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ReWork

Specifications
Repair Instructions

Rework Specifications
Revisions
History of Revisions

Table of Revisions
Date

Page

Changed

Rev.

February 2010
September 2009
July 2009
April 2009
October 2008
February 2008
June 2007
1998

10, 12
10, 13, 22
27
27
27
26, 27
-

Added LDU20, Updated Series 42


fixed typos
060 cylinder block height should be 57.65 [2.2697]
add 060cc to H1B section
add 080cc to H1B section
Add H1 pumps 115/130, Add H1B motors 110
Second edition
First edition

BG
BF
BE
BD
BC
BB
BA
A

2010 Sauer-Danfoss. All rights reserved.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and


other printed material. Sauer -Danfoss reserves the right to alter its products without
prior notice. This also applies to products already ordered, provided that such alterations
can be made without affecting agreed specifications. All trademarks in this material
are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype,
the Sauer-Danfoss S-icon, PLUS+1, What really matters is inside and Know-How in
Motion are trademarks of the Sauer-Danfoss Group.
2

520L1033 Rev BG February 2010

Rework Specifications
Contents
Introduction

Overview............................................................................................................................................................ 4
General instructions....................................................................................................................................... 4
Safety precautions.......................................................................................................................................... 5
Unintended machine movement........................................................................................................ 5
Flammable cleaning solvents................................................................................................................ 5
Fluid under pressure................................................................................................................................. 5
Personal safety............................................................................................................................................ 5
Symbols used in this manual...................................................................................................................... 6

Rework Instructions

Cylinder blocks................................................................................................................................................. 7
Pistons and slippers........................................................................................................................................ 7
Valve plate.......................................................................................................................................................... 8
Bearing plate..................................................................................................................................................... 8
Endcap................................................................................................................................................................ 9
Shaft .................................................................................................................................................................... 9
Swashplate (cradle type).............................................................................................................................. 9

Rework
Specifications

Light duty.........................................................................................................................................................10
Series 40............................................................................................................................................................11
Series 42............................................................................................................................................................12
Series 45............................................................................................................................................................13
Series 90............................................................................................................................................................14
Valve plate..................................................................................................................................................15
Series 20/Series 30........................................................................................................................................16
Cylinder block...........................................................................................................................................16
Piston assembly........................................................................................................................................17
Valve plate..................................................................................................................................................18
Thrust plate................................................................................................................................................18
Bearing plate.............................................................................................................................................19
Series 20............................................................................................................................................................20
Shaft seal identification.........................................................................................................................20
Control link identification.....................................................................................................................21
L Series..............................................................................................................................................................22
LPV . ...................................................................................................................................................................22
L&K Motors......................................................................................................................................................23
LV and LC Motors ....................................................................................................................................23
KV and KC Motors ...................................................................................................................................23
Series 51............................................................................................................................................................24
H1 078/089/100/115/130/147/165 pumps..........................................................................................25
H1 45/53 pumps............................................................................................................................................26
H1B motors......................................................................................................................................................27

520L1033 Rev BG February 2010

Rework Specifications
Introduction
Overview

This manual provides specifications for rework of service parts and assemblies. Only
Sauer-Danfoss Global Service Partners are authorized to perform rework and major
repairs. Sauer-Danfoss trains Global Service Partners and certifies facilities on a regular
basis.
W Warning
Reworking parts to dimensions outside Sauer-Danfoss specifications may reduce unit
performance to unacceptable or unsafe levels and/or cause dangerous unit and system
failure. Do not resurface valve/bearing plates, cylinder blocks, swashplates, or slippers
beyond minimum thickness requirements.
W Warning
Use of components that do not comply with rework specifications may result in loss of
performance, which may constitute a safety hazard. Do not reuse components that dont
comply to given specifications: replace with genuine Sauer-Danfoss service parts.
This manual contains proprietory information. Specifications are subject to change
without notice. This information is current, based on factory data, as of May 1, 2006.

General instructions

w Remove the unit


Prior to performing major repairs, remove the unit from the vehicle/machine. Chock
the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that
hydraulic fluid may be under high pressure and / or hot. Inspect the outside of the pump
and fittings for damage. Cap hoses after removal to prevent contamination.
e Keep it clean
Cleanliness is a primary means of assuring satisfactory pump life on either new or
repaired units. Clean the outside of the pump thoroughly before disassembly. Take care
to avoid contamination of the system ports. Cleaning parts using a clean solvent wash
and air drying is usually adequate.
As with any precision equipment, keep all parts free of foreign materials and chemicals.
Protect all exposed sealing surfaces and open cavities from damage and foreign material.
If left unattended, cover the pump with a protective layer of plastic.
l Lubricate moving parts
During assembly, coat all moving parts with clean hydraulic oil. This assures these parts
are lubricated during start-up.
d Replace all O-rings and gaskets
Sauer-Danfoss recommends you replace all O-rings. Lightly lubricate all O-rings with
clean petroleum jelly prior to assembly.
t Secure the unit
For major repair, place the unit in a stable position with the shaft pointing down. Secure
the pump/motor while removing and torquing the endcap bolts.

520L1033 Rev BG February 2010

Rework Specifications
Introduction
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.
Unintended machine movement
W Warning
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.
Flammable cleaning solvents
W Warning
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.
Fluid under pressure
W Warning
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.
Personal safety
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.

520L1033 Rev BG February 2010

Rework Specifications
Introduction
Symbols used in this
manual

WARNING may result in injury


M Measurement
Flatness specification
a Parallelism
Inspect for wear or damage
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.

520L1033 Rev BG February 2010

Rework Specifications
Rework Instructions
Cylinder blocks

Examine the running face of the cylinder


block. The surface should be smooth
and free of nicks and burrs. Ensure that
no scratches or grooves exist; these may
drastically reduce output flow and life of
pump/motor.
Cracks are not allowed on any surface of
the part. No steel may be visible through
the bronze surface of cast-on bronze
cylinder blocks. No pits, scratches, nicks
or indentations are allowed that extend
more that 50% of the width of the
sealing land surfaces. Irregularities above
the surface are not allowed.
For cylinder blocks without separate
bearing plates, refer to section Bearing
Plates (page 8) to locate the sealing land
surfaces on the cylinder block running
surface.

Pistons and slippers

Lap by hand or machine.


The maximum variance between slipper
foot thicknesses in one cylinder block
kit is 0.002 in. No pits, scratches, nicks or
indentations are allowed that extend
more than 50% of the width of the slipper
sealing land surfaces. Irregularities above
the surface are not allowed.

Inspect cylinder block


B
Cylinder
block
A

flat to 0.002 mm
[0.000079 in]

A
B
C

P101 067E

Cylinder dimensions
Block height
Maximum block bore diameter
Total cylinder block height
(series 30 and H1 only)

Inspect pistons
Maximum end play
Minimum
slipper foot
thickness

Slipper

P104 109E

If piston replacement is
required, replace all pistons
in pump or motor.

Inspect the pistons for damage and


discoloration. Discolored pistons may
indicate excessive heat; do not reuse.
Inspect the running surface of the
slippers. Replace any piston assemblies
with scored or excessively rounded
slipper edges.

520L1033 Rev BG February 2010

Rework Specifications
Rework Instructions
Valve plate

No pits, scratches, nicks, or indentations are allowed that extend more than 50% of the
width of the sealing land surfaces. Irregularities above the surface are not allowed. Cracks
are not allowed on any surface of the part. Scrap valve plates that exhibit smearing or
metal transfer on the running surface or on the running surface of the mating bearing
plate or cylinder block. Use a new valve plate for field repair if you cannot verify that the
valve plate is not cracked or softened.

Inspect valve plate

+0
6.0 +0
-0.15mm [0.24 -0.01 in]

Sealing land

Parallel
0.045 mm
[0.0018 in]
Flatness
0.001 - 0.006 mm
[0.00004 - 0.00023 in]
convex maximum

P106 113E

Bearing plate

Visually inspect for cracks at drive slot and kidneys.


On all bimetal bearing plates, in addition to a visual inspection, preform a penetrant
inspection (for example - magnetic particle inspection) to detect cracks on the bronze
surface of the plate. Scrap bearing plates that exhibit smearing or metal transfer on
the running surface or the running surface of the mating valve plate. No steel may be
visible through the bronze surface of bimetal bearing plates. No pits, scratches, nicks or
indentations are allowed that extend more than 50% of the width of the sealing land
surfaces. Irregularities above the surface are not allowed.

Inspect bearing plate


Sealing land

+0
6.0 +0
-0.15 mm [0.24 -0.01 in]
Parallel
0.045 mm
[0.0018 in]
0.001 - 0.006 mm
[0.00004 - 0.00023 in]
convex maximum

P106 399E

520L1033 Rev BG February 2010

Rework Specifications
Rework Instructions
Endcap

Inspect all machined surfaces for


scratches or pits. Carefully check the
bearing surface for wear. Inspect valve
seats carefully for wear or cracks. Replace
if damaged.

Inspect endcap

E101 342E

Shaft

Ensure the shaft and its splines are


straight and free of damage or heavy
wear. Inspect the sealing land. Replace if
the surface is grooved. Clean the sealing
area with a nonabrasive material if
necessary.

Inspect shaft

E101 329E

Swashplate (cradle
type)

Cracks are not allowed on any surface of the part.

Inspect swashplate

P106 396E

520L1033 Rev BG February 2010

Rework Specifications
Rework specifications
Model
Minimum block height

Light duty
Cylinder block

Piston assembly

Valve plate

Maximum piston bore


diameter
Flatness (TIR)
Minimum slipper foot
thickness
Maximum piston/slipper
end play
Minimum thickness
Minimum thickness
(thick valve plate)
Flatness (TIR)
Parallelism (TIR)

Thrust plate

Minimum thickness (thin


plate)
Minimum thickness (thick
plate)
Flatness
Parallelism

15
38.27
[1.507]
12.898
[0.50780]
0.001905
[0.000075]
3.175
[0.125]
0.1524
[0.006]
3.835
[0.1510]
7.137
[0.2810]
0.00381
[0.00015]
0.0254
[0.001]
NA

18
57.02
[2.245]
16.439
[0.64720]
0.001905
[0.000075]
4.064
[0.160]
0.1524
[0.006]
4.953
[0.1950]
NA

70-BD-10
34.90
[1374]
16.020
[0.6307]
0.00127
[0.000050]
NA

70-BD-21
40.77
[1.605]
17.242
[0.6788]
0.00127
[0.000050]
NA

NA

NA

NA

NA

NA

NA

0.00381
[0.00015]
0.254
[0.001]
NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

1.473
[0.058]
4.420
[0.174]
0.00508
[0.00020]
0.0508
[0.0020

2.413
[0.095]
4.928
[0.194]
0.0508
[0.0020
0.0508
[0.0020

Model

Cylinder block

Piston assembly

Valve plate

Thrust plate

Centersection gasket
mating surface
Centersection valve
plate mating surface

Minimum block height


Maximum piston bore diameter
Flatness (TIR)
Minimum slipper foot thickness
Maximum piston/slipper end play
Minimum thickness
Flatness (TIR)
Parallelism (TIR)
Minimum thickness
Flatness (TIR) housing mating surface
Flatness (TIR) slipper mating surface
Parallelism
Flatness (TIR)
Flatness (TIR)

LDU20
motor side
pump side
45.23 [1.781]
12.978 [0.511]
0.002 [0.000079]
2.748 [0.108]
0.18 [0.007]
4.97 [0.196]
0.0038 [0.00015] convex
0.025 [0.001]
3.95 [0.156]
NA
0.01 [0.0004] convex
NA
0.005 [0.0002] convex
NA
0.01 [0.0004]
NA
0.05
[0.002]
0.012
[0.0004]

Dimensions mm [in]
TIR (Total Instrument Reading)

10

520L1033 Rev BG February 2010

Rework Specifications
Rework specifications
Model

Series 40

M23

M25

M35

M44

M46

53.37
[2.101]
13.715
[0.53996]

45.19
[1.779]
14.201
[0.59910]

54.74
[2.155]
17.943
[0.70640]

62.23
[2.450]
19.797
[0.77940]

3.404
[0.134]

3.861
[0.152]

3.734
[0.147]

3.226
[0.127]

4.950
[0.1949]

3.835
[0.1510]

54.74
[2.155]
16.132
[0.6351]
0.001905
[0.000075]
3.734
[0.147]
0.1524
[0.006]
4.953
[0.1950]

4.953
[0.1950]

4.953
[0.1950]

0.0305
[0.0012]
3.990
[0.1571]
0.00508
[0.00020]
0.01016
[0.0004]
NA

0.254
[0.0010]
NA

0.00381
[0.00015]
0.0254
[0.0010]
NA

0.0254
[0.0010]
NA

0.0254
[0.0010]
NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

Flatness

NA

NA

NA

NA

Parallelism

NA

NA

NA

NA

39.27
[1.546]
0.0635
[0.0025]
0.001905
[0.000075]

Minimum block height


Cylinder block

Maximum piston bore


diameter
Flatness (TIR)

Minimum slipper foot


Piston assembly thickness
Maximum piston/slipper
end play
Minimum thickness
Flatness (TIR)
Valve plate
Parallelism (TIR)
Minimum thickness
(thin plate)
Flatness
Thrust plate
Parallelism
Minimum thickness
Swashplate

Dimensions mm [in]
TIR (Total Instrument Reading)

520L1033 Rev BG February 2010

11

Rework Specifications
Rework specifications
Series 42
Cylinder block

Model
Minimum block height

28cc

Maximum piston bore


diameter
Flatness (TIR)

14.30
[0.5630]

32cc
49.98
[1.968]
15.23
[0.5996]
0.002
[0.000079]

41cc
55.88
[2.200]
16.14
[0.6354]

51cc
55.88
[2.200]
17.98
[0.7079]

3.734
[0.147]

3.759
[0.148]

Minimum slipper foot


Piston assembly thickness
Maximum piston/slipper
end play
Minimum thickness

3.462
[0.1363]

3.86
[0.152]

3.87
[0.152]

Valve plate

0.001-0.006
[0.00004-0.000023]
0.0249
[0.00098]
28.58
25.02
[1.007]
[0.985]
0.0508
[0.002]
0.00254
[0.0001]

25.02
[0.985]

Flatness (TIR)
Parallelism (TIR)
Thickness across journals

Swashplate

Thickness equality
(side to side)
Slipper running
face flatness

0.152
[0.006]
4.97
[0.196]

Dimensions mm [in]
TIR (Total Instrument Reading)

12

520L1033 Rev BG February 2010

Rework Specifications
Rework specifications
Series 45

Dimensions mm [in]
TIR (Total Instrument Reading)
Frame

25cc

30cc

Minimum block height


Cylinder block

Maximum bore diameter

50.8
[2.000]
13.88
[0.5465]

Minimum slipper foot


thickness
Maximum piston/slipper
end play
Minimum thickness

45cc

60cc

75cc

56.48
[2.224]
15.22
[0.5992]

Flatness (TIR)

Piston assembly

38cc

2.67
[0.105]
0.102
[0.004]

62.25
[2.450]

16.44
17.98
[0.6473]
[0.7079]
0.002
[0.000079]
4.03
[0.1587]
0.102
[0.004]
3.88
[0.1528]

Flatness (TIR)

19.8
[0.7795]

21.57
[0.8492]

3.23
[0.1272]
0.05
[0.002]

0.005
[0.0002]
0.025
[0.00098]

Valve plate
Parallelism (TIR)
Minimum height

Swashplate

32.695
See Note:
[1.287]
Note: J Frame swashplate is not reworkable. Servo pads extend above surface of running face, making lapping impossible.
Positioning of servo pads is extremely important; therefore they should not be removed and re-pressed to enable lapping.

Frame

H
57cc

Minimum block height


Cylinder block

Maximum bore diameter

G
75cc

62.23
[2.450]
19.80
[0.7796]

21.57
[0.8491]

Flatness (TIR)

Piston assembly

Minimum slipper foot


thickness
Maximum piston/slipper
end play
Minimum thickness
Flatness (TIR)

Valve plate
Parallelism (TIR)
Flatness (TIR)
Swashplate
Parallelism (TIR)

3.23
[0.127]

74cc

90cc

E
100cc to 147cc
76.68
[2.712]
25.87
[1.01850]

68.88
[2.712]
21.57
22.74
[0.8491]
[0.8953]
0.002
[0.000079]
4.411
[0.1737]
0.05
[0.002]
4.950
[0.1949]

4.91
[0.1933]

0.0038
[0.00015]
0.025
[0.00098]
Note: Swashplate is not reworkable. Servo pads extend above surface
of running face, making lapping impossible.
Positioning of servo pads is extremely important; therefore they should
not be removed and re-pressed to enable lapping.

F
74cc

90cc
68.88
[2.712]

21.57
[0.8491]

22.74
[0.8953]

4.411
[0.1737]

0.0025
[0.0001]
0.0635
[0.0025]

Dimensions mm [in]
TIR (Total Instrument Reading)
520L1033 Rev BG February 2010

13

Rework Specifications
Rework specifications
Series 90

Endcap

Displacement
Flatness
Minimum block height

Cylinder block

Piston assembly

Thrust plate
(motors only)

Maximum piston bore


diameter
Flatness (TIR)
Minimum slipper foot
thickness
Maximum piston/slipper
end play
Minimum thickness

30cc
42cc
55cc
75cc
0.00254-0.00127 [0.000100-0.000500] Convex
60.05
[2.364]
15.288
[0.6019]

2.57
[0.101]

NA

Flatness

NA

Parallelism

NA

Minimum thickness

NA

Swashplate

Flatness

Endcap journal
bearing

Distance below valve


plate surface of the
endcap

64.15
70.00
[2.526]
[2.756]
17.233
18.712
[0.6786]
[0.7367]
0.0006 - 0.0026
[0.000024 - 0.000100] Convex

2.90
3.15
3.505
[0.114]
[0.124]
[0.8169]
0.1524
[0.006]
NA
5.588
5.715
[0.220]
[0.220]
NA
0.00254
[0.001]
NA
0.0127
[0.0005]
38.40
41.30
46.46
[1.512]
[1.626]
[1.829]

0.00254
[0.0001]
Thickness equality, side
0.0635
to side
[0.0025]
Inspect for wear in leveller pad areas. Excessive wear in this area may adversely affect
neutral.
21.00 - 21.49
[0.827 - 0.846]

0 - 0.51
[0 - 0.020]

Dimensions mm [in]
TIR (Total Instrument Reading)

14

77.02
[3.032]
20.749
[0.8169]

520L1033 Rev BG February 2010

Rework Specifications
Rework specifications
Series 90
(continued)

Endcap

Displacement
Flatness
Minimum block height

Cylinder block

Piston assembly

Thrust plate
(motors only)

Maximum piston bore


diameter
Flatness (TIR)
Minimum slipper foot
thickness
Maximum piston/slipper
end play
Minimum thickness
Flatness
Parallelism
Minimum thickness

Swashplate

Flatness

Endcap journal
bearing

Distance below valve


plate surface of the
endcap

100cc
130cc
180cc
250cc
0.00254-0.00127 [0.000100-0.000500] Convex
84.33
[3.320]
22.761
[0.8961]

92.55
103.20
[3.644]
[4.063]
24.897
27.729
[0.9802]
[1.097]
0.0006 - 0.0026
[0.000024 - 0.000100] Convex

3.86
[0.152]

4.216
4.724
[0.166]
[0.186]
0.1524
[0.006]
5.588
5.715
NA
[0.220]
[0.220]
0.00254
NA
[0.001]
0.0127
NA
[0.0005]
51.16
55.88
65.41
[2.014]
[2.200
[2.575]

101.29
[3.988]
30.983
[1.2202]

5.26
[0.207]

NA
NA
NA
67.54
[2.659]

0.00254
[0.0001]
Thickness equality, side
0.0635
to side
[0.0025]
Inspect for wear in leveller pad areas. Excessive wear in this area may adversely affect
neutral.
0 - 0.51
[0 - 0.020]

Dimensions mm [in]
TIR (Total Instrument Reading)
Valve plate
Series 90 valve plates are relatively low cost items. Therefore, replacement is safer and
more econical than inspection and rework.
However, if necessary, the valve plate can be re-lapped. Maintain minimum thickness and
thickness uniformity specifications.

Valve plate
Minimum thickness 1.143 [0.045]
Thickness uniformity 0.003 mm per centimeter
(within)
0.0003 inch per inch

520L1033 Rev BG February 2010

15

Rework Specifications
Rework specifications
Series 20/Series 30

Cylinder block
Series
20-20
20-21
20-22
20-23
20-24
20-25
20-26
20-27
30-33
30-34
30-36

Minimum block height

Maximum bore diameter

Flatness (TIR) convex

63.50
[2.500]
73.41
[2.890]
78.99
[3.110]

14.899
[0.58656]
17.238
[0.67865]
19.072
[0.75085]

0.00127
[0.000050]
0.00127
[0.000050]
0.00127
[0.000050]

83.57
[3.290]
90.17
[3.550]
101.09
[3.980]
110.49
[4.350]
123.70
[4.870]
82.14 Total
[3.234]
89.62 Total
[3.530]
102.36 Total
[4.030]

20.655
[0.81319]
22.758
[0.89597]
25.423
[1.00090]
28.205
[1.11043]
32.126
[1.26482]
18.312
[0.72250]
20.083
[0.79065]
22.992
[0.90520]

0.001397
[0.000055]
0.001524
[0.000060]
0.001778
[0.000070]
0.001905
[0.000075]
0.00127
[0.000050]
0.00127
[0.000050]
0.00127
[0.000050]
0.00127
[0.000050]

Dimensions mm [in]

16

520L1033 Rev BG February 2010

Rework Specifications
Rework specifications
Series 20/Series 30
(continued)

Piston assembly
Series
20-20
20-21
20-22
20-23
20-24
20-25
20-26
20-27
30-33
30-34
30-36

Minimum slipper foot


thickness
3.68
[0.144]
4.24
[0.167]
4.70
[0.185]
5.11
[0.201]
5.61
[0.221]
6.30
[0.248]
7.01
[0.276]
8.99
[0.354]
3.10
[0.122]
3.38
[0.133]
3.89
[0.153]

Maximum piston/slipper
endplay
0.152
[0.006]
0.152
[0.006]
0.152
[0.006]
0.152
[0.006]
0.152
[0.006]
0.152
[0.006]
0.152
[0.006]
0.152
[0.006]
0.152
[0.006]
0.152
[0.006]
0.152
[0.006]

Piston/slipped
endplay
NA
NA
0.0508
[0.002]
0.0508
[0.002]
0.0508
[0.002]
0.0508
[0.002]
0.0508
[0.002]
0.0508
[0.002]
NA
NA
NA

Dimensions mm [in]

Series 20 plastic filled pistons may be replaced with welded pistons if replaced in
multiples of three, being equally spaced within the nine bores.

520L1033 Rev BG February 2010

17

Rework Specifications
Rework specifications
Series 20/Series 30
(continued)

Valve plate
Valve plate
Series

Minimum thickness

Flatness (convex)

Parallelism (TIR)

20-20

63.50 [2.500]

0.00127 [0.000050]

0.0127 [0.0005]

20-21

7.0231 [0.2765]

0.00127 [0.000050]

0.0127 [0.0005]

20-22

7.8232 [0.3080]

0.00127 [0.000050]

0.0127 [0.0005]

20-23

7.8232 [0.3080]

0.001397 [0.000055]

0.0127 [0.0005]

20-24

7.8105 [0.3705]

0.001524 [0.000060]

0.0127 [0.0005]

20-25

10.998 [0.4330]

0.001778 [0.000070]

0.0127 [0.0005]

20-25*

12.0532 [0.4745]

0.00127 [0.000050]

0.0127 [0.0005]

20-26

10.9982 [0.4330]

0.001905 [0.000075]

0.0127 [0.0005]

20-26*

12.8448 [0.5057]

0.00127 [0.000050]

0.0127 [0.0005]

20-27

12.5857 [0.4955]

0.002159 [0.000085]

0.0127 [0.0005]

20-27*

15.2273 [0.5995]

0.00127 [0.000050]

0.0127 [0.0005]

30-33

13.8938 [0.5470]

0.00127 [0.000050]

0.0127 [0.0005]

30-34

6.4262 [0.2530]

0.00127 [0.000050]

0.0127 [0.0005]

30-36

6.4262 [0.2530]

0.00127 [0.000050]

0.0127 [0.0005]

Dimensions mm [in]

* Thin valve plate


Thrust plate
Thrust plate
Series

Minimum thickness

Flatness (convex)

Parallelism (TIR)

20-20

5.8928 [0.2320]

0.00127 [0.000050]

0.0127 [0.0005]

20-21

6.8072 [0.2680]

0.00127 [0.000050]

0.0127 [0.0005]

20-22

7.4168 [0.2920]

0.00127 [0.000050]

0.0127 [0.0005]

20-23

7.2898 [0.2870]

0.00127 [0.000050]

0.0127 [0.0005]

20-24

7.8740 [0.3100]

0.001905 [0.000075]

0.0127 [0.0005]

20-25

8.382 [0.3300]

0.001905 [0.000075]

0.0127 [0.0005]

20-25*

12.0532 [0.4745]

0.00127 [0.000050]

0.0127 [0.0005]

20-26

9.7028 [0.3820]

0.001905 [0.000075]

0.0127 [0.0005]

20-26*

12.8448 [0.5057]

0.00127 [0.000050]

0.0127 [0.0005]

20-27

9.5758 [0.3770]

0.001905 [0.000075]

0.0127 [0.0005]

20-27*

15.2273 [0.5995]

0.00127 [0.000050]

0.0127 [0.0005]

30-33

NA

NA

NA

30-34

NA

NA

NA

30-36

NA

NA

NA

Dimensions mm [in]

18

520L1033 Rev BG February 2010

Rework Specifications
Rework specifications
Series 20/Series 30
(continued)

Bearing plate
(Heavy duty) bearing plates
Series
20-20
20-21
20-22
20-23
20-24
20-25
20-25*
20-26
20-26*
20-27
20-27*
30-33
30-34
30-36

Minimum
thickness
5.9817
[0.2355]
6.2865
[0.2745]
7.7724
[0.3060]

Flatness
(convex)
0.00127
[0.000050]
0.00127
[0.000050]
0.00127
[0.000050]

Parallelism
(TIR)
0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]

7.747
[0.3050]
7.7724
[0.3060]
903599
[0.3685]
8.3058
[0.3270]
10.1524
[0.3997]
8.3058
[0.3270]
10.947
[0.4310]
8.3058
[0.3270]
2.7686
[0.1090]
3.0734
[0.2530]
6.4262
[0.2530]

0.001397
[0.000055]
0.001524
[0.000060]
0.001778
[0.000070]
0.00127
[0.000050]
0.001905
[0.000075]
0.00127
[0.000050]
0.002159
[0.000085]
0.00127
[0.000050]
0.0508
[0.002000]
0.0508
[0.002000]
0.0508
[0.002000]

0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]
0.0127
[0.0005]

* Thick valve plate


Dimensions mm [in]

520L1033 Rev BG February 2010

19

Rework Specifications
Rework specifications
Series 20

Shaft seal identification


No pits, scratches, nicks, or indentations are allowed that extend more than 25% of the
width of the sealing land surface. Irregularities above surface are not allowed.
The O-ring sealing surfaces must be smooth, with no visible marks.

P106 254E

Stationary Seal

Rotating Seal

Feature
Rotating seals

Stationary seals

Dimension

Overall thickness (min.)

11.99 [0.472]

Step thickness (min.)

0.0584 [0.023

Step thickness (min.)

00584 [0.023]

Dimensions mm [in]

20

520L1033 Rev BG February 2010

Rework Specifications
Rework specifications
Control link identification

Series 20
(continued)

Series

Feedback link dimension A


MDC
EDC/HDC
38.91
27.58
[1.532]
[1.086]
38.91
27.58
[1.532]
[1.086]

Link assembly
dimension B
30.73
[1.210]
30.73
[1.210]

Link dimension
C
30.73
[1.210]
30.73
[1.210]

38.91
[1.532]
27.58
[1.086]
47.57 [1.873]

30.73
[1.210]
39.12
[1.540]
44.20

30.73
[1.210]
25.98
[1.023]
30.73

Overall length: 60.27 [2.373]


47.57 [1.873]
Overall length: 60.27 [2.373]
57.63
[2.269]
62.23
[2.450]

[1.740]
45.47
[1.790]
45.47
[1.790]
57.15
[2.250]

[1.210]
27.58
[1.086]
27.58
[1.086]
25.98
[1.023]

20-21
20-22
20-23
(-09 and prior)
20-23
(-10 and up)
20-24
20-25
20-26
20-27

Dimensions mm [in]
TIR (Total Instrument Reading)

You can determine the dash number (configuration code) of 23 Series variable unit
housings by measuring the length of the control opening. This dimension D is 73.91 mm
[2.91 in] on -09 and prior housings and 71.37 mm [2.81 in] on -10 and later housings.
Control shaft assembly

1.210"
C

Control spool

A
Swashplate

P106 397E

Control opening in housing

P106 398E

Control link

Control opening in housing


520L1033 Rev BG February 2010

21

Rework Specifications
Rework specifications
L Series

Displacement
Minimum
block height
Flatness (TIR)
Cylinder block

Piston assembly

Minimum
slipper foot
thickness
Maximum
piston/slipper
end play
Minimum
thickness

15cc
38.28
[1.507]

3.18
[0.125]

50cc
56.007
[2.205]

3.40
[0.134]

3.840
[0.1512]

4.950
[0.1949]

3.886
[0.153]

0.0038
[0.00015]
0.0305
[0.0012]
3.861
[0.152]
0.00508
[0.0002]
0.0102
[0.0004]

Parallelism
(TIR)

0.0013
[0.000050]
4.29
[0.169]

4.75
[0.187]

4.950
[0.1949]

7.023
[0.2765]

7.823
[0.3080]

4.978
[0.196]

0.00127
[0.000050]
0.00127
[0.000050]
6.807
7.417
[0.268]
[0.292]
0.00127
[0.000050]
0.00127
[0.000050]

4.06
[0.160]

Dimensions mm [in]
TIR (Total Instrument Reading)

LPV
Cylinder block

Piston assembly

Model
Minimum block height

25cc

Maximum piston bore


diameter
Flatness (TIR)

13.861
[0.546]

Minimum slipper foot


thickness
Maximum piston/slipper
end play
Minimum thickness
Flatness (TIR)

Valve plate
Parallelism (TIR)
Endcap
Swashplate

Flatness (TIR)
Swashplate is not lappable.

30cc
63.38
[2.495]
15.201
[0.598]
0.002
[0.000079]
2.712
[0.107]
0.152
[0.006]
3.88
[0.153]

35cc

16.439
[0.647]

0.0038
[0.00015]
0.0249
[0.00098]
0.005 [0.0002]

Dimensions mm [in]
TIR (Total Instrument Reading)

22

520L1033 Rev BG February 2010

70cc
79.12
[3.115]

0.1016
[0.004]

Flatness (TIR)

Thrust plate

38cc

0.0019
[0.000075]

Valve plate
Parallelism
(TIR)
Minimum
thickness
Flatness (TIR)

23cc
53.37
[2.101]

Rework Specifications
Rework specifications
L&K Motors

LV and LC Motors
Displacement
Minimum
block height
Maximum
Cylinder block
bore diameter
Flatness (TIR)

Piston assembly

25cc

13.879
[0.546]

Minimum
slipper foot
thickness
Maximum
piston/slipper
end play
Minimum
thickness

35cc

16.439
[0.647]

0.1524
[0.006]
3.88
[0.153]

Flatness (TIR)

0.0038
[0.00015]
0.025
[0.00098]
LV - 25.79[1.015]
LC - 33.845 [1.332]
0.0025
[0.00098]

Valve plate

Swash plate

30cc
50.8
[2.000]
15.219
[0.5999]
0.002
[0.000078]
2.71
[0.107]

Parallelism
(TIR)
Minimum
thickness
Flatness (TIR)

KV and KC Motors
Displacement
Minimum
block height
Maximum
Cylinder block
bore diameter
Flatness (TIR)

Piston assembly

Minimum
slipper foot
thickness
Maximum
piston/slipper
end play
Minimum
thickness
Flatness (TIR)

Valve plate

Swash plate

Parallelism
(TIR)
Minimum
thickness
Flatness (TIR)

520L1033 Rev BG February 2010

38cc

45cc
56.38
[2.22]

16.439
[0.647]

17.979
[0.707]

0.002
[0.000078]
4.07
[0.160]
0.102
[0.004]
3.88
[0.153]
0.0038
[0.00015]
0.025
[0.00098]
KV - 24.59 [0.968]
KC - 32.605 [1.283]
0.0025
[0.00098]

Dimensions mm [in]
TIR (Total Instrument Reading)
23

Rework Specifications
Rework specifications

Series 51

Displacement
Minimum
block height
Maximum
Cylinder block
bore diameter
Flatness (TIR)

Bearing plates

Minimum
thickness
Flatness (TIR)

Dimensions mm [in]
TIR (Total Instrument Reading)

24

520L1033 Rev BG February 2010

60cc
51.4
[2.023]
16.126
[0.6349]

80cc
58.5
[2.303]
17.864
[0.7033]

110cc
160cc
62.9
71.3
[2.476]
[2.807]
19.733
22.466
[0.7769]
[0.8845]
0.004
[0.000157]
not concave
2.850 (0.201 Bronze)
[0.1122] (0.0079 Bronze)
0.0483
[0.0019]

250cc
82.7
[3.256]
25.966
[1.0223]

Rework Specifications
Rework specifications
H1 078/089/100/115/130/147/165
pumps

Cylinder block

Piston assembly

Model
Minimum block
height (A)
Maximum bore
diameter (B)
Flatness (TIR)

078
67.07
[2.64]
20.742
[0.8166]

Total cylinder block


height (C)
Minimum slipper foot
thickness
Maximum piston/slipper
end play
Minimum thickness

83.7
[3.29]
3.52
[0.139]

089

100
72.92
[2.87]

21.364
[0.8411]

22.755
[0.8959]

91.95
[3.62]
3.83
[0.151]

4.85
[0.019]

115
130
78.87
79.87
[3.11]
[3.14]
24.3
25.8
[0.9566]
[1.01657]
0.0026
[0.000102]
98.9
[3.89]
4.18
[0.165]
0.1524
[0.006]

147cc

165cc
87.27
[3.44]

25.250
[0.9940]

26.695
[1.0495]

106.72
[4.201]
4.53
[0.178]

5.25
[0.207]

5.85
[0.230]

Flatness (TIR)
Valve plate

Swashplate
Endcap (raised
cylinder portion)

0.001
[0.0004]
Parallelism (TIR)
0.045
[0.0018]
Swashplate is not reworkable. Control arm extends above surface of running face, making lapping impossible.
Flatness (TIR)

0.0010-0.0050
[0.00004-0.0002]

convex

0.0010-0.0060
[0.00004-0.00023]

convex

Dimensions mm [in]
TIR (Total Instrument Reading)
Cylinder block
B
Cylinder
block
A

flat to 0.002 mm
[0.000079 in]

A
B
C

P101 067E

Cylinder dimensions
Block height
Maximum block bore diameter
Total cylinder block height
(series 30 and H1 only)

520L1033 Rev BG February 2010

25

Rework Specifications
Rework specifications
H1 45/53 pumps
Cylinder Block

Piston Assembly

Model
Minimum block height
(A)
Maximum bore diameter
(B)
Flatness (TIR)
Total cylinder block
height (C)
Minimum slipper foot
thickness
Maximum piston/slipper
end play
Minimum thickness

45cc

53cc
60.62
[2.387]

16.439
[0.6472]

17.9782
[0.7078]

0.002
[0.000079]
76.92
[3.028]
3.66
[0.144]
0.102
[0.004]
4.96
[0.195]

Flatness (TIR)
Valve Plate

Swashplate Plate
End cap/center
section

0.0076
[0.00030]
Parallelism (TIR)
0.0025
[0.00098]
Note: Swashplate is not reworkable. Control arm extends above
surface of running face, making lapping impossible.
Flatness (TIR)
0.013
(raised cylinder portion)
[0.00051]

Dimensions mm [in]
TIR (Total Instrument Reading)
Cylinder block
B
Cylinder
block
A

flat to 0.002 mm
[0.000079 in]

A
B
C

26

P101 067E

Cylinder dimensions
Block height
Maximum block bore diameter
Total cylinder block height
(series 30 and H1 only)

520L1033 Rev BG February 2010

Rework Specifications
Rework specifications
H1B motors
Cylinder Block

Model
Minimum block height
(A)
Maximum bore diameter
(B)
Flatness (TIR)

060
47.13
[1.856]
16.127
[0.635]

Total cylinder block


height (C)
Minimum thickness

57.65
[2.2697]

Flatness (TIR)

080cc
51.80
[2.039]
17.827
[0.7018]
0.004
[0.00016]
63.65
[2.5059]
2.85
[0.1122]

110cc
57.7
[2.272]
19.733
[0.7769]

70.65
[2.7815]

0.008
[0.00031]
0.008
[0.00031]

Bearing plate
Parallelism (TIR)

Dimensions mm [in]
TIR (Total Instrument Reading)
Cylinder block
B
Cylinder
block
A

Flatness (TIR)
P107 854E

A
B
C

Cylinder dimensions
Block height
Maximum block bore diameter
Total cylinder block height

520L1033 Rev BG February 2010

27

Our Products
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Sauer-Danfoss Mobile Power and Control Systems


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Microcontrollers and software
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Sauer-Danfoss provides comprehensive worldwide service for its


products through an extensive network of Global Service Partners
strategically located in all parts of the world.

Displays
Joysticks and control handles

Local address:

Sensors
Orbital motors
Inverters
Electrohydraulic power steering
Hydraulic power steering
Hydraulic integrated circuits (HIC)
Cartridge valves
Directional spool valves
Proportional valves

520L1033 Rev BG February 2010

Sauer-Danfoss (US) Company


2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515 239-6000
Fax: +1 515 239 6618
Sauer-Danfoss GmbH & Co. OHG
Postfach 2460, D-24531 Neumnster
Krokamp 35, D-24539 Neumnster, Germany
Phone: +49 4321 871-0
Fax: +49 4321 871 122

www.sauer-danfoss.com

Sauer-Danfoss ApS
DK-6430 Nordborg, Denmark
Phone: +45 7488 4444
Fax: +45 7488 4400
Sauer-Danfoss-Daikin LTD
Shin-Osaka TERASAKI 3rd Bldg.6F
1-5-28 Nishimiyahara, Yodogawa-ku,
Osaka 532-0004, Japan
Phone: +81 6 6395 6066
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