Stacker service: 5 common problems and how the right lifting equipment solves them

Stacker service is a recurring task in many forklift workshops, logistics centres, warehouses and industrial facilities. The work often involves servicing close to the floor, underneath the machine or in tight spaces around the motor, batteries, brakes and wheel suspension.

Without the right lifting equipment, stacker service can become time-consuming, uncomfortable and difficult to standardise. That is why good forklift workshop equipment is not only about lifting the vehicle. It is also about ergonomics, safety, access and an efficient workflow.

In this article, we look at five common problems in stacker service – and how a dedicated lift for stackers, such as the Dendro Lift DSS2, can solve them.

1. Low and uncomfortable working position during stacker service

One of the most common problems in stacker service is that the technician is forced to work at a low level. This may involve sitting on the floor, lying next to the truck or working with a bent back for long periods of time.

Awkward postures, repeated movements and static working positions are well-known ergonomic risk factors. HSE states that manual handling and workplace tasks should be planned and organised to reduce risks, including risks from poor posture and awkward working conditions.

The solution:
With the DSS2, the stacker can be raised to a better working height. The technician gets a more ergonomic working position and can adjust the height to suit the task.

The DSS2 Premium is designed for the service of stackers and pallet trucks. It provides a comfortable working position when servicing raised vehicles and offers a maximum lifting height of 1,800 mm.

This makes a major difference in recurring service work where the same tasks are carried out several times per day.

2. Poor access to important components

During stacker service, the technician often needs access to several parts of the truck. This may include the motor, batteries, brakes, wheels, caster wheels, fork wheels and wheel suspension.

If the stacker is standing directly on the floor, or if it is lifted with equipment that blocks access, the work becomes more difficult than necessary. Poor access often leads to longer service times, repeated adjustments and more demanding working positions.

The solution:
The DSS2 Premium is tailored for the service of stackers and pallet trucks. Its design makes it easier to access the motor, batteries, brakes and wheel suspension. When the truck is raised, three sides remain free, allowing the technician to work more efficiently around the vehicle.

For workshops that also service counterbalance forklifts, the Dendro Lift CBL6 can complement the DSS2. The CBL6 is a mobile single-post lift for counterbalance forklifts up to 6,000 kg. It is designed for safe, quick and easy lifting of forklifts and provides good access to the motor, batteries, brakes and wheel suspension.

3. Time-consuming lifting before the work can begin

In many forklift workshops, several different methods are used to raise a stacker to service height. This may include jacks, blocks, another forklift or other temporary solutions.

The problem is that the lifting process itself often takes unnecessary time. When the lifting method varies between technicians, it also becomes more difficult to create a standardised service workflow.

The solution:
The DSS2 is built for quick and easy handling. By driving the stacker’s support legs and forks into the lift and securing them with the fastening screws, the truck can be raised to the desired working height in under a minute. The height can then be adjusted with the simple press of a button.

This makes stacker service more predictable. When lifting is quick, safe and repeatable, the technician can focus on the service work itself.

Independent test shows approximately 40% time saving with DSS2

In an independent test carried out by a leading forklift manufacturer, the Dendro Lift DSS2 was compared with traditional methods for stacker service. The test included removing and installing fork wheels, drive wheels and caster wheels. The work was carried out by experienced service technicians under standardised conditions.

Three methods were compared:

• jack and blocks
• lifting with a forklift
• Dendro Lift DSS2

The result showed that the DSS2 provided an average time saving of 39.59% compared with the other methods. The test also showed better ergonomics, good mobility, stable positioning, balanced weight distribution and very good access to components.

Jacks and blocks were considered portable, but the method required more physical effort, resulted in very low-level working and provided poorer access. Lifting with a forklift required additional safety measures, created uneven weight distribution and used equipment that was not designed for this type of service work.

For a forklift workshop, this means that the right lift for stackers can improve not only the working environment, but also the time spent on each service job.

4. Safety risks when lifting with another forklift or an overhead crane

In some forklift workshops, stackers are lifted using another forklift, a counterbalance truck or an overhead crane. This may seem like a quick solution, especially if the equipment is already available in the workshop. The problem is that it often creates a suspended load, or a situation where the vehicle is not securely supported on equipment designed for service work.

During service, the technician often needs to work close to, or underneath, parts of the vehicle. In that situation, it is not enough that the load is simply “raised”. It must be securely supported, and the equipment used must be intended for the task.

HSE states that, where it can be avoided, loads should not be suspended over occupied areas. If it cannot be avoided, risks to people must be minimised through safe systems of work and appropriate precautions. Areas below loads suspended for significant periods should be treated as danger zones with restricted access. OSHA also requires employers to use hoisting routes that minimise employee exposure to hoisted loads where available.

In the independent test carried out by a leading forklift manufacturer, the DSS2 was compared with lifting using a forklift. The test showed that lifting with a forklift required additional safety measures, created uneven weight distribution, limited access and used equipment not designed for this type of service work.

The solution:
With the DSS2, the stacker is raised in equipment specifically developed for stacker and pallet truck service. The truck is stable in the lift, the weight is evenly distributed and the technician has free access from three sides.

The DSS2 is also equipped with self-locking lifting nut assemblies, brake motors, emergency stop and limit switch functions for nut wear and obstacle control. The self-locking trapezoidal screw means no additional securing is required before work can begin on the raised truck.

This makes the DSS2 a safer and more suitable alternative than working close to, or underneath, a load held by another forklift or an overhead crane.

5. Non-standardised workflows in the forklift workshop

A common problem in forklift workshops is that different technicians work in different ways. One person lifts the stacker in one way, another uses a different method. Tools, spare parts and working positions vary between service jobs.

This may work at low service volumes, but with recurring stacker service it quickly becomes inefficient. It also becomes harder to train new technicians and maintain consistent service quality.

The solution:
With a dedicated lift for stackers, the service bay becomes more standardised. The DSS2 provides a clear method for how the stacker is driven in, secured, raised and serviced.

The DSS2 Premium is also equipped with a practical shelf for tools and spare parts. This helps keep the workplace more organised and supports an efficient workflow throughout the service job.

For workshops servicing many stackers and pallet trucks, this can contribute to shorter lead times, better ergonomics and more consistent working routines.

CBL6 complements DSS2 in workshops with mixed forklift fleets

Many forklift workshops do not only work with stackers and pallet trucks. The same workshop often services counterbalance forklifts as well, including electric, gas and diesel-powered models.

In these cases, the DSS2 can be complemented by the Dendro Lift CBL6.

The CBL6 is a mobile single-post lift for counterbalance forklifts up to 6,000 kg. It takes up less space than traditional two-post or four-post lifts and does not need to be bolted to the floor.

The CBL6 can raise the truck to the desired working height in around one minute and offers a maximum lifting height of 1,800 mm. With three free sides and all wheels free, it becomes easier to access the parts that need service.

For complete forklift workshop equipment, the division is clear:

• DSS2 for stacker and pallet truck service.
• CBL6 for counterbalance forklifts up to 6,000 kg.
• Jack stands and customised lifting solutions for special vehicles, loads and service tasks.

Together, DSS2 and CBL6 give the workshop a more flexible and efficient solution for different forklift types.

The right forklift workshop equipment makes a difference

Stacker service requires more than technical skill. It requires the right equipment, the right working position and a safe method for lifting the vehicle.

With the DSS2, the workshop gets a lifting solution developed specifically for stackers and pallet trucks. It is designed to improve access, ergonomics and service safety.

The DSS2 Premium is suitable for most stackers up to 2,500 kg. It has a maximum lifting height of 1,800 mm, stands freely on the floor and only requires a 16A three-phase outlet. It can also be moved with a counterbalance forklift when needed.

For workshops that also service counterbalance forklifts, the CBL6 provides similar advantages for heavier forklifts up to 6,000 kg.

See how DSS2 and CBL6 can improve your service workflow

Do you want to make stacker service, pallet truck service and counterbalance forklift service safer, faster and more ergonomic?

See how DSS2 and CBL6 can improve the service workflow in your forklift workshop.

Contact Dendro Lift for advice on the right lifting equipment for your fleet and working environment.

Lifting Equipment – How to Choose the Right Solution for Industry and Workshops

The right lifting equipment does more than just lift – it improves the working environment, increases safety, and optimizes the entire service process. Whether you work with forklifts, trains, or industrial applications, choosing the right lifting solution is crucial for both productivity and long-term sustainability.

With modern lifting jacks from Dendro Lift, you can work more ergonomically, more safely, and reduce working time by up to 40% compared to traditional methods.

Forklift Maintenance

Forklift service is an area where the right lifting solution makes an immediate difference. Many workshops still rely on basic jacks or improvised solutions, leading to poor ergonomics, limited access, and unnecessary time consumption.

Ergonomics as Standard

With lifting jacks like DSS2 and DSS3, the forklift is quickly raised to an optimal working height. This allows technicians to work standing with full access instead of:

• working on their knees
• reaching into tight spaces
• handling heavy components in awkward positions

Three open sides provide direct access to all key components, making the work both easier and more precise.

For counterbalance forklifts, this is often complemented by the CBL6 – a mobile single-column lift offering the same ergonomic advantages in a flexible solution. It requires no fixed installation and allows quick lifting with full access to motor, batteries, and suspension.

Safety in Every Lift

Safety is built into the design:

• Self-locking lifting systems preventing unintended lowering
• Brake motors and safety nuts
• Emergency stop and monitoring sensors
• CE-certified lifting equipment according to EN 1494:2022

This allows technicians to start working immediately after lifting – safely and under full control.

Up to 40% Faster Work

The biggest advantage is efficiency.
With the right working height and full access, both working time and interruptions are reduced.

Independent studies show that Dendro Lift solutions can reduce service time by up to 40%.

Result: better working conditions, faster service, and higher quality.

Train Maintenance

Train maintenance requires high levels of stability, precision, and safety.

Lifting Systems Tailored to Your Needs

Dendro Lift systems operate in synchronized configurations:

• Synchronized lifting for maximum stability
• Precise control of height and load
• Solutions adapted to vehicles and processes

Each system is developed based on specific customer requirements.

Customized Solutions

Every operation is unique. That’s why Dendro Lift offers a wide range of custom lifting solutions, developed in close cooperation with customers.

We design solutions for:

• Production lines and industrial processes
• Special vehicles and unique lifting points
• Hygienic environments (food & pharma)
• Mobile service operations

Summary – The Right Lifting Solution Makes the Difference

Choosing the right lifting equipment is not just about capacity – it’s about improving the entire workflow.

With Dendro Lift, you get:

• Better ergonomics
• Increased safety
• Up to 40% time savings

The right lifting solution doesn’t just make work easier – it makes your business stronger.

Rewe Dortmund invests in DSS2 – ergonomics, efficiency and safer forklift service

Why Rewe Dortmund chose DSS2

When service volumes are high, traditional solutions are no longer enough. Rewe Dortmund needed a lifting system that:

• Minimizes physical strain
• Improves service efficiency
• Enables standardized workflows
• Increases workshop safety

DSS2 meets all these requirements – and more.

Ergonomics that make a real difference

One of the biggest challenges in forklift workshops is strain injuries caused by working in low or awkward positions.

With DSS2, stackers and pallet trucks are quickly lifted to an ergonomic working height. The technician works in a natural position with full control.

The result:

• Reduced strain on back, neck and shoulders
• Fewer workplace injuries
• Improved endurance throughout the workday

More efficient service and reduced downtime

DSS2 provides full access from all sides of the truck. This allows service work to be carried out faster and more efficiently without repositioning equipment.

For operations with hundreds of trucks, this means:

• Reduced downtime per truck
• Faster workshop throughput
• Increased operational availability

This is where DSS2 directly impacts profitability.

Standardized workshop processes

After the initial installation, Rewe Dortmund expanded to a total of four DSS2 units.

This enables:

• Consistent working methods
• Faster onboarding of new staff
• High and consistent service quality

Standardization is key to scaling a service organization – and DSS2 provides the ideal platform.

Safe service with proven technology

Safety is a critical factor when choosing a lifting system.

DSS2 is built on proven Dendro Lift principles:

• Self-locking lifting system
• Brake motor preventing unintended lowering
• Robust construction for long service life

This allows technicians to work safely – without additional safety steps.

A long-term investment in workshop performance

Rewe Dortmund’s investment clearly demonstrates how the right lifting solution impacts the entire operation:

• Improved ergonomics
• More efficient service
• Increased safety
• Reduced downtime

DSS2 is not just a tool – it is an investment in a more sustainable and productive workshop.

Read the full article in Staplerworld

Adjustable Jack Stands – Benefits, Features and Applications

Adjustable jack stands are essential for creating a safe and efficient working environment when servicing vehicles and industrial equipment.

However, in demanding environments, standard solutions are rarely enough. Dendro Lift is a market leader in custom-made jack stands, offering solutions that combine safety, ergonomics and performance for real-world industrial applications.

What are adjustable jack stands?

Jack stands are used to safely support lifted vehicles or heavy objects during service and maintenance. They are a critical component of any safe workshop environment.

Adjustable jack stands provide flexibility in height, making them ideal for operations involving different vehicle types or industrial equipment.

Key benefits of Dendro Lift adjustable jack stands

1. Built for real loads

Dendro Lift jack stands are designed for heavy-duty use, with capacities up to 100 tons.

Solutions such as trapezoidal screw adjustment provide precise, continuous and self-locking height adjustment, ensuring maximum safety.

2. Unique gas spring system (exclusive to Dendro Lift)

In heavy-duty applications, the center column can weigh up to 100 kg. Manual adjustment creates both strain and safety risks.

Dendro Lift solves this with a gas spring-assisted system – a solution unique to Dendro Lift.

This means:

• the column feels almost weightless
• reduced risk of injuries
• elimination of pinch hazards
• faster and safer adjustments

This is not just an improvement – it sets a new industry standard.

3. Maximum safety standards

Dendro Lift jack stands are developed to meet and exceed industry requirements:

• CE certified
• Compliant with Nordtest NT MECH002
• Designed according to strict safety regulations

They withstand extreme loads and provide exceptional stability in demanding environments.

4. Mobility without compromising stability

Heavy-duty construction is combined with spring-loaded wheels:

• easy positioning
• automatic stabilization under load
• lockable wheels for safety

5. Market-leading customization

Dendro Lift specializes in fully customized solutions:

• capacity from 5 to 100 tons
• adjustable or fixed height
• custom top plates
• application-specific designs

This makes Dendro Lift the preferred choice when standard solutions are not enough.

Applications

• Vehicle workshops
• Heavy industry
• Logistics and warehouses
• Specialized applications (e.g. tractors, containers, heavy components)

Summary

Adjustable jack stands are critical for safety and efficiency – but the right supplier makes all the difference.

With Dendro Lift, you get:

• market-leading custom solutions
• unique gas spring technology
• maximum safety
• products built for real industrial demands

FAQ

What are adjustable jack stands?
Adjustable jack stands support lifted vehicles and allow flexible height adjustment.

What is the benefit of a gas spring?
It makes height adjustment nearly weightless, improving safety and ergonomics.

How much weight can jack stands handle?
Dendro Lift solutions can handle up to 100 tons.

When do you need custom jack stands?
When standard solutions do not meet load, height or safety requirements.