Festo DGC-K Series Setup guide

Repair
instructions
(en)
7DGC-Kb_en
Linear drive
DGC-K-…-

Editorial information
Version:
7DGC-Kb_en 8. April 2015
Copyright:
©Festo AG & Co. KG
Postfach
73726 Esslingen
Germany
Editorial team:
PM-SD
Tel.:
+49 (0) 711 / 347-0
E-mail:
[email protected]
Internet:
http://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 / 49Festo 7DGC-Kb_en
Foreword
These repair instructions are valid for the linear drives listed on the title page to
the exclusion of any liability claims.
The descriptions in these repair instructions may deviate 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.
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 / 49 Festo 7DGC-Kb_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
2.4 Type codes (identifying the features of a linear drive) 7
3 Component overview 8
3.1 DGC-K-18-…-GK 8
3.2 DGC-K-18-…-GK-D2 10
3.3 DGC-K-18-…-GV 12
3.4 DGC-K-18-…-GV-D2 14
3.5 DGC-K-25 / 32 / 40-…-GK 16
3.6 DGC-K-25 / 32 / 40-…-GK-D2 18
3.7 DGC-K-25 / 32 / 40-…-GV 20
3.8 DGC-K-25 / 32 / 40-…-GV-D2 22
3.9 DGC-K-50 / 63-…-GK / GV 24
3.10 DGC-K-50 / 63-…-GK / GV-D2 26
3.11 DGC-K-80-…-GK 28
3.12 DGC-K-80-…-GK-D2 30
4 Repair steps 32
4.1 Preparation 32
4.2 Visual inspection 32
4.3 Repairing the linear drive 32
4.3.1 Linear drive DGC-K-18 33
4.3.2 Linear drive DGC-K-25 / 32 / 40 / 50 / 63 38
4.3.3 Linear drive DGC-K-80 43
5 Cleaning 48
6 Maintenance 48
6.1 Maintenance of the band system 48
7 Tools 48
7.1 Required tools 48
8 Liability 48

5 / 49Festo 7DGC-Kb_en
1 Important information
1.1 About these repair instructions
This document contains important information about the professional repair of the linear drive type DGC-K.
The DGC-K linear drive is largely repairable.
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 complete detailed information. The following documents
should therefore also be available while doing repair work on the linear drive:
– Operating instructions
Contain information about the operating elements and connections for the linear drive, as well as information about
function, construction, application, installation, commissioning, care and maintenance, etc. These 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 (http://spareparts.festo.com).
– Assembly aids
Contains an overview of available assembly aids such as lubricating greases, locking agents, maintenance tools, etc.
(aids for assembly and maintenance). This can be found in the online spare parts catalogue on the Festo website
(http://spareparts.festo.com/xdki/data/SPC/0/PDF_SAFE/Hilfsmittel.pdf ).
1.2 Pictograms used in these repair instructions
Caution
... means that non-observance may result in personal injury and damage to property.
Note
... means that non-observance may result in damage to property.
Marking special information
The following pictograms mark passages in the text which contain special information.
Information:
Recommendations, tips and references to other sources of information.
Environment:
Information on the environmentally-friendly use of Festo products.

6 / 49 Festo 7DGC-Kb_en
1.3 General safety instructions
Caution
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 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.
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 DGC-K is a linear drive with the functional principle of a double-acting piston for power transmission.
This piston is designed so that it has an internal part and an external part – the mechanical customer interface. These
parts are rigidly connected with one another, making them one-piece. When compressed air is applied to the ports
alternately, the piston moves backwards and forwards in the slotted base prole. The slot is provided as a guide and is
covered by a sealing band system (with the exception of DGC-K-18) to seal off the internal part of the piston from the
external part.
The DGC-K, when used properly, is used for transporting loads in a space-saving manner and is suitable for slide
operation.
This illustration provides you with an overview of the construction of the linear drive using the DGC-K-25 as an example.
5
6
7
8
9
aJ
aA
4
1 2 3 1Spring
2Wiper seal
3Regulating screw for end-position
cushioning
4End cap assembly
5Cushioning disc
6Cylinder barrel
7Sealing ring
8Sealing band
9Sealing band guide
aJ Cover strip
aA Flange screws

7 / 49Festo 7DGC-Kb_en
2.2 Types and part numbers
Type Part number
DGC-K-18-… 1312500
DGC-K-25-… 1312501
DGC-K-32-… 1312502
DGC-K-40-… 1312503
DGC-K-50-… 1312504
DGC-K-63-… 1312505
DGC-K-80-… 1312506
The complete overview of features, accessories, type
codes, technical data and dimensions for the DGC-K-…
linear drives can be found in the product catalogue or on
the Festo website (www.festo.com).
2.3 Mounting directions
This illustration gives an overview of the orientation designation of the linear drive using the DGC-K-25 as an example.
Festo = Rating plate as reference
O = Top
U = Underneath
R = Right
L = Left
V = Front
H = Rear
2.4 Type codes (identifying the features of a linear drive)
The precise features of a linear drive can be identi ed with the help of the rating plate on the linear drive. The type
designation is located directly beneath the Festo logo and describes the linear drive's features separated by a hyphen (-).
Example:
DGC-K-25-400-PPV-A-GV-D2
1312501 C708
1
32
1Type designation
2Serial number
3Part number
The type designation on this rating plate provides the following information:
DGC-K Linear drive type DGC-K with double-acting pistons
25 Piston diameter 25 mm
400 Stroke 400 mm
PPV End-position cushioning adjustable at both ends
APosition sensing by magnetic piston
GV Lengthened piston
D2 Supply port on both sides
A list and description of all possible equipment features of the linear drive can be found in the data sheet, which is
available on the Festo website (www.festo.com).

8 / 49 Festo 7DGC-Kb_en
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 (http://spareparts.festo.com).
3 Components list
3.1 DGC-K-18-…-GK
1
2
3
4
5
16
15
17
15
13
16
6
7
8
9
10
11
12
7
14
6
13
10
18
19
4
20
21
22 2
23
1
24
25
5

9 / 49Festo 7DGC-Kb_en
Linear drive DGC-K-18-…-GK
No. Designation Type
1 Self-tapping screw M5×20-10.9
2 Clamping component
3 End cap module
4 O-ring B-11×1-N-NBR70
5 Seal
6 Piston seal
7 Piston cap
8 Cushioning boss
9 Magnet
10 Diverter
11 O-ring B-9.5×1.5-N-NBR70
12 Piston
13 Plain bearing
14 Piston module
15 Cover
16 Pressure support
17 Wiper seal
18 Sealing band
19 Cylinder barrel
20 Connection cap
21 Threaded pin DIN 913-M5×5-45H
22 Threaded pin DIN 913-M5×5-45H
23 End cap module
24 Lubricating grease LUB-KC1, silicone-free
25 Screw locking agent LOCTITE 243

10 / 49 Festo 7DGC-Kb_en
3.2 DGC-K-18-…-GK-D2
18
17
19
17
15
18
8
9
10
11
12
13
14
9
16
8
15
12
20
21
5
4
23
6
1
22
23
7
1
2
34
5
6
7
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 (http://spareparts.festo.com).

11 / 49Festo 7DGC-Kb_en
Linear drive DGC-K-18-…-GK-D2
No. Designation Type
1Self-tapping screw M5×20-10.9
2 Threaded pin DIN 913-M5×5-45H
3 Clamping component
4 Threaded pin DIN 913-M5×5-45H
5 Connection cap
6 End cap module
7 Seal
8 Piston seal
9 Piston cap
10 Cushioning boss
11 Magnet
12 Diverter
13 O-ring B-9.5×1.5-N-NBR70
14 Piston
15 Plain bearing
16 Piston module
17 Cover
18 Pressure support
19 Wiper seal
20 Sealing band
21 Cylinder barrel
22 Lubricating grease LUB-KC1, silicone-free
23 Screw locking agent LOCTITE 243

12 / 49 Festo 7DGC-Kb_en
3.3 DGC-K-18-…-GV
1
2
3
4
5
20
4
25
26
5
21
22
23 2
24
1
19
11
6
7
8
9
10
11
12
7
15
6
13
14
17
16
18
16
13
17
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 (http://spareparts.festo.com).

13 / 49Festo 7DGC-Kb_en
Linear drive DGC-K-18-…-GV
No. Designation Type
1Self-tapping screw M5×20-10.9
2 Clamping component
3 End cap module
4 O-ring B-11×1-N-NBR70
5 Seal
6 Piston seal
7 Piston cap
8 Cushioning boss
9 Magnet
10 Diverter
11 O-ring B-9.5×1.5-N-NBR70
12 Piston
13 Plain bearing
14 Distance sleeve
15 Piston module
16 Cover
17 Pressure support
18 O-ring B-100×1.5-N-NBR70
19 Sealing band
20 Cylinder barrel
21 Connection cap
22 Threaded pin DIN 913-M5×5-45H
23 Threaded pin DIN 913-M5×5-45H
24 End cap module
25 Lubricating grease LUB-KC1, silicone-free
26 Screw locking agent LOCTITE 243

14 / 49 Festo 7DGC-Kb_en
3.4 DGC-K-18-…-GV-D2
1
2
34
5
6
7
18
15
19
8
9
10
11
12
13
14
16
9
17
8
15
12
21
22
7
5
42
3
6
1
23
24
20
19
18
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 (http://spareparts.festo.com).

15 / 49Festo 7DGC-Kb_en
Linear drive DGC-K-18-…-GV-D2
No. Designation Type
1Self-tapping screw M5×20-10.9
2 Threaded pin DIN 913-M5×5-45H
3 Clamping component
4 Threaded pin DIN 913-M5×5-45H
5 Connection cap
6 End cap module
7 Seal
8 Piston seal
9 Piston cap
10 Cushioning boss
11 Magnet
12 Diverter
13 O-ring B-9.5×1.5-N-NBR70
14 Piston
15 Plain bearing
16 Distance sleeve
17 Piston module
18 Cover
19 Pressure support
20 O-ring B-100×1.5-N-NBR70
21 Sealing band
22 Cylinder barrel
23 Lubricating grease LUB-KC1, silicone-free
24 Screw locking agent LOCTITE 243

16 / 49 Festo 7DGC-Kb_en
3.5 DGC-K-25/32/ 40-…-GK
1
2
34
5
6
22
21
20
6
5
24 4
3
25 26
23
1
27
28
16
11
12
9
10
14
7
8
15
17
7
19
14
18
11
8
13
13
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 (http://spareparts.festo.com).

17 / 49Festo 7DGC-Kb_en
Linear drive DGC-K-25-…-GK DGC-K-32-…-GK DGC-K-40-…-GK
No. Designation Type Type Type
1 Flange screw M3×35 M6×50 DZH-40 M6×50 DZH-40
2 End cap module
3 Threaded pin DIN 913-M4×12-45H DIN 913-M4×14-45H DIN 913-M4×14-45H
4 Threaded pin DIN 913-M4×6-45H DIN 915-M4×8-45H DIN 915-M4×8-45H
5 O-ring
6 Seal
7 Wiper seal
8 Compression spring
9 Sealing band
10 Cover strip
11 Piston seal
12 Piston cap module
13 Washer Component not present
14 Belt diverter
15 Wiper seal
16 Blanking plug Component not present
17 Piston
18 Piston cap
19 Piston module
20 Cylinder barrel
21 Magnetic strip
22 Adhesive tape
23 Plug screw GÁ" GÁ" G¼"
24 Connection cap
25 End cap module
26 Plug screw GÁ" GÁ" G¼"
27 End cap module
28 Lubricating grease LUB-KC1, silicone-free LUB-KC1, silicone-free LUB-KC1, silicone-free
29 Adhesive locking agent LOCTITE 243 LOCTITE 243 LOCTITE 243

18 / 49 Festo 7DGC-Kb_en
3.6 DGC-K-25/32/ 40-…-GK-D2
1
4
56
7
8
2
3
25
26
22
23
24
8
1
46
5
72
3
18
13
14
11
12
16
9
10
17
19
9
21
16
20
13
10
15
15
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 (http://spareparts.festo.com).

19 / 49Festo 7DGC-Kb_en
Linear drive DGC-K-25-…-GK-D2 DGC-K-32-…-GK-D2 DGC-K-40-…-GK-D2
No. Designation Type Type Type
1 Flange screw M3×35 M6×50 DZH-40 M6×50 DZH-40
2 Plug screw GÁ"GÁ" G¼"
3 Plug screw GÁ"GÁ" G¼"
4 Connection cap
5 Threaded pin DIN 913-M4×12-45H DIN 913-M4×14-45H DIN 913-M4×14-45H
6 Threaded pin DIN 913 -M4×6-45H DIN 915-M4×8-45H DIN 915-M4×8-45H
7 End cap module
8 Seal
9 Wiper seal
10 Compression spring
11 Sealing band
12 Cover strip
13 Piston seal
14 Piston cap module
15 Washer Component not present
16 Belt diverter
17 Wiper seal
18 Blanking plug Component not present
19 Piston
20 Piston cap
21 Piston module
22 Cylinder barrel
23 Magnetic strip
24 Adhesive tape
25 Lubricating grease LUB-KC1, silicone-free LUB-KC1, silicone-free LUB-KC1, silicone-free
26 Screw locking agent LOCTITE 243 LOCTITE 243 LOCTITE 243

20 / 49 Festo 7DGC-Kb_en
3.7 DGC-K-25/32/ 40-…-GV
1
2
34
5
6
23
22
21
6
5
25 4
3
26 27
24
28
29
1
11
12
9
10
14
7
8
15
18
7
20
14
19 11
8
13
13
16
17
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 (http://spareparts.festo.com).