SKF DCV5-4+924 Manual

5/4-way valve for grease
is intended for use in progressive distribution
lubrication systems with multiple lubrication
circuits running
Product line:
DCV5-4+924
Owner’s Manual - Containing Installation,
Operation and Maintenance Instructions
(Original installation instructions in accordance with EC-
Machinery Directive 2006/42/EC)
Version 04
WARNING:
Read this owner's manual before installing, operating or maintaining the product. Failure to follow the
instructions and safety precautions in this owner’s manual could result in serious injury, death, or property
damage. Keep for future reference.

blank page

Masthead page 3
EN
Masthead
This owner’s manual - containing installation,
operation and maintenance instructions complies
with EC-Machinery Directive 2006/42/EC and is an
integral part of the described product. It must be
kept for future use.
This owner’s manual - containing installation,
operation and maintenance instructions was
created in accordance with the valid standards and
regulations on documentation,
VDI 4500 and EN 292.
© SKF Lubrication Systems Germany GmbH
This documentation is protected by copyright. The
photomechanical reproduction, copying, and distri-
bution of this documentation or parts thereof by
means of processes such as data processing, data
carriers, and data networks is strictly prohibited
without the express permission of SKF Lubrication
Systems Germany GmbH.
SKF Lubrication Systems Germany GmbH reserves
the right to make content and technical changes.
Service
If you have technical queries, please contact one of
the following plants:
SKF Lubrication Systems Germany GmbH
Plant Berlin
Motzener Straße 35/37
12277 Berlin
Germany
Tel. [phone]
Fax [phone]
Plant Hockenheim
2. Industriestraße 4
68766 Hockenheim
Germany
Tel. [phone]
Fax [phone]
lubrication-germ[email protected]
www.skf.com/schmierung

Table of contents page 4
EN
Table of contents
Owner’s Manual - Containing Installation,
Operation and Maintenance Instructions
(Original installation instructions in accordance with
EC-Machinery Directive 2006/42/EC)
Masthead 3
Service 3
Table of contents 4
Information concerning the EC Declaration of
Incorporation 5
Safety information in owner’s manual 6
Meaning of symbols and corresponding
information 6
1. Safety information 8
1.1 Intended use 8
1.2 Authorized personnel 8
1.3 Danger relating to electric current 9
1.4 Danger relating to system pressure 9
1.5 Warranty and liability 9
2. Lubricants 10
2.1 General information 10
2.2 Selection of lubricants 10
2.3 Approved lubricants 11
2.4 Lubricants and the environment 11
2.5 Danger relating to lubricants 11
3. Design and function 12
4. Installation 14
4.3 Elektrical Connection 15
5. Transport, delivery and storage 18
5.1 Transport 18
5.2 Delivery 18
5.3 Storage 18
5.3.1 Storage of electrical devices 18
5.3.2 Storage - general information 18
6. Operation 19
6.1 General information 19
6.2 Startup 19
7. Shutdown 20
7.1 Temporary shutdown 20
7.2 Permanent shutdown 20
8. Maintenance 21
9. Technical data 22

Information concerning the EC Declaration of Incorporation page 5
EN
Information concerning the EC Declaration of Incorporation
For the product(s) designated below:
5/4 way valve
Product line:
DCV5-4+924 for 24V DC
SKF herewith certifies that it conforms to the perti-
nent safety requirements set forth in the following
Council Directive(s) for the harmonisation of the
laws of the Member States...
Machinery Directive 2006/42/EC
Electromagnetic compatibility 2014/30/EU
Electromagnetic compatibility 2004/104/EG
RoHS Directive 2011/65/EU
SKF further declares that the above mentioned
product is meant for integration into a machinery /
for connection to other machinery according to the
EC-Machinery Directive 2006/42/EC, Appendix II
Part B. Starting up the product is not permissible
until it is assured that the machinery, vehicle or the
like in which the product was installed meets the
provisions and requirements of the regulations set
forth in the EC Directive 2006/42/EC.
Notes:
(a) This declaration certifies conformity with the
aforementioned directive(s), but does not
contain any assurance of properties.
(b) The safety instructions in the owner’s manual
must be observed.
(c) The certified product must not be started up
until it is confirmed that the equipment, ma-
chinery, vehicle or the like in which the product
was installed meets the provisions and re-
quirements of the national directives to be ap-
plied. This is in particular important for the
implementation of the Use of Work Directive.
(d) Operation of the products on non-standard
main voltage as well as nonobservance of in-
stallation instructions can affect the EMC
properties and electrical safety.
Notes on the Low Voltage Directive 2014/35/EU
The protective regulations of the Low Voltage
Directive 2014/35/EU are fulfilled according to
annex I (1.5.1) of Machinery Directive 2006/42/EC.
Notes on the Pressure Equipment Directive
2014/68/EU
Due to its performance characteristics, the product
does not reach the limit values defined in Article 4,
Paragraph 1, Subparagraph (a) item (i) and is,
pursuant to Article 4, Paragraph 3, excluded from
the scope of Pressure Equipment Directive
2014/68/EU.
The EC Declaration of Incorporation is part of the
product documentation. This document is delivered
with the product.

page 6
EN
Safety information in owner’s manual
Meaning of symbols and corresponding
information
In this owner’s manual, the symbols and words
shown on this page are meant to communicate a
particular risk to persons, material assets, or the
environment.
Be sure all persons exposed to these risks read this
manual. Keep it near the equipment for future
reference.
Hazard symbols
Instructions attached directly to the equipment,
such as rotational direction arrows and fluid con-
nection labes, must be followed. Replace such
signs if they become illegible.
oRotational direction arrow
oFluid connection label
Keywords in safety informations and their
meanings
Read this Owner's Manual before installing, oper-
ating or maintaining the product. Failure to follow
the instructions and safety precautions in this
owner’s manual could result in serious injury,
death, or property damage. Keep for future refe-
rence.
Note: Not every symbol and corresponding infor-
mation described in the Safety Information is used
in this owner’s manual.
Information symbols
Signal
word
Bedeutung
Danger!
Risk of serious injury or death
Warning!
Danger of damage to property
and the environment
Note!
Provides additional information
Symbol
Standard
Meaning
DIN 4844-2
W000
General
hazard
DIN 4844-2
W008
Electricity
DIN 4844-2
W026
Hot surface
DIN 4844-2
W028
Slipping
hazard
Symbol
Meaning
Note

Prompts an action
○
Used for itemizing

Refers to other facts, causes, or
consequences

Provides additional information

page 7
EN
5/4-way valve for for grease
is intended for use in progressive distribution
lubrication systems with multiple lubrication
circuits running
Product line:
DCV5-4+924
Original assembly instructions
according to the EC Machinery Directive 2006/42 / EC

1. Safety information page 8
EN
1. Safety information
These instructions must be read and
understood by all persons who are in-
volved with the installation, operation,
maintenance, and repair of the product.
These instructions must be kept close to
the equipment for future reference.
Note that these installation instructions
is an integral part of the product. It
must be handed over to the new op-
erator of the product if the product is
sold.
The described product was manufactured in accor-
dance with all generally acknowledged regulations
pertaining to technology, occupational safety, and
accident prevention. However, dangers that can
cause physical injury to persons or damage to
other material assets might still occur during the
use of the product. This product should only be
operated if it has been installed in accordance with
these instructions and is safe to operate. In par-
ticular, malfunctions that might affect the safety of
the product must be rectified immediately.
In addition to the information provided
in the installation instructions, all gener-
ally applicable regulations on accident
prevention and the environment must
be observed.
.
1.1 Intended use
All SKF Lubrication Systems Germany
GmbH products must only be used for
their intended purpose and in
accordance with the specifications of the
installation instructions for the product
in question.
The SKF 5/4 way valve DCV5-4+924 is intended
for use in progressive distribution lubrication
systems with multiple lubrication circuits running
on SKF-approved lubricants.
The 5/4 way valve DCV5-4+924 may
only be used in lubrication systems with
integrated pressure limiting valves.
The information regarding the operating conditions
in Chapter 9 –SPECIFICATIONS (system pressure,
temperature, operating voltage, etc.) must be
adhered to.
Hazardous materials of any kind, especially the
materials classified as hazardous by CLP
Regulation EC 1272/2008 may only be used to fill
SKF centralized lubrication systems and
components and deliv-ered and/or distributed with
the same after consulting with and receiving
written approval from SKF.
None of the products manufactured by SKF
Lubrication Systems Germany GmbH can be used
with gases, liquefied gases, gases dissolved under
pressure, steams or fluids that will reach a steam
pressure of more than 0.5 bar above the normal
atmospheric pressure (1013 mbar) in the permis-
sible application temperature range.
Unless otherwise noted, products of SKF
Lubrication Systems Germany GmbH must not be
used in conjunction with explosive atmospheres
according to the ATEX-Directice 94/9/EC.
1.2 Authorized personnel
The products described in the installation instruc-
tions may only be installed, operated, maintained,
and repaired by qualified experts. Qualified experts
are persons who have been trained, instructed, and
familiarized with the end product into which the
described product is installed. These persons are
considered capable of such tasks due to their
education, training, and experience with valid
standards, conditions, accident prevention regula-
tions, and installation measures. They should be
able to carry out the required tasks and to recog-
nize - and thus avoid - any dangers that might
otherwise occur.
A definition of what constitutes a qualified person
and who are unqualified persons are stipulated in
DIN VDE 0105 and IEC 364.

1. Safety information page 9
EN
1.3 Danger relating to electric current
The electrical connection for the described product
may only be established by qualified, instructed
persons who have been authorized by the operator
or owner to carry out this task. All local electrical
operating conditions and regulations such as DIN
and VDE must be observed. Improperly connected
products can result in considerable damage to
property and serious injury to persons.
Danger!
Working on products that have not been
disconnected from the power supply can
cause serious injury or death to persons.
Installation, maintenance, and repair
work may only be carried out by quali-
fied experts on products that have been
disconnected from the power supply.
The supply voltage must be turned off
before any product components are
opened.
1.4 Danger relating to system pressure
Danger!
Centralized lubrication systems are un-
der pressure when they are being oper-
ated. Such systems must therefore be
depressurized before starting installa-
tion, maintenance, or repair work and
before making any changes to the sys-
tem.
1.5 Warranty and liability
SKF Lubrication Systems Germany GmbH assumes
no warranty and liability if one of the following cir-
cumstance should occur:
oNot intended use
oImproper installation/disassembly or improper
operation of the product
oUse of contaminated lubricants or lubricants
which are not approved
oImproper maintenance or repairing of the
product
oUsing of unoriginal SKF Lubrication Systems
Germany GmbH spare parts
oMaking alterations or modifications to the
product, which are not approved and signed by
SKF Lubrication Systems Germany GmbH
oNon-observance of the advices about trans-
port and storage

2. Lubricants page 10
EN
2. Lubricants
2.1 General information
All SKF Lubrication Systems Germany
GmbH products must only be used for
their intended purpose and in
accordance with the specifications of the
installation instructions for the product
in question.
The intended use of this product is for the central-
ized lubrication/lubrication of bearings and wear
points with lubricants. All physical limitations of use
stipulated in the documentation of the product
such as the owner’s manual, technical drawings
and catalogues must be observed.
Note that hazardous substances of any kind and -
in particular - the substances that are classed as
hazardous in accordance with EC-Directive
67/548/EC Article 2, Paragraph 2 may only be
inserted into and conveyed/distributed by central-
ized lubrication systems and components following
consultation with SKF Lubrication Systems
Germany GmbH and with the express written
permission of the company.
Products manufactured by SKF Lubrication
Systems Germany GmbH are not approved for use
in conjunction with gases, liquefied gases, gases
dissolved under pressure, vapours, and fluids with
a vapour pressure of more than 0.5 bar above
normal atmospheric pressure (1013 mbar) at the
maximum permitted temperature.
als 0,5 bar über dem normalen Atmosphärendruck
(1013 mbar) liegt.
Should there be a need to use the product to
convey media other than lubricants or hazardous
substances, this must be discussed with SKF
Lubrication Systems Germany GmbH first and the
company must give express written permission.
In the opinion of SKF Lubrication Systems
Germany GmbH, lubricants constitute a design
element that must be considered when selecting
components and designing centralized lubrication
systems. The lubrication properties of the lubri-
cants in question must be considered.
2.2 Selection of lubricants
You must observe the machinery or
vehicle manufacturer's or information
on the lubricants to be used in the
machinery.
While the machinery/bearing manufacturer usually
specifies lubricants, it is the owner/operator (or
maintenance person) who must finally select the
appropriate lubricant, with the help of the lubricant
supplier. When selecting a lubricant, the type of
bearing/wear point, the stresses and strains to be
expected during operation, and anticipated ambi-
ent conditions must be taken into account. All
financial/economic aspects must also be consid-
ered.
If required, SKF Lubrication Systems
Germany GmbH can help customers to
select suitable components for the con-
veyance of the selected lubricant and to
plan and design their centralized lubri-
cation system.
If you have further questions, you can contact SKF
Lubrication Systems Germany GmbH. We can test
lubricants in our own laboratory to establish their
suitability for conveyance (e.g. 'oil separation'
behaviour) in centralized lubrication systems.
You can request an overview of lubricant tests
offered by SKF Lubrication Systems Germany
GmbH from our Service department.

2. Lubricants page 11
EN
2.3 Approved lubricants
Caution!
Only lubricants that have been approved
by SKF for use with the product may be
used. Unsuitable lubricants can cause
product malfunctions and damage to
property.
Caution!
Different lubricants must not be mixed
together. Doing so can cause damage
and require extensive cleaning of the
products/centralized lubrication system.
To prevent confusion, we recommend
that you attach information indicating
the lubricant to be used on the lubricant
reservoir.
The described product can be operated with lubri-
cants that comply with the specifications in the
technical data.
Note that some lubricants may have properties
that lie within the permitted limit values and yet
not be suitable for use in centralized lubrication
systems for other reasons. For example, some
synthetic lubricants are not compatible with elas-
tomers.
.
2.4 Lubricants and the environment
Caution!
Lubricants can contaminate the ground
and watercourses. Lubricants must be
used and disposed of properly. Country
specific regulations and laws on the use
and disposal of lubricants must be ob-
served
Note that lubricants are harmful to the environ-
ment and flammable; their transportation, storage,
and processing are subject to special precautionary
measures. For specifications on transportation,
storage, processing, and dangers to the use and
the environment for the lubricant, refer to the
material safety data sheet provided by or available
from the lubricant manufacturer. You can ask the
manufacturer of the lubricant for the material
safety data sheet.
2.5 Danger relating to lubricants
Danger!
Leaking components can cause a slip
hazard. When performing installation,
maintenance, and repairs test the
components for leaks. Leaky parts of the
components of the lubrication
equipment have to be sealed
immediately.
Leaking components of the lubrication equipment
are a source of danger in relation to slip hazard
and the risk of injury. These dangers can cause
physical injury to persons or damage to other
material assets.
Lubricants are hazardous substance.
Refer to safety precautions in the lubri-
cant manufacturer's material safety
data sheet.
You can ask the manufacturer of the lubricant for
the material safety data sheet.

3. Design and function page 12
EN
3. Design and function
3.1 Function
The 5/4 way valve DCV5-4+924 is intended for
use in progressive distribution lubrication systems
in the vehicle as well as in the industrial field. It has
one input that can be switched to use one of four
possible outputs. This valve can be used -
especially in combination with the pump unit
KFGS...-...B - to supply, address and monitor up to
four independent lubrication circuits with lubricant
(Figure 1). This 5/4 way valve DCV5-4+924 can
therefore replace up to four 2/2 way valves.
When switching, there may be a short-term
connection (approx. 0.1 s) between the main line
and non-addressed lubrication lines.
The 5/4 way valve DCV5-4+924 is electrically
supplied with 24 VDC.
Display CAN Bus
24 VDC
M
M
1
2
3
4 5 6 7
CS1 CS2 CS3 CS4
Figure 1. Progressive distribution system with 5/4 way valve DCV5-4+924,split into four
independent lubrication citcuits
1 pump unit KFGS...-...B..., 4 - 7 piston distributors,
2 pressure limiting valve, CS1 –CS4 cycle switch of the lubricants circuits 1-4
3 5/4 way valve DCV5-4+924,

3. Design and function page 13
EN
3.2 Design
Figure 2 shows the setup of the 5/4 way valve
DCV5-4+924. It is equipped with a hydraulic input
(P) to connect it to the pump as well as four
hydraulic outputs
(1, 2, 3 ,4), which are used to connect lubrication
lines of the different lubrication circuits.
The electrical connection is made via a 5-pin plug
(M12x1).
P
M12x1,5 / 13
40
9
1
2
5 6
3
4
65
M12 X1
86,5
152,5
209,5
Figure 2. 5/4 way valvel DCV5-4+924, setup
P hydraulic input 5, 6 fastening borings
1 –4 hydraulic outputs 7 electrical connection
top
bottom

4. Installation page 14
EN
4. Installation
5/4 way valve described in the installation
instructions may only be installed by qualified
experts. These persons are considered capable of
such tasks due to their education, training, and
experience with valid standards, conditions,
accident prevention regulations, and operating
measures. They are entitled to carry out the
required tasks and to recognize - and thus avoid -
any dangers that might otherwise occur.
A definition of what constitutes a qualified person
and who are unqualified persons are stipulated in
DIN VDE 0105 and IEC 364.
Before installing the 5/4 way valve, remove the
packaging material and any transportation safety
devices such as sealing plugs. Keep the packaging
material until you are sure that there are no
delivery discrepancies that need to be clarified.
Caution!
Das 5/4-way valve must not be tipped
up or dropped.
Country specific accident prevention regulations
and the operating and maintenance instructions of
the operator must be observed when carrying out
all installation work on machineries.

4. Installation page 15
EN
4.1 Setup
The valve should be installed in a location that is
protected from dirt, spray water and vibration, but
should be readily accessible to ensure all further
installation tasks can be performed easily.
The valve is installed upright, as shown in Figure
2. The assembly dimensions can also be found in
Figure 2.
The valve is fastened to the vehicle or machine
with two screws M8 (torque 16 Nm).
Possible installation borings can be drilled as seen
in Figure 2.
Please observe the following while
drilling and installing:
do not damage existing supply lines,
do not damage other units,
do not install the valve in the action
range of moving parts,
do not install the valve too close to
heat sources (exhaust, etc.).
4.2 Connecting the lubrication lines
You can use the connection fittings listed in Table 1
to connect the lubrication lines to the inputs and
outputs.
Outputs that are not needed must be plugged with
a lockscrew (DIN 910 - M12x1,5 - 5.8).
Table 1. Connection fitting
Order No.
Designation
441-006-348
Screw connection M12x1.5 for pipe
diameter 6 mm
4.3 Elektrical Connection
The 5/4 way valve DCV5-4+924 is electrically
supplied with 24 VDC.
Only one X1 Pin (1, 2, 3 or 4) may
switched at a time.
In combination with the pump unit KFGS...-...B... ,
this is warranted by the control module of the
pump unit. In other cases, the control must be
programmed accordingly to ensure this.
The PIN number reflects the number markings of
the hydraulic outputs.
Table 2. Accessories for the electrical
connection
Order No.
Designation
179-990-778
Line with plug and female connector
(M12x1); 1.5 m long
1 2
3
5
4
Fig. 3. Connector X1 (female connector)
Table 3. Pin assignment in Fig. 3
X1 Pin
Hydraulic
output
Circuit
Wire colour
*)
1
1
+ 24 V DC
brown
2
2
+ 24 V DC
white
3
3
+ 24 V DC
blue
4
4
+ 24 V DC
black
5
-
- (0 V DC)
grey
*) When using a confectioned cable with a line socket

4. Installation page 16
EN
Table 4. General connection conditions for
the vehicle sector
Designation
Value
Rated current
24V DC
Typical current pickup (load-
dependent) 1)
0.2 A
Start-up current (approx. 20
ms)
approx. 1.4 A
Maximum line fuse 2)
3.0 A
1) Typical value at ambient temperature = 25 °C
and operating pressure = 300 bar
2) Fuse as per DIN72581
Table 5. General connection conditions for
the industrial sector
Designation
Value
Rated current
24 V DC 3)
Typical current pickup (load-
dependent) 1)
0.2 A
Start-up current (approx. 20
ms)
approx. 1.4 A
Maximum line fuse 2)
3.0 A
1) Typical value at ambient temperature = 25 °C
and operating pressure = 300 bar
2) Line: Wire cross section ≥0.34 mm²; Length ≤20 m
3) Applicable safety measures for the intended use:
"Functional low voltage with safe isolation"
Standards: EN 60204-1/ IEC 60204-1
HD 60364-4-41/ DIN VDE 0100-410/
IEC 60364-4-41

4. Installation page 17
EN
5/4-way valve for for grease
is intended for use in progressive distribution
lubrication systems with multiple lubrication
circuits running
Product line:
DCV5-4+924
Operating instructions

5. Transport, delivery and storage page 18
EN
5. Transport, delivery and
storage
5.1 Transport
SKF Lubrication Systems Germany GmbH products
are packaged in accordance with the regulations of
the recipient country and in accordance with DIN
ISO 9001. Our products must be transported with
care. Products must be protected against me-
chanical influences such as impacts. Transport
packaging must be labelled with the information
'Do not drop!'.
Caution!
The product must not be tipped up or
dropped.
There are no restrictions relating to land, air, or
sea transportation.
5.2 Delivery
Following receipt of the shipment, the product or
products must be checked for damage and the
shipping documents should be used to make sure
that the delivery is complete. Keep the packaging
material until you are sure that there are no deliv-
ery discrepancies that need to be clarified.
5.3 Storage
The following conditions apply to the storage of
SKF Lubrication Systems Germany GmbH
products.
5.3.1 Storage of electrical devices
oAmbient conditions: Dry, dust-free environ-
ment; storage in well-ventilated, dry area
oStorage time: 24 months max.
oPermitted air humidity: < 65%
oWarehouse temperature: 10 - 40°C
oLight: Direct sunlight/UV radiation must be
avoided; nearby sources of heat must be screened
5.3.2 Storage - general information
oEnsure that no dust gets into stored products
by wrapping them in plastic film
oStore products on racks or pallets to protect
them from damp floors
oBefore placing products into storage, protect
uncoated metal surfaces - and drive parts and
mount surfaces in particular - from corrosion
using long-term corrosion protection
oAt 6-monthly intervals: Check products for
corrosion. If signs of corrosion are found, remove
the corrosion that has already resulted and im-
prove the corrosion protection measures.
oDrives must be protected against mechanical
damage

6. Operation Seite 19
EN
6. Operation
6.1 General information
The 5/4 way valve described here functions
automatically. The lubricant transport in the
lubrication lines should, however, be subjected to
regular visual inspection.
The lubricant fill level in the lubricant reservoir - if
used - should be subjected to regular visual
checks. If the lubricant fill level is low, lubricant
should be added up to the MAX mark.
There are the notes of the machine
manufacturer and the vehicle
manufacturer to be observed to be used
lubricants.
Caution!
Only clean lubricant may be added.
Contaminated lubricants can result in
serious system malfunctions.
Caution!
Different lubricants must not be mixed
together. Doing so can cause damage..
6.2 Startup
Before starting up the 5/4 way valve, check all
electrical and hydraulic connections.
The lubricant may only be conveyed if it is free
from bubbles. Fill the lubricant reservoir - if used -
with clean lubricant without allowing any bubbles
to form. For deaerating the 5/4 way valve
/centralized lubrication system, start running the
feed pump unit until bubble-free lubricant escapes
all lubricating points.
The process of deaerating the centralized lubrica-
tion system is facilitated by:
oOpening the ends of the main pipe until bub-
ble-free lubricant escapes
oFilling longer pipe sections before connecting
the system to the lubricating point
The lubricant may only be fed without bubbles. Air
pockets in the lubricant adversely affect the
function of the gear pump unit and impair the
reliability of lubricant delivery, which can result in
damage to the lubrication points requiring
lubrication.

7. Shutdown Seite 20
EN
7. Shutdown
7.1 Temporary shutdown
You can temporarily shut down the described
product by disconnecting the electrical, pneumatic,
and/or hydraulic supply connections. For more
information, see the section 'General information'
in this installation instructions.
If you wish to shut down the product temporarily,
refer also to the instructions in the section 'Trans-
port, delivery, and storage' of this owner’s manual.
When placing the product back into operation,
refer to the information in the sections 'Installation'
and 'Startup’of this owner’s manual.
7.2 Permanent shutdown
All country specific legal guidelines and legislation
on the disposal of contaminated equipment must
be observed when shutting down the product for
the final time.
Caution!
Lubricants can contaminate the ground
and watercourses. Lubricants must be
used and disposed of properly. Country
specific regulations and laws on the use
and disposal of lubricants must be ob-
served.
SKF Lubrication Systems Germany GmbH will take
back the product and arrange for its legal disposal.
Costs to the customer will be limited to SKF's
incurred costs.