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)
Copyright:
©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.
aA
aB
aC
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
1
42
3
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).
1
11
9
11
29
27
10
14
15
16
10
22
17
20
22
18
23
19
24
20
21
23
25
26
16
12
13
5
28
2
3
4
5
1
3
4
6
8
7
5
18
17
22
17
20
22
18
19
24
20
21
18
17
17
20
18
19
24
20
21
18
17
30
6
8
7
9
6
8
7

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