Festo DSBG Series Setup guide

Repair
instructions (en)
Standard cylinders to ISO 15552
DSBG
7DSBGa_en

2 / 49 Festo 7DSBGa_en
Imprint
Version:
7DSBGa_en 06.07.2020
Copyright:
©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

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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

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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.

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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.

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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.
aB
aD
aE
aC
aA
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
1
42
3
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).

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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
22
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
28
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
34
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
41

11 / 49Festo 7DSBGa_en
Explanation of the other, optional features
QPiston rod, square (protection against rotation)
LRunning characteristic: low friction
URunning characteristic: constant, slow movement
L1 Low friction for balancer applications
TThrough piston rod
FPiston rod with female thread
PElastic cushioning rings/pads at both ends
PPV Pneumatic cushioning, adjustable at both ends
PPS Pneumatic cushioning, self-adjusting at both ends
APosition sensing option (for proximity switch)
N3 Corresponds to ISO 15552
R3 High corrosion protection
P2 Bellows on the bearing cap
EX4 Approval II 2GD to EU Ex-Protection Directive (ATEX)
VMiddle swivel mounting
...Y Swivel pivot mounting position, positive locking
...E Extended piston rod
...L Extended piston rod thread
M... Piston rod thread
B1 Collar nut with integrated spacer bolt, both ends
B2 Collar nut with integrated spacer bolt, on the bearing cap
B3 Collar nut with integrated spacer bolt, on the end cap
...LB2 Spacer bolt thread length, on bearing cap
...LB3 Spacer bolt thread length, on end cap
Application examples
Example 1 (from Chapter 2.2 on page 9): ISO standard cylinder DSBG-32-100-PPV-A-N3-T1-
The ISO standard cylinder includes the repair-relevant feature “T1”.
Use the instructions in Chapter 4.4 on page 28 for repairs.
Example 2: ISO standard cylinder DSBG-32-100-PPV-A-N3-T1-A6
The ISO standard cylinder includes the repair-relevant feature combination “T1-A6”.
Use the instructions in Chapter 4.6 on page 41 for repairs.

12 / 49 Festo 7DSBGa_en
2.4 Orientation designations
This illustration provides an overview of the orientation designations of the ISO cylinder.
Festo=Product identication (rating
plate) as reference point
O = top
U = bottom
R = right
L = left
V = front
H = rear
2.5 Sizes and part numbers
You will nd the complete overview of features, accessories, type codes, technical data and dimensions in the product
catalogue or on the Festo website (www.festo.com).
Size Module number
DSBG-...-32- - 1634484
DSBG-...-40- - 1645477
DSBG-...-50- - 1646707
DSBG-...-63- - 1646738
DSBG-...-80- - 1646769
DSBG-...-100- - 1646799
DSBG-...-125- - 2045493
DSBG-...-160- - 2036032
DSBG-...-200- - 2344936
DSBG-...-250- - 2732003
DSBG-...-320- - 2776472

13 / 49Festo 7DSBGa_en
3 Components list
3.1 DSBG-.../-A3
This component overview does not apply to ISO standard cylinders with the following features: T1/ T3 /T4 / A2 / A6.
This diagram is intended to provide an overview of the individual components and an aid when ordering. For a more de-
tailed assembly overview, refer to the online spare parts catalogue on the Festo website (www.festo.com/spareparts).

14 / 49 Festo 7DSBGa_en
DSBG-... / A3
Item Designation Note
1 Spacer bolt only DSBG-160 / 200 / 250 / 320-...-LB2-...
2 Collar nut
3 Hex nut
4 Scraper ring
5 Bearing (plastic) interchangeable;
in DSBG-...-Q / L/ U/ EX4: bearing (metal), pressed in, not interchangeable
6 Bearing cap
7 O-ring
8 Cushioning seal only DSBG-...-PPV / PPS-...
9 Holding disc only DSBG-32 / 40 / 50 / 63-...
10 Cushioning element only DSBG-160 / 200 / 250 / 320-...
11 Tie rod
12 Piston rod, round DSBG-... (not in DSBG-...-Q)
13 Piston rod, protected against
rotation
only DSBG-...-Q
14 Cushioning boss /buffer sleeve only DSBG-...-PPV / PPS-...
15 Piston only DSBG-32 / 40 (from E7)-...
16 Piston washer only DSBG-40 (up to E6) / 50 / 63 / 80 / 100 / 125-...
17 Guide band only DSBG-40 (up to E6) / 50 / 63 / 80 / 100 / 125-...
18 O-ring only DSBG-40 (up to E6) / 50 / 63 / 80 / 100 / 125-...
19 Ring magnet only DSBG-40 (up to E6) / 50 / 63 / 80 / 100 / 125-...
20 Washer only DSBG-250 / 320-...
21 Lip ring only DSBG-160 / 200 / 250 / 320-...
22 Piston only DSBG-160 / 200 / 250 / 320-...
23 Guide band only DSBG-160 / 200 / 250 / 320-...
24 O-ring only DSBG-160 / 200 / 250 / 320-...
25 Magnetic strip only DSBG-160 / 200 / 250 / 320-...
26 Threaded coupling only DSBG-... with single-ended piston rod
27 Rear piston rod only DSBG-...-T-... (through piston rod)
28 Cylinder barrel
29 End cap only DSBG-... with single-ended piston rod
30 Rear bearing cap only DSBG-...-T-... (through piston rod)
31 Spacer bolt only DSBG-160 / 200 / 250 / 320-...-LB3-...

15 / 49Festo 7DSBGa_en
3.2 DSBG-...-T1/T4
This component overview does not apply to ISO standard cylinders with feature combinations “T1-A6” or “T4-A6”.
This diagram is intended to provide an overview of the individual components and an aid when ordering. For a more de-
tailed assembly overview, refer to the online spare parts catalogue on the Festo website (www.festo.com/spareparts).

16 / 49 Festo 7DSBGa_en
DSBG-... -T1 / T4
Item Designation Note
1 Spacer bolt only DSBG-160 / 200 / 250 / 320-...-LB2-...
2 Collar nut
3 Hex nut
4 Circlip
5 Scraper ring
6 Bearing (metal) pressed in, not interchangeable
7 Bearing cap
8 O-ring
9 Cushioning seal only DSBG-...-PPV / PPS-...
10 Holding disc only DSBG-32 / 40 / 50 / 63-...
11 Cushioning element only DSBG-160 / 200 / 250 / 320-...
12 Tie rod
13 Piston rod, round DSBG-... (not in DSBG-...-Q-...)
14 Piston rod, protected against
rotation
only DSBG-...-Q-...
15 Cushioning boss / buffer sleeve only DSBG-...-PPV / PPS-...
16 Piston only DSBG-32 / 40 (from E7)-...
17 Piston washer only DSBG-40 (up to E6) / 50 / 63 / 80 / 100 / 125-...
18 Guide band only DSBG-40 (up to E6) / 50 / 63 / 80 / 100 / 125-...
19 O-ring only DSBG-40 (up to E6) / 50 / 63 / 80 / 100 / 125-...
20 Ring magnet only DSBG-40 (up to E6) / 50 / 63 / 80 / 100 / 125-...
21 Washer only DSBG-250 / 320-...
22 Lip ring only DSBG-160 / 200 / 250 / 320-...
23 Piston only DSBG-160 / 200 / 250 / 320-...
24 Guide band only DSBG-160 / 200 / 250 / 320-...
25 O-ring only DSBG-160 / 200 / 250 / 320-...
26 Magnetic strip only DSBG-160 / 200 / 250 / 320-...
27 Threaded coupling only DSBG-... with single-ended piston rod
28 Rear piston rod only DSBG-...-T-... (through piston rod)
29 Cylinder barrel
30 End cap only DSBG-... with single-ended piston rod
31 Rear bearing cap only DSBG-...-T-... (through piston rod)
32 Spacer bolt only DSBG-160 / 200 / 250 / 320-...-LB3-...

17 / 49Festo 7DSBGa_en
3.3 DSBG-...-T3/A2
This component overview does not apply to ISO standard cylinders with the feature combination: “T3-A6”.
This diagram is intended to provide an overview of the individual components and an aid when ordering. For a more de-
tailed assembly overview, refer to the online spare parts catalogue on the Festo website (www.festo.com/spareparts).

18 / 49 Festo 7DSBGa_en
DSBG-... -T3 / A2
Item Designation Note
1 Spacer bolt only DSBG-...-LB2-...
2 Collar nut
3 Hex nut
4 Screw insert only DSBG-32 / 40 / 50 / 63 / 80 / 100-...
5 Circlip only DSBG-125-...
6 O-ring
7 Excluder
8 Insert sleeve
9 Scraper ring
10 O-ring
11 Flanged bearing (plastic)
Bearing (plastic)
only DSBG-32 ... 100-...-T3; interchangeable
only DSBG-125-...-T3; interchangeable
12 Bearing (metal) only DSBG-...-A2; pressed in, not interchangeable
13 Bearing cap
14 O-ring
15 Cushioning seal only DSBG-...-PPV / PPS-...
16 Holding disc only DSBG-32 / 40 / 50 / 63-...
17 Tie rod
18 Piston rod
19 Cushioning boss / buffer sleeve only DSBG-...-PPV / PPS-...
20 Piston only DSBG-32 / 40 (from E7)-...
21 Piston washer only DSBG-40 (up to E6) / 50 /63 / 80 / 100 / 125-...
22 Guide band only DSBG-40 (up to E6) / 50 /63 / 80 / 100 / 125-...
23 O-ring only DSBG-40 (up to E6) / 50 /63 / 80 / 100 / 125-...
24 Ring magnet only DSBG-40 (up to E6) / 50 /63 / 80 / 100 / 125-...
25 Threaded coupling only DSBG-... with single-ended piston rod
26 Rear piston rod only DSBG-...-T-... (through piston rod)
27 Cylinder barrel
28 End cap only DSBG-... with single-ended piston rod
29 Rear bearing cap only DSBG-...-T-... (through piston rod)
30 Spacer bolt only DSBG-...-LB3-...

19 / 49Festo 7DSBGa_en
3.4 DSBG-...-A6
This components list also applies to ISO cylinder with the feature combinations “T1-A6”, “T3-A6” or “T4-A6”.
This diagram is intended to provide an overview of the individual components and an aid when ordering. For a more de-
tailed assembly overview, refer to the online spare parts catalogue on the Festo website (www.festo.com/spareparts).

20 / 49 Festo 7DSBGa_en
DSBG-... -A6
Item Designation Note
1 Spacer bolt only DSBG-160 / 200-...-LB2-...
2 Collar nut
3 Hex nut
4 Circlip
5 Distance sleeve
6 Scraper
7 Insert sleeve
8 Scraper ring
9 O-ring
10 Bearing (plastic) only DSBG-...-...-A6 / T3-A6; interchangeable
11 Bearing (metal) only DSBG-...-T1-A6 / T4-A6 (DSBG-160 / 200-... : 2-piece); pressed in, not interchangeable
12 Bearing cap
13 O-ring
14 Cushioning seal only DSBG-...-PPV / PPS-...
15 Holding disc only DSBG-32 / 40 / 50 / 63-...
16 Cushioning element only DSBG-160 / 200-...
17 Tie rod
18 Piston rod
19 Cushioning boss / buffer
sleeve
only DSBG-...-PPV / PPS-...
20 Piston only DSBG-32 / 40 (from E7)-...
21 Piston washer only DSBG-40 (up to E6) / 50 /63 / 80 / 100 / 125-...
22 Guide band only DSBG-40 (up to E6) / 50 /63 / 80 / 100 / 125-...
23 O-ring only DSBG-40 (up to E6) / 50 /63 / 80 / 100 / 125-...
24 Ring magnet only DSBG-40 (up to E6) / 50 /63 / 80 / 100 / 125-...
25 Lip ring only DSBG-160 / 200-...
26 Piston only DSBG-160 / 200-...
27 Guide band only DSBG-160 / 200-...
28 O-ring only DSBG-160 / 200-...
29 Magnetic strip only DSBG-160 / 200-...
30 Threaded coupling only DSBG-... with single-ended piston rod
31 Rear piston rod only DSBG-...-T-... (through piston rod)
32 Cylinder barrel
33 End cap only DSBG-... with single-ended piston rod
34 Rear bearing cap only DSBG-...-T-... (through piston rod)
35 Spacer bolt only DSBG-160 / 200-...-LB3-...