Project Info
Project Name: Stacker Truck (Forklift) Hydraulic Power Unit & Hydraulic Cylinders
Client Industry: Material Handling & Warehouse Equipment
Requirement:
The client required a compact and reliable hydraulic system for electric stacker trucks operating under intensive daily handling cycles.
Key requirements included:
- Stable lifting of forks and mast under rated load
- Smooth and controllable lowering for operator and cargo safety
- Compact hydraulic layout to fit narrow vehicle chassis
- Long service life under frequent start-stop operations
- Low maintenance and easy service access for fleet uptime
Project Overview
Stacker trucks (electric forklifts) are essential for pallet transport, stacking, and in-aisle warehouse operations.
To ensure safe lifting, precise lowering, and high daily productivity, this solution combines a compact hydraulic power unit with application-matched hydraulic cylinders for mast lifting and auxiliary functions.
The system is engineered to deliver:
1）Stable lifting force for loaded pallet handling
2）Controlled descent speed to prevent cargo impact
3）Reliable load holding and repeatable cycle performance
This solution is suitable for:
- Walkie stackers
- Rider stackers
- Counterbalance electric forklifts
- Reach-type warehouse trucks
AiSoar Hydraulic Solution
AiSoar provided a complete hydraulic package for stacker truck applications, including:
1) Forklift Hydraulic Power Pack (HPU)
AiSoar’s Stacker Truck Hydraulic Power Pack (HPU) is designed for fast response, stable pressure output, and reliable performance in high-frequency warehouse duty cycles.
With an optimized motor-pump configuration, the unit supports smooth fork lifting and steady hydraulic flow for mast operation, even during continuous shift work.
The compact power pack integrates key hydraulic control components, including:
1）Relief valve (overload protection)
2）Check valve (secure load holding)
3）Solenoid directional valve (accurate motion control)
4）Optional proportional lowering valve (finer descent control)
A dedicated controlled lowering circuit helps avoid sudden fork drop, improving operator safety and protecting goods from shock.
To meet different truck platforms, the unit is available in:
- DC power options (12V / 24V / 48V) for battery-driven stackers
- AC configurations for fixed lifting stations or customized industrial platforms
| Model | Volt | Power | Speed | Displacement | Pressure |
|---|---|---|---|---|---|
| HPU-1.6-D12-1.6-20-Y0-G1/4 | 12VDC | 1.6kW | 2800RPM | 1.6CC/REV | 20MPa |
| HPU-2.2-D24-2.7-20-Y0-G1/4 | 24VDC | 2.2kW | 2600RPM | 2.7CC/REV | 20MPa |
| HPU-3.0-D24-3.2-20-Y0-G1/4 | 24VDC | 3.0kW | 2600RPM | 3.2CC/REV | 20MPa |
| HPU-2.0-D48-2.7-20-Y0-G1/4 | 48VDC | 2.0kW | 2800RPM | 2.7CC/REV | 20MPa |
Its compact, low-noise design is ideal for electric material handling equipment where space efficiency and operator comfort are critical.
Whether for new vehicle development or retrofit projects, AiSoar’s hydraulic power pack helps improve fleet uptime, reduce service frequency, and lower total operating cost.
2) Stacker Truck Hydraulic Cylinders
AiSoar provides mast and lifting cylinders engineered for demanding warehouse operation:
1. High-strength cylinder tube and hard-chromed rod for frequent cycling
2. Wear-resistant sealing system to reduce leakage and pressure loss
3. Customized bore, stroke, and mounting dimensions for different mast structures
4. Optional end-stroke cushioning to reduce impact and structural stress
5. Single-acting or double-acting cylinder designs based on vehicle control strategy
Available cylinder applications include:
- Main lift cylinders
- Free-lift cylinders
- Tilt cylinders (for counterbalance forklift configurations)
- Auxiliary attachment cylinders (optional)
Projected Results / Customer Value
By adopting AiSoar’s integrated stacker truck hydraulic solution, customers can achieve:
- Safer and smoother lifting/lowering operation
- More reliable load holding and mast control
- Reduced leakage-related maintenance and downtime
- Faster integration for OEM production and retrofit projects
- Improved warehouse handling efficiency and lower lifecycle cost
Overall, the solution supports high-frequency material handling with better reliability, safety, and long-term operating economy.
