Festo DGC G Series Setup guide

Repair
instructions (en)
Linear drive
DGC-…-G
7DGC-Ga_en

Imprint
Version:
7DGC-Ga_de (09.2009)
Copyright:
©Festo AG & Co. KG
Postfach
D-73726 Esslingen
Editorial department:
SC-S
Phone:
+49 / 711 / 347-0
Email:
[email protected]
Internet:
http://www.festo.com
The reproduction, distribution and
utilisation of this document as well
as the communication of its contents
to others without expressed authori-
sation is prohibited. Violations will
give rise to damage claims. All rights
reserved, in particular the right to
le patent, utility model or registered
design applications.
All product designations and brand
names used are the property of the
owners and not explicitly identied
as such.
All technical data subject to change
according to technical updates.

3 / 48Festo 07DGC-Ga_en
Foreword
These repair instructions are valid for the linear drives 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 specic linear drive.
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.
You will nd further information on this in Chapter 7 “Liability/conditions of use”.
The relevant regulations on occupational safety, safety engineering and interfer-
ence suppression as well as the stipulations contained in these repair instruc-
tions must be observed when working on the products.

4 / 48 Festo 07DGC-Ga_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 Types and part numbers 7
2.3 Mounting directions 7
3 Component overview 8
3.1 DGC-8/12-…-G 8
3.2 DGC-18/25-…-G 10
3.3 DGC-32/40-…-G 12
3.4 DGC-50/63-…-G 14
4 Repair steps 16
4.1 Linear drives DGC-8/12-…-G 17
4.1.1 Dismantling the linear drive 17
4.1.2 Assembling the linear drive 18
4.1.3 Replacing the slide elements in the slide 21
4.1.4 Setting the sliding play on the slide 22
4.1.5 Replacing the coupling on the slide 23
4.1.6 Replacing the cushioning components 24
4.2 Linear drives DGC-18/25/32/40-…-G 25
4.2.1 Dismantling the linear drive 25
4.2.2 Assembling the linear drive 27
4.2.3 Dismantling and repairing the piston module 31
4.2.4 Replacing the buffer strips 32
4.2.5 Replacing the sealing rings for the supply ports in the end caps 32
4.3 Linear drives DGC-50/63-…-G 33
4.3.1 Dismantling the linear drive 33
4.3.2 Assembling the linear drive 36
4.3.3 Replacing the slide elements in the slide 41
4.3.4 Replacing the buffer strips 42
4.3.5 Replacing the sealing rings for the supply ports in the end caps 42
5 Maintenance 43
5.1 Greasing the linear drive 43
6 Tools 44
6.1 Required tools by size 44
7 Liability/Conditions of use 44

5 / 48Festo 07DGC-Ga_en
Important information1
About these repair instructions1.1
This document contains important
information about the professional
repair of the linear drive type DGC-…-G.
The DGC-…-G linear drive is fully
repairable. However, in case of larger
defects, the costs of carrying out a
repair must be considered.
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 while doing repair work on
the linear drive:
Operating instructions•
Contains information about the
control parts and connections
for the linear drive, as well as
information about function, con-
struction, application, installation,
commissioning, care and mainten-
ance, etc. It 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 infor-
mation on their installation. The
spare parts documentation can
be found in the online spare parts
catalogue on the Festo website
(spareparts.Festo.com).
Assembly tools•
Contains an overview of the
available assembly tools such as
lubricants, thread locking agents,
maintenance tools etc. (aids for
assembly and maintenance). They
can be found in the online spare
parts catalogue on the Festo web-
site (www.Festo.com).
Pictograms used in these repair instructions1.2
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 indicates important tips and information that can make your work easier.
Environment
This sign indicates 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.
Documents
This sign indicates references to other chapters or documents containing additional information.

6 / 48 Festo 07DGC-Ga_en
General safety instructions1.3
Warning
The linear drive 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 with-
out 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 as well as the respective 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 envir-
onmental protection regulations.
General product description2
Functional description2.1
The DGC-…-G is the basic version of the DGC linear drive family. It is a linear drive with the functional principle of a
double-acting piston for power transmission. When compressed air is applied to the ports alternately, the piston moves
backwards and forwards in the piston chamber. A rigid connection moves the slide with the attached load (e.g. adapter
plate with drive) on the guide rail. The slot in the cylinder barrel required for this is covered by a band system. The slide is
mounted on slide elements and thus only designed for low-level loads. The operating behaviour in case of torsional loads
is in the medium range.
The DGC-…-G, when used properly, is used for transporting loads in a space-saving manner and is approved for the
operating modes slide mode and yoke mode (adhere to the load limits).
These graphics provide you with an overview of the construction of the linear drive using the DGC-25-…-G as an example.
3
2
5
3
6
21
4
7
8
9
4
8
1Guide rail
2Slide
3Slide-piston connection
4Cover band
5Slide element
6Coupling
7Piston
8Cylinder barrel
9Sealing band

7 / 48Festo 07DGC-Ga_en
Types and part numbers2.2
Type Part number
DGC-8-…-G 530906
DGC-12-…-G 530907
DGC-18-…-G 532446
DGC-25-…-G 532447
DGC-32-…-G 532448
DGC-40-…-G 532449
DGC-50-…-G 532450
DGC-63-…-G 532451
The complete overview of features, accessories,
type codes, technical data and dimensions for the DGC-…
linear drives can be found in the product catalogue or on
the Festo website (www.Festo.com).
Mounting directions2.3
This graphic provides you with an overview of the mounting directions of the linear drive using the DGC-25-…-G as an
example.
DGC-25-
330-G-
PPV-A
123456
W708
Type = Product designation
(name plate)
O = Top
U = Underneath
R = Right
L = Left
V = Front
H = Rear

8 / 48 Festo 07DGC-Ga_en
Component overview3
DGC-8/12-…-G3.1
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 / 48Festo 07DGC-Ga_en
Entry Designation Type Note
DGC-8-…-G DGC-12-…-G DGC-8-…-G DGC-12-…-G
1 Threaded pin or blanking
plug, depending on series
status
Tightening torque 5.0 Nm,
use LOCTITE 222
Tightening torque 5.0 Nm,
use LOCTITE 222
2 Sealing ring
3 Self-tapping screw TPD-WN122-
M3×18-450
M5×20-10.9
Tightening torque 2.0 Nm ± 20%,
use LOCTITE 243
Tightening torque 3.0 Nm ± 20%,
use LOCTITE 243
4 End cap, left
5 Elastic cushioning element Tightening torque 2.0 Nm ± 20%
6 Shock absorber Tightening torque 2.0 Nm ± 20%
7 Shock absorber Tightening torque 2.0 Nm ± 20%
8 O-ring 3×1-N-
NBR75
3×2-N-
NBR70
9 Clip
10 Buffer
11 Buffer/piston seal
12 Cylinder barrel
13 Piston
14 Piston module
15 Wiper seal
16 Slide element
17 Slide element
18 Coupling
19 Stop
20 Screw M2×7.5-8.8
internal Torx T6
Tightening torque 0.3 Nm, use LOCTITE 243
21 Slide
22 Socket head screw DIN 912-
M3×8-8.8
DIN 912-
M4×8-8.8
Tightening torque 1.4 Nm, use LOCTITE 243
Sealed with thread locker 397332
23 Sealing band
24 End cap, right

10 / 48 Festo 07DGC-Ga_en
DGC-18/25-…-G3.2
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
2
3
4
5
6
789
10
11 12 13
14
15
16
17 18
19
20
21
13
13
13
10
4
5
6
8911 12
2
1
22
23
24 25 26
28
27
22
29
30
31
32
31
32
30
3
DGC-18-...-G
DGC-18-...-G
DGC-25-...-G
DGC-25-...-G

11 / 48Festo 07DGC-Ga_en
Entry Designation Type Note
DGC-18-…-G DGC-25-…-G DGC-18-…-G DGC-25-…-G
1 Self-tapping screw M5×20-10.9 DIN 7500-E
M6×30-
A4-70
Tightening torque 7 Nm ± 10%,
use LOCTITE 243
Tightening torque 12 Nm ± 10%,
use LOCTITE 243
2 Threaded pin DIN 913-
M5×5-45H
–
3 End cap, left
4 Buffer strip
5 Seal
6 Sealing ring
7 Buffer, left
8 O-ring 1×0.6-N-
NBR70
1.8×1.2-N-
NBR75
9 Regulating screw
10 Flat-head screw DIN 920-
M3×20-4.8
DIN 84-
M3×28-4.8
Tightening torque 0.2 Nm,
use LOCTITE 243
Tightening torque 0.4 Nm,
use LOCTITE 243
11 Clamp, sealing band
12 Clamp, cover band
13 Buffer/piston seal
14 Buffer, left, sub-assembly
15 Cylinder barrel
16 Cover band
17 Sealing band
18 Socket head screw DIN 912-
M4×12-8.8
DIN 6912-
M5×16-8.8
Tightening torque 0.6 Nm,
use LOCTITE 243
Tightening torque 0.8 Nm,
use LOCTITE 243
19 Washer DIN 433, 4.3 DIN 433, 5.3
20 Slide-piston connection
21 Slide
22 Cushioning seal 8×11.6 P80 9.5×15 P80
23 Piston
24 Magnet
25 Band reverser
26 Coupling
27 Piston module
28 Buffer, right
29 Buffer, right, sub-assembly
30 End cap, right
31 Sealing ring
32 Plug screw Tightening torque 11 Nm

12 / 48 Festo 07DGC-Ga_en
DGC-32/40-…-G3.3
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
2
3
4
5
6
789
10
11 12 13
14
15
16
17 18
19
20
21
13
13
13
10
4
5
6
8911 12
2
1
22
23
24 25 26
28
27
22
29
31
31
32
31
32
30
3
DGC-18-...-G
DGC-18-...-G
DGC-25-...-G
DGC-32-...-G
DGC-40-...-G
DGC-25-...-G
DGC-32-...-G
DGC-40-...-G
33

13 / 48Festo 07DGC-Ga_en
Entry Designation Type Note
DGC-32-…-G DGC-40-…-G DGC-32-…-G DGC-40-…-G
1 Self-tapping screw M8×45-10.9 Tightening torque 30 Nm ± 10%, use LOCTITE 243
2 Threaded pin – –
3 End cap, left
4 Buffer strip
5 Seal 11.5×1.5-N-
NBR75
6 Sealing ring 16×2.5-N-
NBR70
17×2-N-
NBR75
7 Buffer, left
8 O-ring 1.8×1.2-N-
NBR75
3×1.2-N-
NBR70
9 Regulating screw
10 Flat-head screw DIN 84-
M3×30-5.8
DIN 912-
M4×40-10.9
Tightening torque 0.4 Nm,
use LOCTITE 243
Tightening torque 1.0 Nm,
use LOCTITE 243
11 Clamp, sealing band
12 Clamp, cover band
13 Buffer/piston seal
14 Buffer, left, sub-assembly
15 Cylinder barrel
16 Cover band
17 Sealing band
18 Socket head screw DIN 912-
M6×20-10.9
DIN 912-
M8×25-10.9
Tightening torque 1.3 Nm ± 10%,
use LOCTITE 243
Tightening torque 2.5 Nm ± 10%,
use LOCTITE 243
19 Washer DIN 433, 6.4 DIN 433, 8.4
20 Slide-piston connection
21 Slide
22 Cushioning seal 12×18 P80 16×24 P80
23 Piston
24 Magnet
25 Band reverser
26 Coupling
27 Piston module
28 Buffer, right
29 Buffer, right, sub-assembly
30 End cap, right
31 Sealing ring OL-1/4 OL-1/2
32 Plug screw Tightening torque 11 Nm Tightening torque 50 Nm
33 Compression spring –

14 / 48 Festo 07DGC-Ga_en
DGC-50/63-…-G3.4
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
33
4
5
6
789
10
11 12 13
14
15
16
17
20
21
22
23
33
34
3
19
18
24
25
26
27
28
13
10
4
6
8911 12
1
29
30
33
34
31
5
35
34
2
32

15 / 48Festo 07DGC-Ga_en
Entry Designation Type Note
DGC-50-…-G DGC-63-…-G DGC-50-…-G DGC-63-…-G
1 Self-tapping screw M8×55-10.9
Tightening torque 25 Nm ± 20%,
use LOCTITE 243
Tightening torque 30 Nm ± 20%,
use LOCTITE 243
2 End cap, left, sub-assembly
3 End cap, left
4 Buffer strip
5 O-ring 11.5×1.5-N-NBR75
6 O-ring 32×2.5-N-
NBR70
42×3-N-
NBR70
7 Buffer, left
8 O-ring 4×1.5-N-
NBR70
6×1.5-N-
NBR70
9 Regulating screw
10 Socket head screw DIN 912-M4×40-10.9 Tightening torque 1.0 Nm ± 20%, use LOCTITE 243
11 Clamp, sealing band
12 Clamp, cover band
13 Buffer/piston seal
14 Buffer, left, sub-assembly
15 Cylinder barrel
16 Cover band
17 Sealing band
18 Threaded pin Tightening torque 5.0 Nm ± 20%, use LOCTITE 243
19 Slide-piston connection
20 Blanking plug
21 Washer
22 Socket head screw DIN 912-M8×50-10.9 Tightening torque 20 Nm ± 20%, use LOCTITE 243
23 Blanking plug
24 Spring pin SG 12×15
25 Blanking plug
26 Slide
27 Piston
28 Compression spring VL-5/2-4.0
29 Buffer, right
30 Buffer, right, sub-assembly
31 End cap, right
32
End cap, right, sub-assembly
33 Sealing ring OL-1/2 OL-M22
34 Plug screw Tightening torque 16 Nm Tightening torque 18 Nm
35 Socket head screw DIN 912-
M8×16-10.9
DIN 912-
M8×25-10.9
Tightening torque 20 Nm ± 20%, use LOCTITE 243

16 / 48 Festo 07DGC-Ga_en
Repair steps4
This chapter describes how to completely dismantle the linear drives and the individual components or sub-assemblies
within self-contained sub-chapters. The linear drive does not need to be completely dismantled for every fault in order to
replace faulty components. The complete dismantling process described here is designed to provide a complete overview
of the components and how they are accessed in case they need to be replaced. The cause of a defect must therefore
always be determined before starting a repair.
Note
The repair should preferably be carried out on a stable and at work surface with storage for small parts.
Before dismantling the linear drive, it is imperative that the cause of the failure is investigated to prevent, for example,
repeated and premature failure. A linear drive which has been used as intended will not normally exhibit any premature
signs of failure.
This is not necessary in the case of non-premature failure (fatigue time). However, the condition of the slide (wear on
the slide elements, the slide guide setting for sizes DGC-8 and DGC-12, e.g. noticeable bearing clearance, faulty sliding
performance and increased sliding noises etc.), the piston with all components in the cylinder barrel (e.g. piston seals,
sealing band, cover band, buffer) and all sealing rings should also always be assessed. If in doubt, it is recommended to
replace all the components mentioned so as to rule out reciprocal effects during later operation.
If the linear drive suffers premature failure, the operating conditions should be examined more closely.
The following possibilities should be considered, among others:
Overloading•
In case of overloading the application parameters (mass, speed, operating pressure, operation medium) should be
adjusted accordingly.
Ambient conditions/material resistance•
Check whether the ambient temperature is within the permissible range.
Check the chemical and physical ambient conditions for hazardous substances, such as dust, abrasive particles, cool-
ing lubricants, solvents, ozone, radiation, water-soluble greases and oils, etc.
The following chapters describe how to dismantle the different sizes of the linear drives:
Linear drives DGC-8/12-…-G (see• chapter 4.1).
Linear drives DGC-18/25/32/40-…-G (see• chapter 4.2).
Linear drives DGC-50/63-…-G (see• chapter 4.3).

17 / 48Festo 07DGC-Ga_en
Linear drives DGC-8/12-…-G4.1
Dismantling the linear drive4.1.1
Place the linear drive on the work surface with the slide facing upwards.•
Unfasten and remove the two self-tapping screws on both end caps.•
Note
The basic principle of self-tapping screws means they have a high level of
holding force in the thread and require greater force when unfastening them.
Remove the end caps from the cylinder barrel at both ends of the drive.•
Documents
Chapter 4.1.6 describes how to replace the cushioning components on the
end cap.
Pull the clips from the buffers at both ends of the drive.•
Remove the buffers from the cylinder barrel.•
Removed the sealing ring from the buffer.•
Push the slide off the cylinder barrel.•
Note
The slide can only be pushed off the cylinder barrel in conjunction with the
piston.
Note
The black wiper seal on the slide is not fastened and may be lost when pull-
ing out the slide.

18 / 48 Festo 07DGC-Ga_en
Documents
Chapters 4.1.3 and 4.1.4 describe how to dismantle and repair the slide.
Pull the sealing band out of the cylinder barrel on one side.•
Note
It may not be possible to pull out the sealing band on long drives. In this
case, push it into the cylinder barrel with a blunt object and then remove it.
Assembling the linear drive4.1.2
When assembling a linear drive wearing parts, such as the sealing band, seals, buffers, clips and the complete piston,
can be replaced.
The wearing parts are ordered on the online spare parts catalogue (spareparts.Festo.com) quoting the appropriate part
number (dependent on the size of the linear drive).
The part number is an x-stroke part number. In addition to the part number, you must also specify the stroke of your
linear drive when ordering. The stroke can be determined from the type code on the name plate of the linear drive (see
order example below). Using this information you can calculate the necessary sealing band length.
Cutting the new sealing band to length
The exact length of the sealing band is determined by the 0-stroke of the respective type and the stroke of the linear
drive. The stroke is specied by the type code on the name plate. Check the length of the new sealing band and shorten it
to length (0-hub + hub) as necessary. See order example.
Type Length L0
DGC-8-…-G 140 mm
DGC-12-…-G 160 mm

Example: DGC-12-405-G
0-stroke: 160 mm
Stroke: 405 mm
Length of the sealing band = 0-stroke + stroke = 565 mm
The length of the sealing band calculated in this way is a theoretical value. Component tolerances may make it necessary
to adjust the length of the sealing band after installation.
Note
Sturdy general purpose scissors or metal shears are best for cutting the sealing band.
Warning
Do not bend the sealing band as this may cause damage or tearing and reduce its service life.

19 / 48Festo 07DGC-Ga_en
Greasing whilst assembling
When assembling the linear drive, various components have to be greased in accordance with the table below.
Component Lubricant Greasing instructions
Cylinder barrel Festo LUB-KC11) Apply a layer of grease to the slot and all around and along the entire length of
the cylinder bore.
Sealing band Festo LUB-KC11) Apply a layer of grease all around and along the entire length.
Piston Festo LUB-KC11) Grease all around.
Seal, piston Festo LUB-KC11) Grease all around.
Plain-bearing
guide
Festo LUB-KC11) Fill the grease pockets in the slide elements with grease. Apply a thin layer of
grease over the full surface of the contact area.
1) See “Assembly aids” in the online spare parts catalogue on the Festo website (www.Festo.com).
Grease the sealing band, the piston and the inside of the cylinder barrel.•
Observe the greasing instructions in the table at the start of this chapter.
Thread the sealing band into the through-hole in the piston.•
Insert the piston with the threaded sealing band a little way into the cylin-•
der barrel so that the sealing band inserts into the slot in the cylinder barrel.
Note
When inserting the piston, make sure that the magnetic side of the piston is
opposite the cut-outs on the groove for the proximity switches in the cylinder
barrel.
Connect the slide to the piston (1) by plugging in the coupling.•
Grease the cylinder barrel in the area of the plain-bearing guide.•
Observe the greasing instructions in the table at the start of this chapter.
Push the slide, together with the piston, onto the cylinder barrel (2).•

20 / 48 Festo 07DGC-Ga_en
In order to fasten the sealing band in place in the sealing band holder, move•
the slide once to the other end of the cylinder barrel and hold the sealing
band in place with pliers as you do so.
Note
The sealing band is pulled into the cylinder barrel by the draw of the piston.
Make sure that the sealing band protrudes 4 mm from the cylinder barrel.
Note
The sealing band must not protrude beyond the buffer, otherwise the end
cap cannot form an air-tight seal and may have an adverse effect on the
function of the linear drive. The sealing band must be shortened so that it
seals off ush with the outer edge of the buffers. However, it is better if it is
slightly short of the buffers.
Clip the wiper seal in on the side of the slide.•
Attach the buffers to both ends of the cylinder barrel.•
Grease one new sealing ring per buffer and insert them in the buffers.•
Attach the clips to the buffers to fasten the sealing band in place.•
Apply Loctite 243 to the self-tapping screws.•
Attach the end caps to both ends of the cylinder barrel.•
Screw the self-tapping screws into the cylinder barrel through the end cap•
and attach them loosely so that the end caps can still be shifted.
Align the rear and bottom edge of both end caps ush with the cylinder •
barrel.
Tighten the self-tapping screws on both ends using the appropriate torque•
(see table).
Type Torque
DGC-8-…-G 3.0 Nm ± 20%
DGC-12-…-G 3.0 Nm ± 20%
Note
After the linear drive has been assembled, it needs to be commissioned as
described in chapter 7 of the operating instructions.