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Reg.

code
AIB TAB 43
COP 1638
2004–09

Maintenance instructions for

Hydraulic
Rock drill COP 1638
1250 0021 33

ATLAS COPCO ROCK DRILLS AB


ÖREBRO · SWEDEN
© Atlas Copco Rock Drills AB, 2004. All rights reserved.

No. 9852 1653 01


SAFETY REGULATIONS
· Important safety information is given at various points in these instructions.
· Special attention must be paid to the safety information contained in frames and accompanied by a war-
ning symbol (triangle) and a signal word, as shown below:

indicates hazards or hazardous procedures which COULD


WARNING result in serious or fatal injury if the warning is not observed.

indicates hazards or hazardous procedures which COULD


CAUTION result in injury or damage to equipment if the warning is not
observed.

The following safety rules must also be observed:


· Carefully read through all operating- and main- · Use Atlas Copco genuine parts only. Any
tenance instructions for the drill rig and rock damage or malfunction caused by the use of
drill before putting the rock drill to use. Always unauthorized parts is not covered by Warranty
follow the instructions given. or Product Liability.
· Do not use or intervene in the rock drill unless · Never attempt to carry out maintenance while
you have been trained to do so. the drill rig is in operation.
· Those checks and adjustments that must be
· The rock drill may only be used for the pre- made while the drill rig is in operation must be
scribed purposes. carried out by at least two persons. One per-
son must man the control station and keep a
· Make sure that the drill rig has been maintai- strict watch over the work.
ned in accordance with the current instructions.
· To prevent injury during service and mainte-
· Make sure that all safety labels remain in pla- nance, all components that could possibly
ce, and that they are kept clean and fully legib- move or drop must be supported safely on
le. See the spare parts list for details of label blocks or trestles, or secured by means of
locations and part numbers. adequately dimensioned slings.
· Always wear a safety helmet and ear protec- · Before starting work on any of the systems,
tors during drilling. Any local regulations that make sure that the hydraulic, air and water sys-
exist must also be observed. tems are without pressure, and that the electri-
cal system is dead.
· Before moving the drill rig or starting to drill, · Check that the hoses used are of the right qua-
make sure that there are no personnel in the
lity, and that all hose connections are in good
immediate vicinity of the drill rig.
condition and properly tightened.

Contents Page

Safety regulations . . . . . . . . . . . . . . . . 2 Filling with lubricating oil and bleeding the syst. 10
Action list . . . . . . . . . . . . . . . . . . . . . 3 Setting of ECL lubricating system . . . . . . . 10
Hose connections . . . . . . . . . . . . . . . . 4 Lubrication of gear . . . . . . . . . . . . . . . 11
Tightening torques . . . . . . . . . . . . . . . . 5 Setting the damper pressure . . . . . . . . . . 11
Accumulators . . . . . . . . . . . . . . . . . . 6 Removing the front head . . . . . . . . . . . . 12
– Charging the accumulators . . . . . . . . . . 6 Checking the front head . . . . . . . . . . . . 13
– Checks in the event of hose vibration . . . . . 7 Changing the flushing head and driver . . . . 14
– Changing the accumulators . . . . . . . . . . 8 Mounting the front head . . . . . . . . . . . . 14
– Changing the return accumulator . . . . . . . 9 Slinging . . . . . . . . . . . . . . . . . . . . 15
Changing the hydraulic motor . . . . . . . . . . 9 Long-term storage . . . . . . . . . . . . . . . 15
Recommended hydraulic oils and lubricants . 16

2
WARNING Action list
· Before starting any maintenance work, Before starting up a new- or
make sure that the electrical system is
dead. newly overhauled rock drill: Page
There is a risk of injury if these instructions · Connect up the hoses . . . . . . . . . . . . 4
are not observed! · Charge the accumulators . . . . . . . . . . . 6
· Select a suitable hydraulic oil and lubricant . 16
· Fill the lubricating system with oil . . . . . . . 10
· Adjust and set the lubricating system . . . . 10
CAUTION · Set the damper pressure . . . . . . . . . . . 11
· Take care during rod jointing and when
handling the drill bit. Mind your fingers!
· Keep your clothing away from rotating Every shift
machine parts. · Check that air and lubricating oil come out
Carelessness can lead to serious injury. between the shank adapter and front guide
and also out of the hole in the front head . . 13
· Always use ear protectors during drilling. · Check that the damper-pressure gauge on
High noise levels damage hearing.
the drill rig shows the normal value. In case
· Never attempt maintenance or intervene of deviation, adjust the damper pressure . . . 11
in the rock drill, connections or hoses whi- · Check that the shank-adapter threads are
le the hydraulic, lubrication or flushing not damaged . . . . . . . . . . . . . . . . . 13
systems are pressurized.
Air or oil can squirt out at high pressure · Keep an eye on the hydraulic hoses. If they
and high temperature, with the risk of vibrate too much, check the accumulators . . 7
serious injury to the eyes and skin. · Check that there is no leakage from the rock
drill. If the flushing medium leaks out of the
overflow hole in the front head, change the
seals and O-rings . . . . . . . . . . . . . . . 13
· When changing the shank adapter or remov-
ing the front head, check the internal compo-
nents, including the visible parts of the piston,
driver and rotation chuck bushing . . . . . . 13
In the event of defect, remove to a suitable
workshop for repair or replacement.

After the first shift when using a


new- or newly overhauled rock drill
· Tighten all threaded unions . . . . . . . . . 5

After every 40th percussion-hour


IMPORTANT · Grease the gear . . . . . . . . . . . . . . . 11
· Tighten all threaded unions . . . . . . . . . 5
· Observe great cleanliness when interve-
ning in the rock drill or its hydraulic cir- · Check the safety labels on the accumulators.
cuit. Replace them if they are damaged or illegible . 6

· The following parts may be changed at the · Check the return accumulator . . . . . . . . 7
worksite in accordance with the instruc-
tions given:
– shank adapter
Every 400th percussion-hour:
– driver · Remove the rock drill from the drill rig and
– front head parts send it to a suitable workshop for over-
– accumulators hauling*.
– hydraulic motor
– screws
– connections.
* The rock drill should be overhauled at suitable intervals,
based on local conditions. The characteristics of the rock will
Other repairs must be carried out in a sui- have a great influence on the rate of wear, and thus on the
table workshop in accordance with the required frequency of overhauling.

3
Hose connections

8 7

1
AIR

6
1250 0147 23

5
4
2 3
1. Drainage
2. Rotation to the left
3. Rotation to the right
4. Percussion mechanism, return
5. Percussion mechanism, intake
6. Flushing air/water
7. Lubricating air
8. Damper, intake

Connecting the hoses


CAUTION · Clean the hose connections on the rock drill be-
fore removing the protective plugs (or caps).
· Never attempt maintenance or intervene
in the rock drill, connections or hoses whi- · Never remove a protective plug until the hose is
le the hydraulic, lubrication or flushing ready to be connected.
systems are pressurized. · Always store the rock drill with all hose connec-
Air or oil can squirt out at high pressure tions plugged. Use suitable protective plugs or
and high temperature, with the risk of caps, and make sure that they are clean.
serious injury to the eyes and skin.
· Pressure hoses with an internal diameter
of 19 mm (3/4") or more are rated SAE 100
R9R (i.e. high-pressure hose with four lay-
ers of spirally wound steel-wire reinforce-
ment). See spare parts list for drill rig.
For safety reasons, these hoses must not,
under any circumstances, be replaced
with hoses of a lower rating.
There is a risk of injury if these instruc-
tions are not observed!

4
Tightening torques

6
1
5
4

3
14

13
9
12 6

11
7 10
1250 0147 24

9
8

3 2

N.B. Tighten item Nos. 1–3 in the prescribed order.

Ref.No. Qty. Check point Torque Instructions


Nm lbf.ft

1 2 Side bolts 300 220 Tighten the rear nuts


2 1 Front bolt 300 220 Tighten the front bolt
3 2 Side bolts 350 260 Tighten the front nuts
4 3 Back head 220 160 Tighten the screws alternately to full torque
(uppermost screw last)
5 1 Regulating plug 80 60
6 4 Accumulators 220 160 Tighten the screws alternately to full torque
7 4 Hydraulic motor 65 48 Tighten the nuts alternately
8 2 Clamping attachment,
return accumulator 30 22
9 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque
10 1 Plug 45 33
11 4 Valve covers 145 105 Tighten the screws alternately to full torque
12 2 Connection plate 120 90 Tighten the screws alternately to full torque
13 1 Flushing connection 300 220
14 4 Inlet, flushing medium 90 65 Tighten the screws alternately to full torque
15 1 Intake, extractor unit 120 90
16 1 Return, extractor unit 120 90

5
Accumulators

The accumulators are fitted with safety labels as = Read the instruction book carefully
shown in the figure below. before servicing or changing

1250 0020 91
1. Damper accumulator
2. Intake accumulator = Must be charged with nitrogen only
3. Return accumulator
1250 0027 19

Charging the accumulators


WARNING 1. Remove the protective cap (4).
· The accumulators must be charged with 2. Open the valve nut (5) by 2–3 turns, and con-
nitrogen (N2) only! nect the gas hose.
Other gases can cause an explosion. 3. Open the gas valve (6).
4. Charge the accumulators to the correct
pressure, as follows:
– Damper accumulator (1): 20–25 bar
(290–360 psi)
CAUTION – Intake accumulator (2): 30- 40 bar
below the collaring pressure
· Do NOT charge the accumulators until (435 - 580 psi)
they have been fitted to the rock drill. 5. Tighten the valve nut (5) and close the gas val-
There is a risk of injury if these instruc- ve (6).
tions are not observed!
6. Remove the gas hose and fit back the protecti-
ve cap (4) to the accumulator valve.
The return accumulator (3) must not be charged.

6
Checking the accumulators in the event of hose vibration
Damper accumulator (1) and
Intake accumulator (2)
1. Press in the pin on the test valve (7). If the ac-
cumulator is charged, the pin will stick out by
4.5 mm and give a firm resistance when pres-
sed in.
N.B. The damper-accumulator pin is somewhat
easier to press in.
If it is easy to press in the pin, it means that the-
re is no gas pressure (diaphragm damaged).
2. Change the accumulator if it is not functioning
properly (see page 8).
3. After fitting a new accumulator, charge it with
nitrogen.
N.B. The seat of the charging valve can easily
become deformed when opened and closed re-
peatedly. The charging valve should therefore
be changed regularly.

Return accumulator (3)


(Check every 40th percussion-hour)
1. Put the rock drill in the horizontal position, as
shown in the figure.
2. Remove the plug with O-ring (8). If oil comes
out, the diaphragm is damaged.
3. Change the diaphragm if necessary.
4. If the diaphragm is touching the outer pipe,
press down the diaphragm using a blunt,
cylindrical mandrel (ø 7–9 mm). See fig. A.
For the correct diaphragm position, see fig. B.
5. Fit back the plug and O-ring.
1250 0027 20

1. Damper accumulator
2. Intake accumulator
3. Return accumulator
4. Protective cap
5. Valve nut
6. Gas valve
7. Test valve
8. Plug with O-ring

7
Changing the accumulators
5

1250 0147 25
1 B A

B A

4 2

Removal Mounting

CAUTION CAUTION
· Release all gas before removing the ac- · Mount the accumulators to the rock drill
cumulators from the rock drill. using undamaged original screws.
To do this, remove the protective cap (A), The intake accumulator (2) for COP 1638
loosen the valve nut (B) and open it by must have two screws (4) of length 70 mm.
2–3 turns. The damper accumulator (1) must have
There is a risk of injury if these instruc- two screws (5) of length 70 mm.
tions are not observed! Change both screws at the same time,
even if only one of them is corroded (or
Remove the accumulators (1 and 2) together with damaged in some other way).
the sealings (3) by removing the screws (4 and 5 Defective screws can cause dangerous oil
or 6). leakage, or can cause the accumulator to
be blown off.
Now send the accumulators to a workshop for Squirting oil can seriously injure the eyes
overhauling! and skin.
Parts that come loose can cause serious
injury.

Fit the sealings (3) into the grove in the intermedia-


te part (7) and then fit the accumulators (1 or 2) to
the intermediate part (7)
Make sure that the sealings dont get damaged
during the assembly.
Fit the damper accumulator (1) to the left-hand
side of the rock drill. Fit the intake accumulator (2)
to the right-hand side of the rock drill, i.e. the hose
side. Tighten the screws (4 and 5, or 6) alternately
to a torque of 220 Nm (160 lbf.ft).
Now charge the accumulators with nitrogen (N2).
See page 6.

8
Changing the return accumulator Changing the hydraulic
1250 0027 22 motor

8 5
10

1250 0027 23
9
3
2

Removal Removal
Disconnect the hydraulic hoses (1).
CAUTION Remove the return accumulator (3).

· Before intervening in the hydraulic, water Remove the nuts (2) and take off the hydraulic mo-
or air systems, make sure that there is no tor (3).
pressure in the systems.
Pull out the coupling (4).
· Pressure hoses with an internal diameter
of 19 mm (3/4") or more are rated SAE 100
R9R (i.e. high-pressure hose with four lay-
ers of spirally wound steel-wire reinforce-
ment). See spare parts list for drill rig.
For safety reasons, these hoses must not,
under any circumstances, be replaced Mounting
with hoses of a lower rating.
Make sure that the circlip (5) is fitted into the coup-
There is a risk of injury if these instructions ling (4).
are not observed!
Grease the splines inside the coupling, and slide
the coupling on to the output shaft of the hydraulic
Disconnect the hydraulic hose (8) from the return motor (3).
accumulator (3).
Fit the hydraulic motor (3) with gasket (7) to the
Remove the return accumulator (3) by removing cylinder (6). Change the gasket if it is damaged.
the nuts (2), screws (1).
Tighten the nuts (2) to a torque of 65 Nm (48 lbf.ft).
Pull off the clamp (5) and unscrew the accumulator
from the nipple (7 on surface drill rigs) or Connect the hydraulic hoses (1). Check that the
(9 on underground drill rigs). motor rotates in the correct direction.
Now send the accumulator to a workshop for over-
hauling!

Mounting
Fit the return accumulator (3) to the nipple (7 or 9)
and tighten in such a way that the plug (10) is ac-
cessible for checking the accumulator diaphragm.
Slide the clamp (5) on to the accumulator, by me-
ans of the screws (1) and nuts (2).
Connect the hydraulic hose (8) to the return
accumulator (3).

9
Filling with lubricating oil and bleeding the system
· If the lubricating system has been empty of oil, it
CAUTION must be bled after filling.
This is done as follows:
– Loosen the cap (7) and let the lubricating oil
· Never intervene in the lubricating system escape until all air has been discharged from
while it is pressurized.
Lubricating oil can squirt out, with the the lubricating oil pump. Now tighten the cap.
risk of injury to the eyes and skin. – Start the lubricating system and loosen the
hose connection at pressure gauge (8), so that
all air is released from the system. Now
tighten the hose connection.
IMPORTANT – Disconnect the lubricating-air hose (12) from
the nipple (11) on the rock drill.
· Use the recommended lubricating-air pres- – Start the lubricating pump and let it pump until
sure and the recommended lubri- oil comes out of the plastic hose (10).
cating oil. When re-starting (after standstill), oil must
Certain moving parts of the rock drill are come out of the plastic hose directly when the
lubricated by means of oil-mixed compres- lubricating pump is started.
sed air. It is important that these parts re- – Check that the plastic hose (10) for lubricating
ceive good lubrication. oil is of the correct length. It must not protrude
into the machine.
– Re-connect the lubricating-air hose (12).
· Check the oil level in the lubricating-oil container
(1) once a shift. Observe a high standard of cle-
anliness and fill with oil of the right quality (see
page 19). The lubricating-oil container holds 5
litres.

Setting of ECL lubricating system


1. Open the electrical cabinet.
10
2. Start the lubricating system (see the operator’s 3 A
instructions for the drill rig). R
3. Check the lubricating air pressure at the rock T1 T2
B
drill (11) using a pressure gauge (A). The pres- G
sure should be 2–3 bar. If the pressure is too
low, clean the restrictor (9) or increase the dia- 2 1 B
meter of the restrictor.
B
1250 0145 58

Underground drill rigs Min. oljenivÂ


Min. oil level
4. Check that the green light emitting diode (G) 11
indicates power on. 7 12
F
5. Adjust the screw (T1) so that the light emitting
time of the yellow diode (R) is 0.5 seconds.
6. Observe the yellow diode (R) and adjust the 9
+ _
lubricating oil dosage to 35–40 pulses/min, by
8
means of the screw (T2). 24 V

After making the respective setting, check the LED


(F) on the lubricating pump to ensure that the right 1. Lubricating-oil container 11. Lubricating-air connection
pulse frequency has been obtained. Check also 2. Filler cap 12. Lubricating-air hose
that oil comes out of the hole (B) in the front head 3. Pulse relay A. Pressure gauge
and between the shank adapter and front guide. 7. Cap, bleeding F. Light-emitting diode (LED)
8. Pressure gauge G. Green LED
9. Restrictor R. Yellow LED
10. Plastic hose T1. Adjustment screw,
light-emitting time
T2. Adjustment screw,
pulse frequency

10
Lubrication of gear

1. Remove the bleeder plug (1).


2. Grease the gear through the nipple (2) until gre-
ase comes out of the hole (3). Use heat-
resistant grease (see "Recommended hydraulic
oils and lubricants", page 19).
1250 0027 25

3. Fit back the plug (1).

Setting the damper


pressure
1. Shut completely the constant-flow valve (B) on
the drill rig.
2. Connect a pressure gauge (A) [calibrated from
0 to 60 bar] between the hose and the damper
nipple (1).
1250 0027 26

3. Pressurize the damper circuit.


4. Check that the shank adapter is unloaded, and
that it has been pushed into the forward position.
5. Adjust the constant-flow valve until the pressure
gauge (A) reads 30–35 bar.
6. Read off the pressure on the damper pressure
gauge on the drill rig.
If the pressure gauge later shows a different va-
lue, make a new pressure setting.
7. Disconnect the pressure gauge (A) and re-
connect the hose to the nipple (1).

11
Removing the front head

CAUTION
· Never attempt maintenance work while
the drill rig is in operation.
· Before intervening in the hydraulic, water
or air systems, make sure that there is no
pressure in the systems.
There is a risk of injury if these instructions
are not observed!

N.B. Always clean the outside of the rock drill befo-


re disassembly.
1250 0027 30

COP 1638
Remove the flushing hose (5).
Remove the connection plate (1) and nipple (2) by
removing the screws (3) and washers (6).
Remove the cup seal (4).

Remove the front side-bolt nuts (3) with their


washers (2).
Remove the front head (1) by tugging the shank
adapter (4).
Now pull out the shank adapter (4) from the front
head (1).
1250 0027 31

Check the internal components of the front head


when changing the shank adapter.

12
Checking the front head
1250 0071 63

8 7 3 A 3 3 1 5 6 2 9

C
4 B
12

1 1m
m 3 3 4 3 3
5

R38
T38 2 mm

m 2
1m 6 7

39 mm R38
T38

· Check that air and lubricating oil come out be- · Look inside the gear housing and check the spli-
tween the shank adapter (6) and front guide nes of the driver (5). If the splines are less than
(7), and also out of the hole (B). 2 mm in width, the driver must be changed (see
· Blow clean the lubricating oil ducts (A) using page 14).
compressed air, and check that the restrictors Fit a new driver with the aid of a suitable mand-
(9) are open. rel and a copper hammer.
· Change the guide (7) if its internal diameter is · If the rotation chuck bushing (2) is worn by more
greater than 39 mm or 53 mm. than 1 mm, or if the striking surface of the im-
pact piston (12) is damaged in any way, the rock
· Check the O-rings and flushing seals (3) if drill must be sent to a suitable workshop for over-
air/water is escaping from the hole (C) in the
hauling. See the overhauling instructions.
front head. Change the O-rings and flushing
seals if they are worn or damaged. · Change the shank adapter (6) if the thread is
worn out or the impact surface is upset or chip-
· Change the flushing head (4) if it is seriously cor-
ped, or if the front or rear end surfaces of the
roded, or if it contains cracks.
splines are worn.
· Change the stop ring (1) if it is worn by more
· Check that the drill collar (8), which must be
than 1 mm.
used in upwards-directed drilling, is not dama-
· Change the extractor-unit piston (10) if the surfa- ged and that it rotates with the shank adapter.
ce toward the shank adapter has worn by more
than 1 mm.
When changing the extractor-unit piston, check
the seals and O-rings (11). Change them if they
are worn or damaged.

13
Changing the flushing head and driver

CAUTION
· Take care when removing the flushing
head and driver. Mind your fingers!

Mounting the front head


COP 1638
Fit the stop ring and shank adapter (4) into the
front head (1).
Check that the pin (6) is fitted into the cover. Fit
the front head (1) on to the side bolts (5).
Fit the washers (2) and nuts (3).
N.B. Before assembly, smear the threads with gre-
1250 0027 37

ase (type NEVER-SEEZ).


Check the tightening torques of the rear side-bolt
nuts and front side bolt (see 1–2, page 5).
Now tighten the nuts (3) alternately to a torque of
350 Nm (260 lbf.ft).

Fit the cup seal (4) into the flushing head.


Fit the connection plate (1) to the front head using
the washers (6) and screws (3). Tighten the
screws (3) to a torque of 90 Nm (65 lbf.ft).
Change the seal washer (7) if it is damaged.
1250 0027 38

Fit the nipple (2) to the connection plate, and


tighten to a torque of 300 Nm (220 lbf.ft).
Connect the flushing hose (5) and tighten the coup-
ling nut.
After assembly, check that air and lubricating oil
come out of the hole in the front head and also be-
tween the shank adapter and the front guide.

14
Slinging
1250 0027 40

Make sure that the rock drill is safely slung for


lifting. Make sure that the rock drill is securely
anchored for transportation.

CAUTION
· Lifting gear and slings must be approved Rock drill weights, approx.
for a weight of 500 kg (1100 lbs).
COP 1638 . . . . . . 170 kg (375 lbs)
Faulty lifting gear can cause the rock drill
to move unpredictably or drop.
Incorrect handling can result in crush
injuries.

Long-term storage
If the rock drill is not going to be used for a long
time, the following precautions should be taken:

· Check that all connections, including the one for


the flushing medium, are properly plugged or
capped. Use clean protective plugs or caps of
the right size.
· Clean the rock drill thoroughly. Use a degre-
asing agent and hose down the rock drill with wa-
ter.
· Thoroughly clean the front head parts that are in
contact with the flushing medium, especially in
the case of high air humidity. After cleaning, oil
the parts with clean hydraulic oil.
· Release the gas from the accumulators (see in-
structions on page 8).
· Store the rock drill in a dry place.

15
Recommended hydraulic oils and lubricants

Lubricant Recommendation

Hydraulic oil · Use a mineral-base or synthetic (polyalpha-olefin or diester based) hydraulic oil with good anti-wear, anti-rust,
anti-oxidation and foam inhibiting properties, and with good air and water separation characteristics. Choose an
oil with viscosity grade (VG) and viscosity index (VI), in accordance with the table below. An oil with a high
viscosity index is less sensitive to the effects of temperature.

Hydraulic oil temperature in tank oC ( oF) Viscosity Viscosity


Normal operating temp. Min. starting temp. Max. temp. grade VG index VI
(viscosity 25–50 cSt) (viscosity min. 1000 cSt) (ISO 3448)
+50 to +70 (122 to 158) +5 (41) 80 (176) ISO VG 100 Min. 100
+45 to +60 (113 to 140) –5 (23) 75 (167) ISO VG 68 Min. 100
+35 to +50 (95 to 122) –10 (14) 65 (149) ISO VG 46 Min. 100
+25 to +40 (77 to 104) –15 (5) 55 (131) ISO VG 32 Min. 100
+10 to +25 (50 to 77) –25 (–13) 35 (95) ISO VG 15 Min. 100

Air tool oil · Use a mineral base air tool oil.


Ambient temperature oC ( oF) Viscosity grade (ISO 3448)
–30 to 0 (–22 to +32) ISO VG 32–68
–10 to +20 (14 to 68) ISO VG 68–100
+10 to +50 (50 to 122) ISO VG 100–150

Grease · IMPORTANT! Because of the operating temperature in the rock drill gear housing (see "Lubrication of gear"),
always use a high-temperature grease containing an ashless thickening agent and additives that give
resistance to oxidation and rust. The grease should also have good resistance to water.
Grease properties NLGI-number 2 Base oil viscosity 110 cSt at 40 oC (104 oF)
Dropping point 250 oC (480 oF) Operating temp. –20 to +150 oC (–4 to 300 oF)

Printed in Sweden
Atlas Copco, 2004

16
Maintenance instructions for

Hydraulic
Rock drill COP 1638
1250 0021 33

No. 9852 1653 01

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