Festo DSBC Series Setup guide

Repair
instructions (en)
Standard cylinders to ISO 15552
DSBC
7DSBCa_en

2 / 56 Festo 7DSBCa_en
About this magazine
Version:
7DSBCa_en (26.07.2018)
Copyright:
©Festo AG & Co. KG
Postfach
73726 Esslingen
Germany
Editorial team:
Spare Part Documentation and
Support
Phone:
+49 / 711 / 347-0
Fax:
+49 / 711 / 347-2144
E-mail:
[email protected]
Internet:
www.festo.com
The 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 / 56Festo 7DSBCa_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 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 incorrect use of the products.
Further information is given in Chapter 8 on page 55.
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 / 56 Festo 7DSBCa_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 6
1.4 General safety information 7
1.5 Technical requirements 8
1.6 Standards and test values 8
2 General product description 8
2.1 Functional description 8
2.1.1 DSBC-… 9
2.1.2 DSBC-…-C (with clamping unit) 9
2.1.3 DSBC-…-E1 / E2 / E3 (with end-position locking) 10
2.2 Type code 10
2.3 Repair-relevant features 11
2.4 Orientation designations 13
2.5 Sizes and part numbers 13
2.5.1 Standard cylinder DSBC, ISO 15552 13
2.5.2 ISO cylinder DSBC, standard hole pattern, with clamping unit 13
2.5.3 ISO cylinder DSBC, standard hole pattern, with end-position locking 13
3 Components list 14
3.1 DSBC-… / A3 14
3.1.1 DSBC-…-C (with clamping unit) 16
3.1.2 DSBC-…-E1 / E2 / E3 (with end-position locking) 18
3.2 DSBC-…-T1 / T4 / A1 and DSBC-…-L / U / L1 20
3.3 DSBC-…-T3 / A2 22
3.4 DSBC-…-A6 24
4 Repair steps 26
4.1 Preparatory steps 26
4.2 Visual inspection 26
4.3 Repairing the ISO cylinder DSBC-…/ A3 27
4.3.1 Requirements 27
4.3.2 Validity 27
4.3.3 Structure of the bearing cap 27
4.3.4 Removing the bearing and end cap 28
4.3.5 Replacing the piston components 28
4.3.6 Inserting the piston rod into the cylinder barrel 29
4.3.7 Repairing and attaching the bearing and end caps 29
4.4 Additional repair steps for DSBC-…-C (with clamping unit) 32
4.4.1 Structure of the clamping unit 32
4.4.2 Dismantling the clamping unit 32
4.4.3 Repairing the clamping unit 33
4.4.4 Mounting the clamping unit 33

5 / 56Festo 7DSBCa_en
Table of contents
4.5 Additional repair steps for DSBC-…-E1 / E2 / E3 (with end-position locking) 35
4.5.1 Structure of the bearing cap with end-position locking 35
4.5.2 Unlocking the end-position locking manually 35
4.5.3 Dismantling the stop cylinder 36
4.5.4 Mounting the bearing or end cap with end-position locking 36
4.5.5 Mounting the lock cylinder 36
4.5.6 Releasing the end-position locking 36
4.6 Repairing the ISO cylinder DSBC-…-T1/T4/A1 and DSBC-...-L/U / L1 37
4.7 Requirements 37
4.7.1 Validity 37
4.7.2 Structure of the bearing cap 37
4.7.3 Removing the bearing and end caps 38
4.7.4 Replacing the piston components 38
4.7.5 Inserting the piston rod into the cylinder barrel 39
4.7.6 Repairing and attaching the bearing and end caps 39
4.8 Repairing the ISO cylinder DSBC-…-T3/ A2 42
4.8.1 Requirements 42
4.8.2 Validity 42
4.8.3 Structure of the bearing cap 42
4.8.4 Removing the bearing and end caps 43
4.8.5 Replacing the piston components 43
4.8.6 Inserting the piston rod into the cylinder barrel 44
4.8.7 Repairing and attaching the bearing and end caps 44
4.9 Repairing the ISO cylinder DSBC-…-A6 48
4.9.1 Requirements 48
4.9.2 Validity 48
4.9.3 Structure of the bearing cap 48
4.9.4 Removing the bearing and end caps 49
4.9.5 Replacing the piston components 49
4.9.6 Inserting the piston rod into the cylinder barrel 50
4.9.7 Repairing and attaching the bearing and end caps 51
5 Cleaning and greasing 53
5.1 Cleaning 53
5.2 Greasing 53
5.2.1 Thin grease lm 54
5.2.2 Grease reservoir 54
6 Maintenance and care 54
7 Tools 54
7.1 Standard tools 54
7.2 Special tools 54
8 Liability 55

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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 DSBC.
The ISO cylinder DSBC 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
available 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 the available installation resources, e.g. lubricating greases, threadlocking agents,
maintenance tools, etc. (resources for installation and maintenance). The brochure 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 / 56Festo 7DSBCa_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.
Reference to further information
– General list
Underlined, blue text indicates a cross-reference or hyperlink that you can click on in the PDF.
1.4 General safety information
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 device-specic
operating instructions.
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.
Note
• Observe the given tightening torques. If no special information is given the tightening torques given in the relevant
standard apply to the screws, bolts and nuts used.
• Note the strength class of the screws, bolts and nuts!
Note
Carrying out repair work without the respective necessary technical documentation is dangerous, and therefore
not permissible. Repairs must only be carried out in conjunction with these repair instructions and the respective
operating instructions for the device, as well as the documents listed in Chapter 1.1 on page 6.
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.

8 / 56 Festo 7DSBCa_en
Instead of carrying out the repair yourself, your local Festo sales ofce offers the option of having the repair carried
out by Festo.
Components and equipment replaced during repair must be disposed of in accordance with the relevant local
environmental protection regulations.
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
connected 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 / 56Festo 7DSBCa_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.
2.1.1 DSBC-…
aB
aD
aC
aA
aJ9876
13 4 52
Illustrated: DSBC-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 DSBC-…-T:
Rear bearing cap)
aC Holding disc
(only in DSBC-32 … 63)
aD Cylinder barrel
2.1.2 DSBC-…-C (with clamping unit)
1 32
Illustrated: DSBC-32-…-C
Additional components
1Holder of the clamping unit
2Clamping cartridge
3Connection for compressed air or
mounting screw

10 / 56 Festo 7DSBCa_en
2.1.3 DSBC-…-E1/E2/E3 (with end-position locking)
4
3
12
Illustrated: DSBC-32-…-E1 (end-position locking at both ends)
Additional components
1Slot in the piston rod for the end-
position locking:
Piston rod advanced
2Slot in the piston rod for end-
position locking:
Piston rod retracted
3 Rear end-position locking (piston
rod retracted)
4 Front end-position locking
(piston rod advanced)
2.2 Type code
The precise features of an ISO cylinder can be determined with the help of the product labelling on the cylinder. The order
code is positioned directly beneath the Festo logo and describes the ISO cylinder's features separated by a hyphen “-”.
Example:
DSBC-32-100-PPV-A-N3-T1
1463250 C608
pmax. 12 bar
1
42
3
1Order code
2Serial number
3Technical information
4Part number
The order code on the product labelling provides the following information:
DSBC ISO cylinder of the type DSBC
32 Size: Piston diameter 32 mm
100 Stroke 100 mm
PPV Adjustable end-position cushioning
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 11)
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 cylinder is equipped with repair-relevant and other, optional features.
Repair-relevant features require a different repair procedure. The repair-relevant features are listed in the table with a
reference to the corresponding repair description.
Bearing cap variants and repair-relevant features Other optional features Page
DSBC-… Standard version,
without repair-relevant feature
Additional repair steps for :
Q, C, E1, E2, E3, P, PPV, PPS,
T, F, D3, A, N3, R3, P2, EX4,
L1, …E, …L
27
DSBC-…-C (with clamping unit) 32
DSBC-…-E1 / E2 / E3 (with end-position locking) 35
DSBC-…-A3
Suitable for unlubricated operation
P, PPV, PPS, T, F, D3, A, R3,
…E, …L
27
DSBC-…-T1 (without A6)
Heat-resistant seals 0 to +120 °C
DSBC-…-T4 (without A6)
Heat-resistant seals 0 to +150 °C
Q (only with T1), P, PPV, T, F,
D3, A, N3, R3, P2, …E, …L
37
DSBC-L
Low friction
DSBC-U
Constant, slow movement
P, PPV, PPS, F, D3, A, …E, …L
DSBC-L1
Low friction for balancer applications
P, PPS, F, D3, A, …E, …L
DSBC-…-A1
Increased chemical resistance
PPV, T, F, D3, A, N3, R3, P2,
…E, …L

12 / 56 Festo 7DSBCa_en
Bearing cap variants and repair-relevant features Other optional features Page
DSBC-…-T3 (without A6)
Resistant to low temperature –40 to + 80 °C
P, PPV, T, F, D3, A, N3, R3, P2,
…E, …L
42
DSBC-…-A2
Hard scraper
P, PPV, PPS, T, F, D3, A, N3,
EX4, …E, …L
DSBC-…-A6 /T1-A6/T3-A6 /T4-A6
Metal scraper
P, PPV, PPS, T, F, D3, A, N3, T1,
T3, T4, …E, …L
48
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
CClamping unit attached
E1 End-position locking, at both ends
E2 End-position locking, with advanced piston rod
E3 End-position locking, with retracted piston rod
TThrough piston rod
FPiston rod with female thread
D3 Cylinder prole with sensor slots on 3 sides
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)
…E Extended piston rod
…L Extended piston rod thread

13 / 56Festo 7DSBCa_en
2.4 Orientation designations
This illustration provides an overview of the orientation designations of the ISO cylinder.
Festo=Reference point for product
labelling
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).
2.5.1 Standard cylinder DSBC, ISO 15552
Size Module number
DSBC-…-32- - 1463250
DSBC-…-40- - 1461995
DSBC-…-50- - 1463770
DSBC-…-63- - 1463475
DSBC-…-80- - 1463495
DSBC-…-100- - 1463520
DSBC-…-125- - 1722457
2.5.2 ISO cylinder DSBC, standard hole pattern, with clamping unit
Size Module number
DSBC-…-32-C- - 1463250
DSBC-…-40-C- - 1461995
DSBC-…-50-C- - 1463770
DSBC-…-63-C- - 1463475
DSBC-…-80-C- - 1463495
DSBC-…-100-C- - 1463520
DSBC-…-125-C- - 1722457
2.5.3 ISO cylinder DSBC, standard hole pattern, with end-position locking
Size Module number
DSBC-…-32-E1 / E2 / E3- - 1463250
DSBC-…-40-E1 / E2 / E3- - 1461995
DSBC-…-50-E1 / E2 / E3- - 1463770
DSBC-…-63-E1 / E2 / E3- - 1463475
DSBC-…-80-E1 / E2 / E3- - 1463495
DSBC-…-100-E1 / E2 / E3- - 1463520

14 / 56 Festo 7DSBCa_en
3 Components list
3.1 DSBC-…/ A3
Separate component lists for ISO cylinder with clamping unit or end-position locking:
– DSBC-…-C (with clamping unit): Chapter 3.1.1 on page 16.
– DSBC-…-E1 / E2 / E3 (with end-position locking): Chapter 3.1.2 on page 18.
This diagram is intended to provide an overview of the individual components and an aid when ordering.
For a more detailed assembly overview, refer to the online spare parts catalogue on the Festo website
(www.festo.com/spareparts).

15 / 56Festo 7DSBCa_en
DSBC-… / A3
Item Designation Note
1 Flange screw
2 Hex nut
3 Scraper ring
4 Bearing (plastic)
Bearing (metal) for DSBC-…-Q / E1 / E2 / E3 / EX4
5 Bearing cap
6 O-ring
7 Cushioning seal only DSBC-…-PPV / PPS-…
8 Holding disc only DSBC-32 / 40 / 50 / 63-…
9 Piston rod, round DSBC-… (not for DSBC-…-Q-…)
10 Piston rod, protected against rotation only DSBC-…-Q-…
11 Cushioning boss / buffer sleeve only DSBC-…-PPV / PPS-…
12 Piston only DSBC-32 / 40 (from E7)-…
13 Piston washer only DSBC-40 (up to E6) / 50 / 63 / 80 / 100 / 125-…
14 Guide band only DSBC-40 (up to E6) / 50 / 63 / 80 / 100 / 125-…
15 O-ring only DSBC-40 (up to E6) / 50 / 63 / 80 / 100 / 125-…
16 Ring magnet only DSBC-40 (up to E6) / 50 / 63 / 80 / 100 / 125-…
17 Threaded coupling only DSBC-…
18 Rear piston rod only DSBC-…-T-…
19 Cylinder barrel
20 End cap only DSBC-…
21 Rear bearing cap only DSBC-…-T-…

16 / 56 Festo 7DSBCa_en
3.1.1 DSBC-…-C (with clamping unit)
This diagram is intended to provide an overview of the individual components and an aid when ordering.
For a more detailed assembly overview, refer to the online spare parts catalogue on the Festo website
(www.festo.com/spareparts).

17 / 56Festo 7DSBCa_en
DSBC-…-C (with clamping unit)
Item Designation Note
1 Hex nut
2 Flange screw
3 Wiper seal
4 Clamping cartridge with mounting screw
5 Holder of the clamping unit
6 O-ring
7 Flange screws
8 Scraper ring
9 Bearing (plastic)
10 Bearing cap
11 O-ring
12 Cushioning seal only DSBC-…-PPV / PPS-…
13 Holding disc only DSBC-32 / 40 / 50 / 63-…
14 Piston rod, round DSBC-… (not for DSBC-…-Q-…)
15 Piston rod, protected against rotation only DSBC-…-Q-…
16 Cushioning boss / buffer sleeve only DSBC-…-PPV / PPS-…
17 Piston only DSBC-32 / 40 (from E7)-…
18 Piston washer only DSBC-40 (up to E6) / 50 / 63 / 80 / 100 / 125-…
19 Guide band only DSBC-40 (up to E6) / 50 / 63 / 80 / 100 / 125-…
20 O-ring only DSBC-40 (up to E6) / 50 / 63 / 80 / 100 / 125-…
21 Ring magnet only DSBC-40 (up to E6) / 50 / 63 / 80 / 100 / 125-…
22 Threaded coupling only DSBC-…
23 Rear piston rod only DSBC-…-T-…
24 Cylinder barrel
25 End cap only DSBC-…
26 Rear bearing cap only DSBC-…-T-…
The ISO cylinder with clamping unit and non-rotating piston rod (feature Q) is only available with through (double-
ended) piston rod (feature T).
The clamping unit (Items 2 to 6), unlike this illustration, is then located on the rear bearing cap (Item 26).

18 / 56 Festo 7DSBCa_en
3.1.2 DSBC-…-E1/E2/E3 (with end-position locking)
This diagram is intended to provide an overview of the individual components and an aid when ordering.
For a more detailed assembly overview, refer to the online spare parts catalogue on the Festo website
(www.festo.com/spareparts).

19 / 56Festo 7DSBCa_en
DSBC-…-E1 / E2 / E3 (with end-position locking)
Item Designation Note
1 Flange screw
2 Hex nut
3 Scraper ring
4 Bearing (metal)
5Bearing cap (with end-position locking) only DSBC-…-E1 / E2-…
6 Screw
7 Stop cylinder
8 Spacer ring only DSBC-100-…-E1 / E2 / E3-…
9 Bearing cap only DSBC-…-E3-…
10 O-ring
11 Cushioning seal only DSBC-…-PPV / PPS-…
12 Holding disc only DSBC-32 / 40 / 50 / 63-…
13 Piston rod
14 Cushioning boss only DSBC-…-PPV-…
15 Piston only DSBC-32 / 40 (from E7)-…
16 Piston washer only DSBC-40 (up to E6) / 50 / 63 / 80 / 100-…
17 Guide band only DSBC-40 (up to E6) / 50 / 63 / 80 / 100-…
18 O-ring only DSBC-40 (up to E6) / 50 / 63 / 80 / 100-…
19 Ring magnet only DSBC-40 (up to E6) / 50 / 63 / 80 / 100-…
20 Threaded coupling
21 Cylinder barrel
22 End cap (with end-position locking) only DSBC-…-E1 / E3-…
23 End cap only DSBC-…-E2-…

20 / 56 Festo 7DSBCa_en
3.2 DSBC-…-T1/T4/ A1 and DSBC-…-L/U /L1
This diagram is intended to provide an overview of the individual components and an aid when ordering.
For a more detailed assembly overview, refer to the online spare parts catalogue on the Festo website
(www.festo.com/spareparts).