Replacement hydraulic cylinders – how to change hydraulic cylinders? | Magister Hydraulics
Replacing hydraulic cylinders involves a series of steps to ensure a safe and effective installation.

Here’s a straightforward guide using easy technical language:

Tools and materials needed:

  • New hydraulic cylinder
  • Wrenches
  • Hydraulic fluid
  • Rags or absorbent materials
  • Jack and stands (for lifting and supporting equipment)
  • Tubing or hoses (if necessary)
  • Thread sealant or tape

Step-by-Step Guide:


      1. Safety First:

  • Before starting, make sure the hydraulic system is depressurized.
  • Wear appropriate safety gear, including gloves and safety glasses.

     2. Equipment Positioning: 

  • Place the equipment on a stable and level surface.
  • Use a jack to lift and support the equipment securely, using safety stands if needed.

    3 . Identify and Remove Old Cylinder:

  • Locate the hydraulic cylinder you need to replace.
  • Use wrenches to disconnect hydraulic lines from the cylinder.
  • Unscrew the mounting bolts to remove the old cylinder.

    4. Drain Hydraulic Fluid:

  • Place a container beneath the hydraulic cylinder to catch any remaining fluid.
  • Allow the hydraulic fluid to drain completely.

    5. Prepare the New Cylinder:

  • Inspect the new hydraulic cylinder for any damage.
  • Apply thread sealant or tape to the threads of the hydraulic fittings.


   6. Install the New Cylinder:

  • Position the new hydraulic cylinder in place and secure it with mounting bolts.
  • Connect hydraulic lines to the new cylinder using wrenches.
  • Ensure all fittings are tightened securely.

   7. Fill with Hydraulic Fluid:

  • Refill the hydraulic system with the recommended hydraulic fluid.
  • Follow the manufacturer’s specifications for the correct fluid type and fill level.

   8. Bleed the System:

  • To remove air from the hydraulic system, operate the equipment through a few cycles.
  • Check for any leaks and tighten connections if necessary.

    9. Test the Equipment:

  • Confirm that the new hydraulic cylinder operates smoothly and without issues.
  • Look for any unusual noises, leaks, or irregular movements.

 10. Clean Up:

  • Wipe down the equipment to remove any residual hydraulic fluid.
  • Dispose of the old hydraulic fluid properly, following environmental regulations.

Document the Replacement:

  • Keep a record of the hydraulic cylinder replacement, including the date and any observations made during the process.

By following these steps, you can successfully replace a hydraulic cylinder, ensuring the proper functioning and safety of your hydraulic system. If you are unsure about any aspect of the replacement process, it’s advisable to consult the equipment’s manual or seek assistance from a qualified technician from a local hydraulic shop.


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