Service Manual
K and L Frame
Variable Motors, Cartridge Mount
powersolutions.danfoss.com
Service Manual
K and L Frame Variable Motors, Cartridge Mount
Revision history Table of revisions
Date Changed Rev
July 2017 Updated to Engineering Tomorrow 0402
April 2014 Danfoss layout DA
July 2013 add anti-cavitation valve CB
October 2010 new back page CA
November 2006 Added loop flushing valve B
July 2004 First edition A
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Contents
Introduction
Overview..............................................................................................................................................................................................4
Safety precautions............................................................................................................................................................................4
Symbols used in Danfoss literature............................................................................................................................................4
Design...................................................................................................................................................................................................6
The System circuit............................................................................................................................................................................ 6
Technical specifications
Overview..............................................................................................................................................................................................8
Features and options...................................................................................................................................................................... 8
Specifications.....................................................................................................................................................................................8
Operating parameters.................................................................................................................................................................... 8
Fluid specifications.......................................................................................................................................................................... 8
Features
Output shafts...................................................................................................................................................................................10
Controls............................................................................................................................................................................................. 10
Control orificing........................................................................................................................................................................ 10
Brake release port.......................................................................................................................................................................... 10
Pressure measurements
Required tools.................................................................................................................................................................................11
Port locations and gauge installation.....................................................................................................................................11
Initial start-up procedures
General ..............................................................................................................................................................................................12
Start-up procedure........................................................................................................................................................................12
Fluid and filter maintenance
Recommendations........................................................................................................................................................................ 13
Troubleshooting
Excessive noise and/or vibration..............................................................................................................................................14
System operating hot...................................................................................................................................................................14
Motor shifting irregularities....................................................................................................................................................... 14
Minor repair
Shaft seal replacement.................................................................................................................................................................15
Remove the shaft seal.............................................................................................................................................................15
Inspect the components........................................................................................................................................................15
Install the new shaft seal........................................................................................................................................................15
Loop flushing valve.......................................................................................................................................................................15
Remove the loop flushing valve..........................................................................................................................................15
Inspect the components........................................................................................................................................................16
Install the loop flushing valve.............................................................................................................................................. 16
Anti-Cavitation Valve....................................................................................................................................................................16
Remove the anti-cavitation valve.......................................................................................................................................16
Inspect the components........................................................................................................................................................17
Install the anti-cavitation valve............................................................................................................................................17
Notes
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Introduction
Overview
This manual includes information for the installation, maintenance, and minor repair of the K and L Frame
Cartridge Mount Variable Motors. The manual includes a description of the units and their individual
components, troubleshooting information, and minor repair procedures. Performing installation,
maintenance, and minor repair of K and L Frame Variable Motors according to the procedures in this
manual will not affect your warranty.
Performing minor repairs requires the unit to be removed from the vehicle/machine. Thoroughly clean
the unit before beginning maintenance, or repair activities. Since dirt and contamination are the greatest
enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially
important when changing the system filter and when removing hoses or plumbing.
A worldwide network of Danfoss Authorized Service Centers (ASCs) is available for major repairs. Major
repairs require the removal of the unit's endcap, which voids the warranty unless done by an ASC.
Danfoss ASCs are trained by the factory and certified on a regular basis. You can locate your nearest ASC
using the distributor locator at www.powersolutions.danfoss.com.
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others
from injury. Take the following general precautions whenever servicing a hydraulic system.
Warning
Unintended machine movement
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
To protect against unintended movement, secure the machine or disable / disconnect the mechanism
while servicing.
Warning
Flammable cleaning solvents
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area
where a source of ignition may be present.
Warning
Fluid under pressure
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious
injury and/or infection. This fluid may also be hot enough to cause burns. Use caution when dealing with
hydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, or
components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek
medical attention immediately if you are cut by hydraulic fluid.
Warning
Personal safety
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Symbols used in Danfoss literature
WARNING may result in injury
CAUTION may result in damage to product or property
Reusable part
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Introduction
Non-reusable part, use a new part
Non-removable item
Option – either part may exist
Superseded – parts are not interchangeable
Measurement required
Flatness specification
Parallelism specification
External hex head
Internal hex head
Torx head
O-ring boss port
Tip, helpful suggestion
Lubricate with hydraulic fluid
Apply grease / petroleum jelly
Apply locking compound
Inspect for wear or damage
Clean area or part
Be careful not to scratch or damage
Note correct orientation
Mark orientation for reinstallation
Torque specification
Press in – press fit
Pull out with tool – press fit
Cover splines with installation sleeve
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Bias spring
Servo piston
Swashplate
Output
shaft
Piston
Slipper
Cylinder
block
Endcap
Shaft
seal
Bearing
P104 161E
Valve plate
Service Manual
K and L Frame Variable Motors, Cartridge Mount
Introduction
Pressure measurement / gauge location or specification
The symbols above appear in the illustrations and text of this manual. They are intended to communicate
helpful information at the point where it is most useful to the reader. In most instances, the appearance
of the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.
Design
K and L Frame Variable Motors (KC/LC) are low to medium power, two-position axial piston motors
incorporating an integral servo piston. They are designed for operation in both open and closed circuit
applications. KC/LC motors have a cartridge style mounting configuration. The standard control is a direct
acting single line hydraulic control. The integral servo piston controls motor displacement.
The motor is spring biased to maximum displacement and hydraulically shifted to minimum
displacement. Minimum and maximum displacement can be set with fixed internal stops. The large
diameter servo piston allows smooth acceleration and deceleration with relatively large circuit orificing.
The motor is ideally configured for installations requiring compact packaging and optimized plumbing,
such as wheel ends. One face of the motor contains all hydraulic porting.
KC/LC cross section
The System circuit
The circuit below shows the KC/LC motor in a simple closed-loop hydrostatic propel application. The
motor is driven by a Series 42 medium power axial piston pump with manual displacement control.
Control pressure applied through an external control valve shifts the motor to minimum displacement;
spring force returns the motor to maximum displacement in the absence of control input.
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Servo piston
Swashplate
Output
shaft
Reservior
Check valves
w/high pressure
relief valves and
bypass plunger
Charge
pump
Cylinder
block
assembly
Pump
swashplate
Input
shaft
Servo
piston
Displacement
control spool
Filter
High loop pressure
Case pressure
Charge/low loop pressure
Control pressure
Inlet pressure
Charge relief valve
Motor
displacement
control valve
Pump control handle
and feedback linkage
Slipper
P104 250E
Service Manual
K and L Frame Variable Motors, Cartridge Mount
Introduction
System circuit diagram
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Technical specifications
Overview
Specifications and operating parameters for KC/LC motors are given here for reference.
Features and options
Mount
Motor type
Displacement
Rotation
Installation position
Porting
Output shafts
Control options
Displacement limiter
Speed sensor
Loop Flushing Valve
SAE-B (LV/KV) Cartridge (LC/KC)
Inline, axial piston, positive displacement, two-speed variable motors
L: 25, 30, or 35 cm3 [1.50, 1.83, or 2.14 in3] K: 38 or 45 cm3 [2.32 or 2.75 in3]
Bidirectional
Discretionary: Housing must always be filled with hydraulic fluid
SAE O-ring boss, axial or twin radial SAE O-ring boss, twin radial
Splined 13 or 15 tooth 16/32 pitch, 0.875 in. straight
keyed, and 1:8 taper
Single or dual line hydraulic control Single line hydraulic control
Fixed maximum and minimum displacement limiters available
Available on L Frame SAE-B motors, in development* on K frame and cartridge motors
Available
Splined 13 or 15 tooth 16/32 pitch
Specifications
Parameter Unit L25 L30 L35 K38 K45
Displacement (maximum) cm3 [in3] 25 [1.50] 30 [1.83] 35 [2.14] 38 [2.32] 45 [2.75]
Weight (cartridge and SAE-B) kg [lb] 15.4 [34]
Mass moment of inertia of rotating
components
Theoretical torque N•m/bar
2
kg•m
[slug•ft2]
[lbf•in/1000psi]
0.001666
[0.001229]
0.40
[244]
0.001582
[0.001167]
0.48
[293]
0.001530
[0.001128]
0.56
[347]
0.002326
[0.001716]
0.60
[366]
0.002286
[0.001687]
0.72
[439]
Operating parameters
Parameter Unit L25 L30 L35 K38 K45
System pressure continuous bar [psi] 210 [3045] 175 [2540] 140 [2030] 210 [3045] 175 [2540]
maximum 415 [6020] 350 [5075] 280 [4060] 415 [6020] 350 [5075]
Speed limit
(at max. disp)
Speed limit
(at min. disp)
Case pressure continuous bar [psi] 2 [29]
continuous min-1 (rpm) 3400 3500 3600 3600 3500
maximum 3950 4150 4300 4000 3900
continuous 4400 4450 4500 4650 4500
maximum 5000 5150 5300 5200 5050
maximum 6 [87]
Fluid specifications
Ratings and data are based on operation with premium petroleum-based hydraulic fluids containing
oxidation, rust, and foam inhibitors.
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K and L Frame Variable Motors, Cartridge Mount
Technical specifications
Parameter Unit Minimum Continuous Maximum
Viscosity mm2/sec (cSt) [SUS] 7
[47]
Temperature °C [°F] -40 [-40] 82 [180] 104 [220]
Cleanliness ISO 4406 Class 18/13 or better
Filtration efficiency suction filtration β
charge filtration β
=75 (β10≥1.5)
35-44
=75 (β10≥10)
15-20
12-60
[70-278]
1600
[7500]
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Features
Output shafts
KC/LC motors may have a 13 or 15 tooth shaft, 16/32 pitch, and ANSI B92.1 1970-Class 5. For dimensions,
refer to L and K Frame Variable Motors Technical Information, 520L0627.
Controls
KC/LC motors are designed to operate in two positions: maximum and minimum displacement. The
motors are spring biased to maximum displacement and hydraulically shifted to minimum displacement.
KC/LC motors can operate with a single line control only. Pressure applied at port X1 shifts the motor to
minimum displacement. Refer to the table above for control input pressure range.
Control input pressure limits
KC/LC with single line control 14 to 69 bar
Control orificing
KC/LC motors can have optional, internal, supply and drain orifices installed to regulate control response
times.
KC/LC motors rely on external valving and orificing to regulate shift speeds. You can achieve quick
acceleration (shift to min) and slow deceleration (shift to max) simply by installing an orifice in the tank
line of the external control valve.
[200 to 1000 psi]
Brake release port
KC/LC motors are equipped with a brake release port to allow access to the brake-release feature of the
gear box from the rear of the motor. This consists of a simple passage through the motor housing with a
rear-facing 7/16 in. SAE O-ring boss port. Applications using this brake release port require an O-ring to
seal the passage against the gear box.
While all motors will have the brake release port, not all gearboxes are compatible with this motor
feature. Consult your gearbox manufacturer for suitability and compatibility. If your gearbox is not
compatible with this feature, simply leave the port plugged.
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System port (B)
System port (A)
Case drain port
Brake release port
Control port (X1)
P104 249E
Service Manual
K and L Frame Variable Motors, Cartridge Mount
Pressure measurements
Required tools
The service procedures described in this manual can be performed using common mechanic's hand
tools. Special tools, if required are shown. Calibrate pressure gauges frequently to ensure accuracy. Use
snubbers to protect gauges.
Port locations and gauge installation
For economical reasons, the cartridge motor does not contain any designated gauge installation ports.
All pressure measurements can be obtained by installing tee fittings to the connections at the locations
listed in the table / drawing below. Recommended gauge sizes are also listed.
Port information
Port identifier Size Pressure obtained Gauge size, bar [psi]
X1 [0.5625]-18 UNF-2B Control signal 600 [10 000]
Case drain port [0.750]-16 PER SAE Case drain 10 [100]
A [1.0625]-12 PER SAE System pressure 600 [10 000]
B [1.0625]-12 PER SAE System pressure 600 [10 000]
Brake release port [0.4375]-20 PER SAE N/A N/A
Twin radial port locations
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Initial start-up procedures
General
Follow this procedure when starting-up a new motor installation or when restarting an installation in
which the motor has been removed.
Warning
Unintended vehicle or machine movement hazard
When using the RDM in combination with S45 open circuit pumps with LS or EPC be aware that there will
likely be motor movement as long as the engine is turning. Due to the LS-setting of the pump, a standby
pressure will remain in the system even if the normally closed control is fully energized. Lowest standby
pressures to the motor, 15-18 bar or above, may be enough to turn the RDM and has the potential to
cause injury or damage.
Prior to installing the motor, inspect for damage incurred during shipping. Make certain all system
components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.
Start-up procedure
1. Fill the reservoir with recommended hydraulic fluid. Always filter fluid through a 10 micron filter
when pouring into the reservoir. Never reuse hydraulic fluid.
2. Fill the inlet line leading from the pump to the reservoir. Check the inlet line for properly tightened
fittings and be certain it is free of restrictions and air leaks.
3. Fill the pump and motor housing with clean hydraulic fluid. Pour filtered oil directly into the upper
most case drain port.
4. To ensure the pump and motor stay filled with oil, install case drain lines into the upper most case
drain ports.
5. Install a 0 to 35 bar [0 to 500 psi] gauge in the charge pressure gauge port of the pump to monitor
system pressure during start up.
Follow recommendations in the vehicle / machine operator's manual for prime mover start up
procedures.
6. While watching the pressure gauge, jog the prime mover or run at the lowest possible speed until
system pressure builds to normal levels (minimum 11 bar [160 psi]). Once system pressure is
established, increase to full operating speed. If system pressure is not maintained, shut down the
prime mover, determine cause, and take corrective action. Refer to Troubleshooting on page 14.
7. Operate the hydraulic system for at least fifteen minutes under light load conditions.
8. Check and adjust pump control settings as necessary after installation.
9. Shut down the prime mover and remove the pressure gauge. Replace plug at the charge pressure
gauge port.
10. Check the fluid level in the reservoir; add clean filtered fluid if necessary.
The motor is now ready for operation.
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K and L Frame Variable Motors, Cartridge Mount
Fluid and filter maintenance
Recommendations
To ensure optimum life of these motors, perform regular maintenance of the fluid and filter.
Contaminated fluid is the main cause of unit failure. Take care to maintain fluid cleanliness when
servicing.
Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Fluid
contaminated by water may appear cloudy or milky or free water may settle in the bottom of the
reservoir. Rancid odor indicates the fluid has been exposed to excessive heat. Change the fluid
immediately if these conditions occur. Correct the problem immediately.
Change the fluid and filter per the vehicle / machine manufacturer's recommendations or at these
intervals:
Fluid and filter change interval
Reservoir type Max oil change interval
Sealed 2000 hours
Breather 500 hours
Change the fluid more frequently if it becomes contaminated with foreign matter (dirt, water, grease,
etc.) or if the fluid is subjected to temperature levels greater that the recommended maximum.
Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid.
Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to
change the filter. Replace all fluid lost during filter change.
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Troubleshooting
Excessive noise and/or vibration
Item Description Action
Check oil level in reservoir
and oil supply to the motor.
Check for air in the system. Air trapped within the system lines, or the motor itself,
Inspect the output shaft
couplings.
Inspect the output shaft
alignment.
Hydraulic oil viscosity above
limits.
System operating hot
Item Description Action
Check oil level in reservoir
and oil supply to the pump.
Inspect the heat exchanger,
(if so equipped).
Check the system relief
valves.
Insufficient hydraulic fluid could lead to cavitation that
would cause system noise.
could result in cavitation that would cause system noise.
A loose or incorrect shaft coupling will produce vibrations
that could result in system noise.
Misaligned shafts create excessive frictional vibration that
could result in system noise.
Viscosity above acceptable limits will result in cavitation
that would lead to system noise.
Insufficient amount of hydraulic fluid will not meet the
cooling demands of the system.
If the heat exchanger fails, or becomes obstructed, it may
not meet the cooling demands of the system.
If a system relief valve becomes unseated for an extended
period of time or fails for any other reason, the system
could become overheated.
Fill the reservoir to the proper level and ensure that oil
supply to the motor is adequate and the lines are
unobstructed.
Ensure that all of the system lines and components are
purged of air.
Ensure that the correct coupling is used and that it fits
properly onto the shaft.
Ensure that the shafts are properly aligned.
Replace hydraulic oil with appropriate fluid for operating
conditions. Refer to publication 5200L0463 for information
on fluid selection.
Fill the reservoir to the proper level.
Ensure that heat exchanger is receiving adequate air flow
and that the heat exchanger is in good operating
condition. Repair or replace as necessary.
Repair or replace any malfunctioning relief valves as
applicable and verify that the loads on the machine are not
excessive.
Motor shifting irregularities
Item Description Action
Check the electrical
connection and electrical
signal to the shifting valve
coil.
Check valve coil The energized valve coil is moving the valve spool. That
Check shifting pressure. Shifting pressure moves servo piston. Obstruction could
Electrical signal is needed to energize the valve coil. The
energized coil is shifting the motor.
leads to motor shifting.
result in slow or no shift conditions.
Ensure that the electrical connection between controller
valve coil is alright. Check wires and connectors. Check
electric signal. Valve coil can be energized with 12V PWMsignal or directly with 12V.
Measure valve coil resistance. Value needs to be 5,3ohms
+-5%. Replace valve if resistance is differing.
Shifting pressure at full energized valve coil (1500mA)
needs to be at 20-32bar [290-464psi] or system input
pressure, whichever is lower. Replace shifting valve when
measured pressure is differing.
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B002
M004
dM003
p
b
i
P104 251
Service Manual
K and L Frame Variable Motors, Cartridge Mount
Minor repair
Shaft seal replacement
Remove the shaft seal
1. Remove the snap ring (B002) retaining the shaft seal and support washer.
2. Remove the support washer (M004).
3. Carefully pry out the shaft seal (M003).
To avoid damaging the shaft during removal, install a large sheet metal screw into the chuck of a slide
hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal.
4. Discard the seal.
Inspect the components
Inspect the new seal, the motor housing seal bore, and the sealing area on the shaft for rust, wear,
and contamination. Polish the shaft and clean the housing if necessary.
Replacing the shaft seal
Install the new shaft seal
1. Cover the shaft splines with an installation sleeve to protect the shaft seal during installation.
2. Install a new shaft seal (M003) with the cupped side facing the motor. Press seal into housing until it
bottoms out. Press evenly to avoid binding and damaging the seal.
3. Install seal support washer (M004).
4. Install snap ring (B002).
5. Remove the installation sleeve.
Loop flushing valve
Remove the loop flushing valve
1. Using a 11/16 in internal hex wrench remove plug (E020) and (E010).
2. Using a 1/4 in hex wrench remove plug (E042).
3. Remove O-rings (E020B, E042A, and E010B).
4. Using pliers, remove centering springs (E041, E020C, and E010C).
5. Remove spring retaining washers (E020D and E010D).
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E010
E010B
E010C
E010D
E020
E020B
E020C
E020D
E030
E042A
E042
E041
E040
P106 508E
37 N·m
[27 lbf·ft]
11/16 in
37 N·m
[27 lbf·ft]
11/16 in
27 N·m
[20 lbf·ft]
5/8 in
P108 720E
Counter-Clockwise rotation shown.
Anti-cavitation valve is installed
in port A.
E020
E020A
E011
E061
E012
E063
Service Manual
K and L Frame Variable Motors, Cartridge Mount
Minor repair
6. Remove shift spool (E030). Remove orifice poppet (E040).
Loop flushing valve
Inspect the components
Inspect sealing area for rust, wear, or contamination. Also check springs and poppet for wear.
Install the loop flushing valve
1. Install orifice poppet (E040). Install shift spool (E030).
2. Install spring retaining washers onto springs (E020D and E010D).
3. Carefully install centering springs (E041, E020C, and E010C).
4. Install new O-rings (E010B, E020B, and E042A).
5. Using a 1/4 in hex wrench torque plug (E042) to 27 N•m [20 lbf•ft].
6. Using a 11/16 in internal hex, torque plugs (E010 and E020) to 37 N•m [27 lbf•ft].
Anti-Cavitation Valve
Remove the anti-cavitation valve
The anti-cavitation valve is installed into the high pressure port. The high pressure port depends on
motor rotation. If rotation is counterclockwise, the high pressure port is A. If rotation is clockwise, the
high pressure port is B.
1. Using a 5/16 in internal hex wrench remove valve plug (E061). Remove and discard O-ring (E063).
2. Remove spring (E012) and relief valve (E011) from end cap.
3. Using a 5/16 in internal hex wrench remove plug (E020). Remove and discard O-ring (E020A).
Anti-cavitation valve
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Minor repair
Inspect the components
Inspect sealing area for rust, wear, or contamination. Check spring and relief valve for wear and
damage. Relief valve is non-serviceable, replace as complete unit if damaged.
Install the anti-cavitation valve
1. Lubricate and insert relief valve (E011) and spring (E012) in original location.
2. Lubricate and install new O-ring (E063) on valve plug (E061).
3. If needed lubricate and install new O-ring (E020A) on plug (E020).
4. Using a 5/16 inch internal hex wrench to install valve plug (E061) into port with relief valve (E011).
Torque to 80 N•m [59 lbf•ft].
5. If needed using a 5/16 inch internal hex wrench to install plug (E020) into port without relief valve
(E011). Torque to 80 N•m [59 lbf•ft].
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Notes
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
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Danfoss | July 2017 520L0631 | AX00000042en-US0402 | 19
Danfoss
Power Solutions GmbH & Co. OHG
Krokamp 35
D-24539 Neumünster, Germany
Phone: +49 4321 871 0
Danfoss
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DK-6430 Nordborg, Denmark
Phone: +45 7488 2222
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Phone: +86 21 3418 5200
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