Festo DNG Series Setup guide

Repair

instructions (en)

Cylinder with piston rod

Standard cylinder to ISO 15552

DNG/DNGL/DNGLZ

DNGZK / DNGZS

7DNGa_en

2 / 28 Festo 7DNGa_en

Imprint

at:

7DNGa_en (06.2013)

©Festo AG & Co. KG

Postfach

73726 Esslingen

Germany

Editorial team:

SC-S

Tel.:

+49 (0) 711 / 347-0

Fax:

+49 (0) 711 / 347-2144

E-mail:

[email protected]

Internet:

http://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 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 / 28Festo 7DNGa_en

Preface

These repair instructions are valid for the cylinders with piston rod listed on

the title page to the exclusion of any liability claims.

Deviations compared to the descriptions in these repair instructions may arise

depending on the design and/or modication status of the cylinder with piston

rod. The user must check this prior to carrying out the repair and take the

deviation into consideration if necessary.

These repair instructions have been prepared with care.

Festo AG & 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 improper use of the products.

More detailed information on this can be found in chapter 8 "Liability".

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 / 28 Festo 7DNGa_en

Table of contents

1 Important information 5

1.1 About these repair instructions 5

1.2 Pictograms used in these repair instructions 5

1.3 General safety instructions 6

2 General product description 6

2.1 Functional description 6

2.2 Type codes (ascertaining the features of a cylinder) 7

2.3 Repair-relevant features 7

2.4 Mounting direction and bearing cap variants 8

3 Component overview 9

3.1 Component overview up to a piston diameter of 100 mm 9

3.2 Component overview from a piston diameter of 125 mm 11

4 Repair steps 13

4.1 Preparation 13

4.2 Visual inspection 13

4.3 Repairing the cylinders DNG / DNGL / DNGLZ / DNGZK and DNGLZS-… 13

4.3.1 Structure of the bearing cap 14

4.3.2 Removing the bearing and end caps 14

4.3.3 Replacing the piston components 15

4.3.4 Inserting the piston rod into the cylinder barrel 16

4.3.5 Repairing and attaching the bearing and end caps 16

4.4 Repairing the cylinders DNG / DNGL / DNGLZ / DNGZK / DNGLZS-…-S6 19

4.4.1 Structure of the bearing cap 19

4.4.2 Removing the bearing and end caps 20

4.4.3 Replacing the piston components 20

4.4.4 Inserting the piston rod into the cylinder barrel 21

4.4.5 Repairing and attaching the bearing and end caps 22

4.5 Repairing the adjustable end-position cushioning (PPV) 24

4.5.1 Disassembling the adjustable end-position cushioning (PPV) 25

4.5.2 Assembling the adjustable end-position cushioning (PPV) 25

5 Cleaning and greasing 26

5.1 Cleaning 26

5.2 Greasing 26

5.2.1 Extremelythingreaselm 26

5.2.2 Thingreaselm 26

5.2.3 Grease reservoir 26

6 Maintenance and care 26

7 Tools 27

7.1 Standard tools 27

7.2 Special tools 27

8 Liability 27

5 / 28Festo 7DNGa_en

1 Important information

1.1 About these repair instructions

This document contains important

information about the professional

repair of cylinders with piston rod

type DNG / DNGL / DNGLZ / DNGZK /

DNGZS.

The cylinders with piston rod DNG /

DNGL / DNGLZ / DNGZK / DNGZS are

fully repairable in the event of damage

caused by normal wear. The entire

cylinder must be replaced in the event

of damage to the cylinder barrel.

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 complete

detailed information. The following

documents should therefore also be

available when repairing the cylinder

with piston rod:

• Operating instructions for the

respective cylinder with piston rod

Contains information about the

control sections and connections

of the cylinder with piston rod as

well as the function, structure,

application, installation,

commissioning, maintenance

and care, etc. Can be found on the

Festo website (www.Festo.com).

• Spare parts documentation

Contains an overview of the spare

and wearing parts as well as

information on their installation.

Can be found in the online spare

parts catalogue on the Festo

website (spareparts.festo.com).

• Assembly aids

Contain an overview of available

assembly aids such as lubricating

greases, locking agents,

maintenance tools, etc. (aids

for assembly and maintenance).

Can be found in the online spare

parts catalogue on the Festo

website (www.Festo.com).

1.2 Pictograms used in these repair instructions

Warning

This sign indicates a dangerous situation for persons and/or the product. Failure to observe this warning can result in

injury to persons and/or damage to the device.

Note

This sign provides important tips and information that can make your work easier.

Environment

This sign provides information on the steps required for environmentally-friendly use of materials and equipment,

as well as the guidelines and regulations that may need to be observed.

Accessories

This sign contains information on accessories and attachments relevant to the context.

Documents

This sign contains references to other chapters or documents containing additional information.

6 / 28 Festo 7DNGa_en

1.3 General safety instructions

Warning

The cylinder with piston rod must only be repaired by authorised and trained persons in accordance with the

specications in the technical documentation and using original spare parts.

Installation and repair by unauthorised and untrained persons, repairs using non-original spare parts as well as 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 device-specic operating

instructions.

Note

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

out by Festo.

Environment

Components and equipment replaced as part of a repair must be disposed of in accordance with the locally valid

environmental protection regulations.

2 General product description

2.1 Functional description

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

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

aJ981 3 4 6 752 1Piston rod

2Piston rod seal

3Bearing cap

4Front adjustable end-position

cushioning

5Front compressed air connection

6Tie rod

7Cylinder barrel

8Cushioning boss

9Piston (one-piece)

aJ Cushioning boss

aA Rear adjustable end-position

cushioning

aB Rear compressed air connection

aC End cap

(with S2 : Rear bearing cap)

7 / 28Festo 7DNGa_en

2.2 Type codes (ascertaining the features of a cylinder)

The precise features of the current cylinder with piston rod can be ascertained with the help of the rating plate on

the cylinder. The type designation is located directly beneath the Festo logotype and describes the cylinder's features

separated by a hyphen (-).

Example:

DNG-32-100-PPV-A

36325 C508

p max: 12 bar

1Type designation

2Serial number

3Technical information

4Part number

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

DNG Cylinder type DNG

32 Piston diameter 32 mm

100 Stroke 100 mm

PPV Adjustable end-position cushioning

ASensing option (magnetic piston)

Note

A list and description of all possible equipment features of the cylinder with piston rod can be found in the data sheet.

It is available on the Festo website (www.Festo.com).

2.3 Repair-relevant features

Some of the features that the cylinder with piston rod can be equipped with require a different repair approach. These are

referred to as "repair-relevant" features and are listed in the left-hand column in the table below.

If the cylinder to be repaired has one of these repair-relevant features, the appropriate repair description (see right-hand

column in the table below) must be used.

Note

A cylinder can only have one repair-relevant feature. It can additionally be equipped with one or more other features

(see middle column).

Cylinder and repair-relevant feature Other features Described from page

DNG / DNGL / DNGLZ / DNGZK / DNGLZS-… without repair-

relevant feature

PPV, A, S2, S3, S8 13

DNG / DNGL / DNGLZ / DNGZK / DNGLZS-…-S6

(heat-resistant seals up to a max. 120°C)

PPV, A, S3, S8 19

Example for the cylinder in chapter 2.2 "Type codes (ascertaining the features of a cylinder)"

Of the features in the sample cylinder, the feature "S6" is relevant to the repair. The description in chapter

4.4 "Repairing the cylinders DNG / DNGL / DNGLZ / DNGZK / DNGLZS-…-S6" on page 19 must therefore be used to

repair this cylinder with piston rod.

8 / 28 Festo 7DNGa_en

2.4 Mounting direction and bearing cap variants

This diagram provides an overview of the orientation designations of the cylinder with piston rod as well as the different

variants of the bearing cap and seals for repair-relevant features.

Orientation:

Festo=product identi cation

(rating plate) as reference point

O = top

U = underneath

R = right

L = left

V = front

H = rear

Key features:

S6 = Heat-resistant seals

9 / 28Festo 7DNGa_en

3 Component overview

3.1 Component overview up to a piston diameter of 100 mm

This diagram is intended only to provide an overview of the individual components. To order spare and wearing parts, please use the

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

10 / 28 Festo 7DNGa_en

Item Designation Note

1 Hex nut

2 Retaining ring Only with -S6

3 Piston rod seal

4 Bearing

5 Collar nut Use screw locking agent

6 O-ring

7 Regulating screw

8 Serrated ring

9 Bearing cap

10 Sealing ring

11 Cushioning seal

12 Washer

13 Tie rod

14 Piston rod, secured against rotating DNGLZ and DNGLZ only

15 Piston rod

16 Cushioning boss

17 Lip ring (piston seal)

18 Piston, two-piece

19 Socket DNGLZ and DNGLZ only (piston rod, secured against rotating)

20 O-ring

21 Slip ring

22 O-ring Only at a piston diameter of 32 mm and 40 mm

23 Washer Only at a piston diameter of 32 mm

24 Ring magnet

25 Threaded coupling Not S2, use screw locking agent

26 Piston rod Only S2, use screw locking agent?

27 Cylinder barrel

28 Socket head screw DNGLZ and DNGZK only

29 Trunnion mounting DNGLZ and DNGZK only

30 End cap

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