Festo DZF Setup guide

Repair
instructions (en)
Cylinder with piston rod
Flat cylinder
DZF /DZH
7DZF / DZHb_en

2 / 24 Festo 7DZF / DZHb_en
Imprint
Version:
7DZF / DZHb_en (06.2013)
Copyright:
©Festo AG & Co. KG
P.O. Box
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 / 24Festo 7DZF / DZHb_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
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 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 / 24 Festo 7DZF / DZHb_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
2.1.1 Cut-awayillustrationoftheatcylinderDZF 6
2.2 Type codes (ascertaining the features of a cylinder) 7
2.3 Orientation designations 7
3 Component overview 8
3.1 Flat cylinder DZF-… 8
3.2 Flat cylinder DZH-… 10
4 Repair steps 12
4.1 Preparation 12
4.2 Visual inspection 12
4.3 RepairingtheatcylinderDZF-… 12
4.3.1 Structureofthebearingcap 13
4.3.2 Removingthebearingandendcaps 13
4.3.3 Replacingthepistoncomponents 13
4.3.4 Insertingthepistonrodintothecylinderbarrel 14
4.3.5 Repairingthebearingandendcaps 15
4.3.6 Attachingthebearingandendcaps 16
4.4 RepairingtheatcylinderDZH-… 17
4.4.1 Structureofthebearingcap(schematicrepresentation) 17
4.4.2 Removingthebearingandendcaps 17
4.4.3 Replacingthepistoncomponents 17
4.4.4 Insertingthepistonrodintothecylinderbarrel 18
4.4.5 Repairingandattachingthebearingandendcaps 19
4.4.6 Attachingthebearingandendcaps 21
5 Cleaning and greasing 22
5.1 Cleaning 22
5.2 Greasing 22
5.2.1 Extremelythingreaselm 22
5.2.2 Thingreaselm 22
5.2.3 Grease reservoir 22
6 Maintenance and care 22
7 Tools 23
7.1 Standard tools 23
7.2 Special tools 23
8 Liability 23

5 / 24Festo 7DZF / DZHb_en
1 Important information
1.1 About these repair instructions
This document contains important
information about the professional
repair of the cylinder with piston rod
of the type DZF/DZH.
The cylinder with piston rod DZF/ DZH
is fully repairable in the event of
damage due to normal wear. The
entire cylinder must be replaced in
the event of damage to the cylinder
barrel.
These repair instructions are not valid
for the cylinder with piston rod EZH.
This cylinder with piston rod is not
repairable and must be replaced.
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 operating elements 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
Contains an overview of available
assembly aids such as lubricating
greases, screw 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 / 24 Festo 7DZF / DZHb_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 genuine spare parts (of the appropriate type and version).
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 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 forward in the cylinder barrel when the rear cylinder chamber is pressurised. The piston rod transmits
the movement to the outside. The advanced piston rod is retracted again when the front cylinder chamber is pressurised.
2.1.1 Cut-awayillustrationoftheatcylinderDZF
aB
aC
aA
aJ
aA
981 3 4 6 7
5
21Piston rod
2 Piston rod seal
3Bearing cap
4Compressed air connection,
front cylinder chamber
5Front holes for cylinder mounting
6Mounting slot for proximity sensor
7Front piston seal
8Piston with magnet
9Rear piston seal
aJ Compressed air connection,
rear cylinder chamber
aA Rear holes for cylinder mounting
aB End cap
with S2 / S20: Rear bearing cap
aC Cylinder barrel

7 / 24Festo 7DZF / DZHb_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 logo and describes the cylinder's features separated
by a hyphen (-).
Example:
DZF-32-100-A-P-A
161268 AN08
pmax. 10 bar
1
42
3
1Type designation
2Serial number
3Technical information
4Part number
The type designation on this rating plate provides the following information:
DZF Cylinder of the type DZF (double-acting)
32 Piston diameter 32 mm
100 Stroke 100 mm
AMale piston rod thread
PElastic cushioning rings/pads at both ends
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 Orientation designations
This diagram provides an overview of the orientation designations for the cylinder with piston rod.
DZF-32-100-A-P-A
161268 AN08
pmax. 10 bar
Orientation:
Festo = product identication (rating
plate) as reference point
O = top
U = underneath
R = right
L = left
V = front
H = rear

8 / 24 Festo 7DZF / DZHb_en
3 Component overview
3.1 Flat cylinder DZF-…
2
3
5
6
7
8
9
10
15
16
17
11
1
12
13
14
19
18
6
5
7
6
3
2
1
5
4
4
4
8
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).

9 / 24Festo 7DZF / DZHb_en
Item Designation Note
1 Hex nut For piston rod with male thread
2 Piston rod seal
3 Bearing bush
4 Self-tapping screw Use screw locking agent
5 O-ring
6 Threaded pin
7 Bearing cap
8 Seal
9 Piston rod with male thread
10 Piston rod with female thread
11 Piston rod with male thread, hollow S20 only
12 Piston
13 Washer Not S2, not S20
14 Hex nut Not S2, not S20
15 Piston rod with male thread S2 only, use screw locking agent
16 Piston rod with female thread S2 only, use screw locking agent
17 Piston rod with male thread, hollow S20 only, use screw locking agent
18 Cylinder barrel
19 End cap
The feature S6 indicates the design/material variants and is of little or no importance for the order of the repair steps.

10 / 24 Festo 7DZF / DZHb_en
3.2 Flat cylinder DZH-…
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).
2
1
3
2
1
3
6
25
24
8
7
6
6
4
4
9
12
10
10
9
21
5
14
15
16 14
20
17
22
23
23 22
18
5
5
13
11
11
16
26
26
19
8
7
8
7

11 / 24Festo 7DZF / DZHb_en
Item Designation Note
1 Hex nut For piston rod from size DZH-25-…
2 Piston rod seal
3 Bearing bush
4 Bearing cap
5 Self-tapping screw Use screw locking agent
6 O-ring
7 Serrated ring Only from size DZH-32-…
8 Regulating screw
9 O-ring
10 Cushioning seal
11 Washer Only DHZ-25-…-PPV-A and DHZ-25-…-PPV-A-S6
12 Piston rod with male thread
13 Hollow piston rod with male thread Only with DZH-…-S20
14 Groove ring
15 Piston
16 Guiding band
17 Threaded coupling
18 Piston rod extension Only with DZH-…-S2, use screw locking agent
19 Hollow piston rod extension Only with DZH-…-S20, use screw locking agent
20 Cylinder barrel
21 End cap
22 Cushioning boss Only from size DZH-50-…
23 Groove ring Only from size DZH-50-…
24 Piston Only from size DZH-50-…
25 Magnet Only from size DZH-32-…
26 Guiding band Only from size DZH-50-…

12 / 24 Festo 7DZF / DZHb_en
4 Repair steps
4.1 Preparation
• Before starting the repair, remove any attachments on the cylinder barrel, the bearing and end caps or the piston rod
in accordance with the accompanying operating instructions.
• Keep your working environment tidy.
• Only use the spare parts and assembly aids (grease, locking agent, etc.) provided in the set of wearing parts.
Warning
Make sure that the bearing cap cannot suddenly come ying off.
• Remove the non-return valves and tubing connection from the cylinder and depressurise the cylinder completely
so that any pressure present is not suddenly released when the cylinder is opened.
To prevent damage to sealing rims or guide surfaces, do not use pointed or sharp-edged assembly aids.
4.2 Visual inspection
Check the cylinder for visible damage that might impair its function (e.g. warping of the piston rod) as well as deposits
and scoring. The entire cylinder must be replaced if the cylinder barrel is showing signicant damage.
4.3 RepairingtheatcylinderDZF-…
Note
The following cylinders cannot be repaired:
• DZF-12-…
• DZF-18-…
The description in this section can be used to repair cylinders of the type DZF-… with the following features:
Code Description
A Male piston rod thread
No specication Female piston rod thread
P Elastic cushioning rings/pads
A Position sensing
S2 Through piston rod
S6 Seals heat-resistant up to 120°C
S20 Through, hollow piston rod

13 / 24Festo 7DZF / DZHb_en
4.3.1 Structure of the bearing cap
3
2
1
1Bearing cap
2 Piston rod seal
3Bearing
4.3.2 Removing the bearing and end caps
• Loosen the screws in the bearing and end caps (the rear bearing cap on
cylinders with through piston rod (S2/ S20)) and remove them.
• Pull the bearing and end caps (both bearing caps on cylinders with through
piston rod (S2/S20)) away from the cylinder barrel and piston rod.
4.3.3 Replacing the piston components
• Pull the piston rod out of the cylinder barrel.
• Check the cylinder barrel and piston rod for damage.
The entire cylinder must be replaced if the cylinder barrel (particularly the
bearing surface) is showing signicant damage.
• Unscrew the hex nut (the rear part of the piston rod on cylinders with
through piston rod (S2/ S20)) from the piston rod.
• Remove the piston components from the piston rod, noting the order and
orientation.
• Remove any residue of the screw locking agent from the threads of the
piston rod and hex nut (the rear part of the piston rod on cylinders with
through piston rod (S2/ S20)).
• Replace the components with those included in the set of wearing parts and
reassemble the piston components on the piston rod in the correct order.

14 / 24 Festo 7DZF / DZHb_en
• Apply the screw locking agent contained in the set of wearing parts to
the inside of the hex nut (the rear part of the piston rod on cylinders with
through piston rod (S2/ S20)) and screw it onto the piston rod with the
corresponding torque (see table).
Type Torque
DZF-25
DZF-25-…-A-P-A-S20
10 Nm
5 Nm
DZF-32
DZF-32-…-P-A-S2
DZF-25-…-A-P-A-S20
14.5 Nm
20 Nm
10 Nm
DZF-40
DZF-40-…-P-A-S2
DZF-40-…-A-P-A-S2
DZF-40-…-A-P-A-S20
20 Nm
9.5 Nm
9.5 Nm
9.5 Nm
DZF-50-…-P-A
DZF-50-…-A-P-A
DZF-50-…-P-A-S6
DZF-50-…-P-A-S2
DZF-50-…-A-P-A-S2
DZF-50-…-A-P-A-S20
20 Nm
20 Nm
20 Nm
40 Nm
40 Nm
15 Nm
DZF-63
DZF-63-…-P-A-S6
DZF-63-…-A-P-A-S6
DZF-63-…-P-A-S2
DZF-63-…-A-P-A-S2
DZF-63-…-A-P-A-S20
20 Nm
40 Nm
40 Nm
40 Nm
40 Nm
20 Nm
4.3.4 Inserting the piston rod into the cylinder barrel
• Clean the inside surface of the cylinder barrel as described in chapter
5.1 "Cleaning".
• Apply the grease included in the set of wearing parts to the following parts:
Component Greasing
Inside surface of cylinder barrel Thin lm1)
Surface of piston rod Thin lm1)
Piston seals Thin lm1) on outside
Piston surface between piston seals (grease reservoir2)) Fill 2/3 with grease
1) See chapter 5.2.2 "Thin grease lm"
2) See chapter 5.2.3 "Grease reservoir"
• Place the piston at against the front side of the cylinder barrel and insert
the piston seal into the cylinder barrel by tilting it slightly.
The lip of the piston seal must not fold back against the side of the piston.
Note
If necessary use a at and blunt-edged object to insert the piston seal into
the cylinder barrel.
• Insert the piston fully into the cylinder barrel.

15 / 24Festo 7DZF / DZHb_en
• Push the piston far enough into the cylinder barrel so that the  rst piston
seal protrudes slightly at the other end of the cylinder barrel.
• Pull the piston rod back again until the piston is sitting fully in the cylinder
barrel.
Note
This approach ensures that the lips of the two piston seals sit correctly in the
cylinder barrel.
4.3.5 Repairing the bearing and end caps
• Remove the seal 3from the slot of the bearing cap 2and end cap
(the rear bearing cap on cylinders with through piston rod (S2 /S20)).
• Remove the piston rod seal 1from the bearing cap 2(the front and
rear bearing caps on cylinders with through piston rod (S2 /S20)).
1 32
Warning
Check the plain bearing in the bearing cap (the front and rear bearing caps
on cylinders with through piston rod (S2/ S20)) for visible damage that
might impair its function, such as deposits and scoring. The entire bearing
cap must be replaced if the plain bearing is showing signi cant damage.
• Clean the seat of the piston rod seal 1and seal 2.
1 2
• Grease the new piston rod seal (one per bearing cap on cylinders with
through piston rod (S2/ S20)) as follows:
Component Greasing
1Grease reservoir2) for piston rod Fill 2/3 with grease
2External surface for bearing cap Thin  lm1)
3Grease reservoir2) for bearing Fill 2/3 with grease
1) See chapter 5.2.2 "Thin grease  lm"
2) See chapter 5.2.3 "Grease reservoir" 31 2

16 / 24 Festo 7DZF / DZHb_en
• Insert the piston rod seal into the bearing cap (in both bearing caps on
cylinders with through piston rod (S2/S20)) using an appropriate thrust
piece.
Note
Note the mounting direction (individual sealing lips facing out).
• Grease the new seal from the set of wearing parts and insert it into the
slots in the bearing cap and end cap (the rear bearing cap on cylinders with
through piston rod (S2/ S20)).
Note
Note the mounting direction.
The through-holes for the self-tapping screws must not be covered by
the seal and the closed lug 2must be pointing upwards towards the
compressed air connection 1.
2
1
4.3.6 Attaching the bearing and end caps
• To protect the bearing and seals, place the appropriate mounting sleeve
(see chapter 7.2 "Special tools") on the thread of the piston rod to prevent
damage.
• Guide the bearing cap (both bearing caps on cylinders with through piston
rod (S2/ S20)) over the mounting sleeve onto the piston rod as far as the
cylinder barrel.
• Place the end cap at the other end of the cylinder barrel.
• Apply the screw locking agent contained in the set of wearing parts to the
two screws.
• Turn the screws through the bearing and end caps (through both bearing
caps on cylinders with through piston rod (S2/S20)) into the cylinder barrel.
• Align the bearing and end caps ush with the cylinder barrel.
• Tighten the screws using the appropriate torque (see table).
Type Torque
DZH-25 3 Nm
DZH-32 3 Nm
DZH-40 6 Nm
DZH-50 12 Nm
DZH-63
DZF-63-…-P-A
DZF-63-…-P-A-S6
DZF-63-…-A-P-A-S6
DZF-63-…-A-P-A-S2
DZF-63-…-A-P-A-S20
25 Nm
6 Nm
19 Nm
19 Nm
19 Nm
19 Nm
• Perform a functional test as per the operating instructions (enclosed with
the cylinder or can be called up on the Festo website (www.Festo.com)) and
commission the repaired cylinder.

17 / 24Festo 7DZF / DZHb_en
4.4 RepairingtheatcylinderDZH-…
The description in this section can be used to repair cylinders of the type DZH-… with the following features:
Code Description
PPV Pneumatic cushioning adjustable at both ends
A Position sensing
S2 Through piston rod
S6 Seals heat-resistant up to 120°C
S20 Through, hollow piston rod
4.4.1 Structure of the bearing cap (schematic representation)
1
2
4
5
3
1Bearing cap
2O-ring
3Cushioning seal
4Piston rod seal
5Bearing
4.4.2 Removing the bearing and end caps
• Loosen the screws in the bearing and end caps (the rear bearing cap on
cylinders with through piston rod (S2/ S20)) and remove them.
• Pull the bearing and end caps away from the cylinder barrel and piston rod.
• Remove any residue of the screw locking agent from the threads of the
screws.
4.4.3 Replacing the piston components
• Pull the piston rod out of the cylinder barrel.
• Check the cylinder barrel and piston rod for damage.
The entire cylinder must be replaced if the cylinder barrel (particularly the
bearing surface) is showing signi cant damage.

18 / 24 Festo 7DZF / DZHb_en
• Replace the components contained in the set of wearing parts:
– the two groove rings and
– the two-piece guiding band.
4.4.4 Inserting the piston rod into the cylinder barrel
• Clean the inside surface of the cylinder barrel as described in chapter
5.1 "Cleaning".
• Apply the grease included in the set of wearing parts to the following parts:
Component Greasing
Inside surface of cylinder barrel Thin  lm1)
Surface of piston rod Thin  lm1)
Groove rings in piston seal Thin  lm1) on outside
Piston surface between piston seals (grease reservoir2)) Fill 2/3 with grease
Cushioning boss Thin  lm1) on outside
1) See chapter 5.2.2 "Thin grease  lm"
2) See chapter 5.2.3 "Grease reservoir"
• Place the piston  at against the front side of the cylinder barrel and insert
the piston seal into the cylinder barrel by tilting it slightly.
The sealing lip must not fold back against the side of the piston.
Note
If necessary use a  at and blunt-edged object to insert the groove ring into
the cylinder barrel.
• Insert the piston fully into the cylinder barrel.
• Push the piston far enough into the cylinder barrel so that the groove ring
protrudes slightly at the other end of the cylinder barrel.
• Pull the piston rod back again until the piston is sitting fully in the cylinder
barrel.
Note
This approach ensures that the lips of the two groove rings sit correctly in
the cylinder barrel.

19 / 24Festo 7DZF / DZHb_en
4.4.5 Repairing and attaching the bearing and end caps
• Remove the piston rod seal 1from the bearing cap 2(both bearing caps
on cylinders with through piston rod (S2/ S20)).
• Remove the O-Ring 4from the bearing and end caps 2(both bearing caps
on cylinders with through piston rod (S2/ S20)).
• Remove the cushioning seal 3from the bearing cap and end cap (both
bearing caps on cylinders with through piston rod (S2/ S20)).
1 3 42
Warning
Check the plain bearing in the bearing cap (the front and rear bearing caps
on cylinders with through piston rod (S2/ S20)) for visible damage that
might impair its function, such as deposits and scoring. The entire bearing
cap must be replaced if the plain bearing is showing signi cant damage.
• Remove the regulating screw from the bearing cap and end cap.
Note
The serrated ring is only present from size DZH-32-….
– Remove the serrated ring 1from the bearing cap and end cap.
1
– Unscrew the regulating screw 2fully. 2
1
– Remove the O-ring 3 from the regulating screw 2.
– Clean the thread and hole 4of the end-position cushioning in the
bearing cap and end cap.
4
1
2
3

20 / 24 Festo 7DZF / DZHb_en
• Insert the regulating screw into the bearing cap and end cap.
Note
The serrated ring is only present from size DZH-32-….
– Grease the new O-ring 3and insert it in the groove in the regulating
screw 2.
– Screw in the regulating screw 2.
– Insert the serrated ring 1into the bearing cap and end cap using an
appropriate tool.
1
2
3
• Clean the seat of the piston rod seal 1.
• Clean the seat of the O-ring 2.
• Clean the seat of the cushioning seal 3.
See chapter 5.1 "Cleaning"
1 2
3
• Grease the new piston rod seal (one per bearing cap on cylinders with
through piston rod (S2/ S20)) as follows:
Component Greasing
1Grease reservoir2) for piston rod Fill 2/3 with grease
2External surface for bearing cap Thin  lm1)
3Grease reservoir2) for bearing Fill 2/3 with grease
1) See chapter 5.2.2 "Thin grease  lm"
2) See chapter 5.2.3 "Grease reservoir" 1 2 3
• Insert the piston rod seal into the bearing cap (in both bearing caps on
cylinders with through piston rod (S2/S20)) using an appropriate thrust
piece.
Note
Note the mounting direction (individual sealing lips facing out).
• Grease the new O-rings 3and insert them into the slots in the bearing cap
1and end cap (the rear bearing cap on cylinders with through piston rod
(S2 / S20)).
• Apply a thin  lm of grease to the new cushioning seals 2on the front side
with the sealing surface and insert them into the bearing cap 1and end
cap (the rear bearing cap on cylinders with through piston rod (S2 /S20)).
31 2