When an actuator stops moving, stalls under load, or no longer reaches the correct position, you may not need to redesign the entire system. In many cases, the fastest path is to identify the actuator you already have, match its key specifications, and choose a compatible replacement. The most important replacement details are stroke length, retracted and extended mounting distance, force rating, voltage, speed, duty cycle, IP rating, mounting style, and feedback sensor type. If you already have a model number, you can also use the Progressive Automations Replacement Chart to compare your existing actuator against compatible PA models.
Before You Replace an Actuator, Confirm the Failure
Before ordering a new actuator, check whether the problem is actually the actuator or another part of the system. A weak power supply, damaged wiring, loose connector, overloaded mechanism, failed switch, or binding mount can look like actuator failure.
- Confirm the power supply voltage matches the actuator.
- Inspect wires, connectors, switches, and control boxes for damage.
- Check whether the actuator is overloaded or mechanically jammed.
- Look for side loading, bent brackets, corrosion, or debris in the motion path.
- Test the actuator separately when it is safe to do so.
Identify the Type of Actuator You Have
Start by confirming whether the existing actuator is electric, pneumatic, or hydraulic. Electric actuators usually have a motor housing and electrical wires or connectors. Pneumatic actuators use compressed air while hydraulic actuators use pressurized fluid.
If you are replacing a pneumatic or hydraulic actuator with an electric model, do not match by stroke alone. You must also confirm load, speed, duty cycle, mounting geometry, controls, safety requirements, and environmental conditions.
Match the Key Replacement Specifications
Stroke Length
Stroke length is the distance the actuator travels from fully retracted to fully extended. Match the original stroke whenever possible. Too little stroke can stop the system short, while too much stroke can drive the mechanism past its safe travel range.
Retracted and Extended Mounting Distance
Measure from the center of one mounting hole to the center of the other mounting hole. This is often called the hole-to-hole, pin-to-pin, or installation distance. Measure both the retracted and extended mounting distance before choosing a replacement.
Force Rating and Load Direction
Match the original force rating or choose a replacement with appropriate capacity for the application. A slightly higher force rating can be useful when the original actuator was close to its limit, but do not oversize without checking the structure, brackets, current draw, speed, and control system.
Voltage, Current, and Control Compatibility
Confirm whether the linear actuator uses DC or AC power and match the voltage of the existing system. Also check current draw, connector type, polarity, switch compatibility, control box compatibility, and wire routing. For 12V systems, see our 12 volt linear actuator wiring guide. For power and control box selection, review the guide to power supplies and control boxes in our new releases.
Speed, Duty Cycle, and Noise
Speed affects how quickly the actuator extends and retracts. If the replacement is much faster or slower than the original, the machine may behave differently. Duty cycle is also important for applications that run frequently or under heavy load.
IP Rating and Operating Environment
The IP rating indicates protection against dust and moisture. For wet, dusty, outdoor, marine, agricultural, or industrial environments, confirm the IP rating from the product datasheet before ordering.
Feedback Sensor Type
Some actuators include position feedback for synchronized motion, presets, or closed-loop control. Feedback may use potentiometers, Hall effect sensors, or other sensor types. Extra wires may indicate feedback, but the exact sensor type, wiring, and controller requirements must be verified before choosing a replacement.
Replacement Actuator Checklist
| Specification | What to Check | Why It Matters |
|---|---|---|
| Model number | Sticker labels, manual, invoice, or old datasheet | Fastest way to cross-reference |
| Force rating | Push/pull load capacity | Prevents stalling or overload |
| Stroke length | Fully extended minus fully retracted length | Controls travel distance |
| H2H length open & closed | Center-to-center mounting distance when open and closed | Determines whether the unit fits the required measurements |
| Travel speed | Travel distance divided by time required to complete the travel | Operates the application with the suitable response time |
| IP rating | Condition of the unit's seals and surrounding environment | Ensures proper dust and water resistance for longevity |
| Voltage | 12VDC, 24VDC, AC, or other verified rating | Protects actuator and controls |
| Current draw | Multimeter readings at full load | Reduces risk of overheating, stall conditions, or overloads |
| Feedback | None, potentiometer, Hall effect, or other | Maintains control compatibility |
Can You Replace Pneumatic or Hydraulic Actuators with Electric Actuators?
Sometimes, yes. Electric actuators can be a strong replacement option when the application benefits from cleaner installation, simpler maintenance, higher precision control, or reduced fluid and air infrastructure.
However, pneumatic and hydraulic systems should not be converted by matching only stroke and force. Review the full application first, including peak force, speed, duty cycle, shock loading, side loading, safety requirements, available power, controls, and mounting geometry.
How to Use the Progressive Automations Replacement Chart
The Progressive Automations Replacement Chart helps you find a compatible actuator based on your existing model or brand. Search by model number if you know the actuator model, or search by brand if you know the manufacturer but not the exact replacement.
After reviewing the results, confirm the datasheet before ordering. Compare stroke, force, voltage, speed, IP rating, feedback, and mounting dimensions against your existing actuator.
Get Help Choosing a Compatible Replacement
If you are unsure which actuator to choose, gather the old actuator’s model number, label photo, voltage, stroke length, force rating, mounting dimensions, wire count, connector photos, and application details.
Then use the Replacement Chart or contact Progressive Automations for help selecting a compatible model. If you are building or re-sizing the mechanism, the Linear Actuator Calculator can be a reference for estimating force, stroke, angle, and length requirements.
FAQ About Replacing Actuators
How do I find the right replacement actuator?
Start with the model number if available. If not, measure stroke length, retracted length, extended length, mounting ends, voltage, force rating, speed, IP rating, and feedback type. Then compare those specs using the Replacement Chart to find the most similar match.
What specs do I need before replacing a linear actuator?
Confirm stroke length, force rating, voltage, current draw, hole-to-hole length opened and closed, stroke, speed, mounting style, IP rating, and feedback type if the actuator connects to a position-control system.
Does stroke length need to match exactly?
Usually, yes. A shorter stroke may not complete the required motion, while a longer stroke can damage the mechanism if the system does not have safe mechanical stops.
Can I use a replacement actuator with a higher force rating?
Sometimes. A modest increase can help if the old actuator was underpowered, but you must check brackets, structure, power supply, current draw, speed, and controls before increasing force capacity.
How do I know if my actuator has feedback?
Check the datasheet, model number, label, and wiring diagram. Extra wires may indicate feedback, but the exact sensor type must be verified before choosing a replacement. While cycle testing the motor, you can also use a multimeter and/or oscilloscope to test and measure the feedback wires.
Can I replace a hydraulic or pneumatic actuator with an electric actuator?
In some applications, yes. The replacement must be reviewed for force, speed, duty cycle, mounting geometry, controls, environment, and safety requirements. For critical systems, get technical support before converting.
What if the actuator label is missing?
Measure the actuator dimensions and collect application details. Take photos of the actuator, mounting points, wiring, and control box. Use those details to compare against replacement options or contact Progressive Automations for customer support.
Can I reuse my existing control box?
Possibly, but only if the replacement actuator matches the voltage, current requirements, wiring, feedback type, and control logic of the existing system.