Linear Actuator Replacement Guide and Worksheet

Replace the complete requirement, not just the actuator label

A reliable replacement preserves the mechanism's geometry, load capability, speed, electrical interface, control behavior and environmental limits. This worksheet records the minimum evidence needed before comparing current products.

Engineering limitation: this page does not calculate force or guarantee compatibility. De-energize and support the mechanism before measuring. Use current product drawings and specifications, and obtain a qualified review where failure could injure people or damage equipment.

Six-step replacement process

  1. Identify the existing actuator

    Record the complete label, SKU, voltage, wire count, connector, feedback type and machine documentation.

  2. Measure the installed geometry

    Measure retracted pin-to-pin length, extended pin-to-pin length, stroke, mounting-hole size, end orientation and available envelope.

  3. Define the load case

    Determine worst-case push and pull force, loaded speed, direction, side-load risk, shock, friction and a justified safety margin.

  4. Check electrical and control compatibility

    Verify voltage, current capacity, switching, limit switches, feedback signal, synchronization and connector pinout.

  5. Check thermal and environmental limits

    Compare duty cycle, ambient temperature, ingress protection, corrosion, dust, rain, washdown and service access.

  6. Compare current drawings and product data

    Use the exact selected SKU, current drawing, performance curves and product specifications before approving the replacement.

Replacement comparison worksheet

Compare evidence after the worksheet is complete

Do not approve a substitute until the selected SKU's force, stroke, loaded speed, voltage, current, retracted and extended length, mounting, feedback, duty cycle and environmental limits have all been checked.

Frequently asked questions

Can I replace an actuator using force and stroke alone?

No. Force and stroke are only two requirements. Speed, voltage, retracted length, mounting, feedback, duty cycle, environment, current demand and control compatibility can also prevent a safe replacement.

Why does retracted length matter?

The replacement must fit between the mounting points when retracted and still reach the required extended position. Stroke alone does not define the installed length.

Can a higher-force actuator always replace a lower-force model?

No. Higher-force models may move more slowly, draw different current, have different dimensions or mounting, and change the loads in the mechanism. Verify the complete specification and geometry.

What if the original actuator label is unreadable?

Record the installation dimensions, mounting-hole sizes, stroke, voltage, wire count, connector, feedback behavior, loaded speed, duty cycle and environment. Photographs and the machine documentation can help FIRGELLI review the application.

Does this worksheet guarantee compatibility?

No. It organizes the evidence required for comparison. Final compatibility depends on the current product data, the mechanism, controls, safety requirements and an engineering review of the actual application.