4535V60A25-1AA22R Vickers Double Vane Pump 193/81 cc

Product Overview

The 4535V60A25-1AA-22R is a Vickers by Danfoss V Series industrial double fixed-displacement vane pump.

The Danfoss V Series uses an intra-vane cartridge design, hydraulic balancing and a 12-vane hydraulic architecture. The 4535V platform combines two large-displacement pump sections in a single mechanically driven package, making it suitable for high-flow industrial hydraulic circuits.

Danfoss PowerSource currently lists the closely corresponding configuration 4535V60A25 86AA 22R, confirming the 4535V frame, 60/25 displacement combination, SAE 4-bolt flange connections, AA port orientation, Design 22 and clockwise rotation.

The supplied target model is 4535V60A25-1AA-22R. According to Danfoss’s official model-code system:

• 4535V: Double vane pump
• 60: Shaft-end section, 193 cm³/rev
• A: SAE 4-bolt flange
• 25: Cover-end section, 81 cm³/rev
• 1: Standard 1-5/16-in square-key shaft
• AA: Both outlets opposite the inlet for the 4535V configuration
• 22: Design 22
• R: Clockwise rotation.

Because the currently indexed PowerSource product record uses 86 rather than 1 for the shaft code, the two configurations should not be treated as mechanically interchangeable without dimensional verification. This distinction is important in OEM replacement engineering.

Technical Specifications

Primary Model: 4535V60A25-1AA-22R

• Brand: Vickers by Danfoss
• Series: V Series
• Model: 4535V60A25-1AA-22R
• Pump Type: Double fixed-displacement vane pump
• Frame: 4535V
• Shaft-End Displacement: 193 cm³/rev (11.8 in³/rev)
• Cover-End Displacement: 81 cm³/rev (4.9 in³/rev)
• Combined Geometric Displacement: 274 cm³/rev, calculated from the two published section displacements
• Maximum Speed: 1800 r/min
• Continuous Maximum Working Pressure: 172 bar (2500 psi)
• Transient Pressure: Up to 10% above the continuous rating for 0.5 seconds or less; this corresponds to a calculated 189.2 bar transient value for a 172-bar continuous rating.
• Minimum Speed: 600 r/min
• Control: Fixed displacement
• Mounting: Flange mount
• Port Connection: A — SAE 4-bolt flange
• Shaft: 1 — 1-5/16-in square key
• Port Orientation: AA — both outlets opposite the inlet for 4535V
• Design: 22
• Rotation: R — clockwise, viewed from shaft end
• Seal: Standard seal
• Approximate Weight: 53.5 kg (118 lb)
• Approximate Envelope: 185.7 mm high × 453.1 mm long × 212.9 mm wide
• Peak Pressure: No separate unlimited peak-pressure rating is specified; the official technical data uses a short-duration transient-pressure definition.

Other Supplied Model: 4525V-45A25-1CC-22R

The official 4525V model-code and displacement data identify:

• Series: 4525V double vane pump
• Shaft-End Displacement Code: 45
• Shaft-End Geometric Displacement: 147 cm³/rev (9.0 in³/rev)
• Cover-End Displacement Code: 25
• Cover-End Geometric Displacement: 81 cm³/rev (4.9 in³/rev)
• Combined Geometric Displacement: 228 cm³/rev
• Port Connection: A — SAE 4-bolt flange
• Shaft: 1 — 1-5/16-in square key
• Port Orientation: CC — No.1 outlet inline with inlet; No.2 outlet 45° clockwise from inlet for 4525V
• Design: 22
• Rotation: R — clockwise.
• Maximum Continuous Pressure: 172 bar
• Maximum Speed: 1800 r/min
• Minimum Speed: 600 r/min
• Approximate Weight: 46.0 kg (101 lb).

Other Supplied Model: 4535V-60A32-86CC22R

The official V Series coding system confirms:

• 4535V: Double pump
• 60: 193 cm³/rev shaft-end section
• A: SAE 4-bolt flange
• 32: 97 cm³/rev cover-end section
• 86: 3/8-in square-key shaft
• CC: Both outlets inline with the inlet
• 22: Design 22
• R: Clockwise rotation.
• Combined Geometric Displacement: 290 cm³/rev
• Maximum Continuous Pressure: 172 bar
• Maximum Speed: 1800 r/min
• Minimum Speed: 600 r/min
• Approximate 4535V Double-Pump Weight: 53.5 kg.

Key Technical Advantages

1. High-Capacity Double-Pump Architecture

For 4535V60A25:

P1 = 193 cm³/rev
P2 = 81 cm³/rev

At 1800 r/min, the theoretical geometric flows are approximately:

• P1: 347.4 L/min
• P2: 145.8 L/min
• Combined theoretical flow: 493.2 L/min

These are calculated geometric-flow values, not guaranteed delivered flows. Actual flow depends on volumetric efficiency, pressure, temperature, viscosity and speed.

2. Intra-Vane Cartridge Technology

The V Series incorporates an intra-vane cartridge design, which Danfoss identifies as a major technology supporting low noise, performance and serviceability.

The cartridge concept also supports targeted service of the main working components.

3. Hydraulic Balancing

Danfoss uses hydraulic balancing to reduce internally generated radial loading on the shaft and bearings.

For a large double pump, where both sections may operate simultaneously, correct hydraulic balance and mechanical alignment are particularly important.

4. Twelve-Vane System

The V Series incorporates a 12-vane system, which Danfoss describes as producing low-amplitude flow pulsations and helping reduce overall hydraulic-system noise.

5. SAE 4-Bolt Flange Connections

The A port configuration uses SAE 4-bolt flange connections. The 4535V installation documentation also defines the relevant inlet and outlet flange arrangements.

6. Standardized Configuration Coding

The complete 4535V model number defines:

Displacement → Port Connection → Shaft → Port Orientation → Design → Rotation

For example:

CC ≠ AA

Both belong to the 4535V family, but their outlet locations differ.

7. Established Cartridge Service System

Danfoss provides dedicated V Series service literature, including an overhaul manual specifically covering the 4535V platform.

This supports structured maintenance and cartridge-level service operations.

Application Areas

Danfoss’s official V Series application information covers:

• Plastic machinery
• Press machines
• Die-casting machinery
• Machine tools
• Test equipment
• Primary metals
• Pulp and paper
• Wood processing
• Oil and gas
• Marine
• General industrial equipment.

The larger 4525V and 4535V configurations are particularly suitable for:

• Large hydraulic power units
• Metal-forming presses
• Die-casting machinery
• Large injection-molding equipment
• Steel and non-ferrous metal processing
• Material-handling systems
• Industrial production lines
• Oil and gas hydraulic systems
• Marine auxiliary hydraulics

Expert Maintenance Tips

1. Calculate Shaft Torque for Both Sections

Danfoss explicitly states that when both cartridges of a double pump are loaded simultaneously, the individual section torques must be added and compared against the shaft torque limit.

For 4535V60A25, do not evaluate only the 172-bar pressure rating. Calculate the torque contribution from both the 193 and 81 cm³/rev sections.

2. Verify Port Orientation

The 4535V60A25-1AA-22R configuration places both outlets opposite the inlet, whereas:

4535V60A32-86CC22R

uses both outlets inline with the inlet.

A port-orientation mismatch can create significant piping changes during retrofit.

3. Verify the Shaft Code Precisely

This is particularly important for the supplied configurations:

• 1 = 1-5/16-in square-key shaft
• 86 = 3/8-in square-key shaft.

Therefore, 4535V60A25-1AA22R and 4535V60A25 86AA22R must not be treated as mechanically identical without dimensional verification.

4. Treat 172 Bar as the Continuous Rating

The V Series 4535V continuous rating is 172 bar / 2500 psi.

A short-duration transient up to 110% of the continuous rating is allowed for no more than 0.5 seconds.

The transient value should not be advertised as a continuous working pressure.

5. Protect the Suction Circuit

The large displacement of a 4535V double pump means substantial inlet flow. Keep suction lines short and low-restriction and avoid:

• Undersized piping
• Excessive bends
• Local restrictions
• Air leakage
• Blocked inlet filtration

Poor inlet conditions can cause cavitation, noise and reduced volumetric performance.

6. Maintain Drive Alignment

Check:

Motor → Coupling → Pump Shaft

for concentricity, angular alignment, axial movement and correct key fit.

7. Prime and Bleed the System Before Loading

After initial installation or extended shutdown, ensure adequate pump lubrication and remove trapped air before applying high pressure.

Do not immediately start a large double pump under full hydraulic load.

8. Perform 100% Simulated Operating-Condition Testing

For:

4525V-45A25-1CC-22R
4535V-60A32-86CC22R
4535V60A25-1AA-22R

recommended factory testing should cover:

Rotation → P1 Flow → P2 Flow → Pressure → Combined Torque → Leakage → Noise → Temperature Rise

For replacement applications, also verify:

Mounting Dimensions → Shaft Fit → Port Orientation → Coupling Compatibility

This helps establish both mechanical interchangeability and hydraulic functional compatibility.