Festo DSBG Series Einrichtungshandbuch

Repair

instructions (en)

Standard cylinders to ISO 15552

DSBG

7DSBGa_en

2 / 49 Festo 7DSBGa_en

Imprint

Version:

7DSBGa_en 06.07.2020

©Festo SE & Co. KG

Postfach

D-73726 Esslingen

Editorial team:

Spare Part Documentation and

Support

Phone:

+49 / 711 / 347-0

Fax:

+49 / 711 / 347-2144

Email:

[email protected]

Internet:

www.festo.com

Reproduction, distribution or sale of

this document or communication of

its contents to others without express

authorisation is prohibited. Offenders

will be held liable for damages. All

rights reserved in the event that a

patent, utility model or design patent

is registered.

All product designations and brand

names used are the property of the

owners and not explicitly identied

as such.

All technical data are subject to

change according to technical

updates.

3 / 49Festo 7DSBGa_en

Foreword

These repair instructions are valid for the ISO cylinder listed on the title page to

the exclusion of any liability claims.

The descriptions in these repair instructions may differ depending on the

version and/or modication status of the ISO cylinder. The user must check

this prior to carrying out the repair and take the deviations into consideration if

necessary.

These repair instructions have been prepared with care.

Festo SE & Co. KG does not, however, accept liability for any errors in these

repair instructions or their consequences. Likewise, no liability is accepted for

direct or consequential damage resulting from incorrect use of the products.

Further information is given in Chapter 8 on page 48.

The relevant regulations on occupational safety, safety engineering, and

interference suppression as well as the stipulations contained in these repair

instructions must be observed when working on the products.

4 / 49 Festo 7DSBGa_en

Table of Contents

1 Important information 6

1.1 About these repair instructions 6

1.2 Symbols used in these repair instructions 6

1.3 Text designations used in these repair instructions 7

1.4 General safety instructions 7

1.5 Technical requirements 8

1.6 Standards and test values 8

2 General product description 9

2.1 Functional description 9

2.2 Type code 9

2.3 Repair-relevant features 10

2.4 Orientation designations 12

2.5 Sizes and part numbers 12

3 Components list 13

3.1 DSBG-... / -A3 13

3.2 DSBG-...-T1 / T4 15

3.3 DSBG-...-T3 / A2 17

3.4 DSBG-...-A6 19

4 Repair steps 21

4.1 Preparatory steps 21

4.2 Visual inspection 22

4.3 Repairing the ISO standard cylinder DSBG-.../ -A3 22

4.3.1 Requirements 22

4.3.2 Validity 22

4.3.3 Structure of the bearing cap 22

4.3.4 Removing the bearing and end caps 23

4.3.5 Replacing the piston components 23

4.3.6 Inserting the piston rod into the cylinder barrel 24

4.3.7 Repairing and attaching the bearing and end caps 25

4.4 Repairing the ISO standard cylinder DSBG-...-T1 /T4 28

4.4.1 Requirements 28

4.4.2 Validity 28

4.4.3 Structure of the bearing cap 28

4.4.4 Removing the bearing and end caps 29

4.4.5 Replacing the piston components 29

4.4.6 Inserting the piston rod into the cylinder barrel 30

4.4.7 Repairing and attaching the bearing and end caps 31

4.5 Repairing the ISO standard cylinder DSBG-...-T3/ A2 34

4.5.1 Requirements 34

4.5.2 Validity 34

4.5.3 Structure of the bearing cap 34

4.5.4 Removing the bearing and end caps 35

4.5.5 Replacing the piston components 35

4.5.6 Inserting the piston rod into the cylinder barrel 36

4.5.7 Repairing and attaching the bearing and end caps 36

5 / 49Festo 7DSBGa_en

Table of Contents

4.6 Repairing the ISO standard cylinder DSBG-...-A6 41

4.6.1 Requirements 41

4.6.2 Validity 41

4.6.3 Structure of the bearing cap 41

4.6.4 Removing the bearing and end caps 42

4.6.5 Replacing the piston components 42

4.6.6 Inserting the piston rod into the cylinder barrel 43

4.6.7 Repairing and attaching the bearing and end caps 43

5 Cleaning and Greasing 47

5.1 Cleaning 47

5.2 Greasing 47

5.2.1 Thin grease lm 47

5.2.2 Grease reservoir 47

6 Maintenance and care 48

7 Tools 48

7.1 Standard tools 48

7.2 Special tools 48

8 Liability 48

6 / 49 Festo 7DSBGa_en

1 Important information

1.1 About these repair instructions

This document contains important information about professional repair of the ISO cylinder of the type DSBG.

The ISO cylinder DSBG is fully repairable in the event of damage due to normal wear.

The entire ISO cylinder must be replaced in the event of damage to the cylinder barrel.

However, the costs of carrying out a repair must be considered in the case of larger defects.

Before carrying out a repair, the relevant chapter in these instructions must be read in full and followed consistently.

For reasons of clarity, these repair instructions do not contain all detailed information. The following documents should

therefore also be available while performing repair work on the ISO cylinder:

– Operating instructions

Contains information about the operating elements and connections of the ISO cylinder, as well as information about

its function, structure, application, installation, commissioning, maintenance and care, etc. This information is availa-

ble on the Festo website (www.festo.com/sp).

– Spare parts documentation

Contains an overview of the spare and wearing parts as well as information on their installation. This can be found in

the online spare parts catalogue on the Festo website (www.festo.com/spareparts).

– “Tools and repair accessories” information brochure

Contains an overview of available assembly aids (e.g. lubricants, locking agent), special tools, schematic diagrams,

xtures, measuring devices, etc. The information can be found in the online spare parts catalogue on the Festo

website (Tools and repair accessories.pdf ).

1.2 Symbols used in these repair instructions

Danger categories

The following symbols identify text passages which draw attention to specic hazards.

Warning

Caution

Marking special information

The following pictograms mark passages in the text which contain special information.

Note

Information

Environment

7 / 49Festo 7DSBGa_en

1.3 Text designations used in these repair instructions

• Activities that can be carried out in any order.

.1 Activities which should be carried out in the specied order.

– General list

Reference to further information

Underlined, blue text indicates a cross-reference or hyperlink that you can click on in the PDF.

1.4 General safety instructions

Caution

Risk of injury due to unintended switching on and unexpected movements.

– Ensure that the ISO cylinder is depressurised and protected against restarting before any repair or maintenance

work is carried out.

Caution

The ISO cylinder may only be repaired by authorised and trained persons in accordance with the specications in the

technical documentation and using genuine spare parts.

Installation and repair by unauthorised and untrained persons, repairs using non-original spare parts or without the

technical documentation required for installation and/or repair are dangerous and therefore not permitted.

Repairs must only be carried out in conjunction with these repair instructions and the respective operating instruc-

tions for the device, as well as the documents listed in Chapter 1.1 on page 6.

Caution

Lifting large loads can lead to permanent injury.

– The ISO cylinder must be lifted by several people or with suitable lifting gear, depending on its size and weight.

Festo recommends use of LOCTITE 243 threadlocker.

In the event of damage caused by unauthorised manipulation, improper use or use of non-original spare parts, all

warranty and liability claims against the manufacturer expire.

Instead of carrying out the repair yourself, your local Festo sales ofce offers the option of having the repair carried

out by Festo.

Due to the high torques, we recommend use of our repair service for cylinders with piston diameter 160 or larger.

Components and equipment replaced during repair must be disposed of in accordance with the relevant local environ-

mental protection regulations.

8 / 49 Festo 7DSBGa_en

1.5 Technical requirements

Note

The following instructions for safe and proper use must be observed:

– Observe the connection and ambient conditions specied in the technical data of the products and all the connect-

ed components. The product can only be operated in compliance with the relevant safety guidelines if you comply

with the limit values and load limits (see enclosed documentation).

– The ISO cylinder must be in faultless technical condition.

– The ISO cylinder may only be operated in its original condition and without unauthorised modications.

– The ISO cylinder is designed for industrial use.

1.6 Standards and test values

Standards and test values which products comply with and full can be found in the “Technical data” sections of the

enclosed documentation.

9 / 49Festo 7DSBGa_en

2 General product description

2.1 Functional description

The piston moves in the cylinder barrel when the cylinder chamber is pressurised. The piston rod transfers the movement

to the outside. The advanced piston rod is retracted again when the other cylinder chamber is pressurised.

aJ98761 3 4 52

Illustrated: DSBG-32-...-PPV-...

1Piston rod

2Scraper ring

3Bearing cap

4Adjustment of front end-position

cushioning (only with PPV)

5Front compressed air port

6Cushion piston (only with PPV)

7Piston

8Cushion piston (only with PPV)

9Buffer seal (only in PPV / PPS)

aJ Rear compressed air port

aA Adjustment of rear end-position

cushioning (only with PPV)

aB End cap

(in DSBG-...-T:

Rear bearing cap)

aC Holding disc

(only in DSBG-32 ... 63)

aD Cylinder barrel

aE Tie rod

2.2 Type code

The precise features of a standard cylinder can be determined with the help of the rating plate on the cylinder. The type

code is positioned directly beneath the Festo logo and describes the features of a standard cylinder separated by a

hyphen (-).

Example:

DSBG-32-100-PPV-A-N3-T1

1634484 C608

pmax. 12 bar

1Type designation

2Serial number

3Technical information

4Part number

The type designation on this name plate provides the following information:

DSBG ISO cylinder of the type DSBG

32 Piston diameter 32 mm

100 Stroke 100 mm

PPV Pneumatic cushioning, adjustable at both ends

APosition sensing option (for proximity switch)

N3 Conforms to ISO 15552

T1 Heat-resistant seals 0 up to +120 °C (Chapter 2.3 on page 10)

A list and description of all possible equipment features of the ISO cylinder can be found on the data sheet. The data

sheet is available on the Festo website (www.festo.com).

10 / 49 Festo 7DSBGa_en

2.3 Repair-relevant features

The ISO standard cylinder is equipped with repair-relevant and other, optional features.

These features are listed in the table with a page reference to the corresponding repair instructions.

Repair-relevant features (bearing cap variants) Other optional features Page

DSBG-... Standard version,

without repair-relevant feature

Q, L, U, L1, P, PPV, PPS, T, F,

A, N3, R3, P2, EX4, ...V, ...Y, V,

...E, ...L, ...S, M..., B1, B2, B3,

...LB2, ...LB3

DSBG-...-A3

Suitable for unlubricated operation

P, PPV, PPS, T, F, A, R3, ...V,

...Y, V, ...E, ...L, ...S, M..., B1,

B2, B3, ...LB2, ...LB3

DSBG-...-T1 (without A6)

Heat-resistant seals 0 to +120 °C

DSBG-...-T4 (without A6)

Heat-resistant seals 0 to +150 °C

P, PPV, T, F, A, N3, R3, ...V, ...Y,

V, ...E, ...L, ...S, M..., B1, B2,

B3, ...LB2, ...LB3

DSBG-...-T3 (without A6)

Resistant to low temperature –40 to + 80 °C

P, PPV, T, F, A, N3, R3, ...V, ...Y,

V, ...E, ...L, ...S, M..., B1, B2,

B3, ...LB2, ...LB3

DSBG-...-A2

Hard scraper

P, PPV, PPS, T, F, A, N3, EX4,

...V, ...Y, V, ...E, ...L, ...S, M...,

B1, B2, B3, ...LB2, ...LB3

DSBG-...-A6/ T1-A6 /T3-A6 /T4-A6

Metal scraper

P, PPV, PPS, T, F, A, N3, ...V,

...Y, V, ...E, ...L, ...S, M..., B1,

B2, B3, ...LB2, ...LB3

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