring Seal 
5P-0492 Adapter 
8C-9024 Fitting Assembly (Plain) 
7M-8485  O-Ring Seal 
5P-0492 Adapter 
8C-9024 Fitting Assembly (Plain) 
7M-8485  O-Ring Seal 
5P-0492 Adapter 
8C-9024 Fitting Assembly (Plain) 
6V-3966  Nipple (Quick Disconnect) 
3T-0811 Adapter 
6V-3965  Nipple (Quick Disconnect) 
6V-3965  Nipple (Quick Disconnect) 
5P-6944 Adapter 
R (2)  188-2162  Cover 
6V-3966 Nipple Quick Disconnect 
S(2)  188-2162  Cover 
6V-3966 Nipple Quick Disconnect 
T(2)  188-2162  Cover 
6V-3966 Nipple Quick Disconnect 
9U-7500  Transmission Analyzer Group 
OR
277-2362 Transmission Analyzer Gp 
9U-7498 Adapter Cable Assembly (Transmission Analyzer) 
9U-7496 Cable (Test) 
1U-9480 Cable Adapter 
9U-7400  Multitach Tool Group 
211-1774 Adapter Cable Assembly (Speed Sensor) 
(1) See Figure 3.
(2) See Figure 4.


Illustration 3g01299757
Tooling (D)


Illustration 4g01285710
Tooling (R), (S), and (T)

Installation Procedure



    Illustration 5g01288157

  1. Install Tooling (A) to the front of the transmission.


    Illustration 6g01288169

  2. Install Tooling (A) to the rear of the transmission.


    Illustration 7g01288176

  3. Remove plug (1) from the front of the transmission oil sump.


    Illustration 8g01288181

  4. Remove plug (2) from the rear of the transmission oil sump.


    Illustration 9g01288182

  5. Install Tooling (B) to the rear of the transmission.


    Illustration 10g01288186

  6. Install Tooling (B) to the front of the transmission.


    Illustration 11g01288193

  7. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1656 kg (3650 lb).


    Illustration 12g01288201

  8. Install Tooling (C) to the front of the transmission on both sides.


    Illustration 13g01288214

  9. Install Tooling (C) to the rear of the transmission.

    Note: Over-tightening Tooling (C) can jeopardize the tightening ability of the castle nuts on Tooling (A) later in this section.



    Illustration 14g01288313

  10. Install Tooling (D) into Tooling (E).

    Note: For some transmissions, Tooling (D) may not be required. For the specifications regarding Tooling (D) and Tooling (E), refer to Figure 3.



    Illustration 15g01288328

  11. Install Tooling (E) and Tooling (D) to the transmission input shaft.


    Illustration 16g01288334

  12. Install Tooling (F) onto Tooling (E).


    Illustration 17g01288337

  13. Install Tooling (G) onto Tooling (F).


    Illustration 18g01288341

  14. Install Tooling (H) onto Tooling (G).


    Illustration 19g01288345

  15. Install Tooling (J) onto Tooling (H).

    Note: Tooling (J) is only required if the large drive shaft is being used. If the small drive shaft is being used, only Tooling (H) is required.



    Illustration 20g01288352

  16. Align the transmission with the input shaft.

  17. Connect the input shaft to Tooling (J).


    Illustration 21g01288360

  18. Install the drive shaft guard.


    Illustration 22g03802221

  19. Tighten all four castle nuts and jack bolts.

  20. Tighten Tooling (C) to prevent movement of the transmission during testing.


    Illustration 23g01288381

  21. Install Tooling (K).


    Illustration 24g01288386

  22. Install Tooling (L).


    Illustration 25g01288390

  23. Install Tooling (M).


    Illustration 26g01288394

  24. Remove plug (3).


    Illustration 27g01288398

  25. Install Tooling (N).


    Illustration 28g01288400

  26. Remove plug (4).


    Illustration 29g01288404

  27. Install Tooling (P).


    Illustration 30g01288408

  28. Remove plug (5).


    Illustration 31g01288411

  29. Install Tooling (Q).


    Illustration 32g01288433

  30. Remove cover (6).


    Illustration 33g01288472

  31. Install Tooling (R).


    Illustration 34g01288477

  32. Remove cover (7).


    Illustration 35g01288490

  33. Install Tooling (S).


    Illustration 36g01288491

  34. Remove cover (8).


    Illustration 37g01288493

  35. Install Tooling (T).


    Illustration 38g01288494
    (9) Charge Pump Supply

  36. Connect hose assembly (9) from the pressurized flow meter to Tooling (K).


    Illustration 39g01288626
    (10) Cooler Inlet

  37. Connect hose assembly (10) from Tooling (L) to the No. 2 flow meter inlet.


    Illustration 40g01288630
    (11) Lubrication Inlet

  38. Connect hose assembly (11) from the No. two flow meter outlet to Tooling (M).


    Illustration 41g01288649
    (12) Lubrication Bypass Pressure

  39. Connect pressure gauge (12) to Tooling (N).


    Illustration 42g01288658
    (13) Main Relief Valve Pressure

  40. Connect pressure gauge (13) to Tooling (P).


    Illustration 43g01288661
    (14) Cooler Inlet Pressure

  41. Connect a pressure gauge to pressure tap (14).


    Illustration 44g01288634
    (15) Input Shaft Pressure

  42. Connect pressure gauge (15) to Tooling (Q).


    Illustration 45g01288693
    (16) Reverse Shaft Pressure

  43. Connect pressure gauge (16) to Tooling (R).


    Illustration 46g01288704
    (17) Intermediate Shaft Pressure

  44. Connect pressure gauge (17) to Tooling (S).


    Illustration 47g01288707
    (18) Centerline Shaft Pressure

  45. Connect pressure gauge (18) to Tooling (T).


    Illustration 48g01288712
    (19) No. 9 Clutch
    (20) No. 4 Clutch
    (21) No. 3 Clutch
    (22) No. 5 Clutch
    (23) No. 2 Clutch
    (24) No. 6 Clutch
    (25) No. 1 Clutch
    (26) No. 8 Clutch
    (27) No. 7 Clutch

  46. Connect the pressure gauges to the appropriate locations.


    Illustration 49g01288737
    (19) No. 9 Clutch / 9-I Harness Lead
    (20) No. 4 Clutch / 4-D Harness Lead
    (21) No. 3 Clutch / 3-C Harness Lead
    (22) No. 5 Clutch / 5-E Harness Lead
    (23) No. 2 Clutch / 2-B Harness Lead
    (24) No. 6 Clutch / 6-F Harness Lead
    (25) No. 1 Clutch / 1-A Harness Lead
    (26) No. 8 Clutch / 8-H Harness Lead
    (27) No. 7 Clutch / 7-G Harness Lead

  47. Connect Tooling (U) to the appropriate solenoid.


    Illustration 50g01288749

  48. Connect Tooling (U) to an appropriate location.


    Illustration 51g01288753
    Tooling (U)


    Illustration 52g01457869
    Tooling (U)

  49. Connect Tooling (U) to a power source.


    Illustration 53g06064514
    (28) Output Speed Sensor "A"
    (29) Output Speed Sensor "B"


    Illustration 54g01285713

  50. Connect Tooling (V) to output speed sensors "A" and "B".

Test Procedure

TA3 Navigation

  1. Select “OEM Transmissions”.

  2. Select “TA22”.

    Note: Checking 4 Forward and 4 Reverse gears covers all solenoids.

Harness Test (TA3 only)

  1. Make sure that the Tooling (U) is properly connected to the transmission.

  2. Use Tooling (U) to perform the harness test.

  3. Record the values in Table 6.

    Note: Do not continue testing until Harness Test passes.

Solenoid Test (TA2 only)

  1. Make sure that the Tooling (U) is properly connected to the transmission.

  2. Use Tooling (U) to perform the solenoid test.

  3. Record the values in Table 6.

    Note: Do not continue testing until Solenoid Test passes.

Start Checks

  1. If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.

  2. Adjust the supply flow to 146 L/min (39 US gpm).


    Illustration 55g02720621

  3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust input speed to 700 ± 10 rpm.

    Note: The input shaft will be rotated in a counterclockwise direction for the duration of this test. The direction is determined as you face the drive motor of the test bench.

  4. The lubrication pressure must be a minimum of 103 kPa (15 psi).

    Note: If there is no lube pressure after 30 seconds, stop input rotation and check connections on test bench and transmission.

  5. Record the lubrication pressure in Table 8.

  6. Shift the transmission through all gears to eliminate air from the transmission controls.

  7. Confirm the correct clutch engagement with Table 4.

    Table 4
    Clutch Engagement Check 
    Gear  Cl 1  Cl 2  Cl 3  Cl 4  Cl 5  Cl 6  Cl 7  Cl 8  Cl 9 
    N                X   
    F1  X        X         
    F2    X      X         
    F3      X    X         
    F4        X  X         
    R1          X        X 
    R2            X      X 
    R3              X    X 
    R4                X  X 

  8. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 10 rpm.

  9. Record the supply flow, charge pressure, lubrication flow, lubrication pressure, and output speed in Table 8.

    Note: Tooling (U) has been programmed to ensure that the transmission is shifted sequentially into gear ranges. The functionality of some of the input keys has been changed to ensure the requirements of this procedure. Refer to Special Instruction, "Programming Features" for further Information.

  10. Verify all test points with the values in Table 7.

  11. Stop the input rotation.

High Idle Checks

  1. Adjust the inlet flow to 146 L/min (39 US gpm).

  2. Adjust the input rotation to 2100 ± 10 rpm in the NEUTRAL position.

  3. Record the pressures for the active clutches in Table 10.

  4. Verify all test points with the values in Table 9.

  5. Record the values in Table 12 for charge pressure, cooler flow, lubrication pressure, clutch leakages, shaft pressures, and output speed.

    Note: Calculate clutch leakage by subtracting cooler flow from supply flow.

  6. Verify the test points with the values in Table 11.

  7. Adjust input speed to 700 ± 10 rpm.

  8. Shift the transmission through each FORWARD and REVERSE speed range. Repeat steps 2 through 7 for each gear range.

    Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

  9. Adjust the input rotation to 1000 ± 10 rpm.

  10. Stop the input rotation.

Lubrication Bypass Check

  1. Adjust the inlet flow to 146 L/min (39 US gpm).

  2. Adjust the input rotation to 2100 ± 10 rpm.

  3. Slowly adjust the oil supply to 215 L/min (57 US gpm). At the same time, monitor the lubrication bypass pressure.

  4. The lubrication bypass pressure should stabilize at 275 ± 34 kPa (40 ± 5 psi).

  5. Record the values in table 14.

  6. Verify the test points with the values in Table 13.

  7. Stop the input rotation.

Cooler Bypass Check

  1. Adjust the inlet flow to 146 L/min (39 US gpm).

  2. Adjust the input rotation to 2100 ± 10 rpm.

  3. Slowly increase the restriction at the No. 2 flow meter by adjusting the flow meter load valve clockwise until the cooler bypass pressure stabilizes.

  4. The cooler bypass pressure should Stabilize at 34 kPa (75 ± 5 psi).

  5. Record the values in table 16.

  6. Verify the test points with the values in Table 15.

  7. Stop the input rotation.

Contamination Control

  1. Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.

  2. Record the results in Table 17.

  3. Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

Table 5
CATERPILLAR  Transmission Bench Test Data Sheet  Test Date:_______ 
Model:_______
Work Order:_______  Serial No.:_______ 

Solenoid Test

Table 6
Solenoid Test  Solenoid 1  Solenoid 2  Solenoid 3  Solenoid 4  Solenoid 5  Solenoid 6  Solenoid 7  Solenoid 8  Solenoid 9 
______
ohms
______
ohms 
______
ohms 
______
ohms 
______
ohms 
______
ohms 
______
ohms 
______
ohms 
______
ohms 

Start Checks

Table 7
Start Checks 
Pump Flow And Pressures  Input Speed (700 ± 10 rpm)
Input Flow
146 L/min (39 US gpm) 
Gear  Supply Flow  Charge Pressure  Lubrication Flow  Lubrication Pressure  Output Speed 
N  146 L/min (39 US gpm)  2103 ± 35 kPa (305 ± 5 psi)  133 L/min (35 US gpm)  103 kPa (15 psi) minimum  0 rpm 

Table 8
Start Checks 
Pump Flow And Pressures  Input Speed (700 ± 10 rpm)
Input Flow
146 L/min (39 US gpm) 
Oil Temperature  _______°C
_______(°F) 
Gear  Supply Flow  Charge Pressure  Lubrication Flow  Lubrication Pressure  Output Speed 
N 
______________ 

______________ 

______________ 

______________ 

______________ 

Clutch Pressure Check

Table 9
Clutch Pressures 
Gear  Engaged Clutches  Cl 1  Cl 2  Cl 3  Cl 4  Cl 5  Cl 6  Cl 7  Cl 8  Cl 9 
N                2102 ± 34 kPa (305 ± 5 psi)   
F1  2102 ± 34 kPa (305 ± 5 psi)        2102 ± 34 kPa (305 ± 5 psi)         
F2    2102 ± 34 kPa (305 ± 5 psi)      2102 ± 34 kPa (305 ± 5 psi)         
F3      2102 ± 34 kPa (305 ± 5 psi)    2102 ± 34 kPa (305 ± 5 psi)         
F4        2102 ± 34 kPa (305 ± 5 psi)  2102 ± 34 kPa (305 ± 5 psi)         
R1          2102 ± 34 kPa (305 ± 5 psi)        2102 ± 34 kPa (305 ± 5 psi) 
R2            2102 ± 34 kPa (305 ± 5 psi)      2102 ± 34 kPa (305 ± 5 psi) 
R3              2102 ± 34 kPa (305 ± 5 psi)    2102 ± 34 kPa (305 ± 5 psi) 
R4                2102 ± 34 kPa (305 ± 5 psi)  2102 ± 34 kPa (305 ± 5 psi) 

Table 10
Clutch Pressures  Input Speed (2100 ± 10 rpm)
Input Flow
146 L/min (39 US gpm) 
Gear  Engaged Clutches  Cl 1  Cl 2  Cl 3  Cl 4  Cl 5  Cl 6  Cl 7  Cl 8  Cl 9 
N                _____   
F1  _____        _____         
F2    _____      _____         
F3      _____    _____         
F4        _____  _____         
R1          _____        _____ 
R2            _____      _____ 
R3              _____    _____ 
R4                _____  _____ 

High Idle Check

Table 11
High Idle Checks  Input Speed (2100 ± 10 rpm)
Input Flow
146 L/min (39 US gpm) 
Gear  Supply Flow  Charge Pressure
kPa (psi) 
Cooler Flow
L/min (gpm) 
Lubrication Pressure
kPa (psi) 
Leakage 
N  120 L/min (32 US gpm)  2100 ± 34 kPa (305 ± 5 psi)  102 ± 10 L/min (27 ± 3 US gpm)  179 ± 28 kPa (26 ± 4 psi)  24 ± 7 kPa (4 ± 1 psi) 
F1 
F2 
F3 
F4 
R1 
R2 
R3 
R4 
Gear  Input Shaft Lubrication
kPa (psi) 
Reverse Shaft Lubrication
kPa (psi) 
Intermediate Shaft Lubrication
kPa (psi) 
Centerline Shaft Lubrication
kPa (psi) 
Output Speed (rpm) 
N  193 ± 69 kPa (28 ± 10 psi)  193 ± 69 kPa (28 ± 10 psi)  179 ± 69 kPa (26 ± 10 psi)  159 ± 69 kPa (23 ± 10 psi) 
F1  117 ± 35 kPa (17 ± 5 psi)  117 ± 28 kPa (17 ± 4 psi)  103 ± 35 kPa (15 ± 5 psi)  110 ± 35 kPa (16 ± 5 psi)  249 
F2  110 ± 28 kPa (16 ± 4 psi)  110 ± 28 kPa (16 ± 4 psi)  97 ± 28 kPa (14 ± 4 psi)  103 ± 35 kPa (15 ± 5 psi)  315 
F3  117 ± 28 kPa (17 ± 4 psi)  110 ± 28 kPa (16 ± 4 psi)  76 ± 21 kPa (11 ± 3 psi)  97 ± 28 kPa (14 ± 4 psi)  400 
F4  103 ± 21 kPa (15 ± 3 psi)  103 ± 21 kPa (15 ± 3 psi)  62 ± 21 kPa (9 ± 3 psi)  83 ± 28 kPa (12 ± 4 psi)  507 
R1  110 ± 28 kPa (16 ± 4 psi)  97 ± 28 kPa (14 ± 4 psi)  103 ± 28 kPa (15 ± 4 psi)  103 ± 28 kPa (15 ± 4 psi)  200 
R2  103 ± 28 kPa (15 ± 4 psi)  97 ± 28 kPa (14 ± 4 psi)  97 ± 28 kPa (14 ± 4 psi)  103 ± 28 kPa (15 ± 4 psi)  486 
R3  90 ± 21 kPa (13 ± 3 psi)  76 ± 21 kPa (11 ± 3 psi)  76 ± 21 kPa (11 ± 3 psi)  62 ± 21 kPa (9 ± 3 psi)  548 
R4  76 ± 21 kPa (11 ± 3 psi)  69 ± 14 kPa (10 ± 2 psi)  69 ± 14 kPa (10 ± 2 psi)  62 ± 21 kPa (9 ± 3 psi)  1330 

Table 12
High Idle Checks  Input Speed (2100 ± 10 rpm)
Input Flow
146 L/min (39 US gpm) 
Gear  Supply Flow  Charge Pressure
kPa (psi) 
Cooler Flow
L/min (gpm) 
Lubrication Pressure
kPa (psi) 
Leakage 
N           
F1           
F2           
F3           
F4           
R1           
R2           
R3           
R4           
Gear  Input Shaft Lubrication
kPa (psi) 
Reverse Shaft Lubrication
kPa (psi) 
Intermediate Shaft Lubrication
kPa (psi) 
Output Shaft Lubrication
kPa (psi) 
Output Speed 
N           
F1           
F2           
F3           
F4           
R1           
R2           
R3           
R4           

Lubrication Bypass Check

Table 13
Lubrication Bypass 
Lubrication Bypass Pressure  275 ± 34 kPa (40 ± 5 psi) 

Table 14
Lubrication Bypass Check
275 ± 34 kPa (40 ± 5 psi) 
_______kPa
_______(psi) 

Cooler Bypass Check

Table 15
Cooler Bypass 
Cooler Bypass Pressure  517 ± 34 kPa (75 ± 5 psi) 

Table 16
Cooler Bypass Check
517 ± 34 kPa (75 ± 5 psi) 
_______kPa
_______(psi) 

Contamination Control

Table 17
ISO Particle Count  Sample the test bench oil supply.
*ISO 4406 is 16/13 or better 
________/________Particle Count 

Table 18






______________________________________
Technician
 






______________________________________
Supervisor
 

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