Service

Car Zeilhofer HHT

Service

Car Zeilhofer HHT

1/1

01 SAFETY / TESTING OBLIGATION
The UVV inspection for lifting aids and manipulators

Industrial lifting aids, manipulators, and lifting axes are subject to annual accident prevention inspections in accordance with DGUV Regulation 54 and the German Ordinance on Industrial Safety and Health. These inspections are legally required and ensure that the equipment can be operated safely throughout its entire service life. This guide explains the legal basis, inspection procedure, deadlines, defects, and risks—and shows why manufacturer-provided inspections offer a decisive advantage.

02 LEGAL BASIS - WHAT THE LAW REQUIRES
LEGAL BASIS

The obligation to inspect lifting aids arises from three central sets of regulations that are interconnected:

Industrial Safety Ordinance (BetrSichV)

The German Ordinance on Industrial Safety and Health (BetrSichV) obliges every employer to have work equipment inspected before its first use and at regular intervals. Lifting aids and manipulators are considered work equipment requiring monitoring and subject to special safety requirements. Section 14 of the BetrSichV regulates the inspection obligation, and Section 3, Paragraph 6 regulates the risk assessment.

DGUV Regulation 1 (Principles of Prevention)

DGUV Regulation 1 obligates employers to have all technical work equipment regularly inspected by a qualified person. It is the central accident prevention regulation of the statutory accident insurance and therefore binding for every company in Germany.

DGUV Regulation 54 (Winches, lifting and pulling devices)

DGUV V54 is the specific regulation for lifting and load-handling equipment. It defines the scope of testing, testing intervals, and documentation requirements for lifting aids, manipulators, lifting axes, cranes, and load-handling devices. It is the relevant regulation for the annual expert inspection.

Machinery Directive 2006/42/EC

At the European level, the Machinery Directive regulates the fundamental safety requirements for machinery placed on the market. It forms the basis of the CE declaration of conformity and defines the requirements for safety devices, which are verified during the mandatory safety inspection (UVV). Failure to undergo this inspection is not merely a formality. In the event of an accident, the operator faces liability risks, problems with insurance coverage, and fines from the employers' liability insurance association.

03 WHICH DEVICES NEED TO BE TESTED
PLANTS REQUIRING INSPECTION

The UVV inspection applies to all industrial lifting aids and power-operated handling equipment. The Zeilhofer portfolio includes:

Lifting axes (e.g. ZH90) — linear lifting systems with pneumatic, electropneumatic or electric drive
Articulated arm manipulators — with rigid load guidance via rods and rotary bearings
Rope manipulators — with double rope technology and pressure storage
Lever lifts — mobile, battery-powered floor trolleys
Multi-axis modules — rotary and drive modules in robot cells
Lifting attachments — grippers, suction cups, magnets, hooks, special devices
Steel structures and rail systems — subject to inspection as part of the plant

Permanently installed components such as steel structures, monorails, and energy supply lines are also included in the plant inspection. Significant modifications to the plant—such as new equipment, altered load-bearing capacity, or conversions—require an extraordinary repeat inspection.

04 FOUR PHASES OF A STANDARD-COMPLIANT UVV TEST
TEST PROCEDURE

The UVV inspection follows a fixed, documented procedure. Each phase is recorded in the inspection report and confirmed with a signature by the qualified person.

01 Visual inspection

The visual inspection assesses the external condition of the system. Supporting elements are checked for cracks, wear zones, corrosion, deformations, and impermissible changes.

Screw connections are checked for tightness, welds for signs of fatigue. Signs, safety markings, and operating instructions must be complete and legible.

02 Functional test

During functional testing, all movement sequences are simulated under real operating conditions. Lifting, lowering, rotating, swiveling – every movement is checked for smoothness, jerk-free operation, and responsiveness to operator commands. The control handles, joysticks, pedal controls, and emergency stop devices are tested individually.

03 Safety devices

In the third step, all safety-relevant components are tested. These include emergency shutdown, pressure accumulators to prevent load loss in the event of a power failure, load limiting devices, limit switches, rotation limiters, brakes on rotating axes, and electrical safety circuits. Functionality is verified separately under load and at idle.

04 Load test (if required)

In the case of significant repairs or modifications, an additional load test is performed. The system is tested with its rated load or a defined overload to verify the structural integrity of all mechanical components. This requires a special test weight and is part of the extraordinary post-modification inspection.

At the end of each inspection, the system is marked with an inspection sticker indicating the next inspection date. Any defects found are categorized as minor, moderate, or safety-relevant – the latter leading to immediate shutdown.

05 WHEN DOES IT NEED TO BE CHECKED?
TESTING INTERVALS

The inspection intervals are determined by DGUV V54 and the operator's risk assessment. Relevant deadlines:

01 Initial inspection — before first use

Every new system must be inspected by a qualified person before its first use. This initial inspection also includes verification of CE conformity, documentation, and correct installation. At Zeilhofer HHT, the initial inspection takes place during commissioning.

02 Recurring inspection — annually

Lifting aids, manipulators, and lifting axes must be inspected annually. This standard interval applies to normal single-shift operation. For multi-shift, heavy-load, or special operations, the interval can be reduced to 6 months – this is determined by the operator's individual risk assessment.

03 Extraordinary inspection — after repair or conversion

After any significant repair, modification, or conversion, an extraordinary inspection is required before recommissioning. Significant means: interventions in load-bearing components, changes in load-bearing capacity, new devices, modified drive, or modified control system.

04 Event-related inspection — after a damage incident

After every incident of damage, accident or unusual occurrence — such as a crash, collision or overload — the system must be inspected before being put back into operation, regardless of the current time period.

The inspection deadlines are documented in the inspection log. Missed deadlines lead to automatic shutdown—the system may not be operated until the deadlines are met.

06 WHO IS AUTHORIZED
COMPETENT PERSON

The UVV inspection may only be carried out by a qualified person as defined in TRBS 1203. The qualification requirements are clearly defined:

Technical vocational training

The qualified person must have completed relevant technical training—typically in mechanical engineering, mechatronics, electrical engineering, or industrial mechanics. A university degree is not mandatory, but vocational training with additional qualifications is required.

Professional experience with lifting aids

At least one year of professional experience in handling lifting equipment, manipulators, or load-handling devices. Practical knowledge of the function, construction, and maintenance of the types of equipment to be inspected is mandatory.

Current expertise

The qualified person must participate in regular continuing education. They must be familiar with revised standards, new DGUV regulations, and technical advancements. A written appointment by the employer is required.

Independence of production and maintenance

The competent person must be able to act independently during the inspection. They must not pursue any interests that conflict with the inspection result. An inspection by the manufacturer does not preclude this independence—as long as the inspecting employee did not build the system themselves.

Important: A simple crane operator training course or a forklift license is not sufficient. The qualification of a competent person is a separate qualification level that can only be demonstrated through training, experience, and appointment.

Zeilhofer HHT exclusively provides qualified and competent personnel for UVV inspections. Our service technicians are expert according to TRBS 1203, regularly trained, and possess the necessary practical experience with lifting axes, manipulators, and lifting aids.

07 WHAT NEEDS TO BE RECORDED
DOCUMENTATION

Documentation is a key component of the accident prevention regulations (UVV) inspection and serves as proof in the event of damage. Mandatory information in the inspection log:

Date of the exam and date of the next scheduled exam
Name and qualifications of the competent person
Unique asset identifier (serial number, inventory number)
Tested components with condition assessment
Defects identified and classified (minor, medium, safety-relevant)
Recommendations for rectification with a deadline
Signature of the authorized person and confirmation by the operator

The inspection log is auditable, tamper-proof, and must be kept for at least the entire lifespan of the system. The inspection log is transferred with the sale of the system.

08 WHAT WE MOST COMMONLY FIND IN PRACTICE
TYPICAL FINDINGS

With over 25 years of experience with lifting aids, our service technicians are familiar with the typical weak points. The most frequent findings:

Wear on load-bearing components

Ropes, chains, grippers, and load-bearing components are the most heavily stressed. We test them for fracture behavior, corrosion, and deformation. Visible wear zones are documented, and replacement recommendations are made.

Stiff or misaligned limit switches

Limit switches restrict the range of motion and are safety-critical. Over time, they can become misaligned due to vibration or become dirty. We test each end position for reliable triggering.

Compressed air losses in pneumatic systems

In pneumatic manipulators, leaks lead to energy loss and, in the worst case, to load failure due to pressure drop. We systematically inspect pressure accumulators, valves, and hoses.

Corrosion at screw connections

Bolted connections in load-bearing components are subject to special monitoring. Corrosion, loosened bolts, and material fatigue are common findings, especially in humid production environments such as foundries.

Outdated safety markings

Signs fade, become detached, or are damaged during cleaning. Illegible load capacity and safety markings are clear defects and must be replaced immediately.

Software and control status

For electronically controlled systems, we check the status of the control software, the function of the safety PLC and the correct parameterization.

09 WHAT INFLUENCES THE EXAM
TESTING COSTS

The cost of a safety inspection (UVV inspection) depends on several factors – there is no single answer. Key influencing factors include:

Number of devices at the location — when multiple devices are used in one appointment, travel costs are significantly reduced.
System type and complexity — a simple lifting axis can be tested faster than a multi-axis module with special devices.
Special tests such as load tests or weld visual inspections increase the effort required.
Initial inspection vs. follow-up inspection — the initial inspection additionally includes CE verification and document comparison.
On-site defect rectification — if possible, it will be carried out directly and itemized separately.

We will gladly prepare a customized offer tailored precisely to your existing equipment upon request. Reduced rates apply for existing customers with a maintenance contract.

10 WHAT HAPPENS IF CHECKING IS REMAINED
RISKS

A missed UVV inspection has significant consequences that go far beyond a mere formal oversight:

Liability risk for management

In the event of damage, management is personally liable if the duty to conduct due diligence was violated. In cases of personal injury, criminal prosecution for negligent bodily harm or negligent homicide is possible. This liability is not covered by compliance insurance.

Loss of insurance coverage

Business liability and machinery insurance policies make their coverage contingent on proof of proper inspections. If the current inspection entry is missing from the inspection log, the insurance company can reduce or deny coverage. In the case of property damage amounting to millions, this can be a threat to the company's existence.

Fines and shutdown by the employers' liability insurance association

The employers' liability insurance association conducts unannounced inspections. If proof of inspection is missing, the system is immediately shut down and may not be operated until the inspection is completed. In addition, fines of up to €30,000 per system and violation may be imposed.

Increased BG contributions

Repeated violations lead to increased contributions to the employers' liability insurance association. In the event of an accident resulting in personal injury, an additional contribution levy may be imposed, which can amount to several tens of thousands of euros.

Reputational damage

Supplier audits are common practice for major customers in the automotive, e-mobility, and aerospace sectors. Missing safety inspection certificates during the audit process lead to supplier suspension. For existing contracts, this can jeopardize the business foundation.

The investment in regular safety inspections is minimal compared to these risks. It protects not only employees but also the company's existence.

11 THE FIVE KEY ADVANTAGES

MANUFACTURER'S TESTING

You can have the UVV inspection carried out by an external expert or by the manufacturer. Both fulfill the legal requirement—but the quality and efficiency differ significantly. Here are five reasons why having the inspection done by the manufacturer is the better choice:

01 In-depth, first-hand plant knowledge

Those who built the system know it best. Our service technicians were involved in the design and commissioning. They know every component, every weak point, and every typical wear zone. External inspectors work according to checklists—we inspect with contextual knowledge gained from 25 years of our own design experience.

02 Complete documentation is available

Construction drawings, CAD data, parts lists, maintenance history, and modifications are fully archived in our system. We are familiar with every special design, every conversion, and every repair work carried out in recent years. External inspectors must limit themselves to what they find on site.

03 Recognizing subtleties and special designs

Every Zeilhofer manipulator is a project-specific design. Standard checklists often fall short when it comes to custom configurations. We know exactly what to look out for with a double-stroke lifting axis, a manipulator with special equipment, or a battery-powered lifting platform.

04 Fast spare parts supply via the back office

If defects are detected, our service technician can contact the back office in Holzkirchen directly. Spare parts are identified, procured, and ideally installed on-site on the same day as the inspection. With external inspectors, there is often a gap between the defect report and its resolution—which costs production time.

05 Less effort for your organization

We handle all the coordination: scheduling, travel, inspection, documentation, defect rectification, inspection report, and labeling. You don't need to hire external experts or coordinate between the manufacturer and the inspector. One point of contact – everything from a single source.

This combination of knowledge, documentation, capability and efficiency makes manufacturer testing the clearly better choice — for plant safety, production availability and administrative relief.

12 THE UVV SERVICE FROM ZEILHOFER HHT

SERVICE

Our UVV service follows a defined process that is maximally efficient for you and minimizes downtime.

Step 1: Inquiry and appointment scheduling

You can register your system(s) via email, phone, or contact form. We will review your maintenance history and suggest a suitable appointment. If there are multiple systems at your location, we will combine the inspections into a single visit.

Step 2: Preparation

You will receive a checklist in advance of what must be available on the day of the inspection — operating instructions, inspection log, keys to control cabinets. If necessary, we will coordinate the release of the production area for the duration of the inspection.

Step 3: On-site inspection

The service technician arrives at the agreed time, performs the four inspection phases (visual inspection, functionality, safety, and, if necessary, load testing), and documents everything thoroughly. Any defects found are classified, and immediate corrective actions are coordinated with the back office.

Step 4: Immediate rectification of defects — if possible

Minor and moderate defects are repaired directly on-site if the spare part is available in the service vehicle. For more extensive repairs, a follow-up appointment will be scheduled. Goal: maximum system availability.

Step 5: Inspection report and sticker

You will receive the signed inspection report including a list of defects, recommendations, and the next inspection deadline. The system will be affixed with the current inspection sticker. A copy will be kept in our archives.

Step 6: Follow-up and reminder

We will automatically remind you four weeks before the next exam deadline. This way you avoid missed deadlines and can plan your next appointment well in advance.

Our service technicians travel throughout Germany and internationally. For locations outside of Germany, we coordinate travel arrangements individually and can also arrange multi-day inspection missions.

FAQ / Q&A
FREQUENTLY ASKED QUESTIONS

01 How often must a lifting aid be inspected?

Generally, inspections are required annually, according to DGUV V54. In cases of multi-shift operation, heavy load use, or special environmental conditions, the operator's risk assessment may necessitate a shorter interval of 6 months. Additionally, an inspection is required after every repair, modification, or incident.

02 Who is authorized to carry out the UVV inspection?

The inspection may only be carried out by a qualified person in accordance with TRBS 1203. Prerequisites include technical vocational training, at least one year of professional experience with lifting equipment, current expertise through regular continuing education, and a written appointment. Zeilhofer HHT exclusively employs qualified persons.

03 What happens if the exam is missing?

Failure to conduct the required inspection can have serious consequences: personal liability for management, loss of insurance coverage, fines of up to €30,000 per installation, shutdown by the employers' liability insurance association, increased employers' liability insurance association contributions, and potential supplier bans with audited customers. The inspection is a legal obligation of the operator.

04 What is documented in the test log?

The inspection log must include the date of the inspection and the next scheduled inspection, the name and qualifications of the competent person, the plant identification number, the components inspected with their condition assessment, any defects identified with their classification, recommendations for rectification with deadlines, the inspector's signature, and the operator's confirmation. The inspection log must be auditable and retained for the entire lifespan of the plant.

05 How long does a UVV inspection take?

The inspection log fully documents the date, scope, and result of each inspection. It is auditable and serves as proof in case of an incident.

06 What preparations must the operator make?

The equipment must be accessible, clean, and out of service for the duration of the inspection. Operating instructions, inspection log, and keys to control cabinets must be available. For electrical systems, safe voltage isolation must be arranged. We provide a detailed checklist before each appointment.

07 What are the most common defects?

Wear and tear on load-bearing components, stiff or misaligned limit switches, compressed air losses in pneumatic systems, corrosion on screw connections, faded safety markings, and outdated software versions in control systems. All findings are classified in the test report and accompanied by recommendations for corrective action.

08 How much does a UVV inspection cost?

The costs depend on the number of systems, complexity, travel expenses, special inspections, and any necessary defect rectification. We will prepare a customized quote upon request. Existing customers with a maintenance contract receive discounted rates. The unit price decreases significantly for multiple systems at the same location.

09 Does Zeilhofer HHT also test systems from other manufacturers?

Our focus is on testing lifting aids, manipulators, and lifting axes from the Zeilhofer portfolio. We test equipment from other manufacturers only in exceptional cases—the final decision is made by our technical director after reviewing the equipment documentation.

10. Does Zeilhofer HHT remind about the next exam?

Yes. We maintain a follow-up schedule for each existing customer and automatically send reminders four weeks before the next scheduled inspection. This helps you avoid missed deadlines and allows you to integrate the next appointment into your maintenance plan well in advance.

GRUNDLAGEN

What is a lifting axle?

Lineare Lastführung mit Aluminium-Profil bis 1.200 kg erklärt.

Mehr Informationen

COMPARISON

What is a manipulator?

Gelenkarm-Maniupulator mit starrer Lastführung bis 800 kg