MAHA ZS SQUARE II 3.5 User manual

ZS SQUARE II
Two Post Lifts with Flat Head or Swing Arm Supports
Original Operating Instructions
BA322301-en
ZS SQUARE II 3.5
ZS SQUARE II 4.5
ZS SQUARE II 5.5
ZS SQUARE II 6.5

2BA322301-en
BA322301-en
2022-08-08
© MAHA Maschinenbau Haldenwang GmbH & Co. KG
The reproduction, distribution and utilization of this document as well as the communication of its contents
to others without explicit authorization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent, utility model or design.
The contents of this edition have been checked with great care. However, errors cannot be fully excluded.
Subject to technical change without notice.
Manufacturer
MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
87490 Haldenwang
Germany
Phone: [phone]
Fax: [phone]
Mail: [email protected]
Web: www.maha.de
Service
MAHA SERVICE CENTER
Maybachstraße 8
87437 Kempten
Germany
Phone: [phone]
Fax: [phone]
Mail: [e-mail]
Web: www.mahaservicecenter.de
Dear Customer,
MAHA is one of the world's leading manufacturers of testing and lifting technology and
places particular emphasis on quality and performance. The company's concept
includes the development, manufacture and sale of products for use in automotive
workshops, by vehicle manufacturers and testing organisations.
MAHA's claim is to also be a leader in the areas of reliability, safety and sustainability –
this can be seen in many details that have been developed with these aspects in mind.
We are convinced that you will be more than satisfied with the quality and performance
of our products for many years. With the purchase of our products you will also receive
professional assistance in case of need for service and repair.
Please remember to keep these operating instructions in a safe place. Accurately
following their contents will significantly extend the life of your product and also
increase its resale value. If you sell your product, please also pass on the operating
instructions.
MAHA is constantly working on the further development of all products and therefore
reserves the right to make changes, e.g. in shape and appearance, without prior notice.
Extensive accessories, useful assembly material and auxiliary materials are available
for our products. For further information, please ask your dealer or your MAHA contact
person at any time.
Thank you for choosing a MAHA product!

BA322301-en 3
Contents
1General Safety Instructions ............................................................................................................................. 5
1.1 Introduction.................................................................................................................................................. 5
1.2 Symbols and Signal Words ......................................................................................................................... 5
1.2.1 Personal Injury....................................................................................................................................... 5
1.2.2 Property Damage .................................................................................................................................. 5
1.3 What to Do in the Event of Defects or Malfunctions ................................................................................. 6
1.4 What to Do in the Event of an Accident...................................................................................................... 6
1.5 Requirements for the Operating Personnel................................................................................................ 6
1.6 Requirements on Service Personnel........................................................................................................... 6
1.7 Intended Use ................................................................................................................................................ 7
1.8 Safety Instructions for Handling Hydraulic Fluid ....................................................................................... 7
2Description ....................................................................................................................................................... 8
2.1 Applicable Standards and Directives.......................................................................................................... 8
2.2 Service Life................................................................................................................................................... 8
2.3 General Machine Description...................................................................................................................... 8
2.3.1 Design and Basic Functions ................................................................................................................. 8
2.3.2 Control Description ............................................................................................................................... 9
2.3.3 Safety Devices ..................................................................................................................................... 10
2.3.4 Overall View with Components .......................................................................................................... 11
2.4 Technical Data ........................................................................................................................................... 14
2.4.1 Danger Zone ........................................................................................................................................ 14
2.4.2 Technical Data..................................................................................................................................... 15
2.4.3 Set-up Diagrams.................................................................................................................................. 16
3Transport, Handling and Storage .................................................................................................................. 19
3.1 Safety Information ..................................................................................................................................... 19
3.2 Transport, Handling and Storage.............................................................................................................. 19
4Operation ........................................................................................................................................................ 20
4.1 Safety Information ..................................................................................................................................... 20
4.2 Preparations............................................................................................................................................... 22
4.2.1 Initial Position/Ready for Operation................................................................................................... 22
4.2.2 Positioning of the Vehicle................................................................................................................... 22
4.2.3 Positioning of the Supports ................................................................................................................ 23
4.3 Raising and Lowering Cycles .................................................................................................................... 25
4.3.1 Control Elements................................................................................................................................. 25
4.3.2 Checking the Support and the Lifting Process .................................................................................. 27
4.3.3 Lowering Process and CE Stop .......................................................................................................... 27
4.4 Driving off the Lift and Changeover.......................................................................................................... 28
4.5 Emergency Lowering ................................................................................................................................. 29
4.5.1 Electric Emergency Lowering ............................................................................................................. 29
4.5.2 Mechanical Emergency Lowering ...................................................................................................... 30
4.6 Optional Equipment ................................................................................................................................... 31
4.6.1 Hinged Cover Frame ........................................................................................................................... 31
4.6.2 Installation Frame for Flat Head Lifts ................................................................................................ 33

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4.6.3 Wheel Engaging Support..................................................................................................................... 33
4.6.4 Ceiling Light Barrier............................................................................................................................. 34
4.6.5 Cable Remote Control......................................................................................................................... 35
4.7 Troubleshooting......................................................................................................................................... 35
5Troubleshooting............................................................................................................................................. 35
5.1 Safety Information ..................................................................................................................................... 35
5.2 LED Signal Codes....................................................................................................................................... 37
5.3 Error Table.................................................................................................................................................. 39
6Inspection....................................................................................................................................................... 40
6.1 Safety Information ..................................................................................................................................... 40
6.2 Daily Inspection before Starting Work...................................................................................................... 41
6.2.1 Cables and Actuators.......................................................................................................................... 41
6.2.2 Emergency Stop .................................................................................................................................. 41
6.2.3 Limitation of the Support Arm Pull-outs ............................................................................................ 41
6.2.4 Limitation of the Support Arm Lock................................................................................................... 41
6.2.5 Load Supports ..................................................................................................................................... 42
6.2.6 Piston Rod and Toothed Rack ............................................................................................................ 42
6.2.7 Pull-out of the Flat Head Support....................................................................................................... 42
6.3 Six-Monthly Inspection .............................................................................................................................. 43
6.3.1 Oil Level and Hydraulic Oil .................................................................................................................. 43
6.3.2 Tightness of the Hydraulic System .................................................................................................... 44
6.4 Yearly Inspection ....................................................................................................................................... 44
6.4.1 Welded Joints...................................................................................................................................... 44
6.4.2 Tightening Torques ............................................................................................................................. 44
6.4.3 CE Stop ................................................................................................................................................ 44
6.4.4 Hydraulic Hose Line ............................................................................................................................ 44
7Maintenance................................................................................................................................................... 46
7.1 Safety Information ..................................................................................................................................... 46
7.2 Lubrication ................................................................................................................................................. 47
7.2.1 Columns of the lifting unit .................................................................................................................. 47
7.2.2 Support arm pullouts .......................................................................................................................... 47
7.2.3 Support arm lock ................................................................................................................................. 47
7.2.4 Flat Head Support Pull-outs................................................................................................................ 47
7.3 Hydraulic Hose Lines................................................................................................................................. 48
7.4 Bleeding the Hydraulic System ................................................................................................................. 48
8Care Instructions............................................................................................................................................ 50
9Repairs............................................................................................................................................................ 50
10 Decommissioning, Dismantling and Disposal.............................................................................................. 50
11 Declaration of Conformity ............................................................................................................................. 50

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1General Safety Instructions
1.1 Introduction
•These operating instructions must be read carefully and understood before
work commences.
•Please observe the specific safety information provided for the respective
sections of the operating instructions.
•Adhering to the procedures, sequences and corresponding safety instruc-
tions is essential.
•A printed copy of the operating instructions must always be kept by the lift.
•The relevant regulations on accident prevention and health protection must
be observed.
1.2 Symbols and Signal Words
1.2.1 Personal Injury
DANGER
indicates an immediate hazard which, if not avoided, will result in death or
severe personal injury.
WARNING
indicates a potential hazard which, if not avoided, could result in death or severe
personal injury.
CAUTION
indicates a potential hazard which, if not avoided, could result in moderate or
minor personal injury.
1.2.2 Property Damage
NOTICE
indicates a potentially harmful situation which, if not avoided, could result in
damage to the equipment or surrounding objects.

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1.3 What to Do in the Event of Defects or Malfunctions
•If any irregularities occur, immediately lower or support the lift to the basic
position.
•Turn off the main switch and secure against unauthorised use.
•Contact service team.
1.4 What to Do in the Event of an Accident
•Notify first aiders, the ambulance service and/or immediate care doctor:
oWhere did the accident happen (address, workshop ...)?
oWhat happened?
oHow many are injured?
oWhat injuries have occurred?
oWho is reporting the accident?
•Keep calm and answer questions.
1.5 Requirements for the Operating Personnel
All persons involved in the operation of the equipment must
•be 18 years of age or older,
•have the mental and physical capacity for their role,
•be demonstrably trained and instructed in writing in the operation of the
system,
•have read and understood the operating instructions, in particular the in-
structions on what to do in the event of a fault,
•demonstrate experience and knowledge in handling the equipment and the
hazards it presents,
•be instructed in safety guidelines on record.
1.6 Requirements on Service Personnel
Persons who are entrusted with the assembly, maintenance and/or
disassembly of the equipment must in addition:
•be demonstrably trained and instructed in the required work,
•can provide evidence of appropriate qualification for work on the electrical
equipment of the plant (e.g. as a qualified electrician),
•be able to demonstrate expertise for vehicle lifts. This includes, following
DGUV V308-002, sufficient knowledge in the field of lifts and the relevant
statutory occupational health and safety regulations, accident prevention
regulations and generally accepted rules of technology to be able to assess
the safe working condition of the lift to be tested. Qualified persons shall
not only consider the current condition of the lift during the inspection. They
must also be able to estimate how the lift and its structural parts will be-

BA322301-en 7
have under operational conditions in the sequence and how wear, aging and
the like will affect the safety of the lift.
1.7 Intended Use
•The lift is intended exclusively for the safe lifting and lowering of passenger
cars and commercial vehicles up to the total weight according to the type
plate within the scope of service and repair work.
•In compliance with the load distribution regulations of DIN EN 1493, the
permitted load capacity on the identification plate must not be exceeded.
•Only vehicles which are suitable for the lifting equipment due to their shape
and the positioning of their lifting points may be lifted.
•The lift may not be modified without express written permission from the
manufacturer. Non-compliance invalidates the declaration of conformity.
1.8 Safety Instructions for Handling Hydraulic Fluid
•Wear personal protective equipment (PPE).
•Neutralize spilled hydraulic oil with binding agent.
•Immediately remove soiled, saturated clothing.
•After inhalation: Medical treatment in case of complaints.
•After skin contact: Wash skin immediately with soap and water. Consult a
physician if skin irritation persists.
•After eye contact: Rinse thoroughly with plenty of water, consult physician.
•After ingestion: Do not induce vomiting. Call a doctor immediately.

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2Description
2.1 Applicable Standards and Directives
The lift has been designed in accordance with the applicable standards and
regulations. The most important of these are:
•2006/42/EC Machinery Directive
•2014/30/EU Electromagnetic Compatibility Directive
•2014/35/EU Low Voltage Directive
•DIN EN 1493:2011 Vehicle Lifts
•DIN EN 60204-1-100:2019 Electrical equipment of machines - General requi-
rements
•DIN EN ISO 13849-1:2016 Safety-related parts of control systems - General
principles for design
2.2 Service Life
The lift is designed and tested according to DIN EN 1493. The assumptions
therein are valid for 22,000 full load cycles. After reaching this number of cycles,
or after a maximum of 10 years, the lift must be replaced by a new product or
be given a general overhaul.
A general overhaul should only be carried out by the manufacturer or persons
authorized by them. Load-bearing structures must be inspected and, if
necessary, other parts must be replaced according to the manufacturer's
specifications.
2.3 General Machine Description
2.3.1 Design and Basic Functions
The lift consists of lifting units with flat head supports or swing arm supports.
The lifting units are hydraulically operated and mechanically interconnected.
The lifting units are mounted in concreted installation boxes or installation
frames. The hydraulic unit is suspended in the installation box or in the
installation frame, or stands on the floor away from the lift.
The lift is operated via the control element of the control box. Lifting and
lowering of the lift is performed via pushbuttons. The cable routing from the
control box to the lift is underfloor.
Lifting unit
The lifting units consist of a left and a right version. These are of mirror-image
and redundant design and are connected via a mechanical synchronous
connection. The lifting units are welded together from the two components
cylinder head and tank tube. Depending on the version, the cylinder head is
screwed to the installation box or the installation frame or clamped via
clamping elements. The cylinder head thus transfers the load from the vehicle

BA322301-en 9
to the foundation. The piston rod is guided in the cylinder head. An anti-rotation
device mounted in the piston rod and tank tube prevents the piston rod from
rotating. A mechanical end stop limits the maximum stroke of the lift.
The cylinder head also guides the toothed rack. The toothed rack is connected
to the support and to the synchronisation connection, thus establishing
synchronisation between the two lifting units.
The toothed rack also actuates an electric limit switch. This limit switch triggers
the CE stop during the lowering process.
Supports
Flat head support:
Flat head supports consist of flat heads and pull-outs. The pull-outs are
available in various designs. The flat head supports are bolted to the piston rod
and the rack. The pull-outs are suspended on the flat head, guided laterally and
secured against tilting. Two grooved pins are driven into the flat head, which
engage in the holes of the pull-outs. The pull-outs can thus be pinned at fixed
intervals along the flat head, if required. The pull-outs are either equipped with
nubbed rubber plates or have a granular coating.
Swing arm support:
Swing arm supports consist of swing arm carrier and telescopic support arms.
When the lift is lowered, the support arms are rotatably mounted in the swing
arm carriers via swing arm pins. The rotation of the support arms is automati-
cally blocked by the support arm lock when raised. The swing arm supports are
bolted to the piston rod and the rack.
Support plates are screwed into the support arms, these are adjustable in height
via the thread.
Hydraulic power unit
The hydraulic power unit consists of an oil reservoir and a cover. The motor-
pump unit and the hydraulic block are mounted on the cover. The motor-pump
unit is connected to the hydraulic block by means of a hose or pipe. The
hydraulic block contains all valves and connections relevant for the function of
the lift. The cover is bolted to the oil reservoir, the oil reservoir stores the
hydraulic oil.
2.3.2 Control Description
The core of the control system is a control board that performs, monitors and
controls all electrical functions necessary for safe operation of the system. This
control board is mounted on the inside of the control cabinet.
The lift is controlled with pushbuttons on the operating element. These have
arrows, which show the direction of movement. Above the control buttons there
are fault indicators which light up yellow or red periodically or permanently in
the event of a fault. The main switch on the control box is also an emergency
stop switch.
Optionally, the lift can be equipped with a ceiling light barrier, a control panel, or
a cable remote control. An emergency stop switch is also attached to the cable
remote control.
The lift is equipped with the small control element as standard. As soon as the

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lift is equipped with additional options, it is equipped with the large control
element.
2.3.3 Safety Devices
•Synchronisation connection
The lifting units are connected to a synchronous shaft via the toothed
racks. This limits the height offset between the two piston rods to a
maximum of 50 mm.
•Dead man control
Each pushbutton is only active as long as it is pressed (dead man control).
When the corresponding buttons are released, the raising and lowering
movements are immediately interrupted.
•Emergency stop
The main switch on the switch box of the lift is also an emergency stop
switch. An emergency stop switch is located on the optional cable remote
control.
•Pressure relief valve
The hydraulic power unit has a pressure relief valve. The pressure relief
valve is factory set and limits the hydraulic pressure within the lift.
•Seat valves
All valves of the lift are designed as seat valves and are closed in the rest
position. In the event of a leak, controlled lowering is still possible; in the
event of a power failure, the lift will not lower itself.
•Pinch point protection
The lift has an automatic stop at a distance of at least 120 mm between the
support and the workshop floor (pinch point protection). Pressing the
“DOWN”button again lowers the lift with an acoustic signal.
•Support arm lock
The support arm lock automatically locks in the raised state, so that it is not
possible to change the position of the support arms when loaded.
•Ceiling light barrier
Optionally, the lift can be equipped with a ceiling light barrier. The overhead
light barrier prevents a lifting movement beyond a defined range.

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2.3.4 Overall View with Components
Lifting unit
A
Lifting unit left
a
Switch rod
B
Lifting unit right
b
Lifting column
C
Clamping element
c
Synchronisation connection
D
Cover
d
Hydraulic cylinder
E
Hydraulic power unit
F
Installation box (incomplete illustration)
A
B
C
D
E
a
b
c
d
F

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Flat head support
Illustration without rubber pad
A
Flat head
C
Rubber pad
B
Pull-out
D
Grooved pin
A
B
C
B
A
C
D

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Swing arm support
A
Swing arm carrier
C
Support plate
B
Support arm, telescopic
D
Lock
A
C
D
B
D
B
C
B
B

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2.4 Technical Data
2.4.1 Danger Zone
1000 mm
1000 mm
1000 mm
1000 mm
1000 mm
1000 mm
1000 mm

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2.4.2 Technical Data
ZS SQUARE II model
3.5
4.5
5.5
6.5
Rated load capacity [kg]
3500
4500
5500
6500
Stroke height [mm]*
1900
1890
Installation depth incl. installation
box T [mm]*
2395
2690
2395
Post spacing SA [mm]*
1350
2300
2500
2700
Clear width between lifting units
LW [mm]*
SA - 400
Overall width head plate-
head plate KK [mm]*
SA + 400
Operating temperature [°C]
+5 to +40
Drive power [kW]
3.0
Duty cycle
S3-20%
Power supply
3x 400 V, PE, 50/60 Hz
3x 230 V, PE, 50/60 Hz
Fuse
gG 16 A
Hydraulic oil specification
HLP-D 22 (HLP-D 22 Synth)
Operating pressure [bar]
160
215
180
215
Filling quantity of hydraulic unit [l]
28
Lifting time [s] (load-dependent)
28
40
Lowering time [s] (load-depend.)
20
35
Sound pressure level [dB(A)
<70
* The values given here refer to the standard version. Depending on selected
options or special adjustments, these values may vary.

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2.4.3 Set-up Diagrams

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ZS SQUARE II model
3.5 FT
Pull-out
Standard
Long
Wide
a max* [mm]
265
265
405
BG max* [mm]
SA + 530
SA + 530
SA + 810
LG* [mm]
2086
2286
2086

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ZS SQUARE II
model
3.5
4.5
5.5
6.5
F [mm]
100
200
575
350
925
350
925
250
BG* [mm]
SA +
352
SA +
552
SA +
1360
SA +
852
SA +
2030
SA +
852
SA +
2030
SA +
680
DP* [mm]
SA + 2 x F
DW* [mm]
SA + 320
SA +
250
SA +
320
SA +
256
SA +
320
SA +
256
SA +
260
LG* [mm]
2820
3700
3800
4260

BA322301-en 19
3Transport, Handling and Storage
3.1 Safety Information
WARNUNG
•Wear personal protective equipment.
•Standing under a suspended load is prohibited.
•Transport and storage of packages is allowed only in original packaging
•Before removing the packaging straps, secure the packages against falling
and maintain a safe distance. Rebounding packaging straps can cause inju-
ries!
•When handling the packages, always observe the center of gravity position
(COG marking).
•Only use lifting equipment and slings that are suitable in terms of type and
permitted load capacity. The weights are to be taken from the transport
documents.
•Always ensure that the parts to be transported are suspended or loaded
properly and in a fall-proof manner, taking into account their size, weight
and centre of gravity. Observe transport regulations.
•The individual packages are not stackable.
3.2 Transport, Handling and Storage
Transport and handling of the lifts are only permitted in the original packaging.
The packages must be stored in a covered location and protected from direct
sunlight. They must be stored at low humidity and at a temperature between
0 °C and +40 °C.
Packaging waste must be disposed of in accordance with applicable
environmental regulations.

20 BA322301-en
4Operation
4.1 Safety Information
WARNUNG
•Comply with legal accident prevention regulations.
•Wear personal protective equipment.
•Carry out visual and operational checks daily before the commencement of
work (see also section “Inspection and maintenance schedule”).
•Defects must be corrected immediately in a competent manner.
•The permissible load capacity according to the type plate must not be ex-
ceeded.
•Only vehicles suitable for the lifting equipment due to their shape and the
positioning of their pick-up points may be lifted.
•Operation of the lift is only permissible with mounted and intact protective
covers and safety devices.
•Never touch moving parts.
•Never use additional lifting gear for an already raised load.
•Before driving onto the lift, all parts of the support must be in the lower
basic position.
•Support arms of swivel arm exposures must be swiveled back completely.
Otherwise damage to the equipment may occur.
•Only drive on the lift at walking speed, if possible in the center of the punch-
es.
•Vehicles may only be lifted with support arm locks intact and undamaged
support discs. Risk of vehicle falling and causing personal injury.
•Support disc raisers may only be used in their single form. A combination of
support disc raisers per support disc is not permitted.
•Maintain a safe distance from the vehicle and lift in all directions.
•Keep the movement range of the load and lift free from obstacles. Use a
guide if visibility is restricted.
•Vehicle doors must be closed during lifting and lowering.
•The vehicle must be strapped to the lift if necessary. Shifts in the centre of
gravity of the vehicle through installation/removal of heavy vehicle parts
may otherwise lead to the vehicle sliding off.
•After raising just off the floor, check that the vehicle has been picked up
securely and that the support arms are locked correctly. If necessary, lower
the vehicle and pick up again.
•The transport of passengers is prohibited.
•Climbing on the raised vehicle or on the lift is prohibited.
•No persons or objects are allowed within the safety zone of the lift and the