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DGC G Series

manual dgc_g

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0% found this document useful (0 votes)

116 views136 pages

DGC G Series

manual dgc_g

Uploaded by

Mustakimi Muhamad

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Linear drive

DGC-…-G

Repair
instructions (en)

7DGC-Ga_en
Imprint

Version:
7DGC-Ga_de (09.2009)

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
file patent, utility model or registered
design applications.
All product designations and brand
names used are the property of the
owners and not explicitly identified
as such.

All technical data subject to change

according to technical updates.
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 modification status of the specific 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 find 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.

Festo 07DGC-Ga_en 3 / 48

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

4 / 48 Festo 07DGC-Ga_en

1 Important information

1.1 About these repair instructions

This document contains important • Operating instructions • Assembly tools
information about the professional Contains information about the Contains an overview of the
repair of the linear drive type DGC-…-G. control parts and connections available assembly tools such as
The DGC-…-G linear drive is fully for the linear drive, as well as lubricants, thread locking agents,
repairable. However, in case of larger information about function, con- maintenance tools etc. (aids for
defects, the costs of carrying out a struction, application, installation, assembly and maintenance). They
repair must be considered. commissioning, care and mainten- can be found in the online spare
Before carrying out a repair, the ance, etc. It can be found on the parts catalogue on the Festo web-
relevant chapter in these instructions Festo website (www.Festo.com). site (www.Festo.com).
must be read in full and followed • Spare parts documentation
consistently. Contains an overview of the spare
For reasons of clarity, these repair and wearing parts as well as infor-
instructions do not contain complete, mation on their installation. The
detailed information. The following spare parts documentation can
documents should therefore also be be found in the online spare parts
available while doing repair work on catalogue on the Festo website
the linear drive: (spareparts.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 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.

Festo 07DGC-Ga_en 5 / 48

1.3 General safety instructions

Warning
The linear drive must only be repaired by authorised and trained persons in accordance with the specifications 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-specific
operating instructions.

Note
Instead of carrying out the repair yourself, your local Festo sales office 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.

2 General product description

2.1 Functional description

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.

8 1 2 1 Guide rail
2 Slide
4
3 Slide-piston connection
9 4 Cover band
3 5 Slide element
6 Coupling
7 Piston
4 8 Cylinder barrel
2
9 Sealing band
5
3
6
8 7

6 / 48 Festo 07DGC-Ga_en

2.2 Types and part numbers
Type Part number The complete overview of features, accessories,
DGC-8-…-G 530906 type codes, technical data and dimensions for the DGC-
DGC-12-…-G 530907 linear drives can be found in the product catalogue or on
DGC-18-…-G 532446 the Festo website (www.Festo.com).
DGC-25-…-G 532447
DGC-32-…-G 532448
DGC-40-…-G 532449
DGC-50-…-G 532450
DGC-63-…-G 532451

2.3 Mounting directions

This graphic provides you with an overview of the mounting directions of the linear drive using the DGC-25-…-G as an
example.

Type = Product designation

(name plate)
O = Top
U = Underneath
5-
C-2 -

R = Right
DG 330-G V-A
PP 3456
12 W708

L = Left
V = Front
H = Rear

Festo 07DGC-Ga_en 7 / 48

3 Component overview

3.1 DGC-8/12-…-G

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).

8 / 48 Festo 07DGC-Ga_en

Entry Designation Type Note
DGC-8-…-G DGC-12-…-G DGC-8-…-G DGC-12-…-G
1 Threaded pin or blanking Tightening torque 5.0 Nm, Tightening torque 5.0 Nm,
plug, depending on series use LOCTITE 222 use LOCTITE 222
status
2 Sealing ring
3 Self-tapping screw TPD-WN122- M5×20-10.9 Tightening torque 2.0 Nm ± 20%, Tightening torque 3.0 Nm ± 20%,
M3×18-450 use LOCTITE 243 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- 3×2-N-
NBR75 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 Tightening torque 0.3 Nm, use LOCTITE 243
internal Torx T6
21 Slide
22 Socket head screw DIN 912- DIN 912- Tightening torque 1.4 Nm, use LOCTITE 243
M3×8-8.8 M4×8-8.8 Sealed with thread locker 397332
23 Sealing band
24 End cap, right

Festo 07DGC-Ga_en 9 / 48

3.2 DGC-18/25-…-G

DGC-25-...-G

31
21
32
3

4 10 19
18
17
5
DGC-18-...-G

13
12
11
89
7

6 14
16
3
2
1

15 DGC-18-...-G

5 4 2

22 30
27 13
6
12
8 9 11
23 28

13
13 29
22
32
DGC-25-...-G 31

24 25 26 30

10 / 48 Festo 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 Tightening torque 7 Nm ± 10%, Tightening torque 12 Nm ± 10%,
M6×30- use LOCTITE 243 use LOCTITE 243
A4-70
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- 1.8×1.2-N-
NBR70 NBR75
9 Regulating screw
10 Flat-head screw DIN 920- DIN 84- Tightening torque 0.2 Nm, Tightening torque 0.4 Nm,
M3×20-4.8 M3×28-4.8 use LOCTITE 243 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- DIN 6912- Tightening torque 0.6 Nm, Tightening torque 0.8 Nm,
M4×12-8.8 M5×16-8.8 use LOCTITE 243 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

Festo 07DGC-Ga_en 11 / 48

3.3 DGC-32/40-…-G

DGC-25-...-G
DGC-32-...-G
DGC-40-...-G

31
21
32
3

20
33
4 10 19
18
17
5
DGC-18-...-G

13
12
11
89
7

6 14
16
3
2
1

15 DGC-18-...-G

5 4 2

22 31
27 13
6
12
8 9 11
23 28

13
13 29
22
32
DGC-25-...-G 31
DGC-32-...-G
DGC-40-...-G
24 25 26 30

12 / 48 Festo 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- 17×2-N-
NBR70 NBR75
7 Buffer, left
8 O-ring 1.8×1.2-N- 3×1.2-N-
NBR75 NBR70
9 Regulating screw
10 Flat-head screw DIN 84- DIN 912- Tightening torque 0.4 Nm, Tightening torque 1.0 Nm,
M3×30-5.8 M4×40-10.9 use LOCTITE 243 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- DIN 912- Tightening torque 1.3 Nm ± 10%, Tightening torque 2.5 Nm ± 10%,
M6×20-10.9 M8×25-10.9 use LOCTITE 243 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 –

Festo 07DGC-Ga_en 13 / 48

3.4 DGC-50/63-…-G

21
35
25
24 23
22

4 10
5 19 20
18

17
13
12
6 11
89
7

3 14
33
34 33
34
16

1 2

15
4

10 34
5 33

6
12
8 9 11
32
29
27
13
30

14 / 48 Festo 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%, Tightening torque 30 Nm ± 20%,
use LOCTITE 243 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- 42×3-N-
NBR70 NBR70
7 Buffer, left
8 O-ring 4×1.5-N- 6×1.5-N-
NBR70 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- DIN 912- Tightening torque 20 Nm ± 20%, use LOCTITE 243
M8×16-10.9 M8×25-10.9

Festo 07DGC-Ga_en 15 / 48

4 Repair steps

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 flat 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).

16 / 48 Festo 07DGC-Ga_en

4.1 Linear drives DGC-8/12-…-G

4.1.1 Dismantling the linear drive

• 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.

Festo 07DGC-Ga_en 17 / 48

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.

4.1.2 Assembling the linear drive

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 specified 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 Example: DGC-12-405-G
DGC-12-…-G 160 mm 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.

18 / 48 Festo 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-KC1 Apply a layer of grease to the slot and all around and along the entire length of
1)

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 Festo LUB-KC11) Fill the grease pockets in the slide elements with grease. Apply a thin layer of
guide 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).

Festo 07DGC-Ga_en 19 / 48

• 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 flush 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 flush 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.

20 / 48 Festo 07DGC-Ga_en

4.1.3 Replacing the slide elements in the slide
If the slide elements in the slide are faulty or worn, they will have to be replaced.

• Remove the slide as described in chapter 4.1.1 and remove the piston.

• Remove both narrow slide elements from the guide groove.

• Unscrew and remove the mounting screws on the stops with a Torx screw-
driver T6 on both sides of the slide and remove the stops.

Warning
The screws are secured with Loctite 243 and may become damaged if han-
dled carelessly. If the Torx socket on the screw head is damaged, the screw
will have to be drilled out.
Tip: Before unfastening the screws, tap the screw heads with a suitable pin
punch and a hammer in order to loosen the screws.

• Re-cut the threaded holes for the screws with a tapping drill in order to
remove the residue of the locking agent.
• Check the screws for damage and replace them as necessary.

• Remove the wide slide element.

• Grease the slide elements on the contact surfaces (1).

Observe the greasing instructions in the table in chapter 4.1.2.
• Insert the slide elements in the slide (2).

Note
After replacing the slide elements, the sliding play has to be set as described
in chapter 4.1.4.

Festo 07DGC-Ga_en 21 / 48

4.1.4 Setting the sliding play on the slide
If new slide elements are inserted in the slide, the sliding play has to be set.

The setting for the sliding play is adjusted by turning the threaded pins marked
1
1. This causes the respective toggle lever 3 to change the contact pressure of
the slide element 4 on the guide rail. 2
3
The trapezoidal shape of the guide rails distributes the contact pressure over all
three slide elements.
4
The sliding play setting is secured by tightening the side threaded pins 2.
This causes the toggle levers 3 between the threaded pins 2 and the slide
to be clamped.

• Remove the slide as described in chapter 4.1.1 and remove the piston.

• Unscrew the side threaded pins to secure the toggle levers (1).
• Unscrew the threaded pins to set the sliding play (2).

Warning
The threaded pins are secured with Loctite 243 and may become damaged
if handled carelessly. If the internal hexagon socket is damaged (rounded),
it may still be possible to unscrew the threaded pin by driving in a Torx
screwdriver. Otherwise the threaded pin will have to be drilled out.

• Re-cut all four threaded holes for the threaded pins with a suitable tapping
drill in order to remove the residue of the locking agent.
• Check the threaded pins for damage and replace them as necessary.

• Place the slide, including the piston, on the cylinder barrel as described in
chapter 4.1.2.
• Push a feeler gauge (0.02 mm) between the upper slide element and the
guide rail.

• Apply Loctite 243 to both threaded pins to set the sliding play and screw
them in so that the slide rests on the guide rail backlash-free.

22 / 48 Festo 07DGC-Ga_en

• Apply Loctite 243 to both threaded pins to secure the toggle levers and
tighten them using the appropriate torque (see table).
Type Torque
DGC-8-…-G 1.0 Nm
DGC-12-…-G 1.0 Nm

• Remove the feeler gauge.

• Put the side stops on the slide.

• Apply Loctite 243 to both mounting screws and tighten them using the
appropriate torque (see table).
Type Torque
DGC-8-…-G 0.3 Nm
DGC-12-…-G 0.3 Nm

• Fit the buffers and place the end caps on the cylinder barrel as described in
chapter 4.1.2.

4.1.5 Replacing the coupling on the slide

If the coupling (magnifying glass) is faulty or has been lost, it can be replaced
as follows.
• Remove the slide as described in chapter 4.1.1.

Note
The socket head screw for fastening the coupling is filled with thread locker.
To open the screw the thread locker has to be removed using suitable tools.

• Remove the socket head screw completely.

Festo 07DGC-Ga_en 23 / 48

• Remove the coupling.

• Insert the new coupling in the slide. Apply Loctite 243 to the socket head
screw and screw in the socket head screw. Do not tighten the screw yet.
• Place the slide, including the piston, on the cylinder barrel as described in
chapter 4.1.2.
• Tighten the socket head screw using the appropriate torque (see table).
Type Torque
DGC-8-…-G 1.4 Nm
DGC-12-…-G 1.4 Nm

4.1.6 Replacing the cushioning components

• Unfasten the lock nuts on the cushioning components.

Note
The cushioning components can be replaced even when the end caps are
attached.

• Unscrew the cushioning components from the end caps.

• Insert the new cushioning components by repeating the steps in reverse
order and tighten them using the appropriate torque (see table).
Type Torque
DGC-8-…-G 2.0 Nm ±20%
DGC-12-…-G 2.0 Nm ±20%

24 / 48 Festo 07DGC-Ga_en

4.2 Linear drives DGC-18/25/32/40-…-G

4.2.1 Dismantling the linear drive

• Place the linear drive on the work surface with the slide facing upwards.

• Unfasten and remove the three 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.
• Remove the sealing rings from the inside of the end caps and the buffers.

Documents
Chapters 4.2.4 and 4.2.5 describe how to dismantle and repair the end caps.

• Unscrew and remove the flat head screw from the band clamping mecha-
nism on both buffers.

• Remove the clamping mechanism for the cover band from both ends of the
drive and remove the clamping mechanism from the sealing band between
the cover band and sealing band.

Festo 07DGC-Ga_en 25 / 48

• Remove both the buffers from the cylinder barrel.

• Unscrew and remove the socket head screws from the slide-piston
connection.

• Remove the slide-piston connection.

• Push the slide off the cylinder barrel.

• Push the piston out of the cylinder barrel.

Documents
Chapter 4.2.3 describes how to dismantle and repair the piston module.

26 / 48 Festo 07DGC-Ga_en

• Pull the cover band out of the cylinder barrel.

• Push the sealing band inwards and out of the guide slot (1) with a blunt
object and pull it out of the cylinder barrel (2).

4.2.2 Assembling the linear drive

When assembling a linear drive, wearing parts, such as the sealing band, cover band, seals 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 length or sealing band/cover band.

Cutting the new sealing band/cover band to length

The exact length of the sealing band and cover band is determined by the 0-stroke of the respective type and the stroke
of the linear drive. The stroke is specified by the type code on the name plate. Check the length of the new sealing band
and cover band and shorten them to length (0-hub + hub) as necessary. See order example.

Type Length L0 
DGC-18-…-G 220 mm Example: DGC-25-330-G
DGC-25-…-G 250 mm 0-stroke: 250 mm
DGC-32-…-G 290 mm
Stroke: 330 mm
DGC-40-…-G 335 mm
Length of the sealing band/cover band =
0-stroke + stroke = 580 mm

The length of the band calculated in this way is a theoretical value. Component tolerances may make it necessary to
adjust the length of the sealing band/cover band after installation.

Note
Sturdy general purpose scissors or metal shears are best for cutting the sealing band and cover band.

Warning
Do not bend the sealing band and the cover band as this may cause damage or tearing and reduce the service life of
the sealing band/cover band.

Festo 07DGC-Ga_en 27 / 48

Greasing whilst assembling

the cylinder bore.

Sealing band Festo LUB-KC11) Apply a layer of grease all around and along the entire length.
Cover 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 – The plain-bearing guide in these sizes is designed for unlubricated operation.
guide
1)
See “Assembly aids” in the online spare parts catalogue on the Festo website (www.Festo.com).

• Grease the cylinder barrel and the sealing band and cover band.
Observe the greasing instructions in the table at the start of this chapter.
• Insert the sealing band in the cylinder barrel so that approximately 10 mm
of the sealing band protrudes from one end of the cylinder barrel.
• Use your finger or a blunt object to press as much of the sealing band as
possible into the guide slot from inside.

• Thread the cover band into the fixture so that approximately 10 mm of the
cover band still protrude.

• Grease the piston and the band reverser.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the piston into the cylinder barrel. Push the cover band into the slid-
ing notch on the band reverser with a screwdriver.

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.

• Push the sealing band under the band reverser with a screwdriver.

28 / 48 Festo 07DGC-Ga_en

• Insert the piston fully into the cylinder barrel.

• Adjust the excess sealing band and cover band by moving the piston back
and forth and pulling or pushing the respective bands at the same time so
that the excess band is no greater than the width of the contact surface (X)
on the buffer (see table).
Type Width of the contact sur-
face X X
DGC-18-…-G 6 mm
DGC-25-…-G 7 mm
DGC-32-…-G 9 mm
DGC-40-…-G 9 mm

• Grease the buffer.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the buffer into the cylinder barrel.
• Grease the sealing ring and insert it into the buffer.

Note
The sealing band and cover band must not protrude beyond the buffers,
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 and cover band
have to be shortened so that they seal off flush with the outer edge of the
buffers. However, it is better if they are slightly short of the buffers.

• Apply the band clamping mechanism to the sealing band and cover band.
• Apply Loctite 243 to the socket head screw and tighten it using the appro-
priate torque (see table).
Type Torque
DGC-18-…-G 0.2 Nm ±10%
DGC-25-…-G 0.4 Nm ±10%
DGC-32-…-G 0.4 Nm ±10%
DGC-40-…-G 1.0 Nm ±10%

• Move the piston to the other end of the cylinder barrel once in order to
secure the sealing band back in the slot.

Festo 07DGC-Ga_en 29 / 48

• Push the slide onto the guide rail and align it centrally with the piston's
moment compensator.

Note
The slide elements cannot be replaced individually. It is therefore necessary
to replace the entire slide.

• Place the slide-piston connection on the coupling.

• Apply Loctite 243 to the socket head screws and tighten them using the
appropriate torque (see table).
Type Torque
DGC-18-…-G 0.6 Nm ±10%
DGC-25-…-G 0.8 Nm ±10%
DGC-32-…-G 1.3 Nm ±10%
DGC-40-…-G 2.5 Nm ±10%

• Grease the second buffer.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the buffer into the piston chamber on the other side of the cylinder
barrel.
• Grease the sealing ring and insert it into the buffer.

Note
Newly inserted sealing bands and cover bands are generally too long and
protrude beyond the buffer. Shorten the bands as necessary so that they do
not protrude beyond the contact surface of the buffer (see band fastening on
the other side of the cylinder barrel).

• Applying the band clamping mechanism to the sealing band and cover band
• Apply Loctite 243 to the socket head screw and tighten it using the appro-
priate torque (see table).
Type Torque
DGC-18-…-G 0.2 Nm ±10%
DGC-25-…-G 0.4 Nm ±10%
DGC-32-…-G 0.4 Nm ±10%
DGC-40-…-G 1.0 Nm ±10%

• Grease the sealing rings and insert them into the end caps.

30 / 48 Festo 07DGC-Ga_en

• 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 flush with the cylinder
barrel.
• Tighten the self-tapping screws on both ends using the appropriate torque
(see table).
Type Torque
DGC-18-…-G 7.0 Nm ±10%
DGC-25-…-G 12 Nm ±10%
DGC-32-…-G 30 Nm ±10%
DGC-40-…-G 30 Nm ±10%

Note
After the linear drive has been assembled, it needs to be commissioned as described in chapter 7 of the operating
instructions.

4.2.3 Dismantling and repairing the piston module

• Remove the piston as described in chapter 4.2.1.

• Remove the coupling, together with the band reverser, from the piston.

Note
The piston must be replaced completely in case of wear. The spare part
comprises the inner and outer sealing rings and the magnets.

• Bend the band reverser slightly apart and pull it off the coupling.
• Check all parts for wear and replace them as necessary.

Festo 07DGC-Ga_en 31 / 48

• Clip the band reverser in the coupling.

Note
Make sure that the band reverser is aligned properly with the coupling
(see illustration).

• Connect the coupling with the band reverser to the piston.

Note
Make sure that the coupling is properly aligned with the piston. The magnet
in the piston must be positioned on the left-hand side of the piston when the
coupling points backwards.

• Grease the sealing rings and the band reverser.

Observe the greasing instructions in the table in chapter 4.2.2.
• Assemble the linear drive as described in chapter 4.2.2.

4.2.4 Replacing the buffer strips

• Remove the buffer strips from the end caps.

• Grease the backs of the new buffer strips and insert them into the end caps.

4.2.5 Replacing the sealing rings for the supply ports in the end caps

• Unscrew and remove the plug screws for the supply ports from the end caps
and remove the sealing rings.

Note
The sealing rings can be replaced even when the end caps are attached.

• Insert the new sealing rings in the supply ports by repeating the steps in
reverse order and tighten the plug screws using the appropriate torque
(see table).
Type Torque
DGC-25-…-G 11 Nm ±10%
DGC-32-…-G 11 Nm ±10%
DGC-40-…-G 50 Nm ±10%

32 / 48 Festo 07DGC-Ga_en

4.3 Linear drives DGC-50/63-…-G

4.3.1 Dismantling the linear drive

• Place the linear drive on the work surface with the slide facing upwards.

• Unfasten and remove the four 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.
• Remove the sealing rings from the inside of the end caps and the buffers.

Documents
Chapters 4.3.4 and 4.3.5 describe how to dismantle and repair the end caps.

• Unscrew and remove the flat head screw from the band clamping mechanism
on both buffers.

• Remove the clamping mechanism for the cover band from both ends of the
drive and remove the clamping mechanism from the sealing band between
the cover band and sealing band.

Festo 07DGC-Ga_en 33 / 48

• Remove both the buffers from the cylinder barrel.

• Remove both the two front and the two side blanking plugs from the slide-
piston connection.

• Unfasten the threaded pins on the left-hand side of the slide-piston

connection.

• Unfasten the socket head screw on the right-hand side of the slide-piston
connection.

Note
Before this screw can be completely unscrewed, the socket head screws
which are accessible from the front have to be unscrewed and removed.

• Unfasten both the socket head screws on the front of the slide-piston
connection and remove them.

• Remove the socket head screw on the right-hand side of the slide-piston
connection.

34 / 48 Festo 07DGC-Ga_en

• Remove the slide-piston connection.

Note
Both the spring pins and the blanking plugs between the slide and the
slide-piston connection are not fastened and may be lost when removing the
slide-piston connection.

• Push the slide off the cylinder barrel.

Documents
Chapter 4.3.3 describes how to replace the slide elements in the slide.

• Push the piston out of the cylinder barrel.

• Check the springs on the band reverser for damage and replace them as
necessary.

• Pull the cover band out of the cylinder barrel.

• Push the sealing band inwards and out of the guide slot (1) with a blunt
object and pull it out of the cylinder barrel (2).

Festo 07DGC-Ga_en 35 / 48

4.3.2 Assembling the linear drive
When assembling a linear drive, wearing parts, such as the sealing band, cover band, seals and the complete piston,
can be replaced.
The wearing parts are ordered from 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 length or sealing band/cover band.

Cutting the new sealing band/cover band to length

Type Length L0 
DGC-50-…-G 370 mm Example: DGC-50-180-G
DGC-63-…-G 415 mm 0-stroke: 370 mm
Stroke: 180 mm
Length of the sealing band/cover band =
0-stroke + stroke = 550 mm

The length of the band calculated in this way is a theoretical value. Component tolerances may make it necessary to
adjust the length of the sealing band/cover band after installation.

Note
Sturdy general purpose scissors or metal shears are best for cutting the sealing band and cover band.

Warning
Do not bend the sealing band and the cover band as this may cause damage or tearing and reduce the service life of
the sealing band/cover band.

Greasing whilst assembling

the cylinder bore.

36 / 48 Festo 07DGC-Ga_en

• Grease the cylinder barrel and the sealing band and cover band.
Observe the greasing instructions in the table at the start of this chapter.
• Insert the sealing band in the cylinder barrel so that approximately 14 mm
of the sealing band protrudes from one end of the cylinder barrel.
• Use your finger or a blunt object to press as much of the sealing band as
possible into the guide slot from inside.

• Thread the cover band into the fixture so that approximately 14 mm of the
cover band still protrude.

• Grease the piston and the band reverser.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the piston into the cylinder barrel. Push the cover band into the
sliding notch on the band reverser with a screwdriver.

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.
The magnet is moulded-in and is thus not visible. Therefore its position can
be determined using a counter magnet (e.g. compass).

• Push the sealing band under the band reverser with a screwdriver.

• Insert the piston fully into the cylinder barrel.

Festo 07DGC-Ga_en 37 / 48

• Grease the buffer.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the buffer into the cylinder barrel.
• Grease the sealing ring and insert it into the buffer.

• Move the piston to the other end of the cylinder barrel once in order to
secure the sealing band back in the slot.

• Grease the second buffer.

38 / 48 Festo 07DGC-Ga_en

• Push the slide onto the guide rail and align it centrally with the coupling.

• Place the slide-piston connection on the coupling.

• Place the washer on the socket head screw on the right-hand end of the
slide-piston connection and apply Loctite 243 to the socket head screw.

• Only screw the socket head screw in far enough so that the thread of the
socket head screw being inserted from the front is accessible.

• Apply Loctite 243 to the socket head screws for the slide-piston connection
and tighten them slightly so that the slide-piston connection is positioned
at 1-2 mm from the slide.

Festo 07DGC-Ga_en 39 / 48

• Insert the spring pins between the slide and the slide-piston connection as
far as they will go.

Note
When inserting the spring pins, make sure that they rest properly in the
fixture.
The openings of the spring pins must be off-set by 90° to the join between
the slide and the slide-connection.

• Align the upper edge of the slide-piston connection so that it is flush with
the outer edge of the slide using a stop. The parallel offset between the max. 0.5 mm
upper edge of the slide-piston connection and the outer edge of the slide
must not exceed 0.5 mm.

• Tighten the socket head screws for the slide-piston connection using the
appropriate torque (see table).
Type Torque
DGC-50-…-G 20 Nm ±20%
DGC-63-…-G 20 Nm ±20%

• Tighten the socket head screw on the right-hand end of the slide-piston
connection using the appropriate torque (see table).
Type Torque
DGC-50-…-G 20 Nm ±20%
DGC-63-…-G 20 Nm ±20%

• Tighten the threaded pins on the left-hand end of the slide-piston connection
using the appropriate torque (see table).
Type Torque
DGC-50-…-G 5 Nm ±20%
DGC-63-…-G 5 Nm ±20%

• Grease the sealing ring and insert it into the respective fixture in the end
cap.
• Attach the respective end caps to the cylinder barrel on both sides and align
each rear and lower edge flush with the cylinder barrel.

40 / 48 Festo 07DGC-Ga_en

• Apply Loctite 243 to the socket head screws and tighten them using the
appropriate torque (see table).
Type Torque
DGC-50-…-G 25 Nm ±20%
DGC-63-…-G 30 Nm ±20%

• Insert the blanking plugs for the drill holes for the socket head screws,
threaded pins and spring pins into the slide-piston connection.

Note
Once the linear drive has been assembled, it needs to be commissioned as
described in chapter 7 of the operating instructions.

4.3.3 Replacing the slide elements in the slide

• Remove the slide as described in chapter 4.3.1.

• Lever the slide elements inwards and out of the slide with a suitable tool.
• Insert the new slide elements in the slide.

Festo 07DGC-Ga_en 41 / 48

4.3.4 Replacing the buffer strips

• Remove the cushioning components from the end caps.

Note
The cushioning components can be replaced even when the end caps are
attached.

• Grease the backs of the new cushioning components and insert them into
the end caps.

4.3.5 Replacing the sealing rings for the supply ports in the end caps

• Unscrew and remove the plug screws for the supply ports from the end cap
and remove the sealing rings.

Note
The sealing rings can be replaced even when the end cap is inserted.

• Insert the new sealing rings in the supply ports by repeating the steps in
reverse order and tighten the plug screws using the appropriate torque
(see table).
Type Torque
DGC-50-…-G 16 Nm
DGC-63-…-G 18 Nm

42 / 48 Festo 07DGC-Ga_en

5 Maintenance

This chapter contains key technical information about how to carry out maintenance work on the linear drive. A detailed
description of the steps for care and maintenance can be found in the operating instructions. Further information on the
assembly aids and lubricants can be found on the Festo website (www.Festo.com).

5.1 Greasing the linear drive

The linear drive has to be greased when repair work is carried out and at set intervals.

Greasing intervals for the guide rails by size and lubricant

Type Greasing interval Lubricant
DGC-8-…-G 3000 km LUB-KC1
DGC-12-…-G Life-time lubrication LUB-KC1
DGC-18-/-25-/-32-/-40-/ The guides for these drives are designed for unlubricated operation. LUB-KC1
-50-/-63-…G Relubrication is permitted.

Warning
The lubrication intervals are shortened by the following operating conditions:
• Extremely short strokes < 50 mm.
• Large strokes > 2000 mm.
• Speeds > 2 m/s.
• Increased accumulation of dirt in the environment (e.g. sanding dust etc.).
• High ambient temperature > 40 °C.
The guide rail must be relubricated at least every 3 years.

Maintenance of the band system

• Clean the band system if required with a soft cloth.
• Avoid cleaning agents which will damage the band system which is made of PU. Excessive friction or the use of
grease-solvent cleaning agents (e.g. soapsuds) will damage the grease layer.
• Grease the band system superficially with LUB-KC1 type grease if it no longer has a layer of grease.

Festo 07DGC-Ga_en 43 / 48

6 Tools

This chapter provides an overview of the tools and aids required to repair and maintain the linear drive DGC-…-G in its
various sizes.

6.1 Required tools by size

Designation DGC-8-/-12-…-G DGC-18-/-25-/-32-/-40- DGC-50-/-63-…-G
…-G
Allen key 1.5 - 4 mm 4 - 5 mm 3 - 6 mm
Torx screwdriver T10
Screwdriver 5 mm
Torque wrench 1.4 - 3 Nm 0.6 - 50 Nm 1 - 25 Nm
Torque screwdriver 0.2 – 1 Nm
Flat pliers Required
Feeler gauge 0.02 mm
Sturdy general purpose scis- For cutting the cover band For cutting the sealing band and the cover band to
sors or metal shears to length length

7 Liability/Conditions of use

The General Terms and Conditions of Festo AG & Co. KG apply, which can be viewed on the Festo website (www.Festo.com).

44 / 48 Festo 07DGC-Ga_en

Conditions of use for “electronic documentation”

I. Protection rights and scope 2. Copyright note The latter applies particularly to extracts of
of use Every “electronic document” receives a
the documents for the user’s own documenta-
tion. The guarantee and liability for separately
The file of your choice is subject to protec- copyright note. This note must be included on
available/supplied data storage media, i. e.
tive provisions. Festo or third parties have every copy and every printout.
except for the electronic documentation
protective rights concerning this electronic Example: E 2003, Festo AG & Co. KG, available/supplied via the Internet/Intranet,
documentation which Festo makes available D-73726 Esslingen is limited exclusively to proper duplication
on portable data storage media (floppy disks,
of the software, whereby Festo guarantees
CD-Rom, removable disks) as well as on the
3. Transferring the authorisation that in each case the data storage medium
Internet and/or Intranet, hereinafter referred
of use or software contains the latest update of
to as electronic documentation. Provided
The user can transfer the authorisation of the documentation. Concerning electronic
third parties are entitled to partial or full
use in the scope of and with the limitations documentation available on the Internet/
rights concerning this electronic documen-
of the conditions in accordance with items 1 Intranet, there is no guarantee that it will
tation, Festo shall have the corresponding
and 2 completely to a third party. The third have the same version status as the last
rights of use. Festo permits the user to use
party must be made explicitly aware of these printed edition.
the electronic documentation under the fol-
lowing conditions: conditions of use. 2. Furthermore, Festo cannot be held liable
for the lack of economic success or for dam-
1. Scope of use II. Exporting the electronic age or claims by third parties resulting from
documentation the use of the documentation by the user,
a) The user of the electronic documenta-
with the exception of claims arising from
tion is allowed to use this documentation When exporting the electronic documenta-
infringement of the protection rights of third
for his own, exclusively company-internal tion, the licence holder must observe the
parties concerning the use of the electronic
purposes on any number of machines within export regulations of the exporting country
documentation.
his business premises (location). This right and those of the purchasing country.
of use includes exclusively the right to save 3. The limitations of liability as per para-
the electronic documentation on the central III. Warranty graphs 1 and 2 do not apply if, in cases of
processors (machines) used at the location. intent or gross negligence or the lack of war-
1. Festo products are being further developed
ranted quality, liability is absolutely neces-
b) The electronic documentation may be with regard to hardware and software. The
sary. In such a case, Festo’s liability is limited
printed out on a printer at the location of hardware status and, where applicable, the
to the damage discernable by Festo when the
the user as often as desired, providing this software status of the product can be found
definitive circumstances are made known.
printout is printed with or kept in a safe place on the type plate of the product. If the elec-
together with these conditions of use and tronic documentation, no matter in what form,
other user instructions. does not directly accompany the product, i. e.
V. Safety guidelines/documentation
if the product is not supplied together with a Warranty and liability claims in conformity
c) With the exception of the Festo logo, the
portable data storage medium (floppy disk, with the aforementioned regulations (items
user has the right to use pictures and texts
CD-Rom, removable disk), Festo does not III. and IV.) may be raised only if the user has
from the electronic documentation for creat-
guarantee that the electronic documentation observed the safety guidelines of the docu-
ing his own machine and system documen-
corresponds to every hardware and software mentation in conjunction with the use of the
tation. The use of the Festo logo requires
status of the product. In this case, the printed machine and its safety guidelines. The user
written consent from Festo. The user himself
documentation from Festo accompanying the himself is responsible for ensuring that the
is responsible for ensuring that the pictures
product alone is decisive for ensuring that the electronic documentation, when not supplied
and texts used match the machine/system or
hardware and software status of the product with the product, matches the product actu-
the relevant product.
matches that of the electronic documentation. ally used by the user.
d) Further uses are permitted within the fol-
lowing framework: 2. The information contained in this electronic
documentation can be amended by Festo
Copying exclusively for use within the frame-
without prior notice and does not commit
work of machine and system documentation
Festo in any way.
from electronic documents of all documented
supplier components. Demonstrating to third
IV. Liability/Limitations of liability
parties exclusively under guarantee that no
data material is stored wholly or partly in 1. Festo supplies this electronic documenta-
other networks or other data storage media tion in order to assist the user in creating his
or can be reproduced there. machine and system documentation. In the
case that electronic documentation in the
Passing on printouts to third parties outside
form of portable data storage media (floppy
of the provision stated in item 3, as well as
disk, CD-Rom, removable disk), does not
any processing or other use, is not permitted.
accompany a product i. e. is not supplied
together with that product, Festo does not
guarantee that the electronic documentation
available/supplied separately matches the
product actually used by the user.

Festo 07DGC-Ga_en 45 / 48

Linear drive

DGC-…-GF

Repair
instructions (en)

PPV -GF 5-
330 C-2

123 -A -
DG

W7 456
08

7DGC-GFa_en
Imprint

Version:
7DGC-GFa_en (09.2009)

Editorial department:
SC-S

Phone:
+49 / 711 / 347-0

Email:
[email protected]

Internet:
http://www.festo.com

The reproduction, distribution and

All technical data subject to change

These repair instructions have been prepared with care.

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.

Festo 7DGC-GFa_en 3 / 44

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-18/25-…-GF 8
3.2 DGC-32/40-…-GF 10
3.3 DGC-50/63-…-GF 12
4 Repair steps 14
4.1 Linear drives DGC-18/25/32/40-…-GF 15
4.1.1 Dismantling the linear drive 15
4.1.2 Assembling the linear drive 18
4.1.3 Replacing the slide elements in the slide 24
4.1.4 Setting the sliding play on the slide 25
4.1.5 Dismantling and repairing the piston module 26
4.1.6 Replacing the cushioning components 27
4.1.7 Replacing the sealing rings for the supply ports in the end caps 27
4.2 Linear drives DGC-50/63-…-GF 28
4.2.1 Dismantling the linear drive 28
4.2.2 Assembling the linear drive 31
4.2.3 Replacing the slide elements in the slide 36
4.2.4 Setting the sliding play on the slide 38
4.2.5 Replacing the cushioning components 39
4.2.6 Replacing the sealing rings for the supply ports in the end caps 39
5 Maintenance 40
5.1 Greasing the linear drive 40
6 Tools 41
6.1 Required tools by size 41
7 Liability/Conditions of use 41

4 / 44 Festo 7DGC-GFa_en

1 Important information

1.1 About these repair instructions

This document contains all important • Operating instructions • Assembly tools
information about the professional Contains information about the Contains an overview of the
repair of the linear drive type DGC-…-GF. control parts and connections available assembly tools such as
The DGC-…-GF linear drive is fully for the linear drive, as well as lubricants, thread locking agents,
repairable. However, in case of larger information about function, con- maintenance tools etc. (aids for
defects, the costs of carrying out a struction, application, installation, assembly and maintenance).
repair must be considered. commissioning, care and mainten- They can be found in the online
Before carrying out a repair, the ance, etc. It can be found on the spare parts catalogue on the Festo
relevant chapter in these instructions Festo website (www.Festo.com). website (www.Festo.com).
must be read in full and followed • Spare parts documentation
consistently. Contains an overview of the spare
For reasons of clarity, these repair and wearing parts as well as infor-
instructions do not contain complete, mation on their installation. The
detailed information. The following spare parts documentation can
documents should therefore also be be found in the online spare parts
available while doing repair work on catalogue on the Festo website
the linear drive: (spareparts.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 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.

Festo 7DGC-GFa_en 5 / 44

1.3 General safety instructions

Note
Instead of carrying out the repair yourself, your local Festo sales office 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-…-GF is a linear drive with a plain-bearing guide and 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 basic profile required for this is covered by a band system. The slide is mounted on slide elements and
thus designed for low and medium-level loads. The operating behaviour in case of torsional loads is in the medium range.
The DGC-…-GF, when used properly, is used for transporting loads in a space-saving manner and is approved for the oper-
ating 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-…-GF as an example.

9 1 2
1 Guide rail

4
2 Slide
3 Slide-piston connection

aJ 4 Cover band
3 5 Upper slide element
6 Side slide element
4 7 Coupling
2 8 Piston
5 9 Cylinder barrel
6 aJ Sealing band
3
7

9 8

6 / 44 Festo 7DGC-GFa_en

2.2 Types and part numbers
Type Part number The complete overview of features, accessories,
DGC-18-…-GF 532479 type codes, technical data and dimensions for the DGC-
DGC-25-…-GF 532483 linear drives can be found in the product catalogue or on
DGC-32-…-GF 532487 the Festo website (www.Festo.com).
DGC-40-…-GF 532491
DGC-50-…-GF 532495
DGC-63-…-GF 532499

2.3 Mounting directions

This graphic provides you with an overview of the mounting directions on the linear drive using the DGC-25-…-GF as an
example.

Type = Product designation

Ty p (name plate)
O = Top
U = Underneath
5-
C-2 F-
DG 0-G V-A
33 PP 56
R = Right
1234W708

L = Left
V = Front
H = Rear

Festo 7DGC-GFa_en 7 / 44

3 Component overview

3.1 DGC-18/25-…-GF
8

7 29
28 DGC-18-...-GF
6
27
11 35
30
DGC-18-...-GF 26 31
17
16 32
15
14 33
1213
10 9 18 25
24 36
3
23
31
1 2 34
22
38
DGC-25-...-GF DGC-25-...-GF

35 34
31
21 37
5
3 32
4
33
36

20 31 38
30
DGC-18-...-GF
8
7
6
19 10
SPC 46
44 1
2
11 47
9

16
15
14
13
17 45

17 39 4
5
32 DGC-25-...-GF
42
47
41
43
40
17
39

8 / 44 Festo 7DGC-GFa_en

Entry Designation Type Note
DGC-18-…-GF DGC-25-…-GF DGC-18-…-GF DGC-25-…-GF
1 Self-tapping screw M5×20-10.9 DIN 7500-E Tightening torque 7 Nm ± 10%, Tightening torque 12 Nm ± 10%,
M630-A4-70 use LOCTITE 243 use LOCTITE 243
2 Threaded pin DIN 913- DSR-32-
M5×5-45H 180-P
3 End cap, left
4 Plug screw Tightening torque 11 Nm ± 10%
5 Sealing ring
6 Silencer Tightening torque Tightening torque
7 Shock absorber 3 Nm ± 20% 5 Nm ± 20%
8 Shock absorber
9 Seal
10 Sealing ring
11 Flat-head screw DIN 920- DIN 84- Tightening torque 0,2 Nm ± 10%, Tightening torque 0.4 Nm ± 10%,
M3×20-4.8 M3×28-4.8 use LOCTITE 243 use LOCTITE 243
12 Buffer, left
13 O-ring 1×0.6-N- 1.8×1.2-N-
NBR70 NBR75
14 Regulating screw
15 Clamp, sealing band
16 Clamp, cover band
17 Buffer/piston seal
18 Buffer, left, sub-assembly
19 Cover band
20 Sealing band
21 Cylinder barrel
22 Slide element
23 Slide element
24 Pressure piece, sub-assembly
25 Pressure piece
26 Slide
27 Regulating screw
28 Washer
29 Socket head screw ISO 14580- DIN 7984- Tightening torque 0.7 Nm ± 10% Tightening torque 2 Nm ± 10%
M3×8-8.8 M5×10-8.8
30 Hex nut DIN 934- DIN 934-
M4-6AU M5-5
31 Washer DIN 433-4.3 DIN 125-B 5.3
32 Coupling
33 Socket head screw DIN 912- DIN 912- Tightening torque 2.5 Nm ± 10%, Tightening torque 5.7 Nm ± 10%,
M4×8-8.8 M5×16-10.9 use LOCTITE 243 use LOCTITE 243
34 Socket head screw DIN 912- DIN 912- Tightening torque 1.2 Nm ± 10%, Tightening torque 4.5 Nm ± 10%,
M4×35-10.9 M5×40-10.9 use LOCTITE 243 use LOCTITE 243
35 Stop
36 Stop
37 Connection
38 Cover
39 Buffer/piston seal 8×11.6 P80 9.5×15 P80
40 Magnet
41 Piston
42 Band reverser
43 Piston module
44 Buffer, right
45 Buffer, right, sub-assembly
46 Blanking plug
47 End cap, right

Festo 7DGC-GFa_en 9 / 44

3.2 DGC-32/40-…-GF

7 29
28
6
27
11
26
17
16
15
14
1213
10 9 18 24
25

5 23
1 4 3
DGC-32-...-GF 22
DGC-40-...-GF 36
34

35
21
36
32

31
35 33
34

4 38
8 5
7
6 1
19 10
SPC 46
44
DGC-32-...-GF
11
9 47 DGC-40-...-GF

16
15
14
13
17 45
17 39
32
42

41
43
40
17
39

10 / 44 Festo 7DGC-GFa_en

Entry Designation Type Note
DGC-32-…-GF DGC-40-…-GF DGC-32-…-GF DGC-40-…-GF
1 Self-tapping screw M8×45-10.9 M8×45-10.9 Tightening torque 30 Nm ± 10%,
use LOCTITE 243
3 End cap, left
4 Plug screw Tightening torque 11 Nm ± 10% Tightening torque 50 Nm ± 10%
5 Sealing ring OL-1/4 OL-1/2
6 Silencer Tightening torque Tightening torque
7 Shock absorber 8.0 Nm ± 20% 20 Nm ± 20%
8 Shock absorber
9 O-ring 16×2.5-N- 17×2-N-
NBR70 NBR75
10 Sealing ring 11.5×1.5-N-
NBR75
11 Socket head screw DIN 84- DIN 912- Tightening torque Tightening torque
M3×30-5.8 M4×40-10.9 0.4 Nm ± 10% 1.0 Nm ± 10%
12 Buffer, left
13 O-ring 1.8×1.2-N- 3×1.2-N-
NBR75 NBR70
14 Regulating screw
15 Clamp, sealing band
16 Clamp, cover band
17 Buffer/piston seal
18 Buffer, left, sub-assembly
19 Cover band
20 Sealing band
21 Cylinder barrel
22 Slide element
23 Slide element
24 Pressure piece, sub-assembly
25 Pressure piece
26 Slide
27 Regulating screw
28 Washer
29 Socket head screw DIN 7984- DIN 7984- Tightening torque Tightening torque
M5×10-8.8 M6×16-8.8 2.0 Nm ± 10% 3.0 Nm ± 10%
31 Washer DIN 125-B 5.3
32 Coupling Tightening torque 3.6 Nm ± 10% Tightening torque 5.7 Nm ± 10%
33 Socket head screw DIN 6912- DIN 912- Tightening torque 5.7 Nm ± 10%,
M5×12-8.8 M5×16-10.9 use LOCTITE 243
34 Socket head screw DIN 912-M5×40-10.9 Tightening torque 4.5 Nm ± 10%,
use LOCTITE 243
35 Stop
36 Connection
38 Cover
39 Buffer/piston seal 12×18 P80 16×24 P80
40 Magnet
41 Piston
42 Band reverser
43 Piston module
44 Buffer, right
45 Buffer, right, sub-assembly
46 Blanking plug
47 End cap, right

Festo 7DGC-GFa_en 11 / 44

3.3 DGC-50/63-…-GF

6
24
7

9 25
27
26
16
15
14 28
13
12
1011 29
17
4
3
2 20

1 5 37
35

33
36
31

19
30

32 34

18
6
7 1
8 10 2
3
9

42
11
16 43
38 15
14
13
40
39 41

12 / 44 Festo 7DGC-GFa_en

Entry Designation Type Note
DGC-50-…-GF DGC-63-…-GF DGC-50-…-GF DGC-63-…-GF
1 Self-tapping screw M8×55-10.9 M8×55-10.9 Tightening torque 25 Nm ± 20%, Tightening torque 30 Nm ± 20%,
use LOCTITE 243 use LOCTITE 243
2 Plug screw Tightening torque 16 Nm ± 10% Tightening torque 18 Nm ± 10%
3 Sealing ring OL-1/2 OL-M22
4 End cap, left
5 End cap, left, sub-assembly
6 Shock absorber Tightening torque Tightening torque
7 Shock absorber 35 Nm ± 20% 60 Nm ± 20%
8 Silencer
9 Socket head screw DIN 912- DIN 912- Tightening torque 1.0 Nm ± 20%, use LOCTITE 243
M4×40-10.9 M4×40-10.9
10 O-ring 11.5×1.5-N- 11.5×1.5-N-
NBR75 NBR75
11 O-ring 32×2.5-N- 42×3-N-
NBR70 NBR70
12 Buffer, left
13 O-ring 4×1.5-N- 6×1.5-N-
NBR70 NBR70
14 Regulating screw
15 Clamp, sealing band
16 Clamp, cover band
17 Buffer, left, sub-assembly
18 Cover band
19 Sealing band
20 Cylinder barrel
21 Socket head screw DIN 7984- DIN 7984- Tightening torque 6.0 Nm ± 10%, use LOCTITE 243
M6×16-8.8 M6×16-8.8
22 Washer
23 Regulating screw
24 Slide
25 Pressure piece
26 Press nut
27 Pressure piece, sub-as-
sembly
28 Slide element
29 Slide element
30 Stop
31 Spring pin SG 12×15 SG 12×15
32 Threaded pin SLT-25-P-A SLT-25-P-A Tightening torque 5.0 Nm ± 20%, use LOCTITE 243
33 Slide-piston connection
34 Socket head screw DIN 912- DIN 912- Tightening torque 20 Nm ± 20%, use LOCTITE 243
M8×40-10.9 M8×45-10.9
35 Washer
36 Socket head screw DIN 912- DIN 912- Tightening torque 20 Nm ± 20%, use LOCTITE 243
M8×50-10.9 M8×50-10.9
37 Socket head screw DIN 6912- DIN 912- Tightening torque 2.0 Nm ± 20%, use LOCTITE 243
M4×12-8.8 M4×10-8.8
38 Piston module
39 Compression spring VL-5/2-4.0 VL-5/2-4.0
40 Buffer, right
41 Buffer, right, sub-assembly
42 End cap, right
43 End cap, right, sub-assembly

Festo 7DGC-GFa_en 13 / 44

4 Repair steps

Note
The repair should preferably be carried out on a stable and flat 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, 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,
cooling 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-18/25/32/40-…-GF (see chapter 4.1).

• Linear drives DGC-50/63-…-GF (see chapter 4.2).

14 / 44 Festo 7DGC-GFa_en

4.1 Linear drives DGC-18/25/32/40-…-GF

4.1.1 Dismantling the linear drive

• Place the linear drive on the work surface with the slide facing upwards.

• Unfasten and remove the three 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.
• Remove the sealing rings from the inside of the end caps and the buffers.

Documents
Chapters 4.1.6 and 4.1.7 describe how to dismantle and repair the end caps.

• Unscrew and remove the flat head screw/socket head screw from the band
clamping mechanism on both buffers.

• Remove the clamping mechanism for the cover band from both ends of the
drive and remove the clamping mechanism from the sealing band between
the cover band and sealing band.

Festo 7DGC-GFa_en 15 / 44

• Remove both the buffers from the cylinder barrel.

• Push a suitable pin into one of the holes on the front of the cover in order to
release the holding lug behind it (1).
• Insert a screwdriver in the respective recesses on the cover and unfasten it
by turning (2).
Repeat this step on the other side.
• Remove the cover from the slide (3).

• Unscrew and remove both socket head screws from the slide-piston connection.

Note
The method for dismantling the drives DGC-18/25-…-GF and DGC-…-32/40-…-GF
differs in the way in which the slide-piston connection and piston coupling
are fastened.
The DGC-25-…-GF has an additional component on the slide-piston connection
(see chapter 3.1, entry 37).

DGC-18-…-GF and DGC-25-…-GF:

• Unscrew and remove the nut from the screw. Remove the socket head screw
and both washers.
• Lift the slide-piston connection upwards and out.

DGC-32-…-GF and DGC-40-…-GF (not shown in the illustration):

• Remove both socket head screws completely.

• Lift both the modules of the slide-piston connection upwards and out.

16 / 44 Festo 7DGC-GFa_en

Note
The parts of the slide-piston connection are paired with the slide. In order
to ensure the slide and the slide-piston connection fit backlash-free, the indi-
vidual parts of the slide-piston connection must be glued in a very precise
manner.
If the glued parts break apart, they can be placed on top of each other again
and re-installed.
You must not apply any additional glue as this will change the fit.
If a part of the slide-piston connection is faulty, the slide itself has to be
replaced because of the pairing.

• Push the slide off the cylinder barrel.

Documents
Chapters 4.1.3 and 4.1.4 describe how to dismantle and repair the slide.

• Push the piston out of the cylinder barrel.

Documents
Chapter 4.1.5 describes how to dismantle and repair the piston module.

• Pull the cover band out of the cylinder barrel.

• Push the sealing band inwards and out of the guide slot (1) with a blunt
object and pull it out of the cylinder barrel (2).

Festo 7DGC-GFa_en 17 / 44

4.1.2 Assembling the linear drive
When assembling a linear drive, wearing parts, such as the sealing band, cover band, seals and the complete piston,
can be replaced.
The wearing parts are ordered from 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 length or sealing band/cover band.

Cutting the new sealing band/cover band to length

Type Length L0 
DGC-18-…-GF 220 mm Example: DGC-25-330-GF
DGC-25-…-GF 250 mm 0-stroke: 250 mm
DGC-32-…-GF 290 mm
Stroke: 330 mm
DGC-40-…-GF 335 mm
Length of the sealing band/cover band =
0-stroke + stroke = 580 mm

The length of the bands calculated in this way is a theoretical value. Component tolerances may make it necessary to
adjust the length of the sealing band/cover band after installation.

Note
Sturdy general purpose scissors or metal shears are best for cutting the sealing band and cover band.

Warning
Do not bend the sealing band and the cover band as this may cause damage or tearing and reduce the service life of
the sealing band/cover band.

Greasing whilst assembling

When assembling the linear drives, 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.
Cover 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 – The plain-bearing guide in these sizes is designed for unlubricated operation.
guide
1)
See “Assembly aids” in the online spare parts catalogue on the Festo website (www.Festo.com).

18 / 44 Festo 7DGC-GFa_en

• Thread the cover band into the fixture so that approximately 10 mm of the
cover band still protrude.

• Grease the piston and the band reverser.

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.

• Push the sealing band under the band reverser with a screwdriver.

• Insert the piston fully into the cylinder barrel.

Festo 7DGC-GFa_en 19 / 44

• Adjust the excess sealing band and cover band by moving the piston back
and forth and pulling or pushing the respective bands at the same time so
that the excess band is no greater than the width of the contact surface (X)
on the buffer (see table).
Type Width of the contact surface X X
DGC-18-…-GF 6 mm
DGC-25-…-GF 7 mm
DGC-32-…-GF 9 mm
DGC-40-…-GF 9 mm

• Grease the buffer.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the buffer into the cylinder barrel.

Note
When using shock absorbers on the end caps the regulating screw for the
end position cushioning (see chapter 3.1 and 3.2, entry 14) must be "open".
Unscrew it far enough so that it is positioned flush with the buffer.

• Grease the sealing ring and insert it into the buffer.

• Apply the band clamping mechanism to the sealing band and cover band.
• Apply Loctite 243 to the socket head screw and tighten it using the appro-
priate torque (see table).
Type Torque
DGC-18-…-GF 0.2 Nm ±10%
DGC-25-…-GF 0.4 Nm ±10%
DGC-32-…-GF 0.4 Nm ±10%
DGC-40-…-GF 1.0 Nm ±10%

• Move the piston to the other end of the cylinder barrel once in order to
secure the sealing band back in the slot.

20 / 44 Festo 7DGC-GFa_en

• Align the slide so that the shoulder with the drill holes points towards the
piston coupling.
• Push the slide onto the cylinder barrel.

• Use a spring scale to check the displacement force of the slide (refer to the
table in chapter 4.1.4 for the values) and if necessary, adjust the setting for
the sliding play as described in chapter 4.1.4.

• Grease the second buffer.

Observe the greasing instructions in the table at the start of this chapter
and the note on using shock absorbers on the end caps.
• Insert the buffer into the cylinder barrel at the other end.
• Grease the sealing ring and insert it into the buffer.

• Apply the band clamping mechanism to the sealing band and cover band.
• Apply Loctite 243 to the socket head screw and tighten it using the appro-
priate torque (see table).
Type Torque
DGC-18-…-GF 0.2 Nm ±10%
DGC-25-…-GF 0.4 Nm ±10%
DGC-32-…-GF 0.4 Nm ±10%
DGC-40-…-GF 1.0 Nm ±10%

Festo 7DGC-GFa_en 21 / 44

• Align the slide centrally with the piston.

• Insert the parts of the slide-piston connection between the slide and the
piston from above.

Note
The parts of the slide-piston connection are paired with the slide. Observe
the instructions in chapter 4.1.1.

• Apply Loctite 243 to the socket head screws and tighten them using the
appropriate torque (see table).
Type Torque
DGC-18-…-GF 2.5 Nm ±10%
DGC-25-…-GF 5.7 Nm ±10%
DGC-32-…-GF 5.7 Nm ±10%
DGC-40-…-GF 5.7 Nm ±10%

Note
The method for assembling the drives DGC-18/25-…-GF and DGC-…-32/40-…-GF
differs in the way in which the slide-piston connection and piston coupling
are fastened.
The DGC-25-…-GF has an additional component on the slide-piston connection
(see chapter 3.1, entry 37).

DGC-18-…-GF and DGC-25-…-GF:

• Insert the socket head screw with a washer through the piston coupling and
into the drill holes on the slide-piston connection.
• Put on the second washer. Apply Loctite 243 to the thread, screw on the nut
and tighten it using the appropriate torque (see table).
Type Torque
DGC-18-…-GF 1.2 Nm ±10%
DGC-25-…-GF 4.5 Nm ±10%

22 / 44 Festo 7DGC-GFa_en

DGC-32-…-GF and DGC-40-…-GF (not shown in the illustration):

• Place the washers on the socket head screws, apply Loctite 243 to them and
tighten them using the appropriate torque (see table).
Type Torque
DGC-32-…-GF 4.5 Nm ±10%
DGC-40-…-GF 4.5 Nm ±10%

• Place the cover on the slide-piston connection and press it lightly so that it
latches into place.

• Grease the sealing rings and insert them into the end caps.

• Apply Loctite 243 to the self-tapping screws.

Note
After the linear drive has been assembled, it needs to be commissioned as
described in chapter 7 of the operating instructions.

Festo 7DGC-GFa_en 23 / 44

4.1.3 Replacing the slide elements in the slide
If the slide elements in the slide are faulty or worn, they will have to be replaced.
• Remove the slide as described in chapter 4.1.1.
• Remove the slide elements from the slide.

• Unfasten the socket head screws on the top of the slide and remove them.

• Remove both washers from the top of the slide.

Note
The washers can be removed easily with the help of a small magnet.

• Remove the pressure piece from the slide.

• Unscrew both regulating screws a few turns.

• Insert the pressure piece and the new slide elements in the slide and push
the slide onto the guide rail.

Note
After replacing the slide elements, the sliding play has to be set as described
in chapter 4.1.4.

24 / 44 Festo 7DGC-GFa_en

4.1.4 Setting the sliding play on the slide
If new slide elements are inserted in the slide, the sliding play has to be set.

The setting for the sliding play is adjusted by turning the regulating screws 2
1
in the slide 1. The pressure piece 3 is thus used to change the contact pres-
2
sure of the 4 slide elements on the guide rail 5.
The trapezoidal shape of the guide rail 5 distributes the contact pressure over
all three 4 slide elements.
3
The sliding play setting is secured by attaching the washers and tightening the
4
socket head screws (see below). The regulating screws 2 are thus clamped
between the pressure piece 3 and the slide 1. 5

If not yet carried out:

• Remove the socket head screws and washers from the top of the slide as
described in chapter 4.1.3.

• Set the sliding play by feel by turning the regulating screws so that the slide
rests on the guide rail backlash-free but can still be shifted without exerting
much force.
• Check the force required to shift the slide with a spring scale (see table for
values).
• Change the setting of the regulating screws as necessary.
• Repeat this procedure until the measured displacement force matches the
values specified in the table.
Type Displacement force without connection
DGC-18-…-GF 12 N
DGC-25-…-GF 15 N
DGC-32-…-GF 15 N
DGC-40-…-GF 15 N

• Place the washers on the regulating screws.

• Secure the regulating screw setting by inserting and tightening the socket
head screws using the appropriate torque (see table).
Type Torque
DGC-18-…-GF 0.7 Nm
DGC-25-…-GF 2.0 Nm
DGC-32-…-GF 2.0 Nm
DGC-40-…-GF 3.0 Nm

• Fit the remaining parts as described in chapter 4.1.2.

Festo 7DGC-GFa_en 25 / 44

4.1.5 Dismantling and repairing the piston module

• Remove the piston as described in chapter 4.1.1.

• Remove the coupling, together with the band reverser, from the piston.

Note
The piston must be replaced completely in case of wear. The spare part
comprises the inner and outer sealing rings and the magnets.

• Bend the band reverser slightly apart and pull it off the coupling.
• Check all parts for wear and replace them as necessary.

• Clip the band reverser in the coupling.

Note
Make sure that the band reverser is aligned properly with the coupling
(see illustration).

• Connect the coupling with the band reverser to the piston.

Note
Make sure that the coupling is properly aligned with the piston. The magnet
in the piston must be positioned on the left-hand side of the piston when the
coupling points backwards.

• Grease the sealing rings and the band reverser.

Observe the greasing instructions in the table in chapter 4.1.2.
• Assemble the linear drive as described in chapter 4.1.2.

26 / 44 Festo 7DGC-GFa_en

4.1.6 Replacing the cushioning components

• Unfasten the lock nut on the cushioning components.

Note
The cushioning components can be replaced even when the end caps are
attached.

• Unscrew the cushioning components from the end caps.

• Insert the new cushioning components by repeating the steps in reverse
order and tighten them using the appropriate torque (see table).
Type Torque
DGC-18-…-GF 3.0 Nm ±20%
DGC-25-…-GF 5.0 Nm ±20%
DGC-32-…-GF 8.0 Nm ±20%
DGC-40-…-GF 20 Nm ±20%

4.1.7 Replacing the sealing rings for the supply ports in the end caps

• Unscrew and remove the plug screws for the supply ports from the end caps
and remove the sealing rings.

Note
The sealing rings can be replaced even when the end caps are attached.

• Insert the new sealing rings in the supply ports by repeating the steps in
reverse order and tighten the plug screws using the appropriate torque
(see table).
Type Torque
DGC-25-…-GF 11 Nm ±10%
DGC-32-…-GF 11 Nm ±10%
DGC-40-…-GF 50 Nm ±10%

Festo 7DGC-GFa_en 27 / 44

4.2 Linear drives DGC-50/63-…-GF

4.2.1 Dismantling the linear drive

• Place the linear drive on the work surface with the slide facing upwards.

• Unfasten and remove the four 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.
• Remove the sealing rings from the inside of the end caps and the buffers.

Documents
Chapters 4.2.5 and 4.2.6 describe how to dismantle and repair the end caps.

• Unscrew the socket head screw for the band clamping mechanism on both
puffers with an Allen key, size 3.

• Remove the clamping mechanism for the cover band from both ends of the
drive and remove the clamping mechanism from the sealing band between
the cover band and sealing band.

28 / 44 Festo 7DGC-GFa_en

• Remove both the buffers from the cylinder barrel.

• Unscrew the socket head screws on the faces of the slide-piston connection
and remove the stop plates.

• Unfasten the threaded pins on the left-hand side of the slide-piston connection.

• Unfasten and remove the socket head screw on the right-hand side the
slide-piston connection.

• Unfasten both the socket head screws on the front of the slide-piston
connection and remove them.

Festo 7DGC-GFa_en 29 / 44

• Remove the slide-piston connection.

Note
Both the spring pins and the blanking plugs between the slide and the
slide-piston connection are not fastened and may be lost when removing
the slide-piston connection.

• Push the slide off the cylinder barrel.

Documents
Chapters 4.2.3 and 4.2.4 describe how to dismantle and repair the slide.

• Push the piston out of the cylinder barrel.

• Check the springs on the band reverser for damage and replace them as
necessary.

• Pull the cover band out of the cylinder barrel.

• Push the sealing band inwards and out of the guide slot (1) with a blunt
object and pull it out of the cylinder barrel (2).

30 / 44 Festo 7DGC-GFa_en

4.2.2 Assembling the linear drive
When assembling a linear drive, wearing parts, such as the sealing band, cover band, seals and the complete piston,
can be replaced.
The wearing parts are ordered from 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 length or sealing band/cover band.

Cutting the new sealing band/cover band to length

Type Length L0 
DGC-50-…-GF 370 mm Example: DGC-50-180-GF
DGC-63-…-GF 415 mm 0-stroke: 370 mm
Stroke: 180 mm
Length of the sealing band/cover band =
0-stroke + stroke = 550 mm

The length of the bands calculated in this way is a theoretical value. Component tolerances may make it necessary to
adjust the length of the sealing band/cover band after installation.

Note
Sturdy general purpose scissors or metal shears are best for cutting the sealing band and cover band.

Warning
Do not bend the sealing band and the cover band as this may cause damage or tearing and reduce the service life of
the sealing band/cover band.

Greasing whilst assembling

the cylinder bore.

Festo 7DGC-GFa_en 31 / 44

• Grease the cylinder barrel and the sealing band and cover band.
Observe the greasing instructions in the table at the start of this chapter.
• Insert the sealing band in the cylinder barrel so that approximately 14 mm
of the sealing band protrudes from one end of the cylinder barrel.
• Use your finger or a blunt object to press as much of the sealing band as
possible into the guide slot from inside.

• Thread the cover band into the fixture so that approximately 14 mm of the
cover band still protrude.

• Grease the piston and the band reverser.

• Push the sealing band under the band reverser with a screwdriver.

• Insert the piston fully into the cylinder barrel.

32 / 44 Festo 7DGC-GFa_en

• Grease the buffer.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the buffer into the cylinder barrel.
• Grease the sealing ring and insert it into the buffer.

• Move the piston to the other end of the cylinder barrel once in order to
secure the sealing band back in the slot.

• Align the slide so that the drill holes for the centring sleeves point towards
the piston.
• Push the slide onto the cylinder barrel.

• Use a spring scale to check the displacement force of the slide (refer to the
table in chapter 4.2.4 for the values) and if necessary, adjust the setting for
the sliding play as described in chapter 4.2.4.

Festo 7DGC-GFa_en 33 / 44

• Grease the second buffer.
Observe the greasing instructions in the table at the start of this chapter.
• Insert the buffer into the piston chamber on the other side of the base
profile.
• Grease the sealing ring and insert it into the buffer.

• Align the slide centrally with the piston.

• Place the slide-piston connection on the coupling.

• Apply Loctite 243 to the socket head screws for the slide-piston connection
and tighten them slightly so that the slide-piston connection is positioned
at 1-2 mm from the slide.

34 / 44 Festo 7DGC-GFa_en

• Insert the spring pins between the slide and the slide-piston connection as
far as they will go.

Note
When inserting the spring pins, make sure that they sit properly in the
fixture.
The openings of the spring pins must be off-set by 90° to the joint between
the slide and the slide-connection.

• Align the upper edge of the slide-piston connection so that it is flush with
the outer edge of the slide using a stop. The parallel offset between the
upper edge of the slide-piston connection and the outer edge of the slide max. 0.5 mm
must not exceed 0.5 mm.

• Tighten the socket head screws for the slide-piston connection using the
appropriate torque (see table).
Type Torque
DGC-50-…-GF 20 Nm ±20%
DGC-63-…-GF 20 Nm ±20%

• Tighten the socket head screw on the right-hand end of the slide-piston
connection using the appropriate torque (see table).
Type Torque
DGC-50-…-GF 20 Nm ±20%
DGC-63-…-GF 20 Nm ±20%

• Tighten the threaded pins on the left-hand end of the slide-piston connec-
tion using the appropriate torque (see table).
Type Torque
DGC-50-…-GF 5 Nm ±20%
DGC-63-…-GF 5 Nm ±20%

Festo 7DGC-GFa_en 35 / 44

• Place the stop plates on the slide-piston connection from the side.
• Apply Loctite 243 to the socket head screws and tighten them using the
appropriate torque (see table).
Type Torque
DGC-50-…-GF 2.0 Nm ±20%
DGC-63-…-GF 2.0 Nm ±20%

• Grease the sealing rings and insert them into the respective fixture in both
end caps.
• Attach the respective end caps to the cylinder barrel on both sides and align
each rear and lower edge of both end caps flush with the cylinder barrel.

• Apply Loctite 243 to the socket head screws and tighten them using the
appropriate torque (see table).
Type Torque
DGC-50-…-GF 25 Nm ±20%
DGC-63-…-GF 30 Nm ±20%

Note
After the linear drive has been assembled, it needs to be commissioned as
described in chapter 7 of the operating instructions.

4.2.3 Replacing the slide elements in the slide

If the slide elements in the slide are faulty or worn, they will have to be replaced.
• Remove the slide as described in chapter 4.2.1.
• Remove the slide elements from the slide.

• Unfasten the socket head screws on the top of the slide and remove them.

36 / 44 Festo 7DGC-GFa_en

• Remove both washers from the top of the slide.

Note
The washers can be removed easily with the help of a small magnet.

• Remove the pressure piece from the slide.

• Unscrew both regulating screws a few turns.

• Insert the pressure piece and the new slide elements in the slide and push
the slide onto the guide rail.

Note
After replacing the slide elements, the sliding play has to be set as described
in chapter 4.2.4.

Festo 7DGC-GFa_en 37 / 44

4.2.4 Setting the sliding play on the slide

If new slide elements are inserted in the slide, the sliding play has to be set.

If not yet carried out:

• Remove the slide-piston connection as described in chapter 4.2.1.
• Remove the socket head screws and washers from the top of the slide as
described in chapter 4.2.3.

• Place the washers on the regulating screws.

• Secure the regulating screw setting by inserting and tightening the socket
head screws using the appropriate torque (see table).
Type Torque
DGC-50-…-GF 6.0 Nm ±10%
DGC-63-…-GF 6.0 Nm ±10%

• Fit the slide-piston connection as described in chapter 4.2.2.

38 / 44 Festo 7DGC-GFa_en

4.2.5 Replacing the cushioning components

• Unfasten the lock nut on the cushioning components.

Note
The cushioning components can be replaced even when the end caps are
attached.

• Unscrew the cushioning components from the end caps.

• Insert the new cushioning components by repeating the steps in reverse
order and tighten them using the appropriate torque (see table).
Type Torque
DGC-50-…-GF 35 Nm ±20%
DGC-63-…-GF 60 Nm ±20%

4.2.6 Replacing the sealing rings for the supply ports in the end caps

• Unscrew and remove the plug screws for the supply ports from the end caps
and remove the sealing rings.

Note
The sealing rings can be replaced even when the end caps are attached.

Festo 7DGC-GFa_en 39 / 44

5 Maintenance

5.1 Greasing the linear drive

The linear drive has to be greased when repair work is carried out and at set intervals.

Greasing intervals for the guide rails by size and lubricant

Type Greasing interval Lubricant
DGC-18-/-63-…GF The guides for these drives are designed for unlubricated operation. LUB-KC1
Relubrication is permitted.

Maintenance of the band system

40 / 44 Festo 7DGC-GFa_en

6 Tools

This chapter provides an overview of the tools and aids required to repair and maintain the linear drive DGC-…-GF in its
various sizes.

6.1 Required tools by size

Designation DGC-18-/-25-/-32-/-40-…-GF DGC-50-/-63-…-GF

Allen key 2.5 – 5 mm 3 – 6 mm

Slotted head screwdriver –
Torque wrench 1.0 – 60 Nm
Torque screwdriver 0.2 – 10 Nm
Open-ended spanner 8 mm, 15 mm 27 mm
Face pin spanner/retaining ring pliers For turning regulating screws
Flat pliers For positioning the sealing band
Spring scale 0 – 15 N 0 – 35 N
Sturdy general purpose scissors or For cutting the sealing band and the cover band to length
metal shears

7 Liability/Conditions of use

The General Terms and Conditions of Festo AG & Co. KG apply, which can be viewed on the Festo website (www.Festo.com).

Festo 7DGC-GFa_en 41 / 44

Conditions of use for “electronic documentation”

42 / 44 Festo 7DGC-GFa_en

Linear drive

DGC-…-KF

Repair
instructions (en)

7DGC-KFa_en
Imprint

Version:
7DGC-KFa_de (09.2009)

Editorial staff:
SC-S

Tel.:
+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 explicit authorisation
is prohibited. Violations will give rise
to damage claims. All rights reserved,
in particular the right to file patent,
utility model or registered design
applications.
All product designations and brand
names used are the property of the
owners and not explicitly identified
as such.

All technical data subject to change

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.
You will find 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.

Festo 7DGC-KFa_en 3 / 44

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 6
2.3 Mounting directions 7
3 Component overview 8
3.1 DGC-8/12-…-KF 8
3.2 DGC-18/25-…-KF 10
3.3 DGC-32/40-…-KF 12
3.4 DGC-50/63-…-KF 14
4 Repair steps 16
4.1 Linear drives DGC-8/12-…-KF 17
4.1.1 Dismantling the linear drive 17
4.1.2 Assembling the linear drive 19
4.1.3 Replacing the cushioning components 22
4.2 Linear drives DGC-18/25/32/40-…-KF 22
4.2.1 Dismantling the linear drive 22
4.2.2 Assembling the linear drives 24
4.2.3 Dismantling and repairing the piston module 31
4.2.4 Replacing the cushioning components 32
4.2.5 Replacing the sealing rings for the supply ports in the end caps 32
4.3 Linear drives DGC-50/63-…-KF 33
4.3.1 Dismantling the linear drive 33
4.3.2 Assembling the linear drive 36
4.3.3 Replacing the cushioning components 41
4.3.4 Replacing the sealing rings for the supply ports in the end caps 41
5 Maintenance 42
5.1 Recirculating ball bearing guide 42
5.2 Maintenance of the band system 42
6 Tools 42
6.1 Required tools by size 42
7 Liability/Conditions of use 42

4 / 44 Festo 7DGC-KFa_en

1 Important information

1.1 About these repair instructions

This document contains all important • Operating instructions • Assembly tools
information about the professional Contains information about the Contains an overview of the
repair of the linear drive type DGC-… -KF. control parts and connections available assembly tools such as
For the most part, the linear drive for the linear drive, as well as lubricants, thread locking agents,
DGC-…-KF can be repaired. The cylin- information about function, con- maintenance tools etc. (aids for
der barrel and slide form a technical struction, application, installation, assembly and maintenance).
unit, which can only be replaced as a commissioning, care and mainte- They can be found in the online
whole. nance, etc. It can be found on the spare parts catalogue on the Festo
However, in case of larger defects, the Festo website (www.Festo.com). website (www.Festo.com).
costs of a repair must be considered. • Spare parts documentation
Before carrying out a repair, the Contains an overview of the spare
relevant chapter in these instructions and wearing parts as well as infor-
must be read in full and followed mation on their installation. The
consistently. spare parts documentation can
For reasons of clarity, these repair be found in the online spare parts
instructions do not contain complete, catalogue on the Festo website
detailed information. The following (spareparts.Festo.com).
documents should therefore also be
available while doing repair work on
the linear drive:

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 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.

Festo 7DGC-KFa_en 5 / 44

1.3 General safety instructions

Note
Instead of carrying out the repair yourself, your local Festo sales office 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-…-KF is a linear drive with a recirculating ball bearing guide and 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 basic profile required for this is covered by a band system. The one made of stainless
steel provides a precise installation interface. It is mounted on roller bearing elements and thus designed for low and
medium-level loads. The operating behaviour in case of torsional loads is in the very good range.
The DGC-…-KF, when used properly, is used for transporting loads in a space-saving manner and is approved for the oper-
ating 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-…-KF as an example.

7 1 2 1 Guide rail
4 2 Slide
3 Slide-piston connection
8 4 Cover band
3 5 Moment compensator
6 Piston
4 7 Basic profile
2 8 Sealing band

3
5

7 6

6 / 44 Festo 7DGC-KFa_en

2.2 Types and part numbers
Type Part number The complete overview of features, accessories, type
DGC-8-…-KF 530906 codes, technical data and dimensions for the DGC-
DGC-12-…-KF 530907 linear drives can be found in the product catalogue or on
DGC-18-…-KF 532446 the Festo website (www.Festo.com).
DGC-25-…-KF 532447
DGC-32-…-KF 532448
DGC-40-…-KF 532449
DGC-50-…-KF 532450
DGC-63-…-KF 532451

2.3 Mounting directions

This graphic provides you with an overview of the mounting directions on the linear drive using theDGC-25-…-KF as an
example.
Type = Product designation
(name plate)
O = Top
U = Underneath
5-
C-2 F-
DG 0-K V-A
33 PP

R = Right
56
1234W708

L = Left
V = Front
H = Rear

Festo 7DGC-KFa_en 7 / 44

3 Component overview

3.1 DGC-8/12-…-KF

15 11

13
14

7 11

5
12
11
10
8 9 1
4 2

2
3 1
2 2
1 8 21 1
9
10
11

7
20

8 / 44 Festo 7DGC-KFa_en

Entry Designation Type Note
DGC-8-…KF DGC-12-…-KF DGC-8-…-KF DGC-12-…-KF
1 Threaded pin or blanking Tightening torque 5.0 Nm, use LOCTITE 222
plug, depending on series
2 Sealing ring
3 Self-tapping screw TPD-WN122- M5×20-10.9 Tightening torque 3.0 Nm ± 20%, use LOCTITE 243
M3×18-450
4 End cap, left
5 Elastic cushioning element Tightening torque 3.0 Nm ± 20%
6 Shock absorber Tightening torque 3.0 Nm ± 20%
7 Shock absorber Tightening torque 3.0 Nm ± 20%
8 O-ring 3×1-N- 3×2-N-
NBR75 NBR70
9 Clip
10 Buffer
11 Buffer/piston seal
12 Cylinder barrel
13 Piston
14 Piston module
15 Coupling
16 Roller bearing carriage
17 Slide
18 Socket head screws DIN 4762 DIN 7984 Tightening torque 0.4 Nm, Tightening torque 1.1 Nm,
M2×4-10.9 M3×5-10.9 use LOCTITE 243 use LOCTITE 243
19 Socket head screw DIN 912- DIN 912- Tightening torque 1.4 Nm, use LOCTITE 243
M38-8.8 M4×8-8.8 Sealed with thread locker 397332
20 Sealing band
21 End cap, right

Festo 7DGC-KFa_en 9 / 44

3.2 DGC-18/25-…-KF

19
21 DGC-18-KF

7 27
22
6 23
24
11 25

DGC-18-...-KF 17 23
16 26 29
15 DGC-25-KF
14
1213
10 9 18
3
27 26
1 2
23
25
24
DGC-25-...-KF
23
22
29

5
3
4

DGC-18-...-KF
8
7
6

35 1
2
11 38
9

16
15
14
13 DGC-25-...-KF
17 36

17 30
24
33 4
5

32 34
31
38
17
30

10 / 44 Festo 7DGC-KFa_en

Entry Designation Type Note
DGC-18-…-KF DGC-25-…-KF DGC-18-…-KF DGC-25-…-KF
1 Self-tapping screw M5×20-10.9 DIN 7500-E Tightening torque 7.0 Nm ± 10%, Tightening torque 12 Nm ± 10%,
M6x30-A4-70 use LOCTITE 243 use LOCTITE 243
2 Threaded pin DIN 913 – Tightening torque 8.0 Nm –
M5×5-45H
3 End cap, left
4 Plug screw – – Tightening torque 11 Nm
5 Sealing ring – –
6 Silencer Tightening torque 5 Nm ± 20% Tightening torque 20 Nm ± 20%
7 Shock absorber
8 Shock absorber
9 Seal
10 Sealing ring
11 Flat-head screw DIN 920- DIN 84- Tightening torque 0.2 Nm ± 10%, Tightening torque 0.4 Nm ± 10%,
M3×20-4.8 M3×28-4.8 use LOCTITE 243 use LOCTITE 243
12 Buffer, left
13 O-ring 1×0.6-N- 1.8×1.2-N-
NBR70 NBR75
14 Regulating screw
15 Clamp, sealing band
16 Clamp, cover band
17 Buffer/piston seal
18 Buffer, left, sub-assembly
19 Cover band
20 Sealing band
21 Cylinder barrel with slide
22 Hex nut DIN 934 DIN 934
M4-6AU M5-6
23 Washer
24 Coupling
25 Socket head screw DIN 912 DIN 912
M4×8-8.8 M5×12-10.9
26 Socket head screw DIN 912 DIN 912
M4×35-10.9 M5×40-10.9
27 Slide-piston connection
29 Cover
30 Buffer/piston seal
31 Magnet
32 Piston
33 Band reverser
34 Piston module
35 Buffer, right
36 Buffer, right, sub-assembly
38 End cap, right

Festo 7DGC-KFa_en 11 / 44

3.3 DGC-32/40-…-KF

19
21

7 26
27
6 23

DGC-18-...-KF 17 24
16
15 27 25
14
12 13
10 9 18 28
23
3 29
26
1 2

DGC-25-...-KF
DGC-32-...-KF
DGC-40-...-KF

5
3
4

DGC-18-...-KF
8
7
6

35 1
2
11 38
9

16 DGC-25-...-KF
15
14 DGC-32-...-KF
13 DGC-40-...-KF
17 36

17 30
24
33 4
5

32 34
31
38
17
30

12 / 44 Festo 7DGC-KFa_en

Entry Designation Type Note
DGC-32-…-KF DGC-40-…-KF DGC-32-…-KF DGC-40-…-KF
1 Self-tapping screw M8×45-10.9 Tightening torque 30 Nm ± 10%, use LOCTITE 243
2 Threaded pin – – – –
3 End cap, left
4 Plug screw – Tightening torque 11 Nm Tightening torque 16 Nm ± 10%
5 Sealing ring – –
6 Silencer Tightening torque 20 Nm ± 20% Tightening torque 35 Nm ± 20%
7 Shock absorber
8 Shock absorber
9 Seal
10 Sealing ring
11 Flat-head screw DIN 84- DIN 912- Tightening torque 0.4 Nm ± 10%, Tightening torque 1.0 Nm ± 10%,
M3×30-5.8 M4×40-10.9 use LOCTITE 243 use LOCTITE 243
12 Buffer, left
13 O-ring 1.8×1.2-N- 3×1.2-N-
NBR70 NBR75
14 Regulating screw
15 Clamp, sealing band
16 Clamp, cover band
17 Buffer/piston seal
18 Buffer, left, sub-assembly
19 Cover band
20 Sealing band
21 Cylinder barrel with slide
23 Washer
24 Coupling
25 Socket head screw DIN 6912 DIN 912
M5×12-8.8 M5×16-10.9
26 Socket head screw DIN 912
M5×40-10.9
27 Slide-piston connection
28 Spring
29 Cover
30 Buffer/piston seal
31 Magnet
32 Piston
33 Band reverser
34 Piston module
35 Buffer, right
36 Buffer, right, sub-assembly
38 End cap, right

Festo 7DGC-KFa_en 13 / 44

3.4 DGC-50/63-…-KF

19
6
7

9 1 Nm 18

16
15
14
13
12
11
10
17
4
3
2

1 5

21 29
4
3 27
2
5

23 25 28

24 26

6
7
8

10 2 1
3

9 34
35
11

16
15
14
13
2
32
3
33
30 34

14 / 44 Festo 7DGC-KFa_en

Entry Designation Type Note
DGC-50-…-KF DGC-63-…-KF DGC-50-…-KF DGC-63-…-KF
1 Self-tapping screw M8×55-10.9 M8×55-10.9 Tightening torque 25 Nm ± 20%, Tightening torque 30 Nm ± 20%,
use LOCTITE 243 use LOCTITE 243
2 Plug screw Tightening torque 16 Nm ± 10% Tightening torque 18 Nm ± 10%
3 Sealing ring
4 End cap, left
5 End cap, left, sub-assembly
6 Shock absorber Tightening torque 35 Nm ± 20% Tightening torque 60 Nm ± 20%
7 Shock absorber
8 Silencer
9 Socket head screw DIN 912-M4×40-10.9 Tightening torque 1.0 Nm ± 20%, use LOCTITE 243
10 O-ring 11.5×1.5-N-NBR75
11 O-ring 32×2.5-N- 42×3-N-
NBR70 NBR70
12 Buffer, left
13 O-ring 4×1.5-N- 6×1.5-N-
NBR70 NBR70
14 Regulating screw
15 Clamp, sealing band
16 Clamp, cover band
17 Buffer, left, sub-assembly
18 Cover band
19 Sealing band
20 Cylinder barrel
21 Slide
22 Stop
23 Spring pin SG 12×15
24 Threaded pin SLT-25-P-A Tightening torque 5.0 Nm ± 20%, use LOCTITE 243
25 Slide-piston connection
26 Socket head screw DIN 912- DIN 912- Tightening torque 20 Nm ± 20%, use LOCTITE 243
M8×40-10.9 M8×45-10.9
27 Washer
28 Socket head screw DIN 912-M8×50-10.9 Tightening torque 20 Nm ± 20%, use LOCTITE 243
29 Socket head screw DIN 6912- DIN 912- Tightening torque 2.0 Nm ± 20%, use LOCTITE 243
M4×12-8.8 M4×10-8.8
30 Piston module
31 Compression spring VL-5/2-4.0
32 Buffer, right
33 Buffer, right, sub-assembly
34 End cap, right
35 End cap, right, sub-assembly

Festo 7DGC-KFa_en 15 / 44

4 Repair steps

Note
The repair should preferably be carried out on a stable and flat 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 (e.g. notice-
able bearing clearance, faulty sliding performance and increased sliding noises etc.), the piston with all components
in the piston chamber (e.g. piston seals, sealing band, cover band, covers) 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,
cooling 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-…-KF (see chapter 4.1).

• Linear drives DGC-18/25/32/40-…-KF (see chapter 4.2).
• Linear drives DGC-50/63-…-KF (see chapter 4.3).

16 / 44 Festo 7DGC-KFa_en

4.1 Linear drives DGC-8/12-…-KF

4.1.1 Dismantling the linear drive

• 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 4.1.3 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.

Note
The socket head screw for fastening the coupling is filled with locking agent.
To open the screw the locking agent has to be removed using appropriate
tools.

• Unscrew and remove the socket head screw.

Festo 7DGC-KFa_en 17 / 44

• Unfasten and remove the eight mounting screws in the slide.

• Remove the slide upwards from the roller bearing carriage and the coupling.
• Remove the black wiper seal.

Note
Make sure that the roller bearing carriages do not slide off the guide rail as
the roller bearing balls are not secured and will fall out of the guides.

• Push the piston with the coupling out of the cylinder barrel.

• 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.

18 / 44 Festo 7DGC-KFa_en

4.1.2 Assembling the linear drive
When assembling a linear drive wearing parts, such as the sealing band, seals, buffers, covers, clips and the complete
piston, can be replaced.
The wearing parts are ordered from 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 specified 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-…-KF 140 mm Example: DGC-12-405-KF
DGC-12-…-KF 160 mm 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.

Greasing whilst assembling

the cylinder bore.

Festo 7DGC-KFa_en 19 / 44

• Insert the piston with the coupling attached and the threaded sealing band
all the way into the cylinder 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.

• In order to fasten the sealing band in place in the sealing band holder, move
the piston 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.

• 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.

20 / 44 Festo 7DGC-KFa_en

• Push the roller bearing carriages as close together as possible.
• Place the upper section of the slide on the roller bearing carriages.

• Apply Loctite 243 to the mounting screws and screw them into the roller
bearing carriages through the upper section of the slide.
• Tighten the mounting screws to the corresponding torque (see table).
Type Torque
DGC-8-…-KF 0.4 Nm
DGC-12-…-KF 1.1 Nm

• Apply Loctite 243 to the socket head screw on the coupling and screw it into
the coupling through the upper section of the slide.
• Tighten the socket head screw using the appropriate torque (see table).
Type Torque
DGC-8-…-KF 1.4 Nm
DGC-12-…-KF 1.4 Nm

• Clip the wiper seal into the slide from the side.

Note
After the linear drive has been assembled, it needs to be commissioned as
described in chapter 7 of the operating instructions.

Festo 7DGC-KFa_en 21 / 44

4.1.3 Replacing the cushioning components

• Unfasten the lock nuts on the cushioning components.

Note
The cushioning components can be replaced even when the end caps are
attached.

• Unscrew the cushioning components from the end caps.

• Insert the new cushioning component by performing the steps in reverse
order.

4.2 Linear drives DGC-18/25/32/40-…-KF

4.2.1 Dismantling the linear drive

• Place the linear drive on the work surface with the slide facing upwards.

• Unfasten and remove the three 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.

22 / 44 Festo 7DGC-KFa_en

• Remove the end caps from the cylinder barrel at both ends of the drive.
• Remove the sealing rings from the inside of the end caps and the buffers.

Documents
Chapters 4.2.4 and 4.2.5 describe how to dismantle and repair the end caps.

• Unscrew and remove the flat head screw from the band clamping mecha-
nism on both buffers.

• Remove the clamping mechanism for the cover band from both ends of the
drive and remove the clamping mechanism from the sealing band between
the cover band and sealing band.
• Remove both the buffers from the cylinder barrel.

Note
The method for dismantling the drives DGC-18/25-…-KF and DGC-…-32/40-…-KF
differs in the way in which the slide-piston connection and piston coupling
are fastened (see chapter 3).

DGC-18-…-KF and DGC-25-…-KF:

• Unscrew and remove the nut from the screw. Remove the socket head screw
and both washers.

DGC-32-…-KF and DGC-40-…-KF (not shown in the illustration):

• Unscrew and remove both socket head screws.

Festo 7DGC-KFa_en 23 / 44

• Unscrew and remove both socket head screws from the slide-piston connec-
tion.

• Lift the slide-piston connection upwards and out.

• Push the piston out of the cylinder barrel.

Note
The slide remains on the guide rail.

Documents
Chapter 4.2.3 describes how to dismantle and repair the piston module.

• Pull the cover band out of the cylinder barrel.

• Push the sealing band inwards and out of the guide slot (1) with a blunt
object and pull it out of the cylinder barrel (2).

24 / 44 Festo 7DGC-KFa_en

4.2.2 Assembling the linear drives
When assembling a linear drive, wearing parts, such as the sealing band, cover band, seals and the complete piston,
can be replaced.
The wearing parts are ordered from 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 length or sealing band/cover band.

Cutting the new sealing band/cover band to length

Type Length L0 
DGC-18-…-KF 220 mm Example: DGC-25-330-KF
DGC-25-…-KF 250 mm 0-stroke: 250 mm
DGC-32-…-KF 290 mm
Stroke: 330 mm
DGC-40-…-KF 335 mm
Length of the sealing band / cover band =
0-stroke + stroke = 580 mm

The length of the bands calculated in this way is a theoretical value. Component tolerances may make it necessary to
adjust the length of the sealing band/cover band after installation.

Note
Sturdy general purpose scissors or metal shears are best for cutting the sealing band and cover band.

Warning
Do not bend the sealing band and the cover band as this may cause damage or tearing and reduce the service life of
the sealing band/cover band.

Greasing whilst assembling

the cylinder bore.

Sealing band Festo LUB-KC11) Apply a layer of grease all around and along the entire length.
Cover 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.
outside
Seal, piston, Festo LUB-KC11) Grease all around.
inside
Cushion piston Festo LUB-KC11) Grease all around.
Seal, buffer Festo LUB-KC11) Grease all around.
Band reverser Festo LUB-KC11) Grease in the deflection area.
1)
See “Assembly aids” in the online spare parts catalogue on the Festo website (www.Festo.com).

Festo 7DGC-KFa_en 25 / 44

• Thread the cover band into the fixture so that approximately 10 mm of the
cover band still protrude.

• Grease the piston and the band reverser.

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.

• Push the sealing band under the band reverser with a screwdriver.

• Insert the piston fully into the cylinder barrel.

26 / 44 Festo 7DGC-KFa_en

• Adjust the excess sealing band and cover band by moving the piston back
and forth and pulling or pushing the respective bands at the same time so
that the excess band is no greater than the width of the contact surface (X)
on the buffer (see table).
Type Width of the contact surface X X
DGC-18-…-KF 6 mm
DGC-25-…-KF 7 mm
DGC-32-…-KF 9 mm
DGC-40-…-KF 9 mm

• Grease the buffer.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the buffer into the cylinder barrel.

Note
When using shock absorbers on the end caps the regulating screw for the
end position cushioning (see chapter 3.2 and 3.3, entry 11) must be “open”.
Unscrew it far enough so that it is positioned flush with the buffer.

• Grease the sealing ring and insert it into the buffer.

• Apply the band clamping mechanism to the sealing band and cover band.
• Apply Loctite 243 to the socket head screw and tighten it using the appro-
priate torque (see table).
Type Torque
DGC-18-…-KF 0.2 Nm ±10%
DGC-25-…-KF 0.4 Nm ±10%
DGC-32-…-KF 0.4 Nm ±10%
DGC-40-…-KF 1.0 Nm ±10%

• Move the piston to the other end of the cylinder barrel once in order to
secure the sealing band back in the slot.

Festo 7DGC-KFa_en 27 / 44

• Grease the second buffer.
Observe the greasing instructions in the table at the start of this chapter
and the note on using shock absorbers on the end caps.
• Insert the buffer into the cylinder barrel at the other end.
• Grease the sealing ring and insert it into the buffer.

• Apply the band clamping mechanism to the sealing band and cover band.
• Apply Loctite 243 to the socket head screw and tighten it using the appro-
priate torque (see table).
Type Torque
DGC-18-…-KF 0.2 Nm ±10%
DGC-25-…-KF 0.4 Nm ±10%
DGC-32-…-KF 0.4 Nm ±10%
DGC-40-…-KF 1.0 Nm ±10%

• Align the slide centrally with the piston.

• Insert the parts of the slide-piston connection between the slide and the
piston from above.

Note
The parts of the slide-piston connection are paired with the slide.
Observe the instructions in chapter 4.2.1.

28 / 44 Festo 7DGC-KFa_en

• Apply Loctite 243 to the socket head screws and tighten them using the
appropriate torque (see table).
Type Torque
DGC-18-…-KF 2.5 Nm ±10%
DGC-25-…-KF 5.7 Nm ±10%
DGC-32-…-KF 5.7 Nm ±10%
DGC-40-…-KF 5.7 Nm ±10%

Note
The method for assembling the drives DGC-18/25-…-KF and DGC-…-32/40-…-KF
differs in the way in which the slide-piston connection and piston coupling
are fastened.

DGC-18-…-KF and DGC-25-…-KF:

DGC-32-…-KF and DGC-40-…-KF (not shown in the illustration):

• Place the washers on the socket head screws, apply Loctite 243 to them and
tighten them using the appropriate torque (see table).
Type Torque
DGC-32-…-KF 4.5 Nm ±10%
DGC-40-…-KF 4.5 Nm ±10%

• Place the cover on the slide-piston connection and press it lightly so that it
latches into place.

• Grease the sealing rings and insert them into the end caps.

Festo 7DGC-KFa_en 29 / 44

• 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 flush with the cylinder
barrel.
• Tighten the self-tapping screws on both ends using the appropriate torque
(see table).
Type Torque
DGC-18-…-KF 7 Nm
DGC-25-…-KF 12 Nm
DGC-32-…-KF 30 Nm
DGC-40-…-KF 30 Nm

Note
After the linear drive has been assembled, it needs to be commissioned as
described in chapter 7 of the operating instructions.

30 / 44 Festo 7DGC-KFa_en

4.2.3 Dismantling and repairing the piston module

• Remove the piston as described in chapter 4.2.1.

• Remove the coupling, together with the band reverser, from the piston.

Note
The piston must be replaced completely in case of wear. The spare part com-
prises the inner and outer sealing rings and the magnets.

• Bend the band reverser slightly apart and pull it off the coupling.
• Check all parts for wear and replace them as necessary.

• Clip the band reverser in the coupling.

Note
Make sure that the band reverser is aligned properly with the coupling
(see illustration).

• Connect the coupling with the band reverser to the piston.

Note
Make sure that the coupling is properly aligned with the piston. The magnet
in the piston must be positioned on the left-hand side of the piston when the
coupling points backwards.

• Grease the sealing rings and the band reverser.

Observe the greasing instructions int the table in chapter 4.2.2.
• Assemble the linear drive as described in chapter 4.2.2.

Festo 7DGC-KFa_en 31 / 44

4.2.4 Replacing the cushioning components

• Unfasten the lock nut on the cushioning components.

Note
The cushioning components can be replaced even when the end caps are
attached.

• Unscrew the cushioning components from the end caps.

• Insert the new cushioning components by repeating the steps in reverse
order and tighten them using the appropriate torque (see table).
Type Torque
DGC-18-…-KF 3.0 Nm ±20%
DGC-25-…-KF 5.0 Nm ±20%
DGC-32-…-KF 8.0 Nm ±20%
DGC-40-…-KF 20 Nm ±20%

4.2.5 Replacing the sealing rings for the supply ports in the end caps

• Unscrew and remove the plug screws for the supply ports from the end caps
and remove the sealing rings.

Note
The sealing rings can be replaced even when the end caps are attached.

• Insert the new sealing rings in the supply ports by repeating the steps in
reverse order and tighten the plug screws using the appropriate torque
(see table).
Type Torque
DGC-25-…-KF 11 Nm ±10%
DGC-32-…-KF 11 Nm ±10%
DGC-40-…-KF 16 Nm ±10%

32 / 44 Festo 7DGC-KFa_en

4.3 Linear drives DGC-50/63-…-KF

4.3.1 Dismantling the linear drive

• Place the linear drive on the work surface with the slide facing upwards.

• Unfasten and remove the four 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.
• Remove the sealing rings from the inside of the end caps and the buffers.

Documents
Chapters 4.3.3 and 4.3.4 describe how to dismantle and repair the end caps.

• Unscrew the socket head screw for the band clamping mechanism on both
buffers with an Allen key, size 3.

• Remove the clamping mechanism for the cover band from both ends of the
drive and remove the clamping mechanism from the sealing band between
the cover band and sealing band.

Festo 7DGC-KFa_en 33 / 44

• Remove both the buffers from the cylinder barrel.

• Unscrew the socket head screws on the front of the slide-piston connection
and remove the stop plates.

• Unfasten the threaded pins on the left-hand side of the slide-piston connection.

• Unfasten and remove the socket head screw on the right-hand side of the
slide-piston connection.

• Unfasten both the socket head screws on the front of the slide-piston con-
nection and remove them.

34 / 44 Festo 7DGC-KFa_en

• Remove the slide-piston connection.

Note
Both the spring pins and the blanking plugs between the slide and the
slide-piston connection are not fastened and may be lost when removing the
slide-piston connection.

• Push the piston out of the cylinder barrel.

• Check the springs on the band reverser for damage and replace them as
necessary.

• Pull the cover band out of the cylinder barrel.

• Push the sealing band inwards and out of the guide slot (1) with a blunt
object and pull it out of the cylinder barrel (2).

Festo 7DGC-KFa_en 35 / 44

Cutting the new sealing band/cover band to length

Type Length L0 
DGC-50-…-KF 370 mm Example: DGC-50-180-KF
DGC-63-…-KF 415 mm 0-stroke: 370 mm
Stroke: 180 mm
Length of the sealing band/cover band =
0-stroke + stroke = 550 mm

The length of the bands calculated in this way is a theoretical value. Component tolerances may make it necessary to
adjust the length of the sealing band/cover band after installation.

Note
Sturdy general purpose scissors or metal shears are best for cutting the sealing band and cover band.

Warning
Do not bend the sealing band and the cover band as this may cause damage or tearing and reduce the service life of
the sealing band/cover band.

Greasing whilst assembling

the cylinder bore.

Sealing band Festo LUB-KC11) Apply a layer of grease all around and along the entire length.
Cover 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.
outside
Seal, piston, Festo LUB-KC11) Grease all around.
inside
Cushion piston Festo LUB-KC11) Grease all around.
Seal, buffer Festo LUB-KC11) Grease all around.
Band reverser Festo LUB-KC11) Grease in the deflection area.
1)
See “Assembly aids” in the online spare parts catalogue on the Festo website (www.Festo.com).

36 / 44 Festo 7DGC-KFa_en

• Grease the cylinder barrel and the sealing band and cover band.
Observe the greasing instructions in the table at the start of this chapter.
• Insert the sealing band in the cylinder barrel so that approximately 14 mm
of the sealing band protrudes from one end of the cylinder barrel.
• Use your finger or a blunt object to press as much of the sealing band as
possible into the guide slot from inside.

• Thread the cover band into the fixture so that approximately 14 mm of the
cover band still protrude.

• Grease the piston and the band reverser.

• Push the sealing band under the band reverser with a screwdriver.

• Insert the piston fully into the cylinder barrel.

Festo 7DGC-KFa_en 37 / 44

• Grease the buffer.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the buffer into the cylinder barrel.
• Grease the sealing ring and insert it into the buffer.

• Move the piston to the other end of the cylinder barrel once in order to
secure the sealing band back in the slot.

• Grease the second buffer.

Observe the greasing instructions in the table at the start of this chapter.
• Insert the buffer into the piston chamber on the other side of the base
profile.
• Grease the sealing ring and insert it into the buffer.

38 / 44 Festo 7DGC-KFa_en

• Align the slide centrally with the piston.

• Place the slide-piston connection on the coupling.

• Apply Loctite 243 to the socket head screws for the slide-piston connection
and tighten them slightly so that the slide-piston connection is positioned
at 1-2 mm from the slide.

• Insert the spring pins between the slide and the slide-piston connection as
far as they will go.

Note
When inserting the spring pins, make sure that they sit properly in the
fixture.
The openings of the spring pins must be off-set by 90° to the joint between
the slide and the slide-connection.

Festo 7DGC-KFa_en 39 / 44

• Tighten the socket head screws for the slide-piston connection using the
appropriate torque (see table).
Type Torque
DGC-50-…-KF 20 Nm ±20%
DGC-63-…-KF 20 Nm ±20%

• Tighten the socket head screw on the right-hand end of the slide-piston
connection using the appropriate torque (see table).
Type Torque
DGC-50-…-KF 20 Nm ±20%
DGC-63-…-KF 20 Nm ±20%

• Tighten the threaded pins on the left-hand end of the slide-piston connection
using the appropriate torque (see table).
Type Torque
DGC-50-…-KF 5 Nm ±20%
DGC-63-…-KF 5 Nm ±20%

• Apply Loctite 243 to the socket head screws and tighten them using the
appropriate torque (see table).
Type Torque
DGC-50-…-KF 25 Nm ±20%
DGC-63-…-KF 30 Nm ±20%

40 / 44 Festo 7DGC-KFa_en

Note
After the linear drive has been assembled, it needs to be commissioned as
described in chapter 7 of the operating instructions.

4.3.3 Replacing the cushioning components

• Unfasten the lock nut on the cushioning components.

Note
The cushioning components can be replaced even when the end caps are
attached.

• Unscrew the cushioning components from the end caps.

• Insert the new cushioning components by repeating the steps in reverse
order and tighten them using the appropriate torque (see table).
Type Torque
DGC-50-…-KF 35 Nm ±20%
DGC-63-…-KF 60 Nm ±20%

4.3.4 Replacing the sealing rings for the supply ports in the end caps

• Unscrew and remove the plug screws for the supply ports from the end caps
and remove the sealing rings.

Note
The sealing rings can be replaced even when the end caps are attached.

Festo 7DGC-KFa_en 41 / 44

5 Maintenance

5.1 Recirculating ball bearing guide

The linear drive's recirculating ball bearing guide is provided with life-time lubrication and does not need to be relubri-
cated.

5.2 Maintenance of the band system

6 Tools

This chapter provides an overview of the tools and aids required to repair and maintain the linear drive DGC-…-KF in its
various sizes.

6.1 Required tools by size

Designation DGC-8-/-12-…-KF DGC-18-/-25-/-32-/-40- DGC-50-/-63-…-KF
…-KF
Allen key 1.5 – 4 mm 4 – 5 mm 3 – 6 mm
Torx screwdriver T10
Screwdriver 5 mm
Torque wrench 1.4 – 3 Nm 0.6 – 50 Nm 1 – 60 Nm
Torque screwdriver 0.2 – 1 Nm
Flat pliers Required
Feeler gauge 0.02 mm
Sturdy general purpose scissors For cutting the cover band For cutting the sealing band and the cover band to
or metal shears to length length

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42 / 44 Festo 7DGC-KFa_en

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