Professional Documents
Culture Documents
BULLETIN
Current situation
Reports have been received of pressure
loss from accumulators on the CLU4
cylinder lubricating module.
Problem
Pressure loss in the accumulator leads to
damage of the accumulator membrane,
which in turn might influence the
performance of the cylinder lubrication.
Solutions
Check regularly the pre-charge pressure
of the accumulator.
Introduction of a new filling device.
Note 1
The lubricating system with the CLU4-C
pulse lubricating module is excluded from
this bulletin, except point 3.2. For details
on the CLU4-C lubricating module, please
consult the Operating and Maintenance
Manuals, Group 7, Chapter 7218-1.
Note 2
This Technical Bulletin Issue 2 supersedes
Technical Bulletin RT-110 Issue 1, dated
31.05.2011.
Chapter 3.3 and 3.4 were updated to
include also checking of old type
accumulators and the accumulator on the
pressure reducing valve, if applicable.
In addition, a new chapter was added, i.e.
3.10 “CLU4 lubricating module – screw
plug and non-return valve”.
Contents
Page
1 Introduction 2
2 New accumulator filling device 4
3 Lubricating module and accumulator maintenance 4
4 Ordering of spare parts 19
5 Abbreviations 21
6 Appendix 21
7 Contacts 21
1 Introduction
Note:
This Technical Bulletin supersedes Technical Bulletin RT-110, Issue 1, dated
31.05.2011. Chapter 3.3 and 3.4 were updated to include also information about
checking of old type accumulators and the accumulator on the pressure reducing
valve. In addition, a new chapter was added, i.e. 3.10 “CLU4 lubricating module –
screw plug and non-return valve”.
On several engines with the CLU4 Pulse Lubricating System – see Figure 1 – a
significant loss of nitrogen was detected in the accumulator. This pressure loss
may result in a damaged accumulator membrane, irrespectively of the Pulse
Lubricating System (PLS) or the retrofit version (RPLS).
The pulse lubricating module CLU4-C, with the smaller type of accumulator, is
not affected and thus is not part of the improvements as described hereafter.
For the identification of the pulse lubricating module, please refer to Figure 2.
2 1
3 6 4 3
• Module CLU4:
On the first generation of the lubricating module, the accumulator is mounted
horizontally.
• Module CLU4-C:
The second generation of the lubricating module is more compact. The
accumulator is mounted vertically and is smaller compared to the previous
CLU4 module.
1 4
2 3 5 6
Note:
Wärtsilä recommends replacing the former accumulators with the accumulator
incorporating the new filling valve.
The new accumulator can only be filled with the tool 94720c – see chapter 3.3 –
or with the coupling & short hose 94720a-R to the former filling tool – see
chapter 3.6. For ordering the parts please refer to chapter 4.
2 1
Note:
For checking or filling the pre-charge pressure of the accumulator Wärtsilä
strongly advises to use the tool kit No. 94720c.
2 3 4
1. Complete tool kit No. 94720c, 2. Control unit, 3. Hose – length 1 m and 4 m,
4. Pressure reducing valve
Fig. 4
TECHNICAL BULLETIN RT-110
Issue 2, Page 6 / 22
In case of using the filling equipment No. 94720c (as shown in Figure 4) for
checking and/or filling an accumulator of the former design with an M28x1.5
connection, Wärtsilä provides an adapter for this set-up, see Figure 5.
The adapter has to be mounted permanently at each accumulator filling
connection, which means for each accumulator one adapter is required.
Before connecting the adapter No. 94720b-R, release the pressure of the
complete system. Afterwards release the nitrogen pressure of the accumulator.
To release the nitrogen pressure, slowly loosen the hexagon screw at the
nitrogen filling connection (filling screw) by two to three turns until the pressure is
fully released.
After the nitrogen pressure is fully released, the hexagon screw (filling screw) has
to be removed. The hexagon screw must not be reinstalled because the adapter
includes a check valve.
Warning:
Before starting with any maintenance work on pressurised systems, the pressure
must be completely released, see Maintenance Manual Group 0,
Chapter 0011-1, “Safety measures and warnings”.
Risk of injury: Always wear gloves when working on hot components and safety
goggles when working with hot fluids and compressed air.
TECHNICAL BULLETIN RT-110
Issue 2, Page 7 / 22
In order to release the remaining servo oil pressure, please follow the below
preparation either for RTA or RT-flex engines with the CLU4 cylinder lubricating
system.
Note:
Shut-off valve SV2 must remain open during the entire checking and/or refilling
procedure.
2 3 1
Note:
Screw plug (13) must remain open during the entire checking and/or refilling
procedure.
8.06
4.11
4.30–5 PI2041L
13
8.11–1
1 2
1. Stop valve: 4.30–5, 2. Servo oil rail: 4.11, 3. Pressure reducing valve: 8.11–1,
13. Screw plug
Fig. 7
Remark:
Quoted numbers in the control diagram Figure 7 correspond with the numbers as
used in the Maintenance Manual Group 7, Chapter 7218-1 and in the Operating
Manual Group 4, Chapter 4003-2 as well as in Group 7, Chapter 7218-1.
TECHNICAL BULLETIN RT-110
Issue 2, Page 9 / 22
Depending on the engine type and cylinder configuration one or two pressure
reducing valves with respective accumulators are installed. The location of the
pressure reducing valve depends again on the engine type, see example in
Figure 8.
Note:
The pre-charge pressure is the same as on the accumulator of the lubricating
module CLU4, i.e. 25 bar.
4 3
FREE
END
1. Stop valve: 4.30–5, 2. Servo oil rail: 4.11, 3. Pressure reducing valve: 8.11–1,
4. Accumulator
Fig. 8
TECHNICAL BULLETIN RT-110
Issue 2, Page 10 / 22
14
4a C 5 B A 4
For the below work procedure, the accumulator does not have to be
disconnected from the lubricating module.
Note:
During every check a small amount of gas may be lost to atmosphere. Therefore,
in order to make up possible losses make sure a nitrogen bottle is available
before a pre-charge pressure check is made.
Remark:
The accumulator may only be filled with super-clean, Class 4.0 nitrogen,
99.99% N2 by volume.
6. Connect pressure reducing valve (3) to nitrogen bottle (14), see Figure 9.
7. Connect pressure reducing valve (3) to the control unit (5) at valve (C) using
long hose (4a) and adjust the outlet pressure to approx. 30 bar.
8. Close the three valves (A), (B) and (C) on the control unit (5).
9. Open valve (A) and read pressure from gauge (7).
10. Slowly open valve (C) and refill the accumulator (1) to the required pressure
of 25 bar.
11. Close valve (A) and (C) and vent the remaining pressure in control unit (5) by
opening valve (B).
12. Disconnect the hoses (4) and (4a), remove the tools and refit all protection
caps.
13. Perform the final assembly, please refer to chapter 3.8.
3.6 Checking and refilling the gas pre-charge pressure with former filling tool
This instruction for checking and refilling with the former filling tool No. 94720 is
an alternative method to the procedure described in chapter 3.5. However, the
use of the tool No. 94720 directly from the gas bottle without a pressure reducing
valve is not recommended.
Note:
Wärtsilä does not recommend checking and refilling the accumulator without a
pressure reducing valve.
For checking and refilling the pre-charge pressure using the former tool, a
coupling with a short hose is needed. Please refer to chapter 4 for ordering the
coupling & short hose.
3
8
1
9 4 7 5 5
For the below work procedure, the accumulator does not have to be
disconnected from the lubricating module.
Note:
During every check a small amount of gas may be lost to atmosphere. Therefore,
in order to make up possible losses make sure a nitrogen bottle is available
before a pre-charge pressure check is made.
Remark:
The accumulator may only be filled with super-clean, Class 4.0 nitrogen,
99.99% N2 by volume.
7. Very slowly open the valve on the nitrogen bottle and quickly close it again
as soon as the gauge shows a pressure between 25 and 30 bar. The
complete system, including the gas chamber of the accumulator, is now
pressurised with the specified pressure.
8. If the maximum filling pressure is exceeded, it can be adjusted to 25 bar by
means of the relief valve (7) at the filling and testing valve (3), see Figure 10.
9. Firmly close the valve on the nitrogen bottle and carefully remove the
connector (8) from the accumulator (1). The filling plug closes automatically
when removing the connector (8).
10. Refit the protection cap (2) to the filling port on the accumulator (1).
11. Release the remaining pressure from the hose by opening the relief
valve (7).
12. Remove the complete pressure equipment and perform the final assembly.
Please refer also to chapter 3.8.
TECHNICAL BULLETIN RT-110
Issue 2, Page 13 / 22
Note:
The maintenance of electrical connections should be performed every six
months.
Attention:
To avoid electrical shock or possibility of fire, disconnect power to any system
before applying conductive lubricant. Ensure positive and negative contacts
remain isolated. Working on a “live circuit” can result in shorting, arcing, or shock.
2 1
• On RT-flex engines:
− Reopen stop valve 4.30–5 on servo oil rail 4.11, see Figure 7.
− Close screw plug (13) of pressure reducing valve 8.11–1, see Figure 7.
After checking the pressure and refilling the accumulator, ensure to run the servo
oil supply system and vent air from the system before putting the Pulse
Lubricating System into operation. See also chapter 3.9 “Venting the lubricating
pump”.
• Required tools:
− Oil collection tray.
− Cloth to wipe up escaping oil.
• Proceed as follows to vent the lubricating oil section of the lubricating pump:
Attention:
Pressurised oil system.
The servo oil system is under high pressure. Oil may spurt out when you loosen
the screws. Wear safety goggles. Do not loosen the vent plug more than three
turns.
• Proceed as follows to vent the servo oil section of the lubricating pump:
1 2
1. If the non-return valve is leaking and the oil is drained back to the return line,
it could lead to following indications and/or alarms:
Note:
In case the pressure in the leakage line is above 10 bar.
Note:
In case the pressure is below 40 bar with 3 second delay; this alarm is
suppressed at engine stand still.
1.b For lubricating systems controlled by stand-alone unit E40, valid mostly for
PLS and RPLS installations
Due to the lower servo oil pressure the “Deadtime” could as well become
quite long as the lubricating module piston moves slowly. In case the
“Deadtime” reaches 60 ms or more until 10 bar is reached, the alarm
“Lubrication Deadtime MAX Limited Module #[T]” will be shown in flexView.
3. In case the non-return valve is loose (but does not rotate out of position), it
could lead as well to leakage of servo oil. As a result, this might lead to the
same indications and/or alarms as described under point 1.
4. If the non-return valve rotates out, the servo oil supply channel to the
solenoid valve might have a “flow” restriction of servo oil which can lead to
the same phenomenon as described under point 1.
5. In case debris, i.e. particles from the non-return valve spring or other parts
enter into the solenoid valve and in a worst case into the lubricating module
itself, this can lead to same alarms as described under point 1.
3.10.2 Solution
The solution to solve the problem of improperly mounted or loose non-return
valves is already available since 2007/2008. The solution was partly
communicated by SKF with the document “Vogel, 951-130-328-US”, see
Appendix 1.
TECHNICAL BULLETIN RT-110
Issue 2, Page 18 / 22
1 2
3 4
1. Old non-return valve, 2. New non-return valve, 3. Old screw plug, 4. New
screw plug, 5. Ring
Fig. 13
Attention:
It is recommended to modify all affected CLU4 lubricating modules including the
spares. The modification with the new screw plug and non-return valve is also
part of the Wärtsilä remanufacturing service for CLU4 lubricating modules.
Please contact your Wärtsilä representative for more details about Wärtsilä
component remanufacturing services.
TECHNICAL BULLETIN RT-110
Issue 2, Page 19 / 22
3 4
Table 1
The improved accumulator can be ordered through Wärtsilä by quoting the spare
part code number, see also remark below.
Code number of accumulator:
• For RTA engines: D 96369
• For RT-flex engines: DF 96369
TECHNICAL BULLETIN RT-110
Issue 2, Page 20 / 22
Remark:
Designation of Spare Part Code Number: X 12345 or XF 12345.
“X” = Given letter depending on the engine bore size and type – please consult
your Spare Part Code Book.
Letter “F” is the indication for RT-flex engines.
e.g., in this Technical Bulletin spare part numbers are quoted with following
letters:
“D” for RTA96C and RTA96C-B engines
“DF” for RT-flex96C-B engines
“SP” for Service Product parts irrespective of the engine bore size and type.
Table 2
* Note:
If the former design of accumulator is used with the new filling equipment 94720c
then the adapter 94720b-R must be mounted permanently to each accumulator.
5 Abbreviations
Abbreviation Description
CLU4 Cylinder lubricating system of fourth generation
CLU4-C Cylinder lubricating system of fourth generation, with
compact lubricating module
PLS Pulse Lubricating System
RPLS Retrofit Pulse Lubricating System
Table 3
6 Appendix
Appendix 1:
Document entitled “CLU4 Check Valve Retrofitting Instructions”.
Document issued by SKF / VOGEL with document number 951-130-328-US.
7 Contacts
Field service
If you need Wärtsilä Field Service, please send your enquiry to:
Ch.Fieldservice@wartsila.com
or phone 24hrs support: +41 79 255 68 80.
Spare parts
If you need Wärtsilä spare parts and/or tools, please send you enquiry to:
ch.spareparts.wgls@wartsila.com
or phone 24hrs support: +41 52 262 24 02
TECHNICAL BULLETIN RT-110
Issue 2, Page 22 / 22
2;D#2WTRZEP[eTATca^UXccX]V8]bcadRcX^]b
Exchange of the check valve on the CLU4 cylinder lubrication pump
8]SXRPc^abdbTSfXcWbPUTchX]bcadRcX^]bP]ScWTXa =^cT
bXV]XUXRP]RT In order to conduct the retrofitting
of the check valve as described
8]SXRPc^aDbT below, it is necessary
to consult the current operating
3P]VTa SP]VTa^UQ^SX[hX]Ydah instructions for the cylinder lubri-
FPa]X]VSP]VTa^USP\PVTc^_a^_TachP]ScWTT]eXa^]\T]c cation system. Its safety instruc-
tions need to be observed.
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2;D#2WTRZEP[eTATca^UXccX]V8]bcadRcX^]b APPENDIX 1
Inhaltsverzeichnis
Fehlererkennung 2
Umbaubeschreibung der Austausch- 4aa^aXST]cXUXRPcX^]
Hubtaktpumpe 3
Austausch der Hubtaktpumpe am Zylinder 4
Note!
Umbau einer defekten Hubtaktpumpe 5 reason for the defective build-up of pressure
Faulty pressure build-up in the CLU4 cylin-
Hubtaktpumpe entlüften 6 should be ascertained.
der lubrication pump will result in marginal
Hubtaktpumpe-Schmieröl entlüften 6 cylinder lubrication, or no lubrication at all.
The following checklist should serve as a guide.
Hubtaktpumpe-Servoöl entlüften 6 This could imply, though not inevitably, a
Schmiersystem entlüften 7 malfunction due to an improperly-mounted If no cause is determined, even after following
check valve. the checklist, the following retroffiting action is
Thus, prior to disassembly of the pump, the to be carried out.
Timed lubricator not working Servo oil pressure is insufficient Check the servo oil pressure at the measurement
connector and reset to between 45 and 50 bar
4/2 directional solenoid valve defect Exchange 4/2 directional solenoid valve
Pump unit damaged Exchange pump unit
One or more lubricating quills are blocked Check the quills and replace if necessary
Position of shutoff valve(3) (5) in the base Control position of the valve - see operating instructions
plate is incorrect
Leakage between base plate and Seals between base plate and pump unit damaged Exchange seals - see operating instructions
Pump unit
Pressure build-up too slow Servo oil pressure is insufficient Check the servo oil pressure at the measurement connector
and reset to between 45 and 50 bar
Nitrogen pressure in the diaphragm Refill nitrogen (max. 25 bar)
accumulator is too low
Pressure sensor does not give Pressure sensor defect Exchange pressure sensor - operating instructions
any more signals although there Air in the lubrication feed line Vent the lubrication feed line - see operating instructions
is a change in pressure in the Servo oil pressure is insufficient Check the servo oil pressure at the measurement connector
lubricating oil exit. Oil supply is insufficient Exchange filter element - see operating instructions
Check position of shutoff valve
Pump is not supplying oil Filter supply valve is closed Open supply valve
Air in the lubrication line Vent lubrication and servo oil system
L-shutoff valve (5) closed Open valve
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161-140-050
A B
NG6 P T
operation
valve
drain
shut-off
valve (P)
service
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2;D#2WTRZEP[eTATca^UXccX]V8]bcadRcX^]b APPENDIX 1
?aT_PaPcX^])ATca^UXccX]V^UcWTTgRWP]VT_d\_aT_[PRT
\T]c_d\_
Note!
A replacement timed lubricator pump, found in the set of spare parts that is included
in the delivery, belongs to the general scope of delivery of the CLU4 timed lubricator.
The timed lubricator replacement pump is to be retrofitted prior to its mounting.
ATca^UXccX]VbTc
$ 6PbZTc ! 95-1631-7603
Fig. 1 If the mounting plate (1) is available, loosen up mounting plate screws (1) (4x), 5XV Rh[X]STa[dQaXRPcX^]_d\_
remove the mounting plate
1
Loosen up and remove the screw plugs(2) using a hexagon socket screw key (SW8)
Loosen up and carefully remove the check valve (3) from the pump housing, using a
hexagon socket screw key (SW10)
Screw in the new check valve (3) to the pump housing, and tighten with a hexagon socket
R
Made in Germany
Screw in the newscrew plug (2) with seal (5) in the pump housing, and tighten
with a torque of 50 Nm, using a hexagon socket screw key (SW8) 161-140-050
R
A B
NG6 P T
Loosen up and remove the screw plug(4) using a hexagon socket screw key (SW8) 2/5
Screw in the newscrew plug (4(identical to 2)) with seal (5) in the pump housing 4/5
and tighten with a torque of 50 Nm using a hexagon socket screw key (SW8)
Tighten the mounting plate screws (1) (4x) with a tightening torque of 50 Nm
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2;D#2WTRZEP[eTATca^UXccX]V8]bcadRcX^]b APPENDIX 1
4gRWP]VX]VcWTRh[X]STabcX\TS[dQaXRPc^a
Disassembly of the timed lubricator
Close the lubricating oil outlet (if present) - see engine manufacturer's operating
instructions
Close and release pressure on servo oil circulation - see engine manufacturer's operating R
161-140-050
Fig. 2 Slightly loosen the lubricating line screw unions (1) (up to the lubricating quills)
A B
NG6 P T
When the screw unions (1) are loosened up, back-flowing lubricating oil will discharge.
Only when no more lubricating oil escapes at the screw unions (1) should these be fully
loosened up
Fully loosen up the screw unions (1) of the lubricating lines (up to the lubricating quills)
Fig. 3 Loosen up the screw unions (2) (2x) for the servo oil circulation, the pump inlet,
and the pump outlet "P". 5XV"
5
Loosen up the screw union (3) for lubricating oil inlet "L" 6
Loosen up the screw union (4) for the tank return "T" 3
drain off the lubricating oil and servo oil found in the timed lubricator
L
4
T
Loosen up the screws (4x) for mounting plate (5), carefully remove the mounting plate
operation
valve
drain
Loosen up the screws (4x) found on the back side of the mounting plate (5), that are used
to affix the timed lubricator (6), and remove together with the mounting plate
Set aside the mounting plate (5) with the old timed lubricator (6), affix the mounting plate
to the new replacement pump if needed, and tighten with a torque of 50 Nm
Place the mounting plate (5) (with timed lubricator) in the earlier mounting position and
affix with screws (4x)
Position the lubricating line's screws (1) on the timed lubricator and sturdily tighten
without a tool
Position and tighten the screw unions (2) (2x) for the servo oil circulation, pump inlet "P"
and pump outlet "P" on the timed lubricator
Position and tighten the screw union (3) for lubricating oil inlet "L" and (4) for tank return
"T" at the timed lubricator
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2;D#2WTRZEP[eTATca^UXccX]V8]bcadRcX^]b APPENDIX 1
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5XV#
Attention!
If a check valve (8) is damaged, the servo channels must be inspected and cleaned prior to installa-
tion of a new valve. This is to be conducted as described below.
12
Fig. 4 Loosen up and remove the test connection (9) or, optionally, the mounted screw
plug
R
Made in Germany
Loosen up the hexagon socket screws (4x) (SW4) (10) and remove the directional control 11
valve (11) 10
R
161-140-050
The following inspection of the control channels is to be conducted using a piece of wire 8
A B
NG6 P T
(max. ø 2 mm). 7
13
Inspect the control channel between the test connection and directional control valve, vi
sually and with the wire piece, for any foreign matter. If necessary, remove foreign matter 9
with the wire. After, blow some pressurized air through the control channel to clean it.
Clean the flanging surface of the base plate (12) as well as the directional solenoid valve (11)
Place the directional solenoid valve (11) on the base plate (12) and tighten using hexagon 5XV$
socket screws (4x) (SW4) ((12) using a torque of 5 Nm 7
Screw in the new check valve (8) to the pump housing, and tighten using a hexagon
socket screw key (SW8) using a torque of 50 Nm
screw in the new screw plug (7) with seal in the pump housing, and tighten with a 6 L
hexagon socket screw key (SW8), using a torque of 50 Nm
T
operation
Remove the screw plug (13) using a hexagon socket screw key (SW8), and screw in a new 4
valve
drain
screw plug(13 (identical to 7)) with seal in the pump housing, and tighten with a hexagon
shut-off
valve (P)
service
Tighten the mounting plate screws (5) (4x) with a tightening torque of 50 Nm
The repaired timed lubricator is now an exchange pump ready for another pump
retrofitting.
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2;D#2WTRZEP[eTATca^UXccX]V8]bcadRcX^]b APPENDIX 1
Venting of the pump is carried out through two special venting plugs with central
boreholes. Plug "A" is for lubricating oil, plug "B" is for servo oil. By loosening up the plugs, any
air present in the timed lubricator can escape. During normal operation, the pump is
self-venting.
5XV%
Vent the lubricating oil timed lubricator
ET]cQ^aTW^[T
ET]c_[dV1
Attention! ET]c_[dV0
Control the valve positions of the timed lubricator
(see operating instructions)
Open the lubricating oil filter outlet (if present) - see engine manufacturer's operating
instructions
Fig. 6 Loosen the vent plug "A" (lubricating oil) with a max. of 3 turns in
a clockwise direction
Activate the CLU4 pulse lubrication system using manual lubrication, or using
the manual emergency activation
Loosen the vent plug "B" (servo oil) a max. of 3 turns in a counterclockwise direction
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2;D#2WTRZEP[eTATca^UXccX]V8]bcadRcX^]b APPENDIX 1
After the timed lubricator has been vented, the lubrication lines to the
quills are to be vented
5XV&
Place the oil tray under the timed lubricator 1
Fig. 7 Loosen the union nuts (1) in all lubricating quills by one turn
Activate timed lubricator electrically or manually using the manual emergency (2)
Activation of the manual emergency (2) is to be continued until bubble-free lubricating oil
discharges from the lubricating quills.
operation
Carefully tighten union nut (1) at the quill 2
valve
drain
shut-off
valve (P)
service
Repeat these steps with the remaining quills
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