01. ZX470-870-5G (PS-EN097P_H1-4_P25)

Hitachi Authorized Dealer Use Only

Dec. 2011

New

SALES MANUAL

470/670/870

Copyright of this manual belongs to Hitachi Construction Machinery.Photographs, names and data may differ in pat from the specifications. You may modify the format and content depending on the region and country you reside.

ZAXIS-5G series vs. ZAXIS-3&3F series

Model Code ZX470-5G / ZX470LC-5G / ZX470H-5G /ZX470LCH-5G

Engine Rated Power 235 kW( 315 HP)Operating Weight 45 600 – 48 300 kgBackhoe Bucket ISO Heaped : 1.15 – 2.65 m3





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PS-EN097P 11.12(DY/KA)

www.hitachi-c-m.com

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Product Concept

PProductroduct CConceptoncept and Key Benefitsand Key Benefits

Brand Concept

Built on the foundation of superb technological capabilities,Hitachi Construction Machinery is committed to providingleading-edge solutions and services to contribute as areliable partner to the business of customers worldwide.

ProductConcept

As well as customers, dealers and manufacturers also have their own visions and dreams. New ZAXIS is destined toachieve such visions and dreams with flexible and optimumsolutions regardless of the surrounding circumstances andenvironments. We would like to contribute to create anenriched living space. This is our common vision and dream.

New ZAXIS, which is empowered by comprehensive evolution,will realize customers’ visions and dreams, and pioneer your colorful future.

Key Benefits of ZAXIS-5G Series

HighQuality

Low FuelConsumption

HighDurability

Key Benefits : Low Running Costs

New ZAXIS-5G features high quality, low fuel consumption, and highdurability, called the key benefits. The outcome is low running costs.

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Product Concept

Aims of Development

Quick Attachment Replacement for only for ZX470-5G H&R series

Fuel saving

• Quick replacement of attachments, using the multifunctional monitor

• Realize efficient hydraulic control

• Enhanced digging and swing operations

Durable, Reliable Engine Multi-Display Monitor

• Complies with EU stage II and US EPA Tier 2 emission regulations.

• Operation information indicated on the monitor screen

• Machine conditions and settings indicated on the monitor screen, too

Enhanced Operator Comfort

Simplified Maintenance

• Pressurized cab to keep dirt out.

• Ample legroom

• Double-sliding seat/console,reducing rattling

• Easy engine area cleaning

• Dust preventive net

Safety Measures

• Robust cab with OPG top guard (ISO Level II only for H&R series)

• Large 7-inch high-definition color screen on the multifunctional monitor

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CONTENTS

Overview of ZAXIS-5G SeriesChapter 1 Performance

Machine Performance 18Hydraulic System 21Support for Various Attachments 23

Chapter 2 DurabilityEngine 26Front 27Upperstructure 29Undercarriage 30

Chapter 3 MaintenanceMaintainability 32

Chapter 4 SafetySafety Cab 44Safety Measures 46

Chapter 5 Controllability/Operator Comfort Comfortable Cab 50Multi Function Monitor 57

Chapter 6 Environmental ConservationEco-Friendly Devices 62

Chapter 7 Global e-ServiceOptimum Data Communication System 64

Chapter 8 AppendixInstructions for Delivery Personnel 70Arm and Boom Dimensions 71Specifications Comparison 77

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Overview ofZAXIS-5G

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Overview of ZAXIS-5G

ZX-5G vs. ZX-3&3F

Main Sales Points Durable, Reliable Engine

Engine Power ComparisonZX470-5G ZX450-3 ZX450

Without fan 260 kWWith fan 235 kW (235 kW) 235 kW

ZX670LC-5G ZX650LC-3 ZX600Without fan 312 kW 345 kWWith fan 295kW

ZX870-5G ZX850-3 ZX800Without fan 360 kW 397 kWWith fan 340kW

For each series, the same engine as that of ZX-1 model is adopted for better reliability and durability.A new hydraulic system "New HIOS IIIB" is adopted for better fuel efficiencywhile engine's horsepower is lower than that of ZX-3.

This engine has a track record showing impressive durability at countless tough job sites aroundthe world.The engine – associated with a rugged design, a direct fuel injection system and an elaborategovernor – goes green, and complies with EU Stage II and US EPA Tier 2 emissions regulations.The combination of a reliable Bosch-type injection pump and mechanical governor is less prone tofuel quality issues, and thus operable in various areas.A simple cooling system, consisting of a radiator and oil cooler, facilitates smooth cooling air flowfor improved cooling efficiency.

Improved Fuel Consumption

Excavators with priority on fuel consumption per hour, compared to the conventional model (ZAXIS-3):ZX470-5G reduced fuel consumption by 9% in HP mode.ZX670-5G reduced fuel consumption by 6% in HP mode.ZX870-5G reduced fuel consumption by 4% in HP mode.

Enhanced Design Performance for Maintaining Productivity

Enhanced hydraulic powerZX470-5G ZX670-5G ZX870-5G

Boom raise force 3%Arm crowd force 3%Bucket digging force 3%Swing torque 8% 9% 9%Traction force 3%Note: Compared to the conventional ZAXIS-3 model

Improved Comfortability for More Excellent and Light Controllability

• More spacious operator’s cab• More comfortable seat to sit on• Concentratedly arranged switches at hand• Usable Multifunction Monitor• 7-inch wide monitor• LED lighting system interlocked with the cab door• Work light will be turned off 30 seconds after the operation for nighttime work

Improved Maintenance / Serviceability; Reduced Life-cycle Costs

Equipped with the engine available for various fuel quality that has a good track recordin ZAXIS 1 models.• Decreased the number of fuel filters• Improved draining performance by setting a fuel tank apart

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ZX-5G LineupZX-5G vs. ZX-3&3F

Large-sized ZX-5G series adopt a uniform approach to model number as 470, 670 and 870.

The table below shows comparison to the conventional ZX-3 series.

For 45 ton and 85 ton class family machines, Standard version, LC-version, H-version, LCH-version, R-version and LCR-version are set just like ZX-3 models.Conventional 50 ton class are not covered here.For 65 ton class, LC-version, LCH-version and LCR-version only are set just like conventionalmodels.Development schedule of R-version and Loading Shovel (45 ton and 85 ton classes only) will bereported later.

ZX470-5G UndercarriageZX-5G vs. ZX-3&3F

ZX470-5G adopts a welded side frame as standard, considering competitors’ models.The bolting type side frame is available for areas where welded type can’t be transported due torestrictions on imports. Please contact us, if necessary.

Welded Side Frame

Bolting Type Side Frame

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ZX-5G vs. ZX-3&3F

AppearanceZX-5G ZX-3&3F

ZX470-5G Series ZX450-3 Series

ZX670LC-5G Series ZX650LC-3 Series

ZX870-5G Series ZX850-3 Series

ZX470LCH-5G ZX470H-3

ZX670LCH-5G ZX670LCH-3

ZX870LCH-5G ZX870H-3

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ZX-5G vs. ZX-3&3F

CabZX-5G ZX-3&3F

70 mm wider

B

A

Cab entry space increased for easyaccess and left-side visibility.Increased slide distance of seat/consoleA : Seat slide range lengthened by

60 mmB : Console slide range lengthened

by 40mm forwards

45 mm wider

Expanded legroom.

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ZX-5G vs. ZX-3&3F

Multi Function Monitor-1ZX-5G ZX-3&3F

Monitor

Large 7-inch high-definition colorscreen

5.8-inch monitor

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ZX-5G vs. ZX-3&3F

Multi Function Monitor-2ZX-5G ZX-3&3F

Cannot switch/change using the monitor.

Multilingual Support

The operator can switch valves and change set flows using the multifunction monitor for replacingattachments.

Supports 12 languages.Multi function monitor supports 32languages.

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ZX-5G vs. ZX-3&3F

Controllability-1ZX-5G ZX-3&3F

Switches are grouped on the right side

Switches are located separatedly

Easy-to-operate multi function contoller

Many switches for operation

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ZX-5G vs. ZX-3&3F

Controllability-2ZX-5G ZX-3&3F

Ball bearings

Smooth and less rattling withbearings

Without bearings

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ZX-5G vs. ZX-3&3F

DurabilityZX-3&3FZX-5G

Reinforced Structure of Pump Compartment ZX470-5G Series

The pump compartment has been reinforcedby adding another column. This prevents thecover from rattling.

Door Catch which Reduces Rattling of Covers ZX670-5G/ZX870-5G Series

Door catch which reduce cover rattling of covers

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ZX-5G vs. ZX-3&3F

MaintenanceZX-5G ZX-3&3F

Fuel Tank Bottom Cover

Facilitates cleaning inside the tank, using a drainage hole and the cock.

Fuel tank bottom cover provided

Strengthened Boom Top and Foot

Bushings

Bushings areprovided in bracketsat the boom top andboom foot (upperstructureframe side) to increase durability.

ZX470-5G Series

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Memo

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Chapter 1Performance

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Chapter 1 Performance

Machine Performance

Background of the Needs in the Market

Operating Capability Desirable for Large Excavators

Since the large-sized excavators more likely perform main digging and loading work at job sites,operating capability of the large-sized excavators have a close relation to the production andprogress of construction/quarry work. The mid-sized excavators have more works with precisebucket position control for finishing and grading. On the other hand, the large-sized excavators often handle heavier load, for example digging ground and loading material on dump trucks. As aresult, the large-sized machines are used at high pressure more frequently compared with the mid-sized machines. Also, the large-sized machines carry material whose specific gravity is heavier than dirt, like gravel. Therefore there is a tendency that the pump pressure at the time of swing+boom raise becomes higher. In order to keep sufficient pump flow even when the pump pressure is high, it is necessary for this excavator to be able to use its engine horsepower effectively and toaccomplish as much of work as possible.For the new ZAXIS, we have aimed for further advancement of its operating capability.

63% 69% 55%15%

92% 72% 78% 96%24% 21% 23%

52%

21%5%

17%2%

0%25%50%75%

100%

Total Japan Asia China Oceania Europe Af rica North America

E mode

P mode

HP mode

67% 62% 65% 73% 64% 86% 85%

24% 25% 30% 21% 21%

10% 3%

0%25%50%75%

100%

Total Japan Asia Oceania Europe Af rica North America

E mode

P mode

HP mode

52% 43% 40% 35%70% 67% 72% 95%

33% 35% 37% 50%19% 24% 25%

3%

0%25%50%75%

100%

Total Japan Asia China Oceania Europe Af rica North America

E mode

P mode

HP mode

For areas where 5G machines are used actively, frequency of use in P mode is higherthat that in North America and Europe (analyzed with Hitachi’s Global e-Service)

For 45 t class, frequency of use in P mode tends to be higher in Asia and China than in other areas.For 65 t and 85 t classes, that in HP mode is higher in the areas except in China.For each class, excavators are used also in E mode and P mode while frequency of use in HP mode is higher, which means that both fuel consumption and production need to be satisfied.New ZAXIS-5G satisfies both fuel consumption and production requirements by reducing fuel consumption while maintaining production equivalent to that of conventional ZAXIS models.

ZX450-3

ZX650-3

ZX850-3

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Production & Fuel Consumption

Large-sized 5G series have priority on fuel consumption per hour in high demand while there aresome differences among models.

ZX470-5G seriesComparison in H/P mode (most frequently used mode in the market)Compared to the conventional ZX 3 series, production is a little less but fuel consumption isimproved by 9% while fuel efficiency per production is almost equal.

In PWR modeit is economically efficient because fuel consumption is reduced by 8% while production is equivalent to that of ZX 3 series.

Comparison of Production

(Work mode)

Comparison of Fuel Consumption

(Work mode)

ZX470-5GZX450-3

ZX470-5GZX450-3

ZX670LC-5G seriesComparison in H/P mode (most frequently used mode in the market)Compared to the conventional ZX 3 series, production is a little less but fuel consumption isimproved by 6% while fuel efficiency per production is almost equal.



(Work mode)


(Work mode)

ZX670LC-5GZX670LC-3

ZX670LC-5GZX670LC-3

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ZX870-5G seriesComparison in H/P mode (most frequently used mode in the market)Compared to the conventional ZX 3 series, production is equal but fuel consumption is improvedby 4% while fuel efficiency per production is better.



(Work mode)

ZX870-5GZX850-3

ZX870-5GZX850-3

(Work mode)


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Hydraulic System

Efficient Hydraulic Control for Lowering Fuel Consumption

Basic Concept of Hitachi's Hydraulic System

Since the EX-5 model, HIOS hydraulic system has been employed as we believe that thissystem can replicate exactly what the operator wants to do in maneuvering the machine.

Move and stop exactly as the operator desires.Perform smooth combined operations in a seamless way.Speedy operation for less fatigue for the operator.Eliminated the wasted energy.

Setting the basic concept as mentioned above, the new ZAXIS has upgraded its hydraulic system to HIOS IIIB.

Realizes optimum speed of the actuators through the efficient hydraulic control.Reduces pressure loss in the hydraulic circuit which lowers the load of the hydraulic pump and the engine.Supports cost reduction by reducing the fuel consumption.

Note: HIOS Human & Intelligent Operation System

New Hydraulic System (HIOS lll B )

The new hydraulic system (HIOS IIIB) has a two-pumps-and-two-control-valves-system with advanced efficiency, reducing the fuel consumption, while the operability for the combinedoperations and large production remain effective.

The large-sized machines differ from the mid-sized machines by their purpose of use. The works requiring high pump pressure and large flow are frequently assigned to the large-sized machines, for example digging ground and loading material on dump trucks.Prominent operability for finishing works like level finishing has been succeeded to this model to reduce the pressure loss in the hydraulic circuit. This has minimized the wasted work with pump and leads to better fuel consumption.

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Enhanced Controlability of the Arm Roll-out Combined Operation New ZAXISSwing + Arm roll-out) + Boom (lower) + Bucket (roll-out)

When lowering the boom using the machine'sown weight, the machine reduces the supplyof the hydraulic oil to the boom lowering circuitfrom the pump.Lowering the boom using the recirculated oilmainly. Achieved increased efficiency by reducing the resistance of the boomregenerative circuit.

The orifice of the swing circuit has beenchanged from the fixed orifice to the variableorifice, lessening the pressure when performing single swing operation.The pressure loss in the control valve has been reduced.The pressure loss at the high pressure circuithas been reduced.

Swing + Arm (roll-out) + Boom (lower)+ Bucket (roll-out)

Arm roll-out

Bucket roll-out

Swing

Boom lower

Reduced Pressure Loss

The pressure loss of the boom circuit has been reduced.(ZX470-5G Series)The pressure loss of the arm circuit has been reduced.(ZX670LC/850-5G Series)• Conventional model: Merged in the control valve.• New model : Merged in the piping on the boom.The pressure loss in thecontrol valve and the pipingshave been reduced as well.

ZX470-5G Series ZX670LC/850-5G Series

Boom Mode Switch

•With the boom mode switch, two boommodes can be selected. The power modeyields more boom pressing force forhigher production; and the comfort modereduces boom pressing force for pleasantoperation and longer service life.

ONON OFFOFFComfort ModeSMALL boom pressing

Vibration and shock caused by themachine uplifting have been minimized. Powerful digging work

Powerful ModeLARGE boom pressing force

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Support for Various Attachments

Improving Application for Attachments

Further Improved Attachment Replacing Support System (ZX470-5G H&R Series)

Like the conventional ZAXIS models, the new ZAXIS offers the ability to easily switch valves and change set flows using the multi function monitor.The new ZAXIS provides ability to register easy-to-remember names for each of the settings.Total of 11 types for pressure and flow can bepreset.

Hour Meter for the Breaker is Displayed on the Multi Function Monitor

With the new ZAXIS, the number of hours thatthe breaker has been used for can be displayed on the multi function monitor.In addition, since the breaker operation hoursand working ratio can be viewed, the operatorcan verify the time when the hydraulic oil andfilter should be replaced. (with resettable tripfunction)

Breaker Alarm Warns of Continuous Use (Optional)

With the new ZAXIS, the operator can set analarm function that displays a warning icon andsounds a warning buzzer when there is ‘more than one minute of continuous use’ of thebreaker, which is forbidden during breaker work.This is useful in preventing abnormal wear to thechisel and in protecting the hydrauliccomponents.

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Memo

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Chapter 2Durability

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01. ZX470-870-5G (PS-EN097P_H1-4_P25)

Documents

Transcript of 01. ZX470-870-5G (PS-EN097P_H1-4_P25)