LINEAR LIFTING SYSTEM
Summary
ZEILHOFER ZH90 LIFTING AXIS UP TO 1,200 KG
The Zeilhofer ZH90 lifting axis is a pendulum-free vertical manipulator for loads up to 1,200 kg, well above the common 1,000 kg class. It lifts, rotates and positions heavy components with millimeter precision, because the load is rigidly guided and cannot swing. Combined with a vacuum gripper, a magnetic or a mechanical gripping device, it offers precise height adjustment for sensitive parts such as sheet metal, glass or battery packs. The lightweight aluminum base unit weighs around 70 kg, the working stroke is 1,600 mm, with longer strokes available as a custom double-stroke solution. It is driven pneumatically (up to 800 kg), electro-pneumatically or fully electrically (up to 1,200 kg) and mounted on the ceiling or on the floor, stationary or traversing. Every ZH90 is designed and built for the specific project, including the gripping device, by Zeilhofer Handhabungstechnik in Holzkirchen, Germany, certified to ISO 9001 and TISAX Level 2 with prototype protection.
Key points at a glance
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Load capacity up to 1,200 kg including the gripping device, base unit weight around 70 kg.
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Pendulum-free, rigid load guidance: positioning to the millimeter, torsional stiffness of 3,000 Nm at 1,000 mm stroke.
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Working stroke 1,600 mm, longer strokes as custom double-stroke solution, rotary axes on main axis and gripping device 360 degrees endless.
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Drive: pneumatic at 6 bar up to 800 kg, electro-pneumatic or fully electric at 230 V up to 1,200 kg. Mounting on the ceiling or on the floor, stationary or traversing.
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Typical applications: high-voltage batteries in e-mobility, engine and transmission assembly, railway industry, foundries and hardening shops, laser cutting systems, defense manufacturing.
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Pneumatic versions cost around €18,000 to €25,000, fully electric versions around 20 to 30 percent more. Leasing and hire purchase are available through Würth Leasing.
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First design directly with the ZH90 configurator on this page, reply within 24 hours on weekdays.
YOUR ADVANTAGES
WHAT SETS THE ZEILHOFER LIFTING AXIS ZH90 APART
01 LOAD CAPACITY
Up to 1,200 kg with lightweight aluminium construction, setting new standards in efficiency and stability.
04 ERGONOMICS & SAFETY
Reduces physical strain, integrated safety features, easy to maintain.
02 PRECISE POSITIONING
Heavy loads are positioned with repeatable accuracy, without requiring any effort from the operator.
05 DRIVE VARIETY
Pneumatic, electropneumatic or electric, tailored to your process requirements.
03 MODULAR SYSTEM
From simple lifting aids to fully integrated systems, flexibly configurable.
06 COMPLETE SOLUTION
From steel construction to the rail system and the appropriate device, everything from a single source.
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TECHNICAL DATA
CONFIGURE ZH90 ONLINE
Enter the load capacity, stroke, drive type, and installation situation of your application to receive an initial technical assessment of your ZH90 lifting axis. The configurator does not automatically calculate a price; our engineers will review your information and contact you with a customized offer.
TECHNICAL DATA
ALL SPECIFICATIONS AT A GLANCE
The ZH90 is designed for demanding, continuous industrial use. All relevant specifications for your planning documents.
Device abbreviation
ZH90
Drive
pneumatic / electropneumatic / electric
Main axis rotation
360° endless
Load capacity
up to 1,200 kg (pneumatic up to 800 kg)
Energy supply
6 bar compressed air / 230 V
Gripping device rotation
360° endless
Working stroke
1,600 mm, longer as custom double-stroke solution
Torsion around the Z-axis
3,000 Nm at 1,000 mm stroke
Mounting
Ceiling or floor, stationary or traversing
Base unit weight
approx. 70 kg
Moment load
Rigid, pendulum-free load guidance
Rail system
Compatible with all common systems
What does double stroke mean?
The standard working stroke of the ZH90 is 1,600 mm. The custom double-stroke solution adds a second, telescopic lifting segment, significantly extending the usable travel distance. This allows components to be lifted directly from ground level to working or assembly height without an additional intermediate station. The exact lifting height is determined on a project-specific basis, taking into account the component and installation situation.
TECHNICAL PRINCIPLE
Why pendulum-free guidance is crucial at 1,200 kg
0 mm
Pendulum swing of the load during travel
±1 mm
typical repeatability in positioning
3,000 Nm
Absorbable reaction torque at 1,000 mm stroke
With a freely suspended rope or chain hoist, the load acts like a pendulum: every acceleration, every gust of wind in the hall, every slight imbalance in the component sets the load into oscillation. At 1,200 kg, even a pendulum movement of just a few centimeters is enough to damage a component, miss a joint, or, in the worst case, cause an injury. This is precisely where the design of the ZH90 comes in.
The ZH90 guides the load not by a cable, but via a rigid, positive-locking mechanism within the aluminum guide. The load cannot deflect laterally or rotate uncontrollably around its own axis. This ensures that the trajectory remains precisely predictable during lifting, lowering, and movement, regardless of whether the axis is operating at 50 kg or near its maximum load of 1,200 kg.
This has three practical consequences for your process: First, the load can be inserted precisely into a joint, for example, when inserting a high-voltage battery between tightly toleranced body spars. Second, the risk to the operator and the component is reduced, as there is no need to counteract uncontrolled pendulum motion. Third, the movement can be integrated reproducibly into timed processes, since each stroke is exactly the same: a criterion that is inherently unattainable with chain hoists.
IN ACTION
THE ZEILHOFER LIFTING AXIS ZH90 IN OPERATION
See for yourself how the ZH90 lifting axis handles heavy loads weightlessly, live in production.
SAFETY & ERGONOMICS
Safety is built into the mechanism, not retrofitted.
For loads up to 1,200 kg, safety is not an added feature, but a basic requirement. An overview of the most important safety and ergonomic features of the ZH90.
1. Pendulum-free forced guidance
Prevents uncontrolled load movement mechanically, not just through software, see principle above.
4. Emergency stop function
Immediate, safe stopping of the movement is possible directly at the control handle.
2. Overload protection
It limits the load it can bear by design, protecting the mechanics and operator from overload.
5. Ergonomic balance control
The load is guided with almost no force; the operator controls the direction instead of carrying the weight.
3. End position damping
Gentle braking at the upper and lower ends of the stroke reduces wear and noise.
6. Maintenance-friendly design
Accessible wear parts and modular assemblies reduce downtime during servicing.
In addition to its structural safety features, the ZH90 is subject to annual accident prevention testing according to DGUV Regulation 54. All information on legal requirements, procedures, and deadlines can be found in the guide "Accident Prevention Testing for Lifting Aids" .
INSTALLATION SITUATION
Mounting options for the ZH90
The ZH90 lifting axis is mounted on the ceiling or on the floor, stationary or traversing. On the floor it can be anchored, run on rails or used as a lifting table. The mobile, battery-powered version up to 100 kg, built around the lifting axis, is the Hebelift ZH.
Ceiling, stationary
Fixed ceiling mounting saves floor space and keeps the floor clear for forklift and pedestrian traffic. Ideal for stationary workstations with repetitive processes.
Ceiling-mounted
Integration into overhead or crane track systems for large work areas across multiple stations.
Floor, fixed or traversing
Anchored to the floor, running on rails or used as a lifting table, for workstations without suitable ceiling connection. The mobile battery version up to 100 kg is the Hebelift ZH.
Are you looking for a floor-mounted or mobile lifting aid? The Hebelift ZH moves loads up to 100 kg, is battery-powered and requires no ceiling connection; for more information, see the guide "Lifting Aids at a Glance" .
DECISION AID
Lifting axis, chain hoist or manipulator
Three systems, three operational logics. The right choice depends on whether the load only needs to be lifted or also guided within the space.
Lifting axis ZH90
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Rigid, pendulum-free load guidance
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Positioning with millimeter precision
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Up to 1,200 kg, purely vertical movement
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Ideal for timed assembly processes
Chain hoist / cable hoist
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The load hangs freely, can swing and twist.
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Precise positioning is hardly possible
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Low investment costs
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Suitable for simple lifting without precision requirements
Articulated arm manipulator
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Additional swivel movements in space
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Large working radius up to 4.5 m
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Up to 800 kg at ZHHT
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Ideal if positioned not only vertically, but also laterally.
Short decision logic
Three questions usually lead quickly to the right choice. Does the load only need to be moved vertically, without lateral swiveling? Then the ZH90 is the most precise solution. Is simple lifting without positional requirements sufficient, for example, for temporary relief? Then a chain hoist will suffice. Does the component also need to be rotated, swiveled, or moved laterally, for example, when transferring it between two stations? Then an articulated arm manipulator is the more suitable choice. In practice, the ZH90 and manipulator are often combined; the lifting axis handles the vertical movement, and the manipulator takes care of the horizontal positioning.
Detailed comparison in the guide: Manipulator, crane or chain hoist: Which for what? and Lifting column, lifting axis or manipulator: What is the difference?
REFERENCES
The ZH90 in practice
Selected use cases from 18 industries. Detailed case studies in the guide.
E-Mobility
High-voltage battery assembly
In the final assembly of e-mobility vehicles, high-voltage batteries weighing several thousand euros are inserted between tightly toleranced body pillars. Even a lateral tilt of just a few millimeters can damage connection points or endanger the cell itself. Two ZH90 units guide the battery smoothly and without any pendulum movement from the point of delivery to its precise installation position, synchronized via a shared control system.
Railway industry
Assembly of entry systems
Door modules and boarding systems for rail vehicles are heavy, bulky, and yet must be positioned with millimeter precision within the confined interior of the carriage. The ZH90's pendulum-free guidance system allows the assembly to be maneuvered through the door opening in a controlled manner, without the load shifting laterally during insertion.
Foundry / Hardening shop
Heavy castings & batches
When charging in hardening furnaces or transferring raw castings, heavy weights meet high temperatures and confined furnace openings. A swinging load would pose a safety risk here. The ZH90 guides charging racks and castings through the opening in a controlled manner and without vibration, right up to the limit of their load-bearing capacity.
Automotive
Engine & gearbox assembly
From final assembly of passenger cars to the truck engine line: engines and transmissions must be precisely aligned with the assembly point in sync with the production cycle. The ZH90 lifts the assembly without any swaying, up to a weight of 1,200 kg, and holds its position even when the operator needs both hands free for fine-tuning.
Laser cutting
Sheet metal handling in laser cutting systems
Solid sheets must be positioned precisely on the cutting table, and the perforated residual grid must be removed just as cleanly after cutting. In combination with a manipulator up to 800 kg, the ZH90 handles the vertical lift, while the manipulator positions the material laterally, ensuring a continuous, uninterrupted material flow.
Special machine construction
Customized modular solution
Not every application fits into the standard scheme. As a basic component of individually configured systems, the ZH90 is tailored to the stroke, fixture and control concept of each project in collaboration with the engineers at Zeilhofer HHT, from the initial sketch to commissioning.
PROJECT PROGRESS
From initial contact to commissioning
Since each ZH90 is configured specifically for each project, the path to a finished system is clearly structured. Five steps from the initial inquiry to ongoing operation.
1. Technical advice
Clarify requirements
The component's weight, dimensions, and handling logic, as well as the existing hall and ceiling infrastructure and cycle time, will be recorded together with you. This forms the basis for the initial technical assessment.
2. Design & Offer
Design configuration
Load capacity, lifting capacity, drive type, axes of rotation, and fixture are all designed in detail. You will receive a binding offer with all technical specifications and a realistic schedule.
3. Manufacturing
Construction in Holzkirchen
The ZH90 is manufactured in-house in Holzkirchen, including the individually developed fixture and control system. Regular coordination takes place for project-specific special solutions.
4. Preliminary inspection
Inspection before shipping
Before shipping, the system undergoes a preliminary inspection in the Holzkirchen showroom or digitally via video. This allows any deviations to be identified before the lifting axis reaches your factory.
5. Assembly & Commissioning
On-site installation
Installation of the ceiling connection, commissioning, and training of your team will take place on site. From this point on, ZHHT service will be available to you for maintenance and spare parts.
COMPLETE SOLUTION
Every Zeilhofer system is part of a complete solution. Discover suitable fixtures, control options, and industry applications.
More than a product, a complete system
End-of-Arm Tooling
Fixtures
Grippers, suction cups, magnets, hooks and custom solutions, individually developed for your component. CE-compliant, all from a single source.
Drive & control concept
Controls
Pneumatic, electropneumatic or electric, with balancing, safety or automatic control.
Industry-specific
Applications
Automotive, foundry, glass & windows, logistics, mechanical engineering and 13 other industries.
COMPLETE SOLUTION
Further information
Definition, structure, function and costs of linear load guidance with aluminium profile.
The criteria for the right lifting axis: load capacity, drive and design.
Practical applications, from car body construction to hardening.
How the reaction moment is absorbed at the lifting axis and why the catalog value alone is not sufficient.
Requirements for lifting technology during battery assembly in e-mobility production.
Insert full plate, remove remaining grid, combined with manipulator and lifting axis.
Three questions usually lead to the correct solution: load capacity, direction of movement, frequency of repetition.
Glossary of handling technology: all technical terms related to lifting aids explained in a compact format.
ALTERNATIVES & EXTENSIONS
Matching systems around the ZH90
The ZH90 lifting axis is the core of a product family. Depending on load, movement and location, one of these systems may fit better or complement the ZH90.
Lifting axis and articulated arm in one system, up to 200 kg, optionally with 48-volt battery. For applications that need an additional swivel range.
Pendulum-free up to 800 kg, working radius up to 4.5 m, column or ceiling mounting. When the load must be swivelled rather than guided purely vertically.
Mobile and battery-powered up to 100 kg, built around the lifting axis. For use without ceiling or floor anchoring.
Extension for rotation and positioning: Multi-Axis Module ZH3. Not sure which system fits? Product finder or product comparison.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS ABOUT THE ZEILHOFER LIFTING AXIS ZH90
01 What is the load-bearing capacity of the ZH90 lifting axis?
The Zeilhofer ZH90 lifting axis has a load capacity of up to 1,200 kilograms: pneumatic up to 800 kilograms, electro-pneumatic and fully electric up to 1,200 kilograms. This makes it one of the most powerful linear lifting systems in lightweight aluminum construction on the market. Despite this high load capacity, the unit itself weighs only 70 kilograms: thanks to the optimized material combination and design.
02 What is the maximum working stroke of the ZH90?
The standard working stroke of the Zeilhofer ZH90 is 1,600 millimeters. As a custom solution, the double stroke allows the working height to be extended, enabling loads to be raised from ground level to working or assembly height. The stroke is customized to meet specific customer requirements for each project.
03 What drive types are available for the ZH90 lifting axis?
The Zeilhofer ZH90 lifting axis is available with three different drives: pneumatic (operating pressure 6 bar, up to 800 kg), electro-pneumatic or fully electric (230 V power supply, each up to 1,200 kg). The choice of drive depends on the available power supply at the installation site and the requirements for precision, speed, and noise level.
04 In which industries is the ZH90 lifting axis used?
The Zeilhofer ZH90 is primarily used in automotive final assembly, especially for high-voltage batteries in e-mobility production. Other areas of application include logistics, special-purpose machinery construction, foundries, and the railway industry for the assembly of entry systems.
05 Does the ZH90 have a pendulum-free load guidance system?
Yes. The Zeilhofer ZH90 lifting axis features a rigid, pendulum-free load guidance system: a key safety and precision feature. Unlike cable or chain systems, the load cannot swing or oscillate uncontrollably. This enables precise positioning down to the millimeter and reduces the risk of injury during operation.
06 Is the ZH90 compatible with our existing rail system?
Yes. The Zeilhofer ZH90 lifting axis is compatible with all common rail systems and can be easily integrated into existing ceiling or monorail infrastructures. During commissioning, we analyze the existing system and adapt the ZH90 accordingly: either through standardized adapters or custom design solutions.
07 What rotary movements are possible with the ZH90?
The Zeilhofer ZH90 lifting axis enables three independent rotary movements: The main axis and the fixture axis each rotate 360 degrees continuously, while the extension arm rotates up to 330 degrees. This allows for complex 3D movements: such as lifting, rotating, and setting down components in a single operation.
08 Can the ZH90 lifting axis be adapted to our individual requirements?
Yes. The Zeilhofer ZH90 has a modular design and is configured specifically for each project, in collaboration with our engineers, regarding lifting capacity, stroke, drive type, axes of rotation, and fixture. A preliminary inspection in our Holzkirchen showroom or digitally is part of the project process.
09 How does the ZH90 lifting axis differ from a cable or chain hoist?
With rope and chain hoists, the load hangs freely and can swing, making precise positioning nearly impossible. The Zeilhofer ZH90 guides the load without swinging via a rigid mechanism, thus enabling millimeter-precise positioning and defined rotational and swiveling movements.
10 Is the ZH90 lifting axis suitable for handling high-voltage batteries?
Yes. The Zeilhofer ZH90 lifting axis is specifically used in e-mobility production for inserting and positioning high-voltage batteries in final vehicle assembly. Its load capacity of up to 1,200 kg, oscillation-free load guidance, and millimeter-precise positioning meet the requirements for process reliability and ergonomics.
11 How much does a ZH90 lifting axis cost?
Pneumatic lifting axes from Zeilhofer cost between €18,000 and €25,000, depending on load capacity, stroke, and fixture; fully electric versions cost 20 to 30 percent more. The exact price depends on the configuration, fixture, and control system and will be calculated after a free technical consultation.
12 How long is the delivery time for a ZH90 lifting axis?
Since Zeilhofer configures each ZH90 specifically for each project, the delivery time depends on the extent of the customization. Following technical consultation and approval of the design, manufacturing and preliminary acceptance take place in Holzkirchen, followed by assembly and commissioning at the customer's site. Specific dates will be provided in the quotation.
13 Can the ZH90 lifting axis be rented or bought used?
The ZH90 is built new by Zeilhofer exclusively for each project, rental or used units are currently not available. Instead of a one-off payment, leasing over 24, 36 or 48 months and hire purchase over 12 to 48 months are available through Würth Leasing.
14. What is the difference between a lifting axis and a manipulator?
The Zeilhofer ZH90 lifting axis moves loads purely vertically, without pendulum movement, and with a high load capacity of up to 1,200 kg. An articulated arm manipulator lifts, rotates, tilts, and joins components even off-center in space, with a capacity of up to 800 kg and a working radius of up to 4.5 m at ZHHT. In practice, both systems are frequently combined.
15 What must be considered regarding building statics when installing the ZH90?
For ceiling mounting, the static and dynamic forces introduced into the ceiling beams or crane runway are crucial. Zeilhofer HHT provides the necessary load data as part of the project planning; the structural suitability assessment is the responsibility of the operator or a commissioned structural engineer.
16 Can the ZH90 lifting axis also be mounted on the floor?
Yes. Besides ceiling mounting (stationary or traversing), the Zeilhofer ZH90 can be anchored to the floor, run on rails or used as a lifting table, with a higher load capacity than mobile solutions. The mobile, battery-powered version built around the lifting axis is the Hebelift ZH for loads up to 100 kg.
17 What safety devices are integrated into the ZH90 lifting axis?
In addition to its core design principle of pendulum-free forced guidance, the Zeilhofer ZH90 features overload protection, end-position damping, an emergency stop function on the operating handle, and an ergonomic balancing control that guides the load with virtually no effort. The exact safety features are determined on a project-specific basis, depending on the configuration and operating environment.
18 Why is a pendulum-free load guidance relevant for safety when handling heavy loads?
Freely suspended loads on rope or chain hoists can begin to swing due to acceleration, imbalance, or vibration. With loads approaching the 1,200 kg limit, even a slight swinging motion can lead to component damage or pose a risk of injury. The rigid, positive-locking guide of the ZH90 mechanically prevents this swinging motion, independent of the operator or software.
19 Can I configure the ZH90 lifting axis online?
Yes. Using the ZH90 configurator on this page, you can directly enter the load capacity, stroke, drive type, and installation situation and receive an initial technical assessment of your application. The configurator does not automatically calculate a price; your information will be reviewed by our engineers, who will then contact you with a customized offer.