Installing a New Hydraulic Cylinder

This how-to guide provides an overview of the steps needed for replacing and installing a new hydraulic cylinder. We have included prep work, removal of your old cylinder, installation of your new hydraulic cylinder, installation completion instructions, and safety precautions to help you install your new hydraulic cylinder.

Hydraulic Cylinder Installation Prep Work

  1. Before installing a hydraulic cylinder, it is important to keep the cylinders clean and contaminant-free.
    1. Make sure components are greased and hydraulic pipes flushed before connecting to the cylinder.
  2. For safety purposes, make sure the cylinders are not running and unable to start during removal and installation.
  3. Maintain a safe workspace for removal and installation. This also includes making sure the work conditions are acceptable for removal and installation.
  4. Depending on your work environment, additional blocking may be needed in order to prevent movement.
  5. Ensure there are no pressure or external forces added in the hydraulic system when lowering the loads.
  6. Close the shut-off valve, turn off the hydraulic pump, and release circuit pressure before beginning any maintenance.

Removal of Old Hydraulic Cylinder

  1. Check to make sure there is no stored energy that could pose a safety hazard.
  2. Ensure the machine is locked out and unable to move during removal or maintenance.
  3. Make sure there is no pressure in the cylinder.
  4. Plug or cap hydraulic hoses and pipes
  5. Plug or cap hydraulic ports
  6. Remove the base end and rod end hydraulic pins from the cylinder
  7. Mount the hydraulic cylinder into support.
  8. Dismount the hydraulic cylinder supports.
  9. Lower the cylinder.

New Hydraulic Cylinder Installation

Pre-check installation includes:

  • The hydraulic cylinder seals, end dampings, and fittings are all the correct types and sizes.
  • Before mounting, ensure all bearings and pins are greased.
  • Ensure the hydraulic cylinder connections include the correct sizes and correct placement.

Hydraulic Cylinder Installation Instructions

  1. Adjust the installation measure of the hydraulic cylinder to the pre-check value. Lock the eye fastened to the piston rod. If you are not sure about the measure, compare the measured value to the installation measure mentioned in the hydraulic cylinder assembly drawing of the device.
  2. Adjust the new cylinder end damping and replicate them to mirror the old hydraulic cylinder.
  3. Make sure the hydraulic cylinder connection holes are aligned in the correct direction.
  4. Lift the hydraulic cylinder and fasten it into place.
  5. Tighten the fasteners of the hydraulic cylinder.
  6. Remove the protective plugs.
  7. Fasten the hydraulic hoses or pipes.
  8. Remove the lifting equipment from the hydraulic cylinder and/or remove the supports.

Hydraulic Cylinder Installation Completion Instructions

  1. Fasten the removed guards to their proper places.
  2. Connect the system energy sources
  3. Bleed the hydraulic cylinder if test couplings are included/available. Run the cylinder until there is no air in the system and the movement runs smoothly.
  4. Adjust the end cushion of the new hydraulic cylinder so it does not slam at the stroke end.
  5. After testing work cycles, make sure adjustments remain unmoved/stay in place.

Safety Precautions

Before beginning any hydraulic cylinder work, please have the proper protection equipment available. This equipment should include safety goggles/glasses, boots, gloves, ear protection, and safety helmets. Additional safety precautions include keeping your hands and feet away from the cylinder during testing and selecting the proper supports that can hold and support the hydraulic cylinder.

As a general rule, you should never exceed the equipment ratings, nor should you set the relief valve at a higher pressure than the maximum rated pressure.