Volvo EW205D Excavator Service and Repair Manual
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Volvo EW205D Excavator Service and Repair Manual
Size: 189.44 MB
Format: PDF
Language: English
Machine:Excavator
Document: Service and Repair Manual, Hydraulic and Electrical Diagrams
Machine Model: EW205D
Pages: 5421 Pages
The Bookmarks of Volvo EW205D Excavator Service and Repair Manual:
1 Volvo EW205D
Description
2 stage port relief valve, description
2 stage port relief valve, disassembly and assembly
3 way selector valve, description
Air breather, description
Air conditioning unit, description
Air distribution, description
Alternator, description
Alternator, test
Anti-theft system
Arm holding valve, description
Arm regenerating valve, description
Attachment quick coupler
Audio remote controller, description
Auto Idle
Auto Manual pump control switch, description
Automatic engine shut-down
Auxiliary start
Axle lock
Battery charging capacity, checking
Battery, description
Battery, storage
Bearings
Boom cylinder, description
Boom holding valve, description
Boom regenerating valve, description
Boom, description
Boost control, description
Brake accumulator, description
Brake failure warning
Brake line, description1
Brake line, description2
Brake supply valve, description
Brake valve (pedal), structure
Brake valve, description1
Brake valve, description2
Brake, description1
Brake, description2
Bucket cylinder, description
Bucket flow control valve, description
Bucket regenerating valve, description
Cab suspension, description
CareTrack W-ECU, description
CareTrack with anti-theft
Center bypass valve, description
Centre passage, description
Charging, description
Check valve, description
Cleaning prior to repair
Communication with data buses
Component designations
Component list Alternator, batteries, capacitors, electronic units, voltage outlet
Component list, Fuses
Component list, Heating coils
Component list, Lights
Component list, Miscellaneous
Component list, Motors
Component list, Relays
Component list, Sensors
Component list, Solenoid valves
Component list, Switches
Conflux check valve, description
Connectors, overview
Control lockout lever switch, description
Cooling system, component location
Cooling system, description
Crankcase ventilation, description
Creep speed control
Cylinder, description
Cylinder, troubleshooting
Data buses, function
DC–DC converter, description
Description, general
Dipper arm cylinder, description
Dipper arm, description
Disassembly and assembly, general
Display unit
Dozer blade cylinder, description
Driver's seat, description
ECC, I-O list
ECO mode, description
E-ECU, I-O list
Electric center passage, description
Electrical distribution box
Electrical symbols and designations
Electrical system, description
Electrical system, special instructions for servicing, action when working on machine
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator
Electrical system, special instructions for servicing, electrical components, batteries
Electrical system, special instructions for servicing, electronic components
Electrical system, special instructions for servicing, general
Electrical system
Electro hydraulic pump control, description
Electronic climate control unit ECC, description
Electronic climate control unit ECC, description1
Electronic climate control unit ECC, specification
Electronic control system, description
Engine control unit E-ECU, function description
Engine limp home switch, description
Engine oil
Engine system
Engine, description
Explanation of wiring diagrams
Fault tracing
Flow control valve, description
Frame and track unit, description
Front axle, description
Fuel system, component location
Fuel system, description
Fuel tank, description
Fuel
Function description
Fuse, description
Heating system, description
Hoses and tubes
Hour counter, description
HVAC system
Hydraulic components, description
Hydraulic components, storage and transport
Hydraulic cylinders, dieseling
Hydraulic oil cooler, description
Hydraulic oil cooling system, description
Hydraulic oil tank, description
Hydraulic oil, description
Hydraulic oil, storage and handling
Hydraulic pump, description
Hydraulic quickfit, description
Hydraulic system, cleanliness when handling hydraulic components
Hydraulic system, description
Hydraulic system, position of main components
Hydraulic system, repair of hydraulic components in workshop
Hydraulic system, work instructions
Hydraulic system
I-ECU, I-O list
Instrument control unit I-ECU, function description
Instruments and controls, front instrument panel
Instruments and controls, left instrument panel
Instruments and controls, overview
Instruments and controls, rear instrument panel
Instruments and controls, right instrument panel
Internal Exhaust Gas Recirculation (IEGR), description
Keypad, description
Lighting, description
Line rupture valve (arm), air breathing
Line rupture valve (arm), description
Line rupture valve (arm), troubleshooting
Line rupture valve (boom), air breathing
Line rupture valve (boom), description
Line rupture valve (boom), troubleshooting
Line rupture valve relief pressure, measurement
Link, description
Load check valve - single, description
Lower wiper motor, description
Lubrication system, description
MA9109 Quickfit solenoid valve, description
Machine view
Main control valve troubleshooting
Main control valve, description
Main control valve, port size and tightening torque
Main relief valve, description
Microphone control panel, description
Microphone controller, description
Microphone, description
Microphone, system
Mode selection, description
Multi-function lever switch, description
Operating mode selection, description
Overload warning
Pivot axle lock cylinder, description
Port relief valve, description
Power train, description
Power transmission, description
Preheating, description
Pressure accumulator, description
Pressure relief valve, troubleshooting
Pressure testing
Product plates
Propeller shaft, description
Proportional solenoid valve, description
Proportional solenoid valve, description1
Proportional solenoid valve, troubleshooting
Pump, troubleshooting
Quickfit system, operation
Radiator, description
Radio with CD and MP3 player, description
Radio, description
Rear axle, description
Recommended lubricants
Regulator, description
Relay, description
Remote control valve (dozer blade), description
Remote control valve (Lever), description
Remote control valve (Lever), troubleshooting
Remote control valve (pedal), description
Remote control valve (pedal), troubleshooting
Replacement parts
Response mode
Reverse lights
Rotator (X3 Line option), description
Rotator pump, description
Safe start and stop, description
Service connection and programming connection
Service methods
Service positions
Service
Servo hydraulic block
Servo pump, description
Shuttle valve block, description
Solenoid valve (1) for hammer and shear selection
Solenoid valve, description
Solenoid valve, description1
Solenoid valve, troubleshooting
Speaker, description
Stabilisers and stabiliser blade, description
Start lock, description
Starter motor, description
Starter switch, testing
Starting engine with booster cables
Starting operation
Steering axle, description
Steering column, description
Steering pump, description
Steering servo pressure warning
Steering system, troubleshooting
Steering wheel, description
Stop light
Stop valve
Swing flow control
Swing gearbox, description1
Swing gearbox, description2
Swing motor, description
Swing ring gear, description
Tire, description
Tire, structure
Transfer gearbox, description
Travel alarm
Travel control lever switch, description
Travel gearbox, troubleshooting
Travel motor, description
Travel speed control, description
Turbocharger, description
Upper wiper motor, description
VCADS Pro, Operations
VCADS Pro, Operations1
VCADS Pro, Operations2
V-ECU, I-O list
Vehicle control unit V-ECU, function description
Vehicle information
W-ECU, I-O list
Window limit switch, description
Windows, general
Windscreen wiper, description
Wiper controller, description
Wire harness layout
Wiring diagram, electrical distribution box
Work lights and extra lights, description
X1 control, description
X1 Line, description
X3 control, description
Diagrams
Explanations to hydraulic diagram
Hydraulic diagram, with option components Figure 1
Hydraulic diagram, with option components
Wiring diagram SCH01 Power feeding
Wiring diagram SCH02 ECU power and communication
Wiring diagram SCH03 Starting and Engine speed control system
Wiring diagram SCH04 Warning and sensor
Wiring diagram SCH06 Head and stop light
Wiring diagram SCH07 Work lights
Wiring diagram SCH08 Machine control
Wiring diagram SCH09 Travelling
Wiring diagram SCH10 Electronic climate controller
Wiring diagram SCH11 Diesel coolant heater
Wiring diagram SCH12 Audio, horn and alarm
Wiring diagram SCH13 Wiper and washer
Wiring diagram SCH14 Seat heater, beacon light, and room light
Wiring diagram SCH15 X1 control
Wiring diagram SCH16 X3 and cooler control
Wiring diagram SCH17 Attachment quick coupler
Wiring diagram SCH18 Fuel refueling pump
Wiring diagram SCH19 Stabilizer and dozer blade
Wiring diagram SCH25 Air compressor
Wiring diagram SCH26 Microphone
Wiring diagram SCH30 Ground
Wiring diagram, electrical distribution box Figure 1
Installation Instruction
1 pump double acting piping, installing new
2 pump double acting piping, installing new
5.65m boom piping with X1
FOG (Falling Object Guard), installing new
Hammer hydraulic option, installing new1
Hammer hydraulic option, installing new2
Hammer hydraulic option, installing new3
Hammer hydraulic option, installing new4
Hammer hydraulic option, installing new5
Hammer shear arm piping, installing new
Pre-cleaner oil bath type, installing new
Quick fit in basic machine, installing new
Quick fit piping on arm, installing new
Quick fit piping on arm, installing new1
Quick fit piping on arm-UQF, installing new
Quick fit piping on arm-UQF, installing new1
Quick fit piping on Base machine-UQF
Quick fit piping on boom, installing new
Rear view camera, installing new
Slope rotator piping on arm, installing new
Slope rotator piping on arm, installing new1
Slope rotator piping on boom, installing new
Work light extra, installing new
X3 control, X3 valve proportional, installing new
X3 in basic machine, installing new
Repair
2 stage port relief valve, adjustment
Accumulator, replacing
Air compressor, air filter, cleaning
Air compressor, air filter, replacing
Air compressor, air tank water, draining
Air conditioner compressor belt, checking
Air conditioner main filter, cleaning
Air conditioner main filter, replacing
Air conditioning unit, maintenance
Air mix door actuator, replacing
Alternator, replacing incl function check
Antenna, replacing
Arm parallel conflux check valve, disassembly and assembly
Arm parallel conflux valve, disassembly and assembly
Arm regenerating valve, disassembly
Axle locking cylinder, assembly
Axle locking cylinder, disassembly
Axle, installing
Axle, installing1
Axle, removing
Axle, removing1
Backrest, replacing
Batteries, replacing
Battery disconnector, replacing
Battery, charging
Boom back pressure check valve, disassembly
Boom cylinder, replacing
Boom holding valve, disassembly
Boom, replacing
Brake disc wear, measuring
Brake performance
Brake system pressure oil filter, replacing
Brake system, troubleshooting
Breather, replacing
Bucket cylinder bushing lever-link, replacing
Bucket cylinder bushing on dipper arm, changing
Bucket cylinder, replacing
Bucket flow control valve, disassembly
Bucket regenerating valve, disassembly
Cab door, covers, hinges, joints and locks, lubricating
Cab filter, replacing
Cab prefilter, cleaning
Cab prefilter, replacing
Cab, installing
Cab, removing1
Cab, removing2
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, check
CareTrack battery, replacing
Center bypass valve, disassembly and assembly
Center passage, disassembly and assembly
Centre passage, installing
Centre passage, removing
Check valve, replacing
Coasting left and right swing
Component locations Engine
Compressor, replacing incl draining and filling
Compressor, replacing magnetic clutch (compressor removed)
Condenser, replacing incl draining and filling
Connecting rod yoke, replacing
Control lever (dozer blade), replacing
Control lockout lever switch, replacing
Control types for X1 and X3 operation
Control valve, replacing
Coolant freezing point, checking
Coolant, changing
Coolant, changing1
Coolant, checking anti-freeze resistance
Cooler and Heater assembly, replacing
Counterweight, replacing
Creeping of hydraulic cylinder
Cylinder speed
Cylinder, disassembly and assembly
Digging unit, maintenance
Dipper arm connecting rod, replacing
Dipper arm cylinder bushing on boom, replacing
Dipper arm cylinder bushing on dipper arm, replacing
Dipper arm cylinder, replacing
Dipper arm, replacing
Door window, replacing
Door, replacing
Dozer blade cylinder, replacing
Dozer blade, replacing
Drive axles and hubs oil level, checking
Drive axles and hubs oil, changing
Earth lead to battery, replacing
ECC, MID 146, changing non-programmed ECU
ECC, MID 146, changing pre-programmed ECU
E-ECU, MID 128, changing non-programmed ECU
E-ECU, MID 128, changing pre-programmed ECU
Electric pedal control on X1 (proportional), replacing
Electrical distribution box, circuit board replacing
Engine air cleaner primary filter, replacing
Engine air cleaner secondary filter, replacing
Engine hood, replacing
Engine oil and filter, changing
Engine oil pressure sensor, replacing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor, replacing
Engine temperature sensor, replacing
Engine wire harness, replacing
Engine, installing
Engine, removing
Engine, tightening torques
E-tools, NET 8940-00290 Swing motor guide pin
E-tools, NET 8940-00420 Replace tool for the swing ring gear
Evaporator, replacing incl draining and filling
Exhaust pipe, flexible tube, replacing
Expansion tank, replacing
Expansion valve, replacing incl draining and filling
Extra water separator filter element, replacing
Fan alternator belt, checking
Fan belt and or alternator belt, replacing
Fan belt and or alternator-, compressor belt, replacing all belts
Fan motor, replacing
Feed pump, checking feed pressure
Feed pump, replacing
Flow control valve, disassembly and assembly
Fuel filter, replacing
Fuel level sender, replacing
Fuel system, bleeding
Fuel tank breather filter, replacing
General, precautions
General, tools
Handling the tire
Headlights, adjusting
Heater core, replacing
High pressure fuel system, pressure relief
Horn, replacing
Hour meter, replacing
Hub reduction gear, replacing
Hub reduction gear, replacing1
Hydraulic oil drain filter, replacing
Hydraulic oil level, checking
Hydraulic oil return filter, replacing
Hydraulic oil servo filter, replacing
Hydraulic oil suction strainer, cleaning
Hydraulic oil tank breather filter, replacing
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic oil temperature sensor, replacing
Hydraulic oil, changing
Hydraulic pump (removed), changing shaft seal
Hydraulic pump coupling, description
Hydraulic pump, replacing
I-ECU, MID 140, changing non-programmed ECU
I-ECU, MID 140, changing pre-programmed ECU
Ignition switch, replacing
Inlet and exhaust system, component location
Instrument panel, replacing (left)
Instrument panel, replacing (right)
Intake actuator, replacing
Intercooler, replacing
Internal leakage, checking
Line rupture valve (arm), assembly
Line rupture valve (arm), disassembly
Line rupture valve (boom), assembly
Line rupture valve (boom), disassembly
Line rupture valve pressure, checking and adjusting
Load check valve – single, disassembly and assembly
Longitudinal adjustment cable, replacing
Longitudinal suspension cable, replacing
Lower boom cylinder bushing, replacing
Lubrication oil pressure, checking with pressure gauge
Lubrication system, component locations
Lubrication, every 50 hours
Lubrication, every 250 hours
Main pressure relief valve, replacing
Main relief valve, adjustment
Main relief valve, disassembly and assembly
Main spool, disassembly and assembly
Maintenance service, every 10 hours
Maintenance service, every 50 hours
Maintenance service, every 250 hours
Maintenance service, every 500 hours
Maintenance service, every 1000 hours
Maintenance service, every 2000 hours
Maintenance service, every 4000 hours
Maintenance service, every 6000 hours
Maintenance service, first 500 hours
MATRIS and Tech Tool, reading
Measuring condition
Measuring of swing bearing clearance
Mode (foot) actuator, replacing
NET 8940-00390 Adjust tool for the axle steering rod end
NET 8940-00410 Replace tool for the center passage
NET 8940-00430 Replace tool for the travel motor guide pin
Oil cooler line bypass valve (check valve), replacing
Oil cooler, replacing
Oil cooler, replacing1
Oil level gauge, replacing
Oil level sensor, changing
Oil-bath air cleaner reservoir filter insert, cleaning
Oil-bath air cleaner reservoir oil, changing
Oil-bath air cleaner reservoir oil, checking
Operating force of steering wheel
Parking brake performance
Parking brake, manually releasing
Pivot axle lock cylinder, installing
Pivot axle lock cylinder, removing
Port relief valve pressure, checking and adjusting
Port relief valve, disassembly and assembly
Preheating coil, replacing
Pre-heating relay, replacing
Propeller shaft, front, replacing
Propeller shaft, rear, replacing1
Propeller shaft, rear, replacing2
Proportional solenoid valve (power shift), replacing
Proportional solenoid valve, measuring and adjustment
Pump gearbox coupling assembly, replacing
Pump regulator, replacing
Pump, assembly
Pump, disassembly
Pump, installation
Pump, maintenance standard
Pump, tools
Quickfit, replacing
Radiator and hydraulic oil cooler, cleaning
Radiator, replacing
Radio, replacing
Rear window, replacing
Rear-view mirror, changing
Receiver, replacing incl draining and filling
Regulator, disassembly and assembly
Remote control valve (Lever), assembly
Remote control valve (Lever), disassembly
Remote control valve (Lever), maintenance standard
Remote control valve (lever), replacing
Remote control valve (pedal), assembly
Remote control valve (pedal), disassembly
Remote control valve (pedal), maintenance standard
Remote control valve (pedal), replacing
Revolutions of steering wheel
Ring gear grease pipe, replacing
Rotating beacon, replacing
Rotator pump, parts inspection
Rotator valve, adjustment
Rupture valve, replacing (boom cylinder)
Rupture valve, replacing (dipper arm cylinder)
Seat cushion, replacing
Seat heater, checking
Seat support, replacing
Seat, replacing
Servo hydraulic pressure, adjustment
Servo pump, assembly
Servo pump, disassembly
Servo pump, parts inspection
Servo pump, replacing
Side window, replacing
Silencer, replacing
Solenoid valve, disassembly and assembly
Solenoid valve, inspection
Solenoid valve, replacing
Speaker, replacing
Stabilizer cylinder, replacing
Starter motor, replacing
Starter motor, tests
Starter relay, replacing
Steering cylinder, assembly
Steering cylinder, disassembly
Steering system, adjustment
Steering system, troubleshooting
Swing bath grease, checking
Swing gearbox oil level, checking
Swing gearbox oil, changing
Swing gearbox, assembly
Swing gearbox, disassembly
Swing gearbox, maintenance standard
Swing gearbox, replacing
Swing motor relief valve, replacing
Swing motor removed, replacing seal
Swing motor, assembly
Swing motor, disassembly
Swing motor, maintenance standard
Swing motor, replacing brake piston seal
Swing motor, replacing plate (brake)
Swing motor, replacing
Swing ring gear bearing, lubricating
Swing speed
Test running and checking
Thermostat, checking
Thermostat, replacing
Tool box assembly, replacing
Transfer gearbox, lubrication and maintenance
Travel alarm, replacing
Travel gearbox lubrication pump, replacing
Travel gearbox multi-disc, replacing
Travel gearbox oil level, checking
Travel gearbox oil, changing
Travel gearbox output flange seal, replacing
Travel gearbox, assembly
Travel gearbox, disassembly
Travel gearbox, installation
Travel gearbox, removal
Travel motor removed, replacing seal
Travel motor, adjustment
Travel motor, assembly
Travel motor, disassembly
Travel motor, installing
Travel motor, maintenance standard
Travel motor, removing
Turbocharger, replacing
Tyre wear and air pressure, checking
Upper boom cylinder bushing, replacing
Valves, adjusting
Valves, adjusting1
VCADS Pro, connecting problems
VCADS Pro, Operations
V-ECU, MID 187, changing non-programmed ECU
V-ECU, MID 187, changing pre-programmed ECU
Vent actuator, replacing
Voltage converter, replacing
Water separator filter, replacing
W-ECU, MID142, changing non-programmed ECU
W-ECU, MID142, changing pre-programmed ECU
Wheel nuts torque, checking
Wheel, installing
Wheel, removing
Windscreen flusher pump, replacing
Windscreen wiper front, replacing motor
Windscreen wiper, replacing controller
Windscreen wiper, replacing switch
Windscreen, replacing
Work lighting, replacing one head lamp assy
Safety
Cautions during operation
CE-marking, EMC-directive
Checklist after a fire or heat exposure
Decontamination
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Fire prevention measures
Health hazards with paint, plastics and rubber
Move and operate machine safely
Preparations for work
Safety concerns everybody!
Safety rules when servicing
Safety when handling oils and fuel
Safety when handling the machine
Safety when using lifting equipment
Safety when working with air conditioning refrigerant
Safety when working with batteries
Safety when working with hydraulic systems
Service position 1
Some simple rules regarding tyre handling
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Service Bulletins
Air conditioning heater hose clamp looseness
Attachment shims for clearance adjustment of pin joint
Cab filter cover sealing
CareTrack Telematics system
CareTrack, new software version 2008w6
Check method on engine oil consumption
DEF AdBlue AUS32 sampling, method
ECU, functional check
Fuel sampling, method
Hydraulic hose assembly leakage handling
Hydraulic system flushing method
Machine model
Modification of CareTrack wire harness
New product
New product1
New product2
New software for stabilizer buzzer
New TechTool VCADS Pro interface
Oil sampling, method
Oil sampling, sampling points
Portable refillable O-ring kits
Recommendations for Oil Sampling Intervals
Reporting of product misuse & near-miss report
Reports
Routines for reporting cracks on Boom and Arm
Volvo Product incident accident report & Interview Form
W-ECU antenna connector
Special Tools, Misc
Special tool catalog
Special Tools Recommendations
Time Guide Currrent generation
Time Guide Old generation
Time Guide Previous generation
Specifications
Air conditioning unit, specifications
Alternator, specifications
Audio remote controller, specifications
Auto Manual pump control switch, specifications
Axle, specifications
Battery, specifications
Boom cylinder, specifications
Boom, specifications
Boom, tightening torque
Brake accumulator, specifications
Brake system, specifications
Bucket cylinder, specifications
Cab, weight
Center passage, specifications
Change capacities
Control lockout lever switch, specifications
Coolant with freezing and corrosion protection
Coolant
Cooling system, tightening torques
Counterweight, specifications
Counterweight, tightening torques
Current pressure, specifications
Cylinder, specifications
DC–DC converter, specifications
Dipper arm cylinder, specifications
Dipper arm, specifications
Dozer blade cylinder, specifications
Dozer blade, specifications
Dozer blade, tightening torque
Driver's seat, specifications
Electric center passage, specification
Electric horn, specifications
Electrical system, specifications
Electronic climate control unit ECC, specification
Engine - Pump control, specification
Engine hood and frame, tightening torque
Engine limp home switch, specifications
Engine mounting, tightening torque
Engine, specifications
Front axle, specification
Fuel filler pump, specifications
Fuel pressure, specifications
Fuel system, tightening torques
Fuel system, tightening torques1
Fuel tank, volume
Grease
Hour counter, specifications
Hydraulic oil cooling system, specifications
Hydraulic oil
Hydraulic pressure, specifications
Hydraulic pump, specifications
Hydraulic tank, specifications
Inlet and exhaust system, tightening torques
Instrument control unit I-ECU, specifications
Keypad, specification
Lighting, specifications
Line rupture valve (arm), specifications
Line rupture valve (boom), specifications
Lower wiper motor, specifications
Lubrication system, specifications
Machine weight, specifications
Main control valve, specifications
Measurement conversion tables
Microphone control panel, specifications
Microphone controller, specifications
Multi-function lever switch, specifications
Pivot axle lock cylinder, specifications
Preheating, specifications
Pressure accumulator, specifications
Propeller shaft, specifications
Proportional solenoid valve, specifications
Proportional solenoid valve, specifications1
Radio with CD and MP3 player, specifications
Rear axle, specification
Relay, specifications
Remote control valve (dozer blade), specifications
Remote control valve (Lever), specifications
Remote control valve (Lever), tightening torque
Remote control valve (pedal), specifications
Rotating beacon, specifications
Rotator pump, specifications
Servo pump, specifications
Solenoid valve for rotator
Solenoid valve, specifications
Solenoid valve, specifications1
Speaker, specifications
Stabilisers cylinder, tightening torque
Standard tightening torques
Starter motor, specifications
Steering axle, specifications
Steering pump, specifications
Swing gearbox, specifications
Swing motor, specifications
Swing ring gear, specifications
Thermostat, specifications
Tightening torque, specifications
Tightening torques
Tire and rim, specifications
Transfer gearbox, specifications
Travel alarm, specifications
Travel control lever switch, specifications
Travel motor, specifications
Under cover, superstructure
Upper wiper motor, specifications
Valve system specifications
Windscreen flusher pump, specifications
Wiper controller, specifications
Wireless control unit W-ECU, specification
Work lights and extra lights, specifications
X1 electronic proportional pedal, tightening torque
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