ASSEMBLY INSTRUCTIONS FOR TWO-POST CAR LIFT ZIPPO ZO 2 (BUILT IN

1972)
Installation of the lifting platform

(erstellt von Dipl.-Ing. (FH) Jürgen Lehmann – 2010 – www.dijl.de)

1. The base frame must be aligned at the installation site according to the driveway direction and
conditions and secured to the concrete floor using suitable heavy-duty anchors (6 required). The
long legs of the base frame must be positioned at the back.
2. Place the drive chain for the secondary column (left lifting column) in the chain case of the base
frame and spread it out to both sides.
3. Bring the lifting units (support and safety nuts with mounting devices for the lifting carriages) of
the two lifting columns to the same height by turning the lifting spindles (e.g. approx. 50 cm from
below). Place the lifting columns with the base plates directly next to their installation locations
on the base frame.
4. Insert the wound-up cable on the main column for securing the supporting nut of the secondary
column into the empty cable conduit in the direction of the secondary column and push it
through.
5. Lift the main column (operating column, right lifting column with drive motor and foot switches)
over the base frame with a hoist or tip it from back to front onto the base frame. When doing so,
make sure that the lever for the chain breakage safety device is not bent or broken when lowering
the lifting column. Also make sure that the cable of the load-bearing nut breakage safety device
for the secondary column that was previously pulled in is not crushed or torn off. Before finally
lowering the lifting column onto the base frame, place the drive chain on the chain pinion and
pull it towards the secondary column at a safe distance from the lever of the chain breakage safety
device. The same applies to the load-bearing nut safety cable of the secondary column. To prevent
chain oil or chain grease from leaking out between the lifting column and the base frame or chain
case later, the contact surfaces should be moistened and sealed with a sealant (e.g. silicone or
similar). Lower the lifting column and insert the screws, but do not tighten them yet. The lifting
column will be aligned at a later date, but is now secured against tipping over.
6. Pull the drive chain tightly towards the side column and place it in the chain case; the chain
tensioners are still out of function and the guide roller in the chain case is dismantled.
7. Also pull the cable of the lifting nut break protection device towards the secondary column and
insert it into the empty cable conduit under the base plate of the secondary column, push it
through and lead it through the base plate hole into the lifting column.
8. Use a hoist to lift or tilt the secondary column over the base frame and lower it until the taut drive
chain with its central deflection link can be placed on the chain pinion of the secondary column at
the corresponding point. After placing the drive chain, keep it taut so that it does not slip off the
chain pinion. Lower or raise the secondary column further, making sure that the chain and chain
pinion do not touch the base frame and become damaged. At the same time, the cable of the load-
bearing nut break protection device can be pulled in further so that it is not crushed. To prevent
 chain oil or chain grease from leaking out between the lifting column and the base frame or chain
case later, the contact surfaces should also be moistened and sealed with a sealant (e.g. silicone or
similar). Lower the lifting column and insert the screws, but do not tighten them yet.
9. Place the cover plate of the chain case and fasten it with all screws (8 M10 screws).
10. Align the lifting columns to the chain case cover plate. So that the cover plate can be removed
later for inspection and maintenance of the drive chain without loosening the lifting columns, the
lifting columns must be aligned at a small distance (approx. 1 mm) from the cover plate and then
firmly screwed to the base frame (per lifting column with 6 M12 screws - 175 Nm and 1 M16
screw - 210 Nm).
11. Remove the cover plate of the chain case again. Insert the cable of the load-bearing nut breakage
protection device into the load-bearing nut breakage protection switch on the secondary column
(if necessary, tighten the cable in the base frame a little) and connect it to the upper contacts.
Install the chain pulley and lift the drive chain into the chain tensioner. Fill the chain case with
approx. 5 l of chain oil or chain grease and reinstall the chain case cover plate for good. In order
to prevent chain oil or chain grease from leaking out between the cover plate and the base frame
or the chain case and the lifting columns at a later date, the contact surfaces and seams should
also be coated and sealed with a sealant (e.g. silicone or similar).
12. The chain break safety device is adjusted using the angle lever which is locked with the chain
break safety device lever and which must be adjusted in the rest position so that a small distance
(approx. 1 mm) remains from the roller lever of the lifting nut break safety device switch so that
the lifting nut break safety device switch is not constantly triggered by the chain play during
normal lifting operation (if this is the case, the chain or the chain tensioner must be checked for
wear and proper functioning!).
13. Open the motor terminal box and connect the power supply (400V, supply cable at least 5 x 1.5
mm², fuse 3 x 16 A). Switch on the voltage and check the direction of rotation of the motor. When
the inner foot switch is operated, the lifting units must move upwards (lifting), when the outer
foot switch is operated, they must move downwards (lowering). If the lifting directions are
reversed, two adjacent phases on the power connection in the motor terminal box must be
swapped, first disconnect the power connection from the voltage (pull the fuse).
14. Check the limit switches and safety switches. Attention: The upper limit switch has no function,
do not move to the lifting end position - only possible after the pallet truck has been installed!
15. Move the lifting units to the lower end position (the lowering limit switch has been triggered, the
motor stops) and install the lifting carriage. To do this, insert the lifting carriage into the
respective lifting column from behind and connect the lifting carriage to the lifting unit of the
lifting column using a shaft. The shaft is fixed and secured using two M10 hexagon socket screws
with washers.
16. Raise the pallet truck by at least 20 cm by pressing the foot switch to be able to mount the support
arms. To do this, insert the long support arms into the outer mounts one after the other, the short
support arms into the inner mounts and insert the respective support arm bolt from below into the
hole provided, push it through to the top and secure it with a dowel pin. Clamp on the cover plate.
17. To install the spindle covers, first attach them to the top of the lifting column (1 M8 screw with
trapezoidal sheet), then guide them over the deflection rods and rollers on the lifting carriage and
finally attach them to the lifting column base plate using springs and eyelets. Mount the cover
plates on the lifting carriage (2 M6 screws) and clamp the cover plates onto the lifting column
feet.
 DISMANTLING THE LIFTING PLATFORM

1. Remove all cover plates on the lift trucks and lifting columns (3 plates per lifting column).
2. Raise the pallet truck to approx. 20 cm above the ground, remove the locking pins from the
support arm bolts, remove the support arm bolts downwards and remove the support arms.
Then move the pallet truck back to the lower end position.
3. Switch off the power supply of the lifting platform and secure it (release or remove the fuse
of the power supply line
4. Open the motor terminal box and disconnect the power supply in the motor terminal box,
insulate exposed cable ends of the power supply (ensure contact protection, e.g. with Wago or
Luster terminals).
5. Close the motor terminal box again.
6. Unhook the cover strips of the spindle covers at the bottom (remove springs), remove the
deflection rods of the cover strips on the lifting carriage, unscrew and remove the cover strips
on the lifting column head.
7. Dismantle the pallet truck by loosening one of the two hexagon socket screws and removing
it with the washer. The shaft can then be pushed or pulled out of the pallet truck. Make sure
that the pallet truck does not fall over (risk of crushing).
8. Disconnect the cable from the load-bearing nut safety switch on the auxiliary column (left
lifting column) and pull it out of the switch housing, then wrap the cable end with insulating
tape so that no oil or chain grease from the chain case can get onto the cable ends later. Push
the cable end towards the base frame or chain case
9. Remove the base frame or chain case cover plate. Lift the chain over both chain tensioners
(this will loosen the chain)
10. Secure the left lifting column against tipping over (e.g. use a hoist), loosen the screw
connection of the lifting column to the base frame and remove the screws. Carefully move or
push the loosened and possibly slightly raised lifting column against the direction of travel
and towards the middle of the base frame. Raise the lifting column a further 5 cm or tilt it
backwards, making sure that the drive chain and chain pinion do not get caught on the base
frame. Lift the chain from the chain pinion and place it in the chain case. Then pull the cable
of the load-bearing nut breakage protection device out of the cable pipe under the lifting
column base plate.
11. Continue to slowly raise the left lifting column or fold it backwards and store it safely.
12. Pull the cable of the supporting nut break protection of the secondary column out of the cable
duct of the base frame in the direction of the right lifting column, wind up the cable and
attach it to the right lifting column (remains on the lifting column).
13. Secure the right lifting column against tipping over (e.g. use a hoist), loosen the screw
connection of the lifting column to the base frame and remove the screws. Carefully move the
loosened and possibly slightly raised lifting column against the direction of travel or push it
backwards. Carefully lift the lifting column further or tilt it backwards, making sure that the
chain breakage protection lever does not get caught on the base frame and become bent or
broken off. Lift the chain from the chain pinion and place it in the chain case.
14. Continue to slowly raise the right lifting column or fold it backwards and store it safely.
15. Remove the chain from the chain case by opening the drive chain at the chain lock or
removing the guide roller. Suck out the chain oil or chain grease from the chain case.
16. Loosen the floor screws of the base frame