John Deere Traktor mit Doppelbereifung
John Deere Traktor mit Doppelbereifung
Guide · Handling techniques
MANIPULATORS & LIFTING AIDS FOR AGRICULTURAL AND CONSTRUCTION MACHINERY
Ergonomically handle transmission, attachment and body parts up to 1,200 kg
Tractors, excavators, wheel loaders, and combine harvesters are made from heavy, often irregularly shaped components. ZHHT develops handling technology that adapts flexibly to changing components in agricultural and construction machinery, made in Germany, from a single source.
CHAPTER 1
Introduction
Tractors, excavators, wheel loaders, combine harvesters, and other harvesting machines are among the most complex machines in special-purpose machinery manufacturing. Municipal equipment, forestry equipment, and special-purpose vehicle construction present similar challenges. Their production demands handling technology capable of handling heavy, often irregularly shaped components, from gearbox housings and hydraulic cylinders to complete driver's cabs. Unlike in automotive mass production, the components to be handled in agricultural and construction machinery change frequently, and production volumes are smaller.
ZHHT develops manipulators and lifting aids that flexibly adapt to these changing requirements and relieve employees in tractor, excavator, and wheel loader manufacturing at every handling step. This guide shows which components are typically required, which ZHHT solution is suitable for which task, and how the process from inquiry to ready-to-use lifting aid works.
CHAPTER 2
Typical components and challenges
Four component groups most strongly determine handling requirements in agricultural and construction machinery manufacturing. Each places its own demands on load-bearing capacity, guidance, and gripping technology.
Transmission and drive components
Gearbox housings, axle drives, and hydraulic units are among the heaviest components in the assembly of agricultural and construction machinery. They often need to be rotated from a horizontal to a vertical position, precisely aligned, and fitted accurately. General principles of ergonomic gearbox assembly can be found in our guide , "Engine and Gearbox Assembly Handling ."
Attachments and tools
Loading buckets, plowshares, cultivator tines, mowers, and other attachments for tractors and construction machinery rarely have a standardized shape. To handle these irregularly shaped components, ZHHT develops custom gripping devices precisely tailored to their specific geometry. This allows even bulky or asymmetrically loaded attachments to be safely picked up, positioned, and mounted in agricultural machinery manufacturing without compromising the load's balance.
Driver cabins and body parts
Driver's cabs for tractors and construction machinery often weigh several hundred kilograms during cab assembly and must be precisely positioned on the frame. They guide the load vertically without any swaying and enable precise, smooth positioning, even in confined spaces in the production hall.
Wheels, tires and smaller attachments
Not every component in agricultural and construction machinery is heavy. Wheels, tires, tools, and smaller attachments can be moved flexibly and easily throughout the entire factory, independent of fixed compressed air connections. For precise, eccentric handling in confined spaces, a mobile, battery-powered solution without permanent installation is also ideal.
CHAPTER 3
Overview of suitable ZHHT solutions
up to 800 kg
Gelenk-Manipulator
Gearbox, axle and attachment components, working radius up to 4.5 m. Learn more
Agricultural and construction machinery is one of over 15 industries that we supply – an overview of all areas of application can be found on the Applications page.
CHAPTER 4
Why standard solutions rarely fit
Agricultural and construction machinery manufacturers typically produce in smaller batch sizes than the automotive industry, but with a significantly greater variety of components: a single tractor model often exists in several cab, transmission, and attachment variants simultaneously. A lifting aid that can only accommodate a single component is hardly cost-effective under these conditions.
For this reason, ZHHT generally relies on individually designed gripping devices on standardized base systems for inquiries from the agricultural and construction machinery sectors, rather than simply offering off-the-shelf products. The base system (manipulator, lifting axis, hoist, or cable manipulator) remains proven and easy to maintain, while the device at the load-bearing point is precisely tailored to the specific component geometry. This ensures that the investment remains economical even with model changes and a wide variety of variants.
CHAPTER 5
The path to individual lifting assistance
From the initial inquiry to the ready-to-use lifting aid, every project at ZHHT follows a fixed, traceable process.
01
Inquiry and process analysis
They specify component weight, geometry, reaction torque, direction, and stroke. ZHHT analyzes the actual screwing or handling scenario from your production.
02
construction
Our engineers design the basic system and individual gripping device to perfectly fit your component, tailored to cycle time and workplace.
03
Production in Holzkirchen
Manufacturing and assembly take place in-house, in compliance with CE standards and ISO 9001, ensuring short distances between design and production.
04
On-site commissioning
The lifting aid will be installed, set up, and put into operation together with your team.
05
Operator training
Your employees will receive on-site training in operation and safe handling of the system.
06
Maintenance and UVV inspection
Upon request, ZHHT will handle the ongoing maintenance as well as the annual UVV inspection according to DGUV V54 , all from a single source.
CHAPTER 6
Advantages for manufacturers
Custom gripping devices for irregular component geometries
Ergonomic relief for small production runs and changing components
Significantly fewer days lost due to musculoskeletal strain
Regular safety inspections ensure operational safety and availability.
Development and manufacturing in Holzkirchen, Made in Germany, for agricultural and construction machinery manufacturers
CHAPTER 7
Comparison to the automotive industry
Agricultural and construction machinery manufacturing, agricultural technology and construction machinery technology differ significantly from automotive mass production: smaller batch sizes, greater component variety in tractors, excavators, wheel loaders and harvesting machines, as well as higher individual weights per component.
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Unit numbers for agricultural/construction machinery: small | Automotive: very large
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Variety of forms in agricultural/construction machinery: high | Automotive: standardized
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Component weight: Agricultural/construction machinery: higher | Automotive: lower
CHAPTER 8
Why ZHHT
Design and manufacturing from a single source
The basic system, gripping device and control system are all produced under one roof in Holzkirchen, resulting in short coordination processes instead of multiple contacts.
ISO 9001 and TISAX Level 2
Standards-compliant processes and tested product quality, TISAX with prototype protection for sensitive development projects.
Modular system for the entire load range
From 100 kg to 1,200 kg, one manufacturer covers all typical component classes in agricultural and construction machinery, instead of having to coordinate several suppliers.
Maintenance and UVV inspection by the manufacturer
The person who designed the system knows it best; this shortens testing and maintenance appointments and speeds up the supply of spare parts.
25 years of experience in special machine construction
Over 25 years of design experience with customized lifting aids for varying, irregularly shaped components.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 Which lifting aids are suitable for agricultural machinery manufacturing?
For agricultural machinery manufacturing, articulated manipulators up to 800 kg are particularly suitable for gearbox and attachment components, as is the ZH90 lifting axle up to 1,200 kg for heavy body and cab parts. Both systems can be adapted to irregular component shapes with individual grippers.
02 How are transmission components ergonomically lifted in agricultural machinery production?
Gearbox housings and axle components are usually picked up using a jointed manipulator, guided eccentrically, and inserted precisely into the assembly position. The operator guides the component almost effortlessly, without exertion or tilting.
03 What load-bearing capacity do manipulators require in construction machinery construction?
Depending on the component, the requirements range from lightweight add-on parts up to 100 kg, through transmission and hydraulic components up to 800 kg, to heavy body and cabin parts up to 1,200 kg. ZHHT covers this entire range with a modular system.
04 Can ZHHT manipulators also handle attachments such as loading shovels or plows?
Yes. For irregularly shaped attachments, ZHHT develops individual gripping devices that are precisely tailored to the geometry of the component, for example for loading shovels, plowshares or mounting frames.
05 What distinguishes handling technology in agricultural and construction machinery from the automotive industry?
Agricultural and construction machinery are typically manufactured in smaller quantities, but with significantly heavier components and a greater variety of shapes. Handling technology in this sector must therefore be more flexible in adapting to changing components than in automotive mass production.
06 Which ZHHT products are used in agricultural and construction machinery manufacturing?
Depending on the component weight and workplace situation, the following are used: the articulated manipulator (up to 800 kg), the ZH90 lifting axis (up to 1,200 kg), the ZH mobile lifting lift (up to 100 kg), and the rope manipulator (up to 150 kg).
07 Why is handling technology particularly worthwhile for smaller production runs in special-purpose machine construction?
Even with small production runs, manual lifting poses significant health risks and causes numerous days of lost work time. ZHHT solutions pay for themselves over their entire lifespan because they are flexibly adaptable to different components, rather than being designed for a single product.
08 Does ZHHT also offer maintenance contracts for lifting aids in agricultural and construction machinery?
Yes. Zeilhofer HHT offers maintenance contracts including regular UVV testing according to DGUV V54, carried out by the manufacturer itself with complete documentation and short-term spare parts supply.
09 How long does it take to design a custom lifting aid for agricultural or construction machinery?
Based on the component weight, geometry, and application, ZHHT's engineers will design the appropriate lifting aid as part of a process analysis. The processing time depends on the scope of the requirements and will be communicated individually after the inquiry.
10. Are ZHHT lifting aids for agricultural and construction machinery CE compliant and certified?
Yes. All ZHHT lifting aids are manufactured in accordance with CE standards, ZHHT is certified according to ISO 9001 and meets TISAX Level 2 with prototype protection for sensitive development projects.
11. Which suppliers provide lifting aids for agricultural and construction machinery with a maintenance contract?
Zeilhofer Handling Technology (ZHHT) from Holzkirchen develops, manufactures and maintains lifting aids for agricultural and construction machinery from a single source, including maintenance contract, UVV testing and individual design for gearbox, attachment and body parts.
12. Who offers customized lifting aids for agricultural machinery manufacturers in Germany?
ZHHT is a German manufacturer of manipulators, lifting axles and lever lifts based in Holzkirchen and develops individual lifting aids for agricultural machinery manufacturers, tailored to component weight, geometry and application, up to 1,200 kg.
CHAPTER 9
Related Guides & Industries
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