Replacement Cable for Legacy Port Crane Systems

Introduction

Walk around almost any container terminal or bulk port in Australia and you'll find cranes that have been earning their keep for a very long time. Plenty of the machines moving boxes and bulk cargo today were installed ten, twenty, or even thirty years ago — and they're still going strong.

That longevity is a tribute to how well these cranes were built. The mechanical structure of a well-maintained STS or RTG crane can remain perfectly serviceable for decades. But there's a catch, and anyone who maintains older port equipment knows it well: the original cable systems rarely age as gracefully as the steel they run on.

The cables are where the trouble tends to show up first. Operators of legacy crane systems run into a familiar set of headaches:

• Obsolete cable models that are no longer in production

• Long replacement lead times when something does become available

• Spare part costs that climb year after year

• Limited or vanishing support from the original equipment manufacturer

• A steady increase in cable failures as the original installations reach the end of their life

As port modernisation accelerates across Australia and around the world, sourcing suitable replacement cables for ageing crane systems has become a genuinely critical issue — not a minor maintenance footnote, but something that can determine whether a perfectly good crane keeps working or sits idle waiting on parts.

This guide explains how to select replacement reeling cables for older port cranes while preserving the performance, safety, and reliability the original system was designed to deliver. The good news is that with the right approach, replacing an obsolete cable is often one of the most cost-effective upgrades a terminal can make.

Why Legacy Port Crane Systems Need Cable Replacement

Ageing infrastructure creates new challenges

Most of the legacy port cranes in service today came from a familiar group of major manufacturers:

• ZPMC

• Liebherr

• Konecranes

• Kalmar

• Noell

These are serious machines from serious builders, and that's precisely why they're still in service decades later. But there's an awkward mismatch built into the situation: the crane outlives its cable, and often it outlives the cable's availability too. The original cable specification that was standard when the crane was commissioned may simply no longer be readily available.

That leaves operators wrestling with a recurring set of problems:

• Cable models that have been discontinued entirely

• Sourcing that's become difficult and time-consuming

• Lead times that stretch out for months

• Replacement costs that have crept ever higher as supply tightens

The frustrating part is that none of this reflects a problem with the crane itself. The machine is fine. It's the cable supply chain that's aged out from underneath it.

Port modernisation is accelerating

At the same time, terminal operators across the country are actively modernising their equipment. The upgrade wave touches the full range of port machinery:

• RTG cranes

• STS cranes

• RMG cranes

• Ship loaders

• Stacker reclaimers

Modernisation projects vary enormously in scope, from control-system overhauls to full electrical refits. But one theme shows up again and again: replacing the outdated cabling is frequently one of the most cost-effective improvements in the whole project. A modern, properly engineered replacement cable can deliver better reliability and a longer service life than the original, often for a modest outlay relative to the cost of the crane downtime it prevents. Tackling the cables during a planned modernisation — rather than reacting to a failure later — turns a looming maintenance liability into a straightforward upgrade.

Start with a cable audit, not a purchase order

Before any replacement cable is specified or ordered, the smartest first move is to audit what's actually installed. Too many replacement projects start at the supplier's catalogue when they should start at the crane. A proper cable audit answers the questions that everything else depends on:

• Which cable types are installed on which machines, and where?

• What are the genuine electrical, mechanical, and operational ratings of each — not what the faded label says, but what the system actually requires?

• Which cables are showing signs of age, and how close are they to the end of their service life?

• Where are the original specifications documented, and where have they been lost to time?

• Which cable types in the fleet are already obsolete or heading that way?

The value of an audit is that it converts a reactive scramble into a planned program. Once you know what you've got and what condition it's in, you can prioritise replacements, group them into planned downtime windows, source the right cables in advance, and avoid the worst-case scenario — a critical cable failing with no documented spec and a multi-month lead time on a replacement. For an operator running a mixed fleet of legacy cranes from several manufacturers, a single up-to-date cable register is one of the most valuable maintenance documents you can hold.

Why the downtime maths favours proactive replacement

It helps to be clear-eyed about the economics, because they make the case for getting ahead of these replacements. The cable itself is rarely the expensive part of a failure. The real costs sit in what the failure stops:

• Crane downtime, which on a working berth can run into thousands of dollars an hour in lost throughput

• Emergency sourcing, where an obsolete cable has to be found and shipped at speed, often at a premium

• Labour to de-rig and re-rig, frequently at after-hours or call-out rates

• Schedule disruption — vessels that can't be worked to plan, with the costs flowing down the supply chain

• Collateral damage if a failing cable harms the reel, drum, or adjacent equipment

Set against all of that, the cost of a planned replacement — the right cable, sourced in advance, fitted during arranged downtime — is modest and predictable. This asymmetry is the single strongest argument for treating legacy cable replacement as a planned program rather than a series of emergencies. The operators who get this right replace cables on their own schedule; the ones who don't end up replacing them on the cable's schedule, which is always the worst possible time.

Common Legacy Crane Manufacturers and Their Original Cable Types

Knowing which cables came on which machines is the first step in any replacement project. Here's how the major manufacturers map to the legacy cable types you're likely to encounter.

ZPMC crane systems

ZPMC is one of the most prolific crane builders in the world, and its machines are everywhere. Typical equipment includes ship-to-shore cranes, RTG cranes, and RMG cranes.

The common legacy cable types on ZPMC equipment are NSHTOEU and NTSCGEWOEU. These cables have been used extensively in container terminals across Asia, Australia, the Middle East, and South America — which means if you're running ZPMC cranes, there's a good chance one or both of these is somewhere on your machines.

Liebherr port equipment

Liebherr's port range typically covers ship loaders, ship unloaders, and stacker reclaimers — the heavy bulk-handling end of the business.

The common cable types here are Festoonflex and Trommelflex, reflecting the festoon and drum-reel systems these machines rely on.

Konecranes systems

Konecranes equipment commonly includes RTG cranes and STS cranes, and the typical legacy cable types are N3GRD5G and NSHTOEU.

Kalmar equipment

Kalmar's port machinery typically covers RTG cranes and RMG cranes, with N3GRD5G and Festoonflex among the common cable types.

Noell systems

Noell equipment is often found in ship loading and bulk material handling roles, with NSHTOEU and NTSCGEWOEU as the typical legacy cable types — the same heavy-duty constructions that appear across so much of this equipment.

The pattern across all five manufacturers is clear: a relatively small family of cable types — NSHTOEU, NTSCGEWOEU, N3GRD5G, Festoonflex, and Trommelflex — accounts for the great majority of what's installed on legacy port cranes. That's actually encouraging news, because it means a focused replacement strategy can cover a very large share of the installed base.

Obsolete Cable Types Frequently Encountered in Port Upgrades

Let's look more closely at the specific cable types you'll meet most often when modernising older equipment, and what they were built to do.

Before the detail, it's worth understanding why these cables go obsolete in the first place, because it explains the sourcing difficulty operators run into. Cable obsolescence rarely happens because a cable was bad. It happens for ordinary commercial reasons: manufacturers rationalise their ranges, retire older constructions in favour of newer designs, consolidate after mergers, or simply stop making low-volume legacy lines that no longer justify a production run. Materials and standards evolve too, and a construction that was current twenty years ago may no longer align with how cables are built today. None of this reflects on the crane, which carries on working — but it does mean the operator is left holding equipment whose original consumable spec has quietly disappeared from the catalogue. That gap between a long-lived crane and a discontinued cable is exactly the problem this guide exists to solve.

NSHTOEU

NSHTOEU is a heavy-duty reeling cable, built for the most demanding drum-reel applications. Typical ratings include 0.6/1 kV at conductor sizes of 95 mm², 120 mm², and 150 mm².

You'll commonly find it on STS cranes, RTG cranes, and bulk handling equipment. It's one of the workhorses of the legacy port world — and, not coincidentally, one of the cables operators most frequently report difficulty sourcing in its original specification.

NTSCGEWOEU

NTSCGEWOEU is a high-flex reeling cable, with typical ratings again at 0.6/1 kV and conductor sizes of 95 mm², 120 mm², and 150 mm². Historically it's been used in heavy-duty crane systems where flexibility under repeated winding was the priority. Like NSHTOEU, it's increasingly hard to source in its original form.

N3GRD5G

N3GRD5G is a port crane reel-system cable that's especially common on Konecranes, Kalmar, and European-built cranes. If your equipment came from a European manufacturer, there's a strong chance this is the construction you're dealing with.

Festoonflex

Festoonflex is, as the name suggests, a festoon cable system — used where cable is suspended and gathered along a track rather than wound on a drum. It's commonly found on container cranes, yard cranes, and material handling systems. Many operators are now taking the opportunity to upgrade from older Festoonflex installations to newer, higher-performance alternatives during modernisation.

The common thread is that all of these cables were excellent in their day and many are simply reaching the end of both their service life and their commercial availability. The task isn't to mourn them — it's to replace them with modern constructions that match or exceed what they originally delivered.

How to Select the Correct Replacement Cable

This is the heart of the matter, and it's where care pays off. Replacing a legacy crane cable is not a matter of finding something that looks similar and bolting it on. It's a systematic matching exercise across electrical, mechanical, and operational parameters. Here's a step-by-step approach.

Step 1: Match the voltage rating

Start with voltage, because it's non-negotiable. The replacement cable must meet or exceed the original voltage rating — full stop. Common ratings you'll encounter include:

• 0.6/1 kV

• 3.6/6 kV

• 6/10 kV

• 8.7/15 kV

• 12/20 kV

The cardinal rule here is simple: voltage rating should never be reduced during replacement. Going down even one step compromises safety and compliance, regardless of any other apparent advantage. Match it or exceed it, always.

Step 2: Match the conductor size

Next, match the conductor cross-section. Common sizes in legacy port cables are 95 mm², 120 mm², and 150 mm². The replacement should use the same conductor cross-section — or larger where the application warrants it. Under-sizing the conductor risks overheating and voltage drop, so this is another parameter where you match or exceed, never reduce.

Step 3: Verify conductor construction

Voltage and size tell you the cable can carry the load, but for reeling duty you also need the right kind of conductor. Dynamic applications — anything that winds, unwinds, and flexes repeatedly — demand fine-stranded conductors. The recommended classes are:

• Class 5 conductors

• Class 6 conductors

These higher classes use many fine wires to make up each conductor, and the benefits for crane cables are direct: better flexibility, reduced conductor fatigue, and longer service life. A coarser, more rigid conductor won't survive the cycle count a reeling application puts it through, so confirming the construction class is essential — not just the headline size.

Step 4: Confirm the bend radius

Every cable has a minimum bend radius it can tolerate, and for these reeling cables the typical requirement is 6 × the cable diameter. This limit has to be respected throughout both installation and operation. Push the cable tighter than its rated bend radius and you risk:

• Core breakage

• Shield damage

• Reduced service life

It's worth checking that the existing reel and guide geometry actually respects the replacement cable's bend radius, because a cable that's a fine electrical match can still fail prematurely if the mechanical installation forces it into too tight a bend.

Step 5: Check torsional performance

Reeling cables twist as they wind and unwind, and a cable that can't handle that torsion will eventually corkscrew, kink, and fail. Modern crane cables should provide a minimum of ±50°/m torsional resistance. This matters most for:

• RTG cranes

• STS cranes

• Long-travel reel systems

Torsional performance is one of the parameters most often overlooked when people focus only on voltage and size — but on a long-travel reeling system, it can be the difference between a cable that lasts and one that fails early.

Step 6: Evaluate winding speed

Finally, the replacement cable has to suit the actual speed at which the system reels. The typical operating categories are:

• Low speed: below 100 m/min

• Medium speed: 100–180 m/min

• High speed: 180–300 m/min

A cable rated for medium-speed duty may not hold up in a high-speed application, where the cable cycles through its bends more often and under more dynamic load. Confirm the replacement is genuinely suitable for your system's real operating speed, not just its average.

Work through all six steps and you'll have a replacement that matches the original not just in appearance but in every parameter that actually governs performance. Skip steps — and especially skip the mechanical and operational ones — and you're gambling.

A note on Australian compliance

There's one more layer worth flagging for Australian operators specifically. Beyond matching the original cable's parameters, a replacement should also satisfy the relevant Australian requirements for the installation. Reeling and crane cables used in Australian ports should comply with the applicable parts of AS/NZS 5000, and the broader electrical installation has to satisfy AS/NZS 3000. Depending on the application, RCM (Regulatory Compliance Mark) and SAA certification may also be relevant. The guiding principle behind all of these is the same one that runs through Australian standards generally — the cable must be demonstrably fit for purpose in its actual operating environment. A like-for-like replacement of an obsolete cable is a good opportunity to confirm the new cable doesn't just match the old one, but also meets current Australian expectations for documentation and compliance. It's far easier to verify this during a planned replacement than to discover a gap during an audit later.

RTG Crane Retrofit Example

Why RTG upgrades often require cable replacement

RTG cranes are among the most common candidates for cable replacement, partly because so many were originally fitted with NSHTOEU or NTSCGEWOEU cables that are now reaching the end of their availability.

Typical design parameters for an RTG reel system look like this:

• Drum diameter: 600–900 mm

• Cable diameter: 27–35 mm

• D/d ratio: 17.1–33.3

• Reeling speed: up to 180 m/min

Notice the D/d ratio range dips as low as around 17 — slightly below the commonly recommended baseline of 20. That makes cable selection especially important on RTG retrofits, because a drum at the low end of that range gives the cable a tight bend on every wrap, leaving little margin for a poorly matched replacement. During retrofit projects, operators typically take the opportunity to replace ageing cables with modern constructions, improving reliability and cutting maintenance costs in one move.

RTGs are also worth singling out because they tend to work hard in mixed conditions — moving constantly around the yard rather than running a fixed cycle at the quay. That duty pattern, combined with the often-marginal D/d ratios, means RTG reeling cables generally see a tougher mechanical life than their headline specs suggest. When retrofitting, it's wise to lean toward a replacement with strong torsional resistance and fine-stranded Class 5 or Class 6 conductors rather than just meeting the minimum on paper. The modest extra margin pays for itself in a yard machine that may reel thousands of times a day, every day.

STS Crane Upgrade Example

Modernising ship-to-shore cranes

STS cranes operate under some of the highest mechanical loads found anywhere in port applications, which makes getting the replacement cable right especially critical. Typical parameters:

• Drum diameter: 700–1000 mm

• Cable diameter: 31–38 mm

• D/d ratio: 18.4–32.3

• Reeling speed: 180–210 m/min

Older STS systems frequently run NSHTOEU or N3GRD5G cables, and modern upgrades often call for higher-performance constructions to cope with the demanding duty — particularly at the upper end of that reeling-speed range, where a cable's torsional and fatigue performance is genuinely tested.

Example: Konecranes STS Monobox

The Konecranes STS Monobox is a good illustration of the demands these systems place on a cable. Typical characteristics include cable reels mounted on the middle beam, travel distances between 300 and 700 metres, and high-duty operation. Over those distances and at that duty, excellent torsional resistance and mechanical durability aren't optional extras — they're the difference between a cable that survives and one that doesn't. A replacement for this kind of application has to be chosen with those long-travel, high-duty demands front of mind. The combination of long travel and high reeling speed is unforgiving — it stresses torsional capability and fatigue resistance in a way that shorter, slower systems never do, so cutting corners on the cable specification here tends to show up quickly in service.

Comparing Available Replacement Options

When it comes to actual replacement products, there's a healthy field of modern cables suitable for legacy crane upgrades. Here's how the main options compare.

Prysmian TROMMELFLEX-M-PUR

A well-regarded modern reeling cable, with 0.6/1 kV rating, a D/d ratio capability of ≥ 20, a 6 × D bending radius, ±50°/m torsional capability, and reeling speed up to 180 m/min. It's frequently used as a replacement for older reeling cable designs.

LAPP Trommelflex PUR-HF

Another established option, rated at 0.6/1 kV with reeling speed up to 180 m/min, a D/d ratio of ≥ 20, and high flexibility. It's commonly considered for crane modernisation projects.

TKD reeling cable

Built for heavy-duty reeling applications and positioned as an alternative to older NTSCGEWOEU constructions, TKD's reeling cable is suited to demanding crane environments.

Igus Chainflex

Chainflex is designed for energy chain systems, port automation applications, and specialised cable management setups. It's worth being clear about its role: it isn't typically a direct replacement for drum reeling cables, but it may be the right choice in redesign projects where the cable management approach itself is being changed rather than just the cable.

TRATOSFLEX-ESDB®

At the higher-performance end, TRATOSFLEX-ESDB® offers reeling speed up to 300 m/min, medium-voltage options, high tensile performance, and excellent torsional resistance. It's widely used in modern automated terminals where the duty exceeds what the older constructions were designed for.

The takeaway from this comparison is that you have genuine choices. The right one depends on matching the product's capabilities to the six selection parameters covered earlier — voltage, conductor size, construction, bend radius, torsion, and speed — rather than simply picking the most familiar name on the list.

Getting the Installation Right

Specifying the correct replacement cable is most of the battle, but it isn't the whole war. Even a perfectly matched cable can fail early if it's installed badly — and on legacy equipment, where the reel system itself may have worn over the decades, installation deserves real care.

Respect the bend radius in practice, not just on paper. It's easy to confirm a 6 × D bend radius on the spec sheet and then violate it during installation through a poorly positioned guide or a tight routing decision. Check the actual installed geometry, not just the catalogue number, because a cable forced tighter than its rated bend radius will fail no matter how well it matched everything else.

Inspect the reel and drum before fitting new cable. The drum your new cable runs on has been working for as long as the crane has. Over the years, grooves wear, develop ridges or edge peening, and can drift out of their original tolerance. Fitting a brand-new cable onto a worn drum is a way to damage the new cable prematurely. Before installation, check the groove profile against specification — paying particular attention to the exit groove, where stresses concentrate — and address any significant wear. This is also the moment to confirm the drum's D/d ratio still suits the cable you've chosen.

Set the winding tension correctly. Correct tension keeps the cable seated in its groove and prevents the slack accumulation that leads to crossover and crushing. Tension systems on older cranes can drift over time, so commissioning a new cable is the right opportunity to verify and reset them rather than assuming the old settings still hold.

Check the fleet angle. On long-travel reel systems especially, structural movement and wear in guide rollers over the years can quietly push the fleet angle past its sensible limit of around 3.5°. If the geometry has shifted, the new cable will suffer the same sidewall wear the old one did. Confirm the fleet angle as part of commissioning.

Document the new installation. This closes the loop on the audit point from earlier. Record exactly what cable went where, with its full specification, so that the next person who has to replace it isn't starting from a faded label and guesswork. A legacy replacement project is the perfect moment to rebuild the documentation that time has eroded.

Treating installation as carefully as selection is what turns a good replacement cable into a long-lived one. The two go together — the best cable in the world fitted onto a worn, mis-tensioned, badly aligned reel will disappoint, while a well-matched cable fitted onto a properly prepared system will deliver the full service life it was engineered for.

How Feichun Replaces Legacy Crane Cables

Direct replacement solutions

Feichun manufactures replacement cables specifically for the legacy types this article has been discussing:

• NSHTOEU

• NTSCGEWOEU

• N3GRD5G

• Festoonflex

• Trommelflex-type applications

That coverage maps directly onto the cable families that dominate the legacy installed base — which is exactly what an operator needs when the original specification has gone obsolete.

Technical matching process

What matters in a replacement isn't just having a cable with the right name; it's a rigorous matching process. Feichun evaluates the full set of parameters that determine whether a replacement will actually perform:

• Voltage rating

• Conductor size

• Reel design

• Drum diameter

• D/d ratio

• Torsional requirements

• Tensile loading

• Operating speed

This is precisely the systematic, parameter-by-parameter approach that distinguishes a sound replacement from a risky like-for-like guess. The goal is a cable that matches or exceeds the original's performance across every dimension, not just the obvious ones.

Advantages for port operators

Compared with many international brands, Feichun can typically offer:

• OEM replacement solutions

• Customised constructions for non-standard requirements

• Shorter lead times

• Competitive pricing

• Engineering support through the selection process

• Complete technical documentation

For operators facing the long lead times and high costs that make legacy cable sourcing so painful, shorter delivery and engineering support address the two problems that hurt most.

Typical applications

Feichun replacement cables suit the full range of legacy equipment:

• ZPMC cranes

• Konecranes systems

• Kalmar equipment

• Liebherr machines

• Noell bulk handling equipment

• STS cranes

• RTG cranes

• RMG cranes

• Ship loaders

• Stacker reclaimers

As always, the sensible approach for any operator is to apply the full six-step selection process to any proposed replacement — Feichun's included — and confirm that every parameter genuinely matches the original system before committing.

Common Mistakes When Replacing Legacy Crane Cables

It's worth being blunt about the errors that catch operators out, because they're common and they're costly. The fundamental mistake is replacing a cable based on the wrong things. Never select a replacement on the basis of:

• Outer diameter alone

• Part number similarity

• Price

Each of these is a trap. A cable with the same outer diameter can have entirely different conductor construction, voltage rating, or torsional capability. A similar-looking part number can hide significant specification differences. And the lowest price means nothing if the cable fails early or doesn't suit the duty.

Instead, always verify the full set of parameters before committing:

• ✔ Voltage rating

• ✔ Conductor cross-section

• ✔ Torsional performance

• ✔ Bending radius

• ✔ Reel geometry

• ✔ D/d ratio

• ✔ Tensile loading

• ✔ Operating speed

If you can tick every one of these against the original system's requirements, you've done the job properly. If you can't, you're taking a gamble on a critical piece of equipment — and the cost of a wrong replacement failing in service far outweighs the effort of checking these eight items up front.

Frequently Asked Questions

Can I just match the outer diameter and part number of the old cable?

No — and this is the single most common and most costly mistake. Two cables can share an outer diameter or a similar part number while differing significantly in voltage rating, conductor construction, or torsional capability. Always verify the full set of electrical, mechanical, and operational parameters rather than relying on appearance or part-number resemblance.

What's the most overlooked parameter when replacing crane cables?

Torsional performance, closely followed by bend radius. People naturally focus on voltage and conductor size because they're the obvious electrical specs, but on a reeling or long-travel system, a cable that can't handle the twisting loads will fail early regardless of how well it matches on voltage. Aim for at least ±50°/m torsional resistance on demanding reeling applications.

My original cable model has been discontinued. Am I stuck?

Not at all. The fact that an original model is obsolete doesn't mean you can't get an equivalent. Modern replacement cables can be matched to the original's full parameter set — voltage, conductor size and class, bend radius, torsion, D/d ratio, tensile loading, and speed — to meet or exceed the original performance. The discontinued model is a sourcing problem, not an engineering dead end.

Is it worth upgrading to a higher-performance cable rather than matching like-for-like?

Often, yes. Modernisation is a good opportunity to move to a cable that exceeds the original spec — for example, better torsional resistance or a higher speed rating — provided it still satisfies every parameter the system requires. Just be sure any "upgrade" genuinely matches or exceeds the original on every dimension, never trading one capability away for another.

Should I replace cables during a planned upgrade or wait until they fail?

Replacing ageing cables during a planned modernisation is almost always better than waiting for a failure. A planned replacement happens on your schedule, during arranged downtime, with the right cable sourced in advance. A failure happens at the worst possible moment, forces a rushed sourcing decision, and brings unplanned downtime with it. For legacy cables nearing the end of their life, proactive replacement is the lower-risk, lower-cost path.

Why are lead times such a big issue for legacy crane cables specifically?

Because the original specifications are often discontinued, and the international brands that still make comparable cables can have long production lead times. For an operator with a crane down and limited inventory, a multi-month wait is a serious operational problem — which is why shorter lead times from capable alternative manufacturers are so valuable in legacy replacement situations.

Conclusion

Replacing an obsolete crane cable takes more than finding something that looks the part. A cable that matches the original's appearance but falls short on voltage, conductor construction, torsional performance, or any of the other key parameters isn't a replacement — it's a future failure waiting to happen.

Successful modernisation projects rest on a disciplined approach: match the electrical, mechanical, and operational requirements of the original system, while taking the opportunity to bring in the benefits of modern cable technology. Work methodically through voltage, conductor size and class, bend radius, torsion, reel geometry, D/d ratio, tensile loading, and operating speed, and you'll end up with a replacement that performs as well as — or better than — the original ever did.

For operators upgrading ZPMC, Konecranes, Kalmar, Liebherr, and Noell equipment, properly engineered replacement cables can meaningfully improve reliability, cut downtime, and extend the working life of critical port assets that are otherwise still perfectly capable. The crane itself often has plenty of years left in it; getting the cable right is how you unlock them.

Feichun provides engineered replacement solutions for legacy crane systems, helping ports modernise ageing infrastructure without the cost and delay that come with chasing obsolete cable models. Whatever supplier an operator chooses, the principle holds: match every parameter, verify before you commit, and treat the replacement cable as the engineered component it is — not as a commodity to be bought on diameter and price.

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